PANDROL Rosenqvist CD200 Manual

Operation &
Maintenance Manual
Rosenqvist CD200
Issue date:2016-11-11
Dokument ID:ENG_OMM_CD200
Revision:P05
Original instructions
Pandrol AB, Hyggesvägen 4, 824 34 Hudiksvall, Sweden
Phone [phone], www.rosenqvistrail.com, [email protected]

Thank you for choosing CD200!
You are now the owner of a quality product from Rosenqvist Rail AB.
PREFACE
This manual aims to help you get to know your new CD200, to use it in the best way and to
maintain it properly for a long lifetime. It also presents important safety regulations and warnings.
The manual is intended for people who handle and operate CD200. It is originally written in
Swedish and then translated into the local language by Rosenqvist Rail AB. Rosenqvist Rail AB
reserves the right to change specifications, equipment, instructions and maintenance guidelines
without prior notice.
CD200 contains an engine from Subaru. An owner & maintenance manual from Subaru is
therefore included with the product. Please refer to this manual for information regarding the
engine.
The manual contains instructions about the following topics:
• Installation
• Operation
• Safety features and warnings
• Maintenance and troubleshooting
IMPORTANT!
This manual contains ordered actions, e.g.
1. Do this
2. …and then this…
3. …and finally this
These actions must be done in the numerical order presented.
REVISION NOTES
Date Revision Notes
2016-06-23 P04 New layout, updated information, new pictures, added
E-CLIPS work head
2016 -11-11 P05 Added CD200 Electric
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TABLE OF CONTENTS
1 Safety Information 5
1.1 General 5
1.2 Safety Actions 5
1.2.1 Safety Equipment 6
1.3 General Warnings 7
1.4 Specific Warnings 7
1.4.1 Moving Parts 7
1.4.2 Pressurized Hydraulic Oil 7
1.4.3 Live Current 7
1.4.5 Machine in Operation 8
1.4.6 Operator Leaves the Machine Unattended 8
1.5 Qualified Personnel 8
1.4.4 CD200 Electric 8
1.6 Warning Labels and Information Symbols 9
2 General Description 10
2.1 Main Components 10
2.2 Technical Specifications 11
3 Machine Components 12
3.1 Main Unit 12
3.2 Trolley 13
3.3 Controls 14
3.4 Controls CD200 Electric 15
3.5 Electrical System 17
3.6 FASTCLIP-equipped Machine 18
3.6.1 Work Head FC/FE 18
3.6.2 Sleeper Lifter FC/FE 19
3.6.3 Hydraulic System FC/FE 20
3.7 E-CLIPS-equipped Machine 21
3.7.1 Work Head e-CLIPS 21
3.7.2 Indicator 22
3.7.3 Work Head Lifting Mechanism e-CLIPS 23
3.7.4 Hydraulic System e-CLIPS 24
4 Transport and Parking 25
4.1 Preparing for Transport or Storage 25
3.8 Parking on the Track 25
4.2 Parking Off-Track 26
5 Installation on Track 27
5.1 General 27
5.2 On/Off Tracking 27
5.2.1 Off-tracking Using Emergency Handles 29
5.3 Changing the Inclination 30
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5.4 Changing Direction of Operation 31
5.5 Changing Rail Side of Operation 32
6 Operation (FASTCLIP-equipped Machine) 33
6.1 Clipping 33
6.1.1 Settings Before Clipping 33
6.1.2 Clipping Operation 34
6.1.3 Sleeper Lifting Operation 35
6.2 De-clipping 36
6.2.1 Settings Before De-clipping 36
6.2.2 De-clipping Operation 39
6.3 Storing the Shoes when Not Being Used 39
7 Operation (E-CLIPS-equipped Machine) 40
7.1 Settings Before Operation 40
7.1.1 Adjusting the Sliding Plate 41
7.2 Clipping 42
7.3 De-clipping 43
8 Troubleshooting 44
8.1 Clips are moving before sleeper is lifted and preventing installation 44
8.2 Clips are being installed before sleeper is fully lifted 45
8.3 Clips are not being fully installed 45
8.4 Clips are being over driven 45
8.5 Clipping shoe rides over clip on one side 45
8.6 The tools are stuck to the rail 46
9 Maintenance 47
9.1 General 47
9.2 Maintenance Schedule 48
9.3 Grease Points 49
9.3.1 FASTCLIP-equipped Machine 49
9.3.2 E-CLIPS-equipped Machine 49
10 Mounting Torque for Screws & Nuts 50
11 Warranty and Service 51
11.1 Warranty 51
11.2 Service 51
11.3 Contact 51
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1 SAFETY INFORMATION
1.1 General
• Warnings and safety precautions described in this document shall only be considered as a
minimum. National conditions, standards and regulations override conditions, standards and
regulations described in this document.
• Work with the machine is only to be carried out by qualified personnel, well-informed and
educated in general railway workmanship and specifically in the conditions, standards and
regulations on specific rail track.
• The machine may only be used for its specified purpose.
• Any adjustments or service on the machine is only allowed to be done by qualified personnel
that have read and understood this manual and have had training and information from
Pandrol AB.
1.2 Safety Actions
• Read and understand all safety regulations and warnings before installation, operating or
performing maintenance on this machine.
• Locate stop buttons, emergency stop buttons and keys before installation, operating or
performing maintenance on this machine. The emergency stop button is not allowed to be
used to stop the machine normally.
• The machine is never to be used as a transport vehicle for personnel or equipment.
• Be sure that unqualified persons are not in the operating area during installation, use or
maintenance.
• Safety regulations regarding personnel in operating area for the CD200 are valid for this
machine.
• Use standards and regulations, accident prevention regulations and regulations concerning
special ambient conditions (e.g. areas potentially endangered by explosive materials, heavy
pollution or corrosive influences).
• It is of great importance that all service, component replacements or other operations in the
electronic or hydraulic systems are accomplished by qualified personnel only.
• The use of solvents as cleaning agents and the use of lubricants can involve health and/or
safety hazards. The manufacturers of the solvents and lubricants should be contacted for
safety data. The recommended precautions and procedures of the manufacturers should be
followed.
• The use of an air jet, which must be less than 8 bar, to blow parts clean or to blow them dry
after being cleaned with a solvent will cause particles of dirt and/or droplets of the cleaning
solvent to be airborne. These conditions may cause skin and/or eye irritation.
• When using an air jet do not direct it toward another person. Improper use of air jet could
result in bodily injury.
• The machine is not allowed to be used on a track that is open for traffic.
• Before maintenance work on the machine, disconnect the battery connections.
• Caution shall be exercised when the operator leaves the machine especially when adjacent
track is trafficked and can endanger the safety.
• The rail wheels are shorting the rails and the machine could therefore affect railway signals, e.g.
crossings can be affected. National and local regulations are to be followed.
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• Personal eye protection must be worn when undertaking work.
• Personal ear protection must be worn when undertaking work.
• All personnel except for the operator are to be kept at least 3 m from machine when working.
• Operators and service personnel should wear appropriate protective equipment, such as
gloves, goggles and overalls. Skin exposed to hydraulic oils should be washed immediately.
• All personnel should be made aware of the contents of the product data sheets relating to the
hydraulic oil used.
• Pandrol AB recommends the use of biodegradable oils and greases, in order to minimize the
environmental impact in case of an oil leakage.
• CD200 is only to be used by trained personnel, thoroughly familiar with and trained in general
railway workmanship.
• The equipment should be operated according to the conditions and standard regulations
applying to the track they are working on.
•
1.2.1 Safety Equipment
The machine is to be equipped with safety equipment according to national requirements.
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1.3 General Warnings
• Incorrect installation of this equipment may be dangerous and may result in severe personal
injuries.
• Incorrect operation of this equipment may be dangerous and may result in severe personal
injuries.
• Incorrect maintenance of this equipment may be dangerous and may result in severe
personal injuries.
1.4 Specic Warnings
1.4.1 Moving Parts
When operated, some parts of the CD200 are moving. Moving parts can cause personal injury. To
avoid accidents, follow the guidelines below:
• Keep hands etc. away from moving parts when operating the machine
• Make sure no unauthorized personnel are in the working area when working the machine
WARNING! Moving parts - risk of crushing
1.4.2 Pressurized Hydraulic Oil
High pressure fluid is present in operational hydraulic systems. Fluids under high pressure are
dangerous and can cause serious injury.
To avoid accidents, follow the guidelines below:
• Only qualified technicians or engineers are allowed to make modifications, repairs or
adjustments to the hydraulic system.
• Always wear appropriate personal protection equipment.
• Shut the engine off and drain the hydraulic system before doing any maintenance work on the
hydraulic system.
•
1.4.3 Live Current
Contact with electric parts can damage the equipment if live current is present. To avoid
accidents, follow the guidelines below:
• If electricity needs to be connected for testing purposes: keep hands, tools etc. away from all
electrical parts.
In any other case:
1. Shut off the vehicle engine
2. Disconnect the battery terminals
WARNING! Pressurized hydraulic oil - risk of personal injuries
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1.4.5 Machine in Operation
Special precautions must be taken to ensure that operation of the machine will not result in
severe injury and/or damage to the equipment.
To avoid accidents, make sure no one is in the vicinity of the machine before operation is started.
1.4.6 Operator Leaves the Machine Unattended
When the operator leaves the machine unattended, the machine must always be parked
horizontally on the ground, or when it is still on the track with the work head onto ballast or the
sleeper. This is to ensure that the machine doesn’t fall over or run away along the track.
1.5 Qualied Personnel
The CD200 is only to be used by trained personnel, thoroughly familiar with and trained in general
railway workmanship. The equipment should be operated according to the conditions and
standard regulations applying to the track they are working on.
The equipment must be serviced, maintained, or in any way modified only by trained personnel,
who are familiar with the Operation & Maintenance Manual and have received training and
information from Pandrol AB.
In order to avoid personal injury and/or material damage, everyone involved with assembling,
starting-up or overhaul must possess relevant knowledge of the following
• The automation technology sector
• Dealing with dangerous voltages
• Using standards and regulations, accident prevention regulations and regulations concerning
special ambient conditions (e.g. areas potentially endangered by explosive materials, heavy
pollution or corrosive influences)..
WARNING! Live current - risk for damage on equipment and/or
people
• Touching parts that are subject to high voltage may cause grave damage to
health
• All maintenance and service on the electric or hydraulic system is to be carried out
by qualified personnel
WARNING!
1.4.4 CD200 Electric
The machine is equipped with an electric motor. The power connected to the machine
must be as specified in the technical data. Any other can cause cruzial damage to the
motor, machine and the operator.
The electric cable connected to the machine must be assembled by an electrician and
not be damaged in any way.
The cable must be checked on a daily basis to ensure no damage is done.
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1.6 Warning Labels and Information Symbols
Below are examples of warning labels and information symbols on the machine. If any of these
labels become damaged or lost, they are to be replaced with new original warning labels that are
available from Pandrol AB.
Read manual before use
(item no. 710016)
Wear safety goggles
(item no. 710048)
Wear hearing protection
(item no. 710052)
WARNING: Risk of crushing
(item no. 710019)
WARNING: Oil pressure
(item no. 710020)
Do not ride or stand on
machine
(item no. 710021)
Emergency stop
(item no. 710014)
Lifting point
(item no. 710062)
WARNING: Electrical danger
(item no. 710018)
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2 GENERAL DESCRIPTION
The Clip Driver CD200 is designed and manufactured for clipping and de-clipping PANDROL
FASTCLIP and FASTCLIP FE, or PANDROL E-CLIP (depending on how the machine is equipped).
Switching from clipping to de-clipping is easy since the Clip Driver CD200 uses the same head for
both clipping and de-clipping and it is also easy to setup for different rail gauges and inclinations.
The Clip Driver CD200 is rapid and easy to use and it is ergonomically operated by one single
operator. The Clip Driver CD200 can clip on both rails by sliding the unit from one side to the
other. The clipping capacity is up to 30 sleepers per minute. The CD200 can be separated into 2
pieces to allow for transport and easier handling.
From here on the Clip Driver CD200 is named only CD200.
2.1 Main Components
(1)
(2)
(3.1)
(3.2)
(4)
(5)
Fig. 1
Item Description Item Description
(1) Height adjustable handlebar (3.2) Work head e-CLIPS
(2) Control panel (4) Trolley unit
(3.1) Work head FC/FE (5) Main unit
Table 1
* Please note that the machine pictured above may be tted with extra equipment. Rosenqvist Rail AB reserves the
right to change any technical details without prior notice.
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2.2 Technical Specications
Clip Driver
CD200
Fastclip & Fastclip
FE
Clip Driver
CD200
e-CLIP
Clip Driver
CD200
Electric
Measurements Length 2177 mm
Height 1173 mm 1180 mm 1173 mm
Width 2138 mm
Weight 279 kg 284 kg 275 kg
Measurements
(packaged)
Length 2040 mm
Height 114 0 mm
Width 870 mm
Weight 346 kg 351 kg 341 kg
Performance Track gauge 1067-1600 mm
No of clips
being installed/
extracted at the
same time
2 clips per cycle
Capacity (up to) 30 sleepers/min 10 sleepers/min 20 sleepers/min
Engine Manufacturer Subaru SEW-EURODRIVE
Model EX40 FRN100L4
Type Air-cooled, 4-stroke single cylinder,
overhead camshaft
Frequency
controlled AC
motor
Power 7,0 kW @ 3600 rpm 4.0kW 5.4HP
Fuel Automotive gasoline (unleaded) Nomn. curr AC
7,3 A. 400 V AC.
Infeed AC 3x400V
±10%.
Freq 50-60Hz
±10%.
Fuel tank
capacity
11 lit re
Electronics Voltage 12 volt DC 12/24V DC
Ground Negative Negative
Hydraulics Pump Double gear pump
Max flow 27 l/min
Max pressure 235 bar
Hydraulic tank
volume
8-9 litre
Noise data Noise level, idle
running
71 dB(A)
Noise level, full
speed
92 dB(A)
Vibration data Clipping 4,3 m/s²
De-clipping 3,15 m/s²
Table 2
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3 MACHINE COMPONENTS
3.1 Main Unit
The Main Unit is the heart of CD200. It contains the engine, all central hydraulic components such
as pump, block and valves and almost all electronics. The handle bar with the operator controls is
also mounted on the Main Unit.
Item Description Item Description
(1) Working light (6) Support leg
(2) Handle bar (7) Control box
(3) Hydraulic tank (8) Motor
(4) Engine (9) Emergency stop button
(5) Accessory box
Table 3
Fig. 2
(1)
(2) (4)
(5)
(3)
(6)
Fig. 3
(8)
(7)
(9)
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3.2 Trolley
The trolley for the CD200 supports the machine and guides it along the track. The Trolley also
enables the operator to switch direction as well as slide the main unit across to the opposite rail
in a convenient manner. When setup correctly, the trolley gives the machine the right inclination
independent of direction of travel or chosen rail for operation.
Item Description Item Description
(1) Wheel bracket (5) Latch for slide carriage / Handle
(2) Slide bar (6) Setting bolt for slide carriage locking
(3) Connection tray (7) Slide carriage
(4) Lock pin for rotation
Table 4
(1)
(2)
(3)
(4)
(5)
(6)
Fig. 4
(1)
(5)
(6)
(7)
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3.3 Controls
The CD200 is operated by the operator by a control panel, a dead-mans-handle, and two buttons
all located handy on the adjustable handlebar. The CD200 has four different work modes as will be
explained below.
WARNING! Do not operate the machine before performing the
setup procedure.
(1)
(2)
(3)
(7)
Fig. 5
(6)
(4)
(5)
Fig. 6
Item Description Item Description
(1) Push button 1 (5) Light switch
(2) Push button 2 (6) Manual/auto switch
(3) Dead-mans-handle/sleeper lift function (7) Emergency stop button
(4) Extract/Install switch
Table 5
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3.4 Controls CD200 Electric
The machine is driven by electric power. and needs to be connected to an electric outlet
according to technical data.
To start the CD200, connect to electric outlet (2), Nomn. curr AC 7,3 A. 400 V AC. Infeed AC 3x400V
±10%. Freq 50-60Hz ±10%.
Press green button (3) and the electric motor starts. If the emergencybutton is activated, release
and press the blue button (1) before starting the CD200.
Stopp the motor by pushing the red button (4).
Item Description Item Description
(1) Reset (3) On
(2) Power connection (4) Off
Table 6
Fig. 7
(1)
(2)
(3)
(4)
The machine is equipped with an electric motor. The power connected to the machine
must be as specified in the technical data. Any other can cause cruzial damage to the
motor, machine and the operator.
The electric cable connected to the machine must be assembled by an electrician and
not be damaged in any way.
The cable must be checked on a daily basis to ensure no damage is done.
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The description below makes references to Table 5.
Mode 1: Manual Clipping
Set switch 6 to Manual. Set switch 4 to Install. Push button1 to do the clipping operation. Push
button 2 to retract the arms of the work head. This mode is used when the operator is setting up
the machine or for some other reason want to do a manual operation.
Mode 2: Manual De-clipping
Set switch 6 to Manual. Set switch 4 to Extract. Push button 2 to do the de-clipping operation.
Push button 1 to retract the arms of the work head. This mode is used when the operator is
setting up the machine or for some other reason want to do a manual operation.
Mode 3: Auto Clipping
Set switch 6 to Auto. Set switch 4 to Install. Push button 1 to start the clipping cycle, release the
button immediately. The retraction of the arms of the work head is done automatically. This mode
is used for normal clipping operation.
Mode 4: Auto De-clipping
Set switch 6 to Auto. Set switch 4 to Extract. Push button 2 to start the de-clipping cycle, release
the button immediately. The retraction of the arms of the work head is done automatically. This
mode is used for normal de-clipping operation.
The dead-mans-handle needs to be pressed in towards the handlebar at all normal use. This
allows the machine to rest on the jockey wheel. If the handle is released, the machine sinks down
on the ground to prevent runaway on track or to allow for sleeper lifting (see chapter 6.1.3 for
sleeper lifting procedure).
The battery switch shall always be turned off when leaving the machine (see Fig. 8).
Battery switch
Fig. 8
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3.5 Electrical System
The electrical system on the CD200 is robust and built with high quality components. It requires a
minimum of maintenance and is well protected from wear and climate impact.
Item Description Item Description
(1) Controls (5) Valve connectors
(2) Work light (6) Pressure sensor connectors
(3) Relay box (7) Battery
(4) Battery switch (8) Fuse 10A
Table 7
(1)
(2)
(3)
(4)
(5)
(6)
Fig. 9
(8)
(7)
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3.6 FASTCLIP-equipped Machine
3.6.1 Work Head FC/FE
The work head is designed to be able to both clip up and de-clip PANDROL FASTCLIP and
FASTCLIP FE. It is adjustable to facilitate different rail sections (from S49 all the way up to 141 RE, rail
heights from 149-189 mm).
The work head uses the rail head as a datum when it is configured for de-clipping. The work head
can easily be set up for clipping or de-clipping by changing the shoes and turning the mechanical
stops 180 degrees.
(1)
(2)
(3)
(4)
(5)
(6)
Fig. 10
Item Description Item Description
(1) Clipping shoe (4) Adjustable datum part
(2) Datum arm (5) Double pin for shoe
(3) Mechanical stop for de-clipping (6) Main arm
Table 8
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3.6.2 Sleeper Lifter FC/FE
The sleeper lifter device enables the machine to lift low laying sleepers up to 50 mm. This is
done in a certain sequence described in chapter 6.1.3. This device also includes an adjustment
mechanism to accommodate for different rail section heights. When the dead-mans-handle/
sleeper lifter control is pressed in towards the handlebar, the cylinder takes its fully extended
position, which is the normal operation position.
(1)
(2)
(3)
Fig. 11
Item Description Item Description
(1) Height adjustment mechanism (3) Jockey wheel
(2) Sleeper lift cylinder
Table 9
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3.6.3 Hydraulic System FC/FE
The hydraulic system has a double gear-pump assembly, which maximizes the power output
and enables rapid work cycles. The purpose-built valve block assembly, together with the control
system, gives the machines its unique features. The return filter (5) is of the type “spin-on”, which is
easily changed whenever required (see chapter 11 for maintenance). The hydraulic reservoir (3) is
also a part of the machine structure.
(1)
(3) (8)
(2)
(7)
(6)
(4)
(5)
Fig. 12
Item Description Item Description
(1) Clipping/De-clipping cylinder (5) Return filter
(2) Sleeper lifter cylinder (6) Pump assembly
(3) Hydraulic fluid reservoir (7) Valve block assembly
(4) Breather filter/ filler cap (8) Drain plug
Table 10
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