PANDROL 02050RM User manual

Partners in excellence
ENG_OMM_MODULAR_POWER_UNIT_P01
19th November 2021
OPERATION AND MAINTENANCE
MANUAL
Modular
Power Unit
MODEL 02050RM

1. Preface
2. Revision
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OPERATION AND MAINTENANCE MANUAL I ENG_OMM_MODULAR_POWER_UNIT_RM_P01 I 21th February 2022
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Thank you for choosing Modular Power Unit!
You are now the owner of a quality product from Pandrol.
This manual aims to help you get to know your new Modular Power Unit, 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 the machine. It is originally written in English and
translated into the local language by Pandrol.
Pandrol reserves the right to change specications, equipment, instructions and maintenance guidelines without
prior notice.
The manual contains instructions about the following topics:
1. Installation
2. Operation
3. Safety features and warnings
4. Maintenance and troubleshooting
(1) refers to a component in a gure/illustration.
IMPORTANT
This manual contains ordered actions, e.g.
1. Do this
2. ...and then this...
3. ...and nally this
These actions must be done in the numerical order presented.
Revision Date Comments
P01 2022-02-21 New Manual

Table of Contents
1. Preface 2
2. Revision 2
3. Safety Information 4
3.1. General 4
3.2. Safety actions 4
3.3. Personal/Safety equipment 5
3.4. Safety precautions 5
3.5. Qualiedpersonnel  6
4. Summary 7
5. Operation 8
5.1. Changing tools 10
5.2. Coldweatheroperation  10
6. Reviewofhydraulicprinciples  11
6.1. Hydraulicformulas  11
6.2. Backpressure  11
7. Maintenance 12
7.1. General 12
7.2. Warninglabelsandinformationsymbols 13
7.3. Engine maintenance 14
8. Limitedwarranty  15
8.1. Exclusionstolimitedwarranty  15
8.2. Limitation of liability 15
9. Customerinformation  16
10. Assembly 18
10.1. 14Hpkohlerenginebreakdown 18
10.2. Enginemoduleassembly 19
10.3. Enginemoduleassemblybreakdown  20
10.4. Hydraulictankmoduleassembly 21
10.5. Hydraulictankmoduleassemblybreakdown 22
11. Disclaimer 23
12. Contact 23
13. RecyclingandEnvironment  23
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3. Safety Information
3.1. General
• Tooloperatorsandmaintenancepersonnelmustalwayscomplywiththesafetyprecautionsgiveninthis
manual,andwithallstickersandtagsattachedtothetoolandhoses.
• Allsafetyprecautionsaregivenforyoursafety.Readtounderstandandfollowallsafety,maintenanceand
operation instructions before you use or maintain the tool.
• Reviewthemanualdailybeforeusingthetool.
• Followallsafetyguidelinesgivenyoubyyoursupervisor.Donotusethetoolifyouhaveanyquestionsabout
theoperation,safetyormaintenanceofthistool.Failuretofollowtheseinstructionscanresultinpersonal
injuryorequipmentdamage.
• Pandrolhasnocontroloverthetooluseoroperationonceitleavestheplant.Pandrolhasnocontrolover
operator or maintainer selection. The customer must assume responsibility for the tool suitability for a particular
function.
• Duringuseofthetool,goodjudgementmustbeusedtoworksafelyande󰀩cientlywithoutendangering
themselvesorbystanders.
• Understandingoftheoperationandmaintenancemanualisessentialforanyoneusingormaintainingthetool.
• 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qualiedpersonnel,well-informedandeducatedingeneral
railwayworkmanshipandspecicallyintheconditions,standardsandregulationsonspecicrailtrack.
• Themachinemayonlybeusedforitsspeciedpurpose.
• Anyadjustmentsorserviceonthemachineisonlyallowedtobedonebyqualiedpersonnelthathaveread
andunderstoodthismanualandhavehadtrainingandinformationfromPandrol.
3.2. Safety actions
• Readandunderstandallsafetyregulationsandwarningsbeforeinstallation,operatingorperforming
maintenance on this machine.
• Donotoperatethetooluntilyouhavebeenthoroughlyandproperlytrainedorunderthesupervisionofan
instructor.
• Checkpowersourcedailytodetermineifcorrectowandpressureareavailable.Neverexceedowsor
pressuresforthetoolbeingused.Personalinjuryordamagetothetoolcanresult.
• Operatorsmustcleartheworkareaofnon-essentialpersonnel.Flyingdebriscancauseseriousinjury.
• Theoperatormustbefamiliarwithallprohibitedworkareassuchasunsafegrades,poorfootingareasand
overheadhazards.
• 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inuences).
• Maintainbalanceandproperfootingatalltimes.Neveroverreachtotheextentthatabrokenpartorsudden
movementofthetoolcancauseyoutoloseyourbalanceandfall,orcauseinjurytoyourselforsomeoneelse.
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• Donotoperatethetoolatexcessiveuidtemperaturesoperatordiscomfortandpotentialburnscanresultat
high oil temperatures.
• Donotcleaninspectorrepairthetoolwhileconnectedtothepowersource.Accidentalengagementofthetool
can cause serious personal injury.
• Oilinjectionhazardexistswiththistool.Oilinjectionisaconditionwherehydraulicoilisinjectedunderthe
skinfrompressureintheline.Alwayswearglovesandrepairanyleaksimmediately.Nevercarryatoolbythe
hoses.
• Donotusedamagedequipment.Immediatelyreplaceanydamagedhoses,ttings,orothercomponents
showingwirebraid,nicks,cuts,damageorabrasions.Failuretodosomayresultinequipmentdamageand/or
personalinjuryordeath.
• Cleanupanyoiloruidspillsimmediately.
3.3. Personal/Safety equipment
• Neverwearlooseclothingthatcangetentangledintheworkingpartsofthetoolsorbecarelesswithhands,
feetorotherbodypartsaroundtheworkingpartsofthetools.Hydraulictoolsexerthightorqueandforceand
cancauseseriousinjuryordeathifimproperlyused.
• Whenworkingnearelectricalconductors,alwaysassumethattheconductorsareenergizedandthathosesand
clothingcanconductharmfulelectricity.Usehoseslabeledandcertiedasnonconductive.
• Alwayswearsafetyequipmentsuchasoilinjectionresistantworkgloves,safetyglasses,safetyboots,ear
protectionandothersafetyappareldictatedbyyoursupervisorapplicableforthejobyouaredoingandthetool
you are using.
• Theuseofancompressedair,whichmustbelessthan8BAR(116PSI),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.
3.4. Safety precautions
• Alwayswearprotectiveequipmentsuchasgloves,safetyglasses,earprotectionandsafetyshoes.
• Donotwearclothingwhichmaybecomeentangledinthetool.
• Alwayskeepworkareafreeoftoolsoranyotherobjectswhichmayimpairsoundfooting.
• Cautionoilinjectionhazardexistswiththistool.Oilinjectionisaconditionwherethehydraulicoilisforced
undertheskinthroughpressureintheline.Alwaysweargloves,donotcarrythetoolbyhydraulichoses,and
repairleaksimmediately.
• Donotoperatethepowerunituntilyouhavebeenproperlytrainedorunderthesupervisionofaqualied
instructor.
• Neverstoreengineoilorhydraulicoilnearoxygentanksorlines.
• Neveraddengineoilorhydraulicoilwhenaspillmightcomeincontactwithyouroxygenlines,torchorttings.
• Cleanupspillsimmediately.
• Neverperformgrindingorsawingoperationsthatdirectsparksintothecloseproximityofthepowerunitor
ammablematerials.
• Neveroperatethepowerunitwithanypartoftheexhaustsystemortheheatdeectorremoved.
• Periodically,inspectthefueltank,fuellineandttingsforcracksorleaksandrepairorreplaceasrequired.
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• Avoidoverllingthefueltank;wipeupanyspillsimmediatelyandproperlydisposeofthecleaningrags.
• Alwaysturnpowerunit"OFF"anddisconnecthosesbeforeperforminganymaintenance.
3.5. Qualied personnel
Themachine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modiedonlybytrainedpersonnel,whoarefamiliar
withtheOperation&MaintenanceManualandhavereceivedtrainingandinformationfromPandrol.
Inordertoavoidpersonalinjuryand/ormaterialdamage,everyoneinvolvedwithassembling,starting-upor
overhaulmustpossessrelevantknowledgeoftheequipment,itsuse,maintenancerequirementsandprocedures.
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Engine Flow Pressure Dimensions Weight
14hpkohler
Fuel: Gasoline
7.4Qts(7.0L)
Start: Pull
9Gpm(34lpm)
Fluid:hydraulic
3.5Usgal(13.2l)
2000PSI(140BAR) A-29½”(74.9cm)
B-23½”(59.6cm)
C-25”(63.5cm)
161lbs(74kg)
Weight-Engine Module Weighthydraulic Tank module
100lbs(45kg) 61lbs(27kg)
4. Summary
ThePandrolModularPowerUnitisdesignedtobe
easilytransportedintwolight-weightsectionsandit
simplycouplestogetherforimmediateuse.Itdelivers
9GPMofowwhichwilloperateallcriticalhydraulic
tools.Wheresizeandweightareprimaryconcerns,this
unitisperfectforthejob.Twocompactsectionsallow
foreaseofgettingintotightworklocationswhilebeing
lightweightandsafeforoperatorstocarrytothework
site.
Fig 1.
Fig 2. Fig 3.
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5. Operation
Before starting the power unit, check all uid levels. Add fuel, motor oil and hydraulic oil as required.
The two sections of this power unit must be connected together by the associated hoses and interlocked
prior to starting this modualr power unit.
The hydraulic lines that connect the power unit engine to the reservoir must be connected and the frames
interlocked prior to starting the unit.
Tostartthepowerunit,checktomakesurethehydrauliccontrolvalveisinthe“OFF”position.
• Turnfuelshut-OFFvalvetoonposition.
• Startengineasfollows:coldengine:placethrottlecontrolmidwaybetweenslowandfastpositions.Place
chokecontrolintoonposition.Warmengine:placethrottlecontrolmidwaybetweenslowandfastpositions.
ReturnchoketoOFFpositionassoonasenginestarts.Awarmengineusuallydoesnotrequirechokeon.
• Retractablestart:slowlypullstarterhandleuntiljustpastcompression-stop!Returnstarterhandle;rmlypull
straightouttoavoidexcessiveropewearfromstarterropeguide.
• GraduallyreturnchokecontroltoOFFpositionafterenginestartsandwarmsup.Engine/equipmentmaybe
operatedduringwarmupperiod,butitmaybenecessarytoleavechokepartiallyonuntilenginewarmsup.
• Connectiontothepowerunit:turncontrolknobto"OFF"positionbeforeattachingordisconnectingany
transmissionhosestothepowerunitortools.Turncontrolknobto"on"positiontooperateattachedtools.
• To turn OFF engine, turn the fuel shut OFF valve to OFF position.
WARNING!
• Carbon monoxide can cause severe nausea, fainting or death. Avoid
inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide is odorless, colorless, and can cause death
if inhaled.
NOTE!
• Choke position for starting may vary depending upon temperature and other
factors. Once engine is running and warm, turn choke to OFF position.
NOTE!
• Extend starter cord periodically to check its condition. If cord is frayed have
it replaced immediately.
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Hydraulictankmoduleconnectsbymeansoftwoquickdisconnectsintopump
Bothframesjointogetherusinginterlocktabs(oneeachside).
Closeupofinterlockingtabsthatjointheframesof
Hydraulicmoduletoenginemodule(oneeachside).
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5.1. Changing tools
• Alwaysreturntheengineto“IDLE”andturnthecontrolknobstothe"OFF"positionbeforedisconnecting
hoses.
• Oncethetoolhasbeenchanged,advancetheengineto“FULL”throttleandturnthevalve(s)tothe"ON"
positiondependingonowrequirementsofthetooltobeused.
5.2. Cold weather operation
Thepowerunitandtoolswillperformwellinextremecoldweatherifthewarm-upproceduresarefollowed.These
preceduresshouldbeusedanytimethetemperatureisbelow40degreesfahrenheit(4.4C).Inextremelycold
climates,changingtoanaircraftqualityhydraulicoil(mil.Spec.H-5606)willreducethewarmuptimerequired.
Whenwarmweatherreturns,besuretochangebacktoahigherviscosityhydraulicoil.
• StartthepowerunitandletitrununtilitisrunningsmoothlywiththechokeOFF.
• Connectthepowertransmissionhosestothepowerunitandcouplethepowertransmissionhosetoolends
togetherforminga“loop”.
• Turntoolcontrolvalve“ON”tocirculateoilthroughthehose.
• Whentheoilreaches50degreesfahrenheit(10C)youmaybegintooperatethetools.
NOTE!
• Refer to operating procedures of this manual before starting
NOTE!
• Hydraulic system performance is a󰀨ected when the temperature drops
below 50° F. Therefore, measures should be taken to pre-warm tools and
uids before operating.
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6. Review of hydraulic principles
Tool circuit
6.1. Hydraulic formulas
Example:HPrequiredtodeliver10GPMat1500PSI.
EstimatedHPdeliveredbypumporusedbytool
6.2. Back pressure
Backpressuremeasuredatthetoolreturnportmustnotexceedthemanufacturersbackpressurerating.Most
manufacturerslistthemaximumbackpressurefortheirhydraulictoolsat250PSI.Backpressuremeasuredon
thereturnsideofthetoolistheforcerequiredtogettheoilbacktothetank.Inalmostallcasesthelowertheback
pressurethebetterthetoolperformance.First,thebackpressureissubtractedfromthemaximumtoolpressure
toarriveatamaximumtooloperatingpressure.Forexample,toolswith2000PSIoperatingpressureareinstalled
onasystemwith250PSIbackpressure.Thisleaves1750PSIasamaximumtoolpressure.Imagineasystem
with500PSIbackpressure.2000Minus500PSIbackpressureleavesonly1500PSIforthetool.Second,tools
aredesignedforpressuretobuildonthepressuresideofthetool.Iftoomuchpressurebuildsonthereturnside,
notonlyisperformancee󰀨ected,butsealsmayblow.Thisiswhyitisveryimportanttodirecttheowintothetool
correctly.Reversingthehosestotestmayresultinblownseals,damagetothetool,andpersonalinjury.
PSI
GPM 500 1000 1500 2000 2500 3000
31.03 2.06 3.09 4.12 5.15 6.18
51.72 3.43 5.15 6.86 8.58 10.30
10 3.43 6.86 10.30 13.70 17. 2 0 20.60
15 5.15 10.30 15.40 20.60 25.70 30.90
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7. Maintenance
7.1. General
Maintenance and overhaul is to be carried out by qualied personnel only
Warranty is based on parts and spares delivered by Pandrol.
Check tools DAILY for proper operation, leaks, or damage.
Inspect hoses DAILY. Replace cut, burned, or otherwise damaged hoses.
Keep quick disconnect couplers clean and lubricated.
UsehydraulicuidsthatcomplywithHTMASpecication5.7,Thehydraulicuidshouldhaveaviscositybetween
100and400SSU(20-82centistokes)atthemaximumandminimumexpectedoperatingtemperatures.Petroleum
basedhydraulicuidswithanti-wearpropertiesandaviscosityindexofover140workforawiderangeof
operatingconditions.
Havetoolinspected,atleastannually,byPandroloraPandrolqualiedservicerepresentativetodetermineiftool
isinneedofsafetychangesorwornpartreplacement.
ContactPandrolonaperiodicbasis,atleastannually,forserviceBulletins,safetynotices,orotherimportant
information pertaining to this tool.
Other uids that meet or exceed this specication can be used.
* See cold weather operation hydraulic oil note.
The following oils meet HTMA Specication 5.7
WARNING!
• All adjustments work, overhaul and service must take place with the
machine turned OFF. Failure to do so could lead to fatal injury.
• It is of great importance that qualied personnel accomplish all service and
overhaul
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7.2. 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.
DCL-1089
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7.3. Engine maintenance
Follow the hourly or calendar intervals, whichever occur rst. More frequent service is required when
operating in adverse conditions noted below.
• Checkoillevelevery5hoursordaily
• Service air cleaner every 25 hours or season*
• Change oil every 50 hours or season*
• Changeoillterandsparkplugsevery100hoursorseason*
• Serviceaircleanercartridgeevery100hoursorseason**
• Clean cooling system every 100 hours or season**
• Replacein-linefuellterevery50hoursorseason
• Changeoilafterrst5hoursthenafterevery50orseason
*Changeoilmoreoftenwhenoperatingunderheavyloadorhightemperatures.
**Cleanmoreoftenunderdustyconditionsorwhenairbornedebrisispresent.
Replaceaircleanerpartsifverydirty.
Itisveryimportantthattheserviceintervalsarethoroughlyfollowedtoguaranteethesafetyandtheperformance
of the machine
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8. Limited warranty
Pandrol,INCwarrantstotheoriginalpurchaseofthisproductthattheproductwillbefreefromdefectsinmaterial
andworkmanshipfortheperiodofone(1)yearafterthedeliveryofsuchproducttothecustomer.Otherequipment
andpartsused,butnotmanufacturedbyPandrolarecovereddirectlybythewarrantyofthemanufacturerofthose
products.Proofofpurchasemustbedocumentedincludingreferencetoaserialnumberlocatedoneachtool.
Thepurchaser’sonlyremediesunderthislimitedwarrantyshallbelimitedatPandrol’ssoleoptiontothefollowing:
repair,replacementorrefundofthepurchasepriceofthedefectiveproducts.Eachoftheseremediesrequires
timelynoticationofthedefectintheproductandsubstantiationthattheproducthasbeenproperlystored,
maintainedandused.Pandrol’sobligationshereunderextendonlytothepurchaseroftheproductandnottoany
thirdparty.
AsaconditionprecedenttoPandrol’sobligationhereunder,thedefectiveproductmustnothavebeenalteredor
modiedwithouttheexpresswrittenapprovalofPandrol.Theproductmustnothavebeensubjectedtodeliberate
damage,shippingdamage,neglect,tamperingbyunauthorizedpersonnelordamagebyimproperuse,storageor
maintenance.Serialnumbersmustnothavebeenaltered,defacedorremoved.Suchactionvoidslimitedwarranty.
8.1. Exclusions to limited warranty
Thislimitedwarrantyisexclusiveandisinlieuofanyotherwarranty,writtenororal,expressedorimplied,
including,withoutlimitation,anyimpliedwarrantyormerchantabilityortnessforaparticularpurpose.
Limitedwarrantydoesnotcovernormalwearandtearitemssuchaslters,hoses,couplers,bits,sockets,augers,
andbatteries
8.2. Limitation of liability
Exceptasprovidedabove,Pandrolshallinnoeventbeliableorresponsibleforanyinjury,lossordamage,direct,
incidentalorconsequential,arisingoutoftheuseormisuseorinabilitytousetheproduct,howevercausedand
onanytheoryofliabilityincluding,withoutlimitations,breachofcontract,tort,(includingnegligenceorstreet
liability)andnotwithstandinganyfailureofanyremedyhereinofitsessentialpurpose,evenifPandrolwasaware
ofthispossibilityofsuchdamage.Pandrol’slimitedwarrantyassetforthaboveshallnotbeenlarged,diminished
ora󰀨ectedby,andnoobligationorliabilityshallariseorgooutoftherenderingoftechnicaladviceorserviceby
Pandroloritsagents.Theforegoingmaynotbechangedexceptbywrittenagreementsignedbyanauthorized
OFFicerofPandrol,theremediessetforthhereinareexclusive.
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9. Customer information
Name
Company
Serial # of your Pandrol tool
Upon receiving your Pandrol tool, make sure to list serial number above so that a good record is kept for
order information.
Pandrol hydraulic tool list
AllPandrolHydraulicToolsoperateat5GPM(19LPM)or10GPM(38LPM)@2000PSI(140BAR)
Power units:
00100K–Gasolinepowered(1)10GPMor(2)5GPMcircuits
02900A–Diesel(1)10GPMor(2)5GPMcircuits(optionalcatalyticexhaust)
05500–Twinpowerdualcircuit(1)10GPMor(2)5GPMcircuits&5000wattgenerator
02050RM–Modularpowerunit(1)9GPM
03700A–Electricpower(1)10GPMor(2)5GPMcircuits
Grinders:
09200A–Precisionfroggrinder
06000–Prolegrinder
06950&06950A–Multi-purposegrinder
05900–Frog/prolegrinder(triggerversionavailable)
00700–Railsurfacingguide
04600–Straightstonegrindercwrotation(triggerversionavailable)
04700–Straightstonegrinderccwrotation(triggerversionavailable)
07500 – Chamfer tool
04800–6"Cupstonegrinder(triggerversionavailable)
00600–8"Cupstonegrinder
05400–Anglegrinder
09300-Headwashgrinder
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Track tools:
03900A–Reversingrailsaw
05100A&05100B–Powerweldshear
03500–Selffeedraildrill
04500D–1/2”Hydraulicdrillimpactwrench
08200 – Tamper
02800A–60Tonbridgespreader
01200 – Spring anchor applicator
01100A–Spikepuller(Single,2stage&triggerversionsavailable)
00800A–16”Railsaw
05000–Handpumpweldshear
02500–10GPM1”Impactwrench
08300–Spikedriver
01600A–5GPM1”Impactwrench
01100RM–Light-weightspikepuller
Other products:
Hydraulicmanifolds
Hydraulictestgauges
Hosereels
Hydraulichoses
Accessories
Drill bits
ShearBlades
SawBlades
GrindingStones
Sockets
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10. Assembly
10.1. 14 Hp kohler engine breakdown
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10.2. Engine module assembly
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10.3. Engine module assembly breakdown
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