PANDROL 03700A User manual

Partners in excellence
ENG_OMM_ELECTRIC_POWER_UNIT_P01
30th November 2021
OPERATION AND MAINTENANCE
MANUAL
Electric
Power Unit
MODEL 03700A

1. Preface
2. Revision
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Thank you for choosing Electric Power Unit!
You are now the owner of a quality product from Pandrol.
This manual aims to help you get to know your new Electric 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 2021-11-30 New Manual

Table of Contents
1. Preface 2
2. Revision 2
3. Safety Information 5
3.1. General 5
3.2. Safety actions 5
3.3. Personal/Safety equipment 6
3.4. Safety precautions 6
3.5. Qualiedpersonnel  7
4. Summary 8
5. Operation 9
5.1. Valve positioning 9
5.2. Changing tools 10
5.3. Coldweatheroperation  10
6. Troubleshootingguide  11
7. Calibrationproceduresfor03700Amanifold  13
7.1. Flowcalibration 13
8. Relief pressure calibration 14
9. Flowcontrolsetting  15
10. Finalcalibrationanddoublecheck  16
11. Reviewofhydraulicprinciples  17
11.1. Hydraulicformulas  17
11.2. Backpressure  17
12. Maintenance 18
12.1. General 18
12.2. Warninglabelsandinformationsymbols 19
13. Limitedwarranty  20
13.1. Exclusionstolimitedwarranty  20
13.2. Limitation of liability 20
14. Customer information 21
15. Assembly  23
15.1. Flowdiagram  23
15.2. Framepartsdiagram 24
15.3. Framepartslist 25
15.4. Engineandpumppartsdiagram 26
15.5. Engineandpumppartslist  27
15.6. Hydraulicandstarterrelaypartsdiagram  28
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15.7. Hydraulicandstarterrelaypartslist  29
15.8. Toolmanifoldpartsdiagram  30
15.9. Toolmanifoldpartslist  31
15.10. Electricdiagram  32
16. Disclaimer 33
17. Contact 33
18. RecyclingandEnvironment  33
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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.
• Alwaysturnpowerunit"OFF"anddisconnecthosesbeforeperforminganymaintenance.
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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.
WARNING!
• Do not touch electrical connections before you rst ensure the power has
been disconnected. Only qualied personnel should attempt the installation
and maintenance of this equipment.
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Engine Flow Pressure Dimensions Weight
20 Hp electric
240/360/480 Vac
3 Phase
* See note about
hertzrequirements
5GPM(19LPM)
or
10GPM(38LPM)
Fluid:hydraulic
5usgal(18.9)liters
200PSI(140BAR) A-40”(101.6cm)
B-26”(66cm)
C-30”(76.2cm)
486lbs(220kg)
4. Summary
ThePandrolElectricPowerUnitisdesignedtodeliver2-5
GPMcircuitsor1-10GPMcircuitat2000PSIforhydraulic
tooloperationsinbuildingsorotherclosedenvironments.Itis
perfect for maintenance shop testing of tool repairs. The unit is
equippedwithheavydutywheelsformobility.
Accessories:
02326E-Hosereelequippedwith50’transmissionhose.
02323K-Hosereelequippedwith25’transmissionhose.
*Hertzrequirementsvarybycountry.
Specifyrequirementswhenordering.
Fig 1.
Fig 2. Fig 3.
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NOTE!
• When operating a 10 GPM tool you cannot have any other tool connected to
the 5 GPM ports, even if the tool is not being used.
5. Operation
Always check the power unit’s hydraulic uid level and ll reservoir as required before
starting
• Tostartthepowerunit,checktomakesurethatbothcontrolvalvesareinthe"OFF"position.
• Depressthestartbuttononthebreakerboxlocatedonthefrontoftheunit.
• Connectthepowertransmissionhosetoeitherthe5or10GPMports,dependingontheowrequiredforthe
toolyouwillbeusing.
• Connectthetool(s)tothepowertransmissionhosebeforeturningcontrolvalvesatpowerunit"ON".
• Rotateappropriateowcontrolvalves.(See“valvepositioning”inthismanual.)
• Tochangetools,turnthecontrolvalvestotheo󰀨position.
• Toshutdownthepowerunitturnthecontrolvalvestothe"OFF"positionanddepresstheredstopbuttonon
thebreakerbox.
5.1. Valve positioning
The03700apowerunitisdesignedtooperateeither(1)toolat10GPM(38LPM)or(2)toolssimultaneouslyat5
GPM(19LPM).Refertooperatinginstructionsforeachtooltodetermineowrequirements.
BEFORE STARTING!
• This power unit is driven by an electric motor. It is factory wired for the
voltage requested by the purchaser. Electrical contacts and wiring vary at
di󰀨erent locations. Due to this, have a qualied person or technician ensure
electrical system compatibility
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5 GPM tools:
Tooperatea5GPMtool,connectbothtoolstotheportsmarked5GPMandturn"ON"thevalvecorrespondingto
each tool port.
10 GPM tools:
Tooperatea10GPMtool,connectittotheportmarked10GPMandturnonbothcontrolvalves.
5.2. Changing tools
• Turnthecontrolknobstothe"OFF"positionbeforedisconnectinghoses.
• Oncethetoolhasbeenchanged,turnthevalvestothe"ON"positiondependingonowrequirementsofthe
toolbeingused.
5.3. Cold weather operation
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.
NOTE!
• Refer to operating procedures of this manual before starting
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OPERATION AND MAINTENANCE MANUAL I ENG_OMM_ELECTRIC_POWER_UNIT_P01 I 30th November 2021
@Pandrol 2021