PANDROL 02800A User manual

Partners in excellence
ENG_OMM_BRIDGE_SPREADER_P01
02th December 2021
OPERATION AND MAINTENANCE
MANUAL
Bridge
Spreader
MODEL 02800A

1. Preface
2. Revision
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Thank you for choosing Bridge Spreader!
You are now the owner of a quality product from Pandrol.
This manual aims to help you get to know your new Bridge Spreader, 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 2021-12-02 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blades  9
5.2. Coldweatheroperation  9
6. Reviewofhydraulicprinciples  10
6.1. Hydraulicformulas  10
6.2. Backpressure  10
7. Maintenance 11
7.1. General 11
7.2. Warninglabelsandinformationsymbols 12
8. Limitedwarranty  13
8.1. Exclusionstolimitedwarranty  13
8.2. Limitation of liability 13
9. Customerinformation  14
10. Assembly  16
10.1. Schematic  16
10.2. Generalpartsdiagram 17
10.3. Generalpartsdiagram  18
10.4. Generalpartslist  19
10.5. Hydraulichosesandttingsdiagram  20
10.6. Hydraulichosesandttingsdiagram  21
10.7. Hydraulichosesandttingslist  22
10.8. Controlvalvepartsdiagram  23
10.9. Controlvalvepartslist  24
11. Disclaimer 25
12. Contact 25
13. RecyclingandEnvironment  25
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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andrepairleaksimmediately.
• Do not carry the tool by the pigtail hoses.
• Alwayschecktheworkareaforanytrashwhichmayignitefromsparks.
• Alwayschecktheareaforsmolderingtiesortrashbeforeleavingthesite.
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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.
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4. Summary
ThePandrolBridgeSpreaderistheidealtoolforcrewsdoingbridgemaintenance.Thehydrauliccircuitis
equippedwitharemotepowerupanddowncontrolmanifold,withbuiltinowcontrolforprotectionandcomes
witha25’transmissionhose.Cylindersareprepipedterminatingatquickdisconnectcouplerswhichallowfor
quick setup time.
Flow Pressure Dimensions Weight
5GPM(19LPM) 2000PSI(140BAR) L-194”(492.76cm)
W-6”(15.24cm)
H-29”(73.66cm)
1619lbs(734kg)
Accessories:
02850-Jackstandkit
Fig 1.
Fig 1.
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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
• Withthepowersourceinthe"OFF"position,connectthehoses.Donotdragtheservicehosebypulling
withthetool.Looptheservicehoseintheworkareainsuchawaytorelievestressonthehoseandquick
disconnectttingswhileworking.Beawareofhoselocationatalltimes.
• Connectthebridgespreadertothepowersource.
• Turnthepowersource"ON"tosupply5GPMtobridgespreader.
• Pullthecontrolleverbacktoraisethebridgespreader.
• Oncebridgespreaderhasraisedbridgesu󰀩cientenoughtoremovecappowersourcecanbedisconnected
withoutbridgefalling.
• Onceworkhasbeencompleted,connectbridgespreaderbacktopowersourceandpushcontrolleverforward
tolowerbridgebackoncap.
• Turnthepowersource"OFF"beforedisconnectingbridgespreader.
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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.
5.1. 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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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 o󰀨. 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.
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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
o󰀩cer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. Schematic
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10.2. General parts diagram
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10.3. General parts diagram
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10.4. General parts list
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10.5. Hydraulic hoses and ttings diagram
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