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
10av26
OPERATION AND MAINTENANCE MANUAL I ENG_OMM_BRIDGE_SPREADER_P01 I 02th December 2021
@Pandrol 2021