Cembre PCMD-FC Operation And Maintenance Manual Download

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3. DESCRIPTION OF THE MACHINE

TRANSPORTATION HANDLES

OIL COOLING FINS

HYDRAULIC PUMP

WORKLIGHT ON/OFF SWITCH

ELECTRICAL CONNECTOR SOCKET

QUICK RELEASE FEMALE AUTOMATIC HYDRAULIC COUPLER

HANDLEBAR LOCKING WINGNUT

QUICK RELEASE MALE AUTOMATIC HYDRAULIC COUPLER

BRAKE RELEASE CONNECTOR HOLDER (WHEN NOT IN USE)

WORKLIGHT

HANDLEBAR

BRAKE RELEASE LEVER

CLAMP DRIVE BUTTON FOR INSERTION/EXTRACTION

UPLIFT SETTING BUTTON

CLAMP CONTROL SWITCH

CLAMP RETURN BUTTON

STOP/EMERGENCY BUTTON

ENGINE

WORKLIGHT

PUMP UNIT FASTENING/RELEASE KNOB

ELECTRICAL TERMINAL BOX

DISPLAY

FRAME

TRANSPORT HANDLE

CLAMP UNIT LOCATING PINS

PUMP UNIT LOCATING PINS

SLEEPER LIFT PISTON

INSERT/EXTRACT PISTON

ELECTRICAL CONNECTOR

HYDRAULIC FLEXIBLE HOSES

MACHINE LIFT HEIGHT ADJUSTER

TRANSPORTATION HANDLES

REAR ARM WHEEL

EXTRACTION HOOK FASTENING/RELEASE KNOB

HEIGHT SETTING DEVICE

RAM STROKE ADJUSTMENT RING NUT

BRAKE RELEASE CONNECTOR SOCKET

GAS SPRING

REAR ARM WHEEL LOCK/RELEASE KNOB

INSERTION/EXTRACTION TOOTH

CONTRAST FOOT

TRANSPORTATION HANDLES

WHEEL ARM FASTENING/RELEASE KNOB

FRONT HEIGHT ADJUSTMENT KNOB

CLAMP UNIT FASTENING/RELEASE KNOB

CARRIAGE WHEELS

SUPPORT WHEEL

SUPPORT WHEEL ADJUSTMENT LEVER

ARM

Summary of Contents for PCMD-FC

Page 1: ...1 MACHINE FOR PANDROL FASTCLIP FASTENING PCMD FC ENGLISH OPERATION AND MAINTENANCE MANUAL 16 M 197 E ...

Page 2: ...16 4 9 Operation 17 4 9 1 Inserting clips 17 4 9 2 Extracting clips 18 4 9 3 Adjusting the contrast foot for extraction 18 5 Adjusting the piston stroke 19 5 1 Adjusting the piston stroke for clip insertion 19 5 2 Adjusting the piston stroke for clip extraction 20 5 2 1 Parking position 20 5 2 2 Insulator change position 20 6 Display 21 6 1 Information screens 21 6 2 Warnings 21 6 3 Errors 22 7 St...

Page 3: ...priate to your sector of operation Always follow fuelling and refuelling practices and procedures normally required by your employer and or appropriate to your sector of operation Only authorised personnel shall start operate and maintain the machine The design or configuration of the machine shall not be modified other than by Cembre Cannot be used over switches and crossings Not to be used near ...

Page 4: ...t by rope pull with automatic rewind Hydraulic pump Max pressure MPa 25 Oil supply 35 litres minute Oil capacity kg 4 5 Speed rpm 3500 Recommended oil kg lbs PANOLIN HLP SYNTH E68 Acoustic noise 1 dB LpA 86 4 A LpCPeak 130 C LWA 101 0 A Vibration 2 m s2 4 63 max 1 GENERAL CHARACTERISTICS Pandrol Fastclip is a Pandrol Ltd trademark 1 Directive 2006 42 EC annexe 1 point 1 7 4 2 letter u LpA weighted...

Page 5: ...ck 3rd wheel bar forstabilityandverticalpositioning thethirdwheel 47 issupplieddisconnected from the bar 49 2 1 Transporting the machine The four units are well balanced for easy transportation in accordance with the table and diagrams in Fig 1 For uniform weight distribution when carrying the pump and clamp units always use the transportation handles provided Ensure appropriate Personal Protectiv...

Page 6: ...FASTENING RELEASE KNOB 21 ELECTRICAL TERMINAL BOX 22 DISPLAY 23 FRAME 24 TRANSPORT HANDLE 25 CLAMP UNIT LOCATING PINS 26 PUMP UNIT LOCATING PINS 27 SLEEPER LIFT PISTON 28 INSERT EXTRACT PISTON 29 ELECTRICAL CONNECTOR 30 HYDRAULIC FLEXIBLE HOSES 31 MACHINE LIFT HEIGHT ADJUSTER 32 TRANSPORTATION HANDLES 33 REAR ARM WHEEL 34 EXTRACTION HOOK FASTENING RELEASE KNOB 35 HEIGHT SETTING DEVICE 36 RAM STROK...

Page 7: ...7 26 25 27 29 30 39 32 33 35 34 3rd WHEEL BAR CLAMP UNIT CARRIAGE 46 42 45 43 37 PUMP UNIT 38 41 40 31 44 28 24 01 03 04 06 08 10 13 18 19 22 23 14 15 FIG 2 12 02 20 16 09 17 11 07 05 21 36 49 47 48 ...

Page 8: ...dles 01 and handlebar 11 Rest the pump unit on the clamp unit and align pins 26 with the relevant locating holes on the under side of the pump unit Release the knobs to lock 5 Unscrew handlebar locking wingnut 07 and rotate handlebar 11 to a confortable position tighten the wingnut fully to lock the handle 6 Plug electrical connector 29 into socket 05 Attach flexible hydraulic hoses 30 by means of...

Page 9: ...9 4 2 7 6 3 5 1 FIG 4 01 11 09 39 32 33 30 43 25 26 47 RAILS SLEEPER D IR E C T IO N O F M O V E M E N T 24 42 45 12 06 08 07 44 31 29 ...

Page 10: ...dernormalconditions thetimetakento removethemachinefromtherailisapproximately 60 seconds 4 3 Moving the machine To move the machine along the rail the rear arm must be raised to prevent the clamps knocking against the Fastclip as follows 1 Pullandturnknob 39 Thewheelarmwillbefreed Ref to Fig 6 2 Lifttheunitbythehandles thetwogasspringswill facilitatefulllifting thetwospringscanbeadjusted using kno...

Page 11: ...switch 15 Settings button 14 enables the machine to memorise the clamp position set for sleeper lifting Clamp control selector 15 allows the selection of insertion IN or extraction OUT of the clamps Clamp return button 16 enables the clamps to be brought back to their starting position With clamp control selector 15 on OUT it enables insertion of the clamps at a lower speed Stop emergency button 1...

Page 12: ...n of the Pandrol Fastclip FASTCLIPS have 3 positions PARKING POSITION All components are captive INSTALLED POSITION The Fastclip holds the rail INSULATOR CHANGE POSITION The Fastclip is withdrawn to the rear detent to facilitate side post insulator removal FIG 8 FASTCLIP ...

Page 13: ... 3 positions PARKING POSITION All components are captive INSTALLED POSITION The FE clip holds the rail INSULATOR CHANGE POSITION The FE clip is fully extracted and the insulator can be removed Side post insulator Toe insulator FE clip Shoulder FIG 9 FE CLIP ...

Page 14: ... FCX clip Toe insulator Shoulder Side post insulator PARKING POSITION All components are captive INSTALLED POSITION The FCX clip holds the rail INSULATOR CHANGE POSITION The FCX clip is withdrawn to the rear stop to facilitate side post insulator removal FIG 10 FCX CLIP ...

Page 15: ... sleeper Line up the side of the machine so that the clamp unit is parallel with the upper surface of the railhead If this is not the case adjust knob 44 on the carriage Ref to Fig 11 Toliftthemachineturnknob 44 anti clocwise To lower the machine turn it clockwise The measuring scale will facilitate adjustment by precisely defining the correct position of the machine 4 8 2 Stable support of both i...

Page 16: ... the piston 27 and loosen the nut D with a 18 mm wrench Rotate the threaded rod so that the foot is resting on the gauge and then tighten the nut D again Remove the HSD 35 and put it back in its seat 4 8 4 Adjusting the clamp position Procedure to be carried out on the clip in parked position Start the engine see 7 Push the machine so that it is in line with the clip to be operated on see 4 3 Posi...

Page 17: ...peration means see 4 5 4 6 and 4 7 1 Moving from parking position to installation position 2 Moving from insulator change position to installation position Push the machine to the clips on which operations are to be performed see 4 3 IMPORTANT when performing the first insertion operation the correct stroke of the rams will have to be established so the clips are positioned precisely see 5 1 Ensur...

Page 18: ...n stroke Turn the upper ring nuts used for the insertion of the clips to prevent the tooth from scraping the rail web Press the clamp operation button 13 to make the teeth advance 40 bringing the clips to the parked position Once the extraction is complete the clamps are retracted automatically while still holding down the clamp operation button 13 Lift the machine move on to the next clips and re...

Page 19: ...ce X tighten the upper ring nut towards the number three Severalattemptsmaybenecessarytoobtaintheexactclipposition usingthegraduatedscaletomake fine and exact adjustments Having found the exact adjustment for one piston position the ring nut of the other piston at the same value on the graduated scale The lower ring nut establishes the piston stroke when the clamp is returning towards the starting...

Page 20: ...on see 4 9 2 and check the position of the clip In the parked position the cap on the clip should normally be at a predefined distance X from the edge of the spacer insulator Ref to Fig 19 except where stated otherwise If this is not the case to increase the distance X during extraction unscrew the lower ring nut towards zero then re try extraction Conversely to reduce the distance X tighten the l...

Page 21: ... which will then appear each time the tool is started and during the entire work cycle Cembre logo n full cycles n working hours standard factory set screen n of hours since last maintenance n of hours until next maintenance Cembre logo machine model Machine serial n The capacitive menu selection button may not work if touched using objects or when wearing gloves therefore always operate it using ...

Page 22: ...es not work the memory is damaged contact Cembre Failure to store work data in eeprom Electronics board faulty and needs replac ing contact Cembre Pressuresensordisconnectedorfaulty at start up Check the connection If the error persists replace the sensor contact Cembre Pressure offset error at start up Replace the pressure sensor contact Cembre Acceleratorcableerrordisconnectedor disconnected Che...

Page 23: ...ll not start unless the red but ton 17 is lifted Move the fuel stopcock to ON position Ref to Fig 20b Move the air lever to CLOSE position Ref to Fig 20b Do not use the air lever if the engine is hot and the air temperature is high enough Start the engine by pulling the starting cable until resistance is felt then pull with force Ref to Fig 20c IMPORTANT Do not allow the cable knob to return force...

Page 24: ...out by authorised persons in accordance with a safe system of work and Cembre instructions Before servicing or removing any parts of the machine stop the engine and allow it to cool Always removethesparkplugcapfromthesparkplugwhenservicingtheenginetopreventaccidentalstarting 8 1 Routine maintenance of the machine At the end of each day wipe the machine carefully using a clean cloth being careful t...

Page 25: ...oves without resistance and is not damaged With brake released check the wheel rotates freely Check that when handlebar lever 12 is in the raised position the brake is engaged Ensure the wheel is clean of dirt and mud Check that before assembly the wheel does not rotate one full turn in either direction Ensure brake coupling above rear wheel is free of dirt and mud Every 6 months Check wheel pocke...

Page 26: ...not use hydraulic brake fluid 8 1 4 Replacing the hydraulic pump oil filter Detach connector C unscrew ring nut G paying attention to the seal inside it and remove solenoid coil B Ref to Fig 23 Use a 16 mm spanner to unscrew the nut on the filter and replace the filter Ref to Fig 25 Oncethishasbeencompletedrelocatethesolenoid coil of the electro valve its connector and ring nut 8 1 5 Adjusting the...

Page 27: ...formation on the engine refer to the HONDA owner s manual 8 1 6 Changing the gas springs Replace the gas springs when required as follows On both sites loosen screws A with an 8 mm Allen keyandscrews B witha6mmAllenkeythenremove the casing Ref to Fig 27 Unlock the arm in order to extend the springs Ref to Fig 28 Use a finger to release the retaining rings located at the ends of the spring and simu...

Page 28: ...ity Replacement Check reservoir level Top up if necessary Replacement Replacement Replacement Replacement PERIODIC OVERHAUL Performed at the prescribed intervals or at the number of indicated working hours or at the occurrence of indicated extraordinary events At every use 300 hours Presence of evident signs of wear ITEM ACTION Complete machine Bolts and nuts Flexible hose Hydraulic couplers Clamp...

Page 29: ...29 FIG 30 DIMENSIONS mm XXXXXX Pump unit serial number 1223 1892 613 1750 1085 ...

Page 30: ... SETTINGS ADJUSTMENTS We suggest recording all adjustable Ring nut settings in the table alongside to facilitate quick resetting in future From parking position to installation position From insulator change position to installation position Complete insertion of the Fastclip From installation position to parking position From installation position to insulator change position Complete extraction ...

Page 31: ...31 ...

Page 32: ...o 6 y 8 28850 Torrejón de Ardoz Madrid España Teléfono 91 4852580 Telefax 91 4852581 E mail comercial cembre es www cembre es Cembre GmbH Heidemannstraße 166 80939 München Deutschland Telefon 089 3580676 Telefax 089 35806777 E mail sales cembre de www cembre de Cembre Inc Raritan Center Business Park 181 Fieldcrest Avenue Edison New Jersey 08837 USA Tel 732 225 7415 Fax 732 225 7414 E mail sales U...

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