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OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 2023-03-16

@Pandrol 2023

NOTE

This only applies for Fasclip since e-clip does not have any grease nippes.
Lubricate every 40 h or once per week.
Use Shell Alvania EP2, BP Energrease LS-EP-2 or similar. Use grease gun and apply until fresh

grease emerges. Använd en fettpistol och applicera tills färskt fett pressas ut. Wipe off excess

grease.
Replace damaged grease nipples.

11.4. Lubrication points on Fastclip

Fig 103.

Fig 104.

11.5. Engine

Please read the engine user manual for manintanance instructions.

Fig 102.

Summary of Contents for CD200 IQ

Page 1: ...Partners in excellence ENG_OMM_CD200IQ_P03 2023 03 16 CD200 IQ OPERATION AND MAINTENANCE MANUAL...

Page 2: ...2 av 82 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 2023 03 16 Pandrol 2023...

Page 3: ...cription 17 3 1 Intended Use 17 3 2 Main Components 17 3 3 Technical Specifications 18 3 4 Drawings Fastclip 19 3 5 Drawings e CLIP 20 4 Machine Components 21 4 1 Main Unit Power Pack 21 4 2 Trolley 2...

Page 4: ...ide of Operation 51 8 Operation FASTCLIP Machine 54 8 1 Clipping 54 8 2 Sleeper Lifting Operation 57 8 3 De clipping 58 8 4 Storing clip de clipping plates 62 9 Operation E Clip Machine 63 9 1 Adjustm...

Page 5: ...Test 73 11 10 Brake pads 73 11 11 Inspection of rail wheel profile 74 11 12 Examination of clipping pads 77 11 13 Examination of de clipping pads 77 12 Nominal mounting torque Nm 78 13 Warranty and S...

Page 6: ...ine It is originally written in Swedish and then translated into the local language by Pandrol AB Pandrol AB reserves the right to change specifications equipment instructions and maintenance guidelin...

Page 7: ...minimum National conditions standards and regulations override conditions standards and regulations described in this document Any adjustments or service on the machine only allowed to be done by qua...

Page 8: ...d and understand all safety regulations and warnings stated both in the operator manual and in this manual before any installation operating or performing maintenance on this machine Locate the emerge...

Page 9: ...g CD200IQ on track choose a suitable place with as little interfering obstacles and with as firm and flat ground as possible If the permissible per person lifting weight is exceeded when lifting or ca...

Page 10: ...tem is designed to supervise the machine in a safe way to avoid damage or injury to the machine or a person Text within brackets refers to number in figure unless otherwise specified The machine is eq...

Page 11: ...protection according to chapter 2 6 in this manual 1 1 4 Live Current DANGER Live current High voltage live current is very dangerous and can cause serious injury or death of a person Contact with el...

Page 12: ...can be broken down into modules 1 1 8 Danger due to noise WARNING Risk of permanent damage particularly to hearing if the user does not continuously wear suitable hearing protection Wear hearing prote...

Page 13: ...y box should be tied back and insulated after being disconnected Take care to keep electrolyte away from eyes skin and clothing Protective clothing and goggles must be worn during ALL battery repairs...

Page 14: ...for repair must be protected against damage and handled with care Following any reportable incident or accident involving the machine a detailed examination must be carried out around the damaged or s...

Page 15: ...710051 710017 710052 710135 710062 710063 710187 710019 710020 710021 2 6 Warning Signs and Decals The images below describe the valid signs that apply to this machine The signs must remain visible t...

Page 16: ...ence Work on the CD200 IQ machine is only to be carried out by qualified personnel well informed and educated in general railway workmanship and specifically in the conditions standards and regulation...

Page 17: ...and inclinations Choose the type of tool in the control panel 2 The Clip Driver CD200 IQ is rapid and easy to use and it is ergonomically operated by one single operator The Clip Driver CD200 IQ can c...

Page 18: ...ft 19 1 Nm 2 500 rpm 19 77 Nm 2600 rpm Fuel Unleaded 86 octane or higher Automotive gasoline unleaded Fuel tank capacity 5 3 litre 5 3 litre Electronics Voltage 12 volt DC Ground Negative Hydraulics P...

Page 19: ...19 av 82 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 2023 03 16 Pandrol 2023 1142 mm 2202 mm 2111 mm 1410 mm gauge 1435 3 4 Drawings Fastclip Fig 5 Fig 6 Fig 7...

Page 20: ...20 av 82 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 2023 03 16 Pandrol 2023 1103 mm 2111 mm 1410 mm gauge 1435 2202 mm 3 5 Drawings e CLIP Fig 8 Fig 9 Fig 10...

Page 21: ...x 13 Slide carriage 6 Emergency stop 14 Engine starter key 7 Trolley 15 Lifting eye complete machine 8 Beam 16 Lifting eye power pack 4 2 Trolley The trolley for the CD200 IQ supports the machine and...

Page 22: ...trolley there is a possibility that the trolley can run along the track For that reason the CD200 IQ is equipped with brakes that will automatically stop the trolley from running away when removing th...

Page 23: ...ndle sleeper lifter control is pressed in towards the handlebar the cylinder takes its fully extended position which is the normal operation position Pos Description 1 Height adjustment knob 2 Lift cy...

Page 24: ...during the clipping operation The clips are installed when it reaches the center mark It will then move back to the starting position and the cycle is complete When the indicator is in the EXTRACT MO...

Page 25: ...anism e CLIPS The work head is in the operating position low when the dead mans handle is not pressed When it is pressed in towards the handle bar the lifting cylinder 2 will extract to its full lengt...

Page 26: ...for the operator The CD400IQ have four different work modes described here below Fig 19 Fig 20 Pos Description 1 Push button clipping 2 Push button de clipping 3 Dead man s grip Sleeper lift function...

Page 27: ...ight On Off Worklight Off Boost 6 The Boost function can be used in manual mode to gain extra power at de clipping if a clip is jammed due to rust or similar IMPORTANT Always make sure that no damage...

Page 28: ...een tools and select language Switch between fastclip e clip by press and hold the button 6 Pos Description Fig 23 1 Navigate upward 2 Navigate downward 3 Switch menu page 4 Navigate left 5 6 Navigate...

Page 29: ...IQ_P03 I 2023 03 16 Pandrol 2023 1 2 3 4 5 6 5 2 4 Menu page Error codes This page displays error codes in the event of system error Please contact Pandrol in the event of system error Pos Description...

Page 30: ...3 Pull and hold the dead man s grip 4 Press the button 5 to perform clipping 5 Press the button 6 to retract the clipping arms 5 3 2 Manual de clipping Fig 26 Manual de clipping mode is used at machi...

Page 31: ...s grip to lower the tool against the rail 2 Press and hold the button 5 until the tool is pressed against the clips 3 Verify that the tool is fully attached to both clips Pull the dead man s grip to...

Page 32: ...5 4 2 1 5 4 Electrical System The CD200 IQ electrical system consist of high quality components well protected from wear and weather condition The electrical system require a minimum of service and ma...

Page 33: ...in combination with the control system gives the CD200IQ its unique charateristics The hydraulic return filter is a Spin On filter that enables easy replacement during service maintenance The hydraul...

Page 34: ...5 6 Hydraulic System e clip Hydraulic system illustration that describe the difference between FC FE and e clip tools The e clip tool has four hydraulic cylinders working in pairs The FC FE use one hy...

Page 35: ...ation is necessary fasten the machine safely on to a loader platform or lorry standing upright on its supporting legs Only qualified personnel are allowed to operate the lifting machinery The lifting...

Page 36: ...individual parts should only be lifted mechanically Use appropriate slings chains and lifting accessories when lifting CD200 IQ The CD200 IQ can be stored as follows complete unit separated into 2 par...

Page 37: ...ck couplers 6 5 Disassemble CD200IQ 6 5 1 Disassemble the Powerpack The Powerpack is disassembled by sliding backward and lift 1 Disconnect the brake wire from the trolley 2 Disconnect the hydraulic h...

Page 38: ...Fig 38 Fig 36 Fig 37 4 Slide out of position and lift Place the powerpack onto a firm surface 6 5 2 Disassemble the Workhead 1 Unlock the tool from the trolley by opening turning the hatches Fig 37 2...

Page 39: ...nt operator When placing CD200IQ on track choose a suitable place with as little interfering obstacles and with as firm and flat ground as possible Ensure that the road to the workplace is safe and fr...

Page 40: ...be lifted manually The same applies under emergency conditions Use appropriate slings chains and lifting accessories when lifting CD200IQ 1 Choose a suitable place with as little interfering obstacle...

Page 41: ...e lifting eye according to Fig 43 The unit can also be lifted manually 6 Place the powerpack in position above the slider carriage Fig 43 7 Lower the power pack Ensure that both sides of the power pac...

Page 42: ...atically engaged Fig 46 Fig 47 Brake handle 10 To move the CD200IQ and release the brake press and hold red handle 1 As soon as the handle is released the machine is braked release locked 9 Install th...

Page 43: ...metrically and handled with two hands at all times Team lifting of this nature should be controlled by one person who should control the handling operation giving clear instructions Lifting the trolle...

Page 44: ...E MANUAL I ENG_OMM_CD200IQ_P03 I 2023 03 16 Pandrol 2023 Handle Handle WARNING HEAVY WEIGHT Model Weight kg FASTCLIP 254 e CLIP 272 Fig 49 Overview Lifting handles Weight Table 7 4 Lift Weights Manual...

Page 45: ...2023 03 16 Pandrol 2023 Fig 50 Overview lifting handles Powerpack 7 4 2 Manual Handling Power Pack Fig 51 Weight balance Powerpack VARNING HEAVY WEIGHT Description Weight kg Powerpack 103 Weight Tabl...

Page 46: ...03 16 Pandrol 2023 1 3 4 2 Fig 52 FE FC work head Fig 53 Fastclip work head VARNING HEAVY WEIGHT Description Weight kg Fastclip arbetshuvud 97 Weight Table Pos Weight kg 1 22 2 22 3 26 5 4 26 5 Weigh...

Page 47: ...3 03 16 Pandrol 2023 1 3 4 2 Fig 54 e clip work head Fig 55 e clips work head VARNING HEAVY WEIGHT Description Weight kg e tclip arbetshuvud 115 Weight Table Pos Weight kg 1 24 2 24 3 33 5 4 33 5 Weig...

Page 48: ...ANCE MANUAL I ENG_OMM_CD200IQ_P03 I 2023 03 16 Pandrol 2023 Fig 56 Trolley Fig 57 VARNING HEAVY WEIGHT Description Weight kg Trolley 54 Weight Table Pos Weight kg 1 32 5 2 21 5 Weight balance trolley...

Page 49: ...check the inclination setting see inscription on the inclination piece There are three different options 1 20 1 30 and 1 40 see spare parts manual or consult Pandrol AB for more information To change...

Page 50: ...safety zone e g between the rails or on the side that is in the safety zone Fig 60 1 Open the two locking handles on the slide carriage 2 Rotate the machine to desired work direktion NOTE Lift the ma...

Page 51: ...ley is now hold in position by the brakes Fig 66 2 Open the handles Pos 1 Fig 66 on both sides of the trolley 3 Push the slide carriage to the opposite side of the trolley Use one hand on the operatin...

Page 52: ...ise it will not be possible to get it firmly locked There should be some force required to close the latch If it locks too easily the slide carriage will not be rigidly locked This can be adjusted usi...

Page 53: ...53 av 82 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 2023 03 16 Pandrol 2023...

Page 54: ...TE The machine is NOT limited to the combinations stated in this table These combinations are only examples Fig 70 Fig 71 8 1 1 Settings Before Clipping 1 Install the clipping shoe 1 in the correct po...

Page 55: ...pping shoes are in the right height relative the clip This depends on the type and dimension of the actual rail If necessary adjust the height of the work head with the adjustment screw 1 Fig 73 The d...

Page 56: ...et the tool to clipping mode by pressing the button 1 4 Position the work head centered above the clip assembly 5 Pull and hold the dead man s grip 7 6 Press an hold the button 5 to operate the clippi...

Page 57: ...and the sleeper will be lifted up towards the rail 4 When the sleeper is lifted the clipping operation will be completed automatically 5 Move on to the next sleeper and repeat the sequence if necessa...

Page 58: ...e current clip assembly The current position can be determined using the scale on the side of the shoe 2 Fig 78 Fig 78 Fig 79 Clips Rail type No FASTCLIP FE UIC60 2 FASTCLIP FE S49 S54 4 FASTCLIP FC15...

Page 59: ...xt mode by pressing the button 1 Fig 80 5 Activate the dead man s grip 7 Fig 81 check that the de clipping shoes are in the right height relative the clip This depends on the type and dimension of the...

Page 60: ...tes 1 Open the arms by pressing button 5 Fig 81 2 Adjust the four reference plates by opening the excentric lock handle 1 Fig 85 3 Position the reference plate to fit the actual rail type 4 Position t...

Page 61: ...Stop The rubber stop 1 can be reversed to fit different types of clips To reverse the rubber stop 1 Unscrew the four screws 2 2 Reverse the rubber stop unit 1 3 Re tighten the screws 2 Repeat the proc...

Page 62: ...ine to manual mode by pressing the button 2 on the control panel 3 Set the tool to de clipping mode Ext by pressing the button 1 on the control panel 4 Position the work head over the center of a clip...

Page 63: ...not adjust according to instructions below 1 Loosen the four excentric lock handles 3 Fig 92 2 Turn the knob 1 Fig 92 to adjust the height until the workhead is in parallel with the rail Fig 91 3 Tig...

Page 64: ...the frame The frame must slide easily to center with the indicator toward the center marker This adjustment shall be carried out weekly If adjustment is needed 1 Loosen the screws 1 2 Loosen the nuts...

Page 65: ...g the button 2 on the control panel 3 Check that the indicator 1 Fig 97 is set to Installation mode 4 Set the tool to clipping mode Inst by pressing the button 1 5 Position the workhead centered above...

Page 66: ...de clipping function and release the jammed clip 9 3 1 De clipping 1 Make sure that all neccesary adjustments and settings described in previous chapters are carried out 2 Set the machine to manual mo...

Page 67: ...not being fully installed Possible causes Clipping shoe not in correct position Clipping pressure to low Solution Change position of clipping shoe Pressure switch for clipping function may need to be...

Page 68: ...original spare parts are used and the work is carried out by a qualified service provider approved by Pandrol All warranty related work must be approved and documented by Pandrol AB before warranty r...

Page 69: ...ad Lubricate with SKF LEGP 2 or similar X Slide plates on trolley Clean and lubricate with oil X Screws Lubricate with oil X Engine See Honda instruction manual X X X Decals and signs Replace worn and...

Page 70: ...40 h or once per week Use Shell Alvania EP2 BP Energrease LS EP 2 or similar Use grease gun and apply until fresh grease emerges Anv nd en fettpistol och applicera tills f rskt fett pressas ut Wipe o...

Page 71: ...lic fluid level with the dipstick Clean the area around the filling cap and fill with hydraulic fluid if necessary 11 7 Hydraulic filters Check Fig 106 Breathing filter Check fhe following filters Bre...

Page 72: ...ydraulic fluid Hydraulic fluid approved by Pandrol must fulfill one of the standards given below DIN 51524 del 3 SS 15 54 34 ISO 11158 HV Example Shell Tellus S2 M46 BP Bartran HV 46 Hydraulic fluid s...

Page 73: ...the correct values Pressure test Connect a pressure gauge to the quick coupler Start the engine and run at maximum speed Check the pressure value given and compare with the table below Flow test Conn...

Page 74: ...ses or harshness If axial or radial play in the bearing exceeds 0 05 mm or noise or harshness is detected dismantle and replace the bearings and rectify the defects Note This work must be carried out...

Page 75: ...mm of each other and their combined length exceeds 15 mm Re profile wheels to remove cavities and cracks otherwise replace the wheels Fig 111 Maximum allowed wear Fig 112 Wheel with crack Cracks Crack...

Page 76: ...orms on the tread chamfer Figure 153 Rollover The maximum allowable is 5 mm Associated with this are circumferential cracks Figure 152 Circumferential cracking limit associated with rollover which do...

Page 77: ...ine any wear on the clipping pad edge If any part of the edge is less than 1 mm the pad must be replaced To vaoid damage to the insulator at de clipping carry out daily inspection of the surface by se...

Page 78: ...terial preload shall be kept on a level so that tensile stress and torsional stress does not exceeds the yield strength of the screw Its main purpose is to clamp the parts to achieve friction between...

Page 79: ...ol All warranty related work must be approved and documented by Pandrol AB before warranty repair work is carried out 13 2 Service Regular maintenance will make the product more reliable and extends i...

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Page 82: ...Find out more at pandrol com Pandrol AB Hyggesvagen 4 824 34 Hudiksvall Sweden 46 650 16505 info rosenqvistrail pandrol com Pandrol Partners in excellence...

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