PANDROL Rosenqvist CD200 Operation & Maintenance Manual Download

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Operation &

Maintenance Manual

Rosenqvist CD200

Issue date:2016-11-11

Dokument ID:ENG_OMM_CD200

Revision:P05

Original instructions

Pandrol AB, Hyggesvägen 4, 824 34 Hudiksvall, Sweden

Phone +46 650-16505, www.rosenqvistrail.com, [email protected]

Summary of Contents for Rosenqvist CD200

Page 1: ...al Rosenqvist CD200 Issue date 2016 11 11 Dokument ID ENG_OMM_CD200 Revision P05 Original instructions Pandrol AB Hyggesv gen 4 824 34 Hudiksvall Sweden Phone 46 650 16505 www rosenqvistrail com info...

Page 2: ...tructions and maintenance guidelines without prior notice CD200 contains an engine from Subaru An owner maintenance manual from Subaru is therefore included with the product Please refer to this manua...

Page 3: ...ts 12 3 1 Main Unit 12 3 2 Trolley 13 3 3 Controls 14 3 4 Controls CD200 Electric 15 3 5 Electrical System 17 3 6 FASTCLIP equipped Machine 18 3 6 1 Work Head FC FE 18 3 6 2 Sleeper Lifter FC FE 19 3...

Page 4: ...41 7 2 Clipping 42 7 3 De clipping 43 8 Troubleshooting 44 8 1 Clips are moving before sleeper is lifted and preventing installation 44 8 2 Clips are being installed before sleeper is fully lifted 45...

Page 5: ...e Use standards and regulations accident prevention regulations and regulations concerning special ambient conditions e g areas potentially endangered by explosive materials heavy pollution or corrosi...

Page 6: ...aware of the contents of the product data sheets relating to the hydraulic oil used Pandrol AB recommends the use of biodegradable oils and greases in order to minimize the environmental impact in cas...

Page 7: ...c Oil High pressure fluid is present in operational hydraulic systems Fluids under high pressure are dangerous and can cause serious injury To avoid accidents follow the guidelines below Only qualifie...

Page 8: ...ave received training and information from Pandrol AB In order to avoid personal injury and or material damage everyone involved with assembling starting up or overhaul must possess relevant knowledge...

Page 9: ...abels that are available from Pandrol AB Read manual before use item no 710016 Wear safety goggles item no 710048 Wear hearing protection item no 710052 WARNING Risk of crushing item no 710019 WARNING...

Page 10: ...The Clip Driver CD200 can clip on both rails by sliding the unit from one side to the other The clipping capacity is up to 30 sleepers per minute The CD200 can be separated into 2 pieces to allow for...

Page 11: ...0 sleepers min Engine Manufacturer Subaru SEW EURODRIVE Model EX40 FRN100L4 Type Air cooled 4 stroke single cylinder overhead camshaft Frequency controlled AC motor Power 7 0 kW 3600 rpm 4 0kW 5 4HP F...

Page 12: ...lves and almost all electronics The handle bar with the operator controls is also mounted on the Main Unit Item Description Item Description 1 Working light 6 Support leg 2 Handle bar 7 Control box 3...

Page 13: ...nt manner When setup correctly the trolley gives the machine the right inclination independent of direction of travel or chosen rail for operation Item Description Item Description 1 Wheel bracket 5 L...

Page 14: ...work modes as will be explained below WARNING Do not operate the machine before performing the setup procedure 1 2 3 7 Fig 5 6 4 5 Fig 6 Item Description Item Description 1 Push button 1 5 Light swit...

Page 15: ...ore starting the CD200 Stopp the motor by pushing the red button 4 Item Description Item Description 1 Reset 3 On 2 Power connection 4 Off Table 6 Fig 7 1 2 3 4 The machine is equipped with an electri...

Page 16: ...ton 1 to start the clipping cycle release the button immediately The retraction of the arms of the work head is done automatically This mode is used for normal clipping operation Mode 4 Auto De clippi...

Page 17: ...quires a minimum of maintenance and is well protected from wear and climate impact Item Description Item Description 1 Controls 5 Valve connectors 2 Work light 6 Pressure sensor connectors 3 Relay box...

Page 18: ...from 149 189 mm The work head uses the rail head as a datum when it is configured for de clipping The work head can easily be set up for clipping or de clipping by changing the shoes and turning the...

Page 19: ...justment mechanism to accommodate for different rail section heights When the dead mans handle sleeper lifter control is pressed in towards the handlebar the cylinder takes its fully extended position...

Page 20: ...rn filter 5 is of the type spin on which is easily changed whenever required see chapter 11 for maintenance The hydraulic reservoir 3 is also a part of the machine structure 1 3 8 2 7 6 4 5 Fig 12 Ite...

Page 21: ...IPS It is also designed to be able to work on rails with different rail heights Item Description Item Description 1 Parallel adjustment knob 5 Double hook 2 Tower 6 Datum piece 3 Frame 7 Quick locking...

Page 22: ...hen move back to the starting position and the cycle is complete When the indicator is in the EXTRACT MODE ZONE 3 the tool is ready to extract the clips The indicator will move towards the center mark...

Page 23: ...the work head will rise above the clips In this position CD200 can easily be pushed towards the next sleeper This mechanism is also used to adjust the machine to different rail heights and also to mak...

Page 24: ...of the hydraulic system on an e CLIPS equipped machine The difference between FC FE see chapter 3 5 3 is four horizontal cylinders coupled in parallel that work in pairs Clipping de clipping cylinder...

Page 25: ...s is to ensure that the machine does not fall over or run away along the track Fig 17 Fig 18 4 TRANSPORT AND PARKING 4 1 Preparing for Transport or Storage When CD200 is to be transported or stored of...

Page 26: ...the two support legs see Fig 20 The support legs are folded down by removing the locking pin and turning the support leg The support legs are secured with the locking pin in the lower position Fig 21...

Page 27: ...e taken by the operator of the machine The machine operator is also responsible that nobody interferes with CD200 whilst in use and powered When the CD200 operates on track the de clipping shoes follo...

Page 28: ...fted in its lifting eye located on the top of the main unit The red handles are intended for emergency use only or for guiding the main unit into the correct position When longer transportation is nec...

Page 29: ...to quickly move the machine off track Front handles Rear handles Fig 26 1 Pull the locking pin up 2 Pull the handle out until the locking pin lands in the next hole on the handle 3 Lift the machine to...

Page 30: ...fferent options 1 20 1 30 and 1 40 see spare parts manual or consult Rosenqvist Rail AB for more information To change the inclination pieces 1 Unscrew the horizontal bolt 1 and open the latch 2 2 Uns...

Page 31: ...2 1 3 The rotation locking screws will automatically lock with a clicking sound when the machine has been turned around Check that the machine is firmly secured in the correct position before startin...

Page 32: ...he slide carriage in the new position NOTE Consider the rail inclination when locking the slide carriage in position the main unit has to be tilted slightly to match the inclination otherwise it will...

Page 33: ...scale on the side of the shoe 2 Clip Type Rail Type No FASTCLIP FE UIC60 2 FASTCLIP FE S49 S54 4 FASTCLIP FC1501 UIC60 2 FASTCLIP FC1504 1604 UIC60 1 FASTCLIP FC1501 S49 S54 3 Table 14 NOTE The machin...

Page 34: ...sion A in Fig 36 is recommended to be 10 13 mm for FASTCLIP FE and 8 11 mm for FASTCLIP FC 6 1 2 Clipping Operation 1 Make sure all settings described in previous chapters are performed 2 Set the mach...

Page 35: ...the sleeper is lifted the clipping operation will be completed automatically 5 Move on to the next sleeper and repeat the sequence if necessary Fig 38 Fig 39 NOTE FASTCLIPS secure the rail to the sle...

Page 36: ...ead 1 Install the de clipping shoe 1 in the right position for the current clip assembly The current position can be determined using the scale on the side of the shoe 2 2 Make sure the mechanical sto...

Page 37: ...5 4 Position the work head over the center of a clip assembly 5 Start de clipping in manual mode by pressing the button on the left hand side of the handlebar 6 Run the de clipping until the datum ar...

Page 38: ...edure on the other side of the work head Fig 46 Rubber stop set up for FASTCLIP FE Fig 45 Rubber stop set up for FASTCLIP FC 1 2 8 Position the work head in BETWEEN two sleepers and run the clipping d...

Page 39: ...cted FASTCLIP is free from any damage both on clip and insulators 5 Set the machine in auto de clipping mode 6 Push the machine to the next sleeper and trigger the de clipping cycle by the button on t...

Page 40: ...ces to Fig 49 if not otherwise stated 1 Open the four cam levers 3 2 Adjust the height using the parallelity adjustment knob 1 3 It is correctly adjusted when the work head is parallel to the rail in...

Page 41: ...n a weekly basis When adjustments have to be done 1 Loosen the four hex head bolts 1 2 Loosen the two locking nuts 3 3 Adjust the adjustment screws 2 until the required friction between the frame and...

Page 42: ...on neither on the clips nor on the insulators If any damage is discovered go back to step 1 5 Set the machine in automatic clipping mode 6 Activate the dead mans handle push the machine to the next sl...

Page 43: ...tion neither on the clips nor on the insulators If any damage is discovered go back to step 1 5 Set the machine in automatic de clipping mode 6 Activate the dead mans handle push the machine to the ne...

Page 44: ...own by turning screw on cartridge 2 counter clockwise Factory setting 25 bar 1 4 3 2 Fig 58 Item Description Item Description 1 Pressure switch for de clipping function 3 Pressure switch for clipping...

Page 45: ...ition Clipping pressure to low Solution Change position of clipping shoe Pressure switch for clipping function may need to be adjusted This adjustment should only be done after consulting a retailer o...

Page 46: ...pressing down the valve through the cover see Fig 59 while pulling the main arms outward so that the grip around the track recedes This can and shall only be done with the machine turned off hydraulic...

Page 47: ...working shift A lubrication every 40 hours or once a week A more comprehensive overhaul after 500 hours or once a year Warranty is based on parts and spares delivered by Rosenqvist Rail AB All adjustm...

Page 48: ...KF LEGP 2 or equivalent X Roller surface on slide bar Clean and lubricate with oil spray X Bolts Lubricate with oil spray X Engine See Subaru EX40 manual X X X Warning labels Replace worn and replace...

Page 49: ...equipped Machine 9 3 2 E CLIPS equipped Machine The E CLIPS work head does not have any grease points Fig 61 Grease points visible from the side Fig 60 Grease points visible from the backside 49 52 Do...

Page 50: ...ghtening torque in Nm for the screws and nuts that are used These torques do not apply to wheel bearings Thread diameter mm Tightening Torque per bolt grade Nm Grade 8 8 Grade 10 9 Grade 12 9 5 5 7 8...

Page 51: ...or unauthorized modification or if the product has been exposed to fire electrical storms or excessive voltage 11 2 Service Service is offered after the expiration of the warranty as well Please conta...

Page 52: ...Pandrol AB Hyggesv gen 4 824 34 Hudiksvall Sweden Phone 46 650 16505 www rosenqvistrail com info rosenqvistrail pandrol com...

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