Operation and Maintenance manual
Contents
1. n 5 6 litres minute Lo ro 3700 rom 4 r r AGIP ARNICA 32 or eguivalents Acoustic noise Directive 2006 42 EC annexe 1 point 1 7 4 2 letter u The continuous eguivalent weighted level A of noise pressure at the working place Lan egual lO O 84 9 dB A uncertainty Kt 0 9 dB The maximum value of instantaneous weighted noise pressure C at the working place 130 dB C The level of noise force produced Dy the machine E ds equal LO piss ista 99 6 dB A uncertainty K 0 9 dB Risks due to vibration Directive 2006 42 EC annexe 1 point 2 2 1 1 Tests carried out in compliance with the indications contained in ISO 5439 Standard and under operating conditions much more severe than those normally found certify that the weighted root mean square in frequency of the acceleration the upper limbs are exposed is 3 7 m sec 3 2 MACHINE DESCRIPTION Ref to Fig 1 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 TRANSPORT HANDLES LIFTING POINT IN NEUTRAL POSITION HYDRAULIC PUMP OIL TANK ACCELERATOR WORKLIGHT ON OFF SWITCH STOP EMERGENCY BUTTON CLAMP CONTROL LEVER HANDLEBAR OUICK RELEASE MALE AUTOMATIC HYDRAULIC COUPL2. 0 29 000 Resistance between rail and 2 gt 1 MO 2 1110 see Fig 17 page 26 Weight 3 uH endet 311 0 112 kg 5 38 DIRE 50 kg 8 1 9 0 0 7 48 kg EE AN O O O EE O T 9kg MA WH OAI iwi on 5 kg Combustion engine UVA 0119 0 4 stroke overhead valves one cylinder o apnea en Honda GX 760K1 OMD6 TO niin 163 cm O O O O O O O 4 kW 1 E ONA AA A OEE P 3700 rpm exhaust emissions Lera HC NOX 10 53 gr kW h and CO 433 37 gr kW h fae COSTOS somme EIER 2 ERE D UE 31 3 0 0 9 litres hour 7 unleaded regular grade petrol 1515 83 3 6 litres recommended ON T OE OV RSA SAE 10W 30 0 6 litres centrifugal with automatic intervention 010 by rope pull with automatic rewind Hydraulic pump WET AN 42 MPa
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4. FIG 10 Make sure the teeth 33 of the clamps are moved fully back by pulling the control lever to the left EXTRACT Completely lower the machine positioning the yellow locator plates 36 near the E clip retention plates see Fig 114 Ir d I FIG 11a 34 j Pull the control lever to the right in INSERT position to gradually move the teeth for wards with conseguent insertion of both E clips see Fig 11b and 110 When performing the insertion operation each clamp teeth 33 will move in opposite directions FIG 11b NOTE During clip insertion the movement of the teeth may NOT be simultaneous because the two clamps operate independently NOTE movement of one of the clampsis schematically shown in the illustrations the other will have an identical and op posite movement FIG 11c FIG 11d After insertion pull the control lever to EXTRACT position for teeth 33 reversal see Fig 11d Raise the machine and go onto the next E clips Repeat the above operations 15 4 5 2 Simultaneous extraction of 2 E clips Ref to Fig 12 A Make sure the locking knob 27 of the wheel is released see 4 2 Make sure the teeth 33 of the clamps are moved fully forwarded by pulling the control lever to the right in INSERT position Completely lower the machine positioning th
5. Certified Ouality Certified Environmental Certified Occupational Management System Management System Health amp Safety Management System PANDROL E CLIP MACHINE with braking system ON i lt CE OPERATION AND MAINTENANCE MANUAL WARNINGS 1 Before using the machine read the instructions contained in this manual carefully SAVE THESE INSTRUCTIONS this manual contains important safety and operating instructions for the machine 2 During operation keep your hands outside the danger area 3 Always wear protective glasses and working gloves Avoid wearing clothes which may present a risk to personal safety Only authorised personnel shall start or operate the machine The user shall not modify the design or configuration of the machine Cannot be used over switches and crossings Not to be used near live d c conductor rail Not to be used for any purpose other than for which machine is designed Do not exceed walking pace when pushing the machine The machine fulfils the reguirements of the Norm EN 13977 2005 A 1 2007 EN 13977 2 7 Pandrol E clip is Pandrol Ltd trademark 1 GENERAL CHARACTERISTICS Application range suitable for the insertion and extraction of Pandrol E clip used with 75 mm bases on standard gauge rails 1435 mm Developed force single clamp 7777 77 0 0 0 0 959 9
6. pe storio u m ven a m m H d Bd 4 FIG gt CONTROLS 11 4 4 Setting the machine Ref to Fig 6 A Before use always check the height of the clamps with respect to the E clips Taking a retention plate as a reference point check the position of the clamps with respect to the plate itself In working condition both clamps must be Perfectly horizontal with respect to the rail The insertion extraction tooth 33 must be able to slide horizontally with 3 4 mm clear ance above the retention plate see Fig 6 FIG 6 E clip retention plate To adjust proceed as follows 4 4 1 Adjusting the rear height of the machine Ref to Fig 7 Loosen the handle 26 n To raise the machine turn the ad bu justment knob 25 clockwise To lower the machine turn the adjustment knob 25 anticlockwise After making adjustment tighten the handle 26 well FIG 7 4 4 2 Adjusting the height of the front of the machine Ref to Fig 8 To raise the machine turn the graduated adjuster 42 anticlockwise to lower the machine turn the graduated adjuster 42 clockwise using the graduated scale to achieve precise positioning graduated scale Note It may be easier to use the adjuster 42 with the clamp unit partially disconn
7. pump Lubricate the clamp piston rods If necessary change insertion extraction teeth 33 and locator plates 36 as these become damaged or worn by prolonged or improper use 6 1 1 Maintenance of braking device only for versions of machine with braked wheels The braking system is of robust construction and will require very little maintenance however the following routine checks should be performed Dust sand anddirt are a danger for any mechanical device Avoid putting the machine on muddy ground After every use the machine must be wiped with a clean cloth taking care to remove any residue especially around moving parts Rear Carriage wheel A Before every use Check wheel for resistance wheel should not be free rotating Ensure wheel is clean removing any dirt or mud Check for signs of damage Every 6 months Check for excessive braking on wheel Wheel should roll along track when pushed wheel will slide if excessive braking occurs Clamp unit wheel Before every use Check cable linkages springs and wheel for signs of damage Check linkages are free moving Ensure brake cable moves without resistance With brake released check that wheel rotates freely Check that when handlebar lever is in the raised position the brake is engaged Ensure that wheel is clean of dirt and mud Check that before assembly the wheel dos not rotate one full turn in either direction Ensure coupling is free of
8. 3b and c Press the handle 45 to verify the correct engagement and disengagement of release pin P from the wheel Ref to Fig 5 and 3c Duringthe disassembly ofthe machine before removal ofthe pump unit the brake release device must be disassembled as follows Pull the handle C and disconnect the end part A from slot seat B E 2 1 m A ri y WEY 4 fy ja IN3W3A0w 40 0 A18W3SSV 40 A3NANOAS Y Dl4 4 1 2 Disassembly of the machine Ref to Fig 4 and 4a To disassemble the machine Firstlower the rear part and lock with pin 27 block wheel 30 then reverse the process F described in 8 4 1 Before disconnecting the pump unit make sure to have disconnected the hydraulic circuit and the braking device locate the hoses in support x S got on the frame of the pump unit If necessary with the machine fully assembled and the motor switched off the clamps can always be opened or closed manually NOTE Under normal conditions the time taken to remove the machine from the rail is approximately 60 seconds FIG 4a SUPPORT 4 2 Moving the machine Ref to Fig 4b To move the machine along the track the rear part must be raised to prevent the clamps knock ing against the E clip To do this simply Pull and turn knob 27 The wheel arm will be freed 2 Slightly raise the ma
9. Lesseps 25135 Brescia Italia Kingsbury Road Curdworth Sutton Coldfield 91420 Morangis France N Telefono 030 36921 West Midlands B76 9EB Great Britain T l 01 60 49 11 90 Fax 01 60 49 29 10 VO Telefax 030 3365766 Tel 01675 470440 Fax 01675 470220 B P 37 91421 Morangis C dex Z E mail sales cembre com E mail sales cembre co uk E mail info cembre fr o www cembre it www cembre co uk www cembre fr Cembre Espafia S L Cembre AS Cembre GmbH Cembre Inc Calle Verano 6 y 8 P I Las Monjas Fossnes Senter HeidemannstraBe 166 Raritan Center Business Park 28850 Torrej n de Ardoz Madrid Espana N 3160 Stokke Norway 80939 Munchen Deutschland 181 Fieldcrest Avenue Tel fono 91 4852580 Phone 47 33361765 Telefon 089 3580676 Edison New Jersey 08837 USA Telefax 91 4852581 Telefax 47 33361766 Telefax 089 35806777 Tel 732 225 7415 Fax 732 225 7414 E mail comercial cembre es E mail sales cembre no E mail sales cembre de E mail Sales US cembreinc com www cembre es www cembre no www cembre de www cembreinc com
10. Oil change Air filter assistance see double element type Cleaning sediments from sump Spark plug cleaning recommended plugs BPR6ES NGK or W20EPR U DENSE Minimum carburettor setting 6 3 Long periods of inactivity Store the machine in a dry environment and adeguately protect it against accidental damage and contamination Forinformation on the combustion engine refer to the HONDA user s manual 195 01394 1 Jo JensiA ji dn doj 9 9 410 1 AuBaul Jo AuBaul jo JensiA 6 JI ue1ubn 79 ENSIA Jo yay ENSIA 6
11. Pump unit combustion engine hydraulic pump for clamp operation Clamp unit for inserting and extracting E clips Carriage for supporting and moving the machine along the track 3 wheel bar for stability and vertical positioning The machine is supplied complete with 1pc spark plug key 1litre hydraulic pump oil do not use in engine 1pc12V 21W spare worklight bulb 3 1 Transporting the units The four units are well balanced for easy transportation in accordance with the table and dia grams in Fig 2 For uniform weight distribution and to transport the pump and Clamp units always use the transportation handles provided to lift the units Distributed Load per Person kg D gJ CLAMP UNIT PUMP UNIT FIG 2 TRANSPORTING THE UNITS 4 INSTRUCTIONS FOR USE Ref to Fig 4 4 1 Assembly disassembly of the machine Select the rail to be worked on and the direction of operation then assemble the machine as follows referring to Fig 4 1 With pin 27 engaged and wheel 30 blocked raise the clamp unit by means of the handles 20 and 29 and rest this on the selected rail positioning it between two sleepers 2 Rest the support carriage on the track and then pull and turn the fastening release knobs 43 Lift the clamp unit by means of the handle 20 and locate 19 pins fully into their carriage ho
12. the 4 screws from the lid of the terminal box 14 using a screwdriver Pull out fuse carrier and open it Fig 14d FIG 14b Replace faulty fuse with a new one with the same specifications 6 3A 250V CR Push fuse carrier back replace lid and tighten 4 SCrews nut light bulb 12V 21W O tt rd FIG 14c 6 1 4 Changing the gas springs Ref to Fig 15 Replace the gas springs when reguired as follows Release the wheel arm so the springs are in extended position Using a flat blade screwdriver lift the retention collar at the end ofthe spring pulling with force at the same time to release the spring from its locating pins Fitthe new spring on the same pins and press with force until this is properly fitted in the original position Note the two springs differ from one another 6 1 5 Maximum pressure valve Ref to Fig 16 Thehydraulic pump features a maximum pressure valve factory set and sealed at 42 Mpa A NEVER CHANGE THE MAXIMUM PRESSURE VALVE SETTING AS THIS MAY CAUSE SERIOUS DAMAGE TO THE MACHINE To check correct valve setting a special pressure testing gauge is available Ref to S 8 FIG 16 6 2 Routine maintenance of the engine Checks and periodical assistance are indispensable to ensure smooth engine operation Refer to the Honda user s manual supplied with the machine for the following operations
13. ER OUICK RELEASE FEMALE AUTOMATIC HYDRAULIC COUPLER HYDRAULIC PUMP PUMP UNIT FASTENING RELEASE KNOB WORKLIGHT ELECTRICAL TERMINAL BOX ENGINE PUMP UNIT FASTENING RELEASE KNOB OIL COOLING RADIATOR FRAME CLAMP UNIT LOCATING PINS TRANSPORT HANDLES PUMP UNIT LOCATING PINS QUICK RELEASE MALE AUTOMATIC HYDRAULIC COUPLER BRAKE RELEASE DEVICE LOCK QUICK RELEASE FEMALE AUTOMATIC HYDRAULIC COUPLER REAR HEIGHT ADJUSTMENT KNOB KNOB LOCK HANDLE WHEEL LOCK RELEASE KNOB GAS SPRING RIGHT SIDE TRANSPORT HANDLE REAR WHEEL GAS SPRING LEFT SIDE FLEXIBLE HOSES INSERTING EXTRACTING TOOTH HYDRAULIC RAM BRAKE RELEASE DEVICE YELLOW LOCATOR PLATE BAR SUPPORT WHEEL SUPPORT WHEEL ADJUSTMENT LEVER TRANSPORT HANDLES CONNECTING ROD FASTENING RELEASE KNOB GRADUATED FRONT HEIGHT ADJUSTER CLAMP UNIT FASTENING RELEASE KNOBS FRONT CARRIAGE WHEELS 45 BRAKE RELEASE HANDLE 02 LNA TY SY 4 NC SS EAS A Yl a MAE f d KVL Wek A Sz Ar P 7 7 fv SS D A gt VI 07 WAT C U 4 gt d LR aS LEH E A VA 1 A CLAMP UNIT 3 UNPACKING THE MACHINE Ref to Fig 1 To reduce overall dimensions and weight during transport the machine is supplied disassem bled as four units It consists of four main sections which can be easily assembled disassembled Ref Fig 1
14. chine by means of handlebar 08 lifting will be made easier by the two gas springs then release the knob 27 to lock the machine fully up 3 Press brake release handle 45 against the handlebar 08 4 Push the machine along the rail 4 3 Controls Ref to Fig 5 After gripping the handlebar 08 the operator can easily access all the unit controls and more specifically Accelerator control lever 04 changes engine rpm Worklight ON OFF switch 05 in case of night work or bad lighting the clamping area can be illuminated by these side mounted lamps Stop emergency button 06 in a very visible position and easy to operate to stop the unit normally and in case of an emergency NOTE when this button is pressed it remains in OFF position To start the engine the button should be turned clockwise so that it lifts automatically into the ON position A The engine will not start unless the red button 06 is lifted Clamp control lever 07 with swinging movement for operating the clamps right side for inserting E clips INSERT position left side for extracting E clips EXTRACT position Brake release lever 45 for safety reasons the machine is eguipped with an automatic braking device This device is always engaged within the rear wheel By pressing handle 45 the brake is released enabling movement of the machine along the rail 04 e JI
15. dirt and mud Every 6 months Check wheel pockets for excessive wear If braking effectiveness is compromised replace wheel Check extension spring see figure on brake release handle 45 are undamaged Check for wear on pivots Ensure fasteners are secure Check for wear on coupling parts should mate securely Clean all moving parts and lubricate as required extension 6 1 2 Topping up the oil in the hydraulic pump Ref to Fig 14 Periodically checkthe level ofthe oilin the hydraulic pump The oil should always be visible inside the tank 03 If the levelis low top up with the specific oil recommended Unscrew the cap and add sufficient oil to fill the tank do not exceed the oil level After topping up tightly screw the cap back on Always use clean recommended oil see 1 Do not use old or recycled oil Do not use hydraulic brake fluid FIG 14a 6 1 3 Changing worklight bulbs Ref to Fig 14b d Loosen the locking nut Fig 14b Turn worklight upwards and remove the two locking screws in the lens Fig 14c using a screwdriver Remove the faulty bulb and replace with another having the same specifications 12V 21W Replace lens and tighten the two screws Reset worklight to original position and tighten the nut The light bulb power circuit is protected by a fuse against overcurrents and short circuits In case of a fault Remove
16. e yellow locator plates 36 near the E clip retention plates see Fig 12a FIG 12a Pull the control lever 07 to the left in EXTRACT position to gradually move the teeth forwards with conseguent extraction of both E clips see Fig 12b and 120 When performing the extraction operation each clamps teeth 33 will move in opposite directions FIG 12b NOTE During clips extraction the movement of the teeth may NOT be simultaneous because the two clamps operate independently After removal pull the control lever to INSERT position for forward movement of teeth 33 see fig 12d A Raise the machine and go onto the next E clips Repeat the above operations FIG 12d NOTE movement of one of the clamps is schematically shown in the illustrations the other will have an identical and opposite movement 5 STARTING THE ENGINE Move the stop button 06 see 8 4 3 to ON position see Fig 13a FIG 13a A The engine will not start unless the red button 06 is lifted Move the fuel cock to ON position see Fig 13b Move the air lever to CLOSE position FIG 13b Airlever see Fig 13b 4 CLOSE Do not use the air lever if the engine is hot and OPEN gt the air temperature is high enough Move the accelerator c
17. ected from the carriage 4 4 3 Adjusting the vertical alignment of the machine Ref to Fig 9 The distance of the teeth 33 from the retention plates of the Eclips must be the same for both clamps If this is not the case adjust support wheel 38 Loosen handle 39 Lower or raise the rod 37 to change the vertical angle of the machine and achieve correct alignment After adjustment tighten the handle 39 well It may also be necessary to change the machine alignment on track bends 4 5 Operation Before use always check Integrity of the machine The correct coupling of the units making up the machine Correct connection of the guick couplings and the braking device Correct level of oil in pump For any oil leaks in the hydraulic circuit radiator hoses pump Flexible hoses are in good condition and show no signs of wear or crushing Protection devices in the clamp areas are firm and show no signs of damage That the engine fuel tank cap is tight Petrol is highly inflammable and can explode Start the engine see 8 5 With knob 27 released push the machine to the E clips points on which operations are to be performed see 8 4 2 4 5 1 Simultaneous insertion of 2 E clips Ref to Figs 10 11 A Make sure the the locking knob 27 of the wheel is released see 4 2 Position the E clips in the retention plate eyelets on both sides of the rail E clips
18. ock open Is there fuel in the tank Is fuel reaching the carburettor To check loosen the carburettor drainage screw with fuel cock open and refer to the HONDA owner s manual Is the spark plug producing a spark Remove the plug cap clean around the plug and remove the plug using the span ner provided Fitthe plug back in the cap Move button 06 to ON After earthing the side electrode pull the starting cable and check to see whether the plug produces a spark If the engine still fails to start contact Cembre see 8 7 6 MAINTENANCE All electrical and mechanical maintenance shall only be carried 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 A cool Always remove the spark plug cap from the spark plug when servicing the engine to prevent accidental starting 6 1 Routine maintenance of the machine At the end of each day clean the machine carefully using a clean cloth being careful to eliminate all dirt or any oil stains especially near the moving parts such as the clamp teeth and piston rods and wheels Do not rest the machine or units directly on dusty or muddy ground Regularly perform the following operations or inspections Tighten all bolts Check the integrity of the 3 rubber dampers which reduce vibration caused by the engine
19. ontrol lever 04 to mid stroke see Fig 13c Start the engine by pulling the starting cable un til a certain resistance is felt and then pull with force see Fig 13d IMPORTANT Do not allow the cable knob to return forcefully and knock against the engine Return this slowly to its original position This Will prevent damage to the starting device FIG 13c Ap As the engine heats up gradually move the air lever to OPEN position see Fig 13b Move the accelerator control lever 04 fully for ward to achieve the correct rpm see Fig 13c To stop the engine in emergency condition FIG 43d press button 06 gt Starting To stop the engine in normal conditions cable knob move the accelerator control lever 04 fully back Press the button 06 Move the fuel cock to OFF TROUBLESHOOTING When the starting cable is pulled the engine fails to start Is the Stop Emergency button 06 released see 8 4 3 Is there enough oil in the combustion engine The engine features an oil alert system to prevent damage caused by too little oil Before the level drops below safe limits the alarm system automatically stops the engine Refer to the HONDA owner s manual for the type of recommended oil and topping up THE HYDRAULIC OIL SUPPLIED WITH THE MACHINE IS INTENDED ONLY FOR USE IN THE HYDRAULIC PUMP AND IS MUST NOT BE USED IN THE ENGINE Is the fuel stopc
20. ri E G0 7 RETURN TO Cembre FOR OVERHAUL In the case of a breakdown contact our Area Agent who will advise you on the problem and give you the necessary instructions on how to dispatch the machine to our nearest service Centre if possible attach a copy of the Test Certificate supplied by Cembre together with the machine or if no other references are available indicate the approximate purchase date and machine serial number 8 OPTIONAL ACCESSORIES MPC6 PRESSURE GAUGE code 2595209 To check maximum pressure valve setting PROTECTIVE COVER FOR PANDROL CLIP MACHINE TARPCOVER 019 PCM code 2593275 material Polyethylene HDPE UV stabilised 70 C to 40 C TLD 1 LO TI Pah n lel A U GEL CC LE ai 1 LTO ES G ir An oj a zy A Pump unit serial nr ISL ea a _ i y 1000 max SY an This manual is the property of Cembre any reproduction is forbidden without written permission Cembre reserve the right to modify the specifications in this manual without prior notice C e In b XO www cembre com N LA Cembre S p A Cembre Ltd Cembre S a r l m Via Serenissima 9 Dunton Park 22 Avenue Ferdinand de
21. using as far as the stop Release the knobs 43 to lock the clamp unit 7 3 Pull and turn the knob 41 insert the 3 wheel bar in the carriage housing as far as the stop aligning the hole in the end of the rod with the pin knob Release the knob 41 and the wheel 38 which will act as a support on the opposite rail so the assembly is stable and able to slide along the rail the rod can be fitted in carriage from either side for convenience in selecting the direction of work Pull and turn the knobs 12 and 16 at the base of the pump unit Lift the pump unit by means of the handles 01 and handlebar 08 Rest the pump unit on the clamp unit and align the pins 21 with the relevant locating holes on the under side of the pump unit Release the knobs 12 and 16 for locking 5 Restore the oil delivery return hydraulic circuit connecting the flexible hoses by means of the quick couplings 09 and 10 to the respective connectors 24 and 22 on the clamp unit 6 Connect the brake release device 35 ref to 5 4 1 1 4 1 1 Braking device Ref to Fig 3a 3b 3c 5 To run the machine along the rail it is necessary to connect the brake release device 35 proceed as follows Introduce end part A into slot seat B located above the rear wheel of the clamp unit Ref to Fig 3a Pull the handle C upwards release it in position than push until is locked Ref to Fig
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