PANDROL 03700A Manuel utilisateur

Partners in excellence

ENG_OMM_ELECTRIC_POWER_UNIT_P01

30th November 2021

OPERATION AND MAINTENANCE

MANUAL

Electric

Power Unit

MODEL 03700A

1. Preface

2. Revision

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Thank you for choosing Electric Power Unit!

You are now the owner of a quality product from Pandrol.

This manual aims to help you get to know your new Electric Power Unit, 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 2021-11-30 New Manual

Table of Contents

1. Preface 2

2. Revision 2

3. Safety Information 5

3.1. General 5

3.2. Safety actions 5

3.3. Personal/Safety equipment 6

3.4. Safety precautions 6

3.5. Qualiedpersonnel  7

4. Summary 8

5. Operation 9

5.1. Valve positioning 9

5.2. Changing tools 10

5.3. Coldweatheroperation  10

6. Troubleshootingguide  11

7. Calibrationproceduresfor03700Amanifold  13

7.1. Flowcalibration 13

8. Relief pressure calibration 14

9. Flowcontrolsetting  15

10. Finalcalibrationanddoublecheck  16

11. Reviewofhydraulicprinciples  17

11.1. Hydraulicformulas  17

11.2. Backpressure  17

12. Maintenance 18

12.1. General 18

12.2. Warninglabelsandinformationsymbols 19

13. Limitedwarranty  20

13.1. Exclusionstolimitedwarranty  20

13.2. Limitation of liability 20

14. Customer information 21

15. Assembly  23

15.1. Flowdiagram  23

15.2. Framepartsdiagram 24

15.3. Framepartslist 25

15.4. Engineandpumppartsdiagram 26

15.5. Engineandpumppartslist  27

15.6. Hydraulicandstarterrelaypartsdiagram  28

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15.7. Hydraulicandstarterrelaypartslist  29

15.8. Toolmanifoldpartsdiagram  30

15.9. Toolmanifoldpartslist  31

15.10. Electricdiagram  32

16. Disclaimer 33

17. Contact 33

18. RecyclingandEnvironment  33

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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,donotcarrythetoolbyhydraulichoses,and

repairleaksimmediately.

• Donotoperatethepowerunituntilyouhavebeenproperlytrainedorunderthesupervisionofaqualied

instructor.

• Neverstoreengineoilorhydraulicoilnearoxygentanksorlines.

• Neveraddengineoilorhydraulicoilwhenaspillmightcomeincontactwithyouroxygenlines,torchorttings.

• Cleanupspillsimmediately.

• Neverperformgrindingorsawingoperationsthatdirectsparksintothecloseproximityofthepowerunitor

ammablematerials.

• Alwaysturnpowerunit"OFF"anddisconnecthosesbeforeperforminganymaintenance.

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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.

WARNING!

• Do not touch electrical connections before you rst ensure the power has

been disconnected. Only qualied personnel should attempt the installation

and maintenance of this equipment.

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Engine Flow Pressure Dimensions Weight

20 Hp electric

240/360/480 Vac

3 Phase

* See note about

hertzrequirements

5GPM(19LPM)

10GPM(38LPM)

Fluid:hydraulic

5usgal(18.9)liters

200PSI(140BAR) A-40”(101.6cm)

B-26”(66cm)

C-30”(76.2cm)

486lbs(220kg)

4. Summary

ThePandrolElectricPowerUnitisdesignedtodeliver2-5

GPMcircuitsor1-10GPMcircuitat2000PSIforhydraulic

tooloperationsinbuildingsorotherclosedenvironments.Itis

perfect for maintenance shop testing of tool repairs. The unit is

equippedwithheavydutywheelsformobility.

Accessories:

02326E-Hosereelequippedwith50’transmissionhose.

02323K-Hosereelequippedwith25’transmissionhose.

*Hertzrequirementsvarybycountry.

Specifyrequirementswhenordering.

Fig 1.

Fig 2. Fig 3.

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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

Always check the power unit’s hydraulic uid level and ll reservoir as required before

starting

• Tostartthepowerunit,checktomakesurethatbothcontrolvalvesareinthe"OFF"position.

• Depressthestartbuttononthebreakerboxlocatedonthefrontoftheunit.

• Connectthepowertransmissionhosetoeitherthe5or10GPMports,dependingontheowrequiredforthe

toolyouwillbeusing.

• Connectthetool(s)tothepowertransmissionhosebeforeturningcontrolvalvesatpowerunit"ON".

• Rotateappropriateowcontrolvalves.(See“valvepositioning”inthismanual.)

• Tochangetools,turnthecontrolvalvestotheo󰀨position.

• Toshutdownthepowerunitturnthecontrolvalvestothe"OFF"positionanddepresstheredstopbuttonon

thebreakerbox.

5.1. Valve positioning

The03700apowerunitisdesignedtooperateeither(1)toolat10GPM(38LPM)or(2)toolssimultaneouslyat5

GPM(19LPM).Refertooperatinginstructionsforeachtooltodetermineowrequirements.

BEFORE STARTING!

• This power unit is driven by an electric motor. It is factory wired for the

voltage requested by the purchaser. Electrical contacts and wiring vary at

di󰀨erent locations. Due to this, have a qualied person or technician ensure

electrical system compatibility

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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.

10 GPM tools:

Tooperatea10GPMtool,connectittotheportmarked10GPMandturnonbothcontrolvalves.

5.2. Changing tools

• Turnthecontrolknobstothe"OFF"positionbeforedisconnectinghoses.

• Oncethetoolhasbeenchanged,turnthevalvestothe"ON"positiondependingonowrequirementsofthe

toolbeingused.

5.3. 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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OPERATION AND MAINTENANCE MANUAL I ENG_OMM_ELECTRIC_POWER_UNIT_P01 I 30th November 2021

@Pandrol 2021

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