PANDROL 03700A Manuale utente
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 specications, 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. Qualiedpersonnel 7
4. Summary 8
5. Operation 9
5.1. Valve positioning 9
5.2. Changing tools 10
5.3. Coldweatheroperation 10
6. Troubleshootingguide 11
7. Calibrationproceduresfor03700Amanifold 13
7.1. Flowcalibration 13
8. Relief pressure calibration 14
9. Flowcontrolsetting 15
10. Finalcalibrationanddoublecheck 16
11. Reviewofhydraulicprinciples 17
11.1. Hydraulicformulas 17
11.2. Backpressure 17
12. Maintenance 18
12.1. General 18
12.2. Warninglabelsandinformationsymbols 19
13. Limitedwarranty 20
13.1. Exclusionstolimitedwarranty 20
13.2. Limitation of liability 20
14. Customer information 21
15. Assembly 23
15.1. Flowdiagram 23
15.2. Framepartsdiagram 24
15.3. Framepartslist 25
15.4. Engineandpumppartsdiagram 26
15.5. Engineandpumppartslist 27
15.6. Hydraulicandstarterrelaypartsdiagram 28
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15.7. Hydraulicandstarterrelaypartslist 29
15.8. Toolmanifoldpartsdiagram 30
15.9. Toolmanifoldpartslist 31
15.10. Electricdiagram 32
16. Disclaimer 33
17. Contact 33
18. RecyclingandEnvironment 33
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3. Safety Information
3.1. General
• Tooloperatorsandmaintenancepersonnelmustalwayscomplywiththesafetyprecautionsgiveninthis
manual,andwithallstickersandtagsattachedtothetoolandhoses.
• Allsafetyprecautionsaregivenforyoursafety.Readtounderstandandfollowallsafety,maintenanceand
operation instructions before you use or maintain the tool.
• Reviewthemanualdailybeforeusingthetool.
• Followallsafetyguidelinesgivenyoubyyoursupervisor.Donotusethetoolifyouhaveanyquestionsabout
theoperation,safetyormaintenanceofthistool.Failuretofollowtheseinstructionscanresultinpersonal
injuryorequipmentdamage.
• Pandrolhasnocontroloverthetooluseoroperationonceitleavestheplant.Pandrolhasnocontrolover
operator or maintainer selection. The customer must assume responsibility for the tool suitability for a particular
function.
• Duringuseofthetool,goodjudgementmustbeusedtoworksafelyandecientlywithoutendangering
themselvesorbystanders.
• Understandingoftheoperationandmaintenancemanualisessentialforanyoneusingormaintainingthetool.
• Warningsandsafetyprecautionsdescribedinthisdocumentshallonlybeconsideredasaminimum.National
conditions,standardsandregulationsoverrideconditions,standardsandregulationsdescribedinthis
document.
• Workwiththemachineisonlytobecarriedoutbyqualiedpersonnel,well-informedandeducatedingeneral
railwayworkmanshipandspecicallyintheconditions,standardsandregulationsonspecicrailtrack.
• Themachinemayonlybeusedforitsspeciedpurpose.
• Anyadjustmentsorserviceonthemachineisonlyallowedtobedonebyqualiedpersonnelthathaveread
andunderstoodthismanualandhavehadtrainingandinformationfromPandrol.
3.2. Safety actions
• Readandunderstandallsafetyregulationsandwarningsbeforeinstallation,operatingorperforming
maintenance on this machine.
• Donotoperatethetooluntilyouhavebeenthoroughlyandproperlytrainedorunderthesupervisionofan
instructor.
• Checkpowersourcedailytodetermineifcorrectowandpressureareavailable.Neverexceedowsor
pressuresforthetoolbeingused.Personalinjuryordamagetothetoolcanresult.
• Operatorsmustcleartheworkareaofnon-essentialpersonnel.Flyingdebriscancauseseriousinjury.
• Theoperatormustbefamiliarwithallprohibitedworkareassuchasunsafegrades,poorfootingareasand
overheadhazards.
• Usestandardsandregulations,accidentpreventionregulationsandregulationsconcerningspecialambient
conditions(e.g.areaspotentiallyendangeredbyexplosivematerials,heavypollutionorcorrosiveinuences).
• Maintainbalanceandproperfootingatalltimes.Neveroverreachtotheextentthatabrokenpartorsudden
movementofthetoolcancauseyoutoloseyourbalanceandfall,orcauseinjurytoyourselforsomeoneelse.
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• Donotoperatethetoolatexcessiveuidtemperaturesoperatordiscomfortandpotentialburnscanresultat
high oil temperatures.
• Donotcleaninspectorrepairthetoolwhileconnectedtothepowersource.Accidentalengagementofthetool
can cause serious personal injury.
• Oilinjectionhazardexistswiththistool.Oilinjectionisaconditionwherehydraulicoilisinjectedunderthe
skinfrompressureintheline.Alwayswearglovesandrepairanyleaksimmediately.Nevercarryatoolbythe
hoses.
• Donotusedamagedequipment.Immediatelyreplaceanydamagedhoses,ttings,orothercomponents
showingwirebraid,nicks,cuts,damageorabrasions.Failuretodosomayresultinequipmentdamageand/or
personalinjuryordeath.
• Cleanupanyoiloruidspillsimmediately.
3.3. Personal/Safety equipment
• Neverwearlooseclothingthatcangetentangledintheworkingpartsofthetoolsorbecarelesswithhands,
feetorotherbodypartsaroundtheworkingpartsofthetools.Hydraulictoolsexerthightorqueandforceand
cancauseseriousinjuryordeathifimproperlyused.
• Whenworkingnearelectricalconductors,alwaysassumethattheconductorsareenergizedandthathosesand
clothingcanconductharmfulelectricity.Usehoseslabeledandcertiedasnonconductive.
• Alwayswearsafetyequipmentsuchasoilinjectionresistantworkgloves,safetyglasses,safetyboots,ear
protectionandothersafetyappareldictatedbyyoursupervisorapplicableforthejobyouaredoingandthetool
you are using.
• Theuseofancompressedair,whichmustbelessthan8BAR(116PSI),toblowpartscleanortoblowthem
dryafterbeingcleanedwithasolventwillcauseparticlesofdirtand/ordropletsofthecleaningsolventtobe
airborne.Theseconditionsmaycauseskinand/oreyeirritation.Whenusinganairjetdonotdirectittoward
anotherperson.Improperuseofairjetcouldresultinbodilyinjury.
3.4. Safety precautions
• Alwayswearprotectiveequipmentsuchasgloves,safetyglasses,earprotectionandsafetyshoes.
• Donotwearclothingwhichmaybecomeentangledinthetool.
• Alwayskeepworkareafreeoftoolsoranyotherobjectswhichmayimpairsoundfooting.
• Cautionoilinjectionhazardexistswiththistool.Oilinjectionisaconditionwherethehydraulicoilisforced
undertheskinthroughpressureintheline.Alwaysweargloves,donotcarrythetoolbyhydraulichoses,and
repairleaksimmediately.
• Donotoperatethepowerunituntilyouhavebeenproperlytrainedorunderthesupervisionofaqualied
instructor.
• Neverstoreengineoilorhydraulicoilnearoxygentanksorlines.
• Neveraddengineoilorhydraulicoilwhenaspillmightcomeincontactwithyouroxygenlines,torchorttings.
• Cleanupspillsimmediately.
• Neverperformgrindingorsawingoperationsthatdirectsparksintothecloseproximityofthepowerunitor
ammablematerials.
• Alwaysturnpowerunit"OFF"anddisconnecthosesbeforeperforminganymaintenance.
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3.5. Qualied personnel
Themachineisonlytobeusedbytrainedpersonnel,thoroughlyfamiliarwithandtrainedingeneralrailway
workmanship.Theequipmentshouldbeoperatedaccordingtotheconditionsandstandardregulationsapplyingto
thetracktheyareworkingon.
Theequipmentmustbeserviced,maintained,orinanywaymodiedonlybytrainedpersonnel,whoarefamiliar
withtheOperation&MaintenanceManualandhavereceivedtrainingandinformationfromPandrol.
Inordertoavoidpersonalinjuryand/ormaterialdamage,everyoneinvolvedwithassembling,starting-upor
overhaulmustpossessrelevantknowledgeoftheequipment,itsuse,maintenancerequirementsandprocedures.
WARNING!
• Do not touch electrical connections before you rst ensure the power has
been disconnected. Only qualied 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
hertzrequirements
5GPM(19LPM)
or
10GPM(38LPM)
Fluid:hydraulic
5usgal(18.9)liters
200PSI(140BAR) A-40”(101.6cm)
B-26”(66cm)
C-30”(76.2cm)
486lbs(220kg)
4. Summary
ThePandrolElectricPowerUnitisdesignedtodeliver2-5
GPMcircuitsor1-10GPMcircuitat2000PSIforhydraulic
tooloperationsinbuildingsorotherclosedenvironments.Itis
perfect for maintenance shop testing of tool repairs. The unit is
equippedwithheavydutywheelsformobility.
Accessories:
02326E-Hosereelequippedwith50’transmissionhose.
02323K-Hosereelequippedwith25’transmissionhose.
*Hertzrequirementsvarybycountry.
Specifyrequirementswhenordering.
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
• Tostartthepowerunit,checktomakesurethatbothcontrolvalvesareinthe"OFF"position.
• Depressthestartbuttononthebreakerboxlocatedonthefrontoftheunit.
• Connectthepowertransmissionhosetoeitherthe5or10GPMports,dependingontheowrequiredforthe
toolyouwillbeusing.
• Connectthetool(s)tothepowertransmissionhosebeforeturningcontrolvalvesatpowerunit"ON".
• Rotateappropriateowcontrolvalves.(See“valvepositioning”inthismanual.)
• Tochangetools,turnthecontrolvalvestotheoposition.
• Toshutdownthepowerunitturnthecontrolvalvestothe"OFF"positionanddepresstheredstopbuttonon
thebreakerbox.
5.1. Valve positioning
The03700apowerunitisdesignedtooperateeither(1)toolat10GPM(38LPM)or(2)toolssimultaneouslyat5
GPM(19LPM).Refertooperatinginstructionsforeachtooltodetermineowrequirements.
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
dierent locations. Due to this, have a qualied person or technician ensure
electrical system compatibility
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5 GPM tools:
Tooperatea5GPMtool,connectbothtoolstotheportsmarked5GPMandturn"ON"thevalvecorrespondingto
each tool port.
10 GPM tools:
Tooperatea10GPMtool,connectittotheportmarked10GPMandturnonbothcontrolvalves.
5.2. Changing tools
• Turnthecontrolknobstothe"OFF"positionbeforedisconnectinghoses.
• Oncethetoolhasbeenchanged,turnthevalvestothe"ON"positiondependingonowrequirementsofthe
toolbeingused.
5.3. Cold weather operation
Hydraulicsystemperformanceisaectedwhenthetemperaturedropsbelow50°F.Therefore,measuresshouldbe
takentopre-warmtoolsanduidsbeforeoperating.
NOTE!
• Refer to operating procedures of this manual before starting
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