Cembre PCMD-FC Operation And Maintenance Manual

MACHINE FOR PANDROL

"FASTCLIP" FASTENING

PCMD-FC

ENGLISH

OPERATION AND MAINTENANCE MANUAL

1

16 M 197 E

INDEX page

1. General characteristics ....................................................................................................................................................... 4

2. Unpacking .............................................................................................................................................................................. 5

2.1 Transporting the machine ................................................................................................................................................ 5

3. Description of the machine ............................................................................................................................................. 6

4. Instructions for use ............................................................................................................................................................. 8

4.1 Assembling the machine ................................................................................................................................................. 8

4.1.1 Braking device ...................................................................................................................................................................... 8

4.2 Disassembling the machine ........................................................................................................................................... 10

4.3 Moving the machine .......................................................................................................................................................... 10

4.4 Controls ................................................................................................................................................................................... 11

4.5 Description of the Pandrol Fast clip .............................................................................................................................. 12

4.6 Description of the Pandrol FE clip ................................................................................................................................. 13

4.7 Description of the Pandrol FCX clip .............................................................................................................................. 14

4.8 Preliminary machine adjustments ................................................................................................................................ 15

4.8.1 Adjusting the height of the front of the machine .................................................................................................... 15

4.8.2 Stable support of both insertion teeth ........................................................................................................................ 15

4.8.3 Adjusting the piston for lifting sleepers ...................................................................................................................... 16

4.8.4 Adjusting the clamp position .......................................................................................................................................... 16

4.9 Operation ................................................................................................................................................................................ 17

4.9.1 Inserting clips ........................................................................................................................................................................ 17

4.9.2 Extracting clips ..................................................................................................................................................................... 18

4.9.3 Adjusting the contrast foot for extraction .................................................................................................................. 18

5. Adjusting the piston stroke .............................................................................................................................................. 19

5.1 Adjusting the piston stroke for clip insertion ............................................................................................................ 19

5.2 Adjusting the piston stroke for clip extraction ......................................................................................................... 20

5.2.1 Parking position ................................................................................................................................................................... 20

5.2.2 Insulator change position ................................................................................................................................................ 20

6. Display ..................................................................................................................................................................................... 21

6.1 Information screens ............................................................................................................................................................ 21

6.2 Warnings ................................................................................................................................................................................. 21

6.3 Errors ........................................................................................................................................................................................ 22

7. Starting the engine ............................................................................................................................................................. 23

8. Maintenance ......................................................................................................................................................................... 24

8.1 Routine maintenance of the machine ......................................................................................................................... 24

8.1.1 Maintenance of braking device ...................................................................................................................................... 24

8.1.2 Maintenance of clamp unit .............................................................................................................................................. 25

8.1.3 Topping up the oil in the hydraulic pump .................................................................................................................. 26

8.1.4 Replacing the hydraulic pump oil  lter ......................................................................................................................... 26

8.1.5 Adjusting the work lights ................................................................................................................................................. 26

8.1.6 Changing the gas springs ................................................................................................................................................. 27

8.2 Routine maintenance of the engine ............................................................................................................................. 27

8.3 Long periods of inactivity ................................................................................................................................................. 27

9. Return to Cembre for overhaul .................................................................................................................................... 30

2

WARNINGS

-

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.

- During operation keep your hands and all other persons outside the danger area.

- Always use Personal Protective Equipment such as is normally required by your em­ ployer and/or appropriate to your sector of operation.

- Always follow fuelling and refuelling practices and procedures normally required by
your employer and/or appropriate to your sector of operation.

- Only authorised personnel shall start, operate and maintain the machine.

- The design or con guration of the machine shall not be modi ed other than by
Cembre.

- 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 moving the machine along the rail.

3

1. GENERAL CHARACTERISTICS

Application range

suitable for the insertion or extraction of PANDROL* FE, FC

and FCX clips on standard gauge sleepers (1435 mm)

Developed force (single clamp)

Dimensions

Resistance between rail and wheel

N

MΩ

38.000

see Fig. 30 page 29

≥ 1

Weight

Complete machine

Pump unit

Clamp unit

Carriage

3rd wheel bar

kg

143

kg

kg

kg

kg

59

69

9

5

Combustion engine

Type 4-stroke, overhead valve, single cylinder

Model Honda GX200 UT-SMCR OH

Displacement cm³ 196 cm³

Power kW 4.1 (5.6)

Revs. rpm 3600

Exhaust emissions the engine is certi ed Euro 2 and meets U.S. EPA EXH/EVP

and CALIFORNIA SORE EXH/EVP REGS FOR 2013

Fuel unleaded regular grade petrol

Tank capacity lt 3,1

Recommended oil SAE 10W-30 (0,6 litres)

Start by rope pull with automatic rewind

Hydraulic pump

Max. pressure MPa 25

Oil supply 35 litres/minute

Oil capacity kg 4,5

Speed rpm 3500

Recommended oil kg (lbs) PANOLIN HLP SYNTH E68

Acoustic noise

Vibration

(*) "Pandrol Fastclip" is a Pandrol Ltd trademark.

(1)

Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u

L

= weighted continuous acoustic pressure level equivalent.

pA

= maximum value of the weighted acoustic displacement

L

pCPeak

pressure at the work place.

= acoustic power level emitted by the machine.

L

WA

(1)

(2)

m/s

dB

L

86,4 (A) L

pA

2

(2)

Directive 2006/42/EC, annexe 1, point 2.2.1.1

Weighted root mean square in frequency of the acceleration
the upper limbs are exposed to for each biodynamic reference
axis. Tests carried out in compliance with the indications
contained in EN ISO 5349-1/2 Standard, and under operating
conditions much more severe than those normally found.

<130 (C) LWA 101,0 (A)

pCPeak

4,63 max.

4

2. UNPACKING THE MACHINE

To reduce overall dimensions and weight during transport, the machine is supplied disassembled in sturdy
wooden crates.
The four component units are easily reassembled (Ref. to Fig. 1):
– Pump unit: combustion engine/hydraulic pump for clamp operation.
– Clamp unit: for inserting and extracting clips.
– Carriage: for supporting and moving the machine along the track.

rd

– 3

wheel bar: for stability and vertical positioning (the third wheel (47) is supplied disconnected

from the bar (49).

2.1) Transporting the machine

The four units are well balanced for easy transportation in accordance with the table and diagrams in Fig. 1. For
uniform weight distribution when carrying the pump and clamp units, always use the transportation handles
provided.

Ensure appropriate Personal Protective Equipment is used to avoid injury during transportation.

FIG. 1

A

B

C

D

E

F

G

H

D

SC-PCMD

23 kg
23 kg
23 kg

9 kg

5 kg
19 kg
19 kg
21 kg

A

E

CR-PCMD

C

B

CUFC-PCMD

H

F

G

PU-PCMD

5

3. DESCRIPTION OF THE MACHINE

TRANSPORTATION HANDLES

01

OIL COOLING FINS

02

HYDRAULIC PUMP

03

WORKLIGHT ON/OFF SWITCH

04

ELECTRICAL CONNECTOR SOCKET

05

QUICK RELEASE FEMALE AUTOMATIC HYDRAULIC COUPLER

06

HANDLEBAR LOCKING WINGNUT

07

QUICK RELEASE MALE AUTOMATIC HYDRAULIC COUPLER

08

BRAKE RELEASE CONNECTOR HOLDER (WHEN NOT IN USE)

09

WORKLIGHT

10

HANDLEBAR

11

BRAKE RELEASE LEVER

12

CLAMP DRIVE BUTTON FOR INSERTION/EXTRACTION

13

UPLIFT SETTING BUTTON

14

CLAMP CONTROL SWITCH

15

CLAMP RETURN BUTTON

16

STOP/EMERGENCY BUTTON

17

ENGINE

18

WORKLIGHT

19

PUMP UNIT FASTENING/RELEASE KNOB

20

ELECTRICAL TERMINAL BOX

21

DISPLAY

22

FRAME

23

TRANSPORT HANDLE

24

CLAMP UNIT LOCATING PINS

25

PUMP UNIT LOCATING PINS

26

SLEEPER LIFT PISTON

27

INSERT/EXTRACT PISTON

28

ELECTRICAL CONNECTOR

29

HYDRAULIC FLEXIBLE HOSES

30

MACHINE LIFT HEIGHT ADJUSTER

31

TRANSPORTATION HANDLES

32

REAR ARM WHEEL

33

EXTRACTION HOOK FASTENING/RELEASE KNOB

34

HEIGHT SETTING DEVICE

35

RAM STROKE ADJUSTMENT RING NUT

36

BRAKE RELEASE CONNECTOR SOCKET

37

GAS SPRING

38

REAR ARM WHEEL LOCK/RELEASE KNOB

39

INSERTION/EXTRACTION TOOTH

40

CONTRAST FOOT

41

TRANSPORTATION HANDLES

42

3rd WHEEL ARM FASTENING/RELEASE KNOB

43

FRONT HEIGHT ADJUSTMENT KNOB

44

CLAMP UNIT FASTENING/RELEASE KNOB

45

CARRIAGE WHEELS

46

SUPPORT WHEEL

47

SUPPORT WHEEL ADJUSTMENT LEVER

48

ARM

49

6

FIG. 2

PUMP UNIT

01

02

03

04

05

06

07

08

09

10

11

12

23

22

25

24

CLAMP UNIT

42

36

21

26

43

27

44

20

35

28

34

29

19

18

31

30

17

33

32

16

37

38

13

14

15

39

49

46

CARRIAGE

7

45

47

40
41

48

3rd WHEEL BAR

4. INSTRUCTIONS FOR USE

4.1) Assembling 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 knob (09) engaged and wheel (33) blocked, lift the clamp unit by means of the handles (24 & 32) and

rest this on the selected rail, positioning it at a sleeper for stability.

2 – Rest the support carriage on the track then pull and turn the fastening/release knobs (45).

Lift the clamp unit by the handle (24) and locate pins (25) fully into their carriage housings as far as the
stop. Release knob (45) to lock the clamp unit.

3 – Pull and turn knob (43), insert the 3

in the end of the arm with the pin knob.
Release knob (43) so wheel (47) can act as a support on the opposite rail and make the assembly stable
and able to slide along the rail. The arm can be  tted to the carriage from either side for convenience in
selecting the direction of work.

rd

wheel bar in the carriage housing as far as the stop, aligning the hole

4 – Pull and turn knobs (20) at the base of the pump unit. Lift the pump unit by handles (01) and handlebar

(11). Rest the pump unit on the clamp unit and align pins (26) with the relevant locating holes on the
under side of the pump unit. Release the knobs to lock.

5 – Unscrew handlebar locking wingnut (07) and rotate handlebar (11)

to a confortable position, tighten the wingnut fully to lock the handle.

FIG. 3a

6 – Plug electrical connector (29) into socket (05).

Attach  exible hydraulic hoses (30) by means of the quick cou-
plings to the respective sockets (06 & 08) on the clamp unit.

09

7 – Attach brake release (09) (Ref. to § 4.1.1) and adjust the gas springs

of the rear wheel arm using knob (31).

4.1.1) Braking system (Ref. to Fig. 3a, 3b, 3c, 4)

To move the machine along the rail, it is necessary to attach brake release
(09) to socket (37) on the rear arm as follows:

Introduce end part (A) into slot seat (B) located above the wheel of the

rear support arm (Ref. to Fig. 3a).

Pull handle (C) upwards, release it in position then push until it is locked

(Ref. to Fig. 3b and c).

Press lever (12) to verify the correct engagement and disengagement
of pin (P) from the wheel (Ref. to Fig. 3c).
During disassembly of the machine, before removal of the pump unit,
the brake release must be detached as follows:

Pull handle (C) and detach end (A) from slot seat (B).

B

A

37

C

FIG. 3b FIG. 3c

P

8

01

45

44

43

25

2

42

MOVEMENT

DIRECTION OF

SLEEPER

47

3

FIG. 4

11

12

5

4

26

24

1

29

6

30

31

7

32

33

RAILS

06

09

39

07

08

9

4.2) Disassembling the machine

To disassemble the machine:

First lower the rear support arm and lock with pin
(39), block wheel (33) then reverse the process de­ scribed in § 4.1.

On the pump unit, disconnect/detach electrical con­ nector (29), hydraulic hoses (30) (Ref to Fig. 5a) and
brake release (09) (Ref to Fig. 5b), placing the hoses in
their supports in the clamp unit and the brake release
in its support on the handlebar.

FIG. 5a

30

NOTE: Under normal conditions, the time taken to
remove the machine from the rail is approximately
60 seconds.

4.3) Moving the machine

To move the machine along the rail, the rear arm must
be raised to prevent the clamps knocking against the
Fastclip as follows:

1 – Pull and turn knob (39). The wheel arm will be freed

(Ref. to Fig. 6).

2 – Lift the unit by the handles; the two gas springs will

facilitate full lifting; the two springs can be adjusted
using knob (31), turning it clockwise for sti er
springs, anticlockwise for softer.

3 – Press brake release lever (12) against handlebar

(11).

4 – Push the machine along the rail.

39

2

1

31

29

09

FIG. 5b

3

12

FIG. 6

4

10

4.4) Controls

When gripping handlebar (11), the operator can easily access all the unit controls and, more speci cally:

Worklights ON/OFF switch (04): two high e ciency LED lights allow the clamp area to be e ectively lit in

poor light conditions and at night.

Brake release lever (12): for safety reasons the machine is equipped with a "dead man's" braking system on the
rear wheel. It is only possible to release the brake by pressing the lever (12), allowing the machine to move
along the rail.

Clamp operation button (13): enables operation of the clamps according to the mode selected with switch
(15).

Settings button (14): enables the machine to memorise the clamp position set for sleeper lifting.

Clamp control selector (15): allows the selection of insertion "IN" or extraction "OUT" of the clamps.

Clamp return button (16): enables the clamps to be brought back to their starting position.
With clamp control selector (15) on “OUT” it enables insertion of the clamps at a lower speed.

Stop/emergency button (17) in a very visible position and easy to operate to stop the machine 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.

The engine will not start unless the red button (17) is lifted.

FIG. 7

04

17

15

11

14

13

16

12

11

4.5) Description of the Pandrol Fastclip

FASTCLIPS have 3 positions:

PARKING POSITION:

All components are captive.

Side post insulator

Toe insulator

Fastclip

Shoulder

INSTALLED POSITION:

The Fastclip holds the rail.

INSULATOR CHANGE POSITION:

The Fastclip is withdrawn to the rear detent to

facilitate side post insulator removal.

FIG. 8 – FASTCLIP

12

4.6) Description of the Pandrol FE clip

FE CLIPS have 3 positions:

INSTALLED POSITION:

The FE clip holds the rail.

Side post insulator

Toe insulator

FE clip

PARKING POSITION:

All components are captive.

Shoulder

FIG. 9 – FE CLIP

13

INSULATOR CHANGE POSITION:

The FE clip is fully extracted and the

insulator can be removed.

4.7) Description of the Pandrol FCX clip

FCX CLIPS have 3 positions:

PARKING POSITION:

All components are captive.

Side post insulator

Toe insulator

FCX clip

Shoulder

INSTALLED POSITION:

The FCX clip holds the rail.

INSULATOR CHANGE POSITION:

The FCX clip is withdrawn to the rear stop to

facilitate side post insulator removal.

FIG. 10 – FCX CLIP

14

4.8) Preliminary machine adjustments

0

1

2

3

4

5

MACHINE ADJUSTMENT IS ESSENTIAL TO ENSURE CORRECT OPERATION.
SOME ADJUSTMENTS REQUIRE THE ENGINE TO RUN.
SWITCH OFF THE ENGINE WHEN MAKING MANUAL ADJUSTMENTS TO THE CLAMPS AND LIFTING
PISTON.

The PCMD-FC is extremely versatile and adaptable to the many operating situations to be found along a railway
line (di erent types of rails, 60E1 etc. with di erent  ange heights and widths, di erent types of clips, sleepers
and chairs. For this reason, before use, some initial adjustment will be required to de ne the correct machine
setup during work.
Follow the following preliminary adjustments:

4.8.1) Adjusting the height of the front of the machine

Fully lower the machine so it is resting on the
sleeper.

Line up the side of the machine so that the
clamp unit is parallel with the upper surface of
the railhead. If this is not the case, adjust knob
(44) on the carriage (Ref. to Fig.11).
To lift the machine turn knob (44) anti-clocwise.
To lower the machine turn it clockwise.
The measuring scale will facilitate adjustment
by precisely de ning the correct position of the
machine.

FIG. 11

45

44

4.8.2) Stable support of both insertion teeth

Both insertion teeth (40) must be supported equally on the surface of the sleeper. If this is not the case, proceed
to vertically adjust the machine by turning the support wheel on the 3rd wheel bar (47):

Lower the machine completely with the teeth resting on the surface of the sleeper.

Unscrew the quick release handle (48).

Lower or raise the bar (49) to change the vertical angle of the machine and achieve correct alignment.

After making adjustments, fully retighten handle (48).

FIG. 12

49

47

48

40

15

40

4.8.3) Adjusting the piston for lifting sleepers

Procedure to be carried out on the clip in the "installation position".

When manually adjusting the lifting piston ensure THE ENGINE IS SWITCHED OFF.

The lifting piston must be adjusted correctly using the supplied gauge, otherwise the machine could
break the insulators or insert the clips Incorrectly.

Turn the clamp control selector (15) to the “OUT” position; press button (16) repeatedly with short pulses to

put the clamps into contact with the clips already in the “installation position”.

Make sure that the lifting piston (27) is fully up in the starting position.

Place the Height Setting Device (HSD) (35) from the magnetic side on top of the rail in correspondence with
the piston. With a 17 mm wrench, block the piston (27) and loosen
the nut (D) with a 18 mm wrench.

Rotate the threaded rod so that the foot is resting on
the gauge and then tighten the nut (D) again.

Remove the HSD (35) and put it back
in its seat.

17 mm

27

18 mm

D

35

4.8.4) Adjusting the clamp position

Procedure to be carried out on the clip in "parked position".

Start the engine (see § 7).

Push the machine so that it is in line with the clip to be operated on
(see § 4.3).

Position the clamps with the insertion teeth (40) in the open position
(Ref. to Fig. 13b).

Turn the clamp control selector (15) to the “OUT” position.

Press button (16) repeatedly with short pulses to make the clamps
slowly advance towards the clips.

Bring the correctly centred insertion teeth into contact with the clip without the clips being inserted.

Press and hold button (14) to memorise the position.

Three worklight  ashes con rm that the position has been saved.

Turn the clamp control selector (15) back to the "IN" position.

16

FIG. 13a

FIG. 13b

40

4.9) Operation

Before use, always check:

Integrity of the machine.

The correct coupling of the units making up the machine.

Correct connection of the quick couplings and braking system.

Correct level of oil in pump.

For any oil leaks in the hydraulic circuit (hoses, pump).

Flexible hoses are in good condition and show no signs of wear or crushing.

Protection devices in the clamp areas are  rm and show no signs of damage.

That the engine fuel tank cap is tight. Petrol is highly in ammable and can explode.

When manually adjusting the clamps ensure THE ENGINE IS SWITCHED OFF.

Start the engine (see § 7).

4.9.1) Inserting clips

Make sure the locking knob (39) of the rear wheel is released (see § 4.3).

An "Insertion operation" means (see § 4.5, § 4.6, and § 4.7):

1 - Moving from “parking position” to “installation position”.

2 - Moving from “insulator change position” to “installation position”.

Push the machine to the clips on which operations are to be performed (see § 4.3).

IMPORTANT: when performing the  rst insertion operation, the correct stroke of the rams will have to

be established so the clips are positioned precisely (see § 5.1).

Ensure that the clamps are open.

Lower the machine completely, resting the teeth (40) on the surface of the sleeper (Ref. to Fig. 12).

Adjust the upper and lower rings as described in § 5.

Turn the clamp control selector (15) to the insertion position “IN”.

Press the clamp operation button (13) to make the teeth advance (40), bringing the clip into the “installation

position”.

Once the insertion has been completed, the clamps are retracted automatically.

Lift the machine, move to the next clips and repeat the above operations.

17

4.9.2) Extracting clips

Make sure the locking knob (39) of the rear wheel is released (see § 4.3).

An "Extraction operation" means (see § 4.5, § 4.6, and § 4.7):
1 - Moving from “installation position” to “parking position”.
2 - Moving from “installation position” to “insulator change position”.
3 - In exceptional cases, the complete extraction of the clip.

Push the machine to the clips on which operations are to be performed (see § 4.3).

IMPORTANT: when performing the  rst extraction operation, the correct stroke of the rams will have to

be established so the clips are positioned precisely (see § 5.2).

Turn the teeth (40) to the extraction position (Ref. to Fig. 14).

Mount the track spacer (41), adjusting it based on the type of rail and insulator (see § 4.9.3).

Turn the clamp control selector (15) to the extraction position “OUT”.
Turn the lower ring nuts on each side to adjust the extraction stroke.
Turn the upper ring nuts used for the insertion of the clips, to prevent the tooth from scraping the rail web.

Press the clamp operation button (13) to make the teeth advance (40), bringing the clips to the “parked
position”.

Once the extraction is complete, the clamps are retracted automatically (while still holding down the clamp
operation button (13)).

Lift the machine, move on to the next clips and repeat the above extraction operations (avoid lifting over the
railhead with the extraction teeth).

FIG. 14

40

4.9.3) Adjusting the contrast foot for extraction

There are two operations for adjusting the track spacers (Ref. to Fig. 15):

Attach the track spacers to the machine, keeping the reference number
corresponding to the width of the rail  ange facing the rail.

Locate its  xing screw so the track spacer is closest to the side post insulator.

With these adjustments it is possible to operate on many track layouts.
If not suitable for the particular application required, contact Cembre.

FIG. 15

14

15

Ref. n° Rail type

14 56E1 (113 lb)

15 60E1 (UIC60)

18

41

5. ADJUSTING THE PISTON STROKE

5.1) Adjusting the piston stroke for clip insertion

FIG. 16

Reference

line

0

LEFT CLAMP

B

3

RIGHT CLAMP

B

0

3

Reference

line

0

1

2

Upper

ring nut

3

3

3

B

graduated scales:

0 = max. stroke
3 = min. stroke

The upper ring nut establishes the piston stroke when the clamp is advancing towards the rail during clip
installation. To adjust, proceed as follows:

Turn the upper ring nut of one piston so as to bring the reference line to an intermediate position on the

graduated scale (Ref. to Fig. 16).

The reference line corresponds with the end of the ring nut.

Carry out a clip insertion (see § 4.9.1) and check the position of the clip.
The “installation” position is di erent depending on the type of clip, normally they should be at a safe distance
(x) from the edge of the spacer insulator (Ref. to Fig. 17), except where stated otherwise.
If this is not the case, to increase the distance (X) during insertion, unscrew the upper ring nut towards zero,
then re-try insertion. Conversely to reduce the distance (X), tighten the upper ring nut towards the number
three. Several attempts may be necessary to obtain the exact clip position, using the graduated scale to make
 ne and exact adjustments.

Having found the exact adjustment for one piston, position the ring nut of the other piston at the same value
on the graduated scale.

INSTALLATION POSITION

0

2

1

0

Lower

ring nut

Reference

line

Reference

line

X

0

Lower

ring nut

3

2

1

B

3

Rail

0

1

2

3

Upper

ring nut

0

graduated scales:

0 = max. stroke
3 = min. stroke

FIG. 17

Fastclip

Side post insulator

The lower ring nut establishes the piston stroke when the clamp is returning towards the starting position.
To adjust, proceed as follows;

Tighten the lower ring nut of one piston towards the number three to reduce the clamp opening (Ref. to Fig.16).

Unscrew the lower ring nut of one piston towards zero to increase the clamp opening (Ref. to Fig. 16).

19

5.2) Adjusting the stroke for clip extraction

When manually adjusting the clamps ensure

THE ENGINE IS SWITCHED OFF.

If the machine has been running the Exhaust may be

very hot, beware when using the Starting Cable.

The lower ring nut establishes the piston stroke during extrac­tion. To adjust proceed as follows:

Turn the lower ring nut of one piston so as to bring the
reference line to an intermediate position on the graduated
scale (Ref. to Fig. 16).

The reference line corresponds with the end of the ring

nut.

Pull and turn knob (34), release extraction tooth (40) and prepare it for extraction (Ref. to Fig. 18).

Fully lower the machine in correspondence with the clip (Ref. to Fig. 14 & 15).

Once the exact adjustment has been found on one piston, position the ring nut on the other piston at the
same value on the graduated scale.

34

40

FIG. 18

5.2.1) Parked position

Carry out a clip extraction (see § 4.9.2) and check the position of the clip.
In the “parked position” the cap on the clip should normally be at a prede ned distance (X) from the edge of
the spacer insulator (Ref. to Fig. 19), except where stated otherwise.
If this is not the case, to increase the distance (X) during extraction, unscrew the lower ring nut towards zero,
then re-try extraction. Conversely to reduce the distance (X), tighten the lower ring nut towards the number
three. Several attempts may be necessary to obtain the exact clip position, using the graduated scale to make
 ne and exact adjustments.

Once you have found the exact adjustment for one piston, position the ring nut of the other piston at the
same value on the graduated scale.

PARKING POSITION

Toe insulator

X

FIG. 19

Rail

Side post insulator

5.2.2) Insulator change position

Follow the instructions in § 5.2.1 being careful to adjust the lower ring nut to increase the piston stroke, thereby
favouring greater retraction of the clip.
For the FE clip further increase the piston stroke, facilitating the complete release of the clip.

20

6. DISPLAY

The OLED display (22) is located on the outer face of the electrical terminal box (21) and is activated when the
machine is switched on and automatically deactivated around 30 secs after turning the machine o .
The display shows:

The main operational parameters of the machine processed by the circuit board, such as number of full cycles

and hours of work.

Indications of the condition of the machine e.g maintenance requirements.
Any operational or procedural ERRORS.

Use the touch button to navigate through the menu screens to manage
INFORMATION.

6.1) INFORMATION SCREENS: display a pre-determined parameter which will then appear each time the

tool is started and during the entire work cycle.

Cembre logo

3

1000000

h 9999.9

h 9999.9

n° full cycles
n° working hours
(standard factory set screen)

n° of hours since last maintenance
n° of hours until next maintenance

h 9999.9

PU-PCMD

FIRMWARE

The capacitive menu selection button may not work if touched using objects or when wearing gloves,

therefore always operate it using a bare  nger.

One cycle corresponds to one sleeper.

6.2) WARNINGS: these appear during operation and notify the operator of the status of the machine:

NO. OF CYCLES TO MAINTENANCE REACHED: the machine continues to work however,

h 9999.9

it is recommended that it is sent to Cembre for a complete overhaul (see § 9).

NOTE: this message remains on the display.

Cembre logo, machine model
Machine serial n°

21

6.3) ERRORS: these appear during operation and notify the operator of procedural or operational errors.

Message Error description Solution

Accelerator motor reset error. Replace the faulty component, contact

001

Cembre.

002

003

004

005

006

007

009

010

Accelerator motor minimum
positioning error.

Accelerator motor maximum
positioning error.

Generator power supply frequency
out of range.

Motor or pcb driver faulty. Replace the motor or electronics board,

Parameter storage failure in eeprom. Retry, if it does not work the memory is

Failure to store work data in eeprom. Electronics board faulty and needs replac-

Pressure sensor disconnected or faulty
at start up.

Pressure o set error at start up. Replace the pressure sensor, contact

Replace the faulty component, contact
Cembre.

Replace the faulty component, contact
Cembre.

Increase the engine idling speed or
replace the generator, contact Cembre.

contact Cembre.

damaged, contact Cembre.

ing, contact Cembre.

Check the connection.
If the error persists replace the sensor,
contact Cembre.

Cembre.

Accelerator cable error disconnected or

011

Error can be reset by pressing buttons
(B) simultaneously for 5 seconds; if
the error persists contact Cembre.

Error messages remain on the display
until they are reset.

disconnected.

Check the two ends of the cable, contact
Cembre.

B

22

7. STARTING THE ENGINE

If the machine has been running the Exhaust
may be very hot, beware when using the
Starting Cable.

The machine is equipped with an automatic accelera­tor which serves to accelerate the combustion engine
to bring it to different engine speeds according to the
different work phases. When the engine is started it
will adjust automatically, by setting the intermediate
and maximum speed then to find and set its minimum
speed. The procedure for starting the engine is:

17

After start-up wait for the engine to regulate
the three engine speeds.

Put red stop button (17) (see § 4.3) in the "ON"
position (Ref. to Fig.20a) by turning it clock­ wise.

The engine will not start unless the red but-

ton (17) is lifted.

Move the fuel stopcock to "ON" position (Ref. to
Fig. 20b).

Move the air lever to "CLOSE" position (Ref. to Fig.
20b).
Do not use the air lever if the engine is hot and

the air temperature is high enough.

Start the engine by pulling the starting cable until

resistance is felt then pull with force (Ref. to Fig.
20c).

IMPORTANT: Do not allow the cable knob to return
forcefully and knock against the frame.
Return this slowly to its original position.
To prevent damage to the starting device.

As the engine heats up, gradually move the air lever
to "OPEN" position (Ref. to Fig. 20b).

FIG. 20a

Air lever
CLOSE

OPEN

Fuel stopcock

OFF

ON

FIG. 20b

Starting cable knob

To stop the engine in emergency condition, press
red button (17).

To stop the engine in normal conditions:

Press the button (17).
Move the fuel stopcock to "OFF".

23

FIG. 20c

TROUBLESHOOTING

When the starting cable is pulled, the engine fails to start:

Is the Stop/Emergency button (17) released? (see § 4.4).

Is there enough oil in the engine?

– The engine has 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 recommended oil type and topping up procedure.

THE HYDRAULIC OIL SUPPLIED WITH THE MACHINE IS INTENDED ONLY FOR USE IN THE HYDRAULIC PUMP AND MUST

NOT BE USED IN THE ENGINE.

Is the fuel stopcock open?

Is there fuel in the tank?

Is fuel reaching the carburettor?

– To check, loosen the carburettor drainage screw with fuel stopcock 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 it using the spanner provided.

– Fit the plug back in the cap.

– Move button (17) to "ON".

– Earth the side electrode then pull the starting cable and check to see if the plug produces a spark.
If the engine still fails to start, contact Cembre (see § 9).

8. 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 cool. Always

remove the spark plug cap from the spark plug when servicing the engine to prevent accidental starting.

8.1) Routine maintenance of the machine

At the end of each day, wipe the machine carefully using a clean cloth, being careful to eliminate all dirt, espe­cially near the moving parts such as the clamp teeth, 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 rubber dampers under the engine and pump, and on top of the clamp unit which

reduce vibration caused by those components.

Replace the insertion teeth (40) and contrast feet (41) as these become worn or damaged by long or improper

use.

8.1.1) Maintenance of braking system

The braking system is of robust construction and will require very little maintenance, however the following
routine checks should be performed.
Dust, sand and dirt 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.

24

Before every use:

Check rear wheel for resistance, it 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. It should roll along rail when pushed but will slide if excessive braking
occurs.

8.1.2) Maintenance of clamp unit

Before every use:

Check cable, linkages, springs and rear wheel for signs of damage.

Check linkages are free moving.

Ensure brake cable moves without resistance and is not damaged.

With brake released, check the wheel rotates freely.

Check that, when handlebar lever (12) is in the raised position, the brake is engaged.

Ensure the wheel is clean of dirt and mud.

Check that, before assembly, the wheel does not rotate one full turn in either direction.

Ensure brake coupling above rear wheel is free of
dirt and mud.

Every 6 months

Check wheel pockets for excessive wear.
If braking e ectiveness is compromised, replace
wheel.

Check for wear on pivots.

Ensure fasteners are secure.

Check for wear on brake coupling. Parts should
mate securely.

Clean all moving parts and lubricate as required.

FIG. 21

12

FIG. 22

25

8.1.3) Topping up the oil in the hydraulic pump

T

C

Tank

B

G

Periodically check the oil level in the hydraulic pump
tank.
If the level is low, top it up:

Remove and lift the cap, check that the level of oil
is between the two notches on the dipstick, if it is
lower add the quantity of oil necessary (Ref. to Fig. 24).

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  uid.

FIG. 23

FIG. 24

Filter

Top notch

Lower notch

Dipstick

8.1.4) Replacing the hydraulic pump oil  lter

Detach connector (C), unscrew ring nut (G) paying
attention to the seal inside it and remove solenoid
coil (B) (Ref. to Fig. 23).

Use a 16 mm spanner to unscrew the nut on the
 lter and replace the  lter (Ref. to Fig. 25).

Once this has been completed relocate the solenoid
coil of the electro-valve, its connector and ring nut.

8.1.5) Adjusting the worklights

Loosen the nut on the worklight fastening pin (Ref.
to Fig. 26).

Turn the worklight to the desired position then
retighten the nut.

Nut

FIG. 25

FIG. 26

26

8.1.6) Changing the gas springs

Replace the gas springs when required as follows:

On both sites loosen screws (A) with an 8 mm Allen
key and screws (B) with a 6 mm Allen key then remove
the casing (Ref. to Fig. 27).

Unlock the arm in order to extend the springs (Ref .
to Fig. 28).

Use a  nger to release the retaining rings located at
the ends of the spring and simultaneously detach it
from the pins (Ref. to Fig. 29).

Place the new spring on the same pins, pressing it
with force until it is inserted, respecting its original
orientation.

Reposition the retaining rings.

Repeat this process for both springs.

Replace the casing and fasten it by tightening the
screws.

FIG. 27

Casing

B

cacciavite

A

Gas spring

FIG. 29FIG. 28

Retaining

ring

8.2) Routine maintenance of the engine

Checks and periodic servicing are indispensable to ensure smooth engine operation.
Refer to the "HONDA owner’s manual" supplied with the machine for the following operations:

Oil change ( rst change after 20 hours of work)

Air  lter assistance (see double-element type)

Cleaning sediment from sump

Spark plug cleaning; recommended plugs BPR6ES (NGK) or W20EPR-U (DENSE)

Minimum carburettor setting

8.3) Long periods of inactivity

Store the machine in a dry environment and adequately protect it against accidental damage and contamination.

For information on the engine, refer to the "HONDA owner’s manual".

27

of inactivity

Long periods



of evident

300 hours Presence

100 hours

At every use

signs of wear

































PERIODIC OVERHAUL

Performed at the prescribed intervals or at the number of indicated

General cleaning with a clean

cloth, paying attention to

remove settled dirt

ITEM ACTION

working hours or at the occurrence of indicated extraordinary events

Complete machine

Store the machine in a dry place,

protecting it from shocks

and dust

Visual & manual checks

(tighten if necessary)

Complete tightening

Visual check of integrity

Replacement

Visual & manual checks

Bolts and nuts

Flexible hose

(tighten if necessary)

Complete tightening

Hydraulic couplers

Visual & manual checks of integrity

Replacement

Visual & manual checks of

integrity

Inserting and

extraction teeth (40)

Clamp unit rubber

dampers of the unit

Contrast foot (41)

Replacement

Check reservoir level

(Top up if necessary)

Hydraulic oil

28

Replacement

Replacement

Hydraulic oil  lter

Replacement

Replacement

Gas springs

Accelerator cable

613

1892

1223

Pump unit

serial number

XXXXXX

1750

1085

29

FIG. 30 – DIMENSIONS (mm)

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 Certi cate supplied by Cembre to the machine or  ll in and attach the form available in the “ASSISTANCE”
section of the Cembre website.

9.

RETURN TO

Cembre

FOR OVERHAUL

ADJUSTMENTS:

We suggest recording all adjustable Ring nut settings in the table
alongside to facilitate quick ‘resetting’ in future.

From «parking position» to «installation position».

From «insulator change position» to «installation position».

INSERTIONEXTRACTION

Complete insertion of the Fastclip.

From «installation position» to «parking position».

From «installation position» to «insulator change position».

Complete extraction of the Fastclip.

RING NUT SETTINGS

RAIL: RAIL: RAIL:

Ring

Ring

Ring

Ring

nut

upper

nut

lower

nut

upper

nut

lower

Ring

nut

upper

Ring

nut

lower

30

31

Cembre Ltd.

Dunton Park
Kingsbury Road, Curdworth - Sutton Coldfield
West Midlands B76 9EB (UK)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembre.co.uk

Cembre S.a.r.l.

22 Avenue Ferdinand de Lesseps
91420 Morangis (France)
Tél.: [phone] - Fax: [phone]
CS 92014 - 91423 Morangis Cédex
E-mail: [e-mail]
www.cembre.fr

Cembre España S.L.U.

Calle Verano 6 y 8
28850 Torrejón de Ardoz - Madrid (España)
Teléfono: 91 4852580
Telefax: 91 4852581
E-mail: [e-mail]
www.cembre.es

Cembre GmbH

Heidemannstraße 166
80939 München (Deutschland)
Telefon: [phone]
Telefax: 089 35806777
E-mail: [e-mail]
www.cembre.de

Cembre S.p.A.

Via Serenissima, 9
25135 Brescia (Italia)
Telefono: 030 36921
Telefax: 030 3365766
E-mail: [e-mail]
www.cembre.com

Cembre Inc.

Raritan Center Business Park
181 Fieldcrest Avenue
Edison, New Jersey 08837 (USA)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembreinc.com

IKUMA GmbH & Co. KG

Boschstraße 7
71384 Weinstadt (Deutschland)
Telefon: [phone] - 60
Telefax: 7151 20536 - 80
E-mail: [e-mail]
www.ikuma.de

www.cembre.com

This manual is the property of Cembre: any reproduction is forbidden without written permission.

cod. 6261426

3232