1

MACHINE FOR PANDROL

"E-CLIP" FASTENING

PCMD-EC

ENGLISH OPERATION AND MAINTENANCE MANUAL

17

M 0

40

E

2

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 Preliminary machine adjustments ................................................................................................................................. 12

4.5.1 Adjusting the rear height of the machine ................................................................................................................... 12

4.5.2 Adjusting the height of the front of the machine .................................................................................................... 13

4.5.3 Adjusting the vertical alignment of the machine .................................................................................................... 13

4.6 Operation ................................................................................................................................................................................ 14

4.6.1 Inserting clips ........................................................................................................................................................................ 14

4.6.2 Extracting clips ..................................................................................................................................................................... 16

5. Display ..................................................................................................................................................................................... 17

5.1 Information screens ............................................................................................................................................................ 17

5.2 Warnings ................................................................................................................................................................................. 17

5.3 Errors ......................................................................................................................................................................................... 18

6. Starting the engine ............................................................................................................................................................. 19

7. Maintenance ......................................................................................................................................................................... 20

7.1 Routine maintenance of the machine ......................................................................................................................... 20

7.1.1 Maintenance of braking device ...................................................................................................................................... 20

7.1.2 Maintenance of clamp unit .............................................................................................................................................. 21

7.1.3 Topping up the oil in the hydraulic pump .................................................................................................................. 22

7.1.4 Replacing the hydraulic pump oil fi lter ......................................................................................................................... 22

7.1.5 Adjusting the work lights ................................................................................................................................................. 22

7.1.6 Changing the gas springs ................................................................................................................................................. 23

7.2 Routine maintenance of the engine ............................................................................................................................. 23

7.3 Long periods of inactivity ................................................................................................................................................. 23

8. Return to Cembre for overhaul .................................................................................................................................... 26

3

- 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

employer 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 confi guration of the machine shall not be modifi 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.

WARNINGS

4

Application range suitable for the insertion or extraction of PANDROL* e-clip

on standard gauge sleepers (1435 mm)

Developed force (single clamp) N 30.000

Dimensions see Fig. 25 page 25

Resistance between rail and wheel MΩ ≥ 1

Weight

Complete machine kg 128

Pump unit kg 59

Clamp unit kg 54

Carriage kg 9

3rd wheel bar kg 5

Combustion engine

Type 4-stroke, overhead valve, single cylinder

Model Honda GX200 UT2-SMCR OH

Displacement cm³ 196 cm³

Power kW (HP) 4.1 (5.6)

Revs. rpm 3600

Exhaust emissions the engine is certifi 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 litri)

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 (1) dB LpA

86,4 (A) LpCPeak

<130 (C) LWA

101,0 (A)

Vibration (2) m/s2 4,63 max.

1. GENERAL CHARACTERISTICS(*

) "P

an

dro

l" is

a P

an

dro

l Ltd

tra

dem

ark

.

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

LpA

= weighted continuous acoustic pressure level equivalent.

LpCPeak

= maximum value of the weighted acoustic displacement pressure at the work place.

LWA

= acoustic power level emitted by the machine.

(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.

5

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.

– 3rd wheel bar: for stability and vertical positioning (the third wheel (46) is supplied

disconnected from the bar (48)).

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.

AC

B

A 18 kg

B 18 kg

C 18 kg

D 9 kg

E 5 kg

F 19 kg

G 19 kg

H 21 kg

D F

CR-PCMD PU-PCMDSC-PCMD

EG

H

FIG. 1

CUEC-PCMD

6

3. DESCRIPTION OF THE MACHINE

01 TRANSPORTATION HANDLES

02 OIL COOLING FINS

03 HYDRAULIC PUMP

04 WORKLIGHT ON/OFF SWITCH

06 QUICK RELEASE FEMALE AUTOMATIC HYDRAULIC COUPLER

07 HANDLEBAR LOCKING WINGNUT

08 QUICK RELEASE MALE AUTOMATIC HYDRAULIC COUPLER

09 BRAKE RELEASE CONNECTOR HOLDER (WHEN NOT IN USE)

10 WORKLIGHT

11 HANDLEBAR

12 BRAKE RELEASE LEVER

13 CLAMP DRIVE BUTTON FOR INSERTION/EXTRACTION

14 UPLIFT SETTING BUTTON not enabled for e-clip clamp unit CUEC-PCMD

15 CLAMP CONTROL SWITCH

16 CLAMP RETURN BUTTON

17 STOP/EMERGENCY BUTTON

18 ENGINE

19 WORKLIGHT

20 PUMP UNIT FASTENING/RELEASE KNOB

21 ELECTRICAL TERMINAL BOX

22 DISPLAY

23 FRAME

24 TRANSPORT HANDLE

25 CLAMP UNIT LOCATING PINS

26 PUMP UNIT LOCATING PINS

27 HYDRAULIC FLEXIBLE HOSES

28 KNOB ADJUSTMENT HEIGHT SUSPENSION

29 KNOB ADJUSTMENT INTENSITY SUSPENSION

30 TRANSPORTATION HANDLES

31 REAR ARM WHEEL

32 HYDRAULIC FLEXIBLE HOSES

33 INSERTION/EXTRACTION TOOTH

34 LOCATOR PLATE

35 HYDRAULIC PISTON

36 BRAKE RELEASE CONNECTOR SOCKET

37 GAS SPRING

38 REAR ARM WHEEL LOCK/RELEASE KNOB

39 TRANSPORTATION HANDLES

40 3rd WHEEL ARM FASTENING/RELEASE KNOB

41 FRONT HEIGHT ADJUSTMENT KNOB

42 CLAMP UNIT FASTENING/RELEASE KNOB

43 CARRIAGE WHEELS

44 SUPPORT WHEEL

45 SUPPORT WHEEL ADJUSTMENT LEVER

46 ARM

7

0103 04 06

08

10

13

1819

22

23

14

15

FIG. 2

12

26

25

27

38

30

31

34

46

3rd WHEEL BAR

CLAMP UNIT

CARRIAGE

43

39

42

40

36

PUMP UNIT

02

20 16

37

44

45

09

29

41

17

11

24

07

21

28

33

35

32

8

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 (31) blocked, lift the clamp unit by means of the handles (24 & 30) 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 (42). Lift the clamp unit by the handle (24) and locate pins (25) fully into their carriage housings as far as the stop. Release knob (42) to lock the clamp unit. 3– Pull and turn knob (40), insert the 3rd wheel bar in the carriage housing as far as the stop, aligning the hole in the end of the arm with the pin knob. Release knob (40) so wheel (44) 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 fi tted to the carriage from either side for convenience in selecting the direction of work. 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.6– Attach flexible hydraulic hoses (27) by means of the quick couplings to the respective sockets (06 & 08) on the clamp unit. 7– Attach brake release (09) (Ref. to § 4.1.1) and adjust the gas springs of the rear wheel arm using knob (29).

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 (36) 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 disenga-gement 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).

A

B

FIG. 3a

09

FIG. 3b FIG. 3c

4. INSTRUCTIONS FOR USE

36

C

P

9

4

2

7

6

1

3

5

FIG

. 4

01

11

0938 30

31

27

4025

26

44

RA

ILS

SL

EE

PE

R

DIR

ECTI

ON

OF

MO

VEM

ENT

24

39

42

12

06 08

07

41

2928

10

4.2) Disassembling the machine To disassemble the machine:

First lower the rear support arm and lock with

pin (38), block wheel (33) then reverse the process

described in § 4.1.

On the pump unit, disconnect/detach hydraulic

hoses (27) (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.

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 e-clips as follows:

1– Pull and turn knob (38). 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 (29),

turning it clockwise for stiffer springs,

anticlockwise for softer.

3– Press brake release lever (12) against

handlebar (11).

4– Push the machine along the rail.

3

2

4

1

FIG. 6

12

38

FIG. 5a

29

09

27

FIG. 5b

28

11

4.4) Controls When gripping handlebar (11), the operator can easily access all the unit controls and, more specifi cally:

Worklights ON/OFF switch (04): two high effi ciency LED lights allow the clamp area to be eff 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): not enabled for e-clip clamp unit CUEC-PCMD.

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.

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

1613

12

0417 15 1411

12

4.5) Preliminary machine adjustments

MACHINE ADJUSTMENT IS ESSENTIAL TO ENSURE CORRECT OPERATION.

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 clearance

above the retention plate (see Fig. 8).

To adjust, proceed as follows:

4.5.1) Adjusting the rear height of the machine

To raise the machine, turn the adjustment

knob (28) clockwise.

To lower the machine, turn the adjustment

knob (28) anticlockwise.

33

~3

- 4

mm

FIG. 8

FIG. 928

29

e-clip shoulder

13

4.5.2) Adjusting the height of the front of the machine

After making the adjustments described in

§ 4.5.1 proceed to adjust the

machine horizontally as follows:

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 (43) on the carriage (Ref. to Fig.12).

To lift the machine turn knob

(43) anti-clockwise.To lower the machine

turn it clockwise.

The measuring scale will facilitate adjustment by precisely defi ning the correct position of the machine.

4.5.3) Adjusting the vertical alignment of the machine

Both insertion teeth (33) must be supported equally on the surface of the sleeper. If this is not the case, after

having made the adjustments described in § 4.5.1 and § 4.5.2 proceed to vertically adjust the machine by turning

the support wheel on the 3rd wheel bar (44):

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

Unscrew the quick release handle (45).

Lower or raise the bar (46) to change the vertical angle of the machine and achieve correct alignment.

After making adjustments, fully retighten handle (45).

FIG. 10

012345

42

41

44

46

45

FIG. 11

14

4.6) 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 fi rm and show no signs of damage.

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

Start the engine (see § 6).

4.6.1) Inserting clips

Make sure the locking knob (38) of the rear wheel is released (see § 4.3).

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

Position the e-clips in the retention plate eyelets, on both sides of the rail.

Make sure the teeth (33) of the clamps are moved fully back.

Completely lower the machine, positioning the locator plates (34) near the e-clip shoulder (see Fig. 13a).

e-clips

34

33

e-clip shoulder

FIG. 12

FIG. 13a

15

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

Push the button for insertion (13) to gradually move the teeth forwards with consequent insertion of

both e-clips (see Fig. 13b and 13c).

When performing the insertion operation, each clamp teeth (33) will move in opposite directions.

Movement of one of the clamps is schematically shown in the illustrations;

the other will have an identical and opposite movement.

Once the insertion has been completed, the clamps are retracted automatically while still holding down

the clamp operation button (13)(Ref. to Fig. 13d).

Lift the machine, move to the next clips.

Repeat the above operations.

33

33

33

FIG. 13b

FIG. 13c

FIG. 13d

16

4.6.2) Extracting clips

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

Make sure the teeth (33) of the clamps are moved fully.

Completely lower the machine, positioning the yellow locator plates (34) near the e-clip shoulder

(see Fig. 14a).

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

Push the button for extraction (13) to gradually move the teeth forwards with consequent extraction

of both e-clips (see Fig. 14b and 14c).

When performing the extraction operation, each clamps teeth (33) will move in opposite directions.

Movement of one of the clamps is schematically shown in the illustrations;

the other will have an identical and opposite movement.

Once the extraction is complete, lift the machine and move on to the next clips.

Repeat the above extraction operations.

33

33

33

34

e-clip

shoulder

33

FIG. 14a

FIG. 14b

FIG. 14c FIG. 14d

17

5. 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 off .

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.

5.1) 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

n° full cycles

n° working hours

(standard factory set screen)

n° of hours since last maintenance

n° of hours until next maintenance

Cembre logo, machine model

Machine serial n°

1000000 h 9999.9

PCM3P

h 9999.9 h 9999.9

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

gloves, therefore always operate it using a bare fi nger.

One cycle corresponds to one sleeper.

5.2) 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,

it is recommended that it is sent to Cembre for a complete overhaul (see § 8).

NOTE: this message remains on the display.

h 9999.9

18

Message Error description Solution

Accelerator motor reset error. Replace the faulty component, contact Cembre.

Accelerator motor minimum

positioning error.

Replace the faulty component, contact

Cembre.

Accelerator motor maximum

positioning error.

Replace the faulty component, contact

Cembre.

Generator power supply frequency

out of range.

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

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

contact Cembre.

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

damaged, contact Cembre.

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

replacing, contact Cembre.

Pressure sensor disconnected or

faulty at start up.

Check the connection.

If the error persists replace the sensor,

contact Cembre.

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

Cembre.

Error can be reset by pressing buttons 13 and 16 simultaneously for 5 seconds;

if the error persists contact Cembre.

Error messages remain on the display until they are reset.

001

002

003

004

005

006

007

009

010

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

19

6. 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:

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.15a) by turning

it clockwise.

The engine will not start unless the

red button (17) is lifted.

Move the fuel stopcock to "ON" position (Ref. to Fig. 15b).

Move the air lever to "CLOSE" position

(Ref. to Fig. 15b).

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. 15c).

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. 15b).

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".

FIG. 15a

FIG. 15b

FIG. 15c

17

Air lever CLOSE

OPEN

Fuel stopcock OFF ON

Starting cable knob

20

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 § 8).

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.

7.1) Routine maintenance of the machineAt the end of each day, wipe the machine carefully using a clean cloth, being careful to eliminate all dirt, espe-

cially 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 (33) and locator plates (34) as these become worn or damaged by long or

improper use.

7.1.1) Maintenance of braking systemThe 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.

7. 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.

21

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.

7.1.2) 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 eff 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.

12

FIG. 16

FIG. 17

22

7.1.3) Topping up the oil in the hydraulic pump 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 fl uid.

7.1.4) Replacing the hydraulic pump oil fi lter Detach connector (C), unscrew ring nut (G) paying

attention to the seal inside it and remove solenoid

coil (B) (Ref. to Fig. 18).

Use a 16 mm spanner to unscrew the nut on the

fi lter and replace the fi lter (Ref. to Fig. 20).

Once this has been completed relocate the solenoid

coil of the electro-valve, its connector and ring nut.

7.1.5) Adjusting the worklights Loosen the nut on the worklight fastening pin

(Ref. to Fig. 21).

Turn the worklight to the desired position then

retighten the nut.

FIG. 18

FIG. 19

FIG. 20 FIG. 21

Tank

T

Top notch

Lower notch

Dipstick

G

B

C

Filter

Nut

23

7.2) 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 (fi rst change after 20 hours of work)

Air fi lter assistance (see double-element type)

Cleaning sediment from sump

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

Minimum carburettor setting

7.3) 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".

7.1.6) 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. 22).

Unlock the arm in order to extend the springs

(Ref to Fig. 23).

Use a fi nger to release the retaining rings located

at the ends of the spring and simultaneously

detach it from the pins (Ref. to Fig. 24).

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. 22

FIG. 24FIG. 23

A

B

Casing

Gas spring

Retaining ring

24

Gen

eral

cle

anin

g w

ith

a c

lean

cl

oth

, pay

ing

att

enti

on

to

re

mo

ve s

ettl

ed d

irt

Sto

re th

e m

ach

ine

in a

dry

pla

ce,

pro

tect

ing

it fr

om

sh

ock

s an

d d

ust

Vis

ual

& m

anu

al c

hec

ks

(tig

hte

n if

nec

essa

ry)

Co

mp

lete

tig

hte

nin

g

Vis

ual

ch

eck

of i

nte

gri

ty

Rep

lace

men

t

Vis

ual

& m

anu

al c

hec

ks(t

igh

ten

if n

eces

sary

)

Co

mp

lete

tig

hte

nin

g

Visu

al &

man

ual c

heck

s of

inte

grity

Rep

lace

men

t

Visu

al &

man

ual c

heck

s of

inte

grity

Rep

lace

men

t

Ch

eck

rese

rvo

ir l

evel

(To

p u

p if

nec

essa

ry)

Rep

lace

men

t

Rep

lace

men

t

Rep

lace

men

t

Rep

lace

men

t

PE

RIO

DIC

OV

ER

HA

UL

Pe

rfo

rmed

at t

he

pre

scri

bed

inte

rval

s o

r at t

he

nu

mb

er o

f in

dic

ated

wor

kin

g h

ours

or a

t th

e oc

curr

ence

of i

nd

icat

ed e

xtra

ord

inar

y ev

ents

At

ev

ery

use

3

00

ho

urs

Pre

sen

ce

of

ev

ide

nt

sig

ns

of

we

ar

ITE

M

A

CT

ION

Co

mp

lete

mac

hin

e

Bo

lts

and

nu

ts

Flex

ible

ho

se

Hyd

rau

lic c

ou

ple

rs

Cla

mp

un

it r

ub

ber

dam

per

s o

f th

e u

nit

Inse

rtin

g a

nd

extr

acti

on

tee

th (3

3)

Hyd

rau

lic o

il

Hyd

rau

lic o

il fi

lter

10

0 h

ou

rs

Gas

sp

rin

gs

Acc

eler

ato

r ca

ble

Lo

ng

pe

rio

ds

of

ina

ctiv

ity

25

FIG

. 25

– D

IME

NS

ION

S (

mm

)

XXXXXX

Pum

p un

it

seria

l num

ber

1223

19

85

80

01

75

0

1025

26

In the case of a breakdown contact our Area Agent who will advise you on the problem and give you the neces-

sary instructions on how to dispatch the machine to our nearest service Centre. If possible, attach a copy of the

Test Certifi cate supplied by Cembre to the machine or fi ll in and attach the form available in the “ASSISTANCE”

section of the Cembre website.

8. RETURN TO Cembre FOR OVERHAUL

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NOTE

27

2828

This

ma

nu

al i

s th

e p

rop

erty

of C

embr

e: a

ny

rep

rod

uct

ion

is fo

rbid

den

wit

ho

ut

wri

tten

per

mis

sio

n.

cembre.com

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