General Operating and Safety Instructions: For The Use of Plasser & Theurer Permanent-Way Machinery

BS-02.
05
GENERAL OPERATING AND

SAFETY INSTRUCTIONS
for the use of
Plasser & Theurer
Permanent-Way Machinery
Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

Plasser & Theurer, LINZ, AUSTRIA
englisch
Version Date In charge Modification Pages
1.0 05-2010 HGR First version -
Copyright © Plasser & Theurer

All rights reserved, particularly the right to produce copies, to distribute these copies, as
well to translate the work. Without written consent of Plasser & Theurer no part of this work
may be reproduced in any form (photocopy, microfilm or other methods) or stored,
processed, copied or distributed with the help of electronic systems.

© 2005 by Plasser & Theurer, LINZ, AUSTRIA
englisch
BS-02.05 1
TABLE OF CONTENTS
Page
1. IMPORTANT NOTE................................................................................................................... 3
2. OPERATIONAL AND SAFETY INSTRUCTIONS ..................................................................... 4
2.1 STATUTORY PROVISIONS AND COMPANY REGULATIONS .............................................. 4
2.2 ALTERATION AND UPDATE OF REQUIREMENTS ............................................................... 4
2.3 NOTICE OF REGULATIONS .................................................................................................... 5
3. ACCEPTANCE, EQUIPMENT AND APPROVAL ..................................................................... 6
3.1 ACCEPTANCE .......................................................................................................................... 6
3.2 EQUIPMENT ............................................................................................................................. 6
3.3 OPERATIONAL APPROVAL..................................................................................................... 6
4. USE AND AUTHORISATION .................................................................................................... 7
4.1 PURPOSE ................................................................................................................................. 7
4.2 AUTHORISATION AND RESPONSIBILITY ............................................................................. 8
5. INSTRUCTION .......................................................................................................................... 9
5.1 GENERAL REGULATIONS....................................................................................................... 9
5.2 PREREQUISITES...................................................................................................................... 9
5.3 PROOF OF TRAINING.............................................................................................................. 9
6. SAFE OPERATING CONDITION............................................................................................ 10
6.1 SAFETY OF THE PRODUCT SUPPLIED .............................................................................. 10
6.2 GENERAL OPERATING STATE ............................................................................................ 10
7. GENERAL HAZARDS ............................................................................................................. 12
7.1 HAZARDS IN RAILWAY OPERATION ................................................................................... 12
7.2 OPERATIONAL HAZARDS ..................................................................................................... 12
8. RISKS OF HAZARDOUS SITUATIONS AND MINIMISATION OF RISKS ............................ 13
8.1 GENERAL RISKS OF HAZARDOUS SITUATIONS ............................................................... 13
8.2 RISKS DURING SHUNTING WORK ...................................................................................... 15
8.3 RISK DURING TRAVELLING MODE...................................................................................... 15
8.4 DANGERS OCCURRING DURING WORK ............................................................................ 21
9. RISK OF DANGEROUS SITUATIONS WHILST WORKING.................................................. 22
9.1 ANNOUNCEMENT OF RISKS ................................................................................................ 22
9.2 OBSTACLES IN THE OPERATING AREA ............................................................................. 22
9.3 OPERATION ON MULIT-TRACK SECTIONS ........................................................................ 23
9.4 GENERAL OPERATING HAZARDS ....................................................................................... 23
10. FIRE PROTECTION ................................................................................................................ 28
11. REGULATIONS FOR THE OPERATION OF HYDRAULIC SYSTEMS ................................. 31
11.1 GENERAL RISKS OF DANGEROUS SITUATIONS .............................................................. 31
11.2 SAFETY PRECAUTIONS........................................................................................................ 32

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2 BS-02.05
PREFACE
When dealing with technical products, particularly when specialized,

there is a responsibility to protect life, health, property and
environment.
The special features of the product supplied require the fulfilment of all
prerequisites and conditions for its safe operation as a permanent-way
machine / recording vehicle as well as a standard railway vehicle / vehicle
with special status.
The information provided in the technical documentation (product

description, operating and maintenance instructions, application and work
instructions, adjustment and repair instructions, safety instructions, etc.) is
based on data and experience regarded as applicable for skilled staff
under normal working conditions.
It is not possible to provide a detailed list of all the legal and operational
regulations valid in the respective areas of use, which is why we give only
certain, generally valid instructions on safety when working with and on
the supplied product.
For this reason we must expressly point out that this list is not intended to
be complete.
Please pay special attention to our operating and safety instructions.

Ensure that they are read and adhered to by all persons involved.
Always keep this brochure close at hand on the product supplied.
Plasser & Theurer

Export von Bahnbaumaschinen
Gesellschaft m. b. H.
All rights to alterations and amendments reserved

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BS-02.05 3
1. IMPORTANT NOTE
This set of instructions:
GENERAL OPERATING AND SAFETY

INSTRUCTIONS
BS-02.05-*
is a binding part of the documentation for the
product supplied!
READ IT CAREFULLY!
It contains important requirements for the operation,

indications on possible hazards, measures to be taken to
minimize the risk of danger, rules governing emergencies, as
well as further useful information.

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4 BS-02.05
2. OPERATIONAL AND SAFETY INSTRUCTIONS

2.1 STATUTORY PROVISIONS AND COMPANY REGULATIONS
The operator of the product supplied is responsible for the
application of all relevant requirements, particularly of
operational and safety regulations.
2.2 ALTERATION AND UPDATE OF REQUIREMENTS

Due to rapid technical progress and special specifications required by the
purchaser, existing regulations, i. e., safety instructions, construction and
operating regulations, might not be fully applicable to the product supplied, or
may be insufficient in the care of special design solutions.
The circumstances mentioned above, as well as the respective operating

conditions and provisions applicable in the country and region of use of the
product supplied determine the corresponding regulations to be observed
and measures to be taken.
Therefore, the operator of the product supplied also has to determine and
ensure the observation of further regulations and measures individually
adapted to the respective product in order to meet all requirements,
particularly of operational safety, protection of labour and environment.
Should the requirements valid in the area of operation of the product

supplied diverge from the regulations prescribed by the manufacturer,
the stricter regulations shall apply.
If existing regulations should prove insufficient in certain situations, the

operating organisation has to take all the necessary measures to avoid, or at
least to minimise risks.

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BS-02.05 5
2.3 NOTICE OF REGULATIONS
All persons involved must be informed at regular intervals of all

relevant regulations and requirements by the operating organisation.
For clarification additional comments and explanations are to be given.
It is to be clearly stated that these requirements must be observed and

attention drawn to the possible consequences of non-observance.
There must be written proof that the personnel has been informed
accordingly.

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6 BS-02.05
3. ACCEPTANCE, EQUIPMENT AND APPROVAL

3.1 ACCEPTANCE
The purchaser / operating organisation has to check whether the equipment,
the performance and, particularly the safety features of the product supplied
meet the specifications agreed upon and to effect its acceptance according to
the provisions of the contract.
3.2 EQUIPMENT
The operating organisation has to ensure that the product supplied is equipped
with all devices prescribed by the respective operating and safety regulations,
standards, laws or other provisions.
e. g. fire extinguishers, first-aid kit, signalling and communication

equipment, protective clothing, additional safety instructions, etc.
unless otherwise agreed, such equipment is not supplied.
3.3 OPERATIONAL APPROVAL
The purchaser / operating organisation has to apply for and obtain all approvals
required for the operation of the product supplied.
If the manufacturer has to supply documents required for the operating
permit (e. g., descriptions, certificates, etc.), these have to be specified
and agreed upon in the supply contract.
The purchaser / operating organisation has to take any further measures
and bear all further costs in connection with operational permits.

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BS-02.05 7
4. USE AND AUTHORISATION

4.1 PURPOSE
The product supplied may only be used as directed.
The product supplied shows the properties and characteristics of standard railway
vehicles, but due to its purpose and equipment it has to be regarded as a special-
purpose vehicle. Therefore special safety and operational regulations apply.
Any use contrary to the regulations (e. g., as shunting vehicle or as a general
means of transport of passengers / materials, etc.) is not permitted.
The product supplied must be only be operated when in operationally reliable
condition and with a valid operational permit, the provisions of this permit must
not be infringed.
All conditions required for the start-up and operation must be met.
Exact job and operating instructions have to be given for each deployment.

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8 BS-02.05
4.2 AUTHORISATION AND RESPONSIBILITY
Only trained, qualified and authorized personnel is allowed to

operate the product supplied.
The operating personnel must have valid driving and operating licences.
The operating personnel must be familiar with the respective regulations.
The supervising and operating personnel must be familiar with the respective
operating and working conditions.
Unauthorized persons MUST NEVER be on board or within the working area of
the product supplied, the working area is a prohibited zone!
The number of persons on the machine must not exceed the maximum number
stated in the registration papers.
Unauthorized start-up and access must be prevented by appropriate protective
measures.
Supervising and operating personnel are responsible for the operational
reliability and use as directed.

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BS-02.05 9
5. INSTRUCTION
5.1 GENERAL REGULATIONS
Thorough training is required for the operation, maintenance
and repair of technical products, particularly special-purpose
products.
• This training has to be carried out by specialized service personnel from the
manufacturer or his authorized representatives.
• Training must include explanation of the functional principles, operating and service
instructions, instructions on the safe operation of the product supplied, as well as
hands on training.
• Technical documentation and regulations are useful and necessary but can never
replace competent theoretical and practical training.
• Any kind of damage caused by untrained personnel is the sole responsibility of
the owner / operating organisation.
• Plasser & Theurer has a worldwide network of representation offering further advice,
training and other consultation to be individually agreed on.
5.2 PREREQUISITES
The most important prerequisites for instruction are, among others:
• Technically qualified personnel with sufficient knowledge of operating conditions
and all relevant safety regulations.
• Availability of all equipment, working stock and aids required for the start-up of
the product supplied and competent instruction of the operating personnel.
• Unrestricted and secured working sites of sufficient length where the operating
personnel can learn and practise the operation and use of the product supplied.
5.3 PROOF OF TRAINING

A document has to be provided showing the fact of training.
• A report has to be filed stating the contents of training and the names of all trainees.
• As the manufacturer / supplier of the purchased item can in no way influence the
purchaser’s operational and work force situation, he will not bear any responsibility
for the lasting effect of training.
• If the machine is equipped with a hydraulic system, at least once a year practical
training must be held to familiarize the operating personnel with the emergency
system for hydraulics.

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10 BS-02.05
6. SAFE OPERATING CONDITION

6.1 SAFETY OF THE PRODUCT SUPPLIED
The absolutely safe operation of technical products, particularly special-
purpose products, can never be expected.
The product supplied can ensure safety only to such an extent as

can be expected when all regulations for approval, the operating
instructions, any requirements stipulated by the manufacturer,
particularly concerning handling and checks of the product
supplied, as well as any other existing regulations, are observed.
6.2 GENERAL OPERATING STATE
Before start-up check the state of the product supplied and make
sure that all requirements for safe operation are met.
a) Maintenance: maintenance work must be duly carried out in time, according to the
maintenance schedule.
Inadequate maintenance leads to operational failures and consequential
damage.
b) Proper state: proper overall condition of the machine, completeness of
equipment and full operability must be ensured. Otherwise:
defects can lead to serious failures and accidents with serious consequences,
dirt, oil or grease on steps and handles increase the risk of slipping and can
cause serious accidents,
escaping or spilled working stock (fuel and oil) increase the risk of fire and
following contact could adversely affect health.
Check all cables and insulation for their proper condition and fit (terminals etc.)
c) Safety equipment: all measuring systems and working units must be duly
locked and secured.
Working units which have not been fastened or insufficiently fastened, as well as
loose objects, might fall down and cause serious accidents (derailment, injuries,
material damage, operational failures, etc.).
d) Accessories: for transportation, accessories must be stored and secured in
the respective places.
Unfastened accessory parts could be damaged or cause serious hazard and
damage, e. g., when slipping or falling down.

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BS-02.05 11
e) Loose objects: objects transported in the cabins must be stored away or

fastened.
Unsecured objects in the cabin might lead to hindrance, damage or hazard.
Free access to any control, supervisory and safety equipment must be ensured
at any time.
f) Hazardous materials: due to the high safety risk it is strictly forbidden to store
or transport on the machine hazardous materials or objects, such as, e. g.:
Easily inflammable substances, like petrol, kerosene, diesel fuel, oils, turpentine,
dyestuff, etc., which can cause fire.
Chemicals, like acids, solvents, and other aggressive substances can be

detrimental to health (causticization) and lead to damage (corrosion).
Pressurized receptacles (e. g., gas cylinders and sprayers) could explode if
subjected to heat.
Unprotected pointed or sharp objects can lead to serious injuries or damage.
Explosives, detonating agents and radioactive material are extremely hazardous
and must never be on the product supplied.
The built-in cabin heating device must never be operated in enclosed rooms!
g) Loads, such as working accessories, working stock, building materials and
further objects, may be transported on the machine only on the loading and
storage areas provided, if the following is ensured:
The admissible weight loaded must not be exceeded (excess weight leads to
damage, adversely affects the running properties and reduces driving and
braking safety);
The vehicle clearance gauge must not be exceeded (exceeded clearance gauge
can lead to accidents with serious consequences);
The loads must be evenly distributed (uneven load distribution adversely affects
the running properties and reduces driving safety);
Loads must never obstruct the driver’s visibility (obstacles to visibility are
extremely hazardous);
Working stock, such as fuel, oil, grease, etc., may be transported only in sealed
receptacles in the loading or storing areas provided (escaping working stock
endanger safety and environment), and
Loads must be protected from slipping, tilting and falling down (unfastened loads
are hazardous).

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12 BS-02.05
7. GENERAL HAZARDS
7.1 HAZARDS IN RAILWAY OPERATION

It can be assumed that the general hazards of railway operation are
known. We refer to the relevant operating and safety regulations of
the individual railway administrations.
The special properties of the product supplied, as well as the way of use of this
product make it necessary to take into account several different groups of
hazards.
7.2 OPERATIONAL HAZARDS

In particular the following operating states of the product supplied can be
hazardous:
GENERAL RAILWAY HAZARDS
DRIVING MODE
WORKING MODE
TOWING OF OTHER RAILWAY VEHICLES
TRANSPORTATION TOGETHER WITH OTHER VEHICLES
TRANSPORTATION WITHIN A TRAIN FORMATION
SEVERAL VEHICLES WITHIN THE SAME SECTION
SHUNTING
SETTING-UP
WORKING ON A BUILDING SITE
OPERATING FAILURES
EXTRAORDINARY EVENTS

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BS-02.05 13
8. RISKS OF HAZARDOUS SITUATIONS AND MINIMISATION

OF RISKS
8.1 GENERAL RISKS OF HAZARDOUS SITUATIONS
Non-compliance with the general safety and operating regulations can
have immense consequences.
The operating organisation has to ensure that the product supplied is
in an operationally reliable state and all relevant regulations are strictly
observed.
8.1.1 GENERAL OPERATING CONDITIONS
The general risks arising in railway operation must be known. The following
requirements in particular have to be met for the operation of the product supplied:
The product supplied must be in an operationally safe state and may be operated
only with valid operating permission.
The operating personnel must be familiar with all relevant regulations relating to the
operation of the product supplied.
The operating staff (driver) must have a valid driving and operating licence.
The operating staff (driver) must be familiar with the conditions of the individual
track sections.
The convoy man (pilot) must be familiar with the arrangement and operation of the
safety equipment, such as working-mode and emergency brakes, inductive brake,
warning and lighting system, train radio system, intercom, etc.
For each machine trip a job order containing corresponding instructions has to be
given.

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14 BS-02.05
8.1.2 RISKS ARISING WHEN PARKING THE MACHINE

If the machine is parked unattended, appropriate safety measures have to be taken in
order to avoid dangerous situations and damage:
protect the parked vehicle with skid-pans to prevent rolling away;
take suitable measures to prevent other vehicles from crashing into the machine;
store away loose accessory elements in storage areas or cabins;
all locks provided must be locked;
all working units must be properly locked and fastened;
if it is intended to tow the vehicle unattended, take all measures required to ensure
safe towing, e. g., fasten all working units in their transit position, prevent loose
objects from changing their position, disengage the drive units, switch the driver’s
brake valves to end position, release parking brakes which are not accessible from
outside, take all further measures to ensure safe transportation.
If it is intended to park the vehicle for a longer period, all exposed parts must be
protected from weather influence, corrosion, damage, unauthorized use, theft, etc.
Prior to any start up make sure that the vehicle is in proper condition.
For machines with ZF gear box the following safety regulation is valid.
If the machine is being towed the engine has to be stopped , the drive selector and
the engine master key switches (in both cabins) have to be switched off and the
key switches have to be removed.
Further on the battery main switch has to be switched off and removed.
The engine running when the machine is being towed would cause major gear box
damage.
As soon as the engine is running the final drive to the powered axles engages
automatically.
Towing the machine with the engine running is prohibited.

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BS-02.05 15
8.1.3 RISKS ARISING FROM UNAUTHORIZED START-UP

Unauthorized start-up and improper use of the machine can cause all kinds of danger
and damage.
This risk must be assessed by the operating organisation itself.
Unauthorized start-up is strictly prohibited.
The operating organisation is responsible for taking appropriate measures to prevent
unauthorized access.
8.1.4 RISKS ARISING FROM IMPROPER USE OF THE MACHINE

If the machine is not used as directed (e. g., as a shunting vehicle, for passenger and
goods transportation, for hauling of too heavy loads, etc.), this increases, on the one
hand, the security risk and, on the other hand, can cause serious damage.
The product supplied may only be used as directed.
Improper use must be avoided.
8.2 RISKS DURING SHUNTING WORK

Incautious shunting movements can lead to serious damage to the vehicle, therefore
shunting must be carried out with the utmost caution, e. g.:
move the vehicle only if it is under own power or rigidly coupled to a shunting vehicle;
avoid buffing jolts when coupling the vehicle to another vehicle;
fly shunting and gravity shunting are prohibited.
8.3 RISK DURING TRAVELLING MODE

In order to minimise hazards during transit and movements from and to the site observe
the following instructions:
8.3.1 PASSENGERS
If the admissible number of persons on board the product supplied is exceeded, this
might restrict the freedom of action of the driver, reduce his attention and cause
operational hindrances and hazards.
The number of persons stated in the approval documents must not be exceeded. This
number is usually the number of seats provided.
Passengers have to be given instructions, among others, for the use and the location
of the safety devices.
No passengers must be in the loading areas of the machine and outside the cabins.

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16 BS-02.05
8.3.2 LOOSE OBJECTS

Loose objects in the driver’s cabins might endanger the driver and passengers and
also cause damage.
Objects transported on the machine must be securely stored away. Any hindrance
must be avoided.
8.3.3 UNAUTHORIZED INTERVENTION

Unauthorized intervention, particularly in control elements, can cause dangerous
situations.
Passengers have to be instructed correspondingly as well as informed about the
possible consequences of non-compliance.
8.3.4 RUNNING DIRECTION

If the machine is controlled from the cabin opposed to the running direction, no visibility
is ensured on the track in front of the machine.
If the vehicle is equipped with two or more driver’s desks, driving must be controlled
from the cabin in its running direction. The driving control elements at the other
driver’s desks must be switched off and the driver’s brake valves turned to end
position.
If the vehicle is equipped only with one driver’s desk and visibility is obstructed in the
running direction, special care has to be taken. If this vehicle has a second cabin (in
the running direction), this cabin has to be attended by an authorized convoy man
with intercom to the driver.
Vehicles where visibility is ensured only in one direction and no other cabin can be
attended additionally, must be towed by another vehicle if running in the opposite
direction.
8.3.5 RUNNING SPEED

Independent of the respective line speed admitted the following must be taken into
account:
The product supplied is equipped with sensitive measuring and control systems which
might be damaged under heavy vibration. Excess speed, particularly on track with poor
geometry, as well as on switches, could even lead to derailment.
Independent of the respective line speed admitted and the possible maximum driving
speed of the vehicle, the actual driving speed must always be adapted to the
respective track conditions.
Unbraked loads hauled reduce the brake effect, therefore longer stopping distances
have to be taken into account when calculating the maximum speed.

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BS-02.05 17
8.3.6 RAPID AND EMERGENCY BRAKING

Abrupt braking increased the wear of brake blocks and wheelsets. Particularly when
the rails are wet, covered by snow, rust or oil, the wheelsets might lock, the
consequences are flats on the wheels. Insufficiently secured objects might move out of
place.
Rapid and emergency braking must be restricted to emergencies.
When initiating a rapid or emergency braking, passengers must be warned in time.
The reasons for an emergency braking must be found out. Continue driving only if
safety has been ensured.
8.3.7 DRIVING ON ASCENTS

Depending on the drive output, the type of power transmission and drive control
(mechanic, hydrostatic, semiautomatic, fully automatic), as well as on loads hauled, the
running speed might be significantly reduced in adverse conditions, when the machine
is ascending. Failure to observe the operating instruction might cause the vehicle to
stop. In an extreme case, the drive unit might overheat and “stall“ through overload. On
very steep ascents problems might arise when starting to move again. Therefore the
following must be taken into account:
Before setting out on the trip check which loads the drive unit can haul on the ascents
to be covered.
If the running speed – and simultaneously the engine speed - reduces to the upper
range of the next, lower gear, change down in time.
The engine speed should be kept in the upper speed and output range. This is
important to maintain sufficient traction force and to ensure cooling of the engine and
transmission.
It is recommended to drive on steep ascents, particularly with tight curves, at
correspondingly low gear and high engine speed from the very beginning. This
applies particularly when the running speed is low when the machine approaches the
ascent.
When calculating driving times, take the ascents correspondingly into account.
Perform a brake test before starting any trip!

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18 BS-02.05
8.3.8 DRIVING ON SLOPES

When driving on slopes, particularly on steep and long ones, the principle danger of
speeding exists. It is extremely dangerous to drive on slopes with the driving unit idling.
Frequent brake application at too low an engine speed will lead to an insufficient supply
of the air system and, consequently, to reduced brake effect. Therefore, the following
must be observed:
Use the braking effect of the drive unit in order to support the service brake
(depending on the driving gear selected, the reactive rolling forces are transformed to
braking forces).
When approaching a slope, reduce the running speed in time and select the next
lower gear.
The required brake effect has to be obtained with the service brake.
“Rolling“ with the drive unit idling is strictly prohibited!
8.3.9 SEVERAL VEHICLES ON THE SAME SECTION

If several vehicles are on the same track section, they might crash into one another
and are therefore an increased safety risk.
Corresponding safety distances must be observed.
In order to minimise the risk of accidents telecommunications (e. g. train radio
systems) have to be provided between dispatcher and the individual vehicles.

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BS-02.05 19
8.3.10 SEVERAL VEHICLES IN COUPLED FORMATION

A closed formation of several vehicles might lead to operational hindrances and additional
risks of dangerous situations. Observe the following instructions:
a) General Conditions:
All vehicles have to be equipped with the same type of coupling device. If not,
refer to “special cases“, paragraph b).
All working units must be locked and secured.
All vehicles in the formation must be equipped with the same type of brake
systems which can be combined. If not, refer to “special cases”, paragraph b).
The total load of the vehicles towed must not exceed the admissible load to be
hauled by the traction vehicle.
Each vehicle of the formation must be in a condition safe for transportation.
Proper coupling and brake connections, as well as other connections (e. g.,
supply and control lines) must be established.
The brake control valves of the train formation brake must be turned on and set to
the required braking mode on all vehicles. The driver’s brake valves of the
vehicles towed must be in their end position.
When determining the brake effect (stopping distances on different slopes) and
the maximum speed, the total load of the formation, including the unbraked
vehicles, must be taken into account (percentage of brake power = ratio between
brake loading weight and total weight in %).
Before starting to move make sure that the brakes are operative.
Perform a brake test!
The maximum speed for the formation must be restricted to the lowest design
speed of the vehicles towed.
b) Special Cases:
Vehicles without suitable draw and buffing gear (e. g. small-size cars) must be
coupled firmly to the front or rear end of the formation through other suitable and
tested coupling devices.
Vehicle brakes which differ from the type of brake system on the traction vehicle
must be put out of action.
Vehicles without a through brake pipe are preferably coupled to the rear end of
the formation. Coupling such vehicles to the front end is allowed, only if sufficient
visibility is ensured for the driver and the required safety can be guaranteed during
the trip.
If vehicles without a through brake pipe are arranged within the formation, these
vehicles and any others following behind them have to be considered as “total
load hauled“.

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20 BS-02.05
c) The first vehicle of the formation is powered:

All prerequisites according to a) and b) must be fulfilled.
The drive units of all vehicles towed must be disengaged.
The illumination (tail light, if applicable, also stop light) of the last vehicle must be
switched on.
If the vehicles towed are attended, an intercom should be established to the driver
of the traction vehicle.
d) A powered vehicle within or at the end of the formation:
All applicable requirements stated under a) to c) must be fulfilled.

If the vehicles pushed restrict the driver’s visibility and the drive unit of the power
vehicle cannot be controlled from the first driver’s desk via remote control, the first
(front) driver’s desk has to be attended by a convoy man (pilot).
The following equipment must be operative on the first vehicle of the formation:
brake system (at least the emergency brake), warning signalling and lighting,
speedometer, voice communication with the driver, warning equipment, etc. The
convoy man must be familiar with the use of this equipment.
If the power wagon can be remote-controlled, but not supervised from the first
(front) cabin, a competent convoy man has to attend the power wagon.
e) Several or all vehicles of the formation are powered, permanent-way machines

coupled or arranged in tandem
All applicable requirements stated under a) to d) must be fulfilled.

For this operating mode the (adjustable) drive control systems must be adjusted to
one another.
If Plasser & Theurer permanent-way machines are operated in coupled or tandem
mode, for safety reasons at least one driver’s desk of each machine must be
attended by an authorized driver.
Before setting off check all functions required for tandem mode.
Furthermore, carry out a brake test before you start driving.
Furthermore, permanent voice communication between the drivers of the two
machines must be ensured.
The driver of the first vehicle gives the respective instructions.

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BS-02.05 21
8.4 DANGERS OCCURRING DURING WORK

Working at and under overhead lines is by nature very hazardous. Therefore, the
crew has to be very careful and cautious.
Pay particular attention to inductive voltage in the old catenary (old overhead line),
take suitable measures for professional discharge.
Multi-track sections, bridges, underpasses, tunnels, stations etc. require increased
attention.
When operating switches or control elements, you must know before which
reactions will be triggered.
Key-operated switches are switches of special importance. A key-operated switch
must be actuated very carefully and consciously.
The crew is urged to wear appropriate protective clothing.
For work in tunnels you are strongly advised to provide the respective number of
escape hoods on the machine.
Particular safety measures have to be taken for work with a crane, work cage and
cable holding device. Observe the safety regulations. For work under or within the
range of overhead lines the crane lifting limit stop has to be used.
Working sequences should be performed in an organized way without stress.
- Intercommunication is important for safe work.
Bypassing of safety contrivances can have fatal consequences and in certain
circumstances can lead to prosecution.
It is strictly forbidden to climb on the machine roof under overhead lines. For
repair and maintenance work it has to be ensured that the overhead line has to be
switched off and earthed before work is started. These safety measures have to
be enforced and supervised by competent safety officers!
It is strictly forbidden to climb on railings (machine, mobile working platform,
working cage)!
- Danger of falling down!
When you climb on the machine roof you are exposed to the danger of falling
down!
Wear appropriate safety shoes and suitable working clothing (safety vest, etc)
This list is not intended to be complete!!

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22 BS-02.05
9. RISK OF DANGEROUS SITUATIONS WHILST WORKING

9.1 ANNOUNCEMENT OF RISKS
Ignorance or insufficient knowledge of regulations and possible operating hazards as
well as inadequate safety measures increase the risk..
All persons concerned must be informed of possible operating hazards and given
appropriate behavioural instructions.
Depending on the prevailing operating conditions, effective measures to prevent
endangering yourself or others and endangering properties and the environment must
be ensured.
Clearly refer to the possible consequences of non-compliance with or violation of such
instructions.
Qualified and authorized personnel must be employed to supervise operation and
safety measures.
9.2 OBSTACLES IN THE OPERATING AREA

Obstacles in the operating area can lead to hazardous situations. Carelessness can
cause serious accidents, such as collision with other vehicles, crashes with building
machines or items, derailment, etc. Apart from possible injuries, material and
environmental damage, interference with the operational sequences as a
consequence of accidents also must be taken into account.
Obstacles may be approached and passed only at correspondingly reduced speed
and after re-confirmation of safety.
On building sites, vehicles may be moved, in particular reversed, only with supervision
and direction.
If the machine is equipped with video cameras or a so-called reverse monitor
system, these facilities can only provide additional help, but do not release the
machine operator from being personally responsible for monitoring the work
area and the corresponding track area.
Furthermore, we would like to emphasise that the working area is a prohibited

area!

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BS-02.05 23
9.3 OPERATION ON MULIT-TRACK SECTIONS

Adjacent tracks in operation are a particular source of hazards. Due to possible
hindrances on the track under construction (restricted visibility, noise) persons are
highly endangered in the area of operative tracks. Loose objects near the operative
track could be whirled up by trains and cause serious damage.
A sufficient number of look-out men and appropriate warning systems must be used.
Objects and machine parts must never project into the profile of the adjacent track.
Not only are persons in the site area exposed to the immediate risks of their working
area, but also to the dangers arising from the operation of construction machinery.
It must be ensured that no-one is in the immediate operating area of construction
machinery.
Strictly adhere to railway safety regulations.
Vehicle movements are allowed only after corresponding warning signals have been
given and safety has been re-confirmed.
9.4 GENERAL OPERATING HAZARDS

Depending on the type and operation of the product supplied the following operating
conditions involve the risk of hazardous situations:
Preparation for operational deployment, vehicle movements and movements of
vehicle elements, vibrating, movable, rotating or hot machine components, lifted or
moved loads, falling or hurled material, use of laser rays, exhaust gas and noise
emission, darkness and hindrances due to the effect of the weather, persons in the
working and hazard area and unauthorised intervention, derailment through poor
track geometry or gaps in the track, fire hazard through open flames and additional
hazard sources resulting from the respective operating conditions.
The following is therefore particularly applicable:
Operating, supervisory and auxiliary personnel must wear suitable protective clothing.
Keep unauthorised persons away from the area of operation.
Persons or obstacles must not be present in the immediate area of movement of the
vehicle.
No-one is allowed to be present in the immediate working area, particularly in the range
of working units, movable and rotating elements and equipment.
Access to the area of material-conveying systems and under lifted loads is prohibited.
No-one is allowed to be present in the immediate area of escape and spreading of
exhaust gas.
Distinctly audible warning devices as well as other appropriate safety measures must
be provided for persons who have to work close to a source of noise.
Persons who have to be present in the immediate vicinity of the vehicle (e. g., look-out
men, supervisors, auxiliary staff) must be instructed in the operation of the safety
devices fitted on the outer vehicle surfaces, e. g., horn, emergency stop button, safety
rip cords, warning beacon.
Only authorized persons are allowed to be on board the vehicle and in the area of
external control and supervisory elements.

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24 BS-02.05
Unauthorized intervention in operation and control devices must be prevented.
UNAUTHORIZED personnel must never modify the programme control of the
machine. For information contact PLASSER & THEURER.
Do not get near movable, vibrating, rotating or hot machine parts.
Protective devices must not be removed or put out of action.
If the operating condition is changed, make sure that nobody is endangered. Before any
change of operating conditions first a warning signal must be given and safety must be
re-confirmed.
Nobody is allowed to stay in the immediate radiation area of laser devices.
During darkness sufficient illumination of the working areas has to be provided.
Take additional suitable safety measures if hindrances occur due to weather conditions.
Handling open flames or hazardous substances on the machine or in its vicinity must be
prohibited.
Intercom has to be provided between dispatcher, supervisor and machine operating
crew.
Immediately discontinue operation if danger occurs or regulations seem not to be
observed. Continue operation only after safety has been re-confirmed.

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BS-02.05 25
9.4.1 SAFETY GUIDELINES IN PREPARATION FOR ANY REPAIR WORK ON THE

MACHINE:
In working mode the danger zone of the machine is a prohibited area.

Repair work on the machine must be carried out only by authorized and trained
personnel. The adjacent track in train service must NOT be entered.
PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS!
Before carrying out any repair work on the machine the following safety
instructions must be observed:
deactivate hydraulic pressure
deactivate the air system
protect the machine from rolling away
turn off the engine
turn off the working-mode main switch and protect it from unauthorized
operation
turn off the battery main switch and protect it from unauthorized operation
properly disconnect the battery sets (see maintenance instruction – the

machine is currentless) and secure them.
Furthermore, the machine crew and all persons having access to the
machine must be informed of the intended repair work.
A professionally competent person has to be chosen who will bear the main
responsibility for the repair work to be carried out and supervise this work
according to all aspects of safety.
Furthermore, the machine crew has to be informed of the completed repair

work before the operating mode of the machine is restored. Only
professionally competent and trained persons are allowed to restore the
working mode of the machine.

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26 BS-02.05
Repair work should, if possible, be carried out in a well equipped workshop in
order to avoid unnecessary danger to the machine crew.
In working mode the working area is again prohibited

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BS-02.05 27
9.4.2 EXTRAORDINARY EVENTS
Unforeseeable and suddenly occurring extraordinary events can considerably

hinder operation and cause serious damage.
Possible reasons are: persons caught in moving vehicle parts, unauthorised
intervention, operating errors, defects, leaking working stock, collisions,
derailment, contact with live power lines, fire, natural disasters, etc.
The following instructions should be observed in such situations:
If an accident has occurred, immediately discontinue operation. If persons have been

jammed in the area of movable parts, first of all “freeze“ the actual operating
condition. Any further action could cause more danger and damage.
Immediately discontinue operation, if failures have occurred due to unauthorized
intervention or misoperation, restore the original state.
Discontinue operation in case malfunction occurs or parts are damaged. Find out the
reason and the extent of damage and initiate the corresponding repair measures.

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28 BS-02.05
10. FIRE PROTECTION
CAUTION !
Never use open flames and easily inflammable
substances on the vehicle and in its immediate vicinity!
The diesel fuel tank must be refuelled only while the

engine is switched off and has cooled down.
Furthermore it is absolutely forbidden to smoke!
How to provide first aid

• rescue persons
• alert the fire brigade
• try to extinguish the fire
Everybody is obliged to refrain – as far as possible and can be expected - from any action
which might cause a fire or favour its spreading. Furthermore, all possible measures must
be taken in the particular situation to prevent fire from occurring or spreading.
Cloths impregnated with solvents, oil or grease, must be stored in a fire-proof place, as
auto-ignition might lead to their inflammation.
To avoid fire the following elements, particularly units which heat up, have to be kept free
from deposits:
• drive units
• heating devices
• belts
• gearboxes
• control cabinets
• electric distributors
• etc.

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BS-02.05 29
Familiarize yourself in time with the fire fighting regulations of your organization and the
correct use of fire fighting equipment.
Consult the fire-fighting officer at your organization for this purpose!
The fire extinguishers must be ready for service and easily accessible at any time. They
have to be checked periodically and marked with test badges.
The fire-fighting officer responsible checks the date of expiry of these badges!
Whenever a fire extinguisher has been used, the fire-fighting officer responsible has to be
informed of this fact.
He will immediately take the necessary steps to refill all used fire extinguishers and is
obliged to provide spare fire extinguishers in the meantime!

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30 BS-02.05
HOW TO ACT IN CASE OF FIRE

Fire symptoms: unusual development of fumes, smell, vapour, heated-up and discoloured
linings, smouldering, flames.
Immediate actions: immediately discontinue operation, turn off the control units, the engines
and apply the parking brake. If danger is imminent, immediately leave the danger area.
Fire fighting: only qualified staff, without endangering themselves! Find the source of the fire
and use fire extinguishers. Remove flammable substances from the danger area.
Alarm and First Aid: if the extent of the fire is large, immediately leave the danger area and
give alarm (fire brigade, ambulance, technical emergency service). If applicable, provide first
aid to injured persons.

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BS-02.05 31
11. REGULATIONS FOR THE OPERATION OF HYDRAULIC

SYSTEMS
11.1 GENERAL RISKS OF DANGEROUS SITUATIONS
Insufficient maintenance and defects in hydraulic systems increase the risk of
occurrence of hazards!
Escaping hydraulic oil, particularly if heated up and pressurized, highly
endangers health, materials and environment.
Observe the safety specification sheets for the types of oil prescribed which
are stated in the respective maintenance instructions!
Leaks (loose or defective connections, adapters, fittings, seals, pipes, pumps,

engines, valves, cylinders, receptacles, etc.) can have the following dangerous
effect:
Escaping oil contaminates the environment and can catch fire on hot objects.
Sprayed oil mixes with air and thus gets easily inflammable.
Loss of oil can lead to operating failure or damage to the system.
Skin contact with oil can have consequences which are injurious to health (eye
and face injuries, burns, allergic reactions, etc.).

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32 BS-02.05
11.2 SAFETY PRECAUTIONS

Only regular checks, maintenance and operation supervision ensure that the safety
risks remain low.
Remedy defects immediately. The hydraulic system must not be operated with
defective components.
11.2.1 GENERAL STATE AND CORRECTIVE MEASURES
Check the external state of the entire hydraulic system before start-up and after
every use.
Indications of leaks:
Oil shortage in the tank.
Traces of oil on surfaces in the system or the parking / working place.
Oil escaping from the system (tank, pipe connections, pumps, motors, cylinders,
valves, filters, control elements, etc.).
General state of the entire system:
Oil shortage ⇒ replenish
Leaking connections ⇒ re-tighten
Loose connections ⇒ re-tighten
Defective seals ⇒ replace
Defective pipes ⇒ replace
Defective functional elements ⇒ repair or replace
Leaking tank ⇒ refer to “special instructions“
11.2.2 MONITORING THE SYSTEM

Permanent monitoring has to be carried out in order to ensure the proper state of the
system and the correct functioning of operational sequences. If there is any indication of
malfunction or defects, immediately discontinue operation.
Checks to be carried out before start-up:
Check the general condition (as mentioned above).
Ensure safety before start (warning signal, nobody in the danger area).
Checks to be carried out after start-up and during operation:
General safety:
Monitoring and warning system (oil level, pressure, filters, temperature).
Control sequences and movements.
Operating noise, any possible leaks and overall condition of the system.

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BS-02.05 33
11.2.3 SPECIAL INSTRUCTIONS

Collect escaping oil. For repair purposes drip cups and oil absorbing agents have to
be ready at hand.
Special care is required for welding work in the area of hydraulic systems.
Endangered areas must be free of oil and grease and have to be protected by heat
shields. Keep an eye on flying sparks which might cause fire. Fire extinguishers must
be at hand. After welding work the entire system has to be thoroughly checked for
influences which might still take any effect.
Never perform welding on filled tanks. Tanks must be drained and cleaned from
residual oil before welding work is carried out. Failure to observe this instruction leads
to extreme fire hazard!
11.2.4 Explosive atmospheres

There are no explosive areas on this machine according to the EU directive or the
respective national implementation standard.
The machine must not be used in explosive areas without having evaluated the explosion
hazards according to the EU directive or the respective national implementation standard.
If the machine is nevertheless used in areas implying explosion hazards, the machine
operating organisation in agreement with the customer has to evaluate the explosion
hazards and draw up in writing suitable explosion-protective measures and instructions for
the individual sites.

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General Operating and Safety Instructions: For The Use of Plasser & Theurer Permanent-Way Machinery

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BS-02.

GENERAL OPERATING AND

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

1.0 05-2010 HGR First version -

Copyright © Plasser & Theurer

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

When dealing with technical products, particularly when specialized,

The information provided in the technical documentation (product

Please pay special attention to our operating and safety instructions.

Always keep this brochure close at hand on the product supplied.

Plasser & Theurer

All rights to alterations and amendments reserved

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

This set of instructions:

GENERAL OPERATING AND SAFETY

It contains important requirements for the operation,

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

2. OPERATIONAL AND SAFETY INSTRUCTIONS

2.2 ALTERATION AND UPDATE OF REQUIREMENTS

The circumstances mentioned above, as well as the respective operating

Should the requirements valid in the area of operation of the product

If existing regulations should prove insufficient in certain situations, the

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

2.3 NOTICE OF REGULATIONS

All persons involved must be informed at regular intervals of all

For clarification additional comments and explanations are to be given.

It is to be clearly stated that these requirements must be observed and

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

3. ACCEPTANCE, EQUIPMENT AND APPROVAL

e. g. fire extinguishers, first-aid kit, signalling and communication

3.3 OPERATIONAL APPROVAL

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

4. USE AND AUTHORISATION

The product supplied may only be used as directed.

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

4.2 AUTHORISATION AND RESPONSIBILITY

Only trained, qualified and authorized personnel is allowed to

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

5.3 PROOF OF TRAINING

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

6. SAFE OPERATING CONDITION

The product supplied can ensure safety only to such an extent as

6.2 GENERAL OPERATING STATE

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

e) Loose objects: objects transported in the cabins must be stored away or

Chemicals, like acids, solvents, and other aggressive substances can be

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

7.1 HAZARDS IN RAILWAY OPERATION

7.2 OPERATIONAL HAZARDS

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

8. RISKS OF HAZARDOUS SITUATIONS AND MINIMISATION

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

8.1.2 RISKS ARISING WHEN PARKING THE MACHINE

Allgemeine Betriebs- und Sicherheitsbestimmungen, Edition 05.2010

8.1.3 RISKS ARISING FROM UNAUTHORIZED START-UP

8.1.4 RISKS ARISING FROM IMPROPER USE OF THE MACHINE

8.2 RISKS DURING SHUNTING WORK

8.3 RISK DURING TRAVELLING MODE