Operator's Manual

OBW 10 Sprinter BA 5811
OBW 10 Sprinter
Operator’s manual
Machine number: 967-974

BA 5811 OBW 10 Sprinter
PREFACE
The present operating instruction is required in order to guarantee
professional and safe handling of the machine. It must be read thoroughly
and understood before putting the machine into operation.
One copy of the present operating instruction must always be stored on the
machine.
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.
RECORD OF AMENDMENTS
ISSUE REV Nº. DATE RECORD OF REVISION REASON FOR REVISION APPROVED
1 A 26 Apr. Original Issue T. Hagenhuber

OPERATING MANUAL SECTIONS
Manufacturer’s name and address.

General Quality Certificate.
Manufacturer’s Nameplate &Frame Number.
Service Information SI – 0300-01
Service Information SI – 0400-03
Ratings.
A -part Limit Values.
Outline Drawing.
Characteristic Features of the Machine.
Brake Description.
Photographs of the Machine, including indication of control elements

B -part
and structural parts relevant for operating the machine.
Operating Sequence.
C -part Working Instructions – Safety Instructions – Warnings.
Procedure in Case of Malfunction
D - part Procedure in Case of Fire

TABLE OF CONTENTS
PART A
CERTIFICATE ....................................................................................................................1
MANUFACTURES NAMEPLATE .......................................................................................2
FRAME NUMBER ..............................................................................................................3
SERVICE INFORMATION.................................................................................. SI 0300-01
SERVICE INFORMATION.................................................................................. SI 0400-03
TECHNICAL DATA.......................................................................................................... A1
LIMIT VALUES FOR TRANSFER MODE........................................................................ A8
LIMIT VALUES FOR WORKING MODE.......................................................................... A8
CHARACTERISTIC FEATURES OF THE MACHINE ..................................................... A9
PART B
5811B063 MACHINE FRONT................................................................................... B1

5811B064 MACHINE - SECTIONAL VIEW .............................................................. B2
5811B096 CABIN GENERAL VIEW ......................................................................... B3
5811B031 DRIVER’S DESK - SECTIONAL VIEW ................................................... B4
5811B032 DRIVER’S DESK - INSTRUMENTS ........................................................ B5
5811B033 DRIVER’S DESK - FAILURE INDICATION ............................................. B6
5811B034 DRIVER’S DESK - CRANE CONTROL................................................... B8
5811B035 DRIVER’S DESK - MISCELLANEOUS ................................................... B9
5811B036 DRIVER’S DESK - DRIVE CONTROL .................................................. B11
5811B038 DRIVER’S DESK - ENGINE CONTROL................................................ B13
5811B029 PNEUMATIC CONTROL PANEL .......................................................... B14
5811B030 PNEUMATIC CONTROL PANEL DETAIL VIEW................................... B16
5811B098 CABIN GENERAL VIEW R.H.S............................................................. B17
5811B097 CABIN REAR GENERAL VIEW ............................................................ B18
5811B039 HIGH VOLTAGE CONTROL RACK ...................................................... B19
MFSZ 2. 1-A TEMPERATURE MONITORING SYSTEM – CONTROL UNIT............. B20
5811B073 DIESEL FUEL TANK L.H.S. .................................................................. B22
5811B046 DIESEL FUEL TANK R.H.S. ................................................................. B23
5811B045 DIESEL FUEL TANK DETAILED VIEW ................................................ B24
5811B068 AXLE #1 L.H.S. ..................................................................................... B25
5811B048 AXLE #1 R.H.S...................................................................................... B26
5811B074 HYDRAULIC OIL TANK ........................................................................ B27
5811B081 HYDRAULIC OIL TANK REAR VIEW ................................................... B28
5811B066 PARKING BRAKE AREA L.H.S............................................................. B29
5811N024 PARKING BRAKE AREA R.H.S. ........................................................... B30
5811B025 ENGINE ROOM L.H.S........................................................................... B31
5811B015 ENGINE ROOM R.H.S. ......................................................................... B32
5811B060 AXLE #2 L.H.S. ..................................................................................... B33
5811B059 SUPPORT LEG L.H.S. .......................................................................... B34
5811B052 SUPPORT LEG R.H.S .......................................................................... B35
5811B095 CRANE CONTROL CONSOLE ............................................................. B36
5811B093 CRANE CONTROL PANEL ...................................................................B37
5811N001 CRANE REMOTE CONTROL................................................................B38
5811B084 LOADING PLATFORM ..........................................................................B39
5811B056 MACHINE END......................................................................................B40
PART C
1. OPERATING SEQUENCE PLAN ..........................................................................C1

2. ORIGINAL WORKING STOCK FILLINGS.............................................................C8
3. AMBIENT TEMPERATURE ..................................................................................C8
4. SAFETY REGULATIONS TO BE OBSERVED PRIOR TO START-UP ................C9
5. PREPARING THE MACHINE FOR OPERATION ...............................................C10
6. SAFETY REGULATIONS FOR MACHINE OPERATION....................................C12
7. STARTING THE ENGINE ...................................................................................C15
8. SAFETY CONTRIVANCES .................................................................................C19
9. DRIVING .............................................................................................................C31
10. WORKING ...........................................................................................................C37
11. MISCELLANEOUS ..............................................................................................C51
12. STABLING OF THE MACHINE ...........................................................................C54
13. PARKING BRAKE ...............................................................................................C58
14. PROCEDURE IN CASE OF MALFUNCTIONS OF INDIVIDUAL MACHINE
COMPONENTS...................................................................................................C59
PART D
FIRE PROTECTION ........................................................................................................D1

General
Manufacturer’s Name and Address
Quality Certificate
Manufacturer’s Nameplate
Frame Number
Service information SI-0300-01
Service information SI-0400-03

OBW 10 Sprinter BA 5811 1
Head office Linz factory Purkersdorf factory

Johannesgasse 3 Pummererstrasse 5 Wintergasse 56
A-1010 Wien A-4020 Linz A-3002 Purkersdorf
Tel. 1 / 51572 - 0 Tel. 732 / 7666 - 0 Tel. 2231 / 63662 - 0
Telefax 1 / 5131801
2 BA 5811 OBW 10 Sprinter
MANUFACTURER’S NAMEPLATE:
The manufacturer's nameplate is mounted on the front of the vehicle on the
left hand side.
Driver’s desk
2012 967-974
OBW 10 Sprinter
OBW 10 Sprinter BA 5811 3
FRAME NUMBER:
The frame numbers are stamped in on the front of the vehicle on the l.h.s.
and on the rear of the vehicle and on the trailer on the r.h.s.
Driver’s desk
Mach. Nr.: 967-974

Frame number: 5811-5818
ANNOTATION: The certificate folder contains the most important certificates and
numbers.
REFERENCE TO STANDARDS
This operating manual is based on the following standards:
EN 12100-1/2
EN 14033-1; EN 14033-2
SERVICE INFORMATION SI-0300-01
GENERAL DESCRIPTION FOR THE OPERATION, MAINTENANCE, PERIODICAL CHECKING

AND TRACK WORTHINESS OF PLASSER & THEURER TRACK MAINTENANCE MACHINERY
On track Heavy Plant Machinery, Measuring Cars and Inspection Vehicles are subject to certain operation
and periodical maintenance procedures to maintain the correct standard and ensure they meet the safety
requirements.
The end user is responsible to follow the instructions of the manufacturer to keep the vehicles in correct
operational and working condition. For this purpose we the manufacturer hereby supply the following
instructions that should be strictly adhered to:
1) SAFETY REQUIREMENT:
Our Direction; “General Operation and Safety Requirements for Plasser & Theurer Track
Maintenance Machines, BS-02.05” This instruction is a part of the documentation originally delivered
with the machine. The instruction should be carefully read and followed, it contains instructions for
operating, how to reduce danger and risks, and other useful information.
2) TRACK WORTHINESS:
The End User is responsible for ensuring that all necessary requirements related to vehicle safety on
track have been fulfilled.
3) INTENDED USE, OPERATION AND LIABILITY:
a) The delivered vehicle should only be used for the purpose that it is designed for, and should only be
operated and maintained by qualified personnel.
b) In case the machine is not operated and maintained by qualified persons, or repairs are carried out
without following the service instruction, or the use of non original spare parts, the manufacturer can
not be held responsible for any damage.
4) OPERATING CONDITION AND MAINTENANCE:
Before putting the vehicle into operation the end user must ensure that the delivered product is fully
operational:
a) All necessary instructions and maintenance intervals as stipulated in the Service Instructions must
be followed by the machine personnel.
b) Only those materials described in the relevant instructions should be used for cleaning and
maintenance.
5) INSPECTION AND REPAIR:
In addition to the recommended periodical inspection of Track Maintenance Equipment, and with
reference to requirements for Heavy Plant Machinery, it is necessary to carry out frequent checks on;
Undercarriage, Drive Control, Brake System Components, Frame, General Working Functions,
Measuring Systems and Safety Controls. Any problem identified should be immediately reported and
dealt with.
a) The machine must always be repaired in a suitable workshop by qualified personnel using only
approved components.
b) In general a service network for technical assistance has been set up by Plasser & Theurer.
c) The End User (customer) in case of failure can contact the appropriate Plasser & Theurer Service
Branch.
d) The Service Branch is available for providing Technical Assistance for the checking and
commissioning of the machine, in both a practical and technical capacity.
e) To ensure an accurate and reliable performance of the equipment it is strongly recommended that
only original spare parts should be used. During the warranty period it is a condition of the warranty
that original spare parts from Plasser & Theurer have to be used.
f) Modifications, additional installations and using the equipment for purposes other than which it was
designed for, can seriously affect the safety requirements of the equipment, and therefore can only
be carried out with the prior approval of the manufacturer.
Plasser & Theurer

Export von Bahnbaumaschinen
Gesellschaft m.b.H.
SERVICE INFORMATION SI-0400-03
SAFETY GUIDELINES TO PREPARE ANY REPAIR WORK ON THE MACHINE
¾ In working mode the danger area of the machine is prohibited
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:
¾ Deactivate hydraulic pressure!
¾ Deactivate the air system!
¾ Protect the machine from breaking away (parking brake, skid-pans etc.)!
¾ Turn off the engine!
¾ Turn off the working-mode main switch and protect it from unauthorized
operation!
¾ Turn off the battery main switch and protect it from unauthorized operation!
¾ If repair works are carried out in closed workshops the batteries have to be
disconnected (machine without current). The battery terminals have to be
secured accordingly.
¾ Furthermore, the machine crew and all persons having access to the machine
must be informed of the intended repair work!
¾ A professionally competent person has to be chosen who will bear main

responsibility for the repair work to be carried out and supervise this work
according to all aspects of safety!
¾ Furthermore, the machine crew has to be informed of the repair work completed
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!
¾ In working mode the working area is prohibited again!

PART A
Ratings.
Limit Values.
Outline Drawing.
Characteristic Features of the Machine.
Brake Description.
OBW 10 Sprinter BA 5811 A1
TECHNICAL DATA
PERMANENT-WAY CAR 10 Sprinter

Machine #.: 967
Year of construction 2012
GENERAL DATA
Outline drawing OB00.178-1
Driver’s desks 1
Seats / maximum number of persons 6
Structure gauge UIC 505-3
DIMENSIONS
Overall length 12484 mm
Overall height 4035 mm
Overall width 3030 mm
UNDERCARRIAGE
Number of wheelsets 2
Wheel set arrangement B
Axle to axle 6000 mm
Wheel diameter Ø, new 850 mm
Wheel diameter Ø, last re-profiling 804 mm
Wheel diameter Ø, worn 790 mm
Track gauge 1435 mm
A2 BA 5811 OBW 10 Sprinter
WEIGHTS
Total weight 28,10 t
FILLING QUANTITIES
Diesel fuel approx. 690 Liter

Hydraulic oil approx. 450 Liter
ENGINE
Type TCD2013L6/2V/1620/F
Rated power 200 kW at 2300 min-1
DRIVING UNIT
Transmission model hydrostatic
ELEKTRIC EQUIPMENT
Alternator (attached to engine) 28V DC, 55 A
Alternator (hy. driven) 28V DC, 120A
BATTERIES
starter for engine and equipment 2 pcs. 12V DC batteries
225 Ah in series each
HEATING DEVICES
Air condition CC 9
Engine coolant fluid pre-heating depot plug (230V/1000W)
Diesel fuel pre-heating in the diesel fuel filter

COMPRESSED AIR
Working pressure 6,5 - 8 bar
Air receivers 2 pcs. 57 litres for direct and indirect- acting brake
1 pcs. 57/40 litres for indirect brake valve
1 pcs. 100 litres for indirect brake system
1 pcs. 9 litres for indirect brake system
One air drier per engine, for the air compressor - chamber drier 24V DC, 100 W
working pressure max. 10 bar
Trough main air pipe 5 bar

For indirect brake 1 stop cock at each end (red), with hose and coupling
CRANE
Type PK11502B
Slewing range - (with opposite-track block) 450°
Lifting limit 4,50 m
LOADING PLATFORM
Length 4000 mm
Width 2700 mm
Maximum load 6 to
BRAKE
Through main air pipe 5.0 bar

at either end 1 stop cocks with hose and coupling
Indirect brake AAB
Direct brake ZB11

Brake pressure 3,8 bar
Parking brake
Type manual actuation via hand wheel acting on axle #2
Brake blocks 1 brake block per wheel

Type WN146-850.K-5
SAFETY
Shunting humping and pushing off PROHIBITED
Transportation in train formation ONLY when the engine is off
Horn buttons a total of 6 pieces

1 piece at the driver’s desk
1 piece in each machine corner
1 piece at each remote control of the crane
1 piece at the crane control panel
Engine stop a total of 3 pieces

1 piece at the crane control panel
Emergency brake 1 piece at the driver’s desk
Emergency stop a total of 6 pieces

1 piece in each machine corner
1 piece at each control panel of the crane
FIRE EXTINGUISHER 1 piece hand fire extinguisher P6D

LIMIT VALUES FOR TRANSFER:
# Parameter Unit LIMITS

1 Minimum negotiable horizontal radius m 100
2 Minimum negotiable vertical radius m 500
3 Maximum negotiable cant mm 150
4 Maximum negotiable gradient ‰ 25
(also maximum gradient for parking brake)
5 Maximum speed self-propelled km/h 80
6 Maximum speed being towed km/h 90
7 Maximum load hauled to 40
LIMIT VALUES FOR WORKING:

1 Minimum workable horizontal radius m 100
2 Maximum permissible track twist over a base of mm/m 10
3 meter
3 Maximum permissible track twist over a base of mm/m -
9 meter
4 Maximum workable cant mm 150
5 Maximum gradient for the working ramp 1 1:150
LAYOUT DIAGRAM OB00.178-1 - see next page

CHARACTERISTIC FEATURES OF THE MACHINE
The Plasser & Theurer permanent-way car OBW 10 Sprinter is a two axle, diesel-
hydraulic, self-propelled auxiliary permanent-way vehicle.
This machine has been specifically adapted to meet Saudi Arabian conditions and is
suitable for efficient check, repair and maintenance of overhead systems, as well as
transport of people and material.
Transportation of hazardous goods is prohibited!!
The Machine is equipped with:

• one cabin
• An air condition in the cabin
• A water-cooled 6-cylinder diesel engine of the latest generation
• A program control
• A hydrostatic driving mode
• a crane
• Through main air pipe (5.0 bar)at either end 1 stop cock with hose and
coupling
• An indirect brake
• A direct brake
• A parking brake
• A program controlled working brake
• A ZÖLLNER warning device
• One emergency brake handle
• A depot plug
The engine is a water-cooled diesel engine, Type TCD2013L6/2V/1620/F with an output of

200 kW at n= 2300 rpm.
Power transmission for transit (under own power) and working mode is effected from the
engine - cardan shaft - pump distributor gearbox - variable displacement pump - variable-
speed motor - axle gearbox #1&2
The cabins are equipped with hardly inflammable materials and additionally sound and
heat insulated. The front windows are made of safety panes of 14 mm thickness and can
be heated electrically. At an ambient temperature below 5°C it is recommended to switch
on the window heating in order to prevent the panes from steaming up. The cabin is
equipped with one driver’s desk and a seat group (one bench and a seat). Cabin access
via the platform. The driver’s desk is designed for one-man operation. Additionally the
cabin is equipped with an air condition. On the roof of the cabin the air condition and the
macrophones are arranged. The safety regulations concerning the access of the cabin
roof, working cage and the mobile platform must be observed!
WARNING:
Danger of falling on the roof of the cabin. Careful behavior is absolutely
necessary.
A program control controls the working process and should prevent operating errors.
INDIRECT ACTING BRAKE

A driver’s brake valve (Fb-11) is mounted on the driver’s desk.
This valve influences the control valve (AAB).
DIRECT ACTING BRAKE

The direct-acting brake is actuated via the direct brake valve on the driver’s desk.
PARKING BRAKE
The parking brake is controlled via the hand wheel. The parking brake acts on the axle #2.
There is no monitoring or indication of the status (APPLIED – RELEASED) of the parking
brake!
Therefore, increased carefulness is required when dealing with the brake.
WARNING:
Driving / towing the machine with the parking brake “APPLIED“ leads to serious
damage and can cause fire!
EMERGENCY BRAKE
The pull handle for the manual emergency brake is located at the driver’s desk. When the
pull handle is actuated, the mechanical emergency brake valve opens and air emanates
from the indirect brake pipe, the indirect brake valve responds and the indirect-acting
brake “APPLIES“.
Driving can be continued only when the pull handle has been restored by the key to
normal working position and the main air pipe has been refilled. Filling of the main air pipe
is effected via the indirect brake valve.
ATTENTION:
The reason why the emergency brake had been actuated must be found!
Possible dangers and obstacles have to be removed before deactivating the
emergency brake and continuing driving the machine.
COMPRESSED AIR PRESSURE GAUGE

A dual pressure gauges on the pressure indication panel next to the driver’s desks show
pneumatic system pressure and the brake pressure of each brake circuit.
Additionally a single pressure gauge on the pressure indication panel shows the pressure
in the main air pipe.
BRAKE CYLINDERS – BRAKE BLOCKS

Each wheel is braked by a double-brake block.
PART B
Sectionwise Assignment of Illustrations
Photographs of the Machine, including
Indication of Service Elements and
Structural Parts
Relevant for Operating the Machine

OBW 10 Sprinter BA 5811 B1
5811B063
MACHINE FRONT
1= Driver’s desk - see page B4

2= Pn. stop cock for main air line
3= Decoupling rod
4= Small car coupling
5= Pn. macrophones
B2 BA 5811 OBW 10 Sprinter
5811B064
MACHINE - SECTIONAL VIEW
1= Cabin - see page B3

2= Section hydraulic oil tank - see page B27
3= Section engine room - see page B31
4= Crane - here in working position - see page B39
5= Section diesel fuel tank - see page B22
6= Section axle #1 - see page B25
7= Section parking brake area - see page B29
8= Section axle #2 - see page B33
9= Section support leg - see page B34
5811B096
CABIN GENERAL VIEW
1= Driver’s desk - see page B4

2= Pneumatic control panel - see page B14
3= Emergency brake
4= Indication light and buzzer column for temperature monitoring system, see part C 8.
5811B031
DRIVER’S DESK - SECTIONAL VIEW
1= Instruments - see page B5

2= Failure indication - see page B6
3= Crane control - see page B8
4= Miscellaneous - see page B9
5= Drive control - see page B11
6= Engine control - see page B13
5811B032
DRIVER’S DESK - INSTRUMENTS
1= Automatic circuit breakers - see el. plans

2= Engine indication and diagnosis instrument
3= Tachometer with integrated clock and km-counter
4= Diesel fuel gauge
5= Speaker for ETC-S
6= 12V DC socket
7= 24V DC socket
8= Socket for diagnosis instrument of the engine
9= Engine diagnosis enable button (engine has to be stopped)
10 = Engine diagnosis button
5811B033
DRIVER’S DESK - FAILURE INDICATION
1= Indication LED for general engine warning

2= Indication LED for air pressure low
3= Indication LED for battery charge (alternator 1, engine)
4= Indication LED for battery charge (alternator 2, hy. drive)
5= Indication LED for fire warning system failure
6= Not connected
7= Indication LED for hy. oil level low
8= Indication LED for hy. oil temperature excessive
9= Indication LED for ZF gearbox oil filter clogged
10 = Indication LED for drive pump charging pressure low
11 = Indication LED for diesel level reserve
5811B033
12 = Not connected
13 = Warning buzzer
14 = Push button for warning buzzer off
5811B034
DRIVER’S DESK - CRANE CONTROL
1 = Key switch for crane operational mode “support legs - remote control
- manual control"
2 = Key-switch for the crane lifting limit stop - see chapter C10.7.5.2
3 = Key-switch for the opposite track lock - see chapter C10.7.5.1
4 = Indication LED for crane in travel position
5 = Bridge switch for SIFA device
6 = Bridge switch for drive system
7 = Emergency stop
8 = Emergency stop reset
5811B035
DRIVER’S DESK - MISCELLANEOUS
1= Fan regulator
2= El. horn button
3= Cabin light switch
4= Windscreen wiper switch door
5= Step light switch
6= Windscreen washer switch front
7= Windscreen washer switch rear
8= Pn. horn button
9= Windscreen heating “ON rear - OFF - ON front”
10 = Indication LED for windscreen heating rear “ON”
11 = Indication LED for windscreen heating front “ON”
12 = Working light switch
5811B035
13 = Windscreen wiper switch rear

14 = Windscreen wiper switch front
5811B036
DRIVER’S DESK - DRIVE CONTROL
1= Working mode main key switch

2= Key-switch for drive direction forward “ON - OFF”
3= Drive direction selector switch
4= Indication LED for drive direction “FORWARD” selected
5= Key-switch for drive direction reverse “ON - OFF”
6= Drive direction selector switch
7= Indirection LED for drive direction “REVERSE” selected
8= Drive gear selector switch “1st gear - neutral - 2nd gear”
9= Indication LED for drive gear “NEUTRAL” selected
10 = Indication LED for drive gear “1st gear” selected
11 = Indication LED for drive gear “2nd gear” selected
12 = Drive gear engage help button
5811B036
13 = Drive stop button

14 = Driving light switch
15 = Driving light switches front
16 = Driving light switches rear
5811B038
DRIVER’S DESK - ENGINE CONTROL
1= Main battery key switch

2= Engine system master key switch
3= Engine pull starter switch
4= Preheating glow light
5= Pilot lamp for engine control on
6= Engine throttle control
7= Engine stop button
8= Fire alarm bridge push button for engine start enable
5811B029
PNEUMATIC CONTROL PANEL
1= Direct brake valve

2= Indirect brake valve
3= Dual pressure gauge (pneumatic system pressure #1 - white; brake pressure - red)
4= Main air pipe pressure gauge
5= Dual pressure gauge (pneumatic system pressure #2 - white; brake pressure - red)
6= Drive pressure gauge
7= Hy. oil temperature gauge
8= Amperemeter
9= Voltmeter
10 = Drive servo valve current indicator
5811B029
11 = Voltage indication for power supply according to pos. 12

12 = Selector switch for power supply voltage indication
13 = ETC-S device control panel - please refer to separate instruction
5811B030
PNEUMATIC CONTROL PANEL DETAIL VIEW
1 = Pn. stop cock for bridging the cut-off valve

2 = Pn. reducing valve for direct brake pressure
3 = Pn. reducing valve for indirect brake line pressure
5811B098
CABIN GENERAL VIEW R.H.S.
1 = First aid kit

2 = Fire extinguisher
5811B097
CABIN REAR GENERAL VIEW
1= Temperature monitoring system - control unit - see page B20

2= High voltage control rack - see page B19
3= Life hammer
4= Air condition
5= 230 VAC socket
6= Windscreen washer bottle
5811B039
HIGH VOLTAGE CONTROL RACK
1= Circuit breakers - see El. plans

2= Time relay
3= Switch to pos. 2 - here in pos. “OFF”
4= Fault current breaker
WARNING:
Do not open this rack while the depot plug is connected. – DANGER!
MFSZ 2. 1-A
TEMPERATURE MONITORING SYSTEM – CONTROL UNIT
1 = Control unit
2 = Main switch
3 = Operation indication
shows "green" – when at least on sensor is operative
flashes green" – when the system has failed
4 = Warning buzzer
5 = Malfunction warning lamp
shows "yellow" – when the entire system has failed
flashes "yellow" – when part of the system has failed
is not lit – when the system is fully operable
6 = Turns off the warning buzzer
7 = Warning lamp: early warning for measuring circuit 2
shows "yellow" - when at least one temperature sensor of measurement circuit 2
has reached or exceeded the early warning value
is not lit - when all temperature sensors of measurement circuit 2 remain
below the early warning value
8 = Warning lamp: temperature alarm for measurement circuit 2
shows "red" - when at least one temperature sensor of measurement circuit 2
has reached or exceeded the alarm value
below the alarm value
MFSZ 2. 1-A
9 = Warning lamp: early warning for measurement circuit 1

shows "yellow" - when at least on temperature sensor of measurement circuit 1
has reached or exceeded the early-warning value
below the early-warning value
10 = Warning lamp: temperature alarm for measurement circuit 1
shows "red" - when at least one temperature sensor of measurement circuit 1
has reached or exceeded the alarm value
below the alarm value
5811B073
DIESEL FUEL TANK L.H.S.
1= El. horn button

2= Emergency stop
3= Step light key switch
4= Diesel fuel tank
5= Diesel fuel tank level sight hose
6= Diesel fuel tank filler neck
7= Drip cup with drain cock in the indirect brake line
8= Rail guard
5811B046
DIESEL FUEL TANK R.H.S.
1= El. horn button

2= Emergency stop
3= Step light key switch
4= Diesel fuel tank
5= Diesel fuel tank level sight hose
6= Diesel fuel tank filler neck
7= Lever for axle #1 final drive interlock
„PULL“ = ready for travel
„PUSH = ready for towing
8 = Diesel fuel tank detailed view - see page B24
9 = Rail guard
5811B045
DIESEL FUEL TANK DETAILED VIEW
1= Diesel fuel preheating on / off

2= Diesel fuel filter with dirt indicator
3= Diesel stop cock in the engine supply line
4= Diesel stop cock in the engine return flow line
5= Diesel fuel hand pump
5811B068
AXLE #1 L.H.S.
1= 400V AC socket (input)

2= Pn. stop cock for ETC-S device - here in position “OFF”
3= Pn. stop cock for Plasser SIFA - here in position “ON”
4= Air drier
5= Stop cock of the pneumatic pressure regulator – here in pos. “OPEN”
6= Drip cup with automatic drain valve between air compressors and air drier
7= Hy. sol. op. valve for hy. oil cooler on / off
8= Hy. sol. op. valve for air condition on / off
5811B048
AXLE #1 R.H.S.
1= 400V AC socket (input)

2= Service battery main switch
3= Hydraulic oil tank drain cock
4= Access safety barrier
5= Engine oil and coolant fluid drain cock
5811B074
HYDRAULIC OIL TANK
1= Hy. oil tank

2= Hy. oil tank filler neck
3= Vaccumeter (dirt indicator) for hy. suction filters
4= Manual operated hy. emergency pump
5= Stop cock for pressure build up
6= Hy. working drive charging pressure gauge
7= Hy. sol. op. valve for hy working system on / off
8= Axle gearbox oil filler cap
5811B081
HYDRAULIC OIL TANK REAR VIEW
1= Hydraulic oil tank

2= Pn. macrophones
3= Hy. sol. op. valve for working drive Q-max
4= Air condition
5811B066
PARKING BRAKE AREA L.H.S.
1= Pn. stop cock for indirect brake valve off / on Lever for indirect brake valve
2= Retaining valve (for indirect brake)
3= Parking brake
4= Pn. stop cock to the working brake - here in closed position
5= Pn. sol. op. valve for working brake
6= Pn. reducing valve for working brake pressure
7= Quick air coupling
8= Air lubricator for pn. system
9= Water separator for pn. system
10 = 24V DC socket
11 = Locking lever for platform gate
12 = Engine room - see page B31
5811N024
PARKING BRAKE AREA R.H.S.
1= Parking brake
2= Main batteries
3= Locking lever for loading platform gate
4= Engine indication- and diagnosis display
5= 24V DC socket
6= Hy. sol. op. valve for brake control
5811B025
ENGINE ROOM L.H.S.
1 = Engine coolant fluid filler cap

2 = Engine room temperature feeler
3 = Engine coolant fluid preheating
5811B015
ENGINE ROOM R.H.S.
1 = Engine room temperature feeler

5811B060
AXLE #2 L.H.S.
1= Pn. stop cock to the safety brake - here in open position

2= Pn. sol. op.valve for safety brake
3= Pn. reducing valve for safety brake pressure
4= Rail guard
5811B059
SUPPORT LEG L.H.S.
1 = El. horn button

2 = Emergency stop
3 = Lever for axle #2 final drive interlock
„PULL“ = ready for travel
„PUSH = ready for towing
4 = Support leg - here in up position
5 = Safety chain for pos. 4
6 = Proximity switch for support leg in travel position
7 = Pn. drip cup with drain cock in the indirect brake line
5811B052
SUPPORT LEG R.H.S
1= El. horn button

2= Emergency stop
3= Crane control console - see page B36
4= Support leg - here in up position
5= Safety chain for pos. 4
6= Proximity switch for support leg in travel position
7= Lever for lifting / lowering of the l.h.s. support leg
8= Lever for lifting / lowering of the r.h.s. support leg
9= Rail guard
5811B095
CRANE CONTROL CONSOLE
1= Protection flap - here in pos. "open"

2= Emergency stop
3= Manual control lever for the crane - functions according to the inscriptions
4= Paltronic - please refer to separate instruction
5= Crane control panel - see page B37
6= Socket for diagnosis
5811B093
CRANE CONTROL PANEL
1 = L.h.s. = engine start

R.h.s. = engine stop
2 = Pilot lamp for support legs supporting
3 = Illumination "off - desk - desk and crane"
4 = Horn
5 = OLP (overload pressure) on - off
5811N001
CRANE REMOTE CONTROL
1 = l.h.s. = set engine revs to working revs

r.h.s. = set the engine revs to automatic mode (increases with crane movement)
2 = l.h.s = engine start
r.h.s = engine stop
3 = l.h.s. = crane working light
4 = Push button for slow extension of the crane extension arms
5 = Horn button
6 = l.h.s. = reduce crane movement speed
r.h.s. = increase crane movement speed
7 = Paltronic
8 = Emergency stop
9 = Pilot lamp for slow movement on
10 = Operational mode control
11 = Push button for crane remote control on / off
12 = l.h.s. = automatic AOS (active oscillation suppression) off
r.h.s. = automatic AOS (active oscillation suppression ) on
13 = Manual AOS (active oscillation suppression) on
14 = Without function
15 = Without function
16 = Control lever for crane swivel to the left / right
17 = Control lever for main arm lifting lowering
18 = Control lever for folding arm lifting / lowering
19 = Control lever for extension arms shift out / retracting
5811B084
LOADING PLATFORM
1= Crane - here in travel position

2= Crane buttress
3= Access safety barrier
4= Support plate - here in travel position
5811B056
MACHINE END
1 = Pn. stop cock for main air line

2 = Small car coupling
3 = Decoupling rod
PART C
Operating Sequence Plan
Working Instructions
Safety Notices -
Warnings
Procedure in failure events

OBW 10 Sprinter BA 5811 C1
1. OPERATING SEQUENCE PLAN
2.
original working
stock filling
3.
ambient temperature
4.safety before
putting the machine
into operation
5.preparing the
machine for
operation
6.
safety during
operation
7. 7.3
starting the turning off the
engine engine
8. 7.4
safety low
contrivances temperatures
9. 10.
DRIVING WORKING
11. 12.
MISCELLANEOUS PARKING
13.
parking brake
14.
malfunction
C2 BA 5811 OBW 10 Sprinter
9. 9.
transfer travel DRIVING
9.1
limit values for
transfer travel
active passive
9.2
preparing the 10.7 12.2
machine for Working drive towing
driving
10.7.2 12.2.1
9.3 Control position preparing the
starting Driver’s desk machine for towing
9.4 12.3 including the

accelerating machine directly
into train
formation
9.5
maintaining
speed
9.6
driving
9.7
reducing speed
9.8
stopping the
machine
9.9 changing
driving direction
10.
WORKING
10.1 dangers occurring 10.2

during work stability
10.3
limit values for
working mode
10.4 changing to
working mode
10.5
working mode
10.6 10.7
working drive crane
10.8
terminating work
11.
MISCELLANEOUS
11.1
working lights
11.2
remote control
11.3
depot plug
12.
PARKING
12.1
access illumination
12.2
the brakes
12.3.1
12.3 towing the preparing the
machine machine for towing
12.4 including the

machine intro train
formation
SHORTCUTS:
Hy. = hydraulic
Pn. = pneumatic
Pos = position
The
Remarks
mean:
PLEASE NOTE:
- Remark for a better understanding of the system
IMPORTANT:
- Reference to a special operating instruction
ATTENTION:
- Specific feature of the machine
WARNING:
- Safety hazard (material defect and / or personal injury)
• The operating sequence plan shows which chapters of the operating instruction have to
be read or applied to carry out the necessary processes.
EXAMPLE: The following chapters refer to the starting of the engine:
chapter 2 original working stock fillings

chapter 4 safety regulations BEFORE putting the machine into operation
chapter 5 preparing the machine for operation
chapter 6 safety regulations DURING operation of the machine
chapter 7 starting the engine
• If the ambient temperature is around or below zero, the following chapters also have to
be considered:
chapter 3 working stock and ambient temperature

chapter 7.4 low temperatures
ATTENTION:
It goes without saying that before putting the machine into operation
the necessary maintenance works have to be carried out!
IMPORTANT:
The present operating instruction lists the individual instructions
which have to be performed one after another. You may and indeed
should read the operating instruction from ”top” to ”bottom” like a
checklist for fault finding!
If this sequence given will not be observed, malfunctions might
occur!
The present operating instruction describes the machine as on
delivery – subject to change without notice; errors and omissions
excepted.
PLEASE NOTE:
The following description of operating procedures contains figure
and item numbers:
e.g., 3/3 means page B3, item number 3
= emergency brake
If reference is made to a certain page, also the following pages
might be relevant!
2. ORIGINAL WORKING STOCK FILLINGS
• Original working stock fillings – see service instruction of WS-5811
IMPORTANT:
The names of oils are only valid at the time of delivery of the machine. Oil
companies often change their product names in quick succession! Furthermore,
often the same product is sold by different names in different countries.
The oil and lubricant manufacturers' customer service departments will be able
to provide competent information!
3. AMBIENT TEMPERATURE
• It is of particular importance to take into account the ambient

temperature before putting the machine into operation.
• If the ambient temperature is below the minimum temperature of the
working stock, these have to be heated up before starting operation!
• See chapter 7.4
4. SAFETY REGULATIONS TO BE OBSERVED PRIOR TO

START-UP
Familiarize yourself with the machine equipment.
Keep the machine free of oily and flammable materials.
Perform visual checks of the machine to find visible defects or failures.
Keep all handles, steps and platforms free of grease, oil, fuel, dirt, snow and ice.
For climbing on the machine use the stairs and handles only.
Pay attention to trains passing on the adjacent tracks!
Before climbing on the machine make sure that no persons and obstacles are beside or
below the machine.
Observe the operating instructions before starting the machine.
Adjust your seat before starting.
Never drive and operate the machine with defective instruments, pilot lamps and control
elements.
Operate the machine only when you have entirely familiarized with the operating and
control elements, as well as with the principle of work of the machine.
WARNING: Keep the machine clean! – Fire hazard!
In order to avoid inflammation of flammable dirt deposited on the lower

machine surface the machine must be cleaned accordingly (at least once a
year)!
Furthermore, contaminated surfaces (engine unit, gearbox etc.) significantly

worse carry off heat!
Overheating might be the consequence!!
5. PREPARING THE MACHINE FOR OPERATION
• On the assumption of an unknown situation the following measures

will prepare the machine for operation.
• These measures are compulsory if:
- the machine had been stabled for a longer period,
- the operational condition of the machine is unknown,
- a new or untrained crew will put the machine into operation.
• Necessary service works on the machine have been carried out! –

Please refer to the maintenance manual WS 5811
• The brake block play has been set correctly
• All operational stock has been duly checked and, if necessary,
topped up or replaced!
• Check vacuum meter of hydraulic suction filters. 27/3

• Battery sets are connected, battery boxes are "CLOSED ". 30/2
• All air and water drain cocks (valves) of air receivers and drip cups 22/7 etc.
are ”CLOSED ”
ATTENTION:
This machine is equipped with an automatic air drying and 25/4
water draining plant.
In general, additional draining will not be necessary!
However, after longer standstills and/or in case of great
temperature differences additional draining is
recommended.
In contrast, the drip cups between air compressor and air
drier differ from this: they are drained autpmatically in order 25/6
to protect the air drying plant from contamination!!
• The diesel fuel stop cock in the engine suction pipe is “OPEN“. 24/3
• The diesel fuel stop cock in the engine return flow pipe is ”OPEN“. 24/4
• The pn. stop cock of the safety brake is in position “OPEN”. 33/1
• The pn. stop cock of the Plasser SIFA is in position “ON”. 25/3
• The pn. stop cock of the ETC-S device is in position “ON”. 25/2
• The pn. stop cock to the working brake is in pos. “OPEN”. 29/4
• The pn. stop cock to the indirect brake valve is in pos. “OPEN”. 29/1
• The pn. stop cock for bridging the cut-off valve is in pos. “CLOSED”. 16/1
• The stop cock of the idling regulator is "OPEN". 25/5
• The hydraulic oil tank drain cock is closed. 26/3

• The engine oil and coolant fluid drain cocks are closed. 26/5
• Check the hose coupling of the brake pipe of the main air pipe. 1/2; 40/1
IMPORTANT:
The stop cocks to the hose couplings are "CLOSED" when the machine runs
without coupled cars. If machines or cars with brake equipment are connected
to the machine, the hose couplings must be coupled and the respective stop
cocks have to be "OPENED".
• Check brake blocks and running wheels.

• Check rail guard adjustment. 23/9 etc.
• All emergency stops are unlocked. 22/2 etc.
• The emergency brake pull handle is not actuated. 3/3
• Engage the final drives of the gearboxes. 23/7; 34/3
• Switch “ON” the service battery main switch 26/2
• The battery main switch is still "OFF" - 13/1
- during this phase the following modules may be operated:
- the air condition

- the step light
- the temperature monitoring system
• The working-mode main switch is been switched "OFF" 11/1

• Switch "ON" battery main switch. 13/1
• Switch "ON" temperature monitoring system (unlock – switch upward 20/2
- lock).
IMPROTANT:
It is necessary to carry out a functional testing of the plant daily before starting
the machine by switching it "OFF" and "ON" - chapter 8.4.1
• Now the machine has reached the "ready for service" status and
may be put into operation.
6. SAFETY REGULATIONS FOR MACHINE OPERATION
Operate the machine only as directed.
Check operatability of safety contrivances, brakes, lighting, horn and control

elements each time before starting driving.
Observe the operating instructions for the individual process sections.
Whenever starting working, the driver has to make sure in advance, and also after
any break, that nobody is within the danger area.
If necessary he has to give warning signs. He has to immediately discontinue work if

anyone does not leave the danger area despite warning signs.
Never readjust driver’s seat during travel.
In emergencies and in case of danger immediately apply the emergency brake or the
emergency stop.
Do not use emergency brake, machine stop, engine stop and emergency stop as
service brake.
Never drive at excessive speed. The driving speed should always be adapted to the
present track conditions (work site) and has to correspond to regulations (driving
instructions).
Change driving direction only when the machine is stationary.
Use brake shoes whenever stabling the machine on slopes or gradients.
Never (except in emergencies) jump off the machine, but always use ascents and
handles. Always pay attention to adjacent tracks.
Keep all handles, steps and platforms free of grease, oil, fuel, dirt, snow and ice.
If it is dangerous to leave the machine (adjacent track etc.), safety barriers have to be
used for ascents (lift barrier and put it down horizontally on the buttress, thus the
ascent/exit will be locked).
Observe danger signs and information signs next to the ascents and in the machine
interior.
Observe the special safety regulations for catenary.
It is principally forbidden to climb on the machine roof under overhead wire. Before
starting repair and service works make definitely sure that the catenary has been
switched off and earthed. These safety measures have to be carried out and
supervised by the responsible safety service!
Take particular care of inductive voltages within existing catenary (old bearer cable, old
contact wire) and take the respective measures for professional discharging.
Obey the special safety instructions of the crane and the mobile lifting platform.
When operating the machine, pay attention to unusual noise and smoke
development. Find out the reason and repair the malfunction.
Immediately repair even smaller defects, thus you will avoid serious machine outage.
Never readjust safety valves.
Exhaust fumes are hazardous. When starting the machine in enclosed rooms ensure
sufficient air supply.
Keep intakes of engines free of dirt and dust.
Use safety and protection equipment.
Be sure that fire extinguishers are always filled and will be periodically checked.
Do not smoke when refueling the machine or checking the acid level of batteries.
Never check battery acid level, fuel and oil level when handling with an open flame.
Do not refuel the machine while it is raining. Rain water could get into the fuel tank.
Refuel only recommended working stock.
Make sure that the tank will not be contaminated during refueling.
In case of non-compliance with any conditions for putting the machine into operation
and operating the machine (such as contained in operating, service and repair
instructions) or with conditions of approval authorities any indemnification will be
excluded.
The same applies in case the machine is operated by personnel that is not qualified,
instructed properly and authorized.
The machine operating enterprise is obliged to take the necessary safety measures
and to observe any relevant regulations.
We point out especially that the machine operating enterprise has to take note of the
regulation of the railway infrastructure body and to observe them.
The machine operating enterprise must not modify the machine design or configuration
without consultation of the manufacturer and without being given its permission (and
permission of the vehicle approval body).
Safety contrivances have been fitted to the machine in order to safeguard man and
machine. Avoiding these safety contrivances may have fatal consequences and will be
prosecuted in special cases!!
WARNING: It is principally PROHIBITED to produce any switching or operating

conditions on this machine which are not described in this operating
instruction!
Any intervention in and / or modification of the program control unit

(hardware) and the corresponding program (software) is prohibited.
Such authorization can be given only by Plasser & Theurer.
We strongly recommend that the machine operating company instructs the machine crew
regularly as regards danger areas, protection measures and behaviour in emergency
cases (fire - see Part D, derailment, collision etc.).
Emergency exits – see chapter 8.14
Danger area – see chapters 10.7.7
Remember, the machine is a working unit, carrying delicate instruments which are to be
treated correspondingly.
7. STARTING THE ENGINE
WARNING: The engine can only be started when:
- The engine and the gearbox are filled with working stock
• Observe the manufacturer’s engine operating instruction.

• Parking brake “APPLIED” or brake shoes fitted. 29/3
ATTENTION:
The engine can only be started when the machine is stationary!
7.1. PREPARING THE MACHINE FOR STARTING
• Readiness for service has been established - chapter 5

• Turn “ON” the driver’s desk 11/2
• Switch “ON” the engine master key. 13/2
• Select “neutral” gear on the driver’s desk. 11/8
• Turn the engine speed adjustment to idling. 13/6
• Do not press the engine stop button. 13/7
• All emergency-stop buttons are unlocked. 8/7 etc.
• The temperature monitoring system runs without malfunction.
7.2. STARTING PROCEDURE
• Readiness for service has been established - chapter 7.1

• Let a warning signal sound and after having made sure that nobody is 9/2, etc.
within danger area, start the engine. 13/3
NOTE:
Do not start the engine with full throttle.
Continue starting for 20 seconds at most. If the engine does not start, interrupt
the starting procedure, wait for a minute and then repeat starting.
If the engine will not start after two starting procedures, find out the reason
according to the malfunction table (engine manufacturer’s manual).
• Immediately after ignition release the pull starter and check the engine 5/2
instrumentation.
NOTE:
In working mode the engine can also be started via the remote-control unit,
provided it is ready for service, as well as from control panels of the crane.
7.3. TURNING OFF THE ENGINE
• Do not turn off the engine under full load. It is recommended to shortly 13/7
operate the engine (approx. 3-5 min.) at idle running speed in order to
relieve the engine and to equalize temperature (turbocharger).
• Normally, the engine is switched off by pressing the engine stop button.
• Furthermore, the engine is switched off, if an “emergency stop has 23/2 etc.
been depressed.
• When the key-operated battery main switch is switched "OFF", this 13/1
also switches off the engine.
WARNING:
As a rule it is not permitted to switch "OFF" the key-operated battery main
switch while the engine is running!
! O V E R V O L T A G E!
NOTE:
In working mode the engine can also be turned off via the remote-control unit,
provided it is ready for service, as well as from control panels of the mobile
working platform, contact wire holders or the crane.
7.4. INSTRUCTIONS AND PROCEDURES FOR OPERATING THE

MACHINE AT LOW AMBIENT TEMPERATURES
7.4.1. PREHEATING THE COOLANT
• Plug in the depot plug and ensure current supply (230 VAC). 25/1, 26/1
• Ensure that circuit breaker for the coolant preheating is “ON”. 19/4
7.4.2. STARTING THE ENGINE
• Pull the engine start switch to first stage for preheating. 13/3
• The indication LED for engine preheating glow control lights. 13/4
• As soon as the pre-heating procedure has been finished, pull the 13/3
engine start switch to the second stage and start the engine.
7.4.3. ENGINE OPERATION
• Run up the engine at approx. 900 min-1.

• When the engine runs true, increase engine speed step by step to 13/6
approx. 1200 min-1.
7.4.4. HEATING UP THE AXLE GEARBOX
• Slowly start driving and run up the machine at moderate speed.

7.4.5. WINDSCREEN HEATING
• To prevent the panes from steaming up switch “ON the windscreen 9/9
heating.
• Condition for windscreen heating is a running engine
7.4.6. KEEPING THE MACHINE "WARM"
• Stable the machine in heated workshops (garages, boiler rooms,

etc.).
• The machine is immediately ready for service.
8. SAFETY CONTRIVANCES
• This machine is equipped with a multitude of visible and concealed

safety devices.
• The most perfect safety contrivances are useless if the interface of
man is not prepared to use them appropriately.
For example using an emergency braking device as service brake or
failure to use existing safety devices is considered as gross nonsense!
Thus, despite the many safety features the machine crew must have a
clear awareness of safety issues in order to safely operate the
machine!
PLEASE NOTE:
These safety contrivances have to be regularly checked for operability.
ATTENTION:
The optical and audible warning signals should be checked daily.
WARNING:
Avoiding the safety contrivances may have fatal consequences and will be
prosecuted in special cases!!
Operating the machine for a longer period with defect, non-activated or avoided
safety contrivances is
PROHIBITED!
THE INDIVIDUAL SAFETY CONTRIVANCES ARE:
Emergency stop - chapter 8.1

Emergency brake - chapter 8.2
acoustic warning signals - chapter 8.3
temperature monitoring system - chapter 8.4
opposite track block - chapter 8.5
crane lifting stop - chapter 8.6
key-operated switch - chapter 8.7
Access light - chapter 8.8
Hy-emergency pump - chapter 8.9
Fire extinguisher - chapter 8.10
First aid kit - chapter 8.11
Rail guard - chapter 8.12
safety barrier - chapter 8.13
emergency-exit window - chapter 8.14
8.1. EMERGENCY STOP
• The purpose of emergency stop devices is to stop the machine in critical situations
where no controlled measures can be taken and immediate action is required.
WARNING:
If the emergency stop function has been triggered, the machine is no longer in
the "ready for service" status.
Do not actuate these emergency stop devices for no reason!
Everybody who triggers an emergency stop, bears the entire responsibility for
his action.
The machine is allowed to be put into service only after the reason of triggering
the emergency stop has been found, verified and, if necessary, remedied.
• These visible EMERGENCY STOP devices mainly consist of red

mushroom-shaped buttons marked with a yellow signal marker field
and are located:
- at the driver’s desk 8/7
- on the remote control 38/8
- control panel of the crane 36/2
- at each machine corner 34/2 etc
• When pressed this button engages in the "emergency stop" position.

This results in the following:
- the control unit becomes currentless

- the control unit becomes inactive
- the engine is turned off
- the brake applies
ATTENTION:
Before deactivating the "emergency stop" you have to find out why it was
actuated and repair the cause if necessary!
PLEASE NOTE:
When having deactivated the “emergency stop“ press 8/8;
the reset button.
• The "emergency stop" is released by turning the mushroom-shaped

button to the right.
8.2. EMERGENCY BRAKE
• Adjacent to the driver's desk there is a pull handle for the emergency 3/3
brake.
• When this pull handle is pulled, the emergency brake valve opens.
Air escapes from the brake pipe, the indirect brake valve responds and
the indirect-acting brake applies.
ATTENTION:
You must find out why the emergency brake was actuated!
Possible dangers or obstructions must be cleared before you may continue to
travel.
• Driving can be continued only the pull handle has been restored by the 3/3
key to normal working position and the main air pipe has been filled.
Filling of the main air pipe is effected via the indirect brake valve. 14/2
8.3. AUDIBLE WARNING SIGNALS
• This machine is equipped with several devices to give audible warning

signals. These are:
- electric horn signals

- pn. macrophones 1/5; 28/2
• When an el. horn button has been depressed, this actuates the el. 23/1 etc.
horn.
• When a pn. horn button has been depressed, this actuates the air 9/8
macrophones.
8.4. TEMPERATURE MONITORING SYSTEM
• The temperature monitoring system installed is to announce excess temperature and to

prevent fire from breaking out in dangerous machine areas (engine compartment) in
order to provide sufficient time for the crew to take due measures.
• This system will only be effective when supplied by electric energy (24 V DC), when it is
switched "ON", operative and not bypassed.
• The temperature monitoring system mainly consists of:
a visual/audible signal column at the driver’s temperature probes in the engine

desk compartment
- a control unit with switch, pilot lamps and - a fault switch on the drivers desk
warning buzzer
8.4.1. READINESS FOR SERVICE
• Energy supply of the control unit is ensured.

• Switch "ON" the control unit, for this purpose unlock the switch, turn it 20/2
upward and lock it in position “ON".
All warning and pilot lamps and warning buzzers will be activated for 5
seconds in order to check their operativeness.
After this period of 5 seconds the warning and pilot lamps are
extinguished, the warning buzzers are deactivated:
The "yellow" pilot lamp indicating malfunction does not light. 20/5
The pilot lamp next to the control unit main switch shows "green". 20/3
• The system is in "monitoring mode".
IMPORTANT:
Operativeness of the unit by switching it "OFF" and "ON" before putting it into
operation must be checked daily
8.4.2. EARLY WARNING
• If the ambient temperature exceeds the set threshold value on at least

one temperature probe, an early warning will be actuated.
The warning lamp for early warning on the control desk will show
"yellow". 3/4
On the driver’s desk the "red" warning lamp of the signal column will
start flashing.
• The system now is in "early warning" status.
• Reduce the engine speed as close as possible to idling speed in order

to lower the temperature.
• A thorough check of engine instruments will be necessary to find out
possible reasons for this temperature increase.
• Furthermore, the crew should be prepared that the temperature might
not decrease and that temperature alarm will sound.
WARNING:
Turning "OFF" the engine will increase the temperature at first.
ATTENTION:
In the „early warning“ status no region may be entered, where the fire may
expand easily or where human life and environment is endangered.
Is the machine already in a critical region (e.g.: gas depot, tunnel, bridge,
railway station etc.), the machine must leave this region immediately.
8.4.3. TEMPERATURE ALARM (FIRE RISK)
• The system is in the "early warning" status.

• If the temperature will go on increasing (20°C) and will remain above
the alarm value for more than 5 seconds, temperature alarm will be
triggered.
The warning lamp on the control device will show "red" for alarm, and 20-21/8,10
the warning buzzer will sound. 20/4
Since early warning had been triggered the “red” warning lamp on the
driver’s desk goes on flashing.
Additionally, the warning buzzer in the signal column is now activated 3/4
and the white light will indicate the concerned engine. (top light = main
engine / lower light: secondary engine)
• Now, the system is in the "temperature alarm" status.
This requires immediate action!
WARNING:
A temperature warning indicates a grave situation. Stop the machine as soon
as possible and check danger areas.
If the machine is in this moment in a critical place, as e.g., in a tunnel, on a
bridge etc., where immediate stopping would endanger the crew, leave this
area as soon as possible.
Then engine can, however, only be started, if the fire warning
system has been shunted previously. 13/8
If necessary, stop the machine again in a safe place.
At first do not open any large-dimensioned apertures, because this would
drastically increase oxygen supply and even fan a fire!!
Carry out a fire check, if possible, via the fire fighting aperture. Show due
cautiousness because of hot air emanating very quickly!!
If necessary, take fire-fighting steps, - refer to Part D
• Temperature alarm will continue – even if in the meantime lower

temperatures were measured – until the acknowledging button of the
control unit will be pressed. This resets the plant to “monitoring mode".
The warning buzzer and the horn are turned off.
• If the temperature of at least one of the temperature probes remains
above the threshold value, the warning buzzer will be reactivated 5
minutes after acknowledgment.
• The reason for temperature alarm has to be found out and removed
before starting the machine again.
ATTENTION:
If a temperature alarm has been triggered, the machine is no longer in the
"ready for service" status.
8.4.4. FAILURE MESSAGE
• If a failure occurs within the control system,
- the "yellow (orange)" warning lamp on the signal column will 3/4
light up
- the warning lamp indicating malfunctions on the control 20/5

device will show "yellow"
- the engine can no longer be started
- the temperature warning system is not operative
IMPORTANT:
When switching "ON" the fault switch, the engine may be started even
if the temperature monitoring system is defect. 13/8
You may drive the machine to the next workshop, the crew must,
however, pay attention to this particular situation.
• The "yellow (orange)" warning lamp of the signal column at driver’s 3/4
desk is illuminated even if the main switch of the control device is
“OFF.
• Without activation of the fault switch the engine cannot be started. 13/8
8.4.5. TURNING OFF THE SYSTEM
• If it is intended to stable the machine for a longer period, after "turning

off the machine" - chapter 12 - the main switch of the control unit has to
be turned "OFF".
For this purpose unlock the main switch, turn downward and lock it in 20/2
"OFF" position.
• The "green" pilot lamp next to the main switch of the control unit will be 20/3
extinguished.
• The temperature monitoring system is "OFF".
8.5. OPPOSITE TRACK BLOCK
• See chapter 10.7.5 and 10.7.5.1
8.6. CRANE LIFTING LIMIT STOP
• See chapter 10.7.5.2
8.7. KEY-OPERATED SWITCH
• Key-operated switches are switches locked or switched by a key. 11/5 etc.

• Key-operated switches are switches for special functions.
WARNING:
When operating a key-operated switch you have to know in advance what this
will achieve or trigger.
Key-operated switches have to be used with particular caution and awareness.
8.8. ACCESS LIGHT
• Even when the machine is not "ready for service" and/or is stabled, the
ascent illumination may be turned "ON" before entering the machine.
• The ascent illumination lights the respective ascent area.
• It is switched by key-operated switch - chapter 8.7
• Switch “ON” the access light by the key switch. 23/3 etc.
WARNING:
Even when the key-operated battery main machine switch is "OFF" and has
been removed, the ascent light may be on.
This would lead to complete discharging of the battery sets (engine and
system)!!
8.9. HY-EMERGENCY PUMP
• In case the engine fails during working mode, hydraulic energy supply
is also interrupted.
• Any assemblies possibly protruding from the profile are a danger to the
adjacent track and make it impossible to tow the machine.
• For such situations the machine is equipped with an emergency pump
for hydraulic operations. This emergency pump allows the transit
position of the crane to be restored.
• Thus the machine can be towed from a work site if necessary.
• Procedure:
- Close the pressure line stop cock on the emergency pump 27/5
- operate the lever of the emergency pump and the lever of
the function - see list below
- in case the electric system has failed – see Palfinger
instructions.
IMPORTANT:
The working units have to be brought into travel position in the following order:
- crane
- the support legs
• Bring the crane into travel position with operating the manual control 36/3
levers.
• Bring the support legs into travel position with operating the manual 35/7,8
control levers and secure the support legs with the safety chains. 34/5; 35/5
• Open the pressure line stop cock on the emergency pump. 27/5
IMPORTANT:
Working with the emergency unit for hydraulics is forbidden!
8.10. FIRE EXTINGUISHER
• The fire extinguishers is mounted in the cabin. 17/2

8.11. FIRST AID KIT
• The first aid kit is mounted in the cabin. 17/1
8.12. RAIL GUARD
• The front of each wheel in the direction of travel is equipped with a rail 23/9 etc.
guard. The rail guard should be adjusted to the track situation and will
remove obstacles from the track, thus preventing damage or
derailment.
8.13. SAFETY BARRIER
• The machine accesses are secured by safety barriers.

• Whenever it might be dangerous to leave the machine (adjacent track,
during driving, etc.), the safety barriers at the accesses must be used!
• They block the ascents / descents.
8.14. EMERGENCY-EXIT WINDOW
• In emergencies the cabin windows can be used as emergency exits.

• The windows can be smashed with the life hammer.
• Before breaking or removing the windows:
- decide to which side the machine can and shall be left.
Adjacent tracks, unfavourable surrounding, etc., additionally
complicate and / or endanger the exit
- smash the respective window/s with an item of the board
equipment;
- leave the cabin without hurry, paying attention to your safety
9. DRIVING
“DRIVING” MODE IS DIVIDED AS FOLLOWS:
9.
DRIVING
9.
Travel drive active passive
10.6 12.3
Working drive Towing
Transfer travel - chapter 9

The machine runs self-propelled by hydrostatic drive. The both axles
will be driven.
The maximum driving speed is 80 km/h.
Working-mode driving - chapter 10.6

In “working mode” both axles are driven hydrostatically by a fixed
displacement motor.
The maximum driving speed is appr. 13 km/h.
Towing - chapter 12.2

Towing is a condition in which the machine runs unpropelled usually at
the end of a train formation.
The maximum towing speed is 90 km/h.
9.1. LIMIT VALUES FOR TRANSFER

1 Minimum negotiable horizontal radius m 100
2 Minimum negotiable vertical radius m 500
3 Maximum negotiable cant mm 150
4 Maximum negotiable gradient ‰ 25
(also maximum gradient for parking brake)
5 Maximum speed self-propelled km/h 80
6 Maximum speed being towed km/h 90
7 Maximum load hauled to 0
9.2. GETTING THE MACHINE READY FOR TRANSFER
WARNING:
If one or several of the program-controlled conditions are not met, the machine
will not be enabled to drive!!
• The machine is stationary.

• All emergency stops are unlocked. 35/2 etc.
• The emergency brake is not applied. 3/3
• The depot plug is not connected. 25/1; 26/1
• The engine runs at idling speed (approx. 900 rpm).
• The brake pressure does not exceed 1,0 bar. 14/1
• The pn. stop cock of the Plasser SIFA device is “ON” (horizontal) and 25/3
secured in this position.
• The pn. stop cock of the ETC-S device is “ON” and secured in this 25/2
position.
• The crane is in travel position - see chapter 10.7.6
• The support legs are in travel position - see chapter 10.7.8.2
• The working-mode main switch has been switched "OFF" and 11/1
removed.
• The parking brake is “RELEASED”. 29/3
• The final drives of the axle gearboxes are engaged. 23/7; 34/3
• The battery box is “CLOSED”. 34/3
• The indirect brake valve is in position “ON” 37/1
• The support plates are in travel position. 39/4
• The side plates of the loading platform are closed and secured. 29/11; 30/3
• The cover flap of the crane control panel is closed. 35/3
WARNING:
The machine crew is responsible to ensure the safety on the machine to ensure
the structure gauge limit.
9.2.1. FURTHER STEPS
• Carry out brake test (with released parking brake) with both direct- 14/1,2
acting and indirect-acting brakes – all brake blocks must apply. 29/3
IMPORTANT:
After the corresponding brake test the brake blocks must again come off the
wheel.
• Check signaling system.

• Switch on lighting as required.
• If necessary, remove the skid-pans and store them away.
WARNING:
The machine loses its “ready-for-service“ status as soon as one of the brakes
does no longer work properly.
Normal operation of the machine with the brake(s) turned OFF is PROHIBITED!
9.2.2. BASIC INFORMATION ON TRANSFER TRAVEL
• The number of persons in the cabin at one time must comply with
homologation and not exceed the existing number of seats.
• The driver has to ensure that all persons remain seated and do not
obstruct the view to the exterior.
• The driver must ensure that his attention is not distracted or hindered
by other persons.
• Deliberate driving against all kinds of obstacles is PROHIBITED!
• On principal, the machine has to be controlled from the driver’s desk
situated at the machine front in the driving direction.
• Driving (floating) without running engine is prohibited!
• Driving with hanging load is PROHIBITED.
9.3. STARTING
• The conditions for getting the machine “ready for service - transfer
mode” are met - chapter 9.2
• No skid-pans are mounted at the wheels.
• Switch “ON” the transfer travel mode forward 11/2
• Select the drive direction. 11/3
• Select the 1st gear. 11/8
• Release brake, increase the engine revs. 14/1; 13/6
• The machine starts moving.
• Keep an eye on the monitoring instruments also during driving. 12/
9.4. ACCELERATING
• Optimum acceleration is achieved when the engine speed is

approximating the maximum.
• For higher speed switch to the 2nd gear. 11/8
9.5. MAINTAINING SPEED
• Speed is controlled by adjusting the engine speed. 13/6
IMPORTANT:
If loads are hauled by the machine, increased attention has to be paid to the
engine temperature and the engine speed. The maximum engine speed is
important to provide sufficient cooling.
9.6. DRIVING
• Keep an eye on the monitoring instruments also during driving. 5/

• Full brake application only in emergency cases.
• Never drive at excessive speed. Driving speed should always
correspond to the actual track conditions and must meet the
regulations and instructions on driving.
9.7. REDUCING SPEED
• Reduce the engine speed. 13/6

• Apply the direct brake as required. 14/1
9.8. STOPPING THE MACHINE
• Reduce the engine speed to minimum. 13/6

• Brake the machine and keep the brake applied. 14/1
9.9. CHANGING THE DRIVING DIRECTION
• Wait till machine comes to standstill.

• Reduce the engine speed to minimum. 13/6
• For short distances in “REVERSE” drive switch the drive direction 11/3
selector switch to the reverse direction. The driving speed in this
mode is limited.
• For long distances in reverse mode switch off the key switch for 11/2
“FORWARD” drive mode.
• Switch on the “REVERSE” drive mode. 11/5
• Select the drive direction. 11/6
• Driving as described above.

10. WORKING
• "WORKING" is defined as the condition in which the machine is used

to carry out the activity for which it was designed.
• This machine is suitable for the efficient inspection, maintenance and
repair of overhead lines, as well as transport of people and material
Therefore the machine is equipped with a crane and a loading platform.
10.1. DANGERS DURING WORK
• Working at and with overhead lines naturally involves great danger. This requires that
the crew work very carefully and cautiously.
• Take particular care of inductive voltages within existing catenary (old overhead line)
and take the respective measures for professional discharging.
• Multiple-track sections, bridges, underpasses, tunnels, railway stations and the like
require even increased attention.
• When operating switches or control elements, you must know in advance what will be
achieved or triggered.
• Key-operated switches are switches of particular importance. Key-operated switches

have to be used with particular caution and awareness.
• The crew should use adequate protective devices.
• Working with the crane, working cage and the mobile lifting working platform requires
particular safety measures. Observe the safety regulations.
• Working procedures should be carried out duly and without stress.
• Mutual communication is essential for a safe working process.
• Avoiding safety contrivances may have fatal consequences and will be prosecuted in
special cases.
• It is principally forbidden to climb on the machine roof or the mobile working lifting
platform under overhead wire. Before starting repair and service works make definitely
sure that the catenary has been switched off and earthed. These safety measures have
to be carried out and supervised by the responsible safety service!
• Do not step up to the handrails of the machine -

Danger of falling!
10.2. STABILITY
Stability is an essential criterion for the working operations of the machine.
The stability of the machine is proven in compliance with German Industry standard DIN
15120.
10.3. LIMIT VALUES FOR WORKING MODE:

1 Minimum workable horizontal radius m 100
2 Maximum permissible track twist over a base of mm/m 10
3 meter
3 Maximum permissible track twist over a base of mm/m -
9 meter
4 Maximum workable cant mm 150
5 Maximum gradient for the working ramp 1 1:150
10.4. CHANGING FROM TRAVELLING MODE TO WORKING MODE
• After arriving at the work site the machine has to change from traveling
into working mode.
• Changeover and working is subdivided as follows:
- working mode - chapter 10.5

- working mode driving - chapter 10.6
- crane - chapter 10.7
10.5. WORKING MODE
• The machine is stationary

• The following measures will change the machine into the working
mode:
- the machine is stationary and secured against breaking away 29/3
(parking brake)
- the direct-acting brake is in end position 14/1
- the indirect-acting brake valve is in end position 14/2
- the battery main switch is “ON” 13/1
- the engine is running
- switch off the travel mode 11/2,5
• Switch “ON” the working-mode main switch 24/3
- Now the machine is in “working mode”!
WARNING:
It is fully within the scope of the crew's responsibility to ensure that work will be
safe and unobstructed!
10.6. WORKING DRIVE
• "Working mode driving” is effected by a fixed displacement motor

acting as hydrostatic drive on both driving axles.
The max drive speed is appr. 13 km/h.
• As soon as a support leg leaves the travel position, the working drive
will be interrupted.
ATTENTION:
A hanging load has to be in middle of the track behind of the machine.
WARNING:
Shunting runs with the hydrostatic working mode drive are
PROHIBITED!
• Increase the engine throttle. The further the lever is moved, the faster 13/6
the machine will run.
• When the lever is moved to its minimum position, apply the direct 13/6
brake.
NOTE:
Only change the working drive direction when the machine is stationary,
otherwise working drive components may be damaged.
10.7. CRANE
• The crane with the crane control console is arranged at the rear end of
the crane platform.
• The crane can be used with a load hook.
• Additionally the crane is equipped with support legs - chapter 10.7.8
10.7.1. SAFETY REGULATIONS FOR CRANE OPERATION
• Whenever putting the devices into service, observe the special safety
regulations for crane with working cage operation and the operating
instructions of the crane manufacturer – see Palfinger.
• Prior to start operating the crane it must be ensured that the catenary
is switched off and connected to ground. These safety measures have
to be taken and monitored by the responsible safety officers!
• Before operating the crane verify the status of the opposite track lock -
chapter 10.7.5.1. This is to avoid operation of the crane without having
taken into account local conditions and situations!
• At least one person of the crew must stay on the machine, when it is
intended to work with the work cage. It is his task to provide help
whenever necessary, to press the emergency off button in an
emergency and, in case the hydraulic equipment fails, to make sure
that the cage crew gets back safely.
• Maximum permissible wind speed for the operation of the working cage
is 13,87 m/sec = 50 km/h
• Operating the crane in a thunderstorm or with a thunderstorm coming
up is forbidden!
• Work has to be discontinued immediately, if general safety is not
guaranteed.
10.7.2. PREPARING THE CRANE FOR SERVICE
• The machine is in "working mode" - chapter 10.5

• The safety regulations are being observed - chapter 10.7.1
• All emergency stop are unlocked 22/2 etc.
• The crane operator must take into consideration the local conditions
and situations which keep constantly changing, each time before
putting the crane into service!
This means that each time before being able to work with the crane,
and also after an "emergency stop" had been prompted, you have to
determine how the crane turning lock has to be switched in current
conditions!
• In this connection the following procedure in the operating mode 8/1
"manual control" - chapter 10.7.3.1 must be observed regardless of the
current position of the switches:
- first 1x switch “OFF” the opposite track block switch, then switch it 8/3
to stage 2 (acts on either side). Afterwards switch it as required.
10.7.3. CRANE OPERATING MODES
• The key-operated switch on the crane control console is used to 8/1

preselect the operating mode "support legs - manual control – remote
control":
- support legs - chapter 10.7.8

- manual control - chapter 10.7.3.1
- remote control - chapter 10.7.3.2
10.7.3.1. OPERATING MODE - MANUAL CONTROL
• The crane is controlled by the manual control on the crane control 36/3
console.
• The crane has been prepared for work - chapter 10.7.2
• Switch the key-operated switch to "manual control". 8/1
10.7.3.2. OPERATING MODE - REMOTE CONTROL
• The crane is controlled by remote control. 38/

• The crane has been prepared for working - chapter 10.7.2
• Switch the key-operated switch to "remote control". 8/1
WARNING:
If in the "remote control" mode the crane is turned "ON" without active remote
control, the engine will stop automatically!
• Start the remote control -see chapter 11.2.1

10.7.4. START OF THE CRANE FROM TRAVEL POSITION
• Bring the crane off the loading surface and pay attention to any
obstacles, overhead lines and adjacent track.
10.7.5. WORKING WITH THE CRANE
• Brief information – for further details see annex: Palfinger!

• Switch the key-operated switch for pressure supply to "CRANE".
• When slewing the crane and also during working mode driving you
must always exercise utmost caution!
• When performing a movement into end position, this movement will be
interrupted. Actuate the operating direction selected last in opposite
direction.
• Do not operate main jib and swan neck jib at the same time.
• Jerky control movements must be avoided.
• The max. load depends on the positions of the crane and the support
legs - see load diagram 10.7.7
PLEASE NOTE:
As soon as a supporting leg leaves the transport position, driving will be
interrupted.
Additionally the crane load is 100 % centralized over the rail without support
legs.
WARNING:
The position of the crane in relation to adjacent track or obstacles is not
monitored. It is fully within the crew's scope of responsibility to ensure the
necessary unobstructedness and safety!!
If safety cannot be guaranteed, you must stop working immediately.

10.7.5.1. OPPOSITE TRACK BLOCK
• When working on multi-track sections or on track sections where

slewing is possible only to one side, the opposite track block must be
activated before slewing the crane.
• Switch "OFF" the key-operated switch of the opposite track block 1x 8/3
first and then switch to stage 2 (acts on both side). Afterwards switch
according to needs.
• The following options are available:
- switch left = crane turning lock is "OFF",

the crane can be turned into every direction
- stage 1 = crane turning lock acts "left",
the crane cannot be turned to the left.
- stage 2 = crane turning lock acts "both sides",
the crane cannot be turned.
- stage 3 = crane turning lock acts "right",
the crane cannot be turned to the right.
PLEASE NOTE:
The fact that a crane turning lock is active does not release you from the
special caution you need to exercise before slewing the crane!
10.7.5.2. LIFTING LIMIT
• Below overhead lines the crane has to be operated with an active lifting
limit.
• The crane will be stopped at a height of 4,50 m above the rail.
• The lifting limit is switched “ON” with a key-operated switch 8/2
ATTENTION:
Keeping a safe distance to an overhead line is within the responsibility of the
crane operator.
10.7.6. BRINGING BACK THE CRANE INTO TRAVEL POSITION
• Place the crane in transport position in the buttress. 39/2

• Switch off the remote control. 38/11
• Switch the crane operational mode key-switch to “manual control” 36/3
PLEASE NOTE:
If the remote control is switched "OFF" and the switch for the operating mode
on the crane control console is on "REMOTE", you must switch to "MANUAL"
quickly.
If you fail to do so, the engine will stop!
• The support legs are in travel position - chapter 10.8.8.2

• Close the flap of the crane console. 36/1
• The crane is now in travel position.
10.7.7. CRANE LOAD DIAGRAM

10.7.8. SUPPORT LEG
• The supporting legs enable the crane to operate with up to 100% 34/4; 35/4
loading according to crane load diagram - chapter 10.7.7
• The support legs are equipped with big support plates. 39/4
• The support leg has to be lowered on the side of the load.
• As soon as a supporting leg leaves the transport position, the driving
operation is interrupted!
10.7.8.1. SUPPORTING LEGS - STARTING FROM TRAVEL POSITION
• Switch the key-operated switch for hydraulic pressure supply to 8/1

"SUPPORTING LEGS"
• Unlock the safety chains. 34/5; 35/5
• Mount the support plates. 39/4
• Check for clear space and lower the support legs und and lower down 35/7,8
on suitable (solid and possibly flat) ground.
WARNING:
Put down one leg on the side facing the load first. Do not lift the machine!
If the ground yields, the overload protection will respond. Following with the
supporting legs is PROHIBITED!
Either put down supporting leg on another spot or stabilize ground by inserting
a wood board or the like.
10.7.8.2. BRINGING BACK SUPPORTING LEGS INTO TRAVEL POSITION
PLEASE NOTE:
It is only possible to retract the supporting legs when the crane is not in an
overload condition and has assumed a position, together with the load, that
does not require any supporting.
• Switch the key-operated switch for crane operational mode to 8/1

"SUPPORTING LEGS".
• Lift the support legs a little height. 35/7,8
• Dismount, store and secure the support plates 39/4
• Lift the support legs. 35/7,8
• Secure the support legs with the safety ropes. 34/5; 35/5
10.8. TERMINATING WORK
• After work the machine is brought back from “working mode” into
“traveling mode” by the following measures.
• For this purpose the machine should, as far as possible, stand on a
straight and even track section.
• Apply brakes.
• The crane is in travel position - chapter 10.7.6
• The support legs are in travel position - chapter 10.7.8.2
• Clean up the tools.
• Switch off and remove the working mode main switch. 12/1
• The engine runs in idle revs.
- Now the machine is in "driving mode"!

11. MISCELLANEOUS
• This chapter describes operating situations necessary for the system

which were not yet mentioned. These are:
- working searchlights - chapter 11.1

- remote control - chapter 11.2
- depot plug - chapter 11.3
11.1. WORKING SEARCHLIGHTS
• The working searchlights serve to illuminate the working area.

• Adjust the working searchlights that they illuminate only the working
area and spare the surroundings.
• Especially take into consideration opposite direction traffic, do not blind
train drivers!!
• Do not look straight into working searchlights!!
• Do not touch or come close to working searchlights – heat danger!!
11.2. REMOTE CONTROL
• The remote control unit is a radio control unit using the frequency band 38/
from 433,875 to 434,650 MHz.
A quasi-visual connection (eye contact) is required.
WARNING:
The remote control unit can be disturbed in the area of strong magnetic fields
(substations). This will turn the engine off. Working in “manual control” mode is,
however, possible.
11.2.1. START OF THE REMOTE CONTROL
• The remote-control unit is equipped with a charged energy pack.
PLEASE NOTE:
When the remote control is started and the operating mode is on "manual
control", switch to "remote control" mode quickly. If you fail to do so, the engine
will turn off automatically!
• Await two acoustic signals, the green LED is lit. 38/10

• Operate the start button. 38/11
• The remote control is ready for service.
• The remote control searches automatically for the operating frequency.

11.2.2. OPERATION OF THE REMOTECONTROL
• Approximately after 10 hours of operation a rhythmic audible signal will

sound to indicate that the energy pack has been discharged.
• This audible signal will sound for about 30 seconds, then the remote-
control unit turns off automatically.
• If possible, these 30 seconds should be used to establish safe
operating conditions for the machine.
• Replace the energy pack and then restart the remote-control unit.
11.2.3. TURNING OFF THE REMOTE CONTROL
• When safe operating conditions are provided for the stationary

machine, the remote control can be switched "OFF".
ATTENTION:
When the remote control is turned “OFF” and the key-operated switch on the
crane control desk is switched to “remote control”, switch to "manual control"
mode quickly. If you fail to do so, the engine will turn off automatically!
• When the remote control unit is no longer needed, recharge the energy
pack in the charging station, if necessary.
11.3. DEPOT PLUG
• The depot plug is preferred used when the machine is stabled, the
engine is stopped and the working stock should be heated.
• The depot plug is on both sides of the machine.
• Connect the depot plug (input) with 230 VAC current. 25/1; 26/1
• Thus:
- the engine coolant fluid is preheated
12. STABLING OF THE MACHINE
• All measures for restoring "travel mode" have been carried out - see
chapter 10.8.
• The machine is secured against breaking away
• Switch the axle gearboxes to “neutral” position. 11/8
• The direct- and indirect brake are in end position. 14/1,2
• The parking brake is “RELEASED”. 29/3
• Disengage the final drives of the axle gearboxes. 23/7; 34/3
• All emergency stop are unlocked. 23/2 etc.
• The working mode main switch is removed 11/1
• The emergency brake is not actuated. 3/3
ATTENTION:
If you are not sure whether the machine will be stabled or towed in a train
formation, pay due attention to the manifold brake options!! – chapter 12.2
• Turn “OFF” the engine - chapter 7.3

• Switch “OFF” and remove the battery main switch. 13/1
• All air drain cocks on air receivers and drip cups are “CLOSED”. 22/7 etc.
12.1. STEP LIGHT
• Before leaving the machine, switch "OFF" the main light switch. 22/3 etc.
• Even if the key-operated battery main switch is "OFF" and removed,
some lamps (ascent lighting etc.) might be on.
• This would completely discharge the battery sets.
• As a consequence you would have to charge the battery sets first and
could only then put the machine into operation!
• Switch "OFF" the key-operated switch for ascent lights and remove
the key.
12.2. THE BRAKES
• If one of the brakes (parking brake, direct-acting brake) is applied, it is

not possible to later tow the machine in train formation.
Machine damage (wheel flanges, wheels – fire risk)
• If none of the brakes is applied, the brake will apply automatically

when the key-operated battery main switch is switched off
• Towing the machine without further steps is not possible - see chapter
12.3
WARNING:
Towing the machine with brakes applied leads to serious damage to the
machine!!
Due to the enormous heat generation in combination with sparks there is a very
high risk of fire!
12.3. TOWING THE MACHINE IN TRAIN FORMATION
• Towing is a condition in which the machine runs unpropelled in a train

formation.
WARNING:
Towing the machine with running engine is PROHIBITED! - chapter 7.3
Towing with hanging load is
PROHIBITED!
12.3.1. PREPARING THE MACHINE FOR TOWING
• The machine is in driving mode - chapter 10.9

• The machine has been stabled - chapter 12.
• The machine is stationary.
• Secure the machine from breaking away (drag shoes etc.).
• First “RELEASE” the direct-acting brake, and then turn it to the end 14/1
position.
• First “RELEASE” the indirect acting brake, and then turn it to the end 14/2
position.
• The pn. stop cock of the Plasser SIFA is in position off and secured in 25/3
this position.
• The pn. stop cock of the ETC-S device is in position “OFF” and in 25/2
secured in this position.
• The pn. stop cock to the indirect brake valve is “OPEN”. 25/1
• The parking brake is released. 29/3
• Disengage the final drives of the axle gearboxes. 23/7; 34/3
• All emergency stops are unlocked 35/2 etc.
• The emergency brake is not actuated. 3/3
• Switch “OFF” the engine - chapter 7.3
• Switch “OFF” the battery main switch. 13/1
• Secure the machine against unauthorized use.
• Turn “OFF” all key-operated switches and remove the keys. 12/5 etc.
WARNING:
If one or several of the conditions stated above will not be fulfilled, damage to
the machine will be the consequence!
12.4. ADDING THE MACHINE DIRECTLY TO THE TRAIN
• The machine has been made ready for towing - chapter 12.2.1
• Couple drawgear.
• Couple the brake pipe and “OPEN” the stop cock. 1/2; 40/2
WARNING:
The status of the individual brakes is an essential criterion for a towing run.
As long as you handle the brakes as described above and below, no damage to
the machine will occur.
If the status of the brakes is unknown or if when coupling for a towing operation
no one is present who is informed about the brakes of this machine, this has to
be taken into consideration already when parking the machine.
The parking brake must be set “RELEASED” before the planned towing
operation – chapter 13.2.1
IMPORTANT:
Additionally, you must check whether the brake blocks are slack and freely
hang down the wheel.
• If necessary, remove and store drag shoes.
WARNING:
Towing the machine with running engine is
PROHIBITED!
13. PARKING BRAKE
13.1. GENERAL INFORMATION
• The parking brake is a mechanical system consisting of brake rod, 29/3; 30/1
hand wheel, angular gear, etc.
• The parking brake acts on the second powered axle only.
• The status of the parking brake (APPLIED – RELEASED) is not
monitored or indicated!
• Therefore handling the brake requires increased attention.
• Driving the machine with the parking brake “APPLIED“ leads to serious
damage to the machine.
13.2. PARKING BRAKE OPERATING MODES
• The parking brake can have the following operational status:
- Parking brake "RELEASED“ - chapter 13.2.1

- Parking brake "APPLIED" – chapter 13.2.2
13.2.1. PARKING BRAKE RELEASED
• Turn the hand wheel counterclockwise to the ”LEFT“ towards the limit 29/3; 30/1
stop.
• They only way to check whether the parking brake has been entirely
„RELEASED“ is to see whether the brake blocks hang down the wheel
loosely.
13.2.2. PARKING BRAKE APPLIED
• Swing the hand wheel clockwise to the “RIGHT” towards the limit stop. 29/3; 30/1
• With the hand wheel you determine the brake force.
14. PROCEDURE IN CASE OF MALFUNCTIONS OF

INDIVIDUAL MACHINE COMPONENTS
IMPORTANT:
When a malfunction occurs, a trouble shooting has to be done.
According to this trouble shooting has to be decided, whether the malfunction
can be repaired or not.
If the malfunction can’t be repaired and only bridged, the machine is not
allowed to return into normal operation mode.
The procedures in case of malfunctions are only for restoring an emergency
drive mode (towed or self propelled).
14.1. MALFUNCTION IN THE DRIVE CONTROL
The emergency drive should only be used when all other possibilities to
drive the machine are not functionable (Working drive)
OR
in emergency cases like:
- failure in the program control
And enables a drive to under special caution to the next railway station or
workshop.
• Apply the indirect brake. 14/2

• Turn emergency operation “ON“. 8/6
14.2. MALFUNCTION IN THE HYDRAULIC SYSTEM
• See chapter 8.9

14.3. MALFUNCTION IN THE TEMPERATURE MONITORING UNIT
• Switch “OFF” the main switch of the temperature monitoring unit. 20/2
• Switch “ON” the switches for by-passing the temperature warning 13/8
device – remove sealing, open the switch flap and press the switch.
• You may go on traveling to the next station or the next workshop
provided that you take into account and check the critical machine
parts several times.
14.4. MALFUNCTION OF THE DIRECT ACTING BRAKE
• Set the direct acting brake to end position. 14/1

• Provided particular precautions are taken (braking is possible with the 14/2
indirect-acting brake only), the machine is allowed to drive to the
nearest station or workshop.
14.5. MALFUNCTION OF THE INDIRECT ACTING BRAKE
• Protect the machine from breaking away (parking brake, skid-pans

etc.)!
• Switch off the indirect brake valve 29/1
• The direct brake has to be used. 14/1
• You may drive to the next station or the next workshop provided you
observe particular caution, as braking is possible only with the direct-
acting brake.
ATTENTION:
A switched off indirect brake valve switches off every emergency brake
function. (safety brake and emergency brake)
14.6. MALFUNCTION OF THE PLASSER SIFA VALVE
• Switch off the pn. stop cock of the Plasser SIFA valve and secure it in 25/3
this position.
• Switch "ON" the bypass switch of the Plasser SIFA valve - 8/5
- turn the hoop guard to the right and the switch down.
WARNING:
Standard machine operation with the brake not serviceable is PROHIBITED!
• Provided particular precautions are taken, the machine is allowed to

drive to the nearest station or workshop.
14.7. ALARM WARNING
• If a fault occurs in the system the warning buzzer sounds and the fault 7/13
message is output on the alarm list.
• The buzzer tone can be turned off by pressing the quit button. 7/14
PLEASE NOTE:
The warning buzzer should only be quit when the fault has been consciously
acknowledged. It goes without saying that an existing fault requires checking
and the correct countermeasure!
If a fault interrupts normal operation it is sensible to inform the whole crew
about the situation.
If emergency procedures are initiated it is essential that this is clearly
communicated. Everybody should know which actions are planned and which
tasks will have to be carried out.
IMPORTANT:
If the fault cannot be repaired and there is the possibility to continue operation
with a bypass function the machine must not return to normal operation. The
bypass instructions are only intended for establishing ready-to-tow or ready-to
transit status!
14.8. MEASURES AFTER DERAILMENT
• Switch off the engine, get persons out of danger.

• Notification of the infrastructure operating organization.
WARNING:
In the event of a derailment the machine loses its „ready-for-service“ status.
Proceeding to the „order of the day“ after a derailment is
PROHIBITED!
The infrastructure organization has to be notified immediately of the derailment.
A special investigation by a qualified representative of the infrastructure
organization is compulsory.
After serious derailments the axles have to be dismantled, disassembled and
measured.
Afterwards a test run with measurement of the running properties must be
performed!
14.9. WELDING WORKS ON THE MACHINE
• Before starting welding on the machine or coupled wagons please refer

to the service information SI-400-03.
WARNING:
Welding on and in direct vicinity of the machine involve dangers which must not
be underestimated!
Flying sparks and / or red-hot materials can cause fire!!
Take suitable fire protection measures!!
14.10. MALFUNCTION OF THE CUT-OFF VALVE
• In case of an electric or pneumatic failure of the cut-off valve the

indirect brake line can’t be filled with the indirect brake valve.
• Therefore the stop cock has to be opened to fill the indirect brake line 16/1
with the indirect brake valve.
• Now you may drive to the next station or the next workshop provided
you observe particular caution, as braking is possible only with the
direct-acting brake.
14.11. LIFTING OF THE MACHINE
• The machine is stabled - chapter 12
14.11.1. LIFT THE MACHINE WITH HYDRAULIC JACKS
Lifting point - axle #1 l.h.s.
Lifting point - axle #1 r.h.s.
Lifting point - axle #2 l.h.s.
Lifting point - axle #2 r.h.s.

14.12. RE-PROFILING OF WHEELS
• If the wheel profile is worn or deformed by flats to such an extent that

seriously influences the running properties of the machine, the wheel
has to be re-profiled.
• Only UD 00.1035 wheel profile may be used for this machine.
• If another wheel profile is used, the required running properties of the
machine are not guaranteed!
• The last re-profiling may be performed up to ∅ 804 mm of the limb
plane.
ATTENTION:
If the wheel diameter after the last re-profiling is 790 mm, the wheel is
considered to be worn.
LIMB PLAIN
Last re-profiling Ø 804 mm

Part D
Fire Protection By The Operating Organisation,
Preventive Fire Protection Measures,
Early Fire Hazard Detection,
Temperature Monitoring System,
Emergency Plan,
How To Act In Case Of Fire.

OBW 10 Sprinter BA 5811 D1
1. FIRE PROTECTION BY THE OPERATING ORGANISATION
• The machine operating organisation is urged to hold regular fire protection training for
the machine crew where specific equipment and hazard sources of danger of this
machine are treated.
• Emergency exits must not be locked or obstructed.
• Measures for controlled evacuation of the machine (emergency exits), as well as „first
aid“ fire fighting have to be practised regularly.
• Everybody who works on the machine has to know the location of the fire extinguisher.
Its location has to be marked by signs.
• Fire extinguishers have to be serviced regularly (every two years at the latest).
CAUTION: Unintended or careless actuation of a fire extinguisher without compelling

reason is a serious situation.
Although the fire extinguishing substances used are non-toxic, their use within
closed rooms is very unpleasant for men and might be injurious to health.
Their effect on air-cooled engines and electronics is disastrous. Normally,
they become unserviceable if they are contaminated by fire fighting
substances.
By actuating the fire extinguisher (even without fire) on the machine or close
to it the machine loses its “ready-for-service” status and may be put into
operation only after extensive checks.
2. PREVENTIVE FIRE PROTECTION MEASURES
• Do not exceed operating limits when operating the machine.

• Towing of the machine with the parking brake applied will definitely lead to
considerable heat development, flying sparks and, consequently, to fire.
• In order to avoid inflammation of flammable dirt sediments (oil, grease etc.) keep the
machine clean.
Immediately remove oil and grease coming out.
At least once a year carry out a general cleaning of the machine, including its bottom
surface.
• Leaking hoses and tubes with flammable contents must immediately be replaced by
new ones.
Retighten loose connections and replace if necessary.
Clean contaminated areas.
• It is PROHIBITED to transport dangerous goods on the machine!
D2 BA 5811 OBW 10 Sprinter
3. EARLY FIRE HAZARD DETECTION
• Early fire hazard detection is the most important aspect to succeed in preventing a fire.
The earlier you detect a hazard, the more efficiently suitable fire preventing measures
may be taken and the more unlikely it is that a fire will develop.
• Early fire hazard detection is based on careful monitoring the machine.
• Hazardous changes which might hint at a fire are, e.g. (listing does not claim to be
complete):
working stock running out

leakages
exceptional noises
smell of elements running hot
exceptional temperatures
glowing combustion
smoke
flying sparks
• When a fire hazard has been detected, immediately take all measures to prevent fire
from developing!
4. THE TEMPERATURE MONITORING SYSTEM
• The temperature monitoring system provided announces hazardous temperature

increase in the engine compartment. This is to prevent or at least to significantly impair
fire development.
The complete description of this temperature monitoring system is to be found in part
„C“ of the present operating manual – refer to chapter 8.
OBW 10 Sprinter BA 5811 D3
5. EMERGENCY PLAN
• Fire is an EMERGENCY and hazardous!

• The emergency plan comes into force after a fire has broken out or is imminent.
• Stop the machine as soon as possible, secure it against breaking away and start fire
fighting as „first fire extinguishing aid“.
• If the machine is in a critical place, such as a tunnel, bridge etc., where immediate
stopping would be dangerous, leave this area as soon as possible.
• Stop the machine in a safe place, secure it against breaking away and start fire
fighting („first aid“).
• At the moment do not open large apertures, as this might drastically increase oxygen
supply and fan the fire even more!
• Fight the fire through fire fighting apertures (if existing).
• Never let your face or eyes come too close to the fire fighting apertures. Hot air,
smoke and/or fire might come out the aperture under pressure.
• Fight the fire without endangering yourself.
• Members of the crew who are not involved in „first aid“ measures, get out of danger
and, if necessary, secure the surrounding area.
• Leave the machine without panic. Pay attention to trains passing on adjacent tracks.
• The emergency exits must always be freely accessible.
Emergency exits are:
• cabin exits
• machine platform
• ascent and descent ways
• roof windows, if existing – beware the catenary!
• sash windows
• windows with emergency exit, if existing
• windows which have been shattered with the life hammer
• If necessary, send for fire fighting brigade and ambulance.
• If necessary, provide first aid.
D4 BA 5811 OBW 10 Sprinter

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OBW 10 Sprinter BA 5811

Machine number: 967-974

Copyright © Plasser & Theurer

1 A 26 Apr. Original Issue T. Hagenhuber

OPERATING MANUAL SECTIONS

Manufacturer’s name and address.

Photographs of the Machine, including indication of control elements

D - part Procedure in Case of Fire

5811B063 MACHINE FRONT................................................................................... B1

1. OPERATING SEQUENCE PLAN ..........................................................................C1

FIRE PROTECTION ........................................................................................................D1

Manufacturer’s Name and Address

Service information SI-0300-01

Service information SI-0400-03

Head office Linz factory Purkersdorf factory

Mach. Nr.: 967-974

GENERAL DESCRIPTION FOR THE OPERATION, MAINTENANCE, PERIODICAL CHECKING

Plasser & Theurer

SAFETY GUIDELINES TO PREPARE ANY REPAIR WORK ON THE MACHINE

¾ In working mode the danger area of the machine is prohibited

PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS

¾ Deactivate hydraulic pressure!

¾ Deactivate the air system!

¾ Turn off the engine!

¾ A professionally competent person has to be chosen who will bear main

¾ In working mode the working area is prohibited again!

Characteristic Features of the Machine.

PERMANENT-WAY CAR 10 Sprinter

Total weight 28,10 t

Diesel fuel approx. 690 Liter

Engine coolant fluid pre-heating depot plug (230V/1000W)

Diesel fuel pre-heating in the diesel fuel filter

Working pressure 6,5 - 8 bar

Trough main air pipe 5 bar

Through main air pipe 5.0 bar

Indirect brake AAB

Direct brake ZB11

Brake blocks 1 brake block per wheel

Shunting humping and pushing off PROHIBITED

Transportation in train formation ONLY when the engine is off

Horn buttons a total of 6 pieces

Engine stop a total of 3 pieces

Emergency brake 1 piece at the driver’s desk

Emergency stop a total of 6 pieces

FIRE EXTINGUISHER 1 piece hand fire extinguisher P6D

LIMIT VALUES FOR TRANSFER:

# Parameter Unit LIMITS

LIMIT VALUES FOR WORKING:

# Parameter Unit LIMITS

LAYOUT DIAGRAM OB00.178-1 - see next page

CHARACTERISTIC FEATURES OF THE MACHINE

The Machine is equipped with:

The engine is a water-cooled diesel engine, Type TCD2013L6/2V/1620/F with an output of

INDIRECT ACTING BRAKE

DIRECT ACTING BRAKE

COMPRESSED AIR PRESSURE GAUGE

BRAKE CYLINDERS – BRAKE BLOCKS

Photographs of the Machine, including

Indication of Service Elements and

Relevant for Operating the Machine

1= Driver’s desk - see page B4

1= Cabin - see page B3

1= Driver’s desk - see page B4