Machine Number: 6449, 6450: SRM 500 BA 6449

SRM 500 BA 6449
SRM 500
Operating instructions
Machine number: 6449, 6450

BA 6449 SRM 500
Copyright © 2014 by Plasser & Theurer

All rights reserved, particularly the right to produce copies, to distribute these copies, as
well to translate the work.
SRM 500 BA 6449
RECORD OF AMENDMENTS
Revis
No. Date Reason of revision Page
er
1.0 2016-03-01 KLi 1st version -
BA 6449 SRM 500
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.
The operational labelling (machine weights, brake weights, line categories,

etc.) in the images section of this document may not necessarily match
exactly with the actual machine values.
The actual values can be taken from the respective machine documentation (labelling
plan, acceptance certificates, approvals, certificate folders, etc.).
SRM 500 BA 6449
OPERATING MANUAL SECTIONS
Manufacturer’s name and address

GENERAL Quality certificate
Manufacturer’s nameplate and frame number
Service information SI -0300-01
Service information SI -0400-04
Technical data
PART A
Limit values
Outline drawing
Machine characteristics
Description of brakes
Section allocation of illustrations

PART B
Photos of the machine including the names of the operating
elements and components as far as they are relevant for operating
the machine
Outline of operating processes

PART C
Changing operating modes
Safety information
Warnings
Behaviour in fault conditions
Fire protection by the operating organisation

PART D Preventive fire protection measures
Early fire hazard detection
Temperature monitoring system
Emergency plan
How to act in case of fire
SRM 500 BA 6449 I
TABLE OF CONTENTS
MANUFACTURER’S NAME AND ADDRESS ..................................................................... 1

CERTIFICATE ISO 9001 .................................................................................................. 1-2
MANUFACTURER’S NAMEPLATE: ................................................................................... 3
FRAME NUMBER ............................................................................................................... 4
SERVICE INFORMATION .................................................................................. SI-0300-01
SERVICE INFORMATION ................................................................................... SI-0400-04
PART A
TECHNICAL DATA ...................................................................................................... A1-A8
LIMIT VALUES FOR TRANSFER MODE: ......................................................................... A9
LIMIT VALUES FOR WORKING MODE:........................................................................... A9
OUTLINE DRAWING ....................................................................................................... A10
ENGINE, GEARBOX, PUMPS ARRANGEMENT ............................................................ A11
CHARACTERISTIC FEATURES OF THE MACHINE ............................................. A12-A14
PART B
6449B126 MACHINE L.H. SIDE - GENERAL VIEW ................................................. B1
6449B039 CABIN FRONT - GENERAL VIEW........................................................... B2
5860B010 CABIN - BRAKE CONTROLS .................................................................. B3
6449B032 ENGINE CONTROL DESK B5 – OVERVIEW .......................................... B4
6449B034 ENGINE CONTROL DESK B5 – SECTION "A" ....................................... B5
6449B035 ENGINE CONTROL DESK B5 – SECTION "B" ....................................... B6
6449B036 ENGINE CONTROL DESK B5 – SECTION "C" ....................................... B7
6449B036_1 ENGINE CONTROL DESK B5 – SECTION "D" ....................................... B8
6449B030 DRIVE CONTROL PANEL B6 .................................................................. B9
6449B046 WORKING SEAT - GENERAL VIEW ..................................................... B10
6449B023 WORKING CONTROL PANEL B43 ....................................................... B11
6449B022 WORKING CONTROL PANEL B44 ....................................................... B12
5860B008 ELEVATOR CONTROLS ....................................................................... B13
5860B011 CABIN L.H.S. - GENERAL VIEW ........................................................... B14
5740B081 EXTERNAL CONTROL BOX B38 .......................................................... B15
6449B044 CABIN R.H.S. - GENERAL VIEW .......................................................... B16
6449B071 MACHINE FRONT ................................................................................. B17
5740B138 CLEARING BLADE AREA ..................................................................... B18
6449B066 MACHINE FRONT L.H. SIDE ................................................................ B19
6449B062 MACHINE L.H. SIDE - AREA OF AXLE #1 ............................................ B20
6449B061 MACHINE UNDERCARRIAGE – RAIL FASTENING BRUSH ............... B21
6449B102 MACHINE UNDERCARRIAGE - AREA OF AXLE #1 ............................ B22
6449B007 MACHINE L.H. SIDE - DIESEL FUEL TANK AREA............................... B23
6449B006 HYDRAULIC SOLENOID VALVES - DIESEL FUEL TANK AREA ......... B24
6449B058 MACHINE L.H. SIDE - TRANSFER FUNNEL AREA ............................. B25
6449B057 MACHINE L.H. SIDE - AREA OF HY. TURNTABLE .............................. B26
6449B055 MACHINE L.H. SIDE - AREA OF AXLE #2 ............................................ B27
6449B056 BATTERY SERVICE MAIN SWITCH TERMINAL BOX B2 .................... B28
6449B154 PUMP DISTRIBUTOR GEARBOX AREA L.H.S. ................................... B29
II BA 5859 SRM 500
6449B158 PUMP DISTRIBUTOR GEARBOX AREA R.H.S. .................................. B30
6449B135 HYDRAULIC OIL TANK TOP VIEW ...................................................... B31
6449B005 MACHINE L.H. SIDE - AREA OF HYDRAULIC OIL TANK ................... B32
5855B026 SERVICE START HOUSING B14 ......................................................... B33
MFSZ2.1-A ENGINE TEMPERATURE MONITORING CONTROL UNIT B101........ B34
6449B018 MACHINE R.H. SIDE - ENGINE COMPARTMENT ............................... B35
6449B053 MACHINE L.H. SIDE – KE VALVE AREA ............................................. B36
6449B050 MACHINE L.H. SIDE - DISCHARGING CONVEYOR BELT AREA ....... B37
6449B052 MACHINE REAR L.H. SIDE .................................................................. B38
6449B073 MACHINE FRONT R.H. SIDE ............................................................... B39
6449B075 MACHINE R.H. SIDE - AREA OF AXLE #1 ........................................... B40
6449B075_1 MACHINE R.H. SIDE - CABIN ACCESS AREA .................................... B41
6449B014 MACHINE R.H. SIDE - DIESEL FUEL TANK AREA ............................. B42
6449B081 MACHINE R.H. SIDE - TRANSFER FUNNEL AREA ............................ B43
6449B079 MACHINE R.H. SIDE - HY. TURNTABLE AREA................................... B44
6449B080 MACHINE UNDERCARRIAGE – RAIL FASTENING BRUSH ............... B45
6449B130 MACHINE R.H. SIDE - AREA OF AXLE #2 ........................................... B46
6449B113 MACHINE R.H. SIDE - PUMP DISTRIBUTOR GEARBOX AREA......... B47
5860B077 MACHINE R.H. SIDE - HYDRAULIC PUMP AND FILTER DEVICE ..... B48
6449B016 MACHINE R.H. SIDE - AREA OF HYDRAULIC OIL TANK ................... B49
6449B084 MACHINE R.H. SIDE – AIR DRYER AREA .......................................... B50
6449B085 MACHINE R.H. SIDE - DISCHARGING CONVEYOR BELT AREA ...... B51
6449B087 MACHINE REAR R.H. SIDE .................................................................. B52
6449B093 MACHINE REAR ................................................................................... B53
NAVIGATION AID FOR TOUCH SCREEN ..................................................................... B54
6449B045 TOUCH SCREEN .................................................................................. B55
FUNCTIONAL DESCRIPTION OF THE ICONS ............................................................. B56
SCREENSHOT_0 MAIN MENU ............................................................................. B57
SCREENSHOT_1 LIGHTING ................................................................................. B58
SCREENSHOT_2 DRIVING ................................................................................... B59
SCREENSHOT_3 ENGINE CONTROL .................................................................. B60
SCREENSHOT_4 SERVICE .................................................................................. B61
SCREENSHOT_5 DISPLAY FUNCTIONS ............................................................. B62
SCREENSHOT_6 LOGIN ....................................................................................... B63
SCREENSHOT_11 TOPOLOGY .............................................................................. B64
SCREENSHOT_12 BOX 50 ..................................................................................... B65
SCREENSHOT_13 BOX 90 / 91 .............................................................................. B66
SCREENSHOT_14 FUNCTION REFERENCES ...................................................... B67
SCREENSHOT_15 DRIVE STOP ............................................................................ B68
SCREENSHOT_16 EMERGENCY STOP ................................................................ B69
SCREENSHOT_17 TRANSFER DRIVE ................................................................... B70
SCREENSHOT_18 WORKING DRIVE..................................................................... B71
SCREENSHOT_19 TOWING DRIVE ....................................................................... B72
SCREENSHOT_20 LOG BOOK ............................................................................... B73
SCREENSHOT_21 ALARMS ................................................................................... B74
SCREENSHOT_22 WARNINGS .............................................................................. B75
SCREENSHOT_23 EVENTS.................................................................................... B76
SCREENSHOT_24 EVENT HISTORY ..................................................................... B77
SRM 500 BA 6449 III
PART C
1. OUTLINE OF OPERATIONAL PROCEDURES ............................................. 2
2. FACTORY FILLING OF OPERATING FLUIDS .............................................. 3
2.1. THE OUTSIDE TEMPERATURE ................................................................... 3
3. SAFETY REGULATIONS PRIOR TO COMMISSIONING THE MACHINE .... 4
4. GETTING MACHINE READY FOR OPERATION .......................................... 5
5. SAFETY REGULATIONS FOR OPERATING THE MACHINE ....................... 7
6. STARTING THE ENGINE ............................................................................ 10
6.1. GETTING MACHINE READY FOR STARTING ........................................... 10
6.2. STARTING ................................................................................................... 10
6.3. SHUTTING DOWN THE ENGINE ................................................................ 11
6.4. INSTRUCTIONS AND PROCEDURE FOR THE OPERATION OF
PLASSER AND THEURER MACHINES AT LOW
AMBIENT TEMPERATURES ....................................................................... 12
6.4.1. FOR MACHINES WITHOUT HYDRAULIC OIL – PREHEATING ................. 13
6.4.2. FOR MACHINES WITH HYDRAULIC OIL – PREHEATING ........................ 13
7. SAFETY DEVICES ....................................................................................... 14
7.1. EMERGENCY STOP.................................................................................... 15
7.2. WORKING DRIVE STOP ............................................................................. 16
7.3. VISUAL WARNING SIGNS .......................................................................... 17
7.4. AUDIBLE WARNING SIGNS ........................................................................ 17
7.5. TEMPERATURE MONITORING SYSTEM .................................................. 18
7.5.1. READY FOR OPERATION .......................................................................... 19
7.5.2. PRE-WARNING............................................................................................ 19
7.5.3. TEMPERATURE ALARM (FIRE RISK OR FIRE) ......................................... 20
7.5.4. MALFUNCTION DETECTION ...................................................................... 21
7.5.5. SWITCHING THE SYSTEM OFF ................................................................. 21
7.6. EMERGENCY PUMP FOR HYDRAULICS .................................................. 22
7.6.1. PROCEDURE............................................................................................... 22
7.7. BYPASS SWITCHES ................................................................................... 23
7.8. FIRE EXTINGUISHER ................................................................................. 23
7.9. FIRST AID BOX............................................................................................ 23
7.10. EMERGENCY HAMMER ............................................................................. 23
7.11. WINDOW AS ESCAPE ROUTE ................................................................... 24
7.12. RAIL SCRAPER ........................................................................................... 24
8. DRIVING ...................................................................................................... 25
8.1. LIMIT VALUES FOR TRANSITING .............................................................. 26
8.2. GETTING MACHINE READY FOR DRIVING - TRANSITING...................... 27
8.2.1. BASIC CONSIDERATIONS FOR DRIVING MODE ..................................... 28
8.3. STARTING DRIVING ................................................................................... 29
8.4. ACCELERATING.......................................................................................... 29
8.5. MAINTAINING THE SPEED ......................................................................... 29
8.6. DRIVING ...................................................................................................... 30
8.7. REDUCING SPEED ..................................................................................... 30
8.8. STOPPING THE MACHINE ......................................................................... 30
8.9. CHANGING DIRECTION ............................................................................. 30
9. WORKING .................................................................................................... 31
9.1. LIMIT VALUES FOR WORKING MODE ...................................................... 32
9.2. DANGERS OF WORKING ........................................................................... 33
9.3. PREPARATION FOR WORKING MODE ..................................................... 34
9.4. WORKING MODE ........................................................................................ 35
IV BA 5859 SRM 500
9.4.1. WORKING DRIVE ........................................................................................ 35
9.4.2. EXCAVATING UNIT ..................................................................................... 36
9.4.3. RAIL FASTENING BRUSH ........................................................................... 37
9.5. RETURNING TO TRANSITING .................................................................... 37
10. MISCELLANEOUS ....................................................................................... 38
10.1. TURNING THE MACHINE ............................................................................ 38
10.2. OFF-TRACKING DEVICE ............................................................................. 39
10.3. WORKING LIGHTS ...................................................................................... 42
11. STABLING THE MACHINE........................................................................... 43
11.1. BRAKES ....................................................................................................... 43
11.2. TOWING THE MACHINE IN TRAIN FORMATION ....................................... 44
11.2.1. PREPARING THE MACHINE FOR TOWING ............................................... 44
11.3. ADDING THE MACHINE DIRECTLY TO THE TRAIN .................................. 45
12. THE PARKING BRAKE ................................................................................ 46
12.1. THE OPERATING STATUSES OF THE PARKING BRAKE ........................ 47
12.1.1. PARKING BRAKE - ACTIVE ........................................................................ 47
12.1.2. PARKING BRAKE - INACTIVE ..................................................................... 49
13. BEHAVIOUR IN FAULT CONDITIONS OF INDIVIDUAL
MACHINE COMPONENTS ........................................................................... 50
13.1. ALARM WARNING ....................................................................................... 50
13.2. FAULT IN THE TEMPERATURE MONITORING SYSTEM .......................... 50
13.3. BRAKE BLOCK PLAY .................................................................................. 51
13.4. BEHAVIOUR AFTER DERAILING ................................................................ 51
13.5. RAILWAY EARTHING DEVICE .................................................................... 52
13.6. MALFUNCTION OF THE SAFETY BRAKE .................................................. 53
13.7. MALFUNCTION OF THE INDIRECT-ACTING BRAKE ................................ 53
13.8. ENGINE FAULT ............................................................................................ 53
14. LIFTING THE MACHINE .............................................................................. 54
14.1. LIFTING POINTS FOR HAND WINCH OR HYDRAULIC JACK ................... 54
14.2. LIFTING POINTS FOR CRANE .................................................................... 56
PART D
1. FIRE PROTECTION BY THE OPERATING ORGANISATION .................... D1
2. PREVENTIVE FIRE PROTECTION MEASURES........................................ D1
3. EARLY FIRE HAZARD DETECTION........................................................... D2
4. THE TEMPERATURE MONITORING SYSTEM .......................................... D2
5. EMERGENCY PLAN ................................................................................... D3
SRM 500 BA 6449
GENERAL
Manufacturer’s name and address
Quality certificate
Manufacturer’s nameplate
Frame number
Service information SI-0300-01
Service information SI-0400-04

SRM 500 BA 6449 1
2 BA 6449 SRM 500
SRM 500 BA 6449 3
MANUFACTURER’S NAMEPLATE:
Manufacturer’s nameplate is located on the left hand machine.
Cabin
2016 6449
SRM 500
Sandräummaschine
4 BA 6449 SRM 500
FRAME NUMBER:
The frame number has been imprinted on the rear buffer bar.
Cabin
Machine number: 6449 6450

Frame number: 6449 6450
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; EN 12100-2
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:
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.
TRACK WORTHINESS:
The End User is responsible for ensuring that all necessary requirements related to vehicle
safety on track have been fulfilled.
INTENDED USE, OPERATION AND LIABILITY:
 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.
 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.
OPERATING CONDITION AND MAINTENANCE:
Before putting the vehicle into operation the end user must ensure that the delivered product is
fully operational:
 All necessary instructions and maintenance intervals as stipulated in the Service Instructions
must be followed by the machine personnel.
 Only those materials described in the relevant instructions should be used for cleaning and
maintenance
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.
 The machine must always be repaired in a suitable workshop by qualified personnel using only
approved components.
 In general a service network for technical assistance has been set up by Plasser & Theurer.
 The End User (customer) in case of failure can contact the appropriate Plasser & Theurer
Service Branch.
 The Service Branch is available for providing Technical Assistance for the checking and
commissioning of the machine, in both a practical and technical capacity.
 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.
 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.
SAFETY GUIDELINES FOR PREPARING REPAIR WORK

TO BE CARRIED OUT ON THE MACHINE IN THE WORKSHOP
In working mode, the danger zone of the machine is a prohibited area!
Repair work on the machine must only be carried out by authorized and trained personnel.
Before any repair work is carried out on the machine, the following safety instructions must
be observed:
 Deactivate hydraulic pressure (visual check of the pressure gauge reading).
 Deactivate the air system (visual check of the pressure gauge reading).
 Protect the machine from rolling away (parking brake, skid-pans etc.!)
 Turn off the engine!
 Turn off the working-mode main switch and protect it from unauthorized operation!
 Turn off the battery main switch and protect it from unauthorized operation!
 If repair work is carried out in closed workshops, the battery sets have to be
disconnected (machine without current) and the battery terminals have to be secured
accordingly.
 Furthermore, the machine crew and all persons that have access to the machine must
be informed of the intended repair work!
 A professionally competent person has to be nominated who will bear the main
responsibility for the repair work to be carried out and will supervise this work
according to all aspects of safety!
 Before the machine operating mode is restored, the entire crew must be notified of the
repair work carried out; only a professionally competent person is allowed to restore
the machine operating mode!
 In working mode, the working area is again prohibited!

SAFETY GUIDELINES FOR PREPARING REPAIR WORK

TO BE CARRIED OUT ON THE MACHINE OUTSIDE THE WORKSHOP
In working mode, the danger zone of the machine is a prohibited area!
Repair work on the machine must only be carried out by authorized and trained personnel!
PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS!
Before any repair work is carried out on the machine, the following safety instructions must
be observed:
 Deactivate hydraulic pressure (visual check of the pressure gauge reading).
 Deactivate the air system (visual check of the pressure gauge reading).
 Protect the machine from rolling away (parking brake, skid-pans etc.!)
 Turn off the engine!
 Turn off the working-mode main switch and protect it from unauthorized operation!
 Furthermore, the machine crew and all persons that have access to the machine must
be informed of the intended repair work!
 A professionally competent person has to be nominated who will bear the main
responsibility for the repair work to be carried out and will supervise this work
according to all aspects of safety!
 The decision whether to switch off the battery main switch and to protect it from
unauthorised operation for the repair work to be carried out is at the discretion of the
person chiefly responsible!
On the other hand, should an electrical failure have occurred, the battery main switch
MUST be switched off and protected from unauthorised operation before remedy work
is started!
 When repair work needs to be carried out with the battery main switch turned off, the
operating organisation must provide sufficient signal lights according to the respective
national regulations, as well as sufficient lighting of the working areas!
 Before the machine operating mode is restored, the entire crew must be notified of the
repair work carried out; only a professionally competent person is allowed to restore
the machine operating mode!
 In working mode the working area is again prohibited!

SRM 500 BA 6449
PART A
Technical data
Limit values
Outline drawing
Machine characteristics
Description of brakes
SRM 500 BA 6449 A1
Technical Data
Sand removal machine SRM 500

Machine numbers: 6449, 6450
Year of construction: 2016
GENERAL DATA
Outline drawing SR00.54
Cabins 1
DIMENSIONS
Length 16400 mm
Height above head of rail 4220 mm
Overall width 2900 mm
UNDERCARRIAGE
Number of wheel sets 2
Axle base 6000 mm
Wheel diameter of new wheel 730 mm
Track gauge 1435 mm
A2 BA 6449 SRM 500
WEIGHT
Total weight approx. 32 t
FILLING QUANTITIES
Diesel fuel approx. 750 litres
Hydraulic oil approx. 800 litres
ENGINE
Type KHD BF6M1015C
-1
Output 300 kW at 2100 min
DRIVING UNIT
Kind of drive hydrostatic, acting on both axles
SRM 500 BA 6449 A3
ELECTRICAL EQUIPMENT
Current supply - engine 1 three-phase-current generator
Alternator 28V DC, 140 A
BATTERIES
2 nos. 12V DC batteries
225 Ah each in series
AIR CONDITIONING DEVICE

Type CC8
A4 BA 6449 SRM 500
ELVATOR
Chain conveyor with hydraulic drive
Chain speed v = 0 - 1,5 m/sec
Conveying channel hinged cardanically

with hydraulically adjustable rollers, plough blades, elevator height
Clearing paramters
Depth below top of the rail 100 mm
Width 4000 mm
Delivery rate 500t/h
STEEP CONVEYOR BELT

Two hydraulically driven conveyor belts
Belt speed vmax = 2 m/sec
Belt width 800 mm
Belt cover
SRM 500 BA 6449 A5
DISCHARGING BELT
Two hydraulically driven conveyor belts
Belt speed vmax = 4 m/sec
Belt width 800 mm
Hydraulically swivelling
From longitudinal machine axis +/- 70°
Discharging width from track axis aprrox. 6,5 m
Belt cover
RAIL FASTENING BRUSHES

Driven hydrostatically behind axle #2
TURNING DEVICE
Hydraulic lifting cylinder at machine centre of gravity
for turning the entire machine
A6 BA 6449 SRM 500
COMPRESSED AIR
Operating pressure 6,5 - 7,2 bar
Air compressor directly coupled to the engine 1 no. air compressor 300 cm3
Air receiver 2 pieces, 57 litres, for direct acting brake and pneumatic system
1 piece, 100 litres, for indirect acting brake
1 piece, 57 litre, for indirect acting brake
1 piece, 57 litres / 40 litres, for indirect acting brake
1 piece, 9 litres, for indirect acting brake
1 piece, 40 litres, for spring loaded brake
1 piece, 57 litres, for Zöllner warning device
Air drier – for air compressor on engine 2-chamber drier 24 VDC, 100W
Operating pressure max. 10 bar
SRM 500 BA 6449 A7
BRAKE
Main brake pipe 5 bar

2 stop cocks with hose and coupling on the rear side of the machine
Direct-acting brake one circuit brake with

brake valve (Zb03)
Indirect-acting brake control valve DB60
Parking brake spring loaded brake
Brake blocks 1 no. per wheel

Type WN146-730.K-4
A8 BA 6449 SRM 500
SAFETY
Shunting humping and pushing off PROHIBITED
Transfer in train formation ONLY when engine is off
FIRE EXTINGUISHER 1 nos. in total, type PD6G

Functional range -30°C / +60°C
in the cabin
FIRST AID BOX 1 no. in total

in the cabin
LIFE HAMMER 1 nos. in total

in the cabin
SRM 500 BA 6449 A9
LIMIT VALUES FOR TRANSFER MODE:
# Parameter Dimension Limit
1 Smallest practicable horizontal radius m 190

2 Smallest practicable vertical radius m 900
3 Maximum practicable super-elevation mm 160
4 Maximum practicable gradient %o 20
(also maximum gradient for parking brake)
5 Maximum speed when self propelled km/h 80
6 Maximum speed when towed km/h 80
7 Maximum load hauled to 20
LIMIT VALUES FOR WORKING MODE:

2 Maximum permissible track twist over a base of mm/m 10
3 meter (non supported machine)
3 meter (supported machine)
4 Maximum cross level during working mm 180
5 Maximum working ramp gradient 1 1:100
6 Track curvature defect over a basis of 10 m mm 50 (top to top)
A10 BA 6449 SRM 500
OUTLINE DRAWING
SRM 500 BA 6449 A11
ENGINE, GEARBOX, PUMPS ARRANGEMENT

A12 BA 6449 SRM 500
CHARACTERISTIC FEATURES OF THE MACHINE
The Plasser & Theurer ballast profiling machine SRM 500 is a two-axle sand removal
machine.
It is equipped with:
• a cabin with an air conditioning device
• a direct-acting brake
• an indirect-acting brake
• an EMERGENCY STOP device
• a parking brake
• a water-cooled diesel engine
• a temperature monitoring system
• an emergency pump for hydraulics
• a bus system
• a touch panel
• an elevator
• a steep conveyor belt
• a discharging belt
• a rail fastening brush
• a turning device
• a hydrostatic driving unit
SRM 500 BA 6449 A13
The drive engine is an water-cooled diesel engine, type KHD BF6M1015C, with an output
of 300 kW at n = 2100 min-1.
Hydrostatic drive from diesel engine, distribution gear, hydraulic pump, hydraulic motor via
2-speed-gearbox and axle gearbox acting on both axles.
The fully enclosed, sound and heat insulated cabin, mounted on the front part of the
machine above the main conveyor belts, is equipped with large safety glass windows and
contains the driver’s and operator’s seat from which good visibility is guaranteed in both
directions and onto the working units.
Entrance to the cabin is via steps at the side with hand rails and a door in the middle of the
cabin.
The safety regulations for entering the cabin roof have to be adhered to -
- danger from overhead line!
A14 BA 6449 SRM 500
INDIRECT ACTING BRAKE

The machine is equipped with a passive train brake. This consists of a control valve, type
DB60.
Warning:
The stop cocks to the hose couplings are “CLOSED” - when the machine
drives without coupled wagons. If machines or wagons with brake facilities are
added, the hose couplings have to be coupled and the relevant stop cocks be
“OPEN”.
DIRECT ACTING BRAKE

The machine is equipped with an active train braking system. A driver’s brake valve (Fb11)
is located in the driver’s cabin.
The direct-acting brake is designed as one-circuit brake and is operated by brake valve
Zb03. The direct-acting brake on the driver’s desk is actuated via a control lever.
PARKING BRAKE
Spring-loaded cylinders are used as parking brake (hand brake). Additionally, all brake
cylinders are equipped with spring-loaded cylinders. Therefore, the parking brake acts on
all wheels. The current working condition of the parking brake is shown by a indicator lamp
lit.
Warning:
Driving / towing the machine with the parking brake “APPLIED“ leads to serious
damage and can cause fire!
BRAKE CYLINDERS – BRAKE BLOCKS

Each wheel is braked by one brake block. Each axle is equipped with two brake cylinders.
SRM 500 BA 6449
PART B
Section allocation of illustrations
Photos of the machine including
the names of the operating elements and
components as far as they are relevant for
operating the machine

SRM 500 BA 6449 B1
6449B126
MACHINE L.H. SIDE - GENERAL VIEW
1= Cabin
2= Elevator
3= Clearing blade
4= Steep conveyor belt
5= Transfer funnel
6= Discharging conveyor belt (swivelling conveyor belt)
7= Hydraulic turntable (machine turning device)
8= Transversal roller (off-tracking roller)
9= Diesel fuel tank
10 = Pump distributor gearbox area
11 = Hydraulic oil tank area
12 = Engine compartment
B2 BA 6449 SRM 500
6449B039
CABIN FRONT - GENERAL VIEW
1= Engine control desk B5

2= Drive control panel B6
3= Touch screen
4= Emergency brake
5= Signal column for temperature monitoring system
6= Air condition unit
7= Terminal box B51
SRM 500 BA 6449 B3
5860B010
CABIN - BRAKE CONTROLS
1= Brake lever for direct-acting brake

2= Brake lever for indirect-acting brake
3= Pneumatic pressure reducing valve for direct-acting brake (3,8 bar, sealed)
4= Pneumatic pressure regulator for indirect-acting brake (5 bar, sealed)
5= Pneumatic non-return valve for indirect-acting brake
6= Pneumatic test connections for system and brake pressure
B4 BA 6449 SRM 500
6449B032
ENGINE CONTROL DESK B5 – OVERVIEW
1= Section "A"
2= Section "B"
3= Section "C"
4= Section „D“
SRM 500 BA 6449 B5
6449B034
ENGINE CONTROL DESK B5 – SECTION "A"
1 = Speedometer
2 = Air pressure gauge for direct-acting brake
- red pointer = brake pressure
- white pointer = air reservoir pressure
3 = Air pressure gauge for main air line
4 = Key switch for remote maintenance “ON”
5 = Yellow LED to item 4
B6 BA 6449 SRM 500
6449B035
ENGINE CONTROL DESK B5 – SECTION "B"
1= Key-operated switch, on-board supply "OFF - ON" (main battery switch)

2= Engine start key switch
3= Pre-heating indication LED
4= Gas actuation button engine
5= Override push button for fire alarm system
6= Horn button
7= Green luminescent switch for drive desk “OFF - ON”
8= White luminescent button for engine maximum RPM „OFF - ON“
9= 12V DC socket
10 = 24V DC socket
SRM 500 BA 6449 B7
6449B036
ENGINE CONTROL DESK B5 – SECTION "C"
1= Switch for wind screen wiper front l.h.s.

2= Switch for wind screen wiper front middle
3= Wind screen washer front l.h.s button
4= Switch for wind screen wiper rear
5= Wind screen washer rear button
6= Panel light switch „half intensity - OFF - full intensity“
7= White luminescent button for machine head lights
8= White luminescent button for corridor light „OFF - ON“
9= White luminescent button for working light „OFF - ON“
10 = Yellow luminescent button for warning beacon „OFF - ON“
11 = Switch for cabin fan „OFF - ON“
12 = Cabin ventilation selector switch
13 = Yellow luminescent switch for wind screen heating „OFF - ON“
14 = General warning buzzer
B8 BA 6449 SRM 500
6449B036_1
ENGINE CONTROL DESK B5 – SECTION "D"
1 = Emergency stop push-button

Important:
The emergency stop interrupts the el. working system and sequential to this,
releases the hydraulic pressure, interrupts the pneumatic pressure supply and
the engine is switched off.
2= White luminescent button for safety system reset
3= Yellow luminescent button for axle gearbox clutch engagement aid
4= Selector switch „travel drive - OFF - working mode“ (working main switch)
5= Parking brake switch “release - 0 - apply”
6= Indication LED for parking brake “released”
7= Indication LED for parking brake “applied”
SRM 500 BA 6449 B9
6449B030
DRIVE CONTROL PANEL B6
1= Drive control lever

2= Button for releasing of magnetic drive control lever brake (drive enable)
3= Driving direction pre-selector indicator, "forward"
4= Driving direction pre-selector indicator, "backward"
5= Drive direction selector switch „forward - 0 - reverse“
6= Yellow lamp - “STOP” indicator
7= Drive stop push-button
8= Illuminated blue button, “RELEASE“ driving stop
9= Joystick for air horn (Zöllner warning device)
B10 BA 6449 SRM 500
6449B046
WORKING SEAT - GENERAL VIEW
1= Working control panel B43

2= Working control panel B44
3= Elevator controls
4= Emergency brake
5= Water tank for wind screen washing device
6= Socket 220V AC
SRM 500 BA 6449 B11
6449B023
WORKING CONTROL PANEL B43
1= Working drive control lever „forward / reverse“

2= Button for releasing of magnetic drive control lever brake (drive enable)
3= Driving direction pre-selector indicator, "forward"
4= Driving direction pre-selector indicator, "backward"
5= Switch for working drive speed „normal / fast“
Note:
Turn on "fast working mode driving" ONLY under favourable circumstances (e.
g. when minor quantities are to be transported).

7= Drive stop push-button
8= Illuminated blue button, “RELEASE“ driving stop
9= Joystick for air horn (Zöllner warning device)
10 = Switch - steep conveyor belt l.h.s. running direction „forward – 0 – reverse“
11 = Switch - steep conveyor belt r.h.s. running direction „forward – 0 – reverse“
12 = Switch - discharging conveyor belt running direction „forward – 0 – reverse“
13 = Switch - swivel discharging conveyor belt „to the left – 0 – to the right“
B12 BA 6449 SRM 500
6449B022
WORKING CONTROL PANEL B44
1 = Switch for cabin fan „OFF - ON“

2 = Panel light switch „half intensity - OFF - full intensity“
3 = Red luminescent switch for rail fastening brushes l.h.s. „unlocking / locking /
drive ON“
4 = Red luminescent switch for rail fastening brushes r.h.s. „unlocking / locking /
drive ON“
5 = Switch for “lifting / lowering” rail fastening brush l.h.s.
6 = Switch for “lifting / lowering” rail fastening brush r.h.s.
7 = Potentiometer for elevator running speed
8 = Switch for elevator „manual mode / automatic mode“
9 = Green luminescent button for elevator running direction „forward“
10 = Yellow luminescent button for elevator running direction „reverse“
11 = Elevator drive stop button
Important:
SRM 500 BA 6449 B13
5860B008
ELEVATOR CONTROLS
1= Control lever - lift / lower elevator

2= Control lever - lift / lower elevator (up / down adjusting of guide rollers)
3= Control lever - lift / lower l. h. s. clearing blade
4= Control lever - swivel l.h.s. clearing blade in / out
5= Control lever - swivel r.h.s. clearing blade in / out
6= Control lever - lift / lower r. h. s. clearing blade
B14 BA 6449 SRM 500
5860B011
CABIN L.H.S. - GENERAL VIEW
1= Cabin light switch

3= External control box B38
4= Socket 24V DC
SRM 500 BA 6449 B15
5740B081
EXTERNAL CONTROL BOX B38
1 = Switch for „lifting / lowering“ of hydraulic turntable

2 = Switch for transversal rollers (off-tracking rollers) running direction „to the left / to the
right“
B16 BA 6449 SRM 500
6449B044
CABIN R.H.S. - GENERAL VIEW
1= Cabin light switch

3= Fire extinguisher
4= First aid box
5= Terminal box B50
6= Socket 24V DC
SRM 500 BA 6449 B17
6449B071
MACHINE FRONT
1 = Elevator
Attention:
Working on moving and rotating machine parts (chain conveyor, clearing blades,
steep conveyor belts, discharging conveyor belt, etc.) is prohibited due to safety
hazard and injury!.
2= Clearing blade - here: in transport position, locked
3= Clearing blade locking bolt - clearing blade in transport position
4= Clearing blade swivelling cylinder locking bolt and tongue
5= Flash light
B18 BA 6449 SRM 500
5740B138
CLEARING BLADE AREA
1 = Clearing blade – here: in working position, for moving the sand to the track shoulder
2 = Clearing blade locking bolt - clearing blade in working position
SRM 500 BA 6449 B19
6449B066
MACHINE FRONT L.H. SIDE

2 = Drive stop push-button
Important:
The drive stop interrupts the hy. drive.
4= Horn button
5= Elevator
6= Elevator locking device
7= Elevator drive engine
8= Securing plate for swivelling cylinder locking bolt
9= Ballast guide roller
10 = Steep conveyor belt l.h.s.
11 = Steep conveyor belt l.h.s. tensioning device
B20 BA 6449 SRM 500
6449B062
MACHINE L.H. SIDE - AREA OF AXLE #1

Important:
4= Horn button
5= Key-operated switch for ascent illumination
7= Transversal roller drive engine
8= Terminal box B71
9= Rail scraper
10 = Compressed air connection
11 = Pneumatic solenoid valve, locking / unlocking of l.h. rail fastening brush
SRM 500 BA 6449 B21
6449B061
MACHINE UNDERCARRIAGE – RAIL FASTENING BRUSH
1 = Rail fastening brush l.h.s.

2 = Safety chain for rail fastening brush
3 = Locking mechanism with inductive switch for rail fastening brush locked / unlocked
B22 BA 6449 SRM 500
6449B102
MACHINE UNDERCARRIAGE - AREA OF AXLE #1
1= Inductive switch, gearbox switching - 2nd speed

2= Inductive switch, gearbox switchting - neutral
3= Inductive switch, gearbox switchting - 1st speed
4= Filling and equalising reservoir for axle gearbox oil
5= Rail scraper
6= Pulse transducer for axle #1
SRM 500 BA 6449 B23
6449B007
MACHINE L.H. SIDE - DIESEL FUEL TANK AREA
1 = Fuel tank (Diesel fuel)

2 = Fuel filler cap
Warning:
For fuelling take all measures that are relevant to safety.
Smoking and handling open fire and light is prohibited!
3= Diesel fuel level indicator
4= Diesel tank ventilation
5= Hydraulic superfine filter
6= Stop cocks to item 5 (filter change)
Note:
For changing the hydraulic oil superfine filter refer to the maintenance
instructions.
7 = Hydraulic solenoid valve for hydraulic pressure limitation forward / reverse
B24 BA 6449 SRM 500
6449B006
HYDRAULIC SOLENOID VALVES - DIESEL FUEL TANK AREA
1= Hydraulic solenoid valve for machine off-tracking device actuation lifting / lowering
2= Hydraulic solenoid valve for off-tracking roller to the left / to the right
3= Hydraulic solenoid valve to swivel discharging conveyor belt to the left / to the right
4= Hydraulic solenoid valve for off-tracking pressure build-up
5= Hydraulic solenoid valve for elevator pressure build-up
6= Hydraulic solenoid valve for hydraulic oil cooler fan drive „ON“
7= Hydraulic solenoid valve for air conditioning "ON"
SRM 500 BA 6449 B25
6449B058
MACHINE L.H. SIDE - TRANSFER FUNNEL AREA
1= Steep conveyor belt l.h.s.

2= Steep conveyor belt l.h.s. tensioning device
3= Steep conveyor belt l.h.s drive engine
4= Transfer funnel
6= Discharging conveyor belt tensioning device
7= Hydraulic solenoid valve, steep conveyor belt drive, forward / backward
8= Hydraulic oil cooler
9= Hydraulic motor for fan drive
B26 BA 6449 SRM 500
6449B057
MACHINE L.H. SIDE - AREA OF HY. TURNTABLE
1 = Emergency hand pump for hydraulics

2 = Stop cock for emergency hand pump operation
3 = Actuation lever for emergency hand pump
Note:
In the event of a failure of the general hydraulic system the machine can be
made ready for driving with the help of the hand-operated emergency pump!
4= Hydraulic turntable
5= Safety chain for hydraulic turntable
6= Locking mechanism for hydraulic turntable
7= Current regulation valve for air condition motor and cool fan motor
8= Current regulation valve for steep conveyor belt l.h.s.
9= Bus terminal box B91
SRM 500 BA 6449 B27
6449B055
MACHINE L.H. SIDE - AREA OF AXLE #2
1= Socket for external off-tracking device switch box B38

4= Battery service main switch terminal box B2
5= Rail scraper
B28 BA 6449 SRM 500
6449B056
BATTERY SERVICE MAIN SWITCH TERMINAL BOX B2
1 = Batteries service main switch

Switching off the service battery main switch:
The service battery main switch must be switched off approximately 30 sec.
after the battery main switch.
The follow-up time setting is necessary to store the „Deutz“ engine data.
SRM 500 BA 6449 B29
6449B154
PUMP DISTRIBUTOR GEARBOX AREA L.H.S.
1 = Pump distributor gearbox

2 = Variable displacement pump for hydraulic drive unit and steep conveyor belt drive,
l.h.s.
3 = Proportional control valve for drive pump 1 forward / reverse
4 = Variable displacement pump for elevator drive, hydraulic oil cooler and air
conditioner
5 = Proportional control valve for elevator drive forward / reverse
6 = Hydraulic solenoid valve – drive pump 1 bypass
7 = Hydraulic solenoid valve – elevator pump bypass
8 = Hydraulic pressure switch with manometer for filling pressure, pump 2
9 = Hydraulic pressure switch with manometer for filling pressure, pump 1
10 = Hydraulic pressure switch with manometer for filling pressure, elevator
B30 BA 6449 SRM 500
6449B158
PUMP DISTRIBUTOR GEARBOX AREA R.H.S.
1 = Pump distributor gearbox

2 = Variable displacement pump for hydraulic drive unit and steep conveyor belt drive,
r.h.s.
3 = Hydraulic oil pump for hydraulic working system, hydraulic oil cooler and
discharging conveyor belt drive
4 = Proportional control valve for drive pump 2 forward / reverse
5 = Hydraulic solenoid valve – drive pump 2 bypass
6 = Hydraulic solenoid valve for pivoting angle fixation
SRM 500 BA 6449 B31
6449B135
HYDRAULIC OIL TANK TOP VIEW
1= Hydraulic oil tank

2= Hydraulic oil filler cap
3= Hydraulic oil return flow filter
4= Hydraulic oil level indication
B32 BA 6449 SRM 500
6449B005
MACHINE L.H. SIDE - AREA OF HYDRAULIC OIL TANK
1= Hydraulic oil suction filter

2= Indicator box B14
3= Terminal box B72
4= Engine terminal box B3
5= Engine monitoring control unit B101
SRM 500 BA 6449 B33
5855B026
SERVICE START HOUSING B14
1= Engine RPM meter

2= Engine oil temperature gauge
3= Engine oil pressure gauge
4= LED - engine temperature (too high)
5= LED - engine coolant level (too low)
6= LED -engine oil pressure (too low)
7= Key-operated switch, on-board supply "OFF - ON" (battery switch)
8= LED - on-board supply “ON”
9= Engine start key switch
10 = Pre-heating indication LED
11 = LED - ignition “ON”
12 = Socket for engine diagnosis
13 = Engine diagnosis enable button (engine has to be stopped)
14 = Potentiometer for speed-adjustment 0-100% (service mode)
B34 BA 6449 SRM 500
MFSZ2.1-A
ENGINE TEMPERATURE MONITORING CONTROL UNIT B101
1= Temperature monitoring control box

2= Temperature monitoring system on/off switch
3= LED indication for monitoring system on
4= Warning buzzer for monitoring system failure
5= LED indication for monitoring system failure
6= Push button for warning buzzer off (sound)
7= not used
8= not used
9= LED indication for alert phase
10 = LED indication for alarm phase
Note:
For details please refer to separate manual.
SRM 500 BA 6449 B35
6449B018
MACHINE R.H. SIDE - ENGINE COMPARTMENT
1 = Deutz Diesel drive engine

2 = Temperature transducer for temperature monitoring system
B36 BA 6449 SRM 500
6449B053
MACHINE L.H. SIDE – KE VALVE AREA
1= Control valve DB60

2= Pn-stop cock for indirect brake valve “OFF - ON“
3= Retaining valve (for indirect brake)
4= Pneumatic solenoid valve for parking brake “ON”
5= Pneuamtic solenoid valve for relaesing of parking brake
6= Stop cock between container pipe and and parking brake
7= Stop cock between main air line and parking brake
8= Pneumatic reservoirs for direct brake and pneumatic system (57 litres)
9= Pneumatic solenoid valve for working brake
10 = Pneumatic solenoid valve for working air “ON”
11 = Pneumatic pressure reducing valve with manometer for working brake pressure
12 = Pneumatic pressure switch for working air “ON”
13 = Air oiler
14 = Water separator
15 = Pressure switch, parking brake released (4,8 bar)
16 = Pressure switch, parking brake braked (0,4 bar)
17 = Pneumatic solenoid valve for safety brake
18 = Stop cock for safety brake valve
Attention:
The stop cock must be always protected from unauthorized actuation
(padlock)!
SRM 500 BA 6449 B37
6449B050
MACHINE L.H. SIDE - DISCHARGING CONVEYOR BELT AREA
1 = Discharging conveyor belt (swivelling conveyor)

2 = Discharging conveyor belt tensioning device
3 = Locking mechanism with inductive switch for discharging conveyor belt l.h.s. locked
B38 BA 6449 SRM 500
6449B052
MACHINE REAR L.H. SIDE

Important:
4= Horn button
5= Discharging conveyor belt locking lever (in locked position)
6= Safety bolt and padlock of the locking lever
7= Electro horn for fire alarm engine
8= Flashlight for fire alarm engine
9= Brake load valve
10 = Test connection
11 = Pneumatic reservoir for the indirect brake system (40 litres / 57 litres)
12 = Socket, 24V DC
SRM 500 BA 6449 B39
6449B073
MACHINE FRONT R.H. SIDE

Important:
4= Horn button
5= Elevator
6= Elevator locking device
7= Elevator drive engine
8= Securing plate for swivelling cylinder locking bolt
9= Ballast guide roller
10 = Steep conveyor belt r.h.s.
11 = Steep conveyor belt r.h.s. tensioning device
B40 BA 6449 SRM 500
6449B075
MACHINE R.H. SIDE - AREA OF AXLE #1

Important:
4= Horn button
5= Key-operated switch for ascent illumination
8= Axle gearbox engaging / disengaging lever
Important:
For towing the machine both axle gearboxes have to be disengaged, the levers
must be secured by padlocks. The brakes have to be released!
9 = Rail scraper
10 = Shore power connector
SRM 500 BA 6449 B41
6449B075_1
MACHINE R.H. SIDE - CABIN ACCESS AREA
1= Compressed air connection

2= Override switch for safety brake valve
3= Pneumatic solenoid valve, rail fastening brush r.h.s locked / unlocked
4= Bus terminal box B90
5= Stop cock for Zöllner warning device
6= Pneumatic solenoid valves for low tone / high tone macrophones (Zöllner
warning device)
7 = Pneumatic solenoid valves for (from left to right)
- gearbox switchting - neutral
- gearbox switching - 1st speed
- gearbox switching - 2nd speed
8 = Sockets frame - cabin
B42 BA 6449 SRM 500
6449B014
MACHINE R.H. SIDE - DIESEL FUEL TANK AREA
1 = Fuel tank (Diesel fuel)

2 = Fuel filler cap
Warning:
For fuelling take all measures that are relevant to safety.
Smoking and handling open fire and light is prohibited!
3= Diesel fuel level indicator
4= Diesel fuel filter with water seperator, type Hydac
5= Dirt indicator
6= Container for water separation
7= Status indication lamp for diesel fuel filter
8= Diesel fuel return flow stop cock
9= Diesel fuel supply line stop cock
10 = Hydraulic oil cooler
11 = Hydraulic motor for fan drive
SRM 500 BA 6449 B43
6449B081
MACHINE R.H. SIDE - TRANSFER FUNNEL AREA
1= Steep conveyor belt r.h.s.

2= Steep conveyor belt r.h.s. tensioning device
3= Steep conveyor belt r.h.s. drive engine
4= Transfer funnel
6= Discharging conveyor belt drive engine
7= Hydraulic solenoid valve, steep conveyor belt drive, forward / backward
B44 BA 6449 SRM 500
6449B079
MACHINE R.H. SIDE - HY. TURNTABLE AREA
1= Hydraulic turntable
2= Safety chain for hydraulic turntable
3= Locking device with inductive switch for hydraulic turntable
4= Inductive switch for hydraulic turntable in position “up”
5= Current regulation valve for steep conveyor belt r.h.s.
SRM 500 BA 6449 B45
6449B080
MACHINE UNDERCARRIAGE – RAIL FASTENING BRUSH
1= Rail fastening brush r.h.s.

2= Safety chain for rail fastening brush
3= Locking mechanism with inductive switch for rail fastening brush locked / unlocked
4= Scavenging receptacle for diesel fuel filter
5= Lcok to item 4
B46 BA 6449 SRM 500
6449B130
MACHINE R.H. SIDE - AREA OF AXLE #2
1= Socket for external off-tracking device switch box B38

4= Axle gearbox engaging / disengaging lever
Important:
For towing the machine both axle gearboxes have to be disengaged, the levers
must be secured by padlocks. The brakes have to be released!
5 = Switch - operational mode of hydraulic pump and filter device: „automatic / OFF /
manual“
6 = Hydraulic oil filler neck
7 = Drain cock for pump distributor gearbox
8 = Rail scraper
9 = Pneumatic solenoid valves for
- gearbox switchting - neutral
- gearbox switching - 1st speed
- gearbox switching - 2nd speed
SRM 500 BA 6449 B47
6449B113
MACHINE R.H. SIDE - PUMP DISTRIBUTOR GEARBOX AREA
1= Hydraulic manometer for drive pressure, elevator pump

2= Hydraulic manometer for drive pressure, drive pump 2
3= Hydraulic solenoid valve: swivelling of discharging conveyor belt the left / to the right
4= Brake cylinder
5= Axle gearbox ventilation and oil filling reservoir
B48 BA 6449 SRM 500
5860B077
MACHINE R.H. SIDE - HYDRAULIC PUMP AND FILTER DEVICE
1 = Filter catridge with vacuumeter for dirt indication

2 = El. motor for filter unit
3 = Change over lever for filter device
- in left hand position: tank draining
- in latched central position: filtering
- in right hand position: tank filling with filtering
4 = Stop cock for Hydac filter device (hy. oil tank)
SRM 500 BA 6449 B49
6449B016
MACHINE R.H. SIDE - AREA OF HYDRAULIC OIL TANK
1= Hydraulic oil tank

2= Hydraulic oil level indication
3= Hydraulic oil suction filter
4= Suction filter - dirt indicator (vacuumeter)
5= Stop cock for Hydac filter device (hy. oil tank)
B50 BA 6449 SRM 500
6449B084
MACHINE R.H. SIDE – AIR DRYER AREA
1= Twin box air dryer unit

2= Combined pressure regulator
3= Air dryer - heating cartridge
4= Pneumatic 3-way cock for the air dryer activated / overrided
5= Pneumatic stop cock for the pressure releasing from the HBL 1
Note to item 4:
In case of malfunction of the air dryer (item 1), the 3-way cock has to be
changed in OVERRIDE position. The air dryer must be repaired as soon as
possible!
6 = Pressure switches (from front to rear):
- Compressure pressure, warning (4 bar)
- Compressure pressure, no drive permission (3,6 bar)
7 = Drip cup with drain cock for pneumatic system
8 = Release rod pneumatic reservoirs
SRM 500 BA 6449 B51
6449B085
MACHINE R.H. SIDE - DISCHARGING CONVEYOR BELT AREA
1= Discharging conveyor belt (swivelling conveyor)

2= Discharging conveyor belt tensioning device
3= Locking mechanism with inductive switch for discharging conveyor belt r.h.s. locked
4= Engine air cooler
5= Hydraulic motor for fan drive
B52 BA 6449 SRM 500
6449B087
MACHINE REAR R.H. SIDE

Important:
4= Horn button
5= Discharging conveyor belt locking lever (in locked position)
6= Safety bolt and padlock of the locking lever
7= Electro horn for fire alarm engine
8= Flashlight for fire alarm engine
9= Battery box
10 = Pneumatic reservoir for indirect brake system (57 litres)
11 = Socket, 24V DC
12 = Engine oil drain cock
13 = Coolant fluid drain cock
SRM 500 BA 6449 B53
6449B093
MACHINE REAR
1 = Stop cock with hose coupling for main air line

B54 BA 6449 SRM 500
NAVIGATION AID FOR TOUCH SCREEN
Main menu
Lighting Driving Engine control Service Loglist
Display-
functions Login Calibration Working hours
Function
Topology references
Emergency
Box 50 Box 90 / 91 Drive stop stop
Transfer drive Working drive Towing drive

SRM 500 BA 6449 B55
6449B045
TOUCH SCREEN
Note:
The touch screen is switched when an object approaches the screen surface.
At a distance of 1 mm to the surface an infrared filter determines the position. It
is sufficient to touch the touch screen slightly! Pressing the switch point will not
lead to success. A finger pressed towards the surface will cover too large and
inaccurate an area. Switching should be done with your finger tips only. Work
gloves are not suitable. Never touch the Touch Screen with dirty fingers, do not
contaminate it!
Do not damage the touch screen with sharp edges, never hit it by force!
B56 BA 6449 SRM 500
FUNCTIONAL DESCRIPTION OF THE ICONS
No active failure
Calls up the active alarm list
Calls up the menu page with functional instructions
Main menu page
Back to the previous menu level
Back to the previous page
Calls up the next page
Scrolls down the display
Scrolls up the display
Acknowledges alarm and turns the buzzer off

SRM 500 BA 6449 B57
screenshot_0
MAIN MENU
LIGHTING Section icon – calls up the respective section.
DRIVING Section icon – calls up the respective section.
ENGINE CONTROL Section icon – calls up the respective section.
SERVICE Section icon – calls up the respective section.
LOGLIST Section icon – calls up the respective section.

B58 BA 6449 SRM 500
screenshot_1
LIGHTING
1 = Lighting preselection for head and tail lights rear

2 = Lighting preselection for head and tail lights front
SRM 500 BA 6449 B59
screenshot_2
DRIVING
1= Engine speed indicator

2= Coolant temperature indication
3= Diesel engine oil pressure indication
4= Diesel fuel tank level indication
5= Voltmeter
6= Axle gearbox status indication engaged / disengaged – axle 1
7= Axle gearbox status indication engaged / disengaged – axle 2
8= Hydraulic oil tank status indication
9= Status indicator for locking devices working mode
10 = Status indicator for locking devices transfer mode
11 = Emergency stop status indication
12 = Override switch for locking devices (emergency mode)
13 = Hydraulic drive pressure indication
14 = Hydraulic oil tank temperature indication
B60 BA 6449 SRM 500
screenshot_3
ENGINE CONTROL
1= Engine speed indicator

2= Coolant temperature indication
3= Diesel engine oil pressure indication
4= Diesel fuel consumption indication
5= Engine torque indication
6= Engine status indication
- “P” = Protection
-“W” = Warning
- “A” = Alarm
7= Indication of active faults
8= Working hour indicator
9= Voltmeter
10 = Diesel fuel tank level indication
11 = Hydraulic oil tank temperature indication
SRM 500 BA 6449 B61
screenshot_4
SERVICE
DISPLAY FUNCTIONS Section icon – calls up the respective section.
User interface for maintenance technician and

LOGIN
instruced persons

CALIBRATION
instruced persons

WORKING HOURS
instruced persons
TOPOLOGY Section icon – calls up the respective section.
FUNCTION REFERENCES Section icon – calls up the respective section.

B62 BA 6449 SRM 500
screenshot_5
DISPLAY FUNCTIONS
1= Display brightness selection

2= Time selection
3= Day / night switch and system stop override button
4= Language selection
SRM 500 BA 6449 B63
screenshot_6
LOGIN
1 = Login - servicemen’s password

2 = Save file - to restore or modify calibration data
3 = Wheel diameter indication
Back to service menu.

B64 BA 6449 SRM 500
screenshot_11
TOPOLOGY
BOX 90 Section icon – calls up the respective section.
BOX 5/91 Section icon – calls up the respective section.
ETHERNET Section icon – calls up the respective section.

SRM 500 BA 6449 B65
screenshot_12
BOX 50
Note:
Touching the input/output stacks, the node stack and the CPU opens a window
showing the situation.
If one of the modules is defective or cannot be reached, it is represented in red
hachure.
Modules: 30.00 = For digital INPUTS / OUTPUTS

30.01 = For digital INPUTS
30.03 = For analogue INPUTS / OUTPUTS
B66 BA 6449 SRM 500
screenshot_13
BOX 90 / 91
Note:
Touching the input/output stacks, the node stack and the CPU opens a window
showing the situation.
If one of the modules is defective or cannot be reached, it is represented in red
hachure.
Modules: 30.00 = For digital INPUTS / OUTPUTS

30.01 = For digital INPUTS
30.05 = For counter module (16 digital inputs)
SRM 500 BA 6449 B67
screenshot_14
FUNCTION REFERENCES
DRIVE STOP Section icon – calls up the respective section.
EMERGENCY STOP Section icon – calls up the respective section.
TRANSFER DRIVE Section icon – calls up the respective section.
WORKING DRIVE Section icon – calls up the respective section.
TOWING DRIVE Section icon – calls up the respective section.

B68 BA 6449 SRM 500
screenshot_15
DRIVE STOP
Detail view of locality / status of drive stops
Status OK
Status NOK
SRM 500 BA 6449 B69
screenshot_16
EMERGENCY STOP
Detail view of locality / status of emergency stops
Status OK
Status NOK
B70 BA 6449 SRM 500
screenshot_17
TRANSFER DRIVE
Transfer drive conditions
Status OK
Status NOK
SRM 500 BA 6449 B71
screenshot_18
WORKING DRIVE
Working drive conditions
Status OK
Status NOK
B72 BA 6449 SRM 500
screenshot_19
TOWING DRIVE
Towing drive conditions
Status OK
Status NOK
SRM 500 BA 6449 B73
screenshot_20
LOG BOOK
ALARMS Section icon – calls up the respective section.
WARNINGS Section icon – calls up the respective section.
EVENTS Section icon – calls up the respective section.
LOG HISTORY Section icon – calls up the respective section.

B74 BA 6449 SRM 500
screenshot_21
ALARMS
Failure with indication of date, time, number and text.
Failure hierarchy:
Text = alarm – serious failure that requires immediate check or action.

SRM 500 BA 6449 B75
screenshot_22
WARNINGS
Failure hierarchy:
Text = warning concerning a failure that requires speedy check or action.

B76 BA 6449 SRM 500
screenshot_23
EVENTS
Failure hierarchy:
Text = indication of a failure that requires deliberate action.

SRM 500 BA 6449 B77
screenshot_24
EVENT HISTORY

SRM 500 BA 6449
PART C
Outline of operating processes
Changing operating modes
Safety information
Warnings
Behaviour in fault conditions

SRM 500 BA 6449 C1
The operating processes diagram illustrates which chapters of the operating instructions
will have to be read and/or applied for carrying out the work process required.
E.g.: The following chapters are required for starting the engine:
Chapter 2. Factory filling of operating fluids
Chapter 3. Safety regulations PRIOR TO commissioning the machine
Chapter 4. Getting machine ready for operation
Chapter 5. Safety regulations FOR operating the machine
Chapter 6. Starting the engine
If the ambient temperature is around zero degrees centigrade or below, the following
chapter will also have to be observed:
Chapter 6.4. Low temperatures
The numbers in the text below relate to page an position numbers, e.g. 5/4 refers to the
illustration section on page 5, pos. no. 4.
If reference is made to a specific page, subsequent pages may also be relevant for cross
references!
These operating instructions describe the condition of the machine as delivered. They may
be subject to changes and errors.
Attention:
It is naturally assumed that the required maintenance has been carried out on
the machine before it is put into operation.
C2 BA 6449 SRM 500
1. OUTLINE OF OPERATIONAL PROCEDURES
2.
factory filled working stok
3.
safety before putting the
machine into operation
4.
preparing the machine for
operation
5.
safety during operation
6. 6.3.
starting the engine turning off the engine
7. 6.4.
safety contrivances low temperatures
8. 9.
DRIVING WORKING
10. 11.
MISCELLANEOUS PARKING
12.
parking brake
13.
malfunction
SRM 500 BA 6449 C3
2. FACTORY FILLING OF OPERATING FLUIDS

• Factory filling of operating fluids – see maintenance instructions WS-6449.
2.1. THE OUTSIDE TEMPERATURE
• It is particularly important to observe the outside temperature before commissioning the

machine.
• If the outside temperature is below the minimums of the operating fluids these will have
to be heated up before use.
• See Chapter 6.4.
C4 BA 6449 SRM 500
3. SAFETY REGULATIONS PRIOR TO COMMISSIONING THE

MACHINE
• Familiarise yourself with the machine equipment.
• Keep the machine free of oily and flammable material.
• Visually inspect the machine for obvious defects or faults.
• Keep all hand rails, steps and platforms free from grease, oil, fuel, dirt, snow and ice.
• Only use the intended steps and hand rails to board the machine.
• Beware of operations on adjacent tracks!
• Always observe warning signs, in particular those on the stairs to the machine’s roof
(contact wire).
• Before boarding the machine make sure that there are no persons or obstacles next to
or under the machine.
• Observe the operating instructions prior to starting the machine.
• Adjust your seat before starting the machine.
• Do not drive or operate the machine with faulty instruments, control lights or control
devices.
• Only operate the machine once you have familiarised yourself fully with the operating
and control elements and the working mode of the machine.
Attention! Danger of fire!

The machine must be cleaned properly (at least once a year) to avoid the risk
of combustibles on its underside igniting.
A contaminated surface (engine coupling, gearbox housing, etc.) dissipates
heat significantly worse. This could result in overheating!
SRM 500 BA 6449 C5
4. GETTING MACHINE READY FOR OPERATION

• Assuming an unknown situation, the machine will be made ready for
operation by performing the following measures.
• These measures are mandatory if:
- the machine has been shut down for an extended period,
- the operating status of the machine is not known,
- a new or inexperienced crew wants to put the machine into
operation.
• The required maintenance was performed on the machine!
• Check all levers and linkages for free movement.
• Inspect the machine for any obvious signs of damage and loose or
missing parts.
• The brake block play is correctly adjusted.
• All operating fluids have been checked properly and refilled or
replaced as necessary!
• Check the vacuum meter of the hydraulic suction filters. 49/4etc.
• The battery sets are connected, the battery lids are “CLOSED”. 52/9
• All air vent and drain cocks (valves) on air reservoirs and drip cups 55/7etc.
are “CLOSED”.
Note:
This machine is equipped with an automatic air drying and 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 50/7
from this: they must be drained regularly in order to protect the air
drying plant from contamination!!
• The axle gearboxes are „ENGAGED“. 40/8; 46/4
• The diesel stop cocks in the engine suction pipe are “OPEN”. 42/9
• The diesel stop cocks in the engine return line are “OPEN”. 42/8
• The hydraulic oil tank drain cock is “CLOSED”.
• The drain cock for the engine coolant fluid is “CLOSED”. 52/13
• The drain cock for the pump distributor gearbox is “CLOSED”. 46/7
• The engine oil drain cock is “CLOSED”. 52/12
• The Diesel fuel tank drain cock is “CLOSED”.
• Check rail guard adjustment. 46/8 etc.
• Check brake blocks and running wheels.
• All EMERGENCY STOPs are unlocked. 20/1 etc.
• All drive stops are unlocked. 20/2 etc.
• The emergency brake is not applied. 2/4; 10/4
• The batteries service main switch is switched „ON“. 27/4
C6 BA 6449 SRM 500
• The main working mode switch is „OFF“. 8/4

• Check the hose couplings of the indirect brake. 53/1
Attention:
The stop cocks to the hose couplings are “CLOSED” - when the machine drives
without coupled wagons. If machines or wagons with brake facilities are added,
the hose couplings have to be coupled and the relevant stop cocks be “OPEN”.
• The pn. stop cock to the indirect brake is in position “ON”. 36/2
• Turn on the key battery main switch. 6/1
• Check all units their proper locking and fastening.
• Inspect all round the machine for loose, trailing or unsecured parts.
• Turn on the temperature monitoring system (unlock – rotate up - 34/2
lock). It is required to carry out a daily functional check before
putting the machine into operation.
• The machine will now have the status “ready for operation” and can
be put into operation.
SRM 500 BA 6449 C7
5. SAFETY REGULATIONS FOR OPERATING THE MACHINE

• Only operate the machine in accordance with its specified purpose.
• Before each drive check that the safety devices, brakes, lights and horns are working
properly.
• Observe the operating instructions for the individual work processes.
• Before starting work and also after a work break the driver has to make sure that
nobody is in the danger area.
If necessary, he has to give warning signs. He has to stop work immediately if one or
more persons do not leave the danger area despite the given warning.
• Never adjust the driver’s seat during driving.
• Never readjust safety valves.
• In emergencies or dangerous situations the emergency brake or the machine stop

button have to be activated immediately.
• Do not use the emergency brake, machine stop, engine stop and EMERGENCY STOP
buttons as service brakes.
Do not activate the emergency devices without cause to do so!
• Never drive at excessive speed. The driving speed must always be adapted to the given
track conditions (worksite) and must be in line with regulations (driving instructions).
• Change the direction of travel only when the machine is standing still.
• Use scotch blocks when stabling the machine on down-gradients or up-gradients.
• Never jump off the machine (except in emergencies) but always use the steps and hand
rails. Always beware of the adjacent tracks!
• If leaving the machine could be dangerous (adjacent track, etc.) the safety bars on the
steps have to be used – (lift bar and place it horizontally in the skewback rest, this will
lock the access/exit).
• Observe the danger signs and information signs by the steps and in the machine.
• Observe the special safety regulations for overhead lines.

C8 BA 6449 SRM 500
• It is principally prohibited to step on the machine roof under overhead lines. Before
starting repair and maintenance work make absolutely sure and certain that the
overhead line is switched off and earthed. These safety measures have to be carried
out and monitored by the local railway safety authority!
In addition to that beware of the danger of falling off the cabin roof!
• Watch out for unusual noise and smoke when operating the machine. Establish the
causes and repair the damage.
• Repair even small defects immediately, this will prevent more serious machine failures.
• Never adjust the safety valves.
• Exhaust fumes are life-threatening. When starting the machine in closed rooms make
sure that there is sufficient air supply.
• Keep the air intakes for the engines free from dust and dirt.
• Use the safety and protective equipment.
• Ensure that the fire extinguishers are always filled and checked periodically.
• Do not smoke whilst refuelling or checking the acidity level of the battery.
• Avoid refuelling the machine in the rain. Rain water could get into the fuel tank.
• Only use the designated operating fluids.
• When refuelling make sure that no contaminated substances enter the tank.
• Never check the acidity level of the battery, the fuel level or oil level with a naked flame.
• Any compensation for damages does not apply if any of the conditions for
commissioning and using the machine (as e.g. laid down in the operating, maintenance
and repair instructions) or acceptance conditions by an authority are not adhered to.
• This also applies if the machine is operated by unqualified, untrained or unauthorised

personnel.
• The machine operating company is obliged to take the required safety precautions and
to comply with all regulations.
SRM 500 BA 6449 C9
• It is of particular importance that the machine operating company has to acknowledge

and adhere to the regulations of the railway infrastructure operator.
• The machine operating company must not make any changes to the design or
configuration of the machine without having consulted and obtained permission from the
manufacturer (and permission from the acceptance body).
• The safety devices on the machine have been installed for the protection of persons
and machine. Bypassing the safety devices can have fatal consequences and will be
prosecuted in special cases!!
• It is PROHIBITED to set up switching procedures and operating conditions on this

machine which are not described in these operating instructions!
• The machine operating company is required to provide regular training for the crew on
danger areas, protective devices as well as behaviour in emergencies (fire, derailing,
crash, etc.).
Escape routes – see chapter 7.11.; Danger areas – see chapter 13.4.
C10 BA 6449 SRM 500
6. STARTING THE ENGINE

• Observe the operating manual of the engine manufacturer.
• Parking brake “APPLIED” or brake shoes fitted. 8/5,7
6.1. GETTING MACHINE READY FOR STARTING
• The machine is standing still and has the “ready for operation” status –
chapter 4.
• The engine has no failure.
• The temperature monitoring system is “ON”. 34/2
The system has no failure.
• The main working mode switch is “OFF”. 8/4
• The drive control lever is in “0” position. 9/1
• All EMERGENCY STOPs are released. 8/1 etc.
6.2. STARTING
• Sound warning tone and - once you have made sure that nobody is in 6/6
the danger area – start the engine using the engine start switch. 6/2
Important:
Do not start the engine at full throttle. Do not exceed the maximum of 20
seconds for uninterrupted starting. If the engine will not start interrupt the
starting process, wait for a minute and then repeat the starting process.
If the engine does not start after two starting processes the cause will have to
be found, in accordance with the troubleshooting table (engine manufacturer’s
operating manual).
• As soon as the engine starts, let go of the engine start switch and 5/
watch the engine instruments.
Attention:
You must avoid staying within the exhaust stream and breathing in the fumes
as this presents a danger to health and life!
Elements of the engine system must not be touched when at operating
temperature – danger of burns!
SRM 500 BA 6449 C11
6.3. SHUTTING DOWN THE ENGINE
• Do not shut down the engine from full load. It is required to idle the
engine briefly (approx. 3-5 minutes) unloaded in order to equalise the
temperature.
• Normally the engine is shut down by using the engine start switch 6/2
(Level 0) button.
• In addition to that the engine will also shut down when pressing an 8/1 etc.
“EMERGENCY STOP” button.
• If the key battery main switch is turned off the engine will also be 6/1
turned off.
Important:
It is normally not permitted to turn off the key battery main switch while the
engine is running - danger of OVERVOLTAGE!
C12 BA 6449 SRM 500
6.4. INSTRUCTIONS AND PROCEDURE FOR THE OPERATION OF

PLASSER AND THEURER MACHINES AT LOW AMBIENT
TEMPERATURES
Plasser and Theurer track maintenance machines can be operated within a temperature
range of +40°C to -20°C.
At temperatures below freezing the machine should be warmed and taken into service as
described below.
Note: Pay attention to the viscosity figures of the hydraulic oil put in.
Hydrostatic drive filter, suction filter, etc. should be changed or cleaned as
specified in the maintenance schedule.
If the machine is moved at too low a temperature without warming up all the
hydraulic components, it may result in damage to the hydraulic pumps / seals etc.
Frost protection: The engines are protected down to about -35°C by an

antifreeze mixture in the coolant put in at the factory. In addition at temperatures
below the freezing point it is necessary to use a winter diesel fuel (which contains
a special additive) for the diesel engine.
Option: The cooling water preheating of the diesel engine should be activated at
temperatures below 0°C (see Operating Instructions).
The information supplied by the manufacturer for the operation of the diesel
engine must be followed.
Heating the axle gearbox oils:

Start the machine slowly and then warm it up at moderate speed.
Pneumatics - temperatures below 0°C

Drain the water separator of the pneumatic equipment.
Drain the condensed water from the drip cup of the brake equipment.
Drain the condensed water container of the fuel filter.
Activate the cabin heating as temperatures under 0°C affect the measuring
instruments, the computer measuring system (CMS), the automatic guiding
computer (ALC), recorder, etc.
The operation of the machines at temperatures below 0°C is only possible if the
ballast bed is dry, not frozen (note frost days and frost temperatures) and free from
snow.
SRM 500 BA 6449 C13
6.4.1. FOR MACHINES WITHOUT HYDRAULIC OIL – PREHEATING
At temperatures below 0°C the machines should always be parked in a heated

workshop so that they are ready for service.
At temperatures between +10°C and 0°C the machines can be put into service without
hydraulic oil - preheating.
However, in general, the hydraulic oil should be preheated to about 30°C at which point
the machine is ready to start work.
Point 6.4.1.1 Preheating the hydraulic oil

• Start the diesel engine and allow it to warm up for about 10 minutes
(Pumps disengaged if possible)
• The engine should then run for about 15 minutes with pumps engaged
• Hydraulic system about 10 minutes 'On'
Make slow movements of the work units
• Start the conveyor belts
• Lift/lower work units
• Start vibration motor
• Compressor drive 'On'
• Move lifting and lining unit slowly forward and backwards
• etc........
6.4.2. FOR MACHINES WITH HYDRAULIC OIL – PREHEATING
In order to prevent damage to the driving elements (pumps and motors, etc.) and work
units (due to insufficient lubricating film) the hydraulic oil should be preheated.
At temperatures below 0°C the machines should always be left in a heated workshop so
that they are ready for service.
If this is not the case the machine can be put into service if a suitable hydraulic oil
preheating unit is installed.
In addition the thermostats of the hydraulic oil preheating unit should be set to the desired
preheating temperature.
Set the desired heating time on the time relay (see Operating Instructions) and preheat the
hydraulic oil to about 30°C.
For further information on the preheating of the hydraulic oils for the working mode
see Point 6.4.1.1
C14 BA 6449 SRM 500
7. SAFETY DEVICES
• This machine is equipped with many visible and hidden safety devices.
• The most sophisticated safety devices will not be effective if the human
interface is not prepared to make sensible use of them.
For example, using an emergency brake device as a service brake
facility, or not making use of available safety devices is regarded as
gross misconduct!
In this regard and in face of the many safety devices a clear safety
awareness among the crew is required for operating this machine!
• These safety devices have to be checked for functionality and condition
at regular intervals (at least monthly), under working conditions.
• The visual and audible warning devices must be tested for functionality
before starting working.
Attention:
Bypassing the safety devices can have fatal consequences and will be
prosecuted in certain cases!!
It is PROHIBITED to operate the machine for a prolonged period when safety
devices are faulty, have not been activated or have been bypassed!
• THE INDIVIDUAL SAFETY DEVICES:
Emergency stop - chapter 7.1.

Working drive stop - chapter 7.2.
Visual warning signals - chapter 7.3.
Audible warning signals - chapter 7.4.
Temperature warning system - chapter 7.5.
Emergency pump for hydraulics - chapter 7.6.
Bypass switches - chapter 7.7.
Fire extinguisher - chapter 7.8.
First aid box - chapter 7.9.
Emergency hammer - chapter 7.10.
Window as escape route - chapter 7.11.
Rail scraper - chapter 7.12.
SRM 500 BA 6449 C15
7.1. EMERGENCY STOP
• "Emergency stop" devices are situated:
- at the driver’s desk 8/1

- at the operator’s seat 12/12
- at each machine corner 19/1 etc.
- at the machine centre on each side of the machine 20/1 etc.
• Purpose of an emergency stop device:

Bringing machine to a standstill in critical situations, if regular measures are not
possible and immediate action is required!
• If an emergency stop function is activated the machine will lose its “ready for operation”
status!
Important:
The machine may only be put back in operation, when the cause of the
activation has been found, clarified and repaired if necessary!
• The visible EMERGENCY STOP device is essentially a red mushroom 8/1 etc.
button which is marked with a yellow signal field.
• When pressed, it locks in EMERGENCY STOP position, and as a
result:
- the machine control is switched currentless

- the controls become inactive
- the engine is shut down
- the brake is actuated
• A yellow lamp shows if a “STOP”-button has been pushed. 9/4etc.
Important:
Before de-activating the EMERGENCY STOP the cause for its activation will
have to be established and repaired, if necessary!
Note:
Press the Reset button (8/2) after de-activating the EMERGENCY STOP.
When all necessary steps have been carried out, the machine will not restart
but it will be possible to restart the machine!
• The EMERGENCY STOP is released by turning the mushroom button 8/1 etc.
to the right.
C16 BA 6449 SRM 500
7.2. WORKING DRIVE STOP
• Working drive stop buttons are situated:
- at the driver’s desk 9/5

- at the operator’s seat 11/5
- at each machine corner 19/2
- at the machine centre on each side of the machine 20/2
• The "working drive stop” device basically consists of a blue mushroom-

shaped button.
• When pressed this button engages in the "working drive stop" position.
This results in the following:
- the hydraulic working drive is interrupted

- the program-controlled brake applies
• The "working drive stop" is released by pulling the mushroom-shaped

button.
• A yellow lamp shows if a “STOP”-button has been pushed. 20/3 etc.
Important:
Before de-activating the working drive stop the cause for its activation will have
to be established and repaired, if necessary!
Note:
When having deactivated the “emergency stop“ press the reset button (8/2).
SRM 500 BA 6449 C17
7.3. VISUAL WARNING SIGNS
• The machine is equipped with several facilities to give off visual

warning signs. These are:
- active warning signs

- passive warning signs
• The active visual warning can be activated by pressing the flash light 7/10
switch.
• Warning signs and pictograms are passive warnings indicating
dangers.
7.4. AUDIBLE WARNING SIGNS
• The machine is equipped with several facilities to give off audible

warning signs.
• These are:
- electric horn signals

- air horn signals
- intermittent warning signals
• If a horn button is pressed the electric horn signals will respond. 6/7 etc.
• If the air horn operation switch is pushed, the high and low pitch 9/7 etc.
macrophones will respond.
• In backward working drive an intermittent warning signal will sound.
C18 BA 6449 SRM 500
7.5. TEMPERATURE MONITORING SYSTEM
• The built-in temperature monitoring system is designed to detect excessive

temperatures or a fire breaking out in endangered machine areas (engine compartment)
to enable the crew to take appropriate measures in time.
• This system is however only effective if it is supplied with electric power (24 V DC),
switched on, functional and not bypassed.
• The temperature monitoring system essentially consists of:
- an optical-acoustic - temperature sensors in the

signal column in the cabin engine compartment
- a control unit consisting of switch, - a bypass switch

control lamps and warning buzzer on each driver’s desk
SRM 500 BA 6449 C19
7.5.1. READY FOR OPERATION
• The power supply to the control unit is ensured.

• Switch the control unit “ON”; to do this unlock the switch (by pulling the 34/2
switch forward) and rotate it up.
• All warning and control lamps as well as all warning buzzers are then
activated for 5 seconds to test that they are working.
• After 5 seconds the warning and control lamps go out and the warning
buzzers are deactivated.
• The “AMBER” control lamp indicating a malfunction does not light up. 34/5
• The control lamp next to the control unit main switch lights up 34/3
“GREEN“.
• The system is in “monitoring mode“ status.
Attention:
It is required to carry out a daily functional check of the system by switching it
“OFF“ and “ON“ before putting the machine into operation.
7.5.2. PRE-WARNING
• If the ambient temperature exceeds the set limit on at least one of the
temperature sensors, pre-warning will be triggered.
• The warning lamp for the pre-warning on the control unit lights up 34/7,9
“AMBER“.
• The “RED“ warning light of the signal column starts to flash in the 2/5
cabins.
• The system is now in “pre-warning“ status.
• If possible the output of the engines should be reduced to idling speed
to lower the temperature.
• It will be necessary to perform a detailed check of the engine
instruments to find the possible causes of the temperature increase.
• In addition to that the crew should prepare for the event that the
temperature will not go down and the temperature alarm will be
activated.
Note:
Shutting down the engine will first increase the temperature.
Attention:
In the ”pre-warning“ status no area must be entered where the risk of a fire
escalating increases!
If the machine is already in a critical location (storage tank, tunnel, station, etc.)
this area must be left immediately!
C20 BA 6449 SRM 500
7.5.3. TEMPERATURE ALARM (FIRE RISK OR FIRE)
• The system is in the “pre-warning“ status.

• If the temperature rises further (20°C) and remains above the alarm
limit for longer than 5 seconds, the temperature alarm will be triggered.
• The warning light for the alarm lights up “RED“ on the control unit and 34/8,10
the warning buzzer will sound. 34/4
• The “RED“ warning lamp in the cabins has been flashing since the pre-
warning phase.
• The warning buzzer in the signal column will be activated.
• The system is now in the “temperature alarm“ status.
• Immediate action is required!
Attention:
A temperature alarm is a serious situation. The machine needs to be stopped
as quickly as possible and the endangered areas checked.
To start with do not open any big openings; this would drastically increase the
oxygen supply and fan the fire even more.
If possible, try to control the fire through the fire extinguishing opening. Be
particularly careful of possibly hot, fast escaping air!
• Once you have made sure that there is definitely a temperature alarm -
initiate fire-protection measures if necessary, see part E.
Note:
The temperature alarm will keep going - even if lower temperatures have been
recorded in the meantime – until the quit button is pressed on the control unit.
This resets the system to “monitoring mode“.
If the temperature remains above the limit on at least one temperature sensor
the warning buzzer will be reactivated 5 minutes after pressing the quit button.
• If a temperature alarm has been activated the machine loses its “ready
for operation“ status.
SRM 500 BA 6449 C21
7.5.4. MALFUNCTION DETECTION
• If a malfunction occurs in the control system,

- the “AMBER (orange)“ warning lamp lights up on the signal 2/5
column 34/5
- the malfunction warning light on the control unit lights up
“AMBER“.
- the engine cannot be started
- the temperature warning system cannot be used
• If the bypass switch is switched on, the engine can be started even if 6/5
the temperature monitoring system is faulty.
Attention:
It is possible to continue travel to the nearest workshop but the crew must be
aware of this special situation.
• The “AMBER (orange)“ warning light of the signal column by the 2/5
driver’s desks is illuminated even if the main switch of the control unit is 34/2
switched off.
• It is not possible to start the engine without an active bypass switch.
7.5.5. SWITCHING THE SYSTEM OFF
• If it is planned to shut down the machine for a prolonged period the

main switch of the control unit has to be switched off once the machine
has been “shut down” (with the engine cooled down).
• To do this unlock the main switch (by pulling the switch forward) and 34/2
rotate it down.
• The “GREEN” lit control lamp next to the control unit main switch goes 34/3
out.
• The temperature monitoring system is switched off.
C22 BA 6449 SRM 500
7.6. EMERGENCY PUMP FOR HYDRAULICS
• In case the engine fails during working mode, hydraulic energy supply
is interrupted as well.
• 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 26/1
for hydraulic operations.
• This emergency pump allows the transit position of the working units to
be restored.
• Thus the machine can be towed from a work site if necessary.
7.6.1. PROCEDURE
• Position the machine on a track section without super elevation if

possible and secure it from rolling away.
• Inform the crew of the imminent operations and instruct them if
necessary.
Attention:
The emergency pump for hydraulic remains “OFF” until everybody has left the
danger area.
• If these circumstances are provided take the following action:
- Close stop cock for pressure build up. 26/2

- Operate the working control for the respective movement 10/
- Operate the hand pump until the working unit is in the required 26/3
position
- Open stop cock for pressure release 26/2
• All pneumatic locking devices of the working units can be locked /

unlocked only by activating the respective valves in manual mode -
refer to the pneumatic system drawing.
Important:
Bypass functions only serve the purpose of getting the machine ready for
towing or transiting and immediate travel into a suitable workshop.
SRM 500 BA 6449 C23
7.7. BYPASS SWITCHES
• If there is a fault which the program control recognises the program

control will react and prevent potential damage resulting from the fault.
• In order to keep driving in special situations, bypass switches are
provided for individual areas.
• If these bypass switches are activated the program control lock is
bypassed – see chapter 13.
Important:
Bypass functions only serve the purpose of getting the machine ready for
towing or transiting and immediate travel into a suitable workshop.
7.8. FIRE EXTINGUISHER
• The fire extinguisher is mounted in the cabin next to the door. 16/3
7.9. FIRST AID BOX
• The first aid box is mounted in the cabin next to the door. 16/4
7.10. EMERGENCY HAMMER
• The emergency hammer can be used to smash the windows and is

mounted in the cabin next to the door.
C24 BA 6449 SRM 500
7.11. WINDOW AS ESCAPE ROUTE
• In emergencies the cabin windows can be used as escape routes.

• The windows can be smashed in with the emergency hammer.
• Before smashing in or removing the window:
- decide to which side the machine should or can be left. Adjacent

track, adverse surroundings, etc. will make it even more
difficult/dangerous to get off the machine.
- break the window with cabin equipment or by pulling the
emergency trip wire
- leave the cabin without great hurry but bearing in mind safety
considerations
7.12. RAIL SCRAPER
• Each wheel is protected by rail guards. 27/5 etc.

• The rail guard has to be adjusted in accordance with the track
conditions (at least 65 mm) in order to remove foreign matter from the
rails and thus prevent derailment.
SRM 500 BA 6449 C25
8. DRIVING
The operating mode „DRIVING“ is structured as follows:
8.
transiting DRIVING
8.1.
limit values for transiting
8.2. active passive

getting the machine ready
for driving
11.3.
9.4.1.
8.3. the machine as a direct
working drive
starting driving adjunct to the train
8.4.
accelerating
8.5.
maintaining the speed
8.6.
driving
8.7.
reducing the speed
8.8.
stopping the machine
8.9.
changing direction
C26 BA 6449 SRM 500
Transiting - chapter 8.
• During transiting both axles are driven hydrostatically.
• The max. driving speed is 80 kmph.
Working drive – chapter 9.4.1.

• In “working mode” both axles are driven hydrostatically.
Towing drive - chapter 11.2.

• In towing drive the machine is travelling driveless, usually at the tail end of the train
formation.
• The max. towing speed is 80 kmph.
8.1. LIMIT VALUES FOR TRANSITING

2 Smallest practicable vertical radius m 900
3 Maximum practicable super-elevation mm 160
4 Maximum practicable gradient %o 20
(also maximum gradient for parking brake)
5 Maximum speed when self propelled km/h 80
6 Maximum speed when towed km/h 80
7 Maximum load hauled to 20
SRM 500 BA 6449 C27
8.2. GETTING MACHINE READY FOR DRIVING - TRANSITING
• The machine is standing still and secured from breaking away.

• The machine has been made „ready for operation“ - chapter 4.
• Overall check of the machine to make sure that all working devices
are locked and secured.
• NOTICE: transport positions - refer to chapter 9.5.
• Secure all loose parts on the machine.
• Travel drive key switch in position „ON“. 8/4
• Switch the drive desk “ON”. 6/7
• The parking brake is released. 8/5,6
• Carry out brake test (when parking brake is released) with the direct 8/5,6
brake and the indirect brake - all brake blocks have to sit firmly. 3/1,2
• Carry out brake test (when direct brake and indirect brake is released) 3/1,2
with the parking brake - all brake blocks have to sit firmly. 8/5,7
• After each brake test the brake blocks have to release from the wheel!
• The releasing time must be in accordance with regulations!
Note:
The machine will lose its „ready for operation“ status as soon as one of the
brakes is not working properly.
Attention:
It is PROHIBITED to operate the machine with the brake(s) switched „OFF“ or
bypassed!
• Check signalling system.

• Switch on lighting system as required.
• If necessary, remove scotch blocks and stow away.
C28 BA 6449 SRM 500
8.2.1. BASIC CONSIDERATIONS FOR DRIVING MODE
• Only the maximum number of persons permitted and for whom seats
are available are allowed in the cabin.
• The driver has to ensure that all persons remain in their seats and do
not obstruct the view to the outside.
• The driver has to ensure that his attention is not distracted or
hindered in any way.
• It is PROHIBITED to deliberately drive against obstacles of any kind!
• It is PROHIBITED to drive the machine with units protruding from the
clearance gauge or not in ready-for-transport position!
• Activate the access locks in driving mode as required – this will lock
the access/exit.
• Driving (rolling) without a running engine is PROHIBITED!
SRM 500 BA 6449 C29
8.3. STARTING DRIVING
• The conditions for „getting machine ready for driving - transiting“ have
been completed - chapter 8.2.
• The machine is standing still, the brake is applied. 3/1
• The tightness of the brake system complies with regulations.
• The wheels are free of scotch blocks.
• The engine is running at idling speed <900 min-1.
• The 2nd gear is pre-selected at both axles.
• Increase the engine speed to the maximum. 6/4
• Pre-select the direction of travel. 9/3
Important:
The machine has to be at a standstill to pre-select the direction of travel.
• Release brake and operate the drive control lever. 3/1; 9/1,2
• The machine starts moving.
8.4. ACCELERATING
• Optimum acceleration will be achieved if the engine speed is close to 9/1,2

the maximum and the drive lever is declined fully.
8.5. MAINTAINING THE SPEED
• The speed is regulated by the decline degree of the drive lever. 9/1,2
C30 BA 6449 SRM 500
8.6. DRIVING
• Watch the monitoring instruments during driving.

• Never enter a down-gradient without a pre-selected direction of travel.
• Full service braking only in emergencies.
• Never drive at excessive speed. The driving speed must always be
adapted to the given track conditions and must be in line with driving
instruction regulations.
8.7. REDUCING SPEED
• Reduce the decline degree of the drive lever. 9/1,2

• Use the brake as required. 3/1
8.8. STOPPING THE MACHINE
• Move the drive lever to 0-position. 9/1,2

• Bring the machine to a stop applying brakes (to avoid blocking up of 3/1
wheels, brake only with reduced pressure).
• Reduce engine speed to idling. 6/4
• The drive direction switch is in 0-position. 9/5
8.9. CHANGING DIRECTION
• Move the drive lever to 0-position. 9/1,2

• Apply the brakes as required. 3/1
• Wait till machine comes to standstill.
• Change drive direction. 9/5
• Drive as described above.
SRM 500 BA 6449 C31
9. WORKING
The operating mode “WORKING” is structured as follows:
9.
WORKING
9.1. 9.2.
limit values for working
dangers of working
mode
9.3.
preparation for working
mode
9.4.
working mode
9.4.1. 9.4.2.
working drive excavating unit
9.4.3.
rail fastening brush
9.5.
returning to transiting
C32 BA 6449 SRM 500
• “WORKING” is the condition where the machine performs the activity

for which it was built.
• This machine is a continually working sand removal machine.
Important:
For the working mode it is required that all working systems are functional,
correctly adjusted and/or adjusted and calibrated in line with their particular
requirements.
9.1. LIMIT VALUES FOR WORKING MODE

3 meter (non supported machine)
3 meter (supported machine)
4 Maximum cross level during working mm 180
5 Maximum working ramp gradient 1 1:100
6 Track curvature defect over a basis of 10 m mm 50 (top to top)
SRM 500 BA 6449 C33
9.2. DANGERS OF WORKING
• Working on the track inherently brings many risks. This in itself calls for cautious and
vigilant behaviour of the crew.
• Multi-track track sections, bridges, subways, tunnels, stations and similar require
additional attention.
• Those who operate switches or control elements have to know beforehand what their
actions will achieve or trigger.
• Key switches are switches of special significance. Switching with a key switch requires
particular caution and awareness.
• The crew is advised to use adequate protective devices.
• Working procedures should be carried out orderly and without stress.
• Communicating with each other is essential for a safe working process.
• Bypassing safety devices can have fatal consequences and will be prosecuted in
certain cases.
• It is principally prohibited to step on the machine roof under overhead lines. Before
starting repair and maintenance work make absolutely sure and certain that the
overhead line is switched off and earthed. These safety measures have to be carried
out and monitored by the local railway safety authority!
Attention:
In working mode the areas of all units are danger areas which must not be
entered!
For maintenance work special safety measures are required!
If it is necessary to enter a danger area in working mode, chapter 13.4. has to
be applied!
C34 BA 6449 SRM 500
9.3. PREPARATION FOR WORKING MODE
• Starting from transit mode the machine will be brought to working mode
by the following measures:
• The machine is stationary.
If possible, the machine should stand in a straight track section.
• The parking brake is “APPLIED”. 8/5,7
• All switches on the working control panels must be in “OFF” position. 10/1,2
• Potentiometer for elevator running speed to “MIN”. 12/7
• The working drive control lever is in 0-postion. 11/1
• Turn on the working lights.
• Turn “ON” the working mode main switch. 8/4
• The engine is running at working speed.
• Switching on the working mode control circuit at the same time
switches on the working brake and engages the 1st gear of the axle
gearboxes.
• The direct-acting brake and the parking brake may be released. 8/5,7; 3/1
SRM 500 BA 6449 C35
9.4. WORKING MODE
• The working mode is divided into work processes.

• The work processes detailed here will be described briefly.
Important:
Working with this machine can only be learnt in intensive training courses in the
classroom and by hands-on training on the machine.
More detailed additional specifications will help to understand the individual
systems better.
Only an understanding and recognition of the interaction of the systems will
achieve the overview required for being able to operate the machine efficiently!
• The following work processes are described:

- working drive - chapter 9.4.1.
- excavating unit - chapter 9.4.2.
- rail fastening brush - chapter 9.4.3.
9.4.1. WORKING DRIVE
• The “preparations for bringing the machine in working mode” have

been completed – chapter 9.3.
• Operate the working drive lever (forward or reverse), the working brake 11/1
will be released.
• The machine is brought to the desired travelling speed by operating the
working drive lever.
• For stopping move the working drive lever to the 0-position and 11/1
activate the drive stop button. 11/7
Important:
Only change the direction of travel when the machine is standing still.
If the machine is in working mode the working units will have to be lifted for
driving over switches, crossings, level crossings, etc.!
C36 BA 6449 SRM 500
9.4.2. EXCAVATING UNIT
• The excavating unit is located at the front of the machine. It is a

combination of a cutting edge and a scoop with an elevator.
• The sand drops from the excavating unit onto two longitudinal conveyor
belts and is transferred via a funnel onto a slew able conveyor belt in
the rear part of the machine.
• Unlock the clearing blades and extend them. 17/3,4
• Connect the clearing blades with the swivel cylinder. 19,39/8
• Lift the elevator to relief the locking device, unlock the elevator on both 19,39/6
sides and lower it onto the track. 13/1
• Adjust the height of the elevator by means of rail guide rollers as 13/2
required.
• Unlock the discharging conveyor belt. 38,52/5
• Turn the discharging conveyor belt to the desired side. 11/13
• Switch on the discharging conveyor belt. 11/12
• Switch on the steep conveyor belts. 11/10,11
• Select elevator mode “manual” or “automatic”. 12/8
• Switch on the elevator drive. 12/9,10
• In manual mode the elevator running speed is infiitely variable by 12/7
adjusting the potentiometer.
• Lower the clearing blades on both sides to the necessary intervention 13/3,6
level.
• Slew the clearing blades to the necessary working position. 13/4,5
• Switch on the drive unit and actuate the accelerator (refer to chapter
9.4.1.)
• To obtain a constant and even working procedure you have to adjust
the working mode driving speed to the running speed of the conveying
mechanisms.
Warning:
Be aware of persons and obstacles in the working area during working! Risk of
accident!
Warning:
The working system being enabled the working area is prohibited zone.
Entering it is therefore prohibited!
SRM 500 BA 6449 C37
9.4.3. RAIL FASTENING BRUSH
• Lift and unlock rail fastening brushes. 12/3,4

• Lower rail fastening brushes to required position. 12/5,6
• Switch rail fastening brush drive “ON”. 12/3,4
Warning:
Ballast can be thrown off in the working area!
9.5. RETURNING TO TRANSITING
• If possible, stop the machine in a straight track section and apply the 3/1
brakes.
• Shift working drive speed control lever „0“ position. 11/1,2
• Unload the elevator, turn off the elevator drive. 12/9,10
• Having unloaded the steep conveyor, turn off the drive. 11/10,11
• Having unloaded the discharging conveyor, turn off the drive. 11/12
• Turn the discharging conveyor belt parallel to track axis. 11/13
• Lock the discharging conveyor belt and secure the lock. 38,52/5
Note:
The pilot lamp „discharging conveyor - locking position“ must be extinguished.
If the limit switch is not active, transfer will not be possible.
• Readiness for driving may be obtained by pressing the „axle gearbox 8/3
clutch engagement aid“ button.
• Lift the elevator into its locking position and lock it. 13/1
19,39/6
• Move the clearing blades to their locking position and lock them. 17/3,4
• Lift and lock rail fastening brushes. 12/3-6
• Turn the selector switch to „travel drive“ position. 8/4
• Ensure that all working units are properly set into travelling position
and locked.
• Check the machine all round generally.
C38 BA 6449 SRM 500
10. MISCELLANEOUS
10.1. TURNING THE MACHINE
• Drive the machine to an appropriate place.

• Apply the parking brake.
Important:
The machine may be turned only in horizontal, well consildated and good
bearing places.
• Usually only horizontal level crossings with a high bearing capacity,

consilidated panels, are suitable for these purpose.
Attention:
Secure the place chosen for turning the machine regarding trains passing and
road traffic, as well as trespassing persons.
Observe the respective building and operating rules and motor vehicle
regulations.

• Reduce the engine speed (idle-running revs.).
• Untie the securing chains and/or shackle of the hydraulic turntable. 26/5
44/2
• Unlock the hydraulic turntable (remove the locking bolt). 44/3
• Lower the hydraulic turntable by actuating the switch, until the machine 15/1
will be lifted to such an extent, as to ensure that the wheel flanges are
above the top of the rails.
• Turn the machine according to the track direction and into the desired
working direction.
• Retract the machine turning device by actuating the key-operated 15/1
switch and before re-railing it make sure that it is algined with the track.
• After re-railing of the machine completely retract the machine turning 15/1
device, lock it and secure it by shackle. 26/5; 44/2,3
Warning:
Before lifting and turning the machine make sure that nobody is on the machine
or within the danger area!
Staying under the lifted machine is strictly prohibited!
Important:
Oblique positions may lead to damage and accidents. During the turning
procedure watch the ground support.
Should the soil founder or other irregularities appear, immediately break off the
lifting procedure.
SRM 500 BA 6449 C39
10.2. OFF-TRACKING DEVICE
Important:
Lifting and off-tracking the machine or the reverse action for on-tracking is to be
carried out only on horizontal, solid ground with load-carrying capacity!
• For better area-specific load distribution, solid and adequately

dimensioned supports (i.e. square shaped logs) are to be used.
Attention:
The off-tracking/on-tracking place is to be secured by proper measures with
regard to railway and road traffic as well as against access by unauthorized
persons.
Warning:
Make sure that nobody is on the machine or within the danger area!
Important:
Oblique positions may lead to damage and accidents. During the off-tracking
procedure watch the ground support.
Should the soil founder or other irregularities appear, immediately break off the
procedure.
• In this conneciton, the relevant regulations of building and operating

codes as well as road traffic regulations are to be observed.
• Drive the machine to an appropriate place.

• Apply the parking brake.
• Plug-in the control box for the off-tracking mode at the respective side
of the machine.
• Untie the securing chains and/or shackle of the hydraulic turntable. 26/5
44/2
• Unlock the hydraulic turntable (remove the locking bolt). 44/3
• Lower the hydraulic turntable by actuating the switch, until the machine 15/1
will be lifted to such an extent, as to ensure that the 1st part of the off-
tracking rails can be positioned below off-tracking rollers.
Attention:
Be aware of persons in the danger area! Risk of accident!
Staying under the lifted machine is strictly prohibited!
C40 BA 6449 SRM 500
• Mount the 1st part of the off-tracking rails on the rail, so that
the off-tracking rail may not slide away.
• Connect the l.h. and r.h. off-tracking rail with help of safety
rod.
• Position the 2nd part of the off-tracking rails on suitable

supports.
• Connect one side of the 2nd part of the off-tracking rails with
the 1st part of the off-tracking rails.
• Secure it with safety bolt.
• Insert safety rods.

SRM 500 BA 6449 C41
• Connect the other side of the 2nd part of the off-tracking

rails.
• Secure it with safety bolt.
• Secure safety rods on both sides.
• Cross spirit-level has to be observed.
• Lift the hydraulic turntable completely by actuating the switch, so that 15/1
the machine stands with the transversal rollers on the 1st part of the
off-tracking rails.
• Move machine to the l.h.s or r.h.s. - next to the rail (on the 2nd part of 15/2
the off-tracking rails).
Attention:
Watch for solid load-bearing grade!
C42 BA 6449 SRM 500
• The machine is now standing next to the rail.
• Dismantle 1st part of the off-tracking rails so that the rail is

free for traffic.
• On-tracking the machine see above, but in reverse order.

Attention:
In case of caving in, slipping or other irregularities, the procedure is to be
stopped immediately!
If necessary, a different and more suitable site is to be looked for!
10.3. WORKING LIGHTS
• The working lights are for lighting the working area.

• Adjust the working lights in such a way that only the working area is lit
but the sorrounding area is left unlit.
• Especially beware of oncoming trains, they must not be dazzled!
• Do not look directly into the working lights!
SRM 500 BA 6449 C43
11. STABLING THE MACHINE

• All measures for returning the machine to “transit mode” have been
completed – see chapter 9.5.
• Secure the machine from breaking away (skid-pans).
• Switch the direct-acting brake to end position. 3/1
• The running direction pre-selection is “OFF”. 9/5
• The drive lever is in “0”-position. 9/1
• All emergency stops are unlocked. 8/1 etc.
Important:
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!
• Turn off the engine. 6/2

• Switch “OFF” the driver’s desk. 6/7
• Switch selector switch of “travel drive / working drive” in position 8/4
“OFF”.
• Switch off and remove the key-operated battery main switch. 6/1
• Switch off the service battery main switch and remove the lever. 27/4
Switching off the service battery main switch:

The service battery main switch must be switched off approximately 30 sec. after
the battery main switch.
The follow-up time setting is necessary to store the „Deutz“ engine data.
• All air drain cocks on air receivers and drip cups are “CLOSED”.
11.1. BRAKES
• If one of the brakes (parking brake, direct-acting brake, indirect-acting 3/1,2

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 apllied, 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
11.2.
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!
C44 BA 6449 SRM 500
11.2. 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!
11.2.1. PREPARING THE MACHINE FOR TOWING
• The measures for parking the machine have been taken – chapter 11.
• The machine is stationary.
• Secure the machine from breaking away (drag shoes etc.).
• Disengage both axle gearboxes and lock the lever. 40/8; 46/4
• First “RELEASE” the direct-acting brake and then turn it to end 3/1
position.
• First “RELEASE” the indirect-acting brake and then turn it to end 3/2
position.
• The parking brake is released - chapter 12.
• The indirect brake valve has to be switched “ON”. 36/2
• The pn. stop cock to the safety brake has to be switched “OFF” and 36/18
secured in this position.
• Switch “OFF” the engine. 6/2
• Switch “OFF” and remove the key-operated battery main switch. 8/1
• Secure the machine against unauthorized use.
• Turn “OFF” all key-operated switches and remove the keys. 8/1 etc.
• Secure all loose parts on the machine.
• Turn “OFF” the machine lighting.
Warning:
If one or several of the conditions stated above will not be fulfilled, damage to
the machine will be the consequence!
Warning:
In addition to that you must check that all brake blocks are clear of and
released from the wheel.
Towing the machine with brakes actuated will result in considerable damage to
the machine!
High risk of fire from huge generation of heat in addition to flying sparks!
SRM 500 BA 6449 C45
11.3. ADDING THE MACHINE DIRECTLY TO THE TRAIN
• The machine has been made ready for towing – chapter 11.2.1.
• Couple the draw hook and tighten so there is no play.
• Couple the indirect brake pipe and the main reservoir pipe and 53/1
“OPEN” their stop cocks.
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 “LOOSE” before the planned towing operation –
chapter 12.
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!
Warning:
If one or several of the conditions stated above will not be fulfilled, damage to
the machine will be the consequence!
C46 BA 6449 SRM 500
12. THE PARKING BRAKE

• The parking brake is a spring-applied brake.
• The spring cylinder is saddled on the brake cylinder. Therefore no
complicated hand brake linkage is required.
• The parking brake requires 24V DC (battery voltage) and 5 bar
compressed air for operating. If no current / compressed air is available
on the machine, the spring cylinders have to be „DE-ACTIVATED“ in
order to be able to move (tow) the machine.
• The axles are equipped with two brake cylinders with spring brake
cylinders.
1 = Pneumatic service brake cylinder

2 = Pneumatic spring-loaded brake
cylinder
3 = Spring load blocking bolt - here in
position „spring load off
(RELEASED, INACTIVE)“

cylinder
position „spring load on
(ACTIVATE)“
3 = Labeling and arrow: spring load
turn direction for releasing
SRM 500 BA 6449 C47
12.1. THE OPERATING STATUSES OF THE PARKING BRAKE
• For the parking brake two operation modes are available:
- "ACTIVE " - Kapitel 12.1.1

- "INACTIVE" - Kapitel 12.1.2
• The mode „ACTIVE“ consists of the following operating statuses:
- Parking brake "RELEASED" - Kapitel 12.1.1.1

- Parking brake "APPLIED" - Kapitel 12.1.1.2
12.1.1. PARKING BRAKE - ACTIVE
• Starting from the following picture (the spring-loaded brake front is

“INACTIVE“) the spring-loaded brake will be “ACTIVATED“ as follows:
− Screw in the spring load blocking bolt (releasing bolt) „2“ into both
pneumatic spring-loaded brake cylinder front completely.
Important:
For unscrewing / screwing in the bolt “2“ pneumatic pressure for releasing the
parking brake is useful - chapter 12.1.1.1.

cylinder
position „spring load off
(RELEASED, INACTIVE)“
C48 BA 6449 SRM 500
− The following picture shows the “ACTIVE” spring-loaded brake.

cylinder front
position “spring load on
(ACTIVE)”
12.1.1.1. PARKING BRAKE, ACTIVE - RELEASED
• The key-operated battery main switch is „ON“. 6/1

• The pn. system is filled.
• Turn the selector switch for the parking brake to position “RELEASED”, 8/5
the spring brake cylinder will be pressurised and hence the parking
brake “RELEASED”.
• The corresponding indication lamp lights up. 8/6
• Check whether brake blocks hang slackly from the wheel.
12.1.1.2. PARKING BRAKE, ACTIVE - APPLIED
• The key-operated main switch is “ON”. 6/1

• Turn the selector switch for the parking brake to position “APPLIED”, 8/5
the air pressure will vent of the spring brake and the parking brake will
be “APPLIED”.
• The corresponding indication lamp lights up. 8/7
SRM 500 BA 6449 C49
12.1.2. PARKING BRAKE - INACTIVE
Attention:
Set the spring brake cylinder “INACTIVE” only for towing drive, or for shunting
the machine (without pn. pressure and / or missing electric power supply) or for
maintenance in the work shop.
• Before setting the spring-operated brake “INACTIVE” the drawgear must either be
coupled to the shunting railcar or the vehicle must be secured by means of drag shoes.
• Starting from the following picture (the spring-loaded brake front is “ACTIVE“) the
spring-loaded brake will be “DE-ACTIVATED“ as follows:
− Unscrew the spring load blocking bolt (releasing bolt) “2“ out of both pneumatic
spring-loaded brake cylinder front completely.
Important:
For unscrewing / screwing in the bolt “2“ pneumatic pressure for releasing the
parking brake is useful - chapter 12.1.1.1.

cylinder front
2 = Spring load blocking bolt
(releasing bolt) - here in position
„spring load on (ACTIVE)“
− The following picture shows the “INACTIVE” spring-loaded brake.

cylinder front
2 = Spring load blocking bolt
(releasing bolt) - here in position
„spring load off (RELEASED,
INACTIVE)“
C50 BA 6449 SRM 500
13. BEHAVIOUR IN FAULT CONDITIONS OF INDIVIDUAL

MACHINE COMPONENTS
13.1. ALARM WARNING
• If a fault occurs in the system the warning buzzer sounds and the fault 7/14
message is output on the alarm list. 74/
• The buzzer tone can be turned off by pressing the quit button.
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!
13.2. FAULT IN THE TEMPERATURE MONITORING SYSTEM
• Switch “OFF” the main switch of the temperature warning system. 34/2
• Turn “ON” the temperature warning system bypass switch – rotate the 6/5
protective guard to the right and the switch down.
• If the engine was turned off when the temperature alarm responded, it
can now been started using the bypass function to be able to leave
dangerous areas such as tunnels, bridges, stations, etc.
• If the temperature alarm was activated because of a fault in the system
the machine can continue driving to the nearest station or nearest
workshop, being aware of the machine danger areas and checking
them repeatedly.
SRM 500 BA 6449 C51
13.3. BRAKE BLOCK PLAY
• During the lifetime of a brake block the brake block play will have to be readjusted at
least once.
• The brake block play (distance between brake block insert and wheel running surface)
is normally approx. 5mm.
• In principle, the brake block play needs to be readjusted if:
- the brake block play is too big
- the brake blocks are renewed
- the profile of the wheels has been overhauled
Brake block play is adjusted as follows:
- the machine has been secured from breaking away (scotch blocks)
- the parking brake is “RELEASED”
- the brake cylinders are released (brake pressure is zero)
- if new brake blocks are inserted the tensioning buckles are adjusted
beforehand in such a way that the brake clips move back and make
room for the new brake blocks
- adjust the required brake play using the tensioning buckles
- secure the tensioning buckles against unintended turning
Note:
Brake linkage head and brake lever do not need to be dismantled!
Attention:
It is prohibited to operate the machine with incorrectly adjusted brakes!
13.4. BEHAVIOUR AFTER DERAILING
• Shut down engine and move persons to a safe place.

• Report to the infrastructure operator.
Important:
When derailing the machine will lose its “ready for operation” status.
Returning to normal operation after rerailing is PROHIBITED!
The infrastructure operator must be informed about the derailment
immediately.
It is compulsory to have a special check carried out by a qualified member of
staff of the infrastructure operator.
After serious derailments the axles will be disconnected, disassembled and
measured. A final test run measuring the running quality is required!
C52 BA 6449 SRM 500
13.5. RAILWAY EARTHING DEVICE

ATTENTION
Before lifting the machine, for example, after a
derailment (no contact between wheel flanges
and rail), the respective "railway earthing device"
needs to be fitted between earthing bolt and rail
to protect the machine crew.
Otherwise residual voltage or a contact between
the machine and the overhead line might cause
electric shock or, in the worst case, even death.
When fitting the respective "railway earthing device", make sure to mount it on the rail first
and only afterwards on the machine. The earthing bolts are located at the front l. h. and
rear r. h. machine end next to the buffer bar.
When disassembling the devices, make sure to disconnect them from the machine first
and only afterwards from the rail.
SRM 500 BA 6449 C53
13.6. MALFUNCTION OF THE SAFETY BRAKE
• Lock the locked lever for the safety brake and secure it in this position. 36/18
• Turn “ON” the safety brake bypass switch – rotate the protective guard 41/2
to the right and the switch down.
• The machine can be driven to the nearest station or nearest workshop
while being particularly cautious.
Attention:
Normal operation with a non-functional safety brake is prohibited!
13.7. MALFUNCTION OF THE INDIRECT-ACTING BRAKE
• Protect the machine from breaking away (parking brake, skid-pans

etc.)!
• Switch off the indirect brake valve 36/2
• The direct brake has to be used.
• 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:
Normal operation with a non-functional safety brake is prohibited!
13.8. ENGINE FAULT
• If the engine is faulty (is not running) the machine cannot be moved
initially.
• Units which are not in ready-for-transport position prevent the machine
from being towed.
• The working units can be made ready for transport with the hydraulic
emergency pump.
C54 BA 6449 SRM 500
14. LIFTING THE MACHINE

• For lifting the machine it is important to distinguish between lifting a
section of the machine, e.g. a bogie, or lifting the whole machine.
14.1. LIFTING POINTS FOR HAND WINCH OR HYDRAULIC JACK
Jack point for machine

frame front l. h. s.

frame rear l. h. s.

frame front r. h. s.
SRM 500 BA 6449 C55

frame rear r. h. s.
C56 BA 6449 SRM 500
14.2. LIFTING POINTS FOR CRANE
• The machine is in “machine shut down” mode – see chapter 11.

frame front l. h. s.

frame rear l. h. s.

frame front r. h. s.

frame rear r. h. s.
SRM 500 BA 6449
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 Emergency

SRM 500 BA 6449 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.
• 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 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).
ATTENTION: Extinguishing agent may freeze! Please observe funcitonal range

(temperature range) instructions of the producer!
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 6449 SRM 500
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 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.
SRM 500 BA 6449 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 at the moment in a critical position, as, e.g., in a tunnel, on a bridge
etc., where immediate stopping would endanger the crew, leave this area as soon as
possible.
• Stop the machine as soon as possible, secure it against rolling away and start fire
fighting as „first fire extinguishing 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
- Ascents and descents to the machine
- Roof lights, if existing – mind the catenary!!
- Slide windows
- Windows with emergency exits – if provided
- Windows that have been smashed with the life hammer.
• If necessary, send for fire fighting brigade and ambulance.

• If necessary, provide first aid.
D4 BA 6449 SRM 500

Machine Number: 6449, 6450: SRM 500 BA 6449

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SRM 500 BA 6449

Machine number: 6449, 6450

Copyright © 2014 by Plasser & Theurer

The operational labelling (machine weights, brake weights, line categories,

OPERATING MANUAL SECTIONS

Manufacturer’s name and address

Section allocation of illustrations

Outline of operating processes

Fire protection by the operating organisation

MANUFACTURER’S NAME AND ADDRESS ..................................................................... 1

Manufacturer’s name and address

Service information SI-0300-01

Service information SI-0400-04

Machine number: 6449 6450

GENERAL DESCRIPTION FOR THE OPERATION, MAINTENANCE, PERIODICAL CHECKING

Plasser & Theurer

SAFETY GUIDELINES FOR PREPARING REPAIR WORK

In working mode, the danger zone of the machine is a prohibited area!

 Deactivate hydraulic pressure (visual check of the pressure gauge reading).

 Turn off the engine!

 In working mode, the working area is again prohibited!

SAFETY GUIDELINES FOR PREPARING REPAIR WORK

In working mode, the danger zone of the machine is a prohibited area!

PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS!

 Deactivate hydraulic pressure (visual check of the pressure gauge reading).

 Turn off the engine!

 In working mode the working area is again prohibited!

Sand removal machine SRM 500

AIR CONDITIONING DEVICE

Conveying channel hinged cardanically

STEEP CONVEYOR BELT

Belt width 800 mm

Belt width 800 mm

RAIL FASTENING BRUSHES

Operating pressure 6,5 - 7,2 bar

Main brake pipe 5 bar

Direct-acting brake one circuit brake with

Indirect-acting brake control valve DB60

Parking brake spring loaded brake

Brake blocks 1 no. per wheel

Shunting humping and pushing off PROHIBITED

Transfer in train formation ONLY when engine is off

FIRE EXTINGUISHER 1 nos. in total, type PD6G

FIRST AID BOX 1 no. in total

LIFE HAMMER 1 nos. in total

LIMIT VALUES FOR TRANSFER MODE:

# Parameter Dimension Limit

1 Smallest practicable horizontal radius m 190

LIMIT VALUES FOR WORKING MODE:

# Parameter Dimension Limit

1 Smallest practicable horizontal radius m 120

ENGINE, GEARBOX, PUMPS ARRANGEMENT

CHARACTERISTIC FEATURES OF THE MACHINE

INDIRECT ACTING BRAKE

DIRECT ACTING BRAKE

BRAKE CYLINDERS – BRAKE BLOCKS

Photos of the machine including

the names of the operating elements and

components as far as they are relevant for

operating the machine

1= Engine control desk B5

1= Brake lever for direct-acting brake

1= Key-operated switch, on-board supply "OFF - ON" (main battery switch)