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Société des Anciens Etablissements L.GEISMAR
Boite Postale 50327 5 rue d'Altkirch
68006 COLMAR CEDEX FRANCE
Tél : +33 (0) 3 89 80 41 90 - Fax : 33 (0) 3 89 80 42 28
E-mail : sav@geismar.com
OPERATION & MAINTENANCE INSTRUCTIONS
TRACK BRUSHING TOOL
Model
BRV
Type
GB
Société des Anciens Etablissements L.GEISMAR
113 bis, avenue Charles de Gaulle
92200 NEUILLY SUR SEINE
Tél : +33 (0)1 41 43 40 40
E-mail : geismar@geismar.com
- Fax : 33 (0) 1 46 40 71 70
H110200_0118
Code :
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Chapters
Table of Contents
Summary of Contents for GEISMAR BRV
- Page 1 Société des Anciens Etablissements L.GEISMAR Boite Postale 50327 5 rue d’Altkirch 68006 COLMAR CEDEX FRANCE Tél : +33 (0) 3 89 80 41 90 - Fax : 33 (0) 3 89 80 42 28 E-mail : sav@geismar.com OPERATION & MAINTENANCE INSTRUCTIONS...
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Page 3: Table Of Contents
5 – 3 – 3 P ......................26 LACING ON TRACK UNDER LIVE OVERHEAD WIRE 5 – 4 HYDRAULIC ADAPTATION BETWEEN THE BRV AND THE RAIL-ROAD DIGGER ............27 5 – 5 STARTING WORK AT THE JOBSITE ..........................28 CHAPTER - 6 MAINTENANCE... - Page 4 6 – 1 GENERAL MAINTENANCE INSTRUCTIONS........................31 6 – 2 MAINTENANCE TIMETABLE ............................... 31 6 – 3 PREVENTIVE MAINTENANCE ............................31 6 – 4 GREASE EQUIVALENCE TABLE ............................32 6 – 5 WHEEL REMOVAL PROCEDURE............................33 6 – 6 PROCEDURE FOR REPLACING A BRAKE SHOE ......................34 6 –...
- Page 5 Marking H100572 STRIP OF PICTOGRAMS CODE H36803 TICKER H111862 TICKER H83014 IFTING POINT HOOK Page 5 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©...
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Page 7: Warnings
Warnings HE MANUFACTURER WILL ACCEPT NO LIABILITY IN THE FOLLOWING CASES • Improper machine use, contrary to the instructions given in the operation and maintenance manual. • Failure to comply with the periodical checking requirements stipulated by the man- ufacturer. •... - Page 8 Furthermore, modification of the machine without our written authorization could result in the loss of conformity with the relevant standards. The Group "GEISMAR" reminds you that accuracy in ordering of spare parts will enable prompt supply, and consequently ensure the productivity of your equipment.
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Page 9: Chapter - 1 Safety
It might refer to various options of the machine and illustrations included in this handbook may differ from actual details and accessories of your equipment. Basic equipment features may be similar, but the GEISMAR Group reserves the right to make improvements to the equipment. -
Page 10: General Safety Instructions
If the owner does not feel able to ensure correctly the aforementioned training of his personnel, the GEISMAR Group is at its disposal for any assistance about the content of this training. The training must cover the explanation with the various functions of the material, the instructions of use, maintenance and the safety regulations to be observed, as well as some practical exercises. -
Page 11: Special Safety Instructions
– Keep the switch box from water and humidity (might cause several accidents with harm to persons or material damages); – Do not bypass open fuses, respect the current limitation; – Periodically check the good state of battery contacts; Page 11 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 12: Equipment With Hydraulic Devices
The load should be permanently followed visually by the machine driver; if this is not possible, he shall be assisted by a maneuvering head. Never leave a hanging load unattended. Remain permanently aware of the possible consequences of inertia on a hanging load. Page 12 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 13: Chapter - 2 Presentation
2 – 1 General presentation Manufacturer Société des Anciens Établissements L. GEISMAR Boîte Postale 50327 5 rue d’Altkirch 68006 COLMAR CEDEX FRANCE Name of the equipmentt TRACK BRUSHING TOOL Model Type Page 13 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 14: General
The BRV works with wooden or concrete sleepers. The BRV is fitted to the end of the arm of a rail-road digger and pushed along by it. The tool is controlled directly via the digger controls. When going over level crossings and other track equipment, the digger will need to lift the BRV to avoid damaging the rubber tubes. -
Page 15: Chapter - 3 Technical Specifications
Standard brush tubes (other tubes on request) dia. 55 conventional indentations Fitted brush weight ~ 350 kg ONVEYOR Belt width 400 mm Overall length 2500 mm Thickness 180 mm Page 15 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... - Page 16 65 m YDRAULICS Operating pressure (motors) 180 bar Useful hydraulic oil flow rate (motors) 120 l/min Operating pressure (cylinders) 150 bar Useful hydraulic oil flow rate (cylinders) 30 l/min Page 16 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©...
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Page 17: Dimensions
3 – 2 Dimensions Page 17 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 18: Fitment Within Loading Gauges
BRV on or off the rails. Lower section: The BRV exceeds the temporary storage loading gauge (NF 58-002 Appendix D). When passing over track equipment, the digger driver must raise the BRV. Page 18... -
Page 19: Chapter - 4 Equipment
It sweeps the track and throws the ballast onto the conveyor by means of the tubes and as a result of its speed of rotation. Page 19 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 20: Conveyor
4 – 1 – 3 Manual parking brakes (standard) Two screw brakes hold the BRV in position while it is being placed on the track or when parked (on its own or coupled). *Option: Negative brake (see Chapter 7 - Optional equipment) Page 20 Société... -
Page 21: Rail Brush
4 – 1 – 5 Coupling bar The coupling bar connects the rail-road digger and the BRV. As supplied, it is designed for a "Rockinger dia. 40 mm" type coupling on the digger, with a height of between 1.1 and 1.3 metres above the rail. -
Page 23: Chapter - 5 Operating Instructions
Check there are no cut hoses (poor handling) or loose connectors. Visually inspect the tightness of the hydraulic circuit, particularly around the connectors, and the condition of the hoses, which must not show any traces of wear or cuts. Page 23 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 24: Handling And Transport
5 – 3 Handling and transport The BRV can be brought to a jobsite by rail or road. The BRV is unloaded and placed on an empty track using lifting equipment with a lifting capacity greater than 2700 kg. A central lifting bail [a] has been installed on the chassis for this purpose. -
Page 25: Transporting By Road
The BRV is towed by the rail-road digger at two levels: – the central lifting bail [a] of the BRV and the end of the rail-road digger boom; – the drawbar [f] of the BRV with the coupling bar of the rail-road digger. -
Page 26: Placing On Track Under Live Overhead Wire
Placing on track under live overhead wire The BRV can be placed on or taken off the track with a rail-road loader by lifting the machine 200 mm above the track while complying with the clearance height under overhead wires of 4280 mm (NF F 58-003). -
Page 27: Hydraulic Adaptation Between The Brv And The Rail-Road Digger
Connection is to A (for raising) and B (for lowering) of the chosen control valve. When starting the BRV, it is essential to set the pump flow rate to 120 l/min and 180 bars to supply the motors. Setting should preferably be performed by the digger manufacturer. -
Page 28: Starting Work At The Jobsite
– Run the digger for 15 to 20 mins to improve the fluidity of the hydraulic oil. – When placing the BRV on the track, apply the 2 manual parking brakes [3] so it stays in posi- tion. *Option: Negative brake (see Chapter 7 - Optional equipment) –... - Page 29 – Adjust the height of the brush [1] using the joystick which controls the hydraulic cylinders. – Move forward with the rail-road digger Speed must be between 0.5 and 1 km/h. Page 29 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©...
- Page 30 – The ballast is fed onto the whole of the conveyor [2] by the movement of brush [1] and is then ejected depending on which direction the belt is rotating. Page 30 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©...
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Page 31: Chapter - 6 Maintenance
Chapter 6 – Maintenance 6 – 1 General maintenance instructions Before starting operations, the parts which will be in contact with the BRV along with neighbouring areas must be cleaned carefully, to prevent impurities from getting into its mechanisms. 6 – 2 Maintenance timetable ... -
Page 32: Grease Equivalence Table
6 – 4 Grease equivalence table Grease used: IMPERATOR LC 3002 multifunction grease Brand Grease 1st fill IMPERATOR LC 3002 CASTROL LM GREASE SHELL ALBIDA HD 2 ENERGREASE LC 2 MULTIPLEX Page 32 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 33: Wheel Removal Procedure
To remove the wheel (only one person required), proceed as follows: - Unscrew M20 nut 4. - Remove washer 9. - Drift out shaft 2, holding wheel 1 to prevent it falling. Page 33 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 34: Procedure For Replacing A Brake Shoe
1 mm To change the shoe (only one person required), proceed as follows: – Release the brake fully. – Remove pin 6. – Retrieve washer 7. – Remove shoe 2. Page 34 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 35: Procedure For Removing The Conveyor
UNDERSIDE VIEW OF THE BRV 6 – 8 Wear on the inner rubber protection Carry out a visual check as this governs the acoustic comfort of the BRV. If faulty, please contact out after-sales service to carry out a repair. Page 35... -
Page 37: Chapter - 7 Optional Equipment
(red arrow). When the conveyor has been moved, tighten the nuts back up. UNDERSIDE VIEW OF THE BRV – Install the new housings fitted with brakes. Loosen the springs and tighten the M16 screws with their washers (framed in red). Page 37 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 38: Verification Procedure
A system is provided to check whether a brake adjustment is needed. The position of the pins (framed in red) shows how much the brakes are worn. POSITION BEFORE WEAR Page 38 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... - Page 39 (red arrow). These must come lightly into contact with the pin when a pressure of 100 bar is applied to the cylinder (note: the stops may be turned round if needed). Page 39 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©...
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Page 40: Maximum Wear
7 – 6 Grease equivalence table Grease used: IMPERATOR LC 3002 multifunction grease Brand Grease 1st fill IMPERATOR LC 3002 CASTROL LM GREASE SHELL ALBIDA HD 2 ENERGREASE LC 2 MULTIPLEX Page 40 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 41: Chapter - 8 Storage And Recycling
The equipment must be disposed of by an approved body complying with the local standards in force for recovery of waste. Page 31 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... -
Page 43: Chapter - 9 Spare Parts
Enter this information on your parts replacement request. 7 – 2 After-sales service contact details +33 (0) 3 89 80 41 90 +33 (0) 3 89 80 42 28 e-mail sav@geismar.com Page 33 Société des Anciens Établissements L.GEISMAR – Prohibited Reproduction ©... - Page 45 Société des Anciens Etablissements L.GEISMAR Boite Postale 50327 5 rue d’Altkirch 68006 COLMAR CEDEX FRANCE Tél : +33 (0) 3 89 80 41 90 - Fax : 33 (0) 3 89 80 42 28 E-mail : sav@geismar.com SPARE PARTS CATALOG...
- Page 47 BRUSH RAISE/LOWER CYLINDER ..................V10084_NO 38 OPTIONAL COMPONENTS NEGATIVE BRAKE ASSEMBLY WITH WHEELS .............. H111583_NO 42 NEGATIVE BRAKE ASSEMBLY B ..................H111826_NO 44 NEGATIVE BRAKE ASSEMBLY A ..................H111831_NO 46 HYDRAULIC BRAKE DIAGRAM ..................H111868_NO 48 TRACK BRUSHING TOOL TYPE BRV H110200_0118 SUMMARY...
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Page 49: Section A-Mechanical Components
Section A–Mechanical Components... -
Page 50: Rail Brush
Item Qty Description Code 07/17 RAIL BRUSH H110200_NO MECHANICAL ASSEMBLIES ..................H110202_NO HYDRAULIC EQUIPMENT..................H110203_NO COUPLING BAR......................H103160 HYDRAULIC CONNECTION..................H110213_NO SHAFT PIN ......................... D01074 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 52: Mechanical Assemblies
Item Qty Description Code 09/17 MECHANICAL ASSEMBLIES H110202_NO ARM..........................H110315 BRUSH SHAFT ......................H110216_NO FRONT FITTED COVER ....................H110111 RUBBER PROTECTION ....................H110155_NO BELT CONVEYOR ..................... D20357 FRONT WHEEL COVER....................H110220_NO REAR RIGHT WHEEL COVER ..................H110221_NO REAR LEFT WHEEL COVER ..................H110222_NO RIGHT COVER......................H111858 LEFT COVER ...................... -
Page 54: Brush Shaft
Item Qty Description Code 07/17 BRUSH SHAFT H110216_NO BRUSH SHAFT ......................D20355 RUBBER TUBE ......................D20356 HOSE CLIP......................... D20354 OPTION HIGH STRENGTH RUBBER TUBE ................D20435 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 56: Rubber Protection
Item Qty Description Code 09/17 RUBBER PROTECTION H110155_NO FRONT RIGHT SIDE SKIRT ..................H110116 FRONT SKIRT......................H110119 REAR RIGHT SIDE SKIRT..................H110115 FRONT LEFT SIDE SKIRT..................H110160 REAR LEFT SIDE SKIRT ................... H110158 BOLT .......................... C02662 SCREW ........................C00341 WASHER ........................C01022 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 58: Front Wheel Housing
Item Qty Description Code 07/17 FRONT WHEEL HOUSING H110220_NO FRONT HOUSING......................H110128 FITTED NON-INSULATED WHEEL D190 ..............H00108 INNER SECTION KIT ....................H21851 SCREW ........................C00396 WASHER ........................C01818 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 60: Rear Right Wheel Housing
Item Qty Description Code 07/17 REAR RIGHT WHEEL HOUSING H110221_NO REAR RIGHT HOUSING....................H110199 FITTED NON-INSULATED WHEEL D190 ..............H00108 INNER SECTION KIT ....................H21851 SCREW ........................C00396 WASHER ........................C01818 SUPPORT ........................H110201 PILOT .........................H110224 SCREW ........................C00343 NUT ..........................C02608 WASHER ........................C01036 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n°... -
Page 62: Rear Left Wheel Housing
Item Qty Description Code 07/17 REAR LEFT WHEEL HOUSING H110222_NO REAR LEFT HOUSING ....................H110198 FITTED NON-INSULATED WHEEL D190 ..............H00108 INNER SECTION KIT ....................H21851 SCREW ........................C00396 WASHER ........................C01818 SUPPORT ........................H110201 PILOT .........................H110224 SCREW ........................C00343 NUT ..........................C02608 WASHER ........................C01036 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n°... -
Page 64: Baseplate Brush
Item Qty Description Code 06/17 BASEPLATE BRUSH H110123_NO SUPPORT ........................H110124 RUBBER TUBE ......................H111370 HOSE CLIP......................... D20354 SHAFT PIN ......................... D01075 QUICK LINK .......................D06929 CHAIN LEN. 1000....................... D01197 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 66: Manual Parking Brake
Item Qty Description Code 04/17 MANUAL PARKING BRAKE H111183_NO KNOB.......................... H38290 BRAKE SHAFT......................H37715 SPLIT PIN........................C01179 BRAKE SHOE ......................H82317 WASHER ........................C01040 SPLIT PIN........................C01158 SCREW ........................C00331 WASHER ........................C01816 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 68: Hydraulic Connection
Item Qty Description Code 09/17 HYDRAULIC CONNECTION H110213_NO QUICK-RELEASE HALF-COUPLER 3/4"..............DD483910 PLUG .......................... DD483911 QUICK-RELEASE HALF-COUPLER 3/4"..............DD483810 PLUG .......................... DD483811 1" FEMALE COUPLER....................DD483931 PLUG .......................... DD483930 1" MALE COUPLER ....................DD483830 PLUG .......................... DD483829 MALE UNION ......................D00210 THREADED REDUCER ..................... D00253 HYDRAULIC HOSE LEN. -
Page 71: Section B-Hydraulic Components
Section B–Hydraulic Components... -
Page 72: Hydraulic Equipment
Item Qty Description Code 07/17 HYDRAULIC EQUIPMENT H110203_NO HYDRAULIC DIAGRAM ..................... H110217_NO MOTOR HYDRAULIC CIRCUIT ................. H110218_NO BRUSH RAISE/LOWER HYDRAULIC CIRCUIT............H110219_NO BRUSH RAISE/LOWER CYLINDER ................V10084_NO HYDRAULIC MOTOR....................D20351 HYDRAULIC MOTOR....................D20352 FITTED HYDRAULIC UNIT ..................D20360 CONTROL UNIT......................D19878 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 74: Hydraulic Diagram
04/17 HYDRAULIC DIAGRAM H110217_NO *IF YOUR BRV IS FITTED WITH NEGATIVE BRAKES, REFER TO THE HYDRAULIC DIAGRAM (H111868) FOR OPTIONAL COMPONENTS IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... -
Page 78: Motor Hydraulic Circuit
Item Qty Description Code 09/17 MOTOR HYDRAULIC CIRCUIT H110218_NO FEMALE HYDRAULIC COUPLER ................DD483931 PLUG .......................... DD483930 MALE COUPLER......................DD483830 PLUG .......................... DD483829 SWIVELLING COUPLING ..................D00074 DOUBLE UNION ....................... D12211 SWIVELLING BRACKET....................D00119 MALE UNION ......................D00210 THREADED REDUCER ..................... D13643 EQUAL T ........................ -
Page 80: Brush Raise/Lower Hydraulic Circuit
Item Qty Description Code 04/17 BRUSH RAISE/LOWER HYDRAULIC CIRCUIT H110219_NO QUICK RELEASE HALF-COUPLER ................DD483910 PLUG .......................... DD483911 COUPLING ......................... DD483810 PLUG .......................... DD483811 SWIVELLING COUPLING ..................D00071 DOUBLE UNION ....................... D11520 REDUCER ........................D10362 EQUAL T ........................D00301 MALE UNION ......................D09858 HYDRAULIC HOSE LEN. -
Page 82: Brush Raise/Lower Cylinder
Item Qty Description Code BRUSH RAISE/LOWER CYLINDER V10084_NO NOTA : for cylinders spare parts give the indication of the code number incrusted on the cylinder body, then refer to the following table for reference batches of parts (A, B, C,..) CODE DE L’ARTICLE ... -
Page 85: Optional Components
Optional Components... -
Page 86: Negative Brake Assembly With Wheels
Item Qty Description Code 12/17 NEGATIVE BRAKE ASSEMBLY WITH WHEELS H111583_NO PILOT .........................H110224 NUT ..........................C02608 SCREW ........................C00343 WASHER ........................C01036 NEGATIVE BRAKE ASSEMBLY B................H111826_NO NEGATIVE BRAKE ASSEMBLY A................H111831_NO SUPPORT ........................H110201 HYDRAULIC BRAKE DIAGRAM ................H111868_NO IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n° of the machine - Serial number - Order n°... - Page 88 Item Qty Description Code 12/17 NEGATIVE BRAKE ASSEMBLY B H111826_NO FITTED WHEEL ......................H00108 INNER SECTION KIT ....................H21851 SCREW ........................C00393 WASHER ........................C01818 CYLINDER........................D20468 SPLIT PIN........................C02667 ADJUSTABLE STOP....................H111830 WASHER ........................C01035 SCREW ........................C00330 ADAPTER COUPLING ....................D20465 COMPRESSION SPRING ..................D20469 WASHER ........................
- Page 90 Item Qty Description Code 12/17 NEGATIVE BRAKE ASSEMBLY A H111831_NO FITTED WHEEL ......................H00108 INNER SECTION KIT ....................H21851 CYLINDER........................D20468 COMPRESSION SPRING ..................D20469 NUT ..........................C00121 WASHER ........................C01038 SPLIT PIN........................C02667 WASHER ........................C01818 SCREW ........................C00393 WASHER ........................C01035 SCREW ........................C00330 NUT ..........................C00085 ADAPTER COUPLING ....................D20465 NEGATIVE BRAKE GUIDANCE ASSEMBLY ............H111832...
- Page 92 Item Qty Description Code 01/18 HYDRAULIC BRAKE DIAGRAM H111868_NO HYDRAULIC HOSE WITH FITTINGS LEN. 2500 ............D15566 HYDRAULIC HOSE WITH FITTINGS LEN. 4500 ............D16213 REVERSED T......................D00563 SWIVELLING BRACKET....................D00116 MALE UNION ......................D00190 PLUG .......................... D19598 PIPE CLAMP ......................D00606 SCREW ........................C00339 IMPORTANT : To allow prompt and correct delivery of spare parts, always state : Fabrication year and n°...