Operating Instructions
Contents
1. RMAQ U i Catalogue No RS200H Operating and Maintenance Instructions Rail Scrubbing Machine Permaquip Ltd Brierley Industrial Park Stanton Hill Sutton In Ashfield Nottinghamshire NG17 3JZ Tel 44 0 1623 513349 Fax 44 0 1623 517742 www permaquip co uk sales permaquip co uk Contents 10 17 12 13 HS200lss7 Contents Introduction and Specifications Benefits of using the RS200H Warnings and Safety Instructions Risk Assessment Features of the 5200 How does the RS200H unit work Starting the 5200 Using the RS200H Further notes Maintenance Instructions General Maintenance Details General Maintenance Details 3 Sep 07 Introduction The RS200H unit has been designed to allow rapid and easy cleaning of railhead in situations where train borne equipment is either too expensive or impractical The RS200H unit is for use by a single operator on short stretches of track where a clean rail head is required quickly The RS200H unit must only be used by correctly trained personnel under the supervision of a properly certified individual and all relevant Network Rail standards and safety requirement must be strictly adhered to at all times Any and all adjustments to the equipment must be carried out in a position of safety and never on or near the line Specifications Dimensions Height handle upright 985mm Width 335 5 Length 1140mm Weight 47kg Noise emissio2. Before starting the RS200H ensure that the brush operating lever is in the lifted position as shown below The starting procedure can now commence Before attempting to start the engine Turn the engine on off switch to ensure that the brush operating lever is the on position in the lifted position Push the fuel switch to the on position Hold the dead man s lever If starting the engine from cold push Set the throttle lever to 34 s the choke lever to the on position Pull the engine start cord sharply Located above the fuel switch RS200Iss7 3 Sep 07 Using the RS200H Once the engine has started leave the throttle lever in the 34 s position and leave the choke in on position if started cold until the engine has warmed up enough to maintain idle speed Switch the choke to the off position when the engine has warmed up Never attempt to start the engine if the scrubber wheel is in contact with the rail head Increase the speed of the engine to normal running speed by moving the throttle to the hare position Move the brush operating lever to the forward position to allow the wheel to come into contact with the rail head The operator must ensure that he has a tight hold on the machine when lowering the brush as it will try to drive along the track The operator can now move slowly down the track length to be treated moving in both directions if necessary to remove the contaminants The engine c
3. hour intervals whichever occurs first Task First Every 3 Every 6 Annually month months months or or 300hrs or 20hrs 50hrs 100 hrs Check level Change SS Check element Change o o os Change M O O es O l Spark arrester Clean Valve clearance Checkadust J J 0 ES Check Change Check Change oT If necessary CCE JV Check Change CT If necessary CFE J Check Change CT If necessary Drive belt Check Change Engine Oil In areas where extremes of temperature are likely to be encountered please consult the engine manufacturers literature NOTE SAE 10W 40 is recommended for general use Engine oil capacity for the GXV 160 is 0 65 litres refer to the engine manufacturers maintenance manual for details of how to check oil level top up oil and drain the sump to replace with fresh oil NOTE The engine manufacturer s maintenance manual is supplied with this manual NOTE An operator trained in the use and maintenance of this machine can carry out the tasks shown in red All other tasks should be carried by a qualified fitter or Tracman service engineer RS200Iss7 3 Sep 07 General Maintenance Details Exhaust Petrol cap Air Filter cover A Fuel Safety Fill the engine with 4 stroke fuel only Fill in a well ventilated area Use a petroleum approved c
4. 18 m B c T 9 9 A N y ws AL DN he 1569 77 c ENS MN A d S 6 _ T e Li ME 2 2 SECTION D amp P SCALE 1 2 25 6D VA NG SSS yyy 6 SAVES A egi E 20 43 8 2 09 09 SECTION A A SCALE 1 2 RS200Iss7 3 Sep 07 14 979 General Maintenance Details Recommended spares O O Description SCN ff 1 RS2001A4 ROLER ae O 2 is 2 RS200 01B 2 3 RS2000 SCRUBBER CHASSIS 1 4 RS200 03 SCRUBBER LOWER HANDLE 1 1 RS200 15A SCRUBBER CARRY 2 6 RS20045B SCRUBBER CARRY HANDLERH 2 ANTI VIBRATION MOUNT ASSY BRUSH DRIVE SHAFT BRUSH BEARING HOUSING RS200 23 71 X1 SPA 1108 PULLEY RS200 23A V BELT A730MC A27 5MN 13X700LI RS200 24 SWING ARM RS200 25 MOTOR PLATE BELT GUARD PULLEY SPACER WASHER BRUSH SPACER WASHER BRUSH RETAINING WASHER SPRING GUIDE ACTUATING LINK ACTUATING ARM RS200 42 SPRING GUIDE RS200 45 ACTUATING HANDLE 26 a RS200 56 50MM SPACER 2 RS200 57 20MM SPACER 9 RLS4Z LINKS10 BEARING RS200 HA1 HANDLE BAR UPPER THROTTLE CONTROL LEVER HANDLE BOLT BAR TRI HAND WHEEL BEARING 690522 2 BEARING 690577 3 6 DIA X 2 BRUSH 6 X 60 LG CAPSCREW SC860CSK M8 X 60 LG CSK SCREW M8 X 25 LG CSK SCREW M10 FLAT WASHER M10 NYLOC NUT M10 X 60 LG BO
5. LT M16 NYLOC NUT RS200Iss7 3 Sep 07 15 N M IN Jo IN IN N IN IN N IN IN n2 IN C2 A A A Q Q A gt A General Maintenance Details Recommended spares lemNo DrgNo J SC615CAP M6 X 15 CAPSCREW 52 SC1016SB M10 X 16 LG SHOULDER BOLTS 53 LINKS12 RETURN SPRING RETURN SPRING sss M8 X 40 Lg SET SCREW M8 SPRING WASHER NYLOC NUT M8 M8 NYLOC NUT SPWR M6 M6 SPRING WASHER 60 NYLOC NUT M6 M6 NYLOC NUT 61 DWL 6X15 6 DIA X 15 LG DOWEL SC635CAP M6 X 35 LG CAP SCREW 63 SCBACAP MBX40LGCAPSCREW 4 64 SCBI2CAP MBXI2LGCAPSCREW 00 65 FB1040 MIOX40LGBOLT o Z 0 S o 66 NUT MIOLOCK MIOLOCKNUT 0 o 68 GXi HONDAGX160 ENGINE 1 iN 4 PERMAQUIP For further information and spares contact Permaquip Ltd Brierley Industrial Park Stanton Hill Sutton In Ashfield Nottinghamshire NG17 3JZ Sheffield 59 5JF Tel 01623 513349 Fax 01623 517742 www permaquip co uk sales permaquip co uk RS200Iss7 3 Sep 07 16
6. RS200H unit is pushed manually along the rail to be cleaned The cleaning brush mounted beneath the unit scrubs the rail as the unit is pushed along The brush is driven by the engine drive shaft The engine incorporates an electronic cut off feature to ensure that the rotation of brush is stopped when the handle is released NOTE Do not attempt to place the RS200H unit on the track or dismount it whilst the engine is running The RS200H unit is a petrol driven unit and requires checking and maintenance at each use as well as regular maintenance at specified intervals see the maintenance section for details Mounting and Dismounting the RS200H Note Although the RS200H has rollers fitted with ball races it cannot be pushed along the ground The RS200H has a weight of 47kg and as such should only be lifted by two people Once on the track the handle should be extended and the clamping screws tightened and locked in the upright position The machine must be lifted Once on the track lift the handle onto the track by 2 men and tighten the two locking knobs using the lifting handles RS200Iss7 3 Sep 07 Starting the RS200H Important Before starting the engine the user is responsible for checking the level of oil and the level of the fuel Ensure that only UNLEADED fuel is used N w Ensure that relevant safety equipment has been provided and is in use viz Safety glasses ear defenders dust mask safety hat etc
7. an be stopped at any time simply by releasing the dead man s lever This action causes the engine to stop The machine is fitted with two 12v 25watt lights This is to facilitate rail scrubbing when used at night The lamps are powered whilst the engine is running RS200Iss7 3 Sep 07 Further notes NOTE Before attempting to treat a section of rail ensure that all relevant Network Rail and local instructions are in force and are being adhered to e lf at any time it is required that the unit be pushed along the track without the need to clean the rail the rail scrubber brush should be lifted back up to prevent any damage occurring to the brush by sliding it along the track with the engine stationary This can be performed either with the engine running or not If the distance involved is excessive then the engine should be stopped e When dismounting the unit for removal from site the engine should be stopped and a second operator called to help lift the unit from the track e Never lift the unit from the track whilst the engine is running as this could cause instability e lf at any time the unit stops do not attempt any repairs whilst the unit is on or near the line Always remove the unit to a position of safety to carry out any maintenance or adjustments RS200Iss7 3 Sep 07 Maintenance Instructions Schedule of Maintenance Engine Regular service should be carried out at every indicated month or operating
8. ator to eliminate the need to bend over the unit during operation The unit has been designed with a wide handle to allow for two handed safe operation giving good control over the unit in use The operating parts are vibration isolated from the operator contact to reduce operator fatigue and discomfort RS200Iss7 3 Sep 07 Warnings and Safety instructions Read these instructions carefully before operating maintaining or servicing this product Please keep these instructions in a safe accessible place Read and observe the following Always weara dust mask safety precautionsand wamings safety gogglesand ear Careless or improper use of this di protection Weara helmet equipment may result in serious or where applicable fatal injury WARNING CAUTION Indicates instant possibility of Indicatesa possibility of severe personal injury or loss of personal injury orequipment life if instructions are not damage if instructions are not followed followed Operator Safety Tool Safety Always read the instructions carefully so as Inspect the entire piece of equipment to avoid any injury or damage when before use unfamiliar with this equipment Replace damaged components lubricate Always wear heavy clothing boots and where necessary and ensure that all gloves Do not wear loose clothing short fasteners are secure pants sandals etc and ensure that long hair Use only accessories that have been is tied up above
9. ive Belt The drive belt should be checked after the first month of use and replaced ona quarterly basis thereafter Unscrew and remove the guard covering the drive belt Ensure that there is only around 12 of lateral movement on the belt a m Remove the guard to expose Remove the two grubscrews the drive belt to check for retaining the taper lock bush excessive play on the drive pulley screw the grubscrews into the Remove the taper lock bush jacking holes to release the and replace the belt Re fitting taper lock bush is a reversal of this procedure Scrubber Brush Check and replace when necessary Use the spanners supplied to remove the retaining lock nut Remove the wheel and refit the new one NOTE lt is essential that the above maintenance schedules are adhered to in order to keep the RS200H unit in good running order This will ensure that the RS200H unit will perform well each time it is used RS200Iss7 3 Sep 07 General Maintenance Details Recommended spares J 23 z FAN a We s ut 6 CN AES s MX t PULL START RECOIL START 28400 2H8 0237 A HS200lss7 3 Sep 07 General Maintenance Details 9 Hecommended spares 16500 28 821 if J P P d p oe A S x A fi St 4 7 NA t Se j He f 2 LM F ed ff NN LY 0 7 E AY if YTS ff SE M M MN dd HNZ Z j EN N
10. ns 75 5dBA no load adjacent to operator 89dBA full load adjacent to operator Vibration readings Aeq 38 42ms Time to reach EAV Exposure Action Value 42mins man per day Time to reach ELV Exposure Limit Value 2hrs 50mins man per day See www hse gov uk vibration for further information Engine Type Honda GX160 Power 4kW 5 5hp at 3600rpm Engine oil capacity 0 651 Engine oil type SAE 10W 30 Fuel tank capacity 2litres Fuel type Unleaded Spark plug NGK BPH5ES RS200Iss7 3 Sep 07 Benefits of using the RS200H Rail Scrubber Immediate low cost solution to contaminated rail heads ensuring a clean line in minutes The RS200H is fitted with two 25watt 12volt lamps that make working in the dark much easier The RS200H unit is lightweight easy to handle is self powered and is easily operated and maintained by a single operator NOTE Due to HSE lifting requirements the unit will need two operators in order to lift the unit onto the track initially but in an emergency the unit is light enough to be removed from the track by one operator The RS200H unit is safe to operate incorporating a dead man s handle to ensure that the wire scrubber brush is stopped quickly when the unit is de activated The working parts of the scrubber are covered to ensure that the operator is protected from all moving parts when the unit is in operation All the controls are mounted within easy reach of the oper
11. ontainer for the fuel Do not smoke or allow others to smoke when using or refueling the machine When refueling stop the engine and allow it to cool before filling Clean up all fuel spills before starting the engine Air filter cleaning The air filter should be checked at every use and if found to be obstructed with debris should be replaced The filter should be replaced in any case every 3 months or every 50 hours running see the engine manufacturers maintenance manual for details of how to replace the air filter NOTE If the RS200H unit is used in a very dusty environment it may be necessary to check and replace the air filter more frequently as the cleanliness of the air filter has a direct effect on the efficiency of the engine Spark Plug For location of the spark plug and details of setting see the engine manufacturers maintenance manual The spark plug setting should be checked replaced every 6 months or every 100 hours running All these items require to be inspected at least once a year see the engine manufacturers maintenance manual for details Lamp Bulb The lamp bulbs should be checked at each use by starting the engine If necessary the bulbs can be replaced by peeling back the rubber outer to release the lens and parabola This will expose the bulb bayonet fitting Replace the bulb with our part number RS200 LUB and refit the lens and parabola RS200Iss7 3 Sep 07 General Maintenance Details Dr
12. shoulder length recommended by the manufacturer Do not operate this equipment when tired ill Failure to do so could result in damage to or under the influence of alcohol drugs or the product and may invalidate the medication warranty Never allow an inexperienced person to operate this equipment VN WARNING Keep all carrying handles and levers free from oil Never modify the product in any way Do not Keep hands away from the wire brush when use your equipment for any job other than for it is rotating Ensure that it has stopped which it is intended rotating before touching the wire brush Never use a larger diameter wire brush than Maintenance safety specified for use with this equipment Ensure that the wire brush being used is free e Maintain according to the manufacturers from damage recommended procedures Wear safety goggles when operating the Use only genuine replacement machine components as recommended by the manufacturer Transport and Storage e Before moving the product ensure that the wire brush has stopped rotating e Afteruse clean the equipment and accessories and store in a dry place RS200Iss7 3 Sep 07 Features of the RS200H Dead man slever Throttle Lifting handle Scrubbing wheel Petrol cap Honda engine Rear light Air filter NE m 4 Ji IT WHA Brush operating lever Base frame Front light RS200Iss7 3 Sep 07 How does the RS200H Work The
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