USP 2000 SWS: Universal-Schotter Planier Maschine

USP 2000 SWS BA56658
USP 2000 SWS

UNIVERSAL-SCHOTTER PLANIER MASCHINE
Operating instructions
Machine number: 56658-56684

BA56658 USP 2000 SWS
Copyright © 2021 by Plasser India
All rights reserved, particularly the right to produce copies, to distribute these copies, as
well to translate the work.
RECORD OF AMENDMENTS
No. Date Reviser Reason of revision Page
1.0 March 21, 2021 Pawan 1st version -

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.
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 -0400-03
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 organization

PART D Preventive fire protection measures
Early fire hazard detection
Temperature monitoring system
Emergency plan
How to act in case of fire
TABLE OF CONTENTS
CERTIFICATE ............................................................................................................................................ 1
MANUFACTURES NAMEPLATE ........................................................................................................... 2
FRAME NUMBER ...................................................................................................................................... 3
SERVICE INFORMATION......................................................................................... SI 0 3 0 0 -01
SERVICE INFORMATION......................................................................................... SI 0 4 0 0 -03
PART A
TECHNICAL DATA.................................................................................................................A1-A8
THRESHOLD VALUES FOR TRANSFER MODE...................................................................... A9
THRESHOLD VALUES FOR WORKING MODE........................................................................................................ A9
OUTLINE DRAWING ............................................................................................................... A10
MACHINE CHARACTERISTICS.........................................................................................A11-A14
PART B
6156B008 OVERVIEW: L.H.S. OF MACHINE......................................................................................................... B1
6156B366 OVERVIEW: REAR PART OF CABIN .............................................................. B2
6156B068 OVERVIEW: ENGINE CONTROL PANEL B5…………….................................................. B3
6156B076 ENGINE CONTROL PANEL – SECTION “A“………………............................................... B4
6156B079 ENGINE CONTROL PANEL - SECTION “B“ .................................................... B5
6156B078 ENGINE CONTROL PANEL - SECTION “C“.................................................... B7
6156B073 ENGINE CONTROL PANEL - SECTION “D“.................................................... B8
6156B072 ENGINE CONTROL PANEL - SECTION “E“ .................................................. ..B9
6156B071 ENGINE CONTROL PANEL - SECTION “F“.................................................................................. B10
6156B064 DRIVE CONTROL PANEL B6...................................................................................... B11
6156B065 BRAKE CONTROL PANEL REAR................................................................................ B12
6156B063 PRESSURE INDICATION INSTRUMENT...................................................... B13
6156B388 L.H.S. SECTION OF CABIN ………................................................................ B14
4689B020 AIR CONDITION CONTROL BOX…………………......................................................................... B15
6156B361 REAR L.H.S. SECTION OF CABIN ................................................................ B16
6156B373 REAR R.H.S. OF CABIN: OVERVIEW.................................................................................... B17
6156B340 OVERVIEW: FRONT PART OF CABIN.......................................................... B30
6156B341 WORKING CONTROL PANEL B3 (L.H.S.)………...................................................... B31
6156B393 FRONT R.H.S. SECTION OF CABIN .............................................................B33
6156B041 WORKING CONTROL PANEL B4 (R.H.S.) ………………….. .......................B34
6156B041_1 WORKING CONTROL PANEL B4 (R.H.S.) ……………….. .......................B35
6156B036 DRIVING CONTROL PANEL B8…………………………….......................B36
5922B031 PRESSURE INDICATION INSTRUMENT PANEL………………………… B37
5773B003_1 BRAKE CONTROL PANEL FRONT..............................................................B50
6156B085 AREA OF CABIN PLATFORM....................................................................B51
6156B081 MACHINE PLATFORM - AREA OF SAFETY BARS L.H.S.........................B52
6156B034 MACHINE PLATFORM - AREA OF SAFETY BARS R.H.S. .......................B53
6156B089 FRONT PART OF MACHINE .....................................................................B60
6156B097 BALLAST HOPPER AREA .........................................................................B62
6156B096 AREA OF GRADER PLOUGH.....................................................................B63
6156B093 MACHINE PLATFORM - FRONT ...............................................................B64
6156B003 FRONT L.H.S. PART OF MACHINE...........................................................B65
6156B377 MACHINE L.H.S. – AREA OF FRONT BOGIE ...........................................B66
6156B002 MACHINE L.H.S. - SHOULDER PLOUGH AREA.......................................B67
6156B307 MACHINE L.H.S. –
HY. SOLENOID VALVES SHOULDER PLOUGH L.H.S.............................B68
6156B092 AREA OF AXLE 1.......................................................................................B69
5773B096 BALLAST CHUTE SECTION......................................................................B70
6156B006 MACHINE L.H.S. - CENTRE PLOUGH AREA............................................B71
6156B306 MACHINE L.H.S. - HY. SOLENOID VALVES CENTRE PLOUGH .............B72
6156B012 MACHINE L.H.S. - STEEP CONVEYOR BELT AREA................................B73
6156B011 MACHINE L.H.S. - SWEEPER SYSTEM AREA .........................................B74
6156B100 HY. SOLENOID VALVES SWEEPER SYSTEM .........................................B75
6156B013 MACHINE L.H.S. - ROPE WINCH AREA ...................................................B76
6156B099 AREA OF AXLE 3.......................................................................................B77
6156B346 MACHINE L.H.S. – AREA OF REAR BOGIE...............................................B78
6156B106 MACHINE L.H.S. – AREA OF RAIL FASTENING BRUSHES ....................B79
6156B018 MACHINE L.H.S. - DIESEL TANK AREA ...................................................B80
6156B016 REAR L.H.S. PART OF MACHINE............................................................. B90
6156B351 MACHINE L.H.S. - AIR DRYER UNIT AREA.............................................. B91
6156B033 FRONT R.H.S. PART OF MACHINE.......................................................... B92
6156B382 MACHINE R.H.S. – AREA OF FRONT BOGIE .......................................... B93
6156B032 MACHINE R.H.S. - SHOULDER PLOUGH AREA...................................... B94
6156B310 MACHINE R.H.S. –
HY. SOLENOID VALVES SHOULDER PLOUGH R.H.S. ........................... B95
6156B029 MACHINE R.H.S. - CENTRE PLOUGH AREA ........................................... B96
6156B358 MACHINE R.H.S. - HY. SOLENOID VALVES CENTRE PLOUGH........... B100
6156B028 MACHINE R.H.S. - STEEP CONVEYOR BELT AREA............................. B101
6156B026 MACHINE R.H.S. - SWEEPER SYSTEM AREA ...................................... B102
6156B025 MACHINE R.H.S. - ROPE WINCH AREA ................................................ B103
6156B386 MACHINE R.H.S. – AREA OF REAR BOGIE........................................... B104
6156B107 MACHINE R.H.S. – AREA OF RAIL FASTENING BRUSHES ................. B105
6156B021 MACHINE R.H.S. - DIESEL TANK AREA ................................................ B106
6156B316 REAR R.H.S. PART OF MACHINE .......................................................... B107
6156B327 ENGINE ROOM R.H.S. ............................................................................ B108
6156B318 PUMP DISTRIBUTOR GEARBOX AREA................................................. B109
6156B294 HYDRAULIC TANK AREA, L.H.S............................................................. B110
6156B322 PUMP DISTRIBUTOR GEARBOX AREA, R.H.S. .................................... B111
6156B082 ENGINE COMPARTMENT AREA ........................................................... B112
6156B087 REAR SIDE OF MACHINE....................................................................... B113
PART C
1. OUTLINE OF OPERATIONAL PROCEDURES......................................................... C2
2. FACTORY FILLING OF OPERATING FLUIDS .........................................................C3
3. SAFETY REGULATIONS PRIOR TO COMMISSIONING THE MACHINE ................C4
4. GETTING MACHINE READY FOR OPERATION...................................................... C5
5. SAFETY REGULATIONS FOR OPERATING THE MACHINE .................................. C7
6. STARTING THE ENGINE........................................................................................ C10
7. SAFETY DEVICES.................................................................................................. C14
8. DRIVING ................................................................................................................. C29
9. WORKING ............................................................................................................... C36
10. MISCELLANEOUS .................................................................................................. C50
11. STABLING THE MACHINE ..................................................................................... C51
12. THE PARKING BRAKE ........................................................................................... C54
13. BEHAVIOUR IN FAULT CONDITIONS OF INDIVIDUAL
MACHINE COMPONENTS ..................................................................................... C55
14. LIFTING THE MACHINE ......................................................................................... C60
PART D
FIRE PROTECTION ......................................................................................................... D1-D4
BOGIE ADAPTATION MEASURES ............................................................................................... 1-24

GENERAL
Manufacturer’s name and address
Quality certificate
Manufacturer’s nameplate
Frame number
Service information SI-0300-01
Service information SI-0400-03

USP 2000 SWS BA56658 1
2 BA56658 USP 2000 SWS
MANUFACTURER’S NAMEPLATE:
Manufacturer’s nameplate is located on the left hand side of the machine.
USP 2000 SWS BA56658 3
FRAME NUMBER:
The frame number has been imprinted diagonally opposite on the buffer bar.

Frame number: 56658-56684
ANNOTATION: The certificate folder contains the most important certificates and
numbers.
SERVICE INFORMATION SI-0300-1
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 I n d i a P v t . L t d .
13th milestone, Mathura Road,
Gurukul Indraprastha Estate,
PO Amar Nagar, Faridabad - 121003
SERVICE INFORMATION SI-0400-3
SAFETY GUIDELINES TO PREPARE ANY REPAIR WORK ON THE MACHINE
□ In working mode the danger area of the machine is prohibited
Repair work on the machine must be carried out only by authorized and trained personnel.
PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS
Before carrying out any repair work on the machine the following safety instructions must be
observed:
□ Deactivate hydraulic pressure!
□ Deactivate the air system!
□ Protect the machine from breaking 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 works are carried out in closed workshops the batteries have to be
disconnected (machine without current). The battery terminals have to be
secured accordingly.
□ Furthermore, the machine crew and all persons having access to the machine
must be informed of the intended repair work.
□ A professionally competent person has to be chosen who will bear main

responsibility for the repair work to be carried out and supervise this work
according to all aspects of safety.
□ Furthermore, the machine crew has to be informed of the repair work completed
before the operating mode of the machine is restored. Only professionally
competent and trained persons are allowed to restore the working mode of the
machine!
□ In working mode the working area is prohibited again!

PART A
Technical data
Limit values
Outline drawing
Machine characteristics
Description of brakes
USP 2000 SWS BA56658 A1
TECHNICAL DATA
Ballast profiling machine USP 2000 SWS

Year of construction: 2021
GENERAL DATA
Outline drawing BR00.147-3
Cabins 1
DIMENSIONS
Length over buffer 19140 mm
Height above head of rail approx. 4265 mm
Overall width 3250 mm
UNDERCARRIAGE
Number of wheel sets 4
Distance b/w bogie pivots 11500 mm
Running wheel diameter 850 mm
Track gauge 1676 mm
A2 BA56658 USP 2000 SWS
WEIGHT
Total weight (empty) approx. 58 t
Total weight (loaded) approx. 80 t
FILLING QUANTITIES
Diesel fuel 1000 litres
Hydraulic oil 700 litres
ENGINE
Type BF08M1015CP
Output 440 kW at 2100 min-1
DRIVING UNIT
Kind of drive hydrostatic, acting on 4 axles
USP 2000 SWS BA56658 A3
ELECTRICAL EQUIPMENT
Power generation - engine 1 alternator
Alternator 28V DC, 140 A
BATTERIES
Starter for engine and system 4 nos. 12V DC batteries
110 Ah
AIR CONDITIONING DEVICE

Type Webasto Split-Air conditioning unit
SHOULDER PLOUGH
Shoulder angle adjustment range 0° to 45°
Slewing limitation 2500 mm
CENTRE PLOUGH
Type one-piece center plough
A4 BA56658 USP 2000 SWS
SWEEPER UNIT
Brush box with ballast handover
Directly onto cross conveyor
Directly onto steep conveyor
BALLAST HOPPER
With infinitely adjustable hopper floor conveyor vmax = 0.5 m/s
USP 2000 SWS BA56658 A5
BALLAST CHUTE
at the front end of the hopper floor conveyor
RAIL FASTENING BRUSH

in the area of axle #3
A6 BA56658 USP 2000 SWS
COMPRESSED AIR
Operating pressure 6.5 – 8.0 bar
Air compressor directly coupled to the engine 1 no. air compressor 600 cm3
Air reservoir 1 no. 100 litres & 1 no. 57 litres for direct brake
1 no. 100 litres for indirect brake
Air drier – for air compressor on engine 2-chamber drier 24 VDC, 100W
Operating pressure max. 10 bar
Main pneumatic through pipe 5 bar

On both sides 1 no. stop cock with hose and coupling
USP 2000 SWS BA56658 A7
BRAKE
Main pneumatic through pipe 5.0 bar

on both sides 1 no. stop cock with hose and coupling
Direct-acting brake two circuit brake with

brake valve (ZB11)
Indirect-acting brake control valve KE
Parking brake Spindle block, with hand wheel

acting on the rear bogie
Brake blocks
Type WN146-850.K-5
A8 BA56658 USP 2000 SWS
SAFETY
Shunting humping and pushing off PROHIBITED
Transfer in train formation ONLY when engine is off
FIRE EXTINGUISHER 1 no. in total

in the cabin
LIFE HAMMER 1 no. in total

in the cabin
FIRST AID BOX 1 no. in total

in the cabin
USP 2000 SWS BA56658 A9
THRESHOLD VALUES FOR TRANSFER MODE:
# Parameter Dimension Limit
Gauge mm 1676
1 Smallest practicable horizontal radius m 1520
120
2 Smallest practicable vertical radius m 500
3 Maximum practicable super-elevation mm 185
4 Maximum practicable gradient ‰ 180
35
(also maximum gradient for parking brake)
5 Maximum speed when self-propelled km/h 80
6 Maximum speed when towed km/h 90
7 Maximum load hauled ton 65
THRESHOLD VALUES FOR WORKING MODE:
Gauge mm 1676
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 185
5 Maximum working ramp gradient 1 1:100
6 Vertical curvature fault over a distance of 10 meters mm 50 (top to top)
A10 BA56658 USP 2000 SWS
OUTLINE DRAWING
USP 2000 SWS BA56658 A11
MACHINE CHARACTERISTICS
The Plasser USP 2000 SWS is a four-axle ballast distributor and regulator.
Equipped with:
□ an air conditioning system in cabin
□ an emergency brake device
□ an indirect brake
□ a direct brake
□ an EMERGENCY STOP device
□ a parking brake as a spindle hand brake
□ an water-cooled 8-cylinder diesel engine
□ a shoulder plough
□ a center plough
□ a sweeper system
□ a steep conveyor
□ a ballast hopper
□ a rail fastening brush
□ a hydrostatic drive unit
□ a program control
□ a mechanical hand pump for emergency
□ a main pneumatic through-pipe (5 bar)
□ buffer couplings on both sides
A12 BA56658 USP 2000 SWS
The drive engine is an water-cooled diesel engine, type BF8M1015CP, with an output of 440
kW at n= 2100 min-1.
The cabin is mounted in the area of the 3rd axle. The cabin is fitted with highly flame-
retardant materials and is perfectly sound proofed and heat insulated. The cabin houses
two driver’s desk. The driver’s desk is designed for one-man operation. The windows are
made of 14 mm safety glass.
A program control monitors and controls the work processes and is designed to largely
prevent operating errors.
The safety regulations for entering the cabin roof have to be adhered to -
- Danger from overhead line!
USP 2000 SWS BA56658 A13
DIRECT ACTING BRAKE
The direct-acting brake is designed as two-circuit brake and is operated by brake valve
ZB11. The direct-acting brake on the driver’s desk is actuated via a control lever.
INDIRECT ACTING BRAKE

The machine is equipped with a passive train brake. This consists of a control valve, type
KE, with changeover device ensuring that the machine may be braked by the traction
vehicle.
EMERGENCY BRAKE
The pull handle for the manual emergency brake is located at the driver’s desk. When the
pull handle is actuated, the mechanical emergency brake valve opens and air emanates
from the indirect brake pipe, the indirect brake valve responds and the indirect-acting
brake “APPLIES“.
Driving can be continued only when the pull handle has been restored by the key to
normal working position and the main air pipe has been refilled. Filling of the main air pipe
is effected via the indirect brake valve.
Attention:
The reason why the emergency brake had been actuated must be found!
Possible dangers and obstacles have to be removed before deactivating the
Emergency brake and continuing driving the machine.
A14 BA56658 USP 2000 SWS
PARKING BRAKE
The parking brake (stopping brake) is a mechanical system consisting of spindle block,
hand wheel, angular gear, etc.
There is no monitoring or indication of the parking brake status (APPLIED – RELEASED)!
This requires increased attention when using the brake.
Important:
Driving the machine with the parking brake “APPLIED” results in considerable
damage to the machine.
PNEUMATIC GAUGE
On the upper gauges of the rear driver's desk the pressure in the reservoir line is indicated
by the white pointer and the brake pressure of the direct-brake is indicated by the red
pointer.
The gauge below indicates the pressure of the main air.
BRAKE BLOCKS – BRAKE CYLINDERS

A brake block acts on each wheel. Each bogie has a pneumatic cylinder.
USP 2000 SWS BA 56658
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

USP 2000 SWS BA 56658 B1
1
3 4 10 11 12
8
2
5
9
6 7
6156B008
OVERVIEW: L.H.S. OF MACHINE
1 = Cabin
2 = Ballasting chutes
Warning:
It is prohibited to rest under vertical load!
3 = Ballast hopper
4 = Steep conveyor
Attention:
For transiting and towing mode the ballast hopper must be empty and the
steep conveyor belt must be free of ballast! - danger of injury!
5= Shoulder plough
6= Centre plough
7= Sweeper system
8= Rope winch
9= Rail fastening brush
10 = Engine compartment
11 = Hydraulic tank area
12 = Diesel tank
B2 BA 56658 USP 2000 SWS
18
7
6
5
9 3
2
6156B366
OVERVIEW: REAR PART OF CABIN
1. Engine control panel B5

2. Drive control panel B6
3. Pneumatic brake control panel
4. Speedometer instrument
5. Hydraulic pressure indication instruments
6. Display for rear camera
7. Cabin fan
8. Cabin lights
9. Emergency brake pull handle
USP 2000 SWS BA 56658 B3
1
2
3
6 4
6156B068
OVERVIEW: ENGINE CONTROL PANEL B5
1= Section “A“
2= Section “B“
3= Section “C“
4= Section “D“
5= Section “E“
6= Section „F“
B4 BA 56658 USP 2000 SWS
6156B076
ENGINE CONTROL PANEL – SECTION “A“
1 = Display for DATAMATIC

2 = Deutz engine display
Note:
For details see seperate “Deutz” engine warning system instructions.
USP 2000 SWS BA 56658 B5
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16
17
6156B079
ENGINE CONTROL PANEL - SECTION “B“
1. Red LED: engine lub. Oil pressure too low

2. Red LED: engine lub. Oil temperature high
3. Red LED: engine coolant temperature high
4. Red LED: engine coolant level low
5. Red LED: engine lube oil filter choked
6. Red LED: compressed air pressure low (<6 bar)
7. Red LED: SEPAR fuel filter reservoir with water separator full of water
8. Red LED: working air pressure low
9. Red LED: pump filling pressure too low (hydraulic drive pump 1)
10. Red LED: pump filling pressure too low (hydraulic drive pump 2)
B6 BA 56658 USP 2000 SWS
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16
17
6156B079
11. Red LED: hydraulic oil level low
12. Red LED: hydraulic oil temperature high
13. Red LED: hydraulic oil return filter clogged
14. Red LED: charging control (alternator)
15. Red LED: diesel fuel tank reserve warning
16. Red LED: Not in use
17. Indication LED for fire warning system failure
USP 2000 SWS BA 56658 B7
6
7
6156B078
ENGINE CONTROL PANEL - SECTION “C“
1. LED: indicator shoulder plough R.H.S. unlocked / locked

2. LED: indicator center plough unlocked / locked
3. LED: indicator sweeper system unlocked / locked
4. LED: indicator L.H. / R.H. rail fastening brush unlocked/locked
5. Warning buzzer for general malfunction
6. Socket for Deutz engine EMR diagnosis
7. Push button for EMR diagnose reset
B8 BA 56658 USP 2000 SWS
1.
6156B073
3 5 7
1
4 6
2 8
ENGINE CONTROL PANEL - SECTION “D“
1. Switch for hydraulic system pressure ON

2. Switch for safety system RESET
3. Illuminated button: warning buzzer acknowledge (failure)
4. Push button for electric horn
5. Switch for windscreen wiper
6. Switch for windscreen washer system
7. Switch for cabin light ON
8. Switch for roof top flasher light ON
9. Emergency stop push button
Important:
The emergency system 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.
USP 2000 SWS BA 56658 B9
1 2
3 4
6 9
5
8 10
7
6156B072
ENGINE CONTROL PANEL - SECTION “E“
1. Dual air pressure gauge

Red pointer – indirect brake control pressure 5 Bar
Yellow pointer – pneumatic system pressure ~10 Bar
2. Gauge for pneumatic working air pressure
3. Voltmeter
4. Socket for 24 V DC supply
5. Switch for working lights “OFF / ON“ (track control)
6. Push button for warning hooter
7. Cabin fan
8. Switch for headlight (off – low beam – high beam)
9. Switch: driving system ON
10. Selector switch: driving mode "forward / reverse”
B10 BA 56658 USP 2000 SWS
1 2 3
4
9 10
5 6 7 8 11
6156B071
ENGINE CONTROL PANEL - SECTION “F“
1. Key switch: power supply +24V system OFF / ON (battery main switch)
2. Switch for engine RPM automatic
3. Push button for working RPM
4. White illuminated button: working mode “ON” (working main switch)
5. Engine lub. Oil pressure bypass push button
6. Key switch: engine system “ON” and start engine
7. Selector switch for RPM manually increase/decrease
8. Engaging aid switch for axle engage
9. Yellow LED: indication axles disengaged
10. Green LED: indication axles engaged
11. Selector switch for SWEEPING / PLOUGHING
USP 2000 SWS BA 56658 B11
2 3
6156B064
DRIVE CONTROL PANEL B6
1 = D rive control lever

2 = B u t t o n for emergency drive bypass (short drive button)
3 = Push button for headlights ON
4 = Joystick for pneumatic horn
B12 BA 56658 USP 2000 SWS
1
2
3
5
6156B065
BRAKE CONTROL PANEL REAR
1. Brake control lever for direct-acting brake

2. Brake control lever for Indirect-acting brake
3. Pneumatic pressure reducing valve set at 3.8 Bar for brake circuit I
4. Pneumatic pressure reducing valve set at 3.8 Bar for brake circuit II
5. Pneumatic pressure reducing valve set at 5 Bar for indirect brake
USP 2000 SWS BA 56658 B13
6156B063
PRESSURE INDICATION INSTRUMENT
1. Gauge for hydraulic system pressure

2. Gauge for charging pressure pump 2
3. Gauge for driving pressure pump 2
B14 BA 56658 USP 2000 SWS
3
2
6156B388
L.H.S. SECTION OF CABIN
1 = Air condition indoor unit

2 = W i r e l e s s hooter system
3 = Air condition control box
USP 2000 SWS BA 56658 B15
4689B020
AIR CONDITION CONTROL BOX
1 = Air condition control potentiometer (nominal setting)

2 = Air condition air blower setting switch
B16 BA 56658 USP 2000 SWS
1
2
6156B361
REAR L.H.S. SECTION OF CABIN
1 = Pneumatic solenoid valve for pneumatic horn low pitch

2 = Pneumatic solenoid valve for pneumatic horn high pitch
USP 2000 SWS BA 56658 B17
6156B373
REAR R.H.S. OF CABIN: OVERVIEW
1 = Control cabinet B50
2 = Ca bin light
B30 BA 56658 USP 2000 SWS
18
7 7
6
9
1
2 3
6156B340
OVERVIEW: FRONT PART OF CABIN
1 = D i s p l a y for front camera

2 = Working control panel B3 l.h.s.
3 = W o r k i n g control panel B4 r.h.s.
4 = Drive control panel B8
5 = Brake control panel
6 = Pressure indication instruments
7 = Cabin fan
8 = C a b i n light
9 = Speedometer instrument
USP 2010 SWS BA 56658 B31
16 31
24 28 34
12 20
1 3
6 8
35
13 21 25
4
9 29
17 22 26 32
2 7
14 18 30 33
10 27 36
5
11 10
15 19 23
6156B341
WORKING CONTROL PANEL B3 (L.H.S.)
1. Electric main switch for shoulder plough LHS enabling

2. 4-way toggle switch:
Joystick position (up): lift shoulder plough LHS
Joystick position (down): lower shoulder plough LHS
Joystick position (left): extend shoulder plough LHS
Joystick position (right): retract shoulder plough LHS
4. Selector switch for slew in/out of LHS shoulder plough front blade tip
5. Selector switch for slew in/out of LHS shoulder plough rear blade tip
6. Switch for opening/closing of hopper conveyor flap
Joystick position (up): slew out L.H. shoulder plough blade vertically
Joystick position (down): slew in L.H. shoulder plough blade vertically
Joystick position (left): slew out L.H. shoulder plough blade horizontally
Joystick position (right): slew in L.H. shoulder plough blade horizontally
8. Switch for selecting hopper belt movement manual/auto
9. Switch for selecting hopper belt movement direction forward/reverse
10. Joystick for work drive forward/ reverse
11. Switch for work drive stop
B32 BA 56658 USP 2000 SWS
16 31
24 28 35
12 20
1 3
6 8
36
13 21 25
4
9 29
17 22 26 32
2 7
14 18 30 33
10 27 34
5
11 10
15 19 23
WORKING CONTROL PANEL B3 (LHS)
6156B046
12. Switch for cabin fan
13. Switch for wind screen wiper
14. Push button for wind screen cleaning system
16. Joystick for lifting/ lowering of rotary brush unit
17. Toggle switch for adjusting rotary brush shaft up / down
18. Flow adjustment rotary brush drive
20. Lateral lid LHS open/ close
21. Push button for Sweeper brush drive forward
22. Push button for Sweeper brush drive reverse
23. Push button for Sweeper brush drive stop
24. Selection of flap for cross conveyor/ steep conveyor
25. Switch: front cross conveyor belt drive direction “TO THE LEFT / OFF / TO THE RIGHT”
26. Switch: rear cross conveyor belt drive direction “TO THE LEFT / OFF / TO THE RIGHT”
27. Switch for lock/ unlock of sweeper system
28. Switch: steep conveyor belt drive direction “FORWARD / OFF / REVERSE”
29. Push button for sweeper unit center
30. Joystick for sweeper system lift/ lower and it’s on track adjustment
31. Switch for “locking/ unlocking/ lowering” of rail fastening brush LHS
32. Switch for rail fastening brush drive “anticlockwise/ off / clockwise”
33. Joystick for open/ close outer rail ballasting chute LHS
34. Joystick for open/ close inner rail ballasting chute LHS
35. Joystick for slewing of lhs center plough front outer shield horizontally/vertically
36. Joystick for slewing of lhs center plough rear outer shield horizontally/vertically
USP 2000 SWS BA 56658 B33
2
1
7
3
6156B393
FRONT R.H.S. SECTION OF CABIN
1. Direct brake lever

2. Indirect brake lever
3. Pneumatic pressure reducing valve (5 bar) for indirect-acting brake
4. Pneumatic pressure reducing valve (3.8 bar) for direct-acting brake circuit I
5. Pneumatic pressure reducing valve (5 bar) for direct-acting brake circuit II
6. Speedometer instrument
7. Working control panel B4
B34 BA 56658 USP 2000 SWS
1 5 10 15 20 24 25 26
7 11
2
12
21 28
16 22
6
13
3 4 30
17
27
8 9 18 19 23
14
29
WORKING CONTROL PANEL B4 (R.H.S.)
1. Joystick for slewing of rhs center plough front outer shield horizontally/vertically
2. Joystick for slewing of rhs center plough rear outer shield horizontally/vertically
3. Joystick for open/ close inner rail ballasting chute RHS
4. Joystick for open/ close outer rail ballasting chute RHS
5. Switch for “locking/ unlocking/ lowering” of rail fastening brush RHS
6. Switch for rail fastening brush drive “anticlockwise/ off / clockwise”
7. Button for pre-selection of ballast grading plough positions (see symbols)
8. Switch for lock/ unlock of center plough
9. Toggle switch for lifting/lowering of center plough
10. Lateral lid RHS open/ close
11. Switch for opening/closing of LHS hopper flap
12. Switch for opening/closing of RHS hopper flap
13. Switch for opening/closing of front hopper flap
14. Push button for working RPM ON
15. Switch for cabin fan
16. Switch for windscreen wiper
17. Push button for windscreen washing system
20. Switch for travel drive enabling
21. Switch for travel drive direction forward/ reverse
22. Toggle switch for work drive forward/ reverse
23. Push button for work drive stop
USP 2000 SWS BA 56658 B35
1 5 10 15 20 24 25 26
7 11
2
12
21 28
16 22
6
13
3 4 30
17
27
8 9 18 19 23
14
29
6156B041_1
WORKING CONTROL PANEL B4 (R.H.S.)
24. Switch for headlight “OFF/ LOW BEAM/ HIGH BEAM”

26. Electric main switch for shoulder plough RHS enabling
Joystick position (up): lift shoulder plough RHS
Joystick position (down): lower shoulder plough RHS
Joystick position (left): extend shoulder plough RHS
Joystick position (right): retract shoulder plough RHS
28. Selector switch for slew in/out of RHS shoulder plough front blade tip
29. Selector switch for slew in/out of RHS shoulder plough rear blade tip
Joystick position (up): slew out R.H. shoulder plough blade vertically
Joystick position (down): slew in R.H. shoulder plough blade vertically
Joystick position (left): slew out R.H. shoulder plough blade horizontally
Joystick position (right): slew in R.H. shoulder plough blade horizontally
B36 BA 56658 USP 2000 SWS
2 3
6156B036
DRIVING CONTROL PANEL B8
1 = D r ive control lever

2 = B u t t o n for emergency drive bypass (short drive button)
3 = Push button for headlights ON
4 = Joystick for pneumatic horn
USP 2000 SWS BA 56658 B37
1 2 3 4
5922B031
PRESSURE INDICATION INSTRUMENT PANEL
1. Pneumatic pressure gauge for indirect brake

Red pointer –
Yellow pointer –
2. Pneumatic pressure gauge direct brake
Red pointer –
Yellow pointer –
3. Gauge for charging pressure pump 1
4. Gauge for driving pressure pump 1
B50 BA 56658 USP 2000 SWS
5773B003_1
BRAKE CONTROL PANEL FRONT
1. Brake control lever for direct-acting brake

2. Brake control lever for Indirect-acting brake
3. Pneumatic pressure reducing valve set at 3.8 Bar
for brake circuit I
4. Pneumatic pressure reducing valve set at 3.8 Bar
for brake circuit II
5. Pneumatic pressure reducing valve set at 5 Bar
for indirect brake
USP 2000 SWS BA 56658 B51
3
2
6156B085
AREA OF CABIN PLATFORM
1 = E n g i n e EMR control
2 = Socket for 24 V DC
3 = Deutz engine instrument panel
B52 BA 56658 USP 2000 SWS
6156B081
MACHINE PLATFORM - AREA OF SAFETY BARS L.H.S.
1 = Cabin platform safety bar

Warning:
The safety barriers are to be closed according to the local railway regulations!
Observe rail traffic on the adjacent tracks before exiting.
USP 2000 SWS BA 56658 B53
6156B034
MACHINE PLATFORM - AREA OF SAFETY BARS R.H.S.
1 = Cabin platform safety bars

Warning:
B60 BA 56658 USP 2000 SWS
3
2
14
51
1
7 8
6156B089
FRONT PART OF MACHINE
1 = Stop cock with hose coupling for continuous train formation brake pipe (indirect
brake)
2 = Ba lla s t h op pe r
3 =Bench vice
4 = Marker lights front
5 = Tail light front
6 = Front view camera
7 = Electric horn
8 = Warning hooter
USP 2000 SWS BA 56658 B61
2 3
1
6156B089
1= Roof flashing light
2 = Twin beam headlight
3= Air horn
4= Steep conveyor
B62 BA 56658 USP 2000 SWS
4
5
1
6156B097
BALLAST HOPPER AREA
1 = Hopper flap front

2 = Reservoir belt
3 = R e s e r v o i r belt flap
4 = H o p p e r flap LHS
5 = Hopper flap RHS
USP 2000 SWS BA 56658 B63
4 3 2 1
6156B096
AREA OF GRADER PLOUGH
1 = H y d r a u l i c solenoid valve: front inner ballast guide shield to the left / to the right cylinder 1)
2 = H y d r a u l i c solenoid valve: front inner ballast guide shield to the left / to the right cylinder 2)
3 = Hydraulic solenoid valve: rear LHS inner ballast guide to the left/ to the right
4 = Hydraulic solenoid valve: rear RHS inner ballast guide to the left/ to the right
B64 BA 56658 USP 2000 SWS
1 1
6156B093
MACHINE PLATFORM - FRONT
1 = Cabin platform safety bars

Warning:
USP 2000 SWS BA 56658 B65
3 4
1
2
6 7
1
6156B003
FRONT L.H.S. PART OF MACHINE
1 = Emergency stop push button

2 = Push button for electric horn
3 = Pus h bu tton f or wa r ning hoo te r
4 = S o c k e t for 24 VDC
5 = Hydraulic motor for hopper belt
6 = Pneumatic solenoid valve for working brake
7 = Pneumatic reducer with manometer for item 6
8 = Hydraulic solenoid valve block: left to right
- Hydraulic solenoid valve: hopper belt flap open/close
- Hydraulic solenoid valve: hopper flap lhs open/close
- Hydraulic solenoid valve: ballast chute flap LHS inner open/close
- Hydraulic solenoid valve: ballast chute flap LHS outer open/close
B66 BA 56658 USP 2000 SWS
4 3
5 6
8
1
7
9
6156B377
MACHINE L.H.S. – AREA OF FRONT BOGIE
1 = F r o n t Bogie
2 = Panel no. B70
3 = Working light
4 = Hopper flap
5 = Oil reservoir with stop cock for hopper belt lubrication
6 = Shoulder plough LHS
7 = Center plough LHS
8 = Lever for engaging/ disengaging axle no. 2
Important:
For towing the machine, shift the axle gear box to “neutral” position, lock
mechanically and secure the lever. The brake has also have to be released.
To avoid damages, ensure again the above mentioned procedure.
9 = Rail scraper
USP 2000 SWS BA 56658 B67
7
8
2
3
1
6
5
6156B002
MACHINE L.H.S. - SHOULDER PLOUGH AREA
1 = Shoulder plough blade L.H.S.

2 = Front shoulder plough blade tip L.H.S.
3 = Rear shoulder plough blade tip L.H.S.
4 = Working light
5 = S h o u l d e r plough blade - support for transport position
6 = Roller transducer: extend shoulder plough horizontally
7 = Angle transducer for shoulder plough slewing angle
8 = Solenoid valves shoulder plough LHS
9 = Center plough
B68 BA 56658 USP 2000 SWS
1
2 6
3 5
4
8
7
6156B307
MACHINE L.H.S. - HY. SOLENOID VALVES SHOULDER PLOUGH L.H.S.
1= Hydraulic solenoid valve: lift / lower L.H. shoulder plough

2= Hydraulic solenoid valve: extend/ retract L.H shoulder plough
3= Hydraulic solenoid valve: slew in / out L.H. shoulder plough front blade tip (horizontal)
4= Hydraulic solenoid valve: L.H. shoulder plough blade slewing angle (vertical)
5= Hydraulic solenoid valve: slew in / out L.H. shoulder plough blade (horizontal)
6= Hydraulic solenoid valve: slew in / out L.H. shoulder plough rear blade tip (horizontal)
7= Electric horn
8= Pneumatic solenoid valve for shoulder plough lock/unlock
USP 2000 SWS BA 56658 B69
4 3
6156B092
AREA OF AXLE 1
1 = KE valve
2 = Camera for viewing LHS ballasting chute
3 = W o r k i n g light
4 = warning hooter
B70 BA 56658 USP 2000 SWS
2
4 3 1
5773B096
BALLAST CHUTE SECTION
1 = Ballast chute outer L.H.S.

2 = Ballast chute inner L.H.S.
3 = Ballast chute inner R.H.S.
4 = Ballast chute outer R.H.S.
5 = Sensors for engaging/ disengaging of axle no. 1
USP 2000 SWS BA 56658 B71
2
6
3
5
4
3
1
6156B006
MACHINE L.H.S. - CENTRE PLOUGH AREA
1= Centre plough
2= 24 V DC socket
3= Outer ballast guide shields
4= Inner ballast guide shields
5= Centre plough height adjustment for individual rail height
6= Safety chain for center plough L.H.S.
B72 BA 56658 USP 2000 SWS
1 2 3 4
6156B306
MACHINE L.H.S. - HY. SOLENOID VALVES CENTRE PLOUGH
1 = Hydraulic solenoid valve: slew in / out front L.H. outer ballast guide shield
2 = Hydraulic solenoid valve: up/down front L.H. outer ballast guide shield
3 = Hydraulic solenoid valve: slew in / out rear L.H. outer ballast guide shield
4 = Hydraulic solenoid valve: up/down rear L.H. outer ballast guide shield
USP 2000 SWS BA 56658 B73
6156B012
MACHINE L.H.S. - STEEP CONVEYOR BELT AREA
1 = Hydraulic solenoid valve for front cross conveyor belt drive to the left / to the right
2 = Steep conveyor
3 = Oil reservoir with stop cock for steep conveyor belt lubrication
B74 BA 56658 USP 2000 SWS
2
6
4
5
6156B011
MACHINE L.H.S. - SWEEPER SYSTEM AREA
1 = Safety chain for sweeper system

2 = Locking mechanism with inductive switch - sweeper system locked
3 = Deflector plate LHS
Warning:
Be particularly careful in the deflector plate area! Ballast can be thrown out.
Danger of injury!
4 = Cross conveyor belt - drive motor

5 = Fixing lever - rotary brush box rear wall
6 = Rotary brush bearing
Warning:
Working on moving and rotating machine parts (ballast guiding plates, ballast
deflector ploughs and flaps, ballast cross conveyor belt, ballast rotary brush,
ballast outlet plates, cranes, etc.) is prohibited due to safety hazard and injury!
USP 2000 SWS BA 56658 B75
3 7 8
2 4 5 6
1 9 10
6156B100
HY. SOLENOID VALVES SWEEPER SYSTEM
1 = Hydraulic solenoid valve: tank valve for sweeper box steering cylinder 1
2 = Hydraulic solenoid valve: tank valve for sweeper box steering cylinder 2
3 = Hydraulic solenoid valve: move sweeper system to the left / to the right (cylinder 1)
4 = Hydraulic solenoid valve: move sweeper system to the left / to the right (cylinder 2)
5 = Hydraulic solenoid valve: lift / lower sweeper system
6 = Hydraulic solenoid valve: open / close L.H. deflector plate
7 = Hydraulic solenoid valve: lift / lower gauge rollers of sweeper system
8 = Hydraulic solenoid valve: adjust rotary brush shaft up / down
9 = Hydraulic solenoid valve: open / close R.H. deflector plate
10 = Hydraulic solenoid valve: flap for selecting transverse/ steep conveyor
B76 BA 56658 USP 2000 SWS
2
1
5 3
6156B013
MACHINE L.H.S. - ROPE WINCH AREA
1 = G u i d e rail for rope winch

2 = Junction box for tachometer
3 = E m e r g e n c y hand pump
4 = R a i l fastening brush
5 = Rotary brush box rear wall
USP 2000 SWS BA 56658 B77
4
3
6156B099
AREA OF AXLE 3
1 = Engage/ disengage sensors for axle 3

2 = Pneumatic solenoid valve for lift/ lower and lock/ unlock for LHS rail fastening brushes
3 = Hydraulic solenoid valve for LHS rail fastening brush drive forward/ reverse
4 = Hydraulic solenoid valve for RHS rail fastening brush drive forward/ reverse
B78 BA 56658 USP 2000 SWS
6156B346
MACHINE L.H.S. – AREA OF REAR BOGIE
1 = Air dryer unit

2 = Push button for warning hooter
USP 2000 SWS BA 56658 B79
4
3
6156B106
MACHINE L.H.S. – AREA OF RAIL FASTENING BRUSHES
1= Inner rail fastening brush L.H.S.

2= Outer rail fastening brush L.H.S.
3= Safety chain for rail fastening brush L.H.S.
4= Inductive switch: rail fastening brush L.H.S. in locking position
B80 BA 56658 USP 2000 SWS
6156B018
MACHINE L.H.S. - DIESEL TANK AREA
1= Diesel fuel tank

2= Diesel fuel filter and water separator
3= Stop cock to item 2
4= Hydraulic oil cooler
B90 BA 56658 USP 2000 SWS
5
2 3 6
1
8 7
6156B016
REAR L.H.S. PART OF MACHINE

26156B016
= Electric horn button
3 = P u s h button for warning hooter
4 = S o c k et f o r 2 4 V D C
5 = Pneumatic solenoid valve: working air “ON”
6 = Pneumatic pressure reducing valve with manometer to item 5
7= Hand brake
8 = Wa ter separator
9 = Mechanical lever for engaging/ disengaging axle no 4
USP 2000 SWS BA 56658 B91
4 5
6 2
1
6156B351
MACHINE L.H.S. - AIR DRYER UNIT AREA
1 = Twin box air dryer unit

2 = Idle run pressure regulating valve
3 = Pneumatic system stop cock for bypassing air dryer unit
Note:
Never turn the bypass lever in vertical position for longer period, it has to be
use only in case of emergency i.e. for clearing the block section.
4 = Pneumatic safety valve (10.5 bar)

5 = Pneumatic safety valve (12 bar)
6 = Pressure switch (5 bar)
7 = Pressure switch (6 bar)
B92 BA 56658 USP 2000 SWS
5
7
1
4 2
3
6156B033
FRONT R.H.S. PART OF MACHINE
1= Emergency stop push button

2= Push button for electric horn
3= Push button for warning hooter
4= 24 V DC socket
5= Hydraulic motor for hopper conveyor belt
6= Mechanical lever for engaging/ disengaging of axle no. 1
7= Hydraulic solenoid valve: from left to right
- Hydraulic solenoid valve: ballast chute flap RHS outside open/close
- Hydraulic solenoid valve: ballast chute flap RHS inside open/close
- Hydraulic solenoid valve: hopper RHS flap open/close
- Hydraulic solenoid valve: hopper center flap open/close
USP 2000 SWS BA 56658 B93
1
4
3
6
5 2
6156B382
MACHINE R.H.S. – AREA OF FRONT BOGIE
1= Antenna for GPS

2= Hydraulic valve for Q-Max for bogie 1
3= Hydrostatic brake valve forward/ reverse for bogie 1
4= Working light
5= Panel no B71
6= Oil container with stop cock for hopper belt lubrication
7= Oil filling cap for axle no 2
B94 BA 56658 USP 2000 SWS
4
7
8
3
2
1
6 5
6156B032
MACHINE R.H.S. - SHOULDER PLOUGH AREA
1 = Shoulder plough blade R.H.S.

2 = Front shoulder plough blade tip R.H.S.
3 = Rear shoulder plough blade tip R.H.S.
4 = Working light
5 = S h o u l d e r plough blade - support for transport position
6 = Roller transducer: extend shoulder plough horizontally
7 = Angle transducer for shoulder plough slewing angle
8 = Solenoid valves shoulder plough RHS
9 = Center plough
USP 2000 SWS BA 56658 B95
4 3 2 1
6 5
6156B310
MACHINE R.H.S. - HY. SOLENOID VALVES SHOULDER PLOUGH R.H.S.
1= Hydraulic solenoid valve: lift / lower R.H. shoulder plough

2= Hydraulic solenoid valve: extend/ retract R.H shoulder plough
3= Hydraulic solenoid valve: slew in / out R.H. shoulder plough front blade tip (horizontal)
4= Hydraulic solenoid valve: R.H. shoulder plough blade slewing angle (vertical)
5= Hydraulic solenoid valve: slew in / out R.H. shoulder plough blade (horizontal)
6= Hydraulic solenoid valve: slew in / out R.H. shoulder plough rear blade tip (horizontal)
B96 BA 56658 USP 2000 SWS
2
6
3 4
5 3
6156B029
MACHINE R.H.S. - CENTRE PLOUGH AREA
1= Centre plough
2= 24 V DC socket
3= Outer ballast guide shields
4= Inner ballast guide shields
5= Centre plough height adjustment for individual rail height
6= Safety chain for center plough L.H.S.
B100 BA 56658 USP 2000 SWS
1
2
5 4
3
6156B358
MACHINE R.H.S. - HY. SOLENOID VALVES CENTRE PLOUGH
1= Hydraulic solenoid valve: slew in / out front R.H. outer ballast guide shield
2= Hydraulic solenoid valve: up/down front R.H. outer ballast guide shield
3= Hydraulic solenoid valve: lifting/ lowering of centre plough unit
4= Hydraulic solenoid valve: slew in / out rear R.H. outer ballast guide shield
5= Hydraulic solenoid valve: up/down rear R.H. outer ballast guide shield
USP 2000 SWS BA 56658 B101
4
1
6156B028
MACHINE R.H.S. - STEEP CONVEYOR BELT AREA
1 = Hydraulic solenoid valve for rear cross conveyor belt drive left / right
2 = 24V DC socket
3 = Oil reservoir with stop cock for steep conveyor belt lubrication
4 = Steep conveyor
B102 BA 56658 USP 2000 SWS
2
6
3
5
6156B026
MACHINE R.H.S. - SWEEPER SYSTEM AREA
1 = Safety chain for sweeper system

2 = Locking mechanism with inductive switch - sweeper system locked
3 = Deflector plate RHS
Warning:
Danger of injury!
4 = Cross conveyor belt - drive motor
5 = Fixing lever - rotary brush box rear wall
6 = Rotary brush bearing
Warning:
ballast outlet plates, cranes, etc.) is prohibited due to safety hazard and injury!
USP 2000 SWS BA 56658 B103
3 4
6156B025
MACHINE R.H.S. - ROPE WINCH AREA
1= Guide rail for Rope Winch

2= Air condition outdoor unit
3= Rail fastening brushes RHS
4= Rotary brush rear wall
B104 BA 56658 USP 2000 SWS
4 3 2
6
5
6156B386
MACHINE R.H.S. – AREA OF REAR BOGIE
1= Push button for warning hooter

2= Panel no. B72
3= Engine air cleaner
4= Battery box
5= Main battery key
6= Mechanical lever for engaging/ disengaging of axle no. 3
USP 2000 SWS BA 56658 B105
3
4
6156B107
MACHINE R.H.S. – AREA OF RAIL FASTENING BRUSHES
1= Inner rail fastening brush R.H.S.

2= Outer rail fastening brush R.H.S.
3= Safety chain for rail fastening brush R.H.S.
4= Inductive switch: rail fastening brush R.H.S. in locking position
B106 BA 56658 USP 2000 SWS
1 2
6156B021
MACHINE R.H.S. - DIESEL TANK AREA
1= Diesel fuel tank

2= M a x . l evel indicator for diesel fuel tank
3= M i d d l e l evel indicator for diesel fuel tank
4= L o w l evel indicator for diesel fuel tank with warning socket
5= Diesel fuel filling cap
6= Panel B16 for operating diesel filter unit
USP 2000 SWS BA 56658 B107
3 2 1
5
4
6156B316
REAR R.H.S. PART OF MACHINE

2 = Push button for electric horn
3 = Push button for warning hooter
4 = Socket for 24 V DC
5 = Parking brake
B108 BA 56658 USP 2000 SWS
3
1
4
5
6156B327
ENGINE ROOM R.H.S.
1 = Deutz engine
2 = Engine room temperature sensors
Warning:
Openings in the cover of the engine compartment are used for fire fighting.
Don’t look into these openings in case of fire! Danger of injury!
3 = Engine fuel filter

4 = Diesel pre cleaner
5 = Cardan shaft from engine to pump gear box
USP 2000 SWS BA 56658 B109
2
3 4
6
10
9
7
6156B318
PUMP DISTRIBUTOR GEARBOX AREA
1= Hydraulic solenoid valve (bypass-valve) for drive pump 1

2= Hydraulic solenoid valve (bypass-valve) for drive pump 2
3= Hydraulic unloader valve for hydraulic working pressure(140 bar)
4= Hydraulic non-return valve for switch-off valve
5= Hy. pressure relief valve for hydraulic working system (175 bar, sealed)
6= Hydraulic solenoid valve for sweeper brush drive forward/reverse
7= Hydraulic solenoid valve: hydraulic system pressure build-up on/off
Warning:
For emergency operation (power failure) the sol. op. valve can be operated
manually to achieve pressure supply for the corresponding hydraulic by the
silver button.
The machine is able to drive to the next workshop or railway station.
Continuing the work with manual operated valves is PROHIBITED!
No emergency stop function is available.
8 = Hydraulic oil tank – return flow filter
9 = Hydraulic oil filling cap
10 = Hydraulic accumulator
B110 BA 56658 USP 2000 SWS
3 5
6
7
1 2
6156B294
HYDRAULIC TANK AREA, L.H.S.
1 = Hydraulic oil tank

2 = Hydraulic oil suction filter
3 = Suction filter contamination indicator (vacuum meter)
4 = Hydraulic oil filler neck
5 = Hy. superfine filter
6 = Pump gear box
7 = Proportional valve for variable drive pump
Note:
For changing the hydraulic oil fine filter refer to the maintenance instructions.
USP 2000 SWS BA 56658 B111
6
7
8
3
1
5
6156B322
PUMP DISTRIBUTOR GEARBOX AREA, R.H.S.
1 = Hydraulic oil tank

2 = Hydraulic oil suction filter
3 = Suction filter contamination indicator (vacuum meter)
4 = Level sight glass to item 1
5 = Pump gear box
6 = Hy. manometer with mini measuring connection for measurement works
7 = Hydraulic pressure switch with manometer for filling pressure drive pump 1
8 = Hydraulic pressure switch with manometer for filling pressure drive pump 2
B112 BA 56658 USP 2000 SWS
1 4
3 3
6156B082
ENGINE COMPARTMENT TOP AREA
1 = Diesel tank
Warning:
For fuelling take all measures that are relevant to safety.
Smoking and handling open fire and light is prohibited!
3 = E n g i n e air cleaner
4 = Exhaust of engine
USP 2000 SWS BA 56658 B113
5 6
17
81
1
4
3 2
6156B087
REAR SIDE OF MACHINE
1 = Pneumatic stop cock with hose coupling for the continuous train formation brake
pipe (indirect brake)
2 = Water separator
3 = Electrical horn
4 = Rear view camera
5 = Roof top flasher light
6 = Twin beam headlight
7 = Marker lights
8 = Tail lights
USP 2000 SWS BA 56658
PART C
Outline of operating processes
Changing operating modes
Safety information
Warnings
Behaviour in fault conditions

USP 2000 SWS BA 56658 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 56658 USP 2000 SWS
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
USP 2000 SWS BA 56658 C3
2. FACTORY FILLING OF OPERATING FLUIDS

□ Factory filling of operating fluids – see maintenance instructions WS-56658.
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 56658 USP 2000 SWS
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!
USP 2000 SWS BA 56658 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!
□ The diesel filter is drained, the drain cock is “CLOSED”.
□ Check the vacuum meter of the hydraulic suction filters.
□ The battery sets are connected, the battery lids are “CLOSED”.
□ All air vent and drain cocks (valves) on air reservoirs and drip cups
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
from this: they must be drained regularly in order to protect the air
drying plant from contamination!
□ The pn. stop cock for the safety brake is “ON” and secured in this
position.
□ The pn-stop cocks of the direct brake are in position “ON” and
padlocked.
□ The pn. stop cock to the pressure regulator is “OPEN”.
□ The pn. stop cock to the macrophones is open.
□ The axle gearboxes are unlocked (“ready for driving”).
□ The diesel stop cocks in the suction pipe are “OPEN”.
□ The diesel stop cock in the return line is “OPEN”.
□ The diesel stop cocks to the heating systems are “OPEN”.
□ The diesel tank drain cock is closed.
C6 BA 56658 USP 2000 SWS
□ The hydraulic oil tank drain cock is closed.

□ The pump distributor gearbox oil drain cock is closed.
□ Check the hose couplings of the indirect brake.
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”.
□ Check rail guard adjustment.

□ Check brake blocks and running wheels.
□ The KE-valve is in position “ON”.
□ Bleed the KE-valve.
□ Switch the change over handle to “P”.
□ Change over device for “UIC / RZD” as required.
□ All EMERGENCY STOPs are unlocked.
□ All drive stops are unlocked.
□ All systems stops are unlocked.
□ The emergency brake is not applied.
□ The service battery main switch is “ON”.
□ The working main switch is turned off.
□ Turn on the key battery main switch.
□ Check all units their proper locking and fastening:
- Ballast flaps
- Shoulder plough
- Centre plough
- Sweeper system
- Rope winch (guide rail unmounted)
- Rail fastening brushes

□ Turn on the temperature monitoring system (unlock - rotate up -
lock).
□ The machine will now have the status “ready for operation” and can
be put into operation.
USP 2000 SWS BA 56658 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 56658 USP 2000 SWS
□ 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.
USP 2000 SWS BA 56658 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 7.17.; Danger areas – see chapter 13.f.
C10 BA 56658 USP 2000 SWS
6. STARTING THE ENGINE

□ Observe the operating manual of the engine manufacturer.
□ Parking brake “APPLIED” or secured with scotch blocks.
6.1. GETTING MACHINE READY FOR STARTING
The machine is standing still and has the “ready for operation” status –
chapter 4.
Insert engine system key switch and turn it on.
The working main switch is turned off.
The key switch for transiting is turned off.
All EMERGENCY STOPs are released.
All drive stop buttons are released.
All system stop buttons are released.
Do not press the engine stop button.
Note:
After an engine stop, turn off the engine system key first, then turn the it back
on.
USP 2000 SWS BA 56658 C11
6.2. STARTING
□ Sound warning tone and - once you have made sure that nobody is in
the danger area – start the engine using the engine start switch.
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
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!
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 pressing the engine stop button.
□ In addition to that the engine will also shut down when pressing an
“EMERGENCY STOP” button.
□ If the key battery main switch is turned off the engine will also be
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 56658 USP 2000 SWS
6.4. INFORMATION AND PROCEDURES FOR OPERATING THE

MACHINE AT LOW AMBIENT TEMPERATURES
6.4.1. STARTING THE ENGINE
□ Preheat the engine using the ignition key. (Level 1)

□ The preheating control lamp lights up during preheating and flashes
during the 2nd preheating.
□ Once preheating is finished turn the ignition key to the right and start
the engine.
6.4.2. OPERATING THE ENGINE
□ Let the engine run warm at approx. 900 min-1.

□ Once the engine turns smoothly gradually increase the speed to
approx. 1200 min-1.
6.4.3. WARMING UP THE GEARBOX OIL
□ Start driving the machine slowly and run warm at moderate speed.
6.4.4. HEATING UP THE ENGINE COOLANT FLUID
□ Plug in the depot plug and turn on the power supply (230V AC).
□ Pre-heating is turned on automatically as long as the relevant safety
cut-out (140e4) is “ON”.
USP 2000 SWS BA 56658 C13
6.4.5. HEATING UP THE HYDRAULIC OIL
□ Plug in the depot plug and turn on the power supply (230V AC).
□ Pre-heating needs to be turned on and the corresponding safety cut-
out (140e2/3) is “ON”.
6.4.6. HEATING THE CABIN
□ Turn the heating “ON” as required.
6.4.7. HEATING THE WINDSCREEN
□ To prevent the windscreen from misting up turn on the windscreen

heating.
□ A prerequisite for heating the windscreen is a running engine.
6.4.8. KEEPING THE MACHINE WARM
□ Stable the machine in heated halls (depot, boiler house or similar).

□ The machine will be ready for operation straight away.
C14 BA 56658 USP 2000 SWS
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!
USP 2000 SWS BA 56658 C15
7.1. EMERGENCY STOP
□ 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

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
□ EMERGENCY STOP devices are located:
- on the front driver’s desk

- on each machine corner and in the centre of the machine
- on each working control panel
□ An LED field will indicate which EMERGENCY STOP button was

pressed and where it was pressed.
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 (7/1) 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

to the right.
C16 BA 56658 USP 2000 SWS
7.2. WORKING SYSTEM STOP
□ The purpose of the working system stop in working mode is to bring the
machine to a standstill in critical situations, if regular measures are not
possible and immediate action is required!
□ The visible working system stop device essentially consits of yellow
mushroom buttons which are located:
□ When pressed this button engages in the "working system stop"

position. This results in the following:
- the el. working system is interrupted

- the hydraulic pressure is released
- the pn. pressure supply is released
- the brakes apply
□ An LED field will indicate which working sytem stop button was pressed
and where it was pressed.
Important:
□ The "working system stop" will be released by pulling the mushroom-

shaped button.
Attention:
Before deactivating the "working system stop" you have to find out why it was
actuated and repair the cause if necessary!
Note:
After de-activating the “working system stop“ press the reset button (7/1).
USP 2000 SWS BA 56658 C17
7.3. WORKING DRIVE STOP
□ The purpose of a drive stop device in working mode is to stop the

machine in critical situations, if regular measures are not possible and
immediate action is required!
□ The visible drive stop devicee essentially consists of blue mushroom
buttons which are located:

- on the sweeper system remote control
- on every working control panel
□ 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
□ An LED field will indicate which working sytem stop button was pressed
and where it was pressed.
Important:
□ The "working drive stop" is released by pulling the mushroom-shaped

button.
Attention:
Before deactivating the "working system stop" you have to find out why it was
actuated and repair the cause if necessary!
Note:
After de-activating the “working drive stop“ press the reset button (7/1).
C18 BA 56658 USP 2000 SWS
7.4. EMERGENCY BRAKE
□ The emergency brake handle is located in the cabin and is within easy
reach. On activation of the pull handle the preloaded emergency brake
valve opens and air escapes from the main air pipe, the KE-valve
reacts to this and the indirect brake is actuated. To avoid a refilling of
the brake pipe the “CUT-OFF” valves are switched currentless at the
same time.
Attention:
The cause for activating the emergency brake has to be established. Potential
dangers or obstacles need to be cleared before driving can continue!
□ The released emergency brake is reset with a key.

□ Driving can only continue when the emergency brake has been reset
and the main air pipe refilled.
□ The main air pipe is filled via the indirect brake valve.
7.5. VISUAL WARNING SIGNS
□ The machine is equipped with several facilities to give off visual

warning signs. These are:
- active warning signs
- passive warning signs
□ In working mode the active visual warning is activated. This draws

attention to the particular danger in the vicinity of the units.
□ Additional to this the roof flashing light can be switched on by pressing
the button on the driver’s desk.
□ Warning signs and pictograms are passive warnings indicating
dangers.
USP 2000 SWS BA 56658 C19
7.6. AUDIBLE WARNING SIGNS
□ The machine is equipped with several facilities to give off audible

warning signs.
□ These are:
- electric horn signals
- siren signals
- intermittent warning signals
□ If a horn button is pressed the electric horn signals will respond.
□ If the macrophone joystick is pushed forward, the high pitch
macrophones will respond.
□ If the macrophone joystick is pulled, the low pitch macrophones will
respond.
□ In reverse working drive an intermittent warning signal will sound.
□ If the temperature monitoring system responds, the electric horn will
sound.
C20 BA 56658 USP 2000 SWS
7.7. 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 (24V DC),
switched on, functional and not bypassed.
□ The temperature warning system essentially consists of: wherever applicable
- two optical-acoustic signal columns in - temperature sensors in the engine

the cabin compartment
- a control unit consisting of switch, control - a bypass-switch on the driver’s desk

lamps and warning buzzer
USP 2000 SWS BA 56658 C21
7.7.1. 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
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.
□ The control lamp next to the control unit main switch lights up
“GREEN“.
□ The system is in “MONITORING MODE” status.
Warning:
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.
7.7.2. 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
“AMBER“.
□ The “RED“ warning light of the signal column starts to flash in the
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.
Warning:
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!
C22 BA 56658 USP 2000 SWS
7.7.3. 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
the warning buzzer will sound.
□ 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!
Warning:
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 D.
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.
USP 2000 SWS BA 56658 C23
7.7.4. MALFUNCTION DETECTION
□ If a malfunction occurs in the control system,

- the “AMBER (orange)“ warning lamp lights up on the signal
column
- 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
the temperature monitoring system is faulty.
Warning:
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

driver’s desks is illuminated even if the main switch of the control unit is
switched off.
□ It is not possible to start the engine without an active bypass switch.
7.7.5. 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
rotate it down.
□ The “GREEN” lit control lamp next to the control unit main switch goes
out.
□ The temperature monitoring system is switched off.
C24 BA 56658 USP 2000 SWS
7.8. KEY SWITCHES
□ Key switches are switches which are locked or switched with a key.
□ Key switches are swichtes for switching special functions.
Important:
Switching with a key switch requires particular caution and awareness.
7.9. ACCESS LIGHTING
□ When the key battery main switch is “OFF” the access lighting can be
switched “ON” before boarding the machine.
□ The access lighting lights up the respective access area.
□ The access lighting is switched using a key switch.
Note:
Even if the key batterry main switch has been turned “OFF” and removed the
access lighting can be operational.
As a consequence the battery sets (for engine and system) would be empty
completely.
7.10. 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.
USP 2000 SWS BA 56658 C25
7.11. 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
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.
7.11.1.PROCEDURE
□ Position the machine on a track section as level as possible, without

superelevation, and secure it from rolling away.
□ Inform the crew of the imminent operations and instruct them, if

necessary.
Warning:
The emergency pump for hydraulic remains “OFF" until everybody has left the
danger area.
□ An engine failure must be distinguished from a failure of the electric

control system.
Important:
Working with the emergency pump for hydraulics is forbidden!
C26 BA 56658 USP 2000 SWS
7.11.1.1. ENGINE FAILURE
□ The following circumstances must be provided to restore the units’

transit position:
- 24 V system is operable
□ If these circumstances are provided, take the following action:

- turn the electric emergency pump for hydraulics “ON“;
- now hydraulic pressure is being built up;
- all working units can be moved into their transit position as
usual.
7.11.1.2. FAILURE OF THE ELECTRIC CONTROL SYSTEM
□ Proceed as follows in case the 24 V system (electric control system)

has failed:
- Remove the seal and manually arrest the hydraulic solenoid
valve of working-system pressure.
Warning:
When the hydraulic valves are operated in manual mode, the EMERGENCY
OFF function is not available!
If these circumstances are provided, take the following action:

- turn the electric emergency pump for hydraulics “ON“;
- now hydraulic pressure is being built up;
The working units can be moved into their transit position only by
activating the respective valves in manual mode - refer to the hydraulic
system drawing.
All pneumatic and hydraulic locking devices of the working units can be
locked / unlocked only by activating the respective valves in manual
mode - refer to the pneumatic and hydraulic system drawing.
Warning:
When all units have been locked in their transit position, make sure to restore
the original position of all switches and stop cocks mentioned above.
USP 2000 SWS BA 56658 C27
7.12. FIRE EXTINGUISHER
□ The fire extinguisher is mounted in the rear part of the cabin.
7.13. EMERGENCY HAMMER
□ The emergency hammer can be used to smash the windows and is

mounted in the cabin.
7.14. FIRST AID BOX
□ The first aid box is mounted in the cabin.
7.15. SAFETY BAR

□ The machine accesses are secured with safety bars.
□ If leaving the machine could be dangerous (adjacent track, during
driving, etc.) the safety bars on the steps have to be used!
□ This will lock the access/exit!
7.16. 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.
- smash in the window or windows with on-board tools
- leave the cabin without great hurry but bearing in mind safety
considerations
C28 BA 56658 USP 2000 SWS
7.17. RAIL GUARD
□ Each wheel is protected by rail guards.

□ 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.
USP 2000 SWS BA 56658 C29
8. DRIVING
The operating mode „DRIVING“ is structured as follows:
C30 BA 56658 USP 2000 SWS
Transiting - chapter 8.
□ During transit all four axles are driven hydrostatically by a fixed displacement motor.
□ The max. driving speed is 100 kmph.
Working drive – chapter 9.4.1.

□ In “working mode” all four axles are driven hydrostatically by a fixed displacement
motor.
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 100 kmph.
8.1. LIMIT VALUES FOR TRANSITING
Gauge mm 1676
2 Smallest practicable vertical radius m 500
3 Maximum practicable super-elevation mm 185
4 Maximum practicable gradient ‰ 35
(also maximum gradient for parking brake)
5 Maximum speed when self propelled km/h 80
6 Maximum speed when towed km/h 90
7 Maximum load hauled ton 65
USP 2000 SWS BA 56658 C31
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.
All EMERGENCY STOPs are unlocked.
All working system stops are unlocked.
All drive stops are unlocked.
The working main switch is turned „OFF“.
The key switch for transiting is turned „ON“ on one driver’s desk.
The parking brake is “RELEASED”.
The ballast hopper must be empty for transiting.
Warning:
The steep conveyor must be free of ballast when transiting! - Danger of injury!
□ Carry out brake test (when parking brake is released) with the direct
brake and the indirect brake - all brake blocks have to sit firmly.
□ Carry out brake test (when direct brake and indirect brake is released)
with the parking brake - all brake blocks have to sit firmly.
□ 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.
C32 BA 56658 USP 2000 SWS
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!
USP 2000 SWS BA 56658 C33
8.3. STARTING DRIVING
□ The conditions for „getting machine ready for driving - transiting“ have
been completed - chapter 8.2.
□ Transit mode is switched „ON“.
□ The engine is running and speed control has been activated on the
driver’s desk.
□ The machine is standing still, the brake is applied.
□ The tightness of the brake system complies with regulations.
□ The parking brake is released.
□ The wheels are free of scotch blocks.
□ Increase the engine speed to the maximum.
□ Pre-select the direction of travel (only when machine is stopped).
The corresponding button lights up.
Important:
The machine has to be at a standstill to pre-select the drive direction.
Release brake.
Press the button on the drive control lever and decline the lever.
The machine starts moving.
Watch the monitoring instruments during driving.
8.4. ACCELERATING
□ Optimum acceleration will be achieved if the engine speed is close to

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.

C34 BA 56658 USP 2000 SWS
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.

□ Use the brake as required.
8.8. STOPPING THE MACHINE
□ Move the drive lever to 0-position.

□ Bring the machine to a stop applying brakes (to avoid blocking up of
wheels, brake only with reduced pressure).
□ Reduce engine speed to idling.
USP 2000 SWS BA 56658 C35
8.9. CHANGING DIRECTION
Reduce the engine speed to idling.

The drive lever is in 0-position.
Wait until the machine is at a standstill.
Switch “OFF” transit drive mode on driver’s desk #1
The direct and indirect brake are in end position.
The key battery main switch remains “ON”, the engine keeps running.
On the new driver’s desk, at the front (of the direction of travel):
- switch “ON” the transit drive mode on driver’s desk #2
- pre-select the direction of travel
□ Release brake, increase engine speed and decline the drive lever.
□ The machine starts moving.
□ Drive as described above.
Attention:
Beware of different visibility, allow yourself to be directed if visibility is
insuficient!
The regulations with regard to visibility deserve particular attention!
C36 BA 56658 USP 2000 SWS
9. WORKING
The operating mode “WORKING” is structured as follows:
USP 2000 SWS BA 56658 C37
□ “WORKING” is the condition where the machine performs the activity

for which it was built.
□ This machine is a continually working ballast distributor and regulator.
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
Gauge mm 1676
3 meter (non supported machine)
3 meter (supported machine)
4 Maximum cross level during working mm 185
5 Maximum working ramp gradient 1 1:100
6 Vertical curvature fault over a distance of 10 meters mm 50 (top to top)
C38 BA 56658 USP 2000 SWS
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 13.10. has to
be applied!
USP 2000 SWS BA 56658 C39
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.
□ Switch “OFF” the key switches for transit mode on both driver’s desks.
□ Switch the direct brake to end position.
□ Switch the indirect brake to end position.
□ The parking brake is “APPLIED”.
□ Switch “ON” the working mode main switch.
□ For starting the system press the green illuminated button and keep
pressed until the button lights up.
Warning:
From this moment the warning flashing lights will start to flash alternately and
so indicate the danger area.
The danger area must not be entered anymore.
Danger of fatal injuries!
□ Release parking brake.

□ Drive the machine forward when starting working.
□
C40 BA56658 USP 2000 SWS
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.
- shoulder plough - chapter 9.4.2.
- centre plough - chapter 9.4.3.
- sweeper system - chapter 9.4.4.
- rail fastening brush - chapter 9.4.5.
- ballast hopper - chapter 9.4.6.
9.4.1. WORKING DRIVE
□ The “preparations for bringing the machine in working mode” have

been completed – chapter 9.3.
□ First, the working mode has to be pre-selected (sweeping or
ploughing).
□ Bring the engine to the working speed.
□ Press the direction of travel button (forward or reverse), the working
brake will be released.
□ The machine is brought to the desired travelling speed by operating the
drive lever.
□ For stopping move the drive lever to the 0-position and activate the
drive stop button.
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.!
USP 2000 SWS BA56658 C41
9.4.2. SHOULDER PLOUGH
Activate the shoulder plough release “lock / unlock“.

Switch - unlock working units.
The shoulder plough slewing control has to be set for the respective
track centre distance. See attached instructions “Shoulder plough
slewing limits“.
Note:
The shoulder plough slewing limit will always have to be checked and
readjusted, if necessary, BEFORE working starts.
□ Turn the working mode switch to “PLOUGHING” position.
□ Lift shoulder plough
□ Release safety chains on both machine sides.
□ Lower shoulder plough.
□ Set slewing distance.
□ Set shoulder angle.
□ Adjust plough shields and plough tips according to the required ballast
flow and/or the shoulder formation.
□ Working drive – see chapter 9.4.1.
Note:
For achieving a constant and smooth ballast flow the proper working drive
speed has to be selected, which is depending on ballast condition.
Warning:
Be aware of persons and obstacles in the working area during working! Risk of
accident!
Important:
On multiple-track lines it is very important to observe traffic on adjacent tracks!
C42 BA56658 USP 2000 SWS
9.4.3. CENTRE PLOUGH
□ Activate the centre plough release “lock / unlock”.

□ Switch – unlock working units.
□ Turn the working mode switch to “PLOUGHING” position.
□ Lift centre plough.
□ Release safety chains.
□ Lower centre plough to required height (depending on the amount of
ballast).
□ By optionally moving the plough halves and adjusting the plough
shields the required ballast flow can be adjusted.
□ The plough shields are moved to the required position by pressing the
corresponding pre-selection buttons (see symbols next to buttons).
□ Set outer ballast guide shields as required. Working drive
– see chapter 9.4.1.
Note:
For achieving a constant and smooth ballast flow the proper working drive
speed has to be selected, which is depending on ballast condition.
Warning:
Be aware of persons and obstacles in the working area during working! Risk of
accident!
USP 2000 SWS BA56658 C43
9.4.4. SWEEPER SYSTEM
Activate the sweeper system release “lock / unlock”.

Switch - unlock working units.
Turn the working mode switch to “SWEEPING” position.
Lift sweeper system.
Release safety chains on both machine sides.
Lower and re-rail sweeper system.
Adjust ballast deflector plates as required.
Warning:
Danger of injury!
□ Select working mode of conveyors:

- Cross conveyor drive left / right.
- Steep conveyor belt for charging the hopper.
Important:
The filling level of the hopper needs to be observed!
□ Adjust cross conveyor and steep conveyor drive speed if necessary.

□ Visually check the lowered sweeper system for correct working
position.
□ Check the brush shaft for correct adjustment and re-adjust, if
necessary.
Note:
This procedure may also be carried out with the help of an external control
panel (81/).
Switch on the rotary brush drive.

Set working speed.
Important:
Depending on ballast volume, adapt the running speed of the conveyors, rotary
brushes and the working drive speed to the required conditions.
□ When there are obstacles on the track (lines, rods, etc.) the brush shaft
can be lifted by 10 cm of the adjusted setting.
Important:
Beware of obstacles on the track!
C44 BA56658 USP 2000 SWS
□ Working drive - refer to chapter 9.4.1.
Warning:
Never remove jammed objects or ballast from operating working units.
Warning:
ballast outlet plates, cranes, etc.) is prohibited due to safety hazard and injury!.
USP 2000 SWS BA56658 C45
9.4.4.1. BRUSH CHANGER
A brush shaft loading device (lifting gear) and an electric rope winch
are used for changing and loading the brush shaft.
Connect remote control cable for rope winch.
Connect power supply cable for rope winch.
Mount rope winch and fit supports for brush.
Changing the brush shaft:

Lower sweeper system/rotary brush until the brush shaft is lying on the
ground.
Open sweeper system rear wall lock.
Unhook sweeper system rear wall.
Remove cover plates to the central bolts.
Undo central bolts on the L.H.S. and R.H.S. of the shaft ends.
Dismantle half shafts on the left and right by the shaft ends (two
extracting bolts should be used for that).
Lift sweeper system.
Drive the machine forward until the brush shaft lies clear.
Fasten the brush shaft to the loading beam of the rope winch.
The rope winch guide rail is to be extended on the required side by
using an extension piece.
Lay down the rotary brush lengthwise next to the machine.
Undo the loading beam from the rotary brush shaft.
For fitting the new brush shaft,, position it directly behind the sweeper
system (rotary brush box).
Fitting – see above, but in reverse order.
Store the used brush shaft away.
Secure the used brush shaft with locking bolts.
Dismantle the rope winch and stow away the supports for the brush.
Attention:
Do not enter the danger area if engine is running.
Important:
After the brush change has been completed all loading devices have to be
properly put back in their locking positions and secured.
C46 BA56658 USP 2000 SWS
9.4.5. RAIL FASTENING BRUSH
Activate the fastening brush release “lock/unlock” L.H.S./R.H.S..

Switch – unlock working units.
Release safety chains on both machine sides.
Lower rail fastening brushes.
Warning:
Ballast can be thrown off in the working area!
USP 2000 SWS BA56658 C47
9.4.6. BALLAST HOPPER
9.4.6.1. WORK PROCESS FOR BALLAST HOPPER
□ The ballast hopper is filled with the use of the sweeper system and
steep conveyor (see also chapter 9.4.4.).
□ Switch off cross conveyor drive and rotary brush drive by the
sweeper system.
□ Close the deflector plates on the sweeper system.
□ Close hopper flap.
□ Switch on steep conveyor drive “FORWARD”.
□ Switch on rotary brush drive.
□ Adjust steep conveyor running speed using the volume control.
□ Switch on hopper conveyor automatic mode.
Note:
In hopper conveyor automatic mode the hopper level is controlled via sensor.
□ If hopper conveyor automatic mode is switched on, the hopper

conveyor will not be switched on until the set filling level has been
reached and the ballast is moved a bit further to the front.
□ When the ballast hopper is full the hopper conveyor drive will switch
off and the warning buzzer on switch panel B11 will sound.
□ It is absolutely necessary to monitor the ballast hopper filling level.
Important:
Depending on ballast volume, adapt the running speed of the conveyors, rotary
brushes and the working drive speed to the required conditions.
Attention:
Never remove jammed objects or ballast from operating working units.
Note:
panel (74/).
C48 BA56658 USP 2000 SWS
9.4.6.2. BALLASTING THE TRACK
□ By switching over the rotary brush flap, excess ballast which cannot
be swept into the sleeper cribs is swept onto the steep conveyor and
transported into the ballast hopper. From here stored ballast can be
delivered to any required place on the track.
□ Pre-select working mode “SWEEPING” and switch on sweeper
system – see chapter 9.4.4.
□ Close deflector plates.
□ Turn the conveyor pre-selection switch to “steep conveyor forward”
position.
□ Open hopper flap.
□ In automatic mode the hopper ballast level is controlled via sensor.
□ Set hopper conveyor speed.
□ The ballast is transported to the hopper flap by the hopper conveyor.
□ Depending on the required amount of ballast, open and close the
ballast flap.
□ The ballast chute flaps need to be switched inward or outward, as
required.
□ Working drive – see chapter 9.4.1.
Note:
panel (61/).
USP 2000 SWS BA56658 C49
9.5. RETURNING TO TRANSITING
□ If possible, stop the machine in a straight track section and apply the
brakes.
□ Switch off working drive speed.
□ Switch off rotary brush drive.
□ Switch off conveyor drives.
□ Lift fastening brushes R.H.S. and L.H.S. into transport position.
□ Lift shoulder plough R.H.S. and L.H.S. and slew plough shields such
that they can be retracted in the supporting forks.
□ Store the shoulder ploughs in the skewback rest.
□ Slew the centre plough outer shields to the track centre line.
□ Lift the centre plough to transport position.
□ Slew in the deflector plates of the sweeper system.
□ Close the hopper conveyor flap.
□ Close the output chutes of the hopper.
□ Turn off locking release for:
- fastening brushes L.H.S. and R.H.S.
- shoulder plough L.H.S. and R.H.S.
- centre plough
- sweeper system
□ Lock working units.
□ Put in place all transport securing devices:
- Shoulder plough
- Centre plough
- Sweeper system
- Rope winch (guide rail unmounted)
- Rail fastening brushes
□ Switch off working main switch.
□ Ensure that all working units are properly set into travelling position
and locked.
□ Check the machine all round generally.
□ Pull back the idling controller to idling on the driver’s desk located at
the front of the intended direction of travel.
□ Activate the speed control.
□ Turn “ON” the key switch for transit mode.
□ The machine is now in “transit mode”.
C50 BA56658 USP 2000 SWS
10. MISCELLANEOUS
10.1. 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!
□ Do not touch the working lights or get too close - danger from heat!
USP 2000 SWS BA56658 C51
11. STABLING THE MACHINE

□ All measures for returning the machine to “transit mode” have been
completed – see chapter 9.5.
□ Decisive factors for shutting the machine down are the situations that
may occur on the unmanned machine.
□ If constant observation of the shut down and unmanned machine can
be ensured and it is expected to put the machine back in operation
soon, then it is generally sufficient to:
- secure the machine with scotch blocks or parking brake from
breaking away
- turn off the key switch for transit mode
- shut down the engine
- turn “OFF” the key battery main switch
Shutting the machine down with the machine crew going away will
result in an undefined situation.
Important:
If the machine has been shut down and is shunted or towed without any
special preparation - see chapter 11.1. - serious damage to the machine may
occur as a result.
Attention:
Protect the cabin equipment from strong sunshine by pulling down the sun
blinds.
C52 BA56658 USP 2000 SWS
11.1. SHUTTING THE MACHINE DOWN, SHUNTING/TOWING DRIVE
□ When parking the machine in an unsupervised location the following

conditions will have to be met:
- the machine is in transit drive mode – see chapter 9.5.
- secure the machine with scotch blocks from breaking away
- turn “OFF” the key switch for transit drive mode
- switch the axle gearboxes to neutral position
- lock the axle gearboxes (“ready for towing”)
- first “RELEASE” the direct brake, then set to end position
- first “RELEASE” the indirect brake, then set to end position
- all EMERGENCY STOPs are unlocked
- all working system stops are unlocked
- all drive stops are unlocked
- switch “OFF” the pn. stop cock for the safety brake and secure
in this position
- the pn-stop cocks of the direct brake are in position “OFF” and
padlocked
- the emergency brake is not applied
- the parking brake is “RELEASED”
- secure all loose parts on the machine
- the ballast hopper is empty
- turn “OFF” the machine lighting
- shut down the engine
- turn “OFF” the key battery main switch
- remove all key switches
- turn “OFF” the service battery main switch
- the KE valve has to be switched “ON”
- set change over handle to “G"
- close and, if necessary, lock all doors and gates
- secure the machine from unauthorised use
- all air vent and drain cocks are “CLOSED”.
- mark the machine in accordance with regulations
Attention:
In addition to that you must check that all brake blocks are clear of and
released from the wheel.
Towing the machine with the brakes actuated will result in considerable
damage to the machine!
High risk of fire from huge generation of heat in addition to flying sparks!
□ The machine is now shut down, ready for shunting and towing!
Warning:
If one or several of the conditions stated above will not be fulfilled, damage to
the machine will be the consequence!
USP 2000 SWS BA56658 C53
11.2. ADDING THE MACHINE DIRECTLY TO THE TRAIN
□ The machine has been made ready for towing – chapter 11.1.
□ Couple the draw hook and tighten so there is no play.
□ Couple the main air pipes and “OPEN” the relevant stop cocks.
□ If necessary, remove scotch blocks and stow away.
Important:
It is PROHIBITED to tow the machine while the engine is running! This results
in serious gearbox damage!
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 12.2.1
Important:
Additionally, you must check whether the brake blocks are slack and freely
hang down the wheel.
Warning:
If one or several of the conditions stated above will not be fulfilled, damage to
the machine will be the consequence!
C54 BA56658 USP 2000 SWS
12. THE PARKING BRAKE
12.1. GENERAL
□ The parking brake (stopping brake) is a mechanical system consisting

of spindle block, hand wheel, angular gear, etc.
□ The parking brake acts on the front bogie.
□ There is no monitoring or indication of the parking brake status
(APPLIED – RELEASED)!
□ This requires increased attention when using the brake.
□ Driving the machine with the parking brake “APPLIED” results in
considerable damage to the machine.
12.2. THE OPERATING STATUSES OF THE PARKING BRAKE
□ The parking brake has the following operating statuses:

- Parking brake “RELEASED” - chapter 12.2.1.
- Parking brake “APPLIED” - chapter 12.2.2.
12.2.1. PARKING BRAKE RELEASED
□ Turn the hand wheel anti-clockwise "LEFT" to the limit stop.

□ Whether the parking brake was “RELEASED” fully can only be seen
from the brake blocks, if they are clear of and released from the wheel.
12.2.2. PARKING BRAKE APPLIED
□ Quickly turn the hand wheel clockwise “RIGHT” to the limit stop.
□ The hand wheel determines the braking power.
USP 2000 SWS BA56658 C55
13. BEHAVIOUR IN FAULT CONDITIONS OF INDIVIDUAL

MACHINE COMPONENTS
13.1. DRIVING CONTROL MALFUNCTION
□ Use the emergency drive device only if all other possibilities of machine
control have been exploited (working drive, short drive, etc.) or in
emergencies, such as clearing the vehicle from dangerous locations
(bridges, tunnels, storage tanks, etc.).
□ It will only be possible to drive the machine to the nearest station or
workshop and only with extreme caution.
□ For this purpose the machine is equipped with an emergency drive
mode - chapter 13.1.1.
13.1.1.EMERGENCY DRIVE MODE
□ If the main program is faulty take it out of service (18e1).

□ Plug in emergency drive control box.
□ Remove the seal from the emergency drive control and turn the toggle
switch “ON”.
□ The engine is running.
□ The speed is controlled via the speed controller on the driver’s desk.
Move it to full throttle.
□ Check that the gears are “ENGAGED” (visual inspection).
Note:
For enganging by means of emergency drive panel pre-select the desired
direction of travel, marginally rotate the potentiometer for driving speed
adjustment and press the clearance switch shortly.
□ Carry out brake test (when parking brake is released) with the direct
brake and the indirect brake - all brake blocks have to sit firmly.
□ Carry out brake test (when direct brake and indirect brake is released)
with the parking brake - all brake blocks have to sit firmly.
□ After each brake test the brake blocks have to release from the wheel!
□ The releasing time must be in accordance with regulations!
□ Turn the potentiometer of the emergency drive control box to “0”.
□ Switch “ON” transit drive mode for releasing brake.
□ Pre-select the desired direction of travel.
C56 BA56658 USP 2000 SWS
□ Keep clearance switch of the emergency drive control box pressed.

□ Slowly rotate the potentiometer of the emergency drive control box; the
machine starts moving.
Important:
Changing direction of travel is only permitted when the machine is standing
still.
13.2. ALARM WARNING
□ If a fault occurs in the system the warning buzzer sounds and the fault
message is output on the alarm list.
□ 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!
13.3. FAULT IN THE TEMPERATURE MONITORING SYSTEM
□ Switch “OFF” the main switch of the temperature monitoring system.

□ Turn “ON” the temperature monitoring system bypass switch – open
the protective guard and press the switch.
□ 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.
USP 2000 SWS BA56658 C57
13.4. MALFUNCTION OF THE SAFETY BRAKE
□ Lock the locked lever for the safety brake and secure it in this position.
□ Turn on the safety brake bypass switch - rotate the protective guard 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!
13.5. MALFUNCTION OF THE DIRECT-ACTING BRAKE
□ Protect the machine from breaking away (parking brake, skid-pans

etc.)!
□ In case of a malfunction of one direct brake valve the other direct brake
valve can be used!
Warning:
Reduced brake force!
□ Lock the lever for the direct-acting brake and secure it in this position.
□ Turn on the safety brake bypass switch - rotate the protective guard to
the right and the switch down.
Important:
You may drive to the next station or the next workshop provided you observe
particular caution as braking is possible only with the second direct brake
valve.
C58 BA56658 USP 2000 SWS
13.6. FAILURE OF THE INDIRECT-ACTING BRAKE
Protect the machine from breaking away (parking brake, skid-pans

etc.)!
Switch off the indirect brake valve.
The direct brake has to be used.
Important:
You may drive to the next station or the next workshop provided you observe
particular caution as braking is possible only with the second direct brake
valve.
13.7. 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 - see chapter 7.12.
13.8. 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!
USP 2000 SWS BA56658 C59
13.9. 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
Attention:
It is prohibited to operate the machine with incorrectly adjusted brakes!
C60 BA56658 USP 2000 SWS
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
Lifting point - front L.H.S. of machine
Lifting point - rear L.H.S. of machine
Lifting point - front R.H.S. of machine

Lifting point - rear R.H.S. of machine
14.2. LIFTING POINTS FOR CRANE
□ The machine is in “machine shut down” mode – see chapter 11.1.
Lifting point - front L.H.S. of machine
Lifting point - front R.H.S. of machine

USP 2000 SWS
PART D
Fire Protection By The Operating Organization
Preventive Fire Protection Measures
Early Fire Hazard Detection
Temperature Monitoring System
Emergency Plan
How To Act In Case Of Emergency

USP 2000 SWS BA56658 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).
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 BA56658 USP 2000 SWS
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.
USP 2000 SWS BA56658 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.
HOW TO ACT IN CASE OF TEMPERATURE ALARM / FIRE
FIRE SYMPTOMS IMMEDIATE ACTIONS INSTRUCTIONS
IMMEDIATELY LEAVE DANGEROUS AREAS, • Stop the machine in a safe location.

> EARLY WARNING OR
SUCH AS TUNNELS, BRIDGES, ETC.!
ALARM SIGNALLED BY • In case of temperature warning I
THE TEMPERATURE alarm or fire symptoms,carefully
MONITORING SYSTEM STOP THE MACHINEIN A SAFE LOCATION check possible vulnerable areas.
(OPTION) AND PREVENT IT FROM ROLLING AWAY. • Observe the operating instructions.
CHECK VULNERABLE MACHINE SECTIONS! • If necessary,push an engine-stop
> SMOKE
IF NECESSARY, TURN OFF THE ENGINE! button.
If danger is imminent, immediately leave the • Turn off the master switch.
machine!
> ODOUR
> VAPOURS
ONLY QUALIFIED STAFF
EXTREMELY HOT FIRE FIGHTING • Identify the source of the fire.
• Use fire extinguishers.
AND/OR
+ Remove flammable substances from
DISCOLOURED LININGS
Do not endanger yourself! the danger area.
> SMOULDERING
SAFETY AND RESCUE
• Leave the danger area.
FLAMES • Raise the alarm.
! EMERGENCY CALL! • Call for the ambulance, the fire
brigade and initiate fire-fighting
measures and first aid.
Plasser & Theurer ST-0003-GB

USP 2000 SWS: Universal-Schotter Planier Maschine

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USP 2000 SWS BA56658

USP 2000 SWS

Machine number: 56658-56684

Copyright © 2021 by Plasser India

No. Date Reviser Reason of revision Page

1.0 March 21, 2021 Pawan 1st version -

Manufacturer’s name and address

Section allocation of illustrations

Outline of operating processes

Fire protection by the operating organization

BOGIE ADAPTATION MEASURES ............................................................................................... 1-24

Manufacturer’s name and address

Service information SI-0300-01

Service information SI-0400-03

Machine number: 56658-56684

GENERAL DESCRIPTION FOR THE OPERATION, MAINTENANCE, PERIODICAL CHECKING

SAFETY GUIDELINES TO PREPARE ANY REPAIR WORK ON THE MACHINE

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

PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS

□ Deactivate hydraulic pressure!

□ Deactivate the air system!

□ Turn off the engine!

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

□ In working mode the working area is prohibited again!

Ballast profiling machine USP 2000 SWS

AIR CONDITIONING DEVICE

RAIL FASTENING BRUSH

Main pneumatic through pipe 5 bar

Main pneumatic through pipe 5.0 bar

Direct-acting brake two circuit brake with

Indirect-acting brake control valve KE

Parking brake Spindle block, with hand wheel

Shunting humping and pushing off PROHIBITED

Transfer in train formation ONLY when engine is off

FIRE EXTINGUISHER 1 no. in total

LIFE HAMMER 1 no. in total

FIRST AID BOX 1 no. in total

THRESHOLD VALUES FOR TRANSFER MODE:

# Parameter Dimension Limit

THRESHOLD VALUES FOR WORKING MODE:

# Parameter Dimension Limit

INDIRECT ACTING BRAKE

BRAKE BLOCKS – BRAKE CYLINDERS

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

1. Engine control panel B5

1 = Display for DATAMATIC

1. Red LED: engine lub. Oil pressure too low

1. LED: indicator shoulder plough R.H.S. unlocked / locked

ENGINE CONTROL PANEL - SECTION “D“

1. Switch for hydraulic system pressure ON

1. Dual air pressure gauge

ENGINE CONTROL PANEL - SECTION “F“

1 = D rive control lever

BRAKE CONTROL PANEL REAR

1. Brake control lever for direct-acting brake