GEISMAR STUMEC VPS User manual

In accordance with our environmental safety policy, this manual has been printed on recycled paper.
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GEISMAR, the quality choice !
You have just acquired a machine for laying and servicing railway lines. We thank you for choosing equipment developed and constructed by
GEISMAR / STUMEC, the fruit of over eighty years’ experience.
Every day since 1924, the GEISMAR Group has been investing in research and state-of-the-art construction to offer you the quality and
reliability so essential to the requirements of the world of railways.
This machine, built entirely in France from design through to delivery, has been subjected to continuous, extremely strict controls. Formed of
different mechanical elements assembled by highly qualified fitters, your machine has been tested, calibrated and controlled at every stage of its
production.
We are convinced that it will give you every satisfaction and are, of course, at your service to offer you any recommendations you may require
for its use or its maintenance.
We thank you for the confidence you have shown in us and, in the hope that we will remain one of your privileged partners, we would like to
confirm that we are totally available for any comments or recommendations you may care to make.

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LIST OF CONTENTS
CHAPTER 1–SAFETY
1.1 Introduction
1.2 Safety and general operating instructions
1.3 General safety regulations
1.4 Special safety instructions
1.4.1 Possible risks liable to be caused by use of the “VPS”
lightweight portable vibrator
1.4.2 Tip quality and instructions for use
1.4.3 Personal protective equipment
1.4.4 Precautions concerning fuel
1.4.5 Transport - Handling
1.4.6 Working
1.4.7 Pictograms and safety instructions
CHAPTER 2–MACHINE DESCRIPTION
2.1 General
2.2 Overview
2.3 Technical specifications
2.4 Positioning the vibrator on the gauge
CHAPTER 3–INSTALLATION –POSITIONING
3.1 Fuel
3.1.1 Filling up with fuel
3.1.2 Transporting the machine
3.2 Inspection of the lightweight portable vibrator
CHAPTER 4-OPERATION
4.1 Operating conditions
4.2 Starting up the lightweight portable vibrator
4.3 Instructions for using the lightweight portable vibrator
4.4 Stopping the lightweight portable vibrator
4.5 Storage
4.5.1 General storage instructions
4.5.2 Special storage instructions
CHAPTER 5–SERVICING /MAINTENANCE
5.1 Servicing
5.1.1 List of equipment and accessories required for servicing
5.1.2 Engine
5.1.3 Cleaning
5.1.4 Tightening
5.1.5 Removing the engine cover
5.1.6 Carburettor
5.1.7 Spark plug
5.1.8 Cleaning/replacing the air filter
5.1.9 Fuel filter
5.1.10 Replacing the tip on the lightweight portable vibrator
5.1.11 Protective sleeve
5.1.12 Engine coupling
5.1.13 Changing the bearings on the transmission shaft
5.2 Maintenance
5.2.1 Preventive maintenance schedule
5.2.2 List of normal wear parts
CHAPTER 6–ACCESSORIES &OPTIONS
6.1 Accessories
6.1.1 Transport bag
CHAPTER 7–SPAREPARTS CATALOGUE
7.1 Drawings and parts’ lists

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CHAPTER 1 – SAFETY
1.1 Foreword
The following set of rules has been drawn up to ensure the application of precautionary principles that help to preserve the safety of persons and property
when the machine is in use. Any failure to comply with these rules can have serious repercussions (bodily injury, etc.), and can even be fatal, so we must draw
your attention to the fact that all persons involved in the use, maintenance, storage or custody of the machine covered by the present manual must be familiar
with these rules.
Any users who cause an accident through failure to comply with these rules will be held personally responsible for the results of their actions.
1.2 Instructions for safety and general use
All persons using, servicing or repairing this equipment must have undergone the training, possess the skills, and have at their disposal the tools necessary to
carry out any such operations.
Before using the equipment, even in a maintenance context, it is necessary to read the corresponding instruction manual, together with its appendices, and the
safety rules in force in the workplace.
Comply carefully with the general safety instructions drawn up for the site by the person in charge of the site, especially if the work is carried out without
stopping or diverting traffic.
The equipment can only be used, serviced or repaired by competent personnel who have undergone thorough specialized training beforehand. The technical
documentation and the instructions are useful in completing the knowledge acquired during the training courses, but they can in no way replace theoretical and
practical qualifying training, provided in accordance with good professional practice.
If the operating company is not in a position to carry out the necessary training for its staff, at a satisfactory level, the GEISMAR/STUMEC Company is able
to provide advice concerning the training programme to be implemented.
The training must include an explanation of the various equipment functions, the instructions for use and maintenance, and the safety rules applicable, together
with practical exercises.
IMPORTANT! All persons using the machine must comply with the labour regulations in force
The GEISMAR/STUMEC Company cannot be held responsible for any modifications made without its
written approval, or for any assembly work not in conformity with its recommendations, especially in the
case of use of parts other than original manufacturer’s parts.

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1.3 General safety instructions
•The operator and the working environment
To avoid all risks of accident or injury, it is essential to wear:
-Sturdy, non-flammable clothing that is suitably close-fitting
-Strong, non-slip gloves
-Safety shoes
-Protective eyewear
-Safety helmet
-All other equipment necessary on the site or when using the machine
In the case of use of ear defenders, the safety instructions in force on the site must be complied with at all times.
Make sure that the machine vibrations do not lead to a loss of sensitivity in the hands. Adapt the working periods to the level of vibration caused by
the machine, which is shown within the framework of normal use.
Do not work with the machine if you are not sure that you can control it correctly. Do not start working with the machine until you are sure that you
can do so in full safety, for yourself (good conditions of visibility and lighting) and for other people (work calmly and carefully). Take care to ensure
you have a firm, stable footing; all unstable working positions must be prohibited.
The user must be in a physical and mental condition enabling work to be carried out without danger.
The work area must be free of all obstacles. The work area (and the surrounding areas) must be free of all flammable substances.
If anything does not seem clear to you, whether it concerns the machine or the work to be carried out, ask a qualified person for information. Do not
base your work on assumptions.
For underground use (tunnel or gallery), or in a closed area, make sure there is sufficient ventilation or extraction to avoid the risks generated by
inhaling exhaust gases or by their build-up.
This equipment must not be used in an explosive atmosphere.
Avoid working positions in which exhaust gases could come into contact with parts of the body, whether protected or not.
In a general way, take all necessary precautions to prevent flammable products from coming into contact with fire hazards.
The operator must ensure that no one else is within the working area. In particular, it is necessary to make sure that in the direction in which the
machine is travelling, no one can be hit. If someone is nonetheless in the path of the machine, the operator must stop and warn the person of his
passage.
When the machine is installed on the track, it must be handled only by the number of operators strictly necessary for its normal use.
As the overall size of the machines does not enable extinguishers to be carried on them, we strongly recommend placing extinguishers of an
appropriate type to deal with the fire hazards close to the machine.
The user must comply with all the regulatory environmental instructions applicable to the machine in use.

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•The operator and the machine
Before putting the machine into service each time, check that its condition and its operation are in compliance with the instructions.
In particular, make sure that the controls are free and in good working order, and that they are in the “stop” or “neutral” position. Never make any
modifications that could affect correct operation of the control systems.
All the protective elements must be kept carefully in place and in good condition.
Always keep the machine clean and remove any accumulated dust, especially if it could absorb flammable products.
Always move forwards when working.
When working, always hold the machine with both hands to ensure control at all times, and to be able to use it in full safety.
Never bring a machine close to a flame or a source of heat.
The machine must never be positioned close to hot or protruding elements that could damage some parts (tanks, exhaust, housings...).
Never move away from a machine while the engine is running, even when it is idling. Stop the engine immediately if the machine is not in use. After
stopping the engine, wait until all moving parts have come to a complete stop.
Work on the electrical installations on the machine can only be carried out by suitably qualified persons.
Read and make sure you fully understand all the signs placed on the machine, and always comply with all the instructions.
The signs placed on the machine include pictograms, manufacturer’s plates, and instruction labels. Make sure they are kept clean and replaced if
they have been damaged, or if they are missing or illegible. If one of these elements is on a part that is to be replaced, a new element must be present
on the replacement part. Please contact us on this subject.
When using a lifting device, the lifting operations of the machine must be done only using the lifting points indicated on the instruction manual.
When possible, the lifting of the machine is to be done only when the machine needs to be set in or out of the track. If the machine has to stay lifted
(for a maintenance operation for example), the hazardous area must be signaled/marked, so that no one can stay below the machine or walk close by.
THE MACHINE MUST NEVER BE USED FOR A PURPOSE OTHER THAN THAT FOR WHICH IT IS INTENDED
NEVER TOUCH A MOVING PART WITH A TOOL,OR WITH THE HAND,OR WITH ANY OTHER PART OF THE BODY
IT IS E
ES SS SE EN NT TI IA AL L T TO O S ST TO OP P T TH HE E E EN NG GI IN NE EAND SET THE CONTROL TO THE STOP POSITION BEFORE CARRYING OUT :
-ANY HANDLING WORK
-ANY WORK TO CHANGE TOOLS OR SOCKETS
-ANY WORK INVOLVING FUEL OR OIL (FILLING,TOPPING UP,CHECKING LEVELS,ETC.)
-ANY REPAIR,MAINTENANCE OR CLEANING WORK

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•Using and handling fuel and oil
It is essential to stop the engine and set the control to the stop position before carrying out any work involving fuel (filling up, checking
the level, draining, etc.).
Always keep suitable extinguishers ready for use in all areas where fuel is handled (storage, filling up, etc.).
Always store fuel and oil in separate cans specially designed for the purpose and bearing the labels required by regulations. They must be stored in a
safe place, well away from all types of fire hazard.
Each time a machine is started up, and while it is running, make sure that there are no fuel leaks from any part of the machine. If a leak is suspected,
stop the engine immediately and do not restart the machine until the leak has been repaired.
Never carry out any work on a fuel tank or handle fuel to fill a tank, or for any other reason, in an area where there could be a fire hazard (such as a
burning cigarette, a blowtorch, sparks, etc.) or substances that are incandescent or at a high temperature (such as welding spatters, slag, clinker, etc.).
All such work must always be carried out outdoors or in a well-ventilated area.
Always turn all mobile phones off while filling a tank with fuel or handling fuel.
Carefully tighten the fuel filler cap each time, and check that no fuel leaks from it.
Always remove a filler cap slowly, to enable any internal pressure to be released without spraying any fuel out. Take special care if the surrounding
temperature is high.
When putting fuel in a machine that has heated up, never fill the tank completely. Do not put in more than three-quarters of the tank capacity.
If fuel starts to boil in the tank when putting fuel in a machine that has heated up, screw the cap on again immediately and leave the machine to cool
down.
Make sure the fuel used is suitable for the type of engine on the machine. See the user manual for the engine.
Do not inhale fuel vapour.
If it is necessary to drain the fuel tank, pour the fuel into a container designed for the purpose and bearing the labels required by regulations. Always
close them tightly, even if they only contain a small quantity. Never use a glass container.
Never use fuel for cleaning work. Use only non-flammable, non-toxic products that are harmless for the user, the equipment and environment.
If fuel has been spilt near the filling area for any reason, clean it up immediately. Clean straightaway any spillage of fuel on the skin. Make sure no
fuel has been spilt on your clothes; otherwise, change clothes immediately. Remove all rags or other materials used to wipe fuel, and store them in a
safe place well away from all sources of heat or combustion. Move the machine well clear of any spilt fuel before starting it up (at least 6 metres
away), and do not move any closer to the area while the engine is running.
IN CERTAIN CASES HANDLING OIL CAN GIVE RISE TO THE SAME TYPE OF RISKS AS HANDLING FUEL.IT IS THEN ESSENTIAL TO TAKE THE
SAME PRECAUTIONS WITH OIL AS THOSE SET OUT ABOVE FOR FUEL.

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•Tools to be used on the machine
Use only the types of tools intended for normal use of the machine.
Measure the speed of all rotating tools at regular intervals.
Never use tools at speeds greater than the maximum speed for which they have been designed and approved.
Never use damaged tools or tools that have reached their maximum level of wear.
•The engine on the machine
Never touch the hot parts of the engine, and especially the exhaust pipe. If it is necessary to work on the engine, wait until it has cooled down.
The factory setting of engine corresponds to the conditions of the production site (fuel, temperature, altitude, etc...), verify at receipt of the
machine the rotational speed of the engine and correct if necessary.
Check the engine rotation speed at regular intervals, and especially after fitting tools or reassembling the machine. Adjust if necessary.
Never exceed the speed shown in the technical specifications.
After starting with the choke, remember to return the choke to the normal running position.
Never wind the starter rope around your hand, and never release it suddenly.
If the machine does not operate correctly after the engine has been started, stop the engine and inform the head of maintenance.
For petrol engines, use only spark plugs whose tops are as shown in drawing 1 opposite. If the plug is fitted with a
screw top, make sure the top is fully tightened. After fitting the spark plug, make sure that the plug cap is in good
condition and that it stays firmly on the plug. Carefully check the fastening system to make sure that no sparks can
be formed.
•Using trolleys (If applicable)
A machine designed to work on a trolley must not be used without the trolley. The trolley is thus an integral part of the machine. The machine
and the trolley must not be used separately.
Trolleys whose use is dedicated to a machine must never be used to transport equipment or personnel, or attached to a vehicle.
Before fitting the machine on its trolley, it must be placed correctly on the track to ensure that it can run freely. If it is on a sloping section of
track, make sure the trolley is kept immobile while the machine is being put on the track or taken off it.
Attention, the trolley takes up the full width of the track and can cause injuries to the legs if it hits someone.

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1.4 Special safety instructions
1.4.1 Possible risks liable to be caused by the use of the “VPS” lightweight portable vibrator
The main risks that the “VPS” lightweight portable vibrator may cause to users and persons in the vicinity are:
Fires resulting from handling fuel incorrectly.
Inhalation of particles when tamping ballast.
Risks of being burnt by the tip of the vibrator after intensive use.
Ballast being projected by the tip’s vibrations.
1.4.2 Tip quality and instructions for use
•The engine MUST be stopped before the tip is changed.
•Only use tips officially authorized for this type of machine and which
possess technical characteristics (type and dimensions) that comply with
§2.3 Technical characteristics / tip” and with the instruction plate
riveted to the machine.
Users are RESPONSIBLE for all accidents involving non-
authorized tips.
•Never use a cracked or chipped tip. Broken tips must be discarded
immediately and be replaced by tips in perfect condition.
•When the tip is working, never touch it with your hand or any other part
of your body.
•When the tip is working, make sure that it is not close to any
obstacle such as sleepers or rails.
•Regularly check the maximum speed of the engine under NO LOAD
conditions, especially after reassembling the machine. Never check the
machine’s maximum speed when it is working, as risks of accident risks
are extremely high. To avoid all risks of accident, we recommend using
an electronic no-contact tachometer.
1.4.3 Personal protective equipment
•Personnel using this equipment must wear the clothing specified in
paragraph §1.3 “General safety regulations / the operator and his
environment”.
•They must wear safety helmets and safety boots with non-slip soles and
steel toe-caps.
•We also recommend wearing a means of protection to avoid inhaling
any particles when ballast is being tamped.
•Use of ear-muffs is also recommended (However,
railway regulations in force and applicable to the
worksite must be referred to, in order to see whether
muffs may be used or not).

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1.4.4 Precautions concerning fuel
•Clean the area around the filling point, to prevent any impurity entering
the tank or damaging the seal on the fuel cap.
•Open the fuel cap carefully so that any possible overpressure inside can
escape gently, without any fuel being projected.
•Only use lead-free petrol with an octane index of at least 90 RON.
GASOHOL, METHANOL, ETHANOL and ALCOHOL are NOT
ALLOWED. Use of these products increases risks of fire and
explosions that are liable to cause serious or even fatal injury to the
operator and any other persons in the vicinity.
•As petrol is highly inflammable, carry the machine at least 6 meters
away from the filling point before starting it up.
•Regularly check the seal on the fuel cap. Regularly check the state of
the gasket fitted to the oil-filler plug. Replace immediately if there is
any leakage of fuel or oil.
1.4.5 Transport - Handling
•Never transport the lightweight portable vibrator with the engine on,
even when idling.
•Carry the lightweight portable vibrator in its transport bag.
•All operations for on and off-tracking the machine MUST be carried out
with the engine OFF.
•Whenever the machine is transported in a vehicle, attach it carefully to
prevent it from moving.
1.4.6 Working
•The lightweight portable vibrator MUST BE WARMED UP before
use.
•The lightweight portable vibrator must only be used by a single
authorized operator.
•If work is being done on a two-line track, pay close attention to any
traffic on the line that is still open. In all cases, the lightweight portable
vibrator must only be used in compliance with rail-company instructions
for the worksite concerned.
•This machine has been designed and built only for tamping ballast
on railway lines (See 4.3 §4.3 “Instructions for using the lightweight
portable vibrator”). Any other use different from those described in this
manual will be considered “non-compliant” and will release the
manufacturer from all its responsibilities, these being totally assumed
by the user.
“Compliant use” means following the recommendations inherent to
using and servicing the machine as described in this manual. In addition,
it is compulsory to comply with all the standards recommended and
described for preventing occupational accidents, and general regulations
in terms of safety, occupational medicine and legislation in force be
taken into account.
•Before starting the machine, check that the body and tip are held
correctly in position. Never make any modifications to the machine.
•When working, always hold the machine with both hands. Hold the
control handle firmly with one hand in order to keep the machine under
control at all times with the other hand permanently holding the other
handle. Hold the two handles firmly with both fingers and thumbs.
•Always tamp ballast with the engine at maximum speed.
•Never use ether or any other similar product for helping to start the
engine.
•Never leave a lightweight portable vibrator with the engine running at
idling speed. Stop the engine immediately when the machine is no
longer required for use. Before putting the machine down, wait until the
bit has completely stopped moving.