GEISMAR TH 70 VLA Instruction Manual

Société des Anciens Etablissements L.GEISMAR
113 bis, avenue Charles de Gaulle
92200 NEUILLY SUR SEINE
Tél : [phone] — E-mail : [email protected]
Société des Anciens Etablissements L.GEISMAR
Boite Postale 50327 5 rue d’Altkirch
68006 COLMAR CEDEX FRANCE
Tél : [phone] - Fax : [phone] 
E-mail : [email protected]
OPERATION & MAINTENANCE INSTRUCTIONS
Model HYDRAULIC RAIL TENSIONER
Type TH 70 VLA
GB Code : H109120_0816

HYDRAULIC RAIL TENSIONER
H109120_0816
TH 70 VLA
SUMMARY
TENSOR MARKING......................................................................................................................................................5
WARNINGS ...................................................................................................................................................................7
CHAPTER 1 – SAFETY
1 – 1 FOREWORD .........................................................................................................................................................9
1 – 2 WARNING .............................................................................................................................................................9
1 – 3 GENERAL SAFETY REGULATIONS..................................................................................................................10
CHAPTER 2 – PRESENTATION
2 – 1 GENERAL PRESENTATION...............................................................................................................................13
2 – 2 GENERAL INFORMATION .................................................................................................................................14
2 – 3 USING CONDITIONS..........................................................................................................................................14
CHAPTER 3 – TECHNICAL CHARACTERISTICS TENSIONER
3 – 1 GENERAL CHARACTERISTICS.........................................................................................................................15
3 – 2 LOCATION IN LOADING CLEARANCE..............................................................................................................16
CHAPTER 4 – EQUIPMENT TENSIONER
4 – 1 CONSTITUTION OF THE TH 70 VLA RAIL TENSIONER..................................................................................17
CHAPTER 5 – OPERATING INSTRUCTIONS TENSOR
5 – 1 HANDLING INSTRUCTIONS ..............................................................................................................................19
5 – 2 PREAMBLE .........................................................................................................................................................19
5 – 3 INSTALLATION OF TH70 VL..............................................................................................................................19
5 – 3 – 1 A BOVE ALL ................................................................................................................................................................. 19
5 – 3 – 2
PLACING OF TH70 VL ON THE RAIL TRACK ON THE OUTSIDE ...................................................................... 19
5 – 3 – 3 PLACING OF TH70 VL ON THE RAIL TRACK BETWEEN THE RAILS................................................................. 20
5 – 4 WORKING METHOD...........................................................................................................................................20
5 – 4 – 1 F ITTING THE TH70 VL IN T RACTION PHASE ................................................................................................................ 21
5 – 4 – 2 F
ITTING THE TH70 VL IN T HRUST PHASE ................................................................................................................... 23
5 – 4 – 3 P
OSITIONING THE TENSOR IN REVERSE PHASE ............................................................................................................. 23
Reminder 23
Assembling the tightening unit in reverse phase 24
5 – 5 CONNECTION TO THE ENERGY GROUP........................................................................................................25
CHAPTER 6 – MAINTENANCE TENSIONER

HYDRAULIC RAIL TENSIONER
H109120_0816
TH 70 VLA
SUMMARY
6 – 1 GENERAL MAINTENANCE INSTRUCTIONS ....................................................................................................27
6 – 1 – 1 R ULES TO BE FOLLOWED ............................................................................................................................................ 27
6 – 2 CONTROLS.........................................................................................................................................................27
6 – 2 – 1 F LEXIBLE HOSES ......................................................................................................................................................... 27
6 – 2 – 2 S
TIRRUPS .................................................................................................................................................................. 27
6 – 3 MAINTENANCE...................................................................................................................................................28
6 – 3 – 1 C ONTROLS ................................................................................................................................................................. 28
6 – 3 – 2
CLEANING ................................................................................................................................................ 28
6 – 3 – 3 G REASING .................................................................................................................................................................. 28
6 – 3 – 4 T
ABLE OF EQUIVALENCES FOR GREASES ...................................................................................................................... 29
6 – 3 – 5 H
YDRAULIC OIL ........................................................................................................................................................... 29
6 – 3 – 6 T
ABLE OF EQUIVALENCES FOR HYDRAULIC OILS ........................................................................................................... 29
CHAPTER 7 – STORAGE AND RECYCLING
7 – 1 GENERAL STORAGE INSTRUCTIONS .............................................................................................................31
7 – 1 – 1 C HOICE OF STORAGE CONDITIONS ............................................................................................................................... 31
7 – 1 – 2 S
TORAGE PREMISES ................................................................................................................................................... 31
7 – 1 – 3 P
UTTING INTO STORAGE ............................................................................................................................................. 31
7 – 2 DECOMMISSIONING - DISASSEMBLY - DISPOSAL ........................................................................................31
CHAPTER 8 – SPARE PARTS
8 – 1 FOREWORD .......................................................................................................................................................33
8 – 2 AFTER-SALES SERVICE CONTACT DETAILS.................................................................................................33

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Tensor Marking
STRIP OF PICTOGRAMS CODE H102542
STICKER H00021

Warnings
THE MANUFACTURER WILL ACCEPT NO LIABILITY IN THE FOLLOWING CASES
• Improper machine use, contrary to the instructions given in the operation and
maintenance manual.
• Failure to comply with the periodical checking requirements stipulated by the man-
ufacturer.
• Use by unauthorised persons and/or persons lacking the requisite professional
skills.
• Consequences resulting from a misunderstanding of the operation and mainte-
nance manual by the user.
• Failure to comply with the maintenance rules specified herein.
• Modifications or repairs not authorised by the manufacturer
• Use of spare parts whose quality and reliability do not match those of parts sup-
plied by the manufacturer
• Use of lubricants, fuels and consumables different from those recommended in
this maintenance manual.
• Exceptional or unforeseeable events.
USE OF THE OPERATION AND MAINTENANCE MANUAL
• The operation and maintenance manual is intended for heads of operations and
staff in charge of servicing the machine as well as all workers having to carry out
repairs. Their attention is drawn in particular to the chapters dealing with safety at
work.
• The operation and maintenance manual provides the necessary information for
correct use of the work equipment as intended by the manufacturer.
• The manual provides operation and maintenance instructions for the work equip-
ment. It does not exempt the staff using the equipment from a proper training.
• The operation and maintenance manual is an integral part of the work equipment.
It must be kept until the decommissioning of the machine.
• The operating and maintenance manual must be kept in a safe place inside the
control station in order to always be at hand when needed.
• In case of loss or destruction of this manual, the user is bound to order a copy from
the manufacturer.
• Users may ask the manufacturer to provide additional information and supplement
the operation and maintenance manual in their possession with updates. Once
provided, these items will become integral part of the operation and maintenance
manual.
• If the work equipment is transferred, the user is requested to inform the manufac-
turer of the new owner’s details.
• The user is required to deliver this operation and maintenance manual with the
work equipment to the new owner.
In order to ensure permanent compliance with the legislation in force, the
manufacturer reserves the right to make improvements to the work
equipment and to the operating and maintenance manual without having to
update previous editions.

Non contractual photographs illustrations

Dear customer,
Thank you for purchasing this equipment which has been manufactured by the GEISMAR
group of companies.
We trust your confidence in us is rewarded and that you are completely satisfied with the
equipment.
In order to guarantee the quality of its products and in accordance with its commitment to
respect the Quality Assurance Procedures ISO 9001, the GEISMAR group tests all its
products.
If the machine that you have just received is fitted with an hour meter which already displays a
number of operating hours, this is due to all the tests and trials which have been carried out
prior to its delivery.
Please pay detailed attention to the recommendations contained in this document.
To ensure this equipment continues to provide satisfaction care should be taken to use and
maintain it in accordance with the instructions in this manual.
GEISMAR draws your attention to these essential points
• Respect the maintenance periods and use the lubricants recommended
• Use only original parts and do not make any modifications
Failure to do so may affect your warranty rights.
Furthermore, modification of the machine without our written authorization could result in
the loss of conformity with the relevant standards.
The Group "GEISMAR" reminds you that accuracy in ordering of spare parts will enable prompt
supply, and consequently ensure the productivity of your equipment.
Our equipment is designed and manufactured in accordance with the latest advanced
techniques, and should provide you with the services that you expect.
We remain fully at your disposal.
Société des Anciens Établissements L. GEISMAR

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Chapter 1 – Safety
1 – 1 Foreword
The official regulations applied in the user country take priority over the safety regulations and
usages described in this chapter. It is up to the person in charge of the equipment to make sure
that these instructions are in line with legislation.
The "customer" safety manager will complete these instructions with any safety regulations
he judges to be useful in application.
Respecting these regulations will ensure the safety of personnel and property during
operations using the equipment. Three types of pictogram are provided to draw your particular
attention to specific points:

This symbol identifies a potentially hazardous situation which could have serious
or even fatal consequences if the precautions given are not respected.

This pictogram identifies a situation which can lead to personal accident if the
precautions given are not taken.

This pictogram is a reminder of safety practices or warns of the consequences
that carelessness during an intervention can generate.
Everyone concerned with using, maintaining, storing or keeping this working equipment must
be familiar with these rules.
Any user who is the cause of an accident due to failure to respect these rules, will be held fully
responsible.
This manual is designed for users and maintenance personnel. It may include details of the
various options available. The notes and illustrations provided in this manual may show details
and accessories which differ from your equipment.
Indeed, the basic characteristics may be identical, but GEISMAR reserves the right to make
improvements.
Please contact GEISMAR for further information about your equipment working or this
manual. For orders of spare parts, requests for information or intervention, please provide the
type reference, code and serial number of your equipment.
This information is on the manufacturer's plate. It must be kept legible.
1 – 2 Warning
Before using the working equipment, including maintenance, please read this operating and
maintenance manual and its appendices and current workplace safety regulations. You must
have the training, skills and tools required to use, maintain and repair this working equipment
properly.
General site safety regulations provided by the site manager, must be followed scrupulously,
particularly if work is taking place without halting traffic.
The technical documentation and instructions of this equipment will complete the knowledge
acquired during training courses. But they can in no way replace theoretical and practical training
for a qualification, provided in accordance with professional regulations.
If the company is unable to provide this training adequately for its personnel, The GEISMAR
Group is ready to provide any support required concerning this training programme. Training

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must include explanations of the various working equipment functions, operating and
maintenance instructions and safety regulations to be respected, as well as practical exercises.
1 – 3 General safety regulations
The working equipment must be used under normal conditions and must be properly
maintained.
We recommend a period of familiarisation with the working equipment before using it
operationally.
Do not use the equipment before you are sure of being able to do so under optimal safety
conditions.
If in doubt, whether concerning the working equipment or the work to be carried out, ask a
qualified person.
Never the use the working equipment for any purpose other than that for which it is intended.
To prevent any risk of accident or injury, you must wear the clothing or Personal Protective
Equipment which meets current safety standards applied in the workplace (see "Marking"
chapter).
Do not touch moving parts directly or indirectly as long as the working equipment has not
been decommissioned or is in a non-hazardous configuration.
Risk of crushing or shear from all the moving parts of this equipment.
The working equipment must be cleaned regularly. All traces of excess liquid or grease must
be removed.
All markings must remain legible and present on the working equipment. Replace any
illegible, damaged or missing pictograms.
IMPLEMENTATION / MAINTENANCE / INTERVENTIONS
Maintenance operations must be carried out by qualified personnel who are familiar with the
safety regulations applied to the operations concerned.
Draw up an inspection schedule and record all maintenance operations.
Replace any damaged or worn parts.
Never modify the working equipment without a study and the manufacturer's written
authorisation.
DURING OPERATION
Know the working area and its particularities; only authorized persons may enter this area.
Respect the general and particular safety regulations applicable to the working area and
maintain constant safety vigilance throughout all phases of the operations.
Be familiar with the intervention plans in the event of an incident or accident and the
prevention instructions to be respected during different manoeuvres.
Never use equipment in poor condition (wear, deformation...).
In the event of abnormal behaviour, inform the competent personnel.
Never use the equipment to carry people.
Never neutralise the safety devices or limiting equipment.
Make sure that nobody is within the working equipment work zone.
Do not park the machine on a track section with slope.
The track clearance profile must be large enough for the equipment

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Traffic routes must be maintained in adequate condition for the working equipment to move
around without risk.
Use this working equipment only when visibility conditions make it easy to see the areas in
which people are moving and working.
Unless otherwise indicated, this working equipment is not equipped with a lightning protector,
so do not use it when meteorological conditions are adverse.
FOLLOWING APROLONGED PERIOD OF NON-USE OR DURING APERIODIC INSPECTION
Check tightness and connections between assembly components.
If deformation or abnormal wear is noted, the parts must be replaced.

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Chapter 2 – Presentation
2 – 1 General presentation
Manufacturer
Société des Anciens Établissements L. GEISMAR
Boite Postale 50327
5, rue d’Altkirch
68006 COLMAR CEDEX FRANCE
Description of equipment
Modele : HYDRAULIC RAIL TENSIONER
Type : TH 70 VLA

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2 – 2 General information
The TH 70 VLA hydraulic tensioner, easy to install because of the assembly of its various
components by articulation forks and pins, is particularly designed to obtain, through controlled
mechanical traction, the equilibrium (release) of long welded rails (LWR’s). This is achieved by a
mechanical deformation of the rails remaining in the elastic domain. A thermal engine drives the
hydraulic unit that will supply the cylinders.
The TH 70 VLA hydraulic tensioner can also be used for :
reducing gaps during operations of repairing rails or broken welds;
avoiding the removal of bars in the case of replacement of a defective weld that has not
broken or in the case of the creation of a bonded joint on the track;
adjustment of an expansion appliance;
incorporation of appliances.
At any time the traction of thrust force can be modified according to variations in ambient
temperature, and therefore that of the rail, by adjusting the hydraulic pressure.
The traction exerted on the ends of the rails helps to maintain the correct position of the latter
in the horizontal and vertical planes, thus preventing any deformation during the welding
operation and eliminating contraction tensions in the weld.
Thanks to the double-acting cylinders, the hydraulic tensioner can also cancel out the internal
stresses in the rails, thus making it possible to carry out sawing and cutting without risk to the
users, preventing jamming of the tools.
2 – 3 Using conditions
The thrust force must be limited to 200kN with the use of the arches, because of
their resistance. The use into thrust must always be carried out without using the
rods.

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Chapitre 3 – Technical characteristics tensioner
3 – 1 General characteristics
Manufacturer Société des Anciens Établissements L.GEISMAR
Address 5, rue d’Altkirch 68000 COLMAR
Machine HYDRAULIC RAIL TENSIONER
Type TH 70 VLA
Performance
Pressure while pushing 225 bar
Pressure while pulling 660bar
Maximum retraction force (pulling) 700 kN (≈70 t)
Maximum deployed force (pushing) 300 kN (≈30 t)
Maximum deployed force (with arches) 200 kN (≈20 t)
Travel of cylinders 380 mm
Weight Table (in unit KG)
Cylinder (2x) 33,5 Kg
Clamping assemblers (2x) 64 Kg
Tie Rods length 1520 (x2) 25 Kg
Fitting Appliance (x2) 4 Kg
Total weigth of mounted assembly 246 Kg

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3 – 2 Location in loading clearance
Structure gauge of the track according to Annex B low / standard in 13977:2005

7
6
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Chapter 4 – Equipment tensioner
4 – 1 Constitution of the TH 70 VLA Rail Tensioner
The TH 70 VLA Tensioner consists of:
– 2 hydraulic cylinders (1)
– 2 clamping assemblers (2)
– 2 tie rods (3)
– 2 fitting appliances (4)
HYDRAULIC CYLINDERS
Double-acting, these make it possible to exert on the
rail either a traction or a compression. They are equipped
with quick screw couplings (6) and 2 drain screws (7).
Pressure limiters calibrated in the factory, mounted on the
unit, limit the thrust and traction forces. The long travel of
the cylinders serves to compensate for any irregularities in
travel.
2
3
4
1

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CLAMPING ASSEMBLIES
These each consist of 3 parts removable without tools :
:
– 1 stirrup (8)
– 2 eccentrics provided with floating serrated jaws (9)
The rail is gripped by means of 2 facing jaws that grip the rail web.
TIE RODS
For working in traction, these are connecting components that transmit the traction force from
the cylinder rods to the other clamping assembly.
The number of tie rods not being limited, it is possible to frame a piece of rail introduced into
an LWR and to carry out connecting welds in the same interception of traffic on a straight portion.
FITTING APPLIANCES

The 2 fitting appliances make it possible to position vertically, with
great ease, the serrated jaws of the clamping assemblies as
close as possible to the neutral axis of the rail. This gives a
clamping force perfectly at right angles to the rail web.


Remove the equipment by the mounted pressure cylinders.
This equipment can be damaged by the stirrups.

9
8

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Chapter 5 – Operating instructions tensor
5 – 1 Handling instructions
Before any use, we recommend that you refer to chapters:
1-3 - General safety regulations
1-4 - Particular safety regulations
5 – 2 Preamble
When the TH 70 VL tensioner is used, the stirrup deforms elastically in order to return to its
initial shape after work. The clamping as semblies are designed for a maximum load exerted by
the cylinders (maximum pressure of the hydraulic unit obtained with a factory-calibrated pressure
limiter), if the load accidentally exceeds this figure (accidentally or through faulty manipulation,
etc.), permanent deformation of the clevis may occur. It is necessary to carry out an inspection in
order to check whether it is suitable for fulfilling its function.

Before use : Visually check that there is no external defects, deformations,
superficial cracks, wear or corrosion marks (see periodic checks on stirrups)
5 – 3Installation of TH70 VL
5 – 3 – 1 Above all
Protect the working area for fitting the TH70 VL tensioner according to the safety
instructions in force on the railway where working. Once the tensioner is on the
track and under tension and the fitting accessories removed, it is possible for the
site machinery to travel. Please leave free the gauge where traffic is permitted.
5 – 3 – 2 Placing of TH70 VL on the rail track on the outside
WORKING AREA

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5 – 3 – 3 Placing of TH70 VL on the rail track between the rails
5 – 4 Working method
Work in Traction to reduce the gap between 2 rails
Working under thrust to increase or maintain the gap between 2 rails
WORKING AREA
Inter-track protection necessary