F I R S T - H A N D S E R V I C E

Deutsche Plasser

Washing and paint stripping plantFaster processingPage 4

Individual service package

Easy commissioning Page 8

Maintenance workshopA hot winterPage 18

Customer magazine issued by Deutsche Plasser 2015/No. 5

update

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Contents03 Editorial 04 innovativE New washing and paint stripping plant

08 innovativE New vehicle generation for Deutsche Bahn 12 informativE Continuous working action – highly advantageous

14 innovativE New turnout tamping simulator

16 innovativE Even faster to the right course

17 nEws News from Bingen 18 prEvEntivE Opladen maintenance workshop in top gear

21 intErnational Closer to the customer

22 informativE Two USP 2010 SWS for Poland

IMPRESSUM

Publisher:Deutsche Plasser Bahnbaumaschinen GmbHFriedrich-Eckart-Str. 35, 81929 MünchenTelefon: +49 89 93008-0Telefax: +49 89 93008-115E-Mail: info@deutsche-plasser.de

www.deutsche-plasser.de

Photos:Deutsche Plasser, Plasser & Theurer

Printed:Druckwerkstatt, Vienna

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Editorial Deutsche Plasser UPDATE

Dear customers,Esteemed partners

The second Performance and Financing Agreement (LuFV II) is a settled matter! From 1st January 2015 to 2019, about five billion euros will thus be invested in the maintenance of our railway infrastructure every year. Responsible authorities seem to have realised that, in the end, maintenance is more cost-efficient than new track laying. Now, it is vital to invest these funds – on time. As we well know, the annual budget must be spent since amounts remaining unspent would be inevitably lost! Given the meagre past four years, this would be even worse. However, this is what we have to expect. The funds from LuFV I were not entirely spent, either. Now, the LuFV II provides more funding but the planning capacities have not yet been increased. Even though this is apparently lacking.What‘s to be done? That‘s quite simple: As early as in the first quarter, external planning offices need to be involved to be able to make optimum use of the budget this year. In any case, we will not be able to use 100 % of it any more. At the same time, the planning capacities of rail infrastructure operators must now be expanded to at least enable the use of the entire funds next year. Increased planning capacities would not only allow to make full use of the existing funds, but also increase planning security to encourage track maintenance con-tractors to come back to Germany from abroad – and to use their high capacity machines cost-efficiently here. By doing so, we could significantly increase efficiency!For the long term, I have two major requests. Firstly, let us make optimum use of the good conditions created by the LuFV II and focus on employee-friendly and family-friendly planning and less weekend operations. This is an important precondition to attract expert personnel. Secondly, let us promote the exchange of experiences between the railway and track maintenance contractors! We have the knowledge, and we only need to make it available at the right places in the railway system!

Sincerely Peter Josef FlatscherManaging Director, Deutsche Plasser

The washing and paint stripping plant even cleans heavily soiled units. Pre-washing by the customer is not required.

New washing and paint stripping plant enables faster processingTamping units contribute significantly to the efficient, cost-effective and sustainable operation of a tamping machine. If they work properly, the machine works profitably too.

However, tamping units in particular are counted amongst those com-

ponents that are subjected to the grea-test wear. Depending on the operating hours performed and, above all, the operating conditions, a corresponding amount of wear must be expected.

Strong demand for high-quality overhaul As tamping units are crucial to the cost-effective and efficient operation of tamping machines, companies are not willing to compromise when it comes to overhauling these components. The demand for high-quality overhaul has been constantly rising. The ever-growing number of orders is clear proof of this.

New washing and paint stripping plant for faster processing and... To meet this strong demand and to further increase the capacities of repair technology in Munich, Deutsche Plas-ser invested in a new washing and paint stripping plant to clean the units.So far, these have been cleaned manually. Using high-pressure cleaners, the unitscoming right from operation were cleaned and dirt (oil, grease etc.) was removed. Following dismantling, the individual parts were cleaned of remaining oil and grease in a second washing cycle. Sand-blasting, the final preparation for the actu-al overhaul, was not performed in-house.Using the new plant, washing can be performed much faster. In a first wa-

shing cycle the unit coming right from operation is washed as a whole. This takes about 45 minutes. Afterwards, around 90 % of the grease and 80 % of the paint have been removed. Then, the unit is dismantled and the individual components are washed again. This enables thorough cleaning of previously inaccessible spots.The entire cleaning process now only takes several hours. Compared to the entire cleaning process carried out so far, several workdays can be saved!Besides, pre-washing by the customer is not required. The washing and paint stripping plant even cleans heavily soiled units without additional effort.

… an even higher level of overhaul quality This new cleaning method is not only faster, but also enables a higher le-vel of quality and increased outputs to be reached. As sandblasting is no longer carried out, possible cracks can be identified better and repaired individually.

Further operating sequences of overhauls Following cleaning, paint stripping, ins-pection for possible cracks and, if re-quired, repair of cracks, the geometry of the unit‘s individual components is restored by means of build-up welding. Once the welding has been performed, these are stress-relieved to ensure a

iNNoVatiVE Deutsche Plasser UPDATE 05

Overhaul of tamping units

uniform structure enabling a long service life.During the next stage of work the com-ponents are primed. Then, the in-house CNC machining restores the defined geometry based on original drawings. In other words: regarding their geometry, the components exactly correspond to an original part made by Plasser & Theurer.After the parts have been measured, the units are assembled. If necessary, individual components are replaced with Plasser & Theurer original spare parts and wearing parts. Once the unit

has been assembled and painted, the hoses are connected and the testing begins. On a test rig, an eight-hour trialrun is performed. The electronic test report produced is handed over to cus-tomer after completion of all works. Only successfully tested units are sent back to the customer.

Environmental protection further improvedApart from the considerably reduced pro-cessing time and the further increased

overhaul quality, the newwashing and paint strip-ping plant has set new standards regarding en-vironmental protection.In the past only very small quantities of water,well below typical val-ues of comparable high pressure cleaning sys-tems, were used des-pite manual cleaning thanks to high-quality

technical equipment and sophisticated work sequences.However, the new washing plant en-ables the water consumption to be further reduced by half. A complex filtersystem cleans the water used. To a large extent, the water is therefore reused in the cleaning cycle. Only the water evaporating during cleaning has to be replaced.

A catch basin underneath the plant pre-vents a contamination of the environ-ment. The basin can collect the entire amount of water used for cleaning and therefore protects the environment.A lye-based detergent in a ratio of about 13 % is used. This is comparable to conventional detergents for domestic use. However, in detail it differs due to process specific additives prolonging the storage life or preventing foaming. The low ratio contributes significantly not only to environmental protection but also to a safe occupational environ-ment of the staff.

A used, dirty unit prior to washing and paint stripping.

The detergent enables the collection of the substances dissolved during washing, e.g. paint and grease, and allows disposing of them easily in the residual waste.

Moreover, the project team decided to acquire a machine with a high insula-tion allowing the temperatures in the machine to be maintained for as long as possible. This ensures that as little energy as possible has to be used to reach the operating temperature fol-lowing a pause, e.g. after a weekend.

Even higher capacities in future In the past, Deutsche Plasser overhauled about 120 units each year. Thanks to the new washing plant, the processing time has been reduced by approximately 25 %. Therefore, Deutsche Plasser will overhaul even more units in future – in unequalled quality, at fair prices and in the interest of the cost-effective and efficient operation of the tamping ma-chines made by Plasser & Theurer.

The same unit following washing: completely cleaned and without paint.

Test run of the GMTZ self-propelled track recording car in Linz, Austria.

New vehicle generation for Deutsche Bahn

Individual service package ensures easy commissioning

Deutsche Plasser UPDATE 09

DB Netz AG receives a new generation of stan-dardised vehicles made by Plasser & Theurer. Deutsche Plasser put together an individual service package for this customer enablingthe machines to be commissioned without any problems and ensuring the highest level of availability.

Since September 2014, three vehicles have been delivered under a master agreement:

. DVT self-propelled diagnostics train for measuring tasks on the overhead catenary and on the track geometry

. GMTZ self-propelled track recording car in two-part design: for track geometry measuring tasks, sleeper diagnosis and clearance profile measuring system.

. SPZ rail testing train in two-part design for ultrasound and eddy current examination of the rails as well as measuring tasks on overhead lines and track geometry. Moreover, various video inspection systems have been integrated.

Highest manufacturing quality Deutsche Bahn is striving for the standardisation

of multi-purpose vehicles. These include motive power units, measuring vehicles, maintenance vehicles for tunnel inspection as well as track and safety systems. Using the new Plasser & Theurer track measuring vehicles, DB Netz AG continuously monitors the 33,300 kilo-metre long track system of Deutsche Bahn.

The GMTZ self-propelled track recording car has been approved and accepted by the German Federal Railway Office (EBA). It can drive in steep gradients up to 55 ‰.

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For this contract, Deutsche Bahn attached great importance to the highest level of manufacturing quality. The contract was based on specifications with 4,000 re-quired items and seven quality gates to be met. One of the reasons DB Netz AG decided in favour of Plasser & Theurer was the high level of quality required.

Extensive services provided by Deutsche Plasser As usual, Deutsche Plasser was able to successfully contribute to the servicing aspects. Members of the service team vi-sited the Linz factory of Plasser & Theurer during the early phases of manufacture to familiarise themselves on site with these new types of vehicle and their features.It has always been and remains the main objective of Deutsche Plasser to support the customer during the intro-duction of this new generation of vehicles.Deutsche Bahn has assigned a „teacher driver“ for the training of the teams which will work on these machines; he has developed a training programme for DB Training on the basis of the vehicle operating and maintenance manuals.

The service staff of Deutsche Plasser supported this person responsible for training in preparing the processes and relationships of the machine systems and the specifications for servicing and maintaining the machines for the training programme. Thus, the complex relation-ships of the various systems integrated into the machines, e.g. the brake sys-

tem, were prepared so they can be presented in a clear manner.Moreover, the experts of Deutsche Plasser were avail-able to answer the trainees‘ questions. If it was not possi-ble to answer a question im-mediately, clarification was sought from Plasser & Theurer in Linz. This ensured that no question remained unanswered and the machine operating teams were thoroughly fami-liarised with the machines and their service and maintenance requirements.

Delivery started in September 2014 The first machine under this contract – the GMTZ self-propelled track recording car – was delivered at the beginning of September 2014 and presented to an international audience of experts at InnoTrans 2014. The DVT self-propelled diagnostics train followed at the start of December 2014 and the SPZ rail testing train was delivered at the beginning of February 2015. On delivery, Deutsche Plasser became responsible for their servicing. Delivery of a further SPZ is planned for 2017.

First test runs to calibrate the measurement equipment Following delivery of the machines, initial measuring runs to calibrate the mea-surement equipment were carried out. These were accompanied by Deutsche Plasser service engineers so that, in

the event of a malfunction, this could be quickly rectified to ensure the ope-rability of the machines.The picture after completion of the ca-libration runs was extremely positive: there were no machine failures. Assistance in development of themaintenance schedule Deutsche Bahn decided to generally maintain these new vehicles itself. However, this does not mean that the work of the Deutsche Plasser service team is not required – on the contrary.The experts from Munich draw up a detailed service schedule for each ma-chine jointly with the Deutsche Bahn staff. This will be based on the planned use of the machines, but mainly on the specifications of Plasser & Theurer.In contrast to typical track maintenance machines, the use and maintenance of these machines can be easily planned. In general, their use is scheduled and controlled for the medium term so that

The new GMTZ self-propelled track recording car was officially handed over to DB Netz AG during InnoTrans 2014.

The DVT self-propelled diagnostics train for measuring tasks on the overhead catenary and on the track geometry.

Deutsche Plasser UPDATE 11iNNoVatiVE

the maintenance and service dates required can be planned accordingly. Thus high reliability and availability of the machines can be ensured.

Detailed parts list At the same time, the supply of spare and wearing parts can be planned in advance. Deutsche Plasser has deve-loped detailed schedules for mainte-nance planning jointly with Deutsche Bahn. It is ensured not only that suf-ficient spare and wearing parts are available for immediate and unplanned requirements, but also that these parts are available on-site for planned main-tenance and service dates punctually and completely. Thus the machine can be put back into service quickly.The basis for this comprehensive supply is a detailed parts list which was drawn up by Deutsche Plasser based on parts lists of Plasser & Theurer. This forms the basis not only for the spare and wearing parts lists, but has also been entered

in the SAP system of Deutsche Bahn, making it easy for Deutsche Bahn to procure the required parts.

Support of the customer‘s serviceworkshopBut this was not all: Service staff of Deutsche Plasser will take part in each of the first maintenance dates for the new machines at Deutsche Bahn to provide expert instruction for the customer‘s staff on the machine. This ensures that the customer‘s mainte-nance and service staff are thoroughly familiar with the machines.

And Deutsche Plasser will continue to support its customer: If there is a sudden service requirement, the ex-perts from Munich will be available to the customer at any time. True to the company‘s motto: First-hand service!

09-4X Dynamic Tamping Express in train formation with the BDS 2000 ballast management system: today‘s most productive combination for maintaining plain line tracks.

In 1968, a high-speed track relaying train was operated for the first time in continuous working action, instead of cyclic working action. The first continuous-action tamping machine followed in 1983. Since then, this technology has proven its benefits again and again.

Ground-breaking technology

Continuous working action – highly advantageous

To be clear: under certain conditions it can still make sense to use a cyclic-

action machine. These machines are fitted with tamping units that are firmly connected to the machine frame which requires the entire machine to be moved for every tamping operation. However, in the vast majority of cases, the separation of the tamping unit frame and the machine frame, thus, the continuous working action, is highly advantageous.

Using short track possessions effectivelyThe first continuous action machines achieved tamping outputs that exceeded the performance of conventional machines by 30 to 40 %. When in 1996, the first 09-3X 3-sleeper tamping machine was introduced onto the market, the output was increased by the same percentage once more. The 09-4X Dynamic Tamping Express 4-sleeper tamping machine led to a further increase in 2005. Particularly in times of extremely short track pos-sessions, these high working speeds are absolutely crucial.

However, the higher working speeds are not only important for plain line tamping but also for turnout tamping which requires the track sections beforeand after the turnout to be tamped as well. Using the continuous working action, speeds that are up to 40 % higher can be achieved.

Reduced life cycle costs and decisive ecological advantagesTamping, starting, braking ... tam-ping, starting, braking ... Cyclic-ac-tion machines are subjected to higher stresses than continuous-action machi-nes. Lower stresses result in reduced wear on the machine and the material. This leads to considerably reduced overall life cycle costs.Moreover, if large quantities are moved in continuous-action and not in cyclic-action, this has an effect on the envi-ronment. One the one hand, less brake dust is generated. On the other hand, emissions are reduced. Re-garding the strict environ-mental standards in force today, this is all the more important.

Ideal in train formation Today it seems only natural, but it was the continuous working action that made it possible to usefully inte-grate more work stages in tamping machines. All stages can thus be performed at the ideal speed. The Unimat 09-475/4S N-Dynamic, the modern all-in-one machine for turnout and track maintenance, could only be developed thanks to the continuous working action. For the first

time, this machine combines the func-tions of three machines during turnout maintenance: ballasting, tamping, pro-filing, stabilising and control measure-ment. The simplification of work site logistics and the consequential high savings potential also result from the ground-breaking technology of conti-nuous working action.

iNformatiVE Deutsche Plasser UPDATE 13

09-4X Dynamic Tamping Express. The continuous action 4-sleeper tamping machine with integrated track stabilisation is the latest standard for the cost-efficient tamping of railway tracks.

09-3X Tamping Express. The continuous action 3-sleeper level-ling, lifting, lining and tamping machine has been built since 1996. Compared to the fastest machines of that time, it enabled working speeds to be increased by 40 %.

The Unimat 09-475/4S N-Dynamic is the state of the art all-in-one tamping machine for turnouts and tracks. For the first time, this machine combines the functions of three machines during turnout maintenance: ballasting, tamping, profiling, stabilising and control measurement.

The operator‘s view in one of the work cabins of the turnout tamping machine.

In December 2011, Deutsche Plasser presented the first 09-3D tamping simulator in the world in the Bingen Training Centre. In 2015, the next step in this training programme will be taken: the Unimat-3D turnout tamping simulator.

New turnout tamping simulator

Remarkably close to reality

At the Bingen Training Centre, utmost importance has been placed on high

quality instruction and further training from the very beginning. As to be ex-pected by Deutsche Plasser and the machines made by Plasser & Theurer, there is a clear commitment to using state of the art technologies. Therefore, it has been only logical to use 3D tech-nology for the training.

09-3D highly successfulThe expectations placed on the 09-3D tamping simulator were high. However, they have by far been exceeded in practical operation. Detailed reproduc-tion of a tamping machine‘s work cabin, realistic 3D graphic and varying training scenarios: the simulator is a highlight in the training programme.

Deutsche Plasser UPDATE 15

As a reaction to its great success and to further improve the offer, a front wagon workplace was added to the tamping simulator last year. Future operators can thus be trained for any situation or challenge potentially occurring during work site operation.

One step further Now the next step is taken with the turnout tamping simulator. At the same time, another dimension is added to the training. The requirements resembled those of the 09-3D: simulating an Uni-mat 09-4x4/4S in state of the art design including P-IC 2.0 control.It will be possible to realistically operate the machine‘s components such as the lif-ting and lining unit, the tamping units, the subframe and the lining trolley or the addi-tional lifting device. As a turnout tamping machine is simulated, these components can be operated on a plain line and, in particular, in turnouts, crossings, dia-mond crossing with slips and turnout connections.

More complexThe new simulator will be considerablymore complex than its predecessor. Technical further developments in com-puter graphics enable a more detailed design of the machine. Moreover, the virtual line network now must also com-prise turnouts. Compared to the 09-3D tamping simulator, it therefore had to be designed more comprehensibly.

PLC program of real machineIt was a basic objective of this project to use the PLC programme of a „real“ ma-chine and to virtually simulate all necessaryactuators such as hydraulic cylinders,

units, measuring trolleys, ser-vomotors etc. The control system was programmed to act as if it was fitted in a real machine.To ensure a simulation that is as realistic as possible, the programmers of the simulator are actively sup-ported by the Control En-gineering Department of Plasser & Theurer.

Particular focus on external view Particular importance is placed on the three-dimen-sional external view of the virtual machine. At any time, the trainee can switch from cockpit view to external view to take a close look at the machine and the position of the com-ponents.

High-performance computer system A high-performance computer system is used to enable all these features. In total, five computers are used to visualise and simulate the three cabins of the machine on twelve displays. The screen diagonal

of the largest display is 84“. All in all, about 17 million pixels must be calculated in real-time.Moreover, the main screens in the cabin use a so-called „head tracking“ enabling the movements of the operator‘s head to be recorded and his field of view to be changed correspondingly.

Standardised training programmes Contrary to the 09-3D tamping simulator, only pre-defined training scenarios will be used due to the complexity of the line network. The training centre colla-borates closely with the programmers to provide future trainees with a com-prehensive training oriented towards real working conditions.

Start in late summer 2015 The new turnout tamping simulator will be in operation as of late summer 2015. The team of the Bingen Training Centre will be pleased to inform you about the training programme and already accepts registrations for the first courses.Don‘t hesitate and register for one of the first trainings in the new 09-4x4/4S-3D turnout tamping simulator!

Thorough and careful treatment of the turnout with the highest output and quality – the Unimat 09-4x4/4S.

During development, a particular focus was placed on the external view of the machine.

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In future, it will be even easier to register for Deutsche Plasser training courses. An online booking system is under development.

New Online Booking System

Even faster to the right course

In the last few years, the Deutsche Plasser training centre has gained an

excellent reputation for instruction and further training in track maintenance. The programme has been continuously expanded and the number of attendees is growing steadily.

Open and closed courses Right from the start there were two types of courses. On the one hand, courses are designed for individual customers to meet the specific requirements of the machine operator and then implemen-ted with the desired attendees. On the other hand, there are courses with a standardised programme which are freely accessible to all interested customers. An example of these are the MKS/DAS courses in accordance with guideline 046.2552 of DB Netz AG.

There will soon be an important change on the Deutsche Plasser website for the-se „open courses“ making it even easier for potential participants to register for a course: an online booking system.

How will the booking system work? In future, the website of Deutsche Plasser will provide not only an overview of the training programme. It will also show when courses are scheduled and how many places are still available. If inte-rested, users can apply for the course of their choice directly on the website. The overview will be easy to access via a matching link on the home page.

Clicking on „Register“ will open a con-tact form into which the personal data can be entered. Once the form has been completed and sent, a place on the course is reserved and the interes-ted person will receive a formal course offer by email from the training centre. This must only be confirmed in writing or by email which then completes the booking. If an applicant changes his/her mind, a brief note is sufficient to remove the reservation from the system.

It will of course be possible to registerindividuals as well as groups. The group size will be limited to the number of avail-

able places; otherwise the process will be the same as for an individual booking.

The advantagesThe new booking system makes it possible for interested parties to see at any time when a course will take place and how many places are still available. Even better, in case of interest a place on the required course date can be se-cured easily.

Lauching in summer 2015 Work on the booking system is in full swing. We are planning to launch it in summer 2015. Regular visits to the Deutsche Plasser website will, there-fore, pay off.

New Hydraulics Simulator With an innovative hydraulics simulator set up in February 2015, the training portfolio has been extended by additional practical training in hydraulics and mobile hydraulics.Small groups of up to 6 participants can now design hydraulic circuits and analyse them using various measurement equipment at two workstations.The simulator is supplemented by a load unit allowing the effect of loads on the hydraulics to be tested. In addition, it has a programmable logic controller (PLC). This can be used to control the hydraulic circuit electrically or electronically.The next extension is already in the planning stage. From May, the latest Plasser & Theurer P-IC 2.0 control system will bring the hydraulics to life. Sequences, such as lifting and lowering of a unit, will then be simulated realistically. Information on the current hydraulics training programme is available at the website of Deutsche Plasser.

A Significant Economic Benefit

During its five years in business, the training centre has not only acquired an excellent reputation as a centre for in-struction and further training but has also developed into an important econo-mic factor for the region around Bingen.

In addition to the five jobs created by the training centre itself, it is the training courses which provide an important stimulus for Bingen and its environs. As the number of course participants increases year on year, the number of overnight stays is also increasing.

In 2013, there were slightly more than 600 overnight stays, but in 2014, this number had already increased to about 800 overnight stays by course participants. In addition to this, more than 1,000 meals are consumed in theregion‘s restaurants. Moreover, the course participants spend their free time in and around Bingen and thus contribute to the success of the regional economy.

VDEI conferences in Bingen

In early January 2015, several expert committees as well as the Infrastructure Department of the Association of German Railway Engineers (VDEI) met at the Bingen Training Centre. The team of Deutsche Plasser used the opportunity to provide the participants with an over-view of its services, in particular the Training Centre.The participants felt welcome and sent a letter of thanks after their visit. Deutsche Plasser is pleased with the good relations to VDEI and will continue to attend to the association and its members!

NEWS from Bingen

NEWS Deutsche Plasser UPDATE 17

The VDEI visitors with Antonio Intini.

Letter of thanks of the VDEI to the Training Centre in Bingen.

The new hydraulics simulator in the Deutsche Plasser Training Centre.

The hydraulic simulator provides practical training in small groups.

Opladen maintenance workshop in top gear

A hot winterThis winter, the Leverkusen-Opladen maintenance workshop has been working to capacity. Besides the lively every day business, important strategic measures for the future of the maintenance workshop have been taken.

„Full house“ at the Leverkusen-Opladen maintenance workshop. From November 2014 to March 2015, the hall was filled with machines in varying sizes for overhauls, servicing or repairs.

This winter, the team in the Leverkusen-Opladen maintenance workshop

could by no means complain about lack of work. From early November 2014 to March 2015, the workshop was virtually filled with machines of varying sizes. Overhauls, servicing and repairs for customers from Germany, Sweden, Switzerland and the Nether-lands were carried out.

From narrow to extremely longThe 08-75 GS on/off-track tamping ma-chine of RBS (Regionalverkehr Bern-Solothurn), Switzerland, came to Lever-kusen-Opladen for the first time. The machine with 1.000 mm track gauge was completely overhauled – to the full satisfaction of our Swiss customers.The highlight from the other side of the size scale was the RM 800 Super-3S high capacity ballast cleaning machine of Hu-bert, waiting for its annual servicing. With a length of about 110 m, this machine model just fitted in the hall without separation. Moreover, inspections and overhauls ofdifferent types of tamping machines and of the SSP 110 SW universal ballast dis-tributing and profiling machines were carried out.

New electronic workshop in operation When repairing and servicing machines, Deutsche Plasser usually also repairs transducers and pendula. Up to now, these works have been performed in Munich exclusively. Therefore, parts had to be sent from Leverkusen to Munich regularly. Now an electronic workshop has been set up directly in the Leverkusen-Opladen maintenance workshop. Therefore, thetransports are no longer necessary andtime can be saved. In the first two monthsof this year, already 94 transducers and pendula have been maintained here. The highly positive feedback we already received from our customers proves that the decision to extend the range of services offered in Leverkusen-Opladen has been forward-looking. Servicing of recorders and ALC devices is still car-ried out in our headquarters in Munich.

Machine fleet expandedTo be able to react faster and more flexibly when repairing machines, a milling machine and a lathe have been added to the mechanical assembly shop in Leverkusen-Opladen.

PrEVENtiVE Deutsche Plasser UPDATE 19

In the first two months of this year, already 94 transducers and pendula have been maintained in the newly set up electronic workshop.

Moreover, the warehouse capacities have been increased. Amongst others, brake systems are maintained here. This en-ables brake systems to be overhauled and repaired faster by simply installing replacement parts. The defective parts can be repaired later and reused as re-placement parts.

Mechatronics technicians complete their apprenticeship earlyAt the Leverkusen-Opladen maintenanceworkshop we place great importance on the training of qualified specialists. Therefore, we continuously offer six apprenticeships. This summer, for the

first time, two mechatronics apprenticeswill complete their apprenticeship followingthree years of training – six month earlier than scheduled as both guys put their shoulders to the wheel. When they have completed the apprenticeship, we will take over both mechatronics technicians.

In the words of our apprentices

Frank Schmitz, mechatronics apprentice: „I wanted to become a mechatronics technician but it wasn‘t easy to find an apprenticeship in this field. By chance I came across Deutsche Plasser in a newspaper article. Right away I was fascina-ted by the huge machines. Working with them is still really exiting. Currently, I cannot imagine a better job than working here in Lever-kusen-Opladen!“

Dennis Harwege, mechatronics apprentice: „I came here by chance too. But today, I am really grateful. Nice colleagues, great company and the yellow machines are awesome anyway. Being a mechatronics technician really demands a lot from you. This is exciting. I look forward to the summer, when we will be fully working here!“

Dennis Harwege will complete his apprenticeship as mechatronics technician in June 2015. Already now he is working enthusiastically with the „yellow machines“.

Frank Schmitz will complete his apprenticeship as mechatronics technician in June 2015 as well and will be taken over by Deutsche Plasser together with Dennis Harwege.

The more spare parts and wearing parts are available, the faster work can be performed. Therefore, the warehouse capacities in the Leverkusen-Opladen maintenance workshop have now been increased.

The open-plan offices of Deutsche Plasser in Wrocław allow attending to customers optimally in Poland.

About 80 Polish railway experts accepted the invitation of Deutsche Plasser and participated in the official opening of the new office in Wrocław.

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News From Around The World

Closer to the customer The new subsidiary of Deutsche Plasser in Poland provides an improved infrastructure to the customers‘ benefit.

About 80 Polish railway experts met in Wrocław on 18th November 2014

on the occasion of the official opening of the new office of Deutsche Plasser in Poland.In his opening speech, Jürgen Duschner welcomed the guests and pointed out that machines made by Plasser & Theurerhave been in successful operation in Po-land over the past 42 years. He acknow-ledged the good cooperation between the machine operators and Deutsche Plasser that has been in charge of the after-sales service for eight years now.

Mr Duschner anticipates positive prospects for the coming years and expects the long-term cooperation to strengthen as the EU approved funding for the further expansion and modernisation of the Polish railway infrastructure for the pe-riod between 2015 and 2022.Moreover, Jürgen Kübler, Plasser & Theurer,expressed his thanks for many years of successful cooperation with customers

in Poland. He assured the audience that Plasser & Theurer would continue to make a significant contribution towards innovating the railway system and stressed that the EU funding for the rail-way infrastructure amounting to € 12 billion would trigger numerous mo-dernisations and boost mobility in the Polish rail network.The speeches were followed by the official opening of the office. A warehouse and a workshop, including a testing room equipped with exhaust gas suction, for the manually operated machines and devices made by Robel are located next to the office. The light, ergonomi-cally designed workplaces ensure fast handling of enquiries.Following the opening, presentations were held by Deutsche Plasser, Plasser &Theurer and Robel. On the premises, hand-guided machines made by Robel were shown in practical operation.In his presentation, Mr Duschner focused on the entire range of products and ser-vices offered by Deutsche Plasser. He emphasised the clear commitment to the partnership and called the attention to the 24/7 service. Spare parts and wea-ring parts are normally supplied within 24 hours – 7 days of the week. Also the on-site repair service is available to the customers 7 days of the week.Roman Hauke, Plasser & Theurer, pre-sented the latest machine models that will soon be operated on Polish tracks. These include the universal tamping machine type Unimat 09-4x4/4S Dynamic, the USP 2010 SWS-U high capacity ballast plough with integrated ballast management and the ballast cleaning

machine of the RM 80 series. Additionally,state of the art on-board systems such as the machine control system PIC 2.0 – Plasser Intelligent Control as well as PlasserDatamatic, the standard for re-mote diagnosis, were presented.

Finally, Reinhard Daghofer introduced Robel‘s new developments. He con-centrated on special equipment for manipulating rails such as rail trains for safe and careful loading and unloading.On the occasion of the opening, many interesting expert discussions were held with the guests. Their feedback to the new premises was very positive. Customers expect the improved infra-structure to enable the service and the supply of spare parts to become even more flexible and professional. The staff of Deutsche Plasser in Poland is looking forward to meet this expectation.

Official opening of the new subsidiary of Deutsche Plasser in Poland by Jürgen Duschner and Wojtek Musial.

Efficient ballast management

Two USP 2010 SWS for Poland In December 2014, Plasser & Theurer supplied two USP 2010 SWS universal ballast distributing and profiling machines to PKP PLK S.A.,the infrastructure company of Polish Railways. The machines form part of the investment programme for a modern maintenance of the main lines.

Plasser & Theurer supplied two USP 2010 SWS universal ballast distributing and profiling machines to the infrastructure company of Polish Railways in December 2014.

iNformatiVE Deutsche Plasser UPDATE 23

Already between 2008 and 2014, Polish Railways made investments

to modernise the maintenance on the west-east and north-south routes as well as on the Via Baltica. Further in-vestments will be made until 2022. The programme also included two USP 2010 SWS universal ballast distributing and profiling machines acquired above all to increase the quality of ballast ma-nagement. These machines will mainly be used on line sections that allow tra-velling at speeds exceeding 160 km/h. They will be stationed in the PLK bran-ch of ZMT Kraków, responsible for the operation of track maintenance machi-nes and heavy-duty machines.

Up-to-date ballast management for tracks and turnoutsThe USP 2010 SWS universal ballast distributing and profiling machine can be used for both tracks and turnouts. In standard design the machine is equip-ped with shoulder ploughs, a centre plough, a 10 m³ ballast hopper with floor conveyor belt and a sweeper unit with transverse and steep conveyor belt.

The machines in question are additionally fitted with a conveyor belt to transport the ballast to a material conveyor and hopper unit, a water spray system, a Polish PZB train control sys-tem (intermittent automatic train-running control) and a DSAT axle-bearing tempe-rature control.

For the first time with One PassTechnologyMoreover, both USP 2010 SWS are equipped with a BDS system and are –like many new machines from Plasser & Theurer – already fitted with the new P-IC 2.0 control system. Additionally, the machines are designed according to the new One Pass Technology, allowing all works to be performed in one pass. Thus, no follow-up work is required.

Both USP 2010 SWS will be approved in spring 2015. The first machine ope-rations are scheduled to take place in April/May 2015.

The operator‘s stand in ergonomic design is fitted with the new P-IC 2.0 control system.

Thanks to the 10 m³ hopper, surplus ballast can be stored on the machine and returned to the track, if required.

Thanks to its slewable shoulder ploughs and the centre plough, the USP 2010 SWS produces an ideal ballast profile.

F I R S T - H A N D S E R V I C E

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