User Guide Rail Scooter Permaquip Ltd Brierley Industrial Park, Stanton Hill, Sutton-In-Ashfield, Nottinghamshire, NG17 3JZ Tel: +44 (0) 1623 513349 Fax: +44 (0) 1623 517742 E-mail: sales@permaquip.co.uk www.permaquip.co.uk
CONTENTS 1. Introduction... 4 2. Safe and Correct Use... 4 3. Technical Specification... 5 3.1. Physical Data... 5 3.2. Mass Data of Individual Components... 5 3.3. Load Specification... 5 3.4. Camlok Specification... 6 3.5. Product Compliance... 6 4. General layout... 7 5. Operating Instructions... 8 6. Maintenance... 12 6.1. Wheel and Frame Assembly... 13 6.2. Wheels... 13 6.3. Shackle Assembly and Camlok Rail Clamp... 13 7. Test Specification... 13 7.1. Rail Scooter... 13 7.2. Shackle Assembly, Attachments and Camlok Rail Clamp... 14 8. Ordering... 14 Please note Whilst Permaquip Limited has taken every care in preparing this User Guide it is intended as a technical guideline only. Save to the extent that there are statutory rights to the contrary, Permaquip accepts no liability in relation to any use or reliance made of any information in this User Guide. All information, illustrations and specifications in this User Guide are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Equipment operators and installers shall be responsible for ensuring that a safe working environment and safe systems of work are in place and in certain circumstances advice and permission from the controlling authority must be sought before any operation, installation or surveying work is carried out. Permaquip is a trademark of Permaquip Ltd.
2006 Permaquip Ltd.
1. INTRODUCTION The Permaquip Rail Scooter is designed to aid the transportation of rail and sleepers, using existing rail as a guide. It is designed to be taken apart and assembled to ease transportation to and from site. 2. SAFE AND CORRECT USE Please keep this User Guide for future reference. To ensure safe and correct use of the Rail Scooter the following should be noted: Wear feet, head and hand protection when using the Rail Scooter. Additional Personal Protective Equipment (PPE) should be worn according to local regulations. During transit the Rail Scooter should be secured, and kept away from all electrified lines. The Rail Scooter, or parts of, must be replaced if damage occurs. Store the Rail Scooter in a secure position. Do not use the Rail Scooter for any other purpose than as described in the introduction. Do not drag the Rail Scooter along the ballast. The specified SWL is the safe maximum load the Rail Scooter can lift. Before using, undertake a Manual Handling Risk Assessment and follow the assessment guidelines at all times. It is designed to be operated by one person. Use the handle provided. Do not exceed walking pace, noting underfoot conditions. Do not walk on sleepers or the rail head. Do not use the Rail Scooter to move rail or sleepers over excessive distances. Use the Permaquip Ironman or the LinkTrolley. MAN/M/O/104-4 4
3.1. Physical Data 3. TECHNICAL SPECIFICATION Rail Scooter Assembly (only) Rail Scooter Assembly with Camlok Rail Clamp and Shackle Assembly Width 985 mm 985 mm Length 2520 mm (assembled) 2520 mm (assembled) Height 970 mm 970 mm Mass 64 kg 79 kg 3.2. Mass Data of Individual Components Handle Assembly Wheel and Frame Assembly Shackle Assembly Camlok Rail Clamp Mass 18 kg 46 kg 2 kg 13 kg 3.3. Load Specification Mechanical advantage of the Rail Scooter 9:1 Maximum operating load for each Rail Scooter SWL 350kg For transporting sleepers only, Maximum operating load of each Pandrol attachment Maximum operating load of each SHC attachment SWL 200kg SWL 200kg Note that the local Manual Handling Risk Assessment will define the limits that can be lifted by the operator. MAN/M/O/104-4 5
3.4. Camlok Specification The Camlok can be used to lift the following rail types of rail section: Bull head rail Flat bottom rail Conductor rail 85 and 95lb. 98, 109 and 113lb, 110A and 113A, UIC54 and UIC60. 100, 106 and 150lb. For transporting rails only, Maximum operating load for the Camlok Rail Clamp (see Clamp marking for specification) SWL 750 or 1000 kg 3.5. Product Compliance The Rail Scooter is considered as having Network Rail Grandfather Rights. Therefore the Rail Scooter can operate where: The track has a maximum cant of 150 mm. The track has a maximum gradient of 1:30. The Rail Scooter complies with the following: Directive 98/37/EC Safety of Machinery. Directive 93/68/EEC CE Marking. MAN/M/O/104-4 6
4. GENERAL LAYOUT The following layout outlines the main components of the Rail Scooter. MAN/M/O/104-4 7
5. OPERATING INSTRUCTIONS The following procedure outlines the correct method for operation. 1. Ensure that the Rail Scooter has a current Test Certificate. 2. As the Rail Scooter can be easily taken apart to aid transportation, as shown below, it needs to be assembled before use. 3. With two persons, place the Wheel and Frame Assembly wheels onto the rail head, with the larger wheel flange inside the four-foot (this will be the side for the handle). 4. While being held in position on the rail head, the second person should locate the folded Handle Assembly onto the Wheel and Frame Assembly, as shown below. MAN/M/O/104-4 8
5. While being held in the upright position, the second person can attach the appropriate carrying attachment as follows: Rail transportation Attach the Shackle Assembly onto the Handle Assembly with the smaller D shackle and then mount the Camlok Rail Clamp onto the Shackle Assembly as shown below. Sleeper transportation The sleeper lifting attachments available are for sleepers with Pandrol housings, MAN/M/O/104-4 9
Or for sleepers with SHC housings, In both cases the large D shackle on the end of the Shackle Assembly needs to be removed and stored securely. It is common practice to attach the loose D shackle on the Camlok Rail Clamp. Attach the Shackle Assembly onto the Handle Assembly with the smaller D shackle and then mount the appropriate sleeper attachment onto the Shackle Assembly. These are then secured in position with the attached toggle pin. 6. Whilst being supported, unfold the handle and secure in position with the Locking Pin. 7. Lower the attachment to locate onto the rail (refer to the Camlok Operating instructions for further details) or sleeper to be moved by raising the Rail Scooter handle and ensure that it is secure in its position. Sleepers with Pandrol housings Locate the Pandrol Attachment locating lugs into the Pandrol housing and lower the safety lever fully down, as shown in the following photographs. This ensures both lugs are fully located. MAN/M/O/104-4 10
Sleepers with SHC housings Locate the SHC Attachment into the housing as shown in the following photograph. 8. The rail or sleeper is now ready to be lifted and moved. Ensure that; Each Rail Scooter SWL is not exceeded. Check the intended direction of travel is clear. Ensure that 2 Rail Scooters are used for each sleeper. Ensure that 1 Rail Scooter is used for a rail length equal to 350kg max. A Rail Scooter should be positioned approximately 300mm from both ends of the rail to prevent the rail interfering with and therefore damaging the MAN/M/O/104-4 11
rail fasteners this is particularly important when moving along curved track or when old types of rail fasteners are present which have a higher profile. Push down on the Rail Scooter handle to raise the load. This can be seen in the following photographs. It is important that; 6. MAINTENANCE All work should only be performed by competent personnel. Always follow local regulations. Observe Manual Handling Regulations. MAN/M/O/104-4 12
The frequency of the following procedures will depend on usage and should be performed in the sequence shown. 6.1. Wheel and Frame Assembly 1. Check the main frame and beam for deformation. 2. Ensure the wheel axle mounts are straight and in line. 3. Ensure there is no bare metal exposed as this may adversely affect the long term integrity of the scooter. 4. Inspect the condition of the handle pivot lock pin. Replace if worn. 5. Ensure all labels are secure and can be easily read. Replace as required. 6.2. Wheels 1. Check for movement of each wheel. Resistance to movement indicates either a worn axle or cracked bearings. The wheel bearings are sealed for life and do not require lubrication. Damaged bearings should be replaced as necessary. 2. Check wheel profile for excessive wear and damage, particularly on both flanges. If damaged replace with new wheels to prevent derailment. 6.3. Shackle Assembly and Camlok Rail Clamp Lifting equipment should be inspected, maintained and tested by a competent person in accordance with statutory requirements. 1. Inspect the condition of the chain and D shackles; if worn or damaged replace with new parts. 2. The Camlok Rail Clamp, SHC and Pandrol sleeper carrying attachments should be inspected regularly. Inspections are to be six monthly unless adverse working conditions dictate shorter periods. Repairs may only be carried out by a specialist workshop with a test certificate issued on the day of completion. 7. TEST SPECIFICATION Lifting equipment should be inspected, maintained and tested by a competent person in accordance with statutory requirements. If the Rail Scooter has been repaired and/or replacement parts fitted, then the assembly should be tested to the following specification after the Maintenance procedures have been completed. 7.1. Rail Scooter MAN/M/O/104-4 13
1. Note the Rail Scooter Serial Number. 2. Mount the assembled Rail Scooter onto a test section of rail that is securely fixed to the ground. 3. Connect a load cell to the Rail Scooter, with the other end secured to the ground. 4. Apply a downward force onto the handle until the load cell reads 437.5kg (1.25 x SWL). The equipment used for lowering the handle must be securely fixed to the handle itself to prevent unexpected movement. Persons should not manually perform this test and the equipment used must be able to maintain the position without creep. 5. Maintain this for 1 minute. 6. Raise the Rail Scooter handle to release the load. 7. Check the Rail Scooter has no deformation or weld failure. 8. Update the equipment test records, and apply a Date Tested label. 7.2. Shackle Assembly, Attachments and Camlok Rail Clamp 1. The Shackle Assembly, SHC and Pandrol Attachments and Camlok Rail Clamp should all be subjected to a 2 x SWL test. The test loads are therefore; Shackle Assembly SHC Attachment Pandrol Attachment Camlok Rail Clamp 2000kg 400kg 400kg 1500kg 2. Update the equipment test records and apply a Date Tested label. Permaquip Ltd offer a testing and maintenance service please contact us for further details. 8. ORDERING DESCRIPTION PADS Cat. No. PART NO MAN/M/O/104-4 14
Rail Scooter Assembly with Shackle Assembly and Camlok Rail Clamp (not shown) 68/1654 05794 Rail Scooter Assembly (only) 28531 Shackle Assembly 30267 Camlok Rail Clamp 040590057 SHC Attachment (only) 39/68954 09813 Pandrol Attachment (only) 39/68953 09794 MAN/M/O/104-4 15
For spare parts please see the Spare Parts List. Please contact Permaquip Ltd for further information and support. Our contact details are shown on the front of this User Guide. In order to avoid delay and to have your orders fulfilled promptly, Please telephone, e-mail, fax or write giving the following information: 1. Company name. 2. Contact details. 3. Invoicing and delivery details. 4. Purchase order number. 5. Method of delivery. 6. Part number, description and quantity for each item. MAN/M/O/104-4 16
Your Notes MAN/M/O/104-4 17
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