Permaquip Sleeper Squarer User manual
CONTENTS
1Introduction..................................................................4
2Safe and Correct Use..................................................5
3Technical Specification................................................7
3.1 Physical Data for the Portable Sleeper Squarer
Main Components...........................................................7
3.2 Oil Specification.....................................................7
3.3 Fuel Specification..................................................7
3.4 Operating Pressure ...............................................7
3.5 Operating Performance .........................................7
3.6 Power Pack Engine Emissions..............................8
3.7 Power Pack Engine Noise Emissions....................8
3.8 HAV.......................................................................8
3.9 Product Compliance ..............................................8
4General Layout..........................................................10
5Operating Instructions................................................11
5.1 Pre-use Checks...................................................11
5.2 Assembly.............................................................12
5.3 Starting the Engine..............................................13
5.4 Stopping the Engine ............................................13
5.5 Operating Duties..................................................14
5.6 Operating Procedure. ..........................................15
6Maintenance and Test...............................................16
6.1 Prior to despatch to site.......................................16
6.2 Weekly Maintenance/Safety Checks....................17
6.3 Annual/every 250 hours of running (which ever
occurs first)...................................................................17
7Training .....................................................................18
8Ordering ....................................................................19
9Hydraulic Circuit ........................................................20
10 ISO37 Oil Material Safety Data Sheet.....................22
11 Honda Engine Owners Manual...............................26
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 ISSUE AND REVISION RECORD
This document will be updated when necessary by the re-issue of the complete
document.
Issue/
Revision Description Date
Revised
Page
No.
Revised
By.
03
Changes for new MD
31/12/09
All
CH
MAN/M/O/197-03 5
2 INTRODUCTION
The Permaquip™ portable Sleeper Squarer is used to square all types of
monoblock, twinblock, concrete or wooden sleepers to the track.
The unit contains an integral power pack for simple operation. The unit is an
assembly of parts, designed to enable the ease of transportation and operation.
The Permaquip™ portable Sleeper Positioner consists of two Sleeper Squarer units,
working from one power pack, thereby enabling both the squaring and positioning of
sleepers.
3 SAFE AND CORRECT USE
Please keep this User Guide for future reference.
To ensure safe and correct use of the portable Sleeper Squarer the following should
be noted:
Wear ear, eye, feet and hand protection when using the portable Sleeper
Squarer. Additional Personal Protective Equipment (PPE) should be
worn according to local regulations.
During transit the portable Sleeper Squarer should be secured and kept
away from all electrified lines.
The portable Sleeper Squarer, or parts of, must be replaced if damage
occurs. Do not use the portable Sleeper Squarer if any components are
damaged.
Store the portable Sleeper Squarer in a secure position.
Ensure that all hydraulic components and couplings are clean. Retract
the rams.
Before using, undertake a Manual Handling Risk Assessment and follow
the assessment guidelines at all times. Use the handles provided.
MAN/M/O/197-03 6
Always use the correct, clean oil, as defined in the technical
specification. The portable Sleeper Squarer has been filled and tested
with clean, new hydraulic oil to this specification. It must be properly
maintained and not contain contaminated oil. No liability will be accepted
for failure or malfunction of the equipment if this condition is not met.
Always use the correct, clean filtered fuel, as defined in the technical
specification. The portable Sleeper Squarer has been tested with clean,
new fuel to this specification and then drained. Contaminated fuel must
not be used. When fuel is left in the engine it should be ran every for 5
minutes every 4 to 6 weeks. No liability will be accepted for failure or
malfunction of the equipment if this condition is not met.
Keep all components away from extreme temperatures.
The portable Sleeper Squarer is not obstructionless, so adequate
protection must be used.
The portable Sleeper Squarer can affect track stability. Refer to the
railway infrastructure for guidance.
Do not use the Hydraulic Hoses to move the portable Sleeper Squarer.
Do not allow the hoses to kink, twist, curl or bend. Do not allow the
hoses to come into contact with corrosive substances such as paint, oil,
etc. Refer to Permaquip for further advice.
Do not use the portable Sleeper Squarer for any other purpose than as
described in the introduction.
Do not drag the portable Sleeper Squarer along the ballast.
Do not hold off the Brake Handle using mechanical means.
Stopping distances will greatly increase by icy or wet conditions;
gradients; an increase in load; an increase in speed.
MAN/M/O/197-03 7
Dispose of used oil responsibly and in accordance with local regulations.
4 TECHNICAL SPECIFICATION
4.1 Physical Data for the Sleeper Squarer/Positioner Main Components
Assembled data for
Sleeper Squarer
Assembled data for
Sleeper Positioner
Length
1500 mm
Width
2000 mm
Height
1050 mm
Total Mass
386 kg
703 kg
4.2 Oil Specification
The recommended oil for the ram and brake system is;
•Anti-wear hydraulic oil with an ISO viscosity grade 37.
Ensure that any alternatives used are to the same specification.
4.3 Fuel Specification
The fuel for the Power Pack engine is;
•Unleaded 95 RON petrol.
4.4 Operating Pressure
The maximum operating pressure of the portable Sleeper Squarer is 2,500 p.s.i.
(17.2 MNm-2)
4.5 Operating Performance
The performance limits of the portable Sleeper Squarer are;
MAN/M/O/197-03 8
•Hydraulic Pump 1.5 l/min at 1500 rpm
•Maximum sleepers per hour 50
4.6 Power Pack Engine Emissions
Do not use the Power Pack in confined spaces such as tunnels without
adequate ventilation in place.
The Power Pack is fitted with a Honda GX160 engine,that is certified to meet the
emissions shown below for 250 hours providing the correct maintenance is
performed.
g/hp.hr
Hydrocarbons
10.0
NOX
10.0
CO
549
4.7 Power Pack Engine Noise Emissions
The noise emitted by the power pack has been measured at 86 dB(A) at a distance
of 1m at all positions and 90 dB(A) at the operators position.
4.8 HAV
The HAV on the control lever has been measured as less than the action level of 2.5
m/s2and therefore no additional measures need to be taken into account.
4.9 Product Compliance
The portable Sleeper Squarer complies with GM/RT1310.
The portable Sleeper Squarer complies with the following:
•Directive 2006/42/EC
Safety of Machinery.
•Directive 93/68/EEC
CE Marking.
MAN/M/O/197-03 9
MAN/M/O/197-03 10
5 GENERAL LAYOUT
The following shows the main assembly of the portable Sleeper Squarer.
MAN/M/O/197-03 11
6 OPERATING INSTRUCTIONS
The following procedure outlines the correct method for operation.
Should any of the checks fail do not use the equipment.
All work should only be performed by competent personnel.
Always follow local regulations.
Observe Manual Handling Regulations.
Ensure ballast forward of the sleeper and lever arms is removed.
6.1 Pre-use Checks
1. Check engine oil level. Fill if required using the correct specification and to the
required level.
2. Check engine fuel level. Fill if required using the correct specification and to
the required level.
3. Check hydraulic oil tank level. Fill if required using the correct specification
and to the required level.
4. Check that there are no loose fasteners, oil leaks and general damage.
5. Check the hydraulic rams and hoses are not damaged.
6. Note that new hoses are delivered empty of hydraulic oil.
7. Check the quick release couplings are free of damage and clean. Replace if
damaged.
8. Check the condition of the rail clamps, connecting pins and chain are not
damaged.
MAN/M/O/197-03 12
9. Check that the brakes are on and come off when the brake handle is moved.
Check that the brakes go back on when the handle is released.
6.2 Assembly
The portable Sleeper Squarer requires three operators for assembly and dismantling
of the following items:
•Chassis
•Power Pack and outrigger
•Lever arms and cylinders
•Flexible hose assemblies
•Miscellaneous pins and fastenings
Once assembled the portable Sleeper Squarer can be operated by one person.
1. Place the chassis assembly onto the rail; swing down the rail pushing arms to
operating position.
2. Hold the chassis vertical.
3. Fit the outrigger into the chassis and locate the outrigger wheel onto the
adjacent rail head.
4. Fit the washers and ‘R’ clips in position to lock the outrigger onto the chassis.
5. Locate the first rail clamp lever arm to the rail clamp on the inside of the 4-
foot, position and fit the retaining pin.
6. Locate the second rail clamp lever arm to the rail clamp, position and fir the
retaining pin.
7. Locate the hydraulic cylinders to the lever arms and fit the pivot pins.
8. Locate the hydraulic power pack onto the outrigger, ensuring that the recoil
start end is adjacent to the chassis.
9. Connect the hydraulic hoses between the poser pack and control valve,
ensuring that the quick release couplings are clean prior to connection.
10. Connect the brake handle assembly onto the power pack frame and secure
with the thumbnuts provided. Note that the brake hoses are permanently
connected. The brake handle assembly can be operated from either side of
the equipment and are failsafe.
MAN/M/O/197-03 13
11. Start the engine as described in the ‘Starting the Engine’ section; operate the
control valve to raise the chassis clear of the rail head.
12. Stop the engine as described in the ‘Stopping the Engine’ section.
13. Connect the hydraulic hoses between the control valve and the hydraulic
cylinders, ensuring that the quick release couplings are clean prior to
connection.
14. Restart the engine.
15. Operate the control valve to extend the hydraulic cylinders.
16. Locate the fork ends of the hydraulic cylinders to the push bars; fit the pivot
pins and ‘R’ clips.
17. The portable Sleeper Squarer is now fully assembled and ready to use.
Note that on a Sleeper Positioner, both sets of Sleeper Squarer brakes will need to
be operated at the same time. Therefore a crossbar is supplied to facilitate this.
6.3 Starting the Engine
1. Ensure that the directional control valve on the power pack is in the neutral
position.
2. Turn on the fuel valve.
3. Start the engine (see section Honda Engine Owners Manual).
4. When the engine has warmed up, set the throttle to the desired speed.
6.4 Stopping the Engine
1. Move the throttle to low revs.
2. Close the fuel tap.
MAN/M/O/197-03 14
6.5 Operating Duties
The following is a recommended operation based on a three person team.
Person 1
Clears the ballast (if required) from:
•Between the sleeper to be pushed and the next sleeper in front. This is done to
provide clearance for the sleeper being pushed.
•From behind the sleeper being pushed to allow the pushing arms to be lowered
into the working position.
Person 2
Operates the machine.
Person 3
To inform the operator (person 2) when the sleeper has been squared.
MAN/M/O/197-03 15
6.6 Operating Procedure.
Never attempt to square a sleeper if the machine clamp is likely to foul
an obstruction, i.e. Thermit weld, fishplate, etc., as this could result in
damage to the machine.
Where the portable Sleeper Squarer clamp locates immediately above a
rail clip, the clips must be removed from both sides of the rail prior to
squaring. Failure to remove the clips could result in damage to the clamp
assembly.
Where the clamp locates immediately above a rail chair screw, the screw
must be removed. Failure to remove the screw could result in damage to
the clamp assembly.
1. Start the engine.
2. Remove the ballast (if required) as described in the ‘Operating Duties’
section.
3. Operate the control lever to fully retract the hydraulic cylinders.
4. Operate the control lever to raise the chassis onto the rollers.
5. Position the machine at the first sleeper with the pushing arms approximately
25mm from the sleeper.
6. Operate the control lever to lower the chassis onto the rail.
7. Position a set square against the front edge of the sleeper to be squared (or
work to the mark on the rail if one is provided).
MAN/M/O/197-03 16
8. Operate the control lever to extend the hydraulic cylinders (the rail clamp will
engage automatically). Continue to operate the cylinders until the sleeper has
moved to the correct position.
9. Operate the control lever and retract both hydraulic cylinders.
10. Operate the control lever to raise the chassis onto the rollers.
11. Remove the ballast from the next sleeper to be squared.
12. Pull the machine into position at this sleeper.
13. Repeat the above procedure.
Note that the sleepers can usually be squared without removing the rail fastenings.
Depending on the condition of the pads and the amount of sleeper movement, it may
be necessary to follow the operation with a re-padding team using the Permaquip
Rail Jacking Trolley.
7 MAINTENANCE AND TEST
All work should only be performed by competent personnel.
Always follow local regulations.
Observe Manual Handling Regulations.
7.1 Prior to despatch to site
1. Always kept the hydraulic fittings clean, especially the self sealing, quick
release couplings. Replace all dust caps immediately after the couplings are
disconnected.
2. Check the hydraulic oil level and top up using the correct oil, as specified in
the Technical Specification.
3. Inspect the hydraulic hoses and pipes for visible signs of damage. Replace as
required.
4. Check the condition of the rail clamps and chain for damage or wear. Replace
as required.
5. Check that the pins are secure and in good condition. Replace as required.
6. Check that the brakes are on and come off when the brake handle is moved.
Check that the brakes go back on when the handle is released.
7. If the brakes do not come off when the brake handle is operated, then follow
the following procedure:
MAN/M/O/197-03 17
•With the oil gun provided, push onto the fill screw located on the brake
handle assembly.
•Slightly undo this fill screw and push the oil gun to allow oil into the
master cylinder. The brake handle will rise until the cylinder is full. Once
full, tighten the fill screw and remove the oil gun.
•Undo the bleed screw, also located on the brake handle assembly, until
a small amount of oil comes out. This will remove any residual pressure
in the system.
•Recheck the brakes operate as previously described.
7.2 Weekly Maintenance/Safety Checks
1. Check the condition of the self sealing, quick release couplings. Replace if
damaged.
2. Check the hydraulic hoses and pipes for visible signs of damage. Replace as
required.
3. Check the security of the ram connecting pins. Replace as required.
4. Visually check the condition of the rail clamps for damage to welds and pivot
pins. Replace as required.
5. Visually check the condition of the chain for damage and wear. Replace as
required.
7.3 Annual/every 250 hours of running (which ever occurs first)
1. Drain off the hydraulic oil.
2. Remove the suction strainer and filler from the hydraulic oil tank and clean.
3. Check the return line filter indicator and if necessary replace the filter
element.
4. Clean out any silt from the hydraulic oil tank.
5. Refit the suction and filler strainer. Refill the tank with clean hydraulic oil, as
specified in the Technical Specification.
6. Check the condition of the engine anti-vibration mounts. Replace as required.
7. For a Sleeper Squarer, place the assembly on a flat, level test track. With the
brakes on, connect a load cell to the frame and pull horizontally, aligned with
the track. The brakes should prevent the wheels from turning when the load
cell reads a minimum of 30kg.
8. For a Sleeper Positioner, place the assembly on a flat, level test track. With
the brakes on, connect a load cell to the frame and pull horizontally, aligned
MAN/M/O/197-03 18
with the track. The brakes should prevent the wheels from turning when the
load cell reads a minimum of 60kg.
Permaquip Ltd offer a testing and maintenance service – please contact us for
further details.
8 TRAINING
Persons that will operate, maintain and test the Portable Sleeper Squarer should
undertake a programme of training. Permaquip Ltd offer a training service – please
contact us for further details.
This programme of training should include the following aspects:
•Product familiarisation.
•Component location and function.
•Product preparation.
•Safe and Correct Use.
•Maintenance.
•Testing.
•Practical experience.
MAN/M/O/197-03 19
9 ORDERING
DESCRIPTION PADS Cat.
No. PART NO
Portable Sleeper
Squarer
PA05/03681
14469
Portable Sleeper
Positioner
25393
For spare parts please see the Spare Parts List.
MAN/M/O/197-03 20
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.
10 HYDRAULIC CIRCUIT
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