Permaquip Ironman Installation and operation manual

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Operating & Maintenance Manual
Ironman (Standard and LUL)
Permaquip Ltd
Brierley Industrial Park,
Stanton Hill, Sutton-in-Ashfield
Nottinghamshire, NG17 3JZ
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
www.permaquip.co.uk

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CONTENTS
1Issue and Revision Record .............................................................................4
2Introduction.....................................................................................................5
3Safe and Correct Use......................................................................................6
4Technical Specification....................................................................................8
4.1 Physical Data for Ironman Assembled ......................................................8
4.2 Mass Data for Components.......................................................................8
4.3 Physical Data for Sleeper Lifting Attachments...........................................8
4.4 Load Specifications...................................................................................9
4.5 Operational Limits...................................................................................10
4.6 Vibration..................................................................................................10
4.7 Product Compliance................................................................................10
5Storage and Transportation...........................................................................14
5.1 Storage...................................................................................................14
5.2 Transportation.........................................................................................14
6General Layout..............................................................................................15
7Operating Instructions...................................................................................16
7.1 Checks before use..................................................................................16
7.2 Assembly of the Ironman.........................................................................16
7.3 Fitting the red lights.................................................................................19
7.4 Moving the Assembled Ironman..............................................................20
7.5 Operating the Ironman ............................................................................21
7.6 Using the Sleeper Lifting System Attachments........................................28
8Defined Words .............................................................................................. 29
9Document Review.........................................................................................30
10 Maintenance .................................................................................................31
10.1 General................................................................................................32
10.2 Maintenance schedule.........................................................................34
10.3 Mainframe Assembly............................................................................36
10.4 Wheels.................................................................................................36
10.5 Brakes..................................................................................................36
10.6 Carriage and Traverse Mechanism......................................................38
10.7 Lifting Tackle Assemblies.....................................................................38
10.8 Red Light .............................................................................................38
11 Record Sheets .............................................................................................. 38
12 Test Specification..........................................................................................39
13 Training.........................................................................................................40
14 Ordering........................................................................................................41

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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.

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1 ISSUE AND REVISION RECORD
This document will be updated when necessary by the re-issue of the complete
document.
Issue
Description
Date
Revised
Page No.
Revised
By.
15
Changes for new MD
31/12/2009
All
C.H.
16
Maximum length was 300’, increased to
360’. Use of additional Ironmen added.
26/08/2011
19
M.J.K.
17
Transposing usage note now includes
maximum level 150mm
19/09/2011
5
C.D.M.
18
General update to include more
detailed maintenance information.
25/02/2016
All
M.S.
19
Unit of measurement error corrected.
23/06/2017
24
M.S.
Authorised By:
Martin Sheppard BEng
Engineering Manager

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2 INTRODUCTION
The Permaquip™Ironman is proven design which can be used singularly or in
multiples, for the lifting and transportation of rail lengths, or parts of points and
crossings (P&C) from one location to another.
The Ironman can also be used to transpose rail from one side of the track to the other.
Therefore by straddling the running rails, access to the four-foot, six-foot and cess is
possible.
The Ironman has design variations approved to work on various infrastructures with
features including; fail-safe braking system, dismantle-able frame to enable easier
lifting and transportation, rail storage bracket, strong and durable steel construction.
Optional features depending on model include insulated or non-insulated wheels, Yale
Pull-Lift, Camlok Rail Clamp or Rail Lifting Clamp, Single or Double Rail Carriage &
Sleeper Lifting System.

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3 SAFE AND CORRECT USE
Please keep this User Guide for future reference.
To ensure safe and correct use of the Ironman the following should be noted:
Wear eye, feet, head and hand protection when using the Ironman.
Additional Personal Protective Equipment (PPE) should be worn
according to local regulations.
During transit the Ironman should be secure, and kept away from all
electrified lines. Ironman fitted with insulated wheels must not be used in
locations where live AC overhead power lines are present. Do not use the
Ironman near live DC third-rail or fourth-rail systems.
The Ironman, or parts of, must be replaced if damage occurs.
Store the Ironman in a secure position.
The Ironman is designed for manual propelling only and must not be
propelled using a powered vehicle. Use in conjunction with a Permaquip™
Railman if the Ironman is required to be moved by a powered vehicle.
Before using, undertake a Manual Handling Risk Assessment and follow
the assessment guidelines at all times. Use the handles provided. Do not
exceed walking pace, noting underfoot conditions. Do not walk on
sleepers or the rail head. Reduce the walking pace on gradients.
Before placing on track ensure the Ironman has been maintained and
perform a COP0018 pre-use check. Failure to do so may result in injury,
damage to equipment or infrastructure, consist runaway or worse.

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Always ensure there is enough trained personnel present to operate the
Ironmen as detailed later in this manual. Under no circumstances should
fewer staff be used.
Stopping distances will be greatly increased by icy or wet conditions;
gradients; an increase in load; an increase in speed.
For transposing operations ensure the Ironman is on stable and firm
ground and level within the 150mm MAXIMUM on track operating cant,
failure to do so may result in injury. Do not attempt to move the Ironman
when under transposing conditions.
Do not move the Ironman during transporting operations without the
Bottom Cross Beam in position.
Do not hold off the Brake Handle using mechanical means.
Do not ride the Ironmen. Riding the Ironmen puts yourself and others at
risk.
Do not use the Ironman for any other purpose than as described in the
introduction. Please contact Permaquip Ltd for advice on use for other
applications or purposes.
Increases in cant require extra operator effort to hold the load on the
Traverse Hand Wheel once it is disengaged from the locking mechanism.

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4 TECHNICAL SPECIFICATION
4.1 Physical Data for Ironman Assembled
Standard Assembly
LUL Assembly
Width
1935 mm
1935 mm
Depth
1085 mm
1065 mm
Height
1410 mm
1400 mm
Total Mass
153.5 kg
141.5 kg
Centre of mass
Central
Central
4.2 Mass Data for Components
Mass
Top Beam Assembly
31 kg
Braked End Frame Assembly
36 kg (standard) / 32 kg (LUL)
Un-braked End Frame Assembly
34 kg (standard) / 30 kg (LUL)
Bottom Cross Beam
11 kg
Rail Storage Bracket
7 kg
Adaptor Link Assembly
1 kg
Yale Pull-Lift
15 kg
Single Leg Chain Assembly
6 kg
Rail Lifting Clamp
8.5 kg
Camlok Rail Clamp
12.5 kg
4.3 Physical Data for Sleeper Lifting Attachments
Beam
Frame
Width
240 mm
1417 mm
Depth
4000 mm
138 mm
Height
267 mm
850 mm
Total Mass
29 kg
17 kg
Centre of mass
Central
Central

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4.4 Load Specifications
•Maximum SWL of Ironman Frame assembly 1500 kg
•Camlok Rail Clamp (see marking on clamp for details) 750 or 1000 kg
•Rail Lifting Clamp 1500 kg
•Yale Pull-Lift 1500 kg
•Adaptor Link 1500 kg
•Single Leg Chain Assembly 3150 kg
•Maximum SWL of Sleeper Lifting Beam 300 kg
•Maximum SWL of Sleeper Carrying Frame 1000 kg
•Maximum rail overhang on outer Ironman 10’ (3m)
Therefore the maximum operating loads for the various Ironman configurations are as
follows;
1. Rail transportation
For standard rail, using a Yale Pull-Lift, Adaptor Link and Camlok Rail Clamp:
SWL 750 or 1000kg (see rating) when lifting, 1500 kg during transportation
For LUL rail, using a Yale Pull-Lift, Adaptor Link, and Rail Lifting Clamp:
SWL 1500 kg when lifting and during transportation
For all rail types, using the Rail Storage Bracket mounted on the Ironman (in addition
to the appropriate Rail Clamp):
SWL 500 kg during storage only
2. Points and Crossings transportation
For points and crossings, using a Yale Pull-Lift, Adaptor Link and a suitable rated
webbing strap:
SWL 1500 kg when lifting and during transportation
Note that the Single Leg Chain Assembly could be used instead of the webbing.
However a webbing strap is preferable.

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4.5 Operational Limits
•Maximum gradient 1:27
•Maximum cant (on track) 150mm
•Maximum cross level (off track, stationary) 150mm
•Maximum length of rail 360’ 110m
•Maximum length of rail (Network Rail Infrastructure) 300’ 91.5m
4.6 Vibration
The Hand Arm Vibration at the operator’s position has been measured as less than
the action level of 2.5 m/s2and therefore no additional measures need to be taken into
account.
The Whole Body Vibration is not applicable, therefore the action level is less than 0.5
m/s2so no additional measures need to be taken into account.
Uncertainty is 50% of the values stated.
4.7 Product Compliance
The standard Ironman complies with RIS-1701-PLT.
The Ironman also complies with the following:
•Directive 2006/42/EC
Safety of Machinery.
•Directive 93/68/EEC
CE Marking.

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5 STORAGE AND TRANSPORTATION
5.1 Storage
The Ironman and any associated spare partsshould bestored in a dryand
secure environment. Safety critical spare parts must be stored in a dry,
secure and controlled environment.
5.2 Transportation
During transit the Ironman should be secured, and kept away from all
electrified lines. Ensure that any method used to secure the Ironman in/on
a vehicle applies the load uniformly and does not exceed the SWL. Do not
use excessive force when using a ratchet type loading strap.

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6 GENERAL LAYOUT
The following shows the main components of the Ironman before assembly (lifting
gear not shown).
The following outlines the main components once assembled.

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7 OPERATING INSTRUCTIONS
The following procedure outlines the correct method for operation.
Should any checks fail do not use the Ironman.
Always push, never pull, the Ironman.
All work should only be performed by competent personnel.
Always follow local regulations.
Observe Manual Handling Regulations.
7.1 Checks before use
Follow the appropriate Maintenance Programme outlined in the Maintenance section.
7.2 Assembly of the Ironman
The following procedure outlines the correct method for assembling the Ironman.
1. Ensure that all 4 main components are available.
2. It is recommended that the Ironman is assembled by a minimum of two persons.
Once assembled it is recommended that it is lifted by four persons.
3. Check that all parts of the Ironman have the same serial number, the SWL is
shown and the ‘Next Brake Test Due’ has not expired.
4. Check that the brakes are in good working order. To do this, access the braked
wheels and rotate with one hand. Please refer to CoP0018,pre-use checks. The
wheels should resist movement. If in doubt do not use until it has been checked
by a competent person.
5. Check the brake handle when pushed out to one side is between 5° to 10° above
the push handle. If in doubt do not use until it has been checked by a competent
person. See picture below.

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6. On firm level ground or on track, stand one of the End Frame Assemblies
vertically and locate the Top Beam Assembly in position as shown below.
7. Insert the Clamping Screw and tighten, as shown below. This secures the End
Frame and Top Beam Assembly together. Repeat the procedure for the
remaining End Frame Assembly.

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8. Mount the Bottom Cross Beam onto both of the End Frame Assemblies, as
shown below.
9. The Ironman is now assembled. The appropriate lifting equipment can now be
hooked onto the Top Beam carriage, as shown below.
10. If required, mount the Rail Storage Bracket onto the un-braked End Frame
Assembly as shown below. Secure in position with the Clamp Screw.

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7.3 Fitting the red lights
1. The Red Lights are located in two positions on the Ironman Top Beam. There
are no additional fixings required as theyslot into the Light Brackets fitted within
the apertures, as shown below. The two locking screws supplied can be fitted
to prevent unauthorised removal.
2. The Red Lights can be switched from underneath using the on and off switch
positioned between the support tabs. It will need to be actuated using your
fingernail or a small thinflat object. Operation has purposely been made difficult
to prevent false operation.

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7.4 Moving the Assembled Ironman
The fully assembled Ironman is equipped with four rotating lifting handles. Once lifted,
the handles will lock in position to prevent unexpected movement.
It is designed to be lifted by four persons, as shown below.
Once the Ironman is on the track ensure that all four wheels are in contact with the rail
head.
To release the fail-safe brake, hold down the Brake Handle whilst facing the direction
of travel and walking outside of the rail, as shown below.
When operated in pairs, ensure both of the Ironmen have the Brake Handles on the
same safeside. The brake will automatically applywhen the Brake Handle is released.