SPL16 Stovepipe Lifter

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1 Thomson Engineering Design Ltd SPL16 Stovepipe Lifter Operators Instructions, Maintenance Instructions & Parts Book Original Document in English Language Issue 1 September 2016 Copyright: Thomson Engineering Design Ltd all rights reserved

2 Introduction The Thomson Engineering Design SPL16 Stovepipe Li er is designed for the handling and installa on of ver cal posts, stovepipes and similar structures to overhead moun ngs. The device consists of a telescopic support sec on for tubular sec on parts of varying length, two clamps for securing the load and a hand-operated hydraulic li. This manual describes the safe use and maintenance of the SPL16 Stovepipe Li er and includes spare parts lists. Warning The Thomson Engineering Design SPL16 Stovepipe Li er must not be used for any purpose or in any way not described within this document. Using this device for any purpose not described in this document may be dangerous and may invalidate the manufacturer s warranty. KEEP CLEAR OF THE HOST MACHINE WHILST IT IS LIFTING OR MOVING THE STOVEPIPE LIFTER. Warning The maximum hydraulic pressure which may be applied to the circuits of the Manipulator is factory set and must not be altered. Exceeding the set pressures may damage or reduce the life of the hydraulic components. It is extremely dangerous to over pressurise a hydraulic system and doing so can lead to severe injury. 2 Copyright: Thomson Engineering Design Ltd all rights reserved Thomson Engineering Design SPL16 Stovepipe Li ers are proudly designed and made in the United Kingdom.

3 Contents Introduc on 2 Specifica ons 3 Issue Record 3 Descrip on of the SPL16 Stovepipe Li er 4 A aching & Connec ng the SPL16 Stovepipe Li er 5 Se ng the Stovepipe Li er 6 Using the SPL16 Stovepipe Li er 8 Detaching & Transpor ng the SPL16 Stovepipe Li er 10 Maintenance Plan 11 Warnings 37 Contac ng the Manufacturer 38 Cer ficate of Conformity 39 Spare Parts Lists 40 Specifications (typical) Overall Transport Dimensions Overall Weight (with typical head) Transport Weight (inc s llage) Hydraulic System Pressure Maximum Working Load (li ) 1500mm (L) x 1050mm (W) x 1266mm (H) 515 kg 710 kg 150 Bar 350 kg Issue Record Issue 1 September 2016 Copyright: Thomson Engineering Design Ltd all rights reserved 3

4 Description of the SPL16 Stovepipe Lifter The main parts of a Thomson Engineering Design SPL16 Stovepipe Li er are illustrated below. The SPL16 Stovepipe Li er is connected to the host machine by the adapter head. Different adapter heads are available to suit different machine configura ons however the most popular is the two-pin rigid head as shown below which is suitable for use with hydraulic quick couplers. The SPL16 Stovepipe Li er is designed for handling stovepipes and similar structures up to 5m long. Handle for Hydraulic Pump Carriage Assembly Slide Bars A achment Head Clamp Assemblies Clamp Moun ng Flanges Spigot for short Stovepipes Base Plate Locking Pins for Telescopic Sec ons 4 Copyright: Thomson Engineering Design Ltd all rights reserved

5 Attaching the SPL16 Stovepipe Lifter A aching the SPL16 Stovepipe Li er to the Host Machine Connect the SPL16 Stovepipe Li er to the host machine by a aching the boom end to the adapter head of the device. A fixed pin adapter head is supplied for use with host machines equipped with hydraulic quick couplers. A loose pin adapter head can also be supplied for direct pin connec on to the boom end. The host machine must have sufficient li ing capacity for the work to be undertaken and its li ing capacity must include allowance for the weight of the SPL16 Stovepipe Li er itself. No hydraulic connec ons are required between the host machine and the Stovepipe Li er. SPL16 Stovepipe Li er connected to the host machine Respect the Environment Tipping the Stovepipe Li er may cause hydraulic fluid to leak from the hydraulic tank. Hydraulic fluids, even biodegradable fluids, can cause serious damage to the natural environment par cularly if discharged into a watercourse. Respect the environment and handle hydraulic fluids carefully. Contain and remove any fluid spills immediately. Copyright: Thomson Engineering Design Ltd all rights reserved 5

6 Setting the SPL16 Stovepipe Lifter The SPL16 Stovepipe Li er can be adjusted to take different lengths of stovepipes by extending the telescopic sec ons. For stovepipes of 1m to 1.5m length a spigot extension is fi ed. This component is removed for stovepipes longer than 1.5m. For very short stovepipes (1m to 1.5m long) bolt the lower clamp to the middle moun ng point and bolt the spigot extension to the bo om moun ng point as shown in Figure 1. The leg sec ons should be fully closed so that the spigot on the baseplate engages with the tube on the extension spigot piece. Figure 1 Stovepipe Li er set up for short stovepipes For stovepipes longer than 1.5m the extension spigot is removed and the lower clamp assembly is bolted to the bo om moun ng point as shown in Figure 2. Figure 2 Stovepipe Li er set up for stovepipes 1.5m to 2.0m long Warning The telescopic leg sections are heavy. Follow the setting procedure described in this section. 6 Copyright: Thomson Engineering Design Ltd all rights reserved

7 For ease of opera on the fixing plate on the top of the stovepipe should be close to the top of the Stovepipe Li er so that the handle of the hydraulic pump can be easily reached by the operator whilst s ll being able to reach the plate. This is achieved by se ng the length of the Stovepipe Li er using the telescopic leg feature. There are two telescopic sec ons each of which may be adjusted separately by first placing the base plate of the device on the ground, removing the se ng pin (see Figure 5) and then slowly li ing the device le ng the leg slide out. Replace the pin(s) when the desired length is achieved. The device is now set and ready for use. Figure 3 Stovepipe Li er set for 3.0m to 3.5m stovepipes Figure 4 Stovepipe Li er set to full length for stovepipes up to 5.5m long Figure 5 Removing the se ng pin from the inner telescopic sec on Copyright: Thomson Engineering Design Ltd all rights reserved 7

8 Using the SPL16 Stovepipe Lifter Load a stovepipe into the Stovepipe Li er by first removing the pins from the clamp assemblies and hinging them open. Li a stovepipe into the Stovepipe Li er ensuring that the open bo om end of the stovepipe sits over the spigot. Push the stovepipe into the fixed part of the jaw assemblies then close and repin the jaws to secure the stovepipe. Tighten the clamp screws on the clamp assemblies to restrain the stovepipe if required. Clear the area of all personnel so that the host machine operator can safely li the stovepipe into posi on stopping when the plate on the stovepipe is approximately 150mm to 200mm from the fixing bolts. Operators in a Mobile Eleva ng Work Pla orm (MEWP) can then approach the stovepipe li er to install the stovepipe. From the basket of the MEWP close the valve on the hand pump and loosen the clamp screws on the clamp assemblies. Pump the handle of the hand pump to raise the stovepipe, guiding it onto the fixing bolts by hand as it is li ed. Secure the stovepipe to its fixings. Figure 6 Jaw Assemblies hinged open ready to accept a stovepipe To release the stovepipe from the Stovepipe Li er, remove the pins and hinge open the clamp assemblies. Open the valve on the hand pump to lower the Stovepipe Li er carriage and thus disengage the spigot from the bo om of the stovepipe tube. The host machine can now reverse away from the stovepipe and lower its boom ready for the next stovepipe installa on. Figure 7 Valve on the hand pump used to lower the carriage 8 Copyright: Thomson Engineering Design Ltd all rights reserved

9 Figure 8 A short stovepipe being li ed Figure 9 Installing a long stovepipe. Note that if the team had extended the telescopic leg of the Stovepipe Li er only one MEWP would have been needed! Copyright: Thomson Engineering Design Ltd all rights reserved 9

10 Detaching and Transporting the SPL16 Stovepipe Lifter Place the Stovepipe Li er on a firm level surface and detach it from the host machine following the instruc ons for the host machine quick coupler or by removing the a achment pins as appropriate. The Stovepipe Li er should be transported upright as shown to avoid spilling oil from the hydraulic tank. The SPL16 Stovepipe Li er can be supplied with a purpose-designed s llage for transport if required. 10 Copyright: Thomson Engineering Design Ltd all rights reserved

11 Maintenance Plan The Thomson Engineering Design SPL16 Stovepipe Li er is specifically designed for the li ing and installing of stovepipes and similar structures. Use of the SPL16 Stovepipe Li er is described in the Operators Instruc ons Sec on on pages 5 to 10. This part of the document deals with the inspec on and maintenance opera ons necessary to keep the SPL16 Stovepipe Li er in good condi on and to ensure that it is safe for use. This document does not cover repair and overhaul opera ons which are fully described in the SPL16 Stovepipe Li er Repair Opera ons Manual available separately from the manufacturer. This sec on of the document is divided into three sub-sec ons: the first subsec on deals with the periodic inspec on and maintenance of the various parts of the device, the second sec on describes the maintenance opera ons mandated in the first sub-sec on and the last sub-sec on gives guidance on the thorough examina on (under LOLER) of all parts of the Stovepipe Li er which should be carried out at six monthly intervals. Thorough Examina on of Li ing Equipment The SPL16 Stovepipe Li er is an item of li ing equipment as defined under the Li ing Opera on and Li ing Equipment Regula ons (LOLER). Under LOLER it is the responsibility of the owner and users of the SPL16 Stovepipe Li er to: Appoint competent users and inspectors Ensure that the SPL16 Stovepipe Li er is thoroughly examined at least once every six months Record thorough examina ons on a LOLER cer ficate Maintain the SPL16 Stovepipe Li er in a safe condi on This document is intended to assist users, maintainers and examiners by detailing the rou ne maintenance program, describing the rou ne maintenance opera ons and highligh ng where defects may occur due to excep onal wear-and-tear, abuse, transit damage, etc. From me to me this document may be updated and new copies of the document may be obtained from the manufacturer. Copyright: Thomson Engineering Design Ltd all rights reserved 11

12 Competency Standards Competency Standards for Maintenance It is the responsibility of equipment owners to ensure that all staff carrying out maintenance opera ons are competent. Thomson Engineering Design Ltd can provide training in the necessary maintenance and examina on tasks relevant to the SPL16 Stovepipe Li er. As a minimum, all maintenance staff working on the SPL16 Stovepipe Li er should be assessed as competent in: Machinery Maintenance and Repair Skills Fault Finding on Hydraulic Systems Competency Standards for Thorough Examina ons (LOLER) LOLER does not define any specific competency standards or recommend any relevant qualifica ons for li ing examiners. It is the responsibility of employers to define who is competent to carry out LOLER examina ons and different companies may have different standards. The SPL16 Stovepipe Li er is a specialised item of li ing equipment which is not generally covered by li ing industry training courses however its component parts are rela vely simple and of a design which anybody with experience of examining li ing equipment should be able to assess. The guidance given in this document should enable operators and examiners to use and maintain the SPL16 Stovepipe Li er in a safe and efficient manner but we will be pleased to answer any specific queries or assist in the development of any further training material or documenta on which owners may require. Discovery of Cracks, Distor on or Serious Failure In the event of the discovery of cracks or distor on within the load bearing parts of the SPL16 Stovepipe Li er or any other failure which might cause the Stovepipe Li er to drop a load or injure any person, the Stovepipe Li er should be removed from service, quaran ned and the manufacturer should be contacted at once. Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire. GL14 2NZ Tel: Fax: sales@thomsondesignuk.com 12 Copyright: Thomson Engineering Design Ltd all rights reserved

13 Glossary of Defined Maintenance Terms Throughout this document the following terms shall have the meanings given below: Adjust Blueing Change Check Clean Daily Defec ve Dismantle Examine Gauge Gauge Grease Inspect Lubricate Overhaul Paint Re-assemble Record Record Rec fy Refit Remove Renew Repair Test Correct to defined limits Discoloura on of metal components caused by overhea ng Remove the original and fit a new or overhauled part or assembly it its place Determine a par cular nominated condi on, for example completeness, security, posi on, etc.. Remove all dirt and deposits Per working shi (typically not exceeding 8 hours con nuous use) Containing a fault or faults which may impair the normal func oning of a part or assembly Take to pieces Carefully inspect in order to seek out defects for example wear, cracks, leaks, corrosion, etc. (n.) Tool specifically designed for measuring or checking a specific parameter (eg. profile) (vb.) Measure a specific parameter or compare with a calibrated instrument Apply grease via a grease nipple or by hand to a surface Determine general condi on and conformity to required standards Apply lubricant Carry out repair opera ons and inspec ons necessary to return equipment to fitness for use Apply a suitable coloured coa ng to a surface in accordance with the coa ng makers instruc ons Put together all the parts of an assembly to return it to the as-manufactured state. (n.) Wri en or electronically stored data (vb.) Take down data in wri ng or enter into an electronic data store To correct Put back and re-connect Disconnect and take off Replace the original with a new part or assembly Restore to fitness for use Prove correctness by trial (for example correct opera on or func on) Copyright: Thomson Engineering Design Ltd all rights reserved 13

14 Maintenance Facilities All of the maintenance ac vi es and opera ons described in this document may be carried out in a normal plant workshop environment. Where special service tools and gauges are required to complete a task these are noted and part numbers for the tools given. All service tools and gauges may be obtained from the manufacturer. Maintenance staff must ensure that they are familiar with all local safety rules and advice and that they are working under a safe system of work. Warning The SPL16 Stovepipe Li er has a high pressure hydraulic system Hydraulic fluid under pressure can puncture skin and, if injected into so ssue, can cause massive injuries. Changes in temperature can cause a build up of pressure in closed hydraulic systems. Always treat hydraulic systems with great cau on especially when checking for leaks. Wear appropriate PPE especially goggles. Remember that moving machinery can kill! 14 Copyright: Thomson Engineering Design Ltd all rights reserved

15 Section 1: Periodic Maintenance & Inspection The Thomson Engineering Design SPL16 Stovepipe Li er is designed for heavy duty use in a challenging environment. The following maintenance programme has been designed to ensure that the SPL16 Stovepipe Li er is kept in good condi on so that it is safe and reliable in service. Maintenance and Inspec on tasks are listed for Daily (pre-use), Monthly and Six-monthly intervals represen ng 8, 150 and 1,000 hours use respec vely. This programme should be considered as a guide and may be modified if experience demonstrates that modifica on is jus fied. All maintenance and repair ac vi es should be recorded and these records periodically reviewed to look for pa erns of defects. If repeated defects are observed then the manufacturer should be alerted. Sec on 1 Content 2.1: Pre-Use Maintenance & Inspec on : Monthly Maintenance (150 hours use) : 6-Monthly Maintenance (1,000 hours use) : Disposal at End of Life 20 Copyright: Thomson Engineering Design Ltd all rights reserved 15

16 1.1: Pre-Use Maintenance & Inspection Daily checks of the SPL16 Stovepipe Li er are designed to ensure that it is fit for use. Daily maintenance is limited to greasing of the hydraulic cylinder ends. The following is a list of the relevant daily checks. These should be carried out at the start of the shi before pu ng the SPL16 Stovepipe Li er into service. If the device is used for an extended period then these checks and maintenance opera ons should be repeated every eight hours of use. Pump handle moves freely Hand pump valve knob turns freely Adapter head bolts are ght All removable pins are secured with lynch pins Jaws hinge freely All jaw moun ng bolts are ght Hydraulic hose is free from damage All parts free of cracks, wear and distor on Hydraulic system is free from leaks Slide bars are clean and free from burrs Grease should be applied to the following points Hydraulic cylinder ends Lubricants Always use a good quality EP (extreme pressure) rated grease such as Castrol Contractor Special, Castrol Pyroplex, Shell Gadus S3 or similar. 16 Copyright: Thomson Engineering Design Ltd all rights reserved

17 Grease the cylinder rod end Grease the cylinder body end Copyright: Thomson Engineering Design Ltd all rights reserved 17

18 1.3: Monthly (150 Hours) Maintenance A er every month or 150 hours (whichever is soonest) perform the following maintenance checks and opera ons. In addi on to the daily maintenance inspec on opera ons detailed on pages 16 and 17: Thoroughly clean the SPL16 Stovepipe Li er Check the Hydraulic Fluid Level Check ghtness of all bolts Check cylinder rod for damage, scoring and pi ng Check Manufacturers plate is secure and legible Check the cylinder ends & cylinder pins for wear Check the ghtness of the cylinder pin bolts If any significant defect is noted the SPL16 Stovepipe Li er should be quaran ned and correc ve ac on must be taken before returning the SPL16 Stovepipe Li er to service. 18 Copyright: Thomson Engineering Design Ltd all rights reserved

19 1.4: 6-Monthly (1,000 Hours) Maintenance A er every six months or 1,000 hours use (whichever is soonest) complete a daily and a monthly maintenance schedule and then also perform the following checks and opera ons. The following checks are designed to ensure the correct opera on of the hydraulic system: Check the cylinder piston seals Check the frame for cracking, damage and distor on Once the maintenance has been completed the SPL16 Stovepipe Li er should also be given a thorough examina on as required under LOLER. Loler Inspec on A competent person must carry out a thorough (LOLER) examina on every six months. Ideally this should not be the person who carried out the maintenance opera ons. Guidance on inspec ng the SPL16 Stovepipe Li er is given on pages 31 to 34. Copyright: Thomson Engineering Design Ltd all rights reserved 19

20 1.5: Disposal at End of Life At the end of its useful working life almost all of the parts of the SPL16 Stovepipe Li er can be recycled. The SPL16 Stovepipe Li er may be returned to the manufacturer for proper disposal, alterna vely please contact the manufacturer for advice on how each of the component parts may be disposed of in an environmentally sensi ve manner. 20 Copyright: Thomson Engineering Design Ltd all rights reserved

21 Section 2: Maintenance Operations The following sec on describes the maintenance opera ons required under the maintenance programme set out in Sec on 1. Thomson Engineering Design Ltd can provide training in maintenance and hydraulic system repair skills if required. Sec on 2 Content 2.1: Checking the Hand Pump : Checking the Adapter Head : Checking the Se ng Pins : Checking the Jaw Assemblies : Checking the Hydraulic System : Checking Nuts and Bolts are Tight : Checking for Cracks and Distor on : Checking the Slide Bars : Checking for Wear on the Cylinder Pins 30 Copyright: Thomson Engineering Design Ltd all rights reserved 21

22 2.1: Checking the Hand Pump Pump Handle Moves Freely Very slowly pump the handle up and down with the valve knob turned an clockwise to prevent pressure build-up. The handle should move freely throughout its stroke with no evidence of s ffness at any point in its movement. S ffness in the movement may indicate a bent pump rod which may necessitate the replacement of the pump. Valve Knob Turns Freely Open and close the valve by turning the knob an -clockwise by one turn and then clockwise un l it goes ght. NOTE that light hand ghtness is all that is required, over ghtening may damage the valve components and lead to leakage. Hydraulic Fluid Level To check the hydraulic fluid level the Stovepipe Li er the device must be upright so that the tank upper surface is level. Remove the filler / breather plug from the rear le hand corner of the top of the tank and use a clean rod to dip the tank. With the cylinder fully closed (that is with the carriage assembly fully lowered) the hydraulic fluid should be between 25mm and 50mm from the top of the tank. If necessary, top up the tank with ISO32 hydraulic fluid. 22 Copyright: Thomson Engineering Design Ltd all rights reserved

23 2.2: Checking the Adapter Head The adapter head of the Stovepipe Li er can become damaged during connec on and disconnec on of hydraulic quick couplers. Check the pins for burrs and bending, check all welds for signs of cracking. Follow procedure 2.6 to check that the moun ng bolts are ght. Burrs should be filed smooth. Bent pins should be inspected by a competent li ing equipment examiner before the machine is put back into service. No cracking of the welds or steel sec ons is permissible. Any cracks must be repaired before returning the machine to service. Please consult the manufacturer for a suitable repair procedure. Copyright: Thomson Engineering Design Ltd all rights reserved 23

24 2.3: Checking the Setting Pins The se ng pins must be secured with lynch pins and must be free from bending or distor on. Remove the pins and roll them on a flat bench to check for bending. Visually inspect the pins for bruising or other damage. Re-fit the pins ensuring that lynch pins are fi ed. Bruised, bent or damaged pins should be replaced. 24 Copyright: Thomson Engineering Design Ltd all rights reserved

25 2.4: Checking the Jaw Assemblies The Jaw Assemblies must open and close freely, the clamp screws must turn freely throughout their travel and the components must be free of cracking, damage and distor on. The moun ng bolts must be ght, check this using the procedure set out in sec on 2.6. Checking the Clamp Screws Screw the clamp screws fully in and out to check for damage to the threads and bending of the threaded rods. The clamp screws must move freely throughout their travel. Damaged clamp screws must be replaced. Checking the Jaw Opening and Closing Check that the pin can be easily removed and that the jaws open and close freely. Difficulty in removing the pin may be caused by bending of the pin. Difficulty in opening and closing the jaw may indicate corrosion of the hinge pin, distor on of the components or other damage. Any damaged components must be replaced. Copyright: Thomson Engineering Design Ltd all rights reserved 25

26 2.5: Checking the Hydraulic System The hydraulic hose connec ng the pump to the cylinder must be free of defects and the hydraulic system must reliably hold the load without internal or external leakage. The hose should be visually inspected for signs of chafing of the outer surface and for visible wires. Chafing of the outer surface of the hose which has not exposed the wires may be repaired with a suitable tape. If wires have been exposed these will quickly corrode and lead to failure of the hose in service. In this instance the hose must be replaced. Tes ng the Hydraulic System This test will only determine if there is a fault. The fault could be either a piston seal failure or leakage within the pump or a leaking joint. Connect the Stovepipe Li er to a host machine. Place a test load of 150kg to 250kg in the device and operate the hand pump to raise the carriage at least half way through its travel. Measure the distance between the top plate of the carriage and the top plate of the main frame using a ruler or calipers. Leave the device holding the load for 5 minutes then re-measure the distance as described above. The two measurements should be the same. If the carriage has dropped during the test period then proceed as follows. Check the level of hydraulic fluid in the tank. A loss of hydraulic fluid indicates that the piston seal in the hydraulic cylinder is leaking. The seal should be replaced if the carriage has dropped by more than 5mm during the test period. No loss of hydraulic fluid indicates that the valve in the hand pump may be leaking. Replace the hand pump if this internal leakage causes the carriage to drop by more than 10mm during the test period. Pressure should be released by opening the valve on the hand pump before working on the hydraulic system. Hydraulic fluid under pressure can cause very serious injuries. 26 Copyright: Thomson Engineering Design Ltd all rights reserved

27 2.6: Checking Nuts and Bolts are Tight All nuts and bolts should remain ght. Before use a visual / manual examina on should be carried out, at each monthly inspec on a thorough check should be carried out as described below. Normally the bolts will not work loose and this can lead to complacency with regard to checking them. THIS IS AN IMPORTANT CHECK and must not be overlooked. Visual / Manual Examina on As a pre-use inspec on only: Visually inspect the area around all the bolt heads for damaged paint or other signs that the bolts heads may have rotated. Try turning the bolts by hand to check that they are all ght. Thorough Inspec on During a monthly inspec on use a calibrated torque wrench set to the correct torque for each bolt size to check that the fasteners are ght. Bolt Size Grade 8.8 Torque (Nm) Grade 12.9 Torque (Nm) M M M M M M M Copyright: Thomson Engineering Design Ltd all rights reserved 27

28 2.7: Checking For Cracks and Distortion The Thomson Engineering Design SPL16 Stovepipe Li er is a very strong device and should not crack or bend in normal service. Careless handling during transport or accidental impacts could damage the unit and it should be inspected prior to each use for such damage. Visually inspect the paintwork for signs of rust which may indicate an underlying crack in the steel. Pay par cular a en on to the areas close to welds. Stand a short way away from the device and look along the flat faces of the plates for signs of bending. Any cracking or distor on must be repaired before the device is returned to service. 28 Copyright: Thomson Engineering Design Ltd all rights reserved

29 2.8: Checking the Slide Bars The slide bars must be free from burrs and bending so that the carriage can move freely up and down. Any burrs found on the slide bars should be filed smooth. If the slide bars are bent they must be replaced. It is unlikely that the slide bars could become damaged without other parts of the device becoming damaged also. Thoroughly inspect the en re structure for further signs of damage. Copyright: Thomson Engineering Design Ltd all rights reserved 29

30 2.9: Checking for Wear on the Cylinder Pins With no load on the device us a lever to check for play in the cylinder pin joints at both ends of the cylinder. This check should be carried out at least every six months as part of the thorough examina on required under LOLER. The pins should be replaced if there is more than 1mm of play at either end. 30 Copyright: Thomson Engineering Design Ltd all rights reserved

31 Section 3: Guidance on Thorough Examination (LOLER) Every six months the SPL16 Stovepipe Li er must be given a thorough examina on and a new cer ficate of thorough examina on issued before it may be returned to work. The SPL16 Stovepipe Li er has been designed to withstand heavy duty use over a long period and is unlikely to develop cracks or other defects in normal opera on. Careless handling and abuse can cause damage which may ul mately lead to premature and sudden failure and the examiner should be on the look out for evidence of this. This sec on of the Maintenance Plan is designed to guide the examiner by illustra ng areas where damage through abuse may occur and describing ways of checking. It is designed to be a stand alone sec on and therefore repeats many of the normal maintenance checks in Sec on 1. Sec on 3 Content 3.1: General Examina on : Func onal Examina on : Structural Examina on 34 Copyright: Thomson Engineering Design Ltd all rights reserved 31

32 3.1: General Examination Almost all faults may be spo ed by a thorough visual examina on. Begin by ensuring that the SPL16 Stovepipe Li er has been wiped clean of excess grease and thoroughly cleaned. The following checks will give a good indica on of the general condi on of the SPL16 Stovepipe Li er. Hydraulic System The hydraulic system should show no evidence of leakage The hose should be free from chafing and exposed wires All joints should appear ght with no evidence of leakage When operated, the cylinder should move smoothly The Cylinder rod should be free from damage Hydraulic Cylinder Mounts Hydraulic cylinder end joints should have less than 1mm play Cylinder moun ng pin bolts should be ght Adapter Head Moun ng bolts must be ght Pins should be free from bending Cross pins or bolts must be in good condi on where fi ed Head fabrica on should be free of cracks and distor on Clamp Assemblies Clamp screws should move freely Clamps should open and close easily Moun ng bolts must be ght All parts must be free of cracks and distor on 32 Copyright: Thomson Engineering Design Ltd all rights reserved

33 3.2: Functional Examination Carriage Li System Hydraulic hand pump should raise carriage smoothly Carriage must drop smoothly when valve is opened Telescopic Leg Sec ons Se ng pins must have lynch pins Tubular sec ons must be straight Telescopes should move freely when pins are removed Copyright: Thomson Engineering Design Ltd all rights reserved 33

34 3.3: Structural Examination Guide Bars Guide bars must be straight Guide bars must be free of burrs Carriage Carriage parts must be free from cracks, distor on & bending Frame Frame must be free from cracks, twist and distor on Any repairs carried out to the frame should be properly documented and assessed Note that cracking of the paint work may indicate cracking of the metal below. If in doubt, remove the paint and check with a dye penetrant tester. If any weld repairs have been carried out on the SPL16 Stovepipe Li er check that these are of good quality and carried out under a wri en Weld Process Specifica on by a welder qualified under a controlled Welder Approval Scheme. The red areas on the image on page 35 show the highest stressed areas of the frame in normal use. Par cular a en on should be paid to the examina on of these small areas of the frame. 34 Copyright: Thomson Engineering Design Ltd all rights reserved

35 Copyright: Thomson Engineering Design Ltd all rights reserved 35

36 36 Copyright: Thomson Engineering Design Ltd all rights reserved

37 Warnings WARNING ALWAYS STOP THE ENGINE OF THE HOST MACHINE AND RELEASE THE PRESSURE FROM THE HYDRAULIC SERVICES BEFORE ATTEMPTING TO CONNECT OR DISCONNECT HYDRAULIC ATTACHMENTS. MAXIMUM RATED PRESSURE OF HYDRAULIC CIRCUITS MUST NOT BE EXCEEDED. EXCEEDING RATED PRESSURE MAY LEAD TO BURST HOSES OR LEAKAGE FROM COMPONENTS. HYDRAULIC FLUID UNDER PRESSURE MAY CAUSE SEVERE INJURY. WARNING NEVER MOVE ANY LOAD UNTIL YOU ARE SURE THAT THE WORK AREA IS CLEAR OF ALL PERSONNEL. ALWAYS ENSURE THAT LIFTING OPERATIONS ARE PROPERLY PLANNED. REMEMBER THAT INADVERTENT OPERATION OF THE CONTROLS MAY CAUSE INJURY TO PERSONNEL IN THE WORK AREA. WARNING SMOOTH AND STEADY OPERATION OF THE SPL16 STOVEPIPE LIFTER WILL PROLONG ITS WORKING LIFE. ALWAYS ENSURE THAT THE STOVEPIPE IS SECURELY FIXED BEFORE RELEASING THE STOVEPIPE LIFTER WARNING INSTALLING STOVEPIPES IS A LIFTING OPERATION. ALL LIFTING OPERATIONS MUST BE CAREFULLY PLANNED TAKING INTO ACCOUNT THE DUTY CHART OF THE HOST MACHINE TO ENSURE THAT NEITHER THE SPL16 STOVEPIPE LIFTER NOR THE HOST MACHINE CAN BECOME OVERLOADED. OVERLOADING OF THE SPL16 STOVEPIPE LIFTER OR THE HOST MACHINE MAY LEAD TO SERIOUS INJURY OR DEATH. WARNING THE SPL16 STOVEPIPE LIFTER IS DESIGNED FOR THE HANDLING OF STOVEPIPE FABRICATIONS AND SIMILAR TUBULAR STEELWORK IN A VERTICAL ORIENTATION ONLY. IT MUST NOT BE USED FOR ANY OTHER PURPOSE. THE USE OF THE SPL16 STOVEPIPE LIFTER FOR ANY OTHER PURPOSE WILL INVALIDATE THE MANUFACTURER S WARRANTY AND MAY LEAD TO SEVERE INJURY TO PERSONS AND DAMAGE TO THE DEVICE. WARNING ONLY TRAINED AND COMPETENT OPERATORS SHOULD USE THE SPL16 STOVEPIPE LIFTER DO NOT ATTEMPT TO USE THE SPL16 STOVEPIPE LIFTER UNTIL YOU HAVE READ AND UNDERSTOOD THIS OPERATORS MANUAL. ALWAYS COMPLETE THE DAILY CHECKS AND MAINTENANCE BEFORE USING THE SPL16 Stovepipe Lifter If any part of this document is unclear or for any technical advice please contact the manufacturer. Manufacturer s contact details can be found on Page 38. Copyright: Thomson Engineering Design Ltd all rights reserved 37

38 Contacting the Manufacturer Thomson Engineering Design SPL16 Stovepipe Li er is manufactured in the United Kingdom by: Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire England GL14 2NZ Tel: +44 (0) Fax: +44 (0) All spare parts, technical, training and sales enquiries should be directed to the manufacturer. Please note that outside normal business hours all calls are monitored. Queries will be dealt with as soon as an on-call manager becomes free. 38 Copyright: Thomson Engineering Design Ltd all rights reserved

39 Certificate of Conformity We: Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire GL14 2NZ Declare under our sole responsibility that the product known as: SPL16 Stovepipe Lifter To which this declaration relates is in conformity with the following standards: 2006/42/EC Authorised signatory: David Thomson BSc David Thomson BSc CEng MIMechE Oct 2015 Copyright: Thomson Engineering Design Ltd all rights reserved 39

40 Ordering Spare Parts All spare parts for the Thomson SPL16 Stovepipe Li ers are available from the manufacturer and through our agents. Parts may be ordered by giving the device serial number (from the manufacturer s plate affixed to the frame) and the part number/descrip on from the parts lists in the following pages. Clamp assemblies (below) are available in a number of sizes to suit different stovepipe sec ons. When ordering clamp assemblies please specify the stovepipe stem material size. Clamp Assembly 40 Copyright: Thomson Engineering Design Ltd all rights reserved

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42 42 Copyright: Thomson Engineering Design Ltd all rights reserved

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44 44 Copyright: Thomson Engineering Design Ltd all rights reserved

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46 46 Copyright: Thomson Engineering Design Ltd all rights reserved

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48 48 Copyright: Thomson Engineering Design Ltd all rights reserved

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51 Copyright: Thomson Engineering Design Ltd all rights reserved 51

52 Thomson Engineering Design Ltd. Valley Road, Cinderford, Gloucestershire. GL14 2NZ Tel: +44 (0) Fax: +44 (0)

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