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Thomson Engineering Design Ltd SPH214 Small Panel Handler Operator s Instructions Original Document in English Language Issue 2 November 2015 Copyright: Thomson Engineering Design Ltd all rights reserved

Introduction The Thomson Engineering Design Small Panel Handler has been designed for li ing, loading and handling rail panels up to 6,000kg. The Small Panel Handler incorporates a safety valve system to prevent inadvertent release of the load and a pressure control system to make it compa ble with a wide range of host machines. This document is designed to give operators and crane controllers the informa on necessary to use the Small Panel Handler in a safe and efficient manner. It includes details of the maintenance opera ons which are required to keep the device in good working order. The maintenance of this device must be carried out by competent persons. Thomson Engineering Design Ltd can provide training in maintenance opera ons if required. Warning The Thomson Engineering Design Small Panel Handler must not be used for any purpose or in any way not described within this document. Using the Thomson Engineering Design Small Panel Handler for any purpose not described in this document may be dangerous and may invalidate the manufacturer s warranty. Warning The maximum hydraulic pressure which may be applied to the hydraulic circuit of the Small Panel Handler is 210 Bar. The minimum pressure required for safe opera on is 90 Bar. It is important to check that the pressure of the host machine hydraulic output is within this range. It is extremely dangerous to over-pressurise a hydraulic system and doing so may lead to severe injury. Warning Where a two-pin adapter head is fi ed the user s a en on is drawn to the instruc ons on Page 9. The hydraulic service on the host machine must be adjusted to ensure that the maximum pressure ra ng of the Small Panel Handler is not exceeded. If this is not possible then refer to the manufacturer before using the Small Panel Handler. The Thomson Engineering Design Small Panel Handler is proudly designed and made in the United Kingdom. 2 Copyright: Thomson Engineering Design Ltd all rights reserved

Contents Introduc on 2 Specifica ons 3 Issue Record 3 Descrip on of the Small Panel Handler 4 Daily Checks 5 Daily Maintenance 6 A aching & Connec ng the Small Panel Handler 8 Notes on using Two Pin Adapter Heads 9 Opera on of the Jaws and Indicators 11 Using the Small Panel Handler 12 Disconnec ng & Transpor ng the Small Panel Handler 14 Warnings 15 Contac ng the Manufacturer 16 Cer ficate of Conformity 17 Ordering Spare Parts 18 Specifications Overall Dimensions Height 760 mm Width 1,780 mm Length 4,135 mm Overall Weight (according to spec.) 540 kg to 750 kg Minimum Hydraulic Pressure 90 Bar Maximum Hydraulic Pressure 210 Bar Maximum Working Load 6,000 kg Proof Load (Factory Test) 9,000 kg Issue Record Issue 1 August 2014 Issue 2 November 2015 Copyright: Thomson Engineering Design Ltd all rights reserved 3

Description of the Small Panel Handler The main parts of the Thomson Engineering Design Small Panel Handler are illustrated below. The Small Panel Handler is a ached to the host machine by the connec on bracket and connected to the host machine s hydraulic system via the supply hoses. The hydraulic cylinders open and close the jaws of the Small Panel Handler to grip and release the rail. Each cylinder is fi ed with a check valve to lock the cylinders in posi on in the event of a hose burst. To prevent damage during transport the jaws are fully enclosed within the beam fabrica on. Indicators are provided to allow the operator to see whether the jaws are open or closed. 4 Copyright: Thomson Engineering Design Ltd all rights reserved

Daily Checks Daily checks of the Small Panel Handler are designed to ensure that it is fit for use. 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 Small Panel Handler into service. If the Small Panel Handler is used for an extended period then these checks should be repeated every six to eight hours of use. All jaws operate smoothly Frame free from cracks and distor on Jaws not worn to excess All nuts and bolts ght No visible hydraulic leaks Hydraulic hoses free from damage Mechanism moves freely Jaw indicators move freely up and down Adapter head (where fi ed) moves freely No play in adapter head pins Copyright: Thomson Engineering Design Ltd all rights reserved 5

Daily Maintenance Daily maintenance is limited to greasing of the jaws and cylinder ends. The following is a list of the relevant daily maintenance. This should be carried out at the start of the shi before pu ng the Small Panel Handler into service. If the Small Panel Handler is used for an extended period then these maintenance opera ons should be repeated every six to eight hours of use. Oil should be applied to the following point (see illustra on) Safety valve plunger Apply oil to the plunger of the safety valve. 6 Copyright: Thomson Engineering Design Ltd all rights reserved

Daily Maintenance (cont d..) Grease should be applied to the following points (see illustra on) Jaw Pins (2 grease points on each jaw assembly) Cylinder ends (4 points) Apply grease to the jaw hinge pins and the cylinder top boss. Use a lithium based general purpose grease. Copyright: Thomson Engineering Design Ltd all rights reserved 7

Attaching & Connecting the Small Panel Handler Suspend the Small Panel Handler from the Host Machine Connect the a achment bracket of the Small Panel Handler to the host machine following the instruc ons for the host machine coupling device. It is important that the connec on system has a safe working load in excess of 7,000kg. Connect the Small Panel Handler Hydraulic System to the Host Machine Stop the engine of the host machine and de-pressurise the hydraulic system. Connect the supply hoses of the Small Panel Handler to the auxiliary hydraulic connec ons of the host machine. Note: changes of temperature can mean that the closed system of the Small Panel Handler can become pressurised whilst it is being stored. Beware of the risk from release of hydraulic fluid under pressure which can cause very serious injury. Once the hydraulic connec ons are secure, re-start the host machine, li the Small Panel Handler clear of the ground and operate the hydraulic control to open and close the jaws three or four mes. This ensures that any trapped air is discharged from the cylinders and pipes of the Small Panel Handler. A er the device has been operated a few mes check the complete hydraulic system for signs of leakage. Stop the host machine and correct any leakage found before using the Small Panel Handler. Note: hydraulic quick release couplings should be of a type which prevents fluid discharge to the environment on connec on and release. Manually guiding the Small Panel Handler If at any me it becomes necessary to manually guide the Small Panel Handler then this must be done from a posi on of safety and never from below a suspended load. Never hold the Small Panel Handler close to the jaw mechanisms as inadvertent opera on of the mechanism could lead to serious injury. 8 Copyright: Thomson Engineering Design Ltd all rights reserved

Notes on Two-Pin Adapter Heads The Small Panel Handler is frequently fi ed with a two-pin adapter head for use with a quick coupler. It is important when a aching to a two-pin adapter head to ensure that the two pin link of the adapter head can move freely throughout the full working range of the host machine boom. When correctly set the quick coupler is a ached to the two pin link of the adapter head and crowded back to allow the link to pivot freely throughout the machine boom range (see above). Failure to crowd the quick coupler back can lead to the link hi ng the stop blocks which can damage the adapter head and the rotator. Copyright: Thomson Engineering Design Ltd all rights reserved 9

Operation of the Jaws and Indicators red painted indicator A is fi ed to each jaw assembly. When the indicators are raised as shown in the image (le ), this indicates that the jaws are open. When the jaws are closed and gripping the rails of a track panel the indicators drop down into the mechanism. This tells the operator that the jaws are fully locked and that the device is ready to li the panel. Copyright: Thomson Engineering Design Ltd all rights reserved 11

Using the Small Panel Handler Fi ng the Small Panel Handler to a Panel To fit the Small Panel Handler to a track panel follow the pictorial instruc ons on this page. 1. Check that the jaws are open (the indicators will be protruding above the tops of the jaw assemblies). Align the panel handler with the centre of the panel. 2. Lower the Panel Handler onto the rails so that the rail heads fit in the slots in the jaw assemblies. 3. Close the jaws to grip the panel. Check that all the indicators are flush with the top of the jaw housings to check that the jaws are properly closed. The panel may now be li ed. 12 Copyright: Thomson Engineering Design Ltd all rights reserved

Li ing a Panel Li the panel slowly and check that it hangs level. If the panel does not hang level lower the panel again and reposi on the panel li er. X Do NOT li an unbalanced load Releasing a Panel When the handling opera on is complete and the panel is res ng on a firm, level surface, lower the machine boom un l the centre head of the panel li er releases the safety valve. The jaws may now be released. Check that all four indicators have risen before li ing the Panel Handler clear of the track panel. Copyright: Thomson Engineering Design Ltd all rights reserved 13

Disconnecting and Transporting the Small Panel Handler Once the work is complete the Small Panel Handler should be placed on a firm, level surface and disconnected from the host machine. Once the Small Panel Handler is safely supported stop the engine of the host machine and de-pressurise the hydraulic system. Release the hydraulic connec ons and disconnect the a achment system from the host machine hook. Carefully wrap up the hydraulic connec on hoses before transport to ensure that they do not get damaged in transit. 14 Copyright: Thomson Engineering Design Ltd all rights reserved

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 210 BAR MUST NOT BE EXCEEDED. EXCEEDING THIS PRESSURE MAY LEAD TO BURST HOSES OR LEAKAGE FROM COMPONENTS. HYDRAULIC FLUID UNDER PRESSURE CAN CAUSE SEVERE INJURY. WARNING NEVER CARRY OUT ANY LIFTING OPERATION UNTIL YOU ARE SURE THAT THE WORK AREA IS CLEAR OF ALL PERSONNEL. ALL LIFTING OPERATIONS SHOULD BE PROPERLY PLANNED AND DUE CONSIDERATION GIVEN TO THE LIFTING CAPACITY OF THE HOST MACHINE. WHEN PLANNING A LIFTING OPERATION REMEMBER TO TAKE THE WEIGHT OF THE ATTACHMENT INTO ACCOUNT. WARNING DO NOT EXCEED THE SAFE WORKING LOAD OF THE SMALL PANEL HANDLER. LOADS IN EXCESS OF THE SAFE WORKING LOAD MAY CAUSE UNSEEN DAMAGE TO THE DEVICE AND LEAD TO SPONTANEOUS FAILURE AT A LATER DATE. WARNING VISUALLY INSPECT THE DEVICE DAILY FOR CRACKS AND DISTORTION OF THE FRAME, JAWS AND ATTACHMENT SYSTEM. IF ANY DEFECTS ARE NOTED THE DEVICE SHOULD BE REMOVED FROM SERVICE UNTIL THE FAULT IS RECTIFIED. CONTACT THE MANUFACTURER FOR REPAIR INSTRUCTIONS. WARNING THE Small Panel Handler IS DESIGNED FOR THE HANDLING OF TRACK PANELS UP TO 6,000KG. IT MUST NOT BE USED FOR ANY OTHER PURPOSE. THE USE OF THE Small Panel Handler FOR ANY OTHER PURPOSE MAY LEAD TO SEVERE INJURY TO PERSONS AND DAMAGE TO THE DEVICE. WARNING ONLY TRAINED AND COMPETENT OPERATORS SHOULD USE THE Small Panel Handler. DO NOT ATTEMPT TO USE THE Small Panel Handler UNTIL YOU HAVE READ AND UNDERSTOOD THIS OPERATORS MANUAL. ALWAYS COMPLETE THE DAILY CHECKS AND MAINTENANCE BEFORE USING THE Small Panel Handler. If any part of this Operators Instruc on document is unclear or for any technical advice please contact the manufacturer. Manufacturer s contact details can be found on Page 16. Copyright: Thomson Engineering Design Ltd all rights reserved 15

Contacting the Manufacturer The Thomson Engineering Design Small Panel Handler is manufactured in the United Kingdom by: Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire England GL14 2NZ Tel: +44 (0) 1594 82 66 11 Fax: +44 (0) 1594 82 55 60 Email: sales@thomsondesignuk.com All spare parts, technical, training and sales enquiries should be directed to the manufacturer. Please note that outside normal business hours all calls are diverted to an oncall technical advisor. 16 Copyright: Thomson Engineering Design Ltd all rights reserved

Certificate of Conformity We: Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire GL14 2NZ Declare under our sole responsibility that the product known as: SPH214 Small Panel Handler To which this declaration relates is in conformity with the following standards: 2006/42/EC Authorised signatory: David Thomson BSc August 2014 Copyright: Thomson Engineering Design Ltd all rights reserved 17

Ordering Spare Parts All spare parts for the Small Panel Handler 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. 18 Copyright: Thomson Engineering Design Ltd all rights reserved

Thomson Engineering Design Ltd. Valley Road, Cinderford, Gloucestershire. GL14 2NZ Tel: +44 (0) 1594 82 66 11 Fax: +44 (0) 1594 82 55 60 Email: sales@thomsondesignuk.com