HIRD GLASS KAPPEL HYDRAULICA 1200 CURVED User manual

www.hird.co.uk
OPERATOR MANUAL
DISCLAIMER - ALL INSTRUCTIONS ARE SUPPLIED FROM MANUFACTURER AND WHERE CORRECT AT TIME OF PRINT
KAPPEL
Hydraulica 1200
OM 1120-2
Northern (Head Office)
Tel: [phone]
Western
Tel: [phone]
Southern
Tel: [phone]
Central
Tel: [phone]
www.hird.co.uk

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
TECHNICAL DESCRIPTION
The dual circuit Hydraulica multi-purpose vacuum lifter is capable of lifting non-porous loads of up
to 1000kgs (DSH2) or larger area loads of up to 1200kgs (DSH2-1200). It features 270omanual
rotation and hydraulic power tilt from 0 to 90o. Power rotation is available as an optional extra.
It is a dual power machine which can be powered by the on board maintenance free 12V dry cell
rechargeable battery or by 110V supply. The built in charger allows the operator to recharge the
battery during mains operation or overnight before1_ifting-commences.
Safe operation is assured by four independent systems :
Two independent vacuum systems , each with its own vacuum pumps (2 per
circuit), non- return valve, vacuum sensor , vacuum gauge and alarm system .
This ensures that should one circuit loose vacuum due to breakage , etc. the other
circuit will still support the load. Either circuit is capable of supporting the safe
working load (SWL). During thorough examination both circuits are independently
proof tested to 1.5 times the SWL.
N.B. This does not imply that the lifter can be used to lift greater than the SWL
At no time must a load greater than the SWL be lifted.
If electrical power is lost during mains operation the battery will automatically
take over to power the lifter in all its functions; The two vacuum tanks offer a
vacuum reserve which will still hold the load if there is a pump malfunction . The
vacuum is held in the tanks by non-return valves, one for each circuit, which limits
the ingress of air to the system; The pumps are controlled by vacuum sensors
which automatically start the pumps and regenerates the vacuum if a low vacuum
condition (below 61 %) is reached on either circuit. This is accompanied by
audible and visual warnings.
Pump application is reduced by a combination of the vacuum reserve tanks
and vacuum sensors, which switch off the pump when the vacuum reaches
approximately 74% and only restarts when the 61% unsafe limit is reached. This
limits the drain on the battery.
The individual pads are movable on the pad frame to cater for different sized or
odd shaped loads. Shut off valves allow individual pads to be isolated should they
not be required.
N.B. Although it Is possible to apply the vacuum circuits Individually the lifter MUST
NEVER be operated in this manner. Both vacuum circuits must be functioning
correctly and MUST ALWAYS be operated before attempting to lift the load. Failure
to do so could lead to loss of the load with potentially fatal consequences.
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
HEALTH AND”SAFETY INSTRUCTIONS
General
1. The DSH2 Hydraulica variants are-designed in accordance with the relevant European standard
(EN13155:2003). However, operating errors and misuse will result in hazards;
a- to the life of the operator and others;
b- to the lifter and materials of the company and others;
c- to the correct and·efficient operation of the device
2. All persons involved with the set-up, operation and maintenance of the machine must read
and observe the following instructions . The personal safety of yourselves and others that may
encroach upon your operation is at stake.
3. Only operate the DSH2 Hydraulica under the correct environmental conditions, to do otherwise
jeopardises health and safety, and will invalidate the Report of Thorough Examination and any
warranties still in force.
N.B. The DSH2 Hydraulica variants are multi-configuration lifters. Always check the
Report of Thorough Examination to ensure the Safe Working Load (SWL) of the lifters
current configuration is adequate for the load to be lifted.
Intended Use
4. The DSH2 Hydraulica variants are intended for the carriage of gaslight , dry materials with
a solid, smooth surface . The load may be manually rotated through 270oand hydraulically
tilted from 0 to 90o·. Use of additional and sufficient manpower is strongly recommended when
performing the rotation manoeuvre . Other operations involving the lifting of gas permeable or
foil coated materials, wet or unstable loads, loads that are heavier than the SWL or operating
outside the environmental guidelines or using the machine in the rain is regarded as contrary
to intended use. The manufacturer/ supplier is not liable for any damage resulting from such
misuse. That risk lies entirely with the user.
5. Care is to be taken when operating this machine in areas of high electromagnetic disturbance,
e.g. HV power generation facilities, HV transformer sub-stations , as this may lead to the
inadvertent release of materials. Where this work is carried out every opportunity must be taken
to isolate equipment from HV interference by ensuring all covers to distribution boxes, control
boxes, etc. are closed.
6. Unauthorised alteration to the structure or operational controls of the device is prohibited for
safety reasons.
7. Intended use also requires observance of the operating manual and adherence to the conditions
for inspection and maintenance .
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
Emissions
8. The equivalent continuous A-weighted sound pressure level (LpA) approximately 80dbA at a
distance of one meter whilst the pump and warning siren are operating a This is below the first
action level as defined in the Control of Noise at Work Regulations 2005. However in confined
areas this level may be exceeded and personnel may suffer hearing disturbance and should be
issued with the appropriate personal protective equipment.
Environmental Considerations
9. The lifter must not be used in the rain or ·on wet loads. Failure to observe this requirement may
lead to failure of the safety systems with potentially fatal consequences.
10. The operating temperature range is 0°C to +35°C. The storage temperature range is
-5 °C to +50°
Sources of Hazard
11. The lifting frame works on negative pressure (vacuum) to hold the gaslight load. Any failure
of the vacuum system may cause the load to be released with potentially fatal consequences.
Therefore, as far as is reasonably practicable, all measures must be taken to avoid lifting the
load over personnel.
Organisational Measures
12. A job specific risk assessment and method statement must be prepared by a competent person
prior to the commencement of the task.
13. Always have the Hydraulica operating manual available on site.
14. No one under the age of 18 years old may operate this machinery.
Maintenance
15. User maintenance of the device is strictly limited to:
a. pre-use inspection;
b. battery charging;
c. resetting of 2A and 25A circuit breakers .
16. Other than these operations all maintenance , inspection and testing must be carried out by
authorised and competent personnel only.
17. Never clean the pads with solvent based chemicals, this will remove the plasticiser and seriously
degrade the pads shortening their life and rendering them unsafe. In the event of serious
contamination of the pads, a mild solution of soapy water should be used . Care should be
taken that no water enters the system during cleaning via the holes on the pads.
18. As a designated “accessory for lifting” the DSH2 Hydraulica variants are subject to a thorough
examination by a competent person every 6 months in accordance with the Lifting Operations
and Lifting Equipment Regulation 1998, Regulation 9(3)(a)(i) .
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
LIMITED WARRANTY AND LIABILITIES
1In principle, dependent upon type of supply our Hire Terms and Conditions or ‘Sales Terms and
Conditions’ are valid and apply.
2Warranties and liability claims for injury to persons or material damaged are limited to where it
can be proven that aforesaid injury or damage is due to negligence on the part of Hird Ltd or
their authorised representative.
3 In particular the following conditions are strictly excluded from warranty or liability claims:
a- device being used for lifting of materials other than those covered by
the intended use section of the health and safety instructions ;
b- improper mounting, installation , operation or maintenance of the
device;
c- use of the device with safety or protective devices that are not
operating correctly;
d- device being transported, operated, mounted, installed , maintained
or prepared in contradiction of the advice as described in the health
and safety instructions;
e- unauthorised modification or alteration to the device ;
f- use of the device by personnel with inadequate knowledge of the
operation of vacuum devices ;
g- improper repair;
h- natural catastrophe or force majeure.
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
SAFETY DEVICES
The DSH2 Hydraulica variants have several safety devices to prevent the loss of vacuum.
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL
1The non-return valves in the vacuum pumps
prevents loss of vacuum when the pump shuts
of or ails.
2. The vacuum tanks create a vacuum reserve to
hold the load in the event of a vacuum pump
failure . It also prevents the pump switching
on too often during normal operation,
helping to preserve battery
3. Vacuum gauges give a direct indication of the
percentage of vacuum in both circuits .
4. Vacuum sensors with in-line warning light and
siren to indicate when vacuum has dropped
to unsafe level in either circuit.
5. The remote control has a ‘press to apply
and lock - pull to release’ control knob for
each circuit to prevent the inadvertent
release of vacuum .

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
TRANSPORTATION & STORAGE
1. Do not set down the suctions cups, nor try to apply them on a surface that is likely to damage
the sealing lips,·such as; rough stone or concrete, sharp edges. The-resulting damage to the lips
could impair the cups ability to seal when required and may lead to the loss of the load).
2. Likewise, never place the cups down on a dusty or sandy area or one that is covered with grit.
This may lead to sharp grains becoming embedded in the pads. This may lead to the pad not
sealing correctly or damage to the surface ·being lifted.
3. Never lean the lifter against a surface for storage as the lips may become distorted or the lifter
may be knocked over and damaged. If it is necessary to lean the machine against a surface
always ensure the pads are supported clear of the floor and the lifter is adequately secured
against falling.
4. The lifter should always be transported and stored either on a smooth clean surface or by being
freely suspended .
5. Always ensure that the lifter is stored away from areas that are subject to rain, snow or heavy
condensation as the moisture may penetrate the electrical or vacuum system causing severe
damage and creating an electric shock risk and/or impairment of the vacuum system.
6. Temperatures of -5°C should be avoided for storage as this may cause premature perishing of
the pads and render them unsafe and unusable.
7. Preferably the lifter should be stored on its own stand or transport frame in a warm, dry
atmosphere .
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
OPERATION
CHARGING THE BATTERY
1. Ensure that the mains supply voltage corresponds with the charger voltage
i.e. 110 volts.
2. Unwind the supply cable and any extension leads fully.
3. Plug the lead receptacle onto the plug fitted on the lifter prior to inserting any
other plugs. Failure to do so may cause the 2A switch S1 to trip,
4. Once the lead is firmly secured to the lifter , the other end may be plugged
into the mains or transformer.
5. The green POWER light should now illuminate and the battery will begin to
charge . Charging is fully automatic and will take approximately 8 hours.
6. To check the amount of charge in the battery, press the Battery Test button
and the gauge will illuminate and indicate the percentage of charge.
N.B. Never attempt to lift if the battery charge is indicating below 20%
7. If the Power light fails to illuminate , check the 2A trip S1 and reset if required
PRE-USE INSPECTION
Prior to starting any operations, the Provision and Use of Work Equipment
Regulations 1998 states that the lifter must be inspected. You will find the Pre Use
Inspection Check List at the end of the Operating Manual.
1. Check the lifter for damage and distortion , particularly in the area of the
vacuum tanks and any welds.
2. Check the vacuum pads for rips or tears that may affect the vacuum lips.
Check also for perishing or evidence of hardening , and for cleanliness
of the pads
3. Check the vacuum pipes for any damage and security. Where extension arms
are fitted pay particular attention to the security of the quick release fittings.
See Safety Note 1 on page 10
4. Check the electrical cabling for any damage. Inspect the battery
connections for security.
5. Check battery has sufficient charge. Where the lifter
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDR
aulica 1200
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OPERATION
6. Check the test plate of the lifter for:
a. Safe Working Load (SWL), this will always show the
maximum SWL. The current Report of Thorough
Examination must be consulted to confirm the SWL in the
configuration being used.
b. Serial number of the lifter, and that it matches the serial
number on the accompanying Report for Thorough
Examination.
c. The last examination date matches that on the Report of
Thorough Examination and that the current date is within
6 months of the last Thorough Examination.
7. Ensure all pad shut off valves are in the ‘OFF’ position, i.e. not in line with
the pipe. Press both vacuum activation buttons on the remote control and
turn the power switch to ‘ON’
8. Ensure that all warning lights and sirens are on during vacuum build up.
9. Ensure vacuum reaches correct level on both circuits before pump turns off.
10. Using the remote control buttons, check that the lifter tilts from O to 90° and
back again freely.
11. Holding the rotation release handle ensure that the lifter turns 270° freely.
Repeat this operation, this time checking that it will lock every 90°.
12. Turn the power switch to ‘OFF’ and pull both the vacuum actuation valves to
release the vacuum and ensure the vacuum gauges drop to 0.
13. Ensure all pad isolation valves are turned on, i.e. in line with the pipes
14. Apply the lifter to a glass unit, turn the power ‘ON’, press both the vacuum
application buttons until they click. When the correct vacuum levels are
reached and all warnings are extinguished, record the vacuum levels, leave
the lifter applied and wait for a period of 10 minutes. Inspect the gauges
again and check whether the levels have dropped 5% or more from the
recorded values. If so do not use go to step 15.
15. Remove the lifter, clean the load and pads thoroughly. Repeat step 15. If
the lifter is still loosing more than 5% over the 10 minute period from either
circuit, remove the lifter from service and label it ‘Out of Service’ and ring
Hird Ltd Service and Maintenance.
Safety Note 1.
When using the extension arms it is imperative that the pipes from the pads
are correctly connected to the quick release fittings prior to vacuum being
applied. Failure to do so will isolate the relevant pad from the vacuum
system. If the above condition is seen , return load to safe position before
trying to rectify, as any attempt to connect the pipe after the vacuum is
applied may lead
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
LIFTING AND POSITIONING
1. Carry out pre-use check.
2. Position lifter on load within 40mm of centre of gravity.
3. Ensure all pads are in contact with the unit surface and all relevant pad shot off taps are ON
(in-line) and quick release fittings are correctly connected (extension arms only)
4. T urn the power ‘ON’
5. Press both vacuum actuation buttons on the remote control box until they click.
6. Ensure vacuum gauge reaches at least 65% and all warnings cease.
7. Carry out 50mm lift whilst observing vacuum gauge. Vacuum level should not suddenly drop
under load.
8. Check stability of load and lower and adjust if necessary .
9. When confident of stability of load and vacuum the load is raised and if required may now be
rotated and tilted to desired angle. Always ensure that there is sufficient space to rotate and tilt
the load
10. The load may now be banked into position and final adjustments to tilt and/or rotation carried
out by fixers .
11. If mains power is being used it is essential that the cable has an unobstructed pathway both on
the ground and in the air to prevent snagging which could lead to a violent arresting of the lifter
and potential loss of the load.
12. To release the load, both remote control buttons are lifted to release the vacuum then press the
red power switch and ensure all lights are off and vacuum gauges drop to ‘O’.
13. It is VERY IMPORTANT that the power switched to ‘OFF’. If the switch is left ‘ON’ the operating
solenoids will burn out.
14. The vacuum takes a few seconds to release, so it is vital that all pads are free before the crane
or hoisted is raised. This prevents any residual vacuum in the system from lifting the load whilst
no power is applied to the pump.
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

OPERATOR MANUAL | HYDRaulica 1200 www.hird.co.uk
TROUBLESHOOTING
Lifter fails to achieve 65% vacuum
1. Check whether all cups are in contact with the load .
Reposition cups if necessary
2. Check that nothing is stopping the vacuum lips on the cup from forming a seal. This may be
cork spacer pads, an outer lip that has curled under, etc.
Remove litter and check load and pads, reposition lifter
3. Check the hose clamps for security and tightness.
Tighten clamps, but only where necessary
4. Check the pipes for damage .
Contact Hird Ltd for pipe replacement
5. If after rectification the pump will still not achieve
65% vacuum contact Hird Ltd.
Pump fails to run when power switch is set to on
1. Check whether 25A circuit breaker S2 has tripped.
Press S2 to reset, located on top of function panel.
If 82 continually needs resetting there is a problem within the function panel. There are no
user serviceable parts within and the lifter must be returned to Hird Ltd for investigation
2. Check whether battery has sufficient charge.
Either recharge the battery or use the lifter on mains power.
3. If the lifter is on mains power, check the leads (and transformer if 110V)
Replace leads and/or transformer
4. If the lifter still does not function return to Hird Ltd for investigation
Mains operation not possible (POWER light does not Illuminate)
1. Check cables and site supply (and transformer if 110V)
Replace cables and transformer if necessary. Contact site service electrician about
restoration of power .
2. Check whether 2A circuit breaker S1 has tripped.
Press S1 to reset , located on top of function panel.
If 81 continually needs resetting there is a problem within the function panel.
There are no user serviceable parts within and the lifter must be returned to
Hird Ltd for investigation
3. If the lifter still does not function return to Hird Ltd for investigation
DSH2 VARIANTS HYDRAULICA VACUUM LIFTER
OPERATING AND MAINTENANCE MANUAL

PRE1120-2
Daily Pre-Use Checklist
Vacuum Lifter
Machine Model: Site Name:
Date Week Commencing: Fleet No: Address:
Inspected by:
Northern (Head Office) Tel: [phone]
Central Tel: [phone]
Western Tel: [phone]
Southern Tel: [phone]
www.hird.co.uk
PRE1120 Kappel Hydraulica 1200
Kappel Hydraulica 1200
Result of Inspections: List defects or state “No Defects”
Signature: Name: Date:
Daily Pre-use Checks M T W T F S S COMMENTS
1Are all operators manuals present and readable
2Is the Report of Thorough Examination (LOLER) in date
3Complete a visual walk around / Inspection for any noticeable defects
4Are all safety information decals present and readable
Check the following components or areas for damage, or missing parts & unauthorised modifications:
5Is the lifting attachment free from defects and safe to use
6Vacuum pads for rips, tears, quality and cleanliness
7Vacuum pipes and connections (in particular quick release fittings)
8All extension arms are present and free from defects
(where applicable)
9Make sure all individual pad shut off valves are open
(where applicable)
10 Electrical components, wiring, connectors,
11 Check input mains voltage corresponds with charger voltage
(110v or 240v)
12 Charger
13 Check battery has sufficient charge
14 Are rotation and tilting movements functional
15 Check handles security
16 Check remote for any damage or defects (where applicable)
17 Check operation buttons / switches are working and free from defects
18 Energise vacuum on non porus surface
19 Are lights and audible alarms on during vacuum process
20 Does the vacuum reach sufficient level, before switching off
(see gauges)
21 Does battery gauge illuminate when pump switches off
If NO - DO NOT USE
22 Check Safe Working load of vacuum - is it suitable for
the proposed load
23 Carry out full function test
Is the machine safe to use? (please circle)
YES YES YES YES YES YES YES
NO NO NO NO NO NO NO
Operator’s Initials