Backsaver Cranes

Transcription

Backsaver Cranes

Owner’s Manual
Backsaver Crane – Mark II with Extendable Boom (300kg & 500kg)
300kg models
500kg models
advansa
Advansa Pty Ltd 258 Halifax Street, Adelaide SA 5000
(T) +61 (0)8 8243 9100 (F) +61 (0)8 8243 9185
Email: [email protected]
Web: www.advansa.com.au
Toll Free Sales: 1 300 135 935
Backsaver Crane Owner’s Manual
1
Contents:
Warranty
Backsaver Cranes – Options available
Safety Information
300kg Backsaver Crane
Spare Parts List
Exploded View
500kg Backsaver Crane
Spare Parts List
Exploded View
Backsaver Crane Assembly / Operating
Bolt-down Specs
Component Weights
Vehicular Installation
Superwinch S4000 and S5000
Assembly of Superwinch mounting plate to Crane
8000 series Brake Winch Specifications
Attaching Handle
Spare Parts Listing
Front and Side Elevation, Bolt Down Specifications
General Theory of Operation
Installing the Winch
Installing wire cable /fibre rope
Preparing for Operation
Attaching the Load
Moving the Load
Cleaning the Winch
Lubricating the Winch
Inspecting the Winch
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3
4
5
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6
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Warranty
Please note that all goods are supplied by Advansa Pty Ltd to the Purchaser for use only in applications and purposes
for which they were originally designed. Advansa Pty Ltd is not liable for any consequential loss whatsoever from
improper or inappropriate use of the goods supplied, where the goods are used for purposes beyond or outside of the
scope of application for which they were designed and which exceeds their designed performance limit. At all times
please consult Advansa Pty Ltd if unsure of the suitability of the goods for your intended application.
Advansa Pty Ltd Winch Warranty Policy: The Warranty is for the period of twelve months on Jarrett winches /
cranes providing it is used for the purpose that it was designed for. Any modifications or misuse of the winches /
cranes will void the warranty. Winches / cranes will be repaired under warranty providing proof of purchase is supplied.
No credits or replacements will be issued except with approval from Advansa Pty Ltd.
Jarrett Winches and Cranes are not intended for the movement of people
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Backsaver Cranes: - Options available
Backsaver Crane – Mark II with Extendable Boom (300kg) with F18230/5 Brake Winch
F12643
– Backsaver Crane 300kg with Cable
F12643R
– Backsaver Crane 300kg with Fibre Rope
F12643G
– Galvanised Backsaver Crane 300kg with Cable
F12643GR
– Galvanised Backsaver Crane 300kg with Fibre Rope
F12696E12
– Backsaver Crane 300kg with Electric Winch - Superwinch S4000 12V
F12696E24
F13643W
– Powder coated white Backsaver Crane 300kg with Cable
F13643WR
– Powder coated white Backsaver Crane 300kg with Fibre Rope
Backsaver Crane – Mark II with Extendable Boom (500kg) with F18260/5 Brake Winch
F19001
– Backsaver Crane 500kg with Cable
F19001R
– Backsaver Crane 500kg with Fibre Rope
F19001E12
F19001E24
F19001CW
– Powder coated white Backsaver Crane 500kg with Cable
F19001CWR
– Powder coated white Backsaver Crane 500kg with Fibre Rope
F12643 Backsaver Crane mounted on
Holden Utility vehicle
F13643W Backsaver Crane mounted on wharf
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Important Safety Information
DO the following:
Read carefully and comply with the guidelines set forth in the Owner’s Manual.
Keep hands away from the drum, gears, wire cable, and other moving parts of the equipment.
Install the wire cable securely to the winch drum.
Ensure at least 3 turns of wire cable wound on the drum at all times, to serve as an anchor wrap.
Keep all unnecessary personnel away from the winch while in operation.
Keep out of the path of the load should the wire cable break and snap back and cause injury.
DO NOT do the following:
Do not lift people, or objects over people. Do not walk or work under a load or in the line of force of any load.
Do not exceed the load rating of the winch or any other component in the system. To do so could result in failure of
the equipment.
Do not use more than one winch to move a load that exceeds the load rating of a single winch. A shift in load weight
could overload the equipment.
Do not use damaged or malfunctioning equipment. To do so could result in failure of the equipment.
Do not modify the equipment in any way. To do so could cause equipment failure.
Do not apply a load on the winch with the wire cable / fibre rope fully extended. Keep at least three full turns of cable
/ fibre rope on the drum.
Do not wrap the wire cable / fibre rope around the load. This may damage the wire cable / fibre rope and could cause
the load to slip / fall. Use a sling or other approved lifting device.
Do not operate the winch with covers / guards removed or improperly installed.
Do not divert your attention from the operation. Stay alert to the possibility of accidents, and try to prevent them from
happening.
Do not jerk or swing the load. Avoid shock loads by starting and stopping the load smoothly. Shock loads overload the
equipment and may cause damage.
Do not leave a suspended load unattended unless specific precautions have been undertaken and keep people away
from the winch and out from under the load.
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Backsaver Crane – Mark II with Extendable Boom (300kg)
The Jarrett Backsaver Crane is fitted with 3600
mechanical slewing by means of a worm drive
gear. This eliminates the danger of the crane
boom swinging out of control when the load is
taken up. The boom can only be rotated (slewed)
by operating the slewing control handle. This
important safety feature keeps the load under
control at all times – essential for one person
operation.
With a choice of two models, the Backsaver
Crane suits a host of reach and lift requirements.
With an extendable position action, all cranes have
a boom reach of over 1 metre at their 300kg and
500kg lift positions. Both models have a choice of
boom angle settings for even greater adaptability.
If it’s got to be lifted, do it the easy way, with a
Jarrett Backsaver Crane.
Models (refer to page 2 for complete listing):
F12643 – Backsaver Crane 300kg
F12643G – Galvanised
F12696Exx – Electric Winch - Superwinch S4000
F13643W – Powder coated white
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Spare parts listing for Backsaver Crane – 300kg
Exploded view of the F12643 (300kg) Backsaver Crane
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Backsaver Crane – Mark II with Extendable Boom (500kg)
The simple design of the Backsaver Crane means
it is easy to assemble and can be fitted almost
anywhere – to jetties, utes or tray tops and to a
wide variety of fixed platforms. When a Backsaver
Crane is vehicle mounted and the time comes to
change vehicles, it is simple to remove and leaves
only four holes. The Backsaver Crane is then ready
to install elsewhere. The Backsaver Crane’s simple
operation means that little can go wrong and
service support is available through Jarrett
Spare Parts distributors around Australia.
The Backsaver Crane provides the perfect lifting
solution to tradesmen, farmers, delivery drivers
and anyone who has to lift loads of anything
from fuel drums, jet skis, small boats, motor
bikes, car engines, ride-on-mowers, cement
mixers, farm machinery, livestock, fence, brick
cutters and even tractor tyres – the
possibilities are endless. In fact if you have
ever thought, “There’s got to be a better way”,
Models (refer to page 2 for complete listing):
chances are that Jarrett has already found it.
F19001 – Backsaver Crane 500kg
F19001Exx – Electric Winch - Superwinch S5000
F19001CW – Powder coated white
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Spare parts listing for Backsaver Crane – 500kg
Exploded view of the F19001 (500kg) Backsaver Crane
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Backsaver Crane Assembly and Operating Instructions
1.
2.
3.
4.
5.
6.
Ensure the unit is correctly anchored via the base-plate to the operating platform.
Attach the boom to the post with the pivot pin and support pin.
Ensure the spring clips are fitted to the pivot pin and to the support pin.
Bolt the winch to the boom using 4ea M10 bolts, nuts and washers.
Thread the winch cable and hook it through the slot at the front of the boom.
Attach the pulley to the boom with the pulley pin and spring clips.
Please note: The Post and Base of the 500kg Backsaver Crane cannot be separated for installation
Operation
1.
2.
3.
4.
5.
6.
7.
8.
9.
Ensure that the operating platform is steady. If the unit is vehicle mounted then it should be positioned on a stable
and horizontal surface with neutral or park gear selected.
Release the hook from the base of the crane.
Rotate the boom by turning the slewing handle until the hook is positioned directly over the load. (NEVER
ATTEMPT TO LIFT THE LOAD WITHOUT THE BOOM BEING POSITIONED DIRECTLY OVER THE LOAD)
Attach the hook securely to the load.
Standing clear of the load, raise the load by turning the winch handle clockwise.
When the load is at the desired height, slew the load to the required position.
Lower the load by turning the winch handle anticlockwise.
If the load has been lowered onto a vehicle tray then the load should be secured. (DO NOT TRAVEL WITH LOAD
ATTACHED TO THE CRANE)
Secure the hook into one of the four braces and take up the slack in the cable to secure the boom.
Maintenance – Backsaver Crane
1.
2.
Clean and lubricate the following as required with appropriate grease:
● Winch gears and pinion threads
● Slewing worm and handle
● All bushes
● Pivot pin
● Winch cable
● Base tube
Inspect the gears, bushes and cable monthly for wear and replace as required.
Backsaver Cranes – Bolt-down plate specs.
Miscellaneous Notes:
Vertical distance from top of U-plate
to the underside of the safety hook
(with the ferrule against the pulley)
= 240mm
300kg & 500kg Backsaver Crane:
When not in use – secure the hook in
one of the four braces.
500kg Backsaver Crane:
Crane Post and Base cannot be
separated for installation.
Backsaver Cranes – Component weights (approx)
Winch – 7kg
Inner and Outer Boom – 26kg
Post and Base section – 40kg (300kg BSC) - 55kg (500kg BSC)
Boom Support Bar (F19001 – 500kg series) – 3 kg
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Vehicle installation of Backsaver Crane (300kg and 500kg)
To provide a minimum safety factor at the crane’s maximum capacity (jib in short position), the general mounting
arrangement (expected to provide good long term service) should consist of the following additional components and
conditions:
1.
2.
3.
4.
2 ea. 100mm x 10mm x 450mm long steel plates drilled appropriately to suit crane base plate bolt pattern (see
previous page).
4 ea.M16 HH 8.8 bolts with ferrule spacers on each bolt to take up the bolt shank to mounting hole clearance with
M16 nylocs.
Large above floor washers (M16) are used under the bolt heads.
The under floor plates must sit flat against the underside surface.
The Jarrett Backsaver Crane has a large mounting base that sits flat on the vehicle floor and is anchored to the floor
with 10mm flat under floor plates. Each plate is mounted transversely across the full width of the main crane base
(above the floor) and is not less than 100mm wide.
Due to the nature of mounting through corrugated floor structure it is recommended that regular inspection is
undertaken to ensure that the mounting stay secure and no cracking of the floor become evident.
Mountings on vehicle tray top (L) & underside (Above)
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Superwinch S4000 & S5000
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Assembly of Superwinch Mounting Plate to Jarrett Backsaver Crane
Work Instruction for Winch Electric Adaptor Plate Fitment for Jarrett Backsaver Crane
1.0
1.1
1.2
2.0
2.1
2.2
UNPACKING
Open the plastic bag and confirm that it contains the following items - see photo number 1 below.
•
Nut nyloc M10 X 1.5 6 off
•
Bolt M10 X 1.5 X 30mm Socket head cap 2 off
•
Bolt M10 X 1.5 X 35mm Counter sunk socket head cap 4 off
•
Spacer crane mounting 4 off
•
Instruction sheet for electric winch installation
•
Plate crane winch mounting
You will need two 17 mm spanners and a 6 mm Allen-key to assist with the assembly.
INSTALLATION
Having assembled the crane take the electric winch adaptor plate (unpacked in 1.1 above) and lay the plate on the manual
winch mounting plate with the countersunk holes on top. Push the four counter sunk head bolts through counter sunk holes
in the plate from the top – see photo number 2 below.
Lift each counter sunk head bolt and insert a spacer, onto each bolt, in the section between the plates – see photo number
3 below. Secure the mounting plates together with the aid of the M10 Nyloc nuts (4) see photo number 4 below.
Photo No 1
Photo No 2
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Work Instruction for Winch Electric Adaptor Plate Fitment for Jarrett Backsaver Crane cont.
Photo No 3
2.3
2.4
Photo No 4
The mounting plate is now ready for the winch to be attached.
Photo number 5 below shows the orientation of the bolts used to fit the electric winch.
Photo No 5
Please record the following:
Date Purchased: _______________
Where Purchased: ____________________________
Backsaver Crane:
Model No: ____________________
Serial No: ______________________
Winch:
Model No: ____________________
Serial No: ______________________
This information (and receipt) is required should a warranty claim be necessary.
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8000 Series Brake Winch
5:1 / 10:1 ratio models (300-500kg) – available for Backsaver Cranes
Backsaver Crane
F12643
(300kg)
F19001
(500kg)
Cable
Fibre Rope
F18230
F18235
F18260
F18265
Gear Ratio
5:1
10:1
Application
Lifting
Lifting
Rated Capacity
300kg (2940N)
500kg (4900N)
Mass (Winch only)
6kg
6kg
Type of Brake
Self Actuating
Self Actuating
Drum Diameter
Flange Diameter
Drum Width
50mm
130mm
52mm
50mm
130mm
52mm
Cable size
Fibre Rope size
Max. Cable capacity
Max. Fibre Rope capacity
Ø5mm
Ø6mm
15m x Ø5mm
12m x Ø6mm
Ø6mm
Ø6mm
12m x Ø6mm
12m x Ø6mm
Max. Effort on handle
at Rated Load
26kg
18kg
Winch Model:
Cable Breaking Strain
1855kg
Fibre Rope Breaking Strain 2050kg
2712kg
2050kg
Cable (Galv) as supplied
Fibre Rope as supplied
Fastening Device
7.5m x Ø6mm
7.5m x Ø6mm
Snap Hook
7.5m x Ø5mm
7.5m x Ø6mm
Snap Hook
F18230
Notes:
Features include:
Heavy duty 4mm winch body, Steel bushes, Self actuating brake mechanism, Fully enclosed brake, Spare parts
available, Electroplated zinc cobalt, Powder coated finish, Detachable handle
F18230 is used on 300kg Backsaver Crane – Product Code: F12643
F18260 is used on 500kg Backsaver Crane – Product Code: F19001
Recommended for lifting applications.
Note: Common user problem with this range of winches is the brake
mechanism does not work when first assembled. When packaged, the
winch and handle are separate and need to be assembled as per the
instructions included. (see below and next page).
Handle Assembly is:
The handle adaptor is turned clockwise until the ratchet is engaged
prior to attaching the handle and securing with screw.
Self actuating brake requires a minimum of 18kg to operate safely.
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F18260
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Attaching handle to the 8000 Series Brake Winch
Note: Handle instructions (below) are included in packaging
ADVANSA PTY LTD©
CAUTION: ATTACH HANDLE TO WINCH USING EASY STEPS BELOW.
STEP 1:- TURN HANDLE ADAPTOR CLOCKWISE UNTIL RATCHET HAS ENGAGED.
STEP 2:- ATTACH THE HANDLE ONCE THE RATCHET HAS ENGAGED
SHOULD ANY DIFFICULTIES BE ENCOUNTERED, PLEASE CONTACT OUR CUSTOMER SERVICE DEPARTMENT ON +61 8 8243 9100
An F18260 Brake Winch mounted on
a F19001 Backsaver Crane
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8000 Series Brake Winches - Spare parts listing
F18210, F18220, F18230, F18235, F18240, F18260, F18265, F18280
Front and side elevation, and bolt-down specifications / dimensions
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General theory of winch operation
Important !
Limit non-uniform winding by keeping tension on the wire cable.
It is the operators responsibility to detect and account for different factors affecting
the condition and performance of the equipment.
The pull required to move the load must not exceed the load rating of the winch. Consider the total force required to move the load, not the weight of
the load.
The winch can develop forces that will exceed the load rating. It is the responsibility of the winch operator to limit the size of the load. Inspect the
winch regularly for damage according to the instructions contained in the Owner’s Manual.
Performance ratings of the winch are affected by the amount of wire cable wound onto the drum, the way in which it is wound, and the way the
winch is used.
Drum capacity depends on how tightly and evenly the wire cable is wound onto the drum. Actual drum capacities are usually 25-30% less than the
values shown in performance tables, due to loose winding and overlapping.
Load rating represents the maximum pull that can be placed on a new winch. Load ratings are assigned values for specific amounts of load travel or
wire cable accumulation. The load rating decreases as layers of wire cable accumulate on the drum.
Duty ratings refer to the type of use the winch is subject to. Consider the following when determining duty rating.
Environment: harsh environments include hot, cold, dirty, wet or corrosive surroundings. Protect the winch against harsh environments
when possible.
Maintenance: poor maintenance, meaning poor cleaning, lubrication or inspection, leads to poor operation and possible damage of the
winch. Minimise poor maintenance by carefully following the instructions contained in the Owner’s Manual.
Loading: severe loading includes shock loading and moving loads that exceed the load rating of the winch. Avoid shock loads, and do not
exceed the load rating of the winch.
Frequency of operation: frequent or lengthy operations increase wear and shorten the life span of gears, bushes, and other
components. Increase maintenance of the winch if used in frequent operations.
Installing the Winch
Important !
Inspect the winch immediately following installation. This will give provide a record of
the condition of the winch from which to compare future inspections.
Warning
Do not install the Backsaver Crane near corrosive chemicals, flammable materials or other elements that
may damage the winch or injure the operator. Adequately protect the winch and operator from such
elements.
Position the Backsaver Crane so the operator can stand clear of the load, and out of the path of possible
broken wire cable that could snap back and cause injury.
Attach the Backsaver Crane to a rigid and level / flat foundation that will support the winch and its load
under all load / unload conditions, including shock loading. (For Backsaver Crane assembly – see page
8. For vehicular installation – see page 9. )
Fasten the winch securely to the Backsaver Crane winch mounting plate, utilising all four mounting holes to ensure maximum capacity. 4ea. M10
galvanised or G316 stainless steel bolts, flat and spring washers and nuts should be used to secure the winch to the outer boom.
Installing wire cable / fibre rope onto Jarrett winches
Important !
•
•
•
Use wire cable and other rigging equipment rated for the capacity of the winch.
Do not drag the wire cable through dirt or debris that could cause damage, or poor operation.
Always wear protective clothing when handling wire cable.
•
Install the wire cable securely to the winch drum. A poorly secured wire cable could come loose
from its anchor and could release the load.
Ensure the wire cable is wound correctly or the winch may not work properly and could release the load.
Always ensure that a minimum of three full turns remain on the winch drum at all times.
•
•
Where wire cable / fibre rope is not supplied or is to be replaced, purchase the proper wire cable / fibre rope for your application.
Keep the following in mind when selecting. Contact a reputable supplier for assistance.
Breaking strength of new wire cable / fibre rope should be at least 2 times greater than the rating of the winch.
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Wire cable lay must agree with the winding direction of the drum to insure proper winding.
Secure the wire cable / fibre rope to the winch drum as per the securing instructions below.
Test the wire cable / fibre rope installation by operating the winch.
Wind three full turns of wire cable onto the drum by operating the winch whilst holding the wire cable taut. These turns serve as an anchor wraps and
must remain on the drum at all times.
Dependant on Winch model, two securing methods for cable are applicable:
Instruction for securing a cable to a winch using a plate clamp fitting
1.
2.
Tape the cable end using 50mm – 70mm of plastic tape. This is to stop the cable end from fraying and causing injury in use.
Fold the end of the cable (approximately 30mm) back on itself and permanently kink the end.
3.
Feed the taped end of the cable through the round hole of the drum flange (disc)
from inside the drum.
Place one of the cup head bolts into Hole 1 of the clamp fitting, with the head on the inside of
the drum assembly, and pull the cable tight against the bolt. Attach the nut and tighten.
Align the second hole in the plate with Hole 2, and secure with the second bolt and nut.
4.
5.
Instruction for securing a cable to a winch using a single bolt fitting
1.
2.
3.
4.
5.
6.
Place the cup headed bolt into the square hole with the head on the inside of the drum assembly.
Screw on the combination nut and washer only 2-3 threads.
Tape the cable end using 50mm – 70mm of plastic tape. This is to stop the cable end
from fraying and causing injury in use.
Feed the taped end of the cable through the round hole of the drum flange (disc) from inside the drum
and double back to loop the cable under the bolt, behind the washer and back towards the round hole.
While holding the cable in place under the nut with the left hand, pull the cable tight with the right hand.
Using the thumb of the left hand hold the cable in place inside the drum and tighten the nut to secure
the cable in place.
View from outside the drum
showing cable flow
Turn the handle to wind the wire cable onto the winch drum. Uniformly wind the wire cable onto
the winch drum by holding the wire cable taut.
Instruction for securing fibre rope to winch – Note: Fibre rope to be ≤ Ø7mm
1.
2.
3.
4.
5.
6.
Take the winch drum with the gear facing the assembler and the free end of the rope and wrap three turns around the hub of the drum in an
anticlockwise direction.
Take the free end and pass it between the three turns and the drum hub and then pass the free end over the three turns on the drum and under
the last turn.
Pass free end of the rope under the last bite and through the ‘cable’ hole in the flange. Pull firmly so that the turns on the drum lie reasonably flat.
The length protruding needs to be about 150mm.
Insert from inside the drum flange (centre hole) the M6 square neck cup head bolt and screw the M6 flanged serrated hexagon nut onto the bolt.
Wrap the rope around the M6 bolt inside the flanged serrated hexagon nut. Secure the fibre rope by tightening the nut using an M6 spanner.
When securing, ensure that the rope fibres do not catch on the bolt threads and that the rope stays inside the flanged section. Trim any excess
rope.
The turns around the drum will have become loose. Work the turns so that the rope lays flat against the hub and there is no slack.
Preparing for Operation
Important !
When determining whether the load will exceed the load rating, consider
the total force required to move the load.
Consider the operation. Do not begin until you are sure you can perform the entire operation without hazard.
Inspect all components of the system.
Inspect the winch and other equipment in accordance with Inspection instruction.
Operators should be in good health, alert and suitably clothed (i.e. no loose clothing)
The load must be clear of objects and free to move. Ensure the load will not tip, spin, roll away, or in any way move uncontrollably.
Know your load and make sure you do not exceed the load rating of the winch or any other equipment in your system.
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Attaching the Load
Warning
Do not wrap the wire cable / fibre rope around the load. This may damage the wire cable / fibre
rope and could cause the load to slip / fall. Use a sling or other approved lifting device.
Clear objects from the path of the load so you can move it freely and observe it at all times during the operation.
Attach the load using a nylon sling, or other approved rigging device. Follow the recommendations of the sling manufacturer.
Seat the sling in the saddle of the snap hook with the hook latch completely closed. The winch drum is operated slowly to retrieve the slack cable. When
the cable is taut, check to ensure the sling is correctly positioned in the snap hook prior to moving the load.
Centre the load on the hook so it will remain balanced and not tip or rotate to one side.
Moving the Load
Important !
•
•
•
•
•
Obey a stop signal from anyone.
Maintain tension on the wire cable to keep it tightly and evenly wound on the drum.
If the winch and load are not visible during the entire operation, get help from another person.
Appoint a supervisor if more than one person is involved in the operation. This will reduce confusion and increase safety.
Where possible, remove the handle when the winch is not in use, to help avoid unauthorised use.
Move the load slowly and smoothly, only a small distance at first. Make sure the load is balanced and securely attached before continuing.
Observe the wire cable as it winds onto the drum. If it becomes loose. Uneven, or overlapped, stop the operation and rewind before continuing.
Continued operation with overlapped or uneven wire cable can damage and shorten its life.
Cleaning the Winch
Important !
Increase the frequency of maintenance procedures if the winch is:
•
Operated for long periods.
•
Used to pull heavy loads.
•
Operated in wet, dirty, hot or cold surroundings.
Clean the winch to remove dirt and help prevent rust and corrosion.
Clean the winch every three months or whenever it is dirty.
Wipe all components to remove dirt and grease.
Leave a light film of oil on all surfaces to protect them against rust and corrosion.
Ensure no lubricant comes in contact with the brake discs (mechanism)
Wipe off excess amounts of oil to avoid accumulation of dirt.
Remove all unnecessary objects from the area surrounding the winch.
Lubricating the Winch
Important !
Make sure the lubricant has a temperature rating appropriate for the ambient temperatures of the operation.
Lubricate the winch properly to help protect it from wear and rust.
Ensure no lubricant comes in contact with the brake discs (mechanism)
Lubricate the winch at least every three months, by applying a light grade oil to the drum shaft and bushes. Rotate the drum several times to allow oil to
penetrate, and wipe off excess oil to avoid dirt accumulation.
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Inspecting the Winch and other associated equipment
Important !
Keep written records of inspection. This allows comparison with comments from previous inspections so
you can see changes in condition or performance
Warning
Do not use damaged or malfunctioning equipment. Seek immediate repair.
Inspect the winch to detect signs of damage or poor operation before they become hazardous.
Instructions – Frequent Inspection
Perform frequent inspections:
•
Before each operation.
•
Whenever you notice signs of damage or poor operation
VISUALLY INSPECT the entire crane / winch and all other associated equipment involved in the operation.
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•
•
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Check all equipment for cracks, dents, bending, rust, wear, corrosion and other damage.
Check gears, pinions and pawl for wear, and other damage.
Make sure the wire cable is installed correctly and anchored securely to the drum
Make sure the winch is properly lubricated.
Make sure the handle is securely held in place.
Make sure the mounting fasteners are tightened securely
Make sure the foundation is in good condition, and capable of supporting the winch and its load under all load conditions.
TEST WINCH PERFORMANCE by moving a test load equal to 10% of the rated capacity.
•
•
•
•
Listen for unusual noises, and look for signs of damage as you operate the winch.
Make sure the winch cable winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing.
Make sure the handle moves freely in both directions.
Make sure the pawl (ratchet) engages and disengages completely.
Completely correct all problems before continuing. Use the Troubleshooting Chart (at end of this Section) to help determine the cause
of certain problems.
Instructions – Periodic Inspection
Perform periodic inspections:
•
Every three months.
•
Whenever you return the winch to service from storage.
•
Whenever you notice damage or poor operation in a frequent inspection.
•
Whenever you have, or think you may have, overloaded or shock loaded the winch.
Visually inspect the entire winch and all other associated equipment involved in the operation.
•
•
•
•
•
•
•
•
Check the finish for wear, flaking, or other damage.
Check all equipment for cracks, dents, bending, rust, wear corrosion and other damage. If the equipment was overloaded, or if you notice cracks
and other signs of overloading and damage, promptly remove the equipment from use and have it repaired or replaced. Do not continue to use
the damaged or overloaded equipment.
Inspect friction plates/pads and mating surfaces for contamination, dust, corrosion and wear. If necessary, lightly remove surface contamination,
etc. REPLACE friction plates/pads if excessive wear (to 1mm thick) is evident or are either cracked or broken.
Check all fasteners for stripped threads, wear, bending, and other damage.
Check gears, shafts and bushes for wear, and other damage.
Check the foundation for cracks, corrosion, and other damage.
Make sure the winch is properly lubricated.
Make sure all labels and plates are readable, firmly attached, free from damage and clean.
If your winch installed with fibre rope:
Unwind the fibre rope completely.
•
Check the entire length of fibre rope for excessive wear, chafing, cuts, dirt and grit,
and other damage.
THEN
•
Make sure the snap hook is securely attached to the fibre rope.
•
Check the throat opening, thickness, and twist of the snap hook. Replace the hook if
it shows signs of damage. See figure 2.
•
Make sure the hook latch opens without binding and closes when released.
•
Check the anchor holes in the drum flange, clamp fittings and bolts for signs of wear or distortion.
If your winch installed with wire cable:
Remove the wire cable entirely from the drum.
•
Always wear protective clothing when handling wire cable.
(T) +61 (0)8 8243 9100
(F) +61 (0)8 8243 9185
•
•
•
•
•
•
•
20
Check the entire length of wire cable for bent wires, crushed areas, broken or cut wires,
corrosion, and other damage. Carefully inspect areas that pass over sheaves or through
roller guides.
Note the location and concentration of broken wires. Replace the wire cable if more than 6 wires are
broken in one lay, or more than 3 wires are broken in one strand in one lay. See Figure 1.
Make sure the snap hook is securely attached to the wire cable, and the wire cable where it is
attached is not frayed, corroded, broken, or otherwise damaged.
Check the throat opening, thickness, and twist of the snap hook. Replace the hook if it shows
signs of damage. See figure 2.
Make sure the hook latch opens without binding and closes when released.
Check the anchor holes in the drum flange, clamp fittings and bolts for signs of wear or distortion.
Measure the diameter of the wire cable, especially in areas where wear is noticeable. Replace the wire
cable if the diameter measures below the minimum diameter at any point. See figure 3.
REMOVE THE WINCH from the winch mounting plate of the Backsaver Crane.
•
•
Check fasteners for stripped threads, wear, bending, and other damage.
Check the frame (winch body) for bending, distortion, cracks, and other damage. A bent frame is
caused by overloading, and is a sign that your application may require a winch with a larger load rating.
MOVE THE DRUM with your hands.
•
•
Check for excessive movement indicating worn or loose gears, bushings, or shafts.
Disassemble the winch if necessary. Inspect gears, pins, springs and shafts for wear,
corrosion, distortion, and other damage
FASTEN THE WINCH securely to the winch mounting plate of the Backsaver Crane.
INSTALL THE WIRE CABLE.
TEST WINCH PERFORMANCE by operating the winch with a test load equal to the load rating.
•
•
•
•
Listen for unusual noises, and look for signs of damage as you operate the winch.
Make sure the winch cable winds evenly and tightly onto the drum. If it is loose or
uneven, rewind it before continuing.
Make sure the handle moves freely in both directions.
Make sure the pawl (ratchet) engages and disengages completely.
Completely correct all problems before continuing. Use the Troubleshooting Chart (below) to help determine the cause of certain
problems.
Troubleshooting Chart
problem
cause
correction
handle turns, drum doesn’t turn
• loose or broken pins
• loose, stripped or broken gears
inspect winch, repair as necessary
inspect gears and repair as necessary
handle turns hard or not at all
•
•
•
•
•
brake does not operate properly
• friction discs worn or damaged
• friction discs damaged from lubrication
• disc brake ratchet pawl damaged
inspect and replace as necessary
inspect and repair as necessary
excessively worn gears or bushes
• load too heavy
• poor lubrication of gears or bushes
lighten load
inspect and relubricate as necessary
overheating
•
•
•
•
unusual noises
high pitched squeak
grinding noise
rattling noise
gears broken or locked
load too heavy
pins loose or broken on winch
drum shaft broken or seized
brake disc damaged or locked
operated too long without rest
load too heavy
poor lubrication
bushings seized up / damaged
• poor lubrication
• contaminated lubrication
• loose bolts, or other fasteners
inspect and repair as necessary
lighten load
inspect winch, repair as necessary
inspect, repair or replace as necessary
inspect brake, repair as necessary
allow to cool
lighten load
inspect and lubricate as necessary
inspect and lubricate as necessary
clean and relubricate winch
tighten all bolts and other fasteners
(T) +61 (0)8 8243 9100
(F) +61 (0)8 8243 9185

Backsaver Cranes

Transcription

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