Austlift 915210, Service Manual

Page 1: ...SERVICE MANUAL WIRE ROPE INERTIA REEL BLOCK PC 915210 915220 915230 Lifting Your Business to A Higher Level 1300 100 120 www austlift com au AUSTRALIAN LIFTING CENTRE PTY LTD ...

Page 2: ...vice personnel duly endorsed by AUSTLIFT 3 This Service Manual is meant only to be a handbook for ready reckoning of the trained service provider for AUSTLIFT Retractable Fall Arrester Block 4 Once the block has been opened up for servicing by the authorized service personnel AUSTLIFT shall not be responsible for any damages mishaps whatsoever It shall be the duty of the service provider only to r...

Page 3: ... ALC SIM 915210 915220 915230_19 SERVICE MANUAL VOL 3 1300 100 120 WIRE ROPE INERTIA REEL BLOCK 915210 915220 915230 INDEX 4 13 22 Step Wise Illustrations Changing The Coil Spring Standard Torque Values ...

Page 4: ...Servicing of Plastic Aluminium Casing Wire Rope Retractable Fall Arrester AUSTLIFT Retractable Fall Arrester Block 1 Place the Block on the Service table with front side up 2 Ensure that the Allen head of the screw is facing up 3 Now peal off the sticker as shown in the above figure Remove the Main shaft screw by using 4mm Allen Key and place in a container as shown in the above Figure Main shaft ...

Page 5: ...ure that the Allen Head of the screw is facing up Remove the 4 screws one by one as shown in the figure above Now open the casing by just inserting a screw driver in between the two casing with one hand carefully holding the webbing assembly by the other hand to prevent it from abruptly moving out see figure above Casing Screw Wire Rope Assembly Screw Driver ...

Page 6: ...um Now take out the wire rope along with the Hook other Plastic parts from the slot of the Ratchet casing by just pulling it up lightly then release the tension of the spring by unwinding the drum in anti clock wise direction as shown in the above fig You will need to unwind approximately 4 to 5 turns until the drum is completely free of tension After relieving the tension turn the whole assembly ...

Page 7: ...10 915220 915230_19 SERVICE MANUAL VOL 3 1300 100 120 WIRE ROPE INERTIA REEL BLOCK 915210 915220 915230 STEP 7 STEP 8 Now peel off the sticker on the casing Remove the main Shaft screw using 4 mm Allen Key Allen Key ...

Page 8: ...e fig Try to pull out the Brass Brakes one by one using your fingers to check that all Brass Brakes are freely moving in and out the springs pulling them inwards are not worn or damaged If not replace them Ensure that there is no friction whatsoever between the Brass Brakes the pivot on which they rotate The springs should be intact in their position Ratchet Casing Springs Brass Brakes ...

Page 9: ...r opening 2 While loosening the screws if any screw is not able to loose stuck into the hole then we will not try to apply excessive force on allen as it will lead to deform the drive of grub screw 3 Fix the assembly in Three jaw chuck and with the help of chuck nut opening gauge try to move the chuck nut anticlockwise for a bit distance stop when cuck nut start moving 4 Now again use L Type Allen...

Page 10: ...RE ROPE INERTIA REEL BLOCK 915210 915220 915230 STEP 13 STEP 14 Remove the Chuck Nut Remove the Pressure Washer It is essential to replace this Washer Every time you service a Retractable So it would be better to discard it and get a new one in its place Pressure Washer Chuck Nut ...

Page 11: ... wire from the drum and check the entire length for any damages or abrasion marks In case of any doubt about the condition of wire rope replace it with a new one It is not necessary to replace the wire rope assembly every time you service a block Now assemble it backwards doing the opposite of Step 15 14 and Step 13 i e putting back New Aluminium shim washer the New Friction Plate then the Brake P...

Page 12: ...ue indicate in the standard torque chart If not continue to tighten the chuck nut further by 100Kgf cm each time measuring the achieved torque until the measured value will be as indicated on standard torque chart Measuring the Brake Plate Torque It should be as per value indicate in the standard torque chart page No 22 Caution Ensure that the tightening by Torque Wrench is done as smoothly as pos...

Page 13: ...p Lock Retaining Ring by using the external Circlip Plier as shown in above figure Caution When the Circlip Lock Retaining Ring is to be opened the spring will bounce back hence slide your hand in to the cover and open it very carefully as shown in the above figure CHANGING THE COIL SPRING In case the Coil spring is damaged or broken it needs to be replaced following Step 19 to Step 32 External Ci...

Page 14: ... cover as shown in the above fig ensuring that the spring is held downwards using your other hand Spring Cover Holding the Spring down with your hand STEP 22 Quickly put the Safety Bar on the Spring while tightening the Safety Bar Allen Bolt into the main shaft with 5mm Allen Key to prevent the spring from coming out accidently Safety Bar Allen Screw ...

Page 15: ...ng fixture as shown above and Pull out the wire to check if the spring is broken Changing the damaged coil spring After pulling out the wire put the Stopper Block as shown in the fig near to the coil spring screw to create the gap release the wire to achieve the rest position of spring Caution Be careful while handling the coil spring Stopper Block Clamping Fixture ...

Page 16: ... MANUAL VOL 3 www austlift com au WIRE ROPE INERTIA REEL BLOCK 915210 915220 915230 STEP 25 STEP 26 Hold the spring with the help of a Tool Maker Clamp Remove the safety bar with the help of 5 mm Allen key Allen Key Defective Wire rope Assembly ...

Page 17: ... VOL 3 1300 100 120 WIRE ROPE INERTIA REEL BLOCK 915210 915220 915230 STEP 27 Pull the spring with the help of Tool Maker Clamp STEP 28 Open the coil spring screw nut with the help of 8mm Ring Spanner and 3mm Allen Key as shown above Spring Screw Nut ...

Page 18: ...end of the spring inside the drum and tighten with the help of screw nut using 3mm Allen Key and 8mm Ring Spanner Apply Resi Quick Put the Coil Spring inside the drum with the help of Tool Maker Clamp and insert the bend of spring into the slot of the shaft Immediately put the safety bar then release the spring Caution Be careful while handling the coil spring Open End of the Spring ...

Page 19: ...out the whole wire as shown in the above fig to create adequate gap between the coil spring and housing Holding the Spring down with your hand STEP 32 Put the Circlip Lock Retaining Ring by using External Circlip Plier and tighten the 6 Nos of CSK philip head screws of the spring cover one by one CSK Philip Head Screws Circlip Lock ...

Page 20: ...RE ROPE INERTIA REEL BLOCK 915210 915220 915230 STEP 33 STEP 34 Put 2 or 3 washers to maintain the clearance between the casing and the Assembly Put the Ratchet Casing over the Break Plate Assembly as shown in the above figure Tighten the main shaft screw using the 4mm Allen Key ...

Page 21: ...ut the wire rope along with the hook other Plastic parts in the slot of the Ratchet casing then tension the spring by winding the drum in clock wise direction as shown in the above figure Give 4 to 5 turns and check that appropriate retraction tension has been achieved Direction of winding STEP 36 Put 2 washers on the shaft place the Plain casing on the drum Anchorage Eye ...

Page 22: ...NUAL VOL 3 www austlift com au WIRE ROPE INERTIA REEL BLOCK 915210 915220 915230 STANDARD TORQUE VALUES WIRE ROPE INERTIA REEL RANGES Torque as Per EN NORM 915210 10M 1400 KGF CM 915220 20M 1900 KGF CM 915230 30M 1200 KGF CM STANDARD TORQUE VALUES ...

Page 23: ... to change without notice 1300 100 120 AUSTRALIAN LIFTING CENTRE www austlift com au Head Office NSW 43 Frank Street Wetherill Park NSW 2164 Ph 02 9757 2277 WA Office 42 Mulgul Road Malaga WA 6090 Ph 08 9248 6674 VIC Office 475 Dohertys Road Truganina VIC 3029 Ph 03 9314 5525 QLD Office 7 Durbell Street Acacia Ridge QLD 4110 Ph 07 3272 0777 ...