DB Industries 8101006, 8101002, 8101004, 8101101, 8101103 User Instruction Manual

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User Instruction Manual

Salalift® and Salalift® II Winches

8101000 and 8102001 Series

This manual is intended to meet industry

standards, including OSHA 1910.146 and

ANSI Z117.1, and should be used as part

of an employee training program as

required by OSHA.

WARNING: This product is to be used as part of a complete system. T he

user must follow the manufacturer's instructions for each component of the complete system. These instructions must be provided to the user of this equipment. Manufacturer's instructions must be followed for proper use and maintenance of this product. Alterations or misuse of this product, or failure to follow instructions may result in serious injury or death.

IMPORTANT: If you hav e questions on the use, care, application, or

suitability for use of this safety equipment, contact DBI/SALA.

IMPORTANT: Bef ore using this equipment record the product identification

information from the ID label on the winch in the inspection and maintenance log in section 9.0 of this manual.

The 8101000, 8101002, 8101004, and 8101006 Salalift Series Manually Operated Winches are classified b y Underwriters Laboratories, Inc. as to the 350 lbs. load capacity only.

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DBI SALA 8304000 Sealed SRL Salalift Tripod Confined Space Entry Kit DBI SALA 8304010 Sealed SRL Salalift II Confined Space Kit DBI SALA 8304011 Sealed SRL Salalift II Confined Space Kit DBI SALA 8300020 Confined Space Entry Salalift II Winch Tripod 60 Ft DBI SALA 8300030 Confined Space Entry Salalift II 60Ft Winch 7' Tripod

Figure 1 - 8101000 Series Parts Identification

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Figure 2 - 8102001 Series Parts Identification

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DESCRIPTIONS

SALALIFT® Winches: 8101000: 60 feet of 1/4 inch galvanized wire rope, carrying bag. 8101002: 60 feet of 1/4 inch stainless steel wire rope, carrying bag. 8101004: 120 feet of 1/4 inch galvanized wire rope, carrying bag. 8101006: 120 feet of 1/4 inch stainless steel wire rope, carrying bag. 8101101: 140 feet of 1/4 inch galvanized wire rope, carrying bag. 8101103: 140 feet of 1/4 inch stainless steel wire rope, carrying bag.

SALALIFT® II Winches: 8102001: 60 feet of 1/4 inch galvanized wire rope, carrying bag. 8102003: 60 feet of 1/4 inch stainless steel wire rope, carrying bag. 8102009: 90 feet of 3/16 inch galvanized wire rope, carrying bag. 8102011: 90 ft. of 3/16 inch stainless steel wire rope, carrying bag. 8102005: 120 feet of 3/16 inch galvanized wire rope, carrying bag. 8102007: 120 feet of 3/16 inch stainless steel wire rope, carrying bag.

IMPORTANT: F or special (custom) versions of this product, follo w the

instructions herein. See supplemental instructions, if included, for additional instructions on custom equipment.

1.0 APPLICATIONS

1.1 PURPOSE: DBI/SALA Salalift winches are to be used for work

positioning (8101000 series only), personnel riding, material handling, climbing protection, or rescue and ev acuation. These winch models are to be used with a DBI/SALA tripod, davit arm, or other support structure, and may be used in situations where personnel or materials need to be raised or lowered 60-140 feet.

1.2 WINCH APPLICA TION TYPES:

A. WORK POSITIONING: The Salalift winch (8101000 series only) is

used to suspend the worker in a work position, acting as the primary means of support. Applications include suspending a worker in a work seat or harness. A back-up personal fall arrest system must be attached to the suspended employee.

NOTE: OSHA requires that manual or pow ered winches be independently

evaluated and classified for use as a single point suspension system. See OSHA regulation 29 CFR 1926.451, and 29 CFR 1910.28.

B. PERSONNEL RIDING: The Salalift or Salalift II winch is used to r aise

or lower a worker to a work level. At the work level the worker is no longer supported by the winch. It is recommended that the w orker be connected to a back-up arrest system while being raised or lowered.

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C. RESCUE AND EV A CUATION: The Salalift or Salalift II winch is used

to raise or lower an endangered or injured work er, or rescue personnel. Applications include permit and non-permit confined space entry work.

D. CLIMBING PRO TECTION: The Salalift or Salalift II winch is used to

protect a worker ascending or descending a fixed ladder or similar structure. It is recommended that this use of the winch be restricted to structures where other means of climbing protection; such as permanently installed ladder safety systems or personal fall arrest systems are infeasible. For this application, the following conditions must be met:

1. Ladder or steps are in good condition and allows for a straight, continuous climb .

2. The worker climbing the ladder is wearing a full body harness and the winch line is connected to the dorsal (back) D-ring of the harness.

3. The winch operator is trained and competent in the operation of the winch.

4. No slack line is allowed to develop when the worker moves up or down the ladder .

5. DBI/SALA recommends , for the 8101000 series winches only, that an energy absorbing lanyard be connected between the harness dorsal D-ring and the winch line.

1.3 LIMITATIONS: The following application limitations must be considered before using this product. F ailure to observe product limitations could result in serious injury or death.

A. INSTALLATION: The winch must be installed in accordance with the

requirements stated in section 3.0 of this manual.

B. CAPACITY: The maximum working load for this product is 350 lbs.

(160 kg).

C. PERSONAL F ALL ARREST SYSTEMS: P ersonal fall arrest

systems used with the Salalift or Salalift II winch must meet applicable state and federal regulations and the requirements stated in section 3.3.

D. PHYSICAL AND ENVIRONMENT AL HAZARDS: Use of this

equipment in areas with physical or environmental hazards may

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require that additional precautions be taken to reduce the possibility of damage to this equipment or injury to the user. Hazards ma y include, but are not limited to; high heat (welding or metal cutting), acid or caustic chemicals, corrosive environments such as exposure to sea water , high v oltage po wer lines , e xplosive or to xic gases, moving machinery or sharp edges. Contact DBI/SALA if you have questions about the application of this equipment in areas where physical or environmental hazards are present.

E. TRAINING: This equipment is to be installed and used by persons

who have been trained in its correct application and use.

1.4 Refer to national standards, including; ANSI Z117.1, local, state, and OSHA requirements (26 CFR 1910.146), for more information on the application of this and associated equipment.

2.0 SYSTEM REQUIREMENTS

2.1 COMP ATIBILITY OF COMPONENTS: DBI/SALA equipment is

designed for use with DBI/SALA approved components and subsystems only. Substitutions or replacements made with nonapproved components or subsystems may jeopardize compatibility of equipment and may effect the safety and reliability of the complete system.

2.2 COMP A TIBILITY OF CONNECT ORS: Connectors are considered to be compatible with connecting elements when they have been designed to work together in such a way that their sizes and shapes do not cause their gate mechanisms to inadvertently open regardless of how they become oriented. Contact DBI/SALA if you have any questions about compatibility.

Connectors ( hooks, carabiners, and D-rings) must be capable of supporting at least 5,000 lbs. (22kN). Connectors must be compatible with the anchorage or other system components. Do not use equipment that is not compatible. Non-compatible connectors may unintentionally disengage. See Figure 3. Connectors must be compatible in size, shape, and strength. Self locking snap hooks and carabiners are required by ANSI Z359.1 and OSHA.

2.3 Making Connections: Only use self-locking snap hooks and carabiners with this equipment. Only use connectors that are suitable to each application. Ensure all connections are compatible in size, shape and strength. Do not use equipment that is not compatible. Ensure all connectors are fully closed and locked.

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DBI/SALA connectors (snap hooks and carabiners) are designed to be used only as specified in each product’s user’s instructions. See Figure 4 for inappropriate connections. DBI/SALA snap hooks and carabiners should not be connected:

A. To a D-ring to which another connector is attached. B. In a manner that would result in a load on the gate.

NOTE: Large throat opening snap hooks should not be connected to

standard size D-rings or similar objects which will result in a load on the gate if the hook or D-ring twists or rotates. Large throat snap hooks are designed for use on fixed structural elements such as rebar or cross members that are not shaped in a way that can capture the gate of the hook.

C. In a false engagement, where features that protrude from the snap

hook or carabiner catch on the anchor and without visual confirmation seems to be fully engaged to the anchor point.

D. To each other. E. Directly to webbing or rope lanyard or tie-back (unless the

manufacturer’ s instructions for both the lan yard and connector specifically allows such a connection).

Figure 3 - Unintentional Disengagement (Roll-out)

If the connecting element that a snap hook (shown) or carabiner attaches to is undersized or irregular in shape, a situation could occur where the connecting element applies a force to the gate of the snap hook or carabiner. This force may cause the gate (of either a self-locking or a non-locking snap hook) to open, allowing the snap hook or carabiner to disengage from the connecting point.

1. Force is applied to the snap hook.

2. The gate presses against the connecting ring.

3. The gate opens allowing the snap hook to slip off.

Small ring or other non-compatibly shaped element

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F. To any object which is shaped or dimensioned such that the snap

hook or carabiner will not close and lock, or that roll-out could occur .

2.4 SUPPORT STRUCTURE STRENGTH: The support structure to which the winch is installed must meet minimum strength requirements stated in section 3.4

3.0 OPERATION AND USE

W ARNING: Do not alter or intentionally misuse this equipment. Consult

DBI/SALA when using this equipment in combination with components or subsystems other than those described in this manual. Some subsystem and component combinations may interfere with the operation of this equipment. Use caution when using this equipment around moving machinery , electrical hazards, chemical hazards, and sharp edges.

WARNING: Consult your doctor if there is reason to doubt your fitness to safely absorb the shock from a fall arrest. Age and fitness seriously affect a worker's ability to withstand falls. Pregnant women or minors must not use a DBI/SALA winch, unless for unavoidable emergency use situations.

3.1 BEFORE EACH USE: Before each use of this equipment carefully inspect it to ensure it is in good working condition. Check for worn or damaged parts. Ensure all parts are present and secure. Chec k operation of winch; ensure that it will lift, lower , and hold the load under normal operation. Check winch and entire system for damage and corrosion. See section 5.0 f or further inspection details. Do not use if inspection reveals an unsafe condition.

Figure 4 - Inappropriate Connections

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3.2 PLANNING: Plan your system and how it will function bef ore starting your work. Consider all factors that affect your safety during use. Some important points to consider when planning your system are:

A. HAZARD EV ALU A TION: Ev aluate job site hazards prior to starting

work. Consult applicable OSHA and industry standards for guidelines and regulatory requirements on issues such as confined space entry , personal f all arrest systems (PFAS), and single point adjustable suspended scaffolds.

B. WORK SITE GEOMETR Y : The installation and use of the support

structure (tripod, davit arm and base) must be consistent with the geometric requirements stated in the associated manufacturer's instruction manuals. When suspending working lines from the support structure, check for obstructions or sharp edges in the work path. Av oid working where the user may s wing and hit an object, or where lines may cross or tangle with that of another worker .

C. SECONDAR Y OR BA CK-UP F ALL ARREST SYSTEM: When using

the Salalift winch (8101000 series) as a support for w ork positioning, a secondary or back-up fall arrest system is required. See OSHA 29 CFR 1910.28 and 1926.451. The DBI/SALA tripod and davit arm has provisions for connection of a secondary or back-up PFAS. See sections 3.3 and 3.5 (A).

D. RESCUE: A means of dealing with an accident or emergency must

be planned in advance. Response time can pla y an important role in the survival of an injured worker . Users of this equipment must be trained in emergency procedures.

3.3 REQUIREMENTS FOR PERSONAL F ALL ARREST SYSTEMS: PFAS used with the Salalift or Salalift II winch and support structure must meet applicable OSHA requirements.

• The PFAS should be rigged to minimize any potential free fall and

never allow a free fall greater than 6 feet. It is recommended that the PFAS used with this equipment include a full body harness as the body support component. PFAS's that incorporate full body harnesses must maintain fall arrest forces below 1,800 lbs. and arrest the fall within 42 inches. Body belts, unless incorporated into a full body harness, are not recommended for use with this equipment. A typical PFAS includes a full body harness, connecting subsystem or component (self retracting lifeline or lifeline and rope grab), and the necessary connectors to couple the system together.

• Anchorages selected for PFAS must sustain static loads, applied in

the directions permitted by the PFAS, of at least; (A) 3,600 lbs.

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(16kN) when certification exists (see ANSI Z359.1 for certification definition), or (B) 5,000 lbs. (22kN) in the absence of certification. When more than one PFAS is attached to an anchorage, the anchorage strengths set forth in (A) and (B) must be multiplied by the number of PFAS attached to the anchorage. Per OSHA 1926.500 and

1910.66: Anchorages used for attachment of a PFAS shall be independent of any anchorage being used to support or suspend platforms, and must support at least 5,000 lbs. (22kN) per user attached, or be designed, installed, and used as part of a complete PFAS which maintains a safety factor of at least two, and is supervised by a qualified person.

W ARNING: Read and f ollow manufacturer's instructions f or the personal fall arrest equipment selected for use with the winch and support structure.

IMPORTANT: Body belts are not allowed f or free fall situations. Body belts increase the risk of injury during fall arrest in comparison to a full body harness. Limited suspension time and the potential for improperly wearing a body belt may result in added danger to the user’ s health.

3.4 INST ALLA TION OF WINCH T O SUPPORT STRUCTURE:

A. MOUNTING BRACKET: These winches incorporate a “quick-mount”

style brack et for attachment to the support structure. DBI/SALA tripods, davit arms, and other support structures supplied by DBI/SALA, include a bracket that mates with the winch quick-mount bracket. All DBI/SALA winches include the quick-mount bracket. When using the 8102001 series winch with the 8004176 W all Mount Bracket, a mounting adapter kit is required. Contact DBI/SALA for more information.

B. LOAD REQ UIREMENTS: Figure 5 illustrates mounting the winch to

the support structure and the load requirements. The mounting bracket m ust support the loads shown in Figure 5.

C. GEOMETRIC REQUIREMENTS: Refer to the support structure

manufacturer's instructions for geometric requirements. Installations of the winch to support structures other than those provided by DBI/SALA must meet the geometric requirements shown in Figure 5. P osition the support structure so the load and the lifeline of the winch can be directed over the work area when installed. For personnel use, do not position the support structure where the worker will hav e to swing under the support structure to reach the work area. Avoid positioning the support structure where the working line may abrade against sharp edges.

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IMPORTANT: P osition the winch and support structure in a location which

allows the operator to safely use the winch.

D. QUICK-MOUNT INST ALLA TION: See Figure 6. Mount the winch

using the quick-mount bracket as follows:

Step 1. Pull out the locking detent pin by depressing the button on end

of the pin. Lift the winch into place and position the slot in the bracket o v er the fixed pin on the support structure bracket.

Step 2. Push the top of winch in toward the support structure while the

bottom rotates on the fixed pin. Align the holes and push the detent pin through until it stops. Ensure the pin locks in place.

Figure 5 - Load/Geometric Requirements

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Step 3. Slowly pull out the winch line. Route the line o v er the support

structure pulley system. See the support structure manufacturer's instructions for details.

E. WELDED INST ALLATIONS: If w elding the mounting bracket to a

support structure it is recommended that the welding be done by a certified welder. P ortions of the mounting brack et that have been exposed due to welding should be painted or otherwise protected from corrosion.

Figure 6 - Quick-Mount Installation

3.5 OPERA TION OF WINCH:

A. CONNECTING WINCH LINE TO LOAD: See Figure 7. For

applications that do not require a secondary PFAS , the winch line should be connected to the worker's harness back D-ring. For applications requiring a secondary PFAS, the winch line should be connected to a Y-type lanyard and this lany ard should be attached to the worker's harness shoulder D-rings. The secondary lifeline should be connected to the worker's harness back D-ring. For material handling applications, connect the winch line to the load using a tieoff adapter or other anchoring device.

B. SALALIFT WINCH (8101000 Series): Attach the winch to the

support structure as described in section 3.4 (D). Install the winch crank handle onto the high or low speed shaft by aligning the handle with the shaft and pushing firmly inward until the handle snaps in place. To release the handle from the shaft, depress the handle release and pull the handle off the shaft. Pull the ratchet lever downward and feed the line off the drum by rotating the crank handle in the “lower” direction. Route the line ov er the support structure pulley system.

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TO RAISE A LO AD: Rotate the winch crank handle clockwise when using the low speed shaft and counterclockwise when using the high speed shaft. For work er safety, the crank handle incorporates an overload clutch which limits the winch lifting force on the high speed shaft to approximately 250 lbs. and 500 lbs. on the low speed shaft, thus reducing the possibility of injury should a worker become entangled during retrieval. Do not exceed the rated capacity of 350 lbs.

TO LO WER A LO AD: Rotate the winch crank handle in the “raise” direction until the ratchet brake lever can be pulled down, then rotate the crank handle in the “lo wer” direction. When a load is suspended from the winch, use caution when the ratchet brake lever is pulled down since the load will be transf erred to the winch crank handle. To prevent loss of control of the load, do not bloc k or r e strict the ratchet lever from engaging the teeth on the drum, except by normal manual operation. If the operator fatigues, or for any reason desires to “hold” the load, allow the ratchet brake to engage and support the load.

The Salalift® I winch is designed and typically used for manual operation. Certain situations where the speed of the rescue, coupled with fatigue experienced by operator during long lifts, may necessitate the need for a powered drive operation. Contact DBI/ SALA for more information.

C. SALALIFT II WINCH (8102001 Series): Attach the winch to the

support structure as described in section 3.4 (D). Install winch crank handle onto the input shaft by aligning the hub of the crank handle with the square drive marked "winch shaft" and pushing firmly inward until handle snaps in place (the grip on the handle should

Figure 7 - Connection

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face outward). To release the crank handle from the shaft, pull the handle off the shaft. Feed the line off the winch drum by rotating the crank handle in the lowering direction (counterclockwise). Apply slight tension to the line while feeding it off the drum. F ree-wheel mode may also be used, see section 3.5 (C). Route the line over the support structure pulley system.

TO RAISE A LO AD: Rotate the winch crank handle in the raise direction (clockwise). To hold or momentarily suspend the load, stop cranking. The automatic clutch/brak e will hold the load if handle is released. The winch incorporates an overload clutch limiting the lifting force to approximately 700 lbs., reducing the chance of injury if a worker becomes entangled during retrieval. Do not exceed the rated capacity of 350 lbs.

TO LO WER A LO AD: Rotate the winch crank handle in the lower direction (counterclockwise). When low ering line without a load, maintain slight tension on the line to aid payout.

FREE-WHEEL MODE: Remove the crank handle from the raise/lower input shaft. Reverse the crank handle and install it onto the square drive marked "freewheel shaft" by aligning the handle hub with the shaft. See Figure 8. To engage free-wheel mode, rotate the crank handle counterclockwise until it stops and hold. The line can now be freely pulled off of the winch drum. T o a v oid build-up of slack line on the drum, pull the line off the drum smoothly , remo ve slack on the drum by releasing the crank handle and pulling on the line. If the line pays out too rapidly, an ov er speed br ak e will activate and lock, stopping the line. If this happens, return to the winch mode and rotate the crank handle clockwise two turns to unlock the over speed brake. Do not engage free-wheel mode with load on the lifting line, remove load on the line before engaging free-wheel mode. When using the Salalift II for climbing protection applications, freewheel mode is not recommended. The oper ator must be attentive to slack line; paying out and reeling in line as needed.

D. IMP A CT INDICA T OR AND CABLE RESERVE: The Salalift II winch

is supplied with a connecting swiveling hook that incorporates a load indicator . This indicator functions if the winch is sev erely impact loaded or if the lifting capacity is exceeded by a preset amount. See section 5.0 for inspection of load indicator . The Salalift II incorporates a reserve cable retention feature on the cable drum. With the drum near empty (single layer of cable remaining), the shear pin is visible. See Figure 10. The reserve cab le ensures that the shock absorbing feature is available throughout the working range of the winch. If the winch is shock loaded at the reserve point

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of cable pay out, the shear pin will shear , allowing the shoc k absorber to function normally . If the shear pin has been sheared, the unit must be returned for inspection and repair . See section 5.0 for inspection details.

IMPORTANT: Do not use winch f or lifting or lowering of more than one person, except for emergency situations. In this case, if using the 8101000 series, the low speed shaft must be used to pre vent handle slippage. The maximum lifting force is approximately 500 lbs.

W ARNING: If the cr anking tension eases during lowering, the person or material being lowered has reached a work level or obstruction. Do not continue cranking without communicating with the person or checking the material being lowered. Always keep the cable tension firm. Slack cable could cause a free fall.

WARNING: A minimum of four wraps of line must remain on the drum at all

times on the 8101000 series. One complete layer of line must remain on the 8102001 series. Do not attempt to reverse wind the line onto the drum. Line must wind onto the drum by turning the crank handle in the "raise" direction only . Check periodically to see that the line is winding ev enly on the drum. Use gloves when handling line.

4.0 TRAINING

4.1 It is the responsibility of the user to assure they are familiar with these

instructions, and are trained in the correct care and use of this equipment.

Figure 8 - Free-Wheel Mode

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User must also be aware of the operating characteristics, application limits, and the consequences of improper use of this equipment.

IMPORTANT: T raining m ust be conducted without exposing the trainee to a fall hazard. T raining should be repeated on a periodic basis.

5.0 INSPECTION

5.1 FREQUENCY :

• Before Each Use: Visually inspect per steps listed in sections 5.2 and 5.3.

• Monthly: A formal inspection of the winch should be done by a competent person other than the user. See sections 5.2 and 5.3 for guidelines. Record results in the inspection and maintenance log in section 9.0.

• Annual: It is recommended that the winch be serviced by a factory authorized service center or the manufacturer. Extreme working conditions may require increasing the frequency of inspections. Annual servicing shall include, but not be limited to, an intensive inspection and cleaning of all internal and external components. Failure to provide proper service may shorten product life and could endanger performance.

• After An Impact: Inspect entire winch according to section 5.2.

W ARNING: If the winch has been subjected to impact forces, it must be immediately removed from service and inspected. If the winch fails to pass the inspection, do not use. The equipment must be sent to an authorized service center for repair .

IMPORTANT: Extreme working conditions (harsh environment, prolonged use, etc.) may require increasing the frequency of inspections.

5.2 GENERAL INSPECTION STEPS FOR ALL WINCH MODELS:

Step 1. Inspect all screws, bolts and nuts. Ensure they are securely

attached and tight. Check to see if any bolts, nuts or other parts are missing, or have been substituted or altered in any wa y. Inspect covers, housings, guards, etc. Ensure they are free of cracks, dents, or other damage.

Step 2. Crank handle must lock positively onto the shaft and be free of

cracks, bends, or other damage.

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Step 3. Connecting hook must not be damaged, broken, distorted, or

have an y sharp edges, burrs, crac ks, worn parts, or corrosion. Ensure the connecting hook works properly . Hook gate must move freely and loc k upon closing. Hook must swivel freely.

Step 4. Wire Rope: Inspect entire length of wire rope assembly starting

at the hook. Always wear protective gloves when inspecting wire rope.

A. Inspect for broken wires by passing the wire rope through gloved

hands, flexing it every few inches to expose breaks. Broken wires can be removed b y bending the wire back and f orth parallel to the rope length. Do not attempt to pull wires out of rope. Inspect for kinks, cuts, crushed burned areas, or other damage. Wire rope with serious damage must be removed from service.

B. The wire rope assembly must be replaced by an authorized service

center if there are six or more randomly distributed broken wires in one lay, or three or more broken wires in one strand in one la y. Note: A “lay” of wire rope is the length of wire rope that it takes for a strand (the larger groups of wires) to complete one revolution or twist along the rope.

C. The wire rope assembly must be replaced by an authorized service

center if there are any broken wires within one inch of the metal compression sleev es at either end of the assembly. Note: To inspect wire rope area near compression sleeves on hook end, remove counterweight (8101000 series) or slide rubber hook bumper up on wire rope (8102001 series).

D. Inspect entire length of wire rope for signs of corrosion. Severely

corroded wire rope must be replaced.

Synthetic Rope: Inspect for the following if the winch uses synthetic rope: A. Inspect for concentrated wear, frayed strands , brok en yarns, cuts,

and abrasions. The line must be free of knots, e xcessiv e soiling, heavy paint buildup, and rust staining throughout its length.

B. The line must be free of chemical or heat damage, indicated by

brown, discolored, or brittle areas.

C. The line must be free of ultraviolet damage, indicated by discoloration

and the presence of splinters and slivers on the rope surface.

D. All of the above factors are known to reduce rope strength. As a rule

of thumb, rope strength is reduced proportional to the cross

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sectional area of the rope damaged. Damaged or questionable rope should be replaced by an authorized service center.

Step 5. Inspect all identification and warning labels, ensuring that they

are legible and securely attached. See Figure 1 (8101000 series), Figure 2 (8102001 series) and section 8.0.

Step 6. Inspect each system component (support structure, back-up

fall arrest system, body support, connectors, etc.) according to manufacturer's instructions.

Step 7. See additional inspection steps for the winch in sections 5.3,

5.4, and 5.5.

5.3 INSPECTION OF SALALIFT WINCH (8101000 SERIES): The f ollowing steps are additional inspection procedures to those in section 5.2 that must be performed on the 8101000 series winch. See Figure 1.

Step 1. Check operation of the winch in high and low speed positions; it

must crank up and down freely. Stiff or rough operation ma y indicate a worn gear or bearing.

Step 2. Inspect the ratchet brake . With the brak e engaged, the drum

should be prev ented from paying off cab le. The spring must be in place and undamaged. The ratchet brak e lev er must fully engage the teeth on the drum, the drum teeth must be in good condition.

Step 3. Inspect for oil in the gearbox by removing plug on top and tilting

unit so oil can be seen through hole. Inspect for oil leaks.

Step 4. Check operation of the handle over speed brake as follows:

A. Over le v el ground set up support structure and winch as it will be

used.

B. By raising or lowering the winch cable, position the lifting hook to

approximately chest height.

C. Remove the winch crank handle and have someone hold the ratchet

brake lever in its disengaged position, such as when lowering a load.

D. Pull down sharply on the lifting hook to engage the over speed

brake.

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E. If the brake fails to engage or noticeable brake slippage occurs,

remove from service and return to an authorized service center for repair.

Step 5. Check operation of the drum over speed brake as follows, see

Figure 9:

A. To test the drum over speed br ake, remov e the handle ov er speed

brake assembly. Using a snap ring pliers, remo ve the ring that retains the handle over speed brake assembly on the low speed shaft. Remov e the brak e assemb ly, taking care not to damage the pawl springs on the back side of the brake. Note: If damage exists on the shaft such as a nick or corrosion, repair the damaged area using a file or emery cloth before removing the brake assemb ly.

B. With the handle over speed brake removed, on level ground, set up

the support structure and winch as it will be used. To test the drum over speed brake, remove the crank handle and disengage the ratchet brake, then pull down sharply on the winch cable to engage brake.

C. If the brake fails to engage or slippage of more than one inch occurs

(a small amount of brake slippage is normal), remove the winch

Figure 9 - Inspecting level wind 8101000

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from service immediately and return to an authorized service center for repair .

D. If the brake functions properly, reassemble the handle ov er speed

brake. Ensure the pawls are in place and the “A” side is showing on each pawl. Reinstall the retaining ring onto the shaft. Test the handle over speed brake for proper operation using the method given in step 4.

Step 6. See Figure 9. Inspect the level wind assuring that it moves

freely and applies pressure against the line. If the plastic wear pad needs to be replaced, return the winch to an authorized service center.

5.4 INSPECTION OF SALALIFT II WINCH (8102001 SERIES): The following steps are additional inspection procedures to those in section

5.2 that must be performed on the 8102001 series winch. See Figure 2.

Step 1. Check operation of the free-wheel mode and the drum over

speed brake as follows:

A. Engage free-wheel mode by connecting the crank handle to the

free-wheel shaft and rotating the handle counterclockwise. The winch line should pay out freely. Pull down sharply on the winch line with the winch in the free-wheel mode to engage the brake.

B. The brake must lock and hold. If the brake fails to engage or

slippage of more than one inch occurs (a small amount of brake slippage is normal), remove the winch from service immediately and return to an authorized service center for repair .

Step 2. See Figure 10.

Inspect the shear pin. The shear pin should retain one complete wrap of line on the drum. If the shear pin is broken or missing the unit must be returned to an authorized service center for repair .

Figure 10 - Inspecting shear pin

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Step 3. See Figure 11. Inspect the impact indicator on the snap hook. If

the hook is in the indicated mode, return the winch to an authorized service center for repair .

Step 4. See Figure 12. Inspect the level wind assuring that it moves

freely and applies pressure against the line. If the plastic wear pad needs to be replaced return the winch to an authorized service center.

5.5 If inspection or operation reveals a defective condition, remove the winch from service immediately and contact an authorized service center for repair .

NOTE:

Only DBI/SALA or parties authorized in writing may mak e repairs to

this equipment.

6.0 MAINTENANCE, SERVICING, STORAGE

6.1 P eriodically clean the exterior of the winch using water and a mild

detergent solution. Clean labels as required. At least twice a year , clean and lubricate the wire rope. Do not use solvents to clean the wire rope as they will remove internal lubrication. Lubricate wire rope using a cloth (wearing gloves) and a light machine oil.

6.2 LUBRICA TION OF SALALIFT WINCH;

• For the 8101000 series Salalift winch, the gear box contains eight

ounces of high quality gear oil, SAE 80 or 90. The oil does not require changing unless there is evidence of contaminants in the oil. See section 5.3, step 3. If the oil is contaminated or leaking contact DBI/ SALA for repair.

Figure 12 - Inspection level wind 8102000

Figure 11 - Impact Indicator

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• For the 8102001 series Salalift winch, lubrication should be applied periodically to the winch drum gear. Maintain a light film of grease on the drum gear teeth at all times. Apply grease to the drum gear teeth as required. Do not over lubricate.

6.3 Replacement parts, as well as additional maintenance and servicing procedures, must be completed b y a factory authorized service center. An authorization and a return number must be issued by DBI/SALA.

6.4 Store this equipment in a cool, dry , clean environment out of direct sunlight. A v oid areas where chemical v apors e xist. Inspect after any period of extended storage.

6.5 Clean and store body support, support structure, and associated system components according to separate instructions provided with that equipment.

7.0 SPECIFICATIONS

* Note: Speeds given assume 60 rpm cranking rate. Actual rates may

vary depending on cranking speed and the amount of rope on the drum.

• The 8101000, 8101002, 8101004, and 8101006 manually operated

winches are classified by Underwriters Laboratories, Inc. as to the 350 lbs. load capacity only.

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8101000 Series ID Label

8101000 Series UL Label

8101000 Series Brake T esting Label

8.0 LABELING

8.1 The following labels must be present and fully legible:

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8101000 Series W arning Label

8101000 Series Standards Label

8101000 Series Winch Handle Label

8102001 Series W arning Label

8.1 Labeling, continued:

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8102001 Series

Raise/Lower Label

8102001 Series

Free wheel

Engagement Label

8102001 Series Shaft Identification Label

8102001 Series ID Label

8.1 Labeling, continued:

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9.0 INSPECTION AND MAINTENANCE LOG

SERIAL NUMBER: ____________________________________________

MODEL NUMBER: ____________________________________________

DATE PURCHASED: __________________________________________

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9.0 INSPECTION AND MAINTENANCE LOG

SERIAL NUMBER: ____________________________________________

MODEL NUMBER: ____________________________________________

DATE PURCHASED: __________________________________________

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DETON

NOITCAEVITCERROCECNANETNIAM

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9.0 INSPECTION AND MAINTENANCE LOG

SERIAL NUMBER: ____________________________________________

MODEL NUMBER: ____________________________________________

DATE PURCHASED: __________________________________________

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DETON

NOITCAEVITCERROCECNANETNIAM

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9.0 INSPECTION AND MAINTENANCE LOG

SERIAL NUMBER: ____________________________________________

MODEL NUMBER: ____________________________________________

DATE PURCHASED: __________________________________________

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Equipment offered by DBI/SALA is warranted against factory defects in workmanship and materials for a period of two years from date of installation or use by the owner , pro vided that this period shall not exceed two y ears from date of shipment. Upon notice in writing, DBI/SALA will promptly repair or replace all defective items. DBI/SALA reserves the right to elect to have any defective item returned to its plant for inspection before making a repair or replacement. This warranty does not co ver equipment damages resulting from abuse, damage in transit, or other damage beyond the control of DBI/SALA. This w arranty applies only to the original purchaser and is the only one applicable to our products, and is in lieu of all other warranties, expressed or implied.

WARRANTY

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DB Industries 8101006, 8101002, 8101004, 8101101, 8101103 User Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual