CSW-3060
Single Line Use
Double Line Use
PULLEY-MAN CO.,Ltd
www.pulleyman.co.kr
PULLEY-MAN
USER’S MANUAL
MODEL
CSW-3060
MULTIPURPOSE
& PORTABLE
PULLEY-MAN
w w w. p u l l e y m a n . c o. k r
WINCH
INTRODUCTION
Thank you very much for purchasing PULLEY-MAN.
Please read this manual carefully for safe use, improved
productivity and proper maintenance. Specifications may
change without prior notice for product improvement. For
up d a t ed i n f orm a t i on, pl e a se c o n tac t y our d e aler o r
manufacturer.
A single unit of PULLEY-MAN CSW-3060 alone can perform
all the functions of conventional hoist, winch and chain block.
Unlike such conventional products, which wind wire on a
drum and thus can work load only within length of the wound
wire rope, CSW-SERIES is designed to perform its functions
quickly, easily and efficiently under any working conditions
regardless of length or direction, whether it is vertical,
horizontal or slant environment, as long as there is an anchor
to hook the equipment.
Please consult the governing laws, rules or directives before
use for standards of manufacture, safery and inspection.
2
TABLE OF CONTENTS
Ⅰ. Safety Instructions
1. Symbols
2. Definitions
3. Precautions against Danger
4
4
5
Ⅱ. A description for a speed reducer
Ⅲ. Uses & Operations
1. Standard Offerings and Options
2. Specifications
3. Parts and Names
4. Incorporation and Removal of Wire Rope
5. Treatment of Wire Tip
6. In-Put Power Sources
7. Applications
8. PULLEY-MAN used as a Winch
9. Precautions for Non-Professional Users
Ⅳ. Maintenance
Appointment of Maintenance Personnel
1.
Safety Rules for Maintenance & Trouble-Shooting
2.
Warning Labels for Danger
3.
Labels and Details
4.
Grease Replenishment
5.
Assembly and Disassembly
6.
Precautions for Re-Assembly
7.
Check-Up Points after Re-Assembly
8.
Replacement of Parts and Components
9.
Daily and Periodical Maintenance
10.
Trouble-Shooting
11.
Education and Training for User
12.
9
10
11
12
14
16
17
18
22
22
23
23
23
24
24
24
27
27
27
29
31
31
Ⅴ. Limited Warranty
32
3
Ⅰ. Safety Instructions
1. Symbols
May lead to fatal or serious danger when handled improperly.
May lead to physical or property damage when handled improperly.
Caution against electric danger
Physical contacts during operation may immediately lead to bodily injury. Parts with
this symbol must be handled only by qualified technicians. Power must be turned off
while handling such parts.
Caution against hanging load.
Operation under hanging load may lead to a serious accident. Donʼt come under a
hanging load.
Caution for handling during installation.
Thes symbol in this manual indicates warning of all kinds. Disregard of this symbol
may cause damage to PULLEY-MAN or load.
2. Definitions
1) Entrepreneur(person in charge) :
Owner of PULLEY-MAN who uses PULLEY-MAN for his applications, or one who authorizes
someone else to use PULLEY-MAN.
2) Authorized Personnel :
Qualified personnel who are authorized by entrepreneur to install, use and keep maintenance of
PULLEY-MAN.
3) Maintenance Personnel :
Qualified personnel who are authorized by entrepreneur to install, adjust, keep maintenance, and
remove defects of PULLEY-MAN.
4
Ⅰ. Safety Instructions
4) Electrician :
Those who have knowledge and experience in the field along with relevant qualification and can
identify potential factors of danger in electrical and related equipment and take appropriate measures.
5) Knowledgeable Personnel :
Those who have extensive knowledge, technical training and experience with regard to PULLEY-MAN
and can make general decisions regarding safety rules, accident-preventive tips, methods of operation
and conditions of safe operation.
6) Operator :
Person authorized by entrepreneur to operate or to move place of PULLEY-MAN
7) Non-Professional User :
Person not authorized by entrepreneur to operate PULLEY-MAN and needs education and training. He
has to be informed of relevant rules and safety measures along with accident-preventive tips.
8) PULLEY-MAN :
Product having function of lifting and conveying load like crane, hoist, winch and cable car.
3. Precautions against Danger
1) Check below after purchasing PULLEY-MAN.
❶ Type
❷ Lifting Capacity
❸ Diameter and Length of Wire Rope
❹ Standard parts, Components and Accessories
❺ Options (in-put power source)
5
Ⅰ. Safety Instructions
2) Working Environment and Operational Conditions
Continuous operation time: within 25 minutes
3) Safeguards against Danger
❶ Protection over Pulley
- Press Roller Casing is designed with protective cover closed over pulley, which transports wire rope
back and forth
❷ Hook: Must have a latch to prevent load-binding material from slipping off the hook.
❸ End-Stopper: Fixed at the other end of wire rope to prevent wire rope, and load in consequence,
from slipping off the pulley due to excessive load weight.
4) Safe Usage
❶ Do not overload.
❷ Do not operate right beneath hanging load or PULLEY-MAN.
-When operating with hand drill as power source, maintain at least 24in.(60cm) from load.
-When operating with motor as power source, maintain at least 3.3~4.9ft. (1~1.5m).
❸ Fix PULLEY-MAN or wire hook before hooking load.
❹ Do not hold or lay hands on the load while lifting.
❺ Keep workplace in order and maintain at least 300 lux.
❻ Make sure no person or object is in front or rear of moving load.
❼ If fixation of PULLEY-MAN or hooking of load is unstable, take immediate measure.
Do not operate near hazardous gas such as acid and alkali or in surroundings subject to
❽
inflammation.
❾ Make sure no uncovered flame, excessive heat or sparks are near PULLEY-MAN.
❿ Install PULLEY-MAN at least 3.3~4.9ft. (1~1.5m) from the wall or obstacle(s).
Do not operate at humid or wet places on rainy days (except manual usage). It may lead to electric
shock. When operating PULLEY-MAN outdoors or at humid places, take protective measures that
meet IP54 requirements.
6
Ⅰ. Safety Instructions
When using hand drill as in-put power source, use voltage and frequency only u specified in labels.
When standing on a conductive object during operation, make sure to ground it.
When PULLEY-MAN is not in use, or when repairing, cleaning or examining, make sure in-put
power is off.
When assembling, disassembling or replacing parts, follow instructions in this manual.
Use only the parts provided or certified by manufacturer.
Improper usage or usage without proper maintenance is prohibited.
Do not allow children, or anyone unaware of precautions or incapable of proper operation, to
operate PULLEY-MAN.
Be sure to grip a hand drill with both hands when using it.
5) Check-Up Points before Operation
❶ Check PULLEY-MAN if there is a loose connection.
❷ Check wire rope for abrasion or damage.
❸ Check if wire hook is inserted in right direction.
❹ Check if wire rope is properly fitted into the pulley groove and press rollers are pressing wire rope.
❺ Check if nuts are fastened and nut-holding pins are positioned.
❻ Check if gateway latch of wire hook is functioning.
❼ Check if labels and danger signs are attached properly.
6) Preparations before Operation
❶ Wear safety helmet that meets safety standards to protect your head.
❷ Wear safety shoes to protect your feet.
❸ Wear safety gloves that are convenient to wear.
❹ Be careful about loose tip of your costume during operation, such as hanging necktie or sleeves.
7
Ⅰ. Safety Instructions
7) Storage after Usage
❶ Separate in-put power source (e.g. hand drill) from main body before storage.
❷ Separate wire rope from main body in order to prevent warping or bending and keep it properly
rolled.
❸ When keeping for long time unused, clean it properly and keep it oiled.
❹ When main body is damaged, repair it before storage. If replacement part(s) is required, use one(s)
supplied or recommended by manufacturer.
❺ Keep PULLEY-MAN safe from humidity and dust.
8) Exemptions from Liability
❶ Accidents from improper handling.
❷ Accidents occurring from disregard of instructions in this manual.
❸ Accidents in result of improper repair, arbitrary modifications or revisions.
❹ Accidents due to use of parts or components unapproved of by manufacturer
❺ Accident caused due to lifting a person.
❻ If used in lifting a high-priced equipment whose the price is more than twenty thousand US dollars.
men using PULLEY-MAN as a hoist consult relevant laws and rules enacted by your government for
manufacturing, safety and inspection standards.
It is not allowed to we PULLEY-MAN for transportation of people. When that is inevitable, please
contact manufacturer for relevant safety rules or laws to consult.
8
Ⅱ. A description for a speed redueer
The speed reducer is torque-up with 102.5:1 speed ratio of input speed.
So, It can lift up or pull the heavy object without heavy energy.
It consists of wire, speed reducer, wedge-shaped pulley system.
The 9 gears in speed reducer have brake power that multply the blocking frition from output speed.
Wedge - shaped Pulley
1. It is safe if there is no movement of an
input axis in state of lifted up a object.
When you take down a heavy object,
the brake function can be minimize or
lost because of increasing energy of
inertia & potential.
2. Every power source must has own
brake system.
It is safe using in speed 3m/min
3. Do not apply the object heavier than
the proof load.
In - Put Axis
Out - Put
Speed reducer part
Wire rope
9
Ⅲ. Uses and Operations
1. Standard Offerings and Options
CSW-3060
AC Motor Double Line Options
10
Ⅲ. Uses and Operations
2. Specifications
Standard Specifications
Number of
Falls
Hand Drill
Load capacity
Wire Rope
Weight : CSW-3060 of Main Body(kgs/lbs.)
Weight : CSW-3060 of Wire Hook(kgs/lbs.)
Options
✽MPM : meter per minute
✽FPM : feet per minute
Single Line
Doulle Line
Diameter
Standard Spec.
Hand Drill
Cordless Drive Drill
AC Motor
Lifting capacity Line Speed
kgs lbs. No Load(MPM/FPM) Full Load(MPM/FPM)
300
600
Wire Rope 12M(40ft.) with Hook and Wire-Rope Reel, Hook Socket & End-Stopper
600
1,200
3/8˝ (10mm), 18V DC, max. torque 230in./lbs. or above, reversible
single phase 220V, min 1500W, Hz60/50, 5200rpm. reversible.
Working
Distance
6.0/19.8
3.0/9.9
4.76mm(3/16in.) Steel Wire Rope (7×19)
3.8/8.4
1.9/4.2
single phase 220V, min. 550W, 3000rpm, reversible
3.75/12
1.85/6
∞
∞
▶The above instructions should be observed for safety
▶Use indoors only for safety on a rainy, snowy, windy or dark day.
▶Do never lift a person.
11
Ⅲ. Uses and Operations
3. Parts and Names
CSW-3060
Single-Line Use
Main Frames
Gear Box
In-let Lock Pin
Frame Cover
In-Put Axis
Wire-Hook
End-Stopper
Wire-Rope Reel
Wire Rope
Latch
12
Ⅲ. Uses and Operations
Double-Line Use
Hook
Press Roller Casing
Press Roller Casing
Lock Pin
Hand Drill
Hook Cover
Double-Line
Hook Cover
Wire Rope
Socket
Wire Rope
Hook Block
Out-let
Roller
13
Ⅲ. Uses and Operations
4. Incorporation and Removal of Wire Rope
Wire rope of PULLEY-MAN is separate from main body unless it is incorporated.
Before installation, assemble main body with wire rope. Incorporate wire rope into main body in following
procedures. (Follow the procedures backwards when removing wire rope from main body).
1) Procedures of Incorporation: CSW-3060
❶
Pull off In-Let Lock Pin.
Remove split pin and pull loop
of in-let lock pin.
❷
Pull off two press Roller Casing
Lock Pins.
Remove split pins and pull loops of
press roller casing lock pins.
❸ Remove Hook of main body
(Single-Line Use).
Remove nut-holding pin and nut and
pull off hexagon bolt.
❸
Remove Double-Line Hook
Cover (Double-Line Use).
Remove nut-holding pin and nut and
pull off hexagon bolt.
❹
Incorporate Wire Rope into pulley
groove.
lock pin toward press roller casing.
Pull out Wire Rope long enough
for operation before fitting onto pulley
groove.
Inserting direction is from in-let
❺
Push in the pin from gear-side frame
and insert split pin.
❻
(Single-Line Use).
Screw in hexagon bolt, lock nut,
and insert nut-holding pin.
14
Push in In-Let Lock Pin.
Re-assemble main body Hook
Ⅲ. Uses and Operations
❻
Re-assemble double-line Hook
Cover (Double-Line Use).
Screw in hexagon bolt, lock nut, and
insert nut-holding pin.
❼
Press Wire Rope with Press Roller
Casing.
Lift press roller casing about 90° and
pass wire rope between out-let roller
and press roll er casing. Pull wire
rope in end-stopper direction so that
it fits to bottom of pul ley groove.
Cl ose press rol le r casing toward
frame so as to press wire rope.
Check if press rollers are
pressing wire rope.
❽
Push in Press Roller Casing Lock
Pin.
When holes for lock pins on frames and
press roller casing are in line, insert lock
pins from speed-reducer-side frame and
insert split pins.
(Single-Line User : END)
❾
Separate Hook from Wire Rope
Socket.
Remove nut-holding pin, bolt and
nut from wire rope socket, which is
connecting wirerope hook and wire
rope at tip of wire rope.
❿
Insert wire rope over Hook Black
and re-assemble Hook.
Insert wire rope between sheave and
side plates, an d re-assembl e hook
w i th w i r e r o p e so c k e t . B e f o r e
re-assembling hook, check if wire
rope is properly laid in the middle of
sheave groove. Screw in bolt and nut
and insert nut-holding pin.
15
Connect wire rope socket to double-
line hook cover.
Assemble wire rope socket to doubleline hook cover. Screw in nut and insert
nut-holding pin.
Incorporation of Wire Rope comploted.
(Double-Line User : END)
Ⅲ. Uses and Operations
5. Treatment of Wire Tip
1) Clip Fixation
For wire ropes whose diameters are less than 5/8in. (16mm), use 4 clips and give spacing
between clips wider than 6 times diameter of Wire Rope.
2) Press Fixation
Use cold-pressed steel.
▶When using a wire rope longer than the one provided by manufacturer(40ft. (12m)), use one
recommended by manufacturer, and fix wire tip by either method shown above and connect wire
rope socket (wire rope provided by manufacturer is fixed by press fixation method).
▶When fixing wire tip, its safety factor must be at least 5 times and a safety test must be
conducted before using it.
▶Contact manufacturer when employing wire rope longer than 40ft. (12m)
3) Fixation of End-Stopper
Fix the other tip of wire rope with steel cube by press fixation method. Thickness of the steel should be
more than 10㎜ after press. Grind remnant wire rope off the end-stopper.
10㎜
End-stopper
16
Ⅲ. Uses and Operations
6. In-Put Power Sources
1) Hand Drill
❶ Specifications: single phase 110/220V, min. 550W, 3000rpm, reversible
❶
Precautions
●
Install anti-leakage insulator at main power and make sure to ground it.
●
Use voltage of main power as specified in label.
●
When using as in-put power source, check if its chuck is properly connected to hexagonal tip
of in-put axis.
●
Do not touch spinning chuck.
2) Cordless Drive-Drill
❶
Specifications: 3/8˝ (10mm), 18V DC, max. torque 230in./lbs. or above, reversible
❶
Precautions :
●Use when it is fully charged.
●When using as in-put power source, check if its chuck is properly connected to hexagonal tip of
in-put axis.
●
Do not touch spinning chuck.
3) Motor
❶ Specifications: single phase 220V, 50/60Hz, 5,200rpm (max.), remote control switch.
❶
Precautions:
●Apply voltage as specified in the label.
●After attaching motor, check joints and attachment to main body.
▶For products not supplied by manufacturer, check accordingly.
▶When using PULLEY-MAN as a hoist, ground and discharge the in-put power source in
order to protect from thunderbolt.
17
Ⅲ. Uses and Operations
7. Applications (CSW-3060) Caution!
PULLEY-MAN CSW-3060 is designed to be multifunctional and adaptable to perform functions of
conventional hoist, winch and chain block altogether. CSW-3060 can work load quickly and easily
regardless of working length, direction and condition, whether it is vertical, horizontal or slant, as
long as there is an anchor to hook.
Before using PULLEY-MAN for whatever application, consult the governing law.
How to Use & Install CSW-3060
◈
Fixed Pulley-Man
◈
Fixed Wire Hook
◈
Fixed Pulley-Man on the Bottom
600lbs
300kgs
1200lbs
600kgs
600lbs
300kgs
18
1200lbs
600kgs
600lbs
300kgs
1200lbs
600kgs
Ⅲ. Uses and Operations
2) Set-Up Modes of PULLEY-MAN
❶
Fixed PULLEY-MAN
Fix main body at an I-beam, round beam or other stable overhead
structure and hook load with wire rope to move load vertically.
❷
Fixed Wire-Hook
Fix wire-hook at an I-beam,
round beam or other stable
overhead structure and hook
load with main body hook to
move load vertically.
❸
Fixed PULLEY-MAN on Ground
Fix main body at a stable anchor on the ground, pass wire
rope through block fixed at an I-beam, round beam or other
stable overhead structure, and hook load with wire rope to
move load vertically.
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Ⅲ. Uses and Operations
3) Precautions for Installation and Usage of PULLEY-MAN
❶ Requirements for an overhead structure to fix PULLEY-MAN or wire-hook:
●
Should be hard enough to endure load weight.
●
When fixing PULLEY-MAN to a shackle at tip of an extension arm, length of the extension arm should not
be too long. Consult table below for appropriate dimensions of extension arm with regard to moment,
bending stress, etc
❷ Selection of Material for Binding Load
① Steel Wire Rope
② Chain
③ Fibrous Rope or Sling
folding or knot in between.
●
Connection must be made at its tips and there must be no twisting or folding in between.
●
It must have safety factor of at least 5 times the load.
●
A chain with welded connection must be connected in short-connection mode.
●
It must have 4 times safety factor of the load.
●
Except for one without open ends, connection must be made at its tips and there must be no twisting,
●
It must have at least 7 times safety factor of the load.
❸ Methods of Binding Load with Wire Rope or Chain (See table & drawings below.)
● Find center of weight before hooking.
● Bind the load at least twice with a proper binding wire or chain.
● When lifting load, make inner angle between top of load and binding material less than 60° Otherwise, rope or
chain may break off due to load weight.
● When hooking load, place binding material on center of hook.
● Hook must have a protective gateway latch to prevent binding material from slipping off.
20
Ⅲ. Uses and Operations
4) Operation of PULLEY-MAN
When installation of PULLEY-MAN is completed, start operation as instructed in this manual.
❶ Check below before operation.
●
Remove all factors of potential danger and obstacles around work area.
●
Check main body and hook and if there is entanglement or twisting on wire rope.
●
Check if wire moves up and down properly without load.
❷
Get ready to hang load.
●
Hook load with wire rope, chain, I-bolt or shackle safely as instructed in this manual.
❸
Follow guidelines below during operation.
●
12in. (30cm) between bottom of main body and wire hook.
●
●
●
●
●
●
Overloading is prohibited.
To prevent top of binding material from colliding with bottom of PULLEY-MAN main body, maintain at least
Do not ride on moving load.
Do not change direction of in-put power abruptly.
Do not operate under hanging load or PULLEY-MAN and stay away from vertical line of hanging load.
Make it sure that loose wire rope does not entangle with in-put power cable.
Keep loose wire rope away from load being lifted.
Do not step on loose wire rope.
❹
Check-up points after operation
●
Turn off in-put power source after operation.
●
Do not finish operation while load is hanging.
●
After outdoor operation, keep things around in order and keep PULLEY-MAN as instructed in this manual.
21
Ⅲ. Uses and Operations
8. PULLEY-MAN used as a Winch
◈
PULLEY-MAN can function as a winch by moving load horizontally or in slant angle.
◈
Pulling capacity varies by load weight and inclination of wire rope. Refer to table below for maximum capacity at
given condition and inclination.
◈
Set-up modes of PULLEY-MAN used as a hoist are the same as when used as a winch. Choose a mode that best
suits the working condition.
◈
Precautions in using PULLEY-MAN as Winch
❶ When pulling load, make sure that wire rope is in straight line with pulle groove.
❷ When pulling load, do not allow any intermediate obstacle between pulley and load that gives angle
on wire rope. (It may damage or break wire rope)
❸ Make sure no person or object is at front or rear of moving load.
❹ Do not change revolving direction of in-put power source abruptly.
❺ Do not step on loose wire rope during operation.
❻ Keep loose wire rope untangled with in-put power cable.
❼ Keep loose wire rope that just passed pulley away from load being lifted.
❽ When road surface on which load is being pulled is uneven or has depression or pit, use a plate to
make the path even.
Ex) When there is a ditch, stairs or elevation on ground, or when pulling load onto power tractor, etc
❾ When pulling load on a slant surface and load loses balance, take a safety measure to prevent load
from slipping down.
❿ Do not stop operation while pulling load on slant surface without any control or safely measures
Do not ride on moving load.
Do not use PULLEY-MAN for passenger purpose without permission of manufacturer.
Observe other related laws or rules regarding safety.
9. Precautions for Non-Professional Users
Be fully prepared with knowledge about PULLEY-MAN before operation in order to prevent accidents.
Read this manual carefully before operation and conduct a trial operation without load at a safe place
until accustomed to it, following instructions in this manual regarding safety guidelines. Best way would
be to conduct the operation under supervision of maintenance personnel or a knowledgeable person.
22
Ⅳ. Maintenance
For PULLEY-MAN to function to its maximum capacity and stay fit, it must be used and maintained
properly. Refer to relevant laws or rules for detailed information about its maintenance. When
performing maintenance, follow guidelines specified below in presence of personnel in charge.
1. Appointment of Manintenance Personnel
Though PULLEY-MAN is simple to install and operate, it must be used and maintained properly to
function to its maximum capacity and stay fit. Entrepreneur(person in charge) should appoint
maintenance personnel for consistent maintenance of the equipment.
2. Safety Rules for Maintenance & Trouble-shooting
Observe following rules when performing maintenance or trouble-shooting job.
❶ Turn off in-put power source.
❷ Post a label saying 「No Operation」 over the wall socket.
❸ Never start maintenance job while load is hanging.
❹ Maintenance job must be done by maintenance personnel.
❺ When doing maintenance job while PULLEY-MAN is installed in Fixed PULLEY-MAN mode, use a
ladder or a mobile platform for safery.
3. Warning Labels for Danger
Warning labels are attached on PULLEY-MAN for safe use and maintenance job.
Keep the label attached.
23
Ⅳ. Maintenance
4. Labels and Details
Following labels are attached on PULLEY-MAN. Keep them unspoiled for instant reference.
5. Grease Replenishment
Inside speed reducer of PULLEY-MAN is filled with grease. Depending on frequency of operation,
replenish grease at least once a year as a part of maintenance program.
※Grease used: Mos2
6. Assembly and disassembly
Assembly or disassembly must be done by maintenance personnel.
PULLEY-MAN is composed mainly of speed reducer, frame and pulley and is disassembled in
following procedures. Check condition of PULLEY-MAN if there is abrasion or damage at gears,
bushings, bearings, shaft or pulley groove.
❶
Get ready to disassemble
PULLEY-MAN.
❷ Remove frame cover.
Screw off the two M6 bolts and remove
cover from in-put side frame.
24
❸
Pull off In-Let Lock Pins and Press
Roller Casing.
Ⅳ. Maintenance
❹
Take off Hook.
Pull off the nut-holding pin and screw
off hexagon bolt.
❺
Remove Press Roller Casing.
Take off hexagon socket head bolt(M8)
and nut and then remove press roller
casing from between frames.
❻
Remove hexagon socket head
bolt(M8) of Frame Space.
❼
Remove snap ring on in-put side
frame.
❿
Remove Frame Space.
❽
Pull off in-put-side frame from
out-put axis.
Take off pulley from out-put
axles.
25
❾
Remove snap ring which is fixing
pulley on out-put axis.
Remove snap ring which is fixing
out-put-side frame to out-put axis.
Ⅳ. Maintenance
Screw off four hexagon socket
head bolts(M6) which are fixing
speed reducer to frame.
Take off out-put side frame from
out-put axis.
Do not disassemble in-put axis assembly. Once
it is disassembled, it cannot be re-assembled.
When the gears are worn away or damaged by
an external cause, it must be exchanged.
Take off out-put axis from internal
gear casing.
Take off in-put axis assembly
(of planetary and sun gears) from
internal gear casing.
26
Ⅳ. Maintenance
7. Precautions for Re-Assembly
For re-assembly, follow procedures of disassembly in reverse order. When re-assembling, do not
use extraordinary force or impact, which may affect the products life and damage parts and
components. Most of all, do not disassemble in-put axis assembly. Check before re-assembly.
1)
Abrasion and Damage
●
Abrasion at gear, bushing, shaft and pulley groove
●
Deformation of frame
●
Abrasion and rotation of hook and hook cover
2)
Application of Grease
●
Apply grease on gears, bushings and shaft.
●
Apply grease or oil on connection of hook and hook cover.
●
Apply grease on rollers in Press Roller Casing.
●
Disassemble hook block and apply grease on its axis.
3)
Re-assembly
●
Do not give excessive force on gear and axis.
●
Be careful not to damage bushings.
●
Before fixing gear to the frame, apply holding bond on the four hexagon socket head bolts(M6) in advance.
8. Check-Up Points after Re-Assembly
1) Operate PULLEY-MAN without load to see if it is assembled properly.
2) Check if it makes excessive noise.
3) When no problem is detected, incorporate wire rope.
9. Replacement of Parts and Components
Through daily and periodical examination, replace parts or components whose lifetime is due or past with
new ones according to maintenance guidelines.
1) Wire Rope
◈ Conditions and Limits of Usags ◈
●
Less than 10% of elementary strips should break by one twist ( 1 pitch).
●
Less than 7% of wire Ropeʼs diameter should have been reduced.
●
Should not have kink or corrosion.
※
kink: state of wire bended and entangled
●
When replacing wire rope, fix End Stopper at the tip.
●
Treatment of wire tip must be solid without damage, and free of danger of loosening or secession from wire rope.
27
Ⅳ. Maintenance
2) Hook
Must have a latch to keep binding wire rope or chain from slipping off the hook.
Areas most subject to abrasion are gateway and center of hook on which weight lays.
◈ Value Limits of Hook ◈
Gateway
A (mm)
Genter of hook
T (mm)
in.
mm
in.
mm
Normal value
0.72
18.3
0.52
13.15
Limit valueItem
0.8
20.5
0.46
11.8
3) Pulley
Since abrasion at pulley groove occurs by wire rope, check wire rope too when abrasion is detected at pulley groove.
◈ Methods for Recognizing Value Limits of Pulley Groove by Naked Eye ◈
●
After processed and heat-treated, surface of pulley groove is coated with black zinc.
●
When working load, black zinc coating is scratched off down to the point where wire rope does not move
toward bottom of groove any more.
●
As the equipment is continuously used, the scratch line moves toward bottom of groove. The reason that the
scratch line nears toward bottom may be either wire ropeʼs diameter is reduced or pulley groove is worn off.
Time to Replace:
If a new wire rope hanging maximum load touches bottom of groove, it is time to replace pulley.
Item
Measures
Worn Wire Rope touching
bottom off Pulley Groove
1. Replace Wire Rope
2. Paint groove with magic pen
New Wire Rope touching
bottom off Pulley Groove
Replace pulley
4) Gears
When abrasion value(a) reaches 0.15t, it is time to replace it.
28
Ⅳ. Maintenance
10. Daily and Periodical Maintenance
Checking condition of PULLEY-MAN through constant maintenance is critical to its life and user safety.
Keep maintenance schedule always at hand. When trouble(s) occur to the equipment, consult dealer or
manufacturer.
1) Daily Check-up
For safety reason, check below before starting operation.
●
Check if there is loose connection.
●
Check damage or abrasion at wire rope.
●
Check if wire rope is inserted in right direction.
●
Check if wire rope is inserted properly toward pulley and press rollers are pressing wire properly.
●
Check if nuts are screwed up tightly and anti-loosening pins are fixed.
●
Check if hook has a latch and if it works.
●
Check if labels and warning signs are at their positions.
2) Periodical Check-up
Maintenance personnel should make a yearly plan and record damage, abrasion, deformation, malfunction, etc.
in a logbook.
3) Also, consult guidelines set up by government in your location for proper use and maintenance of
PULLEY-MAN.
29
Ⅳ. Maintenance
PULLEY-MAN MAINTENANCE TABLE
Daily Maintenance ☆Monthly Maintenance ★Annual Maintenance
Dividing
Wire
Rope
Hook
Main
Body
In-Put
Power
Source
Maintenance
Daily
Periodical
☆ ★
☆
★
☆
★
☆
☆
☆
★
★
★
★
★
★
☆
☆
☆
Items to Check Method Standards
Snapping of Wire
Abrasion
Deformation &
Corrosion
End Stopper
Gateway
Deformation Naked eyes No warping or twisting.
Latch Naked eyes No abrasion or deformation.
ABrasion & Corrosion Naked eyes No excessive abrasion or corrosion.
Defect & other flaws Naked eyes No kink or other defects
Frame
Gear Case Naked eyes No deformation or corrosion
Gear Measurement No abrasion or corrosion
Bushing Measurement No excessive abrasion or damage.
Press Roller Casing Naked eyes No abrasion, deformation or damage.
Pulley Naked eyes
Accessories Naked eyes No abrasion, damage or corrosion
Hand Drill Measurement
Cordless Hand Drill Measurement
DC 12V Motor Measurement Condition of Switch.
Grounding Measurement Must be completely grounded.
Daily-naked eyes
Peri. -measurement
〃
Naked eyes
〃
Daily-naked eyes
Peri.-measurement
Daily-naked eyes
Peri. -measurement
Less than 10% of elementary strips
should break by one twist (1 pitch).
Less than 7% of dia. is reduced
Should not have kink or corrosion.
Must be firmly fixed at wire tip.
Should not be widened
No deformation or corrosion.
No excessive abrasion or corrosion.
Wire rope must not thouch groove
bottom.(Paint groove with magic pen)
Should perform normally at
90% of required power voltage.
Check condition of rechargeable battery.
30
Ⅳ. Maintenance
11. Trouble-Shooting
Condition Thing(s) to Check Situation Measures
Cannot start
operation
Cannot work
the load.
Slippage
Electric
Accident
Is power on?
Is wire hook
inserted properly?
Is load weight
within capacity?
Slipping during stop mode?
Power leakage
In-put power
switch is turned
off.
In-put power
source produces
excessive noise and heat.
Wire rope abrasion Change wire rope
Pulley groove abrasion Change pulley
Electricity leaked
along main body &
wire rope
※ When operation is abnormal, take measures according to instructions in Trouble-Shooting of this manual.
For other abnormalities, contact your dealer or manufacturer.
☞ Press switch firmly.
☞ Connect power line properly.
☞ Check power cable.
☞ Check power voltage.
☞ Check condition of
in-put power source.
☞ Work load within capacity.
☞ Ground completely.
☞ Check insulation.
☞ Remove moisture and dry up.
12. Education and Training for User
Operator of PULLEY-MAN or maintenance personnel must acquaint himself with daily and periodical check
points and safety rules in this manual. Also, appropriate education must be provided to ensure maintenance
in a timely manner. When troubles arise, take measures according to instructions in Trouble-shooting of this
manual.
31
Ⅴ. LIMITED WARRANTY
Thank you very much for purchasing Pulley-Man. You should be familiar with this user manual for safe
use and high efficiency. It contains essential instructions for maintenance.
1. Warranty service without charge
The warranty service shall apply to:
1) Defects in material and workmanship in normal use.
2) Defects in accessories attached to the machine.
3) Other defects or problems set forth in the warranty information.
2. Warranty service with charge
The warranty service with charge shall apply to:
1) Defects caused after the warranty period.
2) Defects due to improper use by the user.
3) Damages due to acts of God.
4) Defects resulting from unauthorized repair or modification.
5) Troubles due to external causes other than defects in material and workmanship.
6) Troubles due to use of improper voltage.
7) Services to be provided by the userʼs request.
8) Other products not made by PULLEY-MAN CO.,LTD.
3. Exclusions
We shall not be liable for loss, damage or accident resulting from:
1) Unauthorized repair or modification
2) Improper use or misuse by the user
3) Careless use or neglect by the user
4) Improper installation
5) Lifting a person
6) Lifting an expensive equipment with more than twenty million Korean won
7) Use of parts or accessories not approved by us
8) Nonfulfillment of daily or regular check
9) Nonobservance of cautions or warnings
The warranty does not cover loss, damage or accident described above.
We shall not be liable for them.
We will do our best to achieve quality improvement and customer satisfaction.
32
Ⅴ. LIMITED WARRANTY
4. Quality Assurance
Quality Defects
Indemnification
within warranty
period
after warranty
period
Major repair is necessary within
10 days of purchase
Major repair is necessary within
1 month of purchase
Quality
deficiency
or mechnical
defect under
normal
conditions
Mechanical
defect due to
userʼs abuse or
misapplication
▶
Defect or malfunction due to natural disaster such sa fire,
earthquake, flood, thunder, tornado, sea wind and so forth
▶
Defect from misapplication of voltage
▶
Userʼs unauthorized repair/modification on product
▶
Exchange of consumption articles
▶
Discrepancy from other than mechanical defect itself
An exchange needs major repair
within 1 month of purchase
Exchange unavailable
Discrepance Repair (free of charge)
Repairable
Irrepairable
Irrepairable due o lack of parts
Manufacturer lost goods for repair
Damage during delivery
Repairable
Irrepairable
Discrepance
after repair
(4 times)
Eschange or
refund
Exchange
Refund
Repair (charge)
Exchange or
Refund
Exchage
Repair (charge)
Exchange with
charge up to
repairable cost
Repair (charge) Repair (charge)
Refund after
depreciation
amount
Repair (charge)
In accordance
with PULLEY-MAN
U.S.A policy
※ Warranty Period = 1 year from delivery
33
PULLEY-MAN CO.,LTD
CERTIFICATE
OF
INSPECTION AND TEST
This is to certify that the following pulley-man product
has been thoroughly inspected and tested
Single Line
Description : Ton Ft. Lift
Double Line
Model :
Serial# CS-
Load Applied : 125% of Rated Capacity Other
CSW-3060
PULLEY-MAN CO., LTD.
Ⅵ. MEMO
35
Ⅵ. MEMO
36
PULLEY-MAN CO.,Ltd
13-15, Industry material, Sangyeok-2dong
Buk-gu Daegu, 702-010, Republic of Korea
TEL : +82-53-381-4989
FAX : +82-53-604-1317
www.pulleyman.co.kr
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