OPERATOR’S MANUAL
AND
SAFETY INSTRUCTIONS
WITH INSPECTION AND MAINTENANCE INSTRUCTIONS
CIRCULAR ELECTRIC LIFTING MAGNETS
MODELS: CER-5, CER-7, CER-9, CER-12, CER-16, CER-20
CER-20
CER-12
CER-5
WALKER
Always stay clear of
the load.
O.S. Walker Inc., CER Lift Magnet
O.S. WALKER
DANGER
Never lift loads over
people or in close
proximity to people.
I/R CER-7
Never attempt to operate this magnet
until you have read and understand
this Operator’s Manual.
1
CONTENTS
INTRODUCTION ................................................................................................................................... 2
SAFETY INSTRUCTIONS .................................................................................................................... 3
GENERAL SAFETY RULES ......................................................................................................................................3
UNSAFE LIFTING APPLICATIONS FOR YOUR MAGNET ...................................................................................... 4
RECOGNIZE SAFETY INFORMATION ....................................................................................................................4
WAYS TO AVOID A REDUCTION OF LIFTING CAPACITY .....................................................................................5
ADDITIONAL WARNINGS ........................................................................................................................................5
SAFETY PERSON ....................................................................................................................................................5
IMPORTANT FACTS FOR THE OPERATION OF LIFT MAGNETS .................................................... 6
RECOMMENDED LIFTING PROCEDURES ...................................................................................... 10
OPERATING INSTRUCTIONS ............................................................................................................11
MODELS: I/R-CER-5 thru I/R-CER-12 .................................................................................................................... 11
GUIDELINES FOR THE REDUCTION OF THE RATED LIFTING CAPACITY: ................................. 12
ADDITIONAL OPERATING INFORMATION ........................................................................................................... 12
LIFTING GUIDELINES (PLATE) .............................................................................................................................13
LOAD WEIGHT GUIDELINE ...................................................................................................................................15
DUTY CYCLE ..........................................................................................................................................................15
INSPECTION AND MAINTENANCE INSTRUCTIONS ...................................................................... 16
EVERY LIFT ............................................................................................................................................................16
WEEKLY ..................................................................................................................................................................16
DAILY.......................................................................................................................................................................16
SPECIFICATION & PARTS LIST ........................................................................................................ 17
REPAIRS .................................................................................................................................................................18
CER-5, 7 & 9 Replacement Parts List ..................................................................................................................... 19
CER-12 Replacement Parts List .............................................................................................................................. 20
CER-12 with PC Board Replacement Parts List ...................................................................................................... 21
I/R-CER-5 THRU 12 Replacement Parts List ..........................................................................................................22
CER-16 & 20 Replacement Parts List ..................................................................................................................... 23
INTRODUCTION
Thank you for purchasing this O.S. Walker Product. If used and maintained properly, it should
serve you for many years. Thousands of O. S. Walker lift magnets are in service today doing safe, fast,
and efcient magnetic material handling applications. It is often the only way for one person to load,
transport, and unload material.
O.S. Walker Products have proven to be among the best designed and safest in our industry.
However, if used improperly, any CER magnet can be rendered inefcient and unsafe. Therefore, it is
absolutely essential that anyone who uses this lifting magnet and is responsible for its application be
trained on how to use it correctly.
READ THIS MANUAL CAREFULLY TO LEARN HOW TO OPERATE AND MAINTAIN YOUR
MAGNET. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH, TO YOURSELF
AND PEOPLE IN THE AREA.
THIS MANUAL AND SAFETY CD SHOULD BE CONSIDERED A PERMANENT PART OF
YOUR MAGNET AND SHOULD ALWAYS BE AVAILABLE TO ALL OPERATORS AND REMAIN
WITH THE MAGNET IF IT IS RE-SOLD.
To request additional copies of this manual #37-DD10505 call 1-800-962-4638 in the USA;
In Canada: 905-643-3338; In Europe: 31-4973-83835.
O.S. Walker Inc., CER Lift Magnet
2
SAFETY INSTRUCTIONS
GENERAL SAFETY RULES
Danger always exists when loads are transported by lifting devices, especially
when the equipment is not being used properly or is poorly maintained. Because accidents and severe bodily injury or death can result, special safety precautions apply
to the operation, inspection, and maintenance of the Walker Lift Magnets.
Following these simple rules can help to avoid lifting accidents:
DANGER
Always stay clear of the load.
Never lift loads over people or in close proxim-
ity to people.
Never attempt to operate this magnet until you
read and understand the Operator’s Manual.
Never use this magnet to lift, support or trans-
port people.
Never leave any lifted load unattended.
Never lift more than one work piece at a time
with this magnet.
Always make sure that the supporting struc-
ture and load attaching devices (i.e. crane,
chains and hook) are rated to support the
weight of the magnet and load.
Always make sure that the load’s weight and
dimensions are within the Magnet’s Lifting
Guidelines. These Guidelines are located in
the Operator’s Manual.
Always let those near you know that a lift is to
begin.
Remember, proper lifting knowledge and techniques are the responsibility of the operator. Be sure to read and understand the instructions and safety warnings contained in
this manual before using your magnet.
If you do not understand everything in this manual contact O.S. Walker for assistance
before using the magnet.
Call 1-800-W-MAGNET
(In Canada: 905-643-3338; In Europe: 31-4973-83835.)
O.S. Walker Inc., CER Lift Magnet
IN THE USA;
3
SAFETY INSTRUCTIONS
RECOGNIZE SAFETY INFORMATION
This is the safety alert symbol. When you see this symbol on
your magnet or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operat-
ing practices at all times.
DANGER
Red Background, White Letters
WARNING
Orange Background, Black Letters
CAUTION
Yellow Background, Black Letters
UNSAFE LIFTING APPLICATIONS FOR YOUR MAGNET
This indicates a situation in which a hazard
is imminent and will result in a high probability of serious injury or death.
This indicates a potentially hazardous situation, which could result in some probability of serious injury or death.
This indicates a potentially hazardous situation, which could result in minor injury or
moderate injury.
DANGER
Never lift any pipe, solid round or struc-
tural shapes with this magnet.
Never lift any castings that do not have
a machined at lifting surface for the
magnet. The location of the lifting surface should be such to permit the load
to remain level when lifted.
These Hazard
Signal Words
Deserve your
Full Attention
O.S. Walker can provide other type magnets for these applications.
For Model CER type magnets see Lifting Guidelines on Page 11.
DANGER
Never lift a load by its narrowest
dimension.
If you have any difculty lifting a load, DON’T LIFT IT!
WARNING
4
Call Walker for advice at 1-800-962-4638
O.S. Walker Inc., CER Lift Magnet
SAFETY INSTRUCTIONS
WAYS TO AVOID A REDUCTION OF LIFTING CAPACITY
DANGER
To Avoid any Reduction of Lifting Capacity:
The lifting surfaces of the magnet and the area of the load where the magnet will
be located must be clean, smooth, at and free of nicks and burrs.
The full area of the magnet’s lifting surface must be in contact with the load.
The load must be at least 1.0" (24.5 mm) thick for CER-5, 1.5” (38.1 mm) for CER-
7, 2” (51 mm) for models CER-9 through 12 and at least 2.5” (63 mm) for models
CER-16 and 20.
The load must be low carbon steel such as SAE 1020.
The magnet’s lifting surface must stay level and the contacting surface of the load
remain at.
The temperature of the magnet and/or the load must not be greater than 110°F
(43°C).
Repair of this magnet should only be done by the O. S. Walker Co. or a Qualied
Person.*
Do not exceed the magnet duty cycle. Exceeding the duty cycle will result in
reduced lifting capacity.
If you have any difculty lifting a load, DON’T LIFT IT! Call O. S. Walker for advice
at 1-800-962-4638.
ADDITIONAL WARNINGS
WARNING
Never lift loads with any dimension greater than
those shown in the LIFTING GUIDELINES.
Never operate damaged or malfunctioning mag-
nets.
Never remove or damage Operating and Warning
labels.
Persons using pacemakers or other medical de-
vices should not use this magnet until they have
consulted with their physician.
If your magnet was provided with a remote
control unit, NEVER place the control unit in a
position where the switch could be accidentally
turned to “OFF”, “DROP”, OR “LIFT”.
Disassembly or repair of this magnet can result in
reduced holding power and/or cause an unsafe
condition. Therefore, anytime the magnet is disassembled beyond the parts list shown in this manual,
the magnet must be re-tested for breakaway force
in accordance with the test described in ANSI/
ASME B30.20.
Modication of any operating mechanism or
structure of this magnet can reduce the magnet’s
effectiveness and/or cause an unsafe condition.
Repair or modication of this magnet should only be
done by O.S. Walker*.
WARNING
SAFETY PERSON
O.S. Walker recommends that a person be assigned to review all magnetic
handling applications for these magnets to ensure that safe practices and
procedures are being followed.
*Walker replacement parts may be installed by a **Designated Person.
** Designated Person - A person selected or assigned by the employer as being competent to
replace specic replacement parts listed in this manual and is able to verify the proper functioning
of the specic replacement parts and the entire product after the completion of the installation.
O.S. Walker Inc., CER Lift Magnet
5
IMPORTANT FACTS FOR THE
OPERATION OF LIFT MAGNETS
LOAD CHARACTERISTICS OTHER THAN JUST WEIGHT
MUST BE CONSIDERED IN ORDER TO DETERMINE
THE LOAD THAT ANY MAGNET CAN LIFT.
This statement is true for all lifting magnets because they all operate using the same fundamental laws of physics. Magnetic power is often pictured as lines of magnetic force owing
from north pole to south pole. Anything that limits the ow of these magnetic lines of force
obviously reduces the magnet’s lifting capacity. There are many important factors which limit
the ow of these lines of force.
1. LOAD THICKNESS
The greater the number of lines of magnetic force owing from a magnet into the load,
the greater the effectiveness of the magnet. The thicker the load, the more lines of magnetic force are able to ow. After a certain thickness of load, no additional lines of force
will ow because the magnet has reached its full capacity.
Thin material (load) means less iron available, and thus fewer lines of magnetic force
ow from the magnet into the load. Therefore, the lifting capacity of the magnet is
reduced. In some cases the magnet will attract more than one thin plate of material
when set on a stack of thin plates. DO NOT LIFT more than one plate at a time since
the lower plate may not be held sufciently.
The lifting guidelines provide the user with what minimum thickness of load is re-
quired to reach full lifting capacity. Below such thickness of load, the user must accept the reduced lifting capacity of the magnet as shown in the guidelines.
2. SURFACE CONDITIONS
Magnetic lines of force do not ow easily through air. They need iron in order to ow
freely; therefore, anything that creates a space or an air gap between a magnet and the
load limits the ow of magnetic lines of force and, thus, reduces the lifting capacity of a
magnet.
MAGNET’S LIFTING SURFACE CONDITION — The lifting surfaces of a magnet
must be clean, smooth, at and free of nicks and burrs to minimize the air gap between a magnet and the load. This magnet has been designed with soft, low carbon
steel lifting surfaces in order to maximize the lifting capacity; therefore, special care
must be taken to protect these surfaces. Follow the Inspection Instructions in this
manual. Attaching or welding other materials to the lifting surfaces in order to reduce
wear should not be done with this magnet because it will reduce the lifting capacity.
LOAD SURFACE CONDITION — Paper, dirt, rags, rust, paint, and scale act
the same as air. Also, a rough surface nish on the load creates an air gap between the magnet and load. Any of these conditions will reduce the magnet’s
lifting capacity.
O.S. Walker Inc., CER Lift Magnet
6
3. LOAD ALLOY
Low carbon steels, such as SAE 1020 steel, are nearly as good conductors of magnetic
lines of force as pure iron. However, many other alloys contain non-magnetic materials
which reduce the ability of magnetic lines of force to ow into the load. An alloy such as
SAE 300 series of stainless steel is almost as poor a conductor of magnetic lines of force
as air.
Type 416 stainless steel is considered magnetic, but it contains enough chromium
so that a magnet can develop only one-half as much force on a type 416 stainless
steel load as it can on a SAE 1020 steel load. Also, because of the carbon content,
the force developed on cast iron is less than one-half of that developed on SAE 1020
steel. (Chilled cast iron further reduces the force to less than one-quarter.)
4. LOAD LENGTH OR WIDTH
As the length or width of a load increases, it ceases to remain at when lifted and the
edges begin to droop. This drooping or sagging of the load can create an air gap between
the load and the magnet. This is called peel. If this occurs, the lifting capacity of the magnet is greatly reduced.
For plate lifting, where drooping often occurs, rectangular shaped magnets must be positioned so that the length of the magnet is parallel to the width of the load.
5. POSITION OF MAGNET’S LIFTING SURFACE
As the position of the magnet’s lifting surface changes from horizontal to vertical, the lifting capacity of the magnet decreases. When the magnet’s lifting surfaces are vertical, the
lifting capacity of the magnet is minimum and dependent upon the coefcient of friction
between the magnet’s lifting surface and the load.
6. PORTION OF MAGNET SURFACE IN CONTACT WITH
LOAD
The full surface of the magnet must contact the load if the magnet is to achieve rated lift
capacity.
7. LOAD TEMPERATURE
The temperature of the load can cause damage to the magnet and, if high enough, can
even change the magnetic characteristics of the load. For Standard Lift Magnets, Walker
should be consulted if the load or air temperature exceeds 110° F (43° C).
O.S. Walker Inc., CER Lift Magnet
7
SAFETY
FOR FAST, EASY LIFTING WITH YOUR WALKER LIFT
1 NEVER
attempt to operate
this lift magnet until you
read and understand the
OPERATOR’S MANUAL &
SAFETY INSTRUCTIONS
(Manual #37-DD10505)
for CER Lifting Magnets.
MAGNET
2
Check the condition of the magnet prior to
every lift. WIPE clean the bottom of the magnet
and the area on the load where the magnet will
be located. File away burrs.
5 6
Check to be sure no one is near the load to be
lifted. Inform others in the area that a lift is to begin. Lift the load 2 to 3 inches (50 to 75 mm) and
then jar the load to insure that adequate holding
power is available.
ALWAYS STAY CLEAR OF THE LOAD.
If you have any difculty lifting a load, DON’T LIFT IT.
Ask your supervisor for help or call O.S. Walker Co.,
Inc., for advice at 1-800-W-MAGNET
8
When working in an area using lifting magnets, wear safety
glasses, work gloves, steel-toed shoes and a safety hat.
Lift and move the load SMOOTHLY. Avoid jarring
and swinging the load while it is in transit. KEEP
THE LOAD LEVEL. NEVER let the load come in
contact with any obstruction.
O.S. Walker Inc., CER Lift Magnet
RULES
MODELS: CER-5 thru CER-20
3
Position the magnet so the load remains level.
& I/R-CER-5 thru I/R-CER-12
4
Energize the magnet by selecting the “LIFT”
position. An indicator light will illuminate
when electrical power is applied to the
magnet. To obtain maximum lift, allow a few
seconds for the magnet to reach full power
before lifting load.
7
ALWAYS STAY
CLEAR OF THE LOAD.
Guide the load by pushing or pulling the edges.
This keeps your entire body clear of the load at all
times. DO NOT guide the load by pushing or pulling the Magnet. NEVER get in a position where
you could get hit with load if it is dropped.
NEVER re-energize the magnet until it has been placed in contact with the load to
CAUTION
O.S. Walker Inc., CER Lift Magnet
be lifted. Prematurely energizing the magnet could cause unwanted materials to
be attracted to the magnet. PERSONAL INJURY MAY RESULT.
8
Carefully set the load down. De-energize
the magnet by selecting the “DROP” position. Hold for two to three seconds, when
released the magnet will return to the
“OFF” position. Then lift the magnet slightly
to be sure the load has been released.
9
RECOMMENDED LIFTING PROCEDURES
SAFETY HOOK LATCH
Always use a safety hook latch on your
crane hook to hold your magnets.
STAY CLEAR OF THE LOAD
Guide the load by pushing or pulling the
edges of the load.
Keep your entire body clear of the load
at all times.
PLATE LIFTING
Position the magnet so that it is centered
on the plate. Never lift any plate less
than 1/4” (6mm) thick. (See Important
Facts 2 & 4).
BAR LIFTING
When the load width is greater than the
magnet diameter, position the magnet
length so the entire lifting surface of the
magnet is in contact with the load.
When the load width is narrower than the
magnet’s diameter, position the magnet
so that it is centered on the width of the
load.
10
UNSAFE LIFTING APPLICATIONS FOR YOUR CER MAGNET
DANGER
• Never lift any pipe, solid round or struc-
tural shapes with this magnet.
• Never lift any castings that do not have
a machined at lifting surface for the
magnet. The location of the lifting surface should be such to permit the load
to remain level when lifted.
Never lift loads with any dimension greater than:
5 feet (1.5 meters) with CER-5 10 feet (3.1 meters) with CER-12
6 feet (1.8 meters) with CER-7 12 feet (3.7 meters) with CER-16
WARNING
8 feet (2.4 meters) with CER-9 15 feet (4.6 meters) with CER-20
If you have any difculty lifting a load, DON’T LIFT IT!
Call Walker for advice at 1-800-962-4638
DANGER
• Never lift a
load by its
narrowest
dimension.
O.S. Walker Inc., CER Lift Magnet
OPERATING INSTRUCTIONS
MODELS: I/R-CER-5 thru I/R-CER-12
LOCAL PUSH BUTTON OPERATION:
“LIFT MODE”
To Energize the Magnet press and hold the “LIFT” push button until the green ring of the pushbutton
illuminates. The magnet is now in the full “ON” position and will remain on until a release is selected.
As a safety reminder the green lift led will begin to ash after 10 minuets in the “LIFT MODE” indicating you maybe exceeding the magnets rated duty cycle.
“RELEASE MODE”
To De-Energize the magnet press and hold both of the “RELEASE” push buttons until the red rings
of the pushbuttons illuminate this indicates a release pulse is being sent to the magnet. For models
I/R-CER-5 and I/R-CER-7 one to three pulses will be needed to achieve a clean release of the work
piece. For models I/R-CER-9 and I/R-CER-12 three to ve pulses will be needed to achieve a clean
release of the work piece. When the two release push buttons are released the magnet will return to
the off position. There is maximum of twelve release pulses for each release cycle.
REMOTE CONTROL OPERATION:
Check the remote control to verify that the 9-volt battery has been installed. (Alkaline type)Then check
by pressing the Green “LIFT” button while checking the small, Red, LED light at the top center of the
remote. If battery is installed LED should ash when the button is depressed.
With the I/R-CER magnet connected to power point the remote control at the I/R lens above the local
lift drop push buttons. Press and hold the remotes Green “LIFT” button and the top Red “RELEASE”
button simultaneously, the Green lift LED and the 1st Red drop LED will ash hold both buttons until
LED’s stop ashing. This should take about 5 seconds. The I/R remote control is now programmed
and ready for use with your magnet.
Perform a trial lift / drop to verify that the remote is properly programmed. Aiming the remote toward
the magnets I/R lens press and hold the Green “LIFT” button on the remote until the locals Green
“LIFT” LED illuminates. This indicates the magnet is now in the full “ON” position. Press and hold the
two Red “RELEASE” buttons on the remote, both of the local Red “RELEASE” LED’s will ash indicating a release pulse is being sent to the magnet. Operators can select from one to twelve pulses
to achieve a clean release from work piece. When the remotes two release buttons are released the
magnet will return to the off position. The remote control should operate your magnet between one
and fteen feet.
O.S. Walker Inc., CER Lift Magnet
11
GUIDELINES FOR THE REDUCTION OF
THE RATED LIFTING CAPACITY:
CAUTION
: Each Walker magnet model is rated for a different weight limit. Load characteristics will
affect the lifting capacity of the magnets. The lifting guidelines for the various models are shown on the
following pages.
The Lifting Guidelines charts show the effect of air gap, load thickness, load length, and load width on
lifting capacity. As the thickness of the load decreases, so does the rated lifting capacity of the magnet. The tables show the maximum weight or load size, which can be lifted for each thickness under
varying air gap conditions. DO NOT EXCEED EITHER THE MAXIMUM WEIGHT OR SIZE FOR
EACH THICKNESS.
Each value shown on the Lifting Guidelines charts is for SAE 1020 steel, and any increase in alloy
content will result in further reduction of the lifting capacity of the magnet.
THIS TABLE PROVIDES SOME REDUCTION
MATERIAL OTHER THAN SAE 1020 STEEL
Materials
Cast Steel 0.90
3% Silicon Steel 0.80
SAE 1095 Steel 0.70
FACTORS FOR
Reduction Factors for Materials
Other than SAE 1020 Steel
REDUCTION FACTOR
416 Stainless Steel 0.50
Cast Iron (non-chilled) 0.45
Pure Nickel 0.10
For Other Materials Consult O.S. Walker
Rated lift Capacity (For these materials) = Reduction Factor multiplied by Maximum Load Value (For 1020
Steel) from Lifting Guidelines (plate). See page 12.
Example: Lifting SAE 1095 STEEL, ½” thick, ROUGH machined at surfaces (use .020” air gap) with a Model
CER-9 lifting magnet.
Rated Lift Capacity = 0.70 multiplied by 600 = 420 pounds.
ADDITIONAL OPERATING INFORMATION
Avoid dropping, banging, or slamming the magnet into other objects.
These lifting magnets are electromagnetic devices. Therefore, do not allow water to enter the magnet body. Water is
an electrical conductor and could short out the magnet.
DO NOT EXCEED THE RATED 50% DUTY CYCLE OF THESE MAGNETS. (Exceeding the duty cycle will result in
reduced lifting capacity and a shorter magnet life.) (Refer to Page 14 for denition of Duty Cycle.)
If you have any difculty lifting a load, DON’T LIFT IT!
WARNING
Call Walker for advice at 1-800-962-4638
12
O.S. Walker Inc., CER Lift Magnet
MAGNET
MODELS
CER-5
CER-7
LIFTING GUIDELINES (PLATE)
CER-5, CER-7, and CER-9 (plate)
TYPE OF SURFACE CONDITION
CLEAN & SMOOTH
LOAD
THICK-
NESS
Over 1” 600 - 400 - 370 -
* 1” 600 3 x 4 400 3 x 3 370 3 x 3
*3/4” 530 4 x 4 375 3 x 4 350 3 x 3
*1/2” 480 4 x 5 350 4 x 4 330 4 x 4
*3/8” 400 5 x 5 275 4 x 4 200 3 x 4
*1/4” 180 4 x 4 150 3 x 4 125 3 x 4
Over 1-1/2” 1200 - 1100 - 900 -
*1-1/2” 1200 4 x 4 1100 4 x 4 900 3 x 4
*1” 1000 4 x 5 950 4 x 5 900 4 x 5
*3/4” 850 5 x 5 775 5 x 5 700 4 x 5
*1/2” 700 5 x 6 650 5 x 6 550 5 x 5
*3/8” 450 5 x 5 420 5 x 5 400 5 x 5
*1/4” 200 4 x 4 190 4 x 4 180 4 x 4
Similar to a Flat
(32 micro-inch RMS)
Ground Surface
.000” Max. Air Gap †
Max. Load
(lbs.)
NEVER LIFT ANY LOAD WITH ANY DIMENSION GREATER THAN 5 FEET
NEVER LIFT ANY LOADS WITH ANY DIMENSION GREATER THAN 6 FEET
NEVER LIFT ANY LOADS WITH ANY DIMENSION GREATER THAN 8 FEET
Max. Size
(ft.)
RUST OR SCALE
Similar to a Flat Hot
Rolled
Steel Surface
.010” Max. Air Gap †
(.254mm)
Max. Load
(lbs.)
Max. Size
(ft.)
IRREGULAR OR ROUGH
Similar to a Flat Smooth
Cut File
.020” Max. Air Gap †
(.508mm)
Max. Load
(lbs.)
Max. Size
(ft.)
Over 2” 2400 - 2300 - 2000 -
*2” 2400 5 x 5 2300 5 x 5 2000 4 x 5
*1-1/2” 2200 6 x 6 2100 5 x 6 1800 5 x 5
CER-9
*1” 1700 6 x 6 1550 6 x 6 1400 5 x 6
*3/4” 1400 6 x 7 1300 6 x 7 1250 6 x 6
*1/2” 700 5 x 6 650 5 x 6 600 5 x 5
*3/8” 525 5 x 6 480 5 x 6 450 5 x 5
*1/4” 250 4 x 5 220 4 x 5 200 4 x 4
* LIFTING CAPACITY AFFECTED BY PEEL AND THICKNESS. SEE NOTES 1 & 4 OF THE “IMPORTANT FACTS” (PAGE 6 & 7) IN THIS INSTRUCTION MANUAL.
† SEE NOTE 6 OF THE “IMPORTANT FACTS” (PAGE 7) IN THIS INSTRUCTION MANUAL. ALSO READ RECOMMENDED LIFTING PROCEDURES
(PAGE 10).
Values shown are for maximum rated capacities when operating instructions and warnings are followed.
Values are based upon SAE 1020.
Higher alloy steels and other magnetic materials will require further reductions of these rated capacities.
(See Guidelines for the Reduction of Rated Lifting Capacity page 11.)
O.S. Walker Inc., CER Lift Magnet
13
LIFTING GUIDELINES (PLATE)
CER-12, CER-16, and CER-20 (plate)
MAGNET
MODELS
CER-12
CER-16
TYPE OF SURFACE CONDITION
CLEAN & SMOOTH
LOAD
THICK-
NESS
Over 2” 4000 - 3850 - 3475 -
*2” 4000 7 x 7 3850 6 x 7 3475 6 x 7
*1-1/2” 3500 7 x 8 3250 7 x 7 3000 7 x 7
*1” 2800 8 x 8 2600 7 x 8 2300 7 x 8
*3/4” 2100 8 x 8 2000 8 x 8 1900 7 x 8
*1/2” 1100 7 x 7 1050 7 x 7 1000 7 x 7
*3/8” 600 6 x 6 550 6 x 6 500 5 x 6
*1/4” 300 5 x 5 250 4 x 5 200 4 x 4
Over 2-1/2” 7250 - 6750 - 6250 -
*2-1/2” 7250 8 x 8 6750 8 x 8 6250 7 x 8
*2” 6000 8 x 9 5500 8 x 8 5000 7 x 8
*1-1/2” 5000 9 x 9 4600 8 x 9 4300 8 x 8
*1” 4000 9 x 10 3750 9 x 10 3500 8 x 9
*3/4” 2500 9 x 9 2300 8 x 9 2200 8 x 8
*1/2” 1300 7 x 8 1200 7 x 8 1100 7 x 7
*3/8” 750 7 x 7 700 6 x 7 600 6 x 6
*1/4” 350 5 x 6 300 5 x 5 250 4 x 5
Similar to a Flat
(32 micro-inch RMS)
Ground Surface
.000” Max. Air Gap †
Max. Load
(lbs.)
NEVER LIFT ANY LOADS WITH ANY DIMENSION GREATER THAN 10 FEET
NEVER LIFT ANY LOADS WITH ANY DIMENSION GREATER THAN 12 FEET
NEVER LIFT ANY LOADS WITH ANY DIMENSION GREATER THAN 15 FEE
Max. Size
(ft.)
RUST OR SCALE
Similar to a Flat Hot
Rolled
Steel Surface
.010” Max. Air Gap †
(.254mm)
Max. Load
(lbs.)
Max. Size
(ft.)
IRREGULAR OR ROUGH
Similar to a Flat Smooth
Cut File
.020” Max. Air Gap †
(.508mm)
Max. Load
(lbs.)
Max. Size
(ft.)
Over 2-1/2” 10500 - 9800 - 9200 -
*2-1/2” 10500 10 x 11 9800 10 x 10 9200 10 x 10
*2” 10000 11 x 11 9500 10 x 11 9000 10 x 11
CER-20
*1-1/2” 8000 11 x 12 7600 11 x 11 7200 10 x 11
*1” 5500 11 x 12 5200 11 x 11 5000 10 x 11
*3/4” 3000 10 x 10 2800 9 x 10 2600 9 x 9
*1/2” 1500 8 x 9 1400 8 x 8 1300 7 x 8
* LIFTING CAPACITY AFFECTED BY PEEL AND THICKNESS. SEE NOTES 1 & 4 OF THE “IMPORTANT FACTS” (PAGE 6 & 7) IN THIS INSTRUCTION MANUAL.
† SEE NOTE 6 OF THE “IMPORTANT FACTS” (PAGE 7) IN THIS INSTRUCTION MANUAL. ALSO READ RECOMMENDED LIFTING PROCEDURES
(PAGE 10).
Values shown are for maximum rated capacities when operating instructions and warnings are followed.
Values are based upon SAE 1020.
Higher alloy steels and other magnetic materials will require further reductions of these rated capacities.
(See Guidelines for the Reduction of Rated Lifting Capacity page 11.)
O.S. Walker Inc., CER Lift Magnet
14
LOAD WEIGHT GUIDELINE
To estimate the weight of a steel work piece, rst determine the volume of the Load in cubic
inches. Then multiply the volume (cubic inches) by the density of steel (.283) pounds per
cubic inch.
Load Weight (steel) = (volume) multiplied by (density)
= (W x T x L) x (.283)
Example: What is the weight of a 10” wide x 5” thick x 96” long piece
of steel?
Load Weight = (10 x 5 x 96) x (.283) = 1358 lbs
DO NOT EXCEED THE RATED 50% DUTY CYCLE OF THESE MAGNETS. (Exceeding the duty cycle will result
in reduced lifting capacity, and a shorter magnet life.)
Duty cycle rating (D.C.%) is dened as:
(Time On x 100) / (Time Off + Time On) = D.C. % and is expressed as a Percent (with a maximum of 10 minutes
Time On).
Therefore, to maximize the effectiveness of your magnet, keep the power off when the magnet is not in use.
EXAMPLES:
3 MINUTES ON, 1 MINUTE OFF EQUALS: (3 x 100) / (3 + 1) = 75%
5 MINUTES ON, 5 MINUTES OFF EQUALS: (5 x 100) / (5 + 5) = 50%
WARNING
O.S. Walker Inc., CER Lift Magnet
DUTY CYCLE
If you have any difculty lifting a load, DON’T LIFT IT!
Call Walker for advice at 1-800-962-4638
15
INSPECTION AND MAINTENANCE INSTRUCTIONS
EVERY LIFT
Keep the lifting surfaces of the magnet CLEAN, SMOOTH, FLAT, FREE OF RUST and any
FOREIGN MATERIALS. Nicks and burrs on the lifting surfaces will reduce the lifting capacity. If burrs occur, they can be removed by ling them away. However, care must be taken to
protect the neighboring lifting surfaces.
Deep nicks may require regrinding of the entire lifting surfaces. (See Weekly Inspection In-
structions)
Check to assure indicator light has illuminated after selecting the “lift “when the switch is
turned to the “LIFT” position.
DAILY
Check the entire magnet’s case, lifting surfaces, bail or eyebolts, and welds for cracks or
other defects. If present, DO NOT USE THE MAGNET - Contact a Qualied Person or O.S.
Walker.
Check the eyebolt or lift bail for wear. If the eyebolt or lift bail is worn to 80% of its original
dimension, it should be replaced. Retighten the eyebolt if loose.
Check physical condition of power cord, lamp, and switch. Repair or replace any suspicious
components. Also, check that the twist lock type electric connector is securely attached to
the electrical receptacle.
Check the condition of the Operating Instruction label and Product Safety signs. Your mag-
net was supplied with one (1) Lifting Guidelines/Operating Instruction label and one (1) Product Safety sign. If these labels and signs are missing or damaged, they should be replaced.
WEEKLY
The lifting surfaces of the magnet should be checked for atness and wear. Uneven wear
and out of atness can greatly reduce the lifting capacity because it will cause a non-magnetic separation (air gap) between the magnet and the at surface of the load. Some nicks
and burrs will occur on the lifting surfaces due to normal usage. However, when the at
contact area of the entire magnet’s lifting surfaces becomes less than 90% of the original
total lifting surface, it should be taken out of service until the lifting surfaces are reground.*
Check the rigid epoxy of the encapsulated coil. Contact O.S. Walker or a Qualied Person
for repair instructions.
*Regrinding the lifting surfaces.
If regrinding is necessary, all the lifting surfaces must remain at and in the same plane.
After regrinding, the magnet must be re-tested for breakaway force in accordance with the
test described in ANSI/ASME B30.20.
O.S. Walker recommends that your lifting magnet be re-tested for breakaway force each year.
O.S. Walker Inc., CER Lift Magnet
16
SPECIFICATION & PARTS LIST
SPECIFICATIONS
Model No. CER-5 CER-7 CER-9 CER-12 CER-16 CER-20 I/R-CER-5 I/R-CER-7 I/R-CER-9 I/R-CER-12
Power
(Watts)
Net Wt. (LBS) 23 43 94 142 320 560
H2 9.75” 11.25” 11.75” 13.63” 14.5” 15”
Diameter “A” 5.12” 6.75” 9” 12” 16” 20”
Figure No. 1 1 1 2 3 3
58 80 135 340 545 1050
PERFORMANCE RATING ON SAE 1020
STEEL
CER-5 0-600 lbs. Rated Lift
CER-7 0-1,200 lbs. Rated Lift
CER-9 0-2,400 lbs. Rated Lift
CER-12 0-4,000 lbs. Rated Lift
CER-16 0-7,250 lbs. Rated Lift
CER-20 0-10,500 lbs. Rated Lift
FIGURE 1
58 80 135 340
30 50 101 142
10.25” 11.75” 12.25” 13.63”
5.12” 6.75” 9” 12”
4 4 4 4
FIGURE 2
FIGURE 3
O.S. Walker Inc., CER Lift Magnet
REPLACEMENT PARTS DIAGRAMS & LISTS
CER-5 See Page 19
CER-7 See Page 19
CER-9 See Page 19
CER-12 See Page 20
CER-12 with PC
Board
I/R CER-5 THRU 12 See Page 22
CER-16 See Page 23
CER-20 See Page 23
See Page 21
FIGURE 4
17
REPAIRS
For repair of your lift magnet, contact O.S. Walker for you’re nearest Authorized Service
Center TOLL FREE at 1-800-W-MAGNET. A return material authorization number will
be issued along with the address of the nearest Authorized Service Center. Your magnet, after receipt by the Service Center will be inspected and a free estimate of repair
charges will be provided. Authorization for repairs from magnet owners must be given to
the O.S. Walker Service Center before repairs are made. Transportation charges, both
to and from the factory, are to be paid by the magnet owner.
WARNING
Disassembly or repair of this magnet can result in reduced hold-
ing power and/or cause an unsafe condition. Therefore, anytime
the magnet is disassembled beyond the parts list shown in this
manual, the magnet must be re-tested for breakaway force in
accordance with the test described in ANSI/ASME B30.20.
Modication of any operating mechanism or structure of this
magnet can reduce the magnet’s effectiveness and/or cause
unsafe conditions.
Repair or modication of this magnet should only be done by
O.S. Walker.*
*Walker replacement parts may be installed by a **Designated Person.
** Designated Person - A person selected or assigned by the employer as
being competent to replace specic replacement parts listed in this manual and
is able to verify the proper functioning of the specic replacement parts and the
entire product after the completion of the installation.
This product is manufactured in accordance with ANSI/ASME B30.20
For further information, refer to Chapter 20-3 Close Proximity Operated Lifting Magnets.
O.S. Walker Inc., CER Lift Magnet
18
SPECIFICATION & PARTS LIST
WARNING: IMPROPER WIRING CAN RESULT IN REDUCED HOLDING POWER.
CER-5, 7 & 9 Replacement Parts List
ITEM
N0.
1 HOUSING 44-BB9185 44-BB9185 44-BB9185
2 INDICATOR ASSY 54-DD14747 54-DD14747 54-DD14747
3 PLUG, TWIST LOCK 11-2001 11-2001 11-2001
3a RECEPTACLE, TWIST LOCK 11-2010 11-2010 11-2010
4 CORD STRAIN RELIEF 14-1101 14-1101 14-1101
5 AC CORD ASSY 56-DD14748 56-DD14748 56-DD14748
6 PCB ASSY 56-BXM4351-1 56-BXM4351-2 56-BXM43513
7 EYEBOLT ASSY 54-DD14437 54-DD14437 54-DD14437
8 MAGNET ASSY 54-BB12693 54-BB12694 54-BB12695
9 THREAD LOCKING ADHESIVE 36-4015 36-4015 36-4015
10 ELECTRICAL ASSY 54-AA8893-1 54-AA8893-2 54-AA8893-3
11 OPERATING INSTRUCTIONS 37-DD12082 37-DD12082 37-DD12082
12 LIFTING GUIDELINES 37-DD12083 37-DD12084 37-DD12085
13 DANGER TAG 37-DD11636 37-DD10666 37-DD10963
14 DANGER TAG 37-DD11637 37-DD10667 37-DD10667
15 REMOTE ASSY 54-BXM4408 54-BXM4408 54-BXM4408
16 RIGID EPOXY PATCH KIT 06-DD14974 06-DD14974 06-DD14974
PART DESCRIPTION
CER-5 CER-7 CER-9
PART NO.
O.S. Walker Inc., CER Lift Magnet
19
SPECIFICATION & PARTS LIST
WARNING: IMPROPER WIRING CAN RESULT IN REDUCED HOLDING POWER.
CER-12 Replacement Parts List
ITEM
NO.
1 INDICATOR ASSY 56-DD14747
2 PLUG, TWIST LOCK 11-0201
3 RECEPTACLE, TWIST LOCK 11-2010
4 CORD STRAIN RELIEF 17-0014
5 AC CORD ASSY 54-DD14856
6 RECTIFIER ASSY 54-DD11298A
7 TOGGLE SWITCH 15-1010
8 TINNERMAN CLIP 18-4026
9 ELECTRICAL ASSY 54-AA9227
10 MAGNET ASSY W/COIL 54-AA8075
11 OPERATING INSTRUCTIONS 37-DD12082
12 LIFTING GUIDELINES 37-DD12086
13 DANGER TAG 37-DD10963
14 DANGER TAG 37-DD10667
15 EYEBOLT ASSY 54-DD14437
16 REMOTE ASSY 54-BXM2999-10
17 RESISTOR REPAIR KIT 54-DD14929
18 SUPPRESSION RESISTOR REPAIR KIT 54-DD14930
19 SUPPRESSOR REPAIR KIT 54-DD14931
20 RIGID EPOXY PATCH KIT 06-DD14974
PART DESCRIPTION PART NO.
20
O.S. Walker Inc., CER Lift Magnet
SPECIFICATION & PARTS LIST
WARNING: IMPROPER WIRING CAN RESULT IN REDUCED HOLDING POWER.
CER-12 with PC Board Replacement Parts List
ITEM
NO.
1 HOUSING 44-CC9887
2 INDICATOR ASSY 56-DD14747
3 PLUG, TWIST LOCK 11-0201
3A RECEPTACLE, TWIST LOCK 11-2010
4 CORD STRAIN RELIEF, AC 17-0014
5 AC CORD ASSY 54-DD14856
6 PCB ASSEMBLY COMPLETE 56-BXM4872
7 EYEBOLT ASSEMBLY 54-DD14437
8 MAGNET ASSEMBLY W/COIL 54-AA8075
9 THREAD LOCKING ADHEASIVE 36-4015
10 ELECTRICAL ASSEMBLY 54-AA13486
11 OPERATING INSTRUCTIONS 37-DD12082
12 LIFTING GUIDELINES 37-DD12086
13 DANGER TAG 37-DD10963
14 DANGER TAG 37-DD10667
15 REMOTE ASSY 54-BXM-2999-10
16 RIGID EPOXY PATCH KIT 06-DD14974
17 DROP RESISTOR REPAIR KIT 22-9178
18 CERAMIC LIFT RESISTOR REPAIR KIT 22-4360
19 SUPPRESSOR REPAIR KIT 23-6085
PART DESCRIPTION PART NO.
O.S. Walker Inc., CER Lift Magnet
21
ITEM
NO.
PART D ESCRIPTION
PART N O.
I/R-CER-5 I/R-CER-7 I/R-CER-9 I/R-CER-12
1 I/R LEN SE 39-DD16797 39-DD16797 39-DD16797 39-DD16797
2 PLUG, TWIST LOCK 11-2001 11-2001 11-2001 11-2001
3 RECEPTACLE, TWIST LOCK 11-2010 11-2010 11-2010 11-2010
4 CORD GRIP 17-0014 17-0014 17-0014 17-0014
5 COIL CORD 10-5052 10-5052 10-5052 10-5052
6 PCB ASSEMBLY 56-BXM4940 56-BXM4940 56-BXM4940 56-BXM4940
7 TOP COVER 39-CC16255 39-CC16255 39-CC16255 39-CC16255
8 OVERLAY 37-CC16301 37-CC16301 37-CC16301 37-CC16301
9 PUSHBU TTON ( RED) 15-0127 15-0127 15-0127 15-0127
10 PUSHBUTTON ( GREEN) 15-0128 15-0128 15-0128 15-0128
11 RECTIFIER ASSEMBLY COMPLETE 54-AA13988 54-AA13988 54-AA13988 54-AA13988
12 OPERA TING INSTRUCTIONS 37-DD12082 37-DD12082 37-DD12082 37-DD12082
13 LIFTIN G GUIDELI NES 37-DD12083 37-DD12084 37-DD12085 37-DD12086
14 DANGER TAG 37-DD11636 37-DD11666 37-DD11663 37-DD11663
15 DANGER TAG 37-DD11637 37-DD11667 37-DD11667 37-DD11667
16 REMOTE CONTR OL 39-DD14069 39-DD14069 39-DD14069 39-DD14069
17 RIGID EPOXY PATCH KIT 06-DD14974 06-DD14974 06-DD14974 06-DD14974
WARNING: IMPROPER WIRING CAN RESULT IN REDUCED HOLDING POWER.
I/R-CER-5 THRU 12 Replacement Parts List
22
O.S. Walker Inc., CER Lift Magnet
SPECIFICATION & PARTS LIST
WARNING: IMPROPER WIRING CAN RESULT IN REDUCED HOLDING POWER.
CER-16 & 20 Replacement Parts List
ITEM
NO.
1 INDICATOR (PILOT LIGHT) 18-0201
2 DRUM SWITCH 54-BXM3638
3 PLUG, TWIST LOCK 11-2001
4 RECEPTACLE, TWIST LOCK 11-2010
5 CORD STRAIN RELIEF, AC 17-0014
6 CORD STRAIN RELIEF, SWITCH 17-0027
7 RECTIFIER ASSY 54-DD11298A
8 AC CORD ASSY 54-DD14857
9 SWITCH CORD ASSY 54-DD14858
10 CABLE CLAMP 14-1415
11 OPERATING INSTRUCTIONS 37-DD12082
12 LIFTING GUIDELINES 37-DD12088
13 DANGER TAG 37-DD11001
14 DANGER TAG 37-DD10963
15 REMOTE ASSY 54-BB7866-1
16 SUPPRESSOR REPAIR KIT CER-16 54-DD14926
17 RESISTOR REPAIR KIT (7.5 OHM) CER-16 54-DD14927
18 RESISTOR REPAIR KIT (15 OHM) CER-16 54-DD14928
19 SUPPRESSOR REPAIR KIT CER-20 54-DD14904
20 RESISTOR REPAIR KIT (10 OHM) CER-20 54-DD14905
21 RESISTOR REPAIR KIT (5 OHM) CER-20 54-DD14906
22 RIGID EPOXY PATCH KIT 06-DD14974
PART DESCRIPTION PART NO.
O.S. Walker Inc., CER Lift Magnet
23
ALWAYS
STAY CLEAR
OF THE LOAD
Guide the load by pushing
or pulling the edges. This
keeps your entire body clear
of the load at all times.
DO NOT guide the load
by pushing or pulling the
magnet. NEVER get in a
position where you could
get hit with the load if it is
dropped.
FOR FAST RESPONSE, CALL 1-800-W-MAGNET
O.S. WALKER
Rockdale Street, Worcester, MA 01606
(508) 853-3232 FAX (508) 852-8649
1-800-W-MAGNET
WALKER
3508 Glenridge Drive, Chino Hills, CA 91709
(909) 597-4785 FAX (909) 597-0581
901 Arvin Avenue, Stoney Creek, Ontario, L8E5N9 Canada
(905)643-3338
In Canada: 1-800-267-4678 FAX (905) 643-6111
www.walkermagnet.com
e-mail: info@walkermagnet.com
37-DD-10505J Rev. J, April 14, 2009
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