Walker Magnetics NEO-HV User Manual
OPERATOR’S MANUAL
AND
SAFETY INSTRUCTIONS
WITH INSPECTION AND MAINTENANCE INSTRUCTIONS
NEO Permanent Lifting Magnets
Models: NEO-125, NEO-250, NEO-500, NEO-1000,
NEO-2000 NEO-HV-250, NEO-HV-500, NEO-HV-1000
NEO-125, NEO-250, NEO500,
NEO-1000 & NEO-2000
NEO-HV-250, NEO-HV-500, NEO-HV-1000
WALKER
O.S. WALKER
DANGER
• Always stay clear
of the load.
• Never lift loads over
people or in close
proximity to people.
• Never attempt to operate either of
these magnets until you have read and
understand this Operator’s Manual.
CONTENTS
INTRODUCTION ................................................................................................................................... 2
SAFETY INSTRUCTIONS .................................................................................................................... 3
GENERAL SAFETY RULES ......................................................................................................................................3
RECOGNIZE SAFETY INFORMATION ....................................................................................................................4
UNSAFE LIFTING APPLICATIONS FOR YOUR MAGNET ...................................................................................... 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
GUIDELINES FOR THE REDUCTION OF THE RATED LIFTING CAPACITY ...................................11
NEO-125 LIFTING GUIDELINES (PLATE) .............................................................................................................12
NEO-125 LIFTING GUIDELINES (ROUND BARS) ............................................................................................... 13
NEO-250 LIFTING GUIDELINES (PLATE) .............................................................................................................14
NEO-250 LIFTING GUIDELINES (ROUND BARS & PIPES) ................................................................................ 15
NEO-500 LIFTING GUIDELINES (PLATE) .............................................................................................................16
NEO-500 LIFTING GUIDELINES (ROUND BARS & PIPES) ................................................................................ 17
NEO-1000 LIFTING GUIDELINES (PLATE) ...........................................................................................................18
NEO-1000 LIFTING GUIDELINES (ROUND BARS & PIPES) .............................................................................. 19
NEO-2000 LIFTING GUIDELINES (PLATE) ...........................................................................................................20
NEO-2000 LIFTING GUIDELINES (ROUND BARS & PIPES) .............................................................................. 21
INSPECTION AND MAINTENANCE INSTRUCTIONS ...................................................................... 22
EVERY LIFT ............................................................................................................................................................22
DAILY.......................................................................................................................................................................22
WEEKLY ..................................................................................................................................................................22
SPECIFICATION & SPARE PARTS LIST ........................................................................................... 23
NEO-HV 250, NEO-HV 500, NEO-HV 1000........................................................................................ 24
HV INSPECTION AND MAINTENANCE .................................................................................................................27
DAILY ................................................................................................................................................................27
WEEKLY ...........................................................................................................................................................27
ANNUALLY .......................................................................................................................................................27
HV SPARE PARTS LIST ...................................................................................................................................28
INTRODUCTION
Thank you for purchasing this O.S. Walker Product. If used and maintained properly, it
should serve you for many years. Thousands of Walker lift magnets are in service today doing
safe, fast, and effi cient magnetic material handling applications. It is often the only way for one
person to load, transport, and unload material.
Walker Products have proven to be among the best designed and safest in our industry. However, used improperly, any NEO or NEO-HV lifting magnet can be rendered ineffi cient
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 AND WATCH THE SAFETY VIDEO 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 VIDEO 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.
Additional copies of this OPERATOR’S manual ARE AVAILABLE. JUST CALL
1-800-962-4638 AND REQUEST ADDITIONAL COPIES OF MANUAL #37-DD14493.
2
O.S. Walker Inc., NEO Permanent Lifting Magnets
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 lifter.
If you do not understand everything in this manual contact O.S. Walker for assistance
before using the magnet.
Call 1-800-W-MAGNET
O.S. Walker Inc., NEO Permanent Lifting Magnets
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.
These Hazard
Signal Words
Deserve your
Full Attention
DANGER
Never lift more than one workpiece at a time
with this magnet.
Never lift any castings that do not have a ma-
chined fl at lifting surface for the magnet. The
location of the lifting surface should be such to
permit the load to remain level when lifted.
DANGER
Never lift a load by its narrowest
dimension.
WARNING
4
If you have any diffi culty lifting a load, DON’T LIFT IT!
Call Walker for advice at 1-800-962-4638
O.S. Walker Inc., NEO Permanent Lifting Magnets
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, fl 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 2.5" (64 mm) thick.
The load must be low carbon steel such as AISI 1020.
The magnet’s lifting surface must stay level and the contact-
ing surface of the load remain fl at.
The temperature of the magnet and/or the load must not be
greater than 110°F (43°C).
The control actuator must be fully in the “on” or “lift” position.
Repair of this magnet should only be done by the O. S.
Walker Co.or a Qualifi ed Person.*
If you have any diffi culty 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.
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.
Modifi cation of any operating mechanism or
structure of this magnet can reduce the magnet’s
effectiveness and/or cause an unsafe condition.
Repair or modifi cation of this magnet should only be
done by O.S. Walker or a Qualifi ed Person.*
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.
* Qualifi ed Person - A person who by extensive knowledge, training and experience, has
successfully demonstrated the ability to solve or resolve problems related to Walker lifting
magnets. (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 specifi c replacement parts listed in this manual and is able to verify the proper functioning
of the specifi c replacement parts and the entire product after the completion of the installation.
O.S. Walker Inc., NEO Permanent Lifting Magnets
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 fl owing
from north pole to south pole. Anything that limits the fl ow of these magnetic lines of force
obviously reduces the magnet’s lifting capacity. There are many important factors, which limit
the fl ow of these lines of force.
1. SURFACE CONDITIONS
Magnetic lines of force do not fl ow easily through air. They need iron in order to fl ow
freely; therefore, anything that creates a space or an air gap between a magnet and the
load limits the fl 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, fl at and free of nicks and burrs to minimize the air gap be-
tween 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 fi nish on the load creates an air gap be-
tween the magnet and load. Any of these conditions will reduce the magnet’s
lifting capacity.
2. LOAD THICKNESS
The greater the number of lines of magnetic force fl 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 fl ow. After a certain thickness of load, no additional lines of force
will fl ow because the magnet has reached its full capacity.
Thin material (load) means less iron available, and thus fewer lines of magnetic force
fl 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 suffi ciently.
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.
6
O.S. Walker Inc., NEO Permanent Lifting Magnets
3. LOAD ALLOY
Low carbon steels, such as AISI 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 fl ow into the load. An alloy such as AISI 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 AISI 1020 steel load. Also, because of the carbon content, the force developed
on cast iron is less than one-half of that developed on AISI 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 fl 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 coeffi cient 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., NEO Permanent Lifting Magnets
7
SAFETY
FOR FAST, EASY LIFTING WITH YOUR WALKER
NEO-125, NEO-250, NEO-500,
NEVER attempt to turn the magnet on or off
in the “Lifting Guidelines” section of this
on loads that are too thin will result in the
1 NEVER
attempt to operate
this lift magnet until you
read and understand the
OPERATOR’S MANUAL &
SAFETY INSTRUCTIONS
for the NEO-125, NEO-250,
NEO-500, NEO-1000 AND
NEO-2000 Lifting Magnets.
5
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.
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 diffi culty 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
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.
When working in an area using lifting magnets, wear safety
glasses, work gloves, steel-toed shoes and a safety hat.
O.S. Walker Inc., NEO Permanent Lifting Magnets
RULES
LIFT MAGNETS MODELS:
NEO-1000 & NEO-2000
unless the magnet is in contact with a load of a thickness equal to those listed
manual. Attempting to energize or de-energize this magnet without a load or
high probability of personal injury due to handle spring back.
3
Position the magnet so the load remains level.
7
4
To energize magnet, grip the handle fi rmly and pull
the handle from its locked position. Turn the handle to
the “ON” position. Then be sure to return the handle
to the FULLY LOCKED POSITION. Release the
handle.
8
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 dropped.
NEVER re-energize the magnet until it has been placed in contact with the load to
CAUTION
O.S. Walker Inc., NEO Permanent Lifting Magnets
be lifted. Prematurely energizing the magnet could cause unwanted materials to
be attracted to the magnet. PERSONAL INJURY MAY RESULT.
Carefully set the load down. To release the load,
grip the handle fi rmly, unlock the handle shaft, and
turn the handle to the “OFF” position. Lift the mag-
net slightly to be sure the load has been released.
9
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