Asano AK1680 User manual

AK Block Type PB/Type PB-II
Instruction manual
1680 MAE
Before use
Safety precautions
・For proper and safe use of the product, the prevention of injury to yourself and others around
you, and the prevention of damage to property, read and understand this document thor-
oughly before handling the product.
・After reading this document, store it in a place where it can be easily referenced.
・Have an expert plan and install equipment such as cranes that will be used with the product.
・Follow the industrial safety and health regulations and safety ordinance for cranes when han-
dling the product.
・The product is manufactured for the purpose of hoisting or pulling heavy loads. Do not use it
for any other purpose.
・The product is for professional use only. It is not for general home use.
The descriptions in these “Safety precautions” and in the text are for you to follow in order to prevent injuries and property damage.
■The danger and degree thereof resulting from incorrect handling are classied as follows.
Ignoring this indication and handling the product
incorrectly may result in serious injury or death.
Warning
Describes something you must not do.
Ignoring this indication and handling the product incorrectly
may result in minor injury or property damage.
Caution
■The following symbols are used to indicate the descriptions for you to follow.
Describes something you must do.
Warning
Do not use for the purpose of hoisting people or equipment with
people in it.
Doing so may lead to serious injury or a fatal accident.
Do not let the pulley touch sharp objects or abrasive surfaces.
Doing so will cause the pulley to weaken due to damage or abrasion.
Do not let the sheave rotate continuously at high speeds for long
periods of time.
Otherwise the bearing may abrade due to frictional heat, which may cause
the rotation failure of the sheave.
Do not let the rope xture touch the pulley.
Doing so may damage the pulley and lead to an accident of a falling hoisted
load.
Do not use during bad weather such as in strong winds.
Doing so may drop the hoisted load and lead to serious injury or a fatal acci-
dent.
Do not apply loads that exceed the working load limit.
Doing so may damage the pulley, drop the hoisted load, and lead to serious
injury or a fatal accident.
Do not perform modications such as welding or cutting.
Doing so may lead to serious injury or a fatal accident due to a weakened or
broken pulley.
Inspect before use and periodically.
Failure to do so will overlook abnormalities or damage to the pulley, and may
lead to serious injury or a fatal accident.
Attach the hoisted load so that the sheave and hoisted load xture
are in tandem.
If the load is applied to the pulley from the side, it may lead to serious injury
or a fatal accident due to breakage.
After starting to hoist a load, check that the rope is in the groove of
the sheave.
Failure to do so may drop the hoisted load due to rope damage, and lead to
serious injury or a fatal accident.
When attaching, removing, or transporting a pulley, use slip-resistant
protective gloves and perform work in a stable place.
Failure to do so may drop the pulley and lead to serious injury or a fatal acci-
dent.
Do not apply impact loads.
Doing so may lead to serious injury or a fatal accident due to a broken pulley
or other part, or falling hoisted loads.
Do not ride on top of hoisted loads or pulley equipment.
Doing so may lead to serious injury or a fatal accident due to falls or falling
hoisted loads.
Do not use when there are people within the movement range of the
hoisted load or under the pulley.
Doing so may lead to serious injury or a fatal accident.
When hoisting, stay away from the pulley, rope, and around and
under the hoisted load.
Failure to do so may get your hands or body caught or you may get crushed
under the falling hoisted load, lead to serious injury or a fatal accident.
Do not use the swivel for purposes such as constant rotation.
Doing so may damage the swivel, drop the hoisted load, and lead to serious
injury or a fatal accident.
Caution
Do not use while submerged such as in the sea or water.
Doing so will lead severe rotation failure or strength deterioration due to
adhesion of foreign matter or corrosion.
Do not use or store in the following environments.
· Places with extreme temperature changes
· Places with corrosive or acidic gas
Doing so will cause rotation failure or strength deterioration.
In low temperature environments, check that the sheave is not frozen
before working.
Failure to do so may damage the rope from rotation failure of the sheave due
to freezing.
In high temperature environments, lubricate periodically.
In high temperature environments, depletion of lubricant is severe and if the
lubricant dries up, it will cause the rotation failure of the sheave or the shaft.
Use within the temperature range between -18°C and 66°C.
Using outside of this temperature range will cause rotation failure or strength
deterioration.
2866 Tsukioka, Sanjo, Niigata, 955-0803, JAPAN
TEL [phone] FAX [phone]
Homepage http://www.asano-metal.co.jp/en
E-mail [email protected]
Manufacturer Dealer
Issued April 1, 2019
Product specifications
AK Block Type PB, Single Sheave
[With Steel Bearing]
[With Steel Bearing]
Model
AK1680
AK1681
AK1682
[With Stainless Steel Bearing]
[With Stainless Steel Bearing]
AK Block Type PB, Double Sheaves
Material：Body = SCS14 (equivalent to SUS316) , Sheave = Special stainless steel ,
Swivel / Sheave pin / Nut = SUS304 , Bearing = SUS440C
Material：Body = SCS14 (equivalent to SUS316) , Sheave = Special stainless steel ,
Swivel / Sheave pin / Nut = SUS304 , Bearing = Steel
Material：
Body / Sheave / Becket / Nut = Special stainless steel ,
Swivel / Sheave pin / Becket pin / Collar = SUS304 ,
Bearing = SUS440C
Bearing
number
Unit
weight
(kg)
Working
load limit
(kg)
AK Block Type PB-II, Single Sheave
Material：Body / Sheave / Nut = Special stainless steel ,
Swivel / Sheave pin / Becket bolt / Collar = SUS304 ,
Bearing = Steel
B
d
B1
L
L
1
Size
(sheave dia.)
t
t1
L2
D1
Max. rope dia.
Size
(sheave dia.)
B1
L1
d
L2
D1
t1
t
L
B
Max. rope dia.
Size
(sheave dia.)
B1
B
2
L1
d
L2
D1
t
L
B
Max. rope dia.
t1
Size
(sheave dia.)
(mm)
50
75
100
Max.
rope dia.
(mm)
14
16
22
d
10
14.5
16
L
136
194
243
L₁
29
38
44
L₂
82
111
137
D₁
36
59
78
B
56
81
106
B₁
14
19
22
t
20
24
28
Dimensions (mm)
t₁
35
44
50
0.5
1.3
2.5
6000
6002
6203
400
600
1,000
Asano Metal Industry Co., Ltd.
Important
Model
AK10300
AK10301
AK10302
Bearing
number
Unit
weight
(kg)
Working
load limit
(kg)
Size
(sheave dia.)
(mm)
50
75
100
Max.
rope dia.
(mm)
14
16
22
d
10
14.5
16
L
136
194
243
L₁
29
38
44
L₂
82
111
137
D₁
36
59
78
B
56
81
106
B₁
14
19
22
t
20
24
28
Dimensions (mm)
t₁
35
44
50
0.5
1.3
2.5
6000
6002
6203
400
600
1,000
Model
AK10310
AK10311
AK10312
Bearing
number
Unit
weight
(kg)
Working
load limit
(kg)
Size
(sheave dia.)
(mm)
50
75
100
Max.
rope dia.
(mm)
14
16
22
d
10
14.5
16
L
158
229
282
L₁
29
38
44
L₂
83.5
117
142
D₁
36
59
78
B
57
84
109
B₁
14.5
19
22
t
20
24
28
Dimensions (mm)
t₁
77
94
111
0.95
2.2
4.0
6000
6002
6203
400
600
1,000
Model
AK10073
Bearing
number
Unit
weight
(kg)
Working
load limit
(t)
Size
(sheave dia.)
(mm)
125
Max.
rope dia.
(mm)
25
d
22
L
341
L₁
52
L₂
174
D₁
100
B
137
B₁
27
t
34
Dimensions (mm)
t₁
69 4.962/28 1.5

Inspect before using the pulley.
Using the product when there is a problem accelerates the
damage and may lead to strength deterioration, damage
to the product, or an accident of falling hoisted load.
Inspection and maintenance
In case of trouble
Remove the nut using a socket wrench.
* Use adhesive agent that is sticky.
(Loctite 271 is recommended)
When detaching the nut, and then attaching the nut again, apply
adhesive agent to the screw of the nut.
●The sheave pin and the becket bolt are subject to the caulking
operation to prevent looseness.
Socket
Swivel
Body
Sheave pin ●Sheave pin
Sheave
●Sheave
●Sheave pin
●Becket pin
●Becket
●Caulking jig
●Becket
●Sheave
●Sheave pin ●Sheave
Bearing
Nut
Sheave pin
Sheave pin nut
Becket bolt
Caulking jig
(Sold separately)
Hexagon socket wrench
Size 50 75 100
Double face
width of nut
14mm 22mm 24mm
[Replacement parts]
Inspection before use
Warning
In the unlikely event the pulley deforms or breaks and
a load is hanging in midair, first take down the hoisted
load, unload the pulley, and take safety measures to
prevent secondary disaster.
Warning
Do not use products that are in the following conditions.
·Products that are deformed, cracked, or worn out
·Products with signs of corrosion such as rust
stains or galvanic corrosion
Doing so may lead to serious injury or a fatal accident
due to falls or falling hoisted loads.
Do not let the product touch other types of metal
for long periods of time.
Doing so will cause corrosion.
Warning
Be sure to apply adhesive agent.
If adhesive agent is not applied, the nut will come
off and the sheave will fall, leading to accident.
Warning
Do not scrape the body.
Since the body becomes unusable when it is
scraped, do not scrape any more once the
caulking part of the becket bolt is removed.
Caution
Be sure to perform caulking operation. Also be
sure to check that the nut does not become
loose after performing caulking operation.
If not fully caulked, the nut will come off and the
sheave will fall and lead to accident.
Warning
Be sure to perform caulking operation. Also be
sure to check that the nut and bolt do not become
loose after performing caulking operation.
If not fully caulked, the nut or bolt will come off
and the sheave will fall, leading to accident.
Warning
Caution
Caution
●The sheave pin nut and the becket pin nut are subject to the caulking
operation to prevent looseness.
<Inspection of movable parts>
<Nut inspection>
●The swivel and sheave rotate smoothly.
●Applying to the swivel pin and the side surfaces of the sheave
Sheave
pin nut
Becket pin nut
Disc grinder
Socket
Socket wrench
Remove the caulking part.
Size
50
Double
face width
of nut
Sheave pin nut 13mm
Becket pin nut 10mm
75
18mm
16mm
100
22mm
18mm
Size 125
Socket wrench double
face width
Hexagonal socket wrench
double face width
24mm
8mm
Caution
Wipe frequently.
Attached foreign matter such as sea water, soot, or
iron particles will cause corrosion.
③If the nut is unable to be removed
in ②, scrape the caulking part
with a disc grinder and remove it
with a socket wrench.
* Once removed sheave pin/sheave
pin nut/becket pin/becket pin nut
cannot be reused, so replace them
with new ones.
①Apply anti-seizing agent to the caulking part so that the caulking
will not be seized.
②Remove the sheave pin nut and the becket pin nut with a socket
wrench together with caulking.
③If the nut is unable to be removed
in ②, scrape the caulking part
with a disc grinder and remove it
with a socket wrench.
<Removal>
<Removal>
①Apply anti-seizing agent to the caulking part so that the caulking
will not seize.
② Remove the sheave pin nut with a socket wrench together with
caulking.
<Attachment>
①Use new sheave pin/sheave pin
nut/becket pin/becket pin nut,
and tighten them with a socket
wrench.
②Caulk so as to expand the tips of
the sheave pin and becket pin. <Attachment>
①Use new sheave pin/sheave pin
nut/becket bolt, and tighten them
with a hexagon wrench or socket
wrench.
②Perform caulking operation so as
to expand the tips of the sheave
pin and the becket bolt.
●Nuts securing the sheave pin are not loose or defective.
*For the checking method, refer to Removing and attaching the nut.
<Visual inspection of appearance>
<Applying grease (or lubricant)>
<Removing corrosion (rust), dirts, and foreign matter>
●There are no cracks or corrosion in the swivel
and welded part of the swivel pin. There are also
no cracks or corrosion in the other parts.
●There are no bends, twists, distortions, or
stretches.
●There is no excessive wear, denting, or hollowing
out.
●There is no wire scratch marks on the sheave
surface.
●Foreign matter or dirt is not attached.
●Casted characters on the body shall
be readable.
●If a problem occurs while using the pulley, discontinue use immediately,
and check the items in .
①For light dirt (such as hand marks, sand, or mud), wipe with a damp soft cloth or
sponge, and then wipe with a neutral detergent.
②If dirt still remains, wiping with a store-bought cleaner (cleaning solution), remov-
er, or thinner is effective.
③If rust stains (spots of rust caused by iron particles in dirt) remain after perform-
ing ①and ②, use a store-bought rust remover.
④If the rust cannot be removed with a store-bought rust remover, rub it off with
sandpaper or an abrasive compound.
⑤Remove foreign matter by scraping it away with sharp-tipped object such as a
slotted screwdriver, and then perform ①and ②. Rub off persistently attached
foreign matter with a file or abrasive compound because you may damage the
product if you use excessive force.
Do not let grease on the swivel pin dry up.
Drying up will lead to breakage of the swivel pin or
the crack of the welded portion.
Warning
When disassembling the pulley for sheave replacement,
remove it from high places and disassemble on the ground.
Failure to do so may drop the pulley and lead to serious
injury or a fatal accident.
When replacing parts, use ASANO-specied parts.
Failure to do so may result in lower functionality of the
pulley due to incompatible parts.
Warning
Caution
●For inquiries about pulleys, please consult the dealer where you purchased
the product.
●Caulking jig
Sheave
pin nut
Becket
pin nut
Sheave
pin nut
Bearing
Bearing
Becket
Collar
Body
Becket bolt
Sheave
Sheave
Collar
Sheave pin
Sheave pin
Becket pin
Becket bolt
Body
Body
Swivel
Swivel [Replacement parts]
[Sold separately]
[Replacement parts]
[Sold separately]
Double face width
Socket wrench
Socket wrench
Socket
Sheave
pin nut
Disc grinder
Remove
caulking
⑤ If the becket bolt is unable to be
removed in ④, scrape the caulking
part with a drill (ø11mm) and remove
it with a hexagon socket wrench.
* Once removed sheave pin/sheave pin nut/becket bolt cannot be
reused, so replace them with new ones.
Drill (ø11)
Swivel
Sheave
Grease
Swivel Sheave
Sheave pin
Body Swivel pin
Grease
Caulking
Pin
Nut
Caulking jig
(Sold separately)
Caulking
Anti-seizing
agent
Anti-seizing
agent
Caulking
Becket bolt
Inspection and maintenance
AK Block Type PB, Single Sheave (Size 50, 75, 100)
AK Block Type PB, Double Sheaves (Size 50, 75, 100)
AK Block Type PB-II (Size 125)
■Part names
■Part names
■Part names
■Removing and attaching the nut
■Removing and attaching the nut
■Removing and attaching the nut
Adhesive
agent
Maintenance
Periodic inspection
④Remove the becket bolt with a hexagon socket wrench together
with caulking.
Grease
Elongation
Welded part of
the swivel pin
Anti-seizing
agent
If rotation is poor, not
centered, significantly
rattles, or if rotation
stops, discontinue use
and replace the part or
product.
Apply grease to the gap of the
swivel pin in the inner side of the
body to prevent the rotation
failure and abrasion of the swivel.
In order to prevent water invasion
into the bearing, apply grease to the
bearings on the side of the sheave.
●Perform periodic inspection at least once a year.
●If you use the product under harsh conditions such as frequent hoisting of
loads equal to the working load limit, impact loads, or intense rolling, perform
inspection more frequently because the parts will wear out substantially.
●For periodic inspection, inspect all of the items in ,
perform , and check the dimensions of each part. If the
dimensions are 10% different from the original dimensions or the dimensions
in the catalog, replace the part or product.
(Refer to for the dimensions.)
Inspection before use
Maintenance
Product specifications