Austlift 915303 User manual

SERVICE MANUAL
WEBBING INERTIA REEL BLOCK
PC. 915303
Lifting Your Business to A Higher Level
1300 100 120
www.austlift.com.au
AUSTRALIAN LIFTING CENTRE PTY LTD

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
SERVICE MANUAL (VOLUME 1) IS FOR:
Plastic Casing (Webbing Retractable Fall Arrester)
Retractable Fall Arrester Block
Product Code. 915303
STATUTORY CONDITIONS
1. This Service Manual contains step wise illustrations for the servicing of
AUSTLIFT Retractable Fall Arrest Block.
2. This Service Manual shall be in the custody of only a competent authorized
service personnel, duly endorsed by AUSTLIFT.
3. This Service Manual is meant only to be a handbook for ready reckoning of
the trained service provider for AUSTLIFT Retractable Fall Arrester Block.
4. Once the block has been opened up for servicing by the authorized service
personnel, AUSTLIFT shall not be responsible for any damages/ mishaps
whatsoever. It shall be the duty of the service provider only to respond, to
such a situation.
5. It is extremely important to paste back the original label on to the block
casing after completion of the servicing.
6. Please do not forget to complete the service check card provided along with
the block. This will give easy reference for future use of the block.

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
INDEX
4
12
22
25
Step Wise Illustrations
Changing The Coil Spring
Final Assembly
Standard Torque Values

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 1
STEP WISE ILLUSTRATIONS
STEP 2
Follow below mentioned steps for the Servicing of
Plastic Casing (Webbing Retractable Fall Arrester)
AUSTLIFT Retractable Fall Arrester Block.
1. Place the Block on the Service table with front side up
2. Ensure that the Allen head of the screw is facing up
3. Now peal off the sticker as shown in the above figure
Remove the Main shaft screw by using 4mm Allen Key and place in a
container as shown in the above Figure.
Main shaft Screw

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 3
STEP 4
Opening of the Casing
Be sure that the Allen Head of the screw is facing up. Remove the 4
screws , one by one as shown in the figure above.
Now open the casing by just inserting a screw driver in between the two
casing with one hand & carefully holding the webbing assembly by the
other hand to prevent it from abruptly moving out (see figure above).
Casing
Screw
Webbing Assembly
Screw
Driver

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 5
STEP 6
Caution: While lifting the Plain casing, the drum will unwind as you lift the
casing. Hold the webbing assembly to prevent the unwinding of the drum.
(as shown in the figure).
Now, take out the webbing along with the Hook & other Plastic parts from
the slot of the Ratchet casing by just pulling it up lightly & then release the
tension of the spring by unwinding the drum in anti clock wise direction as
shown in the above fig. You will need to unwind approximately 3 to 4 turns,
until the drum is completely free of tension. After relieving the tension, turn
the whole assembly upside down.
Drum
Direction of
Unwinding
Pull out the Webbing
assembly
Plain Casing

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 7
STEP 8
Now peel off the sticker on the casing.
Remove the main shaft screw using 4 mm Allen Key.
Main Shaft Screw

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 9
STEP 10
Remove the Ratchet Casing as shown in the above fig.
Try to pull out the Brass Brakes one by one using your fingers to check that
all Brass Brakes are freely moving in and out & the springs pulling them
inwards are not worn or damaged. If not, replace them. Ensure that there is
no friction, whatsoever between the Brass Brakes & the pivot on which they
rotate. The springs should be intact in their position.
Ratchet Casing
Springs
Brass
Brakes

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 11
STEP 12
We will now plan to replace the wire rope or other wearable parts of the
Retractable, in case they have been damaged or worn out. Open the 3 Nos
Grub Screw with the help of 2.0mm allen key as shown in figure above.
If Grub screw will found stuck or very tight then follow the below steps
of actions to open them:
1. First we will use L-Type Allen key to loosen the grub screw and T-type
Allen key for further opening.
2. While loosening the screws if any screw is not able to loose (stuck into the
hole) then we will not try to apply excessive force on allen, as it will lead
to deform the drive of grub screw.
3. Fix the assembly in Three jaw chuck and with the help of chuck nut
opening gauge try to move the chuck nut anticlockwise for a bit distance
(stop when cuck nut start moving).
4. Now again use L-Type Allen Key and try to loosen the screw, it will get
loose with a ‘click’ sound. Stop and open the grub screw with T-type
Allen key.
Hold the assembly in the Drum Holding Fixture as shown.
Open the Chuck Nut by using the Torque Wrench & the Excel Socket as
shown in above figure.
Torque Wrench
Exel Socket
Drum Holding
Fixture
3 nos Grub Screws to be
opened one by one

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 13
STEP 14
Remove the Chuck Nut.
Remove the Pressure Washer. It is essential to replace this Washer Every
time you service a Retractable. So it would be better to discard it and get
a new one in its place.
Pressure Washer
Chuck Nut

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 15
STEP 16
Pull up the Brake plate.
Remove the Friction Plate.
Immediately replace the Friction Plate with a new one.
Friction Plate
Brake Plate
Friction Plate

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 17
STEP 18
Remove the Web Washer. It is essential to replace this Web Washer Every
time you service a Retractable. So it would be better to discard it and get
a new one in its place.
Check the embossed pin on the drum if they are worn out, if yes, change
the drum with a new one.
Remove the webbing from the drum and check the entire length for any
damages or abrasion marks. In case of any doubt about the condition
of webbing, replace it with a new one. It is not necessary to replace the
webbing Lanyard assembly every time you service a block. Now assemble
it backwards doing the opposite of Step 17, 16,15, 14 and Step 13, i.e putting
back the new web Washer followed by the new Friction Plate, then the
Brake Plate followed by the new Pressure Washer and then the Chuck Nut
Web washer
Embossed
pin

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 19
STEP 20
Tightening Torque (chuck Nut)
It may vary from 400 to 1200 Kgf/cm. It is recommended that we first tight
chuk nut from minimum value (200) and then check as per step 20 below
to ensure that measured torque is “ As per value indicate in the standard
torque chart.” If not, continue to tighten the chuck nut further by 100Kgf/
cm, each time measuring the achieved torque until the measured value
will be as indicated on standard torque chart.
Measuring the Brake Plate Torque
It should be as per value indicate in the standard torque chart (Page No. 24).
Caution: Ensure that the tightening by Torque Wrench is done as smoothly
as possible without giving any jerks or sudden force till the desired Torque
is reached.
Torque reading should be as per value indicate
in the standard torque chart
Torque Wrench
Exel Socket
Drum
Holding
Fixture
Torque
Measuring
gauge

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 21
STEP 22
Using screw driver, remove all CSK Slotted Head screws of the spring cover,
one by one.
Turn the assembly upside down and remove the external circlip lock
(retaining ring) (as shown in the figure). With the help of external circlip plier.
Circlip lock
External circlip
plier
C’sk screw
CHANGING THE COIL SPRING
In case, the Coil spring is damaged or broken, it
needs to be replaced following step 21 to step 35

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 23
STEP 24
Caution: Carefully remove the Spring Cover while keeping the coil spring
down with your other hand (as shown in the figure).
Quickly put the Safety Bar on the Spring while tightening the Safety Bar
Allen Bolt into the main shaft to prevent the spring from coming out
accidently.
Spring Cover
Safety bar

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 25
STEP 26
Hold the assembly in the Clamping fixture as shown above and Pull out the
webbing to check if the spring is broken.
Changing the damaged coil spring
After pulling out the webbing, put the Stopper Block (as shown in the fig.)
near to the bend of coil spring to create the gap & release the webbing to
achieve the rest position of spring.
Caution: Be careful while handling the coil spring.
Stopper Block
Pulling out
the webbing
Clamping
fixture

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 27
STEP 28
Hold the spring with help of a Tool Maker Clamp.
Remove the safety bar with help of 5mm Allen key.
Allen key
Spring Cover

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 29
STEP 30
Pull out the spring with the help of Tool Maker Clamp.
Caution: Be careful while handling the coil spring.
Remove the coil spring from the drum (as shown in the figure).
Bend end of
coil Spring

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
1300 100 120
WEBBING INERTIA REEL BLOCK
915302/915303/915342/915344
STEP 31
STEP 32
Fitting the New Coil Spring
Hold the open end of the spring inside the Drum and hold it tightly.
Put the Coil Spring inside the housing with the help of Tool Maker Clamp
and insert the bend of spring into the slot of the shaft.
Caution: Be careful while handling the coil spring.
Open end
of the spring

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ALC SIM 915303_19
SERVICE MANUAL (VOL:1)
www.austlift.com.au
WEBBING INERTIA REEL BLOCK
915303
STEP 33
STEP 34
Put the spring cover back as shown in the above fig, ensuring that the
spring is held downwards using your other hand.
Put the Circlip Lock (Retaining Ring) by using External Circlip Plier.
Circlip lock
External
Circlip Plier