Austlift 915210 User manual

SERVICE MANUAL
WIRE ROPE INERTIA REEL BLOCK
PC. 915210, 915220, 915230
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 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
SERVICE MANUAL (VOLUME 3) IS FOR:
Plastic Casing (Wire Rope Retractable Fall Arrester)
Retractable Fall Arrester Block
Product Code. 915210. 915220, 915230
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 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
INDEX
4
13
22
Step Wise Illustrations
Changing The Coil Spring
Standard Torque Values

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 1
STEP WISE ILLUSTRATIONS
STEP 2
Follow the below mentioned steps for the
Servicing of Plastic/ Aluminium Casing (Wire Rope
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 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
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
Wire Rope Assembly
Screw
Driver

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 5
STEP 6
Caution: While lifting the Plain casing, the drum will unwind as you lift the
casing. Slide your hand into the drum to prevent the unwinding of the drum.
Now, take out the wire rope 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 4 to 5 turns,
until the drum is completely free of tension. After relieving the tension, turn
the whole assembly upside down.
Drum
Direction of
Unwinding
Pulling out the Wire
Rope assembly
Plain Casing

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 7
STEP 8
Now peel off the sticker on the casing.
Remove the main Shaft screw using 4 mm Allen Key.
Allen
Key

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
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 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
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/1.5mm 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 Three Jaw Chuck as shown.
Open the Chuck Nut by using the Torque Wrench & the Excel Socket as
shown in above figure.
Torque Wrench
Excel socket
Three Jaw
Chuck
3 nos Grub Screws to be
opened one by one

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
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 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 15
STEP 16
Pull up the Brake plate and the Friction Plate. Immediately replace the
Friction Plate with a new one.
Also, remove the al. shim washer by removing 4 Nos. of CSK screws
Remove the wire from the drum and check the entire length for any
damages or abrasion marks. In case of any doubt about the condition of wire
rope, replace it with a new one. It is not necessary to replace the wire rope
assembly every time you service a block. Now assemble it backwards doing
the opposite of Step 15, 14 and Step 13, i.e putting back New Aluminium
shim washer the New Friction Plate, then the Brake Plate followed by the
New Pressure Washer and then the Chuck Nut.
Brake Plate
Brake Plate
Friction
Plate
Al. shim

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 17
STEP 17
Tightening Torque (chuck Nut)
It may vary from 500 to 1300 Kgf/cm. It is recommended that we first tight
chuk nut from minimum value (200) and then check as per step 18 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. 22).
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.

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 19
Using screw driver, remove the 6 Nos. CSK Philip Head screws of the spring
cover, one by one.
STEP 20
Now remove the Circlip Lock ( Retaining Ring) by using the external Circlip
Plier as shown in above figure
Caution: When the Circlip Lock (Retaining Ring) is to be opened, the spring
will bounce back, hence slide your hand in to the cover and open it very
carefully as shown in the above figure.
CHANGING THE COIL SPRING
In case, the Coil spring is damaged or broken, it
needs to be replaced, following Step 19 to Step 32.
External
Circlip Plier
Circlip lock
CSK Philip Head Screws

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 21
Remove the spring cover as shown in the above fig, ensuring that the spring
is held downwards using your other hand.
Spring Cover
Holding the
Spring down
with your
hand
STEP 22
Quickly put the Safety Bar on the Spring while tightening the Safety Bar
Allen Bolt into the main shaft with 5mm Allen Key to prevent the spring
from coming out accidently.
Safety Bar
Allen Screw

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 23
STEP 24
Hold the assembly in the Clamping fixture as shown above and Pull out the
wire to check if the spring is broken.
Changing the damaged coil spring
After pulling out the wire, put the Stopper Block (as shown in the fig.) near
to the coil spring screw to create the gap & release the wire to achieve the
rest position of spring.
Caution: Be careful while handling the coil spring.
Stopper Block
Clamping
Fixture

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 25
STEP 26
Hold the spring with the help of a Tool Maker Clamp.
Remove the safety bar with the help of 5 mm Allen key.
Allen Key
Defective Wire
rope Assembly

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 27
Pull the spring with the help of Tool Maker Clamp.
STEP 28
Open the coil spring screw nut with the help of 8mm Ring Spanner and
3mm Allen Key as shown above.
Spring
Screw Nut

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 29
STEP 30
Fitting the New Coil Spring
Hold the open end of the spring inside the drum and tighten with the help of
screw & nut using 3mm Allen Key and 8mm Ring Spanner. Apply Resi- Quick.
Put the Coil Spring inside the drum with the help of Tool Maker Clamp and
insert the bend of spring into the slot of the shaft.\
Immediately put the safety bar & then release the spring.
Caution: Be careful while handling the coil spring.
Open End of the Spring

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
1300 100 120
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 31
Pull out the whole wire as shown in the above fig. to create adequate gap
between the coil spring and housing.
Holding the
Spring down
with your
hand
STEP 32
Put the Circlip Lock (Retaining Ring) by using External Circlip Plier and
tighten the 6 Nos of CSK philip head screws of the spring cover one by one.
CSK Philip Head Screws
Circlip Lock

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ALC SIM 915210/915220/915230_19
SERVICE MANUAL (VOL:3)
www.austlift.com.au
WIRE ROPE INERTIA REEL BLOCK
915210/915220/915230
STEP 33
STEP 34
Put 2 or 3 washers to maintain the clearance between the casing and the
Assembly.
Put the Ratchet Casing over the Break Plate Assembly as shown in the
above figure.
Tighten the main shaft screw using the 4mm Allen Key.