Challenger CCL110 User manual

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Imported exclusively by Pacific Hoists Pty. Ltd. & Pacific Hoists Ltd.
In support of cancer charities in Australia & New Zealand
INSTRUCTION
MANUAL
PLATE CLAMPS
Universal Plate Clamp Horizontal Plate Clamp

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INTRODUCTION
Thank you for purchasing your new Challenger Plate Clamp. This lifting device now uses the latest
technology to ensure you of a higher quality, robust design with a high level of operator safety
which is easier and safer to use, ensuring a longer service life. Choosing the Challenger brand
also directly supports cancer charities in Australia & New Zealand.
It is important that this manual be kept in a safe place where any operator of the Challenger
Plate Clamp can refer to it and understand the operating principles of this device. All users of
this Challenger Plate Clamp should read this manual in full and understand the safe operating
principles of the device.
FEATURES
FEATURES OFTHE CHALLENGER PLATE CLAMPS INCLUDETHE FOLLOWING
■The Challenger Plate Clamps are manufactured to comply with AS4991.
■Designed for the lifting and transferring of steel plates and other materials in a wide variety
of industries such as; shipbuilding, construction, aircraft and offshore applications.
■The Challenger vertical and horizontal plate clamps are suitable for the lifting and transfer in
vertical and horizontal position of non-sagging steel plates.
■These plate clamps are manufactured from high quality steel to guarantee the safety and
durability required by industrial applications.
■All clamps have been ergonomically designed to be user-friendly (smaller, lighter and more
compact) while not sacrificing strength and durability.
■For every model sold, a donation will be made to the McGrath Foundation in Australia and the
Child Cancer Foundation in New Zealand.
IMPORTANT
PLEASE READ THIS OPERATION MANUAL BEFORE USING THIS PRODUCT. THIS MANUAL CONTAINS
IMPORTANT INFORMATION REGARDING SAFETY, OPERATION, INSTALLATION & MAINTENANCE.

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SPECIFICATIONS
Model CCL110 CCL111 CCL112 CCL113 CCL115
Capacity (Kg) 500 1000 2000 3000 5000
Jaw (mm) 0 - 15 0 - 20 0 - 25 0 - 30 0 - 50
Dimensions (mm) A ɸ30 ɸ48 ɸ68 ɸ74 ɸ80
B43 63 78 85 100
C34 50 61 57 66
D0 - 17 0 - 22 0 - 27 0 - 32 0 - 52
Emin 106 145 174 207 240
F10 12 16 20 24
Gmax 216 292 369 428 481
H50 66 76 102 110
Net weight (Kg) 2 4.5 7.3 15 21.6
Challenger Universal Plate Clamps
HIGHER CAPACITY AVAILABLE UPON REQUEST

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SPECIFICATIONS (CONT.)
Challenger Horizontal Plate Clamps
Model CCL121 CCL122 CCL123 CCL124
Capacity per unit (Kg) 750 1500 2500 4500
Capacity per pair (Kg) 1500 3000 5000 9000
Jaw (mm) 0 - 50 0 - 50 0 - 60 0 - 100
Dimensions (mm) Amax 50 50 60 100
B127 220 260 290
C100 110 130 165
Dmax 218 270 315 425
Eɸ30 ɸ36 ɸ40 ɸ40
Net weight per unit (Kg) 4.1 7.4 13.8 28.6
Net weight per pair (Kg) 8.2 14.8 27.6 57.2

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SAFETY INSTRUCTIONS
THE FOLLOWING SAFETY INSTRUCTIONS OUTLINETHE CARE AND SAFE USE OF UNIVERSAL
AND HORIZONTAL PLATE CLAMPS AND ARE BASED ON SECTION 22 OF THE LEEA CODE OF
PRACTICE FOR THE SAFE USE OF LIFTING EQUIPMENT.
This information is of a general nature; only covering the main points for the safe use of plate
clamps. It may be necessary to supplement this information for specific applications.
SELECTING THE CORRECT PLATE CLAMP
Challenger offers two basic types of plate clamps but the facility they offer may vary with
make.
■ Universal Plate Clamp – they can be used for either horizontal or vertical plates and to
rotate them. They may also permit angular loading in the plane of the plate
■Suitable for material surface hardness upto 37 HRC
■ Horizontal plate clamp – designed to be used in pairs to lift horizontal plates only. Some
are in the form of a specially shaped hook without a cam, others have a cam which grips
the plate. They are used in conjunction with a sling which must be of the right type to
ensure that the geometry and therefore the gripping forces are correct.
GENERAL SAFETY INSTRUCTIONS
■ Check the clamp before use – do not use a defective plate clamp.
■ Ensure that the clamps are suitable for the thickness of plate to be lifted.
■ Never exceed the maximum or minimum thickness for which the clamps are designed.
■ Put the clamp onto the plate as far as it will go.
■ Do not use clamps at an angle to the edge of the plate or for lowering from vertical to
horizontal, or vice-versa, unless they are designed for the purpose.
■ Keep oil, grease and similar contaminates away from jaws which use a friction grip
material to hold the plate.
■ Never use plate clamps on hard or polished plate unless they have been specifically
designed for that purpose.
■ Take great care to ensure the plate is fully supported before attempting to release the
clamp.
■ Keep all persons clear of the danger zone and remember that a falling plate can ‘glide’
sideways. A large thin plate is likely to glide further. Also the higher it falls from, the
bigger the danger zone.

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SAFETY INSTRUCTIONS
(CONT.)
USING THE UNIVERSAL PLATE CLAMP SAFELY
■ Some designs of clamp, particularly those with a moving cam action jaw where the
initial grip is provided by a spring, have a minimum load and minimum plate thickness
they can safely lift. Wherever possible refer to the manufacturer’s instructions but in the
absence of specific guidance the load should not be less 10% of the rated capacity. The
minimum plate thickness should not be less than 20% of the maximum jaw range. For
more information contact Pacific Hoists technical support.
■ Some designs of plate clamp are suitable for lifting plates from the horizontal to the
vertical and the inclusion of a pendant chain to provide articulation between the clamp
and lifting hook is essential. However the use of pendant chains should always be
considered to prevent the hook weight being imposed on the clamp as this might cause
the clamp to be released.
■ Position the clamp correctly. Place the clamp over the centre of gravity of the plate. If
the plate is long and has a tendency to bend, use two clamps equally disposed about the
centre of gravity in conjunction with a spreader beam.
■ Take care to ensure no one clamp takes more than its rated capacity.
■ Ensure the clamp is fully locked or tightened onto the plate before lifting.
■ Under no circumstances should packing be placed between the plate and the jaws nor
any attempt made to lift more than one plate in the clamp.
■ When using the universal type, check the manufacturer’s instructions for the limitations
on the angles they may be used at.
DON’T FORGET!!
■ Never overload a clamp
(if more than one is used ensure each can take its share)
■ Never exceed the permitted maximum or minimum thickness
■ Never use beyond the permitted angles
■ Never use on hard or polished plate unless designed for that purpose
■ Never try to lift more than one plate
■ Never place packing between the plate and the jaws

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SAFETY INSTRUCTIONS
(CONT.)
USING THE HORIZONTAL PLATE CLAMP SAFELY
■ Always use horizontal plate clamps in pairs with the correct type, size and length sling
and reeved in the manner for which they are designed. Some of these clamps are
designed to be used with an endless loop of chain whilst others are for use with a two
leg sling. Under no circumstances must an endless loop be substituted for a two leg sling
or vice versa as this will alter the geometry and therefore the gripping forces on which
the clamps rely for their safe operation.
■ If the plates are likely to sag transversely, clamps which grip the plate by a cam must
be used.
■ Position the clamps correctly. Place the clamps over the centre of gravity of the plate.
If the plate is long and has a tendency to bend use two or more pairs of clamps in
conjunction with a spreader beam, equally disposed about the centre of gravity, to
minimise the sag. Ensure the clamps face each other to balance the horizontal clamping
forces.
■ Take care to ensure no one clamp takes more than its rated capacity.
■ Put the clamps onto the plate as far as they will go.
■ If the sling is adjustable to accommodate various widths of plate ensure it is adjusted to
give the correct geometry.
■ Never attempt to rotate from the horizontal to the vertical or vice versa with this type of
clamp.
DON’T FORGET!!
■ Never overload a plate clamp
■ Never use a single clamp – always in pairs
■ Never exceed the permitted maximum or minimum thickness
■ Never substitute an endless loop for a two-leg sling or vice versa
■ Never exceed the permitted range of sling leg angles
■ Never use the cam-less type if the plate can sag
■ Never attempt to rotate from the horizontal to the vertical with this type of
clamp

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SERVICE & MAINTENANCE
IN-SERVICE INSPECTION
Regularly inspect the plate clamp. If any of the following defects are found, refer to a
Competent Person:.
■ Wear, damage or distortion to fixed and moving jaws.
■ Frame opening out or cracked.
■ Insecure, worn or bent pins, bolts etc.
■ Worn friction grip material.
■ Damaged, bent or unsatisfactory action locking lever.
■ Tight, bent or damaged clamping threads etc.
■ Corrosion.
■ Illegible marking.
MAINTENANCE
Plate clamps should be cleaned and any moving parts lubricated at appropriate intervals,
unless the suppliers specific instructions indicate otherwise. In the case of clamps with
smooth jaws lined with a friction material, care must be taken to ensure no lubricant comes
into contact with the friction material.
WARNING: Teeth of jaws must not be re-sharpened or re-cut unless this has been specifically
approved by the maker.

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OPERATING INSTRUCTIONS
■ Commence to open the plate clamp by pulling the latch lever towards the jaw
■ Continue to place the plate clamp securely to the to-be lifted material and make sure that
the jaw of the place clamp rests on the material.
■ The plate clamp will close by pulling the latch lever towards to lifting eye. The clamp will
now stay attached to the to-be lifted material in the pretensioned position.
■ The lifting application can begin.
■ After the lifting application is completed, make sure the clamp is fully free of load by
decending the crane hook. The lifting eye of the plate clamp can now move freely and
you are able to open the clamp by pulling the latch lever towards to jaw.
■ When storing the plate clamp, please leave the clamp in an opened position. This position
will protect the teeth from damaging.