Doughty Zenith Mk3 User manual

www.doughty-engineering.co.uk
Doughty Engineering Ltd
Zenith Mk3
Winch Stand
Operating Manual

www.doughty-engineering.co.uk
Page 2 of 12 Issue: 04
Date: 05-03-13
Table of Contents
Revision History ............................................................................................................................... 2
Contact Details ................................................................................................................................. 2
Purpose ............................................................................................................................................. 3
Introduction....................................................................................................................................... 3
Safety Precautions ........................................................................................................................... 4
Assembly........................................................................................................................................... 6
Operation........................................................................................................................................... 6
Maintenance and Cleaning .............................................................................................................. 7
Parts Illustrations ............................................................................................................................. 8
Declaration of Conformity ............................................................................................................. 10
Revision History
Issue Amendment Date
1 New document 27-01-09
2 Introduction modified 18-06-09
3 Page 7, lowering instructions text changed 28-09-11
4 Pages 11 & 12 added 05-03-13
Contact Details
Doughty Engineering Ltd
Crow Arch Lane
Ringwood
Hants
BH24 1NZ
England
Telephone [phone]
Fax [phone]
www.doughty-engineering.co.uk
[email protected].uk

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Page 3 of 12 Issue: 04
Date: 05-03-13
This manual applies to the following products:
Part No.
Description
Height
T55580 Zenith 520 Roller Base 5M
T55582 Zenith 520 Turnbuckle Base 5M
T55590 Zenith 620 Roller Base 6M
T55592 Zenith 620 Turnbuckle Base 6M
Purpose
The Zenith Mark 3, 520 & 620 stands are a four section winch stand with a safe working
load of 200Kg. Zenith stands are supplied with a 28mm (1-1/8”) receiver accepting
standard TV spigots. Accordingly these stands are suitable for use with small trusses,
loudspeakers, lighting equipment etc. The Zenith Mk 3 is available in two styles,
consisting of turnbuckle or roller base arrangements.
Caution: Before using please read, note and retain these operating and safety
instructions
Introduction
To ensure reliable operating of the Zenith range of stands, please read these
instructions before use.
The Zenith stands are subjected to stringent tests prior to manufacture and each stand
is inspected through the manufacturing and assembly processes. In order to maintain
this guarantee of function and safety, whenever any spare parts are required,
these must be supplied by Doughty Engineering Ltd. The user forfeits all rights to
claim if parts are not of original specification, or if the stand is modified in any way.
Due to our policy of continuous improvement, Doughty Engineering Limited reserve the
right to amend or alter the specifications of the product at any time without prior notice.
When requiring spares or service, please quote the model type and year of manufacture
as indicated on the stand.
Type Part No. Min
Load
Max
Load
Closed
Height
Extended
Height
Unit
Weight
520R T55580 15Kg 200Kg 1815mm 5123mm 93.5Kg
520T T55582 15Kg 200Kg 1692mm 4984mm 76.0Kg
620R T55590 15Kg 200Kg 2048mm 6238mm 99.5Kg
620T T55592 15Kg 200Kg 1925mm 6100mm 82.0Kg
The stand is manufactured from mild steel (DIN 2394) box sections throughout, and
primarily comprises 4 telescopic mast sections, steel stabiliser legs and struts. The
cable used is of DIN 15020 2350N/mm² (6mm/7x19) grade and must be replaced with
this specification.

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Page 4 of 12 Issue: 04
Date: 05-03-13
The stand is available in two configurations. The roller configuration (T55580/T55590)
features a 4 castor base plate, with removable legs which slot into the base plate when
the stand is in use. When the stand is not in use the legs can be removed and slotted
into their transport position parallel to the main body of the stand (figure 4).
The turnbuckle base (T55582/T55592) comprises of a flat base plate with all four legs
permanently attached. The legs rotate outwards from their transport position until they
contact the ground, and retract into their transport position (figure 5). There are two
transport wheels fitted to the reverse side of the stand base as illustrated, to aid
transportation.
Safety Precautions
The Zenith stands provide easy and smooth lifting and lowering. The user must
determine if the product has the necessary characteristics to fulfil the required
application.
Excluded applications:
•Not tested for construction hoists
•Not approved for lifting persons
•Not approved for motorised use
Automatic mechanical brake: The TÜV approved winch used on these stands is fitted
with an automatic brake. The minimum load as marked on the stand should be met to
ensure the brake performs correctly. For any matters relating to the winch, please refer
to the winch operating instructions supplied.
Note: Do not apply oil or grease to the brake mechanism. The brake washers are pre-
greased with pressure resistant grease.
Before loading, the stand must be placed on a suitably firm and level surface, with the
stabiliser legs in place and in firm contact with the ground. Confirm that the mast section
of the stand is vertical prior to use. A spirit level is located on the baseplate of the
turnbuckle stand to assist.
The cable should be visually inspected at all accessible points for frays, cuts or kinks
before the stand is used. If any defects are found then the stand should be removed
from service until a suitable repair can be made. Do not attempt to use the stand with a
damaged cable. Do not shorten the cable at the winch connection.
The winch handle must not be removed from the stand while a load is fitted, as this will
disengage the brake and allow the load to drop. The minimum load as listed on the
table above and on the stand must be met to ensure correct braking action on the
winch.

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Page 5 of 12 Issue: 04
Date: 05-03-13
If using the stand in open air, ensure the stand is firmly supported by guy ropes to allow
for weather conditions.
The stand should not be moved with a load attached, whether the mast is extended or
retracted. Do not lean ladders or stairways onto the stand. The stand is not to be used
for lifting or supporting personnel. The stand should only be used for vertical lifting, do
not attempt to operate the stand off vertical. All loads must be evenly distributed.

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Page 6 of 12 Issue: 04
Date: 05-03-13
Assembly
Roller Base:
1. Manoeuvre the stand to the desired location, ensuring the base of the stand is in
contact with the supporting surface.
2. Remove the legs from their transport position.
3. Insert the leg into the base leg receiver (see figure 4), ensuring the adjustable
foot is orientated to contact the supporting surface.
4. Turn the foot support to lower or raise the foot. The foot should be in firm contact
with the supporting surface.
5. Repeat the above actions for all four legs.
6. Once the legs are secured the load may be attached to the stand by using a
28mm TV spigot. This must be secured in the receiver by the Tommy Bar
provided (see figure 2).
7. To disassemble the stand prior to moving, perform the above actions in reverse
order.
Turnbuckle Base:
1. Manoeuvre the stand to the desired location and raise the mast to the vertical,
ensuring the base of the stand is in contact with the supporting surface.
2. Release the legs from their transport position by removing the R clip and locking
pin (see figure 5).
3. Rotate the legs about the pivot point, ensuring the pivot foot is orientated to
contact the supporting surface, and lock the turnbuckle into the leg support
bracket with the locking pin. Ensure the R clip retains the locking pin.
4. Repeat the above actions for all four legs.
5. Adjust the turnbuckles to centralise the spirit level and ensure the mast is
vertical. The base of the stand must remain in direct contact with the ground.
6. Once the mast section is vertical and the legs are secured the load may be
attached to the stand by using a 28mm TV spigot. This must be secured in the
receiver by the Tommy Bar provided (see figure 2).
7. To disassemble the stand prior to moving, perform the above actions in reverse
order.
Operation
Lifting:
1. To start raising the stand, pull and rotate the upper locking pin (figure 1) to locate
in the raise position (see figure 1) and rotate the winch handle (figure 2-8)
clockwise, as indicated on the body of the winch.
2. Once located in the raising position, the locking pin will operate on a ratchet
when the winch handle is turned and the stand is raised.
3. Continue winding the handle until the mast either stops moving (top of stroke), or
the desired height is achieved.
4. To release the next mast section, pull and rotate the locking pin to locate it in the
raise position (see figure 1).
5. Repeat steps 3 and 4 for the remaining section.

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Page 7 of 12 Issue: 04
Date: 05-03-13
6. Ensure that all locking pins are engaged on the mast sections by rotating the
winch handle counter-clockwise until the masts stop descending. Rotate the
handle clockwise to remove any slack from the wire after checking.
Lowering:
1. To start lowering the load, ensure that the cable is tight and supporting the load.
2. Disengage the locking pin from the mast section by pulling and holding the pin
outwards.
3. While holding the locking pin outwards, rotate the winch handle (see figure 3)
counter-clockwise as indicated on the winch body to lower the mast section.
4. Rotate the winch handle (see figure 3) counter-clockwise as indicated on the
winch body to lower the mast section.
5. When the mast section reaches its base position, pull and rotate the locking pin
into the lock position to secure the mast (see figure 1).
6. Repeat the above actions for the remaining mast sections until the stand is fully
retracted.
7. The load may now be removed from the stand and the stand folded ready for
transport.
Before attempting to move the stand, ensure the load is removed, and the
locking pins (figure 2-7) retain the mast sections.
Maintenance and Cleaning
The cable must be inspected before each use of the stand, as detailed above (section
3), and also given at least an annual inspection to ensure that there are no kinks,
deformations, single strand breakage or cuts in the wire. Defective wires must be
replaced before the stand is returned to service.
The winch and stand are checked and lubricated during assembly, it is recommended
that the gear drive and handle threads be lubricated, and oil applied to the bearings on
the drum hub and the drive shaft. On no account should oil or grease be applied to
the brake mechanism.
The mast locking strips and locking pins should be checked at least annually to ensure
secure locking of the stand in its raised position. Particular attention should be paid to
the leading edges of the pin and strip, and to the return spring.
The Zenith stand should be inspected annually by trained personnel. If spares are
required, these should be obtained from Doughty Engineering Limited. Please quote the
reference number from the drawings included, the year of manufacture and serial
number as marked on the stand. If parts not of original manufacture are used, or if the
stand is modified in any way, the user forfeits all rights to claim.

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Page 8 of 12 Issue: 04
Date: 05-03-13
Parts Illustrations
Figure 1
Lock
Raise
Winch Guide
Pulley
Winch
Handle
Figure 3Figure 2
Upper Pulley
Assembly
Locking Pin
Assembly
Locking Pin
Assembly
Tommy Bar

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Page 9 of 12 Issue: 04
Date: 05-03-13
Figure 5:
Turnbuckle Base
Spirit Level
Turnbuckle
Pivot Foot
‘R’ Clip &
Locking Pin
Leg Support
Bracket
Adjustable
Foot
Base Leg
Receiver
Foot
Support
Figure 4:
Roller Base

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Page 10 of 12 Issue: 04
Date: 05-03-13
Declaration of Conformity

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Page 11 of 12 Issue: 04
Date: 05-03-13

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Page 12 of 12 Issue: 04
Date: 05-03-13
Doughty Engineering Ltd
Crow Arch Lane
Ringwood, Hampshire, BH24 1NZ
Tel: [phone] Fax: [phone]
email: [e-mail]
Web: www.doughty-engineering.co.uk
Note: Whilst every effort has been made to ensure that the information contained within this manual is
correct Doughty Engineering does not accept any liability for errors or omissions. Specifications and
technical data are intended for guidance purposes only and may vary.