Nemag Quick Release Links User manual

Nemag
user manual
quick release link
Nemag | User Manual | Quick Release Link EN | Revision 1.3
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Table of contents
1GENERAL INFORMATION............................................................................................................................................................3
2SAFETY INFORMATION ...............................................................................................................................................................4
3TECHNICAL SPECIFICATIONS ....................................................................................................................................................5
4DESCRIPTION AND FUNCTION ...................................................................................................................................................9
5OPERATION................................................................................................................................................................................11
6MAINTENANCE...........................................................................................................................................................................13
7REJECTION.................................................................................................................................................................................15
8TRANSPORT AND STORAGE ....................................................................................................................................................16
Disclaimer
All rights reserved.
Copyright
No part of this manual may be reproduced, transmitted, stored in any retrieval system or translated into any language, without the prior
written permission of NEMAG B.V. The products and trademarks are protected by copyright ©, various trademarks ® and patents.
Changes
All possible care has been taken in the preparation of this manual. All information, illustrations and specifications are based on the latest
information available at the time of publication. NEMAG B.V. reserves the right to make changes without notice to both this manual
(including dimension tables) and to the products that are described in this manual.
Product warranty
Any warranties, expressed or implied, concerning the use of Rope Pear Sockets and Quick Release Links apply to new, unused
products when tested in a standard testing machine under controlled conditions, in direct tension, and at a uniform rate of speed. The
term “Breaking load” contains no implication of what load a Rope Pear Socket and Quick Release Link will withstand if not properly
used, or if it suffers abuse. All equipment using Rope Pear Sockets and Quick Release Links must be properly maintained. Rope Pear
Sockets and Quick Release Links must be properly stored, handled, used and maintained within the rules of user manual. Most
importantly, Rope Pear Sockets and Quick Release Links must be regularly inspected before and during each use. Inspections must
meet local or applicable national safety regulations. Damage, abuse, overloading or improper maintenance can cause failure and
accidents. If in doubt about the safe and proper use of Rope Pear Sockets and Quick Release Links consult manufacturer.
© Copyright NEMAG B.V., the Netherlands

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1 General information
1.1 Purpose of the document
This manual gives the information that is necessary for safe use of the product. Read and understand this manual before you use
the product. The information provided is based on general data known at the time of publication of this manual. Nemag BV has a
policy of continuous improvement and reserves the right to change or modify the product.
1.2 Conventions
1.2.1 Language
The original text of the manual is written in US English. Any translation is a derivative of the original text.
1.2.2 Illustrations
The illustrations in the manual are a typical example of the delivered product. Essential differences in configuration between
product types are indicated in the text.
1.2.3 Units
All data in this manual is given in accordance with metrical European units and standards.
1.3 Admonitions
DANGER
Indicates a hazard with a high level of risk which, if not avoided or if the instruction is executed incorrectly,
will cause death,
serious personal injury, or damage to the product.
WARNING
Indicates a hazard with a medium level of risk which, if not avoided or if the instruction is executed incorrectly, can cause
death, serious personal inju
ry, or damage to the product.
CAUTION
Indicates a hazard with a low level of risk which, if not avoided or if the instruction is executed incorrectly, can cause mi
nor
personal injury, or damage to the product.
NOTE
Indicates important information for correct use of the product.
1.4 Availability and storage
Keep this manual at a safe location for future reference. All manuals can be downloaded from our website. NEMAG B.V. can
supply more copies on request.

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2 Safety information
2.1 Marking
The following information is given on the NEMAG Quick Release Link:
A
Safe working load (SWL) in tons
E
CE mark
B
Brand name and country of origin
F
Size
C
Registration number
G
Batch code
D
Date (month + year) of the final test
H
Patent number
The various figures and values in the illustration are an example.
2.2 Safety instructions
Read this manual carefully and keep the manual for future reference.
•Always obey the safety instructions in this manual and in the manual(s) of associated equipment that is used with the NEMAG
Quick Release Link.
•The NEMAG Quick Release Link and any associated equipment must be used, maintained and stored in accordance with this
manual, the manual(s) of the associated equipment, and the applicable local legislation.
•The NEMAG Quick Release Link must be inspected before and during each use, as described in this manual, and in
accordance with the applicable local legislation.
•Do not use the NEMAG Quick Release Link without a valid certificate.
•Only use the NEMAG Quick Release Link when the locking piece is installed and locked.
•Do not use the NEMAG Quick Release Link if you have any doubts about the correct functioning of the bolt in the locking piece.
•Do not subject the NEMAG Quick Release Link to temperatures that are higher than 200° C.
•Do not use the NEMAG Quick Release Link in substances that stimulate oxidation.
•Do not use the NEMAG Quick Release Link if the number of undergone load cycles is more than 250,000 loads at SWL.
•Do not use the NEMAG Quick Release Link if it has been overloaded by more than 200%.
•Do not use the NEMAG Quick Release Link if it is permanently deformed or seriously damaged.
•Do not weld or heat-treat the NEMAG Quick Release Link.
•Do not replace parts with non-NEMAG parts.
•Reject and destroy the NEMAG Quick Release Link if any of the conditions in chapter 7.
When you are in doubt about the safe and correct use of the NEMAG Rope Pear Socket, refer to NEMAG B.V.

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3 Technical specifications
NOTE
The working load is the recommended maximum load for grabbing operations when NEMAG Quick Release Links and
NEMAG Rope Pear Sockets pass over a wide ‘U’ cable sheave. For other applications, you must adhere to a safety factor that
is in li
ne with official local and international directives.
3.1 NEMAG Quick Release Links
Link
size Working load (kg) Breaking load (kg) Dimensions (mm) Weight (kg)
A B C D E F G
4 3,000 25,000 76 76 24.5 19 30 21 25.2 1.0
5
4,500 33,000 84 84 27 21 32.5 23 28 1.3
6
5,000 37,500 92 92 29.5 23 35 25 30.3 1.6
7 7,000 49,000 100 100 32 25 38 28 32.8 2.0
8 8,000 54,000 108 108 34.5 27 40.5 31 35.3 2.6
9 9,500 60,000 116 116 37 29 43.5 34 38 3.0
10
12,000 75,000 128 128 40.5 32 48 37 41.6 4.2
11
15,000 95,000 140 140 44 35 53 40 45.8 5.5
12 17,000 110,000 152 152 47.5 38 57 43 49.6 7.1
13 21,000 135,000 164 164 51 41 61.5 46 53.4 9.1
14 26,000 160,000 176 173 54 44 66 50 58 10.8
15
30,000 175,000 188 188 58 47 70.5 52 61 13.7
17
42,500 260,000 222 222 68 56 84 62 71 22.8
NOTE
The force transmitting parts of the NEMAG Quick Release Link are made of material in accordance with the specifications laid
down in standard EN 1677
-1 Components for slings – Forged steel components – Grade 8.

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3.2 NEMAG Rope Pear Sockets
Pear
size Wire rope diam. (mm) Working load (kg) Breaking load (kg)
Dimensions (mm)
L
(mm) Weight (kg)
A
B
C
D
E
F
G
H
I
2 12-13 2,000 14,000 95 56 25 195 15.5 13.5 22 25 16 41 0.4
3 14-15 2,500 17,500 109 64 28 220 17.5 15.5 24 29 19 48 0.7
4
16-17 3,000 22,500 123 70 31 220 19.5 17.5 26 31 21 58 0.9
5
18-19 4,500 27,500 135 84 33 245 21 19 30 42 23 64 1.4
6
20-21
5,000
35,000
152
84
36
310
23
21
33
38
26
74
1.6
7 22-24 7,000 42,500 166 100 40 310 26 23 37 48 30 78 2.2
8 25-27 8,000 52,500 186 100 43 350 28 25 39 44 32 90 2.5
9
28-30 11,000 70,000 202 120 45 350 32 28 40 58 35 98 3.7
10
31-33 13,000 85,000 222 120 52 445 32 28.5 45 56 39 110 4.0
11
34-36
15,000
95,000
239
142
55
445
36
31.5
50
70
42
110
6.1
12 37-39 17,000 110,000 264 142 60 495 39 34.5 51 64 45 130 6.3
13 40-42 21,000 125,000 285 166 63 555 43 36.5 59 80 48 132 8.8
14
43-45 26,000 155,000 312 166 68 595 47 40 62 72 51 155 10.7
15
46-48 30,000 180,000 337 170 75 595 51 44 66 68 55 170 11.6
17
52-56
42,500
240,000
400
220
84
880
60
54
75
90
63
200
22.1
NEMAG Rope Pear Sockets type S
Pear
size Wire rope diam. (mm) Working load (kg) Breaking load (kg)
Dimensions (mm)
L
(mm) Weight (kg)
A
B
C
D
E
F
G
H
I
924 22-24 11,000 70,000 192 133 40 325 31 27 40 58 29 96 4.1
1026 25-27 13,000 85,000 212 143 43 375 35 30.5 43 60 32 108 5.0
1130
28-30 15,000 95,000 239 156 45 400 36 31.5 50 70 35 122 6.0
1232
31-33 17,000 110,000 249 165 52 425 39 34.5 57 72 38 118 8.2
1336
34-36
21,000
125,000
257
184
62
450
43
36.5
60
80
42
118
9.1
1440 37-40 26,000 155,000 297 192 60 475 47 40 62 80 46 142 11.8
3221 42-44 32,500 189,000 314 204 66 425 53 46 70 80 49 144 13.8
1548
46-48 30,000 180,000 329 192 67 575 51 44 66 80 57 157 12.4
1648
46-48 36,000 215,000 343 218 70 500 56 50 75 90 54 157 16.3

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3.3 Connection between NEMAG Rope Pear Sockets and
NEMAG Quick Release Links
A NEMAG Rope Pear Socket can be connected with a NEMAG Quick Release Link of the same size, or to a NEMAG Quick
Release Link of a different size as shown in the table below. The example below shows how you can find the correct size Quick
Release Link and Rope Pear Socket. An additional safety factor can be included.
Given:
•Steel wire rope with a diameter of 26 mm
•Safe working load of the steel wire rope: 10,000 kg
1. According to section 3.1 select NEMAG Rope Pear Socket no. 1026
2. Then, according section 3.1 and the table below, NEMAG Quick Release Link no.10 is possible
NEMAG Quick Release Link
size 4 5 6 7 8 9 10 11 12 13 14 15 17
NEMAG Rope Pear Socket
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
type s
924
1026
1130
1232
1336
1440
3221
1548
1648
Connection possible
Connection not possible

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3.4 Wide ‘U’ cable sheaves
Pear
size Wire rope diam. (mm) Link sizes
Dimensions (mm)
A
B
C
D
E
R
4 16-17 4 560 694 750 60 9 7
5 18-19 4-5-6 630 788 850 70 10 9
6 20-21 5-6-7 710 880 960 75 11 12
7 22-24 6-7-8 710 890 970 80 12 10
924 22-24 8-9-10 710 890 970 80 12 10
8 25-27 7-8-9 800 984 1060 80 14 13
1026 25-27 9-10 800 984 1060 80 14 13
9 28-30 8-9-10 900 1116 1210 95 15 13
1130 28-30 10-11-12 900 1116 1210 95 15 13
10 31-33 9-10-11 1000 1240 1360 105 17 16
1232 31-33 11-12-13 1000 1240 1360 105 17 16
11 34-36 10-11-12 1000 1240 1360 105 19 14
1336 34-36 12-13-14 1000 1240 1360 105 19 14
12 37-39 11-12-13 1200 1450 1560 110 20 12
1440 37-40 13-14-15 1200 1450 1560 110 20 12
13 40-42 12-13-14 1200 1450 1560 110 21 12
3221 42-44 15 1200 1455 1560 110 23 16
14 43-45 13-14-15 1400 1655 1760 110
23
16
15 46-48 14-15 1600 1870 1960 110 25 25
1548 46-48 14-15 1400 1655 1760 110 25 16
1648 46-48 15-17 1400 1680 1760 122 25 16
17 52-56 17 1800 2085 2200 122 29 18
NOTE
Wide ‘U’ cable sheaves
generally have the dimensions as shown in the table above. In case of different dimensions, refer to
NEMAG B.V.
NOTE
Diameter C has been designed for a NEMAG Quick Release Link that is one size larger than the NEMAG Rope Pear
Socket
that is indicated in the table.
Radius E depends on the diameter of the applied steel wire rope.

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4 Description and function
4.1 Overview
‘C’ section
The 'C' section is forged of a steel alloy that is not subject to ageing. It is quenched
and tempered up
to a tensile strength of 1000-1100 N/mm2. The inside of the bow
is induction hardened for extra wear resistance.
The 'C' section has been accurately machined, so that exchange of parts is possible
.
Locking piece
The locking piece closes the 'C'
section. A spring-loaded bolt that can be operated
swiftly with the key secures the locking piece. The locking piece has these parts:
•
The force transmitting body, which is forged of steel that is not subject to
ageing. It is quenched and tempered up to a tensile strength of 800-1000
N/mm2.
•
The locking mechanism, which is made of high-tensile CrMo steel. It is sealed
to prevent the ingress of dirt and lifetime lubricated with a compound lubricant.
•
The spring-loaded 10 mm inside hexagon bolt, which is fully countersunk in the
body.
Key
The key has a 10 mm outer hexagon tip that fits in the inside hexagon bolt of the
locking piece. The handle is big enough to exert a rotating as well as a pressing
force.
One side of the handle has a chisel point to clean
the inside hexagon bolt if
necessary. The other side of the handle has a hammer face.

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4.2 Intended use
The NEMAG Quick Release Link has been developed for quick, straightforward, safe and wear-resistant coupling and uncoupling
of steel wire ropes, chains or other equipment such as grabs on cranes.
Typical connections that can be made with the NEMAG Quick Release Link (B) are:
•
2 chain outer ends
•
1 outer end of a steel wire rope fitted with a NEMAG Rope Pear Socket (A)
and 1 chain outer end (C)
•
1 outer end of the steel wire rope fitted with a NEMAG Rope Pear Socket (A) and
1 piece of equipment that is fitted with a fixed eye (C).
•
2 outer ends of steel wire ropes fitted with NEMAG Rope Pear Sockets (A, C).
This combination is suitable to pass over a special rope sheave, called a wide 'U'
sheave.
See also section 3.
F
or other applications, refer to NEMAG B.V.

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5 Operation
5.1 Install the locking piece
1.
Slide the locking piece (B) on the ‘C’ section (C).
2.
Place the hexagon tip of the key (A) in the inside hexagon bolt of the locking
piece.
3.
Rotate the key (A) 90° to the left or to the right. This locks the locking piece (B)
on the ‘C’ section (C).
WARNING
The locking piece is only safely locked if:
•
A ‘click’ is heard.
•
The inside hexagon bolt cannot be rotated any further with the key.
•
The inside hexagon bolt comes up at least 3.5 mm in the chamber of
the locking piece.

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5.2 Remove the locking piece
NOTE
If necessary, use the chisel point of the key
to remove dirt from the inside hexagon bolt of the locking piece.
1.
lace the hexagon tip of the key (A) in the inside hexagon bolt of the locking
piece.
2.
Use the key to push the mechanism inside to the stop.
3.
Keep the mechanism pressed in and rotate the key (A) 90° to the left or to the
right. The locking piece (B) is released.
4.
Take the locking piece (B) out of the ‘C’ section (C).

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6 Maintenance
Carry out maintenance (lubrication, cleaning, inspection and tests, removing burrs) as described in this chapter and according to
the applicable local legislation.
6.1 Lubrication
•
Grease the contact areas (A). This extends the lifetime of both the NEMAG
Quick Release Link and the NEMAG Rope Pear Socket.
•
Use EP3 or EP4 grease (lubricant for high-pressure contact surfaces).
•
Apply grease after every 24 hours of use.
NOTE
Do not grease the NEMAG Rope Pear Socket when it is used in an environment with large quantities of abrasive particles. For
example during transshipment of alumina or other abrasive / dusty ores.
6.2 Cleaning
During use, particles that stimulate wear can become embedded in the lubricant. Therefore, regularly clean the bow of the NEMAG
Quick Release Link.
6.3 Visual inspection
Visually examine the NEMAG Quick Release Link for defects after every 200 hours of use.
6.4 Removing sharp hard points and burrs
Through contact with other equipment, burrs or small bumps can occur on the edges of the contact surfaces of the locking piece.
This can make it difficult to slide the locking piece on the ‘C’ section. Use a file to remove these burrs or small bumps, until the
locking piece functions correctly again, as described in chapter 5.
WARNING
When you remove any defects, make sure that the play between the ‘C’ section and the locking piece, and the overall wear of
the ‘C’ section, do not exceed the values that are given in chapter.7.
6.5 Magnetic Particle Inspection (MPI)
•
To avoid failures that are the result of fatigue cracks, the NEMAG Quick Release
Link must undergo a Magnetic Particle Inspection (MPI) after at least every
125,000 cycles at safe working load (SWL).
•
Do the MPI at the areas that are shown in the illustration.
•
Do the MPI at the intervals that are given in section 6.6.
•
If required by the applicable local legislation, test the NEMAG Quick Release
Link after inspection

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6.6 Inspection interval and lifetime indication
CAUTION
The data in the tables below are indicative lifetimes, based on our experience and general applications. High
dynamic
forces in the application decreases the lifetime significantly. You must assess the application to determine the required
inspection interval and lifetime. At new applications, additional inspection intervals must be applied in order to determine
t
he lifetime for that application. The number of load cycles per grab cycle is affected by the average amount of trimming
works and the crane system.
Refer to section 6.3 for the methods of inspection.
Refer to chapter 7 for the criteria of rejection.
Criterion: Number of cycles at Safe
Work Load (SWL)
Grab operation
General purpose and container operation
60 cycles / hour
1,6 load cycle during one grab cycle.
60 cycles / hour
1 load cycle during one operation cycle.
Inspection after
125,000 cycles at SWL
125,000 cycles at SWL
Do not use after
250,000 cycles at SWL
250,000 cycles at SWL
Criterion: Hours of operation
Grab operation
General purpose and container operation
Inspection after
1300 hours of operation
2000 hours of operation
Do not use after
2600 hours of operation
4000 hours of operation
Criterion: Shifts of operation
Grab operation
General purpose and container operation
24 hours per day operation Inspection after 8 weeks
Do not use after 16 weeks
Inspection after 12 weeks
Do not use after 24 weeks
16 hours per day operation Inspection after 12 weeks
Do not use after 24 weeks
Inspection after 18 weeks
Do not use after 36 weeks
8 hours per day operation Inspection after 24 weeks
Do not use after 48 weeks
Inspection after 36 weeks
Do not use after 72 weeks

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7 Rejection
WARNING
If any of the rejection criteria below are exceeded, the NEMAG
Quick Release Link must be rejected and destroyed.
•
Play between the ‘C’ section and the locking piece (difference between the
dimensions ‘S’ minus ‘T’) is more than the value given in the table.
•
Wear of the ‘C’ section is more than 15% of the nominal dimension at any place.
•
Heating in excess of 200° C has taken place.
•
Any form of welding work or heat treatment has taken place.
•
Any permanent deformation.
•
Any cracks, or indication of cracks, in the material.
•
The number of undergone load cycles is more than 250,000 loads at SWL.
•
The bolt in the locking piece does not function correctly, as described in chapter 5.
•
Any overloading has taken place.
size
S-T [mm]
W [%]
4
> 0.6
> 85% D
5
> 0.6
> 85% D
6
> 0.8
> 85% D
7
> 0.8
> 85% D
8
> 0.8
> 85% D
9
> 0.8
> 85% D
10
> 1.0
> 85% D
11
> 1.0
> 85% D
12
> 1.0
> 85% D
13
> 1.0
> 85% D
14
> 1.0
> 85% D
15
> 1.25
> 85% D
17
> 1.25
> 85% D
WARNING
If
the NEMAG Quick Release Link is seriously damaged, it must be sent to NEMAG B.V. for assessment or destroyed..
WARNING
If the NEMAG Quick
Release Link does not have a certificate, it must be returned to NEMAG B.V. for assessment. If found
OK, a certificate can be issued
.

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8 Transport and storage
8.1 Conservation for shipment
The NEMAG Quick Release Link has been conserved for shipment with a rust-proofing agent. Make sure that the NEMAG Quick
Release Link does not make contact with substances that stimulate oxidation.
8.2 Storage
The minimum requirement for storage is protection against humidity. Check the conservation every 3 months if storage takes place
in very humid conditions. If necessary, correct the conservation.