Tractel Supertirfor TU16H Manual

supertirfor
motorised lifting and pulling machines
1
models TU-16H
TU-32H
HYDRAULIC POWER PACKS
1, 2 or 4 way operation
®®
equipment in
accordance with
CE directives
106925-03 - ind 01 - 09/02
operating and
maintenance
instructions

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ORIGINAL MANUAL
Always concerned to improve the quality of its
products, the TRACTEL Group reserves the right
to modify the specifications of the equipment
described in this manual.
The companies of the TRACTEL Group and their
agents or distributors will supply on request
descriptive documentation on the full range of
TRACTEL products: lifting and pulling machines,
permanent and temporary access equipment,
safety devices, electronic load indicators,
accessories such as pulley blocks, hooks, slings,
ground anchors, etc.
CONTENTS Page
General warning 2
Technical data 3
1. Description of equipment 4
2. Rigging arrangements 4
3. Installation 6
4. Releasing and engaging the jaws 8
5. Anchoring 9
6. Operation 10
7. Taking out of service and storage 11
8. Safety devices 12
9. Replacing the shear pins 12
10. Wire rope 13
11. Maintenance instructions 14
12. Warnings against hazardous operations 14
13. Troubleshooting 15
14. Health and safety at work 15
Fig. 1
B : Rope release lever
C : Safety catch
E : Rope guide
F1-F2 : Operating instruction
labels
G : Shear pins
L1 : Forward operating lever
L2 : Reverse operating lever
S : Rope exit
V : Double-acting hydraulic
ram
P1 : Position of ram for
forward operation
P2 : Position of ram for
reverse operation
R : Ram anchor bracket
A : Pressure gauge
B : Control block
C : Guard and carrying
frame
D : Flow regulator
H : Reservoir filler cap
J : Oil level indicator
(petrol engine)
L : Starter cord
(petrol engine)
M : Motor (electric or petrol
engine)
N : Hydraulic oil level
indicators
R : Hydraulic oil reservoir
T : ON/OFF switch
(electric motor)
S : Filter
TU32H fitted with ram
TU16H fitted with ram
Petrol Power Pack Electric Power Pack
The TRACTEL network is able to supply an
after-sales and regular maintenance service.
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!
GENERAL WARNING
!
1. Before using the SUPERTIRFOR®machine(s) and hydraulic power pack(s), it is essential for the
safe and correct operation of the equipment that this manual be read and fully understood and
that all the instructions be followed. This manual should be made available to every operator.
Extra copies of this manual will be supplied on request.
2. The SUPERTIRFOR®machine allows the operator to carry out work with complete safety. Ensure
that this machine is only handed over for use or rigging to an operator who is trained to operate it
in a responsible manner.
3. Neverusea machinewhich is notin goodworking condition. Replace anywornor damaged wire
rope or hydraulic hose. Continuous monitoring of the condition of the machine, its wire rope and
anchor sling, the hydraulic power pack and its motor and the hydraulic hoses is an important
safety consideration.
4. The manufacturer declines any responsibility for the consequences of dismantling or altering the
machine by any unauthorised person. Specially excluded is the replacement of original parts by
parts of another manufacturer.
5. The models as described in this manual must not be used for lifting people.
6. Never apply to the machine a load or effort greater than the maximum working load.
7. SUPERTIRFOR®machines are not designed for use in explosive atmospheres.
8. IMPORTANT : If the equipment described in this manual is supplied to an employed person,
check that you meet your obligations with respect to safety at work regulations (see section 14 on
page 15).
9. Onthe electricpowerpack, checkthatthe directionofrotationof themotoris correct,byswitching
the motor ON, then OFF. The motor should rotate clockwise. (See section 3.3.1 on page 7.)
LIFTING PEOPLE AND SPECIALAPPLICATIONS
For further information on equipment for lifting people, and for any special application, please refer to
TRACTEL
TECHNICAL DATA
SUPERTIRFOR®
MODEL TU-16H TU-32H
Working load limit t 1.6 3.2
Weight
machine kg 28 54.1
telescopic operating handle kg 2.4 2.4
standard 20m of wire rope, complete kg 13 31
Machine dimensions
length mm 788 1070
length with optional hook mm — 1290
height mm 360 430
width mm 185 204
telescopic handle : closed/extended cm 68/119 68/119
TIRFOR®wire rope
diameter mm 11.5 16.3
guaranteed breaking strain* daN 9600 19200
weight per metre kg 0.54 1.06
Rope travel**
forward, without load mm 45 32.5
forward, with WLL mm 37 14
reverse, without load mm 42 35
reverse, with WLL mm 44 25
* Including end fittings of the wire rope
** One complete cycle of the operating lever
HYDRAULIC POWER PACK
No. of rams to be supplied 1 2 4
Control block BC S BC 2d BC 4d
No. of hoses 2 4 8
Flow per ram l/min 8 6.5 3.25
13*
Speed
forward operation WLL*** TU16H m/min 2 1.5 0.75
reverse operation WLL*** TU16H m/min 2.3 2 1
forward operation WLL*** TU32H m/min 0.7** 0.35 0.17
reverse operation WLL*** TU32H m/min 1.6** 0.8 0.4
*
NEVER CONNECT A TU16H MACHINE TO AN OUTPUT OF 13 l/min.
** Connected to the 13 l/min outlet.
*** Working Load Limit
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1. DESCRIPTION OF EQUIPMENT
1.1. SUPERTIRFOR®
TheSUPERTIRFOR®machineisapower-operated
liftingand pullingmachine. Itis versatile, portable
and multi-purpose, not only for pulling and lifting
but also for lowering, tensioning and guying. The
originality of the SUPERTIRFOR®machine is the
principle of operation directly on the wire rope
which passes through the mechanism.
The effort is applied to the operating levers
(forward or reverse) by a double-acting hydraulic
ram (or, if required, by a telescopic operating
lever). The SUPERTIRFOR®is fitted with a hook
or anchor pin, depending on the model, so that it
can be secured quickly to any suitable anchor
point.
1.2. Hydraulic power pack
1.2.1 Hydraulic power pack with electric motor
The hydraulic power pack may be supplied with
anelectricmotor for400Vor230V, 3phasesupply.
It is operated from a push-button control box and
allows 1 to 4 SUPERTIRFOR®machines to be
operated simultaneously. The power pack has a
pumpwhichdelivers a flowof8l/min.forthe model
fittedwithaone-waycontrolblockorapumpwhich
delivers a flow of 13 l/min. for the model fitted with
a one-, two- or four-way control block.
1.2.2 Hydraulic power pack with petrol engine
The hydraulic power pack may be supplied with a
petrol engine. It allows 1 to 4 SUPERTIRFOR®
machines to be operated simultaneously. The
power pack has a pump which delivers a flow of
13 l/min. and is fitted with a one-, two- or four-way
control block.
1.2.3 Control blocks
The hydraulic power pack may control from one
to four SUPERTIRFOR®machines simultaneously.
For this the control block must have as many
outlets as machines.
NOTE : The one-way control block on a power
packfitted witha13 l/min.pumphas twoseparate
outlets: one delivers a flow of 13 l/min for
connecting only to a model TU32H and the other
delivers a flow of 8 l/min. for connecting to the
model TU16H. Never connect the
SUPERTIRFOR®TU16H to the outlet delivering
a flow of 13 l/min.; to do so would damage the
hydraulic ram.
The 2 or 4 way control blocks have a 1 or 2 stage
flow dividing device which delivers to each ram a
half or quarter of the flow from the pump,
independently of the pressure or length of the
hoses on each ram.
1.2.4 Standard set of equipment
A standard set of equipment comprises :
• a hydraulic power pack fitted with an electric
motor or petrol engine
• one or more sets of hydraulic hoses
• one or more SUPERTIRFOR®machines fitted
with an anchor bracket and self-reciprocating
hydraulic ram
• a 25 l drum of special hydraulic oil
• one or more special wire ropes with end fittings
and wound onto a reeler
This manual and a guarantee card are attached
toeach machine,togetherwith theCEdeclaration
of conformity.
IMPORTANT : TIRFOR®wire rope has been
specially designed to meet the particular
requirementsoftheSUPERTIRFOR®machine. The
manufacturer does not guarantee the safe
operation of the machines used with wire rope
other than TIRFOR®wire rope.
2. RIGGING ARRANGEMENTS
The machine may be anchored to a fixed point
with the wire rope travelling towards the machine
(Figs. 2.1, 2.2, 2.3), or travel along the wire rope,
with the load, the wire rope itself anchored to a
fixed point (Fig. 2.4).
Fig. 2.1 Fig. 2.2
Fig. 2.3 Fig. 2.4
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N.B. : Whatever the rigging arrangement, and if
the machine is anchored to a fixed point, ensure
thatthere are no obstructionsaroundthemachine
which could prevent the wire rope, the machine
and anchor from operating in a straight line. It is
therefore recommended to use a sling of an
appropriate capacity between the anchor point
and the machine (Fig. 3).
N.B. : Where the rigging arrangement shown in
Fig. 2.4 is used the user’s attention should be
drawn to the danger of trapping the hydraulic
hoses, pressure and return. The rigging
arrangementmusttakeintoaccountthe movement
of the hoses with the machine. As far as possible
this rigging arrangement is to be avoided.
N.B. : Whatever the rigging arrangement, always
make sure that the hydraulic hoses, pressure and
return, are free to move and are not restrained or
trapped, particularly over sharp edges.
!
WARNING
!
: Any rigging arrangement
whichrequires thecalculationoftheforcesapplied
shouldbe checkedbya competentengineer,with
special attention to the appropriate strength of
fixed point used.
For work such as guiding the trunk in tree felling,
the operator should ensure that he is outside the
danger area by passing the wire rope around one
or more return pulleys.
The capacity of the machine may be increased
considerably for the same effort by the operator
by using multiple sheave blocks. (See the
examples set out in Figs. 6.1 and 6.2).
The increase in the capacity shown is reduced
depending on the efficiency of the pulleys.
The diameter of the pulleys used should be equal
to at least 18 times the diameter of the wire rope.
(Refer to the applicable regulations).
For any rigging arrangement other than those
described in this manual, please consult
TRACTEL or a competent specialist
engineer before operating the machine.
Fig. 3
Fig. 4 Fig. 5
FORBIDDEN CORRECT
1
1
1
2
2
1
1
12
1
2
3
1
1
12
1
2
4
1
12
1
1
14
1
3
4
1
1
1
Fig. 6.1 - Pulling
Fig. 6.2 - Lifting
2
1
2
1
1
2
2
1
1
111
2
2
1
1
11
2
1
3
2
2
1
1
11
2
1
2
1
4
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A click may be heard when the anchor pin is
correctly locked into position. Ensure that the
anchor pins are well lubricated.
3.1.2. TU32H
Mount the VA3 ram onto the TU32H fitted with its
anchorbracket by usingtheanchorpin, attheend
ofthe machinewherethe wire ropeis inserted into
the SUPERTIRFOR®. Then fit the other end of the
ram, with its protective rubber cover pointing
downwards, to the forward or reverse operating
lever, using the anchor pin attached. The anchor
pins are fitted with spring clips. Check that these
are correctly fitted and locked into position
(see Fig. 9).
3.2. Wire rope
N.B. : When handling the wire rope it is
recommendedtoprotect the handsby usingwork
gloves.
If the wire rope is to be anchored to a high anchor
point, the wire rope should be anchored before
fitting the wire rope in the machine.
1. Uncoil the wire rope in a straight line to prevent
loops or kinks.
2. Releasethe internalmechanismof themachine
(see section 4 : Releasing and engaging the
jaws).
3. Insertthewireropethroughtheropeguideatthe
end opposite to the anchor point (hook or
anchor pin).
4. Push the wire rope through the machine, and if
necessary, helping it by operating the forward
operating lever.
5. Whenthewireropeappearsthroughtheanchor
point, pull the slack wire rope through the
machine, to the point required.
6. Engage the jaws by operating the rope release
mechanism (see section 4 : Releasing and
engaging the jaws).
7. AnchortheSUPERTIRFOR®machineorthewire
ropetotheappropriatefixedpoint(seesection 5 :
Anchoring)takingcaretoensurethattheanchor
point (hook or anchor pin, depending on the
model) is correctly fixed.
3. INSTALLATION
3.1. SUPERTIRFOR®machines
3.1.1 TU16H
1. If not already fitted, mount the anchor bracket
onto the machine. To do this, use a 13mm tube
spanner. Remove the 6 screws and washers,
item 1, the bolt and its washer, item 2, and
slightly loosen the 4 screws, item3, as shown in
Fig.7. Mount the anchorbracket,takingcareto
centre the fixing holes. Refit the 6 screws and
washers,item1,repositionandfittheboltandits
washer, item 2, and retighten all the screws,
items 1, 2 and 3 (see Fig. 7).
!
WARNING
!
: Whilstremovingthe screws,
item 1, and during their replacement, take great
care not to let any of the washers fall inside the
TU16H. If any of the washers does fall inside the
machine, it must be removed.
DO NOT USE ANY MACHINE INTO WHICH A
WASHER HAS FALLEN UNTIL IT HAS BEEN
REMOVED
2. Using the anchor pin, fit the VA2 ram onto the
bracketR(see Fig.8) atthe appropriateanchor
point, depending on the direction required.
3. Usingtheanchorpinattachedtotheclevisatthe
end of the ram cylinder, fit the clevis to the
appropriate operating lever.
NOTE : The anchor pin may be more easily fitted
by moving the operating lever. Check that the
anchor pins are correctly fitted into their housing.
Fig. 7
Fig. 8
Fig. 9
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3.3. Hydraulic power pack
NOTE : Thefollowingoperationsshouldpreferably
be carried out at the factory before going to site.
N.B. : The hydraulic power packs are supplied
withoutoilin thereservoirfor safety reasons during
transport.
1. Removethereservoircap(H)andfillthereservoir
with hydraulic oil.
ATTENTION : Do not remove the filter. Fill the
reservoir until the level reaches the upper oil level
indicator N.
2. Refit the reservoir filler cap correctly.
ATTENTION: Thisoperationof fillingthe reservoir
should be carried out with great care to avoid the
introduction of dust or any foreign matter into the
reservoir. If possible this should be done before
leaving the factory or warehouse for the
construction site.
3. Fit the hydraulic hoses to the power pack.
The pressurehoses,whichhaveanindentmark
ontheconnectingnut,shouldbeattachedtothe
outlet on the control block with the same
indentation.
NOTE : On a one-way control block, connect the
hose to the 8 l/min. output for use with a TU16H or
aTU32H. The13l/min.outputisforuseexclusively
with a TU32H. Where a power pack with an
8 l/min. pump is used, the 13 l/min. output
becomes 8 l/min. and the 8 l/min. output should
be blocked off (see Fig. 10).
NEVER CONNECT A TU16H MACHINE TO AN
OUTPUT OF 13 l/min.
3.3.1 Power pack with electric motor
Check the voltage of the power supply: 400V or
230V, 3phase,50 Hz. Themotors ofthehydraulic
power packs are wired at the factory for use with
a voltage of 400V. The hydraulic power packs will
operate on 230V. Changing the voltage should
only be carried out by a qualified electrician.
To change the voltage, proceed as follows :
1. Check that the machine is not connected to the
mains power supply.
2. Opentheelectriccontrolbox,usingan8mmflat
or tube spanner to unscrew the 4 hexagonal
headed screws with washers.
3. Remove the cover, taking care not to damage
the weatherproofing seal.
4. Make the electrical connections according to
the layout in Fig. 11 and connect the electrical
contactor spool depending on the voltage
required.
Itis possible thatthe mainssupplyis reversedwith
regardto thedirection shownon theelectric motor.
In case of phase reversal, using a screwdriver,
turn the phase inverter, inside the male plug,
180 degrees, to put the phases into the correct
order (see Fig. 11a).
Fig. 11a : Reversing the phases on the power
supply plug
3.3.2 Power pack with petrol engine
1. Fill the petrol tank with ordinary petrol (with or
without lead).
2. Checktheengineoillevelandrefillifnecessary,
in accordance with the engine manufacturer’s
instructions.
3. Connect the two hoses together, pressure and
return,usingthequickconnectingcouplings,to
"bleed" the hydraulic circuit.
Fig. 10
Fig. 11
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4. OpentheflowregulatorDfully(ONposition)and
put the lever(s) to the open position (with the
lever pointing upwards).
5. Starttheengine,usingthestartercordL. Follow
the engine manufacturer’s instructions.
6. Let the engine idle for 4-5 minutes to bleed the
hydraulic circuit.
7.Stop the engine by operating the circuit
breaker W.
8. Closethelevers(backtothehorizontalposition)
and turn the flow regulator to the OFF position.
Top up the hydraulic oil reservoir to the middle
of the upper sight glass (N). The quantity of oil
tobeaddeddependsonthelengthofthehoses
andthenumberoframsconnectedtothesystem.
9. When the "bleeding" operation is completed,
disconnectthehydraulichoses. Ifthehosesare
notimmediatelyconnectedtothehydraulicrams,
replace the dust caps on the couplings.
3.3.3 Hydraulic hoses
Each ram is connected to the control block of the
power pack by two hoses. One hose is for the
pressure circuit (HP) and the other for the return
circuit (BP). A combination of male and female
end fittingswith quickconnectors ensurescorrect
assembly. The hoses are available with standard
10mm diameter (NW10) and standard lengths of
3,6 and 10m, available on request. Extension
hoses are also available on request. If the
application requires hoses of a different length,
the table below shows the maximum length of
hoses that may be used.
Table showing the maximum length of
pressure and return hoses (per machine) as a
function of the diameter (10 mm) of hose and
the flow of hydraulic fluid.
HOSE TU16H TU32H
1 way - 8 l/mn 14 m 10 m
2 way - 13 l/mn 16 m 10 m
4 way - 13 l/mn 25 m 15 m
N.B.
- The lengths stated are for a single continuous
hose without intermediate connectors.
- For greater distances, use 13 mm diameter
hoses and consult the manufacturer.
4. RELEASING AND ENGAGING THE JAWS
4.1. TU16H (Fig. 12)
Releasing :
1. Completely press the rope release safety catch
(5) and lift the rope release lever (4).
2. Release the safety catch and continue to lift the
ropereleaseleveruntilitlocksintoposition.The
internal mechanism is in the released position.
Engaging :
1. Lift the rope release lever slightly.
2. Pressandmaintainpressureontheroperelease
safetycatch,allowingthereleaselevertoslowly
travel back to its original position. Release the
safety catch. The release lever locks in position
under the effect of its spring.
Fig. 12 - TU16H. Rope release lever
NOTE : For the TU16H, releasing or engaging
the jaws may be carried out before or after the
ram has been mounted in the anchor bracket.
4.2. TU32H (Fig. 13)
Fig. 13 - TU32H. Rope release lever
Place the anchor point against a support.
Releasing :
1. Completely press the rope release safety catch
(5) and push the rope release lever (4) towards
the anchor point.
2.
Release the safety catch and continue to push
the rope release lever until it locks into position.
Theinternalmechanismisinthereleasedposition.
4
5
RELEASED
ENGAGED
ENGAGED RELEASED
4
5
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Engaging :
1. Push the rope release lever towards the anchor
point.
2. Pressandmaintainpressureontheroperelease
safetycatch,allowingthereleaselevertoslowly
travel back to its original position. Release the
safety catch. The release lever locks in position
under the effect of its spring.
NOTE : For the TU32H, releasing or engaging the
jaws must be carried out before connecting the
ram to the forward or reverse operating lever.
Should the ram be already mounted, disconnect
the anchor pin from the operating lever and rotate
the ram vertically on the other anchor pin at the
rear of the anchor bracket. This allows access to
the rope release lever.
5.
!
ANCHORING
!
Failure to anchor the SUPERTIRFOR®machine
correctly runs the risk of a serious accident.
The usermustalways ensurebeforeoperation that
the anchor point(s) for the machine and wire rope
is/are of sufficient strength to hold the load.
Itis recommendedthat SUPERTIRFOR®machines
should be anchored to a fixed point or to the load
using an appropriate capacity sling. It is
forbidden to use the machine’s wire rope as a
sling by passing it around the load and hooking it
back onto itself (Fig. 14 : incorrect anchoring
arrangement; Fig. 14a : correct anchoring
arrangement).
The anchor arrangement on the model TU16H is
a hook fitted with a safety catch (Fig. 15 and 16).
In all cases, the anchor arrangement should
alwaysallowthesafetycatchtobeclosedcorrectly
(Fig. 16). These same recommendations apply to
the hook fitted to the wire rope.
The model TU32H is anchored by a removable
anchor pin, passing through each end of the side
case (Fig. 17 and 18) and locked in position by a
two-position spring clip, closed or open (see
Fig. 19 and 20).
If required, a hook arrangement is available to
attach to the anchor pin of the model TU32H.
Fig. 15 - Machine anchor hook with catch in open
position Fig.16 -Machine anchorhookwith catchinclosed
position
Fig. 14 - Incorrect slinging Fig. 14a - Correct slinging
INCORRECT CORRECT
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To anchor using the anchor pin, follow the
procedure below:
1. Open the spring clip of the anchor pin.
2. Remove the spring clip from the anchor pin.
3. Slide the anchor pin out of the side cases
(Fig. 18).
4. Fit the anchoring arrangement, such as a sling,
between the side cases.
5. Refit the anchor pin through the side cases and
theanchoringarrangement,suchastheeyesof
a sling.
6. Refit the spring clip to the anchor pin.
7. Closethespringclip,ensuringthatitfitscorrectly
over the end of the anchor pin and cannot fall
out.
Fig. 17 - Anchor pin in position Fig. 18 - Anchor pin removed
Fig. 19 - Spring clip closed Fig. 20 - Spring clip open
!
Warning
!
: It is essential for the safe
operation of the machine to ensure that, before
loading the machine, the anchor points, hooks or
pins, are correctly secured, (with the safety catch
correctly located on the hook - Fig. 16).
6. OPERATION
1. Starting the motor of the hydraulic power pack.
Hydraulic power pack with electric motor:
Press the start button on the control box and
manuallyholdthebuttondepressed.Neverblock
this button in the start position by any other
means.
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Hydraulic power pack with petrol engine :
Start the engine (see description in paragraph
3.3.2) refering to the instruction manual of the
engine manufacturer.
2. Adjusting the speed of movement of the wire
rope :
• Ona1-waycontrol,starting,stoppingandspeed
of movement of the wire rope may be adjusted
by turning the flow regulator (see item 1 on
Fig.10)whichsuppliesallorpartoftheflowfrom
the pump to the ram.
• On 2-way or 4-way controls, the speed of
operation of the rams when used together is
adjustedbyturningtheflowregulator(seeitem 1,
Fig.21). Thespeedofeachramcanbeadjusted
separately by operating the control lever
provided (see item 2, Fig. 21).
NOTE : The 2-way control, as an option, may be
usedasa 1-way blockby connecting thehydraulic
hose to the auxiliary outlet (S) for 13 l/lin. flow.
This usage must only be used in conjunction with
a model TU32H.
NEVER CONNECT A TU16H TO A FLOW OF
13 l/min. Should this auxiliary outlet for 13 l/min.
flow be used, outlets "01" and "02" (see Fig. 21)
must be blanked off using special blanking plugs
OBF10 (Code 0519325).For the returnhose, only
one will be used; the other must be blanked off.
Whenoperationstops,bothjawsautomaticallygrip
the wire rope and hold the load which is spread
equally between the jaws.
The to-and-fro operation of the forward or reverse
lever by the action of the self-reciprocating
hydraulic ram gives continuous movement of the
load.
In case of manual operation, SUPERTIRFOR®
machines are very easy to use. Remove the
hydraulic ram from the anchor bracket. Place the
telescopic operating handle on either the forward
or reverse operating lever, lock it into position by
twisting and move the operating handle to-and-
fro. The operating arc is variable for ease of
operation.
7. TAKING OUT OF SERVICE AND STORAGE
Stop the hydraulic power pack. Open the flow
regulator and the separate operating levers on
the 2- and 4-way systems. Disconnect the hoses.
Immediately fit the dust caps on the couplings.
NEVER ALLOW THE ENDS OF THE HOSES TO
TRAIL ON THE GROUND.
Rollupthehoses in aswide a diameteras possible
for storage. For electric power packs reel the
electric cable around the electric motor.
NEVER HANDLE THE POWER PACK BY ITS
SUPPLY CABLE.
For power packs with petrol engine, check that
the motor has been correctly stopped.
TAKE GREAT CARE TOAVOID TOUCHING THE
HOTEXHAUST SYSTEM, EVENAFTER HAVING
TURNED THE ENGINE OFF FOR SOME TIME.
It is essential to take the load off the machine
before attempting to release the jaws.Todothis,
operate the reverse operating lever until there is
no tension in the wire rope.
Remove the hydraulic ram from the anchor
bracket.
Release the machine and follow the instructions
forinstalling the wireropeinthe reverseorder(see
paragraph 3.2). Re-engage the jaws of the
machine before putting it into storage.
Store the machine and ram, wire rope, hoses and
thehydraulicpowerpack in adryplace, awayfrom
theeffectsoftheweather.Whereahydraulicpower
pack with petrol engine is used, make sure that
the storage area is well ventilated. The wire rope
should be completely removed from the machine
and rewound onto its reeler.
Before reeling the wire rope, it is recommended to
inspect it, clean it with a brush and then grease it.
Ideally, the hoses should be stored laid out
horizontallyin astraightline; or,in aslargea circle
as possible.
Fig. 21
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8. SAFETY DEVICES
8.1. SUPERTIRFOR®machines
8.1.1 Overload limiting safety devices
All machines incorporate a shear pin system.
In case of overload, one or more pins (depending
onthe model), fittedtothe forwardoperating lever,
shear and prevent further forward or lifting
operations. Reverse operation is still possible to
enable the load to be lowered or the wire rope to
be slackened.
When using a multiple control block, if one of the
machines exceeds the working load limit, without
shearing the shear pins, the whole of the
installation stops. To remedy this situation, reduce
theload orspread theload moreevenlyover each
of the machines, or release (or lower) the load by
operating,(using therams), the reverseoperating
levers of the 2 or 4 SUPERTIRFOR®machines.
8.1.2 Rope release safety device
The machines are fitted with a "two-handed" rope
releasesystemwhichrequiresdeliberateoperation
bythe user toreleasethe machine. Seesection 4 :
Releasing and engaging the jaws.
8.2. Hydraulic power packs
8.2.1 "Dead man" device
A safety device, called "dead man", is fitted to
electrically operated hydraulic power packs.
It operates to stop the power pack if the push-
button is released.
8.2.2 Safety valve
The hydraulic power packs are fitted with a
pressure valve which is factory set to prevent
excess pressure in the power pack. If the valve
opens, it is no longer possible to lift the load.
The loadremainsstationary.However,lowering(or
releasing) is possible by operating the reverse
operating lever either manually or by using the
rams.
8.2.3 Thermal protection device
The electric motor of the hydraulic power pack is
fitted with a thermal cut-out. Should the motor
overheat, it will stop. Allow the motor to cool down
before starting again. Should this happen several
times, consider additional means of ventilation to
cool the motor.
9. REPLACING THE SHEAR PINS
Figures 22 and 23 show the position of the shear
pins for the various models. Spare shear pins are
in the stub of the forward operating lever for the
model TU16H and in the rope release lever for the
model TU32H. Remove the sheared pins with a
suitable punch.
On the TU16H, remove the screw on the end of
the crank and its washer and then remove the
forward operating handle stub by using an
extractor. Remove the sheared pins and clean
the grooves for the pins. Refit the forward
operating handle stub on the crank and align the
grooves for the shear pins.
On the TU32H, align the holes of the upper and
lower sections of the forward operating lever.
Position the spare shear pin(s) and drive it/them
in with a hammer.
Fig. 22 - TU16H
Fig. 23 - TU32H
!
Warning
!
: It is forbidden to replace
sheared pins by anything other than genuine
SUPERTIRFOR®shear pins of the same model.
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dia.
Fig. 24
max. 1.5 dia.
Fig. 25
Before putting the machine back into operation,
ensure that the cause of the overload is removed.
If necessary, use multiple sheave blocks
(See Fig. 6).
Remember to re-order spare shear pins and put
them back in the correct place.
10. WIRE ROPE
!
To guarantee the safe operation of
SUPERTIRFOR®machines, it is essential to use
them exclusively with SUPERTIRFOR®wire
ropewhichhasbeenspecially designed to meet
the requirements of the SUPERTIRFOR®
machines. SUPERTIRFOR®wire ropes have a
yellow strand which is visible on new rope.
One end of the wire rope has an end fitting, such
asasafety hook, fittedto athimble fixedby ametal
ferrule(see Fig.24).The other endofthe wirerope
is fused and tapered (see Fig. 22).
!
A wire rope in good condition is a guarantee
of safety, to the same extent as a machine in good
condition. It is necessary to continuously monitor
the state of the wire rope, to clean and oil it with a
rag soaked with motor oil or grease.
Grease or oil containing graphite additives or
molybdenum disulphide must not be used.
Visual examination of the wire rope
The wire rope should be examined daily to detect
any signs of wear (damage or broken wires : see
examples in Fig. 26).
Fig. 26 - Examples of damaged wire rope
In case of any apparent wear, have the wire rope
checked by a competent person. Any wire rope
withareductionfromthenominaldiameterbymore
than 10% should be replaced. (See Fig. 27 for the
correct method of measuring the diameter of a
wire rope.)
IMPORTANT : It is recommended, specially for
liftingapplications,to ensurethat the lengthof wire
rope is greater than actually required. Allow an
extra meter approximately which should always
go beyond the machine side case at the anchor
point.
When lifting or lowering loads over long lengths of
wire rope, steps should be taken to stop the load
from rotatingtopreventthewireropefromunlaying.
Neverallowatensionedwireropetorub over sharp
edges. The wire rope must only be used with
pulleys of an appropriate diameter.
Never expose the wire rope to temperatures
beyond 100°C.
Never use wire rope that has been subject to
damage such as fire, corrosive chemicals or
atmosphere, or exposed to electric current.
Storage : see section 7 : Taking out of service and
storage.
d
correct method
of measuring
the diameter
of a wire rope
Fig. 27
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11. MAINTENANCE INSTRUCTIONS
11.1. SUPERTIRFOR®machines
The machine should be inspected, cleaned and
lubricated at regular intervals, at least annually,
by an approved TRACTEL repairer.
Never use grease or oil containing graphite
additives or molybdenum disulphide.
To clean the machine, allow it to soak in a bath of
some proprietary cleansing fluid such as paraffin,
petrol or white spirit but not acetone and
derivativesorethylene trichloride and derivatives.
Then shake the machine vigorously to loosen
foreign matter. Turn it upside down to allow the
dirt to come out through the openings for the
operatinglevers.Allowthemechanismtodrainand
become dry.
Afterthistreatment,ensurethatthe machine iswell
lubricated by applying a quantity of oil (type SAE
90-120) onto the internal mechanism through the
openings in the side cases as well as through the
special lubrication hole for the TU16H. To carry
out this procedure, it is best for the machine to be
not under any load and in the released position
and operate the forward and reverse operating
levers to allow the lubricant to penetrate all parts
of the mechanism.
11.2. Hydraulic power pack and hoses
The hydraulic power pack should be cleaned and
inspected regularly, at least annually, by an
approved TRACTEL repairer.
Fill the oil reservoir with hydraulic fluid leaving the
filter in place at the entrance to the reservoir.
Check that the ball valves on the ram and hoses
areclean.Thesearefittedwithdustcovers for each
hose connection, which should be refitted each
time the hose is disconnected.
Where there is a high level of operation, it is
recommendedtochange thehydraulicfluid every
6 months. For less frequent operation, the oil
change should be every year.
Toempty the reservoirof the hydraulicpowerpack,
remove the screw which is underneath the
reservoir itself. Dispose of the old hydraulic oil
appropriately.
DO NOT THROW THE HYDRAULIC OIL AWAY
OR POUR IT DOWN THE DRAIN.
The drain screw comprises a magnetic section to
recover the metal particles.
CLEAN THE DRAIN SCREW FULLY BEFORE
REPLACING IT IN ITS HOUSING.
Checkthatthe drain screwiscorrectlyfittedbefore
refilling the reservoir with hydraulic fluid.
12.
!
WARNINGS AGAINST HAZARDOUS
OPERATIONS
!
The operation of SUPERTIRFOR®machines, in
accordancewith theinstructions ofthis manual,is
a guarantee of safety. Nevertheless, it is useful to
draw the attention of users to the following
warnings :
- NeverconnectaTU16Htoanoutputof13l/min.
- Never allow an electric motor to rotate anti-
clockwise.
- Never allow a hydraulic power pack to operate
without hydraulic fluid in the reservoir.
- Neverconnect more thanfourhydraulicramsto
a power pack.
- Never connect a hydraulic power pack with
electricmotorto a powersupply without correct
earthing.
- Never smoke near a hydraulic power pack with
petrol engine whilst the fuel tank is being filled.
- Neverrefill the fueltankwhilstthepowerpackis
running.
- Never use a fuel other than that recommended.
- SUPERTIRFOR®machines as described in this
manual must not be used for lifting people.
- SUPERTIRFOR®machines must not be used
beyond their maximum working load.
- SUPERTIRFOR®machinesmustnotbeusedfor
applications other than those for which they are
intended.
- Never attempt to operate the rope release
mechanism whilst the machine is under load.
- Never obstruct the operating levers or the rope
release lever.
- Neveroperatetheforwardandreverseoperating
levers at the same time.
- TooperatetheSUPERTIRFOR®machine,never
useanythingotherthanthehydraulicramorthe
telescopic operating handle supplied.
- It is forbidden to replace sheared pins by
anything other than genuine SUPERTIRFOR®
shear pins of the same model.
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- Never anchor the machine other than by its
appropriate anchor point.
- Neverobstructthemachine,whichcouldprevent
the machine, the wire rope and the anchor
points from operating in a straight line.
- Never use the wire rope as a sling.
- Neverapplyaloadtotheloosewireropeexiting
from the anchor point of the machine.
- Never subject the controls to sharp knocks.
- Neverattempttoreversethewireropecompletely
through the machine whilst under load.
- Do not operate the SUPERTIRFOR®machine
whentherope ferrule getsto within10 cmof the
machine.Otherwisetheferruleislikelytofoulthe
casing and push the rope guide inside the
machine.
- Never put the telescopic operating handle on
the forward or reverse operating lever when the
ram is fitted to the SUPERTIRFOR®machine.
13. TROUBLESHOOTING
1)The forward operating lever moves freely
and does not operate the mechanism : the
machine has been overloaded and the shear
pins have sheared. See section 9 for replacing
the shear pins.
2)Pumping : a lack of lubricant in a machine
sometimes brings about a condition known as
"pumping" which is not at all dangerous, but
whichisinconvenient.Thissituationoccurswhen
the jaw which is gripping the rope becomes
locked onto it preventing the other jaw from
taking over the load. As the operating lever is
moved in one direction the machine travels a
few centimeters, but when the operating lever
travelsintheotherdirectionthemachinemoves
back the same distance in sympathy with the
jawwhich is lockedontotherope. Themachine
should be thoroughly lubricated and it will
recommence working normally.
3)Jerkiness : this is also a symptom of lack of
lubrication. The machine should be thoroughly
lubricated.
4)Blockage: ifthewireropebecomesblockedin
the machine, generally because a damaged
section of wire rope is stuck within the jaws,
it is imperative to stop operating the machine.
The load should be taken by another machine
on a separate wire rope, or by another means,
whilst ensuring that all safety precautions are
taken. When the blocked machine is no longer
underload,thedamagedropemaybereleased
and removed. Should this not be possible,
return themachineandwireropetoaTRACTEL
approved repairer.
5)The electric motor turns in the wrong
direction : should this occur there is a risk of
very quickly damaging the hyraulic pump. Stop
the power pack, disconnect the mains power
supply. Reversetwophasesinthepowersupply
plug by using a screw driver. This should be
carried out by a qualified electrician.
6)Not enough hydraulic oil in the reservoir :
Refill the oil reservoir with hydraulic fluid up to
the middle of the upper sight glass.
7)The flow regulator shows the maximum
pressure and the rams do not operate : the
maximum capacity has been reached.
In systems with 2, 3 or 4 machines, if one of the
machines exceeds the maximum capacity, the
wholesystemstops. Reducetheloadorspread
theloadmoreevenlyovereachofthemachines.
8)Theelectricmotorstartswithdifficulty:check
that the 3 phases of the power supply are
correctlyconnected tothepower packandthat
the mains power supply itself is correct for the
power pack. This should be carried out by a
qualified electrician.
14. HEALTH AND SAFETY AT WORK
It is the responsibility of every company to ensure
that their employees have been fully and properly
trained in the safe operation of their equipment.
Anglia Handling Services Ltd