Vlume 1 OPERATIONAL MANUAL MODEL: 100KG/300KG/600KG/1000KG/2000KG MAGNETIC LIFTER by BLUEROCK Tls
100KG/3 0 0 K G / 6 0 0 K G / 1 0 0 0 K G / 2 0 0 0 K G M A G N E T I C L I F T E R UNPACKING THE ITEM Cautin: This device is packed tgether with items that may be sharp, ily and verly heavy bjects. Remve the device frm the packaging in a safe manner. Check t ensure all accessries are included with the item while unpacking. If any parts are fund t be missing, cntact the retailer as sn as pssible. D nt thrw away the packaging until the item is ut f the guarantee perid. Dispse f the packaging in an envirnmentally respnsible manner. Recycle if pssible. Keep all plastic bags away frm children due t risk f suffcatin. BLUEROCK TOOLS 2015 1100 SW 16 th St Suite D Rentn, WA 98057 Phne 206.604.8363 Fax 425.572.5167 www.bluercktls.cm
Table f Cntents SAFETY 1 PRE-OPERATIONAL SAFETY CHECKS 1 OPERATIONAL SAFETY CHECKS 1 LIFTING SAFETY 2 INCLUDED ACCESSORIES 3 ADDITIONAL DEVICES 3 ADDITIONAL SIZE MAGNETIC LIFTERS CAN BE FOUND IN BLUEROCK TOOLS ONLINE SHOP AT WWW.BLUEROCKTOOLS.COM OR FROM YOUR LOCAL RETAILER. 3 SPECIFICATIONS 3 DEFINITIONS 3 ACTUAL LIFTER CAPACITY 4 EFFECTIVE PERCENTAGE OF RATED CAPACITY 4 STEEL THICKNESS GRAPH 5 FORMULA FOR RANGE OF LIFTING CAPACITY 6 OPERATIONS 7 PURPOSE 7 OPERATIONAL PRINCIPLES 7 DEVICE COMPONENTS 7 TRANSPORTING THE DEVICE 8 USING THE DEVICE 8 GENERAL MAINTENANCE 9 BREAKDOWN VIEW 10
Chapter 1 Safety DO NOT USE THIS DEVICE UNLESS YOU HAVE READ THE OPERATING INSTRUCTIONS! Safety glasses must be wrn at all times in wrk areas. Lng and lse hair must be cntained. Apprpriate ftwear must be wrn. Clse fitting/prtective clthing must be wrn. Safety glves shuld be wrn at all times and jewelry must nt be wrn. Read peratinal manual prir t use. PRE-OPERATIONAL SAFETY CHECKS Examine the bdy f the device and inspect fr damage r defects. Ensure that the n/ff handle is crrectly attached t the device. Make certain the n/ff handle is in the ff psitin. OPERATIONAL SAFETY CHECKS ONLY t be perated by qualified persnal wh have read instructins. NOTE: Failure t read and fllw instructins culd result in prperty damage and/r serius injury! DO ensure all nn-essential peple are clear f the immediate wrk area. DO keep bdy parts, clthing & pwer crds clear f wrk area. Stay alert and use cmmn since when using this device. DO NOT make adjustments t device while the device is lifting. DO NOT use this device in water r any type f liquids. DO NOT leave the device actively lifting when nt in use. DO NOT perate device utside f device specificatins. DO NOT walk under lifted materials as death r dismemberment culd ccur. DO NOT remve device panel. Only t be remved fr service by qualified persnal and put back n the device after service is cmplete. Magnets inside are extremely strng and adjustments withut prper equipment can result in serius injury. 1
1 0 0 K G / 3 0 0 K G / 6 0 0 K G / 1 0 0 0 K G / 2 0 0 0 K G M A G N E T I C L I F T E R DO NOT allw children r untrained persnal t perate device. DO NOT use this device in the rain r a wet envirnment. If using utdrs, make sure the surface is clean and dry. DO NOT use n a wrk area that may cntain a live electrical wire/circuit. DO NOT perate this device n the same wrk surface where welding is being perfrmed. This culd result in severe damage t the device r persnal injury t the user. DO NOT engage the handle t the n psitin withut magnetic material under the lifter. DO NOT drp, heat r shck the lifter as it culd cause permanent damage t the lifter. LIFTING SAFETY Make certain material surface is free f debris r bstructins. D nt use multiple magnets withut prper spreader bar. D nt carry material ver r near peple. Make certain the material is prperly distributed. D nt allw peple t stand n lifted materials. N shear lifts. D nt allw the magnet f lifted material t cme int cntact with any bstructins while lifting. Make certain t lift material evenly s as t avid an instable lift. 2
Chapter 2 Included Accessries DESCRIPTION QTY Instructin Manual 1 Primary Handle with Blt 1 Additinal Devices Additinal size magnetic lifters can be fund in BLUEROCK Tls nline shp at www.bluercktls.cm r frm yur lcal retailer. DEFINITIONS Specificatins AIR GAP Anything that prevents the magnet frm making full cntact with the material being lifted is cnsidered an air gap. Examples f an air gap wuld be items like paint, rust, ice, water, machine grves, hles, il, rust, debris, etc. It is always recmmended that there is a limited air gap s the device can make full cntact with the material. BREAKAWAY FORCE The frce required t separate the magnet frm the material being lifted is cnsidered the breakaway frce. This is the frce when the magnet is being pulled in a directin perpendicular t the magnet s face. The breakaway frce is directly prprtinal t the materials specificatins. The lifter s breakaway frce increases until the material being lifted exceeds the saturatin thickness f the material. 3
LIFTER MODEL 100KG 300KG 600KG 1000KG 2000KG Lifting Capacity (lbs) 220 660 1320 2200 4400 Max rated lad fr rund steel (lbs) 99 297 594 990 1980 Max rated lad fr flat steel (lbs) 220 660 1320 2200 4400 Max "Breakaway frce" (lbs) N/A 2315 4629 7716 15432 Distance (in) A 3.6 6.4 9.1 10.2 14.9 C 5.7 5.9 7.7 11.2 16.8 E 2.5 3.6 4.8 6.9 9.2 F 2.8 3.5 4.6 6.4 8.3 Net Weight (lbs) 7 22 50 100 200 ACTUAL LIFTER CAPACITY Material Thickness The actual lifting capacity f the magnet is affected by the fllwing factrs Air Gap Carbn Cmpsitin Rund Bar r Pipe Sheet The thickness f the steel plate (see steel thickness graph belw). A gap between the lifting magnet and the steel lad prduced by paint, dirt, rughness, r uneven surface f material (see air gap graph belw) When lifting high carbn steel, the lifting capacity will be 30% less. If lifting cast irn, the lift value will be 50% less. A rund bar must cntact the V shape slt at the bttm f the lifting magnet. The actual capacity value will be apprximately 40% f that plate. When lifting pipes, its thickness shuld als be taken int accunt. The actual capacity value is als affected by the diameter f the material. A large thin steel sheet can be bent in an arc prfile and then peeled ff when lifted, even thugh it is light. When lifting a sheet frm a stack, the magnetic flux may penetrate thrugh the sheet and adhere t lwer pieces. This is an extremely unsafe lift. EFFECTIVE PERCENTAGE OF RATED CAPACITY Thickness 6000KG 3000KG 2000KG 1000KG 600KG 300KG 100KG (mm) 100 100% 90 85% 80 70% 100% 70 55% 80% 100% 60 45% 60% 80% 100% 50 35% 45% 60% 90% 100% 40 25% 35% 45% 75% 90% 100% 30-25% 30% 55% 70% 90% 100% 20 - - 20% 35% 50% 70% 80% 4
STEEL THICKNESS GRAPH 5
AIR GAP GRAPH Cautin: Always cnsider the air gap when chsing the prper magnetic lifter fr the material. FORMULA FOR RANGE OF LIFTING CAPACITY Actual Capacity = Nminal Capacity (lbs) x T Factr (%) x A Factr (%) T Factr = Thickness Hlding Pwer (%) A Factr = Air Gap Hlding Pwer (%) Example: Mdel 600KG s rated lifting pwer is 1,320lbs. In the example we will lift 3/8 standard steel plate with 8 mils f paint n it. 3/8 = 0.375 = 9.5mm 9.5mm = T Factr (%) = 35% 8 mils = 0.20mm = 8 Thusandth f an Inch 0.20mm = A Factr (%) = 80% Actual Capacity = 1320 (lbs) x 35 (%) x 80 (%) = 369.60 (lbs) S the 600KG can lift 369.60 lbs wrth f 3/8 sheet with 0.20mm wrth f paint n it. 6
Chapter 3 Operatins Nte THOROUGHLY READ THROUGH THE ENTIRE MANUAL BEFORE OPERATING THIS DEVICE! PURPOSE The purpse f the 100KG/300KG/600KG/1000KG/2000KG magnetic lifter is t lift steel, irn, rund and ther magnetic material. These are cmmnly used in manufacturing and warehusing peratins fr handling magnetic material. These magnets eliminate the need fr clamps, slings and chains increasing wrking efficiency. These lifters d nt require a pwer surce. OPERATIONAL PRINCIPLES The lifter has a magnetic path prduced by Nd-Fe-B rare earth magnets. In the n psitin, the magnet is engaged in the pathway and wrks t lift material. In the ff psitin, the magnets pathway is nt engaged and the device will have very little residual magnetism. The magnet will nt engage int the n psitin unless it is psitined tuching magnetic material. DEVICE COMPONENTS The main cmpnents f the magnetic lifter are the lifter bdy and main handle. 7
TRANSPORTING THE DEVICE When transprting the device, always carry with bth hands. If transprting inside a vehicle, it is recmmended t transprt it flat s as t avid the item falling ver. DO NOT carry the device by the handle. DO NOT allw the lifter base t get damaged when transprting. USING THE DEVICE D all pre-peratinal and peratinal safety checks frm Chapter 1. Cnsider yur security and stability as well as the rientatin f the device in the wrk area. Cnsider the material type, weight, cnditin, strength, density and rigidity. These factrs directly affect the tls peratin and user safety. The magnetic adhesin is highly affected by the cmpsitin f the material being lifted. Allys with higher irn cntent are typically mre susceptible t magnetic fields than thse with lwer irn cntent. Knw the material yu are lifting. IMPORTANT: Cnsult the peratinal chart t make sure the planned lift is within the capabilities f the device. Ensure the handle is securely attached. Ensure the wrk surface is clean and free f debris, il, rust, paint, dirt, etc. If yu d nt take this int accunt, lifting capacity will be reduced. Psitin the lifter n the steel gently s as nt t cause and dents n the lifter r surface. Take care t place the lifter n the center f the material lad. This wuld be a center pint f mass s that the weight is distributed evenly n all remaining sides. Press the buttn at the tp f the handle and turn the handle frm the ff psitin t the n psitin. Ensure the safety lck is engaged twards the machine t keep the device in the n psitin. Mve r lift the lad. T disengage the magnet when in the n psitin, simply press the buttn at the tp f the handle t disengage the lck and slwly mve the handle t the ff psitin. 8
Chapter 4 General Maintenance CAUTION! INTERNAL MAGNETS ARE EXTREMELY STRONG AND CAN CAUSE SERIOUS INJURY TO PERSONS HANDLING OR ADJUSTING! DO NOT TAKE THEM OUT OR REPLACE WITHOUT UNDERSTANDING THE PROPER HANDLING PROCEDURES! Inspect all device surfaces fr damage. Keep device clean and free f debris. Check fr misalignment, binding and breakage f all mving parts. If damaged, repair tl befre use. Prtect magnet frm rusting by iling the bttm base after use. Stre in a dry area. Check handle t ensure the safety buttn mves freely. Annual calibratin check is recmmended. 9
Chapter 6 Breakdwn View 10