ALUMI-LITE OZA500DAV Alumi Lite Davit Crane Instruction Manual

ALUMI-LITE OZA500DAV Alumi Lite Davit Crane

5455 W. 6th St.
P.O. Box 845
Winona, MN 55987
Phone 800-749-1064
(507)474-6250
Fax 507-452-5217
sales@ozliftingproducts.com
www.ozliftingproducts.com

TWO YEAR WARRANTY

OZ Lifting Products LLC® guarantees this product to be free of defects in materials and workmanship for two years from the date of shipment.
This warranty does not apply to products that show signs of misuse, overloading, alteration, improper maintenance or negligence. The normal wear and tear of moving parts is excluded from the warranty. Moving parts are defined as brake discs, wire rope and other wear components that are subject to use conditions. This warranty does not cover any costs related to removal of this product, lost time, or any other incidental or consequential damages/costs resulting from the claimed defects.
If this product fails during the first two years of operating due to defective materials or workmanship, it will be repaired or replaced at the discretion of OZ Lifting Products LLC®. Any product subject to a warranty claim must be returned, prepaid, to an authorized OZ Lifting Products LLC® warranty depot along with proof of purchase. Upon repair, the product will be returned to the customer free of charge. If no defect is found,the customer will be responsible for return shipping costs. The product’s warranty will be effective for the remainder of the original warranty period (two years from shipment date).

All OZ Lifting Products LLC® manual and electric winches are subject to a one year limited warranty.
It is the operator’s responsibility to ensure that the product is used in accordance with all applicable local codes, regulations, and safety standards. OZ Lifting Products, LLC assumes no liability for any damages or injuries resulting from the improper use of the product.

OZ Lifting Products LLC® will not be held liable for the following arising from the use of this product: injuries to persons or property, death, incidental, consequential, or contingent damages, whether negligent or deliberate. It is the sole responsibility of the owner to install and operate the product properly and safely.

This is OZ Lifting Products LLC®‘s only written warranty. This warranty is in lieu of all other warranties implied by law such as merchantability and fitness. The sale of products from OZ Lifting Products LLC® under any other warranty or guarantee, expressed or implied, is not authorized.

NOTE : OZ Lifting Products LLC® has the right to alter the design of or discontinue the production of any product without prior notice.
For more information please contact:

Product Precautions

• The information in this manual should be used only for the Alumi-Lite® Davit Crane. This manual contains general instructions for normal installation, operation, and maintenance of the product described herein. The information provided should not be expected to prepare the user for all possible circumstances.
• This product should not be installed, operated, or maintained by any person who has not read all the contents of this manual. Failure to read and comply with these instructions, warnings, or limitations may result in bodily injury, death, or property damage.
• It is the responsibility of the owner/user to install, test, maintain, and operate this product in accordance with OSHA regulations as well as all other federal, state, and local regulations. Only trained and qualified personnel shall operate and maintain this product.
• Regularly inspect Alumi-Lite® Davit Crane for signs of wear, elongation of holes, surface cracks, gouges, damage or any abnormal conditions.
• Product owners should schedule and keep record of regular inspection and maintenance. Record your Alumi-Lite® Davit Crane serial number and purchase date on the front cover of this manual for reference.
• Do not use the Alumi-Lite® Davit Crane in conjunction with other equipment unless the necessary safety devices are in place. Modifications to this product should only be authorized by the original manufacturer.

Safety Warnings

• Failure to read and comply with the following warnings may result in a hazardous situation that could lead to death, serious injury, or property damage. Keep this manual near the equipment at all times. Do not remove, alter, or obscure the labels attached to the winch. Contact OZ Lifting Products LLC® for replacement manuals and labels.
• Do Not operate a damaged or malfunctioning product.
• Do Not operate if guards are improperly installed or removed.
• Do Not lift more than the rated load of the crane or its attached components.
• Do Not use additional cranes to move a load that is heavier than the load rating of any single crane in use.
• Do Not modify this product in any way.
• Do Not use for other functions except those for which this product is intended.
• Do Not remove, deface, or obscure warning labels.
• Do Not allow load to swing or jerk. Operate smoothly to avoid shock loads.
• Do Not lift any load that is not located directly below the crane. This product is not intended to drag a load sideways.
• Do Not wrap the load with the wire rope. Use only a sling or another manufacturer-approved device.
• Do Not operate without 4 anchor wraps (8 anchor wraps for Dyneema based synthetic cables) of wire rope around the winch drum.
• Do Not operate without assuring wire rope is securely attached to the winch drum.
• Do Not operate without checking for proper lubrication.
• Do Not put hands in areas with moving parts such as sheaves, wire ropes, and gears.
• Do Not lift people.
• Do Not lift loads over people.
• Do Not operate until personnel are warned of approaching loads and are cleared from the area.
• Do Not leave a suspended load unattended.
• Do Not substitute smaller diameter pins. Use only the pins supplied with the crane.
• Do Not use chains, cables, or rigid devices to lift crane. Nylon or other synthetic slings should be used instead.

Initial Crane Inspection

Check for damage during shipment. Do not install or use a damaged product. Be sure to maintain records of product information and contact your OZ Lifting Products LLC® dealer with any problems that arise.
Refer to applicable codes and regulations before installing equipment. Contact a qualified professional to obtain structure and foundation specifications for product mounting.
Before installing, select a location where the crane is:

• Visible throughout its entire operation.
• Free of traffic and any possible operational interference.
• Positioned so the operator is clear of both the load and the path of the wire rope.
• Accessible for maintenance.
• Attached to a strong, level foundation that can properly support it under all conditions.
• Removed from any corrosive, flammable, explosive, or potentially damaging materials.

Please refer to the diagram on pg. 8 before assembling the crane.
Inspect the crane to assure there are no missing or damaged parts. Do not discard the crane’s shipping containers as they can be reused if the crane needs to be repackaged. Contact you OZ Lifting Products LLC® dealer if any problems arise.
Assure that all components, including the pin that the load sheave rides on, are properly lubricated before assembling. Refer to Cleaning & Lubricating the Crane on pg. 11.
During assembly, perform an inspection according to the procedures found on pgs. 11, 12 and 13 on this document and resolve any issues. This will provide a comparison for later inspections.

Installing the Base

• NOTE: The accompanying base for the Alumi-Lite® Davit Crane is sold separately through
• OZ Lifting Products LLC® dealers. It is necessary for proper operation of this product.
• The base of the Alumi-Lite® 500 – OZA500DAV must be securely fastened to the foundation using ½-13-inch coarse thread fasteners of at least grade 5. A torque of 75 ft-lb should be used for grade 5 fasteners without lubrication.
• The base of the Alumi-Lite® 1000 – OZA1000DAV must be securely fastened to the foundation using ⅝-11-inch coarse thread fasteners of at least grade 5. A torque of 80 ft-lb should be used for grade 5 fasteners without lubrication.
• Assure that mounting surface is located directly above a strong, level, solid foundation that supports the crane under all circumstances.
• Non-standard products that have been altered from the original design may require alternative fastening requirements. Contact your OZ Lifting Products LLC® dealer for more information.

Assembling the Crane

Assembly
NOTE : Fasteners should not be over-tightened during assembly as this may strip the threads and lead to damage. For the purpose of assembly, two identical clevis pins are included. Both are necessary for assembly.
Once the OZ Lifting Products LLC® base has been installed, assemble the crane with the following steps:

1. Remove the lynch pin from the pin being utilized as a hinge and remove the pin from mast/boom assembly. This will free the mast from the boom.

2. Install the mast into the base.
   NOTE – the mast/boom assembly is free to move. The mast will slide easily down into the base (no tools are necessary). Assure that the mast is properly positioned on the pin at the bottom of the base. This can be confirmed by moving the mast from side to side to check for excessive play. The mast should fit snugly.

3. Remove the lynch pin from the pin located in mast and remove the pin from mast.

4. Lift boom into position such that it is 90 degrees to mast and insert pins and lynch pins.

NOTE : Releasing your grip on the boom prior to installation of pins and lynch pins may cause the boom to swing down into the mast. This could result in injury or damage to the product.
NOTE : The Alumi-Lite® Davit Crane will ship from the factory partially assembled.

Assembly Diagram

Field Test
There is no ASME standard for davit cranes. OZ Lifting Products® Alumi-Lite® Davit Cranes have a minimum 2.7:1 design factor. We load test and certify our davit cranes to 125% of the rated capacity. A test certificate is generated that includes the serial number.
If a load test is required on site, we recommend contacting a civil engineer to determine if the base has been properly mounted to a secure location. We provide the information on the moment a base would pull away from the mounting bolts.

Installing the Cable
The OZ Lifting Products LLC® cable assembly that can be ordered with the Alumi-Lite® Davit Crane may come with a swaged ball on one end to facilitate easy assembly. Standard bare end cable can also be used. The hardware for bare end cable installation is included. Please refer to the accompanying winch owner’s manual for instructions on installing a bare end cable.

To install the OZ Lifting Products LLC® supplied cable:

1. Lay the cable out on a flat surface to ensure it is not knotted or looped.
2. Remove the cable retainer pin from the sheave end of the boom.
3. Locate the ball end of the cable.
4. Locate the “keyhole” in the winch drum that accepts the ball end of the cable.
5. Thread the ball end of the cable over the load sheave pulley and towards the winch.
6. Re-insert the cable retainer pin.
7. Insert the ball end fitting of the cable into the “keyhole” feature in the winch.
8. Ensure that the ball end of the cable slides into the slot in the “keyhole” and cannot be pulled out.
9. Manually spool at least 4 full wraps of cable neatly onto the winch drum. There must be at least 4 full anchor wraps of cable on the winch drum at all times.

NOTE : To ensure the maximum amount of cable can be spooled onto the winch, the cable must be neatly spooled onto the winch drum. If the cable is not spooled neatly onto the winch drum, the cable capacity will be reduced, and handle effort may increase. Cable that is not spooled neatly can consume 30% more space on the winch drum, reducing cable capacity.

Operating the Crane

Warnings & Precautions
Operators should read and fully comprehend this entire manual and all warnings on the Alumi-Lite® Davit Crane before beginning crane operation. If this manual is not read and followed completely, injuries and damage may occur. For questions regarding operation, please contact your OZ Lifting Products LLC® dealer.

Before operating the crane, be sure all parts are clean and properly lubricated. The crane must be in proper working condition and maintenance records must be up to date to proceed with operation. The area of operation must be clear of all flammable materials.
It is important to maintain secure footing while operating the crane. Confirm that the crane is attached securely to a strong, level, solid foundation before operation. Slowly take up a load, verifying that it is well supported and balanced before proceeding with operation.

All operators MUST

• Be trained in proper crane operation and in dealing with potential malfunctions.
• Abstain from use of alcohol, medications, or drugs while operating.
• Avoid operation while tired or distracted.
• Avoid operation if they have a history of seizures or other medical issues that may interfere with crane operation.
• Have proper coordination and vision.

Operating Guidelines

• The Alumi-Lite® 500 by OZ LIfting Products LLC® has a maximum operating load rating of 500 lbs at 45 degrees (see rating chart on page 14).
• The Alumi-Lite® 1000 by OZ LIfting Products LLC® has a maximum operating load rating of 1000 lbs at 45 degrees (see rating chart on page 14).
• The Alumi-Lite® Davit Crane by OZ Lifting Products LLC® is capable of generating forces that are in excess of this maximum load rating, but this should not be attempted.
• NOTE : It is the responsibility of the user to ensure that the loads being handled are within the operating limits of the Alumi-Lite® Davit Crane at all times. Shock loads must be minimized as they can lead to higher forces than the rated capacity of the Alumi-Lite® Davit Crane.
• A load rating table is provided on pg. 14 as well as on the Alumi-Lite® Davit Crane itself. This load rating table is calculated based on both the position of the crane’s boom as well as the amount of cable spooled onto the winch drum. While the position of the crane’s boom should not change during a lift, the amount of cable spooled onto the winch will change during a lift (especially long lifts).
• NOTE: It is the responsibility of the user to determine the maximum amount of cable that will be spooled onto the winch at any given time during the lift and size the load to be lifted accordingly.
• The manual or electric winch that is supplied with the Alumi-Lite® Davit Crane has been specifically chosen to match the rating of the crane. The quick-disconnect handle on this winch has also been specifically designed to operate within the load range of the winch. The effort required to operate the winch at the maximum rated capacity will be significant on the Alumi-Lite® 1000. This is an intentional design feature and not a defect. The increased effort required when nearing rated capacity (at any percentage of drum capacity) is a sign that the load being lifted may be too heavy.
• NOTE : Check the weight of the load being lifted and reduce the weight if necessary.

This Alumi-Lite® Davit Crane has a main structure made from aluminum. At maximum rated load, this material may exhibit some deflection. The crane will return to its original position upon releasing the load. At no time should the crane emit any abnormal noises during use. Any abnormal sounds are cause for immediate removal of load and inspection. There are multiple sources for abnormal noises including, but not limited to:

• If the cable is not spooled neatly, under tension, when load is applied.
• If the crane is severely overloaded.
• If the crane has suffered severe damage from abuse and/or mishandling.

NOTE : This list is not exhaustive and does not cover all possibilities.

Cleaning & Lubricating the Crane

The Alumi-Lite® Davit Crane should be periodically cleaned to preserve its appearance and to prevent corrosion. The Alumi-Lite® Davit Crane will last longer and perform better when it is kept clean and lubricated.
NOTE : No solvents should be used on any parts of the Alumi-Lite® Davit Crane for cleaning or any other purpose.

Instructions

1. Wipe the surfaces of the crane with a wet cloth. Detergents are not necessary.

2. The aluminum surfaces are powder coated. Wipe surfaces clean of debris.
   It is not necessary to oil the components as they are impervious to corrosion from moisture.

3. Lubricate the shaft bearing surfaces on the winch with a light coat of grease, taking care not to get any oil or grease on the brake pads of the winch.
   NOTE: No lubricants of any kind should be applied to the brakes in the winch. If the brake pads get contaminated with oil, they may slip.

4. Remove any excess oil with a clean cloth.

5. Lubricate the bushing in the load sheave with a light coat of grease.

Inspecting the Crane
In order to maintain quality operation of the product, a regular inspection schedule should be followed by each operator. All inspections should be reported and maintained in a dated record log. These records should be available to all personnel involved with the product and should be made available to OZ Lifting Products LLC® when a warranty issue is in question.

Definitions

• Designated Person – The person who is selected or assigned as being competent to perform specific duties.
• Qualified Person – The person that—by possession of a recognized degree or certificate of professional standing, or through extensive knowledge, training, and experience—has successfully demonstrated they are able to resolve problems relating to the subject matter and work.
• Normal Service – Service that involves operation with randomly distributed loads within the rated load limit, or uniform loads less than 65% of rated load for not more than 15% of the time.
• Heavy Service – Service that involves operation within the rated load limit and exceeds normal service.
• Severe Service – Service that involves normal or heavy service with abnormal operating conditions. This also includes service that involves shock loading.

Inspection Classifications
Frequent Inspections – Completed by the operator or designated person. Performed by doing a visual examination and listening for unusual sounds during operation. These inspections are usually performed before each operation, every few hours during operation, and if problems arise.
Periodic Inspections – Completed by a designated person. Performed, with more detail than a frequent inspection, by doing visual examinations of internal and external conditions. These inspections are done on the following schedule:

• Normal Service – Semi-annually
• Heavy Service – Quarterly
• Severe Service – Immediately after completion of lift
• Following prolonged storage or if operation issues arise.

NOTE : Label crane as “Out of Service” if an inspection deems it damaged or if maintenance is required. Do not remove this label until a qualified person has resolved the issue. Discontinue use of wire rope and equipment if damage or overloading occurs.

Important Inspection Notes

• Brakes require more than audible and visual inspection. Check brakes daily by operating the crane with and without a load and by stopping at various positions to ensure safe operation. If the load coasts or creeps, contact the factory for friction disc replacements.
• Proper inspection may require disassembly of some parts. Contact the OZ Lifting Products LLC® factory before doing so or the applicable warranty may be voided.
• For wire rope inspections, please contact the specific manufacturer of the rope. The inspection provided in the following chart is for a general inspection only and is in no way the complete inspection required.
• Before operation, assure all deficiencies on the inspection chart are resolved and inspections are up to date. Refer to the troubleshooting chart on pg. 14 for further assistance.
• Be aware of applicable codes and regulations for crane inspection.
  • See specific winch owner’s manual for instructions and complete inspection instructions.

Inspection Chart

NOTE : Disassemble crane including mast, boom, and winch periodically to inspect each for damage. Use the following chart to determine what type of inspection is necessary. Frequent Inspection (F) and Periodic Inspection (P).

X
Fasteners

(including moutning fasteners)

| Firmly installed| X|
Properly tightened| X|
Stripped threads, bent, or damage (check by removing crane from foundation)| | X
Handle| Rotates freely in both directions| X|

NOTE : Please refer to the winch owner’s manual for the winch inspection chart.

Repairs
All repairs must have factory authorization. Contact OZ Lifting Products LLC® to prevent voiding of the two year warranty and potential damage.
Perform recommended inspections to identify which parts should be replaced. Only use OZ Lifting Products LLC® replacement parts. To order replacement parts, contact OZ Lifting Products LLC® directly or an authorized dealer. Please have the serial number, part number and a description available when calling.

Load Rating

Alumi-Lite® 500 – OZA500DAV
*Table based on 3/16” Wire/Synthetic Rope

Alumi-Lite® 1000 – OZA1000DAV
*Table based on 1/4” Wire or 3/16 Ultrex Synthetic Rope

Troubleshooting Chart

evenly under tension
Dirty brakes or gears| Clean
Broken gears or bearings| Replace
Rattling noise| Loose bolts, screws, fasteners| Tighten
Boom turns on its own| Foundation unlevel or unsecured| Repair
Mast bent or damaged| Replace
Boom bounces| Overloaded| Reduce load and inspect crane for damage
Loose mounting bolts| Tighten to correct torque
Foundation unlevel or unsecured| Repair
Winch gears worn or damaged| Replace
Sheave worn or damaged| Replace

References

• OZ LIFTING PRODUCTS: Lifting & Material Handling Equipment

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