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6.6
Winches maintenance
Safety checks by a qualified person
Safety checks of the endless winches must be carried out at least once a year by a certified specialist. Please
check the local regulations for the frequency of the safety checks with the local authorities.
Exceptional ambient conditions or conditions of operation may require additional safety checks according to the
relevant accident prevention regulations for “Hoists, lifting and towing devices” (BGV D8) and the
standard “Cranes – Power driven winches and hoists” (EN14492-1).
The winches must be subjected to a general overhaul after 200 hours at the latest, of
operation, by the manufacturer. All results of the annual and extraordinary inspections
must be entered at the back of the manual. This is the responsibility of the operating company.
Annual Inspection
We recommend performing safety reviews at the Blastrac plant. The deadline for performing the review starts
when the review report is created by Blastrac on delivery, or for the general overhaul, or on completion of the
preceding annual review. The contents of this review are to be sourced from the service instructions.
Before performing the service, source the latest service plan from Blastrac. The system operator is responsible
for complying with the annual service requirement.
If the system is used in special operating conditions, it may be necessary to perform a safety inspection and
test in line with the accident prevention regulations for hoists, lifting and hoisting equipment (DGUV Regulation
54) and the standard "Safety requirements of suspended access equipment" (EN 1808). This is to be agreed
upon in advance with Blastrac in line with the application.
All the results of the annual inspection need to be entered into the logbook. This is the responsibility of the
system operator.
General Overhaul
In order to ensure the safe use of the equipment until the next inspection the winches and safety devices need
to be overhauled by the manufacturer following every 200 hours of operation or after four years at the latest.
The first period completed is decisive here. Initially decisive for the beginning of the period is the test report
issued on delivery and the test report issued later after the last overhaul. The system operator is to lock the
hoist or the safety devices for operation until the overhaul is completed.
The overhaul is to take place in the plant where the hoist/ safety device was manufactured and needs to be
documented in the logbook.
Repairing Hoists
All repairs to the winches and safety devices are only allowed to be performed by Blastrac, DualLift
GmbH or one of its authorized hoist workshops using DualLift original replacement parts only.
Please refer to the service instructions for the information required for performing the repair.
Each repair is to be recorded in the logbook.
When refilling or replacing gear oil, only use the gear oil referred to in the amended version of the service
instructions!
Maintenance and Upkeep
The hoists and safety devices are virtually maintenance free. Temperature fluctuations above 30°C over the
course of one day are to be avoided. The equipment is also not allowed to be packed airtight and the relative
humidity is not allowed to exceed a value of 60%.
Regular lubrication of the wire rope ensures that the wire rope drive remains sufficiently lubricated.
Please use standard multi-purpose oil or grease for lubrication. Do not use lubricants that contain molybdenum
disulphide (MoS2) or PTFE!
Lubrication substantially increases the service life of the wire rope drive. Proper lubrication does not adversely
affect the drive capability.
Wire Rope for Hoists/Safety Devices
a) Always keep the wire rope slightly lubricated. Make sure the surroundings are clean, i.e. do not place any
parts or components on dusty floors or in dirty surroundings.
b) Never use wire ropes for attaching a load.
c) Always wind and unwind wire ropes properly onto reels.
d) Never pull wire ropes over edges. Instead, use pulleys or other protective measures.
Motor Hood
The electric motor on the hoist is maintenance-free. The motor hood is only to be cleaned
when it is very dirty, so that the motor receives a sufficient air supply.
