operator manual - safety eng
TRANSCRIPT
Oct 20181
Operator Manual Onbelay autobelay device
Model: Onbelay 8, Onbelay 11, Onbelay 14, Onbelay 17
The Operator Manual contains information relating to
the safe use of the Onbelay autobelay and includes all
product registration and warranty information.
Ensure that this Operator Manual is readily available on
site to operators and users at all times.
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Oct 20182
Limited warranty 4General information 5Description of the Onbelay autobelay device 6
Technical specifications Onbelay 6
Device identification 7
Cable identification 8
Safety rules 9Inspection routine 11Daily inspection 11
Cable 11
Swivel carabiner/connector inspection 12
Pulleys 12
Air pressure 13
Oil level 13
Testing the brake action and pull up force 13
Daily check List 14
Monthly inspection 15
Cable full length Inspection 15
Pulleys Inspection 15
Fasteners inspection 16
Monthly check List 17
Maintenance18Аir pressure 18
Аir leaks 18
Oil adding 18
Oil leaks 19
Warranty claim 20Onbelay autobelay service form 21Maintenance log 22c
on
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Oct 20183
PLEASE READ CAREFULLY!DO NOT OPERATE THE DEVICE UNTIL YOU HAVE READ AND FULLY UNDERSTOOD THIS MANUAL! FAILING TO DO SO MAY LEAD TO SERIOUS INJURIES OR DEATH OF THE USER!
Onbelay autobelay device is designed and certified for climbing,
mountaineering and technical rope work.
All climbing activities are inherently dangerous and present a risk of serious
injury and death if the device is not properly maintained and operated!
Improper use, abuse and/or lack of proper maintenance increases the risk
of serious injury or death and voids any warranty.
Operators shall inspect all equipment as per manufacturer’s guidelines
provided in the Operator Manual and replace any part or component that
appears to be damaged, worn-out or somehow fails to pass inspection
before the device can be used again.
Owners and operators are responsible for the proper and timely
maintenance of the Onbelay devices.
Owners and operators are responsible for following all applicable regional
and international standards and regulations regarding the use of the
product.
Owners and operators must have devised an emergency rescue plan for
any climber in distress at all sites operating Onbelay devices. Operators
must inform users of the autobelay of the procedure for rescuing a climber
in distress prior to climbing.
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Oct 20184
ONBELAY AUTOBELAY LIMITED WARRANTY
The benefits granted by this Limited Warranty are in addition to any rights and/or remedies you may have under
applicable consumer protection legislation.
SAFETY ENGINEERING (the “Seller”) warrants to you, the original purchaser, that this Product will be free from
defects in materials and workmanship for a period of one (1) year from the date of purchase (the “Warranty
Period”). This Limited Warranty is not transferable.
If, within the specified Warranty Period, the Product shall be reasonably proven to be defective, the Seller will,
at its option, repair or replace the Product, or a defective part thereof, without charge to you for either parts or
Labour. To the extent permitted by applicable law, such repair or replacement shall be your exclusive remedy
under this Limited Warranty. The Seller may, in its sole discretion, replace the defective Product with the same
or a functionally equivalent product. Replacement products or parts may be refurbished or contain refurbished
materials. Repaired or replacement products will be warranted for the remainder of the original Warranty Period.
This Limited Warranty does not apply to consumable parts (such as cables and pulleys) and does not extend
to any product that has been damaged or rendered defective (a) as a result of normal wear and tear; (b) by the
use of parts not manufactured or supplied by the Seller; (c) by modification of the Product; (d) as a result of
service rendered by anyone other than the Seller or its authorized service provider; (e) as a result of the Product
being operated otherwise than in accordance with the Sellers’s User’s Manual and/or instructions; (f) as a result
of accident, misuse, abuse, improper or inadequate maintenance.
No reseller, agent, or employee of the Seller is authorized to make any modification, extension, or addition to this
Limited Warranty.
To the maximum extent permitted by applicable law, the foregoing warranties and remedies are exclusive and are
in lieu of all other warranties, representations, and conditions of any kind, express or implied, including, but not
limited to, the implied warranties or conditions of merchantability and fitness for a particular purpose and/or any
implied warranty or condition of non-infringement. Some States and jurisdictions do not allow the exclusion of ex-
press or implied warranties, so the above exclusion may not apply to you. In that event, such warranties apply to
the extent required by law and are limited in duration the Warranty Period. No warranties apply after that period.
Some States or jurisdictions do not allow limitations on how long an implied warranty lasts, so the above limita-
tion may not apply to you.
To the maximum extent permitted by applicable law, in no event shall the Seller or its suppliers be liable for any
damages whatsoever (including without limitation, direct or indirect damages for personal injury, loss of business
profits, business interruption, loss of business information, or any other pecuniary loss) arising out of the use
of or inability to use this product, even if the Seller has been advised of the possibility of such damages. Some
States or jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so this
limitation or exclusion may not apply to you.
This Warranty is issued in two originals.I have received an original of the Limited Warranty
Client’s signature:
Name:
Serial Number of the Autobelay:
Date:
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Oct 20185
GENERAL INFORMATION
1
2
3
4
5
6
7
8
9
10
10
1112
13
14
15
1 Pressure gauge
2 Pressurised tank
3 Oil level check glass
4 Oil hose
5 Oil hose fitting
6 Body
7 Hydraulic rams
8 Flow controls
9 Pulley system
10 Davit pulleys
11 Davit
12 Steel cable 6 mm
13 Protection sleeve
14 Triple locking swivel carabiner
15 Cable end mount
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Oct 20186
TECHNICAL SPECIFICATIONS
Onbelay autobelay device is an automatized safety device for controlled descend for artificial climbing walls,
mountaineering and technical rope work. It is used for belaying an individual without the need of assistance by a
second person.
Onbelay autobelay is an air-over-hydraulics unit that consists of body, hydraulic rams, pulleys, pressurized tank
and a steel cable.
The climber is attached to the steel cable by means of a certified connector.
When the climber ascends – the pressure in the tank forces the fluid into the pistons thus retracting them through
series of pulleys.
When a person falls or descends, the created pull forces the hydraulic fluid out through an orifice thus limiting
the descent speed to approximately 1 m/s regardless of the climber’s weight. The forced hydraulic fluid then goes
into the pressurized tank.
The Onbelay autobelay is mounted behind the climbing wall and the steel cable is guided above and in front of
the climbing wall through pulleys on a davit.
DESCRIPTION
Dimensions (H/W/D): 2000x160x390 mm
2500x160x390 mm
3125x160x390 mm
2500x230x390 mm
Onbelay 8
Onbelay 11
Onbelay 14
Onbelay 17
Weight: 60 kg
75 kg
100 kg
85 kg
Onbelay 8
Onbelay 11
Onbelay 14
Onbelay 17
Stroke: 7.35 m
10 m
13 m
16 m
Onbelay 8
Onbelay 11
Onbelay 14
Onbelay 17
Autobelay cable: Steel cable, 6mm, DIN3069
Safe load: 1 Person
Min.user weight: 15 kg
Max.user weight: 125 kg
Retract speed: approx 1.50 m/s
Descend speed: 1 m/s
Brake: Air over hydraulic system with 2 pistons
Device complete Inspection interval:
1 year
Device standards:
Onbelay 8/11/14/17 EN 341:2011 / EN 360:2002 0158
Swivel carabiner/connector: EN 362:2005 / EN 12275 Type B/T 0194/0158
Instructions for use/identification: EN 365
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Oct 20187
DEVICE IDENTIFICATION
Type Autobelay
Class of the device Class A
Standard/Year EN 341:2011 / EN 360:2002
Model Onbelay 8, Onbelay 11, Onbelay 14 or Onbelay 17
(For walls up to 8m, 11 m, 14m or 17 m high)
Serial No AA-MMYY-LLLL-NNNN
(AA - 08 for Onbelay 8; 11 for Onbelay 11, 14 for Onbelay 14 or 17 for Onbelay 17 – model of
the unit ; MMYY - Month & year of manufacture; LLLL- cable length in cm; NNNN – Number of
the unit of this model)
Min. Climber Weight Minimal bodyweight of the climber, in kg
Max. Climber Weight Maximal bodyweight of the climber, in kg
Read the instruction for use Pictogram (book)
Manufacturer Name SAFETY ENGINEERING
Web address www.safetyeng.eu
E-mail [email protected]
Manufacturer:
SAFETY ENGINEERING Ltd
Tsarigradsko shose 111B,
1784 Sofia, Bulgaria
Notified body:
DEKRA EXAM GmbH
Dinnendahlstr. 9
D-44809 Bochum,
Germany 0158
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Oct 20188
CABLE IDENTIFICATION
WARNING: The steel cable of the Onbelay MUST be changed every 12 calendar months, counting from the date marked on the cable identification tag. If the identification tag information is not retrievable, immediately stop using the unit and order a new cable. The cable change must be performed by Safety Engineering authorized personnel only.
The cable length and cable manufacturing date (month and year) are marked on a sleeve at the user’s end of
the cable.
The cable length, in centimetres, could be found on 2 more locations:
On the serial number:
Digits 7, 8, 9 and 10 are the cable length in centimetres
On the cable replacement log table:
L (length in centimetres) MM.YY (manufacturing date)
1750
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Oct 20189
SAFETY RULES
Onbelay
The Onbelay device must only be used when in accordance with the requirements of the Operator Manual and
for intended purpose only.
Onbelay may only be used by one individual at a time and under the supervision of trained personnel.
The supplier and manufacturer shall not be held liable for any damage due to the improper use of the device or
device alterations of any kind.
Onbelay becomes an effective system only in combination with anchoring (mounting) construction and a personal
protective equipment (harness).
Anchoring (mounting) construction shall comply with manufacturer’s installation requirements.
The steel cable must not run over any edges or be hindered by other equipment, surfaces and obstacles other
than the specifically designed pulleys, plates and other components of the belay system.
The Onbelay cable must be kept free of dirt and small particles. Cable should be cleaned with household
cleaning products without acetone. Do not use solvents to remove grease and dirt.
In case of any malfunctioning, Onbelay’s operation must be suspended immediately and the unit has to be fully inspected both from the front and from the back. The cable has to be visually inspected in its entire length and
The Onbelay autobelay device does not hold the user static in place, but rather allows them to descend with
controlled speed, therefore there must be no hindrance to the descent or opportunities for snagging, banging
or bumping. This shold be enforced by the operator who has to ensure the routes set and the climbing surface
topography are appropriate for Onbelay autobelay line.
If the descent process is interrupted or the user freezes during the climb, they must not change the position they
have taken, even if it is uncomfortable. The safety cable must remain tautly connected to the user. It is forbidden
to unlatch from the carabiner/connector or pull the safety cable out. A rescue operation would then have to be
initiated.
If the cable is loose or flabby during the ascent, the climber should stop climbing immediately! Rescue operation
must take place. The operator must conduct full inspection of the device to identify the cause. Device shall be
rectified and properly maintained before next use.
The cable should be retracted when out of operation. Do not let the cable retract freely but rather use a pilot rope
attached to the end of the autobelay cable.
In case a user or operator misses to attach the belay rope to the bottom anchor and it retracts to the top of the
wall, the operator should ensure safe ascent of a staff member to the belay rope end and their safe descent in
case no belay accessories are provided in prior by the manufacturer. In this case, there is a risk of uneven coiling
of the steel cabel of the Onbelay on the pulleys because of the unusual fast speed of retraction. Before next
use, the operator needs to check the retraction of the cable with a pilot rope at least three (3) times in order to
ensure it retracts smoothly and with constant speed.
Exploitation conditions
Operation of Onbelay outdoors must be discontinued if there are any indications of thunderstorms and adverse
weather conditions.
The autobelay device must not be exposed to extreme temperatures (<-15°C, >+65°C) and weather conditions,
chemicals, high humidity over a long period of time or to be splashed with water, aggressive sea-air, sand, dust.
all pulleys both inside and outside the device need to be inspected for damage or irregularities before resumingoperation.
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Oct 201810
SAFETY RULES
Operator safety notice
WARNING: These safety instructions shall not replace the health and safety procedures, User instructions and other operational regulations and practises for the site required by law!
Operator shall introduce all users to the correct use of the Onbelay autobelay (attachment to the carabiner and/
or other connector, ways to ascend, descend and land) and any other site specific safety rules by conducting
individual or group instructions (safety briefings) prior to each climbing session.
Operator shall oversee the adherence to the safety rules and regulations and shall provide a written version of
the rules on-site for reference.
Operator has to ensure that there are no obstacles in the way of the climber during ascent and descent on the
climbing line.
Operator has to ensure clear space for the safety zone on the floor in front of each climbing route for landing of
the climber by means of indication signs, safety briefing instructions and verbal instructions during the session.
User safety requirements
Users must be in good physical condition suitable for this sport.
Harnesses and clothing have to fit tight but not painful on the body.
Excessive crosswise movement and jumping onto the safety cable is not allowed.
The user must not twist while descending or after landing.
If not otherwise arranged by the operator, liability shall be ruled out for:
o Individuals under the influence of drugs and alcohol
o Individuals weighing under 15 kg
o Using one’s own harness or carabiner and the consequences associated with such
o Clothes stained by hydraulic liquid and cable grease
User safety equipment
Only full body harness or seat harness in compliance with EN 361 shall be used.
The user harness must be in perfect condition and maintained as per it’s manufacturers requirements.
The operator must ensure that the user’s harness fits tight but not tense and the user cannot fall out of the
harness irrespectively of his/her body position at any time.
User’s harness shall be attached to the the autobelay carabiner/connector as pointed in the instructions by the
harness manufacturer.
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Oct 201811
INSPECTION ROUTINE
Perform the below operations as scheduled and in full scale! Do not skip or overlook any of the topics! Negligence may result in device malfunction and serious injuries or death of the user! Maintain your corresponding log books correctly filled.
Daily inspection
Perform the below operations daily before the first use for the day. Fill in the results in the Daily inspection log book.
Cable inspection
Necessary equipment: gloves, rags or other hand protective equipment.
WARNING: The steel cable MUST be changed every 12 calendar months, counting from the date marked on the cable identification tag. If this period is exceeded immediately stop using the autobelay and order new cable. Any other service or maintenance activities, not described in this manual, including the cable change must be performed by Safety Engineering authorized personnel only.
We strongly recommend keeping track of the cable manufacturing date and ordering replacement cables in order
to reduce the unit’s downtime.
Examine the retraction function of the cable - When the cable is pulled out, the person attached should be able to feel slight tension of the cable pulling
upwards. Use a pilot rope to test the full retraction.
- The cable has to retract all the way up in a smooth, steady motion. If abnormal noise or uneven pull is
detected immediately suspend the use of the device and perform thorough inspection!
Examine the steel cable over the entire length, both in front and behind the climbing structure in the handling range (section above the protection sleeve where users have access to)
Pull the cable all the way out and let the cable run back slowly through your hand up to the protection sleeve.
The steel cable has to be suspended immediately in case inspection identifies any the following defects:
- Missing or damaged cable identification tag
- One or more broken wires
- If there are any deformations and/or defects of the cable as shown in the images below:
Cable fraction at the thimble
Basket like deformation
Kink BruiseRust damage
Cable fraction
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Oct 201812
SWIVEL CARABINER/CONNECTOR INSPECTION
PULLEYS
WARNING: Make sure that the swivel carabiner/connector is properly aligned prior each use! Please follow all instructions for use and maintenance of the carabiner/connector provided by the manufacturer!
Examine whether the carabiner/connector is clean and if it locks smoothly. It is only safe if it locks automatically. Immediately replace the carabiner/connector if the rotation cylinder (closing mechanism) does not
function smoothly even after cleaning or if there is any deformation/wear.
The pulleys should be visually inspected for dents, burrs, rust & corrosion, cracks, gouges, deformations, excessive
wear or grooves created by rope, movement of side plates, sheaves and loose nuts.
Acceptable parameters:Inner diameter: 87.4 mm – 85 mm
Inner channel gap: 6.5 mm – 8 mm
87.4 - 85 mm
6.5 - 8mm
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Oct 201813
OIL LEVEL
TESTING THE BRAKE ACTION AND PULL UP FORCE
Check the oil level through the sight glass while the autobelay is in vertical
position and the cable is fully retracted. The oil must be visible and above
the middle of the glass. If it is less suspend the device from operation and perform the оil adding procedure before next use.
Negligence over the fluid level may result in uncontrolled speed of descend that may lead to serious injuries or death of the user!
AIR PRESSURE
The acceptable air pressure level for all Onbelay models must be 4.8 ÷ 5.2 bar (70 ÷ 75 PSI) when the cable is fully retracted.To perform air pressure check:
1) Check the indication on the pressure indicator gauge.
2) Let the cable retract all the way up to the top of the wall using a pilot rope, then check the air
pressure in the tank again.
3) If the air pressure is less than 4.8 bar / 70 PSI suspend device from operation and use an air
compressor or a large bicycle/automotive pump to adjust pressure to the correct level before next use.
Negligence may result in insufficient cable retraction and slack formation that may lead to serious injuries or death of the user!
Grab the cable end and pull with significant amount of force. You should feel the braking force of the Onbelay
autobelay and in the same time be able to pull the cable with a constant speed.
Attach a pilot rope to the carabiner/connector and let the cable retract all the way to the top of the wall. During
the entire retraction you should fill a constant pulling force of approximately 5 kg (10-11 lbs). The cable retraction
must be with uniform speed and tension.
If the movement is jerky or full retraction to the top of the wall is not possible check for any obstructions on the
way:
Jammed pulleys on the davit
Low air pressure and/or oil level
If these parameters are in the allowed range then open the top cover and perform full length cable inspection.
Negligence may result in a device malfunction and serious injuries or death of the user!
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Oct 201814
DAYLY CHECK LISTDevice SN / Identification:
Inspection performed by: (print name clearly)
Date:
Signature:
INSPECTION POINTCritical
ApplicationAction
Contact
Supplier
Inspection of cable outside the device
Cable identification tag present and
readableYES
Stop using theYES
Rust damage YES Stop using the device and replace the cable YES
Kink YES Stop using the device and replace the cable YES
Bruise YES Stop using the device and replace the cable YES
Cable fraction at the thimble or
within the reach of handYES Stop using the device and replace the cable YES
Swivel carabiner/connector inspection
Mechanical damage/cracks on main
bodyYES
Stop using the device and replace the cable
with the carabiner or the connectorYES
Uneven/rough swivel operation YESStop using the device and replace the cable
with the carabiner or the connectorYES
Uneven/rough auto locking operation YESStop using the device and replace the cable
with the carabiner or the connectorYES
Missing parts YESStop using the device and replace the cable
with the carabiner or the connectorYES
Brake action and pull up force test
Smooth full retraction with constant
speed and tensionYES
Inspect for obstructions including inside device.
Check air pressure and oil level. If NOT OK – stop using the device and contact the supplier
YES
Braking effect test YESCheck air pressure and oil level. If NOT OK –
stop using the device and contact the supplierYES
Oil Check
Oil level with cable fully retracted YES Add oil NO
Big oil stains on the floor, Oil tank,
hosesNO
Inspect and tighten with up to ¼ turnYES
Air pressure range 4.8 ÷ 6 bar (70
÷ 87 PSI) YES when fully retracted.Add air pressure if pressure lower than 4.8 bars
NO
Pulleys
Cable pulleys (abnormal wear or
noise). Acceptable parameters:
Inner diameter: 87,4mm – 85mm
Inner channel gap: 6.5mm – 8mm
YES then resume operations.
Stop using the device, replace the pulley and
YES
WARNING: Descriptions in the table are brief and as a reminder! They DO NOT substitute the full understanding of the procedures. If in doubt, refer to the full instructions in the manual for the complete inspection steps description!
If not present and readable -device and contact the supplier
Check oil level and add if necessary
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Oct 201815
MONTHLY INSPECTION
Perform the below operations each month before first use for the day. Fill in the results in the Monthly inspection log book.
Monthly inspection includes the Daily inspection of each component and function plus the following:
Cable full length inspection
Necessary equipment: gloves, rags or other hand protective equipment, 10 mm, 13 mm, 17 mm, 24 mm spanners, 30 mm capacity adjustment spanner.
WARNING: The steel cable MUST be changed every 12 calendar months, counting from the date marked on the cable identification tag. If this period is exceeded immediately stop using the autobelay and order new cable. Any other service or maintenance activities, not described above, including the cable change must be performed by Safety Engineering authorized personnel only.
We strongly recommend keeping track of the cable manufacturing date and ordering replacement cables at least one month earlier in order to reduce the unit’s downtime.
Each month perform the cable inspection on the entire cable length! Remove the top cover of the autobelay box in order to revise the cable inside the device. Inspection of free span of
the cable (outside the box) shall be performed in compliance with the local health and safety rules and regulations
for work at height.
The autobelay cable has to be suspended immediately in case the inspection identifies any the following defects: Missing or damaged cable identification sleeve/tag
One or more broken wires in the handling range
If there are more than 10 wire(s) breakage within the whole length of the cable
If the cable shrinks to < 5.6 mm
If there are any deformations and/or defects of the cable as shown on page 11
Pulley inspection
Check top pulleys on the davit and all pulleys inside the body of the autobelay for any signs of wear. If defects such as, but not limited to the listed below are present immediately stop using the device and replace the worn ones! Grooves and dents
Cracks
Uneven and/or noisy rotation
If there are any deformations and/or defects of the pulleys as shown on page 12
Remove the top cover of the auobelay to inspect all plastic and steel pulleys inside.
Negligence will result in a destroyed cable and may lead to serious injuries or death of the user!
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Oct 201816
MONTHLY INSPECTION
Fasteners Inspection
With the top cover removed, use the corresponding size spanner and check if all bolts, nuts and screws are still
tightened.
Pay special attention to the cable end clamping nuts!
Tightening torque chart
Bolt Diameter (mm) Nm Kgf-m Lb-ft
M6 5.5 0.55 4.0
M8 13 1.3 9.5
M10 29 2.9 21.0
M12 45 4.5 32.5
M14 65 6.5 47.0
M16 105 10.5 76.0
Device body covers are structural components of the Autobelay! Make sure all bolts are present and tightened. Never operate the device with loosen or disassembled body. Negligence and over torque may result in serious injuries or death of the user.
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Oct 201817
MONTHLY CHECK LISTDevice SN / Identification:
Inspection performed by: (print name clearly)
Date:
Signature:
INSPECTION POINTCritical
ApplicationAction
Contact
Supplier
Cable FULL LENGHT inspectionCable identification tag present and
readableYES
If not present and readable - Stop using the YES
Rust damage YES Stop using the device and replace the cable YES
Kink YES Stop using the device and replace the cable YES
Bruise YES Stop using the device and replace the cable YES
Cable fraction at the thimble or within
the reach of handYES Stop using the device and replace the cable YES
Cable fraction within the whole length
of the cable, including inside the
device (more than 10 wire breakages)
YES Stop using the device and replace the cable YES
Swivel carabiner/connector inspectionMechanical damage/cracks on main
bodyYES
Stop using the device and replace the cable with the
carabiner or the connectorYES
Uneven/rough swivel operation YESStop using the device and replace the cable with the
carabiner or the connectorYES
Uneven/rough auto locking operation YESStop using the device and replace the cable with the
carabiner or the connectorYES
Missing parts YESStop using the device and replace the cable with the
carabiner or the connectorYES
Brake action and pull up force Test
Smooth full retraction with constant
speed and tensionYES
Inspect for obstructions including inside device. Check
air pressure and oil level If NOT OK – stop using the
device and contact the supplierYES
Braking effect test YESCheck air pressure and oil level. If NOT OK – stop using the
device and contact the supplier YES
Oil CheckOil level with cable fully retracted YES If oil not visible through hole - Add oil NO
Big oil stains on the floor, Oil tank,
hosesNO
Inspect and tighten with up to 1/4 turn
Check oil level and add if necessary YES
Air pressure – 4.8 ÷ 6 bar
(70 ÷ 87 PSI)YES
Add air pressure if pressure lower than 4.8 barsNO
Cable pulleys
Grooving YES Replace pulley YES
Cracks YES Stop using the device and replace pulley YES
Uneven and/or noisy rotation YES Stop using the device and replace pulley YES
FastenersCable end fasteners loose YES Stop using the device, tighten, resume operations. YES
Pulley blocks fasteners loose YES Stop using the device, tighten, resume operations. YES
General fasteners loose YES Tighten, then resume operations. NO
WARNING: Descriptions in the table are brief and as a reminder! They DO NOT substitute the full understanding of the procedures. If in doubt, refer to the full instructions in the manual or contact the manufacturer!
when fully retracted
device and contact the supplier
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Oct 201818
MAINTENANCE
Follow the below procedures strictly! Always mark clearly the climbing area of the Onbelay being serviced with ‘OUT OF SERVICE’ sign and make sure this unit is out of use! Failing to do so may result in serious injury or death of the user!
Adjusting the air pressure
Throughout the exploitation of the Onbelay a small amount of air may escape through the seals and the pressure
in the tank may drop. In order to maintain the pressure in the admissible range you should monitor and pump the
tank when necessary:
1. Let the cable retract all the way to the top of the wall using a pilot rope.
2. In this condition check the air pressure in the tank. It must be in the following range 4.8 ÷ 5.2 bar (70 ÷ 75 PSI)
3. If it is less – use an air compressor or a large bicycle/automotive pump to add pressure.
4. Fill in the information and remarks about the procedure into the device’s Service and maintenance log book.
Checking for air leaks
If the pressure begins to drop rapidly below the minimal acceptable pressure level in less than one week, and in
the same time there are no hydraulic leaks, you should perform the following check:
1. Pressurize the tank and spray soapy water over the tank, weld seams, valves, gauges and fittings and observe
for bubbles coming out.
2. If it is leaking from a thread connection – tighten with up to ¼ of a turn. If the problem persists – DO NOT
TIGHTEN ANY MORE! Release the pressure fully, unscrew the corresponding fitting, change the seal/teflon
tape and reassemble. Perform the soap water check again.
3. If there is a mechanical failure such as crack in the tank or in the welds, broken valve or gauge – immediately
stop using the device and contact manufacturer for replacement parts and services.
4. Fill in the information and remarks about the procedure into the device’s Service and maintenance log book.
Oil adding
Throughout the exploitation of the autobelay a small amount of oil may seep through the seals.
Monitor the oil level and add oil when needed to ensure it is within the acceptable levels. To add oil perform the
following procedure:
1. Retract the cable all the way to the top of the wall using a pilot rope.
2. Make sure that the hydraulic rams are fully retracted by looking through the gap
between the top and bottom covers of the autobelay body.
3. Release the air pressure in the tank by pressing the valve pin until the pressure gauge
shows no pressure and the air stops coming out (fig.1).
4. Open the upper device cover (the one with the tank) and place it in a horizontal position.
5. Using spanner unscrew the nut on the sight glass for the oil level check.
6. Using a small funnel pour the hydraulic fluid into the tank until it is half full and above
the sight glass.
Pay attention not to damage any of the parts during this operation!Use only ATF fluid DEXRON III / MERCON oil!
7. Clean the old teflon tape from the sight glass/nut and apply a new one. Screw in to the tank using spanner.
Pay attention not to cross thread!
fig. 1
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MAINTENANCE
groundground
8. Pressurize the tank back to the admissible range by following the manufacturers procedures in the above
chapter.
9. Using soap water, check for any air leaks around the sight glass/nut thread and pressurizing valve.
10. Using the pilot rope, cycle the autobelay all the way up and down 4 – 5 times to make sure that it works
properly.
11. Perform Brake action and pull up force test. 12. Re-check the oil level and the air pressure.
13. Fill in the information and remarks about the procedure into the device’s Service and Maintenance log book.
Oil leaks
If significant oil leaks appear perform the following steps:
1. Unscrew the bottom cover of the Onbelay and carefully turn it aside so that you can see inside the autobelay
body.
2. Inspect all fittings and hoses. Use a spanner to tighten the loose fittings with up to ¼ of a turn.
3. Wipe clean the area.
4. Check the oil level and if it is below the admissible level continue with the Oil adding procedure as described
above.
5. Keep inspecting for fresh oil stains.
If the problem persists – DO NOT TIGHTEN ANY MORE! 6. Release the pressure fully, drain the hydraulic fluid and unscrew the corresponding fitting.
7. Change the seal / fitting and reassemble.
8. Continue with the Oil adding procedure.
9. Fill in the information and remarks about the procedure into the device’s Service and Maintenance log book.
If at any point you detect a mechanical failure such as broken hose, crack in the tank or in the tank welds, release all the pressure and immediately stop using the device! Contact manufacturer for replacement parts and services!
Oil tank working direction
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WARRANTY CLAIM
In the event of a Warranty claim or in case you need service, fill in the Onbelay autobelay Service/repair request
form on the next page and submit it along with all required additional documents to the SAFETY ENGINEERING
Customer service department at:
111V Tsarigradsko Shose blvd. 1784 Sofia, Bulgaria and to [email protected]
Warranty claim service must be performed as approved by SAFETY ENGINEERING Customer Service Department. Warranty replacement hardware components or parts will be furnished freight prepaid. Labour cost to repair or replace will be limited to the amount of the original purchase price of the systems and components. The replaced warranty products or parts become the property of SAFETY ENGINEERING and must be returned to the SAFETY ENGINEERING Customer Service Department freight prepaid, unless prior arrangements have been made.
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ONBELAY AUTOBELAY SERVICE/REPAIR REQUEST FORMDate:
Client name:
Site location (address):
Project name:
Contact Info on the site - place of use, operator’s name, tel., e-mail:
Onbelay Model:
Serial No:
The request is for Repairs and/or technical service
The request is for Spare parts
The Unit is under Warranty
The Unit is NOT in Warranty
The operator is aware and understands the User manual and is familiar with the use and daily maintenance
Description of the problem:
I have problem with the Oil
I have problem with the Air
I have Cable problem
I have another problem
Please submit copies of the following mandatory documents:1. Copy of the original signed Warranty Card
2. Copy of the Service and Maintenance logbook with the entries from the past 3 months
3. Copy of the last Monthly check list
4. Copies of the Daily Check List for the past 14 days of operation
NOTE: In order to provide you with the best service - Please fill in this form completely and submit ALL
required info, including photos of the problem!
This page may be copied
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ONBELAY AUTOBELAY SERVICE/REPAIR REQUEST FORMUse this log to keep a record of the maintenance services and repair activities during Daily and Monthly inspection
checks. Include information such replacement of parts, contacts with manufactirer, etc.
Onbelay autobelay Serial No:
Date Reason/Problem Activity description Name & SignatureDate of
next inspection
This page may be copied