Rail Blocks Rev. 2-1/18 Document No. - Instruc ons_11-180and11-190series 6200 Brent Drive Toledo, Ohio 43611 1
Table of Contents Overview... 3 Hazards... 3 Description... 4 Specifications... 5 Installation... 5 Tools Needed... 5 Bill of Materials... 7 Declaration of Conformity..12 Maintenance Log... 13 Rev. 2-1/2018 2
Overview The purpose of this manual is to provide the user with detailed instructions on the proper installation and use of the Wurtec Rail Blocks. This includes: Hazards associated with the use of this product Explanations of the Features and Functions of this product Installation and Operation instructions Daily Inspection & Maintenance After reading this manual, the reader will be able to install the U onto a Capstan hoist, and use it to provide a safe means for controlling the lift rope while hoisting materials. CAUTION! The equipment covered in this manual should only be installed, used, and serviced by qualified personnel trained in proper work and safety procedures. This manual is intended to assist such trained individuals in the installation and use of this equipment and is not intended as a substitute for proper training and experience. This document or any other information regarding this equipment is not intended to cover all of the possible situations which may be encountered while using the equipment described herein. Should specific situations arise which are not covered by the information provided, or should the user desire further details, the specifics should be directed to Wurtec, Inc. Note: In the effort of continuous product improvement, Wurtec, Inc. reserves the right to modify the design and specifications of this product at any time without notice. Acquire the most current version on Wurtec.com. WARNING! Working at height is an inherently dangerous activity during which serious injury or death may occur due to you falling, or you causing an object to fall. ALWAYS use safe means to access a high work area ALWAYS have an accessible safe means to evacuate in case of emergency ALWAYS employ personal fall protection equipment ALWAYS employ guardrails ALWAYS keep the work area free of loose objects and trip hazards Rev. 2-1/2018 3
ALWAYS provide falling object protection Wire ropes, fittings and pulleys WILL FAIL if worn out, misused, abused, damaged or improperly maintained. Failure may cause serious injury or death! ALWAYS INSPECT wire ropes, fittings that are WORN OUT, DAMAGED or ABUSED BEFORE USE NEVER USE wire ropes, fittings or pulleys that are WORN OUT, DAMAGED OR ABUSED. REPLACE THEM IMMEDIATELY. ALWAYS CHECK that the capacity of wire ropes, fittings and pulleys are rated for the load to be applied NEVER OVERLOAD wire ropes, fittings or pulleys! ALWAYS CHECK that fittings and pulleys match the wire rope being used NEVER MODIFY wire ropes, fittings, pulleys or attachment points INFORM YOURSELF: Read, understand and follow the manufacturer s instructions for use, inspection, maintenance and replacement of all protection equipment. INFORM YOURSELF: Read, understand and follow all regulatory agency rules and guidelines for working at height. DANGER! Overhead loads can fall causing damage to equipment and property, severe injury, or death. Do not allow people to stand under or near the load during installation. Use correct unit based on rail size outlined in the Specifications section of the manual. Use outside of specifications can result in damage to equipment and property, severe injury or death. Rail Blocks shall only be used with included hardware. Alternate hardware can fail resulting in damage to equipment and property, severe injury or death. Contact Wurtec Customer Service for replacement parts if misplaced, damaged or worn. Description: Rail Blocks are a simple way to establish sturdy connections with the rail from which to lift loads, build cars or support cross members. Personal Protective Equipment: The following PPE are recommended when installing and using the Rail Blocks. Safety Glasses Hard Hat Work boots with steel toe and sole Abrasion resistant gloves Harness and attached Lifeline Rev. 2-1/2018 4
Installation Tools The following tool list is the minimum required for installing and performing the daily checks on the Wurtec Rail Blocks. The Rail Blocks can be installed by one person who would have all of these tools: Torque wrench and bits for the 5/8 or 1 bolts (see Specifications) Maintenance Ensure Warning Plate is in place and set screw cups are still sharp and in tact before each use. Record in Maintenance Log, located in the back of this manual. Installing Rail Blocks All blocks weigh less than 55 pounds, they can be positioned by one man but may require another in order to hold in place while tightening the set screws. TOP VIEW ISO VIEW A. Position Rail Blocks When placing the rail block onto the rail, ensure that the back of the throat is flush with the rail. Each Rail Block will have a tag indicating which direction to point upward. Misalignment or inversion may result in failure, causing severe injury or death. B. Tighten Set Screws Tighten all six set screws to the prescribed torque. Afterward, mark the rail directly below the rail block as a reference for daily checks. DANGER! Failure to tighten to the prescribed torque may result in failure, causing severe injury or death. Daily Checks Inspect block to ensure it s flush with the rail and has not slid down the rail. Check all hardware denoted by the Wear/Spare column of the BOM. Confirm that all set screws are in place and tightened. Rail Marking Rev. 2-1/2018 5
Intended Use DANGER! All Rail Blocks have intended rail sizes listed on their tags as well as denoted in the specifications table. Use of rail blocks outside or their intended use may result in failure, leading to severe injury or death. Standard Rail Blocks These blocks are designed for a large load to rest on top of the block. A common use is to rest a car on them. They should be oriented with the larger face pointing upwards. Car Building Blocks These blocks are designed to build a car sling upon. They should be oriented with the large face upward to build the car upon. Per Machinery Direc ve 2006/42/EC Rail Blocks with Clevis These blocks are intended to have all their load applied to the shackle. Loads are to be applied with fifteen degrees of a true vertical load. These should be oriented so that the shackle hangs downward in the hoistway. Heavy Duty Rail Blocks w/clevis These blocks are intended to have all their load applied to the shackle. Loads are to be applied with fifteen degrees of a true vertical load. These should be oriented so that the shackle hangs down in the hoistway. Green Cone displays allowable area to load Rail Blocks with Clevis DANGER! When using rope with Rail Blocks, ensure that the rope is of adequate strength for load. Inadequate strength of rope could result in serious injury or death. DANGER! Do NOT allow anyone to stand under or near the load during hoisting. Use Fall Protection Device to ensure safety while securing Rail Blocks at height. Rev. 2-1/2018 6
Bill of Materials Standard Rail Block QTY Spare ITEM Part No. Description Size Length 11-180 11-181 11-183 Wear 1 1 11-180-00 RAIL BLOCK, 5/8" RAIL - - - 1 1 11-181-00 RAIL BLOCK, 3/4" RAIL - - - 1 1 11-183-00 RAIL BLOCK, 1 1/8" & 1 1/4" RAIL - - - 2 1 70-10017398 DANGER STICKER (T127-2) - - - 2 1 70-10017500 DANGER STICKER (T140-1) - - - 2 1 70-10017501 DANGER STICKER (T140-2 & T140-3) - - - 3 4 4 4 32213 #2-8X0.25 METALLIC DRIVE SCREW #2-8 1/4" - 4 6 6 6 26160 SQUARE HEAD SET SCREW 5/8-11 1 3/4" Spare Rev. 2-1/2018 7
Car Building Rail Block ITEM QTY 11-185 11-185-04 11-186 Part No. Description Size Length Spare Wear 1 1 11-185-01 5/8" & 3/4"RAIL BLOCK WELDMENT - - - 1 1 11-185-04-02 5/8" & 3/4" RAIL BLOCK WELDMENT - - - 1 1 11-186-01 1 1/8" & 1 1/4" RAIL BLOCK WELDMENT - - - 2 6 6 6 26160 SQUARE HEAD SET SCREW 5/8-11 1 3/4" SPARE 3 4 4 4 32213 #2-8X0.25 METALLIC DRIVE SCREW #2-8 1/4" - 4 1 1 70-10017502 DANGER STICKER (T127-2 & T140-1) - - - 4 1 70-10017501 DANGER STICKER (T140-2 & T140-3) - - - Rev. 2-1/2018 8
Rail Block w/clevis QTY ITEM 11-190 11-190-M 11-191 11-191-M 11-193 11-193-M 70-10002008 Part No. Description Size Length SPARE WEAR 1 1 11-190 RAIL BLOCK W/ CLEVIS, 5/8" RAIL - - - 1 1 11-190-M RAIL BLOCK W/ CLEVIS, 5/8" RAIL - 1 1 11-191 RAIL BLOCK W/ CLEVIS, 3/4" RAIL - 1 1 11-191-M 3/4" MACHINED RAIL BLOCK - - - 1 1 11-193 RAIL BLOCK W/ CLEVIS, 1 1/8" & 1 1/4" RAIL - 1 1 11-193-M 1-1/8" AND 1-1/4" MACHINED RAIL BLOCK - - - 1 1 70-10002009 RAIL BLOCK W/ CLEVIS, 8-10MM RAIL - - - 2 1 16-033 ANCHOR SHACKLE 6 1/2 TON - - 2 1 1 16-034 ANCHOR SHACKLE 8 1/2 TON - - 2 1 1 1 1 16-037 ANCHOR SHACKLE 14 TON - - 3 1 70-10017503 DANGER STICKER (T70-2 & T75-3) - - - 3 1 1 70-10021622 DANGER STICKER (T127-2 CE MARKED) - - - 3 1 1 70-10021623 DANGER STICKER (T140-1 CE MARKED) - - - 3 1 1 70-10021624 DANGER STICKER (T140-2 & T140-3 CE MARKED) - - - 4 4 4 4 4 4 4 4 32213 #2-8X0.25 METALLIC DRIVE SCREW #2-8 1/4" - 5 6 6 6 6 6 6 6 26160 SQUARE HEAD SET SCREW 5/8-11 1 3/4" SPARE Rev. 2-1/2018 9
Rail Block Body, Heavy Duty QTY Spare ITEM Part No. Description Size Length 70-10001612 70-10008459 Wear 1 1 70-10001613 RAIL BLOCK BODY, JUMBO HD - - - 1 1 70-10008460 RAIL BLOCK BODY, HD - - - 2 1 70-10017504 DANGER STICKER (JUMBO T140-1) - - - 2 1 70-10017505 JUMBO STICKER (T140-2 & T140-3) - - - 3 1 1 16-037 ANCHOR SHACKLE 14 TON - - 4 4 4 32213 #2-8X0.25 METALLIC DRIVE SCREW #2-8 1/4" - 5 6 6 26256 SQUARE HEAD SET SCREW 5/8-11 2" Spare Rev. 2-1/2018 10
Specifications: The types and rail size of each Rail Block is specified in the table below. Rail Blade Width Type Part No. ISO Code (in/mm) Rail Wt. (lbs./.) Size of Set Screws (in) Wt. (lbs./kg) WLL per block (lbs./kg.) Standard Rail Blocks Car Building Blocks Rail Blocks with Clevis 11-180 0.625/16 T89, T127-1 & T127-2 8, 12 & 15 12,500/5,670 11-181 0.75/19 T140-1 18 0.625 15.55/7.04 12,500/5,670 11-183 1.125-1.25/29-32 T140-2 & T140-3 22 & 30 0.625 17.2/7.79 12,500/5,670 11-185 0.625 0.75/16-19 T89, T127-1, 8,12,15 0.625 22.28/10.09 12,500/5,670 T127-2, & T140-1 & 18 11-185-04 0.625 0.75/16-19 T89, T127-1, 8,12,15 0.625 35.89/16.26 7,500/3,402 T127-2, & T140-1 & 18 11-186 1.125-1.25/29-32 T140-2 & T140-3 22 & 30 0.625 23.49/10.64 12,500/5,670 11-190 0.625/16 T89, T127-1 & T127-2 11-190-M 0.625/16 T89, T127-1 & T127-2 8, 12 & 15 8, 12 & 15 0.625 0.625 0.625 10.46/4.74 17.33/7.85 20.21/9.17 12,500/5,670 12,500/5,670 11-191 0.75/19 T140-1 18 0.625 33.32/15.09 12,500/5,670 11-191-M 0.75/19 T140-1 18 0.625 28.45/12.89 12,500/5,670 11-193 1.125-1.25/29-32 T140-2 & T140-3 22 & 30 0.625 33.69/15.26 12,500/5,670 11-193-M 1.125-1.25/29-32 T140-2 & T140-3 22 & 30 0.625 28.46/12.89 12,500/5,670 70-10002008.315-.394/8-10 T170-2 & T75-3 5 & 6 0.625 14.01/6.35 7,000/3,175 Heavy Duty Rail Blocks w/ Clevis 70-10008459 0.75/19 T140-1 19 1.000 35.71/16.18 17,500/7,938 70-10001612 1.125-1.25/29-32 T140-2 & T140-3 22 & 30 1.000 41.4/18.75 17,500/7,938 Rev. 2-1/2018 11
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Maintenance Log DATE Warning Plate Inspection Set Screw Replacement & Inspection Rev. 2-1/2018 13