Doughty Zenith Mk3 - User Manual

www.doughty-engineering.co.uk
Doughty Engineering Ltd
Zenith Mk3
Winch Stand
Operating Manual

Summary

Product Purpose and Application

Zenith Stands Overview

Explains the Zenith Mark 3, 520 & 620 stands are four-section winch stands suitable for various equipment.

Introduction to Zenith Stands

Operating Instructions and Maintenance

Stresses reading instructions for reliable operation and maintaining the guarantee of function and safety with genuine spare parts.

Zenith Stand Safety Precautions

Excluded Applications

Lists applications for which the Zenith stands are not approved, such as construction hoists or lifting persons.

Automatic Brake Operation

Details the automatic brake, minimum load requirements, and notes on avoiding oil/grease on the mechanism.

Pre-Use Safety Checks

Details checks before loading, including surface levelness, mast verticality, and cable condition.

Winch Handle Safety

Warns against removing the winch handle with a load attached and meeting minimum load for brake action.

Zenith Stand Assembly Guide

Roller Base Assembly Steps

Step-by-step guide for assembling the roller base configuration, including leg placement and securing the load.

Turnbuckle Base Assembly Steps

Step-by-step guide for assembling the turnbuckle base, focusing on leg orientation and mast verticality.

Zenith Stand Operation Procedures

Lifting Procedure

Instructions for raising the stand, engaging locking pins, and winding the winch handle to the desired height.

Lowering Procedure

Details the procedure for safely lowering the load and retracting the mast sections.

Zenith Stand Maintenance and Cleaning

Cable Inspection and Care

Instructions for pre-use and annual inspection of the cable for defects like frays, cuts, or kinks.

Lubrication and Bearing Care

Recommendations for lubricating gear drives, handle threads, and bearings, avoiding the brake.

Locking Mechanism Checks

Annual checks for secure locking of mast sections, focusing on pins, strips, and return springs.

Annual Professional Inspection

Emphasizes annual inspection by trained personnel and using genuine spare parts for safety.

Zenith Stand Parts Identification

Raise and Lock Mechanism Illustration

Shows the raise and lock components, including the pin and its locking function.

Upper Assembly Components Illustration

Illustrates the upper pulley assembly, locking pin assembly, and Tommy Bar.

Winch and Handle Illustration

Depicts the winch handle, winch guide pulley, and the overall winch mechanism.

Roller Base Diagram

Shows the roller base configuration with its components like base leg receiver and adjustable foot.

Turnbuckle Base Diagram

Depicts the turnbuckle base configuration, including spirit level, pivot foot, and leg support bracket.

Declaration of Conformity

Manufacturer and Address

Details the manufacturer's name and address as stated in the declaration.

Product Identification and Accessories

Lists the product name, model numbers, and accessories covered by the declaration.

Product Specifications and Safety Standards

Outlines the product specifications and conformity to relevant safety standards and directives.

Supplementary Compliance Information

Provides additional compliance details, including CE marking and test certificate number.

Overview

1. Function Description
2. Important Technical Specifications
3. Model Specifics
4. Usage Features
5. Maintenance Features

The Doughty Zenith Mk3 Winch Stand is a robust and versatile four-section winch stand designed for lifting and supporting various equipment in professional settings. It is available in two main series, the 520 and 620, each with roller base and turnbuckle base configurations.

Function Description:

The Zenith Mk3 Winch Stand is primarily used for vertical lifting and supporting loads up to 200kg. It features a winch mechanism with an automatic mechanical brake, ensuring safe and controlled lifting and lowering operations. The stand is equipped with a 28mm (1-1/8”) receiver, compatible with standard TV spigots, making it suitable for a wide range of applications including supporting small trusses, loudspeakers, and lighting equipment.

Important Technical Specifications:

• Safe Working Load (SWL): 200kg
• Minimum Load: 15kg (essential for correct brake performance)
• Mast Sections: 4 telescopic sections
• Receiver: 28mm (1-1/8”) for standard TV spigots
• Construction Material: Mild steel (DIN 2394) box sections, steel stabilizer legs, and struts.
• Cable Specification: DIN 15020 2350N/mm² (6mm/7x19) grade. Replacement cables must meet this specification.
• Winch: TÜV approved with an automatic brake.
• Compliance: Conforms to EC Machinery Directive 89/392 EEC (as amended), DIN 15560, EN 292 Part 1, EN 292 Part 2, and VBG70 (GUV 6.15). Carries CE and GS markings.

Model Specifics:

• Zenith 520 Roller Base (T55580):
  • Min Load: 15kg
  • Max Load: 200kg
  • Closed Height: 1815mm
  • Extended Height: 5123mm
  • Unit Weight: 93.5kg
• Zenith 520 Turnbuckle Base (T55582):
  • Min Load: 15kg
  • Max Load: 200kg
  • Closed Height: 1692mm
  • Extended Height: 4984mm
  • Unit Weight: 76.0kg
• Zenith 620 Roller Base (T55590):
  • Min Load: 15kg
  • Max Load: 200kg
  • Closed Height: 2048mm
  • Extended Height: 6238mm
  • Unit Weight: 99.5kg
• Zenith 620 Turnbuckle Base (T55592):
  • Min Load: 15kg
  • Max Load: 200kg
  • Closed Height: 1925mm
  • Extended Height: 6100mm
  • Unit Weight: 82.0kg

Usage Features:

• Easy and Smooth Operation: Designed for effortless lifting and lowering of loads.
• Two Base Configurations:
  • Roller Base (T55580/T55590): Features a 4-castor base plate with removable legs. Legs slot into the base plate for use and into a transport position parallel to the main body when not in use.
  • Turnbuckle Base (T55582/T55592): Comprises a flat base plate with four permanently attached legs that rotate outwards for deployment and retract for transport. Includes two transport wheels on the reverse side for easy movement. A spirit level is integrated into the baseplate to assist with vertical alignment.
• Adjustable Feet: The legs feature adjustable feet to ensure firm contact with the supporting surface and to level the stand.
• Locking Pins: Multiple locking pins secure the mast sections in position during both raising and lowering, enhancing safety.
• Winch Handle: The winch handle is used to operate the lifting mechanism. It must remain attached when a load is fitted to prevent disengagement of the brake.
• Safety Precautions:
  • Always ensure the stand is placed on a firm, level surface with stabilizer legs in firm contact with the ground.
  • The mast section must be vertical before use.
  • Do not move the stand with a load attached, whether extended or retracted.
  • Not approved for lifting persons, construction hoists, or motorized use.
  • All loads must be evenly distributed.
  • In open-air use, firmly support the stand with guy ropes to account for weather conditions.
  • Do not lean ladders or stairways onto the stand.
  • Only use for vertical lifting; do not operate off-vertical.

Maintenance Features:

• Cable Inspection:
  • Visually inspect the cable for frays, cuts, or kinks before each use.
  • Conduct an annual inspection for kinks, deformations, single strand breakage, or cuts.
  • Defective cables must be replaced with DIN 15020 2350N/mm² (6mm/7x19) grade cable before returning the stand to service. Do not shorten the cable at the winch connection.
• Lubrication:
  • The gear drive and handle threads should be lubricated.
  • Oil should be applied to the bearings on the drum hub and the drive shaft.
  • Crucially, do not apply oil or grease to the brake mechanism. The brake washers are pre-greased with pressure-resistant grease.
• Locking Strip and Pin Check:
  • Annually check mast locking strips and locking pins to ensure secure locking in the raised position. Pay particular attention to the leading edges of the pin and strip, and the return spring.
• Annual Inspection: The Zenith stand should be inspected annually by trained personnel.
• Spare Parts: Only use spare parts supplied by Doughty Engineering Ltd. Using non-original parts or modifying the stand voids all rights to claim. When ordering spares or service, quote the model type, year of manufacture, and serial number.

Doughty Zenith Mk3 Specifications

General

Brand	Doughty
Model	Zenith Mk3
Category	Racks & Stands
Language	English