Operator s Manual. Wahoo Innovations, Inc. Pole Dancer Model Portable Pole Setter. US Patent Numbers: US 61/497,131; US 61/534,930

Transcription

1 Operator s Manual Pole Dancer Model 1000 Portable Pole Setter US Patent Numbers: US 61/497,131; US 61/534,930 CAUTION: Before using this tool, please read this Pole Dancer Operator s Guide, the Warn Installation and Operator s Guide, and the Duracell PowerPack 600 Owner s Guide and follow all safety rules and operating instructions. Please work safely. Wahoo Innovations, Inc E. Prince Road, Farmville, NC U.S.A.

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3 Created by an Electrician for Electricians Thank you for your purchase of this new, award-winning innovation that will save electricians time and money. After setting and servicing light poles for over twenty-five years, spending thousands of dollars renting expensive bucket trucks and dangerous tow-behind lifts, an experienced electrical contractor has created the innovative tool called the Pole Dancer. A serious accident involving an employee and the collapse of a tow-behind lift provided even more inspiration to develop a better and safer way to set and service light poles. The patented Pole Dancer is a lightweight, portable tool that will install or service up to forty-foot pedestal-mounted light poles eliminating the need to rent or purchase boom trucks or other expensive lifting equipment. The Pole Dancer can be transported in the back of a truck or van or it can be attached directly to a trailer hitch. It is designed to service or set poles with or without a raised pole base. Crafted from high-grade aluminum alloy, the durable Pole Dancer will save time and money for years to come. Most importantly, it is designed to keep your feet on the ground while setting or servicing light poles. The Pole Dancer Model 1000 was named a 2011 SHOWSTOPPER winner at the convention of the National Electrical Contractor Association (NECA) in San Diego, CA. Electrical Contractor Magazine has presented the annual NECA SHOWSTOPPER Winners for the past 15+ years. The NECA SHOWSTOPPER Showcase and Awards is the most prestigious recognition event in the electrical construction industry. The Showcase is designed to highlight new products and services designed to help electrical contractors on the job. Wahoo Innovations, Inc. is honored to receive this award for our new product. 3

4 This Booklet Every effort has been made to ensure the accuracy and completeness of the information in this manual. Wahoo Innovations, Inc. reserves the right to change, alter and/or improve the product and this document at any time without prior notice. 4

5 Table of Contents Introduction 3 Diagram 6 Parts List 7 Customer Service and Parts 8 Accessories 8 Warnings and Cautions 9 Overload Interrupter 12 Instructional Video 12 Pre-Operation 12 Operation 14 Disassembly 17 Tips for Servicing Light Poles 18 Warranty Statement 19 5

6 Diagram 6

7 Parts List Part Label Part Description Qty MBA Mast and Base Plate 1 HBA Hoist Bracket 1 VHA1 Vehicle Hitch 1 VHA2 Hitch Bar 1 VHA3 Hitch Pin 1 LBA Leg Brace 2 JA Jack 2 LMA Lower Mast 1 AB Angle Brace 2 AB1 Angle Brace Sock 2 WH Wheel 2 CMA Center Mast 1 TMA9 9 Top Mast 1 TMA5 5 Top Mast 1 PMA Pulley Mast 1 PW1 Pulley Wheel 1 BA Battery Pack 1 JC Jumper Cables 1 HST 12v Hoist 1 RC Remote Control 1 CB Control Box 1 OLI Overload Interrupter 1 QCC Quick Connect Cable 2 WRH Wire Rope with Hook 1 SWLP Small Wire Lock Pin 5 LWLP Large Wire Lock Pin 8 LHP Large Handle Pin 3 RSTP Ratchet Strap 2 PD14T 14 Pole Dancer Strap 1 PD19T 19 Pole Dancer Strap 1 PD23T 23 Pole Dancer Strap 1 PDB Pole Dancer Bucket 1 BC Bungee Cord 1 PB1 Center Pedestal 1 Protector Board PB2 Pedestal Protector 2 Board PB3 30 Pedestal Adapter Optional 7

8 Customer Support and Parts Always replace parts with only authorized parts from Wahoo Innovations, Inc. Contact Wahoo Innovations at immediately for replacement parts. Someone will be available 9:00 am to 5:00 pm ET Mon- Fri, except holidays, to assist with any questions at Our fax number is Accessories Wahoo Innovations, Inc. manufactures and sells accessories designed to help you get the most from your purchase. To find out more, please contact our website at 8

9 Warnings and Cautions Please read this Pole Dancer Operator s Guide, the Warn Installation and Operator s Guide, and the Duracell PowerPack 600 Owner s Guide and follow all safety rules and operating instructions before operating the Pole Dancer following all safety rules and operating instructions. Avoid the following: NEVER: Never operate Pole Dancer in winds in excess of 10 mph. Never operate Pole Dancer if lightening or thunder is in the area. Never operate the Pole Dancer within ten feet of electrical lines. Never lift a person. Never stand or sit on any part of the Pole Dancer. Never operate Pole Dancer without an assistant. Never exceed load limits. Never attempt to lift boom without an assistant s help. Never lift pole in excess of 40 in length. Never lift a pole in excess of 800lbs. Never stand under pole to be lifted or lift pole over people. Never stand near the hoist during a lift. Never touch the hoist, wire rope or any moving components during a lift. Never leave load unattended. Never operate without leather gloves or protective eyewear. Never operate without wearing a hard hat. Never allow load to be positioned more than 5 away from boom. Never over tighten wire rope. Never use straps other than the straps recommended. Never operate Pole Dancer without leveling booms. Never use 5 top mast with 9 top mast. Never operate Pole Dancer if any pin is missing or unattached. Never operate Pole Dancer without support stands, legs, and jacks. Never use Pole Dancer straps if load limit label is detached, defaced or unreadable. Contact Wahoo Innovations before lifting to order additional straps. Never use jacks or any component of the Pole Dancer for any purpose other than its intended use. 9

10 Never allow pole or light fixture to come into contact with support stands, jacks, boom or pulley. Never operate the Pole Dancer if you are tired, distracted, in a hurry or under the influence of drugs, alcohol or any medication that inhibits alertness or judgment. Do the following: ALWAYS: Always wear a hard hat. Always wear leather gloves. Always follow lockout procedures. Always know your situation and plan your lift carefully. Always know your load limits and the weight of load. Always operate Pole Dancer with at least one other person. Always check the weather conditions for possible wind gusts and lightening. Always be alert. Always use only Pole Dancer straps that are recommended for the length and weight of pole to be lifted (CAUTION: Getting past the center of gravity with the strap is extremely important!). Always, prior to operating, inspect the straps, hooks, booms, wire rope, hook, mounting structure and/or other accessories for signs of damage. Replace damaged components prior to a lift. Always take up any slack in the wire rope slowly, keeping tension on rope. Always tightly coil wire rope around drum evenly. Caution: Loose and uneven wire rope may slip on the drum during a lift. Always level the boom. Always use pins to attach each part of the Pole Dancer. Always begin the lift slowly. If there is any evidence of overloading or imbalance, immediately lower the load and correct the situation. Always verify that the lifting point of the pole to be lifted is directly aligned with the boom no more than 5 away from base. Always verify that all persons are standing clear of hoist, wire rope and load to be lifted. Always verify that no person is standing directly under load. Always stand in a safe position guiding the load away from angle braces. Always carefully guide load away from jacks, angle braces and booms. Always inspect and carefully rewind wire rope after each use. Cuts, kinks, or frayed areas reduce the tensile strength of wire rope. Replace wire rope if damaged. Always keep wire rope clear of support stands. Always be sure wire rope is not tangled with boom, pole, angle braces, jacks, or anything else. Always keep remote control away from drum, rope or rigging. Always replace parts with only authorized parts from Wahoo Innovations, Inc. Contact Wahoo Innovations at immediately for replacement parts. 10

11 Additional Guidelines: For additional information, refer to the operation section of American national Standard ANSI/ASME B30.16 and B30-9 (rigging) and the operation section of Department of Energy Hoisting and Rigging Standards DOE-STD Overload Interrupter (OLI) For your safety, the Pole Dancer 1000 is equipped with an Overload Interrupter (OLI) located in the control box. This module will not permit you to lift a load over the load limit of 800 pounds with a 5% variance. It will permit you to lower the load back to the ground. After load is on the ground, the OLI will reset and will be ready for another lift. To ensure that the OLI is working properly before each lift, a light located on the control box will blink once when control box is plugged into a power source. This means that your OLI is working. WARNING: Do not use if light does not blink when unit is plugged into a power source. Contact Wahoo Innovations, Inc. to repair or replace order OLI. Note: Some customers prefer to mount the control box to the back of the base plate near the hoist, whereas some customers prefer to leave it with the battery so it can be stored inside a van or the cabin of a truck when not in use. Therefore, the control box is not mounted to the base plate when shipped. Instructional Video An instructional video including set-up and operation is available at If you have any questions or concerns before operating this tool, please contact Wahoo Innovations for free assistance at Someone will be available 9:00 am to 5:00 pm ET Monday through Friday except holidays. Pre-Operation Additional Tools Needed: step ladder, level. Follow all lock-out/tagout procedures before servicing any light pole. Inspect the booms, legs, supports, and welds for cracks. Do not use if crack is found anywhere on the product. Inspect wire rope and hook. Do not use if rope has broken strands or is frayed, cut, kinked, knotted, or mashed. Do not use if hook is cracked, missing keeper or does not lock securely. Replace damaged parts before using. 11

12 Inspect straps. Do not use if straps are frayed or load limit tag is missing or unreadable. Inspect pulley for cracks, chips, cuts and do not use if either is discovered. Know all load limits and weight to be lifted. Do not exceed load limits. Never lift more than 800 lbs. Check weather. Do not use if wind speed exceeds 10 mph or lightening is in the area. If setting pole, position pole within 5 of boom. Never strap to raised bases that are trapezoid-shaped or square-shaped. Service these raised bases only from trailer hitch.* *Pole Dancer is designed for round 24 raised pole bases. Inserts can be ordered from Wahoo Innovations to service square-shaped bases with ratchet straps. For a 30 raised pedestal, order Part PB3, adapter. Yes NO straps!! Service from hitch. If using a raised pole base, be certain ratchet straps are tight and wrapped horizontally around pole base. (CAUTION: Do not over tighten so as to bend base plate.) If using directly from hitch of vehicle, place parking breaking on. Choose recommended strap size for pole to be lifted. Use only Pole Dancer straps. Choose recommended boom attachments for pole to be lifted.* *In most situations, the following chart is recommended; however, it is more important to know the center of gravity of the pole to be lifted (for example: a 30 four-headed pole that is very top-heavy may require a PD23T strap with a 9 top mast): Pole Length Strap Boom(s) on Center Mast 20 or less PD14T 4 Pulley Mast PD19T 5 Top Mast, 4 Pulley Mast PD23T 9 Top Mast, 4 Pulley Mast CAUTION: NEVER USE 5 Top Mast with 9 Top Mast. Operation Setup Follow all pre-operation instructions and carefully read all safety rules. 12

13 Attach hoist (motor on the right; wire rope spools from back) with pins (LHP). Attach base plate to raised pole base with ratchet straps. Attach legs and jacks with pins (LWRP). Level boom. Note: you may need to loosen and adjust ratchet straps while leveling. After boom is level, tighten ratchet straps. Lower base boom (lower mast) from base by detaching pin (LHP) and swiveling the base boom down. Always attach center mast first (9 mast with brackets for angle braces) in order to attach the angle braces. The mast should be attached with eyelet facing away from pole and brackets facing toward the pole. IMPORTANT: Be sure to support boom keeping it 2 to 3 feet off the ground. Dropping the boom to the ground will cause permanent damage to the boom.) Note: a five-gallon bucket works great. Attach and pin the recommended top mast if needed (LHP) and the pulley mast. Connect the remote to control box. Connect the control box to 12v power supply by following power supply instructions while checking for light on control box to blink once. This is the signal that the OLI is working properly. Do not use if light does not blink and contact Wahoo Innovations to order a new OLI. Use remote to thread the wire rope through the eyelets and around the pulley to the lifting point of pole. Attach the keeper pin (LWLP) at the top of the pulley. Note: the keeper pin hole should be toward the side of the pole to be lifted. Using 2 persons, lift the boom to its upright position and pin (LHP). Using a step ladder, attach angle braces to center mast with pins (SWLP). Attach angle braces to legs with pins (SWLP). Check again to make sure boom is level by adjusting jacks if necessary. Setting a Pole Inspect wire rope at the top of the boom to ensure that it is on the pulley. Determine the center of gravity point of pole to be lifted by lifting the pole by hand with a strap. IMPORTANT: Center of gravity will vary depending on the size, weight and number of fixtures on the pole. It is very important to know the pole s weight and its center of gravity. Attach the correct length strap to the pole by placing the hook in the hand hole located near the bottom of the pole. Slide the protective sock around the hook and attach the keeper strap around the pole to keep the hook securely in place by tightening the cam buckle. Wrap the top of the Y at the opposite end of the strap around the pole past the center of gravity point. Use the wire rope hook to attach the triangles in the Y of the straps to the wire rope of hoist. (CAUTION: Align this attachment with the boom and position within 5 of boom.) The pole is now ready to be lifted. 13

14 With one person operating the remote and keeping an eye on the boom and pulley while checking for falling objects, another person guides the pole as it is being lifted aligning the hook with the boom. Lift pole until pole is over the bolts and wire in base. CAUTION: Never place hands under the pole base while being lowered. Align light fixture and thread the light pole wire through bottom of pole. Carefully lower the pole about halfway over the bolts. CAUTION: Do not lower pole completely keeping weight of pole on the strap. Attach washers and thread nuts. Lower the pole completely. Tighten nuts. Using the remote, lower and detach the strap from pole. To service another pole, attach hook to bungee cord and attach to base plate (there is a hole drilled in the triangle next to the mast base for the bungee cord). Detach battery from control box, detach ratchet straps. With two persons, lean the Pole Dancer back and roll to the next base. Lowering a Pole to Be Serviced Follow the pre-operation and setup instructions above. Attach the hook of the lifting strap into the hand hole, sliding the protective sock around the hook and attaching the keeper around the pole to keep the hook securely in place by tightening the cam buckle. Wrap the Y at the opposite end of the strap around the pole and use the wire rope hook to attach the eyelets in the Y of the straps to the wire rope of hoist. With the remote, raise the strap until it is ALMOST tight CAUTION: Do not over tighten strap while nuts are still tight as it may damage the hoist and wire rope. Loosen but do not remove nuts from the bolts of base. Loosen until nuts are at the top of the bolts with all nut threads on bolts. With the remote tighten the strap to lift the pole a few inches until strap has the weight of the pole. As the strap now has the weight of the pole, remove nuts from bolts. Lift pole over the bolts, keeping an eye on the hook and the pulley insuring that hook does not come into contact with the pulley. CAUTION: Never stand directly under the pole. With the remote, carefully lower the pole. Another person guides the pole down aligning the hook with the boom. Do not lower the pole more than five feet from the boom. Lower until fixture is at an appropriate height for servicing. Disassembly Detach angle braces from legs. With a step ladder, detach angle braces from center mast. With two persons, carefully unpin and lower the boom (support boom by keeping it 2 to 3 feet off the ground). 14

15 Remove keeper pin from around pulley and remove wire rope from pulley and boom. With remote, spool rope tightly and evenly onto hoist. Detach power supply. Detach remote. Detach boom attachments. Detach jacks and legs. Raise base boom (lower mast) and pin to base. Detach hoist. Tips for Servicing Light Poles Never attempt to take down any light pole if you do not know the weight of the pole. Never exceed the 800lb load limit. Keep battery power pack fully charged. Nuts and bolts are not always galvanized. Lubricate nuts and bolts thoroughly and liberally. Use a wire brush to clean threads of rust and debris. Use a torque, impact or pneumatic wrench to loosen stubborn nuts. Loosen nuts slightly before strapping Pole Dancer to base. Be certain that the wire rope is wound tightly and evenly around drum of hoist. Have one person operate remote and watch for falling debris, while the other guides the pole. Lubricate and clean threads of bolts and nuts before retightening. Clean fixture glass before resetting pole. 15

16 Wahoo Innovations Limited One (1) Year Warranty Statement Wahoo Innovations, Inc. warrants to the original purchaser that the components of the Pole Dancer specified below will be free of defects in material or workmanship for a period of one (1) year from the original date of purchase. This warranty applies only to the original purchaser of the Pole Dancer. To obtain any warranty service, the original purchaser must provide Wahoo Innovations, Inc. with proof of purchase and date of purchase acceptable to Wahoo Innovations, Inc., such as a copy of your purchase receipt. Wahoo Innovations, Inc. will, at its option, repair or replace the product or refund the purchase price of the defective product or component, provided the original purchaser returns the defective product or component during the warranty period, transportation charges prepaid, to Wahoo Innovations, Inc.. Attach your name, address, telephone number, a description of the problem, and a copy of your receipt and original bill of sale bearing the Wahoo Innovations, Inc. serial number of the defective product and date of purchase. The warranty does not apply to components excluded below, or if the product has been damaged by accident, misuse, abuse, collision, overloading, modification, misapplication, improper installation, or improper service. The warranty is void if the Wahoo Innovations serial number has been removed or defaced. The warranty is void if replacement parts are not ordered and authorized by Wahoo Innovations, Inc. Wahoo Innovations, Inc. reserves the right to change the product design without notice. In situations in which Wahoo Innovations, Inc. has changed a product design, Wahoo Innovations, Inc. shall have no obligation to upgrade or otherwise modify previously manufactured products. No Wahoo Innovations, Inc. employee or representative is authorized to make any modification, extension or addition to this warranty. Warranty inquiries and products returned for warranty service should be sent to: (Warranty Statement Continued on Next Page) Wahoo Innovations, Inc E. Prince Road Farmville, NC Components not covered by this warranty: Wire Rope Pole Dancer Straps Ratchet Straps 12v wire and Battery Finish Components covered by this warranty: Aluminum booms, base, legs, angle braces Pulley 16

17 Jacks Pins Wheels Warn Industrial Hoist, remote, control pack The warranty set forth above is the only warranty. There are no other warranties, expressed or implied, including but not limited to implied warranty of merchantability or fitness for a particular purpose. Any implied warranty which by law may not be excluded is limited in duration to one (1) year from the date of original retail purchase of the product. Wahoo Innovations, Inc. shall not be liable for special, indirect, incidental or consequential damages (including, but not limited to, lost profits, down time or loss of use) under any legal theory, even if Wahoo Innovations, Inc. was advised of the possibility of such damages. Some states do not allow the exclusion of implied warranties or the exclusion of limitation of liability for incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights. You may also have other rights that vary from state to state. 17

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