Changing the consumable parts on a Kenco Barrier Lift is essential to maintain safety, performance, and longevity. Consumable parts, such as the elastomer pads and actuator components, wear over time due to repetitive use, environmental conditions, and the abrasive nature of concrete barriers. Below is a detailed guide on when to change the consumable parts on a Kenco Barrier Lift, based on Kenco’s maintenance guidelines and industry best practices.

Key Consumable Parts on a Kenco Barrier Lift

The primary consumable parts on a Kenco Barrier Lift include:

1. Elastomer Pads: These are the gripping surfaces that contact the concrete barrier, providing friction to secure the load.
2. Actuator Components: The actuator mechanism (including screws, springs, or pivot points) triggers the automatic clamping and release action.
3. Mounting Bolts: Bolts securing the pads or other components may loosen or wear over time.
4. Optional Wear Items: Depending on the model (e.g., KL9000V4, KL12000, KL30000), additional wear items like bushings or pivot pins may be present.

When to Change Consumable Parts

The timing for replacing consumable parts depends on visual inspections, usage frequency, and operational conditions. Below are the specific indicators and schedules for changing these parts:

1. Elastomer Pads

• When to Change:
  • Visible Wear (10–20% Material Loss): Replace pads if they show significant wear, such as 10–20% loss of material, deep cracks, or smooth surfaces that reduce grip. Worn pads can slip, compromising safety.
  • Tears or Gouges: If pads are torn, gouged, or have chunks missing, replace them immediately, as this affects clamping force.
  • Loss of Elasticity: If pads feel hard or brittle (due to UV exposure or chemical contamination), they may not conform to the barrier’s surface, requiring replacement.
  • After 1,000–2,000 Lifts (Estimate): For high-use scenarios (e.g., daily barrier placement), pads may need replacement after approximately 1,000–2,000 lifts, depending on barrier weight, surface texture, and environmental conditions (e.g., abrasive dust or extreme temperatures).
• Inspection Frequency:
  • Daily: Visually inspect pads before each shift or use, checking for cracks, tears, or wear.
  • Weekly/Monthly: For regular use, perform a detailed inspection of pad thickness and surface condition.
• Additional Notes:
  • Pads are critical for gripping barriers (e.g., jersey walls or T-walls). Kenco specifies that pads should be replaced as a set to ensure even clamping pressure.
  • Check mounting bolts during pad inspections, as loose bolts can cause pads to shift or detach.

2. Actuator Components

• When to Change:
  • Binding or Sticking: If the actuator mechanism (e.g., screws, springs, or pivot points) binds, sticks, or fails to engage/disengage smoothly, replace worn components. This indicates wear in the pivot points or springs.
  • Visible Damage: Replace actuator parts if they show signs of bending, cracking, or corrosion, as these can cause clamping failure.
  • After 2,000–5,000 Lifts (Estimate): Depending on the model and load (e.g., 9,000–30,000 lb capacity), actuator components may need replacement or servicing after 2,000–5,000 lifts, especially for heavy barriers like 40 ft jersey walls.
  • Lubrication Failure: If regular lubrication (with penetrating oil like WD-40) does not restore smooth operation, internal components may be worn and require replacement.
• Inspection Frequency:
  • Daily: Test actuator movement during pre-use checks to ensure it engages and releases freely.
  • Monthly: Inspect actuator screws, springs, and pivot points for wear or corrosion, especially in harsh environments (e.g., coastal or dusty sites).
• Additional Notes:
  • The actuator is the heart of the automatic grab-and-release mechanism. Failure to replace worn components can lead to unsafe lifting or inability to release the barrier.
  • Avoid using grease on the actuator, as it attracts dirt and gums up the mechanism; use penetrating oil as recommended by Kenco.

3. Mounting Bolts

• When to Change:
  • Looseness: Replace bolts if they are loose, as this can cause pads or other components to misalign, reducing clamping effectiveness.
  • Corrosion or Thread Damage: Replace bolts showing rust, pitting, or stripped threads, as these weaken the connection.
  • After 1–2 Years of Regular Use: In high-vibration environments (e.g., frequent lifting of 20–30 ft barriers), bolts may need replacement every 1–2 years, even if no visible damage is present.
• Inspection Frequency:
  • Daily: Check bolt tightness during pre-use inspections, using a torque wrench to ensure proper tension (per Kenco’s specifications).
  • Monthly: Inspect bolts for corrosion or wear, especially in wet or salty environments.
• Additional Notes:
  • Use only Kenco-specified bolts, as they are designed to withstand the lift’s operational stresses.
  • Replace bolts as a set to ensure consistent performance.

4. Other Wear Items (Bushings, Pins, etc.)

• When to Change:
  • Excessive Play: If bushings or pivot pins show excessive play or wobbling, replace them to maintain structural integrity.
  • Cracks or Deformation: Replace any cracked or deformed pins or bushings immediately, as they can compromise the lift’s stability.
  • After 3,000–5,000 Lifts (Estimate): These components typically last longer than pads or actuators but may need replacement in high-use scenarios.
• Inspection Frequency:
  • Monthly: Inspect bushings and pins during detailed maintenance checks.
  • Annually: Perform a thorough inspection of all moving parts, especially for lifts used in demanding conditions (e.g., unloading T-walls from trucks).
• Additional Notes:
  • These components are model-specific (e.g., KL12000 vs. KL30000). Contact Kenco for replacement parts tailored to your lift.

Factors Influencing Replacement Timing

The frequency of replacing consumable parts varies based on:

• Usage Intensity: High-volume projects (e.g., 100 lifts per day) accelerate wear compared to occasional use.
• Barrier Type: Rough or abrasive barriers (e.g., unfinished concrete) wear pads faster than smooth surfaces.
• Environmental Conditions: Dust, moisture, salt, or extreme temperatures (e.g., freezing or high heat) can degrade pads, actuators, and bolts.
• Load Weight: Heavier barriers (e.g., 30,000 lb capacity for KL30000) put more stress on components, shortening their lifespan.
• Maintenance Practices: Regular lubrication (with penetrating oil) and cleaning extend the life of actuators and pads, while neglecting maintenance accelerates wear.

General Maintenance Schedule

To determine when to change consumable parts, follow this inspection and replacement schedule:

• Daily (Pre-Use):
  • Visually inspect pads for cracks, tears, or wear.
  • Check actuator for smooth operation.
  • Verify bolt tightness and look for corrosion.
• Weekly (For Regular Use):
  • Clean pads and actuator to remove dirt or concrete dust.
  • Lubricate actuator and pivot points with penetrating oil (e.g., WD-40).
  • Inspect pads for 10% material loss or deeper damage.
• Monthly:
  • Perform detailed inspections of pads, actuator components, bolts, and bushings/pins.
  • Check for alignment leg condition, as they can affect pad wear if damaged.
• Annually or After 2,000–5,000 Lifts:
  • Conduct a comprehensive inspection, potentially with Kenco’s recertification service.
  • Replace pads, actuator components, or bolts showing significant wear, even if not fully damaged.
• As Needed:
  • Replace any part showing critical damage (e.g., torn pads, bent actuator screws) immediately.
  • Remove the lift from service until repairs are completed.

Kenco’s Recommendations

• Use Genuine Kenco Parts: Always replace consumable parts with Kenco-supplied components to ensure compatibility and safety. Non-Kenco parts may not meet the lift’s design specifications.
• Remove Damaged Equipment: Per Kenco’s guidelines, remove any lift with damaged or worn consumable parts from service until repaired or recertified.
• Contact Kenco for Support: For replacement parts, recertification, or maintenance advice, email sales@kenco.com or call Kenco’s service team. Parts like pads and actuators are readily available for models like KL9000V4, KL12000, or KL30000.
• Follow OSHA/ASME Standards: Inspections and replacements should comply with OSHA regulations and ASME B30.20 standards for below-the-hook lifting devices.

Practical Example

For a Kenco KL12000 Barrier Lift used daily to place 20 ft jersey walls (approx. 8,000–10,000 lbs per lift):

• Pads: May need replacement after 1,500 lifts (e.g., 3–6 months at 10 lifts/day) if 10–20% material loss is observed.
• Actuator: Could last 3,000 lifts (6–12 months) but requires monthly lubrication and inspection for binding.
• Bolts: Check daily for looseness; replace annually or if corrosion appears in coastal environments.
• Efficiency Tip: Keep spare pads and bolts on-site to minimize downtime, as these are the most frequently replaced parts.

Conclusion

Change the consumable parts on a Kenco Barrier Lift when:

• Elastomer Pads show 10–20% material loss, tears, or loss of elasticity (typically after 1,000–2,000 lifts).
• Actuator Components bind, stick, or show damage (after 2,000–5,000 lifts or if lubrication fails to restore function).
• Mounting Bolts are loose, corroded, or damaged (every 1–2 years or as needed).
• Other Wear Items (bushings, pins) show excessive play or deformation (every 3,000–5,000 lifts).

Daily visual inspections, weekly cleaning/lubrication, and monthly detailed checks are critical to catch wear early. Replace parts immediately if damage compromises safety, and use only Kenco-supplied components. For high-use scenarios or harsh environments, plan for more frequent replacements and keep spares on hand. If you have a specific model (e.g., KL9000V4 or KL30000) or usage pattern, let me know, and I can provide a more tailored replacement schedule!