The content of this alert is borrowed largely from a Fairbrother Industries Limited letter originally sent to their distributors and customers on 29 May 2006. It is provided here to inform interested parties visiting the Department of Labour website of this issue.

As a result of a recent fatal accident the requirement for urgent design modifications to all Series III Kinghitter post drivers has been identified.

The accident was caused by a broken top link bolt which, having fractured, worked its way completely out of the top link arm resulting in the post driver mast falling and striking the operator fatally injuring him.

An analysis by SGS M&I of the recovered broken bolt found it had been subject to a repetitive loading process that had produced a fatigue crack that eventually led to the bolt being unable to support the load. The conclusion reached from the analysis undertaken was that the grade of bolt used to secure the Series III top link arm was not adequate for its task.

These changes have already been implemented into the new Series III machines. Series III machines manufactured and shipped after the 8th May 2006 include the following design alterations/improvements.

• Changing the two quadrant pin bolts to longer high tensile bolts.
• Adding two safety bolts (complete with washers and nuts) to each side of the top link arm.
• Adding a safety sticker indicating the requirement for safety bolts.

The purpose of these improvements is to provide additional support for the top link arm and, in the event of failure of the quadrant pin bolts, prevent the base and beam from falling over.

A bolt upgrade kit containing two quadrant pin bolts, two safety bolts, the safety sticker and fitting instructions will be supplied at no charge to facilitate the upgrade of all existing Kinghitter Series III post drivers still in operation. The drawing below shows what this modification involves.

If you or someone you know has a Kinghitter Series III machine, or if you have further questions regarding this notice, please contact either Ken Lawson or Brent Pownall at Fairbrother Industries at the address below so that the bolt upgrade kits can be supplied to owners and the modifications implemented in a timely manner.

Fairbrother Industries Limited
9 Bay Park Place, Auckland
phone (09) 482 0866
fax (09) 482 0877

Series III Safety Bolt Kit Upgrade

Please replace the bolts holding the top link arm with the longer high tensile bolts supplied and fit extra safety bolts (M16) either side of the top link arm. Clean the side of the quadrant plate for placing the safety sticker indicating the requirement for safety bolts. Nuts and safety sticker should face the operator as shown.

Ensure the beam is supported when you are changing the bolts.

Click image for larger copy

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Issued by the Department of Labour, New Zealand
http://www.osh.dol.govt.nz

No. 16 - August 2006