User manual LEVER HOIST - Carl Stahl Hebetechnik
Contents
1. 12 6 Range of lubricants FUCHS SHELL ESSO MOBIL TOTAL CASTROL Renolit FEP 2 FEP 2 Alvania EP 2 EP 2 Unirex EP 2 EP 2 Mobilux EP 2 EP 2 MULTIS EP2 EP2 BEER 5006 Kl beroil Viscoleb 1500 4UH 1 1500 12 7 Range of lubricants for the food industry optional Load hook Pulleys FM Grease HD2 Mobilegrease FM 222 Sprockets Drive pinion 13 Faults In the event of faults the follovving must be noted e Faults must only be eliminated by qualified personnel Safeguard the devices against accidental start up Use a warning sign to indicate that the device is not ready for operation Secure the action area of the moving device parts Read the General safety instructions section Troubleshooting information can be found in the table below To eliminate faults contact our service department Faults caused by worn or damaged components such as ropes chains chain wheels axles bearings brake parts etc must be eliminated by replacing the respective parts with original spare parts www carlstahl lifting com 21 14 22 Troubleshooting Check the lever hoist by listening for noises When lifting move the lever backwards and forwards it should click When lowering only move the lever backwards not forwards it should click B Reduce the load to the nominal load replace the brake pads Load not lifted Faulty chain gear unit or chain wheels Conduct maintenance and replace faulty parts w2. 9 Safety inspection The following must be checked before the initial use and prior to subsequent use e Any mounting screws are tight and pins linchpins and safety fittings are present and secured e The chains are correctly positioned oiled and in a good condition 10 Servicing 10 1 General information The purpose of all monitoring maintenance and servicing work is to ensure that the device operates safely and reliably t must therefore be conducted carefully e Only allow work to be conducted by competent people e Only conduct work when the device is not subject to a load e Keep a written record of all inspection results and any measures taken 10 2 Monitoring The monitoring and maintenance intervals specified apply to normal conditions and single shift operation In the case of tougher usage conditions e g frequent use under full load or certain ambient conditions such as heat dust etc the intervals must be accordingly shortened 10 3 Replacing the load chain The chain must be replaced in the event of visible damage but in all events by no later than upon reaching the discard stage i e if e g one or more dimensions shown in the table are reached when inspecting the chain or if the chain has become corroded or malleably elongated Whenever the chain is replaced the chain wheels must also be inspected and replaced if necessary Procedure e Only retract the new chains without a load and exactly as the existin
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4. Parts of the load sag when lowered Foreign bodies between the brake parts Remove foreign bodies clean the area Do not grease Load sags when lowered Brake pad missing incorrectly installed Replace or correctly install the brake pad or worn Switch knob does not work Faulty or deformed Inspect and replace parts Load sags if the switch knob is set to Missing or faulty chain springs Conduct maintenance and replace faulty free run parts with original spare parts Hoist does not lower the load www carlstahl lifting com Carl Stahl 15 Decommissioning To prevent damage to the device or life threatening injuries when decommissioning the device the following points must be observed Always conduct the steps to decommission the devices in the following order e Secure a work area of an adequate size Read the Safety instructions section De installation occurs in the reverse order to installation Dispose of the equipment in an environmentally sound manner 15 1 Temporary decommissioning e Measures as previously e Read the Storage and Transport sections 15 2 Final decommissioning disposal e Measures as previously e Following de installation dispose of devices in an environmentally sound manner based on the substances contained 16 Documents on request Installation instructions brake system This work must only be conducted by competent persons www carlstahl lifting com 23 17 24 Sp
5. used for tensioning purposes Only in this case may the tip of the hook be subjected to a load The lever hoist is classed as a ready to use device according to the valid national regulations with an appropriate CE declaration of conformity www carlstahl lifting com CarlStahl NOTE If the devices are not properly used their safe operation cannot be guaranteed The operator bears sole responsibility for any personal injuries or damage to property arising as a result of improper use DANGER The following are prohibited in particular e Use for towing stationary loads or angled pulling if the device cannot be aligned to the load Use in potentially explosive environments Use to transport people Use in entertainment and production sites for scenic representations Use if people are under the suspended load Use as a motorised drive Use if the loose chain end is blocked Use if the loose chain end is subjected to a load Use for dragging loads with motorised devices 2 5 Basic safety measures Observe the installation operating and maintenance manuals Observe warning notices on the devices and in the manuals Observe safety clearances Ensure clear visibility during work Only use the devices as intended The devices are solely intended to be used to move goods People must never be transported Never exceed the specified permissible working load limit Observe the German accident prevention regulations UVV Dur
6. www carlstahl lifting com CarlStahl 11 2 Inspection load chain pursuant to DIN EN 685 part 5 L11 pitch increase over 11 chain links L11 L1 pitch increase over 1 chain link ES DES AEE ne EEE dm average link thickness Figure 11 Chain dimensions Dimensions Chain size m If the table dimensions are reached due to wear or deformation the chain must be replaced 11 3 Inspection load hook 4 Load hook X measuring distance hook mouth width Y measuring distance from hook no 6 H hook basic thickness Figure 12 Dimensions for load and suspension hooks Enter the measure mensen met data before itil use en T vi ion l si si us If the hook mouth width dimensions are exceeded by 1096 due to deformation or the minimum hook base thickness is breached by 596 due to vvear the hook must be re placed www carlstahl lifting com 17 11 4 Inspection retaining catch A 11 5 Inspection brake system Locking wheel with brake pads tn Dimensions in mm 18 www carlstahl lifting com CarlStahl 12 Maintenance 12 1 Load chain Chain wear in the link points is usually caused by insufficient chain maintenance To ensure the optimum lubrication of the links the chain must be lubricated at regular intervals tailored to the usage e Use penetrative lubricant e g transmission oil to lubricate the chain e Always lubricate the chain without a load so that the oil can mois
7. 4 u q SArY au JO s nin e pue zis y JEU SI 5141 USVSYGIYRJSUONYUN4 pun A EWXJEWSJENEND ueBunssaway rp ssep 4 pM HUWUSIH o N 1S L pue uono dsui JO uoe bunbuiur uos qinid pun 011UOY www carlstahl lifting com 26 eineu is yuyosistun 972 J91deyn 006 001 AND uep nsul 1u piooy jenos pue OS Dag UonNEINBayY Ajayes eLISNPU UELLLSE jeuoeu v o pawioped usaq sey UONDSdSUI oul Lynja ysunp g z dey 0095 00 s p AYDISJ1989 1852 1 s p YORU ap nm Bunynid ai 10 08dsuI SWEN USpUajNId OWEN ynsay punjog reyeq uunyeq 64 1591 IEUOHOUDL pue uono dsul lensiA pun 149IS eineu is yuyosis tun 10 08dsuI SWEN USPUajNId OWEN ynsay punjog reyeq uunyeq 1591 IEUOHOUDL pue uono dsul lensiA pun 149IS eineu is yuyosisjtun Bineu ISs yUyos s un 10 08dsuI SWEN USpUajNId OWEN 10 08dsuI SWEN USPUSjNId SWEN ynsay punjog ynsay punjog oyeqyunjeg oyeqyunjeg 1591 jeuolJoun pue uono dsul lensiA pun 14015 159 IEUOHOUDL pue uono dsul lensiA 11nidabsuonyu
8. LO 102 01 82 User manual xxx l Lift LEVER HOIST CLLHOOOSF CLLHOO10F CLLHOO16F CLLHOO25F CLLHO032F CLLHOO63F The following information does not claim to be exhaustive Further information about lever hoists should be taken from the relevant employers insurance association and state regulations Intended use For anchoring and lifting loads only www carlstahl lifting com f 7 3 gt NOTE For incomplete machines the assembly installation instructions can be found in the Assembly section O by Carl Stahl GmbH Tobelstr 2 D 73079 Suessen Germany www carlstahl com The original operating manual is in German Versions in other languages have been translated from the German original A copy can be requested in writing from Carl Stahl Subject to modifications Contents fa Led gr ge SE 4 SE ON a Dan 4 Warnings and ICONS REE NE 4 LUTT duties EE 5 Requirements to be met by operating Dersonnel 6 mended U EE EE EE MN werner asd 6 Basic SAN MEASUrES ad nda 7 Transport and storage 8 Ueleg 9 Securing for transportation ENEE 9 UO ACS EE ae EN EE ee 9 DESCHPUON NEE 9 Application areas 9 SLA EE SO a amad yaaa b l 9 FO AL SO WEE 10 inportant COMMON SANS EEE RE 10 ee d ei 11 MTT nn 11 in EL EE 11 PENN de 11 Devices from 0 8
9. al use Ready to use devices according to the valid national regulations vvith an appropriate CE declaration of conformity are exceptions in this regard Definition of a competent person formerly expert A competent person means a person who has the technical knowledge necessary for inspecting the work equipment because of his her vocational training profes sional experience and current activity on the job Definition of an accredited competent person formerly accredited expert An accredited competent person means a person who has knowledge in the field of the vvork equipment to be inspected and is familiar vvith the applicable national regulations on occupational health and safety employers insurance association regulations and generally acknovvledged technical standards because of his her specialist training and experience This competent person must regularly inspect and provide expert evaluations on work equipment in line with the model and provisions The accreditation is issued by authorised monitoring bodies Load chain e The load chain must be correctly positioned and oiled before its initial use e Remove the warning sign and fixing wire from the chain Do not use grease to lubricate the load chain The liability and warranty shall become void without lubrication gt NOTE Consistently good lubrication vastly extends the chain service life www carlstahl lifting com CarlStahl
10. are parts list Top hook for lever hoist 7311F4187430840 7311F4187451040 7311F4187511640 7311F4187562540 7311F4187603240 7311F4187676340 Hook locking mechanism for lever hoist 7311F4187430837 7311F4187451037 7311F4187511637 7311F4187562537 7311F4187603237 7311F4187676337 Gear unit cover for lever hoist 7311F4187451001 7311F4187511601 7311F4187562501 7311F4187603201 Ratchet lever for lever hoist 7311F4187451024 7311F4187511624 7311F4187603224 Bottom hook for lever hoist 7311F4187430838 7311F4187451038 7311F4187511638 7311F4187562538 7311F4187603238 7311F4187676338 Brake housing for lever hoist 7311F4187451016 7311F4187511616 7311F4187562516 7311F4187603216 CLLH 0 8 t CLLH 1 01 CLLH 1 6t CLLH 2 51 CLLH 3 2 t CLLH 6 3 t CLLH 0 8 t CLLH 1 0t CLLH 1 61 CLLH 2 51 CLLH 3 2t CLLH 6 3t CLLH 0 8t 1 0t CLLH 1 6 t CLLH 2 51 CLLH 3 2t 6 3t CLLH 0 8t 1 0t CLLH 1 6t 2 5t CLLH 3 2t 6 3t CLLH 0 8 t CLLH 1 0t CLLH 1 6 t CLLH 2 51 CLLH 3 2 t CLLH 6 3t CLLH 0 8t 1 0t CLLH 1 6t CLLH 2 51 CLLH 3 2t 6 3t www carlstahl lifting com L Carl Stahl We hereby declare that the machine equipment indicated below in its design and construction and in the version that we market conforms to the fundamental safety and health requirements of the EC Machinery Directive 2006 42 EC and the harmonized and national standard
11. cates a hazard with a medium level of risk which if not avoided could result in death or serious iniury Indicates a hazard vvith a lovv level of risk vvhich if not avoided could result in slight or moderate injury or damage to the product or its environment Indicates user advice and other useful information gt NOTE 4 www carlstahl lifting com CarlStahl AN Fisk of electric shock Are in potentially explosive atmospheres 2 2 Operator duties of care The device has been designed and built under consideration of a risk assessment and following the careful selection of the harmonised standards as well as other technical specifications to be observed It is therefore in line with the latest technology and guarantees optimum safety The interface of our scope of delivery is the complete device from the suspension point to the load hook and control unit if this is included in the order Other equipment tools slings and main energy supply systems must be installed in accordance with the appropriate regulations and directives For devices protected against explosions all of these parts must be approved and suitable for explosion protection Responsibility for this rests with the operator However the high level of safety can only be achieved during operations if all of the necessary measures have been met The operator s duty of care for the device involves planning these measures and checking their implementation The o
12. e pulley must be replaced 12 4 Gear unit Recommendation Load hook bearing FUCHS plain bearing bushings RENOLIT FEP2 are maintenance free As required 12 months Regular lubricant checks are required Clean and re lubricate the teeth after approx 3 years We recommend using a class EP2 lubricant or similar products Shorter maintenance intervals are required for tougher operating conditions e g dust per manent use with nominal load etc 12 5 Threaded load actuated brake The brake pad wear is checked during the inspection Replace the brake pads if the wear limit is reached at any point on the pad as may be the case if the pads are unevenly worn The brake pads must be free from cracks Oil grease dirt and moisture on the pads should be avoided wherever possible as this causes increased wear The brake pad has been tested for the entire service life of the device under intended use and should only be replaced in the event of unusual wear 20 www carlstahl lifting com EN CarlStahl According to EN 13157 the service life is 1500 work cycles lifting lowering processes with a 300 mm stroke under a nominal load and normal conditions As harsher working conditions can shorten the service life the brake pad thickness must be checked more than once a year in such situations The lever hoist with the brake pad must in all events be replaced if the wear limit is reached or the pad has clearly become worn on one side
13. ed with only a low load this is not a malfunction The brake system functions automatically if the load is greater than 30 kg for working load limits of up to 1000 kg and more than 3 of the working load limit for devices over 1000 kg DANGER Never use force to try and activate the chain free run under load Switching ON the chain free run e Turn the switch knob to the central position e Pull up the free run wheel in the direction of the arrovv A Figure 6 www carlstahl lifting com 7 2 7 3 CarlStahl e The chain can be pulled through A Free run is OFF in both directions B Switch ON free run Figure 7 Switching OFF the chain free run C Switch OFF free run e Use one hand to turn the free run wheel in the D Free run is OFF direction of the arrow lt while simultaneously c D pulling on the load chain leg e The free run wheel jumps back to the OFF position e Chain free run is switched off E Figure 8 Brake and retaining catch The brake remains closed clamped shut if e the load is removed from the lever hoist without being lowered this is possible e g in the case of vertical lifting lowering if the load is transferred or in the case of horizontal dragging tensioning e the load hook is pulled against the housing and becomes clamped shut there The chain does not move and the load cannot be released Troubleshooting e Re subject the lever hoist to a load e Release the brake by setting down
14. functions when the device is subject to extreme ambient conditions is to use it regularly 4 4 Important components Gear unit Gear unit parts are made from premium quality materials Load pressure brake For holding the load in any position A new kind of brake system has been used for the devices The brake discs are made from sintered on pad segments and are wear free for the life of the devices providing they are used as intended According to DIN 13157 the service life is 1500 work cycles lifting lowering processes with a 300 mm stroke under a nominal load Figure 3 Housing Made from sheet steel Load chain Pursuant to EN 818 7 T in special grades All individual components are precisely aligned Only use original chains Load hook Forged steel Pivotable thereby preventing the chain from twisting during attach ment With hook locking mechanism Chain free run For pulling through the chain without a load www carlstahl lifting com CarlStahl 5 Specifications EE Tel lrlelsl ls Load chain dimensions mm 5 6x15 8 5 6x15 8 7 1x20 1 9 0x24 8 10x28 1 10x28 1 Smale mm 20 soo s ors os sw Poor In aw so so mo so Poor vem insandan ko s7 s so ma 150 20 5 1 Main dimensions 577 1 1 6 25 32 6 3 load limit int deg CLLHO10 CLLHO16 CLLHO25 CLLH032 CLLH063 code pss e e a a s Tus Pos 6 Installation The following instructions mus
15. g chains in the device e Loosen the chain from the end attachment and hang a laterally open chain link on it a e To create a laterally open chain link simply grind out a piece The opening must have the same thickness as the chain link Figure 10 e Also hang a new and oiled original chain of the same size in the laterally open chain link and retract e Do not install the chain twisted e Ensure the chain links are aligned e Attach the chain to the end attachment www carlstahl lifting com 15 11 Inspection 11 1 Recurring inspections Regardless of the regulations in the individual countries the functional reliability of the lifting devices must be inspected at least once a year by a competent person or an accredited competent person in the case of cranes 11 1 1 Parts to be checked The following must be checked e Dimensions of the load chain load hook retaining catches screws locking wheels and brake pads These must be compared with the dimensions in the table e Visual inspection to check for deformities wear cracks and corrosion On reaching the relevant wear limit the part must be replaced with a new original part Daily 1st main Inspection Inspection commis inspec tenance mainte mainte sioning After nance nance If the upper or lower thresholds are breached for one or more dimensions or if cracks or corrosion are found the parts must be replaced with original spare parts 16
16. gging we recommend using devices with a slipping clutch e Motorised operation is not permitted The following are prohibited Lifting a load that exceeds the devices nominal load Manipulating the slipping clutch Continued use of worn out or damaged chains Immediately replace worn chains with new original chains Using the load chain to encircle a load and placing the chain over an edge or dragging it Reshaping damaged load hooks e g by hitting them with a hammer They must be replaced with original hooks Operating the device by stepping on the lever Using a lever extension Attaching loads to the tip of the load hook exception versions with a ship hook Conducting welding or cutting work on attached loads Swinging the load Using the load for earthing purposes while welding Using the device if it makes abnormal noises Operating the lever without a rubber handle Leaving the hoisted load unattended for a prolonged period Transport and storage Transport activities must only be conducted by qualified personnel No liability is accepted for damage caused by improper transportation or storage www carlstahl lifting com 3 1 3 2 3 3 4 1 4 2 CarlStahl Transport The devices are inspected and where applicable duly packaged before delivery e Do not drop or throw the devices e Use suitable means of transport The form and means of transport are based on the local conditions Transport locks g
17. id 0052 49200 HTTIO y 0072 peo 1891 1SElinid 0091 49100 HT19 0032 peo Isa 1SElinid 000S 4090 8919 y 005r peo 1891 1SElinid 0002 4060 8210 0522 peo 1891 1SElinid OOS I 4910 4212 OG2 peo 1591 3SElinid 00S 4900 W110 GZE peo 1591 1981114 y 0051 peo 1891 1SElinid 0001 40100 HT19 0021 peo 1891 1SElinid 0051 peo 1891 1SElinid 0001 4010 9079 OG2 peo 1891 ISE NIH By 092 4600 IUIN MOOI0 Uleyd INdS 1SI0H 19497 lulu Bnzudyose q Bnzyosjey SP UEISPEO MMM USYNS 62082 c A4SI9Q0L HOWE lyes HED 008 48000 H719 00S 4900 8272 EH x A x a A A ch Sult S Zr Ina aA A aA a SIOH 49197 MOOI0 ulpu unds Bnzyosjey Enzu uoselpe u ns ueqey 1YDBIQJ essiuqebiy auf sojswiyeusne unjnid rp ssep pun puls Yn da 1SE INId USUSGaUYDSEBIOn Jap BUNPUSMUY Jan UOR 4OJOB SIES ase y Jo IS PUB 0 JSUIYDEN PSUISOUOD YIM SOUBPIODDE Ul u 5iqnel6 q uolu HO uoa Bunpuemuan pun YDI PUNID USUIYDSEIN An peol 188 PepuIWEe ep aid ay Aq lA p peZUOYINE UUM pas PUB p o dsul UBNOJOU us unww nseg Usp puayoeldsjue uaueqauyoseq WI yes
18. ing use outside Germany observe the relevant national regulations Building walls ceilings floors or structures to on which the devices are attached or suspended must be sufficiently stable In the event of doubt always consult a structural engineer e After a prolonged period of non use of the device conduct a visual inspection of all components that affect its functioning and replace any damaged components with new original spare parts Never use a faulty device listen for abnormal operating noises In the event of faults immediately stop work and eliminate the fault Immediately report damage or faults to a responsible person Warn people in the immediate vicinity when using the device Observe the provisions on load suspension equipment established in the UVV on the positive and non positive slinging of loads www carlstahl lifting com T e The sling or load must be securely hung in the load hook and positioned on the base of the hook e The safety catches on hooks must be closed e The housing must not lie against anything Stop lowering the load if the lower block or load has been set down or is prevented from being lowered any further The load chain must not be twisted Twisted chains must be untwisted before the load is hung The weld seam indicates that the chain links are running correctly The chain links must always be aligned in a single direction EEE ERE Figure 1 e To prevent overloads when using the device for ri
19. ith original spare parts Retaining catch not correctly engaged Check the retaining catch and replace it if necessary Switch knob incorrect setting Select the correct setting Retaining catch spring missing Conduct maintenance and replace faulty parts with original spare parts Reduce the load to the nominal Toad Load difficult to lift Dirty chains gear unit or chain wheels Conduct maintenance lubricate chains gear unit and chain wheels Faulty chain gear unit or chain wheels Conduct maintenance and replace faulty parts with original spare parts Load lifted intermittently Retaining catch spring missing or faulty Conduct maintenance and replace faulty parts with original spare parts Hoist will not lift without a load Brake spring missing Conduct maintenance and replace faulty parts with original spare parts Hoist does not lift over the whole dis Hook tilted chain twisted Move the hook and chain into the correct tance positions The load has been removed from the Re attach the load lower the load Brake remains closed clamped shut lever hoist without being lowered detach the load The load hook has been pulled against Release the hook re attach the load the housing and clamped shut there lower the load detach the load Brake too tight Set the switch knob to v or DN Move the lever vvhile simultaneously pulling on the load side chain leg Rust has stopped the brake from working Conduct an inspection and replace rusty parts
20. n4 pun 1YIIS 21NJEUBIS HUYDSJEIUN 21NJEUPIS HUYDSJEIUN 10 08dsuI JO SWEN USpUajNid SWEN 10 08dsuI JO SWEN USpUajNid SWEN ns H punl q reyeq uunyeq reyeq uunyeq 1591 IEUOHOUDL pue uono dsul lensiA pun 14015 1591 IEUOHOUDL pue uono dsul lensiA 11nidabsuonyun4 pun 1YIIS 21NJEUBIS YUYDSJELUN 10 08dsuI SWEN USpuUajNid SWEN ynsay punjog reyeq uunyeq 1591 IEUOHOUDL pue uono dsul lensiA pun 1YIIS eineu is yuyosis tun eineu is yuyosis tun Bineu IS yUyos o uNn 21NJEUBIS HUYDSJEIUN 10 08dsuI JO SWEN USpUajNid S P SWEN 10 08dsuI JO SWEN USpUajNid SWEN 10 08dsuI SWEN USpUajNId SWEN 4008dsul JO SWEN USpUajNid SWEN ynsay punjog ynsay punjog ynsay punjog ynsay punjog reyeq uinyeq reyeq uunyeq eyeq uinyeq reyeq uinyeq 1591 IEUOHOUDL pue uono dsul lensiA pun 1YIIS 1591 IEUOHOUDL pue uono dsul lensiA yn da suo punJ pun 1YIIS 1591 leuonoun pue uono dsul ENSIN 11nidabsuonyun4 pun 1YIIS 1591 IEUOHOUDL pue uono dsul lensiA pun 1YIIS eineu is yuyosis tun 10 08dsuI JO SWEN USpUajNId OWEN Sao21A9P Sunui jenuew 104 9 E21j11182 uono dsui ynsay punjog oyeqywnjeg 159 leuonoun
21. perating manual should be supplemented with further instructions including supervisory duties and duties to communicate information in consideration of special operational features e g with regard to the organisation of work workflows or the personnel used The operator must in particular ensure that the device is solely used as intended e the device is solely operated in a fault free fully functional condition and in particular that the functioning of the safety equipment is regularly checked e necessary personal protective equipment for the operating maintenance and repair staff is available and used e the operating manual is always available in a legible format at the place where the device is used e only qualified and authorised personnel operate service and repair the device e these members of personnel receive regular training on all relevant matters relating to occupational health and safety and environmental protection and they comply with the operating manual and in particular the safety instructions this contains e any safety and warning notices affixed to the device are not removed and remain legible e devices specially designed for explosion protection must be grounded on site with a conductive resistance to earth of lt 10 Q Design modifications to the device are prohibited www carlstahl lifting com 5 2 3 2 4 Requirements to be met by operating personnel Only persons who are suitably q
22. s and the technical specifications below Any modification to the machine equipment that the manufacturer has not authorized voids this declaration This declaration shall also become invalid if the machinery equipment is not used in line with the intended use illustrated in the user manual and if the regular inspections required in accordance with the Industrial Health and Safety Ordinance and DGUV regulation 100 500 are not conducted Description Lever hoist CLLHO008F CLLHO010F CLLH0016F CLLHOO25F CLLHOO32F CLLHOO63F Manufacturer Carl Stahl GmbH Tobelstr 2 D 73079 S en Applied harmonized standards DIN EN ISO 12100 DINEN 13157 DIN EN 818 7 Applied national standards and DGUV regulation 100 500 technical specifications DGUV regulations 52 and 54 Industrial Health and Safety Ordinance Person authorised Michael Baumann to compile the Carl Stahl GmbH Declaration of Conformity D 73079 S en S en 26 01 2015 Michae Baumann CE agent Name position and signature of the agent www carlstahl lifting com 25 UONPJUSWNOOG JO lqisuods ki uuewneg Lyo 94NIEUPDIS JSYDI HOMJUBJSASUONPJUSWNXYOG uuewneg SCYDIN LUYDSJEHUN OSr6 Peo 1891 1SElinid 00 9 4 900 HTTIO USYNS HAWY 4819 HEO 0922 peo 1891 3sehnud OOS I 4051 y GZ peo 1891 188 nad By 092 4920 0087 peo 1891 1SElinid 0022 44200 11 OSZE peo 1891 1SElin
23. t NOTE On devices with a transport lock this must be removed before the device is used for the first time Storage e Store the device in a clean dry place e Use a suitable cover to protect the device against dirt moisture and damage e Protect chains hooks ropes and brakes against corrosion Description Application areas Wherever possible the devices should be installed in a room with a roof When installing the devices outdoors they must be protected against influences that can cause weathering e g rain snow hail direct sunlight dust etc We recommend using a weather protection roof in the park position In damp environments with major temperature fluctuations the formation of condensation poses a risk to the functioning of the device Ambient temperature of 20 C 50 C for all motorised devices 20 C 40 C Humidity 100 or less but not under water DANGER As in potentially explosive atmospheres is prohibited Structure CARL STAHL lever hoists are compact devices with a suspension hook for stationary use Figure 2 www carlstahl lifting com 9 4 3 Functional description The load is lifted lowered or tensioned by operating the lever A load pressure brake prevents the load from automatically lowering NOTE Undefined forces can occur during overhead work and rigging In such situations we recommend using a device with a slipping clutch NOTE The best way to prevent mal
24. t be observed in order to avoid personal injury and damage to property e Read the Safety section e When using the device with a load ensure the hook is securely fitted The hook locking mechanism must be closed Ensure that the attachment position cannot be changed by either the load or other influences 7 Operation Lifting devices and cranes must only be operated by people who have been suitably trained They must be instructed to operate the device by the contractor The contractor must ensure that the operating manual is provided with the device and accessible to the operating personnel www carlstahl lifting com 11 7 1 Devices from 0 8 t to 6 3 t Before starting work ensure that the chain free run is switched off Violent pulling can potentially close the brake and stop the chain being transported Set the switch knob to the lowering position v conduct several lowering processes and then re start the lifting process Lifting or dragging Turn the switch knob to the mark 1 indicated on the rating plate for lifting or dragging and move the load by ratcheting the hand lever Lowering or releasing Turn the switch knob to the mark 2 for lowering or releasing and move the load with the hand lever Figure 5 7 1 1 Chain free run When the device is used properly and as intended it is not possible to accidentally activate the chain free run function while subject to a load The brake system can be releas
25. ten the links subject to wear t is not sufficient to simply lubricate the chains externally as this does not ensure that a film of lubricant forms in the link points The adjacent link points must always have a film of lubricant as increased chain wear otherwise occurs e n the case of a constant chain travel length particular attention must be paid to the deflection point of the lifting and lovvering movements e Carefully lubricating the chain extends its service life to about 20 times that of a dry non lubricated chain e Use petroleum or a similar cleaning agent to clean dirty chains never heat the chain In the case of ambient influences that promote wear e g sand a rock lubricant such as graphite powder should be used e When lubricating the chain also check its wear status Do not use grease to lubricate the load chain JS JS A A Transmission oil E g FUCHS Load chain RENOLIN PG 220 3 months or chain lubricant Do NOT use grease The liability and warranty shall become void without lubrication www carlstahl lifting com 19 12 2 Pulleys Recommendation Xara IDA I FUCHS l Pulleys PNAN O J td As required 12 months PL No RENOLIT FEP2 12 3 Load hook e Check the load hook and pulleys once a year e Clean the hook bearings and pulleys once a year and lubricate them with grease e Plain bearing bushings are maintenance free f the bearings or plain bearing bushings are worn the entir
26. the load e Alternatively set the switch knob to the lower mark and release the hand lever by forcefully jerking it in the v direction Transferring loads In work processes such as the transferral of loads the device from which the load has been transferred cannot be used for lifting or lowering as the brake was not closed during the transfer In such instances please proceed as follows e Use device A to lift the load e Hang the load in the hook on device B and lift it until it hangs securely in the hook but has not yet been removed from device A e Continue the lowering process with device A until device B supports the entire load e The load has now been removed from device A and the brake is open again Figure 9 www carlstahl lifting com 13 8 1 8 2 Commissioning General information Use in the Federal Republic of Germany Observe the valid national accident prevention regulations Use in other countries Inspections as above Observe the national regulations and the information in this manuall gt NOTE Devices with a working load limit of up to 1000 kg and without motorised transport or lifting drives must be approved by a competent person before their initial use Devices vvith a vvorking load limit of over 1000 kg or vvith more than one motorised crane movement e g cross travel in addition to lifting must be approved by an accredited competent person before their initi
27. tto 6 3 t ey aaa geben 12 Brake and retaining catch EEE EN 13 TANNER 13 www carlstahl lifting com CarlStahl CIS SI ONIN Varer 14 8 1 ET OU OO nen 14 6 TIO 0 CAND een 14 9 Safety NSD SC ne 15 10 Se 15 10 1 General information EE 15 MONO Le E 15 10 3 Replacing the OAC Cnain ME 15 11 MESEN EG 16 W glate Weer 1 EE 16 TL2 Mis De CHO EE REE EE NA xayal 17 VEN 0 10 NOOK en 17 11 4 Inspection retaining catch EEE ee 18 11 5 Inspection brake system E 18 11 6 Inspection suspension and load hook bolts 18 12 Tiuinlonaonee ii 0 00 19 TENNE ea 19 PPU EE 20 2 00 HOON E 20 DATEN E 20 12 5 Threaded load actuated 20 126 Range of UDICA 21 12 7 Range of lubricants for the food industry optional 21 10 FNS a acta 0 E EE 21 14 TONEN MN He 22 15 DeCOMmMISSIONIRG sa 23 15 1 Temporary decommissioning BEE 23 162 Final decommissioning disposal anna en 23 16 Documents on request 2 u00a200au0nan0nannnnnnnanunannnanunannnunnnununnnnnanununnnnnnnanunnnnnanen 23 17 Spare parts list 2 52 2 522 2 24 www carlstahl lifting com 3 1 Information The prod
28. ualified trained and familiar with the devices may independently operate them They must be instructed to operate the devices by the contractor Personnel must have read the operating manual especially its Safety instructions section before starting work This particularly applies to personnel who only work on the device occasionally e g during its set up maintenance or servicing DANGER To prevent the most serious injuries the following must be observed when using the device e Use personal protective equipment Tie back long hair Do not wear rings chains or other jewellery Do not wear loose clothing Intended use The permissible working load limit of the devices must not be exceeded The only exception to this rule is in the case of a potential load test by an accredited competent person prior to initial use e The permissible ambient temperature when operating the devices is 20 C 50 C or 20 C 40 C for all motorised devices e Faulty devices and load suspension equipment may only be used again once they have been repaired Only original equipment spare parts may be used Non compliance with this stipulation will void the warranty e Independent modifications to the devices by the operator will void liability and warranty claims e Vertical lifting and lowering as well as dragging and tensioning of loads e t must be possible to align the device to the load DANGER Lever hoists with ship hooks must only be
29. ucts fulfil the European Union requirements especially those established by the EC Machinery Directive Our entire company is certified to the quality assurance system ISO 9001 The production of individual parts is subject to ongoing strict interim checks After installation the products are subjected to a final inspection with overload In Germany lifting operations are subject to the national provisions established by the accident prevention regulations among other provisions The stated performance of the devices and the validity of any warranty claims are subject to compliance with all information in these instructions The products are duly packaged but you should still check them for transport damage upon receipt Please notify the transport company immediately of any complaints This manual enables the quick and efficient use of the device Figures in the manual are provided to enable a general understanding and may differ from the actual design NOTE Please take note of the tests inspections that are required prior to the device s initial and subsequent uses as well as the regularly recurring tests inspections In countries other than Germany the applicable national regulations must also be observed 2 Safety 2 1 VVarnings and icons Risks and information are classified and presented as follovvs in this document Indicates a hazard with a high level of risk which if not avoided will result in death or serious injury Indi
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