Schmalz SCH-L Operating And Maintenance Instructions Manual Download Page 34 | Manualshive

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SERVICE AND MAINTENANCE

34 | EN

www.schmalz.com

30.30.01.01117/06

7 Service and Maintenance

7.1 General Guidelines for Maintenance and Service Work

Service and maintenance work must be performed only by qualified electrical and mechanical
specialists (see chapter 1.9). Inform operating personnel in advance of any upcoming repair work.
Before working on electrical components, switch off the main switch and secure it so that it cannot be
switched on again inadvertently.

Malfunctions that could compromise operational safety must be rectified immediately.

WARNING

Risk of injury due to system maintenance by untrained personnel

This can result in serious injury.

►

When working on the crane system, cordon off a wide area around the danger
zone to prevent unauthorized persons from entering.

►

If the operator performs maintenance work on a chain hoist on his own
responsibility, the kind of maintenance work and the date on which it was
performed must be recorded in the inspection book.

WARNING

Risk of injury from worn, unmaintained parts

Worn and unmaintained parts can cause damage, which can also result in
failure of the chain hoist and potentially cause severe injury.

►

Observe the operating, maintenance and servicing requirements specified in
these operating instructions.

WARNING

Risk of injury due to falling parts or persons

This can result in serious injury.

►

An appropriate climbing aid, lifting platform or fall prevention device must be
used when working over 2 m above ground level.

►

Do not use machine parts as a climbing aid.

►

Safety features that are removed during mounting or during maintenance and
repair work, must be refitted and checked as soon as the maintenance and
repair work is complete.

►

Screw connections that are loosened for maintenance or repair purposes must
be tightened again in accordance with the specifications.

►

Replace any mounting elements and seals that cannot be reused (e.g. self-
locking nuts, washers, cotter pins, O-rings and gaskets).

►

Only perform service and maintenance work on unladen chain hoists.

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Summary of Contents for SCH-L

Page 1: ...www schmalz com EN Ergonomic Handling Solutions OPERATING AND MAINTENANCE INSTRUCTIONS Chain hoist SCH S SCH M SCH L 30 30 01 01117 06 09 2019 ...

Page 2: ...ument is protected by copyright J Schmalz GmbH retains the rights established thereby Reproduction of the contents in full or in part is only permitted within the limits of the legal provisions of copyright law Any modifications to or abridgments of the document are prohibited without explicit written agreement from J Schmalz GmbH Contact J Schmalz GmbH Johannes Schmalz Str 1 72293 Glatten Germany...

Page 3: ...quipment 10 2 Product Description 11 2 1 Description 11 2 2 Operating Conditions 12 2 3 Identification 14 2 3 1 Type Plate 14 2 3 2 Data Plate 14 3 Technical Data 15 3 1 Drive Group 15 3 2 Voltage Versions 15 3 3 Sound Pressure Level 16 3 4 Chain and Load Hook 16 3 4 1 Standard Load Hook 16 3 4 2 Safety Load Hook Option 16 4 Delivery Packaging and Transport 17 4 1 Transport 17 4 2 Delivery 17 4 2 ...

Page 4: ...t to Do in an Emergency 33 7 Service and Maintenance 34 7 1 General Guidelines for Maintenance and Service Work 34 7 2 Brake System 35 7 3 Load Chain 36 7 3 1 Wear Inspection 36 7 3 2 Inserting a New Chain 37 7 4 Load Hook and Suspension Eye 37 7 5 End Stop 38 7 6 Gear Unit 38 7 7 Sliding Clutch 38 7 8 Suspension Components 38 7 9 Service Table 39 7 9 1 Service Overview 39 7 9 2 Maintenance Overvi...

Page 5: ...njury if it is not avoided WARNING Type and source of danger Consequence Remedial action Caution This warning informs the user of a risk that could result in injury if it is not avoided CAUTION Type and source of danger Consequence Remedial action Attention This warning informs the user of a risk that could result in damage to property if it is not avoided ATTENTION Type and source of danger Conse...

Page 6: ...datory Symbols Explanation of the mandatory symbols used in the operating and maintenance instructions Mandatory symbol Description Mandatory symbol Description Adhere to the operating instructions Wear protective work shoes Wear protective gloves Disconnect mains plug Wear protective head gear 1 4 Information Symbols Explanation of the mandatory symbols used in the operating and maintenance instr...

Page 7: ... or disassembly work only when the device is disconnected from the power supply Personnel and animals are not permitted to sit or stand in the danger zone Only use the lifting device for its intended use chapter 1 7 Danger zones must be cordoned off and clearly labeled with warning signs You are also responsible for third parties in the working area of the system For this reason the responsibiliti...

Page 8: ...ey are checked for safety by the manufacturer The chain hoists are approved by independent classification companies BG among others The chain hoists in the above mentioned series must only be used when in perfect technical working order in accordance with their intended purpose and by safety conscious and hazard aware trained personnel The maximum permitted lift capacity and the drive group must b...

Page 9: ...stood the operating instructions Can be expected to reliably perform the tasks assigned to them The operating instructions must be accessible at all times The type plate and warning signs must be legible The operator is obligated to perform a risk assessment for the ambient conditions at the installation location A qualified employee is defined as an employee who has received technical training an...

Page 10: ...nt temperature must lie within the range of 15 C to 50 C If you have doubts consult the manufacturer before starting operations 1 11Workplace Requirements Ensure that The operator has a good view of the entire working area The operator s work station is sufficiently lit and free of glare The work station environment is neat and clean 1 12Danger Zone Definition When lifting or transporting the load...

Page 11: ...escription 1 Control unit 2 Motor 3 Rotor shaft 4 Housing 5 Brake 6 Electrical controller 7 Gear unit 8 Limit switch 9 Control pendant 10 Suspension eye 11 Load hook 12 Chain box 13 End stop 14 Safety latch 1 2 3 4 5 Single chain 6 7 8 9 Fig 3 Single chain Dual chain 10 14 12 13 11 14 11 ...

Page 12: ...o is as follows The drive group of the chain hoist can be found on the data plate Step 1 Determining the load collective factor k The daily load collective of a chain hoist forms a comparison value for the chain hoist capacity The load collective can be calculated based on the percentage of the indicated maximum load of the chain hoist and the corresponding running time percentage of the chain hoi...

Page 13: ...drive group according to switching operations To calculate the switching load the number of lifting operations must be multiplied by a factor of six 6 Calculation of the number of switching operations per hour Switching operations per hour lifting operations per hour x 6 The drive group is selected according to the following table Step 4 Determining the drive group according to the duty cycle The ...

Page 14: ...rranty claims or placing other inquiries regarding the lifting device always provide the device type the part number the order number and the year of manufacture Fig 4 Fig 5 2 3 2 Data Plate Each chain hoist bears a data plate indicating the drive group based on the duty cycle and the maximum permissible lift capacity see also chap 3 1 ...

Page 15: ...1 2 m min 1 250 kg 1 000 kg 800 kg 650 kg SCH M FU 1 6 9 0 7 m min 6 9 0 7 m min 650 kg 500 kg SCH M FU 21 3 5 0 3 m min 3 5 0 3 m min 1 250 kg 1 000 kg SCH L 1 8 2 m min 9 6 2 4 m min 1 600 kg 1 250 kg 1 000 kg 800 kg 650 kg SCH L 2 4 1 m min 4 8 1 2 m min 2 500 kg 2 000 kg 1 600 kg 1 250 kg SCH L FU 1 6 9 1 2 m min 6 9 1 2 m min 1 250 kg 1 000 kg SCH L FU 2 3 5 0 6 m min 3 5 0 6 m min 2 500 kg 2...

Page 16: ...th DIN 45 635 a Use in the factory hall b Use outdoors Series Measurement range 1 m 2 m 4 m 8 m 16 m Measurement mode dB A SCH S SCH M a b 65 65 62 59 59 53 56 47 53 41 SCH L a b 80 80 77 74 74 68 71 62 68 56 3 4 Chain and Load Hook The steel chain conforms to quality class DAT 8SS in accordance with DIN EN 818 7 3 4 1 Standard Load Hook Load hook in accordance with DIN 15400 with safety latch 3 4...

Page 17: ...ve work shoes S1 and work gloves safety category 2133 4 2 Delivery 4 2 1 Items Included in Delivery Refer to the order confirmation for precise details of what is included in the delivery The delivery documents list the weights of the individual components and the dimensions The operating and maintenance instructions are an integral part of the chain hoist and must accompany the device whenever it...

Page 18: ...WARNING Danger due to parts with sharp edges and pinch points There is a risk of cutting when fitting the parts Falling parts can hit and injure people Danger of being crushed in the pinch points Wear an industrial safety helmet in accordance with EN 397 Wear work gloves in accordance with EN 388 safety category 2133 Wear protective work shoes in accordance with EN 20345 safety class S1 Do not rea...

Page 19: ...nection 1 Voltage supply from the Schmalz crane system Connection 2 Voltage supply for a load suspension device Connection 3 Control pendant operating panel for VacuMaster Comfort Power supply Connect the flat cable from the Schmalz crane system to connection 1 Fig 6 If you do not have the appropriate plug and cable specifically for your crane system you can obtain them from J Schmalz GmbH power s...

Page 20: ...stop 10 Orange ATTENTION Incorrect operating voltage frequency Material damage to chain hoist Before connecting the chain hoist check that the operating voltage frequency specified on the type plate matches the available voltage supply The power must be supplied with a clockwise rotation field Check the rotation field before starting operations Open the terminals Fig 8 5 2 Inserting a New Chain Re...

Page 21: ...ded seam on the chain links must face inwards on the chain wheel Fig 9 5 Press and hold down the rocker 4 when inserting or replacing the chain in order to deactivate the gear limit switch see chapter 5 3 Inserting a new chain 1 Connect the end of the chain 1 to a flexible wire and feed it into the chain hoist via the chain wheel 3 2 Pull in the chain 1 using short switching pulses Fig 9 Note A sp...

Page 22: ...ions check that the system switches off at the end stops highest and lowest hook positions Load hook in highest position Load hook in lowest position Fig 11 Fig 12 The hook must be adjusted to its highest and lowest positions in turn in order to ensure that the end stop 1 and the hook fitting 2 do not hit the housing Press and hold down the rocker 4 when inserting or replacing the chain in order t...

Page 23: ... and simultaneously move the hook to the lowest position 5 Turn the green control wheel 4 downward to the switch cam of the limit switch 8 turn counter clockwise for higher hook position clockwise for lower hook position 6 Turn the red control wheel 5 upward to the switch cam of the limit switch 6 turn counter clockwise for higher hook position clockwise for lower hook position See Fig 13 7 Releas...

Page 24: ...e load hook is attached see chapter 5 3 5 4 1 Single Chain 1 Attach the load hook 1 using the clamping piece 2 Correct mounting of the bolt 3 is important for the power transmission Fig 14 Fig 14 2 Ensure that the suspension unit is arranged according to Fig 15 dimension k1 41 mm 3 Grease bearing positions well Fig 15 3 2 1 ...

Page 25: ...nnect the end of the chain that takes the load to the chain fastener 3 and fix in the guide rails in the housing 3 Secure the chain fastener with screw 4 and spring washer 5 Fig 16 4 Ensure that the suspension unit is arranged according to Fig 17 dimension k2 52 mm 5 Grease bearing positions well Fig 17 6 Do not twist the chain axially Fig 18 Fig 18 ...

Page 26: ...ain box according to Fig 19 Note the orientation of the chain box 3 Lower the chain into the box 5 6 Preparing the System for Operation Before starting operations ensure the following All mechanical connectors have been correctly installed and secured All screws have been tightened according to torque specifications All components have been installed The safety distances are observed The emergency...

Page 27: ...fy the fault WARNING Non observance of the general safety instructions for start of operations and normal operation This can result in personal injury or material damage Before the start of operations the area around the crane must be secured against unauthorized access If damage or faults occur during the start of operations or while the crane system is in operation the system must be immediately...

Page 28: ...ea Never lift loads at an angle and never drag or pull them Cordon off the working area The maximum lift capacity must not be exceeded Never transport the load above people The swiveling point of the load must always be located within the working area of the crane Starting a movement in high gear can lead to premature wear of the sliding clutch It is recommended to start each movement in low gear ...

Page 29: ...rmediate plate 1 to the transport trolley 2 with the suspension bolt 1 1 2 Secure the suspension bolt 1 1 with the retaining element 1 2 3 Hook the chain hoist with the suspension eye 3 on the lower suspension bolt 1 3 4 Secure the suspension bolt 1 3 with the retaining element 1 4 5 Ensure that both suspension bolts 1 1 1 3 are correctly secured with the retaining element 1 2 1 4 see fig 2 1 1 1 ...

Page 30: ...sling or similar must be used It is forbidden to loop the chain around the load or divert the chain in any way 6 4 Control 6 4 1 Pendant Controller Operation using the control pendant Fig 21 6 4 2 Handy Lift Operator Handle Option The Handy Lift option is only available for chain hoist SCH S Operation with Handy Lift 1 Suitable for right handed and left handed people 2 Delivered pre assembled Fig ...

Page 31: ...he operator handle to its original position after each transport 6 4 3 Remote Control Option The remote control option is available for chain hoists for mains voltage of 400 V 50 Hz without frequency control WARNING Operation of the chain hoist without a view of the working area Risk of injury in the working area When using the remote control always keep an eye on the working area In the event of ...

Page 32: ...trol in the charging unit after work has finished See the installation instructions for the remote control in the appendix 6 4 4 VacuMaster Comfort Design Using the operating panel of the lifting device VacuMaster Fig 24 The buttons for upward and downward motion are each equipped with a catch point for normal movement Rapid traverse is achieved by depressing the buttons fully causing the chain ho...

Page 33: ...thers The chain hoist must not be used while work is being performed on it Loads must not be left suspended Once work is complete the chain hoist moist must be moved into a position that does not present any danger or obstruction CAUTION Risk of limbs being crushed or trapped when guiding the load on the chain Skin and fingers can become crushed or trapped between the chain links Always guide the ...

Page 34: ...e on which it was performed must be recorded in the inspection book WARNING Risk of injury from worn unmaintained parts Worn and unmaintained parts can cause damage which can also result in failure of the chain hoist and potentially cause severe injury Observe the operating maintenance and servicing requirements specified in these operating instructions WARNING Risk of injury due to falling parts ...

Page 35: ...ive work shoes in accordance with EN 20345 safety class S1 Do not reach into pinch points Exercise caution observe accident prevention guidelines Service and maintenance work must be carried out at the intervals specified in chapter 7 9 7 2 Brake System The brake must be capable of holding the nominal load properly when there is no current The brake does not have air gap adjustment If the maximum ...

Page 36: ...ain guide must be checked for wear at the same time and replaced if necessary Use only original chains The chain links must not be welded For instructions on how to insert the new chain see chapter 5 2 Note For convenience the old and the new chain can be connected to a flexible wire Table 7 Load chain wear values SCH S SCH M SCH L Chain designation d x t mm 3 75 x 10 75 5 25 x 15 7 45 x 23 Fig 26...

Page 37: ...subject to tension 4 The mouth width B1 is less than B1max see table below 5 The wear measurement h is greater than hmin see table below 6 No cracks or other defects on the bottom of the hook 7 No deformations 8 The safety latch can be properly reset Load hook in accordance with DIN 15401 Safety hook Suspension eye Table 8 Wear limits for suspension components SCH S SCH M SCH L Load hook in accord...

Page 38: ...st from overloading and serves the function of an emergency limit switch for the highest and lowest hook positions The sliding clutch is based on the DIN EN 14492 2 1 standard and is factory preset using the following force limit factors Maximum lift capacity Force limit factor 80 kg 2 0 100 kg SCH S 1 6 SCH M 1 8 120 kg 1 45 based on DIN EN 14492 2 The sliding clutch must be adjusted and checked ...

Page 39: ...ly inspected by a technical expert This inspection must include Visual and functional inspections damage wear corrosion or other changes to components Completeness and proper function of the safety features Disassembly may be required in order to assess the condition of wear parts The entire length of suspension elements including the covered parts must be inspected All periodic inspections are to...

Page 40: ...cessories X Check for cracks Check screw torques Measure wear on the hook See chapter 7 8 5 Gear unit X Visual inspection of wear See chapter 7 6 6 Limit switch function X Check switching elements See chapter 5 2 7 Sliding clutch X Functional test See chapter 7 7 Ensure safe and environmentally friendly drainage collection and disposal of operating and auxiliary materials 7 10Cleaning Use only cle...

Page 41: ... tested once a year by an expert As a special service within Germany J Schmalz GmbH offers an inspection contract for an annual test with a certificate from an expert Please refer to the test seal affixed to the crane system in this regard see right We would be happy to provide you with a quotation for this service Service department phone number 49 0 7443 2403 401 ...

Page 42: ...ing theoretical usage periods converted into full load hours apply for chain hoists that are classified according to ISO 4301 1 M3 M4 M5 M6 M7 400 h 800 h 1 600 h 3 200 h 6 300 h 8 1 Determining the Actual Usage Period The periodic readings or calculated values are documented in the inspection book The actual usage period depends on the daily operating time and the load collective The running time...

Page 43: ...ance with Table 11 The inspection and approval for continued use must be performed by a specialist company authorized by the manufacturer or by the manufacturer themselves The inspector determines What new theoretical usage period is possible The maximum period of time until the next general overhaul This information must be recorded in the inspection book Table 11 General overhaul Components for ...

Page 44: ...DECOMMISSIONING 44 EN www schmalz com 30 30 01 01117 06 9 Decommissioning Clean and take measures to preserve oil grease chain hoists before decommissioning or storing for long periods of time ...

Page 45: ...enance is not carried out in accordance with these operating instructions Repairs and emergency maintenance under warranty must only be performed by qualified persons following consultation and appointment by the manufacturer supplier Any modifications to the product or the use of non original spare parts shall void the warranty ...

Page 46: ...www schmalz com 30 30 01 01117 06 09 2019 ...

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