0 WD951 EM610 00079 Rev 0 Operation and Maintenance Manuals For Cranes

0-WD951-EM620-00079 1
OPERATION AND MAINTENANCE

MANUALS
TOTAL 421 PAGES
(Including Cover)
PROJECT CODE : A70003EA

PROJECT NAME : ANGAMOS THERMOELECTRIC POWER PLANT

DOCUMENT No. : 0-WD951-EM610-00079

TITLE : OPERATION AND MAINTENANCE MANUALS FOR CRANES

OWNER: EMPRESA ELCTRICA ANGAMOS S.A.

Purpose

For Review
For Approval
For Construction
For Bid
For Information

0 2010/05/24 T.C.MAH ERIC PUA M.W.TUNG For Construction

PREP REVIEW APPR REVIEW REVIEW APPR
Rev.
No.
DATE
EXCELLIFT
DESCRIPTION
POSCO E&C
Owner

Contractor: Subcontractor:

SDN BHD

SDN BHD
MAIN INDEX
1.0 EQUIPMENT INFORMATION SHEET
2.0 OPERATION AND MAINTENANCE INSTRUCTION
3.0 GANTRY CRANE FOR STEAM TURBINE
3.1 OUTLINE AND ASSEMBLY DRAWING
3.2 RUNWAY CONDUCTOR AND RAIL INSTALLATION DETAILS
3.3 BILL OF MATERIAL
3.4 LUBRICANT LIST
3.5 ELECTRICAL GENERAL ARRANGEMENT DRAWING
3.6 ELECTRICAL AND CONTROL WIRING DIAGRAM
3.7 TECHNICAL DATA
4.0 GANTRY CRANE FOR CWP STATION
4.4 LUBRICANT LIST
4.7 TECHNICAL DATA
5.0 GANTRY CRANE FOR INTAKE FACILITIES
5.4 LUBRICANT LIST
5.7 TECHNICAL DATA

SDN BHD
6.0 EOT CRANE FOR BFP
6.4 LUBRICANT LIST
6.7 TECHNICAL DATA
7.0 EOT CRANE FOR WORKSHOP
7.4 LUBRICANT LIST
7.7 TECHNICAL DATA
8.0 EOT CRANE FOR WAREHOUSE
8.4 LUBRICANT LIST
8.7 TECHNICAL DATA
9.0 APPENDIX

SDN BHD
1.0 EQUIPMENT INFORMATION SHEET

SDN BHD
EQUIPMENT INFORMATION SHEET
PURCHASE ORDER NO : 2008FS0130
DATE OF PO : 4-SEPTEMBER-2008
PROJECT : ANGAMOS THERMOELECTRIC POWER PLANT
EQUIPMENT : CRANE PACKAGE
EQUIPMENT DESCRIPTION EQUIPMENT NO. SERIAL NO.
1
2
3
4
5
6
7
Gantry Crane for Steam Turbine
Gantry Crane for CWP Station
Gantry Crane for Intake Facilities
EOT Crane for BFP (1
st
unit)
EOT Crane for BFP (2
nd
unit)
EOT Crane for Workshop
EOT Crane for Warehouse
02SMA10AW001
02SMP10AW001
02SMP20AW001
12SMA10AW001
22SMA10AW001
00SMB10AW001
00SMB20AW001
2024/2009
2025/2009
2026/2009
2027/2009
2028/2009
2029/2009
2030/2009
VENDOR INFORMATION
Company Name: EXCELLIFT Sdn bhd
Company Address: 288, Jalan Pulau Carey,
Telok Panglima Garang,
42500, Kuala Langat,
Selangor, Malaysia
Tel/Fax No: +60-3-31222888 /
+60-3-31222333
Contact Person: Eric Pua/ T.C.Mah

REMARKS:

SDN BHD
2.0 OPERATION AND MAINTENANCE INSTRUCTION
2.1 Safety instruction
2.1.1 Symbols
Symbols Description
Safety at work
This symbol marks all information on safety at work where risks to
life and limb are entailed.
Warning of electrical voltage
Covers such as hoods and caps which are marked with this symbol
may only be opened by qualified persons or suitable instructed
personnel.
Warning of suspended load
It is forbidden for persons to stand under suspended loads. This
entails risks to life and limb.
Safety in operation
Information marked with this symbol must be observed to avoid
damage to the crane or the goods transported.
In these operating instructions, these symbols mark particularly important information on
risks and safety in operation.

SDN BHD
2.1.2 Operating Instruction
Read carefully and follow the operating instructions.
2.1.3 Use for intended purpose
x Crane components are intended for the construction of crane
and similar installation. They may only be used in accordance
with their design principles.
x Do not carry out any alterations or modifications. Additional
fitments must be authorized by the manufacturer. Non-
compliance will invalidate the declaration of conformity.
If the crane is not used for the intended purpose, dangers may arise
from:
x Exceeding the safe working load.
x Continually running into the end stops on the crane and crane
runway.
x Manipulating the overload cut-off.
x Pulling loads at an angle
x Transporting persons.
x Pulling loads loose, dragging or towing loads.
x Operation with slack rope.
x Unsupervised suspended loads.
x Moving loads above people
x Operating a damaged hoist.
2.1.4 Safety-conscious operation
The crane components are constructed according to the state of the
art and equipped with an overload device or slipping clutch to
prevent overloads. In spite of this, we recommend:
x Read the operating instructions before starting to work with
the crane.
x The operator is responsible for ensuring that work is carried
out with safety in mind and avoiding risks.
x Before starting work, find out where the EMERGENCY STOP
facility is. (usually in the control pendant)

SDN BHD
x Observe the "Duties of crane operator "
x Report damage and defects to the crane component (abnormal
noises, impaired braking function, deformation) to the
person responsible immediately. Do not use the component
until the faults have been eliminated.
2.1.5 Maintenance and repairs
Maintenance
x Maintenance work may only be carried out when the crane is
in a no-load condition and has been secured.
x The main isolator must be switched off and secured against
being switched on in error or by unauthorized persons.
x The accident prevention regulations must be observed.
Repairs
x Use only original spare parts for repairs, otherwise the
warranty will expire.
x Do not carry out any alterations or modifications.
x Additional fitments must be approved by the manufacturer.
x Electrical connection and
Roof is provided to protect the hoist, travel motor and crane
control for outdoor crane.
2.1.6 Warranty
x The warranty will become invalid if these operating instructions are not observed for
operation, inspection, and maintenance.
x Repairs and elimination of faults within the scope of the warranty may only formed by
qualified personnel.
x The warranty will become invalid if the crane components is modified or original spare
parts not used

SDN BHD
2.1.7 Periodic tests
Crane and hoist must be inspected by a qualified person at least
once a year, possibly more frequently if so required by national
regulations. The results of the test must be recorded and filled in
the test log book
2.2 General Layout
Refer to section Outline and assembly drawing, Runway conductor and rail installation
details and Bill of material for each crane.
2.3 Operating Crane
2.3.1 Duties of crane operator
When working with cranes, the following must be observed:
x Every day before starting work, check safety facilities and
inspect the system for any visible defects.
x Discontinue working with the crane if there are any defects
which might prejudice its safety in operation, and inform the
person in charge.
x Rope drum and load chain must be free of coarse foreign
matter.
x Do not move load above people.
x Do not leave load unattended, the control switch must be
within easy reach.
x Do not load above rated capacity.
x Pulling load at angles, dragging loads, or towing vehicles with
the load or load suspension equipment is forbidden.
x Do not heave up any loads which are jammed.
x As far as possible, avoid inching operation (briefly switching
on the motor to achieve small movements). Otherwise
switchgear and motors could be damaged.
x At close of work, secure cranes which are exposed to wind
with the wind safety device.

SDN BHD
2.3.2 Operating control pendant

Safety note
If the rocker switch is no longer depressed by the operator, it
returns to the 0 position, the hoist motion is automatically stopped
(dead mans control).
If the hoist malfunctions, e.g. the actual motion does not
correspond to the motion intended in activating the rocker switch,
release the rocker switch immediately. If the motion continues,
press the emergency stop button.
2.3.3 Emergency stop
Every crane must have a means of disconnecting the power supply
to all drives under load with the emergency stop at the control
station.
After an emergency stop, the operator must not restart the hoist or
crane system until a qualified person has determined that the fault
which led to this function being activated has been eliminated and
no danger can arise from the continued operation of the system.
Note:
The emergency stop button is on the control pendant
Press emergency stop, the system comes to a halt.
To release the emergency stop: turn the button in the direction
shown.
2-step rocker switch
1
st
step: Slow speed motion
2
nd
step: Fast speed motion

SDN BHD
Caution! The conductor line is still live when the emergency stop
function has been activated.
2.4 Inspecting and servicing crane
Although the crane components are practically maintenance-free, the components subject
to wear must be inspected regularly. This is required by the accident prevention
regulations.
The inspections must be carried out by qualified persons.
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Inspection and Maintenance table
1 Brake functionality *6
2
Brake, measure displacement and adjust if
necessary *6
3 Travel limit switches
4 Crane spacing
5 EMERGENCY STOP, crane switch
6 Warning devices
7 Wind safety devices
8 Screw connections *5
9 Buffers, stops
10 Gearing wheel shaft/wheel: wear, lubrication *6
11 Change oil/grease on travel drive *6
12 Power supplies
13 Cable glands
14 Cable trolleys
15 Connection terminals
16 Control pendant, control cable

SDN BHD
*1 By a fitter engaged by the manufacturer
*2 By the operator
*3 Periodic maintenance every 12 months, possibly earlier if so prescribed by national regulations, to be
performed by a fitter engaged by the manufacturer.
*4 In manufacturers works.
*5 If screws are replaced, use only those of the same quality.
*6 See operating instructions for travel drives
Note: Refer appendix for operating and maintenance instruction for AS hoist, SH hoist
and travel drives.
2.5 Technical Data
Refer to technical data for each crane.

SDN BHD
3.0 GANTRY CRANE FOR STEAM TURBINE

SDN BHD
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SDN BHD
3.4 LUBRICANT LIST
JOB NO. : 10933
PROJECT NAME : ANGAMOS PROJECT
SHEET NO. : 1 OF 6
INITIAL
GRADE CHARGE QUANTITY INTERVAL REMARK
RECOMMEND EQUIVALENT (LITERS) (LITERS) (MONTHS)
7 End carriage Wheel Shell Retinax AM
Mobil Special
Grease
KPF1K 50g 50g 12 months
KPF1K 100g 100g 12 months 6 Hoist
Cross Travel
Shaft
Shell Retinax AM
Lifetime oil
lubrication
Lifetime oil
lubrication
Lifetime oil
lubrication
3L
5L
600-2500g
During overhaul
During overhaul
During overhaul
12 months
Mobil Gear 634 CLP460 16L 16L 2 18T Hoist Motor Gearbox
Shell Omala Oil
460
15L 15L During overhaul
Lifetime oil
lubrication
1 70T Hoist Motor Gearbox
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
3L
5L
600-2500g
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobil Gear 634 CLP460
REPLACEMENT CHARGE
ITEM
NO
EQUIPMENT LUBRICATED
PART TO BE
LUBRICANT LIST
ITEM
NO.
02SMA10AW001 EQUIP. NAME
Gantry crane for steam
turbine
(For Erection, Commissioning, Performance Test)

SDN BHD

SDN BHD
0-WD951-EE165-00023 1
ELECTRICAL AND CONTROL
WIRING DIAGRAM (GANTRY
CRANE FOR STEAM TURBINE)
TOTAL 17 PAGE
(Including Cover)
DOCUMENT No. : 0-WD951-EE165-00023
TITLE : ELECTRICAL AND CONTROL WIRING DIAGRAM (GANTRY
CRANE FOR STEAM TURBINE)
Purpose
For Review
For Approval
For Construction
For Bid
For Information
B 2009/08/21 H.W.YOW ERIC PUA M.W.TUNG Revised As Built
A 2009/01/12 H.W.YOW ERIC PUA M.W.TUNG For Approval
Rev.
No.
DATE
EXCELLIFT
DESCRIPTION
POSCO E&C
Owner
SDN BHD

SDN BHD
3.7 TECHNICAL DATA
ln-door
Out -door
Manufacture
Main 70 Main -
Aux. 18 Aux. -
Span (m)
Main 23.2
Aux. 26.5
Wire Rope Reeving Main True Vertical Main Rams horn
Aux. Standard Aux. Rams horn
Fast 3.2 Fast 20
Precision 0.5 Precision 5.0
Fast 32 Cross Travel Square Rail
Precision 8.0 Long Travel UlC 60
Brake
Trolley Weight (ton) Bridge Weight (ton)
Total Crane Weight (ton)
Control Method
Bldg. Clearance (mm) A
-
B - C
3700
D 1800 Forward 4500
E 2500 Backward 4500
Hook (mm) F
1253
G 13700 H
9048
R
7000
Q
8100
Wheel Load (ton) PV
26.6
PH 2.42 PL
4.84
Lifting Height (m) Gantry Girder Type
Malaysia / Germany
Rated Load (ton)
25.9 112
Place of Manufacture
Open Cabin
1. Gantry crane for steam turbine Equipment No. 02SMA10AW001
Gantry Steam Turbine Building Location
Hoisting Speed
(m/min)
Long Travel Speed
(m/min)
Excellift - Stahl
Cross Travel
Hook Approach (mm)
End Carriage (mm)
8
172
Crane Rail Height (mm)
Number of Wheel (ea)
Long Travel
Hook Approach (mm)
Pendant Control
59
12
Close Cabin
27
Rail Type
Disk (Conical brake is not acceptable)
Crane Type
Cross Travel Speed
(m/min)
Hook Type
Service Class
Runway Length (m)
1 of 19
REV.0
MOTOR BELOW 200kW
Gantry crane for steam turbine
UNIT DATA
Siemens
02SMA10AW001
70T Hoisting Motor
2
4. Mounting (Vert.,Hor) Horizontal
3 Phase Induction
KW 24/3.8
380/3/50
RPM 2850/450
Volt 380
F or B F
1.0
12. Temp Rise by Resistance at Service Factor B B
IP IP55
Outdoor
240/120
Bi-directional
M40
LHS RHS
Bottom
-
160L
s 5
s 2
-
A 46/21
A 243/44
182/150
261/168
178/143
83/47
-
-
0.91/0.55
-
-
Shell Omala Oil 460 36. Recommended Lubricant Type
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
29. Pull Up Torque %
30. Eff - Full Load %
31. Eff - 3/4 Load %
24. Outline Drawing No.
25. Full Load Amps
26. Locked Rotor Amps
27. Starting Torque %
28. Breakdown Torque %
11. Service Factor
13. Enclosure protection class
14. Indoor or Outdoor
19. Cable Entrance( bottom, side, top )
15. Permissible number of start (cold/warm)/hour
16. Rotation
17. Cable hole size (main box/ aux.box)
18. Terminal box location (seen from pump/fan side)
3. Quantity
22. Permissible Locked Rotor Time
5. Motor Type :
6. Rated kw / Horsepower (Nameplate)
20. Space Heater (Watts @ 220V)
21. Manufacturer Frame Designation
7. Rated Volts/ Phase/ Hz
8. Synchronous Speed
9. Rated Voltage
10. Insulation Class
Angamos Thermoelectric Power Plant
Technical Specification for Cranes
23. Acceleration Time
GENERAL ELECTRICAL REQUIREMENTS
Motor Data Sheet(s), one for each motor supplied, shall be in
accordance with the following format. Supplier shall provided all
fill in data as required for Purchaser's review and/ or records.
I. Manufacturer
1. Item No.
2. Driven Equipment
2 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Siemens
02SMA10AW001
18T Hoisting Motor
1
3 Phase Induction
KW 15.5/2.4
380/3/50
RPM 2860/450
Volt 380
F or B F
1.0
IP IP55
Outdoor
240/120
Bi-directional
M40
LHS RHS
Bottom
-
160L
s 5
s 2
-
A 32/13.1
A 175/26
212/146
247/162
189/142
80/48
-
-
0.87/0.56
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
36. Recommended Lubricant Type
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
3 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Stahl CraneSystems
02SMA10AW001
Cross Travel Motor
2
3 Phase Induction
KW 2.0/0.5
380/3/50
RPM 2680/665
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.0/1.8
A 16/4.4
244/168
215/189
145/129
76/54
-
-
0.95/0.74
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment
4 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
SEW
02SMA10AW001
Long Travel Motor
4
3 Phase Induction
KW 3.0
380/3/50
RPM 1400
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 6.5
A 36.4
270
220
220
83
-
-
0.83
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load

SDN BHD
4.0 GANTRY CRANE FOR CWP STATION

SDN BHD
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A
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P
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A
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. 2025/2009
S
W
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Q
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. N
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. 02S
M
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10A
W
001
F
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A
P
P
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A
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F
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A
P
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9
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0
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0
0
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F
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A
P
P
R
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A
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F
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A
P
P
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SDN BHD
4.4 LUBRICANT LIST
JOB NO. : 10934
SHEET NO. : 2 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
During overhaul
During overhaul
12 months
1.5L
5L
600-2500g
Lifetime oil
lubrication
1 Hoist Motor Gearbox
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.
02SMP10AW001
02SMP10AW002
EQUIP. NAME
Gantry crane for CWP
station

SDN BHD

SDN BHD
0-WD951-EE165-00123 1
CRANE FOR CWP STATION)
TOTAL 11 PAGE
(Including Cover)
CRANE FOR CWP STATION)
Purpose
For Review
For Approval
For Construction
For Bid
For Information
Rev.
No.
DATE
EXCELLIFT
DESCRIPTION
POSCO E&C
Owner
SDN BHD

SDN BHD
4.7 TECHNICAL DATA
ln-door
Out -door
Manufacture
Main 20 Main -
Aux. - Aux. -
Span (m)
Lifting Height (m)
Aux. - Aux. -
Fast 3.1 Fast 20
Precision 6.3 Long Travel JlS 50N
Brake
Control Method
-
B - C
2500
D 1000 Forward 3000
Hook (mm) F
546
G 3000 H
6275
R
4600
Q
5250
Wheel Load (ton) PV
16
PH 1.45 PL
2.9
Crane Type
Cross Travel Speed
(m/min)
Hook Type
Service Class
Runway Length (m)
9.2
Rail Type
Pendant Control
16.7
2.1
Close Cabin
Cross Travel
Hook Approach (mm)
End Carriage (mm)
4
153
Long Travel
Hook Approach (mm)
Open Cabin
2. Gantry crane for CWP station Equipment No. 02SMP10AW001
Gantry CWP station Location
Hoisting Speed
(m/min)
Long Travel Speed
(m/min)
Excellift - Stahl
Gantry Girder Type
Malaysia / Germany
Rated Load (ton)
21.0 76
10.0 (from EL. -3.0)
5 of 19
REV.0
MOTOR BELOW 200kW
Gantry crane for CWP station
UNIT DATA
Siemens
02SMP10AW001
Hoisting Motor
1
3 Phase Induction
KW 15.5/2.4
380/3/50
RPM 2860/450
Volt 380
F or B F
1.0
IP IP55
Outdoor
240/120
Bi-directional
M40
LHS RHS
Bottom
-
160L
s 5
s 2
-
A 32/13.1
A 175/26
212/146
247/162
189/142
80/48
-
-
0.87/0.56
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment
6 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Stahl CraneSystems
02SMP10AW001
Cross Travel Motor
1
3 Phase Induction
KW 2.0/0.5
380/3/50
RPM 2680/665
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.0/1.8
A 16/4.4
244/168
215/189
145/129
76/54
-
-
0.95/0.74
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
7 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
SEW
02SMP10AW001
Long Travel Motor
2
3 Phase Induction
KW 1.5
380/3/50
RPM 1410
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
90
s 5
s 2
-
A 3.7
A 19.6
260
230
230
79
-
-
0.78
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment

SDN BHD
5.0 GANTRY CRANE FOR INTAKE FACILITIES

SDN BHD
F
O
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A
P
P
R
O
V
A
L
F
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A
P
P
R
O
V
A
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SDN BHD
F
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A
P
P
R
O
V
A
L

SDN BHD
F
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A
P
P
R
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A
L
C
s
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m
s
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1
8
T
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SR
. N
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. 2026/2009
S
W
L
EQ
U
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O
. 02SM
P20AW
001
F
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A
P
P
R
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A
L
F
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A
P
P
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A
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m
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1
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T
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S
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. N
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. 2026/2009
S
W
L
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Q
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. N
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. 02S
M
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20A
W
001
F
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A
P
P
R
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A
L
F
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A
P
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A
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F
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A
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1
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T
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SR
. N
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. 2026/2009
S
W
L
EQ
U
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O
. 02SM
P20AW
001
F
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A
P
P
R
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A
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F
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A
P
P
R
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A
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m
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1
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T
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. 2026/2009
S
W
L
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Q
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. N
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. 02S
M
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20A
W
001
F
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A
P
P
R
O
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A
L
F
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A
P
P
R
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SDN BHD
5.4 LUBRICANT LIST
JOB NO. : 10933
SHEET NO. : 1 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
turbine
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
3L
5L
600-2500g
MARKER'S BRAND
Mobilith SHC460
CLP460
CLP460
GOOF
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Shell Omala Oil
460
Mobil Gear 634 CLP460 15L 15L During overhaul
Lifetime oil
lubrication
Shell Omala Oil
460
Mobil Gear 634 CLP460 16L 16L
3L
5L
600-2500g
During overhaul
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10934
SHEET NO. : 2 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
1.5L
5L
600-2500g
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
LUBRICANT LIST
ITEM
NO.
02SMP10AW001 EQUIP. NAME
station
JOB NO. : 10935
SHEET NO. : 3 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
Gantry crane for intake
facilities
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobil Gear 634
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10936
SHEET NO. : 4 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.
02SMA20AW001
02SMA20AW002
EQUIP. NAME EOT crane for BFP
JOB NO. : 10937
SHEET NO. : 5 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
00SMB10AW001 EQUIP. NAME EOT crane for workshop
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10938
SHEET NO. : 6 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
3L
600-2500g
During overhaul
During overhaul
12 months
1.5L
3L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.
00SMB20AW001 EQUIP. NAME EOT crane for warehouse

SDN BHD

SDN BHD
0-WD951-EE165-00223 1
CRANE FOR INTAKE FACILITIES)
TOTAL 11 PAGE
(Including Cover)
CRANE FOR INTAKE FACILITIES)
Purpose
For Review
For Approval
For Construction
For Bid
For Information
Rev.
No.
DATE
EXCELLIFT
DESCRIPTION
POSCO E&C
Owner
SDN BHD

SDN BHD
5.7 TECHNICAL DATA
ln-door
Out -door
Manufacture
Main 18 Main -
Aux. - Aux. -
Span (m)
Lifting Height (m)
Aux. - Aux. -
Fast 3.1 Fast 20
Precision 6.3 Long Travel JlS 50N
Brake
Control Method
-
B - C
2500
D 1000 Forward 4800
Hook (mm) F
546
G 12.6 H
13278
R
8000
Q
9000
Wheel Load (ton) PV
16.3
PH 1.48 PL
2.96
Crane Type
Cross Travel Speed
(m/min)
Hook Type
Service Class
Runway Length (m)
9.4
Rail Type
Pendant Control
21.7
4
Close Cabin
Cross Travel
Hook Approach (mm)
End Carriage (mm)
4
153
Long Travel
Hook Approach (mm)
Open Cabin
3. Gantry crane for intake facilities Equipment No. 02SMP20AW001
Gantry lntake facilities Location
Hoisting Speed
(m/min)
Long Travel Speed
(m/min)
Excellift - Stahl
Gantry Girder Type
Malaysia / Germany
Rated Load (ton)
22 40
26.6 (from EL. -12.6)
8 of 19
REV.0
MOTOR BELOW 200kW
Gantry crane for intake facilities
UNIT DATA
Siemens
02SMP10AW001
Hoisting Motor
1
3 Phase Induction
KW 15.5/2.4
380/3/50
RPM 2860/450
Volt 380
F or B F
1.0
IP IP55
Outdoor
240/120
Bi-directional
M40
LHS RHS
Bottom
-
160L
s 5
s 2
-
A 32/13.1
A 175/26
212/146
247/162
189/142
80/48
-
-
0.87/0.56
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
9 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Stahl CraneSystems
02SMP10AW001
Cross Travel Motor
1
3 Phase Induction
KW 2.0/0.5
380/3/50
RPM 2680/665
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.0/1.8
A 16/4.4
244/168
215/189
145/129
76/54
-
-
0.95/0.74
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment
10 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
SEW
02SMP20AW001
Long Travel Motor
2
3 Phase Induction
KW 2.2
380/3/50
RPM 1410
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.9
A 28.9
270
230
230
82
-
-
0.83
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load

SDN BHD
6.0 EOT CRANE FOR BFP

SDN BHD
F
O
R

C
O
N
S
T
R
U
C
T
I
O
N

SDN BHD
F
O
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A
P
P
R
O
V
A
L

SDN BHD
F
O
R

I
N
F
O
R
M
A
T
I
O
N
1
8

T
O
N
S
R
. N
O
. 2
0
2
7
/2
0
0
9
S
W
L
E
Q
U
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O
. 1
2
S
M
A
1
0
A
W
0
0
1
F
O
R

I
N
F
O
R
M
A
T
I
O
N
F
O
R

I
N
F
O
R
M
A
T
I
O
N
1
8

T
O
N
S
R
. N
O
. 2
0
2
7
/2
0
0
9
S
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2
S
M
A
1
0
A
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0
0
1
F
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I
N
F
O
R
M
A
T
I
O
N
F
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I
N
F
O
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M
A
T
I
O
N
F
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I
N
F
O
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M
A
T
I
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N
1
8

T
O
N
S
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O
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0
2
7
/2
0
0
9
S
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U
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2
S
M
A
1
0
A
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0
0
1
F
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I
N
F
O
R
M
A
T
I
O
N
F
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I
N
F
O
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M
A
T
I
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N
1
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T
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S
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0
2
7
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0
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9
S
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2
S
M
A
1
0
A
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0
0
1
F
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I
N
F
O
R
M
A
T
I
O
N
F
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I
N
F
O
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M
A
T
I
O
N
F
O
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I
N
F
O
R
M
A
T
I
O
N

SDN BHD
6.4 LUBRICANT LIST
JOB NO. : 10933
SHEET NO. : 1 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
turbine
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
3L
5L
600-2500g
MARKER'S BRAND
Mobilith SHC460
CLP460
CLP460
GOOF
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Shell Omala Oil
460
Lifetime oil
lubrication
Shell Omala Oil
460
3L
5L
600-2500g
During overhaul
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10934
SHEET NO. : 2 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
1.5L
5L
600-2500g
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
LUBRICANT LIST
ITEM
NO.
station
JOB NO. : 10935
SHEET NO. : 3 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
facilities
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobil Gear 634
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10936
SHEET NO. : 4 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.
02SMA20AW001
02SMA20AW002
JOB NO. : 10937
SHEET NO. : 5 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10938
SHEET NO. : 6 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
3L
600-2500g
During overhaul
During overhaul
12 months
1.5L
3L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.

SDN BHD

SDN BHD
0-WD951-EE165-00323 1
WIRING DIAGRAM (EOT CRANE
FOR BFP)
TOTAL 10 PAGE
(Including Cover)
TITLE : ELECTRICAL AND CONTROL WIRING DIAGRAM (EOT CRANE
FOR BFP)
Purpose
For Review
For Approval
For Construction
For Bid
For Information
Rev.
No.
DATE
EXCELLIFT
DESCRIPTION
POSCO E&C
Owner
SDN BHD

SDN BHD
6.7 TECHNICAL DATA
ln-door
Out -door
Manufacture
Main 18 Main -
Aux. - Aux. -
Span (m) Unit 1:47.5 Unit 2:49.0
Lifting Height (m)
Aux. - Aux. -
Fast 4.0 Fast 20
Precision 6.3 Long Travel Square Rail
Brake
Control Method
2164
B Min. 230 C
1964
D 1000 Forward 2200
Hook (mm) F
690
G - H
4100
R
3600
Q
4300
Wheel Load (ton) PV
9.85
PH 0.9 PL
1.79
Double Girder Girder Type
12SMA10AW001
22SMA10AW001
Crane Type
Malaysia / Germany Place of Manufacture
Hoisting Speed
(m/min)
Cross Travel Speed
(m/min)
Hook Type
Service Class
Runway Length (m)
Long Travel Speed
(m/min)
Excellift - Stahl
Pendant Control
4.67
Rated Load (ton)
6.2
4. EOT crane for BFP Equipment No.
Gantry Workshop building Location
Close Cabin
Cross Travel
Hook Approach (mm)
End Carriage (mm)
4
50
Long Travel
Hook Approach (mm)
Open Cabin
1.2
Rail Type
2.6
1.8
11 of 19
REV.0
MOTOR BELOW 200kW
EOT crane for BFP
UNIT DATA
Siemens
02SMA20AW001
02SMA20AW002
Hoisting Motor
per crane 1
3 Phase Induction
KW 15.5/2.4
380/3/50
RPM 2860/450
Volt 380
F or B F
1.0
IP IP55
Indoor
240/120
Bi-directional
M40
LHS RHS
Bottom
-
160L
s 5
s 2
-
A 32/13.1
A 175/26
212/146
247/162
189/142
80/48
-
-
0.87/0.56
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
12 of 19
REV.0
MOTOR BELOW 200kW
EOT crane for BFP
UNIT DATA
Stahl CraneSystems
02SMA20AW001
02SMA20AW002
Cross Travel Motor
per crane 1
3 Phase Induction
KW 2.0/0.5
380/3/50
RPM 2680/665
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.0/1.8
A 16/4.4
244/168
215/189
145/129
76/54
-
-
0.95/0.74
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment
13 of 19
REV.0
MOTOR BELOW 200kW
EOT crane for BFP
UNIT DATA
Stahl CraneSystems
02SMA20AW001
02SMA20AW002
Long Travel Motor
per crane 2
3 Phase Induction
KW 1.25/0.32
380/3/50
RPM 2550/660
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 3.0/1.4
A 9.2/2.9
224/162
241/185
145/136
68/48
-
-
0.88/0.69
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load

SDN BHD
7.0 EOT CRANE FOR WORKSHOP

SDN BHD
F
O
R

A
P
P
R
O
V
A
L

SDN BHD
F
O
R

A
P
P
R
O
V
A
L

SDN BHD
F
O
R

I
N
F
O
R
M
A
T
I
O
N
2
0

T
O
N
S
R
. N
O
. 2
0
2
9
/2
0
0
9
S
W
L
E
Q
U
lP
. N
O
. 0
0
S
M
B
1
0
A
W
0
0
1
F
O
R

I
N
F
O
R
M
A
T
I
O
N
F
O
R

I
N
F
O
R
M
A
T
I
O
N
2
0

T
O
N
S
R
. N
O
. 2
0
2
9
/2
0
0
9
S
W
L
E
Q
U
lP
. N
O
. 0
0
S
M
B
1
0
A
W
0
0
1
F
O
R

I
N
F
O
R
M
A
T
I
O
N
F
O
R

I
N
F
O
R
M
A
T
I
O
N
F
O
R

I
N
F
O
R
M
A
T
I
O
N
F
O
R

I
N
F
O
R
M
A
T
I
O
N
2
0

T
O
N
S
R
. N
O
. 2
0
2
9
/2
0
0
9
S
W
L
E
Q
U
lP
. N
O
. 0
0
S
M
B
1
0
A
W
0
0
1
F
O
R

I
N
F
O
R
M
A
T
I
O
N
F
O
R

I
N
F
O
R
M
A
T
I
O
N

SDN BHD
7.4 LUBRICANT LIST
JOB NO. : 10933
SHEET NO. : 1 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
turbine
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
3L
5L
600-2500g
MARKER'S BRAND
Mobilith SHC460
CLP460
CLP460
GOOF
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Shell Omala Oil
460
Lifetime oil
lubrication
Shell Omala Oil
460
3L
5L
600-2500g
During overhaul
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10934
SHEET NO. : 2 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
1.5L
5L
600-2500g
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
LUBRICANT LIST
ITEM
NO.
station
JOB NO. : 10935
SHEET NO. : 3 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
facilities
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobil Gear 634
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10936
SHEET NO. : 4 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.
02SMA20AW001
02SMA20AW002
JOB NO. : 10937
SHEET NO. : 5 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10938
SHEET NO. : 6 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
3L
600-2500g
During overhaul
During overhaul
12 months
1.5L
3L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.

SDN BHD

SDN BHD
0-WD951-EE165-00423 1
FOR WORKSHOP)
TOTAL 10 PAGE
(Including Cover)
FOR WORKSHOP)
Purpose
For Review
For Approval
For Construction
For Bid
For Information
Rev.
No.
DATE
EXCELLIFT
DESCRIPTION
POSCO E&C
Owner
SDN BHD

SDN BHD
7.7 TECHNICAL DATA
ln-door
Out -door
Manufacture
Main 20 Main -
Aux. - Aux. -
Span (m)
Main 6
Aux. -
Aux. - Aux. -
Fast 4.0 Fast 20
Brake
Control Method
1930
B Min. 230 C
1730
D 1200 Forward 2600
Hook (mm) F
967
G - H
6000
R
3800
Q
4450
Wheel Load (ton) PV
13.1
PH 1.2 PL
2.4
Crane Type
Cross Travel Speed
(m/min)
Hook Type
Service Class
Runway Length (m)
5.5
Rail Type
Pendant Control
6.9
1.8
Close Cabin
Cross Travel
Hook Approach (mm)
End Carriage (mm)
4
50
Long Travel
Hook Approach (mm)
Open Cabin
5. EOTcrane for workshop Equipment No. 00SMB10AW001
Gantry Workshop building Location
Hoisting Speed
(m/min)
Long Travel Speed
(m/min)
Excellift - Stahl
Lifting Height (m) Double Girder Girder Type
Malaysia / Germany
Rated Load (ton)
15.6 40
14 of 19
REV.0
MOTOR BELOW 200kW
EOT crane for workshop
UNIT DATA
Siemens
00SMB10AW001
Hoisting Motor
per crane 1
3 Phase Induction
KW 15.5/2.4
380/3/50
RPM 2860/450
Volt 380
F or B F
1.0
IP IP55
Indoor
240/120
Bi-directional
M40
LHS RHS
Bottom
-
160L
s 5
s 2
-
A 32/13.1
A 175/26
212/146
247/162
189/142
80/48
-
-
0.87/0.56
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment
15 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Stahl CraneSystems
00SMB10AW001
Cross Travel Motor
1
3 Phase Induction
KW 2.0/0.5
380/3/50
RPM 2680/665
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.0/1.8
A 16/4.4
244/168
215/189
145/129
76/54
-
-
0.95/0.74
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment
16 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Stahl CraneSystems
00SMB10AW001
Long Travel Motor
2
3 Phase Induction
KW 1.25/0.32
380/3/50
RPM 2550/660
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 3.0/1.4
A 9.2/2.9
224/162
241/185
145/136
68/48
-
-
0.88/0.69
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment

SDN BHD
8.0 EOT CRANE FOR WAREHOUSE

SDN BHD
F
O
R

A
P
P
R
O
V
A
L

SDN BHD
F
O
R

A
P
P
R
O
V
A
L

SDN BHD
F
O
R

A
P
P
R
O
V
A
L
2
0

T
O
N
S
R
. N
O
. 2
0
3
0
/2
0
0
9
S
W
L
E
Q
U
lP
. N
O
. 0
0
S
M
B
2
0
A
W
0
0
1
F
O
R

A
P
P
R
O
V
A
L
F
O
R

A
P
P
R
O
V
A
L
2
0

T
O
N
S
R
. N
O
. 2
0
3
0
/2
0
0
9
S
W
L
E
Q
U
lP
. N
O
. 0
0
S
M
B
2
0
A
W
0
0
1
F
O
R

A
P
P
R
O
V
A
L
F
O
R

A
P
P
R
O
V
A
L
2
0

T
O
N
S
R
. N
O
. 2
0
3
0
/2
0
0
9
S
W
L
E
Q
U
lP
. N
O
. 0
0
S
M
B
2
0
A
W
0
0
1

SDN BHD
8.4 LUBRICANT LIST
JOB NO. : 10933
SHEET NO. : 1 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
turbine
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
3L
5L
600-2500g
MARKER'S BRAND
Mobilith SHC460
CLP460
CLP460
GOOF
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Shell Omala Oil
460
Lifetime oil
lubrication
Shell Omala Oil
460
3L
5L
600-2500g
During overhaul
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10934
SHEET NO. : 2 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
During overhaul
During overhaul
12 months
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
1.5L
5L
600-2500g
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
LUBRICANT LIST
ITEM
NO.
station
JOB NO. : 10935
SHEET NO. : 3 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
facilities
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobil Gear 634
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10936
SHEET NO. : 4 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.
02SMA20AW001
02SMA20AW002
JOB NO. : 10937
SHEET NO. : 5 OF 6
INITIAL
LUBRICANT LIST
ITEM
NO.
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Gearbox
Gearbox
Wire Rope Hoist
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
During overhaul
During overhaul
12 months
1.5L
1.5L
600-2500g
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
1.5L
600-2500g
12 months
Mobil Special
Grease
KPF1K 50g 50g
JOB NO. : 10938
SHEET NO. : 6 OF 6
INITIAL
Mobil Special
Grease
Lifetime oil
lubrication
Lifetime oil
lubrication
6 Hoist
Cross Travel
Shaft
Shell Retinax AM
1.5L
3L
600-2500g
During overhaul
During overhaul
12 months
1.5L
3L
600-2500g
Lifetime oil
lubrication
3
4
5
Cross Travel Motor
Long Travel Motor
Hoist
Gearbox
Gearbox
Wire Rope
Mobilith SHC460
CLP460
CLP460
GOOF
Mobil Gear 634
Mobil Gear 634
Mobilux Liquid
Grease EP004
Shell Omala Oil
460
Shell Omala Oil
460
Shell Special
Gear Grease H
Shell Omala Oil
460
CLP460
REPLACEMENT CHARGE
ITEM
NO
PART TO BE
MARKER'S BRAND
Mobil Gear 634
LUBRICANT LIST
ITEM
NO.

SDN BHD

SDN BHD
0-WD951-EE165-00523 1
FOR WAREHOUSE)
TOTAL 10 PAGE
(Including Cover)
FOR WAREHOUSE)
Purpose
For Review
For Approval
For Construction
For Bid
For Information
Rev.
No.
DATE
EXCELLIFT
DESCRIPTION
POSCO E&C
Owner
SDN BHD

SDN BHD
8.7 TECHNICAL DATA
ln-door
Out -door
Manufacture
Main 20 Main -
Aux. - Aux. -
Span (m)
Main 7
Aux. -
Aux. - Aux. -
Fast 4.0 Fast 20
Brake
Control Method
2600
B Min. 230 C
2400
D 1000 Forward 3000
Hook (mm) F
694
G - H
6000
R
4200
Q
4950
Wheel Load (ton) PV
15.2
PH 1.4 PL
2.8
Lifting Height (m) Double Girder Girder Type
Malaysia / Germany
Rated Load (ton)
24.6 60
Open Cabin
6. EOT crane for warehouse Equipment No. 00SMB20AW001
Gantry Warehouse building Location
Hoisting Speed
(m/min)
Long Travel Speed
(m/min)
Excellift - Stahl
Cross Travel
Hook Approach (mm)
End Carriage (mm)
4
50
Long Travel
Hook Approach (mm)
Pendant Control
13.4
1800
Close Cabin
11.6
Rail Type
Crane Type
Cross Travel Speed
(m/min)
Hook Type
Service Class
Runway Length (m)
17 of 19
REV.0
MOTOR BELOW 200kW
EOT crane for warehouse
UNIT DATA
Siemens
00SMB20AW001
Hoisting Motor
per crane 1
3 Phase Induction
KW 15.5/2.4
380/3/50
RPM 2860/450
Volt 380
F or B F
1.0
IP IP55
Indoor
240/120
Bi-directional
M40
LHS RHS
Bottom
-
160L
s 5
s 2
-
A 32/13.1
A 175/26
212/146
247/162
189/142
80/48
-
-
0.87/0.56
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
18 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Stahl CraneSystems
00SMB20AW001
Cross Travel Motor
1
3 Phase Induction
KW 2.0/0.5
380/3/50
RPM 2680/665
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.0/1.8
A 16/4.4
244/168
215/189
145/129
76/54
-
-
0.95/0.74
-
-
Shell Omala Oil 460
I. Manufacturer
1. Item No.
2. Driven Equipment
3. Quantity
5. Motor Type :
9. Rated Voltage
11. Service Factor
16. Rotation
31. Eff - 3/4 Load %
25. Full Load Amps
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
19 of 19
REV.0
MOTOR BELOW 200kW
UNIT DATA
Stahl CraneSystems
00SMB20AW001
Long Travel Motor
2
3 Phase Induction
KW 2.0/0.5
380/3/50
RPM 2680/665
Volt 380
F or B F
1.0
IP IP55
Outdoor
300/150
Bi-directional
M25
LHS RHS
Bottom
-
100
s 5
s 2
-
A 4.0/1.8
A 16/4.4
244/168
215/189
145/129
76/54
-
-
0.95/0.74
-
-
32. Eff - 1/2 Load %
33. Pf Full Load
34. Pf - 3/4 Load
35. Pf - 1/2 Load
31. Eff - 3/4 Load %
25. Full Load Amps
11. Service Factor
16. Rotation
3. Quantity
5. Motor Type :
9. Rated Voltage
I. Manufacturer
1. Item No.
2. Driven Equipment

SDN BHD
9.0 APPENDIX

SDN BHD
9.1 AS HOIST O & M
Wire Rope Hoists
_

Operating and Maintenance Instructions
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Fundamental information
You have purchased a product manufactured by STAHL CraneSystems GmbH.
This wire rope hoist has been constructed in compliance with the applicable
standards and regulations.
Inspect hoist for damage caused in transit immediately upon delivery.
Report damage caused in transit and after consulting the manufacturer/supplier
repair or have repaired before installation and commissioning.
Do not install or commission a damaged hoist!
- Assembly
- installation
- commissioning
- tests
- maintenance and elimination of faults
may only be carried out by a qualified person
Terms employed
User
Whoever uses and employs the wire rope hoist or has it operated by suitable trained
personnel is considered to be the user (employer/company).
Trained personnel
Trained personnel are persons who have been instructed and trained in the duties
with which they are entrusted and the risks which may arise from incorrect
behaviour, have been advised on the necessary protective devices, precautions,
applicable regulations, accident prevention regulations and prevailing conditions
and have proven their ability.
Skilled electrician
A skilled electrician possesses knowledge and experience on electrical equipment
arising from specialist training and, with knowledge of the applicable standards and
regulations, is able to assess the work with which he is entrusted and detect and
avoid possible risks.
Definition of a qualified person (specialist):
A qualified person is one with the necessary qualification, based on theoretical and
practical knowledge of hoists, for the required activities as listed in the operating
instructions.
The person must be in a position to assess the safety of the installation in
conjunction with the application. Persons with the authority to undertake certain
maintenance work on our products include service engineers of manufacturer and
trained fitters with the corresponding certification.
Seminars:
Comprehensive understanding of material handling products is a prerequisite for the
correct use of equipment. Competent and practically oriented, we impart the special-
ist knowledge required for the correct use, monitoring and care of your installation.
Ask for our seminar programme.
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Table of contents
1 Safety instructions
1.1 Symbols ........................................................................................................................... 4
1.2 Operating instructions .................................................................................................. 4
1.3 Use for intended purpose............................................................................................. 5
1.4 Safety-conscious operation......................................................................................... 5
1.5 Organisational safety precautions.............................................................................. 5
1.6 General regulations....................................................................................................... 5
1.7 Installation, commissioning, maintenance and repairs .......................................... 6
1.8 Warranty.......................................................................................................................... 6
1.9 Periodic tests.................................................................................................................. 6
1.10 After sales service......................................................................................................... 6
2 Getting to know the wire rope
hoist
..................................................................................................................................................... 7
3 Installation
3.1 Stationary wire rope hoist ............................................................................................ 8
3.2 Double rail crab.............................................................................................................. 9
3.3 Travel limit switch........................................................................................................ 10
3.4 Electrical equipment ................................................................................................... 11
3.5 Hoists with frequency converter............................................................................... 12
3.6 Reeving rope................................................................................................................. 13
4 Commissioning
4.1 Commissioning ............................................................................................................. 16
5 Operating
5.1 Duties of crane operator ............................................................................................ 17
5.2 Using control pendant................................................................................................. 18
5.3 Emergency stop ........................................................................................................... 18
6 Inspection and maintenance
................................................................................................................................................... 19
6.1 Inspection table ........................................................................................................... 19
6.2 Maintenance table ...................................................................................................... 20
6.3 Hoist brake.................................................................................................................... 21
6.4 Travel motor brake....................................................................................................... 21
6.5 Hoist limit switch versions ......................................................................................... 22
6.6 Hoist limit switch on standard crane - version I..................................................... 23
6.7 Hoist limit switch on standard crane - version II ................................................... 26
6.8 Crane test ...................................................................................................................... 30
6.10 Rope drive ..................................................................................................................... 31
6.11 Crab................................................................................................................................ 36
6.12 Gear................................................................................................................................ 37
6.13 Remaining service life................................................................................................. 37
6.14 General overhaul ......................................................................................................... 38
7 Fault-finding
7.1 What should be done if...?.......................................................................................... 39
8 Technical data
8.1 FEM classification ....................................................................................................... 42
8.2 Conditions of use ......................................................................................................... 42
8.3 Hoist ............................................................................................................................... 43
8.4 Cable cross-section and length of supply cable .................................................... 44
8.5 Tightening torques for screws................................................................................... 45
8.6 Lubricants...................................................................................................................... 45
8.7 Sound pressure level .................................................................................................. 46
8.8 Circuit diagrams........................................................................................................... 46
9 Wearing parts
9.1 Serial number ............................................................................................................... 47
9.2 Hoist ............................................................................................................................... 47
Subject to technical alterations; errors and printing errors excepted
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1.1 Symbols
Transport
The wire rope hoist is delivered on a special pallet. This enables the hoist to be
loaded and unloaded safely with a fork-lift truck.
If the wire rope hoist is to be transported suspended, it must be attached at the top
by the eyebolts (M24), see sketch.
Safety at work
This symbol marks all information on safety at work where risks to life and limb are
entailed.
Covers such as hoods and caps which are marked with this symbol may only be
opened by "qualified persons or suitably instructed personnel".
It is forbidden for persons to stand under suspended loads. This entails risks to life
and limb!
Safety in operation
Information marked with this symbol must be observed to avoid damage to the wire
rope hoist or the goods transported.
1.2 Operating instructions
Read carefully and observe the operating instructions.
In these operating instructions, these symbols mark particularly important infor-
mation on risks and safety in operation.
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1.3 Use for intended purpose
Wire rope hoists are intended for lifting freely movable and guided loads that
cannot tilt. Depending on their design, they are for stationary or mobile use. If
loads are to be towed horizontally, or in the case of guided loads, automatic opera-
tion, continual deadweight or constantly repeated hoisting motions, the individual
application must be assessed. Please contact the manufacturer in case of doubt.
Do not carry out any alterations or modifications. Additional fitments must be
authorised by the manufacturer. The declaration of conformity may be invalidated.
Not permitted:
Exceeding the safe working load
Transporting persons
Pulling loads at an angle
Pulling loads loose
Pulling or towing loads if the wire rope hoist has not been especially designed for
this application.
Manipulating the overload cut-off, apart from corrections as described on page 41.
Operating the hoist with slack rope.
If the hoist forms "part of a machine," the person placing it on the market must
ensure that the hoist meets the specific regulations of the application
1.4 Safety-conscious operation
The AS wire rope hoists are constructed according to the state of the art and equip-
ped with an overload cut-off. In spite of this, dangers may arise from incorrect use or
use for an unintended purpose.
The user is responsible for ensuring that work is carried out with safety in mind
and avoiding risks.
Read the operating instructions before starting to work with the wire rope hoist.
Observe the "Duties of crane operator", see page 17.
Before starting work, find out where the EMERGENCY STOP button is (usually in
the control pendant).
Do not put your hand between edges which might pinch or cut.
Do not use the emergency limit switch (ultimate limit switch for highest and lowest
hook position) as an operational limit switch.
Report damage and defects to the wire rope hoist (abnormal noises, impaired
braking function, deformations, ...) to the person responsible immediately. Do not
use the wire rope hoist until the faults have been eliminated.
Do not remove information plates from the wire rope hoist. Replace illegible or
damaged plates.
Have hoist inspected by the relevant authority before commissioning.
1.5 Organisational safety precautions
Only direct persons to operate the hoist if they have been trained or instructed in
its use. Observe the legal minimum age!
At regular intervals, check that work is being caried out in a safety-conscious
manner.
Observe the intervals specified for periodic tests. File the test reports in the test log
book.
Store the operating instructions within easy reach where the wire rope hoist is
operated.
1.6 General regulations
Safety regulations and accident prevention regulations.
National regulations
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1.7 Installation, commissioning,
maintenance and repairs
Installation, commissioning, maintenance and repairs may be carried out by
qualified persons only, (see page 2).
We recommend having installation carried out by personnel engaged by the
manufacturer.
Use only original spare parts for repairs, otherwise the guarantee will become
invalid.
Do not carry out any alterations or modifications.
Additional fitments must be approved by the manufacturer.
If the wire rope hoist is constantly operated out of doors and exposed to the
elements without protection, we recommend fitting a small roof or at least "parking"
the hoist under a roof.
1.8 Warranty
The guarantee will become invalid if these operating instructions are not observed
for installation, operation, inspection and maintenance.
Repairs and elimination of faults within the scope of the warranty may only be per-
formed by qualified personnel (see page 2) after the manufacturer/supplier has
been consulted and has given his approval.
The warranty will become invalid if the hoist is modified or original spare parts not
used.
1.9 Periodic tests
Hoists and cranes must be inspected by a qualified person (see page 2) at least once
a year. The results of the test must be recorded and filed in the test log book.
The remaining service life of the hoist acc. to FEM 9.755 must also be established
during this inspection.
The periodic tests must be adapted to the hoists use. Intensive use entails shorter
maintenance intervals.
All tests must be initiated by the user, see page 2.
1.10After sales service
With the purchase of this wire rope hoist, you have decided on a high-quality piece
of lifting equipment. Our after sales service will give you advice on its correct use.
In order to maintain the safety and constant availability of your wire rope hoist, we
recommend concluding a maintenance agreement on the basis of which we will
undertake the "periodic tests" on your behalf.
Repairs will be carried out professionally and quickly by our trained personnel.
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2 Getting to know the wire rope hoist
The modular concept of our series of wire rope hoists permits a multitude of
variations on the basis of series components.
Our certified quality assurance system to DIN ISO 9001/EN 29001 guarantees
consistently high quality.
If you have any questions, for example on hoists modified to customers specific
applications, please contact one of our branches or subsidiaries. We will be pleased
to advise you!
1 Connection box
2 Gear
3 Rope drum
4 Rope guide with tensioning spring
5 Rope drum bearing
7 Motor
8 Brake
9 Fan
10 Fan cover
12 Stationary hoist, "hoist for installation"
13 Hoist with double-rail crab
12 13
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3 Installation
3.1 Stationary wire rope hoist
Possible installation positions
In standard design with rope lead-off vertically downwards, the wire rope hoist is
bolted onto a horizontal surface by means of the foot holes. Please consult us in the
case of other rope lead-offs.
Use the fixing elements specified (see sketch).
Take care that no distortion arises from unevenness, etc.
Take up any lateral forces in the attachment by a support bar (see sketch *3).
3.1.1 Fleet angles
The fleet angles given in the table can be obtained by rotating the rope guide on the
rope drum and positioning the wire rope hoist accordingly. The rope guide must be
adapted to the fleet angle. Observe also the radial rope exit angle .
3.1.2 Angles of installation
Install the wire rope hoist within the permissible range of angles. Hoists with rope
drives with bottom hook blocks must always be installed horizontal to their
longitudinal axis.
The max. permissible rope exit angle acc. to standard is 4 for non-twist-free wire
ropes, 1.5 for twist-free wire ropes. However at these angles a reduction in ser-
vice life is to be expected. The wire rope must not touch the rope guide or structu-
ral elements.
2/1 4/1 4/2-1 2/2-1 6/1 8/1 8/2-1
Standard reevings
10/2-1
Type
Standard by rotating rope guide
A B C
o1 | o o
AS 70
18 30 3-10 on request 55
W0765
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3 Installation
3.2 Double rail crab
Check track gauge Spw on crab and rail.
L1 max - L1 min = 5 mm, see sketch.
Check lateral play between rail and flange, see sketch.
Bolt rubber buffers to crab or runway end stop.
Fit suitable stops. Dimensions see sketch and table.
The runway must meet the requirements of DIN 4132.
The rail joints must be even on both running and guide surfaces; grind down if
necessary.
Check that the crab runs smoothly over the whole runway without jamming or
increased friction at the wheel flanges. Increased friction at the flanges due to poor
beam quality or incorrect crab adjustment may lead to increased wear.
S as per table if crab is positioned symmetrically on runway.
If asymmetrically, S
left
+ S
right
= 2 x S
End stops
The crabs are equipped with buffers.
Suitable end stops must be provided at the end of the runway.
D S
[mm]
315 4,5-7
400 4,5-7,5
Wheel
D
b
[mm]
315 160
400 240
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3 Installation
3.3 Travel limit switches
Double rail crab
The travel limit switch assembly is supplied ready-wired but not mounted and must
be secured to the towing arm for the power supply.
The switching contacts are designed for control current.
Switching functions:
1. Limit switching in both directions of travel (1 two-way switch, 2 ramps).
2. Pre-switching and limit switching in both directions of travel (1 two-way switch, 4
ramps).
The speed is switched over from "fast" to "slow" before the end of the runway is
reached, and is cut off at the end of the runway
X = stop, left
Y = stop, right
Z = fast / slow
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3 Installation
3.4 Electrical equipment
For the sake of safety, have the wire rope hoist connected by a skilled electrician.
Observe the relevant safety and accident prevention regulations!
3.4.1 Supply cable
As fixed installed cables:
NYY, NYM
As flexible cables:
H07RN-F or NGFLGu, or equivalent cables.
For minimum cross-section and max. length of supply cable see page 44.
3.4.2 Fusing
NEOZED, DIAZED or NH fuses in operating class gL/gG see page 43.
Observe the correct fuse sizes so that the crane switch contacts do not weld if
there is a short circuit and overload protection of lead is ensured!
3.4.3 EMERGENCY STOP
It must be possible to disconnect the system electrically from the operating position.
This function can be provided by:
EMERGENCY STOP button in the control pendant in conjunction with the crane
switch contactor,
main isolator, if this is directly accessible and positioned close to the operating
position.
3.4.4 Main isolator
must disconnect the wire rope hoist on all poles,
must be lockable in OFF position,
must be installed in an easily accessible place in the system,
must be marked as such to avoid mistakes.
3.4.5 Disconnecting switch
is necessary if more than one floor-operated hoist is supplied with power,
must be lockable in OFF position.
3.4.6 Overload cut-off
prevents an overload being lifted. If an overload has been established, the load can
only be lowered.
In certain applications, wire rope hoists may also be used without an overload cut-
off. However in this case they do not meet the requirements of the EC directives
and are not marked with the CE symbol.
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3 Installation
(continued)
3.4.7 Connecting to mains
Compare existing mains voltage and frequency with the information on the rating
plate.
Route cables into the hoist connection box through the cable glands.
Connect according to the circuit diagrams supplied.
Measure control voltage. If the measured value exceeds the rated control voltage
by more than 10%, a different tapping point must be selected on the primary side of
the control transformer.
Do not connect any live lead to the temperature sensors! Damaged temperature
sensors cannot protect the motor.
Check that the direction of rotation of the rope drum corresponds to the symbols
on the control pendant : Press "slow up" button on control pendant. Never press
"down" button first! If the hook moves upwards or does not move because the limit
switch has disconnected in top hook position, the phase connection is correct.
Crosscheck by pressing "slow down" button on control pendant.
If the movement of the hook does not correspond to the symbols on the control
pendant, interchange two phase conductors of the supply cable.
Caution! Risk of accident! If this is not observed, serious accidents or damage to
the hoist may occur!.
Controls by others
If the controls are supplied by others, connect the temperature sensors of the hoist
motor, the hoist brake, the overload cut-off and the emergency hoist limit switch
according to our connection diagrams.
Construct the control according to the circuit diagrams supplied.
The declaration of conformity is valid only for the scope supplied by the manufac-
turer.
3.5 ASF hoists with frequency
inverter
See concise operating instructions HOISTING - TRAVEL (Siemens)
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3 Installation
3.6 Reeving rope
The wire rope is wound onto the drum in the factory. If not, see page 33, "Fitting wire
rope".
Proceed as follows to reeve the bottom hook block:
Gripper pliers hold the rope securely.
The wire rope hoist must be switched on in order to reeve the rope. All work must
therefore be carried out with extreme care: for your safety and for troublefree
functioning of the wire rope hoist!
1. Lay out the end of the rope not wound on the drum, or let it hang freely.
2. Check that the wire rope lies snugly on the rope drum, tighten if necessary. Avoid
slack rope on the drum! Slack rope can destroy the rope guide and the wire rope.
3. Colour code the beginning of the rope on one side.
4. Reeve the end of the rope into the rope sheave(s) of the bottom hook block and
return pulley(s), see page 14.
Do not twist the rope; the colour coding facilitates checking.
5. Fasten the end of the rope in the rope anchorage, see page 15.
6. Perform several runs over the full height of lift without load.
7. Repeat with increasing loads.
8. Make any twisting in the rope visible by sticking on a paper tag. Severe twisting is
shown by the bottom hook block's turning, especially when not under load.
9. If any twisting should occur, remove the wire rope and untwist by letting it hang
freely or laying it out. Twisting in the wire rope prejudices safety and service life.
Any twisting should therefore be removed before subjecting the hoist to any further
load. The rope could otherwise be permanently distorted and might have to be
replaced!
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3 Installation
Reeving rope
Reeve the rope as shown in the schematic drawings and attach the end of the rope
at the rope anchorage.
Caution! The bottom hook block must hang horizontally (./2-1)
Length L Fig.
1/1 L1 - L4 1
2/1 L1 - L4 2
4/1
L1- L3
L4
3
4
6/1 L1 - L4 5
8/1 L1 - L4 6
2/2-1 L1 - L4 7
4/2-1 L1 - L4 8
8/2-1 L1 - L4 9
10/2-1 L2 - L4 10
1 2 3
4 6 5
9 8
L
L L
L L
R L R L 10 R L
8/2-1
8/1
4/2-1 10/2-1
6/1 4/1
1/1
L
2/1 4/1
7 R L
2/2-1
L = left-hand thread
R = right-hand thread
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3 Installation
Rope anchorage
Note information plate at rope anchorage.
Insert end of rope into rope anchorage according to reeving, see sketches 11-16.
Place rope around rope wedge 11.2 and pull it into the tapered rope recess 11.1
until the loose end of the rope projects by approx. 100 mm.
Secure loose end of rope with rope clamp 11.3 approx. 50 mm from the end of the
rope. Tightening torque [Nm] see table
Replace split pin (11.4) after dismantling it; bend ends of split pin up
11 12
13
14
18
15 16
*1 *1
17
*1
*1
19
*1
Rope-
[mm]
M.. Tightening torque
[Nm]
20 M 16 130
24/26 M 20 250
Length L Fig.
1/1 L1 - L4 12
2/1 L1 - L4 13
4/1
L1 - L3
L4
14
15
6/1 L1 - L4 16
8/1 L1 - L4 16
2/2-1 - -
4/2-1 L1 - L4 17
8/2-1 L1 - L4 18
10/2-1 L2 - L4 19
*1 Gear side
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4 Commissioning
4.1 Commissioning
The wire rope hoist has been subjected to a final inspection by the manufacturer in
accordance with the EC Machinery Directive.
Commissioning must be carried out by a qualified person, see page 2.
The "Safety instructions" on page 4...6 must also be observed.
The following checks must be carried out:
Check that the wire rope hoist is completed with the original accessories as supplied
(e.g. bottom hook block), see page 13.
Check correct selection and installation of all electrical equipment, see page 11,
"Electrical equipment".
Electrical connection, see page 12.
Check that the seating of fixing screws is firm and secure, see page 8, 33, 45.
Check correct functioning of runway end stops.
The direction of motion of the load hook must correspond to the symbols on the
control pendant.
Check the presence and correct functioning of all safety devices.
Check emergency hoist limit switch or combined operational and emergency hoist
limit switch, see page 23.
Check overload cut-off, see page 26, 29.
Confirm that commissioning has been duly carried out in the test log book in
section "Confirmation of commissioning".
If the wire rope hoist in conjunction with a crane system is to be subjected to a test
load during the acceptance test, the overload cut-off must be bridged (see 6.9
page 30), see circuit diagram.
Run rope in under partial load (will improve service life).
Any fundamental alterations and modifications to the wire rope hoist, such as e.g
welding on load-bearing components, structural alterations to load-bearing
components, alteration of drives, alteration of speeds and motor outputs, replacing
trolleys, etc. must be authorised by the manufacturer.
Also any work on or additions to the control must be authorised by the manufacturer.
The manufacturer cannot accept any liability for malfunctioning after unauthorised
work on the control.
Our qualified personnel is available to perform a reacceptance test after authorised
modifications.
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5 Operating
5.1 Duties of crane operator
When working with wire rope hoists, the following points must be observed:
Every day before starting work, check brakes and limit switches and inspect the
system for any visible defects.
Stop working with the crane if there are any defects which might prejudice its
safety in operation.
At close of work, secure cranes which are exposed to wind with the wind
safeguard mechanism.
The rope drum must be free of coarse foreign matter.
Do not move loads above people.
Do not leave suspended loads unattended, the control pendant must be within
easy reach.
Do not use emergency limit switch during normal operation.
Do not load above rated capacity.
Pulling loads at angles, dragging loads, or towing vehicles with the load or load
suspension equipment is forbidden!
Do not heave up any loads which are jammed.
Approach final positions for hoisting, lowering and travel in normal operation only
if an operational limit switch is fitted.
Inching operation (repeated brief activation of the motor to achieve small
movements) is not permissible. Motors and brakes could be subjected to an
impermissible temperature rise. This would lead to the temperature control
disconnecting and the load could then not be set down for some time. Switchgear
and motors could be damaged.
Do not move in the opposite direction until the hoist has come to a stop.
Observe the safety instructions, see page 4-6.
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5 Operating
5.2 Operating from control pendant
Safety note
If the rocker switch is no longer depressed by the operator, it returns to the 0 posi-
tion, the hoist motion is automatically stopped (dead mans control).
If the hoist malfunctions, e.g. the actual motion does not correspond to the motion
intended in activating the rocker switch, release the rocker switch immediately. If the
motion continues, press the emergency stop button.
5.3 Emergency stop
Every hoist must have a means of disconnecting the power supply to all drives under
load from the ground.
After an emergency stop, the operator must not restart the hoist /crane system until a
qualified person has determined that the fault which led to this function being activa-
ted has been eliminated and no danger can arise from the continued operation of the
system.
The emergency stop button is on the control pendant.
To release the emergency stop: turn the button in the direction shown.
1st step: slow
2nd step: fast
1st step: slow
2nd step: fast
1st step: slow
Long travel: right/left
Cross travel: right/left
Lifting/lowering:
2nd step: fast
Emergency stop
Standard design
2-step
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This section deals with operational reliability, availability, and maintaining the value
of your wire rope hoist.
Although this wire rope hoist is practically maintenance-free, the components
subject to wear (e.g. wire rope, brake) must be inspected regularly. This is required
by the accident prevention regulations.
Inspection and maintenance must be carried out by qualified persons, see page 2.
General information on inspection and maintenance
Maintenance and repair work may only be carried out when the winch is unloaded.
Before starting, switch off and lock main isolator.
Observe the requirements of the accident prevention regulations.
Periodic tests including maintenance every 12 months, possibly earlier if so pres-
cribed by national regulations, are to be performed by a fitter engaged by the
manufacturer.
The specified inspection and maintenance intervals apply for normal conditions of
use.
The inspection and maintenance intervals must be adapted accordingly if one or
more the following conditions apply:
if after evaluating the acutual use it can be seen that the theoretical useful life of
the winch will be less than 10 years,
in the case of operation in more than one shift or heavy duty
in the case of adverse conditions (dirt, solvents, temperature, etc.)
If abrasive dusts are present (foundry, cement industry, glass manufacture or pro-
cessing, etc.) the maintenance intervals for the rope guide (cleaning, lubricating,
checking and if necessary replacing tension spring, etc.) must be reduced.
A general overhaul must be carried out after the useful lifetime has expired.
Lubricants and lubrication points, see page 45.
6.1 Inspection intervals
6.1.1 Every day
Before starting work
Check function of brake, see page 21
Emergency hoist limit switch (2) if there is no operational hoist limit switch, opera-
tional hoist limit switch, if any, see page 23, 26
EMERGENCY STOP, crane switch, see page 11
Rope (10), see page 32
6.1.2 Once a year
Check suspension of control pendant (cable and steel wire must be correctly atta-
ched)
Load hook (9), cracks, cold deformation, wear
Overload cut-off (6), see page 29
Disconnect switch and main isolator, see page 11
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6.1 Inspection intervals (continued)
6.1.2 Once a year
Emergency limit switch (2) if there is an operational limit switch, see page 23, 26
PE connections and equipotential bondin
Establish remaining service life, see page 37
Rope attachment, see page 23, rope sheaves, see page 35
Rope guide (12), see page 32, 34
Drive parts (13), flanges, wheels etc., see page 36
Screw connections, welds
End stops, buffers (14)
Gear (15) see page 37
Safety clearances
Power supply cable
Cable glands
Switching functions
6.2 Maintenance intervals
6.2.1 Once a year
Brake (30), measure air gap, replace brake disc if necessary, see page 21
Grease rope (31), see page 45
Grease rope guide (32) and rope guide stop, see page 45
Drive parts (33) grease gearing
Tighten clamping points for electric leads
6.2.2 Every 10 years
Grease spline shaft gear/rope drum, toothed coupling of travel drive (34)
Change oil in hoist gear (35)
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6.3 Hoist brake
Carry out work on the hoist brake only when the hoist is unloaded and the bottom
hook block has been set down.
6.3.1 Checking brake
Remove fan cover (1)
Remove plug (2)
Measure air gap (S) with feeler gauge (F). N.B.: When measuring, ensure that the
feeler gauge is pushed in at least as far as depth "a" and does not catch on
shoulder (!). See table for max. permissible air gap (S). The brake is not adjustable.
If the max. permissible air gap (S) has been reached, the brake disc (brake rotor)
must be replaced.
6.3.2 Replacing brake disc (brake rotor)
Pull off fanwheel (3), remove feather key
Disconnect brake
Unscrew fixing screws (4)
Remove magnet piece (5) together with armature disc (6)
Remove brake disc (brake rotor) (7)
Clean brake (wear a dust protection mask)
Check friction surfaces for wear
Push new brake disc (brake rotor) (7) onto hub (8) and check radial play. If there is
increased play in the gearing between brake disc (7) and hub (8) the hub (8) must
be pulled off the motor shaft and replaced.
Before removing hub (8) please contact the manufacturer.
Replace in reverse order. Ensure that the check hole for measuring the air gap is
underneath.
Check brake data according to rating plate on hoist motor!
6.4 Travel motor brake
See operating instructions for travel motors
"A"
Hoist motor
type
Hoist
brake
S
max.
[mm]
a
[mm] Nm
12/2H73 M150 1.6 30 22
24/4H92 M500 2 40 22
4H73 M150 1.4 30 22
4H82 M250 1.5 40 22
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6.5 Hoist limit switch (versions)
N.B-:
The version of hoist limit switch installed must be determined on the baasis of the
sticker in the limit switch (see stickers).
6.5.1 Standard crane - version I (Fig. 1/2)
See chapter 6.6 for description of system
6.5.2 Standard crane - version II (Fig. 3)
Fig. 1/2
Fig. 3
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6.6 Hoist limit switch(standard crane)
6.6.1 Description of system
The wire rope hoist is equipped as standard with an emergency limit switch for
disconnecting in top and bottom hook position. (Switching points A| and A!). The
gear limit switch (GE-S) is installed in the panel box on the gear.
If the original controls/circuit diagrams are used, the corresponding hoisting
direction and the cross travel if any are disabled when the limit switch is activated.
The opposing hoisting direction is clear.
An additional operational limit switch *2 for disconnecting in top and bottom hook
position during normal operation can be fitted as an option. (Additional switching
points B| and B!).
The control pendant includes an override button for checking the emergency limit
switch (S260).
If the operational limit switch fails, the hoist can only leave the end position by
activating this override button.
6.6.2 Safety notes
The limit switch is constructed according to the state of the art and is safe in operation.
However dangers may arise if it is used incorrectly and not for its intended purpose.
6.6.3 Testing emergency hoist limit switch
Test at fast and creep speed without load.
1 Activate the "up" button on the control pendant carefully, observing the hoisting
motion, until the limit switch disconnects in top hook position (A|).
2 Minimum clearance "a" between bottom hook block and nearest obstacle, see
table, if necessary reset the limit switch, see page 24.
3 Press the "down" button and check bottom hook position in the same way.
4 Minimum clearance between rope guide (S) and clamping claws (K) for rope
anchorage = 20 mm, see sketch, if necessary reset limit switch, see page 24.
6.6.4 Testing combined operational and emergency hoist limit switch
1 Activate the "up" button on the control pendant carefully, observing the hoisting motion,
until the limit switch disconnects in the highest operational hook position (B|).
2 Press the override button in the control and at the sametime the "up" button until
the emergency limit switch disconnects (A|). If the hoist does not continue to
move, the emergency limit switch was activated in step 1 and the operational limit
switch is not working. (As an option, the override button is also possible in the con-
trol pendant.)
3 Minimum clearance "a" see table.
4 Press "down" button and check bottom hook position in the same way.
anchorage = 20 mm, see sketch, if this is not the case, reset limit switch.
The clearances between the switching points for operational and emergency limit
switches are set for normal operating conditions, however they can be adjusted if
necessary.
a [mm]
50 Hz 60 Hz
130 150
70 80
40 50
*1 Effective hook path with operational limit switch
*2 Option
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6.6.5 Adjusting limit switch
The cover of the limit switch must be removed to set the contacts. This exposes live
contact connections. There is thus a danger of contact with live parts!
The limit switch can be adjusted at the setscrews (S1)-(S2) or (S1)-(S4):
Turning to the left: switching point is moved "downwards",
Turning to the right: switching point is moved "upwards".
Adjusting en bloc
All the cam discs can be moved together with the aid of the black setscrew (S0). The
settings of the individual contacts relative to one another remain unchanged.
Set the limit switch using a socket spanner (04 430 50 99 0) and without using
excessive force. Do not use a power screwdriver or similar.
Adjust the switching points in the following sequence:
Emergency limit switch:
1. A| (S2)
2. A! (S1)
Combined emergency and operational limit switch
1. A| (S2)
2. B| (S4)
3. A! (S1)
4. B! (S3)
Switching point A| (S2)
"Emergency limit switch top hook position"
Lift bottom hook block 2/1 to a+10 mm or to a+5 mm for 4/1 (sketch, table).
If necessary turn setscrew (S2) to the right beforehand.
Turn setscrew (S2) to the left until contact S2 switches audibly.
Check cut-off point in main and creep hoist
Switching point B| (S4)
"Operational limit switch top hook position"
(Minimum clearance to A| 60 mm for 2/1, 40 mm for 4/1)
Lift bottom hook block 2/1 to 10 mm, or to 5 mm for 4/1, below the desired cut-off
point, if necessary turn setscrew (S4) to the right beforehand.
Check cut-off point in main and creep hoist.
a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1
8/2-1
40 50
6/1
8/1
40 50
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6.6.5 Setting limit switch (continued)
Switching point A! (S1)
"Emergency limit switch bottom hook position"
(Minimum clearance between rope guide (S) and clamping claws (K) for rope
anchorage = 20 mm, see sketch)
Set bottom hook position so that the bottom hook block does not touch the ground
(would cause slack rope).
Lower bottom hook block 2/1 to 120 mm, or 60 mm for 4/1, above desired hook
position, if necessary turn setscrew (S1) to the left beforehand.
Turn setscrew (S1) to the right until contact S1 switches audibly.
Switching point B! (S3)
"Operational limit switch bottom hook position"
Lower bottom hook block 2/1 to 120 mm, or 60 mm for 4/1, above desired hook posi-
tion, if necessary turn setscrew (S3) to the left beforehand
Turn setscrew (S3) to the right until contact S3 switches audibly
.
6.6.6 Servicing limit switch
Maintenance work is restricted to checking the cut-off points. No maintenance or
inspection is necessary for the gear limit switch itself.
Any dust deposits that may be visible when the housing is opened must on no
account be removed with compressed air as this would force the dust into the
contacts and impair the switching function.
On no account must benzene or other solvents be used to clean the limit switch!
a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1
82-1
40 50
6/1
8/1
40 50
Safety note:
Incorrectly set limit switches may cause serious accidents!
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6.7 Hoist limit switch (standard crane)
disconnecting in top and bottom hook position. (Switching points A| and A!).
The hoist is also equipped with an operational and emergency limit switch for
disconnecting in top hook position during normal operation. (Switching points B| and
B||). Switching point B|| disconnects the fast speed and B| the slow speed in
upwards direction.
If the operational limit switch (B|, B||) is overrun during a fault, the emergency hoist
limit switch (A|) disconnects the main contactor / hoist contactor. The hoist can only
leave the end position by activating switch S261 in the hoist control after the fault has
been eliminated.
The gear limit switch (GE-S) is in the panel box on the gear.
6.7.2 Safety notes
The limit switch is constructed according to the state of the art and is safe in operation.
However dangers may arise if it is used incorrectly and not for its intended purpose.
Test at creep speed without load.
motion, until the limit switch disconnects in the highest operational hook position
(B|).
2 Press the override button (S260) in the control and at the same time the "up" button
until the emergency limit switch disconnects (A|). If the hoist does not continue to
switch is not working.
3 Minimum clearance "a" - "c" between bottom hook block and nearest obstacle, see
table, if necessary reset limit switch, see page 27.
4 Press the override button (S261) in the control panel and at the same time the
"down" button to leave the limit switch area.
5 Press the "down" button until the emergency hoist limit switch disconnects (A!).
necessary.
6.7.4 Testing operational hoist limit switch
Test without load.
(B|).
2 Minimum clearance between bottom hook block and nearest obstacle, see table, if
necessary reset limit switch, see page 27.
a/b [mm] c
[mm] 50 Hz 60 Hz
130 150 40
70 80 20
40 50 10
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6.7.5 Setting limit switch
Adjusting en bloc
1. A| (S1)
2. B| (S3)
3. B|| (S4)
4. A! (S2)
Lift bottom hook block to "a" - "c", (sketch, table). If necessary turn setscrew (S1) to
the right beforehand.
Press override button (S261) in panel box and at the same time "down" button to
leave the limit switch area.
Switching point B|/B|| (S3/S4)
Lift bottom hook block 2/1 to a+10 mm, or to a+5 mm for 4/1, if necessary turn
setscrew (S1) to the right beforehand.
Turn setscrew (S3) to the left until contact S3 switches audibly
Lower and lift bottom hook block until B| (S3) is activated.
Lower bottom hook block by b (sketch, table).
Turn setscrew S4 to the left until contact S4 switches audibly.
(Minimum clearance between rope guide (S) and clamping claws (K) for rope attach-
ment = 20 mm, see sketch)
(would cause slack rope)
Lower bottom hook block to desired hook position, if necessary turn setscrew (S2)
to the left beforehand.
a/b [mm] c
[mm] 50 Hz 60 Hz
130 150 40
70 80 20
40 50 10
Safety note:
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6.8 Overload cut-off
The SLE21 / Multicontroller SMC21 load monitor with its electronic sensor is set in
the factory. Corrections are only permitted in special cases, see page 41.
The factory settings are shown under the front cover of the SLE 21 load monitor
(sketch).
6.8.2 Testing overload cut-off
If an overload is detected, the wire rope hoist is switched off in the upwards
direction. Only lowering is then possible. Lifting is not possible until the wire rope
hoist has been unloaded.
Attach rated load +10% overload and take load up slowly. After the rope has been
tautened the overload cut-off must disconnect the hoist.
6.8.3 Sensor of overload cut-off
The sensor measures the axial force in the hoist gear and is maintenance-free.
The setting may only be altered if the factory setting (4 mA without load) has
changed.
Measure current in "green" lead (at terminal 21). Disconnect lead and measure cur-
rent. A current of 40.3 mA must flow without load.
Closed-circuit current >4mA
Turn adjusting spindle (S) clockwise
Closed-circuit current <4mA
Turn adjusting spindle (S) anti-clockwise
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6.9 Crane test
SLE21 / SMC21
1. Carefully remove front cover of SLE21 / SMC21.
2. The cut-off point is increased by pressing button (S5) permitting the test load of
125% to be lifted.
The device automatically returns to the original cut-off point after 45 minutes.
I I I I I I pw r er r
Button (S5) pressed.
Cut-off threshhold is raised.
Safety note:
Extremely heavy loads can be lifted.
Risk of accident!
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6.10Rope drive
6.10.1Rope and rope attachment - general information
After commissioning a new wire rope hoist, or after replacing the rope, the rope of
multi-fall hoists may twist.
This can be seen from the bottom hook block turning, particularly when unloaded.
Twisting in the rope prejudices safety and service life.
Remove any twists!
Regularly inspect the rope for twisting. To do so, run the hoist into highest and
lowest hook positions without load.
If any twisting is detected, untwist the rope immediately. See page 14, "Reeving
rope" and see page 33, "Removing rope".
Check rope. Take particular note of the sections of rope near rope pulleys, return
pulleys or equalizing pulleys and in the region of the rope anchorage.
If any of the following damage occurs, replace the rope immediately.
1. Excess visible wire fractures, see page 32, table.
The rope must be free of load for testing to facilite detecting any broken wires
when bending the rope by hand (approximately by radius of rope sheave).
2. Nest of wire fractures or broken strand.
3. Diameter reduced by 10% due to corrosion or wear (independent of breakage).
4. Diameter reduced due to structural changes over considerable sections.
5. Formation of baskets or loops, knots, necking, kinks or other mechanical damage.
6. Corkscrew-type deformation. Divergence due to deformation: > 1/3x rope diameter.
7. In addition, the rope must be replaced as required by DIN 15020, FEM 9.661 and
ISO 4309.
8. In certain applications (e.g. twist-free wire rope, constant deadweight, recurrent
stopping position, automatic operation etc.) wire fractures may occur inside the
rope without being visible from outside.
Risk of accident!
In case of doubt please contact the manufacturer.
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6.10.2 Broken wires necessitating replacement of wire rope
Twist-free wire rope
Non-twist-free wire rope
* See data sheet for rope make-up
6.10.3 Removing rope guide
Unscrew stop (a) of rope guide.
Unscrew screws (d).
Remove half-rings.
Unhook rope tensioning spring.
Rope diameter [mm] 20 25
Number of external strands 18
Rope make-up * 36X7+SE
Broken wires visible 1Bm, 1Am
(FEM 9.661) 2m - 4m
6
11
over a length of [mm] 120
or
(FEM 9.661) 2m - 4m
11
22
over a length of [mm] 600
Rope diameter [mm] 20 25
Number of external strands 9 8
Rope make-up * 6x35+7FE 8x36W
(FEM 9.661) 2m - 4m
9
18
12
24
over a length of [mm] 120 150
or
(FEM 9.661) 2m - 4m
18
35
24
48
over a length of [mm] 600 750
a
d
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6.10.4 Replacing wire rope
AS7 wire rope hoists have a special rope which is the optimum for the most common
applications. The substitute rope must be equivalent to the original in terms of
quality, strength and make-up. Please consult the works certificate or the rope
certificate to see which rope is fitted.
In the case of 2 wire ropes with different lays
wire rope with right-hand lay (DS1) on rope drum with left-hand groove
wire rope with left-hand lay (DS2) on rope drum with rigth-hand groove

The direction of lay of the wire ropes makes a V-pattern (see sketch).
Removing rope
Lower bottom hook block to just above the lowest hook position and set it down on
a firm support.
Release end of wire rope in rope anchorage (rope clamp with rope wedge).
Run the remaining rope off the drum.
Unscrew the fixing screws in the clamping plates on the rope drum.
Fitting rope
Unroll new rope out straight if possible, without twists, kinks or loops. Protect rope
from dirt.
Attach rope to rope drum with all the clamping plates (do not forget the lock
washers!) Allow the rope end to project by approx. 30-40 mm.
Tightly wind about 5-10 turns onto the drum under power. Let the rope run through
a greased rag. Type of grease see page 45.
Fit rope guide, see page 33 "Fitting rope guide".
Reeve the loose end of the rope according to the number of falls, fasten with the
rope wedge and secure with a rope clamp, see page 14 "Reeving rope".
Retighten clamping plates. Tightening torques see table.
Caution! Risk of accident!
After fitting a new rope, or shortening the old one, reset the hoist limit switch. See
page 24, 27, "Setting emergency hoist limit switch".
If the new rope twists after some time in operation, untwist the rope immediately.
See page 14, "Reeving rope" and "Removing rope".
M..
Nm
M16
M20
210
410
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6.10.5 Fitting rope guide
Grease thread and groove in rope guide thoroughly.
Push the half-ring with the threaded holes onto the drum (1).
Block half-ring against the supporting frame with a wooden wedge (2).
Push the spring into the guide groove of the half-ring (3) and hook the ends of the
spring together. (Use special tool (a), see sketch).
Push the half-ring with the rope exit slot onto the drum so that the first empty
groove of the drum engages the corresponding thread of the half-ring (4).
Screw half-rings together with compression springs and bolts (5).
The rope guide must rest lightly on the drum and be able to be turned by hand. If
this is not the case, the guide has been fitted incorrectly or the rope drum is
damaged.
Screw down stop to prevent it turning and grease (6).
1
2
3 4
5 6
!
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6.10.6 Inspection and maintenance of rope sheave
Check rope sheaves for wear. We recommend having them checked by personnel
trained by us. They should also be checked for easy running, indicating that the
ball bearings are in good condition.
Wear on rope sheave
Notes on limits for wear
The rope sheave must be replaced if the wall thickness as measured is < t min or the
groove depth as measured is > h max. Furthermore, the rope sheave must be
replaced when replacing the wire rope if the rope strands have dug into the base of
the groove. Impressions of single wires are acceptable.
A rope sheave must also be replaced if the radius of the base of the groove R has
become too small for the new rope due to reduction in diameter of the old rope or
wear.
N.B.
The negative profile of the rope in the base of the groove may provide optimum
contact to the wire rope currently fitted.
Rope sheaves should be rotated without load on the rope to check the easy and
concentric running of the bearings.
Bottom hook blocks
The bottom hook block must be checked for damage. Deformations, cracks and cuts
caused by impact must be assessed.
The damage can only be assessed by trained maintenance personnel.
6.10.7 Checking load hook
y
neu
see hook certificate
y
zul
= s 1,1 x y
neu
If value h
min
and/or y
zul
are reached replace hook
Rope sheave
Part no. D new t min h max h new
25 330 00 53 0 375 6,5 37,5 34
25 330 03 53 0 375 6,5 36 32,5
46 330 00 53 0 400 7 33,5 30
26 330 01 53 0 450 10 39 35
09 430 00 53 0 450 10 39 35
46 330 01 53 0 480 10 36,5 32,5
on one side
and at base
on both sides
and at base
on both sides
and at base
Measuring depth of
base of groove with
depth gauge
Measuring thickness of wall
with special caliper gauge
RSN,
RS, RF
5 10 20 32 40 10 20 32 40
[mm]
h 75 106 150 190 212 95 132 170 190
h
min.
71,25 100,7 142,1 180,1 200,8 90 125,1 161,1 180,0
h
y y
h
y
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6.11Crab
Wheels, wheel drive and runway
Visual inspection of wheels for wear. See tables for limits for wear.
Visual inspection of runway girder for wear.
Visual inspection of wheel flanges for wear.
A high degree of wear on the flanges indicates that the trolley cants or is running
with its weight heavily on one side. The causes of this must be ascertained and
eliminated. The running characteristics can be improved by using a guide system.
This avoids abrasion and the play of the track gauge can be reduced.
If any one of the limits for wear d1, b2 (b*-k) is attained, the part must be replaced.
( ) for machined facesr
Inspection of lower flange on cranes with sectional gider
The running surface of the trolley wheels must be checked for uneven wear and
the causes of any such wear ascertained. Driven wheels must not display any
slippage to the running surface which would cause increased abrasion and
temperature rise.
Inspection of rails on cranes and crane runways
The rails must be laid parallel within the permissible tolerances (see page 9) to
prevent the crab or crane jamming. Rail joints must provide a smooth surface to
avoid impact and deformation.
Inspection of buffer and buffer stop.
Ensure that the buffer impact is taken up by the centre of the stop elements
provided and that the materials exhibit no detrimental characteristics, see page 9.
Bild 1
Bild 2
bLR
W0903
Nominal value Limit for wear
Fig. d bLR b k b1 d1 b2 Max. play =b*-k
min max kmin kmax
[mm]
2 200 100
100
100
54
64
74
40
50
60
45
55
65
23
18
13
190 10,5
10,5
10,5
18
18
18
18
18
14
2 315 115
115
115
54
64
74
40
50
60
45
55
65
30,5 (29)
25,5 (24)
20,5 (19)
300 13,5
13,5
13,5
18
18
18
18
18
18
2 400 118,5
118,5
118,5
65
75
85
50
60
70
55
65
75
27,5 (26)
22,5 (21)
17,5 (16)
385 16
16
16
20
20
16,5
20
20
11,5
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6.12 Gear
The gearing of AS hoists is hardened, hard-machined and has a high safety factor.
With their minimum classification of 1Bm or 1Am to FEM 9.511 the gears have a long
service life. All bearing points have roller bearings.
Oil level
When the wire rope hoist is horizontal the oil level should reach the inspection plug.
(The oil level inspection plug is marked in red.)
See page 40 for type and quantity of oil.
Dispose of used oil correctly to protect the environment.
a = Oil drainage plug
b = Oil inspection plug
c = Oil filling plug
6.13 Remaining service life
According to FEM 9.755, the operating mode and operating time must be established
by the user and recorded in the test log book in order to calculate the remaining
service life. After the service life has expired a general overhaul (S.W.P.) *1 must be
carried out.
Wire rope hoists are equipped ex factory with a suitable registration device.
6.13.1 Operating hours counter in SLE21 load monitor
The operating hours counter in the load monitor of the overload cut-off adds up the
operating time of the hoist. In order to obtain the lifetime expired in full load hours,
the operating hours must be calculated with load factor "k".
This is carried out by qualified personnel, see page 2, during the annual "periodic
test".
If 90% of the theoretical full load lifetime has expired, a general overhaul (GO) must
be scheduled and carried out at the earliest possible date.
6.13.2 STAHL SMC21 Multicontroller (optional)
The operating time of the hoist and the full load operating hours are recorded in the
SMC21. The SMC21 calculates the full load operating hours from the relevant hoisted
load and the operating hours of the hoist.
The remaining service life is calculated with reference to the mechanism group and
can be read off by means of a PC (laptop).
If the theoretical full load lifetime has expired, this is also indicated by an illuminated
red LCD, a general overhaul must be scheduled and carried out.
Note:
Reading the full load operating hours does not replace the prescribed tests including
inspecting the wearing parts (rope, return sheaves...)
c
c
b
a
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6.14 General overhaul
The mechanism (motor and gear; not applicable to wearing parts) of the AS 7.. wire
rope hoist is classified according to FEM 9.511. The theoretical full load lifetime in
hours shown opposite (D) is applicable for normal hoist applications.
If the full load lifetime (D) minus the lifetime expired is nought, the wire rope hoist
must be overhauled by the manufacturer.
The rope drive is classified according to FEM 9.611.
Components which are in the power flux may only be overhauled by the
manufacturer.
As the service life of components such as gears is limited in accordance with the
classification, it must be ensured that this is not exceeded. After the scheduled
service life has expired hazards may arise. Thus the operator must take responsibility
for the remaining service life and the necessity of a general overhaul. We cannot
accept any liability for damage occasioned by non-observance.
FEM9.511 1Bm 1Am 2m 3m 4m
D [h] 400 800 1600 3200 6400
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7 Fault-finding
7.1 What is to be done if?
7.1.1 Wire rope hoist does not start, motor hums
Not all power phases are present.
1. Check fuses,
2. Check supply cable,
3. Check control pendant and switchgear.
7.1.2 Wire rope hoist does not start after a long stoppage, or starts with difficulty,
motor hums
Hoist brake is stuck.
1. Remove fan cover
2. Dismantle brake
7.1.3 Loud clicking when switching on
Measure air gap, see page 21.
Replace brake disc if necessary, see page 21.
7.1.4 Braking path too long
Brake displacement too long.
Brake lining worn.
Replace brake disc, see page 21, "Hoist motor brake",
7.1.5 Bottom hook block and rope rotate
Rope is twisted.
Untwist rope, see page 33, "Replacing rope".
7.1.6 Cross travel not possible
Hoist is in highest hook position, cross travel is disconnected.
Lower bottom hook block until up motion is possible again
7.1.7 Lowering not possible
Hoist is in bottom hook position
Operational or emergency hoist limit switch is faulty
Check hoist limit switch
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7 Fault-finding
7.1 What is to be done if? (continued)
7.1.8 Load is not lifted
SLE21 load monitor / SMC21 Multicontroller has been actuated or is faulty.
1. Check setting, see page 29.
2. Actions for SLE21 / SMC21
LED I...III "on" and LED err => error.
Actions to eliminate an error may only be performed by trained personnel.
Error specification - Sensor current <1 mA or > 24 mA
Elimination of error - Check voltage supply
- Check sensor current (terminal 21)
- Check sensor cable
- Replace sensor
Error specification - Overload
Elimination of error - Remove load from hoist
Error specification - Overtemperature (hoisting motion not possible)
Elimination of error - Allow motor to cool down - check PTC thermistors
Error specification - Control error
Elimination of error - Check wiring
(lifting terminal 3 and lowering terminal 4 are activated
simultaneously)
Error specification - System error
Elimination of error - Check voltage (terminal 6)
- Switch SLE21 / SMC21 off/on
- Replace SLE21/SMC21
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7 Fault-finding
7.1.9 Correction of cut-off threshhold for SLE21 with electronic sensor
Corrections to the cut-off threshhold may be carried out by trained personnel only.
The load monitor will only accept alterations of -20% to +8% on the factory setting.
If these limits are exceeded, I and II flash.
- Rough adjustment with S4, ~16%/ switching position,
- Fine adjustment with S2,~1%/switching position,
see page 29.
Caution: Do not exceed 110% nominal load
7.1.10 Correction of cut-off threshhold for SMC21
A laptop and the Config Tool software is required for this.
W0795
S5
Permissible cut-off range exceeded or below target
-lower cut-off threshhold (S2/S4)
-raise cut-off threshhold (S2/S4)
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8 Technical data
8.1 FEM classification
Classification of mechanism, rope drive and motor acc. to FEM
8.2 Conditions of use
The hoist is designed for use in industry and for the ambient conditions usual in
industry.
Special measures must be taken for particular applications such as e.g. high degree
of chemical pollution, outdoor use, offshore application, etc.
The manufacturer will be pleased to advise you.
Protection against dust and moisture to EN 60 529
IP 54 (IP66)
Permissible ambient temperatures
AS: -20C ... +40C (option +60)
ASF: 0C ... +40C, max. humidity 85%, ensure freedom from dewing.
1/1 2/1
4/2-1
4/1 6/1 8/1
6300 12500 25000 40000 50000
8000 16000 32000 50000 63000
10000 20000 40000 63000 80000
12500 25000 50000 80000 100000
FEM
1Bm 1Am 2m 3m
AS 7163-20
AS 7163-25
ASF 7163-20
ASF 7163-25
AS 7080-16
AS 7080-20
AS 7080-25
ASF 7080-16
ASF 7080-25
AS 7100-12
AS 7100-16
AS 7100-20
ASF 7100-12
ASF 7100-20
AS 7125-10
AS 7125-12
AS 7125-16
ASF 7125-10
ASF 7125-12
ASF 7125-16
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8 Technical data
8.3 Hoist
8.3.1 Hoist motor data, pole-changing
The motors are designed for rated voltage ranges.
In accordance with EN 60034 a voltage tolerance of 5% and a frequency tolerance
of 2% apply on top of the rated voltage ranges.
The maximum current occurring in the rated voltage range is given.
Motor currents and main fuses 440...480 V, 60 Hz = 380...415 V, 50 Hz
550...600 V, 60 Hz = 480...525 V, 50 Hz
Hoist
type
Motor 50 Hz Main fuse
Type
kW %DC c/h 220...240V 380...415V 480...525V cos
phi N
220...
240V
380...
415V
480...
525V
In [A] Ik[A] In [A] Ik[A] In [A] Ik[A] [A]
AS 7063-20
AS 7080-16
AS 7100-12
AS 7125-10
12/2H73
*1)
3,8/24 20/40 240/120 37/83 77/423 22/48 44/243 17,2/38 35/194 0.49/0,63 125 80 63
AS 7063-25
AS 7080-20
AS 7080-25
AS 7100-16
AS 7100-20
AS 7125-12
AS 7125-13
24/4H92
*1
4,6/30
4,6/30
5,6/38
4,6/30
5,6/38
4,6/30
5,6/38
20/50
20/50
20/30
20/50
20/30
20/50
20/30
240/120
240/120
120/60
240/120
120/60
240/120
120/60
*3 45/64
45/64
45/73
45/64
45/73
45/64
45/73
66/471 36/51
36/51
36/58
36/51
36/58
36/51
36/58
53/377 0.51/0.63
-
100 80
ASF 7063-20
ASF 7080-16
ASF 7100-12
ASF 7125-10
4H73 24 40 81 111* 47 64* 36 63 .,98 100
(gL/gG)*2
100
(gR)
63
(gL/gG)*2
63
(gR)
63
(gL/gG)*2
63
(gR)
ASF 7063-25
ASF 7080-15
ASF 7100-20
ASF 7125-16
4H82 30
38
38
38
50
40
40
40
*3 64
75
75
75
98* 51
60
60
60
83* 0.98
-
100
(gL/gG)*2
100
(gR)
80
(gL/gG)*2
80
(gR)
Hoist
type
Motor 60 Hz Main fuse
Type
kW %DC c/h 220...240V 380...415V 480...525V cos
phi N
220...
240V
380...
415V
480...
525V
In [A] Ik[A] In [A] Ik[A] In [A] Ik[A] [A]
AS 7063-24
AS 7080-19
AS 7100-15
AS 7125-12
12/2H73
*1)
4,6/29 20/40 240/120 43/96 88/486 25/55 51/279 17,2/38 35/194 0.49/0.63 125 80 63
AS 7063-30
AS 7080-24
AS 7100-19
AS 7125-15
24/4H92
*1
5,5/36
4,6/30
5,6/38
4,6/30
20/50 240/120 *3 52/73 76/542 36/51 53/377 0.51/0.63
-
100 80
ASF 7063-24
ASF 7080-19
ASF 7100-15
ASF 7125-10
4H73 29 40
*3
47 64* 36 63 0.98
-
80
(gL/gG)*2
80
(gR)
63
(gL/gG)*2
63
(gR)
ASF 7063-30
ASF 7080-25
ASF 7100-20
ASF 7125-16
4H82 36
38
38
38
50
40
40
40
*3 74
75
75
75
98* 51
60
60
60
83* 0.98
-
100
(gL/gG)*2
80
(gR)
80
(gL/gG)*2
63
(gR)
01.08
* Max. current of frequency inverter
*1 Operation only with special starting and braking circuit via 12-pole winding
*2 Protection not 100% with gL/gG we recommend additional semiconductor fuses gR
*3 On request
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8 Technical data
8.4 Cable cross-section
and length of supply cable
S = Minimum cross-section
L1...L5 = Max. supply cable length of the individual types of power supply > sum of
voltage drops <5 %.
A loop impedance of max. 250 mO was taken as basis for coordinating the short
circuit protection of the power contactors and calculating the cable lengths.
The minimum cross-sections take into consideration the overload protection of the
cables corresponding to the types of cable and installation.
S
(550...600 V, 60 Hz)
= S
(480...525 V, 50 Hz)
L
(550...600 V, 60 Hz)
= L
(480...525 V, 50 Hz)
x 1.15
S
(440...460 V, 60 Hz)
= S
(380...415 V, 50 Hz)
L
(440...460 V, 60 Hz)
= L
(380...415 V, 50 Hz)
x 1.15
For larger cross-sections, the max. cable lengths are calculated as follows:
L* = L x S* / S
Type of hoist motor
Stationary
Fixed installation in PVC
conduit
Power supply to hoist
Trolley/crab
Bridge crane
conduit
Power supply to infeed
(rising mains)
Trolley/crab
Festoon cable in free air -
flexible rubber-sheathed
cable
along runway
Bridge crane
cable
along crane runway
Bridge crane
cable
along crane bridge
A U s 5% A U s 1% A U s 4% A U s1.5% A U s 2,.%
50 Hz
380...415 V 480...525 V 380...415 V 480...525 V 380...415 V 480...525 V 380...415 V 480...525 V 380...415 V 480...525 V
S L1 S L1 S L2 S L2 S L3 S L3 S L4 S L4 S L5 S L5
[mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m]
12/2 H73 16 69 10 67 16 14 10 13 10 30 10 47 16 14 10 14 16 34 10 33
24/4H92 25 55 16 55 50 22 35 24 25 39 16 39 35 16 25 19 25 27 16 27
4H73 on request
4H82 on request
60 Hz
440...480 V 440...480 V 440...480 V 440...480 V 440...480 V
S L1 S L2 S L3 S L4 S L5
[mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m]
12/2 H73 10 49 10 10 10 35 10 11 16 39
24/4H92 25 64 50 25 16 29 35 20 25 32
4H73 on request
4H82 on request
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8 Technical data
8.5 Tightening torques for screws
All screws should be tightened with a torque spanner.
See table for the torques generally applicable for screws grade 8.8.
8.6 Lubricants
Tightening torquest for screws grade 8.8
Thread M.. M6 M8 M10 M12 M16 M20 M24 M30 M36
Tightening torque [Nm] 10 25 51 87 215 430 730 1500 2600
W0769
W0743
Position of
lubrication point
Type of
lubricant
Designation Quantity Charakteristics, makes
a Hoist gear Oil
CLP 460
(PG 220)
AS 7..: 15000 ml 1
1 Viscosity: 460 /s/40C (220/s/40C), pour point: -20C (-40C)
flash point: +265C (+320C), e.g.: Fuchs Renolin CLP 460*, Aral Degol BG 460, BP
Energol GR-XP 460, Esso Spartan EP 460, Mobil Gear 634, Tribol 1100/460, (Shell
Tivela Oil WB)
2 Soap base: Lithium + MoS2, dripping point: approx. 185C
penetration: 310-340, operating temperature: -20to +120C
e.g.: Aralub PMD1*, BP Multi-purpose Grease L21M, Esso Multi-purpose
Grease M, Mobilith SHC 460, Shell Retinax AM, STABYL L-TS 1 Mo
3 Soap base: Synthetic (lithium), dripping point: approx 150C
penetration: 400-430 (400-430), operating temperature: -20to +80C (-35to
+130C), e.g.: Aralub FDP00, BP Energrease HT-00 EP, Esso Liquid Gear Grease,
Shell Special, Gear grease H*, Mobilux Liquid grease EP 004,
(Tivela Compound A)
b
Rope guide
Wire rope
Grease
GOOF
(GPGOOK)
2500 g 3
k Spline shaft Grease
CLP 460
(PG 220)
SA-C 67 ..: 3000 ml 1
l Travel gear Oil KPF1K SA-C 67 ..: 100 g 2
n
Wheel bearing
(only for 400)
Grease KPF1K 400: 50 g 2
() (Lubricants for low operating temperatures, -40 ... +40C)
* Factory filling
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8 Technical data
8.7 Sound pressure level
The sound pressure level was measured at a distance of 1 m from the wire rope
hoist. The mean sound pressure level is calculated for one operating cycle (50% with
nominal load, 50% without load).
Instead of stating an emission value based on a workplace, the values from table 1
and 2 at measuring distance "h" can be used.
1
2
8.8 Circuit diagrams
See separate enclosure.
Type [db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
AS 7... 77 74 71 68 65
Type
[db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
AS 7.... 77 71 65 59 53
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9 Wearing parts
9.1 Serial number
When ordering original spare parts, please always indicate the serial number of the
hoist.
9.2 Hoist
Hoist brake
Rope guide
Wire rope (E)
See works certificate or rope certificate for length and number of rope.
Replacement and repairs may only be carried out by qualified personnel.
Hoist type Hoist
motor
Hoist
brake
A
Order No.
AS 7. 12/2H73
24/4H92
4H73
4H82
M150
M500
M150
M225
22 Nm
22 Nm
22 Nm
22 Nm
04 430 67 65 0
05 430 10 65 0
04 430 92 65 0
05 430 00 65 0
Hoist type B C D
Order No. Order No. Order No.
AS 7. 47 330 00 43 0 46 330 08 43 0 46 330 00 43 0
05.08
Vertriebspartner
Tochtergesellschaft
Subsidiary
Sales partner
F
-
B
A
-
2
.
1
-
E
N
-
1
0
.
0
8
-
m
p
STAHL CraneSystems GmbH, Daimlerstr. 6, 74653 Knzelsau, Germany
Tel +49 7940 128-0, Fax +49 7940 55665, marketing@stahlcranes.com
Tochtergesellschaft/Subsidiary
Austria
Steyregg
Tel +43 732 641111-0
Fax +43 732 641111-33
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Vertriebspartner/Sales partner

SDN BHD
9.2 SH HOIST O & M
Wire Rope Hoists
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This wire rope hoist has been constructed in compliance with the applicable
Inspect hoist for damage caused in transit immediately upon delivery.
Do not install or commission a damaged hoist!
- Assembly
- installation
- commissioning
- tests
- maintenance and elimination of faults
Terms employed
User
Whoever uses and employs the wire rope hoist or has it operated by suitable trained
personnel is considered to be the user (employer/company).
Trained personnel
Skilled electrician
instructions.
The person must be in a position to assess the safety of the installation in
conjunction with the application. Persons with the authority to undertake certain
maintenance work on our products include service engineers of manufacturer and
trained fitters with the corresponding certification.
Seminars:
Ask for our seminar programme you will find information on it on the last page.
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Contents
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1.1 Symbols ........................................................................................................................... 4
1.2 Operating instructions .................................................................................................. 4
1.3 Use for intended purpose............................................................................................. 5
1.4 Safety-conscious operation......................................................................................... 5
1.5 Organisational safety precautions.............................................................................. 5
1.6 General regulations....................................................................................................... 6
1.7 Installation, commissioning, maintenance and repairs .......................................... 6
1.8 Warranty.......................................................................................................................... 6
1.9 Periodic tests.................................................................................................................. 6
1.10 After sales service......................................................................................................... 6
..................................................................................................................................................... 7
3 Installation
3.1 Stationary wire rope hoist ............................................................................................ 8
3.2 Fleet angles..................................................................................................................... 9
3.3 Trolleys/crabs ............................................................................................................... 11
3.3.1 KE-S monorail trolley................................................................................................... 11
3.3.2 UE-S4 monorail trolley ................................................................................................ 13
3.3.3 UE-S776 monorail trolley ............................................................................................ 14
3.4 DKE-S articulated trolley ............................................................................................ 16
3.5 Double rail crab............................................................................................................ 19
3.6 Travel limit switches.................................................................................................... 20
3.7 Electrical equipment ................................................................................................... 21
3.8 Hoists with frequency converter............................................................................... 23
3.9 Reeving rope................................................................................................................. 24
4 Commissioning
4.1 Commissioning ............................................................................................................. 29
5 Operation
5.1 Duties of crane operator ............................................................................................ 30
5.2 Operating control pendant ......................................................................................... 31
5.3 Emergency stop ........................................................................................................... 31
................................................................................................................................................... 32
6.1 Inspection intervals..................................................................................................... 32
6.2 Maintenance intervals................................................................................................ 33
6.3 RSM hoist motor brake ............................................................................................... 34
6.5 NM hoist motor brake ................................................................................................. 35
6.7 Hoist limit switch versions ......................................................................................... 37
6.8 Hoist limit switch on standard crane - version I..................................................... 38
6.9 Hoist limit switch on standard crane - version II ................................................... 41
6.10 Hoist limit switch on radio-controlled crane - version III ..................................... 44
6.11 Overload cut-off ........................................................................................................... 48
6.12 Crane test ...................................................................................................................... 49
6.13 Rope drive ..................................................................................................................... 50
6.14 Trolley/crab................................................................................................................... 55
6.15 Remaining service life................................................................................................. 56
6.16 General overhaul ......................................................................................................... 56
7 Fault-finding
7.1 What is to be done if? ................................................................................................. 57
8 Technical data
8.1 FEM classification ....................................................................................................... 60
8.2 Conditions of use ......................................................................................................... 60
8.3 Hoist ............................................................................................................................... 61
8.4 Cable cross sections and lengths of supply cables............................................... 67
8.5 Tightening torques for screws................................................................................... 68
8.6 Lubricants...................................................................................................................... 69
8.7 Lubricants for travel drive .......................................................................................... 69
8.8 Sound pressure level .................................................................................................. 70
8.9 Circuit diagrams........................................................................................................... 70
9 Wearing parts
9.1 Serial number ............................................................................................................... 71
9.2 Hoist ............................................................................................................................... 71
Subject to technical alterations; errors and printing errors excepted.
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1.1 Symbols
Transport
The wire rope hoist is delivered on a special pallet. This enables the hoist to be
loaded and unloaded safely with a fork-lift truck. If the wire rope hoist is to be
transported suspended, it must be attached by the suspension lugs provided, see
sketch.
Safety at work
entailed.
and limb!
Safety in operation
Information marked with this symbol must be observed to avoid damage to the wire
rope hoist or the goods transported.
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Wire rope hoists are intended for lifting freely movable and guided loads that
cannot tilt. Depending on their design, they are for stationary or mobile use. If
loads are to be towed horizontally, or in the case of guided loads, automatic opera-
tion, continual deadweight or constantly repeated hoisting motions, the individual
application must be assessed. Please contact the manufacturer in case of doubt.
Any fundamental alterations and modifications to the wire rope hoist, such as e.g
welding on load-bearing components, structural alterations to load-bearing com-
ponents, alteration of drives, alteration of speeds and motor outputs, replacing
trolleys, etc. must be authorised by the manufacturer, otherwise the declaration of
conformity will be invalidated.
Also any work on or additions to the control must be authorised by the manufactu-
rer. The manufacturer cannot accept any liability for malfunctioning after unautho-
rised work on the control.
Not permitted:
Exceeding the safe working load
Transporting persons
Pulling loads at an angle
Pulling loads loose
Pulling or towing loads if the wire rope hoist has not been especially designed for
this application.
Manipulating the overload cut-off, apart from corrections as described on page 59.
Operating the hoist with slack rope.
If the hoist forms "part of a machine," the person placing it on the market must
ensure that the hoist meets the specific regulations of the application
SH wire rope hoists are constructed according to the state of the art and equipped
with an overload cut-off. In spite of this, dangers may arise from incorrect use or use
for an unintended purpose.
The user is responsible for ensuring that work is carried out with safety in mind
and avoiding risks, see page 2.
Read the operating instructions before starting to work with the wire rope hoist.
Do not lift any loads heavier than the rated load.
Standing under a suspended load is forbidden. Danger to life and limb!
Observe the "Duties of crane operator", see page 30.
Do not put your hand between edges which might pinch or cut.
Do not use the emergency limit switch (ultimate limit switch for highest and lowest
hook position) as an operational limit switch.
Report damage and defects to the wire rope hoist (abnormal noises, impaired
braking function, deformations, ...) to the person responsible immediately. Do not
use the wire rope hoist until the faults have been eliminated.
Do not remove information plates from the wire rope hoist. Replace illegible or
damaged plates.
Have hoist inspected by the relevant authority before commissioning.
Only direct persons to operate the hoist if they have been trained or instructed in
its use. Observe the legal minimum age!
manner.
book.
Store the operating instructions within easy reach where the wire rope hoist is
operated.
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Installation, commissioning, maintenance and repairs may be carried out by quali-
fied persons only, see page 2.
We recommend having installation carried out by personnel engaged by the
manufacturer.
Do not carry out any alterations or modifications.
Additional fitments must be approved by the manufacturer.
(During welding work, electrode and ground must be in contact with the same
component!)
Use only original spare parts for repairs.
If the wire rope hoist is constantly operated out of doors and exposed to the
elements without protection, we recommend fitting a small roof or at least "parking"
the hoist under a roof.
1.8 Warranty
The warranty will become invalid if these operating instructions are not observed
The warranty will become invalid if the hoist is modified or original spare parts not
used.
1.9 Periodic tests
Hoists and cranes must be inspected by a qualified person see page 2 at least once
a year. The results of the test must be recorded and filed in the test log book.
The remaining service life of the hoist acc. to FEM 9.755 must also be established
during this inspection.
The periodic tests must be adapted to the hoists use. Intensive use entails shorter
maintenance intervals.
All tests must be initiated by the user, see page 2.
With the purchase of this wire rope hoist, you have decided on a high-quality piece
of lifting equipment. Our after sales service will give you advice on its correct use.
You will find information on our after sales service on the back cover.
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The modular concept of our series of wire rope hoists permits a multitude of
variations on the basis of series components.
Our certified quality assurance system to DIN ISO 9001/EN 29001 guarantees
consistently high quality.
If you have any questions, for example on hoists modified to customers specific
applications, please contact one of our branches or subsidiaries. We will be pleased
to advise you!
1 Panel box with connection parts
2 Gear limit switch
3 Gear
4 Mounting point for safety brake (SH4 - SH6)
5 Rope drum
6 Rope guide with rope tensioning spring
7 Clamps for rope attachment
8 Rope drum bearing
9 End cover
10 Motor
11 Brake
12 Fan
13 Fan cover
14 Stationary wire rope hoist, hoist for installation
15 Wire rope hoist with "short headroom" monorail trolley
16 Wire rope hoist with "standard headroom" monorail trolley
17 Wire rope hoist with "articulated" monorail trolley
18 Wire rope hoist with double rail crab
14
15
18
16 17
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3.1 Stationary wire rope hoist
Possible fixing positions and rope lead-off
Feet "at bottom," and "at top" are possible for designs with bottom hook block (rope
lead-off vertically downwards).
The SH wire rope hoist with 1/1 and 2/2 rope lead-off can be installed in various posi-
tions. The fleet angles possible can be seen from the sketches on pages 9 and 10.
If possible, install the hoist in the preferred installation position ***, see page 9.
Use the fixing elements specified, see sketches and tables.
Take care that no distortion arises from unevenness, etc.
(see sketch, max. 0.5, max. 2mm)
The customer's substructure must take up the torque M
T
from the rope drum. It
must therefore be torsion resistant.
If the rope lead-off is not vertical, the shearing forces arising must be taken up by a
support bar.
For tightening torques, see page 68
3.1.1 Feet at bottom
3.1.2 Feet at top
M
T
(Rope drum torque)
SH 3: M
T
= 0.5 x F x 126 mm
SH 4: M
T
= 0.5 x F x 167 mm
SH 5: M
T
= 0.5 x F x 219 mm
SH 6 : M
T
= 0.5 x F x 356 mm
Standard reevings
1/1 2/1 4/1 4/2-1 2/2-1 8/2-1
SH 3 SH 4 SH 5 SH6 / SHR6 SH 6
2/1, 4/1, 4/2-1 1/1
SH3 SH4 SH5 SH6 1/1
*1 Tractive force at rope drum
*2 Lock washer (Schnorr)
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3.2 Fleet angles
3.2.1 Feet at bottom
3.2.2 Feet at top
1/1, 2/2
SH 3 SH 4 SH5 SH6
o1 4 5 8 8
o2 23 13 20 18
o3 27 30 30 30
o4 74 73 76 80
o5 30 30 30 25
o6 113 103 110 108
o7 83 81 60 60
o8 11 12 18 20
o9 24 26 30 12
o10 7 7 8 8
o12 90 90 90 -
SH 3
SH 4
SH 5
SH 6
1/1, 2/2
SH 3 SH 4 SH 5 SH 6
o1 4 5 8 8
o2 23 13 20 18
o3 27 30 30 12
o4 74 73 76 80
o5 16 17 14 -
o6 34 32 36 -
o7 74 73 76 -
o12 90 90 90 8
o13 90 90 90 30
SH 3
SH 4
SH 5
SH 6
*** Preferred installation position

*1 Standard
*2 By turning rope guide
*4 By turning rope guide and grease pan; version G, H not possible for SH 6
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3.2.3 Fleet angles
The rope guide must be adjusted to the fleet angle. Observe also the radial rope exit
angle .
3.2.4 Angles of installation
Instal the wire rope hoist within the permissible range of angles. Hoists with rope
drives with bottom hook blocks must always be installed horizontal to their
longitudinal axis.
The max. permissible rope exit angle acc. to standard is 4 for non-twist-free wire
ropes, 1.5 for twist-free wire ropes. However even at these angles a reduction in
service life is to be expected.
The wire rope must not touch the rope guide or structural elements.
Type
SH 3 53
SH 4 60
SH 5 53
SH 6 53
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3.3 Trolleys/crabs
3.3.1Monorail trolley (KE-S33 - 76)
with SH 3, SH 4, SH 5, SHR 6, SH 6 wire rope hoists
Check flange width "B" and clearance "c" against table 1 and set trolley to beam
width if necessary.
Caution! If the flange width is altered (by customer), it may be necessary to alter
the counterweight to prevent the trolley canting. Please have it checked by our
after-sales service.
Installation if end of runway is freely accessible
Slide trolley onto end of runway and check play f/2.
Installation if end of runway is not accessible
Unscrew nuts (2) on threaded bolts (1) and slide trolley side cheek (3) outwards by
approx. "x" mm or until dimension "B+y" is reached (table 1).
Push hoist side of trolley onto lower flange of runway beam and secure against
slipping.
Push trolley side cheek (3) towards the runway beam on support bolt (4).
Adjust dimension "c" with nuts (2), tighten nuts (2).
Check track gauge "c" and play "f/2".
Tighten nuts (2) with torque spanner.
For tightening torques see table 1.
Drive shaft for travel drive (trolleys KE-S33 - KE-S65)
Fit drive shaft in mounting position X3 or X4 depending on flange width (B) of
runway beam and length (L) of drive shaft (D).
Fit circlips (S).
See sketch and table 2.
Table 1
Hoist
D
Trolley
c f/2 x y
mm INP IPE IPB " mm Nm
SH 3 80 KE-S33
B= 90...500
B+67*1 1.5 70 137 210
SH 4 100 KE-S44 B+67*1 1.5 80 147 210
SH 5 140 KE-S65 B= 119...500 B+67*1 1.5 95 162 210
SHR 6, SH 6 200 KE-S76 B= 124...500 B+92*1 1.5 95 187 210
Table 2
D
[mm]
B
[mm]
Drive shaft
L [mm] Position
80
100
90 - 145
390
X3 -
146 - 195 - X4
196 - 250
495
X3 -
251 - 306 - X4
301 - 350
595
X3 -
351 - 399 - X4
400 - 450
695
X3 -
451 - 500 - X4
140
119 - 145
505
X3 -
146 - 200 - X4
201 - 250
505
X3 -
251 - 305 - X4
330 - 400
710
X3 -
401 - 500 - X4
200
124 - 220 510
see page 12 221 - 400 740
401 - 500 780
Table 3
D
[mm]
L3 2
[mm]
L4 2
[mm]
80
100
96.4 46.4
140 124.6 46.4
*1 with INP beam: -2 mm
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Drive shaft for trolley drive (trolley KE-S76)
The drive shaft is suitable for girder flange widths "B" from 124 to s220, >221 to s400
and >401 to 500 mm; see table 2, page 11 for length "L".
Insert drive shaft (5) into the two drive pinions (6) from the counterweight side,
then assemble spacer tube (7) and adjusting ring (8).
Adjust drive shaft (5) so that on the hoist side the shaft end projects by between
"min. 0 mm" and "max. 120 mm" beyond the drive pinion (6) and on the
counterweight side the shaft end projects by between "min. 48 mm" and "max. 160
mm" beyond the trolley side cheek (10).
Lock adjusting ring (8) with adjusting screw so that on spacer tube (7) lying against
drive pinion (6) there is a play of approx. "3 mm" to adjusting ring (8).
After fitting travel drive, check drive shaft (5) for ease of movement.
For dimensions B, c, f/2, x and y see tables 1 and 2, page 11
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3.3.2Monorail trolley (UE-S4)
with SH 4, SH 5 1/1 wire rope hoists (single fall)
Check flange width "B" and clearance "c2" against the table and set trolley to
beam width if necessary. Ensure that the connection piece (square tube) (6) is in
the centre (of dimension "c") between the trolley side cheeks ("z1" = "z2").
After unscrewing nuts (3) together with nuts (2), adjust clearance "c2" and tighten
nuts (3).
Tighten nuts (3) with torque spanner. Tightening torques see table.
Clearance "c" results in a flange play of "f/2+1" on each side. If necessary, correct
flange play by means of clearance "c".
Loosen nuts (3) on threaded bolts (1) in the square tube of the trolley side cheeks
(4) and unscrew by dimension "x".
Push trolley side cheeks (4) apart in parallel up to the unscrewed nuts (3) until
dimension "B+y or c+x" is reached, and lift trolley onto runway from below.
Slide trolley onto the bottom flange of the runway beam on the axle keep plate side
(8) and secure against shifting.
Push trolley side cheeks (4) back to nuts (2), retighten nuts (3).
Check track gauge "c2" and play of guide rollers "f/2".
Tighten nuts (3) with torque spanner. Tightening torques see table.
Centering connection piece
Loosen nuts (5) and shift connection piece (6) on connecting bolt (7) so that dimen-
sions "z1" and "z2" between trolley side cheeks (4) and connection piece (6) are
equal on both sides.
Tighten nuts (5) with torque spanner. For tightening torques see table.
Connecting bolt and drive shaft
Use connecting bolt and drive shaft suitable for beam range "B".
(For dimensions, see sketch and table 2, page 11).
D
Trolley
c f/2 x y
100 UE-S4 B= 90...500 B+67*1 1.5 75 142 210
*1 for INP beam: -2 mm
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3.3.3Monorail trolley (UE-S776)
with SH 6, 4/1 wire rope hoists (four-fall)
Check flange width "B" and clearance "c2" against the table and set trolley to
beam width if necessary. Ensure that the connection piece (square tube) (6) is in
the centre (of dimension "c") between the trolley side cheeks ("z1" = "z2").
After unscrewing nuts (3) together with nuts (2), adjust clearance "c2" and tighten
nuts (3).
Do not distort plate (10)! Tighten nuts (5) lightly and then unscrew by a quarter turn.
Lock nuts 9 against nuts 5 with a torque spanner. See table for tightening torques.
Tighten nuts (3) with torque spanner. See table for tightening torques.
Clearance "c" results in a flange play of "f/2+1" on each side. If necessary, correct
Slide trolley onto the bottom flange of the runway beam on the axle keep plate side
(8) and secure against shifting.
Check track gauge "c2" and play of guide rollers "f/2".
Tighten nuts (3) with torque spanner. For tightening torques, see table.
Centering connection piece
Loosen nuts (5) and shift connection piece (6) on connecting bolt (7) so that dimen-
sions "z1" and "z2" between trolley side cheeks (4) and connection piece (6) are
equal on both sides.
Tighten nuts (5) with torque spanner. For tightening torques see table.
Connecting bolt and drive shaft
Use connecting bolt and drive shaft suitable for beam range "B".
(For dimensions, see sketch on page 15).
D
Trolley
c f/2 x y
200 UE-S776 B= 185....500 B+92 1.5 95 187 210
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Drive shaft for trolley drive (trolley UE-S776)
The drive shaft is suitable for girder flange widths "B" from 185 to 500 mm, see table
for length "L".
Insert drive shaft (1) into the two drive pinions (6) from the counterweight side,
then assemble spacer tube (3) and adjusting ring (4).
Adjust drive shaft (1) to dimension L1, dimension L2 must lie between the values
given in the table.
Lock adjusting ring (4) with adjusting screw.
After fitting travel drive, check drive shaft (1) for ease of movement. The axial play
should be approx. 3 mm.
For dimensions f/2 see table on page 14
B
[mm]
L
[mm]
L1
[mm]
L2
[mm]
185 - 220 510 84 191 - 95
221 - 360 620 84 172 - 33
361 - 450 740 134 98 - 9
451 - 500 740 84 58 - 9
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3.4 Articulated trolley
(DKE-S4 / DKE-S6)
with SH 3, SH 4, SH 5 wire rope hoists
Check flange width "B" and clearance "c" against the table and set trolley to beam
width if necessary. Ensure that the connection piece (square tube) (6) is in the
centre (of dimension "c") between the trolley side cheeks ("z1" = "z2").
After unscrewing nuts (3) together with nuts (2), adjust clearance "c" and tighten
nuts (3).
See table for tightening torques.
Clearance "c" results in a flange play of "f/2" on each side. If necessary, correct
Slide trolley onto end of runway.
Lift trolley onto runway from below.
Slide trolley onto the bottom flange of the runway beam on the hoist side and
secure against shifting.
Check track gauge "c" and play of guide rollers "f/2".
See table for tightening torques.
Centering bogie
Loosen nuts (5) and shift bogie (6) on connecting bolt (7).
Dimension "z" between trolley side cheeks (4) and bogie (6) is equal on both sides.
For tightening torques see table.
Hoist D Trolley B f/2 c x y
Nut (3) Nut (5)
[mm] [mm] [Nm]
SH 3
SH 4
100 DKE-S 4 90 - 220 1.5 B+80 67 147 215 85
SH 5 140 DKE-S 6 119 - 300 1.5 B+84 75 159 215 85
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Drive shaft for travel drive (DKE-S4 / DKE-S6)
Trolleys with one travel drive
Mount a drive shaft of a length (L) suitable for the beam width (B)
Fit lockwashers (S) acc. to dimension L4
The mounting position of the drive shaft does not change over the corresponding
beam range (B).
Trolleys with two travel drives
Drive shaft is completely independent of the beam width
Mount lockwashers (S) acc. to sketch
D
[mm]
B
[mm]
Drive shaft
L
[mm]
L4 2
[mm]
100 90 - 128 390
46.4
129 - 220 495
140 119 - 280 495
281 - 300 710
W0904
D100 D 140
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End stops
Mount end stops with rubber buffers at end of runway.
Suggestion for solution by customer
*1 Incl. counterweight
*2 Travel speed V max.: 20 m/min.
*3 E = 0.1415 mka v
2
x (Nm) mka (t), v (m/min)
x = with travel limit switch: 0.72
x = without travel limit switch: 1.0
Type B
max
L
max
E max
*3 *1
D Order no.
mm mm kg Nm kg mm
PA 50/200 200 350
3200 200 700
63
80
100
01 740 24 27 0
PA 50/300 300 450 01 740 25 27 0
PA 50/500 500 650 01 740 26 27 0
PA 63/200 200 350
10000 440 3200
100
140
01 740 27 27 0
PA 63/300 300 450 01 740 28 27 0
PA 63/500 500 650 01 740 29 27 0
D b c d e f g
M..
*2
Order no.
mm
80 L80x80x10 30 34 9 32 34 40 M10,M12 577 985 0
100 L80x80x10 30 57,5 9 32 34 40 M10,M12 577 985 0
125 L80x80x10 30 68,5 11 32 42 50 M10,M12 577 971 0
160 L80x80x10 30 68,5 11 32 42 50 M10,M12 577 971 0
200
L80x80x10
L100x100x10
40
50
95
105
11
14
32
36
53
66
63
80
M10,M12
577 992 0
577 993 0
*4
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3.5 Double rail crab (OE-S )
Check track gauge Spw on crab and rail.
L1 max - L1 min = 5 mm, see sketch.
Check lateral play between rail and flange, see sketch.
Bolt rubber buffers to crab or runway end stop.
Fit suitable stops. For dimensions see sketch and table.
Remove transport anchor screw TS (only on crabs with wheel 125).
The runway must meet the requirements of DIN 4132.
The rail joints must be even on both running and guide surfaces; grind down if
necessary.
S as per table if crab is positioned symmetrically on runway. If asymmetrically,
S
left
+ S
right
= 2 x S
End stops
100
D S
100 2,5-5
125 2,5-5
160 3,5-6
200 4,5-7
Crane
125 - 200
Crane
D h
100 45
125 97
160 100
200 100
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3.6 Travel limit switch
3.6.1 Monorail trolley
The travel limit switches (optional) are mounted on the trolley.
3.6.2 Double rail crab
The travel limit switch assembly is supplied ready-wired but not mounted and must
be secured to the towing arm for the power supply.
The switching contacts are designed for control current.
Switching functions:
1. Limit switching in both directions of travel (1 two-way switch, 2 ramps).
2. Pre-switching and limit switching in both directions of travel (1 two-way switch, 4
ramps).
The speed is switched over from "fast" to "slow" before the end of the runway is
reached, and is cut off at the end of the runway.
X = stop, left
Y = stop, right
Z = fast / slow
Monorail trolley Double rail crab
Type
H C
[mm]
OE-S 04 77 795
OE-S 05 85 915
OE-S 06 87 915
OE-S 07 107 915
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For the sake of safety, have the wire rope hoist connected by a skilled electrician
(see page 2). Observe the relevant safety and accident prevention regulations!
3.7.1 Supply cables
As fixed installed cables:
NYY, NYM
As flexible cables:
H07RN-F or NGFLGu, or equivalent cables.
See page 67 for minimum cross-section and max. length of supply cable.
3.7.2 Terminals
Check that all terminals are firmly attached.
3.7.3 Fusing
NEOZED, DIAZED or NH fuses in operating class gL/gG, see page 61-66.
Observe the correct fuse sizes so that the crane switch contacts do not weld if
there is a short circuit and overload protection of lead is ensured!
3.7.4 EMERGENCY STOP
It must be possible to disconnect the system electrically from the operating position.
This function can be provided by:
EMERGENCY STOP button in the control pendant in conjunction with the crane
switch contactor,
main isolator, if this is directly accessible and positioned close to the operating
position.
3.7.5 Main isolator
must disconnect the wire rope hoist on all poles,
must be lockable in OFF position,
must be installed in an easily accessible place in the system,
must be marked as such to avoid mistakes.
3.7.6 Disconnecting switch
is necessary if more than one floor-operated hoist is supplied with power,
must be lockable in OFF position.
3.7.7 Electromagnetic compatibility
No particular protective measures are taken on electric wire rope hoists with control
by customer or crane manufacturers control. In order to comply with the require-
ments of EN 55014-1, suitable precautions must be taken by the customer.
In order to achieve an optimum result with minimum effort, we recommend using our
FEM1 radio interference suppression module for the SH wire rope hoist.
Order no. 578 525 0 s 415V.
Order no. 578 526 0 s 800V.
Clip the module onto the tophat rail and connect to the mains supply cable.
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3.7.8 Overload cut-off
Description of system
prevents an overload being lifted. If an overload has been established, the load can
only be lowered. The switch is set in the factory. Corrections are only permissible
in special cases, see page 59.
In certain applications, wire rope hoists may also be used without an overload cut-
off. However in this case they do not meet the requirements of the EU directives
and are not marked with the CE symbol.
Load measurement at rope anchorage
With LET electronic sensor
The overload cut-off is set to rated load +10%.
Load measurement at gear
With LEI electronic sensor
The overload cut-off is set to rated load +10% overload.
On stationary SH4 and SH5 wire rope hoists, remove the transport anchor screws
marked in red after installation and before commissioning.
W0788
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3.7.9 Connecting to mains
Compare existing mains voltage and frequency with the information on the rating
plate.
Route cables into the hoist connection box through the cable glands.
Connect according to the circuit diagrams supplied.
Measure control voltage. If the measured value exceeds the rated control voltage
by more than 10%, a different tapping point must be selected on the primary side of
the control transformer.
Check that the direction of rotation of the rope drum corresponds to the symbols
on the control pendant : Press "slow up" button on control pendant. Never press
"down" button first! If the hook moves upwards or does not move because the limit
switch has disconnected in top hook position, the phase connection is correct.
Crosscheck by pressing "slow down" button on control pendant.
If the movement of the hook does not correspond to the symbols on the control
pendant, interchange two phase conductors of the supply cable.
Caution! Risk of accident! If this is not observed, serious accidents or damage to
the hoist may occur!
Controls by others
If the controls are supplied by others, connect the temperature sensors of the hoist
motor, the hoist brake, the overload cut-off and the emergency hoist limit switch
according to our connection diagrams.
Construct the control according to the circuit diagrams supplied.
The declaration of conformity is valid only for the scope supplied by the manufac-
turer.
3.8 SHF hoists with frequency inverter
See separate operating instructions
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3.9 Reeving rope
The wire rope is wound onto the drum in the factory. If not, see page 52, "Replacing
wire rope".
If the bottom hook block is not fitted, proceed as follows:
Gripper pliers hold the rope securely.
The wire rope hoist must be switched on in order to reeve the rope. All work must
therefore be carried out with extreme care: for your safety and for troublefree
functioning of the wire rope hoist!
1. Lay out the end of the rope not wound on the drum, or let it hang freely.
2. Check that the wire rope lies snugly on the rope drum, tighten if necessary. Avoid
slack rope on the drum! Slack rope can destroy the rope guide and the wire rope.
3. Colour code the beginning of the rope on one side.
4. Reeve the end of the rope into the rope sheave(s) of the bottom hook block and
return pulley(s), see page 25.
Do not twist the rope; the colour coding facilitates checking.
5. Fasten the end of the rope in the rope anchorage, see page 26-28 (12-35).
6. Perform several runs over the full height of lift without load.
7. Repeat with increasing loads.
8. Make any twisting in the rope which may occur visible by sticking on a paper tag.
Severe twisting is shown by the bottom hook block's turning, especially when not
under load.
9. If any twisting should occur, remove the wire rope and untwist by letting it hang
freely or laying it out. Twisting in the wire rope prejudices safety and service life.
Any twisting should therefore be removed before subjecting the hoist to any further
load. The rope could otherwise be permanently distorted and might have to be
replaced!
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Reeving rope (SH3 - SH6)
Reeve the rope as shown in the schematic drawings and attach the end of the rope
at the rope anchorage.
Caution! The bottom hook block must hang horizontal (./2-1)
SH3 - SH5

SH6
1/1 1 1
2/1 2 4
4/1 3 5
2/2-1 6 6
4/2-1 7 8
8/2-1 - 9
SH3 - SH5 SH6
2/1 4 4
4/1 5 5
4/2-1 8 8
SH3 - SH5

SH6
2/1 4 4
4/1 5 5
4/2-1 8 8
8/2-1 - 9
2/1
1 3
L L
2
L
4 5
L L
6 7 8
L R L L R
2/1 1/1 4/1 4/1
2/2-1 4/2-1 4/2-1 4/2-1
R
8/2-1
1/1
1/1 4/1 4/1
9
R L
L = left-hand thread
R = right-hand thread
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Rope anchorage (SH3 - SH6)
Note information plate at rope anchorage.
Insert end of rope into rope anchorage according to reeving, see sketches 11-35
and tables on pages 26, 27, 28.
Place rope around rope wedge (2) and pull it into the tapered rope recess (1) until
the loose end of the rope projects by approx. 100 mm.
Secure loose end of rope with rope clamp (3) approx. 50 mm from the end of the
rope. See table for tightening torque.
Max. projection of rope wedge SH 3 - SH 4 x
max.
= 6mm ; SH 5 - 6 x
max.
= 15mm
Replace split pin (4) after dismantling it; bend ends of split pin up.
11
4
Rope
[mm]
M.. Tightening torque
[Nm]
5-6,5 M6 6
7-8 M8 10
8,5-10 M8 20
12-12,5 M12 40
14-16 M14 95
20 M16 130
12
14
18
17
Length L SH 3 SH 4 SH 5
2/1
L2
L3
L4
12
12
-
12
12
-
12
12
-
4/1
L2
L3
L4
21
21
-
14
14
-
22
22
22
4/2-1
L2
L3
L4
17
17
-
18
18
-
17
17
17
*1 Gear side
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2/1
L2
L3
L4
12
12
-
12
12
-
12
12
-
4/1
L2
L3
L4
21
21
-
14
14
-
22
22
22
4/2-1
L2
L3
L4
17
17
-
18
18
-
17
17
17
2/1 24 24 24
4/1 23 23 23
4/2-1
L2
L3
L4
25
26
-
25
26
-
25
26
26
2/1 28 28 28
4/1 27 27 27
4/2-1
L2
L3
L4
29
29
-
29
30
-
29
29
29
21
22
23
24
25
26
27
28
29
30
a b
SH3.. 216 241
SH4.. 265 290
SH5.. 334 366
a b
SH3.. 216 241
SH4.. 265 290
SH5.. 334 366
*1 Geear side
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Rope anchorage(SH6)
SH 6
Length L
2/1 L2-L5 32
4/1 L2-L5 31
2/2-1 -
4/2-1 L2-L5 34
8/2-1 L3-L5 35
SH 6
Length L
2/1 L2-L5 32
4/1 L2-L5 31
4/2-1 L2-L5 34
SH 6
Length L
2/1 L2-L5 32
4/1 L2-L5 31
4/2-1 L2-L5 34
8/2-1 L3-L5 35
31
32
34
35
*1 Gear side
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4.1 Commissioning
The wire rope hoist has been subjected to a final inspection by the manufacturer in
accordance with the EC Machinery Directive.
Commissioning must be carried out by a qualified person, see page 2.
The "Safety instructions" on page 4...6 must also be observed.
The following checks must be carried out:
Check that the wire rope hoist is completed with the original accessories as
supplied (e.g. bottom hook block), see page 24.
Check correct selection and installation of all electrical equipment, see page 21,
"Connecting to mains", see page 23.
Check that the seating of fixing screws is firm and secure, see page 8, 11, 13, 14, 68.
Check correct functioning of runway end stops.
The direction of motion of the load hook must correspond to the symbols on the
control pendant.
Check the presence and correct functioning of all safety devices.
Check emergency hoist limit switch or combined operational and emergency hoist
limit switch, see page 38, 41, 44, 45.
Check overload cut-off, see page 48
Confirm that commissioning has been duly carried out in the test log book in
section "Confirmation of commissioning".
If the wire rope hoist in conjunction with a crane system is to be subjected to a test
load during the acceptance test, the overload cut-off must be deactivate
(see 6.12, page 49), see circuit diagram.
Run rope in under partial load (will improve service life).
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5.1 Duties of crane operator
When working with wire rope hoists, the following points must be observed:
Every day before starting work, check brakes and limit switches and inspect the
system for any visible defects.
Stop working with the crane if there are any defects which might prejudice its
safety in operation.
At close of work, secure cranes which are exposed to wind with the wind
safeguard mechanism.
The rope drum must be free of coarse foreign matter.
Do not move loads above people.
Do not leave suspended loads unattended, the control pendant must be within
easy reach.
Do not use emergency limit switch during normal operation.
Do not load above rated capacity.
Pulling loads at angles, dragging loads, or towing vehicles with the load or load
suspension equipment is forbidden!
Do not heave up any loads which are jammed.
Approach final positions for hoisting, lowering and travel in normal operation only
if an operational limit switch is fitted.
Inching operation (repeated brief activation of the motor to achieve small
movements) is not permissible. Motors and brakes could be subjected to an
impermissible temperature rise. This would lead to the temperature control
disconnecting and the load could then not be set down for some time. Switchgear
and motors could be damaged.
Do not move in the opposite direction until the hoist has come to a stop.
Observe the safety instructions, see page 4-6.
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5.2 Operating from control pendant
Safety note
If the rocker switch is no longer depressed by the operator, it returns to the 0 posi-
tion, the hoist motion is automatically stopped (dead mans control).
If the hoist malfunctions, e.g. the actual motion does not correspond to the motion
intended in activating the rocker switch, release the rocker switch immediately. If the
motion continues, press the emergency stop button.
5.3 Emergency stop
Every hoist must have a means of disconnecting the power supply to all drives under
load from the ground.
After an emergency stop, the operator must not restart the hoist /crane system until a
qualified person has determined that the fault which led to this function being activa-
ted has been eliminated and no danger can arise from the continued operation of the
system.
The emergency stop button is on the control pendant.
To release the emergency stop: turn the button in the direction shown.
1st step: slow
2nd step: fast
1st step: slow
2nd step: fast
1st step: slow
Long travel: right/left
Cross travel: right/left
Lifting/lowering:
2nd step: fast
Emergency stop
Standard design
2-step
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This section deals with operational reliability, availability, and maintaining the value
of your wire rope hoist.
Although this wire rope hoist is practically maintenance-free, the components
subject to wear (e.g. wire rope, brake) and components important for ensuring
explosion protection must be inspected regularly. This is required by the accident
prevention regulations.
Inspection and maintenance must be carried out by qualified persons who have
received special training in explosion protection, see page 2.
Maintenance and repair work may only be carried out when the winch is unloaded.
Before starting, switch off and lock main isolator.
Observe the requirements of the accident prevention regulations.
Periodic tests including maintenance every 12 months, possibly earlier if so pres-
cribed by national regulations, are to be performed by a fitter engaged by the
manufacturer.
The specified inspection and maintenance intervals apply for normal conditions of
use.
The inspection and maintenance intervals must be adapted accordingly if one or
more the following conditions apply:
if after evaluating the acutual use it can be seen that the theoretical useful life of
the winch will be less than 10 years,
in the case of operation in more than one shift or heavy duty
in the case of adverse conditions (dirt, solvents, temperature, etc.)
If abrasive dusts are present (foundry, cement industry, glass manufacture or pro-
cessing, etc.) the maintenance intervals for the rope guide (cleaning, lubricating,
checking and if necessary replacing tension spring, etc.) must be reduced.
A general overhaul must be carried out after the useful lifetime has expired.
Lubricants and lubrication points, see page 69.
6.1 Inspection intervals
6.1.1 Every day
Before starting work
Check function of brake(s) (1)
Emergency hoist limit switch (2) if there is no operational hoist limit switch, opera-
tional hoist limit switch, if any, see page 38, 41, 45
EMERGENCY STOP, crane switch, see page 21
Rope (4), see page 51
W0789
12
5
4
12
1
12 12
W0791
11 6 10 2
1
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6.1.2 Once a year
Emergency limit switch (2) if there is an operational limit switch, see page 35
Check suspension of control pendant (cable and steel wire must be correctly
attached)
Load hook (5), cracks, cold deformation, wear
Disconnect switch and main isolator, see page 21
PE connections and equipotential bonding
Establish remaining service life, see page 56
Rope attachment (10), see page 50, rope sheaves, see page 54
Rope guide (11), see page 51, 53
Drive parts (12), flanges, wheels etc., see page 55
Screw connections, welds
End stops, buffers
Safety clearances
Power supply cable
Cable glands
Current collectors
Switching functions
6.2 Maintenance intervals
6.2.1 Once a year
Brake (20), measure air gap, replace brake disc if necessary, see page 34-36
Grease rope (22) with brush, see page 69
Grease rope guide (23) with brush, see page 69
Tighten clamping points for electric cables
W0792
22
20 23 21
20
W0793
20
W0794
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6.3 Hoist motor brake (RSM)
Switch off and padlock main isolator.
Remove plug (2)
must be replaced.
Disconnect brake
Before removing hub (8) please contact the manufacturer.
underneath.
Observe tightening torques.
See operating instructions for travel motors.
"A"
Hoist motor
type
Hoist
brake
S
max.
[mm]
a
[mm]
12/2H33
4H33
RSM16
RSM16
0,8
0,7
25 9 Nm
9 Nm
12/2H42
4H42
RSM32
RSM32
0,9
0,8
25 9 Nm
9 Nm
12/2H62
4H62
RSM60
RSM60
1,7
1,7
25 22 Nm
22 Nm
12/2H71
4H71
RSM100
RSM100
1,8
1,8
30 22 Nm
22 Nm
12/2H72
4H72
RSM150
RSM100
1,8
1,2
30 22 Nm
22 Nm
12/2H73
4H73
RSM150
RSM150
1,6
1,4
30
30
22 Nm
22 Nm
4H82 RSM250 1,5 40 45 Nm
24/4H92 RSM500 2,0 40 45 Nm
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6.5 Hoist motor brake (NM)
(pole-changing)
Remove plug (2)
must be replaced.
Pull off fanwheel (3), remove bushing with V-ring (IP66)
Disconnect brake
underneath.
Hoist motor type Hoist brake S
max.
[mm]
a
[mm]
12/2H33-MF10Z-106 NM38722 0,6 25 9 Nm
12/2H42-MF10X-106 NM38732 0,6 25 9 Nm
12/2H62-MF-11X-106 NM38742 0,8 25 22 Nm
12/2H71-MF-11X-106 NM38742 0,8 25 22 Nm
12/2H72-MF-13Z-106 NM38754 0,9 30 22 Nm
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6.5 Hoist motor brake (NM)
(4-pole)
Remove plug (1)
Remove plug (2) with pliers
must be replaced.
Remove cover of housing (3)
Unscrew stud screw (4) (short hexagon socket s2)
Pull off shaft encoder and leave it hanging on the connectingn cable
Remove bottom section of housing (13)
Remove fanwheel (5)
Unscrew stud screws (6) on adapter shaft
Remove adapter shaft with lifting screws (M6)
Remove circlip from fanwheel
Pull off fanwheel (7), remove V-ring (IP66)
Remove circlip (14)
Disconnect brake
Remove fixing screws (8)
Remove brake rotor (11)
Push new brake disc (brake rotor) (11) onto hub (12) and check play. If there is
increased play in the gearing between brake disc (11) and hub (12) the hub (12)
must be pulled off the motor shaft and replaced.
Always contact the manufacturer before removing hub (12).
aligned with the opening in the fanwheel cover. Lock stud screws (6) with locking
varnish.
Hoist motor type Hoist brake S
max.
[mm]
a
[mm]
4H33-MF10MB-200 NM38720 0,6 25 9 Nm
4H42-MF10MC-200 NM38730 0,6 25 9 Nm
4H62-MF-11MA-200 NM38740 0,8 25 22 Nm
4H71-MF-11MB-200 NM38740 0,8 25 22 Nm
4H72-MF-13Z-200 NM38741 0,8 30 22 Nm
4H73-MF-13ZB-200 NM38753 0,9 30 22 Nm
4H81-MF-13ZC-200 NM38753 0,9 30 22 Nm
4H82-MF-13X-200 NM38781 0,9 30 22 Nm
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6.7 Hoist limit switch (versions)
N.B.:
The hoist limit switch version installed must be determined on the basis of the sticker
in the limit switch (see stickers).
6.7.1 Standard crane - version I (Fig. 1/2)
6.7.2 Standard crane - version II (Fig. 3)
6.7.3 Radio-controlled crane - version III (Fig. 4/5)
Fig. 1/2
Fig. 3
Fig. 4/5
*2 Option
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If the original controls/circuit diagrams are used, the corresponding hoisting
direction and the cross travel if any are disabled when the limit switch is activated.
The opposing hoisting direction is clear.
An additional operational limit switch *2 for disconnecting in top and bottom hook
position during normal operation can be fitted as an option. (Additional switching
points B| and B!).
The control includes an override button for checking the emergency limit switch
(S260).
If the operational limit switch fails, the hoist can only leave the end position by
activating this override button.
6.8.2 Safety notes
The limit switch is constructed according to the state of the art and is safe in
operation. However dangers may arise if it is used incorrectly and not for its intended
purpose.
(B|).
2 Press the override button in the control and at the sametime the "up" button until
the emergency limit switch disconnects (A|). If the hoist does not continue to
switch is not working. (As an option, the override button is also possible in the con-
trol pendant.)
necessary.
a [mm]
50 Hz 60 Hz
130 150
70 80
40 50
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Adjusting en bloc
1. A| (S2)
2. A! (S1)
Combined emergency and operational limit switch
1. A| (S2)
2. B| (S4)
3. A! (S1)
4. B! (S3)
a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1 40 50
*2 Option
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6.8.5 Setting limit switch (continued)
Lower bottom hook block 2/1 to 120 mm, or 60 mm for 4/1, above desired hook
position, if necessary turn setscrew (S1) to the left beforehand.
.
a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1 40 50
Safety note:
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41
disconnecting in top and bottom hook position. (Switching points A| and A!).
The hoist is also equipped with an operational and emergency limit switch for
disconnecting in top hook position during normal operation. (Switching points B| and
B||). Switching point B|| disconnects the fast speed and B| the slow speed in
upwards direction.
If the operational limit switch (B|, B||) is overrun during a fault, the emergency hoist
limit switch (A|) disconnects the main contactor / hoist contactor. The hoist can only
leave the end position by activating switch S261 in the hoist control after the fault has
been eliminated.
The gear limit switch (GE-S) is in the panel box on the gear.
6.9.2 Safety notes
operation. However dangers may arise if it is used incorrectly and not for its intended
purpose.
Test at creep speed without load.
(B|).
2 Press the override button (S260) in the control and at the same time the "up" button
until the emergency limit switch disconnects (A|). If the hoist does not continue to
switch is not functioning.
3 Minimum clearance "a" - "c" between bottom hook block and the nearest obstacle
see table, if necessary reset the limit switch, see page 42.
4 Press the override button (S261) in the control panel and at the same time the
"down" button to leave the limit switch area.
5 Press the "down" button until the emergency hoist limit switch disconnects (A!).
anchorage = 20 mm, see sketch, if this is not the case, reset limit switch, see page
42.
necessary.
6.9.4 Testing operational hoist limit switch
Test without load.
(B|).
2 Minimum clearance between bottom hook block and the nearest obstacle, see
table, if necessary reset limit switch, see page 42.
a/b [mm] c
[mm] 50 Hz 60 Hz
130 150 40
70 80 20
40 50 10
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Adjusting en bloc
1. A| (S1)
2. B| (S3)
3. B|| (S4)
4. A! (S2)
Lift bottom hook block to "a" - "c", (sketch, table). If necessary turn setscrew (S1) to
the right beforehand.
Press override button (S261) in panel box and at the same time "down" button to
leave the limit switch area.
Switching point B|/B|| (S3/S4)
Lift bottom hook block 2/1 to a+10 mm, or to a+5 mm for 4/1, if necessary turn
setscrew (S1) to the right beforehand.
Turn setscrew (S3) to the left until contact S3 switches audibly
Lower and lift bottom hook block until B| (S3) switches.
Lower bottom hook block by b (sketch, table).
Turn setscrew S4 to the left until contact S4 switches audibly.
(Minimum clearance between rope guide (S) and clamping claws (K) for rope attach-
ment = 20 mm, see sketch)
(would cause slack rope)
a/b [mm] c
[mm] 50 Hz 60 Hz
130 150 40
70 80 20
40 50 10
Safety note:
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6.10Hoist limit switch
(radio-controlled crane)
6.10.1 Description of emergency hoist limit switch system
If the original controls/circuit diagrams are used, only the corresponding hoisting
direction is disabled when the limit switch is activated. The opposing hoisting
direction is clear.
It is equipped with an additional safety hoist limit switch (S|) above top hook posi-
tion. If during a fault the emergency limit switch for top hook position is overrun, the
safety hoist limit switch disconnects the hwole hoist and the fault indicator light
(H252) on the electronics box lights up. Leaving the limit switch region is not possible
until the faulthas been elminated and terminals 110 to 116 on the terminal strip in the
hoist control have been bridged.
The gear limit switch (GE-S) is in the control box on the gear.
6.10.2 Safety notes
operation. However dangers may arise if it is not set and used for its intended
purpose.
6.10.4 Testing emergency hoist limit switch and indicator light
The safety hoist limit switch (S|) is set in the factory and does not need to be tested
on-site.
It is possible to test the indicator light (H252) using a bridging wire between indicator
light and terminal strip.
a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1 40 50
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6.10.5 Description of optional operational hoist limit switch system
An additional operational limit switch for disconnecting in top and bottom hook
position during normal operation can be fitted as an option. In this case 2 cut-off
points for the operational hoist limit switch (B| and B!) are wired in advance of the 2
cut-off points for the emergency hoist limit switch (A| und A!). There is an override
button (S260) in the electronics box for testing the emergency hoist limit switch. If the
operational limit switch fails, the hoist can only leave the end position by activating
this button (S260).
The indicator light lights up when the emergency hoist limit switch has disconnected.
(A|)
(B|).
2 Press the override button in the electronics box and at the same time the "up" but-
ton until the emergency limit switch disconnects (A|). In addition the indicator
light (H252) on the electronics box lights up. If the hoist does not continue to move,
the emergency limit switch was activated in step 1 and the operational limit switch
is not working.
anchorage = 20 mm, see sketch, if this is not the case, reset limit switch, see page
47.
necessary.
6.10.7 Servicing gear limit switch
Override button
a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1 40 50
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6.10.8 Setting hoist limit switch
Adjusting en bloc
Set the limit switch using a socket spanner (04 430 50 99 0) and without using exces-
sive force. Do not use a power screwdriver or similar.
1. A| (S3/S4))
2. S| (S1)
2. A! (S2)
Switching point A| (S3/S4)
If necessary turn setscrew (S3/S4 and S1) to the right beforehand.
Turn setscrew (S3 or S4) to the left until contact S3 or S4 switches audibly.
Switching point S| (S1)
"Safety limit switch above top hook position"
Lift bottom hook block until emergency hoist limit switch is reached, if necessary
turn setscrew (S1) to the right beforehand.
Turn setscrew (S1) back to the right by approx. turn.
a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1 40 50
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6.10.8 Setting hoist limit switch (continued)
Combined operational and emergency hoist limit switch:
1. A| (S1)
2. B| (S3)
3. A! (S2)
4. B! (S4)

a [mm]
50 Hz 60 Hz
1/1
2/2-1
130 150
2/1
4/2-1
70 80
4/1 40 50
Safety note:
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6.11Overload cut-off
The SLE21 / Multicontroller SMC21 load monitor with its electronic sensor is set in
the factory. Corrections are only permitted in special cases, see page 59.
The factory settings are shown under the front cover of the SLE 21 load monitor
(sketch).
6.11.2 Testing overload cut-off
If an overload is detected, the wire rope hoist is switched off in the upwards
direction. Only lowering is then possible. Lifting is not possible until the wire rope
hoist has been unloaded.
Attach rated load +10% overload and take load up slowly. After the rope has been
tautened the overload cut-off must disconnect the hoist.
6.11.3 Maintenance of LET overload cut-off
After off-loading hoist, check all moving parts for ease of movement. Clean without
dismantling and grease from the outside with a thin-bodied lubricant.
See page 22 for a description of the system.
6.11.4 Maintenance of LEI overload cut-off
Check thickness of plate (min. 1.5 mm). If necessary, replace plate after removing
screw (D).
S5
W0788b
LET
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6.12Crane test
SLE21 / SMC21
1. Carefully remove front cover of SLE21 / SMC21.
2. The cut-off point is increased by pressing button (S5) permitting the test load of
125% to be lifted.
The device automatically returns to the original cut-off point after 45 minutes.
Button (S5) pressed.
Cut-off threshhold is raised.
Safety note:
Extremely heavy loads can be lifted.
Risk of accident!
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6.13 Rope drive
6.13.1 Rope and rope attachment - general information
After commissioning a new wire rope hoist, or after replacing the rope, the rope of
multi-fall hoists may twist.
This can be seen from the bottom hook block turning, particularly when unloaded.
Twisting in the rope prejudices safety and service life.
Remove any twists!
Regularly inspect the rope for twisting. To do so, run the hoist into highest and
lowest hook positions without load.
If any twisting is detected, untwist the rope immediately. See page 25, "Reeving
rope" and see page 52, "Removing rope".
Check rope. Take particular note of the sections of rope near rope pulleys, return
pulleys or equalizing pulleys and in the region of the rope anchorage.
If any of the following damage occurs, replace the rope immediately.
1. Excess visible wire fractures, see page 51, table.
The rope must be free of load for testing to facilite detecting any broken wires
when bending the rope by hand (approximately by radius of rope sheave).
2. Nest of wire fractures or broken strand.
3. Diameter reduced by 10% due to corrosion or wear (independent of breakage).
4. Diameter reduced due to structural changes over considerable sections.
5. Formation of baskets or loops, knots, necking, kinks or other mechanical damage.
6. Corkscrew-type deformation. Divergence due to deformation: > 1/3x rope diameter.
7. In addition, the rope must be replaced as required by DIN 15020, FEM 9.661 and
ISO 4309.
8. In certain applications (e.g. twist-free wire rope, constant deadweight, recurrent
stopping position, automatic operation etc.) wire fractures may occur inside the
rope without being visible from outside.
Risk of accident!
In case of doubt please contact the manufacturer.
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6.13.2 Replacement of wire rope due to broken wires
Twist-free wire rope
Non twist-free wire rope
* See data sheet for rope make-up
6.13.3 Removing rope guide
1st method (preferable!)
Unscrew protective plate (1) under the rope drum at points (a). The rope guide can
then be rotated freely. Do not unscrew stop with bearing (2)!
Unscrew screws (3).
Unscrew rope guide safety cable (4) (if any) on one side.
Remove half-rings.
Unhook rope tensioning spring.
2nd method
Unscrew stop with bearing (2) from rope guide. The rope guide can then be rotated
freely. Continue as described under 1.
Caution: The stop with bearing (2) is locked with a conical spring washer DIN 6796.
This must be refitted correctly.
Rope diameter [mm] 5,5 7 9 12 14 20
Number of external strands 12 12 15 15 15 18
Rope make-up * 18X7+SE d1315z d1315z d1315z d1315z d1318
(FEM 9.661) 2m - 4m
4
8
4
8
5
10
5
10
5
10
6
11
over a length of [mm] 33 42 54 72 84 120
or
(FEM 9.661) 2m - 4m
8
16
8
16
10
16
10
19
10
19
11
22
over a length of [mm] 165 210 270 360 420 600
Rope diameter [mm] 5,5 7 9 9 12 12,5 14 20
Number of external strands 6 8 8 8 8 8 8 8
Rope make-up * 6x19W 8x19W 8x19W Alphalift Turbolift 8x19W 8x19W 8x36WS
(FEM 9.661) 2m - 4m
5
10
6
13
6
13
6
13
9
18
6
13
6
13
12
24
over a length of [mm] 33 42 54 54 72 75 84 120
or
(FEM 9.661) 2m - 4m
10
19
13
26
13
26
13
26
18
35
13
26
13
26
24
48
over a length of [mm] 165 210 270 270 360 375 420 600
SH3 - SH5
SH6
SH6 - 2/1
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6.13.4 Replacing wire rope
SH wire rope hoists have a special rope which is the optimum for the most common
applications. The substitute rope must be equivalent to the original in terms of
quality, strength and make-up. Please consult the works certificate or the rope
certificate to see which rope is fitted.
In the case of 2 wire ropes with different lays
wire rope with right-hand lay (DS1) on rope drum with left-hand groove
wire rope with left-hand lay (DS2) on rope drum with rigth-hand groove

The direction of lay of the wire ropes makes a V-pattern (see sketch).
Removing rope
Lower bottom hook block to just above the lowest hook position and set it down on
a firm support.
Release end of wire rope in rope anchorage (rope clamp with rope wedge).
Run the remaining rope off the drum.
Unscrew the fixing screws in the clamping plates on the rope drum.
Fitting rope
Unroll new rope out straight if possible, without twists, kinks or loops. Protect rope
from dirt.
Attach rope to rope drum with all the clamping plates (do not forget the lock
washers!) Allow the rope end to project by approx. 30-40 mm.
Tightly wind about 5-10 turns onto the drum under power. Let the rope run through
a greased rag. For type of grease see page 69.
Fit rope guide, see page 53, "Fitting rope guide".
Reeve the loose end of the rope according to the number of falls, fasten with the
rope wedge and secure with a rope clamp, see page 26, "Rope anchorage".
Retighten clamping plates. For tightening torques see table.
Run rope in with partial load.
Caution! Risk of accident!
After fitting a new rope, or shortening the old one, reset the hoist limit switch. See
page 39, 42, 46, "Setting hoist limit switch".
If the new rope twists after some time in operation, untwist the rope immediately.
See page 25, "Reeving rope" and "Removing rope".
Type M..
Nm
SH 3
M6 10
M10 40
SH 4 M10 50
SH 5
M10 50
M12 87
SH 6
M12
M16
87
210
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6.13.5 Fitting rope guide
Grease thread and rope guide groove thoroughly.
Place the half-ring (1) with the short window section onto the rope drum next to the
last rope winding so that the rope exits from the region of the window (x).
Push rope tensioning spring (2) into the guide groove of the half-ring (1) and hook
the ends of the spring together. A special tool (a), see sketch, will make this easier.
Place the second half-ring (3) with the long rope exit window on the rope drum so
that the rope exits from the drum groove through the window straight and without
kinking. The second half-ring must lie flush against the first.
Bolt the two half-rings together with pressure screws and bolts (5)
The rope guide must rest lightly on the drum and be able to be turned by hand.
If this is not the case the guide has been fitted incorrectly or the rope drum is
damaged.
Bolt stop with bearing and conical spring washer (6) to the rope guide.
Fit rope guide safety catch (7) (SH6 - 2/1 L4-L5)
Bolt on protective plate (8).
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6.13.6 Inspection and maintenance of rope sheave
Check rope sheaves for wear. We recommend having them checked by personnel
trained by us. They should also be checked for easy running, indicating that the
ball bearings are in good condition.
Wear on rope sheave
Notes on limits for wear
The rope sheave must be replaced if the wall thickness as measured is <t min or the
groove depth as measured is >h max. Furthermore, the rope sheave must be
replaced when replacing the wire rope if the rope strands have dug into the base of
the groove. Impressions of single wires are acceptable.
A rope sheave must also be replaced if the radius of the base of the groove R has
become too small for the new rope due to reduction in diameter of the old rope or
wear.
N.B.
The negative profile of the rope in the base of the groove may provide optimum
contact to the wire rope currently fitted.
Rope sheaves should be rotated without load on the rope to check the easy and
concentric running of the bearings.
Bottom hook blocks
The bottom hook block must be checked for damage. Deformations, cracks and cuts
caused by impact must be assessed.
The damage can only be assessed by trained maintenance personnel.
6.13.7 Checking load hook
y
neu
see hook certificate
y
zul
= s 1,1 x y
neu
If value h
min
and/or y
zul
are reached replace hook
Rope sheaves
Part number D t min h max h new
01 430 01 53 0 98 4 13 11
01 430 04 53 0 100 4 13 10
01 430 00 53 0 125 4 14 12
22 330 00 53 0 140 4 16 14
01 430 06 53 0 154 4 21,5 19,5
03 330 20 53 0 160 4 19 16,5
24 330 00 53 0 200 5,5 24 21
01 430 05 53 0 218 5,5 26,5 24,5
01 430 03 53 0 225 5,5 24 21
03 330 40 53 0 250 5,5 28 25
25 330 00 53 0 375 6,5 37,5 34
25 330 03 53 0 375 6,5 36 32,5
46 330 00 53 0 400 7 33,5 30
26 330 01 53 0 450 10 39 35
09 430 00 53 0 450 10 39 35
46 330 01 53 0 480 10 36,5 32,5
on one side
and at base
on both sides
and at base
on both sides
and at base
Measuring depth of
base of groove with
depth gauge
Measuring thickness of wall
with special caliper gauge
RSN,
RS, RF
0,25 0,4 0,5 0,8 1 1,6 2,5 4 5 6 10 2,5 4 5 6 10
[mm] [mm]
h 24 29 31 37 40 48 58 67 75 85 106 58 67 75 85 106
h
min.
18,24 27,55 29,45 35,15 38,0 45,6 55,1 63,65 71,25 80,75 100,7 55,1 63,65 71,25 80,75 100,7
h
y y
h
y
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6.14Trolley/crab
Wheels, wheel drive and runway
Visual inspection of wheels for wear. See tables for limits for wear.
Visual inspection of runway girder for wear.
Visual inspection of wheel flanges for wear.
If any one of the limits for wear d1, b2 (b*-k) is attained, the part must be replaced.
( ) for machined faces
Fig. Nominal value Limit for wear
d
[mm]
b
[mm]
d1
[mm]
b2
[mm]
1 80 27,5 76 29,5
1 100 33 95 35
1 125 38 119 40
1
140
44,5
133
47
2 42,5 45
1 160 44,5 152 47
2 200 42,5 190 45
Bild 1
Bild 2
bLR
W0903
Nominal value Limit for wear
Fig. d bLR b k b1 d1 b2 Max. play =b*-k
min max kmin kmax
[mm]
1 100 80
80
50
60
40
50
45
55
15
10
95 5,5
5,5
13
13
13
13
2 125 80
80
50
60
40
50
45
55
15
10
118,75 7
7
13
13
13
11
2 160 85
85
52
62
40
50
45
55
16,5
11,5)
152 8
13,5
16
18
16
18
2 200 100
100
100
54
64
74
40
50
60
45
55
65
23
18
13
190 10,5
10,5
10,5
18
18
18
18
18
14
2 315 115
115
115
54
64
74
40
50
60
45
55
65
30,5 (29)
25,5 (24)
20,5 (19)
300 13,5
13,5
13,5
18
18
18
18
18
18
2 400 118,5
118,5
118,5
65
75
85
50
60
70
55
65
75
27,5 (26)
22,5 (21)
17,5 (16)
385 16
16
16
20
20
16,5
20
20
11,5
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6.15 Remaining service life
According to FEM 9.755, the operating mode and operating time must be established
by the user, see page 2, and recorded in the test log book in order to calculate the
remaining service life.
After the service life has expired a general overhaul (S.W.P.) *1 must be carried out.
Wire rope hoists are equipped ex factory with a suitable registration device.
Various devices are used:
6.15.1 Operating hours counter in SLE21 load monitor
The operating hours counter in the load monitor of the overload cut-off adds up the
operating time of the hoist. In order to obtain the lifetime expired in full load hours,
the operating hours must be calculated with load factor "k".
This is carried out by qualified personnel, see page 2, during the annual "periodic
test".
If 90% of the theoretical full load lifetime has expired, a general overhaul (GO) must
be scheduled and carried out at the earliest possible date.
6.15.2 STAHL SMC21 Multicontroller (optional)
The operating time of the hoist and the full load operating hours are recorded in the
SMC21. The SMC21 calculates the full load operating hours from the relevant hoisted
load and the operating hours of the hoist.
The remaining service life is calculated with reference to the mechanism group and
can be read off by means of a PC (laptop).
If the theoretical full load lifetime has expired, this is also indicated by an illuminated
red LCD, a general overhaul must be scheduled and carried out.
Note:
Reading the full load operating hours does not replace the prescribed tests including
inspecting the wearing parts (rope, return sheaves...)
6.16 General overhaul
The mechanism (motor and gear; not applicable to wearing parts) of the SH.. wire
rope hoist is classified according to FEM 9.511. The theoretical full load lifetime in
hours shown opposite (D) is applicable for normal hoist applications.
If the full load lifetime (D) minus the lifetime expired is nought, the wire rope hoist
must be overhauled by the manufacturer.
Components which are in the power flux may only be overhauled by the
manufacturer.
The rope drive is classified according to FEM 9.661, see works certificate.
FEM9.511 1Am 2m 3m 4m
D [h] 800 1600 3200 6400
09.05
*1 Safe Working Period
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7 Fault-finding
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7.1 What is to be done if?
7.1.1 Wire rope hoist does not start, motor hums
Not all power phases are present.
1. Check fuses,
2. Check supply cable,
3. Check control pendant and switchgear.
7.1.2 Wire rope hoist does not start after a long stoppage, or starts with difficulty,
motor hums
Hoist brake is stuck.
1. Remove fan cover
2. Dismantle brake
7.1.3 Loud clicking when switching on
Measure air gap, see page 34-36
Replace brake disc if necessary, see page 34-36.
7.1.4 Braking path too long
Brake displacement too long.
Brake lining worn.
Replace brake disc, see page 34-36, "Hoist motor brake",
7.1.5 Bottom hook block and rope rotate
Rope is twisted.
Untwist rope, see page 50, "Replacing rope".
7.1.6 Cross travel not possible
Hoist is in highest hook position, cross travel is disconnected.
Lower bottom hook block until up motion is possible again
7.1.7 Lowering not possible
Hoist is in bottom hook position
Operational or emergency hoist limit switch is faulty
Check hoist limit switch
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7.1 What is to be done if? (continued)
7.1.8 Load is not lifted
SLE21 load monitor / SMC21 Multicontroller has been actuated or is faulty.
1. Check setting, see page 48.
2. Actions for SLE21 / SMC21
LED I...III "on" and LED err => error.
Actions to eliminate an error may only be performed by trained personnel.
Error specification - Sensor current <1 mA or > 24 mA
Elimination of error - Check voltage supply
- Check sensor current (terminal 21)
- Check sensor cable
- Replace sensor
Error specification - Overload
Elimination of error - Remove load from hoist
Error specification - Overtemperature (hoisting motion not possible)
Elimination of error - Allow motor to cool down - check PTC thermistors
Error specification - Control error
Elimination of error - Check wiring
(lifting terminal 3 and lowering terminal 4 are activated
simultaneously)
Error specification - System error
Elimination of error - Check voltage (terminal 6)
- Switch SLE21 / SMC21 off/on
- Replace SLE21/SMC21
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7.1.9 Correction of cut-off threshhold for SLE21 with electronic sensor
Corrections to the cut-off threshhold may be carried out by trained personnel only.
The load monitor will only accept alterations of -20% to +8% on the factory setting.
If these limits are exceeded, I and II flash.
- Rough adjustment with S4, ~16%/ switching position,
- Fine adjustment with S2,~1%/switching position,
see page 48.
Caution: Do not exceed 110% nominal load
7.1.10 Correction of cut-off threshhold for SMC21
A laptop and the Config Tool software is required for this.
W0795
S5
Permissible cut-off range exceeded or below target
-lower cut-off threshhold (S2/S4)
-raise cut-off threshhold (S2/S4)
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60
8.1 FEM classification
Classification of mechanism, rope drive and motor in acc. with FEM for SH
The hoist is designed for use in industry and for the ambient conditions usual in
industry in non-hazardous areas.
Protection against dust and moisture to EN 60 529
IP 55
-20C ... +40C (standard)
-20C ... +60C (option
-5C ... +80C (option)
-40C ... +40C (off-standard design)
Type FEM 9.661 FEM 9.511 FEM 9.683 Type FEM 9.661 FEM 9.511 FEM 9.683
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1/1
2/2-1
2/1
4/2-1
4/1 6/1 8/1
500 1000 2000 SH 3005-25
SH 3005-40
3m 4m 4m
630 1250 2500 SH 3006-25
SH 3006-40
2m 3m 4m
800 1600 3200 SH 3008-20
SH 3006-32
2m 2m 4m SH 4008-25
SH 4008-40
3m 4m 4m
1000 2000 4000 SH 4010-25
SH 4010-40
2m 3m 4m
1250 2500 5000 SH 4012-20
SH 4012-32
2m 2m 4m
1600 3200 6300 SH 4016-16
SH 4016-25
1Am 1Am 4m SH 5016-25
SH 5016-40
3m 4m 4m
2000 4000 8000 SH 5020-25
SH 5020-40
2m 3m 4m
2500 5000 10000 SH 5025-20
SH 5025-32
2m 2m 4m SHR 6025-20
SHR 6025-32
SHR 6025-40
2m 4m 4m
3200 6300 12500 SH 5032-16
SH 5032-25
1Am 1Am 4m SHR 6032-16
SHR 6032-25
SHR 6032-40
2m 4m 4m
4000 8000 16000 SHR 6040-12
SHR 6040-20
SHR 6040-32
1Am 3m 4m SH 6040-12
SH 6040-20
SH 6040-32
3m 3m 4m
5000 10000 20000 SH 6050-16
SH 6050-25
2m 2m 4m SH 6050-40 2m 2m 1Am
6300 12500 25000 SH 6063-12
SH 6063-20
1Am 1Am 4m SH 6063-32 1Am 1Am 1Am
8000 16000 32000 50000 63000
10000 20000 40000 63000 80000
12500 25000 50000 80000 100000
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8.3 Hoist
8.3.1 Pole-changing hoist motors 50Hz
Motor currents at other voltages:
Formula
*1 Operation only with special starting circuit via 12/24-pole winding
*2 On request
*3 The 2-pole starting current for main hoist and the rated current for the travel motor were
taken into consideration when selecting the main fuse.
*4 The motors are designed for rated voltage ranges.
In accordance with EN 60034 a voltage tolerance of 5% and a frequency tolerance of
2% apply on top of the rated voltage ranges.
Hoists Motor
*4
50 Hz Main fuse
gL / gG *3
220...240 V 380...415 V 480...525 V

220...
240 V
380...
415 V
480...
525 V
kW % DC c/h In [A] Ik [A] In [A] Ik [A] In [A] Ik [A] cos phi k [A]
SH 3005-25
SH 3006-25
SH 3008-20
12/2H33 0,4/2,4
0,5/3,0
0,5/3,0
20/50
20/40
20/40
360/180
240/120
240/120
7,0/10,6
7,0/11,8
7,0/11,8
8,3/43,0 4,0/6,1
4,0/6,8
4,0/6,8
4,8/25,0 3,2/4,9
3,2/5,4
3,2/5,4
3,8/20,0 0,82/0,91 16 10 10
SH 3005-40
SH 3006-40
SH 3008-32
SH 4008-25
SH 4010-25
SH 4012-20
SH 4016-16
12/2H42 0,6/3,9
0,7/4,8
0,7/4,8
0,7/4,8
20/50
20/40
20/40
20/40
360/180
240/120
240/120
240/120
8,7/15,7
8,9/17,4
8,9/17,4
8,9/17,4
13,0/82,0 5,0/9,0
5,1/10,0
5,1/10,0
5,1/10,0
7,5/47,0 4,0/7,2
4,1/8,0
4,1/8,0
4,1/8,0
6,0/38,0 0,79/0,87 25 16 16
SH 4008-40
SH 4010-40
SH 4012-32
SH 4016-25
12/2H62 1,0/6,1
1,1/7,6
1,1/7,6
1,1/7,6
20/50
20/40
20/40
20/40
480/240
360/180
360/180
360/180
10,1/21,0
10,4/25,0
10,4/25,0
10,4/25,0
19,1/165 5,8/12,0
6,0/15,0
6,0/15,0
6,0/15,0
11,0/95,0 4,6/9,6
4,8/11,6
4,8/11,6
4,8/11,6
8,8/76,0 0,74/0,77 50 25 20
SH 5016-20
SH 5016-25
SH 5020-25
SH 5025-20
-
-
SHR 6025-20
SHR 6032-16
SHR 6040-12
SH 6040-12
12/2H71 1,0/6,1
1,3/7,6
1,5/9,5
1,5/9,5
1,5/9,5
1,5/9,5
20/60
20/50
20/40
20/40
20/40
20/40
600/300
480/240
300/150
300/150
300/150
300/150
13,7/24,0
14,8/28,0
16,7/37,0
16,7/37,0
16,7/37,0
16,7/37,0
32,2/183 7,9/13,7
8,5/16,0
9,6/21,0
9,6/21,0
9,6/21,0
9,6/21,0
18,5/105 6,3/11,0
6,8/12,8
7,7/16,9
7,7/16,9
7,7/16,9
7,7/16,9
14,8/84,0 0,62/0,64 50 35 25
SH 5016-40
SH 5020-40
SH 5025-32
SH 5032-25
-
SHR 6025-32
SHR 6032-25
SH. 6040-20
SH 6050-16
SH 6063-12
12/2H72
*1
1,9/12,0
2,4/15,5
2,4/15,5
2,4/15,5
2,4/15,5
2,4/15,5
20/50
20/40
20/40
20/40
20/40
20/40
480/240
240/120
240/120
240/120
240/120
240/120
19,5/43,0
23,0/59,0
23,0/59,0
23,0/59,0
23,0/59,0
23,0/59,0
45,2/304 11,2/25,0
13,4/34,0
13,4/34,0
13,4/34,0
13,4/34,0
13,4/34,0
26,0/175 9,0/20,0
10,7/27,0
10,7/27,0
10,7/27,0
10,7/27,0
10,7/27,0
20,8/140 0,62/0,64 80 50 35
SHR 6025-40
SHR 6032-40
SH. 6040-32
SH 6050-25
SH 6063-20
12/2H73
*1
3,1/19,0
3,8/24,0
3,8/24,0
3,8/24,0
3,8/24,0
20/50
20/40
20/40
20/40
20/40
360/180
240/120
240/120
240/120
240/120
38,0/63,0
38,0/83,0
38,0/83,0
38,0/83,0
38,0/83,0
77,0/423 22,0/36,0
22,0/48,0
22,0/48,0
22,0/48,0
22,0/48,0
44,0/243 17,6/29,0
17,6/38,0
17,6/38,0
17,6/38,0
17,6/38,0
35,0/194 0,59/0,63 100 63 63
SH 6050-40
SH 6063-32
24/4H92
*1
5,6/38,0
5,6/38,0
10/20
10/20
120/60
120/60
-
-
-
-
53,0/73,0
53,0/73,0
76,0/471 42,0/58,0
42,0/58,0
61,0/377 0,51/0,63 *2 100 80
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8.3.2 Pole-changing hoist motors 60Hz
Formula
Hoists Motor
*3
60 Hz Main fuse
gL / gG *2
380...415 V 440...480 V 550...600 V

380...
415 V
440...
480 V
550...
600 V
kW %DCD c/h In [A] Ik [A] In [A] Ik [A] In [A] Ik [A] cos phi k [A]
SH 3005-25
SH 3006-25
SH 3008-20
12/2H33 0,4/2,9
0,6/3,6
0,6/3,6
20/50
20/40
20/40
360/180
240/120
240/120
4,6/7,0
4,6/7,8
4,6/7,8
5,5/29,0 4,0/6,1
4,0/6,8
4,0/6,8
4,8/25,0 3,2/4,9
3,2/5,4
3,2/5,4
3,8/20,0 0,82/0,91 16 10 10
SH 3005-40
SH 3006-40
SH 3008-32
SH 4008-25
SH 4010-25
SH 4012-20
SH 4016-16
12/2H42 0,7/4,7
0,9/5,8
0,9/5,8
0,9/5,8
20/50
20/40
20/40
20/40
360/180
240/120
240/120
240/120
5,8/10,4
5,9/11,5
5,9/11,5
5,9/11,5
8,6/54,0 5,0/9,0
5,1/10,0
5,1/10,0
5,1/10,0
7,5/47,0 4,0/7,2
4,1/8,0
4,1/8,0
4,1/8,0
6,0/38,0 0,79/0,87 20 16 16
SH 4008-40
SH 4010-40
SH 4012-32
SH 4016-25
12/2H62 1,2/7,3
1,3/9,1
1,3/9,1
1,3/9,1
20/50
20/40
20/40
20/40
480/240
360/180
360/180
360/180
6,7/13,8
6,9/17,0
6,9/17,0
6,9/17,0
12,7/109 5,8/12,0
6,0/15,0
6,0/15,0
6,0/15,0
11,0/95,0 4,6/9,6
4,8/11,6
4,8/11,6
4,8/11,6
8,8/76,0 0,74/0,77 35 25 20
SH 5016-20
SH 5016-25
SH 5020-25
SH 5025-20
-
-
SHR 6025-20
SHR 6032-16
SHR 6040-12
SH 6040-12
12/2H71 1,2/7,3
1,5/9,1
1,8/11,4
1,8/11,4
1,8/11,4
1,8/11,4
20/60
20/50
20/40
20/40
20/40
20/40
600/300
480/240
300/150
300/150
300/150
300/150
9,1/15,8
9,8/18,4
11,0/24,0
11,0/24,0
11,0/24,0
11,0/24,0
21,3/121 7,9/13,7
8,5/16,0
9,6/21,0
9,6/21,0
9,6/21,0
9,6/21,0
18,5/105 6,3/11,0
6,8/12,8
7,7/16,9
7,7/16,9
7,7/16,9
7,7/16,9
14,8/84,0 0,62/0,64 35 35 25
SH 5016-40
SH 5020-40
SH 5025-32
SH 5032-25
-
SHR 6025-32
SHR 6032-25
SH. 6040-20
SH 6050-16
SH 6063-12
12/2H72
*1
2,3/14,4
2,9/18,6
2,9/18,6
2,9/18,6
2,9/18,6
2,9/18,6
20/50
20/40
20/40
20/40
20/40
20/40
480/240
240/120
240/120
240/120
240/120
240/120
12,9/29,0
15,4/39,0
15,4/39,0
15,4/39,0
15,4/39,0
15,4/39,0
29,9/201 11,2/25,0
13,4/34,0
13,4/34,0
13,4/34,0
13,4/34,0
13,4/34,0
26,0/175 9,0/20,0
10,7/27,0
10,7/27,0
10,7/27,0
10,7/27,0
10,7/27,0
20,8/140 0,62/0,64 50 50 35
SHR 6025-40
SHR 6032-40
SH. 6040-32
SH 6050-25
SH 6063-20
12/2H73
*1
3,7/23,0
4,5/29,0
4,5/29,0
4,5/29,0
4,5/29,0
20/50
20/40
20/40
20/40
20/40
360/180
240/120
240/120
240/120
240/120
25,0/41,0
25,0/55,0
25,0/55,0
25,0/55,0
25,0/55,0
51,0/279 22,0/36,0
22,0/48,0
22,0/48,0
22,0/48,0
22,0/48,0
44,0/243 17,6/29,0
17,6/38,0
17,6/38,0
17,6/38,0
17,6/38,0
35,0/194 0,59/0,63 80 63 63
SH 6050-40
SH 6063-32
24/4H92
*1
6,8/46,0
6,8/46,0
10/20
10/20
120/60
120/60
61,0/84,0
61,0/84,0
87,0/542 53,0/73,0
53,0/73,0
76,0/471 42,0/58,0
42,0/58,0
61,0/377 0,51/0,63 125 100 80
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8.3.3 Pole-changing hoist motors ../....-MF 50Hz
Formula
Hoists Motor
*3
50 Hz Main fuse
gL / gG *2
220...240 V 380...415 V 500...525 V 220...
240 V
380...
415 V
480...
525 V
kW % ED c/h In [A] Ik [A] In [A] Ik [A] In [A] Ik [A] cos phi k [A]
SH 3005-25
SH 3006-25
SH 3008-20
12/2H33-MF 0,35/2,4
0,4/2,9
0,4/2,9
20/50
20/40
20/40
360/180
240/120
240/120
6,6/12,2
7,1/14,3
7,1/14,3
13,0/68,0 3,8/7,0
4,1/8,2
4,1/8,2
7,6/39,0 3,0/5,6
3,3/6,6
3,3/6,6
6,1/31,0 0,78/0,83 16 10 10
SH 3005-40
SH 3006-40
SH 3008-32
SH 4008-25
SH 4010-25
SH 4012-20
SH 4016-16
12/2H42-MF 0,5/3,6
0,7/4,5
0,7/4,5
0,7/4,5
20/50
20/40
20/40
20/40
360/180
240/120
240/120
240/120
8,7/14,6
9,6/17,0
9,6/17,0
9,6/17,0
15,0/77,0 5,0/8,4
5,5/9,9
5,5/9,9
5,5/9,9
8,6/44,0 4,0/6,7
4,4/7,9
4,4/7,9
4,4/7,9
6,9/35,0 0,77/0,84 25 16 16
SH 4008-40
SH 4010-40
SH 4012-32
SH 4016-25
12/2H62-MF 1,0/6,0
1,2/7,5
1,2/7,5
1,2/7,5
20/60
20/50
20/50
20/50
480/240
360/180
360/180
360/180
15,5/23,5
15,7/27,8
15,7/27,8
15,7/27,8
28,0/144 8,9/13,5
9,0/16,0
9,0/16,0
9,0/16,0
16,0/83,0 7,1/10,8
7,2/12,8
7,2/12,8
7,2/12,8
13,0/66,0 0,69/0,77 50 25 20
SH 5016-20
SH 5016-25
SH 5020-25
SH 5025-20
-
-
SHR 6025-20
SHR 6032-16
SHR 6040-12
SH 6040-12
12/2H71-MF 1,0/6,0
1,2/7,5
1,4/9,0
1,4/9,0
1,4/9,0
1,4/9,0
20/60
20/50
20/40
20/40
20/40
20/40
480/240
360/180
240/120
240/120
240/120
240/120
15,5/23,5
15,7/28,3
19,1/33,0
19,1/33,0
19,1/33,0
19,1/33,0
28,0/144 8,9/13,5
9,0/16,0
11,0/19,0
11,0/19,0
11,0/19,0
11,0/19,0
16,0/83,0 7,1/10,8
7,2/13,0
8,8/15,2
8,8/15,2
8,8/15,2
8,8/15,2
13,0/66,0 0,69/0,77 50 35 25
SH 5016-40
SH 5020-40
SH 5025-32
SH 5032-25
-
SHR 6025-32
SHR 6032-25
SH. 6040-20
SH 6050-16
SH 6063-12
12/2H72-MF
*1
2,0/12,0
2,5/15,0
2,5/15,0
2,5/15,0
2,5/15,0
2,5/15,0
20/50
20/40
20/40
20/40
20/40
20/40
360/180
240/120
240/120
240/120
240/120
240/120
20,9/43,5
24,3/55,7
24,3/55,7
24,3/55,7
24,3/55,7
24,3/55,7
43,0/252 12,6/25,0
14,0/32,0
14,0/32,0
14,0/32,0
14,0/32,0
14,0/32,0
25,0/145 9,6/20,0
11,2/25,6
11,2/25,6
11,2/25,6
11,2/25,6
11,2/25,6
20,0/116 0,69/0,77 80 50 35
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64
8.3.4 Pole-changing hoist motors ../....-MF 60Hz
Formula
The maximum current occurring in the rated voltage range is give
Hoists Motor
*3
60 Hz Main fuse
gL / gG *2
380...400 V 440...480 V 575...600 V

380...
415 V
440...
480 V
550...
600 V
kW % ED c/h In [A] Ik [A] In [A] Ik [A] In [A] Ik [A] cos phi k [A]
SH 3005-25
SH 3006-25
SH 3008-20
12/2H33-MF 0,4/2,9
0,5/3,5
0,5/3,5
20/50
20/40
20/40
360/180
240/120
240/120
4,7/8,8
4,8/10,0
4,8/10,0
8,8/52,0 3,9/7,3
4,0/8,3
4,0/8,3
7,3/43,0 3,1/5,8
3,2/6,6
3,2/6,6
5,8/34,0 0,73/0,77 20 16 16
SH 3005-40
SH 3006-40
SH 3008-32
SH 4008-25
SH 4010-25
SH 4012-20
SH 4016-16
12/2H42-MF 0,7/4,3
0,9/5,4
0,9/5,4
0,9/5,4
20/50
20/40
20/40
20/40
360/180
240/120
240/120
240/120
5,9/10,3
6,5/13,0
6,5/13,0
6,5/13,0
10,2/59,0 4,9/8,5
5,4/10,0
5,4/10,0
5,4/10,0
8,4/49,0 3,9/6,8
4,3/8,3
4,3/8,3
4,3/8,3
6,7/39,0 0,77/0,84 20 16 16
SH 4008-40
SH 4010-40
SH 4012-32
SH 4016-25
12/2H62-MF 1,2/7,2
1,4/9,0
1,4/9,0
1,4/9,0
20/60
20/50
20/50
20/50
480/240
360/180
360/180
360/180
10,3/16,3
10,5/19,4
10,5/19,4
10,5/19,4
18,0/97,0 8,5/13,5
8,7/16,0
8,7/16,0
8,7/16,0
15,0/80,0 6,8/10,8
7,0/12,8
7,0/12,8
7,0/12,8
12,0/64,0 0,69/0,77 35 25 20
SH 5016-20
SH 5016-25
SH 5020-25
SH 5025-20
-
-
SHR 6025-20
SHR 6032-16
SHR 6040-12
SH 6040-12
12/2H71-MF 1,2/7,2
1,4/9,0
1,6/11,0
1,6/11,0
1,6/11,0
1,6/11,0
20/60
20/50
20/40
20/40
20/40
20/40
480/240
360/180
240/120
240/120
240/120
240/120
10,3/16,3
10,5/19,4
12,1/24,2
12,1/24,2
12,1/24,2
12,1/24,2
18,0/97,0 8,5/13,5
8,7/16,0
10,0/20,0
10,0/20,0
10,0/20,0
10,0/20,0
15,0/80,0 6,8/10,8
7,0/12,8
8,0/16,0
8,0/16,0
8,0/16,0
8,0/16,0
12,0/64,0 0,69/0,77 35 35 25
SH 5016-40
SH 5020-40
SH 5025-32
SH 5032-25
-
SHR 6025-32
SHR 6032-25
SH. 6040-20
SH 6050-16
SH 6063-12
12/2H72-MF
*1
2,3/14,0
3,0/18,0
3,0/18,0
3,0/18,0
3,0/18,0
3,0/18,0
20/50
20/40
20/40
20/40
20/40
20/40
360/180
240/120
240/120
240/120
240/120
240/120
15,7/31,5
15,7/38,7
15,7/38,7
15,7/38,7
15,7/38,7
15,7/38,7
30,0/180 13,0/26,0
13,0/26,0
13,0/26,0
13,0/26,0
13,0/26,0
13,0/32,0
20,0/119 10,4/20,8
10,4/25,6
10,4/25,6
10,4/25,6
10,4/25,6
10,4/25,6
20,0/119 0,69/0,77 35 35 25
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8.3.5 Frequency-controlled hoist motors 50Hz
8.3.6 Frequency-controlled hoist motors 60Hz
*1 Protection not 100% with gL/gG, we recommend additional semiconductor fuses (gR)
In accordance with EN 60034 a voltage tolerance of 5% and a frequency tolerance of 2%
apply on top of the rated voltage ranges. If these are fully utilised, the permissible limit tempe-
rature of the temperature class may be exceeded by 10 K.
50 Hz
Hoist motor kW DC

%
380-415 V 480-525 V cos FU Mains fuse
380-415 V 480-525 V
In [A] I max. FU [A] In [A] I max. FU [A] [A]
4H33 2,4 60 6,3 12,8 5,0 0,98 16
3,0 7,1 5,7
4H42 3,9 60 9,4 16 7,5 0,98 16
4,8 10,6 8,5
4H62 6,1 60 13,6 32,8 10,9 0,98 16
7,6 15,6 12,5 25
4H71 7,6 60 17 32,8 13,6 0,98 25
9,5 19,6 15,7 35
4H72 12,0 60 28 54,4 22 0,98 35
15,5 32 25 40
4H73 19,0 60 41 75 33 74 0,98 63 50
24,0 47 37
4H82 30,0 60 65 115 52 97 0,98 80 63
38,0 75 60
60 Hz
Hoist motor kW DC

%
380-415 V 440-480 V 550-600 V cos FU Mains fuse
380-415 V 440-480 V 550-600 V
In [A] I max. FU [A] In [A] I max. FU [A] In [A] I max. FU [A] [A]
4H33 2,9 60 7,2 6,3 12,8 5,0 0,98 16
3,6 8,2 7,1 5,7
4H42 4,7 60 10,8 9,4 16 7,5 0,98 16
5,8 12 10,6 8,5
4H62 7,3 60 15,6 13,6 32,8 10,9 0,98 16
9,1 17,9 15,6 12,5 25
4H71 9,1 60 19,6 17 32,8 13,6 0,98 25
11,4 23 19,6 15,7 35
4H72 14,4 60 32 28 54,4 22 0,98 35
18,6 37 32 25 40
4H73 22,8 60 47 94 41 75 33 74 0,98 63 63 50
28,8 53 47 37
4H82 36,0 60 75 115 65 115 52 97 0,98 80 80 63
46,0 86 147 75 60 100 80 63
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8.3.7 Frequency-controlled hoist motors ../....-MF 100 Hz
8.3.8 Frequency-controlled hoist motors ./....-MF 120 Hz
*1 Protection not 100% with gL/gG, we recommend additional semiconductor fuses (gR)
In accordance with EN 60034 a voltage tolerance of 5% and a frequency tolerance of 2%
apply on top of the rated voltage ranges. If these are fully utilised, the permissible limit tempe-
rature of the temperature class may be exceeded by 10 K.
100 Hz
Hoist motor
*
kW ED
DC
FM
%
380...415 V 500...525 V 660...690 V Main fuse gl
380...415 V 500...525 V 660...690 V
In [A] In [A] In [A] [A] *1
4H33-MF 2,9 70 8,3 6,6 5,0 10 10 10
3,6 60 9,4 7,5 5,7
4H42-MF 3,6 70 9,3 7,4 5,6 16 16 10
4,5 60 10,7 8,6 6,5
4H62-MF 6,0 70 15,5 12,4 9,4 20 20 20
7,5 60 18,0 14,4 10,9
4H71-MF 7,5 70 18,0 14,4 10,9 25 25 20
9,0 60 21,0 16,8 12,7
4H72-MF 12,0 70 25,0 20,0 15,2 32 32 32
15,0 60 31,0 24,8 18,8
4H73-MF 18,0 70 34,0 27,2 20,6 50 50 40
23,0 60 42,0 33,6 25,5
4H81-MF 23,0 70 45,0 36,0 27,3 63 63 50
28,0 60 55,0 44,0 33,3
4H82-MF 28,0 70 57,0 45,6 34,5 80 80 63
35,0 60 64,0 51,2 38,8
120 Hz
Hoist motor
*
kW ED
DC
FM
%
360...400 V 440...480 V 575...600 V Main fuse gl
360...400 V 440...480 V 575...600 V
In [A] In [A] In [A] [A] *1
4H33-MF 3,5 70 9,9 8,2 6,6 10 10 10
4,3 60 11,3 9,3 7,4
4H42-MF 4,3 70 11,3 9,3 7,4 15 15 15
5,4 60 13,1 10,8 8,6
4H62-MF 7,2 70 20,6 17,0 13,6 20 20 20
9,0 60 23,0 19,0 15,2
4H71-MF 9,0 70 23,0 19,0 15,2 25 25 25
11,0 60 26,6 22,0 17,6
4H72-MF 14,0 70 26,0 20,8 18,1 35 35 35
18,0 60 37,5 31,0 24,8
4H73-MF 21,0 70 43,6 36,0 28,8 50 50 50
27,0 60 53,3 44,0 35,2
4H81-MF 28,0 70 55,7 46,0 36,8 60 60 60
34,0 60 67,8 56,0 44,8
4H82-MF 34,0 70 67,8 56,0 44,8 80 80 80
42,0 60 78,7 65,0 52,0
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8.4 Cable cross sections
and lengths of supply cable
For larger cross-sections, the max. cable lengths are calculated as follows:
L* = L x S* / S
S = Recommended cross-section for cable length stated
L1...L5 = Max. supply cable length of the individual types of power supply. Sum of voltage drops
s5 %.
A loop impedance of max. 250 mO was taken as basis for coordinating the short circuit
protection of the power contactors and calculating the cable lengths.
The cross-sections take into consideration the overload protection of the cables correspon-
ding to the types of cable and installation.
Depending on the lengths of the individual sections, the percentual voltage drops given above
may be distributed differently in particular cases to find an economical solution.
The cross-sections must be adapted in the case of longer cables and other types of power
supply.
1 2 3 4 5 6 7
Hoist motor
type
Stationary
conduit
Power supply to hoist
Trolley/crab
Crane
conduit
Power supply to infeed (custo-
mers cable to beginning of
rising mains)
Trolley/crab
Festoon cable in free air as
flexible PVC-sheathed cable
from end of rising mains to hoist
Rising mains
max. 10 m
Fixed
installation in
PVC conduit
from main
isolator to end of
rising mains
Crane
from end of rising mains along
crane runway to crane control
Crane
power supply along crane
bridge to hoist
A U s 5% A U s 1% A U s 4% (4 + 5) A U s 2,5%
A U s1,5% (5 + 6)
50 Hz
220-240 V 380-415 V 480-525 V 220-240 V 380-415 V 480-525 V 220-240 V 380-415 V 480-525 V 230 V 400 V 500 V 220-240 V 380-415 V 480-525 V 220-240 V 380-415 V 480-525 V
S L1 S L1 S L1 S L1 S L1 S L1 S L1 S L1 S L1 S S S S L1 S L1 S L1 S L1 S L1 S L1
[mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [mm] [mm] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m]
12/2H33 6,0 57 2,5 72 1,5 68 10,0 18 4,0 22 2,5 21 6,0 37 2,5 48 1,5 44 10,0 4,0 2,5 10,0 17 2,5 14 2,5 22 6,0 27 2,5 34 1,5 32
12/2H42 10,0 53 4,0 64 2,5 63 16,0 16 6,0 18 4,0 19 10,0 34 4,0 42 2,5 41 16,0 6,0 4,0 16,0 14 6,0 17 4,0 18 10,0 25 4,0 30 2,5 30
12/2H62 16,0 48 6,0 54 4,0 56 25,0 14 10,0 17 6,0 16 16,0 31 6,0 36 4,0 37 25,0 10,0 6,0 25,0 12 10,0 16 6,0 15 16,0 23 6,0 26 4,0 27
12/2H71 16,0 52 6,0 59 4,0 61 25,0 16 10,0 19 6,0 18 16,0 34 6,0 40 4,0 41 25,0 10,0 6,0 25,0 14 10,0 19 6,0 17 16,0 25 6,0 29 4,0 30
12/2H72 25,0 49 10,0 59 6,0 55 35,0 13 16,0 18 10,0 18 35,0 44 10,0 40 6,0 40 35,0 16,0 16,0 35,0 10 16,0 18 6,0 13 25,0 24 10,0 29 6,0 27
12/2H73 35,0 50 16,0 69 10,0 67 35,0 10 16,0 14 10,0 13 35,0 32 10,0 30 10,0 47 50,0 25,0 16,0 50,0 11 16,0 14 10,0 14 50,0 35 16,0 34 10,0 33
24/4H91 25,0 31 16,0 60 10,0 59 70,0 17 35,0 26 25,0 29 35,0 29 16,0 44 10,0 42 70,0 50,0 25,0 50,0 11 25,0 23 10,0 13 35,0 22 16,0 30 10,0 29
24/4H92 - 25,0 55 16,0 55 - 50,0 22 35,0 24 - 25,0 39 16,0 39 - 50,0 35,0 - 35,0 16 25,0 19 - 25,0 27 16,0 27
60 Hz
380-415 V 440-480 V 550-600 V 380-415 V 440-480 V 550-600 V 380-415 V 440-480 V 550-600 V 400 V 460 V 575 V 380-415 V 440-480 V 550-600 V 380-415 V 440-480 V 550-600 V
S L1 S L1 S L1 S L1 S L1 S L1 S L1 S L1 S L1 S S S S L1 S L1 S L1 S L1 S L1 S L1
[mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [mm] [mm] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m] [mm] [m]
12/2H33 2,5 63 1,5 50 1,5 78 4,0 19 2,5 15 1,5 14 2,5 41 2,5 56 1,5 52 4,0 4,0 2,5 4,0 18 2,5 17 1,5 16 2,5 29 2,5 39 1,5 36
12/2H42 4,0 56 4,0 74 2,5 72 6,0 16 4,0 14 2,5 14 4,0 40 4,0 49 2,5 48 16,0 6,0 4,0 6,0 20 4,0 14 2,5 14 4,0 26 4,0 35 2,5 34
12/2H62 6,0 47 6,0 62 4,0 65 10,0 15 10,0 20 6,0 19 6,0 33 6,0 42 4,0 44 16,0 10,0 6,0 10,0 17 6,0 12 6,0 18 6,0 23 6,0 30 4,0 31
12/2H71 6,0 51 6,0 68 4,0 70 10,0 17 10,0 22 6,0 21 6,0 34 4,0 31 2,5 30 10,0 10,0 6,0 10,0 15 6,0 14 4,0 14 6,0 25 6,0 33 4,0 34
12/2H72 10,0 51 10,0 68 6,0 63 16,0 16 16,0 21 10,0 21 16,0 58 10,0 47 6,0 46 25,0 16,0 16,0 16,0 18 10,0 14 6,0 15 10,0 25 10,0 33 6,0 31
12/2H73 16,0 60 10,0 49 10,0 77 16,0 12 10,0 10 10,0 15 16,0 41 10,0 35 6,0 33 25,0 25,0 16,0 16,0 11 10,0 11 6,0 10 16,0 29 16,0 39 10,0 38
24/4H91 16,0 52 16,0 69 10,0 68 50,0 32 35,0 30 25,0 33 16,0 37 10,0 30 10,0 47 35,0 25,0 16,0 25,0 17 16,0 14 10,0 14 25,0 40 16,0 34 10,0 33
24/4H92 35,0 68 25,0 64 16,0 64 70,0 27 50,0 25 35,0 28 25,0 33 16,0 29 10,0 29 50,0 50,0 35,0 50,0 19 35,0 20 25,0 23 35,0 33 25,0 32 16,0 32
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8.5 Tightening torques for screws
All screws should be tightened with a torque spanner. See table for the tightening
torques generally applicable for screws grade 8.8 and 10.9.
Values (Y) apply for the attachment of the mounting plate to the gear.
M..
Screw grade
8.8 10.9 10.9
standard Y
[Nm] [Nm]
M6 10 19 -
M8 25 42 -
M10 51 85 75
M12 87 130 87
M16 215 330 250
M20 430 - -
M24 740 - -
M30 1500 - -
M36 2600 - -
Other screw connections and applicable tightening torques
No.
Screw connection Type Screw connection
Part 1 / Part 2 M.. Grade MA [Nm]
1 Gear casing/panel box SH 3 - SH 4 M6 8.8 6
2 Gear casing/support plate SH 3
SH 4
SH 5
M10
M12
M16
100
100
100
75
87
310
3 Rope drum/gear drive shaft
SH 5 M12 100 130
4 Rope drum/clamping plate SH 3 M6/8 8.8 10/25
5 Rope drum bearing journal/holding washer SH 3
SH 4-SH 5
SH 6
M8
M10
M16
100 42
75
260
6 Rope drum flange bearing/support plate (fan side) SH 3
SH 4-SH 5
SH 6
M8
M10
M16
100 42
75
215
7 Grease pan/guide rail SH 6 M10 100 75
8 Support plate (fan side)/grease pan SH 3-SH 4
SH 5
M8
M8
C45K
RSt37
20
10
9 Support plate (gear side, fan side)/fixing tube (Dg) SH 3-SH 4 M16 100 330
10 Axle holder/trolley side cheek (hoist side) (kBh-Dg) SH 3-SH 5 (kBh)
SH 6 (kBh)
SH3-SH4 (Dg)
SH5 (Dg)
M8
M8
M8
M8
8.8
100
8.8
100
25
42
20
42
11 Threaded bolt/trolley side cheek (hoist side/counterweight) SH3-SH 6 M16 100 215
12 Return pulley bearing plate/bearing pedestal (kBh) SH 6 M12 100 115
13 Suspension bearing plate/bearing pedestal (kBh) SH 6 M12 100 115
14 Pivot pin/mounting bracket (Dg) SH 3-SH 5 M12 8.8 85
15 Pivot pin/pivot pin (Dg) SH 3-SH 5 M12 8.8 85
16 Guide roller holder/trolley side cheek (Dg) SH 3-SH 5 M8 100 42
kBh = "short headroom" trolley
Og = double rail crab
Dg = articulated trolley
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8.6 Lubricants
8.7 Lubricants for travel drive
See operating instructions of travel drive
W0572a
c c c
F0450a
c
SH 30
SH 40
SH 50
SH 60
SHR 60
SH 30
SH 40
SH 50
SH 60
* Oil filling/oil drainage screw
Depending on installation position of gear, the
filling screw is "at the top" and the drainage
screw "at the bottom".
Position of
lubrication point
Type of
lubricant
Designation Quantity of
lubricant
Characteristics, makes
a Oil
CLP 460
(PG 220)
SH 30..: 1500 ml
SH 40..: 2000 ml
SH 50..: 6000 ml
SH 60..: 16000 ml
SH 60..: 18000 ml *1
1
1 Viscosity: 460 /s/40C (220/s/40C), pour point: -20C (-40C)
flash point: +265C (+320C), e.g.: Fuchs Renolin CLP 460*, Aral Degol BG 460,
BP Energol GR-XP 460, Esso Spartan EP 460, Mobil Gear 634, Tribol 1100/460,
(Shell Tivela Oil WB)
2 Soap base: Lithium + MoS2, dripping point: approx. 185C
penetration: 310-340, operating temperature: -20to +120C
e.g.: Aralub PMD1*, BP Multi-purpose Grease L21M, Esso Multi-purpose
Grease M, Mobilith SHC 460, Shell Retinax AM, STABYL L-TS 1 Mo
3 Soap base: Synthetic (lithium), dripping point: approx 150C
+130C), e.g.: Aralub FDP00, BP Energrease HT-00 EP, Esso Liquid Gear Grease,
Shell Special, Gear grease H*, Mobilux Liquid grease EP 004,
(Tivela Compound A)
4 Soap base: Lithium + MoS2 (Synthetic + lithium), dripping point: approx. +180C,
+130C), e.g.: Aralub LFZ 0, Renolit FLM 0*, Tribol Molub-Aloy MPG 00, (Tivela
Compound A)
5 Soap base: Lithium, dripping point: approx. +170C (+260), penetration: 220-250
(265-290), operating temperature: -20to +120C (-40to + 120C), e.g.: Aralub
HL3, BP Energrease RBB3, ESSO Roller Bearing Grease Andak C AC 205,
Mobilux 3* (Mobil Mobilgrease 28)
b Grease
GOOF
(GPGOOK)
600 - 2500 g 3
c Grease KPF1K 100 g 2
d Grease
K3K
(KE2N)
500 - 1000 g 5
g
Grease
KPFOK
(GPON)
SH 30..: 100 g
SH 40..:
4
Oil CLP 460
(PG 220)
SH 50..: 2500 ml
SH 60..: 2500 ml
SHR60..: 2500 ml
1
( ) Lubricants for low operating temperatures, -40 ... +40C)
* Factory filling
*1 SH 60, motor at top
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The sound pressure level was measured at a distance of 1 m from the wire rope
hoist. The mean sound pressure level is calculated for one operating cycle (50% with
nominal load, 50% without load).
Instead of stating an emission value based on a workplace, the values from table 1
and 2 at measuring distance "h" can be used.
1
2
8.9 Circuit diagrams
See separate enclosure
Type
[db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
SH 30 76 73 70 67 64
SH 40 76 73 70 67 64
SH 50 78 75 72 69 66
SH 60 78 75 72 69 66
Type [db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
SH 30 76 70 64 58 52
SH 40 76 70 64 58 52
SH 50 78 72 66 60 50
SH 60 78 72 66 60 50
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9.1 Serial number
When ordering original spare parts, please always indicate the serial number of the
hoist. This is affixed to the inside of the bearing support plate (see sketch).
9.2 Hoist
Brake rotor RSM Brake rotor NM
Rope guide
Wire rope (E)
See works certificate or rope certificate for length and number of wire rope.
Hoist motor Hoist motor
brake
A
Hoist motor Hoist motor
brake
A
Order-No. Order-No.
12/2H33
4H33
RSM16
RSM16
04 430 00 65 0
04 430 17 65 0
9 Nm
9 Nm
12/2H33-MF...
4H33-MF...
NM 38722
NM 38720
567 474 0
567 474 0
9 Nm
9 Nm
12/2H42
4H42
RSM32
RSM32
04 430 23 65 0
04 430 34 65 0
9 Nm
9 Nm
12/2H42-MF...
4H42-MF...
NM 38732
NM 38730
567 475 0
567 475 0
9 Nm
9 Nm
12/2H62
4H62
RSM60
RSM60
04 430 40 65 0
04 430 50 65 0
22 Nm
22 Nm
12/2H62-MF...
4H62-MF...
NM 38 732
NM 38 740
567 805 0
567 805 0
22 Nm
22 Nm
12/2H71
4H71
RSM100
RSM100
04 430 57 65 0
04 430 81 65 0
22 Nm
22 Nm
12/2H71-MF...
4H71-MF...
NM 38 742
NM 38 740
567 805 0
567 805 0
22 Nm
22 Nm
12/2H72
4H72
RSM150
RSM100
04 430 67 65 0
04 430 81 65 0
22 Nm
22 Nm
12/H72-MF...
4H72-MF...
NM 38 754
NM 38 741
567 549 0
567 805 0
22 Nm
22 Nm
12/2H73
4H73
RSM150
RSM150
04 430 67 65 0
04 430 92 65 0
22 Nm
22 Nm
-
4H73-MF...
-
NM 38 753
-
567 549 0 22 Nm
4H82 RSM250 05 430 00 65 0 45 Nm 4H81-MF... NM 38753 567 549 0 22 Nm
24/4H92 RSM500 05 430 10 65 0 45 Nm 4H82-MF... NM 38781 567 568 0 22 Nm
Hoist type B C D
Order-No. Order-No. Order-No.
SH 30 03 430 02 43 0 03 430 01 43 0 03 430 00 43 0
SH 40 04 430 00 43 0 04 430 02 43 0 04 430 01 43 0
SH 50 05 430 01 43 0 05 430 02 43 0 05 430 00 43 0
SH 60 - 2/1, L4 - L5 06 430 08 43 0 - -
SH 60 06 430 03 43 0 06 430 04 43 0 06 430 00 43 0
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E
N
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5
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9
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s
c
Tochtergesellschaften/Subsidiaries
Austria
Steyregg
Tel +43 732 641111-0
Fax +43 732 641111-33
Great Britain
Birmingham
Tel +44 121 7676400
Fax +44 121 7676485
Portugal
Lissabon
Tel +351 21 44471-60
Fax +351 21 44471-69
Switzerland
Dniken
Tel +41 62 82513-80
Fax +41 62 82513-81
info@stahlcranes.ch
China
Shanghai
Tel +86 21 6257 2211
Fax +86 21 6254 1907
info@stahlcranes.cn
India
Chennai
Tel +91 44 4352-3955
Fax +91 44 4352-3957
Singapore
Singapore
Tel +65 6271 2220
Fax +65 6377 1555
Dubai
Tel +971 4 805-3700
Fax +971 4 805-3701
info@stahlcranes.ae
France
Paris
Tel +33 1 39985060
Fax +33 1 34111818
info@stahlcranes.fr
Italy
S. Colombano
Tel +39 0185 358391
Fax +39 0185 358219
info@stahlcranes.it
Spain
Madrid
Tel +34 91 484-0865
Fax +34 91 490-5143
info@stahlcranes.es
USA
Charleston, SC
Tel +1 843 767-1951
Fax +1 843 767-4366
Vertriebspartner/Sales partners

SDN BHD
9.3 TRAVEL DRIVE O & M
Travel Drives
_

SU-A
SF
SA-C
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These crane components have been constructed in compliance with the applicable
Inspect components for damage caused in transit immediately upon delivery.
Do not install or commission damaged components!
- Assembly
- installation
- commissioning
- testing
- maintenance and fault clearance
Terms employed
User
Whoever uses and employs the crane components or has them operated by suitable
trained personnel is considered to be the user (employer/company).
Trained personnel
Skilled electrician
instructions.
The person must be in a position to assess the safety of the installation in con-
junction with the application.
Persons with the authority to undertake certain maintenance work on our products
include service engineers of STAHL CraneSystems GmbH and trained fitters with the
corresponding certification.
Seminars:
Ask for our seminar programme you will find information on it on the last page.
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Content
1.1 Symbols .......................................................................................................................... 4
1.2 Operating instructions ................................................................................................. 4
1.3 Use for intended purpose............................................................................................ 5
1.4 Safety-conscious operation........................................................................................ 5
1.5 Organisational safety precautions............................................................................. 5
1.6 General regulations...................................................................................................... 5
1.7 Installation, commissioning, maintenance and repairs ......................................... 6
1.8 Warranty......................................................................................................................... 6
1.9 Periodic tests................................................................................................................. 6
1.10 After sales service........................................................................................................ 6
2 SU-A travel drive
2.1 Installation .................................................................................................................... 7
2.1.1 Description.................................................................................................................... 7
2.1.2 Permissible mounting position .................................................................................. 7
2.1.3 Electrical connection .................................................................................................. 8
2.2 Maintenance ................................................................................................................ 8
2.3 Maintenance work ...................................................................................................... 9
2.3.1 Inspection and maintenance table........................................................................... 9
2.3.2 Travel motor brake....................................................................................................... 9
2.3.3 Grease change........................................................................................................... 10
2.4 Motor data .................................................................................................................. 11
2.5 Sound pressure level ................................................................................................ 12
2.6 Operating conditions................................................................................................. 12
2.7 Wearing parts............................................................................................................. 12
3 SF travel drive
3.1 Installation .................................................................................................................. 13
3.1.1 Description.................................................................................................................. 13
3.1.2 Permissible mounting position ................................................................................ 13
3.1.3 Electrical connection ................................................................................................ 15
3.2 Maintenance .............................................................................................................. 17
3.3 Maintenance work .................................................................................................... 17
3.3.1 Inspection and maintenance table......................................................................... 17
3.3.2 Travel motor brake..................................................................................................... 18
3.3.3 Replacing brake disc................................................................................................. 18
3.3.4 Gear.............................................................................................................................. 19
3.3.5 Oil change ................................................................................................................... 19
3.4 Motor data .................................................................................................................. 20
3.7 Wearing parts............................................................................................................. 23
4 SA-C travel drive
4.1 Installation .................................................................................................................. 24
4.1.1 Description.................................................................................................................. 24
4.1.2 Permissible mounting position ................................................................................ 24
4.1.3 Electrical connection ................................................................................................ 25
4.2 Maintenance work .................................................................................................... 28
4.3.1 Inspection and maintenance table......................................................................... 28
4.3.2 Travel motor brake..................................................................................................... 28
4.3.3 Replacing brake disc................................................................................................. 28
4.3.4 Gear.............................................................................................................................. 29
4.3.5 Oil change ................................................................................................................... 30
4.4 Motor data .................................................................................................................. 31
4.7 Wearing parts............................................................................................................. 34
5 General information
5.1 Seminar programme.................................................................................................. 35
Subject to alterations
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1.1 Symbols

Safety at work
entailed.
and limb!
Safety in operation
Information marked with this symbol must be observed to avoid causing damage.
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The travel drives are intended for driving cranes and similar installations. They may
only be used in accordance with their design principles.
Do not carry out any alterations or modifications. Additional fitments must be
authorised by the manufacturer. Non-compliance will invalidate the declaration of
conformity.
The travel drives are constructed according to the state of the art. In spite of this,
dangers may arise from incorrect use or use for an unintended purpose.
The operator is responsible for ensuring that work is carried out with safety in
mind and avoiding risks, see page 2.
Read the operating instructions before starting work.
Report damage and defects to the travel drives (abnormal noises, impaired braking
function, deformations, ...) to the person responsible immediately. Do not use the
system until the faults have been eliminated.
Only direct persons to operate the system if they have been trained or instructed in
its use. Observe the legal minimum age! You will find information on our seminar
programme on the last page.
manner.
book.
Store the operating instructions within easy reach where the travel drives are
operated.
Statutory regulations relating to the EC Directive.
Installation, commissioning, maintenance and repairs may be carried out by
qualified persons only, see page 2.
We recommend having installation carried out by the manufacturers personnel.
Use only original spare parts for repairs, otherwise the guarantee will become
invalid.
Additional fitments must not prejudice safety.
Electrical connection and the electrical function test may only be performed by a
trained electrician.
Our after-sales service will advise you on correct use of the equipment. Repairs
will be carried out professionally and quickly by our trained personnel.You will find
information on this on the back cover.
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1.8 Warranty
The warranty will become invalid if these operating instructions are not observed
The warranty will become invalid if the travel drives are modified or original spare
parts not used
Die Gewhrleistung erlischt, wenn die Montage, Bedienung, Prfung und Wartung
nicht nach dieser Betriebsanleitung erfolgt.
Reparaturen und Strungsbeseitigungen im Rahmen der Gewhrleistung drfen
nur von Fachkrften (siehe Seite 2) nach Rcksprache und Beauftragung durch
den Hersteller ausgefhrt werden.
Bei nderungen an den Fahrantrieben sowie bei Einsatz von nicht Original-Ersatz-
teilen erlischt die Gewhrleistung
1.9 Periodic tests
Travel drives must be inspected by a qualified person, see page 2 at least once a
year, possibly more frequently if so required by national regulations. The results of
the test must be recorded and filed in the test log book.
The periodic tests must be adapted to the use of the crane components. Intensive
use entails shorter maintenance intervals.
All tests must be initiated by the user (see page 2).
With the purchase of these travel drives, you have decided on a high-quality product.
Our after sales service will give you advice on its correct use. You will find
information on our after-sales service on the back cover.
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3 SF travel drive
3.1 Installation
3.1.1 Description
The travel drive is a high-quality drive with smooth starting and braking characteri-
stics such as are required in particular for material handling. The pole-changing
motor must be activated in a certain way to achieve this (see block circuit diagram,
chapter "Electrical connection").
The SF 11 and SF 18 can be further extended with a flange bearing with pinion and a
drive shaft.
3.1.2 Permissible mounting position
The travel drive can be rotated around its main horizontal axis in 90 steps.
Caution! A larger quantity of lubricant is required for the SF 1.2. in mounting posi-
tion "motor at bottom" (see lubrication table).
Tighten the fixing screws with the prescribed tightening torque.
X: Screw can only be inserted in direction of arrow.
Check oil level before commissioning. (SF 25, SF 35)
SF 14
W0930
SF 15/17
W0931
SF 25/35
W0932 W0933
SF 25/35
X
W0929
SF 11/ 18
2 mm
W0935
W0934
M6: 10 Nm
M8: 25 Nm
M10: 51 Nm
M8: 25 Nm
M6: 10 Nm
M8: 25 Nm
M10: 51 Nm
M12: 87 Nm
M10: 51 Nm
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3 SF travel drive
3.1 Installation (continued)
3.1.3 Electrical connection
The mains voltage must match that given on the rating plate.
Electrical connection with plug connection or cable gland.
If using cable gland, follow the terminal diagram.
Block terminal diagram

M 25
W0938
W0943
W0944
8/2 F.. motor 4 F.. motor
W0942
Standard settings for frequency inverter
Speed m/min 8 10 12,5 16 20 25 32 40 50 63 80 100
Max. frequency Hz 80 100 50 63 80 100 80 100 80 100 100 100
Motor connection A A Y Y A A A A A A A A
Run-up time [s] 2,1 2,4 2,8 3,3 3,8 4,2 4,7 5,2 5,6 6,0 6,7 8,4
Stopping time [s 1,7 2,0 2,3 2,7 3,0 3,4 3,8 4,2 4,5 4,8 5,4 6,7
01.09
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3 SF travel drive
Block circuit diagram
Crane travel motor 1 Crane travel motor 2
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3 SF travel drive
*1 Option: temperature control
*2 Option: travel limit switch
The time-lag relays -K624 and -K625 shown in the circuit diagram are pre-set (approx.
3 sec.). The time-lag relay -K625 should be reset on commissioning depending on
load and travel speed. The switching time should be set in such a way that no sudden
increase in speed occurs in the drive when the slow speed is activated.
Method of functioning:
On start-up, -K624 activates start-up with 8 poles for the time set.
On braking, -K625 activates brake action for the time set, thus
avoiding dynamic braking and high torque forces on the drive.
We recommend start-up control from motor size 8/2 F42...
Brake control is required for all drives.
Temperature control forwards reverse fast
slow
Switching time
fast-slow
Slow start-up
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3 SF travel drive
3.2 Maintenance
This section deals with the operational reliability, availability, and maintaining the
value of your travel drives.
Although they are practically maintenance-free, the components subject to wear
must be inspected regularly. This is required by the accident prevention regulations.
The inspections must be performed by qualified personnel, see page 2.
Maintenance and repair work may only be carried out when the crane is not under
load.
Follow the accident prevention regulations.
Please also note the "Safety instructions" on page 5.
Wearing parts, see page 23.
3.3 Maintenance work
3.3.1
*2 By the operator
Similarly, heavy-duty applications and adverse conditions (dirt, solvents, multi-shift operation etc.)
necessitate shortening this inspection and maintenance interval.
No.
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1
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*
4
Inspection and maintenance table
(Classification: 1 Bm)
See
page
1 Travel drive: attachment, torque support 13
2 Check braking effect of travel drive
3 Oil level 19
4 Change gear/oil of travel drive 19
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3 SF travel drive
3.3 Maintenance work (continued)
3.3.2 Travel motor brake
Check brake at regular intervals. The intervals must be adapted in accordance with
the application.
Move carriage into a safe position
Remove plug (2)
Measure air gap (S) with feeler gauge (F). See table for max. permissible air gap
(S).
The travel motor brake needs no adjustment.
must be replaced.
Disconnect brake
underneath.
Replacement and repairs may only be carried out by qualified personnel!
Travel drive Motor type Brake Braking
torque
[Nm]
S
min.
[mm]
S
max.
[mm]
t
min
[mm]
(4)
Nm
SF xx xxx 123 8/2F12/2xx.223 FDW 08 1,3 0,2 2,0 5,7 3xM4 3
SF xx xxx 133
SF xx xxx 184
8/2F13/2xx.233
4F18/2xx.233
FDW 08
FDW 08
2,5
2,5
0,2
0,2
1,6
1,6
6,1
3xM4
3xM4
3
3
SF xx xxx 313 8/2F31/2xx.423 FDW 13 5 0,3 2,0 8,8 3xM6 10
SF xx xxx 384
SF xx xxx 423
4F38/2xx.433
8/2F42/2xx.433
FDW 13
FDW 13
8
8
0,3
0,3
2,0
2,0
8,8
3xM6
3xM6
10
10
SF xx xxx 484 4F48/2xx.443 FDW 13 13 0,3 1,2 9,6 3xM6 10
SF xx xxx 523 8/2F52/2xx.523 FDW 15 13 0,3 2,0 10,8 3xM6 10
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3 SF travel drive
3.3.4 Gear
The gear has a long service life. All bearing points have roller bearings. The gearing
is hardened, hard-machined and has high safety factors.
During annual maintenance, check whether any oil has leaked (puddle of oil
underneath the gear, drops of oil on the gearbox). If any loss of oil is ascertained,
the oil must be changed and repairs scheduled if necessary.
Note any gear noises from the crane when under load and without load. Rough,
noisy running, knocking sounds indicate possible faults.
If any faults are detected, repairs must be scheduled.
If there is any uncertainty, a fresh diagnosis can be made after consulting experts,
e.g. from the manufacturer (see back cover).
3.3.5 Changing grease/oil of travel drive
Lubricating toothed boss of wheel
The SF 1. .. travel drives have a gear with grease lubrication, the SF 25.., SF 35.. with oil
lubrication.
The toothed boss (a) is lubricated with grease (see table).
Run gear oil off while warm.
The type and quantity of oil or grease can be seen from the table.
( ) = Lubricants for low operating temperatures,max. -30C
* Factory filling
*1 Only down to -20C
*2 Mounting position "motor at bottom"
Position of lubrication point Type of
lubricant
Designa-
tion
Quantity
Charakteristics, makes Order. No.
a Toothed boss of wheel Grease KPF 1K 50 gr Soap base: Lithium + MoS2
Dripping point: approx. 185C (180C)
Penetration: 310-340 (310-340)
Operating temperature: -20to +120C, (-50 to +150C),
e.g.: Aral Fett P 64037*, Aralub PMD1, BP Multi-purpose
Grease L21M, Esso Multi-purpose Grease M, Mobil Grease
Special, Shell Retimax AM *1, Texaco Molytex Grease EP2,
Fuchs Renolit FLM2, (Fuchs Renolit FLM2)
b SF 1. 1..
SF 1. 2..
SF 1. 2..
Grease KPF 0K-20 100 gr
200 gr
600 gr *2
Soap base: Lithium + MoS2
Dripping point: ca. +180C
Penetration: 355-385
Operating temperature: -30to +130C
e.g.: Aral Grease P64037*, Aralub PMD0, Tribol Molub-
Aloy Multi-purpose grease
32 250 09 65 0
(0.75 kg)
Gear SF 25..
Gear SF 35..
Gear SA-. 5..
Gear SA-. 6..
Oil CLP 460 1000 ml
1500 ml
1000 ml
3000 ml
Viscosity: 460 cSt/40C (240 cSt/40C)
Pourpoint: -20C (-40)
Flash point: +265C (+270C)
e.g.: Fuchs Renep Compound 110*, Aral Degol BG 460,
BP Energol GR-XP 460, Esso Spartan EP 460, Mobil Gear
634, Shell Omala Oel 460, Texaco Meropa 460, (Shell
Tivela Oil 82)
32 250 07 65 0
(1 kg)
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3 SF travel drive
3.4 Motor data
SF .. 50 Hz
Index No. Type P n1 TN TA TH TB Jrot Jschw cos N cos K DC Ac
T3
Wmax PB
kW 1/min Nm Nm Nm Nm kgm
2
kgm
2
% J/br W
123 8/2F12/220.223 0,09
0,36
590
2420
1,46 3,8
3,6
2,3
2,3
1,3 0,0005 0,0053 0,55
0,83
0,77
0,93
20
40
800 3000 54
133 8/2F13/220.233 0,13
0,55
600
2540
2,07 5,1
5,1
3,5
3,5
2,5 0,0007 0,0085 0,55
0,82
0,72
0,92
20
40
500 3000 54
313 8/2F31/210.423 0,32
1,25
660
2550
4,68 7,6
10,5
6,4
6,8
5,0 0,0032 0,0165 0,69
0,88
0,89
0,90
20
40
600 12000 84
423 8/2F42/210.433 0,50
2,00
665
2680
7,13 12,0
17,4
9,2
10,4
8,0 0,0057 0,0267 0,74
0,95
0,87
0,90
20
40
360 12000 84
523 8/2F52/210.523 0,80
3,20
610
2550
11,96 21,0
24,0
18,0
18,0
13,0 0,0104 0,0408 0,74
0,96
0,83
0,82
20
40
300 25000 100
Index No. Type In Ik
220...240V 380...415V 480...525V 220...240V 380...415V 480...525V
[A] [A] [A] [A] [A] [A]
123 8/2F12/220.223 1,7
2,3
1,0
1,3
0,8
1,0
2,4
5,6
1,4
3,2
1,1
2,6
133 8/2F13/220.233 2,1
2,8
1,2
1,6
1,0
1,3
2,8
7,6
1,6
4,5
1,1
2,6
313 8/2F31/210.423 2,4
5,2
1,4
3,0
1,1
2,4
5,0
16,0
2,9
9,2
2,3
7,4
423 8/2F42/220.433 3,1
7,0
1,8
4,0
1,4
3,2
7,7
28,0
4,4
16,0
3,5
13,0
523 8/2F52/210.223 4,7
12,7
2,7
7,3
2,2
5,6
10,6
43,0
6,1
25,0
4,9
20,0
SF .. 400 V, 60 Hz
T3
Wmax PB
2
kgm
2
% J/br W
123 8/2F12/220.223 0,09
0,36
590
2420
1,46 3,8
3,6
2,3
2,3
1,3 0,0005 0,0053 0,55
0,83
0,77
0,93
20
40
800 3000 54
133 8/2F13/220.233 0,13
0,55
600
2540
2,07 5,1
5,1
3,5
3,5
2,5 0,0007 0,0085 0,55
0,82
0,72
0,92
20
40
500 3000 54
313 8/2F31/210.423 0,32
1,25
660
2550
4,68 7,6
10,5
6,4
6,8
5,0 0,0032 0,0165 0,69
0,88
0,89
0,90
20
40
600 12000 84
423 8/2F42/210.433 0,50
2,00
665
2680
7,13 12,0
17,4
9,2
10,4
8,0 0,0057 0,0267 0,74
0,95
0,87
0,90
20
40
360 12000 84
523 8/2F52/210.523 0,80
3,20
610
2550
11,96 21,0
24,0
18,0
18,0
13,0 0,0104 0,0408 0,74
0,96
0,83
0,82
20
40
300 25000 100
220...240V 380...415V 480...525V 220...240V 380...415V 480...525V
[A] [A] [A] [A] [A] [A]
123 8/2F12/220.223 1,2
1,5
1,0
1,3
0,8
1,0
1,6
3,7
1,4
3,2
1,1
2,6
133 8/2F13/220.233 1,47
1,8
1,2
1,6
1,0
1,3
1,8
5,2
1,6
4,5
1,3
3,6
313 8/2F31/210.423 1,6
3,5
1,4
3,0
1,1
2,4
3,3
10,6
2,9
9,2
2,3
7,4
423 8/2F42/220.433 2,1
4,6
1,8
4,0
1,4
3,2
5,1
19,
4,4
16,0
3,5
13,0
523 8/2F52/210.223 3,1
8,4
2,7
7,3
2,2
5,8
7,0
28,0
6,1
25,0
4,1
16,7
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3.4 Motor data (continued)
SF .. 400 V, 50 Hz 400 V, 100 Hz
Index No. Type fN P n1 TN TA TH TB Jrot IN IK cos
N
cos
K
DC Ac x
-Y -A -Y -A -A -A Y A O
Hz kw 1/min
Nm
Nm Nm Nm kgm
2
A A %
184 4F18/220.233
4F18/231.233
50 100 0,38 0,75 1220 2440 2,94 5,1 3,8 1,3 0,0005 1,1 2,2 2,7 0,73 0,82 60 500 34,1
384 4F38/210.233
4F38/221.233
50 100 1,1 2,20 1370 2740 7,7 17 13 8 0,0032 2,8 5,2 9,5 0,8 0,87 60 320 5,6
484 4F48/210.233
4F48/220.233
50 100 1,60 3,20 1425 2850 10,7 31 34 13 0,0057 4,3 8,6 23 0,71 0,83 60 300 2,6
Ac [(c:h) x s]
cos K
cos N
DC [%]
IK [A]
IN [A]
Jrot [kgm2]
Jschw [kgm2]
Jges [kgm2]
Switching frequency factor
Power factor (short circuit)
Power factor (nominal)
Duty cycle
Short circuit current
Rated current
Moment of inertia, rotor
Moment of inertia, centrifugal mass
Moment of inertia of motor as a whole
n1 [1/min]
PB [W]
P [kW]
TA [Nm]
TB [Nm]
TH [Nm]
TN [Nm]
Wmax [J/Br]
*1
x =
Motor r.p.m.
Coil output (brake)
Motor output
Motor starting torque
Braking torque (motor shaft)
Run-up torque (motor shaft)
Rated motor torque
Max. permissible friction energy (brake)
Terminal resistance
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3 SF travel drive
Measured at a distance of 1 m from the crane contour.
The mean sound pressure level calculated for one operating cycle (50% with nominal
load, 50% without load) can be seen in the tables.
Instead of stating an emission value based on a workplace, the values from the
tables at measuring distance "h" can be used.
Indoors
Outdoors
The components are designed for use in industry and for the ambient conditions
usual in industry.
Protection against dust and humidity in acc. with EN 60 529 / IEC
Standard: IP 55
Option: IP66
Standard: -20C ... +40C
Option: +60
Frequency inverters can be used from -20C to +50C (non-dewing).
Type of
travel drive
[db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
SF .. 2.. ... 72 69 66 66 63
SF .. 8.. ... 78 75 72 69 66
Type of
travel drive
[db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
SF .. 2.. ... 72 66 60 54 48
SF .. 8.. ... 78 72 66 60 54
W0923
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3.7 Wearingi parts
Brake disc (brake rotor)

Travel drive Motor Order No.
Brake disc
SF xx xxx 123 8/2F12/2xx.223 21 270 23 65 0
SF xx xxx 133
SF xx xxx 184
8/2F13/2xx.233
4F18/2xx.233
21 270 23 65 0
21 270 23 65 0
SF xx xxx 313 8/2F31/2xx.423 21 270 36 65 0
SF xx xxx 384
SF xx xxx 423
4F38/2xx.423
8/2F42/2xx.433
21 270 36 65 0
21 270 36 65 0
SF xx xxx 484 4F48/2xx.443 21 270 36 65 0
SF xx xxx 523 8/2F52/2xx.523 21 270 42 65 0
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4 SA-C travel drive
4.1 Installation
4.1.1 Description
The travel drive is a high-quality drive with smooth starting and braking characteri-
stics such as is required in particular for material handling.The pole-changing motor
must be activated in a certain way to achieve this (see block circuit diagram, chapter
"Electrical connection").
4.1.2 Permissible mounting position
The travel drive can be rotated around its main horizontal axis in 90 steps.
The gear vent plug must always be at the highest point of the gear
Remove sticker from vent plug.
Tighten fixing bolts with specified torque
Check oil level before commissioning
A
W0936
W0939
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4 SA-C travel drive
4.1.3 Electrical connection
The mains voltage must match that given on the rating plate.
Electrical connection with plug connection or cable gland.
If using cable gland, follow the terminal diagram.
Block terminal diagram
M 25
W0938
W0943
W0944
8/2 F.. motor 4 F.. motor
W0942
Standard settings for frequency inverter
Speed m/min 8 10 12,5 16 20 25 32 40 50 63 80 100
Max. frequency Hz 80 100 50 63 80 100 80 100 80 100 100 100
Motor connection A A Y Y A A A A A A A A
Run-up time [s] 2,1 2,4 2,8 3,3 3,8 4,2 4,7 5,2 5,6 6,0 6,7 8,4
Stopping time [s 1,7 2,0 2,3 2,7 3,0 3,4 3,8 4,2 4,5 4,8 5,4 6,7
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4 SA-C travel drive
Crane travel motor 1 Crane travel motor 2
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4 SA-C travel drive
*1 Option: temperature control
*2 Option: travel limit switch
The time-lag relays -K624 and -K625 shown in the circuit diagram are pre-set (approx.
3 sec.). The time-lag relay -K625 should be reset on commissioning depending on
load and travel speed. The switching time should be adjusted so that no sudden
increase in speed occurs in the drive when the slow speed is activated.
Method of functioning:
On start-up, -K624 requires start-up with 8 poles for the time set.
On braking, -K625 requires the brake to act for the time set, thus
avoiding dynamic braking and a high torque load on the drive.
We recommend start-up control from motor size 8/2 F42...
Brake control is required for all drives.
Temperature control forwards reverse fast slow
Switching time
fast-slow
Slow start-up
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4 SA-C travel drive
4.2 Maintenance
This section deals with the operational reliability, availability, and maintaining the
value of your travel drives.
Although they are practically maintenance-free, the components subject to wear
must be inspected regularly. This is required by the accident prevention regulations.
The inspections must be performed by qualified personnel, see page 2.
Maintenance and repair work may only be carried out when the crane is not under
load.
Follow the accident prevention regulations.
Please also note the "Safety instructions" on page 5.
Wearing parts, see page 40.
4.3.1
*2 By the operator
Similarly, heavy-duty applications and adverse conditions (dirt, solvents, multi-shift operation etc.)
necessitate shortening this inspection and maintenance interval.
No.
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g
*
1
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w
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2
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y

1
2

m
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*
3
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y

1
2

m
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s

*
2
M
a
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t
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a
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a
f
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1
0

y
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a
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a
l

o
v
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*
4
Inspection and maintenance table
(Classification: 1 Bm)
See
page
1
Attachment of travel drive, torque support
24
2
Check braking effect of travel drive
3
Oil level
30
4
Change gear oil/grease of travel drive
30
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4 SA-C travel drive
4.3 Maintenance work (continued)
4.3.2 Travel motor brake
Check brake at regular intervals. The intervals must be adapted in accordance with
the application.
Move carriage into a safe position
Remove plug (2)
Measure air gap (S) with feeler gauge (F). See table for max. permissible air gap
(S).
The travel motor brake needs no adjustment.
must be replaced.
Disconnect brake
underneath.
Replacement and repairs may only be carried out by qualified personnel!
Travel drive Motor type Brake Braking
torque
[Nm]
S
min.
[mm]
S
max.
[mm]
t
min
[mm]
(4)
Nm
SA-C ... 133
SA-C ... 184
8/2F13/2xx.233
4F18/2xx.233
FDW 08
FDW 08
2,5
2,5
0,2
0,2
1,6
1,6
6,1
3xM4
3xM4
3
3
SA-C ... 313 8/2F31/2xx.423 FDW 13 5 0,3 2,0 8,8 3xM6 10
SA-C ... 384
SA-C ... 423
4F38/2xx.433
8/2F42/2xx.433
FDW 13
FDW 13
8
8
0,3
0,3
2,0
2,0
8,8
3xM6
3xM6
10
10
SA-C ... 484 4F48/2xx.443 FDW 13 13 0,3 1,2 9,6 3xM6 10
SA-C ... 523 8/2F52/2xx.523 FDW 15 13 0,3 2,0 10,8 3xM6 10
09.06
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4 SA-C travel drive
4.3.4 Gear
The gear has a long service life. All bearing points have roller bearings. The gearing
is hardened, hard-machined and has high safety factors.
During annual maintenance, check whether any oil has leaked (puddle of oil
underneath the gear, drops of oil on the gearbox). If any loss of oil is ascertained,
the oil must be changed and repairs scheduled if necessary.
Note any gear noises from the crane when under load and without load. Rough,
noisy running, knocking sounds indicate possible faults.
If any faults are detected, repairs must be scheduled.
If there is any uncertainty, a fresh diagnosis can be made after consulting experts,
e.g. from the manufacturer (see back cover).
4.3.5 Changing oil of travel drive
Lubricating toothed boss of wheel
The SA-C .. travel drives have a gear with oil lubrication.
The toothed boss of the wheel (a) and the gear (b) is lubricated with grease (see
table).
Run gear oil off while warm.
The type and quantity of oil or grease can be seen from the table.
( ) = Lubricants for low operating temperatures,max. -30C
* Factory filling
*1 Only down to -20C
W0941
Position of lubrication point Type of
lubricant
Designa-
tion
Quantity
Charakteristics, makes Order. No.
a
b
Toothed boss of wheel
Toothed boss of gear
Grease KPF 1K 50 gr Soap base: Lithium + MoS2
Dripping point: approx. 185C (180C)
Penetration: 310-340 (310-340)
Operating temperature: -20to +120C, (-50 to +150C),
e.g.: Aral Fett P 64037*, Aralub PMD1, BP Multi-purpose
Grease L21M, Esso Multi-purpose Grease M, Mobil Grease
Special, Shell Retimax AM *1, Texaco Molytex Grease EP2,
Fuchs Renolit FLM2, (Fuchs Renolit FLM2)
Gear SA-. 5..
Gear SA-. 6..
Oil CLP 460 1000 ml
1500 ml
1000 ml
3000 ml
Viscosity: 460 cSt/40C (240 cSt/40C)
Pourpoint: -20C (-40)
Flash point: +265C (+270C)
e.g.: Fuchs Renep Compound 110*, Aral Degol BG 460,
BP Energol GR-XP 460, Esso Spartan EP 460, Mobil Gear
634, Shell Omala Oel 460, Texaco Meropa 460, (Shell
Tivela Oil 82)
32 250 07 65 0
(1 kg)
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4 SA-C travel drive
4.4 Motor data
SA-C .. 50 Hz
T3
Wmax PB
2
kgm
2
% J/br W
123 8/2F12/220.223 0,09
0,36
590
2420
1,46 3,8
3,6
2,3
2,3
1,3 0,0005 0,0053 0,55
0,83
0,77
0,93
20
40
800 3000 54
133 8/2F13/220.233 0,13
0,55
600
2540
2,07 5,1
5,1
3,5
3,5
2,5 0,0007 0,0085 0,55
0,82
0,72
0,92
20
40
500 3000 54
313 8/2F31/210.423 0,32
1,25
660
2550
4,68 7,6
10,5
6,4
6,8
5,0 0,0032 0,0165 0,69
0,88
0,89
0,90
20
40
600 12000 84
423 8/2F42/210.433 0,50
2,00
665
2680
7,13 12,0
17,4
9,2
10,4
8,0 0,0057 0,0267 0,74
0,95
0,87
0,90
20
40
360 12000 84
523 8/2F52/210.523 0,80
3,20
610
2550
11,96 21,0
24,0
18,0
18,0
13,0 0,0104 0,0408 0,74
0,96
0,83
0,82
20
40
300 25000 100
220...240V 380...415V 480...525V 220...240V 380...415V 480...525V
[A] [A] [A] [A] [A] [A]
123 8/2F12/220.223 1,7
2,3
1,0
1,3
0,8
1,0
2,4
5,6
1,4
3,2
1,1
2,6
133 8/2F13/220.233 2,1
2,8
1,2
1,6
1,0
1,3
2,8
7,6
1,6
4,5
1,1
2,6
313 8/2F31/210.423 2,4
5,2
1,4
3,0
1,1
2,4
5,0
16,0
2,9
9,2
2,3
7,4
423 8/2F42/220.433 3,1
7,0
1,8
4,0
1,4
3,2
7,7
28,0
4,4
16,0
3,5
13,0
523 8/2F52/210.223 4,7
12,7
2,7
7,3
2,2
5,6
10,6
43,0
6,1
25,0
4,9
20,0
SA-C .. 60 Hz
T3
Wmax PB
2
kgm
2
% J/br W
123 8/2F12/220.223 0,11
0,44
710
2900
1,46 3,8
3,6
2,3
2,3
1,3 0,0005 0,0053 0,55
0,83
0,77
0,89
20
40
800 3000 54
133 8/2F13/220.233 0,16
0,66
720
3050
2,07 5,1
5,1
3,5
3,5
2,5 0,0007 0,0085 0,55
0,82
0,72
0,92
20
40
500 3000 54
313 8/2F31/210.423 0,36
1,50
790
3060
4,68 7,6
10,5
6,4
6,8
5,0 0,0032 0,0165 0,69
0,86
0,89
0,90
20
40
600 12000 84
423 8/2F42/210.433 0,60
2,40
800
3220
7,13 12,0
17,4
9,2
10,4
8,0 0,0057 0,0267 0,74
0,95
0,87
0,90
20
40
360 12000 84
523 8/2F52/210.523 0,90
3,80
730
3060
11,96 21,0
24,0
18,0
18,0
13 0,0104 0,0408 0,74
0,96
0,83
0,82
20
40
300 25000 100
220...240V 380...415V 480...525V 220...240V 380...415V 480...525V
[A] [A] [A] [A] [A] [A]
123 8/2F12/220.223 1,2
1,5
1,0
1,3
0,8
1,0
1,6
3,7
1,4
3,2
1,1
2,6
133 8/2F13/220.233 1,47
1,8
1,2
1,6
1,0
1,3
1,8
5,2
1,6
4,5
1,3
3,6
313 8/2F31/210.423 1,6
3,5
1,4
3,0
1,1
2,4
3,3
10,6
2,9
9,2
2,3
7,4
423 8/2F42/220.433 2,1
4,6
1,8
4,0
1,4
3,2
5,1
19,
4,4
16,0
3,5
13,0
523 8/2F52/210.223 3,1
8,4
2,7
7,3
2,2
5,8
7,0
28,0
6,1
25,0
4,1
16,7
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4 SA-C travel drive
4.4 Motor data (continued)
SA-C .. 380...480 V, 50 Hz 380...415 V, 100 Hz
Index No. Type fN P n1 TN TA TH TB Jrot IN IK cos
N
cos
K
DC Ac x
-Y -A -Y -A -A -A Y A O
Hz kw 1/min
Nm
Nm Nm Nm kgm
2
A A %
184 4F18/220.233
4F18/231.233
50 100 0,38 0,75 1220 2440 2,94 5,1 3,8 1,3 0,0005 1,1 2,2 2,7 0,73 0,82 60 500 34,1
384 4F38/210.233
4F38/221.233
50 100 1,1 2,20 1370 2740 7,7 17 13 8 0,0032 2,6 5,2 9,5 0,8 0,87 60 320 5,6
484 4F48/210.233
4F48/220.233
50 100 1,60 3,20 1425 2850 10,7 31 34 13 0,0057 4,3 8,6 23 0,71 0,83 60 300 2,6
Ac [(c:h) x s]
cos K
cos N
DC [%]
IK [A]
IN [A]
Jrot [kgm2]
Jschw [kgm2]
Jges [kgm2]
Switching frequency factor
Power factor (short circuit)
Power factor (nominal)
Duty cycle
Short circuit current
Rated current
Moment of inertia, rotor
Moment of inertia, centrifugal mass
Moment of inertia of motor as a whole
n1 [1/min]
PB [W]
P [kW]
TA [Nm]
TB [Nm]
TH [Nm]
TN [Nm]
Wmax [J/Br]
*1
x =
Motor r.p.m.
Coil output (brake)
Motor output
Motor starting torque
Braking torque (motor shaft)
Run-up torque (motor shaft)
Rated motor torque
Max. permissible friction energy (brake)
Terminal resistance
01.09
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4 SA-C travel drive
Measured at a distance of 1 m from the crane contour.
The mean sound pressure level calculated for one operating cycle (50% with nominal
load, 50% without load) can be seen in the tables.
Instead of stating an emission value based on a workplace, the values from the
tables at measuring distance "h" can be used.
Indoors
Outdoors
The components are designed for use in industry and for the ambient conditions
usual in industry.
Protection against dust and humidity in acc. with EN 60 529 / IEC
Standard: IP 55
Option: IP66
Standard: -20C ... +40C
Option: +60
Frequency inverters can be used from -20C to +50C (non-dewing).
Type of
travel drive
[db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
SA-C .. 72 69 66 66 63
Type of
travel drive
[db (A)] + / - 3
h [m]
1 m 2 m 4 m 8 m 16 m
SA-C .. 72 66 60 54 48
W0923
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4.7 Wearing parts
Brake disc (brake rotor)
Travel drive Motor Order no.
Brake disc
SA-C ... 133
SA-C ... 184
8/2F13/2xx.233
4F18/2xx.233
21 270 23 65 0
21 270 23 65 0
SA-C ... 313 8/2F31/2xx.423 21 270 36 65 0
SA-C ... 384
SA-C ... 423
4F38/2xx.423
8/2F42/2xx.433
21 270 36 65 0
21 270 36 65 0
SA-C ... 484 4F48/2xx.443 21 270 36 65 0
SA-C ... 523 8/2F52/2xx.523 21 270 42 65 0
01.09
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5 General information
5.1 Seminars
We offer seminars covering all main product groups, such as seminars for crane
operators, wire rope hoist seminar, chain hoist seminar, seminar on load suspension
equipment and seminar for material conveying equipment.
However we would be please to offer a special programme orientated on your in-
dividual specifications and requirements.
The seminars are individual modules or can form part of a long-term training course;
they are held in German or English.
Each seminar is concluded with a certificate.
You can obtain information on our seminar programme from:
STAHL CraneSystems GmbH
Daimlerstrae 6 | D-74653 Knzelsau | Tel. +49 7940 128-0
marketing@stahlcranes.com
Or you can find information at www.stahlcranes.com
09.06
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-
E
N
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0
3
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0
9
-
s
c
Tochtergesellschaften/Subsidiaries
Austria
Steyregg
Tel +43 732 641111-0
Fax +43 732 641111-33
Great Britain
Birmingham
Tel +44 121 7676400
Fax +44 121 7676485
Portugal
Lissabon
Tel +351 21 44471-60
Fax +351 21 44471-69
Switzerland
Dniken
Tel +41 62 82513-80
Fax +41 62 82513-81
info@stahlcranes.ch
China
Shanghai
Tel +86 21 6257 2211
Fax +86 21 6254 1907
info@stahlcranes.cn
India
Chennai
Tel +91 44 4352-3955
Fax +91 44 4352-3957
Singapore
Singapore
Tel +65 6271 2220
Fax +65 6377 1555
Dubai
Tel +971 4 805-3700
Fax +971 4 805-3701
info@stahlcranes.ae
France
Paris
Tel +33 1 39985060
Fax +33 1 34111818
info@stahlcranes.fr
Italy
S. Colombano
Tel +39 0185 358391
Fax +39 0185 358219
info@stahlcranes.it
Spain
Madrid
Tel +34 91 484-0865
Fax +34 91 490-5143
info@stahlcranes.es
USA
Charleston, SC
Tel +1 843 767-1951
Fax +1 843 767-4366
Vertriebspartner/Sales partners

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0-WD951-EM620-00079 1

OPERATION AND MAINTENANCE

*** Preferred installation position

Block terminal diagram

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