CarlStahl CGSMVS 120 Service manual

Operating and Service Manual
Lifting clam CGSMVS - 120 / 240
Version 1.3
Carl Stahl Süd GmbH
Standort München
D-85521 Ottobrunn
Christa-McAuliffe-Str. 3
Telefon [phone]
Telefax [phone]
[email protected]
www.carlstahl-muenchen.de

Operating and Service Manual
Lifting clam CGSMVS - 120 / 240
2 / 24 Version 1.3

Operating and Service Manual
Lifting clam CGSMVS - 120 / 240
Version 1.3 3 / 24
1 Introduction 4
2 Notes on these Instructions 5
2.1 General remark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Icon usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Product description 6
4 Components and functional elements 7
5 Safety 7
5.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Selection and qualification of staff . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Dangers arising from the lifting clamp . . . . . . . . . . . . . . . . . . . . . . 8
5.3.1 General dangers arising from crane operation . . . . . . . . . . . . . . . 8
5.3.2 Danger due to the weight of the lifting clamp . . . . . . . . . . . . . . . . 8
5.3.3 Danger due to the load slipping out . . . . . . . . . . . . . . . . . . . . . . . 8
5.3.4 Danger due to wrong clamping jaws . . . . . . . . . . . . . . . . . . . . . . 8
5.3.5 Danger of being crushed by moving parts . . . . . . . . . . . . . . . . . . 9
5.4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Scope of delivery 10
7 Operation 11
7.1 Changing the clamping jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Adjusting clamping jaw distance . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.3 Correct lifting and lowering of loads . . . . . . . . . . . . . . . . . . . . . . . 13
7.4 Operation, lifting and lowering of loads with the lifting clamp . . . . 14
7.5 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Service 15
9 Technical data 15
10 Spare parts 16
11 Declaration of Conformity 19
12 Inspection reports 20
Contents

Operating and Service Manual
Lifting clam CGSMVS - 120 / 240
4 / 24 Version 1.3
1 Introduction
We are pleased that you have decided in favor of one our products. We wish you a smooth and
successful operation.
The Lifting clam CGSMVS - 120 / 240 has been specially developed and manufactured for your
requirements. If used properly, it will perform as expected for a long time.
We would like to invite you to help us in our efforts to maintain our quality standard at the utmost level.
Please let us know if there is any we can further improve our products.
Do you have any questions? We are looking forward to hearing from you.
Carl Stahl Süd GmbH
Standort München
D-85521 Ottobrunn
Christa-McAuliffe-Str. 3
Phone [phone]
Fax [phone]
E-mail: [email protected]

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Version 1.3 5 / 24
2 Notes on these Instructions
2.1 General remark
This operating manual contains all instructions and descriptions required for the operation of the
lifting clamp. We have created this documentation with all due diligence. We appreciate your
suggestions and comments.
For better comprehensibility, descriptions are accompanied by photos and diagrams of the machine
or its components.
All mentioned company, product and/or brand names are property of their respective owners, and
are generally protected by law with regard to brand names, patents or utility models.
2.1.1 Icon usage
The following icons are used in this manual:
WARNING: Warns of a hazard to persons and material. Disregarding the instructions
marked with this icon might result in serious injury and material damage.
CAUTION: Warns of material damage. Disregarding the instructions marked with this icon
might result in material damage.
NOTE: Technical information that requires particular attention.
• Step
1. Step, in numbered sequence
- List
(1) (A) Legend number for component in illustration
* Reference to a note
Bold text Structure, note

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3 Product description
The lifting clamp consists of a sturdy steel construction that is capable of safely lifting the load
(panels, plates) by means of a form-locking clamping jaw.
The required contact force is generated by the own weight of the load via a lever mechanism with
chain sling. The contact force of the clamping jaws depends on the own weight of the load. Different
load thicknesses can be adjusted by means of a perforated grid on the lifting clamp.
A deviation of thickness (<10 mm) of the load is compensated for by the lever of the lifting clamp. A
tension spring provides the necessary retention force for the lifting clamp to be held without
load.

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4 Components and functional elements
5 Safety
5.1 Intended use
The lifting clamp is intended for the lifting, lowering
and moving of individual so-called self-supporting
sandwich elements with rigid polyurethane foam
core (manufactured to DIN EN 14509:2013-12) in
the context of the conditions listed in chapter 9,
Technical data, with operation by one person.
Any use going beyond the above is considered
contrary to intended use.
Use in a potentially explosive atmosphere is
prohibited.
Any
- alterations or extensions
- use of non-original spare parts
- repairs carried out by companies or individuals that are not authorized by the manufacturer
may result in loss of warranty, unless specifically approved by the manufacturer in writing.
5.2 Selection and qualification of staff
Staff that operate or install the lifting clamp must
- be at least 18 years old.
F Grip (rear)
G Grip and lever for opening the clamping jaws
14 Clamping jaw closing spring
15 Chain sling
16 Ball locking pin to adjust distance of clamping jaws
17 Oval suspension ring
33 Ball locking pin to change fixed clamping jaw
38 Movable clamping jaw
39 Fixed clamping jaw
38
14
33
16
39
15
17
G
F
Fig. 1

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- be adequately trained for the respective tasks.
- know and observe the relevant technical rules and safety regulations.
The operating company decides upon the required qualifications for the
- operating staff
- service staff
- maintenance staff
The operating company must ensure that only authorized staff will perform any task on the lifting
clamp.
Staff that are to be trained, taught, instructed or placed in an apprenticeship may only work on the
lifting clamp under constant supervision of an experienced person.
Work on electrical and pneumatic components must only be performed by qualified staff with
appropriate training and in compliance with all applicable rules in the accident prevention regulations
(UVV).
5.3 Dangers arising from the lifting clamp
The operating company must ensure that the operator has been adequately instructed regarding
potential dangers, and will comply with these instructions.
5.3.1 General dangers arising from crane operation
If a crane that carries a load by means of a lifting clamp is operated incorrectly (pulling at angles, load
swing, excessive weight, attaching the load in an unsafe or unbalanced way, sudden change of load
direction, etc.) it may topple or be damaged. This might result in personal injury and/or material
damage. Before the lifting clamp is put into operation, the safety regulations for the crane must be
read, understood and observed.
5.3.2 Danger due to the weight of the lifting clamp
The lifting clamp is heavy. If it falls, this may result in personal injury and/or material damage.
Operators must wear personal protective equipment adequate to the circumstances (gloves, head
protection, protective footwear, etc.).
5.3.3 Danger due to the load slipping out
If one or both clamping jaws are damaged or soiled, this might reduce the friction at the clamping
jaws that is necessary for safe operation. As a result, the contact force required for lifting the load
might be reduced to the extent that the load cannot be held safely anymore, and the load might slip
out. A falling load might cause personal injury and/or material damage.
Both clamping jaws must be clean and undamaged.
5.3.4 Danger due to wrong clamping jaws
Unless the lifting clamp is operated with at least one form-locking clamping jaw, the load can no
longer be held safely in case of an inadvertent loss of friction. A falling load might cause personal
injury and/or material damage.
The clamping jaws must be installed according to the load and in correct position (see 7.1).

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5.3.5 Danger of being crushed by moving parts
As a result of the tension on the chain (1) and the
movement of the lever (at the grip G) there is a risk of
being crushed between the parts in the marked areas (X)
(e.g. for fingers, hands, ball of the thumb, etc.).
Do not reach into the marked areas (X).
Do not touch the lifting clamp while it is being closed (the
chain (1) is being pulled in the direction of the arrow).
Only touch the lifting clamp at the grip (G) while the load
is being conveyed.
Do not touch the chain when the lifting clamp is opened
as it will be drawn into the housing.
Fig. 2
X
1
X
X

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5.4 Safety devices
The operating company must ensure that trained staff will
- regularly check all safety devices.
- immediately rectify any detected faults on safety devices.
- secure the lifting clamp against being put into operation unless all safety devices are in place and
fully functional.
6 Scope of delivery
- Lifting clamp
- Clamping jaws (option, according to order specification)
- Operating and service manual
F Grip (rear)
G Grip and lever for opening the clamping jaws.
14 Clamping jaw closing spring
16 Ball locking pin to adjust distance of clamping jaws.
33 Ball locking pin to change fixed clamping jaw* with
both sleeves
(10 see Fig. 12).
38 Movable clamping jaw. The rubber lining must cover
the entire surface and have a minimum profile depth
of 1 mm.
39 Fixed clamping jaw
The rubber lining must cover the entire surface.
Clamping jaw version D: The rubber lining must
have a minimum profile depth of 1 mm over the
entire surface.
Clamping jaw versions A-C: The elements that
provide the positive locking must be complete,
undamaged and bolted to all fastening points (see
Fig. 4).
41 Adhesive label clamping width
42 Attached to clamping jaw (38) (Engraving): “Dry,
clean and grease-free”
Adhesive safety label "Warning of hand
injuries". Clearly and visibly applied to the
side part
Fig. 3

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7 Operation
7.1 Changing the clamping jaws
The installed clamping jaws (45) must provide a positive locking with the load. Moving loads without
appropriate clamping plates is dangerous; the load might fall (see 5.3.4).
Suitable clamping jaws
A Megatec
B H-Wall 10-Trapeze
C H-Wall 8-Wave
D G4
Make sure that the movable clamping jaw
(38) is installed in correct position (as
shown).
• Select the clamping jaw appropriate to the load
• Pull out ball locking pin (33)
• Remove clamping plate (39) with both sleeves (10)
• Install selected clamping jaw in reverse order. During installation,
observe installation position Fig. 4 (see fastening leg (45))
45
ABCD
38
Fig. 4
10
39
33
Fig. 5

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7.2 Adjusting clamping jaw distance
• Determine width (A) of the load (core thickness)
• On the adhesive label (41), read the positioning of the ball locking pin
that corresponds to the width of the load
• Pull out ball locking pin (16)
• Shift side parts (1 and 2) in such a way that the ball locking pin can
be inserted into the position corresponding to the width of the load
• Insert ball locking pin (16)
A
Fig. 6
2
16
141
Fig. 7

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7.3 Correct lifting and lowering of loads
- When lifting with a two-leg chain sling, the spread angle (A) must not be greater than 30°
- Angle (B) between chain and clamp housing must not be greater than 10°
- CAUTION: Long load elements might move inadvertently due to wind or to weight differences. As
a result, angle (B) might be exceeded. It is strongly recommended to use a beam (C) with two
lifting clamps
- Make sure that the clamping jaws will not compress the load (core thickness (A)) by more than
10 mm
A
B
C
Fig. 8
A
Fig. 9

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7.4 Operation, lifting and lowering of loads with the lifting clamp
Before operation, perform a visual inspection of the lifting clamp. All components must be complete,
fully functional and correctly installed (see also chapter 5.3 and 5.4). If there are any doubts regarding
the full functionality of the lifting clamp or its safe operation, do not lift any load with it. Perform a
professional assessment of the lifting clamp first.
• Correctly attach the lifting clamp to the crane
• Grab the lifting clamp by both handles (G and F)
• Move grip (G) all the way in the direction of the arrow, against the spring force; the clamping jaws
are open
• Position the lifting clamp as shown (example) above the load, and release both grips (not
suddenly). The clamping jaws are pressed against the load by spring force
• Make sure that it is possible to reach the tensioning distance that is required for a sufficient
clamping force. For this purpose, check if the countersunk screw (13) is positioned as shown. Its
left edge must be at least in alignment to edge (44) of side part (1)
7.5 Decommissioning
Store the lifting clamp according to the requirements described in the technical data.
G
F
13
44
11
Fig. 10

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Version 1.3 15 / 24
8 Service
Service intervals
In case of operation under special conditions (e.g., heavy soiling or heavy-duty use), the
recommended intervals are shortened accordingly.
9 Technical data
Daily, at each operation Visual and functional check
At least once a year Check according to regulations (UVV, accident prevention) performed by
competent person or manufacturer
CGSMV-120 CGSMV-240
Dimensions (WxDxH in mm)
(Smallest clamping width set) 250 x 255 x 360 360 x 255 x 360
Grab width (mm) 30 - 120 120 - 240
Load capacity kg 250
Weight (approx. kg) 11
Ambient operating conditions -20 to +80 °C (-4 to +176 °F) (TA); Air pressure 1 bar
Storage conditions dry and free from dust, 0 to +40 °C (+32 to +104 °F)
Fig. 11

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10 Spare parts
Fig. 12

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Version 1.3 17 / 24
Item number
CGSMVS...
Position Description 30-120 120-240
Lifting clamp, complete 71882002 71882013
A Set 1, Suspension, consisting of: Set 1 Set 1
1 x Oval ring
1 x Chain
1 x Bolt M10x55
2 x Disc
2 x Pulley (1A only for CGSMVS 120-240)
1A Only for CGSMVS 120-240
B Set 2, Lever/spring/grip, consisting of: Set 2 Set 2
2 x Lever
1 x Bow handle
1 x Bolt M10x56
1 x Countersunk screw M6x25
1 x Washer, plastic
1 x Tension spring
1 x Spring pin 6x40
1 x Spring pin 5x24
C Set 4, Side parts, consisting of: Set 4 Set 4
2 x Side part
2 x Bolt M10x56
1 x Nameplate
1 x Adhesive label “Check”
2 x Protective cap, nut M10
2 x Nut M10
2 x Disk B10
1 x Sleeve
D Set 5, Adjustment, consisting of: Set 5 Set 5
1 x Steel plate with counterbore
1 x Steel plate without counterbore
4 x Cylinder bolt M10
4 x Hexagon nut M10
4 x Protective cap, nut M10
4 x Disk B10
1 x Adjustment pin 12x60 mm incl. rope & plate
1 x Adhesive label “Adjustment grid”

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* Make sure to install in correct position. See Fig. 4
2 x Sleeve 20x40 mm
1 x Sleeve 20x26.5
1 x Bow handle
2 x Bolt M10
E Set 6, Grab jaws, consisting of: Set 6 Set 6
2 x Grab jaw *
2 x Washer, plastic 20x16
1 x Washer, plastic 20x8.5
1 x Pin
1 x Adjustment pin 10x60 mm incl. rope & plate
Item number
CGSMVS...
Position Description 30-120 120-240

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Version 1.3 19 / 24
11 Declaration of Conformity
EC Declaration of Conformity according to EC Machinery Directive 2006/42/EC, Appendix II A
The manufacturer / distributor hereby declares that the following product
Carl Stahl Süd GmbH
Standort München
D-85521 Ottobrunn
Christa-McAuliffe-Str. 3
Lifting clamp CGSMV
complies with the basic safety and health requirements of the above mentioned Directive in its design and construction and in
the form in which it is marketed by us.
Description Variable-width lifting clamp with contact force generated by own weight of
the load.
Model Condor
Type CGSMVS - 120
CGSMVS - 240
Applied harmonized standards
DIN EN 13155:2003+A2:2009 Cranes - safety - non-fixed load-handling attachments
DIN EN 1090-1:2012-02 Execution of steel structures and aluminum structures - Part 1
DIN EN 1090-2:2011-10 Execution of steel structures and aluminum structures - Part 2
DIN EN 1993 Design of steel structures
DIN EN 818 Short link chain for lifting purposes
DIN EN 1677 Components for slings
The following additional directives apply
DGUV Rule 100-500 Occupational Safety and Health Rules by Employer's Liability Insurance
Association (BGR)
Authorized person for compilation of technical documentation: Andreas Kammerer
Address see above
_________________________________________
Andreas Kammerer, Senior Design Engineer
Munich, August 6, 2015

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12 Inspection reports
Inspection by manufacturer on (date) Inspector (name in block letters)
Stamp Inspector’s signature
RegularUVVinspection Defects present: No Yes
Date of inspection Inspected by company (full name)
Inspection record number Inspector (name in block letters)
Stamp Inspector’s signature
Defects remedied on (date) Defects remedied by company (full name)
RegularUVVinspection Defects present: No Yes
Date of inspection Inspected by company (full name)
Inspection record number Inspector (name in block letters)
Stamp Inspector’s signature
Defects remedied on (date) Defects remedied by company (full name)