Stahl ST05, Original Instructions Manual

Page 1: ...Chain Hoists Original instructions ...

Page 2: ......

Page 3: ...ty 12 2 10 Safety conscious operation 13 2 11 Attaching load 13 3 Introduction 14 4 Installation 15 4 1 Stationary chain hoist 15 4 2 Chain hoist with trolley 16 4 2 1 Assemble the trolley 16 4 2 2 Adjust trolley to runway width 19 4 3 Installing trolley on chain hoist 21 4 4 Attach the trolley to the runway beam 23 4 5 Connecting electric trolley 24 4 6 Mounting guide rollers 24 4 7 Mounting supp...

Page 4: ...ssemble bottom hook block 42 7 11 2 Assemble new bottom hook block 43 7 12 Replacing two fall bottom hook block 43 7 13 Replacing return sheave 43 7 14 Checking hook for wear 44 7 15 Oil change 44 7 16 Trolley 45 7 17 Operating hours counter 45 7 18 General overhaul 45 8 Wearing parts 46 8 1 Hoist 46 8 2 Trolley 47 8 3 Dismantling 47 8 4 Scrap disposal 47 9 Technical data 48 9 1 Classification to ...

Page 5: ...imminent danger to health and life Ignoring these warning notices will lead to severe injuries possibly resulting in death WARNING This symbol gives warning of situations that are potentially dangerous to health and life Ignoring these warning notices may lead to severe injuries possibly resulting in death CAUTION This symbol gives warning of situations which are potentially dangerous to health Ig...

Page 6: ...sonnel 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 ex...

Page 7: ...fork lift truck If the product is to be transported suspended it must be attached to the sling points provided Do not allow the hoist to drop The product must always be set down on the ground correctly Avoid damage to the product and its components by loading and unloading it correct ly Storage Store the product and its accessories in a dry place Store it in a stable position secure it against top...

Page 8: ...recommend fitting a canopy or at least parking the hoist under a roof 1 11 After sales service You have purchased a high quality product A contracted after sales service will give you advice on its maintenance and correct use In order to maintain the safety and constant availability of the product we recommend concluding a maintenance agreement 1 12 Periodic tests Hoists and cranes must be inspect...

Page 9: ... Life cycle assessment The stages of the product service life are Production of materials components and energy transport to factory manufacture and assembly transport to customer on site installation operating phase including maintenance and modernisation dismantling and recycling of materials at end of service life 1 13 2 Energy consumption The energy consumption during the operating phase has t...

Page 10: ...wind dust splash water snow water etc For hoists which work in combination and have more than one control tandem operation action must be taken to coordinate the controls This applies also to the reaction of the protective devices For hoists intended for automatic operation the control must be designed accordingly In the case of chain hoists with multiple load bearing equipment ensure that the loa...

Page 11: ...e to unsuitable or damaged load bearing equipment Risk of electric shock Preventative measures The machine functions with high voltage Switch the machine off and ensure it cannot be switched on again before carrying out maintenance cleaning and repair work Switch off the power supply before all work on the electrical system Check that the components to be replaced are free of current and voltage D...

Page 12: ...thing jewellery etc being drawn into equipment 2 7 Protection against falling Work over 2 m above the ground may only be performed from work platforms Fitters working outside work platforms must be secured with a fall protection system 2 8 Sound pressure level Fig 3 The sound pressure level was measured at a distance of 1 m from the chain hoist The mean sound pressure level is calculated for one o...

Page 13: ... into the hoist s load bearing equipment Before lifting loads ensure that the stated maximum working load is not exceeded When lifting and setting down loads ensure that they are in a stable position in order to avoid accidents due to the load toppling or overturning Secure the load if the power is cut Have a damaged hook safety latch repaired Do not kink or crush control cables Choose a safe plac...

Page 14: ...require ments of hoist operation Our certified quality assurance system to DIN ISO 9001 EN 29001 guarantees consistent ly high quality Fig 4 1 Chain drive 2 Motor 3 Gear 4 Slipping clutch 5 Brake 6 Panel box 7 Chain box 8 Plug for control pendant 9 Plug for travel drive 10 Plug for mains connection 11 Socket for control pendant 12 Socket for travel drive 13 Socket for mains connection 14 Suspensio...

Page 15: ...r due to falling parts Check correct assembly of the overhead suspension prior to commissioning ST 05 ST 10 ST 60 Fig 5 Fig 6 1 Threaded connection of the overhead suspension Tightening torque of the screws 1 15 Nm For the assembly procedure please refer to the chapter Assemble trolley on chain hoist ...

Page 16: ... Attach the snap ring 2 to the suspension bolt 3 4 Set the correct dimension through the symmetrical distribution of the distance wash ers 5 5 Fit the trolley side cheek 1 on the suspension bolt 3 6 Screw on castellated nut 6 with distance washers 5 7 Repeat steps 2 to 6 with the second side 8 Adjust runway width with adjusting washers see chapter Adjust trolley to runway width Overhead suspension...

Page 17: ...sion bolt 4 Set the correct dimension through the symmetrical distribution of the distance wash ers 3 5 Fit the trolley side cheek 7 on the suspension bolt 6 Screw the nut 2 with the distance washers 3 7 Repeat steps 2 to 6 with the second side 8 Adjust runway width with adjusting washers see chapter Adjust trolley to runway width Overhead suspension must be central to the trolley 9 Tighten the nu...

Page 18: ...ymmetrical distribution of the distance wash ers and spacer sleeves Insert the suspension bolt 2 in position 2 without spacer sleeves Set the correct dimension through the symmetrical distribution of the distance wash ers 2 Fit the trolley side cheeks on the suspension bolts 3 Adjust runway width with adjusting washers see chapter Adjust trolley to runway width Overhead suspension must be central ...

Page 19: ... the nut 2 with the distance washers 3 4 Overhead suspension must be central to the trolley 6 Tighten the nut 2 with the specified torque 52 Nm 7 Attach screw locks 4 2 2 Adjust trolley to runway width WARNING Danger due to falling parts The chain hoist must not be operated without screw locks Check correct assembly of the overhead suspension prior to commissioning If the runway width deviates fro...

Page 20: ...n one side WARNING Danger due to falling parts An unsecured chain hoist can cause falls and injuries Secure chain hoist against falling 1 Secure chain hoist against falling 2 Remove screw lock 1 3 Loosen the nut 2 4 Remove the trolley side cheek 5 from the suspension bolt 5 Set the correct dimension through the symmetrical arrangement of the distance washers 3 and 4 6 Fit the trolley side cheek 5 ...

Page 21: ...e head screw c with medium strength thread locker e g Loctite 245 see sketch KFN 10 32 with ST10 ST20 ST32 ST50 ST60 1 1 KFN 63 with ST50 ST60 2 1 Fit suspension piece to chain hoist Note installation position of suspension piece Fit bolt a and locking plate b lock cheese head screw c with medium strength thread locker e g Loctite 245 see sketch US G10 with ST05 1 1 2 1 Fig 13 US G10 with ST10 1 1...

Page 22: ...lley onto runway or push on from below after swivelling the side cheeks up 3 Check that screws and nuts are tightened with specified torque see page 53 4 Ensure screws are locked KFK 1 Turn wheel d by means of cam e until it is in contact with the running surface of the runway Tighten screw f N B The guide roller must be flush with the wheels NOTICE Danger of increased wear Poor beam quality or lo...

Page 23: ...the trolley fits on the runway beam 2 Attach the trolley to the runway beam 3 Make sure that the track clearance a is not greater than 3 mm on one side if necessary readjust the trolley see chapter Adjust trolley to runway width 4 Tighten the nut 2 with the specified torque see table 5 Attach screw locks 1 Type Nm US G10 Tighten castellated nut and then release to the next cotter pin hole K T 22 5...

Page 24: ...ng electric trolley Plug connection cable into chain hoist and secure Fig 20 Fig 21 4 6 Mounting guide rollers Fig 22 KFN KFK 10 32 B 260 KFN KFK 63 B 300 4 7 Mounting support rollers Fig 23 The support wheel a must be in contact with the runway when mounted ...

Page 25: ...grind on components Lubricate chain with the chain grease supplied Chain bucket must move freely For max chain length see sticker on the chain bucket 4 9 1 Disassemble chain bucket 1 CAUTION An unsecured chain bucket can fall and cause injuries 2 Secure the chain bucket 2 against toppling and falling 3 Move the chain hoist downwards into the bottom limit position Make sure that the chain bucket 2 ...

Page 26: ...ey washer 4 3 Remove the chain box 1 4 Assembly takes place in reverse order 5 Splint 3 muss erneuert werden Splint must be replaced Fig 27 Select the appropriate drilled hole depending on the version of the attachement ST 32 ST 50 ST 60 1 chain box 2 suspension bolt 3 clip Fig 28 1 Remove clip 3 2 Remove suspension bolt 3 Remove the chain box 4 Assembly takes place in reverse order ...

Page 27: ...Danger from potentially lethal voltage The chain hoist must connected by a skilled electrician see chapter1 6 The mains power supply cable must meet the requirements given in the technical data The relevant safety and accident prevention regulations must be observed Plug in mains connection Fig 30 Mains connection with cable gland 4 11 1 Protective conductor WARNING With a missing protective condu...

Page 28: ... load chain clean and oiled must not be twisted Check chain box attachment Attach chain stopper to chain with hook at floor level and check chain anchorage Measure and record hook aperture Check that chain drive runs smoothly Check electrical connection Check runway clean free of grease and paint even end stops present Check tightening torque of screw connections of suspension piece or trolley sus...

Page 29: ...re 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 Do not move loads above people Before starting work ensure there is sufficient workspace Do not leave suspended lo...

Page 30: ...f and secured to prevent re activation STH Fig 31 Emergency stop Lifting lowering 1st step slow 2nd step fat Cross travel right left 1st step slow 2nd step fas Crane travel forward reverse 1st step slow 2nd step fast 6 3 Emergency stop WARNING Danger of bodily injury After an emergency stop the operator must not restart the hoist crane system until a qualified person has determined that the fault ...

Page 31: ...very 12 months possibly earlier if so pre scribed by national regulations are to be performed by a certified fitter The specified inspection and maintenance intervals apply for normal conditions of use If major components are replaced further tests must be performed Replacement of electrical equipment and renewal of electric leads and connections Insulation resistance test and testing the continui...

Page 32: ... or trolley suspension Clean and lubricate chain Check chain attachment 7 1 4 Every year Check the screw and bolt connections tightening torques corrosion wear Adjust brake Adjust slipping clutch function of limit switch is also tested when allowing clutch to slip under overload Calculate service life expired Read operating hours counter if any Check chain stopper visual inspection 7 1 5 Every fiv...

Page 33: ...on the slipping clutch When starting to adjust the slipping clutch the chain drive must be off loaded We recommend consulting our after sales service Before being adjusted the function of the slipping clutch must be checked 7 3 Adjusting slipping clutch without load The slipping clutch can be tested easily with the FMD1 slipping clutch testing device and adjusted if required without any danger to ...

Page 34: ...jury It is forbidden to hoist test load to top hook position and activate the slipping clutch The test load may be lifted by a maximum of 300 mm In bottom hook position attach a test load of 1 25 x maximum working load Remove cover 1 A small amount of gear oil may escape when the cover is removed n a for ST05 Bend back locking plate 2 ST05 Release slipping clutch setting with clamping screw 2a ST3...

Page 35: ...down paths of up to 10 cm are permissible ST05 Fig 36 Measure distance between fan cover and motor shaft 1 with motor standing still 2 with motor running The brake displacement is the difference between these two values If value S is greater than 1 5 mm the brake must be adjusted Nominal dimension 1 0 25 mm 7 5 2 Adjusting brake WARNING Danger of bodily injury The brake may only be adjusted by a q...

Page 36: ...r shim Example Brake displacement measured 1 8 mm Remove 2 shims 1 0 mm New brake displacement 0 8 mm Lever off cover 1 with a screwdriver Remove 4 screws 2 Pull off brake flange 3 Remove number of shims 4 calculated Push on brake flange Reassemble in reverse order Check brake displacement Replace brake slipping clutch unit if all shims have been removed Then reset brake displacement ...

Page 37: ...ature disc 8 Remove brake disc brake rotor 9 Clean brake wear a dust protection mask Check friction surfaces for wear Push new brake disc brake rotor 9 onto hub 10 and check radial play If there is increased play in the gearing between brake disc 9 and hub 10 the hub 10 must be pulled off the motor shaft and replaced NOTICE Danger of damage Always contact the manufacturer before removing the hub 1...

Page 38: ...nd wear of the chains chain drive wheel and return sheaves 5 If necessary perform relubrication or replace worn components 7 7 2 Check wear of the chains Type ST 05 mm ST 10 mm ST 20 mm ST 30 mm ST 32 mm ST 50 60 mm dxt 4x12 5x16 7x21 9 9x27 9x27 11 3x31 d min 3 6 4 5 6 3 8 1 8 1 10 2 t max 12 5 16 8 23 28 3 28 3 32 5 k max 134 4 179 66 245 92 303 18 303 18 350 37 The dimension k can be checked wi...

Page 39: ...om unsuitable chain Use only original chain from the manufacturer as replacement Do not turn and refit a used chain suspension bolt Max length of chain see sticker on chain box ST05 The welds of the upright chain links must point to the outside over the chain sprocket Fig 41 ST10 ST60 Fig 42 ST10 ST32 short headroom with double chain guide Fig 43 WARNING Danger of injury from moving chain Keep han...

Page 40: ... the nuts 2 3 Remove the chain stopper 3 7 10 2 Assemble chain stopper WARNING Danger due to falling load An incorrectly mounted chain stopper can lead to a load crash and cause serious injuries Ensure the correct mounting direction Tighten the screws with the specified tightening torque 1 Align the screw holes in the chain stopper 3 in the direction of the gear side 2 Mount the chain stopper 3 su...

Page 41: ...hain designation Type X min 4x12 5x16 7x21 9 9x27 11 3x31 mm Installation in chain link ST 05 Stationary 130 12 Normal height Short height ST 10 Stationary 110 8 Normal height Short height 140 10 ST 20 Stationary 110 6 Normal height Short height 150 8 ST 30 Stationary 100 5 Normal height Short height 150 7 ST 32 Stationary 150 7 Normal height Short height ST 50 ST 60 Stationary 160 6 Normal height...

Page 42: ...on bolt 1 with retention 2 Replace chain suspension bolt if any grooves or distortion are visible 7 12 Replace bottom hook block 1 2 screw 2 2 nut 3 Side cheeks 4 Bolt 5 Chain Fig 50 7 12 1 Disassemble bottom hook block 1 Lower the bottom hook block and set it down on a level surface 2 Disconnect the machinery from the power supply and attach a lock out tag out LOTO maintenance lock 3 Remove the s...

Page 43: ...2 Tighten the screws 1 to the prescribed tightening torque for torque see chapter Tightening torque for bolted connections 7 13 Replacing two fall bottom hook block Fig 51 1 Unscrew chain anchorage 2 Run chain into new bottom hook block 3 Refit chain anchorage 4 Grease moving parts 5 Run through hook path check that chain is not twisted 7 14 Replacing return sheave Fig 52 ...

Page 44: ...1 2 1 mm mm mm mm mm mm Load hook h 19 24 19 24 24 31 31 37 31 40 37 48 h min 18 22 8 18 22 8 22 8 29 5 29 5 35 2 29 5 38 35 2 45 6 Suspension hook h 24 24 24 24 37 37 37 37 39 5 39 5 39 5 39 5 h min 22 8 22 8 22 8 22 8 35 1 35 1 35 1 35 1 37 5 37 5 37 5 37 5 ynew see hook certificate yperm 1 1 x ynew If value h min and or yperm is reached replace hook If the load hook or suspension hook should di...

Page 45: ...ure that the trolley runs smoothly over the whole distance 7 18 Operating hours counter Fig 56 The integrated operating hours counter measures the hoisting time only thus the value measured must be doubled Example 123 h measured 246 h to be recorded 7 19 General overhaul ISO M3 M4 M5 M6 M7 D h 400 800 1600 3200 6400 The mechanism motor and gear not applicable to wearing parts of the ST chain hoist...

Page 46: ...290V E22 14 320 10 64 0 E32 16 320 40 64 0 E32 16 320 40 64 0 E42 MF 18 320 36 64 0 100V 18 320 37 64 0 180V 18 320 38 64 0 240V 18 320 39 64 0 290V E42 MF 18 320 36 64 0 100V 18 320 37 64 0 180V 18 320 38 64 0 240V 18 320 39 64 0 290V E42 MF 18 320 36 64 0 100V 18 320 37 64 0 180V 18 320 38 64 0 240V 18 320 39 64 0 290V 6 Chain box 32 320 00 26 0 32 320 03 20 0 2 12m 35 322 04 32 0 25m 33 320 26 ...

Page 47: ...8 3 Dismantling WARNING Falling parts Secure hoist when dismantling Dismantle hoist correctly First of all remove lubricants 8 4 Scrap disposal NOTICE Electronic components electric scrap lubricants and other auxiliary substances are hazardous waste and may only be disposed of by approved recycling companies Overload devices must be returned to the manufacturer Dismantled components must be recycl...

Page 48: ...00 1250 1000 800 3200 2500 2000 1600 ST 3016 8 1600 1250 3200 2500 ST 3216 8 1600 1250 1000 3200 2500 2000 ST 3216 12 2500 2000 1600 5000 4000 3200 ST 5025 3200 2500 2000 1600 6300 5000 4000 3200 ST 6032 6 9 2 Conditions of use The hoist is designed for use in industry and for the ambient conditions usual in industry in non hazardous areas Special measures are necessary for particular applications...

Page 49: ... 6 6 6 ST 2006 12 ST 2006 12 3 ST 2010 8 ST 2010 8 2 ST 2010 12 ST 2010 12 3 2E31 2 8E31 2E31 2 8E31 2E32 2 8E32 1 5 1 5 0 37 1 5 1 5 0 37 2 3 2 3 0 57 60 40 20 60 40 20 60 40 20 360 120 240 360 120 240 300 120 240 6 3 6 8 3 7 6 3 6 8 3 7 9 0 9 9 5 2 3 6 3 9 2 1 3 6 3 9 2 1 5 7 5 7 3 0 2 9 3 1 1 7 2 9 3 1 1 7 4 6 4 6 2 4 28 9 25 6 7 3 28 9 25 6 7 3 55 7 42 6 10 6 16 6 14 7 4 2 16 6 14 7 4 2 24 5 2...

Page 50: ...6 6 6 6 6 6 6 ST 2006 12 ST 2006 12 3 ST 2010 8 ST 2010 8 2 ST 2010 12 ST 2010 12 3 2E31 2 8E31 2E31 2 8E31 2E32 2 8E32 1 8 1 8 0 44 1 8 1 8 0 44 2 8 2 8 0 68 60 40 20 60 40 20 60 40 20 360 120 240 360 120 240 360 120 240 4 1 4 5 2 4 4 1 4 5 2 4 6 6 6 6 3 5 3 6 3 9 2 1 3 6 3 9 2 1 5 7 5 7 3 0 2 9 3 1 1 7 2 9 3 1 1 7 4 1 4 6 2 4 19 1 16 9 4 8 19 1 16 9 4 8 28 2 28 2 7 0 16 6 14 7 4 2 16 6 14 7 4 2 ...

Page 51: ... Hoist motor type 2A04 2 8A04 57 170 269 94 283 29 80 120 49 2E21 8 2E21 17 18 50 55 79 87 28 31 84 92 131 144 10 11 30 33 47 52 17 18 50 55 79 87 2E22 8 2E22 13 14 38 42 60 65 21 23 64 70 99 109 8 8 23 25 36 39 13 14 38 42 60 65 2E31 8 2E31 11 11 34 34 53 53 19 19 57 57 89 89 7 7 21 21 32 32 11 11 34 34 53 53 Contactor control 50 Hz Max cable length with contactor control m Chain hoist Stationary...

Page 52: ...ntrol 60 Hz Max cable length with contactor control m Chain hoist Stationary 3 Stationary 3 Cable cross section 1 5 mm 2 5 mm 1 5 mm 2 5 mm 400 V 460 V 575 V 400 V 460 V 575 V 400 V 460 V 575 V 400 V 460 V 575 V Hoist motor type 2A04 8 2A04 113 340 531 71 214 334 118 2E21 8 2E21 36 40 109 122 170 190 60 67 181 203 283 317 27 29 81 89 126 139 44 49 134 148 210 231 2E22 8 2E22 27 30 81 90 112 141 45...

Page 53: ...bed tightening torques with a torque wrench Thread size Property class 08 8 8 8 010 9 10 9 VERBUS RIPP 100 Nm Nm Nm Nm Nm M5 6 11 M5 1 1 M6 8 2 10 3 19 M8 20 25 28 35 42 M10 39 49 55 69 85 M12 69 86 98 122 130 M14 109 136 152 190 M16 170 210 240 300 330 M18 232 290 328 410 M20 330 410 472 590 M22 448 560 632 790 M24 570 710 800 1000 M27 832 1040 1168 1460 M30 1130 1410 1600 2000 M33 1528 1910 2160...

Page 54: ...en 0 3 Klüberplex AG 11 3 ST 05 200 g b Hoist motor bearing Grease Mobilux EP 3 FUCHS RENOLIT RHF1 1 ST 05 50 g c Travel wheel gearing Return sheave Grease Mobil Mobilux EP 3 FUCHS RENOLIT RHF 1 1 Rivolta F L G 3 1 3 FUCHS RENOLIT DURAPLEX EP 3 3 BP Energrease LS EP3 Klüberplex BEM 41 132 1 100 g d Chain Grease FUCHS RENOLIT LZR 000 1 FUCHS RENOLIT G 7 FG 1 3 Rivolta F L G 3 13 Aral fluid grease N...

Page 55: ...1 005 9 320 12 5 20 ST10 5 331 006 9 500 20 32 ST20 7 331 001 9 1000 40 60 ST30 9 331 004 9 1600 63 100 ST32 9 331 004 9 1600 63 100 ST50 11 3 331 013 9 2500 100 160 ST60 11 3 331 023 9 3200 100 160 See factory certificate for chain length required 1 Tractive force on chain 2 Test load 3 Minimum breaking load ...

Page 56: ...STAHL CraneSystems GmbH Daimlerstr 6 74653 Künzelsau Germany Tel 49 7940 128 0 Fax 49 7940 55665 marketing scs stahlcranes com Printed in Germany ba o 1 8 0 en 3 1 ...