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Summary of Contents for Stahl ST05
- Page 1 Chain Hoists Original instructions...
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Page 3: Table Of Contents
Content General information ........................................ 5 Copyright........................................... 5 Symbols ............................................. 5 Warranty ............................................ 6 Declaration of conformity / declaration of incorporation ..........................6 Spare parts ..........................................6 Terminology ..........................................6 Test book / crane logbook ..................................... 7 Transport and storage ......................................7 Weight ............................................ - Page 4 Adjusting slipping clutch - without load ................................33 Adjusting slipping clutch with test load ................................34 Hoist motor brake ........................................35 7.5.1 Checking brake ......................35 7.5.2 Adjusting brake ......................35 7.5.3 Replacing brake disc (brake rotor) ................37 Travel motor brake ........................................ 38 7.6.1 Check condition of the chain..................
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Page 5: General Information
Read carefully and observe the operating instructions. Store the operating instructions within easy reach at the place of operation. Copyright Copyright STAHL CraneSystems GmbH, 2015. All rights reserved. Reproduction and copying, including excerpts, not permitted without written permission from the publisher. No liability for errors. -
Page 6: Warranty
General information Tips / recommendations Tips for use and other particularly important information. Warranty Observance of the operating instructions is essential for safe operation and achieving the stated product characteristics and performance features. Non-observance will lead to loss of warranty for the product and the machine in which the product is installed. In addition to the instructions given in the operating manual, all official and statutory regulations must be observed when operating the product. -
Page 7: Test Book / Crane Logbook
General information Test book / crane logbook A completed test logbook must be kept for each hoist. The results of the periodic tests must be entered in the logbook and certified by the test engineer. Transport and storage Transport CAUTION Danger of falling parts •... -
Page 8: Installation, Commissioning, Maintenance And Repairs
General information 1.10 Installation, commissioning, maintenance and repairs • Installation, commissioning, maintenance and repairs may be carried out by qualified persons only. • We recommend having installation carried out by qualified personnel engaged by the manufacturer. • Do not carry out any alterations or modifications. •... -
Page 9: Environmental Information
General information 1.13 Environmental information Environmental aspects have been taken into account when developing and manufactur- ing this equipment. Please note the instructions on safe lubrication and waste disposal to avoid pollution risks during use. Appropriate use and correct maintenance will improve the environmental performance of this product. -
Page 10: Safety Instructions
Safety instructions Safety instructions Use for intended purpose • Chain hoists are intended for lifting freely movable loads. Depending on their design, they are for stationary or mobile use. • Chain hoists for "guided loads" have to be specially designed for this type of applica- tion. -
Page 11: Residual Dangers
Safety instructions • Operating the chain hoist without a phase monitoring relay if a control supplied by the customer is not installed in an electrical connection box on the chain hoist, but e.g. in a stationary control cabinet. • If the product forms "part of a machine," the person placing it on the market must ensure that the product meets the specific regulations of the application. -
Page 12: General Regulations
Safety instructions General regulations • Safety and accident prevention regulations. • Official and statutory regulations. • National regulations. Personal protective equipment Personal protective equipment to be provided by the user • Safety shoes • Gloves (only if there is no danger of them being drawn into equipment) Fig. -
Page 13: Safety-Conscious Operation
Safety instructions 2.10 Safety-conscious operation • ST chain hoists are constructed according to the state of the art and equipped with a slipping clutch as overload protection. In spite of this, dangers may arise from inap- propriate use or use for an unintended purpose. •... -
Page 14: Introduction
Introduction Introduction Chain hoists are intended for lifting freely movable loads. The modular system permits a multitude of combinations of the components. The hoist drive is a cylindrical rotor motor with a separately activated D.C. brake. Its design complies with the FEM calculation regulations which are adapted to the require- ments of hoist operation. -
Page 15: Installation
Installation Installation Stationary chain hoist WARNING Danger due to falling parts ➢ Check correct assembly of the overhead suspension prior to commissioning. ST 05 ST 10 - ST 60 Fig. 5 Fig. 6 Threaded connection of the overhead For the assembly procedure please refer to the chapter Assemble trolley on chain hoist. suspension Tightening torque of the screws (1) 15 Nm. -
Page 16: Chain Hoist With Trolley
Installation Chain hoist with trolley 4.2.1 Assemble the trolley US-G10 Trolley side cheek Snap ring Suspension bolt Washer Distance washers Castellated nut Fig. 7 1. Fit the overhead suspension (if available) on the suspension bolt (3). 2. Fit the washer (4) on the suspension bolt (3). 3. - Page 17 Installation KFN 10 / 63 KFK 10 / 63 Screw lock Distance washer Snap ring Washer Overhead suspension Trolley side cheek Fig. 8 1. Fit the overhead suspension (6) on the suspension bolt. 2. Fit the washer (5) on the suspension bolt. 3.
- Page 18 Installation KFN 32 KFK 32 Fig. 9 Suspension bolt with spacer sleeves Suspension bolt Fig. 10 1. Insert the suspension bolt in the overhead suspension. Insert the suspension bolt (1) in position (1) with spacer sleeves. ➢ Set the correct dimension through the symmetrical distribution of the distance wash- ers and spacer sleeves.
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Page 19: Adjust Trolley To Runway Width
Installation K.T 22 Hexagon head screw Distance washer 3 mm Distance washer 1 mm Trolley side cheek Runway width Track clearance Fig. 11 1. Fit the first trolley side cheek (5) on the hexagon head screw (1). 2. Set the correct dimension through the symmetrical distribution of the distance wash- ers (3, 4). - Page 20 Installation Screw lock Distance washer 3 mm Distance washer 1 mm Trolley side cheek Runway width Track clearance Fig. 12 The trolley is set to the runway width (B) specified in the order. The track clearance (a) per side is 3 mm. If necessary, the track clearance (a) can be readjusted by moving the distance washers (3) and (4) as described in the following.
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Page 21: Installing Trolley On Chain Hoist
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 US-G10 with ST10 1/1 Fig. 14 Fig. - Page 22 Installation 1. KFK Fit suspension piece with suspension bolt (a) to chain hoist. Observe installation posi- tion of suspension piece for 1/1 and 2/1 reeving! Lock bolt (a) with washer (b) and circlip (c), see sketch. KE-T 22 KFK .. W0761 Fig.
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Page 23: Attach The Trolley To The Runway Beam
Installation Attach the trolley to the runway beam Screw lock Trolley side cheek Track clearance Fig. 19 1. On one side, loosen the screw lock (1) and nut (2) and open the trolley side cheek (6) sufficiently far that the trolley fits on the runway beam. 2. -
Page 24: Connecting Electric Trolley
Installation Connecting electric trolley Plug connection cable into chain hoist and secure. Fig. 20 Fig. 21 Mounting guide rollers KFN / KFK 10/ 32: B ≥260 KFN / KFK 63 B: >300 Fig. 22 Mounting support rollers Fig. 23 The support wheel (a) must be in contact with the runway when mounted. 01.2019... -
Page 25: Runway Endstop
Installation Runway endstop WARNING Danger of falling parts If there are no end stops, there is a danger of the trolley travelling over the end of the runway. ➢ Mount suitable end stops at the end of the runway before commissioning the hoist. Fig. - Page 26 Installation ST 10 / ST 20 / ST 30 chain box suspension bolt splint saftey washer Fig. 26 1. Draw out splint (3) 2. Remove the suspension bolt (2) and saftey washer (4). 3. Remove the chain box (1). 4. Assembly takes place in reverse order. 5.
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Page 27: Mounting Control Pendant
Installation 4.10 Mounting control pendant Ensure sufficient clearance between cable and chain by turning the plug if necessary (±360°)! The cable must not touch the chain. 1. Plug in and secure cable. 2. Fit strain relief wire. NOTICE Danger of damage to cable The control pendant must be suspended from the strain relief wire and not from the cable! The circuit diagram must be followed if the customer connects the control cable by... -
Page 28: Commissioning
Commissioning Commissioning The chain hoist has been subjected to a final inspection by the manufacturer in accord- ance with the EC Machinery Directive. WARNING Danger of bodily injury The test before first commissioning must be carried out by a qualified person, see chapter 1.6. -
Page 29: Operating
Operating Operating Duties of crane operator Personal protective equipment to be provided by the user See chapter 2, Safety instructions. Requirements for workplace • The operator must not stand in the hazard area. • The hazard area must be clearly visible. •... -
Page 30: Operating Control Pendant
Operating Operating control pendant NOTICE Danger of unintentional movement of hoist If the rocker switch is no longer depressed by the operator, it returns to the 0 position, the hoist motion is automatically stopped (dead man’s 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. -
Page 31: Inspection And Maintenance
Inspection and maintenance Inspection and maintenance This section deals with operational reliability, availability, and maintaining the value of your chain hoist. Although this chain hoist is practically maintenance-free, the components subject to wear (e.g. chain, brake) must be inspected regularly. This is required by the accident preven- tion regulations. -
Page 32: Inspection Intervals
Inspection and maintenance Inspection intervals 7.1.1 Every day • Check correct functioning of brake(s). • Check load chain (visual inspection) - clean, lubricated and not twisted • Check that chain drive runs smoothly • Check bottom hook block (visual inspection) 7.1.2 Every month •... -
Page 33: Checking Function Of Slipping Clutch Without Load
Inspection and maintenance Checking function of slipping clutch without load 1. Without load, run bottom hook block to top or bottom hook position. 2. Allow clutch to slip in top or bottom hook position for a maximum of 3 sec. The chain must not move, the motor must rotate. -
Page 34: Adjusting Slipping Clutch With Test Load
• 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). -
Page 35: Hoist Motor Brake
Inspection and maintenance ST05 ST10/ST20/ST30 ST32/ST50/ST60 Fig. 33 Fig. 35 Fig. 34 Hoist motor brake WARNING Danger of falling loads ➢ Check brake at regular intervals 7.5.1 Checking brake 1. Attach test load 2. Activate brake during lifting and lowering. - Page 36 Inspection and maintenance ST05 • Set load down. • Calculate number of shims to be removed. The brake displacement is altered by 0.5 mm per shim. • Example: Brake displacement measured: 1.8 mm Remove 2 shims: -1.0 mm New brake displacement: 0.8 mm...
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Page 37: Replacing Brake Disc (Brake Rotor)
Inspection and maintenance ST10 - ST60 • 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" (see Tab.) and does not catch on shoulder (!). -
Page 38: Travel Motor Brake
Inspection and maintenance Check backlash of motor shaft - brake. • Bottom hook block unloaded • Brake closed Turn the motor shaft with the fanwheel (4) back and fore. If there is noticeable backlash the brake must be replaced. Travel motor brake See operating instructions of travel drive Checking chains 7.7.1... -
Page 39: Lubricate The 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 ST10 - ST60 ST10 - ST32 short headroom with double chain guide The welds of the upright chain links must point to the outside over the chain sprocket. -
Page 40: Replace The Chain Stopper
Inspection and maintenance 7.10 Replace the chain stopper WARNING Danger due to falling chain The chain hoist must not be operated without the chain stopper. Check the correct assembly of the chain stopper 7.10.1 Disassemble chain stopper ST 05, ST 10, ST 20, ST 50/60 2×screw 2×nut Chain stopper... - Page 41 Inspection and maintenance ST 10, ST 20, ST 10, ST 20, ST 50, ST 60 ST 50, ST 60 ST 05 ST 05 ST 30, ST 32 ST 30, ST 32 Stationary Stationary Stationary Normal height Short height Normal height Short height Normal height Short height...
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Page 42: Checking And Mounting Chain Anchorage
Inspection and maintenance 7.11 Checking and mounting chain anchorage ST05 ST10 - ST30 ST32/ST50/ST60 Fig. 49 Fig. 48 Fig. 47 WARNING Danger from falling parts Check chain suspension bolt for wear regularly. Always secure chain suspension bolt with screw retention. -
Page 43: Assemble New Bottom Hook Block
Inspection and maintenance 7.12.2 Assemble new bottom hook block 1. Assemble the new bottom hook block in the reverse sequence to disassembly. 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 1. -
Page 44: Checking Hook For Wear
Deformations, cracks, cuts caused by impact and corrosion must be as- sessed. The hook safety latch must close completely, replace if necessary. The damage can only be assessed by a qualified person. • The hook dimensions must not exceed those specified in the following table. ST05 ST10 ST20 ST30 ST32... -
Page 45: Trolley
Inspection and maintenance 7.17 Trolley Wheels, wheel drive and runway • Visual inspection of wheels for wear. • Visual inspection of runway beam for wear. • Inspection of flanges for wear. Nominal value Limit for wear Ø d Ø d1 [mm] [mm] [mm]... -
Page 46: Wearing Parts
Wearing parts Wearing parts Hoist Fig. 57 Fig. 58 Designation ST05 ST10 ST20 ST30 ST32 ST50 ST 60 Chain 331 005 9 331 006 9 331 001 9 331 004 9 331 004 9 331 013 9 331 023 9... -
Page 47: Trolley
Wearing parts Trolley Designation Wheel 50 63 - KE-T 63 - KF. 10 80 125 02 250 01 40 0 02 250 03 40 0 03 250 01 64 0 05 250 04 40 0 01 250 00 41 0 02 250 01 41 0 02 250 02 41 0... -
Page 48: Technical Data
Technical data Technical data Classification to ISO Type [kg] [kg] ST 0501-8 ST 0501-16 ST 0502-8 ST 0503-6 ST 1004-16 1000 ST 1005-.. 1250 ST 2006-12 ST 2008-16 1000 2000 1600 ST 2010-8 1000 2000 1600 1250 ST 2010-12 1250 ST 3212-16 1600 1250... -
Page 49: Hoist
Technical data Hoist 9.3.1 Hoist motor data 50Hz 50 Hz Mains fuse cos k Type Hoist motor 230V 400V 500V 230V 400V 500V 230 V 400 V 500 V type ST 0501-8 2A04 0.88 ST 0501-8/2 2/8A04 0.2/0.05 35/15 120/240 2.3/1.9 1.3/1.1... -
Page 50: Hoist Motor Data 60Hz
Technical data 9.3.2 Hoist motor data 60Hz 60 Hz cos k Mains fuse Type Hoist motor 400V 460V 575V 400V 460V 575V 400 V 460 V 575 V type ST 0501-8 2A04 0.24 0.88 ST 0501-8/2 2/8A04 0.24/0.06 35/15 180/360 1.6/1.3 1.4/1.1 1.1/0.9... -
Page 51: Specifications For Mains Connection
Technical data Specifications for mains connection • All poles of the mains cable must be disconnected by a lockable switch. • The mains voltage must correspond to that stated on the rating plate. • Fixed installed cables e.g. NYM, NYY •... -
Page 52: Max. Length Of Supply Cable 60Hz
Technical data Max. length of supply cable 60Hz 9.4.2 Direct control 60 Hz Max. cable length with direct control [m] Chain hoist Stationary *1 Stationary *1 Cable cross-section 1.5 mm² 2.5 mm² 1.5 mm² 2.5 mm² 230 V 400 V 460 V 230 V 400 V... -
Page 53: Tightening Torques For Bolted Connections
Technical data Tightening torques for bolted connections WARNING parts can loosen and fall down due to incorrect tightening torques. Severe injuries or death can be the result. ➢ Tighten bolted connections to the prescribed tightening torques with a torque wrench. Thread size Property class VERBUS RIPP... -
Page 54: Lubricants
Technical data Lubricants ST 05 ST 10 - ST 60 Lubricant product name Lubricant Item Lubrication point Quantity type Factory filling Alternative ST 10: 700 ml ST 10: 1000 ml ST 20: 1200 ml ST 20: 1500 ml MOTUL DEXRON III ST 30: 1200 ml Hoist gear TOTAL ATF DEXRON III... -
Page 55: Chain Certificate
Technical data Chain certificate Type Order no. [mm] [kg] [kN] [kN] ST05 12,5 331 005 9 ST10 331 006 9 ST20 331 001 9 1000 ST30 331 004 9 1600 ST32 331 004 9 1600 ST50 11.3 331 013 9... - Page 56 STAHL CraneSystems GmbH Daimlerstr. 6, 74653 Künzelsau, Germany Tel +49 7940 128-0, Fax +49 7940 55665 marketing.scs@stahlcranes.com...
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