Betriebs- und Instandhaltungsanleitung Operating and maintenance instructions Notice d'utilisation et d'entretien Instrucciones de servicio y de mantenimiento Manual de instrues

e da manuteno Manuale di istruzioni e della manutenzione Gebruiks- en onderhoudsaanwijzing

db_ba

leers

Englisch

Contents

In these Operating instructions, you will find all the information on installa-tion, operation and maintenance necessary for transporting your loads safely with the ST chain hoists. All information on additional equipment possible, e.g. an electric hoist limit switch, is marked with this symbol. If your chain chain hoist is provided with additional equipment, please check in the Appendix whether there are additional points you must observe. 1 Safety instructions ................................................................................................................. 4 2 Getting to know the chain hoist.......................................................................................... 5 3 Installation .............................................................................................................................. 7 Installing the chain hoist ....................................................................................................... 7 Installing trolley ....................................................................................................................... 7 Fitting chain box ...................................................................................................................... 9 Fitting the control pendant .................................................................................................. 10 Check screw connections .................................................................................................. 10 Mains connection ................................................................................................................. 11 Decommissioning ................................................................................................................. 11 4 Commissioning ..................................................................................................................... 12 Checklist for commissioning ............................................................................................... 12 5 Operation ............................................................................................................................... 13 6 Maintenance ......................................................................................................................... 14 Maintenance table ............................................................................................................... 15 Maintenance work ............................................................................................................... 16 7 Repairs .................................................................................................................................... 19 What is to be done if ........................................................................................................ 19 Replacing parts ..................................................................................................................... 20 8 Technical data ...................................................................................................................... 22 Motor data ............................................................................................................................. 22 Length of supply cable ......................................................................................................... 23 Ambient conditions............................................................................................................... 23 Sound level ............................................................................................................................. 23 Weight ..................................................................................................................................... 23 Trolley ...................................................................................................................................... 23 Classification to FEM ........................................................................................................... 24 List of lubricants.................................................................................................................... 24 Chain certificate .................................................................................................................... 25 9 Appendix ................................................................................................................................ 26 Certificate of conformity ...................................................................................................... 26 Circuit diagrams .................................................................................................................... 27 10 Original parts ........................................................................................................................ 32

Guarantee The guarantee expires if installation, commissioning, operation and testing are not carried out in accordance with these operating instructions.
Subject to modifications 3

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Use for intended purpose

Safety instructions

Use hoist only for lifting freely movable loads. Do not carry out any alterations or modifications to the chain hoist. Danger of injury if not used for intended purpose: The following are not allowed, e.g.: - Exceeding the maximum permissible load. - Transporting persons. - Pulling loads at an angle. - Tearing loose, pulling or towing loads. - Manipulating the slipping clutch. - Slack chain - Activating the chain stopper (lowest hook position) under load.

Safety-conscious operation

Read and observe these instructions. Observe safety and accident prevention regulations. Do not remove information plates from the chain hoist. Replace illegible or damaged plates. It is forbidden for persons to stand under suspended loads. This entails risks to life and limb!

Organisational safety precautions

Only direct persons to operate the hoist if they have been trained or instructed in its use. Installation, commissioning, maintenance and repairs may only be carried out by qualified persons*. Use only original spare parts. Have the chain hoist tested at least once a year by a qualified person*. The result of the test must be recorded and kept in the test log book. All tests must be initiated by the operator.

Electrical current

The chain hoist functions with electrical voltages which involve danger to life. Disconnect the chain hoist before opening covers with this symbol. The chain hoist may only be opened by qualified persons* or personnel which has been instructed in its use. If a phase of the supply voltage fails, the load drops slowly during the lifting motion. Stop chain hoist by releasing control switch!

* A qualified person has the necessary theoretical and practical knowledge to carry out the actions specified in the operating instructions.

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Getting to know the chain hoist

ST... chain hoist The chain hoists of the ST... series cover a S.W.L. range of 160 kg to 5000 kg. Construction and method of functioning are similar for all chain hoists of the ST... series. Applications The following applications are possible for the ST... chain hoist:

Stationary

with push trolley

with electric trolley standard headroom short headroom

single-fall

two-fall

Special equipment With the aid of the extensive range of optional equipment, you can adapt the ST... chain hoist to your requirements. Please refer to the appendix, or ask your STAHL representative. You will find all the information necessary on the optional equipment you have ordered in the appendix.

These symbols appear every time a section refers to a particular version.

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Getting to know the chain hoist

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Chain guide Motor Gear Connection box Chain box Plug for control pendant Plug for travel drive Plug for mains connection Socket for control pendant Socket for travel drive Socket for mains connection Suspension hook Suspension eye Single-fall bottom hook block Load hook Two-fall bottom hook block Control pendant

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Installing stationary chain hoist

Installation

Note position of suspension eye or suspension hook for 1/1 or 2/1 reeving, sketch

1/1

2/1

Installing trolley

Adjusting trolley to runway flange 1. Adjust play of wheel flanges, sketch and table 2. Attach rubber buffers to trolley or to end stops. Rubber buffers for the trolley are available as optional equipment.

UE-P 40 B [mm] 66-110 113-150 155-190 200-240 260-300 L [mm] 277 325 367 413 473 d [mm] B [mm] 82-110 115-154 155-190 200-240 260-300 400

KFU / KFK 50 L [mm] 304 344 386 431 492 608 d [mm]

B+58*

B+61*

* for I-beam: - 2 mm

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Installing trolley on chain hoist

Installation

1. UE-P 40 Fit trolley to chain hoist with suspension bolt (a). Observe position of suspension piece for 1/1 or 2/1 reeving! Lock bolt (a) with washer (b) and circlip (c), sketch.

KFU / KFK 50 Fit trolley to chain hoist with suspension bolt (a). Observe position of suspension piece (KFU 50)! Lock bolt (a) with washer (b) and circlip (c), sketch. 2. Slide trolley onto runway or push on from below after swivelling the side cheeks up. 3. Check that nuts and bolts are firmly tightened. 4. The screw retentions must be fitted. 5. Press pressure roller (d) against the runway with the aid of screw (e) until all wheels are in contact with the running surface of the runway. Lock screw (e) with nut (f).

UE-P40 1/1 2/1

KFU 50 2/1

KFK 50

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Connecting electric trolley
M

Installation

1. Plug connection cable into chain hoist and secure.

2. Fit guide rollers for UE-P 40: B 300 mm KFU / KFK 50: B 300 mm

Fitting chain box

Lubricate chain with the chain grease supplied (see chap. 6).

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Installing control pendant

Installation

1. Plug in and secure cable. 2. Insert strain relief wire and screw tight. Note The control pendant must hang from the strain relief wire and not from the cable! Ensure sufficient clearance of the cable to the chain by turning the plug if necessary (360)!

If control cable is connected by customer by means of plug kit, the circuit diagram must be followed (parts marked "A" are supplied loose). Prepare ends of cable acc. to sketch "Mains connection, plug-type", page 11.

For connection of control pendant without plug, see circuit diagram in appendix. (Terminal strip X1, terminals 1...9. Connection is via a cable gland Pg 16).

Check screw connections

Load hook attachment (21, 23) Attachment of chain guide (10) Distance bolt on trolley (1) Trolley suspension

M5 M6 M8 M10 M12 M16 M24 M30 M36 Plastite 45 M5 *2 *3

[Nm] 6 (5)*1 10 24 (20)*1 48 83 120 320 640 1100 1,5 1,0 1,5

10

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*1 Self-locking/self-tapping screws *2 Connector *3 Cable gland (Plastic)

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Mains connection

Installation

Safety note The chain hoist may only be connected by a skilled electrician. The mains cable must fulfil the specifications given in the technical data (chap. 8).

Mains connection, plug-type

Q R S

* Crimp contacts

Mains connection via PG gland

Dismantling

Dismantling chain hoist 1. Disconnect chain hoist from mains at main isolator. 2. Remove electrical connections. 3. Remove chain hoist. 4. Remove trolley, if any. 5. Clean chain hoist and oil lightly. 6. Seal air vent screw in gear.

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Checklist for commissioning

Commissioning

The chain hoist may only be commissioned by a qualified person. When recommissioning after a period in storage or stoppage, the following test steps must be repeated.

Test steps Remove sticker from air vent screw in gear Check suspension hook or suspension, see chap. 3. Check tightening torque of bolt connections of hook, locking plate and chain guide, see chap. 3. Check load chain, see chap. 6. - clean and oiled - not twisted Check chain box, see chap. 3 - attachment - rubber buffer Check chain stopper and chain anchorage, see chap. 7. Measure and record hook aperture, see chap. 6. Check electrical connection, see chap. 3. Check runway - clean, free of grease and paint - end stops Check tightening torque of bolt connections of rigid suspension part or trolley suspension. Open step of travel drive greased.

During the following test steps, you must be able to activate the emergency off button at all times. Check function of chain hoist, see chap. 3, chap. 5. - Direction of movement must correspond to the symbols on the control pendant. If not, reverse two phases of the mains connection. Check function of slipping clutch, see chap. 6. If the chain hoist does not lift the overload, adjust slipping clutch. Check function of brake, see chap. 6. Subject chain hoists in conjunction with a crane system to a test load. Check function of travel drive, see chap. 5, chap. 6. - Direction of motion must correspond to the symbols on the control pendant. - Function of brake. Confirm correct commissioning in test log book.

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Duties of crane operator

Operation

The load must be securely attached. No-one must be in the danger area of the moving load. The crane operator must be able to see the whole working area. If this is not the case, an assistant must guide the operator. If slack chain occurs, tauten the chain at slow speed before starting to lift. Always bear in mind the position of the emergency stop button. The slipping clutch is a safety facility and must not be activated during normal operation. Do not use inching operation on the control pendant.

Operating the control pendant Hoist 1st step: 2nd step: slow fast

Trolley (1/2 speeds) 1st step: slow 2nd step: fast

Crane travel (1/2 speeds) 1st step: slow 2nd step: fast

Emergency stop

The emergency stop button is in the control pendant. Press the emergency stop button, the system stops immediately. Release the emergency stop: turn the button in the direction shown.

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FEM classification

Maintenance

Maintenance work on the chain hoist may only be carried out by qualified persons. Maintenance work beyond that described in these operating instructions may only be carried out by the manufacturer or trained after-sales service personnel.

The maintenance intervals given in the following table apply for a chain hoist operated in mechanism group 1 Bm to FEM 9.511. If the hoist is operated in a different mechanism group, the maintenance work specified must be carried out more frequently corresponding to the correction factors.

Mechanism group (operation) Correction factor Example: Check hook attachment 1 Bm 1 x per quarter, 2 m 4 x per quarter

1Bm 1

1Am 2

2m 4

3m 8

General overhaul after expiry of service life The general overhaul is intended to determine invisible wear (e.g. gear). According to FEM 9.755, the service life expired must be recorded in order to calculate that remaining. Depending on the gear classification according to FEM 9.511, which is given in the hoist data sheet, the theoretical full load lifetimes (D) stated below apply, see table.
FEM 9.511 D (h) 1Bm 400 1Am 800 2m 1600 3m 3200

If the full load lifetime has expired, the chain hoist must be overhauled by the manufacturer.

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Maintenance intervals

Maintenance

Every day Check correct functioning of brake. Check load chain - clean, lubicated and not twisted Check suspension of control pendant - cable and steel wire must be fitted. Check load chain for wear.

Every month Check function of slipping clutch

Every 3 months Check hooks for wear Check hook attachment Check attachment of locking plate Grease output pinion and open step of gearing on electric trolley Check attachment of suspension part or trolley suspension

Every year Check bolt connections of hook, locking plate and chain guide - tightening torques, corrosion Grease idler sheave Adjust brake* Adjust slipping clutch* Calculate service life expired. Read operating hours counter if existing Adjust brake* Check buffer or stop

* These jobs may only be carried out by a qualified person.

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Maintenance work

Maintenance

Check brake function 1. Attach nominal load. 2. Activate brake when lifting and lowering. Slowing-down paths of up to 10 cm are permissible.

Check function of slipping clutch Allow slipping clutch to slip for max. 3 seconds in highest hook position. The chain must not move, the motor must rotate.

Check and grease load chain

*1

N.B.: Grease load chain above all at the joints. If the load chain does not display the required dimensions at any point, - table if distortion, breaks, cracks or corrosion impair the lifting capacity; if the joints of the chain show wear: Replace load chain, see chap. 7. Check chain guide and idler sheave on the bottom hook block and replace if necessary, see chap. 7. Check chain anchorage, if necessary get in touch with our after-sales service.

ST3200 [mm] dxt d min. t max. 11 t max 9x27 8,1 28,3 302,9

ST5000 [mm] 11,3x31 10,2 32,5 347,8

Check hook for wear

If load hook or suspension hook no longer display the required dimensions or if distortion, breaks, cracks or corrosion impair the lifting capacity: Replace bottom hook block or suspension hook, see chap. 7.
ST3200 1/1 2/1 ST5000 1/1 2/1

[mm] *2 h h min. z z max. *3 h h min. z z max. 31 29,5 30 34,5 39,5 37,5 42 48,3 40 38 35 40 39,5 37,5 42 48,3

[mm] 37 35,2 33 38 39,5 37,5 42 48,3 48 45,6 41 47 39,5 37,5 42 48,3

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*1 grease *2 load hook *3 suspension hook

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Adjusting slipping clutch

Maintenance

Slipping clutch and brake(s) may only be adjusted by a qualified person. When starting to adjust the slipping clutch, the load must lie on the ground!

Carefully remove the cover (1) with a blunt instrument. Release setting of slipping clutch with clamping screw (2). At lowest hook position, attach 1.25 x nominal load. Adjust the slipping clutch by turning the nut (3) until the load is just lifted while the clutch slips. Increasing hoisting force: turn nut clockwise. Decreasing hoisting force: turn nut anti-clockwise. Lock setting of slipping clutch with clamping screw (2). If adjustment is no longer possible (if stamped dimension x -2mm is reached), replace clutch. If the cover (1) cannot be fitted correctly (damage during removal), there is a spare cover in the connection box.

Checking brake 1. Remove fan cover (1) 2. Remove plug (8) 3. Measure air gap (S) with feeler gauge (F). See table for max. permissible air gap (S). If the max. permissible air gap (S) has been reached, the brake disc (brake rotor) must be replaced.
S max. [mm] 1 1

Type Typ
ST 3200 ST 5000

Hubwerksbremse Hoist brake FDB 13 FDB 13

Replacing brake disc (brake rotor) 1. Remove fan cover (1) 2. Release clamp (2) of fanwheel 3. Remove fanwheel (3) 4. Disconnect brake 5. Unscrew fixing bolts (4) 6. Remove magnet piece (5) complete with armature disc (6) 7. Remove brake disc (brake rotor) (7)

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Replace in reverse order. Take care that the check hole for measuring the air gap is in the lower section.
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Trolley brake

Maintenance

FU-A 14 .. Checking brake Measure clearance between fan cover and motor shaft: 1. with motor at a standstill 2. with motor running The difference between the two values is the brake lifting path. If the value is greater than 2.5 mm, the brake housing with brake lining must be replaced.

0,5 - 2,5 mm

SF 14 ..

Checking brake 1. Remove fan cover (1) 2. Remove plug (2) 3. Measure air gap with feeler gauge (F). See table for max. permissible air gap. If the max. permissible air gap has been reached, the brake disc (brake rotor) must be replaced.
Type Brake Braking Bremstype moment Bremstyp moment Screw Tight. S T Anziehtorque max. min. Schraube moment [mm] [mm] [Nm]

Typ SF ...123 SF ...133

[Nm] FDB 08 FDB 08 1,3 2,5

0,2...2,0 4,5 0,2...2,0 4,5

3xM4 3xM4

3 3

Replacing brake disc (brake rotor) 1. Remove fan cover (1) 2. Remover fanwheel (3), remove feather key 3. Disconnect brake 4. Unscrew fixing bolts (4) 5. Remove magnet piece complete with armature disc (6) 6. Remove brake disc (brake rotor)

Replace in reverse order. Take care that the check hole for measuring the air gap is in the lower section.

Reading operating hour counter

(Only on version with operating hour counter) 1. Open connection box and take a reading from operating hour counter. 2. Multiply the value by the factor of 2 and record in the form enclosed in the test log book. Example: Reading Record 123 h 246 h

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What is to be done if

Repairs

Repairs to the chain hoist must be carried out by qualified persons. Repairs beyond those described in these operating instructions may only be carried out by the manufacturer or trained service personnel. Hoist does not work Emergency stop activated Release emergency stop, see chap. 5 Main fuse tripped Reset main fuse Connection terminals or contactor fixing screws loose Tighten terminals or screws, see chap. 3 Fuse in chain hoist tripped Replace fuse, see chap. 7 Load cannot be lifted Overload Reduce load Slipping clutch wrongly set Reset slipping clutch, see chap.6 Slipping clutch worn Replace slipping clutch assembly, see chap. 6 Brake does not open If necessary, replace brake lining, see chap. 6 Slowing-down path of brake above 10 cm Brake linings worn Adjust brake, see chap. 6 If necessary, replace brake lining, see chap. 6 Loud noise when load is moved Chain not lubricated Lubricate chain Chain worn Replace chain, see chap. 7 Chain guide worn Replace chain guide, see chap. 7 Idler sheave worn Replace idler sheave, see chap. 7 Trolley does not move Connection cable to chain hoist not plugged in Plug in cable, see chap. 3 Brake does not open Check brake air gap, see chap. 6 Check rectifier (SF 14)
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Replacement of parts

Repairs

Fitting chain 1. Insert chain fitting aid into last chain link. 2. Run chain into chain guide at slow speed.

Replacing chain stopper

Fitting chain anchorage Fix chain fixing bolt (1) with lock washer (2) and fixing screw (3).

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Repairs

Replacing single-fall bottom hook block

Replacing 2-fall bottom hook block (21) 1. Unscrew chain anchorage. 2. Insert chain into new bottom hook block. 3. Refit chain anchorage.

Replacing idler sheave

Replacing ejector

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Technical data

Motor data Specifications for mains connection A switch must enable all poles of the connection cable to be switched off. The mains voltage must correspond to that stated on the rating plate. Fixed installed cables e.g. NYM, NYY Flexible cables e.g. RN-F, NGFLGu, H07VVH2-F Cable cross section min. 1.5 mm Mains voltage 380 VAC - 415 VAC, 50 Hz. Other mains voltages are available as options.

50 Hz

Hoists Hubwerke

kW

ED %

c/h

In [A]

Ik [A]

cos

Anschlusicherung Main fuse

(400 V) 1/1 ST 3200 SG1 ST 3200 SG3 ST 3200 SG2 ST 5000 SG1 ST 5000 SG4 ST 3200 SG1 ST 3200 SG2 ST 3200 SG3 ST 5000 SG1 ST 5000 SG4 FU-A 14 .. SF 14 1600 1600 1250 2500 2500 1600 1600 1250 2500 2500 2/1 3200 3200 5000 5000 3200 3200 5000 5000 2,4 3,8 3,8 3,8 3,0 0,6 / 2,4 0,9 / 3,8 0,9 / 3,8 0,8 /3,8 0,7 / 3,0 0,05 / 0,2 0,09 / 0,37 60 40 40 40 50 20 / 50 15 /35 15 / 35 15 / 35 20 / 40 20 / 40 20 / 40 360 240 240 240 300 320 / 160 200 / 100 200 / 100 200 / 100 240 / 120 6,6 9,2 9,2 9,2 7,3 3,7 / 6,6 4,0 / 9,2 4,0 / 9,2 4,0 / 9,2 3,8 / 7,3 0,9 / 0,9 0,8 / 1,0

(400 V) 230 V [A] 32 32 32 32 32 8,2 / 32 8,2 / 32 8,2 / 32 8,2 / 32 8,2 / 32 1,1 / 2,4 1;3 / 3,3 0,69 0,85 0,85 0,85 0,78 0,50 / 0,69 0,67 / 0,85 0,67 / 0,85 0,67 / 0,85 0,49 / 0,78 0,62 / 0,82 0,52 / 0,8 16 16 400 V [A] 10 10 500 V [A] 10 10

16 16 -

10 10 -

10 10 -

60 Hz Hubwerke Hoists kW ED c/h In [A] Ik [A] cos Anschlusicherung Main fuse

% (460 V) 1/1 ST 3200 SG1 ST 3200 SG3 ST 3200 SG2 ST 5000 SG1 ST 5000 SG4 ST 3200 SG1 ST 3200 SG3 ST 3200 SG2 ST 5000 SG1 ST 5000 SG4 FU-A 14 ... SF 14 .. 1600 1600 1250 2500 2500 1600 1600 1250 2500 2500 2/1 3200 3200 5000 5000 3200 3200 5000 5000 2,9 4,6 4,6 4,6 3,6 0,7 / 2,9 1,1 / 4,6 1,1 / 4,6 1,1 / 4,6 0,9 / 3,6 0,06 / 0,24 0,11 / 0,44 60 40 40 40 50 20 / 50 15 / 35 15 / 35 15 / 35 20 / 40 20 / 40 20 / 40 360 240 240 240 300 320 / 160 200 / 100 200 / 100 200 / 100 240 / 120 6,6 9,2 9,2 9,2 7,3 3,7 / 6,6 4,0 / 9,2 4,0 / 9,2 4,0 / 9,2 3,8 / 7,3 0,9 / 0,9 0,8 / 1,0 32 32 32 32 32 8,2 / 32 8,2 / 32 8,2 / 32 8,2 / 32 8,2 / 32 1,2 / 3,3 0,69 0,85 0,85 0,85 0,78 0,5 / 0,69 0,67 / 0,85 0,67 / 0,85 0,67 /0,85 0,49 / 0,78 1,1 / 2,4 0,52 / 0,8 (460 V) 230 V [A] 20 20 460 V [A] 10 10 575 V [A] 10 10

20 20 -

10 10 -

10 10 -

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Length of supply cable

Technical data

*1 ST 3200 [m] 11 34 53 14 56 88 29 39 61 16 49 65 101 ST 5000 [m] 11 34 53 14 56 88 29 39 61 16 49 65 101 ST 3200 [m] 9 27 42 15 45 71 24 31 49 13 39 52 81 ST 5000 [m] 9 27 42 15 45 71 24 31 49 13 39 52 81

1,5 mm 50 Hz 2,5 mm

1,5 mm 60 Hz 2,5 mm

230 V 400 V 500 V 230 V 400 V 500 V 230 V 400 V 460 V 575 V 230 V 400 V 460 V 575 V

*1 Conductor cross-section (Min. cross-section 1.5 mm)

Ambient conditions Protection class Storage Operation

IP 55 -20 C...+60 C -20 C...+40 C

IP 55 -20 C...+60 C -20 C...+40 C

[dB [A] 74

Sound level Sound level at 1 m from chain hoist, averaged out for an operating cycle of 50% with nominal load and 50% without load.

Weight

ST3200 -1/1 -2/1 ST 5000 -1/1 -2/1

110 kg 123 kg 118 kg 136 kg

US-P 40 140 kg UE-P 40 158 kg US-P 40 148 kg UE-P 40 165 kg

- kg - kg

US-P40 153 kg UE-P40 171 kg KFK 50 187 kg - kg KFU 50 201 kg KFK 50 205 kg

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ST 3200 ST 5000 1/1 UEP 40 1700 kg

ST 5000 2/1 KFU / KFK 50 2600 kg

Trolley Max. wheel load per pair of wheels

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Classification to FEM 9.511 Gear

Technical data

1/1 1000 1250 1600 2000 2500

2/1 2000 2500 3200 4000 5000

1Bm

1Am

2m

3m 4m ST 3200 SG3 ST3200 SG1 ST 3200 SG2

ST 3200 SG2 ST 3200 SG1 ST 3200 SG3 ST 3200 SG3 ST 5000 ... ST 5000 ... ST 5000 ... ST 3200 G1

Lubricants

A a b

D 1 2 3

E 2000 ml FU-A: 180 g SF 14 1... 100 g FU-A: 180 g SF 14 1... 100 g 500 - 1000 g

CLP 460 PG 220 G00F

GPG00K 4 c d G00F 3 GPG00K 4 5

A Lubrication point a Hoist gear b Trolley gear c Wheel gearing d Chain B Type of lubricant Grease Oil C Designation D Characteristics, makes E Quantity
(Lubricant for low ambient temperatures, max. -40C)

Characteristics, makes
1 Viscosity 460 cSt/40C Pour point -20C Flash point +265C e.g. Fuchs Renep Compound 110*, Aral Degol BG 460, BP Energol GR-XP 460, Esso Spartan EP 460, Mobilgear 634, Shell Omala Oil 460, Texaco Meropa 460 2 Viscosity 460 cSt/40C Pour point -40C Flash point +320C e.g. Shell Tivela Oil WB 3 Soap base: natron Dripping point approx. +150C Penetration: 400-430 Operating temperature: -30C to 80C e.g. Aralub PDP 00, BP Energrease HT 00 EP, ESSO Liquid Gear Grease 4 Soap base: Li/polyglycol oil Dripping point approx. + 180C Penetration 400 - 430 Operating temperature: bis -40C e.g. Esso liquid grease S 420 5 Oil or liquid grease Normal ambient conditions: Ceplattyn Chain Lubricant Fluid Extreme applications, food industry, medicinal baths: SKD 3000

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Chain certificate

Technical data

Standard
#

*1

*2

*3

[mm]

(1 A m) [kg]

1/1 [kN] [kN] L [m]

2/1

ST 3200 ST 5000

9 11,3

331 004 9 331 013 9

1600 2500

63 100

100 Hwt 730 160 2Hwt 1010

# *1 *2 *3

Order-No. Tractive force on chain 1/1 Test load (chain) Minimum breaking load (chain)

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Anhang / Appendix

EG-Konformittserklrung
im Sinne der EG-Maschinenrichtlinie 89/392/EWG, Anhang IIA Hiermit erklren wir, da das STAHL Hubwerk Typ ST.., mit oder ohne Fahrwerk folgenden einschlgigen Bestimmungen entspricht: - EG- Maschinenrichtlinie 89/ 392/ EWG - EG- Maschinenrichtlinie 91/ 368/ EWG (1. nderung) - EG-Maschinenrichtlinie 93/ 44/ EWG (2. nderung) - EG-Maschinenrichtlinie 93/ 68/ EWG (3. nderung) - EG- Niederspannungsrichtlinien 73/ 23/ EWG - EG-Niederspannungsrichtlinien 93/ 68/ EWG (1. nderung) - EG-EMV-Richtlinien 89/ 336/ EWG - EG-EMV-Richtlinien 92/ 31/ EWG (1. nderung) - EG-EMV-Richtlinien 93/ 68/ EWG (2. nderung) Angewandte harmonisierte Normen: - EN 292 Teil 1 und Teil 2 (Sicherheit von Maschinen) - EN 55014 / 1993 (Funktentstrung von elektrischen Betriebsmitteln und Anlagen - EN 50081-1 / EN 50082-2 (Elektromagnetische Vertrglichkeit) - EN 60034-1 (Umlaufende elektrische Maschinen) - EN 60034-5 (IP- Schutzarten) - EN 60204 (Elektrische Ausrstung von Maschinen) Angewandte Normen und technische Spezifikationen: - FEM 9.511 (Triebwerkseinstufung) - FEM 9.671 (Kettenabmessungen) - FEM 9.811 (Lastenheft) - FEM 9.683 (Auswahl von Hub- und Fahrmotoren) - FEM 9.941 (Bildzeichen fr Steuerorgane) - FEM 9.755 (Manahmen fr sichere Betriebsweise - S. W. P.) - IEC 947-5-1 (Niederspannungsschaltgerte) Entsprechend Anhang V der EG- Maschinenrichtlinie: - CE-Zeichen wird am Hebezeug angebracht - Technische Dokumentation ist im Herstellerwerk hinterlegt R. STAHL FRDERTECHNIK GMBH Knzelsau, 25.05.1999

i.V. M. Finzel Leitung Entwicklung

i.V. B. Hofmann Leitung Qualitt und Kundenservice

Die EG- Konformittserklrung ist nur gltig in Verbindung mit der Besttigung einer ordnungsgemen Inbetriebnahme nach Betriebsanleitung R. STAHL FRDERTECHNIK GMBH Daimlerstrae 6 D-74653 Knzelsau Tel. 0 79 40/1 28-0 Fax 0 79 40/5 56 65 E-Mail: info@stahl.de Internet: http://www.stahl.de
F-KE-1.4

EC declaration of conformity
as defined by machinery directive 89/392/EEC, Annexe IIA We herewith declare that the STAHL hoist type ST.., with or without trolley, complies with the following provisions applying to it: - EC machinery directive 89/ 392/ EEC - EC machinery directive 91/ 368/ EEC (1st amendment) - EC machinery directive 93/ 44/ EEC (2nd amendment) - EC machinery directive 93/ 68/ EEC (3rd amendment) - EC low voltage directive 73/ 23/ EEC - EC low voltage directive 93/ 68/ EEC (1st amendment) - EC EMC directive 89/ 336/ EEC - EC EMC directive 92/ 31/ EEC (1st amendment) - EC EMC directive 93/ 68/ EEC (2nd amendment) Applied harmonized standards: - EN 292 Part 1 and Part 2 (Safety of machines) - EN 55014 / 1993 (Radio interference suppression of electrical equipment and installations) - EN 50081-1 / EN 50082-2 (Electromagnetic compatibility) - EN 60034-1 (Rotating electrical machines) - EN 60034-5 (IP protection classes) - EN 60204 (Electrical equipment of machines) Applied national technical standards and specifications: - FEM 9.511 (Classification of mechanisms) - FEM 9.671 (Chain qualities, selection criteria and requirements) - FEM 9.811 (Specifications) - FEM 9.683 (Selection of hoist and travel motors) - FEM 9.941 (Control symbols) - FEM 9.755 (Safe working periods - S. W. P.) - IEC 947-5-1 (Low voltage switchgear) As stipulated by Annexe V of the EC machinery directive: - CE symbol affixed to hoist - Technical documentation filed in manufacturer's works R. STAHL FRDERTECHNIK GMBH Knzelsau, 25.05.1999

i.V. M. Finzel Director - Development

i.V. B. Hofmann Director - Quality and Customer Service

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The EC declaration of conformity is valid only in conjunction with confirmation that commissioning has been effected correctly according to Operating Instructions R. STAHL FRDERTECHNIK GMBH Daimlerstrae 6 D-74653 Knzelsau Tel. 0 79 40/1 28-0 Fax 0 79 40/5 56 65 E-Mail: info@stahl.de Internet: http://www.stahl.de

F-KE-1.4

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1

Anhang / Appendix

Verdrahtete Schtz-Steuerung Hard-wired contactor control

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Legende 53 Legend 54

<0> = Option / Option <1> = Steuergert steckbar/ plug-in control pendant

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2

Anhang / Appendix

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Legende 53 Legend 54

<0> = Option / Option <1> = Steuergert steckbar/ plug-in control pendant <2> = entfllt bei einer Geschwindigkeit/ n/a for single speed

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Chain hoist without control

Anhang / Appendix

Wird der Kettenzug ohne Steuerung geliefert, sind alle Anschlsse fr Motor und Bremse auf eine Klemmenleiste X16 bzw. X17 gefhrt. Von dort sind die elektrischen Anschlsse zur bauseits beigestellten Schtzsteuerung zu fhren. (Siehe Stromlaufplan). If the chain hoist is supplied without controls, all connections for motor and brake are collected onto a terminal strip X16 or X17. The electrical connections must be led from here to the contactor control supplied by the customer (see circuit diagram).

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Legende 53 Legend 54

<0> = Option / Option <1> = entfllt bei einer Geschwindigkeit / n/a for single speed

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Anhang/ Appendix

Legende A41 D1...D4 F1-F2-F3 F111-F112-F113 F100 F291-F491-F492 G21 G41 K10 K21/K22 K25 M21 M41 P251 Q1 R1...R8 S110 S211/S212 S221/S222 S411/S412 S421/S422 S425 T41 T100 X0 X1 X2 X22 X23 X24 Y21 Y41 <0> Fahrwerkssteuerung Dioden Anschlusicherungen Steuersicherungen Temperaturwchter Gleichrichter Bremse Hubmotor Gleichrichter Bremse Katzfahrmotor Schtz Not-Halt Schtz auf/ab Umschaltschtz Hubmotor Fahrmotor Betriebsstundenzhler Netzanschluschalter Varistoren Taster Not-Halt Taster auf/ab Grenztaster auf/ab Taster rechts/links Grenztaster rechts/links Umschalter Fahrgeschwindigkeit Anpassungstransformator Steuertransformator Klemmenkasten Laufbahn Klemmenleiste Hubwerk Klemmenleiste Fahrwerk Steckverbindung Anschluleitung Steckverbindung Steuergert Steckverbindung Fahrwerk Bremslfter Hubmotor Bremslfter Fahrmotor Option

Hubgeschwindigkeiten, langsam - schnell Katzgeschwindigkeiten, langsam - schnell auf / ab links / rechts

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Anhang/ Appendix

Legend A41 D1...D4 Control unit travel drive Diode

F1-F2-F3 Main fuses F111-F112-F113 F100 Control fuses F291-F491-F492 Temperature sensors G21 G41 K10 K21/K22 K25 M21 M41 P251 Q1 R1...R8 S110 S211/S212 S221/S222 S411/S412 S421/S422 S425 T41 T100 X0 X1 X2 X22 X23 X24 Y21 Y41 <0> Rectifier hoist motor brake Rectifier travel motor brake Contactor emergency stop Contactor up/down Changeover contactor Hoist motor Travel motor Operating hours counter Main isolator Varistors Emergency stop button Button up/down Limit switch up/down Button right/left Limit switch right/left Change-over switch fast/slow speed (travel drive) Matching transformer Control transformer Terminal box Terminal strip/hoist Terminal strip/travel motor Plug and socket connector power supply Plug and socket connector control pendant Plug and socket connector trolley Brake releasing device for hoist motor Brake releasing device for travel motor Option

Hoisting speeds, slow - fast Trolley speeds, slow - fast up / down

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left / right
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Hoist motor

Original parts

Replacements and repairs may only be carried out by trained personnel. The indications in the "Designation" column are for internal use only.

Item Pos

Part No. Teil-Nummer

18 320 89 11 0

Qty Stck
1 1 1 1 1 100V 190V 240V 290V 220V - 240V 50/60Hz 380V - 480V 50Hz 380V - 480V 60Hz 480V - 600V 50Hz 550V - 600V 60Hz 575V - 720V 50/60Hz

Description Beschreibung
1) 2) 2) 2) 2) (Pos.1-4, 9-15) (Pos.2) (Pos.2) (Pos.2) (Pos.2)

Designation Benennung
Motor kompl. Bremse

567 167 0 567 168 0 567 169 0 567 170 0

2 4 8 9 10 17 18

567 192 0 576 002 0 18 320 04 64 0 .. ... .. .. 9 .. ... .. .. 9 18 320 04 64 0 18 320 05 64 0

1 1 1 1 1 1 1

(Pos.4.1) (Pos.6+17) 3) 4)

Bremsrotor Lfterrad Motordeckel Stator Rotor Schrauben-Set Dichtungs-Set

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1) 2) 3) 4)

Please state operating voltage, frequency and hoisting speed Motor voltage Please state operating voltage and frequency Please state hoisting speed

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Gear

Original parts

Item Pos

Part No. Teil-Nummer

18 320 00 30 0 18 320 01 30 0 18 320 02 30 0 18 320 03 30 0

Qty Stck
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6,3 m/min 1/1 8 m/min 1/1 12 m/min 1/1 16 m/min 1/1 3,2m/min 2/1 4m/min 2/1 6m/min 2/1 8m/min 2/1

Description Beschreibung

Designation Benennung
Getriebe kompl.

17 18 20 22 24

25 27 28 29 30 32 34 36 38

18 320 04 64 0 18 320 05 64 0 18 323 01 01 0 18 323 01 02 0 18 323 00 16 0 18 323 01 16 0 18 323 04 16 0 18 323 05 16 0 23 273 01 19 0 18 320 00 36 0 18 323 00 15 0 18 323 03 16 0 18 323 00 23 0 18 320 00 64 0 18 320 01 64 0 18 320 02 64 0 518 035 0 32 250 07 65 0

6,3 m 8m 12 m 16 m

Schrauben-Set Dichtungs-Set Getriebegehuse Getriebedeckel Zahnrad Z2

(Pos.31)

Zahnrad Z3 Zahnrad Z4 kompl. Zahnrad Z5 Zahnrad Z6 Abtriebsritzel Rutschkupplungs-Set Lager-Set Sicherungs-Set Deckel Getriebel

1000 ml

1)

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1) Gear oil: quantity required 47 33

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Chain drive / suspension

Original parts

Pos Item 17 36 40 46 50

Teil-Nummer Part No. 18 320 04 64 0 18 320 02 64 0 17 320 00 41 0 18 320 00 41 0 17 320 00 45 0 18 320 00 45 0 17 320 00 64 0 18 320 06 64 0 18 322 00 58 0 18 320 00 28 0 521 009 0 18 320 00 57 0 17 320 00 24 0 18 320 00 24 0

Stck Qty 1 1 1 1 1 1 1 1 1 1 5 1 1 1 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000

Beschreibung Description

Benennung Designation Schrauben-Set Sicherungs-Set

(Pos.41,43+46) (Pos.41,43+46)

Kettenfhrung Auswerfer Kettennu

52 54 55 62 66

(Pos.55)

Aufhngese Aufhngehaken Aushngesicherung Aufhngebolzen-Set

2/1 2/1

Set-Aufhngung
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Bottom hook block ST 3200

Original parts

ST 5000

Item Pos
70

Part No. Teil-Nummer

36 320 00 59 0 18 320 00 59 0 36 325 00 13 0 18 325 01 01 0 36 325 00 92 0 18 325 00 92 0 36 320 02 52 0 18 320 00 52 0 24 330 50 57 0 521 008 0 36 320 00 50 0 18 320 01 50 0 35 325 00 01 0 18 325 03 01 0 36 320 00 53 0 18 320 00 53 0 21 330 03 52 0 18 320 01 52 0 24 330 50 57 0 521 009 0

Qty Stck
1 1 2 2 1 1 1 1 5 5 1 1 2 2 1 1 1 1 5 5 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000 ST 3200 ST 5000

Description Beschreibung
1) 1) 1/1

Designation Benennung
Hakengeschirr kompl.

71 72 75 76

Tragschale Bolzen RSN 08 RSN 08 (Pos.76) (Pos.76) Lasthaken Aushngesicherung

80

1) 1)

2/1

Hakenflasche kompl.

81 82 85 86

Tragschild Kettenrolle RSN 1 RSN 1,6 (Pos.83) (Pos.86) (Pos.86) Lasthaken Aushngesicherung

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1) Please state S.W.L

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Chain box / chain stopper

Original parts

Pos Item 90

Teil-Nummer Part No. 18 320 00 32 0 18 320 00 26 0 18 320 01 32 0 18 320 02 32 0 18 320 00 26 0 18 320 01 32 0 18 320 02 32 0 18 320 03 32 0

Stck Qty 1 1 1 1 1 1 1 1 1 1 1 ST 3200 ST 5000 6m 12 m 20 m 50 m 8m 12 m 30 m 50 m

Beschreibung Description 1) 2) 3) 3) 2) 3) 3) 3) ST 3200 ST 3200 ST 3200 ST 3200 ST 5000 ST 5000 ST 5000 ST 5000 (Pos.92)

Benennung Designation Kettenspeicher

91 95

18 320 10 26 0 20 320 00 27 0 18 320 00 27 0

Aufhnge-Set Kettenanschlagnu

1) Plastic 2) Textile 3) Sheet steel

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Control

Original parts

Pos Item 1 2 3 5

Teil-Nummer Part No. 18 320 86 90 9 18 320 89 91 9 18 320 87 90 9 579 285 0 579 286 0 579 289 0 579 287 0 579 292 0 579 288 0 579 294 0 18 320 00 95 0 18 320 01 95 0 15 320 00 83 0 12 390 00 86 0 15 320 01 83 0 15 320 02 83 0

Stck Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Pg 16 Pg 21 43VA 380.415V/ 48V 43VA 420.460V/ 48V 43VA 500V/ 48V 43VA.230/460/ 115V 40VA 575V/ 115V 43VA 380.415V/ 230V 40VA 500V/ 230V

Beschreibung Description 1) 2) 1) (Pos.5)

Benennung Designation Hubmodul kompl. Fahrmodul kompl. Hubmodul Kransteuerung kompl. Trafo

10 11 13

(Pos.17,18)

Gertekasten kompl. Gertekastendeckel kompl. Stromzufhrungs-Set Steckerset-Steuerleitung Verschluplatte Anschluteile

14 15

17 18

18 320 04 64 0 18 320 05 64 0

Schrauben-Set Dichtungs-Set

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1) When ordering, please state supply and control voltage 2) When ordering, please state control voltage 37

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Standard -Steuerung / Standard control 400V / 50Hz Gerteliste / Parts list Benennung Designation

Originalteile / Original parts

Beschreibung Description

Einsatz bei Steuerspannung Used for control voltage

Teilnummer Part number

Schtz / Contactor

K10 K21/K22 K25 K41/K42 K45

LC1-D0901 LC1-D0901 LC1-D12008 LC1-K0601 LC1-K09008

-E7 -E7 -E7 -E7 -E7

48V 48V 48V 48V 48V

579 174 0 579 174 0 579 133 0 579 134 0 578 428 0

Schmelzeinsatz / Fuse element

F103

5x20 0,8 A/T 250V

48V

510 848 0

Gleichrichter / Rectifier

G21

32 173 53 E 00 max.400V AC / 3,0 A

578 530 0

Pos. 20 Item 20

SWH 1102 - 003

11 390 68 20 0

SWH 1102 - 009

11 390 04 20 0

SWH 1202 - 028

11 390 79 20 0

SWH 1202 - 021

11 390 24 20 0

Pos. 21 Item 21

Steuerkabel Control cable

Steuerkabellnge Length of control cable 1,8 m 2,3 m 2,8 m 4,0 m 6,0 m 10,0 m

Teil-Nummer Part number 11 390 00 82 0 11 390 01 82 0 11 390 02 82 0 11 390 03 82 0 11 390 04 82 0 11 390 05 82 0

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