Gis GP Series User manual

06.20 Translation 9500.9002.1
TRANSLATION OF THE
ORIGINAL INSTRUCTION MANUAL
ELECTRIC CHAIN HOIST GP

3Swiss Lifting Solutions
Table of contents
Spare parts / Ordering spare parts ...................................................................................... 4
0 General information ..................................................................................................... 5
0.1 General safety instructions ................................................................................................................................................................... 5
0.1.1 Safety and hazard information.............................................................................................................................................................. 5
0.2 General safety regulations and organisational measures .................................................................................................................... 5
0.2.1 Warning markings / Legends / Warning plates ..................................................................................................................................... 5
0.3 Particular safety instructionsTransport and assembly: ......................................................................................................................... 5
0.4 Instructions for hazard protection ......................................................................................................................................................... 6
0.4.1 Hazards - Mechanical ........................................................................................................................................................................... 6
0.4.2 Hazards - Electrical............................................................................................................................................................................... 7
0.4.3 Sound pressure level ............................................................................................................................................................................ 7
0.5 Technical status .................................................................................................................................................................................... 7
0.5.1 Periodic checks..................................................................................................................................................................................... 8
0.5.2 Warranty................................................................................................................................................................................................ 8
0.6 Appropriate use..................................................................................................................................................................................... 8
0.6.1 Use of the instruction manual ............................................................................................................................................................... 9
1 Description .................................................................................................................. 9
1.1 Operating conditions............................................................................................................................................................................. 9
1.2 General description............................................................................................................................................................................. 11
1.3 Emergency stop .................................................................................................................................................................................. 12
2 Start-up ......................................................................................................................12
2.1 Transport and assembly...................................................................................................................................................................... 12
2.2 Connections ........................................................................................................................................................................................ 12
2.2.1 Electrical connections......................................................................................................................................................................... 12
2.2.2 Load chain........................................................................................................................................................................................... 14
2.2.3 Limit switch.......................................................................................................................................................................................... 16
2.2.4 Chain container................................................................................................................................................................................... 16
3 Care and maintenance................................................................................................17
3.1 General guidelines for maintenance and repair.................................................................................................................................. 17
3.2 Care and maintenance........................................................................................................................................................................ 18
3.2.1 Care overview ..................................................................................................................................................................................... 18
3.2.2 Maintenance overview ........................................................................................................................................................................ 18
3.2.3 Brake system....................................................................................................................................................................................... 19
3.2.4 Load chain........................................................................................................................................................................................... 19
3.2.5 Limit stop............................................................................................................................................................................................. 20
3.2.6 Transmission....................................................................................................................................................................................... 20
3.2.7 Slipping clutch..................................................................................................................................................................................... 20
3.2.8 Suspension parts ................................................................................................................................................................................ 20
4 Measures for achieving safe operating periods ...........................................................21
4.1 Determining the actual operating time ................................................................................................................................................ 21
4.2 General overhaul................................................................................................................................................................................. 22
4.3 Disposal .............................................................................................................................................................................................. 22
5 Annex .........................................................................................................................23
5.1 Technical data..................................................................................................................................................................................... 23
5.2 Electrical parameters .......................................................................................................................................................................... 24
5.3 EC Declaration of conformity .............................................................................................................................................................. 26
5.4 EC Declaration of incorporation.......................................................................................................................................................... 27

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Resellers / Agent
Original spare parts for the electric chain hoists can be acquired from the following addresses:
Manufacturer
GIS AG
Swiss Lifting Solutions Tel. [phone]
Luzernerstrasse 50 [e-mail]
CH-6247 Schötz www.gis-ag.ch
The correct order numbers for original spare parts can be obtained from the corresponding spare parts list. Please ensure that you
have the following data on your electric chain hoist to hand. This will enable the correct spare parts to be supplied without delay.
Electric chain hoist type:
Serial number:
Year of manufacture:
Load capacity:
Spare parts / Ordering spare parts

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Transport / assembly:
• Electric chain hoists, single parts and large components should be carefully fixed to suitable and technically acceptable hoisting
apparatus / load handling devices.
Connection:
• Connection work is only to be performed by personnel specifically designated and trained for the job.
0.3 Particular safety instructionsTransport and assembly:
Figure 0-1 Figure 0-2 Figure 0-3 Figure 0-4 Figure 0-5
0.2.1 Warning markings / Legends / Warning plates
• Oil chain.................................................................figure 0-1
• CE sign ..................................................................figure 0-2
• Type plate ............................................................. figure 0-3
• Data plate ............................................................. figure 0-4
• Voltage.................................................................. figure 0-5
The instruction manual for the electric chain hoist must always be available within the operating area of the hoist. The information
on the electric chain hoist's type and data plate must be checked against Table 5-1 or 5-2, page 23 and the corresponding dimensioned
drawing. The dimensioned drawing also shows the dimensions of the electric chain hoist. This ensures that this instruction manual can
be clearly assigned to the electric chain hoist. The instruction manual must be strictly adhered to. Furthermore, supplementary to the i
nstruction manual, the statutory regulations governing general accident prevention and environmental protection are to be enforced.
Operating and service personnel must have read and understood the instruction manual, in particular the safety instructions, before
commencing work. Protective equipment must be made available for operating and service personnel and worn at all times. The
operator or their representative is responsible for supervising operating personnel and ensuring they are aware of the hazards and
safety implications of working with the electric chain hoist.
The manufacturer reserves the right to make technical changes to the product or changes to these instructions and assumes no liability
for the completeness and up-to-dateness of these instructions. The original version of these instructions is in the German language.
In case of doubt, the original German original version is exclusively valid as a reference document.
0.2 General safety regulations and organisational measures
0.1.1 Safety and hazard information
The following symbols and terms are used in this instruction manual for safety and hazard instructions:
WARNING !
Non-compliance, either in part or full, with operating instructions with this symbol can result in serious personal injury or
fatal accidents. Warning information must be strictly adhered to.
ATTENTION !
Non-compliance, either in part or full, with operating instructions with this symbol can result in major damage to
machinery, property or material. Information in the "Caution" category is to be exactly adhered to.
NOTE
Following the instructions marked with this symbol will lead to more effective and straightforward operation.
"Note" directions make work easier.
0.1 General safety instructions
0 General information

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0.4.1 Hazards - Mechanical
Physical injury:
Unconsciousness and injury through:
• crushing, shearing, cutting and twisting
• drawing in, ramming, piercing and rubbing
• slipping, stumbling and falling
Causes:
• crushing, shearing and twisting
• parts rupturing or bursting
Safety options:
• keep floor, equipment and machinery clean
• eliminate leakages
• observe the required safety distance
Hazardous areas must be clearly marked by warning plates and cordoned off. It must be ensured that warnings regarding hazardous
areas are given due attention.
Hazards can stem from:
• incorrect application
• not following safety directions properly
• not carrying out test and service work thoroughly
0.4 Instructions for hazard protection
Start-up / operation:
• Before initial start-up as well as daily start-up, carry out a visual check and carry out the stipulated user-checks routine.
• Only operate the electric chain hoist if the protective and safety equipment provided is ready and working.
• Damage to the electric chain hoist and changes in its operational characteristics must be reported immediately to the responsible
person.
• After use, or when in a non-operational mode, the electric chain hoist should be secured against unauthorised and unintentional use.
• Refrain from hazardous procedures.
See also operational parameters (chapter 0.6).
Cleaning / service / repair / maintenance / refitting:
• Use working platforms provided for assembly work at high level.
• Do not use machine parts for this purpose.
• Check electrical cables for damage or wear.
• Ensure any oils or other agents used are collected and disposed of safely and in an environmentally sound manner..
• Reassemble and check safety devices that have been disassembled for maintenance or repair of the hoist once service and repair work
has been completed.
• Adhere to predefined testing and service intervals specified in the instruction manual.
• Follow the directions in the instruction manual regarding exchanging parts.
• Operating personnel should be informed before commencing special or repair work.
• Secure the repair working area.
• Prevent the electric chain hoist from being unexpectedly switched on during maintenance or repair work.
• Attach warning plates.
• Disconnect the power cable and ensure it cannot be switched on again by unauthorised personnel.
• Retighten screw connections that have been loosened for repair or maintenance work.
• Replace non-reusable fixing elements (e.g. self-locking nuts, washers, cotter pins, O-rings and seals).
Shut down / storage:
• Clean and preserve (lubricate/grease) the electric chain hoist before long periods of inactivity or storage.

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This instruction manual was issued in 2020. It corresponds to directive 2006/42/EC of the European Parliament and council of 17 May
2006 (including its amendments). The GP models are calculated for the case of operation with a shock factor of 1.4 (per DIN EN 818-7
with max. 8 m/min). The accidents audited by the laboratory generate smaller shock factors than the normal mode.
0.5 Technical status
When working in a noisy environment, the use of ear protection is recommended.
Measuring distance 1 m 2 m 4 m 8 m 16 m
Series Measurement type dBA
GP 250/500, GPM 250 a
b
65
65
62
59
59
53
56
47
53
41
GP 250/500 1Ph, GPM 250 1Ph a
b
76
76
73
70
70
64
67
58
64
52
GP 1000, GP 1000 1Ph a
b
80
80
77
74
74
68
71
62
68
56
GP 1600/2500 a
b
80
80
77
74
74
68
71
62
68
56
Table 0-1 Sound pressure level
0.4.3 Sound pressure level
Tests on the chain hoist sound level are performed at a range of 1, 2, 4, 8 and 16 metres from the centre of the electric chain hoist
motor to the measuring device. Measurement of SPL per DIN 45635.
The sound pressure level was measured:
a) During operation of electric chain hoists on factory site.
b) During open-air operation of electric chain hoists.
Physical injury:
Death from electrical shock, injury and burns through:
• contact
• faulty insulation
• faulty maintenance or repair work
• short circuit
Causes:
• contact with, touching or standing too close to uninsulated power and live parts
• use of uninsulated tools
• exposed electricity supply terminals following insulation failure
• inadequate safety checks following repair work
• incorrect fusing
Safety options:
• Isolate machinery and equipment designated for repair or maintenance work before commencing such work.
• First check isolated parts for voltage.
• Regularly check electrical fittings.
• Replace loose or damaged cables immediately.
• Always replace blown fuses with fuses of the correct type/value.
• Avoid contact with or touching live terminals.
• Only use insulated tools.
0.4.2 Hazards - Electrical
Work on electrical apparatus or machinery may only be performed by qualified electricians or persons under the supervision and
guidance of qualified electricians, in accordance with electrical regulations.

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Improper use comprises:
• exceeding the defined maximum permissible load capacity
• pulling the load diagonally (maximum angle 4°, see figure 0-6)
• heaving, pulling or dragging the load
• transporting persons
• moving loads over persons
• standing under suspended loads (see Figure 0-7)
• transporting excessive loads
• pulling on the control cable
• failing to observe the load hook constantly
• running the chain over edges
• failing to observe the load constantly
• allowing the load to fall due to a slack chain
• use in an explosive environment
Refer also to chapter 0.3.
General operating conditions:
• Ambient temperature ............................. : -15 °C to +50 °C
• Humidity................................................. : max. 80% relative humidity
• Protection class ..................................... : IP 65
• Electromagnetic compatibility................ : Immunity, industrial area
We recommend equipping GIS chain hoists working outdoors with a canopy to protect them from the weather or to move the chain hoist,
trolley and travel drive under a canopy when not in use. Special operating conditions can be agreed in individual cases with the manu-
facturer. After consultation, appropriate, optimised equipment, and important information for safe, low-wear use can be supplied. The
intended use of the electric chain hoist likewise assumes the adherence to the operating, maintenance and servicing prescribed by the
manufacturer.
The electric chain hoists of the GP types are lifting equipment for various loads. They can be installed as stationary or mobile units, while
a lateral oscillation must be ensured. The electric chain hoists are manufactured in accordance with the latest technical developments and
recognised safety standards, and are tested for safe operation by the manufacturer. Electric chain hoists are approved by various interna-
tional classification societies such as TÜV and others. Electric chain hoists of the above types may only be used when in an acceptable
technical condition, in accordance with their intended use, by trained personnel in a safe and responsible manner.
0.6 Appropriate use
0.5.2 Warranty
The warranty is void if the installation, operation, testing and maintenance is not carried in accordance with this instruction manual. Re-
pairs and troubleshooting under warranty may only be carried out by qualified persons after consultation and agreement with the
manufacturer/supplier. Any modifications to the product or the use of non-original spare parts will void the warranty.
0.5.1 Periodic checks
Each device/unit operator should adequately note all checks, maintenance and inspections performed in the inspection pass, and have
these confirmed by the competent person in charge. Incorrect or missing entries will lead to forfeiture of the manufacturer's warranty.
Devices and cranes are to be checked periodically by a specialist. Primarily, visual and functional checks are to be carried out,
whereby the state of components with respect to damage, wear, corrosion or any other changes is determined. In addition,
safety equipment is assessed for completeness and efficiency. It may be necessary to dismantle the equipment to correctly
assess wear parts.
Load-bearing parts must be inspected over their entire length, including covered or hidden parts.
All periodical inspections should be arranged by the operator.

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Classification according to application requirements:
Electric chain hoists and trolleys are categorised in accordance with the following regulations into classifications:
• DIN EN 14492-2 (A5 = 125,000 cycles)
• ISO 4301-1 (M5 = 1 600 h)
• DIN 15401 / DIN EN 13001 (load hook)
• Remarks about general overhaul (see chapter 4)
There is different coefficient data for the classifications that must be adhered to in operation.
1.1 Operating conditions
The GP series includes the following models: GPM, GP, GP special versions.
1 Description
0.6.1 Use of the instruction manual
This instruction manual includes the following chapters:
0 General information 3 Care and maintenance
1 Description 4 Measures for achieving safe operating periods
2 Start-up 5 Appendix
Supplementary to the instruction manual, the following documentation from the operator must be noted:
• Declaration of conformity
• Inspection pass
• Spare parts list(s)
• Circuit diagrams
Page and figure numbering:
The pages are consecutively numbered. Blank pages are not numbered, however are calculated together with the consecutive pages.
Figures are numbered consecutively by chapter. Example: Figure 3-1 means: in chapter 3, figure 1.
Excessive inching operations, slack chains and driving against the limit stops should be avoided. The loads shall be lifted
off the ground with the lowest available lifting speed (per EN 14492). If these instructions are not followed, the manufacturer
accepts no liability for damage to equipment and third parties caused by such actions.
With pole-changeable motors the slow speed is only suitable for driving and braking. In short time operation max. 20% of
the fast gear duty cycle.
Figure 0-6 Figure 0-7

10
90
100
80
50 50
100
33
16.7 50
100
0
~
40
16.716.7
70
10 40 50
100
0
~
40
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Example 1: Calculate permissible operating time of the electric chain hoist
An electric chain hoist of the classification A4 is to be used for medium stress load tasks throughout its whole calculated service life.
This corresponds to the type of load "Q4 heavy" (see table 1-1). Corresponding to the values in table 1-2, the electric chain hoist should
not be used for more than 60 cycles per day.
Example 2: Calculate the permissible type of load
An electric chain hoist of the classification A5 is to be used for approximately 400 cycles per working day, throughout its whole service life.
Thus, the electric chain hoist must be operated in accordance with the characteristics of the type of load 'Q2 light' (see table 1-1).
Ascertaining the correct type of application for an electric chain hoist:
Either the number of cycles or expected type of load can be used as a basis for ascertaining the correct type of application for the electric
chain hoist.
Before initial start-up of the electric chain hoist, it is necessary to ascertain which of the load types in table 1-1 applies to the
operation of the electric chain hoist. Assignment to a load type or a load spectrum (Q) applies for the whole service life of the
equipment and may not be altered for operational safety reasons.
Classification according to
DIN EN 14492-2 (ISO 4301-1) A3 (M3) A4 (M4) A5 (M5) A6 (M6) A7 (M7)
Load spectrum Number of cycles per working day
(hoisting classes Dh2 - Dh5, lifting speed 8 m/min)
Q2 - light Q < 0.50 120 240 480 960 1 920
Q3 - medium 0.50 < Q < 0.63 60 120 240 480 960
Q4 - heavy 0.63 < Q < 0.80 30 60 120 240 480
Q5 - very heavy 0.80 < Q < 1.00 15 30 60 120 240
Table 1-2 Operating conditions
Q = Load spectrum (type of load)
Load type Q2
light
Q < 0.50
Q = 0.50
Load type Q3
medium
0.50 < Q < 0.63
Q = 0.63
Load type Q4
heavy
0.63 < Q < 0.80
Q = 0.80
Load type Q5
very heavy
0.80 < Q < 1.00
Q = 1.00
% of lifting capacity % of lifting capacity % of lifting capacity % of lifting capacity
% of operating time % of operating time % of operating time % of operating time
Full load only by way
of an exception,
however predominantly
low loads
Often fully loaded,
however continuously
lightly loaded
Frequently fully loaded
continuous average
loading
Regularly fully loaded
Table 1-1 Load spectrums
The manufacturer will only guarantee the safety and lasting operation of the electric chain hoist when used for applications in accordance
with valid standard values that fall within its classification.
Before the initial start-up, the user must estimate according to the parameters in table 1-1, which of the four types of load is applicable to
the use of the electric chain hoist during its whole life cycle. The table 1-2 shows standard values for the operating conditions of the
classifications depending on the type of load and number of cycles.
The travel trolley must have at least the same lifting capacity as the electric chain hoist.
The classification of the electric chain hoist can be found on the data plate.

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The electric chain hoist meets the requirements of the EC Machinery Directive and the harmonized EN standards. Housing and cover of
the electric chain hoist are made of a sturdy die-cast aluminium. Cooling fins and a fan on the attached motor ensure optimum cooling.
The chain container can be attached to the compactly constructed housing. A drilled hole is provided for the power supply cable gland
and for the cable gland for the control cable. The eyebolt suspension or optional hook suspension are attached on the housing.
GIS electric chain hoists are driven by asynchronous motors. Two-speed models include a pole-changeable version of the motor.
The braking system consists of one DC-operated magnetic brake. When there is no current, pressure springs generate the braking torque.
The slipping clutch is installed in front of of the braking system due to its function. It protects the chain hoist from overload and takes on
the function of an emergency stop for the highest and lowest hook positions. A geared limit switch is installed to limit the highest and
lowest hook position. Optionally, downstream forced disconnecting emergency stop contacts can be retrofitted.
The electric chain hoists are equipped with a 42 V contactor control as standard. The generally built-in emergency stop contactor
disconnects all three main phases from the mains when the red emergency stop button is pressed.
The high tensile profile steel chain corresponds to grade DAT (8SS) per DIN EN 818-7. The chain wheel is hardened. The load hook,
which complies with DIN 15401 / DIN EN 13001, is fitted with a safety catch. The 3-stage enclosed spur gears are generally helical.
The gears are mounted on roller bearings and run with grease lubrication.
The standard equipment of the electric chain hoist includes a control switch (up/down with emergency stop). The special versions are
described in a separate instruction manual.
Control switch Single fall Double fall
1) Control unit box
2) Rotor shaft
3) Motor
4) Housing
5) Brake
6) Electrical control
7) Transmission
8) Limit switch
6
7
8
1
2
3
4
5
Figure 1-1
1.2 General description

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2.2.1 Electrical connections
Electrical installations may only be performed by authorised specialists.
The mains connection cable, the mains connection fuse and the main switch for connecting the electric chain hoist to the mains power
supply must be provided by the customer. A 4-wire cable with a PE protective conductor is needed as a supply line for three-phase
versions. A 3-wire cable with a protective conductor is adequate for single-phase version. The length and cross-section must be
appropriate for the power consumption of the electric chain hoist.
2.2 Connections
The safety directions for handling with loads should be followed (see chapter 0.3) when transporting and assembling the electric chain
hoist. Electric chain hoists must be assembled by qualified staff, always bearing in mind the accident prevention directions in chapter 0.2.
Before assembly, the electric chain hoist must be stored in an closed room or covered area. Should the electric chain hoist be destined for
operation outdoors, then it is recommended that a protective cover is erected to shield it from the effects of the weather.
Wherever possible, the electric chain hoist should be transported in its original packaging. The goods delivered should be checked for
completeness and the packaging disposed in an environmentally sound manner. It is recommended that the electric chain hoist is assem-
bled and connected on-site by qualified personnel.
2.1 Transport and assembly
Mechanical adjustments may only be performed by authorised specialists.
Operating staff must carefully read the instruction manual of the electric chain hoist before initial start-up and carry out all the
checks. The device shall be put back into operation only after operational safety has been established. Unauthorised persons
may not operate the device or carry out work with it.
The operator must create an inspection pass during the commissioning of the electric chain hoist. The inspection pass con-
tains all the technical data and the date of commissioning. It provides a record of all servicing and maintenance work.
2 Start-up
By pressing the emergency stop button, the power supply to the electric chain hoist is interrupted in all phases. The movement of the
electric chain hoist is stopped immediately. To unlock the emergency stop button, it must be turned in the indicated direction.
After an emergency stop, the operator may only restart the electric chain hoist after a competent person is satisfied that the
cause which led to the emergency stop has been eliminated and that there is no longer any danger from further operation of
the system.
1.3 Emergency stop

8-9 mm
1
NA
1 speed
4
2
3
1
4
4
1 speed
3
3
3
4
2 speed
2 speed
2
red
21
red
1
2 1 10 4 3
4
3
1
2
1
0
1
2
3
4
10
L3
L2
L1
PE
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Figure 2-4 Figure 2-5
The protective conductor should not conduct any current during operation. With the installation of a motor protection breaker,
the current of the electric chain hoist must be observed in accordance with the type plate.
• Checking direction of rotation: If the directions of movement do not match the button symbols of the control switch, the
supply line wires L1 and L2 must be transposed.
• In the single-phase version, inching operations can cause malfunctions.
• With the cover removed, observe the rotating fan wheel (1, see Figure 2-4).
Open the terminal used in accordance with figure 2-5.
Figure 2-1 Figure 2-2 Figure 2-3
• Before connecting the electric chain hoist, check whether the operating voltage and frequency specified on the type plate
correspond to the available power supply.
• Remove the cover from the control unit box.
• Introduce the connection cable with cable gland M25 × 1.5 through the lower or side hole and connect in accordance with
the attached electrical chart to L1, L2, L3 and PE (see figure 2-1).
• Introduce the control cable through cable gland M20 × 1.5 in the hole below the housing and connect to terminals 1, 2, 3, 4, 10
(see figure 2-2).
• Mount strain relief to housing (see Figure 2-3).
• Re-fit the cover from the control unit box.
• To maintain the predetermined protection class IP 65, all cables must fit into the corresponding cable glands and the
cover screws must be tightened after the connection with the torque specified in table 3.2.8.
•Open holes must be provided with a sealing plug.
• The control switch must be attached to the strain relief cord and not to the cable.

1
3
2
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Figure 2-7 Figure 2-8 Figure 2-9
Chain end:
The chain end is to be fixed to the housing in accordance with figure 2-7 or figure 2-8 and the limit stop in accordance with figure 2-9.
Ensure that the end of the chain is not twisted. The section of chain after the limit stop (1) must be adjusted to the height of the chain
container. Here, the length of the chain section must be selected such that the limit stop lies on the floor of the container when the chain is
pulled into it (see figure 2-10).
1 fall operation:
The load hook (1) is connected to the chain with a single fall hook clamp (2). For the power transmission, the mounting of the bolt (3) is
important (see figure 2-11).
• Note correct arrangement of suspension (dimension k1, see figure 2-12 or for GP 2500 see figure 2-13):
GPM 250 = symmetrical, GP 250/500 = 41 mm, GP 1000 = 43 mm, GP 1600 = 53 mm, GP 2500 = 87 mm.
• Grease the bearings thoroughly (load hook).
Figure 2-6
2.2.2 Load chain
• Only use original chains.
• Welding seam of the chain links must face inward on the chain wheel (see figure 2-6).
• The geared limit switch must be mechanically deactivated for pulling in the chain, see chapter 2.2.3.
Before start-up and during operation, the load chain must be oiled along its full length. Oil must constantly be present on the internal,
contacting and rubbing surfaces of the chain links. Lubrication is carried out by submersion or with an oil can, using a creeping gear oil
(GIS chain oil or SAE 15W-40). The end of the chain (1) should be attached to a flexible piece of wire or chain pulling loop (2) and fed
through the chain wheel (3) of the electric chain hoist. Through short switching impulses, the chain will be pulled in correctly in
accordance with figure 2-6. The lifting height must be adjusted such that the hook fittings lie on the ground in the lowest hook position.

k2
k2
2
1
5
4
3
GP 250/500
10 Nm
k1
k1
3
1
2
1
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Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17
Double fall operation (GP 250/500, GP 1000, GP 1600/2500):
Fit load hook (1) with double fall hook clamp (2) in accordance with figure 2-14. Connect load-side chain end with the chain holder (3)
(Tightening torque for model GP 250/500: 10 Nm) and fasten into the guide rail of the housing. Secure the chain holder with screw (4)
and spring washer (5).
• Note correct arrangement of suspension (dimension k2, see figure 2-15 or for GP 2500 see figure 2-16):
GP 250/500 = 52 mm, GP 1000 = 62 mm, GP 1600 = 73 mm, GP 2500 = 130 mm.
• No longitudinal twisting of the chain (see figure 2-17).
• Grease the bearings thoroughly (deflection roller / load hook).
Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13

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2.2.4 Chain container
• Extend the chain on the load side until the limit switch is triggered.
• Attach the free end of chain to housing (see chapter 2.2.2).
• Fit the chain container and allow the chain to run in: Plastic chain container (see figure 2-20) or textile chain container:
GPM 250: see figure 2-21, GP 250/500: see figure 2-22, GP 1000: see figure 2-23, GP 1600/2500: see figure 2-24.
Adjustment description (see gure 2-18):
• Provision only with model GPM 250: Loosen screws (1 + 2) and turn clamping strip (3) away (see figure 2-19).
• The geared limit switch must be deactivated mechanically by pressing the rocker switch (1) before drawing the chain in or when
changing the chain.
• Draw the chain in.
• Move to the highest hook position and turn the red switch wheel (2, rear) until it reaches the switch cam on the top limit switch (3)
(turn clockwise for the lowest hook position and anticlockwise for higher hook positions).
• Activate the rocker switch (1) (the rocker switch must latch into the switch wheel).
• Move to the lowest hook position, press the rocker switch (1) and turn the green switch wheel (4, front) until it reaches the switch cam
on the bottom limit switch (5) (turn clockwise for the lowest hook position and anticlockwise for higher hook positions).
• Activate the rocker switch (1) (the rocker switch must latch into the switch wheel).
Check the limit switch function: the limit stop and the bottom hook block may not touch the housing.
GP 2500
Transmission Colour 1 fall lifting height [m] 2 falls lifting height [m]
i = 1:1 black 42 21
i = 1:1.5 red 63 31.5
i = 1:3 yellow 126 63
i = 1:6 blue 252 126
GP 1600
Transmission Colour 1 fall lifting height [m] 2 falls lifting height [m]
i = 1:1 black 34 17
i = 1:1.5 red 51 25.5
i = 1:3 yellow 102 51
i = 1:6 blue 204 102
GP 1000
Transmission Colour 1 fall lifting height [m] 2 falls lifting height [m]
i = 1:1 black 30 15
i = 1:1.5 red 45 23
i = 1:3 yellow 90 45
i = 1:6 blue 192 96
GP 250/500
Transmission Colour 1 fall lifting height [m] 2 falls lifting height [m]
i = 1:1 black 19 9.5
i = 1:1.5 red 28 14
i = 1:3 yellow 57 28.5
i = 1:6 blue 114 57
GPM 250
Transmission Colour 1 fall lifting height [m] 2 falls lifting height [m]
i = 1:1 black 14 -
i = 1:1.5 red 21 -
i = 1:3 yellow 42 -
i = 1:6 blue 90 -
2.2.3 Limit switch
A geared limit switch is built in as standard in the electric chain hoists. This is also suitable as a regular limit stop with high switching
precision. The limit switch function (highest and lowest hook position) must be tested during start-up. Four different transmissions are
available depending on the lifting height:

1
2
3
3
1
2
5
4
17Swiss Lifting Solutions
Operating failures in electric chain hoists affecting the safe operation of the device should be remedied immediately.
Maintenance and repair work on the electric chain hoist may only be carried out by qualified and trained personnel.
If the operator performs maintenance work on an electric chain hoist on their own, the type of maintenance performed
together with the date carried out must be entered in the inspection pass.
Alternations, as well as modifications and additions to electric chain hoists, which may affect safety, must be authorised by the
manufacturer in advance. Structural alterations to chain hoists not authorised by the manufacturer exempt the manufacturer from liability
in the event of damage. Material warranty claims will only be recognised as valid if original manufacturer's spare parts are used exclusi-
vely. We explicitly advise that original parts and accessories not delivered by us are also not checked or approved by us.
3.1 General guidelines for maintenance and repair
3 Care and maintenance
Figure 2-21 Figure 2-22 Figure 2-23 Figure 2-24
Figure 2-18 Figure 2-19 Figure 2-20

18 Swiss Lifting Solutions
Designation d3 M 12 M Task Remark
1. Load chain x
x
Oil
Measure wear
see chapter
2.2.2 / 3.2.4
2. Brake system x x Function check with load see chapter 3.2.3
3. Electrical equipment xFunction check
4. Fixing screws on suspension parts
and load hook with accessories
xCheck for cracks
Check screw torque
see chapter 3.2.8
5. Limit switch xCheck switching elements see chapter 2.2.3
6. Slipping clutch xFunction check see chapter 3.2.7
7. Leaktightness xCheck screw torques of the covers
Check cable glands
see chapter 3.2.8
3.2.2 Maintenance overview
Table 3-2 Maintenance overview
Designation d3 M 12 M Task Remark
1. Load chain xVisual check
Clean and lubricate as needed
see chapter 2.2.2
2. Lifting device and trolley xCheck for abnormal noise / sealing
3. Electric power supply cable xVisual check
4. Limit switch xFunction check see chapter 2.2.3
5. Sealing xVisual check
6. Strain relief control cable xVisual check
3.2.1 Care overview
Table 3-1 Care overview
3.2 Care and maintenance
General:
Care and maintenance tasks are preventive measures designed to preserve the full functionality of electric chain hoists. Non-compliance
with care and maintenance routines can result in limited use and damage to electric chain hoists.
Care and maintenance should be carried out in accordance with the instruction manual at predefined time intervals (table 3-1 and 3-2).
During care and maintenance work, general accident prevention directions, special safety directions (chapter 0.3) as well as hazard pro-
tection instructions (chapter 0.4) should be followed.
Care and maintenance work should be performed only on electric chain hoists with no loads. The main switch must be off. The
hook fittings must lie on the ground or on the maintenance platform.
Care work encompasses visual checks and cleaning routines. Maintenance work includes additional functional checks. During the functio-
nal checks, all fixing elements and cable clamps must be checked for tightness. Cables must be inspected for dirt, discolouration and arc
spots.
Used operating materials (oil, grease, etc.) should be safely collected and disposed of in an environmentally friendly manner.
Care and maintenance intervals are defined as follows:
d (daily), 3 m (quarterly), 12 m (annually)
The predefined care and maintenance intervals should be reduced when the loading of the electric chain hoist is exceptionally large or
when frequently operated in adverse conditions (e.g. dust, heat, humidity, steam, etc.).

t
b
a=11t
d
d1
d2
a
19Swiss Lifting Solutions
Figure 3-1 Figure 3-2
Designation GPM/GP 250 GP 500 GP 1000 GP 1600 GP 2500
Chain type d x t [mm] 3.75 x 10.75 5.25 x 15 7.45 x 23 9.4 x 27.4 11.75 x 32.9
Limit values according to
DIN 685, part 5, DIN EN 818-7
1. Measurement over 11 chain links, a = 11t [mm] 120.6 168.3 258.1 3 07.4 369.1
2. Measurement over 1 chain link, 1t [mm] 11.3 15.7 24.1 28.7 34.5
3. Measurement of the chain link diameter
dm = d1 + d2 / 2 (dm min. = 0.9 x d) [mm] 3.4 4.7 6.7 8.5 10.6
Table 3-4 Load chain wear values
3.2.4 Load chain
The load chain should be periodically checked for abrasion. The check is based on three measurements: see permissible wear values
(table 3-4) and measuring points (figure 3-2).
The chain should be replaced when the measurements no longer comply with those defined in the table. The chain wheel
and chain guidance should be checked for wear at the same time and, where necessary, be replaced. Only use original
chains. The chain links should not be welded.
The new chain is installed in accordance with chapter 2.2.2.
For ease of installation, the old chain and new chain can be connected by a piece of flexible wire.
Designation GPM/GP 250 GP 500 GP 1000 GP 1600/2500
Nominal value air gap (a) [mm] 0.3 (+0.1 / -0.05) 0.3 (+0.1 / -0.05) 0.3 (+0.15 / -0.05) 0.3 (+0.15 / -0.05)
Air gap (a max.) [mm] 0.7 0.7 0.9 0.9
Holding torque [Nm] 4 7 12 22.5
Screw tightening torque [Nm] 3 3 6 6
Table 3-3 Air gap
3.2.3 Brake system
The spring-loaded brake is a solenoid-operated, single disc brake with two friction surfaces. The braking force is applied by springs.
The braking torque is generated when no current is applied. The brake release is solenoid-operated. The brake operates with DC
current. The brake must be able to hold the nominal load in power free mode without any problems.
The brake coil voltage must be the same as the operating voltage.
The brake has no air gap adjustment. If the maximum air gap is reached (a max., table 3-3 and figure 3-1) reached, the
lining and the brake disc must be replaced.

20 Swiss Lifting Solutions
Suspension part GPM 250 GP 250 GP 500 GP 1000 GP 1600 GP 2500
Load hook h[mm] 18.0 28.0 28.0 35.5 48.0 48.0
h min. [mm] 17.1 26.6 26.6 33.8 45.6 45.6
Hook suspension h[mm] 18.0 28.0 28.0 35.5 48.0 48.0
h min. [mm] 17.1 26.6 26.6 33.8 45.6 45.6
Eyebolt suspension h[mm] 11.0 15.0 15.0 20.0 22.5 29.0
h min. [mm] 10.5 14.3 14.3 19.0 21.4 27.5
Hook opening l[mm] 24.0 34.5 34.5 42.6 44.6 44.6
l max. [mm] 26.4 37.9 37.9 46.8 49.0 49.0
Table 3-5 Wear values suspension parts
If hook or eyebolt shows damage, cracks, deformation or corrosion, it must be replaced. If the prescribed dimensions
(min. / max.) no longer comply with table 3-5 and figure 3-3, the parts must also be replaced. The hook safety catch must be
fully functional and fully closed, replace if necessary.
M 4 M 5 M 6 M 8 M 10 M 12
3.3 Nm 6.5 Nm 10 Nm 24 Nm 48 Nm 83 Nm
3.2.8 Suspension parts
All statically loaded parts are considered to be suspension parts. The bearing surfaces of the slewing suspension parts must be periodi-
cally greased. Torque values for screws of strength class 8.8 per DIN ISO 898:
3.2.7 Slipping clutch
The slipping clutch is set to 125% at the factory and reliably prevents overloading of the chain hoist (the power limiting factor per DIN EN
14492-2 is ΦDAL = 1.6). In the case of the two lowest lifting capacities in tables 5-1 to 5-5, the factor is ≤ 2. The resultant forces arising from
the adjustment of the slipping clutch must be able to be absorbed by the suspension parts. The coating is wear resistant.
Adjustment and testing of the slipping clutch may only be carried out by authorised personnel and must be recorded in the
inspection pass. If the nominal load is no longer lifted, or there is delay in achieving the lifting speed, the slipping clutch must
be adjusted.
3.2.6 Transmission
The transmission has permanent lubrication.
The housing of the transmission may not be opened.
3.2.5 Limit stop
Check screw fittings at the limit stop and single fall hook clamp and tighten with the correct torque if necessary. See chapter 3.2.8 for
guide values.
A damaged stop plate, at the bottom of the housing, must be replaced.