Verlinde STAGEMAKER COMPACT SM1 Instruction Manual

STAGEMAKER
INSTALLATION
MAINTENANCE
SPARE PARTS
VERLINDE reserve the right to alter or amend the above information without notice 03.2001 –
VESEGBSM10A1

9807
Table of contents
page Up date ref
1 EC Declaration of conformity 1 9803
2 What not to do 2 9803
3 What to do 3 9803
4 Guarantee 4 9803
5 General
5-1 Acceptance of the material 5 9803 A
5-2 Installation 5 9803 A
6 Description - technical characteristics
6-1 Types of hoists 6.1 9807
6-2 Main sub-assemblies 6.1 9807
6-3 Hoist dimensions and weight 6.2 9807
6-4 Environmental data 6.2 9807
6-5 Operation of the hoist 6.2 9807
7 Brake/limiter assembly
7-1 Operation 7 9803 C
7-2 Adjustment of the limiter 7 9803 C
7-3 Adjustment of the brake 7 9803 C
8 Lifting assembly
8-1 Slack fall stop (in the chain bucket) 8.1 9807
8-2 Chain "certificate" 8.1 9807
8-3 Removal of the chain 8.2 9807
8-4 Replacement of the chain (1- fall & 2 - fall chain) 8.2 9807
8-5 Hook "certificate" 8.3 9807
8-6 Suspension hook 8.3 9807
8-7 Measurement of the wear on the hooks 8.3 9807
9 Electricity
9-1 Generals 9.1 9807
9-2 Low voltage control 9.1/2/3/4 9807
9-3 Direct control 9.5 9807
10 Maintenance - replacement
10-1 Maintenance table 10.1 9803 C
10-2 Lubricants 10.1 9803 C
10-3 Spare parts replacement table 10.2 9803 C
10-4 Screw tightening torques 10.2 9803 C
10-5 Discarding the hoist 10.2 9803 C
11 Troubleshooting 11 9803
12 Illustrated catalogue
12-1 Casings 12.1 9807
12-2 Mechanism/Brake 12.2 9803 C
12-3 Lifting assembly 12.3 9807
12-4 Electric box 12.4 9803 C
12-5 Upper and Lower Limit Switch (OPTIONAL) 12.5 9803 C

1 - EC Declaration of conformity
As defined by the EC directive relating
to machinery 98/37/EEC.
Annex II A
Vernouillet - France Herewith, we declare that the product:
z
Wire rope hoist
Belt hoist
Electric chain hoist Manual chain hoist Electric trolley
Manual winch
Complies with the following provisions applying to it:
zzzzzz - Machinery directive 98/37/EEC.
zzz z - Directive 73/23/CEE.
zzz z - "EMC" Directive 89/336/EEC
Applied harmonized standards, in particular:
zzz z - EN 60204-1,
zzz z - EN 292, parts 1 and 2 (safety of the machines).
National regulations, standards and specifications:
zzzzzz - order of June 9, 1993 / circular of September 22, 1993.
zzzzzz - decree no. 92-765, 92-766, 92-767, of July 29, 1992.
zzz - DIN 15400; DIN 15401,
Quality system applied:
zzzzzz - EN29001/ISO9001
Technical standards and specifications complied with, in particular:
zzzzz - FEM 9.511 "classification of the mechanisms".
z- FEM 9.661 "dimensions and quality of the drive and cable lifting block
elements for mass-produced lifting devices".
zz - EN 818 "chain quality, choice criteria and technical requirements".
zzz z - FEM 9.683 "choice of motors".
z- FEM 9.755 "steps to be taken to determine the operating periods for mass-
produced motorized lifting mechanisms (S.W.P.)".
zzz - FEM 9.751 "Motorized lifting mechanism: safety"
zzz - FEM 9.901 "bases of design for the mass-produced lifting devices
for travelling cranes equipped with mass-produced lifting devices".
Bernard DELEFOSSE

0002 / 2
2 - What not to do
Never move or lift the hoist by the electric cables.
Do not set down the hoist without having an adapted support, to avoid
damaging the components on the underside (electric cable, lifting chain,
fixed point, PG cable gland, chain bucket...).
Never modify the hoist unless the manufacturer has studied and
authorized the modification.
Never modify the values and adjustments of the safety components,
outside the limits provided for in the manual, or without the approval of the
manufacturer.
Never try to repair or intervene on the hoist (welding...) without the
authorization of the manufacturer or a trained maintenance agent.
Do not let an unqualified person use the hoist.
Do not allow unqualified
person use the hoist.
Never lift more than the maximum working load indicated on the hoist. Shocks or accidental collision of the load with objects
can cause excess loads.
Never remove the hook safety catches.
Never block, adjust or remove the limit switches or stops to go higher or lower moving distances.
Never swing the load intentionally.
Never use the hoist to extract, loosen, or pull sideways.
Never use the hoist to transport people.
Do not touch the moving components.
Do not operate the hoist if your physical condition does not allow it.
Never use the hoist when in bad repair (wear, deformation...).
Never use suspect spare parts or parts whose origin is not known.
Never swing the load intentionally.
Do not subject the hoist to loading shocks.
Do not use the mechanical stops as a repetitive means of stopping.
Never use the lifting chain as a sling.
Never sling onto the hook jaw (as there is a risk of damage to the hook
and of the load falling).
Never use a hook other than in the vertical position.
Never twist the load chains (turning the hook block around...).
Never distract the operator while the hoist is being operated.
Never leave a suspended load hanging.
Never use the hoist as grounding for welding.
Do not use the hoist for a purpose or in an area for which it is not intended.
Do not expose the hoist to an inappropriate atmosphere (temperature,
acidity... Refer to 6.7: Environmental data).
Never side pull the load.
Do not use the safety components as operation components.
Do not use the controls needlessly (avoid inching - stop-start operation of the buttons). This can cause overheating and even
damage to the hoist.
Never angle pull the load, maximum angle 3 degrees.
Do not use the hoist with a power supply that is different to the one recommended (undervoltage or overvoltage, absence of
phase...).
Never transport a load with people nearby. Do not move the hook, with or without a load, over personnel.

0002 / 3
3 - What to do
Handle the hoist by its structure, or by the devices provided for this
purpose, or in its original packing.
Store the hoist in its normal operating position (without load) away from
aggressive atmospheres (dust, humidity...).
Make sure that the hoist is always clean and protected from corrosion
(lubrication...).
The hoist should be installed by a competent.
Make sure that the hoist attaching structure is rigid.
Make sure that the safety rules are followed (harness, clearance of work
areas, posting up of instructions to be followed in the area...).
The hoist should be maintained regularly, following the instructions in this
manual. Make sure that the hoist is always clean.
Keep the moving components clean and oiled as indicated in this manual.
The components should only be replaced by original parts that are compatible with the type of hoist.
Make sure that the limit stops are in place.
Always be ready during operation to press the emergency stop button. This makes all functions inactive.
Before operation, check that the load is correctly fastened and installed on the hook. The hook safety catches should be closed
correctly.
Make sure that the load is correctly balanced before moving it. Avoid lifting using only one point of the load. Use adequate
accessories (slings, lifting beam...). Pay attention to the center of gravity of the load to be moved.
The elements used to hang the load should be free in relation to the load to be moved (prefer a sling to a rigid beam).
When moving the load, make sure that it is sufficiently raised and clear surrounding machines and other objects.
Make sure that the hoist is vertical to the load before hoisting.
If manually moving the hoist, push the load.
Use plastic stops, or better still, electric limit switches, to avoid repetitive stops on the stops.
If manually moving the hoist, push the load. Material used outdoors should be protected as well
as possible against bad weather conditions.
The prevention instructions to be carried out during the different operations should be well known.
Avoid rocking the load or the hook when using the traveling trolley or crane, by limiting the starting and braking jerks.
In the case of several speeds, do the starting and braking operations at low speed.
Use the material under normal working conditions (ambient temperature, atmosphere...).
Material used outdoors should be protected as well as possible against bad weather conditions.
The use of several machines to move a single load should be done by an experienced supervisor. All the necessary
precautions should be taken to carefully ensure the distribution of the loads and to avoid overloading a single machine. The
machines should be carefully checked before such an operation.
Notify the necessary people after a dangerous operation or if the hoist seems problematic (abnormal noise, abnormal
behavior...).
Material used outdoors should be protected as well as possible against bad weather conditions. Hoist should be covered to avoid
water going inside the chain bucket. A hole must be made to the chain bucket’s bottom to let water to drain out.

0002 / 4
4 - Guarantee
Our electric chain hoists are guaranteed for two years from
the date of delivery.
If for a reason outside the control of the vendor, the delivery
is delayed, the delay cannot exceed three months.
If the use (installation) of the hoist is delayed, the
corresponding extension of the guarantee (a single
extension limited to three months) must be requested, and
written confirmation obtained.
The vendor undertakes to eliminate all operating errors
originating from the concept, the execution, the components
or the materials themselves.
The guarantee does not cover normal wear*, nor the
failures resulting from lack of regular and periodic
maintenance. It does not cover damage due to a lack of
supervision, to false operation or to a bad utilization of
the hoists, particularly due to overload conditions,
slantwise drawing, undervoltage or overvoltage or a
connection error.
The guarantee does not apply when there is disassembly,
modification or replacement of parts (mechanical or
electrical) by an unauthorized party or prior agreement with
manufacturer.
The guarantee only applies for original, factory-installed
spare parts, including the chain.
For the duration of the guarantee, the vendor undertakes to
replace or repair, free of charge, the parts that are
acknowledged to be damaged following examination by a
qualified and authorized technical service.
The guarantee excludes any other services or indemnities.
The repairs covered by the guarantee are carried out, as a
rule, in the workshops of the vendor or authorized agent.
When servicing of the equipment is done outside these
workshops, the labor costs for disassembly or assembly of
these parts are borne by the vendor when these are done
exclusively by his staff or by an authorized agent. The
replaced parts become the property of the vendor and must
be returned to the vendor at his expense.
For components of a relative particular importance that are
not manufactured by the vendor and which carry the brand
name of specialized manufacturers, the manufacturer’s
guarantee (which can vary according to the manufacturer) is
applicable.
*The guarantee does not apply for expendable parts
defined by the manufacturer :
- Lifting chain
- Chain guide
- Rubber buffer
- Sprockets
- Chain bucket
- Hooks
- Friction and brake discs
- Control box cable

9803 / 5 A
5 - General
5-1 Acceptance of the material
Visually inspect the packaging to ensure that it is intact.
If not, notify it as required.
Check that the hoist corresponds to your order.
For transport reasons the chain bucket is delivered disassembled.
5-2 Installation
The service life of the hoist depends on the way it is installed.
The instructions in this manual must be followed carefully for the installation, use and maintenance of the hoist.
Any use contrary to our instructions can be dangerous. In this case, the manufacturer will not accept any
responsibility.
Do not use the hoist until this manual has been fully read and assimilated.
Always keep this manual near the hoist, available to the operator and the person in charge of maintenance.
Make sure that the safety rules are followed (harness, clearance of work areas, posting up of instructions to be followed in
the area...).
Carry out:
•The electrical connection (refer to 9-4: Electrical connection).
•Fitting of the chain bucket (refer to 8.1: Chain bucket).
•Check that the suspension hook is correctly positioned, depending on whether for 1 or 2 falls.
•Check that the tightening torques of the hook blocks, locking plates and chain guide conform to the torques indicated in this
manual (refer to 10.5: Screw tightening torques).
•Check that the chain is not twisted.
•Check that the slack fall stop is correctly attached in the chain bucket and that the fixed point and the 2-fall chain are
correctly held.
•Check that the rubber buffer is correctly fitted.
•Measure the dimension of the opening of the suspension hooks and the hook block. Note it for a follow-up.
Once these checks have been completed, proceed as follows (be ready to press the emergency stop button at all
times).
•Oil and start to run in the chain by a few movements without load.
•Check, when not under load, that the movement of the hook corresponds to the
direction of the arrows on the control box. If not, invert 2 supply phases.
•Check the operation of the limiter: operate the hoist, without a load, until it
reaches the upper and lower hook positions and let the limiter slip for a
maximum of 3 seconds. The chain should not move and the motor should
continue to run.
•Check the operation of the brake: lift up a nominal load and then
lower it.
•Check the operation and the adjustment of the limit switch.
Carry out dynamic tests with +10% of the nominal load and static tests
with +50% of the nominal load on your installation equipped with our
hoist.
IMPORTANT !
The slack fall stop is a safety componet , not a functional one.
A correct lenght of chain is required to avoid using it .

9807 / 6.1
6 - Description - technical characteristics
6-1 Types of hoist
Type Load Load Speed Speed Power Brins Chain
kg (T) m / min. ft / mn mot. / kW falls d/t
SM10 1004 m1 1000 1 4 16 0.9 1 6,8 / 17,8
SM10 1008 m1 1000 1 8 32 1,75 1 ,,
SM10 2002 m1 2000 2 2 8 0,9 2 ,,
SM10 2004 m1 2000 2 4 16 1,75 2 ,,
6-2 Main sub-assemblies
1- Main casing 5- Chain guide
2- Gears 6- 1-fall hook block/hook
3- Brake/limiter/housing 7- 2-fall hook block/hook
assembly 8- Chain bucket
4- Chain sprocket with 9- Electric box
output shaft 10- Handles
Identification plate
The hoist which you have just purchased should only be used with a maximum load equal
to the nominal load (refer to the table above).
The length of its useful service life depends on the demands placed on it, the average
operating time, the number of start-ups and its maintenance.

9807 / 6.2
6-3 Hoist dimensions and weight
6-4 Environmental data
Ambient temperature: -20°C to +40°C
Protection class: IP55 as standard
Side pulling angle: 3 degrees maximum
Impact on the environment:
Sound level: 70 decibels
6-5 Operation of the hoist
Kinematic chain
1. Motor
2. Chain sprocket
3. Gear
4. Brake/limiter
Technical advantage
The position of the limiter allows, should it slip, the load to be held in all cases by releasing the control box button.

9803 / 7 A
7- Brake/limiter assembly
7-1 Operation
The parts of the limiter are mounted on the gear input shaft
(1). Other brake parts are mounted on the brake cap.
The spring (2) keeps a pressure between the limiter lining
(3) and the brake disc (4).
The nut (5) maintains the assembly on the gear input
shaft.
When the coil (6) is energized, during lifting or lowering, it
is pulled against the anchor disk (7) releasing the brake
disk (4) (there is a play X’for this purpose).
The disks (3 and 4) turn freely, transmitting the movement
to the pinion (8).
Braking occurs when the coil is no longer energized and
the springs (9) drive back the coil and its lining against the
brake disk (4).
7-2 Adjustment of the limiter:
1. Hook a load of 1.4 times the nominal load onto the
hoist.
2. Remove the brake endcap and the sealing.
3. Raise the load at slow and fast speed.
4. Use a key to turn the adjusting nut (5) in the required
direction.
•Turn the nut clockwise to increase the torque.
•Turn the nut counterclockwise to decrease the
torque.
5. Repeat steps 3 and 4 until the load can barely be
lifted at fast speed. The limiter is now adjusted.
6. Fit the sealing and the brake endcap.
7. Check, at fast speed, the lifting of a nominal load.
Note: That when the limiter is adjusted the brake end cap
must be removed and the motor must be running.
Do no touch the moving components. Before
pressing the "lift" button on the control box, check
that there is nothing in contact with the adjusting
nut (key, for example).
7-3 Adjustment of the brake
1. Before starting the adjustment, remove the load and switch off the power supply.
2. Remove the brake endcap and the sealing.
3. Use feeler gauge to measure the air gap (X’) between the anchor disk (7) and the electromagnet at at least three points
around the electromagnet.
4. To ajust the brake :
•Unscrew one of the locking screw (10).
•Adjust the air gap by turning the adjusting screw (11) counterclockwise to reduce the airgap, clockwise to increase it.
•Thigten the locking screw (10).
•Make the same operation with the 2 other adjustment points.
•Control the air gap adjustment all around the magnet.
5. Check the operation of the brake
6. Fit the sealing and the brake endcap
Brake air gap Minimum air gap (mm) Maximum air gap (mm)
Between anchor disk (7) and coil (6) X’ = 0.2 X’ = 0.5
Note: To replace the brake/limiter assembly, the electromagnet supply wires inside the electric box must first of all be
disconnected.

9807/ 8.1
8 - Lifting assembly
CAUTION !
Only a genuine, manufacturer's chain may be used.
Never use the lifting chain as a sling.
Never twist the lifting chain.
Do not bundle the chain into the chain bucket.
Always keep the chain clean and oiled and check that it is in good condition every day.
8-1 Slack fall stop (in the chain bucket)
CAUTION !
The slack fall stop is a safety component, not a functional one.
A correct length of chain is required to avoid using it.
REMOVAL:
1. Remove the pin.
2. Remove the tube from the stop.
3. Remove the two halves of the stop.
REPLACEMENT:
1. Check that there is at least 150 mm of
chain under the slack fall stop.
Position the two halves of the stop
around the chain.
2. Insert the tube around the stop.
3. Insert the pin.
Note: Make sure that the stop is correctly fitted. The locking tube should be turned towards the hoist.
8-2 Chain « certificate »
Chain type: standard
Diameter (d) / pitch (t): 6.8 mm /17.8 mm
Class: DAT
Grade: H8S or HE G80 RAS
Maximum working stress: 135.1 N/mm2
Hardened surface: 580 or 700 HV
Thickness: 0.14 to 0.28 mm
Standard: DIN 5684 - 8
Marking ( 6 x t): ❒1 or ❒16
H 8 S or A 8
Maximum working load, 1 fall: 1000 kg
Breaking load: 58,1 kN
Maximum breaking stress: 800 N/mm2
Total breaking elongation: >10% min.
Weight for 1 m : 1.08 kg
Measuring the wear on the chain
This should be done by measuring the dimensions, at several points of the chain, of one link (d) and (t),
and over 11 links (11 t).
Maximum wear allowed:
Minimum link thickness allowed (d): 6,1 mm
Maximum pitch allowed (t): 18,7 mm
Maximum length allowed (11 t): 199,7 mm
If these limits are exceeded, the chain must be replaced
immediately. In this case, the wear on the guide chain
and chain sprocket should also be checked and they
should be replaced if necessary. If a single link is defective
in any way whatsoever, the chain must be replaced.

9807/ 8.2
8-3 Removal of the chain
1-fall chain:
1. Remove the load from the hook.
2. Disassemble the hook block.
3. Lower the chain into the chain bucket.
4. Remove the chain bucket and unscrew and remove the
lower chain guide.
2-fall chain:
1. Raise the hook block to about 30 cm from the hoist
body.
2. Remove the chain bucket.
3. Carefully remove the lower chain guide.
4. Disassemble the fixed point of the chain.
5. Remove the 2-fall hook block, without disassembling it,
letting the chain run through it.
6. Let the rest of the chain slide through the chain
sprocket.
8-4 Replacement of the
chain
The chain should always be fitted
using the flexible plastic insertion
tool (1). Use of this tool always
ensures that the chain is fitted
correctly.
1-fall chain:
1. Insert the last link in the small plastic hook of the
insertion tool.
2. Insert the other side of the tool in the sprocket, chain
bucket side.
3. Raise the chain at slow speed so that the tool and the
chain come out the other side of the sprocket.
Note: the welds (1) of the vertical chain links should be
towards the chain sprocket.
2-fall chain:
1. Insert the last link in the small plastic hook of the
insertion tool.
2. Insert the other side of the tool in the sprocket, chain
bucket side.
3. Raise the chain at slow speed so that the tool and the
chain come out the other side of the sprocket. Continue
until about 50 cm of chain are visible.
4. Put the chain through the idler sprocket, taking care
not to twist the chain
5. Carefully remove the chain anchor (5) removing the 4
screws. Take out the pin (6).
6. Insert the end of the chain into the hole of the chain
anchor.
7. Insert the pin (6) into the hole of the chain anchor.
8. Insert the chain anchor and tighten the 4 screws (torque
20 Nm).
Note: the welds (1) of the vertical chain links should be
to the side away from the idler sprocket.

9807/ 8.4
8-5 Hook « certificate »
Load FEM Test Number Minimum Marking Dimensions
capacity group load of falls ruin load Class (mm)
(kg) (kg) (kg) Ø M Ø a1 a2 a3 b1 b2 e1 h1 h2 t1 t2
630 2 m 1260 1 3970 025 T 16 36 26 41 22 19 96 28 24 38 13
1000 1 Bm 2000 1 5000 025 T 16 36 26 41 22 19 96 28 24 38 13
1250 2 m 2500 2 7875 05 T 20 43 34 49 29 24 105 37 31 43 14
2000 1 Bm 4000 2 10000 05 T 20 43 34 49 29 24 105 37 31 43 14
Mark: ISO 2766 DIN 15400 class: T
DIN model number: 15401 DIN 15401 material: 35 CD 4
8-6 Suspension hook
REMOVAL:
1. Remove the screw and the locking plate.
2. Remove the two pins.
3. Take the hook out.
REPLACEMENT:
1. Put the hook into its housing.
2. Place the two pins inside the hook
3. Fit the screw and the locking plate without
forgeting the safety washer.
(Refer to paragraph 10-4 for the tightening torque).
Note: The hook should be set depending on 1/1
and 2/1 revings.
8-7 Measurement of the wear on the suspension and lifting hooks
The wear on the suspension and lifting hooks (dimension a2 and 32.5- see drawing at top of page) should be checked
regularly.
Damaged safety catches should be replaced immediately.
If the maximum dimension (a2) on the lifting hook is greater than the initial dimension by more than 15%, the hook should be
replaced immediately.
•Bottom hook
Class: 025 05
a2, max. allowed: 30 mm 39 mm
•top hook
maximum allowed for the throat opening ( dimention )32.5mm ): 37mm
If it found to be worn please contact an authorised agent.

9807 / 9.1
9 - Electricity
CAUTION!
Before any operation on the electric box, check that the hoist supply is disconnected.
An isolator switch should be installed at a maximum of 6 meters from the hoist.
9-1 GENERALS
•The customer must supply the power supply cable, the fuses and the main isolator switch (refer to the wiring diagram).
•Check that the mains system is correct for the hoist.
•Check that the voltage does not vary by more than + 5% from the nominal value.
•Neutralize the electric sources.
•Make sure that the main hoist electric power switch is off.
•Do not use binding posts (luster terminals, etc.) to connect the power supply cable to the hoist.
•Do not use rigid cable or cable with a section different to that indicated below to supply the hoist.
•Never shunt the isolators, the power switches or the limitation or prevention equipment.
•Never block, adjust or remove the limit stops or switches to go higher or lower than these allow.
PS: Power supply
PB: Control box connection
Minimum cable sections:
Power supply: 1.50 mm2
Auxiliary current: 0.75 mm2
Control box/hoist: 1.00 mm2
Fuses for control voltage T 1,25 A
Fuses for power supply
- 230 V 10 A
- 400 V 10 A
9-2 LOW VOLTAGE CONTROL
9-2.1 ELECTRICAL CONNECTION
Connection:
1. Remove the control box cover.
2. Insert the cable (PS) into the box through the PG cable gland.
3. Connect phases L1 - L2 - L3, and the ground wire to the terminal board X1(see 9.2).
4. Check that the terminals are correctly tightened.
5. Close the box.
6. Check the hoist operation.
CAUTION!
The supply cable must be equiped with a power switch or an isolator in conformity with the regulation.
The supply cable and main isolator switch must be supplied by the costummer.

9807 / 9.2
9-2.2 Printed circuit board (2 lifting speeds with emergency stop)
HOIST SUPPLY
L1 hoist supply
L2 hoist supply
L3 hoist supply
K21-2 _brake
K21-4 + brake
K10-1 1U-2U motor supply
K25-R3 1V motor supply
K25-3 2V motor supply
K25-R1 1W motor supply
K25-1 2W motor supply
GROUND WIRES
ground terminal, 4 connections
PE motor
PE p.c. board
PE trolley connection
PE power supply
TROLLEY CONNECTION (X24)
K10-1 L21 electric trolley supply
K10-3 L22 electric trolley supply
CONTROL BOX PLUG (X23)
PRINTED CIRCUIT BOARD
Terminal X1
10 Common
1 Lifting
4 Lowering
6 Right, electric trolley
7 Left, electric trolley
8 Travelling speed selector
9Earth
1-2 thermal protection (replace the shunt)
2-3 top limit switch (replace the shunt)
4-5 bottom limit switch (replace the shunt)
10 Fuse T 1,25 A
K10 Emergency stop contactor
K21 Lifting contactor
K22 Lowering contactor
K25 Speed selector
T100 Control transformer
9 Counter (Option)
K22-22 Counter (Option)
1 Common control box
2 Lifting
3 Lowering
4 Speed selector
5 Emergency stop
6 Right, electric trolley
7 Left, electric trolley
8 Travelling speed selector

9807 / 9.3
9-2.3 Power diagram
DSupplied by customer
A Electric trolley
Y21 Brake
F1-F2-F3 Fuse (customer)
M Motor
Q1 Power switch (customer)
K10 Emergency stop contactor
K21 Lifting contactor
K22 Lowering contactor
K25 Speed selector
T100 Control transformer
X1 Terminal board
X22 Supply connection plug (OPTION)
X24 Trolley connection plug
G41 Rectifier
CAUTION !
The supply cable must be equiped with a power switch or an isolator in conformity with the regulation.
The supply cable and the main isolator switch must be supplied by the customer.

9807 / 9.4
9-2.4 Control diagram (2 lifting speeds with emergency stop)
A Electric trolley
AU Emergency stop
T100 Control transformer
F100 T 1,25 A fuse
K10 Emergency stop control
K21 Lifting control
K22 Lowering control
K25 Speed selector
X1 Hoist terminal
X23 Control box plug
X24 Trolley connection plug
F291 Bimetal thermal cutoff
S221 Top limit switch
S222 Bottom limit switch
P251 Hour counter (OPTION)*
*Note: The counter add only the
times during lifting operation.
Do not use the controls needlessly
(avoid inching - stop-start operation).

9807 / 9.5
9-3 DIRECT CONTROL
ACF board (Option)
The ACF board control electronicaly the brake. It enables a rapid brake acceleration. (As the hoist is not equipped with
contractor control electrics).
ACF 1, 1 lifting speed
POWER SUPPLY :
L1 L2 L3 PE MOTOR CONNECTION : B- BRAKE :
+ –brake
ACF 2, 2 lifting speed
POWER SUPPLY :
1U 1V W 2U 2V PE
MOTOR :
1U 1V low speed
2U 2V high speed
1W 2W common
B- MAIN BRAKE
C- EMMERGENCY BRAKE (OPTION)
+ –brake

9803 / 10.1
10 - Maintenance - Replacement
10-1 Maintenance table
Check Interval Qualification of the
customer’s personnel
Brake operation Daily Operator
Visual inspection of the chain Daily Operator
Suspension of the control box by the steel wire Daily Operator
Cleanness and lubrication of the chain Monthly Operator
Limiter operation Monthly Operator
Measuring of the wear on the chain Every 3 months Operator
Measuring of the wear on the hooks Every 3 months Operator
Tightening of the hook block screws Every 3 months Operator
Checking of the locking plate screws Every 3 months Operator
Lubrication of the idler sprocket Annually Operator
Checking of the screw tightening torques and checking for signs
of corrosion
Annually Qualified mechanic
Adjustment of the limiter and brake Annually Qualified mechanic
Lubrication of the gears Lubricated for life
CAUTION! These intervals should be shortened if the
hoist is used a lot, if it is used with maximum
loads or in difficult ambient conditions.
Oil the chain regularly.
10-2 Lubricants
Lubrication point Specifications Possible brands Quantity
■Chain Oil or liquid grease Chain lubricating fluid (Ceplattyn or
similar)
As required
sIdler sprocket
slide bearing + bearing
Grease (without MoS2)
KP 2 (DIN 51 502)
Soap-based lithium
Approx. drip point + 260°C
Worked penetration 265 - 295°
Operating temperature
- 20°C à + 130°C
Aral : Aralub FK 2
BP : BP Energrease LS - EP 2
Esso : Unirex N2
Mobil : Mobilgrease HP
Shell : Shell Alvanio EP Grease 2
DEA : Paragon EP 2
Fuchs : Renolit Duraplex EP 2
As required
●Gears KP 0 K grease (DIN 51502)
Soap-based lithium + MoS 2
Approx. drip point + 180°C
Worked penetration 355 - 385°
Operating temperature
- 30°C à + 130°C
Tribol: Molub Alloy multi-purpose grease
Aral: Aral P 64037 grease Aralub PMD0
BP: Multi-purpose grease L 21 M
Esso: Multi-purpose grease M
Mobil: Mobilgrease Special
Shell: Shell Retimax AM
Texaco: Molytex grease EP 2
Fuchs: Renolit FLM0
0.2 liter

9803 / 10.2
10-3 Spare parts replacement table
CAUTION! Disconnect the power supply before replacing any parts.
Spare part To be replaced by Qualification of the
personnel
Upper chain guide
Idler sprocket
PG cable gland
Motor input shaft + adjusting nuts
Motor endcap
Gearing (1st/2nd stage)
Brake cap/endcap sealing
Other sealings and O-rings
Brake-limiter
Brake endcap
Lower chain guide
Rubber buffer
Electric box
PC-board
Plugs
Chain
Chain bucket
Slack fall stop
Suspension hook
Hook block (1/1; 2/1)
Control box
Authorized manufacturer personnel
Authorized manufacturer personnel
Authorized manufacturer personnel
Authorized manufacturer personnel
Authorized manufacturer personnel
Authorized manufacturer personnel
Customer
Authorized manufacturer personnel
Authorized manufacturer personnel
Customer
Customer
Customer
Authorized manufacturer personnel
Authorized manufacturer personnel
Customer
Customer
Customer
Customer
Customer
Customer
Customer
Qualified mechanic
Qualified mechanic
Qualified electrician
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified electrician
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified electrician
Qualified electrician
Qualified electrician
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified electrician
Once a part has been replaced, check the operation of the hoist (refer to 5.2: Installation).
10-4 Screw tightening torques (Nm)
M5 M6 M8 M10 M12 Plastic*
Standard screws 6 10 24 48 83 1
Self-tapping screws 5 8 20 40 72 1
(*) Screws for fixing plastic parts
10-5 Discarding the hoist
Once the hoist has been used for the FEM class duration, all of the components must be checked by an authorized agent or
by the manufacturer. The hoist should no longer be used, unless agreement is obtained from the authorized agent or the
manufacturer.
Remove all greases and oils from the hoist before discarding it.