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Stagemaker VERLINDE SL10 1004 M2 A D8+ Owner's Manual

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OWNER'S MANUAL
CHAIN HOIST SL10 1004 M2 A D8+
DOC351689A / X234661en-US / A / 18 Apr 2020 / X192723/A
02910816470010 Order 27/03
This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S. Copyright 2020 © Verlinde S.A.S. All
rights reserved.

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  • Page 1 OWNER’S MANUAL CHAIN HOIST SL10 1004 M2 A D8+ DOC351689A / X234661en-US / A / 18 Apr 2020 / X192723/A 02910816470010 Order 27/03 This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S.

  • Page 3: Table Of Contents

    OWNER’S MANUAL TABLE OF CONTENTS INTRODUCTION....................... About these instructions..................1.1.1 Use of the instructions.................. 1.1.2 Copyright notice................... 1.1.3 Definition of terms..................1.1.4 Symbols used in the instructions..............1.1.5 Available technical documents..............About this product....................1.2.1 Use of the product..................1.2.2 Terms of warranty..................
  • Page 4 TABLE OF CONTENTS 3.3.1 Key parts of the chain hoist................31 3.3.2 Chain drive....................31 Controller........................32 3.4.1 Pendant controller..................32 Options........................32 3.5.1 Manual brake release................... 32 3.5.2 Rotating geared limit switch................. INSTALLATION......................37 General instructions for installation............... 37 Safety during installation..................
  • Page 5 OWNER’S MANUAL Load handling......................6.5.1 Load handling methods................59 6.5.2 Slipping clutch operation................70 6.5.3 Hoisting limit switch operation..............70 Shutting down the equipment................. 70 MAINTENANCE......................Safety during maintenance..................Maintenance preparations..................71 7.2.1 Service personnel..................7.2.2 Preservation of protection class..............Maintenance schedule.....................
  • Page 6 TABLE OF CONTENTS This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non- 4/2020 public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S. Copyright 2020 ©...

  • Page 7: Introduction

    OWNER’S MANUAL INTRODUCTION About these instructions These instructions offer guidance to enable safe and efficient operation of the product. Take the time and read these instructions. Knowing the instructions helps you prevent damage to the product, and, most importantly, to the personnel that are situated close to the product. The product is safe when you use it correctly.

  • Page 8: Symbols Used In The Instructions

    1 INTRODUCTION ANSI American National Standards Institute Authorized personnel Persons who the owner authorizes and who have the necessary training to carry out operation or service actions. CE marking The CE marking indicates that the product complies with the appropriate CE regulations. Chain hoist A machine for lifting and lowering the load.

  • Page 9: Available Technical Documents

    OWNER’S MANUAL Symbol Description Indicates that the product slows down or moves at its slowest speed. Indicates that the product accelerates or moves at its highest speed. NOTE Indicates items which require special attention by the reader. There is no obvious risk of injury that is associated with notes. 1.1.5 Available technical documents A set of technical documents is available for this product.

  • Page 10: Terms Of Warranty

    1 INTRODUCTION DANGER GENERAL HAZARD Unauthorized use of the product could lead to death, severe injury, or property damage. The product may only be used for lifting people with the approval of the manufacturer. The manufacturer must declare in writing that the product may be used for lifting people.

  • Page 11: Identification Of The Product

    OWNER’S MANUAL Further, e.g. each of the following invalidates any warranty of seller and relieves seller from any responsibility and liability for accidents, injury or physical or property damage: failure to operate and/or maintain products in accordance with the applicable installation and/or operator's manuals, owner's manuals, maintenance manuals, recommendations, and any other manuals, guidelines or recommendations concerning the maintenance and operation of products that may be communicated from time to time;...

  • Page 12: Standards And Directives

    1 INTRODUCTION Pos. Marking Description Power of traveling motor Power output of the traveling motor Manufacturing date Manufacturing day/month/year Empty space Hoist duty class Hoist duty class according to standards Lifting height Maximum height of the lifting motion Rated input of hoisting motor Rated input of current to the hoisting motor in amperes Rated input of traveling motor Rated input of current to the traveling motor in amperes Fuse...
  • Page 13 OWNER’S MANUAL 2, Boulevard de l'Industrie BP 20059 28509 VERNOUILLET CEDEX FRANCE www.verlinde.fr This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non- 4/2020 public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S.

  • Page 14: Health, Safety And The Environment (Hse)

    2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) HEALTH, SAFETY AND THE ENVIRONMENT (HSE) Safety messages and signals This section includes explanations of the safety symbols, signs, signals, and labels used on the product and in the documentation. 2.1.1 Signal words The following signal words and symbols are used to identify safety messages in these instructions.
  • Page 15 OWNER’S MANUAL Mechanical hazard symbols Foot crushing hazard Hand crushing hazard Cutting hazard Falling hazard Falling load hazard Slipping hazard Falling objects hazard Crushing hazard Hanging load hazard Electrical hazard symbols Electrical hazard Overhead power line hazard Noise hazard symbols Noise hazard This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non- 4/2020...

  • Page 16: Mandatory Action Symbols

    2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) 2.1.3 Mandatory action symbols Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are indicated by white symbols on a blue background. All personnel working on or in proximity of the equipment must understand and follow the information that is given in the mandatory action symbols.

  • Page 17: Responsibilities Of The Owner

    OWNER’S MANUAL Plus Figure 2. Classification stickers D8 and D8 Plus Safety label Description A chain hoist with the D8 classification can be used to lift loads during set-up. D8 Plus A chain hoist with the D8 Plus classification can be used to lift loads during set-up, and hold loads in resting position above people.
  • Page 18 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) • Hard hat • Eye-protector • Hearing protectors • Safety shoes • Respirator • Safety gloves • Protective clothing • Safety harness when working at heights • High-visibility clothing Do not wear loose clothing or jewelry that can get caught on controls or pulled into moving parts of the product.

  • Page 19: Incident Reporting

    OWNER’S MANUAL • Inspection and proper maintenance of fall protection equipment • Measures to prevent falling objects • Rescue plans If necessary, contact your supplier or service organization for assistance with designing your fall protection program. 2.2.3 Incident reporting Product safety issues that you must report are events in which the manufacturer's product has been involved in an accident or near-miss incident.

  • Page 20: Changes To The Product

    2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) WARNING! MACHINE MALFUNCTION HAZARD Using the product outside the limits of its duty class or operating conditions could cause malfunction of the product and lead to death, severe injury, or property damage. Only use the product within the limits of its duty class or operating conditions. Prohibited use of the product includes, but is not limited to the following: •...

  • Page 21: Safety Devices

    OWNER’S MANUAL Safety devices WARNING! MACHINE MALFUNCTION HAZARD Removing or modifying the safety devices could cause malfunction of the safety devices, which could lead to death, severe injury, or property damage. Do not remove or modify any safety devices on the equipment without written approval from the manufacturer.

  • Page 22: Main Isolation Switch

    2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) There are two main types of emergency stop buttons: • Emergency stop button with a twist-release mechanism which latches in the activated position • Emergency stop button with a push-pull mechanism which remains pushed in To reset the latching type of an emergency stop button, twist the button in the direction of an arrow in the mushroom head.

  • Page 23: Lockout-Tagout-Tryout Procedure

    OWNER’S MANUAL 2.5.3 Lockout-tagout-tryout procedure Before installation, inspection, and maintenance, the power sources must be de-energized, isolated, locked out, and tagged out. Lockout-tagout-tryout procedures are primarily intended to protect the personnel. The procedures prevent accidental starting of the machinery or exposure to electric shocks.

  • Page 24: Fire Safety

    2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) 2.5.4 Fire safety WARNING FIRE AND EXPLOSION HAZARD Ignition sources, such as smoking, open flames, welding work, and sparks, together with combustible materials, such as fuel, can cause fire and, if not avoided, could lead to death or severe injury.

  • Page 25: Personnel Requirements

    OWNER’S MANUAL When the distance between the operating location and the hoist and associated moving components is more than 5 m (16 ft), the average combined sound pressure level due to the hoist and its associated components does normally not exceed 65 dB(A) at the operating location.

  • Page 26: Handling Waste Material

    2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) Figure 5. Product life cycle stages 2.8.2 Handling waste material Handle and dispose of the waste material from installation, maintenance, or dismantling according to local regulations. From the sustainability point of view, the preferred waste handling methods are reuse, recycle as material, energy recovery and, as a final resort, safe disposal.
  • Page 27 OWNER’S MANUAL Material Waste handling method Packing materials Reuse or recycle packing materials, such as plastics, wood, and cardboard. Rubber Recycle rubber according to local regulations. Whenever possible, return the used rubber tires to the tire supplier for recycling. This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non- 4/2020 public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S.

  • Page 28: Product Description

    3 PRODUCT DESCRIPTION PRODUCT DESCRIPTION Technical data 3.1.1 Hoist duty class When the product is designed and purchased, the predicted lifetime of the product is agreed, based on the expected use of the product. This expected use is known as the duty class. A hoisting machinery which is used continuously and to lift heavy loads is clearly in a different duty class than a hoisting machinery of the same size which is used occasionally and to lift light loads.

  • Page 29: Functional Description

    OWNER’S MANUAL Functional description 3.2.1 Functional principle of the electrical chain hoist Figure 6. Main components of the lifting function 1. Electrical panel 1 (configuration A) 5. Hoisting motor 2. Hoisting gear 6. Slipping clutch 3. Chain sprocket 7. Brake (single brake in the example) 4.

  • Page 30: Kinematic Chain For Electrical Chain Hoist

    3 PRODUCT DESCRIPTION 3.2.2 Kinematic chain for electrical chain hoist 1. Adjustment screw 5. Slipping clutch 2. Hoisting gear 6. Brake 3. Chain sprocket 7. Motor torque 4. Motor 8. Brake torque Motor torque path The motor (4) rotates the axle, which makes the hoisting gear (2) helical steps turn. The gear reducer transfers the motor power over the chain sprocket (3) to the chain, which then moves according to the selected direction (up or down).

  • Page 31: Chain Hoist

    OWNER’S MANUAL Chain hoist 3.3.1 Key parts of the chain hoist Figure 7. Main components of the electrical chain hoist 1. Hoisting machinery 6. Chain bag 2. Buffer 7. Chain guide 3. Handle 8. Suspension (rotating suspension hook or bracket suspension) 4.

  • Page 32: Controller

    3 PRODUCT DESCRIPTION Controller The layout of the direction controls may vary from product to product. The function of each direction control is indicated by a symbol. It is important that the operator knows the meaning of each symbol to be able to operate the product safely. WARNING UNINTENDED MOVEMENT HAZARD Pressing an incorrect control button on the controller can lead to unintended...

  • Page 33: Rotating Geared Limit Switch

    OWNER’S MANUAL 1. Place the manual brake release lever (1) on the brake (2). Insert one arm of the lever into the brake gap (3) on the left side of the upper screw (4). 2. Turn the manual brake release lever so that its second arm fits into the brake gap on the opposite side of the brake.
  • Page 34 3 PRODUCT DESCRIPTION Figure 8. 4-step rotating geared limit switch 1. Coupling 3. Rotating geared limit switch 2. Fixing plate Rotating geared limit switch types Figure 9. 2-step rotating geared limit switch The 2-step rotating geared limit switch works together with the internal controls as an adjustable upper and lower stop limit.
  • Page 35 OWNER’S MANUAL Figure 10. 4-step rotating geared limit switch The 4-step rotating geared limit switch has a similar operating function as the 2-step geared limit switch, but provides four separately adjustable switching units. There are several configuration possibilities for this feature, but the configuration 1 (see table 4-step geared limit switch) is the standard configuration.
  • Page 36 3 PRODUCT DESCRIPTION Config. GLS type Description Switch unit Limit switch safety UP stop Switch X3A Limit switch safety DOWN stop Switch X4A 4-step GLS + Limit switch working UP stop GLS UP 1 microswitch or magnetic limit Limit switch working DOWN stop GLS DOWN 1 switch Slow speed UP...

  • Page 37: Installation

    OWNER’S MANUAL INSTALLATION General instructions for installation Safety during installation Ensure that the installation personnel are professionally competent, qualified, and are provided with adequate instructions for carrying out the work. Ensure that the test loading, test drive, and commissioning have been executed properly. Check that the handover log has been completed properly.

  • Page 38: Installation Preparations

    4 INSTALLATION Installation preparations 4.3.1 Transport, packing, scope of delivery The product is packed in a box for transportation. Before starting to install the hoist, visually check that the package in which the product has been delivered to you is intact. Also check that the content of the delivery matches with your order.

  • Page 39: Fitting The Chain Bucket

    OWNER’S MANUAL Always follow the instructions that are provided by the lifting device manufacturer and NOTE the local authorities. The manufacturer of the hoist is not responsible for lifting accessories that are provided by other manufacturers. WARNING! FALLING LOAD HAZARD Overloading can damage the auxiliary lifting devices.

  • Page 40: Removing And Installing The Hoist Covers

    4 INSTALLATION Removing and installing the hoist covers 1. Make sure that you have disconnected the chain hoist from the main power supply network. 2. To access the components on the brake side, loosen the four screws of the end cover on the brake side.

  • Page 41: Installation Steps

    OWNER’S MANUAL 4. To install the end covers, put the end cover back on its place on the hoist frame. Tighten the fours screws to the correct tightening torque. For more information, see chapter Tightening torques for the chain hoist. Installation steps Unpack the product.

  • Page 42: Supporting Structure

    4 INSTALLATION WARNING FALLING HAZARD The chain hoist may fall, which could lead to serious injury, death, or damage to the product. If the suspension type of the chain hoist is a suspension bracket, do not move the chain hoist or leave it unattended when the suspension bracket is open. 4.7.1 Supporting structure According to DIN EN 14492-2, the force limitation factor is ϕDAL = 1,6 for chain hoists with a...

  • Page 43: Electrical Connections

    OWNER’S MANUAL Electrical connections 4.8.1 Cable gland positions on the hoist Figure 12. Cable gland positions of the chain hoist configuration A 1. Power supply This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non- 4/2020 public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S.

  • Page 44: Connecting The Hoist To Power Supply

    4 INSTALLATION Figure 13. Cable gland positions of the chain hoist configuration B 1. Power supply 2. Control cable 4.8.2 Connecting the hoist to power supply If the chain hoist is ordered without plugs, these instructions show you how to connect the chain hoist to the power supply.
  • Page 45 OWNER’S MANUAL 1. Remove the plug of the power supply cable from the power supply socket. Open the cable gland. Remove the temporary power supply cable by pulling it out through the cable entry and the cable gland. 2. Place the main power supply cable through the cable gland and the cable entry.

  • Page 46: Adjusting The Rotating Geared Limit Switch

    4 INSTALLATION 5. Check that the phase sequence is correct. To check the phase sequence, check that all motions (upward and downward movement of the hoist) occur to the correct direction. Check that desired functions are activated when you press the controller buttons UP and DOWN. Check also that the traveling motion directions correspond to the controller directions.
  • Page 47 OWNER’S MANUAL UP 1 DOWN 1 UP 2 DOWN 2 53566220 1. Upper (UP) limit 1 4. Lower (DOWN) limit 2 2. Lower (DOWN) limit 1 5. Identification number 3. Upper (UP) limit 2 Figure 14. 2-step rotating geared limit switch The set screw 1 is the upper limit and the set screw 2 is the lower limit.

  • Page 48: Adjusting The Lower Hook Position

    4 INSTALLATION 4.10 Adjusting the lower hook position When you determine the hook path or lifting height, ensure that the lower hook touches the ground in the lower hook position. Secure the limit stop to the fifth chain link at the unloaded end of the chain.

  • Page 49: Commissioning

    OWNER’S MANUAL COMMISSIONING Safety during commissioning • Use personal protective equipment. • Use fall protection measures. • Use voltage rated tools VDE EN 60900. • Use lock and tag out signs to prevent unauthorized use of the equipment. • Ensure, so far as is reasonably practicable, that the health and safety of people near and around the workplace is not put at risk.

  • Page 50: Before Lifting

    5 COMMISSIONING • Check the bolted and mechanical connections. • Check the connection with the hoist frame and the suspension part. • Check the connection with the suspension part and the trolley, if applicable. • Torque the bolts with a proper torque wrench. For more information, see chapter Tightening torques for the chain hoist.

  • Page 51: Testing The Hoist Without Load

    OWNER’S MANUAL 5.3.3 Testing the hoist without load 1. Check the electrical connections • Turn on the power to the chain hoist. • Check that the rated voltages correspond to the main voltage. • Check that the power supply to the chain hoist is protected with fuses of the correct size. •...

  • Page 52: Testing The Hoist With Test Load

    5 COMMISSIONING • Listen to the operating sounds during lifting or traveling movements. Pay attention to unusual noises such as squealing. • Check that the chain hoist runs smoothly and without any strong vibration. If any defects or abnormalities are detected during the commissioning, they must be NOTE investigated and corrected.

  • Page 53: After Commissioning

    OWNER’S MANUAL • Check that the hoisting brake operates correctly in both upward and downward directions. The braking distance is normal when it is two chain links or less. 4. Check the motor current • Check the motor current at each phase during the lifting and lowering motion with the rated capacity.

  • Page 54: Operation

    6 OPERATION OPERATION Safety during operation WARNING! FALLING LOAD HAZARD Operating the product with people underneath or near the load could cause a falling load hazard. A falling load could cause serious injury or death to the people situated underneath or near the load. When operating the product, make sure that no people are situated underneath or near the load.

  • Page 55: Movements

    OWNER’S MANUAL Movements 6.2.1 Controls for movements The speed corresponds to the position of the direction control. The equipment moves at the slowest speed when the push button is partially pressed and at the maximum speed when the push button is fully pressed. The equipment stops moving when the push button is released. When the push button is released, the equipment stops moving.
  • Page 56 6 OPERATION The motor runs at one of two preset speeds corresponding to the force that the operator applies to the direction control push button. When you press the direction control push button half-way down, the motor runs at its slowest speed. When you press the direction control push button fully down, the motor runs at its maximum speed.

  • Page 57: Checks Before Operating

    OWNER’S MANUAL Push button released: Motor does not run. Push button step 1 pressed: Motor accelerates until it reaches the preset slow speed. Push button step 2 pressed: Motor accelerates towards maximum speed. Push button step 1 pressed: Motor maintains the current speed. Push button step 2 pressed: Motor accelerates until it reaches maximum speed.

  • Page 58: Checking The Operation With The Emergency Stop Button Pressed Down

    6 OPERATION 4. Check the operation of the emergency stop button Check that the emergency stop button can be pressed down and that it stays in that position. NOTE Never operate the product if it is locked or tagged out. 5.

  • Page 59: Starting The Equipment

    OWNER’S MANUAL Listen for unusual noises. 5. Check the mechanical or magnetic limit switch operation Check the upper and lower mechanical or magnetic limit switches. Check the condition of the rubber plate on top of the hook. The rubber plate activates the mechanical or magnetic upper and lower limit switches on the chain hoist.
  • Page 60 6 OPERATION Do not use the overload device of the lifting equipment to determine whether the load can be lifted. Overload devices, such as the slipping clutch, are not accurate enough to determine whether a load can be lifted. A load which does not trigger the overload device may still be heavier than the maximum permitted load.
  • Page 61 OWNER’S MANUAL WARNING! UNSTABLE LOAD HAZARD Trying to balance an unbalanced load with your hands could cause death or serious injury. Never try to balance an unbalanced load with your hands. Lower the load and adjust the lifting point. Shock loading The hoist and accessories are designed to take up the weight of loads gradually and steadily.
  • Page 62 6 OPERATION • If the load is unstable, it can exert a sudden force on the chain. Fasten the contents of the packing cases securely, so that they cannot move around during lifting. • Sudden loss of the load can cause the trolley or hoist to jump. OVERLOAD HAZARD NOTICE Shock loading could damage the product or the load.
  • Page 63 OWNER’S MANUAL Handling the load • To avoid damaging the hook, position the lifting device only on the load bearing surface of the hook. In this way, the lifting device is positioned on the lowest point of the hook. • Ensure that the hook safety latches are closed. Check that the safety latch is not subjected to any force by the load.
  • Page 64 6 OPERATION • Check that the load is balanced and safely fastened at the lifting points. The load must not be able to slide, slip, or detach itself when suspended. • Chain hoist must be positioned directly above (perpendicular to) the load so that there are no side-pulling forces.
  • Page 65 OWNER’S MANUAL • Observe the load always while it is in motion to ensure that it does not collide with anything or fall from the lifting device. • Do not drag loads or pull loads from the side. • Do not twist the load chains. •...
  • Page 66 6 OPERATION Ensure that everything is ready for lifting. Do not move the load before ensuring that it is properly attached to the lifting device. If the hoist has an alarm horn, press the alarm horn push button to warn people nearby that a load is about to be moved.
  • Page 67 OWNER’S MANUAL Continue to press the push button UP until the load is barely clear of the ground. Press the UP push button to lift the load at high speed. Release the UP push button gently when the load is at the desired height. Do not raise the load higher than is necessary to avoid colliding with objects.
  • Page 68 6 OPERATION WARNING! MOVING LOAD HAZARD Operating the product when people are underneath or near the load could cause serious injury or death. When operating the product, make sure that there are no people who are situated underneath or near the load. Keep yourself and bystanders away from the danger zone during lifting.
  • Page 69 OWNER’S MANUAL Press the DOWN push button to lower the load. Decrease the lowering speed by gradually releasing the DOWN push button when the load approaches the ground. Fully release the DOWN push button when there is slack in the lifting device but before the hook or lifting device impacts the load.

  • Page 70: Slipping Clutch Operation

    6 OPERATION 6.5.2 Slipping clutch operation The chain hoist is equipped with a slipping clutch that activates when an overload occurs. The brake activates then automatically, and the power to the motor is turned off. After the slipping clutch is activated, only the lowering motion is possible. Therefore, it is not possible to lift an overload from the ground.

  • Page 71: Maintenance

    OWNER’S MANUAL MAINTENANCE Safety during maintenance WARNING IGNORING INSTRUCTIONS HAZARD Failure to follow the given instructions could cause serious injury or death. Read the general safety instructions at the beginning of these instructions and in this chapter. Special safety information is provided in the component-specific instructions. The safety information that is provided here is of general nature.

  • Page 72: Service Personnel

    7 MAINTENANCE WARNING! MACHINE MALFUNCTION HAZARD Unauthorized changes or modifications to the product could lead to serious injury, death, or damage to the product. Unauthorized changes or modifications could also invalidate the guarantee of the product. The manufacturer takes no responsibility for accidents that are caused by unauthorized modifications to the product.
  • Page 73 OWNER’S MANUAL different DWP. For example, the main hoisting machinery and the auxiliary hoisting machinery can have a different design working period. The DWP is the period in which the equipment can be operated safely, as long as the use and maintenance of the equipment has been in line with the original expectations.
  • Page 74 7 MAINTENANCE Check the following values for this inspection interval: • J = Number of working days during the inspection interval [days] • H = Average lifting height [m] • N = Average number of work cycles per hour [cycles/h] •...
  • Page 75 OWNER’S MANUAL Step 3: Calculate the partial duration of service, S Use T and K in the following formula to calculate S [hours]: = X * K Select the value of X from the following table: Record type Value of X Hour counter and log book With log book No hour counter, log book, or CMS...
  • Page 76 7 MAINTENANCE Check the hoist duty group which can be found on the hoist data plate. In the appropriate column of the following table, find the number closest to S. The two final columns on the same row tell you the remaining DWP% and the estimated remaining service life.

  • Page 77: General Overhaul

    OWNER’S MANUAL When the DWP% reaches zero, a general overhaul (GO) must be conducted. For more information, see chapter General overhaul. 7.3.2 General overhaul In the general overhaul (GO) service, the product is assigned with a new, runtime-based design working period (DWP), provided that it is safe to continue the operation. The runtime-based DWP means the lifetime of the interchangeable rotating components of the hoist, for example, the hoisting gear and the hoisting motor.

  • Page 78: Daily Inspections

    7 MAINTENANCE • Gearbox frame, sealing, bearing, gears, and oil or grease • Hook block, coupling, connection pins • Brake The small parts (such as screws and washers) to be replaced during maintenance and assembly work are not listed separately. The general overhaul carried out by the manufacturer or an authorized specialist company fulfills the condition for continued operation of the chain hoist.

  • Page 79: Quarterly Inspections

    OWNER’S MANUAL General monthly inspections Component Objective Chain Check the overall condition and the lubrication of the chain. Limit switch activator Check the condition of the limit switch activator. Check the function of the upper and lower mechanical limit switches by raising and lowering the hook.

  • Page 80: Log Book

    7 MAINTENANCE Annual inspections of the electrical components Component Objective Main isolation switch Check the condition and operation of the main isolation switch. Wiring Check the condition of the wiring and the connections. Contactors Check the condition and operation of the contactors. Fuses Check the condition of the fuses.

  • Page 81: Maintaining The Hoist

    OWNER’S MANUAL Product reference data - details of the product, its ownership, and persons who are qualified to work with it. Faults noticed in daily inspections, together with corrective actions. Records of service inspections and lubrication. Records of repairs. Records of condition monitoring unit or hour counter. Calculations of design working period and remaining lifetime.

  • Page 82: Checking The Brake Lining

    7 MAINTENANCE Figure 17. Measuring wear on the suspension bracket (option) Table 3. Wear dimensions of the suspension bracket (option) Bracket type Frame size Short [DIM mm] Long [DIM mm] Nominal DIM Min. DIM W Nominal DIM Min. DIM W 21.50 19.00 21.50...

  • Page 83: Replacing The Single Brake

    OWNER’S MANUAL IQ BFK457-06 COMPACT 190V DC Nr: 13319905 2.8NM DD.MM.YY max@ 20°C ; xx.x mm The brake wear value varies according to the brake manufacturer and brake series. For each brake type, the maximum value for the wear is indicated on the brake data NOTE sticker on the brake.
  • Page 84 7 MAINTENANCE For more information, see chapter Removing and installing the hoist covers. 4. Check that the brake data of the replacement brake matches with the data of the original brake. You can find the brake data in the sticker that is attached to the brake.
  • Page 85 OWNER’S MANUAL 7. Remove the brake carefully. 8. Install the new brake on the shaft. Secure the fixation with the three screws. 9. Plug in the brake cable (1). 10. Install the end cover on the brake side. For more information, see chapter Removing and installing the hoist covers. 11.

  • Page 86: Replacing The Single Brake

    7 MAINTENANCE For more information, see chapter Tightening torques for the chain hoist. 12. Turn on the power to the chain hoist. 13. Check that the brake works normally. First test the brake without any load. Then test the brake with a dynamic test load of 110% (EUR) or 125% (US) of the rated capacity.
  • Page 87 OWNER’S MANUAL 7. Pull the brake cable carefully out on the brake side. The brake cable is led through the hoist frame from the brake side to the motor side. Pay attention to how the brake cable is led through the hoist frame. NOTE When you have installed the new brake, you must lead the brake cable again...
  • Page 88 7 MAINTENANCE 10. Remove the brake carefully. 11. Install the new brake on the shaft. Secure the fixation with the three screws. 12. Lead the brake cable through the hoist frame. Pull the brake cable carefully out on the motor side. This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non- 4/2020 public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or...

  • Page 89: Replacing The Double Brake

    OWNER’S MANUAL 13. Plug in the brake cable (1). 14. Push in the control board. 15. Install the end cover on both the motor side and brake side. For more information, see chapter Removing and installing the hoist covers. 16. Tighten the screws of the end covers to the correct tightening torque. For more information, see chapter Tightening torques for the chain hoist.
  • Page 90 7 MAINTENANCE 5. Unplug the brake cables (1) and (2) from the control board. 1. Main brake 2. Secondary brake 6. Remove the three screws that hold the brake in place. 7. Remove the brake carefully. Hold the complete double brake NOTE assembly with your hands so that the parts do not fall apart.
  • Page 91 OWNER’S MANUAL 8. Assemble the new double brake. Pay attention to the orientation of the NOTE brake lining. 9. Install the new brake on the shaft. Secure the fixation with the three screws. Pre-tighten the screws by hand. Tighten the screws with a tool. If the brake has two more screws, remove the screws.

  • Page 92: Replacing The Double Brake

    7 MAINTENANCE First test the brake without any load. Then test the brake with a dynamic test load of 110% (EUR) or 125% (US) of the rated capacity. Size of the dynamic test load depends on the country regulations. In the European countries, test the brake also with a static test load of 125% of the rated capacity.
  • Page 93 OWNER’S MANUAL 7. Pull the brake cables carefully out on the brake side. The brake cables are led through the hoist frame from the brake side to the motor side. Pay attention to how the brake cables are led through the hoist NOTE frame.
  • Page 94 7 MAINTENANCE 10. Remove the brake carefully. Hold the complete double brake NOTE assembly with your hands so that the parts do not fall apart. 11. Assemble the new double brake. Pay attention to the orientation of the NOTE brake lining. 12.
  • Page 95 OWNER’S MANUAL 13. Lead the brake cables through the hoist frame. Pull the brake cables carefully out on the motor side. 14. Plug in the brake cables (1) and (2). 1. Main brake 2. Secondary brake 15. Push in the control board. 16.

  • Page 96: Adjusting The Slipping Clutch

    7 MAINTENANCE 7.4.7 Adjusting the slipping clutch WARNING MOVING MACHINERY HAZARD When you adjust the slipping clutch, the motor must not run. Contact with the moving parts of the motor could lead to serious injury, death, or damage to the product. Always turn off the power to the chain hoist before starting to work with the clutch adjustment tools.
  • Page 97 OWNER’S MANUAL 5. Test the slipping clutch. 5.1 Turn on the power to the chain hoist. 5.2 Attach the original test load to the hook. 5.3 Check that the chain hoist is able to lift the load with both slow and fast speed. 5.4 Attach a maximum load of 160% of the rated capacity of the chain hoist to the hook.

  • Page 98: Replacing The Control Voltage Fuse

    7 MAINTENANCE 7.4.8 Replacing the control voltage fuse Figure 18. Power supply board with control voltage fuse The control voltage fuse (1) is on the chain hoist power supply board, on the brake side of the chain hoist. 1. Disconnect the chain hoist from the main power supply network. 2.

  • Page 99: Inspecting The Chain Wear

    OWNER’S MANUAL 2. Remove the chain bucket (1) from the connection part (2). 7.5.2 Inspecting the chain wear WARNING FALLING LOAD HAZARD Premature wear of the chain can lead to a load drop, which could cause serious injury, death, or damage to the equipment. Special operating conditions or the design of the product may shorten the required maintenance and inspection intervals of the product.
  • Page 100 7 MAINTENANCE 2. Check the bearing surfaces between the chain links for wear. 3. Measure the link thickness. Measure the link thickness dimension (d) at several points of the chain. Calculate the dimension (d Link thickness measurement criteria Chain size d * t 4.1 x 12.1 5.1 x 15.1...
  • Page 101 OWNER’S MANUAL Chain size d * t 4.1 x 12.1 5.1 x 15.1 7.2 x 21.1 t = Overall length of 1 chain link, measured on the inside. = (d1 + d2) / 2. Use only a "knife-edge" caliper or a tool that is sold by the Crane Part Center for measuring the link thickness.

  • Page 102: Lubrication Instructions For The Chain

    7 MAINTENANCE 7.5.3 Lubrication instructions for the chain Initial lubrication of the chain Lubricating the chain is part of the commissioning procedures of the chain hoist. For cleaner installation routines, the chain hoist is delivered with an unlubricated chain. Even if the chain feels oily, it is not lubricated, but has only a corrosion protection.
  • Page 103 OWNER’S MANUAL Figure 20. Correct positioning of the grease tube or oil bottle Checking the lubrication of the chain Maintaining the chain is one of the most important service tasks of a chain hoist. Lubrication, including the initial lubrication of the chain, is part of the chain maintenance. If you do not maintain the chain properly, the lifetime of the chain and the complete chain drive reduces drastically.
  • Page 104 7 MAINTENANCE Figure 22. Completely dry and damaged chain Lubrication intervals of the chain Defining the required maintenance interval for the chain depends on the use of the product, and must be determined case-by-case. To fully optimize the lifetime of the components, define the exact maintenance interval for each hoist application individually.

  • Page 105: Replacing The Chain

    OWNER’S MANUAL Chain lubrication intervals Cycle = One work cycle, from pick-up to release of the load. LH = Low headroom hoist. 7.5.4 Replacing the chain Replacement of the chain sprocket If the chain wear exceeds 2% when you replace the chain, also the chain sprocket must NOTE be replaced.
  • Page 106 7 MAINTENANCE 6. Insert the new chain by using the plastic chain insertion tool. 6.1 Attach the chain to the chain insertion tool. 6.2 Place the chain insertion tool to the chain output on the load side of the chain fall. 6.3 Feed the chain insertion tool into the chain guide.

  • Page 107: Replacing The Chain

    OWNER’S MANUAL 8. Pull the rubber plate or the limit switch activator up on the chain. Attach the end stop to the chain end on the chain bucket side of the chain fall. The dimension 'W' should be at least 150 mm (5.9 in).
  • Page 108 7 MAINTENANCE 4. Remove the chain from the fixed end position. 4.1 Remove the locking screw (1). 4.2 Free the chain of all tension. 4.3 Push out the pin (2) that holds the chain in place. You can push out the pin using, for example, a piece of wire.
  • Page 109 OWNER’S MANUAL 7. Insert the new chain by using the plastic chain insertion tool. 7.1 Attach the chain to the chain insertion tool. 7.2 Place the chain insertion tool to the chain output on the load side of the chain fall. 7.3 Feed the chain insertion tool into the chain guide.

  • Page 110: Maintaining The Hook

    7 MAINTENANCE 10. Attach the chain to the fixed end position. 10.1Place the first chain link into the slot of the suspension point. 10.2Insert the pin (2), which holds the chain in place, into the hole on the side. 10.3Push in the pin completely using a hexagon key or a similar tool.

  • Page 111: Checking The Limit Switch Activator

    OWNER’S MANUAL 3. Check that the hook is not twisted. Check that the hook opening is not opened more than 10 degrees from the plane of the unbent hook. If the hook is twisted or the hook opening is opened more than 10 degrees from the plane of the unbent hook, the hook safety latch could bypass the hook tip.

  • Page 112: Lubrication

    7 MAINTENANCE • Check the condition visually during the annual inspection. • Check the wear. • Check for damage, cracks, and tears. Lubrication 7.7.1 Safety during lubrication • Familiarize yourself with the information on the safety data sheet of each lubricant. The safety data sheet contains instructions on safe handling and risks that are related to the use of the lubricant.

  • Page 113: Lubrication Points

    OWNER’S MANUAL 7.7.3 Lubrication points Figure 23. Lubrication points of the chain hoist Pos. Component Intervals Hoisting gear Lubricated for the design working period of the product Chain From 1 week up to a year (depending on the usage) Only lubricate the instructed components. Other components are lubricated for the NOTE design working period of the product.
  • Page 114 7 MAINTENANCE 2 Chain Lubricated with oil. • Lubricate the chain carefully before the first run (commissioning). ◦ Apply a substantial amount of lubricant over the full length of the chain ◦ Make sure that the chain is lubricated all over its surface and links, especially on all contact areas between the chain links.

  • Page 115: Troubleshooting

    OWNER’S MANUAL TROUBLESHOOTING Troubleshooting instructions Problem Possible cause Solution The emergency stop button is Deactivate the emergency stop activated. button. Check the fuse for the main power supply. Check the control voltage fuse. For instructions on how to A fuse is triggered. check or replace the control voltage fuse, see chapter Replacing the control voltage fuse.
  • Page 116 8 TROUBLESHOOTING Problem Possible cause Solution Valid only for the 3-phase hoist versions. Valid only for the 2-fall hoist versions. This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non- 4/2020 public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S.

  • Page 117: Transportation, Storage, And Dismantling

    OWNER’S MANUAL TRANSPORTATION, STORAGE, AND DISMANTLING Transporting the product When transporting the product or its components, take the following precautions: • Load and transport the product with caution and using appropriate methods. Make proper preparations and take appropriate caution. • Do not load or transport products if your alertness or working ability is impaired, for example, by medication, illness, or injury.
  • Page 118 9 TRANSPORTATION, STORAGE, AND DISMANTLING Waste handling methods Material Waste handling method Metals Recycle the metals. Electronics and Some electrical parts may be treated as hazardous waste. electromechanical Collect and recycle the electronics and electromechanical components components separately. Batteries Batteries and other energy storage components may contain hazardous substances.

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