CONTENTS ENGLISH - 2 -

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1 CONTENTS GENERAL PRECAUTIONS... Page 48 General technical information... Page 49 Photograph of complete gearbox - MF type - MB type... Page 50 Gearbox and motor data plates...page 51 Packing and transport... Page 52 Opening the plywood crates... Page 54 Gearbox weight table... Page 54 Removal from packing and handling of MF gearbox... Page 55 Removal from packing and handling of MB gearbox... Page 56 MB gearbox motor positioning Removal and installation of B3 motor... Page 58 Removal and installation of flanged motor... Page 59 Positioning on the frame: Case A Slow shaft with external support, ropes direction downwards... Page 60 Case B Slow shaft with external support, ropes direction upwards... Page 61 Case C Slow shaft with middle support, ropes direction downwards... Page 61 Case D Slow shaft with middle support, ropes direction upwards... Page 62 Case E Slow shaft with intermediate support, ropes direction upwards... Page 62 Using the support rafter for motor bedplate... Page 63 Start-up... Page 65 Start-up of gear type MB Page 66 Oil table... Page 67 Lubrication... Page 68 Machine start Motors AC2... Page 69 Motors VF... Page 70 Motor 240 VF 4/4E... Page 71 Motors VF 4/4E... Page 72 Electric connections... Page 73 Braking adjustment... Page 74 Brake adjustment... Page 75 Instruction on manual operation in case of emergency... Page 76 Periodic maintenance checks... Page 77 Checking the back-lash for the worm-wormwheel... Page 78 Adjustment for thrust bearing ring nut... Page 79 Tightening torque... Page 80 Slow shaft bushing position locking pin... Page 81 Instructions on sheave replacement... Page 81 Equipment for handling MB gearboxes... Page 83 Equipment for handling MF... Page 84 Tacho-dynamo assembly table... Page 86 Encoder assembly table... Page 87 Wiring diagram for 2-speed motor... Page 88 Chart for oil change... Page

2 GENERAL PRECAUTIONS MAKERS N MATRICOLA N TYPE TIPO GEAR RAPPORTO RATIO ORDER N ORDINE N LIFT N IMPIANTO N The manufacturer must be notified of the following when ordering parts: 1) Gearbox type 2) Machine serial number indicated on the order confirmation, or on the gearbox data plate, or engraved on the gearbox body (see page 51). This data enables SASSI S.p.A. to provide spare parts together with detailed instructions for their use. PAY CAREFUL ATTENTION TO THE PERFORMANCE DATA CONTAINED IN THE SASSI S.p.A. GENERAL CATALOGUE FOR CONDITIONS AND LIMITS REGARDING USE. ALL OPERATIONS INDICATED IN THIS HANDBOOK MUST BE CARRIED OUT BY AUTHORIZED PERSONNEL. THE GUARANTEE IS NO LONGER CONSIDERED EFFECTIVE IF ANY PARTS ARE REMOVED FROM THE GEARBOX

3 GENERAL TECHNICAL INFORMATION COMPLETE GEARBOX WITH MOTOR (GEARS MF) - European reference norm: EN 81-1: Vibrations: IEC CEI 2-23 Noise: IEC 34-9 CEI EN THREE-PHASE ASYNCHRONOUS MOTOR 1 OR 2 POLARITIES (GEARS MF) - Constructive norms: IEC 34-1 IEC 34-2 IEC 34-5 CEI 2-3 CEI 2-8 CEI 44-5 EN CEI 2-16 EN EMC norms: EN EN EN 50081: 1991 EN 55011: 1991 EN 55014: 1991 ELECTROMAGNETIC BRAKE (GEARS MF AND MB) - European reference norm: EN 81-1: EMC norms: EN EN EN 50081: 1991 EN 55011: 1991 EN 55014:

4 GEARBOXES FOR LIFTS Fan MF Sheave Flywheel MF External support Flanged motor Electromagnetic Brake Brake open lever Encoder tachodynamo B3 type motor MB

5 MOTOR AND GEARBOX DATA PLATES EXAMPLE OF DATA PLATES ON THE MACHINE WHICH MAY VARY IN QUANTITY AND POSITION IN ACCORDANCE WITH THE CONFIGURATION A B C SERIAL NUMBER MARKING E F D A. PRE-DRILLED DATA PLATE - ATTACH TO THE SURFACE INDICATED USING SCREWS PROVIDED, POSITIONING CAR UP AND CAR DOWN ARROWS IN ACCORDANCE WITH THE ACTUAL SITUATION. B. MOD. VT. 330 FAN DATA PLATE C. MOD. VT. 180/240 FAN DATA PLATE D. ELECTRIC MOTOR DATA PLATE E. DATA PLATE WITH INSTRUCTIONS FOR THE TYPE OF OIL USED FOR MACHINE BREAK-IN DATA PLATE INDICATING RECOMMENDED LUBRICATION OILS F. DATA PLATE WITH MANUFACTURER DATA REGARDING THE GEARBOX TYPE

6 PACKING AND TRANSPORT 1. PALLET ARRANGEMENT The wooden pallet under the machine can be picked-up by either a fork lift or a transpallet. The pallet is composed of, at least, two beams and three cross-pieces. Gearboxes with external supports or specially manufactured items may be packed in pallets with four beams. Pallets are used with all gearboxes and if additional protection is not required, the machine is shipped in this way. Cardboard Boxes (see point 2) or crates (see point 3) are provided if necessary. 2. CARDBOARD BOX ARRANGEMENT DO NOT over-storage this type of box during transport

7 PACKING AND TRANSPORT 3. CRATE ARRANGEMENT One crate (one and not more than one!!) of identical dimensions can be stacked onto another crate. Crates are made of phenolic coated plywood for sea transport and are hinged at the corners. The bottom of the crate is fitted with wooden crosspieces to facilitate pick-up with a fork-lift. The pallet is nailed to the bottom of the crate. The cover is fitted and nailed to the sides. PACKING SEQUENCE ACCORDING TO NORM F.A.O. ISPM 15 BOTTOM (A) PALLET (B) GEARBOX PLACEMENT (C) CRATE PLACEMENT (D) NAILING THE BOTTOM (E) NAILING THE COVER (F)

8 OPENING THE PLYWOOD CRATES The nails must be removed to open the plywood crates. In order to prevent the wood from splintering, use the tool shown in figures A and B. This special tool is a right-angle tube. Its short end has a V shaped groove with a sharpened edge. Place the centre of the sharpened side on the nail and strike the tube with a hammer until the lip is inserted in the wood, then turn the tube using the tube elbow as leverage so that the nail head is lifted upwards. Continue lifting so that the nail head fits into the V groove and is then removed. A B MF 48 MB 82 MF 82 GERARBOX WEIGHT CHART GEAR TYPE WITH MOTOR MB 94 WITHOUT SHEAVE Kg. 245 (HP 4,8 5,5) Kg. 251 (HP 6,7) Kg. 268 (HP 7,5 10) MF 94 WITHOUT MOTOR AND WITHOUT SHEAVE Kg. 360 WITH MOTOR WITHOUT SHEAVE Kg. 410 (HP 12,5) Kg. 416 (HP 15) Kg. 473 (HP 16 18,5) Kg. 481 (HP 20 21) Kg. 511 (HP 22 24) Kg. 518 (HP 26) Kg. 522 (HP 28) MB 95 MB 108 WITHOUT MOTOR AND WITHOUT SHEAVE Kg. 535 WITH MOTOR WITHOUT SHEAVE Kg. 639 (HP 20) Kg. 670 (HP 22) Kg. 677 (HP 25) Kg. 684 (HP 28) WITHOUT MOTOR AND WITHOUT SHEAVE Kg. 980 WITHOUT MOTOR AND WITHOUT SHEAVE Kg

9 REMOVAL FROM PACKING AND HANDLING OF MF GEARBOXES (For equipment see page 83) Machines must be used in clean environments and should be protected from dust and foreign bodies. MF 48 In this case a sling must be made from both belts which are secured from above by a single central ring. Carefully position the belt under the thrust bearing from the front, pass the second belt under the brake jaw from the rear behind the stop screws of the jaw pivot from the flywheel. A third securing point must be added in the form of a chain fixed to the same lifting hook. The hook located at the end must be anchored to one of the slots on the pulley hub so that transversal balancing of the machine is ensured. When the special slow shaft is present, use an extension to anchor the chain to the pulley hub. Adjust the length of the two belts so that the gearbox is balanced horizontally during lifting. Imbalance could cause the belt to slip from the correct position indicated. USE EQUIPMENT No. 1 MF 48 CODE MF 82 Position the belt behind the stop screws of the jaw pivot and at the front, position the belt under the thrust bearing, as seen for the MF 48. Then use the chain with hook as seen previously with the MF 48. Use an extension if the special slow shaft is present. USE EQUIPMENT No. 1/MF82 CODE MF 94 Use two belts as indicated for the MF 82 gearbox and the chain equipped with the pivot, suitable for use with the smallest holes of the pulley-bearing flange for supporting the gearbox transversally. Again, an extension must be used as indicated previously if the gearbox has a special slow shaft. USE EQUIPMENT No. 1/MF94 CODE

10 REMOVAL FROM PACKING AND HANDLING OF MB GEARBOXES (For equipment see page 83) MB 82 In the hole in the motor base which serves to house the support rafter, fix the hoist with two rings; connect the two metal cables to the rings. At the front, attach two metal cables under the edge of the base head located below the thrust bearing. For large sheaves, also use the chain with hook for transversal support of the gearbox. If the motor is already fitted, use longer cable for lifting to prevent any damage to the fan. Use equipment: Front code Rear code

11 REMOVAL FROM PACKING AND HANDLING OF MB GEARBOXES (For equipment see page 83) MB 94 Sling description: as with MB 82. Use equipment: Front code Rear code MB 95 Sling description: as with MB 82. Use equipment: Front code Rear code

12 MOTOR PLACEMENT ON THE MB TYPE GEARBOX Removal and installation of the B3 motor Removing the B3 motor These instructions refer to the gearbox with the B3 motor installed by Sassi S.p.A. The removal of the motor-gearbox coupling must be carried out only if necessary by authorized personnel. Before removing the motor from the gearbox, take care to mark (using a felttipped pen) the relevant positioning of the coupling of the gearbox joint to the motor flywheel-bearing hub (MPV), and the orientation and position of the spacers under the motor feet. It is now possible to remove the electromagnet and open the brake jaws to their maximum. After having loosened the Reference MPV Flywheel-Bearing Hub screws of the motor-gearbox coupling, check that the machine slides easily by manually turning the flywheel several times in both directions. This operation will allow us to check, during the next phase of motor installation, if sliding has been modified due to faulty alignment. We can now completely remove the motor. The next phase of installation comprises the replacement of spacers in the same position under the motor feet, also paying attention to the marks made on the painted surface. In fact, not considering the presence of the thin layer of paint can negatively influence accurate alignment. GEARBOX MOTOR COUPLING

13 DETAIL K fig. 1 If the motor rotor is mounted on bushings, check that it is CENTERED with respect to the maximum lengthwise run possible along the X axis shown in the figure. At this point, move the two semi-couplings closer checking that they are in the same position with regards to their original position (the pen markings must coincide). Tighten the coupling screws and turn the flywheel to check freedom of movement. x DETAIL K dial gauge on the flywheel as seen in the figure in positions A and B. Slide the motor axis backwards (hold the body still) so that the MPV is freed from the drum. Now turn the flywheel-bearing hub ± 90º reading the values indicated on the dial gauge (Detail K), and add or remove shims to adjust the height along the Z axis until the dial gauge reading is displaced by ± 0.02 mm max. from starting point B. To adjust alignment along the Y axis on the horizontal surface, the same procedure is repeated, placing the instrument in position A. Drill holes 1, 2, 3, and 4 (if not previously done) and the support bedplate. Position and tighten the fixing bolts to the Installing the B3 motor The procedure differs when installing a motor on an MB type gearbox released from the factory WITHOUT a motor. Most important, four shims (1, 2, 3, 4 in fig. 1) must be either prepared or ordered from SASSI so that height h is obtained. Then remove the electromagnet brake and open the brake shoes towards the outside to their maximum width. Insert the MPV, with flywheel, already fitted to the motor shaft, in its place in the brake drum, by moving the motor body along the X axis for motors equipped with bearings or by sliding the rotor shaft forward for motors equipped with bushings. The motor rotor must be centered with regards to the total possible run. Now position (see detail K) the bedplate always manually checking the freedom of movement of the assembled gearbox motor. If any changes are found, repeat the alignment procedure, readjusting the shims used. To adjust braking and for brake registration, see relative chapters (pages 74 and 75). Removal and installation of flanged motor for MF Gearboxes Each case must be individually examined since each one requires different equipment Contact Sassi directly

14 POSITIONING ON THE FRAME These operations are standard practice with all machines mounted on a frame and serve to keep the slow shaft perfectly horizontal once the plant is in traction. They prepare the frame for the inevitable structural deformations which could occur. CASE A: Slow shaft with external support, ropes direction downwards DIAL GAUGE GEARBOX BOLTS SUPPORT BOLTS Alignment diagram Set the gearbox on the frame and check that a space exceeding 0.5 mm remains between FRAME TYPE the required height is reached. Fit and completely tighten the bolts to fix the gearbox to the frame. Mount the magnetic base with dial gauge as shown in the drawing. After re-setting the dial gauge, insert the calibrated shims between the support and the support surface so that the dial gauge indicates a change in height of approx mm. Now fit the fixing bolts for the external support and completely tighten. For tightening torque see chart on page 80. The dial gauge, after fixing, must show a change in height of approx mm. If not, add or remove shims under the external support until achieving the value indicated above. the frame and the support. If not, the gearbox should be raised using calibrated shims until

15 CASE B: slow shaft with external support, ropes direction upwards Alignment diagram Set the gearbox on the frame in alignment with the appropriate fixing holes and check that a space exceeding 0.5 mm remains. If not, the gearbox should be raised using calibrated shims until the required height is reached. Insert and completely tighten the Alignment diagram Set the gearbox on the frame in alignment with the appropriate fixing holes, position the shims, if needed, under the support, and check that a space exceeding 0.5 mm remains between the shim and support. If not, the gearbox should be raised using calibrated shims until the required height is reached. Fit and completely tighten the bolts fixing the gearbox to the frame. Mount the magnetic base with dial gauge as shown in the drawing. After re-setting the dial gauge, insert the calibrated shims between the support and the support surface so that the dial gauge indicates a change upwards of approx mm. Now fit the fixing bolts for bolts fixing the gearbox to the frame. Mount the magnetic base with dial gauge as shown in the drawing. After re-setting the dial gauge, insert calibrated shims between the support and the support surface (a smaller amount than that indicated in case A) so that a space is left of approx. 0.1 mm. Fit and completely tighten the fixing bolts to the external support. For tightening torque see chart on page 80. The dial gauge, after fixing, must show a lowering of approx mm. If not, add or remove shims under the external support until achieving the value indicated above. DIAL GAUGE GEARBOX BOLTS SUPPORT BOLTS CASE C: slow shaft with intermediate support, ropes direction downwards DIAL GAUGE GEARBOX BOLTS SUPPORT BOLTS the external support and completely tighten. For tightening torque see chart on page 80. The dial gauge, after fixing, must show a change upwards of approx mm. If not, add or remove shims under the external support until achieving the value indicated above.

16 CASE D: slow shaft with intermediate support, ropes direction upwards Alignment diagram Set the gearbox on the frame in alignment with the appropriate fixing holes, position the shims, if needed, under the support, and check that a space exceeding 0.5 mm remains between the shim and support. If not, the gearbox should be raised using calibrated shims until the required height is reached. Fit and completely tighten the bolts fixing the gearbox to the frame. Mount the magnetic base with dial gauge as shown in the drawing. After re-setting the dial gauge, insert the calibrated shims between the support and the support surface so that the dial gauge indicates a change inferior to that indicated in case C so that a space of approx. 0.1 mm remains. Now fit the fixing bolts for the support and completely tighten. For tightening torque see chart on page 80. The dial gauge, after fixing, must show a lowering of approx mm. If not, add or remove shims until achieving the value indicated above. DIAL GAUGE GEARBOX BOLTS SUPPORT BOLTS CASE E: slow shaft with intermediate support, ropes direction upwards Alignment diagram Set the gearbox on the frame in alignment with the appropriate fixing holes position the shims, if needed, under the support, and check that a space exceeding 0.5 mm remains between the shim and support. If not, lower the gearbox support surface until the indicated value is reached. Fit and completely tighten the bolts fixing the gearbox to the frame. Mount the magnetic base with dial gauge as shown in the drawing. After re-setting the dial gauge, insert the calibrated shims between the support and the support surface without ever forcing the shims which could otherwise alter the dial DIAL GAUGE GEARBOX BOLTS SUPPORT BOLTS gauge value of 0. Now fit the fixing bolts for the support and completely tighten. For tightening torque see chart on page 80. The dial gauge, after fixing, must indicate a ± 0.04 mm value modification. If not, add or remove shims until achieving the value indicated above.

17 USING THE SUPPORT RAFTER FOR MOTOR BEDPLATE CHART A THEY ARE BALANCED (Car, counterweight, etc) ARGANO TIPO TREUIL TIPO GETRIEBE TYP GEAR TYPE PESO MAX MOTORE SENZA PUNTONE POIDS MAX MOTEUR SANS TIGE MAX MOTORGEWICHT OHNE DRUCKSTAB MAX MOTOR WEIGHT WITHOUT RAFTER FIT RAFTER IN THIS HOLE ON THE BEDPLATE MB 82 MB 94 MB Kg 400 Kg 450 Kg For MB type gearboxes with motors weighing (including the flywheel) more than the maximum limits indicated in chart A, the support rafter MUST be used. For correct use, follow the procedures indicated below: 1) The motor must be mounted and perfectly aligned on the axis of the worm screw, WITHOUT the rafter. 2) After installing the gearbox and motor, the rafter is locked to a fixed part of the plant (such as the underlying frame) using nuts and lock nuts (No. 1 of fig. 1) or similar. 3) ATTACH THE PLANT LOADS SO THAT RAFTER SUPPLIED 4) Two dial gauges should be attached jointly to the slab (fig. 1 and fig. 2). 5) After re-setting the dial gauges, tighten the nut and lock nut (No. 2 of fig. 1) making sure that the dial gauge pointers remain in the 0 position. fig. 2 fig

18 START-UP OIL FILL CAP OIL LEVEL WINDOW OIL DRAIN PLUG Before machine start-up, make sure that the oil level reaches the level window (supplied with all our machines). Use oil types indicated in the chart below, or other types having the same characteristics (viscosity, Extreme Pressure additives) and of highest quality. Except where specified otherwise, mineral oil must be used since this is the type of oil used during running-in, or in case the customer has specified otherwise at the time of the order. If topping up is required, never mix synthetic oil with mineral oil, or vice versa!!! TABELLA OLI MINERALI - TABLEAU DES HUILES MINERALES - MINERAL OIL TABLE - TABELLE MINERALÖLE - TABLA ACEITES M Marca Marque I N E R A Mark CASTROL GULF ESSO SHELL MOBIL AGIP BP Mark Marca Tipo Type ALPHA SP EP Lubricant Spartan Omala oil Mobilgear Blasia Energol Typ Type 220 HD 220 EP GR-XP 220 Tipo Viscosità a 50 C Viscositè à 50 C Viskosität bei 50 C Viscosity at 50 C Viscosidad 50 C 16.5 [ E] 16.7 [ E] 15.1 [ E] 15.0 [ E] 15.8 [ E] 18 [ E] 16 [ E] TABELLA OLI SINTETICI - TABLEAU DES HUILES SYNTÉTIQUES - SYNTETIC OIL TABLE - TABELLE SYNTETIKÖLE - TABLA ACEITES S I Marca N T E T I C O S Marque Mark CASTROL GULF ESSO SHELL MOBIL AGIP BP Mark Marca Tipo Type Typ Type Tribol 800/220 EP Lubricant SY 220 Ezl 502 Tivela WB Gligoyle 30 Blasia S 220 Enersyn SG-XP 220 Tipo Viscosità a 50 C Viscositè à 50 C Viskosität bei 50 C Viscosity at 50 C Viscosidad 50 C 17 [ E] 17.2 [ E] 19 [ E] 20.0 [ E] 19.4 [ E] 21.0 [ E] 17.5 [ E]

19 SHEAVE GEARBOXES MF GEARBOXES MB FLYWHEEL Manually turn the sheave one complete turn, driving the flywheel so that the ring gear is lubricated before start-up. Pay special attention to running-in phase: the first machine movements must take place before the machine is placed under load. Apply and balance the load. Check machine resistance in both directions. If this resistance is anomalous check the alignment of the external support, when present. The faulty alignment can be caused by an higher bending of the frame portion under the external support with respect to the portion under the gear. When the machine is under load run the gear (15-30 ) with a cabin load at 60 % of its duty load and without the gear oil fill cap; the presence of a stream of smoke coming out from the hole indicates a faulty working. Having done this, load the cabin at 3/4 of its capacity and operate the machine alternating ascent and descent movements for about 30 minutes as done in the previous point, constantly checking the machine state and making sure that the oil input hole is left uncovered to check for smoke. Load the cabin at its full capacity and repeat the test runs for about 15 minutes. Unload the cabin leaving 1/4 of duty load and repeat the test runs. At the end unload the cabin completely and repeat the test runs. Should smoke come out from the hole during these operations, stop immediately the machine and contact SASSI FLYWHEEL

20 START UP OF GEAR TYPE MB 108 IMPORTANT! MB 108 Your MB108 has been correctly run-in in our works, but this operation cannot create the effective working conditions, in case of very high loads. For this reason, at machine startup, You have to carry out the following operations.it is also very important to run the gear with synthetic oils additivated for extreme pressures with PAO base (polyalfaolefinic) or even with PAG base (polyalchilenglicolic) and with viscosity ISO 320 or 460, depending on the supposed temperatures in machine rooms. We must be previously notified of the oil type. For installations with powers higher or equal to those indicated (see chart) absolutely follow the operations indicated: Chart RATIO POWER POWER (kw, 1000 rpm) (kw, 1500 rpm) 1/64 22,1 29,4 1/48 25,0 33,1 2/71 30,9 36,8 2/57 35,3 44,1 3/68 38,2 51,5 4/59 42,6 58,8-66 -

21 1) Manually check that the machine (without loads) runs correctly in both directions; 2) To ensure that the oil flows without obstructions, run the gear, without loads, electrically for 3 minutes in each direction; 3) Install the ropes on the sheave and load the cabin with half load in cabin and then repeat procedure of point 1; this check helps to find out an anomalous frame bending underneath the externa support. 4) Important: do not immediately run the installation with the empty cabin; 5) Avoid also long travels during maintenance; 6) Load the cabin with half of duty load (see point 3), check the correct balancing of the counterweight and measure the current absorbed by the motor at half travel in both running directions: they must be always the same, and (important!) must be measured between the mains supply and the inverter, if present; 7) Load the cabin with 60% of duty load and carry out 20 travels (not very long) at intermediate floors, keeping the hole for oil inlet open to check for smoke. Stop the installation and let the gear get cool; 8) Load the cabin with 75% of duty load and carry out 20 travels alternating many short travels upwards and downwards to few long travels with the cabin moving upwards. Check again for smoke coming out from the oil inlet plug. With high running temperature oil could slightly vaporize, thus creating a fine mist: this phenomenon is not dangerous; in case of thick vapour stop the installation and let the machine get cool before repeat test travels. Should the mist disappear with cooler machine, repeat the running-in increasing the loads, or slightly decrease the load in cabin (5% at the time) till the phenomenon stops. Then gradually load to 75%. This running-in phase has to last for about 10 working hours and must be alternated with stops to cool the system; ) Load the cabin with 90% of duty load and repeat the procedures of the previous point; 10) Load the gear with 100%: the machine has to be at room temperature. Carry out short travels for minutes, checking for smoke from oil inlet hole. Should vapour appears, repeat the procedures of point 9, or proceed directly with what indicated in point 8, following the same operations with the same duration; 11) With cold gear, download the cabin leaving 40% of duty load and repeat the same procedures seen with 60% of duty load (see point 7); 12) Then, with cold gear download the cabin again leaving 25% of duty load and follow the procedures indicated at point 8 for duty load at 75%; Capacità olio Capacitè huile Erforderliche Ölmenge Oil Capacity Capacidad aceite Capacità olio Capacitè huile Erforderliche Ölmenge Oil Capacity Capacidad aceite Capacità olio Capacitè huile Erforderliche Ölmenge Oil Capacity Capacidad aceite CAPACITÀ OLIO litri l. l. l. MF 48 MF 82 MB 82 3,8 7,5 7,5 MF 94 MB 94 MB 95 9 MB ) Load the cabin with 10% of duty load, with cold gear, repeat what seen for 90% (see point 9); 14) Then, with cold gear, download completely the cabin and repeat what seen under full load conditions (see point 10). N.B. In case of test of the safety gear, pay attention that with very high masses (cabin and duty load) to avoid damages to the worm wheel - for the release operation - do not use the motor, but a hoist or similar.

22 LUBRICATION OIL LEVEL Always use the oil types recommended in the chart on page 18 making sure not to mix mineral and synthetic oils. When mineral oil is used, the first oil change should be made after approx. 350 operation hours. If synthetic oil is used, the first oil change should be made after approx. 700 operation hours. Successive changes should be made every 12/18 months for mineral oil, and every 24/36 months for synthetic oil, according to intensity of use. Please take note of oil changes in the specific chart at page 89. When mineral oil is replaced by synthetic oil, follow the procedure described below: 1. Use synthetic oil with the characteristics indicated in the oil chart at page Remove the cables and with the machine at a standstill, drain off all the mineral oil ensuring that it drains completely. 3. Pour enough KEROSENE to fill the gearbox sump and run the machine at high speed for few turns and then drain the liquid from the oil drain outlet. Repeat this operation 2 or 3 times and then accurately drain the cleaning mix. 4. Fill with the required amount of synthetic oil. 5. Run the machine at high speed in both directions for 10 minutes with the oil fill inlet open in order to check for any smoke. 6. With the machine at a standstill, completely drain the used synthetic oil and then add the required amount of new synthetic oil. 7. After replacing the cables on the sheave, load 2/3 of useful capacity in the lift car. 8. Operate the machine for the first 10 minutes using short runs (a max. of 2 floors) alternating ascent and descent movements, constantly checking the machine state and making sure that the oil input hole is left uncovered to check for smoke. Note The bearing for the slow shaft support is life lubricated and does not require any maintenance.

23 MACHINE START Open the cover of the terminal box to take the wire clamps and the eletric plan. Carry out the connections according the the following indications: MOTORS AC2 motor 240 motor 270 /

24 MOTORS VF motors 240 motors 270 /

25 MOTOR 240 VF 4/ 4E IMPORTANT: For AC2 and VF motors always connect the 220 alternating voltage to the terminals of the fan

26 MOTORS VF 4/4E MOTORS VF 4/4E The principal winding of this type of motor has a Star connection (with feeding at V), while the secondary emergency one has a Delta connection (with feeding V). The thermoresistant cables are connected to terminals 5 and 6 for motor thermal protection. An appropriate monitoring amplifier for the resistance of the thermistors must also be connected to terminals 5 and 6. Without this device, thermal protection of the motor is NOT ensured and burn-out of the windings is possible. The monitoring amplifier should be connected between the control board and the terminals. The characteristics are: Power voltage V, Frequency Hz. Command relay: a change over contact with closed circuit current of 6 A, contact voltage V can be supplied by SASSI S.p.A. upon customer request. Caution: the maximum voltage allowed for terminals 5 and 6 is 5 volts; a higher value would burnout the thermistors. Connect always the AC voltage 220V to terminals 1 and 2 of the fan. Finally connect the brake to terminals + and - (terminals 8-9), checking that the input voltage corresponds to the electromagnet data plate.

27 ELECTRIC CONNECTIONS Motors AC2 The Star and Delta connections in AC2 motors depend to the feeding voltage ( V). To change from Star to Delta connection, disconnect the red wires U2, V2 and W2 from Star centre, both for high and low sped, and connect them according to the plan (U2 with V1, V2 with W1 and W2 with U1) of page 69. On the contrary, to change from Delta to Star connection, disconnect the red wires U2, V2 and W2 from the terminals of the previous point and connect them in the terminal of Star centre both for high and low speed. IMPORTANT: connect always the AC voltage 220V to terminals 1 and 2 of the fan. BEFORE ANY CHANGE TO ELECTRICAL CONNECTIONS IN AC2 MOTORS, PLEASE CHECK THE EXISTING FEEDING VOLTAGE. Motors VF the connection type Star or Delta depends on the feeding voltage. With feeding voltage V the connection is Star type, while with voltage V is Delta type. To change from Star to Delta connection, disconnect the red wires U2, V2 and W2 from Star centre and connect them according to the plan (U2 with V1, V2 with W1 and W2 with U1) at page 70. On the contrary, to change from Delta to Star connection, disconnect the red wires U2, V2 and W2 from the terminals of the previous point and connect them in the terminal of Star centre. IMPORTANT: connect always the AC voltage 220V to terminals 1 and 2 of the fan. Motors VF 4 / 4E The principal winding of this type of motor has a Star connection (with feeding at V), while the secondary emergency one has a Delta connection (with feeding V). IMPORTANT: connect always the AC voltage 220V to terminals 1 and 2 of the fan The plan present at page 71refers to motor size For the disposition of auxiliaries of motor 270 refer to the VF plans at page

28 BRAKING ADJUSTMENT TAV X Adjustment should be done with the machine UNDER LOAD. When the machine is operating and therefore when the electromagnet is energised, loosen locking nut 31 and slightly loosen adjustment screw 30 until the brake unit rubs against the brake drum (see chart X). At this point tighten screw 30 the minimum necessary until rubbing ceases between the shoes and the brake drum when the machine is moving. Re-tighten lock nut 31. Intervention is then possible on the spring pre-load to adjust braking intensity. Unscrew safety locking nut 6 and use the remaining nut to increase or decrease spring tension 32 until desired braking is achieved; then re-lock external locking nut 6. Repeat the procedure for the other shoe. Periodically observe the wear of the brake linings on the gearbox which reduces braking efficiency due to the decrease in spring preload. Do not perform any intervention on the brake by only increasing the preload, the complete adjustment procedure must be carried out using the adjustment screw 30, as seen at the beginning of this chapter, so that the end stops 13 is not increased. To replace the shoes, see the next chapter on Brake adjustment to ensure perfect fitting of the new brake linings to the brake drum. Please note that it is practically impossible to determine how often the brake should be adjusted, in fact, this depends on the type of machine, its use and the timing of the brake shoe opening and closing movements. N.B. Brake shoes with linings must be replaced when the thickness is 2 mm at the point of maximum wear

29 BRAKE ADJUSTMENT Adjustment should be done when the lift car is SUP- PORTED. First check that when the electromagnet is turned on, the brake unlocks. If this does not occur, proceed as follows: (consult chart x). When the brake is turned off, loosen locking nuts 31 and loosen set screws 30 so that they are distanced by a few millimeters (approx. 4) from end stops 13, manually checking that the end stops 13 are in the external end position. Loosen nuts 6 leaving washers 33 in contact with springs 32. With the shoes in contact with the drum, re-tighten set screws 30 moving end stops 13 towards the brake centre by 1 mm, and then tighten locking nuts 31. With the electromagnet energised, check that the friction lining of the shoe does not touch the brake drum; just check that in point B of the drawing a space of at least approx. 0.5/0.8 mm exists. This space should extend along the complete arc of the brake lining even if it slightly decreases up to point A. If this does not occur, only in this case, it becomes necessary to adjust the eccentric pin which regulates the brake shoe-drum coupling. With the electromagnet de-energised, loosen set screws 30 so that they are distanced by several mm (approx. 4) from end stops 13 manually checking that the end stops 13 are in the external end position. Loosen nuts 6 leaving TAV X washers 33 in contact with springs 32. Back off screws 38, disconnect the pin connection 37 from the Belleville springs 39. Loosen the nuts 34 and screws 35 and adjust the eccentric pins 36 (using a spanner or screwdriver according to machine version) until the shoes fully engage with the brake drum. Tighten screws 35 and nuts 34, fit the Belleville springs 39, pin connection 37 and tighten screws 38. Next, with shoes in contact with drum, tighten the adjusting screws 30 to move the end stops 13 approximately 1mm toward the brake centre, and tighten the locknuts 31. This done, adjust spring 32 as described in the chapter Braking adjustment

30 INSTRUCTIONS ON MANUAL OPERATION OF GEARBOXES IN CASE OF EMERGENCY FOR USE BY AUTHORISED PERSONNEL ONLY CARRY OUT THE FOLLOWING JOBS IN THE FOLLOWING ORDER 1. Switch off the main switch in the machine room. 2. Firmly grip manual-control flywheel B. 3. Open the brake shoes 41 using lever A by constantly exerting sufficient force to open the shoes. Move the flywheel B in the most suitable direction in order to take the cabin to the nearest floor, and level using the reference mark (if provided) on the steel ropes. 4. Release brake lever A. WARNING: NEVER REDUCE BRAKE SPRING TENSION TO FACILITATE MANUAL OPERATION. GEARBOXES MF GEARBOXES MB

31 PERIODIC MAINTENANCE CHECKS CHART 1 VALUES OF RADIUS IN mm TO BE SPECIFIED ON SHEAVE FLANGE RATIO MF 48 MB 82 MF 82 MB 94 MF 94 MB 95 MB 108 1:58 223,5 1:26, ,5 1: : : , :19,5 157,5 1: ,5 1:16, : : :26, : :16, :60 118,5 1:47 117,5 1:18,66 118,2 1:35,5 119, ,1 1: :22,66 282,5 1:14, :28, SASSI gearboxes have been designed with the intent of reducing maintenance procedures to a minimum. However, there are a few simple operations which should be carried out periodically to ensure optimum machine operating conditions. After having made the first oil change as described in the LUBRICATION chapter, check the oil and oil viscosity every six months. Make successive oil changes according to actual machine use using the specifications indicated in the LUBRICA- TION chapter. Check the wear of the brake friction lining every 4-6 months. If wear is excessive, make adjustments using the appropriate set screws (see chapter on BRAK- ING ADJUSTMENT ) and if the brake friction lining is worn to a thickness of approx. 1.5 or 2 mm at the point of maximum wear, replace the shoes.

32 CHECKING THE WORM/WORMWHEEL BACK-LASH fig.1 It is extremely important to check: WORM/ WORMWHEEL GEAR BACK-LASH (fig. 1) Remove the cables from the sheave, place a dial gauge on one of the surfaces of the gearbox head so that the probe is positioned against the head of one of the screws joining the flange with the cable sheave. Close the brake and manually turn the sheave to the left and to the right so that radial back lash measurement can be read on the dial gauge. NOTE The position of the flange bolts on the sheaves corresponds more or less to the position of the wormwheel reference radius of the ring gear. If more detailed information is required, consult table 1 on page 75 which includes a chart providing this data. WORM/WORMWHEEL GEAR BACK-LASH VALUES Check every 3000 running hours or at least once a year whether the maximum values of the a/m back-lash exceed 0.3 mm in case of gear with sheave diameters of more than 560 mm., or 0.5 mm. in case of gear with sheave diameters less/equal than 560 mm. In case this happens, please CONTACT SASSI S.p.A. for more information.

33 ADJUSTMENT OF THE RING NUT ON THE THRUST BEARING The following operations should be made when the gearbox is not under load (see chart Y): 1. Loosen screws 74, remove cover 73 and OR ring Loosen ring nut 71 and distance it from the bearing. 3. Tighten ring nut 71 so that it comes into contact with bearing Run the gearbox with the motor and carefully tighten ring nut 71 until the knocking caused by the balls and bearing cage is reduced in intensity (for tightening moments see chart 1). 5. Fit ring 70 and cover 73 and tighten screws Use a calibrated torque wrench. TIGHTENING TORQUE FOR THRUST BEARING RING NUTS CHART 1 (PARTICOLARE N 71 - Tav. Y) GEARBOX (Nm) GEARBOX (Nm) NOTES MF-MB 82 6 MB MF-MB

34 TIGHTENING TORQUES USED (Nm) MB 108 * GEARS MANU- FACTURING DATE RING NUT TYPE GUP SCREWS WITH CLASS 8.8 LARGE PITCH ISO THREADING LOCKING RING NUTS ON WORM DIAMETER MOMENT MF Nm M10 50,1 Nm MB - MF Nm M12 84,8 Nm MB - MF Nm M Nm MF 48 09/2000 ** 1111 Nm M Nm MB - MF 82 MB - MF 94 MB 108 * ** LOCKING RING NUTS ON SLOW SHAFT 09/2000 ** 01/2001 ** 2032 Nm 3398 Nm M20 M22 M Nm 532 Nm 691 Nm * FOR VALUES REFERRING TO GEARBOX MB 108, CONSULT THE INSTRUCTION HANDBOOK. ** FOR GEARBOXES MANUFACTURED AFTER THIS DATE, PLEASE REFER TO SPECIFIC DISMANTLING INSTRUCTIONS (NUTS WITH FRONT SCREWS)

35 SLOW SHAFT BUSHING POSITION LOCKING PIN DO NOT LOOSEN OR REMOVE THE PIN WITHOUT AUTHORIZATION FROM SASSI S.p.A. THE O-RING LOCATED ON THE SLOW SHAFT MUST NOT BE MOVED SINCE IT SERVES AS AN ACCESSORY TO THE O-RING ALREADY FITTED ONTO THE SUPPORT BUSHING, LOCATED INSIDE THE CASING. INSTRUCTIONS TO REPLACE SHEAVES For gears MF48, MF/MB82, MF/MB94, MB95 and MB108 the fixing of the sheaves to the flange for sheave is carried out by means of interference fit and 6 screws equipped with their relative safety self-locking ring nuts. The standard one are M14, while those inserted in the calibrated holes are M16 according to DIN 609 (see table nr. 2) Table nr. 2 GEAR TYPE: STANDARD BOLTS CALIBRATED BOLTS MF 48 n 5 M14 x 50 n 1 M16 x 55, code MF/MB 82 n 4 M14 x 55 n 2 M16 x 55, code MF/MB 94 n 4 M14 x 60 n 2 M16 x 60, code MB 95 n 4 M14 x 60 n 2 M16 x 60, code MB 108 n 3 M14 x 70 n 3 M16 x 70, code

36 To replace the sheave in machines equipped with external support, first of all remove the support following the specific instructions. During this operation take care not to damage the bearing and the relative oil tight shields, where present. Then unscrew the bolts (nr. 57 and 58 showed in picture) and insert three out the M14 screws in the threaded holes present in the traction sheave to help the extraction of the flange 48 from the interference fit (ref. A in picture). Do not unfit flange 48 from slow shaft. For tightening torque see table at page 80. As far as spare parts are concerned, we will supply sheaves with fixing holes suitable for bolts M14 still present (3,4 or 5 according to the models - see table 2 ref. B). The drilling with Ø 17 and H7 tolerance has to be carried out (once, twice or three times according to machine type) in connection with the flanges to allow the perfect boring of the hole according to the desired measure, at the moment of the mounting of the sheaves on the pre-existing flanges. The calibrated bolts have k6 tolerance. A A B B

37 EQUIPMENT FOR MB GEARBOX HANDLING MB 82 MB 94 MB 82 MB COD COD CABLE LENGHT BETWEEN RINGS (L in cm, Ø in mm.) MB 82 MB94 MB 95 / Ø CABLE L = 85 L = 85 L = 215 FRONT Ø 9 L = 127 L = 127 L = 242 REAR Ø 9 MB 95 Ø 14 MB 95 Ø

38 EQUIPMENT FOR MB GEARBOX HANDLING CABLE AND BRACKET SET MB 95 SINGLE CABLE L=CABLE 20 GEARBOXES MB Note For details of handling equipment for gearbox MB 108, refer to the relevant instruction handbook. COD L=CABLE MB 95 Warning Purchase order procedure for gearbox lifting tackle: quote the equipment code and the updating reference of the lifting tackle handbook FRONT BRACKET COD

39 EQUIPMENT FOR MF GEARBOX HANDLING EXTENSION GEARBOXES MF EQUIPMENT CODE BELT WITH 2 LOOPS CHAIN WITH HOOK BELT WITH 2 LOOPS BELT CHARACTERISTICS LENGHT 50 mm CAPACITY Kg 1000 CAPACITY Kg 600 SAFETY COEFFICIENT = 6 100% POLYESTER - L LENGHTS ARE INDICATED IN cm. MF 48 L = 100 MF 48 L = 113 MF 48 L = 102 N MF 82 L = 100 MF 82 L = 113 MF 82 L = 102 N MF 94 L = 100 MF 94 L = 113 MF 94 L = 102 N

40 TABLE CODE Fig. A Fig. B Fig. C ASSEMBLY OF THE TACHODYNAMO FOR PREDISPOSED MB/MF GEARBOXES Fig. A When there is no dynamo coupled to the gearbox, the latter is despatched supplied with the dynamo support flange consisting of the elements numbered in the diagram: Support 4, upper lid 3, front cover 15, shaft 8, gaskets 9 with the spacer 13 prepostioned to apply a little pressure on 9. The coupling 2 is supplied on request by the client Fig. B Remove the front cover 15. Insert the dynamo shaft in the elastic coupling 2 bore, centring the dynamo flange step in the predetermined area inside support 4. Fig. C Turn the dynamo until its fixing holes are in line with those of the support 4. Put the bolts with their relative washer in and tighten the nuts equally. Remove the lid 3, insert through the hole a key 16 supplied with the gearbox and tighten the screws 14 which link the coupling 2 to the dynamo shaft. Put the lid 3 back in place.

41 TABLE CODE Fig. A Fig. B Fig. C FITTING THE ENCODER ON PREDISPOSED MB/MF GEARBOXES Fig. A When the ENCODER is not fitted, the gearbox is shipped with the ENCODER mounting end complete with the parts shown in the figure namley: support 4, upper plug 3, front cover 21, shaft 9 and gasket 8 with the spacer 12 disposed in such a way as to exert slight pressure on it. The coupling 2 may not be present, according to whether or not it has been ordered by the client. The washer 13 and a bag containing the ENCODER fixing screws 14 are also to be found in the support 4. Fig. B Take off the front cover 21. Remove the support 4 by taking out the screws 5. Fit the ENCODER in the support 4 by means of the washer 13 fastened with the screws 14 which fix onto the body of the ENCODER. Insert the ENCODER shaft into the hole in the flexible coupling 2, centre the step on the flange of support 4 and fasten srews 5, tightening them gradually and symmetrically. Fig. C Having removed the plug 3, insert the wrench 16 supplied with the gearbox through the hole and tighten the screws 15 which fix the connection between the coupling 2 and the ENCODER shaft. Refit the plug 3.

42 WIRING DIAGRAM FOR TWO SPEED MOTOR TMA TMI V1 TA TB C1 U V W U V W 2.2µF 250Vac x2 IG T1 TF TA TB VF = Main switch = Transformer = Brake contactor = High speed contactor = Low speed contactor = Brake voltage TMA = Forward contactor TMI = Reverse contactor V1 = Diode bridge BF = Brake coil * CAPACITOR INSTALLED FOR CONFORMITY WITH CONDUCTION INTERFERENCE LIMITS C1: ARCOTRONICS - SERIES 1,47 MKT, 2.2 µf 250 Vac x

43 CHART FOR OIL CHANGES (See pag. 64) GEAR SERIAL NUMBER MINERAL* OIL TYPE ENTRATA IN SERVIZIO / / SYNTHETIC** NOTES *FIRST CHANGE AFTER 350 HOURS CHANGE DATE TRAVEL NUMBER SIGNATURE **FIRST CHANGE AFTER 700 HOURS