Beruflich Dokumente
Kultur Dokumente
for
D 2/1
DB 4/1 LIS–SE
Size GM 7000 DQA 6/1 LIS–SV
Z 4/2 LIS–AV
ZB 6/2
8/2
Manufacturer
Stand : 16. August 2001
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to
pay compensation for any breach of this provision. All patent and registered design rights reserved.
AN 17360
A 516.GB
These installation, operation and maintenance instructions are intended for use in an English–
speaking country by English–speaking specialist personnel.
Explanations concerning type designationas
Model D Model Z
5 Commissioning . . . . . . . . . . . 26
3 Description . . . . . . . . . . . . . . . 9 5.1 Electrical Systems . . . . . . . . . . . . . . . . 26
A 516.GB Page 3
7 Maintenance . . . . . . . . . . . . . . 29 7.6.3 Dismounting the brake
bearing plate and the brake . . . . . . . . 48
7.1 Classification of the gears . . . . . . . . . . 30
7.6.4 Mounting the brake
7.2 Action to Ensure bearing plate and the brake . . . . . . . . 48
Safe Operating Periods . . . . . . . . . . . . 31
7.7 Trolley brakes AZF . . . . . . . . . . . . . . . . 48
7.2.1 Declaration of
Theoretical Service Life D . . . . . . . . . . 31 7.7.1 Adjustment of the air–gap . . . . . . . . . . 48
A 516.GB Page 5
For the safe and reliable operation of the product and 1.4 Other Notes
for the retention of warranty rights, it is essential to use
The declaration of conformity / manufacturer’s
genuine ABUS parts when you need spare parts.
declaration you’ll find in section 10..
Safe operation is only possible within the service life
The year of manufacture is stated in the data
stated if the crane/hoist is operated within its rating and
sheet in the test book.
the installation, operation and maintenance instruc-
tions are followed. You will find the hoist class, load
group and FEM group of your crane/hoist in the test The product will only continue to perform reliably to
book or data sheet for the product concerned. your satisfaction in the long term if it is operated, main-
Notes on the theoretical service life of the hoist are tained and repaired by persons assigned to these
given in the appropriate installation, operation and tasks by the operator. Such persons must be familiar
maintenance instructions. with the installation, operation and maintenance in-
ABUS products must be maintained and repaired only structions and the applicable safety regulations and
by trained, authorized, specialist personnel. accident prevention regulations.
It is recommended that repair and mainten-
ance work should be carried out by the ABUS The operating instructions must be available to the per-
service department. sonnel responsible for repair and maintenance work at
all times.
2 Safety
2.1 General Notes VBG 8 Accident prevention regulations
for winches, hoists and traction
The installation, operation and maintenance instruc-
systems
tions must always be stored near the ABUS travelling
VBG 9 Accident prevention regulations
crane and must be available to operating personnel at
for cranes
all times.
VBG 9a Accident prevention regulations
for load carrying systems
Operating, maintenance and repair personnel must ZH 1/27 Principles for the testing of cranes
have read and understood the operating instructions and the codes and standards referred to in these docu-
before starting work. ments.
The organization operating an ABUS crane is respon-
sible for supervising operating personnel to ensure that 2.2 Safety Instructions for the
travelling cranes are properly operated. User
Caution !
For safe working, it is absolutely essential for
operation and maintenance personnel to re-
ceive thorough instruction in the require-
2.1.1 Requirements ments of this Installation, Operation and
ABUS products manufactures and tested and must be Maintenance Manual.
operated in accordance with the requirements of Euro- Release all locking devices before starting work.
pean and German codes, standards and regulations. Switch off the crane switch in hazardous situations.
The following codes, standards and regulations are ap- At the end of a day’s work, put the load suspension de-
plicable and must be observed by the operator: vices such as grab or magnet on the ground, pull up the
empty hook, and home the crane. Any locks which are
98/37/EC Machinery Directive available must be operated and the crane switch must
DIN EN 292 Safety of Machines be switched off.
DIN 15018 Cranes: Principles for Steel Struc- All accident prevention regulations and regulations is-
tures sued by local authorities, especially the operating in-
DIN 15020 Basic Principles for Rope Drives structions for cranes indicated on the respective plate
EN 60204 Part 32 Electrical equipment of machines; have to be adhered to when operating or attending to
requirements for hoists the crane.
A 516.GB Page 7
set up the corresponding work schedule and the hoisting rope or chain; hoisting ropes or chains or
procedure be carried out under the supervision of a such like shall not be bent or pulled over sharp
person appointed by the contractor. edges .
20. Maintenance work must only be carried out after 25.
the crane has been switched off. Any maintenance It is prohibited to drag or to pull the load
work that cannot be carried out from the ground sideways or to move vehicles with the
must be effected from working stands or platforms . load or the load suspension devices.
When carrying out maintenance or repair work at
the crane, the crane must be unloaded and the
mains or isolating switch (protected against un- Caution !
authorized switching) be switched off. Each of The crane must not be used for breaking
these switches can be provided with several pad- loose loads, pulling, dragging, or trans-
locks. This enables each person working on the versely pulling loads since this could re-
crane to lock and secure the crane against unauth- sult in overloading.
orized switching–on by means of his own padlock. Loads that have got stuck must only be pulled off by
For the maintenance of and repair work at cranes cranes equipped with overload protection.
with no servicing platform a stationary or movable 26. After repair or maintenance work or after any work
working platform must be available. carried out in the crane travelling area, crane oper-
21. (1) For repair and maintenance work on cranes and ation shall only be started if the contractor or his
in the crane travelling area the contractor or his agent have consented to do so. Before releasing a
agent must see to and supervise the following crane for operation, the contractor or his agent
safety measures must make sure that
1. The crane must be switched off and safe- 1. the aforementioned jobs have been completed
guarded against erroneous or unauthorised reclos- 2. conditions for a safe operation of the whole
ing. crane have been restored
2. If there is any risk of objects falling down, the risk 3. all persons having participated in such work
area underneath the crane must be shut off or by have left the crane.
posting guards to the site. 27. When operating additional crane equipment
3. The crane must be safeguarded against colli- and/or accoutrements, the corresponding special
sion with other cranes by means of rail stoppers or instructions may have to be followed. If additional
by stationing guards on the crane in motion. appliances and accoutrements are subsequently
4. The crane operators of adjoining cranes, if need installed on the crane, it is the responsibility of the
be also the ones of adjoining craneways, must be establishment <contractor> operating the crane
informed about the kind and location of operations. to check whether such additional equipment is ad-
This applies as well to the relief in the case of shift missible and suited for the crane installation.
change–over. 28. When using a lifting beam, it is essential to ensure
(2) If the aforementioned safety measures have not that the beam is not pulled under the main girder.
been taken properly or were not arranged for on The limit switches must be set in accordance with
operational grounds or turn out to be insufficient, the new conditions.
the contractor or his agent must arrange for differ- Caution !
ent or supplementary measures to be taken and Otherwise, there is a risk of rope break-
supervise the execution thereof. age and accidents.
22. (1) Unauthorized persons are not allowed to walk
onto a crane. Make sure the control devices operate correctly when
(2) Cranes which are being operated by a crane starting the crane or working at the main current supply
operator shall only be entered or left with the con- cables; wrongly connected wires will disturb operation
sent of the crane operator or when the crane has and create the danger of accident.
come to a standstill.
23. It is strictly prohibited to carry passengers together The operator must ensure that the workplace is ad-
with the load or by means of the load suspension equately lit
devices.
24. The load may not be directly slung by means of the
A 516.GB Page 9
3.1.5 Limit of lift changing, there is a standard precision hoisting speed
The lift is limited in the highest and lowest hook position in the ratio of approx. 1:4 to the main hoisting speed.
by means of a rotary geared limit switch directly The hoist is balanced at the factory by counterweight-
coupled to the rope drum. The standard hoist limit ing the side opposite the hoist motor.
switch (–S31) comes with 3 switching contacts which
have the following functions:
1. upper limit safety switch – lifting
2. emergency limit switch – lifting 3.2 Electrical equipment
3. emergency limit switch – lowering The contactor box is installed on the wire rope hoist and
The upper limit safety switch (–S31.1) interrupts power has IP 54 protection.
to the mainline contactor (K1). This switch point is set Reversing contactors are fitted with mechanical inter-
by the manufacturer, sealed with lead, and must only locks.
be reset by authorized personnel. If for any reason the Delay circuits (time delay: 0.5 sec.) are connected to all
emergency limit switch (–S31.2), fails to limit the travel reversing contactors, preventing inching operation and
of the block in the up direction, the crane is shut down protecting the contactors, motors and mechanical sys-
by this upper limit safety switch. Subsequent operation tems.
of the hoist should only be attempted by a trained ser- A special ABUS circuit generally prevents the start–up
vice technician. current of the motors from being switched off. This ex-
If the hoist is run to the lowest and/or highest hook posi- tends the service life of the contactors.
tion se veral times per day, the switch or the circuit must All wire rope hoists are equipped with motor circuit
be equipped for operational cut–off. breakers for motor protection. The motor circuit
If an operational upper limit switch is installed as de- breakers are set at the factory in accordance with the
scribed above, the emergency upper limit should be rated motor current and sealed.
checked at the beginning of each work shift. This is ac- In addition, all ABUS wire rope hoists are equipped with
complished with a ”test” button located on the push bimetal relays for protection against high winding tem-
button station. peratures.
For adjustment of the hoist limit switch see section 9. When braking from high speed to a standstill, the drive
is briefly switched via the slow speed, using the motor
for braking. This significantly extends the service life of
3.1.6 Overload protection the brake linings.
This device is installed to prevent overloading of the Contactor boxes are equipped with ducted circuitry on
electric wire rope hoist. mounting boards.
Details of other types of overload safety devices are If maintenance is required, contactors may be removed
given in the separate operating instructions attached. from their mounts without disconnecting any wiring.
A 516.GB Page 11
3.3.3 Electrical Data of Motors
Hoist lifting drives
Please take the type designation of your hoist
from the nameplate of the hoist data sheet in
the test book.
The ED (c/h) values are the total from the precision and
1,73 * L * I A * cos j A
main hoisting speed: A= (mm2)
u*k
They are split up at 1/3 (2/3) into prec. hoisting, and at
2/3 (1/3) into main hoisting operation. u*k*A
L= (m)
The required fuses and feed line cross sections are de- 1,73 * I A * cos j A
termined according to the hoist motor data. They are
also applicable to electrically operated trolleys.
u = voltage drop in V
(max. 5% of the rated voltage) z.B.:
The feed line U=400 V u=U * 5% = 400 * 0,05 = 20 V
Cable cross section (A) and cable length (L) are calcu-
lated acc. to the following formula: 57 m
k = conductivity (for copper = )
W * mm2
A 516.GB Page 13
Trolley drives
a) Performance data (50 Hz)
A 516.GB Page 15
1)
3.3.4 Weights and Dimensions The length is valid for a trolley–span of 2500 mm.
2) Height figures in brackets apply to a trolley track
Dimensions of the ABUS Electric rope hoist GM 7000.1
width of 2000 mm.
Dimensions [m]
Type Model l th 1) x width
length idth Weights for the hoist are given in the data sheet in-
x height 2) cluded in the test book.
2/1 D 3,0 x 1,9 x 1,0
Weights for travel drives are given in the table below.
2/1 DB 3,7 x 2,5 x 1,2
4/1 D 3,1 x 2,0 x 1,0
4/1 DB 3,7 x 2,4 x 1,2 Trolley Weight/
type drive
4/1 DQA 3,0 x 2,7 x 0,9 (HW=8m)
kg
4/1 DQA 3,0 x 3,2 x 0,9 (HW=15m)
AZP 200 40
4/2 D 3,0 x 1,9 x 1,0
AZP 280 50
4/2 DB 3,7 x 2,5 x 1,2
AZF 400 65
6/1 D 3,1 x 2,5 x 1,2 (1,4)
AZF 500 85
6/1 DB 3,8 x 3,3 x 1,2 (1,4)
8/2 D 3,1 x 2,1 x 1,0
8/2 DB 3,7 x 2,7 x 1,2
4/2 Z 3,1 x 2,3 x 1,1
4/2 ZB 3,7 x 3,2 x 1,2
6/2 Z 3,2 x 2,5 x 1,2 (1,4)
6/2 ZB 3,8 x 3,3 x 1,2 (1,4)
8/2 Z 400 3,2 x 2,5 x 1,2 (1,4)
8/2 ZB 400 3,8 x 3,3 x 1,2 (1,4)
8/2 Z 500 3,2 x 2,5 x 1,3 (1,5)
8/2 ZB 500 3,8 x 3,3 x 1,3 (1,5)
A 516.GB Page 17
load case H load case HZ load case HS
load
FSKA 2)
capacity Rmax 1) RKAmin 1) FMKA 3) FPUKR 4) in (kN / trolley) at
(kg) (kN / trolley
t ll
(kN) (kN/wheel) (kN / trolley) 5/20 m/min 7,5/30 m/min
track)
GM 7000.1 8/2–D trolley drive AZP 280
16000 48 8,6 13,0 5,2 35,0 47,0
20000 58 8,6 16,0 5,2 39,0 50,0
25000 70 8,6 19,0 5,2 44,0 54,0
32000 88 8,6 23,0 5,2 51,0 56,0
40000 107 8,6 28,0 5,2 57,0 ––
GM 7000.1 8/2–DB trolley drive AZP 280
16000 49,5 10,0 13,0 6,0 37,0 52,0
20000 60,2 10,0 16,0 6,0 41,0 54,0
25000 71,4 10,0 19,0 6,0 46,0 56,0
32000 88,6 10,0 23,0 6,0 52,0 56,7
40000 108,2 10,0 28,0 6,0 57,0 ––
GM 7000.1 4/2–Z trolley drive AZP 280
16000 51,5 12,1 12,7 7,3 40,0 59,0
20000 61,5 12,1 15,0 7,3 44,0 62,0
25000 74,0 12,1 18,0 7,3 49,0 65,0
32000 91,0 12,1 22,5 7,3 53,0 68,0
40000 110,5 12,1 27,0 7,3 60,0 ––
GM 7000.1 6/2–Z trolley drive AZF 400
25000 77 15,5 19,0 9,2 40,6 55,0
32000 94 15,5 23,0 9,2 40,6 55,0
40000 115 15,5 28,0 9,2 40,6 55,0
50000 138 15,5 34,0 9,2 40,6 55,0
63000 170 15,5 42,0 9,2 40,6 ––
GM 7000.1 6/2–ZB trolley drive AZF 400
25000 79 17,0 19,0 10,1 42,0 58,0
32000 96 17,0 23,0 10,1 42,0 58,0
40000 117 17,0 28,0 10,1 42,0 58,0
50000 140 17,0 34,0 10,1 42,0 58,0
63000 172 17,0 42,0 10,1 42,0 ––
A 516.GB Page 19
3.3.5 Tightening torques
Tightening torques (in Nm) and safety devices for screwed connections
Unless otherwise stated, all screws and bolts are self–locking.
15 Nm
75 Nm
42 Nm 45 Nm 75 Nm 16 Nm 425 Nm 85 Nm 75 Nm 85 Nm
19 Nm
425 Nm locked with Loctite Nr. 243
42 Nm
42 Nm
115 Nm
Figure 2
15 Nm
19 Nm
425 Nm locked with Loctite Nr. 243
42 Nm
75 Nm
210 Nm
42 Nm
Figure 3
115 Nm
42 Nm
Fig. 4
45 16 75 75 75 75 15 Nm 425 75 85
Nm Nm Nm Nm Nm Nm Nm Nm Nm
19 Nm
210 Nm
42 Nm
42 Nm
115 Nm
Figure 5
A 516.GB Page 21
3.3.5.5 Model D, Reeving 6/1
115 Nm
75 Nm
425 Nm
locked with Loctite 243
42 Nm
75 Nm
42 Nm
Figure 6
425 Nm
locked with Schnorrsicherung VS 20
15 Nm
75 Nm
19 Nm
425 Nm locked with Loctite Nr. 243
42 Nm
75 Nm
42 Nm
210 Nm
Figure 7
75 Nm
15 Nm
19 Nm
425 Nm
locked with Loctite 243
42 Nm
75 Nm
Figure 8
210 Nm
115 Nm
75 Nm
45 Nm 16 Nm
115 Nm 75 Nm 425 42 210 75 Nm 200 Nm
Nm Nm Nm locked with
Schnorrsicherung
19 Nm VS 20
425 Nm
locked with Schnorrsicherung VS 20
425 Nm
locked with Loctite 243
42 Nm
75 Nm
Figure 9
210 Nm
A 516.GB Page 23
3.3.5.9 Model Z, Reeving 8/2
115 Nm
75 Nm
16
45 Nm Nm
115 Nm 75 Nm 425 Nm 42 Nm 210 Nm 75 Nm 200 Nm
locked with
19 Nm Schnorrsiche-
rung VS 16
425 Nm
locked with Schnorrsicherung VS 20
425 Nm
locked with Loctite 243
42 Nm
75 Nm
210 Nm Figure 10
Figure 11
A 516.GB Page 25
4 Assembly
4.1 Preparations for Assembly 4.2.2 Electrical installation
Switch off power supply before starting work at any
electrical installation. Have work carried out by trained
personnel only.
4.1.1 Storage and interruption of oper- Connect the cables in the crane or trolley control panel
ation as shown in the circuit diagram.
If the crane system cannot be installed directly after Caution !
being delivered, or if the crane system will not be used EN 60204 must be observed!
for a longer period after being installed, or if there are
longer periods of intermission, the crane system has to
be stored in a dry and clean place. The rope hoist must be wired to a three phase fused
The crane system and its components have to be pro- disconnect or circuit breaker (per NEMA) properly
tected against damages, dirt and corrosion. sized and grounded. The maximum voltage deviations
If necessary, the manufacturer has to be asked for ap- are –5% from the lower and +5% from the upper volt-
propriate measures. age limit. The hoist can operated in the voltage ranges
shown.
See section 3.3.3 for cable cross section and fuse
protection.
4.2 Assembly Instructions
The hoist must be assembled only by specialist per-
sonnel.
4.2.2.1 Connection to the mains
The operator must connect the system to the mains
power supply in accordance with EN 60204.
4.2.1 Mecanical installation
The installation of ABUS–electric rope hoists must only
be carried out by authorized persons.
ABUS–electric wire rope hoists are supplied with read- 4.2.2.2 Mains switch
ily–mounted wire rope and with reeved lower block. The mainline disconnect switch must be wired so as to
The trolley gauge is adjusted to the desired gauge switch off all poles of the incoming power. The mainline
width of the double girder crane. The lateral play be- switch has to be installed at an easily accessible loca-
tween the trolley track and the wheel flanges should tion and must be secured against erroneous or unauth-
amount to 2–5 mm on each side. orized entry.
_________________________________
5 Commissioning
Before starting to operate the installation check the fol- Caution !
lowing points : Before starting any work on electrical sys-
Have all fastening screws been properly tightened tems during commissioning, the crane sys-
and locked ? tem must be disconnected from the power
Check the oil–level in the hoisting gear ! OIL supply.
Has transport caused damage to the wire rope ? The main switch or isolator switch must be switched off
Make sure the wire ropes fit tight at the screw and secured against unauthorized operation. Each of
thread undercuts of the rope drum? the switches is so designed that several padlocks can
Are the track ends equipped with operative buffers be used. Each person working on the crane can there-
? fore use his own padlock to secure the switches
Does the moving direction of the hook or the trolley against unauthorized operation.
correspond to the symbol at the pendant control ? Wiring diagrams with details of power supply to the
In case of a wrong moving sense, 2 phases of the crane are placed in the crane contactor box.
feed line must be exchanged; only then can the op-
erativeness of the emergency hoist–limit switch in 5.1 Electrical Systems
the contactor box be guaranteed.
The service life of electrical switchgear depends on the
For adjustment of the hoist limit switch see section
way in which it is operated. The crane operator must be
9.
informed that inching is not the best way of reaching a
Does the hoist limit switch cut off the highest and
precise position.
lowest hook position ?
As the crane has two speeds, inching operation can
largely be avoided.
A 516.GB Page 27
point must be clarified with the crane manu- mum load capacity, frequency of operation and ambi-
facturer before testing is started. ent conditions. At any rate, the crane must be
inspected at least once per year.
For example, cranes with high operating hours which
are often operated at full load capacity will need to be
inspected more frequently than cranes which are used
5.3.2 Inspections Following Major only occasionally for assembly work. In the case of oc-
Modifications casional use, one inspection per year will be adequate.
Following any major modifications to a crane system, It may also be necessary to reduce the inspection inter-
the system must be inspected by an inspector before it val in the case of dusty or corrosive atmospheres. Or-
is recommissioned. ganizations operating cranes must therefore determine
Examples of major modifications are: more frequent inspection intervals than one year taking
- changes in the type of power supply operating conditions into account. In case of doubt, the
- replacement of trolleys organization operating the crane must agree on in-
- conversion or modification of motors spection intervals with the crane manufacturer.
- increases in the load capacity of a crane
- extension of a crane track
- movement of cranes to other crane tracks in the The results of these inspections must be recorded in
case of stationary crane systems the crane test book.
- welding work on load–carrying structural compo- The main items to be covered by scheduled inspec-
nents tions are as follows:
- design changes to supporting structures - inspection of the identity of the crane (comparison
- modifications to components of supporting struc- with the data in the test book)
tures including for example crane track girders, - inspection of the condition of components and sys-
crane track supports, crane girders, trolley track tems and inspection for any damage, wear, cor-
girders, trolley frames, etc. rosion and other deterioration
- changes in operating conditions including the duty - inspection of the completeness and effectiveness
cycle and the load range of the crane of safety systems and brakes
- inspection of the crane track, including connec-
tions and supports
- for hoists: determination of the used–up portion of
5.3.3 Scheduled Inspections the theoretical service life
The plant must be inspected by an inspector as re- - repetition of inspection after any defects relevant to
quired in view of service conditions (utilization of maxi- safety have been remedied
_________________________________
6 Operation
6.1 Before Starting Work Slinging the load
Never lift loads exceeding the weight indicated on the
In general, the following points must be checked by the
load plate !
hoist operator not only before the hoist is started up
When slinging loads, also make sure not to acciden-
each day but also at the beginning of each shift and
tally topple over, break apart, slide or roll off the load
when a new crane operator starts work during a shift:
while lifting it up or putting it down.
Testing the travelling brakes
Testing the hoist brake Control switch
The crane operator sends out his control commands
Limit switches through the control switch which is a vital unit and
Does the lift limit switch cut off the lifting motion in the should therefore be handled with due care and atten-
top hook position in good time ? This has to be checked tion; do not let the pendant control swing uncontrolla-
by carefully approaching the top postion. Do the limit bly after use but only release it when it hangs down
switches provided for the delimitation of crane and vertically.
trolley travel work according to their preset functions ?
Test them by means of a careful start–up. Buffers
The crane is equipped with elastic buffers to absorb the
Wire ropes impact when the crane runs up against the crane track
Are the wire ropes still in good condition? For notes on end stops or collides with a neighbouring crane. Buffer
this point, see Section 7.4.1, ”Replacement condition impacts are special load cases which should be
for wire ropes”. avoided where possible. Cranes must not be run
against the end stops or other cranes intentionally as
7 Maintenance
The hoist must be inspected by an expert inspector at nents.
regular intervals determined in accordance with the op- It is expressly stated that ABUS will only accept any
erating and service conditions of the crane. Such in- warranty claims if only genuine ABUS parts have been
spections must be carried out at least once per year. used.
The results of all inspections must be recorded in the Irrespective of these requirements, the following main-
crane test book. It is recommended that the crane tenance schedule applies to the entire crane. The
should be maintained at least as frequently as it is in- maintenance intervals stated are based on single shift
spected. operation in accordance with FEM 9.511, with a 1AM
Operation in shifts affects both inspection and mainten- FEM group. In more difficult conditions, more frequent
ance intervals. maintenance will be necessary.
Crane trolley wheel bearings and crane motor gear- ABUS specialists will be pleased to assume responsi-
boxes have permanent lubrication and do not require bility for this maintenance work for you. Our experts are
any maintenance. experienced in maintenance and have the right tools
Hoists must be maintained in accordance with the ap- with them. Any wear parts are available either immedi-
propriate hoist operating instructions. ately or within a very short time.
During maintenance, any excessively worn or faulty Maintenance work may be performed by ABUS
parts must be replaced. specialists either on the basis of individual orders or
For safe and reliable operation, it is essential to use only within the framework of a maintenance contract.
genuine ABUS parts when replacing any compo-
A 516.GB Page 29
7.1 Classification of the gears 1. Medium operating time per working day:
Criteria for selection
2 x mean stroke (m) x cycle (1/h) x working time (h/day)
– What is the weight of the maximum load? tm =
– At what speed is the load to be lifted? 60 x lifting speed (m/min)
– To which height does the load have to be lifted?
– What are the operating conditions?
The following criteria are necessary for classing an 2. Nature of load:
electric rope hoist into a certain driving gear group acc. This load can be estimated with the aid of 4 ideal collec-
to DIN 15020 or FEM 9.511 and for selecting the suit- tive loads in dependence on the operating conditions
able type. (k = cubic mean value of the collective load in relation
to the load capacity).
10
% of operat. time 0
20
% of operat. time 0
0
% of operat. time
0
% of operat. time
7.2.2 Records of Service determine whether the hoist is still being utilised within
The organisation operating the standard hoist is re- its safe working period (S.W.P.).
sponsible for recording the actual type of service of the
hoist and documenting it at least once per year in the
test book. 7.2.4 Action to Be Taken on Reaching
Theoretical Service Life D
If the actual operating conditions are not verified or When a standard hoist has reached its theoretical ser-
such verification is not possible or operating conditions vice life, it must be overhauled by a specialist autho-
are only estimated, a full overhaul in accordance with rised by ABUS before it can continue in service.
Section 7.2.4 must be carried out 10 years after the
delivery of the standard hoist or earlier. During an overhaul, the authorised specialist must de-
termine:
- which parts must be replaced (the oil in the hoist
7.2.3 Assessment of Safe Working gearbox must be changed during all overhauls)
Period (S.W.P.) - the new theoretical service life D
During each scheduled inspection, the inspector re- - the new maximum interval before the next over-
sponsible for the inspection of the standard hoist must haul.
A 516.GB Page 31
7.3 Maintenance Schedule
every
at scheduled
Work to be performed daily 10
inspections
years
Inspection
Maintenance
Tightening
rope Trolley type d [mm] a,zul [mm] torque
socket [Nm]
7000.1 20.0 26 +1 107
The spacings must be checked during annual inspec-
tions. If the maximum a dimension is exceeded, the
rope socket and wedge must be replaced.
rope Following loading with the rated load (once only), the
claming spacing between the rope clamp and the nearest edge
wedge (rope wedge or pocket) should be at least 1 x rope dia-
meter.
Tightening torque values for the mounting of the rope
rope clamp are given in the table below.
a,zul
min 1 x d
d Figure 12
_________________________________
A 516.GB Page 33
7.4.2 Reeving 2/1 – D(B)
X
turned
7 5 6 1 3 4
Y
20 19 15 16 18 17 13 14
10
2
11
12
2 Figure 13
7.4.2.2 Installation of a new wire rope and of the 10. Fit the fixed cross member (16) to the cross
rope guide member mounting using bolts (17) and bearing
1. Pay out the original spare rope on the ground under bushings (18) and fasten it in place with the lid and
the electric wire rope hoist. Make sure the rope is screws (19,20).
twist– and buckling–free. Attach a rope clamp (12) to the free rope end.
For tightening torque values and rope clamp pro-
jections, see section 7.3.1.
Figure 14
2. Clean the rope drum (1) and evenly spray it with
chainlife S spray grease.
3. From below, push the wire rope (2) underneath the Figure 16
rope clamps (8, 9) until the rope end protrudes by
approx. 3 cm. Tighten the fastening screws accord- 11. Entirely coil up the rope and adjust the limit switch
ing to the prescribed torques. See chapter 3.3.5 to the highest and lowest position. See section 9
4. Tautly wind the rope around the drum (1) by ap- “Hoist limit switch”
prox. 6–8 turns. Make sure the rope is twist–free.
5. Grease the rope drum around the rope guide ring
with the special grease PG 75. 7.4.2.3 Removing twist
6. Spread the rope guide (3) and lead it over the drum Over the course of time, a twist may develop in wire
(1) in such a way that its threaded segments en- ropes. The result is that the bottom block twist when the
gage in the grooves of the rope drum and that the rope is unloaded.
ending rope line (2) exits through the guide slit. To eliminate this tendency to twist, the bottom block
7. Suspend tension parts (4) and adjust them by turn- must be lowered to the ground, the rope lock released
ing the eye bolt until the rope guide ring is fitting and the rope turned 180° ”tighter”. The rope must then
tight. be attached firmly to the bottom block again. The effec-
8. Twist the rope guide ring (3) until the guide edge tiveness of the action taken must be checked by raising
engages in the aperture of the catch (5) at the drum and lowering the hoist without a load.
casing. Then fasten the catch on the rope guide It may be necessary to repeat this procedure several
ring (6). times.
9. Reeve the free rope end without twisting and fasten
it in the rope socket (10 – 15) of the fixed point tie– With large hook path, a twist inhibitor is installed. See
bar (16). For reeving, see figure 15. section 7.4.7 and 7.4.7.1.
A 516.GB Page 35
7.4.3 Reeving 4/1 – D(B), DQA
X
turned Y
7 5 6 1 3 4
20 19 15 16 18 17 13 14
10
11
12
2
2
21
Y
Figure 17
Figure 18
2. Clean the rope drum (1) and evenly spray it with
chainlife S spray grease.
3. From below, push the wire rope (2) underneath the
rope clamps (8, 9) until the rope end protrudes by
approx. 3 cm. Tighten the fastening screws accord-
ing to the prescribed torques. See chapter 3.3.5
4. Tautly wind the rope around the drum (1) by ap- Figure 20
prox. 6–8 turns. Make sure the rope is twist–free. 11. Entirely coil up the rope and adjust the limit switch
5. Grease the rope drum around the rope guide ring to the highest and lowest position. See section 9
with the special grease PG 75. “Hoist limit switch”
6. Spread the rope guide (3) and lead it over the drum
(1) in such a way that its threaded segments en-
gage in the grooves of the rope drum and that the 7.4.3.3 Removing twist
ending rope line (2) exits through the guide slit. Over the course of time, a twist may develop in wire
7. Suspend tension parts (4) and adjust them by turn- ropes. The result is that the bottom block twist when the
ing the eye bolt until the rope guide ring is fitting rope is unloaded.
tight. To eliminate this tendency to twist, the bottom block
8. Twist the rope guide ring (3) until the guide edge must be lowered to the ground, the rope lock released
engages in the aperture of the catch (5) at the drum and the rope turned 180° ”tighter”. The rope must then
casing. Then fasten the catch on the rope guide be attached firmly to the bottom block again. The effec-
ring (6). tiveness of the action taken must be checked by raising
9. Reeve the free rope end without twisting and fasten and lowering the hoist without a load.
it in the rope socket (10 – 15) of the fixed point tie– It may be necessary to repeat this procedure several
bar (16). times.
A 516.GB Page 37
7.4.4 Reeving 6/1 – D(B)
X
turned
Figure 21
Figure 22
2. Clean the rope drum (1) and evenly spray it with
chainlife S spray grease.
3. From below, push the wire rope (2) underneath the
rope clamps (8, 9) until the rope end protrudes by Figure 24
approx. 3 cm. Tighten the fastening screws accord-
11. Entirely coil up the rope and adjust the limit switch
ing to the prescribed torques. See chapter 3.3.5
to the highest and lowest position. See section 9
4. Tautly wind the rope around the drum (1) by ap-
“Hoist limit switch”
prox. 6–8 turns. Make sure the rope is twist–free.
5. Grease the rope drum around the rope guide ring
with the special grease PG 75. 7.4.4.3 Removing twist
6. Spread the rope guide (3) and lead it over the drum Over the course of time, a twist may develop in wire
(1) in such a way that its threaded segments en- ropes. The result is that the bottom block twist when the
gage in the grooves of the rope drum and that the rope is unloaded.
ending rope line (2) exits through the guide slit. To eliminate this tendency to twist, the bottom block
7. Suspend tension parts (4) and adjust them by turn- must be lowered to the ground, the rope lock released
ing the eye bolt until the rope guide ring is fitting and the rope turned 180° ”tighter”. The rope must then
tight. be attached firmly to the bottom block again. The effec-
8. Twist the rope guide ring (3) until the guide edge tiveness of the action taken must be checked by raising
engages in the aperture of the catch (5) at the drum and lowering the hoist without a load.
casing. Then fasten the catch on the rope guide It may be necessary to repeat this procedure several
ring (6). times.
A 516.GB Page 39
7.4.5 Reeving 4/2 and 8/2 – D(B)
7 5 6 1 3 4
X
turned
2
Y
21
Bild 25
Figure 27
A 516.GB Page 41
7.4.6 Reeving 4/2, 6/2 and 8/2 –Z(B)
X
turned
7 5 6 1 3 4
2 Figure 29
7.4.6.1 Discarding of the rope and removal of 7.4.6.2 Installation of a new wire rope and of the
the rope guide rope guide
1. Let down and place bottom block. 1. In order to avoid kinks and twists, first pay out the
2. Set the hoist limit switches at both lifting gears so original spare wire rope in full length on the floor
that lowering beyond the lowest hook position is under the twin lifting gear.
possible.
3. Remove the catches (5 and 6) from both rope
guide rings (3) .
4. Loosen the straining parts (4) and demount both
rope guides (3).
5. Pull off the lifting motor connector from lifting gear 1
and completely reel off the rope end of lifting gear 2.
Detach rope clamps (8 and 9).
6. Plug the connector of the lifting motor into lifting
gear 1 and pull off the one from lifting gear 2. Let the
Figure 30
rope end of lifting gear 1 entirely reel off and detach
rope clamps (8). 2. Clean the rope drum (1) and evenly spray it with
chainlife S spray grease.
3. Plug the connector of the lifting motor into lifting
gear 1 and pull off the one from lifting gear 2. Push
the wire rope (2) from below under the rope clamps
Figure 31
A 516.GB Page 43
7.4.7 Twist inhibitor
With a HW of 45 m, 55 m and only for type 2/1, a twist
inhibitor is installed on the rope anchor point to com-
pensate for the twist caused by expansion.
Caution!
Twist inhibitors must only be used together
with twist---free ropes. Fixed point
cross head
Twist
7.4.7.1 Admissible wear on twist inhibitor inhibitor
The twist inhibitor requires very little maintenance. Du-
ring regular inspections, the twist inhibitor must be
checked for damage and wear. Especially the clea-
rance ”X” between the top and bottom part must be
checked. The results of this check must be recorded in
the crane test book.
If the clearance ”X” exceeds 4.0 mm, the twist inhibitor
must be replaced.
Rope
socket
Figure 34
A 516.GB Page 45
2. Remove ventilator cowl (1) with the motor being tighten the fastening screws (2) so that the dis-
switched off. tance plates (3) can still be removed.
3. Disconnect connectors for power supply to brake 6. Unscrew the 3 socket screws (4) from the magnet
and ventilation system. assembly (9) until they make firm contact with the
4. Undo 3 screws (16) and remove axial flow fan with motor bearing shield.
mounting plate (15). 7. Tighten the fastening screws (2) at 25 Nm. Then
5. Press out 0–ring (7). check the evenness of the air gap (at approx. 6
6. Unscrew the fastening screws (2). points) and readjust, if necessary.
7. Remove magnet assembly (9) complete with an- 8. Press in the 0–ring (7).
chor disk (6) and socket screws (4). 9. Fasten axial–flow fan with mounting plate (15) to
8. Remove brake rotor (5). magnet assembly (9) using 3 screws (16).
9. Remove locking ring (10). 10. Connect connectors for power supply to brake and
10. Pull off catch hub (8) by means of the pull–off de- ventilation system.
vice. 11. Install the ventilator cowl (1).
12. Carry out test tun to check brake and ventilation
system.
7.5.3 Installation of the brake
a) Motor with additional unit for ventilation, see Figu- 7.5.4 Replacement of Brake Rotor and
re 35 Anchor Disk
1. Slightly grease the motor shaft (13), install catch 1
hub (8) and secure with locking ring (10).
2. Push brake rotor (5) on the catch hub (8) and
check whether it can be slightly axially displaced.
3. Mount the magnetic body (9) complete with anchor
disk (6) and socket screws (4) and slightly tighten
by means of the 3 fastening screws (2).
4. Screw 3 socket screws (4) into the magnet assem- 2
bly (9). (screw–in depth limited)
5. Place distance plates (3) (thickness: 0.4 ± 0,05
mm) between the anchor plate (6) and the mag-
netic body (9) each next to the 3 socket screws (4);
tighten the fastening screws (2) so that the dis-
tance plates (3) can still be removed. Hubbe-
6. Unscrew the 3 socket screws (4) from the magnet grenzung
assembly (9) until they make firm contact with the
motor bearing shield.
7. Tighten the fastening screws (2) at 25 Nm. Then
check the evenness of the air gap (at approx. 6
points) and readjust, if necessary. Figure 37 1.1
8. Press in the 0–ring (7).
If the brake lining is worn to the point where dimension
9. Push on the ventilator (14) and secure with locking
t = 13.8 mm and it is no longer possible to set the re-
ring (11).
quired clearance, the brake rotor Figure 35 / 36, Item
10. Connect connectors for power supply to brake.
(5) and the anchor disk Figure 35 / 36, Item 6) must
11. Install the ventilator cowl (1).
both–be replaced.
12. Carry out test tun to check brake.
For the replacement of the brake rotor and anchor disk,
the following work is necessary:
b) Motor with additional unit for ventilation, see Figu- Dismantling of the brake in accordance with sub–sec-
re 36 tion 7.5.2
Dismantling of the anchor disk in accordance with the
1. Slightly grease the motor shaft (13), install catch following instructions:
hub (8) and secure with locking ring (10). 1. Screw the socket screws Figure 35 / 36, Item (4)
2. Push brake rotor (5) on the catch hub (8) and on the dismantled brake into the magnet assembly
check whether it can be slightly axially displaced. up to the stop.
3. Mount the magnetic body (9) complete with anchor 2. Remove and destroy the lifting travel limiting
disk (6) and socket screws (4) and slightly tighten screws Figure 37, Item (2) (The emergency lower-
by means of the 3 fastening screws (2). ing bar Figure 37, Item (1) will then be released.)
4. Screw 3 socket screws (4) into the magnet assem- 3. Remove and destroy the socket screws Figure 35 /
bly (9) 36, Item (4) (This rele ases the load on the springs
5. Place distance plates (3) (thickness: 0.4 ± 0,05 between the anchor disk Figure 35 / 36, Item (6)
mm) between the anchor plate (6) and the mag- and the magnet assembly Figure 35 / 36, Item (9)
netic body (9) each next to the 3 socket screws (4); 4. Remove anchor disk.
b
Figure 39
a
Figure 38
7.6.2 Replacing the brake lifter wing
with brake lining and the anchor
disk
The brakes of the drives are electro–magnetic disk 1. Remove the fan cowl (15) with the motor being
brakes. In order to guarantee a safe release, the brakes switched off. For this purpose, pull the snaps (11)
are equipped with an air gap limiter. The optimum air outwards and release them from their lock. The fan
gap width (a) is 0.4±0,05 mm. With increasing wear of cowl can then be pulled off in axial direction.
the brake lining, the air gap also becomes wider and 2. Hold the fan blade (6) and unscrew the self–locking
must thus be regularly checked and re–adjusted to adjusting nut (8).
achieve its optimum value (a)=0.4±0,05 mm. This 3. Pull off the brake fan blade (6).
A 516.GB Page 47
4. Unscrew the lift–limiting srews (5) and remove an- 7.7 Trolley brakes AZF
chor disk (7).
5. When fastening the new anchor disk (7) with the
lift–limiting screws (5) see to a correct fitting of the
pressure springs (3) and the O–ring (4).
6. Clean the motor shaft and slightly grease it.
7. Mount the new brake fan blade with brake lining
(6), hold it while fitting the self–locking adjusting
nut (8). 7 6 8 10 13
8. Set the air gap as described under 7.6.1 12
9. Mount the fan cowl (15).
10. Do a trial run to check the brakes.
11
A 516.GB Page 49
7.9 Problems, Causes and Remedies
All the malfunctions described below must be remedied by a specialist.
Problem Possible cause Remedy Remarks
Crane does not run Mains power not available Check current collector(s)
Check emergency OFF–button
and contactor K1
Motor does not turn in any Mains power not available Check voltage
direction and does not hum Mains connection not properly Connect all three phase
when the pendant control is made conductors correctly
operated
Faulty fuses Replace fuses Follow wiring diagram
Plug–in connectors for Plug–in Insert connectors firmly and lock
connectors for control not using bracket
properly inserted or not locked
Loose contacts in pendant Check wires for breakage; if Caution! All work
control, broken wires in power necessary replace control cable must be performed
supply line or in pendant control with all equipment
or, possibly, on travel drive disconnect from the
power supply
Motor does not turn in Faulty mains connection or Check mains connection
any direction but mains fude
hums when the pen-
dant control is oper- Faulty contactor Replace contactor Caution! All work
ated must be performed
WARNING with all equipment
disconnect from the
Motorwindings may
power supply
burn out
Motor starts slowly Break does not release, motor See breake problems
runs against closed breake
Crane movement only possible Faulty switch element in pendant Check and if necessary replace
on one direction control switch element
Breake does not release No power on brake coil, no AC Check and repair connections Caution! Pull mains
voltage at rectifier input Check motor connector out before
starting work!
Rectifire faulty or incorrectly Check DC voltage at brake coil; Follow wiring diagram
connected connect rectifier correctly or
replace rectifier
Brake coil has no electrical Replace brake coil Follow operating instructions
continuity and is fault
Braking distance too long Max. clearance reached (limit on Set brake and adjust clearance Follow operating instructions
lining wear)
Hoist does not lift the load Overload safety device actuated Check or correct setting
Reduce load to maximum load
capacity
The bottom block with 2/1, 4/1 The rope has twisted. Remove twist
or 6/1 reeving twists when it is see Section 7.4.2.3, 7.4.3.3 or
unloaded. 7.4.4.3.
Load lifted – brake fails LIS shuts down entire system Before the load can be lowered
(both) the brakes must be re-
leased manually. Then the load
must be lowered with caution.
A 516.GB Page 51
8 Disposal, Decommissioning
When ABUS products are no longer needed, they may and low maintenance requirements.
be disposed of in an environmentally compatible way. Details of the disposal and re–use of components are
ABUS produces cranes, hoists and crane system com- given in the following table:
ponents characterized by high quality, long service life
sealing
caps
connenction plug
with 6 poles
max 75
(125) turns
146 3 2 1
switch cams
=360 ˚
.1 1 .2 3 .3 5 planetary gear
2 4 6
C1
C2
ting
HW
Bu
A 516.GB Page 53
Adjustment table hoist limit switch
hoist type Gene- reeving trolley C–di- switch point 1 switch point 2 switch point 2 switch point 1 switch point 2
ration span men- Normal opera- ABULiner ABULiner ABULiner
[mm] sion tion operation operation operation
50 / 60 Hz 50 / 60 Hz 50 Hz 100 Hz 100 Hz
C1 A1 C2 A2 C2 A2 C1 A1 C2 A2
[mm] [mm] [mm] [mm] [mm] [mm]
GM 7000–D(B) 1 2/1 all 572 532 1007 632 1107 692 1167 690 1165 1290 1765
GM 7000–D(B) 1 4/1 all 500 480 945 530 995 560 1025 500 965 800 1265
GM 7000–D(B) 1 4/2 all 236 196 678 296 778 356 838 360 842 960 1442
= 2000 542 522 1272 562 1312 572 1322 540 1290 740 1490
GM 7000–D(B) 1 6/1
> 2000 722 702 1272 742 1312 752 1322 720 1290 920 1490
GM 7000–D(B) 1 8/2 all 521 501 991 551 1041 581 1071 520 1010 820 1310
GM 7000–Z(B) 1 4/2 all 473 433 903 533 1003 593 1063 595 1065 1195 1665
= 2000 542 512 1262 592 1342 612 1362 580 1330 980 1730
GM 7000–Z(B) 1 6/2
> 2000 722 692 1262 772 1342 792 1362 760 1330 1160 1730
8/2 = 2000 607 587 1337 637 1387 667 1417 610 1360 910 1660
GM 7000–Z(B) 1
(DL=400) > 2000 787 767 1337 817 1387 847 1417 790 1360 1090 1660
8/2 = 2000 480 460 1337 510 1387 540 1417 480 1357 780 1657
GM 7000–Z(B) 1
(DL=500) > 2000 740 720 1337 770 1387 800 1417 740 1357 1040 1657
8/2
A ..
GM 7000–Z(B) 64 64 85.5
(DL=400)
C ..
8/2
GM 7000–Z(B) 64 64 85.5
(DL=500)
Figure 44
Model D Default settings of lifting limit switches
The limit switches of hoists must be preset for dimen-
sions C1 ad C2 at the factory in accordance with the
above table on the basis of reeving, frequency range
and mode of operation.
Caution!
A ..
A 516.GB Page 55
adjustment by means of screw adjustment nuts adapter
driver Ø 6mm 4 3 2 1 0 push--- on shaft
sealing
caps
connection plug
with 8 poles
max 75
(125) turns
4 3 2 1
switch cams
146
.1 1 .2 3 .3 5 .4 7 planetary gear
=360 ˚
C1
2 4 6 8
C2
.2 operating limit switch lifting
Bo
hook path
effective
HW
Bu
A 516.GB Page 57
10 Declaration of Conformity
applies if this wire rope hoist is operated as an independent machine.
Manufacturer’s declaration
applies if this wire rope hoist is installed in another machine. In addition, the wire rope hoist must nut be commis-
sioned until it has been confirmed that the machine in which the wire rope hoist is installed conforms in its entirety
with the provisions of the stated EC directives in the version in force on the date of issue.
Department Manager
Wire rope hoist
Gummersbach, 16.08.2001 ___________________________ _________________________
Signature of authorized person indication for the subscriber
A 516.GB
The lubrication has to be executed according to the maintenance schedule (see section 7.3)
: Established from the production. When the lubricant is changed, the mechanism has to be washed. In case of relubricating with a grease with other
basis, the old grease has to be taken way before.
E100 –
Ener- KOK–35
Filling of E160 Glissando Centoplex Alvania
grease GOK–35
grease AZP130 EP 0 CX 4/375 EP (LF) 1
LS 0 DIN 51502
AZP280
Trolley drives
Deafluid
Electric Filling of AZF400 – Autran II D od. II ATF D ATF
ATF 22 4011 or Donax TA
Wire rope Lubricant 500 DX II E 25233 21611 Type II D
5060
hoists
External
splines con- Wheel, Klüberpa- No DIN
Glissando Retinax
nection, joint drum, ste 46 MR DX PBC norms
M EP 2 LX2
and plug bolt, Grease, wall side 401 existant
locating pin with the
hand
Wire rope,
rope drum,
disk spring
assemblies Lubricant Unolit Grafloscon Chainlife Malleus Machine
can Chain EP 1 S KL 23 GL 95 lubricant
S 1 Plus
Chain
sprocket
Electric
Chain
hoists Deafluid
Filling of Autran DX II D od. II ATF D ATF
Gearing ATF 22 4011 od. Donax TA
Lubricant II E 25233 21611 Type II D
5060
Page 59