Kransysteme

Installation, Operation and Maintenance Instructions

for

ABUS – Wire rope hoist Model Type Overload protection

device type

 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

Serial No. _______________

Manufacturer
Stand : 16. August 2001

ABUS Kransysteme GmbH Tel. ##49 2261 / 37–0

Sonnenweg 1 Fax. ##49 2261 / 37247
D – 51647 Gummersbach

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

GM 7320 H6 – 20 1. 41. 081. D 280

track wheel diameter

trolley; type: D, DB, DQA; Z, ZB
model generation
hook path (m)
rope reeving 4/1
motive power unit group 1 Am
rope speed (m/min)
type of motor
load capacity (kg x 10–2)
model size
line of products

Model D Model Z

Page 2 Data : 16.08.2001

Contents
1 General . . . . . . . . . . . . . . . . . . . 5 3.3.4 Weights and Dimensions . . . . . . . . . . 16

1.1 General Notes on Hazards . . . . . . . . . 5 3.3.5 Tightening torques . . . . . . . . . . . . . . . . 20

1.2 Use for the Intended Purpose . . . . . . 5

1.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . 5 4 Assembly . . . . . . . . . . . . . . . . . 26
1.4 Other Notes . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Preparations for Assembly . . . . . . . . . 26
4.1.1 Storage and interruption of operation 26
2 Safety . . . . . . . . . . . . . . . . . . . . 6 4.2 Assembly Instructions . . . . . . . . . . . . . 26

2.1 General Notes . . . . . . . . . . . . . . . . . . . . 6 4.2.1 Mecanical installation . . . . . . . . . . . . . 26

2.1.1 Requirements . . . . . . . . . . . . . . . . . . . . 6 4.2.2 Electrical installation . . . . . . . . . . . . . . 26

2.2 Safety Instructions for the User . . . . . 6

5 Commissioning . . . . . . . . . . . 26
3 Description . . . . . . . . . . . . . . . 9 5.1 Electrical Systems . . . . . . . . . . . . . . . . 26

3.1 Components . . . . . . . . . . . . . . . . . . . . . 9 5.2 Checking the Direction of

Rotation of Motors . . . . . . . . . . . . . . . . 27
3.1.1 Trolley frame . . . . . . . . . . . . . . . . . . . . . 9
5.3 Inspection and Testing
3.1.2 Hoist motor with brake . . . . . . . . . . . . 9 (Responsibilities of the operator) . . . . 27
3.1.3 Hoisting gear . . . . . . . . . . . . . . . . . . . . . 9 5.3.1 Inspection Before
3.1.4 Rope drive . . . . . . . . . . . . . . . . . . . . . . . 9 Initial Commissioning . . . . . . . . . . . . . 27
3.1.5 Limit of lift . . . . . . . . . . . . . . . . . . . . . . . 10 5.3.2 Inspections Following
Major Modifications . . . . . . . . . . . . . . . 28
3.1.6 Overload protection . . . . . . . . . . . . . . . 10
5.3.3 Scheduled Inspections . . . . . . . . . . . . 28
3.1.7 Trolley travelling gear . . . . . . . . . . . . . . 10
3.2 Electrical equipment . . . . . . . . . . . . . . 10
3.3 Technical Data . . . . . . . . . . . . . . . . . . . 11 6 Operation . . . . . . . . . . . . . . . . . 28
3.3.1 Sound Emissions . . . . . . . . . . . . . . . . . 11 6.1 Before Starting Work . . . . . . . . . . . . . . 28
3.3.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . 11 6.2 Normal Operation . . . . . . . . . . . . . . . . . 29
3.3.3 Electrical Data of Motors . . . . . . . . . . . 12 6.2.1 Other Operating Conditions . . . . . . . . 29

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

7.2.2 Records of Service . . . . . . . . . . . . . . . . 31 7.7.2 Dismounting the brake . . . . . . . . . . . . 49

7.2.3 Assessment of Safe 7.7.3 Installation of the brake . . . . . . . . . . . . 49

Working Period (S.W.P.) . . . . . . . . . . . . 31 7.7.4 Replacement of brake rotor,
anchor disk and friction plate . . . . . . . 49
7.2.4 Action to Be Taken on Reaching
Theoretical Service Life D . . . . . . . . . . 31 7.8 Changing Lubricant . . . . . . . . . . . . . . . 49
7.3 Maintenance Schedule . . . . . . . . . . . . 32 7.9 Problems, Causes and Remedies . . . 50
7.3.1 Rope wedge protrusion, 7.10 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 51
spacing to the rope clamp . . . . . . . . . 33
7.4 Wire rope and rope guide . . . . . . . . . . 33
7.4.1 Maturity for discarding . . . . . . . . . . . . . 33
8 Disposal, Decommissioning 52
7.4.2 Reeving 2/1 – D(B) . . . . . . . . . . . . . . . . 34
7.4.3 Reeving 4/1 – D(B), DQA . . . . . . . . . . 36 9 Adjustment instruction
7.4.4 Reeving 6/1 – D(B) . . . . . . . . . . . . . . . . 38 hoist limit switch . . . . . . . . . . 53
7.4.5 Reeving 4/2 and 8/2 – D(B) . . . . . . . . 40 9.1 Hoist limit switch GPK 75.3–1
with 3 switch points . . . . . . . . . . . . . . . 53
7.4.6 Reeving 4/2, 6/2 and 8/2 –Z(B) . . . . . 42
9.1.1 Adjustment instructions . . . . . . . . . . . . 53
7.4.7 Twist inhibitor . . . . . . . . . . . . . . . . . . . . 44
9.1.2 Adjust switch points . . . . . . . . . . . . . . . 55
7.5 Hoisting gear brake . . . . . . . . . . . . . . . 45
9.2 Adjustment instruction hoist
7.5.1 Adjustment of the air–gap . . . . . . . . . . 45 limit switch GP with option
7.5.2 Dismounting the brake . . . . . . . . . . . . 45 “operating limit switch”
with 4 switch points . . . . . . . . . . . . . . . 55
7.5.3 Installation of the brake . . . . . . . . . . . . 46
9.2.1 Adjustment instructions . . . . . . . . . . . . 55
7.5.4 Replacement of Brake
Rotor and Anchor Disk . . . . . . . . . . . . 46 9.2.2 Adjust switch points . . . . . . . . . . . . . . . 57

7.5.5 Emergency Lowering of Load . . . . . . 47

7.6 Trolley brakes AZP . . . . . . . . . . . . . . . . 47 10 Declaration of Conformity . . 58
7.6.1 Adjustment of the air gap . . . . . . . . . . 47
7.6.2 Replacing the brake lifter wing
with brake lining and the anchor disk 47 11 Lubricants table . . . . . . . . . . . 59

Page 4 Data : 16.08.2001

1 General
1.1 General Notes on Hazards
Except for products designed solely for operation by
human agency, the product is designed for operation
on industrial power systems. When the product is in
operation, there will be hazardous exposed live compo-
nents and hazardous rotating or moving components
inside the product.
Contact with concentrated acids or caustic solutions
may result in damage to plastic components or the cor-
rosion of metal parts; any parts affected by such dam-
age or corrosion must be replaced in good time.
Severe personal injury or damage to property may
occur as a result of
- the forbidden removal of covers
- improper use
- incorrect operation
- inadequate repair and maintenance.
Failure to comply with the safety instructions given in
this Manual may lead to injury or even to fatal acci-
dents.
The product may present hazards to life and limb if it is
operated other than for the intended purpose or by
non–trained or inadequately trained personnel.
The operator of the product must ensure that operation
and maintenance personnel are instructed in good
time before starting work with or on the product.
Because of the risk of injury due to clothes or parts of
the body catching on or being drawn into the equip-
ment, personnel working with the product must not
wear any loose clothing, unprotected long hair or jewel-
lery. Rings (!) must not be worn when working with the
product!
Persons under the influence of alcohol, drugs or medi-
cines impairing their reactions must not perform any
work on or with the product.
The product must not be operated in hazardous atmos-
pheres except where the product has been specifically
designed for such use.
During operation:
Compliance with all the precautions required by this
manual before, during and after commissioning and all
the general safety requirements, especially those con-
cerning operational safety and accident prevention, is
essential. Failure to comply with these precautions and
requirements may lead to personal injury or even fatal
accidents.
The use of non–approved or unsuitable tools or auxili-
ary equipment may result in injury.
A 516.GB
In connection with the movement of components,
squeeze and shear points may occur on the equipment
and between the equipment and its surroundings. You
must therefore always keep sufficient safety distance
from moving or rotating components to prevent parts of
the body, clothes or your hair from being caught in the
equipment.
Extreme heat (e.g. during welding), sparking as a result
of the use of detergents or open flames in the vicinity of
components which are combustible or may be de-
formed by heat (e.g. wood, plastics, oil, grease, electri-
cal systems or wiring) must be avoided. Otherwise,
there may be a risk of fire resulting in the development
of toxic fumes or damage to insulation or parts of the
equipment.
1.2 Use for the Intended Purpose
The system described in this document is fit for the
carrying and lifting of loads subject to the maximum
load capacity and the FEM or load group for which it
has been designed. Load capacity, FEM group and
load group are indicated in the data sheet or test book
of each product.
”Use for the intended purpose” also includes strict
compliance with the installation, operating and main-
tenance instructions.
Among other things, equipment is not considered to
have been used for the intended purpose if
- the maximum admissible load capacity is ex-
ceeded,
- loads are pulled diagonally,
- loads are torn away, dragged or pulled,
- it is used to catch falling loads,
- it is used to lift persons with or without loads.
- inching operation
- reversing operation (operation of opposite direc-
tion when system is in motion)
- intentional operation against emergency end stops
(See also Section 2.2 ”Safety Instructions for Users”.)
1.3 Warranty
ABUS will assume no liability for any damage to the
crane or hoist resulting from operation abnormal or
work performed improperly or by unauthorized person-
nel or for claims by third parties.
Caution !
If you modify any components under your
own responsibility, assemble components
other than in accordance with the installation
instructions and/or plans or use any compo-
nents other than genuine ABUS compo-
nents, ABUS will be released from any war-
ranty obligations for the entire equipment.
Page 5
For the safe and reliable operation of the product and
for the retention of warranty rights, it is essential to use
genuine ABUS parts when you need spare parts.
Safe operation is only possible within the service life
stated if the crane/hoist is operated within its rating and
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
book or data sheet for the product concerned.
Notes on the theoretical service life of the hoist are
given in the appropriate installation, operation and
maintenance instructions.
ABUS products must be maintained and repaired only
by trained, authorized, specialist personnel.
It is recommended that repair and mainten-
ance work should be carried out by the ABUS
service department.
_________________________________
2 Safety
2.1 General Notes
The installation, operation and maintenance instruc-
tions must always be stored near the ABUS travelling
crane and must be available to operating personnel at
all times.
Operating, maintenance and repair personnel must
have read and understood the operating instructions
before starting work.
The organization operating an ABUS crane is respon-
sible for supervising operating personnel to ensure that
travelling cranes are properly operated.
2.1.1 Requirements
ABUS products manufactures and tested and must be
operated in accordance with the requirements of Euro-
pean and German codes, standards and regulations.
The following codes, standards and regulations are ap-
plicable and must be observed by the operator:
98/37/EC Machinery Directive
DIN EN 292 Safety of Machines
DIN 15018 Cranes: Principles for Steel Struc-
tures
DIN 15020 Basic Principles for Rope Drives
EN 60204 Part 32 Electrical equipment of machines;
requirements for hoists
Page 6
1.4 Other Notes
The declaration of conformity / manufacturer’s
declaration you’ll find in section 10..
The year of manufacture is stated in the data
sheet in the test book.
The product will only continue to perform reliably to
your satisfaction in the long term if it is operated, main-
tained and repaired by persons assigned to these
tasks by the operator. Such persons must be familiar
with the installation, operation and maintenance in-
structions and the applicable safety regulations and
accident prevention regulations.
The operating instructions must be available to the per-
sonnel responsible for repair and maintenance work at
all times.
ABUS–products are largely maintenance–free.
The little maintenance work which is required must be
performed in accordance with the operating instruc-
tions and the maintenance schedule.
If you wish, maintenance work can be performed by the
ABUS service department.
VBG 8 Accident prevention regulations
for winches, hoists and traction
systems
VBG 9 Accident prevention regulations
for cranes
VBG 9a Accident prevention regulations
for load carrying systems
ZH 1/27 Principles for the testing of cranes
and the codes and standards referred to in these docu-
ments.
2.2 Safety Instructions for the
User
Caution !
For safe working, it is absolutely essential for
operation and maintenance personnel to re-
ceive thorough instruction in the require-
ments of this Installation, Operation and
Maintenance Manual.
Release all locking devices before starting work.
Switch off the crane switch in hazardous situations.
At the end of a day’s work, put the load suspension de-
vices such as grab or magnet on the ground, pull up the
empty hook, and home the crane. Any locks which are
available must be operated and the crane switch must
be switched off.
All accident prevention regulations and regulations is-
sued by local authorities, especially the operating in-
structions for cranes indicated on the respective plate
have to be adhered to when operating or attending to
the crane.
Data : 16.08.2001
The instruction plate has to be affixed in a position
where it is clearly visible to the crane operator at any
time.
The Federal Republic of Germany therefore requires
the application of UVV (Accident Prevention Regula-
tions) (VBG 9) for ”Cranes”; any other country or region
must observe the following instructions for the user of
ABUS–crane installations and ABUS–trolleys running
on rails.
These notes mainly consist of excerpts from the Ger-
man Accident Prevention Regulations, VBG 8, for
”Winches, hoisting and pulling devices”, article IV
”operation” (as amended on 01.04.90), and VBG 9
”cranes”, article IV ”operation” (as amended on
01.04.83).
The term ”crane” which will be used in the text below,
also stands for trolleys running on rails. ”Crane oper-
ator” is the person operating the crane whereas ”crane
attendant” means the person responsible for the main-
tenance of the crane or the trolley.
If the operator or operating establishment of cranes
have to abide to existing national regulations, the fol-
lowing notes shall remain valid insofar as they do not
expressly conflict with these national regulations.
1. Before the initial start–up of a crane or before re-
operation after major modification have been ef-
fected, cranes must be inspected by an expert
commissioned by the contractor.
2. Cranes must be inspected by an expert commis-
sioned by the contractor at least once a year and if
need be, more frequently, depending on their oper-
ating conditions and the conditions within the fac-
tory.
(See Section 5.3.3 ”Scheduled Inspections”.)
3. Results of such inspections must be put down in
writing.
4. The following groups of persons may be employed
as crane operators or crane attendants:
1. persons who have completed their 18th year of
age.
2. persons who are physically and mentally suited
to those activities
3. persons who have been instructed in the oper-
ation and maintenance of a crane and who were
able to furnish proof of their qualifications to the
company.
4. persons who can be expected to reliably fulfill the
tasks assigned to them.
These persons are required to have been ap-
pointed crane operators or attendants by the es-
tablishment.
5. Before starting daily work, the crane operator must
check on the performance of the brakes and
emergency stop devices and see whether he can
detect any defect on the crane.
The crane operator must proceed with great care
regardless of the existence of safety devices. These
devices are to provide the necessary safety in the
event of operator’s mistakes.
6. The crane operator must stop crane operation as
soon as any defect jeopardizing operating safety
becomes apparent.
A 516.GB
7. The crane operator must notify the responsible
supervisor –and at the end of his shift also the relief
operator – of any defect detected on the crane.
8. Controlling equipment must only be operated from
operating stands
9. The crane operator has to make sure that
1. before releasing power supply to the drive units,
all control units are in switch–off or neutral position
2. before leaving the operating stand all controlling
units have been put back to switch–off or neutral
position and energy supply has been stopped.
10. In the event of storm or when finishing work, the
crane operator must make sure that cranes ex-
posed to wind are properly secured by means of
locking devices.
For cranes in outdoor service, see attachment A
258.GB.
11. If the crane operator cannot observe the load in all
crane movements or if in the case of no–load oper-
ation he cannot keep an eye on the load suspen-
sion device, he may only operate the crane by fol-
lowing the instructions of a second person. This
does not apply to program–controlled cranes.
12. If need be, the crane operator must give warning
signals.
13. The load must not be lifted over passenger areas
unless detachment or falling of the load or of parts
of the load from the load suspension device are ex-
cluded.
14. To move a manually slung load the crane operator
must wait until the corresponding signal has been
given of the signalman, of a guard posted on or
near the (crane) installation or by a competent per-
son who had been appointed by the contractor. In-
sofar as the communication with the crane operator
requires the use of signals, the latter have to be
previously agreed upon between the crane oper-
ator and such competent person.
15. As long as the load is suspended from the hook, the
crane operator must keep the controlling unit within
easy reach.
16. Regular crane operations approaching the final
position which is limited by an emergency stop de-
vice are only admissible if an additional stopping
device is series connected.
With program–controlled cranes all working and
traffic areas must be safeguarded in such a way
that the crane in motion or any falling object do not
cause damage to persons or objects.
17. Crane loads may not exceed the admissible maxi-
mum weight.
18. The contractor has to make sure that when placing
objects to be lifted near the crane there is a safe dis-
tance of at least 0,5 m between the external mov-
able parts of the crane and these objects.
19. (1) In the event of an overlap of the working ranges
of several cranes, the contractor or his agent must
previously set up a work schedule and create all the
conditions for a trouble–free communication be-
tween the crane operators.
(2) If one load has to be jointly lifted by several
cranes, the contractor or his agent must previously
Page 7
 set up the corresponding work schedule and the
procedure be carried out under the supervision of a
person appointed by the contractor.
20. Maintenance work must only be carried out after
the crane has been switched off. Any maintenance
work that cannot be carried out from the ground
must be effected from working stands or platforms .
When carrying out maintenance or repair work at
the crane, the crane must be unloaded and the
mains or isolating switch (protected against un-
authorized switching) be switched off. Each of
these switches can be provided with several pad-
locks. This enables each person working on the
crane to lock and secure the crane against unauth-
orized switching–on by means of his own padlock.
For the maintenance of and repair work at cranes
with no servicing platform a stationary or movable
working platform must be available.
21. (1) For repair and maintenance work on cranes and
in the crane travelling area the contractor or his
agent must see to and supervise the following
safety measures
1. The crane must be switched off and safe-
guarded against erroneous or unauthorised reclos-
ing.
2. If there is any risk of objects falling down, the risk
area underneath the crane must be shut off or by
posting guards to the site.
3. The crane must be safeguarded against colli-
sion with other cranes by means of rail stoppers or
by stationing guards on the crane in motion.
4. The crane operators of adjoining cranes, if need
be also the ones of adjoining craneways, must be
informed about the kind and location of operations.
This applies as well to the relief in the case of shift
change–over.
(2) If the aforementioned safety measures have not
been taken properly or were not arranged for on
operational grounds or turn out to be insufficient,
the contractor or his agent must arrange for differ-
ent or supplementary measures to be taken and
supervise the execution thereof.
22. (1) Unauthorized persons are not allowed to walk
onto a crane.
(2) Cranes which are being operated by a crane
operator shall only be entered or left with the con-
sent of the crane operator or when the crane has
come to a standstill.
23. It is strictly prohibited to carry passengers together
with the load or by means of the load suspension
devices.
24. The load may not be directly slung by means of the
Page 8
hoisting rope or chain; hoisting ropes or chains or
such like shall not be bent or pulled over sharp
edges .
25.
It is prohibited to drag or to pull the load
sideways or to move vehicles with the
load or the load suspension devices.
Caution !
The crane must not be used for breaking
loose loads, pulling, dragging, or trans-
versely pulling loads since this could re-
sult in overloading.
Loads that have got stuck must only be pulled off by
cranes equipped with overload protection.
26. After repair or maintenance work or after any work
carried out in the crane travelling area, crane oper-
ation shall only be started if the contractor or his
agent have consented to do so. Before releasing a
crane for operation, the contractor or his agent
must make sure that
1. the aforementioned jobs have been completed
2. conditions for a safe operation of the whole
crane have been restored
3. all persons having participated in such work
have left the crane.
27. When operating additional crane equipment
and/or accoutrements, the corresponding special
instructions may have to be followed. If additional
appliances and accoutrements are subsequently
installed on the crane, it is the responsibility of the
establishment <contractor> operating the crane
to check whether such additional equipment is ad-
missible and suited for the crane installation.
28. When using a lifting beam, it is essential to ensure
that the beam is not pulled under the main girder.
The limit switches must be set in accordance with
the new conditions.
Caution !
Otherwise, there is a risk of rope break-
age and accidents.
Make sure the control devices operate correctly when
starting the crane or working at the main current supply
cables; wrongly connected wires will disturb operation
and create the danger of accident.
The operator must ensure that the workplace is ad-
equately lit
Data : 16.08.2001
3 Description
3.1 Components
3.1.1 Trolley frame
ABUS Series D, DB, DQA, Z and ZB electric wire rope
hoists are equipped with a trolley frame made from
welded steel sections or sheets.
The connection between the main girder and the trolley
track girder is jointed to ensure that all four wheels are
evenly loaded when the hoist is not loaded.
In the case of type DQA, the connection between the
main girder and the end carriage is articulated on one
side and bolted on the other side.
The bolts must not be tightened using power drills and
the ”angle of rotation” method must not be used.
After they have been tightened using the correct torque
value, the main girder connection bolts may be loos-
ened and tightened again in the course of assembly.
However, if the crane is dismantled after some time in
service, new bolts of the same quality must be used
when it is reassembled; the old bolts must be
scrapped.
In the case of larger bolt patterns, the bolts must be
tightened alternately up to about 60 % of the specified
torque value and then tightened to the full value in a
second step. The screws at the ends of the connection
assembly must be tightened to the full torque last.

3.1.2 Hoist motor with brake

The hoisting gear is driven by a 12 pole, dual speed
squirrel cage motor with integral D.C. restified mag-
netic disc brake. Insulation class F, protection type IP
54. Due to the pole changing there is a standard preci-
Fig. 1 sion hoisting speed in the ratio of approx. 1:6 or approx.
1:10 to the main hoisting speed. The asbestos–free
The contact surfaces on the trolley track girders and the brake lining achieves a service life of approx. 1x106
main girder connection plates (4) must be free from shiftings.
rust, dust, oil, paint and other foreign matter. The con-
tact surfaces are marked *** in Figure 1.
3.1.3 Hoisting gear
The bolted joint consists of the following components:
The transmission of the motor speed to the rope drum
(1) Hexagon bolt M 20
is effected through the spur gear in a light alloy casing.
Material 10.9 DIN 6914
The helical gear wheels are hardened and polished or
(2) Washer HV 21
shaved and run in a closed oil bath with lifetime lubrica-
Material C 45 DIN 6916
tion.
(3) Hexagon nut M 20
Material 10 DIN 6915
(4) Connection plate Ultra sonical 3.1.4 Rope drive
S 235 JRG2 DIN EN 10025
The rope drive corresponds to the FEM–calcuation
Note: Only bare, non-galvanized bolts may be used.
rules for series hoists. The load hook with safety catch
Position the main and trolley track girders with the holes complies with DIN 15400. None of the bearing points
matching and insert the high-strength connection bolts need maintenance. The rope guide is made of wear re-
(1) (M20, material 10.9) through the hand holes into the sisting, sliding synthetic material and provides trouble–
trolley track girders. The washers (2) under the bolt free rope reel–off and careful treatment of the rope and
head and the nut are essential for effective joints. the rope drum. The high–tensile hoisting rope in
Tighten the nuts (3) from the outside using a torque special design has considerably higher breaking resis-
wrench. tance and life than a rope of conventional design and
structure. That is why only original ropes from the
The torque required for the M20 bolts is 554 Nm. manufacturer’s should be used as spare parts.

A 516.GB Page 9
3.1.5 Limit of lift
The lift is limited in the highest and lowest hook position
by means of a rotary geared limit switch directly
coupled to the rope drum. The standard hoist limit
switch (–S31) comes with 3 switching contacts which
have the following functions:
1. upper limit safety switch – lifting
2. emergency limit switch – lifting
3. emergency limit switch – lowering
The upper limit safety switch (–S31.1) interrupts power
to the mainline contactor (K1). This switch point is set
by the manufacturer, sealed with lead, and must only
be reset by authorized personnel. If for any reason the
emergency limit switch (–S31.2), fails to limit the travel
of the block in the up direction, the crane is shut down
by this upper limit safety switch. Subsequent operation
of the hoist should only be attempted by a trained ser-
vice technician.
If the hoist is run to the lowest and/or highest hook posi-
tion se veral times per day, the switch or the circuit must
be equipped for operational cut–off.
If an operational upper limit switch is installed as de-
scribed above, the emergency upper limit should be
checked at the beginning of each work shift. This is ac-
complished with a ”test” button located on the push
button station.
For adjustment of the hoist limit switch see section 9.
3.1.6 Overload protection
This device is installed to prevent overloading of the
electric wire rope hoist.
Details of other types of overload safety devices are
given in the separate operating instructions attached.
3.1.7 Trolley travelling gear
Maintenance–free, directly driven flanged wheels
made by drop–forging or of spherulitic graphite iron
and positioned in roller bearings assure good and
smooth running and also take care of the running
treads. The trolley drive wheels are directly driven by 2,
TEFC dual wound squirrel cage motors. D.C. rectified
disc brakes are included as standard. Due to the pole
Page 10
changing, there is a standard precision hoisting speed
in the ratio of approx. 1:4 to the main hoisting speed.
The hoist is balanced at the factory by counterweight-
ing the side opposite the hoist motor.
3.2 Electrical equipment
The contactor box is installed on the wire rope hoist and
has IP 54 protection.
Reversing contactors are fitted with mechanical inter-
locks.
Delay circuits (time delay: 0.5 sec.) are connected to all
reversing contactors, preventing inching operation and
protecting the contactors, motors and mechanical sys-
tems.
A special ABUS circuit generally prevents the start–up
current of the motors from being switched off. This ex-
tends the service life of the contactors.
All wire rope hoists are equipped with motor circuit
breakers for motor protection. The motor circuit
breakers are set at the factory in accordance with the
rated motor current and sealed.
In addition, all ABUS wire rope hoists are equipped with
bimetal relays for protection against high winding tem-
peratures.
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
the brake linings.
Contactor boxes are equipped with ducted circuitry on
mounting boards.
If maintenance is required, contactors may be removed
from their mounts without disconnecting any wiring.
The consistent use of plug–type connectors ensures
easy, rapid and safe electrical connection.
ABUS modules are fitted with easy plug–type con-
nectors ready for operation as standard equipment.
Work on electrical systems must be performed only by
qualified personnel. The power supply must be discon-
nected before starting work.
Details of the electrical equipment are given in the cir-
cuit diagram.
Data : 16.08.2001
3.3 Technical Data Trolley gear
Quantity
Type Trolley
[g]
3.3.1 Sound Emissions GM 7000.1
As the distance between the noise source and the AZP 200 ≤30 m/min 160
21–D(B)
workplace is normally not fixed in the case of hoists, the
sound power level is quoted in addition to the required GM 7000.1
AZP 280 ≤20 m/min 240
sound pressure level figure (given for a distance of 4 m 41–D(B)
in this case). GM 7000.1
AZP 280 >20 m/min 160
The sound power level may be used to calculate the 41–D(B)
sound pressure level at any distance (under free field GM 7000.1
conditions ± 2dB (A)). AZF 400 ≤30 m/min 2000
41–DQA
Hoist Sound pressure Sound power GM 7000.1
AZP 200 ≤30 m/min 160
Type level LP,m dB (A) level 42–D(B)
at 4 m LW,m db (A) GM 7000.1
AZF 400 ≤30 m/min 2000
GM 7000.1 70 90 61–D(B)

The measurements made were based on DIN 45635, GM 7000.1

AZP 280 ≤20 m/min 240
Part 61 and were made by the substitution method 82–D(B)
using a sound power source. GM 7000.1
AZP 280 >20 m/min 160
82–D(B)
GM 7000.1
3.3.2 Lubricants AZP 280 ≤20 m/min 240
42–Z(B)
All roller bearings are provided with lifetime lubrication.
GM 7000.1
The hoist gear is oil–lubricated. AZP 280 >20 m/min 160
42–Z(B)
The gears of the trolley drives are provided with a fluid-
ized–grease lubrication. GM 7000.1
AZF 400 ≤30 m/min 2000
The wire rope and the rope drum must be lubricated in 62–Z(B)
compliance with the indications of the maintenance GM 7000.1
schedule. AZF 400 ≤ 40 t 2000
82–Z(B)
The locating pins at the hoisting gear, the external
GM 7000.1
splines at the rope drum and at the travel drives have to AZF 500 ≤ 80 t 3200
82–Z(B)
be lubricated when the drive is replaced or in the
course of a general overhaul.
The hinge and socket pins of twin rail trolleys must also
be lubricated during a general overhaul.
Details of lubricants are given in section 11.

3.3.2.1 Quantities of lubricants 3.3.2.2 Alternative Lubricants

The quantities of lubricants in the hoists are stated in For a table of series and alternative lubricants, see sec-
the following table. tion 11.

Hoist gear Caution!

Type Quantity [litres] Synthetic oils must not be mixed with mineral--
based oils.
GM 7000.1 27

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.

a) Performance data (50 Hz)

P [kW] ED [%] c/h cos FN cos FA
1,2 / 8 60 420 0,50 / 0,88 0,84 / 0,79
1,5 / 10 60 360 0,53 / 0,91 0,84 / 0,79
L6
1,9 / 12,5 50 300 0,62 / 0,92 0,84 / 0,79
2,4 / 16 40 240 0,67 / 0,94 0,84 / 0,79
2,4 / 16 60 420 0,50 / 0,88 0,84 / 0,79
3,0 / 20 60 360 0,53 / 0,91 0,84 / 0,79
H6
3,8 / 25 50 300 0,62 / 0,92 0,84 / 0,79
4,8 / 32 40 240 0,67 / 0,94 0,84 / 0,79
2,0 / 12,6 60 360 0,63 / 0,80 0,85 / 0,80
M6 2,5 / 16 50 300 0,66 / 0,84 0,85 / 0,80
3,0 / 20 40 240 0,75 / 0,91 0,85 / 0,80
4,0 / 25,2 60 360 0,63 / 0,80 0,85 / 0,80
U6 5,4 / 32 50 300 0,66 / 0,84 0,85 / 0,80
6,0 / 40 40 240 0,75 / 0,91 0,85 / 0,80
b) Rated current (IN) and starting current (IA) A with 50 Hz

220–240V 380–415V 460–500V

P [kW]
IN IA IN IA IN IA
1,2 / 8 17,4 / 25 40 / 270 10 / 14,5 23 / 155 8,3 / 12,1 19 / 129
1,5 / 10 17,4 / 31 40 / 270 10 / 18 23 / 155 8,3 / 15 19 / 129
L6
1,9 / 12,5 17,4 / 38 40 / 270 10 / 22 23 / 155 8,3 / 18,3 19 / 129
2,4 / 16 19,1 / 51 40 / 270 11 / 29,5 23 / 155 9,2 / 24,6 19 / 129
2,4 / 16 34,8 / 50 80 / 540 20 / 29 46 / 310 16,6 / 24,2 38 / 258
3,0 / 20 34,8 / 62 80 / 540 20 / 36 46 / 310 16,6 / 30 38 / 258
H6
3,8 / 25 34,8 / 76 80 / 540 20 / 44 46 / 310 16,6 / 36,6 38 / 258
4,8 / 32 38,2 / 102 80 / 540 22 / 59 46 / 310 18,4 / 49,2 38 / 258
2,0 / 12,6 21 / 47 43 / 415 12 / 27 25 / 240 10 / 22,5 21 / 201
M6 2,5 / 16 21 / 47 43 / 415 12 / 32 25 / 240 10 / 27 21 / 201
3,0 / 20 23,4 / 69 43 / 415 13,5 / 39,5 25 / 240 11,3 / 33 21 / 201
4,0 / 25,2 42 / 94 86 / 830 24 / 54 50 / 480 20 / 45 42 / 402
U6 5,0 / 32 42 / 110 86 / 830 24 / 64 50 / 480 20 / 54 42 / 402
6,0 / 40 46,8 / 138 86 / 830 24 / 79 50 / 480 22,6 / 66 42 / 402

M6 and U6 drives have separate ventilation as standard equipment.

Page 12 Data : 16.08.2001

c) Performance data (60 Hz)
P [kW] ED [%] c/h cos FN cos FA
1,44 / 9,6 60 420 0,50 / 0,88 0,84 / 0,79
1,8 / 12 60 360 0,53 / 0,91 0,84 / 0,79
L6
2,28 / 15 50 300 0,62 / 0,92 0,84 / 0,79
2,88 / 19,2 40 240 0,67 / 0,94 0,84 / 0,79
2,88 / 19,2 60 420 0,50 / 0,88 0,84 / 0,79
3,6 / 24 60 360 0,53 / 0,91 0,84 / 0,79
H6
4,56 / 30 50 300 0,62 / 0,92 0,84 / 0,79
5,76 / 38,4 40 240 0,67 / 0,94 0,84 / 0,79
2,4 / 15,1 60 360 0,63 / 0,80 0,85 / 0,80
M6 3,0 / 19,2 50 300 0,66 / 0,84 0,85 / 0,80
3,6 / 24 40 240 0,75 / 0,91 0,85 / 0,80
4,8 / 30,2 60 360 0,63 / 0,80 0,85 / 0,80
U6 6,0 / 38,4 50 300 0,66 / 0,84 0,85 / 0,80
7,2 / 48 40 240 0,75 / 0,91 0,85 / 0,80
d) Rated current (IN) and starting current (IA) A with 60 Hz
208–230V 440–480V 550–600V
P [kW]
IN IA IN IA IN IA
1,44 / 9,6 18,3 / 27 42 / 283 10 / 14,5 23 / 155 8,3 / 12,1 19 / 129
1,8 / 12 18,3 / 33 42 / 283 10 / 18 23 / 155 8,3 / 15 19 / 129
L6
2,28 / 15 18,3 / 40 42 / 283 10 / 22 23 / 155 8,3 / 18,8 19 / 129
2,88 / 19,2 20,1 / 54 42 / 283 11 / 29,5 23 / 155 9,2 / 24,6 19 / 129
2,88 / 19,2 36,6 / 54 84 / 566 20 / 29 46 / 310 16,6 / 24,4 38 / 258
3,6 / 24 36,6 / 66 84 / 566 20 / 36 46 / 310 16,6 / 30 38 / 258
H6
4,56 / 30 36,6 / 80 84 / 566 20 / 44 46 / 310 16,6 / 36,6 38 / 258
5,76 / 38,4 40,2 / 108 84 / 566 22 / 59 46 / 310 18,4 / 49,2 38 / 258
2,4 / 15,1 22 / 48 45 / 438 12 / 27 25 / 240 10,0 / 22,5 21 / 201
M6 3,0 / 19,2 22 / 59 45 / 438 12 / 32 25 / 240 10,0 / 27 21 / 201
3,6 / 24 25 / 73 45 / 438 13,5 / 39,5 25 / 240 11,3 / 33 21 / 201
4,8 / 30,2 44 / 96 90 / 876 24 / 54 50 / 480 20,0 / 45 42 / 402
U6 6,0 / 38,4 44 / 118 90 / 876 24 / 64 50 / 480 20,0 / 54 42 / 402
7,2 / 48 50 / 146 90 / 876 27 / 79 50 / 480 26,6 / 66 42 / 402

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)

Trolley n [min–1] ED [%] c/h P [kW] cos FN cos FA

AZP 200 630/2750 40 240 0,14/0,65 0,67/0,86 0,80/0,82
AZP 280 630/2750 40 240 0,14/0,65 0,67/0,86 0,80/0,82
AZP 280 620/2760 40 240 0,18/0,80 0,65/0,84 0,75/0,85
AZF 400 v=5/20
700/2830 50 300 0,18/0,75 0,59/0,85 0,80/0,82
GL 40 t
AZF 400 v=7.5/30
700/2840 50 300 0,25/1,10 0,59/0,88 0,80/0,81
GL 40 t
AZF 400 v=5/20
700/2840 50 300 0,25/1,10 0,59/0,88 0,80/0,81
GL > 40 t
AZF 400 v=7.5/30
690/2820 50 300 0,37/1,50 0,61/0,87 0,81/0,81
GL > 40 t
AZF 500 v=5/20
700/2840 60 240 0,25/1,10 0,59/0,88 0,82/0,81
GL 63 t
AZF 500 v=7.5/30
690/2820 60 240 0,37/1,50 0,61/0,87 0,81/0,81
GL 63 t
AZF 500 v=5/20
690/2820 60 240 0,37/1,50 0,61/0,87 0,81/0,81
GL=80 t
AZF 500 v=7.5/30
700/2850 60 240 0,55/2,20 0,58/0,87 0,78/0,82
GL=80 t

b) Rated current (IN) and starting current (IA) A with 50 Hz

n 220–240V 380–415V 460–500V

Trolley
[min–1] IN IA IN IA IA IA
AZP 200 630/2750 1,17/2,90 2,50/14,1 0,68/1,68 1,45/8,10 0,53/1,34 1,16/6,40
AZP 280 630/2750 1,17/2,90 2,50/14,1 0,68/1,68 1,45/8,10 0,53/1,34 1,16/6,40
AZP 280 620/2760 1,58/3,70 3,00/17,5 0,92/2,10 1,75/10,1 0,73/1,69 1,40/8,10
AZF 400 v=5/20
700/2830 1,58/3,30 3,80/16,5 0,95/1,95 2,30/9,80 0,75/1,55 1,80/7,90
GL 40 t
AZF 400 v=7.5/30
700/2840 2,00/4,60 5,10/24,3 1,30/2,65 3,00/13,5 0,98/2,20 2,40/11,6
GL 40 t
AZF 400 v=5/20
700/2840 2,00/4,60 5,10/24,3 1,30/2,65 3,00/13,5 0,98/2,20 2,40/11,6
GL > 40 t
AZF 400 v=7.5/30
690/2820 ––– ––– 1,60/3,55 4,00/16,5 ––– –––
GL > 40 t
AZF 500 v=5/20
700/2840 2,00/4,60 5,10/24,3 1,30/2,65 3,00/13,5 0,98/2,20 2,40/11,6
GL 63 t
AZF 500 v=7.5/30
690/2820 ––– ––– 1,60/3,55 4,00/16,5 ––– –––
GL 63 t
AZF 500 v=5/20
690/2820 ––– ––– 1,60/3,55 4,00/16,5 ––– –––
GL=80 t
AZF 500 v=7.5/30
700/2850 ––– ––– 2,30/28,2 3,00/13,5 ––– –––
GL=80 t

Page 14 Data : 16.08.2001

c) Performance data (50 Hz)

Trolley n [min–1] ED [%] c/h P [kW] cos FN cos FA

AZP 200 780/3360 40 240 0,17/0,78 0,66/0,87 0,76/0,78
AZP 280 780/3360 40 240 0,17/0,78 0,66/0,87 0,76/0,78
AZP 280 765/3330 40 240 0,22/0,96 0,64/0,85 0,69/0,81
AZF 400 v=6/24
850/3430 50 300 0,22/0,90 0,56/0,83 0,80/0,82
GL 40 t
AZF 400 v=9/36
850/3435 50 300 0,30/1,30 0,60/0,86 0,78/0,79
GL 40 t
AZF 400 v=6/24
850/3435 50 300 0,30/1,30 0,58/0,88 0,78/0,79
GL > 40 t
AZF 400 v=9/36
845/3415 60 240 0,44/1,80 0,61/0,86 0,78/0,78
GL > 40 t
AZF 500 v=6/24
850/3440 60 240 0,30/1,30 0,60/0,86 0,78/0,79
GL 63 t
AZF 500 v=9/36
845/3415 60 240 0,44/1,80 0,61/0,86 0,78/0,78
GL 63 t
AZF 500 v=6/24
845/3415 60 240 0,44/1,80 0,61/0,86 0,78/0,78
GL=80 t
AZF 500 v=9/36
850/3440 60 240 0,66/2,65 0,57/0,89 0,73/0,79
GL=80 t

d) Rated current (IN) and starting current (IA) A with 60 Hz

n 208–230V 440–480V 550–600V

Trolley
[min–1] IN IA IN IA IN IA
AZP 200 780/3360 1,35/3,60 3,15/18,1 0,68/1,80 1,55/8,90 0,53/1,40 1,27/7,20
AZP 280 780/3360 1,35/3,60 3,15/18,1 0,68/1,80 1,55/8,90 0,53/1,40 1,27/7,20
AZP 280 765/3330 1,90/4,50 3,70/22,4 0,94/2,25 1,85/11,0 0,72/1,75 1,52/9,00
AZF 400 v=6/24
850/3430 2,00/4,10 5,50/24,2 0,90/1,90 2,40/10,7 ––– –––
GL 40 t
AZF 400 v=9/36
850/3435 2,55/5,75 7,45/34,5 1,30/2,65 3,20/15,6 ––– –––
GL 40 t
AZF 400 v=6/24
850/3430 2,00/4,10 5,50/24,2 0,90/1,90 2,40/10,7 ––– –––
GL > 40 t
AZF 400 v=9/36
850/3435 ––– ––– 1,48/3,50 4,40/19,0 ––– –––
GL > 40 t
AZF 500 v=6/24
850/3440 2,55/5,75 7,45/34,5 1,30/2,65 3,20/15,6 1,48/3,30 4,30/20,8
GL 63 t
AZF 500 v=9/36
845/3415 ––– ––– 1,48/3,50 4,40/19,0 ––– –––
GL 63 t
AZF 500 v=6/24
845/3415 ––– ––– 1,48/3,50 4,40/19,0 ––– –––
GL=80 t
AZF 500 v=9/36
850/3440 ––– ––– 2,10/4,50 6,70/30,5 ––– –––
GL=80 t

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)

3.3.4.1 Load data for trolley track

load case H load case HZ load case HS

load
capacity FSKA 2) FPUKR 4) in (kN/trolley) at
Rmax 1) RKAmin 1) FMKA 3)
(kg) (kN / trolley
t ll
(kN) (kN/wheel) (kN/trolley) 5/20 m/min 7,5/30 m/min
track)
GM 7000.1 2/1–D trolley drive AZP 200
8000 26,4 6,8 8,3 4,1 25,9 41,2
10000 31,3 6,8 9,7 4,1 27,9 43,2
12500 37,4 6,8 12,6 4,1 30,3 45,6
16000 46,1 6,8 14,4 4,1 33,8 49,0
20000 55,8 6,8 17,6 4,1 37,8 51,5
GM 7000.1 2/1–DB trolley drive AZP 200
8000 27,8 8,2 8,7 4,9 29,1 47,8
10000 32,7 8,2 10,1 4,9 31,0 49,9
12500 38,8 8,2 12,8 4,9 33,4 52,3
16000 47,4 8,2 14,8 4,9 36,9 55,7
20000 57,2 8,2 17,9 4,9 40,8 56,3

Page 16 Data : 16.08.2001

 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 4/1–D trolley drive AZP 280
16000 48 8,6 14,0 5,2 36,0 44,0
20000 58 8,6 17,0 5,2 40,0 49,0
25000 70 8,6 21,0 5,2 44,0 55,0
32000 88 8,6 26,0 5,2 51,0 57,0
40000 107 8,6 32,0 5,2 58,0 ––
GM 7000.1 4/1–DB trolley drive AZP 280
16000 50 10,1 14,0 6,1 38,0 52,0
20000 60 10,1 17,0 6,1 42,0 56,0
25000 72 10,1 21,0 6,1 47,0 57,5
32000 90 10,1 26,0 6,1 53,0 59,0
40000 109 10,1 32,0 6,1 58,0 ––
GM 7000.1 4/1–DQA trolley drive AZF 400
16000 57 10,9 12,0 6,5 38,0 53,0
20000 71 10,9 15,0 6,5 38,0 53,0
25000 88.3 10,9 18,0 6,5 38,0 53,0
32000 113 10,9 22,0 6,5 38,0 53,0
40000 141 10,9 26,0 6,5 38,0 53,0
GM 7000.1 4/2–D trolley drive AZP 200
8000 26,2 6,5 6,7 4,0 25,6 40,5
10000 31,1 6,5 8,0 4,0 27,5 42,4
12500 37,2 6,5 9,6 4,0 30,0 44,9
16000 46,0 6,5 11,7 4,0 33,4 48,3
20000 55,6 6,5 14,3 4,0 37,3 51,1
GM 7000.1 4/2–DB trolley drive AZP 200
8000 27,6 8,0 7,1 4,8 28,9 47,0
10000 32,5 8,0 8,3 4,8 31,0 49,0
12500 38,6 8,0 9,9 4,8 33,2 51,5
16000 47,2 8,0 12,2 4,8 36,6 55,0
20000 57,0 8,0 14,7 4,8 40,6 55,7
GM 7000.1 6/1–D trolley drive AZF 400
25000 75 12,0 19,0 7,2 38,5 49,0
32000 93 12,0 24,0 7,2 38,5 49,0
40000 112 12,0 30,0 7,2 38,5 49,0
50000 137 12,0 36,0 7,2 38,5 49,0
63000 168 12,0 43,0 7,2 38,5 ––
GM 7000.1 6/1–DB trolley drive AZF 400
25000 75 13,7 20,0 8,2 40,0 52,0
32000 93 13,7 24,5 8,2 40,0 52,0
40000 112,2 13,7 30,0 8,2 40,0 52,0
50000 137 13,7 36,0 8,2 40,0 52,0
63000 168,1 13,7 44,0 8,2 40,0 ––

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 ––

Page 18 Data : 16.08.2001

 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–Z trolley drive AZF 400
25000 78 15,8 19,0 9,5 42,0 56,0
32000 95 15,8 23,0 9,5 42,0 56,0
40000 116 15,8 27,0 9,5 42,0 56,0
GM 7000.1 8/2–ZB trolley drive AZF 400
25000 78,5 17,1 19,0 10,5 43,0 59,0
32000 96 17,1 23,0 10,5 43,0 59,0
40000 116 17,1 27,5 10,5 43,0 59,0
GM 7000.1 8/2–Z trolley drive AZF 500
50000 140 16,0 34,0 9,5 50,0 66,0
63000 172 16,0 42,0 9,5 50,0 66,0
80000 213 16,0 52,0 9,5 50,0 66,0
GM 7000.1 8/2–ZB trolley drive AZF 500
50000 141 17,6 35,0 10,6 51,0 69,0
63000 173 17,6 43,0 10,6 51,0 69,0
80000 214 17,6 53,0 10,6 51,0 69,0
1) Wheel load without coefficient
2) Load across track to DIN 4132 --- 3.2.1. per trolley track
3) Load along track to DIN 4132 --- 3.2.2.
4) Total buffer force if ABUS buffers are used

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.

3.3.5.1 Model D, Reeving 2/1

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

3.3.5.2 Model D, Reeving 4/1

15 Nm

45 Nm 16 Nm 115 Nm 75 Nm 425 Nm 42 Nm 210 Nm 200 Nm

19 Nm
425 Nm locked with Loctite Nr. 243
42 Nm
75 Nm

210 Nm
42 Nm

Figure 3

Page 20 Data : 16.08.2001

3.3.5.3 Model DQA, Reeving 4/1

554 425 42 Nm 75 Nm 42 Nm 115 Nm 42 Nm 115 Nm

16 45 200 Nm
Nm Nm Nm Nm locked with
19 Nm 425 Nm Schnorrsi-
425 Nm cherung
locked with locked with VS 16
Loctite Nr. 243 Schnorrsicherung
VS 20

115 Nm

42 Nm

Fig. 4

3.3.5.4 Model D, Reeving 4/2

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

16 Nm 42 Nm 45 Nm 115 Nm 75 Nm 425 42 Nm 210 Nm 75 Nm 200 Nm

Nm locked with Schnorrsi-
cherung VS 16
19 Nm

425 Nm
locked with Loctite 243

42 Nm
75 Nm

42 Nm

Figure 6
425 Nm
locked with Schnorrsicherung VS 20

3.3.5.6 Model D, Reeving 8/2

15 Nm

75 Nm

45 Nm 16 Nm 75 Nm 115 Nm 75 Nm 425 Nm 210 Nm 75 Nm 75 Nm 200 Nm

19 Nm
425 Nm locked with Loctite Nr. 243
42 Nm
75 Nm

42 Nm
210 Nm
Figure 7

Page 22 Data : 16.08.2001

3.3.5.7 Model Z, Reeving 4/2

75 Nm

15 Nm

75 Nm 45 Nm 115 Nm 16 Nm 425 Nm 42 Nm 210 Nm 200 Nm

locked with
210 Nm Schnorrsiche-
locked with Schnorrsicherung VS 16
rung VS 16

19 Nm

425 Nm
locked with Loctite 243

42 Nm

75 Nm
Figure 8
210 Nm

3.3.5.8 Model Z, Reeving 6/2

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

Page 24 Data : 16.08.2001

3.3.5.10 Model DB and ZB

42 Nm (Model DB) 42 Nm 300 Nm

locked with Loctite 243
75 Nm (Model ZB)

Figure 11

A 516.GB Page 25
4 Assembly
4.1 Preparations for Assembly
4.1.1 Storage and interruption of oper-
ation
If the crane system cannot be installed directly after
being delivered, or if the crane system will not be used
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 crane system and its components have to be pro-
tected against damages, dirt and corrosion.
If necessary, the manufacturer has to be asked for ap-
propriate measures.
4.2 Assembly Instructions
The hoist must be assembled only by specialist per-
sonnel.
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-
ily–mounted wire rope and with reeved lower block.
The trolley gauge is adjusted to the desired gauge
width of the double girder crane. The lateral play be-
tween the trolley track and the wheel flanges should
amount to 2–5 mm on each side.
_________________________________
5 Commissioning
Before starting to operate the installation check the fol-
lowing points :
 Have all fastening screws been properly tightened
and locked ?
 Check the oil–level in the hoisting gear ! OIL
 Has transport caused damage to the wire rope ?
 Make sure the wire ropes fit tight at the screw
thread undercuts of the rope drum?
 Are the track ends equipped with operative buffers
? fore use his own padlock to secure the switches
 Does the moving direction of the hook or the trolley
correspond to the symbol at the pendant control ?
In case of a wrong moving sense, 2 phases of the
feed line must be exchanged; only then can the op-
erativeness of the emergency hoist–limit switch in
the contactor box be guaranteed.
 For adjustment of the hoist limit switch see section
9.
Does the hoist limit switch cut off the highest and
lowest hook position ?
Page 26
4.2.2 Electrical installation
Switch off power supply before starting work at any
electrical installation. Have work carried out by trained
personnel only.
Connect the cables in the crane or trolley control panel
as shown in the circuit diagram.
Caution !
EN 60204 must be observed!
The rope hoist must be wired to a three phase fused
disconnect or circuit breaker (per NEMA) properly
sized and grounded. The maximum voltage deviations
are –5% from the lower and +5% from the upper volt-
age limit. The hoist can operated in the voltage ranges
shown.
See section 3.3.3 for cable cross section and fuse
protection.
4.2.2.1 Connection to the mains
The operator must connect the system to the mains
power supply in accordance with EN 60204.
4.2.2.2 Mains switch
The mainline disconnect switch must be wired so as to
switch off all poles of the incoming power. The mainline
switch has to be installed at an easily accessible loca-
tion and must be secured against erroneous or unauth-
orized entry.
Caution !
Before starting any work on electrical sys-
tems during commissioning, the crane sys-
tem must be disconnected from the power
supply.
The main switch or isolator switch must be switched off
and secured against unauthorized operation. Each of
the switches is so designed that several padlocks can
be used. Each person working on the crane can there-
against unauthorized operation.
Wiring diagrams with details of power supply to the
crane are placed in the crane contactor box.
5.1 Electrical Systems
The service life of electrical switchgear depends on the
way in which it is operated. The crane operator must be
informed that inching is not the best way of reaching a
precise position.
As the crane has two speeds, inching operation can
largely be avoided.
Data : 16.08.2001
5.2 Checking the Direction of
Rotation of Motors
When the motors are first switched on, the direction of
rotation must be compared with the rotation direction
required by the control system.
The direction of rotation depends on the phase se-
quence of the mains connection. After unlocking the
red mushroom switch, the precision lifting button
must be pressed first. Never press the lowering but-
ton first. If the hook is raised or no movement is pro-
duced because the upper limit switch had already
been tripped, the phase sequence is correct. Press
the precision lowering button as a countercheck. If
the equipment does not move in the direction indicated
on the controls, the connections of two phase conduc-
tors of the power supply cable must be interchanged.
If you do not ensure that motors rotate in the correct
direction, damage may occur.
5.3 Inspection and Testing
(Responsibilities of the operator)
Caution !
If tests and inspections are not conducted by
specialist personnel of the crane manufac-
turer and third parties are commissioned for
such work, the organization operating the
crane is responsible for selecting suitably
qualified personnel commissioning and con-
ducting the tests.
Requirements to be met by inspectors:
- comprehensive knowledge of the mechanical and
electrical systems of cranes
- sufficient experience in the assembly and repair of
cranes
- comprehensive knowledge of the state of the art of
crane testing and of the applicable codes, stan-
dards and should the occasion arise savety regula-
tions e.g. accident prevention regulations
The requirements of all applicable national regulations
must also be taken into consideration, such as the acci-
dent prevention regulations for cranes in Germany.
5.3.1 Inspection Before Initial Commis-
sioning
The acceptance test before initial commissioning must
be performed by the inspector on a crane ready for
operation under normal operating conditions.
During the inspection, no–one must be exposed to
avoidable risks.
Personnel required for operation during the inspection
including crane operators and load handlers must be
provided by the organization operating the crane and
must be suitably qualified for the work which is in-
volved.
All persons involved in the inspection must be able to
communicate effectively with each other during the in-
spection. If direct communication between control
points and load handling points is not possible, the or-
A 516.GB
ganization operating the crane must provide suitable
communication systems.
The inspection must include at least the following
items:
- inspection of the crane test book you see in the list
of contents
- inspection of compliance between the completed
system and the technical data
- inspection of compliance with all applicable safety
rules, for example: accident prevention regulations
- testing of all safety systems and precautions and all
brakes for effectiveness
- inspection of possible to requireing safety dis-
tances
- dynamic load test at 1.1 times the rated load capac-
ity of the crane
This test must be conducted at rated speed and cover
the most unfavourable load positions of the crane.
- In the case of slewing jib cranes, the most unfavour-
able position is the position with the jib fully ex-
tended.
- In the case of all other cranes, such as bridge
cranes, ceiling–mounted travelling cranes and sus-
pended monorail systems, the most unfavourable
positions are with the trolley positioned at the
centre of the span or operated in the trolley start–up
distance.
If the crane control system allows several simultaneous
movements (such as lifting and crane travel), these
movements must be performed simultaneously during
the test. It is not admissible to use a spring balance or a
similar device between the crane and the ground an-
chor as a substitute for a test load.
- Static load test (no further movement apart from lift-
ing movement). This test has also to be carried out
under most unfavourable load conditions.
Cranes on which all movements are produced by
human effort must be tested:
- at 1.5 times rated load.
- All other cranes must be tested at 1.25 times rated
load.
The load must be lifted slowly until it is just above
ground level. There must be no permanent deforma-
tion or evident defects in the crane.
- The results of the inspection must be recorded in
the crane test book.
- The inspector must decide whether the system
may be commissioned.
- The organization operating the crane is respon-
sible for remedying any defects detected during
the inspection. The inspector must decide whether
a further inspection is required after the defects
have been remedied.
Caution !
The acceptance test in accordance with this
Section is not intended as a substitute for any
other tests which may be required by appli-
cable national regulations. Such tests must
be conducted in addition to the acceptance
test.
Where national testing regulations require
higher test loads than those specified in this
Section for dynamic or static testing, this
Page 27
 point must be clarified with the crane manu-
facturer before testing is started.
5.3.2 Inspections Following Major
Modifications
Following any major modifications to a crane system,
the system must be inspected by an inspector before it
is recommissioned.
Examples of major modifications are:
- changes in the type of power supply
- replacement of trolleys
- conversion or modification of motors
- increases in the load capacity of a crane
- extension of a crane track
- movement of cranes to other crane tracks in the
case of stationary crane systems
- welding work on load–carrying structural compo-
nents
- design changes to supporting structures
- modifications to components of supporting struc-
tures including for example crane track girders,
crane track supports, crane girders, trolley track
girders, trolley frames, etc.
- changes in operating conditions including the duty
cycle and the load range of the crane
5.3.3 Scheduled Inspections
The plant must be inspected by an inspector as re-
quired in view of service conditions (utilization of maxi-
_________________________________
6 Operation
6.1 Before Starting Work
In general, the following points must be checked by the
hoist operator not only before the hoist is started up
each day but also at the beginning of each shift and
when a new crane operator starts work during a shift:
Testing the travelling brakes
Testing the hoist brake
Limit switches
Does the lift limit switch cut off the lifting motion in the
top hook position in good time ? This has to be checked
by carefully approaching the top postion. Do the limit
switches provided for the delimitation of crane and
trolley travel work according to their preset functions ?
Test them by means of a careful start–up.
Wire ropes
Are the wire ropes still in good condition? For notes on
this point, see Section 7.4.1, ”Replacement condition
for wire ropes”.
Page 28
mum load capacity, frequency of operation and ambi-
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
only occasionally for assembly work. In the case of oc-
casional use, one inspection per year will be adequate.
It may also be necessary to reduce the inspection inter-
val in the case of dusty or corrosive atmospheres. Or-
ganizations operating cranes must therefore determine
more frequent inspection intervals than one year taking
operating conditions into account. In case of doubt, the
organization operating the crane must agree on in-
spection intervals with the crane manufacturer.
The results of these inspections must be recorded in
the crane test book.
The main items to be covered by scheduled inspec-
tions are as follows:
- inspection of the identity of the crane (comparison
with the data in the test book)
- inspection of the condition of components and sys-
tems and inspection for any damage, wear, cor-
rosion and other deterioration
- inspection of the completeness and effectiveness
of safety systems and brakes
- inspection of the crane track, including connec-
tions and supports
- for hoists: determination of the used–up portion of
the theoretical service life
- repetition of inspection after any defects relevant to
safety have been remedied
Slinging the load
Never lift loads exceeding the weight indicated on the
load plate !
When slinging loads, also make sure not to acciden-
tally topple over, break apart, slide or roll off the load
while lifting it up or putting it down.
Control switch
The crane operator sends out his control commands
through the control switch which is a vital unit and
should therefore be handled with due care and atten-
tion; do not let the pendant control swing uncontrolla-
bly after use but only release it when it hangs down
vertically.
Buffers
The crane is equipped with elastic buffers to absorb the
impact when the crane runs up against the crane track
end stops or collides with a neighbouring crane. Buffer
impacts are special load cases which should be
avoided where possible. Cranes must not be run
against the end stops or other cranes intentionally as
Data : 16.08.2001
part of normal operation. The buffers themselves must
be inspected regularly (at least during the regular in-
spection of the crane; see Section 7.3) to ensure that
they are serviceable. Buffers with cracks or permanent
deformation are not serviceable.
6.2 Normal Operation
Standard ABUS rope hoists are designed for operation
in enclosed buildings with normal atmospheres and
normal temperatures between –5°C and 40°C. Tem-
peratures may reach +65°C on a short–term basis.
If a hoist is required for other operating conditions, this
must be stated so that the hoist can be checked for
operation under such conditions and appropriate ac-
tion can be taken.
_________________________________
7 Maintenance
The hoist must be inspected by an expert inspector at
regular intervals determined in accordance with the op-
erating and service conditions of the crane. Such in-
spections must be carried out at least once per year.
The results of all inspections must be recorded in the
crane test book. It is recommended that the crane
should be maintained at least as frequently as it is in-
spected.
Operation in shifts affects both inspection and mainten-
ance intervals.
Crane trolley wheel bearings and crane motor gear-
boxes have permanent lubrication and do not require
any maintenance.
Hoists must be maintained in accordance with the ap-
propriate hoist operating instructions.
During maintenance, any excessively worn or faulty
parts must be replaced.
For safe and reliable operation, it is essential to use only
genuine ABUS parts when replacing any compo-
A 516.GB
6.2.1 Other Operating Conditions
1. If the crane is to be operated outside the tempera-
ture range stated above, a grease or oil grade ap-
propriate for the actual operating conditions must
be used in the gearboxes of any motors.
Lubricant grades for normal operating conditions
are listed in Section 3.3.2 ”Lubricants”.
2. Cranes which are to be operated wholly or partly in
the open air require canopies over the motors,
hoists and contactor boxes.
If the admissible loads on the hoist are exceeded as
a result of wind, care must be taken to ensure that
the hoist is not exposed to such loads in operation.
In this case, the hoist may be fixed in position by
suitable devices (such as wind locks).
3. ABUS electric rope hoists are not suitable for condi-
tions where they may be exposed to explosive or
corrosive substances.
Other operating conditions include:
4. Electric rope hoists service in humid atmospheres
(e.g. in paper mills)
5. Electric rope hoists service with skirt entry or strip
curtain.
6. Handling of molten substances
7. Magnet operation
8. Guided load
nents.
It is expressly stated that ABUS will only accept any
warranty claims if only genuine ABUS parts have been
used.
Irrespective of these requirements, the following main-
tenance schedule applies to the entire crane. The
maintenance intervals stated are based on single shift
operation in accordance with FEM 9.511, with a 1AM
FEM group. In more difficult conditions, more frequent
maintenance will be necessary.
ABUS specialists will be pleased to assume responsi-
bility for this maintenance work for you. Our experts are
experienced in maintenance and have the right tools
with them. Any wear parts are available either immedi-
ately or within a very short time.
Maintenance work may be performed by ABUS
specialists either on the basis of individual orders or
within the framework of a maintenance contract.
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).

Load– Definition of load collective mean operating time tm per wor-

collectiv king day in h
1 (k ≤ 0,50) 0 10 50 100
(light) only exeptionally peak
stress, mainly very low
strain, small dead load
% of max. ult. load

2 2–4 4–8 8–16 >16

40

10

% of operat. time 0

2 (0,50 < k ≤ 0,63) 0 16,7 33,3 50 100

(medium) Frequently peak stress,
permanent low strain, me-
dium dead load 73
% of max. ult. load

47 1 1–2 2–4 4–8 8–16

20

% of operat. time 0

3 (0,63 < k ≤ 0,80) 0 50 100

(heavy) Often peak stress, perma-
nent medium strain, heavy
dead load
% of max. ult load

0,5 0,5–1 1–2 2–4 4–8

40

0
% of operat. time

4 (0,80 < k ≤ 1) 0 90 100

(very heavy) Regularly max. stress,
very heavy dead load
80
0,25
% of ma. ult. load

0,25 – 0,5–1 1–2 2–4

0,5

0
% of operat. time

Driving gear group acc. to DIN 15020 or FEM 9,511 1 Bm 1 Am 2m 3m 4m

Page 30 Data : 16.08.2001

7.2 Action to Ensure Safe Operating Periods
The EU machinery directive requires precautions to prevent hazards due to fatigue and ageing on hoists. The fol-
lowing precautions have therefore been taken in order to achieve safe working periods (S.W.P.).

7.2.1 Declaration of Theoretical Service Life D

The manufacturer or supplier of a standard hoist is required to state the theoretical service life D in the operating
instructions. These values for ABUS electric chain hoists are given in the following table:

Theoretical service life D, (h)

1Dm 1Cm 1Bm 1Am 2m 3m 4m 5m
FEM groups
M1 M2 M3 M4 M5 M6 M7 M8
Line load group / load factor Theoretical service life D (h)
light 1 / L1
1 K = 0.5 800 1600 3200 6300 12500 25000 50000 100000
(Km1 = 0.125 º 0.53)
medium 2 / L2
2 0.5 < K < 0.63 400 800 1600 3200 6300 12500 25000 50000
(Km2 = 0.25 º 0.633)
heavy 3 / L3
3 0.63 < K < 0.8 200 400 800 1600 3200 6300 12500 25000
(Km3 = 0.5 º 0.83)
very heavy 4 / L4
4 0.8 < K < 1 100 200 400 800 1600 3200 6300 12500
(Km4 = 1 º 13)

7.2.2 Records of Service
The organisation operating the standard hoist is re-
sponsible for recording the actual type of service of the
hoist and documenting it at least once per year in the
test book.
If the actual operating conditions are not verified or
such verification is not possible or operating conditions
are only estimated, a full overhaul in accordance with
Section 7.2.4 must be carried out 10 years after the
delivery of the standard hoist or earlier.
7.2.3 Assessment of Safe Working
Period (S.W.P.)
During each scheduled inspection, the inspector re-
sponsible for the inspection of the standard hoist must
determine whether the hoist is still being utilised within
its safe working period (S.W.P.).
7.2.4 Action to Be Taken on Reaching
Theoretical Service Life D
When a standard hoist has reached its theoretical ser-
vice life, it must be overhauled by a specialist autho-
rised by ABUS before it can continue in service.
During an overhaul, the authorised specialist must de-
termine:
- which parts must be replaced (the oil in the hoist
gearbox must be changed during all overhauls)
- the new theoretical service life D
- the new maximum interval before the next over-
haul.

A 516.GB Page 31
7.3 Maintenance Schedule
every
at scheduled
Work to be performed daily 10
inspections
years

Inspection

Check functioning of brakes X

Check functioning of limit switches X

check rope for damage and wire breakage X

Edge protector available in bottom block and not faulty X

Check functioning of overload protection device In the case of electrome- X

chanical overload protectiondevices, grease the disc spring packages as
required

Maintenance

Check oil level in hoist gearbox X

Change oil in hoist gear unit X

Check hoist gearbox for leakage X

Check travel drives for leakage X

Lifting brake, check clearance and adjust as appropriate X

Lubricate gears of hoist drive and rope drum X

Trolley travel brake, check clearance and adjust as appropriate X

Lubricate gears of travel drives and wheels X

Lubricate wire rope and rope drum X

Check rope mounts and guides X

Check bottom block and load hook suspension X

Check hooks for cracks and permanent deformation X

Check the condition of all buffers X

Check all bolted joints and welds

Check the tightness of bolted joints, especially the tighteningtorques of
X
the long bolts connecting the motor housing and thegearbox on hoist lift-
ing and trolley travel motors

Check power supply systems, especially current collectors

X
(check rollers and sliding contacts for wear)
Check wheels of trolleys
X
(especially conditions of wheel flanges; no plastic deformation)
Check electrical switchgear and wiring X

Check paintwork; repair if necessary X

Check any wind locks and lubricate joints X

Rope wedge protrusion (section 7.3.1) X

Page 32 Data : 16.08.2001

7.3.1 Rope wedge protrusion, spacing between the rope clamp
The maximum protrusions of the rope wedges are indi-
cated in the table below.

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

_________________________________

7.4 Wire rope and rope guide

Wire rope and rope guide are parts subject to wear
whose life can be increased by regular lubrications ac-
cording to the maintenance schedule. Clean drum and
rope guide before lubrication.
7.4.1 Maturity for discarding
You can take the working up of the rope in your ABUS
electric wire rope in the wire certificate of the crane
book.
Wire ropes must be immediately replaced in the follow-
ing cases: breakage of a strand, opening of the rope
structure, crushing, buckling, extreme wear, serious
damage or considerable rust deposits.
In order to check the wire rope for breakages, the load
must be removed and the rope be manually bent in the
working range. Wire breakages thus are more clearly
visible. The bending radius should approximately
correspond to the rope pulley radius.
ABUS–electric wire rope hoists are equipped with
high–tensile ropes which have been developed for spe-
cific applications and which have a high degree of
breaking strength, fatigue strength under reversed
bending stresses, and structural resistance. When re-
placing a rope, make sure only original spare ropes are
used. They can be directly obtained from our ware-
house.
Wire ropes must be replaced if the number of visible
wire breakages on one of the reference lengths
achieves the value indicated in the following table.

Wire breaks on a rope length of Wire breaks on a rope length of

6x rope diameter 30x rope diameter
W ki
Working
Rope– 1 Bm / 1 Am 2m–5m 1 Bm / 1 Am 2m–5m
Type up of the
Ø
rope Number Rope Number Rope Number Rope Number Rope
of wire length of wire length of wire length of wire length
breaks [mm] breaks [mm] breaks [mm] breaks [mm]
14 SKZ 8–P 5 84 10 84 10 420 19 420

GM SKZ 8–P 9 120 18 120 18 600 35 600

20
7000.1 D 1315 Z 5 120 10 120 10 600 19 600
20.5 PZ 371 9 123 18 123 18 615 35 615

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

Page 34 Data : 16.08.2001

7.4.2.1 Discarding of the rope and removal of
the rope guide
1. Lower the bottom block and place it on the working
platform or floor.
2. Set the hoist limit switch so that a lowering beyond
the lowest hook position becomes possible.
3. Remove the tie–bar (16) with its security elements,
remove the rope sockets (2, 10–15) and detach the
rope end (2, 11, 12).
4. Demount the catch (5, 6) of the rope guide ring (3).
5. Loosen the tensioning parts (4) and demount the
rope guide (3).
6. Completely reel off the rope and detach rope
clamps (8 and 9). Figure 15

7.4.2.2 Installation of a new wire rope and of the
rope guide
1. Pay out the original spare rope on the ground under
the electric wire rope hoist. Make sure the rope is
twist– and buckling–free.
10. Fit the fixed cross member (16) to the cross
member mounting using bolts (17) and bearing
bushings (18) and fasten it in place with the lid and
screws (19,20).
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
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-
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.
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
ending rope line (2) exits through the guide slit.
7. Suspend tension parts (4) and adjust them by turn-
ing the eye bolt until the rope guide ring is fitting
tight.
8. Twist the rope guide ring (3) until the guide edge
engages in the aperture of the catch (5) at the drum
casing. Then fasten the catch on the rope guide
ring (6).
9. Reeve the free rope end without twisting and fasten
it in the rope socket (10 – 15) of the fixed point tie–
bar (16). For reeving, see figure 15.
Figure 16
11. Entirely coil up the rope and adjust the limit switch
to the highest and lowest position. See section 9
“Hoist limit switch”
7.4.2.3 Removing twist
Over the course of time, a twist may develop in wire
ropes. The result is that the bottom block twist when the
rope is unloaded.
To eliminate this tendency to twist, the bottom block
must be lowered to the ground, the rope lock released
and the rope turned 180° ”tighter”. The rope must then
be attached firmly to the bottom block again. The effec-
tiveness of the action taken must be checked by raising
and lowering the hoist without a load.
It may be necessary to repeat this procedure several
times.
With large hook path, a twist inhibitor is installed. See
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

Page 36 Data : 16.08.2001

7.4.3.1 Discarding of the rope and removal of Note: the diversion roller cross member (21) has a
the rope guide self–locking suspension. In other words, no secur-
1. Lower the bottom block and place it on the working ing component is used.
platform or floor. For reeving, see figure 19.
2. Set the hoist limit switch so that a lowering beyond
the lowest hook position becomes possible.
3. Remove the tie–bar (16) with its security elements,
remove the rope sockets (2 and 10 – 15) and de-
tach the rope end (2, 11, 12).
4. Demount the catch (5, 6) of the rope guide ring (3).
5. Loosen the tensioning parts (4) and demount the
rope guide (3).
6. Completely reel off the rope and detach rope
clamps (8 and 9).

7.4.3.2 Installation of a new wire rope and of the Figure 19

rope guide
1. Pay out the original spare rope on the ground under
the electric wire rope hoist. Make sure the rope is
10. Fit the fixed cross member (16) to the cross
twist– and buckling–free.
member mounting using bolts (17) and bearing
bushings (18) and fasten it in place with the lid and
screws (19,20).
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 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-
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.
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
ending rope line (2) exits through the guide slit.
7. Suspend tension parts (4) and adjust them by turn-
ing the eye bolt until the rope guide ring is fitting
tight.
8. Twist the rope guide ring (3) until the guide edge
engages in the aperture of the catch (5) at the drum
casing. Then fasten the catch on the rope guide
ring (6).
9. Reeve the free rope end without twisting and fasten
it in the rope socket (10 – 15) of the fixed point tie–
bar (16).
Figure 20
11. Entirely coil up the rope and adjust the limit switch
to the highest and lowest position. See section 9
“Hoist limit switch”
7.4.3.3 Removing twist
Over the course of time, a twist may develop in wire
ropes. The result is that the bottom block twist when the
rope is unloaded.
To eliminate this tendency to twist, the bottom block
must be lowered to the ground, the rope lock released
and the rope turned 180° ”tighter”. The rope must then
be attached firmly to the bottom block again. The effec-
tiveness of the action taken must be checked by raising
and lowering the hoist without a load.
It may be necessary to repeat this procedure several
times.

A 516.GB Page 37
7.4.4 Reeving 6/1 – D(B)

X
turned

Figure 21

Page 38 Data : 16.08.2001

7.4.4.1 Discarding of the rope and removal of 9. Reeve the free rope end without twisting and fasten
the rope guide it in the rope socket (10 – 15) of the fixed point tie–
1. Lower the bottom block and place it on the working bar (16). For reeving, see figure 23.
platform or floor.
2. Set the hoist limit switch so that a lowering beyond
the lowest hook position becomes possible.
3. Remove the tie–bar (16) with its security elements,
remove the rope sockets (2, 10–15) and detach the
rope end (2, 11, 12).
4. Demount the catch (5, 6) of the rope guide ring (3).
5. Loosen the tensioning parts (4) and demount the
rope guide (3).
6. Completely reel off the rope and detach rope
clamps (8 and 9).

7.4.4.2 Installation of a new wire rope and of the Figure 23

rope guide
10. Fit the fixed cross member (16) to the cross
1. Pay out the original spare rope on the ground under member mounting using bolts (17) and bearing
the electric wire rope hoist. Make sure the rope is bushings (18) and fasten it in place with the lid and
twist– and buckling–free. screws (19,20).
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 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
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-
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.
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
ending rope line (2) exits through the guide slit.
7. Suspend tension parts (4) and adjust them by turn-
ing the eye bolt until the rope guide ring is fitting
tight.
8. Twist the rope guide ring (3) until the guide edge
engages in the aperture of the catch (5) at the drum
casing. Then fasten the catch on the rope guide
ring (6).
Figure 24
11. Entirely coil up the rope and adjust the limit switch
to the highest and lowest position. See section 9
“Hoist limit switch”
7.4.4.3 Removing twist
Over the course of time, a twist may develop in wire
ropes. The result is that the bottom block twist when the
rope is unloaded.
To eliminate this tendency to twist, the bottom block
must be lowered to the ground, the rope lock released
and the rope turned 180° ”tighter”. The rope must then
be attached firmly to the bottom block again. The effec-
tiveness of the action taken must be checked by raising
and lowering the hoist without a load.
It may be necessary to repeat this procedure several
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

Page 40 Data : 16.08.2001

7.4.5.1 Discarding of the rope and removal of
the rope guide
1. Lower the bottom block and place it on the working
platform or floor.
2. Set the hoist limit switch so that a lowering beyond
the lowest hook position becomes possible.
3. Demount the catch (5, 6) of the rope guide ring (3).
4. Loosen tensioners (4) of the two rope guides (3)
and remove the rope guides.
5. Allow the rope to unroll completely and release the
rope clamps (8 and 9) at both ends of the drum.
7.4.5.2 Installation of a new wire rope and of the
rope guide
1. Pay out the original spare rope on the ground under
the electric wire rope hoist. Make sure the rope is
twist– and buckling–free.
Figure 26
2. Clean the rope drum (1) and evenly spray it with
chainlife S spray grease.
3. Position the rope on the roller cross arm (21) in
such a way that the two loose ends of the rope have
about the same length.
4. Insert the rope without twisting.
Reeving 4/2 see Figure 27
Reeving 8/2 see Figure 28
(from the roller cross arm to the outer rollers of the
bottom block, then to the top block, the inner rollers
of the bottom block and the rope drum)
Figure 28
5. Insert both ends of the rope (2) under the rope
clamps (8 and 9) from below until the ends
protrude about 3 cm. Tighten the fastening screws
according to the prescribed torques. See chapter
3.3.5
6. Tautly wind the rope around the drum (1) by ap-
prox. 6–8 turns. Make sure the rope is twist–free.
7. Grease the rope drum around the rope guide ring
with the special grease PG 75.
8. 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
ending rope line (2) exits through the guide slit.
9. Suspend tension parts (4) and adjust them by turn-
ing the eye bolt until the rope guide ring is fitting
tight.
10. Twist the rope guide ring (3) until the guide edge
engages in the aperture of the catch (5) at the drum
casing. Then fasten the catch on the rope guide
ring (6).
11. Entirely coil up the rope and adjust the limit switch
to the highest and lowest position. See section 9
“Hoist limit switch”

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

Page 42 Data : 16.08.2001

 (8 and 9) of the rope drum (1) until the rope end For reeving 6/2, see figure 32
protrudes by approxim. 3 cm.
Tighten the fastening screws (9) according the pre-
scribed torques. See chapter 3.3.5
4. Wind the rope around the drum with approximately
6–8 turns; make sure the rope is taut and twist–free.
5. Grease the rope drum around the rope guide ring
with special grease PG 75.
6. Spread the rope guide ring (3) and lead it over the
drum until its threaded segments engage in the
grooves of the rope drum and the ending rope line
(2) comes out through the guide aperture.
7. Suspend straining parts (4) and adjust them by
turning the eye bolts until the rope guide ring is fit- Figure 32
ting tight.
8. Turn the rope guide ring until the guide edge en- For reeving 8/2, see figure 33
gages in the aperture of the catch (5) at the drum
casing. Then fasten the catch on the rope guide
ring (6).
9. Pay out the wire rope until the rope drum (1) is com-
pletely covered.
10. Pull off the lifting motor connector from lifting gear 1
and plug it into lifting gear 2.
11. Reeve the free rope end without twisting and push it
from below under the rope clamps (8) of the rope
drum (2) until the rope end protrudes by approx. 3
cm. Tighten the fastening screws according to the
prescribed torques.
For reeving 4/2, see figure 31 Figure 33

12. Apply steps 4–9 also to the rope drum 2.

13. Set the hoist limit switch for highest and lowest
position. See chapter 9 “Hoist limit switch”

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

Page 44 Data : 16.08.2001

7.5 Hoisting gear brake optimum value of 0.4 ± 0.05 mm (1/64th inch.). This en-
sures optimm brake performance and minimm wear.
Attention!
In order to prevent the brake lining thickness from fal-
The following instructions apply to the
ling below the minimum value tmin, the screw–in depth
versions with walkway (DB and ZB). When
of the socket screws (4) in the magnet assembly (9) is
performing work which requires dismantling
limited.
of the hoist drive, the hoist drive must not
Caution!
under any circumstances be placed on the
The following work must be performed with
walkway. Otherwise, there is a risk of
the power supply disconnected. This work
accidents caused by overloading.
must be performed only by specialists.

a) Motor without additional unit for ventilation, see

Figure 35 7.5.1 Adjustment of the air–gap
1 2 3 4 Motor with or without additional unit for ventilation,
see Figure 35 or 36
14 0,4 1. Remove the ventilator cowl (1) with the motor being
switched off.
2. Remove locking ring (11)
3. Loosen 3 fastening screws (2) by half a turn
13
4. Screw 3 socket screws (4) about one turn info
magnet assembly (9) (screws–in depth limited)
12 5. Place distance plates (3) (thickness: 0.4 ± 0,05
mm) between anchor plate (6) and magnetic body
(9) each next to the 3 socket screws (4) ; tighten the
11 fastening screws (2) so that the distance plates (3)
can still be removed.
10 5 6. Unscrew the 3 socket screws (4) from the magnet
assembly (9) until they make firm constact with the
6 motor bearing shield.
7. Tigthen the fastening screws (2) at a torque of 25
Nm. Then check the evenness of the air gap (at ap-
tmin prox. 6 places and readjust, if required.
Figure 35 8. Press in 0–ring (7)
9 8 7 9. Install the ventilator cowl (1)
10. Do a trial run to check the brake.
b) Motor with additional unit for ventilation, see Figu-
re 36
1 2 3 4 7.5.2 Dismounting the brake
a) Motor without additional unit for ventilation, see
Figure 35
0.4 1. Lower the bottom block and place it on the working
platform, the ground, etc.
2. Remove ventilator cowl (1) with the motor being
switched off.
3. Remove locking ring (11)
4. Pull off fan (14).
13 5. Remove feather key (12).
6. Press out 0–ring (7).
10 7. Disconnect connectors for power supply to brake.
8. Unscrew the fastening screws (2).
16 9. Remove magnet assembly (9) complete with an-
chor disk (6) and socket screws (4).
15 10. Remove brake rotor (5).
11. Remove locking ring (10).
tmin 12. Pull off catch hub (8) by means of the pull–off de-
vice.
9 8 6 7 5 Figure 36
b) Motor with additional unit for ventilation, see Figu-
The hoisting gear brake is a magneto–electric disk re 36
brake. In order to guarantee safe release, the brake is
equipped with an air–gap limiter. The air–gap of the 1. Lower the bottom block and place it on the working
brake must be checked regularly and adjusted to its platform, the ground, etc.

A 516.GB Page 45
2. Remove ventilator cowl (1) with the motor being
switched off.
3. Disconnect connectors for power supply to brake
and ventilation system.
4. Undo 3 screws (16) and remove axial flow fan with
mounting plate (15).
5. Press out 0–ring (7).
6. Unscrew the fastening screws (2).
7. Remove magnet assembly (9) complete with an-
chor disk (6) and socket screws (4).
8. Remove brake rotor (5).
9. Remove locking ring (10).
10. Pull off catch hub (8) by means of the pull–off de-
vice.
7.5.3 Installation of the brake
a) Motor with additional unit for ventilation, see Figu-
re 35
1. Slightly grease the motor shaft (13), install catch
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-
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.
6. Unscrew the 3 socket screws (4) from the magnet
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.
8. Press in the 0–ring (7).
9. Push on the ventilator (14) and secure with locking
ring (11).
10. Connect connectors for power supply to brake.
11. Install the ventilator cowl (1).
12. Carry out test tun to check brake.
b) Motor with additional unit for ventilation, see Figu-
re 36
1. Slightly grease the motor shaft (13), install catch
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-
bly (9)
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);
Page 46
tighten the fastening screws (2) so that the dis-
tance plates (3) can still be removed.
6. Unscrew the 3 socket screws (4) from the magnet
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.
8. Press in the 0–ring (7).
9. Fasten axial–flow fan with mounting plate (15) to
magnet assembly (9) using 3 screws (16).
10. Connect connectors for power supply to brake and
ventilation system.
11. Install the ventilator cowl (1).
12. Carry out test tun to check brake and ventilation
system.
7.5.4 Replacement of Brake Rotor and
Anchor Disk
1
2
Hubbe-
grenzung
Figure 37 1.1
If the brake lining is worn to the point where dimension
t = 13.8 mm and it is no longer possible to set the re-
quired clearance, the brake rotor Figure 35 / 36, Item
(5) and the anchor disk Figure 35 / 36, Item 6) must
both–be replaced.
For the replacement of the brake rotor and anchor disk,
the following work is necessary:
Dismantling of the brake in accordance with sub–sec-
tion 7.5.2
Dismantling of the anchor disk in accordance with the
following instructions:
1. Screw the socket screws Figure 35 / 36, Item (4)
on the dismantled brake into the magnet assembly
up to the stop.
2. Remove and destroy the lifting travel limiting
screws Figure 37, Item (2) (The emergency lower-
ing bar Figure 37, Item (1) will then be released.)
3. Remove and destroy the socket screws Figure 35 /
36, Item (4) (This rele ases the load on the springs
between the anchor disk Figure 35 / 36, Item (6)
and the magnet assembly Figure 35 / 36, Item (9)
4. Remove anchor disk.
Data : 16.08.2001
To install the new anchor disk, proceed in reverse order.
The socket screws Figure 35 / 36, Item ( (4) and the
lifting travel limiting screws Figure 37, Item (2) must
be replaced.
The clearance between the anchor disk and the
magnet assembly Figure 35 / 36, Item (9) must be set
to 1.1 mm with the brake dismantled using the lifting
travel limiting screws Figure 37, Item (2)
Assemble the brake in accordance with sub–section
7.5.3
7.5.5 Emergency Lowering of Load
Caution !
The hoist must be disconnected from the
power supply before the following steps are
taken!
Figure 35 / 36 / 37
If it is necessary to lower the load in an emergency fol-
lowing a power failure or problems with the hoist motor
or brake coil, the following steps must be taken:
1. Remove fan cover Figure 35 / 36, Item (1)
2. Screw stud bolt (M8) into emergency lowering bar
Figure 37, Item (1)
3. Release the brake by carefully moving the lowering
bar and lower the load slowly.
7.6 Trolley brakes AZP
min. 2 mm
b
a
Figure 38
The brakes of the drives are electro–magnetic disk
brakes. In order to guarantee a safe release, the brakes
are equipped with an air gap limiter. The optimum air
gap width (a) is 0.4±0,05 mm. With increasing wear of
the brake lining, the air gap also becomes wider and
must thus be regularly checked and re–adjusted to
achieve its optimum value (a)=0.4±0,05 mm. This
A 516.GB
value assures optimum brake performance and mini-
mum wear.
If the minimum thickness of 2 mm of the brake lining
has been reached, the brake lifter wing with brake
lining as well as the anchor disk must be exchanged.
The difference in clearance between the two travel
drives must not exceed 0.1 mm.
Caution !
All work on the brakes must be performed by
specialists.
7.6.1 Adjustment of the air gap
Figure 39
1. Remove the fan cowl (15) with the motor being
switched off. For this purpose, pull the snaps (11)
outwards and release them from their lock. The fan
cowl can then be pulled off in axial direction.
2. By means of the selflocking adjustment nut (8),
turn the brake fan blade (6) and the anchor plate
(7) against the pressure springs (3) and the O–ring
(4) so that the control dimension b = 3,1 (+ 0,2
mm) between the anchor plate (7) and the brake
bearing shield (12) will be observed.
When tightening or unscrewing the self–locking
nuts (8), the fan blade (6) must be held tight.
3. Mount the fan cowl (15).
4. Do a trial run to check the brakes.
7.6.2 Replacing the brake lifter wing
with brake lining and the anchor
disk
1. Remove the fan cowl (15) with the motor being
switched off. For this purpose, pull the snaps (11)
outwards and release them from their lock. The fan
cowl can then be pulled off in axial direction.
2. Hold the fan blade (6) and unscrew the self–locking
adjusting nut (8).
3. Pull off the brake fan blade (6).
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

7.6.3 Dismounting the brake bearing

plate and the brake 0,2 14
1. Remove the complete gear motor and place it on
the ground with the drive shaft pointing down-
wards. 9
2. Loosen the plug insert (2) and detach the brake t min
cable from clamps 7 and 8. Figure 40
3. Hold brake fan blade (6) and unscrew the self–lock- 5 15 4 3 2 1
ing adjusting nut (8). The brakes of the drives are magneto–electric disk
4. Pull off the fan blade (6). brake. In order to guarantee safe release, the brake is
5. Loosen 4 screws (14) and pull off brake bearing equipped with an air–gap limiter. The air–gap of the
plate (12) against the motor shaft. brake must be checked regularly and adjusted to its
6. Pull the brake connecting cable from the protecting optimum value of 0.2 ± 0.05 mm. This ensures optimm
sleeve (13). brake performance and minimm wear.
7. Leave the feather key (9) at its place , this helps to In order to prevent the brake lining thickness from fal-
keep the spring washers (10) prestressed. ling below the minimum value tmin, the screw–in depth
8. If they are still in a good condition, the O–ring (4), of the socket screws (4) in the magnet assembly (9) is
pressure springs (3), and anchor plate (7) can be limited.
re–used after loosening the hoist limiting screws. Caution !
The anchor plate (7) must be free of grease. All work on the brakes must be performed by
specialists.

7.7.1 Adjustment of the air–gap

7.6.4 Mounting the brake bearing plate
and the brake
1. Push the brake connection cable through the pro-
tecting sleeve (13) into the terminal box (1).
2. Fasten the brake bearing plate (12) with four
screws (14). Tighten the screws (14) stepwise and
transversely to avoid jamming of the brake bearing
plate. Observe the indicated tightening torques.
3. Bolt the brake connection cable to the clamps 7
and 8.
4. Fit the plug insert (2).
5. Insert pressure springs (3).
6. Insert O–ring (4) without twisting.
7. Fasten the anchor plate (7) with the hoist–limiting
screws (5). Fix the hoist–limiting screws with ”Loc-
tite 243”.
8. Fit brake fan blade (6) and hold it while inserting the
self–locking adjusting nut (8).
9. For adjustment of the air gap (a), see 7.6.1
10. Tightening torque of the screws (14), quality 8.8
M 5 TA = 5 Nm
M 6 TA = 7 Nm
4. Remove the ventilator cowl (1) with the motor being
switched off.
5. Remove locking ring (11)
6. Pull off fan (14)
7. Loosen 3 fastening screws (2) by half a turn
8. Screw 3 socket screws (4) about one turn info
magnet assembly (9) (screws–in depth limited)
9. Place distance plates (3) (thickness: 0,2 ± 0,05
mm) between anchor plate (6) and magnetic body
(9) each next to the 3 socket screws (4) ; tighten the
fastening screws (2) so that the distance plates (3)
can still be removed.
10. Unscrew the 3 socket screws (4) from the magnet
assembly (9) until they make firm constact with the
motor bearing shield.
11. Tigthen the fastening screws (2) at a torque of 7
Nm. Then check the evenness of the air gap (at ap-
prox. 6 places and readjust, if required.
12. Place the fan (14) on the motor shaft (13) and lock
with locking ring (11)
13. Install the ventilator cowl (1)
14. Do a trial run to check the brake.

Page 48 Data : 16.08.2001

7.7.2 Dismounting the brake
1. Remove ventilator cowl (1) with the motor being
switched off.
2. Remove locking ring (11)
3. Pull off fan (14).
4. Remove feather key (12).
5. Loosen contactor insert and unscrew brake con-
nection line from terminals 7 and 8.
6. Loosen cable gland and pull out brake connection
line.
7. Unscrew the fastening screws (2).
8. Remove magnet assembly (9) complete with an-
chor disk (6) and socket screws (4).
9. Remove brake rotor (5).
10. Remove friction plate (7)
11. Remove locking ring (10).
12. Pull off catch hub (8) by means of the pull–off de-
vice.
7.7.3 Installation of the brake
1. Slightly grease the motor shaft (13), install catch
hub (8) and secure with locking ring (10).
2. Position friction plate on motor bearing plate.
3. Push brake rotor (5) on the catch hub (8) and
check whether it can be slightly axially displaced.
4. 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).
5. Push brake connection line through cable gland.
Tighten cable gland.
6. Screw brake connection line to terminals 7 and 8.
Tighten connector insert.
7. Screw 3 socket screws (4) into the magnet assem-
bly (9)
8. Place distance plates (3) (thickness: 0,2 ± 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.
9. Unscrew the 3 socket screws (4) from the magnet
assembly (9) until they make firm contact with the
motor bearing shield.
10. Tighten the fastening screws (2) at 7 Nm. Then
check the evenness of the air gap (at approx. 6
points) and readjust, if necessary.
11. Push on the ventilator (14) and secure with locking
ring (11).
A 516.GB
12. Install the ventilator cowl (1).
13. Do a trial run to check the brake.
7.7.4 Replacement of brake rotor, an-
chor disk and friction plate
If the brake lining is worn to the point where dimension
tmin = 7.3 mm and it is no longer possible to set the re-
quired clearanceIf the brake lining is worn below mm
and it is no longer possible to adjust the clearance, the
brake rotor (5) and the anchor disk (6) and the friction
plate must be replaced together.
For the replacement the following work is necessary:
Dismantling of the brake in accordance with sub–sec-
tion 7.7.2
Dismantling of the anchor disk in accordance with the
following instructions:
1. Remove and destroy the socket screws (4) (This
rele ases the load on the springs between the an-
chor disk (6) and the magnet assembly (9)
2. Remove anchor disk.
To install the new anchor disk, proceed in reverse order.
The banjo screws (4) must be replaced.
Assemble the brake in accordance with sub–section
7.7.3
7.8 Changing Lubricant
All motors have permanent lubrication suitable for nor-
mal operating conditions (see Section 6.2 ”Normal
Operation”).
It is only necessary to change the lubricant if the crane
system is overhauled.
Under abnormal operating conditions, it may be
necessary to change the lubricant at appropriate inter-
vals.
To change the lubricant on crane travel motors, the
gearbox must first be removed and the gearbox com-
ponents and housing must be cleaned using suitable
proprietary cleaning compounds.
The gearbox must then be filled with the new lubricant
and closed.
Lubricant quantities and grades are given in chapter
3.3.2 and in the lubricants table in section 11.
Used lubricant must be brought to a used oil
collection point or disposed of properly.
Page 49
7.9 Problems, Causes and Remedies
All the malfunctions described below must be remedied by a specialist.
Problem
Crane does not run
Motor does not turn in any
direction and does not hum
when the pendant control is
operated
Motor does not turn in
any direction but
hums when the pen-
dant control is oper-
ated
WARNING
Motorwindings may
burn out
Motor starts slowly
Crane movement only possible
on one direction
Breake does not release
Page 50
Possible cause
Mains power not available
Emergency limit switch of hoist
has tripped
No control voltage
Mains power not available
Mains connection not properly
made
Faulty fuses
Plug–in connectors for Plug–in
connectors for control not
properly inserted or not locked
Loose contacts in pendant
control, broken wires in power
supply line or in pendant control
or, possibly, on travel drive
Faulty mains connection or
mains fude
Faulty contactor
Break does not release, motor
runs against closed breake
Crane span deviates from spec-
ification
Faulty switch element in pendant
control
Broken wires
Faulty contactor
Gradiant an crane track too
steep
Travel limit switch (if installed)
was operated
No power on brake coil, no AC
voltage at rectifier input
Rectifire faulty or incorrectly
connected
Brake coil has no electrical
continuity and is fault
Remedy Remarks
Check current collector(s)
Check emergency OFF–button
and contactor K1
Check phase sequence
Check functioning of emergency
limit switch
check setting of limit switch
Check control voltage fuse on
control transformer
Check voltage
Connect all three phase
conductors correctly
Replace fuses Follow wiring diagram
Insert connectors firmly and lock
using bracket
Check wires for breakage; if Caution! All work
necessary replace control cable must be performed
with all equipment
disconnect from the
power supply
Check mains connection
Replace contactor Caution! All work
must be performed
with all equipment
disconnect from the
power supply
See breake problems
Check play on wheel flanges
Check and if necessary replace
switch element
Check control cable
Replace contactor
Re–align crane track
Check limit switch
Check and repair connections Caution! Pull mains
Check motor connector out before
starting work!
Check DC voltage at brake coil; Follow wiring diagram
connect rectifier correctly or
replace rectifier
Replace brake coil Follow operating instructions
Data : 16.08.2001
Problem Possible cause Remedy Remarks

Braking distance too long Max. clearance reached (limit on Set brake and adjust clearance Follow operating instructions
lining wear)

Gradiant an crane track too Re–align crane track

steep

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.

7.10 Repairs or hoists not properly performed or performed other

Caution !
All repairs must be carried out only by
specialist personnel!
ABUS cranes, electric wire rope hoists and electric
chain hoists must be repaired and maintained only by
qualified, authorized personnel.
ABUS will assume no liability whatsoever for loss or
damage due to or in connection with repairs to cranes
than by authorized personnel.
We recommend that repair and maintenance
work should be performed by ABUS service
personnel.
We must point out that you will only retain your warranty
rights if only genuine ABUS spare parts are used.
Our service department and the responsible techni-
ciens will be at your disposal for all further questions.

A 516.GB Page 51
8 Disposal, Decommissioning
When ABUS products are no longer needed, they may
be disposed of in an environmentally compatible way.
ABUS produces cranes, hoists and crane system com-
ponents characterized by high quality, long service life
and low maintenance requirements.
Details of the disposal and re–use of components are
given in the following table:

Product Materials Disposal

Crane brigdes
Track girders Separation of materials
Trolley frames Metals
Motors Recycle by remelting
Gearboxes
Drive component
Multi–purpose On special landfills in according with
Brake linings
components applicable local regulations
Protection hoods Recycle by remelting
Cellulose buffers Plastics incineration
Housings or to special landfills
Treatment or disposal in according
Lubricants Öils and greases
with regulations, e.g. incineration
Cables, Housings Rubber, PVC, Separation of materials
Connectors Silicone
Pendant controls PCP Recycle by remelting
Electronic– Plastics, Metals On special landfills in according with
components Elektrolytes applicable local regulations

Painted products must either be recycled or disposed

of on special landfills in accordance with the applicable
local regulations.

Page 52 Data : 16.08.2001

9 Adjustment instruction hoist limit switch
9.1 Hoist limit switch GPK 75.3–1
with 3 switch points
9.1.1 Adjustment instructions
The ABUS–hoist limit switch GP protects the electric
wire rope hoist as an independantly working emerg-
ency–stop–device to limit the up and down movements
at the highest respectively at the lowest hook position.
As a further improvement of safety the standard system
is always equipped with the “safety limit switch”, a sec-
ond switch for the highest hook position.
If the control panel of your system has got a switch
“emergency limit switch test”, section 9.2 must be con-
sidered for adjustment.
Switching points 1 and 2 of ABUS hoists are normally
set at the factory and sealed with lead seals. The
switching points are set in accordance with the table
”Setting of lifting limit switches” on the basis of the reev-
ing, frequency range, mode of operation and flange
width.
Switch points must be adjusted by specialist personnel
according to respective table ”Setting of lifting limit
switches” before the first operation as well as after
maintenance works at the rope drive (e.g. rope ex-
change). Depending on your choice of the reference
edge, values of column C1, A1, C2 or A2 can be used
(see Figure 42, 43 and 44). Adjust the switch points at
the adjusting nuts 1 – 3 with a screw driver of 6 mm or
an Allan key of 4 mm. 146 turns at the adjusting nut
corresponds with 360° at the cam disk. The table ”Set-
ting of lifting limit switches” indicates what hook path
corresponds with one turn at the ajusting nut.
Turning the adjusting nut to the right = adjust switch
point to a lower position
Turning the adjusting nut to the left = adjust switch
point to a higher position.
The standard type GP_ 75 is designed for 75 turns of
the cam disk. For larger lifting heights the hoists can be
equipped with the type GPM125 for 125 turns.

adjustment by means of screw adjustment nuts adapter

driver Ø 6mm 3 2 1 push--- on shaft

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

.1 safety limit switch lifting

20--40

C2

.2 emergency limit switch lif-

Bo

ting
HW
Bu

.3 emergenca limit switch lo-

wering Figure 41

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–DQA 1 4/1 all 998 978 –– 1028 –– 1058 –– 1000 –– 1300 ––

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

hoist type reeving switch hysteresis hook path per

Model DQA
[mm] turn at the ad-
up down justment nut
Bo Bu [mm]

GM 7000–D(B) 2/1 254 254 342

GM 7000–D(B) 4/1 127 127 171

C ..

GM 7000–DQA 4/1 127 127 171

GM 7000–D(B) 4/2 254 254 342 Figure 43

GM 7000–D(B) 6/1 85 85 114
Model Z
GM 7000–D(B) 8/2 127 127 171

GM 7000–Z(B) 4/2 127 127 171

GM 7000–Z(B) 6/2 85 85 114

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 ..

After the settings have been completed, it is

essential to carry out a test of functions at ma-
C ..

ximum speed to check whether the settings

Figure 42 are correct and the hoist does not run up to
the emergency limit switch.
It may be necessary to correct the settings.

Page 54 Data : 16.08.2001

9.1.2 Adjust switch points
Switch point .1 “Safety limit switch lifting”
The switch point is adjusted and sealed by the manu-
facturer to dimension C 1. Changes are only allowed in
case of maintenance works and must be carried out by
specialist personnel. After maintenance works, we rec-
ommend to let the adjustment be checked and sealed
by ABUS service personnel.
The dimension C 1 should not fall below
this minimum on safety reasons!
Adjustment: Lift the load hook up to 5 mm (with reeving
4/1) or 10 mm (with reeving 2/1) to the highest hook
position (dimension C1 + 5 (10) mm). If necessary,
previously turn adjusting nut 1 to the left.
Turn adjusting nut 1 to the right until switch contact
audibly switches.
Check switch point by running two starts (max. speed)
to the highest hook position and if necessary correct
the adjustment. A test run to reach switch point .1 is
only possible by manual bridging of the “emergency
limit switch lifting.”
Switch point .2 “emergency limit switch lifting”
Switching point 2 is set to dimension C2 at the factory
and sealed with a lead seal. If necessary (especially for
low lifting speeds), this point may be set nearer to
switching point C1. The minimum clearance between
the switching point and the emergency limit switch
must be set so that the hoist does not reach the emerg-
ency limit switch.
Adjustment: Lift the load hook up to 5 mm (for 4/1) or 10
mm (for 2/1) to the desired hook position (min. dimen-
sion C2 + 5 (10) mm). If necessary, previously turn ad-
justing nut 2 to the left. Turn adjusting nut 2 to the right
until switch contact audibly switches.
Check switch point by running two starts (max. speed)
to the desired hook position and if necessary correct
the adjustment in this case. The switch “safety limit
switch lifting” must not switch in this case.
Switch point .3 “emergency limit switch lowering”
The switch point is only preadjusted by the manufac-
turer. The lowest hook position must be suited to oper-
ating conditions so that the unloaded hook never
touches the floor. (Formation of slack rope !!)
A 516.GB
Adjustment: Lowering of load hook to 500 mm above
the lowest hook position required. If necessary, turn ad-
justing nut 3 previously to the right.
Turn adjusting nut 3 to the left until switch contact 3
audibly switches. Check switch point by running two
tests (max. speed) to the lowest hook position and if
necessary correct the adjustment.
The dimension HW must not exceed the di-
mension lifting height ( “Hakenweg”)
see type plate of the hoist.
9.2 Adjustment instruction hoist
limit switch GP with option
“operating limit switch” with 4
switch points
9.2.1 Adjustment instructions
The ABUS–hoist limit switch GP protects the electric
wire rope hoist as an independantly working emerg-
ency–stop–device to limit the up and down movements
at the highest respectively at the lowest hook position.
If the hoist is run to the highest (and/or lowest) hook
position several times per day, there must be a further
switch (operating limit switch) prior to the emergency
limit switch.
The emergency limit switch should be checked at the
beginning of each work shift. The button “emergency
limit switch test” may also be used for the adjustment of
the “emergency limit switch”. For special purposes the
function of the particular switch points may differ from
the following description. In this case the special in-
struction must be observed.
Switch points must be adjusted by specialist personnel
according to respective table ”Setting of lifting limit
switches” before the first operation as well as after
maintenance works at the rope drive (e.g. rope ex-
change). Depending on your choice of the reference
edge, values of column C1, A1, C2 or A2 can be used.
Adjust the switch points at the adjusting nuts 1 – 3 with
a screw driver of 6 mm or an Allan key of 4 mm. 146
turns at the adjusting nut corresponds with 360° at the
cam disk. The table ”Setting of lifting limit switches”
indicates what hook path corresponds with one turn at
the ajusting nut.
Turning the adjusting nut to the right = adjust switch
point to a lower position
Turning the adjusting nut to the left = adjust switch
point to a higher position.
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

.1 emergency limit switch lifting

20--40

C2
.2 operating limit switch lifting
Bo

hook path
effective

HW
Bu

.3 operating limit switch lowering

D

.4 emergency limit switch lowe-

ring
Figure 45

Page 56 Data : 16.08.2001

9.2.2 Adjust switch points
Switch point .1 “emergency limit switch lifting”
The switch point is adjusted and sealed by the manu-
facturer to dimension C 1. Changes are only allowed in
case of maintenance works and must be carried out by
specialist personnel. After maintenance works, we rec-
ommend to let the adjustment be checked and sealed
by ABUS service personnel.
This dimension should not fall below this
minimum on safety reasons!
Adjustment: Lift the load hook up to 5 mm (with reeving
4/1) or 10 mm (with reeving 2/1) to the highest hook
position (dimension C 1 + 5 (10) mm). If necessary,
previously turn adjusting nut 1 to the left. Turn adjusting
nut 1 to the right until switch contact audibly switches.
Check switch point by running two starts (max. speed)
to the highest hook position and if necessary correct
the adjustment.
Switch point .2 “operating limit switch lifting”
Switching point 2 is set to dimension C2 at the factory
and sealed with a lead seal. If necessary (especially for
low lifting speeds), this point may be set nearer to
switching point C1. The minimum clearance between
the switching point and the emergency limit switch
must be set so that the hoist does not reach the emerg-
ency limit switch.
Adjustment: Lift the load hook up to 5mm (for 4/1) or 10
mm (for 2/1) to the desired hook position (min. dimen-
sion C 1 + 5 (10) mm). If necessary, previously turn ad-
justing nut 2 to the left. Turn adjusting nut 2 to the right
until switch contact audibly switches.
Check switch point by running two starts (max. speed)
to the desired hook position and if necessary correct
the adjustment. The switch “emergency limit switch lift-
ing” must not switch in this case!
Switch point .4 (.3) “emergency limit switch lower-
ing”
The switch point is only preadjusted by the manufac-
turer. The lowest hook position must be suited to oper-
ating conditions so that the unloaded hook never
touches the floor. (Formation of slack rope!)
Adjustment: Lowering of load hook to 500 mm above
the lowest hook position required. If necessary, turn ad-
justing nut 4 previously to the right.
A 516.GB
Turn adjusting nut 4 to the left until switch contact 4
audibly switches. Check switch point by running two
tests (max. speed) to the lowest hook position and if
necessary correct the adjustment.
The dimension HW must not exceed the di-
mension lifting height ( “Hakenweg”) see
type plate of the hoist.
Switch point .3 “operating limit switch lowering”
(only for GP with 4 switch points)
The switching point can be set to any point between the
normal limit switch for the highest hook position and the
emergency limit switch for the lowest hook position.
The minimum spacing ”D” must be taken from the fol-
lowing table:
Normal opera- ABUliner operation
tion
reeving
g
50 / 60 Hz 50 Hz 100 Hz
2/1 – 4/2 D = 100 D = 160 D = 600
4/1 – 8/2 D = 50 D = 80 D = 300
6/1 D = 40 D = 50 D = 200
6/2 D = 80 D = 100 D = 400
Adjustment: Lower load hook down to 50 mm (for 4/1)
or 100 mm for (2/1) to the desired lowest hook position.
If necessary, turn adjusting nut 3 previously to the right.
Turn adjusting nut 3 to the left until switch contact 3
audibly switches. Check switch point by running two
starts (max. speed) to the desired hook position and if
necessary correct the adjustment.
Adjustment screw .0 “block adjustment” (sealed)
The purpose of block adjustment is to shift all the
switching points by the same amount without changing
the switching point spacing. 626 turns of the adjust-
ment screw correspond to 360° on the cam disc for the
switching points.
After a rope exchange the four switch points can be re-
adjusted simultaneously using the block adjustment.
Adjust switch point .1 following the above mentioned
instruction by using Adjustment screw 0. Now the other
switch points are also in the initial position again. We
recommend to let the adjustment be checked and
sealed by ABUS service personnel.
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.

We ABUS Kransysteme GmbH

Adress Sonnenweg 1
D – 51647 Gummersbach
hereby declare, that the product:

Designation ABUS–Wire rope hoist

Hoist GM 7000.1
Model D 2/1 , D 4/1 , DQA 4/1
D 6/1 , D 4/2 , D 8/2
Z 4/2 , Z 6/2 , Z 8/2
in series production
the regulations of the european guideline
98/37/EG Machines
73/23/EG Low voltage
89/336/EG Electromagnetic compatibility

is in accordance with the version in force on the date of issue.

The following harmonized standards were used:

EN 292 Safety of machinery, tools and plants
EN 60204 T32 Electrical equipment of machines; requirements for hoists
EN 60947 Low–voltage switchgear
EN 50081 Electromagnetic compatibility; Interference emission
EN 50082 Electromagnetic compatibility; Resistance to interferences

and the national standards, instructions and specifications

DIN 15018 Cranes; principles for steel structures
DIN 15020 Hoists; principles for rope drives

FEM 9.511 FEM groups

FEM 9.661 Size and design of rope drives
FEM 9.683 Selection of hoist and travel motors
FEM 9.755 Action to ensure safe working periods
FEM 9.811 Specification for electric hoists
FEM 9.941 Symbols for controls

and the standards referred to therein.

Technical documentation is completely available.

The operating instructions belonging to it are in the language of the land of users.

Name: Wolfgang Wagner

Department Manager
Wire rope hoist
Gummersbach, 16.08.2001 ___________________________ _________________________
Signature of authorized person indication for the subscriber

This declaration is in accordance with EN 45014.

The ABUS Kransysteme GmbH entertains security system of quality under DIN EN ISO 9001 (08.94).

Page 58 Data : 16.08.2001

 11 Lubricants table

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.

Lubrication Lubrica- Observa- Moly- Standard

Product Aral BP DEA Dexron ESSO Klüber Mobil Moly Paul Optimol Shell Texaco Kuhbier
place tion way tion cote indication

Use of tem- Energol Klüberoil CLP ISO

perature Degol BG Falcon Spartan Mobilgear Omala Oil Meropa
GR–XP GEM VG 680
over 0°C 680 CLP 680 EP 680 636 680 680
680 1–680 DIN 51502
Hoisting gears Filling of
Lubricant
Use of tem- Energol Klüberoil CLP ISO
Degol BG Falcon Spartan Mobilgear Omala Oil Meropa
perature GR–XP GEM VG 220
220 CLP 220 EP 220 630 220 220
below 0°C 220 1–220 DIN 51502

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

Locking Isoflex KHC 2 K–60

Rope guide PG 75
ring, guide Topas L 32 DIN 51502

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

Filling of Degol GS Syntheso Glygoyle Tivela Oil CLP PG

Gearing
Lubricant 220 D 220 EP 30 WB DIN 51502

Jib motor G 50–100 Multi– Multipurpose

External Grease, Multi– Multi– Mobil- Kuhbinol grease
purpose Unimoly Retinax Texalube
splines con- with the purpose purpose grease Spezialfett NGLI2 m.
grease L GL 402 EPX2 F
nection hand grease F grease M Special 3261 Feststoff
21 M
MoS2KF2

Page 59