Service Manual

DANISH CRANE BUILDING A/S
Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

Phone +45 98 35 31 33 Fax + 45 98 35 30 33
Web www.dcb.dk E-mail dcb@dcb.dk
Marinequip China Co., Ltd
WENCHONG SHIPYARD
HULL No. GWS382
Service Manual
for
6.3 t DCB SINGLE GIRDER E/R CRANE

DCB No. 50146000 / 2009 - 47
DANISH CRANE BUILDING
A/S

Phone +45 98 35 31 33 Fax + 45 98 35 30 33
www.dcb.dk dcb@dcb.dk
Table of Contents
Drawing No.
1.
Certificates
2.
Technical data
3.
Drawing
50143000-75-01
4.
Parts list, drawing

Flat cable conductor system
Switch box and Junction box
50143000-71-01
DCB 07-64
DCB 07-59
5.
Installation of crane
Welding of tooth racks
DCB 07-62
50143000-36-01
6.
Lubrication
7.
Main and key diagram
8.
Manual and parts list:

Hoist
Reduction unit
A/S

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Wenchong Shipyard
Hull No. GWS 382
Crane No.:
50146000/2009-47
Drawing No.:
50145000-75-01
6,3 t DCB Single Girder E/R Crane
HOIST
Maker
Star Lifket
Model
111/54
No. 920651
EFB3/FGA1353/4D90LAX-4
No. F645283 0009
Gear
ASA 66A
No. F645283 0008
Motor
EFB3/FGA1353/4D90LAX-4
TROLLEY DRIVE
Gear
CRANE DRIVE

sterlandsvej 2 DK 9240 Nibe Denmark Phone +45 98 35 31 33 Fax +45 98 35 30 33
TEST REPORT FOR ENGINE ROOM CRANE

(Page 1)
CRANE NO.:
No. 50146000/2009-47
HULL NO.:
Wenchong Shipyard GWS 382
(Always state this number when ordering spare parts)
The crane identification number is located on the front of main cubicle located on the end carriage
Star Lifket type 111/54
HOIST:
No. 920651
Safe Working Load
6300 kg
SWL + 25 %
7875 kg
Power Supply
3 x 440 V
Hoist speed
3,8 / 0.9
60 Hz
m / min
The materials used as basis for manufacturing the hoist are guaranteed of prima quality.
Power Supply
The crane construction has been subjet to a static test load of
6300 kg + 25% =
Nibe, 19-11-2009

Claus Pedersen
7875 kg
A/S

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A/S

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TECHNICAL DATA
Drawing No.:50143000-75-01
6,3 t DCB Single Girder E/R Cranes for Wenchong Shipyard

Hull No.:GWS379-84,93-98
TEU 2800 Container Vessel
Specification:
6.3 t ENGINE ROOM CRANE - DRW. NO. 50143000-75-01.
SPAN : 5000 mm
LIFTING CAPACITY : 6300 kg
TEST CAPACITY : 7875 kg
HOOK STROKE : 16 m
HOISTING SPEED : 3.8 AND 0.9 m/min
HOISTING MOTOR POWER : IP55 - CLASS F - 4.2/0.9 kW
CRANE BRIDGE SPEED : APP. 8 m/min
CRANE BRIDGE MOTOR : IP55 - CLASS F. - 1.1 kW
TROLLEY SPEED : APP. 6 m/min
TROLLEY MOTOR : IP55 - CLASS F. - 1.1 kW
POWER SUPPLY ON 3 PHASES : 440 V, 60 Hz.
OPERATING VOLTAGE : 48 V
HOISTING AS WELL AS LONGITUDINAL AND TRANSVERSAL
MOVEMENTS ARE STOPPED BY ELECTRICAL LIMIT SWITCHES.
THE PENDANT CONTROL IS ATTACHED TO RELAY CABINET OF THE
HOIST / TROLLEY.
LENGTH OF CONTROL CABLE : 15 m
PAINTING COLOUR : Munsell 10GY 8/4
2 x 15 m TOOTH RACKS, 30x30 mm, MODUL=5. LENGTH OF 3 m
15 m FLAT CABLE CONDUCTOR SYSTEM
1 PCS. SWITCH BOX and JUNCTION BOX.
300 W WORKING LAMP.
4 pcs. RUBBER BUFFER TO BE SUPPLIED.
Class: GL
17-11-08
A/S

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A/S

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A/S

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Parts List
Drawing No.:50143000-71-01
6,3 t DCB Single Girder E/R Cranes for Wenchong Shipyard
Hull No.:GWS379-84,93-98
TEU 2800 Container Vessel
Pos. No. Part

Crane bridge
Trolley
1
Wheel Assembly
2
Reduction Unit, Crab, Leroy
3
Drive Pinion
4
Chain Hoist, Liftket
5
Wheel Assembly
6
Drive Pinion
7
Ball Bearing
8
Reduction Unit, Crane Bridge
9
Drive Shaft for Crane Bridge
10
Ball Bearing
11
Relay box
12
Flat cable conductor sys., crane
Track section
Joint sleeve
Leading trolley
Trolley
End anchor
Intermediate top support bracket
Anchor top support bracket
Flat Cable
13
Flat cable conductor sys., Longitudinal
Main Switch
Junction box
Track section
Leading trolley
Trolley
End anchor
Joint sleeve
Intermediate top support bracket
Anchor top support bracket
Flat Cable
14
Limit switch, Crane, Telemecanique
15
Tooth rack
16
Limit switch, Crab, Telemecanique
17
Ball Bearing
18
Drive Shaft for Crab
19
Pendant control, Telemecanique
20
Working Lamp
21
Rubber Buffer
Dimension
Mb 2401, LS80 FAST, i=50:1

m=5, z=13, 35 M7
Liftket Star 6300kg
m=5, z=13, 40 M7
PCTJY 40
40
PSHE 40
500x150x120
2300
2384
2319/21/41
2319/21
2151/21
2357
2358
8x1,5
2300
2319/21/41
2319/21
2151/21
2384
2357
2358
4x1,5
ZCK-J404-Y43
30x30, m=5
ZCK-J404-Y43
PCTJY 35
35
XCA-A08
300 W
80x80, M12
Quantity
1
1
4
1
1
1
8
2
2
1
1
3
1
1 set
2
1
1
5
1
4
1
9m
1 set
1
1
16 m
1
15
1
3
11
1
22 m
1
2x15 m
1
1
1
1
1
4
Drawing
10A453-02
10A47-28b
20B012-005
21B-003-02
10B007-10
21B-003-02
10B453-03
10A47-16b
A/S

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A/S

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Lubrication
6.3 t DCB Single Girder E/R Crane
A/S
Reduction Unit, Crane, ABM
Wheel Assembly
Wheel Assembly
Drive Pinion and Tooth Rack
Ball Bearing
Ball Bearing
Drive Pinion and Tooth Rack
Ball Bearing
4
5
6
7
8
9
10
Part No. Part

1
Chain Hoist
Chain
Bearings
Gears
Idler sprocket
2
Reduction Unit, Trolley, ABM
As required
As required
Mobilgrease HP
2.4 litre
To be advised
As required
2.9 litre
Mobilgrease HP
Mobilgear ?
Mobilgrease HP
Oil (acc. to ISO 6743/6)
Mobilgear 630
Oil (acc. to ISO 6743/6)
Mobilgear 630
Mobilsynthetic Chain Lube As required
Every month
Lubricated for life
Lubricated for life
Annually
Lubricated for life,
every 10000 hours
Lubricated for life,
every 10000 hours
Lubricated for life
Lubricated for life
Every three months
Lubricated for life
Lubricated for life
Every three months
Lubricated for life
Quantity
Shell product
Interval
Hull No.GWS379-84 / 93-98 (DCB 50143000)

Phone +45 98 35 31 33 Fax + 45 98 35 30 33
Keep chain clean
Notes
A/S

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A/S

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Electric chain hoists

Operating instructions
Please dont use the hoist

before all operators have carefully read this manual and have
signed the form on its rear
cover.
Contents
1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
3
3.1
3.1.1
3.1.2
3.1.3
3.1.3.1
3.1.3.2
3.1.3.3
3.1.4
3.1.5
3.1.5.1
3.1.6
3.1.7
3.1.8
3.2
3.2.1
3.2.1.1
3.2.1.2
3.2.2
3.2.3
4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.3
4.4
4.5
5
5.1
5.2
5.3
6
6.1
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.3
7.3.1
7.3.2
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.5
7.5.1
7.6
7.6.1
7.6.2
8
8.1
8.2
8.3
9
10
11
11.1
11.2
11.3
12
Safety advice
Advice for the use of electric chain hoists
European Regulations
Spare parts
Technical overview
Assembly options
Explanation of type designation
Sectional view
Illustration of the load chain configuration
Assembly
Mechanical assembly
Hook tackle
Hook block
Stationary suspended hoists
Version Suspension with suspension eye
Version Suspension with single-hole eyeVersion Suspension with hook suspension
Gear ventilation
Mounting the chain box
Outside chain bags
Assembling the load chain - Single fall version without pre-assembled piece of chain
Assembling the load chain double fall version without pre-assembled piece of chain
Replacing the load chain and hold-down
Electric connections
Mains power
Direct control
Low voltage control 24 V
Electric limit switches for lift limitation
Mains / Power voltages
Electric chain hoist with trolley
Mechanical assembly
Positioning the hoist underneath the trolley
Assembly of a trolley with two connecting bolts
Assembly of a trolley with one connecting bolt
Electric trolleys with counterweight
Electric connection of electric trolleys
Technical data for trolleys with two suspension bolts
Technical data for trolleys with one suspension bolt
Tests
Test when used according to BGV D8, section 23 (VBG 8, section 23)
Regular tests
Operations
Prohibitions on use
Maintenance
Maintenance and checks
Construction of the brake
Assembly of the brake
Electric control of the brake
Faults on brake
Checking brake functioning
Safety clutch
Construction of sliding clutch
Adjustment of the sliding clutch
Load chain
Lubricating the load chain before starting and during operation
Testing of wear of the load chain
Measuring wear and replacing chain
Measuring wear and replacing load hook
Maintenance work on trolley
Construction of the trolley brake
Dismantling and assembly of the lifting motor
Dismantling the lifting motor
Assembling the lifting motor
Duty rate of an electric chain hoist
Short- time duty
Intermitted duty
Example
Duty rate of a motorized trolley
Strainer clamp for the control cable
Lubrication
Lubrication of the gear
Lubrication of the hook block and hook tackle
Lubrication of the trolleys
Disposal
3
3
3
3
4
4
4
5
6
6
6
6
7
7
7
7
8
8
9
9
10
11
12
12
12
12
13
13
14
14
15
15
15
15
16
16
17
18
18
18
18
18
18
19
19
19
20
20
20
21
21
21
21
21
22
22
22
22
22
23
23
23
24
24
24
24
25
25
25
25
26
26
26
26
26
Safety advice
1.1
Advice for the use of electric chain hoists
Electric chain hoists are designed to lift and to lower loads vertically and to travel horizontally with those lifted loads (with
trolleys). Every other mode of use is prohibited and the risk is on the operators responsibility. Especially if carrying out
prohibited operations (see topic 6.1) you can get into life trouble.
Please ask the producer for any special mode of use in advance.
Using the hoist to carry people is strictly prohibited!
The modern design of the LIFTKET hoists guarantees safety and economic use.
The patented safety clutch system is located between motor and brake.
This enables the brake to hold the load without any power transmitted by the clutch. The brake acts directly onto the load
via the gearbox by using form fit elements only. The friction clutch does not transmit any load while brake is on.
Before first use please make sure, that all electrical wires are connected safely, that all wires are without
damages and that the whole equipment could be switched off by a main switch.
It is the responsibility of the operator to make sure that all suspension points of the hoist are calculated
to withstand the dynamic forces caused by the lifting equipment safely.
The chain hoist is usable when it is safely suspended and the outgoing chain can leave the hoist safely
in the relevant direction.
Therefore the container for the dead end of the chain outside the hoist must be big enough to allow the
chain coming out. If not, the chain can be trapped inside the hoist and can brake the casing of the hoist.
For use of the hoist in an aggressive environment please consult the producer.
For use in an aggressive environment, in may be necessary to use components made from different materials
The following safety advice is issued for both the maintenance and the operation of the hoist and for most standard uses. It may not necessarily cover all situations. If you are in any doubt, please contact your dealer. This manual will tell you how to operate the hoist and how to handle its suspension or its loads safely.
It is compulsory to take care of the following safety advice. They may not be complete for each mode of use,
please ask the producer or your local service partner if any question came up.
You should keep this manual clean, complete and in a legible condition.
Neither the manufacturer nor dealer accept responsibility for any damage or lack of functionality due to the following:
o Carrying out inappropriate operations for an electric chain hoist
o Product modification without the express authorization of the manufacturer
o Inappropriate operation of the hoist
o Operational errors
o Failure to use the product as instructed in the manual
1.2
European Regulations
The basis for the assembly, first use, certification and maintenance of electric chain hoists are within Germany and within
the area of the European community, the following regulations, and all recommendations of this manual.
Local legislation and directives for different countries may apply in addition to the regulations as stated in this manual
(German/European).
Please pay particular attention to the rules for the prevention of accidents and the statutory regulations
Machine directive
98/37/EG
Low voltage regulation
73/23/EWG
EMV-regulations
89/336 EWG
Electrical equipment for machines
EN 60 204 part 32
Selection of lifting gears
FEM 9.682
BGV accident prevention regulation for electric winches, lifting and pulling equipment
BGV D8 (VBG 8)
BGV accident prevention regulation for use in a crane system
BGV D6 (VBG 9)
BGV accident prevention regulation for slings and load devices
VBG 9a
Certification of the crane by authorised people
ZH 1/27
Certification of hoisting equipment by authorised people
ZH 1/25
The producers guarantee depends on consideration of these regulations and all of this manual. Other national regulations are valid for countries outside of the European community.
Please pay attention to chapter 6 and 6.1 especially!
Maintenance work for hoisting equipment has to be carried out by trained and authorised people only.
The main switch has to be switched off before.
Authorised people have to have a theoretical training as well as experience in the field of cranes and
hoists. They have to have an excellent know-how of the special regulations and must be able to decide whether the lifting
equipment is in a safe working condition or not. They have to fill in the forms of any maintenance work, repair work or
test (for example: maintenance work on brake or clutch).
The hoist is allowed to be used only by people who have complete knowledge of this manual, the manual should always
be available showing who has signed the form on the rear cover of this brochure.
1.3
Spare parts
Only original spare parts must be used. The producers guarantee is given for those spare parts only.
The producer cannot be held responsible for failures and breakdowns caused by use of non-original or wrong spare
parts.
3
Technical overview
2.1
Assembly options
The simple building block system makes it easy to convert the electric chain hoists. This allows the choice of single or
double fall versions, stationary or mobile with manual or electric travelling trolleys, and the installation of greater hoisting and operating heights.
trolley
specially shaped shackle
hook
suspension
single hole
suspension
eye (special)
chain box
suspension
eye
hoisting gear
operating
buttons with
emergency
stop
lift limiter
with elastic washers
hook block with elastic bumper
hook tackle
with elastic bumper
figure 1: Assembly options
2.2
Explanation of type designation
Example:
version 021 / 51
type 2 5 0 / 1 - 8 / 2
version
02 1 / 51
Model- Number
Index for number of lifting speeds
0 lifting gear with one lifting speed
1 lifting gear with two lifting speeds
index of number of hoist body
02 size of hoist body I with chain 4x12
03 size of hoist body I with chain 5,2x15
05 size of hoist body II with chain 5,2x15
09 size of hoist body III with chain 9x27
type 2 5 0 / 1 -
8 / 2
slow lifting speed [m/min]
main lifting speed [m/min]
number of falls
capacity [kg]
According to the Machine directive 98/37 EG you will find all the technical data in the technical documentation attached
to each hoist.
2.3
Sectional view
Number
1
2
3
4
5
6
7
8
9
designation
Cap for control
Control
Cap for fan
Fan
Motor pinion
Stator
Rotor
Clutch unit
Hoist body
1
2
3
Number
10
11
12
13
14
15
16
17
18
Designation
Pinion 1
Load chain
Suspension eye
Sprocket wheel
Gear cover
Cap for gear cover
Terminal block board for power supply, pendant control and motorized trolley
Brake unit
Double fall hook
12
13
14
4
15
5
6
7
8
9
16
10
11
17
18
figure 2: sectional view
2.4
Illustration of the load chain configuration
Use manufacturers original parts only, as these meet the high stress and service life standards required.
chain sprocket
wheel
hold- down
chain guide
chain box
lift limiter
(limit stop)
hook tackle
chain fork
hook block
figure 3:
3.1 single- fall version
3.2 double- fall version
3 Assembly
Assembly work should only be carried out by a trained specialists in accordance with BGV D8, section 24 (VBG 8, section 24).
3.1
Mechanical assembly
3.1.1
Hook tackle
The hook tackle is used to attach loads for hoists in single- fall version.
special
rubber- metal
bumper
special rubber
2 screws
special rubber
2 screws
4 screws
plastic cover
with capacity
label and
threaded bolt
threaded bolt
casing
mark 5
mark 4
casing
load hook
complete
(incl. axial
pressure
bearing)
chain 4x12
chain 5,2x15
figure 4: details of the hook tackle
chain 7,2x21
pressure disc
casing
load hook complete

(incl. axial
pressure bearing)
load hook complete

(incl. axial
pressure bearing)
chain 9x27
chain 11,3x31
During maintenance work the condition of the load hook has to be checked (wear and centre punch spacing, on page of
hook certificate). For the 4 mm and 5 mm hook tackle the plastic cover has to be checked additionally and changed if
worn. Check the condition of the pin, which secures the hook nut, the pressure bearing and the safety latch at regular
intervals.
For the assembly of the hook tackles and hook blocks please tighten the connection screws with the following torques:
Max. load capacity [kg]
Dimension of screws Qty
Tightening torque [Nm]
Hook tackle description
Hook tackle for chain 4x12
250
Hook tackle for chain 5,2x15
500
1250
M10x30 DIN 912
2
51
Hook tackle for chain 9x27
1600
M12x25 DIN 912
2
87
3200
M12x50 DIN 912
4
87
Hook block for chain 4x12
500
M5x25 DIN 912
3
6
Hook block for chain 5,2x15
1000
M6x30 DIN 912
3
10,4
2500
M8x50 DIN 912
3
25,3
Hook block for chain 9x27
3200
M10x45 DIN 912
3
51
6300
M12x55 DIN 912
2
87
M12x60 DIN 912
1
table 1:connection screws with torques for hook tackles and hook blocks
3.1.2
Hook block
The hook block is used to attach the load in double fall version.
rubber
block
casing
screws
bearing
sprocket wheel
safety pin for hook nut
secured by two centre
punches
load hook complete (incl. pressure bearing
hook block for chain

4x12, 5,2x15, 7,2x21, 9x27 and
11,3x31
At all maintenance work the condition of all the parts has to be checked (according to 3.1.1).
figure 5: details of the hook block
3.1.3
Stationary suspended hoists

- basic version
3.1.3.1 Version Suspension with suspension eye

Assembly: The suspension eye section, which forms part of the standard delivery, must be inserted
into the specially provided suspension holes on the electric chain hoist and pinned into
place with the two bolts. Use washers with the lock bolts and secure position with split
pins.
Caution!
The blue marking arrow on the suspension eye must be on the chain box side.
suspension eye
blue arrow
bolt
chain box side
figure 6: suspension with suspension eye

3.1.3.2 Version Suspension with single-hole eyeAssembly
When changing from single fall use to double fall use, remember to reverse the direction of
the single hole suspension eye. The hole should be positioned directly above the load
hook.
Caution!
The label on the suspension eye must be on the chain box side.
label
single fall use
For changing the suspension with single hole eye for the different
numbers of falls it has to be turned additionally by 180 degrees
so that the relevant symbol is at the chain box side.
small side
large side
label
double fall use
bolt
chain box side
figure 7: suspension with single hole eye
one fall: hook tackle
two falls: hook block
3.1.3.3 Version Suspension with hook suspension

Assembly: The hook suspension included as an option in the delivery has to be pinned with two pins
to the casting and secured with washer and split pins.
label
single
fall use
label
double
fall use
For changing the hook suspension for the different numbers

of falls the traverse of the suspension has to be turned additionally by 180 degrees so that the relevant symbol is at the
chain box side.
small side
large side
chain box side
When changing from single fall use to double fall

use, remember to reverse the direction of the suspension hook. The hook should be positioned directly above the load hook. The label on the suspension hook must be on the chain box side.
one fall: hook tackle
two falls: hook block
figure 8: suspension with hook suspension
3.1.4
Gear ventilation
Having completed assembly, the split washer has to be placed under the oil-filler plug (top side of casing) to avoid oil
leakage due to high pressure inside the gearbox. (see figure 9b)
You will find this split washer fastened with a piece of self adhesive tape next to the oil filler plug.
3.1.5
Mounting the chain box
The following chain boxes are made from plastic (see figure 9a):
chain diameter Max. filling quantity chain box type
4 x 12
16 m
4/16 5/10 7/8
5,2 x 15
10 m
7,2 x 21
8m
table2: plastic chain box
Chain boxes with bigger capacity as shown in the table and chain boxes for STAR 09../ and STAR 11../ are made
from canvas material. (see figure 9b).
canvas
chain box
plastic chain
box
special washer for gear

ventilation
maximal
Kette / chain
16 m 4 mm
10 m 5 mm
8 m 7 mm
maximal
Kette / chain
4/30
chain 4x12 max. 30m
figure 9a
figure 9: oil- filling plug and chain box mounting
figure 9b
Figure 9 illustrates how the chain box is mounted with screw and nylock. The nylock has to be replaced after repeated
use when the nylon becomes noticeably worn.
Caution!
Ensure that the chain box/container is sufficient for the amount of chain you are using.
(Chain dimension and capacity is shown on the canvas chain box/container or at the side
of the plastic one.) Insert the chain end with lift limiter and its rubber bumper loosely into
the chain box. After running the entire chain length through the hoist into the chain box,
check that the box is not overloaded (see capacity mark at the chain box). DO NOT
OVERLOAD THE CHAINBOX.
3.1.5.1 Outside chain bags
If the chain weight is more than 20 kg the strain of the chain bag has to be relieved with a special textile
strap. When fitting the chain bag to the suspension the customer must correctly adjust its position using
the ratchet strap with a load of app. 10 kg inside the bag.
The suspension point of this strap for a stationary suspended hoist has to be provided by the buyer (see
picture 11).
If the hoist is fitted to a trolley the producer provides a dual trolley to fit the chain bag strainer strap (see
picture 12).
Please take care that the strainer strap has to be tightened in accordance with this manual and inspected in regular intervals.
Please use the edge protectors at the suspension points (see pictures 11 and 12).
suspension point
edge protector
canvas strainer strap

not suitable
for single
bolt trolleys
ratchet
figure 10: stationary suspended hoist. The suspension

figure 11: electric chain hoist with chain bag suspended
point for the strainer strap has to be provided
at the tandem trolley (If running around bends
by the user.
please ask the producer first).
The end of the strainer strap has to be fixed and tightened as shown in figure 12.
free end of
the strainer
strap
strainer strap
with ratchet
figure 12: Scheme of the fixed strainer strap
3.1.6
Assembling the load chain - Single fall version without pre-assembled piece of chain
see figure 13
1. Push the pull-in wire (special tool) into and through the chain guide cross plate shown in figure 13-A until the wire
hook is pushed out on the opposite side.
2. Starting with the flat chain link (see figure 13-A); When feeding the chain into the hoist, ensure that the first link is
aligned parallel to the ends (hence at right angles to the sides).
3. Move the chain in by inching the pendant (Fig 13-B)
4. Put the rubber bumper on the chain and assemble the load hook (Fig 13-C)
5. Lower load hook to leave 50cm of dead end load chain yet to run through the hoist.
6. Attach rubber end stop onto the remaining dead end of chain.
7. Attach lift limiter onto the 3rd link of the dead end (Fig 13-D).
This lift limiter exists to prevent the chain from running through the hoist. It should not be
Caution!
used as an operational limit.
8. Assemble chain bag according to 3.1.5.
9. Allow the chain to run into the chain bag and lubricate the entire length of the chain. Allow filling of
the chain box only by running the chain through the hoist by using the motor. To prevent knots inside the chain collector do not put the chain in the bag directly.
*Lift limiter
The lift limiter is designed to prevent the dead end of chain running out of the hoist.
It is used in emergency and cannot be used regularly as an operational low limit switch. For safe operation, the rubber washer under the dead end stop cant possibly do that without being worn or lost.
figure 13 A
10
figure 13 B
figure 13 C
figure 13 D
figure 13: Assembling the load chain single fall version
figure 13 E
3.1.7
Assembling the load chain double fall version without pre-assembled piece of chain
1. First insert the load chain into the basic hoist casing as described either under 3.1.6 or 3.1.7 depending on version.
2. Pull the chain through the hook block using the pull in wire (special tool) (figure 14-A). When feeding the chain into
the hoist, ensure that the first link is aligned parallel to the ends (hence at right angles to the sides)
3. Move the chain in by inching the pendant (Fig 14-C)
4. Insert the pull in wire through the hook block (Fig 14-B)
Never allow the chain to be twisted between the chain outlet and the hook block! If the assembly according with figure 14-B or 14-C is not possible without a twisted chain one chain
Caution!
link has to be cut and removed to allow correct assembly.
Do not turn or swivel the hook block around the horizontal axis between the two chain falls.
5. Loosen the four screws (Part#1Fig 15) of the chain guide and take the chain guide out of the hoist.
6. Pull the fork out of the hoist, which is available for securing the second chain fall and then pull the chain end from
the hook up to the cross chain hole on the under casing of the hoist to the point where the first link protrudes inside
the casing. (Fig 14-C) The fork should then be inserted into the hoist to capture this link.(Fig 14-D)
Caution!
This link must engage the hole without twisting the chain. If the chain presents itself to the
hole at right angles, you may either remove the first link or re-thread the chain at 90 degrees
7. Pull hard on the chain to ensure that it is securely fixed.
8. Re-assemble chain guide (Fig 14-E)
9. Check that the chain is not twisted
10. Lubricate entire length of chain
Figure 14-A
figure 14-B
Cross chain
hole on the
under casing of
the hoist
figure 14-D
figure 14-E
figure 14: Assembling the load chain double fall version
figure 14-C
figure 14-F
11
3.1.8
Replacing the load chain and hold-down
The chain guide and the hold-down must also be changed when load chain is being replaced.
1. Let worn chain move out
2. Loosen 4 screws (1)
3
3. Take out chain guide (2)
4. Press the hold down (3) out, using the screwdriver (arrow in
figure 12)
5. Put new hold down in by turning it trough the groove over the
sprocket wheel
6. Push in chain guide and screw tight
2
7. Fit new chain in single- fall designs as described in the preceding section
figure 15: Replacing the load chain and hold-down

3.2
Electric connections
Electrical installation must comply with DIN EN 60204-32 or relevant national regulations.
After having completed the installation, checks have to be executed in accordance with the European
Regulation DIN EN 60 20432, section 19 or national regulations.
Details of the control can be seen in the wiring diagram. The electric installation complies with the currently
valid DIN EN 60 204 part 32.
3.2.1
Mains power
The mains supply (main incoming line conductor) must be able to be disconnected at all poles by means of a mains
switch (in accordance with DIN EN 60 204-32 section 5.3).
Works on the electric installation may only be carried out by trained specialists and equipment must first be disconnected
from the power mains supply.
Fuses (slowly blowing) at 400 V (3 phase) in front of main switch:
table 3:
fuse (slowly blowing)
example for version
6A
STAR 02../ and 03../
10A
STAR 05../ and 07../
STAR 09../ and 11../
Check if the main voltage complies with that specified on the type plate.
Connect mains supply lines and control line in accordance with wiring diagram.
The L1, L2, L3 and PE terminals for the main connection are located under the gear cap. Line 3 + PE
(minimum cross section 1,5 mm2) are necessary for the connection.
After connecting, press button for lifting. If the load moves downwards, interchange the L1 and L2 supply
cores. (The mains supply must be turned off!).
If the hoist is equipped with an emergency stop (according to DIN EN 60 204 32) it will be a read mushroom shaped button on the pendant.
The cessation of the use of the hoist by the use of the emergency stop does not constitute the correct shutting down of
the equipment.
The connection terminal for the control cable and the electric trolley are located under the gear cap.
The polarity of the supply network phases must be set for clockwise (right turning) rotation. If they are incorrectly set, the
hoist will operate in reverse and will lift when the Down button on the controller is pressed. Please ask your electrician
to set the power supply correctly. The polarity of the supply network is correct if the hoist will lift the load upwards when
the Up button is pressed.
3.2.1.1 Direct control
brake side
brake
brake contactor
or contactor to
switch current
figure 16: direct control

12
cable screw motorized trolley

cable screw main supply
rectifier
terminal block
board
Motor control is been done by direct switching of the mains in the control pendant.
3.2.1.2 Low voltage control 24 V
This mode of control is available as an option.
The contactors are easily accessible on a plate underneath the cover next to the lifting motor. On the same plate, you will
find the optional limit switches. See wiring diagram.
transformer
fuses primary and secondary

1,25 A
brake side
contactors
emergency stop K1
lifting / lowering K2/K3
lifting main K4
Motor side
1
2
3
terminal block board
rectifier
terminal block board
figure 17: low voltage

control
1 connection for motorized trolley

2 connection for main supply
3 connection for control cable
limit switch for lifting / lowering the load
Control occurs in the control circuit, which receives 24 Volts through a safety transformer. This safety transformer can
also be used for other primary voltages (reserve of terminal connections). Other secondary voltages are possible.
If the control is fitted out with an emergency stop in accordance with DIN EN 60204 part 32, a main contactor is also
located under the motor side cap for control and the emergency stop button is fitted on the control pendant.
3.2.2
Electric limit switches for lift limitation
As an additional option, all electric chain hoists equipped with low voltage control may be fitted with limit switches. (Top
and bottom limits).
These limit switches are operated by two buttons protruding out of the chain guide which can be activated either by the
hook (top limit) or lift limiter (bottom position).
Caution! For the proper function of limits, the Up/Down directions at the pendant (see chapter 3.2.1)
must be set correctly. Check the function for switching off by the limit switches for lifting and lowering.
13
limit switch for upper end position

limit switch for lower end position
figure 18: additional electric limit switches for 24 V low voltage
3.2.3
Mains / Power voltages
The electric hoist supply is 400 volts, 3 phase 50 Hz. Different voltages and frequencies are available on request and are
marked on the motor plate.
The electric chain hoists with one lifting speed are suitable for operation with a voltage of 380 - 415 Volt (3 phases).
4 Electric chain hoist with trolley
All trolleys are suitable for
flanges with small width in accordance with DIN 1025 and European regulations 24-62
flanges with medium width in accordance with DIN 1025
flanges with large width in accordance with DIN 1025
Elastic bumpers, level to the centre of the running wheels, must be mounted as limit stops at each end of the track.
Additionally the trolley can be fitted out with an electric cross-bar limit switch. Actuating bars at the travelling girder must
be installed by user.
Radius of curves:
table 4
If the electric trolley has to run along curves the trolley motor has to be assembled at the outer side
of the curve at all times.
trolley with max. carrying load [kg]
up to 1000
up to 2500
up to 6300
4
3 1
electric trolley
radius of curves [m]

1
1,5
2
2
4
3
push trolley - standard
2
3
4
trolley with one connecting bolt
(special version)
1
2
3
4
5
5
electric trolley with low voltage control
14
figure 19: trolley
trolley motor
suspension bolts
spacing washers
suspension eye
contactor control (optional)
4.1
Mechanical assembly
4.1.1
Positioning the hoist underneath the trolley
Fit suspension eye, included in delivery, onto electric chain hoist as described in 3.1.3.1.
Please take care of the following assembly advice:
direct control
low voltage control
trolley motor
connection for the
trolley low voltage
control
cable for trolley

motor supply
mains cable
figure 20: positioning the hoist underneath the trolley

4.1.2
Assembly of a trolley with two connecting bolts
The two trolley connecting bolts are to be fixed to the lateral boards so as to allow a clearance of one to
two millimetres between the running wheel flange and the girder flange. The width is adjusted by inserting spacing washers symmetrically. The suspension eye is mounted between the spacing bushes on
the trolley connecting bolts.
Tighten the nylock nuts with a torque wrench.
table 5
nylock nut in accordance to DIN 985
M16x1,5
M22x1,5
M36x1,5
torque
75 Nm
150 Nm
560 Nm
Movement in the directions shown by the arrows in figure

21 must still be possible between the hoist and the trolley
when assembly is complete.
figure 21: flexibility between chain hoist and trolley

Caution!
The type of suspension eye employed depends on the respective chain hoist type and
trolley type (girder flange width).
When retrofitting a trolley to an electric chain hoist, the suspension eye must be selected
in accordance with table 6 or table 7.
4.1.3
Assembly of a trolley with one connecting bolt
The one trolley connecting bolt is to be fixed to the lateral boards so as to allow a clearance of one to two millimetres
between the running wheel flange and the girder flange. The width is adjusted by inserting spacing washers symmetrically.
Tighten the nylock nuts with a torque wrench. Take care, that the spacing bushes might not be overbraced! The relevant
tightening torque moments are listed in table 5.
15
4.2
Electric trolleys with counterweight
If electric trolleys, especially with double speed, are used on girders with a very
small width it may be necessary to provide a counterweight which prevents
tipping up of the trolley. This unit can be retrofitted to each trolley. This kit
doesnt influence any features of a standard trolley.
figure 22: counterweight for electric trolley
4.3
Electric connection of electric trolleys
Direct control
An electric cable clearly labeled which is approx. 0.5 m long is located on the travel
motor of the electric trolley for connecting to the electric chain hoist. The terminals
are in the electric chain hoist casing. Connection should be carried out as shown in
wiring diagram.
The control pendant has push buttons for controlling the travel motion. The motorized trolley for fast and precision travelling speed has push buttons with two-step
switching.
Low voltage control 24 V (option)
The contactors for switching the trolley motor are located in a special contactor box.
The contactor box must be assembled with two screws M8x16 DIN 912 on the sideplate without motor. Connect the two leads protruding from the contactor box to the
terminal section and to the trolley motor as shown in wiring diagram. After electric
figure 23: hoisting gear with motorconnection, check that the electric chain hoist and trolley are functioning correctly.
ized trolley
16
4.4
Push
type
Technical data for trolleys with two suspension bolts

trolley Motorized
ley type
trol- / Travelling
speed [m/min]
HFS2/3200
EFN
EFN
EFN
EFS1
EFS1
EFS1
EFS2
EFS2
EFS2
EFN
EFN
EFN
EFS1
EFS1
EFS1
EFS2
EFS2
EFS2
EFN
EFN
EFN
EFS1
EFS1
EFS1
EFS2
EFS2
EFS2
EFN
EFN
EFN
EFS1
EFS1
EFS1
EFS2
EFS2
EFS2
EFN
EFN
EFN
EFS1
EFS1
EFS1
EFS2
EFS2
EFS2
EFN
EFN
EFN
EFS1
EFS1
EFS1
EFS2
EFS2
EFS2
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
1000
1000
1000
1000
1000
1000
1000
1000
1000
2000
2000
2000
2000
2000
2000
2000
2000
2000
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
3200
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
16
25
5+20
8
12
5+20
8
12
5+20
8
12
5+20
8
12
5+20
8
12
5+20
8
12
5+20
HFN/5000
HFS1/5000
HFS2/5000
EFN
EFS1
EFS2
/
/
/
5000
5000
5000
/
/
/
3,5+16
3,5+16
3,5+16
HFN/500
HFS1/500
HFS2/500
HFN/500
HFS1/500
HFS2/500
HFN/1000
HFS1/1000
HFS2/1000
HFN/2000
HFS1/2000
HFS2/2000
HFN/3200
HFS1/3200
HFS2/3200
HFN/3200
HFS1/3200
HFN/6300
HFS1/6300
HFS2/6300
EFN
EFS1
EFS2
/
/
/
6300
6300
6300
/
/
/
3,5+16
3,5+16
3,5+16
Load
capacity
[kg]
Girder width /
setting range
[mm]
Suspension eye
type
For version
STAR ___/__
50-106
500
N,S1
500
500
N,S1
110-200
500
S2
210-300
500
S2
020/50
020/52
021/50
021/51
021/52
021/53
030/50
50-106
500
500
N, S1, S2
110-200
050/52
051/52
051/55
210-300
1000
2000
3200
3200
66-135
1000
N
137-215
1000
S1
220-300
1000
S2
66-135
2000
N
137-215
2000
S1
220-300
2000
S2
82-155
3200
N
137-215
3200
S1
220-300
3200
S2
82-155
3200
N
137-215
3200
S1
220-300
3200
S2
90-155
160-226
5000
N,S1
240-310
5000
S2
90-155
160-226
240-310
6300
N,S1
6300 S2
5000
6300
030/51
030/52
030/53
050/53
070/51
070/53
070/54
070/55
070/57
071/53
071/55
070/56
090/52
090/53
090/54
090/57
091/51
091/52
091/53
091/55
091/56
091/58
091/59
091/60
110/51
110/52
110/56
111/50
111/51
111/52
110/54
111/53
table 6: technical data for selecting trolleys for electric chain hoists
Explanation of trolley type designation
HF
EF
EF
HF- push trolley
EF- motorized trolley
N
S1
S2
girder
width
/
/
/
1000
1000
1000
load capacity
for motorized trolley
/16
/5+20
travelling speed
17
4.5
Technical data for trolleys with one suspension bolt
Push trolley
type
EHFN 1000
EHFS1 1000
EHFS2 1000
EHFN 2000
EHFS1 2000
EHFS2 2000
EHFN 3200
EHFS1 3200
EHFS2 3200
EHFN 5000
EHFS1 5000
EHFS2 5000
EHFN 6300
EHFS1 6300
EHFS2 6300
Motorized trolley
EEFN 1000
EEFS1 1000
EEFS2 1000
EEFN 2000
EEFS1 2000
EEFS2 2000
EEFN 3200
EEFS1 3200
EEFS2 3200
EEFN 5000
EEFS1 5000
EEFS2 5000
EEFN 6300
EEFS1 6300
EEFS2 6300
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
table 7: technical data for selecting trolleys

Explanation of trolley type designation
EHF N
/
1000
EEF S1
/
1000
/
EHF- push trolley
EEF- motorized trolley
girder width
N,S1,S2
travelling speed
[m/min]
16 oder 25 oder 5+20 oder 7,5+30
16 oder 25 oder 5+20 oder 7,5+30
16 oder 25 oder 5+20 oder 7,5+30
16 oder 25 oder 5+20 oder 7,5+30
16 oder 25 oder 5+20 oder 7,5+30
16 oder 25 oder 5+20 oder 7,5+30
5+20 oder 7,5+30
5+20 oder 7,5+30
5+20 oder 7,5+30
5+20 oder 3,5+16
5+20 oder 3,5+16
5+20 oder 3,5+16
5+20 oder 3,5+16
5+20 oder 3,5+16
5+20 oder 3,5+16
load capacity [kg]

1000
2000
3200
5000
6300
Girder width
[mm]
66-135
137-215
220-300
66-135
137-215
220-300
82-155
137-215
220-300
90-155
160-226
240-310
90-155
160-226
240-310
7,5+30
load capacity
kg
travelling speed
m/min
5 Tests
Use of the electric chain hoist is possible in accordance with: Accident prevention regulations for
Winches, lifting and pulling equipment BGV D8 (VBG 8) (according to German law)
Cranes
BGV D6 (VBG 9) (according to German law)
5.1
A trained specialist must test the equipment before starting operation for the first time and after extensive alterations.
5.2
An authorised person must test the cranes before starting operation for the first time and after extensive alterations. The
electric chain hoists are type approved.
5.3
Regular tests
A trained specialist must test the equipment, cranes and supporting structures once a year. It may be necessary to
carry out tests more often if the operating conditions are very harsh, that means for example high percentage of use
with full load, dusty or aggressive environment, high duty rate, high number of operation cycles.
Only an authorised person appointed by the BG - associations and experts from the Technical Control Association
(TV) are considered qualified to test cranes.
Trained specialists are highly qualified specialist personnel or the manufacturers after-sales service personnel.
6
Operations
The load may only be moved if it is slung securely and no person is standing near enough to be at risk and when the
operator has received an all clear signal from the person slinging the load (BGV D8, section 29.1, paragraph 1 (VBG
8, section 29.1, paragraph 1)).
All electric chain hoists are suitable for an environment temperature of 20Celsius to +40Celsius as standard.
For use at higher environmental temperature the duty rate has to be reduced correspondingly.
The standard protection class is IP 54.
The motors are manufactured according to the requirement of Insulation Class F.
The load must be placed vertically under the electric hoist before lifting.
The motion directions are indicated with symbols on the control buttons.
Do not turn the chain over edges.
Only the load, the hook block or the hook tackle may be pulled to move an electric chain hoist horizontally with manual travelling gear.
Consult the manufacturer or supplier, if the hoist is to be used in an aggressive environment (for instance acid or
alkaline or dusty environment or to transport inflammable or other dangerous loads).
Dont lower the double fall hook if the chain gets slack.
Repair work has to be done only if mains supply is switched off and no load is suspended on the hook.
After switching off the emergency stop the reason for this failure has to be found out by trained people and the hoist
can only be used if all possible failures are removed.
Lifting the load from the ground has to be done with the lowest possible speed. Before doing this slack sling chains
or ropes have to be tightened carefully.
Cranes in outdoor use require a roof for the park position.
The S.W.L. of the trolley must be equal to the S.W.L. shown on the load-hoisting accessory.
The second chain fall must only be fitted with the fork supplied by the manufacturer.
If the hoist travelling girder is located <2,5 m above ground or platform level it is prohibited to grasp into the travelling area. Grasping into the chain during operation is prohibited.
Prevent oil and grease from getting access to brake and clutch linings
18
6.1
Prohibitions on use
Inching mode
Permanent run against the rubber washers of the lowest and highest hook position (ultimate
safety limit)
Lifting loads with bigger weight as marked on the specification plate
Transporting people
Using the hoist with people being underneath the load
Starting initial operation before an expert or a trained specialist has inspected the equipment.
Moving loads heavier than the nominal load
Pulling loads which are tilted or dragging loads
Tearing off loads
Removing the cover of vessels which are under vacuum
Moving trolley by pulling control pendant or control cable, even if these are relieved of strain
Carrying out repairs without disconnecting the current supply and without special knowledge
Use of hoists with worn rubber elements or without rubber washer on hook tackle, hook block or lift
limiter
Using the lifting chain to sling the loads
Operation with twisted chain, caused by swivelled hook block or wrong mounted fix chain end
Using the lifting chain longer than that stated at the chain bag (see 3.1.5)
Using the hoist with higher duty rate as marked on the specification plate
Using the hoist without having done the regular inspection
Operation after S.W.P. is exceeded
Fitting the second chain fall with a fork not supplied by the manufacturer
7
Maintenance
Trained specialists must carry out all maintenance work.
The maintenance table 7 lists the parts and functions to be tested and the necessary maintenance
work. Defects must be rectified immediately by a trained specialist. Defects have to be reported immediately to the owner. The owner is responsible to get defects remedied by a trained specialist.
Maintenance work may only be carried out if the electric chain hoist is not loaded and the main
switch is switched off so that the power supply is disconnected.
Shorten the periods between maintenance works in very harsh operating conditions, e.g. multi-shift
operation, high number of switching actuation, poor environmental conditions.
Checking for wear

Check suspension hook and load hook for deformation (measure punch spacing) and cracks.
The chain sprocket in the hook block must be replaced if the running surface is worn by about 1 mm.
Replace rubber bumper if worn!
7.1
Maintenance and checks
(note point 1.2 too!)
If the hoist is working under hard conditions (two or three shifts, high percentage of work with nominal load, dusty or high
temperature environment) this maintenance work has to be done more frequently.
daily
visual check of the whole equipment
function check
of the brake
of the lift limiter

check of the brake
check
3 month
maintenance or adjustment of the clutch

wear of the load chain (point 7.4)
lubrication of the load chain
wear of the rubber elements (visual check)
lubrication of single and double fall hooks thrust bearings (point 11.2),
check condition of safety latch, of the pin which prevent the hook nut from
loosening and chisel punch marks
universal checks of
all screws

hold down, chain guide, twisted chain

safety devices
check of the condition and safe positioning of the chain bag and condition
check of the electric cable, power cable and pendant control
check of the trolleys and wheels
yearly

table 8
19
The electric chain hoist is designed in accordance with FEM 9.511. If the hoist is used under the conditions of FEM 9.511, including the described frequency of maintenance work, the electric chain hoist
must be overhauled after 10 years.
7.2
Construction of the brake

SL
Distance
bush
Label
Flange
Spring
Hub
Rotor with
brake lining
Anchor
plate
Magnetic
coil
screw DIN 912

figure 24: construction of the brake
7.2.1
1.
2.
3.
4.
5.
Assembly of the brake

Press the hub onto the shaft
Secure the hub by use of a retaining ring against axial movement
Assemble brake unit to the hub
Screw the unit on by use of three cylindrical screws
Tighten the three screws with equivalent torque taking care to increase torque gradually by rotation setting as in table 8.
STAR
Brake type Screws DIN 912
LIFTKET
STAR 02../...
BFK457-06
3 x M4
STAR 03../...
STAR 05../...
BFK 457-08
3 x M5
STAR 07../...
1)
STAR 09../... BFK 457-10
3 x M6
STAR 09../...2)
BFK 457-12
STAR 11../...
table 9: data of the brake
Torque [Nm]
Coil
resistance Air gap SL
R20 nominal []
nominal
2,8
2101
5,5
1681
9,5
Maximal
[mm]
0,2
0,5
1273
0,2
0,7
1051
0,3
0,8
1)
2)
not valid for STAR 090/54 und 090/57

valid for STAR 090/54 und 090/57
For order of spare parts the complete STAR LIFTKET model no. and type is to be submitted.
Bearing plate
Hub
Brake
Hub
Retaining ring
Assembly of the hub on the wheel Assembly of the brake on bearing

plate
Assembly with torque wrench

figure 25: Assembly of the brake
Dismantling has to be done in the opposite order!

7.2.2
Electric control of the brake
Mode of functioning
The disk brake is supplied through a rectifier circuit. It operates according to the fail safe principle. If there is a power
failure, the brake acts automatically so that the load is held securely in every position. To shorten the braking time the
brake is operated in a DC circuit. The different methods of connection in direct control and low voltage control can be
seen in the respective wiring diagram.
20
7.2.3
Faults on brake
Troubleshooting and fault elimination
Faults
Cause
Remedy
Brake does not
Coil has contact to
Replace the brake (see table 10)
release, air gap ground or between
is not zero
the windings
Wiring wrong or
defect
Rectifier defective or
wrong
Check and correct wiring
Compare wiring at rectifier with wiring diagram; especially correct setting of

the bridge. Measure DC voltage between terminals 5 and 6. If differences
occur change the rectifier
Air gap too large
Replace the brake
table 10: troubleshooting and fault elimination
If rectifier defects occur repeatedly, brake shall be replaced even if no winding short circuit can be detected. Defect may
occur only in warm operating condition.
7.2.4
Checking brake functioning
When breaking the nominal load during the lowering process, the load should be broken after approx.
two chain link lengths and the load should be in a jerking manner.
7.3
Safety clutch
The sliding clutch is located between the lifting motor and main pinion shaft and transmits the torque.
The secondary function is that it limits the transmission of torque depending on the setting, hence preventing overloading of the unit and/or suspension points.
The safety clutch acts as an emergency stop should the hook or end stop limiter run against the hoist body in top/bottom
positions. This must only be used as a genuine emergency limit and must not be employed as a part of the regular running of the hoist. The clutch unit acts as a sliding clutch with asbestos free linings. It is easily adjustable and accessible
and the low wearing lining material doesnt require re-adjustment under normal operational circumstances.
7.3.1
Construction of sliding clutch
1
2
3
4
5
6
7
8
9
10
11
12
1
10
main shaft
clutch hub
teeth ring
drive disc with clutch liner
main pinion shaft
bearing
clutch lining
tension rod
adjusting nut
pressure spring with plate
self locking nut
cap for gear cover
9 11 12
figure 26: Construction of the sliding clutch

7.3.2
Adjustment of the sliding clutch
Adjusting the sliding clutch should only be carried out by a trained or competent person.
1. Test load =1,1 times the nominal/rated load and for maintenance work, the test load is the nominal load.
2. Switch on the chain hoist and check that the test load can be lifted or if the spring balance shows approximately
1.35 times the nominal load (setting of a spring balance is depending on the hoisting speed, higher hoisting speed
will require a higher setting based on the spring balance value)
3. Lower the test load to the floor
4. Decrease or increase clutch torque until the test load is just lifted or the spring balance shows a required value
5. Adjusting the clutch torque as follows:
A
Loosen and remove cap for gear cover (12)
B
Using a spanner hold the retaining self-locking nut (11)
C
Using a second spanner, loosen/tighten the adjusting nut (9) until the required test
load is just lifted or the spring balance shows the required value.
D
Re check clutch torque by lifting the test load.
21
10 11
12
The sliding clutch is set with the test load by the manufacturer.
After changing or replacing the lift motor, it is not necessary to
reset the clutch.
A test with nominal load is required. The original distance between the end of the tension rod and the pressure plate of the
coupling is marked on a tag on the brake coil.
figure 27: Adjustment of the sliding clutch

Note: The clutch has to be adjusted in such a manner, that the nominal load can be lifted safely under all operating conditions.
The sliding clutch acts as an direct actuated lifting load limiter acc. to DIN EN 14492, part 5.2.2.2.1. With hanging load on
the hook, the correctly adjusted clutch shall start to slide at approx. 130 % of the nominal load. Deviations may occur due
to very high or very low lifting speeds.
7.4
Load chain
Hoist chains are means of carrying which require official approval. Therefore, it is important to observe the guidelines
issued by the trade associations centre for accident prevention with regard to round steel chains in hoisting operation,
the guidelines for general inspection and test specifications in accordance with DIN 685, section 5, Nov 1981, the accident prevention regulations in BGV D8 (VBG 8 of April 1997 and in BGV D6 (VBG 9 of April 2001) (valid for Germany) or
equivalent regulations in the respective country.
7.4.1
Lubricating the load chain before starting and during operation
The links along the entire length of the load chain must be lubricated with penetrating gear lubricant oil
before starting operation for the first time and during operation with no load. Subsequent lubrication,
whereby the links must be cleaned first, depends on the degree of use and the operating conditions.
A dry-film lubricant, e.g. lubricating varnish, graphite powder, should be used when ambient influences
are conducive to wear (sand, emery).
7.4.2
Testing of wear of the load chain
The continuous monitoring of the load chain is compulsory according to DIN 685 section 5 and the accident prevention regulations in BGV D8, section 27 (VBG 8, section 27). The load chain must be tested
before starting operation and after approx. 200 operating hours or 10,000 load cycles under normal
conditions or more often under harsh and severe conditions.
Testing must cover checking links, particularly at their points of contact, for wear, cracks, deformation
and other damages.
The chain must be replaced:
if the nominal thickness at the points of contact is reduced by 10%,
if the chain or a link is elongated by 5 %, or an eleven links piece of chain is elongated by 2%
if the links are rigid
The chain guide and hold-down must also be replaced with the chain.
Caution! Replacement of chain shall only be done if spare parts are obtained from the manufacturer or
his approved service agent.
7.4.3
Measuring wear and replacing chain
Chain dimensions mm
Chain measurements
Measure 1 link inside
max. measurement t
4 x 12
12,6
5,2 x 15
15,8
7,2x21
22,1
9 x 27
28,4
11,3 x 31
32,6
11 chain links
134,6
168,3
235,6
302,9
347,8
4,7
6,5
8,1
10,2
Measure chain link diameter

d1 + d2
dm =
2
minimum measurement
3,6
dm=0,9d
See the points 3.1.6 and following for how to change the chain
table 11
7.4.4
Measuring wear and replacing load hook
According to DIN 15401 / part 1 load hooks have to be replaced if the length between the chisel punch marks (dimension
Y) widened more than 10 %. The permissible values are shown on the hook certificate in the Inspection and test logbook.
22
7.5
Maintenance work on trolley
The checks and maintenance work on the motorized trolley and push trolley have to be done in accordance with table 7 of point 7.1.
7.5.1
Construction of the trolley brake

3
3 pieces
screws
M3x8 DIN
912
at a circle
diameter of
58 mm
motor pinion
shaft
figure 28: construction of the brake type BFK

The brake operates absolutely maintenance
free.
figure 29: construction of the brake type EFB

If the brake linings are worn so that the air gap is about 0,9 mm it is
necessary to adjust the gap.
1. Dismantle cover (1).
2. Loosen fan screws (2).
3. Remove rubber gasket (3) and put a thickness gauge 0,25 mm between plate (4) and anti- sticking plate (5).
4. Tighten screw (6) so far that you can remove the thickness gauge
easily.
5. Tighten fan screws (2) symmetrically. Tighten first the screws
opposite the key (torque 4-5,5 Nm).
6. Tighten screw (6) again.
7. Remove thickness gauge.
8. Assemble fan cover (1).
9. Watch the test run of the trolley.
7.6
Dismantling and assembly of the lifting motor
The lifting motor (1) is an independent assembly group. The cooling fan is mounted on the shaft on the B-side under the
fan cap. The clutch hub (4) with coupling teeth (5) is mounted with a key and retaining ring onto the A- side (drive side) of
the motor. The motor flange (8) has a centering and four bore holes for fixing it to the gear housing. The motor cables (9)
are leaving the motor at the motor flange A- side.
10 11
2 3 1 13
14
4
18
15
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
lifting motor
cap of fan
fan
clutch hub
coupling teeth
feather key
retaining ring
motor flange
motor wires
control cover
screws
distribution panel
screws of motor flange
rubber seal
gear housing
main power supply
shaft
paper seal / sealing paste
drive disc
23
17
figure 30: Dismantling and assembly of the lifting motor
15
19 5
6,7 16
7.6.1
Dismantling the lifting motor
1. Loosen the screws of the control cover (10) and remove cover
2. Loosen the 4 screws (11) of the fan cover (2) and remove
3. Disconnect the motor wires from the distribution panel (12) at the control plate using the wiring diagram.
4. At hoists with direct control the motor wires are directly lead through the gear housing and they are clamped on the
terminal board under the cap on the brake side
5. Loosen the 4 screws of the motor flange (13) and remove the motor from the gear casing. Please take care not to
damage the motor wires and do not loose the rubber seal (14) for the motor cables, which is located in the gear
casing (15)
7.6.2
Assembling the lifting motor
Described is the assembly of a complete hoisting motor with fan.
1. Press coupling hub with coupling teeth onto the motor shaft until the shaft collar is reached. Take care that the
feather key (6) is tightly connected between shaft (17) and hub (4)
2. Secure the clutch hub with a retaining ring (7) onto the shaft
3. Attach paper seal or sealing paste (18) on the motor flange (8) (lubricate the paper seals lightly so that it doesnt
slip off)
4. Put the lifting motor on the gear casing (15). The motor cables must be placed in the provided gap in the gear casing and sealed with a rubber profile. Prevent the cables from damage or pinching. When attaching the clutch hub
(19), it may be necessary to rotate the hub gently until the theeth engage.
5. Tighten the 4 screws of the motor flange using spring washers.
6. Connect the motor wires to the distribution panel (12) at the control plate using the wiring diagram. Check that the
wires are not pinched or obstructed and that they are well sealed.
Following the assembly of the control and fan covers, check the rotation orientation of the
motor. If the direction shown on the buttons is reversed, change the positions of motor
wires L1 and L2.
8 Duty rate of an electric chain hoist

The duty rate and the number of operating cycles in one
hour must not be higher than as shown on the specification
plate of the hoist or in a technical data table. (European
regulation FEM 9.682).
s
in m
lifting height [m]
Caution!
1 lifting cycle
lifting
break time
lowering
break time
The duty rate, expressed as the cyclic duration factor

(c.d.f.) is the ratio of
running time to running time + period of rest
formula:
c.d.f. =
running time x 100%

running time + period of rest
t in min
The duty rate is limited by the permissible temperature of the windings in the lifting motor. The running time is depending
on the necessary lifting height, lifting speed of the electric chain hoist and the number of lifting motions required for a particular transport procedure (unloading trucks, feeding machines). It is difficult in practice to take note of the duty rate
during the lifting operation. We, therefore, give the following practical guidelines:
8.1
Short- time duty
table 12: Permissible operatc.d.f.
Driving gear group DIN 5684 part 3
Operating period [min]
ing period without cooling
25 %
1 Bm
20
interval when operation
40 %
2m
40
starts and with a motor tem50 %
3m
40
perature of approx. 20 C.
60 %
3m
60
The duty type is not permissible for the slow speed of 2 speed hoisting motors. After having reached the maximum running time a break is required and the hoist can be further used in intermitted mode.
24
8.2
Intermitted duty
table 13: Operation must be interrupted whenever the highest permissible operating time is reached. The
following breaks are necessary depending on the c.d.f. of the hoist:
c.d.f. [duty rate]

15 %
20 %
25 %
30 %
40 %
50 %
60 %
break
5times running time
4times running time
3times running time
2,5times running time
1times running time
8.3
Example
The electric chain hoist type STAR 030/50 is to lift loads of 250 kg to a height of 6 m.
Performance data:
Carrying load
250 kg
Lifting speed
12 m/min
Duty rate
40 %
At the beginning of the work of unloading the vehicle, the electric chain hoist has a temperature of approx. 20 C.
6 m lifting + 6 m lowering
c.d.f . =
= 1 min
12 m / min lifting speed
Approx. 40 minutes operation without break is possible.
After 40 minutes of running time, 1.5 minutes break for each minute of operating time must be taken (i.e. 1.5 times the
operating time). This break is usually necessary for slinging and taking off loads.
Caution! Cooling periods are imperative for extreme lifting heights (from 10 metres on). Low lifting
speed should only be used for precise lowering and lifting. It is not suitable when greater lifting
heights shall be driven through.
Option!: To protect the lifting motor a thermal overload device is offered as an option (24 Volts low
voltage control is required!).
9 Duty rate of a motorized trolley
If the hoist is equipped with an electric trolley the operators have to take care of the duty rating of the trolley as well.
Motorized trolley
Duty rate
Running time
type
(min)
*The ratings are relevant for
the fast travelling speed
Trolley with a single speed
40 %
40
Trolley with a double speeds
40/20%
40*
table 14: duty rate for electric trolley
10 Strainer clamp for the control cable
The strainer clamp must be fixed in such a way as to
prevent any tensile forces affecting the control cable.
Pulling the chain hoist at the control pendant by means of
the strainer clamp is not permitted.
Strainer clamp
figure 31: Assembly of the strainer clamp
25
11 Lubrication
11.1
Lubrication of the gear
The gear is filled with oil already by the manufacturer. The oil must be changed if the hoist is going to be overhauled.
The oil has to be disposed in accordance with the law of environmental protection.
Use oil with a viscosity of 220 mm2/s at 40 C.
amount of oil:
version (basic type)
STAR 020 to 031
STAR 050 bis 071
STAR 090 bis 111
amount [ml]
175
350
525
table 15
Alternative oils are:

supplier
Castrol
ESSO
Mobil
Shell
ELF
BP
oil type
Alpha Zn 200
EP 220
Mobilgear 630
Omala 220
Reductelf SP 220
XP 220
table 16
BP Energol GR
11.2
Lubrication of the hook block and hook tackle
Lubricate the anti-friction bearings on the hook and the chain sprocket after approx. 20,000 lifting cycles
or once a year, if in heavy use shorten the interval, use a special anti- friction bearing grease.
11.3
Lubrication of the trolleys
The geared wheels of the electric trolley have to be lubricated with grease once a year or after 10,000
driving cycles, if in heavy use the interval has to be shortened.
12 Disposal
After the hoist or its components are taken finally out of operation the parts have to be disposed in accordance to the
laws of environmental protection. Metals, rubber, plastics have to be disposed or recycled separately.
26
ELECTRIC CHAIN HOISTS
The operators have been instructed how to use this hoist and have read the manual and especially the safety
advice.
Name, Surname
Date
Signature
The advice contained in this manual is limited to such matters / facts which are necessary to ensure a safe operation and maintenance of the industrial hoists, to be observed by appropriate skilled and qualified operators.
Further information about other operational conditions are not considered herewith.
In case of any deviations to the normal operations (such as unusual noise, vibrations, higher input current or
frequently blowing fuses) the hoist has to be taken out of operation. The area underneath the load has to be
secured and blocked off; a possible fault could result in danger to people or goods.
The operator or owner of the hoist has to call a trained specialist to repair the hoist.
HOFFMANN Frdertechnik GmbH Wurzen

Dresdener Strae 67/72 04808 Wurzen BR Deutschland
Telefon: (03425) 89 24 0 Fax: (03425) 89 24 99 E-Mail: sales@liftket.de Internet: http://liftket.de
27
Ho 12/2004
We put ideas into gear
Operating Instructions
Rotary Current Low-Voltage Motors
with Cage Rotors, IP54
Safety Precautions:
Work on the motor or the transmission must only be
carried out when these are switched off and secured
against power being restored.
Please refer to the Notes on Safety

and Guarantees
1. General Information
1.1 Area of application
These Operating Instructions apply to totally enclosed fancooled rotary current cage rotor motors and generators for
low-voltage operations. Motor protection type IP54 in
compliance with DIN VDE 0530/Part 5, EN60034, Part5,
IEC 34-5 and DIN EN 60529 Higher protection types are
indicated on the rating plates. The motors are operated at a
height of 1000m above mean sea level at a coolant
temperature of max. 40C. Exceptions are indicated on the
ratings plate.
2.1.2 Mounting surface

The motors must be fixed to a level, vibration-free surface.
The motor feet must be level with the surface to avoid
distortion of the motor body.
2.1.3 Aligning
For coupling operations the shafts must be axially and
radially aligned. Dial gauges must be firmly mounted.
Measurements must be taken at four measuring points each
offset at 90 while the two halves of the coupling are
turned simultaneously.
2.1.3.1 Axial measurements
Compensate for differences by placing steel plates
underneath. Do not exceed an inaccuracy of 0.03mm with
a given measurement diameter of 200mm.
2.1.3.2 Radial measurement
Compensate for differences by moving or by placing steel
plates underneath so that a residual inaccuracy of 0.03mm
is not exceeded. The axial clearance between the two
halves of the coupling (measurement "E") should be set in
accordance with the manufacturer's instructions.
2.2.5 Star/Delta start

To prevent unacceptable current surges on change-over
and instantaneous surges the change-over from star to
delta should only be carried out when the starting current
of the delta level has faded.
2.2.6 Motor protection

Connect the built-in semiconductor temperature sensor
with the reactor as per the switching plan. Any necessary
circuit checks should be carried out with a measuring
bridge (max. 5V) only.
To achieve complete thermal protection for the motors a
thermal time element must be provided in addition as an
overload protection. Fuses by themselves usually only
protect the mains supply and not the motor.
3. Maintenance
Safety Precautions:
Work on the motor or the transmission must only be
carried out when these are switched off and secured
against power being restored.
Check the alignment when the motor is warm.
3.1 Cleaning
The cooling air channels of the motors should be cleaned
regularly depending of the amount of dirt.
3.2 Bearing lubrication
The motor bearings have a LIFETIME LUBRICATION.
1.2 Transport
3.3 Bearing Changes

Shackles (from motor size 100 upwards)
Use only the shackles provided or the transmission
torque support for suspending the flat geared motors. Do
not install any additional loads; the shackles have been
designed to support the weight of the flat geared motors
only.
1.3 Ventilation
The distance between motor air inlets and walls and
components etc. should be 1/4 of the diameter of the air
inlet opening, with a minimum distance of 40mm. The air
flow is from the opposite side to the drive side.
Outflowing air should not be sucked in again directly.
Keep the air inlets and outlets free of all obstructions.
If the motor is fitted with a upper ventilator hood, the air
inlet opening must be fitted with a suitable cover to
prevent foreign bodies falling in. The cover must not
affect ventilation.
1.4 Condensation drain holes

The condensation drain holes must be at the lowest part of
the motor following assembly. The holes must be protected
from impurities.
1.5 Radio interference suppression
The motors comply as a minimum with the radio
interference level N in accordance with DIN EN55014-1,
IEC/CISPR14-1. It is recommended that a local noise
voltage measurement be carried out and suitable noise
suppression means be installed.
1.6 Type of balancing key
Designated on rating plate behind product number.
full key
(full = F)
half key
(half = H)
2. Installation and starting

2.1 Mechanical starting
2.1.1 Transmission elements
When using transmission elements with cause radial or
axial shaft loads during operations (e.g. pulleys, cog
wheels etc.) care must be taken that the maximum
permitted loads are not exceeded. The permitted loads are
shown in the ABM Works Catalogue.
Axial measurement
(angle offset)
Radial measurement
(mismatch)
4. Information on repairs
2.2 Electrics
2.2.1 Insulation resistance - cf. 6.3
2.2.2 Voltage and switching
The voltage details on the rating plates must be observed
and the motor operating voltage compared with the supply
voltage.
The permitted supply fluctuations are 5%. Exceptions,
are shown on the rating plates.
2.2.3 Connection
Each motor has a connection plan in the inside of the
terminal box lid.
The cross sections of the connection cables must be
adjusted to the rated current values.
The cable entries can each be turned by 90 or 180.
Connection of the supply mains and the earth wire must
be carried out carefully so that permanent safe
connections are guaranteed.
To prevent strain on the terminals the connection cables

must be installed with strain relief glands. Care must be
taken that the connection box is free of all foreign bodies,
dirt and humidity.
To guarantee the protection the original seals must be
reused when sealing the connection box. Cable entries not
in use must be watertight and dustproof.
2.2.4 Direction of rotation
The motors are normally suitable for operations in both
directions. The following stator connections are given for
each direction of rotation:
Connection of L1, L2,
L3
Direction seen from

power take-off side
U1, V1, W1
Right
W1, V1, U1
Left
Check for direction of rotation

Use elastic couplings only; stiff couplings require special
bearings.
The motor rotors are dynamically balanced with

completely fitting feathers. Couplings, pulleys, cog wheels
etc. must be balanced with an empty feather slot on a
smooth shaft. Other balancing methods (e.g. with half
feathers) only after prior agreement. Remove the corrosion
protection from the end of the shaft with a suitable solvent
and grease the end of the shaft. Heat part to be mounted to
80-100C. Use the threaded shaft centre/suitable pullers
when fitting/removing additional transmission elements.
Avoid hammering.
To check the direction of rotation switch the motor,

uncoupled and connected in accordance with the
regulations, "On/Off" quickly.
Reversal of direction of rotation:

Type of connecting / winding
Direct connection and changepole motors with separate
winding
S/D connection and change-pole
motors with Dahlander winding
Bearing changes during the guarantee period require the

prior approval of the motor manufacturer.
Measure
Exchange two supply wires
on motor terminal board
Repair work during the guarantee period requires the

prior approval of the motor manufacturer.
4.1 General
It is recommended that original spare parts only are used in
all repair work.
5. Spare parts
5.1 Ordering spare parts
When ordering spare parts please quote the drive type and
the drive number. These are shown on the nameplate.
When ordering spare bearings the resetting sign for the
bearing type (can be seen on the installed bearings, e.g. C3
or C4) must also be observed.
6. Information on storage
Unused Motors have a long shelf life if stored under the
following conditions:
6.1 Storage area
Clean, dry, well ventilated, area with a constant
temperature and free of vibrations.
Before starting check:

6.2 Bearings
After a longer idle period (>1 year) the bearings must be
checked.
6.3 Insulation resistance
The insulation resistance of each phase must be measured
against the earth for a minute with a hand generator (max.
DCV 630V).
If the resistance is lower than as shown below, dry the
winding. Remove the connection lid to change the air.
The temperature of the windings should not exceed
80C. Dry using a standstill or other heater or by feeding
an alternating voltage of 5-6% of the motor voltage
(with switching) to the stator connection terminals U1
and V1.
Measure at intervals until on of the values shown below is

reached.
Winding temp in C
Isolation resistance in M
at Un1KV
15
60
25
30
35
15
75
1

at the feed to the combined
earth
Shocks must not be transmitted to the bearings.
ABM Greiffenberger Antriebstechnik, D-95614 Marktredwitz, Phone (09231)67-0, Telefax (09231)62252, http://www.abm-antriebe.de

Safety information
For electrical operating appliances for use in industrial heavy current facilities.
This Information Sheet with warnings shall apply in addition to the
operating instructions specific to the product and for safety reasons
particular attention must be paid to it.
Danger
The electrical machines and/or appliances are operating
appliances for use in industrial heavy current facilities.
When being operated, the appliances have dangerous live
parts, and in some cases moving or rotating parts as well.
They can therefore cause serious injury or damage, e.g. if
the necessary coverings are removed without cause, if they
are operated in an improper manner, if they are incorrectly
operated or if they are insufficiently maintained.
Those responsible for safety in the plant must therefore guarantee:

- that only qualified persons work with the machines and/or
appliances;
- that the operating instructions and other documentation delivered
with the machine/appliance are available to such persons at all
times and that they are obliged to observe the regulations
contained therein;
- that unqualified persons are forbidden to work at or near the
machines/appliances.
Qualified persons are persons who, by reason of their training,
experience and instructions, as well as their knowledge of the
relevant standards, regulations, accident prevention regulations and
operating relations have been empowered by the person(s)
responsible for plant safety to carry out the necessary work and are
able to recognize and avoid possible dangers (definitions for skilled
workers - cf. DIN VDE 0105 or DIN VDE 0100-300 as well).
Among other things, acquaintance with first-aid measures
and the local rescue devices is required. The prohibition on
the employment of unqualified personnel in work on heavy
current facilities is regulated, for example, in DIN
VDE0105 or DIN VDE 0100-300.

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Note: The ABM assembly brochures, witch can be obtained where

necessary from the distributors, contain further detailed information
on general work, e.g. checking incoming deliveries (transport
damage), long-term storage and conservation of machines, checking
foundations, fitting couplings, fitting and aligning machines, and
installing measures.
Warning To prevent breakdowns it is necessary that
the prescribed maintenance, inspection and revision
measures are carried out regularly by experienced
servicing staff (see above).
Changes to normal operations (increased power consumption, higher
temperatures, increased vibrations, noises etc. or responses from the
monitoring equipment) can mean that functions are impaired. To
prevent breakdowns, which can directly or indirectly lead to serious
injuries or damage, the maintenance staff must be informed without
delay.
IF IN DOUBT SWITCH THE APPLIANCE OFF

IMMEDIATELY!
It should be pointed out that the contents of the Operating
Instructions and product documentation are not part of, and are not
intended to amend, any earlier or existing agreement, undertaking or
legal relationship. All obligations on the part of ABM result in each
case form the Sales Agreement, witch also contains the complete and
exclusive guarantee provisions. These contractual guarantee
provisions are neither extended nor limited by the contents of these
instructions and documentation.
'7
17! & 5"A!':0"!' 1 H6 ! * 18Y
ABM Greiffenberger Antriebstechnik GmbH, D-95614 Marktredwitz, Phone (09231)67-0, Telefax (09231)62252, http://www.abm-antriebe.de
ABM Flat Geared Motors
Safety Precautions:
Work on the motor or the transmission must
only be carried out when these are switched
off and secured against power being restored.
Please refer to the Notes on

Safety and Guarantees
2.3.1 Aligning
Reversal of direction of rotation:
For coupling operations the shafts must be axially and

radially aligned. Dial gauges must be firmly mounted.
Measurements must be taken at four measuring points each
offset at 90 while the two halves of the coupling are
turned simultaneously.
2.3.2 Axial measurements

Do not exceed an inaccuracy of 0.03mm with a given
measurement diameter of 200mm.
2.3.3 Radial measurement

Do not exceed an inaccuracy of 0.03mm. The axial
clearance between the two halves of the coupling
(measurement "E") should be set in accordance with the
manufacturer's instructions.
Check the alignment when the motor is
warm.
1.1 Area of application
1.2 Transport
Use only the shackles provided or the
transmission torque support for suspending
the flat geared motors. Do not install any
additional loads. The shackles have been
designed to support the weight of the flat
geared motors only.
1.3 Ventilation
The distance between motor air inlets and walls and
components etc. should be 1/4 of the diameter of the air
inlet opening, with a minimum distance of 40mm. The air
flow is from the opposite side to the drive side.
Outflowing air should not be sucked in again
directly. Keep the air inlets and outlets free of
all obstructions.
If the motor is fitted with a upper ventilator hood the air
inlet opening must be fitted with a suitable cover to
prevent foreign bodies falling in. The cover must not affect
ventilation.
1.4 Condensation drain holes

The condensation drain holes must be at the lowest part of
the motor following assembly. The holes must be protected
from impurities
1.5 Radio interference suppression

The motors comply as a minimum with the radio
interference level N (Normal) in accordance with DIN EN
55014-1, IEC/CISPR 14-1. It is recommended that a local
noise voltage measurement be carried out and suitable
noise suppression means be installed.
2. Installation and starting
When using transmission elements with cause radial or

axial shaft loads during operations (e.g. pulleys, cog
wheels etc.) care must be taken that the maximum
permitted loads are not exceeded. The permitted loads are
shown in the technical specifications.
2.2 Assembly of detachable geared motors

The detachable gears are placed on the drive shaft of the
machine to be driven and are supported statically by this
shaft. The reaction moment of the gears is supported either
on the torque support of the gear casing or on the flange.
The torque support must be assembled without strain.
2.3 Assembly of flat geared motors flange

construction with an output shaft

at the feed to the combined
earth
2.2.4 Star/Delta start

To prevent unacceptable current surges on
change-over and instantaneous surges the
change-over from star to delta should only be
carried out when the starting current of the
delta level has faded.
2.4.5 Motor protection
To achieve complete thermal protection for

the motors a thermal time element must be
provided in addition as an overload
protection. Fuses by themselves usually only
protect the mains supply and not the motor.
Axial measurement
(angle offset)
Radial measurement
(mismatch)
Knocks and blows will damage the bearings.

Use only suitable devices to fit and remove
the transmission elements.
2.4 Electrical starting

An electrical motor must be installed by an electrician
familiar with the relevant VDE regulations. In particular,
VDE Regulation 0100 on the installation of heavy current
appliances up to 1000V and DIN EN 60204-1, IEC 602041 must be noted. In addition the applicable Regulations of
the provisions laid down by the appropriate (German)
employers' liability insurance association and the
connected switching arrangements must be observed.
2.4.1 Voltage and switching

Compare the switching details on the rating plates as well
as the motor operating voltage and the supply voltage.
The permitted supply fluctuations are 5%. Exceptions,
such as e.g. multirange voltages, are shown on the rating
plates.
2.4.2 Connection
Each motor has a connection plan in the inside of the
terminal box lid.
The cross sections of the connection cables must be
adjusted to the rated current values.
Connection must be carried out carefully in
accordance with the enclosed wiring diagram.
Permanent safe connections for all wiring
including the earth wire must be guaranteed.
To prevent tensile strain on the terminals the connection
cables must be installed with strain relief. Care must be
taken that the connection box is free of all foreign bodies,
dirt and humidity.
To guarantee the protection the orginal seals must be
reused when sealing the connection box. Cable entries not
in use must be watertight and dust-proof.
2.1 Mechanical starting

The flat geared motors may only be operated
in the structural shape as ordered and
indicated on the name plate.
Measure
on motor terminal board
The usual protective motor switches are not sufficient for

motors with a high switching frequency. This type of
motor should be ordered with a temperature sensor in the
winding and monitored by a release device.
1. General Information
These Operating Instructions apply to flat geared motors
with totally enclosed fan-cooled rotary current cage rotor
motors for low-voltage operations. Motor protection type
IP54 and terminal protection box IP55 in compliance with
DIN VDE 0530/Part 5, DIN EN 60529. Higher protection
types are indicated on the rating plates. The flat geared
motors are operated at a height of <= 1000m above mean
sea level at a coolant temperature of max. 40C.
Exceptions are indicated on the ratings plate.
Type of connecting/ winding

Direct connection and changepole motors with separate
winding
S/D connection and change-pole
motors with Dahlander winding
The flat geared motors are normally suitable for operations

in both directions. Before connecting the flat geared
motors the phase sequence in the power supply must be
determined. The following stator connections are given for
each direction of rotation:
U1, V1, W1
W1, V1, U1
3.1 Lubrication
ABM flat geared motors have a LIFETIME
LUBRICATION. Refilling is not usually required under
normal conditions.
Oil
Grease
ca.10000
ca.8000
operating hours
operating hours
3.2 Lubricant
ABM Flat Geared Motors are delivered ready for operating
with ARAL DEGOL BG 220 oil. The amount of oil
corresponds to the design. The required amounts can be
taken from the lubrication plan shown overleaf.
3.3 Bearing changes

Bearing changes during the guarantee period
require the prior approval of the motor
manufacturer.
3.4 Information on storage

The drive motors must be stored in a clean, dry, well
ventilated area with a constant temperature and free of
vibrations.
After a longer idle period (1 year) the bearings must be
checked. The insulation resistance of each phase must be
measured against the earth for a minute with a hand
generator (max. DCV 630V).
4. Information on repairs
Repair work during the guarantee period
requires the prior approval of the motor
manufacturer.
4.1 General
2.4.3 Direction of rotation
Connection of L1, L2, L3
3. Maintenance
Direction seen from

power take-off side
2/4-stages 1/3-stages
right
left
left
right
It is recommended that original spare parts only are used in

all repair work.
5. Spare parts
5.1 Ordering spare parts
For spares orders it's absolutely necessary to know the type
of drive and number of the drive. Please mention the part
number according to the spares drawing.
Check for direction of rotation

To check the direction of rotation switch the
motor, uncoupled and connected in
accordance with the regulations, "On/Off"
quickly.
If the gear shaft and the machine shaft are directly coupled
the shafts must be in alignment with one another.

Safety information
for electrical operating appliances for use in industrial heavy current facilities
WARNING
It is assumed that the basic

planning work in the facility, as well as all
work
regarding
transport,
assembly,
installation, starting up, maintenance and
repairs will be carried out by qualified
personnel and/or checked by the responsible
skilled staff.
This Information Sheet with warnings shall apply in addition to the

operating instructions specific to the product and for safety reasons
particular attention must be paid to it.
DANGER
The electrical machines and/or appliances are
operating appliances for use in industrial heavy
current facilities. When being operated, the appliances
have dangerous live parts, and in some cases moving
or rotating parts as well. They can therefore cause
serious injury or damage, e.g. if the necessary
coverings are removed without cause, if they are
operated in an improper manner, if they are
incorrectly operated or if they are insufficiently
maintained.
Those responsible for safety in the plant must therefore guarantee:

that only qualified persons work with the machines and/or
appliances;
that the operating instructions and other documentation
delivered with the machine/appliance are available to such
persons at all times and that they are obliged to observe the
regulations contained therein;
that unqualified persons are forbidden to work at or near the
machines/appliances.
Qualified persons are persons who, by reason of their training,
experience and instructions, as well as their knowledge of the
relevant standards, regulations, accident prevention regulations and
operating relations have been empowered by the person(s)
responsible for plant safety to carry out the necessary work and are
able to recognize and avoid possible dangers (definitions for skilled
workers - cf. VDE0105 or DIN VDE 0100-300 as well).
Among other things, acquaintance with firstaid measures and the local rescue devices is
required. The prohibition on the employment
of unqualified personnel in work on heavy
current facilities is regulated, for example, in
DIN VDE0105 or DIN VDE 0100-300.
The following must be particularly observed:

-
Technical data and details as to the permitted application

(conditions for the assembly, connection, environment and
operations), with are contained, among other places, in the
catalogue, in the order documentation, in the operating
instructions, on the rating plates and in other product
documentation;
general assembly and safety regulations;
local provisions and requirements specific to the facility;
the correct use of tools and lifting and transport devices;
the use of personal protective clothing;
assembly conditions for appliances delivered in accordance
with IPOO (without covering): during operations the required
protection against accidental contact must be present and/or
dangerous approaches prevented.
For the sake of clarity the operating instructions cannot contain all
the detailed information on possible model variations, and
particularly cannot take into consideration every possible case of
installation, operation or maintenance. For this reason the Operating
Instructions can basically only contain information which is required
for the correct use of the machine or appliance by qualified personnel
(see above) in industrial applications.
If in special cases more exacting demands are made for the planned
utilization of the machine or appliance in non-industrial areas (e.g.
child-proof safety devices or similar) these conditions must be
fulfilled on assembly by the customer with additional safety devices.
It is recommended that the services of the ABM Customer Service

Department are used for all servicing.
NOTE: The ABM assembly brochures, witch can be obtained

where necessary from the distributors, contain further detailed
information on general work, e.g. checking incoming deliveries
(transport damage), long-term storage and conservation of machines,
checking foundations, fitting couplings, fitting and aligning
machines, and installing measures.
WARNING To prevent breakdowns it is

necessary that the prescribed maintenance,
inspection and revision measures are carried
out regularly by experienced servicing staff
(see above).
Changes to normal operations (increased power consumption, higher
temperatures, increased vibrations, noises etc. or responses from the
monitoring equipment) can mean that functions are impaired. To
prevent breakdowns, which can directly or indirectly lead to serious
injuries or damage, the maintenance staff must be informed without
delay.
IF IN DOUBT SWITCH THE APPLIANCE

OFF IMMEDIATELY!
It should be pointed out that the contents of the Operating

Instructions and product documentation are not part of, and are not
intended to amend, any earlier or existing agreement, undertaking or
legal relationship. All obligations on the part of ABM result in each
case form the Sales Agreement, witch also contains the complete and
exclusive guarantee provisions. These contractual guarantee
provisions are neither extended nor limited by the contents of these
instructions and documentation.
If there are any uncertainties regarding this, especially if detailed

information specific to the product is lacking, clarification can be
obtained from the competent ABM distribution agency. Please quote
the machine or appliance type description and manufacturing
number.
Structural shape in compliance with DIN EN 60034-7, VDE 0530-7, IEC 4-7
Gear

850
(950)
1700 (1900)
1700 (1900)
1700 (1900)
1700 (1900)
3000 (3300)
2900 (3200)
2800 (3100)
2700 (3000)
12500 (13800)
12100 (13300)

700
1200
1200
1200
1200
3000
2900
2800
2700
8500
8100
Mounting position of the flat gear motors

(800)
900
(1000)
(1400) 1600 (1800)
(1400) 1600 (1800)
(1400) 1600 (1800)
(1400) 1600 (1800)
(3500) 2900 (3300)
(3400) 2800 (3200)
(3300) 2800 (3200)
(3200) 2700 (3100)
(10000) 11000 (12600)
(9500) 10800 (12400)
Lubrificant: Oil ARAL DEGOL BG220
700
1250
1250
1250
1250
2500
2400
2400
2300
8400
8000
(800)
(1450)
(1450)
(1450)
(1450)
(2900)
(2800)
(2800)
(2650)
(9700)
(9200)

700
1280
1280
1280
1280
2700
2600
2600
2500
8000
7800

(800)
(1500)
(1500)
(1500)
(1500)
(3100)
(3000)
(3000)
(2900)
(9200)
(9000)
700
1250
1250
1250
1250
2700
2600
2600
2500
8000
7800
(800)
(1450)
(1450)
(1450)
(1450)
(3100)
(3000)
(3000)
(2900)
(9200)
(9000)
Lubricants
When changing the lubricant the transmission must be
thoroughly cleaned. The helical gear bearings must be
checked and if necessary exchanged for new bearings.
Do not mix lubricants. This applies in
particular to mineral and synthetic lubricants.
When using synthetic lubricants check their
tolerance with the conical nipples. Too much
lubricant can lead to overheating.
The datas mentioned in () apply to semi-fluid grease

1.3. Description of construction and operation
Wiring diagram 1:
The EFB disc brake is mounted onto the motor end shield
(3). The magnet body (2) lies therein this with the coil
enclosed in it. The armature disc (42) is situated between
ABM Brakes Type EFB 2 and 3
magnet body and brake lining, to which the fan is attached

and which, with this, forms the fan assembly (43). The
pressure spring (9) and the number of adjusting washers
Safety Advice:
(11) beneath the pressure spring determine the amount of
braking torque. The screws (6) and cylinder bearing (7)
Work must only be carried out on the
fix the armature disc to the motor end shield.
and
armature disc (42) which is axially mobile. In this way,
brakes
when
when
power
they
are
is
in
disconnected
position
in
which they cannot be turned on again.
central
pressure
spring
(9)
exerts
pressure
onto
the
it is pressed against the brake lining attached to the fan

assembly (43) and produces braking torque by friction.
By providing a DC current to the winding of the magnetic

coil (2), a counterforce is produced on the armature disc
Check
Safety
particularly:
and
(42) by a magnetic field.
Guarantee
The armature disc is drawn towards the magnet body (1),
advice
across the ventilation gap s , against the pressure of the

A
pressure spring. The braking surface and the fan assembly
(43) are released and braking torque reduced to zero. If
You
must
also
observe
the
safety
the electrical supply is again disconnected, the armature
information given in motor or gearbox
disc is pushed against the braking surface once again by
used
A manual release (13) is provided to release the brakes
instructions
in
for
electrical
industrial
power
equipment
systems.
the
pressure
spring
and
braking
torque
is
produced.
when power is switched off.
By AC switching the brakes, a more gentle onset of the
braking may be achieved, providing more protection for

the drive and less switch noise. As a result, there is a
longer switch off delay.
1.4. Electrical connection
1. General Advice
1.5.2. AC switching (wiring diagram 2)
In the standard version, the coil in the magnet body is
Wiring diagram 2:
fed with direct current. The direct current is drawn from

a Type E2 or G30 rectifier. A 1-pulse circuit (one way
1.1. Range of application

The EFB brake is an additional item of equipment for ABM
motors.
It
is
instructions
which
goes
only
in
the
with
to
it.
be
used
operating
in
conjunction
instruction
of
with
the
the
motor
EFB brakes / single surface brakes are electro-magnetically

activated spring powered brakes with a friction surface.
They work on the off power principle, i.e. the braking
torque is produced by off power friction. If switched off
or if power is lost, the drive is automatically braked. In
this way, the brake meets the requirements of a safety

Apart
from
the
standard
version,
the
brakes
are
also
available with anticorrosion armature plate and manual

release.
ABM
(bridge circuit) is used with the Type G30 rectifier. Stan-
dard supply voltage is 230V / 50-60 Hz (see technical

data).
Maximum
level,
brake
available
1.2. General
brake.
circuit) is used with the E2 rectifier. A 2-pulse circuit
Greiffenberger
Antriebstechnik
on
voltage
request.
By
actuation
is
400V.
selecting
time
application of the machine.
may
Lower
the
be
voltages
suitable
adapted
are
voltage
to
the
1.5. Braking circuit

The brake may be conrolled by a contact wired into the
AC circuit (before rectifier) or into the DC circuit (after

rectifier).
1.5.1. DC switching (wiring diagram 1)

With DC switching, the switch off time t2 is shortest. It
is therefore used wherever exact braking must be applied.
GmbH,
95614
Marktredwitz,
Telefon
( 09231 )
67-0,
Telefax
( 09231 )
62252

3.2. Insert new bearing (38) into bearing housing with
1.6. Adjusting braking torque

In
the
standard
version,
the
brakes
are
supplied
two
with
sealing
3.3. Fix special securing ring (8) onto motor end shield
maximum braking torque. This torque is produced via a
(3) with sloping side outwards.
central pressure spring. Up to 4 adjusting washers are
(8) onto rotor shaft.
be reduced, change the pressure spring and/or reduce the
number of adjusting washers (see table below). Depending
Check
on the adjustment of the brake torque an adhesive plate
holes
may be necessary between the motor end shield and the

armature disc.
steps
configuration.
3.5.
may
not
rotor
apply,
depending
(15) after loosening the fixing screws. Remove

with
compressed
air.
2.3. Remove disc (33) with the hexagonal

toothed
washer
(32).
In
configurations
screw (31) and
with
2nd
Pull
bearing
shaft
over
Brake
Motor

2.2. Unscrew manual release (13) bolts and remove fan

dust
shaft
31, 32 and 33.
fan
thickness
is
assembly
less
than
(43)
1,5
if
2.7.
Withdraw
2.8.
Withdraw
(22).
manual
release
hexagonal
(13)
screws
lever
(6)
and
ring
adjusting
washers
(41)
in
into
Configuration
with
follows:
special
securing
motor
from
(38),
the
operating
fitting
appropriate
edge,
removal
disc
out
of
the
rotor
apparatus
for
with
ball
bearing
and
unscrew
retaining
bolts
fixing
shaft,
ring
with
(8)
the
edge and bearing (38).
!"
in
simultaneously
the
correct
position
retaining
bolts
according
bearing
to
into
the
with
table).
motor
torque
end
key
according
ring:
bearing
adjusting
to
Place armature disc (42) in correct position on pressure

side.
Put
and
push
bearing
manual
operating
disc
packing
washer.
Threaded pin
the
screw
thread,
243.
through armature disc (42). Screw hexagonal screws (6)

3.12. Tighten up hexagonal screws (6) with torque key
(tightening
torque
Push
4 Nm
M4 * 60
6 Nm
M5 * 80
the
pressure
according
pressure
spring
to
(22)
table).
and
lever
for
manual
shaft, with brake lining being appropriate to the adjusted

brake
torque.
3.15. Fix disc (33) and toothed washer (32) and screw
flat head screw (31) into the rotor shaft so that the spacing
plates may just be removed. In configuration with 2nd
shaft end, a nut is screwed onto the rotor shaft instead
of
these
removed.
parts,
so
that
the
spacing
plates
may
just
be
(tightening
torque
Tighten
the
3.17.
Tighten
key
up
flat
according
up
the
table).
fixing
first.
head
to
screw
screw
(31)
opposite
again.
Remove
armature disc (42) and motor end shield (3).

3.18.
Push
cable
into
flat
plug
3.19. Screw on fan cover. Screw in manual release (13)

bolts.
3.20.
Connect
up
brakes
and
test
operation
4. Adjustment of brakes
The brakes must be adjusted when brake wear is so far
advanced that the maximum possible working ventilation
gap s max (see table below) is reached. Otherwise no safe

A
separation
and
braking
can
be
4.1. Switch off power to drive.
maintained.
4.2. Unscrew bolts from manual release (13) and remove

fan cover (15) after slackening fixing screws.
4.3. Check minimum thickness of braking surfaces. Renew

fan assembly if minimum thickness falls below 1,5mm.
4.4. Slacken fixing screws (14) and insert two spacing

(thickness
according
to
adjusted
braking
torque
in table) between motor end shield (3) or, if available,

adhesive sheet (18) and armature disc (16).
4.5.
Screw
flat
head
screw
(31)
into
rotor
shaft
until
spacing plates can just be removed. On the version with
2nd shaft, screw a nut onto the rotor shaft instead of these
parts
spring
(9)
shield.
until
spacing
plates
can
just
be
removed.
4.6. Tighten fixing screws (14) evenly with a torque key
(tightening torque see table). Begin with screw opposite

key. Tighten flat head screw (31) again
4.7. Remove spacing plates. Fix O-ring (62) into groove

between armature disc (42) and motor end shield.
Observe
below).
washer.
on
Loctite
spacing plates and fix O-ring (62) into groove between
release
and
glue
example
3.11. Push cylinder bearing (7) and hexagonal screws (6)
(131)
Tightening torque
cylinder screw (Pos. 71)
table)
metal
for
key
appropriate for the desired braking torque into the motor

end
end
3.16. Tighten up fixing screws (14) evenly with a torque
3.7
cover:
3.7. Screw threaded pins (29) into motor end shield.
When operating with a loose bearing,
!
screw
3.8. Insert adjusting washers (11) (number and thickness
securing
motor
3.10. Attach adhesive sheet (16) to the magnet body (1).
plates

fitting
corresponding
the
3.14. Fix key (30). Push fan assembly (43) onto rotor
shield
table).
3.1. Put operating disc (131) onto motor end shield (3).
bolts
edge,
end
3.6. Tighten up cylinder screws and retaining bolts (69)
3. Assembly of brake
use
fitting
motor
screws.
(41) out of motor end shield (3).
special
the
shield. Remove threaded pin and screw in the 4 cylinder
2.13. Take operating disc (131) and shaft sealing ring
with
the
as
with a torque key (tightening torque according to the
sealing ring (41) and operating disc (131) from
into
the holes of armature disc (42).
cover, until the bearing cover fits onto the motor end
(69).
(thickness
table)
(13) handle is parallel with the motor end shield (3) on
holes of the motor end shield (3) as far into the bearing
cover:
in
self-locking hexagonal nuts (25) until the manual release
3.5. Screw the three cylinder screws (71) via the free
2.12. Withdraw motor end shield (3) complete with shaft
Configuration
31
screw in.
2.11. Unscrew cylinder screws (71) from motor end shield

(3)
38
3.4. Push retaining bolts into motor end shield (3) and
2.15. Remove bearing (38) and operating discs (131) from

Configuration
102 (178)*
plates
setting
release handle (13) onto threaded pins (20). Tighten up
Check correct position of fixing holes
shield.
the motor end shield (3).
26
disc (131) and shaft sealing ring (41) onto rotor shaft
2.14. Slacken off special securing ring (8) from the motor
end
33
3.3. Push motor end shield (3) complete with operating
ring:
and
95 (158)*
up
spacing
torque
shield.
3.13.
bearing cover (70)
(69).
(131)
21
3.2. Screw threaded pin (see table for dimensions) into
2.13. Withdraw motor end shield (3) complete with ball

bearing
two
into motor end shield (3).
27
shield
use
(3) via hole for the shaft sealing ring.

bolts
by
When operating with a loose bearing,
(3) and withdraw securing ring (98) from motor end shield
retaining
onto
79 (127)*
with
end
2.11. Remove shaft sealing ring (41) from motor end shield
Unscrew
shield
touching,
18
torque
(11).
(3).
as
end
until
24
into motor end shield (3).
Depending on configuration of the motor, proceed with
2.12.
Place
braking
3.1. Press shaft sealing ring (41) in the correct position
and
(3) and pull off electrical plug connections on motor end
dismantling
the
Configuration
2.10. Unscrew threaded screws (20) from motor end shield
further
motor
ring
73 (119)*
soon
Tighten
(tightening
pressure
2.9. Remove armature disc (42), O-ring (62), pressure

and
on
bearing
in motor end shield (3) and press a new shaft sealing

shield.
alternately
evenly from the motor end shield (3)
shield
fixing
3.6. Attach securing ring (98) onto rotor shaft via hole
lining
mm.
2.6. Remove self locking hexagonal nuts (25).
(8)
release.
of
Length [mm] Outside- [mm] Inside- [mm]
retaining
2.5. Check minimum thickness of brake lining.
Renew
mounted
meets
and key (30) .
spring
manual
inner
As
2.4. Slacken fastening screws (14), withdraw fan assembly
springs
for
positioning
*Values in parentheses for configuration with 2nd shaft end
end, a nut with keyway is to be removed instead of parts
(43)
to
spring (9), with gap for O-ring on the motor end shield
correct
means of an appropriate bush.
on
2.1. Switch off power to drive.
friction
3.9.
3.4. Push retaining bolts (69) onto motor end shield (3).
2. Dismantling the brakes
cover
Push motor end shield
(3) complete with bearing (38) and special securing ring
situated under the pressure spring. Should braking torque
Individual
discs.
the
Braking torque
Pressure spring
Adhesive sheet
in Nm
(colour mark)
requisite
1*
2*
6,0 - 7,5
No
6,0
6,8
7,5
3,8 - 5,4
White
No
3,8
4,2
4,6
5,0
2,9 - 3,7
Green
No
2,9
3,1
3,3
2,1 - 2,8
Green
Yes
2,1
2,3
1,5 - 2,0
Yellow
Yes
1,5
1,0 - 1,4
Tan
Yes
1,0
colour
marks
(see
table
4.8. Put on fan cover (15) and fasten. Screw in manual

release (13) bolts.
4.9. Connect up brakes and test operation.
Number and thickness of adjusting washers
Spacing plate
Max. working venti-
Brake
thickness (mm)
lation gap sA max
Lining
Hex. screw (6)
Retaining bolts (69)
Fix. screws (14)
0,25 - 0,3
0,6
WS 5907
4,5 + 0,5
3,8
4 - 5,5
5,4
0,25 - 0,3
0,7
WS 5907
4,5 + 0,5
3,8
4 - 5,5
3,5
3,7
0,25 - 0,3
0,9
WS 5907
4,5 + 0,5
3,8
4 - 5,5
2,5
2,6
2,8
0,25 - 0,3
0,55
WS 5900
4,5 + 0,5
3,8
4 - 5,5
1,6
1,8
1,9
2,0
0,25 - 0,3
0,65
WS 5900
4,5 + 0,5
3,8
4 - 5,5
1,1
1,2
1,3
1,4
0,25 - 0,3
0,9
WS 5900
4,5 + 0,5
3,8
4 - 5,5
1,0
1,1
3*
4*
Tightening torque in Nm
0,7 - 1,1
Light-red
Yes
0,7
0,8
0,9
20,2 - 25,0
No
20,2
22,6
25,0
0,25 - 0,3
1,1
WS 5900
4,5 + 0,5
3,8
4 - 5,5
0,25 - 0,3
0,6
WS 5907
7 + 0,5
6,5
15,2 - 21,6
White
No
15,2
16,8
18,4
20,0
7-9
21,6
0,25 - 0,3
0,8
WS 5907
7 + 0,5
6,5
8,9 - 13,3
Blue
No
8,9
10,0
11,1
7-9
12,2
13,3
0,25 - 0,3
1,0
WS 5907
7 + 0,5
6,5
4,1 - 7,9
Green
Yes
4,1
5,0
6,0
7-9
6,9
7,9
0,25 - 0,3
0,85
WS 5900
7 + 0,5
6,5
7-9
2,9 - 4,7
Yellow
Yes
2,9
3,3
3,8
4,3
4,7
0,25 - 0,3
1,2
WS 5900
7 + 0,5
6,5
7-9
1,3 - 2,3
Light-red
yes
1,3
1,5
1,8
2,0
2,3
0,25 - 0,3
1,4
WS 5900
7 + 0,5
6,5
7-9

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DANISH CRANE BUILDING A/S

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

Marinequip China Co., Ltd

6.3 t DCB SINGLE GIRDER E/R CRANE

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

Parts list, drawing

Main and key diagram

Manual and parts list:

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

DANISH CRANE BUILDING A/S

6,3 t DCB Single Girder E/R Crane

No. F645283 0009

No. F645283 0008

DANISH CRANE BUILDING A/S

TEST REPORT FOR ENGINE ROOM CRANE

Wenchong Shipyard GWS 382

(Always state this number when ordering spare parts)

Star Lifket type 111/54

Safe Working Load

DANISH CRANE BUILDING A/S

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

6,3 t DCB Single Girder E/R Cranes for Wenchong Shipyard

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

Pos. No. Part

Mb 2401, LS80 FAST, i=50:1

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

Reduction Unit, Crane, ABM

Part No. Part

Mobilsynthetic Chain Lube As required

Hull No.GWS379-84 / 93-98 (DCB 50143000)

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

DANISH CRANE BUILDING

Keep chain clean

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

DANISH CRANE BUILDING

Postbox 54 sterlandsvej 2 DK-9240 Nibe Denmark

Electric chain hoists

Please dont use the hoist

figure 2: sectional view

load hook complete

load hook complete

load hook complete (incl. pressure bearing

hook block for chain

Stationary suspended hoists

3.1.3.1 Version Suspension with suspension eye

figure 6: suspension with suspension eye

figure 7: suspension with single hole eye

one fall: hook tackle

two falls: hook block

3.1.3.3 Version Suspension with hook suspension