Professional Documents
Culture Documents
for
3
HF 6
Type Size 11
EF 22
36
Manufacturer
ABUS Kransysteme GmbH Tel. ##49 2261 / 37–0
Sonnenweg 1 Fax. ##49 2261 / 37247
D – 51647 Gummersbach
Stand : 10. December 1999
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to
pay compensation for any breach of this provision. All patent and registered design rights reserved.
A 466.GB
These installation, operation and maintenance instructions are intended for use in an English-
speaking country by English–speaking specialist personnel.
Contents
HF EF
A 466.GB Page 3
1.5 Other Notes The operating instructions must be available to the per-
sonnel responsible for repair and maintenance work at
The declaration of conformity/manufacturer’s
all times.
declaration is included in the test book. The
ABUS---products are largely maintenance---free.
year of manufacture is stated in the data sheet
The little maintenance work which is required must be
in the test book.
performed in accordance with the operating instruc-
tions and the maintenance schedule.
The product will only continue to perform reliably to
your satisfaction in the long term if it is operated, main-
tained and repaired by persons assigned to these
If you wish, maintenance work can be per-
tasks by the operator. Such persons must be familiar
formed by the ABUS service department.
with the installation, operation and maintenance in-
structions and the applicable safety regulations and
accident prevention regulations.
_________________________________
2 Safety
2.1 Organisational Notes Failure to comply with the safety instructions given in
this Manual may lead to injury or even to fatal acci-
Operating, maintenance and repair personnel must
dents.
have read and understood the operating instructions
The product may present hazards to life and limb if it is
before starting work.
operated other than for the intended purpose or by
The company operating a hoist is obligated to ensure
non---trained or inadequately trained personnel.
safe operation and to prevent hazards. Among other
The operator of the product must ensure that operation
things, the following precautions must be taken:
and maintenance personnel are instructed in good
time before starting work with or on the product.
- The operating instructions must be made available
Because of the risk of injury due to clothes or parts of
and the attention of personnel must be drawn to
the body catching on or being drawn into the equip-
them.
ment, personnel working with the product must not
- The hoist must be inspected before initial commis-
wear any loose clothing, unprotected long hair or jewel-
sioning and after any major changes. lery. No rings (!) must be worn when working with the
- Regular inspections must be made. product!
Persons under the influence of alcohol, drugs or medi-
The organisation operating an ABUS chain hoist is re- cines impairing their reactions must not perform any
sponsible for supervising operating personnel to en- work on or with the product.
sure that chain hoists are properly operated. Contact with concentrated acids or caustic solutions
Before you commission the trolley and after completing may result in damage to plastic components or the cor-
any work on power supply systems, the control sys- rosion of metal parts; any parts affected by such dam-
tems must be tested to ensure that they function cor- age or corrosion must be replaced in good time.
rectly. If these systems are not connected to the correct The product must not be operated in hazardous atmos-
conductors, they may not function as intended and pheres except where the product has been specifically
there may be a risk of accidents. designed for such use.
During operation:
2.2 General Notes on Hazards Compliance with all the precautions required by this
Except for products designed solely for operation by manual before, during and after commissioning and all
human agency, the product is designed for operation the general safety requirements, especially those con-
on industrial power systems. When the product is in cerning operational safety and accident prevention, is
operation, there will be hazardous exposed live compo- essential. Failure to comply with these precautions and
nents and hazardous rotating or moving components requirements may lead to personal injury or even fatal
inside the product. accidents.
The use of non---approved or unsuitable tools or auxili-
Attention! ary equipment may result in injury.
Severe personal injury or damage to property In connection with the movement of components,
may occur as a result of squeeze and shear points may occur on the equipment
and between the equipment and its surroundings. You
- the forbidden removal of covers must therefore always keep sufficient safety distance
- improper use from moving or rotating components to prevent parts of
- incorrect operation the body, clothes or your hair from being caught in the
- inadequate repair and maintenance. equipment.
3 Technical Description
3.1 Functions
3.1.1 Design
The illustrations show the outer parts of the trolleys. 1. trolley pin
2. trolley side plate
4 3. wheel
4. track section
3 5. lift ---off protection device
6. eye with load attached
7. connector for trolley travel motor
8. geared brake motor
5 9. wheel with gear rim
2 10. counterweight
11. power supply
12. ABUS---chain hoist
A 466.GB Page 5
3.2 Technical Data
3.2.1 Push trolleys
90- 55 28,6
Fig. 3
HF 36 156- 200 3200 112 60 54 29,9
* The load capacity stated applies to units classed in drive group 2m in accordance with FEM 9511.
Counter-
Flange Capa- Travelling Perfor- Nominal Starting ED Wheel Pin dia. [mm] Weight
weight as
Type width F city* speed** mance** current** current** Æ DL D H
standard
[mm] [kg] [m/min] [kW] [A] [A] [%] [mm] (new) (min.) [kg]
equipment
EF 11 126 - 200 1100 5 / 20 .06 / .25 .45 / .75 .7 / 2.5 40 80 34 30 32,2 yes
EF 22 151 - 200 2200 5 / 20 .06 / .25 .45 / .75 .7 / 2.5 40 112 50 44 33,4 ---
EF 36 156 - 200 3200 5 / 20 .06 / .25 .45 / .75 .7 / 2.5 40 112 60 54 37,7 ---
* The load capacity stated applies to units classed in drive group 2m in accordance with FEM 9511.
** These data apply to a 400 V/50 Hz power supply must be increased by 20 % in the case of a 60 Hz
and power supply.
A 466.GB Page 7
4 Assembly and start---up
4.1 Scope of delivery nuts (4) using a torque wrench. For tightening
torque on trolley pins, see Section 3.2.3.
The trolley is delivered with side plates installed and
prefabricated trolley pins.The installation work required
on the equipment supplied is described below. 4 5 7 6 7
If the trolley is not assembled directly at the point of use,
all the components must be stored in a clean, dry
place.
3
2
Caution!
The trolley and the suspended load, if appli-
cable, must be installed from a safe place by
at least two persons.
max. 2
Fig. 6
Caution!
The flange clearance must not exceed 2 mm!
F =? Fig. 4 cf. Figure 6
1. Measure the flange width of the girder. With electric traveling gears EF (Figure 7) the module
2. Check whether dimension F is within the range motor with gearing (1) and counterweight (2) is addi-
stated on the sticker on the trolley pin (1). If not, you tionally attached to the trolley plate ; only types EF11 /
must first obtain a trolley pin of the correct size with EF 22 in connection with a small flange width need a
the appropriate washers. counterweight.
3. The trolley must be adapted to the flange width by Assembly is the same as for the push trolley HF.
moving the 2.5 mm spacers (6) and the 5 mm
spacers (7) to different positions on the trolley pin.
The spacers should be positioned to ensure that
forces resulting from suspended loads are trans- 2 1
ferred to the trolley at a central point. With this con-
figuration, the load is evenly distributed between
the four wheels.
Caution!
At least one 5 mm spacer (7) must always be
positioned under the washer (5) and the
nut (4).
Fig. 7
4. Attach the trolley pin (1) to one trolley side plate (2)
and place the side plate on the girder (Fig. 5). See chapter 4.3 ”Assembly of electrical equipment” for
5. Lift the load to be suspended and push it onto the electric connections.
free end of the trolley pin with the load support (8) When using a suspension track system (HB) follow the
(eye or hook), Position the plastic tube (3) and operating instructions for HB.
spacers. If the trolley is used with a crane system or any other
6. Push the other trolley side plate onto the shaft (with type of equipment, please follow the special operating
the wheels on the girder, Fig. 6) and tighten the instructions or the instructions given in the plan.
ABUS modules are fitted with easy plug ---type con- Fig. 9
nectors ready for operation as standard equipment.
Fig. 10
Bridge
195V
DC
/ 50W
Fig. 8
Caution! In order to ensure that the brake cir-
cuit is effective, the phase conductors for
connections 1 U/2 U or 1 W/2 W must be inter-
connected either in the connector upper sec- Fig. 11
tion or in the control unit.
A 466.GB Page 9
4.4 Installation of trolley towing In the case of special control systems, the trolley towing
arm is combined with the mounting console (3) for the
arm switchgear box. In this case, the towing arm and the
Together with the power supply system, a towing arm mounting console must be installed in accordance with
(1) is supplied for the trolley. The towing arm must be Fig. 13.
installed on the side plate of the trolley in accordance 2
with Fig. 12. 1
1 2
Fig. 13
Fig. 12 The length of the vertical towing tube (2) must be
adapted to the position of the power feeder.
_________________________________
5 Maintenance
The trolley must be inspected by an inspector as re- year taking operating conditions into account. In case
quired in view of service conditions of doubt, the organisation operating the crane must
- utilization of maximum load capacity agree on inspection intervals with the trolley / crane
- frequency of operation and manufacturer.
- ambient conditions. The main items to be covered by scheduled inspec-
At any rate, the trolley must be inspected at least once tions are as follows:
per year.
For example, trolleys / cranes with high operating hours - inspection of the condition of components and sys-
which are often operated at full load capacity will need tems and inspection for any damage, wear, cor-
to be inspected more frequently than trolleys which are rosion and other deterioration
used only occasionally for assembly work. In the case - inspection of the completeness and effectiveness
of occasional use, one inspection per year will be ad- of safety systems and brakes
equate. It may also be necessary to reduce the inspec- - repetition of inspection after any defects relevant to
tion interval in the case of dusty or corrosive atmos- safety have been remedied
pheres. Organisations operating cranes must therefore
determine more frequent inspection intervals than one
_________________________________
1 2
3
9 9 2
4
8 7
a
Fig. 14
A 466.GB Page 11
6 Problems, Causes and Remedies
All the malfunctions described below must be remedied by a specialist.
Motor does not turn in any Mains power not available Check voltage
direction and does not hum Mains connection not properly Connect all three phase
when the pendant control is made conductors correctly
operated
Faulty fuses Replace fuses Follow wiring diagram
Plug --- in connectors for power Insert connectors firmly and lock
supply or pendant control not using bracket
properly inserted or not locked
Loose contacts in pendant Check wires for breakage; Caution! All work
control, broken wires in power if necessary replace control must be performed
supply line or in pendant control cable with all equipment
or, possibly, on travel drive disconnect from the
power supply
Motor does not turn in Faulty mains connection or Check mains connection
any direction but hums mains fuse
when the pendant
Faulty contactor Replace contactor Caution! All work
control is oprated
must be performed
WARNING with all equipment
Motor windings may disconnect from the
burn power supply
Motor starts slowly Brake does not release, motor See brake problems
runs against closed brake
Crane movement only possible Faulty switch element in pendant Check and if necessary replace
in one direction control switch element
Brake does not release No power on brake coil, Check and repair connections Caution ! Pull mains
No AC voltage at rectifier input Check motor connector out before
starting work
Brake coil has no electrical Replace brake coil Follow operating instructions
continuity and is faulty
Braking distance too long Max. clearance reached Set brake and adjust clearance Follow operating instructions
(limit of lining wear)
8 Disposal, Decommissioning
When ABUS products are no longer needed, they may be disposed of in an environmentally compatible way.
ABUS produces cranes, hoists and crane system components characterized by high quality, long service life and
low maintenance requirements.
Painted products must either be recycled or disposed of on special landfills in accordance with the applicable local
regulations.
A 466.GB Page 13
9 Manufacturer’s Declaration
98/37/EC Machines
73/23/EEC Low voltage
89/336/EEC Electromagnetic compatibility
Department manager
Chain hoist
13 12 11
10 9 6 5 4 8
1 24
17
15
16
23
22
14 2
18 19 20 21 Fig. 15
A 466.GB Page 15
Product Item Part no. Qtity Designation
Individual parts available
3 11269.01 1 right side plate HF 22
4 3223.01 2 grooved ball bearing 6206 Z DIN 625
5 236.01 2 circlip 62x2 Fe, St DIN 472
HF 22 6 229.01 2 circlip 30x1.5 Fe, St DIN 471
7 2391.01 2 wheel without gear rim DL = 112
Sets available
11708.01 2 wheel, complete 112 Item 4 ---7
11625.01 1 right side plate HF 22 Item 3 ---7
Individual parts available
3 13360.01 1 right side plate HF 36
4 3223.01 2 grooved ball bearing 6206 Z DIN 625
5 236.01 2 circlip 62x2 Fe, St DIN 472
HF 36 6 229.01 2 circlip 30x1.5 Fe, St DIN 471
7 2391.01 2 wheel without gear rim DL = 112
Sets available
11708.01 2 wheel, complete 112 Item 4 ---7
13336.01 1 right side plate HF 36 Item 3 ---7
Individual parts available
1 10527.01 1 right side plate EF 11
4 3222.01 2 grooved ball bearing 6005 Z DIN 625
5 3704.01 2 circlip 47x1,75 Fe, St DIN 472
6 2609.01 2 circlip 25x1,2 Fe, St DIN 471
8 2399.01 2 wheel with gear rim DL = 80
EF 11 12 4182.01 4 hexagonal head screw M6 x 20 8.8 DIN EN 24017
13 5487.01 4 spring washer A6 Fe, St DIN 127
Sets available
10713.01 2 wheel with gear rim, complete 80 Item 4 ---6, 8
11149.01 1 right side plate EF 11 Item 4 ---6, 8,
12 ---13
Individual parts available
1 11440.01 1 right side plate EF 22
4 3223.01 2 grooved ball bearing 6206 Z DIN 625
5 236.01 2 circlip 62x2 Fe, St DIN 472
6 229.01 2 circlip 30x1,5 Fe, St DIN 471
8 2400.01 2 wheel with gear rim DL = 112
EF 22 12 4182.01 4 hexagonal head screw M6 x 20 8.8 DIN EN 24017
13 5487.01 4 spring washer A6 Fe, St DIN 127
Sets available
11709.01 2 wheel with gear rim, complete 112 Item 4 ---6, 8
11626.01 1 right side plate EF 22 Item 4 ---6, 8,
12 ---13
Individual parts available
1 13361.01 1 right side plate EF 36
4 3223.01 2 grooved ball bearing 6206 Z DIN 625
5 236.01 2 circlip 62x2 Fe, St DIN 472
6 229.01 2 circlip 30x1,5 Fe, St DIN 471
8 2400.01 2 wheel with gear rim DL = 112
EF 36 12 4182.01 4 hexagonal head screw M6 x 20 8.8 DIN EN 24017
13 5487.01 4 spring washer A6 Fe, St DIN 127
Sets available
11709.01 2 wheel with gear rim, complete 112 Item 4 ---6, 8
13337.01 1 right side plate EF 36 Item 4 ---6, 8,
12 ---13
A 466.GB Page 17
Product Item Part no. Qtity Designation
Individual parts available
1 13359.01 1 left side plate HF/EF 36
4 3223.01 2 grooved ball bearing 6206 Z DIN 625
5 236.01 2 circlip 62x2 Fe, St DIN 472
6 229.01 2 circlip 30x1,5 Fe, St DIN 471
HF/EF 36 8 2391.01 2 wheel without gear rim DL = 112
9 10887.01 1 name plate Al
10 4871.01 2 grooved pin 4x6 St DIN EN 28746
Sets available
10708.01 2 wheel, complete 112 Item 4 ---7
13335.01 1 left side plate HF/EF 36 Item 2, 4 ---7
A 466.GB Page 19
Product Item Part no. Qtity Designation
17 3381.01 1 trolley pin FB 201 --- 300
18 4640.01 2 lock nut M24 8 DIN EN ISO 10511
HF/EF 22 19 201.01 2 washer 25 St DIN 125
Flange 21 10426.01 2 plastic tube FB 201 --- 300
width FB 22 3318.01 6 spacer ring 2.5
201 --- 23 3319.01 24 spacer ring 5
300 Sets available
11673.01 1 trolley pin, complete Item 17-19,21-23
Individual parts available
17 13322.01 1 trolley pin FB 90 --- 155
18 13534.01 2 lock nut M30 8 DIN EN ISO 10511
HF/EF 36 19 13832.01 2 washer 31 St DIN 125
Flange 21 10427.01 2 plastic tube FB 90 --- 155
width FB 22 13474.01 4 spacer ring 2.5
90 --- 155 23 13475.01 18 spacer ring 5
Sets available
13338.01 1 trolley pin, complete Item 17-23
Individual parts available
17 13323.01 1 trolley pin FB 156 --- 200
HF/EF 36 18 13534.01 2 lock nut M30 8 DIN EN ISO 10511
19 13832.01 2 washer 31 St DIN 125
Flange
21 10428.01 2 plastic tube FB 156 --- 200
width FB
22 13474.01 4 spacer ring 2.5
156 ---
23 13475.01 14 spacer ring 5
200
Sets available
13339.01 1 trolley pin, complete Item 17-23
Individual parts available
17 13324.01 1 trolley pin FB 201 --- 300
HF/EF 36 18 13534.01 2 lock nut M30 8 DIN EN ISO 10511
Flange 19 13832.01 2 washer 31 St DIN 125
width FB 21 10429.01 2 plastic tube FB 201 --- 300
201 --- 22 13474.01 6 spacer ring 2.5
300 23 13475.01 24 spacer ring 5
Sets available
13340.01 1 trolley pin, complete Item 17-23
A 466.GB Page 21
10.6 Brake motor for trolley drive
M176 M69 M6 M9 M73 M7 M131 M98 B41 B42 B43 B30 M14
M218
M219
M220
M202
M204
M213 M270
M265
M266
Fig. 17
A 466.GB Page 23
10.7 Fax Order
Just copy this form, fill it in and fax it to us
Serial no. No. of ope- Page no. of Item Part no. Quan-
of trolley rating in- spare part no. tity
structions
A 466.GB