Installing the powered wheel

 

If the wheel is damaged or worn, it must be replaced by a new wheel.

 

Fitting the wheel

 

Wheel

Bearing bolt

Bearing flange

*   Hold the wheel in the end carriage. It does not matter which side faces inwards or outwards.

*   Insert the bearing bolt and bearing flange. If necessary, lightly hammer the bearing bolt and bearing flange.

 

 

Retaining screw

 

Bearing flange

Rib screw

*   Tighten the rib screws in stages.

Wheel Ø

Strength category

Number

Screw

Tightening torque

130

10.9

5x

M8x25

42 Nm

160

10.9

5x

M8x25

42 Nm

200

10.9

5x

M10x30

85 Nm

280

10.9

5x

M12x40

130 Nm

350

10.9

8x

M12x40

130 Nm

420

10.9

8x

M16x40

330 Nm

 

 

Only with size 420 with drive 420V

This work step only applies if an end carriage size 420 is to be installed with a drive size 420V.

 

Mounting the adapter

Rib screw

 

*   If necessary: insert the pins (4x) in the bearing flange.

*   Turn the adapter to match the hole pattern.

*   Place the adapter on the pins on the bearing flange.

*   Insert the rib screws M16x70 (10x) through the adapter and bearing flange.

 

 

 

 

Fastening the bearing flange

 

Retaining screw

Rib screw

Bearing flange

*   Tighten the rib screws in stages.

Wheel Ø

Strength category

Number

Type

Tightening torque

130

10.9

7x

M8x25

42 Nm

160

10.9

7x

M8x25

42 Nm

200

10.9

7x

M10x30

85 Nm

280

10.9

7x

M12x40

130 Nm

350

10.9

10x

M12x40

130 Nm

420 with crane travel drive 420

10.9

10x

M16x40

330 Nm

420 with crane travel drive 420 V

10.9

10x

M16x70

330 Nm

 

 

Assembling the end carriage

Only with end carriages of the sizes 280, 350 and 420

This work step applies only to end carriages of the sizes 280, 350 and 420.

 

Wheel

 

Clamping piece

Bracket

*   Insert clamping piece.

*   Tighten screws (2x).

Wheel Ø

Type

Kind

Tightening torque

130

M8x45

Rib screw

42 Nm

160

M10x50

Rib screw

85 Nm

200

M10x50

Rib screw

85 Nm

280

M12x60

Hexagon head screw

130 Nm

350

M20x75
or
M20x70

Hexagon head screw

300 Nm

420

M20x75
or
M20x70

Hexagon head screw

300 Nm

 

 

 

 

 

Buffer plate

Self-locking nut

Plastic washer

*   Slide the buffer plate onto the threaded bolt.

*   From size 160: fit the plastic washers (4x) in place.

*   Tightly screw the self-locking nuts M10 (4x). 6 Nm.

The self-locking nuts may only be reused maximally 3 times. After this, new self-locking nuts must be used.

 

 

Installing the drive

*   Determine the weight of the drive. See the ABUS Drive product manual.

*   Secure the drive so that the weight can be held safely and the output shaft will not be subject to load (e.g. insert in round sling).

 

Only with AZP drives

This work step only applies when an AZP drive is to be mounted on the end carriage.

 

Output shaft

 

Bearing flange

Drive

*   Lubricate the gearing on the output shaft. Apply lubricant with brush to coat surface completely.

Lubricant: “High temperature paste PBC 1574”. See the ABUS Drive product manual for details.

 

 

Output shaft

 

Bearing flange

Drive

*   Push the drive into the wheel.

 

 

 

 

Rib screws

Drive

*   Bolt on the drive with the rib screws (4x).

Size

Type

Tightening torque

130

M8x25

35 Nm

160

M10x30

75 Nm

200

M12x30

115 Nm

280

M16x40

300 Nm

 

 

 

 

Only with AZF drives

This work step only applies when an AZF drive is to be mounted on the end carriage.

 

Bearing flange

Drive

Output shaft

 

*   Lubricate the gearing on the output shaft. Apply lubricant with brush to coat surface completely.

Lubricant: “High temperature paste PBC 1574”. See the ABUS Drive product manual for details.

 

 

Bearing flange

Drive

Output shaft

 

*   Push the drive into the wheel.

 

 

 

Drive

Fillister-head screw

 

*   Screw the drive in place using fillister-head screws and washers (4x).

Size

Type

Tightening torque

350

M12x100

85 Nm

420

M12x100

85 Nm

V420

M16x140

210 Nm

V500

M16x140

210 Nm

 

 

 

 

Connecting the drive

Only with contactor control

 

Pin multipoint connector on the drive

Pin multipoint connector on the drive

Connection cable of drive

Rectifier for brake

*   Insert the connection cable for the drive in the pin multipoint connector on the drive.

*   Insert the rectifier for the brake in the pin multipoint connector on the drive.

*   Lay the plug-in connections and connection cable in the connector housing.

 

 

 

 

Only for frequency converter

 

Pin multipoint connector on the drive

Pin multipoint connector on the drive

Bush multipoint connector for drive

Bush multipoint connector for brake

*   Insert the bush multipoint connector for the drive on the pin multipoint connector on the drive.

*   Insert the bush multipoint connector for the brake on the pin multipoint connector on the drive.

 

 

Plug-in connection

Cable bushing

Screening clamp connection

Connection cable

*   Push the front end of the connection cable (where the sheathing around the shield has been removed) into the screening clamp connection.

*   Fasten the connection cable to the screening clamp connection using cable ties.

*   Lay the plug-in connections and connection cable in the connector housing.

*   Close the housing cover.

 

 

 

 

Checking the wire rope hoist

*   Set the wire rope hoist down again.

*   Put the wire rope hoist into operation.

*   Check the function of the wheel.