Replacing deflection roller crosshead for reeving 4/1 or 6/1

 

If the deflection roller crosshead is damaged, it must be replaced.

 

Disassembling the deflection roller crosshead

Only with wire rope hoist with hoist drive GM 800 to GM 6000 with reeving 4/1

On a wire rope hoist with hoist drive GM 800 to GM 6000, the deflection roller crosshead hangs on bearing bushes and is secured with bolts and SL safety clips.

 

SL safety clip

Bolt

*   Pull the SL safety clips from the bolts.

 

 

Bolt

 

Deflection roller crosshead

*   Pull the bolts (2x) out of the deflection roller crosshead.

 

 

 

Deflection roller crosshead

Bearing bush

*   Lift the deflection roller crosshead from the bearing bushes.

 

 

 

 

Only with wire rope hoist with hoist drive GM 7000 and reeving 4/1

On a wire rope hoist with hoist drive GM 7000 and a reeving 4/1, the deflection roller crosshead is installed on the outside of the trolley frame.

 

On both sides:

SL safety clip

 

 

Bolt

*   Pull SL safety clip from the bolt.

 

 

Safety plate

Bolt

*   Pull the bolt out of the safety plate and the side panel.

 

 

 

Side panel

Safety plate

 

*   Pull out the safety plate.

 

 

Side panel

 

Deflection roller crosshead

*   Lift the deflection roller crosshead out of the side panels.

 

 

 

 

Only with wire rope hoist with hoist drive GM 7000 and reeving 6/1

On a wire rope hoist with hoist drive GM 7000, the deflection roller crossheads are installed in the trolley frame.

 

 

Metal plate

Rib screws M10x16

*   Release the rib screws M10x16 (4x) on the plate.

*   Lift the plate off the trolley frame.

 

 

Deflection roller crosshead

Suspension

*   Lift the deflection roller crosshead out of the trolley frame.

 

 

Deflection roller crosshead

Suspension

*   Lift the second deflection roller crosshead out of the trolley frame.

 

 

 

 

Disassembling the deflection roller

Only with wire rope hoist with hoist drive GM 800 to GM 6000 with reeving 4/1

On a wire rope hoist with hoist drive GM 800 to GM 6000 and a reeving 4/1, the deflection roller is secured on the deflection roller crosshead using a bolt with a cover.

 

Cover

Rib screw

*   Release the rib screws (2x) on the cover.

*   Take the cover off the deflection roller crosshead.

 

 

Bolt

Deflection roller crosshead

Deflection roller

 

*   Pull the bolt out of the deflection roller crosshead and deflection roller.

*   Pull the deflection roller out of the deflection roller crosshead.

 

 

 

 

Only with wire rope hoist with hoist drive GM 7000

On a wire rope hoist with hoist drive GM 7000, the deflection roller is secured on the deflection roller using a bolt with a cover.

 

Rib screw

 

Cover

 

*   Release the rib screws (2x) on the cover.

*   Take the cover off the deflection roller crosshead.

 

 

Deflection roller crosshead

Bolt

Deflection roller

 

*   Pull the bolt out of the deflection roller crosshead and deflection roller.

*   Pull the deflection roller out of the deflection roller crosshead.

 

 

 

 

Only with wire rope hoist with hoist drive GM 6000 and reeving 6/1

On a wire rope hoist with hoist drive GM 6000 and a reeving 6/1, the deflection roller crossheads are welded to the trolley frame. Only the deflection rollers themselves can therefore be replaced.

 

SL safety clip

*   Pull the SL safety clip (2x) off the bolts (2x).

 

 

Crosshead

Cover

Bolt

*   Pull the bolt out of the crosshead and the cover.

 

 

Deflection roller

Cover

*   Lift the cover off the deflection roller.

 

 

Cover

Rib screw M8x16

*   Release the rib screws M8x16 (4x) on the cover.

The outer rib screws can be removed fully. The inner rib screws must stay loosely fastened on the cover because the cover is screwed to the bolt.

 

 

 

Deflection roller

Cover

Crosshead

*   Lift the deflection roller out of the crosshead.

 

 

Cover

Rib screw M8x16

*   Lay the deflection roller on an even surface with the bolt facing downward.

*   Fully release the rib screws M8x16 (2x) on the cover.

 

 

 

Cover

Bolt

Deflection roller

*   Lift the cover off the bolt.

 

 

 

Bolt

Deflection roller

 

*   Lift the deflection roller off the bolt.

 

 

*   Move exactly the same with the second deflection roller.

 

 

 

 

Assembling the deflection roller

Only with wire rope hoist with hoist drive GM 800 to GM 6000 with reeving 4/1

 

 

Deflection roller crosshead

 

Deflection roller

*   Push the deflection roller into the deflection roller crosshead.

 

 

Bolt

Deflection roller crosshead

Deflection roller

 

*   Push the bolt through the deflection roller crosshead and deflection roller.

 

 

Cover

Rib screw

*   Screw on the cover from the other side at the bolt with rib screws (2x).

Size

Rib screw

Tightening torque

GM 800

M6x12

19 Nm

GM 1000

M6x12

19 Nm

GM 2000

M8x16

42 Nm

GM 3000

M10x20

75 Nm

GM 5000

M10x20

75 Nm

GM 6000

M10x20

75 Nm

 

 

 

 

Only with wire rope hoist with hoist drive GM 7000

 

Deflection roller crosshead

Bolt

Deflection roller

 

*   Push the deflection roller into the deflection roller crosshead.

 

 

Rib screw

 

Cover

 

*   Screw the cover tight with the rib screws M10x20 on the bolt. 75 Nm.

 

 

 

 

Only with wire rope hoist with hoist drive GM 6000 and reeving 6/1

On a wire rope hoist with hoist drive GM 6000 and a reeving 6/1, the deflection roller crossheads are welded to the trolley frame. Only the deflection rollers themselves can therefore be replaced.

 

Preparing the deflection roller

With both deflection rollers:

 

Bolt

Deflection roller

 

*   Place the bolt on an even surface.

*   Lubricate the bolt.

Lubricant: “High temperature paste PBC 1574”. For details see Lubricants.

*   Push the deflection roller onto the bolt.

 

 

 

Cover

Bolt

Deflection roller

*   Push the cover onto the bolt.

 

 

Cover

Rib screw M8x16

*   Loosely screw on the cover with rib screws M8x16 (2x).

 

 

Assembling the deflection roller

Deflection roller

 

Crosshead

Cover

*   Lift the deflection roller into the crosshead.

The cover must be in front of the crosshead suspension.

 

 

Rib screw M8x16

Deflection roller

Crosshead

Cover

*   Screw the deflection roller cover with rib screws M8x16 (2x) on the crosshead. 42 Nm.

*   Tighten the rib screws M8x16 (2x) on the cover. 42 Nm.

 

 

 

Cover

 

Deflection roller

*   Place the cover on the deflection roller.

 

 

Crosshead

Cover

Bolt

*   Push the bolts (2x) through the crosshead and the cover.

 

 

Bolt

SL safety clip

*   Push the SL safety clips (2x) onto the bolt.

 

 

*   Move exactly the same with the second deflection roller.

 

 

 

 

Mounting the deflection roller crosshead

Only with wire rope hoist with hoist drive GM 800 to GM 6000 with reeving 4/1

On a wire rope hoist with hoist drive GM 800 to GM 6000, the deflection roller crosshead hangs on bearing bushes and is secured with bolts and SL safety clips.

 

 

Deflection roller crosshead

Bearing bush

*   Mount the deflection roller crosshead on the bearing bushes.

When doing this, ensure that the deflection roller points in the direction of the hoist drive.

 

 

Bolt

 

Deflection roller crosshead

*   Push the bolts (2x) into the deflection roller crosshead.

 

 

SL safety clip

Bolt

*   Push the SL safety clips (2x) onto the bolts.

 

 

 

 

Only with wire rope hoist with hoist drive GM 7000 with reeving 4/1

On a wire rope hoist with hoist drive GM 7000 and a reeving 4/1, the deflection roller crosshead is installed on the outside of the trolley frame.

 

Bolt

Deflection roller crosshead

Bearing surface of the side panel

 

*   Lubricate the bearing surface of the side panel.

Lubricant: “OKS 511 bonded coating”. For details, see Lubricants.

*   Let the bonded coating dry for 30 minutes!

*   Lubricate the side panel bearing surface again.

Lubricant: “High temperature paste PBC 1574”. For details, see Lubricants.

 

 

Side panel

 

Deflection roller crosshead

*   Lift the deflection roller crosshead into the side panel.

You must be able to move the deflection roller crosshead back and forth by hand.

 

 

On both sides:

 

Side panel

Safety plate

 

*   Push the safety plate into the side panel.

 

 

Safety plate

Bolt

*   Push the bolt through the safety plate and the side panel.

 

 

SL safety clip

 

 

Bolt

*   Push the SL safety clip onto the bolts.

 

 

 

 

Only with wire rope hoist with hoist drive GM 7000 and reeving 6/1

On a wire rope hoist with hoist drive GM 7000, the deflection roller crossheads are installed in the trolley frame.

 

Fit the first deflection roller crosshead:

Lifting tackle

 

Bearing bush

Washer

*   Push the washer (2x) onto both bearing bushes.

 

 

Deflection roller crosshead

Suspension

*   Lift the deflection roller crosshead into the trolley frame.

 

 

Fit the second deflection roller crosshead:

Bearing bush

Washer

*   Push the washer (2x) onto both bearing bushes on the deflection roller crosshead.

 

 

Second deflection roller crosshead

Suspension

*   Lift the second deflection roller crosshead into the trolley frame.

 

 

 

Metal plate

Rib screws M10x16

*   Place the plate on the trolley frame over the deflection roller crossheads and screw in with rib screws M10x16 (4x). 75 Nm.