Installing the powered wheel

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

The figures show the assembly of a size 130 wheel. The mounting of larger wheels does not essentially differ from this.

Fitting the wheel

Bearing bolt	Bearing flange

Wheel

Clamp 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.

Rib screws

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 for size 420 with crane travel drive 420 V

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

Mounting the adapter

Bearing flange

Pin

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


Adapter	Bearing flange

Turn the adapter to match the hole pattern.

Place the adapter on the pins on the bearing flange.

Rib screws

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

Fastening the bearing flange

Rib screws

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.

Screws		Clamping element

	Clamping piece

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

Only for guide rollers

This work step only applies if the end carriage has guide rollers.

Screws		Clamping element

Bracket	Guide rollers

Insert bracket with guide rollers.

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

Only for derailing protection device

This work step only applies if the end carriage has a derailing protection device.

Small side

Large side	Crane travel drive

Rotate the derailing protection device in such a way that the large side faces towards the crane travel drive.

Insert the derailing protection device.

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

Plastic washer	Self-locking nut

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 crane travel 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).

	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.

Push the drive into the wheel.

Only with AZP drives

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


AZP drive	Rib screw

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 for crane travel drive AZF

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


Fillister-head screw	Crane travel drive AZF

Insert the crane travel drive in the wheel.

Bolt on the crane travel drive with the 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.

Inspecting the crane

Replace the crane on the crane track.

Put the crane into operation.

Inspect the function of the wheel.