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 flange

Bearing bolt

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.

 

 

Retaining screw

 

 

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

 

 

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

Pin

Bearing flange

 

Retaining screw

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

 

 

Retaining screw

Bearing flange

Pin

Adapter

*   Turn the adapter to match the hole pattern.

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

 

 

Bearing flange

Rib screws

Adapter

Pins

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

 

 

 

 

Fastening the bearing flange

Retaining screw

Rib screws

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

 

 

Only for derailing protection device

 

Fitting the derailing protection device

Wheel

Screw M20

Clamping element

Large side

*   Clean the joining surfaces.

The joining surfaces must be free of paint, grease and oil!

*   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

 

 

 

 

Only for clamping piece

 

Fitting the clamping piece

Wheel

Screw M20

Clamping element

Large side

*   Clean the joining surfaces.

The joining surfaces must be free of paint, grease and oil!

*   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

 

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).

 

 

 

Output shaft

*   Lubricate the gearing on the output shaft.

Lubricant - Fuchs Lubritech high temperature paste PBC 1574.

 

 

Only with AZP drives

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

 

Rib screws

AZP drive

*   Push the drive in the wheel.

*   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.

 

Crane travel drive AZF

 

Fillister-head screws

*   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

30 Nm

420

M12x100

30 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 drive

*   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.

 

 

 

 

Closing the connector housing

 

Intermediate plate

*   Press the intermediate plate in.

*   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.