Exchanging the chain and chain sprocket

 

If the chain exhibits signs of wear or is too stretched from operation (see page 30), it must be exchanged.

Chain, chain sprocket and chain guide are wearing parts that are subjected to great strain from the load. During operation they wear against each other. The chain, chain sprocket and chain guide should therefore always be replaced together.

Because of the modular construction of the chain hoist, the gear unit does not need to be disassembled in order to exchange the chain guide and chain sprocket. Instead, the gear unit is pulled off and the chain sprocket is then exposed.

 

 

Removing the chain box

 

Bolt

 

Chain box

*   Release the SL safety clip(s) (1x or 2x) from the bolt.

*   Hold the chain box firmly and pull out the bolt(s) (1x or 2x).

*   Remove the chain box.

 

 

Only for GM2, GM4 and GM8

 

C-link

 

 

Tensioner sleeve

*   Hammer the tensioner sleeve out of the C-link.

 

 

Only for GM6

 

Fillister-head screw M6x30

C-link

*   Unscrew the fillister-head screw M6x30 (2x).

*   Remove the halves of the C-link from the chain.

 

 

 

Opening the chain hoist

Bayonet nut

Motor cover

*   Release the bayonet nuts.

*   Detach the connection cable and control cable.

*   Unscrew the motor cover from the housing.

●   The fillister-head screws are secured by O-rings and thus do not fall out of the motor cover.

*   Detach the couplings of the hoist motor and brake from the control in the motor cover.

 

 

Only with an electronic hoist limit switch

This work step is only applicable if the hoist limit switch PCB is visible in the housing:

Housing

 

Hoist limit switch PCB

 

 

 

Removing the hoist limit switch

 

Hoist limit switch PCB

 

Fillister-head screws with ribs M5x10

*   Pull the connector off the hoist limit switch PCB.

*   Unscrew the fillister-head screws with ribs M5x10 (3x).

*   Take the hoist limit switch PCB out of the chain hoist.

 

 

The magnet carrier of the hoist limit switch is firmly screwed to the output shaft of the gear unit. It must be unscrewed as otherwise it would damage components when the gear unit is pulled off.

 

Magnet carrier

 

*   Unscrew the magnet carrier.

 

 

 

Taking out the chain guide

 

Only for GM2

 

Locking screw

 

Fillister-head screws

 

*   Unscrew the fillister-head screws (3x).

*   Leave the locking screw tightened.

It later ensures that the gear unit cannot not fall down.

 

 

Only for GM4

 

Locking screw

 

Fillister-head screws

*   Unscrew the fillister-head screws (3x).

*   Leave the locking screw tightened.

It later ensures that the gear unit cannot not fall down.

 

 

Only for GM6

 

 

Locking screw

Fillister-head screws

*   Unscrew the fillister-head screws (3x).

*   Leave the locking screw tightened.

It later ensures that the gear unit cannot not fall down.

 

 

Only for GM8

 

Tip:

The chain guide, chain and gear unit of the chain hoist are very heavy. Therefore unhook the chain hoist and remove the chain guide lying flat.

 

Fillister-head screws

 

Locking screw

*   Unscrew the fillister-head screws (3x).

*   Leave the locking screw tightened.

It later ensures that the gear unit cannot not fall down.

 

 

 

Warnung Vorsicht

Caution - danger of injury!

When pulling off the gear unit, the chain guide can fall down and injure people. Hold the chain guide firmly or otherwise secure it!

 

Gear unit

Housing

Chain guide

 

*   Hold the chain guide firmly.

*   Pull the gear unit from the housing.

The locking screw secures the gear unit so that it need not be completely removed.

●   The chain guide is now released.

*   Pull the entire chain guide downward out of the housing.

 

 

Only for single-fall chain hoists

 

Disassembling the load hook

Hook assembly

 

*   Screw the hook assembly apart.

 

 

Chain fastening element half

Deep groove ball thrust bearing

*   Push the three-piece deep groove ball thrust bearing upward.

*   Remove both chain fastening element halves from the chain.

*  Note the layout position of the deep groove ball thrust bearing and remove it from the chain.

 

 

Only for twin-fall chain hoists GM2 and GM4

 

Disassembling the bottom block and chain anchor point

Bolt

Brake bearing shield

Second fall

Tab washer

*   Unscrew the tab washer on the brake bearing shield.

*   Hold the second fall while pulling out the bolt.

●   The chain is now released.

*  Pull the chain out of the bottom block on the load hook.

 

 

Only for twin-fall chain hoist GM6

 

Disassembling the bottom block and chain anchor point

Tab washer

 

Second fall

Bolt

*   Unscrew the tab washer.

*   Hold the second fall while pulling out the bolt.

●   The chain is now released.

*  Pull the chain out of the bottom block on the load hook.

 

 

Only for twin-fall chain hoist GM8

 

Disassembling the bottom block and chain anchor point

Flange sleeve

 

*   Take the flange sleeve out of the housing.

 

 

Chain fastening element halves

 

 

Flange sleeve

*   Slide the flange sleeve downward.

*   Remove both chain fastening element halves from the chain.

*  Pull the chain out of the bottom block on the load hook.

 

 

 

Assembling a new chain guide

 

Chain sprocket

Cylindrical pins

Chain guide

Stripper

*   Lubricate the new chain sprocket as shown in the figure.

Lubricant: “High-Lub LT1 EP”. For details, see page 83.

*   Place the chain sprocket in the new chain guide.

*   Push the stripper from below into the chain guide.

*   Hammer in the cylindrical pin(s) (1x or 2x).

 

 

Drawing in the new chain

Use exclusively ABUS genuine replacement chains. For technical data on the chain, see page 31.

 

 

Vertical chain link

*   Turn the chain as shown in the figure. The first chain link should be pulled into the chain guide upright (on edge).

The position of the weld seam to the chain link (toward the inside or the outside) does not need to be taken into account.

*   Pull the chain into the chain guide.

 

Tip:

Affix cable ties or wire to the end of the chain and use that to pull the chain through the chain guide.

 

 

Tip:

Depending on the hook path, the new chain may be very heavy.

 

For easier installation:

 

Old chain

 

New chain

C-shaped chain link

*   Detach about a half metre from the old chain and pull this short piece as described into the chain guide and install the chain guide.

*   Once the chain hoist functions again, use a cut open C-shaped chain link to insert the new chain into the old remainder and allow the new chain to slowly be run in.

 

 

 

Only for twin-fall chain hoists

 

Installing the bottom block

 

Second fall

Cable ties

Bottom block

*   Fasten cable ties to the end of the second fall.

*   Turn the second fall so that it is straight and pull the chain through the bottom block with the cable ties.

The second fall should not be allowed to twist as it is pulled through the bottom block.

 

 

Only for twin-fall chain hoists GM2 and GM4

 

Installing the chain anchor point

Chain anchor point

 

Second fall

 

*   Turn the chain so that it is straight and push the second fall from below into the chain anchor point.

The chain should not be allowed to twist as it is pushed into the chain anchor point.

*   If necessary: Remove a single chain link so that the second fall can be inserted straight.

 

 

Warnung stürzende Last

Danger from falling suspended load!

The bolt can become loosened by vibration. The chain and load could fall, injuring or killing people.

Bolt on the tab washer!

 

Bolt

Brake bearing shield

 

Tab washer

*   Insert the bolt.

●   The second fall is now held by the bolt.

*   Bolt the tab washer with fillister-head screw onto the brake bearing shield.

Size

Type and length

Tightening torque

GM2

M5x20

4 Nm

GM4

M5x20

4 Nm

 

 

Only for twin-fall chain hoist GM6

 

Installing the chain anchor point

Chain anchor point

 

Second fall

 

*   Turn the chain so that it is straight and push the second fall from below into the chain anchor point.

The chain should not be allowed to twist as it is pushed into the chain anchor point.

*   If necessary: Remove a single chain link so that the second fall can be inserted straight.

 

 

Warnung stürzende Last

Danger from falling suspended load!

The bolt can become loosened by vibration. The chain and load could fall, injuring or killing people.

Bolt on the tab washer!

 

Tab washer

 

 

Bolt

*   Insert the bolt.

●   The second fall is now held by the bolt.

*   Bolt on the tab washer with the M5x10 fillister-head screw. 3 Nm.

 

 

Only for twin-fall chain hoist GM8

 

Installing the chain anchor point

 

Chain fastening element halves

 

Flange sleeve

*   Push the flange sleeve onto the second fall of the chain.

*   Place the chain fastening element halves from both sides on the last chain link and slide a flange sleeve over it.

 

 

Flange sleeve

 

*   Push the flange sleeve into the housing.

 

 

 

 

Installing the chain guide

Gear rim

 

 

Coupling halves

*   Check the position of the coupling halves. The claws must be situated so that they grip precisely in the gear rim.

 

 

If necessary:

*   Turn the coupling halves on the gear unit until the claws are in the correct position.

 

 

*   Push the chain guide from below into the housing and hold it firmly.

 

 

*   Push the gear unit into the housing. Pull the chain slightly until the output shaft of the gear unit meshes with the chain sprocket.

*   Tighten the fillister-head screws (3x) in the housing.

Size

Size and length

Tightening torque

GM2

M6x85

7 Nm

GM4

M6x105

7 Nm

GM6

M8x110

18 Nm

GM8

M10x140

25 Nm

 

 

Only for single-fall chain hoists

 

Installing the hook assembly

 

Inside chain end

*   Use the inside end of the chain to install the load hook.

 

 

Ball bearing race (large inner diameter)

Ball bearing cage

Ball bearing race (small inner diameter)

 

*   Push the deep groove ball thrust bearing onto the chain facing the right direction: First push on the ball bearing race with the larger inner diameter (smoothed), then the ball bearing cage, then the ball bearing race with the smaller inner diameter (not smoothed).

*   Place the chain fastening element halves on the chain from both sides.

 

 

 

Deep groove ball thrust bearing

 

Chain fastening element halves

*   Push the deep groove ball thrust bearing over the chain fastening element halves.

*   Lubricate the deep groove ball thrust bearing.

Lubricant: “High-Lub LT1 EP”. For details, see page 83.

 

 

 

Deep groove ball thrust bearing with chain fastening element halves

Hook assembly

 

*   Insert the deep groove ball thrust bearing with chain fastening element halves into one half of the hook assembly.

*   Assemble the hook assembly.

*   Bolt the hook assembly with the fillister-head screw and self-locking nut (2x).

Size

Size and length

Tightening torque

GM2

M6x25

10 Nm

GM4

M6x25

10 Nm

GM6

M6x45

12 Nm

GM8

M8x50

30 Nm

 

 

 

Only with an electronic hoist limit switch

 

Installing the magnet carrier

Magnet carrier

 

*   Apply threadlocker (lightly) to the thread of the magnet carrier.

*   Screw the magnet carrier in place. 6 Nm.

 

 

Installing the hoist limit switch PCB

Fillister-head screws with ribs M5x10

Hoist limit switch PCB

Protective conductor

 

*   Attach the protective conductor to the fillister-head screw at the bottom right.

*   Place the hoist limit switch PCB over the magnet carrier.

*  Use the fillister-head screws with ribs M5x10 (3x) to screw the hoist limit switch PCB tight. 3 Nm.

 

 

 

Connecting the chain hoist

*   Attach the couplings of the hoist motor and brake to the pin multipoint connectors of the control in the motor cover.

Only connect couplings and pin multipoint connectors of identical colour (orange and grey).

For the assignment, see page 92.

*   With electronic hoist limit switch: Insert the connector on the hoist limit switch PCB.

 

 

Closing the chain hoist

Long fillister-head screws

Short fillister-head screw

Bayonet coupling

Motor cover

*   Hold the motor cover on the housing.

*   Note the different screw lengths and screw in the fillister-head screws.

Size

Size and length

Number

Tightening torque

GM2

M5x65

3x

4 Nm

GM2

M5x45

1x

4 Nm

GM4

M5x60

3x

4 Nm

GM4

M5x50

1x

4 Nm

GM6

M8x110

3x

15 Nm

GM6

M8x60

1x

15 Nm

GM8

M10x95

3x

20 Nm

GM8

M10x50

1x

20 Nm

*   Insert the bayonet coupling of the connection cable and the bayonet connector of the control cable. Due to a notch, the plug-in connections will only fit together in one position.

*   Slide on and tighten the bayonet nuts.

 

 

 

Installing the C-link

Only for GM2, GM4 and GM8

 

C-link

 

 

Tensioner sleeve

*   Use the outside end of the chain to install the C-link.

*   Turn the C-link so that the opening, when installed, points in the direction of the inner fall (the fall under load).

*   Push the C-link onto the second-last or third-last chain link (depending on the orientation from the previous step).

*   Hammer the tensioner sleeve into the C-link.

*   Place the chain in the chain box.

*   Check whether the chain completely fits in the chain box. If the chain box is too small, contact ABUS Service. See page 89.

 

 

Only for GM6

 

C-link

 

Fillister-head screw M6x30

Self-locking nut

*   Use the outside end of the chain to install the C-link.

*   Turn the C-link so that the heads of the fillister-head screws point in the direction of the inner fall (the fall under load) when installed.

*   Place the halves of the C-link on the second-last or third-last chain link (depending on the orientation from the previous step).

*   Tighten the C-link with the fillister-head screws M6x30 (2x) and self-locking nuts M6 (2x). 10 Nm.

*   Place the chain in the chain box.

*   Check whether the chain completely fits in the chain box. If the chain box is too small, contact ABUS Service. See page 89.