Exchanging the chain and chain sprocket

If the chain exhibits signs of wear or is too stretched from operation (see Inspecting the chain), 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 motor cover is removed and the chain sprocket is then exposed.

Detaching the connection cable and control cable

Connection cable	Socket

	Control cable with bayonet connector and bayonet nut

Detach connection cable.

Remove bayonet nut of the control cable.

Detach control cable.

Removing the chain box


Chain box	Bolt

Detach the SL safety clip from the bolt.

Hold the chain box firmly and pull out the bolt.

Remove the chain box.

Removing the C-link

C-link

	Tensioner sleeve

Hammer the tensioner sleeve out of the C-link.

Removing the motor cover

Motor cover	Housing

	Fillister-head screw

Unscrew the motor cover from the housing.

	Connector

Motor connection cable	Motor cover

Unplug the connector of the motor connection cable from the circuit board.

Taking out the chain guide


Housing	Seal

Remove seal.

Chain sprocket

Upper half of chain guide	Screw

Unscrew the screws (4x) from the chain guide.

Take out upper half of chain guide.

Lower half of chain guide	Chain sprocket

Axial alignment plate	Chain

Remove lower half of the chain guide with chain sprocket, chain, and axial alignment plate from 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

Disassembling the bottom block and chain anchor point

Cylindrical pin

End of 2nd fall

Firmly hold the end of the 2nd fall and pull out the pin.

● The chain is now released.

	2nd fall of chain

Bottom block

Pull the chain out of the bottom block.

Installing the new chain guide

Chain sprocket

Axial alignment plate

Chain

Lay lower half of chain guide in the housing.

Lubricate the new chain sprocket.

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

Pull the new chain through the left opening in the housing.

Place the new chain around the chain sprocket.

Push the axial alignment plate in the chain sprocket.

Lower half of chain guide	Chain sprocket

Axial alignment plate	Chain

Lay the chain sprocket with axial alignment plate and chain in the lower half of the chain guide.

Pull the end of the chain out of the housing through the right opening.

Chain sprocket

Upper half of chain guide	Screw

Place the upper half of the chain guide flush on the lower half of the chain guide.

Screw the chain guide tight with screws (4x). 3 Nm

Only for single-fall chain hoists

Installing the hook assembly


	Inside end of chain

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 Lubricants.

	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).

Only for twin-fall chain hoists

Installing the bottom block and chain anchor point

2nd fall of chain	Deflection roller

Load hook	Lower half of bottom block

Align the 2nd fall of the chain so it is without any twists.

Place the 2nd fall around the deflection roller of the bottom block.

The 2nd fall should not be twisted.

	2nd fall of chain

Upper half of the bottom block	Fillister-head screw with self-locking nut

Place the upper half of the bottom block flush on the lower half of the bottom block.

Screw the bottom block together with fillister-head screws (2x) and self-locking nuts. Tighten with 10 Nm.

Cylindrical pin

End of 2nd fall

Push the end of the 2nd fall into the housing recess on the right.

Hammer in the cylindrical pin.

● The end of the chain is fixed.

If only the chain is to be replaced:

Tip:

	New chain

Old chain	Cable ties

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

Closing the chain hoist


Housing	Seal

Press seal flush onto the housing.

	Connector

Motor connection cable	Motor cover

Plug the connector of the motor connection cable into the circuit board in the motor cover.

Motor cover	Housing

	Fillister-head screw

Hold the motor cover on the housing.

Screw the motor cover tight with M4x55 fillister-head screws (3x) and a M4x20 fillister-head screw (1x). 5 Nm.

Installing the C-link

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 ABUS Service.

Installing the chain box


Chain box	Bolt

Turn the chain box so that it appears as shown in the figure.

Place the chain in the chain box.

Use the bolt to install the chain box on the chain hoist.

	Bolt

SL safety clip	Chain box

Push the SL safety clip onto the bolt.

Note

If the chain is not adequately lubricated, it must be relubricated. See Lubricating the chain.

Connecting the chain hoist

Connection cable	Socket

	Control cable with bayonet connector and bayonet nut

Insert the connector of the connection cable into the chain hoist.

Slide on the bayonet nuts of the pendant control.

Insert the bayonet connector in the chain hoist.

Tighten the bayonet nuts of the pendant control.