Installing the powered wheel

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

Fitting the wheel

	Wheel

Bearing bolt	Bearing flange

Hold 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

Bearing flange	Rib screw

Tighten the rib screws in stages.

Wheel Ø	Strength category	Number	Screw	Tightening torque
160	10.9	5x	M8x25	42 Nm
200	10.9	5x	M10x30	85 Nm
280	10.9	5x	M12x40	130 Nm

Fastening the bearing flange

	Retaining screw

Rib screw	Bearing flange

Tighten the rib screws in stages.

Wheel Ø	Strength category	Number	Rib screws	Tightening torque
160	10.9	7x	M8x25	42 Nm
200	10.9	7x	M10x30	85 Nm
280	10.9	7x	M12x40	130 Nm

Assembling the end carriage

	Clamping element

Guide roller	Bracket with guide rollers

Insert the bracket with guide rollers and clamping element.

Tighten screws (2x).

Wheel Ø	Rib screw	Tightening torque
160	M10x50	85 Nm
200	M10x50	85 Nm
280	M12x60	130 Nm

	Buffer plate

Self-locking nut	Plastic washer

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 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

Bearing flange	Drive

Lubricate the gearing on the output shaft.

Lubricant “High temperature paste PBC 1574”. For details, see the ABUS Drive product manual.

Rib screw

		Drive

Push the drive into the wheel.

Bolt on the drive with the rib screws (4x).

Wheel Ø	Rib screw	Tightening torque
160	M10x30	75 Nm
200	M12x30	115 Nm
280	M16x40	300 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 connector housing.

Checking the wire rope hoist

Set the wire rope hoist down again.

Put the wire rope hoist into operation.

Check the function of the wheel.