068 - Att. 4 - Operating Instruction Hoisting Gear ELK-8000kg-ABUS

Original operating manual
for
ABUS single-girder overhead travelling crane ELK
order: 16735993 / 1
EOT crane serial number 110-034551

type ELK 8 t x 7000mm
wheel diameter 160.3
number of wheels 4
hoist serial number 250-068733

size 3000
type E
reeving 4/1
wheel diameter 160 mm
Push button pendant 611 S
documentation:
Spare parts catalogue ABUETK, A120250_001

Product Manual Operating the Crane, A120192GB_001
Product Manual General information, A120197GB_001
Product Manual crane EL, A120139GB_006
mounting instructions for drive gear AZP, A120009GB_001
Technical Data for End carriage 160, A120069GB_002
installation, operating and maintenance instructions for ABUS wire rope hoist, A120055GB_002
Operating instructions for lifting gear drive, A120056GB_001
Operating instructions for emergency limit switch, A120064GB_003
Operating instructions for rope guide GM800-GM6000, A120057GB_002
Technical data for wire rope hoist GM3000, A120061GB_004
installation, operating and maintenance instructions for push button pendant, A120028GB_003
installation, operating and maintenance instructions for ABUS LIS-SV, A120077GB_000
Operation instructions Cross-type limit switch KHS, A120216GB_000
Electric parts list
wiring diagram, no. 500000GB_004; 600167GB_000
ABUS Kransysteme GmbH

D-51647 Gummersbach, 03.02.2017
ABUS Kransysteme GmbH, DruckDoku Version 5.11w101

Kransysteme
Product Manual
for Operating the ABUS Crane

Sonnenweg 1
51647 Gummersbach Germany
110-034551 Tel. 0049 2261 37-0
Serial number Fax. 0049 2261 37-247
info@abus-kransysteme.de
250-068733
Distribution or reproduction of this document, or the utilisation and disclosure of its contents without explicit
approval is prohibited. Violations will incur liability for damage compensation. All rights are reserved in
regard to patent issuance or registered designs.
Instructions regarding safety (page 3)

Instructions regarding safety when slinging a load (page 8)
Emergency stop (page 10)
Check before beginning work and switching on (page 11)
Operating the crane with the pendant control (page 16)
Switching off the crane (page 23)
AN 120192EN001 2014-02-28 Translation of the original operating instructions
Contents
Contents
1. Instructions regarding safety .................... 3
2. Instructions regarding safety when

slinging a load .......................................... 8
3. Preventing damage to the crane............... 9
4. Emergency stop...................................... 10
5. Check before beginning work and

switching on ............................................ 11
6. Operating the crane with the pendant

control..................................................... 16
7. Lifting and lowering................................. 16
8. Crane travel, trolley travel and slewing ... 17
9. Overload protection ................................ 18
10. Inching counter ....................................... 19
11. Observe the specified duty cycles .......... 19
12. Working in the range of the travel limit

switch ..................................................... 20
13. Load display and tare ............................. 22
14. Securing the crane in a power failure ..... 22
15. Switching off the crane ........................... 23
Page 2
Operating the ABUS crane Instructions regarding safety
Operating the ABUS crane

This section applies to anyone who lifts loads using the crane or works nearby.
Be sure to read and observe the product manual of

the entire crane! The instructions given here apply Only with cranes with one trolley
in addition to the other product manuals.
Observe the maximum load

1. Instructions regarding safety capacity!
Observe these instructions for safe handling of the

crane. Special hazard notices are located in the
corresponding sections in which the danger arises.
Observe the product manuals!

In addition to the points described
here, all information in the section
Instructions regarding safety in
the other supplied product manuals If the maximum load capacity is
also applies. exceeded, the crane and the
supporting structure could be
damaged.
Only trained and authorised This could cause the load to fall,
personnel may operate the crane! killing or injuring people.
Special technical expertise is Observe the maximum load capacity of
required to correctly sling and safely the trolley and the crane and do not
lift and move loads. exceed it!
The maximum load capacity is specified
Otherwise, accidents could occur.
on the trolley and on the bottom block or
Personnel working with the crane (e.g. crane hook assembly. The maximum load
operators and load handlers) must first have capacity of the crane is also given:
received instruction regarding operation and
For overhead travelling cranes: on
be assigned this work by the end user.
the main girder
For jib cranes: on the jib arm
For HB cranes: on the crane girder
Always work safely!
For single-rail trolley tracks: on the
Suspended loads always pose a
trolley track
hazard when working with the crane.
Always keep your own safety as well as the
safety of others in mind when working with
the crane. The technical knowledge gained
from the instruction and the supplied ABUS
product manuals will be aid you in working
safely with the crane.
Page 3
Instructions regarding safety Operating the ABUS crane
Only with cranes with multiple If the maximum load capacity of the crane
trolleys cannot be accurately added together from
several trolleys, first the maximum load
capacity of the crane is given, then the
Observe the maximum load maximum load capacity of the trolleys,
specified in brackets with a /.
capacity!
Maximum load capacity of crane
16 t trolley 10 t trolley
If the maximum load capacity is

exceeded, the crane and the
supporting structure could be Additional rules:
damaged. If the maximum load capacity of the crane
corresponds exactly to that of the largest
This could cause the load to fall, trolley, the maximum load capacity of the
killing or injuring people. crane and the brackets are omitted.
Observe the maximum load capacity of the Maximum load capacity of the crane and, at
trolleys and the crane and do not exceed it! the same time, of the largest trolley
The maximum load capacity is specified on
the trolley and on the bottom block or hook
assembly. The maximum load capacity of
the entire crane is also given on the crane
itself: Maximum load capacity of
the smaller trolley
For overhead travelling cranes: on
the main girder
Maximum load capacity of the crane and, at
For jib cranes: on the jib arm
the same time, of the largest trolley
For HB cranes: on the crane girder
For single-rail trolley tracks: on the
trolley track
Maximum load capacity of the
smaller trolleys
If the maximum load capacity of the crane
can be added together exactly from several
trolleys, the load capacities of the respective
trolleys are given with a +. The total is the
maximum load capacity of the crane. In this case as well, the maximum load
capacity of the crane can be added together
First 5 t trolley Second 5 t trolley from several trolleys.
20 t trolley 5 t trolley 10 t trolley
Total 10 t, maximum load capacity of crane

20 t trolley 10 t trolley 5 t trolley
Page 4
Only with cranes with partial load Note the weight of the load lifting
ranges attachment!
This section only applies if the main girder (for
overhead travelling cranes), the jib arm (for jib
cranes), the crane girder (for HB cranes) or the
trolley track (for single-rail trolley tracks) are divided
into different areas with different maximum load
capacities.
The weight of the load lifting

Observe the differing maximum attachments (e.g. crossheads) can
load capacities of the crane! be very heavy and thus reduce the
maximum load capacity of the
crane.
If this weight is not factored in, the
maximum load capacity of the
crane could be exceeded.
The weight of the load lifting attachment
must be taken into account in the crane
If the maximum load capacity is operator's decision of whether a load can
exceeded, the crane and the be lifted with the crane.
supporting structure could be
damaged.
Only with cranes with warning
This could cause the load to fall, devices
killing or injuring people.
This section only applies if the crane has a warning
Depending on the position of the trolley, the device (e.g. horn or bell).
crane will have different maximum load
capacities. Observe the maximum load
capacity of the partial load range in which Sound alarm in the event of
the trolley is currently located. Do not danger!
exceed the maximum load capacity!
The maximum load capacities of the
individual areas on the main girder (for
overhead travelling cranes), the jib arm (for
jib cranes), the crane girder (for HB cranes)
or on the trolley track (for single-rail trolley
tracks) are separated from each other by
vertical lines. The respective maximum
load capacity of the partial load range is
given within the lines.
Especially when the crane operator

is not standing directly at the crane
(e.g. if using radio remote control),
personnel nearby may not
necessarily be aware that the crane
is in use.
This could result in dangerous
situations where people can be
killed or injured.
Use the warning device (e.g. horn or bell)
to warn persons nearby of suspended
loads.
Page 5
Instructions regarding safety Operating the ABUS crane
Do not pull loads at an angle! Do not attempt to catch loads!
If an attached load is pulled or towed

at a slant (e.g. over the floor), the
trolley can tip due to the lateral
forces and fall. The trolley can also
be damaged by wire ropes or chains If a load in the load hook, the lifting
running askew. tackle or the load lifting attachment is
This in turn means the load or crane dropped and then caught with the
itself could fall and kill or injure crane (e.g. a component is only
people. loosely suspended and then
detached), the strong jolt could
Always only lift the load vertically! Do not pull
any vehicles or carriages! cause the trolley to fall.
As a result of this people can be
killed or injured.
Do not jerk the load free!
Do not attempt to catch loads!
Do not turn loads!
If an immobile or jammed load (e.g.

due to rusted together or bolted
together parts) is jerked free, the
trolley could fall due to the strong jolt If a load in the lifting tackle or load
from the sudden release of the load. lifting attachment is rotated or
turned, it can suddenly tilt. The
As a result of this people can be strong jolt could cause the trolley to
killed or injured. fall.
Do not jerk the load free with the crane. As a result of this people can be
killed or injured.
Only turn the load if the crane is installed
with a load lifting attachment specially
designed for turning loads.
Page 6
Do not attempt to transport any Do not cause loads to swing!

persons!
The crane is not equipped with the A load that swings too heavily from
necessary safety devices to safely side to side can no longer be safely
transport people. controlled.
This means that persons could fall As a result of this people can be
during the transport and be killed or struck by the load and killed or
injured. injured.
Do not lift persons either together with a load During crane travel and trolley travel, avoid
or without one. If any persons step onto the swinging the load too much from side to
load or the load lifting attachment (e.g. side.
climbing into a pallet cage or sitting on the
crosshead), do not lift the load.
Do not intentionally run the load

Do not transport loads above to the emergency limit switch!
anyone!
The emergency limit switch (in wire

rope hoists) and the friction clutch (in
chain hoists) can be damaged if
subjected to regular use, and will
therefore no longer function if the
load hook is run too high or too low.
This could damage the crane and
cause the load to fall.
If the load is not slung correctly or
the lifting tackle snaps, the load can Do not intentionally or under normal
fall. operating conditions run the load so as to
engage the emergency limit switch or the
As a result of this people can be friction clutch. If work needs to be performed
killed or injured. near the highest or lowest hook position
during normal operation, an additional
Do not transport a suspended load above operating limit switch must be employed to
anyone. avoid damaging the emergency limit switch.
Page 7
Instructions regarding safety when slinging a load Operating the ABUS crane
Do not allow the pendant control Do not sling the chain or wire
to swing about! rope of the hoist around the load!
The chain of the chain hoist and the

wire rope of the wire rope hoist are
Uncontrolled swinging of the not lifting tackle. They must always
pendant control can cause it to strike run in a straight line. If twisted or laid
something and become damaged. around sharp edges, they will be
This could expose voltage- damaged.
conducting parts.
The chain or wire rope could thereby
This poses the risk of electrical break, causing the load to fall.
shocks.
Do not sling the chain of the chain hoist or
Do not allow the pendant control to swing the wire rope of the wire rope hoist around
back and forth! the load and use them for lifting. Instead, use
suitable lifting tackle or load lifting
attachments.
2. Instructions regarding safety Close the hook safety latch!

when slinging a load

the other supplied product manuals
also applies.
If the hook safety latch is not closed,

the lifting tackle or load lifting
attachment can inadvertently slip
from the load hook.
This could cause the load to fall.
Hang the lifting tackle or the load lifting
attachment fully in the load hook and allow
the hook safety latch to spring back to
secure it.
Page 8
Operating the ABUS crane Preventing damage to the crane
Observe the maximum angle of 3. Preventing damage to the crane

spread and maximum load
capacity of lifting tackle!
Follow these instructions to ensure a long service
life of the crane.
No inching operation!
To position a load precisely, do not use inching
operation (button pressed repeatedly in quick
succession).
Instead, use low speed or the slow lifting speed
If the maximum angle of spread or (button pressed halfway).
the maximum load capacity of the
lifting tackle is exceeded, it can
break.
Do not run against the safety buffer!
This could cause the load to fall.
The safety buffers are designed to absorb the total
Always observe the maximum angle of energy of movements. Nevertheless, an impact on
spread and maximum load capacity of the the safety buffer is an extreme situation and places
lifting tackle. strain on the crane and the entire supporting
structure.
For overhead travelling cranes: Do not run
Lift the load at slow lifting speed the crane with the safety buffer against the
and with lifting tackle under end of the crane track.
tension!
For overhead travelling cranes: Do not run
the trolley against the end of the main girder.
For overhead travelling cranes: Do not allow
the crane to run against another crane.
For jib cranes: Do not run the jib arm against
the safety buffer at the end of the slewing
range.
For jib cranes: Do not run the trolley against
the safety buffer on the jib arm.
For HB cranes: Do not run the HB crane
against the end of the crane track.
For HB cranes: Do not run the trolley against
the end of the crane girder.
Due to the jolt when lifting from the
ground with a fast lifting speed, the
crane is heavily strained and can be
overloaded. This jolt is amplified if Report any unusual noises and abnormal
the lifting tackle is slack while behaviour!
switching directly to fast lifting Be watchful for any unusual noises or abnormal
speed. behaviour of the crane during operation.
The jolt could break the lifting tackle Unusual noises and abnormal crane behaviour can
or the crane could be damaged, indicate defects and signs of wear.
causing the load to fall. If there is any damage or problems arise, do not
work with the crane; inform coworkers and
Lift the load from the ground at slow lifting
supervisors. If necessary, stop the crane.
speed until the lifting tackle is tensioned and
the load hangs freely. Only then continue In the early stages, such damage can usually be
lifting, if necessary, with fast lifting speed. simply and inexpensively rectified.
Page 9
Emergency stop Operating the ABUS crane
Use electrically isolated lifting tackle for

welding! 4. Emergency stop
Electrically isolated lifting
tackle

Emergency stop in the other
supplied product manuals also
applies.
In dangerous situations with the crane:

Emergency stop switch
Component to be welded
If the crane is used to hold components on which
welding work is performed, be sure to use
electrically isolated lifting tackle (e.g. insulated
swivel, round sling made of non-conductive
material).
Otherwise, the welding current can flow through the
crane and damage the electrical controls, the wire
rope and the bearing.
Press the emergency stop switch.
The crane brakes immediately; the load hook

halts.
When the danger has been eliminated:

Turn the emergency stop switch a quarter-

turn clockwise.
The crane is ready for use.
Page 10
Operating the ABUS crane Check before beginning work and switching on
5. Check before beginning work Only with wire rope hoists

and switching on
Inspect the entire wire rope for damage. The
damage shown here or any similar damage
Check the following points before beginning work should not be detectable on the wire rope.
with the crane. If there is any damage or problems
arise, do not work with the crane; inform coworkers Examples of damage:
and supervisors.
Observe the product manuals! The joining of the wire rope has opened. The
In addition to the points described inner strands of the wire rope are visible.
Check before beginning work and
switching on in the other supplied
product manuals also applies.
External check of crane Loops have formed in the wire rope.
In all supplied product manuals, check

whether additional points need to be checked
before switching on.
There is a kink in the wire rope. This results

from violent external forces being applied to
Can any damage be detected on the crane
the wire rope.
or its accessories (e.g. rust, loose parts,
leaking oil, missing screws,...)?
Is the load hook turnable and otherwise OK?

The wire rope is flattened at one point. This
results from the wire rope being pinched.
A bird cage has formed in the wire rope. This

results from violent untwisting of the wire
rope.
Load hook
The wire rope has a corkscrew-type

deformation.
Page 11
Check before beginning work and switching on Operating the ABUS crane
Switching on
Check the wire rope for detectable broken
wires. If broken wires are found in the wire In all supplied product manuals, check
rope, do not work with the crane. Have a whether additional points need to be checked
comprehensive wire rope test performed. for switching on.
See General Product Manual for ABUS
Cranes.
Only with chain hoists
Is the chain lubricated with oil?
Inspect the entire chain for damage. The

damage shown here or any similar damage
should not be detectable on the chain.
Examples of damage:
Mains switch of the crane installation

Only if the crane installation has a mains
switch: Turn on the entire crane installation
using the mains switch.
The chain link is heavily worn.

Emergency stop
switch
The chain link is mechanically damaged.

Turn the emergency stop switch a quarter-
turn clockwise.
The crane is switched on.
Page 12
Only with radio remote control Checking the emergency stop

switch, hoist drive and brakes on
Logging in the hoist drive
Switch on the transmitter of the radio remote

Test the following before beginning work:
control and log in to the receiver. See the Press the Lift button completely.
radio remote control product manual.
The load hook moves up.
The load hook halts.
The brake makes a clicking noise and the
load hook immediately comes to a stop.
The functional checks of the emergency stop
switch, hoist drive and brakes on the hoist
drive are now completed.
Switch the crane back on using the pendant
control.
Only with trolleys with electrically

Red signal lamp powered trolley travel and cranes
The red signal lamp lights up when the with electrically powered crane
transmitter has been logged in and enabled.
travel
The radio remote control can now be used.
Checking the drive and the brakes
of the drive

Fully push the trolley travel and crane travel
buttons.
The trolley and crane run in the
corresponding direction.
The trolley and crane stop running.
The brakes engage with an audible click
and the trolley and crane immediately come
to stop.
The functional test of the drive and the drive
brakes is now completed.
Switch the crane back on using the pendant
control.
Page 13
Check before beginning work and switching on Operating the ABUS crane
Only with jib cranes with Only with chain hoists with an
electrically powered slewing electronic hoist limit switch
Testing the slewing drive Checking the switching points
Test the following before beginning work: Test the following before beginning work:
Press the Slewing button completely. Move the load hook until it reaches the set
switching points.
The crane pivots in the corresponding
direction. The chain hoist no longer travels in the
respective direction.
The crane stops pivoting and slowly comes
to a stop. Only with chain hoists without a
The slewing drive has no brake, therefore hoist limit switch
the crane slowly swings out.
The functional check of the slewing drive is
The chain hoist has a friction clutch. It prevents
now completed.
damage to the chain hoist if the load hook in the
Switch the crane back on using the pendant highest hook position knocks against the housing
control. from below.
Danger from falling suspended

Only with wire rope hoists and for load!
chain rope hoists with a Never run the load hook so far up
that the friction clutch engages.
mechanical hoist limit switch
This would damage the friction
Testing the hoist limit switches clutch long-term and the load
could fall, killing or injuring people.
Press the 'Lift' button halfway and move the Therefore, also refrain from testing the
load hook completely up with slow lifting friction clutch before performing work.
speed.
At the highest hook position, the load hook
halts.
For hoists without operating limit switches:
The functioning of the top emergency limit
switch has now been tested.
For hoists with operating limit switches: The
functioning of the top operating limit switch
has now been tested.
Page 14
Only with travel limit switches with Only with travel limit switches with
braking function braking and shut-down functions
Test the travel limit switch Test the travel limit switch
Test the following before beginning work: Test the following before beginning work:
Testing the braking function: Check the braking function as previously
described.
For overhead travelling cranes: Run the
crane at high speed until it reaches the end Check the shut-down function:
of the crane track.
For overhead travelling cranes: Run the crane until it reaches the end of the crane
trolley at high speed until it reaches the end track.
of the main girder.
For jib cranes: Pivot the jib arm with fast trolley until it reaches the end of the main
slewing speed until it reaches the end of the girder.
slewing range.
For jib cranes: Pivot the jib arm until it
For jib cranes: Run the trolley at high speed reaches the end of the slewing range.
until it reaches the end of the jib arm.
For jib cranes: Run the trolley until it
For HB cranes: Run the HB crane at high reaches the end of the jib arm.
speed until it reaches the end of the crane
For HB cranes: Run the HB crane until it
track.
reaches the end of the crane track.
For HB cranes: Run the trolley at high
For HB cranes: Run the trolley until it
speed until it reaches the end of the crane
reaches the end of the crane girder.
girder.
For single-rail trolley tracks: Run the trolley
For single-rail trolley tracks: Run the trolley
until it reaches the end of the trolley track.
at high speed until it reaches the end of the
trolley track. At the end, the crane/trolley brakes to a
Shortly before the end, the crane/trolley
standstill.
brakes and continues running at low speed. The crane/trolley comes to a stop just
before the end.
Testing additional warning and

safety devices
If the crane has additional warning and

safety devices:
Test the warning devices.
Test the safety devices.
Page 15
Operating the crane with the pendant control Operating the ABUS crane
6. Operating the crane with the 7. Lifting and lowering

pendant control

Lifting and lowering in the other
applies.
Buttons for lifting/lowering
Lifting or lowering with slow lifting

Line of vision speed
Take the pendant control in your hand.
With the pendant control in hand, turn so that
the crane is in your line of vision.
This is the optimum position for operating the
crane. Half-press the button (stage 1).
In this position, the directions of the The hoist lifts or lowers with slow lifting
operating direction signs (arrows) on the speed.
pendant control match the actual direction of
travel of the crane and the trolley.
Lifting or lowering with fast lifting

speed
Operating direction signs on the
crane
Press the button completely (stage 2).
The hoist lifts or lowers with fast lifting speed.
Operating direction signs on the pendant

control
Independent of their respective position, the
colours of the operating direction signs
(yellow and black arrows) always point the
correct running direction of the crane and the
trolley.
Observe the operating direction signs.
Page 16
Operating the ABUS crane Crane travel, trolley travel and slewing
Braking
8. Crane travel, trolley travel and
slewing
Release the button halfway (back to stage 1).
The hoist brakes and then lifts or lowers Observe the product manuals!
again with slow lifting speed. In addition to the points described
Crane travel, trolley travel and
slewing in the other supplied
Standstill product manuals also applies.
Only with electrically powered

Release the button. trolley travel, crane travel and
slewing
The hoist brakes and comes to a stop.
Button for crane travel Button for trolley travel
At low speed
Half-press the button (stage 1).

For cranes: The crane runs at low speed.
For trolleys: The trolley runs at low speed.
For jib cranes: The crane pivots with slow
slewing speed.
At high speed
Press the button completely (stage 2).

For cranes: The crane runs at high speed.
For trolleys: The trolley runs at high speed.
For jib cranes: The crane pivots with fast

slewing speed.
Page 17
Overload protection Operating the ABUS crane
Braking 9. Overload protection
Only with wire rope hoists

Release the button halfway (back to stage
1).
The wire rope hoist has an LIS-SE or LIS-SV load
For cranes: The crane brakes and runs indicator system. It measures the suspended load
again at low speed. and ensures that the wire rope hoist cannot lift any
load which exceeds the maximum load capacity.
For trolleys: The trolley brakes and runs Nevertheless, do not exceed the maximum load
again at low speed. capacity of the wire rope hoist!
For jib cranes: The crane brakes and pivots
again with slow slewing speed.
load!
Despite this overload protection,
Standstill the crane could be damaged by a
load that is too heavy, causing the
load to fall.
Do not exceed the maximum load
capacity of the crane!
Release the button.
For cranes: The crane brakes and comes to
a stop. If the wire rope hoist no longer lifts with
For trolleys: The trolley brakes and comes the button pressed:
to a stop.
The load indicator system has triggered.
For jib cranes: The crane brakes and comes
With load display: The load display flashes.
to a stop.
Release the Lift button.
Press the Lower button and set down the
load.
Only with crane travel, trolley In addition, the load indicator system has a
travel, slewing by hand protective device to prevent lifting the load with a
sudden jolt (sudden load increase).
Pull or push on the load, the bottom block,

the hook assembly, the lifting tackle or load If the wire rope hoist briefly halts when
lifting attachment to move the load. lifting a load:
Do not pull on the pendant control in order
to move the load or the empty load hook. The load indicator system has detected
lifting with a sudden jolt (sudden load
Only pivot or move the load if it can be increase).
easily and safely stopped by hand.
The wire rope hoist briefly lifts only at slow
lifting speed.
Continue to hold the 'Lift' button completely
pressed (stage 2).
Once the sudden load increase is over, the
wire rope hoist accelerates again to the fast
lifting speed.
Page 18
Operating the ABUS crane Inching counter

11. Observe the specified duty
cycles
The chain hoist has a special overload protection
(friction clutch). This ensures that the chain hoist
cannot be used to lift loads that could cause direct The motors on the crane are not designed for
mechanical damage to the chain hoist. It also continuous operation. They must have break
prevents damage to the chain hoist if the load hook intervals for cooling down.
in the highest hook position knocks against the
housing from below.
Intermittent duty
Nevertheless, do not exceed the maximum load
capacity of the chain hoist!
Normally, an individual motor on a crane (e.g. the
motor on the trolley drive) is not operated
If the load hook no longer moves, but the continually over a lengthier period, but rather only
chain hoist is still running: briefly with corresponding break intervals (in which
then, for example, the crane travel drive is
The friction clutch has engaged. operated). This operating mode is called intermittent
duty.
Release the Lift button.
How long an individual motor should be operated
Press the Lower button and set down the and how long the breaks for cooling down must be
load. is determined by the duty cycle.
The duty cycle of the hoist drive and travel drive can
Danger from falling suspended be found in the test log book of the crane or in the
load! section Technical data in the production manual of
the respective hoist drive or travel drive. The values
Never run the load hook so far up can also be taken from this table.
that the friction clutch engages.
This would damage the friction Observe the maximum permissible duty
clutch long-term and the load cycle and the maximum switching rate of the
could fall, killing or injuring people. hoist and the travel drives.
Total duty cycle
Duty cycle at
Duty cycle at
high speed
low speed
10. Inching counter
Only with wire rope hoists with LIS- 25 %

SE 2.5 min 0.8 min 1.7 min
30 %
3 min 1 min 2 min
The LIS-SE has an inching counter. It ensures that
the wire rope hoist is not used too long in inching 40 %
operation (button pressed repeatedly in quick 4 min 1.3 min 2.7 min
succession).
50 %
5 min 1.7 min 3.3 min
If the wire rope hoist no longer lifts after
repeated brief presses of the button: 60 %
6 min 2 min 4 min
The inching counter has triggered. The wire
Table: The specified values (percentage and
rope hoist has been raised 16 times in
minutes) refer to a duration of ten minutes.
inching operation.
Example: a duty cycle of 40% means that the motor
Lower the load hook for two seconds. may run for a maximum of four minutes and must
remain stationary for six minutes within any 10-
The inching counter is reset. The wire rope minute period.
hoist can be normally operated again. Furthermore, the total duty cycle is divided into 1/3
of the duty cycle at low speed and 2/3 of the duty
cycle at high speed.
Page 19
Working in the range of the travel limit switch Operating the ABUS crane
Short term duty cycle for hoist drives:
Switching rate at
Switching rate at
Total switching
Duty cycle of hoist drive

in intermittent duty (see
cycle in short term duty
cycle in short term duty

high speed
Corresponding duty
Corresponding duty
low speed
previous table)
for high speed

for low speed
rate
150 c/h 100 c/h 50 c/h

180 c/h 120 c/h 60 c/h
240 c/h 160 c/h 80 c/h 25 % 3 min 15 min
300 c/h 200 c/h 100 c/h 30 % 3.5 min 30 min
360 c/h 240 c/h 120 c/h 40 % 4 min 30 min
Table: The values are given in switches per hour.
Example: 240 switches per hour means that the 50 % 5 min 60 min
motor may switch up to a maximum of 240 times 60 % 6 min Over 60 min
within one hour.
Table: Duty cycle in intermittent duty and the
Furthermore, the total maximum switching rate is
corresponding duty cycle if the hoist drive is
divided into 2/3 of the switches at low speed and 1/3
operated in short term duty. Likewise in short term
of the switches at high speed.
duty, the total duty cycle is divided into 1/3 of the
duty cycle at low speed and 2/3 of the duty cycle at
high speed.
Short term duty
In special situations, a motor may need to run Operating the drive in short term duty:
continuously for a longer period than allowed in
intermittent duty (e.g. for a long crane run or if a If the crane was previously just used: Wait
longer hook path must be travelled). In these cases, until the motor has cooled down to the
the motor can be run in short term duty. ambient temperature.
The motor may only be run up to the maximum

Only run the motor at low and high speed
maximally as specified in the table.
period given in the table. The motor must then be
allowed to cool down. In short term duty, the motor may not be
switched on more than 10 times.
Short term duty cycle for drives:

Wait until the motor has cooled down to the
ambient temperature.
duty cycle in short
duty cycle in short

term duty for high
term duty for low
Then run the motor again in either short term

intermittent duty
Corresponding
Corresponding
duty or intermittent duty.

(see previous
Duty cycle of
drive in
speed
speed
table)
12. Working in the range of the

25 % 2.5 min 15 min travel limit switch
30 % 3 min 15 min
40 % 3.5 min 30 min
50 % 4 min 30 min
60 % 5 min 60 min here, all information in the section
Table: Duty cycle in intermittent duty and the Working in the range of the travel
corresponding duty cycle if the drive is operated in limit switch in the other supplied
short term duty. Likewise in short term duty, the total
duty cycle is divided into 1/3 of the duty cycle at low
speed and 2/3 of the duty cycle at high speed.
Page 20
Operating the ABUS crane Working in the range of the travel limit switch
Only with travel limit switches with Only with travel limit switches with
braking function braking and shut-down functions
The crane (or the trolley) has a travel limit switch The crane (or the trolley) has a travel limit switch
with a braking function. The braking function with braking and shut-down functions. The braking
prevents the crane (or the trolley) from impacting function prevents the crane (or the trolley) from
the safety buffer at high speed. impacting the safety buffer at high speed. The shut-
down function additionally prevents the crane (or
the trolley) from impacting the safety buffer at low
speed.
If the crane (or the trolley) runs at high
speed:
The crane (or the trolley) brakes at the If the crane (or the trolley) runs into the
switching point for the braking function: limit switch range of the braking function:
For overhead travelling cranes: The crane The crane (or the trolley) brakes at the
brakes a small distance before the end of switching point for the shut-down function:
the crane track.
For overhead travelling cranes: The crane
For overhead travelling cranes: The trolley brakes just before the end of the crane
brakes a small distance before the end of track.
the main girder.
For overhead travelling cranes: The trolley
For jib cranes: The jib arm brakes a small brakes just before the end of the main
distance before the end of the slewing girder.
range.
For jib cranes: The jib arm brakes just
For jib cranes: The trolley brakes a small before the end of the slewing range.
distance before the end of the jib arm.
For jib cranes: The trolley brakes just before
For HB cranes: The HB crane brakes a the end of the jib arm.
small distance before the end of the crane
track. For HB cranes: The HB crane brakes just
before the end of the crane track.
For HB cranes: The trolley brakes a small
distance before the end of the crane girder. For HB cranes: The trolley brakes just
before the end of the crane girder.
For single-rail trolley tracks: The trolley
brakes a small distance before the end of For single-rail trolley tracks: The trolley
the trolley track. brakes just before the end of the trolley
track.
The crane (or the trolley) continues running
at low speed. The crane (or the trolley) is at the outermost
limit of the traversing range and cannot go
Continue running the crane (or the trolley), if
any further.
necessary, at low speed.
Run the crane (or the trolley), if necessary,
Run the crane (or the trolley), if necessary,
in the opposite direction out of the limit
in the opposite direction out of the limit
switch range.
switch range.
Page 21
Load display and tare Operating the ABUS crane
13. Load display and tare 14. Securing the crane in a power
failure
Only with cranes with load display

In the event of a power failure:
Load display
The load display shows the weight of the
load currently suspended in the load hook. Travel drive and hoist drive remain stationary
due to the power failure.
The travel motors and the hoist motors are
immediately and reliably braked even without
Only with cranes with load display electricity.
and tare The entire crane halts. The load cannot sag
or fall.
Tare Due to the abrupt braking, the load can

swing more than usual.
The load display of the crane can be reset to zero Release all buttons on the pendant control
using Tare. This enables a differential and press the emergency stop button.
measurement, e.g. in order not to include the This ensures that the crane cannot be
weight of a load lifting attachment (such as a inadvertently operated once the power is
crosshead). restored.
If necessary: Secure the area under the
Press the 'Tare' button. suspended load.
The display of the suspended load is set to
zero.
Page 22
Operating the ABUS crane Switching off the crane
15. Switching off the crane Only with cranes with a rail clamp
type wind anchor
This section only applies if the crane is operated
completely outdoors and if it can be secured from
Observe the product manuals! wind by means of a rail clamp.
Switching off the crane in the
Switch on the rail clamp.
other supplied product manuals Make sure the crane is secured.

also applies.

Load hook
Lifting tackle
If possible, set down or remove lifting tackle
(wire ropes, chains, ...) and load lifting For lengthier interruptions:
attachments (crossheads, ...).
After the end of work, run the load hook to
just below the highest hook position.
Only with cranes which are partially

operated outdoors
This section is only applicable if the crane can be
operated either in a building or outdoors (if the
crane track leads out of the building).
Move the crane to the resting position in the

building.
Only with cranes with a wind

anchor secured by a falling latch
This section only applies if the crane is operated
completely outdoors and if it can be secured from
wind by means of a falling latch.
Mains switch
Move the crane to the resting position at the Switch off the crane at the mains switch.
end of the crane track.
Run the crane until the falling latch closes.
Make sure the crane is secured.
Page 23
AN 120192EN001 2014-02-28
Kransysteme
General Product Manual

for ABUS Cranes
ABUS single and double girder travelling crane,

underslung travelling crane, wall travelling crane
and semi-goliath crane
ABUS pillar slewing jib crane and wall jib crane
ABUS HB crane
ABUS single-rail trolly track
ABUS mobile gantry crane
ABUS chain hoist and wire rope hoist
First read the product manual!
The various product manuals for this crane supplement each
other. Read this product manual first. It contains important
information and references to other manuals.

Sonnenweg 1
Tel. 0049 2261 37-0
Fax. 0049 2261 37-247
Order No. 16735993 / 1 info@abus-kransysteme.de
General instructions regarding safety (page 9)

Machine description (page 15)
Instructions regarding safety - Putting into operation (page 24)
Connecting the crane to the mains supply (page 28)
Test before initial commissioning (page 33)
Regular inspection (page 36)
Basics for determining the remaining service life (page 43)
Instructions regarding safety - Performing maintenance (page 51)
work
Lubricants (page 54)
AN 120197EN001 2014-02-28 Translation of the original operating instructions
Crane: various types, versions and options
This product manual applies to cranes of various types, versions and options. The work steps described and the
technical data will vary according to the type, version and options of the crane. The areas of this product manual
which do not apply to all cranes, but are applicable only under certain conditions, are enclosed in a dashed box.
At the start of the box, the types, versions and options to which the section is applicable are specified.
Crane (type)
Single-girder Double-girder Underslung Wall Semi-goliath

travelling crane travelling crane travelling crane travelling crane crane
Pillar slewing jib crane Wall jib crane
HB crane Single-rail trolley track Mobile gantry crane
Chain hoist Single rail trolley Side-mounted trolley Double-rail trolley

Cranes with overlapping operating range
Two cranes (overhead travelling crane and wall travelling crane shown here) whose operating ranges overlap
(here for example, two overlapping crane levels)
Crane on a crane track
Two cranes on a shared crane track
Tandem operation (optional)
Two cranes in tandem operation

Two trolleys on one crane (optional)
Crane with two trolleys
Crane and trolley with walkway
Trolley with walkway
Crane with walkway
Crane travel limit switch with braking function and/or shut-down function
(optional)
In the test log book of the crane, check whether the crane has a crane travel limit switch.
In the test log book of the crane, check whether the crane travel limit switch can be used for braking or
shut-down.
Trolley travel limit switch with braking function and/or shut-down function
(optional)
In the test log book of the crane, check whether the crane has a trolley travel limit switch.
In the test log book of the crane, check whether the trolley travel limit switch can be used for braking or
shut-down.
ABULiner Lifting/Lowering
In the test log book of the crane, check whether the hoist is equipped with the ABULiner frequency
converter.
Contents
Contents
3.6 Inspecting the chain................................ 42
1. GENERAL INFORMATION..................... 6
3.7 Basics for determining the remaining
1.1 At the start ................................................ 6 service life .............................................. 43
1.2 Instructions regarding safety: For 3.8 Checking the remaining service life ........ 44
anyone who performs work with or on
the crane, or works nearby ....................... 9 3.9 Checking the test log book ..................... 45
1.3 Instructions regarding safety: For the 3.10 Documenting the test.............................. 45
end user of the crane.............................. 11
3.11 Acceptance test after substantial
1.4 The crane ............................................... 15 changes .................................................. 45
1.5 Storage of the crane ............................... 23 3.12 Testing of components subject to

especially high stress ............................. 46
2. INSTALLING AND CONNECTING .......... 24
3.13 Test plan and maintenance schedule ..... 47
2.1 Instructions regarding safety: Before
putting into operation .............................. 24 4. MAINTENANCE ............................... 49
2.2 Instructions regarding safety: When 4.1 Switching off the crane ........................... 49
putting into operation .............................. 25
4.2 Instructions regarding safety: Prior to
2.3 Instructions regarding safety: After maintenance ........................................... 51
putting into operation .............................. 26
4.3 Instructions regarding safety: During
2.4 Installation overview ............................... 26 maintenance ........................................... 52
2.5 Equipping the crane for operation in 4.4 Instructions regarding safety: After
unprotected environments ...................... 27 maintenance ........................................... 52
2.6 Connecting the crane to the mains 4.5 Releasing the crane................................ 53
supply ..................................................... 28
4.6 Modifying the crane ................................ 53
2.7 Ensuring electromagnetic compatibility
(EMC) ..................................................... 32
4.7 ABUS Service ......................................... 54
2.8 Test before initial commissioning............ 33
4.8 Lubricants ............................................... 54
2.9 Shutting down the crane ......................... 34
4.9 Wiring diagrams...................................... 68
2.10 Disassembly ........................................... 35
4.10 Declaration of Conformity, Declaration
of Incorporation....................................... 69
2.11 Reassembling the crane ......................... 35
3. INSPECTION .................................... 36
3.1 At the start .............................................. 36
3.2 Scope of the test..................................... 37
3.3 Checking the load hook .......................... 39
3.4 Inspecting the conductor system ............ 40
3.5 Inspecting the wire rope ......................... 41
Page 5
At the start General information
1. General information
This section applies to anyone who lifts loads using the crane, performs work on the crane, or works
nearby.
1.1 At the start Instructions for the product manual
Read the product manual through carefully before

beginning work. Also be sure to observe additional
Using this product manual product manuals for accessories and components.
Afterwards, keep the product manual available in
The following symbols are used in this product the vicinity of the crane. It must be accessible to all
manual: who work with or on the crane.
In the case of reselling or hiring out, always provide
Danger to persons! the product manual together with the crane.
This warning notice indicates
hazards for persons and provides Observe the safety instructions
instructions for avoiding these and warnings!
hazards. The safety instructions (general)
and the warnings (before the
respective operative instruction) in
Danger from electric shock! this product manual warn against
This warning notice indicates dangers that cannot be eliminated
hazards for persons due to incorrect through design.
handling of the electrical system
and electricity. Failure to heed these safety
instructions or warnings can result
in people being killed or injured.
Danger from falling suspended Carefully read and follow the safety
load! instructions and warnings and the
This warning notice describes entire product manual!
hazardous situations that can lead
to the suspended load falling.
Observe the technical
documentation of third-party
This is an instruction regarding an action and manufacturers!
prompts you to perform a work step. The technical documentation for
This is the result of an action and describes additional components (e.g. radio
what happens on the device. remote control, lifting tackle,...)
This is a list. contains important information on
operation as well as additional
safety instructions.
Only with...
Carefully read and observe all
A section enclosed in a dashed box is only
applicable for certain types, versions or options.
documentation!
Which type, version or option this is can be seen in
the first line. You can find out whether or not the
section is applicable for your crane by referring to
the section Various types, sizes, versions and
options at the beginning of this manual.
Page 6
General information At the start
Note regarding the designation

crane Proper use
The term crane as used in all product manuals The crane is designed for the lifting and lowering of
refers to every ABUS product with which a load can correctly attached loads and, depending on design,
be lifted and/or transported. moving them as well.
The term crane also refers to all overhead

travelling cranes, jib cranes, HB cranes and other Observe the product manuals!
cranes including trolley (with wire rope hoist or chain
hoist). Solo wire rope hoists and solo chain hoists
are also referred to as crane. here, all information in the section
Proper use in the other supplied
Printing out product manuals or

making them available per computer ABUS cranes are designed for these applications:
Overhead travelling crane for all-round
The product manuals belonging to this crane are
moving of loads.
available on the enclosed CD as files in PDF format.
Some of these product manuals may also be Jib crane for moving loads in a circular
enclosed in printed format in the documentation direction.
folder of the crane.
HB crane for all-round moving of lightweight
All supplied product manuals (on CD or printed) loads.
must be made continually available to all persons
working with or on the crane. Single-rail trolley track for moving loads in a
linear direction.
Mobile gantry crane for location-independent
Print out all product manuals supplied on the
all-round moving of lightweight loads.
CD and store them near the crane. Keep the
product manuals in a place accessible to all Solo chain hoist and solo wire rope hoist for
persons who work with or on the crane. the stationary lifting and lowering of loads.
Alternatively, make all product manuals During operation, observe the classification
supplied on the CD available per computer. according to FEM, duty cycle and switching
In doing so, make sure the computer is able rate. See the product manual Operating the
to display the PDF files and is always ABUS crane.
operational, and that all persons who work
with or on the crane can access this Only operate the hoist if the actual hours of
computer. use are fewer than the number of hours
representing the theoretical service life.
Keep the product manual Operating the
ABUS crane available in the vicinity of the Only use the crane in chemically non-
crane. This product manual contains aggressive environments that pose no risk of
important information for the crane operator explosion.
and should be within easy reach at all times. Long-term usage of the crane only in
weatherproof areas. Temporary use in
unprotected environments (outdoors in rain,
snow or cold weather) is permitted. For
longer operation in unprotected
environments, modifications must be made
to the crane. See Equipping the crane for
operation in unprotected environments page
27.
In windy environments, even short-term use
is prohibited. If the crane is to be used in
windy conditions, modifications must be
made to the crane. See Equipping the crane
for operation in unprotected environments.
page 27.
Page 7
Regulations Warranty
The installation has been built and tested according ABUS assumes no liability for damages that
to European standards, rules and regulations were caused by improper use, inadequately
applicable at the time of its manufacture. The trained personnel, incorrect performance of
conventions applied during design and construction work, as well as any changes, reconstruction
are specified in the Declaration of Conformity or the or other modification of the crane or crane
Declaration of Incorporation. The conventions must components which was not approved by
also be observed for installation, operation, ABUS.
inspection and maintenance, as must the applicable
occupational health and safety regulations. Any warranty claim becomes invalid if
components were modified without consent,
the crane or crane components were
Danger to persons! installed, used or serviced in any way other
Non-observance of the regulations than that described in this product manual, or
if parts other than original ABUS replacement
can result in the death of persons or parts were used.
serious accidents.
Safe operation of the crane or crane
To ensure work safety, thorough components is only guaranteed if original
instruction in regard to this product ABUS replacement parts are used.
manual and the regulations is
necessary.
Creating a risk assessment
Which provision applies in individual cases will In connection with the crane, dangerous situations
greatly depend on the cranes use and the national can arise in all operating modes (during operation,
regulations. Review and observe all applicable and at a standstill, during maintenance work) and in all
current regulations, including the occupational product phases.
health and safety regulations. Refer also to the
Declaration of Conformity or Declaration of Why, when and where these hazards occur as well
Incorporation. as who causes them and how, depends on a great
number of different conditions. Among these are the
application area of the crane, the conditions and
This product manual is based on the regulations work routine within the building, the interaction with
and directives applicable in Germany and the other machines, etc.
European Union. The hazards described in this and all other product
If the crane is operated in a different country, the manuals refer to the standard applications of the
instructions given in this product manual still apply. crane and especially cover the dangers arising
They then supplement the national regulations. The directly from the crane itself.
content specified in this product manual should then In order to take all other arising hazards into
be considered the minimum requirements, which account, the end user must create a risk
must be met in any case. The national regulations assessment and factor in all possible risks in all
supplement these requirements, but do not reduce modes of operation.
them.
The end user must then undertake the appropriate
Exception: If the national regulations represent an measures and precautions to minimise or eliminate
explicit contradiction to the contents of the product these risks.
manual, the national regulations have priority.
The end user is responsible for the risk assessment
and the implementation of appropriate
countermeasures.
Page 8
Instructions regarding safety: For anyone who performs work
General information with or on the crane, or works nearby
1.2 Instructions regarding safety: Wear protective clothing!

For anyone who performs work with
or on the crane, or works nearby
Observe these instructions for safe handling of the

crane. Special hazard notices are located in the
corresponding sections in which the danger arises.

also applies.
These instructions specify basic dangers that can In all work there is a risk of head
arise from the crane. Additional dangers must be injury (e.g. collision with load hook),
determined through a risk assessment and then
eliminated.
hands being crushed (e.g. on the
load hook or when slinging the load)
and injuries to the feet (e.g. due to
falling lifting tackle).
Keep out! As a result of this people can be
injured.
Wear suitable protective clothing (e.g.
industrial safety helmets, safety shoes with
reinforced toes, protective gloves) for all
work on or using the crane. The actual
combination of personal safety gear will
depend on the conditions in the building and
the use of the crane, and is determined by
There are various hazards on the the risk assessment.
crane and crane track, e.g. due to
the height, electricity, temperature,
risk of slippage (from oil and dirt),
unintended travelling, etc.
killed or injured.
Unauthorised persons are not permitted to
step into the crane or onto the crane track.
This also applies to cranes and wire rope
hoists with walkways. Only trained and
authorised persons may enter the crane or
crane track.
Page 9
Instructions regarding safety: For anyone who performs work with
or on the crane, or works nearby General information
Do not wear any loose clothing or No alcohol, drugs or unallowable

long hair! medications!
Alcohol, drugs and certain

medications can impair a person's
reaction time and ability to
concentrate.
For all items which are worn loosely, This could result in hazards not
(e.g. jewellery, open jackets, ties, being recognised quickly enough.
scarves, long hair), there is a danger
of these inadvertently catching on Persons working with or on the crane may
not be under the influence of drugs, alcohol,
the crane (e.g. on the load hook or medications which inhibit their reaction
when lifting a load or in a motor time or motor coordination.
during repair work).
injured.
Before beginning all work, tie long hair back,
do not wear any open clothing and remove
any jewellery.
Page 10
General information Instructions regarding safety: For the end user of the crane
1.3 Instructions regarding safety: No environments at risk of

explosion!
For the end user of the crane
Follow these instructions to ensure employees use

the crane safely.

also applies. Electrical sparks can occur within
the panel on the crane or in the
pendant control, causing the gases
to explode.
No chemically aggressive As a result of this people can be
environments! killed or injured.
The entire crane is prohibited from use in
areas at risk of explosion. This includes the
pendant control or transmitter. If used in
areas at risk of explosion, the panel and
motors, among other components, must be
of an explosion-proof design. This is not the
case for the standard version.
Fumes from corrosive materials (e.g.

acids and lyes) attack metallic and
plastic parts on the crane and
corrode them.
This could damage the crane and
cause the load to fall.
The crane may not be used in chemically
aggressive environments. Only use cranes in
corrosive environments if they have been
specially designed for those conditions.
Page 11
Instructions regarding safety: For the end user of the crane General information
No continuous outdoor operation! Ensure clear communication!
Continuous operation outdoors could

cause damage to the crane which
could result in the load falling or
electric shock.
killed or injured.
Do not operate the crane outdoors on a If persons working simultaneously
permanent basis. The crane is designed for with the crane (e.g. crane operators
continuous use in weatherproof and load handlers) cannot make
environments. Temporary use outdoors in
rain or snow is permitted. For longer
themselves perfectly understood,
operation outdoors, modifications must be dangerous situations with the load
made to the crane. See Equipping the crane can occur, such as lifting the load
for operation in unprotected environments prematurely.
page 27.
In windy environments, even short-term use
is prohibited. If the crane is to be used in injured!
windy conditions, modifications must be Especially in loud workplaces, the
made to the crane. See Equipping the crane communication must be agreed upon in
for operation in unprotected environments advance. Ways of ensuring one is
page 27. understood include clear hand signals, signal
tones or wireless equipment.
Page 12
General information Instructions regarding safety: For the end user of the crane
Instruct crane operators and load Check the highest hook position!
handlers!
Special technical expertise is

required to correctly sling and safely
lift and move loads.
Otherwise, accidents could occur.
Personnel working with the crane (e.g. crane
operators and load handlers) must first have
received instruction. The required knowledge
must be imparted through regular trainings
providing the operator with instruction. The
end user is responsible for this instruction.
The instruction is to be given based on the
following documentation:
All supplied ABUS product manuals
National training requirements For certain lifting tackles and crane
Operating instructions created by the types, dangerous situations can
end user occur if the load hook is run to the
General occupational health and very top. For example, a crosshead
safety requirements under the main girder can impact
Regulations based on the risk against a double-girder travelling
assessment crane. Or a round sling can be torn
from the main girder of a crane with
It is recommended to document this
instruction in writing. a side-mounted trolley.
This could cause the load to fall,
killing or injuring people.
When carrying out a risk assessment, check
how high the load hook should be allowed to
travel with the respective lifting tackle for
which it is designed. Dangerous situations
must be determined through a risk
assessment and then avoided, for example,
by moving the hoist limit switch.
Page 13
Instructions regarding safety: For the end user of the crane General information
Only with cranes with overlapping Only with tandem operation

operating ranges
Avoid dangerous situations in
Avoid dangerous situations tandem operation!
arising from use of multiple
cranes!
If a load is transported by two

separately controlled cranes, there
If several cranes are used in is the danger that the two crane
succession on a single crane track operators will control the cranes
or above one another on multiple differently.
levels, their respective operating If a load is transported by two
ranges may overlap. cranes with a tandem control
This can give rise to dangerous system, there is a risk that a
situations (e.g. the load from the breakdown of one crane will not be
top crane can collide with the detected immediately.
bottom crane). This could cause the load to fall,
Dangerous situations involving overlapping killing or injuring people.
operating ranges must be determined in
advance through a risk assessment and If a load is transported by several cranes,
then avoided, for example, by employing an dangerous situations must be determined
anti-collision device. through a risk assessment and then
avoided, for example, by having a
supervisor oversee the operation or by
employing a tandem control system. The
cranes and the load must be monitored
continuously during tandem operation.
Page 14
General information The crane
Description of the
1.4 The crane
underslung travelling crane
This section provides a rough overview of the ABUS
product range. Other combinations of cranes and 1 2 3 4 5
trolleys are possible. Additional types of cranes and
trolleys are also available.
Description of the
single-girder travelling crane
1 2 3 4
7 6
1: Main girder
2: Trolley (wire rope hoist or chain hoist)
3: Crane travel drive
4: Crane trolley
6 5 5: End carriage
6: Crane track
1: Main girder (ELV version) 7: Bottom block and load hook
4: End carriage Description of the device
5: Bottom block and load hook
Wall travelling crane
6: Crane track
1 2
Description of the
double-girder travelling crane
1 2 3 4
6 5 4 3
1: Main girder
6 5
3: Crane track
1: Main girder
2: Trolley (wire rope hoist)
5: End carriage
3: End carriage
6: Crane track
Page 15
The crane General information
Description of the Description of the

semi-goliath crane pillar slewing jib crane
1 2 3 4 1 2 3 4
5 11
10
5
6
6
7
2: Upper end carriage
4: Main girder 9 8
5: Portal support
6: Lower end carriage 1: Jib arm
2: Trolley power supply
3: Hoist trolley
4: Mobile control (optional)
6: Load hook
7: Pendant control
8: Pillar
9: Pillar base
10: Slewing gear
11: Jib bracket
Page 16

wall jib crane HB crane monorail system
1 2 3 4 5 1 2 3
10
6 5 4
9
1: Suspension
1: Jib arm 2: Trolley track
2: Slewing gear 3: Hoist trolley
3: Trolley power supply 4: Trolley (chain hoist)
4: Hoist trolley 5: Load hook
5: Mobile control (optional) 6: Trolley power supply
7: Load hook
Description of the
8: Pendant control HB crane double-rail system
9: Jib bracket
10: Wall mounts 1 2 3
7 6 5 4
1: Suspension
2: Trolley track
3: Hoist trolley
4: Trolley (chain hoist)
5: Load hook
6: Trolley frame
Page 17

HB crane, single-girder crane HB crane, double-girder crane
1 2 1 2 3 9
3
4
4
5 9 5
8
1 6
8 6
7
1 7
1: Crane track
1: Crane track
2: Suspension
2: Suspension
3: Crane trolley
3: Crane trolley
4: Trolley frame
4: Crane girder
5: Hoist trolley
5: Hoist trolley
7: Load hook
7: Load hook
9: Crane girder
Description of the
single-rail trolley track
1 2
4 3
1: Trolley track
4: Pendant control
Page 18

mobile gantry crane solo chain hoist
1 2 3
1
8
7 4
4 4
6
3 2
1: Main girder
2: Hoist trolley
4: Portal support 1: Housing
5: End carriage 2: Bottom block and load hook
6: Pendant control 3: Pendant control
7: Load hook 4. Chain box
Page 19
Description of the device Description of the device

Single-rail trolley Side-mounted trolley
1 2 3 1
5 3
4
4
6 1:Trolley frame
2: Hoisting gear
3: Hoist motor
5: Hoist trolley
5
1: Hoisting gear
Description of the device
Double-rail trolley
2: Trolley frame
3: Hoist trolley 1 2
4: Trolley drive
3
6: Hoist motor
7 6 5
1: Hoisting gear
2: Trolley frame
3: End carriage
4: Hoist trolley
5: Trolley drive
7: Hoist motor
Page 20
Performance features The wall jib crane:

The crane is designed for the moving of
The single- and double-girder travelling crane and loads in an arc within the operating range
the underslung travelling crane: around the wall mounting.
The cranes are designed for all-round The crane is fixedly anchored to the building
moving of loads in a building or within a wall, building support, or a concrete support.
section of a building.
The crane has a wire rope hoist or a chain
The crane travels on a crane track, which is hoist with a manually driven or electric trolley
fastened to building supports or concrete (HF/EF), depending on type.
supports beneath the hall ceiling or on a
separate supporting structure.
The cranes have a wire rope hoist or a chain
hoist with a manually driven or electric trolley
The HB crane:
(HF/EF).
The HB single-girder and double-girder
cranes are designed for all-round moving of
lightweight loads within the operating range.
The wall travelling crane: The monorail and double-rail systems are
designed for moving lightweight loads in a
The crane is designed for all-round moving of linear direction.
loads within the operating range on a
building wall. The cranes are suspended from HB crane
runways, which are fastened under the hall
The crane travels on a crane track, which is ceiling or on a separate supporting structure.
fastened laterally to building supports or
concrete supports. The crane has a chain hoist as a trolley.
(HF/EF).
The single-rail trolley track:
The crane is designed for moving loads in a
linear direction within the operating range.
The semi-goliath crane:
The crane track is fastened to the building
The crane is designed for all-round moving of wall, on building supports, concrete supports,
loads within the operating range on a or on a separate supporting structure.
building wall.
The semi-goliath crane travels on the hoist with a manually driven or electric trolley
building wall with the upper end carriage on a (HF/EF).
crane track. It runs to the middle of the
building with the lower end carriage on the
floor of the building.
The crane has a wire rope hoist as a trolley. The mobile gantry crane:
The crane is designed for location-
independent moving of lightweight loads.
The crane runs on four castors, freely
The pillar slewing jib crane:
movable on level ground.
The crane is designed for the moving of
The crane has a chain hoist as a trolley.
loads in a circular direction or arc within the
operating range around the crane pillar.
The crane pillar is fixedly anchored to the
floor of the building or a foundation specially
created for it.
(HF/EF), depending on type.
Page 21
The solo chain hoist: Technical data

The solo chain hoist is designed for the
stationary lifting and lowering of loads. Observe the product manuals!
It is stationary and fastened to an In addition to the points described
appropriately dimensioned supporting here, all information in the section
structure. Technical data in the other
applies.
The single-rail trolley:
The wire rope hoist serves as a trolley on
Normal ambient conditions during operation:
single-girder travelling cranes.
Range
The wire rope hoist has a hoist trolley with
which it travels along the lower flange of the Ambient temperature -10C to +40C
main girder. Elevation Up to 1000 m above sea
level
Ambient conditions for a complete crane including
control.
The side-mounted trolley:
The wire rope hoist serves as a side-
Operation in other ambient conditions (e.g. at a
mounted trolley on single-girder travelling
higher ambient temperature) is in many cases
cranes.
possible. For questions regarding individual on-site
The wire rope hoist has a two-part hoist conditions in the building (e.g. duration and type of
trolley. One part is used to run the wire rope heat and its influence on the crane), ABUS Service
hoist along the trolley track, which is will gladly be of assistance. See ABUS Service
mounted on the side of the main girder. The page 54.
load hook hangs from the side of the main
girder on which the trolley track is mounted.
On the other side of the main girder, the
other part of the hoist trolley grips onto the
upper flange.
Only with travel drives and hoist
drives
This section only applies to travel drives and hoist
drives.
The double-rail trolley:
The wire rope hoist serves as a trolley on Range
double-girder travelling cranes.
Ambient temperature -10C to +40C
The wire rope hoist has two end carriages
with which it travels along the trolley track of Ambient temperature +40C to +65C
the main girder. (for reduced duty cycle)
Ambient conditions exclusively for travel and hoist
drives.
Travel and hoist drives can also be used at a

reduced duty cycle and switching rate from +40C
to +65C.
Page 22
General information Storage of the crane
Operation at higher ambient

temperatures:
1.5 Storage of the crane
Duty cycle Modified duty cycle at ambient
according to temperatures of
type plate +40C to +65C
60 % 30 %
50 % 25 % here, all information in the section
40 % 20 % Storage in the other supplied
Switching rate Modified switching rate at
according to ambient temperatures of
type plate +40C to +65C If the crane is not installed immediately:
420 210
360 180
300 150
240 120
180 90
At ambient temperatures of +40C to +65C,

reduce the duty cycle and switching rate Rainwater on the Film
according to the tables. main girder
Wipe off any rainwater.
Cover unpainted surfaces and openings with
Operation at higher elevations: film and mask it.
At higher elevations, the crane will be less well Unpack components wrapped in film (e.g.
cooled due to the reduced air pressure. pillars and jib arms from the jib crane).
Otherwise, condensation collects under the
film.
Reduce the duty cycle and switching rate at
higher elevations.
Store unpainted metallic parts, wire rope
hoists, chain hoists, electrical and electronic
components in a dry, dust-free place.
Store painted metallic parts as dry and dust-
free as possible.
Mechanical design life
The mechanical design life of the crane is 20 to 25

years. Inspection after lengthier storage
Should the crane be installed after it has

been in storage for a lengthier period:
Perform a visual inspection of all
components. They should be neither heavily
soiled nor dusty.
Inspect the paintwork. The paint should not
be cracked or peeling.
Inspect metallic parts. They should exhibit no
rust.
Inspect electrical components. Live parts
(e.g. bushes, pins and terminals) should not
be oxidised (e.g. discoloured or roughened
surface).
Page 23
Instructions regarding safety: Before putting into operation Installing and connecting
2. Installing and connecting

This section applies to anyone who works on the crane prior to its use
The crane is delivered ready-assembled. To install,

perform the described points here in the sequence 2.1 Instructions regarding safety:
given.
Before putting into operation
The end user of the crane is responsible for the Comply with the following safety instructions before
proper qualifications of the commissioning beginning with putting the crane into operation:
personnel.

Danger to persons! In addition to the points described
Persons can be injured if the crane here, all information in the section
is incorrectly put into operation. Instructions regarding safety in
If personnel other than that of the the other supplied product manuals
ABUS company are employed to also applies.
perform the commissioning, it is the
end users responsibility to ensure
that these persons are adequately Use suitable lifting platforms and
qualified. Follow the procedures fall protection equipment!
described here precisely.
Examples of qualified persons:

Persons with comprehensive knowledge
from specialist training in engineering and in
the electrical systems of cranes.
Persons with sufficient experience in the
operation, installation and maintenance of
cranes.
regarding the relevant technical rules,
directives and safety regulations applicable
in the respective country.
Persons receiving regular training from Falls from great heights can result in
ABUS. people being killed or injured.
Always use suitable lifting platforms and fall
ABUS assumes no liability for damage due to protection equipment. If the crane has a
incorrectly performed commissioning work done by walkway on the main girder or on the wire
unqualified personnel. rope hoist, a suitable lifting platform or fall
protection equipment must be used for
ABUS recommends having the commissioning work entering the walkway.
performed by the ABUS assembly team.
Page 24
Installing and connecting Instructions regarding safety: When putting into operation
Cordon off the work area! Only electricians should work on

the crane electrical system!
Special expertise is required for
working on electrical installations.
Without this expertise, there is a risk
of electric shock.
Only trained electricians should work on the
crane electrical system!
2.2 Instructions regarding safety:

When putting into operation
Falling objects (e.g. tools) can kill or Comply with the following safety instructions when
putting the crane into operation:
injure people. The lifting platforms
can also be overturned, e.g. by
forklifts. Observe the product manuals!
Adequately cordon off the work area. In addition to the points described
Switch off cranes on the same the other supplied product manuals
crane track! also applies.
Do not permanently remove the

covers!
Other cranes can overturn the lifting

platforms or impact the crane that is
being serviced.
Switch off any other cranes using the same
crane track or cranes working above or
below. Secure the mains switch so that it When covers (e.g. panel lids, fan
cannot be unintentionally switched back on.
covers, motor covers,...) are
removed, dangerous areas are no
Notify personnel of putting the longer protected.
crane into operation! As a result of this people can be
Personnel working in the area may injured!
not necessarily be aware of the Remount covers after working on the crane.
dangers when putting the crane into Do not permanently remove the covers in
operation. order to improve the cooling of components.
They might be hit, for example, by

falling tools.
Notify personnel in the area regarding the
crane being put into operation.
Page 25
Instructions regarding safety: After putting into operation Installing and connecting
Protect components from the 2.4 Installation overview

effects of heat!

Installation overview in the other
applies.
The effects of heat from work
performed on the crane (e.g.
welding, open flames, flying sparks) For assembly of an entire crane
can set parts on fire. installation:
This can cause harmful gases to In all supplied product manuals, read the
form and parts to become deformed sections Installation overview and
or damaged. Checking the requirements.
Cover the parts or otherwise protect them First fulfil the requirements in the building
from becoming too hot. After completing the (e.g. for overhead travelling cranes, install
work, inspect the condition of the parts. the crane track; for jib cranes, prepare the
foundation,...).
Then, depending on the individual
components, define the order of the
installation work.
Finally, follow the respective sections for
After putting into operation Putting into operation in all product
manuals according to the defined order to
Comply with the following safety instructions once assemble the crane.
putting into operation has been completed: If necessary: Protect the crane from rain,
snow, wind or cold. See Equipping the crane
for operation in unprotected environments
Observe the product manuals! page 27.
In addition to the points described Next, connect the crane to the mains supply.
here, all information in the section See Connecting the crane to the mains
Instructions regarding safety in supply page 28.
the other supplied product manuals Finally, carry out the test before initial
also applies. commissioning. See Test before initial
commissioning page 33.
Remove tools and separate parts!
Loose parts can fall from the crane

during operation, killing or injuring
people.
Remove tools and separate parts (spare
parts, removed parts,...).
Page 26
Equipping the crane for operation in unprotected
Installing and connecting environments
Attaching a wind anchor

2.5 Equipping the crane for
operation in unprotected
Strong wind can cause the crane to move in an
environments uncontrolled manner (even when switched off).
For cranes which are operated completely
Long-term usage of the crane only in weatherproof outdoors: The crane must be able to be
areas. Temporary use in unprotected environments secured in a resting position (at the end of
(outdoors in rain, snow or cold weather) is the crane track) when work is completed. A
permitted. wind anchor is located at this resting position
Should the crane be operated on a long-term or for securing the crane.
continual basis in environments without protection For cranes which are operated partly
from the weather (outdoors, in rain, snow or cold), outdoors: If the crane can be moved inside
modifications will need to be made to the crane. the building when work is finished, a wind
In windy environments, even short-term use is anchor is not necessary.
prohibited. If the crane is to be used in windy
conditions, modifications must be made to the
crane.
For the ambient conditions, see Technical data Only with cranes which can only be
page 22. safely operated up to a defined
wind speed
This section only applies to cranes which can only
be safely operated up to a defined wind speed.
Protecting from rain and snow
Rain and snow can penetrate the electrical

components of the crane and cause malfunctions Attaching the wind measuring
(e.g. a short).
system
Attach a rain hood over the crane travel
The crane must be equipped with a wind
motor.
measuring system. The wind measuring system
Attach a rain hood over the entire wire rope warns if a certain wind speed has been exceeded.
hoist. The crane must then be able to travel to its resting
position (at the end of the crane track) within a
Attach rain hoods over all panels. specified time.
A wind anchor is located at this resting position for
securing the crane. Alternatively, the wind anchor
can be of a design that secures the crane at any
desired position.
The corresponding wind speed up to which the
crane can be operated and the time in which the
crane must be able to move to its resting position
are both specified in the test log book.
Page 27
Connecting the crane to the mains supply Installing and connecting
2.6 Connecting the crane to the Only with pillar slewing jib cranes
mains supply
Overview: Electrical connection of
the crane
Only with overhead travelling
cranes 1 2 3 4

the crane
1 2 3 4 5 6
8 7 7 6 5
The power supply for the crane begins at The power supply for the crane begins at
the sub-distribution (8) of the mains supply. the sub-distribution (7) of the mains supply.
From there, a line (7) runs to the mains From there, a line (6) runs to the pillar base
switch (1) of the crane installation. of the jib crane and is led through the
foundation into the pillar (1).
A mains switch is the best option for
isolating the entire crane installation. The line runs to the mains switch (5) of the
crane.
The mains switch must be secured against
inadvertent switching back on. A mains switch is the best option for
isolating the entire crane.
The mains switch is usually located under
the mains power supply of the crane, e.g. The mains switch must be secured against
on the building wall or on a building support inadvertent switching back on.
or concrete support.
The mains switch is located in the pillar at
From the mains switch, the riser (2) extends operating height.
to the feed unit (3).
From the mains switch, a line runs inside
The feed unit connects the riser with the the pillar and is led out at the top.
mains power supply (4) (usually a conductor For types LS and LSX: The line is led
system) of the crane. directly out of the pillar.
For type VS: The line runs in the pillar up to
The mains power supply contains a mobile the slip ring (3).
current collector (5) which travels with the
crane along the crane track. For types LS and LSX: The line out of the
pillar is connected directly to the trolley
The crane is connected to the mains power power supply (4).
supply with the mains disconnector plug (6). For type VS: From the slip ring, the line runs
This mains disconnector plug is used to either to the jib arm panel (2) and from there
isolate the individual crane. The mains to the trolley power supply (4) or directly
disconnector plug can be secured against from the slip ring to the trolley power supply.
inadvertent switching back on.
Instead of the mains disconnector plug, a
separate circuit isolator (in the form a mains
switch) can also be mounted on the crane
panel.
Page 28
Installing and connecting Connecting the crane to the mains supply
Only with wall jib cranes Only with HB cranes, monorail

system and double-rail system
the crane Overview: Electrical connection of
the HB crane
1 2 3
1 2 3 4
6 5
The power supply for the HB crane begins
6 5 4 at the sub-distribution (6) of the mains
supply.
The power supply for the crane begins at
the sub-distribution (6) of the mains supply. From there, a line (5) runs to the mains
switch (1) of the HB crane installation.
From there, a line (5) runs to the mains
switch (4) of the crane. A mains switch is the best option for
isolating the entire HB crane installation.
isolating the entire crane. The mains switch must be secured against
inadvertent switching back on. The mains switch is usually located under
the mains power supply of the HB crane,
The mains switch is usually located under e.g. on the building wall or on a building
the crane, e.g. on the building wall or on a support or concrete support.
building support or concrete support.
From the mains switch, the riser (2) extends
From the mains switch, the riser (1) extends to the feed unit (3).
to the crane.
There the line is connected with the trolley
For types LW and LWX: The line is power supply (4).
connected directly to the trolley power
supply (4).
For type VW: The line runs either to the jib
arm panel (2) and from there to the trolley
power supply (4) or directly to the trolley
power supply.
Page 29
Connecting the crane to the mains supply Installing and connecting
Only with HB cranes, single-girder The HB crane is connected to the mains

crane and double-girder crane power supply.
If the HB crane installation consists of a
single HB crane, the mains power supply is
Overview: Electrical connection of connected directly to the HB crane.
the HB crane
If the HB crane installation consists of
several HB cranes, there is a circuit isolator
1 2 3 4 5 6 on the crane.
This circuit isolator is used to isolate the
individual HB cranes. The circuit isolator
must be secured against inadvertent
switching back on.
Only with single-rail trolley tracks

the crane
8 7 1 2
The power supply for the HB crane begins
at the sub-distribution (8) of the mains
supply.
From there, a line (7) runs to the mains
switch (1) of the HB crane installation.
isolating the entire HB crane installation.
The mains switch is usually located under
5 4 3
the mains power supply of the HB crane,
e.g. on the building wall or on a building The power supply for the crane begins at
support or concrete support. the sub-distribution (3) of the mains supply.
From the mains switch, the riser (2) extends From there, a line (4) runs to the mains
to the feed unit (3). switch (5) of the crane.
The feed unit connects the riser with the A mains switch is the best option for
mains power supply (4) of the crane. isolating the entire crane.
For conductor systems: The mains power The mains switch must be secured against
supply contains a mobile current collector inadvertent switching back on.
(5) which travels with the HB crane along
the HB crane runway. The mains switch is usually located under
For festoon cable systems: The line of the the crane, e.g. on the building wall or on a
mains power supply hangs in loops on the building support or concrete support.
HB crane runway and is towed by the HB From the mains switch, the riser (1) extends
crane. to the crane.
There the line is connected to the trolley
power supply (2).
Page 30
Installing and connecting Connecting the crane to the mains supply
Only with mobile gantry cranes Only with solo wire rope hoists
Overview: Electrical connection of Overview: Electrical connection of

the crane the crane
1
1
3 2
4 3 2
The power supply for the solo wire rope
The power supply for the crane begins at a hoist is connected according to the on-site
three-phase socket (4). conditions in the building.
From there, a suitable line with a CEE plug The mains disconnector plug (1) on the wire
(3) runs to the mains disconnector plug (2) of rope hoist can be secured against
the crane. inadvertent switching back on.
A line then runs to the mains switch (1) of the However, it is still recommended that the
crane. line (3) have a mains switch as general
The mains switch is located on one of the mains switch (2) for the entire crane
portal legs on the crane. installation.
Only with solo chain hoists Checking the on-site mains supply
Overview: Electrical connection of For cranes without voltage adapting

transformer: Compare the operating voltage
the crane and mains frequency of the crane with the
mains voltage and frequency of the local
1 mains supply.
The operating voltage and mains frequency
are specified on the type plates on the crane
and in the test log book.
Operating voltage and mains voltage as well
as mains frequency must be matched for one
another.
For cranes with voltage adapting
transformer: The mains voltage of the local
3 2 mains supply must be converted to the
operating voltage of the crane by a voltage
The power supply for the solo chain hoist is adapting transformer.
connected according to the on-site
conditions in the building. Compare the operating voltage and mains
frequency at the input of the voltage adapting
The line (3) must have a mains switch as transformer with the mains voltage and
general mains switch for the entire crane frequency of the local mains supply.
installation (2) or a plug-in connection as a
mains disconnector plug.
The bayonet coupling (1) on the chain hoist
cannot be secured against switching back
on and is therefore not suitable as a mains
disconnector plug.
Page 31
Ensuring electromagnetic compatibility (EMC) Installing and connecting
Connecting the crane

2.7 Ensuring electromagnetic
Danger from electric shock! compatibility (EMC)
Work on electrical systems and
components may only be
performed by a qualified electrician
Electrical devices and lines normally generate
when the system is in a voltage- electromagnetic fields. These fields can negatively
free state. affect other devices and cause malfunctions. To
best avoid such disturbances, certain basic
principles must be observed when working with
electrical equipment.
Lay the lines, attach the mains switch and
connect the crane.
For any electrical work performed on the
crane:
Checking the rotary field In order for the crane to operate without faults, all
electrical components and all connection cables
must be installed by professionals.
The crane can only be operated on a 3-phase mains
supply with a clockwise rotary field. Observe the following points amongst others:
Do not lay signal lines together with current-
conducting lines.
Unlock the emergency stop switch.
With frequency converters: guide connection
Press the Lift button halfway. cables for braking resistance and connection
The load hook must run slowly upward or cables for motors through the cable fittings in
remain stopped (if the top emergency limit the panel and lay them in a direct path to the
switch has already been triggered). frequency converter.
Lay the shields of shielded cables over a
wide area and earth them.
If the load hook instead travels downward: Do not twist, braid or solder shields. Instead,
use the supplied installation material.
The phases in the mains supply have been Earth the unused wires of cables in the
interchanged. panel.
Correct the interchanged phases.
If possible, correct the phases at the point
where they were interchanged. Only in
exceptional cases should the phases be
interchanged again directly on the power
line.
Page 32
Installing and connecting Test before initial commissioning
Overview: Inspecting the crane

2.8 Test before initial
commissioning
The qualified person inspecting the crane is
responsible for the type and scope of the test.
Before the crane can be put into operation for the
The items to be checked in the following list
first time, a test must be carried out. The end user is
represent a general overview regarding the scope of
responsible for this test prior to initial
testing of ABUS cranes. Depending on the type, not
commissioning.
all components will be present on the crane.
The decision as to whether the crane is in perfect
condition may be made only by the person
Requirements for the examiner inspecting the crane. Any inadequacies, if found,
must be eliminated. The examiner decides whether
the crane has to be tested again afterward.
The end user of the crane is responsible for the
proper qualifications of the examiner. If locally applicable regulations specify further tests,
these are likewise to be carried out.
The examiner tests the operational crane. In doing
Danger to persons! so, it must be ensured that no one is subjected to
Persons can be injured if the avoidable dangers.
inspection is performed incorrectly.
If personnel other than that of the At least the following points must be checked:
ABUS company are employed to Check the general condition. The
perform the inspection, it is the end components of the crane installation may not
user's responsibility to ensure that be damaged or rusted, or exhibit any other
dangerous material changes.
these persons are adequately
qualified. Check the condition of the supporting
structure. It should not exhibit any damage.
Check that the crane has been correctly
installed and connected. It must be installed
and connected in accordance with this and
other product manuals.
Check the hoist drive, trolley drive and crane
travel drive. They must be functioning
flawlessly. For the test for switching on, see
the product manual Operating the ABUS
Persons with sufficient experience in the crane.
operation, installation and maintenance of Test the brakes on the hoist drives, trolley
cranes. drives and crane travel drives. They must be
Persons with comprehensive knowledge functioning flawlessly. For the test for
regarding the relevant technical rules, switching on, see the product manual
directives and safety regulations applicable Operating the ABUS crane.
in the respective country. Check the hoist limit switches (switching
Persons receiving regular training from points for safety limit switches and
ABUS. emergency limit switches). The hoist must
switch off at the appropriate switching points.
If available: Check the operating limit
switches. The hoist must switch off at the
appropriate switching points.
Check the travel limit switch. The crane
travel drives and the trolley drives must
Check screws. All screws must be tightened
and secured. If they are not, tighten the
screws with the appropriate tightening torque
and secure them.
If available: Check warning devices. They
must function as intended.
Page 33
Shutting down the crane Installing and connecting
Check the overload protection (e.g. load

indicator system LIS or friction clutch). It
must function as intended. Documenting the test before initial
Check all other safety devices on the crane.
commissioning
They must function as intended.
Also in countries which do not require a test log
If available: Check the condition of the wind
book, it is recommended to document the test in the
anchor. It must function as intended.
test log book.
Check the signage. The required signs on
the crane must be present and legible.
Otherwise, replace the signs. Test log book of crane
Perform a static test of the maximum load

capacity.
Test using a test load with 1.25 times the
maximum load capacity of the crane.
Perform a dynamic test of the maximum load
capacity.
Test using a test load with 1.1 times the
maximum load capacity of the crane.
Only if necessary: Perform additional
country-specific tests.
Document the result of the entire test in the
Only within the EU: Check whether there is a test log book.
Declaration of Conformity or a Declaration of
Incorporation. Type and scope of the test
Items of the test still to be evaluated
Checking the test log book Inadequacies detected
Assessment of whether the crane may be
Also in countries which do not require a test log operated
book, it is recommended to document the test in the
test log book. Decision on whether a re-check is necessary
The test log book and the complete
documentation for the crane must be within
Check the test log book: easy reach of all persons working on or with
It must be available the crane.
It must be within easy reach of all persons

working on or with the crane.
It must be clearly identified as belonging to
the crane.
All tests carried out (e.g. test before initial
commissioning, regular inspections, tests of
the crane track, etc.) must be documented.
2.9 Shutting down the crane
Should the crane need to be put out of

service for a longer period:
Switch off the crane. See the product manual
Operating the ABUS crane.
Secure the mains switch so that it cannot be
unintentionally switched back on.
Page 34
Installing and connecting Disassembly
2.10 Disassembly
If the crane is to be disassembled:

ABUS recommends having personnel who
performed the initial commissioning carry out the
disassembly. See Installing and connecting
page 24.
Disassemble the crane by reversing the

sequence of steps described in the section
Putting into operation in all product
manuals.
Dispose of high-tensile bolts, high-tensile
nuts and self-locking nuts. They are only to
be used once.
2.11 Reassembling the crane
If a disassembled crane is to be
reassembled:
ABUS recommends having personnel who
performed the initial commissioning carry out the
reassembly. See Installing and connecting
page 24.
Reassemble the crane as described in the

section Putting into operation in all product
manuals.
Be sure to use new high-tensile bolts, new
high-tensile nuts and new self-locking nuts.
After reassembly, a new test before initial
commissioning is required. See Test before
initial commissioning page 33.
Page 35
At the start Inspection
3. Inspection
This section applies to anyone who inspects and accepts the crane in accordance with occupational
health and safety requirements
The crane must be regularly inspected in order to

guarantee safe operation. The end user is Requirements for the examiner
responsible for this regular inspection.

proper qualifications of the examiner.
3.1 At the start

Danger to persons!
Persons can be injured if the
Test intervals inspection is performed incorrectly.
If personnel other than that of the
The regular inspection is performed at least once ABUS company are employed to
annually. perform the inspection, it is the end
Under certain conditions, more frequent regular user's responsibility to ensure that
inspections may be necessary. Reasons include: these persons are adequately
Frequent operation at the load capacity qualified.
Working in multiple shifts
Frequent use
Dusty or chemically aggressive environment
The end user is responsible for checking the
prerequisites and determining the test intervals. Persons with comprehensive knowledge
ABUS will gladly assist you if questions arise. from specialist training in engineering and in
cranes.
Persons receiving regular training from
ABUS.
Page 36
Inspection Scope of the test
3.2 Scope of the test

Additionally, at least the following points must be
checked:
The qualified person inspecting the crane is
responsible for the type and scope of the test. Check the general condition. The
components of the crane installation may not
be damaged or rusted, or exhibit any other
Overview: Inspecting the crane dangerous material changes.
Check the condition of the supporting
structure. It should not exhibit any damage.
In addition to the points described Check that the crane has been correctly
installed and connected. It must be installed
here, all information in the section and connected in accordance with this and
Scope of the test in the other other product manuals.
supplied product manuals also Check the hoist drive, trolley drive and crane
applies. travel drive. They must be functioning
flawlessly. For the test for switching on, see
the product manual Operating the ABUS
crane.
The items to be checked in the following list
represent a general overview regarding the scope of Test the brakes on the hoist drives, trolley
testing of ABUS cranes. Depending on the type, not drives and crane travel drives. They must be
all components will be present on the crane. functioning flawlessly. For the test for
switching on, see the product manual
Operating the ABUS crane.
Check the hoist limit switches (switching
points for safety limit switches and
In addition to the points described here, all points
emergency limit switches). The hoist must
outlined in the other supplied product manuals must
also be checked.
If available: Check the operating limit
The decision as to whether the crane is in perfect switches. The hoist must switch off at the
condition may be made only by the person appropriate switching points.
inspecting the crane. Any inadequacies, if found,
must be eliminated. The examiner decides whether Check the travel limit switch. The crane
the crane has to be tested again afterward. travel drives and the trolley drives must
If locally applicable regulations specify further tests,
these are likewise to be carried out. Check screws. All screws must be tightened
and secured. If they are not, tighten the
screws with the appropriate tightening torque
and secure them.
For an overview of the points to be checked: If available: Check warning devices. They
See Test plan and maintenance schedule must function as intended.
page 47. Check the overload protection (e.g. load
indicator system LIS or friction clutch). It
For an overview of the lubricants changed in
must function as intended.
a general overhaul or regular inspection, see
Lubricants page54. Check all other safety devices on the crane.
They must function as intended.
If available: Check the condition of the wind
anchor. It must function as intended.
Check the signage. The required signs on
the crane must be present and legible.
Otherwise, replace the signs.
Check weld seams. They should not be
cracked or broken.
Check the condition of the paintwork. It
should not be scratched or peeling.
Otherwise, remove peeling paint and touch
up the paint coat.
Check the load hook. See Checking the load
hook, page 39.
Page 37
Scope of the test Inspection
Check the hoist drive, trolley drive and crane Check the test log book. See Checking the
travel drive for tightness. The drives should test log book page 45.
not exhibit any exterior cracks or traces of
leaked lubricant.
Determine the already elapsed portion of the
theoretical service life. See Checking the
Check the air gap and brake lining thickness remaining service life page 44.
of the brakes on the hoist drives, trolley
drives and crane travel drives. The air gap
Only if necessary: Perform additional
country-specific tests.
width must match that specified in the
corresponding product manual. The brake Document the test. See Documenting the
lining thickness must match that specified in test page 45.
the respective product manual. If this is not
the case, adjust the air gap and replace the Also in countries which do not require a test
brake lining. log book, it is recommended to document the
test in the test log book.
If necessary: Check the load capacity.
Check the load capacity using a test load
approaching the maximum load capacity of
the crane.
Check the lubrication of all moving parts. See
Lubricants page 54.
If applicable: Inspect conductor system. See
Inspecting the conductor system page 40.
Only with wire rope hoists
Examine the wire rope. See Inspecting the

wire rope page 41.
Check the wire rope (on the cable drum and
on the fixed point crosshead) and check the
cable guide. The components should not be
damaged, heavily worn, broken or loose.
Check the wheel flange wear of the wheels
on the wire rope hoist.
Check the braking distance of the trolley
drive.
Check the diameter of the guide rollers on
the wire rope hoist.
Check the wheel diameters on the wire rope
hoist.
Check the condition of the safety buffer on
the wire rope hoist.
Check the condition of the bottom block
(visual inspection).
Check the edge protection on the bottom
block (visual inspection).
Check the rope wedge protrusion.
Inspect the chain. See Inspecting the

chain page 42.
Check additional components. See the
product manual for the chain hoist.
Page 38
Inspection Checking the load hook
3.3 Checking the load hook Only with wire rope hoists
Measure the widening e of the load hook or

distance y between the two stamped
markings.
Measure the widening e of the load hook. Measure the base height 'f' of the load hook.
Measure the base height 'f' of the load hook. Compare the measured values with the
table.
The measured values should neither
exceed nor fall short of the values in the The widening e may not be larger than the
table. value in the table. (The table specifies the
maximum widening.)
Type of load hook
Max. widening e
Size of load hook
The measured distance y minus 10% may

Min. base height
not be larger than the value in the table.

(The table specifies the nominal
measurement. The nominal measurement
Material
'f' [mm]
may not be exceeded by more than 10%.)

[mm]
The measured base height f may not be

smaller than the value in the table. (The
012 single 26.4 18.1 STE 355 table specifies the minimum base height.)
025 single 30.8 22.8 STE 355
Type of load hook
Max. widening e
Nominal distance
Size of load hook
05 single 37.5 29.5 34 CrMo 4 Min. base height

1 single 44.0 38.0 34 CrMo 4
y [mm]
1.6 single 49.5 45.6 34 CrMo 4

'f' [mm]
[mm]
1 single 44 Test log 38

If the load hook has been widened to a book
greater degree than is allowed or if the base
1.6 single 49.5 Test log 45.6
height is below the permissible limit, replace
book
the load hook.
2.5 double 44 Test log 47.5
book
2.5 single 55 Test log 55.1
If the load hook is deformed (even if within book
the measurements given above): Inspect
the surface for cracks. 4 double 49.5 Test log 57
book
4 single 61.6 Test log 63.7
book
6 double 61.6 93 71.3
6 single 78.1 130 80.8
Page 39
Inspecting the conductor system Inspection
3.4 Inspecting the conductor
Max. widening
system
height 'f' [mm]

Type of load
Size of load
distance y
Min. base
Nominal
e [mm]
[mm]
hook
hook
Only with conductor system as
8 double 69.3 104.5 80.8
mains power supply or trolley
power supply
8 single 88 145 90.3
This section is only applicable if a conductor
10 double 78.1 117.5 90.3 system is used as the mains power supply or the
10 single 99 160 100.7 trolley power supply.
12 double 88 132.5 100.7

12 single 110 180 112.1 Danger from electric shock!
The conductor system is under
16 double 99 148.5 112.1
live current. Before performing any
16 single 123 200 125.4 work on the conductor system,
20 double 110 165.5 125.4 switch off the crane and secure it
against being switched back on.
20 single 138 225 142.5
25 double 123 185 142.5
25 single 154 255 161.5 Danger due to failure of
32 double 138 207 161.5 protective conductor!
32 single 176 290 180.5
The protective conductor is also
connected to the crane through
40 double 154 233 142.5 the conductor system. If the
40 single 198 320 201.4 conductor system and the current
The nominal distance y for load hooks size collector are not carefully
1 to 6 is specified in the test log book. inspected and maintained, it is
possible that the protective
If the load hook has been widened to a conductor may be broken.
greater degree than is allowed or if the base
height is below the permissible limit, replace
the load hook.
Inspecting the conductor system
If the load hook is deformed (even if within
the measurements given above): Inspect
the surface for cracks. Inspect the sections of the conductor
system, the joints of the sections and the
suspensions. The parts should not be
broken, deformed or otherwise damaged.
Inspect the inside of the conductor system.
It should not be heavily soiled (e.g. due to
rubbing of the carbon strip or dirt in the
surroundings).
Inspect the sections of the conductor
system. The surface of current-conducting
rails must be smooth.
If the conductor system is heavily soiled or

the surface of the rails is not smooth, blow
off with compressed air or clean with a
cleaning trolley.
The cleaning trolley is supplied through
ABUS Service. See ABUS Service
page 54.
Page 40
Inspection Inspecting the wire rope
Inspecting current collectors 3.5 Inspecting the wire rope
Check the running characteristics of the

current collector. It must run smoothly and Only with wire rope hoists
without resistance in the conductor system.
Take the current collector out of the Inspect the entire wire rope for damage. The
conductor system. damage shown here or any similar damage
Check the thickness of the carbon strips. should not be detectable on the wire rope.
The carbon strips should not show more Examples of damage:
wear than is permissible.
How much wear the carbon strips are
allowed to have is either specified on the
current collector (according to the conductor The joining of the wire rope has opened. The
system) or the maximum wear is indicated inner strands of the wire rope are visible.
by a marking on the carbon strip itself.
Check the wheels of the current collector.
They must run smoothly and be free of
damage.
If the current collector does not run Loops have formed in the wire rope.
smoothly or the carbon strips are more
heavily worn than is allowed, replace the
current collector completely, or (if possible)
replace the carbon strips.
There is a kink in the wire rope. This results

from violent external forces being applied to
the wire rope.
The wire rope is flattened at one point. This

results from the wire rope being pinched.
A bird cage has formed in the wire rope. This

results from violent untwisting of the wire
rope.
The wire rope has a corkscrew-type

deformation.
Page 41
Inspecting the chain Inspection
Check the entire wire rope for broken wires.

3.6 Inspecting the chain
The wire rope may not exhibit more broken
wires in a length of 6 times its diameter or 30
times its diameter than is specified for these
lengths on the ABUS manufacturer's
certificate for wire ropes in the test log book.
Examples of broken wires: Inspect the condition of the chain
(lubrication, corrosion, surface damage) and
check the chain's wear (length of the chain
over 11 chain links). See the product manual
for the chain hoist.
Examples of damage:
Multiple broken wires. Broken wires are

signs of normal wear of the wire rope. They
occur when the wire rope is bent on the reels
under load.
The chain link is heavily worn.

Broken wire with protruding wire end.
If damage such as that pictured or similar

damage is detected on the wire rope, replace
the wire rope with a new one.
If the wire rope has broken wires, but not
exceeding the permissible number, shorten
the test interval until the next test.
If the wire rope has more broken wires than The chain link is mechanically damaged.
permitted, replace the wire rope with a new
one.
Page 42
Inspection Basics for determining the remaining service life
Examples:
Maximum stress only in Otherwise very
3.7 Basics for determining the exceptional instances little stress
remaining service life
To avoid accidents with the crane due to wear and

age, it is essential to always ensure that the hoist
operates within a safe working period.
Actual hours of use (S) and

theoretical service life (D) Usually little stress
Example of the light load spectrum (Km =
0.5)
The hoist operates within a safe operating period if
the actual hours of use (S) are fewer than the
number of hours representing the theoretical service Maximum stress only in Otherwise little
life (D). exceptional instances stress
The theoretical service life (D) is determined and
specified by ABUS according to the generally
accepted engineering standards. The theoretical
service life is given in full-load hours. A full-load
hour is defined as the hoist having operated at its
maximum load capacity for one hour.
The actual hours of use (S) of the hoist must be
determined by the end user. The value must be
determined based on the operating hours, the load
spectrum and additional factors. Frequently Consistently
high stress medium stress
Example of the medium load spectrum (Km
= 0.5 to 0.63)
Load spectrum
Otherwise medium
In order to also take into account the operating stress
phases of the hoist in which the hoist was not
operating at maximum load capacity, but instead
lifted lesser loads, there are four different load
spectrums (Km). The load spectrum (Km) is a
mathematical factor. It specifies how great a load is
actually placed on the hoist during operation.
There are four load spectrums
Light (Km = 0.5)
Medium (Km = 0.5 to 0.63)
Frequently
Heavy (Km = 0.63 to 0.8) maximum stress
Example of the heavy load spectrum (Km =
Very heavy (Km = 0.8 to 1.0)
0.63 to 0.8)
In the light load spectrum, for example, the hoist
often runs with an empty load hook and transports
light loads (in relation to its maximum load capacity).
In the very heavy load spectrum, for example, the
hoist seldom runs with an empty load hook and
nearly always transports loads at its maximum load
capacity.
The load spectrum thus specifies the degree to
which the hoist is subjected to its maximum load
capacity or only to lesser operating demands.
Page 43
Checking the remaining service life Inspection
Otherwise high stress Determining the remaining service

life
The exact procedure for determining the

remaining service life can be found in FEM
9.755.
Overview:
Constant maximum stress The classification according to FEM for the
hoist drive can be read on the type plate.
Example of the very heavy load spectrum
(Km = 0.8 to 1.0) Read the corresponding theoretical service
life D in the table.
Classification 1Bm 1Am 2m 3m 4m

3.8 Checking the remaining service according to
life FEM
Load
The actual hours of use (S) must be documented spectrum
within the scope of a regular inspection at least
once yearly. Light 3200 6300 12500 25000 50000
(Km = 0.5)
The remaining service life will continue to be
evaluated during the regular inspection. This is done Medium 1600 3200 6300 12500 25000
by determining whether the actual hours of use (S) (Km = 0.5 to
are still fewer than the number of hours representing 0.63)
the theoretical service life (D). Heavy 800 1600 3200 6300 12500
If the remaining service life is very limited or zero, (Km = 0.63 to
the hoist may no longer be used. In this case, a 0.8)
general overhaul of the entire hoist by ABUS as Very heavy 400 800 1600 3200 6300
manufacturer is required. (Km = 0.8 to
1.0)
Determine the actual hours of use.

This can be done using a load population
recorder, an operating hours counter,
through documentation of usage or by
estimating.
Compare the theoretical service life (D) and
the determined actual hours of use (S).
The calculated remaining service life of the
hoist is to be be documented in the test log
book.
If the theoretical service life of the hoist has
been reached: Take the hoist out of service
and have ABUS perform a general overhaul.
Page 44
Inspection Checking the test log book
3.9 Checking the test log book 3.11 Acceptance test after
substantial changes
book, it is recommended to document the test in the Once substantial changes have been made, these
test log book. require an acceptance test.
This test is identical to the test before initial
Check the test log book: commissioning. See Test before initial
commissioning page 33.
It must be available
The test is only necessary on the parts of the crane
It must be within easy reach of all persons
that have undergone substantial change.
working on or with the crane.
It must be clearly identified as belonging to
the crane. Examples of substantial changes are:
All tests carried out (e.g. test before initial Changing the power supply
commissioning, regular inspections, tests of
the crane track, etc.) must be documented. Replacement of trolleys
Converting or modifying the travel drive or
hoist drive
Increasing the maximum load capacity of a
3.10 Documenting the test crane installation
Extension of a crane track
book, it is recommended to document the test in the Using cranes on different crane tracks
test log book. Welding on load-bearing structural elements
Design modifications to a supporting
Test log book of crane structure
Conversion of components of the supporting
structure. This includes the crane track, the
mountings, the building beams, the building
supports, the concrete girders and the
concrete supports.
Change of the operating conditions of the
crane installation in relation to the
classification according to FEM.
Conversion to a different type of control (e.g.
radio remote control).
Document the result of the entire test in the Changing the mode of operation in regard to
test log book. the operating time class and the load
spectrum (e.g. switching from single-shift
Type and scope of the test operation to multiple-shift operation).
Items of the test still to be evaluated
Inadequacies detected
Assessment of whether the crane may be
operated
Decision on whether a re-check is necessary
The test log book and the complete
documentation for the crane must be within
easy reach of all persons working on or with
the crane.
Page 45
Testing of components subject to especially high stress Inspection
The crane was placed under unusually high

stress due to a near-accident.
3.12 Testing of components subject
Example: A load was inadvertently caught
to especially high stress with the crane. The load-bearing components
of the crane, especially the wire rope, must
During operation of the crane, situations can arise in be checked more frequently in addition to the
which the individual components are subject to regular inspection until damage can be ruled
higher stress than expected. out.
This can result in damage that might be detected

too late in the regular inspection at the previously The end user is responsible for the inspection of
specified test intervals. components under especially high stress. The end
Nevertheless, safe operation must be ensured for user also specifies the inspection and test intervals
these components as well. at which the highly stressed components are to be
checked. These test intervals can be considerably
shorter than the regular inspection.
It may thus be necessary to check individual ABUS Service will gladly provide assistance if
components of a crane or entire modules especially needed. See ABUS Service page 54.
frequently. These additional tests are then regularly
required at briefer intervals in addition to the regular The end user of the crane is responsible for the
inspection. proper qualifications of the examiner. For the
qualifications, see Test before initial
Examples: commissioning page 33.
The risk assessment has revealed that
certain components (e.g. brakes or wire
ropes) are subject to especially high stress.
Example: In a food-processing facility, a wire
rope is not permitted to be lubricated for
reasons of hygiene. The risk assessment
clearly shows that this wire rope is subject to
especially high stress. It must therefore be
checked more frequently in addition to the
regular inspection.
The repeated failure of a component has
subjected it to especially high stress.
Example: On a crane, the brake lining
became worn a second time within a short
period due to especially high stress. It must
therefore be checked more frequently in
addition to the regular inspection.
The operating conditions were changed and
it is not known if these operating conditions
place more stress on the crane than before.
Example: The crane is used for a new
operation. The load-bearing components of
the crane, especially the wire rope, must be
checked more frequently in addition to the
regular inspection until damage due to the
new operating conditions can be ruled out.
Page 46
Inspection Test plan and maintenance schedule
These tasks are therefore listed in all product

manuals in the section Tests. See Scope
of the test page 37.
3.13 Test plan and maintenance Lubricant change, which must be performed
schedule in a general overhaul or regular inspection, is
normally performed by ABUS Service, by
maintenance personnel or specialist service
In this test plan and maintenance schedule you will
companies.
find listed all the tests and maintenance tasks which
must be performed on the crane at various intervals. These tasks are therefore listed in the
section Maintenance. See Lubricants
This test plan and maintenance schedule is a
page 54.
summary of the information from different chapters.
Information on the tasks to be carried out can be
found under the following: Observe the product manuals!
The points listed here are a
summary of the sections Check
Tasks which must be done every day (these
are primarily functional tests), usually
before beginning work and
performed by the crane operator prior to switching on and Tests in this
beginning work. product manual.
These tasks are therefore listed in all product Additionally observe the sections
manuals under Operation in the section Check before beginning work and
Check before beginning work as well as in
the product manual Operating the ABUS switching on and Tests in the
crane. other supplied product manuals.
Tasks performed in a regular inspection
(these are primarily basic functional tests)
are normally performed by ABUS Service, by
maintenance personnel or specialist service
companies.
travelling crane
Wire rope hoist
Chain hoist
inspection
Overhead
HB crane
Jib crane
Regular
HF EF
Daily
Functional tests
X X X X X X Are the hoist drive and travel drives functional? X X
X X X X X X Are the brakes functional on the hoist drive and travel drives? X X
X X X X X X Is the emergency stop switch functional? X
X X Is the overload protection functional? X
X X For hoists without an operating limit switch: Is the top emergency limit X X
switch functional?
X X For hoists with an operating limit switch: Is the top operating limit switch X X
functional?
X X For hoists with an operating limit switch: Is the top emergency limit switch X
functional?
X X Is the safety limit switch functional? X
X X X X Are the trolley travel and crane travel limit switches functional (braking X X
function / shut-down)?
X X X X X X If available: Are the warning devices functional? X X
X X X X X X Are all other safety devices functional? X X
X X X If available: Is the wind anchor functional? X
Inspection of components
Page 47
Test plan and maintenance schedule Inspection
travelling crane
Wire rope hoist
Chain hoist
inspection
Overhead
HB crane
Jib crane
Regular
HF EF
Daily
X X X X X X Can any damage be detected (rust, loose parts, leaking oil, missing X X
screws,...)?
X X X X X X Can any damage be detected on the supporting structure? X
X X X X X X Is the crane properly installed and connected? X
X X X X X X Are all screws tightened and secured? X
X X Is the load hook turnable and otherwise OK? X
X X Can any damage be detected on the wire rope or the chain? X X
X Can any broken wires be detected on the wire rope? X X
X Can any damage be detected on the mountings of the wire rope (on the X
cable drum and on the fixed point crosshead) or on the cable guide?
X Is the rope wedge protrusion correct? X
X X X X X X Are the required signs present and legible? X
X X X X X Can any damage be detected on the weld seams? X
X X X X X X Can any damage be detected on the paintwork? X
X X Is the load hook worn, misshapen or damaged? X
X X X X X Are the gear units of the travel drives and hoist drives sealed? X
X X X X X X Is the air gap and the brake lining thickness of the brakes on the hoist X
drives and travel drives correct?
X X X X X X Does the crane reach its maximum load capacity? X
X X X X X X Are all moving parts lubricated? X
X X If applicable: Is the conductor system in order, clean and running X
smoothly on the current-conducting rails?
X X If applicable: Are the carbon strips on the current collector still adequate X
and does the current collector run smoothly?
X X X Are the wheel flanges of the wheels worn? X
X X X X X Is the braking distance of the travel drives OK? X
X X If available: Is the diameter of the guide rollers OK? X
X X X Is the wheel diameter OK? X
X X Is the bottom block OK? X
X Is the edge protection on the bottom block OK? X
X X X X X Are the safety buffers OK? X
X X X X X X Is the test log book OK? X
X X Has the theoretical service life been reached? X
X X X X X X Do country-specific tests need to be performed? X
Page 48
Maintenance Switching off the crane
4. Maintenance
This section applies to anyone who maintains, repairs or modifies the crane.

selection and proper qualifications of the
maintenance personnel.
4.1 Switching off the crane
Danger to persons! Before performing any work on the crane:

Persons can be injured if the crane
is incorrectly serviced. Switch off the crane.
Otherwise, components of the crane
If personnel other than that of the electrical system will be carrying voltage.
ABUS company are employed to
It could also happen that another person
perform maintenance on the crane, inadvertently uses the crane, resulting in
it is the end user's responsibility to objects being thrown from the crane or
ensure that these persons are persons falling from the lifting platforms.
adequately qualified. Follow the
procedures described here
Danger from electric shock!
precisely.
If an emergency stop button has
been pressed, there will still be
voltage in the panel and in the
Examples of qualified persons: pendant control. Completely switch
Persons with comprehensive knowledge off the crane before working on it!
cranes.
If the crane must remain switched on for
maintenance work (e.g. changing the wire
Persons with comprehensive knowledge rope):
directives and safety regulations applicable Take other measures to ensure that the risk
in the respective country. of electric shock is prevented and that other
Persons receiving regular training from persons do not inadvertently use the crane.
ABUS.
ABUS assumes no liability for damage due to

incorrectly performed maintenance work done by
unqualified personnel.
ABUS recommends having the maintenance work
performed by ABUS Service.
Use only original ABUS replacement parts.
Otherwise, all warranty claims will be rendered
invalid.
Page 49
Switching off the crane Maintenance
Switching off the crane at the mains Only with cranes with crane panels
switch
This section only applies if the crane has a crane
panel (e.g. overhead travelling cranes and,
Mains switch depending on the version and options, possibly also
jib cranes and HB cranes).
Switching off the crane with a mains

disconnector plug
This is primarily useful if the entire crane installation

cannot be switched off with a general mains switch.
Mains disconnector plug
Padlock
Turn the mains switch to 0.
Secure with one or more padlocks.
Socket
Pull the mains disconnector plug out of the
socket on the crane panel.
Secure the socket with a padlock so that the
mains disconnector plug is not
unintentionally re-inserted.
Only with chain hoists: The bayonet coupling
on the chain hoist cannot be secured against
switching back on and is therefore not
suitable as a mains disconnector plug.
Page 50
Maintenance Instructions regarding safety: Prior to maintenance
4.2 Instructions regarding safety: Cordon off the work area!

Prior to maintenance
Comply with the following safety instructions before

beginning with maintenance:

also applies.
Use suitable lifting platforms and Falling objects (e.g. tools) can kill or
fall protection equipment! injure people. The lifting platforms
can also be overturned, e.g. by
forklifts.
Adequately cordon off the work area.
Switch off cranes on the same

crane track!
Other cranes can overturn the lifting

Falls from great heights can result in
platforms or impact the crane that is
people being killed or injured.
being serviced.
Always use suitable lifting platforms and fall
protection equipment. If the crane has a Switch off any other cranes using the same
walkway on the main girder or on the wire crane track or cranes working above or
rope hoist, a suitable lifting platform or fall below. Secure the mains switch so that it
protection equipment must be used for cannot be unintentionally switched back on.
entering the walkway.
Notify personnel that

maintenance work will be
performed!
Personnel working in the area may
not necessarily be aware of the
dangers when maintenance is
performed on the crane.
They might be hit by falling tools, or
they might mistakenly try to use the
crane being serviced.
Notify personnel in the area that
maintenance work will be performed.
Page 51
Instructions regarding safety: During maintenance Maintenance
Only electricians should work on Protect components from the

the crane electrical system! effects of heat!
Special expertise is required for
working on electrical installations.
Without this expertise, there is a risk
of electric shock.
Only trained electricians should work on the
The effects of heat from work

performed on the crane (e.g.
welding, open flames, flying sparks)
can set parts on fire.
During maintenance This can cause harmful gases to
form and parts to become deformed
Comply with the following safety instructions during or damaged.
maintenance: Cover the parts or otherwise protect them
from becoming too hot. After completing the
work, inspect the condition of the parts.
also applies. 4.4 Instructions regarding safety:
After maintenance
Comply with the following safety instructions once

maintenance has been completed:
Do not permanently remove the
covers!
also applies.
When covers (e.g. panel lids, fan

Remove tools and separate parts!
covers, motor covers,...) are
removed, dangerous areas are no
longer protected.
injured!
Remount covers after working on the crane.
Do not permanently remove the covers in
order to improve the cooling of components.
Loose parts can fall from the crane
during operation, killing or injuring
people.
Remove tools and separate parts (spare
parts, removed parts,...).
Page 52
Maintenance Releasing the crane
Observe at least these points when making

4.5 Releasing the crane extensive changes to the crane:
The crane must be able to be switched off by
a mains switch or otherwise be isolated from
Release after repair work by the end user: the mains supply at any time.
The unit must be connected to a protective
Check whether all work has been fully
conductor according to the local and national
completed.
regulations, the user must be protected from
Check whether the crane is in a secure and the voltage and the motors protected from
operational state. overloading.
Check whether all separate parts, tools, aids, An emergency stop device must be available
etc. have been removed. at all times.
If the hoist motors or travel motors are
controlled via frequency converter by a third
party, the frequency converter
Put the crane into operation. manufacturer's specifications for installation
Perform a thorough functional test of the and adjustment must be observed.
entire crane. See the product manual To keep voltage peaks from damaging the
Operating the ABUS crane. windings of the hoist motor or travel motor, a
general mains filter must be used if the
frequency converter is used by a third party.
ABUS recommends using the ABULiner
4.6 Modifying the crane control system, since the frequency
converter is optimally matched for the motors
ABUS accepts no liability for modifications or used.
changes which were not approved or agreed upon.
The Declaration of Conformity or Declaration

of Incorporation issued by ABUS becomes
invalid if independent reconstruction or
modifications to the crane are performed.
Page 53
ABUS Service Maintenance
4.7 ABUS Service 4.8 Lubricants
Only in Germany Do not lubricate the hubs on the

brakes!
If available, have the product number, serial If the hub on the brake of the hoist
number and customer number handy. motor or travel motor is lubricated,
Call the ABUS Service Centre: the lubricant can run onto the
brake lining and considerably
Phone: +49-2261-37-237
impair the braking. This could
cause the load to slip or delay the
If calling outside the usual business hours, stopping of the crane.
leave a message on the answering
machine. Do not lubricate the hubs on the
ABUS Service will return your call promptly.
brakes!

If necessary, send a problem description by In addition to the points described
fax or e-mail:
Fax: +49-2261-37-265 Lubricants in the other supplied
E-mail: service@abus-kransysteme.de product manuals also applies.
Note:
Only outside Germany
Synthetic lubricants may not be mixed with mineral-
based lubricants!
Call the local ABUS branch or crane service
partner.
Your local ABUS branch or crane service
partner will provide details of contact data, Changing lubricants
contacts and availability.
Disassemble the respective components

(travel drive, hoist drive,...) and lay them
open.
Remove the old lubricant at operating
temperature.
Remove residual lubricant with a suitable
cleaning agent.
Refill or apply new lubricant.
Reassemble the respective components and
check that they are sealed.
Page 54
Maintenance Lubricants
Only with wire rope hoists Hoisting gear GM 1000
Hoisting gear GM 800
Lubrication ex works using lubricant with the

standard designation CLP ISO VG 680 DIN
51502
standard designation SAE POW-90 DIN 51502.
Quantity: 1600 ml
Quantity: 1500 ml
Alternatively: use lubricant with the standard The hoisting gear is lubricated for its entire
designation CLP ISO VG 680 DIN 51502 service life. At the end of its service life (in a
general overhaul), assess whether the
lubricant needs to be changed.
The hoisting gear is lubricated for its entire

service life. At the end of its service life (in a
general overhaul), assess whether the Hoisting gear GM 2000

standard designation CLP ISO VG 320 DIN
51502
Quantity: 500 ml
Alternatively: use lubricant with the standard
designation CLP ISO VG 680 DIN 51502

Page 55
Lubricants Maintenance
Hoisting gear GM 3000 Hoisting gear GM 5000
Lubrication ex works using lubricant with the Lubrication ex works using lubricant with the
standard designation CLP ISO VG 320 DIN 51502 standard designation SAE 80W-90 DIN 51502.
Quantity: 800 ml Quantity: 4000 ml

Alternatively: use lubricant with the standard Alternatively: use lubricant with the standard
designation CLP ISO VG 680 DIN 51502 designation CLP ISO VG 680 DIN 51502
The hoisting gear is lubricated for its entire The hoisting gear is lubricated for its entire
service life. At the end of its service life (in a service life. At the end of its service life (in a
general overhaul), assess whether the general overhaul), assess whether the
lubricant needs to be changed. lubricant needs to be changed.
Hoisting gear GM 6000, GM 7000

standard designation CLP ISO VG 680 DIN 51502
Quantity GM 6000: 13000 ml

Quantity GM 7000: 27000 ml

Page 56
Only with wire rope hoists Gearing in the cable drum
Lubricant repository in the cable

drum
Lubrication ex works with Moly Paul PBC

AN 6758.
Lubrication ex works with Moly Paul PBC-SF Quantity: Apply lubricant with brush to coat surface
AN 303678 completely.
Quantity GM 800: 25 g
Quantity GM 1000: 25 g Lubricate the gearing in the cable drum:
Quantity GM 2000: 50 g
Quantity GM 3000: 50 g When the hoisting gear is disassembled and
Quantity GM 5000: 70 to 75 g reassembled
Quantity GM 6000: 70 to 75 g When carrying out a general overhaul
Quantity GM 7000: 70 to 75 g
After 10 years at the latest
The specification of 10 years applies to
single-shift operation with an average daily
Fill the lubricant repository (behind the hoist running time of less than one hour with
gearing): a medium or limited load spectrum. If the
hoist is used more intensively or the
When the hoisting gear is disassembled and operating conditions are more difficult (e.g.
reassembled multiple-shift operation, higher ambient
When carrying out a general overhaul temperature, aggressive environmental
conditions), shorter intervals will be
After 10 years at the latest necessary.
hoist running time of less than one hour with
a medium or limited load spectrum. If the
operating conditions are more difficult (e.g.
multiple-shift operation, higher ambient
temperature, aggressive environmental
necessary.
Page 57
Gearing on output shaft on the Cable guide

hoisting gear,
pins on the hoisting gear

standard designation KHC 2 K-60 DIN 51502.

AN 6758.
Lubricate the cable guide from the beginning
to the 8th to 10th turn and behind the last
Quantity: Apply lubricant with brush to coat surface turn (the area which does not contact the
completely. wire rope):
When changing the wire rope
When changing the cable guide
Lubricate pins:
At a regular inspection
When the hoisting gear is disassembled and
reassembled When carrying out a general overhaul
Lubricate the gearing on the output shaft:

When the hoisting gear is disassembled and
reassembled
When carrying out a general overhaul
After 10 years at the latest
hoist running time of less than one hour with
a medium or limited load spectrum. If the
operating conditions are more difficult (e.g.
multiple-shift operation, higher ambient
temperature, aggressive environmental
necessary.
Page 58
Wire rope and cable drum Rope guide runner on the cable
guide
Lubrication ex works with Moly Paul Chainlife S

AN 2717.
standard designation KHC 2 K-60 DIN 51502.
Alternatives:
Castrol Viscogen KL 23 Lubricate the rope guide runner on the cable
guide:
Klber Grafloscon CA 901 Ultra Spray
Optimol KL 23
When changing the cable guide
Shell Malleus GL 95
Lubricate the wire rope and cable drum

behind the 8th to 10th turn up to the last turn:
When changing the wire rope Bottom block

AN 6758.
Quantity: Apply lubricant with brush to coat surface

completely.
Lubricate the journals on the crosshead:

When the load hook is disassembled and
reassembled
Page 59
Only with wire rope hoists for Only with wire rope hoists with LIS-
double-girder travelling cranes SE
Hinge pin Flanged bolt on the rope socket of

the fixed point crosshead

AN 6758. Lubrication ex works with Moly Paul PBC
AN 6758.

completely. Quantity: Apply lubricant with brush to coat surface
completely.
Lubricate the hinge pin:

When the end carriage is disassembled and Apply lubricant to the rope socket before
reassembled installing the rope socket:
Do not lubricate the flanged bolt or the fixed
point crosshead. No lubricant should contact
the fixed point crosshead.
Hinge pin When removing and installing the rope
socket

AN 6758.

completely.
Lubricate the hinge pin:

When the end carriage is disassembled and
reassembled
Page 60
Only with wire rope hoists with LIS- Only with wire rope hoists GM 800,
SE GM 1000, GM 2000, GM 3000,
GM 5000, GM 6000
Flanged bolt on the rope socket of
the fixed point crosshead Bearing bush (on flanged bolt) on
the deflection roller crosshead and
on the fixed point crosshead
Lubrication ex works with Moly Paul PBC Lubrication ex works with Moly Paul PBC
AN 6758. AN 6758.
Quantity: Apply lubricant with brush to coat surface Quantity: Apply lubricant with brush to coat surface
completely. completely.
Apply lubricant to the rope socket before Lubricate bearing bush (on flanged bolt):
installing the rope socket:
When removing or installing the deflection
Do not lubricate the measurement bolt or roller crosshead or fixed point crosshead
the fixed point crosshead. No lubricant
should contact the fixed point crosshead. When carrying out a general overhaul
When removing and installing the rope

socket
Page 61
Only with wire rope hoist GM 7000 Self-aligning roller bearing on the
cable drum
Deflection roller crosshead

standard designation Multi-use grease NGLI2 with
solid matter MoS2 KF2.
Quantity: Apply a liberal coating of lubricant with

Lubrication ex works with Molycote D321 R anti- brush.
friction coating AN 18930
Lubricate the self-aligning roller bearing:

Quantity: Apply lubricant to coat surface When removing and installing the self-
completely. aligning roller bearing
Lubricate the contact surfaces of the

deflection roller crosshead:
When removing or installing the deflection Only with wire rope hoists with
roller crosshead guide rollers
When carrying out a general overhaul or cranes with guide rollers
Cylindrical roller bearings of the

guide rollers

standard designation Multi-use grease NGLI2 with
Quantity: Apply a liberal coating of lubricant with

brush.
Lubricate the cylindrical roller bearing:

When removing and installing the guide
rollers
Page 62
Only with wheels of size 350, 420, Only with 8-wheel cranes
500 on the end carriage and with
wheels of size 200 on the single-rail
trolley Flanged bolt on the coupling bar
Self-aligning roller bearings in

wheel

AN 6758.
Lubrication ex works using lubricant with the Quantity: Apply lubricant with brush to coat surface
standard designation Multi-use grease NGLI2 with completely.
Quantity: Apply a liberal coating of lubricant with Lubricate the flanged bolt:
brush.
When the coupling bar is disassembled and
reassembled (e.g. when the inner wheels
are removed and installed).
Lubricate the self-aligning roller bearing:

When removing and installing wheels
Page 63
Only with E and AZP drives

Gearing on the output shaft on the
Gear unit in drives E 100, E 130, gear unit of the drive
E 160, E 200, AZP 130, AZP 160,
AZP 200, AZP 280

AN 6758.

completely.
Lubrication ex works with Klber Centoplex CX

4/375
Quantity E 100: 40 g When the drive is disassembled and
Quantity E 130: 50 g reassembled
Quantity E 160: 50 g
After 10 years
Quantity AZP 130: 50 g When carrying out a general overhaul
Quantity AZP 160: 90 g
Quantity AZP 280 (reduction ratio i=125.7, i=62.92,
i=48.45): 240 g
Quantity AZP 280 (reduction ratio i=86.67, i=61.11,
i=48.33, i=41.17, i=42.86): 160 g
The gear unit in the drive is lubricated for its

entire service life. At the end of its service life
(in a general overhaul), assess whether the
Page 64
Only with AZF drives Only with AZF V drives
Gear unit in drives AZF 350, AZF 420 Gear unit in drives AZF V420,
AZF V500

standard designation CLP ISO VG 460 DIN 51502 Lubrication ex works using lubricant with the
standard designation ATF Type II D.
Quantity: 1200 ml
Quantity: 3000 ml
The gear unit in the drive is lubricated for its The gear unit in the drive is lubricated for its
entire service life. At the end of its service life entire service life. At the end of its service life
(in a general overhaul), assess whether the (in a general overhaul), assess whether the
lubricant needs to be changed. lubricant needs to be changed.
Page 65
Only with AZF and AZF V drives Only with underslung travelling
cranes
drive gear unit, Gear rims on the wheel
pins on the gear unit
Lubrication ex works with Moly Paul PBC Lubrication ex works using lubricant with the
AN 6758. standard designation Multi-use grease NGLI2 with

completely. Quantity: Apply a liberal coating of lubricant with
brush.
Lubricate pins:
Lubricate gear rims:
When the gear unit is disassembled and
reassembled When the drive is disassembled and
reassembled
Regularly check that the gear rims are
When the drive is disassembled and completely lubricated and the lubricant is not
reassembled soiled.
After 10 years If the lubricant is dirty: Clean the gear rims
When carrying out a general overhaul and reapply lubricant.
Page 66
Only with HB cranes Only with jib cranes
Gear unit in drives HBF 520, HBF Gear rims on supporting rolls
1040

Lubrication ex works using lubricant with the standard designation Multi-use grease NGLI2 with
standard designation ATF Type II D. solid matter MoS2 KF2.
Quantity: 800 ml Quantity: Apply a liberal coating of lubricant with

brush.
entire service life. At the end of its service
life (in a general overhaul), assess whether
the lubricant needs to be changed. Lubricate gear rims:
When the slewing drive is disassembled and
reassembled
Regularly check that the gear rims are
completely lubricated and the lubricant is not
soiled.
If the lubricant is dirty: Clean the gear rims
and reapply lubricant.
Page 67
Wiring diagrams Maintenance
Gear unit in slewing drives

standard designation CLP PG DIN 51502.
Quantity for pillar diameter 273: 0.34 l

The gear unit in the slewing drive is

lubricated for its entire service life. At the
end of its service life (in a general overhaul),
assess whether the lubricant needs to be
changed.
4.9 Wiring diagrams
The wiring diagrams of the crane are found

in the crane's documentation folder and on
the CD ROM ABUDoku.
For overhead travelling cranes: A copy of the
wiring diagrams can also be found in the
crane panel.
Page 68
Maintenance Declaration of Conformity, Declaration of Incorporation
4.10 Declaration of Conformity, Declaration of Incorporation

Declaration of Incorporation
If the crane is sold by ABUS as a component, in
separate components or for installation in another
machine, a Declaration of Incorporation is issued in
Only within the EU terms of the machinery directive of Appendix II 1B.
It can be found in the test log book of the crane.
Declaration of Conformity Putting into service is then prohibited until it has
been ascertained that the installation into which the
ABUS components are to be installed meet all
If the crane is sold by ABUS as a stand-alone requirements of the EU directive versions
machine, a Declaration of Conformity is issued. It applicable at the time of issuance.
can be found in the test log book of the crane.
A test must be performed on the ABUS
The Declaration of Conformity or Declaration of components prior to initial commissioning, before
Incorporation issued by ABUS becomes invalid if the Declaration of Conformity for the entire
independent reconstruction or modifications to the installation is issued. See Test before initial
crane are performed. commissioning page 33.
1 1
2 2
3 3
4 4
5 5
1: ABUS company address

1: ABUS company address 2: Person responsible for putting together
2: Person responsible for putting together the special technical documentation
the special technical documentation 3: Technical specifications identifying the
3: Technical specifications identifying the crane
crane 4: Information on the fundamental standards
4: Information on the fundamental standards underlying development and production.
underlying development and production. 5: Signature of responsible person
5: Signature of responsible person
Page 69
AN 120197EN001 2014-02-28
Kransysteme
Product Manual
Single girder travelling crane ELV, ELK
and ELS
ABUS single girder travelling crane

Sonnenweg 1
Tel. 0049 2261 37-0
Order No. 110-034551 Fax. 0049 2261 37-247
regard to patent issue or registered designs.
Fixing the end carriages onto the main girder (page 15)
Lifting the overhead travelling crane onto the crane track (page 20)
Installing the mains power supply (page 21)
Installing the cross-type limit switch (page 21)
Fastening the end carriages tightly (page 23)
Disassembling the powered wheel (page 32)
Disassembling the non-powered wheel (page 39)
AN 120139EN006 2016-03-17 Original operating instructions
Single girder travelling crane: various sizes,
versions and options
This product manual applies for overhead travelling cranes in various sizes, versions and with various options.
The work steps described and the technical data will vary according to the overhead travelling crane size,
versions and options. The parts of this product manual which do not apply to all overhead travelling cranes, but
only apply under certain conditions, are enclosed in a dashed box. The sizes, versions and options to which the
section applies are specified at the start of the box.
End carriage (size)
Wheel diameter (end carriage) Size
End carriage (options)
Derailing protection device Guide rollers Clamping piece
Wheel design (version)
Wheel with wheel flange Wheel without wheel flange

Main girder (version)
ELV main girder ELK main girder ELS main girder
Trolley power supply (version)
Energy chain Festoon cable system
Trolley (type)
Wire rope hoist, type E Wire rope hoist, type E Wire rope hoist, type S Wire rope hoist, type U
(single-rail trolley) for single (single-rail trolley) for single (side-mounted trolley) for (lower flange trolley) for
girder travelling cranes in girder travelling cranes in single girder travelling single girder travelling
modular design GM compact design cranes cranes
modular
Crane travel drive (version)
Crane travel drive AZP Crane travel drive AZF Crane travel drive AZF V
(Size 130, 160, 200, 280) (Size 350, 420) (Size 420 V with adapter)
Contents
Contents
3. INSPECTION ................................... 25
1. GENERAL INFORMATION..................... 5
3.1 At the start .............................................. 25
1.1 At the start ................................................ 5
3.2 Scope of the test .................................... 25
1.2 The single girder travelling crane ............. 7
3.3 Inspecting the wheel flange wear ........... 26
1.3 Transporting the overhead travelling
crane on a lorry ...................................... 10 3.4 Checking the braking distance ............... 26
1.4 Loading and unloading the overhead 3.5 Checking the wear on the guide rollers .. 27
travelling crane ....................................... 10
3.6 Checking the diameter of the wheels...... 28
1.5 Disposing of the overhead travelling
crane ...................................................... 11 3.7 Inspecting the condition of the safety
buffer ...................................................... 29
2. INSTALLATION ................................. 12
4. MAINTENANCE ............................... 30
2.1 Installing the crane track ......................... 12
4.1 Instructions regarding safety when
2.2 Checking the requirements ..................... 13 performing maintenance work ................ 30
2.3 Installation overview ............................... 14 4.2 Changing the fuses................................. 31
2.4 Fixing the end carriages onto the main 4.3 Disassembling the powered wheel ......... 32
girder ...................................................... 15
4.4 Installing the powered wheel .................. 34
2.5 Connecting the crane travel drives ......... 18
4.5 Disassembling the non-powered wheel .. 39
2.6 Connecting connection cables to crane
panels ..................................................... 18 4.6 Installing the non-powered wheel ........... 40
2.7 Installing the safety buffers ..................... 18 4.7 Replacing the cross-type limit switch ...... 42
2.8 Pre-installing the mains power supply .... 19 4.8 Wiring diagram of the cross-type limit
switch ..................................................... 42
2.9 Repairing damage to paintwork .............. 19
4.9 Checking after a lightning strike ............. 43
2.10 Attaching operating direction signs ......... 19
4.10 Screwing with tightening torque .............. 43
2.11 Lifting the overhead travelling crane
onto the crane track ................................ 20 4.11 ABUS Service ......................................... 45
2.12 Installing the mains power supply ........... 21 4.12 Lubricants ............................................... 46
2.13 Installing the cross-type limit switch........ 21
2.14 Fastening the end carriages tightly ......... 23
2.15 Overview of screw tightening torques ..... 23
Page 4
General information At the start
This section applies to anyone who lifts loads using the crane, performs work on the crane, or works
nearby.

hazards for persons and provides
instructions for avoiding these
hazards.
Regulations
The installation has been built and tested according

Danger from electric shock! to European standards, rules and regulations
applicable at the time of its manufacture. The
This warning notice indicates conventions applied during design and construction
hazards for persons due to incorrect are specified in the Declaration of Conformity or the
handling of the electrical system Declaration of Incorporation. The conventions must
and electricity. also be observed for installation, operation,
inspection and maintenance, as must the applicable
occupational health and safety regulations.
Danger due to falling load!

This warning notice describes Danger to persons!
hazardous situations that can lead Non-observance of the regulations
to the suspended load falling. can result in the death of persons or
serious accidents.
This is an instruction regarding an action and To ensure work safety, thorough
prompts you to perform a work step. instruction in regard to this product
This is the result of an action and describes manual and the regulations is
what happens on the device. necessary.
This is a list.
Only with... Which provision applies in individual cases will

greatly depend on the cranes use and the national
A section that appears in a box framed by a dotted regulations. Review and observe all applicable and
line is only applicable for certain types, versions or current regulations, including the occupational
options. Which type, version or option this is can be health and safety regulations. Refer also to the
seen in the first line. You can find out whether or Declaration of Conformity or Declaration of
not the section is applicable for your crane by Incorporation.
referring to the section Various types, sizes,
versions and options at the beginning of this
manual.
Page 5
Warranty
ABUS assumes no liability for damages that

were caused by improper use, inadequately
trained personnel, incorrect performance of
work, as well as any changes, reconstruction
or other modification of the crane or crane
components which was not approved by
ABUS.
Any warranty claim becomes invalid if
installed, used or serviced in any way other
than that described in this product manual, or
parts were used.
Safe operation of the crane or crane
components is only guaranteed if original
ABUS replacement parts are used.
Page 6
General information The single girder travelling crane
1.2 The single girder travelling

crane
View of the crane:

1 2
3
5
7 6 5 4
Detailed view of end carriage:

4 8 5
11 10 9
1: Main girder
(ELK version here)
(energy chain version here)
3: Crane panel
4: End carriage
(AZP version here)
6: Pendant control
8: Joint face
9: Wheel, powered
10: Wheel, not powered
11: Safety buffer
Page 7
The single girder travelling crane General information
Performance features The end carriages:

The end carriages are fully-automatic,
The single girder travelling crane EL: welded box girders.
The overhead travelling crane is The end carriages are connected to the main
manufactured as an ELV overhead travelling girders using high-tensile bolts.
crane from a solid-walled I-beam.
The end carriages (according to the
The overhead travelling crane is respective width of the crane track) have
manufactured as an ELK overhead travelling wheels with wheel flanges, which enable
crane from a welded, torsion-rigid box girder. even running on the crane track and prevent
All four outer welds are welded at the same the overhead travelling crane from derailing.
time.
The end carriages have safety buffers to
The overhead travelling crane is prevent damage if the crane runs into the
manufactured as an ELS overhead travelling end of the crane track or into another crane.
crane from a welded, torsion-rigid box girder,
The end carriages can be fitted with an
on which the trolley runs on the upper flange
and lifts the load laterally next to the main additional derailing protection on all four
girder. wheels (option).
The overhead travelling crane is equipped The end carriages can be fitted with guide
with a wire rope hoist, type E (single-rail rollers (option) to equalise the tolerances of
trolley), S (side-mounted trolley) or U (lower the crane track. For this, one of the two end
flange trolley). The single-rail trolley can be carriages is fitted with two horizontal guide
executed in a compact design or as a rollers on both wheels. These run left and
modular wire rope hoist GM modular. right close to the crane track. The crane is
thus closely guided on one side. The other
The standard crane is equipped with a side has very wide wheels to compensate for
mobile control. This ensures the position of the tolerance.
the pendant control is independent of the
trolley position. The other end carriages (without guide
rollers) can also be fitted with a derailing
The crane is controlled using the pendant protection device on both wheels (option).
control ABUCommander. The pendant
control has two-stage buttons with which the
crane can be controlled at low and high
speed for travel or lifting. As a variation, the
crane can also be controlled using a radio The end carriages of the sizes 280, 350 and 420:
remote control. The end carriages of the sizes 280, 350 and
The trolley and the mobile control come as 420 have a clamping piece on the powered
standard with an energy chain connected to wheel.
the rest of the cranes electrics. As a The end carriages of the sizes 280, 350 and
variation, the trolley and the mobile control 420 have a special rigidity aid on the inside,
can be connected to the rest of the cranes called a clamp brace, which transfers the
electrics with a festoon cable system. stress from the main girder to the end
The crane is supplied with power via a carriages.
conductor system. This is mounted parallel to
the crane track. The conductor system is
designed according to the conditions
(thermal stress, length, voltage drop,).
The single girder travelling crane with two trolleys:

The crane is equipped with two trolleys.
These can be controlled using a joint
pendant control (or transmitter). This
improves safety during the transportatio of
e.g. long or bulky loads.
The trolleys are labelled Trolley I and
Trolley II on the wire rope hoist and on the
pendant control.
Page 8
General information The single girder travelling crane
The crane travel drives: The crane electrical system:
The drives are designed as pole-variable The crane electrical system is stored in the
rotary current motors with electromagnetic crane panel on the end carriage.
brakes and gear units. The crane electrical system has the
The drives have a low and a high speed. The protection rating IP 55.
ratio of the two speeds is 1:4. The crane electrical system is protected by
The drives have a modular construction of regular fuse links in its main fuse.
motor and gear unit to enable easy The crane electrical system has
replacement. mechanically interlocked directional
Using plug-in connections in the connector contactors. This ensures that the drives
housing directly on the drive, the drives can cannot be connected to both directions of
be quickly separated from the rest of the travel at the same time. This would cause a
cranes electrics. short circuit.
The drives can be continuously adjusted in The crane electrical system is particularly
speed by the ABULiner frequency converter service-friendly due to screwless terminals
(optional). and wiring in cable ducts.
The drives are connected to the motor The crane electrical system is switched
protection switch in the crane panel. centrally through the main contactor. It is
located in the crane panel. If the emergency
The acceleration of the drives to high speed stop button is pressed or if an emergency
is switched on after a brief time delay. The stop is triggered for other reasons, the main
delay avoids the drive running in a starting contactor switches off the power for all
current in inching mode (rapid switching back drives.
and forth). This would eventually damage the
motor. As a result of plug-in connections between all
crane components, the crane electrical
When braking from the high to low speed, for system is particularly maintenance-friendly.
a short period only two of the three phases of
the drive are switched to the low speed. In
doing so, the drive does not jerk to a halt but
brakes softly. As a result, the load does not
swing as greatly. This function controls the The crane travel limit switches:
standard SU1 device.
Crane travel limit switches are mainly used in
When braking from high speed to a complete the direction of the crane track end as motion
stop, for a short period prior to stopping the restrictors.
drive is switched to low speed. In doing so,
The crane travel limit switches (option) can
the drive initially brakes dynamically. There is
be designed with a braking and/or shut-down
thus less wear on the brake lining and the
function.
lining does not need to be replaced so
frequently. (Optional, control by the SU2 The crane travel limit switches switch the
device) crane to low speed with the braking function
just before the end of the crane track. This
prevents the crane from running into the end
of the crane track at high speed and causing
the load to swing.
The crane travel limit switches with the shut-
down function (option) completely switch off
the crane travel drive immediately before the
end of the crane track. The shut-down
function is particularly useful for certain
safety switches.
Page 9
Transporting the overhead travelling crane on a lorry General information
Observe the following points amongst

others:
1.3 Transporting the overhead
travelling crane on a lorry
Attaching the main girders
Clamping buffer Edge protection

Danger from falling components!
The crane can fall from the lorry and
kill or injure people if it is not
correctly loaded and secured. Crane
transportation and load securing
should only be carried out by trained
persons.
Observe the following points, amongst

others:
Secure the load according to regional
regulations. Lifting tackle
Lay suitable blocks of wood on the loading

Place suitable lifting tackle around the main
girders.
area beneath the main girders.
It is best to lay the blocks of wood beneath
Cover all edges of the main girder with
suitable edge protection.
the main girders in the places they were laid
before to avoid damage to the paint.
Secure the main girders to the loading area Only with energy chains
with suitable lifting tackle. If the profile rails (in which the energy chain
Also secure individual components such as is) protrude to the side, lay wooden beams
end carriages, trolleys, etc. to the loading (wider than the profile rails) over the profile
area using suitable lifting tackle. rails so that they are not damaged on lifting.
Secure all loose parts and wiring.

Cover unpainted surfaces and openings with
film and secure with adhesive tape.
Only for ELK and ELV main girders
Adjust the trolley or lifting tackle in such a
way that the main girder hangs straight
when it is lifted.
Secure the trolleys with clamping buffers so
1.4 Loading and unloading the that they do not slip on lifting.
overhead travelling crane
Only for ELS main girders

Secure the trolley onto the main girder with
a tension belt or similar.
The crane can fall and kill or injure
people if it is not correctly attached Adjust the lifting tackle in such a way that
the main girder hangs vertically and
and lifted. Attachment and loading horizontally straight when it is lifted.
Due to the laterally running trolley track and
persons. the overhanging trolley, the main girder is
unbalanced on one side.
Page 10
General information Disposing of the overhead travelling crane
Setting down the main girders
Set down the main girders on stands which

have sufficient load capacity.
With the trolley installed underneath the main
girder: The stands must be at least high
enough that the rope is not buckled or
pinched. Ideally, the stands should be high
enough that the trolley load hook hangs
freely.
1.5 Disposing of the overhead

travelling crane
If the overhead travelling crane needs to

be disposed of:
Dismantle the overhead travelling crane to

the extent possible.
Observe local regulations concerning
disposal and recycling.
Dispose of the individual parts sorted by
material in an environmentally sound
manner.
Dispose of electronic components as scrap
electronic parts.
Plastic parts should be recycled with plastic
waste.
Remove brake linings and friction clutch
linings and dispose of these multiple
components as hazardous waste.
Remove oil or grease from the crane travel
drives and dispose of as a lubricant.
Sort lines, plug-in connections and pendant
controls by material and bring them to a
recycling centre.
The end carriages and main girders should
be recycled as scrap metal.
Page 11
Installing the crane track Installation
2. Installation
This section applies to anyone who works on the crane prior to its use
The crane is delivered ready-assembled. To install,

perform the described points here in the sequence
given.
2.1 Installing the crane track
proper qualifications of the commissioning So that the overhead travelling crane travels
personnel. steadily, smoothly and without great wear and tear,
the crane track must be properly installed.
Otherwise the overhead travelling crane will travel
unsteadily and the wheels will wear out more
Danger to persons! rapidly.
is incorrectly put into operation. The design and installation of the crane track must
be taken into consideration upon construction of the
If personnel other than that of the building and planned together with the architects
ABUS company are employed to and structural engineers.
perform the commissioning, it is the
end users responsibility to ensure Observe the following points amongst
that these persons are adequately others:
qualified. Follow the procedures
The building supports and building beams or
described here precisely. concrete supports or concrete girders as well
as the brackets should be designed in such a
way that the crane track can be welded onto
them without difficulty.
Only have welding work done by companies
Persons with comprehensive knowledge certified as per EN 1090 EXC-3.
the electrical systems of cranes. Monitor welded joints according to this
standard.
operation, installation and maintenance of Design welded joints to at least quality class
cranes. B of DIN EN ISO 5871.
Persons with comprehensive knowledge Clean the anchor plates (in the concrete
regarding the relevant technical rules, brackets) or the steel brackets (to the
directives and safety regulations applicable building supports) prior to welding. They
in the respective country. must be free of dirt, rust, scaling, paint,
grease and oil.
ABUS.
Cut the crane track joints at an angle of 45
degrees. Deburr the cut edges and clean.
The gaps between the crane tracks should
be as small as possible. The abutting crane
ABUS assumes no liability for damage due to track segments should not be misaligned
incorrectly performed commissioning work done by laterally nor offset in height.
For bolted crane tracks: firmly tighten all
ABUS recommends having the commissioning work bolts with the correct tightening torque.
Clean the crane tracks. They must be free of
grease, oil, paint and dirt.
Depending on the size, design and method of Secure the crane track with suitable end
transport of the crane, some work steps will already stoppers.
have been completed ex works. Skip these work
steps. Provide the entire crane track with an
appropriate corrosion protection (e.g. paint)
Page 12
Installation Checking the requirements
Height of the crane tracks in relation to

2.2 Checking the requirements each other E:
The following requirements must be met in order for

the crane to be installed:
Cross-sectional view.
Checking the crane track
Where S 10 m, the following applies:
maximum difference in height E = 10 mm.
The tolerances of the crane track must
correspond to the following criteria. Where S > 10 m the following applies:
difference in height of the crane tracks
E (in mm) must not be greater than
The tolerances specified correspond to DIN EN E = Span S / 1000.
1090 for Class 2 crane classifications.
Site of a crane track in floor plan B: Deviation from span A:
View from above.

Deviation B across the entire length of the
crane track: B = 5 mm. View from above.
Within 2 m, the deviation may not be greater When S 16 m, then A = 5 mm applies.

than b = 1 mm. When S > 16 m, then: A = [5 + 0.25 (S-
16] mm applies.
With S in m and the result in mm.
Height of crane track C:
Position of the end stoppers in relation to

each other F:
Wall (view from the side)

View from the side.
Deviation C across the entire length of the
crane track: C = 10 mm.
View from above.
Deviation C across the entire length of the
The offset of end stoppers F must not be
crane track must not be greater than
greater than F = Span S /1000.
C = Crane track length / 1000 mm.
Maximum offset F = 10 mm.
Within 2 m, the deviation may also not be
greater than c = 2 mm.
Page 13
Installation overview Installation
Incline of the crane track from the

horizontal vertex G:
2.3 Installation overview
The following sections show how the single girder

travelling crane is assembled.
Where overhead travelling cranes are
delivered disassembled, the end carriages
are affixed first.
Cross-sectional view. The crane travel drives are then connected

on the ground.
Deviation G = 0.6 % of the width K.
The connection cables are then connected to
the crane panels on the ground.
The safety butters are then installed on the
Incline of the crane tracks to each other: ground.
The mains power supply is then pre-installed
on the ground.
The crane is then raised onto the crane track
using a truck-mounted crane.
The mains power supply is then installed on
the crane track and connected.
The crane travel limit switch is then installed.
View from the side (perspectively) As a final step the screws of the end
Incline of the crane tracks to each other: carriages are tightened with the correct
Incline between A1 and B1 (wheel base) tightening torque.
incline between A2 and B2 (without algebraic Perform the following steps in the sequence
sign) must not be greater than L (distance specified.
between A1 and B1) / 1000.
Checking the layout plan
The supplied overhead travelling crane must

correspond to the overhead travelling crane
that was provided for in the layout plan.
Only with multiple overhead

travelling cranes on the crane track
Checking the crane position
The order of the overhead travelling cranes

on the crane track must be decided.
Page 14
Installation Fixing the end carriages onto the main girder
2.4 Fixing the end carriages onto Preparing the screw connection
the main girder
Danger of fatal injury!
Travelling cranes with end carriages which are a The crane and the load can fall if
maximum of 2.5 m wide can, in the majority of the end carriages are not correctly
cases, be transported fully assembled on the road. screwed onto the main girders.
If the end carriages are installed, skip this section.
Prepare and screw in the screws
Continue with Installing the safety buffers on
page 18. carefully!
For travelling cranes with end carriages which are
more than 2.5 m wide, the end carriages are
dismantled for transportation. Continue reading.
Residual paint
Assigning the end carriages
Letter position markers
Joint face
Thoroughly clean the joint faces on the entire
surface. There should not be any rust, dirt,
paint or similar impurities on them.
Lift the end carriages in front of the main
girders. The hole patterns must overlap.
Joint faces
Look for the letter position markers A and B
(for the installation sequence) on the main
girders and end carriages.
Lay both end carriages on the joint faces of
the main girder in such a way that the letter
position markers match.
Page 15
Fixing the end carriages onto the main girder Installation
Checking the high-tensile bolts Bolting on the end carriage
Check the high-tensile bolts. The high-tensile Clamp brace

bolts must meet these requirements:
Lubrication
Material
Size
High-tensile bolt 10.9 M20
(hexagonal) HV
tZn
Washer C 45 HV 21 MoS2
HV
tZn
High-tensile nut 10 M20 MoS2
(hexagonal) HV
tZn
The high-tensile bolts and mounting plate

with high-tensile nuts may only be installed a
maximum of two times. If they are installed
more than twice, scrap the high-tensile bolts Mounting plate
as well as the mounting plates with the high-
tensile nuts and use new ones.
Only with end carriages of size 280, 350 and
Should it be necessary to loosen the high- 420: Do not move, dismantle or damage the
tensile bolts during installation (e.g. because clamp brace in the end carriage.
the hole pattern does not fit exactly) the Place the mounting plate in the end carriage
same high-tensile bolts can be used again. and hold it so the hole pattern properly
The high-tensile nuts and washers must be overlaps.
galvanised and lubricated with MoS2.
High-tensile bolts that have been installed on
a crane for a lengthier period may not be
High-tensile bolt with
used again.
washer
The end carriages are initially only installed by

manually screwing until hand-tight. They are finally
firmly screwed (with a tightening torque) only after
the crane is on the crane track and the trolley and
all other components are installed. By doing so, the
main girders can settle and the crane is not warped
on the crane track. See Fastening the end
carriages tightly, page 23.
Place the washers on the high-tensile bolts

with the bevel (chamfered edge) to the head
of the screw.
Insert the high-tensile bolts and washers
from the outside into the screw holes and
screw on so they are somewhat loose.
Screw on the second end carriage following

the same sequence of steps.
Page 16
Installation Fixing the end carriages onto the main girder
Sealing the access portal Only for rainwater or condensation

water
Access portal This work step only applies if the crane comes into
contact with rainwater or condensation water (e.g.
outdoor operation, semi-exposed building etc.)
Sealing the joint faces
The gap between the two joint faces must be sealed

so that no water can penetrate and rust the metal
parts.
Joint
Cap
Seal the access portal with a cap.
Sealant
Squeeze sealant (supplied) with a cartridge
applicator gun into the joints between the
main girders and the end carriages. Only left,
right and above.
The joints below remain free so that
entrapped water can drain off.
Smooth the sealant in the joint.
Clean away any smeared sealant.
If necessary, reapply the sealant. The
sealant can be handled wet on wet, no
drying time is necessary.
Page 17
Connecting the crane travel drives Installation
Crane panel
2.5 Connecting the crane travel

drives
Connection cable
Connectors and
coupler plugs
Insert connectors and coupler plugs in the
socket on the crane panel.
Lay the connection cables in the cable duct.
Connector housing Drive
Lay the connection cable for the drive.
Secure the connection cables with cable
clips.
Lay the connection cable in the connector
housing.
Plug the coupler plug into the drive and close
the housing cover.
Secure the connection cable with cable ties 2.7 Installing the safety buffers
to the end carriage.
In case the safety buffers are not installed:

Buffer plate
2.6 Connecting connection cables
to crane panels
Cable fasteners
Safety buffer
Screw safety buffers (4x) into the buffer
plates.
Installation channel
Push the installation channel on the crane
panel onto the bolt on the end carriage.
Fasten the installation channel with cable
fasteners.
Page 18
Installation Pre-installing the mains power supply
2.8 Pre-installing the mains power 2.10 Attaching operating direction

supply signs
Threaded bracket
Operating direction signs

Rotate the operating direction signs to match
Mount Pipe clamp how they are marked in the layout plan.
Attach the mount to the end carriage on For spans under 10 m only: Attach operating
which the crane panel is installed. direction signs for the crane and trolley under
the middle of the main girder.
Bolt the mount onto the threaded bracket.
Only for spans greater than 10 m: Attach
Threaded bracket Tightening torque operating direction signs for the crane and
M8 25 Nm trolley to the left and right, in each case 2.5
m away from the end carriage.
M10 50 Nm
M12 75 Nm
Slide on the two pipe clamps and secure
them.
2.9 Repairing damage to paintwork
Repair damage to paintwork caused during

transportation and installation.
Page 19
Lifting the overhead travelling crane onto the crane
track Installation
Only for ELK and ELV main girders

2.11 Lifting the overhead travelling Adjust the trolley or lifting tackle in such a
way that the main girder hangs straight
crane onto the crane track when it is lifted.
Secure the trolleys with clamping buffers so
that they do not slip on lifting.
The crane can fall and kill or injure
people if it is not correctly attached Only for ELS main girders
and lifted. Attachment and lifting Secure the trolley onto the main girder with
a tension belt or similar.
persons. Adjust the lifting tackle in such a way that
the main girder hangs vertically and
horizontally straight when it is lifted.
Due to the laterally running trolley track and
the overhanging trolley, the main girder is
Attaching the main girders unbalanced on one side.
Lifting tackle
Placing the overhead travelling

crane on the crane track
Observe the occupational health and safety

Clamping buffer requirements and lift the overhead travelling
crane.
Place suitable lifting tackle around the main
girder and insert it. Rotate the overhead travelling crane in such
a way that the direction corresponds to that
Cover all edges of the main girder with
in the layout plan.
suitable edge protection.
Place the overhead travelling crane with
wheels onto the crane track.
For guide rollers only: Do not set the
Only with energy chains overhead travelling crane down with the
If the profile rails (in which the energy chain guide rollers. Otherwise, they will be
is) protrude to the side, lay wooden beams damaged.
(wider than the profile rails) over the profile Check whether all wheels come into contact
rails so that they are not damaged on lifting. with the crane track.
Page 20
Installation Installing the mains power supply
2.12 Installing the mains power 2.13 Installing the cross-type limit
supply switch
Installing the mains power supply to Only with cross-type limit switch
the crane track This section is only applicable if the overhead
travelling crane has a cross-type limit switch in the
Install the mains power supply parallel to the direction of crane travel.
crane track. See the product manual for the Where and for which travel limit the cross-type limit
mains power supply. switch is designed is specified on the wiring
diagram.
Installing the mains power carrying Installing the cross-type limit switch
fork on the overhead travelling
crane Danger due to malfunction!
If the cross-type limit switch is
Vertical square tube screwed on too tightly, the parts on
the inside can become jammed
and no longer function properly.
The tightening torque of 4 Nm
must be precisely observed.
Locking washer Hexagonal nut
Screw the vertical square tube onto the

mount using pipe clamps (2x). 15 Nm.
Fillister-head Mounting bracket
screw M5x50
Screw the mounting bracket onto the cross-
Screw the mount for the current collector to type limit switch with the fillister-head screws
the vertical tube. M5x50 (2x).
See the product manual for the conductor Screw on the mounting bracket using locking
system. washers and M5 hex nuts (2x). 4 Nm.
Insert the current collector in the conductor
system and fasten it to the mount.
See the product manual for the conductor
system.
Connect the current collector to the crane
panel and lay the cable neatly.
Page 21
Installing the cross-type limit switch Installation
Attaching the actuating cam

Installing the cross-type limit switch
on the mains power carrying fork
End stopper
The cross-type limit switch can be installed on the

mains power carrying fork, for example.
Crane travel
limit switches
Conductor system Actuating cam

Suspend a load on the load hook which
corresponds to the maximum load capacity
of the crane.
Determine the necessary distance between
Turn the crane travel limit switch to the the actuating cam and the end stopper:
position 0. For braking function: The distance must be
The position of the cross-type limit switch is such that the crane is only travelling at a low
marked with an arrow that can be rotated speed shortly before the end stopper.
further, depending on the switching state. For shut-down: The distance must be such
Hold the crane travel limit switch on the that the crane is at a standstill shortly before
square tube so that the actuating cam the end stopper.
operates the crane travel limit switch. Add 0.5 m to 1 m to the calculated distance.
Screw the crane travel limit switch onto the This will compensate the brake wear on the
vertical square tube using pipe clamps (2x). crane travel drive.
15 Nm. Install the actuating cam for the crane travel
limit switch to the crane track or conductor
system at the determined distance.
Connecting the cross-type limit

switch
Route the connection cable (round cable or

flat cable) from the cross-type limit switch to
the panel.
Route the connection cable with cable fitting
into the panel.
If necessary, connect the connection cable to
a coupler plug or connector.
Fasten the connection cable with cable ties,
cable ducting and adhesive clips.
Page 22
Installation Fastening the end carriages tightly
2.14 Fastening the end carriages 2.15 Overview of screw tightening

tightly torques
Once all components have been installed, the entire

crane has settled as a result of the weight, and the End carriages
stress is relieved. For this reason, the end carriages
can only now be tightened with the tightening
torque. Check the high-tensile bolts. The high-tensile
bolts must meet these requirements:
Central high-tensile bolt
Lubrication
Material
Size
High-tensile bolt 10.9 M20
(hexagonal) HV
tZn
Washer C 45 HV 21 MoS2
HV
tZn
High-tensile nut 10 M20 MoS2
(hexagonal) HV
Remaining high- tZn
tensile bolts
The high-tensile bolts and mounting plate
Only tighten high-tensile bolts with the with high-tensile nuts may only be installed a
appropriate torque wrench. maximum of two times. If they are installed
more than twice, scrap the high-tensile bolts
Do not use an impact wrench.
as well as the mounting plates with the high-
Do not tighten high-tensile bolts using turn- tensile nuts and use new ones.
of-nut tightening.
Should it be necessary to loosen the high-
Tighten the central high-tensile bolts on both tensile bolts during installation (e.g. because
sides (left and right on the end carriage). Use the hole pattern does not fit exactly) the
a torque wrench to 300 Nm. same high-tensile bolts can be used again.
Next, tighten the remaining high-tensile bolts, The high-tensile nuts and washers must be
alternating between left and right. Use a galvanised and lubricated with MoS2.
torque wrench to 300 Nm.
High-tensile bolts that have been installed on
Then tighten all high-tensile bolts in the same a crane for a lengthier period may not be
sequence. Use a torque wrench to 450 Nm. used again.
Initially, only install the end carriages hand-

tight.
Next, place the entire crane on the crane
track and install completely. As a result of the
weight, the crane settles and the stress is
removed.
Then tightly screw all high-tensile bolts (with
tightening torque).
Page 23
Overview of screw tightening torques Installation
Central high-tensile bolt Pipe clamps on the mains power

carrying fork
Rib nut M8
Remaining high-
tensile bolts 4x per pipe clamp
Only tighten high-tensile bolts with the 15 Nm

appropriate torque wrench.
Do not use an impact wrench.
Do not tighten high-tensile bolts using turn- Crane travel limit switches
of-nut tightening.
Tighten the central high-tensile bolts on both
sides (left and right on the end carriage). Use
a torque wrench to 300 Nm.
Next, tighten the remaining high-tensile bolts,
alternating between left and right. Use a
torque wrench to 300 Nm.
Then tighten all high-tensile bolts in the same
sequence. Use a torque wrench to 450 Nm.
Mount on the mains power carrying Rib nut M8

fork
4x per pipe clamp
15 Nm
Threaded bracket
Tightening torque
Type and size
Number
M8 Rib nut M8 2x 25 Nm
Page 24
Inspection At the start
3. Inspection
This section applies to anyone who inspects and accepts the crane in accordance with occupational
health and safety requirements.
The crane must be regularly inspected in order to

guarantee safe operation. The end user is
responsible for this regular inspection. Examples of qualified persons:
3.1 At the start cranes.
Inspection intervals directives and safety regulations applicable
The regular inspection is performed at least once Persons receiving regular training from
annually. ABUS.
Under certain conditions, more frequent regular
inspections may be necessary. Reasons include:
Frequent operation at the load capacity
3.2 Scope of the test
Working in multiple shifts
Frequent use The qualified person inspecting the crane is
responsible for the type and scope of the test.
prerequisites and determining the test intervals. Overview: Inspecting the crane
ABUS will gladly assist you if questions arise.
In addition to the points described here, all points
outlined in the other supplied product manuals must
also be checked.
Requirements for the examiner The decision as to whether the crane is in perfect
The end user of the crane is responsible for the inspecting the crane. Any inadequacies, if found,
proper qualifications of the examiner. must be eliminated. The examiner decides whether
the crane has to be tested again afterward.
Danger to persons! these are likewise to be carried out.
Persons can be injured if the
perform the inspection, it is the end
user's responsibility to ensure that
these persons are adequately
qualified.
Page 25
Inspecting the wheel flange wear Inspection

checked:
3.4 Checking the braking distance
Check the wheel flange wear. See
Inspecting the wheel flange wear on
page 26. Only for braking function or shut-
Only for braking function or shut-down: down
Check the braking distance of the crane in
the limit switch range. See Checking the
braking distance, page 26. The brake on the crane travel drives is worn during
operation. This lengthens the braking distance of
Check the wear on the guide rollers. See the crane. The crane may therefore strike the end
Checking the wear on the guide rollers on stopper of the crane track too fast and put excess
page 27. pressure on the supporting structure (e.g. the
Check the diameter of the wheels. See building).
Checking the diameter of the wheels,
page 28.
Suspend a load on the load hook which
Check the condition of the safety buffer. See corresponds to the maximum load capacity
Inspecting the condition of the safety buffer of the crane.
on page 29.
Move the crane into the limit switch range.
Check the condition of the crane track and
the supporting structure. They must be Check the braking distance:
adequate for the expected loads. For braking function: the crane must run
only at low speed just in front of the end
stopper.
For shut-down: the crane must come to a
standstill just in front of the end stopper.
If the braking distance is too long: Adjust the
brake on the crane travel drive. See the
3.3 Inspecting the wheel flange wear product manual for the crane travel drive.
Only for wheels with a wheel flange
The undercuts in the wheel flanges are a sign of

wear on the wheel flange.
Wheel flange
Undercuts
Inspect the wheel flanges of the wheels: The
wheel flanges must not be worn so much that
a continuous crack can be seen in the wheel
flange (rather than undercuts). If they are,
replace the wheels.
Page 26
Inspection Checking the wear on the guide rollers
Only for guide rollers

3.5 Checking the wear on the guide
rollers
The wear on the guide rollers is checked based on
the clearance between the guide rollers and the
crane track.
Only for four-roller guide rollers Checking the wear

This working step is only applicable if the guide
roller unit is made up of four guide rollers per end Guide roller
carriage side.
The guide rollers must be clamped tight first in

order to check wear.
Clamping the support tight
Rotatable support for Support on the end

guide rollers carriage
Crane track
Measure the distance between guide roller
and crane track on both sides.
The distance (between guide roller and crane
track) on both sides together may not be
greater than that specified in the table.
If the distance is greater than this, the guide
rollers must be replaced.
Distance (total) on both

the crane track on both
Max. distance (total) to
Size (wheel diameter)
sides with new guide

Gap between
rotatable support and
support on the end
carriage

rollers
sides.
Turn the rotatable support in such a way

that it is parallel to the crane track.
Insert a wedge in the gap between the 130 11 mm 5 mm
support on the end carriage and the
rotatable support in order to clamp the guide 160 11 mm 5 mm
roller unit tight. 200 11 mm 5 mm
The rotatable support can now no longer be 280 11 mm 5 mm
displaced.
350 14 mm 5 mm
Now measure the distance between the 420 14 mm 5 mm

front and rear pairs of rollers and the crane
track as described below.
Page 27
Checking the diameter of the wheels Inspection
Determining the diameter for new 3.6 Checking the diameter of the
guide rollers wheels
If the distance between guide roller and crane track

is too large (see previous section), the guide rollers
must be replaced. The running surfaces of the wheels become worn
during operation. This reduces the diameter of the
During operation of the crane however, both the wheels.
guide rollers AND the crane track are subjected to
wear. Since only the guide rollers can be replaced,
they may need to be exchanged for larger ones Exposing the wheel
than were previously used in order to compensate
for the wear on the crane track.
Buffer plate
Guide roller Plastic washer Self-locking nut

If possible: Measure the diameter of the Unscrew the self-locking nuts (4x).
guide roller above the crane track.
From size 160: Remove the plastic washers
This area of the guide roller frequently has (4x).
no contact with the crane track and can
therefore be used to determine the original Remove the buffer plate.
diameter.
Determine the diameter of the new guide
roller:
Measuring the diameter
The distance between the guide rollers and
the crane track should be as close possible
to 5 mm (see also previous table). This
applies to the entire length of the crane
track.
The distance between the guide rollers and
the crane track may not be smaller than 5
mm. This applies to the entire length of the
crane track.
Measure the diameter of the wheel at

multiple points over the width of the wheel.
Page 28
Inspection Inspecting the condition of the safety buffer
The diameter may not be smaller than is

specified in the table.
If the diameter is smaller, the wheel must be 3.7 Inspecting the condition of the
replaced. safety buffer
Size Maximum Minimum
permissible diameter of
wear wheel
130 -3 mm 127 mm
160 -3 mm 157 mm
200 -4 mm 197 mm
280 -5 mm 275 mm
350 -5 mm 345 mm
420 -5 mm 415 mm
500 -5 mm 495 mm
Measuring the difference in Safety buffer

diameter Check all the safety buffers. The safety
buffers must not be broken, pinched, bent or
otherwise damaged.
In addition, the power-driven wheels of the crane
must be of uniform diameter so that the crane runs Check the material of the safety buffers all
evenly on the crane track. the way round. The plastic must not be
cracked anywhere on the surface.
This means that the permissible deviation in the
diameter of opposite-lying power-driven wheels is
Press the safety buffers with your finger. The
safety buffers must be able to be pressed in
limited.
slightly and be formable.
Only with a 4-wheel crane travel drive and 8-wheel
cranes: The diameter does not need to be as similar
as possible between all power-driven wheels, but
only between the respective opposite-lying wheels If any of the safety buffers is damaged in any
of the crane. way whatsoever, replace all the safety
buffers on the entire crane.
Determine the difference in diameter of the If any of the safety puffers cannot be pressed
opposite-lying power-driven wheels. in, replace all the safety buffers on the entire
crane.
The difference in diameter may not be larger
than is specified in the table.
If the respective diameters of the wheels
deviate from each other by more than this,
the wheels must be replaced.
Size For cranes For cranes
subject to lesser subject to
loads greater loads
(formerly crane (formerly crane
classification B3) classification B4)
130 2 mm 1 mm
160 2 mm 1 mm
200 2 mm 1 mm
280 3 mm 1.5 mm
350 3 mm 1.5 mm
420 3 mm 1.5 mm
500 3 mm 1.5 mm
Maximum difference in diameter of the two
power-driven wheels.
Page 29
Instructions regarding safety when performing
maintenance work Maintenance
4. Maintenance
This section applies to anyone who maintains, repairs or modifies the crane.

selection and proper qualifications of the
4.1 Instructions regarding safety
when performing maintenance work
Danger to persons!
is incorrectly serviced.
Please follow the following safety instructions during
If personnel other than that of the all repair work on the crane:
Switch off the mains switch. Secure the
perform maintenance on the crane, switch so that it cannot be unintentionally
it is the end user's responsibility to switched back on.
ensure that these persons are Unplug the mains disconnector plug from the
adequately qualified. Follow the socket on the crane panel. Secure the socket
procedures described here with a padlock so that the mains
precisely. disconnector plug is not unintentionally re-
inserted.
Use suitable lifting platforms and fall
protection equipment.
Adequately cordon off the work area around
Persons with comprehensive knowledge the lifting platform.
the electrical systems of cranes. Switch off any other cranes using the same
crane track or cranes working above or
Persons with sufficient experience in the below the crane undergoing maintenance.
operation, installation and maintenance of Secure the switch so that it cannot be
cranes. unintentionally switched back on. Otherwise,
Persons with comprehensive knowledge other cranes could overturn the hoisting
regarding the relevant technical rules, platform or crash into the crane undergoing
directives and safety regulations applicable maintenance.
in the respective country. Notify personnel in the area that
Persons receiving regular training from maintenance work will be performed.
ABUS. Only trained electricians should work on the
ABUS assumes no liability for damage due to Even after the emergency stop button has
incorrectly performed maintenance work done by been pressed, life-threatening high voltages
unqualified personnel. are still present in the panels.
ABUS recommends having the maintenance work

Use only original ABUS replacement parts.
Otherwise, all warranty claims will be rendered
invalid.
Page 30
Maintenance Changing the fuses
4.2 Changing the fuses Changing the control current circuit

input fuses F10 and F11
Changing the main fuse F1 Fuse holder
If the fuse is used in a circuit breaker:

Fuse link
Fuse link
Flip open the fuse holder.
Open the fuse holder.
Replace the fuse link.
Circuit breaker Close the fuse holder.
Pull out the circuit breaker. Click the fuse holder back into place.
Click the circuit breaker back into place.
Changing the control current circuit

output fuse F12
If the fuses are individually screwed in:
Screw cap Fuse holder
Unscrew the screw cap.

Screw the screw cap back on. Detach the fuse holder from the mount on
the transformer.
Reinsert the fuse holder.
Page 31
Disassembling the powered wheel Maintenance
Screws
4.3 Disassembling the powered

wheel
If the wheel is damaged or worn, it must be replaced

by a new wheel.
The figures show the disassembly of a size 130

wheel. The removal of larger wheels does not Crane travel drive
essentially differ from this. Unscrew and remove screws (4x).
Pull out the crane travel drive.
Preparing the crane

Exposing the wheel
Comply with occupational health and safety
requirements.
Buffer plate
Prop up the end carriage close to the wheel.
Disassembling the crane travel drive
Coupler plug
Plastic washer Self-locking nut

Unscrew the self-locking nuts (4x).
(4x).
Remove the buffer plate.
Connector housing
Open the connector housing to the drive.
Detach the coupler plug.
Determining the weight of the drive. See the

Technical data section Dimensions and
weights.
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).
Page 32
Maintenance Disassembling the powered wheel
Only for guide rollers, derailing Retaining screw

protection device or end carriages
of the sizes 280, 350 and 420
This section only applies if the end carriage has
guide rollers or a derailing protection device. This
work step also applies to end carriages of the sizes
280, 350 and 420.
Screws
Rib screws
Unscrew and remove all rib screws on the
bearing bolt. Do not unscrew and remove the
retaining screw(s).
Bearing bolt Bearing flange

Guide rollers
Release screws (2x).
Take out the guide rollers or derailing
protection device or clamping piece.
Removing the wheel

Wheel
Retaining screw Take out the bearing bolt, bearing flange and
wheel.
Note:
Only for size 420 with crane travel drive 420 V: An
adapter is also inserted on the bearing flange. If this
cannot be easily taken off, it can remain on the
bearing flange when the wheel is removed.
Tip:
To be able to easily remove the bearing flange from
Rib screws the end carriage, screw two or four screws in the
Unscrew and remove all rib screws on the corners of the bearing flange and thereby lift the
bearing flange. Do not unscrew and remove bearing flange off the end carriage.
the retaining screw(s).
Page 33
Installing the powered wheel Maintenance
4.4 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 Rib screws

Tighten the rib screws in stages. Screws of
Bearing bolt Bearing flange strength category 100.
Wheel Number Screw Tightening
torque
130 5x M8 x 25 42 Nm
160 5x M8 x 25 42 Nm
200 5x M10x30 85 Nm
280 5x M12x40 130 Nm
350 8x M12x40 130 Nm
420 8x M16x40 330 Nm
Wheel
Only for size 420 with crane travel
Clamp the wheel in the end carriage. It does
not matter which side faces inwards or drive 420 V
outwards. This work step only applies if an end carriage size
Insert the bearing bolt and bearing flange. If 420 is to be installed with a crane travel drive size
necessary, lightly hammer the bearing bolt 420 V.
and bearing flange.
Mounting the adapter
Bearing flange
Pin
If necessary: Insert the pins (4x) in the
bearing flange.
Page 34
Maintenance Installing the powered wheel
Fastening the bearing flange
Rib screws
Tighten the rib screws in stages. Screws of
strength category 100.
Tightening
Wheel
Number
torque
Adapter Bearing flange
Type
Turn the adapter to match the hole pattern.
Place the adapter on the pins on the bearing 130 7x M8 x 25 42 Nm
flange.
160 7x M8 x 25 42 Nm
200 7x M10x30 85 Nm
280 7x M12x40 130 Nm
Rib screws
350 10x M12x40 130 Nm
420 with crane 10x M16x40 330 Nm
travel drive 420
420 with crane 10x M16x70 330 Nm
travel drive 420 V
Insert the rib screws M16x70 (10x) through

the adapter and bearing flange.
Page 35
Assembling the end carriage Only for derailing protection device

This work step only applies if the end carriage has a
derailing protection device.
Only for guide rollers or end
carriages of the sizes 280, 350 and Small side
420
This work step only applies if the end carriage has
guide rollers. This work step also applies to all end
carriages of the sizes 280, 350 and 420.
Screws
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).
Guide rollers
Insert guide rollers or clamping piece.

Tightening
Wheel
torque
Type
Kind
Tightening
Wheel
130 M8x45 Rib screw 42 Nm

torque
Type
Kind

280 M12x60 Hexagon head 130 Nm
160 M10x50 Rib screw 85 Nm screw
200 M10x50 Rib screw 85 Nm 350 M20x75 Hexagon head 300 Nm
280 M12x60 Hexagon head 130 Nm or screw
screw M20x70
350 M20x75 Hexagon head 300 Nm 420 M20x75 Hexagon head 300 Nm
or screw or screw
M20x70 M20x70

or screw
M20x70
Page 36
Maintenance Installing the powered wheel
Only with AZP drives

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

Slide the buffer plate onto the threaded bolt.
From size 160: Fit the plastic washers (4x) in
place.
AZP drive
Tightly screw the self-locking nuts M10 (4x).
Push the drive in the wheel.
6 Nm.
Bolt on the drive with the rib screws (4x).
Wheel Type Tightening torque
Installing the crane travel drive 130 M8x20 35 Nm

160 M10x25 75 Nm
Determining the weight of the drive. See the 200 M12x30 115 Nm
Technical data section Dimensions and
weights. 280 M16x40 300 Nm
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 Moly Paul PBC, AN 6758.
Page 37
Only for crane travel drive AZF Coupler plug
This work step only applies if an AZF crane travel

drive is to be mounted on the end carriage.
Crane travel drive AZF
Connector housing
Insert the coupler plug.
housing.
Close the connector housing.
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). Inspecting the crane
Wheel Type Tightening
torque Replace the crane on the crane track.
350 M12x100 85 Nm Put the crane into operation.
420 with crane M12x100 85 Nm Inspect the function of the wheel.
travel drive 420
420 with crane M16x140 210 Nm
travel drive 420
V
Page 38
Maintenance Disassembling the non-powered wheel
4.5 Disassembling the non-powered Only for guide rollers or derailing

wheel protection device
This section only applies if the end carriage has
If the wheel is damaged or worn, it must be replaced guide rollers or a derailing protection device.
by a new wheel.
Screws
The figures show the disassembly of a size 130

wheel. The removal of larger wheels does not
essentially differ from this.
Preparing the crane
Comply with occupational health and safety

requirements.
Prop up the end carriage close to the wheel.
Exposing the wheel Guide rollers

Release screws (2x).
Buffer plate Take out the guide rollers or the derailing
protection device.
Removing the wheel
Distance bush Bolt

Unscrew the self-locking nuts (4x).
(4x).
Remove the buffer plate.
Wheel
Take out the bolt, distance bush and wheel.
Circlip
Remove the circlip.
Page 39
Installing the non-powered wheel Maintenance
Only for guide rollers

4.6 Installing the non-powered This work step only applies if the end carriage has
wheel guide rollers.
If the wheel is damaged or worn, it must be replaced Screws

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
Distance bush Bolt
Guide rollers
Insert guide rollers.
Tightening
Wheel
torque
Type
Kind
Wheel
Clamp the wheel in the end carriage. It does
not matter which side faces inwards or 160 M10x50 Rib screw 85 Nm
outwards.
Insert the bolt and distance bush. If
necessary, lightly hammer the bolt and
screw
distance bush.
or screw
M20x70
or screw
M20x70
Circlip
Attach the circlip and neatly lock into place.
Turn the wheel. It must move easily.
Page 40
Maintenance Installing the non-powered wheel
Only for derailing protection device

This work step only applies if the end carriage has a Buffer plate
derailing protection device.
Small side

Slide the buffer plate onto the threaded bolt.
From size 160: Fit the plastic washers (4x) in
place.
Large side Inner side Tightly screw the self-locking nuts M10 (4x).
Rotate the derailing protection device in such 6 Nm.
a way that the large side faces inwards
(towards the crane travel drive).
Insert the derailing protection device.
Inspecting the crane
Replace the crane on the crane track.

Tightening

Wheel
Put the crane into operation.

torque

Type
Inspect the function of the wheel.

Kind

screw
or screw
M20x70
or screw
M20x70
Page 41
Replacing the cross-type limit switch Maintenance
4.7 Replacing the cross-type limit 4.8 Wiring diagram of the cross-type
switch limit switch
If the cross-type limit switch is damaged, it must be

replaced. The plug-in connection allows you to carry
out the replacement without any wiring work.
Danger due to malfunction!

If the cross-type limit switch is
screwed on too tightly, the parts on
the inside can become jammed and
no longer function properly.
The contact numbering shown on the wiring
The tightening torque of 4 Nm must
diagram starts on the left ascending from 1.
be precisely observed.
The designation of the microswitches starts
on the left of the installation position with S1.
Coupling
Switch position
Position arrow
S1 closed
S2 closed
S3 closed
S4 closed
S1 open
S2 open
S3 open
S4 open
0 0 3.4 5.6 7.8 9.10
1 90 3.4 5.6 7.11 9.10
2 180 3.4 5.6 7.11 9.12
Cable fitting Cover
3 270 3.1 5.6 7.8 9.12
Unscrew and remove the screws (2x) on the
cover. 4 360 3.1 5.2 7.8 9.10
Remove the cover. 5 450 3.4 5.2 7.8 9.10
Disconnect the coupling of the connecting 0 540 3.4 5.6 7.8 9.10
cable from the circuit board.
The cable fitting on the cover does not need
to be unscrewed. The existing cover can be
fitted with the attached connection cable to a
new cross-type limit switch.
Insert the coupling onto the new cross-type
limit switch.
Close the cover.
Tighten screws (2x). 4 Nm.
Page 42
Maintenance Checking after a lightning strike
4.9 Checking after a lightning strike 4.10 Screwing with tightening

torque
If a crane has been struck by lightning or if it is
suspected that a crane has been struck by lightning,
the following points must be checked:
Bearing bolt
Inspect the wire rope. See General Product
Manual for ABUS Cranes.
Move the crane and trolley and listen out for
unusual noises made by the wheels and
wheel bearings.
Check the crane completely for the correct
function. In particular, check hoist limit
switches, travel limit switches, overload
protection and all the other safety devices.
See General Product Manual for ABUS
Cranes.
Tightening torque
Type, size and
Number
length
Size
130 Rib screw M8x25 5x 42 Nm

Page 43
Screwing with tightening torque Maintenance
Bearing flange Guide rollers, clamping piece,

derailing protection device
Tightening torque
and length
Tightening
Type, size
Type, size and
Number
torque
Size
Number
length
Size

130 Rib screw 7x 42 Nm 160 Rib screw M10x50 2x 85 Nm
M8x25 200 Rib screw M10x50 2x 85 Nm
160 Rib screw 7x 42 Nm 280 Hexagon head screw 2x 130 Nm
M8x25 M12x60
M10x30 M20x75 or M20x70
M12x40 M20x75 or M20x70
350 Rib screw 10x 130 Nm
M12x40
420 with crane Rib screw 10x 330 Nm
travel drive 420 M16x40 Buffer plate
420 with crane Rib screw 10x 330 Nm
travel drive 420 V M16x70
(adapter required)
Self-locking nut M10

From size 160: Plastic washers
4x per buffer plate
6 Nm
Page 44
Maintenance ABUS Service
Crane travel drive AZP

4.11 ABUS Service
Only in Germany
If available, have the product number, serial

number and customer number handy.
Call the ABUS Service Centre:
Phone: +49-2261-37-237
Type, size and
If calling outside the usual business hours,

Tightening

Number
machine.
torque
length
Size

If necessary, send a problem description by
200 Rib screw M12x30 4x 115 Nm fax or e-mail:
280 Rib screw M16x40 4x 300 Nm Fax: +49-2261-37-265
E-mail: service@abus-kransysteme.de
Crane travel drive AZF

Only outside Germany
Call the local ABUS branch or crane service

partner.
partner will provide details of contact data,
Type, size and
Tightening
Number
torque
length
Size
350 Fillister-head 4x 85 Nm
screw M12x100
420 with crane Fillister-head 4x 85 Nm
travel drive 420 screw M12x100
420 with crane Fillister-head 4x 210 Nm
travel drive 420 screw M16x140
V (adapter
required)
Page 45
Only with AZF and AZF V drives

4.12 Lubricants
drive gear unit,
Note:
pins on the gear unit
Synthetic lubricants may not be mixed with mineral-
based lubricants!
Only with AZP drives

gear unit of the drive

AN 6758.

Lubrication ex works with Moly Paul PBC completely.
AN 6758.
Quantity: Apply lubricant with brush to coat surface Lubricate pins:

completely.
When the gear unit is disassembled and
reassembled
Lubricate the gearing on the output shaft: Lubricate the gearing on the output shaft:
When the drive is disassembled and When the drive is disassembled and
reassembled reassembled
After 10 years After 10 years
When carrying out a general overhaul. When carrying out a general overhaul
Page 46
AN 120139EN006 2016-03-17
Kransysteme
Product Manual
AZP and E drive

Drive for crane or trolley

Sonnenweg 1
110-034551 51647 Gummersbach Germany
Serial number Tel. +49-2261-37-0
250-068733 Fax. +49-2261-37-247
Installing the drive (page 8)

Connecting the drive to an ABUS crane (page 9)
Overview (page 14)
Checking the air gap and brake lining thickness (page 16)
Setting the air gap on the brake (page 19)
Replacing the brake lining and anchor plate (page 20)
AN 120009EN001 2013-12-18 Original operating instructions
Drive: various types and sizes
This product manual applies to drives of various types and sizes. The work steps described and the technical data
will vary according to the type and size of the drive. The areas of this product manual which do not apply to all
drives, but are applicable only under certain conditions, are enclosed in a dashed box. At the start of the box, the
types and sizes to which the section is applicable are specified.
Type and size
AZP drive AZP drive AZP E drive

for single girder travelling cranes and for double-rail trolleys (types D, DA, for single-rail trolleys (type E) and
double girder travelling cranes DQA, Z and ZA) and side-mounted lower flange trolleys (type U)
trolleys (type S)
Size = wheel diameter Size = wheel diameter
130, 160, 200, 280 Size = wheel diameter 100, 130, 160, 200
130, 160, 200, 280
Contents
Contents
3.1 At the start .............................................. 15
1. GENERAL INFORMATION..................... 4 3.2 Scope of the inspection .......................... 16
1.1 At the start ................................................ 4 3.3 Checking the air gap and brake lining
thickness ................................................ 16
1.2 Instructions regarding safety .................... 5
3.4 Checking the O-ring................................ 17
1.3 The drive .................................................. 5
4. MAINTENANCE ............................... 18
1.4 Loading and unloading the drive............... 6
4.1 Instructions regarding safety when
1.5 Disposing of the drive ............................... 7 performing maintenance work ................ 18
2. INSTALLING AND CONNECTING ............ 8 4.2 Setting the air gap on the brake ............. 19
2.1 Installing the drive..................................... 8 4.3 Replacing the brake lining and anchor
plate........................................................ 20
2.2 Connecting the drive to an ABUS
crane ........................................................ 9 4.4 ABUS Service ......................................... 23
2.3 Connecting the drive to a non-ABUS 4.5 Lubricants ............................................... 23

crane ...................................................... 11
2.4 Overview of tightening torques ............... 14
3. INSPECTION .................................... 15
Page 3
This section applies to anyone who works with the drive, on the drive or nearby.

hazards for persons and provides
instructions for avoiding these
hazards.
Proper use
The AZP drive is planned as a crane travel drive (up

to a wheel diameter of 280 mm) or as a trolley drive
Danger from electric shock! on a double-rail trolley (types D, DA, DQA, Z and
This warning notice indicates ZA) or as a trolley drive on a side-mounted trolley
hazards for persons due to incorrect (type S).
handling of the electrical system The E drive is planned as a trolley drive on a single-
and electricity. rail trolley (type E) or as a trolley drive on a lower
flange trolley (type U).
The output shaft of the drive is connected directly
with the wheels.
load! The drive control can be connected pole-
changeable with two different travel speeds,
This warning notice describes with a defined speed or infinitely variable with
hazardous situations that can lead a frequency converter.
to the suspended load falling. The drive can be used as a drive in other
machines within its electrical and mechanical
performance limits.
This is an instruction regarding an action and The drive cannot be operated in a delta
prompts you to perform a work step. connection.
This is the result of an action and describes
what happens on the device.
This is a list.
Only with...
A section enclosed in a dashed box is only
applicable for certain types, versions or options.
Which type, version or option this is can be seen in
the first line. You can find out whether or not the
section is applicable for your crane by referring to
the section Various types, sizes, versions and
options at the beginning of this manual.
Page 4
General information Instructions regarding safety
Regulations
1.2 Instructions regarding safety
The installation has been built and tested according
to European standards, rules and regulations
applicable at the time of its manufacture. The Observe these instructions for safe handling of the
conventions applied during design and construction crane. Special hazard notices are located in the
are specified in the Declaration of Conformity or the corresponding sections in which the danger arises.
Declaration of Incorporation. The conventions must
also be observed for installation, operation,
inspection and maintenance, as must the applicable Danger through rotating parts! If a drive is
occupational health and safety regulations. not mounted, the output shaft is not
protected. If the non-mounted drive is
operated, the output shaft is a source of
Danger to persons! danger (e.g. it can become caught in loose
Non-observance of the regulations parts). Do not operate the drive if it is not
mounted or take suitable measures to ensure
can result in the death of persons or safety.
serious accidents.
Do not permanently remove the fan cover! If
To ensure work safety, thorough the fan cover is removed, hazardous areas
instruction in regard to this product (fast-rotating fan blades) are no longer
manual and the regulations is protected. As a result of this people can be
injured! Remount the fan cover after working
necessary. on the drive. Do not permanently remove the
fan cover to improve cooling.
Which provision applies in individual cases will

greatly depend on the cranes use and the national
regulations. Review and observe all applicable and
current regulations, including the occupational
health and safety regulations. Refer also to the
1.3 The drive
Declaration of Conformity or Declaration of
Incorporation.
Warranty 1 2 3
ABUS assumes no liability for damages that

were caused by improper use, inadequately
trained personnel, incorrect performance of
work, as well as any changes, reconstruction
or other modification of the crane or crane
components which was not approved by
ABUS.
Any warranty claim becomes invalid if
installed, used or serviced in any way other 5 4
than that described in this product manual, or
parts were used. 1: Fan cover
Safe operation of the crane or crane 2: Connector housing
components is only guaranteed if original
ABUS replacement parts are used. 3: Output shaft with gearing
4: Gear unit
5: Motor
Page 5
Loading and unloading the drive General information
Performance features
1.4 Loading and unloading the drive
The AZP and E drives:
The drives are designed as pole-variable
rotary current motors with electromagnetic
brakes and gear units.
Observe the following points amongst
others:
The drives have a low and a high speed. The
ratio of the two speeds is 1:4.
The drives have a modular construction of Only with AZP 130 and 160 drives
motor and gear unit to enable easy and E 100, 130, 160 and 200 drives
replacement.
Using plug-in connections in the connector
No eyebolts can be screwed into the drive.
housing directly on the drive, the drives can
be quickly separated from the rest of the
cranes electrics. Sling the drive in suitable lifting tackle (e.g.
The drive's gear unit is a maintenance-free, round slings).
two-stage or three-stage planetary gear.
Two drives are used for crane travel on a
crane. One or two drives are used for trolley
travel on a trolley. Only with AZP 200 and 280 drives
The crane can also be equipped with four
crane drives (4-wheel crane travel drive, all- Lifting tackle
wheel. Optional). This is required whenever
the crane travel drive needs to be particularly
sturdy (e.g. for operation outdoors with a
headwind, or travelling through curtains)
Technical data
See the Technical data of the respective drive.

Eyebolt Drive
Screw suitable eyebolt into the drive.
Sling suitable lifting tackle into the eyebolt.
The drive will not be suspended horizontally
depending on the motor.
Page 6
General information Disposing of the drive
1.5 Disposing of the drive
If the drive must be disposed of:
Dismantle the drive as far as possible.

Observe local regulations concerning
disposal and recycling.
Dispose of the individual parts sorted by
material in an environmentally sound
manner.
Dispose of metal parts as scrap metal.
The motor stator is permanently shrunk into
the housing. Cut the housing open to
separate the stator from the housing.
Plastic parts should be recycled with plastic
waste.
Dispose of brake linings as multiple
components (hazardous waste).
Remove oil or grease from the drive and
dispose of as a lubricant.
Dispose of cables and plug-in connections as
scrap electronic parts.
Page 7
Installing the drive Installing and connecting
2. Installing and connecting

This section applies to anyone who works on the drive prior to its use
To install, perform the described points here in the

sequence given.
2.1 Installing the drive

proper qualifications of the commissioning
personnel.
The images show the installation of an AZP drive on
a crane. There is no major difference between the
Danger to persons! installation of an AZP drive on a double-rail trolley or
Persons can be injured if the crane side-mounted trolley or an E drive on a single-rail
is incorrectly put into operation. trolley or lower flange trolley.

ABUS company are employed to Only for a drive which is installed
perform the commissioning, it is the on an ABUS crane
end users responsibility to ensure
that these persons are adequately Determine the weight of the drive. See the
qualified. Follow the procedures Technical data section Dimensions and
described here precisely. weights.
Secure the drive in such a way that the
weight can be held safely and the output
shaft is not stressed during installation (e.g.
Examples of qualified persons: fasten in a carrying strap).
cranes.
Persons receiving regular training from Lubricate the gearing on the output shaft.
ABUS. Apply lubricant with brush to coat surface
completely.
Recommendation: Moly Paul PBC
ABUS assumes no liability for damage due to AN 6758.
incorrectly performed commissioning work done by
ABUS recommends having the commissioning work
Page 8
Installing and connecting Connecting the drive to an ABUS crane
Rib screws
2.2 Connecting the drive to an
ABUS crane
Opening the connector housing
Open the housing cover.

Take out the intermediate plate.
Drive Laying the connection cable

Push the drive in the wheel.
Bolt on the drive with the rib screws (4x).
Wheel Drive Type Tightening Connection cable
torque
130 AZP M8x20 35 Nm
160 AZP M10x25 75 Nm
200 AZP M12x30 115 Nm
280 AZP M16x40 300 Nm
Tightening torque
Wheel diameter
Connector housing Drive

Lay the connection cable for the drive.
Drive
Type
housing.
100 E M8x20 35 Nm
130 E M8x20 35 Nm
160 E M8x20 35 Nm
200 E M10x25 75 Nm
Page 9
Connecting the drive to an ABUS crane Installing and connecting
Connecting the drive Only with frequency converter
Only with contactor control Bush multipoint Pin multipoint

connector for drive connector on the drive
Connection cable Pin multipoint

of drive connector of drive
Bush multipoint Pin multipoint

connector for drive connector on the drive
Insert the bush multipoint connector for the
drive on the pin multipoint connector on the
Rectifier for brake Pin multipoint drive.
connector of drive
Insert the connection cable for the drive in Insert the bush multipoint connector for the
the pin multipoint connector on the drive. brake on 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.
Cable lug for shield

Insert the cable shoe for the shield on the
drive.
Lay the plug-in connections and connection
cable in the connector housing.
Intermediate plate
Press the intermediate plate in.

Close the housing cover.
Page 10
Installing and connecting Connecting the drive to a non-ABUS crane
Low and high speed:

2.3 Connecting the drive to a non-
ABUS crane
The drive is connected in the connector

housing on the drive using a plug-in
connection.
The plug-in connection is available as a set,
AN 105581.
When connecting, ensure that the rectifier for
the brake is provided with alternating current
in the connector housing with the drive
switched on. This will require a jumper in the
circuitry.
The drive can be connected three ways:
pole-changeable (high and low speeds), with
only one of the two speeds, and through a
frequency converter.
The drive cannot be operated in a delta
connection.
Heed the duty cycle of the drives for high and
low travel speed.
M61: Crane drive 1, M62: Crane drive 2, V61 and

V62: Rectifier, U61: Smooth switching relay, K63:
Contactor for high speed, K62: Contactor for crane
travel forward, K61: Contactor for crane travel
backward
Connect the protective conductors to both

drives.
Connect contacts 1, 2 and 3 for low speed.
Connect contacts 4, 5 and 6 for high speed.
When switching from low to high speed
(contactor K63) plan a delay of 0.5 seconds
in the circuit. The delay avoids the drive
running in a starting current for a longer
period in inching mode (rapid switching back
and forth). This would eventually damage the
motor.
Page 11
Connecting the drive to a non-ABUS crane Installing and connecting
To prevent excessive fluctuation of the load

during braking from high speed to low speed,
plan the SU1 device. When braking from the
High speed only:
high to low speed, for a short period only two
of the three phases of the drive are switched
to the low speed. In doing so, the drive does
not jerk to a halt but brakes softly.
When high speed is switched (contactor K 63
switched) always switch a single phase of
the low speed as well (contact 1). Otherwise
there will be no voltage between the star
points of the high speed and the low speed
and the brake will not be aerated.
When low speed is switched (contactor K 63
not switched) always switch a single phase
of the high speed as well (contact 6).
Otherwise there will be no voltage between
the star points of the high speed and the low
speed and the brake will not be aerated.
M61: Crane drive 1, M62: Crane drive 2, V61 and

V62: Rectifier, K62: Contactor for crane travel
forward, K61: Contactor for crane travel backward

drives.
Connect contacts 4, 5 and 6 for high speed.
When high speed only is switched, always
switch a single phase of the low speed as
well (contact 1). Otherwise there will be no
voltage between the star points of the high
speed and the low speed and the brake will
not be aerated.
When switching the drive to high speed (from
standstill), allow the drive to run at low speed
for 0.5 seconds first. The dlay avoids the
drive running in a starting current for a longer
period during switch-on. This would
eventually damage the drive.
Page 12
Installing and connecting Connecting the drive to a non-ABUS crane
Frequency converter:
Low speed only:
drives.
Connect contacts 1, 2 and 3 for low speed.
When low speed only is switched, always
switch a single phase of the high speed as
well (contact 6). Otherwise there will be no
voltage between the star points of the high
speed and the low speed and the brake will
not be aerated.
M61: Crane drive 1, M62: Crane drive 2, V61:

Rectifier, U61: Frequency converter
Connect the shields for the connection

cables to the protective conductor on the
drive.
Only use shielded connection cables for the
drives.
drives.
Connect contacts 4, 5 and 6.
Connect contacts 7 and 8 for the brake
control. The electrical circuit must be open at
a frequency of 0 Hz.
Brake performance data: 195 Volt DC,
50 Watt.
Page 13
Overview of tightening torques Installing and connecting
E drive
2.4 Overview of tightening torques
AZP drive
and length
Tightening
Type, size
and length
Tightening
Type, size
Number
torque
Number
torque
Size
Size

Page 14
Inspection At the start
3. Inspection
Concerns anyone who inspects and accepts the drive in accordance with occupational health and
safety requirements.
The drive must be regularly inspected in order to

guarantee safe operation. The end user is
responsible for this regular inspection.
Requirements for the examiner

3.1 At the start proper qualifications of the examiner.
Danger to persons!
Test intervals Persons can be injured if the
The regular inspection is performed at least once
annually.
Under certain conditions, more frequent regular perform the inspection, it is the end
inspections may be necessary. Reasons include:
user's responsibility to ensure that
Frequent operation at the load capacity these persons are adequately
Working in multiple shifts qualified.
Frequent use
prerequisites and determining the test intervals. Examples of qualified persons:
ABUS will gladly assist you if questions arise.
cranes.
ABUS.
Page 15
Scope of the inspection Inspection
3.2 Scope of the inspection 3.3 Checking the air gap and brake
lining thickness
The qualified person inspecting the drive is

responsible for the type and scope of the test. Overview:
Dimension Value
Overview: Inspecting the drive Reference gap between Between 3.1 mm and
anchor plate and brake 3.7 mm
In addition to the points described here, all points bearing shield
outlined in the other supplied product manuals must Brake lining thickness At least 2 mm
also be checked.
Brake lining thickness New: 4 mm
The decision as to whether the drive is in perfect
inspecting the crane. Any inadequacies, if found,
must be eliminated. The examiner decides whether
the drive has to be tested again afterward.
these are likewise to be carried out.

checked:
Check the air gap and the brake lining

thickness. See Checking the air gap and
brake lining thickness page 16. Fan cover
Check the O-ring. See Checking the O-ring Take off fan cover.
page 17.
The air gap can only be accessed with difficulty.

Therefore, a reference gap is measured outside on
the motor in order to obtain information on the width
of the air gap.
Page 16
Inspection Checking the O-ring
Measuring the reference gap

3.4 Checking the O-ring
The area between the brake bearing shield and the

anchor plate (reference gap) is protected from dust
by an O-ring. The O-ring must not become
damaged or missing.
Anchor plate Brake bearing shield
Reference gap
Measure the distance between brake bearing
shield and anchor plate.
If the reference gap is larger than 3.7 mm:
adjust the brake. See Setting the air gap on
the brake, page 19. The brake may be
readjusted twice. After that, the brake lining
must be replaced. See Replacing the brake
lining and anchor plate, page 20. O-ring
Check the O-ring (between brake bearing
shield and anchor plate).
The O-ring must not be torn, dented or
Measuring brake lining thickness damaged in any other way or be missing
completely.
If the O-ring is damaged or missing, fit a new
O-ring. See Replacing the O-ring, plate
springs, compression springs and feather
key page 20.
Brake lining
Check the thickness of the brake lining with a
calliper.
If the brake lining is less than 2 mm thick,
replace it. See Replacing the brake lining
and anchor plate, page 20.
Page 17
Instructions regarding safety when performing
maintenance work Maintenance
4. Maintenance
Concerns anyone who maintains, repairs or modifies the drive.
The end user of the crane is responsible for the 4.1 Instructions regarding safety
selection and proper qualifications of the when performing maintenance work
Danger to persons! Please follow the following safety instructions during

Persons can be injured if the crane all repair work on the drive:
is incorrectly serviced.
If personnel other than that of the Switch off the mains switch. Secure the
ABUS company are employed to switch so that it cannot be unintentionally
perform maintenance on the crane, switched back on.
it is the end user's responsibility to Pull the mains disconnector plug out of the
ensure that these persons are socket on the crane panel. Secure the socket
adequately qualified. Follow the with a padlock so that the mains
procedures described here disconnector plug is not unintentionally re-
inserted.
precisely.
Use suitable lifting platforms and fall
protection equipment.
Adequately cordon off the work area around
Examples of qualified persons: the lifting platform.
Persons with comprehensive knowledge Switch off any other cranes using the same
from specialist training in engineering and in crane track or cranes working above or
the electrical systems of cranes. below the crane being serviced. Secure the
Persons with sufficient experience in the switch so that it cannot be unintentionally
operation, installation and maintenance of switched back on. Otherwise, other cranes
cranes. could overturn the hoisting platform or crash
into the crane that is being serviced.
regarding the relevant technical rules, Notify personnel in the area that
directives and safety regulations applicable maintenance work will be performed.
in the respective country. Only trained electricians should work on the
Persons receiving regular training from crane electrical system!
ABUS. Even after the emergency stop button has
been pressed, life-threatening high voltages
are still present in the panels.
ABUS assumes no liability for damage due to
incorrectly performed maintenance work done by
These safety instructions apply especially
ABUS recommends having the maintenance work to the drive:
Do not permanently remove the fan cover! If
Use only original ABUS replacement parts. the fan cover is removed, hazardous areas
Otherwise, all warranty claims will be rendered (fast-rotating fan blades) are no longer
invalid. protected. As a result of this people can be
injured! Remount the fan cover after working
on the drive. Do not permanently remove the
fan cover to improve cooling.
Page 18
Maintenance Setting the air gap on the brake
4.2 Setting the air gap on the brake

The self-locking nut is now released in order to
optimally adjust the air gap of the brake. The
releasing of the self-locking nut is oriented to the
individual segments of the fan blade.
If the air gap is narrower than permitted, it must be
readjusted. The air gap may be readjusted
maximally twice. After that, the brake lining must be
replaced. See Replacing the brake lining and
anchor plate, page 20.
Overview:
Dimension Value
Reference gap between Between 3.1 mm and
brake bearing shield and 3.7 mm
anchor plate.
Air gap Setting 0.4 mm
Hold the fan blade firmly and release the
self-locking nut by the amount of two and
one half segments of the fan blade.
Setting the air gap The air gap is now set to the optimal width of
0.4 mm.
To make sure, check that the distance
between the brake bearing shield and the
anchor plate (reference gap) is between
3.1 mm and 3.7 mm. See Checking the air
gap and brake lining thickness, page 16.
Close motor
Nut
Hold the fan blade firmly and screw the self-
locking nut until hand-tight. The fan blade
should just be tight enough that it almost
cannot be turned.
The air gap is now set to 0 mm. This serves
as the starting point for the following setting.
Fan cover
Attach fan cover.
Page 19
Replacing the brake lining and anchor plate Maintenance
4.3 Replacing the brake lining and Removing the anchor plate
anchor plate
When replacing the brake lining, it is useful to
replace the anchor plate as well. If the anchor plate
is not to be replaced, this section may be skipped.
If the brake lining is thinner than permitted, it must
be replaced. The brake lining must also be replaced Anchor plate
if the air gap has already been readjusted twice.
When replacing the brake lining, it is recommended
that the anchor plate be replaced as well.
Removing the old brake lining
Fan blade with brake lining
Collar screws
Screw the collar screws (2x) out.
The anchor plate is pressed away from the
motor. It is tensioned by a spring.
Remove the anchor plate. Ensure that the
compression springs do not fall out.
Replacing the O-ring, plate springs,

Self-locking nut
compression springs and feather
Hold the fan blade firmly and unscrew the
self-locking nut. key
Remove the fan blade with brake lining.
If the O-ring, plate springs, compression springs or
the feather key are missing or damaged, they must
be replaced. If the components are in a good
condition, this section may be skipped.
Plate springs
Assemble the plate springs as shown in the

illustration.
Page 20
Maintenance Replacing the brake lining and anchor plate
Feather key Plate springs

Installing the anchor plate
Compression springs
Insert new anchor plate and press it against
the compression springs.
O-ring Compression springs

Tighten the collar screws (2x). 5 - 7 Nm.
Secure with thread-locking compound
Push the plate springs onto the motor shaft. (medium tightness).
Insert the feather key.
Place the O-ring into the groove on the brake
bearing shield.
Insert the compression springs.
compression
Type & size
Power (see
type plate)
Number of
springs
E 100 0.12 kW 4
E 130 / AZP 130 0.18 kW 4
E 160 / AZP 130 0.28 kW 6
AZP 130 0.37 kW 8
E 200 / AZP 160 0.48 kW 4
AZP 200 / AZP 280 0.65 kW 4
AZP 200 / AZP 280 0.80 kW 6
AZP 280 1.10 kW 8
Page 21
Replacing the brake lining and anchor plate Maintenance
Installing a new brake lining
Fan blade with brake lining
Hold the fan blade firmly and release the

self-locking nut by the amount of two and
one half segments of the fan blade.
The air gap is now set to the optimal width of
0.4 mm.
To make sure, check that the distance
Motor shaft between the brake bearing shield and the
Slide the new fan blade with brake lining onto anchor plate (reference gap) is between
the motor shaft. 3.1 mm and 3.7 mm. See Checking the air
gap and brake lining thickness page 16.
Screw the new self-locking nut loosely to the
motor shaft.
Do not use the old self-locking nut.
Closing the motor
Setting the air gap
Fan cover
Attach fan cover.
Nut
Hold the fan blade firmly and screw the self-
locking nut until hand-tight. The fan blade
should just be tight enough that it almost
cannot be turned.
The air gap is now set to 0 mm. This serves
as the starting point for the following setting.
The self-locking nut is now released in order to

optimally adjust the air gap of the brake. The
releasing of the self-locking nut is oriented to the
individual segments of the fan blade.
Page 22
Maintenance ABUS Service
4.4 ABUS Service 4.5 Lubricants
Gear unit in drives E 100, E 130,

Only in Germany E 160, E 200, AZP 130, AZP 160,
AZP 200, AZP 280
If available, have the product number, serial
number and customer number handy.
Call the ABUS Service Centre:
Phone: +49-2261-37-237
If calling outside the usual business hours,

machine.
If necessary, send a problem description by

fax or e-mail: Lubrication ex works with Klber Centoplex CX
4/375
Fax: +49-2261-37-265
E-mail: service@abus-kransysteme.de
Only outside Germany Quantity AZP 130: 50 g
Call the local ABUS branch or crane service Quantity AZP 280 (gear ratio 125): 240 g
partner. Quantity AZP 280 (gear ratio less than 125): 160 g
partner will provide details of contact data,
entire service life. At the end of its service life
(in a general overhaul), assess whether the
Page 23
Gearing on the output shaft

AN 6758.

completely.

When the drive is disassembled and
reassembled
After 10 years
Page 24
AN 120009EN001 2013-12-18
Kransysteme
Technical data
for
ABUS Travelling crane
with wheel diameter - 160
Factory No. ___________________

110-034551
Manufacturer
ABUS Kransysteme GmbH Tel. ##49 2261 / 370
Sonnenweg 1 Fax. ##49 2261 / 37247
D 51647 Gummersbach info@abus- kransysteme.de
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to
pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an English-
speaking country by Englishspeaking specialist personnel.
AN 120069.002_EN 31.10.2016 Original operating manual
Contents
1 Technical Data . . . . . . . . . . . . 3 1.3.1 Lubricants Used in
Crane Travel Drives . . . . . . . . . . . . . . . 4
1.1 Tightening torque . . . . . . . . . . . . . . . . 3
1.3.2 Alternative Lubricants . . . . . . . . . . . . . 4
1.2 Sound Emissions . . . . . . . . . . . . . . . . . 4 1.4 Electrical Data of Motors . . . . . . . . . . 5
1.3 Lubricants . . . . . . . . . . . . . . . . . . . . . . . 4 1.5 Weights and Dimensions . . . . . . . . . . 6
AN120069.002_EN Page 2
1 Technical Data
1.1 Tightening torque
120 Nm
80 Nm
450 Nm
50 Nm
36 Nm
75 Nm
42 Nm2)
25 Nm
Fig. 1
AN120069.002_EN Page 3
1.2 Sound Emissions 1.3 Lubricants
As the distance between the noise source and the
workplace is normally not fixed in the case of cranes, 1.3.1 Lubricants Used in Crane Travel
the sound power level is quoted in addition to the re- Drives
quired sound pressure level figure (given for a distance
All ball bearings are permanently lubricated.
of 3 m in this case).
All gearboxes have been filled with the required amount
The sound power level may be used to calculate the
of lubricant at the factory.
sound pressure level at any distance (under free field
conditions). Travel dri- Quantity
Lubricants ex works
ve [litres]
Sound pressure Sound power
Travel drive AZP 160 Klber Centoplex CX 4 / 375 0.10
level level
Type
LP,m dB (A) at 3 m LW,m dB (A) The pinion connecting the motor shaft to the wheel has
AZP 160 60 77 been lubricated with Moly-Paul PBC grease at the fac-
tory.
The measurements made were based on DIN 45635,
Part 61 and were made by the substitution method 1.3.2 Alternative Lubricants
using a sound power source. for Moly-Paul grease PBC
The values given only apply to the crane travel drives. D DEA Glissando M EP 2
The values which apply to the hoist are given in the ap- D Klber Klberpaste 46 MR 401
plication operating instructions. D Moly-Cote DX
D Shell Retinax LX2
D or equivalent greases of other brands with the des-
ignation GP 00 K-45 in accordance with DIN 51502.
for Klber Centoplex CX4 / 375

D BP Energrease CS 0
D DEA Glissando EP 0
D Shell Alvania EP (LF) 1
D or equivalent greases of other brands with the des-
ignation KOK-35 or GOK-35 in accordance with DIN
51502.
Caution !
Synthetic oils must not be mixed with mineral-
based oils.
Page 4 Data : 31.10.2016

1.4 Electrical Data of Motors
The serial number of your crane drive motor is given in the travelling crane data sheet in the test book.
AZP 160
Operating voltage V 220-240 380-415 460-500 208-230 440-480 550-600
Frequency Hz 50 50 50 60 60 60
Duty cycle FEM % 40 40 40 40 40 40
Travel speed m/min 5/20 6/24

Part number AN 313818 313818
Operating frequenzy FEM c/h 240 240
Motor rating kW 0.10/0.48 0.12/0.58
Motor speed 1/min 550/2760 735/3370
Starting current A 0,92/5,90 0.96/6.50
Rated current A 0,53/1,59 0.54/1.63
Power factor - starting 0,71/0,91 0.64/0.88
Power factor - norm. operation 0,66/0,80 0.65/0.83
Travel speed m/min 7,5/30 9/36

Motor rating kW 0.10/0.48 0.12/0.58
Motor speed 1/min 550/2760 735/3370
Rated current A 0,53/1,59 0.54/1.63
Travel speed m/min 10/40 12/48

Motor rating kW 0.10/0.48 0.12/0.58
Motor speed 1/min 550/2760 735/3370
Rated current A 0,53/1,59 0.54/1.63
Travel speed m/min 12,5/50 15/60

Motor rating kW 0.10/0.48 0.12/0.58
Motor speed 1/min 550/2760 750/3370
Rated current A 0,53/1,59 0.54/1.63
AN120069.002_EN Page 5
AZP 160
Operating voltage V 220-240 380-415 460-500 208-230 440-480 550-600
Frequency Hz 50 50 50 60 60 60
Duty cycle FEM % 40 40 40 40 40 40
Travel speed m/min 15/60

Part number AN 314280
Operating frequenzy FEM c/h 150
Motor rating kW 0.10/0.48
Motor speed 1/min 550/2760
Starting current A 0,92/5,90
Rated current A 0,53/1,59
Power factor - starting 0,71/0,91
Power factor - norm. operation 0,66/0,80
1.5 Weights and Dimensions Travel drive Weight

The weights, dimensions, etc. of the travelling crane Type [kg]
and the load data for the crane track are given in the
AZP 160 30
data sheet and the corresponding diagram in the test
book.
The weights of crane travel motors are given in the fol-
lowing table:
Page 6 Data : 31.10.2016

Kransysteme
Installation Instructions
for
E D DQA
Z S U
ABUS Wire rope hoist
-E -Z
Model -D -S
- DQA -U
250-068733
Serial No. __________________
Manufacturer
Sonnenweg 1 Fax. ##49 2261 / 37247
D 51647 Gummersbach info@abus-kransysteme.de
AN 120055.002_EN / A 766.EN 30.03.2012 Original operating manual
Explanations concerning type designationas
GM 2000.6300 H 20 1. 4 1. 6000.3. E 160.20
travel speed (m/min)

track wheel diameter (mm)
trolley type: E; D, DQA, DB; Z, ZB; S; U
model generation
hook path (m)
strands under tension
load strands
motive power unit group
rope speed (m/min)
type of motor
load capacity (kg)
model size
line of products
Page 2 Data : 30.03.2012

Contents
1 Description . . . . . . . . . . . . . . . 4 1.2 Electrical equipment . . . . . . . . . . . . . . 5
1.1 Components . . . . . . . . . . . . . . . . . . . . . 4 1.2.1 Wire rope hoist . . . . . . . . . . . . . . . . . . . 5
1.1.1 Trolley frame . . . . . . . . . . . . . . . . . . . . . 4 1.2.2 Solotrolleys (not for size GM 7000) 5
1.1.2 Hoist motor with brake . . . . . . . . . . . . 4
1.1.3 Hoisting gear . . . . . . . . . . . . . . . . . . . . 4
1.1.4 Rope drive . . . . . . . . . . . . . . . . . . . . . . . 4 2 Assembly . . . . . . . . . . . . . . . . . 8
1.1.5 Limit of lift . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Assembly Instructions . . . . . . . . . . . . . 8
1.1.6 Overload protection type . . . . . . . . . . 5 2.1.1 Mechanical installation . . . . . . . . . . . . 8
1.1.7 Trolley travelling gear . . . . . . . . . . . . . 5 2.1.2 Electrical installation . . . . . . . . . . . . . . 11
AN 120055.002_EN / A 766.EN Page 3

1 Description
1.1 Components (2) Washer HV 21
Material C 45 DIN 6916
(3) Hexagon nut M 20
Material 10 DIN 6915
1.1.1 Trolley frame (4) Connection plate Ultra sonical
S 235 JRG2 DIN EN 10025
1.1.1.1 Model E Note: Only bare, non-galvanized bolts may be used.
ABUS Series E electric wire rope hoists are equipped Position the main and trolley track girders with the holes
with a trolley frame made from welded steel sheets with matching and insert the high-strength connection bolts
an integrated counterweight. (1) (M20, material 10.9) through the hand holes into the
The track width can be adapted to all normal section trolley track girders. The washers (2) under the bolt
girders or steel sheet widths. head and the nut are essential for effective joints.
Tighten the nuts (3) from the outside using a torque
1.1.1.2 Model D, DQA and Z wrench.
ABUS Series D, DB and DQA electric wire rope hoists The torque required for the M20 bolts is 554 Nm.
are equipped with a trolley frame made from welded
steel sections or sheets. The bolts must not be tightened using power drills and
The connection between the main girder and the trolley the angle of rotation method must not be used.
track girder is jointed to ensure that all four wheels are After they have been tightened using the correct torque
evenly loaded when the hoist is not loaded. value, the main girder connection bolts may be loos-
ened and tightened again in the course of assembly.
1.1.1.3 Model S However, if the crane is dismantled after some time in
ABUS Series S electric wire rope hoists are equipped service, new bolts of the same quality must be used
with a trolley frame made from welded steel sections or when it is reassembled; the old bolts must be
sheets. scrapped.
The track width can be adapted to normal steel sheet In the case of larger bolt patterns, the bolts must be
widths. tightened alternately up to about 60 % of the specified
torque value and then tightened to the full value in a
1.1.1.4 Model U second step. The screws at the ends of the connection
assembly must be tightened to the full torque last.
ABUS Series U electric wire rope hoists are equipped
with a trolley frame made from welded steel sections or
sheets.
1.1.2 Hoist motor with brake
The hoisting gear is driven by a 12 pole, dual speed
1.1.1.5 Model GM 7000 squirrel cage motor with integral D.C. restified mag-
ABUS Series D, DB, DQA, Z and ZB electric wire rope netic disc brake. Insulation class F, protection type IP
hoists are equipped with a trolley frame made from 55. Due to the pole changing there is a standard preci-
welded steel sections or sheets. sion hoisting speed in the ratio of approx. 1:6 or approx.
The connection between the main girder and the trolley 1:10 to the main hoisting speed. The asbestosfree
track girder is jointed to ensure that all four wheels are brake lining achieves a service life of approx. 1x106
evenly loaded when the hoist is not loaded. shiftings.
In the case of type DQA, the connection between the
main girder and the end carriage is articulated on one
side and bolted on the other side. 1.1.3 Hoisting gear
The transmission of the motor speed to the rope drum
is effected through the spur gear in a light alloy casing.
The helical gear wheels are hardened and polished or
shaved and run in a closed oil bath with lifetime lubrica-
tion.
Fig 1 1.1.4 Rope drive

The rope drive corresponds to the FEMcalcuation
The contact surfaces on the trolley track girders and the
rules for series hoists. The load hook with safety catch
main girder connection plates (4) must be free from
complies with DIN 15400. None of the bearing points
rust, dust, oil, paint and other foreign matter. The con-
need maintenance. The rope guide is made of wear
tact surfaces are marked *** in Fig 1.
resisting, sliding synthetic material and provides
The bolted joint consists of the following components: troublefree rope reeloff and careful treatment of the
(1) Hexagon bolt M 20 rope and the rope drum. The hightensile hoisting rope
Material 10.9 DIN 6914 in special design has considerably higher breaking
Page 4 Data : 30.03.2012

resistance and life than a rope of conventional design changing, there is a standard precision hoisting speed
and structure. That is why only original ropes from the in the ratio of approx. 1:4 to the main hoisting speed.
manufacturers should be used as spare parts. The hoist is balanced at the factory by counterweight-
ing the side opposite the hoist motor.
1.1.5 Limit of lift

The lift is limited in the highest and lowest hook position 1.2 Electrical equipment
by means of a rotary geared limit switch directly ABUS wire rope hoist control units feature advanced
coupled to the rope drum. The standard hoist limit technology and cover a wide range of applications
switch (S31) comes with 3 switching contacts which thanks to their modular design.
have the following functions: Movement in all directions is possible in two---stage
1. upper limit safety switch lifting pole---changing operation.
2. emergency limit switch lifting All motors, power and control lines are connected
3. emergency limit switch lowering using plug---type connectors for easy maintenance.
The upper limit safety switch (S31.1) interrupts power Attention!
to the mainline contactor (K1). This switch point is set Work on electrical systems must be per-
by the manufacturer, sealed with lead, and must only formed only by qualified personnel. The
be reset by authorized personnel. If for any reason the power supply must be disconnected before
emergency limit switch (S31.2), fails to limit the travel starting work.
of the block in the up direction, the crane is shut down Details of the electrical equipment are given in the cir-
by this upper limit safety switch. Subsequent operation cuit diagram.
of the hoist should only be attempted by a trained ser-
vice technician.
If no additional operating limit switches are installed, 1.2.1 Wire rope hoist
the functions of the emergency limit switches must be
checked each time you start work. If the highest and/or
lowest hook position is reached in normal operation, 1.2.1.1 Contactor box
the switch or switching circuit must be designed for The contactor box is installed on the wire rope hoist and
normal shut ---down. The functions of the operating limit has IP 55 protection.
switches must be tested each time you start work. Reversing contactors are mechanically interlocked
In the case of type Z ABUS electric wire rope hoists with each other.
(twin hoists), this test, which must always be carried out The design of the control systems with ducted wiring
before starting work, also compensates for the winding and no fuses ensures ease of maintenance. Easy to as-
of the ropes on the two rope drums. This ensures that semble screwless terminals ensure reliable operation.
the rope is evenly wound on both drums. For this rea- Each drive system is largely protected against inadmis-
son alone, regular testing each time you start work with sible overloading by a standard motor circuit breaker or
the crane is already absolutely essential. an electronic overload protection device.
For adjustment of the hoist limit switch see Operating In order to prevent thermal overloading of the motor as
manual for Emergency limit switch in Section 2. a result of repeated inching operation, the changeover
contacts for pole---changing hoist and trolley travel mo-
tors are released with a time delay of 0.5 s.
1.1.6 Overload protection type
If required by standards or regulations, the hoists are
equipped with an overload protection device (see hoist 1.2.2 Solotrolleys (not for size GM
data sheet). Provided that the hoist is properly oper- 7000)
ated, this device prevents overloading of the hoist.
Attention!
Overload protection devices are safety sy- 1.2.2.1 Mains connection line
stems and must not be adjusted or overrid- Conductor cross sections for power supply circuits
den. from the distribution assembly via the mains switch to
Details of other types of overload safety devices are the contact conductor input terminals must be deter-
given in the separate operating instructions attached. mined by the operator. The mains power cable must be
sized so that the voltage at the contact conductor sup-
ply point does not fall below the minimum limit of the
voltage range even when the start ---up current (see
1.1.7 Trolley travelling gear
Technical Data section 1.3 Electrical Data of Motor-
Maintenancefree, directly driven flanged wheels s) of the hoist motor is flowing.
made by dropforging or of spherulitic graphite iron
and positioned in roller bearings assure good and
smooth running and also take care of the running 1.2.2.2 Mains switch
treads. The trolley drive wheels are directly driven by 2, In accordance with EN 60204, Part 32, it must be possi-
TEFC dual wound squirrel cage motors. D.C. rectified ble to disconnect a hoist using a mains switch and to
disc brakes are included as standard. Due to the pole lock out the power supply.
AN 120055.002_EN / A 766.EN Page 5

The mains switch is not included in hoist system (see The unit may be moved out of the advance slow ---down
circuit diagram) and is intended to disconnect the area at high speed in the opposite direction.
crane or hoist system from the power supply for repair Where there is a high risk or special safety circuitry is
and maintenance work. If necessary, this switch may required, an end shutdown system is used to slow
also be used for emergency shutdowns or emergency the system to a halt. A limit switch for both directions of
stopping. travel switches crane or hoist travel off. The crane can
Mains switches may be obtained from ABUS. then only be operated in the other direction. For
speeds above 30 m/min., an end shutdown system is
always combined with an advance slowdown switch.
1.2.2.3 Disconnector
The function of the disconnector, namely the discon-
nection of the hoist for repair and maintenance work, is 1.2.2.8 Pendant control
performed by the mains connector, A. Operation
The mains connector is installed on the wire rope hoist,
on contactor box SKA, with coding X0
For repair or maintenance work, the hoist or crane sys-
tem must be disconnected by unplugging the mains
connector. The mains connector can be secured
against unauthorized connection by up to three pad- 3
locks.
1.2.2.4 Crane switch

The crane switch is installed in the crane contactor box 4
(SKR) or the trolley contactor box (SKA) directly behind
the mains connector. The crane switch is a contactor
coded K1. The function of the crane switch is to cut
off power supply to all motors in the event of an emerg-
ency shutdown (see circuit diagram).
1.2.2.5 Contact conductor

The ABUS ASL safety contact conductor system is
used for solo trolleys. Four copper busbars (three 1
phase conductors + protective earth) with contact
protection are installed in the plastic housing. The con-
tact conductor is installed on mounting brackets paral-
2
lel to the crane or trolley track. The bracket spacing
must be 2000 mm or less.
The type of contact conductor depends on operating
conditions, the maximum admissible thermal load and
the maximum admissible voltage drop.
Startup current must be carefully evaluated taking the
high startup currents of motors with direct starting Fig 2
systems into account.
The drive of the change-pole motor is carried out by the

1.2.2.6 Contactor box two-step push buttons. A locking mechanism within
In the case of wire rope hoists installed on solo trolleys, the pendant control prevents a simultaneous activation
the contactor box (SKA) houses a standard fuse link as of two opposed moving directions. Jogging should be
the main fuse (F1), the main contactor (K1) and a con- avoided as this might cause contact burning and thus
trol transformer with fine fuses on the primary and sec- premature wear of the control gear.
ondary sides in accordance with the transformer rating.
For further information, please refer to Section 1.2.1.1 The following functions can be carried out by the pen-
dant control :
1.2.2.7 Trolley travel limit switch (optional) no pressure on push-button

Advance slowdown switches to slow the crane or standstill
trolley to low speed before the end of the track is
reached are normal practice. This configuration pre- pressed with half pressure (Fig 2.1)
vents the crane or hoist from being run against the end precision hoisting/slow travel
stops at high speed, causing severe load swinging,
with the attendant risk of damage and injury. A limit full pressure on push button (Fig 2.2)
switch recognizes the speed limit in both directions. main hoisting/fast travel
Page 6 Data : 30.03.2012

1.2.2.9 Replacing fuses
red emergency switch pressed (Fig 2.3) The main fuse (F1) is a standard fuse link. To replace
standstill, also if other button is the fuse, unscrew the safety cap, remove the old fuse
link and push in a new fuse link.
turn red emergency switch (Fig 2.4)
release of all functions The control circuit is protected by a fine fuse (F12) on
the secondary side of the control transformer and
B. Emergency stopping earthed on one side. The fuse is installed in the connec-
The emergency stopping function required by EN tion terminal strip directly on the transformer. To replace
60204, Part 32, is provided by a red mushroom switch the fuse, pull the fuse holder out of its mount, change
operated from ground level and from the point of oper- the fuse and push the fuse holder back into place.
ation.
Attention! Fuses F10 and F11 are mounted on the contactor box
An emergency stop is not the same as an terminal strip. To replace these fuses, swing the fuse
emergency shutdown. Only the power sup- holder up, change the fuse and swing the holder back
ply to the travel drives is cut off and the brakes into position.
are operated. The system is not discon-
nected from the power supply.
An emergency stop is initiated by pushing the
mushroom switch. The system can be re-
started by turning the switch to the left. An
emergency stop must be initiated under the
following conditions:
D if the crane travel motors fail to obey normal control
commands and hazardous situations may occur
D if the crane operator leaves the control position
AN 120055.002_EN / A 766.EN Page 7

2 Assembly
2.1 Assembly Instructions frame split. The hoist must be properly secured and
lifted into place. The trolley bolts and nuts must then be
The hoist must be assembled only by specialist per-
retightened.
sonnel.
During commissioning, it may be found that not all of
the four wheels are in contact.
In this case, the trolley must be adapted to the track.
To do so, attach a load of about 25 % of the load capa-
2.1.1 Mechanical installation city to the load hook and lift it about 5 cm.
The installation of ABUSelectric rope hoists must only Then loosen the nuts of the four tensioner bolts one
be carried out by authorized persons. turn and tighten them with the specified torque (see
ABUS electric wire rope hoists are supplied as com- Technical Data section 1.6 Tightening torques).
plete units with the wire rope inserted and the bottom
block fully reeved. In the case of type E, the counter-
weight is also installed.
2.1.1.2 Model D and Z
2.1.1.1 Model E The trolley gauge is adjusted to the desired gauge

Monorail hoist trolleys are delivered preadjusted for width of the double girder crane.
the specified flange width.
The clearance between the beam and wheel flanges
should amount to 1/16th inch on each side.
MA =
25 Nm
1,52 mm 1,52 mm
Fig 4
Following the installation of the double---rail trolley, the

two hooks, which are supplied loose with the trolley
Fig 3 and are intended to provide lift ---off protection, must be
installed in the openings of the non---driven wheels.
The pre---assembled U ---bolt/clamping bracket assem-
bly must be pushed over the hooks so that the long side
If necessary, corrections can be made by inserting of the clamping bracket fits into the recess in the hook.
washers or by reducing the length of the spacer tubes. The hook must be inserted into the wheel opening from
If the beam is open at the ends, the trolley can be below and pushed in the direction of travel until it fits
pushed on. Proper end stops must be installed and are into the hole (only drilled from one side (Fig 4).
available from ABUS if they are not in place. In the case of cranes with a rail width above 50 mm and
Rubber wheel stops must be used as end stops. Order a rail height above 40 mm, the end carriage must be
them as ABUS clamping buffers. They are attached to lifted 20 mm before the hooks are installed.
the track end as shown in the illustration. (see Techni- The hook must be fastened to the end carriage, across
cal Data section 1.6 Tightening torques). the clamping bracket, using the two nuts.
If it is not possible to push the hoist on to the end of the The nuts must be tightened using the specified torque
beam, the trolley bolts must be loosened and trolley values.
Page 8 Data : 30.03.2012

2.1.1.3 Model DQA
The trolley gauge is adjusted to the desired gauge
width of the double girder crane.
Fig 5 1 2 1
Trolley with wheel flange guidance Fig 7
Remove the lock plate (Fig 7, Pos.1).
Position the double---rail trolley on the crane bridge in
such a way that the hook (Fig 7, Pos.2) passes under
the top flange of the crane bridge.
Install the lock plate (Fig 7, Pos.1) on the opposite
side.
The nuts must be tightened using the specified torque
values (see Technical Data, Section 1.6, Torque
Specifications.
Fig 6
Trolley with roller guidance
The double flanges of the wheels protect the trolleys

against derailing. They contain information on the ad-
missible wear (1).
The wheels are guided by the wheel flanges or by
rollers.
In the case of flange guidance, the play between the rail 1
Fig 8
and the flanges is 7 mm.
In the case of roller guidance, the play between the rail Trolley with wheel flange guidance
and the rollers is 3 mm.
In this case, flanged wheels with increased play are
used.
Fig 9
Trolley with roller guidance
The double flanges of the wheels protect the trolleys

against derailing. They contain information on the ad-
missible wear (1).
The wheels are guided by the wheel flanges or by
rollers.
In the case of flange guidance, the play between the rail
and the flanges is 7 mm.
AN 120055.002_EN / A 766.EN Page 9

In the case of roller guidance, the play between the rail
and the rollers is 3 mm.
In this case, flanged wheels with increased play are
used.
2.1.1.4 Model S
The trolley is adapted to the width of the crane track.
The lateral play between the trolley rail and the guide
rollers is 3 mm.
2 3 1
Fig 12
End stops are required on the track girders to limit
travel.
2.1.1.5 Model U
Monorail hoist trolleys are delivered preadjusted for
the specified flange width.
The clearance between the beam and wheel flanges
should amount to 1/16th inch on each side.
Fig 10
Before installing the sidemounted trolley, the two

safety plates (Fig 10, Item 5) must be removed.
After the trolley has been placed on the crane girder, 1,5---2 mm
the safety plates must be screwed back into place and
the trolley must be set to a horizontal position by turning
the eccentric bolt (Fig 11, Item 3)
1,5---2 mm
Fig 13
1
If necessary, it may be reduced by inserting washers.
With the end of the track freely accessible, the stops
must be removed and the trolley pushed on from the
Fig 11 side. The stops must then be mounted and secured.
The four detailing protection devices must be bolted to
the two buffer plates using the specified torque values
The mounting screws for the eccentric bolt (Fig 12, (see Technical Data, Section 1.6 Torque Values).
Item 3) must be tightened to the appropriate torque If the end of the track is inaccessible, the complete
specified. (see Technical Data section 1.6 Tighten- trolleys with trolley travel motors must be removed from
ing torques). the two jointed bolts.
Page 10 Data : 30.03.2012

The electric wire rope hoist is lifted under the track and screwed back onto both sides of the buffer plates. The
the four derailing protection devices are bolted to the electric wire rope hoist is then secured against derail-
buffer plates on both sides using the specified torque ing.
values (see Technical Data, Section 1.6 Torque Va- Finally, the trolley must be mounted again and the bolts
lues). must be tightened with the specified torque. (see
The electric wire rope hoist must be lifted under the Technical Data section 1.6 Tightening torques).
track and the four derailing protection devices must be
_________________________________
2.1.2 Electrical installation shown.

Switch off power supply before starting work at any
electrical installation. Have work carried out by trained See Technical Data section 1.3 Electrical Data of
personnel only. Motors for cable cross section and fuse protection.
Connect the cables in the crane or trolley control panel
as shown in the circuit diagram. 2.1.2.1 Connection to the mains
The operator must connect the system to the mains
Caution ! power supply in accordance with EN 60204.
EN 60204 must be observed!
2.1.2.2 Mains switch

The rope hoist must be wired to a three phase fused The mainline disconnect switch must be wired so as to
disconnect or circuit breaker (per NEMA) properly switch off all poles of the incoming power. The mainline
sized and grounded. The maximum voltage deviations switch has to be installed at an easily accessible loca-
are 5% from the lower and +5% from the upper volt- tion and must be secured against erroneous or unauth-
age limit. The hoist can operated in the voltage ranges orized entry.
AN 120055.002_EN / A 766.EN Page 11

Kransysteme
Installation, Operation and Maintenance Instructions
for
ABUS Lifting gear drive
250-068733
Factory No. ___________________
Manufacturer
Sonnenweg 1 Fax. ##49 2261 / 37247
D 51647 Gummersbach info@abus---kransysteme.de
Contents
1.1 Hoist motor with brake . . . . . . . . . . . . 2 1.3.2 Dismounting the brake . . . . . . . . . . . . 3
1.2 Hoisting gear . . . . . . . . . . . . . . . . . . . . 2 1.3.3 Installation of the brake . . . . . . . . . . . 3

1.3.4 Replacement of Brake Rotor
1.3 Hoisting gear brake . . . . . . . . . . . . . . . 2 and Anchor Disk . . . . . . . . . . . . . . . . . 4
1.3.1 Adjustment of the airgap . . . . . . . . . 3 1.3.5 Emergency Lowering of Load . . . . . . 4
_________________________________
1.1 Hoist motor with brake optimum value of 0.4 0.05 mm (1/64th inch.). This en-
sures optimm brake performance and minimm wear.
The hoisting gear is driven by a 12 pole, dual speed
In order to prevent the brake lining thickness from fal-
squirrel cage motor with integral D.C. restified mag-
ling below the minimum value tmin, the screwin depth
netic disc brake. Insulation class F, protection type IP
of the socket screws (4) in the magnet assembly (9) is
55. Due to the pole changing there is a standard preci-
limited.
sion hoisting speed in the ratio of approx. 1:6 or approx.
Caution!
1:10 to the main hoisting speed. The asbestosfree
The following work must be performed with
brake lining achieves a service life of approx. 1x106
the power supply disconnected. This work
shiftings.
must be performed only by specialists.
a) Motor without additional unit for ventilation, see

1.2 Hoisting gear Figure 1
The transmission of the motor speed to the rope drum
is effected through the spur gear in a light alloy casing. M6 : 10 Nm
The helical gear wheels are hardened and polished or M8 : 25 Nm
shaved and run in a closed oil bath with lifetime lubrica-
tion. 1 2 3 4
14 0,4
1.3 Hoisting gear brake
Attention!
In the case of GM 700 hoists with platforms 13
(models DB and ZB), the following
instructions must be observed. If it is
12
necessary to dismantle the hoist drive, the
drive unit must not be placed on the platform.
Otherwise, the platform may be overloaded
11
and there is a risk of accidents.
Attention! 10 5
An external fan for the hoist motor is not avai-
lable as an option for size GM 800. 6
The hoisting gear brake is a magnetoelectric disk

brake. In order to guarantee safe release, the brake is tmin
equipped with an airgap limiter. The airgap of the 9 8 7
brake must be checked regularly and adjusted to its Figure 1
Page 2 Data : 13.04.2010

b) Motor with additional unit for ventilation, see 7. Disconnect connectors for power supply to brake.
Figure 2 8. Unscrew the fastening screws (2).
1 2 3 4 9. Remove magnet assembly (9) complete with an-
chor disk (6) and socket screws (4).
10. Remove brake rotor (5).
11. Remove locking ring (10).
M6 : 10 Nm 0.4 12. Pull off catch hub (8) by means of the pulloff de-
M8 : 25 Nm vice.
b) Motor with additional unit for ventilation, see

Figure 2
13 1. Lower the bottom block and place it on the working

platform, the ground, etc.
10 2. Remove ventilator cowl (1) with the motor being
switched off.
16 3. Disconnect connectors for power supply to brake
and ventilation system.
15 4. Undo 3 screws (16) and remove axial flow fan with
tmin mounting plate (15).
5. Press out 0ring (7).
6. Unscrew the fastening screws (2).
9 8 6 7 5 Figure 2 7. Remove magnet assembly (9) complete with an-
chor disk (6) and socket screws (4).
8. Remove brake rotor (5).
9. Remove locking ring (10).
1.3.1 Adjustment of the airgap 10. Pull off catch hub (8) by means of the pulloff de-
Motor with or without additional unit for ventilation, vice.
see Figure 1 or Figure 2
1. Remove the ventilator cowl (1) with the motor being 1.3.3 Installation of the brake
switched off.
2. Remove locking ring (11) a) Motor with additional unit for ventilation, see
3. Loosen 3 fastening screws (2) by half a turn Figure 1
4. Screw 3 socket screws (4) about one turn info
magnet assembly (9) (screwsin depth limited) 1. Slightly grease the motor shaft (13), install catch
5. Place distance plates (3) (thickness: 0.4 0,05 hub (8) and secure with locking ring (10).
mm) between anchor plate (6) and magnetic body 2. Push brake rotor (5) on the catch hub (8) and
(9) each next to the 3 socket screws (4) ; tighten the check whether it can be slightly axially displaced.
fastening screws (2) so that the distance plates (3) 3. Mount the magnetic body (9) complete with anchor
can still be removed. disk (6) and socket screws (4) and slightly tighten
6. Unscrew the 3 socket screws (4) from the magnet by means of the 3 fastening screws (2).
assembly (9) until they make firm constact with the 4. Screw 3 socket screws (4) into the magnet assem-
motor bearing shield. bly (9). (screwin depth limited)
7. Tigthen the fastening screws (2). Then check the 5. Place distance plates (3) (thickness: 0.4 0,05
evenness of the air gap (at approx. 6 places and re- mm) between the anchor plate (6) and the mag-
adjust, if required. netic body (9) each next to the 3 socket screws (4);
8. Press in 0ring (7) tighten the fastening screws (2) so that the dis-
9. Install the ventilator cowl (1) tance plates (3) can still be removed.
10. Do a trial run to check the brake. 6. Unscrew the 3 socket screws (4) from the magnet
assembly (9) until they make firm contact with the
motor bearing shield.
7. Tighten the fastening screws (2). Then check the
1.3.2 Dismounting the brake evenness of the air gap (at approx. 6 points) and re-
a) Motor without additional unit for ventilation, see adjust, if necessary.
Figure 1 8. Press in the 0ring (7).
1. Lower the bottom block and place it on the working 9. Push on the ventilator (14) and secure with locking
platform, the ground, etc. ring (11).
2. Remove ventilator cowl (1) with the motor being 10. Connect connectors for power supply to brake.
switched off. 11. Install the ventilator cowl (1).
3. Remove locking ring (11) 12. Carry out test tun to check brake.
4. Pull off fan (14).
5. Remove feather key (12). b) Motor with additional unit for ventilation, see
6. Press out 0ring (7). Figure 2
AN 120056.001_EN / A 712.EN Page 3

1. Slightly grease the motor shaft (13), install catch 1. Screw the socket screws Figure 1 / Figure 2, Item
hub (8) and secure with locking ring (10). (4) on the dismantled brake into the magnet as-
2. Push brake rotor (5) on the catch hub (8) and sembly up to the stop.
check whether it can be slightly axially displaced. 2. Remove and destroy the lifting travel limiting
3. Mount the magnetic body (9) complete with anchor screws Figure 3, Item (2) (The emergency lower-
disk (6) and socket screws (4) and slightly tighten ing bar Figure 3, Item (1) will then be released.)
by means of the 3 fastening screws (2). 3. Remove and destroy the socket screws Figure 1 /
4. Screw 3 socket screws (4) into the magnet assem- Figure 2, Item (4) (This rele ases the load on the
bly (9) springs between the anchor disk Figure 1 /
5. Place distance plates (3) (thickness: 0.4 0,05 Figure 2, Item (6) and the magnet assembly
mm) between the anchor plate (6) and the mag- Figure 1 / Figure 2, Item (9)
netic body (9) each next to the 3 socket screws (4); 4. Remove anchor disk.
tighten the fastening screws (2) so that the dis- To install the new anchor disk, proceed in reverse order.
tance plates (3) can still be removed. The socket screws Figure 1 / Figure 2, Item ( (4) and
6. Unscrew the 3 socket screws (4) from the magnet the lifting travel limiting screws Figure 3, Item (2) must
assembly (9) until they make firm contact with the be replaced.
motor bearing shield. The clearance between the anchor disk and the
7. Tighten the fastening screws (2). Then check the magnet assembly Figure 1 / Figure 2, Item (9) must
evenness of the air gap (at approx. 6 points) and re- be set to 1.1 mm with the brake dismantled using the
adjust, if necessary. lifting travel limiting screws Figure 3, Item (2)
8. Press in the 0ring (7). Assemble the brake in accordance with subsection
9. Fasten axialflow fan with mounting plate (15) to 1.3.3
magnet assembly (9) using 3 screws (16). Wear table for brake linings (lifting motor)
10. Connect connectors for power supply to brake and
ventilation system. tmin (mm)
11. Install the ventilator cowl (1). Typ
L6 H6 U6
12. Carry out test tun to check brake and ventilation
system. 800.4 9.3 9.3 9.3
1000.7 9.3 9.3 11.3
1.3.4 Replacement of Brake Rotor and 2000.3 9.3 11.3

Anchor Disk 3000.4 11.3 12.3
5000.3 12.3 13.8
1 6000.3 13.8
7000.1 13.8 13.8 13.8
2
1.3.5 Emergency Lowering of Load
Caution !
The hoist must be disconnected from the
power supply before the following steps are
Limiting taken!
device for Figure 1 / Figure 2 / Figure 3
lifting If it is necessary to lower the load in an emergency fol-
lowing a power failure or problems with the hoist motor
or brake coil, the following steps must be taken:
1. Remove fan cover Figure 1 / Figure 2, Item (1)

2. Screw stud bolt(s) (M8) into emergency lowering
Figure 3 1.1
bar Figure 3, Item (1)
If the brake lining is worn below tmin (see table) and it is 3. Open brake(s) by carefully swivelling release
no longer possible to adjust the clearance, the brake bracket(s) and slowly lower the load.
rotor (Figure 1 / Figure 2, Item (5) and the anchor disk Attention!
Figure 1 / Figure 2, Item 6) must bothbe replaced. The lowering speed must not exceed the ra-
For the replacement of the brake rotor and anchor disk, ted speed.
the following work is necessary: The rated speed is reached after a very short
Dismantling of the brake in accordance with subsec- time. Lowering with the brakes applied may
tion 1.3.2 lead to overheating of the brake linings. Follo-
Dismantling of the anchor disk in accordance with the wing emergency lowering, the brakes must
following instructions: be inspected and the brake linings replaced.
Page 4 Data : 13.04.2010

Kransysteme
Operation Instructions
for
ABUS Emergency limit switch
- 800 - 2/1 - E
- 1000 - 4/1 - D, DB
- 2000 - 6/1 - DA
Wire rope hoist GM - 3000 - 4/2 Model - DQA
- 5000 - 6/2 - Z, ZB, ZA
- 6000 - 8/2 - S
- 7000 - 10/2 - U
- 12/2
250-068733
Serial No. __________________
Manufacturer
Sonnenweg 1 Fax. ##49 2261 / 37247
Contents
1 Limit of lift . . . . . . . . . . . . . . . . 3 2.2 Adjustment instruction
hoist limit switch GP with option
operating limit switch
with 4 switch points . . . . . . . . . . . . . . . 10
2 Adjustment instruction
hoist limit switch . . . . . . . . . . 3 2.2.1 Adjustment instructions . . . . . . . . . . . 10
2.1 Hoist limit switch GPK 75.31 2.2.2 Adjust switch points . . . . . . . . . . . . . . 11
with 3 switch points . . . . . . . . . . . . . . . 3
2.3 Testing the restart function for
2.1.1 Adjustment instructions . . . . . . . . . . . 3
hoists with transmission
2.1.2 Adjust switch points . . . . . . . . . . . . . . 10 limit switches (option) . . . . . . . . . . . . . 12
Page 2 Data : 15.10.2010

1 Limit of lift
The lift is limited in the highest and lowest hook position If no additional operating limit switches are installed,
by means of a rotary geared limit switch directly the functions of the emergency limit switches must be
coupled to the rope drum. The standard hoist limit checked each time you start work. If the highest and/or
switch (S31) comes with 3 switching contacts which lowest hook position is reached in normal operation,
have the following functions: the switch or switching circuit must be designed for
1. upper limit safety switch lifting normal shut ---down. The functions of the operating limit
2. emergency limit switch lifting switches must be tested each time you start work.
3. emergency limit switch lowering In the case of type Z ABUS electric wire rope hoists
The upper limit safety switch (S31.1) interrupts power (twin hoists), this test, which must always be carried out
to the mainline contactor (K1). This switch point is set before starting work, also compensates for the winding
by the manufacturer, sealed with lead, and must only of the ropes on the two rope drums. This ensures that
be reset by authorized personnel. If for any reason the the rope is evenly wound on both drums. For this rea-
emergency limit switch (S31.2), fails to limit the travel son alone, regular testing each time you start work with
of the block in the up direction, the crane is shut down the crane is already absolutely essential.
by this upper limit safety switch. Subsequent operation For adjustment of the hoist limit switch see Operating
of the hoist should only be attempted by a trained ser- manual for Emergency limit switch in Section 2.
vice technician.
_________________________________
2 Adjustment instruction hoist limit switch

2.1 Hoist limit switch GPK 75.31 maintenance works at the rope drive (e.g. rope ex-
change). Depending on your choice of the reference
with 3 switch points edge, values of column C1 and C2 or A1 and A2 or B1
or B2 can be used (see Figur 2 --- Figur 8). C1 and C2
apply only to standard hooks.
2.1.1 Adjustment instructions
It should be noted that the settings shown in Adjust the switch points at the adjusting nuts 1 3 with
the tables apply to wire rope hoists operated a screw driver of 6 mm or an Allan key of 4 mm. 146
at mains frequency. In the case of hoists turns at the adjusting nut corresponds with 360 at the
equipped with frequency converters, the ap- cam disk. The table Setting of lifting limit switches
propriate values must be taken from the ABU- indicates what hook path corresponds with one turn at
liner documentation. the ajusting nut.
The ABUShoist limit switch GP protects the electric
wire rope hoist as an independantly working emerg- Turning the adjusting nut to the right = adjust switch
encystopdevice to limit the up and down movements point to a lower position
at the highest respectively at the lowest hook position. Turning the adjusting nut to the left = adjust switch
As a further improvement of safety the standard system point to a higher position.
is always equipped with the safety limit switch, a sec-
ond switch for the highest hook position. The standard type GP_ 75 is designed for 75 turns of
If the system is equipped with (optional) operating limit the cam disk. For larger lifting heights the hoists can be
switches, the setting instructions in Section 2.2 must be equipped with the type GPM125 for 125 turns.
followed.
Switching points 1 and 2 of ABUS hoists are normally Caution!
set at the factory and sealed with lead seals. Carry out Following the completion of the adjustments,
preliminary adjustment using the table Settings for repeated tests of functions must be carried
limit switch out to check whether the setting is correct
Switch points must be adjusted by specialist personnel and the unit is not moved up to the safety limit
according to respective table Setting of lifting limit switch.
switches before the first operation as well as after It may be necessary to correct the settings.
AN 120064.003_EN / A 740.EN Page 3

F
adjustment nuts
sealing 1 2 3
caps
rope guide
max 75
146 (125) 1 2 3 planetary
turns switch cams gear
=360
.1 1 .2 3 .3 5
2 4 6
B1
A1
.1 safety limit switch lifting
C1
Bo 20--40
B2
C
A2
.2 emergency limit switch
lifting
C2
HW
.3 emergency limit switch

Bu
lowering Figur 1
Page 4 Data : 15.10.2010

Setting of limit switch for mains operation
Model E Settings
hoist type genera- reeving flange CDimen- switch point 1 switch point 2 switch hysteresis hook path per FDimension
tion width sion A1 B1 C1 A2 B2 C2 turn at the ad-
Festlagerseite
* standard standard up down justment nut
hook hook Bo Bu
[mm] [mm] [mm] [mm] [mm] [mm]
GM 800 E 4 4/1 300 400 163 72 380 213 122 430 55 55 71 42 2
2/1 567 210 106 527 310 206 627 60 60 77

GM 1000 E 6 300 56 2
AN 120064.003_EN / A 740.EN
4/1 500 229 125 480 279 175 530 120 120 154
2/1 580 180 68 540 280 168 640 65 65 86

GM 2000 E 3 300 59 2.5
4/1 500 195 83 480 245 133 530 130 130 172
2/1 664 214 68 624 314 168 734 80 80 107

GM 3000 E 4 300 73 2.5
4/1 580 235 89 560 285 139 610 160 160 214
2/1 830 295 108 790 395 208 890 89 89 119

GM 5000 E 3 350 87.5 3
4/1 825 377 190 805 427 240 855 178 178 238
GM 6000 E 3 2/1 350 830 295 108 790 395 208 890 194 194 260 102 3
* Wider flanges result in larger C dimensions. In such cases, the increase in dimension C must be added to the switching points C1, A1, B1, C2 , A2 and B2
indicated by the table in Technical Data Section 1.4 Dimensions and Weights; Model E.
Model S / U Settings
hoist type genera- reeving CDimen- switch point 1 switch point 2 switch hysteresis hook path per FDimension
tion sion A1 B1 C1 A2 B2 C2 turn at the ad-
Festlagerseite
standard standard up down justment nut
hook hook Bo Bu
GM 800 S 4 4/1 343 336 245 323 386 295 373 55 55 71 42 2
GM 1000 S 6 4/1 420 419 315 400 469 365 450 60 60 77 56 2
GM 2000 S 3 4/1 440 405 293 420 455 343 470 65 65 86 59 2.5
2/1 699 519 373 659 619 473 759 160 160 214
GM 3000 S 4 73 2.5
4/1 550 540 394 530 590 444 580 80 80 107
GM 5000 U 3 4/1 1132 270 83 1112 320 133 1162 89 89 119 87.5 3
2/1 1256 235 48 1216 335 148 1316 194 194 260
GM 6000 U 3 102 3
4/1 1241 260 73 1221 310 123 1271 97 97 130
GM 7000 U 1 2/1 1615 329 88 1575 429 188 1675 254 254 342
Page 5
131 4
Model D / DB Settings
hoist type genera- reeving trolley CDimen- switch point 1 switch point 2 switch hysteresis hook path per FDimension
Page 6
tion span sion A1 B1 C1 A2 B2 C2 turn at the ad-
Festlager-
standard standard up down justment nut seite /
hook hook Bo Bu hoisting gear
[mm] [mm] [mm] [mm] [mm] [mm] [mm]
GM 800 D 4 4/1 144 172 81 124 222 131 174 55 55 71 42 2
GM 1000 D 6 4/1 195 189 85 175 239 135 225 60 60 77 56 2
2/1 295 160 48 255 260 148 355 130 130 172
GM 2000 D 3 59 2.5
4/1 215 175 63 195 225 113 245 65 65 86
GM 3000 D 4 2/1 315 196 50 275 296 150 375 160 160 214 73 2.5
GM 3000 D130 4/1 230 84 280 134

4 260 240 290 80 80 107 73 2.5
GM 3000--- D160 4/1 225 79 275 129
GM 3000 D 4 4/2 250 250 138 210 350 238 310 160 160 214 73 2.5
GM 3000 D160 469 449 499

4 6/1 224 77 274 127 53 53 71 73 2.5
GM 3000 --- D200 429 409 459
GM 5000 D 3 2/1 440 240 53 400 345 153 500 178 178 238 87.5 3
GM 5000 D160 287 100 150

3 4/1 385 365 337 415 89 89 119 87.5 3
GM 5000 --- D200 307 120 170
GM 5000 D 3 4/2 320 330 218 280 430 318 380 178 178 238 87.5 3
GM 5000 D200 611 370 183 591 420 233 641

3 6/1 59 59 79 87.5 3
GM 5000 --- D280 606 355 168 586 405 218 636
2/1 520 235 48 480 335 148 580 194 194 260
GM 6000 D 3 4/1 267 260 73 247 310 123 297 97 97 130 102 3
6/1 606 355 168 586 405 218 636 65 65 87
2/1 572 344 103 532 444 203 632 254 254 342
GM 7000 D 1 131 4
4/1 501 380 139 481 430 189 531 127 127 171
2000 717 697 747

GM 7000 D 1 6/1 522 281 572 331 85 85 114 131 4
> 2000 897 877 927
4/2 236 240 53 196 340 153 296 254 254 342
GM 7000 D 1 87/ 84 3
8/2 516 260 73 496 310 123 546 127 127 171
Date: 15.10.2010
Model DA Settings
Festlager-
GM 800 DA 4 4/1 429 172 81 409 222 131 459 55 55 71 42 2
GM 1000 DA 6 4/1 520 189 85 500 239 135 550 60 60 77 56 2

2/1 621 161 49 581 261 149 681 130 130 172
GM 2000 DA 3 59 2.5
4/1 544 175 63 520 225 113 570 65 65 86
AN 120064.003_EN / A 740.EN
2/1 700 193 46 660 290 144 760 160 160 214
GM 3000 DA 4 4/1 620 225 79 600 275 129 650 80 80 107 73 2.5
6/1 853 225 77 833 275 127 883 53 53 71
2/1 825 240 53 785 340 153 885 178 178 238
GM 5000 DA 3 87.5 3
4/1 813 285 98 793 335 148 843 89 89 119
GM 6000 DA 160 2/1 949 235 48 909 335 148 1009 194 194 260
GM 6000 --- DA 200 4/1 470 260 73 450 310 123 500 97 97 130
3 102 3
GM 6000 --- DA1 280 4/1 832 260 73 812 310 123 862 97 97 130
GM 6000 --- DA 280 6/1 1068 352 165 1048 402 215 1098 65 65 87
GM 7000 DA 1 2/1 1284 344 103 1244 444 203 1344 254 254 342 131 4
4/1 913 375 134 893 425 184 943 127 127 171
GM 7000 DA 1 131 4
6/1 1370 517 276 1350 567 326 1400 85 85 114
Model DQA Settings
Festlager-
2/1 525 125 13 485 225 113 585 130 130 172
GM 2000 DQA 3 59 2.5
4/1 445 140 28 425 190 78 475 65 65 86
2/1 639 189 43 599 289 143 699 160 160 214
GM 3000 DQA 4 73 2.5
4/1 555 210 64 535 260 114 585 80 80 107
2/1 810 275 88 770 375 188 870 178 178 238
GM 5000 DQA 3 87.5 3
4/1 712 264 77 692 314 127 742 89 89 119
2/1 870 335 148 830 435 248 930 194 194 260
GM 6000 DQA 3 102 3
4/1 745 250 63 725 300 113 775 97 97 130
GM 7000 DQA 350 970 374 133 950 424 183 1000
1 4/1 127 127 171 131 4
GM 7000 --- DQA 400 998 402 161 978 452 211 1028
Page 7
Model Z / ZB / ZA Settings
hoist type genera- reeving trolley CDimen- switch point 1 switch point 2 switch hysteresis hook path per FDimension
Page 8
tion span sion A1 B1 C1 A2 B2 C2 turn at the ad-
Festlager-
hook hook Bo Bu hoist gear
[mm] [mm] [mm] [mm] [mm] [mm] [mm]
4/2 413 490 303 373 590 403 473 178 178 238
GM 5000 Z 3 87.5 3
8/2 631 504 317 611 554 367 661 89 89 119
GM 6000 Z 3 4/2 414 485 298 374 585 398 474 194 194 260 102 3
GM 6000 Z 280 638 498 311 618 548 361 668

3 8/2 97 97 130 102 3
GM 6000 --- Z 350 643 448 261 623 498 311 673
GM 7000 Z 1 4/2 668 527 286 628 627 386 728 127 127 171 87/ 84 3
2000 717 697 747
GM 7000 Z 1 6/2 522 281 572 331 85 85 114 87/ 84 3
> 2000 897 877 927
GM 7000 Z 420 1 8/2 915 525 284 895 575 334 945 64 64 85.5 87/ 84 3
GM 7000 Z 1 10/2 960 482 241 940 532 291 990 51 51 46.5 87/ 84 3
GM 7000 Z V500 1 12/2 1378 761 482 1358 811 532 1408 85 85 57 87/ 84 3
GM 5000 ZA 3 8/2 1195 494 307 1175 544 357 1225 89 89 119 87.5 3
GM 6000 ZA 280 1253 493 306 1233 543 356 1283

3 8/2 97 97 130 102 3
GM 6000 --- ZA 350 1163 443 256 1143 493 306 1193
GM 7000 ZA 1 6/2 1370 517 276 1350 567 326 1400 85 85 114 87/ 84 3
8/2 1430 517 276 1410 567 326 1460 64 64 85.5
GM 7000 ZA 1 87/ 84 3
10/2 1312 482 241 1292 532 291 1342 51 51 46.5
Date: 15.10.2010
Model E FB Model Z
B ..
A ..
B ..
C ..
A ..
Figur 2
C ..
Model D
Figur 6
B ..
A ..
Model S
C ..
B ..
A ..
Figur 3
C ..
Model DA
B ..
Figur 7
A ..
C ..
Model U
Figur 4
Model DQA
B ..
C ..
B ..
A ..
A ..
C ..
Figur 8
Figur 5
AN 120064.003_EN / A 740.EN Page 9

2.1.2 Adjust switch points tests to the lowest hook position and if necessary cor-
rect the adjustment.
Switch point .1 Safety limit switch lifting The dimension HW (see Figur 1) must not
The switch point is adjusted and sealed by the manu- exceed the dimension lifting height (
facturer to dimension C 1. Changes are only allowed in Hakenweg) see type plate of the hoist.
case of maintenance works and must be carried out by For safety reasons, the dimension F (see
specialist personnel. After maintenance works, we rec- Figur 1 and table) must also never be lower
ommend to let the adjustment be checked and sealed than the value shown.
by ABUS service personnel.
For safety reasons, the dimension C1 must
never be lower than the value shown. 2.2 Adjustment instruction hoist
The installation situation and mode of
operation of the wire rope hoist must be limit switch GP with option
taken into consideration (e.g. spreader operating limit switch with 4
operation). Depending on the hazard
analysis of the operator, it may then be
switch points
necessary to increase dimensions A1, B1,
C1 and A2, B2, C2. 2.2.1 Adjustment instructions
It should be noted that the settings shown in
Adjustment: Lift the load hook up to 5 mm (with reeving the tables apply to wire rope hoists operated
4/1) or 10 mm (with reeving 2/1) to the highest hook at mains frequency. In the case of hoists
position (dimension C1 + 5 (10) mm). If necessary, equipped with frequency converters, the ap-
previously turn adjusting nut 1 to the left. propriate values must be taken from the ABU-
Turn adjusting nut 1 to the right until switch contact liner documentation.
audibly switches. The ABUShoist limit switch GP protects the electric
Check switch point by running two starts to the highest wire rope hoist as an independantly working emerg-
hook position and if necessary correct the adjustment. encystopdevice to limit the up and down movements
A test run to reach switch point .1 is only possible by at the highest respectively at the lowest hook position.
manual bridging of the emergency limit switch lifting. If the highest and/or lowest hook position are reached
in normal operation, another switch, the operating
Switch point .2 emergency limit switch lifting limit switch must be installed ahead of the emergency
Switching point 2 is set to dimension C2 at the factory limit switch. Each time work is started, the functions of
and sealed with a lead seal. the operating limit switch must be tested.
Adjustment: Lift the load hook up to 5 mm (for 4/1) or 10 The reset switches on the trolley contactor box must be
mm (for 2/1) to the desired hook position (min. dimen- used for setting the emergency limit switch (see also
sion C2 + 5 (10) mm). If necessary, previously turn ad- 2.3).
justing nut 2 to the left. Turn adjusting nut 2 to the right Switch points must be adjusted by specialist personnel
until switch contact audibly switches. according to respective table Setting of lifting limit
Check switch point by running two starts to the desired switches before the first operation as well as after
maintenance works at the rope drive (e.g. rope ex-
hook position and if necessary correct the adjustment
change). Depending on your choice of the reference
in this case. The switch safety limit switch lifting must
edge, values of column C1 and C2, or A1 and A2, or B1
not switch in this case. or B2 can be used. C1 and C2 apply only to standard
hooks.
Switch point .3 emergency limit switch lowering Adjust the switch points at the adjusting nuts 1 3 with
The switch point is only preadjusted by the manufac- a screw driver of 6 mm or an Allan key of 4 mm. 146
turer. The lowest hook position must be suited to oper- turns at the adjusting nut corresponds with 360 at the
ating conditions so that the unloaded hook never cam disk. The table Setting of lifting limit switches
touches the floor. (Formation of slack rope !!) indicates what hook path corresponds with one turn at
Adjustment: Lowering of load hook to 500 mm above the ajusting nut.
the lowest hook position required. If necessary, turn ad- Turning the adjusting nut to the right = adjust switch
justing nut 3 previously to the right. point to a lower position
Turn adjusting nut 3 to the left until switch contact 3 Turning the adjusting nut to the left = adjust switch
audibly switches. Check switch point by running two point to a higher position.
Page 10 Data : 15.10.2010

F
adjustment nuts
0 1 2 3 4
sealing
rope guide caps
max 75
(125)
turns
1 2 3 4
planetary
switch cams gear
B1
146
A1
.1 1 .2 3 .3 5 .4 7
=360
2 4 6 8
C1
.1 emergency limit switch lifting
Bo 20--40
B2
A2
C
.2 operating limit switch lifting
C2
hook path
effective
HW
operating limit switch lowering

Bu
.3
D
.4 emergency limit switch lowe-

ring Figur 9
2.2.2 Adjust switch points For safety reasons, the dimension C1 must
never be lower than the value shown.
The installation situation and mode of
Switch point .1 emergency limit switch lifting operation of the wire rope hoist must be
The switch point is adjusted and sealed by the manu- taken into consideration (e.g. spreader
facturer to dimension C 1. Changes are only allowed in operation). Depending on the hazard
case of maintenance works and must be carried out by analysis of the operator, it may then be
specialist personnel. After maintenance works, we rec- necessary to increase dimensions A1, B1,
ommend to let the adjustment be checked and sealed C1 and A2, B2, C2.
by ABUS service personnel.
AN 120064.003_EN / A 740.EN Page 11

Adjustment: Lift the load hook up to 5 mm (with reeving Adjustment: Lower load hook down to 50 mm (for 4/1)
4/1) or 10 mm (with reeving 2/1) to the highest hook or 100 mm for (2/1) to the desired lowest hook position.
position (dimension C 1 + 5 (10) mm). If necessary, If necessary, turn adjusting nut 3 previously to the right.
previously turn adjusting nut 1 to the left. Turn adjusting Turn adjusting nut 3 to the left until switch contact 3
nut 1 to the right until switch contact audibly switches. audibly switches. Check switch point by running two
Check switch point by running two starts to the highest starts to the desired hook position and if necessary cor-
hook position and if necessary correct the adjustment. rect the adjustment.
Switch point .2 operating limit switch lifting
Switching point 2 is set to dimension C2 at the factory
Adjustment screw .0 block adjustment (sealed)
and sealed with a lead seal.
The purpose of block adjustment is to shift all the
Adjustment: Lift the load hook up to 5mm (for 4/1) or 10
switching points by the same amount without changing
mm (for 2/1) to the desired hook position (min. dimen-
the switching point spacing. 626 turns of the adjust-
sion C 1 + 5 (10) mm). If necessary, previously turn ad-
ment screw correspond to 360 on the cam disc for the
justing nut 2 to the left. Turn adjusting nut 2 to the right
switching points.
until switch contact audibly switches.
After a rope exchange the four switch points can be re-
Check switch point by running two starts to the desired
adjusted simultaneously using the block adjustment.
hook position and if necessary correct the adjustment.
Adjust switch point .1 following the above mentioned
The switch emergency limit switch lifting must not
instruction by using Adjustment screw 0. Now the other
switch in this case!
switch points are also in the initial position again. We
Switch point .4 (.3) emergency limit switch lower- recommend to let the adjustment be checked and
ing sealed by ABUS service personnel.
The switch point is only preadjusted by the manufac-
turer. The lowest hook position must be suited to oper-
ating conditions so that the unloaded hook never
touches the floor. (Formation of slack rope!)
Adjustment: Lowering of load hook to 500 mm above
the lowest hook position required. If necessary, turn ad-
justing nut 4 previously to the right. 2.3 Testing the restart function
Turn adjusting nut 4 to the left until switch contact 4 for hoists with transmission
audibly switches. Check switch point by running two
tests to the lowest hook position and if necessary cor- limit switches (option)
rect the adjustment. If the hoist has passed the operating limit switch and
The dimension HW must not exceed the di- the emergency limit switch has been operated, you
mension lifting height ( Hakenweg) see must check whether movement in both directions is im-
type plate of the hoist. possible before restarting the unit.
For safety reasons, the dimension F (see
Figur 9 and table) must also never be Test
lower than the value shown. Move the hoist up to the top limit switch or down to the
bottom limit switch. Override the operating limit switch
Switch point .3 operating limit switch lowering by turning the reset up (down) switch on the contac-
(only for GP with 4 switch points) tor box towards lifting (lowering). If the up (down) but-
The switching point can be set to any point between the ton on the control unit is pressed at the same time, the
normal limit switch for the highest hook position and the hoist will be moved to the emergency limit switch and
emergency limit switch for the lowest hook position. the main contactor will be tripped. The crane can no
The minimum spacing D must be taken from the fol- longer be operated from the control unit.
lowing table:
Restart
Normal operation
Reeving Turn the main contactor on by turning the reset up
50 / 60 Hz (down) switch on the contactor box towards lowering
2/1, 4/2 D = 100 (lifting). If the down (up) button on the control unit is
4/1, 8/2, 10/2 D = 50 pressed at the same time, the hoist will leave the area of
the operating limit switch and move into the normal op-
6/1, 12/2 D = 40
erating area. The crane can then be operated normally
6/2 D = 80 from the control unit.
Page 12 Data : 15.10.2010

Kransysteme
Installation Instructions
for
ABUS Rope, rope guide
- 800 - 2/1 - E
- 1000 - 4/1 - D - S
Wire rope hoist GM - 2000 - 6/1 Model - DA - U
- 3000 - 4/2 - DB - Z
- 5000 - 6/2 - DQA - ZB
- 6000 - 8/2
250-068733
Serial No. __________________
Manufacturer
Sonnenweg 1 Fax. ##49 2261 / 37247
Contents
1 Rope drive . . . . . . . . . . . . . . . . 3 3.1.1 Size
GM 800.4, 1000.6, 2000.3, 3000.4 . . 4
3.1.2 Size GM 5000.3, 6000.3 . . . . . . . . . . . 4
3.1.3 Size GM 3000.4, 5000.3 . . . . . . . . . . . 6
2 Rope wedge protrusion, spacing
3.2 Installation of a new rope
between the rope clamp . . . 3 and of the rope guide . . . . . . . . . . . . . 7
3.2.1 Size
GM 800.4, 1000.6, 2000.3, 3000.4 . . 7
3 Wire rope and rope guide . . 3 3.2.2 Size GM 5000.3, 6000.3 . . . . . . . . . . . 8
3.2.3 Size GM 3000.4, 5000.3 . . . . . . . . . . . 12
3.1 Removing the wire rope
and the rope guide . . . . . . . . . . . . . . . 4 3.3 Elimination of stretch twisting . . . . . . 12
Page 2 Data : 30.03.2012

1 Rope drive
The rope drive corresponds to the FEMcalcuation in special design has considerably higher breaking
rules for series hoists. The load hook with safety catch resistance and life than a rope of conventional design
complies with DIN 15400. None of the bearing points and structure. That is why only original ropes from the
need maintenance. The rope guide is made of wear manufacturers should be used as spare parts.
resisting, sliding synthetic material and provides Information on the use and maintenance of the ropes is
troublefree rope reeloff and careful treatment of the given in EN 12385---3 Steel wire ropes --- Safety --- In-
rope and the rope drum. The hightensile hoisting rope formation for use and maintenance.
_________________________________
2 Rope wedge protrusion, spacing between the rope clamp

The maximum protrusions of the rope wedges are indi-
cated in the table below.
Trolley type d [mm] a,zul [mm]
800.4 6.5 18 +1
rope 1000.6 8.0 3 +1
socket
2000.3 9.0 0 +2
3000.4 11.0 16 +2
5000.3 14.0 19 +3
6000.3 16.2 28 +3
rope The spacings must be checked during annual inspec-
claming tions. If the maximum a dimension is exceeded, the
wedge rope socket and wedge must be replaced.
Following loading with the rated load (once only), the

rope spacing between the rope clamp and the nearest edge
(rope wedge or pocket) should be at least 1 x rope dia-
a,zul
meter.
min 1 x d
d Figure 1
_________________________________
3 Wire rope and rope guide

Wire rope and rope guide are parts subject to wear according to the maintenance schedule. Clean drum
whose life can be increased by regular lubrication and rope guide before lubrication.
AN 120057.002_EN / A 767.EN Page 3

3.1 Removing the wire rope and 5. Turn the rope guide ring (11) until the joining tie
(14,15) can be untightened and removed.
the rope guide 6. Expand the rope guide ring (11) and remove it.
7. Demount the extension spring (17) and remove the
rope straining ring (16).
3.1.1 Size GM 800.4, 1000.6, 2000.3, 8. Completely reel off the rope and detach rope
clamps (12,13).
3000.4
3.1.1.1 Model E, D, DB, DQA and S 3.1.2 Size GM 5000.3, 6000.3

Type 2/1, 4/1 und 6/1
3.1.2.1 Model E and DQA

1 Type 2/1
3
2 1
3
2
1
4
1
4
5
5
6
6
8
4 8
9 4
7
9 7
Figure 2
Figure 4
10 16
12 14 15 11 18 19 14
16
15
11
7 7
13 17
13 12
Figure 3
Figure 5
1. Lower the bottom block and place it e.g. on the
working platform or on the floor. 1. Lower the bottom block and place it on working
2. Set the hoist limit switch so that lowering beyond platform, ground etc.
the lowest hook position becomes possible. 2. Set the hoist limit switch in such a way that lowering
3. Remove the locking stud (4) at the fixed point tie beyond the lowest hook position becomes poss-
bar (3), take off the tiebar, remove the rope ible.
sockets (2 and 59) and detach the rope ends 3. Remove the locking stud (4) at the fixed point tie
(6,7,8). bar (3), take off the tiebar, remove the rope
4. Demount the catch (18,19) of the rope guide ring sockets (2 and 59) and detach the rope ends (6,7
(11). amd 8).
Page 4 Data : 30.03.2012

4. Demount the catch (18,19) of the rope guide ring 3. Remove the tiebar (14) with its security elements,
(11). remove the rope sockets (612) and detach the
5. Loosen the tensioning parts (16) and demount the rope end (6,7,8).
rope guide (11). 4. Demount the catch (20,21) of the rope guide ring
6. Completely reel off the rope and detach rope (17).
clamps (12 and 13). 5. Loosen the tensioning parts (22) and demount the
rope guide (17).
6. Completely reel off the rope and detach rope
3.1.2.2 Model D, DB and U clamps (18 and 19).
Type 2/1, 4/1 and 6/1
3.1.2.3 Model DQA

12 13 Type 4/1 (Figure 6 and Figure 7 )
1. Lower the bottom block and place it on the working

platform or floor.
14 2. Set the hoist limit switch so that a lowering beyond
the lowest hook position becomes possible.
11 12 3. Remove the tiebar (14) with its security elements,
10 remove the rope sockets (612) and detach the
11 rope end (6,7,8).
10 4. Demount the catch (20,21) of the rope guide ring
(17).
5. Loosen the tensioning parts (22) and demount the
rope guide (17).
6. Completely reel off the rope and detach rope
15 6 clamps (18 and 19).
9
3.1.2.4 Model Z
8
7 1 2
Figure 6
16 22
20
Typ 8/2
Figure 8
21
17
1 2
7
19 18
Figure 7
1. Lower the bottom block and place it on the working

platform or floor.
2. Set the hoist limit switch so that a lowering beyond Typ 4/2 Figure 9
AN 120057.002_EN / A 767.EN Page 5

1. Let down and place bottom block.
1/2 8 2. Set the hoist limit switches at both lifting gears so
that lowering beyond the lowest hook position is
6 possible.
3. Remove the catches (7) from both rope guide rings
(3) .
4. Loosen the straining parts (8) and demount both
rope guides (3).
5. Pull off the lifting motor connector from lifting gear 1
and completely reel off the rope end of lifting gear 2.
Detach rope clamps (5).
6. Plug the connector of the lifting motor into lifting
7 gear 1 and pull off the one from lifting gear 2. Let the
rope end of lifting gear 1 entirely reel off and detach
3 rope clamps (5).
10
5 4
Figure 10
_________________________________
3.1.3 Size GM 3000.4, 5000.3 2. Set the hoist limit switch so that a lowering beyond
3. Remove the flights (9, 10) on both cable guides (5).
4. Turn the cable guides until the tension springs (8)
3.1.3.1 Model E and D can be unhooked.
Type 4/2 5. Unhook the tension springs by unlocking the as-
sembly hooks on both cable guides.
1. Lower the bottom block and place it on the working 6. Allow the cable to run out completely and release
platform or floor. the cable clamps (3, 4).
10
5
6
8
3
7 Typ 4/2
4
2
1 2
Figure 11
Page 6 Data : 30.03.2012

3.2 Installation of a new rope and 8. Pull the ending rope line through the guide aperture
of the rope guide ring and fasten the joining tie (15).
of the rope guide 9. Twist the rope guide until the guide edge engages
in the slit of the catch (18) at the drum casing. Then
3.2.1 Size GM 800.4, 1000.6, 2000.3, fasten the catch on the rope guide ring. (11,18 and
3000.4 19).
10. Clean the hole in the rope lock (9) and lubricate
3.2.1.1 Model E, D, DB, DQA and S with PBC installation paste.
Type 2/1, 4/1 and 6/1 11. Reeve the free rope end without twisting and fasten
it in the rope sockets (2 and 59) of the fixed point
see Figure 2 and Figure 3 tiebar (3). For reeving, see Figure 14.
1. Pay out the new original spare rope on the ground
under the electric rope hoist. Make sure the rope is 2/1 4/1
twist and bucklingfree.
Figure 12
2. Clean the rope drum (10) and evenly spray it with
chailife S spray grease. 6/1
3. Push the wire rope (7) from below under the rope
clamps (12,13) so that the rope end protrudes by
approx. 3 cm. Tighten the fastening screws accord-
ing to the prescribed torques. Figure 13 (1) and
Technical Data; Wire rope hoist, Section 1.6 --
Tightening torques.
Figure 14
12. Suspend fixed point tiebar and install the locking
stud (1 and 4).
13. Install a rope clamp (8 see figure Figure 2) at the
free rope end. For tightening torque values see
Technical Data; Wire rope hoist, Section 1.6 --
Tightening torques. and rope clamp projections,
see section 2.
Figure 13 14. Completely coil up the rope and adjust the hoist
limit switch to the highest and lowest position. See
4. Wind the rope around the drum by approx. 68 Operating instruction Hoist limit switch
turns ; make sure the rope is taut and twistfree.
5. Conduct the straining ring (16) over the drum and
suspend the tension spring (17) in such a way that
the straining ring firmly encloses the rope turns.
The straining ring frame points towards the hoist
gear.
6. Grease the rope drum around the rope guide ring
with special grease PG 75.
7. Spread the rope guide ring (11) and lead it over the
drum so that its threaded segments engage in the
grooves of the rope drum and that the groove
engages over the frame of the straining ring.
AN 120057.002_EN / A 767.EN Page 7

3.2.2 Size GM 5000.3, 6000.3 5. Grease the rope drum around the rope guide ring
with the special grease PG 75.
6. Spread the rope guide (11) and lead it over the
3.2.2.1 Model E drum (10) in such a way that its threaded segments
Type 2/1 engage in the grooves of the rope drum and that
the ending rope line (7a) exits through the guide
see Figure 4 and Figure 5
slit.
1. Pay out the original spare rope on the ground under
7. Suspend tension parts (16) and adjust them by
the electric rope hoist. Make sure the rope is twist
turning the eye bolt until the rope guide ring is fitting
and bucklingfree.
tight.
8. Twist the rope guide ring (11) until the guide edge
engages in the aperture of the catch (15) at the
drum casing. Then fasten the catch on the rope
guide ring (14).
with PBC installation paste.
10. Reeve the free rope end without twisting and fasten
it in the rope socket (2and 59) of the fixed point
tiebar (3). For reeving, see Figure 17
Figure 15
chainlife S spray grease.
3. From below, push the wire rope (7) underneath the
rope clamps (12,13) until the rope end protrudes
by approx. 3 cm. Tighten the fastening screws
according to the prescribed torques. Figure
Figure 16 (1) and Technical Data; Wire rope
hoist, Section 1.6 -- Tightening torques.
Figure 17
11. Suspend the fixed point tiebar (3) and install the
locking stud (1 and 4). Attach a rope clamp (8 see
Figure 4) to the free rope end. For tightening
torque values see Technical Data; Wire rope
Figure 16 hoist, Section 1.6 -- Tightening torques. and
rope clamp projections, see section 2.
12. Entirely coil up the rope and adjust the limit switch
4. Wind the rope around the drum (10) by approx. 68 to the highest and lowest position. See Operating
turns. Make sure the rope is taut and twistfree. instruction Hoist limit switch
Page 8 Data : 30.03.2012

3.2.2.2 Model D, DB, DQA 7. Suspend tension parts (22) and adjust them by
Type 2/1, 4/1 and 6/1 turning the eye bolt until the rope guide ring is fitting
(see Figure 6 and Figure 7) tight.
1. Pay out the original spare rope on the ground under engages in the aperture of the catch (21) at the
the electric wire rope hoist. Make sure the rope is drum casing. Then fasten the catch on the rope
twist and bucklingfree. guide ring (20).
it in the rope socket (6,8,9,10,11,15) of the fixed
point tiebar (14). For reeving, see Figure 20.
2/1 4/1
Figure 18
rope clamps (18, 19) until the rope end protrudes
according to the prescribed torques. Figure 19 6/1
(1) and Technical Data; Wire rope hoist, Sec-
tion 1.6 -- Tightening torques.
Figure 20
Figure 19 with PBC installation paste.
11. Fit the fixed cross member (14) to the cross
member mounting using bolts (13) and bearing
4. Tautly wind the rope around the drum (16) by bushings (12) and fasten it in place with the lid and
approx. 68 turns. Make sure the rope is twistfree. screws (10,11).
5. Grease the rope drum around the rope guide ring Install a rope clamp (8) at the free rope end. For
with the special grease PG 75. tightening torque values see Technical Data;
6. Spread the rope guide (17) and lead it over the Wire rope hoist, Section 1.6 -- Tightening tor-
drum (16) in such a way that its threaded segments ques, and rope clamp projections, see section 2.
engage in the grooves of the rope drum and that 12. Entirely coil up the rope and adjust the limit switch
the ending rope line (7a) exits through the guide to the highest and lowest position. See Operating
slit. instruction Hoist limit switch.
AN 120057.002_EN / A 767.EN Page 9

3.2.2.3 Model U 6. Spread the rope guide (17) and lead it over the
drum (16) in such a way that its threaded segments
see Figure 6 and Figure 7 engage in the grooves of the rope drum and that
the ending rope line (7a) exits through the guide
1. Pay out the original spare rope on the ground under
slit.
the electric wire rope hoist. Make sure the rope is
7. Suspend tension parts (22) and adjust them by
twist and bucklingfree.
turning the eye bolt until the rope guide ring is fitting
tight.
engages in the aperture of the catch (21) at the
drum casing. Then fasten the catch on the rope
guide ring (20).
with PBC installation paste.
it in the rope socket (6,8,9,10,11,15) of the fixed
Figure 21 point tiebar (14). For reeving, see Figure 23.
rope clamps (18, 19) until the rope end protrudes
according to the prescribed torques. Figure 22
(1) and Technical Data; Wire rope hoist, Sec-
tion 1.6 -- Tightening torques.
2/1 4/1
Figure 23
11. Fit the fixed cross member (14) to the cross

member mounting using bolts (13) and bearing
bushings (12) and fasten it in place with the lid and
screws (10,11).
Figure 22 Install a rope clamp (8) at the free rope end. For
tightening torque values see Technical Data;
Wire rope hoist, Section 1.6 -- Tightening tor-
4. Tautly wind the rope around the drum (16) by ques, and rope clamp projections, see section 2.
approx. 68 turns. Make sure the rope is twistfree. 12. Entirely coil up the rope and adjust the limit switch
5. Grease the rope drum around the rope guide ring to the highest and lowest position. See Operating
with the special grease PG 75. instruction Hoist limit switch
Page 10 Data : 30.03.2012

3.2.2.4 Model Z 4. Wind the rope around the drum with approximately
see Figure 10 68 turns; make sure the rope is taut and twistfree.
1. In order to avoid kinks and twists, first pay out the 5. Grease the rope drum around the rope guide ring
original wire rope in full length on the floor under the with special grease PG 75.
twin lifting gear. 6. Spread the rope guide ring (3) and lead it over the
2. Clean the rope drum (1) and evenly spray it with drum until its threaded segments engage in the
chainlife S spray grease. grooves of the rope drum and the ending rope line
3. Plug the connector of the lifting motor into lifting (10a) comes out through the guide aperture.
gear 1 and pull off the one from lifting gear 2. Push 7. Suspend straining parts (8) and adjust them by
the wire rope (10) from below under the rope turning the eye bolts until the rope guide ring is fit-
clamps (5) of the rope drum (1) until the rope end ting tight.
protrudes by approxim. 3 cm. 8. Turn the rope guide ring until the guide edge
Tighten the fastening screws (4) according the pre- engages in the aperture of the catch (7) at the drum
scribed torques. Figure 24 (1) and Technical casing. Then fasten the catch on the rope guide
Data; Wire rope hoist, Section 1.6 -- Tightening ring (6).
torques. 9. Pay out the wire rope until the rope drum (1) is com-
pletely covered.
1 10. Pull off the lifting motor connector from lifting gear 1
and plug it into lifting gear 2.
11. Reeve the free rope end without twisting and push it
from below under the rope clamps (5) of the rope
drum (2) until the rope end protrudes by approx. 3
cm. Tighten the fastening screws according to the
prescribed torques.
12. Apply steps 49 also to the rope drum (2).
13. Set the hoist limit switch for highest and lowest
position. See Operating instruction Hoist limit
switch
Figure 24
AN 120057.002_EN / A 767.EN Page 11

3.2.3 Size GM 3000.4, 5000.3 3. Reeve the wire rope (2) without kinks into the bot-
tom block and slide it through at both drum ends
3.2.3.1 Model E and D under the cable clamps (3,4) until each of the cable
Type 4/2 ends protrude about 3 cm. Tighten the fastening
1. Roll out the original replacement wire rope either screws with the specified torque. Figure 25 (1)
under the electric wire rope hoist and onto the floor and Technical Data; Wire rope hoist, Section
without twists so that no kinks occur, or have ready 1.6 -- Tightening torques.
a kink ---free wire rope wound on a special reel (with 4. Wind the rope around the drum with approximately
two cable ends guided outward). 68 turns; make sure the rope is taut and twistfree.
2. Clean the rope drum (1) and evenly spray it with 5. Grease the rope drum around the rope guide ring
chainlife S spray grease. with special grease PG 75.
10
5
6
8
3
7
4
Figure 25
2
1 2
6. Lay one cable guide (5) around the drum so that click.
the rope fall runs through the guide slot. The guide 9. Turn the cable guide until the guide edge on the
elements (6) will then lie next to the already wound drum housing engages in the slot of the flight (9).
cable toward the centre of the drum. Insert the pla- Bolt the flights onto the cable guide. (5, 9 and 10)
stic ends (7) of the cable guide into one another 10. Perform steps 5---9 on the second cable guide as
7. Aligning the cable guide: The unwinding wire rope well.
must be positioned in the centre of the guide slot 11. Wind the wire rope completely and reset the hoist
and the guide elements must lie flush in a drum limit switch for the highest and lowest hook positi-
groove. ons. See Operating instruction Hoist limit
8. Attach the springs (8). The assembly hooks the- switch
reby latch into the second position with an audible
_________________________________
3.3 Elimination of stretch twisting

Where ropes are used, a tendency to twist develops firmly to the bottom block again. The effectiveness of
over the course of time. The result is that the bottom the action taken must be checked by raising and lower-
block twist when the rope is unloaded. ing the hoist without a load.
To eliminate this twist, the bottom block must be low- It may be necessary to repeat this procedure several
ered to the ground, the rope lock released and the rope times.
turned 180 tighter. The rope must then be attached
Page 12 Data : 30.03.2012

Kransysteme
Technical data
incl. Declaration of Conformity / Declaration of installation
for
ABUS Wire rope hoist
E S
D DA DQA
-E - 130
-D - 2/1 - 160
Type GM 3000.4 - DA - 4/1 Wheel diameter - 200
- DQA - 280
-S
250-068733
Serial No. ___________________
Manufacturer
Sonnenweg 1 Fax. ##49 2261 / 37247
D 51647 Gummersbach info@abus---kransysteme.de
Contents
1 Technical Data . . . . . . . . . . . . 3 1.5.1 Model GM 3000.4 E2/1 . . . . . . . . . . 10
1.1 Sound Emissions . . . . . . . . . . . . . . . . . 3 1.5.2 Model GM 3000.4 E4/1 . . . . . . . . . . 11
1.2 Electrical Data of Motors . . . . . . . . . . 4 1.5.3 Model GM 3000.4 D2/1 . . . . . . . . . . 12
1.3 Weights and Dimensions . . . . . . . . . . 5 1.5.4 Model GM 3000.4 DQA2/1 . . . . . . . 13
1.3.1 Dimensions series E . . . . . . . . . . . . . . 5 1.5.5 Model GM 3000.4 D4/1 . . . . . . . . . . 14
1.3.2 Dimensions series D . . . . . . . . . . . . . . 5 1.5.6 Model GM 3000.4 DQA4/1 . . . . . . . 15

1.5.7 Model GM 3000.4 DA2/1 . . . . . . . . . 16
1.3.3 Dimensions series S . . . . . . . . . . . . . . 5
1.5.8 Model GM 3000.4 DA4/1 . . . . . . . . . 17
1.4 Load Data for Trolley Track . . . . . . . . 6
1.5.9 Model GM 3000.4 S2/1 . . . . . . . . . . 18
1.4.1 Model E . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5.10 Model GM 3000.4 S4/1 . . . . . . . . . . 19
1.4.2 Model D . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.3 Model S . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Tightening torques . . . . . . . . . . . . . . . 10 2 Declaration of Conformity . . 20
Page 2 Data : 15.05.2012

1 Technical Data
1.1 Sound Emissions Sound pressure Sound power
As the distance between the noise source and the Hoist
level LP, m level
workplace is normally not fixed in the case of hoists, the type
dB(A) at 4m LW, m dB(A)
sound power level is quoted in addition to the required
sound pressure level figure (given for a distance of 4 m GM 3000.4 67 87
in this case).
The sound power level may be used to calculate the The measurements made were based on DIN 45635,
sound pressure level at any distance (under free field Part 61 and were made by the substitution method
conditions 2dB (A)). using a sound power source.
AN 120061.004_EN / A 772.EN Page 3

1.2 Electrical Data of Motors
Hoist lifting drives
P ED c/h Rated and start. current in A with 50 Hz cos N cos A
Type [kW] [%]
380 415 V
IN IA
1,2/7,6 60 360 6,1/16,8 9,4/75 0,59/0,83 0,68/0,88
1,0/6,2 60 420 5,4/13,0 9,4/75 0,52/0,78 0,68/0,88
L6 GM 3000.5
0,8/4,8 60 420 5,1/11,5 9,4/75 0,45/0,73 0,68/0,88
0,6/3,7 60 420 4,9/10,0 9,4/75 0,39/0,67 0,68/0,88
1,9/12,3 50 300 8,2/22,9 13,8/117 0,71/0,94 0,80/0,77

1,5/9,9 60 360 7,8/18,9 13,8/117 0,62/0,93 0,80/0,77
H6 GM 3000.5
1,3/8,0 60 420 7,5/16,3 13,8/117 0,53/0,89 0,80/0,77
1,0/6,2 60 420 7,5/14,0 13,8/117 0,45/0,82 0,80/0,77
The ED (c/h) values are the total from the precision and
1,73 * L * I A * cos A
main hoisting speed: A= (mm2)
They are split up at 1/3 (2/3) into prec. hoisting, and at u*
2/3 (1/3) into main hoisting operation.
The required fuses and feed line cross sections are u**A
L= (m)
determined according to the hoist motor data. They are 1,73 * I A * cos A
also applicable to electrically operated trolleys.
u = voltage drop in V
The feed line (max. 5% of the rated voltage) z.B.:
Cable cross section (A) and cable length (L) are calcu- U=400 V u=U * 5% = 400 * 0,05 = 20 V
lated acc. to the following formula:
= conductivity (for copper = 57 m
)
* mm2
Trolley drives
380 415 V
Trolley n [min 1] ED [%] c/h P [kW] cos N cos A
IN IA
E 130 620 / 2690 50 240 0.04 / 0.18 0.37 / 0.57 0.52 / 2.10 0.75 / 0.85 0.91 / 0.91
E 160 595 / 2770 50 240 0.06 / 0.28 0.35 / 0.83 0.57 / 3.20 0.65 / 0.84 0.82 / 0.92
AZP 130 620 / 2690 50 240 0.04 / 0.18 0.37 / 0.57 0.52 / 2.10 0.75 / 0.85 0.91 / 0.91
AZP 130 595 / 2770 50 240 0.06 / 0.28 0.35 / 0.83 0.57 / 3.20 0.65 / 0.84 0.82 / 0.92
AZP 160 550 / 2760 50 240 0.10 / 0.48 0.53 / 1.59 0.92 / 5.90 0.66 / 0.80 0.71 / 0.91
AZP 200 620 / 2750 50 240 0.14 / 0.65 0.68 / 1.68 1.45 / 8.10 0.67 / 0.86 0.80 / 0.82
AZP 200 620 / 2780 50 240 0.18 / 0.80 0.92 / 2.10 1.75 / 10.1 0.65 / 0.84 0.75 / 0.85
AZP 280 620 / 2750 50 240 0.14 / 0.65 0.68 / 1.68 1.45 / 8.10 0.67 / 0.86 0.80 / 0.82
AZP 280 620 / 2780 50 240 0.18 / 0.80 0.92 / 2.10 1.75 / 10.1 0.65 / 0.84 0.75 / 0.85
Page 4 Data : 15.05.2012

1.3 Weights and Dimensions
1.3.1 Dimensions series E

Increase in C
CDimension dimension for
Dimensions [m]
Size Type Hook path [m] for standard each 50 mm
length x width x height
flange widths increase in
flange width
GM 3000.4 2/1 12 1.05 x 1.40 x 0.65 1)
GM 3000.4 2/1 20 1.25 x 1.40 x 0.65 1) 665 1) 62 1)
GM 3000.4 2/1 30 1.55 x 1.40 x 0.65 1)
GM 3000.4 4/1 6 1.05 x 1.40 x 0.65 1)
580 1) 80 1)
GM 3000.4 4/1 10 1.25 x 1.40 x 0.65 1)
1) standard flange widths N=300 mm; For other flange width, the width is changed accordingly.
Weights for the hoist are given in the data sheet in the test book.
1.3.2 Dimensions series D

Sizes Type Model Dimensions m
length x width x height
GM 3000.4 2/1 D 2.90 x 1.20 x 0.70
GM 3000.4 2/1 DB 2.80 x 2.20 x 1.10
GM 3000.4 2/1 DQA 2.90 x 1.80 x 0.70 1)
GM 3000.4 DL=130 4/1 D 2.90 x 1.40 x 0.70
GM 3000.4 DL=160 4/1 D 3.00 x 1.50 x 0.70
GM 3000.4 4/1 DB 2.80 x 2.20 x 1.10
GM 3000.4 4/1 DQA 2.90 x 1.80 x 0.70 1)
GM 3000.4 2/1 DA 2.80 x 1.50 x 0.80
GM 3000.4 4/1 DA 2.90 x 1.20 x 0.70
The length is valid for a trolleyspan of 2500 mm. Trolley Type Weight [kg]
1) The width of trolleys of series DQA is valid for the
largest hook travel of the hoist. AZP 130 20
Weights for the hoist are given in the data sheet AZP 160 30
included in the test book.
AZP 200 40
Weights for travel drives are given in the table below.
1.3.3 Dimensions series S

Sizes Type hook travel Dimensions m
[m] length x width x height
GM 3000.4 4/1 6 / 10 1.80 x 1.95 x 0.65 ( 0.80 )
GM 3000.4 2/1 12 / 20 1.65 x 1.90 x 0.65 ( 0.80 )
Weights for the hoist are given in the data sheet in the Trolley Weight [kg]
test book.
( ) Dimensions incl. transport support AZP 200 40
Weights for travel drives are given in the table below. AZP 280 50
AN 120061.004_EN / A 772.EN Page 5

1.4 Load Data for Trolley Track
1.4.1 Model E
Lifting
g Load case H Load case HZ Load case HS
capaci- i
ty Rmax 1) RKAmin 1) FSKA 2) FMKA 3) FPUKR 4) in (kN/Katze) at
(kg) (kN) (kN/Wheel) (kN/Trolley) (kN/Trolley) 4/16 m/min 5/20 m/min 7/28 m/min
GM 3000.4 2/1E Trolley drive E 130 (HW 12m / 20m)

2500 10.3 1.6 1.6 1.0 8.1 9.9 14.3
3200 12.7 1.6 1.9 1.0 8.7 10.5 15.0
4000 15.5 1.6 2.3 1.0 9.5 11.3 15.7
5000 19.0 1.6 2.8 1.0 10.6 12.3 16.7
GM 3000.4 2/1E Trolley drive E 160 (HW 12m / 20m)

6300 27.3 2.0 3.5 1.2 14.3 15.0 21.0
GM 3000.4 2/1E Trolley drive E 160 (HW 30m)

2500 13.0 2.0 1.7 1.2 10.4 11.2 17.2
3200 15.6 2.0 2.0 1.2 11.0 11.8 17.9
4000 18.7 2.0 2.4 1.2 11.8 12.7 18.7
5000 22.2 2.0 2.9 1.2 12.9 13.6 19.6
6300 27.3 2.0 3.5 1.2 14.3 15.0 21.0
GM 3000.4 4/1E Trolley drive E 160

4000 14.0 1.8 2.4 1.1 16.4 24.1
5000 18.5 1.8 2.8 1.1 17.7 26.8
6300 22.9 1.8 3.5 1.1 19.0 28.1
8000 28.5 1.8 4.3 1.1 20.7 29.7
10000 35.1 1.8 5.3 1.1 22.6 31.7
12500 43.4 1.8 6.5 1.1 24.9
1) Wheel load without coefficient 3) Load along track according to DIN 4132 3.2.2.
2) Load across track according to DIN 4132 3.2.1. 4) Total buffer force if ABUS buffers are used
1.4.2 Model D_
Load case H Load case HZ Load case HS
Lifting 1)
Rmax RKAmin 1) FSKA 2) FMKA 3) FPUKR 4) in (kN/Trolley) at
capacity
(kg) (kN/Trolley-
(kN) (kN/Wheel) track) (kN/Trolley) 5/20 m/min 7,5/30 m/min
GM 3000.4 2/1---D Trolley drive AZP 130

2500 8.2 2.0 2.7 1.2 10.1 14.6
3200 9.9 2.0 3.3 1.2 10.8 15.2
4000 11.9 2.0 3.9 1.2 11.5 16.0
5000 14.4 2.0 4.7 1.2 12.5 17.0
6300 17.5 2.0 5.8 1.2 14.3 20.0
Page 6 Data : 15.05.2012

Lifting 1)
capacity Rmax RKAmin 1) FSKA 2) FMKA 3) FPUKR 4) in (kN/Trolley) at
(kg) (kN/Trolley-

4000 12.3 2.35 3.6 1.4 12.6 17.4
5000 14.7 2.35 4.4 1.4 13.5 18.3
6300 17.9 2.35 5.3 1.4 14.3 19.6
8000 22.1 2.35 6.6 1.4 16.0
10000 27.0 2.35 8.0 1.4 18.0
12500 33.6 3.0 9.7 1.8 21.6 28.6
GM 3000.4 2/1---DB Trolley drive AZP 130
2500 9.5 3.5 2.5 2.1 12.3 19.3
3200 11.1 3.5 3.1 2.1 12.9 20.0
4000 13.0 3.5 3.5 2.1 13.6 20.8
5000 15.5 3.5 4.3 2.1 14.6 21.8
6300 19.0 3.5 5.1 2.1 17.1 25.2
4000 13.4 3.4 3.5 2.1 14.2 21.9
5000 15.8 3.4 4.0 2.1 15.1 22.9
6300 19.0 3.4 4.8 2.1 16.4 24.2
8000 23.1 3.4 5.8 2.1 18.1
10000 28.1 3.4 7.2 2.1 20.1
12500 35.3 4.5 9.3 2.7 25.1 36.0
GM 3000.4 2/1---DQA Trolley drive AZP 160
2500 12.3 2.6 3.2 1.6 11.1 17.4
3200 15.1 2.6 3.8 1.6 11.8 18.1
4000 18.2 2.6 4.6 1.6 12.5 18.9
5000 22.5 2.6 5.7 1.6 13.5 19.9
6300 24.5 2.6 6.9 1.6 15.0 21.5
GM 3000.4 4/1---DQA Trolley drive AZP 160
4000 14.0 2.7 4.1 1.6 12.8 19.0
5000 18.8 2.7 5.0 1.6 13.5 20.1
6300 23.0 2.7 5.9 1.6 14.8 21.5
8000 28.3 2.7 7.2 1.6 16.5 23.0
10000 34.6 2.7 8.8 1.6 18.5 25.0
12500 43.0 2.7 10.8 1.6 21.0 27.3
1) Wheel load without coefficient

2) Load across track to DIN 4132 3.2.1. per trolley track
3) Load along track to DIN 4132 3.2.2.
4) Total buffer force if ABUS buffers are used
AN 120061.004_EN / A 772.EN Page 7

Lifting 1)
capacity Rmax RKAmin 1) FSKA 2) FMKA 3) FPUKR 4) in (kN/Trolley) at
(kg) (kN/Trolley-
GM 3000.4 2/1---DA Trolley drive AZP 130

2500 8.2 2.0 2.7 1.2 10.1 14.6
3200 9.9 2.0 3.3 1.2 10.8 15.1
4000 11.9 2.0 3.9 1.2 11.5 16.0
5000 14.4 2.0 4.7 1.2 13.5 17.0
6300 17.5 2.0 5.8 1.2 14.3 20.0
GM 3000.4 4/1---DA Trolley drive AZP 160
4000 12.7 2.89 3.3 1.75 13.1 20.0
5000 15.1 2.89 4.0 1.75 14.0 21.0
6300 18.3 2.89 5.3 1.75 15.3 22.3
8000 22.5 2.89 6.6 1.75 17.0 24.0
10000 27.5 2.89 8.0 1.75 18.9 25.9
12500 33.6 2.89 9.7 1.75 21.4 28.3

Page 8 Data : 15.05.2012

1.4.3 Model S
Lifting FPUKR 4) in (kN/Trolley)
capacity Rmax 1) Rmin 1) RGmax RGmin FSKA 2) FMKA 3) at
(kg)
(kN/ (kN/ (kN/Trolley- 7,5/30
(kN) Wheel) (kN) Wheel) track) (kN/Trolley) 5/20 m/min m/min
GM 3000.4 2/1S Trolley drive AZP 200

for S1 (Top flange width 600mm):
2500 30.5 23 19.0 0.3 1.5 1.6 11.2 15.9
3200 37.0 29 24.0 0.3 1.9 1.8 12.6 17.3
4000 44.8 35 30.0 0.3 2.3 2.1 14.2 18.9
5000 54.8 42 37.5 0.3 2.8 2.3 16.2 20.9
2500 29.0 22.0 15.9 0.2 1.45 1.55 11.0 15.6
3200 36.0 27.0 20.5 0.2 1.8 1.8 12.5 17.0
4000 43.0 32.6 25.3 0.2 2.2 2.0 14.0 18.5
5000 52.6 39.8 31.4 0.2 2.7 2.25 15.8 20.4
GM 3000.4 4/1S Trolley drive AZP 280
4000 43.0 5.4 31.0 0.6 2.3 2.5 14.4 20.3
5000 52.0 5.4 38.0 0.6 2.65 2.8 16.8 22.5
6300 64.5 5.4 47.2 0.6 3.25 3.2 18.5 24.5
8000 80.0 5.4 60.0 0.6 4.1 3.6 21.6 27.5
10000 98.4 5.4 74.5 0.6 5.0 4.1 24.7 31.1
4000 40.0 5.1 25.5 0.4 2.0 2.5 13.9 20.0
5000 49.0 5.1 32.0 0.4 2.5 2.7 16.5 22.0
6300 60.0 5.1 40.0 0.4 3.0 3.0 18.0 24.0
8000 74.0 5.1 50.0 0.4 3.7 3.5 21.0 27.0
10000 92.0 5.1 63.0 0.4 4.6 3.9 24.2 30.8
Dimensions S1 S3: Dimension sheet MES103..

AN 120061.004_EN / A 772.EN Page 9

1.5 Tightening torques
1.5.1 Model GM 3000.4 E2/1
M24: 150 42 Nm 25 Nm 4 Nm 1) 10 Nm 25 Nm
M30: 290
6,5 Nm 25 Nm 1) 5 Nm 35 Nm 50 Nm
6,5 Nm
85 Nm
1)locking with Loctite 243

120 Nm 2)without safety device
Safety devices all other screws are selflocking
t
from flange thickness t (mm)
Figure 1
< 12 60 Nm
12 80 Nm
Tightening torques (in Nm) and safety devices for screwed connections
Page 10 Data : 15.05.2012

1.5.2 Model GM 3000.4 E4/1
10 Nm 290 Nm 75 Nm 4 Nm 1) 75 Nm 25 Nm
6,5 Nm 25 Nm1) 5 Nm
35 Nm 50 Nm
6,5 Nm
85 Nm

120 Nm 2)without safety device
t
from flange thickness t (mm)
< 12 60 Nm
12 80 Nm Figure 2
AN 120061.004_EN / A 772.EN Page 11

1.5.3 Model GM 3000.4 D2/1
50 Nm
75 Nm 10 Nm
42 Nm
25 Nm
42 Nm
42 Nm
50 Nm2)
42 Nm
25 Nm
5 Nm
6.5 Nm
35 Nm
25 Nm1)
25 Nm
42 Nm
85 Nm
42 Nm
5,9 Nm1)

2)without safety device
Safety devices all other screws are selflocking Figure 3
Page 12 Data : 15.05.2012

1.5.4 Model GM 3000.4 DQA2/1
50 Nm
115 Nm
42 Nm 25 Nm 10 Nm
50 Nm2)
42 Nm 6.5 Nm 5 Nm 25 Nm1)
42 Nm
75 Nm
75 Nm
75 Nm
85 Nm
42 Nm
42 Nm
1) 10 Nm1)
locking with Loctite 243
Figure 4
AN 120061.004_EN / A 772.EN Page 13

1.5.5 Model GM 3000.4 D4/1
50 Nm
10 Nm 50 Nm
75 Nm 75 Nm 75 Nm 42 Nm 25 Nm
75 Nm
42 Nm
5 Nm
6.5 Nm
D130: 35 Nm
D160: 75 Nm
25 Nm1)
25 Nm
85 Nm
42 Nm
D130: 42 Nm
D130: 5,9 Nm1)
D160: 85 Nm
1)
D160: 10 Nm1)
locking with Loctite 243
2)without safety device Figure 5
Page 14 Data : 15.05.2012

1.5.6 Model GM 3000.4 DQA4/1
25 Nm
50 Nm
115 Nm
10 Nm 75 Nm 75 Nm
42 Nm 6.5 Nm 5 Nm 25 Nm1)
50 Nm2)
42 Nm
75 Nm
42 Nm
75 Nm 85 Nm 75 Nm
10 Nm1) 42 Nm
AN 120061.004_EN / A 772.EN Page 15

1.5.7 Model GM 3000.4 DA2/1
50 Nm 10 Nm
42 Nm
25 Nm
50 Nm
42 Nm
450 Nm 35 Nm
5 Nm
6.5 Nm
42 Nm
25 Nm1)
85 Nm 25 Nm
25 Nm
42 Nm
75 Nm
5,9 Nm1) 42 Nm
Page 16 Data : 15.05.2012

1.5.8 Model GM 3000.4 DA4/1
75 Nm
75 Nm
42 Nm
10 Nm 50 Nm 50 Nm
25 Nm
5 Nm
6.5 Nm
450 Nm
42 Nm
25 Nm1)
25 Nm
35 Nm 42 Nm
85 Nm
42 Nm
85 Nm
10 Nm1)
75 Nm
AN 120061.004_EN / A 772.EN Page 17

1.5.9 Model GM 3000.4 S2/1
75 Nm
25 Nm
75 Nm
115 Nm
10 Nm
42 Nm
25 Nm 42 Nm
50 Nm2)
6.5 Nm 5 Nm
42 Nm
450 Nm
25 Nm1)
19 Nm
85 Nm
85 Nm 115 Nm
42 Nm
85 Nm
10 Nm1)
1) locking with Loctite 243

2) without safety device
Page 18 Data : 15.05.2012

1.5.10 Model GM 3000.4 S4/1
50 Nm
115 Nm
10 Nm 75 Nm 75 Nm 210 Nm 75 Nm
50 Nm 25 Nm1)
6.5 Nm
5 Nm
85 Nm
25 Nm 130 Nm
10 Nm1) 130 Nm
450 Nm
19 Nm
300 Nm 42 Nm
1) locking with Loctite 243

2) without safety device Figure 10
AN 120061.004_EN / A 772.EN Page 19

2 Declaration of Conformity
applies if this wire rope hoist is operated as an independent machine.
Declaration of installation under the terms of the machinery directive of Appendix II 1B

applies if this wire rope hoist is installed in another machine. In addition, the wire rope hoist must nut be commissioned until it has been confirmed
that the machine in which the wire rope hoist is installed conforms in its entirety with the provisions of the stated EC directives in the version in force
on the date of issue.
We ABUS Kransysteme GmbH

Adress Sonnenweg 1
D 51647 Gummersbach
Authorised person for assembly of the special technical documentation:
Name, function, company designation Michael Mller
Department head of technical documentation
address Sonnenweg 1
D ---51647 Gummersbach
hereby declare, that the product:
Designation ABUS---Wire rope hoist
Hoist GM 3000.4
Model E 2/1 , D 2/1 , DB 2/1 , DQA 2/1
E 4/1 , D 4/1 , DB 4/1 , DQA 4/1
S 2/1 , S 4/1 , DA 2/1 , DA 4/1
in series production
the regulations of the european guideline
2006/42/EG Machines
2006/95/EG Low voltage
2004/108/EG Electromagnetic compatibility
is in accordance with the version in force on the date of issue.
The following harmonized standards were used:
EN ISO 12100 Safety of machinery, tools and plants
EN 12077 Limiting and indicating devices
EN 13586 Access
EN 12644--- 1+2 Instructions and marking
EN 60204 T32 Electrical equipment of machines; requirements for hoists
EN 60947 Low--- voltage switchgear
EN 61000--- 6--- 4 Electromagnetic compatibility; Interference emission
EN 61000--- 6--- 2 Electromagnetic compatibility; Resistance to interferences
EN 12385--- 3 Steel wire ropes --- Safety --- Information for use and maintenance
and the national standards, instructions and specifications
DIN 15018 Cranes; principles for steel structures
DIN 15020 Hoists; principles for rope drives
FEM 9.511 FEM groups
FEM 9.661 Size and design of rope drives
FEM 9.683 Selection of hoist motors and of travel motors
FEM 9.755 Action to ensure safe working periods
FEM 9.811 Specification for electric hoists
FEM 9.941 Symbols for controls
and the standards referred to therein.
Technical documentation is completely available.
The operating instructions belonging to it are in the language of the land of users.
Name: Dr. Eckhard Bube
Board of
Management
Gummersbach, 15/05/2012 ___________________________ _________________________
Signature of authorized person indication for the subscriber
This declaration is in accordance with EN ISO 17050.

The ABUS Kransysteme GmbH entertains security system of quality under DIN EN ISO 9001.
Page 20 Data : 15.05.2012

Kransysteme
Installation, Operation and Maintenance Instructions
for
ABUS - Pendant control BJ 24
- 211 -D
Type HT 611
-
- 1011 -S
16735993 / 1
Factory No. ___________________
Manufacturer
ABUS Kransysteme GmbH Tel. ##49 2261 / 37-0
Sonnenweg 1 Fax. ##49 2261 / 37247
D - 51647 Gummersbach info@abus- kransysteme.de
These Installation, Operation and Maintenance Instructions are intended for use in an English-
speaking country by English- speaking specialist personnel.
AN 120028.003_EN 01.02.2016 Original operating manual
Contents
1 General . . . . . . . . . . . . . . . . . . . 3 4.2 Extension of sheathed control line
with BJ24 connector system . . . . . . . 11
1.1 Use of Operating Instructions . . . . . . 3
4.3 Sheathed control line on
1.2 Use for the Intended Purpose . . . . . . 3 mobile control carrier . . . . . . . . . . . . . 12
1.3 Standards and Regulations . . . . . . . . 3
1.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Other notes . . . . . . . . . . . . . . . . . . . . . . 4
5 Operation . . . . . . . . . . . . . . . . . 13
2 Safety . . . . . . . . . . . . . . . . . . . . 4 6 Maintenance . . . . . . . . . . . . . . 13
2.1 Organizational Notes . . . . . . . . . . . . . . 4 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Replacement of Switch Unit . . . . . . . . 13
6.2.1 Direct control . . . . . . . . . . . . . . . . . . . . 13
3 Description . . . . . . . . . . . . . . . 5
6.2.2 Contactor- type control . . . . . . . . . . . 13
3.1 Type Overview / Type Codes . . . . . . . 5
6.3 Replacement of
3.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Protective Rubber Cap . . . . . . . . . . . . 14
3.2.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . 6 6.4 Replacement of Housing . . . . . . . . . . 14
3.2.2 Bayonet Mount . . . . . . . . . . . . . . . . . . . 7 6.5 Replacement of Microswitch for
3.2.3 Strain Relief . . . . . . . . . . . . . . . . . . . . . . 7 Emergency Shut - Down Function . . 14
3.3 Technical data . . . . . . . . . . . . . . . . . . . 7 6.6 Replacement of Surround

and Head of Emergency
3.4 Declaration of conformity . . . . . . . . . . 8 Shut - Down Switch . . . . . . . . . . . . . . . 14
3.5 Circuit Diagrams . . . . . . . . . . . . . . . . . 9
7 Disposal . . . . . . . . . . . . . . . . . . 14
4 Adaptation of control line . . 10
4.1 Shortening of sheathed control line
with BJ 24 connector system . . . . . . 10 8 Service . . . . . . . . . . . . . . . . . . . 14
Page 2 Data : 01.02.2016

1 General
1.1 Use of Operating Instructions D inching operation
These installation, operation and maintenance instruc-
tions must be read carefully before using the ABUS
pendant control for the first time and must be available 1.3 Standards and Regulations
to operating personnel at all times during the use of the When installing the pendant control, you must comply
pendant control. with the general regulations concerning electrical in-
stallation work.
Apart from During the operation of our products, compliance with
the applicable accident prevention regulations and
. instructions for action general safety regulations is also essential.
these instructions also include hazard, warning and

safety instructions highlighted by the following sym-
bols: IEC 60364- 5- 56
Regulations concerning the installation of power sys-
Caution: Hazard to Personnel tems with rated voltages up to 1000 V
If you fail to comply with these instructions,
EN 60204- 32
there may be an immediate risk of personal
Safety of machinery: Electrical equipment of machines;
injury; premature damage to the equipment
requirements for hoists.
may also result in further risks of injury.
In the case of special applications, it may be necessary
Compliance with the instructions given in these warn- to comply with other applicable regulations.
ings is essential.
Note:
These notes are important for the proper, ra-
1.4 Warranty
tional use of the product or may concern ABUS will assume no liability for damage to the pen-
special features of the product. dant control or hoists or other equipment controlled
using the pendant control arising out of or in connec-
tion with the use of the pendant control other than for
the intended purpose or work carried out incorrectly or
1.2 Use for the Intended Purpose by unauthorized persons. ABUS will assume no liability
ABUS HT pendant controls are intended for the control for any loss or damage suffered by third parties.
of machinery, preferably for the control from ground
level of all types of hoists (electric hoists, site hoists, tra- Caution!
velling cranes, etc.). If you modify any components under your
The pendant controls are designed either for use in own responsibility, assemble components
contactortype control systems or for direct control. other than in accordance with the installation
Pendant controls are resistant to attack by oils, instructions or use any components other
greases, fuels, caustic solutions, salts and solvents. than genuine ABUS components, ABUS will
They are designed to degree of protection IP 65 in ac- be released from any warranty obligations for
cordance with EN 60529 and may be used at ambient the entire equipment.
temperatures ranging from - 20 C to +70 C.
ABUS pendant controls are largely maintenancefree.
Other operating conditions and modes of operation will For the safe operation of the product, it is essential to
require special investigation and agreement. It may be use genuine ABUS parts if any spare parts are requi-
necessary to obtain the manufacturers approval. red.
In particular, the following types of use are classed as
use other than for the intended purpose: It is recommended that repair and mainten-
D the movement of loads by pulling the control line ance work should be carried out by the ABUS
D intentional damage by impact etc. service department.
AN120028.003_EN Page 3
1.5 Other notes ral attitude of the hand and arm of the operator, reduc-
ing fatigue and having a positive effect on the position
We are very pleased that you have decided to use an
of the entire body.
ABUS pendant control and hope that the pendant con-
The newly developed configuration of the controls fa-
trol will continue to perform its task reliably and to your
cilitates optimum single- handed operation with sen-
complete satisfaction for many years.
sory feedback as an added safety feature. In addition to
having a visual indication of the position of the controls,
Pendant controls are designed with ergonomic con-
the operators finger or thumb can feel which control is
siderations in mind. The controls of the pendant control
actually being operated at any time.
are inclined slightly from the vertical to facilitate a natu-
_________________________________
2 Safety
2.1 Organizational Notes . The product must be tested before it is commis-
Operating, maintenance and repair personnel must sioned for the first time and following any major
have read and understood the operating instructions modifications.
before starting work. Please follow the instructions given in the docu-
The owner of the product is responsible for ensuring mentation for the machine or equipment controlled
safe and non- hazardous operation. In this connec- using the pendant control.
tion, compliance with the following requirements is es-
sential:
. The operating instructions must be made available
to operating personnel and operating personnel
must be familiarized with these instructions.
Page 4 Data : 01.02.2016

3 Description
3.1 Type Overview / Type Codes

The ABUS range of pendant controls includes the following models, see Fig. 1:
ABUS type HT- D pendant control for controlling power circuits (direct control)
ABUS type HT- S pendant control for controlling control circuits (contactortype control)
HT 211 D HT 211 S
300
300
30
30
78
78
HT 611 S HT 1011 S
40 45 40 40 30
460
40 30
380
45
78 78
Fig. 1
AN120028.003_EN Page 5
The complete type designation of the pendant control is based on the ABUS type code which is explained below:
HT 6 1 1 D N 2 2 2 K BJ24
Use of lower row
K = crane travel drive
S = slewing drive
Crane travel: 2 = 2stage
Trolley travel: 2 = 2stage
Hoist drive: 2 = 2stage
N = emergency shutdown
Control type:
D = direct control
S = contactortype control
1 reserve space
Installation space for
emergency shutdown switch
Number of Installation spaces (2, 6 or 10)
ABUS pendant control
3.2 Design
Fig. 2 shows the external and internal parts of a pen- 8
dant control
1. upper section of housing 7

2. Emergency stop switch
3. protective cap 2
4. cover
5. switch unit
6. lower section of housing
7. pin contacts
8. isolator of connector
3
6
3.2.1 Controls
The controls and indicators on an ABUS pendant con-
trol are installed in two separate control areas depend-
ing on their importance and the frequency of use. The 5 1
section with the controls which are used most often is Fig. 2
extremely compact and is inclined towards the oper-
ator to facilitate use.
The upper section also includes the emergency shut -
down switch, which has a central control function. The
emergency shut - down switch is positioned for opti-
mum operation and ease of access at all times.
Page 6 Data : 01.02.2016

3.2.2 Bayonet Mount
ABUS pendant controls are designed for ease of use
and for comfortable holding and access. You must not
attempt to move a load by pulling the pendant control.
For maintenance work and in emergencies, the pen-
dant control can easily be disconnected from the strain
relief device and from the electrical cabling. The unit is
equipped with a quick - acting bayonet mount for this
purpose (Fig. 3). 2
The bayonet lock of the sheathed control line consists
of the bayonet nut, the conical sleeve and the socket
insert with pin contacts. To disconnect the pendant
control unit from the control lines, it is only necessary to
turn the bayonet nut (2) a quarter of a turn (90 ) to the
left.
3.2.3 Strain Relief

Strain relief is provided by the sheath of the control line.
Fig. 3
3.3 Technical data

Housing
Degree of protection to EN 60529: IP65
total insulation to EN 60204- 32 Section
Protection:
6.2.2
impactresistant plastic, weatherproof and
Material:
corrosion resistant
Ambient temperature range: -20C to +70C
Switches
a. ABUS pendant control unit for direct control
designed for the direct switching of power circuits
Short circuit current: 16 A
Rated insulation voltage Ui (Group C) 500 V
Rated operating current Ie (with 400 V / 50 Hz): 5A
Service life in mixed operation: with motor output:
(75% AC3 und 25% AC4, switching frequency 1.5 kW 1.5x106 S
600 operations per hour, duty cycle 40%) 2.2 kW 0.6x106 S
Mechanical service life 2.0x106 S
(S = number of switching operations)
b. ABUS pendant control unit for contactortype control systems
designed for the switching of control circuits
Short circuit current: 10 A
Rated insulation voltage Ui (Group C) 500 V
Rated operating current Ie (with 250 V / 50 Hz): 5A
Service life in mixed operation: (S = number of switching operations)
(AC11 230 V) 2.0x106 S
AN120028.003_EN Page 7
3.4 Declaration of conformity

Address Sonnenweg 1
D - 51647 Gummersbach
address Sonnenweg 1
Designation ABUS pendant control

Types HT 211, HT 611, HT 1011
in Series production
is in accordance with the european guidlines

referring to the version in force on the date of issue.
EN ISO 12100 Safety of machinery, tools and plants

EN 61000- 6- 4 Electromagnetic compatibility; interference emission
EN 61000- 6- 2 Electromagnetic compatibility; resistance to interferences
and the national standards, instructions and specifications
EN ISO 13850 Safety of machinery, Emergency shut - down systems

EN 60947 Low - voltage switchgear

Name: Gerald Krebber
Department manager
Development
Gummersbach, 01.02.2016 ___________________________ _________________________

Signature of authorised person Indication for the subscriber

The company ABUS Kransysteme GmbH runs a certified quality management system according to DIN EN
ISO9001.
Page 8 Data : 01.02.2016

3.5 Circuit Diagrams
The diagrams below show the circuitry of ABUS pendant controls and the pin allocation of the control cable con-
nection socket.
A A
2 - X2
1 - X2
1 - S1
1 - S1
4 2
2
3
3
4 - S21
4 - S21
5 - S22
5 - S22
- S42 6 7 - S41
6 7 5
- S62 8 9 - S61
- N222S- B
HT 211D - N200-B HT 611D - N220-B

30.1 30.1 32.1
30.2 30.2 32.2
1 1 1
2 2 2
- S1 2 2 - S21012 1323 - S22012 43 53 - S21 13 23 - S22 43 53 - S41 13 23 - S42 43 53
- S1 2 2 012 012 012 012
1 1 1424 44 54
Emer- lifting lowering 1 1 lifting 14 24 lowering
44 54 14 24 left
44 54
gency Emergency right
stop stop
2 3161 2 33 63
2 31 61 2 33 63 2 31 61 2 33 63
3262 34 64
32 62 34 64 32 62 34 64
31.1
29.1
31.2
31.3
31.4
29.2
31.1
29.1
31.2
31.3
33.1
31.4
29.2
33.2
33.3
33.4
- X2 1 2 3 4 5 6
- X2 1 2 3 4 5 6 7 8 9 10
HT 211S - N200-B HT 611S - N220-B

33
- S1 1 - S21
012 115 21 - S1 - S21 - S41 11
4 115 21 1b 1a 21
12 14- S22 22 24 1 012 4 012 6 5
2
lifting 012 315 41
2 12 14- S22 22 24 12 14- S42 22 24
Emer- 4
Emergency lifting 012 315 4
41 right 012 317 6
41
gency 32 34 42 44
30
stop lowering
stop 32 34 42 44 32 34 42 44
30
1a 1b lowering left
1a 1b
2 3 4
2 3 4 2 3 4
31.1
31.2
31.3
29
32
31.1
31.2
31.3
34.1
34.2
34.3
29
32
- X21 2 3 4 5 - X21 2 3 4 5 6 7 8
Fig. 4
AN120028.003_EN Page 9
Notes: Caution! If the control line is used with an
ABUS pendant control for direct control, this
D If item 24 (4) on the socket insert is not used, this blind contact pin must always be in position.
position must be equipped with a coding pin, which
- must be removed in combination with a contactor- D If S41 / S42 or S61 / S62 are to be used for the con-
type pendant control trol of a slewing drive or other equipment with a ro-
- must be broken off at the marked point in combina- tating motion, symbol (5) should be used instead of
tion with a direct control system, so that the pin can symbol (6).
no longer be removed D If a symbol is rotated 45 , the guide lugs (7) must
be removed.
HT 611D - N202K/S-B
30.1 32.1
30.2 32.2
1 1
2 2
- S1 2 2
- S21 13 23 - S22 43 53 - S61 1323 - S62 43 53
012 012 012 012
1 1 lifting 14 24 44 54 forward 1424 backward 44 54

Emer- lowering
gency
stop 2 31 61 2 33 63 2 3161 2 33 63
32 62 34 64 3262 34 64
31.1
29.1
31.2
31.3
33.1
31.4
29.2
33.2
33.3
33.4
- X21 2 3 4 5 6 11 12 13 14
HT 611D - N222K/S-B
30.1 32.1 32.3
30.2 32.2 32.4
1 1 1
2 2 2
- S12 2 - S21012 1323 - S22012 4353 - S41012 1323 - S42012 4353 - S61012 1323 - S62012 4353
1 1 lifting
1424 4454 right 1424 left 4454 forward 1424 backward 4454
Emer- lowering
gency
stop 2 3161 2 3363 2 3161 2 3363 2 3161 2 3363
3262 3464 3262 3464 3262 3464
31.1
29.1
31.2
31.3
33.1
31.4
34.1
29.2
33.2
33.3
33.4
34.2
34.3
34.4
- X21 2 3 4 5 6 7 8 9 10 1112 1314
HT 611S - N202K/S-B
33
- S1 - S21 115 21 1b 1a - S61 116 21

1 012 4 012 5
2 12 14- S22 22 24 forward12 14- S62 22 24
Emer- lifting 012 315 4
41 012 317 6
41
gency 32 34 42 44 32 34 42 44
backward
30
stop lowering
1a 1b
2 3 4 2 3 4
31.1
31.2
31.3
34.1
34.2
34.3
29
32
- X21 2 3 4 5 9 10 11
HT 611S - N222K/S-B
33 35
- S21 - S41 - S61

- S1 1 012 115 4
21 1b 1a
012 116 5
21 1a 1b
012 118 7
21
2 lifting 12 14- S22 22 24 right

12 14- S42 22 24 forward12 14 - S62 22 24
Emer- 012 315 41 012 317 41 012 318 41
4 6 8
gency
stop 32 34 42 44 left
32 34 42 44 32
backward 34 42 44
lowering
30
1a 1b
2 3 4 2 3 4 2 3 4
31.1
31.2
31.3
36.1
34.1
36.2
36.3
34.2
34.3
29
32
- X2 1 2 3 4 5 6 7 8 9 10 11
Fig. 5
4
4.1 Adaptationofof
Shortening controlcon-
sheathed line
Page 10 Data : 01.02.2016
4.2 Extension of sheathed control Any standard sheathed control line may be used for ex-
tension in combination with spare parts set AN 102282.
line with BJ24 connector sys-
tem
If a control line needs to be extended, you must use a
connection element consisting of:
1. coupling
2. socket spacer ring
3. plug spacer ring
The coupling sides and the spacer rings are marked
with plug and socket symbols.
(see Fig. 7).
Bayonet lock BJ 30
socket
spacer ring
Snap hou-
sing BJ 30
Socket part
socket symbol
coupling
plug symbol
Connector
part
Snap hou-
sing BJ 30
plug spa-
cer ring
Bayonet lock BJ 30
Fig. 7
AN120028.003_EN Page 11
Installation of connection element: 4.3 Sheathed control line on mo-
bile control carrier
3b
3a
2a
2b
Fig. 9
Fig. 8
Extension of control line
1. Insert spacer rings into the bayonet lock in accord-

ance with the symbols.
The spacer rings are slotted.
2. a. Insert plugtype connector into coupling.
b. Lock bayonet lock.
3. a. Insert plugtype connector into coupling.
b. Lock bayonet lock.
Page 12 Data : 01.02.2016

5 Operation
The pendant control is used for the control of the ma- If you release the switch, the unit is decelerated to a
chines to which it is connected (normally hoists and standstill.
hoist trolleys). The pendant control is ergonomically If you operate the emergency stop switch, the unit is
designed, allowing operation with one hand. stopped immediately, whatever the operating situation.
The two- stage push buttons of the pendant control

cab be used for operating pole- changing motors. A
mechanical or electrical interlock in the pendant control
prevents simultaneous operation in two opposite direc-
tions.
Inching operation should be avoided. 3
Inching may lead to severe erosion of the contacts and
premature wear of the switch unit.
The functions of the pendant control are as follows

(Fig. 10):
. If the button is released 4

the unit is at a standstill.
. button pressed to first stage (1)

precision / slow speed
. button pressed to second stage (2)

main / fast speed 1
. Red emergency stop switch pressed (3)

unit is stopped even if another button is pressed.
2
. To reset the unit, turn red emergency stop switch to
right. (4).
In combination with infinitely variable speed control,

the first stage ensures a constant speed while the se-
cond stage activates an acceleration ramp set at the Fig. 10
factory.
If you release the switch from stage 2 to stage 1, the
speed which you have reached is maintained.
_________________________________
6 Maintenance
6.1 General 6.2 Replacement of Switch Unit
Each time you start work, the strain relief components,
the pendant control housing and the control cable
must be inspected for any damage.
Compliance with accident prevention regulations and 6.2.1 Direct control
general safety regulations is essential during the oper- see separate ducumentation AN120086
ation of our products (see Section 2 above).
Caution:
Work on pendant controls must only be per-
formed by electricians or other suitably quali- 6.2.2 Contactor- type control
fied personnel. see separate ducumentation AN120085
AN120028.003_EN Page 13
6.3 Replacement of Protective 6.5 Replacement of Microswitch
Rubber Cap for Emergency Shut- Down
see separate ducumentation AN120089 Function
see separate ducumentation AN120088
6.6 Replacement of Surround and

Head of Emergency Shut-
6.4 Replacement of Housing Down Switch
see separate ducumentation AN120090 see separate ducumentation AN120087
_________________________________
7 Disposal
When an ABUS pendant control is no longer needed, it Recycle the separated materials.
can be disposed of in an environmentally compatible
way. ABUS pendant controls are high- quality prod- If recycling is not possible, dispose of the pendant con-
ucts with a long service life which require almost no trol as special waste.
maintenance.
For disposal of the pendant control, proceed as
follows:
dismantle the pendant control into its constituent ma-
terials (plastic, rubber and metals).
_________________________________
8 Service
Note:
The ABUS service centre can be reached day Phone: ##49 2261 / 37 - 237
and night on the following numbers: Fax: ##49 2261 / 37 - 265
Page 14 Data : 01.02.2016

Kransysteme
Operation Instructions
for
ABUS load indication system
LIS SV
16735993 / 1
Factory No. ____________________
Manufacturer
Sonnenweg 1 Fax. ##49 2261 / 37247
These installation, operation and maintenance instructions are intended for use in an English
AN120077.000_EN 01.03.2016 Original operating manual
1 General . . . . . . . . . . . . . . . . . . . 3 4.2 LISFC Signal Converter System . . . 8
1.1 System Description . . . . . . . . . . . . . . . 3 4.3 LAZ / GLZ Load Indicator . . . . . . . . . . 9
1.2 Use for the Intended Purpose . . . . . . 3
1.3 Notes on warranty . . . . . . . . . . . . . . . . 3
5 Operation . . . . . . . . . . . . . . . . . 9
1.4 Replacement of unit . . . . . . . . . . . . . . 3
5.1 Digital Operator Terminal . . . . . . . . . . 9
5.2 Basic Settings . . . . . . . . . . . . . . . . . . . 10
2 Functions . . . . . . . . . . . . . . . . . 4 5.3 Reading the Load
2.1 Overload ShutDown . . . . . . . . . . . . . 4 Population Recorder . . . . . . . . . . . . . . 10
2.2 PartLoad Switch . . . . . . . . . . . . . . . . . 4
2.3 Taring . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Installation . . . . . . . . . . . . . . . . 10
2.4 Load Population Recorder (optional) 5
6.1 Housing and wiring diagrams . . . . . . 10
2.4.1 FEM Groups . . . . . . . . . . . . . . . . . . . . . 5
6.2 Regulations . . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Integrated Control Functions . . . . . . . 6
2.6 Frequency converter control system 6 7 Malfunctions . . . . . . . . . . . . . . 15
2.7 Safety Functions . . . . . . . . . . . . . . . . . 6
7.1 Causes and Remedies . . . . . . . . . . . . 15
2.8 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . 6
7.2 Service . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Components . . . . . . . . . . . . . . 7
8 Disposal . . . . . . . . . . . . . . . . . . 16
3.1 LISSV evaluation unit . . . . . . . . . . . . 7
3.2 Current Measurement Module . . . . . 7
3.3 LISFC Signal Converter . . . . . . . . . . 7 9 LIS SV parameter list . . . . . 17
3.4 Load Signal Transmitter . . . . . . . . . . . 7
3.5 Load Indicator (OPTIONAL) . . . . . . . 8
3.5.1 Function of load indicator . . . . . . . . . . 8 10 Description of
LIS SV parameters . . . . . . . 20
4 Technical Data . . . . . . . . . . . . 8
4.1 Load Indicator System LISSV . . . . . 8 11 Declaration of conformity . . 25
Page 2 Data : 01.03.2016

1 General
The operating instructions must always be stored near D display of fault messages on operator terminal and
the ABUS rope hoist and must be available to operating load indicator
personnel at all times. D compact spacesaving design
D all connections made by plugtype connectors for
Operating, maintenance and repair personnel must easy maintenance
have read and understood the operating instructions D control function for external part - load relay
before starting work.
1.2 Use for the Intended Purpose

The ABUS LIS- SV is designed for use in the control
systems of hoists of all types not subject to the risk of
1.1 System Description tipping- over.
The ABUS LISSV load indicator system is a compact It is intended for installation in a closed housing and for
universal load recording and evaluation system for use under the conditions listed in Section 4 below.
hoists and cranes. The LISSV operates on the prin- Special investigations must be made concerning the
ciple of microprocessorcontrolled evaluation of sig- suitability of the unit for use in other conditions and
nals from strain gauges installed on each hoist to be modes of operation. It may be necessary to obtain the
monitored in the form of measurement axles, measure- manufacturers approval for any deviations.
ment bolts or similar devices. The load calculated can
be indicated using an ABUS type LAZ or GLZ load indi-
cator. 1.3 Notes on warranty
The basic LISSV module with integrated load popula-
ABUS assumes no liability for any loss or damage
tion recorder also offers the optional feature of record-
caused by use other than for the intended purpose or
ing and evaluating the actual operating conditions of a
any work performed improperly or by unauthorized
crane system in accordance with FEM 9.755.
persons. ABUS assumes no liability as towards third
As a standard feature, the maximum load of up to three
parties.
hoists may be monitored.
See also information on parameter 5.10 in Section 10.
Attention!
In addition, the system monitors the total carrying ca-
If you modify any components under your
pacity of a crane system. The functions available in-
own responsibility, assemble components
clude part load switch, totalization and indication
other than in accordance with the installation
and load population recorder (optional). The unit can
instructions and/or plans or use any compo-
easily be adapted to a variety of load signal sources
nents other than genuine ABUS compo-
and is therefore a highly functional, universal unit.
nents, ABUS will be released from any war-
Special features:
ranty obligations for the entire equipment.
D overload shutdown function
ABUS assumes no liability whatsoever for
D load evaluation possible for three hoists
any damage to cranes or hoists which may
D total load measurement and monitoring for three
be caused by the incorrect setting of the unit.
hoists
D LAZ and/or GLZ load display (OPTIONAL)
It is recommended that repair and mainten-
D load population recorder in accordance with FEM
ance work should be carried out by the ABUS
9.755 (optional)
service department.
D second shut - down point (adjustable in 2 % steps)
D shutdown of main lifting speed on rapid load in-
crease
D Overload shutdown points can be set up to a 1.4 Replacement of unit
maximum of 110 % of the rated load capacity of the If a unit with load population recorder is replaced, the
hoist. last value of the load population recorder must be read
D integrated digital operator terminal for adjustment out and entered as the starting value for the new unit. In
of unit addition, a note must be made in the crane test book.
AN120077.000_EN Page 3
2 Functions
General: ture shutdown caused by dynamic load peaks. If
For load recording and evaluation, the LISSV load the static load measured exceeds 110 % of the
indicator system needs a load signal transmitter rated value, the two output relays are shut down.
(measurement axle, measurement bolt, etc.) installed
on the hoist. b) Dynamic overload shutdown. If any dynamic peak
For load evaluation on two or three hoists, the signals exceeds 125 % of the rated value, the output relays
from the measurement axles of LIS- FC or SV units are for the two hoist speeds are immediately shut
converted into a frequency signal proportional to the down.
load measured. This ensures interference- free trans- The control algorithm is specially programmed for
mission to the master LIS- SV. hoists and ensures that the hoist is not shut down
The load sensor receives a highly constant 10 V DC by dynamic load peaks below the limit.
power supply from the LIS- SV or LIS- FC and returns
a loadproportional voltage signal to the LIS- SV / c) Shutdown on sudden load increase. If the load in-
LIS- FC. creases too rapidly, the relay for the main lifting
In the LISSV unit, the signal is amplified and evaluated speed is shutdown. The relay is only reactivated
by a microcontroller system. when the load has ceased to increase, provided
that the maximum load has not been exceeded.
If the preset load limits are exceeded, hoist movement This function prevents rope breakage as a result of
is stopped or other appropriate action is initiated using lifting an excessive load with a loose rope at main
relay contacts. In addition, the load signal is processed lifting speed. Also, excessive force on the rope is
for display on a load indicator and fed to the LAZ load prevented if the crane hook is suddenly blocked.
indicator in the pendant control (and/or a large load dis-
play). The LISSV unit monitors both the individual load Note:
signals and the total load measured. Either the load Even in the event of an overload shut - down,
measured by one of the three load measurement de- the load may be lowered at any time. When
vices or the total load may be displayed. the load has been lowered (load below 90 %
of static load threshold), the overload shut
down is reset.
2.1 Overload ShutDown
The LISSV unit monitors up to three hoists for com- Depending on the system configuration, lo-
pliance with their maximum load capacity rating and wering is only possible with individual or joint
operation of the hoists.
the maximum load capacity of the entire system. Over-
load shutdown thresholds can be set between 0 and
110 % of rated load using the DBE operator terminal
(see list of parameters in Section 9). The values given in 2.2 PartLoad Switch
this section are based on the standard setting of 110 %. In some applications, another shutdown point below
The LISSV is equipped with two relays for enabling the the rated load is required in addition to the overload
main and precision lifting speed. If the overload thresh- shutdown. This may be the case if part of the hall
old is exceeded, these relays shut the hoist down. At structure is not designed for the entire load capacity of
the same time, the load indicator display flashes at in- a crane system.
tervals of one second. If the unit is used for monitoring The LIS- SE allows the user to set an additional shut -
more than one hoist, the other hoists are also shut down point (which can be adjusted via parameter 4.40
down if the overload threshold of one hoist is exceeded. - 4.43). As soon as a signal is available at input EA of
the unit, the relays for lifting movement are tripped
The unit implements three types of overload shut when the set value is exceeded.
down function: The unit is then switched to the overload mode.
A current transformer module with an additional switch-
a) Static overload shutdown. Static loads must not ing relay may be used for more complex applications.
exceed 110 % of the rated value. The actual load The switching point for this relay may be set to any
value is averaged over the measurement time and value between 0 and 110 % of rated load capacity using
compared with the threshold. This prevents prema- parameter P 4.5.
Page 4 Data : 01.03.2016

2.3 Taring For this purpose, the unit evaluates the load measure-
ments on a continuous basis.
The load indicated can be set to zero with a defined
The LISSV unit calculates the actual use S, the load
load on the hook (for example, the weight of load
spectrum factor Km and the remaining service life of the
supports) using the tare button (TARA) which is
hoist in accordance with FEM 9.755 from these values.
normally incorporated in the pendant control.
The load spectrum factor is equivalent to the load po-
Each hoist selected and the total load may be tared pulation with which the hoist was operated.
separately. The tare function always applies to the load
on the hoist currently selected.
To tare the load, press the tare button until the display 2.4.1 FEM Groups
indicates 0.000. The EU machinery directive calls for precautions to be
To delete a tare setting, press the tare button with no taken to prevent risks caused by fatigue and ageing on
load on the hook for about 5 seconds. hoists and cranes. The following precautions have
While the tare button is pressed, the current gross load therefore been taken in order to achieve safe working
is displayed. periods (S.W.P.).
Cranes and hoists are subdivided into various groups
In the event of overloading, the tare value is deleted and in accordance with FEM 9.511.
the current gross load is indicated. The operator of a standard hoist is responsible for en-
suring that the actual operating conditions of the hoist
are recorded and documented in the test book at least
2.4 Load Population Recorder once per year. In the course of regular inspection, the
inspector must verify and determine whether the hoist
(optional) is still being operated within its safe working period.
If a load population recorder is integrated in the LISSV,
the actual operating conditions of a hoist can be re- The following table shows the theoretical service life D
corded. In addition to the total running time T, which is as a function of the FEM group and the load spectrum
equivalent to the time during which the motor is factor.
switched on, the actual load on the hoist is recorded.
Theoretical service life D, (h)

1Dm 1Cm 1Bm 1Am 2m 3m 4m 5m
FEM groups
M1 M2 M3 M4 M5 M6 M7 M8
load group / ropes|load
Line Theoretical service life D (h)
factor
light 1 / L1
1 K = 0.5 800 1600 3200 6300 12500 25000 50000 100000
(Km1 = 0.125 0.53)
medium 2 / L2
2 0.5 < K < 0.63 400 800 1600 3200 6300 12500 25000 50000
(Km2 = 0.25 0.633)
heavy 3 / L3
3 0.63 < K < 0.8 200 400 800 1600 3200 6300 12500 25000
(Km3 = 0.5 0.83)
very heavy 4 / L4
4 0.8 < K < 1 100 200 400 800 1600 3200 6300 12500
(Km4 = 1 13)
When the theoretical service life D has elapsed, cranes conditions are recorded electronically. The inspector
and hoists connected to them may represent a risk to can have the actual hours of use S and other para-
persons and machines. If a load population recorder is meters displayed at any time (see Section 5.3).
used, it is easier to determine the actual hours of use S,
from which the remaining service life is calculated. The FEM group is stored in the LISSV unit and can be
displayed using the operator terminal. The group is
In the case of standard hoists equipped with anLISSV indicated in hours at full load.
with integrated load population recorder, the operating
AN120077.000_EN Page 5
2.4.2 Definitions Following a shut - down, the unit display flashes
Theoretical service life and the current measured is indicated.
The theoretical service life D is the calculated hours of The unit is switched back on automatically after a
service of a crane or a hoist over a period of about 10 delay of 2 minutes.
years taking into consideration the group determined To reset the unit before this delay has elapsed, pro-
in accordance with FEM 9.511. ceed as follows:
Actual hours of use a. Switch off the power supply.
The actual hours of use S represent the effective use of b. Press the up and down buttons on the
the unit determined on the basis of operating hours and digital operator terminal at the same time.
load populations.
Total service life
The total service life of a standard hoist is the period 2.6 Frequency converter control
from initial commissioning through to final decommis-
sioning of the hoist. system
Remaining service life The integration of the individual components LIS- SV
The remaining service life or theoretical remaining ser- overload protection device and frequency converter for
vice life of a hoist is the difference between the actual hoist motors results in a special control configuration.
hours of use S and the theoretical service life D. When Further details are given in the special documentation
the theoretical service life has elapsed, the hoist must Frequency converter for lifting with LIS- SV.
be overhauled.I
Safe working period (SWP)
The hoist is within its safe working period if S/D is less
than or equal to 1.
2.7 Safety Functions
The LIS- SV is a microprocessorcontrolled unit. In
order to ensure the highest level of operational safety,
the unit is equipped with an additional switching relay
2.5 Integrated Control Functions which only enables lifting or lowering if the correct
In addition to overload protection functions, the LIS- mode of operation of the microprocessor is detected.
SV features a number of integrated hoist control func- The mode of operation is monitored by integrated logic
tions. which operates independently of the microprocessor.
D AC- 4 disable control Before hoist motor starting is enabled, the system
In order to prolong the service life of the high lifting checks whether the switching relay is in rest position. If
speed contactor, the LIS- SV unit prevents the con- this is not the case, for example as a result of welding
tactor from being switched off until the set start - up of the relay contacts, the monitoring system positively
delay of the motor has elapsed. This function sig- prevents hoist start - up.
nificantly reduces contact erosion. As a further safety function, the system monitors
D Braking with the motor acting as a generator whether the lifting or lowering signal is present at all
Each time the hoist is braked from high speed, the times when the hoist motor is in operation. If the logic
LIS- SV unit ensures that the hoist is first braked by circuitry does not detect a control signal at any time, the
operating the motor as a generator at low speed hoist is automatically shut down by the safety circuit.
before the brake is activated. This significantly ex- The hoist is also shut down if the control signals for lift-
tends the service life of the brake rotor. ing and lowering are active at the same time.
D Motor current monitoring function
LIS- SV continuously monitors the current inputs. If
an inadmissibly high motor current is detected, the
unit immediately switches off main contactor K1. 2.8 Accuracy
The motor circuit breakers installed in the electrical The accuracy of the load measurement system is lar-
control system are therefore no longer required gely determined by the measurement error of the load
The main contactor is also switched off if a motor signal transmitter.
current is detected without a lifting or lowering con- Normally, accuracies of the order of 2- 5 %, of the ra-
trol signal. ted load capacity of the hoist are reached.
Page 6 Data : 01.03.2016

3 Components
3.1 LISSV evaluation unit Measuring Rated cur- Art.No. Adaptation
The LISSV unit (Fig. 1) is designed to evaluate the range rent [A] factor
measurement axle signal of one hoist. The measure- 0 3 19683 115
ment axle is connected to terminals B+, B, U+ and U
of the unit. B+ and B supply a stabilized voltage of 10 I 8 9743 306
V to the measurement axle. The loadproportional volt- II 16 9744 613
age signal at terminals U+ and U is in the range from 0
III 23 9745 873
to 20 mV.
If the unit is used for monitoring two or three hoists, the IV 36 9746 1381
loadproportional frequency signals from the LISFC V 60 9747 2344
units are connected to terminals F2GND and
F3GND. VI 136 19682 5169
The terminals for motor voltage evaluation are desig-
nated L1 to L3 and the current module terminals are The marked conductors of the current terminal are con-
designated I1 to I3. nected to terminals I1, I2, I3 and GND of the SV unit.
The functions of the isolated control inputs E1 to E7, EA The maximum measuring range is: rated current x 1.35
are as follows:
E1 E2 E3 E4 E5 E6 E7 EA
lifting control signal x
lowering control signal x 3.3 LISFC Signal Converter
The LISFC signal converter (Fig. 2) is used to extend
fast control signal x
the system for monitoring 2 or 3 hoists. It supplies a sta-
Malfunction signals
x bilized, shortcircuitproof voltage of 10 V at a maxi-
HW2
mum current of 100 mA at terminals B+ and B for
monitoring of fast lifting
x power supply to the load signal transmitter. The LISFC
speed HW2 unit requires no adjustment and converts the millivolt
activation of second signal of the transmitter (U+, U) into a loadpropor-
overload shutdown x tional frequency signal (F).
point
The LISSV and LISFC units are coordinated using the
taring control signal x operator terminal incorporated in the LISSV.
Equalization signal of
synchronization control x
system
Total load display x

3.4 Load Signal Transmitter
Output Q supplies a serial data protocol for the control Strain gauges with a voltage of 10 V and a sensitivity of
of the ABUS load indicators LAZ (display in pendant 1- 2 mV/V may be used as load sensors.
control) and GLZ (large load display). Any measurement bolts, tension straps and load cells
The 5V power supply for the LAZ unit is provided by the- in accordance with the technical data may be used.
LISSV unit.
The LISSV allows the signal amplification to be ad-
The GLZ unit has an integrated 24 V AC power supply.
justed to the sensitivity of the load signal transmitter
The integrated digital operator terminal DBE is used for
used. Even if the sensitivity of the transmitter is not
reading and setting the variable parameters of the LIS
known, it is possible to calibrate the system using a
SV unit (see also Section 5.1).
known load. As the output signal of the transmitter is
only of the order of a few millivolts, it must be connected
to the LISSV or LISFC unit using a shielded cable.
3.2 Current Measurement Module The cable should be as short as possible and must not
The current module is selected on the basis of the rated be routed via any terminals. In addition, the connecting
current of the hoist motor in main lifting speed (see cable must not be installed directly next to a power
table). cable.
AN120077.000_EN Page 7
3.5 Load Indicator (OPTIONAL) 3.5.1 Function of load indicator
The LISSV is equipped with contacts for the connec- 1. The load is continuously measured and indicated.
tion of an ABUS load indicator. The load may be indi-
cated by a four digit LAZ load display integrated in the 04.93
pendant control or by a GLZ large load display. The 2. If the hoist is shut down as a result of overloading,
load display is designed so that the load value can be the display flashes at one- second intervals.
clearly read even in poor visibility.
16.57
The driver stage of the display is updated by the LIS
SV at intervals of one second, ensuring rapid indication 3. In the case of mutual monitoring of two hoists, this
of any load changes. A threeconductor cable, cross symbol appears on the display in the event of a
section 1 mm@, must be installed for the load indicator. hoist failure as long as the up or down button on the
The cable need not be shielded. pendant control is pressed:
H2
_________________________________
4 Technical Data
4.1 Load Indicator System LISSV

LIS SV 17790 17791 17792
Power supply voltage A1,A2: 230VAC 10% 110VAC 10% 48VAC 10%
Input voltage E1E7; EA 150250VAC 90120VAC 3855VAC
Measuring range L1, L2, L3 0 627 V AC
Transformer output voltage I1, I2, I3 0 7,24 V AC
Power supply frequency 50 60 Hz
Switch contacts (3u,1a): 250 V AC, 8A
Power required max. 15VA
Ambient temperature range 20 to +55 C; no condensation
Output voltage for LAZ 5V, max. 250 mA
Indicator signal Q Serial data protocol 12V
Power supply for transmitter B+, B 10V; max. 100mA
Input voltage U+,U 0 20mV
4.2 LISFC Signal Converter System

Power supply voltage A1, A2 48, 110, 230 VAC +/ 10%
Power supply frequency 50 60 Hz
Power required ca 4,0 VA
Ambient temperature range 20 until +55 C
Power supply for transmitter B+, B 10V; max. 100 mA
Input voltage U+, U 0 25 mV
Output voltage F +12V
Output frequency F 500Hz until 30 kHz
Page 8 Data : 01.03.2016

4.3 LAZ / GLZ Load Indicator
Pendant control Large load indicator
LAZ GLZ
Power supply voltage 5VDC 24VAC
Digit size 10 mm (LED) 127 mm (LED)
_________________________________
5 Operation
5.1 Digital Operator Terminal 16.57
The integrated digital operator terminal (DBE) with LED
display and threebutton keypad ( Fig. 1, items 1 to 4) If a load lower than the previous tared load is lifted, the
is used for operating the unit and reading operating display indicates
parameters. The unit is normally in the power down
mode. This is indicated on the display (4) by a horizon- - 0.00
tal bar running from left to right. instead of the operating hours.

The system has 3 menu levels; access to level 3 is only
If the unit detects a lift signal (E7), the display show available to ABUS personnel (a special CODE number
steps running from bottom left to top right. is required).
Menu level 2 is accessed by entering the PIN number
0055.
In the case of a lower signal (E2,) the steps run from top Menu level 1 us used solely for reading the values of the
left to bottom right. load population recorder and is only available if the load
population recorder has been enabled. To reach this

menu level, press the ENTER button for about 2 sec-
Following each operation of the hoist, the current read- onds and then enter the appropriate CODE number
ing of the operating hours meter is shown on the dis- (see Section 5.3)
play for about 3 seconds. If four incorrect attempts are made to enter a PIN or
CODE number, the menu level concerned is entirely
15 disabled and can only be enabled by ABUS.
In this case, the display indicates
In the event of overloading, the display flashes and the [no]
current load is indicated.
95 Height: 112
1 Enterbutton
4 is used for selecting parameters
and acknowledging values
5 2 downbutton
is used for displaying the previous
parameter or for reducing nu-
3 meric values and parameter set-
tings.
2 3 upbutton
100
75
is used for displaying the follow-

6 ing parameter or for increasing
numeric values and parameter
settings.
1
4 Display
7 5 digital operator terminal (DBE)
6 Unit interface
7 Connection of measurement bolt
Fig. 1 100
AN120077.000_EN Page 9
5.2 Basic Settings
TheLISSV is adjusted at the factory. Any fine adjust-
ments or new adjustments which may be necessary
can be carried out in accordance with the adjustment
instructions in Section 10 using a test load. Where
possible, the test load should be equal to the rated
load.
If the test load is lower, there will be a significant deterio-
ration in system accuracy. As a basic principle, the
higher the test load, the higher the accuracy. It is rec-
ommended that a test load of at least 80 % of the rated
load should be used.
At this load, the specified accuracy can generally be
ensured. The minimum load which can be used for set-
ting is 40 % of the rated load capacity. If this load is
used, it is not always possible to obtain the specified
accuracy.
If it is necessary to use a load of 40% to 80% for setting,
this must be stated in the inspection report.
5.3 Reading the Load Population

Recorder
Menu level 1
Fig. 2
The work required for enabling the load population
recorder can only be performed by ABUS.
If a valid code number 2223 is entered, the values sto-
red and calculated by the load population recorder are
displayed in sequence. To return to level 1, you must
press the enter button (1, Fig. 1) for a little longer.
_________________________________
6 Installation
Attention! If the LISSV is retrofitted to an existing crane, inspec-
Before commissioning the unit, it is essential tion by an independent inspector may be necessary
to check whether the system has been wired (see BGV D6, Section 25).
up in accordance with the attached wiring
diagrams.
The ABUS LISSV must only be installed by qualified 6.1 Housing and wiring diagrams
electricians The dimensions required for the installation of the
LISSV are given in Fig. 1 and Fig. 2.
Page 10 Data : 01.03.2016

Standard
rot
blau
gelb
braun
grn
wei
gelb
Fig. 3
AN120077.000_EN Page 11
Total load monitoring
Fig. 4
Page 12 Data : 01.03.2016

Total load monitoring with display control / central contactor box
load indication
yellow
blue
red
Trolley 1 Trolley 2
yellow
yellow
brown
brown
green
green
white
white
Fig. 5
AN120077.000_EN Page 13
Standard wiring diagram, LIS- SV with twin hoist
LIS- SV LIS- SV
fast
LIS- SV LIS- SV LIS- SV
Fig. 6
Page 14 Data : 01.03.2016

6.2 Regulations Safety warnings:
You must not carry out any work inside the
The load indicator system LISSV is in accordance with
unit.
the following codes and standards:
In the event of a defect in an LISSV unit, please contact
NSR 2014/35/EG (low voltage)
our service department.
In order to avoid the risk of serious injury and severe
EMV 2014/30/EG (electromagnetic compatibility)
damage, only persons qualified to work on electric
power systems may work on the units. Before installing
EN 61000- 6 Electromagnetic compatibility
any commissioning the units, these persons must care-
fully read the operating instructions and observe the
Electrical installation work must be performed in ac-
safety instructions.
cordance with the following general codes and stan-
dards:
Attention!
Any modifications to ABUS products and any
IEC 60364- 5- 56
parts installed in or on ABUS products which
Requirements for the installation of power systems with
could impair the safety of the products must
rated voltages up to 1000V
be approved by the manufacturer. ABUS will
not be liable for any injury, loss or damage
EN 60204- 32
which may occur as a result of modifications
Safety of machinery: Electrical equipment of machines;
which have not been approved or the use of
requirements for hoists.
products other than for the intended pur-
pose.
For special applications, other standards and regula-
tions may also be applicable.
Note:
ELECTROMAGNETIC COMPATIBILITY
The unit has been designed in accordance
with the EMC directive no. 2014/30/EC.
_________________________________
7 Malfunctions
7.1 Causes and Remedies
TheLISSV displays the following error codes on the operator terminal or the load display.
ErrCode Explanation Remedy
Errors following unit start - up

Err 0 Total load not entered Check unit settings, parameters P 0.0, P 1.0
Rated load capacity of hoist 1 set to higher value
than total load
Err 1 Unit not set for hoist 1 Check settings P 1.3, P 1.4
Err 4 Adaptation factor for current measurement not Enter value under P 5.6
entered
Errors in normal operation

F1 Zero load frequency hoist 1 too low
AN120077.000_EN Page 15
ErrCode Explanation Remedy
Errors on setting
Err 6 Setting error: frequency at zero load <100Hz Check frequency input.
Err 7 Setting error: frequency at setting load too low Increase setting load. If necessary, replace
measurement axle.
Err 0 Rated load capacity for hoist 1 not entered. Enter value under P 1.0
Other error messages

Err 8 Internal data storage error Replace unit
Err 5, Data read error Press enter repeatedly until function is selected
Err 9 again. If necessary, enter parameter again.
The input and output voltage data required for trouble- 7.2 Service
shooting are stated in Section 4 Technical Data.
Notes:
If any other malfunctions occur, please contact our ser-
The ABUS Service Centre can be reached
vice centre (see Section 7.2).
day and night.
_________________________________
8 Disposal
ABUS products are designed with a view to recycling The electronic components may be disposed of at
and have a modular structure which facilitates environ- special disposal sites in accordance with the appli-
mentally compatible disposal when they are no longer cable local regulations.
required.
Page 16 Data : 01.03.2016

9 LIS SV parameter list
Para- Range Unit Description Display Code Remarks

meter
Basic setting parameters

P 0.0 0 320 t Total load setting Setting value
P 1.0 0 100 t Load capacity setting for hoist 1 Setting value
P 2.0 0 100 t Load capacity setting for hoist 2 Setting value
P 3.0 0 100 t Load capacity setting for hoist 3 Setting value only available if para-
meter 5.11=0
P 4.0 0 110 % Total load shut - down point Setting value
P 4.1 0 110 % Shut - down point, hoist 1 Setting value
P 4.40 0 110 % 2nd total load shut - down point Setting value
P 4.41 0 110 % 2nd shut - down point, hoist 1 Setting value
P 4.5 0 110 % Switching point, external part - load Setting value

switch
P 5.01 Sensitivity to rapid load increase Setting value
P 5.1 h Display of theoretical service life Setting value

load population recorder
P 5.2 h Read load population recorder 2223 Values can only be
read out if load popula-
tion recorder is activa-
ted
P 5.3 Acceptance test 1443

P 5.4 Unit diagnosis CodE 1443
P 5.5 Delete settings LOE 1443
P 5.6 1- 9999 Enter adaptation factor for current mea- Setting value 1443
surement
P 5.7 0,1,2 Operation on twin hoist Setting value 1443
P 5.8 0,1 Operation with an ABUS synchronization Setting value 1443
system
P 5.10 P 5.11 - Setting parameters for operation with a For a description, plea-
ses refer to the opera-
P 5.99 frequency converter ting instructions for
operation with a fre-
quency converter
P 9.9 Return from parameter level
AN120077.000_EN Page 17
Para- Range Unit Description Display Code Remarks
meter
Unit setting parameters
P 1.1 Hz Zero load adjustment, hoist 1 CodE 1443
P 1.2 Hz Setting overload protection device for hoist 1 Last
P 1.3 0- 64999 Hz Display / enter Setting value 1443
zero load frequency, hoist 1
amplification factor, hoist 1
Parameters for load population recorder

P 6.1 1012400 h Activate load population recorder / enter CodE
theoretical service life Setting value
P 6.2 012400 h Display / enter starting value for hoist Setting value
load population recorder
P 6.3 Delete load population recorder values CodE Only for inspectors
P 6.4 021845 h Display of actual hours of use S for hoist

P 6.5 065535 h Display of total operating hours T for hoi-
st
Page 18 Data : 01.03.2016

Display / diagnosis parameters
P 7.00 0.000 t Display total load or load on hoist 1; de-
408.0 pending on position of selector switch
P 7.01 0127.0 t Display load on hoist 1 (no tare function)
P 7.1 0.000 - Display: measuring frequency, input F1
65535
65535
65535
P 7.4
P 7.5 00.00 - A Display motor current
185.0
P 7.6 0.000 - V Display power supply voltage
627.0
P 7.61 V Display voltage plot
P 7.7 00.00 - Hz Display motor frequency Only for operation with
120.0 frequency converter
P 8.0 Enter CODE for higher operating level Operating level only
available to ABUS
P 9.9 Return from parameter level
AN120077.000_EN Page 19
10 Description of LIS SV parameters
0015 Operating hours are displayed on unit. 9. In the case of all parameters protected by a code
This display appears if (apart from P1.1,P2.1 and P3.1), the value stored
1. after the hoist has been shut down for about 3 sec. will appear when the parameter is selected. To
2. after you have pressed the Enter button briefly change the value, press enter until CodE appears
on the display. You can then change the parameter
value after entering the correct code.
Menu level 1 10. On level 2, if no entries are made for 5 minutes, the
unit switches to the operating mode.
All entries made and saved up to that point are
CodE Readout of load population maintained.
recorder by customer:
Appears on the display if you press the Enter key for Parameter: P 0.0
some time, provided that the load population recorder Total load capacity of crane system. If only one hoist is
has been enabled by ABUS. evaluated, the total load capacity is always equal to the
load capacity of hoist 1.
For total load evaluation, the total load capacity must
Menu level 2 not be set to a higher value than the sum of the individ-
ual load capacities.
Before carrying out any settings on the LIS
SV, you should read the notes on the para- Parameter: P 1.0
meters carefully. Load capacity of hoist 1.
Always remember that incorrect settings may The maximum load capacity of the hoist must be en-
cause malfunction. tered.
ABUS will assume no liability whatsoever for
any damage to the crane or any consequen- Parameter: P 2.0
tial damage resulting from incorrect settings. Load capacity of hoist 2.
The maximum load capacity of the hoist must be en-
General: tered.
To display and change parameters, proceed as follows:
1. Press Enter until the parameter number appears on Parameter: P 3.0
the display. Release the Enter button. Load capacity of hoist 3.
2. If the load population recorder is activated, CodE The maximum load capacity of the hoist must be en-
will appear on the display. tered.
Press Enter briefly. The display will switch to para- Note: This parameter cannot be set if a value
meter number. is entered under P 5.11. In this case, you
3. Press Enter until 0000 is displayed. The left digit will must first set P 5.11 to zero.
flash.
4. Use the up and down buttons to change values. Parameter: P 4.0 - P 4.3
Confirm each value by pressing Enter briefly. Overload shut - down points for total load, hoist 1, hoist
5. After entering the last digit, press Enter until the dis- 2, hoist 3.
play switches to P 0.0. The value must be set as a percentage of the load ca-
6. Use the up and down buttons to switch to the pacity.
previous/following parameter. If the set value is exceeded, the hoist concerned is shut
7. Select each parameter by pressing Enter briefly. down and the overload protection system is set to over-
8. The value stored in the parameter list will appear on load. The load is displayed on the digital operating unit,
the display. which flashes at intervals of one second.
Page 20 Data : 01.03.2016

Parameter: P 4.40 - P 4.43 Adjustment:
Second shut - down points for total load, hoist 1, hoist It is only possible to read out the data of the load
2, hoist 3. population recorder if the recorder has been enabled.
The value must be set as a percentage of the load ca- Only ABUS can enable the load population
pacity. recorder.
If the set value is exceeded, the hoist concerned is shut If the load population recorder is not enabled, it is not
down and the overload protection system is set to over- possible to call up any data for the recorder.
load. The load is displayed on the digital operating unit, If the load population recorder has been enabled and
which flashes at intervals of one second. The second activated, the data can be called up on menu level 1
shut - down point is activated if a control voltage is ap- after entering CODE 2223.
plied to input EA of the LIS- SV unit.
Warning: in order to avoid overriding the
safety circuit installed in the unit, the input Parameter: P 5.3 Acceptance test
must not be activated until contactors This parameter can be used to switch the outputs of the
K21/K22 have been switched over. LISSV manually (main lift, precision lift, Y1 and Y2).
In this mode of operation, the overload protection
function is overridden (no overload shutdown).
Parameter: P 4.5 Caution: The switch contacts are always switched in
Switching point for external part - load switch. If the set- accordance with the control signal received.
ting is exceeded, the relay on the printed circuit board
of the current measurement module is switched. The
setting always refers to the total load capacity set in
parameter P 0.0. Value on
Function
display
Parameter: P 5.01
As already described under Section 2.1, Overload 1 lifting/lowering not possible
shutdown, item c, the LIS- SV also monitors the rate of 2 slow lifting/lowering possible
increase in the load.
The sensitivity can be adjusted after entering a code 3 fast lifting/lowering possible
number. 4
5
Parameter: P 5.1
This parameter indicates the fullload hours of the
corresponding FEM group. It cannot be used to
change the fullload hours or the FEM group. (0 = contact open, 1 = contact closed)
If this parameter is set to 0000, the load population You must leave this parameter following each test.
recorder is not active. If the LIS- SV continues to be set to this parameter, the
hoist will operate, but the overload protection function
FEM group Fullload hours will be deactivated. For this reason, a time limit has
been incorporated for this parameter. When this para-
1Dm M1 100 meter has been selected for about 45 minutes, the
1Cm M2 200 LIS- SV is switched automatically back to normal oper-
ation, and the overload protection function is active
1Bm M3 400 again.
1Am M4 800
2m M5 1600 Parameter: P 5.4
3m M6 3200 This parameter can be used for manual switching of the
LIS - SV output relays;
4m M7 6300
in addition, the signals at inputs E1 - E7 and EA can be
5m M8 12500 checked.
The hoist cannot be operated when this parameter is
selected.
Parameter: P 5.2 Load population recorder To access the diagnosis parameter, enter CODE no.
This parameter can be used to read out the data of the 1443.
load population recorder: This parameter allows you to perform the following
1. Theoretical service life D tests:
2. Actual hours of use S - output relay test
3. Load spectrum factor kmi - part - load switch test
4. Total operating hours Ti - input test
5. Remaining service life To call up the various tests in sequence, press the Enter
6. Starting value key.
AN120077.000_EN Page 21
Output relay test
Error dis-
Switch contact status Display Note
play
Test Monito-
Lift Lower Fast
point ring
--0- 0 0 0 0 0001 all relays at rest 0000
--1- 1 0 0 0 1000 relays set to lift 1001
--2- 0 1 0 0 0100 relays set to lower 0101
--3- 0 0 1 1 0011 relays set to fast
Part- load switch test
--4- Part - load switch operated
--5- not active
Input test E6 / E2 / E7 / EA
Error dis-
Input status Display Note
play
E6 E2 E7 EA
--6- 0 0 0 0 4000 no signal at inputs monitoring ok 0000
1 0 0 0 0001 lift signal at input 4000
0 1 0 0 0020 lower signal at input 4000
1 0 0301 fast and lift signal at input
1 1 4000
0 1 0320 fast and lower signal at input
Input test E1 / E3 / E4 / E5
Error dis-
Input status Display Note
play
E5 E4 E3 E1
--7- 0 0 0 1 0005 signal at input E1 evaluated 0000
0 0 1 0 0060 signal at input E3 evaluated 0000
(0 = contact open, 1 = contact closed) Parameter: P 5.5

You must leave this parameter following each test. It can only be accessed using CODE 1443.
For safety reasons, a time limit has been incorporated Caution !!
for this parameter. When this parameter has been This parameter deletes all parameters except
selected for 45 minutes, the unit is switched automati- for those of the load population recorder.
cally back to normal operation.
To leave the diagnosis parameter, press the Enter key
for some time.
Page 22 Data : 01.03.2016

Parameter: P 5.6 Parameter: P 1.2, P 2.2, P 3.2
This parameter defines the correction factor for the cur- Setting hoist under load.
rent measurement modules. In order to prevent unintentional adjustment of the
The correction factor must be taken from the table value, LAST is initially displayed. If you press Enter
correction factors for current measurement modules. briefly, you leave this parameter without making any
Input: change.
1. display of correction factor stored If you wish to change the setting, press Enter until the
2. entry of correction factor from table 1 display switches to 0.000. The digit on the right will
flash; you can then enter the individual load, digit by
Parameter: P 5.7 digit. After you have acknowledged the last digit en-
Parameter P5.7 is used to set the unit for special opera- tered, a step graph running from top to bottom will ap-
ting conditions. The parameter can be set to 0, 1 or 2. pear on the display. During this display, you can use the
Depending on the mode of operation, select the follo- hoist normally to lift the load.
wing value: As soon as the load has been lifted clear of the ground,
press the emergency off button on the pendant control.
Mode of operation Unit 1 Unit 2 MESS will appear on the display, followed by the fre-
One hoist 0 - - - quency value measured. To ensure safe operation,
lower the load when the measurement has been com-
Two parallel hoists 1 1 pleted.
Operation on twin hoist 1 2 Each time you press the Enter button, the following va-
lues are displayed in sequence:
D amplification factor
Parameter: P 5.8 D zero load frequency
If the hoist is to be used with an ABUS synchronization D difference between zero load and load frequency
system, parameter P 5.8 must be set to 1. D rated load
D individual load setting
Parameter: P 5.10
If the unit is used to control an ABUS frequency conver- Note:
If you have not already carried out zero load
ter, the parameter group for setting the LIS is enabled
on the frequency converter after selecting this parame- adjustment using parameter P1.1 or P2.1 or
ter. P3.1, Err6 will appear on the display. After you
You must note that, if an entry is made in parameter press Enter, the unit will switch automatically
to the correct parameter for zero load adjust-
5.11, the total load evaluation function is limited to two
hoists. ment. When adjustment has been com-
pleted, you can continue with settings, as de-
scribed.
Parameter: P 9.9
After Err7 has been indicated, the hoist can
Following acknowledgement, the current software ver-
be used for moving the load. To repeat the
sion (e.g. 1.03) is briefly indicated on the display. The
measurement, press the Enter button for
unit then switches from the parameter level back to the
about 2 sec.
normal operating mode.
The overload protection function is active again.
Parameter: P 1.3, P 2.3, P 3.3
Attention! Display/entry of zero load frequency for selected hoist.
The parameters described below should not After the unit has been replaced, zero- load adjust-
be adjusted unless the unit has been ment should be repeated.
switched off for at least 15 minutes.
Parameter: P 1.4, P 2.4, P 3.4
Parameter: P 1.1, P 2.1, P 3.1 Display/entry of amplification factor for selected hoist.
Adjustment of zero load for the selected hoist. In order After the unit has been replaced, operation can con-
to prevent unintentional setting of zero load, you must tinue using the value from the old unit. However, it is
enter a code number before these parameters can be recommended to repeat adjustment.
changed. MESS then appears on the display. The
zero load value is set and the current measured is dis- Parameter: P 6.1
played. Press Enter until the display returns to the para- This parameter is used to set the FEM group and to
meter level. The value measured is stored. activate the load population recorder. It can only be
used if the load population recorder has been enabled
Notes: by ABUS.
You can only quit the parameter setting func-
tion if the frequency measured is higher than Adjustment:
100 Hz. If you wish to quit the parameter set- This parameter can only be enabled by ABUS.
ting function although a lower value was The theoretical service life stated by the manufacturer
measured, you must press all the buttons at is entered (in hours at full load). (See also table 1 in FEM
the same time for about 2 sec. 9.755.)
AN120077.000_EN Page 23
Parameter: P 6.2
This parameter is used to enter a starting value (in Note:
hours) which must be deducted from the theoretical In parameters 7.01 to 7.6, the overload
hours at full load when calculating the remaining ser- protection function is disabled.
vice life.
(For example, this parameter is used when installing a The special display mode remains active for
newLISSV on an existing system.) about 20 min, after which the unit automati-
Adjustment: cally switches back to the normal display
This parameter has two levels: mode.
1. Level 1 = display stored starting value
2. Level 2 = set new starting value If you wish to quit the special display mode
before the 20 min. have elapsed, you must
CODE 1443 must be entered in order to access level 2. return to the normal display mode by select-
ing parameter P 9.9.
Parameter: P 6.3
This parameter is used to erase the values stored in the Parameter: P 7.61
load population recorder This parameter allows simple, rapid diagnosis of the
Adjustment power supply voltage with the hoist in operation.
A special CODE must be entered in order to access this If the unit is in normal operation, the power supply volt-
parameter. age is recorded for 500 ms each time main lift is acti-
vated.
Parameter: P 6.4 After this parameter has been selected, the r.m.s. value
To display the value stored, press Enter. of the supply voltage is calculated for intervals of 50 ms
each. To switch to the value for the next interval, simply
Parameter: P 6.5 press the Enter key.
To display the value stored, press Enter.
Parameter: P 8.0
Parameter: P 7.0 - P 7.7 When this parameter is selected, level 3 can be
These are display and diagnosis parameters. The va- accessed by entering a code. This code no. is only
lues shown in the parameter table are displayed. available to ABUS.
Page 24 Data : 01.03.2016

11 Declaration of conformity
under the terms of the machinery directive of Appendix II 1A

Address Sonnenweg 1
address Sonnenweg 1
Designation Load indicator system

Types LIS- SV
in Series production
is in accordance with the european guidlines
2006/42/EG Machines
referring to the version in force on the date of issue.
EN 954- 1 Safety of machinery

EN ISO 12100- 1 Safety of machinery, tools and plants
EN ISO 12100- 2 Safety of machinery, Basic concepts, general principles for design
EN 61000- 6- 4 Electromagnetic compatibility; interference emission
EN 61000- 6- 2 Electromagnetic compatibility; resistance to interferences

Name: Dr. Eckhard Bube

Board of
Management
Gummersbach, 01.03.2016 ___________________________ _________________________
Signature of authorised person Indication for the subscriber

The company ABUS Kransysteme GmbH runs a certified quality management system according to DIN EN
ISO9001.
AN120077.000_EN Page 25
Kransysteme
Installation and operating instructions for cross-- type limit

switch KHS 6.41 -- 2
Installation
Technical data
--- Fit an S5 lock washer to two M5x50 pan head
screws and insert them into the mounting holes of Ambient temperature ---20 C to +70 C
the cross---type limit switch.
--- Position the switch on a mounting bracket or Degree of protection in
mounting plate. accordance with IEC IP 65
--- Position another S5 lock washer and an M5 hexag- 60947---1
onal nut on the screws and tighten using a torque
wrench. Electrical/mechanical ser- > 3 million switch
vice life operations
Attention! Operating torque 0.30 Nm
Tightening torque for screws 4 Nm.
Max. start ---up speed 1.5 m/s
--- If the cross---type limit switch is used without a
Continuous current rating 3.0 A
mounting bracket or board (e.g. directly on a
trolley), the screws must also be tightened using a Utilization category ~ Ue= 230 V;
torque of 4 Nm. AC---15 Ie= 1.5 A
Cable glands 2x M20
Cable cross section 0.14 --- 1 mm2
Housing plastic
4 changeover
Switch elements
contacts
Weight 235 g
Tightening torque/M5
4 Nm
fastening bolts
A 120216.000_EN 31.03.2014 AN 310101 Original operating manual

Electrical connection --- The contact numbers indicated in the wiring dia-
gram start with 1 and increase from left to right (as
The cross---type limit switch may be connected using can be seen on the 12---pole circuit board con-
round or ribbon cables on both sides, as appropriate. nector).
--- The microswitches are numbered in ascending
The appropriate cable gland with M20 connecting order starting with S1 on the left.
thread must be used for the type of cable. If the cable
does not have a pre-assembled switch, the 12-pole Safety advice
board connector must be connected according to the
enclosed circuit diagram. Opening actuation of the cross-type limit switch meets
Performance Level c, Category 1 of DIN EN ISO
You must make sure that the individual conductors of 13849-1.
the connecting cable are properly installed inside the
switch and are of the correct lengths. The safety-related parts have been designed and con-
structed using proven components and safety prin-
The cross---type limit switch must only be installed by ciples as follows:
a qualified electrician or other trained personnel. --- The actuation system for initiating and implement-
ing the necessary opening movement is posit-
Additional notes: ive-locking.
--- The switch position is clearly indicated by the posi- --- The positive opening operation of the micro-switch
tion arrow on the switch and defined in the switch does not depend on spring-loaded parts and thus
configuration table. complies with DIN EN 60947-5-1.
Wiring diagram
--- S1 12 14 --- S2 22 24 --- S3 32 34 --- S4 42 44

40--- 60 mm
11 21 31 41
1 2 3 4 5 6 7 8 9 10 11 12
40 mm
Switch S1 S2 S3 S4
Contacts
Switch
position
0 0 3,4 5,6 7,8 9,10
1 90 3,4 5,6 7,11 9,10
2 180 3,4 5,6 7,11 9,12

Switch position 3 270 3,1 5,6 7,8 9,12
4 360 3,1 5,2 7,8 9,10
5 450 3,4 5,2 7,8 9,10
0 540 3,4 5,6 7,8 9,10

Electrical parts list printed on: 03.02.2017
Order Number: FX-16735993-0020 Client: 185911 FAIST Anlagenbau GmbH
Assembly: 200347 ABUS mains power supply
Production ident no.: 5922688
Wiring diagrams:
CL Prod-ID / CL op. mat. no. Quantity Units u.o.m. Part number Designation 1 Designation 2
Designation 3 Designation 4
1 5922688-70 1 1, pcs 105838 Mains power supply Festoon cable
Special
.2 5933893-20 1 1, pcs 21431 Upper part end terminal AEK with square nut
.2 5933893-70 5 1, pcs 21422 Top part cable carrier ALK-S Steel roller with ball bearing
.2 5933893-120 1 1, pcs 21430 Upper part of towing trolley AMK-S
Steel wheel with ball bearing
.2 5933893-160 1 22.000, mm 763 Flat cable 4G 6 H07VVH6-F
7,2x22,3mm
1 5922688-80 1 1, pcs 71414 Terminal box 3x6+1PE 1xM25r 1xM40f
T221
1 1 1, pcs 751 Housing T221 200x120x 75
with mounting plate
1 3 1, pcs 124274 Cable clamp 2006 6 1-L / 1-L
oA 0,5-10, mA 0,5-6, 41A tension spring, gray, 7,5mm
1 1 1, pcs 124276 Cable clamp 2006 6 PE 1-L / 1-L
oA 0,5-10, mA 0,5-6 green-yellow, 7,5mm
1 5922688-100 1 1, pcs 77366 Isolating switch 63A fitted K: 2x2xM40 V: 2xM40
160x250x165 (+45)
Page 1 of 1
Electrical parts list printed on: 25.01.2017
Assembly: 200201 Single-girder travelling crane ELK
Production ident no.: 5933713
Wiring diagrams: 500000E-004, 500000GB-004, 600167E-000, 600167GB-000

Technical data: operating voltage: 3/PE~50 Hz 400 V
control voltage: 230 V
span: 7000 mm
Hoist type trolley 1: GM 3000.8000 L-202.41.6000.4
Load cap. trolley 1: 8000 kg
Serial number: 110-034551
.2 5933718-220 Elektrik Seilzug VT Endmontage
.2 5933718-240 -S31 1 1, pcs 5400 Gear limit switch 75.3 GPK75.3-3
Lug 15 51/3B 75NE-399L
1 20 1 1, pcs 86445 Pin multipoint connector 721 7-5,00
lettering 6-4,PE,3-1 mainspring, light gray
1 21 1 1, pcs 86447 Pin multipoint connector 721 4-5,00
lettering 7-10 mainspring, light gray
1 31 1 1, pcs 71377 Connector
.2 5933718-430 Elektrik Seilzug VT Zwischenmontage
.2 5933718-450 +SKA 1 1, pcs 81611 Contactor control SKA 80.362K-E 380-500/230V 50Hz
GM3000L Te LIS SGR 536 Q41= 2,5A
1 Socket HUB SKA 18A Te 230V TS 50/60Hz 25.18 GE3Z.K43
.2 -K21, 22 2 1, pcs 14921 Contactor Te 230V 25A 4MNO1NO 1NC, LC1-DT40P7
230V 50/60Hz
.2 -K21, 22 1 1, pcs 71256 Mechanical locking Te LAD-9V2
for LC1-D09-D32 TeSys
.2 -K23 1 1, pcs 75197 Contactor Te 230V 18A 1NO1NC LC1-D188P7
2MNO2MNC
230V 50/60Hz
.2 -U32-X1 1 1, pcs 74172 Bush multipoint connector 8413 5-7,62
coded 4-5, lettering 230V Screw, grey
.2 -U32-X2 1 1, pcs 19454 Bush multipoint connector 8113 11-5,08 lateral
Screw, grey
.2 -U32-X3 1 1, pcs 19455 Bush multipoint connector 8113 19-5,00 lateral
Screw, grey
.2 -V21 1 1, pcs 310497 Rectifier GE3Z500-A
..3 1 1, pcs 123294 Housing 12,5 UT GN 99x114,5x12,5
..3 1 1, pcs 123295 Housing bottom part ME 12,5 OT set
.2 -X1: 1-8 8 1, pcs 124264 Cable clamp 2002 2,5 1-L / 1-L
oA 0,25-4, mA 0,25-2,5, 24A tension spring, gray, 5,2mm
.2 -X20 2 1, pcs 124264 Cable clamp 2002 2,5 1-L / 1-L
.2 -X20 2 1, pcs 124266 Cable clamp 2002 2,5 PE 1-L / 1-L
oA 0,25-4, mA 0,25-2,5 green-yellow, 5,2mm
1 Connection cable HUB TS -W21 12G2,5 3100mm
7B16+4B16
.2 -W21 1 3.100, mm 6902 Round cable PVC-JZ 12G 2,5 numbered
14,7mm
Page 1 of 6
Electrical parts list
.2 +KA-X21.1 1 1, pcs 86446 Bush multipoint connector 721 7-5,00

.2 +KA-X21.2 1 1, pcs 86815 Bush multipoint connector 721 4-5,00
lettering 10-7 mainspring, light gray
1 Socket KAF SKA 9A Te 230V TS 50/60Hz 09.09
.2 -K41, 42 2 1, pcs 5267 Contactor Te 230V 9A 3MNO1NO 1NC, LC1-D09P7
230V 50/60Hz
.2 -K43 1 1, pcs 75194 Contactor Te 230V 9A 2MNO2MNC 1NO1NC, LC1-D098P7
230V 50/60Hz
.2 -X40 2 1, pcs 124266 Cable clamp 2002 2,5 PE 1-L / 1-L
oA 0,25-4, mA 0,25-2,5 green-yellow, 5,2mm
.2 -K45 1 1, pcs 3916 Time relay ZR 0,5-B 0,5s
24-240V, 0-60Hz
.2 -X1:9-16(14-21) 8 1, pcs 124264 Cable clamp 2002 2,5 1-L / 1-L
1 -Q41 1 1, pcs 123701 Motor circuit breaker 1,6-2,5A GV2-ME07
1 Connection cable KAF -W41 TS 7G1,5 1450mm
7B16
9,1mm
.2 +KA-X41 1 1, pcs 86446 Bush multipoint connector 721 7-5,00
1 Connection cable KAF -W42 TS 7G1,5 1350mm
7B16
9,1mm
.2 +KA-X42 1 1, pcs 86446 Bush multipoint connector 721 7-5,00
1 Socket outlet -X4 6S35 TS
.2 -X4 1 1, pcs 5303 Add-on box 16p 500V
.2 -X4 1 1, pcs 5308 Pin insert 6S35 500V 35A
Lettering 1-6
1 Schnittstelle Steuerung SKA TS 16S16 Krankatze
.2 -X1:17(9,14,22) 1 1, pcs 124264 Cable clamp 2002 2,5 1-L / 1-L
.2 -X5 1 1, pcs 5303 Add-on box 16p 500V
Lettering 1-16
1 Pin base 8-pole -X31 HUG
.2 -S31-X1 1 1, pcs 18067 Bush multipoint connector 8-3, 50 for printed circuit board
coded, lettering 1-8 Screw, grey
1 Connection cable HUG -W31 TS 8x1,0 2100mm
.2 -W31 1 2.100, mm 577 Round cable PVC-OZ 8X 1,0 numbered
9,5mm
1 Currant transformer module 16A TS
.2 -T32 1 1, pcs 9744 Current transformer module 16A
Page 2 of 6
.2 +SKA 1 1, pcs 71284 Steel housing M SGR 536 536x480x202

.2 +SKA 1 1, pcs 9350 Mounting plate SGR 536 492x446x2,5
..3 5933722-10 -U32 1 1, pcs 17790 Load indicator system LIS-SV 0-600V/230V/50-60Hz
1 1 1, pcs 7073 Bush multipoint connector 733 4-2,50
.2 5933718-590 -S51 1 1, pcs 123029 Cross-type limit switch KHS 6.41-2+ Ru8X1 L= 1,8m
1 Cross-type limit switch KHS 6.41 TS -S51
40fl
.2 1 1 1, pcs 27224 Housing cover
.2 6 1 1, pcs 304600 .
.2 -X1 1 1, pcs 18068 Bush multipoint connector 12-3 ,50 for printed circuit board
.2 -W_1 1 1.870, mm 577 Round cable PVC-OZ 8X 1,0 numbered
9,5mm
1 5933713-440 Elektrik Laufkran VT
1 5933713-480 +SKR 1 1, pcs 108072 Contactor control SKR 80.36K 400/230V 50Hz
Te 25A NEO SGV 600 -Q61= 6,3A
1 Main fuse 25A gG NEO TS
.2 -F1 1 1, pcs 2260 Fuse socket E18 3-pole
Snap-on mounting
.2 -F1 3 1, pcs 2994 Screw cap E18
.2 -F1 3 1, pcs 2270 Fuse link E18 25A gG 400V
.2 -F1 3 1, pcs 2948 Screw-in sleeve socket for fuses E18 25A
1 Main contactor 18A Te 230V TS 50/60Hz
.2 -K1 1 1, pcs 6951 Contactor Te 230V 18A 3MNO1NO 1NC, LC1-D18P7
230V 50/60Hz
1 Socket KRF SKR 9A Te 230V 50/60Hz 09.09 ZR
.2 -K61, 62 2 1, pcs 5267 Contactor Te 230V 9A 3MNO1NO 1NC, LC1-D09P7
230V 50/60Hz
.2 -K63 1 1, pcs 75194 Contactor Te 230V 9A 2MNO2MNC 1NO1NC, LC1-D098P7
230V 50/60Hz
.2 -K65 1 1, pcs 3916 Time relay ZR 0,5-B 0,5s
24-240V, 0-60Hz
.2 -X61, 62 2 1, pcs 5302 Add-on box 10p 500V
.2 -X61, 62 2 1, pcs 5312 Socket insert 10S16 500V 16A
1 -Q61 1 1, pcs 123703 Motor circuit breaker 4,0-6,3A GV2-ME10
1 Smooth switching relay -U61 TS SU-1 380-415V 50/60Hz
.2 -U61 1 1, pcs 4127 Smooth switching relay SU-1 380-415V 50/60Hz
1 Power unit control TS 100VA 400/230V
.2 -F10, 11 2 1, pcs 124286 Safety clamp 281 - 6,3x32 cylindrical fuse 1-L / L-1
oA 0,5-10, mA 0,5-6, 10A tension spring, gray, 7,5mm
.2 -F10, 11 4 1, pcs 14881 Fine wire fuse 6,3x32 1,0A-T 500V
.2 -T1 1 1, pcs 5259 Control transformer 100VA 400/230V, 5% Si 0,5A
STT 0,1 Quick fastening device
Page 3 of 6
.2 -T1-F12 2 1, pcs 3920 Fine wire fuse 5,0x20 0,5A-T 250V

1 Socket outlet -X0 6S35 TS
.2 -X0 1 1, pcs 310338 Add-on box 16p 500V
Lettering 1-6
.2 -X1:0 1 1, pcs 300957 Earth terminal KN 4-25 11-3, 60mm
.2 -X1:0 1 1, pcs 300959 Adapter KN Top hat rail
1 Socket outlet -X2 24B16 TS
.2 -X2 1 1, pcs 3930 Add-on box 24p 500V
.2 -X2 1 1, pcs 4172 Socket insert 24S16 500V 16A
.2 -X4 1 1, pcs 5303 Add-on box 16p 500V
.2 -X5 1 1, pcs 5303 Add-on box 16p 500V
.2 -X71: 1-4 4 1, pcs 124264 Cable clamp 2002 2,5 1-L / 1-L
.2 +SKR, SKA 1 1, pcs 5333 Steel housing SGV 600 600x270x190
.2 +SKR, SKA 1 1, pcs 5318 Mounting plate SGV 600 570x250x2,5
.2 +SKR 1 1, pcs 71268 Flange plate M FP13-1 168x266x1,5
.2 +SKR 1 1, pcs 71271 Flange plate M FP17-1 168x266x1,5
1 5933713-500 +KSZ 1 1, pcs 109178 Festoon cable for trolley DS Connector system S
.2 5933724-20 2 1, pcs 21421 Top part cable carrier ALK-K Plastic rollers bushed bearing
.2 5933724-130 1 1, pcs 21430 Upper part of towing trolley AMK-S
Steel wheel with ball bearing
.2 5933724-180 -W4 1 9.600, mm 761 Flat cable 4G 2,5 H07VVH6-F
5,8x17,9mm
.2 5933724-190 -W5.1 1 9.600, mm 304084 Flat cable 12G 1 LIFY2YKFFL-JZ
2,6x25,5mm Ribbon cable
.2 5933724-220 +SKR-X4 1 1, pcs 79015 Connector housing 16p M32s 500V
.2 5933724-230 +SKR-X4 1 1, pcs 5308 Pin insert 6S35 500V 35A
Lettering 1-6
.2 5933724-260 +SKA-X4 1 1, pcs 79015 Connector housing 16p M32s 500V
.2 5933724-270 +SKA-X4 1 1, pcs 5314 Socket insert 6S35 500V 35A
Page 4 of 6

Lettering 1-16
.2 5933724-360 +SKA-X5 1 1, pcs 79016 Connector housing 16p M40s 500V
.2 5933724-370 +SKA-X5 1 1, pcs 5313 Socket insert 16S16 500V 16A
.2 5933725-20 3 1, pcs 21421 Top part cable carrier ALK-K Plastic rollers bushed bearing
.2 5933725-120 1 1 1, pcs 4775 Control carrier support 16/24-pole
.2 5933725-140 8 1 1, pcs 21421 Top part cable carrier ALK-K Plastic rollers bushed bearing
.2 5933725-150 9 1 1, pcs 21422 Top part cable carrier ALK-S Steel roller with ball bearing
.2 5933725-210 -W2.1 1 10.400, mm 304083 Flat cable 12X 1 LIFY2YKFFL-OZ
2,6x25,5mm Ribbon cable
High housing
Lettering 1-24
1 5933713-520 -W61, -W62 1 1, pcs 106398 Connection cable KRF 2 Mot 10S16- 7G1,5- 7B16
.2 5933726-10 W61 1 2.700, mm 6753 Round cable PVC-JZ 7G 1,5 numbered
9,1mm
.2 5933726-20 W62 1 9.650, mm 6753 Round cable PVC-JZ 7G 1,5 numbered
9,1mm
.2 5933726-30 Connector parts KRF 2 Mot
10S16 7G1,5 7B16 20r KG10R/6R
.2 5933726-50 +SKR-X61 1 1, pcs 108834 Pin insert 10K16 500V 16A
Lettering 1-10
.2 5933726-90 +SKR-X61 1 1, pcs 86446 Bush multipoint connector 721 7-5,00
.2 5933726-110 +SKR-X62 1 1, pcs 108834 Pin insert 10K16 500V 16A
Lettering 1-10
.2 5933726-150 +SKR-X62 1 1, pcs 86446 Bush multipoint connector 721 7-5,00
1 5933713-540 +HT-S1 1 1, pcs 70278 Pendant control HT611S-N222K- B24
1 5933713-550 -W3 1 1, pcs 70358 Control cable SC15X1 L=4250mm BJS24/15-SC15X1-BJB24/15
1 -W3 1 4.309, mm 35971 Control cable 15X1 OZ without sheath numbered, stranded
9,4mm
1 5933713-560 Crane travel limit switch -S71 TS
Braking function KHS6.4 L= 10,0m M20
1 5933713-570 -S71 1 1, pcs 123032 Cross-type limit switch KHS 6.41-2+ Ru8X1 L=10,0m
1 Cross-type limit switch KHS 6.41 TS -S51
40fl
.2 1 1 1, pcs 27224 Housing cover
.2 6 1 1, pcs 304600 .
1 1 1, pcs 123955 Connection cable slewing motor KHS P12p-8X1
L=10000mm
.2 -X1 1 1, pcs 18068 Bush multipoint connector 12-3 ,50 for printed circuit board
Page 5 of 6
.2 -W_1 1 10.070, mm 577 Round cable PVC-OZ 8X 1,0 numbered

9,5mm
1 1 1, pcs 82281 Switching lug KHS-EK straight 6x240
1 5933713-770 Switching lug limit switch TS straight 10x400
to be fitted to runway 30/32
1 5933713-780 2 1, pcs 21406 Switching lug KHS-30/32 straight 8x400
To be fitted on C-rail 30/32
1 1 1, pcs 79016 Connector housing 16p M40s 500V
1 1 1, pcs 5314 Socket insert 6S35 500V 35A
Page 6 of 6
drawn with ELCAD (R) Copyright by ABUS - Germany Ausgabe: English
- wiring diagram of the crane

fabr.-nr./customer: /
functions: standard with LIS-SE/SV
net: operating voltage: 3/PE ~___Hz, ___V (clockwise rotating field); control voltage: 1~___Hz, ___V
drawing-nr. sheet kind of plan designation notes

500000-004 1 2SL wiring diagram/main power power supply/crane drive
500000-004 2 2SL wiring diagram/control current emergency stop/crane drive
500000-004 3 2SL wiring diagram/main power lifting gear/trolley drive
500000-004 4 2SL wiring diagram/control current lifting gear
500000-004 5 2SL wiring diagram/control current trolley drive
500000-004 6 3KL terminalplan/ +SKR-X0,+SKR-X1,+SKR-X2,+SKR-X4
500000-004 7 3KL terminalplan/ +SKR-X5,+SKR-X32,+SKR-X61,+SKR-X62
500000-004 8 3KL terminalplan/ +SKA-X1,+SKA-X4,+SKA-X4.1,+SKA-X5, +SKA-X20
500000-004 9 3KL terminalplan/ +SKA-X40
500000-004 10 5IS installation plan/ crane
500000-004 11 5IS installation plan/ trolley
unit characteristic located +KA1 trolley 1 +SGM hoisting limit sw. box
=A1 crane 1 +FKA inverter on hoist +KA2 trolley 2 +SKA trolley panel
=A2 crane 2 +FKR inverter on crane bridge +KB crane track +SKA1 trolley panel 1
trolley trolley +HSZ main power supply +KR crane bridge + end truck +SKA2 trolley panel 2
left right +HT push button pendant +KSZ trolley power supply +SKB crane track panel
crane crane +HW wall of the building +KSZ1 trolley power supply trolley 1 +SKR crane bridge panel
backward forward +KA trolley +KSZ2 trolley power supply trolley 2 +VFS sliding control
c 004 08.09.11 GG date 20.04.2000 parts list unit location
b 003 21.09.04 GG drawn G.Grzen register
500000-004
a 002 25.08.00 GG proof. W.Dick sheet from
00 11
1IH
revision date drawn symbol-file: LK12 origin: 500000 replacement for: replacement by:
Copyright by ABUS - Germany drawn with ELCAD (R)
1 2 3 4 5 6 7 8
-X4 1 1L1
/3.1
1
2 1L2
2
/3.1
3 1L3
+KSZ-W4 PE 3
/3.1
PE 1PE
/3.1
-Q61 1 3 5
2 4 6
-K1 I>> I>> I>>
/2.2
1 3 5 2 4 6
1 3 5 1 3 5
-K61 -K62
/2.5 /2.5
-F10 -F11 2 4 6 2 4 6
___
-T1 +5% 0 R1 R3 1 3
-F1 -K63 -K63
/2.6 /2.6
___ 0 R2 R4 2 4
-F12
-U61
1 B1
box 2 SU-1 B2
smooth switching
mounting-plate -X1 17 2)
-X1 0 -X1 1 -X1 16

PE-S L01 L02
-X0 1 4 2 5 3 6 PE
-X61 1 2 3 4 5 6 PE -X62 1 2 3 4 5 6 PE
-W1.1 1 2 3 PE
-W1.2 1 2 3 PE
+KR -W61 1 2 3 -V61 4 5 6 PE -W62 1 2 3 -V62 4 5 6 PE
~ ~ - + ~ ~ - +
Disconnecting from
ctrical net via plug, -X61 1 2 3 9 10 7 8 4 5 6 PE -X62 1 2 3 9 10 7 8 4 5 6 PE
not in time of 8Y 2Y BR BR 8Y 2Y BR BR
elecrical loading -Y1 2U -Y1 2U
L02
1U 1U
PE
L01
L2
L3
L1
1V M 2V 1V M 2V
/2.1
/2.1
1W 3~ 2W 1W 3~ 2W
8/2P 8/2P
main power supply control voltage -M1 -M1
3/PE~___Hz; ___V ___V, ___Hz -M61 -M62
clockwise rotating field bridge drive 1 bridge drive 2
2) option
c 004 08.09.11 GG date 20.04.2000 wiring diagram/main power parts list unit location
b 003 21.09.04 GG drawn G.Grzen power supply/crane drive +SKR
500000-004
11
2SL
revision date drawn symbol-file: LK12 origin: 500000 replacement for:500000 replacement by: 1
1 2 3 4 5 6 7 8
L01 ___V, ___Hz -X5 1 1L01
/1.3 /4.1
+KSZ-W5 1
-X2 1
emergency stop horn fast
2 -X2 12 14 15 16 PE 9 10 11
-X5 2
+KSZ-W5 2
+SKA
-X5 2
-X1 2
-W31 1
-X1 1
-S31 .1 1
security -X1 4 6 8 -W74 3
switch lifting 2 -W71 1 -W71 3 -W71 5
+SGM -X1 2 3
-X1 3 -X1 9 5 13 -B74 4
-W31 2 -S71 .1 11 .4 41 .2 21
-K62 7
5 5
crane travel 14 +KR
-X1 3 4
forward 12
limit switch backward 42 forward 22 -W74 4
+KR -X1 4 10 6 -W71 6 -X1 9
-W71 2 -W71 4 7 -W71 7 -X1 10
-X1 5 7 .3 31 -W75 3
13
backward 32 -K61 3
5
14 -B75 4
8 8
+KR 5
-W71 8 4
11 -W75 4
11
-U32 -X1 2 -X1 3
/4.4
14 12 L013
/4.4
-X5 3 -W74 1 -W75 1
1 1
-X1 12 2
+KSZ-W5 3
-K65
-X5 3 -W11 1 0,5sec. t
1
0
-B74 -B75
+KR 3 +KR 3
A1 -H11 A1 A1 A1
4 5
7 4 5
7
-K1 +KR -K61 -K62 -K63 2 2
-W74 2 -W75 2
-W11 2
A2 A2 A2 A2
L02 -X1 13 -X1 14 -X1 15 -X5 11 1L02
+KSZ-W5 11
/1.3 /4.1
light barrier forward 2)
main contactor horn forward backward fast
light barrier backward 2)
1 2 2) 1 2 1 2 1 2
/1.1 /1.5 /1.6 /1.6
3 4 3 4 3 4 R1 R2
/1.1 /1.5 /1.6 /1.5
5 6 5 6 5 6 R3 R4
/1.1 /1.5 /1.6 /1.5
13 14 13 14 13 14 3 4
/4.5 7 7 /1.6
21 22
2) option
c 004 08.09.11 GG date 20.04.2000 wiring diagram/control current parts list unit location
b 003 21.09.04 GG drawn G.Grzen emergency stop/crane drive +SKR
500000-004
11
2SL
revision date drawn symbol-file: LK12 origin: 500000 replacement for: replacement by: 2
1 2 3 4 5 6 7 8
1L1 -X4 1 -X4.1 1 -X4.1 2
/1.8
1L2 2 3 4
/1.8
1L3 3 5 6
/1.8
1PE PE
/1.8
3)
-Q41 1 3 5
1 2 3
-T32 I>> I>> I>>
2
3
1
4
I1 I2 I3 GND control
current 2 4 6
transformer -U32 LIS-SE/SV
see
current /4.4
control L1 L2 L3
1 3 5 1 3 5 1 3 5 1 3 5
-K21 -K22 -K41 -K42
/4.4 /4.5 /5.2 /5.3
2 4 6 2 4 6 2 4 6 2 4 6
R1 R3 R1 R3
-K23 -K21 7-K22 7
-K23 1 3
-K43 -K43 1 3
/4.5 /4.4 /4.5 /4.5 /5.4 /5.4
R2 R4 8 8 2 4 R2 R4 2 4
mounting-plate
1 2 5 6
~ ~
-V21 box
~ ~ + -
1 2 3 4
-X20 1 -X20 2 3 -X40 1 3 5 2 4 6

PE PE PE
+KA -W21.1 1 2 3 9 10 7 8 -W21.1 4 5 6 PE -W41 1 2 3 -V41 4 5 6 PE -W42 1 2 3 -V42 4 5 6 PE
(6) (7) (4) (5) (-W21.2 1) (2) (3)

~ ~ - + ~ ~ - +
-X21 1 2 3 9 10 7 8 4 5 6 PE
-X41 1 2 3 9 10 7 8 4 5 6 PE -X42 1 2 3 9 10 7 8 4 5 6 PE
12Y 2Y BR BR 8Y 2Y BR BR 8Y 2Y BR BR
1U -Y1 2U 1U -Y1 2U 1U -Y1 2U

1V M 2V 1V M 2V 1V M 2V
1W 3~ 2W 1W 3~ 2W 1W 3~ 2W
12/2P 8/2P 8/2P
-M1 (n) ab GM3000H -M1 -M1
-M21 -M41 -M42
2) option
hoist motor trolley drive motor 1 trolley drive motor 2
3) only with cross section > 2,5mm
c 004 08.09.11 GG date 20.04.2000 wiring diagram/main power parts list unit location
b 003 21.09.04 GG drawn G.Grzen lifting gear/trolley drive +SKA
500000-004
11
2SL
1 2 3 4 5 6 7 8
1L01 -X5 1 1L01
/2.8 /5.1
fast tare LAZ
-X2 13 -X2 3 4 5 -X2 17 18 19 20 21 22 23 24

+SKR 13
-K1 -X32 1 2 3 4
/2.2
14
-X5 4 -X5 5 6 7
+KSZ-W5 4 +KSZ-W5 5 6 7
+KSZ-W32 1 2 3 4
-X5 4 -X5 5 6 7
2) E3 +5V Q GND
+ - F
-U32 LIS-SE/SV
GND
+12
-12
-X1 4 -X1 7
B+
B-
U+
U-
F1
-W31 3 -W31 5
control
-X1 3 -X1 5
yellow
brown
-W32 green
white
see: 4
-S31 .2 1 .3 1
hoisting limit sw.
+SGM lifting 2 lowering 2
-X1 4 -X1 6
-W31 4 -W31 6
-X1 5 -X1 8 B+ B- U+ U-
-X1 6 l
+KA-B32
3) transmitter
L013
/2.2
current
E6 E2 E4 E5 E7 11 EA A1
-U32
1L01
2L01
transformer
/3.3
overload load indicator
device
21 22 23 12 14 A2 E1 7
/2.2
/2.2
A1 A1 A1
-K21 -K22 -K23
A2 A2 A2
1L02 -X5 11 1L02
/2.8 /5.1
lifting lowering fast

1 2 1 2 1 2
/3.2 /3.3 /3.4
3 4 3 4 R1 R2
/3.2 /3.3 /3.2
5 6 5 6 R3 R4
/3.2 /3.3 /3.2
7 8 7 8 3 4
/3.3 /3.3 /3.4
2) option
3) only with LIS-SV
b 003 21.09.04 GG drawn G.Grzen lifting gear +SKA
500000-004
11
2SL
1 2 3 4 5 6 7 8
1L01 -X1 1
/4.8
L01
fast
-X2 6 7 8
+SKR
-X5 8 9 PE 10
+KSZ-W5 8 9 PE 10
-X5 8 9 PE 10
-X1 9 -X1 11 13
-W51 1 -W51 3 -W51 5
-X1 3 9 5 13
-S51 .1 11 .4 41 .2 21
-K42
3
trolley 14
travel limit switch right 12 left 42 right 22 6 -W51 6 -X1 14
+KA -X1 4 10 7 -W51 7 -X1 15
-W51 2 -W51 4 .3 31
-X1 10 -X1 12 13
left 32 -K41
2
14
8
-W51 8
-X1 16
1
-K45
0,5sec. t 0
2
A1 A1 A1
-K41 -K42 -K43
A2 A2 A2
1L02 -X1 17
/4.8
L02
right left fast
1 2 1 2 1 2
/3.5 /3.6 /3.6
3 4 3 4 R1 R2
/3.5 /3.6 /3.5
5 6 5 6 R3 R4
/3.5 /3.6 /3.5
13 14 13 14 3 4
5 5 /3.6
2) option
b 003 21.09.04 GG drawn G.Grzen trolley drive +SKA
500000-004
11
2SL
-W11
-W71
-W1.1
a 002
b 003
c 004
-W1.2
intern
extern
2) option
revision
+KSZ-W4
terminal block
cable no.
cable no.
target blip
target blip
date
08.09.11
21.09.04
25.08.00
Copyright by ABUS - Germany
GG
GG
GG
drawn
flat cab. 4G__
round cab. 8X1

round cab. 4G__
round cab. 4G__
round cab. 4G1,5
date
terminal no.
connection
page/path
-characteristic
operating material
terminal number
terminal jumper
-characteristic
terminal commentary
operating material
terminal number
equipment commentary equipment commentary
drawn
proof.
-X0 7 terminals
symbol-file: LK12
main power supply +HSZ-W0 L1 1 1 /1.1 -F1 1 main fuse
W.Dick
G.Grzen
2
20.04.2000
3/PE~___Hz; ___V +HSZ-W0
" L2 2 /1.1 -F1 3 "
clockwise rotating field +HSZ-W0
" L3 3 3 /1.2 -F1 5 "
+HSZ-W0
" L1 1 4 /1.1 -F1 1 "
drawn with ELCAD (R)
+HSZ-W0
" L2 2 5 /1.2 -F1 3 "
+HSZ-W0
" L3 3 6 /1.2 -F1 5 "
+HSZ-W0
" PE PE PE /1.2 -X1 0 PE-S
origin: 500000
+HSZ-W0
" PE PE
-X1 18 terminals
mounting-plate -Z-SGV PE 0 PE-S /1.2 -X0 PE

control circuit sec. -T1-F12 ___ 1 L01 /1.3 -X2 1
2 /2.7
3 /2.8 -X5 1
2) crane travel lm.sw. +KR-S71-X1 3 1 4 /2.5 -X2 9
replacement for:
" +KR-S71-X1 4 2 5 /2.5 -K61 A1 forward
" +KR-S71-X1 9 3 6 /2.5 -X2 10
" +KR-S71-X1 10 4 7 /2.5 -K62 A1 backward
" +KR-S71-X1 5 5 8 /2.6 -K62 13
" +KR-S71-X1 6 6 9 /2.7 -K62 14
" +KR-S71-X1 7 7 10 /2.7 -K61 13
" +KR-S71-X1 8 8 11 /2.6 -K61 14
horn +KR-H11 1 12 /2.3 -X2 14
replacement by:
2) " +KR-H11 2 13 /2.3
14 /2.7 -K62 A2 backward
15 /2.8 -X5 11
16 L02 /1.3 -K1 A2 main contactor
-T1 0 17 /1.3 PE-SSP
-X2 25 terminals
1 /2.2 -X1 1 L01
terminalplan/
2 /2.2 -X5 2
3 /4.4 -X5 5
4 /4.5 -K1 13
5 /4.5 -X5 7
6 /5.2 -X5 8
7 /5.3 -X5 9
8 /5.4 -X5 10
9 /2.5 -X1 4
10 /2.5 -X1 6
11 /2.6 -K62 13
12 /2.2
+SKR-X0,+SKR-X1,+SKR-X2,+SKR-X4 13 /4.2 -X5 4
14 /2.3 -X1 12
15 /2.3
16 /2.3 -K61 A2 forward
17 /4.7
18 /4.7
parts list
19 /4.7
20 /4.7
21 /4.7 -X32 1
22 /4.7 -X32 2
unit
23 /4.7 -X32 3
24 /4.8 -X32 4
PE /2.3
500000-004
-X4 4 terminals
3KL
+SKA-X4 1 1 1 /1.8 -K1 2

sheet
6
2
location
+SKA-X4 2 2 /1.8 -K1 4

+SKR
+SKA-X4 3 3 3 /1.8 -K1 6

+SKA-X4 PE PE PE /1.8 -Z-SGV PE mounting-plate
from
11
-W61
-W62
a 002
b 003
c 004
intern
extern
2) option
revision
+KSZ-W5
terminal block
+KSZ-W32
cable no.
cable no.
target blip
target blip
date
08.09.11
21.09.04
25.08.00
GG
GG
GG
drawn
flat cab. 12G1
flat cab. 12X1
round cab. 7G1,5

round cab. 7G1,5
date
connection
page/path
-characteristic
terminal no.
operating material
terminal number
terminal jumper
-characteristic
terminal commentary
operating material
terminal number
drawn
proof.
-X5 12 terminals
symbol-file: LK12
+SKA-X5 1 1 1 /2.8 -X1 3
W.Dick
G.Grzen
2
20.04.2000
+SKA-X5 2 2 /2.2 -X2 2
+SKA-X5 3 3 3 /2.2 -K1 A1 main contactor
+SKA-X5 4 4 4 /4.2 -X2 13
+SKA-X5 5 5 5 /4.4 -X2 3

+SKA-X5 6 6 6 /4.5 -K1 14
+SKA-X5 7 7 7 /4.5 -X2 5
origin: 500000
+SKA-X5 8 8 8 /5.2 -X2 6
+SKA-X5 9 9 9 /5.3 -X2 7
+SKA-X5 10 10 10 /5.4 -X2 8
+SKA-X5 11 11 11 /2.8 -X1 15
+SKA-X5 PE PE PE /5.4
-X32 4 terminals
LIS-SE/SV +SKA-U32 E3 1 1 /4.7 -X2 21
replacement for:
" +SKA-U32 +5V 2 2 /4.7 -X2 22
" +SKA-U32 Q 3 3 /4.7 -X2 23
" +SKA-U32 GND 4 4 /4.8 -X2 24
-X61 7 terminals
bridge drive 1 +KR-X61 1 1 1 /1.5 -K63 1

" +KR-X61 2 2 2 /1.5 -K63 R2
replacement by:
" +KR-X61 3 3 3 /1.5 -U61 2 smooth switching
" +KR-X61 4 4 4 /1.6 -U61 B1 2) "
" +KR-X61 5 5 5 /1.6 -U61 B2 "
" +KR-X61 6 6 6 /1.6 -K62 4
" +KR-X61 PE PE PE /1.6 -Z-SGV PE mounting-plate
-X62 7 terminals
bridge drive 1 +KR-X62 1 1 1 /1.7 -K63 R2
terminalplan/
" +KR-X62 2 2 2 /1.7 -K61 2
" +KR-X62 3 3 3 /1.7 -U61 2 smooth switching
" +KR-X62 4 4 4 /1.8 -K63 2 2)
" +KR-X62 5 5 5 /1.8 -K63 R3
" +KR-X62 6 6 6 /1.8 -K63 4
" +KR-X62 PE PE PE /1.8 -Z-SGV PE mounting-plate
+SKR-X5,+SKR-X32,+SKR-X61,+SKR-X62
parts list
unit
500000-004
3KL
sheet
7
location
+SKR
from
11
-W51
-W31
a 002
b 003
c 004
-W21.1
intern
extern
2) option
revision
+KSZ-W5
+KSZ-W4
terminal block
cable no.
cable no.
target blip
target blip
date
08.09.11
21.09.04
25.08.00
GG
GG
GG
drawn
flat cab. 12G1
flat cab. 4G__
round cab. 8X1

round cab. 8X1
round cab. 12G1,5
date
connection
page/path
-characteristic
terminal no.
operating material
terminal number
terminal jumper
-characteristic
terminal commentary
operating material
terminal number
drawn
proof.
-X1 17 terminals
symbol-file: LK12
1 L01 /5.8 -X5 1
W.Dick
G.Grzen
1
20.04.2000
security switch +SGM-S31-X1 1 2 /2.2 -X5 2
" +SGM-S31-X1 2 2 3 /2.2 -U32 11
hoisting limit sw. +SGM-S31-X1 3 3 4 /4.4 -X5 5
" +SGM-S31-X1 4 4 5 /4.4

6 /4.4 -U32 E6 overload
hoisting limit sw. +SGM-S31-X1 5 5 7 /4.5 -X5 6 device
origin: 500000
" +SGM-S31-X1 6 6 8 /4.5 -U32 E2 overload
2) trolley travel lm.sw. +KA-S51-X1 3 1 9 /5.2 -X5 8 device
" +KA-S51-X1 4 2 10 /5.2 -K41 A1 right
" +KA-S51-X1 9 3 11 /5.3 -X5 9
" +KA-S51-X1 10 4 12 /5.3 -K42 A1 left
" +KA-S51-X1 5 5 13 /5.4 -K42 13
" +KA-S51-X1 6 6 14 /5.5 -K42 14
" +KA-S51-X1 7 7 15 /5.5 -K41 13
" +KA-S51-X1 8 8 16 /5.4 -K41 14
replacement for:
17 L02 /5.8 -K41 A2 right
-X4 4 terminals
+SKR-X4 1 1 1 /3.1 -X4.1 1

+SKR-X4 2 2 2 /3.1 -X4.1 3
+SKR-X4 3 3 3 /3.1 -X4.1 5
+SKR-X4 PE PE PE /3.1 -Z-SGR PE mounting-plate
replacement by:
-X4.1 6 terminals
-X4 1 1 /3.2 -K22 1

2 /3.3 -Q41 1
-X4 2 3 /3.2 -K22 3
4 /3.3 -Q41 3
-X4 3 5 /3.2 -K22 5
6 /3.3 -Q41 5
terminalplan/
+SKA-X20
-X5 12 terminals
+SKR-X5 1 1 1 /4.1 -X1 1 L01

+SKR-X5 2 2 2 /2.2 -X1 2
+SKR-X5 3 3 3 /2.2 -U32 14
+SKR-X5 4 4 4 /4.2
+SKR-X5 5 5 5 /4.4 -X1 4
+SKR-X5 6 6 6 /4.5 -X1 7
+SKR-X5 7 7 7 /4.5 -U32 E7 overload
+SKR-X5 8 8 8 /5.2 -X1 9 device
+SKR-X5 9 9 9 /5.3 -X1 11
+SKR-X5 10 10 10 /5.4 -K42 13
+SKA-X1,+SKA-X4,+SKA-X4.1,+SKA-X5,
+SKR-X5 11 11 11 /4.1 -K21 A2 lifting

+SKR-X5 PE PE PE /5.4
-X20 11 terminals
parts list
hoist motor +KA-X21 2 2 /3.2 -K23 R2

" +KA-X21 3 3 /3.2 -K23 R4
" +KA-X21 9 9 /3.3 -V21 1 lifting gear
unit
" +KA-X21 10 10 /3.3 -V21 2 "

" +KA-X21 7 7 /3.3 -V21 3 "
" +KA-X21 8 8 /3.3 -V21 4 "
500000-004
" +KA-X21 5 5 /3.4 -K23 2

" +KA-X21 6 6 /3.4 -K23 4
3KL " +KA-X21 1 1 1 /3.2 -K21 2
" +KA-X21 4 4 2 /3.4 -K22 2
sheet
8
location
" +KA-X21 PE PE 3 PE /3.4 -Z-SGR PE mounting-plate

+SKA
from
11
equipment commentary
PE mounting-plate
R2
R4
2
4
R2
R4
2
4
2
4
terminal number
target blip
intern
-Z-SGR
operating material
-K43
-K43
-K43
-K43
-K43
-K43
-K43
-K43
-K42
-K41
-characteristic
cable no.
14 terminals
/3.5
/3.5
/3.6
/3.6
/3.7
/3.7
/3.8
/3.8
/3.5
/3.7
/3.6
/3.8
/3.6
/3.8
page/path
terminal block
connection
-X40
PE
PE
terminal commentary
terminal jumper
terminal no.
4
2
6 3
PE 5
6
1 1
-W41 round cab. 7G1,5

4
2
3
-W42 round cab. 7G1,5

PE
4
2
3
6
1
cable no.
2
3
4
5
2
3
4
5
1
1
6
6
PE
PE
terminal number
target blip
extern
+KA-X42
+KA-X42
+KA-X42
+KA-X42
+KA-X42
+KA-X42
+KA-X42
+KA-X41
+KA-X41
+KA-X41
+KA-X41
+KA-X41
+KA-X41
+KA-X41
operating material
-characteristic
equipment commentary
motor 2
2
motor 1
1
motor
motor
motor
motor
motor
motor
trolley drive
trolley drive
trolley drive
trolley drive
trolley drive
trolley drive
trolley drive
trolley drive
"
"
"
"
"
"
2) option
c 004 08.09.11 GG date 20.04.2000 terminalplan/ parts list unit location
b 003 21.09.04 GG drawn G.Grzen +SKA-X40 +SKA
500000-004
11
3KL
1 2 3 4 5 6 7 8
crane bridge panel

+SKR
-X4 +KSZ-W4
/11.1
W4
-X5 +KSZ-W5
/11.1
W5
-W1.1, -W1.2 -X0 +KSZ-W32
/11.1
W32
-X1 -X1 -X1 -X32

-X2
2)
-X61 -X62
main power supply

control
-W74, -W75
-W62
-W61
-W71
-W11
crane bridge
+KR
-X61 -X62
-B74
-M61 -M62 -S71 -H11
-B75
2) 2) 2)
bridge drive 1 bridge drive 2 crane travel light barrier horn

limit switch
11 2) option
c 004 08.09.11 GG date 20.04.2000 installation plan/ parts list unit location
b 003 21.09.04 GG drawn G.Grzen crane +SKR
500000-004
11
5IS
1 2 3 4 5 6 7 8
trolley panel hoisting limit sw. box

+SKA +SGM
-X1
+KSZ-W4 -X4
/10.8
W4
+KSZ-W5 -X5
/10.8
W5 -W31 -X1
+KSZ-W32 2)
-S31
/10.8
W32
hoisting limit sw.
-U32 -X20 -X40 -X40 -X1

LIS-SE/SV
-W21.2
-W21.1
-W42
-W32
-W41
-W51
2)
trolley
+KA
-X41 -X42
-X21.1 -X21.2
-B32 -M21 -M41 -M42 -S51
2)
hoist motor
transmitter trolley drive motor 1 trolley drive motor 2 trolley
3) travel limit switch
2) option
11 3) only with LIS-SV
c 004 08.09.11 GG date 20.04.2000 installation plan/ parts list unit location
b 003 21.09.04 GG drawn G.Grzen trolley +SKA
500000-004
11
5IS
1 2 3 4 5 6 7 8
30 32
1
L011
-S1.1 3 2
-S1 -S21
012 11 21 1a 1b -S41
012 11 21 1a 1b -S61
012 11 21
27
4 3 6 5 8 7
button pendant OFF-ON 4 1
lifting 12 14
-S22 22 24 right 12 14
-S42 22 24 forward 12 14
-S62 22 24
2) 012 31 41 012 31 41 012 31 41
4 4 6 5 8 7
-S1 11 lowering 32 34 42 44 left 32 34 42 44 backward 32 34 42 44
1a 1b
emergency stop 12
2 3 4 2 3 4 2 3 4
28.2
28.3
33.2
33.3
28.1
31.2
31.3
33.1
26
29
31.1
-X2 1 2 3 4 5 6 7 8 9 10 11
control cable-W3 1 2 3 4 5 6 7 8 9 10 11
+VFS-X2 -X2 1 2 3 4 5 6 7 8 9 10 11
ion-box trolley +VFS-W2.1 1 +VFS-W2.1 2 +VFS-W2.1 3 4 5 6 7 8 9 10 11
+SKR-X2 1 2 3 4 5 6 7 8 9 10 11
push button pendant

-S1
8
L011
1a 1b 1a 1b 1a 1b 1a 1b 1a 1b 1a 1b 1a 1b 1a 1b -P32
load indicator
-S12
trolley
1-1+2-2 11 21 -S11 11 -S71 11 -S71 3 2 -S27 11 -S85 11 -S81 11 -S82 11 -S32 11 + -
red
yellow
blue
preselection 14 12 22 24 horn 12 14 Super 12 14 12 14 load-lifting attachment 12 14 load-lifting attachment 12 14 tare 12 14
bridge 12 14 4 1
trolley precision hoist crane light
2 3 5 4 3 2 over-ride control 3 2 3 2 3 2 3 2 3 2 3 2
/travel
limit switch
-X2 12 13 14 15 16 17 18 19 20 -X2 21 22 23 24
control cable-W3 12 13 14 15 16 17 18 19 20 21 22 23 24
+VFS-X2 -X2 12 13 14 15 16 17 18 19 20 -X2 21 22 23 24

junction-box trolley
+VFS-W2.1 12
+VFS-W2.2 1 2 3 4 5 6 7 8 9 10 11 12
+SKR-X2 12 13 14 15 16 17 18 19 20 21 22 23 24
Optionen
(siehe Baugruppe)
2) option
c date 14.05.2014 plan of wiring up/ parts list unit location
b drawn G.Grzen push button pendant +HT
600167-000
a proof. S.Karthaus sheet from
2
2SL
revision date drawn symbol-file: origin: 600167 replacement for: replacement by: HT 611/1011S-N222K/S-B 1
1 2 3 4 5 6 7 8
view -A- by BJ24 view -A- by BJ24
14 13 14 13
15 12 15 12
-A- 16 4 -A- 16 4
plug-in connector -X2 5 3 11 plug-in connector -X2 5 3 11
17 17
connection control cable 6 1 2 10 connection control cable 6 1 2 10
18 18
7 9 24 7 9 24
19 8 24 = position pin 19 8 24 = position pin
20 21 22 23 20 21 22 23
1 -S1 1 -S1
2 option 2 option
3 3
4 -S21 4 -S21
5 -S22 5 -S22
-S42 6 7 -S41 -S42 6 7 -S41
-S62 8 9 -S61 -S62 8 9 -S61
10 11
option
by -N222S
12 13
by -N222S
c date 14.05.2014 wiring diagram/ parts list unit location

b drawn G.Grzen push button pendant HT611S-N222K/S
600167-000
a proof. S.Karthaus sheet from
2
2SL
revision date drawn symbol-file: LK12 origin: 600167 replacement for: replacement by: push button pendant HT1011-N222K/S 2

068 - Att. 4 - Operating Instruction Hoisting Gear ELK-8000kg-ABUS

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068 - Att. 4 - Operating Instruction Hoisting Gear ELK-8000kg-ABUS

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Original operating manual

ABUS single-girder overhead travelling crane ELK

EOT crane serial number 110-034551

hoist serial number 250-068733

Push button pendant 611 S

Spare parts catalogue ABUETK, A120250_001

ABUS Kransysteme GmbH

ABUS Kransysteme GmbH, DruckDoku Version 5.11w101

ABUS Kransysteme GmbH

Instructions regarding safety (page 3)

1. Instructions regarding safety .................... 3

2. Instructions regarding safety when

3. Preventing damage to the crane............... 9

5. Check before beginning work and

6. Operating the crane with the pendant

7. Lifting and lowering................................. 16

8. Crane travel, trolley travel and slewing ... 17

9. Overload protection ................................ 18

10. Inching counter ....................................... 19

11. Observe the specified duty cycles .......... 19

12. Working in the range of the travel limit

13. Load display and tare ............................. 22

14. Securing the crane in a power failure ..... 22

15. Switching off the crane ........................... 23

Operating the ABUS crane

Be sure to read and observe the product manual of

Observe the maximum load

Observe these instructions for safe handling of the

Observe the product manuals!

If the maximum load capacity is

Total 10 t, maximum load capacity of crane

Total 35 t, maximum load capacity of crane

The weight of the load lifting

Especially when the crane operator

Do not pull loads at an angle! Do not attempt to catch loads!

If an attached load is pulled or towed

Do not turn loads!

If an immobile or jammed load (e.g.

Do not attempt to transport any Do not cause loads to swing!

Do not intentionally run the load

The emergency limit switch (in wire

The chain of the chain hoist and the

2. Instructions regarding safety Close the hook safety latch!

Observe the product manuals!

If the hook safety latch is not closed,

Observe the maximum angle of 3. Preventing damage to the crane

Use electrically isolated lifting tackle for

Observe the product manuals!

In dangerous situations with the crane:

Press the emergency stop switch.

The crane brakes immediately; the load hook

When the danger has been eliminated:

Turn the emergency stop switch a quarter-

The crane is ready for use.

5. Check before beginning work Only with wire rope hoists

External check of crane Loops have formed in the wire rope.

In all supplied product manuals, check

There is a kink in the wire rope. This results

Is the load hook turnable and otherwise OK?

A bird cage has formed in the wire rope. This

The wire rope has a corkscrew-type

Only with chain hoists

Is the chain lubricated with oil?