AT A GLANCE:

General information

This section applies to anyone who lifts loads using the crane, performs work on the crane, or works nearby.

At the start

Using this product manual

The following symbols are used in this product manual:

This is an instruction regarding an action and prompts you to perform a work step.

This is the result of an action and describes what happens on the device.

This is a list.

Only with...

A section that appears in a box framed by a dashed line is only applicable for certain types, versions or options. The condition to which the section applies is specified at the beginning in the heading “Only with...”.

Instructions for the product manual

Read the product manual through carefully before beginning work. Also be sure to observe additional product manuals for accessories and components.

Afterwards, keep the product manual available in the vicinity of the crane. It must be accessible to all who work with or on the crane.

In the case of reselling or hiring out, always provide the product manual together with the crane.

Proper use

The chain hoist is suitable for the lifting and lowering of attached loads.

The chain hoist is designed for these applications:

Independently as a solo chain hoist for the stationary lifting and lowering of loads.
On a trolley running along an I-beam for moving loads in a linear direction.
On a jib crane (with hoist trolley) for moving loads in a circular direction.
On an HB crane installation for all-round moving of lightweight loads.
On a single girder travelling crane (with hoist trolley) for all-round moving of loads.

During operation, observe the classification according to FEM, duty cycle and switching rate.
Only use the chain hoist within its theoretical service life.
Do not use in aggressive environments.
Long-term usage only in weatherproof areas. Temporary use outdoors in rain or snow is permitted, preferably with electronic control.

Regulations

The installation has been built and tested according to European standards, rules and regulations applicable at the time of its manufacture. The conventions applied during design and construction are specified in the Declaration of Conformity or the Declaration of Incorporation. The conventions must also be observed for installation, operation, inspection and maintenance, as must the applicable occupational health and safety regulations.

Which provision applies in individual cases will greatly depend on the crane’s use and the national regulations. Review and observe all applicable and current regulations, including the occupational health and safety regulations. Refer also to the Declaration of Conformity or Declaration of Incorporation.

Warranty

ABUS assumes no liability for damages that were caused by improper use, inadequately trained personnel, incorrect performance of work, nor for any changes, reconstruction or other modification of the crane or crane components which were not approved by ABUS.
Any warranty claim becomes invalid if components were modified without consent, the crane or crane components were installed, used or serviced in any way other than that described in this product manual, or if parts other than original ABUS replacement parts were used.
Safe operation of the crane or crane components is only guaranteed if original ABUS replacement parts are used.

Instructions regarding safety

Observe these instructions for safe handling of the crane. Special hazard notices are located in the corresponding sections in which the danger arises.

Falling loads: Suspended loads can fall, injuring or killing people. Do not stand under suspended loads!
Do not exceed the maximum load capacity!
Do not pull, cut loose or tow loads at an angle!
Do not transport any persons along with the load!
Never twist suspended loads in the load hook or allow the load to fall into the load hook. The momentum can cause the load or chain hoist to fall, injuring or killing people.
Only use the chain hoist if there are no visible signs of damage on it.
Observe the current occupational health and safety regulations for working with the chain hoist.

The chain hoist

Description of the device

1: Motor cover
2: Suspension bracket
3: Housing with hoist motor
4: Gear unit
5: Chain, first fall
6: Chain, second fall (version)
7: Bottom block
8: Load hook
9: Pendant control
10: Control cable
11. Chain box
12: Connection cable with bayonet coupling

Performance features

The chain hoist:

The chain hoist has a slow lifting speed and a fast lifting speed.
The chain hoist is controlled using the “ABUCommander” pendant control. Depending on the version, the pendant control hangs directly on the chain hoist or on a mobile control (version).

Alternatively, the chain hoist can be equipped with an “ABURemote AC” radio remote control. The receiver is thereby directly mounted on the chain hoist.

Single-fall chain hoist: The chain hoist has a rotating hook assembly with a fixed load hook. The load hook can thus be guided by the hook assembly.
The chain hoist has a chain.
The chain hoist is equipped with a folding, removable suspension bracket for easier installation. A hinged suspension hook can be used as an option.
The chain hoist is equipped with an adjustable friction clutch. This is factory set for 1.3 to 1.4 times the maximum load capacity. It is used as an emergency stop device and to protect against occasional mechanical overload. For chain hoists with a maximum load capacity over 1000 kg, the friction clutch fulfils the function of overload protection. It conforms to the requirements for direct-acting overload protection according to DIN EN 14492-2.
The chain hoist is of a modular construction. Gear unit and housing can thus be easily removed and exchanged.
The chain hoist has a removable chain guide and chain sprocket. This enables quick exchange of wearing parts.
The chain hoist can be equipped with an ABULiner for continuously variable control of the lifting speed (optional).
Only for chain hoist with electronic control: The chain hoist can be equipped with an operating hours counter (optional).

For the chain hoists GM2 and GM4:

The suspension bracket can be rotated 90°.

For the chain hoists GM2, GM4 and GM6:

The chain hoist is equipped with direct control 400 V / 50 Hz as standard.
Only for direct control without electric trolley travel and for direct control with electric trolley travel: The chain hoist has three-pole protection with integrated fuses.
The chain hoist can be equipped with electronic control using maintenance-free semiconductor technology with 48 V control voltage (optional).

For chain hoist GM8:

The chain hoist is equipped with electronic control using maintenance-free semiconductor technology with 48 V control voltage.

For chain hoists with electronic control:

The chain hoist can be equipped with ABURemote AC radio remote control (optional),

For chain hoists with a mechanical hoist limit switch:

The chain hoist can be equipped with a mechanical hoist limit switch (optional).
An upper and a lower switching point can be set with the mechanical hoist limit switch. When the load hook reaches one of the switching points, the chain hoist brakes and halts.
The switching points of the mechanical hoist limit switch can be used in combination with a contactor control as a hoist limiter.
The switching points may be triggered during normal operation. If the microswitches of the hoist limit switch wear out due to regular use, the friction clutch of the chain hoist serves as an emergency end stop device.

For chain hoists with an electronic hoist limit switch:

The chain hoist can be equipped with an electronic hoist limit switch with teach-in function (optional).
An upper and a lower switching point can be set with the electronic hoist limit switch. When the load hook reaches one of the switching points, the chain hoist brakes and halts.
Optionally, an additional switching point can be located between the two switching points as an intermediate switching point. If this additional switching point is programmed, the chain hoist brakes as soon as the load hook approaches the intermediate switching point and halts there. The switching point can then be overrun by releasing the button for lifting/lowering and pressing it again (stop-and-go).
The switching points on the electronic hoist limit switch are programmed with a supplied teach-in module, which is plugged in instead of the pendant control.

Alternatively, a pendant control with an additional teach-in button is also available.

With ABURemote AC, the teach-in function can be operated remotely (optional).

Technical data

Electrical connection

	GM2 (all versions)
Operating voltage	220 –240 V	380 –415 V	460 –500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	60 %	60 %	60 %
Switching rate	360 c/h	360 c/h	360 c/h
Rated power	0.09 kW 0.35 kW	0.09 kW 0.35 kW	0.09 kW 0.35 kW
Start-up current IA	1.77 A 5.70 A	1.02 A 3.30 A	0.85 A 2.75 A
cos phi A	0.85 0.93	0.85 0.93	0.85 0.93
Rated current IN	1.35 A 1.90 A	0.80 A 1.14 A	0.65 A 0.92 A
cos phi N	0.56 0.71	0.56 0.71	0.56 0.71

	GM 2 (all versions)
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	60 %	60 %	60 %
Switching rate	360 c/h	360 c/h	360 c/h
Rated power	0.11 kW 0.42 kW	0.11 kW 0.42 kW	0.11 kW 0.42 kW
Start-up current IA	1.77 A 5.70 A	1.02 A 3.30 A	0.85 A 2.75 A
cos phi A	0.85 0.93	0.85 0.93	0.85 0.93
Rated current IN	1.35 A 1.90 A	0.80 A 1.14 A	0.65 A 0.92 A
cos phi N	0.56 0.71	0.56 0.71	0.56 0.71

	GM4 (all versions)
Operating voltage	220 – 240 V	380 – 415 V	460 – 500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	60 %	60 %	60 %
Switching rate	360 c/h	360 c/h	360 c/h
Rated power	0.22 kW 0.90 kW	0.22 kW 0.90 kW	0.22 kW 0.90 kW
Start-up current IA	4.80 A 20.0 A	2.80 A 11.5 A	2.30 A 9.60 A
cos phi A	0.85 0.90	0.85 0.90	0.85 0.90
Rated current IN	2.60 A 3.60 A	1.50 A 2.10 A	1.30 A 1.80 A
cos phi N	0.70 0.80	0.70 0.80	0.70 0.80

	GM 4 (all versions)
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	60 %	60 %	60 %
Switching rate	360 c/h	360 c/h	360 c/h
Rated power	0.26 kW 1.10 kW	0.26 kW 1.10 kW	0.26 kW 1.10 kW
Start-up current IA	4.80 A 20.0 A	2.80 A 11.5 A	2.30 A 9.60 A
cos phi A	0.85 0.90	0.85 0.90	0.85 0.90
Rated current IN	2.60 A 3.60 A	1.50 A 2.10 A	1.30 A 1.80 A
cos phi N	0.70 0.80	0.70 0.80	0.70 0.80

	GM6 (all versions)
Operating voltage	220 – 240 V	380 – 415 V	460 – 500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.40 kW 1.70 kW	0.40 kW 1.70 kW	0.40 kW 1.70 kW
Start-up current IA	7.80 A 29.8 A	4.50 A 17.2 A	3.75 A 14.3 A
cos phi A	0.70 0.90	0.70 0.90	0.70 0.90
Rated current IN	3.80 A 8.30 A	2.20 A 4.80 A	1.80 A 4.00 A
cos phi N	0.84 0.93	0.84 0.93	0.84 0.93

	GM 6 (all versions)
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.50 kW 2.00 kW	0.50 kW 2.00 kW	0.50 kW 2.00 kW
Start-up current IA	7.80 A 29.8 A	4.50 A 17.2 A	3.75 A 14.3 A
cos phi A	0.70 0.90	0.70 0.90	0.70 0.90
Rated current IN	3.80 A 8.30 A	2.20 A 4.80 A	1.80 A 4.00 A
cos phi N	0.84 0.93	0.84 0.93	0.84 0.93

	GM8 800.8-1 and 1600.4-2
Operating voltage	220 – 240 V	380 – 415 V	460 – 500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.2 kW 1.30 kW	0.2 kW 1.30 kW	0.2 kW 1.30 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	1.40 A 4.30 A	2.10 A 5.00 A
cos phi N	0.56 0.70	0.56 0.70	0.56 0.70

	GM 8 800.8-1, 1600.4-2
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.24 kW 1.60 kW	0.24 kW 1.60 kW	0.24 kW 1.60 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	1.40 A 4.30 A	2.10 A 5.00 A
cos phi N	0.56 0.70	0.56 0.70	0.56 0.70

	GM8 800.10-1, 1000.8-1, 1600.5-2 and 2000.4-2
Operating voltage	220 – 240 V	380 – 415 V	460 – 500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.3 kW 1.60 kW	0.3 kW 1.60 kW	0.3 kW 1.60 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	1.60 A 4.50 A	2.10 A 5.00 A
cos phi N	0.56 0.72	0.56 0.72	0.56 0.72

	GM 8 800.10-1, 1000.8-1, 1600.5-2, 2000.4-2
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.36 kW 1.90 kW	0.36 kW 1.90 kW	0.36 kW 1.90 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	1.60 A 4.50 A	2.10 A 5.00 A
cos phi N	0.56 0.72	0.56 0.72	0.56 0.72

	GM8 800.12-1, 1000.10-1, 1250.8-1, 1600.6-2, 2000.5-2 and 2500.4-2
Operating voltage	220 – 240 V	380 – 415 V	460 – 500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.33 kW 2.00 kW	0.33 kW 2.00 kW	0.33 kW 2.00 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	1.90 A 4.80 A	2.10 A 5.00 A
cos phi N	0.57 0.75	0.57 0.75	0.57 0.75

	GM 8 800.12-1, 1000.10-1, 1250.8-1, 1600.6-2, 2000.5-2, 2500.4-2
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	50 %	50 %	50 %
Switching rate	300 c/h	300 c/h	300 c/h
Rated power	0.4 kW 2.40 kW	0.4 kW 2.40 kW	0.4 kW 2.40 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	1.90 A 4.80 A	2.10 A 5.00 A
cos phi N	0.57 0.75	0.57 0.75	0.57 0.75

	GM8 800.16-1, 1000.12-1, 1250.10-1, 1600.8-1, 1600.8-2, 2000.6-2, 2500.5-2 and 3200.4-2
Operating voltage	220 – 240 V	380 – 415 V	460 – 500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	40 %	40 %	40 %
Switching rate	240 c/h	240 c/h	240 c/h
Rated power	0.4 2.50	0.4 2.50	0.4 2.50
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	2.20 A 5.30 A	2.10 A 5.00 A
cos phi N	0.59 0.79	0.59 0.79	0.59 0.79

	GM 8 800.16-1, 1000.12-1, 1250.10-1, 1600.8-1, 1600.8-2, 2000.6-2, 2500.5-2 and 3200.4-2
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	40 %	40 %	40 %
Switching rate	240 c/h	240 c/h	240 c/h
Rated power	0.48 kW 3.00 kW	0.48 kW 3.00 kW	0.48 kW 3.00 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	2.20 A 5.30 A	2.10 A 5.00 A
cos phi N	0.59 0.79	0.59 0.79	0.59 0.79

	GM8 800.20-1, 1000.16-1, 1250.12-1, 1600.10-1, 2000.8-1 1600.10-2, 2000.8-2, 2500.6-2, 3200.5-2 and 4000.4-2
Operating voltage	220 – 240 V	380 – 415 V	460 – 500 V
Mains frequency	50 Hz	50 Hz	50 Hz
Duty cycle	40 %	40 %	40 %
Switching rate	240 c/h	240 c/h	240 c/h
Rated power	0.5 3.00	0.5 3.00	0.5 3.00
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	2.50 A 6.00 A	2.10 A 5.00 A
cos phi N	0.65 0.85	0.65 0.85	0.65 0.85

	GM 8 800.20-1, 1000.16-1, 1250.12-1, 1600.10-1, 2000.8-1 1600.10-2, 2000.8-2, 2500.6-2, 3200.5-2, 4000.4-2
Operating voltage	208 – 230 V	360 – 400 V	440 – 480 V
Mains frequency	60 Hz	60 Hz	60 Hz
Duty cycle	40 %	40 %	40 %
Switching rate	240 c/h	240 c/h	240 c/h
Rated power	0.6 kW 3.60 kW	0.6 kW 3.60 kW	0.6 kW 3.60 kW
Start-up current IA	6.00 A 43.30 A	3.50 A 25.00 A	2.90 A 20.80 A
cos phi A	0.75 0.90	0.75 0.90	0.75 0.90
Rated current IN	4.30 A 10.4 A	2.50 A 6.00 A	2.10 A 5.00 A
cos phi N	0.65 0.85	0.65 0.85	0.65 0.85

Ambient conditions for operation:

Ambient temperature (for normal operation)	-10 °C to +40 °C
Ambient temperature (for reduced duty cycle)	+40 °C to +80 °C
Housing	IP 55
Insulation class	F

Fuses:

3x ceramic tube fuse 32x6.3
10A, slow-blow

Noise emissions:

Table: Noise emissions based on DIN 45635, Part 61 following the substitution process with an acoustic power source
Size	Sound pressure level LP, m dB(A) at distance of 3 m	Sound pressure level LW, m dB(A)
GM2	55	72
GM4	55	72
GM6	61	78
GM8	62	79

In the table, the sound pressure level LP is specified for a distance of 3 m from the chain hoist. To calculate the sound pressure level LW, the sound pressure level at any distance may be used.

Transporting the chain hoist

Removing the chain box

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenspeicher abnehmen 3.jpg — Chain box

Release the SL safety clip(s) (1x or 2x) from the bolt.
Hold the chain box firmly and pull out the bolt(s) (1x or 2x).
Remove the chain box.

Place the detached chain box next to the chain hoist.

Protecting plug-in connections

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Transportieren 3.jpg — Transport guard

Attach the transport guard (from the original packaging or, for example, firm cardboard) to the socket.
Take care that the socket is not damaged and set the chain hoist down.

Loading and unloading the chain hoist

Load the chain hoist in the original packaging.

The chain hoist does not always lie in the middle of the original box.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenzug laden 3.jpg

When loading and unloading, note the centre of gravity symbol on the box.

Disposing of the chain hoist

If the chain hoist must be disposed of:

Dismantle the chain hoist 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 the oil from the gear unit as a lubricant.
Dispose of brake linings and friction clutch linings as multiple components (hazardous waste).
Dispose of electronic components as scrap electronic parts.
Dispose of the housing, chain sprocket, chain guide, chain, suspension bracket, gear unit and load hook as scrap metal.
Parts of the chain hoist that have been repainted are to be disposed of in accordance with the paint manufacturer's instructions.
Dispose of cables, plug-in connections and pendant controls as scrap electronic parts.

elektrogesetz_muelleimer_ohne_balken_002 — This product or electrical device may not be disposed of at the end of its service life with regular domestic waste.

Installing and connecting

This section applies to anyone who works on the crane prior to its use

The end user of the crane is responsible for the proper qualifications of the commissioning personnel.

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.
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
Persons receiving regular training from ABUS.

ABUS assumes no liability for damage due to incorrectly performed commissioning work done by unqualified personnel.

ABUS recommends having the commissioning work performed by the ABUS assembly team.

Checking the requirements

The following requirements must be met in order for the chain hoist to be mounted.

Checking the load capacity

The supporting structure (steelwork, building, crane installation) from which the chain hoist is to be suspended must have a sufficient load capacity.

The load capacity of the supporting structure is derived from the weight of the chain hoist, the maximum load capacity of the chain hoist, the weight of the trolley (if applicable) and possibly the additional weight of the chain as well.

For the weight of the chain hoist, refer to the table.
If the hook path of the chain hoist is longer than 3 metres: Add the additional weight of the chain.

Table: Weight of the chain hoists. The specifications are based on a hook path of 3 metres.
Size	Number of falls	Weight without trolley	Additional weight per metre hook path for hook paths longer than 3 metres
GM2	Single-fall	22 kg	0.34 kg
GM2	Twin-fall	25 kg	0.68 kg
GM4	Single-fall	30 kg	0.65 kg
GM4	Twin-fall	34 kg	1.30 kg
GM6	Single-fall	57 kg	1.24 kg
GM6	Twin-fall	63 kg	2.48 kg
GM8	Single-fall	94 kg	2.27 kg
GM8	Twin-fall	108 kg	4.54 kg

Add the maximum load capacity.
Only for trolley: Add the weight of the trolley.
Check the entire supporting structure as to whether it will support the expected load.

Installation overview

The following sections show how the chain hoist is installed.

First, the suspension bracket of the chain hoist is prepared and the chain hoist is attached to the supporting structure. See “Installing the chain hoist”.
Then, the bayonet connector is connected to the connecting cable and the connecting cable is inserted into the chain hoist. See “Connecting the chain hoist”.
Then the chain box is installed. See “Installing the chain box”
Finally, the chain is lubricated. See “Lubricating the chain”.
Only with chain hoists with a hoist limit switch: Lastly, the switching points of the mechanical hoist limit switch (“Setting the switching points of a mechanical hoist limit switch”) or the electronic hoist limit switch (“Setting the switching points of an electronic hoist limit switch”) and, if applicable, the intermediate switching point of the electronic hoist limit switch (“Setting the intermediate switching point of an electronic hoist limit switch”) are set.

Installing the chain hoist

Only for GM2 and GM4

Turning the suspension bracket by 90° or removing it

Depending on the installation site, the suspension bracket can be turned by 90°.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Aufhängebügel drehen, abnehmen 3.jpg — Bolt

Detach the SL safety clip from each of the bolts (2x).
Pull out the bolt.
Pull out the suspension bracket, turn it 90° and reinsert it.
Insert the bolt.
Secure the bolts with the SL safety clips (1x each).

Folding out the suspension bracket and attaching the chain hoist

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Aufhängebügel aufklappen 3.jpg

Detach the SL safety clip from the bolt.
Pull out the bolt.
Fold out the suspension bracket.
Lift the chain hoist and attach it under the supporting structure, under the trolley or under the crane.
Fold the suspension bracket over an appropriate anchorage or the travelling gear bolt of the trolley.
Insert the bolt.
Secure bolt with SL safety clip.

Only with suspension hook

If required, the chain hoist can be installed with an optional suspension hook.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Aufhängehaken Bolzen rein 3.jpg — Bolt

Insert suspension hook.
Insert bolts (2x).
Secure bolts with SL safety clips (2x).

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Aufhängehaken Haken auf 3.jpg — Safety deviceSuspension hook

Undo the safety device and open the suspension hook.
Lift the chain hoist and attach it under the supporting structure, under the trolley or under the crane.
Close the suspension hook over an appropriate anchorage or the travelling gear bolt of the trolley.

Only for GM8

Turn second fall straight

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenfestpunkt GM8 drehen 3.jpg — Chain anchor pointSecond fall

Check the chain anchor point: The second fall should extend straight to the bottom block and not be twisted.

If necessary:

Turn the chain anchor point.

Connecting the chain hoist

Only for electronic control or ABULiner

Selecting a fault current protection switch

If fault current protection is used as a safety measure, be sure to use fault current protection that is sensitive to universal current.

The chain hoist can cause leakage current during operation, which could cause a fault current protection switch to trigger.

If the fault current protection triggers due to leakage current during normal operation:

If possible, exchange the fault current protection switch for one with 0.3 A. This will no longer guarantee personnel safety.
Alternatively, a leakage current compensating filter can be installed.

Connecting the bayonet coupling to the connection cable

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Netzstecker vorbereiten 3.jpg

Insert the bayonet nut on the connection cable.
Insert the connector housing on the connection cable.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Aderendhülsen aufpressen 3.jpg

Leave the protective conductor somewhat longer than the other wires and connect it in advance.
Press the wire end bushings onto the wires.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Netzstecker O-Ringe aufstecken 3.jpg — Bush insertO-ring, thin

Insert the O-rings on the bush insert.

U:\Allgemein\Produkthandbücher\Ersatzteildoku Fotos\Schlauchsteuerleitung\Ansicht Buchse BJ8 3.jpg

Check that the assignment is correct (view of drawing from front) and connect the wires to the bush insert.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kabelbinder an Steckerteil anbringen 3.jpg — Cable tiesStrain reliever

Slide the strain reliever onto the connection cable so that 26 mm clearance remains between the strain reliever and the bush insert.
Fasten the strain reliever with cable ties (2x).

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Netzstecker zusammenbauen 3.jpg — Connector housing

Press the connector housing onto the bush insert until it clicks.
Slide the bayonet nut over it.

Connecting the chain hoist

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Stecker anschließen 3.jpg — Bayonet coupling of connection cableBayonet connector of control cable

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

Installing the chain box

Only for GM2, GM4 and GM6 (GM6 with plastic chain box)

The illustrations show a chain box being installed on the GM6 chain hoist. Installation on a GM2 or GM4 chain hoist is very similar.

Installing the chain box

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenspeicher GM6 montieren 3.jpg — Chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (slanted side facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM2: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with one hole: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with two holes: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the chain box. The outer holes remain free.
For GM6 and plastic chain box: Use two bolts to fix the chain box to the chain hoist.

Secure the bolts with the SL safety clips (1x or 2x).

Only for GM8

Attach buffer

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Puffer GM8 einschieben 3.jpg — BufferBolt

Turn the buffer as shown in the figure (rounded side facing inward).
Push the buffer between the suspension straps on the chain hoist.
Push the short bolt through the outer holes of the suspension straps and the buffer.

Only for GM6 (GM6 with chain box with metal frame) and GM8

The illustrations show a chain box being installed on the GM8 chain hoist. Installation on a GM6 chain hoist is very similar.

Installing the chain box

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenspeicher GM8 montieren 3.jpg — Chain boxSL safety clip

Place the chain in the chain box.
Turn the chain box as shown in the figure (bar facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM6 and chain box with metal frame: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The outer holes of the suspension strap remain free.
For GM8: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The buffer is fixed to the outer holes of the suspension straps.

Secure the bolts with the SL safety clips (2x).

Lubricating the chain

A well-lubricated chain wears much slower and can be used considerably longer. The chain must be lubricated before operation.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette schmieren 3.jpg

Press the LIFT button and allow the chain to run into the chain box. Lubricate the chain during its movement.

Lubricant: “Chainlife S”. For details, see “Lubricants”.

Apply additional lubricant to the unstressed chain in the chain box so that it flows into the joints of the chain links.

Setting the switching points of a mechanical hoist limit switch

Only with a mechanical hoist limit switch

This section only applies to chain hoists with a mechanical hoist limit switch of the sizes GM4, GM6 and GM8.

Overview:

Size	Number of falls	Hook path	Mechanical hoist limit switch	Switching hysteresis B [mm]	Hook path per revolution [mm]	Hook path per revolution of block adjustment [mm]
GM4	1	≤8 m ≥9 m	GPK 48.2 GPK 205.2	28 118	58 251	14 58
GM4	2	≤4 m ≥5 m	GPK 48.2 GPK 205.2	14 59	29 126	7 29
GM6	1	≤10 m ≥11 m	GPK 48.2 GPK 205.2	34 145	72 310	17 72
GM6	2	≤5 m ≥6 m	GPK 48.2 GPK 205.2	17 73	36 155	8 36
GM8	1	≤14 m ≥15 m	GPK 48.2 GPK 205.2	49 207	103 440	24 103
GM8	2	≤7 m ≥8 m	GPK 48.2 GPK 205.2	25 104	52 220	12 51

Size

Number of falls

Hook path

Mechanical hoist limit switch

Switching hysteresis B [mm]

Hook path per
revolution [mm]

Hook path per revolution of block adjustment [mm]

GM4

≤8 m

≥9 m

GPK 48.2

GPK 205.2

118

251

GM4

≤4 m

≥5 m

GPK 48.2

GPK 205.2

126

GM6

≤10 m

≥11 m

GPK 48.2

GPK 205.2

145

310

GM6

≤5 m

≥6 m

GPK 48.2

GPK 205.2

155

GM8

≤14 m

≥15 m

GPK 48.2

GPK 205.2

207

103

440

103

GM8

≤7 m

≥8 m

GPK 48.2

GPK 205.2

104

220

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGm Schrauben Übersicht 3.jpg — Black adjusting screw (block adjustment)

Unscrewing the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Motordeckel abschrauben 3.jpg — Motor cover

Unscrew the motor cover from the housing.

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

Secure the motor cover.

The power supply must remain switched on while setting the switching points.

Setting the upper switching point

Raise the load hook to the desired switching point.

Bottom block or hook assembly must not come into contact with the housing.
The friction clutch must not be triggered.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGm oben einstellen 3.jpg — Microswitch

The upper switching point is set with the middle adjusting screw.

If necessary: Turn the adjusting screw until the control cam is to the left of the microswitch. It should not be either directly on or to the right of the microswitch.
Turn the adjusting screw to the left until the control cam presses in an anti-clockwise direction against the microswitch and an audible click is heard.

Turn the adjusting screw to the right (the control cam turns clockwise) to move the switching point upwards.
Turn the adjusting screw to the left (the control cam turns anticlockwise) to move the switching point downwards.

Checking the setting

Lower the load hook.
Raise the load hook at slow as well as fast lifting speed and check that the load hook halts at the correct hook position.

The upper switching point is set.

Setting the lower switching point Lower the load hook to the desired lower switching point. The load hook must not come into contact with the floor of building. The chain must not be slack. The C-link in the chain box must not come into contact with the housing. This would trigger the friction clutch and then damage it in regular movement. The hook path (distance between the highest hook position and the lowest hook position) must not be greater than specified on the type plate. Control camOuter adjusting screw $U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGm unten einstellen 3.jpg$ The lower switching point is set with the outer white adjusting screw. If necessary: Turn the adjusting screw until the control cam is to the right of the microswitch. It must not be on the left of the microswitch or exactly on it. Turn the adjusting screw to the right until the control cam presses in a clockwise direction against the microswitch and an audible click is heard. Turn the adjusting screw to the right (the control cam turns clockwise) to move the switching point upwards. Turn the adjusting screw to the left (the control cam turns anticlockwise) to move the switching point downwards.
Checking the setting Raise the load hook. Lower the load hook at slow as well as fast lifting speed and check that the load hook halts at the correct hook position. The lower switching point is set.

Setting the lower switching point

Lower the load hook to the desired lower switching point.

The load hook must not come into contact with the floor of building.
The chain must not be slack.
The C-link in the chain box must not come into contact with the housing.

This would trigger the friction clutch and then damage it in regular movement.

The hook path (distance between the highest hook position and the lowest hook position) must not be greater than specified on the type plate.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGm unten einstellen 3.jpg

The lower switching point is set with the outer white adjusting screw.

If necessary: Turn the adjusting screw until the control cam is to the right of the microswitch. It must not be on the left of the microswitch or exactly on it.
Turn the adjusting screw to the right until the control cam presses in a clockwise direction against the microswitch and an audible click is heard.

Turn the adjusting screw to the right (the control cam turns clockwise) to move the switching point upwards.
Turn the adjusting screw to the left (the control cam turns anticlockwise) to move the switching point downwards.

Checking the setting

Raise the load hook.
Lower the load hook at slow as well as fast lifting speed and check that the load hook halts at the correct hook position.

The lower switching point is set.

Only with a mechanical hoist limit switch

Shifting both switching points together (block adjustment)

If both switching points are moved equally, both switching points can be set at the same time.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGm Block einstellen 3.jpg

Turn the black adjusting screw to the left or right to set both switching points at the same time.

Turn the adjusting screw to the right (the control cam turns clockwise) to move the switching point upwards.
Turn the adjusting screw to the left (the control cam turns anticlockwise) to move the switching point downwards.

Closing the chain hoist

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Motordeckel anschrauben 3.jpg — Bayonet couplingMotor cover

Hold the motor cover on the housing.
Note the different screw lengths and screw in the fillister-head screws.

Size	Size and length	Number	Tightening torque
GM2	M5x65	3x	4 Nm
GM2	M5x45	1x	4 Nm
GM4	M5x60	3x	4 Nm
GM4	M5x50	1x	4 Nm
GM6	M8x110	3x	15 Nm
GM6	M8x60	1x	15 Nm
GM8	M10x95	3x	20 Nm
GM8	M10x50	1x	20 Nm

Setting the switching points of an electronic hoist limit switch

Only with an electronic hoist limit switch

The switching points of the electronic hoist limit switch can be set without opening the chain hoist. This requires the supplied teach-in module or a pendant control with teach-in button, or an ABURemote AC receiver with teach-in.

The switching points do not need to be reset if the chain and chain sprocket are replaced. If the chain and chain sprocket are replaced, only the reference point needs to be reset. See “Exchanging the chain and chain sprocket”.

Overrunning the previous switching point

If the new upper or lower switching point is in an area that cannot be approached due to the previous switching point, the previous switching point must first be overrun.

To overrun a switching point:

Move to the previous switching point until the load hook stops.

Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 5 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 5 seconds.

Raise or lower the load hook over the previous switching point.

The previous switching point has been overrun.

Setting the upper switching point

Overview of setting the upper switching point:

(Described in detail below)

Move to the new switching point.
The last movement command before teach-in must be the “Lift” button.
Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 5 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 5 seconds.

Moving to the upper switching point:

Raise the load hook to the desired switching point.

Bottom block or hook assembly must not come into contact with the housing.
The friction clutch must not be triggered.
The new switching point must not be too close (about 10 cm) to a previous switching point. If it is too close, the following sequence is interpreted as the “Overrun previous switching point” function.

If a new switching point is to be set within this range, a switching point further away must first be temporarily set and only then the switching point at the desired hook position set.

The switching point cannot be above the reference point because the load hook cannot be moved up beyond the reference point.

Normally, this situation should not occur because the reference point is usually programmed to be at the highest hook position (bottom block or hook assembly just below the housing) and therefore the load hook cannot move any higher.

Finally, briefly press the “Lift” button.

Before teach-in, the “Lift” button must be pressed last if the upper switching point is to be set.

Inserting the teach-in module

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Teach-In einstecken kurz 3.jpg — Teach-in module

Remove the pendant control.
Insert the teach-in module.
Wait at least 5 s.
Remove the teach-in module.
Only with pendant control with teach-in button: Instead of inserting the teach-in module, press and hold the teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Instead of inserting the teach-in module, press and hold the “teach-in” direct access button (T with arrow) for 5 seconds.

Inserting the pendant control

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Hängetaster an Kabel 3.jpg — Emergency stop buttonPendant control

Only with teach-in module: Insert pendant control.
Only with teach-in module: Unlock emergency stop button.

The upper switching point is saved.

Setting the lower switching point

Overview of setting the lower switching point:

(Described in detail below)

Move to the new switching point.
The last movement command before teach-in must be the “Lower” button.
Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 5 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 5 seconds.

Moving to the lower switching point:

Lower the load hook to the desired switching point.

The load hook must not come into contact with the floor of building.
The chain must not be slack.
The C-link in the chain box must not come into contact with the housing.

This would trigger the friction clutch and then damage it in regular movement.

The hook path (distance between the highest hook position and the lowest hook position) must not be greater than specified on the type plate.
The new switching point must not be too close (about 10 cm) to a previous switching point. If it is too close, the following sequence is interpreted as the “Overrun previous switching point” function.

If a new switching point is to be set within this range, a switching point further away must first be temporarily set and only then the switching point at the desired hook position set.

Finally, briefly press the “Lower” button.
Before teach-in, the “Lower” button must be pressed last if the lower switching point is to be set.

Inserting the teach-in module

Remove the pendant control.
Insert the teach-in module.
Wait at least 5 s.
Remove the teach-in module.
Only with pendant control with teach-in button: Instead of inserting the teach-in module, press and hold the teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Instead of inserting the teach-in module, press and hold the “teach-in” direct access button (T with arrow) for 5 seconds.

Inserting the pendant control

Only with teach-in module: Insert pendant control.
Only with teach-in module: Unlock emergency stop button.

The lower switching point is saved.

Setting the intermediate switching point of an electronic hoist limit switch

Only for electronic hoist limit switches with an intermediate switching point

This section only applies to a chain hoist with an electronic hoist limit switch combined with a pendant control with an “intermediate switching point” rotary switch or a radio remote control with an “intermediate switching point” function.

With the intermediate switching point function, any hook position between the upper and lower switching point can be moved to during normal operation.

The intermediate switching point of the electronic hoist limit switch can be set without opening the chain hoist. This requires the supplied teach-in module or a pendant control with teach-in button, or an ABURemote AC receiver with teach-in.

The intermediate switching point does not need to be reset if the chain and chain sprocket are replaced. If the chain and chain sprocket are replaced, only the reference point needs to be reset. See “Exchanging the chain and chain sprocket”.

Setting the intermediate switching point:

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Hängetaster Positionswahl 3.jpg — Rotary switch

Set the rotary switch on the pendant control to “1”.

The “Set intermediate switching point” function is activated.

Set the intermediate switching point in the same way as with the upper or lower switching point. See “Setting the switching points of an electronic hoist limit switch”.

Move to the intermediate switching point.
The last move command before teach-in is irrelevant.
Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 5 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 5 seconds.

Deleting the intermediate switching point:

To prevent the load hook from stopping at the intermediate switching point, there are two options:

Delete all switching points. See “Deleting all switching points on the electronic hoist limit switch”. This will also delete the saved intermediate switching point.
Reprogramme the intermediate switching point to set a hook position that is outside the switching points, for example, below the lower switching point. To do this, the saved upper or lower switching point must be overrun when making the setting. See “Setting the switching points of an electronic hoist limit switch”.

Moving to the intermediate switching point:

The rotary switch is only required to set the intermediate switching point.

In normal operation, the chain hoist brakes as soon as the load hook approaches the intermediate switching point and halts there. The intermediate switching point can then be overrun by releasing the button for lifting/lowering and pressing it again (stop-and-go).

Inspection

This section applies to anyone who inspects and accepts the crane in accordance with occupational health and safety requirements

The chain hoist must be regularly inspected in order to guarantee safe operation. The end user is responsible for this regular inspection.

At the start

Test intervals

The regular inspection is performed at least once annually.

Under certain conditions, more frequent regular inspections may be necessary. Reasons include:

Frequent operation at the load capacity
Working in multiple shifts
Frequent use
Dusty or chemically aggressive environment

The end user is responsible for checking the requirements and determining the test intervals. ABUS will gladly assist you if questions arise.

Requirements for the examiner

The end user of the crane is responsible for the proper qualifications of the examiner.

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.
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
Persons receiving regular training from ABUS.

Scope of the test

The qualified person inspecting the chain hoist is responsible for the type and scope of the test.

Overview: Testing the chain hoist

In addition to the points described here, all points outlined in the other supplied product manuals must also be checked.

The decision regarding the technically faultless condition of the chain hoist lies solely with the examiner. Any inadequacies, if found, must be eliminated. The examiner will decide if the chain hoist then requires additional testing.

If locally applicable regulations specify further tests, these are likewise to be carried out.

Additionally, at least the following points must be checked:

Check the load hook. See “Checking the load hook”.
Check the suspension bracket. See “Checking the suspension bracket”.
Check the condition of the chain. See “Checking the condition of the chain” and “Checking the wear on the chain”.
Check the friction clutch. See “Checking the friction clutch”.
Check the air gap and brake lining thickness. See “Checking the brake on the chain hoist”.
Check the lubrication of the chain. The chain may not be dry; lubricant must be visible on its surface. If it is not, lubricate the chain. See “Lubricating the chain”.
Check the installation of the chain. It may not be installed twisted. If it is, remove the chain and reinstall it so that it is free of any twisting.
Check the C-link. It must be present and attached to the penultimate or third-last chain link in such a way that the opening, when installed, points in the direction of the inner fall (the fall under load). Otherwise, reinstall the C-link.
Check the chain anchor point. The bolt must be inserted and secured. If it is not, push the bolt in and secure it with the SL safety clip.
Test the deep groove ball thrust bearing on the load hook. It must turn easily and exhibit no damage. Otherwise, replace the deep groove ball thrust bearing.

Document the test:

If the chain hoist is part of a crane installation: Document the results of the test in the test log book of the crane installation.
If the chain hoist is operated independently: Document the results of the test in the test log book. See “Test log book”.

Checking the load hook

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Lasthaken prüfen 3.jpg

Measure the opening width 'e' of the load hook.
Measure the base height 'f' of the load hook.
The measured values should neither exceed nor fall short of the values in the table.

Size of load hook	Type of load hook	Max. opening width 'e' [mm]	Min. base height 'f' [mm]	Material
012	single	26.4	18.1	STE 355
025	single	30.8	22.8	STE 355
05	single	37.4	29.9	34 CrMo 4
1	single	44.0	38.0	34 CrMo 4
1.6	single	49.6	45.6	34 CrMo 4

If the load hook has been widened to a greater degree than is allowed or if the base height is below the permissible limit, replace the load hook.
If the load hook is deformed (even if within the measurements given above): Inspect the surface for cracks.

Checking the suspension bracket

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Aufhängebügel prüfen 3.jpg

Remove the suspension bracket. See “Installing the chain hoist”.
Measure the bracket height ‘h’ of the suspension bracket.
Depending on the bracket height ‘h’, select the appropriate row in the table.
Measure the bracket thickness ‘g’ of the suspension bracket.
The measured value ‘g’ must not be below the value ‘g’ in the table.

Bracket height ‘h’	Min. bracket thickness ‘g’	Size
87 mm	18 mm	GM2
97 mm	18 mm	GM4
90 mm	22.8 mm	GM6
132 mm	22.8 mm	GM6
138 mm	26.6 mm	GM8
173 mm	31.3 mm	GM8

If the bracket thickness is thinner than is allowed, replace the suspension bracket.

Checking the suspension hook or safety load hook

Only with a suspension hook or safety load hook

This step only applies if a suspension hook is used instead of a suspension bracket or if a safety load hook is used instead of a normal load hook.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Aufhängehaken prüfen 3.jpg

Safety load hooks (left) and suspension hooks (right) are tested according to the same procedure.

Measure the base height ‘H’ of the suspension hook or safety load hook.
Measure the gap ‘A’ between the hook safety latch and the hook body.
Measure the lateral displacement ‘B’ between the hook safety latch and the hook body.
The measured values should neither exceed nor fall short of the values in the table.

Size of load hook	Maximum gap ‘A’ [mm]	Maximum lateral displacement ‘B’ [mm]	Minimum base height ‘H’ [mm]
BKT 6-10	2.2	3.5	17.1
BKT 7-10/8	2.7	4.5	20.7
BKT 10-10	3	6	26.1
BKT 13-10	3.3	7	34.2

If the load hook has been widened to a greater degree than is allowed or if the base height is below the permissible limit, replace the load hook.

Checking the condition of the chain

Check the lubrication of the chain.

The chain must be lubricated over its entirety.
Pay particular attention to the area of the joints.

Check for chain corrosion.

There must be no visible corrosion.

Check for surface damage on the chain links and between the joints.

There should be no visible damage such as undercuts, constrictions or abrasion.

Inspect the entire chain for damage. The damage shown here or any similar damage should not be detectable on the chain.

Examples of damage:

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaden abgenutzte Kettenglieder 3.jpg — The chain link is heavily worn.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaden mechanische Beschädigung 3.jpg — The chain link is mechanically damaged.

If there are signs of damage or corrosion on the chain, replace the chain and chain sprocket. See “Exchanging the chain and chain sprocket”.

Checking the wear on the chain

To check the wear, the length of eleven chain links is measured. Depending on the calliper used and the chain hoist, this can be measured directly or in three stages.

Raise a lightweight load slightly to tension the chain.

Measuring directly:

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette prüfen direkt 3.jpg

Measure the length ‘l’ over 11 chain links of the chain (from outer edge to outer edge).
Compare the measured value with the table (see “Checking the wear on the chain”). The measured value should not exceed the maximum ‘l’.
Measure again at several points and compare them.
If the length exceeds the specified value, the chain has been stretched too much through operation. Exchange the chain and chain sprocket. See “Exchanging the chain and chain sprocket”.

Measure in steps:

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette Ansicht 3.jpg

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette prüfen stufenweise 3.jpg — 3 chain links

Measure 3 chain links from outside to outside ‘l1’.
Measure 5 chain links from inside to inside ‘l2’. When doing so, do not measure the five chain links completely from inside to inside, but only place the calliper on the respectively next chain link.
Measure 3 chain links from outside to outside ‘l3’.
Add the measured values together.
Compare the measured value with the table. The measured value should not exceed the maximum ‘l’.
Measure again at several points and compare them.
If the length exceeds the specified value, the chain has been stretched too much through operation. Exchange the chain and chain sprocket. See “Exchanging the chain and chain sprocket”.

Size	GM2	GM4	GM6	GM8
Standard designation of chain	HEP – 3.7 x 12 DATC	HEP – 5 x 14.3 DATC	HEP – 7 x 21 DATC	HEP – 9.6 x 30 DATC
Thickness in the joint, setting ‘dm’	3.7 mm	5 mm	7 mm	9.6 mm
Thickness in the joint, min. ‘dm’	3.3 mm	4.5 mm	6.3 mm	8.6 mm
Individual spacing, inside, setting ‘t’	12 mm	14.3 mm	21 mm	30 mm
Individual spacing, inside, max. ‘t’	12.5 mm	14.9 mm	21.8 mm	31.2 mm
Length over 11 chain links, max. ‘l’	142.2 mm	170.7 mm	249.9 mm	356.2 mm
Surface	galvanised
Material	special chain steel
Max. load capacity per fall	320 kg	630 kg	1250 kg	2000 kg
Min. manufacturing test force	12.5 kN	22.3 kN	43.5 kN	82.5 kN
Min. breaking strength	20 kN	35.7 kN	70 kN	132 kN
Min. elongation at fracture	10 %
Weight per metre	0.34 kg/m	0.65 kg/m	1.24 kg/m	2.27 kg/m
Stamp	H 16

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenglied Ansicht 3.jpg

Checking the friction clutch

To test the friction clutch, the slip force test unit must be available. Be sure to observe the product manual of the slip force test unit.

Hang the slip force test unit in the chain about 20 cm beneath the chain hoist.
Lift at a slow lifting speed until the slip force test unit is run under the chain hoist and the friction clutch responds.
Read off the measured value on the slip force test unit.
If the displayed value deviates from the range of 1.3 to 1.4 times the maximum load capacity: Adjust the friction clutch; see “Adjusting the friction clutch”.
Hook up a test load with the maximum load capacity of the chain hoist and raise it.

Checking the brake on the chain hoist

To check the brake, a measurement is made of the air gap between magnet body and anchor plate, as well as the brake lining thickness.

Overview:

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\HF-EF\Bremse Übersicht 3.jpg — Magnet body and anchor plateBrake rotor with brake lining

Size	Air gap target value	Maximum air gap	Minimum air gap
GM2	0.25 mm	0.6 mm	0.2 mm
GM4	0.3 mm	0.6 mm	0.2 mm
GM6	0.35 mm	0.6 mm	0.3 mm
GM8	0.35 mm	0.6 mm	0.3 mm

Due to the wear of the brake lining as the motor is braked, the brake rotor gradually becomes thinner. The anchor plate is thereby pressed ever further toward the brake rotor during braking and the air gap thus becomes wider. If the air gap has reached its maximum width, a gap limiter prevents the anchor plate from being pressed any further, thus ensuring that the anchor plate is reliably ventilated. When the gap limiter is employed, the braking effectiveness gradually lessens.

This is the point at which the air gap must be readjusted at the latest. If the minimum lining thickness has been reached, the brake rotor must be replaced.

If the width of the air gap is within the permitted range but usage behaviour leads to the expectation that the air gap will be wider than permitted before the next regular inspection, the air gap must be readjusted now.

Opening the chain hoist

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Motordeckel abnehmen 3.jpg — Bayonet nutMotor cover

Release the bayonet nuts.
Detach the connection cable and control cable.
Unscrew the motor cover from the housing.

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

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

Uncovering the brake

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Manschette abstreifen 3.jpg

Pull off the dust guard ring.

Measuring the air gap

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Luftspalt ausmessen 3.jpg — Feeler gaugeAnchor plate

Insert the feeler gauge next to one of the hexagon head screws in the air gap between magnet body and anchor plate and measure the distance.

If the air gap has reached the maximum width of the operating range, adjust the brake. See “Setting the air gap on the brake”.

Size	Air gap target value	Maximum air gap	Minimum air gap
GM2	0.25 mm	0.6 mm	0.2 mm
GM4	0.3 mm	0.6 mm	0.2 mm
GM6	0.35 mm	0.6 mm	0.3 mm
GM8	0.35 mm	0.6 mm	0.3 mm

Repeat the steps for all hexagon head screws (3x).
Clean the entire brake with compressed air.

Measuring brake lining thickness

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Bremsbelag ausmessen 3.jpg — Brake rotor

Check the thickness of the brake lining with a calliper.

Size	Brake lining thickness, new	Brake lining thickness, minimum
GM2	7.5 mm	4.5 mm
GM4	8.5 mm	5.5 mm
GM6	10.5 mm	7.5 mm
GM8	10.5 mm	7.5 mm

If the brake rotor is thinner than permitted, replace the brake rotor. See “Replacing the brake rotor ”.

Covering the brake

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Manschette überstreifen 3.jpg

Pull the dust guard ring over the brake.

Connecting the chain hoist

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

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

For the assignment, see “Wiring diagrams”.

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

Closing the chain hoist

Hold the motor cover on the housing.
Note the different screw lengths and screw in the fillister-head screws.

Size	Size and length	Number	Tightening torque
GM2	M5x65	3x	4 Nm
GM2	M5x45	1x	4 Nm
GM4	M5x60	3x	4 Nm
GM4	M5x50	1x	4 Nm
GM6	M8x110	3x	15 Nm
GM6	M8x60	1x	15 Nm
GM8	M10x95	3x	20 Nm
GM8	M10x50	1x	20 Nm

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

Maintenance

This section applies to anyone who maintains, repairs or modifies the crane.

The end user of the crane is responsible for the selection and proper qualifications of the maintenance personnel.

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.
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
Persons receiving regular training from 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.

Instructions regarding safety when performing maintenance work

Observe the following safety instructions for any maintenance work on the chain hoist:

Switch off the mains switch. Secure the switch to ensure it cannot be turned back on accidentally.
Unplug the mains disconnector plug from the socket on the crane panel. Secure the socket with a padlock to ensure it is not plugged back in accidentally.
Use suitable lifting platforms and fall protection equipment.
Adequately cordon off the operating range around the lifting platform.
Switch off any other cranes using the same crane track or cranes working above or below the crane undergoing maintenance. Secure the switches to ensure they cannot be turned back on accidentally. Otherwise, other cranes could overturn the hoisting platform or crash into the crane undergoing maintenance.
Notify personnel in the area that maintenance work will be performed.
Only trained electricians should work on the crane electrical system!
Even after pressing the emergency stop button, life-threatening high voltages are still present in the chain hoist.

Changing the fuses

Only for GM2, GM4 and GM6 with direct control

Opening the chain hoist

Release the bayonet nuts.
Detach the connection cable and control cable.
Unscrew the motor cover from the housing.

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

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

Replacing the fuses

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Sicherungen auswechseln 3.jpg — Fuse holderSafety device

Pull the cover upwards and off the fuse holder.
Replace the fuse.

Use 3x ceramic tube fuse 32x6.3, 10A, slow-blow.

Fit the cover onto the fuse holder and lock in place.

Connecting the chain hoist

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

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

For the assignment, see “Wiring diagrams”.

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

Closing the chain hoist

Hold the motor cover on the housing.
Note the different screw lengths and screw in the fillister-head screws.

Size	Size and length	Number	Tightening torque
GM2	M5x65	3x	4 Nm
GM2	M5x45	1x	4 Nm
GM4	M5x60	3x	4 Nm
GM4	M5x50	1x	4 Nm
GM6	M8x110	3x	15 Nm
GM6	M8x60	1x	15 Nm
GM8	M10x95	3x	20 Nm
GM8	M10x50	1x	20 Nm

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

Exchanging the chain and chain sprocket

If the chain exhibits signs of wear or is too stretched from operation (see “Checking the condition of the chain”), it must be exchanged.

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

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

Removing the chain box

Release the SL safety clip(s) (1x or 2x) from the bolt.
Hold the chain box firmly and pull out the bolt(s) (1x or 2x).
Remove the chain box.

Only for GM2, GM4 and GM8

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenanschlag entfernen 3.jpg — Tensioner sleeve

Hammer the tensioner sleeve out of the C-link.

Only for GM6

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenanschlagstück GM6\Anschlagstück ab.png

Unscrew the fillister-head screw M6x30 (2x).
Remove the halves of the C-link from the chain.

Opening the chain hoist

Release the bayonet nuts.
Detach the connection cable and control cable.
Unscrew the motor cover from the housing.

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

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

Only with an electronic hoist limit switch

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Platine Ansicht 3.jpg — Hoist limit switch PCB

Removing the hoist limit switch

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Platine herausnehmen 3.jpg — Fillister-head screws with ribs M5x10

Pull the connector off the hoist limit switch PCB.
Unscrew the fillister-head screws with ribs M5x10 (3x).
Take the hoist limit switch PCB out of the chain hoist.

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Magnetträger ausbauen 3.jpg — Magnet carrier

Unscrew the magnet carrier.

Taking out the chain guide

Only for GM2

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Getriebeschrauben GM2 ausschrauben 3.jpg — Fillister-head screws

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.

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

Only for GM4

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Getriebeschrauben GM4 ausschrauben 3.jpg — Fillister-head screws

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.

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

Only for GM6

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Getriebeschrauben GM6 ausschrauben 3.jpg — Fillister-head screws

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.

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

Only for GM8

Tip:

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Getriebeschrauben GM8 ausschrauben 3.jpg — Locking screw

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenführung GM4 rausziehen 3.jpg — Chain guide

Hold the chain guide firmly.
Pull the gear unit from the housing.

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

The chain guide is now released.

Pull the entire chain guide downward out of the housing.

Only for single-fall chain hoists

Disassembling the load hook

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Hakengeschirr auseinanderschrauben 3.jpg — Hook assembly

Screw the hook assembly apart.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Axiallager auseinandernehmen 3.jpg — Chain fastening element halfDeep groove ball thrust bearing

Push the three-piece deep groove ball thrust bearing upward.
Remove both chain fastening element halves from the chain.
Note the layout position of the deep groove ball thrust bearing and remove it from the chain.

Only for twin-fall chain hoists GM2 and GM4

Disassembling the bottom block and chain anchor point

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM4 rausziehen 3.jpg — Second fallTab washer

Unscrew the tab washer on the brake bearing shield.
Hold the second fall while pulling out the bolt.

The chain is now released.

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

Only for twin-fall chain hoist GM6

Disassembling the bottom block and chain anchor point

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM6 rausziehen 3.jpg — Second fallBolt

Unscrew the tab washer.
Hold the second fall while pulling out the bolt.

The chain is now released.

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

Only for twin-fall chain hoist GM8

Disassembling the bottom block and chain anchor point

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM8 herausnehmen 3.jpg — Flange sleeve

Take the flange sleeve out of the housing.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM8 auseinandernehmen 3.jpg — Flange sleeve

Slide the flange sleeve downward.
Remove both chain fastening element halves from the chain.
Pull the chain out of the bottom block on the load hook.

Assembling a new chain guide

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenführung GM4 zusammenbauen 3.jpg — Chain guideStripper

Lubricate the new chain sprocket as shown in the figure.

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

Place the chain sprocket in the new chain guide.
Push the stripper from below into the chain guide.
Hammer in the cylindrical pin(s) (1x or 2x).

Drawing in the new chain

Use exclusively ABUS genuine replacement chains. For technical data on the chain, see “Checking the wear on the chain”.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette in Kettenführung GM4 einziehen 3.jpg — Vertical chain link

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

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

Pull the chain into the chain guide.

Tip:

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

Tip:

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

For easier installation:

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette mit C-Glied GM4 einziehen 3.jpg — New chainC-shaped chain link

Detach about a half metre from the old chain and pull this short piece as described into the chain guide and install the chain guide.
Once the chain hoist functions again, use a cut open C-shaped chain link to insert the new chain into the old remainder and allow the new chain to slowly be run in.

Only for twin-fall chain hoists

Installing the bottom block

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette GM6 durch Unterflasche 3.jpg — Cable tiesBottom block

Fasten cable ties to the end of the second fall.
Turn the second fall so that it is straight and pull the chain through the bottom block with the cable ties.

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

Only for twin-fall chain hoists GM2 and GM4

Installing the chain anchor point

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette in Festpunkt GM4 schieben 3.jpg — Second fall

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

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

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM4 einschieben 3.jpg — Tab washer

Insert the bolt.

The second fall is now held by the bolt.

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

Size	Type and length	Tightening torque
GM2	M5x20	4 Nm
GM4	M5x20	4 Nm

Only for twin-fall chain hoist GM6

Installing the chain anchor point

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

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

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM6 einschieben 3.jpg — Bolt

Insert the bolt.

The second fall is now held by the bolt.

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

Only for twin-fall chain hoist GM8

Installing the chain anchor point

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM8 zusammensetzen 3.jpg — Flange sleeve

Push the flange sleeve onto the second fall of the chain.
Place the chain fastening element halves from both sides on the last chain link and slide a flange sleeve over it.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Festpunkt GM8 einsetzen 3.jpg — Flange sleeve

Push the flange sleeve into the housing.

Installing the chain guide

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kupplungshälften prüfen 3.jpg — Coupling halves

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

If necessary:

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenführung GM4 einschieben 3.jpg

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenführung und Getriebe GM4 einschieben 3.jpg

Push the gear unit into the housing. Pull the chain slightly until the output shaft of the gear unit meshes with the chain sprocket.
Tighten the fillister-head screws (3x) in the housing.

Size	Size and length	Tightening torque
GM2	M6x85	7 Nm
GM4	M6x105	7 Nm
GM6	M8x110	18 Nm
GM8	M10x140	25 Nm

Only for single-fall chain hoists

Installing the hook assembly

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Innere Kette verwenden 3.jpg — Inside chain end

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Axiallager aufschieben 3.jpg — Ball bearing race (small inner diameter)

Push the deep groove ball thrust bearing onto the chain facing the right direction: First push on the ball bearing race with the larger inner diameter (smoothed), then the ball bearing cage, then the ball bearing race with the smaller inner diameter (not smoothed).
Place the chain fastening element halves on the chain from both sides.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Axiallager zusammensetzen 3.jpg — Chain fastening element halves

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

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

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Hakengeschirr zusammenschrauben 3.jpg — Hook assembly

Insert the deep groove ball thrust bearing with chain fastening element halves into one half of the hook assembly.
Assemble the hook assembly.
Bolt the hook assembly with the fillister-head screw and self-locking nut (2x).

Size	Size and length	Tightening torque
GM2	M6x25	10 Nm
GM4	M6x25	10 Nm
GM6	M6x45	12 Nm
GM8	M8x50	30 Nm

Only with an electronic hoist limit switch

Installing the magnet carrier

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Magnetträger einbauen 3.jpg — Magnet carrier

Apply threadlocker (lightly) to the thread of the magnet carrier.
Screw the magnet carrier in place. 6 Nm.

Installing the hoist limit switch PCB

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Platine einbauen 3.jpg — Protective conductor

Attach the protective conductor to the fillister-head screw at the bottom right.
Place the hoist limit switch PCB over the magnet carrier.
Use the fillister-head screws with ribs M5x10 (3x) to screw the hoist limit switch PCB tight. 3 Nm.

Connecting the chain hoist

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

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

For the assignment, see “Wiring diagrams”.

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

Closing the chain hoist

Hold the motor cover on the housing.
Note the different screw lengths and screw in the fillister-head screws.

Size	Size and length	Number	Tightening torque
GM2	M5x65	3x	4 Nm
GM2	M5x45	1x	4 Nm
GM4	M5x60	3x	4 Nm
GM4	M5x50	1x	4 Nm
GM6	M8x110	3x	15 Nm
GM6	M8x60	1x	15 Nm
GM8	M10x95	3x	20 Nm
GM8	M10x50	1x	20 Nm

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

Installing the C-link

Only for GM2, GM4 and GM8

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenanschlag befestigen 3.jpg — Tensioner sleeve

Use the outside end of the chain to install the C-link.
Turn the C-link so that the opening, when installed, points in the direction of the inner fall (the fall under load).
Push the C-link onto the second-last or third-last chain link (depending on the orientation from the previous step).
Hammer the tensioner sleeve into the C-link.
Place the chain in the chain box.
Check whether the chain completely fits in the chain box. If the chain box is too small, contact ABUS Service. See “ABUS Service”.

Only for GM6

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kettenanschlagstück GM6\Anschlag montieren.png — Fillister-head screw M6x30Self-locking nut

Use the outside end of the chain to install the C-link.
Turn the C-link so that the heads of the fillister-head screws point in the direction of the inner fall (the fall under load) when installed.
Place the halves of the C-link on the second-last or third-last chain link (depending on the orientation from the previous step).
Tighten the C-link with the fillister-head screws M6x30 (2x) and self-locking nuts M6 (2x). 10 Nm.
Place the chain in the chain box.
Check whether the chain completely fits in the chain box. If the chain box is too small, contact ABUS Service. See “ABUS Service”.

Lubricating the chain

A well-lubricated chain wears much slower and can be used considerably longer. The chain must be lubricated before operation.

Press the LIFT button and allow the chain to run into the chain box. Lubricate the chain during its movement.

Lubricant: “Chainlife S”. For details, see “Lubricants”.

Apply additional lubricant to the unstressed chain in the chain box so that it flows into the joints of the chain links.

Only for GM2, GM4 and GM6 (GM6 with plastic chain box)

The illustrations show a chain box being installed on the GM6 chain hoist. Installation on a GM2 or GM4 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (slanted side facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM2: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with one hole: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with two holes: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the chain box. The outer holes remain free.
For GM6 and plastic chain box: Use two bolts to fix the chain box to the chain hoist.

Secure the bolts with the SL safety clips (1x or 2x).

Only for GM8

Attach buffer

Turn the buffer as shown in the figure (rounded side facing inward).
Push the buffer between the suspension straps on the chain hoist.
Push the short bolt through the outer holes of the suspension straps and the buffer.

Only for GM6 (GM6 with chain box with metal frame) and GM8

The illustrations show a chain box being installed on the GM8 chain hoist. Installation on a GM6 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (bar facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM6 and chain box with metal frame: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The outer holes of the suspension strap remain free.
For GM8: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The buffer is fixed to the outer holes of the suspension straps.

Secure the bolts with the SL safety clips (2x).

Only for GM8

Turn second fall straight

Check the chain anchor point: The second fall should extend straight to the bottom block and not be twisted.

If necessary:

Turn the chain anchor point.

Only with an electronic hoist limit switch

Referencing the electronic hoist limit switch

The electronic hoist limit switch needs to be referenced again. See “Referencing the electronic hoist limit switch”.
Check the switching points (upper and lower) and correct if necessary.

The saved switching points are retained after referencing and therefore do not need to be reset.
If the switching points are moved equally, all the switching points can be corrected at the same time by changing the reference point accordingly.

Referencing the electronic hoist limit switch

Only with an electronic hoist limit switch

Referencing the hoist limit switch is a basic operation and has nothing to do with setting the upper and lower switching points, but is the reference point for all switching points.

The reference point is set at the factory. It must be reset if the chain and chain sprocket are replaced.

The saved switching points do not need to be reset after referencing.

The saved switching points are derived from the reference point that is set in this section. Consequently, the reference point should always be saved in the same place (bottom block or hook assembly just below the housing).

Since all the switching points are derived from the reference point, all the switching points can be corrected at the same time by changing the reference point accordingly.

Overview of referencing the hoist limit switch:

(Described in detail below)

Switch off the chain hoist, wait 30 seconds, then switch on the chain hoist again.
Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 5 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 5 seconds.

Move to the reference point. This should be as high up as possible without the load hook coming into contact with the housing.
The last movement command before teach-in must be the “Lift” button.
Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 5 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 5 seconds.

Switching the chain hoist off and on

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anschlussleitung ab 3.jpg — Connection cable

Loosen the bayonet nut and unplug the connection cable.

Or:

Switch off the chain hoist at the mains switch.

Wait at least 30 s.
Plug in the connection cable.

Switch on the chain hoist at the mains switch.

Performing teach-in

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Teach-in kurz oder lang 3.jpg — Teach-in moduleWaiting time depending on the desired function

Only with teach-in module: Loosen the bayonet nut and remove the pendant control.
Plug the teach-in module into the control cable, press and hold the teach-in button on the pendant control, or press and hold the “teach-in” direct access button (T with arrow).
Wait at least 5 s or more than 30 s:

If the waiting time is 5 s to 29 s, the hoist limit switch is referenced and the saved switching points are retained.
If the waiting time exceeds 30 s, the hoist limit switch is referenced. In addition, all saved switching points are deleted.

Remove the teach-in module or release the teach-in button or "teach-in" direct access button (T with arrow).

Referencing (with or without deleting the switching points) has started. Continue with the next steps.

Inserting the pendant control

Only with teach-in module: Insert pendant control.
Only with teach-in module: Unlock emergency stop button.

Moving to the reference point

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\HUGe Referenzposition anfahren 3.jpg

For the reference point, move up as far as possible without the hook block or hook assembly coming into contact with the housing.
Finally, briefly press the “Lift” button.

Before teach-in, the “Lift” button must be pressed last if the reference point is to be set.

Inserting the teach-in module

Remove the pendant control.
Insert the teach-in module.
Wait at least 5 s.
Remove the teach-in module.
Only with pendant control with teach-in button: Instead of inserting the teach-in module, press and hold the teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Instead of inserting the teach-in module, press and hold the “teach-in” direct access button (T with arrow) for 5 seconds.

Inserting the pendant control

Only with teach-in module: Insert pendant control.
Only with teach-in module: Unlock emergency stop button.

The reference point is saved.

Check the switching points (upper and lower) and correct if necessary.

The saved switching points are retained after referencing and therefore do not need to be reset.
If the switching points are moved equally, all the switching points can be corrected at the same time by changing the reference point accordingly.

Deleting all switching points on the electronic hoist limit switch

Only with an electronic hoist limit switch

If necessary, all the set switching points can be deleted.

For this, the electronic hoist limit switch must be referenced again. During referencing, the switching points can be deleted as well.

Overview of referencing the hoist limit switch and deleting the switch points:

Switch off the chain hoist, wait 30 seconds, then switch on the chain hoist again.
Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 30 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 30 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 30 seconds.

Move to the reference point. This should be as high up as possible without the load hook coming into contact with the housing.
The last movement command before teach-in must be the “Lift” button.
Only with teach-in module: Remove the pendant control, plug in the teach-in module, wait 5 seconds, then remove the teach-in module and insert the pendant control.

Only with pendant control with teach-in button: Press teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Press “teach-in” direct access button (T with arrow) for 5 seconds.

The hoist limit switch is referenced again and the switching points are deleted.

For a detailed description of the process, see “Referencing the electronic hoist limit switch”.

Overrunning the switching points of the electronic hoist limit switch

Only with an electronic hoist limit switch

In some situations, it may be necessary to overrun a set switching point (upper or lower).

Approach the switching point

Move to the switching point to be overrun until the load hook stops.

If the load hook is within about 10 cm of the switching point, the following sequence overruns the set switching point. Beyond this range, this sequence is used to set a switching point.

Inserting the teach-in module

Remove the pendant control.
Insert the teach-in module.
Wait at least 5 s.
Remove the teach-in module.
Only with pendant control with teach-in button: Instead of inserting the teach-in module, press and hold the teach-in button for 5 seconds.

Only with ABURemote AC with teach-in: Instead of inserting the teach-in module, press and hold the “teach-in” direct access button (T with arrow) for 5 seconds.

Inserting the pendant control

Only with teach-in module: Insert pendant control.
Only with teach-in module: Unlock emergency stop button.

Overrunning a switching point

Move the chain up or down over the set switching point.

The set switching point has been overrun.

Lubricating the chain

If the chain is dry and no lubricant can be seen on its surface, it must be lubricated.

For very dusty or dirty operations:

The lubricant enables dirt to adhere to the chain, making it stiff and susceptible to greater wear in the chain hoist. Under these conditions, the chain may require more frequent replacement instead of lubrication. Shorten the test intervals.

Lubricating the chain

A well-lubricated chain wears much slower and can be used considerably longer. The chain must be lubricated before operation.

Press the LIFT button and allow the chain to run into the chain box. Lubricate the chain during its movement.

Lubricant: “Chainlife S”. For details, see “Lubricants”.

Apply additional lubricant to the unstressed chain in the chain box so that it flows into the joints of the chain links.

Disassembling the bottom block

Only for twin-fall chain hoists

For repairs or replacing, it may be necessary to disassemble the bottom block.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Unterflasche demontieren 3.jpg — Fillister-head screws

Unscrew the fillister-head screws (2x).
Dismantle the bottom block.

Installing the bottom block

Only for twin-fall chain hoists

Assembling the bottom block

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Unterflasche demontiert 3.jpg — Deep groove ball thrust bearingDeflection roller

Insert the load hook in the bottom block.
Lubricate the deep groove ball thrust bearing on the load hook.

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

Insert the buffer.
Twist the chain straight and place it around the deflection roller. The chain must not be allowed to twist when it is placed on the deflection roller.
Insert the deflection roller and bolt in the bottom block.
Lubricate the needle bush on the deflection roller.

Lubricant: "Kluber Staburags NBU 12 Alltemp". For details, see "Lubricants"

Assembling the bottom block

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Unterflasche montieren 3.jpg

Lay the bottom block halves flush against one another.
Tighten the fillister-head screws (2x) with self-locking nuts.

Size	Size and length	Tightening torque
GM2	M6x30	10 Nm
GM4	M8x35	25 Nm
GM6	M10x45	36 Nm
GM8	M12x75	49 Nm

Setting the air gap on the brake

If the air gap is wider than permitted, it must be readjusted.

Overview:

Size	Air gap target value	Maximum air gap	Minimum air gap
GM2	0.25 mm	0.6 mm	0.2 mm
GM4	0.3 mm	0.6 mm	0.2 mm
GM6	0.35 mm	0.6 mm	0.3 mm
GM8	0.35 mm	0.6 mm	0.3 mm

As soon as the chain hoist stops running, the anchor plate presses against the brake rotor by spring force, braking the motor. An air gap is created between the magnet body and the anchor plate. When the chain hoist starts up, the magnetic body pulls the anchor plate away from the brake rotor and the motor can rotate freely again.

If the brake lining is worn, the air gap will be larger. See “Checking the brake on the chain hoist”. If the air gap is larger than the maximum permitted, the brake must be readjusted. If the brake lining on the brake rotor is worn too thin, it must be replaced. See “Replacing the brake rotor ”.

Removing the chain box

Release the SL safety clip(s) (1x or 2x) from the bolt.
Hold the chain box firmly and pull out the bolt(s) (1x or 2x).
Remove the chain box.

Opening the chain hoist

Motor cover

Release the bayonet nuts.
Detach the connection cable and control cable.
Unscrew the motor cover from the housing.

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

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

Uncovering the brake

Pull off the dust guard ring.

Setting the air gap

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Luftspalt einstellen 3.jpg — Feeler gaugeBanjo bolts

Unscrew the hexagon head screws (3x) by a half turn.
Screw in the banjo bolts (3x) by a half turn in the direction of the magnet body.
Read off the set width of the air gap from the table.

Size	Air gap target value	Maximum air gap	Minimum air gap
GM2	0.25 mm	0.6 mm	0.2 mm
GM4	0.3 mm	0.6 mm	0.2 mm
GM6	0.35 mm	0.6 mm	0.3 mm
GM8	0.35 mm	0.6 mm	0.3 mm

Insert the appropriate feeler gauge directly next to one of the hexagon head screws in the air gap between magnet body and anchor plate.
Tighten the hexagon head screws so that the feeler gauge can still be pulled from the air gap.

The air gap on this hexagon head screw is now adjusted to the set width.

Repeat the steps for all hexagon head screws (3x).

Concluding the setting of the air gap

Screw in the banjo bolts (3x) in the direction of the travel motor until hand-tight.
Tighten the hexagon head screws (3x).

Size	Size and length	Tightening torque
GM2	M4x45	3 Nm
GM4	M5x55	6 Nm
GM6	M6x65	10 Nm
GM8	M6x65	10 Nm

The brake is fixed with screws.

Check the air gap next to all three hexagon head screws. If different than the set width, repeat the adjustment.

Covering the brake

Pull the dust guard ring over the brake.

Connecting the chain hoist

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

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

For the assignment, see “Wiring diagrams”.

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

Closing the chain hoist

Hold the motor cover on the housing.
Note the different screw lengths and screw in the fillister-head screws.

Size	Size and length	Number	Tightening torque
GM2	M5x65	3x	4 Nm
GM2	M5x45	1x	4 Nm
GM4	M5x60	3x	4 Nm
GM4	M5x50	1x	4 Nm
GM6	M8x110	3x	15 Nm
GM6	M8x60	1x	15 Nm
GM8	M10x95	3x	20 Nm
GM8	M10x50	1x	20 Nm

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

Only for GM2, GM4 and GM6 (GM6 with plastic chain box)

The illustrations show a chain box being installed on the GM6 chain hoist. Installation on a GM2 or GM4 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (slanted side facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM2: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with one hole: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with two holes: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the chain box. The outer holes remain free.
For GM6 and plastic chain box: Use two bolts to fix the chain box to the chain hoist.

Secure the bolts with the SL safety clips (1x or 2x).

Only for GM8

Attach buffer

Turn the buffer as shown in the figure (rounded side facing inward).
Push the buffer between the suspension straps on the chain hoist.
Push the short bolt through the outer holes of the suspension straps and the buffer.

Only for GM6 (GM6 with chain box with metal frame) and GM8

The illustrations show a chain box being installed on the GM8 chain hoist. Installation on a GM6 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (bar facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM6 and chain box with metal frame: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The outer holes of the suspension strap remain free.
For GM8: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The buffer is fixed to the outer holes of the suspension straps.

Secure the bolts with the SL safety clips (2x).

Replacing the brake rotor

If the brake rotor on the chain hoist is thinner than permitted, the brake rotor must be replaced.

Removing the chain box

Release the SL safety clip(s) (1x or 2x) from the bolt.
Hold the chain box firmly and pull out the bolt(s) (1x or 2x).
Remove the chain box.

Opening the chain hoist

Motor cover

Release the bayonet nuts.
Detach the connection cable and control cable.
Unscrew the motor cover from the housing.

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

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

Uncovering the brake

Pull off the dust guard ring.

Disassembling the magnet body

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Bremse abschrauben 3.jpg — Magnet body

Disconnect the power supply of the magnet body.
Release the hexagon head screws M6x70 (3x).
Pull the magnet body from the motor shaft.

Removing the old brake rotor

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Bremsbelag abnehmen 3.jpg — Friction disc

Pull the brake rotor from the hub.

The friction disc lies loosely against the brake bearing shield.

Do not remove the friction disc.

Installing the new brake rotor

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Bremsbelag aufschieben 3.jpg — Friction disc

Check whether the friction disc is still lying on the brake bearing shield.
Push the new brake rotor onto the hub.

Mounting the magnet body

Slide the magnet body onto the motor shaft.
Screw on the hexagon head screws (3x). 7 Nm.

Then the air gap must be readjusted. See “Setting the air gap on the brake”.

Connect the power supply of the magnet body.

Covering the brake

Pull the dust guard ring over the brake.

Connecting the chain hoist

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

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

For the assignment, see “Wiring diagrams”.

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

Closing the chain hoist

Hold the motor cover on the housing.
Note the different screw lengths and screw in the fillister-head screws.

Size	Size and length	Number	Tightening torque
GM2	M5x65	3x	4 Nm
GM2	M5x45	1x	4 Nm
GM4	M5x60	3x	4 Nm
GM4	M5x50	1x	4 Nm
GM6	M8x110	3x	15 Nm
GM6	M8x60	1x	15 Nm
GM8	M10x95	3x	20 Nm
GM8	M10x50	1x	20 Nm

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

Only for GM2, GM4 and GM6 (GM6 with plastic chain box)

The illustrations show a chain box being installed on the GM6 chain hoist. Installation on a GM2 or GM4 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (slanted side facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM2: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with one hole: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with two holes: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the chain box. The outer holes remain free.
For GM6 and plastic chain box: Use two bolts to fix the chain box to the chain hoist.

Secure the bolts with the SL safety clips (1x or 2x).

Only for GM8

Attach buffer

Turn the buffer as shown in the figure (rounded side facing inward).
Push the buffer between the suspension straps on the chain hoist.
Push the short bolt through the outer holes of the suspension straps and the buffer.

Only for GM6 (GM6 with chain box with metal frame) and GM8

The illustrations show a chain box being installed on the GM8 chain hoist. Installation on a GM6 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (bar facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM6 and chain box with metal frame: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The outer holes of the suspension strap remain free.
For GM8: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The buffer is fixed to the outer holes of the suspension straps.

Secure the bolts with the SL safety clips (2x).

Adjusting the friction clutch

If the chain hoist does not lift the test load or if the measured value deviates from the maximum load capacity, the friction clutch must be readjusted.

Preparing the chain hoist

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Verschlußkappe entfernen 3.jpg — Sealing plugs

Remove the sealing plugs. A slight amount of oil may thereby run out.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Kette blockieren 3.jpg

Hoist motor, gear unit and chain may not move when adjusting the friction clutch. Block the chain in the chain guide or use the slip force test unit to block the chain.

Adjusting the friction clutch

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Rutschkupplung einstellen 3.jpg

Set the friction clutch to 1.3 to 1.4 times the maximum load capacity. Turning to the right causes the friction clutch to engage at higher loads, turning to the left causes it to engage at lower loads.
Check the friction clutch; see “Checking the friction clutch”.

If the friction clutch can no longer be readjusted, it must be exchanged. For this, contact ABUS Service. See “ABUS Service”.

Disassembling the gear unit

For repairs or replacing, it may be necessary to disassemble the gear unit.

Removing the chain box

Release the SL safety clip(s) (1x or 2x) from the bolt.
Hold the chain box firmly and pull out the bolt(s) (1x or 2x).
Remove the chain box.

Opening the chain hoist

Motor cover

Release the bayonet nuts.
Detach the connection cable and control cable.
Unscrew the motor cover from the housing.

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

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

Only with an electronic hoist limit switch

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

Removing the hoist limit switch

Pull the connector off the hoist limit switch PCB.
Unscrew the fillister-head screws with ribs M5x10 (3x).
Take the hoist limit switch PCB out of the chain hoist.

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

Unscrew the magnet carrier.

Taking out the chain guide

Only for GM2

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.
It later ensures that the gear unit cannot not fall down.

Only for GM4

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.
It later ensures that the gear unit cannot not fall down.

Only for GM6

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.
It later ensures that the gear unit cannot not fall down.

Only for GM8

Tip:

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

Unscrew the fillister-head screws (3x).
Leave the locking screw tightened.
It later ensures that the gear unit cannot not fall down.

Hold the chain guide firmly.
Pull the gear unit from the housing.
The locking screw secures the gear unit so that it need not be completely removed.
The chain guide is now released.

Pull the entire chain guide downward out of the housing.

Removing the gear unit

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Arretierschraube GM4 ausschrauben 3.jpg — Locking screw

Unscrew the locking screw.

The gear unit is now released.

Remove the gear unit.

Installing the gear unit

Preparing the gear unit

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Dom und Ritzel schmieren 3.jpg — Seal

Lubricate the gear unit dome and output shaft.

Lubricant: “High temperature paste PBC 1574”. For details, see “Lubricants”.

Press on the seal.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Federn, Kupplung, Stift einsetzen 3.jpg — Cylindrical pin

Insert compression springs (2x, 3x, or 4x). Apply some grease if necessary.
Set the gear rim on the coupling half.
Insert the cylindrical pin.

Installing the gear unit

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Getriebe aufschieben 3.jpg

Push the gear unit into the housing. The correct position of the gear unit is determined through the gear unit dome and cylindrical pin.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Arretierschraube GM4 einschrauben 3.jpg — Locking screw

Screw in the locking screw (fillister-head screw).

Size	Size and length	Tightening torque
GM2	M6x105	7 Nm
GM4	M6x105	7 Nm
GM6	M8x110	10 Nm
GM8	M10x110	10 Nm

Installing the chain guide

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

If necessary:

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

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

Push the gear unit into the housing. Pull the chain slightly until the output shaft of the gear unit meshes with the chain sprocket.
Tighten the fillister-head screws (3x) in the housing.

Size	Size and length	Tightening torque
GM2	M6x85	7 Nm
GM4	M6x105	7 Nm
GM6	M8x110	18 Nm
GM8	M10x140	25 Nm

Only with an electronic hoist limit switch

Installing the magnet carrier

Apply threadlocker (lightly) to the thread of the magnet carrier.
Screw the magnet carrier in place. 6 Nm.

Installing the hoist limit switch PCB

Attach the protective conductor to the fillister-head screw at the bottom right.
Place the hoist limit switch PCB over the magnet carrier.
Use the fillister-head screws with ribs M5x10 (3x) to screw the hoist limit switch PCB tight. 3 Nm.

Connecting the chain hoist

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

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

For the assignment, see “Wiring diagrams”.

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

Closing the chain hoist

Hold the motor cover on the housing.
Note the different screw lengths and screw in the fillister-head screws.

Size	Size and length	Number	Tightening torque
GM2	M5x65	3x	4 Nm
GM2	M5x45	1x	4 Nm
GM4	M5x60	3x	4 Nm
GM4	M5x50	1x	4 Nm
GM6	M8x110	3x	15 Nm
GM6	M8x60	1x	15 Nm
GM8	M10x95	3x	20 Nm
GM8	M10x50	1x	20 Nm

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

Only for GM2, GM4 and GM6 (GM6 with plastic chain box)

The illustrations show a chain box being installed on the GM6 chain hoist. Installation on a GM2 or GM4 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (slanted side facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM2: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with one hole: Use a bolt to fix the chain box to the chain hoist.
For GM4 and chain box with two holes: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the chain box. The outer holes remain free.
For GM6 and plastic chain box: Use two bolts to fix the chain box to the chain hoist.

Secure the bolts with the SL safety clips (1x or 2x).

Only for GM8

Attach buffer

Turn the buffer as shown in the figure (rounded side facing inward).
Push the buffer between the suspension straps on the chain hoist.
Push the short bolt through the outer holes of the suspension straps and the buffer.

Only for GM6 (GM6 with chain box with metal frame) and GM8

The illustrations show a chain box being installed on the GM8 chain hoist. Installation on a GM6 chain hoist is very similar.

Installing the chain box

Place the chain in the chain box.
Turn the chain box as shown in the figure (bar facing outward).
Use the bolts to install the chain box on the chain hoist.

For GM6 and chain box with metal frame: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The outer holes of the suspension strap remain free.
For GM8: Use a bolt to fix the chain box to the chain hoist. Use the inner holes of the suspension strap. The buffer is fixed to the outer holes of the suspension straps.

Secure the bolts with the SL safety clips (2x).

Only with an electronic hoist limit switch

Referencing the electronic hoist limit switch

The electronic hoist limit switch needs to be referenced again. See “Referencing the electronic hoist limit switch”.
Check the switching points (upper and lower) and correct if necessary.

The saved switching points are retained after referencing and therefore do not need to be reset.
If the switching points are moved equally, all the switching points can be corrected at the same time by changing the reference point accordingly.

Available accessories

Shortening the control cable

The sheath of the control cable serves to protect the wiring while also acting as a strain reliever. Therefore do not simply wind up the control cable and glue the ends together to shorten it. This would eliminate any function as a strain reliever.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Steuerleitung kürzen 3.jpg

To shorten the control cable, use the kit for shortening the control cable sheath, AN 308859.

Lengthening the control cable

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Steuerleitung verlängern 3.jpg — Additional control cable

To lengthen the control cable, use the kit for lengthening the control cable sheath, AN 102282.

Installing additional strain relief

The sheath of the control cable serves to protect the wiring while also acting as a strain reliever. In some cases it can be useful to install an additional strain relief.

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Steuerleitung Zugentlastung 3.jpg

Use the kit for strain relief, AN 109795 for additional strain relief.

Connecting the chain hoist

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anschlussleitung Zubehör 3.jpg — Flexible connection cable, 10 mBayonet connector

To connect the chain hoist, for example, use the set “Chain hoist connection cable” AN 316482.
If necessary, reverse the phases with the phase inverter in the CEE connector. See the subsection “Checking the rotary field” in the main section “Connecting the crane to the mains supply” of the “General Product Manual for ABUS Cranes”.

Lubricants

Note:

Synthetic lubricants may not be mixed with mineral-based lubricants!

Chain

On-site lubrication with “Chainlife S”, ABUS item number 2717

Lubrication ex works with “Chainlife S”, ABUS item number 2718.

Alternatives:

Castrol “Viscogen KL 23”
Klüber “Grafloscon CA 901 Ultra Spray”
Optimol “KL 23”
Shell “Malleus GL 95”

Lubricate the chain during:

installation
Regular inspection
Exchanging the chain and chain sprocket

For details, see “Lubricating the chain”.

Chain sprocket

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schmierstoffe Kettenrad 3.jpg

On-site lubrication with “High-Lub LT1 EP”, ABUS item number 318490.

Lubrication ex works with “High-Lub LT1 EP”, ABUS item number 317880.

Lubricate the chain sprocket during:

Exchanging the chain and chain sprocket

For details, see “Assembling a new chain guide”.

Output shaft on gear unit

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schmierstoffe Dom und Ritzel 3.jpg

On-site lubrication with “High temperature paste PBC 1574”, ABUS item number 6758.

Lubrication ex works with “High temperature paste PBC 1574”, ABUS item number 1571.

Lubricate the output shaft during:

Installation of the gear unit

For details, see “Installing the gear unit”.

Gear units GM2 and GM4

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schmierstoffe GM4 Getriebe 3.jpg

Lubrication ex works using lubricant with the standard designation CLP ISO VG 460 DIN 51502.

Quantity, GM2: 200 cm³
Quantity, GM4: 350 cm³

The gear unit is lubricated for its entire service life.

Gear unit GM6

Lubrication ex works using lubricant with the standard designation CLP ISO VG 680 DIN 51502.

Quantity: 700 cm³

The gear unit is lubricated for its entire service life.

Gear unit GM8

Lubrication ex works using lubricant with the standard designation CLP ISO VG 680 DIN 51502.

Quantity: 1700 cm³

The gear unit is lubricated for its entire service life.

Only for twin-fall chain hoists

Deflection roller on the bottom block

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schmierstoffe Unterflasche 3.jpg

Lubrication on-site/ex works with “Klüber Staburags NBU 12 Alltemp”, ABUS item number 14980.

Lubricate the deflection roller during:

Installation of the bottom block

For details, see “Installing the bottom block”.

Load hook on the bottom block

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schmierstoffe Lasthaken 3.jpg

On-site lubrication with “High-Lub LT1 EP”, ABUS item number 318490.

Lubrication ex works with “High-Lub LT1 EP”, ABUS item number 317880.

Lubricate the load hook during:

Installation of the bottom block

For details, see “Installing the bottom block”.

Only for single-fall chain hoists

Hook assembly

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schmierstoffe Lager Hakengeschirr 3.jpg

On-site lubrication with “High-Lub LT1 EP”, ABUS item number 318490.

Lubrication ex works with “High-Lub LT1 EP”, ABUS item number 317880.

Lubricate the hook assembly during:

Exchanging the chain and chain sprocket

For details, see “Installing the hook assembly”.

Overview of screw tightening torques

Motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben Motordeckel 3.jpg

Size	Type, size and length	Number	Tightening torque
GM2	Fillister-head screw M5x65	3x	4 Nm
GM2	Fillister-head screw M5x45	1x	4 Nm
GM4	Fillister-head screw M5x60	3x	4 Nm
GM4	Fillister-head screw M5x50	1x	4 Nm
GM6	Fillister-head screw M8x110	3x	15 Nm
GM6	Fillister-head screw M8x60	1x	15 Nm
GM8	Fillister-head screw M10x95	3x	20 Nm
GM8	Fillister-head screw M10x50	1x	20 Nm

Gear unit

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben Getriebe 3.jpg

Size	Type, size and length	Number	Tightening torque
GM2	Fillister-head screw M6x85	3x	7 Nm
GM4	Fillister-head screw M6x105	3x	7 Nm
GM6	Fillister-head screw M8x110	3x	18 Nm
GM8	Fillister-head screw M10x140	3x	25 Nm

Locking screw

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben Arretierschraube 3.jpg

Size	Type, size and length	Number	Tightening torque
GM2	Fillister-head screw M6x105	1x	7 Nm
GM4	Fillister-head screw M6x105	1x	7 Nm
GM6	Fillister-head screw M8x110	1x	10 Nm
GM8	Fillister-head screw M10x110	1x	10 Nm

Magnet body

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben Bremsschild 3.jpg

Size	Type, size and length	Number	Tightening torque
GM2	Hexagon head screw M4x45	3x	3 Nm
GM4	Hexagon head screw M5x55	3x	6 Nm
GM6	Hexagon head screw M6x65	3x	10 Nm
GM8	Hexagon head screw M6x65	3x	10 Nm

Brake bearing shield

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben Bremslagerschild 3.jpg

Size	Type, size and length	Number	Tightening torque
GM2	Fillister-head screw M5x20	3x	4 Nm
GM4	Fillister-head screw M5x20	4x	4 Nm
GM6	Fillister-head screw M8x25	4x	18 Nm
GM8	Fillister-head screw M10x30	4x	25 Nm

With the chain hoists GM2 and GM4, the fillister-head screw below on the left is also used to attach the tab washer for the bolt on the chain anchor point.

Only for twin-fall chain hoists

Bottom block

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben Unterflasche 3.jpg

Size	Type, size and length	Number	Tightening torque
GM2	Fillister-head screw with self-locking nut M6x30	2x	10 Nm
GM4	Fillister-head screw with self-locking nut M8x35	2x	25 Nm
GM6	Fillister-head screw with self-locking nut M10x45	2x	36 Nm
GM8	Fillister-head screw with self-locking nut M12x75	2x	49 Nm

Only for single-fall chain hoists

Hook assembly

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben Hakengeschirr 3.jpg

Size	Type, size and length	Number	Tightening torque
GM2	Fillister-head screw with self-locking nut M6x25	2x	10 Nm
GM4	Fillister-head screw with self-locking nut M6x25	2x	10 Nm
GM6	Fillister-head screw with self-locking nut M6x45	2x	12 Nm
GM8	Fillister-head screw with self-locking nut M8x50	2x	30 Nm

Only for GM6

Tab washer for bolt on chain anchor point

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Anziehmoment Schrauben GM6 Festpunktbolzen 3.jpg

Fillister-head screw M5x10
3 Nm
Only the chain hoist GM 6 has a separate fillister-head screw for the tab washer.
With the chain hoists GM2 and GM4, the fillister-head screw below on the left of the brake bearing shield is used to attach the tab washer.
With the chain hoist GM8, the chain anchor point is designed differently and requires no tab washer.

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

If calling outside the usual business hours, leave a message on the answering machine.

ABUS Service will return your call promptly.

If necessary, send a description of the problem by fax or e-mail:

Fax: +49-2261-37-265
E-mail: service@abus-kransysteme.de

Only outside Germany

Call the local ABUS branch or crane service partner.

Your local ABUS branch or crane service partner will provide details of contact data, contacts and availability.

Eliminating errors on the chain hoist

If the chain hoist is not working or functions other than as expected, a malfunction of the chain hoist may be the cause.

Fault	Possible cause	Eliminating the fault
The chain hoist does not lift or lower; hoist motor does not hum when a button on the pendant control is pressed.	No mains voltage.	Check the power line. See “Connecting the chain hoist”.
	Power line not correct.	Check the rotary field and phases. See “Connecting the chain hoist”.
	Emergency stop button pressed.	Unlock the emergency stop button.
	Main contactor is defective.	Check the main contactor.
	With electronic control: No control voltage.	Check the fuse on the supply PCB.
	Fuse is defective.	Check the fuse.
	Bayonet couplings of the connection cable or control cable are not properly inserted.	Insert the bayonet couplings. See “Connecting the chain hoist”.
	Broken wire in the control cable.	Replace the control cable.
	Pendant control is defective.	Replace the pendant control.
	For hoist limit switch: Switching point is incorrectly set.	Reset the switching point.
The chain hoist does not lift or lower; hoist motor hums when a button on the pendant control is pressed.	Fuse is defective.	Check the fuse.
	Power line is defective (2-phase running).	Check the power line. See “Connecting the chain hoist”.
	The couplings of the hoist motor and brake are interchanged on the control.	Connect the hoist motor and brake correctly. See “Wiring diagrams”.
	With electronic control: control is defective.	Replace the control.
	With direct control: pendant control is defective.	Replace the control.
Hoist motor starts up sluggishly.	Brake does not release.	Check the brake.
Brake does not release.	Brake electronics are defective.	Measure the voltage on the brake. It must be approximately 90 V DC. If it is not, replace the electronics for the brake.
	Brake coil in the magnet body is defective.	Measure the electrical continuity. If the brake coil has no continuity, replace the magnet body.

Fault	Possible cause	Eliminating the fault
The load sags when stationary.	Brake lining on the brake rotor is worn.	See “Replacing the brake rotor ”.
The load does not immediately come to a stop.	The air gap is too large.	Readjust the brake. See “Setting the air gap on the brake”.
The load sags during lifting or lowering.	The friction clutch is set too weak.	Adjust the friction clutch. See “Adjusting the friction clutch”.
The chain becomes worn very quickly.	The chain is not sufficiently lubricated.	Lubricate the chain. See “Lubricating the chain”.
Loud clacking noises.	Chain and chain sprocket are worn.	Replace the chain and chain sprocket. See “Exchanging the chain and chain sprocket”.
Loud clacking noises.	The chain is not sufficiently lubricated.	Lubricate the chain. Lubricate the chain. See “Lubricating the chain”.

Wiring diagrams

Special wiring diagrams can be obtained from ABUS Service. See “ABUS Service”.

Only for GM2, GM4 and GM6 with direct control

Control in the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltpläne - Direktsteuerung ohne Katzfahren 3.jpg — Pin plug for hoist motor

The electricity for the hoist motor is controlled directly through the buttons of the pendant control and is switched from there.

Only for GM2, GM4 and GM6 with electric hoist trolley

Control in the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltpläne - Direktsteuerung mit Katzfahren 3.jpg — Pin plug for hoist motorPin plug for trolley travel motor

The electricity for the hoist motor and the trolley travel motor is controlled directly through the buttons of the pendant control and is switched from there.

Only for GM2 and GM4 with electronic control

Control in the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltpläne - Elektroniksteuerung klein ohne Katzfahren 3.jpg — Supply PCBPin plug for brake

The electricity for the hoist motor is controlled through a semiconductor relay which is switched from a 48 V control voltage.
The control voltage can be switched using a pendant control or radio remote control.
The control consists of a supply PCB and a semiconductor relay PCB attached above it.

Only for GM2 and GM4 with electronic control and electric hoist trolley

Control in the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltpläne - Elektroniksteuerung klein mit Katzfahren 3.jpg — Pin plug for star pointsSemiconductor relay PCBPin plug for brake

The electricity for the hoist motor is controlled through a semiconductor relay which is switched from a 48 V control voltage.
The control voltage can be switched using a pendant control or radio remote control.
The control consists of a supply PCB and two semiconductor relay PCBs attached above it. One of them controls the hoist motor, the other controls the trolley travel motor.
In the GM2, the installation of this electronic control is only possible through an additional housing.

Only for GM6 and GM8 with electronic control

Control in the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltpläne - Elektroniksteuerung groß ohne Katzfahren 3.jpg — Pin plug for star pointsPin plug for brake

The electricity for the hoist motor is controlled through a semiconductor relay which is switched from a 48 V control voltage.
The control voltage can be switched using a pendant control or radio remote control.
The control consists of a supply PCB on which there are also semiconductor relays.

Only for GM6 and GM8 with electronic control and electric hoist trolley

Control in the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltpläne - Elektroniksteuerung groß mit Katzfahren 3.jpg — Supply PCBPin plug for trolley travel motorSemiconductor relay PCB

The electricity for the hoist motor is controlled through a semiconductor relay which is switched from a 48 V control voltage.
The control voltage can be switched using a pendant control or radio remote control.
The control consists of a supply PCB on which there are also semiconductor relays for the control of the hoist motor and a semiconductor relay PCB attached above for the control of the trolley travel motor.

Only for external control

Control in the motor cover

U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltpläne - Externe Steuerung 3.jpg — Pin plug for hoist motor

The electricity for the hoist motor is controlled in an external control (e.g. inside a panel).
The circuit board of the external control conducts the electricity to the hoist motor and handles the control of the brake.

Only for ABULiner

The electricity of the hoist motor is controlled by a frequency converter in a variable frequency. This enables continuous control of the speed of the chain hoist. The frequency converter is mounted on the chain hoist in an additional housing. With additional frequency converters, the trolley and crane speeds can also be continuously controlled. Wiring diagrams for this can be obtained from ABUS Service. See “ABUS Service”.

Abbreviation	Designation
+HT	Pendant control
-S1	Emergency stop button
-S21	Lift button
-S22	Lower button
-S41	Trolley travel toward right button
-S42	Trolley travel toward left button
-S31	Teach-in hoist limit switch
+VFS-X2	Mobile control
+KA-M41	Trolley travel motor
-M21	Hoist motor
+HU	Chain hoist
-V21	Electronics for brake of hoist
-V41	Electronics for brake of hoist trolley
-A1	Supply PCB, direct control PCB or external control PCB
+HW	Power line
+KA-S51	Trolley travel limit switch
+KA-S51.1	Right limit stop
+KA-S51.4	Left limit stop
+KA-S51.2	Braking function, right
+KA-S51.3	Braking function, left
-A40	Semiconductor relay PCB, trolley travel motor
HGS	Hoist limit switch
-P21	Operating hours counter
-X0	Plug-in connection for connection cable
-X2	Plug-in connection for pendant control
-X41	Plug-in connection for trolley travel motor
-X21	Plug-in connection for hoist motor
-X22	Plug-in connection for star points of hoist motor
-X23	Plug-in connection for brake of hoist motor
-A31	Hoist limit switch PCB
+SKR	Crane panel
-A20	Semiconductor relay PCB
-X31.1	For electronic hoist limit switch: detach jumper
-K1	Main contactor
-T1	Control transformer
- F1-3	Fuses

Direct control – wiring diagram

$U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltplan Direkt Stromlaufplan 3.jpg$

Direct control – wiring diagram

$U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltplan Direkt Bauschaltplan 3.jpg$

Electronic control – wiring diagram

$U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltplan Halbleiter Erster Bauschaltplan 3.png$

Electronic control – wiring diagram

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External control – wiring diagram

$U:\Allgemein\Produkthandbücher\Produkthandbücher Fotos\Kettenzug\Schaltplan Extern Bauschaltplan 3.tif$

Contactor control - wiring diagram

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Contactor control - wiring diagram

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