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Abus ABUCompact GMC Product Manual

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PRODUCT MANUAL
ABUS chain hoist
ABUCompact GMC
AT A GLANCE:
Page 24
AN 120282EN001
2023-08-24
Original Operating Instructions
(with test log book)

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  • Page 1: Table Of Contents

    PRODUCT MANUAL (with test log book) ABUS chain hoist ABUCompact GMC AT A GLANCE: Installing the chain hoist: Page 11 Inspecting the chain: Page 17 Exchanging the chain and chain sprocket: Page 24 Lubricating the chain: Page 32 Eliminating errors on the chain hoist: Page 49...

  • Page 2: Type Plate

    ABUCOMPACT: VARIOUS VERSIONS AND OPTIONS This product manual applies to GMC chain hoists in various versions and options. The work steps described and the technical data will vary according to the version or options of the chain hoist. The areas of this product manual which do not apply to all chain hoists, but are applicable only under certain conditions, are enclosed in a dashed box.
  • Page 3 NUMBER OF FALLS (VERSION) Single-fall Twin-fall SAFETY LOAD HOOK (OPTIONAL) SUSPENSION HOOK (OPTIONAL)
  • Page 4 C o n t e n t s CONTENTS GENERAL INFORMATION ....5 MAINTENANCE ........23 A t t h e s t a r t ........5 I n s t r u c t i o n s r e g a r d i n g s a f e t y w h e n p e r f o r m i n g m a i n t e n a n c e w o r k .

  • Page 5: General Information

    G e n e r a l i n f o r m a t i o n A t t h e s t a r t GENERAL INFORMATION THIS SECTION APPLIES TO ANYONE WHO LIFTS LOADS USING THE CRANE, PERFORMS WORK ON THE CRANE, OR WORKS NEARBY.

  • Page 6: Warranty

    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...

  • Page 7: The Chain Hoist

    G e n e r a l i n f o r m a t i o n Th e c h a i n h o i s t PERFORMANCE FEATURES THE CHAIN HOIST The chain hoist: DESCRIPTION OF THE DEVICE ─...

  • Page 8: Technical Data

    G e n e r a l i n f o r m a t i o n T r a n s p o r t i n g t h e c h a i n h o i s t TECHNICAL DATA TRANSPORTING THE CHAIN HOIST Electrical connection...

  • Page 9: Loading And Unloading The Chain Hoist

    G e n e r a l i n f o r m a t i o n L o a d i n g a n d u n l o a d i n g t h e c h a i n h o i s t LOADING AND UNLOADING THE DISPOSING OF THE CHAIN HOIST CHAIN HOIST...

  • Page 10: Installing And Connecting

    ─ Persons receiving regular training from ABUS. ABUS assumes no liability for damage due to incorrectly performed commissioning work done by Single-fall 10.7 kg 0.34 kg unqualified personnel.

  • Page 11: Installing The Chain Hoist

    I n s t a l l i n g a n d c o n n e c t i n g I n s t a l l a t i o n o v e r v i e w ONLY WITH SUSPENSION HOOK INSTALLATION OVERVIEW If required, the chain hoist can be installed with an...

  • Page 12: C O N N E C T I N G T H E C H A I N H O I S

    I n s t a l l i n g a n d c o n n e c t i n g C o n n e c t i n g t h e c h a i n h o i s t CONNECTING THE CHAIN HOIST INSTALLING THE CHAIN BOX DANGER FROM ELECTRIC...

  • Page 13: L U B R I C A T I N G T H E C H A I

    I n s t a l l i n g a n d c o n n e c t i n g L u b r i c a t i n g t h e c h a i n LUBRICATING THE CHAIN If the chain is dry and no lubricant can be seen on its surface, it must be lubricated.

  • Page 14: A T T H E S T A R

    ─ Persons with comprehensive knowledge from The end user is responsible for checking the specialist training in engineering and in the requirements and determining the test intervals. ABUS electrical systems of cranes. will gladly assist you if questions arise. ─...

  • Page 15: S C O P E O F T H E T E S

    I n s p e c t i o n S c o p e o f t h e t e s t Document the test: SCOPE OF THE TEST If the chain hoist is part of a crane installation: The qualified person inspecting the chain hoist is Document the results of the test in the test log responsible for the type and scope of the test.

  • Page 16: C H E C K I N G T H E L O A D H O O

    I n s p e c t i o n C h e c k i n g t h e l o a d h o o k CHECKING THE SUSPENSION HOOK CHECKING THE LOAD HOOK OR SAFETY LOAD HOOK ONLY WITH A SUSPENSION HOOK OR SAFETY LOAD HOOK This step only applies if a suspension hook is used...

  • Page 17: Inspecting The Chain

    I n s p e c t i o n I n s p e c t i n g t h e c h a i n CHECKING THE WEAR INSPECTING THE CHAIN To check the wear, the length of eleven chain links is INSPECTING THE CONDITION measured.
  • Page 18 I n s p e c t i o n I n s p e c t i n g t h e c h a i n Measure in steps: Size Standard designation of HEP – 3.7 x 12 DATC chain Thickness in the joint, 3.7 mm...

  • Page 19: Te S T L O G B O O

    I n s p e c t i o n Te s t l o g b o o k TEST LOG BOOK TEST BEFORE INITIAL OPERATION OR TEST FOLLOWING MAJOR MODIFICATIONS The observance of structural and building requirements in accordance with EU guideline 2006/42/EC is confirmed by the enclosed Declaration of Conformity or Declaration of Incorporation.

  • Page 20: Regular Inspections

    I n s p e c t i o n Te s t l o g b o o k REGULAR INSPECTIONS Inspected on Remarks Remaining service life of chain hoist In hours Determination (see attachment) The regular inspection has been performed. ...
  • Page 21 I n s p e c t i o n Te s t l o g b o o k LOAD HOOK AND SUSPENSION BRACKET Hook designation DIN 15401 (see “Checking the load hook”, page 16) Type Single load hook Maximum load capacity see label on front Classification according to FEM...
  • Page 22 I n s p e c t i o n Te s t l o g b o o k CHAIN For data on the chain, see “Inspecting the chain”, page 17. Use a separate sheet for each chain! Inspected on Measurement over Measurement Measurement...

  • Page 23: Maintenance

    ─ Persons receiving regular training from ABUS. the chain hoist. 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.

  • Page 24: Exchanging The Chain And Chain Sprocket

    M a i n t e n a n c e E xc h a n g i n g t h e c h a i n a n d c h a i n s p r o c k e t REMOVING THE CHAIN BOX EXCHANGING THE CHAIN AND CHAIN SPROCKET...
  • Page 25 Ma i n t e n a n c e E xc h a n g i n g t h e c h a i n a n d c h a i n s p r o c k e t REMOVING THE MOTOR COVER Chain sprocket Motor cover...

  • Page 26: D I S A S S E M B L I N G T H E B O T T O M B L O C

    M a i n t e n a n c e E xc h a n g i n g t h e c h a i n a n d c h a i n s p r o c k e t ONLY FOR SINGLE-FALL CHAIN ONLY FOR TWIN-FALL CHAIN HOISTS...
  • Page 27 Ma i n t e n a n c e E xc h a n g i n g t h e c h a i n a n d c h a i n s p r o c k e t INSTALLING THE NEW CHAIN GUIDE Lower half of chain guide...
  • Page 28 M a i n t e n a n c e E xc h a n g i n g t h e c h a i n a n d c h a i n s p r o c k e t ONLY FOR SINGLE-FALL CHAIN HOISTS Deep groove ball...

  • Page 29: I N S T A L L I N G T H E B O T T O M B L O C

    Ma i n t e n a n c e E xc h a n g i n g t h e c h a i n a n d c h a i n s p r o c k e t ONLY FOR TWIN-FALL CHAIN HOISTS Cylindrical pin...
  • Page 30 Place the chain in the chain box. Check whether the chain completely fits in the chain box. If the chain box is too small, contact ABUS Service. See page 48. Motor connection cable Motor cover Plug the connector of the motor connection cable into the circuit board in the motor cover.
  • Page 31 Ma i n t e n a n c e E xc h a n g i n g t h e c h a i n a n d c h a i n s p r o c k e t INSTALLING THE CHAIN BOX CONNECTING THE CHAIN HOIST Connection cable...

  • Page 32: Lubricating The Chain

    M a i n t e n a n c e L u b r i c a t i n g t h e c h a i n DISASSEMBLING THE BOTTOM LUBRICATING THE CHAIN BLOCK If the chain is dry and no lubricant can be seen on its surface, it must be lubricated.
  • Page 33 Ma i n t e n a n c e I n s t a l l i n g t h e b o t t o m b l o c k INSTALLING THE BOTTOM BLOCK ASSEMBLING THE BOTTOM BLOCK ONLY FOR TWIN-FALL CHAIN HOISTS ASSEMBLING THE BOTTOM BLOCK...
  • Page 34 M a i n t e n a n c e E xc h a n g i n g t h e c a r b o n b r u s h e s REMOVING THE CHAIN BOX EXCHANGING THE CARBON BRUSHES If the carbon brushes have reached their wear limit,...
  • Page 35 Ma i n t e n a n c e E xc h a n g i n g t h e c a r b o n b r u s h e s REMOVING THE MOTOR COVER DISASSEMBLING THE MOTOR Motor cover Housing Fillister-head screw...
  • Page 36 M a i n t e n a n c e E xc h a n g i n g t h e c a r b o n b r u s h e s PULLING OUT THE CARBON BRUSHES Carbon brush Carbon brush...

  • Page 37: Installing The Motor

    Ma i n t e n a n c e E xc h a n g i n g t h e c a r b o n b r u s h e s INSTALLING THE MOTOR Motor Carbon brush Brown strand Motor Motor connection cable...
  • Page 38 M a i n t e n a n c e E xc h a n g i n g t h e c a r b o n b r u s h e s CLOSING THE CHAIN HOIST Motor Housing Seal...
  • Page 39 Ma i n t e n a n c e E xc h a n g i n g t h e c a r b o n b r u s h e s INSTALLING THE CHAIN BOX CONNECTING THE CHAIN HOIST Connection cable Socket Chain box...

  • Page 40: R E P L A C I N G T H E M O T O

    M a i n t e n a n c e R e p l a c i n g t h e m o t o r REMOVING THE CHAIN BOX REPLACING THE MOTOR DETACHING THE CONNECTION CABLE AND CONTROL CABLE Connection cable Socket Chain box...
  • Page 41 Ma i n t e n a n c e R e p l a c i n g t h e m o t o r REMOVING THE MOTOR COVER DISASSEMBLING THE MOTOR Motor cover Housing Fillister-head screw Gearbox cover Fillister-head screw Turn housing over.
  • Page 42 M a i n t e n a n c e R e p l a c i n g t h e m o t o r INSTALLING THE NEW MOTOR Motor Motor ● The motor shaft sits precisely in the plastic pinion of the gear unit.
  • Page 43 Ma i n t e n a n c e R e p l a c i n g t h e m o t o r CLOSING THE CHAIN HOIST INSTALLING THE CHAIN BOX Chain box Bolt Turn the chain box so that it appears as shown Housing Seal in the figure.

  • Page 44: A C C E S S O R I E

    M a i n t e n a n c e A c c e s s o r i e s CONNECTING THE CHAIN HOIST ACCESSORIES Connection cable Socket SHORTENING THE CONTROL CABLE The sheath of the control cable serves to protect the wiring while also acting as a strain reliever.

  • Page 45: L U B R I C A N T

    CHAIN On-site lubrication with “High-Lub LT1 EP”, ABUS item number 318490. Lubrication ex works with “High-Lub LT1 EP”, ABUS On-site lubrication with “Chainlife S”, ABUS item item number 317880. number 2717 Lubrication ex works with “Chainlife S”, ABUS item Lubricate the chain sprocket during: number 2718.

  • Page 46: Hook Assembly

    HOISTS HOISTS DEFLECTION ROLLER ON THE HOOK ASSEMBLY BOTTOM BLOCK On-site lubrication with “High-Lub LT1 EP”, ABUS item number 318490. Lubrication ex works with “High-Lub LT1 EP”, ABUS item number 317880. Lubrication on-site/ex works with “Klüber Staburags NBU 12 Alltemp”, ABUS item number 14980.

  • Page 47: O V E R V I E W O F S C R E W T I G H T E N I N G T O R Q U E

    Ma i n t e n a n c e O v e r v i e w o f s c r e w t i g h t e n i n g t o r q u e s ONLY FOR TWIN-FALL CHAIN OVERVIEW OF SCREW TIGHTENING HOISTS...

  • Page 48: A B U S S E R Vi C

    ─ 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.

  • Page 49: Eliminating Errors On The Chain Hoist

    Ma i n t e n a n c e E l i m i n a t i n g e r r o r s o n t h e c h a i n h o i s t 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.

  • Page 50: W Ir I N G D I A G R A

    M a i n t e n a n c e W i r i n g d i a g r a m WIRING DIAGRAM Abbreviation Terminal Designation Operating voltage 1 Lifting 2 Lowering 3 Acceleration 4 Black Brown Blue Protective conductor...
  • Page 51 EU directive versions applicable at the time of issuance. If the chain hoist is part of an ABUS crane installation, the Declaration of Conformity in the test log book of the crane is valid. The declaration here is then invalid.
  • Page 52 ABUS Kransysteme GmbH Sonnenweg 1 51647 Gummersbach Germany Tel. 0049 – 2261 – 37-0 Fax. 0049 – 2261 – 37-247 info@abus-kransysteme.de Distribution or reproduction of this document, or the utilisation and disclosure of its contents without express consent is prohibited. Violations will result in liability for damages.

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