Table of Contents
Advertisement
Quick Links
PRODUCT MANUAL
ABUS Trolley
Push trolley HF
Electric trolley EF
At a glance:
Mounting the trolley: page 12
Connecting the trolley: page 23
Inspecting the brake on the drive: page 32
Setting the air gap on the brake: page 38
Replacing the brake rotor and anchor plate:
page 42
AN 120133EN011
2024-10-02
Original Operating Instructions
Advertisement
Table of Contents
Related Manuals for Abus EF
Summarization of Contents
TROLLEY TYPES, SIZES, VERSIONS AND OPTIONS
TROLLEY TYPE OVERVIEW
Briefly describes Push trolley HF and Electric trolley EF models.
TROLLEY SIZE DETERMINATION
Explains how to identify trolley size based on load capacity and flange width.
DRIVE AND COMPONENT OVERVIEW
DRIVE SPECIFICATIONS AND VERSIONS
Details drive sizes, versions (helical vs. planetary), and dimensions.
TRAVEL LIMIT SWITCH OPTION
Describes the function and mounting of the travel limit switch.
POWER SUPPLY OPTIONS
Discusses power supply methods like energy chains or festoon cables.
GENERAL INFORMATION AND SAFETY
MANUAL USAGE AND SYMBOLS
Guide on navigating the manual and understanding hazard symbols.
SAFETY WARNINGS AND HAZARDS
Details critical safety notices for personnel and equipment.
PROPER USE GUIDELINES
Specifies intended applications and operational limits of the trolleys.
REGULATIONS, WARRANTY, AND TROLLEY DESCRIPTION
REGULATIONS AND WARRANTY TERMS
Outlines compliance standards and ABUS warranty conditions.
PUSH TROLLEY HF COMPONENT DESCRIPTION
Identifies and labels the components of the push trolley HF.
ELECTRIC TROLLEY EF AND PERFORMANCE FEATURES
ELECTRIC TROLLEY EF COMPONENT DESCRIPTION
Identifies and labels the components of the electric trolley EF.
TROLLEY PERFORMANCE FEATURES
Details capabilities like mounting on I-beams and curve-travelling.
TECHNICAL DATA
DIMENSIONS, WEIGHTS, AND LOAD CAPACITY
Provides detailed specifications including flange width, weight, and load limits.
ELECTRICAL AND ENVIRONMENTAL DATA
Covers voltage, power, operating temperatures, and noise emissions.
DISPOSAL OF THE TROLLEY
ENVIRONMENTALLY SOUND DISPOSAL PROCEDURES
Instructions for dismantling and disposing of trolley parts according to local regulations.
INSTALLATION REQUIREMENTS
I-BEAM AND LOAD CAPACITY CHECKS
Prerequisites for trolley mounting including I-beam compatibility and load capacity assessment.
INSTALLATION OVERVIEW AND FLANGE MEASUREMENT
INSTALLATION SEQUENCE
Outlines the step-by-step sequence for installing the trolley and power carrier.
MEASURING I-BEAM FLANGE WIDTH
Procedure for accurately measuring the I-beam flange width for trolley compatibility.
PRE-ASSEMBLING THE TROLLEY
ADAPTING TRAVELLING GEAR BOLT
Steps to adapt the travelling gear bolt using distance rings for track gauge.
MOUNTING SIDE PANELS AND BOLTING TOGETHER
SIDE PANEL MOUNTING FOR HF/EF TROLLEYS
Specific instructions for mounting side panels on HF and EF trolleys.
BOLTING TROLLEY COMPONENTS TOGETHER
Assembling trolley parts using distance rings, washers, and self-locking nuts.
MOUNTING TROLLEY ON I-BEAM AND COUNTERWEIGHT
MOUNTING COUNTERWEIGHT
Installing a counterweight on specific electric trolleys for load balance.
MOUNTING THE TROLLEY ON THE I-BEAM
Procedures for attaching the trolley to an I-beam, including lift-off prevention.
TRACK GAUGE TOLERANCE AND DRIVE INSTALLATION
TRACK GAUGE TOLERANCE CHECK
Safety check for track gauge tolerance with critical warnings.
INSTALLING THE DRIVE (ELECTRIC TROLLEY EF)
Steps for installing the drive unit on the electric trolley EF.
POWER CARRIER AND CHAIN HOIST INSTALLATION
LUBRICATING THE GEAR RIM
Instructions for lubricating the gear rims on the trolley wheels.
ATTACHING THE CHAIN HOIST
Procedure for suspending the chain hoist onto the trolley's suspension bracket.
MOUNTING VERTICAL TUBE POWER CARRIER
Procedure for mounting a vertical square tube as a power carrier.
POWER CARRIER MOUNTING VARIATIONS
HORIZONTAL TUBE MOUNTING
Optional mounting of an additional horizontal square tube for the power carrier.
VERTICAL LEFT MOUNTING FOR POWER CARRIER
Alternative procedure for mounting the power carrier vertically on the left side panel.
ENERGY CHAIN POWER SUPPLY CONFIGURATION
Specific mounting considerations for energy chains as power supply.
HORIZONTAL SQUARE TUBE POWER CARRIER MOUNTING
MOUNTING HORIZONTAL TUBE AS POWER CARRIER
Procedure for mounting a horizontal square tube as a power carrier.
CONNECTING POWER CARRIER TO POWER SUPPLY
FESTOON CABLE SYSTEM CONNECTION
Connecting the power carrier for festoon cable systems.
ENERGY CHAIN CONNECTION
Connecting the power carrier for energy chains.
TRAVEL LIMIT SWITCH INSTALLATION
DETERMINING SWITCH POSITION
Procedure for determining the correct position for the travel limit switch.
INSTALLING CROSS-TYPE LIMIT SWITCH
Steps for installing the cross-type limit switch with torque warnings.
BUFFER RODS AND LIMIT SWITCH CONNECTION
BUFFER ROD MOUNTING AND SHORTENING
Mounting and adjusting buffer rod lengths based on trolley and hoist combination.
CONNECTING CROSS-TYPE LIMIT SWITCH CABLE
Cable connection procedures for the cross-type limit switch.
BUFFER ROD MOUNT INSTALLATION AND SHORTENING
INSTALLING BUFFER ROD MOUNTS
Procedures for installing mounting plates for buffer rods on trolleys.
SHORTENING BUFFER ROD
Steps for shortening the buffer rod evenly on both sides.
DRIVE CONNECTION TO ABUS CRANE AND MAINS SUPPLY
INSTALLING THE BUFFER ROD
Procedure for installing the buffer rod.
CONNECTING DRIVE TO ABUS CRANE
Procedure for connecting the drive to ABUS crane installations.
CHECKING THE MAINS SUPPLY
Verifying mains voltage and frequency compatibility for the drive.
DRIVE CONNECTION METHODS
CONTACTOR CONTROL DRIVE CONNECTION
Connecting the drive with contactor control using multipoint connectors.
FREQUENCY CONVERTER DRIVE CONNECTION
Connecting the drive with frequency converter using plug-in connections.
NON-ABUS CRANE INSTALLATION AND TESTING
ELECTRIC TROLLEY EF FUNCTIONAL TESTING
Performing operational tests on the electric trolley EF.
CONNECTING DRIVE TO NON-ABUS CRANES
Procedures for connecting the drive to third-party crane installations.
MAINS SUPPLY CHECK FOR NON-ABUS INSTALLATIONS
Verifying power compatibility for non-ABUS setups.
DRIVE CONNECTION WIRING FOR NON-ABUS INSTALLATIONS
WIRING FOR LOW AND HIGH SPEED OPERATION
Wiring configurations for dual-speed drive operation.
WIRING FOR LOW SPEED ONLY OPERATION
Wiring configuration for single low-speed drive operation.
WIRING FOR HIGH SPEED ONLY OPERATION
Wiring configuration for single high-speed drive operation.
WIRING FOR FREQUENCY CONVERTER CONTROL
Wiring configurations for frequency converter motor control.
CONNECTION CABLE LAYING AND TORQUES
LAYING CONNECTION CABLE FOR THE DRIVE
Routing and securing the drive's connection cable with cable ties.
OVERVIEW OF SCREW TIGHTENING TORQUES
General table of screw tightening specifications for various components.
SCREW TIGHTENING TORQUES
TRAVELLING GEAR BOLT NUT TORQUES
Specific torques for self-locking nuts on travelling gear bolts.
SQUARE TUBE MOUNTING TORQUES
Torques for mounting vertical and horizontal square tubes.
CROSS-TYPE LIMIT SWITCH TORQUES
TORQUES FOR CROSS-TYPE LIMIT SWITCH
Tightening torques required for the cross-type limit switch.
INSPECTION PROCEDURES AND REQUIREMENTS
TEST INTERVALS
Guidelines for regular inspection intervals and frequency.
QUALIFICATIONS FOR INSPECTORS
Requirements for qualified personnel conducting inspections.
TROLLEY INSPECTION SCOPE
CHECKING TRAVELLING GEAR BOLT
Procedure for inspecting the travelling gear bolt diameter.
CHECKING WHEEL FLANGE AND RAIL CLEARANCE
Measuring clearance between wheel flange and rail for proper operation.
WHEEL FLANGE CLEARANCE AND HELICAL DRIVE BRAKE INSPECTION
CHECKING WHEEL FLANGE TO RAIL CLEARANCE
Measuring clearance and method for readjustment using distance rings.
INSPECTING BRAKE ON HELICAL GEAR DRIVE
Checking air gap and brake lining thickness on the helical gear drive.
HELICAL DRIVE BRAKE AIR GAP INSPECTION
TAKING OFF FAN COVER
Procedure for removing the fan cover to access the brake.
CHECKING BRAKE AIR GAP
Measuring the air gap between magnet body and anchor plate.
PLANETARY DRIVE BRAKE INSPECTION
MEASURING BRAKE LINING THICKNESS
Procedure to measure brake lining thickness with a caliper.
CLOSING MOTOR HOUSING
Reassembling the motor housing after inspection.
INSPECTING BRAKE ON PLANETARY GEAR DRIVE
Checking reference gap and brake lining thickness for planetary gear.
PLANETARY DRIVE BRAKE INSPECTION DETAILS
FAN COVER REMOVAL AND LINING MEASUREMENT
Procedure for fan cover removal and brake lining thickness measurement.
REFERENCE GAP MEASUREMENT AND O-RING CHECK
Measuring reference gap and checking O-ring integrity.
CLOSING THE FAN COVER
REATTACHING THE FAN COVER
Procedure for attaching the fan cover back onto the motor.
MAINTENANCE SAFETY INSTRUCTIONS
GENERAL MAINTENANCE SAFETY
General safety precautions to be observed during maintenance work.
DRIVE-SPECIFIC MAINTENANCE SAFETY
Safety notes specific to working on the drive, including fan cover precautions.
SETTING WHEEL CLEARANCE AND ADJUSTING HELICAL DRIVE BRAKE AIR GAP
SETTING WHEEL FLANGE AND RAIL CLEARANCE
Procedure to adjust clearance by removing distance rings from the travelling gear bolt.
ADJUSTING AIR GAP ON HELICAL GEAR DRIVE BRAKE
Steps to readjust the brake air gap on the helical gear drive.
SETTING THE BRAKE AIR GAP (HELICAL DRIVE)
TAKING OFF FAN COVER
Procedure for removing the fan cover to access the brake.
SETTING AIR GAP (HELICAL DRIVE)
Detailed steps for setting the air gap using hexagon head screws and feeler gauge.
ADJUSTING PLANETARY DRIVE BRAKE AIR GAP
CLOSING MOTOR HOUSING
Reassembling the motor housing after brake adjustment.
ADJUSTING AIR GAP ON PLANETARY GEAR DRIVE BRAKE
Steps for adjusting the reference gap on the planetary gear drive.
SETTING THE BRAKE AIR GAP (PLANETARY DRIVE)
TAKING OFF FAN COVER
Procedure for removing the fan cover.
SETTING AIR GAP (PLANETARY DRIVE)
Detailed steps for setting the air gap using the self-locking nut.
CLOSING FAN COVER
Procedure for reattaching the fan cover.
REPLACING BRAKE ROTOR AND ANCHOR PLATE (HELICAL DRIVE)
TAKING OFF FAN COVER
Procedure for removing the fan cover.
REMOVING FAN BLADE (SIZE 140)
Steps for removing the fan blade on size 140 drives.
DISASSEMBLING MAGNET BODY
Steps for disassembling the magnet body from the drive.
REPLACING BRAKE ROTOR COMPONENTS
REMOVING AND FITTING FRICTION DISC
Procedures for removing and fitting the friction disc.
REMOVING AND FITTING THE HUB
Procedures for removing and fitting the drive hub.
MOUNTING THE BRAKE ROTOR
Steps for mounting the new brake rotor onto the hub.
REPLACING FAN BLADE AND ANCHOR PLATE (PLANETARY DRIVE)
FITTING FAN BLADE (SIZE 140)
Steps for fitting the fan blade onto the motor shaft for size 140.
TAKING OFF FAN COVER
Procedure for removing the fan cover.
REMOVING FAN BLADE WITH BRAKE LINING
Steps for removing the fan blade with brake lining assembly.
REPLACING ANCHOR PLATE AND INTERNAL COMPONENTS
REMOVING ANCHOR PLATE
Procedure for removing the anchor plate from the drive.
REPLACING O-RING, SPRINGS, AND FEATHER KEY
Replacing internal drive components like O-ring, springs, and feather key.
SETTING THE BRAKE AIR GAP (PLANETARY DRIVE)
SETTING AIR GAP (PLANETARY DRIVE)
Detailed steps for setting the air gap using the self-locking nut.
CLOSING THE FAN COVER
Procedure for reattaching the fan cover.
REPLACING AND WIRING CROSS-TYPE LIMIT SWITCH
REPLACING CROSS-TYPE LIMIT SWITCH
Procedure for replacing the cross-type limit switch.
WIRING DIAGRAM FOR LIMIT SWITCH
Schematic diagram for wiring the cross-type limit switch.
ABUS SERVICE AND LUBRICATION GUIDELINES
ABUS SERVICE CONTACT INFORMATION
How to contact ABUS service for support and inquiries.
LUBRICATING GEAR RIMS
Specific instructions for lubricating the gear rims on the trolley wheels.
GEAR UNIT LUBRICATION AND TORQUE OVERVIEW
GEAR UNIT LUBRICATION SPECIFICATIONS
Lubricant details for helical and planetary gear units.
TRAVELLING GEAR BOLT NUT TORQUES
Specific torques for self-locking nuts on travelling gear bolts.
BRAKE AND FRICTION DISC TORQUES
BRAKE ASSEMBLY TORQUES
Tightening torques for brake components.
FRICTION DISC TORQUES
Tightening torques for the friction disc.
TROUBLESHOOTING GUIDE FOR TROLLEY FAULTS
TROUBLESHOOTING RUNNING ISSUES
Diagnosing and fixing issues where the trolley does not run or switch on.
TROUBLESHOOTING SLUGGISH OPERATION AND BRAKE ISSUES
Diagnosing sluggish movement and brake disengagement problems.
CONTINUED TROUBLESHOOTING AND SMOOTH RUNNING ISSUES
TROUBLESHOOTING ONE-WAY OPERATION AND CONTACTORS
Fixing issues with single-direction running and faulty contactors.
TROUBLESHOOTING SMOOTH RUNNING AND BEARINGS
Addressing issues with smooth operation and wheel bearing problems.
DECLARATION OF INCORPORATION
PRODUCT COMPLIANCE AND TECHNICAL DOCUMENTATION
Statement on EU directive compliance and availability of technical documentation.
Need help?
Do you have a question about the EF and is the answer not in the manual?
Questions and answers