01 - Operating Instructions

Documentation
FINAL DRAWING
Shipyard: Daewoo Mangalia Heavy

Industries (Romania)
Designation: Engine Room Crane
Type: DMHI 4073
Hull No.: 07 04 1232
Serial No.: 12,5t
Safe Working Load: English
Language of Documentation: Germanischer Lloyd
Test/Examination Certificate
Classification: FUCHS Fördertechnik AG
Am Knick 18
D-22113 Oststeinbek
Supplier: +49 (0)40 7100 100
+49 (0)40 7100 1099
info@fuchs-ag.de
Edition: 1 Date: Okt-08
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FUCHS Fördertechnik AG Am Knick 18 22113 Oststeinbek Tel.: +49 40 7100100 Fax: +49 40 71001099
TABLE OF CONTENTS
Table of Contents ..........................................................................................................................2
Scope of Supply ............................................................................................................................4
Paint System: ................................................................................................................................4
Technical Specifications...............................................................................................................5
Description of the System ............................................................................................................6
Crane Conditions: .........................................................................................................................7
Tolerances of Runway ..................................................................................................................8
General Assembly Drawing ..........................................................................................................9
Drawing of Carriage Details........................................................................................................10
Sectional Drawing .......................................................................................................................11
Runway by Yard – Dimensions and Measures ..........................................................................12
Lifting Eye Capacity 4,0t .............................................................................................................13
Hook Details for Size 4................................................................................................................14
Limit Switch Crane Travelling ....................................................................................................15
Junction Box K9065 ....................................................................................................................16
Main Switch TER-Switch 3P32A-G Spez. ..................................................................................17
Drawing Hand Control Pendant..................................................................................................18
Safety Instructions ......................................................................................................................19
General ......................................................................................................................................19
Safety.........................................................................................................................................20
General Guidance on Hazards ...................................................................................................23
General Instruction for Welding Work on the Crane / Trolley ..................................................27
Initiation of Engine Room Cranes and Monorail Trolleys.........................................................28
Testing of Cranes and Hoists with Test Load ...........................................................................28
Principle of Travelling .................................................................................................................29
Assembling Instruction for Welding Toothed Rack ..................................................................31
Please take care that toothed rack and pinion are always well greased! ....................................31
General Lubrication Oil Chart.....................................................................................................33
Initiation of Engine Room Cranes and Monorail Trolleys.........................................................34
Testing of Cranes and Hoists With Test Load...........................................................................35
Travelling Motor - Operating and Maintenance Instructions....................................................36
Installation..................................................................................................................................37
Connection of Motor...................................................................................................................37
Starting up..................................................................................................................................37
Maintenance ..............................................................................................................................37
Type of Lubricant .......................................................................................................................38
General Part List ........................................................................................................................42
Helical Shaft Mounting Gear Unit ...............................................................................................45
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Single-Disc Spring Pressure Brake - Operating Instructions...................................................47
Conditions of Use.......................................................................................................................48
Installation..................................................................................................................................48
Adjustment and Readjustment of Clearance ..............................................................................49
Replacing the Brake Disc ...........................................................................................................50
Energy Supply Program 230 and 240 Operating and maintenance instructions ....................51
Energy Supply Assembly ...........................................................................................................53
Rail Mounting To Ceiling Construction Tools Required...............................................................53
Mounting Steps ..........................................................................................................................53
Mounting The Components In The C Rail ..................................................................................54
Special Steps During Assembly .................................................................................................55
Track Coupler ............................................................................................................................56
End Clamp .................................................................................................................................56
Special Precautions During Assembly........................................................................................56
Drawings for Energy Supply Program 230 and 240 ..................................................................58
Towing Trolley Dwg.No. 23 958 .................................................................................................58
Cable Clamp Dwg.No. 23 269 ....................................................................................................59
Track Support Bracket Dwg.No.23 222 ......................................................................................60
Track Coupler Dwg.No. 23 210 / End Stop Dwg.no. 23 219 .......................................................61
Flat Cable Trolley Dwg.No. 23 943.............................................................................................62
Chain Hoist B13 - Operating Instructions..................................................................................63
Safety advice .............................................................................................................................64
Technical overview.....................................................................................................................65
Sectional view ............................................................................................................................66
Assembly ...................................................................................................................................67
Electrical Connection .................................................................................................................76
Operation ...................................................................................................................................77
Maintenance ..............................................................................................................................77
Rectifier control of hoist motor....................................................................................................84
Emergency Procedure................................................................................................................85
Lubrication .................................................................................................................................86
Rectifier Control of Hoist Motor .................................................................................................87
Emergency Procedure................................................................................................................88
Lubrication .................................................................................................................................89
Appendix......................................................................................................................................90
A3 Drawings
Circuit diagrams
Certificates
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SCOPE OF SUPPLY
Pos. Menge Description

1 1 Engine room crane (normal headroom type) hanging execution
Type: ED-A 12,5-7.505 EKZ
according to DIN 15018 H2/B3 for ship-operation „under deck”
2 2 Toothed rack m5 30x30 Total length = 2x23m
3 1 Mounting piece m5 30x30 L=0,3m
4 1 C-Rack 25,0m
5 1 24m Current supply
28,0 m Flat cable 4x4²
16 pcs. Flat cable wagon
1 pc. Towing trolley
1 pc. End clamp
5 pcs. Track couplers
10 pcs Track support bracket
1 pc Junction box type: K9065
1 pc Main switch type: 3P32A-G
6 1 Remote control
7 1 Emergency hand control pendant
Spare parts
8 1 1 cardboard box
1 set fuses
3x20A / 3x16A / 3x10A / 3x1A
1 pc rectifier - one of each type

(hoist part no.: 200004000040); drive unit part no.: 19141000)
PAINT SYSTEM:
 Crane: steel surfaces sandblasted SA 2,5 one coat of anti-corrosion basic primer two
final coats of synthetic enamel
Munsell No. 7.5 BG 7/2
 Hoist: after sandblasting and primer one coat of synthetic enamel

Munsell No. 7.5 BG 7/2
 Motors: after sandblasting and primer one coat of synthetic enamel Munsell No. 7.5
BG 7/2
 Contactor after sandblasting and primer one coat of synthetic enamel Munsell No. 7.5
control box: BG 7/2
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TECHNICAL SPECIFICATIONS
Hull: ............................................ DSME 4212/13 , DMHI 4073/5
Type: .......................................... ED-A 125-7.505 EKZ
Capacity: .................................... 12500 kg

Testload: .................................... 15625 kg
Chain: ......................................... 16 x 45
Length of chain: .......................... approx. 37000mm
Hoisting speed: ........................... approx. 3,4 / 0,8 m/min

Span: .......................................... 7505 mm
Lifting height: .............................. 18000 mm
Control cable length: .................. 10000 mm
Speed of crane: ........................... 4 m/min
Speed of trolley: .......................... 4 m/min
Travelling distance (crane): ........ approx. 24,0m – 1,24m = 22,76m

Traversing distance (trolley): ...... approx. 24,0m – 1,24m = 22,76m
Runway (by yard): ...................... 400 x 150 x 12.5 / 25

Weight: ....................................... approx. 3200
Dimensions (LxWxH): ................. 8305 x 1240 x 1700
Protection mode of motor: .......... IP 54

Insulation class of motor: ............ F
Overload protection: ................... sliding clutch
Supply voltage: ........................... 440V / 60 Hz
Control voltage: .......................... 220V / 60 Hz
Power:......................................... 7,2kW + 4 x 0,86kW + 2x500W = 11,64kW
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Description of the System
Engine room crane (normal headroom type) hanging execution
Type: ED-A 12,5-6.710 EKZ according to DIN 15018 H2/B3 for ship-operation „under deck”
Crane- and hoist travelling with rack and pinion drive. Limit switches for all travelling and hoisting
directions.
All motors for hoisting, travelling and traversing with electro-magnetic brake.
Crane- and trolley travelling with built-on brake-motors, so it is possible to fix the crane and the
trolley at any position of the runway.
An additional clamping device is not necessary. Shipyard will provide an eye plate for the load
hook as second device for each crane.
Contactor control built on the crane. Normal operation by wireless remote control. Control cable
with hand control pendant (length of cable 10 m) as second device, if wireless remote control is out
of order.
Halogen flood light (2 x 500W) is operated by on/off switch of hand control pendant.
Hoist motor protection: Temperature monitoring by thermistor with releasing device.
24 m Current supply line along the crane runway incl. main switch and junction box.
Current supply line along the crane bridge by cable chain without cable duct.
Crane with working platform according to encl. sketch.

Warning plate of „SAFETY FIRST” to be fitted on crane body.
Flood light fitted to trolley.
Crane with turning device.
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CRANE CONDITIONS:
Crane bridge
Hoisting class: H2 Stress group: B3 according to DIN 15018
Capacity: 12.5t
Wheelloads without impact factor, per wheel / wheel pair
Rmax.: 70,0 kN Rmin.: 5,0 kN
Hs.: 7,0 kN
Travelling speed: 4,0 m / min.
2 x 0,86 kW, S1 %ED
Hoist
Mechanism group: 1Bm according to DIN 15020
Type: BF13 2/1
Main hoisting speed: 3,4 m/min 7,2 kW 60 %ED
Precision hoisting speed: 0,8 m/min 1,8 kW 40 %ED
Carriagetype: special
Travelling speed: 4,0 m/min 2x0,86 kW S1 %ED
Lifting height: 18 m
Electrical equipment
Supply voltage: 440 V 60 Hz
Control voltage: 220 V Safety class: IP 54
Control unit: connected to crane, connected to hoist, sliding
Crane rail is supplied by: FUCHS Fördertechnik / Customer

Hoisting class: Stress group: according to DIN 4132
Service conditions
Location: indoors, occasionally outdoors, permanently outdoors
Ambient temperature: -0° to + 45°C
Change of design reserved
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TOLERANCES OF RUNWAY
Tolerances of runway
max S= S+ds
min S= S-ds
ds = 2 mm
dh = 1,5 mm / m [span S]
dh 1,5 x S
dh = ----------
span S 1000
+ C
- C
2000
C = 10 mm
c
c = +- 1,5 mm
d rack = +- 5 mm
= =
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±2
500 portside
7505 starboard
open
runway by
*1 A1
yard:
400x150x12.5/25
A0
FUCHS Fördertechnik AG
A2
Am Knick 18
lifting eye
for 4,0t
645
1285
GENERAL ASSEMBLY DRAWING
22113 Oststeinbek
10000
400 Cr a ne b r i d ge
Ho i st i ng cl a ss : H2 S tr e s s g r o u p : B 3 ac c or di n g t o DI N 1 50 18
Nur Prinzipskizze für Kunden Ca pa ci t y : 1 2. 5 t
W h e e l lo a d s w i t h o u t i m p a c t f a c t o r , p e r w h e e l / w h e e l p a i r
Detailierte Darstellung Rma x. : 7 0, 0 k N R m i n .: 5, 0 kN
H s. : 7 ,0 k N
siehe Zeichnung 4ff T r a v e l l i n g s p e e d : 4 ,0 m / m i n.
2 x 0, 8 6 k W, S 1 %ED
Ho i s t
Mec h an i sm gr ou p: 1B m ac co r di n g t o D I N 1 50 20
T yp e: BF 1 3 2 /1
Mai n ho i st i n g sp ee d: 3 ,4 m / mi n 7, 2 kW 60 %E D
P r e c i s io n h o i s t i n g s p e e d : 0 ,8 m / mi n 1, 8 kW 40 %E D
C ar r i ag et y pe : sp ec i al
Tr av el l i n g s pe ed : 4 ,0 m / mi n 2x 0, 8 6 kW S1 %E D
L i f t i n g h e ig h t: 1 8 m
E l e c t r i c a l e qu i p me n t
Su pp l y v ol t ag e: 4 40 V 6 0 Hz
C on t ro l vo l t ag e: 2 20 V Sa f et y cl a ss : I P 5 4
C o n t r o l u n it : c o n n e c t e d t o c r a n e , c o n n e c t e d t o h o i s t , s li d i n g
Tel.: +49 40 7100100

Cr a ne r a i l i s su pp l i ed b y: FU CH S F ör de rt e ch ni k / C us t om er
To l e r a n c e s o f r u nw a y H o i s t in g c l a s s : St r es s g r ou p: ac c or di n g t o DI N 4 13 2
S e r v i c e c on d i t i o n s
*1 L o c a t i o n : in d o o r s , o c c a s i o n a l l y o u t d o o r s , p e r m a n e n t l y o u t d o o r s
Am bi en t t em pe ra t ur e: -0 ° t o + 4 5° C
ds = 2 mm
max S= S+ds
min S= S-ds
yards suppor t ar ms Ch a ng e o f d e si g n r es er v ed
f. example: angle steel Ge n e h m i g t /
a p pr o v e d :
dh = 1, 5 mm / m [ span S] 65x65x6T O rt / p l a c e Datum / Dat e Fi r m e n s t e m p e l / t r a d e s t a m p
1 ,5 x S Kunde /
dh
d h = - --- -- --- - DS ME 4 2 1 2 /1 3 , DMHI H 40 7 3 / 5
s p an S 1000 radio remo te control suspension distances as per Cu s t o m e r
F re i m a ß t o l e r a n z We r k s t o f f Au f t r a g - N r .
Hand control pendant

with control cable for
emergency operation only.
+ C
20 00 A.07.04.1231/32/33/34
- C
for stand ard o peration;
c
C = 1 0 mm mounting instructions 4 V e r v i e l f ä l t ig u n g u n d M it t e i l u n g a n D r i t t e i s t u n z u lä s s i g . F ü r d i e s e Z e i ch n u n g
c = +- 1 , 5 m m with storage box 3 2005 N a me b e h a l t e n w i r u n s a l l e R e c h t e g e mä ß d e m U r h e b e r s c h u t z v o r .
D atum
2 Be a r b . 14.01. Schulz Ma ß s t a b
1 12.12.07 Auftr agsnum mer geänder t. Li u G e p r . 14.01. Bock
Engi ne Room Crane 12 ,5t 1:5
Änderung F re i g . ED-A 125-7. 505 EKZ
Übersicht
d r ac k = + - 5 mm -FUCHS Fördertechnik AG- Ze i c h n un g s - N r . Bl a t t
= =
A m Kn i ck 18 D -2 2 11 3 Os t st e i nb ek
T el . : 04 0 -7 10 01 00 Fa x: 0 40 -7 10 01 0 99 04.09.1410-1 1/9
Fax: +49 40 71001099

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Portside Carriage Starboard Carriage
500 300 210 290
r unway by
yar d:
runway by 400x150x12.5/25
yar d:
400x150x12.5/25 A1
50
320
170 180
A0
Am Knick 18
830
DRAWING OF CARRIAGE DETAILS
22113 Oststeinbek
approx. 500
lifting eye
Tel.: +49 40 7100100

for 4,0t
G en e hm i g t /
a pp r ov e d:
Or t / p l a c e Datum / Date F i r me n s t em p e l / t r a d e s t a m p
K un d e /
C u st om e r
D S ME 42 12 / 1 3, D MH I H 4 07 3 / 5
F re i m aß t o l er a n z We r k s t o f f Au f t r a g - N r .
5 A.07.04.1231/ 32/ 33/34
4 Ve r vi e lf ä l t i g u n g u n d M i t t e i lu n g a n D r it t e i s t u n z u l ä s s i g . F ü r d i e s e Z e i c h n u n g
3 Name beh al te n w i r un s al l e Rec ht e gem äß dem Ur heb ers c hut z v or.
20 04 Datum
7 B e a rb . 2 9. 09 . Sc hul z
6 12. 12.07 Auftragsnummer geändert. Liu G e p r .
Engine room c rane SWL 12,5t
Än d e r un g Freig. Ty p e E D- A 1 2 5 - 7 . 5 0 5 E K Z
C ar r i a g es d e t a i l e d
-FUCHS Fördertechnik
Am Kni ck 18
AG-
D- 22 113 Os t st ei nb ek
Ze i c h nu n g s - N r .
Tel . : 0 40- 71 00 100 Fa x: 0 40 -7 100 10 99 04.09.1410-2
Fax: +49 40 71001099

- Seite / Page 10 -
600 640
forebody
aftbody
SECTIONAL DRAWING
Am Knick 18
22113 Oststeinbek
160
Tel.: +49 40 7100100

240
18000
G e n e h mi g t /
app rov ed:
O rt / pl ace D a t u m / Da t e Firm enst empel / trade st amp
Kunde /
Customer
D SM E 42 12 /1 3, D MH I H 40 73 / 5
Frei maßtol eran z W erks tof f A u f t r a g - Nr .
5 A.07.04.1231/32/33/34
4 V er v i e l f äl t i gu ng un d M i t t e i l un g a n D r i t t e i s t u nz u l ä ss ig . F ü r d ie s e Z ei c h nu n g
3 Na m e be ha l t en w i r un s al l e R ec h t e ge m ä ß d e m U r he b er s ch u t z v o r .
20 0 4 Da t u m
7 Bearb . 2 9 .0 9 . S c h ul z M aß s t a b
6 12.12.07 Auf trags num mer geändert. Liu G e p r .
Engine room crane SWL 12,5t
T y p e ED - A 1 2 5 - 7 . 5 0 5 EK Z 1: 5
Ände rung Frei g.
Sect ional drawing

-FUCHS Fördertechnik AG- Zeic hnung s-N r. B l at 4
A m Kn i c k 1 8 D - 2 21 1 3 Os t s te i n b ek
T el . : 0 40 - 7 1 00 1 0 0 F a x: 0 4 0- 7 1 00 1 0 99 04.09.1410-3 3/9
Fax: +49 40 71001099

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RUNWAY BY YARD – DIMENSIONS AND MEASURES
34.375
25
400
12.5
150
- Seite / Page 12 -
LIFTING EYE CAPACITY 4,0T
ø60
ø110
- Seite / Page 13 -
HOOK DETAILS FOR SIZE 4
Size Load (kN) a1 a2 a3 b1 b2 d1 e1 e2 e3 f1 f2 f3

4 125 71 56 80 63 53 48 172 190 148 45 - -
g1 h1 h2 l1 r1 r2 r3 r4 r5 r6 r7 r9
16 80 67 285 8 12 71 150 150 103 90 160
ATTENTION: Due to the safety ledge the dimension a2 will be

reduced approx. 6mm
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LIMIT SWITCH CRANE TRAVELLING
50.45
20
72
101.5
Freimaßtoleranz Werkstoff Auftrag-Nr.
4 Vervielfält igung und Mit teilung an Dritte ist unzulässig. Für diese Zeichnung
3 1997 Name behalten wir uns alle Rechte gemäß dem Urheberschutz vor.
Datum
2 Bearb. 1 8 . 0 6 . 9 7 B u b e l a c h Maßst ab
1 21.03.00 new Bock Gepr. Endschalter T V7H 335 01/01z
Freig.
Ä nderung
Limit swit ch
-FUCHS Fördertechnik AG- Zeichnungs-Nr. Blatt
Am Knick 18 D-22113 Oststeinbek
Tel.: 040-7100100 Fax: 040-71001099
041013-BO-TV7H
Limit Switch TV7H 335 01/01z
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JUNCTION BOX K9065
80
M25/32 flat
ø4
K 9065
60
M25/32 round
4 Vervielfältigung und Mitteilung an Dritte ist unzulässig. Für diese Zeichnung

3 2004 Name behalten wir uns alle Rechte gemäß dem Urheberschutz vor.
Datum
2 Bearb. 16.09.04 Bock Maßstab
1 Gepr. Junction box K9065
Änderung Freig. 1:2
Tel.: 040-7100100 Fax: 040-71001099
040916-Bo-K9065
Junction Box K9065
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MAIN SWITCH TER-SWITCH 3P32A-G SPEZ.
Types
Technical Specifications
- Seite / Page 17 -
DRAWING HAND CONTROL PENDANT
500
Emergency stop
Light on / off
Up
310
Down
Trolley Left
Trolley right
Crane forward
Crane backward
Freimaßtoleranz Werk s toff Auftrag-Nr.

80
4 Ver vielf ältigu ng und Mitt eilung an D ri tte ist unzulässig. Für die se Zei chn ung
3 Name behal ten wir uns alle Rechte gemäß dem Urh eberschutz vor.
Datum
2 Bearb. 24.06.03 Schulz Maßstab
1 Gepr. Control pendant ./.
Änderung Freig.
Type XAC-A 089
Am Knick 18
AG-
D-22113 Oststeinbek
Zeichnungs-Nr. Blatt
Tel.: 040-7100100 Fax: 040-71001099
Drawing Hand Control Pendant
- Seite / Page 18 -
SAFETY INSTRUCTIONS
General
Important information: The crane / lifting gear must not be put to use before the final
load- and function test carried out by the classification society.
How to Use These Instructions
These assembly, operating and service instructions must be read thoroughly and understood
before the FUCHS Fördertechnik AG lifting appliance ( crane, chain hoist, wire rope hoist or trolley)
is commissioned, and must be accessible by operators at all times during use.
By its nature a lifting appliance represents a potential hazard as a result of the lifting and handling
of loads, and so this chapter should be read with particular care and attention.
These instructions also contain danger, warning and safety advice and instructions.
Failure to comply with these instructions can expose persons to direct risk or to risk from
premature damage to the product.
This hazard information must be complied with. Subject to technical modification without notice.
Proper Use
FUCHS Fördertechnik AG lifting appliances are designed solely for lifting and also for the
horizontal off-floor handling of loads when used in conjunction with travel trolleys.
The Safe Working Load (SWL) as stated in the Inspection Schedule and on nameplates, the FEM
classification and the operating time and number of switching operations must be observed.
The lifting gear can be operated as hoists mounted on static supporting structures or as traveling
hoists suspended from suitable running rails by means of manual or electric travel trolleys. In all
cases the supporting structure must be adequately designed having regard to the SWL and dead
weight of the hoists and the relevant regulations.
The lifting appliances are designed essentially for operation indoors within non-aggressive
environments and at temperatures between -10°C and +45°C. Higher ambient temperatures will
require a reduction in the maximum operating times.
Non-standard operating conditions and configurations must be specially inspected and agreed,
and the manufacturer's approval may be necessary.
Improper use includes:
 Exceeding the SWL
 Dragging loads at an angle
 Using the hoists in explosive area
 Pulling jammed loads free, dragging or towing loads
 Catching falling loads
 Carrying persons with the load or load carrying devices
 “Jogging” ('inching') operations
 Persons standing under suspended loads .
 Slack chaining
 Straight reversing, i.e. reversing the hoist while it is running
 Intentionally running up against emergency limit switches and end stops
(see also Chapter 2.2 "Safety Guidance for the User')
Regulations'
FUCHS lifting appliances are designed, manufactured, tested and must be operated in accordance
with European and German standards and regulations.
Warranty
FUCHS Fördertechnik AG can accept no liability for damage to the crane or hoist caused by
improper use or by work which has not been properly carried out or carried out by unskilled
personnel, and can accept no liability for claims made by third parties.
- Seite / Page 19 -
The terms of the warranty for the lifting appliance are voided if the user alters parts arbitrarily,
assembles the item other than as directed in these instructions or uses parts that are not FUCHS
Fördertechnik AG original parts. It is essential for the safe operation of the product that only
FUCHS Fördertechnik AG original parts are used.
Safe operation within the stated service life can only be guaranteed when the lifting appliance is
operated according to its product classification and when these assembly, operating and service
instructions are followed. Please refer to the Inspection Schedule or product data sheet for the
drive group of your lifting appliance.
Information on the theoretical service life of the lifting appliance will be found in the appropriate
assembly, operating and service instructions.
Other Information
The year of manufacture is shown on the product nameplate.
To ensure that the product performs its tasks reliably and satisfactorily it may only be operated,
serviced and maintained by personnel who are duly appointed by the user and who are familiar
with these assembly, operating and service instructions and the relevant safety regulations, e.g.
Accident Prevention Regulations.
The assembly, operating and service instructions must be made available to the appointed
personnel at all times. FUCHS Fördertechnik AG products are essentially maintenance-free.
The limited amount of service work that is necessary must be carried out carefully and according to
the assembly, operating and service instructions and the service schedule.
Safety
Organizational lnformation
The operating, service and maintenance personnel must have read and understood the operating
instructions before they start work.
The user has a duty to ensure that operation is safe and hazard-free. This can be assisted by a
number of measures including:
 Providing and publishing the operating instructions
 Testing the product prior to commissioning and after major modifications
 Performing the routine tests and inspections
 Logging test results in the Inspection Schedule and keeping the Inspection Schedule in a safe
place
 Keeping a recording of elapsed service life
Only reliable, trained and properly appointed personnel may carry out work on or with the lifting
appliance.
The user has a duty to supervise the safety conscious handling of the lifting appliance by his
personnel.
Safety Information for the User
A thorough knowledge of these assembly, operating and service instructions by operating and
maintenance personnel is an essential of safe working practice.
Any and all arresting devices must be released before the start of operation.
The rotary "Emergency Stop" switch must be turned off in case of danger.
At the end of work load carrying devices such as grippes and magnets must be detached, the
empty hook pulled up and the lifting appliance moved to its park position.
Any arresting device must be engaged and the red rotary "Emergency Stop" switch turned off.
The relevant safety regulations, e.g. Accident Prevention Regulations (UW) and official
requirements, specifically the operating regulations for hoists, must be followed when operating
and servicing the lifting appliance.
- Seite / Page 20 -
In the Federal Republic of Germany these are the UW (BGV 0 8) "Winches, Hoists and Pulling
Gear". In other countries the users of lifting appliances must follow the safety instructions given
below.
Safety instructions 1 - 37 are reproduced from or based closely on German Accident Prevention
Regulation BGV 0 8 (VBG 8) "Winches, Hoists and Pulling Gear" , Section III "Testing" and Section
IV "Operation" (revised 01.04.1996). Safety instructions 38 - 40 summarize and/or reproduce the
safety instructions for the operation of lifting appliances as set out in German Accident Prevention
Regulation BGV D 6 (VBG 9) "Cranes" , Section IV "Operation" (revised 01.10.1993).
If the user or company is governed by other national regulations for the use of lifting appliances
then the following instructions still apply unless expressly contradicted by the national regulations.
1. The user must ensure that lifting appliances and their supporting structures are inspected and
tested by an expert before first-time commissioning and before re-commissioning following
major modifications.
2. The user must ensure that lifting appliances and their supporting structures are inspected and
tested at least once a year by an expert. He must also have them inspected by an expert at
other times as the need arises depending on the conditions of use and internal company
circumstances.
3. The inspection and test before first-time commissioning referred to in Point 1 includes
examining for proper assembly and operational readiness.
4. During the inspection referred to in Point 2 the user must determine the elapsed proportion of
the theoretical service life of lifting appliances. He should appoint an expert to do this if
necessary.
5. The user must ensure that records are kept of the results of the tests on lifting appliances
carried out in accordance with Points 1 to 4.
6. The results of tests on the lifting appliance must be logged in an Inspection Schedule.
7. The user may only entrust the assembly, servicing and unsupervised operation of the lifting
appliance to insured persons who are suitable and familiar with it.
8. Insured persons may not assemble, service or operate lifting appliances unsupervised unless
they have been appointed by the user for this purpose.
9. The User must ensure that the operating instructions supplied by the manufacturer is available
and accessible to those insured persons to whom the assembly, servicing or unsupervised
operation of the lifting appliance has been entrusted.
10. If internal company circumstances so require, the user must produce readily understandable
operating procedures in the language of the insured persons and based on the operating
instructions supplied by the manufacturer, setting out measures for safe operation in
accordance with company circumstances.
11. The insured persons must observe these operating instructions and procedures.
12. When assembling the lifting appliance the user must ensure that its control stand is positioned
or protected such that the lifting appliance operator is not put at risk by the lifting appliance,
load carrying devices or the load itself.
13. The user must ensure that the lifting appliance is only mounted on structures and suspensions
which are capable of safely accepting the anticipated forces.
14. The user must ensure that the lifting appliance is assembled, positioned or attached such that
its position cannot be accidentally changed by the forces which occur during operation.
15. The user must ensure that the lifting appliance is assembled or positioned such that load
carrying devices is not drawn across edges and the chain is not deflected to the side when it
enters the lifting appliance.
16. The lifting appliance operator must ensure that load carrying devices is not drawn across
edges.
17. The user and lifting appliance operator must ensure that the safe working load of the lifting
appliance is not exceeded.
- Seite / Page 21 -
18. Where loads are lifted by several lifting appliances together, then the user must ensure that the
lifting appliances are selected and positioned such that individual lifting appliances are not
overloaded even when the load is unevenly distributed.
19. The lifting appliance operator must test emergency stop equipment - except slipping clutches -
at the beginning of each working shift.
20. If the lifting appliance operator finds obvious defects with the lifting appliance including the load
carrying devices, rollers, equipment and supporting structure, he must rectify these
immediately. If this is not his responsibility or if he does not possess the necessary skills he
must take the lifting appliance out of service if necessary and report the defect to the user.
21. The user must ensure that loads are not slung by being wrapped around with the lifting chain.
22. Insured persons must not sling loads by wrapping the lifting chain around them.
23. The lifting appliance operator must not initiate any load movement until he is satisfied that the
load is safely slung and that personnel have cleared the danger area, or after he has received
a sign from the slinger.
24. The lifting appliance operator must keep all movements by the loads and load carrying devices
under observation.
25. If the lifting appliance operator cannot observe all movements by the load or load carrying
devices from the control stand, then the user must take precautions to ensure that persons are
not at risk from the load or load carrying devices.
26. Where work is to be carried out on or beneath loads lifted with lifting appliances, the user must
ensure that the loads are additionally secured against dropping on stable supports before work
commences.
27. Where work is to be carried out on or beneath loads lifted with the lifting appliance, the lifting
appliance operator must additionally secure the loads against dropping on stable supports
before work commences.
28. The lifting appliance operator must not leave the control stand of the lifting appliance when the
load is suspended.
29. If contrary to Point 28 the lifting appliance operator has to leave the control stand when the
load is suspended, then the user must create the conditions whereby the danger area beneath
the load can be protected.
30. If contrary to Point 28 the lifting appliance operator has to leave the control stand when the
load is suspended, then he must protect the danger area beneath the load.
31. The lifting appliance operator must not carry persons with the load or load carrying devices.
32. The user must ensure that the lifting appliance is not used to handle molten substances.
33. The lifting appliance must not be used to handle loads which are jammed or which can become
caught, snagged or obstructed as they move.
34. The lifting appliance operator must not drive the lifting appliance against emergency limits as
part of normal operating practice.
35. The user must take the lifting appliance out of service at the end of its theoretical service life.
36. Contrary to Point 35 the lifting appliance may continue in operation provided an expert
a) confirms that there are no objections to continued operation, and
b) the conditions for continued operation have been established. These conditions must be
recorded in the Inspection Schedule.
37. The user must ensure that continued operation complies with the conditions according to Point
36 b).
38. Insured persons may not carry out service and inspection work unless they are satisfied that
the lifting appliance has been switched off and locked out. They may only carry out service
work that cannot be done from the ground from work stands or staging.
39. The user must direct and supervise the following safety precautions for all repairs and
modifications to the lifting appliance and for work in areas where persons may be at risk from
the lifting appliance:
a) The lifting appliance must be switched off and a locked out.
- Seite / Page 22 -
b) If there is a risk from falling objects, then the danger area beneath the lifting appliance must
be protected with barriers or by posting safety assistants.
c) If the safety precautions described in a) and b) are not appropriate or not relevant or
adequate for company reasons, then the user must direct and supervise other or additional
safety precautions.
40. Following repairs or modifications, or work carried out within its danger area, the lifting
appliance may only be put into service when the user has approved the resumption of
operation. Before giving his approval, the user or his representative must satisfy themselves
that
a) the work has definitely been completed
b) the complete lifting appliance is in a safe condition
c) all personnel involved in the work have cleared the danger area.
Caution!
Where the lifting appliance is suspended from a traveling trolley or crane, then the Accident
Prevention Regulations BGV D 6 (VBG 9) "Cranes" which are not reproduced here in full must be
observed and complied with in addition to the safety instructions listed.
General Guidance on Hazards
The product is designed to be operated on industrial power systems. There are hazardous live
bare parts and moving/rotating parts in the interior of the product while it is in operation.
Serious injury to persons and damage to property may result from
 the prohibited removal of covers
 improper use
 incorrect operation
 inadequate servicing and maintenance.
Failure to observe the safety information given in these instructions may cause injury or even
death. The product may constitute a danger to life and limb if it is operated or used by untrained or
inadequately trained persons or if it is not operated for its intended purpose. The user must ensure
that his operator and maintenance personnel receive training in good time before they work with or
on the product. Owing to the risk of injury, e.g. from becoming caught pulled into the product, this
personnel must wear no loose clothing, loose long hair or jewelry, including rings (!).No work of any
kind with or on the product may be carried out by persons who are under the influence of narcotics,
alcohol or medication which affects their ability to react. Contact with concentrated acids or alkalis
can attack plastic housings and cause dangerous corrosion of metal parts; any parts affected in
this way must be promptly replaced. The product must not be used in areas subject to explosion
hazards unless specifically prepared for this purpose.
During operation:
All actions specified in the instructions both before, during and after commissioning, and guidance
on general safety, especially those affecting operational safety and accident prevention, must be
strictly followed; failure to do so may cause accidents with fatal consequences.
The use of prohibited or unsuitable tools or equipment can cause injury. The movement or rotation
of parts can cause pinch and/or shear hazards both on the product and between the product and
parts of its surrounding area; adequate safety distances from moving or rotating parts should be
maintained at all times to prevent persons from reaching into them and clothing, parts of the body
or hair from being caught.
Extreme heat (e.g. from welding), sparks produced when using cleaning agents and naked flame in
the vicinity of materials that are flammable or which can distort in heat (e.g. wood, plastics, oils,
greases, electrical plant or cables) must be avoided, otherwise there is a risk of fire with the
release of hazardous gases or damage to insulation etc.
- Seite / Page 23 -
Measures for Ensuring Safe Working Periods
The EC Machine Directive stipulates safety measures for avoiding hazards with hoists as a result
of material fatigue and aging. The following measures have therefore been taken to ensure safe
working periods (S.W.P.).
- Seite / Page 24 -
Theoretical Service Life D
The manufacturer or supplier of the production hoist is required to state the theoretical service life
D in his operating instructions. This is shown in the following table for FUCHS electric lifting
appliances.
Theoretical Service Life D (h)
Drive groups DIN..15 1 Dm 1Cm 1 Bm 1Am 2m 3m 4m 5m

020
FEM M1 M2 M3 M4 M5 M6 M7 M8
Line Load populations /

Factor of load Theoretical service life D (h)
spectrum
1 Light 1/L1 800 1600 3200 6300 12500 25000 50000 100000
K= 0,5
(Km1 =0,125=
3
0,5 )
2 Medium 2 / L2 400 800 1600 3200 6300 12500 25000 50000

0,5Q K 0,63
(Km2=0,25 =
3
0,63
3 Heavy 3 / L3 200 400 800 1600 3200 6300 12500 25000

0,63K0,8
3
(Km3=0,5=0,8 )
4 Very heavy 4 / L4 100 200 400 800 1600 3200 6300 12500
0,8K1
3
(Km4=1=1 )
Record of Operating Performance

The user has a responsibility to ensure that the actual operating performance of the lifting
appliance is recorded and documented in the Inspection Schedule at least once a year.
The actual operating performance is not inspected or if this is not possible or if it is only estimated,
then the general overhaul (GO) according to Point 2.4.4 must be carried out after 10 operating
years at the latest.
Assessment of the Safe Working Period (S.W.P.)

The expert responsible for inspecting the production hoist must check at every routine inspection
whether the production hoist is still being used within the S.W.P.
Measures when the Theoretical Service Life D is Reached

1. The user must take the lifting appliance out of service at the end of its theoretical service life.
2. Contrary to Point 1 the lifting appliance may continue in operation provided an expert
a) confirms that there are no objections to continued operation, and
b) the conditions for continued operation have been established. These conditions must be
recorded in the Inspection Schedule.
3. The user must ensure that continued operation complies with the conditions according to Point 2
b).
- Seite / Page 25 -
Further Safety Instructions
Please also pay attention to the relevant information given within the operating instructions of the
individual components.
- Seite / Page 26 -
GENERAL INSTRUCTION FOR WELDING WORK ON THE CRANE /
TROLLEY
p i ct ure 1 el ec t ro w el di ng o n c rane bri dg e
Es i s t Si c he rzu s te l l en ,
daß de r S ch w ei ß s t rom nur
übe r d i e Er de v om Sc hw e i ß -
agg reg at g eht !
You h av e t o be a ss ure ,
th at t he w e l di ng c urre nt
p i ct u re 2 el e ct ro w e l di ng on t rol l e y m us t go t hro ug h gro und i ng
fro m t he we l di ng ap pa rat us !
ATTENTION:
Welding on the crane / trolley is primary allowed, when crane / trolley is grounded!
- Seite / Page 27 -
INITIATION OF ENGINE ROOM CRANES AND MONORAIL TROLLEYS
1. After assembling the engine room crane or the monorail trolley it is necessary to check every
bolt connection, which was unscrewed for assembling. Please note the required torque of the
screws.
2. Before first-time commissioning the user must ensure that there are no obstructions such as
cables, ladders, pipes etc. in the line of travel.
3. The equipment must be operated from a three-phase power supply with a clockwise phase
sequence to ensure the correct functioning of the limit switches. Please compare the direction
of symbols on the control pendant with the motions of the crane / trolley.
4. The stopping cams of the limit switches on the crane / trolley have to be installed and
adjusted. The crane / trolley has to break with a distance of 100 mm to the end of the track or
an obstruction. The stopping cams must be made available by yard and must be modified in
accord with the given circumstances.
5. Important: Before initial operation the chain, pinion and toothed rack must be greased.
ATTENTION:
During welding on crane or trolley, the welding has must have an absolutely separate
welding ground. If not, any guarantee will expire.
TESTING OF CRANES AND HOISTS WITH TEST LOAD
1. Testing of cranes / hoists with overload was carried out during the Work´s Test and the
Inspection Test. The tests were carried out by crane experts or a surveyor of a classification
society resp.
2. The overload protection of cranes and hoists is adjusted at delivery so that working load can
be lifted safely. The cranes and hoist are herewith protected against overload. An adjustment
for higher load is not allowed.
- Seite / Page 28 -
PRINCIPLE OF TRAVELLING
Motor and Pinion Travelling
Distance Pinion
- Seite / Page 29 -
Principle of Travelling
Please take care that toothed rack and pinion are always well greased!
- Seite / Page 30 -
ASSEMBLING INSTRUCTION FOR WELDING TOOTHED RACK
Mounting Instruction of Toothed Rack
Material of the toothed rack: C45k

Please take care that toothed rack and pinion are always well greased!
- Seite / Page 31 -
Kranbahn / runway
Zahnstange /
toothed rack
Zahnstange / Zahnstange /
toothed rack toothed rack
Montage-Hilfsstück /
mounting piece
a4
Assembling procedure:
1. Arrange and fix toothed racks. Pay attention to correct tooth pitch (Use mounting piece).
2. Fixation with screw clamps
3. Before welding all, toothed racks have to be arranged and fixed.
4. Pre-heat tooth rack to approx. 100 degrees Celsius and keep this temperature.
5. Beginning in the middle, weld toothed rack using step-back welding procedure.
- Seite / Page 32 -
Equipment Application Amb.temp. Oil brand Quantity Change Intervall
point
E/R--crane / shaft -5 .... 40 °C 1. ARAL Degol BG 220 10.000 service
FUCHS mounting 2. BP Energol GR-XP 220 hours or 2 years
travelling motors gear boxes 3. DEA Deagear DX SAE 85W ~ 1,0 ltr (SK
SK 1282 4. Esso Spartan EP 220 1282)
SK 2282 5. Mobil Mobilgear 630 ~1,7 ltr. (SK
6. Shell Shell Omala Oil 220 2282)
7. FAMM Meropa 220 ~4,7 ltr. (SK
Anti friction -30 .... 60 °C 1. ARAL Aral HL 2 ~ 50 g 10.000 service
bearings 2. BP Energrease LS 2 hours or 2 years
3. DEA Glissando 20
Am Knick 18
4. Esso Beacon 2
5.Mobil Mobilex 2
6. Shell Alvania grease R2
7. FAMM Multifak EP2
engineroom crane hoist gear -10 ...40°C 1. ARAL Degol BG 220 ~ 0,4 ltr. 12 months after
GENERAL LUBRICATION OIL CHART
/ FUCHS; box 2. BP Energol GR-XP 220 commissioning and

hoist AK 9, B13 3. DEA Deagear DX SAE 85W then every 2 years
22113 Oststeinbek
4. Esso Spartan EP 220 or during general
5. Mobil Mobilgear 630 overhaul
6. Shell Shell Omala Oil 220
7. FAMM Meropa 220
engineroom crane chain+toothe -5 ...45°C 1. grease NLGI 00/000 ~ as needed before
/ FUCHS; d 2. FAMM Multifak EP 00 commissioning
chain , toothed rack+pinion and then every 3
rack, pinion months
Tel.: +49 40 7100100

Fax: +49 40 71001099
- Seite / Page 33 -
Initiation of Engine Room Cranes and Monorail Trolleys
1. After assembling the engine room crane or the monorail trolley it is necessary to check every
bolt connection, which was unscrewed for assembling. Please note the required torque of the
screws.
2. Before first-time commissioning the user must ensure that there are no obstructions such as
cables, ladders, pipes etc. in the line of travel.
3. The equipment must be operated from a three-phase power supply with a clockwise phase
sequence to ensure the correct functioning of the limit switches. Please compare the direction
of symbols on the control pendant with the motions of the crane / trolley.
4. The stopping cams of the limit switches on the crane / trolley have to be installed and adjusted.
The crane / trolley has to break with a distance of 100 mm to the end of the track or an
obstruction. The stopping cams must be made available by yard and must be modified in
accord with the given circumstances.
5. Important: Before initial operation the chain, pinion and toothed rack must be greased.
ATTENTION:
During welding on crane or trolley, you have to take care that the welding has an
absolutely separate welding ground. If not, any guarantee will expire.
- Seite / Page 34 -
Testing of Cranes and Hoists With Test Load
1. Testing of cranes / hoists with overload was carried out during the Work’s Test and the
Inspection Test. The tests were carried out by crane experts or a surveyor of a classification
society resp.
2. The overload protection of cranes and hoists is adjusted at delivery so that working load can be
lifted safely. The cranes and hoist are herewith protected against overload. An adjustment for
higher load is not allowed.
- Seite / Page 35 -
TRAVELLING MOTOR - OPERATING AND MAINTENANCE
INSTRUCTIONS
Helical Gearboxes
Shaft Mounting
Gearboxes
Helical-Bevel
Gearboxes
Wormgears
- Seite / Page 36 -
Caution
It is presumed that the planning stage of the project as well as all workmanship in regard to
transport, assembly, installation, stalling up, service and repair is done by qualified personnel or
under responsibility of skilled labours.
Installation
- foundation (base) of unit in question has to have adequate size, vibration-proof
- install geared unit or geared motor rigid and graceless
- take care for sufficient ventilation.
- make use of tapped hole (DIN 332) to suit fastening to the shaft end
- avoid shocks on shafts (bearing damage!)
- use flexible coupling between output shaft and driven machine
- use torque arm with rubber buffer on shaft mounting gearboxes
Connection of Motor
- connect motor according to diagram
- check electric source with voltage / frequency on name plate
- if motor is running in reverse direction, interchange two phases
- install protective device, necessary
- set motor protection to nominal current
- connection diagram see below
Starting up
- in case of extended storage proceed according to works norm sheet "Extended Storage"
- check position of oil plugs with help of mounting position sheet
- check oil level
- take away peg from vent plug (excess pressure!), if available set spring-loaded vent plug
- first oil filling as shown in list of lubricants
Caution
Any different data in current, temperature, vibration, noise etc. compared with nominal data, as well
as release of any control device indicates malfunction. To avoid a fault and to prevent direct or
indirect damage of equipment or injury to a person, responsible maintenance has to be informed
immediately,
In case of doubt disconnect the machine!
Maintenance
Motor
 lubricate the bearings together with oil filling of gear
 remove dust deposit (overheating)
 cleaning of bearings
 fill half of bearing cage with special bearing grease
- Seite / Page 37 -
Gear
 regular oil level check
 change lubricant every 10000 working-hours (after two years at the latest) and at the same
time clean and refill bearings 1/3 with grease.
 combine the lubricant change with thorough cleansing of the gear unit
 synthetic oil (grease) will double period of time
 period of time is shortened in case of extreme working condition (high humidity of ambient
air, aggressive ambience and high variation change in temperature)
 list of lubricants
Do not mix synthetic lubricant with mineral lubricant!
Type of Lubricant
Lubrication
Before starting and before storing for a long period, the seal in the vent plug must be removed in
order to prevent excessive pressure and oil leaks.
Gear units and geared motors leave the factory ready for operation filled with mineral oil. All
units shipped are filled with the lubricant (normal) listed in the ambient temperature column of
the following chart. For other ambient temperatures the listed lubricants are available at an
additional charge.
The lubricant should be changed every 10.000 service hours or after two years. For synthetic
products, the tube should be changed every 20.000 service hours or after four years. In case of
extreme operating conditions, e.g. high humidity, aggressive environment and large temperature
variations, shorter intervals between changes are recommended. It is advisable to combine the
lubricant change with thorough cleansing of the gear unit. The bearings filled with grease must
also be cleaned every 10.000 service hours and packed with fresh grease. When doing so
ensure that the bearing is packed to about 1/3 with grease.
Note: Synthetic and mineral lubricants must not be mixed.
- Seite / Page 38 -
- Seite / Page 39 -
- Seite / Page 40 -
- Seite / Page 41 -
General Part List
201 Driven gear 250 Locking cap
202 Pinion shaft 254 Spacer
205 Driving gear 900 Rotor with shaft, plain
206 Driving pinion 901 Rotor with shaft, gearcut
207 Output shaft (Hollow shaft) 902 End shield A
208 Key 903 Oilflinger
209 Shaft seal 904 Shaft seal
210 Shaft seal 905 Bearing A
211 Circlip 906 Bearing shim
212 Shim 907 Terminal box frame
213 Ball bearing 908 Terminal box cover
214 Seal 909 Terminal box frame gasket
215 Gear case cover 910 Terminal box cover gasket
217 Vent plug 911 Terminal board
218 Seal 914 Cable-gland
219 Socket head screw 916 Stator case
220 Key 918 Key
221 Circlip 919 Circlip
222 Ball bearing 920 Oil-plug
223 Locking cap 921 Seal
224 Washer 922 Spring washer
225 Washer 923 Hexagon screw
226 Socket head screw 924 Collar screw
227 Socket head screw 925 Hexagon nut
228 Seal 928 Hexagon screw
229 Supporting disc 929 Bearing B
230 Gearbox cover 932 End shield B
231 Circlip 938 Second motor shaft end
232 Seal 939 Fan
233 Key 940 Fan cover
234 Drain plug 941 Key
235 Seal 942 Circlip
236 Supporting disc 943 Key
237 Pinion shaft bearing 947 Circlip
238 Pinion shaft bearing 948 Circlip
239 Circlip 949 Oval flat - head screw
240 Locking cap 950 Oval flat - head screw
241 Shim
242 Supporting disc
243 Gear case
- Seite / Page 42 -
- Seite / Page 43 -
- Seite / Page 44 -
Helical Shaft Mounting Gear Unit
- Seite / Page 45 -
- Seite / Page 46 -
SINGLE-DISC SPRING PRESSURE BRAKE - OPERATING
INSTRUCTIONS
- Seite / Page 47 -
Conditions of Use
The use of the spring pressure brake presents no problems. The only requirements are that the
size is carefully selected and that grease and oil are not allowed to penetrate into the friction
surfaces. Moderate dust deposits have no harmful effect.
The brake can be equipped subsequently with a dust-proof seal in connection with a second
friction disc when there is increased dust accumulation.
If due to the operation conditions there is a danger of friction linings rusting onto the armature (4)
or onto the brake flange (1), the armature and brake flange can be supplied additionally with a
friction disc made from non-rusting material (extra charge).
We also recommend this version if the drives have to be stored of for lengthy periods.
Installation
Attach the driver to the shaft in the axial direction and secure against rotation. Ensure that the
driver cannot touch the secondary friction surface. Clearance to secondary friction surface 0,5–1
mm taking into consideration the shaft end play (Fig.2).
Push brake disc onto driver. Fasten ready assembled magnet system to cover plate or
intermediate flange using machine screws.
- Seite / Page 48 -
Adjustment and Readjustment of Clearance
Set the clearance using a feeler gauge by turning the adjustment screws. Tighten machine screws.
The clearance should be uniform all round (Fig. 1).
The braking torque is set to the rated moment. It can be reduced by turning the adjustment ring to
50%.
Adjustment of the Braking Torque
t MB [Nn] 5 10 20 40 60 100 150 250 400 800

Braking torque
P 20 [W] 22 28 39 42 50 64 76 100 140 140

Power of coil
lt X [mm] 0,2 0,2 0,2 0,3 0,3 0,4 0,4 0,5 0,5 0,6
Normal air gap X
Xn [mm] 0,6 0,7 ./. 0,9 1,0 1,1 1,1 1,2 1,2 1,2
Readjustment
recommended at Xn
V [mm] 3,0 3,0 1,0 3,0 3,5 3,5 3,5 3,5 3,5 3,5
max. permissible
wear V
[mm] 4,5 5,5 7,5 9,5 11,5 12,5 14,5 16,5 16,5 16,5
min. permissible
lining thickness
Fig.1: Clearance adjustment Fig.2: Driver Installation Fig.3:Hand release attachment
- Seite / Page 49 -
Replacing the Brake Disc
Loosen magnet system and pull back. Replace brake disc. Fasten magnet system and adjust
clearance as described above.
Subsequent Attachment of Hand Release
Push screws with washers and springs through the holes provided in the magnet and armature.
Position hand release mechanism and tighten with self-locking nuts. Adjust the hand release so
that dimension m in table 1, (see also Fig.3) is maintained under all circumstances. Dimension m
applies only for rated torque. For reduced braking torque m must be increased so that the hand
release does not obstruct the armature stroke even at the greatest possible grab.
- Seite / Page 50 -
ENERGY SUPPLY PROGRAM 230 AND 240
OPERATING AND MAINTENANCE INSTRUCTIONS
- Seite / Page 51 -
Principle sketch of power supply system c-rack Runway (mostly by yard)
H:\Vorlagen\Dokumentation\Stromzuführung\
C-Schiene-Hängeleitung\C-Schiene_Montageanleitung.prt
Towing arm Towing arm
Track
Cableclamp coupler Flat cable trolley *)
Track support brackets Towing trolley
C-Rail track
Track
support
bracket
Junction box
Principle of Power Supply Line
Flat cable Crane carriage
Crane bridge
Principle of Power Supply Line
Am Knick 18
Am Kni ck 18
AG-
D-22113 Oststeinbek
Tel .:+49( 0)40-7100100 Fax:+49( 0)40-71001099 *)
be careful of
minimum distance
(see general drawing)
22113 Oststeinbek
Track Picture of C-rack-Power-System
Track
coupler
support Flat cable
bracket trolley
Tel.: +49 40 7100100

Cable
Towing
clamp
trolley
Fax: +49 40 71001099

Illustration: Completely mounted energy supply system
- Seite / Page 52 -
Mounting Preparations
Prior to mounting the rails the rail pieces and, if applicable, the rail curves are to be cut to size
according to the track run. At all track joints a track coupler is to be provided.
Energy Supply Assembly
Rail Mounting To Ceiling Construction Tools Required
Standard Tools
For mounting the energy supply system, standard metric tools are necessary.
Mounting Steps
The rails are mounted on an existing ceiling construction by means of track support brackets.
Rail Mounting To I-Beam
Illustration: Rail mounting with support arms

If the ambient conditions of the application allow it, it is also possible to mount the rail with support
arms. No drillings in the existing steel construction are required.
The support arms and girder clips are not part of the normal scope of supply.
This method of rail track suspension will allow complete horizontal adjustability and greatly assist in
aligning the rail track.
- Seite / Page 53 -
Mounting The Components In The C Rail
Install terminal box and end clamp to the rail at the feeding point of the energy supply system.
Install cable trolleys into the rail, inserting the towing trolley or the ideal control unit trolley last.
Finally the open rail ends are closed with end caps.
Mounting The Cables
Depending on the type of application the cables have to be mounted with a length addition of 10 -
25 % in addition to the actual track travelling length. The max. permissible cable loop is often
determined by the existing conditions. In curved tracks the max. permissible cable loop is 35% of
the smallest curved track radius.
h [m]
Application 0,5 – 0,8 > 0,8 – 1,25 > 1,25 – 2 >2
v [m/min]
bis 32 1,10 1,10 1,10 1,10
> 32 – 40 1,15 1,10 1,10 1,10
Standard Operation > 40 – 50 1,15 1,15 1,10 1,10
> 50 – 63 1,20 1,15 1,15 1,10
> 63 – 80 On inquiry 1,20 1,15 1,15
> 80 – 100 On inquiry On inquiry 1,20 1,15
Ideal control unit Up to 63 1,10 1,15 1,20 1,25
Round cables
spiral mounted Up to 63 1,25 1,20 1,20 1,15
Table: Length addition
After the C rail has been installed the cable trolleys are inserted into the rail. The cables are
installed onto the support saddle starting from the end clamp, then all the cable trolleys are pushed
together towards the end stop and the loops are aligned to equal length. Finally the cables are
clamped.
If several flat cables are placed on a cable trolley the thickest flat cable has to be placed on top. In
case of round cables, the main cables are placed at the edge of the support; the cables with the
largest diameters are placed in the centre.
Illustration: Examples for the arrangement of cable packets
The electrical connection of the system must be carried out by a trained electrician.
Cable Organisers
If there are large cable packages and long cable loops (starting with 2 m cable loop) it is
recommended to install the cable organiser at the bottom of the loop. This will ensure the cable
package is kept neat, and any twisting of a single cable or loop is prevented.
- Seite / Page 54 -
Connection To Hoist Unit
A towing arm is mounted to the hoist unit to tow the energy supply system. This towing arm
interfaces with the towing trolley installed at the end of the energy supply system. The towing arm
is supplied by the customer because the dimensions depend on the location of the current supply
and can differ.
Energy Supply With Flat Cables
By yard
Illustration.. Assembled energy supply with flat cables
Special Steps During Assembly
Track Support Bracket
Illustration: Track support bracket with locking screw
The track support brackets are slipped onto the C rail and mounted to the suspension construction
with the rail. With the locking screw the C rail is clamped in the track support bracket.
Alternatively, it is also possible to mount the track support brackets to the suspension construction
first, and to insert the C rail pieces and to clamp them with the locking screws afterwards.
- Seite / Page 55 -
Illustration: Securing the rail against sliding
In the first and last track support bracket the C rail has to be secured against sliding in the
horizontal direction. Therefore, holes with 6.2 mm diameter are drilled into the side of the rail where
the locking screws can interface.
It has to be ensured, that the locking screws do not protrude on the inner wall of the rail as the
rollers of the trolleys might get damaged.
Track Coupler
Illustration: Track coupler

The track coupler is slid halfway onto the first joint of the C rail and then clamped. The correct
position can be verified at the sight hole of the coupler. The second C rail piece is inserted and
clamped gap-free. The C rails need to be cut in a right angle and deburred. Be sure that the
locking screws are tightened equally to avoid any displacement of the rails in the coupler area.
End Clamp
The end clamp is inserted behind the end stop and then clamped tightly.
Illustration: End clamp for round cables
Special Precautions During Assembly

During the assembly of the rail track it is recommended to check that there is trouble-free
movement of the trolleys within the rail with the help of one of the supplied cable trolleys. If a trolley
with horizontal guide rollers is used, even a slight lateral deformation of the rail can cause a
displacement or even jamming of the trolley.
- Seite / Page 56 -
Attention should be paid to the positioning of the towing trolley. The connection between towing
arm and towing trolley prevents damage to the cable. The towing unit should be positioned in such
a way that the travel unit (crane carriage) of the crane can be used as space for stowing the towing
trolleys etc. (compare following diagram)
- Seite / Page 57 -
DRAWINGS FOR ENERGY SUPPLY PROGRAM 230 AND 240
Towing Trolley Dwg.No. 23 958
125
53
80

3 behalten wir uns alle Rechte gemäß dem Urheberschutz vor.
1998 Datum Name
2 Bearb. 21.01. Märker Maßstab
1 Gepr. Mitnehmerwagen 1:2
Änderung Freig.
-FUCHS Fördertechnik AG- Towing trolley

Tel.:+49(0)40-7100100 Fax:+49(0)40-71001099 NO 2 3 9 5 8
- Seite / Page 58 -
Cable Clamp Dwg.No. 23 269
50
36
54
80

1 9 9 8 Datum Name
2 Bearb. 2 1 . 0 1 . M ä r k e r Maßstab
1 Gepr. Kabelfestpunkt 1:2
Änderung Freig.
-FUCHS Fördertechnik AG- Cable clamp

Tel.:+49(0)40-7100100 Fax:+49(0)40-71001099 NO 23 2 69
- Seite / Page 59 -
Track Support Bracket Dwg.No.23 222
16
9
63
M6
4 Verv ielfält igung und Mitt ei lung an Drit te ist unzuläss ig. Für diese Zei chnung
1998 Datum Name
1 Gepr. Schienenhalter 1:1
Änderung Freig.
T ra ck s u p p o rt b ra c k e t
Am Knick 18
AG-
D-22113 Oststeinbek
Tel.:+49(0)40-7100100 Fax:+49(0)40-71001099 NO 2 3 2 4 0
60
34
M8x16
84 40
4 Verv ielfält igung und Mitt ei lung an Drit te ist unzuläss ig. Für diese Zei chnung
1998 Datum Name
1 Gepr. Schienenhalter 1:1
Änderung Freig.
T ra ck s u p p o rt b ra c k e t
Tel.:+49(0)40-7100100 Fax:+49(0)40-71001099 NO 23 222
- Seite / Page 60 -
Track Coupler Dwg.No. 23 210 / End Stop Dwg.no. 23 219
31
M6
10 0 33
Freimaßtoleranz Werk stoff Auftrag-Nr.

1998 Datum Name
1 Gepr. Schienenverb. 1:1
Änderung Freig.
-FUCHS Fördertechnik AG- Track coupler

Tel.:+49(0)40-7100100 Fax:+49(0)40-71001099 NO 2 3 2 1 0
53 25
25
Freimaßtoleranz Werk stoff Auftrag-Nr.

1998 Datum Name
1 Gepr. Endanschlag 1:1
Änderung Freig.
-FUCHS Fördertechnik AG- End stop

Tel.:+49(0)40-7100100 Fax:+49(0)40-71001099 NO 2 3 2 19
- Seite / Page 61 -
Flat Cable Trolley Dwg.No. 23 943
80
24
15
50 80
4 Vervi elfälti gung und Mittei lung an Drit te ist unzulässi g. Für diese Zeic hnung
1998 Datum Name
1 Gepr. Flachkabelwagen 1:1
Änderung Freig.
-FUCHS Fördertechnik AG- Flat cable trolley

Tel.:+49(0)40-7100100 Fax:+49(0)40-71001099 NO 2 3 9 4 3
- Seite / Page 62 -
CHAIN HOIST B13 - OPERATING INSTRUCTIONS
- Seite / Page 63 -
Safety advice
Advice for the use of electric chain hoists
Electric chain hoists are designed to lift and to lower loads vertically and to travel horizontally with
those lifted loads (with trolleys). Every other mode of use is prohibited and the risk is the operator’s
responsibility and will be fully at the risk of the operator. Please ask the producer for any special
mode of use in advance.
Using the hoist to carry people is strictly prohibited!
The modern design of the hoists guarantees safety and economic use.
The patented safety clutch system is located between motor and brake.
This enables the brake to hold the load without any power transmitted by the clutch.
Electric chain hoists are driven by use of electrical energy.
Before first using please make sure, that all electrical wires are connected safely, that all wires are
without damage and that the whole equipment could be switched off a main switch.
It is the responsibility of the operator to make sure that all suspension points of the hoist are
calculated to safely withstand the dynamic forces caused by the lifting equipment.
The chain hoist is usable when the hoist is safely suspended and the outgoing chain can leave the
hoist safely in the relevant direction.
Therefore the container for the dead end of the chain outside the hoist must be big enough to allow
the chain coming out. If not the chain can be trapped inside the hoist and can brake the casing of
the hoist.
For use of the hoist in an aggressive environment – please consult the producer.
European regulations
The basis for the assembly, first use, certification and maintenance of electric chain hoists are
within Germany and within the area of the European community, the following regulations, and all
recommendations of this manual.
Please pay particular attention to the rules for the prevention of accidents and the statutory
regulations
 for electric chain hoists VBG 8
 for use in a crane system VBG 9
 for slings and load devices VBG 9a
 selection of lifting gears FEM 9.682
 design of electrical equipment with high voltage for
 lifting equipment
 DIN VDE 0100 part 726
 electrical equipment for machines EN 60 204 part 1 and part 32
 certification of the crane by authorized people ZH 1/27
 certification of hoisting equipment by authorized people ZH 1/25
 EMV-regulations 39/336 EWG
The producers guarantee depends on consideration of these regulations and all of this manual.
Other national regulations are valid for countries outside of the European community.
Maintenance work for hoisting equipment is to be carried out by trained and authorized people
only.
The main switch has to be switched off before and the load area has to be secured first.
Authorized people have to have had theoretical training and experience in the field of cranes and
hoists.
They have to have an excellent know-how of the special regulations and must be able to decide
whether the lifting equipment is in safe working condition or not.
They have to fill in the forms of any maintenance work, repair work or test (for example:
maintenance work on brake or clutch).
- Seite / Page 64 -
The hoist is allowed to be used only by people who have complete knowledge of this manual, the
manual should be available at all times.
Spare parts
It is allowed to use original spare parts only. The producers guarantee is given for those spare
parts only.
The producer will not be responsible for failures and breakdowns caused by use of non-original or
wrong spare parts.
Technical overview
Schematic sketch
- Seite / Page 65 -
Sectional view
Picture Designation Picture Designation

No. No.
1 Casing 11 Pinion shaft III (without illustration)
2 Gear Cover 12 Geared wheel IV (without illustration)
3 Stator 13 Pinion shaft V (without illustration)
4 Rotor 14 Pinion shaft VII
5 Motor pinion shaft 15 Geared wheel VI
6 Bearing plate B 16 Geared wheel VIII
7 Brake unit 17 Sprocket wheel
8 Fan 18 Cover for low voltage control
9 Fan screw 19 Load chain
10 Geared wheel II (without illustration) 20 Hold down
Sectional view
- Seite / Page 66 -
Schematic sketch of the load chain configuration
Only use manufacturer’s original parts as these meet the high stress and service life standards
required.
Version with single fall hook Version with double fall hook
Assembly
Assembly work should only be carried out by trained specialists in accordance with VBG 8, section
24.
Mechanical assembly
Hook tackle
The hook tackle used to attach loads for hoists in single- fall version.
Single fall hook for 16x45 diameter chain
- Seite / Page 67 -
If maintenance work is carried out do not forget to inspect the condition of the hook (check the
distance between the centre punch markings to check hook throat), the thrust bearing, the safety
latch and the hook nut with safety pin.
Caution ! The hook nut of the load hook for the single fall hook is locked by using a safety pin 90°
degrees to the hook axis.
Hook block
The hook block used to attach the load in double fall version.
Double fall hook for 16x45 chain diameter

If maintenance work is carried out, do not forget to inspect the condition of all the hook parts.
Caution ! The hook nut of the load hook is secured by a safety pin 90° degrees to the hook axis.
Stationary suspended hoists

- basic version -
Suspension with suspension eye
Assembly: The suspension eye section, which forms part of the standard delivery, must be
inserted into the specially provided suspension holes on the electric chain hoist and pinned into
place with the two bolts. Use washers with the lock bolts and secure position with split pins.
Suspension with suspension eye
- Seite / Page 68 -
Special version –Suspension with single-hole eye –
Assembly: The suspension with single- hole eye section, which forms part of the standard
delivery, must be
inserted into the specially provided suspension holes on the electric chain hoist and pinned into
place
with the two bolts. Use washers and a nylock to secure the position of the bolts.
Suspension with single hole eye
Caution! The single hole eye must be

assembled in such a way that the centre of
gravity for single fall or double fall of chain has
to be vertically in line with the suspension hole
of the suspension eye. The correct location is
shown by the blue arrows on the suspension
eye and on the hoist body which have to be at
the same side of the hoist.
If a hoist with a single hole eye has to be
converted to a different number of load falls the
single hole eye has to be dismantled, turned by
180° degrees and to be refitted to the
suspension holes of the hoist.
Conversion to a different number of load falls for hoists with a single hole eye
- Seite / Page 69 -
Gear ventilation
Having completed assembly, the split washer is placed under the oil-filler plug (top side of casing).
Mounting the chain box

The figure above shows how the chain box is mounted.
The chain collector has to be mounted with a screw M 20x180 DIN 931 and secured with a nylock
nut.
The chain collector is equipped with a piece of chain which secures the box and fixes the correct
position.
 This piece of chain has to be put into the pocket in the casing of the hoist and must be
secured with a screw M 8x30 DIN 933 with washer.
 The last link of this chain (7x22) fits into the special seat of the chain collector and has to be
secured with a screw M8x35 and nylock.
 Please make sure that this chain is tightened and not twisted at all.
Caution! Check if the size of the chain box at hand is sufficient to accommodate the respective
chain length of the chain hoist (chain dimensions and holding capacity can be read on the bottom
of the chain box). Insert the chain end with lift limiter loosely into the chain box.
After running in the chain box, check again to make sure that the chain bag is not filled more than
the capacity level mark shows.
Don’t use chain bags which are filled more than this level mark indicates.
Please make sure that any parts of the load or any slings (chain, rope or canvas material) cannot
touch the chain bag.
Suspension of chain collector
- Seite / Page 70 -
Fitting the load chain – single fall version –
Fitting the load chain – single fall version –

1. The hoist is prepared with a short piece of chain on the sprocket wheel.
2. The connecting piece included in delivery has to be linked with the short piece of chain
always at the side of the chain collector. The load chain has to be linked with this connecting
piece too.
3. Insert the load chain by pressing the down button
4. Remove the short piece of chain and the connecting piece.
5. Fit the single fall hook to the end of the load chain.
6. Lower the load hook to its final position
7. Attach the end* stop to the third chain link.
8. Fit the chain collector.
9. Allow the chain running into the chain collector and lubricate the whole chain length well.
Caution! When changing the load chain and converting to other numbers of falls never allow the
chain to come out of the casing completely, always pull in new chain or a short piece of chain with
the connecting piece. After having mounted the new load chain remove the short piece of chain
and connecting piece.
Let the dead end of the chain go into the chain bag by pressing the up button and using the hoist
motor to prevent knots inside the chain collector.
* End stop
The end stop operates the limit switch during the down movement of the chain and prevents the
chain from running out of the hoist. In the unlikely event of a failed limit switch the end stop
operates as an emergency stop and lets the clutch slide. It is not allowed to use this emergency
stop permanently.
- Seite / Page 71 -
Fitting the load chain – double fall version –
Fitting the load chain for double fall version

1. Insert the load chain as described above.
2. Insert the load chain into the sprocket wheel of the double fall hook with a special wire.
Caution! Ensure that the load chain is not twisted between the chain guide of the hoist and
the double fall hook. This would be dangerous. If it is not possible to fit the load chain
according with figure 12 without being twisted one link has to be cut off.
3. Remove the short piece of chain and the connecting piece.
4. Loosen the screws of the axle suspension.
5. Loosen the two bolts of the chain suspension.
6. Remove the chain suspension.
7. Put the chain - coming out of the double fall hook – into the pocket of the hoist without being
twisted between the double fall hook and the hoist (see drawing above).
8. Insert the chain suspension again.
9. Secure the chain suspension with bolts.
10. Fit the axle suspension and tighten the two screws.
11. Check again that the chain is not twisted at all.
12. Lower the load hook to it’s final position.
13. Attach the end stop to the third chain link of the dead end.
14. Fit the chain collector.
15. Allow the chain to run into the chain bag by pressing the up button and lubricate the chain
well.
- Seite / Page 72 -
Replacing of the load chain, the chain guide and the hold down
If the load chain has to be replaced, the chain guide and the hold down have to be replaced too.
Replacing load chain, chain guide and hold down
For single fall version

Dismantling the worn out chain
1. Remove the chain collector
2. Remove the load hook (four screws M12x60 DIN 912
3. Remove the end stop (two screws M12x60 DIN 912)
4. Fit the connecting piece to the worn chain and connect a short piece of chain
5. Remove the load chain by pressing the button.
6. Remove the load chain by pressing the button until the short piece of chain has completely
run into the hoist.
7. Remove the worn chain.
Replacing the chain guide and holding down
8. Remove the cover of the contactor control (four screws M6x75 DIN 912)
9. Dismantle the shaft of the limit switches as follows:
Remove the two tension pins 5x30
Remove the snap ring and the torsion spring
Remove the shaft of the limit switches
10. Remove the two screws M16x120 DIN 912 of the chain guide in the control compartment of
the hoist.
11. Remove the chain guide. (underside of casing)
12. Remove the hold down (press it out with a screw driver)
13. Insert the new hold down and the new chain guide
The pick up of the two screws M16x120 DIN 912 should not be more than 60 Nm
– insert the screws with new gasket rings
14. Insert the shaft for the limit switches.
15. Assemble the cover of the contactor control compartment.
Replacement of the load chain

16. Hang the connecting piece, include in the delivery, into the inserted chain on the chain box
side and then attach the load chain to be drawn in.
17. Allow the load chain to run into the chain guide by pressing the down button.
18. Remove the connecting piece and the short piece of chain.
- Seite / Page 73 -
19. Attach the single fall hook to the load chain.
20. Lower the load hook to the lowest position.
21. Attach the end stop to the third chain link.
22. Mount the chain of the dead end.
23. Let the dead end of chain run into the chain box by pressing the up button and using the
hoist motor to prevent knots inside the chain box.
Caution! If the chain has for any reason been completely removed from the hoist and the short
piece of chain is inserted, the clutch setting has be down rated to a minimum before a new chain
can be inserted. Please follow this advice to prevent serious damages to the hoist in the case that
the first chain link does not meet the pocket of the sprocket wheel.
Double fall operation
Removing the worn load chain
1. Remove the chain box.
2. Remove the two screws M6x20 DIN 912 and the axle suspension; remove the chain
suspension and second chain fall from the pocket, remove the double fall hook
3. Remove the end stop by removing its two screws M12x60 DIN 912
4. Hang the connecting piece and the short piece of chain into the worn load chain and insert
them by pressing a button.
5. Remove the worn load chain from the connecting piece
Replacement of chain guide and hold down
6. Remove the cover of the contactor control (four screws M6x75 DIN 912)
7. Dismantle the shaft of the limit switches as follows:
Remove the two tension pins 5x30
Remove the snap ring and the torsion spring
Remove the shaft of the limit switches
8. Remove the two screws M16x120 DIN 912 of the chain guide in the control compartment of
the hoist.
9. Remove the chain guide. (underside of casing)
10. Remove the hold down (press it out with a screw driver
11. Insert the new hold down and the new chain guide. The pick up of the two screws M16x120
DIN 912 should not be more than 60 Nm.
– insert the screws with new gasket rings
12. Insert the shaft for the limit switches
13. Assemble the cover of the contactor control compartment.
Replacement of the load chain
14. Hang the connecting piece, include in the delivery, into the inserted chain on the chain box
side and then attach the load chain to be drawn in.
15. Allow the load chain running into the chain guide by pressing the down button.
16. Remove the connecting piece and the short piece of chain.
17. Attach the double fall hook to the load chain.
Caution! Never allow the chain to be twisted between the chain outlet and the hook block!
If the assembly according with figure “Fitting the load chain for double fall version “is not
possible, one chain link has to be cut and removed to allow correct assembly.
18. Pull the chain out of the hook block and attach the first link horizontally into the double fall
suspension pocket.
19. Lock the chain with the suspension bracket and secure it with the bolt.
20. Check again that the chain is not twisted.
21. Secure the axle suspension with the cylindrical screws.
22. Lower the load hook to the lowest position.
23. Attach the end stop to the third chain link.
24. Mount the chain of the dead end.
- Seite / Page 74 -
25. Let the dead end of chain run into the chain box by pressing the up button and using the
hoist motor to prevent knots inside the chain box.
Caution! If the chain has been completely removed from the hoist from any reason and short piece
of chain has inserted the clutch setting has be down-rated to a minimum before a new chain can
be inserted. Please follow this advice to prevent serious damage to the hoist in the case that the
first chain link does not meet the pocket of the sprocket wheel.
- Seite / Page 75 -
Electrical Connection
The connection work has to be done in accordance with the relevant national regulations.
After having completed the installation carry out the tests according to sections 20.2 and 20.3 of
DIN EN 60 204-1 (Europe).
Details on the control can be seen in the wiring diagram. The electric installation complies with the
currently valid DIN VDE 0100, section 726 and DIN EN 60204-32 (Europe).
Mains connection
The mains current supply (main incoming line conductor) must be disconnected at all poles (in
emergency cases) by means of a mains switch (in accordance with EN 60 204-1).
Work on the electric installation may only be carried out by trained specialists and equipment must
first be disconnected from the current supply.
Check if the mains voltage agrees with that specified on the rating plate.
Connect mains current supply lines and control line in accordance with wiring diagram.
The terminals for L1, L2, L3 and neutral for mains power supply lines are located in the control box.
A cable with three cores + neutral (min. 1,5 mm²) is required for mains current supply lines.
After connecting, press button for lift. If the load moves downwards, interchange the L1 and L3
supply cores. (disconnect mains supply before!).
Electric limit switch for lift limitation
The hoist comes with electric limits for the highest and lowest hook position (figure 14 and 16).
Please make sure during first operation that the lifting direction shown on the pendant control
agrees to the real hoist movements as this is absolutely necessary for the safe operation of the
limit switches.
Electric limit switches

Tests
The use of the electric chain hoist is possible in accordance with accident prevention regulations
for
 Windlasses, lifting and pulling equipment VBG 8
 Cranes VBG 9 (German regulations)
Test when used according to VBG 8, section 23
The equipment must be tested by a trained specialist before starting operation for the first time and
after extensive alterations.
Test when used according to VBG 9, section 25
- Seite / Page 76 -
The cranes must be tested by an expert before starting operation for the first time and after
extensive alterations.
The electric chain hoists are type tested.
Regular tests
The equipment, cranes and supporting structures must be tested by a trained specialist once a
year. It may be necessary to carry out tests more often if the operating conditions are very
demanding, that means for example high percentage of use with full load, dusty or aggressive
environment, high duty rate, high number of operation cycles. If carried out this regular test the
remaining period of operation has to be calculated and recorded (for Germany only)
Only experts appointed by the trade associations and experts from the Technical Control
Association are considered qualified to test cranes.
Trained specialists are highly-qualified specialist personnel or the manufacturer’s after-sales
assemblers.
Operation
 The load may only then be moved if it is slung securely and no person is standing near
enough to be at risk and when the operator has received an all clear signal from the person
slinging the load (VBG 8, section 29.1, paragraph 1).
 The load must be placed vertically under the electric hoist before lifting.
 The motion directions are indicated with symbols on the control buttons.
 Do not turn the chain over edges.
 Consult the manufacturer or supplier, if the hoist is to be used in aggressive environment (for
instance acid or alkaline or dusty environment or to transport inflammable or other dangerous
loads).
 Don’t lower the double fall hook if the chain gets slack.
 Repair work has to be done only if mains supply is switched off and no load is suspended on
the hook.
 After switching off the emergency stop the reason for this failure has to be found out by
trained people and the hoist can only be used if all possible failures are removed.
 Lifting the load from the ground has to be done with the lowest possible speed. Before doing
this slack sling chains or ropes have to be tightened carefully.
 Don’t touch the chain near the lifting gear if in operation.
Prohibitions on Use
Inching mode
 Permanent run against the rubber washers of the lowest and highest hook position or
lifting loads with bigger weight as marked on the specification plate
 Transporting people
 Using the hoist with people being underneath the load
 Starting initial operation before an expert or a trained specialist has inspected the equipment.
 Moving loads heavier than the nominal load.
 Pulling loads which are tilted or dragging loads.
 Tearing off loads.
 Removing the cover of vessels under vacuum.
 Carrying out repairs without disconnecting the current supply and without special knowledge.
 Using the lifting chain to sling the loads.
 Using the lifting chain longer than that stated under the chain bag.
 Using the hoist with higher duty rate as marked on the specification plate.
 Using the hoist without having done the regular inspection.
Maintenance
 All maintenance work must be carried out by trained specialists
- Seite / Page 77 -
 The maintenance table 1 lists the parts and functions to be tested and the necessary
maintenance work. Defects must be rectified immediately by a trained specialist
 Maintenance work may only be carried out if the electric chain hoist is not loaded and the
mains is switched off so that the current supply is disconnected
 Shorten the periods between maintenance work in very demanding operating conditions, e.g.
multi-shift operation, high number of switching actuation, poor environmental conditions
Checking for Wear
 Check suspension hook and load hook for deformation (measure grain spacing) and cracks
 The chain sprocket in the hook block must be replaced if the running surface is worn by
about 1 mm
 Check the load chain
- Seite / Page 78 -
Maintenance and checks in accordance with maintenance table
If the hoist is working hard (two or three shifts, high percentage of work with nominal load, dusty or
high temperature environment) this maintenance work has to be done more frequently.
check
daily 3 month yearly
Visual inspection of the whole equipment X
Function check of the brake X
of the lift limiter X
Maintenance or adjustment of the brake X
of the clutch X
Wear of the load chain X
Lubrication of the load chain X
Lubrication of single and double fall hooks, pressure bearing X
and wheel bearings check condition of safety latch and of the
pins which prevent the hook nut from loosening
Universal checks of all screws X
hold down X
chain guide X
Check of the condition and safe positioning of the chain bag X
Check of the electrical cable, power cable and pendant control X
Table 1
The electric chain hoist is designed in accordance with FEM 9.511. If the hoist is used under the
conditions of FEM 9.511, including the described frequency of maintenance work, the electric chain
hoist must be overhauled after 10 years.
Maintenance and adjustment of the D.C. disk brake
The D.C. disk brake needs very little maintenance.
Construction of the brake
Construction of the brake
- Seite / Page 79 -
Explanation by function
The anchor plate (2) is axially moveable and is pressed by the brake pressure springs (4) to the
brake linings (7), the brake disc (9) and the basic plate (6) and provides the brake torque by that
way.
The brake linings (7) are vulcanized on the brake disc (9) which is positively counted by the
coupling sleeve (11) (by key grooves) with the motor pinion shaft (10).
Between anchor plate (2) and anchor plate (2) and magnetic coil (1) has to be an air gap of 0,4
mm.
If the magnetic coil gets a D.C. power it will establish a magnetic field and pulls the anchor plate
towards the coil. Now the brake is released and the hoist is ready to lift or lower the load. If the
D.C. power is cut off, the anchor plate moves back caused by force of the pressure springs, the
brake is closed and the load securely stopped
Adjusting the brake
(see sketch: Construction of the brake)
The air gap between anchor plate (2) and magnetic coil (1) has to be checked. It is set to 0,4 mm
during production. After many lift operations this air gap may increase caused by wear of the brake
linings. If it is about 0,7 mm the brake has to be readjusted as follows:
1. Disconnect the hoist from mains supply
2. Remove the fan cap after loosening the screws
3. Pull the dust protection ring (16) out of the groove in the magnetic coil and pull it over the
basic plate (6) to get access to the brake disc
4. Remove the dust by using compressed air
5. Check the thickness of the brake disc (9) with the vulcanized linings (7). If it is less than 9,5
mm the whole brake disc has to be replaced
6. Loosen the screws (14) approximately a half turn (After about two adjustment procedures
these screws have to be replaced)
7. Tighten the hollow screws (5) approximately 1 mm towards the magnetic coil (1)
8. Tighten the screws (14) as much as an air gap of 0,4 mm between anchor plate (2) and
magnetic coil (1) is reached (use a thickness gauge to check)
9. Turn the hollow screws (5) out of the magnetic coil until they press against the basic plate (6)
again
10. Tighten the screws (14) again equally
11. Double check the air gap again by using a thickness gauge
Make sure that the air gap has the same size all around the brake
12. If necessary readjust the air gap again
13. Use a torque wrench to tighten the screws (14) with 10 Nm
14. Refit the O- ring (15) and the dust protection ring (16) to the groove between magnetic coil
and brake disc
15. Connect the cable with the plug
16. Mount the fan cap
17. Connect mains supply again
18. Check for proper operation
If stopping the lowering movement with nominal load there should be a slide of not more than two
chain links. The load should not stop immediately to avoid any impact stress.
Electric control of brake / Sliding clutch
Mode of functioning
The disc brake is supplied through a rectifier circuit. It operates according to the fail safe principle.
If there is a power failure, the brake acts automatically so that the load is held securely in every
position. To shorten the braking distance the brake is operated in a D.C. circuit.
- Seite / Page 80 -
Sliding clutch
The sliding clutch is located between the motor and the brake so that the power from the brake to
the load is transmitted by gear parts in form-fitting connection. Even if the clutch is seriously worn,
the load will not fall uncontrolled as the load can be held in every position by the brake. The sliding
clutch operates as a dry clutch. The difference between the static and the sliding friction
coefficients of the asbestos-free lining is so slight that it has no effect on the functional reliability.
The sliding clutch is an emergency stop and it is not allowed to use it permanently.
Therefore the hoist is equipped with limit switches for lifting and lowering as standard.
Construction of the sliding clutch
Construction of the sliding clutch

The sliding clutch from two clutch hubs (17) which are connected with the motor shaft by
one feather key at each side, the clutch linings (18), two clutch discs (19) with two
cylindrical bolts (20) with connect the rotor (12) with the clutch discs (19). The compressor
(23), the pressure bolt (24) with O- ring (25), the compressor 2 (23), the pressure bush (26),
the pressure spring (27), the fan (28) and the lock nut (29) are located on the motor shaft.
Adjustment of the sliding clutch

If the load is measured with a compression spring tool the load value reading for setting the clutch
is up to 30% higher.
1. Loosen the lock nut (29)
2. Compress the clutch spring sensitively by tightening the threaded bush with the fan (28) until
the load is just lifted.
If turning the bush clockwise the clutch torque will increased
If turning the bush counterclockwise the clutch torque will decrease.
3. Lock the threaded bush using the lock nut (29) after having completed the adjustment.
4. Test the clutch setting once more by raising the nominal load to the uppermost load position
and letting clutch slip. The clutch should not slip for longer than 2 - 3 seconds.
Load chain
Hoist chains are means of carrying which require official approval. It is, therefore, important to
observe the guidelines issued by the trade association’s centre for accident prevention with regard
to round steel chains in hoisting operation, the guidelines for general inspection and test
specifications in accordance with DIN 685, section 5, Nov 1981, the accident prevention
- Seite / Page 81 -
regulations in VBG 8 of April 1980/1990 and in VBG 9 of December 1979 / April 1983 or equivalent
regulations in the country in question.
Lubricating the load chain before starting and during operation

The links along the entire length of the load chain must be lubricated with a penetrating gear
lubricant oil before starting operation for the first time and during unloaded operation. Subsequent
lubrication, whereby the links must be cleaned first, depends on the degree of use and the
operating conditions.
A dry-film lubricant, e.g. lubricating varnish, graphite powder, should be used when ambient
influences are conducive to wear (sand, emery).
Testing wear in the load chain

The continuous monitoring of the load chain is compulsory according to DIN 685 section 5 and the
accident prevention regulations in VBG 8 section 27. The load chain must be tested before starting
operation and after approx. 200 operating hours or 10,000 load cycles under normal conditions or
more often under demanding and severe conditions.
Testing must cover checking links, particularly at their points of contact, for wear, cracks,
deformation and other damages.
The chain must be replaced:
 if the nominal thickness at the points of contact is reduced by 10%,
 if the chain or a link is elongated by 5 %, or an eleven links piece of chain is elongated by 2%
 if the links are rigid
The chain guide and hold-down must also be replaced with the chain.
Caution! Replacement of chain can only be filled if obtained from the manufacturer or his
approved service agent.
Measuring wear and replacing chain
Measuring wear and replacing chain

Duty rate of an electric chain hoist
The duty rate and the number of operating
cycles in one hour must not be higher than as on
the specification plate of the hoist or in a
technical data table.
(European regulation FEM 9.682)
The duty rate, expressed as the cyclic duration
factor (c.d.f.) is the ration of
running time to running time + period of rest
Formula 2:
The duty rate is limited by the permissible degree of heat in the lifting motor. The running time is
dependent on the necessary lifting height, lifting speed of the electric chain hoist and the number
- Seite / Page 82 -
of lifting motions required for a particular transport procedure (unloading trucks, feeding machines).
It is difficult in practice to take note of the duty rate during the lifting operation. We, therefore, give
the following practical guidelines:
Short- time duty

Permissible operating period without cooling interval when operation starts and with a motor
temperature of approx. 20° C.
c.d.f. driving gear group operating period
[duty rate %] DIN 5684 part 3 [min]
25 % 1 Bm 20
This duty type is not permissible for the slower speed of precision hoisting motors. After having
reached the maximum running time a break is required and the hoist can be continued to be used
in intermittent duty mode.
Intermittent duty
Operation must be interrupted whenever the highest permissible operating time is reached.
The following breaks are necessary depending on the c.d.f. of the hoist::
c.d.f. break [min]
[duty rate %]
25% 3 times running time
- Seite / Page 83 -
Rectifier control of hoist motor
The hoist motor (M21..) is equipped with a control function of the brake rectifier. This means:
When the operator activates the - hoist up slow or fast - function via the control pendant, the
operating voltage (Uo) is switched on to the winding of the motor. At the same time, the output
voltage (Uv_out) of the rectifier is measured.
If it is not measured within 1 sec, the hoist upward motion is blocked (refer to “MALFUNCTION”).
Power supply (Uo) Brake power supply (Uv_out)

400VAC 50/60Hz ~180VDC
440VAC 50/60Hz ~205VDC
690VAC 50/60Hz ~180VDC
In the case of a malfunction of the rectifier, the hoist motor drives briefly against the blocked brake,
before the upward hoist motion is brought to a halt. However, this has no effect either on the
functionality or the durability of the brake.
In the case of malfunction the rectifier should be exchanged immediately!
Malfunction:
1
PB Hoist up
slow or fast
0
(Uv_out)
0VDC
440VAC
(Uo)
0VAC
~1s
PB= Push button
- Seite / Page 84 -
Emergency Procedure
The hoist motion -downward slow or fast- is independent of the control function, so that the hook
can be lowered at any time.
Attention:
If the rectifier fails, the load may only be lowered in steps of 1m with at least 20sec pause in
between, in order to avoid an overheating of the brake coil or melting of the brake lining.
1
PB Hoist down
slow or fast
0
(Uv_out)
0VDC
440VAC
(Uo)
0VAC
~1m
~1m ~1m
~20s ~20s
PB= Push button
- Seite / Page 85 -
Example
The electric chain hoist type 6300/1-5,6/1,4 is to lift loads of 6300 kg to a height of 3 m.
Performance data:
Carrying load 6300 kg
Lifting speed 5,6 m/min – main speed
1,4 m/min – slow speed
Uninterrupted duty 25 % – main speed
10 % – slow speed
On starting the work of unloading the vehicle, the electric chain hoist has a cold temperature of
approx. 20 °C.
3m lifting + 3m lowering
Running time = -------------------------------------- = 1 min, 4 sec
5,6m (lifting speed)
Approx. 20 minutes operation without break is possible. This covers 18 lifting cycles x 6300 kg
carrying load = 113.400 kg goods can be transported.
After 20 minutes of running time, 3 minutes break for each minute of operating time must be taken
(i.e. 3 times the operating time). This break is usually necessary for slinging and taking off loads.
Caution! Cooling periods are imperative for extreme lifting heights (from 10 meters on). Precision
lifting should only be used for precise lowering and lifting. It is not suitable when greater lifting
heights are involved.
Option! To protect the lifting motor a thermal overload device is offered as an option.
Lubrication
Gear lubrication
The gear is filled with two liters of oil by the manufacturer. If the oil is drained it has to be disposed
in accordance with the laws of environmental protection. The oil has to be changed only if the hoist
is going to be overhauled. If the oil has to be changed, use oil for a temperature range of -20°
to+40°C and viscosity of 220 mm²/s at 40°C.
Lubrication of the hook block and hook tackle
Lubricate the anti-friction bearings on the hook and the chain sprocket after approx. 20,000 lifting
cycles or a year, if in heavy use shorten the interval, use a special anti- friction bearing grease.
Disposal
After the hoist or its components are taken finally out of operation the parts have to be disposed in
accordance to the laws of environment protection.
Metals, rubber, plastics have to be disposed or recycled separately.
ATTENTION
The advice contained within this manual should only be implemented by the appropriate
skilled and qualified operators of industrial hoists.
Further information for other fields of operation are not considered herewith.
If changes to the normal operations are discovered (such as unusual noise, vibrations,
higher input current or frequently blowing fuses) the hoist should be taken out of operation
and the load area has to be isolated because a fault is possible and could result in danger
to people or goods.
The operator or owner of the hoist has to call a trained specialist to repair the hoist.
- Seite / Page 86 -
RECTIFIER CONTROL OF HOIST MOTOR
The hoist motor (M21..) is equipped with a control function of the brake rectifier. This means:
When the operator activates the - hoist up slow or fast - function via the control pendant, the
operating voltage (Uo) is switched on to the winding of the motor. At the same time, the output
voltage (Uv_out) of the rectifier is measured.
If it is not measured within 1 sec, the hoist upward motion is blocked (refer to “MALFUNCTION”).
Power supply (Uo) Brake power supply (Uv_out)

400VAC 50/60Hz ~180VDC
440VAC 50/60Hz ~205VDC
690VAC 50/60Hz ~180VDC
In the case of a malfunction of the rectifier, the hoist motor drives briefly against the blocked brake,
before the upward hoist motion is brought to a halt. However, this has no effect either on the
functionality or the durability of the brake.
In the case of malfunction the rectifier should be exchanged immediately!
MALFUNCTION:
1
PB Hoist up
slow or fast
0
(Uv_out)
0VDC
440VAC
(Uo)
0VAC
~1s
PB= Push button
- Seite / Page 87 -
Emergency Procedure
The hoist motion -downward slow or fast- is independent of the control function, so that the hook
can be lowered at any time.
Attention:
If the rectifier fails, the load may only be lowered in steps of 1m with at least 20sec pause in
between, in order to avoid an overheating of the brake coil or melting of the brake lining.
1
PB Hoist down
slow or fast
0
(Uv_out)
0VDC
440VAC
(Uo)
0VAC
~1m
~1m ~1m
~20s ~20s
PB= Push button
- Seite / Page 88 -
Example
The electric chain hoist type 6300/1-5,6/1,4 is to lift loads of 6300 kg to a height of 3 m.
Performance data: Carrying load 6300 kg
Lifting speed 5,6 m/min – main speed 1,4 m/min – slow speed
Uninterrupted duty 25 % – main speed 10 % –
slow speed
On starting the work of unloading the vehicle, the electric chain hoist has a cold temperature of
approx. 20 °C.
3m lifting + 3m lowering
Running time -------------------------------- = 1 min, 4 sec
= ------
5,6m (lifting speed)
Approx. 20 minutes operation without break is possible. This covers 18 lifting cycles x 6300 kg
carrying load = 113.400 kg goods can be transported.
After 20 minutes of running time, 3 minutes break for each minute of operating time must be taken
(i.e. 3 times the operating time). This break is usually necessary for slinging and taking off loads.
Caution! Cooling periods are imperative for extreme lifting heights (from 10 meters on). Precision
lifting should only be used for precise lowering and lifting. It is not suitable when greater lifting
heights are involved.
Option! To protect the lifting motor a thermal overload device is offered as an option.
Lubrication
Gear lubrication
The gear is filled with two liters of oil by the manufacturer. If the oil is drained it has to be disposed
in accordance with the laws of environmental protection. The oil has to be changed only if the hoist
is going to be overhauled. If the oil has to be changed, use oil for a temperature range of -20°
to+40°C and viscosity of 220 mm²/s at 40°C.
Lubrication of the hook block and hook tackle
Lubricate the anti-friction bearings on the hook and the chain sprocket after approx. 20,000 lifting
cycles or a year, if in heavy use shorten the interval, use a special anti- friction bearing grease.
Disposal
After the hoist or its components are taken finally out of operation the parts have to be disposed in
accordance to the laws of environment protection.
Metals, rubber, plastics have to be disposed or recycled separately.
ATTENTION
The advice contained within this manual should only be implemented by the appropriate
skilled and qualified operators of industrial hoists.
Further information for other fields of operation are not considered herewith.
If changes to the normal operations are discovered (such as unusual noise, vibrations,
higher input current or frequently blowing fuses) the hoist should be taken out of operation
and the load area has to be isolated because a fault is possible and could result in danger
to people or goods.
The operator or owner of the hoist has to call a trained specialist to repair the hoist.
- Seite / Page 89 -
APPENDIX
A3 Drawings
Circuit diagrams
Certificates
- Seite / Page 90 -

01 - Operating Instructions

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01 - Operating Instructions

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Shipyard: Daewoo Mangalia Heavy

Pos. Menge Description

1 pc rectifier - one of each type

 Hoist: after sandblasting and primer one coat of synthetic enamel

Type: .......................................... ED-A 125-7.505 EKZ

Capacity: .................................... 12500 kg

Hoisting speed: ........................... approx. 3,4 / 0,8 m/min

Travelling distance (crane): ........ approx. 24,0m – 1,24m = 22,76m

Runway (by yard): ...................... 400 x 150 x 12.5 / 25

Protection mode of motor: .......... IP 54

Crane with working platform according to encl. sketch.

Crane rail is supplied by: FUCHS Fördertechnik / Customer

Change of design reserved

Tel.: +49 40 7100100

Hand control pendant

Fax: +49 40 71001099

Tel.: +49 40 7100100

Tel . : 0 40- 71 00 100 Fa x: 0 40 -7 100 10 99 04.09.1410-2

Fax: +49 40 71001099

Tel.: +49 40 7100100

Sect ional drawing

Fax: +49 40 71001099

Size Load (kN) a1 a2 a3 b1 b2 d1 e1 e2 e3 f1 f2 f3

ATTENTION: Due to the safety ledge the dimension a2 will be

Freimaßtoleranz Werkstoff Auftrag-Nr.

Limit Switch TV7H 335 01/01z

Freimaßtoleranz Werkstoff Auftrag-Nr.

4 Vervielfältigung und Mitteilung an Dritte ist unzulässig. Für diese Zeichnung

Junction Box K9065

Freimaßtoleranz Werk s toff Auftrag-Nr.

Tel.: 040-7100100 Fax: 040-71001099

Drawing Hand Control Pendant

Drive groups DIN..15 1 Dm 1Cm 1 Bm 1Am 2m 3m 4m 5m

Line Load populations /

2 Medium 2 / L2 400 800 1600 3200 6300 12500 25000 50000

3 Heavy 3 / L3 200 400 800 1600 3200 6300 12500 25000

Record of Operating Performance

Assessment of the Safe Working Period (S.W.P.)

Measures when the Theoretical Service Life D is Reached

p i ct ure 1 el ec t ro w el di ng o n c rane bri dg e

TESTING OF CRANES AND HOISTS WITH TEST LOAD

Motor and Pinion Travelling

Mounting Instruction of Toothed Rack

Material of the toothed rack: C45k

/ FUCHS; box 2. BP Energol GR-XP 220 commissioning and

Tel.: +49 40 7100100

In case of doubt disconnect the machine!

Do not mix synthetic lubricant with mineral lubricant!

Note: Synthetic and mineral lubricants must not be mixed.

Adjustment of the Braking Torque

t MB [Nn] 5 10 20 40 60 100 150 250 400 800

P 20 [W] 22 28 39 42 50 64 76 100 140 140

Fig.1: Clearance adjustment Fig.2: Driver Installation Fig.3:Hand release attachment

Tel.: +49 40 7100100

Fax: +49 40 71001099

Illustration: Rail mounting with support arms

Ideal control unit Up to 63 1,10 1,15 1,20 1,25

Table: Length addition

Illustration: Examples for the arrangement of cable packets

Energy Supply With Flat Cables

Illustration.. Assembled energy supply with flat cables

Special Steps During Assembly