Setting switching points for backup limiter and top hoist limiter

The wire rope hoist has a gear limit switch with three switching points.

The switching points for the top hoist limiter and the backup limiter placed above it are set and sealed at the factory.

If required, (e.g. if the load hook cannot be run right up to the top due to a crosshead), after changing the wire rope or after repairs, the switching point for the top hoist limiter may need to be reset.

Determining switching points

Backup limiter switching point C1

Hook headroom (dimension C)	Top hoist limiter switching point C2

─ The hook headroom (dimension C) is principally the highest position that the load hook may travel to without damaging the wire rope. A certain safety buffer is factored into this.

─ The hook headroom (dimension C) is always the distance between the lower edge of the wheel on the wire rope hoist and the inner edge of the load hook.

─ The hook headroom (dimension C) always refers to a standard series load hook. In the case of larger or smaller load hooks, see the wire rope data sheet for details of the hook headroom.

─ The switching point for the backup limiter is designated as C1 and lies slightly above the hook headroom. This is the absolute uppermost position up to which the load hook may move without damaging the wire rope.

─ The switching point for the top hoist limiter is designated as C2 and lies slightly below the hook headroom.

─ Both switching points (C1 and C2) each have two additional reference edges: A1 and A2 (distance between the lower edge of the wheel on the wire rope hoist and the axis of the deflection rollers on the bottom block) as well as B1 and B2 (distance between the lower edge of the wheel on the wire rope hoist and the upper edge of the bottom block). These additional dimensions can be used as an alternative to the hook headroom and can make measuring easier. They are also independent of the load hook size and can thus be used with smaller or larger load hooks.

Warnung stürzende Last

Danger due to a suspended load falling!

In certain situations it can be necessary to enlarge the hook headroom to enable the load hook to brake more quickly (e.g. so that a crosshead cannot crash under the main girder or lifting tackle on the main girder are not broken open).

Always carry out and heed a hazard analysis on site!

Select the appropriate reference edge on the wire rope hoist and on the bottom block from the following drawing.

Read the dimensions C1 and C2, or alternatively A1 and A2 or B1 and B2, from the following table.

Reference edges on the wire rope hoist according to type:

Reference edge for dimensions A, B and C on wire rope hoist E.

Reference edge for dimensions A, B and C on wire rope hoist S.

Reference edge for dimensions A, B and C on wire rope hoist U.

Reference edge for dimensions A, B and C on wire rope hoist D.

Reference edge for dimensions A, B and C on wire rope hoist DA.

Reference edge for dimensions A, B and C on wire rope hoist DQA.

Reference edge for dimensions A, B and C on wire rope hoist Z.

Reference edges on the bottom block:

Hook headroom	Backup limiter switching point

Bottom hoist limiter switching point	Top hoist limiter switching point

Fundamentally:

─ 146 rotations of the adjusting screw completely rotate the control cam on the gear limit switch 360° once.

─ How many millimetres of hook path correspond to one rotation of the adjusting screw is specified in the following table.

─ Rotating the adjusting screw to the right moves the switching point downwards, rotating the adjusting screw to the left moves the switching point upwards.

─ How many millimetres of hook path the load hook travels in the dead range of the Microswitch (switching hysteresis) is specified in the following table.

					Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Track gauge [mm]	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
E	800	4/1	Up to 300	400	165	70	380	215	120	430	55	71
E	1000 *	2/1	Up to 300	567	210	105	525	310	205	625	120	154
E	1000 *	4/1	Up to 300	500	230	125	480	279	175	530	60	77
E	2000	2/1	Up to 300	580	180	70	540	280	170	640	130	172
E	2000	4/1	Up to 300	500	195	80	480	245	130	530	65	86
E	3000	2/1	Up to 300	664	215	70	625	315	170	734	160	214
E	3000	4/1	Up to 300	580	235	90	560	285	140	610	80	107
E	5000	2/1	Up to 350	830	295	110	790	395	210	890	178	238
E	5000	4/1	Up to 350	825	375	190	805	425	240	855	89	119
E	6000	2/1	Up to 350	830	295	110	790	395	210	890	194	260

Table: Hook headroom for wire rope hoists of type E. With larger hoist spans please heed the following!

* The specified values apply for the GM 1000 compact and for the GM 1000 modular. The values are identical for both designs.

Only for E design wire rope hoist with large track gauge

This section only applies to wire rope hoists of the design "E" with a larger track gauge than given in the table above.

Calculating larger hook headroom

The hook headroom has to be enlarged as of a certain track gauge.

Add the additional dimension from the above table to the hook headroom.

Track gauge	Installation size 800 Reeving 4/1	Installation size 1000 Reeving 2/1	Installation size 1000 Reeving 4/1	Installation size 2000 Reeving 2/1	Installation size 2000 Reeving 4/1	Installation size 3000 Reeving 2/1	Installation size 3000 Reeving 4/1	Installation size 5000 Reeving 2/1	Installation size 5000 Reeving 4/1	Installation size 6000 Reeving 2/1
300	0	0	0	0	0	0	0	-	-	-
350	49	39	45	43	53	62	80	0	0	0
400	98	78	89	86	106	124	160	76	74	76
450	146	117	134	129	159	187	240	152	148	152
500	195	156	178	172	212	249	320	228	222	228
550	-	-	-	-	265	311	401	304	296	304
600	-	-	-	-	318	373	481	380	370	380
650	-	-	-	-	371	435	561	456	444	456
700	-	-	-	-	424	498	641	532	518	532

				Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
S	800	4/1	343	335	245	323	385	295	377	55	71
S	1000	4/1	420	420	315	400	470	365	450	60	77
S	2000	4/1	440	405	290	420	455	340	470	65	86
S	3000	2/1	699	520	370	659	620	470	760	160	214
S	3000	4/1	550	540	395	530	590	445	580	80	107

Table: Hook headroom for wire rope hoists of type S

				Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
U	5000	4/1	1132	270	80	1110	320	130	1160	89	119
U	6000	2/1	1256	235	50	1215	335	150	1315	194	260
U	6000	4/1	1241	260	70	1220	310	120	1270	97	130
U	7000	2/1	1615	330	90	1575	430	190	1675	254	342

Table: Hook headroom for wire rope hoists of type U

					Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Track gauge [mm]	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
D	800	4/1		144	170	80	125	220	130	175	55	71
D	1000	4/1		195	190	85	175	240	135	225	60	77
D	2000	2/1		295	160	50	255	260	150	355	130	172
D	2000	4/1		215	175	60	195	225	110	245	65	86
D	3000	2/1		315	190	45	275	290	150	375	160	214
D130	3000	4/1		260	230	85	240	280	134	290	80	107
D160	3000	4/1		260	225	80	240	275	129	290	80	107
D	5000	2/1		440	240	50	400	340	150	500	178	238
D	5000	4/1	160	385	285	100	365	335	150	415	89	119
D	5000	4/1	200	385	305	120		355	170
D	5000	4/2		320	330	220	280	430	320	380	178	238
D	6000	2/1		520	235	50	480	335	150	580	194	260
D	6000	4/1		267	260	73	247	310	123	297	97	130
D	6000	6/1		606	355	168	586	405	218	636	65	87
D	7000	2/1		572	344	103	532	444	203	632	254	342
D	7000	4/1		501	380	139	481	430	189	531	127	171
D	7000	6/1	to 2000	717	520	280	690	570	330	745	85	114
D	7000	6/1	from 2000	897	520	280	875	570	330	925	85	114
D	7000	4/2		236	240	50	195	340	150	295	254	342
D	7000	8/2		516	260	70	495	310	120	545	127	171

Table: Hook headroom for wire rope hoists of type D

				Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
DA	800	4/1	429	170	80	410	220	130	460	55	71
DA	1000	4/1	520	190	85	500	240	135	550	60	77
DA	2000	2/1	621	160	50	580	260	150	681	130	172
DA	2000	4/1	544	175	60	520	225	110	570	65	86
DA	3000	2/1	700	193	45	660	290	145	760	160	214
DA	3000	4/1	620	225	80	600	275	130	650	80	107
DA	5000	2/1	825	240	50	785	340	150	885	178	238
DA	5000	4/1	813	285	100	795	335	150	845	89	119
DA160	6000	2/1	949	235	50	910	335	150	1010	194	260
DA200	6000	4/1	470	260	70	450	310	120	500	97	130
DA280	6000	4/1	832	260	70	810	310	120	860	97	130
DA280	6000	6/1	1068	352	165	1050	400	215	1100	65	87
DA200	7000	2/1	1284	345	105	1245	445	205	1345	254	342
DA	7000	4/1	913	375	135	895	425	185	943	127	171
DA	7000	6/1	1370	515	275	1350	565	325	1400	85	114

Table: Hook headroom for wire rope hoists of type DA

				Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
DQA	2000	2/1	525	125	10	485	225	110	585	130	172
DQA	2000	4/1	445	140	30	425	190	80	475	65	86
DQA	3000	2/1	639	190	40	600	290	140	700	160	214
DQA	3000	4/1	555	210	65	535	260	115	585	80	107
DQA	5000	2/1	810	275	90	770	375	190	870	178	238
DQA	5000	4/1	712	265	75	690	315	125	740	89	119
DQA	6000	2/1	870	335	150	830	435	250	930	194	260
DQA	6000	4/1	745	250	60	725	300	110	775	97	130
DQA350	7000	4/1	970	375	135	950	425	185	1000	127	171

Table: Hook headroom for wire rope hoists of type DQA

					Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Track gauge [mm]	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Z	5000	4/2		413	490	300	375	590	400	475	178	238
Z	5000	8/2		631	505	315	610	555	365	660	89	119
Z	6000	4/2		414	485	300	375	585	400	475	194	260
Z280	6000	8/2		638	450	310	620	550	360	670	97	130
Z350	6000	8/2		643	450	260	625	500	310	675	97	130
Z	7000	4/2		668	525	285	630	625	385	730	254	342
Z	7000	6/2	to 2000	717	522	281	697	572	331	747	170	228
Z	7000	6/2	from 2000	897	522	281	877	572	331	927	170	228
Z	7000	8/2		915	525	284	895	575	334	945	127	171
Z	7000	10/2		960	482	241	940	532	291	990	102	137
Z	7000	12/2		1378	761	482	1358	811	532	1408	85	114

Table: Hook headroom for wire rope hoists of type Z

				Backup limiter switching point			Top hoist limiter switching point			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
ZA	5000	8/2	1195	495	305	1175	545	355	1225	89	119
ZA280	6000	8/2	1253	495	305	1235	545	355	1285	97	130
ZA350	6000	8/2	1163	445	255	1145	495	305	1195	97	130
ZA	7000	6/2	1370	515	275	1350	565	325	1400	170	228
ZA	7000	8/2	1430	515	275	1410	565	325	1460	127	171
ZA	7000	10/2	1312	480	240	1290	530	290	1340	102	137

Table: Hook headroom for wire rope hoists of type ZA

Travelling to the backup limiter switching point

The backup limiter switching point may only be adjusted by a qualified person for service purposes.

	Dimensions A1, B1, C1

Bridge top hoist limiter manually, so that the backup limiter can be travelled to.

Raise the load hook up to dimension A1, B1 or C1.

Only with gear limit switch "GGS"

Detaching seals

	Seals

Open the housing cover of the electrical system housing on the cable drum.

Press the seals apart in the centre with a screwdriver and remove them.

Setting backup limiter

The backup limiter is set with the right adjusting screw.

White pointer of cam ring	Orange pointer

	Left adjusting screw

Remove the adjusting key. It is fastened on two mounts on the gear limit switch.

Alternatively, a hexagon wrench key size 3.0 (ideally with rotary plate) can be used.

An electrically operated screwdriver may NOT be used.

Press the adjusting key into the adjusting screw. Press it into the adjusting screw with light pressure.

If necessary: Turn the adjusting screw until the white pointer of the cam ring lies to the left of the orange pointer. It should be neither to the right of the orange pointer nor exactly on it.

The middle white arrow shows the exact position of the switching point; the two white arrows to the left and right of it indicate the start and end of the switching phase (switching hysteresis).

If necessary: Turn the adjusting screw until the white pointer of the cam ring rotates clockwise. Continue turning until the white pointer lies exactly on the orange pointer and a clicking sound is audible.

─ Turning to the right shifts the switching point downward.

─ Turning to the left shifts the switching point upward.

● The switching point for the backup limiter is now set.

ABUControl switches off the main conductor of the crane at this switching point. This switching point is only activated if the top hoist limiter has not switched (e.g. because it is faulty).

Turn the adjusting screw three-quarters of a turn to the left.

● The microswitch switches again; the main contactor switches back on.

Lower the load hook slightly.

Turn the adjusting screw three-quarters of a turn back to the right.

Travelling to the switching point of the top hoist limiter


	Dimensions A2, B2, C2

Move the load hook up to dimension A2, B2 or C2.

Setting top hoist limiter

The top hoist limiter is set with the middle adjusting screw.

White pointer of cam ring	Orange pointer

	Middle adjusting screw

Remove the adjusting key. It is fastened on two mounts on the gear limit switch.

Alternatively, a hexagon wrench key size 3.0 (ideally with rotary plate) can be used.

An electrically operated screwdriver may NOT be used.

Press the adjusting key into the adjusting screw. Press it into the adjusting screw with light pressure.

If necessary: Turn the adjusting screw until the white pointer of the cam ring lies to the left of the orange pointer. It should be neither to the right of the orange pointer nor exactly on it.

The middle white arrow shows the exact position of the switching point; the two white arrows to the left and right of it indicate the start and end of the switching phase (switching hysteresis).

─ Turning to the right shifts the switching point downward.

─ Turning to the left shifts the switching point upward.

● The switching point for the highest hook position is now set.

At this switching point the load hook stops during normal operation after it has previously braked. The braking distance is automatically determined by ABUControl in the next step.

Only with "Kübler" gear limit switch

Setting backup limiter

The backup limiter is set with the backmost adjusting screw.

Control cam		Microswitch

Adjusting screw

If necessary: Turn the adjusting screw until the control cam is to the left of the Microswitch. It should not be either directly on or to the right of the microswitch.

Turn the adjusting screw to the right until the control cam presses in a clockwise direction against the Microswitch and an audible click is heard.

● ABUControl switches off.

● The switching point for the backup limiter is now set.

ABUControl switches off the main conductor of the crane at this switching point. This switching point is only activated if the top hoist limiter has not switched (e.g. because it is faulty).


Adjusting screw

Turn the adjusting screw three-quarters of a turn to the left.

● The Microswitch switches again, ABUControl switches on again.

Lower the load hook slightly.

Turn the adjusting screw three-quarters of a turn back to the right.

Travelling to the switching point of the top hoist limiter


	Dimensions A2, B2, C2

Move the load hook up to dimension A2, B2 or C2.

Setting top hoist limiter

The top hoist limiter is set with the adjusting screw second from the back.

Adjusting screw

Control cam	Microswitch

If necessary: Turn the adjusting screw until the control cam is to the left of the Microswitch. It should not be either directly on or to the right of the microswitch.

Turn the adjusting screw to the right until the control cam presses in a clockwise direction against the Microswitch and an audible click is heard.

● The switching point for the highest hook position is now set. At this switching point the load hook stops during normal operation after it has previously braked. The braking distance is automatically determined by ABUControl in the next step.

Determining braking distance

In normal operation, the load hook brakes at a slow lifting speed before it stops at the highest hook position.

The braking distance is also determined automatically by ABUControl.

Raise the load hook without load a few metres downwards.

Lower the load hook with fast lifting speed upwards.

● At the highest hook position, the load hook halts.

Depending on how the switching point was changed, it may be that the load hook with fast lifting speed moves to the switching point and then suddenly stops there or that the load hook brakes earlier than is necessary and a long stretch moves only at slow lifting speed.

If the load hook has to travel a long way at slow lifting speed, the end position of the brake phase can be changed manually. See Temporarily changing the end position of the brake phase of the hoist drive ‚ [2].

● ABUControl saves the new switching point of the highest hook position automatically and now calculates the necessary braking distance automatically.

During the next travel to the switching point:

● The load hook brakes (depending on the current lifting speed) shortly before the highest hook position at slow lifting speed.

● The load hook only still travels with slow lifting speed immediately before the switching point.

● The load hook stops at the switching point.

Checking the setting

Lower the load hook.

● Lift the load hook at both slow and fast lifting speed and check whether it halts at the correct point.

Only with gear limit switch "GGS"

Sealing the adjusting screws

	Seals

Insert seals (2x) onto the adjusting screws and press them in.