If necessary, the reeving of the wire rope hoist can be changed from four-fall (4/1) to twin-fall reeving (2/1). This may be necessary if the conditions in which the wire rope hoist is used change, or if a new or used wire rope hoist is resold.

The pictures show the procedure on a GM 1000 modular wire rope hoist. The procedure on GM 800 does not differ significantly from this.

Overview of the conversion:

This is an overview of the conversion for changing the reeving on the wire rope hoist. The individual steps are described in detail on the next pages.

Four-fall wire rope hoist before conversion

─     To change to reeving to 2/1, the following new components are required: a new wire rope, new bottom block, and bearing bushes (2x) for the fixed point crosshead.

If rope socket and rope wedge are undamaged, they may be reused. If the components are damaged however, they must be replaced.

─     On the drum side, the fixed point crosshead must be removed and the bearing bushes of the previous fixed point crosshead must be knocked out.

─     Two new bearing bushes for the fixed point crosshead must be driven in on the counterweight side, and the fixed point crosshead must be converted.

─     A new type plate then needs to be affixed.

─     A new test log book is required for the wire rope hoist. This new test log book can be issued by ABUS. See ABUS Service.

─     Before the wire rope hoist is used for operation, a test for major changes must be carried out. See “General Product Manual for ABUS Cranes”.

─     The hoist limit switch must be readjusted.

─     The overload protection must be readjusted.

On the drum side and the counterweight side:

   Remove the SL safety clip of the outer bolt (on both sides) and push the bolt out.

   Hold the deflection roller crosshead / fixed point crosshead and push the inner bolts (on one or both sides) inwards.

   If necessary: Pull the deflection roller crosshead / fixed point crosshead out of side panel bearing bush on the side of the fixed bolt.

●   The deflection roller crosshead or fixed point crosshead is released.

   Remove the deflection roller crosshead/fixed point crosshead from the wire rope hoist from the bottom.

The bearing bushes for the deflection roller crosshead used previously must be driven out on the counterweight side, and two new bearing bushes for the fixed point crosshead must be driven in next to them.

On the side panel for the fixed point crosshead (counterweight side):

   Hold the bearing bush for the fixed point crosshead at the opening (facing the outer side) from the inside.

   Drive the bearing bush (e.g. using a striking tool) into the side panel uniformly.

   Drive out the current bearing bushes (2x) for the deflection roller crosshead used previously.

   Remove the SL safety clip and bolts from the rope socket.

   Remove the rope socket from the fixed point crosshead.

If rope socket and rope wedge are undamaged, they may be reused. If the components are damaged however, they must be replaced.

   Push the rope socket on the drilled hole for reeving 2/1 into the fixed point crosshead from below.

   Secure the rope socket using the bolt and SL safety clip.

   Install the fixed point crosshead on the counterweight side.

Observe the label on the fixed point crosshead regarding the installation direction.

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

   Fit a new, shorter wire rope.

   Pull the wire rope through the bottom block for 2/1.

   Fasten the wire rope onto the fixed point crosshead.

   Affix a type plate on the wire rope hoist.

For further details on the listed assembly steps, see Replacing the wire rope, cable guide, rope socket and rope wedge.

   If the wire rope hoist has already been in use: Determine the remaining service life and inform ABUS Service.

   Request a new test log book from ABUS Service. See ABUS Service.

   Carry out a test for major changes. See “General Product Manual for ABUS Cranes”.

   Readjust the overload protection. See product manual “ABUS Load indicator system”.

   Readjust the hoist limit switch. See product manual “ABUS gear limit switch”.