If the wire rope is damaged or has more wire breaks than permitted (see the "Inspecting the wire rope" section in the "General Product Manual for ABUS Cranes"), it must be replaced.

If the cable guide is damaged (see Inspecting the cable guide), it must be replaced.

The wire rope and cable guides are wearing parts that are subject to heavy loads. They subject each other to wear during operation. This is why the wire rope and cable guide should always be replaced together.

The wire rope is a special lifting rope with a very high breaking strength. This ensures it has a longer service life than a normal wire rope. This is why only genuine wire ropes from ABUS may be used.

If the rope wedge or the rope socket are damaged (see Inspecting the fixed point on the fixed point crosshead (rope socket and rope wedge)), they need to be replaced. They are usually replaced when the wire rope and cable guide are replaced.

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

   For hoists with frequency converters: Move the load hook upwards until the top hoist limiter switching point is activated.

For hoists with contactor control: Move the load hook so that the top hoist limiter switching point is NOT activated.

   Measure, and note, the position of the load hook.

This makes adjusting the hoist limit switch after replacing the wire rope in many cases unnecessary.

   Pull off the cover.

●   This provides access to the cable drum and cable guide.

To ensure the wire rope can be unwound from the cable drum using a motor, the hoist limit switch must be removed. Otherwise the cable drum will stop at the lowest hook position.

   Open the hoist limit switch housing.

   Unscrew and remove screws (2x).

   Pull off the hoist limit switch.

   Leave the shaft of the hoist limit switch in the same position, and do not turn it.

This makes adjusting the hoist limit switch after replacing the wire rope in many cases unnecessary.

If the shaft is accidentally twisted, the message "F_ _ 34 Wire rope change: Absolute rotary encoder 1 not removed" or "F_ _ 33 Wire rope change: Absolute rotary encoder 2 not removed" is displayed.

   Secure the hoist limit switch to ensure it does not fall down or hang from the connection cables.

So that the cable drum can be motor-driven, even though ABUControl does not receive a signal from the absolute rotary encoder (because the hoist limit switch is dismantled with the absolute rotary encoder), the wire rope change must be activated in ABUControl.

The wire rope change can be activated in the trolley control by coupling or by KranOS.

Either activate the wire rope change by coupling:

   Open trolley control.

   Search for prong terminal block -X104.

   Remove the coupling from the parking position (upper pin multipoint connector).

   Insert coupling on the upper pin multipoint connector.

●   The wire rope change is activated. The cable drum can now be motor-run without ABUControl receiving a signal from absolute rotary encoder.

●   The message "F_ _ 28: Wire rope change activated" is displayed.

●   All the wear values for calculating the maximum acceptable wear are deleted so that the calculation for the new wire rope can start over.

Or activate rope change via KranOS:

See the ABUControl product manual.

   Unscrew the rope guide runner.

   Push the rope guide runner away to one side of the rope guide ring.

●   The rope guide ring can now be turned freely on the cable drum.

   Turn the rope guide ring so that the screws (4x) are easily accessible (e.g. upwards).

   Loosen screws (4x).

   Remove the joining element and unthread it from the wire rope.

   Force the rope guide ring apart and pull it inwards and off the cable drum.

   Remove the tension spring from the rope tension ring.

   Force the rope tension ring apart and pull it inwards and off the cable drum.

●   The cable guide has now been disassembled. The wire rope is now lying loose on the cable drum.

   Remove the SL safety clip on the fixed point crosshead.

   Pull the bolt out of the fixed point crosshead.

   Pull the rope socket with the wire rope out of the fixed point crosshead from the bottom.

If the rope socket and rope wedge are to be used again:

   Release the dead end rope grip.

   Drive the rope wedge with the wire rope out of the rope socket from the bottom.

   Take the rope wedge out of the grommet.

   Pull the wire rope out of the rope socket.

The rope guard in the bottom block will be damaged if the wire rope is pulled along the rope guard quickly to remove it from the bottom block. If the rope guard is to be used again, then the rope guard should be disassembled beforehand.

ABUS recommends replacing the rope guard together with the wire rope.

On all openings on the bottom block:

   Insert the screwdriver between the rope guard and bottom block cover at the side, as shown in the figure.

   Use the screwdriver to unhook the load hooks on the left and right of the rope guard at the same time.

   Pull the rope guard (2x) apart and remove it from the bottom block.

   Fit the bottom block.

   Pull the wire rope out of the bottom block.

   Allow the wire rope to run off the cable drum using the motor.

●   The cable drum only turns at a slow lifting speed once it passes the switching point for the lowest hook position.

   Release the end clamps (2x).

   Remove the wire rope from the cable drum completely.

   Clean the cable drum.

   Lubrication on the cable drum:

─     Lubricate the cable drum from the start to about the 8th or 10th turn.

─     Lubricate the cable drum behind the last turn (the area that does not come into contact with the wire rope).

─     Pipe of side panel (the area which comes into contact with the rope guide runner) and rope guide runner of cable guide.

Lubricant: “Molykote PG-75”. For details, see Lubricants.

   Lubricate the wire rope and cable drum behind the 8th to 10th turn up to the last turn:

Lubricant: “Chainlife S”. For details, see Lubricants.

   Unroll the wire rope without twisting it.

   Thoroughly clean the fillister-head screws of the end clamps.

The fillister-head screws were previously bolted with a thread lock coating or a thread lock. The residues must be completely removed before the fillister-head screw may be used again.

The thread lock coating as well as the thread lock are single-use only.

   Push the wire rope under the end clamps far enough that the rope protrusion is about 30 mm.

   Tighten the end clamps (2x) with fillister-head screws and secure with (medium strength) thread lock.

   Tauten the wire rope and use the motor to wind it onto the cable drum by 6 to 8 turns, ensuring it is taut and not twisted.

   Turn the rope tension ring so that the ridge is facing the hoisting gear.

   Spread the rope tension ring and guide it over the wire rope on the cable drum.

   Hook the tension spring into one of the notches so that the rope tension ring is firmly seated on the wire rope but can still be turned freely.

   Force the rope guide ring apart and push it over the cable drum.

   Place the rope guide ring with the groove into the ridge on the rope tension ring.

   Place the rope guide ring with the threaded segments into the free section of the cable drum.

   Check that the rope guide ring is only seated in one groove of the cable drum (the ends of the rope guide ring form one line).

The ends of the rope guide ring must be aligned.

   Thread the joining element onto the wire rope.

   Push the joining element upwards and place it onto the rope guide ring.

   Tighten the joining element.

   Turn the rope guide ring as far as is shown in the figure.

   Push the rope guide runner under the tube on the side panel and into the rope guide ring.

   Tighten the rope guide runner.

   For reeving 2/1: Pull the wire rope from the cable drum and through the bottom block, without twisting it.

   For reeving 4/1: Pull the wire rope from the cable drum and through the bottom block, without twisting it, and through the deflection roller and once again through the bottom block.

If the rope socket and the rope wedge are still in good condition (see Inspecting the fixed point on the fixed point crosshead (rope socket and rope wedge)), they can be used again. Otherwise use a new rope socket and rope wedge.

   Double up the wire rope and thread it through the rope socket from below.

   Place the rope wedge in the loop.

   Pull the wire rope downwards with force.

●   The rope wedge slips into the rope socket and clamps the wire rope.

●   The rope wedge later becomes finally fixed when a larger load is hung in the hook.

   Clean and lubricate the drilled hole in the rope socket.

Lubricant: “High temperature paste PBC 1574”. For details, see Lubricants.

   Push the dead end rope grip onto the wire rope end and tighten it.

   Lubricate the drilled hole in the rope socket.

Lubricant: “High temperature paste PBC 1574”. For details, see Lubricants.

   Push the rope socket into the fixed point crosshead, without twisting it, from below.

   Insert the bolt into the fixed point crosshead and rope socket, and secure it using SL safety clips.

On all openings on the bottom block:

   Hold the rope guard on the wire rope as shown in the figure.

   Push the rope guard down along the wire rope with the front fork and bring the rear end under the connecting profile.

   First push the rope guard on the side with the short bracket into the bottom block cover.

   Then push the rope guard on the side with the long bracket into the bottom block cover.

   Push the second rope guard at the bottom into the connecting profile.

   Push the rope guard downwards behind the connecting profile and attach it to the top of the wire rope.

   First push the rope guard on the side with the short bracket into the bottom block cover.

   Then push the rope guard on the side with the long bracket into the bottom block cover.

   Connect the lugs of the rope guard (2x) and push them together.

   Attach the cover to the cable drum.

   Use the motor to roll up the wire rope completely.

   Move the load hooks to the position you noted previously.

   Connect the hoist limit switch to the pins on the cable drum.

   Screw the hoist limit switch tight.

   Check the positions of the switching points.

As soon as the wire rope has been changed:

   Remove the coupling from the lower pin multipoint connector on the prong terminal block -X104 and insert in the parking position (upper pin multipoint connector).

or

Click on the "Rope change cable drum 1" button.

●   The wire rope change is switched off.

●   The button's background is no longer green.

   To acknowledge the message "F_ _ 28: Wire rope change activated", press the emergency stop button or horn.

If the switching points have moved:

Normally, the adjustment of the hoist limit switch after replacing the wire rope can in many cases be omitted, since the position of the load hook was previously measured and then travelled to again. In special cases (e.g. if the wire rope is severely damaged or has been incorrectly rolled onto the cable drum), the switching points may need to be readjusted.

   Reset switching points for the bottom hoist limiter, the top hoist limiter and the backup limiter.

See the ABUControl product manual.

   Suspend the load from the load hooks, raise it and load the wire rope this way.

   Measure the rope wedge protrusion and check whether the dimensions specified in the table have been complied with.