If the wire rope is damaged or has more broken wires than permitted (see Inspecting the wire rope), 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 Exchanging the fixed point crosshead with rope socket and rope wedge), they need to be replaced. They are usually replaced when the wire rope and cable guide are replaced.

These safety instructions apply specifically to changing the wire rope:

─     Cordon off a generous space for the work area under the wire rope hoist.

─     Ensure the floor is swept clean.

This reduces soiling of the new wire rope.

─     Scissors lift platform with adequate surface area for setting down the bottom block.

Observe the load capacity of the lift platform!

─     If an unrolling device is available to unroll the wire rope, sufficient free space for this is required.

─     Position a scrap container or similar receptacle in the immediate vicinity of the lift platform and bottom block for the old wire rope.

─     For a wire rope diameter larger than 11 mm, the rope change should be performed with the aid of a second person.

   Run the load hook to the highest hook position.

Only with ABUS electrics 3 with ABULiner: move the load hook under the upper limit switch range.

   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.

   Release the dead end rope grip.

   Pull the dead end rope grip from the end of the wire rope.

   Drive the rope wedge out of the rope socket and take it out.

If the rope wedge is stuck:

   Disassemble the rope socket.

   Turn the rope socket over and knock out the rope wedge from above.

The rope wedge can in this way be more easily knocked out of the rope socket.

   Push the end of the wire rope out of the rope socket.

   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, it 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 laterally between the rope guard and bottom block cover 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.

Several wire rope windings should remain on the cable drum.

   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.

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

   Release the end clamps (2x).

   Completely remove the wire rope from the cable drum.

   Clean 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.

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

   Lubricate the cable drum behind the 8th/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.

   Pull the wire rope taut 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.

   Force the rope tension ring apart 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.

   Grease the groove of the rope guide ring.

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

   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 both ends of the rope guide ring lie in the same groove of the cable drum.

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 with self-tapping screws M6x16 (4x). 5 Nm.

When doing this, first secure the upper screws which do not lie in the elongated hole.

   Put the rope guide runner on the drum housing and push it laterally into the rope guide ring.

   Screw on the rope guide runner with the self-tapping screw M6x16. 5 Nm.

   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.

   Check the lubrication of the rope socket and grease it if necessary.

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

   Push the end of the wire rope into the rope socket from below.

   Push the end of the wire rope into the rope socket from above so that a loop forms.

The end of the wire rope protrudes below about 150 mm out of the rope socket.

   Place the rope wedge in the loop.

   Give the wire rope a jolting tug.

●   The rope wedge slips into the rope socket and the wire rope is tightly clamped.

   Push the dead end rope grip over the end of the wire rope.

The dead end rope grip lies about 30 mm below the rope socket.

   Screw the dead end rope grip tight.

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 above on 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 brackets of the rope guards (2x) and push them together.

●   A snapping sound can be heard.

   Use the motor to wind up the wire rope completely.

   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.