Crush Guard - Service - Genie ALC500/ALC1000 Rope Switch & Cable
The purpose of this Tech Doc is to help with the Servicing of the Rope Switch
The wire rope running through the frame is connected to the rope switch and:
- It is connected to the control module using an M12 cable
- It monitors the tension on the wire rope
Damage to Rope Switch
If the rope switch has been damaged from an impact, causing the reset button to not
function correctly (or caused a breach in the seal) then the rope switch will need to be
replaced.
Follow the instructions below to replace the rope switch.
Replace Rope Switch
Once the replacement rope switch has been ordered and received follow the
instructions below to swap out the rope switch.
1. Disconnect the cable from the rope switch into the control module
2. Cut any cable ties and remove the rope switch cable from the snake tubing
3. Remove the cable from the p-clip, (done by removing the bolts on the cover of the User
Interface enclosure) to access the bolt attached to the p-clip
4. Remove the magnet from the anchor point to release the tension on the wire
5. Undo the bolt holding the rubber cover on the right post (above the rope switch) and pull the rubber cover up onto the blue hose covering the wire rope
6. Remove the locking pin on the fork terminal (attached to the ring on the rope
switch)
7. Undo the bolts attaching the rope switch to the frame
8. Install and secure the replacement rope switch to the frame
9. Attach the locking pin from the fork terminal to the ring of the replacement rope
switch
10. Attach the magnetic anchor to the anchor point on the frame to return tension to
the wire
11. Test the wire tension is adjusted correctly for the new magnetic anchor and
re-calibrate if required.
Follow the instruction in the Maintenance section to calibrate the wire tension.
12. Move the rubber cover back in place over the right post and replace the securing
bolt
13. Run the cable through the p-clip and reattach the p-clip and replace the cover on
the User Interface enclosure
14. Run the cable through the snake tube, reconnect to the control module and
secure using cable ties
The rope switch cable can be ordered separately (if the damage is localised to only the cable).
Follow the instructions below to replace the rope switch cable.
Replace Rope Switch Cable
Once the replacement rope switch cable has been ordered and received, follow the
instructions below to swap out the cable.
1. Disconnect the cable from the rope switch into the control module
2. Cut any cable ties and remove the rope switch cable from the snake tubing
3. Remove the cable from the p-clip, by removing the bolts on the cover of the User
Interface enclosure, to access the bolt attached to the p-clip
4. Release the two bolts attaching the rope switch cover. Rotate the cover 90
degrees on its hinge then pull the cover down at the hinge to separate the cover
from the base.
5. Undo the four screw terminals securing the cable wires
6. Rotate the top nut on the cable gland in a counter-clockwise direction to release
the cable
7. Remove and discard the damaged cable
8. Insert the wire end of the new replacement cable in through the cable gland
9. Secure the wires to the terminals according to the table below:
10. Rotate the top nut on the cable gland in a clockwise direction to secure and seal
the cable
11. Clip the cover back into the base on the hinge position and secure using the two
bolts attaching the cover to the base
12. Run the cable through the p-clip and reattach the p-clip and replace the cover on
the User Interface enclosure
13. Run the cable through the snake tube, reconnect to the control module and
secure using cable ties
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