TL;DR
A limit switch that does not stop the hoist is a safety-critical failure. Lock out the crane immediately. Test the switch contacts with a multimeter and replace if contacts do not close at the correct actuator position.
What you might see
- hoist does not stop at top of travel
- hoist fault code related to overtravel
- limit switch indicator lamp not lighting
- hook raises or lowers past normal end positions
Likely causes
Limit switch contacts worn or pitted, no longer making a reliable circuit at the trigger point
Actuator cam shifted out of position, not striking the limit switch at the correct hook height
Limit switch enclosure filled with moisture or contamination causing contact corrosion
Wiring connection loose at the limit switch terminal block
Required tools
- Multimeter (continuity mode)
- Small screwdrivers (set screw access)
- Replacement Konecranes limit switch
- LOTO kit
Safety first
- Lock out the crane before accessing the limit switch housing.
- A non-functioning upper limit switch is an out-of-service condition. Do not operate the crane until the switch is repaired and tested.
Procedure
- 1
Lock out the crane immediately. Do not attempt to operate the hoist with a suspected limit switch fault.
Warning: A failed upper limit switch allows the hook block to overtravel into the drum mechanism, causing rope damage and potential load drop. - 2
Access the limit switch housing on the hoist body. Test each switch contact with a multimeter on continuity mode at the switch terminal block.[1]
- 3
Manually actuate the switch cam and verify the contacts switch state. If contacts do not change, the switch internals have failed.
- 4
Check the cam position relative to the actuator lever. If the cam is mis-timed, loosen the cam set screw and reposition to activate the switch at the correct hook height.[1]
- 5
Inspect the switch enclosure seals for moisture ingress. Dry the enclosure before installing a replacement switch.
- 6
Replace the faulty switch with an identical Konecranes-specified part. Do not substitute a generic switch; the rated operating force and contact material must match.
- 7
After replacement, perform a full functional test: raise the hook slowly until the switch activates. Verify the hoist stops at the correct position before restoring to service.
Sources
Konecranes CXT Wire Rope Hoist & Crane Maintenance Manual, Konecranes
Konecranes CXT Wire Rope Hoist Maintenance Manual, limit switch inspection and adjustment procedures (general)
View source
More guides for Konecranes CXT
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A rhythmic jerk during travel is almost always a flat spot on one travel wheel. Lock out and rotate each wheel by hand to find the flat spot, then replace the wheel.
Stop fixing the same fault twice.
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