VOLUME 2 OPERATING AND MAINTENANCE INSTRUCTIONS 126050039

9. COMPONENTS REPLACEMENT

9.1. Replacement of crowd rope (Ref. Fig. 9.22 - 9.23 - 9.24 – 9.25)

CAUTION !
Safety harnesses and suitable means for gaining access to the work places above
the mast are obligatory.

Disassembly

• Make sure that the tracks are at their maximum extension.

• Move the mast to the horizontal position with the rotary in trasport position for around 1,10
metres from the lower limit position. Lock the rotary in this position.

• Loosen the crowd rope (2) with the tightener (A) using the following procedure:
- block the rope with recovery clamp S;
- completely free the screws of the pressure ring V;
- rotate deviator P to "R" while the shaft returns to the limit switch and completely
remove clamps Q;
- free the rope from recovery clamp S.

• Remove the rope from tightener (A) and from pulleys (E) located at the lower end of the
mast.

• Remove the rope from the lower pulley (F) located on the rotary slide and from the tilted
rope return pulleys (G) located in the lower part of the mast.

• Remove the pin from the rope stop (H). To make the operation easier, make the winch
operate slightly.

• Remove rope stop H from rope 1.

• Remove rope 1 from pulleys I and L.

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VOLUME 2 OPERATING AND MAINTENANCE INSTRUCTIONS 126050039

• Disconnect rope 1 from the drum of winch M and remove it, by operating the winch if
necessary.

• Operate the winch and unwind rope 2 completely.

• Disconnect rope 2 from the drum of winch N.

• Remove ropes 1 and 2 from the mast completely.

Assembly

• Make one end of rope 1 pass through pulley L until it coincide with the winch.

• Connect rope 2 to the drum of winch N, operate the winch and wind 19 coils as indicated
in the drawing (slide in trasport position for around 1,10 metres from the lower limit
position).

• Wind the rope manually for 4,5 coils and connect it to the drum of winch M as indicated in
the drawing (slide in trasport position for around 1,10 metres from the lower limit position).

• Wind the free end of rope 1 onto the upper pulley I of the slide.

• Fit rope stop H onto the rope so that it can be attached by means of the pin to attachment
H1.

• Bring the slide to a completely raised position and block it

• Make the free end of rope 2 pass onto pulley G1 until it reaches pulleys G. Now proceed
as follows :

- wind it onto pulleys G;

- wind it onto the lower pulley F of the trolley;
- wind it onto the pulleys E;
- make it pass through the tightener A.

NOTE:
The shaft of tightener A must return completely. Lever P must be in "R" (release).
Blocking clamp Q must be free to move, or better yet, removed.

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VOLUME 2 OPERATING AND MAINTENANCE INSTRUCTIONS 126050039

• Pass the rope through recovery clamp S.

• Insert blocking clamps Q (if previously removed).

• Place at least 3 screws in pressure ring V.

NOTE:
If it should be too difficult to wind the rope on pulleys F and I, it is necessary to remove them,
place the ropes on their housing and reassemble the pulleys.

NOTE:
The surplus parts of rope 1 and 2 must be cut off.

Rope tightening

• Turn the deviator P to “T" (tightening).

The shaft must come out recovering the rope (the recovery clamp S must be free).

NOTE:
If the first stroke is not sufficient to tighten the rope, proceed as follows:
- block the rope with recovery clamp S;
- completely free the screws of pressure ring V;
- rotate the deviator P to "R". The shaft must return to its final position;
- block the screws of pressure ring V again;
- free the rope from recovery clamp S;
- rotate the deviator R to "T".

The shaft must start coming out again while recovering rope.
If the shaft does not come out completely it means that the rope is at the desired tension
and any lengthening will be taken up automatically as far as the tensioner stroke permits.
If necessary the aforementioned operations can be repeated several times.

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VOLUME 2 OPERATING AND MAINTENANCE INSTRUCTIONS 126050039

Adjustment of upper and lower limits of trolley travel

• After having fitted or replaced the rope, check that the trolley travel on the upper part of
the mast stops at about 1.5 metres from pulleys L and does not interfere while the trolley
travel on the lower part of the mast must stop about 0.7 metres from its end and must not
interfere with the pulley G.

) IMPORTANT!
Always respect the above limits. Any adjustments made near pulley L or pulley G
can cause danger hazards during work operations due to possible rope
slackening or wear.

• If it is necessary to adjust the trolley travel limits, the rotary limit switch eccentric located
on the winch must be adjusted as described hereunder :

- remove the protection from the limit switch;

- identify the eccentric which controls the lower limit and the one which controls the
upper limit.
- move the winch and bring the carriage to the limit to be adjusted. Check that the
position corresponds to the prescribed one. If not, properly adjust the cam concerned
as needed by means of the corresponding screws.

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VOLUME 2 OPERATING AND MAINTENANCE INSTRUCTIONS 126050039

9.22

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9.23

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9.24

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9-7