OPERATION

MAINTENANCE HOIST WINCH

SUMMARY

35M - HOISTING WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. WORKING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. FREQUENCY CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. 1. PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. 2. POWER MODUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. 3. CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. 4. USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. INCREMENTAL ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. 1. CONNECTION ON THE CONVERTER SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. 2. CONNECTION ON THE MOTOR SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. 3. CONNECTING THE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. 1. PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. 2. DESCRIPTION - WORKING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. 3. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. 1. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. 2. AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. 3. REPLACEMENT OF THE BRAKE DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6. 4. REPLACEMENT OF THE ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6. 5. MANUAL BRAKE RELEASE OF THE HOIST WINCH . . . . . . . . . . . . . . . . . . . . . . . 23
6. 6. INSTRUCTIONS FOR ADJUSTING THE AIR GAP INDICATOR . . . . . . . . . . . . . . 25
7. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. 1. GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. 2. DISMANTLING THE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7. 3. CHECKING THE FUNCTIONING OF THE OVERSPEED CARD . . . . . . . . . . . . . . 31
7. 4. PERIODICAL CHECKING OF THE CARD FUNCTIONING . . . . . . . . . . . . . . . . . . . 31
7. 5. FAULTS DISPLAYED BY THE FREQUENCY CONVERTER . . . . . . . . . . . . . . . . . . 32
7. 6. FAULTS LINKED TO THE HOISTING APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 36
7. 7. CONTROLLING THE SAFETY DEVICES BY MEANS OF THE FREQUENCY
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7. 8. AID TO FAULT CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7. 9. FAULTS DISPLAYED BY THE FREQUENCY CONVERTER (CONT’D) . . . . . . . . 40
7. 10. FAULT CLEARANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

EDITION : 5.07.04 35M-0000-270-1-GB 1

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OPERATION
MAINTENANCE HOIST WINCH

35M - HOISTING WINCH

1. CHARACTERISTICS

Only in case of danger

Hoist winch 33LVF20 AC

Motor Type PVF54 Power 22 KW

Motor Speed (r.p.m.) 1500 Connection

Air gap (mm)Air 400 V - 47 Hz

Motor 0,6+/ - 0,2 Supply
gap (mm)

FEM3 Classification Group M5

EDITION : 5.07.04 35M - 0100 - 217 - 1 2

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 OPERATION
HOIST WINCH MAINTENANCE

2. WORKING METHOD
Moving the load is carried out either with a 4 - fall or 2 - fall reeving.
The speed changings are controlled by the converter according to the acceleration and deceleration
ramps.
The main safety devices are :
` the upper and lower hoist limit switches.
` the upper and lower decelerating limit switches.
` the maximum safe working load and maximum moment cutouts.
` the dead man’s safety devices on the control switches.
` the safety against overspeed of the winch motor.
` a speed difference (set value, frequency, speed feedback).
` the emergency stop.
` encoder break.
` the converter safety devices.
` the control of the low temperature in the electrical control panel.
` the regulation of the high temperature in the electrical control panel.
` the brake relay.

400 V 50Hz
460 V 60Hz

Temperature ON
>0°C
Chain of safety devices with
Emergency
contact : Load, Moment, Control
switch
Limit switches switch
released

Converter fault
Frequency converter

Hoisting safety
device cutoff

Brake resistance
Hoist
Encoder motor
Brake resistor

Holding brake

3 35M - 0200 - 033 - 0 EDITION : 5.07.04

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OPERATION
MAINTENANCE HOIST WINCH

3. FREQUENCY CONVERTER

3. 1. PRESENTATION
It allows the access to the adjustment parameters and the frequency converter.

888888 1
8888 2
3

5 M
4

1 Upper display composed of 6 indicators, 7 segments allow the display of:

operating mode,
parameter content,
fault code.

2 Lower display composed of 4 indicators, 7 segments allow the display of:

the working condition of the frequency converter,

3 1 mode key M allows to change from normal mode to parametering mode (in parameter mode, the
upper display flashes).

4 2 keys for shifting under the 7 - segment indicators of the upper display in order to modify
its value or to go from a menu to an other.

5 2 keys for scrolling the parameters or their value in ascending or descending order.

6 3 keys allowing the controls at the control board of:

(green key): ON, (not used)

(red key): Stop, deleting the fault, RESET, (not used)

(blue key): Reversal of the direction of rotation (not used)

EDITION : 5.07.04 35M - 0600 - 014 - 0 4

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 OPERATION
HOIST WINCH MAINTENANCE

3. 2. POWER MODUL
It is composed of:
a three - phase rectifier supplied via the inductors which protect the network against the harmonics.
a capacitor battery which gets loaded as soon as the frequency converter is alive.
a transistorized inverter (IGBT) which creates a three - phase network with variable voltage and
frequency starting from d.c. voltage. This considerably reduces the noise and motor heating at
variable speed.

i During the working periods as generator, the energy returned by the motor is dissipated
by the resistors.

3. 3. CONTROL UNIT
The converter is controlled by a control unit which ensures, around a microprocessor, the control functions
of components of power, dialogue, protection and safety. It comprises 2 additional cards:
a card specific to POTAIN hoisting application: it allows to control the brake sequences and to ensure
monitoring specific to hoisting.
an input - output card: allows to use the monitoring functions of the brake relay and the limit switch
control.
` The controls are directly sent (without relaying) to the converter via the control switch in + 24 V
supplied by the frequency converter (terminal 22).
` At low frequency, when controlling a speed higher than 1350 r.p.m. (3rd notch), the frequency
converter measures the torque necessary for the motor for lifting the load (during 500 m/s at 1350
r.p.m.) and deduces the permissible maximum speed.

POWER
Rectifier Brake resistance Inverter
+ V CC
Network

+
M

- V CC

Encoder
CONTROL
Motor current

Inverter control

Microprocessor
D.c. bus Inverter control
voltage Speed

5 35M - 0600 - 014 - 0 EDITION : 5.07.04

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OPERATION
MAINTENANCE HOIST WINCH

3. 4. USE

3. 4. 1. Modification of the parameters

ACTION Display Remarks

Frequency converter alive During 1 second after

C L. V E C t making alive, the upper
r d Y display indicates the control
mode which was selected.

1 second after making alive 0 The upper display indicates

r d Y the motor speed.

Passing to parameter mode M The parameter 0.10

0
usable for resetting to zero corresponds to the motor
0. 0 0 speed.

Positioning on the various The “upward” key allows to

parameters go from a parameter to the
0 following one. The
0. 1 1 parameter content is
indicated on the upper
display.

The “downward” key allows

0
to go from a parameter to the
0. 1 0 preceding one.

Without any operation on the control board during 8 sec., the display returns to the
i parameter 0.10 (motor speed).
A continious action on the “upward” and “downward” keys allows rapid scrolling.

Closed loop
1st notch 120 r.p.m. at motor
2nd notch 480 r.p.m. at motor
3rd notch 1350 r.p.m. at motor
Load weighing

4th notch 2400 r.p.m. at motor

5th notch 3600 r.p.m. at motor

Optimized speed

EDITION : 5.07.04 35M - 0600 - 014 - 0 6

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 OPERATION
HOIST WINCH MAINTENANCE

4. INCREMENTAL ENCODER

Detection of forward or
A
A

backward direction
5V B
Supply B

4. 1. CONNECTION ON THE CONVERTER SIDE

Connecting is carried out by the SUB - D 15 - pin socket.

Mark Designation Function

- 15000
rdy 1 B (green)
2 B (yellow)
Encoder feedback
3 A (pink) 2 channels
M complemented
4 A (grey)

5 Not used
6 Not used
13 +5 V (white) Encoder supply
14 0V (brown)
15 - Do not use
Encoder connector SUB - D 15 - pin
1 2 3 4 5 6 7 8 9 10 11
socket
21 22 23 24 25 26 27 28 29 30 31 5 1

10 6
15 11
L1 L2 L3 U V W+ . - 1
CHANNEL B 2
3
CHANNEL A 4
5
TOP 0
6
+5 V 13
0V 14
Encoder

7 35M - 0600 - 014 - 0 EDITION : 5.07.04

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OPERATION
MAINTENANCE HOIST WINCH

4. 2. CONNECTION ON THE MOTOR SIDE

Connecting is carried out by the socket of the encoder. The encoder connector is located near the brake.

Mark Designation Function

1 0V Encoder supply

ÉÉÉÉÉÉ
ÇÇÇÇ
ÉÉ
2 + 5V DC

ÉÉÉÇÇÇÇÇ
ÉÉÉÉÉÉ
ÇÇÇÇ
ÉÉÉ
3 A

ÉÉ ÉÉ
ÉÉÉÇÇÇÇ
ÇÇÇÇÇ
ÉÉÉ 4 B

ÉÉÉ ÉÉ ÇÇÇÇ
ÉÉ
ÇÇÇÇ
ÉÉÉÉ
É 5 Not used Encoder feedback

ÉÉÉ ÇÇÇÇ
ÉÉÉÉ 6 2 channels

ÉÉ
ÉÉÉÉ
A
complemented

ÉÉ
ÉÉÉÉ ÉÉÉÉ
ÉÉ
ÇÇÇÇ
ÉÉÉÉ
7 B

ÉÉ
ÉÉ
ÉÉÉ ÇÇÇÇ
ÉÉÉÉ 8 Not used

ÉÉ
ÉÉÉ ÇÇÇÇ
ÉÉ
ÇÇÇÇ
ÉÉÉ
ÉÉ
É
ÉÉ
9 Free terminal -

ÉÉÉÉÉÉ
ÉÉ ÇÇÇÇ
ÉÉ
ÇÇÇÇ É
Encoder 10 -

ÉÉÉÉ
ÉÉÉÉÉÉ Ç
ÇÇÇÇ
connector 11 - Do not use
12 -

The converter permanently controls the good working order of the encoder.
i If the connector must be disconnected from the motor, it is compulsory to store it in the
control panel.

4. 3. CONNECTING THE CONVERTER

4. 3. 1. Power terminal
Remove the plastic cover from the control part by slightly deviating the 2 lower edges.

- 15000
rdy L1 L2 L3 U V W + . -

Mark Designation
L1 - L2 -
Three - phase supply of the converter
L3
Earthing of converter and motor
Motor connection (observe the order of the
U-V-W
motor/converter phases)
Connecting the braking resistances via a
+ . thermal relay. (+) access to + dc bus.

- - of dc bus

EDITION : 5.07.04 35M - 0600 - 014 - 0 8

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 OPERATION
HOIST WINCH MAINTENANCE

4. 3. 2. Control terminal
The control terminal is composed of 2 pull - out connectors of 11 terminals each, accessible by removing
the plastic cover of the control module.

1 11

- 15000
21 31
rdy
1- 2 Outputs of the fault relays. Contact 1 - 2 is open if the converter is
faulty
M
3 to 11 Not used
21 Not used
22 + 24V
23 0V
24 Not used
25 Input of converter validation
26 Input of brake contactor feedback

L1 L2 L3 U V W + . -
27 Input of lower limit switch
28 Input of upper decelerating switch
29 Input of upper limit switch, maximum load, maximum moment
30 Input of external fault not used (must be shorted - out at + 24 V)
31 1- 2

4. 3. 3. Pull - out terminals of the input/output extension card

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

40 Relay output (speed < Ů ) (K490A), contact open if speed > 50 r.p.m. when hoisting

41 Relay outpuf of brake control (K409A)

42 Relay common wire (48 V)

43 0V

44 Input of hoisting control (S410X)

45 Input of lowering control (S415X)

46 Preadjusted speed 2nd notch (S420X)

48 Preadjusted speed 3rd notch (S430X)

49 Preadjusted speed 4th notch (S440X)

50 Preadjusted speed 5th notch (S450X)

9 35M - 0600 - 014 - 0 EDITION : 5.07.04

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OPERATION
MAINTENANCE HOIST WINCH

4. 3. 4. Brake control

4. 3. 4. 1. Brake release control

At an ON control, the converter makes a current in the motor in order to build up a torque. When this torque
is higher than the unlocking torque = 50 % Cn, brake release is controlled and it functions at zero speed
during 200 ms. The converter follows then the customer speed set value.

Speed

Making the magnetizing

current (torque)

Functioning at zero
speed (Ɔ)
“Customer” speed set
value

Time
200ms
Locking delay time
Control

Order of unlocking
the brake

4. 3. 4. 2. Braking control
At a stopping control, the speed decreases to 20 r.p.m.. The control of brake application is given and it
goes to operating at zero speed during 200 ms, then the converter is locked.

Speed

Running at zero
speed

Time

Speed of brake Locking delay time Converter

application (200 ms) locking

EDITION : 5.07.04 35M - 0600 - 014 - 0 10

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 OPERATION
HOIST WINCH MAINTENANCE

5. HOIST LIMIT SWITCH

5. 1. PURPOSE
Its purpose is to avoid any possible driving error. It allows :
to stop the ”hoisting” motion as soon as the pulley block comes near the jib trolley.
to forbid, when lowering, that the rope completely unwinds and winds up onto the drum in the reverse
direction.

5. 2. DESCRIPTION - WORKING PRINCIPLE

A limit switch with reduction gear driven either directly by the drum shaft or through a pinion meshing
a toothed ring rigidly fitted to the drum, records the number of drum revolutions and so the wound rope
length. This reduction gear drives cams (1) which operate the circuit breakers (2), thus cutting off the
corresponding movement.
Each time when starting a new site and before putting into service, it is ESSENTIAL to remove the
plug located at the lowest part of the limit switch in order to eliminate the condensation water. This
plug is to be replaced for crane transport.

90M
Optional indicators

92M
Optional interference control

11 35M - 0700 - 021 - 0 EDITION : 5.07.04

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OPERATION
MAINTENANCE HOIST WINCH

5. 3. ADJUSTMENTS
They are carried out WITHOUT LOAD.

5. 3. 1. Adjusting the ”Slowing down - Hoisting” safety device

4m
1 Loosen the screw

2 Turn the cam (1) until the

contact (2) is depressed

4
3

3 Retighten the
screw

EDITION : 5.07.04 35M - 0700 - 021 - 0 12

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 OPERATION
HOIST WINCH MAINTENANCE

5. 3. 2. Adjusting the upper hoist limit switch

1m
1
Loosen the screw

2 Turn the cam (3) until the

contact (4) is depressed

2
1

3 Retighten the
screw

13 35M - 0700 - 021 - 0 EDITION : 5.07.04

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OPERATION
MAINTENANCE HOIST WINCH

5. 3. 3. Adjusting the lower hoist limit switch

Operate ”lowering” with 4 falls (for SM/DM version trolleys) so that the hook stops before reaching
the ground or that only three rope turns remain wound on the drum.

1 Loosen the screw

ÎÎÎÎÎÎÎÎ
Turn the cam (7) until the contact (8)
2 is depressed

8
7

3 Retighten the
screw

The adjustments must be checked daily at each putting into service.

Adjust so that the 2 cams are overlapping in order to avoid any
interruption of the deceleration before the motion is cut off.

EDITION : 5.07.04 35M - 0700 - 021 - 0 14

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 OPERATION
HOIST WINCH MAINTENANCE

6. BRAKE

6. 1. DESCRIPTION
It is an electromagnetic brake which operates as soon as the current is switched off. It has a separate
current supply. It consists of :
a brake disk (1) sliding on a splined sleeve, which is fitted onto the second motor shaft end
a fixed plate (2), which is an integral part of the rear motor flange
a mobile assembly (3)
a yoke (4)
prestressed springs (5) defining the value of the braking torque
2 sets of shims (6) for adjusting the air gap “E”
an encoder (7)
a microcontact (8)

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15 35M - 0800 - 026 - 3 EDITION : 5.07.04

3 1
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OPERATION
MAINTENANCE HOIST WINCH

6. 2. AIR GAP ADJUSTMENT

This adjustment is necessary as soon as the air gap value reaches 1,6 mm. However,
it is recommended to carry out an intermediate adjustment at 1,1 mm.

Before any operation on the brake it is essential to disconnect

the brake motor.
Make sure that it does not hold a load.
If necessary, lock the drum.

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ÏÏ
ÉÉ Ï ÏÏÏÏÏÏÏ
ÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÉÉ
ÏÏÏÏ
ÏÏÏ ÏÏÏÏÏÏÏ
ÏÏ
the cover (b). b
7

ÏÏÏÏÏÏÏÏ
ÉÉ
ÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Disconnect the encoder (7).

ÏÏÏÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÑÑ
Ñ ÑÑ
Ñ ÏÏÏÏÏÏÏ
Ñ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
Ï
ÏÏÑÑ
Ñ ÑÑ
Ñ Ñ
ÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ ÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ ÑÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÑÑÑÑÑÑ
ÏÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï
ÑÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÑÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏ
ÉÉ ÑÑÑÑÑÑ
ÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÉÉÏÏÏÏ
Ï
Ï ÏÏ
Check the air gap “E” with a set of
ÑÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑÑ
shims (see data of the mechanism).
ÏÏ
ÏÏ
ÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏ ÏÏ
ÑÑÑÑÑÑ
ÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏ
ÑÑÑÑÑ
“E”

ÏÏ
ÏÏÏÏÑ
ÑÑÑ
ÑÑ
ÑÑÑÑÑ
Ï Ñ
ÑÑÑÑÑ

EDITION : 5.07.04 35M - 0800 - 026 - 3 16

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

ÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏ
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏ 4

ÏÏÏÏÏ
ÏÏÏ ÏÏ ÏÏÏÏÑÑÑÑÑ
ÑÑÑÑÑ ÏÏÏÏÑÑÑÑÑ
ÏÏ
c

ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏ
ÉÉ ÏÏÏÏÑÑÑÑÑ
If “E” ƒ1,1 mm:

ÉÉÑÑÑÑÑ
ÏÏÏ ÏÏ ÏÏÏÏ
ÏÏÏÏ
4
Partially unscrew by 3 mm the
8 screws (c) fixing the yoke (4).
ÉÉ
ÏÏÏÏÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏ Ñ ÑÑ
Ñ
ÑÑÑÑÑ
ÏÏ Ñ
ÑÑÑÑÑ
ÏÏÏ ÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ ÏÏÏÏ ÑÑÑÑÑ c

ÏÏÏ
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
Ï ÏÏ ÏÏÏÏ ÑÑÑÑÑ
ÏÏÑÑÑÑÑÏÏÏÏ
ÏÏ
Ï ÑÑÑÑÑ
Unscrew completely one of the
screws (c).

ÏÏÏÏÏ
ÏÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ ÏÏÏÏ
Free one side of the shim punched
ÑÑÑÑÑ
ÏÏÏÏ
ÉÉ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏ
5/10th.

Unscrew in the screw (c).

ÉÉ
ÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ 7/10

Unscrew the following screw in order

to free the 2nd side of the shim.
ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
5/10

Carry out the same procedure for the

next 3 shims
ÏÏÏ
ÑÑÑÑÑ
ÏÏÑÑÑÑÑ
ÑÑÑÑÑ
7/10

ÑÑÑÑÑ 5/10

It is absolutely necessary to remove the 4 shims of the same thickness.

ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï
20 N.m

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ ÏÏÏÏ
ÏÏÏÏÑÑÑÑÑ
ÑÑÑÑÑ
c

ÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏÏ ÏÏÏÏÑÑÑÑÑ
ÉÉÏÏÏÏ
Ï ÏÏ ÏÏÏÏÑÑÑÑÑ
Tighten the screws (c) applying the

ÉÉ
ÏÏÏÏÏÏ
Ï
ÑÑÑÑÑ
ÏÏ ÏÏÏÏ
tightening torque of 20 N.m.

ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏÑ ÑÑ
Ñ
ÑÑÑÑÑ Ñ
17 35M - 0800 - 026 - 3 EDITION : 5.07.04
3 1
2
OPERATION
MAINTENANCE HOIST WINCH

ÏÏÏÏ d 1

ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ
Connect the encoder (7).
ÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
a

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏ
Check the seal (d) condition.

ÉÉÏÏÏÏÏÏÏ
ÏÏÏÏ
Ï
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏÏÏ
Refit the cover (b) and screw in the 7

ÉÉ
ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏ
screws (a).

ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ b

ÏÏ ÑÑÑÑÑÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏÏÏÏÏÏ
Ñ Ñ Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ
i Connect the brake motor.

ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏ
4

ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÑÑÑÑÑ
c

ÏÏÏÏÏ
ÏÏ
ÏÏÏÏ
ÑÑÑÑÑ ÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏ ÏÏÏÏÑÑÑÑÑ
ÑÑÑÑÑ
If “E” ƒ1,6 mm: 4

Partially unscrew by 3 mm the 8

ÉÉÏÏÏ ÏÏ ÏÏÏÏ
ÏÏÏÏ
ÑÑÑÑÑ
screws (c) fixing the yoke (4)
ÉÉ
ÏÏÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï Ñ ÑÑ
Ñ
ÑÑÑÑÑ
ÏÏÏ Ñ
ÏÏÑ Ñ
ÑÑÑÑÑ Ñ
ÏÏÏÏ
Unscrew completely one of the
ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÑÑÑÑ c

ÑÑÑÑÑ ÏÏÏÏ ÑÑÑÑ

screws (c).

ÏÏÏÏÏ
ÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï ÏÏ ÏÏÏÏ ÑÑÑÑ
20 N.m
Free one side of the shims punched
5/10th and 7/10th.
ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï ÏÏÏÏ
ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏ
ÉÉÏÏÏ
Screw in the screw (c).

ÉÉÏÏÏÏ
Ï ÏÏ
7/10
Unscrew the following screw in order

ÉÉÏÏ
ÏÏÏÏÏÏ
Ï
ÑÑÑÑÑ
to free the 2nd side of the shims. 5/10
Carry out the same procedure for the
ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑ
next 3 sets of shims
7/10
Tighten all the screws (c) applying a
torque of 20 N.m ÑÑÑÑÑ
ÏÏ
Ï Ñ ÑÑ
Ñ
ÑÑÑÑÑ Ñ 5/10

EDITION : 5.07.04 35M - 0800 - 026 - 3 18

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

ÏÏÏÏ
ÏÏÏ d 1

ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏ ÏÏÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏ
ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
a

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ ÏÏÏÏÏÏÏ
Check the seal (d) condition.

Refit the cover (b) and screw in the

ÏÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏÏÏ
screws (a).
ÉÉ
ÉÉ
ÏÏÏÏÏÏÏ
ÏÏÏÏ
Ï
ÑÑÑÑÑ
ÏÏ ÏÏ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏ
Ï
ÏÏÏÏÏÏÏ
b

ÏÏ ÑÑÑÑÑÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
Ï
ÏÏ ÏÏÏÏÏÏÏ
Ñ Ñ Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ

19 35M - 0800 - 026 - 3 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

6. 3. REPLACEMENT OF THE BRAKE DISK

ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï ÏÏ ÏÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï ÏÏÏÏÏÏÏÏ a

ÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏÏ
Unscrew the screws (a) and remove
the cover (b).

ÉÉ
ÉÉ
ÏÏÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
7
Disconnect and dismantle the
encoder (7). ÏÏ
ÏÏ
ÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏÏ b

ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÑÑ
Ñ ÑÑ
Ñ Ñ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÏÏÏ ÑÑÑ ÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÑÑÑ
Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
Ï Ï
ÏÏ
ÏÏ
ÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï Ï
ÏÏ
ÑÑÑÑÑ
ÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏ
ÉÉÑÑÑÑÑ
Unscrew both nuts (e).
ÉÉ
ÉÉ
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏ
ÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ ÏÏÏÏÑÑÑÑÑÑ
ÏÏÑÑÑÑÑ
ÏÏ ÑÑÑÑÑÑ
Insert the spacer (f) (or possibly two
M12 nuts) and completely screw in
the nut (e).
ÏÏÏ
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏ ÏÑ
ÑÑ
Ñ ÑÑÑ ÑÑÑÑÑÑ
e

ÑÑÑÑÑ
ÏÏ
Ï
ÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑ
ÑÑ
Ñ Ñ Ñ e

ÑÑÑÑÑÑ
f
15 mm

ÏÏÏÏÏ
ÏÏÏÏÏÏ ÑÑÑÑÑ ÑÑÑÑÑ
ÏÏ ÑÑÑÑÑÏÏ
ÏÏ ÑÑÑÑÑ
c
3

ÏÏÏÏÏ
ÏÏÏÏÏ Ï
ÏÏ ÑÑÑÑÑ
ÏÏ
ÏÏÏ 1
ÑÑÑÑÑ
ÏÏÏ
ÏÏ 4

ÏÏ
Ï ÑÑÑÑÑ
ÏÏ ÑÑÑÑÑ
ÏÏ
3

ÏÏÏÏÏÏ ÏÏ ÑÑÑÑÑ ÑÑÑÑÑ

ÏÏ
Unscrew the screws (c).

Lay down the mobile assembly (3)

ÉÉ
ÉÉ
Ï ÏÏ
ÏÏÏÏ
ÏÏÏÏ
ÑÑÑÑÑÏÏ
ÏÏ
ÑÑÑÑÑ
Ï
with the yoke (4) and clean the friction
surfaces.
ÉÉÏ ÏÏ ÑÑÑÑÑ
ÑÑÑÑÑÏÏ ÑÑÑÑÑ
ÏÏÏ
ÑÑÑÑÑ
Replace the brake disk (1).
Ï
ÏÏ
Ï
ÑÑÑÑÑ
ÏÏ ÑÑÑÑÑ
ÏÏ
ÏÏ
Ï
ÏÏÏÏ
ÑÑÑÑÑ
ÏÏÑÑ
Ñ ÑÑ
Ñ
ÑÑÑÑÑ Ñ ÑÑÑÑÑ
ÏÏÏ
ÑÑÑ Ñ
ÑÑ
Ñ ÑÑ
Ñ Ñ ÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑÑÑÑÑÑ Ï
ÑÑÑÑ
Ñ Ñ

EDITION : 5.07.04 35M - 0800 - 026 - 3 20

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

ÏÏÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑ
ÑÑÑÑÑc 20 N.m

ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
Ï
ÏÏÏÏ
ÏÏÏ ÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï ÏÏ ÑÑÑÑÑ
ÏÏ
Refit the mobile assembly (3) with the 4
yoke (4). 3

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ ÑÑÑÑÑ
ÏÏ
ÏÏÑÑÑÑÑ
ÉÉÏÏÏÏ
ÏÏ ÑÑÑÑÑ
ÏÏ
Push in the shims supplied with the

ÉÉÏÏÏÏ
ÏÏ ÏÏ ÏÏ
new disk (*).

Unscrew the nut (e), remove the

ÉÉ
ÏÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ ÏÏ
ÑÑÑÑÑ
ÏÏÑÑÑÑÑ
ÏÏ ÑÑÑÑÑ
ÏÏ
spacer (f) and screw in the nut (e).

Screw in the screws (c) by applying a

ÏÏÑÑÑÑÑ
Ï
ÏÏ
ÏÏÏÏÏÏÑÑ
Ñ
ÑÑÑÑÑ Ñ ÑÑÑÑÑ
ÏÏ
Ñ Ñ Ñ
torque of 20 N.m.
Ï ÏÏÑ
ÑÑÑ
ÑÑÑÑÑ f ÑÑÑÑÑ
ÏÏ
ÑÑÑ
ÑÑÑÑÑ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
Ï ÏÏ
ÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
Ï
ÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏ
ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÉÉ ÏÏ
ÉÉÑÑÑÑÑ
ÏÏÏÏ
ÏÏ
ÉÉÑÑÑÑÑ ÏÏ
(*) 2 shim types are supplied in order

ÉÉÏÏÏÏ
ÏÏ ÏÏ
to adjust as precisely as possible the
ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï ÏÏ
air gap

ÏÏÑÑÑÑÑ
Ï
ÏÏÏÏÑÑ
Ñ Ñ
ÑÑÑÑÑ
ÏÏÏ
ÏÏÏÏÑÑ
ÑÑÑÑÑ
e

ÏÏÏÏ ÑÑÑÑÑ
ÏÏÏÏ ÑÑÑÑÑ
Ï
Ï
d 1 Ï
ÑÑÑÑÑ
ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑ
Ï
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
Ï
ÏÏÏÏÏÏÏ
ÏÏ
Ï ÏÏ ÏÏÏÏÏÏÏ
Fit and connect the encoder (7).
“E”

ÏÏÏÏÏ
ÏÏÑÑÑÑÑÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
a
Check the air gap “E”.

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏÏÏ
Check the seal (d) condition.

ÏÏÏÏÏÏÏ
ÉÉÏÏÏÏ
Ï
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏÏÏ
7
Refit the cover (b) and screw in the
screws (a).
ÉÉ
ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
b

ÏÏÑÑÑÑÑ
ÏÏ
Ï Ñ ÑÑ
Ñ
ÑÑÑÑÑ
ÏÏÏ Ñ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ
ÏÏÑ Ñ Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ
i Connect the brake motor.

21 35M - 0800 - 026 - 3 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

6. 4. REPLACEMENT OF THE ENCODER

ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï ÏÏ ÏÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï ÏÏÏÏÏÏÏÏ a

ÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏÏ
Unscrew the screws (a) and remove
the cover (b).

ÉÉ
ÉÉ
ÏÏÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ 7
Disconnect and
encoder (7).
dismantle the
ÏÏ
ÏÏ
ÏÏÏÏ
Ï
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ b

ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÑÑ
Ñ ÑÑ
Ñ Ñ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÏÏÏ ÑÑÑ ÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÑÑÑ
Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ ÏÏÏÏÏÏÏÏ
2 mm max.

ÏÏ
7

ÏÏ
Fit, tighten and connect the new
encoder (7).
ÏÏ
ÏÏ

ÏÏÏÏ
ÏÏÏÏ
ÏÏÏ d 1

ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏ ÏÏÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏ
ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
a

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ ÏÏÏÏÏÏÏ
Check the seal (d) condition.

Refit the cover (b) and screw in the

ÏÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÉÉÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ ÏÏÏÏÏÏÏÏÏ
screws (a). 7

ÉÉ
ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ b

ÏÏ ÑÑÑÑÑÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
Ï
ÏÏ ÏÏÏÏÏÏÏ
Ñ Ñ Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ

EDITION : 5.07.04 35M - 0800 - 026 - 3 22

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

6. 5. MANUAL BRAKE RELEASE OF THE HOIST WINCH

In case of interruption of circuit, it is possible to release the hoist winch brake.

ÏÏÏÏÏ
ÏÏÏÏÏ ÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
a

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏ ÏÏÏÏÏÏÏÏ
ÉÉÏÏÏÏÏÏÏ
ÏÏÏÏ
Ï
ÑÑÑÑÑ
ÏÏ ÏÏ ÏÏÏÏÏÏÏÏ
Unscrew the screws (a) and remove

ÉÉ
ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏÏ
the cover (b).

ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ b

ÏÏÑÑÑÑÑ
ÏÏÏ
ÏÏÑ ÑÑÑ ÏÏÏÏÏÏÏÏ
ÑÑÑ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
Ï
ÏÏ ÏÏÏÏÏÏÏÏ
Ñ Ñ Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏÏ ÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏ ÑÑÑÑÑ
ÏÏ
Ï Ï
ÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ ÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏÏ
ÉÉÑÑÑÑÑ
ÉÉ
ÉÉ
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏ
ÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ ÏÏ
Slightly unscrew the 2 nuts (e).

ÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
ÑÑÑÑÑ
Ï
ÑÑÑÑÑ
ÏÏ
Ï Ï
ÑÑ
Ñ ÑÑ
Ñ Ñ
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑ
e

ÏÏÏÏÏÑÑÑÑÑ ÏÏÏÏÏ
ÏÏÏÏÏÑÑÑÑÑÏÏÏÏÏÑÑÑÑÑÑÑÑÑÑ
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
Ï Ï
ÏÏ ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï Ï
ÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
Ï ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
Ï
ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
ÉÉ
ÉÉ
ÑÑÑÑÑ
ÏÏÏ
ÏÏÏÏ
ÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏÏ
Release the brake by means of the 2

ÉÉÑÑÑÑÑ
ÏÏÏ ÏÏÏ ÉÉÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ ÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ ÉÉ
ÏÏÑÑÑÑÑ
ÏÏ
levers.

ÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÑÑÑÑÑ
ÏÏ
Ï ÑÑÑ
ÑÑÑÑÑ
ÏÏ
ÏÏÏ ÑÑ Ñ ÏÏÑÑÑÑÑ
ÏÏ
Ï ÑÑÑ Ñ
Ï Ñ
ÑÑÑÑÑ Ñ ÏÏÑÑÑÑÑ
ÏÏ
Ï ÑÑ
Ï Ñ
ÑÑÑÑÑ Ñ

If the load tends to speed up, slightly release the levers.

After this operation, it is necessary to remove the brake release assembly and
to store it on the motor.

23 35M - 0800 - 026 - 3 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

ÏÏÏÏ d 1

ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ
Tighten the screws (e).
ÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
a

Check the seal (d) condition.

ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏÏÏ
Refit the cover (b) and screw in the
ÉÉ
ÉÉ
ÏÏÏÏÏÏÏ
ÏÏÏÏ
Ï
ÑÑÑÑÑ
ÏÏ ÏÏ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ
screws (a).

ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ b

ÏÏ ÑÑÑÑÑÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏÏÏÏÏÏ
Ñ Ñ Ñ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ e

i Make sure that there are no foreign bodies in the brakes (cement, sand, grease, etc.).

EDITION : 5.07.04 35M - 0800 - 026 - 3 24

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

6. 6. INSTRUCTIONS FOR ADJUSTING THE AIR GAP INDICATOR

The microcontact is adjusted ex works. In theory it is not necessary to carry out a microcontact
i adjustment except in case of a brake yoke replacement.
The microcontact adjustment must always be carried out with released brake.

6. 6. 1. Fitting

g ÏÏÏÏ
ÏÏÏÏ
Screw in the nut (g) and put the
j h ÏÏÏÏ
ÏÏÏÏ 3
washer (h) on the screw (j).
ÏÏÏÏ
Screw onto the mobile
assembly (3).
ÏÏÏÏ
ÏÏÏÏ
ÏÏÏÏ
ÏÏÏÏ
ÑÑ
ÑÑ
ÑÑ
ÏÏ
ÑÑ
ÏÏ
ÑÑÏÏÏÏ
ÏÏ ÏÏÏ
Fix the microcontact on the

ÑÑ
ÏÏ ÏÏÏ
ÏÏÏ ÏÏÏ
yoke (4) with screws and spring wash-

ÑÑ ÏÏÏ
ers.
1,2 N.m
Tighten applying a torque of
ÑÑ
ÑÑ ÏÏÏ
ÏÏÏ
1,2 N.m. 4

ÏÏÏ
ÏÏÏ
ÏÏÏ
6. 6. 2. Brake release

ÏÏÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï Ï
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏ
ÉÉÏÏÏ
Unscrew both nuts (e).
ÉÉÏÏÏÏ
Ï ÏÏÏÏ
ÉÉÏÏ
ÏÏÏÏÏÏ
Ï
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÏÏÑÑÑÑÑ
ÏÏ ÑÑÑÑÑÑ
Push in the spacer (f) (or if not two
M12 screws) and completely screw in
the nut (e).
ÏÏÏ
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÑÑ
Ñ ÑÑ
Ñ Ñ ÑÑÑÑÑÑ
ÑÑÑÑ
Ñ Ñ Ñ
e

ÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑ
ÑÑÑÑ
ÑÑÑÑÑÑ
e

ÑÑÑÑÑÑ
f
15 mm

25 35M - 0800 - 026 - 3 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

6. 6. 3. Adjustment

ÑÑ
ÑÑ
ÏÏ
ÑÑ
ÏÏ
ÑÑ
ÏÏ ÏÏÏ
ÑÑ
ÏÏÏÏÏÏ ÏÏÏ
ÑÑÏÏÏÏ
ÏÏ ÏÏÏ
ÏÏÏ
Disconnect the microcontact.

Connect an ohmmeter to the wires.

ÑÑ
ÑÑ ÏÏÏ
ÑÑ ÏÏÏ
ÏÏÏ
ÏÏÏ
ÏÏÏ
ÑÑ
ÑÑ
ÑÑ
ÏÏ
ÑÑ
ÏÏ
ÑÑ
ÏÏ
k
ÏÏÏ
ÏÏÏÏ
ÑÑÏÏÏÏ
ÏÏ ÏÏÏ
ÏÏÏ
Slightly unlock the nut (k).
ÑÑ
ÏÏ
ÑÑ ÏÏÏ
ÑÑ ÏÏÏ
ÏÏÏ
ÑÑ ÏÏÏ
ÏÏÏ
ÏÏÏ
By unscrewing bring the screw (j) into ÑÑ
ÑÑ
ÑÑ
ÏÏ
contact with the pusher until triggering

ÑÑ
ÏÏ ÏÏÏÏ
of the microcontact. No more resist- k
ance.

ÑÑ
ÏÏ
ÏÏ
ÑÑ ÏÏ j
ÏÏÏÏ
Continue unscrewing the screw (j)
ÏÏ
ÏÏ
ÑÑ ÏÏ ÏÏÏÏ
between 1/4 and 1/3 revolution (1/3

ÑÑ ÏÏÏÏ
ÏÏÏÏ
revolution corresponds to 2 flats of the

ÑÑ ÏÏÏÏ
screw). The resistance becomes infi-
nite again.

Lock (k) by maintaining (j) ÏÏÏÏ

ÏÏÏÏ
Check the working order of the micro-
contact
ÏÏÏÏ

EDITION : 5.07.04 35M - 0800 - 026 - 3 26

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

ÏÏÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏ
ÑÑÑÑÑ
Ï
ÏÏÏÏÏ
ÏÏÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï ÏÏ
ÏÏÏÏÏ
ÏÏÑÑÑÑÑ
ÏÏ ÑÑÑÑÑÑ
ÏÏÑÑÑÑÑ
ÉÉÏÏÏÏ
ÏÏÏÏ ÑÑÑÑÑÑ
Unscrew the nut (e), remove the
ÉÉ
ÉÉÏÏÏÏ
ÏÏÏÏ
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÏÏÑÑÑÑÑ
ÏÏ ÑÑÑÑÑÑ
spacer (f) and screw in the nut (e).

ÏÏÑÑÑÑÑ
ÏÏ
ÏÏÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑ
Ñ ÑÑ
Ñ Ñ
Ï
ÏÏÏÏ
ÑÑ
Ñ
ÑÑÑÑÑ
ÏÏÏÏ
Ï ÏÏ Ñ ÑÑÑÑÑÑ
ÑÑ
Ñ Ñ
ÑÑÑÑÑÑÑ
Ñ
ÑÑÑÑÑÑ f
e

ÏÏÏÏ d 1

ÏÏÏÏÏ
ÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏÏ ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏÏÏÏÏ
ÏÏ
Ï ÏÏ
ÏÏÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
Ï
ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ
a
Check the seal (d) condition.
ÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏ ÏÏÏÏÏÏÏ
Refit the cover (b) and screw in the
ÏÏÏÏÏÏÏÏÏ
ÉÉÑÑÑÑÑ
ÏÏ
ÏÏÏÏ
Ï ÏÏÏÏÏÏÏ
screws (a).
ÉÉ
ÉÉ
ÏÏÏÏÏÏÏ
ÏÏÏÏ
Ï ÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏ
ÏÏÏÏ
ÑÑÑÑÑ
ÏÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ ÏÏÏÏÏÏÏ b

ÏÏÏÏÏÏÏÏÏ
ÑÑÑÏÏÏÏÏÏÏ
ÑÑÑÑÑ
ÏÏ
ÏÏÏ
ÏÏ
Ï
ÑÑ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑ
Ñ ÑÑ
Ñ Ñ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÑÑÑÑÑÏÏÏÏÏÏÏ

27 35M - 0800 - 026 - 3 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

7. MAINTENANCE

7. 1. GREASING

Grease POLYGLYCOL/LITHIUM grade NLGI 000 (Special)

E.P. grease LITHIUM/CALCIUM grade NLGI 2

i In case of dismantling, clean and fill up with grease (35 cm3).

80 cm3

24 Nm

Greased for reduction gear lifetime

EDITION : 5.07.04 35M - 0850 - 089 - 0 28

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

7. 2. DISMANTLING THE MOTOR

OK

1- 2
1
1- 1
1- 3

2- 1
2 2- 2

3 3 - 1 Manual brake release of the motor so that the drum can be

rotated in order to reach the screws (1) with the screwdriver
bit (2) (see page 35M - 0800 - )

3- 2
2

3- 3
1
2 3- 4

29 35M - 0850 - 089 - 0 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

4 4- 1

4- 4 4- 2 4- 2-2 4- 3 4- 3-2

4- 3-1
4- 2-1

32 to 37 Nm

4- 5 4- 6 4- 7

4- 8 41 - 82 - 1

41 - 82 - 2

EDITION : 5.07.04 35M - 0850 - 089 - 0 30

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

7. 3. CHECKING THE FUNCTIONING OF THE OVERSPEED CARD

Starting from the speed information supplied by the encoder, the card checks that the motor speed does
not exceed 3800 r.p.m. and that it receives correctly the pulses during “Hoisting” (83 - 84 closed). In case
of overspeed or lack of pulses, the mains supply of the converter and the brake is cut.

The green LED blinks at each motor rotation.

i The red LED indicates a fault detection. It lights as long as the converter is not switched
off.

Overspeed card

Terminals 81 - 82

Green
Led
Red Led

Terminals 83 - 84
Terminals 85 - 86

Terminals 81 - 82: Overspeed fault contact

Terminals 83 - 84: Speed information higher than 50 r.p.m.
Terminals 85 - 86: Input of “O” signal of encoder (1 pulse per rotation).

7. 4. PERIODICAL CHECKING OF THE CARD FUNCTIONING

In order to check the good working order of this safety function, it is necessary to carry out at each erec-
tion or once a year the following procedure :
Switch off the crane by pressing upon the emergency stop.
Disconnect the wire connected to the terminal 86 (signal O of the encoder).
Switch- in the crane.
Operate “Hoisting”, about 120 r.p.m. (at least higher than 50 r.p.m.).
Check if the winch stops in less than 5 seconds (K400M releases).
Switch off the crane by pressing upon the emergency stop.
Reconnect the wire to terminal 86.
Check if the hoist winch correctly functions.

31 35M - 0870 - 002 - 0 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

7. 5. FAULTS DISPLAYED BY THE FREQUENCY CONVERTER

7. 5. 1. Faults linked to the frequency converter use

Mnemonics Reason of fault Check points Solution

No
On display

UU DC bus undervoltage - Power supply - Check the supply

terminals L1, L2, L3 network
mains undervoltage - 10 % + 6 % with load at
1
crane foot
- 15 % + 6 % at the
converter

OU DC bus overvoltage - Too fast decelerating - Check the longer

(inertial load) decelerating time at
- Terminals L1, L2, L3 00.04
2
mains overvoltage - Check the braking
resistors (resistors in
use)

OI. AC Excess current at - Power terminals U, V, - Suppress the

frequency converter W short - circuit at the
output - Wiring converter output
3 - Check the accelerating
time at 00.03
- Check the motor
insulation

OI. br Braking resistor excess - Power terminals +, . , - - Eliminate the

current - Braking resistor, value short - circuit at the
4 resistor output
- Check the resistor
insulation and value

PS Internal supply fault - Terminals + 10V and + - Check the voltage level
24V on +10V and +24V
5 - Suppress the
short - circuit on +10V or
+24V

Et Forced external fault - Terminal 30 in open - Check that the terminal

6 controlled in open loop loop mode 30 is connected to +24V
mode by the external wiring

OV. Spd Overspeed - Motor speed higher - Check that the load is
than the overspeed not driving
7
threshold - Check the speed loop
gains

Prc2 Fault of microprocessor - Load card HOISTING - Switch off the

2 when the load card converter, then make it
8 HOISTING is used alive again. If the fault
lasts, consult POTAIN
- Delete the fault

EDITION : 5.07.04 35M - 0900 - 019 - 0 32

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

Mnemonics Reason of fault Check points Solution

No
On display

SEP .dis Fault of the extension - Extension card : Check the following
card I/O UMV Inputs - Outputs (I/O) point:
(I/O) : overload of the
digital outputs
- Delete the fault
9
- Switch off the
converter, then make it
alive again. If the fault
persists, consult
POTAIN

ENC. OVL Encoder ASIC fault - Control card - Delete the fault
(frequency supply and - Switch off the
direction) converter, then make it
10
alive again. If the fault
persists, consult
POTAIN

ENC. PH5 Encoder channel A is - Encoder feedback on - Delete the fault

15 missing the D15 socket - Check the converter/
- Encoder encoder wiring
- Check the connection
ENC. PH6 Encoder channel B is
16 of the encoder wire
missing
shielding

ENC. PH7 Reversal of channel A - Encoder feedback on - Delete the fault

and B of the encoder D15 socket - Check the
Inversion of U, V, W - Encoder converter/encoder
17
phases between the wiring
motor and the converter - Check the wiring U, V,
W of the converter motor

it. br Overload of the braking - Braking resistor - Check the wiring

resistor - Wiring of the braking
19
resistor
- Braking cycle too long

it. AC Motor overload I x t - Motor load - Check that the motor is

not overloaded
20 - Check that the motor
nominal current is
correctly adjusted

Oh 1 Thermal simulation of - Adjustment of IN motor

21 the heatsink depending
on I x t

Oh 2 Heatsink overheating - Cooling fan (for those Check that :

detected by thermal equipped with one) * the fans are running
22
probe (above 90°C) - Ambient temperature * the cooling openings
are not obstructed
* that the temperature is
OA Overheating of the lower than 50°C
23 control card * there is enough space
around the converter

33 35M - 0900 - 019 - 0 EDITION : 5.07.04

3 1
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OPERATION
MAINTENANCE HOIST WINCH

Mnemonics Reason of fault Check points Solution

No
On display

OP. OVLd Overload of + 24V - Terminal + 24V - Check the load circuit
26
supply or digital outputs of + 24V

EEF EEPROM fault - Control card - Switch off and then

make it alive again.
31
- If the fault persists,
consult POTAIN

Ph Loss of a supply phase - L1, L2, L3 - Check the supply

32 network (motor standstill
before fault indication)

rs Fault during measuring - Matching of motor - Check the ohmic value

33 the stator resistor power to the converter of the stator resistors
power

Communication fault of - Optional module - Check the correct

optionnal encoder installation of the option
35 SEP EC - Menu 16
module
- Check the supply
voltage of the encoder

Fault during measuring - Optional module - Check the correct

36 SEP EF the stator resistor installation of the option
- Replace the module

7 OV.Spd Overspeed

The fault indications above given by the converter do not always correspond to the displayed fault, but
can be the consequence of an other fault.

i The thermal devices must not be reset several times in succession.

7. 5. 2. Signalling of the converter state by display

Display Output state Functioning

rdY Inactive The converter is waiting for an

order.
The motor is ready for running

run Active The motor is controlled

inh Inactive Free wheel stop

dEC Active Decelerating after a stop order

triP Inactive Converter fault. The fault code is

displayed

i The signallings above do not indicate a fault state, but the states of the converter.

EDITION : 5.07.04 35M - 0900 - 019 - 0 34

3 1
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 OPERATION
HOIST WINCH MAINTENANCE

7. 5. 3. Signalling of the converter alarms by the display

br.rs Overheating of the braking resistor

OVLd Motor overload I x t

hot Heatsink overheating

Air Excessive temperature of the control card

i When an alarm is displayed, the converters continues functioning and the lower display
alternatively indicates the normal message and the alarm code.

35 35M - 0900 - 019 - 0 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

7. 6. FAULTS LINKED TO THE HOISTING APPLICATION

7. 6. 1. List of faults

HF82 Switching off of the load card HOISTING when the

frequency converter is alive

HF83 to HF99 In case of display of these faults, try to

reinitialize, if this does not work, replace the
frequency converter

7. 6. 2. Faultsaults linked to the disconnection of the cards

Disconnecting the HOISTING card leads to a fault HF82 which causes the release of the main contactor
(K400M).
Disconnecting the input/output card leads to a fault Sep. dis which causes the release of the main
contactor (K400M).

7. 6. 3. Other faults controlled by the converter

a speed deviation (set value/frequency/speed feedback).
the encoder break.
the brake relay by terminal 26.
the overspeed.
the control switch coherence.
operating on 2 motor phases.

In case of a fault detected by the converter, the K405A relay releases and cuts the main
contactor K400M which causes also the brake application.

7. 7. CONTROLLING THE SAFETY DEVICES BY MEANS OF THE FREQUENCY

CONVERTER
The safety devices of upper and lower limit switches, upper decelerating, maximum load and maximum
moment are relayed and sent to the frequency converter at + 24V. The converter controls the standstills.
terminal 29 : immediate cutout of the hoisting movement; lowering is permissible at maximum speed.
terminal 28 : decelerating for hoisting: hoisting speed limited to 480 r.p.m.
maximum lowering speed authorized (according to the load).
terminal 27 : standstill on lowering ramp (1,8 s of max. speed at 0)
hoisting authorized at maximum speed (according to the load).
The upper limit switch is secured by an electromechanic redundancy. If the frequency converter does not
take into account the hoisting stopping, the K490A relay is not activated and the main supply relay for
hoisting K400M releases due to the action of the temporized contact of K480A. The good working order
of the K490A relay is tested at each putting into service of the crane. If the contacts stick (either those of
K490A, or terminal 40 - 42 of the converter), K400M could not close.

At normal functioning, during an operation of the upper limit switch, the converter controls
the immediate motor standstill. During a lowering control, the K490A relay shunts the
temporized contact of K480A before this latter cuts the supply of the main hoisting
contactor.
K320A allows operating the horn at a maximum load and a maximum moment cutout (The
horn must not be operated for a limit switch cutout).

EDITION : 5.07.04 35M - 0900 - 019 - 0 36

3 1
2
 OPERATION
HOIST WINCH MAINTENANCE

7. 8. AID TO FAULT CLEARANCE

7. 8. 1. Counter reading table

7. 8. 1. 1. Menu 0

Converte Size Software Serial no. Motor Motor no. Option Putting
r type type into
service

ADJUSTMENT
PARA -
DESIGNATION UNITY
METER Normal Displayed

0.00 Memorization
Return to the factory adjustments
Selection of the operating mode
Code for access to the other menus
Selection of the preset configurations
0.01 Minimum speed limit r.p.m. 0
0.02 Maximum speed limit r.p.m. 3600
0.03 Acceleration ramp s/ 0,6
tion
applicatio

0.04 Deceleration ramp s/ 0,6

thiss applic

0.05 Selection of speed references 3

0.06 Current limitation % of In 150
us d iin th

0.07 Proportional speed loop gain 400

Nott used

0.08 Complete speed loop gain 20

0.09 Gain derived from the speed loop 0
No

0.10 Encoder feedback (motor speed)

0.11 Reading of speed reference before limitation
0.12 Reading of speed reference after limitation
0.13 Encoder feedback
0.14 Converter ready
0.15 * Reading logic input 4 inputs on 4 bits
0.16 * Reading logic input 4 inputs on 4 bits
0.17 * Reading logic input 3 inputs on 3 bits
0.18 * Relay state 3 outputs on 3 bits
0.19 Motor current
0.20 DC bus voltage
0.21 Current torque % Cn
0.22 Measured torque % Cn
0.23 Alarm of overheat IxI
0.24 Integration of overload of braking resistor

37 35M - 0900 - 019 - 0 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

ADJUSTMENT
PARA -
DESIGNATION UNITY
METER Normal Displayed

0.25 Last fault detected List of last 4

faults
0.26 Fault preceding 0.25 For resetting,
type in the
0.27 Fault preceding 0.26 code 33 in
the parameter
0.28 Fault preceding 0.27
0.00
0.29 Time meter h
0.30 Converter software version + POTAIN
programme

7. 8. 2. (*) Logic inputs / outputs

Parameters Bit3 Bit2 Bit1 Bit0

00.15 5th notch 4th notch 3rd notch 2nd notch

00.16 K480 (29) K485 (27) K482 (28) External fault (30)

00.17 Hoisting Lowering

00.18 K405 (1 - 2) K490 (40 - 42) K409 (42 - 41)

Termi Termi Termi Termi Termi Termi Motor Parameter Parameter

nal 44 nal 45 nal 46 nal 48 nal 49 nal 50 speed 00.15 00.17
without
load

1 0 0 0 0 0 120 0 10
1 0 1 0 0 0 480 1 10
1 0 1 1 0 0 1350 11 10
1 0 1 1 1 0 2400 111 10
1 0 1 1 1 1 3600 1111 10
0 1 0 0 0 0 120 0 1
0 1 1 0 0 0 480 1 1
0 1 1 1 0 0 1350 11 1
0 1 1 1 1 0 2400 111 1
0 1 1 1 1 1 3600 1111 1

EDITION : 5.07.04 35M - 0900 - 019 - 0 38

3 1
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 OPERATION
HOIST WINCH MAINTENANCE

400 V TRI 50 Hz

Limitation of Current loop RECTIFIER

active current gain
Motor control
Torque
Moment PID Number of poles 0.42
Conversion Cos phi nominal 0.43
Nominale voltage 0.44
Nominal speed 0.45
Motor nominal current 0.46
Nominal frequency 0.47
Current
0.06
Limitation
D.C.Bus
0.20
Thermal 0.23
Protection MODULATION
total I
0.19 Switching frequency
0.41
I active

CALCULATION
I mag Current measure
OF CURRENT
AND TORQUE

Motor
0.21 Current torque
0.22 Measured torque
PID

Encoder
Torque ref.

0.13 Speed output

with feedback
Ramps
Overspeed
control
Speed 3800 r.p.m.
reference
before ramp

Stopping +
decelerating Optimised power
limitation limitation
0.22
0.16 0.17

0.11 Speed
reference

0.15

39 35M - 0900 - 019 - 0 EDITION : 5.07.04

3 1
2
 7. 9. FAULTS DISPLAYED BY THE FREQUENCY CONVERTER (CONT’D)
EDITION : 5.07.04

MAINTENANCE
OPERATION
Fault Formu - Duration of Description Source of errors Fault clearance
lation checking
tr63 >65º C tem- Ambient air > 65ºC Turn to summer position
perature
fault
tr64 Motor At each control Check that the correct The programmed torque Check:
connection torque level is reached level is not reached after - the motor wiring
fault before 300 cycles in step 20 1,5 s - the motor windings
- the validity of parameter 0.46
tr65 Speed Permanently Check that the speed Goes off if there is a Check:
deviation deviation (3.03) between deviation of more than - the encoder operation
fault reference after ramp and 540 r.p.m. between the - the brake operation
35M - 0900 - 020 - 0

speed feedback does not reference and the speed - the network supply voltage
exceed 15 % of the max. feedback
speed
tr66 Rotation At each control ABS feedback (speed) The motor cannot move Same checking as for tr64
direction must be > 100 r.p.m.; check the load
fault during a time from 150 to
250 ms that reference
speed and speed feedback
are in the same direction
3

tr67 Encoder Permanently Operate a delay time of 350 The encoder position Check:
fault ms when controlling and does not change during - the good brake working order
2
1

check that the position more than 100 ms - the tightening of the connections
changes. Release if the - the connection cable and the encoder operation
position has not changed
20 consecutive cycles (100

HOIST WINCH
ms)
40
 41

tr68 Brake or Permanently The brake feedback must The brake contactor Check:

HOIST WINCH
brake be = control after a time feedback (or contact on - the brake contactor wiring
contactor <500 ms the yoke) is not equal to - the feedback wiring (B26)
fault its control - the wiring and adjustment of the contact on the yoke (if there
is one)
- the air gap adjustment and disk wear. Check the B41 output
(control of K409 contactor)
- K405 state (cut by overspeed card (81/81) if it is faulty)
tr69 Control Permanently Supervision of coherence Incoherence in the Check the arrival of the notches in 0.15 and 0.17
switch fault of the notches 2, 3, 4, 5 control notches
(order and number)
3 OIAC Permanently Excess current at converter DC at converter output, Check:
output or motor current loss motor insulation fault, - the motor and connection wiring and their insulation
brake or encoder fault - the brake operation
- the encoder operation
35M - 0900 - 020 - 0

If it is possible, control low speed and check the feedback displayed in 0.10 (closed loop). It must be stable and indicate 120 or 180
r.p.m. (according to the programme version).
If it is not possible, disconnect the encoder from the motor shaft and turn the encoder manually in one direction and then in the other
one. Supervise the speed (displayed in r.p.m. in 0.10). It must change positively and negatively.
Checking the encoder These 2 procedures allow to detect a straight encoder failure. In order to go farther, see the next paragraph. Check the earthing of the
operation plaiting and all the connections.
If available on the converter (programme version sup 2002 26), go to open loop. Without load or with a small load, operate 3rd notch.
The parameter 0.13 displays the speed feedback. It must be between 1340 > feedback > 1350 for a hoisting control, and - 1360 <
3

feedback < - 1350 for a lowering control. The lowering speed must be higher than the hoisting speed.
2
1

Checking the brake Check:

- the air gap
- the brake supply voltage 180 V DC (33 and 75LVF) or 360 V DC during 500 ms, then 180V DC (50 and 100 LVF).
EDITION :

MAINTENANCE
OPERATION
5.07.04
 EDITION : 5.07.04

MAINTENANCE
OPERATION
Do not carry out a control and check the following points
When making alive the converter, the green LED can be lit or switched off. The red LED is switched off if there is no fault and the contact
81/82 is closed.
If the red LED is switched off and the contact 81/82 is open, the SV card is in “internal fault” : replace the equipment.
Checking the If the red LED lights a few seconds after making alive (therefore cuts K405 and K400):
“runaway” card check that the contact 83/84 is open when the crane is stopped (K490 relay)
Carry out a shunt between 83 and 84. The card must turn to faulty state (red LED is lit) after 5 to 10 seconds
Operate the 1st notch and check the following points
The green LED must regularly flash (1 flashing per motor revolution). If this is not the case, check the connection of the 0 signal of the
encoder which arrives on the terminal strips 85 / 86 (square pulse 0 / 5 V).
35M - 0900 - 020 - 0
3
2
1

HOIST WINCH
42
 OPERATION
HOIST WINCH MAINTENANCE

7. 10. FAULT CLEARANCE INSTRUCTIONS

7. 10. 1. REPLACEMENT OF THE “HOISTING” CARD OR OF THE FREQUENCY

CONVERTER

Winch Menu

0.43 0.45 0.46

33LVF 0,928 1380 46 A
50LVF 0,936 1384 70 A
75LVF 0.916 1385 116A

7. 10. 2. METHODOLOGY FOR REPLACING THE FREQUENCY CONVERTER

L1 L2 L3 U V W + . -
Disconnect the power wires and mark the wires.

1 2 3 4 5 6 7 8 9 10 11

Disconnect the logic input and logic output terminal

strips. 21 22 23 24 25 26 27 28 29 30 31

ÉÉÉÉÉ
ÇÇÇ
ÉÉÉÉÉ
ÇÇÇ
É
ÉÉ
ÉÉÉÉÉ
ÇÇÇ
É
ÉÉÉ
É
ÉÉÉÉÉ
ÉÉ É
ÇÇÇ
ÉÉÉ
ÉÉÉÉÉ
ÇÇÇ
É
ÉÉÉ
Disconnect the encoder cable.

ÉÉÉÉÉ
ÇÇÇ
É
ÉÉ
ÉÉÉÉÉ É
ÇÇÇ

43 35M - 0950 - 009 - 0 EDITION : 5.07.04

3 1
2
OPERATION
MAINTENANCE HOIST WINCH

On the top of the frequency converter

Remove the ventilation cap.

Lay down the wedges.

Remove the frequency converter.

EDITION : 5.07.04 35M - 0950 - 009 - 0 44

3 1
2