Instruction Manual IB-2405.A MITSUBISHI

MITSUBISHI MITSUBISHI INVERTER HOIST

Type UR-H (lifting type inverter hoist) Type UR-S (lifting/traversing type inverter hoist)

INSTRUCTION MANUAL

☆ Be sure to hand this instruction manual to the person in charge of facilities before starting

operation. ☆ Be sure to have the person in charge of facilities and operators read this manual thoroughly

before starting operation.

Standard Version

Instruction Manual IB-2405.A

Safety Precautions You Must Observe ■ The following headings and symbols are used in this

manual to explain the dangerous conditions and their degrees if the hoist is operated or handled incorrectly.

! DANGER Incorrect operation may cause dangerous conditions due to load or electrical shock that may result in death or severe personal injuries.

! CAUTION Incorrect operation may cause dangerous conditions that may result in personal injuries or loss of properties.

1. Installation and Operation in General

DANGER

Persons without compulsory or statutory qualification must not operate the hoist crane or sling an article. See page 2. Only personnel thoroughly understanding the instruction manual and caution plate descrip-tions are allowed to operate the hoist crane.

Be sure to check the hoist crane before starting operation. Carry out periodical, self-elected inspection. Install stoppers at the ends of the longitudinal and traverse rails.

Only specialists or persons with appropriate, particular knowledge are allowed to install the hoist crane.

Be sure to install the hoist crane on a structure that is sufficiently strong.

Do not install the hoist crane in any place or area that do not comply with the installation requirements, such as where the hoist crane is exposed to rain or water.

Be sure to install ground wiring. Install an earth leakage circuit breaker in the electrical power line.

2. Operation

DANGER

■ To avoid personal injuries, observe the following precautions. ⋅ Do not step on the suspended article. ⋅ Do not come under the suspended article. ⋅ Do not operate the hoist crane if anyone is

within the area where a suspended article moves. (Do not carry an article over a person.)

■ Operational precautions ⋅ Do not leave the hoist crane with the hoist

crane suspending an article. ⋅ Keep paying attention to the suspended

article while operating the hoist crane. ⋅ Do not operate the hoist crane in a manner

that the suspended article or load block is swung.

■ Do not operate the hoist crane if pre-operation inspection reveals an abnormality, such as follows. ⋅ If the pushbutton switches do not operate

normally. ⋅ If the hoist crane operates in a manner not

intended by the pushbutton operation. ⋅ If the brake system does not operate

securely. ⋅ If the hoist crane is damaged or generates

abnormal noises or vibration. ⋅ If the wire ropes are found abnormal.

If the number of broken element wires exceeds the standard. Or, the element wires are worn excessively.

■ Do not operate the hoist crane in the following manners. ⋅ Do not operate the hoist crane exceeding the

rated load. ⋅ Do not operate the hoist crane in a manner that

the over-winding limit switch is used often to stop lifting the load.

⋅ Do not pull load with the hoist crane. (Be sure to place the hoist hook right above the load before lifting it.)

⋅ Do not lift any articles that are installed on the ground, such as a building structure.

⋅ When lowering an article, do not exceed the lower limit.

⋅ Do not use the hoist crane to turn over or rotate an article. (Use a dedicated equipment for such purposes.)

<Abnormal use> ⋅ Do not arc-weld an article while it is suspended

by the hoist crane. ⋅ Do not connect the grounding cable of an

welding machine to the wire ropes. ⋅ Do not let welding electrode come in contact

with the wire ropes.

■ The following symbols are used.

NEVER

Be sure to follow instructions.

Be sure to ground electrically.

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CAUTION

⋅ Operate the hoist at the rated voltage only. ⋅ Never operate the hoist if the wire stopper on

the hook is left broken. ⋅ Do not pluck (abrupt reversal). Do not jog

(inching) the hoist excessively. ⋅ Do not let the suspended article be caught on a

structure or electrical wiring. ⋅ Do not let the pushbutton box cable be caught

on others. Do not pull it hard.

⋅ Do not let the hoist main body or trolley run into a stopper or a structure.

⋅ Never operate the hoist exceeding its duty cycle or start/stop frequency.

⋅ Do not remove the warning or caution plates from the hoist main body. Always make them clearly legible.

⋅ Do not use the phase advancer capacitor designed for power factor improvement.

⋅ Check that the hook swivels smoothly before use.

⋅ Engage the slings and sling devices correctly with the hoist hook.

⋅ Stop winding up the wire rope once when it becomes tight.

⋅ Clean the pushbutton switches free from dust or sand.

3. Check, Maintenance and Modification

DANGER

⋅ Never modify or alter the product or its accessories.

⋅ Never use anything other than Mitsubishi genuine parts.

■ Before starting maintenance, inspection and repair: ⋅ Be sure to cut off the power supply. ⋅ Be sure to assign the plant-designated

personnel having appropriate, particular knowledge.

⋅ Make sure that the hoist crane is not loaded. ⋅ If an abnormality is observed, do not leave it

unattended. Repair it immediately.

CAUTION

Before maintenance, check or repair, be sure to put up appropriate signs such as “Now inspected” or “Do not turn on power.”

Cautions

• For inspections that involve disassembling and reassembling the hoist, be sure to order the services to Mitsubishi Electric Hoist Corporation (see the back cover of the instruction manual) or your local Mitsubishi Electric dealer.

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Contents

Checking Products and Regulatory Restrictions ................................................................ 1 Checking When You Receive the Hoist ............................................................................. 1 Hoist Crane Application Chart (Shaded area) .................................................................... 1 Regulatory Requirements ................................................................................................... 2

Installation Instructions ......................................................................................................... 4 Installation of Hoist and Stoppers ...................................................................................... 4 Ground Wiring and Installing Earth Leakage Circuit Breaker ........................................... 4 Electrical Wiring................................................................................................................. 5 Installation on I-Beam ........................................................................................................ 7 Adjusting the Pushbutton Pendant Height .......................................................................... 9

Test Run ................................................................................................................................ 10 No-Load Operation ........................................................................................................... 10 Load Test Run .................................................................................................................. 11

Operation .............................................................................................................................. 12 Lifting/lowering operation ................................................................................................ 12 Traversing operation (in inverter mode) ........................................................................... 13 Error indicator lamp.......................................................................................................... 13 Operation using programmable controller ........................................................................ 14

Setting/Changing Speeds ..................................................................................................... 15 Speed Setting before Delivery .......................................................................................... 15 Setting/Changing Low Lifting Speed ............................................................................... 15 Setting/Changing Traversing Speed and Traversing Operation Acceleration/ Deceleration Time ............................................................................................................ 17

Maintenance and Inspection of Brake ................................................................................ 18 Electromagnetic Hoisting Brake ....................................................................................... 18 Traversing Electromagnetic Brake ................................................................................... 21

Inspection and Maintenance of Wire Rope ....................................................................... 22

Structure, Disassembly and Re-assembly of Reduction Gears ........................................ 23 Hoisting unit ..................................................................................................................... 23 Traversing Unit ................................................................................................................. 24

Maintenance and Inspection ............................................................................................... 25 Daily Inspection of Hoist .................................................................................................. 25 Monthly Inspection ........................................................................................................... 27 Annual Inspection ............................................................................................................. 30 Lubrication........................................................................................................................ 31 Operation Limit of Main Parts.......................................................................................... 32 Replacement of Controller Parts....................................................................................... 33

General Troubleshooting ..................................................................................................... 34 Developed Connection Diagram of Electric Hoist ............................................................. 39 Structural Drawing of Hoist Main Body ............................................................................ 43 Procedure for Straightening Entangled Wire Rope ......................................................... 53

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Checking Products and Regulatory Restrictions

Checking When You Receive the Hoist When you receive the hoist, check it as follows.

(1) Check that the hoist corresponds to your purchase order (by the nameplate). (2) Check that the hoist is not damaged during transportation. (3) Check that the insulation resistance of each electrical component with a 500 V insulation

resistance tester (or a megger tester). (The hoist is acceptable if the insulation resistance tester reads 1 MΩ or greater in each measurement.) * Insulation resistance test procedure ● Turn off the power. ● Connect the hoist power receive terminals R, S and T to short the R-S-T line. ● While turning on the hoist main body and the contactors of the hoist power receive

terminals R, S, and T sequentially in the manual mode, measure the insulation resistance using the 500 V insulation resistance tester.

Write down the type designation and the manufacturing number that are described on the nameplate. (For inquiries about your hoist, these pieces of information are necessary.)

Hoist Crane Application Chart (Shaded area)

Standard type application chart Operating time of

hoisting devices

Load condition

Less than 800 hrs

800 hrs or more and less than 1,600 hrs

1,600 hrs or more and less than 3,200 hrs

3,200 hrs or more and less than

6,300 hrs

6,300 hrs or more and less

than 12,500 hrs

12,500 hrs or more and less

than 25,000 hrs

25,000 hrs or more

Hoist crane usually handling less than 50% of rated load A A A B C D E

Hoist crane usually handling 50% or more and less than 63% of rated load.

A A B C D E F

Hoist crane usually handling 63% or more and less than 80% of rated load.

A B C D E F F

Hoist crane usually handling 80% or more of rated load. B C D E F F F

Applicable types

Type E Type R Type UR

Type S Type U ,U2 Type HU

Type S special modelType U special modelType HU special model Large cranes

Symbols A through F (Class A through Class F) represent the crane structural standards application groups.

(Note) Class C types may be applied to hoist cranes requiring a lift of more than 12 meters. Allowable duty time and start frequency

Type

Allowable duty

Type E

Type R Type UR

Type U (7.5 t - ) Type HU

Type S Type U, U2(-

5 t)

Duty ratio (%) 25 25 40 Start frequency (cycles/hour) 150 250 400

* The maximum start frequency per hour is shown in the above table. * Special design is needed if the duty ratio is more than the above

value.

* Duty ratio: During 1 hour of hardest operation = Total of motor energized time (min)

60 ×100

CAUTION ● NEVER operate the hoist crane exceeding the duty ratio or start frequencies.

* Or else, a suspended article may fall due to deterioration in strength of parts.

Crane type and applicable categories

Power plant cranes, cranes for disassembly and inspection A Cranes in machine shops and assembly shops A General workshop cranes B-DOverhead cranes (with bucket, magnet) D-FLadle crane E-FCharging crane F Forge crane F General purpose bridge cranes (with hooks) B-C

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Regulatory Requirements

DANGER

● Do not use a hoist for any purpose of transporting persons. * Personal injuries may result due to falling. It is prohibited by law to use a hoist for use in a

device for lifting persons. ● Only personnel thoroughly understanding the instruction manual and caution plate descriptions are

allowed to operate the hoist crane. ● Persons without compulsory or statutory qualification must not operate the hoist crane or sling an

article. Do not let such persons do so, either.

Use of hoists are regulated by the labor safety and health code and related government ordinance and ministerial ordinance. Refer to these regulations in detail for full compliance. The key points are described as follows.

1. Application for Installation To use this hoist as a crane or a simplified lift, you should submit an installation report or installation notice to the local Labor Standards Inspection Office in accordance with the crane safety code. See the table below.

Type of crane Capacity

Crane manufacturer Crane user

Manufacturing permit

Installation notice and performance

inspection Installation

report Maintenance

obligation

Crane Suspended load

≥3 t ○ ○ ○ ≥1/2 t <3 t ○ ○

* The Type UR Hoist cannot be used as a lift because the ratio of the drum diameter to the rope diameter (D/d) is less than 20.

● Regarding the crane manufacturing permit, where a hoist crane is concerned, the hoist and crane manufacturer must apply jointly.

● To use the hoist as a crane or a simplified lift, you should observe the crane structural standard or the simplified lift structural standard.

● When the hoist is used, it is governed by the crane safety code.

2. Operator Qualification To be associated with slinging 0.5t or heavier articles or with operating a hoist of 0.5t capacity or greater, one must be qualified in accordance with ordinance by the Ministry of Labor. See the table below.

Operation method Suspended load <0.5 t ≥0.5 t <5 t ≥5 t

Monorail hoist (Ls) (Sk) (Sp) General personnel

(Ls) (Sk) (Sp) (Ls) (Sk) (Sp) Floor-operated (Ls) (Sk) (Sp) (Ls) (Sk)

Remote control or equipped with operator cab (Ls) (Sk) (Sp) (Ls)

Applicable clauses of crane safety code — Clauses 21 and 22

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Slinging Suspended load

<0.5 t ≥0.5 t <5 t ≥5 t

Slinging (Ls) (Sk) (Sl) (Jb) (Sp)General personnel (Sl) (Jb) (Sp) (Sl) (Jb)

Applicable clauses of crane safety code — Clauses 221 and 222

(Ls) ... Personnel who have license to operate cranes (Sp) ... Personnel who receive special education and training on cranes and slinging from the company

undertaker (Jb) ... Personnel who receive training in accordance with the Vocational Training Act (Sk) ... Personnel who complete the course of operating skill for floor-operated cranes (Sl) ... Personnel who complete the course of slinging skill

3. Maintenance Obligation by Regulations To use a hoist, the user is obliged to carry out periodical self-elected inspections and to retain the inspection records. ● Daily inspection. Monthly and annual self-elected inspections ● Retention of monthly and annual self-elected inspection records for three years

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Installation Instructions

Installation of Hoist and Stoppers

Consult your dealer or the nearest Mitsubishi Electric Service Center about the rail and hoist installation. Be sure to have a specialist firm carry out the installation. If traversing distance is too long, and connection of another I-beam is needed, carefully weld the two I-beams so that they are properly aligned with each other. After welding, smoothly finish the welded joint section, and the wheel and flange running section. If joint plates are needed, attach them to both the upper and lower surfaces of the I-beam joint section. Install a stopper on both ends of I-beam to prevent overrun of wheels. Do not frequently contact the hoist to the stoppers to stop the hoist. Be sure to attach cushioning material, such as rubber to each stopper. Be sure to use stoppers larger than half of the diameter of the wheels. Use identical size stoppers to the double-rail type also.

DANGER

● Only specialists or persons with special knowledge are allowed to install the hoist. * Personal injuries may result due to electrical shock or falling hook block.

● Do not install the hoist in any environment that are not specified, such as where the hoist is exposed to rain or water spray.

● Be sure to install stoppers at the ends of the traversing and the longitudinal travel rails. * Personal injuries may result due to falling hoist.

● Check that the hoist is installed on a structure that is sufficiently strong. * Personal injuries may result due to falling hoist.

Ground Wiring and Installing Earth Leakage Circuit Breaker

To avoid electrical shock due to fault current, be sure to install a ground wiring and install an earth leakage circuit breaker in the electrical line. Install class C or Class D electrical grounding according to Electrical Equipment Technical Standard and Internal Wiring Standard. (For a Class 400 V power line, use Class C electrical grounding and grounding resistance of 10 Ω or less.) ○ For motored traversing hoists Ground the I-beam or rail as shown above. Do not coat the wheel running surfaces.

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Joint section

(Wheel running surface)

No-coating required

Smooth finishing

StopperCushioning material

Cushioning material

Rail

Double-rail stopper

I-beam

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○ For suspended hoists Remove paint coating and rust from the point of installation. Install it on a steel structure

that complies with Class C or Class D electrical grounding requirements. (Make sure that the main body will not be electrically insulated.)

When the hoist is installed on a wooden structure, ground the hoist main body with electrical wire of 2.6 mm in diameter or greater.

DANGER

● Be sure to install a ground wiring. In addition to the grounding wiring, install an earth leakage circuit breaker in the electrical line.

● Adopt the Class C or Class D grounding work for this hoist. ● Install electrical grounding and earth leakage circuit breakers according to the

requirements of Electrical Equipment Technical Standard and Internal Wiring Standard. * This is to prevent electrical shock injuries in the event of fault current

Electrical Wiring

Observe the technical standards for electric equipment and the regulations for internal wiring. The hoist can be supplied with power through trolley wire or power supply cable.

1. Trolley type To prevent accidents, such as an electrical shock, use an insulated trolley. Various insulated trolleys are commercially available. Select a trolley wire conductor with proper capacity and specifications.

2. Power supply cable type When supplying power through cable, use a specified cabtyre cable. ○ Do not connect cables. Use a cable having a required length, and connect the cable

directly to the terminal in the control box. ○ Retain the cable in such an appropriate manner that the cable tension is not applied directly

to the terminal.

Determine the cable size depending on the cabling distance so that a voltage drop will not occur.

Power supply cabtyre cable allowable length

Hoist capacity (t)

Motor capacity (at 60 Hz)

Cabtyre cable allowable length (m) for 3-core cable Nominal sectional area of conductor (mm2)

1.25 2 3.5 5.5 8 14 1 1.4 39 62 115 179 2 2.6 25 40 75 117 (165)

2.8 3.6 ⎯ 21 39 61 (86) (152)

(Note) (1) The table shown above is applicable to 200V class hoists in the case when a voltage drop between the transformer and hoist is kept at 10%.

(2) The values shown above are determined on consumption that only the hoisting motor is provided. When a hoist crane is used, the capacity of the crane traveling motor must be added.

(3) If the hoisting motor is not a standard type (the starting current and power factory may differ), see the table. (4) If the transformer capacity is lower than 3 EIs, a voltage drop in the transformer must be taken into

consideration. (5) When an allowable cable size enclosed in parentheses is adopted, the cable outlet hole must be additionally

machined, and the solderless terminal or the terminal block must be modified.

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3. Others (1) Reactor installation

If it is necessary to improve the power factor, or if it is necessary to install the hoist near a high-voltage power supply unit (1,000 kVA or more, cable length = 10 m or less), be sure to install a reactor. Without a reactor, the inverter may be damaged. To install a reactor, please contact us.

(2) Measures against noise There are several types of noises. The noise sent from the external unit may cause abnormal operation of the inverter. The noise generated by the inverter may be sent back to the power supply line. The radiated noise may cause abnormal operation of the peripheral units. ● Suppression of noise sent from external units

Install a surge killer on each peripheral unit that may generate large noise.

● Suppression of noise generated by inverter We recommend use of noise filter SF1259.

Characteristics of noise filter SF1259

Approximate weight (kg) Loss (W) Leakage current

(reference value) (mA) 2.4 2.7 33

<Measures against leakage current>

If the electric current leaks from the hoist, the peripheral units may perform abnormal operation, and you may get an electric shock. To prevent electric current leakage, take the following measures: 1) Before connecting the power supply line, be sure to ground the noise filter. At the

completion of grounding, check that the noise filter is surely grounded to the earth via the grounding part of the control panel.

2) When selecting a leakage current breaker or leakage current cut-off relay, be sure to consider the leakage current of the noise filter. The leakage current of the noise filter is very large. If the leakage current breaker or the leakage current cut-off relay is not used, be sure to ground the noise filter as described in 1).

4. Do not use any phase advancer capacitors. Do not connect any phase advancer capacitors to the secondary side of the inverter. This is because a phase advancer capacitor on the secondary side may cause explosion. In addition, the higher harmonics of the inverter may affect the phase advancer capacitor on the primary side.

5. Consideration of leakage current The motor of this hoist is driven by the inverter, and the output voltage of the inverter contains higher harmonics. For this reason, ground leakage current may be generated depending on the grounding capacitance of the electric line between the inverter and the motor and also depending on the floating capacity between the motor winding and the iron core.

2 mm

dia hole

Dimensional outline drawing

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Earth leakagecircuit breaker Inverter

Power supply

Motor

Leakage current to the earth

Hoist

Leakage current flows through the own inverter system. In some cases, however, leakage current may flow into the other system via the grounding line. To prevent unnecessary operation caused by the leakage current, set the rated sensitivity current of the leakage current breaker to 100 mA or more. In this case, the leakage current breaker also functions as a fire preventive device.

Installation on I-Beam

The I-beam can be used in two or three ways. Before shipment, the I-beam width has been set as shown in the following table. Change the spacer position as shown in Fig. 1-1 through Fig. 1-3 depending on the I-beam to be used.

Washer (1.6 mm thick)

Frame

Traversing side plate

Spacer (6 mm thick)

Slotted nut

Split pin

Clamping bolt

Fig. 1-1 Applicable I-beam:

Minimum width

Fig. 1-2 Applicable I-beam: Intermediate width

Fig. 1-3 Applicable I-beam:

Maximum width

I-beam width 1 t 2 t 2.8 t Remarks:

1. For the 2.8t type, the width of the I-beam can be adjusted in two ways. For them, two spacers (6mm length) are required on one side.

2. The asterisked figures indicate the states before shipment.

75 mm Fig. 1-1

100 mm *Fig. 1-2 Fig. 1-1

125 mm Fig. 1-3 *Fig. 1-2 Fig. 1-2

150 mm Fig. 1-3 * Fig. 1-3

The clearance between the inner side of the wheel flange and the I-beam is approximately 4.6 mm. Check the clearance before installation (see the following figure). To adjust this clearance, change the washer (1.6 mm) positions to the inside or the outside of the traversing side plate. Fit the same number of spacers and washers on both sides of the flame. Consider the balance when fitting the spacers and washers.

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The hoist could be installed most easily from one end of the I-beam. However, in most cases, the I-beam ends are not open. So pull out the split pin (see Fig.1) and loosen the nut to open the traversing side plates to the respective sides. The side plates are tightened with slotted nuts. When aligning the pin hole with the slot of the slotted nut, be sure to tighten the nut (do not loosen the nut). In addition, when a new hoist is installed on the existing I-beam, the I-beam may be worn out. For these reasons, be sure to adjust the clearance using the actual hoist installed on the I-beam.

4.6 mm (3.6 - 5.6 mm)

I beamWheel

With flange

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Adjusting the Pushbutton Pendant Height

The pushbutton is hung with a wire rope. The upper end of the wire rope is clipped. Change the clipped position of wire rope, and then adjust the pushbutton height to the optimum position for the work. After adjustment, fix the excess cable with a bundling band to prevent sagging. Carefully adjust the pushbutton height so that the cable can be kept away from the heated area of the discharging resistor, etc. Carefully adjust the pushbutton height so that the cable can be kept away from the heated area of the discharging resistor, etc.

Pushbutton pendant

Adjust

Clip

Clip

Cable

Adjusting the pushbutton pendant height

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Test Run

No-Load Operation

(1) Press the DN pushbutton switch to the first step. The hook block will be lowered at a low speed, and there will be margin for lifting operation.

(2) Press the DN pushbutton switch to the second step, and check whether the hook lowers at the high-speed operation mode. If the hook is lifted, exchange the connected terminals of the R-phase and T-phase wires with each other. The power cable has 3 wires: R-phase, T-phase, and grounding wires. To operate 2 or more hoists on the same trolley line, be sure to exchange the wires on the terminal boards of the current collection area and the motive power connection area in the control box. In this case, do not exchange the wires of the pushbutton switches.

(3) If the hook is lifted by pressing the DN pushbutton switch due to reverse winding of the wire rope, the hook will move to the second stage limit switch. After this operation, the hoist will not be operated by any pushbutton switches. In this case, follow the procedure below to restore operation:

1) Remove the connection rod linking the lever and the limit switch.

2) Turn the clockwise the shaft beside the control box to restore the limit switch. Keep the arm on the shaft. The shaft of the low-head type, however, is in a different direction. For this reason, turn the shaft of the low-head type clockwise to restore the limit switch.

3) Press the DOWN button to lower the hook gradually by inching. Before lowering the hook, be sure to exchange the connected terminals of the R-phase and T-phase wires with each other.

(4) Re-assemble in the order reverse to the disassembling order. “EAST” and “WEST” shown on the pushbuttons respectively indicate the traveling directions when the hoist is viewed from the control box (see the figure shown on the right side). Last of all, run the hoist over the whole length with no load, and make sure that there are no abnormalities.

Connection rod Arm

Traversing

Lever

West (Left)

East (Right)

Control box

(In the case of a double rail type, the control box is located in the east, and the opposite side is in the west.)

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CAUTION

● Do not correct reverse phase connection by changing the pushbutton wiring. * The limit switches will be made inoperative, causing the wire ropes to be cut off. This

may in turn cause personal injuries due to falling load.

Load Test Run

(A) Rated load test run Hang a rated load, and lift and lower the load to check the effect of the brake. Run the hoist over the whole length to make sure that the I-beam and trolley wire for nonconformities. Then, conduct characteristic test and performance test.

(B) Overload test run Hang a load of 125% of the rated load, and lift and lower the load several times. The hoist has been certified by carrying out overload test runs with a load of 125% before shipment. However, the user is recommended to carry out the overload test runs from the viewpoint of safety because the installation of I-beam and other devices can be checked by this test. The test is designed to check the mechanical strength of each part. The performance test shall be carried out with the rated load. * For this test, lift the load at a high speed. If the load is lifted at a low speed, the torque

may be reduced. During high-speed lifting operation, however, the hoist may be stopped due to the overloaded inverter (tripping). This is not an error. So if the hoist is stopped, release the pushbutton switch, and then press the switch again.

(C) Adjusting the traversing brake (If commercial power is used for traversing operation) If the brake is too effective when traversing is stopped, load collapse may occur. On the contrary, if the brake is not effective, the hoist may coast and cause an accident. Open the steel plate cover of the traversing motor, and turn the bolt in the cover for adjusting the traversing brake to an optimum force at which load collapse will not occur. The brake adjustment range is 0% to 100% of the motor torque. Before delivery from our factory, the brake is adjusted to 50%.

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Operation

Lifting/lowering operation

The UP (lifting) and DN (lowering) pushbutton switches are the 2-step type. Press each switch to the first step to perform lifting/lowering operation at a low speed. Press each switch to the second step to perform lifting/lowering operation at a high speed.

Speed change between high speed and low speed (lifting/lowering operation)

PressingPushbutton

1st step 2nd step

Lifting Low speed (operation in inverter mode) High speed (operation in inverter mode)

Lowering Low speed (operation in inverter mode) High speed (operation in commercial power supply mode)

* If you press the DN pushbutton switch to the first step, the lowering operation will be performed at a low speed in the inverter mode. If you press the DN pushbutton switch to the second step, the lowering operation will be performed at a high speed in the commercial power supply mode.

There are slide switches at the lifting operation inverter. During low-speed operation, change the set positions of these slide switches to change the speed. For a detailed description, refer to “Setting/Changing Low Lifting Speed”.

Caution in operation (1) If the first upper limit switch is activated during lifting operation, the DN switch will not

be valid for 0.5 seconds after releasing the UP switch. (2) If the power failure detector detects instantaneous power failure, the operation will be

stopped and will not be restarted for 0.5 seconds. If the operation pushbutton switch (UP or DN switch) currently held down is not released during instantaneous power failure, the operation will be restarted 0.5 seconds later.

(3) If a problem, such as overload, voltage drop, or hoisting motor temperature rise, occurs, the operation may be stopped. In addition, the load may be lowered or dropped. In this case, take the following measures: • Immediately stop the operation. • If the problem is caused by voltage drop, raise the power supply voltage. • If the problem is caused by hoisting motor temperature rise, wait until the motor is

cooled enough. (4) If operation is performed with a disconnected phase:

The operation conditions will be as shown in the following table. In this case, immediately connect the phase.

Disconnected phase

Connected phase

Lifting Lowering

Low-speed operation High-speed operation Low-speed operation High-speed

operation R S-T Stops operation.

(The error indicator lamp (LED lamp) will not light.) S R-T

T R-S

Continues normal operation, or stops operation. (The error indicator will indicate that the voltage is too low.)

Stops operation. (The error indicator will indicate that the voltage is too low.)

Continues normal operation, or stops operation. (The error indicator will indicate that the voltage is too low.)

Stops operation, or continues operation in the single-phase commercial power supply mode (the hoist may generate abnormal noise).

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Traversing operation (in inverter mode)

The EA (eastward) and WE (westward) pushbutton switches are the 2-step type. Press each switch to the first step to perform eastward/westward traversing operation at a low speed. Press each switch to the second step to perform eastward/westward traversing operation at a high speed.

Speed change between high speed and low speed (traversing operation)

PressingPushbutton

1st step 2nd step

Traversing EA/WE Low speed (operation in inverter) High speed (operation in inverter)

There are DIP switches at the traversing operation inverter. Use these switches to change the speed or acceleration/deceleration time. For a detailed description, refer to “Setting/Changing Traversing Speed and Traversing Operation Acceleration/Deceleration Time”.

Error indicator lamp

(1) There is an error indicator lamp (LED lamp) on the lifting operation inverter board and the traversing operation inverter board. Each error indicator lamp will flash as shown in the following table to inform the inverter conditions.

Error indication by LED indicator lamp Inverter condition Lamp condition

Normal Repeats the following cycle: Flashes once. → Kept at the OFF status for 1 second.

Voltage too low Repeats the following cycle: Flashes twice. → Kept at the OFF status for 1 second.

Pushbutton error Repeats the following cycle: Flashes 3 times. → Kept at the OFF status for 1 second.

Overvoltage Repeats the following cycle: Flashes 4 times. → Kept at the OFF status for 1 second.

Overcurrent Flashes every 0.1 seconds.

(2) If the problem is solved, releasing the pushbutton switch (UP or DN switch for lifting/lowering operation/EA or WE pushbutton switch for traversing operation) will cancel the error status. Press the pushbutton switch again to restart operation.

(3) Just after power-on, the error indicator lamp may flash to inform that the voltage is too low. In this case, however, the voltage will be normal soon. So ignore the error indicator lamp, and press a pushbutton switch. The operation will be started, and the error indicator lamp will inform the normal condition.

- 14 -

Operation using programmable controller

If the output circuit of the programmable controller is the SSR type, the leakage current of the snubber circuit may cause the hoist to perform unstable operation, or may turn on the hoist.

Measures: Connect resistor R to the external circuit to bypass the leakage current.

Sequencer output circuitHoist input circuit

Snubber circuit

Bypassing leakage current from the snubber circuit

R = Approx. 30 kΩ, 3 W

- 15 -

Setting/Changing Speeds

Speed Setting before Delivery

Before delivery, the speeds for various operations are factory-set as follows:

Speed setting before delivery

Capacity 1t 2t 2.8t

Lifting/lowering speed

50 Hz

Lifting (Low speed) 0.0133 m/s

(High speed)0.133 m/s

(Low speed)0.012 m/s

(High speed) 0.12 m/s

(0.8 m/min) (8 m/min) (0.72 m/min) (7.2 m/min)

Lowering (Low speed) 0.0133 m/s




(0.8 m/min) (6.7 m/min) (0.72 m/min) (6 m/min)

60 Hz (Low speed) 0.0133 m/s




(0.8 m/min) (8 m/min) (0.72 m/min) (7.2 m/min)

Traversing speed (in inverter mode)

Mono rail



(2.5 m/min) (25 m/min)

Double rail - (Low speed)

0.0417 m/s (High

speed)

0.417 m/s

(2.5 m/min)

(25 m/min)

Traversing operation acceleration/deceleration time (sec)

2

Use the following method to change the low lifting speed, traversing speed, and traversing operation acceleration/deceleration time.

Setting/Changing Low Lifting Speed

Change the set positions of the following slide switches to change the speed.

Slide switches

Lifting operation inverter (The photo shows the lifting operation inverter of the 1-t type.

The same inverter is adopted for the 2t and 2.8t types.)

- 16 -

The following figure and the table show the relations between the slide switch set positions and the set speeds. Before changing the set positions of the switches, be sure to turn off the power.

Slide switches

Left Right

Before delivery from our factory, both the right and left slide switches are set to the bottom positions as shown in the left figure.

Capacity

Slide switch positions and set low lifting speeds

Left Right Left Right Left Right

Lower Lower Lower Upper Upper Lower

1t 0.0133 m/s (0.8 m/min)

0.0222 m/s (0.133 m/min)

0.0333 m/s (2.0 m/min)

2t, 2.8t 0.012 m/s (0.72 m/min)

0.02 m/s (1.2 m/min)

0.03 m/s (1.8 m/min)

If both the right and left switches are set to the top positions, the lifting speed will be set to the lowest speed; the same speed when both switches are set to the bottom positions.

- 17 -

Setting/Changing Traversing Speed and Traversing Operation Acceleration/Deceleration Time

Change the set positions of the slide switches shown in the following figure to change the speed and the acceleration/deceleration time.

Traversing operation inverter

Slide switches

The following figure shows the relations between the slide switch set positions and the set speeds or the set acceleration/deceleration time values. Before changing the set positions of the switches, be sure to turn off the power.

Slide switch

High speed Low speed Acceleration/deceleration time

(sec)

Top

Top

Bottom

Bottom

Top

Bottom

Top

Bottom

Top

Bottom

Before delivery from our factory, the slide switches are set to the bold character positions as shown in the left figure.

- 18 -

Maintenance and Inspection of Brake

Electromagnetic Hoisting Brake

The hoisting brake is located on the end face of the hoisting motor. The brake stops and holds a load. For the 1t type, the involute spline is adopted to engage the brake disk to the end of the motor shaft in the brake box. For the 2t to 2.8t types, the brake gear is engaged to the motor shaft. The 1t to 2.8t types are provided with an automatic adjusting device that keeps the gap constant between the iron cores even if the brake disk is worn out. The gap therefore does not need to be adjusted. If the brake does not work effectively and the load travels a considerably long distance after applying the brake, judge that the brake disk is worn out to the limit. In this case, replace the brake disk with a new one.

[Procedure for disassembling and re-assembling the brake and replacing the brake disks for the 1t to 2.8t types]

(1) Remove the lid screwed on the end face of the stationary core, and remove the helical compression spring. Evenly loosen the bolts. Remove the spring, taking care not to damage the packing.

CAUTION!: When loosening the bolts of the lid, you may notice that the lid is sticking to the casing due to the sticky packing. In this case, apply a shock to the lid before completely removing the bolts. In this way, you can prevent the lid from springing out.

(2) Using the bolts removed from the lid, temporarily tighten the movable iron core and the pressure plate.

CAUTION!: If the movable iron core and the pressure plate are not temporarily tightened, the adjusting ring may fall off, or two retaining springs (small springs that ensure easy falling down of the adjusting ring) may be missing.

(3) Remove the stationary core, taking care not to damage the packing. The brake coil is in the stationary core.

CAUTION!: This packing prevents “entering of water into the brake casing”, and also prevents “electromagnetic leakage from the electromagnet”. If the packing is broken, replace the packing with a new one. If the brake is reassembled without a packing, the suction gap will be narrowed by 0.8 mm (= packing thickness “t”). In this case, the brake may be locked up, and the motor may be seized. If the electromagnetic leakage occurs, the responsibility of the brake may be deteriorated.

(4) Remove the temporarily tightened movable iron core, adjusting ring, and pressure plate to remove the brake disk and the braking plate.

CAUTION!: When replacing the brake disk, clean the inside of the break box. Be sure to remove abrasion particles from the back of the braking plate, contact face of the brake box, and the guides (lugs) of the brake disk and braking plate.

- 19 -

Electromagnetic

brake casing

Packing

Movable core

Adjusting ring Stationary core

Brake coil

Helical compres-sion spring

(Assembly bolt)

Lid

Retaining spring

Brake disk

Braking platePressing plate

Motor shaft

Brake gear

Motor shaft

Brake disk

Spline connection

Structure of 1t type

DC electromagnetic brake

(5) Fit a new brake disk to the motor shaft or the brake gear. Lightly turn the brake disk

clockwise and counterclockwise with your hand to check for backlash.

CAUTION!: Even after replacing the brake disk with a new one, if the backlash is too large, judge that the brake gear is worn out. Use of the worn brake gear may damage the braking plate due to the shock at starting or stoppage. For this reason, be sure to replace the worn brake gear. The brake gear is tightly engaged with the motor shaft by the involute serration. Use a tool to remove the brake gear. (Use two threaded holes (size: M8) for removal of the brake gear.) Before reassembly, be sure to fill the inner groove with Moly PS grease No. 2.

(6) After inserting the retaining springs, fit the adjusting ring into the deeper side (upper side) of the eccentric groove of the pressure plate. After that, attach the movable iron core to the adjusting ring, and then tighten the movable iron core using the assembly bolts. Use the lid clamping bolts as the assembly bolts.

(7) Mount the assembly in the brake casing. Make sure that the adjusting ring is located upward. If the ring is not located correctly, it will not automatically adjust the gap.

(8) Before fitting the stationary core, make sure that the clearance between the adsorbing surface and the center is in the range from 0.1 to 0.3 mm. If the clearance is less than 0.1 mm and almost 0, replace the core.

CAUTION!: If the clearance is less than 0.1 mm (almost 0), the braking operation may be delayed and the braking distance may be elongated.

- 20 -

(9) Remove the assembly bolt used in Step (6), fit the spring, and put the lid. Evenly tighten the bolts in the same matter when they were loosened.

Up

Adjusting ring When the braking When the braking plate is new. plate is worn out.

Points of Maintenance (1) Checking the brake disks for wear

An inspection window is provided diagonally above the brake casing. Remove the rubber lid, and you can see the brake disks. Make sure that the approximate thickness of each brake disk is more than that shown right. If the brake disk is thinner than the disk shown right, remove the brake disk, and check the size of the remaining lining on each side.

Depending on working conditions, the lining on the sides has worn unevenly. Measure the lining thickness on both sides.

The brake disk working life has reached the limit when the lining on one side is 0.5 mm thick. When the lining has worn to such an extent, replace the brake disk with a new one.

(2) Check the gap between adsorbing surface and the center of the stationary core The gap should be in the range of 0.1 mm to 0.3 mm, normally.

(3) Check that the edges of the shoulders of the pressure plate and the adjusting ring are chamfered properly. Normally, the chamfer should be C0.2 or less (refer to the following figure).

(4) If the brake gear has been disassembled, apply grease to the inner circumference (for 2t to 2.8t types).

(5) Do not forget to fit the packing between the electromagnetic brake casing and the stationary core and between the stationary core and the lid. If the packing has been damaged, replace it with a new one.

(6) Check the wear limit gauge. If the wear limit gauge (at the groove or the shoulder) of the pressure plate or the braking plate is invisible (the plate is worn out to the wear limit), replacing the brake disk with a new one cannot reduce the gap and cannot prevent the adjusting ring from falling off. In this case, replace the braking plate with a new one. (The 1t type does not have any braking plates. For this type, replace the brake box with a new one.)

Core

Lining 0.5 mm or more

0.5 mm or more 1t type : 7.8 mm or more2t type : 6.3mm or more 2.8t type : 5.0mm or more

Cross section of lining Note: The lining wear limit shown above is a limit for

mechanical use. If the inverter is used for operation, observe the limit dimension specified for “annual inspection”.

- 21 -

Chamfer the edge

Pressure plate

Adjusting ring

Wear limit Wear limit

Inspection windowWear limit

Wear limit gauge

Wear limit gauge that can be seen through inspection window

Edges of the shoulders of the pressure plate and the adjusting ring

Traversing Electromagnetic Brake

It does not need to adjust the brake gap. The brake torque has been set to such a braking force that a proper coast can be obtained (50% of the motor torque). To change the braking force according to loading conditions, adjust the brake torque in the following procedure. Remove the brake cover, and you can see the adjusting bolt (hexagon head bolt) in the center. To increase the brake torque, turn clockwise the adjusting bolt. To decrease, turn counterclockwise. (The adjustment range is 0 to 100% of the motor torque.) In the monthly inspection, remove the stationary core, check the lining thickness, and remove lining particles caused by friction. The brake disk thinner than 5.5 mm may not show brake attraction. Replace the brake disk if it has worn to such an extent.

- 22 -

Inspection and Maintenance of Wire Rope

Check the wire rope during daily inspection, and check the rope ends, equalizer sheave and drum winding part during monthly inspection. If the rope strands have been broken or the rope has been deformed, immediately replace the rope with a new one. (It is recommended to prepare a spare rope for replacement.)

Replacing the Rope

Regarding the 2-fall type, remove the pin of the stationary side, and the rope can be removed easily. The 4-fall type has a tapped hole for hanging in the upper part of the hanger. Lift the hanger using the tapped hole, and draw out the hanger shaft. Then, the rope can be removed. For any of 2-fall and 4-fall types, unwind completely the rope on the drum, and the rope can be removed easily. * The wire rope assembly is a critical part for strength. Replace the rope with the genuine

part of Mitsubishi. (The genuine wire rope has a stamp of the Mitsubishi mark at the end.)

* The rope stationary end easily comes off the drum while the wire rope is being replaced. Tie the rope with a string as a measure to prevent the wire rope from falling when the rope stationary end comes off the drum.

* When replacing the wire rope, be sure to lubricate the equalizer sheave shaft on the 4-fall rope stationary side. In addition, after replacement, be sure to check that the wire rope in the hanger area (hidden area) is not twisted.

2-fall rope stationary side 4-fall rope stationary side

Drum side

To remove the hook block cover, loosen the bolts or nuts on the sheave cover sides. In the case of the 2-fall type, remove the hook sheave. To re-assemble, tighten the mounting bolts and slotted nuts, and, in the case of the 4-fall type, fit the split pins of the slotted nuts.

- 23 -

Structure, Disassembly and Re-assembly of Reduction Gears

Hoisting unit

The simplified 2-step speed reducer with helical gears is adopted for the hoisting unit. To disassemble this unit, sequentially remove the parts from the outside. Important points for disassembly and reassembly are described below: (1) Remove the helical gear while turning the gear along the helix angle. Be careful not to flaw

the gear when you remove it. (2) After disassembly, replace the oil seal with a new one.

Carefully reassemble the oil seal so that the lip cannot be flawed. Completely clean the sliding area, and then apply a thin coat of grease.

(3) At the completion of reassembly, check that the C-ring, etc. are attached properly. If a part is distorted or chipped, replace it with a new one.

(4) To reassemble the unit, follow the above disassembly procedure in the reversed order. Apply grease to the gears first, and then tighten the G-cover. Before tightening the G-cover, completely degrease the mating faces of the G-cover and the frame, and apply the liquid packing (Three Bond No. 1208D or No. 1104) to both mating faces.

Lubrication (when reassembling the disassembled unit): Remove the oil plug (the word “GREASE” is written on the plug), and then supply grease while referring to the grease quantity shown in the following table. Note that supply of too much grease may cause leakage of grease. For this reason, be sure to observe the quantity shown in the following table. We recommend use of EPNOC Grease AP-0 (manufactured by Nippon Oil Co.Ltd.).

Grease quantity (kg)

Capacity (t) 1 2 2.8

Grease quantity (kg) 0.54 1.3 2.2

G-cover

G-cover Frame

Oil seal

Frame

Oil plug

- 24 -

Traversing Unit

The simplified 2-step speed reducer is adopted for the traversing unit. The gears are sealed in the gearbox, and the grease lubrication system is adopted. For the double-rail type, the simplified 2-step speed reducer is also adopted. In addition, the inner gearbox grease lubrication system is also adopted for this type. The gearbox can be split into two parts: upper and lower parts. This type is the axial speed reducer, and ensures easy disassembly and reassembly. The following table shows the appropriate grease quantity for each type. During reassembly, apply liquid packing (Pos seal manufactured by CEMEDINE Co., Ltd. or Three Bond No. 1208D) to the mating faces between the traversing side plate and the G-case.

Capacity (t) 1 2t, 2.8t

Quantity (g) 200 250

We recommend use of Albania EP-2 grease (manufactured by Showa Shell Sekiyu Co.Ltd.).

- 25 -

Maintenance and Inspection

Hoist check items are described in details below. Crane Safety Code (Clauses 34, 35 and 36) prescribes to carry out daily inspection and periodic self-imposed inspection. Be sure to carry out the maintenance and inspection.

Daily Inspection of Hoist

Before starting the daily work, the person responsible shall operate the hoist without load, and check the following points.

No. Daily inspection item Description

1 Check the hoist operator working range for obstacles. Ensure safety in the working area.

2 Look over the traversing rail on the floor to check for abnormalities. Check also the stoppers.

3 Check that the limit switches function correctly. If pushbuttons are not wired correctly, the limit switches may not be effective. After releasing your finger from a pushbutton, check that the hook block traveling distance is within 20 to 50 mm. If the traveling distance is in this range, the hoist can perform operation properly. (For Type UR, check that the braking distance (hook block traveling distance after releasing the pushbutton) is within 30 mm during low-speed lowering operation, and within 60 mm during high-speed lowering operation. If the braking distance is in this range, the hoist can perform operation properly.) Also check the operation and the time required for starting. If it takes 1 second or more to start the operation, or if operation is not smoothly performed, judge that the hoist is defective.

4 Check for strange noise, odor and vibration.

5

Check whether the brake is effective. (For Type UR, check whether the immediate stoppage is possible during high-speed lifting operation.)

6

Check that the hoist smoothly moves as directed by the pushbuttons.

● Check that the hoist moves correctly at low and high speeds.

● Check that the speed can be switched smoothly between low and high speeds without abnormalities.

● Check that the hoist stops after decelerating. Check that the distance required to stop is uniform as usual.

The time required for acceleration to the high speed (60 Hz) should be 1 second, and the time required for deceleration from the high speed (60 Hz) to stoppage should be 0.5 seconds. After releasing the pushbutton switch, if the hook block traveling distance is in the range of 50 to 80 mm, judge that there is no problem.

If the acceleration/deceleration time for lifting operation is approximately 0.3 seconds, the hoist can perform operation properly.

7

Check that the hook block sheave rotates smoothly. Check that the hook rotates easily, and that the hook nut has been secured normally. Check that the wire rope cannot come off the sheave.

Prevention of drop of load

8 Check that the wire rope has been properly wounded on the drum.

Improper winding will result in reduction in service life and wire breakage.

9 Check the slinging tools for defects.

10 Check the whole body for abnormal overheat and color change.

: For Inverter Type U and Type UR

: For Inverter Type UR

- 26 -

DANGER

● In no case attempt to modify the product or accessories. ● Do not use any parts other than Mitsubishi genuine parts.

● Before starting maintenance or repair, be sure to disconnect the power. ● Maintenance and repair shall be carried out by specialists authorized by the company

management. ● The hoist shall be maintained and repaired without load. ● If any abnormality is found during maintenance, do not use the hoist. Immediately repair it.

* It is very dangerous to use the hoist without solving a problem. An accident may occur.

CAUTION

● Before starting maintenance or repair, put up an appropriate sign ("UNDER INSPECTION" or "DO NOT TURN ON POWER.").

!

!

- 27 -

Monthly Inspection

The person responsible for maintenance of hoist shall check the following items directly touching the hoist, and repair defective parts. The time of inspection of each part shall be determined depending on importance from the viewpoint of safety, difficulty in maintenance, frequency of uses, and wearability. The parts are classified as shown below.

Class A

No. Check item Description

Month

Acc

epta

bilit

y

Problem and remedy

Date of completion

of repair

1 Check that there are no obstacles within the traversing range.

Check that the load will not hit against other articles.

2 Check the stoppers on both the ends of rail for deformation and missing, and check the mounting bolts for looseness.

3

Check the ground lead of the pushbutton pendant metallic casing for breakage, check the screws for looseness, and check the pushbutton cable through holes for abnormalities.

If the metallic casing leaks, an electrical shock can occur. Look over the inside.

4 State of the operation buttons Check that the interlocks are complete.

Check that the buttons return to position smoothly.

5

Check the operation of the overwinding limit switch lever.

If the pin has been dropped, the switch lever will not function. Check that the lever functions cor-rectly. Check that the lever has been properly adjusted.

6 Wire rope

Check the strands for breakage. Less than 10% of number of strands in one twisted wire

Check for wear. 7% or less of the nominal diameter

Check for kink, deformation, and corrosion.

Kink, deformation, and corrosion should not be allowed.

Check the frame fixing parts, pins, and sheaves.

Stoppers, split pins, wear

Check the terminal fitting inlet for corrosion.

Insufficient lubrication, breakage, and corrosion on the root of the rope

7 Hook block

Check that the thrust ball bearing rotates smoothly.

Check that the nut stopper is not damaged.

Check that the foot nut is provided with loosening preventive means.

Check the split pin and setscrew for missing.

Check the sheave for damage. Check for flaws and wear of the groove.

Check the sheave case and key plate (nameplate) for damage and looseness. Check the slinging wire latch.

Check the clamping screws for looseness and damage. Check for backlash and spring effect.

Items to be surely checked every month and to be regarded as important items from the viewpoint of safety.

- 28 -


Month

Acc

epta

bilit

y

Problem and remedy

Date of completion

of repair

8 Check the hook for cracking, wear and deformation.

Check for visually detectable ab-normalities.

9 Check the slinging tools for abnormalities. Check for deformation, slack and breakage.

10 Check the traversing side plates and nuts for looseness. Check the split pins for missing.

Visually check the side plates for deformation and opening.

11 Check that the I-beam or the hoist main body has been grounded.

Check the grounding point. Visually check the screws for looseness.

12 Rotation sensor

Check the installation condition of the printed board. Also check the appearance of the rotation sensor.

Remove the cover, and then visually check the RRS board for dust and corrosion, and the rotational shaft for distortion.

13 Inverter Check the installation condition of the inverter. Also check the appearance of the inverter.

Check the inverter tightening screws for looseness.

14 Control box

Check the inside of the control box for dust.

Check the printed boards particularly carefully.

Check the control box for corrosion and discoloration caused by moisture or gas.

Check the crimp-style terminal screws for looseness.

Terminal board, terminal board of printed circuit board

15 Check the appearance of the external cable for abnormality.

Check the sheath for damage and distortion.

16 Display Check that the segment display is lit up.

17 No-load test run Check the operation conditions in accordance with check items No. 2 through No. 6 described in the daily inspection table.


: For Inverter Type U

- 29 -

Classes B and C


Month

Acc

epta

bilit

y

Problem and remedy

Date of completion

of repair

1 Check the pushbuttons for damage. Check the inside and contacts.

2

Electro-magnetic

brake electro-magnet

Check the screws for looseness. Check the parts for wear and damage. Check that the gap between the cores is proper. Check that the lining thickness is proper. Check that no pins have dropped.

Open the cover, and check. Lubricate the sliding and revolving parts. Replace the brake disks with new ones.

3

Check that the diode (in the control box) for the hoisting brake and the diode for the traversing operation are not damaged. Also check that their lead wires are not disconnected.

Open the cover to check the diodes.

4

Check the pushbutton pendant cable and power cable for external flaws. Check the messenger and hanging wire for damage. Check the hanger for disconnection.

Check the leading-out ports. Check the wire for sagging.

5 Check that the wire rope has been lubricated. If the wire rope is dry, apply wire rope oil.

6 Check the electromagnetic contactor, contacts, insulated parts and mechanical parts for damage and wear. Check the screws for looseness.

Check visually. Check that all the screws are tightened firmly.

7

Check the overwinding limit switch and contacts for wear. Check the clamping screws for looseness.

Check that the switch and the contacts are tightened properly. Check that the switch and the contacts operate properly.

8 Check the trolley wire for looseness and rust. Check the wires.

9 Check the current collector for contact failure and wear.

Check the rotation. Check the wire connections for looseness. Check the spring force.

10 Check the traversing wheels and guide rollers for wear.

Wear must be less than 5% of the diameter and less than 50% of the flange thickness.

11 Check the traversing brake for attraction, release and coasting condition.

12

Check the rail for abnormal wear, loosened seams, external flaws and cracks. Check the clearance between the rail and the guide roller or the wheel flange.

Wear less than 5% in width and less than 10% in thickness is allowed. Clearance between the rail and the guide roller or the wheel flange less than the specified value is acceptable. (Refer to “Installation on I-Beam”.)

13 Check the hoisting brake resistor for damage. Check visually.

14 Check the bolts for looseness. Check visually. Tighten the bolts again.

The rules prescribe to prepare a monthly inspection sheet based on these items and store the results for three (3) years.

Items to be checked every 3 or 6 months and to be regarded as important items from the viewpoint of safety. Frequently used parts shall be checked every one to three months.

- 30 -

Annual Inspection

No. Item Schedule Description

1 Capacitor rush current preventive contactor (2t to 5t types)

Annually Every 6 months if rush current flows frequently

Disassemble the contactor, and then check the contact for wear. If the inner mechanism is damaged or worn out, replace the contactor.

2 Smoothing capacitor Same as above. Check the capacitor for liquid leakage and bulge. Also check that the safety valve is not activated.

3 Brake disk thickness

Every year Every 6 months if the frequency of uses is high.

Remove the rubber lid obliquely above the bottom of the brake casing, and check the thickness. For a detailed description of the replacement standards, refer to “Maintenance and Inspection of Brake”.

Every year Every 6 months if the frequency of uses is high.Every 3 months if the no-load high-speed function is used

Remove the lid on the bottom of the brake casing, and check the thickness. If the brake disk thickness is near the following value, replace. * These values are reference values that enable suction even if the supplied power is the minimum. For a detailed description of the replacement standards, refer to “Maintenance and Inspection of Brake”. Hoisting brake 1/2 t 10.5 mm (New disk 11 mm thick) 1 t 9.0 mm (New disk 9.5 mm thick) 2 t - 3 t 7.8 mm (New disk 8.3 mm thick) 5 t 7.8 mm (New disk 8.3 mm thick) Traversing brake disk thickness 1/2 - 5 t 5.5 mm (New disk 8 mm thick)

Prior to the thickness check, check the engagement between the brake disk teeth and the motor shaft or the brake gear for abnormalities (wear and backlash).

Annually Every 6 months if the brake is used frequently

Use the same inspection method, inspection standards, and replacement standards as the inverter. Hoisting brake disk 1 t 10.5 mm (New disk 11 mm thick) 2 t 9.0 mm (New disk 9.5 mm thick) 2.8 t 7.8 mm (New disk 8.3 mm thick) Traversing brake disk 1 t - 2.8 t 5.5 mm (New disk 8 mm thick)

4 DC electromagnet Every year Every 6 months if the frequency of uses is high.

Remove the stationary core, and disassemble the parts. After that, check the movable parts for wear and backlash. At the completion of check, lubricate each part. Check operation of the automatic adjustment mechanism, and record the operation.

5 Inside of the hoisting gear case Every year Open the bracket on the end face, and check the gears, shafts and

bearings for abnormalities (wear and backlash). Change the oil.

6 Overhaul

Every 2 years Every year when the frequency of uses is high or when the hoist is on an important line

Lower the hoist from the I-beam, disassemble it, and check the parts and the traversing rail.

7 Hoisting motor shaft and spline serration part

Every year Every 6 months if the frequency of uses is high.

Remove the electromagnet casing, disassemble the parts, and check the engagement between the hoisting motor shaft and the brake gear (wear and backlash).



: For Inverter Type UR

The inspection results shall be stored for three (3) years. * Before providing maintenance services, please consult the nearest office of Mitsubishi Electric

Hoist Corporation.

- 31 -

Lubrication

Please execute an inspection as well as oiling in accordance with the following table. However, the table will provide typical example data relative to a standard hoist, and therefore, the standard of lubrication oiling can be substantially varied in response to usage frequency as well as usage condition.

Lubricated part Kind of lubricant Method Frequency

Hoisting gear case Refer to the “speed reducer” described in “Structure, Disassembly, and Reassembly of Reduction Gears”.

Lubrication and replacement Once per year

Traverse traveling gear box

Refer to the “traversing unit” described in “Structure, Disassembly, and Reassembly of Reduction Gears”.

To be applied to the gear surface.

Once per year

Each individual ball bearing

section

Lithium series grease No. 2 or equivalent, Multi-purpose grease.

Refill lubrication oil up to around 1/3 of the entire space. At overhaul

Both sides sealed up ball bearing

The external part only shall be cleaned, while, it is not required to overhaul the internal parts. If any abnormality is observed, it shall be replaced. (High-temperature resistant bearings are used for the motor.)

At overhaul

Sliding revolution part Grease equivalent to No. 2 and No. 3 To be applied. At overhaul

Spline serration part

Moly PS grease No. 2 (SUMIKO LUBRICANT) To be applied. Once per

year

- 32 -

Operation Limit of Main Parts

Part Limit

Wire

rope

Part Limit

Hoist gear When the depth of wear on the surface reaches 10% of the tooth thickness (Fig. 3)

Strand breakage

10% of the number of strands in one twisted wire Reference

replacement schedule: * Approx. 40,000

cycles

Traversing gear When the depth of wear on the surface reaches 20% of the tooth thickness Wear 7% of the nominal

diameter

Gear shaft When the wear reaches 1% of the original diameter

Deformation and corrosion

Significant deform-ation and corrosion

Other shafts When the wear reaches 2% of each original diameter Rope end Breakage

Clearance between shaft and bearing

Gear shaft: 2% or less of the original diameter

Motor pinion: 1% or less of the drum shaft original diameter.

Other shafts: 4% or less of the original shaft diameter

Contactor contact When the contact thickness reaches 0.5 mm

Hoisting brake disk When the lining thickness is reduced to 0.5 mm or less on one side

Rolling bearing Damage, harmful flaws, or abnormal noise

Traversing brake disk

When the thickness of the traversing brake disk is reduced to 5.5 mm, or when the lining thickness is reduced to 0.5 mm or less on one side

Oil seal Harmful flaws on the lip or the shaft surface with which the lip gets into contact

Electromagnetic brake cores

When there is no clearance between the center legs of the movable and stationary cores which have been fitted to each other.(New core: Approx. 0.3 mm)

Brake mechanism Abnormal operation Current collector wheel

When the center diameter reaches 35 mm (New wheel 45 mm in diameter)

Traversing wheel tread

Wear of 5% of the original size Difference between left and right wheel diameters of 1% (Fig. 5)

Cable When the cable has deteriorated due to external flaws, especially when the ground wire is breaking

Traversing wheel flange 50% of the original thickness (Fig. 4) Insulation of all

circuits 200 V class; 0.2 MΩ 400 V class; 0.4 MΩ

Sheaves Wear on the groove bottom 30% of the wire rope diameter Ground

The traversing rail and metallic push-button pendant must have been grounded properly. Ground resistance; 100 Ω or less

Key spline serration

Deformation, significant backlash, and abnormal wear Hook Apparent gap, large flaws and wear

(Fig. 2)

Initial dimension “b”

1 t 32

2 t 40

2.8 t 50

Punch mark

Tooth thickness

Amount of gear

Pitch circle

(Monorail type)

Wear

Wear

Fig. 2 Fig. 3

Fig. 4 Fig. 5

(Double rail type)

- 33 -

Replacement of Controller Parts

Part Standard replacement schedule Replacement method, etc.

Smoothing capacitor of main circuit Every 5 years The direct current section of the main circuit is equipped with a

large-capacity aluminum electrolytic capacitor to ensure smoothness. In addition, the control circuit is also equipped with an aluminum electrolytic capacitor to ensure stabilization of control. Ripple current, however, may deteriorate the characteristics of these electrolytic capacitors. Note that deterioration of the characteristics greatly depends on the ambient temperature and the operation conditions. After operation for a certain period, the capacitor will be rapidly deteriorated. For this reason, be sure to annually check the capacitor or more frequently (if the end of the service life is close at hand, it is preferable to check the capacitor every 6 months or more frequently).Check the appearance of the capacitor in accordance with the following criteria: 1) Case condition: Expansion of side surface or bottom surface of

the case 2) Sealing plate condition: Noticeable distortion or extreme cracking3) Others: Cracking on sheath, discoloration, liquid leakage, etc.

From the viewpoint of quantity, if the capacity of the capacitor is reduced to 85% of the rated capacity, judge that the service life comes to the end. In these days, simple and easy-to-use units designed for measurement of capacitor capacity are sold at market. Use such convenient measuring units.

Replace the capacitor with a new capacitor, or replace the board with a new board.

Smoothing capacitor mounted on board Every 5 years

Contactor When the contact

thickness is reduced to 0.5 mm

If the contact thickness is too thin, the contactor may cause imperfect contact. For this reason, it is necessary to replace the contactor depending on the total number of opening/closing times (switching operation limit). Replace the contactor with a new contactor.

Relay After 5 years of operation or more

Replace the relay with a new relay.

Other

Item Operation limit Insulation of all circuits 200V class: Approx. 0.2 MΩ or less 400V class: Approx. 0.4 MΩ or less

Grounding Grounding resistance: 100 Ω or less

- 34 -

General Troubleshooting

If the hoist has been used under unfavorable working condition, handled roughly or become old, like general machines, it shows various troubles and nonconformities. All troubles and nonconformities cannot be described here. General troubles are listed below for your reference. Most of troubles not listed below are caused special factors. Regarding such troubles, consult the nearest distributor or Mitsubishi Electric Hoist Corporation.

General troubleshooting

Problem Cause Remedy

1. Touching the hoist or pushbutton pendant causes an electric shock.

(1) I-beam or pushbutton pendant metallic casing grounding failure

(1) Ground completely. 100 Ω or less at 200 V

(2) Adhesion of paint to the I-beam surface (2) Use the hoist suitable for the ambient conditions (waterproof type, etc.). Remove paint completely.

Leakage current increases due to high-frequency component of inverter output voltage. The rated sensitivity current of the earth-leakage circuit breaker shall be 100 mA or more to prevent unnecessary operations.

The circuit breaker is designed nor for prevention of electrical shocks, but for prevention of a fire caused by electrical leakage. For this reason, remedies (1), (2), and (5) described on the right side should be observed.

(3) Hoist or pushbutton pendant insulation failure (3) Check, and repair. (4) Current leaking from other equipment or wiring

reaches the hoist through the I-beam. (4) Check, and repair.

(5) The floor conductivity is high. • The floor is wet with a highly conductive liquid,

such as water. • The hoist is on a highly conductive surface, such

as an iron plate, steel structure and surface plate.

(5) Install the hoist on a floor with low conductivity, such as a dry concrete floor.

2. Operation in reverse direction to that indicated on pushbutton.

(1) Incorrect connection of power supply line (1) Exchange the phases R and T of the power supply.

(If the commercial power is used for traversing operation) Even if the power line is not connected correctly, operation will not be performed in the opposite direction.

(2) Wire rope wound reversely. (2) Wind the rope correctly.

3. Wire rope wears badly.

(1) The rope wears soon because it is frequently pulled laterally and vertically.

(1) Correct the using method.

(2) Disordered winding (2) See Item 4.

(3) Use of wire rope other than parallel stranded rope (3) Replace the wire rope with a proper one.

(4) Wire rope oil not applied. (4) Apply oil.

4. Wire rope is wound ununiformly.

(1) Pulling laterally and vertically at too large angles (Less than 10° for pulling laterally or less than 3° for pulling vertically)

(1) Correct the using method.

(2) Wire rope distorted (2) Replace.

- 35 -


5. The 2nd-stage limit switch operates.

(1) Incorrect connection of power supply line (2) Wire rope wound reversely

(1) Exchange the phases R and T of the power supply.

(3) Although the use of the no-load high-speed function has been specified, the upper limit stop point has not been set. Or the upper limit set position is too high.

(2) Set the upper limit correctly.(3) Set the upper limit to the

proper position.

6. Wire rope is cut. (1) The rope catches on something during hoisting. (2) Corrosion due to chemicals (3) Use of badly worn wire rope

(1) Handle and maintain the rope properly. Replace the defective wire rope. (Use the Mitsubishi genuine wire rope.)

7. The hoist does not start even if the pushbutton is pressed.

(1) Pushbutton defective, or pushbutton cable broken

(1) Repair, replace, or cut out.

(2) Incorrect wiring of power switch, fuse, contactor, or pushbutton, imperfect contact of trolley line, loose screws, etc.

(2) Check, and repair. See the expanded connection diagram.

(3) The inverter does not give 3-phase output. (3) Check the inverter. (4) No signal is returned from the sensor, or one of

the rotation signals (signals for 2 phases) is not returned from the RRS board.

(4) Check and replace the RRS board. Check the signal line (microphone cord) for dis-connection.

(5) The hoisting motor torque is insufficient for overload, and the hoist stops.

(5) Reduce the load.

(6) The hoisting motor overheats due to too frequent use, the torque drops, and the hoist stops.

(6) Use the hoist at appropriate intervals.

8. The hoist lowers and stops during hoisting

(1) Overload (1) Reduce the load. (2) Hoisting motor overheat (2) Use the hoist at appropriate

intervals. (3) Hoisting motor wire breakage (3) Check, and repair.

9. The hoist stops suddenly during hoisting.

(1) Inverter trip due to overvoltage caused by hoisting an overload.

(1) Reduce the load.

(2) Inverter overvoltage tripping is caused due to rise in the resistance value that is caused by temperature rise of the discharging resistor due to too frequent use.

(2) Use the hoist at appropriate intervals.

(3) Disconnection of discharging resistor (3) Check, and repair.

10. Power is applied to the traversing motor, but the motor growls and takes a longer time (2 sec. or more) to start.

(1) Electric resistance is high due to wiring, switch or trolley contact failure or loosened screws. (Voltage drop at start)

(1) Check, and repair.

(2) Wires too thin or long (2) Change the wiring in accordance with the selection table.

(3) Supply voltage too low. (3) Change the transformer taps. (4) Electromagnetic brake not released. (4) See Item 14.

(5) Defective electromagnetic brake coil. (5) Replace the coil.

11. The hoist suddenly stops during lifting or lowering operation.

(1) The 1st-stage limit switch functions. (1) Lower the load. (2) Inverter trip due to too low supply voltage (2) Change the transformer taps. (3) Hoisting brake works. (3) See Item 14. (4) Inverter trip due to overload or ground lifting (4) Re-examine the lowering

method and load. (5) Fall caused by overload is detected. (5) Re-examine the lowering

method and load. (6) Malfunction due to noise. (6) Fit a noise filter to the 3-phase

power supply.

- 36 -


12. The motor overheats (1) Inching operation is performed too frequently. (1) Apply a special design. (2) Electromagnetic brake not released. (2) See Item 14. (3) Operating time long (3) Adopt the same remedies as

Item 10, or do not use the motor too frequently.

(4) Overload. (4) Reduce the load.

13 Pressing a pushbutton rattles the contactor.

(1) Extreme voltage drop (1) See Item 10.

14. The relay functions, but the electromagnetic brake is not released. The electromagnet will not attract.

(1) Too large voltage drop, or too low supply voltage

(1) See Items 10 and 11.

(2) Too large core gap (2) Replace the brake disk. (3) No gap, or gap adjusted too large. (3) Re-adjust. (4) Movable parts catch on something. (4) Repair. (5) Brake circuit cable broken, or screws

loosened. (5) Check, and repair.

(6) Brake circuit diode (DC) defective (6) Replace the diode assembly. (7) Coil burnt out. (7) See Item 15. (8) Too large center clearance (8) Correct.

15. The electromagnetic brake coil has been burnt out.

(1) High frequency of uses (1) Correct the operation method, and replace the coil.

16. The electromagnetic brake does not work effectively.

(1) Too large core gap (1) Replace the brake disk. (2) The relay does not function properly. (2) Replace the relay. (3) The electromagnetic contactor cannot properly

cut off the power. (3) Check the internal wiring.

(4) Adhesion of oil to the brake disk (4) Degrease the brake disk, or replace the brake disk.

(5) The immediate cut-off contactor does not operate properly. (Direct current)

17. The traversing brake is too effective or ineffective.

(1) Brake adjustment failure (1) Adjust the brake properly with the adjusting bolt.

18. Rotation with the traversing brake applied.

(1) Brake coil wire breakage, or mis-connection Replace, or repair. (2) Diode defective, or mis-connection (3) Too small or large gap

19. The traversing motor does not have enough rotation power, or will not function.

(1) Brake coil wire breakage, or mis-connection Replace, or repair. (2) Diode defective, or mis-connection (3) Too small or large gap

20. The gears make too loud noise.

(1) Gears and bearings worn out (1) Replace.

21. Traversing wheels spin. (1) The traversing wheel on the driving side is lifted due to the inclined I-beam.

(1) Install the hoist in the reverse direction.

(2) Paint, oil, or dust is on the transfer surface of the I-beam.

(2) Clean, or, if necessary, grind.

22. The trolley wheels are easily disconnected.

(1) The trolley wire has not been stretched as specified.

(2) The trolley pole has been installed in the reverse direction.

(3) Wheels not on the same level

Improve.

- 37 -


23. The overload alarm does not function properly.

(1) The power supply line is not correctly connected to the board.

(1) Correctly connect the power supply line. Connect “1” and “S” to “A” and “B” on the board.

24. The pushbutton will not go down smoothly or will not smoothly pop up.

(1) Foreign material caught by inner unit (2) Defective inner unit

(1) Check or repair. (2) Replace.

25. Pressing the DOWN pushbutton lowers the load, but pressing the UP pushbutton also lowers the load.

(1) Rotor slippage (The rotor is not properly engaged with the motor shaft.)

(1) Replace. * In this case, releasing the

pushbutton will immediately stop the lowering operation.



- 38 -

Inspection of Power Supply System (Measurement of lowest voltage at start up)

Inspection procedure Judgment and remedy

1. Turn off the power switch to the trolley line. Connect a voltmeter or electric tester near the insulated shaft of the trolley pole.

2. Turn on the trolley line power switch. Read the voltage.

3. Take this measurement between the phases (R-S and S-T).

Acceptable if all the three phases are read 200-220 V (up to 240 V for 60 Hz). If not, change the tap connection on the transformer. If the readings of the three phases vary, check the transformer wiring.

4. Press the "UP" pushbutton with the voltmeter connected and the power switch on as above. Due to the high starting current lasting for a moment, the hand on the voltmeter first swings into the low range then swings back into the high range. Read the lowest voltage.

5. Take measure in step 4 above on all the three phases.

Acceptable if all the three phases are 180 V or more. Can be used if all the three phases are 170 V (60 Hz) or 160 V (50 Hz) or more. Cannot be used if the voltage is below the above value. (For a detailed description of the corrective method, see Item 10 described in the previous table.) If three phases are not balanced, the cause of unbalance is cause (1) of Item 10 described in the previous table. In this case, repair the problem part.

(Note) The voltage readings in step 4 above represent the lowest values when the electromagnet attracts the elements or the motor starts up. Judge the situation based on these voltage readings. When you contact us, please let us know the power supply voltage (see above inspection step 2) and the lowest voltage (see above inspection step 4).

(Instructions for measurement of inverter power supply current) 1. During lowering operation, regenerative energy returns from the hoisting motor to the

inverter. This may cause power current not to flow. 2. When lifting/lowering very light load or no load at all, little electric power is consumed.

Since power is in this case supplied through two high-voltage power wires, no current may flow through the remaining one wire.

3. During lifting operation, the inverter input current may fluctuate. This is because this current is not sinusoidal.

- 39 -

Developed Connection Diagram of Electric Hoist (1t, 2t): Lifting Type Inverter Hoist Suspension type Chain-driven traversing type Manual traversing type

SOURCE (2-step)

(1-step)

HOISTINGMOTOR

Down

PENDANT SWITCH

P1: UP P2: DOWN

HOISTING BRAKE COIL

LIFTING TYPE INVERTER HOIST

DOWN

Electric traversing type

SOURCE (2-step)

(1-step)

TRAVERSING MOTOR

PENDANT SWITCH

HOISTING MOTOR

TRAVERSING BRAKE COIL

LIFTING TYPE INVERTER HOIST

BRAKE COIL

Down

P1: UP P2: DOWN P3: EAST P4: WEST P5: SOUTH P6: NORTH

DOWN

- 40 -

Developed Connection Diagram of Electric Hoist (2t): Lifting Inverter Hoist Suspension type Chain-driven traversing type Manual traversing type

SOURCE (2-step)

(1-step)

HOISTING MOTOR

Down

PENDANT SWITCH

P1: UP P2: DOWN

HOISTING BRAKE COIL

HOISTING INVERTER

DOWN

Electric traversing type

SOURCE (2-step)

(1-step)

TRAVERSING MOTOR

PENDANT SWITCH

HOISTING MOTOR


BRAKE COIL

Down


DOWN

HOISTING INVERTER

- 41 -

Developed Connection Diagram of Electric Hoist Hoisting/Traversing Inverter Hoist (1t, 2t)

SOURCE (2-step)

(1-step)

HOISTING MOTOR

RESISTOR

PENDANT SWITCH

HOISTING BRAKE COIL

INVERTER FOR TRAVERSING

TRAVERSING MOTOR

Down



DOWN

INVERTER FOR HOISTING

(2.8t)

SOURCE

(2-step)

(1-step)

TRAVERSING MOTOR

PENDANT SWITCH

HOISTINGMOTOR



BRAKE COIL

Down


OPERATION


RESISTOR

DOWN

- 42 -

Wiring for Use of 4-Point Independent Pushbutton Switch



Lifting at low speed

Lowering at low speed

Lifting at high speed

Lowering at high speed

Eastward at low speed

Westward at low speed

Eastward at high speed

Westward at high speed

Southward

Northward

PENDANT SWITCH (4-point independent type)

- 43 -

Structural Drawing of Hoist Main Body (1t)

Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description

G01 Air breather G09 Cover G17 Snap ring G25 Key H01 Drum M01 L bracket M09 Ball bearing B01 Magnetic brake case B09 Cushion rubber B17 Terminal box

G02 G cover G10 No. 4 gear G18 Ball bearing G26 No. 4 gear shaft H02 Wire rope M02 Joint M10 Washer B02 Brake disk B10 Spring B18 Rubber bush

G03 Ball bearing G11 Joint G19 Washer H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover

G04 Washer G12 Washer G20 No. 2 gear M04 Ball bearing B04 Pressure plate B12 Packing

G05 No. 1 gear G13 Ball bearing G21 Spacer M05 Rotor assembly B05 Movable core B13 Spring

G06 Ball bearing G14 Oil seal G22 No. 3 gear M06 Stator assembly B06 Adjusting ring B14 Stationary core

G07 Snap ring G15 Ball bearing G23 Ball bearing M07 Ball bearing B07 Brake coil B15 Snap ring

G08 Oil seal G16 Snap ring G24 Drum frame M08 Terminal box B08 Cover B16 Cover

P145537B

- 44 -

Structural Drawing of Hoist Main Body (2t, 2.8t)

Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description

G01 Air breather G09 Cover G17 Snap ring G25 Key H01 Drum M01 L bracket M09 Ball bearing B01 Magnetic brake case B09 Cushion rubber B17 Terminal box

G02 G cover G10 No. 4 gear G18 Ball bearing G26 No. 4 gear shaft H02 Wire rope M02 Joint M10 Washer B02 Brake disk B10 Spring B18 Rubber bush

G03 Ball bearing G11 Joint G19 Washer H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover B19 Brake gear

G04 Washer G12 Washer G20 No. 2 gear M04 Ball bearing B04 Pressure plate B12 Packing B20 Cover

G05 No. 1 gear G13 Ball bearing G21 Spacer M05 Rotor assembly B05 Movable core B13 Spring B21 Cover

G06 Ball bearing G14 Oil seal G22 No. 3 gear M06 Stator assembly B06 Adjusting ring B14 Stationary core

G07 Snap ring G15 Ball bearing G23 Ball bearing M07 Ball bearing B07 Brake coil B15 Snap ring

G08 Oil seal G16 Snap ring G24 Drum frame M08 Terminal box B08 Braking plate B16 Snap ring

P148183

- 45 -

Structural Drawing of Electric Traversing Unit (Monorail Type (1t))

Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description

B01 Rubber bush B10 Brake coil assembly M01 Ball bearing M10 Washer T01 Gear case T10 Bolt T19 Traversing wheel (L) A01 Washer

B02 Terminal block B11 Movable core M02 L bracket M11 Ball bearing T02 No. 2, 3 gear shaft T11 Clip plate T20 Snap ring A01 Spacer

B03 Adjusting screw B12 Pin M03 Washer T03 Snap ring T12 Disk plate T21 Traversing wheel (F) A01 Slotted nut

B04 Spring B13 Brake disk M04 Stator coil T04 Ball bearing T13 Key T22 Ball bearing A01 Split pin

B05 Clamp B14 F bracket M05 Stator core T05 Snap ring T14 No. 4 gear T23 Snap ring A01 Clamping bolt

B06 Diode assembly M06 Rotor T06 Key T15 Ball bearing T24 Wheel axle

B07 Cover M07 Stator frame T07 Snap ring T16 Traversing plate (L) T25 Traversing plate (F)

B08 Cushion rubber M08 Motor shaft T08 No. 3 gear T17 Boss

B09 Stationary core M09 Rubber bush T09 No. 2 gear T18 Ball bearing

P145535

- 46 -

Structural Drawing of Electric Traversing Unit (Monorail Type (2t, 2.8t))

Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description

B01 Rubber bush B10 Brake coil assembly M01 Ball bearing M10 Washer T01 Gear case T10 Bolt T19 Traversing wheel (L) A01 Washer

B02 Terminal block B11 Movable core M02 L bracket M11 Ball bearing T02 No. 2, 3 gear shaft T11 Clip plate T20 Snap ring A01 Spacer

B03 Adjusting screw B12 Pin M03 Washer T03 Snap ring T12 Disk plate T21 Traversing wheel (F) A01 Slotted nut

B04 Spring B13 Brake disk M04 Stator coil T04 Ball bearing T13 Key T22 Ball bearing A01 Split pin

B05 Clamp B14 Friction disk M05 Stator core T05 Snap ring T14 No. 4 gear T23 Snap ring A01 Clamping bolt

B06 Diode assembly B15 F bracket M06 Rotor T06 Key T15 Ball bearing T24 Wheel axle

B07 Cover M07 Stator frame T07 Snap ring T16 Traversing plate (L) T25 Traversing plate (F)

B08 Cushion rubber M08 Motor shaft T08 No. 3 gear T17 Boss

B09 Stationary core M09 Rubber bush T09 No. 2 gear T18 Ball bearing

P145536

- 47 -

Structural Drawing of Electric Traversing Unit (Double-Rail Type (2.8t))

Item Description Item Description Item Description Item Description Item Description Item Description Item Description

B01 Rubber bush B09 Stationary core M01 Rubber bush M00 Washer T01 Ball bearing T09 Ball bearing T17 Lower gear case

B02 Terminal block B10 Brake coil assembly M02 Ball bearing M10 Ball bearing T02 Spacer T10 Traversing wheel T18 Ball bearing

B03 Adjusting screw B11 Movable core M03 Washer M11 L bracket T03 Upper gear case T11 Key plate T19 Dustproof cover

B04 Spring B12 Pin M04 Stator frame T04 Frame T12 Key T20 Driving shaft

B05 Clamp B13 Brake disk M05 Stator coil T05 No. 3 gear T13 Washer

B06 Diode assembly B14 Friction disk M06 Stator core T06 Ball bearing T14 Ball bearing

B07 Cover B15 F bracket M07 Rotor T07 Cover T15 Key

B08 Cushion rubber M08 Motor shaft T08 No. 4 gear T16 No. 2 gear

P145383A

- 48 -

Structural Drawing of Chain-Driven Traversing Unit (1t, 2t, 2.8t)

Item Description Item Description Item Description Item Description Item Description

1 Chain 6 Clamping bolt 11 Snap ring 16 Wheel axle 21 Traversing wheel (F)

2 Washer 7 Chain pulley 12 Shaft support 17 Snap ring 22 Traversing plate (F)

3 Spacer 8 Snap ring 13 Metal 18 Ball bearing

4 Slotted nut 9 Key 14 Chain-driven gear 19 Snap ring

5 Split pin 10 Chain guide 15 Traversing plate (L) 20 Traversing wheel (L)

P271705

Note 1: If the part number is double-circled, we cannot supply the part as a single part.

Note 2: If the part number is circled with a bold line, the part will be supplied as a set, normally. For a detailed description, please contact Mitsubishi Electric Hoist Corporation or our service shop.

- 49 -

Structural Drawing of Manual Traversing Unit (1t, 2t)

Item Description Item Description Item Description

1 Traversing wheel 6 Traversing plate 11 Clamping bolt

2 Snap ring 7 Washer

3 Ball bearing 8 Spacer

4 Snap ring 9 Slotted nut

5 Wheel axle 10 Split pin

P271704

Note 1: If the part number is double-circled, we cannot supply the part as a single part.

Note 2: If the part number is circled with a bold line, the part will be supplied as a set, normally. For a detailed description, please contact Mitsubishi Electric Hoist Corporation or our service shop.

- 50 -

Structural Drawing of Hook Block (for Wire Rope of 2-Fall Threading Type) (1t, 2t, 2.8t)

PG37602 PG37604 PG37440

Item Description

1 Sheave

2 Ball bearing

3 Snap ring

4 Ball bearing

5 Whirl-stop

6 Bolt

7 Spring washer

8 Shaft

9 Cover

10 Bolt

11 Spring washer

12 Wire rope

13 Hanging ring

14 Split pin

15 Slotted nut

16 Dustproof cover

17 Thrust ball bearing

18 Latch

19 Twist spring

20 Spring pin

21 Hook

Capacity 1t 2t 2.8t

A 45 56 71

B 28 34 45

C 22 28 36

D 189.6 236.2 293.4

E 215 264 323

F 309.8 382.1 469.7

G 60 74 93

H 88.2 118 130.4

K 180 225 280

L 160 200 250

M 32 36 40

Rope diameter φ8 φ10 φ12.5

Weight (kg) 7.5 15 27

- 51 -

Structural Drawing of Hook Block (for Wire Rope of 4-Fall Threading Type) (1t)

PG37603

Item Description

1 Sheave

2 Dustproof cover

3 Thrust ball bearing

4 Snap ring

5 Trunnion

6 Spacer

7 Ball bearing

8 Cover

9 Wire rope

10 Split pin

11 Slotted nut

12 Split pin

13 Slotted nut

14 Spacer

15 Nameplate

16 Latch

17 Spring pin

18 Twist spring

19 Hook

Capacity 1t

Rope diameter φ6.3

Weight (kg) 8

- 52 -

Structural Drawing of Hook Block (for Wire Rope of 4-Fall Threading Type) (2t, 2.8t)

PG37605 PG37441

Item Description

1 Sheave

2 Ball bearing

3 Snap ring

4 Spacer

5 Split pin

6 Slotted nut

7 Spacer

8 Trunnion

9 Cover

10 Wire rope

11 Cover

12 Split pin

13 Slotted nut

14 Dustproof cover

15 Ball bearing

16 Bolt

17 Spring washer

18 Latch

19 Twist spring

20 Spring pin

21 Hook

Capacity 2t 2.8t

A 56 71

B 34 45

C 28 36

D 207 232

E 168.5 198

F 263.7 305.7

G 74 93

H 193.6 216.6

K 180 205

L 160 180

M 32 30

N 147 164

P 95 106

Rope diameter φ8 φ9

Weight (kg) 15 25

- 53 -

Procedure for Straightening Entangled Wire Rope

When the wire rope has been twisted (entangled), straight it in the following procedure.

1. Checking the direction in which the wire rope has been entangled Check the direction in which the wire rope has been entangled. * Definition of entanglement ....... When the hook block turns 360°, the rope is entangled

twice. When there are two falls, the rope is entangled once. (The hook block turns 180°.)

4-fall type 2-fall type 4-fall type 2-fall type

[S-twist] [Z-twist]

2. Untangle the wire rope until the rope supports (wire rope ends) can be seen.

Rope supportRope support

4-fall type

3. Then, before removing the rope supports, mark the rope supports or rope with a chalk so that the current rope positions can be found later.

Marking

2-fall type

- 54 -

4. If the hoist hook block has been twisted in the Z direction, lower the hook block on to the ground to sag the wire rope, and give several turns (number of twists + 1 twist) to the wire rope, turning the wire rope in the direction shown below. (In the case of the 4-fall type, carry out this operation on each side.)

Ex.: In the case of the 2-fall type shown in Item 1

Number of twists + 1 twists

↓

1 + 1 = 2 twists Give two clockwise turns to the rope support.

5. If the hoist hook block has been twisted in the S direction, lower the hook block on to the ground to sag the wire rope, and give several turns (number of twists + 1 twist) to the wire rope, turning the wire rope in the direction shown below.

(In the case of the 4-fall type, carry out this operation on each side.)

6. After straightening the wire rope, turn the hook 180° clockwise and counterclockwise, and make sure that the hook returns to the initial position. (If there is a nonconformity, straighten the rope again increasing the number of turns more than the number of turns stated in Steps 4 and 5.)

* The wire rope assembly is an important part from the viewpoint of strength. When replacing it, use the Mitsubishi genuine part. (The genuine wire rope has a stamp of the Mitsubishi mark at the end.)

- 55 -

Warrantee

1. Warrantee Description and Period (1) Warrantee Regarding the genuine parts that constitute the hoist, the manufacture warrants against

failure and damage due to faulty material or poor workmanship during the warrantee period stated below. The manufacturer replaces or repair defective parts at no cost to the customer.

(2) Warrantee period and scope The period and parts that are covered by warrantee are as shown in the table below.

Parts to be warranted Warrantee period All the parts installed and accessories before the deliv-ery from the factory except those specified in Section 2 “Parts and Events not to be Warranted”.

One year after delivery or 18 months after shipping from the factory, whichever comes first.

2. Parts and Events not to be Warranted (1) Defects caused by the following events.

1) The hoist is handed or operated in a manner that differs from the instructions specified in the instruction manual. The hoist is operated in a condition that exceeds the specifications, such as too frequent use, overloading or operation in an unfavorable environment that exceeds the specifications.

2) Insufficient or incorrect maintenance 3) The hoist is modified, altered or operated in a manner that are not admitted by

regulations or by the manufacturer. (2) Defects caused by the following events

1) Defects due to external factors and causes such as smoke, chemicals, metal particles or radiated heat.

2) Conditions judged as defects by personal feeling which do not affect the normal functions of the hoist. (Noise, vibration, inclination of main body, etc.)

3) Wear by use or deterioration with time (Wear of wheel, natural discoloration of paint, etc.)

4) Defects due to wear or damage of consumable parts, lubricants or similar items (3) The manufacturer will not bear the following expenses even in the warrantee

period. 1) Expense of inspection, adjustment, lubrication or cleaning 2) Repair expense done by any party other than the authorized firms or representatives

of Mitsubishi Electric Hoist Corporation 3) Any expense secondary to repair or liquidated damage consequent to repair due to

unavailability of this hoist. (Communication expenses to notify failure of the hoist, consequent loss such as stop of business operation due to failure of the hoist)

★ When consulting us about your hoist, let us know the type designation and manufacturing number so that the problem can be attended and disposed of promptly.

Fill out the boxes below for later use.

Type designation Manufacturing number Date of purchase

Instruction Manual IB-2405.A MITSUBISHI

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Transcript of Instruction Manual IB-2405.A MITSUBISHI