instruction manual standard version

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MITSUBISHI MITSUBISHI INVERTER HOIST ( 1/2 t - 5 t )

Type U2-H (lifting type inverter hoist) Type U2-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

SOUKAITEI

Instruction Manual PHN-05A037A

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Safety Precautions That Must Be Observed

The following table explains the types of hazards and their degree of seriousness associated with incorrect operation or handling.

! Danger Indicates a situation of immediate danger that may result in death or serious injury if not avoided.

! Warning Indicates a dangerous situation that may result in death or serious injury if not avoided.

! Caution Indicates a dangerous situation that may result in minor or moderate injury or in only a property loss if not avoided.

1. Safety precautions for handling in general

Danger

!!!! Control the duration of the product life. Totally overhaul the product or replace it with a new one before reaching the end

of the life.

Warning

Do not allow anyone to operate the crane if he or she does not fully understand the contents of the instruction manual or the meaning of the warning signs.

Anyone without the required regulatory qualification must not operate the crane or arrange slings to lift a load. Do not allow such a person to do the same.

!!!! Be sure to check the crane and associated items before starting the work. Be sure to carry out the periodical voluntary

inspections.

Caution

!!!! Keep the instruction manual until the product is no longer used. Make the instruction manual available in a place for ready

perusal at any time.

2. Installation and mounting

Danger

!!!! Be sure to provide both ends of the rails of the cross and longitudinal travel tracks with stoppers. Check that the structure where the crane is to be installed has the required strength.

Warning

!!!!

Make absolutely sure that only a specialized subcontractor or persons with the expert knowledge are allowed to install the crane.

Install the crane only in an environment of the specified conditions. Avoid rain or water that the crane is not designed for.

Be sure to ground the crane. In addition to the grounding, provide the electrical circuit with a ground fault circuit breaker.

3. Operation

Danger

Check that the brake device operates normally before starting to use. Do not operate the crane if the brake device does not operate normally.

Do not operate the crane if the crane is damaged or if it generates abnormal noise or vibration. Never operate the crane if the wire rope has any of the following defects.

⋅ The wire rope is kinked, deformed or corroded. ⋅ If more strands than specified are broken or worn out.

Do not attempt arc welding to the suspended load. Do not connect the ground cable of an arc welding machine to the wire rope. Never let the electrode of an arc welding machine come in contact with the wire rope. Never operate the crane if the sling device stopper on the hook is broken or damaged. Do not let the crane main body or the current collector (trolley) run into the stopper or the building structure. Do not operate the crane if the wire rope is not wound on the wire drum normally.

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Stop operating the crane immediately if the crane operates in the different direction from the intended pushbutton instruction. ⋅ The crane operates incorrectly or abnormally, possibly causing an injury.

If you have to press any of the pushbuttons harder than usual, the particular pushbutton switch may be broken. Stop operating the crane. Disassemble the pushbutton switch for inspection.

If an earthquake occurs while operating the crane, immediately lower the load on the floor and turn off the crane power.

Explanation on symbols

Prohibition (Things you must not do or attempt by all means.)

!!!! Instruction (Things you must do by all means.)

Be absolutely sure to ground the crane.

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Warning

Never attempt to lift a load that exceeds the rated capacity. ⋅ See the rating plate on the hook block for the rated capacity.

Do not let anyone ride on or step on the suspended load. Never use the crane to transport or lift a person.

Stay away from under a suspended load. Do not operate the crane if anyone is in the course of the crane motion. Do not move over the load above a person. Do not leave the operating position while the load is being suspended.

Do not operate the crane in a manner that the crane always carries a load. Always pay attention to the load while operating the crane. Do not operate the crane in a manner that the load or the hook block swings or sways. Do not use the limit switch for the over-wind prevention device to stop the lifting operation. Do not attempt to lift a load with the hoist not right above the load.

⋅ Be sure to locate the hoist right above the load before lifting it. Do not use the crane to handle a fixed item such as the building structure. When lowering a load, do not release the wire rope to the extent that it exceeds the lower limit.

⋅ Operate the crane in a manner that the wire rope always remains at least two turns on the drum. Do not operate the crane if the wire rope is wound on the drum in the opposite direction.

Do not turn over the suspended load in an unsafe manner. ⋅ Use a dedicated turnover device to turn over the suspended load.

Check the pushbutton for normal action and function before starting to operate the crane. Do not operate the crane if any of the pushbuttons does not operate normally.

Caution

Operate the crane only from the rated voltage which the crane is designed for. Do not apply braking effort by bragging (or rapid reversing the direction). Do not excessively jog the crane. Do not let the suspended load caught on other structure or wiring. Do not pull on the switch box cable hard with the cable caught on something. Never operate the crane beyond the specified duty factor or the allowable number of startup cycles. Do not remove the warning or caution labels affixed to the main body. Do not operate the crane with the warning or

caution labels left illegible. Before releasing the operation box from your hand, put it back to the naturally suspended position. Do not have the

operation box hit a person or a thing.

!!!!

Before operating the crane, check that the lower part of the hook rotates smoothly and freely. Be sure to engage the sling ropes and sling devices properly with the hook. Stop lifting the load once when the wire rope becomes tight. Keep clean the operation box so that dust or sand does not collect around the pushbuttons. Before releasing the operation box from your hand, put it back to the naturally suspended position. Do not have the

operation box hit a person or a thing. Make sure that the crane has a sufficient lift for the intended work. Be sure to turn off the power before leaving the operating position.

4 Maintenance, inspection and modification

Danger

Do not use any part or device of the crane beyond its service limit.

Warning

Never modify any part of the crane or its accessories. Never use any part or device other than the specified genuine parts or devices.

!!!!

Be sure to turn off the power before starting maintenance, inspection or repair. Only the personnel with the expert knowledge designated by the firm are allowed to maintain, inspect or repair the crane. Make sure that the crane is free of a load before starting maintenance, inspection or repair. If maintenance or inspection reveals a defect with the crane, do not use the crane until the defects is repaired and rectified. Do not use the brake linings beyond its wear limit.

Caution

!!!!

Before starting maintenance, inspection or repair, be sure to post or hang proper signs saying “Maintenance in progress” or “NEVER turn on power” for positive indication

The motors, brake devices and controllers may be very hot. Before starting maintenance, inspection or repair, make sure such devices are safely cool.

Adjust the brake device to the normal play.

⋅ After reading the instruction manual, keep it at a place available for ready perusal for the personnel involved in the crane.

⋅ Be sure to place an order with us for any inspection that involves disassembling and reassembling the crane (refer to the back cover of the instruction manual for the contact details) or with our official dealers.

Attention

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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..........................................................................8

Test Run ..................................................................................................................................9

No-Load Operation.............................................................................................................9 Load Test Run...................................................................................................................10

Operation ..............................................................................................................................11

Inverter Lifting Operation Status Data Output Circu it...................................................13

Setting/Changing of Lifting/lowering Operation Functions and Indication on Segment Indicator ................................................................................................................14

Setting/Changing of Traversing Operation Functions and Indication on Segment Indicator ................................................................................................................23

Error Detection Function ....................................................................................................28

Maintenance and Inspection of Brake................................................................................30 Electromagnetic Hoisting Brake.......................................................................................30 Traversing Electromagnetic Brake ...................................................................................33

Inspection and Maintenance of Wire Rope........................................................................34

Structure, Disassembly and Re-assembly of Reduction Gears ........................................35

Speed Reducer ..................................................................................................................35 Traversing Unit.................................................................................................................37

Maintenance and Inspection ...............................................................................................39 Daily Inspection of Hoist..................................................................................................39 Monthly Inspection...........................................................................................................41 Annual Inspection.............................................................................................................44 Lubrication........................................................................................................................45 Operation Limit of Main Parts..........................................................................................46

General Troubleshooting.....................................................................................................47

Electric Hoist Sectional Views.............................................................................................60

Electric Hoist Motor Trolley Sectional Views ...................................................................64

Hook Block Sectional Views................................................................................................69

Procedure for Straightening Entangled Wire Rope..........................................................75

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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

Type E Type R Type UR

Type S Type U ,U2 Type HU Applicable types

Type S special model Type U special model Type 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 crane beyond the specified duty factor or the allowable number of startup cycles. ⋅ Or else, it deteriorates the strength of the parts and components of the crane, possibly causing the suspended load

to fall off.

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-D Overhead cranes (with bucket, magnet) D-F Ladle crane E-F Charging crane F Forge crane F General purpose bridge cranes (with hooks) B-C

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Regulatory Requirements

Warning

Never attempt to use the crane for any purpose that has a person ride on. ⋅ The person may fall off, causing an injury. It is prohibited by law to use the crane as a lifting device that carries a person.

Do not allow anyone to operate the crane if he or she does not fully understand the contents of the instruction manual or the meaning of warning signs.

Anyone without the required regulatory qualification must not operate the cranes or arrange slings. Do not allow such a person to do the same.

Use of hoists is 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.

Crane manufacturer Crane user

Type of crane Capacity Manufacturing

permit Installation notice and performance

inspection

Installation report

Maintenance obligation

≥3 t Crane Suspended

load ≥1/2 t <3 t

Simplified lift Payload ≥1/4 t <1 t

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.

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

Monorail hoist (Ls) (Sk) (Sp) (Ls) (Sk) (Sp)

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

Remote control or equipped with operator cab

(Ls) (Sk) (Sp) General personnel

(Ls) (Sk) (Sp) (Ls)

Applicable clauses of crane safety code — Clauses 21 and 22

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Suspended load Slinging

<0.5 t ≥0.5 t <1 t ≥1 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. (For installation of a 3t or heavier machine, it is necessary to acquire permission for production.) 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 guide roller 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

Make absolutely sure that only a specialized subcontractor or persons with the expert knowledge is allowed to install the crane. ⋅ Or else, electric shock, falling hook block and other accident may occur, causing an injury.

Install the crane only in an environment of the specified conditions. Avoid rain or water that the crane is not designed for.

Warning

!!!!

Be sure to provide both ends of the rails of the cross and longitudinal travel tracks with stoppers. ⋅ Or else, an accident such as the hoist falling off may occur, causing an injury.

Check that the structure where the crane is installed has the required strength. ⋅ Or else, an accident such as the hoist falling off may occur, causing an injury.

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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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.

Warning

Be sure to ground the crane. In addition to the grounding, provide the electrical circuit with a ground fault circuit breaker. Ground the crane to type C or type D grounding specification. Comply with Electrical Standard for Industrial Machinery and Naisen Kitei (Japanese Standard for Electrical

Wiring) for the grounding and installation of the ground fault circuit breaker. ⋅ This is to prevent electric shock if a ground fault occurs.

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

Cabtyre cable allowable length (m) for 3-core cable

Nominal sectional area of conductor (mm2) Hoist capacity

(t)

Motor capacity kW

(at 60 Hz) 1.25 2 3.5 5.5 8 14 22 30

1/2 1.2 39 62 115 179

1 2.4 25 40 75 117 (165)

2 3.5 21 39 61 (86) (152)

2.8 4.9 28 44 (62) (109) (170)

3 5.3 28 44 (62) (109) (170)

5 7.5 35 (49) (87) (135) (182)

(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 just below 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 for noises 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 or SF1260. (Refer to the catalog of the Mitsubishi optional general inverter of separate type.)

Characteristics of Noise Filter

Outside dimensions (Unit: mm) Model Applicable

hoist W H D W1 H1 C

Approximate weight (kg)

Loss (W)

Leakage current (Ref. value)

(mA)

SF1259 U2-1/2 - 2 142 410 65 105 386 6 2.4 27 33 200 V

SF1260 U2-2.8 - 5 222 468 80 190 449 7 5 118 440

<Measures against leakage current> This hoist uses an inverter to drive the motor. Since high harmonics is included in the inverter output voltage, leakage current to the ground is created due to the capacitance to the ground of the line from the inverter to the motor and the floating capacitance between the motor winding and the iron core. The leakage current not only flows through its own line of the inverter but penetrates other lines through the ground wiring. To avoid malfunction due to the leakage current, use an earth leakage circuit breaker with rated sensitivity current of 100 mA or greater. In this case, the earth leakage circuit breaker functions to prevent disasters such as a fire due to leakage current.

2 mm dia hole

Dimensional outline drawing

Earth leakage circuit breaker Inverter

Power supply

Motor

Leakage current to the earth

Hoist

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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

1/2t 1/2t high lift, 1t 2t 2.8t 3t 5t

75 mm Fig.1-1

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

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

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

175 mm Fig.1-2

Remarks: 1. The applicable I-beams for the

1/2t standard low-lift low-head type, 2.8t type, 3t type, and 5t type can be used in two ways. For them, two spacers (6mm length) are required on one side.

2. The asterisked figures indicate the states before shipment.

Adjust the clearance between the guide roller (or the flange inner side if the flanged wheel is used) and the I-beam to approximately 2.6 mm on each side (approx. 4.6 mm if the flanged wheel is used) (see the following figure). The rail width may slightly vary within the tolerance range because of the bending stress applied to the rail, abrasion on one side (caused at changing the load), etc. For this reason, be sure to check the width for the entire rail, and at the widest point, adjust the clearance so that the guide roller or the flange inner side cannot come in contact with the rail. To adjust this clearance, change the positions of the spacers (6 mm) and the washers (1.6 mm) to the inside or the outside of the traversing side plate. If the traversing rail is curved, the rail may be slightly deformed. So the rail width at the curved area may differ from that of the linear area. If the rail width is reduced at the curved area, minimize the clearance at the linear area so that clearance cannot be enlarged at the curved area. If the clearance is too large at the curved area, the hoist main body cannot keep the balance, or the wheel may come off the rail. As a result, the hoist main body may fall. For this reason, if the rail is curved, install the hoist so that the driving wheel can travel on the outer rail at the curve. If the hoist is installed in this way, the curve traveling performance will be improved during no-load operation. To install a trolley on the hoist, be sure to consider the balance in no-load operation.

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After raising the hoist, once loosen the nut under no-load condition, and re-tighten the nut after eliminating the gap between the clamping bolt and the frame bolt hole. If there is a gap between the clamping bolt and the frame bolt hole, the wheels may be suspended, or the hoist main body may tilt. 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.

Pushbutton pendant

Adjust

Clip

* Lifting-lowering gearbox side for 1/2t type

Clip

Cable

Adjusting the pushbutton pendant height

Guide roller Traversing side plate

2.6 mm (1.6 - 3.6 mm)

With guide roller

4.6 mm (3.6 - 5.6 mm)

S-5 6.6 mm

(5.6 - 7.6 mm)

I beam Wheel

With flange

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Test Run

No-Load Operation

During operation using the commercial power, if traversing operation is performed in the opposite direction, 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 between the current collector and the electromagnetic contactor. In this case, do not exchange the wires of the pushbutton switches. If the hook is lifted by pressing the DOWN button due to reverse winding of wire rope, the hook will operate to the second stage limit switch. After this operation, the hoist will not move even if the UP or DOWN button is pressed. 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.

(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 dis-assembling 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.

Warning

When correcting the phase sequence, do not change the electrical connection of the pushbuttons on the operation box. ⋅ Or else, the limit switch is disabled. This causes the wire rope to break and the suspended load to fall off, possibly

causing an injury.

(Left) (Right)

Connection rod Arm

Lever

(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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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. * Lift the load not at a low speed at which the torque will drop, but at a high speed. While

the load is being lifted, undue force may be applied to the inverter to trip and stop. This is not a trouble. Once release the pushbutton, and press it again. To lower a load, use a low speed, not a high speed. This is because high-speed lowering operation needs a regenerative energy. In addition, high-speed lowering operation may overload the inverter, and may cause tripping and stoppage. This is not a problem, either. In this case, release your finger from the pushbutton, and then press the pushbutton 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.

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Operation

After turning on the power of the U2-H type, the lifting and lowering operations will be performed in the inverter mode. After turning on the power of the U2-S type, the lifting, lowering, and traversing operations will be performed in the inverter mode.

(1) Inverter-driven lifting/lowering operation The UP and DOWN 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 rated speed operation (inverter output = approx. 60 Hz). If the light-load high-speed function is set, the ultra high speed will be automatically selected. (Before delivery from our factory, the light-load high-speed function is canceled. So set this function whenever necessary.) To set the high speed or low speed, use the operation function setting area (equipped for the standard type). The mode button is in this area. Using this button, enter the frequency setting mode, and change the frequency to set the desired speed.

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

Pressing

Pushbutton

Light-load high-speed function

1st step 2nd step

With function

Low speed Rated high speed In light-load mode only

Ultra high speed

Lifting/ lowering

UP/DOWN Without function

Low speed High speed

(2) Inverter-driven traversing operation The EAST and WEST pushbutton switches are the 2-step type. Press each switch to the first step to perform traversing operation at a low speed. Press each switch to the second step to perform traversing operation at a high speed. Using the operation function setting area, you can respectively set the high speed and low speed to the desired values. Before delivery from our factory, the high speed is set to the maximum value (60 Hz), and the low speed is set to the minimum value (6 Hz).

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

Pressing

Pushbutton 1st step 2nd step

Traversing EA/WE Low speed High speed

Plucking (rapid deceleration) is possible. Using the mode button in the operation function setting area, enter the frequency setting mode. In this mode, you can respectively set the high speed and low speed to the desired values. For a detailed description, refer to “Setting/Changing of Traversing Operation Functions and Indication on Segment Indicator”.

- 12 -

Operation with a sequencer

When the sequencer output circuit gives SSR output, the hoist may become unstable or enter the ON state due to leakage current from the snubber circuit. Countermeasure: Externally fit a resistance, R, to bypass the leakage current.

Sequencer output circuit Hoist input circuit

Snubber circuit

Bypassing leakage current from the snubber circuit

R = Approx. 30 kΩΩΩΩ, 3 W

- 13 -

Inverter Lifting Operation Status Data Output Circu it

The CPU board has output terminals that can output the operation status data to the outside. These terminals are OUT1 through OUT4 terminals on the terminal board of the CPU board.

OUT1 and OUT2 terminals: The status data “hook at upper limit position” and the status data “hook at lower limit position” will be output from the OUT1 and OUT2 terminals, respectively.

CPU board for

lifting operation OUT1 : Outputs the status data “hook at upper limit

position”. (This data can be also used as an error data.)

OUT2 : Outputs the status data “hook at lower limit position”. (This data can be also used as an error data.)

Upper limit stop point

OUT1 : Opened OUT2 : Closed

Lower limit stop point

OUT1 : Closed OUT2 : Closed

Set lift

OUT1 : Closed OUT2 : Opened

At abnormal stoppage

OUT1 : Closed OUT2 : Opened

Contact capacity: 200 VAC, 0.5 A

Terminal box (20P)

OUT3 and OUT4 terminals: You can change the data output from the OUT3 and OUT4 terminals. To use two hoists for lifting a load, set the external output signal to “Y2”, and connect the OUT3 terminal of one hoist to the IN4 terminal of the other hoist, and vice versa. After this, two hoists can be simultaneously operated in the light-load high-speed mode. The overload signal will be output even if the overload stoppage function is disabled. The light-load signal, however, will not be output if the light-load high-speed function is disabled. To use two hoists for lifting a load, set the same lifting/lowering operation conditions for both hoists. When the light-load signal is on, if a load is detected or the speed is changed from a high speed to a low speed or from a low speed to a high speed, the output light-load signal will be canceled.

External output signal Between OUT3 and CM34

During normal operation : Open When operation is stopped : Open Y1 (Set to “Y1” before delivery

from factory) When overload is detected : Closed During operation : Closed

When light load is not detected : Open When operation is stopped : Open Y2 (*1)

When light load is detected : Closed During operation : Closed

*1: If “Y2” (light load) is selected as the external output signal, the light-load high-speed operation permission signal will be input to the IN4 terminal.

- 14 -

Setting/Changing of Lifting/lowering Operation Functions and Indication on Segment Indicator

Switching of segment indicator mode (basic setting mode, extended setting mode, and history display mode): When the power is turned on, the segment indicator will enter the basic setting mode. Press and hold down the button for 2 seconds or more to switch the segment indicator mode. Note

that the segment indicator mode will be sequentially switched to the extended setting mode, history display mode, and basic setting mode. Each mode has various setting items or display items. So switch the segment indicator to the desired mode to change the set operation functions or to display the stored history data.

Be sure to check that the protective cover is attached to the CPU board. If you use the CPU board without the protective cover, you may get an electric shock.

CPU board for lifting/ lowering operation

Segment indicator

Function selector switch: Correctly set this switch to perform operation.

Names of buttons

Red White BlackBlue

Extended setting mode

Hook operation limit switch enable/disable mode (See the above figure.) Light-load high-speed function enable/disable mode Light-load high-speed frequency setting mode Overload stoppage function enable/disable mode External output signal selection mode

Basic setting mode

Current frequency display mode (See the above figure.) Frequency setting mode Hook operation limit position setting mode Light-load high-speed function setting mode Overload stoppage function setting mode

Press and hold down the MOD button for 2 seconds or more.



Error history display mode (See the above figure.) (**: Numeric values or nothing will be indicated.) Number of starting times display mode Operation time display mode

Power-on

History display mode

- 15 -

Settings before delivery from factory

Function Conditions factory-set before delivery

Setting range Mode Remarks

Low-speed lifting

Low-speed lowering 7 Hz

High-speed lifting

High-speed lowering 56 Hz

6 - 60 Hz Basic setting mode

Light-load high-speed lifting

Frequency setting

Light-load high-speed lowering

90 Hz 60 - 90 Hz Extended setting mode

Automatically judged during high-speed operation

Upper-limit stop point 10 mm below the LS lever

Upper-limit speed-reduction point

150 mm below the upper-limit stop point

Lower-limit speed-reduction point

150 mm above the lower-limit stop point

Operation limit

position setting

Lower-limit stop point Position where 2 turns

of rope are left wound

Adjusted to any point in the range of lift Fin adjustment setting range: 1 to 9999

Basic setting mode


The limit switches can be respectively turned on and off.

Butch adjustment of all points is possible.

Light-load high-speed setting OFF ON/OFF

Judgment value: 0 to 25

Basic setting mode


The judgment level can be respectively adjusted for the lifting operation and the lowering operation.

Overload stoppage function setting OFF ON/OFF

Judgment value: 0 to 99

Basic setting mode


The judgment level can be respectively adjusted for the low-speed operation and the high-speed operation.

- 16 -

List of functions of basic setting mode

Press the button to switch the setting mode. (The setting mode will be switched cyclically).

Current frequency setting mode

Frequency setting mode

Operation limit positions setting mode

Light-load high-speed function setting mode

Overload stoppage function setting mode

Press the button to switch the frequency type

Low-speed lifting frequency Low-speed lowering frequency High-speed lifting frequency High-speed lowering frequency

Press the button to switch the limit point.

All limit points

Upper-limit stop point

Upper-limit speed- reduction point

Lower-limit speed-reduction point

Lower-limit stop point The

lim

it sw

itche

s ca

n be

dis

able

d.

Press the button to determine the fine-adjusted operation limit position(s).

Press the button to switch the light-load high-speed operation type.

Light-load high-speed operation

Light-load high-speed lifting operation

Light-load high-speed lowering operation

The

ligh

t-load

hi

gh-s

peed

ope

ratio

n ca

n be

dis

able

d.

Press the button to switch the overload stoppage function type.

Overload stoppage function

Overload stoppage for low-speed operation

Overload stoppage for high-speed operation

The

ove

rloa

d st

oppa

ge

func

tions

ca

n be

dis

able

d..

Press the button to increase the frequency by 1 Hz.

Press the

button to lift the set position by 1 mm.

will

flash.

Press the button to raise the light-load

judgment level by 1.

Press the button to raise the overload


For low speed

For high speed

Press the button to reduce the frequency by 1 Hz.

Press the +S and -S buttons

at the same time to store the current position.

Press the

button to lower the set position by 1 mm.

will flash.

Press the button to lower the light-load judgment level by 1.

Press the button to lower the overload


For low speed

For high speed

• Current frequency display mode

During operation, the displayed frequency value fluctuates. Note that this fluctuation is not abnormal. (To keep the speed constant during the lifting/lowering operation, the speed should be controlled by changing the frequency.)

• Frequency setting mode The optimum frequency value depends on the mode. After changing the frequency value, be sure to change the light-load judgment level and the overload judgment level.

• Operation limit position setting mode After fine adjustment of an operation limit position(s), be sure to press the button to determine the adjusted position(s). (The fine-adjusted value will flash until the value is determined.)

- 17 -

Before replacing the wire rope, display , and disable the limit switch of this position. In the extended setting mode, if operation limit switches are respectively disabled, through will flash. Evan if the operation limit switches are disabled, the set position data will not be erased. If the upper limit for operation is not set, the light-load high-speed function will be disabled for the lifting operation.

• Light-load high-speed function setting mode The value set for the light-load judgment level represents the target level. This value, therefore, does not represent a physical quantity of the load. If the light-load judgment level is raised, the light-load high-speed operation will be smoothly started (light-load high-speed operation can be started even if the load is heavier). The optimum light-load judgment level depends on the model. The optimum light-load judgment level depends on the operation conditions (voltage, temperature, etc.). For this reason, after installing the hoist, change the set light-load judgment level value. In the extended setting mode, if the light-load high-speed function for lifting or lowering operation is disabled, or will flash. If the upper limit for operation is not set, the light-load high-speed function will be disabled for the lifting operation.

• Overload stoppage function setting mode The value set for the overload judgment level represents the target level. This value, therefore, does not represent a physical quantity of the load. In the extended setting mode, if the overload stoppage function is disabled for low-speed or high-speed operation, or will flash.

The optimum overload judgment level depends on the model. If the overload judgment level is raised, the overload stoppage function will not be easily activated (a heavier load can be lifted because the overload stoppage function is not easily activated). If the power supply voltage is low, overload may be detected even if the applied load is 100%. The optimum overload judgment level depends on the operation conditions (voltage, temperature, etc.). For this reason, after installing the host, change the set overload judgment level value. If the overload judgment level is extremely raised, operation may be stopped due to overcurrent, starting error, speed adjustment error, etc. before detecting overload.

- 18 -

Examples of basic settings

(1) Follow the procedure shown below to increase the lifting low-speed (to increase the frequency):

Power-on

Press this button several times, or press and hold down this button for several seconds to change the set frequency (speed) value.

(2) Follow the procedure shown below to set the current hook position as the upper-limit stop point:

Power-on

Press this button several times to display ALP on the segment indicator (to enable the limit switches).

Press these two buttons at the same time (to store the current position).

Press this button several times to display LoC1 on the segment indicator.

(3) Follow the procedure shown below to raise all the limit positions by 100 mm:

Power-on

Press this button several times, or press and hold down this button for several seconds to set the positional raise value.

Press this button several times to display ALP on the segment indicator.

(4) After adding a hoisting accessory, if the light-load high-speed function cannot be activated during lifting operation, follow the procedure shown below to activate the light-load high-speed operation (to lower the light-load judgment level for lifting operation):

Power-on

Press this button several times.

Lifting operation

Press this button several times to display nLHu on the segment indicator.

Increase the judgment value.

Press this button several times to display nLHu on the segment indicator. Repeat these steps until the light-load

high-speed function can be activated.

- 19 -

(5) Follow the procedure shown below to activate the overload stoppage function at the load of 2t for the hoist of 2.8t class (to lower the overload judgment level):

Power-on

Press this button several times.

Low-speed lifting operation

Press this button several times to display oL-L on the segment indicator.

Reduce the judgment value.

Press this button several times to display oL on the segment indicator.

Repeat these steps until the overload stoppage function can be activated.

Follow the same procedure to change the judgment level for high-speed lifting operation.

The actual load is needed.

Power-on This represents the operation to be performed, such as turning on the power and lifting/lowering operation.

The value represents the value indicated on the segment indicator of the CPU board.

On the CPU board, press this button once. The characters shown on the button represents the type of the button.

On the CPU board, press this button several times, or press and hold down this button for several seconds. The characters shown on the button represents the type of the button.

- 20 -

List of functions of extended setting mode


Operation limit switch enable/ disable mode

Light-load high-speed function enable/

disable mode

Light-load high-speed

frequency setting mode

Overload stoppage function enable/

disable mode

External output signal selection mode

Press the button to

switch the limit point.

Upper-limit stop point Upper-limit speed- reduction point Lower-limit speed- reduction point Lower-limit stop point

Press the button to switch the light-load high-speed operation type.

Light-load high-speed lifting operation

Light-load high-speed lowering operation

Press the CH button to switch the frequency type.

Frequency for light-load high-speed lifting operation

Frequency for light-load high-speed lowering operation

Press the CH button to switch the overload stoppage function type.

Overload stoppage for low-speed lifting operation

Overload stoppage for high-speed lifting operation

Press the CH button to switch the external output signal.

OUT3: Overload

stoppage signal OUT4: “Running” signal

OUT3: Light-load judgment signal

OUT4: “Running” signal

Press the button to enable the limit switch of the set point.

will light.

Press the button to enable the light-load high-speed function for the selected operation type.

will light.


Press the button to enable the overload stoppage function for the selected operation type.

will light.

Press the button to disable the limit switch of the set point.

will flash.

Press the button to disable the light-load high-speed function for the selected operation type.

will flash.


Press the button to disable the overload stoppage function for the selected operation type.

will flash.

If the upper limit stop point or the upper limit speed-reduction point is disabled, the light-load high-speed function will not be activated for the lifting operation. If “Y2” (light-load judgment output) is selected for the external output signal, the light-load high-speed operation of two hoists can be simultaneously performed using the IN4 input terminal. To simultaneously perform the light-load high-speed operation of two hoists, additional wiring is needed between two hoists (refer to the sequence diagram).

- 21 -

Examples of extended settings

(1) Follow the procedure shown below to disable the lower limit switches only (limit switches of lower-limit speed-reduction point and lower-limit stop point):

Power-on

Flashes Press this button several times to display LoC3 on the segment indicator.

Press and hold down this button for 2 seconds.

Flashes

(2) When lowering a load to the basement, disable the light-load high-speed function for the lowering operation only by following the procedure shown below:

Power-on


Flashes

(3) If the girder resonates and generates a noise, reduce the frequency for the light-load high-speed operation by following the procedure shown below:

Power-on

Press this button several times to display nu90 on the segment indicator.


Press this button several times, or press and hold down this button for several seconds to reduce the frequency to the desired value.

Press this button several times, or press and hold down this button for several seconds to reduce the frequency to the desired value.

(4) When the lifting operation is performed at a high speed, the power supply voltage may drop and the operation may be stopped due to overload. In this case, disable the overload stoppage function for the high-speed lifting operation only by following the procedure shown below:

Power-on

Press this button several times to display oL-L on the segment indicator.


Flashes

(5) When two hoists are simultaneously used for lifting a load, the load may be inclined due to difference in the light-load high-speed operation start timings between two hoists. In this case, adjust the timings of two hoists by following the procedure shown below:

Power-on

Press this button several times to display Y1 on the segment indicator.

Press and hold down this button for 2 seconds. Additional wiring is needed.

- 22 -

List of functions of history display mode


Error history display mode

Number of starting times display mode

Operation time display mode

Press the button to switch the error data.

Latest error data

**: Displays the error number.

Oldest error data

Press the button to switch the displayed digits.

Displays the upper 4 digits.

Displays the lower 4 digits.

(Number of starting times: 12,345,678)


Upper 4 digits of hour

Lower 2 digits of hour + minute

(Operation time: 123,456 hours and 10 minutes)

Press the button to display the number of starting times or the operation time stored at detection of the error.

Press the

and buttons at the same time to

delete the error history data.

The number of starting times and the operation time cannot be deleted. The number of starting times can be displayed in the range of 0 to 99,999,999 times. (The displayed number of starting times is the total number of starting times of both the lifting and lowering operations.) The operation time can be displayed in the range of 0 hour and 0 minute to 999,999 hours and 59 minutes. (The displayed operation time is the total operation time of both the lifting and lowering operations.)

Example of operation in history display mode: (1) If you want to know the number of starting times and the operation time stored at detection

of the latest error, follow the procedure shown below:

Power-on



If the error history data is stored, the error number will appear in the ** area. If no error history data is stored, nothing will appear in the ** area. In this case, pressing the +S button will display no data.

Upper 4 digits of number of starting times

Lower 4 digits of number of starting times

If the number of starting times is 12,345,678, this number will appear on the segment indicator as shown above. (Actually, a different number may appear on the segment indicator.)

Upper 4 digits of operation hour

Lower 2 digits of operation hour + minute

If the operation time is 123,456 hours and 10 minutes, the value of this operation time will appear on the segment indicator as shown above. (Actually, a different value may appear on the segment indicator.)

- 23 -

Setting/Changing of Traversing Operation Functions and Indication on Segment Indicator

Switching of segment indicator mode (basic setting mode and history display mode): When the power is turned on, the segment indicator will enter the basic setting mode. Press and hold down the and buttons for 2 seconds or more to switch the basic setting mode to

the history display mode. Each mode has various setting items or display items. So switch the segment indicator to the desired mode to change the set operation functions or to display the stored history data.

Be sure to check that the protective cover is attached to the CPU board. If you use the CPU board without the protective cover, you may get an electric shock.

CPU board for traversing operation

Segment indicator

Function selector switch: Correctly set this switch to perform operation.

Names of buttons

Red White BlackBlue

Basic setting mode

Current frequency display mode (See the above figure.) Frequency setting mode Acceleration time setting mode Deceleration time setting mode Rapid deceleration time setting mode

Press and hold down the CH and +S

buttons at the same time for 2 seconds or

more.

Error history display mode (See the above figure.) (**: Numeric values or nothing will be indicated.) Number of starting times display mode Operation time display mode

Power-on

History display mode

Settings before delivery from factory: Function Conditions factory-set before delivery Setting range Remarks

Low speed 6 Hz Frequency setting High speed 60 Hz

6 - 60 Hz If the special operation function is used, the frequency can be set in the range of 3 to 90 Hz.

Acceleration time

Deceleration time 3 sec Acceleration/

deceleration time Rapid deceleration

time 1 sec

0.5 - 9.9 sec

If the opposite direction operation signal is input during deceleration, the operation will be stopped in a short time in accordance with the set rapid deceleration time, and then the operation will be restarted in the opposite direction. (Plucking operation)

- 24 -

List of functions of basic setting mode (for traversing operation)


Current frequency setting mode

Frequency setting mode

Acceleration time setting mode

Deceleration time setting mode

Rapid deceleration time setting mode

Press the button to switch the frequency type

Low-speed frequency

High-speed frequency

Acceleration time: 3 sec

Deceleration time: 3 sec

Rapid deceleration time: 1 sec


Press the button to prolong the acceleration time by 0.1 sec.

Press the button to prolong the deceleration time by 0.1 sec.

Press the button to prolong the rapid deceleration time by 0.1 sec.

Press the button to reduce the frequency by 1 Hz.

Press the button to shorten the acceleration time by 0.1 sec.

Press the button to shorten the deceleration time by 0.1 sec.

Press the button to shorten the rapid deceleration time by 0.1 sec.

In the frequency setting mode, when 6 Hz is displayed, press and hold down the button for 5 seconds or more to further reduce the frequency to 5 to 3 Hz. In the frequency setting mode, when 60 Hz is displayed, press and hold down the button for 5 seconds or more to further increase the frequency to 61 to 90 Hz. Note that if the frequency is too low, the motor cannot be started. Also note that if the frequency is more than 60 Hz, the motor cannot supply enough power. In this case, reduce the load. If the frequency is more than 60 Hz, the gears may be abraded, and a collision may be caused. As a result, the load and the hoist may be damaged. If the acceleration time is too short, tripping may be caused due to overcurrent (Er16). If the deceleration time is too short, tripping may be caused due to overvoltage (Er13).

- 25 -

Examples of settings in basic setting mode (for traversing operation)

(1) Follow the procedure shown below to increase the high-speed frequency to 90 Hz:

Power-on

Press and hold down this button for 5 seconds or more to increase the frequency to 61 Hz or more. When the frequency is increased to 90 Hz, release the button.

(2) At starting, tripping may occur due to overcurrent. In this case, prolong the acceleration time by following the procedure shown below:

Power-on

Press this button several times, or press and hold down this button for several seconds to prolong the acceleration time.

(3) At stoppage, tripping may occur due to overvoltage. In this case, shorten the deceleration time by following the procedure shown below:

Power-on

Press this button several times, or press and hold down this button to prolong the deceleration time.

- 26 -

List of functions of history display mode (for traversing operation)


Error history display mode

Number of starting times display mode

Operation time display mode

Press the button to switch the error data.

Latest error data

**: Displays the error number.

Oldest error data


Displays the upper 4 digits.

Displays the lower 4 digits.

(Number of starting times: 12,345,678)


Upper 4 digits of hour

Lower 2 digits of hour + minute

(Operation time: 123,456 hours and 10 minutes)

Press the and buttons at the same time to delete the error

history data.

The number of starting times and the operation time cannot be deleted. The number of starting times can be displayed in the range of 0 to 99,999,999 times. (The displayed number of starting times is the total number of starting times of both the eastward and westward traversing operations.) The operation time can be displayed in the range of 0 hour and 0 minute to 999,999 hours and 59 minutes. (The displayed operation time is the total operation time of both the eastward and westward traversing operations.)

- 27 -

Example of operation in history display mode (for traversing operation)

(1) Follow the procedure shown below to check the error history:

If the error history data is stored, the error number will appear in the ** area. If no error history data is stored, nothing will appear in the ** area.

Press and hold down these buttons at the same time for 2 seconds.

Power-on

(2) Follow the procedure shown below to check the operation time:

Upper 4 digits of operation hour

Lower 2 digits of operation hour + minute

If the operation time is 123,456 hours and 10 minutes, the value of this operation time will appear on the segment indicator as shown above. (Actually, a different value may appear on the segment indicator.)


Power-on

(3) Follow the procedure shown below to delete the error history:


Power-on

Press these buttons at the same time.

- 28 -

Error Detection Function

If an error is detected, the 7-segment LED indicator will flash the error number, and the hoist will be stopped. In this case, release the pushbutton switch, and then press it again, or stop supplying the electric power, eliminate the cause of the error, and then restart operation.

List of lifting/lowering errors

Error Description of error Measures Cause Restarting Display

Power failure The AC power is turned off. Immediate stoppage

Error indication Power failure Imperfect contact of trolley

Possible Ｅｒ０１Ｅｒ０１Ｅｒ０１Ｅｒ０１

Power supply voltage too low

The voltage of the PN line is 230 V or less.

Immediate stoppage Error indication

Power supply capacity shortage Imperfect contact caused in trolley line

Possible Ｅｒ０２Ｅｒ０２Ｅｒ０２Ｅｒ０２

Defective pushbutton

Both the lifting and lowering commands are input at the same time. The pushbutton signal input circuit is defective.

Deceleration and stoppage Error indication

Wiring error Defective CPU board

Possible Ｅｒ１１Ｅｒ１１Ｅｒ１１Ｅｒ１１

Starting error

During lifting/lowering operation, the 2-phase signal sent from the rotation sensor cannot be received for 0.5 sec or more.


Overloaded during lifting operation (Note 4) Defective hoisting brake Defective inverter

Possible Ｅｒ１２Ｅｒ１２Ｅｒ１２Ｅｒ１２

Regenerative voltage too high

The voltage of the PN line is 380 V or more.


Overloaded during lowering operation (Defective regenerative circuit)

Possible Ｅｒ１３Ｅｒ１３Ｅｒ１３Ｅｒ１３

Lowered during lifting operation

During lifting operation or stoppage of operation, the hook is lowered.


Defective hoisting brake Defective inverter Possible

Ｅｒ１４Ｅｒ１４Ｅｒ１４Ｅｒ１４

Speed adjustment impossible

The error value counted by the error counter is out of the tolerable range.


Overload (Note 4) Defective inverter Possible

Ｅｒ１５Ｅｒ１５Ｅｒ１５Ｅｒ１５

Overwork Overcurrent

Control power supply error

The “Fout” signal is output. (Overcurrent or overheat)


Overwork Overload (Note 4) Defective IPM

Possible (Note 2) Ｅｒ１６Ｅｒ１６Ｅｒ１６Ｅｒ１６

(Note 1) Defective rotation

sensor

One of 2 signals is missing. Deceleration and stoppage Error indication

Disconnection Defective rotation sensor Inhibited

Ｅｒ２１Ｅｒ２１Ｅｒ２１Ｅｒ２１

Over-speed The speed is higher than the maximum speed 110%.


Motor line disconnection Defective inverter

Inhibited Ｅｒ２２Ｅｒ２２Ｅｒ２２Ｅｒ２２

(Note 1) Limit position

overrun

Counter overflow Deceleration and stoppage Error indication

Noise Defective rotation sensor Defective CPU board

Inhibited Ｅｒ２３Ｅｒ２３Ｅｒ２３Ｅｒ２３

Overload (Note 3)

The applied load is more than the judgment value.

Deceleration and stoppage

Overload Possible

oLoLoLoL

Note 1: Set the electronic operation limit position again. Note 2: If the hoist is stopped due to overheat, restarting the hoist will not possible until the power module is cooled enough. Note 3: This error will not be recorded in the error history. Note 4: This error may occur if the overload stoppage function is not used or if an extremely large load is applied, e.g. earth lifting

is performed.

- 29 -

List of traversing errors

Error Description of error Measures Cause Restarting Display

Power failure (Note 1)

The AC power is turned off. Immediate stoppage Error indication

Power failure Imperfect contact of trolley

Possible Ｅｒ０１Ｅｒ０１Ｅｒ０１Ｅｒ０１

Defective pushbutton

Both the southward and northward traveling commands are input at the same time. The pushbutton signal input circuit is defective.


Wiring error Defective CPU board

Possible ＥＥＥＥｒ１１ｒ１１ｒ１１ｒ１１

Regenerative voltage too high

The voltage of the PN line is 380 V or more.


Vibrated load Deceleration time too short Defective regenerative circuit

Possible Ｅｒ１３Ｅｒ１３Ｅｒ１３Ｅｒ１３

Overcurrent Control power supply error

The “Fout” signal is output from the IPM.


Overload Defective IPM Possible

Ｅｒ１６Ｅｒ１６Ｅｒ１６Ｅｒ１６

Note 1: If instantaneous power failure continues for 15 msec or more, power supply will be stopped for 5 to 6 seconds, and operation cannot be performed during stoppage of power supply.

- 30 -

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 1/2t type, the involute spline is adopted to engage the brake disk to the end of the motor shaft in the brake box. For the 1t to 5t types, the brake gear is engaged to the motor shaft. The 1/2t to 5t 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 1/2t to 5t 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.

- 31 -

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 1/2t 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.

- 32 -

(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 1t to 5t 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 1/2t 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 1/2t type : 7.8 mm or more 1t type : 6.3 mm or more 2t, 2.8(3),5t type : 5.0 mm 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”.

- 33 -

Chamfer the edge

Pressure plate

Adjusting ring

Wear limit Wear limit

Inspection window Wear 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.

- 34 -

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.

- 35 -

Structure, Disassembly and Re-assembly of Reduction Gears

Speed Reducer

The simplified 2-step speed reducer is adopted for the 1/2t to 3t types, and the simplified 3-step speed reducer is adopted for the 5t type. Excluding the final step of the speed reducer for the 5-t type, the helical gears are adopted for these speed reducers. An oil-bath lubrication system is adopted for lubrication. All the bearings are ball bearings.

(1) Disassembly procedure for 1/2t to 3t types 1) (For Type U only) Remove the cover from the rotation sensor. You can see the shaft

end of the first gear. In this condition, you can remove the RRS board. 2) Loosen and remove the tightening bolts from the gearbox and the G-cover, and then

remove the G-cover. (If your hoist is Type U, remove the G-cover together with the sensor case.)

3) Remove the C-shaped snap ring from the fourth gear shaft. 4) Remove the second and third gears. These gears are helical gears. To remove each

gear, turn the gear along the spiral angle. Be careful not to flaw the gear surface. 5) Pull out the first gear. 6) Pull out the fourth gear.

(2) Disassembly procedure for 5t type 1) (For Type U only) Remove the cover from the rotation sensor. You can see the shaft

end of the first gear. In this condition, you can remove the RRS board. 2) Loosen and remove the tightening bolts from the gearbox and the G-cover, and then

remove the G-cover. (If your hoist is Type U, remove the G-cover together with the sensor case.)

3) Remove the C-shaped snap ring from the fourth gear shaft. 4) Remove the second and third gears. These gears are helical gears. To remove each

gear, turn the gear along the spiral angle. Be careful not to flaw the gear surface. 5) Remove the C-shaped snap ring from the fourth gear shaft. 6) Pull out the fourth gear. (Using the screw hole of the fourth gear, screw a bolt (M14

thread) into the hole so that the bolt can come in contact with the gearbox, and then pull out the gear.)

7) The gearbox and the G-bracket are tightened to the frame by bolts (M14). Loosen these bolts to remove the gears. When removing the gears, the winding drum and the G-bracket may be removed together with the gears. Attach something to the winding drum and the G-bracket so that they can be left on the frame.

(3) Reassembly procedure (for 1/2t to 5t types) 1) Follow the above disassembly procedure in the reversed order to reassemble the speed

reducer. Before tightening the G-bracket (for the 5t type only), however, be sure to completely degrease the mating faces between the G-bracket and the gearbox and the mating faces between the G-cover and the gearbox, and then apply liquid packing (Three Bond No. 1208D or No. 1104) to both faces. (Before applying the liquid packing, remove the old packing completely.) * At the completion of disassembly, replace the oil seal with a new one, and apply grease

to the contact areas. In addition, carefully assemble the parts so that no parts can be flawed.

- 36 -

2) Supply oil to the lifting/lowering gearbox. Remove the oil supply plug (the word “OIL” is written on the plug), and then supply lubrication oil until the oil level is raised to the center of the level gauge. Supply of too much oil may cause oil leakage. Be sure to refer to the following table to supply the lubrication oil. The following table shows the necessary oil quantity for each type:

Oil quantity

Type (t) 1/2 1 2 2.8 3 5

Oil quantity (L) 0.25 0.5 0.95 1.7 1.7 3.3

Sensor case

Cover

Gearbox

Oil seal

Oil seal

G-cover

G bracket

RRS board

Oil seal

RRS board

Cover

Sensor case

Oil seal

G-cover 4G Gearbox

* The recommended oils are listed below: Gear oil JIS : Class 1, No. 4,

or equivalent oil Shell Morlina : S2BA220 (manufactured by

Showa Shell Sekiyu Co.Ltd.). This oil is used for this hoist.

Diamond Lub : RO150 (manufactured by Mitsubishi Oil Co.Ltd.)

- 37 -

Rotation sensor

Traversing Unit

1/2t monorail low-head type: This type is the simplified 2-step speed reducer. For the first step, the inner gearbox grease lubrication system is adopted. For the second step, the covered dustproof grease lubrication system (Moly PS Grease No. 2) is adopted. The fourth gear (final gear) is fixed to the wheel using bolts. During inspection, apply grease to the gears to ensure smooth operation of the gears.

1t to 3t monorail low-head type: This type is the simplified 2-step speed reducer. The gears are sealed in the gearbox, and the grease lubrication system is adopted. To ensure high performance in traversing operation, the flange is removed from the wheel, and the guide roller is adopted. To remove the guide roller, just remove the pin. This guide roller is the easy-removal type.

5t monorail low-head type: This type is the simplified 2-step speed reducer. For the first step, the inner gearbox grease lubrication system is adopted. For the second step, the covered dustproof grease lubrication system (Moly PS Grease No. 2) is adopted. The fourth gear (final gear) is fixed to the wheel using bolts.

2.8t to 5t double-rail type: This type is also the simplified 2-step speed reducer, and the inner gearbox grease lubrication system is 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.

- 38 -

Grease quantity

Monorail (low-head) Double-rail

1/2t low-lift 1/2t high-lift,

1t 2t-3t 5t 2.8t-5t Model

1st step 2nd step ― ― 1st step 2nd step ―

Quantity (g)

150 Application to entire gear surface

200 250 100 Application to

entire gear surface 300

Recommended grease

Albania EP-2 (Showa Shell)

Moly PS Grease No. 2

(Manufactured by Sumiko Lubricant)




Moly PS Grease No. 2

(Manufactured by Sumiko Lubricant)


Traversing unit of monorail

- 39 -

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.

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.)

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.

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.

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.

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

- 40 -

Danger

Never modify any part of the crane or its accessories. Be sure to use Mitsubishi genuine parts only.

Warning

!!!!

Be sure to turn off the power before starting maintenance, inspection or repair. Only the personnel with the expert knowledge designated by the firm are allowed to maintain, inspect or repair the crane. Make sure that the crane is free of a load before starting maintenance, inspection or repair. If maintenance or inspection reveals a defect with the crane, do not use the crane until the defects is repaired and

rectified. ⋅ Never use the crane with a defect as it is dangerous. Or else, an accident may occur.

Caution

!!!! Before starting maintenance, inspection or repair, be sure to post or hang proper signs saying “Maintenance in

progress” or “NEVER turn on power” for positive indication

!

!

!

- 41 -

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

Month

No. Check item Description

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.

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 6

Wire rope

Check the terminal fitting inlet for corrosion.

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

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.

7 Hook block

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.

- 42 -

Month


Acc

epta

bilit

y

Problem and remedy


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.

Check the inside of the control box for dust.

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

Check the printed boards particularly carefully.

14 Control box

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 and Type UR : For Inverter Type U

- 43 -

Classes B and C

Month


Acc

epta

bilit

y

Problem and remedy


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.

- 44 -

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.

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 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).

3 Brake disk thickness

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


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 U and Type UR : For Inverter Type U : 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.

- 45 -

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

- 46 -

Operation Limit of Main Parts

Part Limit 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

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

Wire

ro

pe

Rope end Breakage

Reference replacement schedule: * Approx. 40,000

cycles

Contactor contact When the contact thickness reaches 0.5 mm

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

Hoisting brake disk Refer to the annual inspection.

Rolling bearing Damage, harmful flaws, or abnormal noise

Traversing brake disk

See the annual inspection table on p. 28.

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. 0.5 mm (5 t)

Approx. 0.3 mm (1/2 - 3 t))

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)

Joints (pins and holes)

Wear of hole and shaft 20% of the nominal diameter Inverter

When the overload drop preventive device frequently functions When noise is abnormally loud

* The service life greatly depends on the use conditions.

Hook dimensions (Reference dimensions)

Unit: mm

a b

1/2 t - 28

1 t - 32

2 t - 40

2.8 t 110 50

3 t 110 50

5 t 135 63

* Reference dimensions are shown in the above table. Before using a new hook, be sure to measure the actual dimension.

Punch mark

Tooth thickness

Amount of gear

Pitch circle

(Monorail type)

Wear

Wear

Fig. 2 Fig. 3

Fig. 4 Fig. 5

(Double rail type)

- 47 -

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) 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

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

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.

(2) Use the hoist suitable for the ambient conditions (waterproof type, etc.). Remove paint completely.

(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.

(1) Incorrect connection of power supply line

(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.

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

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

(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.

(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. 4. Wire rope is wound ununiformly.

(2) Wire rope distorted (2) Replace.

- 48 -


(1) Incorrect connection of power supply line

(2) Wire rope wound reversely

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

5. The 2nd-stage limit switch operates.

(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.)

(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.

7. The hoist does not start even if the push-button is pressed.

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

(6) Use the hoist at appropriate intervals.

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

intervals.

8. The hoist lowers and stops during hoisting

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

(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.

9. The hoist stops suddenly during hoisting.

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

(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.

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

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

(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.

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

(6) Malfunction due to noise. (6) Fit a noise filter to the 3-phase power supply.

- 49 -


(1) Inching operation is performed too frequently. (1) Apply a special design. (2) Electromagnetic brake not released. (2) See Item 13. (3) Operating time long (3) Adopt the same remedies as

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

12. The motor overheats

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

13 Pressing a pushbutton rattles the contactor.

(1) Extreme voltage drop (1) Refer to Item 10.

(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.

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

(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.

(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.

16. The electromagnetic brake does not work effectively.

(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.

(1) Brake coil wire breakage, or mis-connection Replace, or repair. (2) Diode defective, or mis-connection

18. Rotation with the traversing brake applied. (3) Too small or large gap

(1) Brake coil wire breakage, or mis-connection Replace, or repair. (2) Diode defective, or mis-connection

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

(3) Too small or large gap

20. The gears make too loud noise.

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

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

(1) Install the hoist in the reverse direction.

21. Traversing wheels spin.

(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.

- 50 -


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.

: For Inverter Type U and Type UR : For Inverter Type U

- 51 -

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, refer to 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.

- 52 -

Developed Connection Diagram of Electric Hoist (1/2t, 1t): Lifting/Lowering Inverter Hoist Suspension type Floor installation type (Excluding the 1/2t class) Chain-driven traversing type Manual traversing type

Power supply

ULS (2-step)

ULS (1-step)

Hoisting motor

Resistor

Pushbutton switch

P1: UP P2: DOWN

Hoisting brake coil

Shield Hoisting inverter

RRS board

Twist

Electric traversing type

Power supply

ULS (2-step)

ULS (1-step)

Hoisting motor

Resistor

Pushbutton switch

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

Hoisting brake coil


RRS board

Twist

Traversing brake coil

Traversing motor

- 53 -

Developed Connection Diagram of Electric Hoist (2t, 2.8(3)t): Lifting/Lowering Inverter Hoist Suspension type Floor installation type Chain-driven traversing type Manual traversing type (Excluding 2.8(3)t class)

Power supply

ULS (2-step)

ULS (1-step) Hoisting motor

Resistor

Pushbutton switch

P1: UP P2: DOWN

Hoisting brake coil

Shield

Hoisting inverter RRS board

Twist


Power supply

ULS (2-step)


Resistor

Pushbutton switch


Hoisting brake coil


RRS board

Twist


Traversing motor

- 54 -

Developed Connection Diagram of Electric Hoist (5t): Lifting/Lowering Inverter Hoist Suspension type Floor installation type

Power supply

ULS (2-step)


Resistor

Pushbutton switch

P1: UP P2: DOWN

Hoisting brake coil

Shield

Hoisting inverter RRS board

Twist


Power supply

ULS (2-step)


Resistor

Pushbutton switch


Hoisting brake coil


RRS board

Twist


Traversing motor

- 55 -

Developed Connection Diagram of Electric Hoist Hoisting/Traversing Inverter Hoist

(1/2t, 1t) Power supply

ULS (2-step)

ULS (1-step)

Hoisting motor

Resistor

Pushbutton switch


Hoisting brake coil

Shield

Traversing inverter

RRS board

Twist


Traversing motor

Resistor

Operation

Twist

Power supply

ULS (2-step)


Pushbutton switch


Hoisting brake coil


RRS board

Resistor Twist


Traversing motor

(2t, 2.8(3)t)

Operation

Traversing inverter

Resistor Twist

- 56 -

Developed Connection Diagram of Electric Hoist Hoisting/Traversing Inverter Hoist

(5t) Power supply

ULS (2-step)


Resistor

Pushbutton switch


Hoisting brake coil

Shield

Traversing inverter

RRS board

Twist


Traversing motor

Resistor

Operation

Twist

Developed Connection Diagram of Electric Hoist Wiring for Simultaneous Lifting Operation with Two Hoists Using Light-Load High-Speed Function

(Hoisting inverter hoist)

Power supply

ULS (2-step)

ULS (1-step)

Pushbutton switch

P1: UP P2: DOWN

Hoisting inverter To OUT3 of other hoist

To IN4 of other hoist

- 57 -

Developed Connection Diagram of Electric Hoist Wiring for Use of 4-Point Independent Pushbutton Switch

(Hoisting inverter hoist)

Power supply

ULS (2-step)

ULS (1-step)

Hoisting motor

Resistor

Pushbutton switch

Hoisting brake coil


RRS board

Twist

Low UP

Low DOWN

High UP

High DOWN

(Hoisting/Traversing Inverter Hoist)

Power supply

ULS (2-step)

ULS (1-step)

Pushbutton switch

Low UP Hoisting inverter

Traversing inverter

Low E

Low DOWN

High UP

High DOWN

Low W

High E

High W

- 58 -

System Block Diagram of Electric Hoist (1/2t, 1t)

Power supply

Drive board

Main circuit

Rush current preventive resistor

Smoothing capacitor

Power supply

Power supply board

Discharge resistor

Power failure detection circuit

Regenerative discharger drive

circuit

Inverter (IPM) drive circuit

Overvoltage/ voltage-drop

detection circuit

AC input circuit

Power reset

External output: 4 points

Function selector DIP switches

Rotation sensor

Brake drive circuit

IPM drive signal, Fout

Brake drive signal

Operation function setting pushbuttons

CPU board 7-segment LED indicator

Blue

Upper limit switch

Black White Red

Converter

Te

rmin

al

boa

rd

Inverter (IPM)

Brake

Power supply line

Signal line

Pushbutton

Te

rmin

al

boa

rd

Te

rmin

al

boa

rd Terminal

board

-58-

- 59 -

System Block Diagram of Electric Hoist (2t, 2.8(3)t, 5t))

Power supply

Drive board

Main circuit

Rush current preventive resistor

Smoothing capacitor

Power supply

Power supply board

Discharge resistor

Power failure

detection circuit

Regenerative discharger drive

circuit

Inverter (IPM) drive circuit

Overvoltage/ voltage-drop

detection circuit

AC input circuit

Power reset

External output: 4 points

Function selector DIP switches

Rotation sensor

Brake drive circuit

IPM drive signal, Fout

Brake drive signal

Operation function setting pushbuttons

CPU board 7-segment LED indicator

Blue

Upper limit switch

Black White Red

Converter Inverter (IPM)

Brake

Power supply line

Signal line

Pushbutton

Electromagnetic contactor drive

circuit

Relay board

Te

rmin

al

boa

rd

-59-

- 60 -

Structural Drawing of Hoist Main Body (1/2t)

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

S01 Cover G01 Oil filler plug G09 Cover G17 Drain oil plug G25 Drum frame H01 Drum M01 L bracket M09 Ball bearing B01 Magnetic brake case B09 Cushion rubber B17 Terminal box

S02 RSS card G02 G cover G10 No. 4 gear G18 Ball bearing G26 Key H02 Wire rope M02 Joint M10 Washer B02 Brake disk B10 Spring B18 Rubber bush

S03 Moving vane G03 Ball bearing G11 Joint G19 Washer G27 No. 4 gear shaft H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover

S04 Washer G04 Washer G12 Washer G20 No. 2 gear M04 Ball bearing B04 Pressure plate B12 Packing

S05 Oil seal G05 No. 1 gear G13 Ball bearing G21 Spacer M05 Rotor assembly B05 Movable core B13 Spring

S06 Packing G06 Ball bearing G14 Oil seal G22 No. 3 gear M06 Stator assembly B06 Adjusting ring B14 Stationary core

S07 Rubber bush G07 Snap ring G15 Ball bearing G23 Ball bearing M07 Ball bearing B07 Brake coil B15 Snap ring

G08 Oil seal G16 Oil level gauge G24 Gear case M08 Terminal box B08 Cover B16 Cover

P145371C

-60-

- 61 -

Structural Drawing of Hoist Main Body (1t, 2t)



S02 RSS card G02 G cover G10 No. 4 gear G18 Ball bearing G26 Key H02 Wire rope M02 Joint M10 Washer B02 Brake disk B10 Spring B18 Rubber bush

S03 Moving vane G03 Ball bearing G11 Joint G19 Washer G27 No. 4 gear shaft H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover B19 Brake gear

S04 Washer G04 Washer G12 Washer G20 No. 2 gear M04 Ball bearing B04 Pressure plate B12 Packing B20 Cover

S05 Oil seal G05 No. 1 gear G13 Ball bearing G21 Spacer M05 Rotor assembly B05 Movable core B13 Spring B21 Cover



G08 Oil seal G16 Oil level gauge G24 Gear case M08 Terminal box B08 Braking plate B16 Snap ring

P148166 P148167

-61-

- 62 -

Structural Drawing of Hoist Main Body (2.8(3)t)



S02 RSS card G02 G cover G10 No. 4 gear G18 Ball bearing G26 Key H02 Wire rope M02 Joint B02 Brake disk B10 Spring B18 Rubber bush

S03 Moving vane G03 Ball bearing G11 Joint G19 Washer G27 No. 4 gear shaft H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover B19 Brake gear

S04 Washer G04 Bush G12 Washer G20 No. 2 gear M04 Ball bearing B04 Pressure plate B12 Packing B20 Cover

S05 Oil seal G05 No. 1 gear G13 Ball bearing G21 Spacer M05 Rotor assembly B05 Movable core B13 Spring B21 Cover



G08 Oil seal G16 Oil level gauge G24 Gear case M08 Terminal box B08 Braking plate B16 Snap ring

P148168

-62-

- 63 -

Structural Drawing of Hoist Main Body (5t)


S01 Cover G01 Oil filler plug G09 Gear case G17 Ball bearing G25 Ball bearing H01 Drum M01 L bracket M09 Ball bearing B01 Magnetic brake case B09 Cushion rubber B17 Terminal box

S02 RSS card G02 Oil level gauge G10 Joint G18 No. 2 gear G26 No. 5 gear H02 Wire rope M02 Joint M10 Washer B02 Brake disk B10 Spring B18 Rubber bush

S03 Moving vane G03 Drain oil plug G11 Ball bearing G19 Spacer G27 Ball bearing H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover B19 Brake gear

S04 Washer G04 G cover G12 Oil seal G20 No. 3 gear G28 Ball bearing M04 Ball bearing B04 Pressure plate B12 Packing B20 Cover

S05 Oil seal G05 Ball bearing G13 No. 6 gear G21 Snap ring G29 Key M05 Rotor assembly B05 Movable core B13 Spring B21 Cover

S06 Packing G06 Bush G14 Spacer G22 No. 4 gear G30 No. 6 gear shaft M06 Stator assembly B06 Adjusting ring B14 Stationary core

S07 Rubber bush G07 No. 1 gear G15 Oil seal G23 Spacer G31 Drum frame M07 Ball bearing B07 Brake coil B15 Snap ring

G08 Ball bearing G16 G bracket G24 Ball bearing M08 Terminal box B08 Braking plate B16 Snap ring

P148169

-63-

- 64 -

Structural Drawing of Electric Traversing Unit (Mon orail Low-Lift Type (1/2t), Low-Head Low-Lift Type (1/2t))

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

B01 Rubber bush B09 Stationary core M01 Ball bearing M09 Rubber bush T01 Snap ring T09 Traversing plate (L) T17 Cover R01 Roller axle A01 Washer

B02 Terminal block B10 Brake coil assembly M02 L bracket M10 Washer T02 Ball bearing T10 Tongued washer T18 Traversing wheel (F) R02 Spacer A01 Spacer

B03 Adjusting screw B11 Movable core M03 Washer M11 Ball bearing T03 Spacer T11 No. 4 gear T19 Traversing plate (F) R03 Snap ring A01 Slotted nut

B04 Spring B12 Pin M04 Stator coil T04 No. 2 gear T12 Drip-proof cover R04 Ball bearing A01 Split pin

B05 Clamp B13 Brake disk M05 Stator core T05 Gear case T13 Wheel axle R05 Guide roller A01 Clamping bolt

B06 Diode assembly B14 F bracket M06 Rotor T06 Ball bearing T14 Traversing wheel (L) R06 Split pin

B07 Cover M07 Stator frame T07 Snap ring T15 Ball bearing

B08 Cushion rubber M08 Motor shaft T08 No. 3 gear T16 Snap ring

P145374

-64-

- 65 -

Structural Drawing of Electric Traversing Unit (Mon orail High-Lift Type (1/2t), (1t))


B01 Rubber bush B09 Stationary core M01 Ball bearing M09 Rubber bush T01 Gear case T09 No. 2 gear T17 Boss R01 Roller axle A01 Washer

B02 Terminal block B10 Brake coil assembly M02 L bracket M10 Washer T02 No. 2, 3 gear shaft T10 Bolt T18 Ball bearing R02 Spacer A01 Spacer

B03 Adjusting screw B11 Movable core M03 Washer M11 Ball bearing T03 Snap ring T11 Clip plate T19 Traversing wheel (L) R03 Ball bearing A01 Slotted nut

B04 Spring B12 Pin M04 Stator coil T04 Ball bearing T12 Disk plate T20 Snap ring R04 Snap ring A01 Split pin

B05 Clamp B13 Brake disk M05 Stator core T05 Snap ring T13 Key T21 Traversing wheel (F) R05 Guide roller A01 Clamping bolt

B06 Diode assembly B14 F bracket M06 Rotor T06 Key T14 No. 4 gear T22 Ball bearing R06 Split pin

B07 Cover M07 Stator frame T07 Snap ring T15 Ball bearing T23 Snap ring

B08 Cushion rubber M08 Motor shaft T08 No. 3 gear T16 Traversing plate (L) T24 Wheel axle

T25 Traversing plate (F)

P145375A

-65-

- 66 -

Structural Drawing of Electric Traversing Unit (Mon orail Type (2t, 2.8(3)t))


B01 Rubber bush B09 Stationary core M01 Ball bearing M09 Rubber bush T01 Gear case T09 No. 2 gear T17 Boss R01 Roller axle A01 Washer

B02 Terminal block B10 Brake coil assembly M02 L bracket M10 Washer T02 No. 2, 3 gear shaft T10 Bolt T18 Ball bearing R02 Spacer A01 Spacer

B03 Adjusting screw B11 Movable core M03 Washer M11 Ball bearing T03 Snap ring T11 Clip plate T19 Traversing wheel (L) R03 Ball bearing A01 Slotted nut

B04 Spring B12 Pin M04 Stator coil T04 Ball bearing T12 Disk plate T20 Snap ring R04 Snap ring A01 Split pin

B05 Clamp B13 Brake disk M05 Stator core T05 Snap ring T13 Key T21 Traversing wheel (F) R05 Guide roller A01 Clamping bolt

B06 Diode assembly B14 Friction disk M06 Rotor T06 Key T14 No. 4 gear T22 Ball bearing R06 Split pin

B07 Cover B15 F bracket M07 Stator frame T07 Snap ring T15 Ball bearing T23 Snap ring

B08 Cushion rubber M08 Motor shaft T08 No. 3 gear T16 Traversing plate (L) T24 Wheel axle

T25 Traversing plate (F)

P145395

-66-

- 67 -

Structural Drawing of Electric Traversing Unit (Mon orail Type (5t))


B01 Snap ring B10 Cushion rubber M01 Ball bearing M10 Base T01 Tongued washer T10 Gear case T19 Ball bearing T28 Traversing plate (F) A01 Washer

B02 Rubber bush B11 Stationary core M02 L bracket M11 Packing T02 Ball bearing T11 Wheel axle T20 Snap ring T29 Wheel axle A01 Spacer

B03 Terminal block B12 Brake coil assembly M03 Snap ring M12 Terminal box base T03 Spacer T12 High tension bolt T21 Spacer A01 Slotted nut

B04 Spacer B13 Movable core M04 Motor shaft M13 Terminal box cover T04 No. 2 gear T13 No. 4 gear T22 Snap ring A01 Split pin

B05 Adjusting screw B14 Pin M05 Stator frame M14 Terminal block T05 Traversing plate (L) T14 Spacer T23 Snap ring A01 Clamping bolt

B06 Spring B15 Brake gear M06 Rotor M15 Rubber bush T06 No. 3 gear T15 Rubber cover T24 Spacer

B07 Clamp B16 Brake disk M07 Stator core T07 Snap ring T16 Cover T25 Snap ring

B08 Diode assembly B17 F bracket M08 Stator coil T08 Ball bearing T17 Pin T26 Ball bearing

B09 Cover M09 Ball bearing T09 G bracket T18 Traversing wheel (L) T27 Traversing wheel (F)

P145376

-67-

- 68 -

Structural Drawing of Electric Traversing Unit (Dou ble-Rail Type (2.8(3)t, 5t))

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 Clip 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 Frame T15 Key

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

P145383A

-68-

- 69 -

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

PG37600

Item Description

1 Sheave

2 Ball bearing

3 Snap ring

4 Spacer

5 Shaft

6 Sheave casing

7 Wire rope

8 Nut

9 Dustproof cover

10 Thrust ball bearing

11 Cover

12 P.P screw

13 Spring washer

14 Nameplate

15 P.P screw

16 Spring washer

17 Split pin

18 Latch

19 Twist spring

20 Spring pin

21 Hook

Capacity 1/2t

Rope diameter φ6.3

Weight (kg) 4.5

-69-

- 70 -

Structural Drawing of Hook Block (for Wire Rope of 2-Fall Threading Type) (1t, 2t, 2.8(3)t)

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


18 Latch

19 Twist spring

20 Spring pin

21 Hook

Capacity 1t 2t 2.8(3)t

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

-70-

- 71 -

Structural Drawing of Hook Block (for Wire Rope of 4-Fall Threading Type) (1/2t)

PG37601

Item Description

1 Sheave

2 Dustproof cover


4 Snap ring

5 Ball bearing

6 Spacer

7 Wire rope

8 Split pin

9 Slotted nut

10 Split pin

11 Slotted nut

12 Trunnion

13 Cover

14 Latch

15 Twist spring

16 Spring pin

17 Hook

18 Spacer

Capacity 1/2t

Rope diameter φ4

Weight (kg) 5.5

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

PG37603

Item Description

1 Sheave

2 Dustproof cover


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

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Structural Drawing of Hook Block (for Wire Rope of 4-Fall Threading Type) (2t, 2.8(3)t)

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 2.8(3)t

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

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Structural Drawing of Hook Block (5t)

M42 screw

Punch mark

PG20785

Item Description Item Description

1 Sheave 11 Spacer

2 Split pin 12 Ball bearing

3 Slotted nut 13 -

4 Dustproof cover 14 Cover

5 Thrust ball bearing 15 Wire rope

6 Snap ring 16 Latch

7 - 17 Spring pin

8 Split pin 18 Twist spring

9 Slotted nut 19 Hook

10 Trunnion 20 Spring washer

Capacity 5t

Rope diameter φ11.2

Weight (kg) 42

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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 support Rope 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

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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.)

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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 standard version

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