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

Transcription

1 Instruction Manual PHN-06A004A MITSUBISHI MITSUBISHI INVERTER HOIST Type UR-H (lifting type inverter hoist) Type UR-S (lifting/traversing type inverter hoist) INSTRUCTION MANUAL Standard Version 400 V CLASS 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. i

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3 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! Warning! Caution Indicates a situation of immediate danger that may result in death or serious injury if not avoided. Indicates a dangerous situation that may result in death or serious injury if not avoided. 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 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.!! 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. 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. ii

4 !! 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. Attention 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. iii

5 Contents Checking Products and Regulatory Restrictions...1 Checking When You Receive the Hoist...1 Hoist Crane Application Chart (Shaded area)...1 Regulatory Requirements...2 Installation Instructions...4 Installation of Hoist and Stoppers...4 Ground Wiring and Installing Earth Leakage Circuit Breaker...4 Electrical Wiring...5 Installation on I-Beam...7 Adjusting the Pushbutton Pendant Height...9 Test Run...10 No-Load Operation...10 Load Test Run...11 Operation...12 Lifting/lowering operation...12 Traversing operation (in inverter mode)...13 Error indicator lamp...13 Operation using programmable controller...14 Setting/Changing Speeds...15 Speed Setting before Delivery...15 Setting/Changing Low Lifting Speed...15 Setting/Changing Traversing Speed and Traversing Operation Acceleration/ Deceleration Time...17 Maintenance and Inspection of Brake...18 Electromagnetic Hoisting Brake...18 Traversing Electromagnetic Brake...21 Inspection and Maintenance of Wire Rope...22 Structure, Disassembly and Re-assembly of Reduction Gears...23 Hoisting unit...23 Traversing Unit...24 Maintenance and Inspection...25 Daily Inspection of Hoist...25 Monthly Inspection...27 Annual Inspection...30 Lubrication...31 Operation Limit of Main Parts...32 Replacement of Controller Parts...33 General Troubleshooting...34 Developed Connection Diagram of Electric Hoist...39 Structural Drawing of Hoist Main Body...43 Procedure for Straightening Entangled Wire Rope...53 iv

6 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 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. Hoist crane usually handling 63% or more and less than 80% of rated load. A A B C D E F A B C D E F F Hoist crane usually handling 80% or more of rated load. B C D E F F F Applicable types Type E Type R Type UR Type S Type U2 Type HU2 Type S special model Type U2,HU2 special model Large cranes 25,000 hrs or more 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 Allowable duty Type Type E Type R Type UR Type U2 (7.5 t - ) Type HU2 Type S Type U2 (- 5 t) Duty ratio (%) Start frequency (cycles/hour) * 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. Crane type and applicable categories Power plant cranes, cranes for disassembly and inspection Cranes in machine shops and assembly shops General workshop cranes Overhead cranes (with bucket, magnet) Ladle crane Charging crane Forge crane General purpose bridge cranes (with hooks) A A B-D D-F E-F F F B-C * Duty ratio: During 1 hour of hardest operation = Total of motor energized time (min) ! 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

7 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 are regulated by the labor safety and health code and related government ordinance and ministerial ordinance. Refer to these regulations in detail for full compliance. The key points are described as follows. 1. Application for Installation To use this hoist as a crane or a simplified lift, you should submit an installation report or installation notice to the local Labor Standards Inspection Office in accordance with the crane safety code. See the table below. Type of crane Crane Capacity Crane manufacturer Manufacturing permit Installation notice and performance inspection Crane user Installation report Maintenance obligation Suspended 3 t load 1/2 t <3 t * The Type UR Hoist cannot be used as a lift because the ratio of the drum diameter to the rope diameter (D/d) is less than 20. Regarding the crane manufacturing permit, where a hoist crane is concerned, the hoist and crane manufacturer must apply jointly. To use the hoist as a crane or a simplified lift, you should observe the crane structural standard or the simplified lift structural standard. When the hoist is used, it is governed by the crane safety code. 2. Operator Qualification To be associated with slinging 0.5t or heavier articles or with operating a hoist of 0.5t capacity or greater, one must be qualified in accordance with ordinance by the Ministry of Labor. See the table below. Operation method Suspended load <0.5 t 0.5 t <5 t 5 t Monorail hoist (Ls) (Sk) (Sp) (Ls) (Sk) (Sp) Floor-operated (Ls) (Sk) (Sp) (Ls) (Sk) (Sp) (Ls) (Sk) General personnel Remote control or equipped (Ls) (Sk) (Sp) (Ls) with operator cab Applicable clauses of Clauses 21 and 22 crane safety code - 2 -

8 Slinging Suspended load <0.5 t 0.5 t <1 t 1 t Slinging (Ls) (Sk) (Sl) (Jb) (Sp) General personnel (Sl) (Jb) (Sp) Applicable clauses of crane safety code Clauses 221 and 222 (Sl) (Jb) (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 - 3 -

9 Installation Instructions Installation of Hoist and Stoppers Consult your dealer or the nearest Mitsubishi Electric Service Center about the rail and hoist installation. Be sure to have a specialist firm carry out the installation. If traversing distance is too long, and connection of another I-beam is needed, carefully weld the two I-beams so that they are properly aligned with each other. After welding, smoothly finish the welded joint section, and the wheel and flange running section. If joint plates are needed, attach them to both the upper and lower surfaces of the I-beam joint section. Install a stopper on both ends of I-beam to prevent overrun of wheels. Do not frequently contact the hoist to the stoppers to stop the hoist. Be sure to attach cushioning material, such as rubber to each stopper. Be sure to use stoppers larger than half of the diameter of the wheels. Use identical size stoppers to the double-rail type also. (Wheel running surface) I-beam Joint section Cushioning material Stopper Smooth finishing No-coating required Cushioning material Rail Double-rail stopper! 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

10 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 Hoist capacity Motor capacity (t) (at 60 Hz) Nominal sectional area of conductor (mm 2 ) (165) (86) (152) (Note) (1) The table shown above is applicable to 200V class hoists in the case when a voltage drop between the transformer and hoist is kept at 10%. (2) The values shown above are determined on consumption that only the hoisting motor is provided. When a hoist crane is used, the capacity of the crane traveling motor must be added. (3) If the hoisting motor is not a standard type (the starting current and power factory may differ), see the table. (4) If the transformer capacity is lower than 3 EIs, a voltage drop in the transformer must be taken into consideration. (5) When an allowable cable size enclosed in parentheses is adopted, the cable outlet hole must be additionally machined, and the solderless terminal or the terminal block must be modified

11 3. Others (1) Reactor installation If it is necessary to improve the power factor, or if it is necessary to install the hoist near a high-voltage power supply unit (1,000 kva or more, cable length = 10 m or less), be sure to install a reactor. Without a reactor, the inverter may be damaged. To install a reactor, please contact us. (2) Measures against noise There are several types of noises. The noise sent from the external unit may cause abnormal operation of the inverter. The noise generated by the inverter may be sent back to the power supply line. The radiated noise may cause abnormal operation of the peripheral units. Suppression of noise sent from external units Install a surge killer on each peripheral unit that may generate large noise. Suppression of noise generated by inverter We recommend use of noise filter SF mm dia hole Characteristics of Noise Filter Model Applicable Outside dimensions (Unit: mm) hoist W H D W1 H1 C Approximate weight (kg) Loss (W) Leakage current (Ref. value) (ma) 400 V SF1197 UR <Measures against leakage current> If the electric current leaks from the hoist, the peripheral units may perform abnormal operation, and you may get an electric shock. To prevent electric current leakage, take the following measures: 1) Before connecting the power supply line, be sure to ground the noise filter. At the completion of grounding, check that the noise filter is surely grounded to the earth via the grounding part of the control panel. 2) When selecting a leakage current breaker or leakage current cut-off relay, be sure to consider the leakage current of the noise filter. The leakage current of the noise filter is very large. If the leakage current breaker or the leakage current cut-off relay is not used, be sure to ground the noise filter as described in 1)

12 4. Do not use any phase advancer capacitors. Do not connect any phase advancer capacitors to the secondary side of the inverter. This is because a phase advancer capacitor on the secondary side may cause explosion. In addition, the higher harmonics of the inverter may affect the phase advancer capacitor on the primary side. 5. Consideration of leakage current The motor of this hoist is driven by the inverter, and the output voltage of the inverter contains higher harmonics. For this reason, ground leakage current may be generated depending on the grounding capacitance of the electric line between the inverter and the motor and also depending on the floating capacity between the motor winding and the iron core. Power supply Earth leakage circuit breaker Inverter Hoist Motor Leakage current to the earth Leakage current flows through the own inverter system. In some cases, however, leakage current may flow into the other system via the grounding line. To prevent unnecessary operation caused by the leakage current, set the rated sensitivity current of the leakage current breaker to 100 ma or more. In this case, the leakage current breaker also functions as a fire preventive device. Installation on I-Beam The I-beam can be used in two or three ways. Before shipment, the I-beam width has been set as shown in the following table. Change the spacer position as shown in Fig. 1-1 through Fig. 1-3 depending on the I-beam to be used. Washer (1.6 mm thick) Traversing side plate Spacer (6 mm thick) Slotted nut Clamping bolt Frame Split pin Fig. 1-1 Applicable I-beam: Minimum width Fig. 1-2 Applicable I-beam: Intermediate width Fig. 1-3 Applicable I-beam: Maximum width I-beam width 1 t 2 t 2.8 t 75 mm Fig mm *Fig. 1-2 Fig mm Fig. 1-3 *Fig. 1-2 Fig mm Fig. 1-3 * Fig. 1-3 Remarks: 1. For the 2.8t type, the width of the I-beam can be adjusted in two ways. For them, two spacers (6mm width) are required on one side. 2. The asterisked figures indicate the states before shipment

13 The clearance between the inner side of the wheel flange and the I-beam is approximately 4.6 mm. Check the clearance before installation (see the following figure). To adjust this clearance, change the washer (1.6 mm) positions to the inside or the outside of the traversing side plate. Fit the same number of spacers and washers on both sides of the flame. Consider the balance when fitting the spacers and washers. The hoist could be installed most easily from one end of the I-beam. However, in most cases, the I-beam ends are not open. So pull out the split pin (see Fig.1) and loosen the nut to open the traversing side plates to the respective sides. The side plates are tightened with slotted nuts. When aligning the pin hole with the slot of the slotted nut, be sure to tighten the nut (do not loosen the nut). In addition, when a new hoist is installed on the existing I-beam, the I-beam may be worn out. For these reasons, be sure to adjust the clearance using the actual hoist installed on the I-beam. Wheel I beam 4.6 mm ( mm) With flange - 8 -

14 Adjusting the Pushbutton Pendant Height The pushbutton is hung with a wire rope. The upper end of the wire rope is clipped. Change the clipped position of wire rope, and then adjust the pushbutton height to the optimum position for the work. After adjustment, fix the excess cable with a bundling band to prevent sagging. Carefully adjust the pushbutton height so that the cable can be kept away from the heated area of the discharging resistor, etc. Carefully adjust the pushbutton height so that the cable can be kept away from the heated area of the discharging resistor, etc. Clip Cable Clip Pushbutton pendant Adjust Adjusting the pushbutton pendant height - 9 -

15 Test Run No-Load Operation (1) Press the DN pushbutton switch to the first step. The hook block will be lowered at a low speed, and there will be margin for lifting operation. (2) Press the DN pushbutton switch to the second step, and check whether the hook lowers at the high-speed operation mode. Connection rod Arm If the hook is lifted, exchange the connected terminals of the R-phase and T-phase wires with each other. The power cable has 3 wires: R-phase, T-phase, and grounding wires. To operate 2 or more hoists on the same trolley line, be sure to exchange the wires on the terminal boards of the current collection area and the motive power connection area in the control box. In this case, do not exchange the wires of the pushbutton switches. (3) If the hook is lifted by pressing the DN Lever pushbutton switch due to reverse winding of the wire rope, the hook will move to the second stage limit switch. After this operation, the hoist will not be operated by any pushbutton switches. In this case, follow the procedure below to restore operation: 1) Remove the connection rod linking the lever and the limit switch. 2) Turn the clockwise the shaft beside the control box to restore the limit switch. Keep the arm on the shaft. The shaft of the low-head type, however, West (Left) Control box East (Right) Traversing (In the case of a double rail type, the control box is located in the east, and the opposite side is in the west.) is in a different direction. For this reason, turn the shaft of the low-head type clockwise to restore the limit switch. 3) Press the DOWN button to lower the hook gradually by inching. Before lowering the hook, be sure to exchange the connected terminals of the R-phase and T-phase wires with each other. (4) Re-assemble in the order reverse to the disassembling order. EAST and WEST shown on the pushbuttons respectively indicate the traveling directions when the hoist is viewed from the control box (see the figure shown on the right side). Last of all, run the hoist over the whole length with no load, and make sure that there are no abnormalities

16 ! 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. Load Test Run (A) Rated load test run Hang a rated load, and lift and lower the load to check the effect of the brake. Run the hoist over the whole length to make sure that the I-beam and trolley wire for nonconformities. Then, conduct characteristic test and performance test. (B) Overload test run Hang a load of 125% of the rated load, and lift and lower the load several times. The hoist has been certified by carrying out overload test runs with a load of 125% before shipment. However, the user is recommended to carry out the overload test runs from the viewpoint of safety because the installation of I-beam and other devices can be checked by this test. The test is designed to check the mechanical strength of each part. The performance test shall be carried out with the rated load. * For this test, lift the load at a high speed. If the load is lifted at a low speed, the torque may be reduced. During high-speed lifting operation, however, the hoist may be stopped due to the overloaded inverter (tripping). This is not an error. So if the hoist is stopped, release the pushbutton switch, and then press the switch again. (C) Adjusting the traversing brake (If commercial power is used for traversing operation) If the brake is too effective when traversing is stopped, load collapse may occur. On the contrary, if the brake is not effective, the hoist may coast and cause an accident. Open the steel plate cover of the traversing motor, and turn the bolt in the cover for adjusting the traversing brake to an optimum force at which load collapse will not occur. The brake adjustment range is 0% to 100% of the motor torque. Before delivery from our factory, the brake is adjusted to 50%

17 Operation Lifting/lowering operation The UP (lifting) and DN (lowering) pushbutton switches are the 2-step type. Press each switch to the first step to perform lifting/lowering operation at a low speed. Press each switch to the second step to perform lifting/lowering operation at a high speed. Speed change between high speed and low speed (lifting/lowering operation) Pushbutton Pressing 1st step 2nd step Lifting Low speed (operation in inverter mode) High speed (operation in inverter mode) Lowering Low speed (operation in inverter mode) High speed (operation in commercial power supply mode) * If you press the DN pushbutton switch to the first step, the lowering operation will be performed at a low speed in the inverter mode. If you press the DN pushbutton switch to the second step, the lowering operation will be performed at a high speed in the commercial power supply mode. There are slide switches at the lifting operation inverter. During low-speed operation, change the set positions of these slide switches to change the speed. For a detailed description, refer to Setting/Changing Low Lifting Speed. Caution in operation (1) If the first upper limit switch is activated during lifting operation, the DN switch will not be valid for 0.5 seconds after releasing the UP switch. (2) If the power failure detector detects instantaneous power failure, the operation will be stopped and will not be restarted for 0.5 seconds. If the operation pushbutton switch (UP or DN switch) currently held down is not released during instantaneous power failure, the operation will be restarted 0.5 seconds later. (3) If a problem, such as overload, voltage drop, or hoisting motor temperature rise, occurs, the operation may be stopped. In addition, the load may be lowered or dropped. In this case, take the following measures: Immediately stop the operation. If the problem is caused by voltage drop, raise the power supply voltage. If the problem is caused by hoisting motor temperature rise, wait until the motor is cooled enough. (4) If operation is performed with a disconnected phase: The operation conditions will be as shown in the following table. In this case, immediately connect the phase. Disconnected phase R S T Connected phase S-T R-T R-S Low-speed operation Continues normal operation, or stops operation. (The error indicator will indicate that the voltage is too low.) Lifting High-speed operation Low-speed operation Lowering Stops operation. (The error indicator lamp (LED lamp) will not light.) Stops operation. (The error indicator will indicate that the voltage is too low.) Continues normal operation, or stops operation. (The error indicator will indicate that the voltage is too low.) High-speed operation Stops operation, or continues operation in the single-phase commercial power supply mode (the hoist may generate abnormal noise)

18 Traversing operation (in inverter mode) The EA (eastward) and WE (westward) pushbutton switches are the 2-step type. Press each switch to the first step to perform eastward/westward traversing operation at a low speed. Press each switch to the second step to perform eastward/westward traversing operation at a high speed. Speed change between high speed and low speed (traversing operation) Pushbutton Pressing 1st step 2nd step Traversing EA/WE Low speed (operation in inverter) High speed (operation in inverter) There are DIP switches at the traversing operation inverter. Use these switches to change the speed or acceleration/deceleration time. For a detailed description, refer to Setting/Changing Traversing Speed and Traversing Operation Acceleration/Deceleration Time. Error indicator lamp (1) There is an error indicator lamp (LED lamp) on the lifting operation inverter board and the traversing operation inverter board. Each error indicator lamp will flash as shown in the following table to inform the inverter conditions. Error indication by LED indicator lamp Inverter condition Normal Voltage too low Pushbutton error Overvoltage Overcurrent Lamp condition Repeats the following cycle: Flashes once. Kept at the OFF status for 1 second. Repeats the following cycle: Flashes twice. Kept at the OFF status for 1 second. Repeats the following cycle: Flashes 3 times. Kept at the OFF status for 1 second. Repeats the following cycle: Flashes 4 times. Kept at the OFF status for 1 second. Flashes every 0.1 seconds. (2) If the problem is solved, releasing the pushbutton switch (UP or DN switch for lifting/lowering operation/ea or WE pushbutton switch for traversing operation) will cancel the error status. Press the pushbutton switch again to restart operation. (3) Just after power-on, the error indicator lamp may flash to inform that the voltage is too low. In this case, however, the voltage will be normal soon. So ignore the error indicator lamp, and press a pushbutton switch. The operation will be started, and the error indicator lamp will inform the normal condition

19 Operation using programmable controller If the output circuit of the programmable controller is the SSR type, the leakage current of the snubber circuit may cause the hoist to perform unstable operation, or may turn on the hoist. Measures: Connect resistor R to the external circuit to bypass the leakage current. R = Approx. 30 kω, 3 W Sequencer output circuit Hoist input circuit Snubber circuit Bypassing leakage current from the snubber circuit

20 Setting/Changing Speeds Speed Setting before Delivery Before delivery, the speeds for various operations are factory-set as follows: Speed setting before delivery Capacity 1t 2t 2.8t m/s m/s m/s 0.12 m/s Lifting/lowering speed 50 Hz Lifting Lowering (Low speed) (Low speed) (0.8 m/min) (High speed) (8 m/min) (Low speed) (0.72 m/min) (High speed) (7.2 m/min) m/s m/s m/s 0.1 m/s (0.8 m/min) (High speed) (6.7 m/min) (Low speed) (0.72 m/min) (High speed) (6 m/min) 60 Hz (Low speed) m/s m/s m/s 0.12 m/s (0.8 m/min) (High speed) (8 m/min) (Low speed) (0.72 m/min) (High speed) (7.2 m/min) Mono rail (Low speed) m/s m/s (High speed) (2.5 m/min) (25 m/min) Traversing speed (in inverter mode) Double rail (Low m/s speed) (2.5 m/min) (High m/s speed) (25 m/min) Traversing operation acceleration/deceleration time (sec) 2 Use the following method to change the low lifting speed, traversing speed, and traversing operation acceleration/deceleration time. Setting/Changing Low Lifting Speed Change the set positions of the following slide switches to change the speed. Slide switch

21 The following figure and the table show the relations between the slide switch set positions and the set speeds. Before changing the set positions of the switches, be sure to turn off the power. Left Right Slide switches Before delivery from our factory, both the right and left slide switches are set to the bottom positions as shown in the left figure. Capacity 1t 2t, 2.8t Slide switch positions and set low lifting speeds Left Right Left Right Left Right Lower Lower Lower Upper Upper Lower m/s (0.8 m/min) m/s (0.72 m/min) m/s (0.133 m/min) 0.02 m/s (1.2 m/min) m/s (2.0 m/min) 0.03 m/s (1.8 m/min) If both the right and left switches are set to the top positions, the lifting speed will be set to the lowest speed; the same speed when both switches are set to the bottom positions

22 Setting/Changing Traversing Speed and Traversing Operation Acceleration/Deceleration Time Change the set positions of the slide switches shown in the following figure to change the speed and the acceleration/deceleration time. Traversing operation inverter Slide switches The following figure shows the relations between the slide switch set positions and the set speeds or the set acceleration/deceleration time values. Before changing the set positions of the switches, be sure to turn off the power. Slide switch High speed Low speed Acceleration/ deceleration time (sec) Top Top Bottom Top Bottom Top Bottom Before delivery from our factory, the slide switches are set to the bold character positions as shown in the left figure. Top Bottom Bottom

23 Maintenance and Inspection of Brake Electromagnetic Hoisting Brake The hoisting brake is located on the end face of the hoisting motor. The brake stops and holds a load. For the 1t type, the involute spline is adopted to engage the brake disk to the end of the motor shaft in the brake box. For the 2t to 2.8t types, the brake gear is engaged to the motor shaft. The 1t to 2.8t types are provided with an automatic adjusting device that keeps the gap constant between the iron cores even if the brake disk is worn out. The gap therefore does not need to be adjusted. If the brake does not work effectively and the load travels a considerably long distance after applying the brake, judge that the brake disk is worn out to the limit. In this case, replace the brake disk with a new one. [Procedure for disassembling and re-assembling the brake and replacing the brake disks for the 1t to 2.8t types] (1) Remove the lid screwed on the end face of the stationary core, and remove the helical compression spring. Evenly loosen the bolts. Remove the spring, taking care not to damage the packing. CAUTION!: When loosening the bolts of the lid, you may notice that the lid is sticking to the casing due to the sticky packing. In this case, apply a shock to the lid before completely removing the bolts. In this way, you can prevent the lid from springing out. (2) Using the bolts removed from the lid, temporarily tighten the movable iron core and the pressure plate. CAUTION!: If the movable iron core and the pressure plate are not temporarily tightened, the adjusting ring may fall off, or two retaining springs (small springs that ensure easy falling down of the adjusting ring) may be missing. (3) Remove the stationary core, taking care not to damage the packing. The brake coil is in the stationary core. CAUTION!: This packing prevents entering of water into the brake casing, and also prevents electromagnetic leakage from the electromagnet. If the packing is broken, replace the packing with a new one. If the brake is reassembled without a packing, the suction gap will be narrowed by 0.8 mm (= packing thickness t ). In this case, the brake may be locked up, and the motor may be seized. If the electromagnetic leakage occurs, the responsibility of the brake may be deteriorated. (4) Remove the temporarily tightened movable iron core, adjusting ring, and pressure plate to remove the brake disk and the braking plate. CAUTION!: When replacing the brake disk, clean the inside of the break box. Be sure to remove abrasion particles from the back of the braking plate, contact face of the brake box, and the guides (lugs) of the brake disk and braking plate

24 Braking plate Pressing plate Electromagnetic brake casing Brake disk Motor shaft Spline connection Brake disk Retaining spring Movable core Adjusting ring Stationary core Brake coil Helical compression spring (Assembly bolt) Structure of 1t type Motor shaft Brake gear Lid Packing 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

25 (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. 0.5 mm or more Lining 0.5 mm or more 1t type : 7.8 mm or more Core 2t type : 6.3mm or more Cross section of lining 2.8t type : 5.0mm or more 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. The brake disk working life has reached the limit when the lining on one side is 0.5 mm thick. When the lining has worn to such an extent, replace the brake disk with a new one. (2) Check the gap between adsorbing surface and the center of the stationary core The gap should be in the range of 0.1 mm to 0.3 mm, normally. (3) Check that the edges of the shoulders of the pressure plate and the adjusting ring are chamfered properly. Normally, the chamfer should be C0.2 or less (refer to the following figure). (4) If the brake gear has been disassembled, apply grease to the inner circumference (for 2t to 2.8t types). (5) Do not forget to fit the packing between the electromagnetic brake casing and the stationary core and between the stationary core and the lid. If the packing has been damaged, replace it with a new one. (6) Check the wear limit gauge. If the wear limit gauge (at the groove or the shoulder) of the pressure plate or the braking plate is invisible (the plate is worn out to the wear limit), replacing the brake disk with a new one cannot reduce the gap and cannot prevent the adjusting ring from falling off. In this case, replace the braking plate with a new one. (The 1t type does not have any braking plates. For this type, replace the brake box with a new one.)

26 Wear limit Wear limit Pressure plate Chamfer the edge Adjusting ring Wear limit gauge Wear limit Inspection window Edges of the shoulders of the pressure plate and the adjusting ring Wear limit gauge that can be seen through inspection window 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

27 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

28 Structure, Disassembly and Re-assembly of Reduction Gears Hoisting unit The simplified 2-step speed reducer with helical gears is adopted for the hoisting unit. To disassemble this unit, sequentially remove the parts from the outside. Important points for disassembly and reassembly are described below: (1) Remove the helical gear while turning the gear along the helix angle. Be careful not to flaw the gear when you remove it. (2) After disassembly, replace the oil seal with a new one. Carefully reassemble the oil seal so that the lip cannot be flawed. Completely clean the sliding area, and then apply a thin coat of grease. (3) At the completion of reassembly, check that the C-ring, etc. are attached properly. If a part is distorted or chipped, replace it with a new one. (4) To reassemble the unit, follow the above disassembly procedure in the reversed order. Apply grease to the gears first, and then tighten the G-cover. Before tightening the G-cover, completely degrease the mating faces of the G-cover and the frame, and apply the liquid packing (Three Bond No. 1208D or No. 1104) to both mating faces. Lubrication (when reassembling the disassembled unit): Remove the oil plug (the word GREASE is written on the plug), and then supply grease while referring to the grease quantity shown in the following table. Note that supply of too much grease may cause leakage of grease. For this reason, be sure to observe the quantity shown in the following table. We recommend use of EPNOC Grease AP-0 (manufactured by Nippon Oil Co.Ltd.). Grease quantity (kg) Capacity (t) Grease quantity (kg) Frame G-cover Frame Oil plug G-cover Oil seal

29 Traversing Unit The simplified 2-step speed reducer is adopted for the traversing unit. The gears are sealed in the gearbox, and the grease lubrication system is adopted. For the double-rail type, the simplified 2-step speed reducer is also adopted. In addition, the inner gearbox grease lubrication system is also adopted for this type. The gearbox can be split into two parts: upper and lower parts. This type is the axial speed reducer, and ensures easy disassembly and reassembly. The following table shows the appropriate grease quantity for each type. During reassembly, apply liquid packing (Pos seal manufactured by CEMEDINE Co., Ltd. or Three Bond No. 1208D) to the mating faces between the traversing side plate and the G-case. Capacity (t) 1 2t, 2.8t Quantity (g) We recommend use of Albania EP-2 grease (manufactured by Showa Shell Sekiyu Co.Ltd.)

30 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. 3 Check that the limit switches function correctly. 4 Check for strange noise, odor and vibration Check whether the brake is effective. (For Type UR, check whether the immediate stoppage is possible during high-speed lifting operation.) 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. 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. Check that the wire rope has been properly wounded on the drum. 9 Check the slinging tools for defects. 10 Check the whole body for abnormal overheat and color change. Check also the stoppers. 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. If the acceleration/deceleration time for lifting operation is approximately 0.3 seconds, the hoist can perform operation properly. Prevention of drop of load Improper winding will result in reduction in service life and wire breakage. : For Inverter Type U2 and Type UR : For Inverter Type UR

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

32 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 Items to be surely checked every month and to be regarded as important items from the viewpoint of safety. Month No. Check item Description Acceptability Problem and remedy Date of completion of repair Check that there are no obstacles within the traversing range. Check the stoppers on both the ends of rail for deformation and missing, and check the mounting bolts for looseness. 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. State of the operation buttons Check that the interlocks are complete. Check the operation of the overwinding limit switch lever. Wire rope Hook block Check the strands for breakage. Check that the load will not hit against other articles. If the metallic casing leaks, an electrical shock can occur. Look over the inside. Check that the buttons return to position smoothly. If the pin has been dropped, the switch lever will not function. Check that the lever functions correctly. Check that the lever has been properly adjusted. 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. Check the frame fixing parts, pins, and sheaves. Check the terminal fitting inlet for corrosion. Check that the thrust ball bearing rotates smoothly. Check that the foot nut is provided with loosening preventive means. Check the sheave for damage. Check the sheave case and key plate (nameplate) for damage and looseness. Check the slinging wire latch. Kink, deformation, and corrosion should not be allowed. Stoppers, split pins, wear Insufficient lubrication, breakage, and corrosion on the root of the rope Check that the nut stopper is not damaged. Check the split pin and setscrew for missing. Check for flaws and wear of the groove. Check the clamping screws for looseness and damage. Check for backlash and spring effect

33 Month No. Check item Description Acceptability Problem and remedy Date of completion of repair Check the hook for cracking, wear and deformation. Check the slinging tools for abnormalities. Check the traversing side plates and nuts for looseness. Check the split pins for missing. Check that the I-beam or the hoist main body has been grounded. Rotation sensor 13 Inverter Control box Check the installation condition of the printed board. Also check the appearance of the rotation sensor. Check the installation condition of the inverter. Also check the appearance of the inverter. Check the inside of the control box for dust. Check the control box for corrosion and discoloration caused by moisture or gas. Check the crimp-style terminal screws for looseness. Check the appearance of the external cable for abnormality. 16 Display 17 No-load test run Check that the segment display is lit up. Check for visually detectable abnormalities. Check for deformation, slack and breakage. Visually check the side plates for deformation and opening. Check the grounding point. Visually check the screws for looseness. Remove the cover, and then visually check the RRS board for dust and corrosion, and the rotational shaft for distortion. Check the inverter tightening screws for looseness. Check the printed boards particularly carefully. Terminal board, terminal board of printed circuit board Check the sheath for damage and distortion. Check the operation conditions in accordance with check items No. 2 through No. 6 described in the daily inspection table. : For Inverter Type U2 and Type UR : For Inverter Type U2-28 -

34 Classes B and C 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. Month No. Check item Description Acceptability Problem and remedy Date of completion of repair 1 Check the pushbuttons for damage. Check the inside and contacts. 2 Electromagnetic brake electromagnet 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 4 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. Check the pushbutton pendant cable and power cable for external flaws. Check the messenger and hanging wire for damage. Check the hanger for disconnection. Open the cover to check the diodes. Check the leading-out ports. Check the wire for sagging Check that the wire rope has been lubricated. Check the electromagnetic contactor, contacts, insulated parts and mechanical parts for damage and wear. Check the screws for looseness. Check the overwinding limit switch and contacts for wear. Check the clamping screws for looseness. Check the trolley wire for looseness and rust. Check the wires. Check the current collector for contact failure and wear. Check the traversing wheels and guide rollers for wear. Check the traversing brake for attraction, release and coasting condition. 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. 13 Check the hoisting brake resistor for damage. Check visually. 14 Check the bolts for looseness. If the wire rope is dry, apply wire rope oil. Check visually. Check that all the screws are tightened firmly. Check that the switch and the contacts are tightened properly. Check that the switch and the contacts operate properly. Check the rotation. Check the wire connections for looseness. Check the spring force. Wear must be less than 5% of the diameter and less than 50% of the flange thickness. 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.) 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

35 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 2 Smoothing capacitor Same as above. 3 Brake disk thickness 4 DC electromagnet Every year Every 6 months if the frequency of uses is high. Every year Every 6 months if the frequency of uses is high. Every 3 months if the no-load high-speed function is used Annually Every 6 months if the brake is used frequently Every year Every 6 months if the frequency of uses is high. Disassemble the contactor, and then check the contact for wear. If the inner mechanism is damaged or worn out, replace the contactor. Check the capacitor for liquid leakage and bulge. Also check that the safety valve is not activated. 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. 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) 7.5 t~ 5.0 mm (New disk 8.3 mm thick) Traversing brake disk thickness 1/2-5 t 5.5 mm (New disk 8 mm thick) 7.5 t~ 7.0 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). 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 t 5.5 mm (New disk 8 mm thick) 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 6 Overhaul 7 Hoisting motor shaft and spline serration part Every year Every 2 years Every year when the frequency of uses is high or when the hoist is on an important line Every year Every 6 months if the frequency of uses is high. Open the bracket on the end face, and check the gears, shafts and bearings for abnormalities (wear and backlash). Change the oil. Lower the hoist from the I-beam, disassemble it, and check the parts and the traversing rail. 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 U2 and Type UR : For Inverter Type U2 : 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.

36 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

37 Operation Limit of Main Parts Part Limit Part Limit Hoist gear Traversing gear Gear shaft Other shafts Clearance between shaft and bearing Rolling bearing Oil seal When the depth of wear on the surface reaches 10% of the tooth thickness (Fig. 3) When the depth of wear on the surface reaches 20% of the tooth thickness When the wear reaches 1% of the original diameter When the wear reaches 2% of each original diameter 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 Damage, harmful flaws, or abnormal noise Harmful flaws on the lip or the shaft surface with which the lip gets into contact Brake mechanism Abnormal operation Traversing wheel tread Traversing wheel flange Sheaves Key spline serration Wear of 5% of the original size Difference between left and right wheel diameters of 1% (Fig. 5) 50% of the original thickness (Fig. 4) Wear on the groove bottom 30% of the wire rope diameter Deformation, significant backlash, and abnormal wear Wire rope Strand breakage Wear Deformation and corrosion Rope end Contactor contact Hoisting brake disk Traversing brake disk Electromagnetic brake cores Current collector wheel Cable Insulation of all circuits Ground Hook 10% of the number of strands in one twisted wire 7% of the nominal diameter Significant deformation and corrosion Breakage Reference replacement schedule: * Approx. 40,000 cycles When the contact thickness reaches 0.5 mm When the lining thickness is reduced to 0.5 mm or less on one side When the thickness of the traversing brake disk is reduced to 5.5 mm, or when the lining thickness is reduced to 0.5 mm or less on one side When there is no clearance between the center legs of the movable and stationary cores which have been fitted to each other. (New core: Approx. 0.3 mm) When the center diameter reaches 35 mm (New wheel 45 mm in diameter) When the cable has deteriorated due to external flaws, especially when the ground wire is breaking 200 V class; 0.2 MΩ 400 V class; 0.4 MΩ The traversing rail and metallic pushbutton pendant must have been grounded properly. Ground resistance; 100 Ω or less Apparent gap, large flaws and wear (Fig. 2) Initial dimension b 1 t 32 2 t t 50 Punch mark Amount of gear Pitch circle Tooth thickness Fig. 2 Fig. 3 Wear Wear (Double rail type) (Monorail type) Fig. 4 Fig

38 Replacement of Controller Parts Part Smoothing capacitor of main circuit Smoothing capacitor mounted on board Contactor Relay Standard replacement schedule Every 5 years Every 5 years When the contact thickness is reduced to 0.5 mm After 5 years of operation or more Replacement method, etc. The direct current section of the main circuit is equipped with a large-capacity aluminum electrolytic capacitor to ensure smoothness. In addition, the control circuit is also equipped with an aluminum electrolytic capacitor to ensure stabilization of control. Ripple current, however, may deteriorate the characteristics of these electrolytic capacitors. Note that deterioration of the characteristics greatly depends on the ambient temperature and the operation conditions. After operation for a certain period, the capacitor will be rapidly deteriorated. For this reason, be sure to annually check the capacitor or more frequently (if the end of the service life is close at hand, it is preferable to check the capacitor every 6 months or more frequently). Check the appearance of the capacitor in accordance with the following criteria: 1) Case condition: Expansion of side surface or bottom surface of the case 2) Sealing plate condition: Noticeable distortion or extreme cracking 3) Others: Cracking on sheath, discoloration, liquid leakage, etc. From the viewpoint of quantity, if the capacity of the capacitor is reduced to 85% of the rated capacity, judge that the service life comes to the end. In these days, simple and easy-to-use units designed for measurement of capacitor capacity are sold at market. Use such convenient measuring units. Replace the capacitor with a new capacitor, or replace the board with a new board. If the contact thickness is too thin, the contactor may cause imperfect contact. For this reason, it is necessary to replace the contactor depending on the total number of opening/closing times (switching operation limit). Replace the contactor with a new contactor. Replace the relay with a new relay. Other Item Operation limit Insulation of all circuits 200V class: Approx. 0.2 MΩ or less 400V class: Approx. 0.4 MΩ or less Grounding Grounding resistance: 100 Ω or less

39 General Troubleshooting If the hoist has been used under unfavorable working condition, handled roughly or become old, like general machines, it shows various troubles and nonconformities. All troubles and nonconformities cannot be described here. General troubles are listed below for your reference. Most of troubles not listed below are caused special factors. Regarding such troubles, consult the nearest distributor or Mitsubishi Electric Hoist Corporation. General troubleshooting Problem Cause Remedy 1. Touching the hoist or pushbutton pendant causes an electric shock. 2. Operation in reverse direction to that indicated on pushbutton. 3. Wire rope wears badly. 4. Wire rope is wound ununiformly. (1) I-beam or pushbutton pendant metallic casing grounding failure (1) Ground completely. 100 Ω or less at 200 V (2) Adhesion of paint to the I-beam surface (2) Use the hoist suitable for the Leakage current increases due to high-frequency ambient conditions component of inverter output voltage. The (waterproof type, etc.). rated sensitivity current of the earth-leakage Remove paint completely. circuit breaker shall be 100 ma or more to prevent unnecessary operations. The circuit breaker is designed nor for prevention of electrical shocks, but for prevention of a fire caused by electrical leakage. For this reason, remedies (1), (2), and (5) described on the right side should be observed. (3) Hoist or pushbutton pendant insulation failure (3) Check, and repair. (4) Current leaking from other equipment or wiring (4) Check, and repair. reaches the hoist through the I-beam. (5) The floor conductivity is high. (5) Install the hoist on a floor The floor is wet with a highly conductive liquid, with low conductivity, such as such as water. a dry concrete floor. The hoist is on a highly conductive surface, such as an iron plate, steel structure and surface plate. (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) Wire rope wound reversely. (2) Wind the rope correctly. (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 (1) Correct the using method. (Less than 10 for pulling laterally or less than 3 for pulling vertically) (2) Wire rope distorted (2) Replace

40 Problem Cause Remedy 5. The 2nd-stage limit switch operates. (1) Incorrect connection of power supply line (2) Wire rope wound reversely (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. (1) Exchange the phases R and T of the power supply. (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 7. The hoist does not start even if the pushbutton is pressed. 8. The hoist lowers and stops during hoisting 9. The hoist stops suddenly during hoisting. 10. Power is applied to the traversing motor, but the motor growls and takes a longer time (2 sec. or more) to start. 11. The hoist suddenly stops during lifting or lowering operation. (1) Handle and maintain the rope properly. Replace the defective wire rope. (Use the Mitsubishi genuine wire rope.) (1) Pushbutton defective, or pushbutton cable (1) Repair, replace, or cut out. broken (2) Incorrect wiring of power switch, fuse, contactor, or pushbutton, imperfect contact of trolley line, (2) Check, and repair. See the expanded connection diagram. loose screws, etc. (3) The inverter does not give 3-phase output. (3) Check the inverter. (4) No signal is returned from the sensor, or one of (4) Check and replace the RRS the rotation signals (signals for 2 phases) is not board. Check the signal line returned from the RRS board. (microphone cord) for disconnection. (5) The hoisting motor torque is insufficient for (5) Reduce the load. overload, and the hoist stops. (6) The hoisting motor overheats due to too frequent (6) Use the hoist at appropriate use, the torque drops, and the hoist stops. intervals. (1) Overload (1) Reduce the load. (2) Hoisting motor overheat (2) Use the hoist at appropriate intervals. (3) Hoisting motor wire breakage (3) Check, and repair. (1) Inverter trip due to overvoltage caused by hoisting an overload. (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. (1) Reduce the load. (2) Use the hoist at appropriate intervals. (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. (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. (6) Malfunction due to noise. (6) Fit a noise filter to the 3-phase power supply

41 Problem Cause Remedy 12. The motor overheats 13 Pressing a pushbutton rattles the contactor. 14. The relay functions, but the electromagnetic brake is not released. The electromagnet will not attract. 15. The electromagnetic brake coil has been burnt out. 16. The electromagnetic brake does not work effectively. 17. The traversing brake is too effective or ineffective. 18. Rotation with the traversing brake applied. 19. The traversing motor does not have enough rotation power, or will not function. 20. The gears make too loud noise. 21. Traversing wheels spin. 22. The trolley wheels are easily disconnected. (1) Inching operation is performed too frequently. (1) Apply a special design. (2) Electromagnetic brake not released. (2) See Item 14. (3) Operating time long (3) Adopt the same remedies as Item 10, or do not use the motor too frequently. (4) Overload. (4) Reduce the load. (1) Extreme voltage drop (1) See Item 10. (1) Too large voltage drop, or too low supply (1) See Items 10 and 11. voltage (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 (5) Check, and repair. loosened. (6) Brake circuit diode (DC) defective (6) Replace the diode assembly. (7) Coil burnt out. (7) See Item 15. (8) Too large center clearance (8) Correct. (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 (3) Check the internal wiring. cut off the power. (4) Adhesion of oil to the brake disk (4) Degrease the brake disk, or replace the brake disk. (5) The immediate cut-off contactor does not (5) Replace the contactor. operate properly. (Direct current) (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 (3) Too small or large gap (1) Brake coil wire breakage, or mis-connection Replace, or repair. (2) Diode defective, or mis-connection (3) Too small or large gap (1) Gears and bearings worn out (1) Replace. (1) The traversing wheel on the driving side is lifted due to the inclined I-beam. (2) Paint, oil, or dust is on the transfer surface of the I-beam. (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 (1) Install the hoist in the reverse direction. (2) Clean, or, if necessary, grind. Improve

42 Problem Cause Remedy 23. The overload alarm does not function properly. 24. The pushbutton will not go down smoothly or will not smoothly pop up. 25. Pressing the DOWN pushbutton lowers the load, but pressing the UP pushbutton also lowers the load. (1) The power supply line is not correctly connected to the board. (1) Foreign material caught by inner unit (2) Defective inner unit (1) Rotor slippage (The rotor is not properly engaged with the motor shaft.) (1) Correctly connect the power supply line. Connect 1 and S to A and B on the board. (1) Check or repair. (2) Replace. (1) Replace. * In this case, releasing the pushbutton will immediately stop the lowering operation. : For Inverter Type U2 and Type UR : For Inverter Type U2 : For Type S

43 Inspection of Power Supply System (Measurement of lowest voltage at start up) Inspection procedure 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). 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. Judgment and remedy Acceptable if all the three phases are read 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. Acceptable if all the three phases are 180 V or more. Can be used if all the three phases are 170 V (60 Hz) or 160 V (50 Hz) or more. Cannot be used if the voltage is below the above value. (For a detailed description of the corrective method, see Item 10 described in the previous table.) If three phases are not balanced, the cause of unbalance is cause (1) of Item 10 described in the previous table. In this case, repair the problem part. (Note) The voltage readings in step 4 above represent the lowest values when the electromagnet attracts the elements or the motor starts up. Judge the situation based on these voltage readings. When you contact us, please let us know the power supply voltage (see above inspection step 2) and the lowest voltage (see above inspection step 4). (Instructions for measurement of inverter power supply current) 1. During lowering operation, regenerative energy returns from the hoisting motor to the inverter. This may cause power current not to flow. 2. When lifting/lowering very light load or no load at all, little electric power is consumed. Since power is in this case supplied through two high-voltage power wires, no current may flow through the remaining one wire. 3. During lifting operation, the inverter input current may fluctuate. This is because this current is not sinusoidal

44 UR-Type Electric Hoist Expanded Connection Diagram (Commercial power driven type traversing operation) Power supply 電源 R S T R S TR R9 S9 MC5 MC6 MC6 MC5 P1 R9 B1 P2 P3 P4 P5 P6 B2 B3 B6 B7 B9 B10 B6 B7 MC3 MC4 S9 S9 押ボタンスイッチ Pushbutton switches T B R ULS(2 段 ) R1 R1 U S S S V T T1 T1 W M1 M2 R9 ULS(1 段 ) LS LS R9 R9 R9 S9 S9 S9 BMC B9 B10 B1 B2 UP B3 DN HU HD Hoisting 巻上インバータ部 inverter MC3 MC4 MC3 MC4 U3 V3 W3 M1 M2 下 INV S9 S9 BMC S9 IM X 下 R1 BMC V1 V2 S ブレーキコイル Brake coil T1 INV BR1 V1 V2 U V W BR2 INVERTER BOARD 横行モータ Traversing motor 横行ブレーキコイル Traversing brake coil U V2 W IM 巻上モータ Hoisting motor

45 UR-Type Electric Hoist Expanded Connection Diagram (Inverter-type traversing operation) Operation 操作 Power supply 電源 R S T R9 S9 PS PN PH R S TR R9 S9 R9 P1 B1 P2 B2 B3 P3 EA P4 P5 WE TH PS P6 PN PH Pushbutton switches オシボタンスイッチ T B R S T R9 S9 EA WE TH PS PN PH (2nd stage) ULS(2 段 ) (1st stage) ULS(1 段 ) R1 S R9 T1 LS R9 S9 B1 B2 B3 S9 EA WE TH R1 U S V T1 W LS R9 S9 M1 M2 UP DN BMC HU HD Hoisting inverter 巻上インバータ部 R S T BR1 BR2 U S GS V GN W GH P B Traversing 横行インバータ部 inverter R1 下 V1 BMC V2 S ブレーキコイル Brake coil T1 U V INV BR1 V1 V2 W BR2 M1 M2 Down 下 INV S9 S9 BMC S9 Traversing brake 横行ブレーキ INVERTER BOARD U3 V3 IM W3 横行モートル Traversing motor ヒューズ ツイスト Twist 抵抗 Resistance Fuse U V2 W IM 巻上モータ Hoisting motor

46 UR-Type Electric Hoist Expanded Connection Diagram (Suspended type, manually-pushed traversing type, chain-driven traversing type) Power supply 電源 R S T R S TR R9 S9 R9 P1 B1 P2 B2 B3 押ボタンスイッチ Pushbutton switches T B R S T (2nd stage) ULS(2 段 ) R1 S T1 R1 S T1 U V W M1 (1st stage) M2 ULS(1 段 ) R9 LS LS R9 R9 R9 S9 S9 S9 BMC B1 UP B2 DN B3 HU HD Hoisting inverter 巻上インバータ部 M1 下 Down M2 INV BMC S9 S9 S9 R1 S T1 U INV V W 下 BMC V1 V2 Brake coil ブレーキコイル V1 BR1 V2 BR2 INVERTER BOARD U V2 IM W 巻上モータ Hoisting motor

47 UR-Type Connection Diagram of 4-Point Independent Lifting/Lowering/Traversing Pushbutton Switches R1 U S V T1 W R9 MC5 MC6 MC6 MC5 R9 S9 EA WE TH B9 B10 R9 S9 B1 B2 B3 B4 LS R9 S9 UP DN HU HD M1 M2 BMC P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 B1 B2 B3 B4 B5 B6 B9 B10 オシボタンスイッチ Pushbutton switches B7 B8 S9 EA WE SH NH 巻上インバータ部 Hoisting inverter R S T S GS GN SH NH 横行インバータ部 Traversing inverter BR1 BR2 U V W P B

48 Structural Drawing of Hoist Main Body (1t) -43- Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description G01 Air breather G09 Cover G17 Snap ring G25 Key H01 Drum M01 L bracket M09 Ball bearing B01 Magnetic brake case B09 Cushion rubber B17 Terminal box G02 G cover G10 No. 4 gear G18 Ball bearing G26 No. 4 gear shaft H02 Wire rope M02 Joint M10 Washer B02 Brake disk B10 Spring B18 Rubber bush G03 Ball bearing G11 Joint G19 Washer H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover G04 Washer G12 Washer G20 No. 2 gear M04 Ball bearing B04 Pressure plate B12 Packing G05 No. 1 gear G13 Ball bearing G21 Spacer M05 Rotor assembly B05 Movable core B13 Spring G06 Ball bearing G14 Oil seal G22 No. 3 gear M06 Stator assembly B06 Adjusting ring B14 Stationary core G07 Snap ring G15 Ball bearing G23 Ball bearing M07 Ball bearing B07 Brake coil B15 Snap ring G08 Oil seal G16 Snap ring G24 Drum frame M08 Terminal box B08 Cover B16 Cover P145537B

49 Structural Drawing of Hoist Main Body (2t, 2.8t) -44- Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description G01 Air breather G09 Cover G17 Snap ring G25 Key H01 Drum M01 L bracket M09 Ball bearing B01 Magnetic brake case B09 Cushion rubber B17 Terminal box G02 G cover G10 No. 4 gear G18 Ball bearing G26 No. 4 gear shaft H02 Wire rope M02 Joint M10 Washer B02 Brake disk B10 Spring B18 Rubber bush G03 Ball bearing G11 Joint G19 Washer H03 Intermediate shaft M03 Snap ring B03 Packing B11 Cover B19 Brake gear G04 Washer G12 Washer G20 No. 2 gear M04 Ball bearing B04 Pressure plate B12 Packing B20 Cover G05 No. 1 gear G13 Ball bearing G21 Spacer M05 Rotor assembly B05 Movable core B13 Spring B21 Cover G06 Ball bearing G14 Oil seal G22 No. 3 gear M06 Stator assembly B06 Adjusting ring B14 Stationary core G07 Snap ring G15 Ball bearing G23 Ball bearing M07 Ball bearing B07 Brake coil B15 Snap ring G08 Oil seal G16 Snap ring G24 Drum frame M08 Terminal box B08 Braking plate B16 Snap ring P

50 Structural Drawing of Electric Traversing Unit (Monorail Type (1t)) -45- Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description B01 Rubber bush B10 Brake coil assembly M01 Ball bearing M10 Washer T01 Gear case T10 Bolt T19 Traversing wheel (L) A01 Washer B02 Terminal block B11 Movable core M02 L bracket M11 Ball bearing T02 No. 2, 3 gear shaft T11 Clip plate T20 Snap ring A01 Spacer B03 Adjusting screw B12 Pin M03 Washer T03 Snap ring T12 Disk plate T21 Traversing wheel (F) A01 Slotted nut B04 Spring B13 Brake disk M04 Stator coil T04 Ball bearing T13 Key T22 Ball bearing A01 Split pin B05 Clamp B14 F bracket M05 Stator core T05 Snap ring T14 No. 4 gear T23 Snap ring A01 Clamping bolt B06 Diode assembly M06 Rotor T06 Key T15 Ball bearing T24 Wheel axle B07 Cover M07 Stator frame T07 Snap ring T16 Traversing plate (L) T25 Traversing plate (F) B08 Cushion rubber M08 Motor shaft T08 No. 3 gear T17 Boss B09 Stationary core M09 Rubber bush T09 No. 2 gear T18 Ball bearing P

51 Structural Drawing of Electric Traversing Unit (Monorail Type (2t, 2.8t)) -46- Item Description Item Description Item Description Item Description Item Description Item Description Item Description Item Description B01 Rubber bush B10 Brake coil assembly M01 Ball bearing M10 Washer T01 Gear case T10 Bolt T19 Traversing wheel (L) A01 Washer B02 Terminal block B11 Movable core M02 L bracket M11 Ball bearing T02 No. 2, 3 gear shaft T11 Clip plate T20 Snap ring A01 Spacer B03 Adjusting screw B12 Pin M03 Washer T03 Snap ring T12 Disk plate T21 Traversing wheel (F) A01 Slotted nut B04 Spring B13 Brake disk M04 Stator coil T04 Ball bearing T13 Key T22 Ball bearing A01 Split pin B05 Clamp B14 Friction disk M05 Stator core T05 Snap ring T14 No. 4 gear T23 Snap ring A01 Clamping bolt B06 Diode assembly B15 F bracket M06 Rotor T06 Key T15 Ball bearing T24 Wheel axle B07 Cover M07 Stator frame T07 Snap ring T16 Traversing plate (L) T25 Traversing plate (F) B08 Cushion rubber M08 Motor shaft T08 No. 3 gear T17 Boss B09 Stationary core M09 Rubber bush T09 No. 2 gear T18 Ball bearing P

52 Structural Drawing of Electric Traversing Unit (Double-Rail Type (2.8t)) -47- Item Description Item Description Item Description Item Description Item Description Item Description Item Description B01 Rubber bush B09 Stationary core M01 Rubber bush M00 Washer T01 Ball bearing T09 Ball bearing T17 Lower gear case B02 Terminal block B10 Brake coil assembly M02 Ball bearing M10 Ball bearing T02 Spacer T10 Traversing wheel T18 Ball bearing B03 Adjusting screw B11 Movable core M03 Washer M11 L bracket T03 Upper gear case T11 Key plate T19 Dustproof cover B04 Spring B12 Pin M04 Stator frame T04 Frame T12 Key T20 Driving shaft B05 Clamp B13 Brake disk M05 Stator coil T05 No. 3 gear T13 Washer B06 Diode assembly B14 Friction disk M06 Stator core T06 Ball bearing T14 Ball bearing B07 Cover B15 F bracket M07 Rotor T07 Cover T15 Key B08 Cushion rubber M08 Motor shaft T08 No. 4 gear T16 No. 2 gear P145383A

53 Structural Drawing of Chain-Driven Traversing Unit (1t, 2t, 2.8t) -48- Item Description Item Description Item Description Item Description Item Description 1 Chain 6 Clamping bolt 11 Snap ring 16 Wheel axle 21 Traversing wheel (F) 2 Washer 7 Chain pulley 12 Shaft support 17 Snap ring 22 Traversing plate (F) 3 Spacer 8 Snap ring 13 Metal 18 Ball bearing 4 Slotted nut 9 Key 14 Chain-driven gear 19 Snap ring 5 Split pin 10 Chain guide 15 Traversing plate (L) 20 Traversing wheel (L) Note 1: If the part number is double-circled, we cannot supply the part as a single part. Note 2: If the part number is circled with a bold line, the part will be supplied as a set, normally. For a detailed description, please contact Mitsubishi Electric Hoist Corporation or our service shop. P

54 Structural Drawing of Manual Traversing Unit (1t, 2t) -49- Item Description Item Description Item Description 1 Traversing wheel 6 Traversing plate 11 Clamping bolt 2 Snap ring 7 Washer 3 Ball bearing 8 Spacer 4 Snap ring 9 Slotted nut 5 Wheel axle 10 Split pin Note 1: If the part number is double-circled, we cannot supply the part as a single part. Note 2: If the part number is circled with a bold line, the part will be supplied as a set, normally. For a detailed description, please contact Mitsubishi Electric Hoist Corporation or our service shop. P

55 Structural Drawing of Hook Block (for Wire Rope of 2-Fall Threading Type) (1t, 2t, 2.8t) -50- Item Description 1 Sheave 2 Ball bearing 3 Snap ring 4 Ball bearing 5 Whirl-stop 6 Bolt 7 Spring washer 8 Shaft 9 Cover 10 Bolt 11 Spring washer 12 Wire rope 13 Hanging ring 14 Split pin 15 Slotted nut 16 Dustproof cover 17 Thrust ball bearing 18 Latch 19 Twist spring 20 Spring pin 21 Hook Capacity 1t 2t 2.8t A B C D E F G H K L M Rope diameter φ8 φ10 φ12.5 Weight (kg) PG37602 PG37604 PG

56 Structural Drawing of Hook Block (for Wire Rope of 4-Fall Threading Type) (1t) -51- Item Description 1 Sheave 2 Dustproof cover 3 Thrust ball bearing 4 Snap ring 5 Trunnion 6 Spacer 7 Ball bearing 8 Cover 9 Wire rope 10 Split pin 11 Slotted nut 12 Split pin 13 Slotted nut 14 Spacer 15 Nameplate 16 Latch 17 Spring pin 18 Twist spring 19 Hook Capacity 1t Rope diameter φ6.3 Weight (kg) 8 PG

57 Structural Drawing of Hook Block (for Wire Rope of 4-Fall Threading Type) (2t, 2.8t) -52- Item Description 1 Sheave 2 Ball bearing 3 Snap ring 4 Spacer 5 Split pin 6 Slotted nut 7 Spacer 8 Trunnion 9 Cover 10 Wire rope 11 Cover 12 Split pin 13 Slotted nut 14 Dustproof cover 15 Ball bearing 16 Bolt 17 Spring washer 18 Latch 19 Twist spring 20 Spring pin 21 Hook Capacity 2t 2.8t A B C D E F G H K L M N P Rope diameter φ8 φ9 Weight (kg) PG37605 PG

58 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 2-fall type 3. Then, before removing the rope supports, mark the rope supports or rope with a chalk so that the current rope Marking positions can be found later