MM-16-2 OH Crane Manu (E) PDF [PDF]

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HANDLING MANUAL 取 扱 説 明 書 S，NO．522 2.6ｔ OVERHEAD CRANE AND ELECTRIC CHAIN HOIST WITH GEARED TROLLEY



株式会社 二葉製作所 FUTABA MFG. CO., LTD. 3－10－9 MOROFUKU TEL 072－872－0347



DAITO



OSAKA JAPAN



No. Date.



2009.8,18



IMO 9478482



ＭＭ-１６-２



COTENTS Inspection prior to operation How to use the crane



‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐１



‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐１



Cautions ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐１～３ Braking section , motor section structure sectional view (Geard motor for travelling)



‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐４



How to adjust the clearance and how to replace the brake lining



‐‐‐‐‐‐‐‐‐‐‐５



Countermeasure in case the electro-magnetic brake section(brake lining)is not released ‐６ Item to be checked and Records ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐７・８



Inspection prior to operation. 1. Check if there is any abnormal condition on the crane body. 2. Check if there is any abnormal condition on the cables, messenger wires or cable hangers. Check also if the gland for cables is firmly fastened. 3. Check if the power supply is correctly connected and if there is any wrong wiring. For inspecting the wrong wiring, push the push button(↑), (↓), (F)and(A) by inching motion for confirm if the crane is operated just as per the push button sketch indication.



How to use the crane. 1.Push button operation. Push the button(↑), then the load is lifted upward. Push the button(↓)then it goes down. Push(F)and(A)then the crane moves forth and back. 2. Traversing operation. Pull the hand chain for traversing operation which is hanged from the geared trolley, then the trolley is traversing. The hand chain for the rail clamp is also hanged from the end of the geared trolley, so do not mix up the chain. 3. How to lift up. When the load is lifted up by means of a hoist, do not use the inching motion until the chain hanging then load is completely stretched, and when completely stretched, then stop the lift up motion once, then continue the lift up motion by inching motion by taking care of the chain condition and the balance of the load. Lift up the load in one step until the load reaches some level of height immediately when the load is lifted up from the ground. 4. Be careful of the instant reverse operation. Be careful not to push the push button(↑)and(↓)or (F)and(A) in reverse direction by mistake as it leads to abnormal tension to any part of the instrument. 5. Avoid any unnecessary inching motion. The electric current in 5~6 times as much as the rated current is required at start for the inching motion, therefore it is to be noted that any unnecessary inching operation makes the life of the instrument short.



Cautions 1. Please do not operate the unit in load of over the rated capactity for the crane. The operation of the unit in less than the rated capacity will ensure safety and long liftetime. 2. Proper hooking Lifting up work by inserting the load at the top edge of the hook or load lifting by hooking wire in wider angle or any other improper handling shall not be made. 3. Keep out of beneath the hoist. Nobody shall stand beneath the hoist to avoid any accident such as being pressed under the load. ― １ ―



4. Do not pull the load diagonally.



※ There is any danger of being jammed or being hit by the load. ※ Any unreasonable load will be charged on the crane. 5. Do not let the trolley get in contact with the stopper. Do not let the trolley get in contact with I beam steel stopper on the chain block with traversing trolley. In case the trolley is getting in contact with the stopper so often, then any overload is changed on the trolley and it resuts in shortening the normal life time. 6. How to make the proper hooking. (1) It is imperative to know the load to be lifted up exactly. (2) It is important to guess the centroid of load in case the load to be lifted up is of any complicate shape. (3) Please select the hanger most safety and most suitable for the weight and shape of the load. (4) Please do not take over 60 degrees in hanging angle when using any rope or chain as the hooking means. The tension of the wire rope or chain becomes larger when the lifting angle becomes bigger. Comparison of Tension in Angle Per 1 hooking wire.



(5) Do not lift up the load by any single rope or chain because of (1) difficulty in confirming the centroid and (2) possibility of movement of any abnormal force in case the load is put aside.



― 2 ―



(6) Please select any wire rope, chain or the like suitable for the load to be lifted up. It is dangerous to select any wire rope which is too thick to lift up any light material. The proper selection of wire reopes is important. . 7. During the lifting up, lowering or travelling or traversing the load special care shall be made so as not to cause any collision or contact of the load with any other things. 8. Please do not leave the crane while keeping the load. 9. Please switch off power by all means after the termination of operation. 10. Inspect the crane periodically and check if there is any abnormal condition on each part of the instrument and if there is any loose on bolts and nuts. 11. Oil the chain for lifting periodically to avoid any rust. 12. Keep off any grease or oil absolutely on the travelling way for the travelling or traversing wheels as it is apt to cause any slippage. 13. Handling of geared motor brake refer to P4～P6 14. Recommended lubricants Hoist



Speed reducer for travelling and traversing (Rollar chain)



grease ‐‐‐‐Extreme pressure grease use for high load contain molybdenum disulfide gear oil ‐‐‐‐ISO VG220～320 grease ‐‐‐‐Extreme pressure grease use for high load contain molybdenum disulfide



― 3 ―



Geard motor for travelling



[Braking section, motor section structure sectional view]



No. 1－ 1 1－ 2 1－ 3 1－ 4 1－ 5 1－ 6 1－ 8 1－ 9 1－ 10 1－ 11 1－ 12 1－ 13



Parts name Hexagon socket head bolts Bracket Cross recessed head machine screw Shim Stop ring Ball bearing Bearing cover Hexagon socket head bolts Spacer Brake lining Lining base Armature



No. 1－ 14 1－ 17



Parts name Stop ring Brake spring



1－ 19



Rotor



1－ 21 1－ 22 1－ 23 1－ 24 1－ 25 1－ 26 1－ 27 1－ 30



Ball bearing Shaft Spring washer Hexagon socket head bolts Bracket Frame Stator Bush



― 4 ―



[How to adjust the clearance and how to replace the brake lining] In case the brake lining is not effective and slippy or when pushing the button no sound of "phon" to evidence the release of brake is heard, it resulted from the fact that the clearance rated at 0.5mm must have extended to 2.0mm or over. Adjust the clearance in such a way as indicated hereunder, only provided that you had never made the clearance adjustment in the past. Should any previous adjustment have ever been made, then replace all the parts from (1－9) to (1－13) in set. The clearance adjustment makes the lifetime of the unit duplicate. (Don't push the button when the voltage is extremely dropped as it will sometimes not release the brake.)



(Clearance adjustment) Refer to the structure sectional view. Make adjustment and replacement in the sequence as indicated. Part No. (1－1) to (1－13) shows the disassembly order generally. Note) The brake lining (1 － 11) is attached to the lining base (1 －12) therefore these are to be replacement together, (1) Take off the hexagon socket head bolts (1－1) and bracket (1－2). By this, all the components upto Part (1－22) can be detached in set. Be careful so that any components should not be lost. (2) After the completion of the job as per (1), measure the clearance G by using a clearance gauge. The limit clearance is 2mm but if it is over 2mm, then take the following procedures. (3) Take off the cross recessed head machine screws (1－3) fastening the bearing cover (1－8) and detach the bracket (1－2) and the revolving section. Be careful so as not to miss the skim. (4) Take off the stop ring (1－5), then ball bearing (1－6) and the collar (1－7). Now all the components from (1－9) to ( 1－13) can be detached from the motor shaft in set. (5) Take off the bolt with hexagonal recessed head (1－9), armature (1－13) and the lining base. Be careful so as not to miss the spacer for gap adjustment attached to the bolt. Note) In case any adjustment for clearance had ever been made in the past, the space for the clearance adjustment is between the lining base and the armature. It is noted that the bolt with hex. recessed head has been coated with any specific adhesives for protection against loosening therefore it is sometimes hard for loosening. The adhesives are available for disassemblies upto 3 times. (6) In case any previous clearance adjustment has never been made, then the clearance adjustment shall be in accordance with (7). If already made, then, replace the brake lining. (7) Clearance adjustment Lay 4- spaces for the clearance adjustment between the lining base and the armature and fasten the bolt with hex. recessed head firmly. Confirm that the clearance G is more than 0.5mm. In case of 0.4mm or less, the bracket ( 1－2) is apt to get in touch with the brake lining (1－11). (8) Assembly The assembly work is to be executed just with the reverse sequence to the disassembly. Note) In case the bearing cover cannot be firmly fastened for assembly, then screw any longer bolt and stud in the screw section of the bearing cover in advance and set the position of bearing cover hole and that of the bracket hole, and then fasten the cross recessed head machine screw equally. ― 5 ―



[Countermeasure in case the electro-magnetic brake section (brake lining)is not released] Situation: When pushing the push button switch, the motor is rotating but the release of brake is not made (no sound of release of brake) Cause: When using the unit in open air or in any places where it is wet or there are a great deal of temperature difference or when using the unit with a long interval from the previous use, it sometimes happens that rain water soaks into between the brake lining (1－11) and the bracket (1－2) or it leads to the occurrence of moisture. In such a case, the braking surface becomes a sort of vacuum condition and owing to the absorption effect, the brake release becomes difficult. Countermeasures: When the brake wheel section is floated by any outer force even once, then it runs smoothly from the next time. Proceed with the work in accordance with the following steps. (1) Take off the bush (1－30) set in the bracket (1－2) as per the structure sectional view.



(2) Prepare 1 hex bolt in length of M8×20mm or more or 1-bolt with hex. recessed head. Set the bolt onto the ho]e (having threads for M8) where the bush (1－30) is set and faten it completely by monkey wrenches or spanners. (Now the brake is released). After fastened once, take off the bolt immediately.



You may use the shaft φ6.5 to φ5 (round bar) instead of the bolt. Put the shaft on the hole from which the bush (1－30) is taken off as per the figure indicated hereunder and hit the top of the shaft two or three times lightly.



(3) When finishing the above mentioned job, then confirm if the brake will run normally and set the bush (1－30) to the bracket (1－2). Don’t forget to set the bush as otherwise rain water will enter.



― 6 ―



Items to be checked and Records Items to be checked



Point for inspection The travelling surface shall not be worn 1.Use limitation for B1 96% of B 2.Use limitation for t1 95% of t



Main girder and travelling rail (travelling surface)



1



Weariness of travelling surface B1



2



Change



No harmful change



3



Measurement of span



Span±5mm



4



Change



No harmful change



5



Loosening on bolts



No loosening



6



Change



No harmful change



7



Loosening on bolts



No loosening



8



Weariness of gear wheel



Gear thickness reduction shall be less than 20% of the initial thickness on pitch circle.



9



Interlocking gear condition



No abnormal weariness



10



Weariness of wheel



No abnormal weariness



11



Weariness of brake lining



No crack nor weariness



Saddle frame



Stopper



Gear wheel (Outer) Wheel



Brake 12



Weariness of brake mechanism



No operational trouble



― 7 ―



Good/ Not Good



Details of defective & countermeasures



Items to be checked Other mechanism



Motor



13



Damage Loosening on bolts



14



Damage on stator or No harmful damage nor crack rotor



15



Lead-in wire



Normal outer covering & no disconnection of wire



16



Insulating resistance



Over 1M ohm for 200V class Over 1M ohm for 400V class



17



Appearance



No crack nor damage



18



Weariness of component



No operational trouble



19



Appearance lead-in wire condition



No damage and abnormal outer covering and no wire disconnection



20



Induction



Normal induction



21



Cabtyre cable leadin wire



No scar, no deterioration, no disconnection of wire and normal edge treatment.



22



Terminal stand



No crack no abnormal damage



Contactor



Transformer



Electrical Section and Wiring



Point for inspection



23



General matters



24



Function



25



Press-fitting and fastening sections Lubrication (for gear section) Operation on no load



No harmful damage No loosening



No abnormal screw looseness Greasy condition The function shall be normal as indicated.



― 8 ―



Good/ Not Good



Details of defective & countermeasures



"SPEED" BRAND FH MODEL ELECTRIC CHAIN HOIST INSTRUCTION MANUAL



ＦＵＴＡＢＡ ＭＦＧ.ＣＯ.,ＬＴＤ．



CONTENTS [Warnings on wiring]・・・・・・・・・・・・・・・・・・・・・・・・・ 1 [Preparation and checking before operation] ・・・・・・・・・・・・・ 2 [Warnings on handling]



・・・・・・・・・・・・・・・・・・・・・・・ 3～5



[Cares after using the units]・・・・・・・・・・・・・・・・・・・・・5 [Braking section, motor section structure sectional view] (Electric chain hoist) ・・・・・・・・・・・・・・・・・・・・・・



6



[Adjustment of electro-magnet brake and replacement brake disc] (Electric chain hoist) ・・・・・・・・・・・・・・・・・・・・・・



7



[Assembly and parts replacement for the mechanical brake section] (Electric chain hoist)・・・・・・・・・・・・・・・・・・・・・・・・8 [Sectional view of inner structure or gear case] (Electric chain hoist)・・・・・・・・・・・・・・・・・・・・・・・・9 [Oil and grease for gears] ・・・・・・・・・・・・・・・・・・・・・・10 [Items to be checked and records]



・・・・・・・・・・・・・・・・・・11～13



[How to use the chain limit gauge] ・・・・・・・・・・・・・・・・・・14 [Troubles and troubleshooting]



・・・・・・・・・・・・・・・・・・・ 15～16



[Warnings on Wiring] [1] Connection of Power supply （1）There are 4 lead in wires coming from the power supply cable as per Fig. 1. Connect the lead wires in red(R), white(S) and black (T) to the power source. As the negative phase protector is fixed, there is no fear of reverse revolution. Fig.1 Should it be in case of reverse phase, the motor does not work by means of the negative phase protector. In case it does not work even if pushing the push-button, it results from wrong wiring therefore two wires (red wire and black wire) of the total 3 wires shall be interchanged. （2）In case the distance from the power connecting sport to the unit is more than 30 meters, then any voltage drop will be inevitable and the proper operation cannot be made. In such a case, adopt the duct power supply system or use 3.5 mm2. or 5.5mm2. cables.



[2] Connection of power supply As shown in Fig.1, four leads have come from the power supply cable. Please connect red(R) and white(S), and a black(T) line with a power supply. In this case, when rotation is reverse, please put in and replace red and a black line with promptly. A machine will be crushed if it is used with reverse rotation. Please connect a black line with the neutral line of a power supply. Moreover, since a green line is an earth wire, please be sure to ground it.



[3] Fuses Use the fuses for power source without fail for safety operation.



[4] Grounding Work The wire in green color is for earthling. Execute the grounding work by all means as otherwise it will cause any electrification even if insulation is perfectly made.



― 1 ―



[Preparation and checking before operation] [1] Fitting of the chain bucket Fit 3 link chains for fitting as per Fig. 2. Don't make these link chains too shorter than stipulated when fitting.



[2] Applying oil on the load chain Apply oil on the load chains at the start of operation and also during the operation to prolong the lifetime of chains. (Recommended oil: Machine oil or Gear oil ISO VG68～320)



Fig.2 [3] Chain hoist gear section At the time of delivery of the chain hoist gear section, oil gear has been filled as stipulated therefore no oil feed is necessary. As the oil port has been set with a pan head screw with cross recessed head as per Fig.3, this screw shall be taken off after the chain Hoist assembly so as to escape from any internal pressure of the gear box.



[4] Twist of the load chains



Fig.3



It sometimes happens that the load chains are twisted in such a way that the lower hook passes through the chain as per Fig. 4. Don't operate the unit in such a condition as the load cannot be lifted up owing to the fact that the load chain is getting in contact with the limit levers. Confirm that the load chain is in proper condition before the start of operation. When the load chain is in order, the welded section of the load chains faces in the same direction. Normal



Twisted



Fig.4 [5] Voltage In case of voltage drop by more than 10% of the rated voltage, the electrical components do not work properly. Make wiring properly to avoid such a voltage drop.



[6] Operation The load is lifted up when pushing the up-button ↑and is lowered when pushing the down-button↓. Don’t operate the unit in reverse revolution. The push button shall be properly pushed. ― 2 ―



[Warnings on Handling] [1] Hang the hook properly



Fig. 5 Hang the hooks properly as per Fig. 5. Any unreasonable hanging will lead to deformation of hooks.



[2] No overloading In case of operation in overload, the lifetime of the unit and motor will be shortened and will cause any accident. The lifting operation in which the load chains pass around a globe-shaped load shall be avoided.



Over load



[3] Confirm if the latch are properly fitted The bottom hooks are fitted with the latch to protect against any deviation of hangers. Confirm if the latch are properly fitted. (Ref. Fig. 5)



[4] Check any twist or direction of the load chains (1) The correct direction of the load chains is in such a condition where the chains are lifted up in the condition that the welded sections are on the outer side against the electric chain hoist body. Check it even after the replacement of the load chains. (2) Don't operate the unit in kink condition. ( ) (3) Take care when using the double type load chains as it is apt to be twisted. It is dangerous to operate the load chain in twisted condition. (4) Warning on the replacement of load chain. 1. Take off the chain end stopper recessed head. 2. Hang the connection link ( ) onto the last link. 3. Hang the new load chain onto the connection link ( ) and push the push button (↓) for replacement. Move the load chain to the direction indicated. 4. The load chain is in correct direction where the welded section is facing outward to the chain hoist body. (Ref. Fig. 6)



Fig. 6



― 3 ―



[5] The limit switch shall not be operated always. The limit switch (overwinding prevention device) is for safety therefore it shall be used only for a case where the limit switch is to be really operated.



[6] Don't make the reversing operation and don't make any sharp inching work. When operating the unit for lifting up or lowering or during running any sharp reversing operation lead to any trouble, and shall be avoided. Let the load stand still once, then make the reverse operation.



[7] Lifting in two chain hoists. It is dangerous to lift the load by two electric chain hoists. If such a work has to be made, then use the blocks fitted with safety fittings by confirming the sufficient capacity.



[8] Don't pull diagonally. Any unreasonable diagonal pulling leads to any trouble.



Oblique pulling



[9] Don't pull the push button cable. When pulling the push button cable, then the wires are cut inside the cable sheath. Especially the trolley traversing while pulling the cable shall not be made.



― 4 ―



Horizontal pulling



[10] Don't push up the chain bucket. When lifting up the load fully by hanging the load at the bottom hook directly, then the load pushes up the chain bucket and it leads to any accident.



[1l] Open door installation. If the unit is installed in open air without shelter, then it gives any damage on the electric chain hoist and trolley by water Install the shelter in case of operation in open air.



[12] Ensure safety Stop the operating work once at the stage when the chain is extended for lifting, and ensure the safety and continue further operation. Don't operate the unit just below the load lifted up. Be careful so that no contact with any other goods is made.



[Cares after using the units] [1] Power source and push buttons Confirm that the power is completely off. Also confirm that the push button is perfectly returned to the initial position.



[2] Cleaning and oiling for the load chain Clean any foreign matters attached to the load chains and apply oil by all means.



[3] Accommodation (1) Install any shelter when using the unit outdoors for protection against any rain or dew. (2) Don't keep the unit in any dusty and wet place.



[4] Checks (1) Check periodically if there is any loosening on bolts and screws. (2) Check the electrical components. (3) Execute the voluntary periodical inspection.



― 5 ―



[Braking section, motor section structure sectional view] (Electric chain hoist)



Fig. 7 No. 201A 201B 202 203 204 205 206 207 208 212 214



Parts name Stator Rotor Rotor Shaft Brake coil Motor frame Joint collar Motor bearing case Plant bolt Armature Brake plate Brake disc



No. 220 221 223 229 230 231 232 236 237 239 240



― 6 ―



Parts name Slip gear Brake spring Balance spring Brake cover Ball bearing Hexagon Socket head bolts Hexagon Socket head bolts Shaft nut Stop ring Shaft washer Spring washer



[Adjustment of electro-magnet brake and replacement of brake disc] (Electric Chain Hoist) Adjustment of electro-magnet braking section



If (1) the braking effect is improper and it is slippy in no load or light load condition, or if (2) The action of the electro-magnet brake is not sharp and the braking is not released and the motor does not rotate properly (if so it will lead to the damage of the motor) , it resulted from the expansion of the clearance between brake coil (203) and armature (208), that is, from the stipulated range of 0.2～0.3mm to 0.6mm or over.



How to make adjustment Take off the brake cover (229) first of all. Release the fixed section of shaft nut (236) by using the shaft washer(239) and adjust the clearance between the brake coil (203) and the armature (208) to have the stroke of 0.2 to 0.3mm by using the shaft nut(236). Fasten the shaft washer (239) onto the shaft nut (236).



Precaution on adjustment Don't make the adjusting work with load. Use the clearance gauge for the gap adjustment. Be careful so that any parts shall not be lost.



Replacement of brake disc The brake disc thickness is finished with 10mm. Replace the brake disc if it is less than 7mm owing to the weariness. For replacement: Take off the brake cover (229) and also shaft washer (239) and shaft nut (236), then take off the brake plate (212). Now the brake disc (214) can be easily taken off. (Parts arrangement shall be communicated as FH-214)



Warning on replacement Don't make any replacing work with load. Don't miss any components or parts taken off. Use the clearance gauge for the clearance adjustment.



― 7 ―



[Assembly and parts replacement for the mechanical brake section] (Electric chain hoist) Replacement of components of the mechanical brake section Situation： You will find sometimes that the mechanical brake is not effective and the load is slippy. In such a case, replace the latchet wheel (29) by new one as it must be surely caused by the wear of the disc section of the latchet wheel (29) even if there is no abnormity on other components. （Parts arrangement: to be communicated as FH-29, or FH-A29 in case of 1 complete set of mechanical brake section.）



Assembly and how to replace. (1) Take off gear oil in the gear case (12). Take off the body cover (13) and wiring of the control panel then take off the gear cover (11). Now you can see the gear wheel section. When you intend to replace all the complete set of the mechanical brake (Fig.10), then take off the complete set of the mechanica1 brake section which had been set in the unit, and clean the gear case (12) completely. Now set the new mechanical brake (comp1ete set) in such a way that the c1aw shall be well inter1ocked with the latchet wheel (29).



Warning on assembly. You shall not set the complete set of the mechanical brake on the conditon that the pawl(36) is not well interlocked as otherwise the setting work cannot be made well and itresults in slippy operation. (2) Proceed with the assemblying work in the sequgnce as shown on Fig.10 when parts of the latchet wheel (29) on1y are replaced.



Warning on assembly: ⅰ) Apply oi1 of both sides of the latchet wheel (29). ⅱ) Ensure that the direction of teeth of the latchet wheel (29) wou1d be just as per Fig.9. If reversely set, the gear section of the pawl (36) is not interlocked with the teeth of the latchet wheel (29) and it lead to slippy operation. ⅲ) When setting 2 pcs of the 3rd gear half co1lar (37A) onto the groove section of the 3rd gear (17), then make arrangement in such a way that the larger chamfering section of the 3rd gear half collar (37A) shall be situated on the screw side of the 3rd gear (17). After setting, set the mechanical collar (37B) comp1etely.



― 8 ―



[Sectional View of Inner Structure of Gear Case] (Electric chain hoist)



Fig.8



Fig.9



Fig.10



― 9 ―



[Oil and Grease for Gears] Oil for the gearing section (Electric chain hoist) Gear Oil has been filled in the gear case as stipulated before the delivery of the unit but it is necessary to check it at least once per 3 months and if insufficient, then, replenish oil. Exchange all oil at least once per year. The oil exchange is to be carried out in such a way as mentioned hereunder: Take off the bolts for the oil supply port on the upper surface of the gear case of the unit and also take off the bolts for oil discharge port on the lower part and discharge old oil. Fasten the bolts for the oil discharge port and discharge old oil. Fasten the bolts for the oil discharge port and replenish new oil from the oil supply port. Make sure of the oil volume by measuring it by inserting any wire and the like vertically from the oil supply port. Rated load Oil volume rated Rated oil volume Gear oil available (ｔ) （ｌ） （ｃｍ） 0.49～1



0.8



4～5



1.5～7.5



1.2



6～7



10 以上



1.2×2



6～7



ISO



viscosity



(common to all makers)



Fig.11



― 10 ―



ISO VG220～320



[Items to be checked and Records] Mechanical Section (for lifting up) Items to be checked 1



Brake 2



Weariness of brake lining Weariness of braking mechanism



Point for inspection No crack and no weariness No improper braking function Check if the original thickness is



3



Weariness of hook



reduced by more than 6%. (at the portion where hangers are hanged.)



4 5



Hook



Opening of hooks



Check if there is any harmful scar



deformation of hooks



or deformation



interior section of hook hangers



7 8 9 Joint block, suspending plate and pin



Load Sheave and Idle sheave



10 11 12



Check if there is any harmful crack or weariness



Weariness of thrust



Check if there is any harmful



bearings



Damage



Latch and safety spring condition Bolt condition



It should be normal Check if there is any harmful scar or deformation



Scar, deformation or



Check if there is any harmful



weariness



scar, deformation or weariness



Weariness of pin



Check if the size reduction shall be less than 2% of the original size



Weariness or scar of



Check if there is any abnormal



grooves



weariness or scar



Weariness of needle 13



Size (Record the initial size)



Scar and Abnormity of the



6



Compare the size with the standard



bearings (for Idle sheave)



Check if there is any damage or harmful scar



14



Oil



Check if it is still greasy



15



Weariness condition



Ref. to the separate list



Deformation or



Check if there is any remarkable



corrosion



deformation, kinking or corrosion



16



Load chain 17



Scar



Check if there is any crack or harmful damage Check if the twist shall not be more



18



Twist



than 90 degrees in angle per 3 meters



Other mechanism



19



Abnormity Scar



No deformation nor abnormal weariness No harmful scar



― 11 ―



Good／



Details of defective



Not Good



& countermeasures



Items to be checked



Motor



Contactor



Transforme r



Overwinding limit switch



Push button switch



Point for inspection



20



Damage on stator and rotor



21



Lead-in wires



22



Insulating resistance



Normal outer covering and no disconnection of wire Over 1MΩ for 200V class Over 1MΩ for 400V class



23



Appearance



No crack nor damage



24



25



Weariness of components Appearance Lead-in wire condition



Good／



Details of defective



Not Good



& countermeasures



No harmful damage nor crack



No operational trouble No damage and abnormal outer covering and no wire disconnection



26



Induction



Normal induction



27



Appearance Lead-in wire condition



No crack nor damage Normal outercovering and no disconnection of wire



28



Weariness of components



No operational trouble



29



Appearance



No harmful damage



30



Weariness of component



No operational trouble



31



Indication



The correct indication is made



32



Cabtyre cable leadin wire



33



Pres-fitting and fastening sections



No scar, no deterioration no Electrical



Parts & general wiring



disconnection normal



of



wire



and



edge treatment No abnormality and no looseness of



Screws



Mechanical Section (for traversing) Items to be checked



Point for inspection



34



Weariness of gear wheel



Gear thickness reduction shall be less than 10% of the initial thickness on pitch circle



35



Interlocking gear condition



No abnormal weariness



Wheel



36



Weariness of wheel



No abnormal weariness



Suspending pin



37



Weariness of suspending pin



It shall be less than 2% of the initial size



Other mechanism



38



Damage



No harmful damage



Gear wheel (Outer)



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Good／



Details of defective



Not Good



& countermeasures



General Items Items to be checked General



Point for inspection



Lubrication 39 (for gear section) Operation load



on



no



40



Overwinding limit switch



Working condition 41 with no load with rated load Slipping at the time of pushing the 42 button while lowering the load at the rated load Lifting up and lowering function



Lifting up



43



within load



the



Details of defective



Not Good



& countermeasures



Greasy condition



Function



Brake



Good／



The function shall be normal as Indicated. The function shall be normal.



The slip of hook shall be less then 1% of the lowering stroke per 1 minute. No abnormity in lifting up and Lowering.



rated



wire dia



Load chain Wire dia 6.3



Standard size



Limit size



95.0ｍｍ



96.9ｍｍ



7.1 10.0 11.2



105.0ｍｍ 151.0ｍｍ 170.0ｍｍ



107.1ｍｍ 154.0ｍｍ 173.4ｍｍ



Chain 5 link size



Kinds of hook （ｔ） 0.49、1/2 0.9、1 1.5、2 2.5、2.6、3 5 7.5、10



― 13 ―



Standard Size A （mm） 25（30） 30 36（45） 45 50 75



How to use the chain limit gauge



Insert the gauge as per the above figure on the load condition on the chain, and if the gauge cannot be insert as per the left figure then it is usable but if inserted as per the right figure then it cannot be used because of over-weariness limit or over prolongation limit.



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The weariness limit for the chain wire dia: If the chain wire dia is bigger than the gauge dia, then it is still usable (as per the upper figure) but if it is just like the lower figure, it cannot be used as it is over the weariness limit.



[Troubles and troubleshooting] Trouble condition



Cause Countermeasures Remarks ・Owing to the action of ・Exchange 2 pcs out of negative phase 3 power wires protector. ・Negative phase ・Replace the negative Interphase shortcircuit. protector is broken. phase protector. Short-circuit by Thunderfall. ・Switch on. ・Replace fuses.



・No switching on ・Fuse is out



Use the rated fuse.



No action is made even if pushing the ・Disconnection of power wire. push button. ・Connect the ・Disconnection of push disconnected section button wire. or replace the wire. In case the motor generates the sound ・Voltage drop. ・Confirm the voltage but does not start and raise the stop the operation immediately. voltage as rated. ・Brake is not released. ・Adjust the brake completely. Rated lifting up ・Braking disc is worn can out. be made but any (electro-magnet section) slippage is incurred ・Worn out, crack or at the time of defect of mechanical lowering. brake. ・Grounding work is incomplete. ・Owing to disclosure of the connecting section, it gets in contact with the main body. ・Water drip of foreign matters get in the Electrification. electrical Braker is cut. components. ・Motor is completely burnt.



・Rectifier is short circuited.



・Replace the whole set If it happens on the mechanical brake of brake disc. side, it slips with no ・Replace mechanical load or with light load. brake. ・Execute the grounding work properly.



・Check the wiring section. ・Dry or eliminate any It may be possible to foreign matters. have a trouble from other devices. ・Replace motor or rewind the motor coil.



・Replacement of short Inter-phase shortcircuit or short rectifier. circuit by thunder.



― 15 ―



Trouble condition



Cause ・No overwinding up



Countermeasures ・Make proper wiring.



protection device (limit switch) or no proper wiring. ・Abnormal lifting work ・Keep the rated load. or overload operation. Take any proper lifting method. ・Shocking load. ・Don't make any shocking work. ・ Pulling extremely ・ Don't make any Weariness or diagonally. pulling diagonally. damage of load chain, gear or other ・Lubrication shortage. ・Keep oil always. ・Corrosion. ・Wipe away anything components. which incurs corrosion. ・Use of the load chain ・Reform the chain to intwist condition. avoid twist. ・Oil shortage in gear ・Replenish oil. case. (electric chain hoist)



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Remarks