KAMIUCHI ELECTRIC HOIST MANUAL TB A KaMIUCHI 7. Nreleo Aspley Glass Ind wo.rossroor,, BLtense tA q __ AWARNING | Do not operate the hoist unless you have read and understand the instructions and warnings in this book, Failure to follow the instructions or heed the ‘warnings could result in injury or death. Consuit us for replacement book. Proper care is your responsi- bility Kamiuchi hoist is intended for industrial use only. Do not use Kamiuchi hoist for passenger elevator applications. Securely tighten every nut which was loosened for instaling the hoist. ‘Check every nut atter installation. ‘Tum off the main switch and lock it as the following picture shows, before wiring andlor correcting wiring, Use letters in your popular language on the board with the same meaning as the following picture shows. ‘Tum off the main switch and lock itas the following picture shows, before checking, repairing, discard- ing the electrical part and mounting the new one. Use letters in your popular language on the board with the same meaning as the following picture Do not itt the overload. Lift the rated load or less. Do not lift the earth, Lift the rated load or less, Do net lit the imbalanced load. Lift the well balanced load. Do not obliquely fift the load. Vertically itt the load. Do not danglingly lift the toad. Vertically itt the load. Conot setinactive or remove such safety devices as the upper limit switch. Always keep them to properly work. ‘After checking the weight of the load and the mov. ing direction of the hoist, firmly press the button in the pendant control unit. (Check them. Know the hand signals and who gives them. ‘Accept signals from one person only. Check the signals and who gives them. Use the sling with sufficient strength for the rated load. Check the strength of the sling. Do not use the defective sling. Use the flawless sting: Donotuse the exclusive sting for the other purpose. Use the proper sling for the load. Do not leave the hoist while it lifts the load. Leave the hoist after lowering and unhooking the sling and the load, and after lifting the hook block up_ to the safe height, not to hit any person. Do not leave danglingly the pendant control unit. Leave it vertically suspended. Do not walk, run, stay or work under the lied load, Keep every person away from the lifted load, Do not climb, mount or work on the lifted load. Keep every person away from the lifted load.Foreword This book is a reference for the new operator and for the experienced one. Read-study and keep it handy. Your safety and the safety of others depends upon care and judgment in the operation of the hoist. A care- ful operator is good insurance against an accident. Some photographs and illustrations may show details or attachments that may be different from your hoist. Also covers may have been removed for illustrative purposes. Continuing improvement and advance- ment of product design may have caused changes to your hoist which may not be included in this book. Whenever a question arises regarding your hoist or this book; please consult us for the latest available information. Warranty Kamiuchi will supply without charge any parts proven to Kamiuchi's satisfaction to have been defective in material or workmanship. Claims must be made within one (1) year after the date of delivery from hi's factory, and only ifthe ciaimed defect arose during normal use, applications and service. 1ot supply any parts that become inoperative because of improper maintenance, eccentric loading, overloading, chemical or abrasive action, excessive heal, or other abuse. Equipment and accessories not of Kemiuchi’s manufacture are warranted only to the extent that they are warranted by the manufacturer, and only if the claimed defect arose during normal use, applications and service. Equipment which has been altered or modified by anyone without Kamiuchi’s authorization is not warranted by Kamiuchi. EXCEPT AS STATED HEREIN, WE MAKE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR, PURPOSE. “Normal use, applications and service": Those conditions during which a hoist andlor other products is (are) being operated and is (are) performing functions within the scope of the original design.Contents Glossary Safety .. Hoist Views Hoist Controls - Installation - Lubrication ........+5 Wiring « (Groundang teers vet sen slenectitectstc Test RUD -sesseeeeeeeeenes Before Operating the Hoist ...... Moving and Stopping the Hoist ..: After Operating ‘the Hoist ....... Maintenance .....sseesecee ewes eee Troubleshooting i..+ecssseeeeeeeeGlossary Hoist: A compact machinery unit that is used for vertically lifting and lowering a load by making reduced revolution of drum wound round the rope, driven by three phase squirrel-cage induction motor. Amachinery unit which trolleys is included. Flange, Load Carrying: The lower flange of the track of the monorail systen, or of the bridge girder of a suspension type crane, on which the load bearing wheels roll. Liges The hook movement in an upward direction. Lifting Height: The meximm vertical distance through which the hook can move, as determined by the length of rope and/or the number of grooves on ‘the drum. Load: The total weight superimposed on the hook. Load, Rated: The meximun static vertical load for which a hoist or a crane is designed. Lower: The hook movement in a downward direction. Main Switch: A switch controlling the entire power supply to the hoist, the monorail system or the crane. Pendant Control Unit: An electrical control device consisting of pushbutton operated contacts in an enclosure used by operator for control of the powered motions of the hoist and other auxiliary equipment. Track: The structural menber upon which the hoist trolley wheels operate. Trolley: The hoist movenent in a direction parallel to the track. -4 Safety Read and understand all safety pre- cautions and warnings before operat- ing the hoist. The hoist is designed to vertically lift and lower the load. Wear a hard hat and other protective equipment as required by job conditions. Do not wear loose clothing or jewelry that can catch on parts of the hoist, the sling or the load. Know the hand signals and who gives then. Accept signals from one person only. Cautions should be used to avoid breathing, dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. Components in our products that may contain asbestos fibers are brake linings, brake discs, clutch plates and some gaskets. The asbes- tos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not gen- erated. If dust which may contain asbestos is present, there ere several common sense guidelines that should be followed. 1, Never use compressed air for cleaning. 2, Use vacuum or wet methods for cleanup. 3, Use exhaust ventilation on perma~ nent machining jobs. 4, Wear -2n approved respirator if there is no other way to control the dust. 5, Follow environmental rules and regulations in your area for disposal of abestos. 6, avoid areas where asbestos particles may be in the air. Report all needed repairs inmediate- ly: weww Hoist Views switch Case Hoist Motor Hoist Controls Ue button in the pendant The hook will move upward. Release the button, the hook will stop moving. Press control unit. Press DOWN button in the pendant control unit. The hook will move downward. Release the button, the hook will stop moving. Trolley Motor Gear Case Hook Pendant Control Unit ©9®9 Press other button when installed in the pendant control unit. The hoist will operate as the function mark on the button shows. Release the but ton, the hoist will stop operating. DC Magnetic Brake Limit Switch LeverInstallation A WARNING Failure to follow the under-mentioned warnings could result in injury or death, ‘Securely tighten every nut which was loosened for the installation. Check every nut after installation. ‘After adjusting the distance between the trolley ‘wheels, securely tighten every nut, Check every nut after adjustment ‘When installing the hoist, make sure every trolley wheel keeps contact with the track, Check every contact. NOTE Recommended is your close consulta~ tion with the specialist in this field of work to install. the hoist under the "Safety-First" policy and to get the best operating condi- tions. The hoist must be installed with adequate working spaces for safety Method A Remove stops. Method B Method C KA type hoist of the rated load 7.5 t or more. Put trolley Remove trolley wheels in. a dy oh3, Adjustment of the distance be~ tween the trolley wheels. The hoist, has been shipped with our standard distance between the trolley wheels as the following table shows with the double cir- cle (@). It can be adjusted to as shown with the single circle co). Type Flange yp Wider, | 73 | 100] 125 | 150] 175 } 190 Hoist | Rated Load ie Sieber eee ee 1/2 tf, 1 te O,O|@e PA |2 te Oo}@}o KA [2.8 c8, 3 te @| 0 5 te oO; @/0 —Flange}-— Width KA ]7.5 t€ or more O;@{ 90 See the following figure for the adjustment. Adjusting Collar A @e Narrower Flange Hl ake sure every trolley jwheel keeps contact with the track. Ig it is hard that all trolley wheels contact with the track, reason- ably load onto the hoist just before securely tightening every nut. After checking every contact, securely tighten every nut. if T Wider Flange WidthLubrication Periodically grease every such com- ponent as the rotating part of hook block, the gears on trolley mechanism. Use the grease meeting the service conditions. The proper quantity of gear oil should be poured in the gear case. The following table shows the proper quantity of gear oil. When you change the gear oil, the following. see 4 CAUTION Do not excessively pour the gear oil. The excess oil runs to other mechanical components and will dan- age thea. The following table shows the proper quantity of gear oil. Rated Load [| proper Quanttey 1/2 tf 300 ec 200 cc ite 300 cc 300 ce 2 te 800 cc 700 ce 2.8 tf + 3 tt 950 ce 800 cc See 1,700 ec [1,700 ce 7.5 tf 1,700 cc 10 tf + 20 ef | 2,300 ce 15 tf + 30 t£ | 3,000 cc Gur gear oil: DAPHNE SUPER GEAR DIL 460. Manufacturer; Idemi tsu Kosan Co. ,Ltd.(Japan) Corresponding to JIS K 2219, Type 2, 1SD V6460. Proceed as follows to change the gear ofl. Gear case Red-head plug 3 041 plug or oil gauge oC me U Oil drain plug ry Remove top of the red~head plug at the the gear case. Remove the oil drain plug at the bottom of the gear case, the dirty gear oil will pour out of the gear case. Tighten the oil drain plug at the bottom of the gear case, after all dirty gear oil pours out of the gear case. Pour the proper quantity of new, clean gear of1 into the gear case through the hole at the top which is left by removed red-head plug. Secreuly tighten the red-head plug at th top of the gear case. cy| Wiring (_AWARNING | Failure to follow the under-mentioned warnings ‘could result in injury or death. Turn off the main switch and lock it as the following = picture shows. Use letters in your popular language on the board with the same meaning as the following picture shows. See our connection diagram of the hoist furnished inthe switch case. Make sure that there are no mis- wirings. Grounding AWARNING | Failure to follow the under-mentioned warnings could result in injury or death Correctly follow the grounding rules end regulations in your area. When the hoist is installed on..a electricity: conductive beam, polish clean the contactsuriace of the hoist and the beam, and ground the beam. When the hoist is installed on a electricity. nonconduetive beam, ground the hoist itselfTest Run : 4 WARNING Failure to follow the under-mentioned warning could result in injury or death. “Tum off the main switch and tock it as the following icture shows, belore checking, repairing, discard ing the electrical part and mounting the new one, andior before correcting the wiring, Use letters in your popular language on the board with the same meaning as the following picture shows. & CAUTION Do not interchange wires for UP and DOWN in the pendant control unit, otherwise the only second upper Limit switch works regardless of the working order from the first upper Limit switch to the seocnd one. The hook block will not move upward nor downward. 1. ue and DOWN Movements Turn on the main switch. Press UP button in the pendant control unit. Check chat the hook block will move upward. T£ the hook block moves down~ ward, immediately release the Dutton and see the "Trouble~ shooting, 4." 1-3. Releas@ UP button. The hook block will stop moving. 1-4. Press DOWN button in the pendant control unit, Check that the hook block will mo downward. Tf the hook block moves up~ ward, immediately release the button and see the "Trouble- shooting, 4." 1-5. Release DOWN button. The hook block will stop moving. 1-6. Turn off the main switch. 1-7. In case of correcting the wiring, 1-7-1. Turn off the main switch. 1-1-2. See the "Troubleshooting, 4 and 5." 1-7-3. Turn on the main switch.2. Upper Limit Switch aie 2-2. 2-4. 2-5. 2-7. 2-8 2-9. 2-12. turn on the main switch. Press UP button in the pendant control unit. The hook block will move upward. | Release UP button when the hook block nearly reaches to the limit switch lever. Inch up the hook block. Check that the hook block pushes up the Limit switch lever, consequently the upper limit’ switch works well to stop the hook block from mov~ ing. Press DOWN button in the pend- ant control unit. The hook block will move downward. Release DOWN button when the hook block reaches to about 1 meter below the limit switch lever. Press UP button. The hook block will move upward. Check that the hook block pushes up the limit switch lever, consequently the upper limit” switch works well to stop the hook block from mov~ ing. Press DOWN button. The hook block will move downward. + Release DOWN button when the hook block reaches to about 1 meter below the-limit switch lever. Turn off the main switch. 3, Reeving a. 32. Turn on the main switch. Press UP button in the pendant control unit. The hook block will move upward. 3-3. Check that the wire rope will wind correctly in the groove of the drum. If not, take proper procedure to put the wire vope correctly in the groove of the drum. See the “Troubleshooting, 8." 3-4. Press DOWN button in the pendant control unit. The hook block will move downward. 3+5. Release DOWN button when the hook block reaches to the lowest position of the lifting hei ght provided. 3-6. Check that the wire rope still remains 2 or more turns on the drun, If not, consult us. 3-7, Press UP button. The hook block will move upward. 3-8. Release UP button when the hook block reaches to about 1 meter below the Limit switch lever. 3-9. Turn off the main switch. 4. Other Movement (s) 4-1. Turn on the main switch. 4-2. Press other button when in- stalled in the pendant control unit, 4-3. Check the hoist will operate as the function mark on the button shows. If not, immedi- ately release the button. See our connection diagram and check the wirings are correct. 4-4, Release the button. The hoist will stop operating. 4-5. Turn off the main switch. 5. Stops Check that the stops on the both sides of the track are securely tightened with bolts and nuts, and/or completely welded.Before Operating the Hoist WALK-AROUND INSPECTION For your own safety, the safety of others and the maximum service life of the hoist, make a thorough i spection before operating the hoist. Look around the whole working range of the hoist for such items as gear oil leak or loose bolt. When such items are found, it is important to correct the cause of the condition. Otherwise the problem will quickly return and continue to get worse. 1. wamk way Inspect for such items as crash buildup and oil. 2, Track Inspect for excessive wear, de~ formation, paint, oil or dirt. 3, Controls Turn on the main suiteh. Inspect for incomplete work of lifting, lowering, braking and other movement(s). Inspect for abnormal noise or vibration. Turn off the main switch. 4, safety Devices Inspect for incomplete works. 5. Hook Block Inspect for worn sheave(s) and bent cover. Inspect for wear, gouging and visible cracks in the bowl and back of the hook. Inspect for incomplete setting of hook aut on the hook shank. Inspect for uneasy swiveling of the hook. Wire Rope Inspect for incorrect winding in the groove of the drum. Sling Inspect for improper sling for the load. Inspect for insufficient strength for the rated load. Inspect for defective sling.Moving and : Stopping the Hoist & WARNING Failure to follow the undermentioned warnings could result in injury or death. Do not lit the overload. Lif the rated load or less. Do not lft the earth. Litt the rated load or less. Do not lift the imbalanced load, Lift the well balanced load, Do not obliquely litt the load. Vertically litt the load. Do not danglingly lift the load. Vertically lift the load. Donot setinactive or remove such safety devices as ‘the upper limit switch, Always keep them to properly work. ‘After checking the weight of the load and the mov- Leave the hoist after lowering and unhooking the sling andthe load, and after lifing the hook block up to the safe height, not to hit any person. Do not leave danglingly the pendant control unit. Leave it vertically suspended. Do not watk, run, stay or work under the lifted load. Keep every person away from the lifted load. Do not climb, mount or work on the lifted load. Keep every person away from the lited load. & CAUTION Do not excessively inch up or down the hook block or the load. Do not excessively inch the movement of the hoist. Do not do the plugging of thea 8 a 10. 13. du 1b. 16, 7 Turn on the main switch. Fix the sling completely on the load. See the hand signal-person. signal from a Move the hoist just above the Joad or move the load just below the hoist. Press DOWN button in the pendant control unit. The hook will move downward. Release the button when the hook reaches to proper height to lift the load. Push the safety latch on the hook. Hook the sling completely. Release the safety latch on the hook. Press UP button in the pendant control unit. The hook will move upward. Release the button, just before the load completely takes off (ynamic Lift off). Check the load is completely slung. Check the hook, the sling or the load does not catch on perm son(s), machine(s) or structural member(s). Press UP button in the pendant control unit. The hook will move upward, lifting the load. Release the button when the load reaches to proper height for handling. Press other button when install- ed in the pendant control unit. The hoist will move in the sane direction as the function mark on the button shows. Release the button when the load reaches to the place where it will be lowered. Press DOWN button in the pendant control unit. The hook will move downvard, lowering the load. Release the button when the load reaches to the floor. Push hook. Unhook the sling and the load. the safety latch on the Release the safety latch on the hook. After Operating the Hoist 4 5 ere Remove the sling from the hook. Press UP button in the pendant control unit. The hook block wil? move upward. Release the button when the hook block reaches to the safe height, not to hit any person. Turn off the main switch. Look around the whole working range of the hoist for such items as gear oil leak or loose bolt. When such items are found, it is important to correct the cause of the condition. Otherwise the problem will quickly return and continue to get worse.i i | i i | seecencen cy Maintenance ee ec Tighten every bolt, nut and screw at every maintenance. when bolt, aut or screw is missing from components, tighten then with new one immediately. It is important to correct the cause of the con- dition. Otherwise the problem will quickly return and continue to get worse. NOTE Clean the name plate. Every MONTH MAINTENANCE 1. Pendant Control Unit. Check every button is easily pressed or released. Tf not, repair it of replace it with new one. 2. Magnetic Contactor Check every magnetic contactor works well, when the button in the pendant control unit is pressed or released. Tf not, repair it or replace it with new one. 3, Upper Limit Switch. Check, the hook block pushes up the iimit switch lever, conse- quently the upper ‘limit switch works well to stop the hook block from moving. 4. Wire Rope. A CAUTION | To completely inspect the wire rope, draw full length of it out of the drum. Never fail to check the parts close to the rope ends, and also close to the equalizer sheave as to the low headroom type hoist and the double rail type hoist. When replacing the wire rope, never use the twisted wire rope. See the following figures. Wrong straight. -12-[Ordinary Type| ser Deo seer © edge o Righe eons pul the vire rope Hy ® About to fixie q 100 5 to the slot. ‘This method is right. This method cause: Hook block breaking of wire ros Wind the wire cope around che drum tvo or three turns vith che sotor. © Confirmation of Work Before operate the hoist, never fail to do the test run to make sure the perfect work. [Low Headroom Type, Double Rail Type] step © to Step © Rope end (small) Rope end (large) Equalizer sheave Double Rail type Reeving the wire rope for low head room type is different from that for double rail type. Hook block —{ After setting everything, gradually wind the wire rope with the motor. -13-i | | i { | eee 4-1. Inspect 10% or more of the wire making up one strand have been cut off. Tf yes, replace it with new one. “@-2. Inspect the diameter of it has reduced to 93% or less of its nominal diameter. If yes, re~ place it with new one. 4-3. Inspect it is kinked. If yes, replace it with new one. LY Kink q Z, 4-4, Inspect there is an extreme deformation or corrosion. If yes, replace it with new one. Corrosion Deformation’ 4-5. If the wire rope is running out of oil, lubricate the wire rope oil. Hook Block. Check the thrust bearing and other bearings work smoothly. If not, replace it with new one. Later-model hook has punch marks showing the original hook throat opening as the following figure and table show. -14- Rated Daa A (am) | B (om) 1/2 te 60 26 ite 65 | 28 2 tf 80 32 3 te 100 42 3 tf 140 34 7.5 tf 150 65 10 te 170 77 iS te 210 8 20 tf 230 93 30 te 250 104 5-2. Measure 5-1. If there is visible traverse crack(s) in the area showed above or in hook shank, re- place it with new one. between punch marks (or. at hook throat if there are no marks.) If "A" measures more than 1.15 x original dimension, replace it with new one. 5-3. I€ hook is twisted more than 10°, replace it with new one. won eeEverY THREE (3) MONTH MAINTENANCE 1, Track Check the ‘stops are securely tightened with bolts and nuts, and/or completely welded. If not, firmly tighten them and/or completely weld them. 2, DC Magnetic Brake. Measure the gap. If the adjustment is necessary, see the "Troubleshooting, 10-21 and 10-2-2." Equalizer Sheave- (Formerly we called it the wire wheel.) Equalizer sheave is mounted when the wire-rope-falls is 4 or more. 3-1. Check it rotates smoothly. Tf not, replace it with new one. 3-2. Check it is defective If yes, replace it with new one. 4, oiling 4o1. Check the gear oil is clean. T£ not, see the "Lubrication." Drain all dirty gear oil fron the gear case, and pour the new clean gear oil into the gear case. 4-2. Check the gear case contains adequate gear oil. I£ not, see the "Lubrication. Add the new clean gear oil into the gear case. --1s-Troubleshooting A WARNING Failure to foliow the undermentioned warning could result in injury or death. | *Turn off the main switch and lock it as the following jcture shows, before checking, repairing, discard- ing the electrical part and mounting the new one, andlor before correcting the wiring. Use letters in your popular language on the board with the same meaning as the following picture shows. 1, The hoist ‘does not move, though every button is pressed. tt. 147. - 16 - Power failure. Uconsult the electric pover company. Main switch OFF. “Turn ON the main switch. Incomplete collector's contact with conductor. i “Completely make contact. Broken wire. ‘Replace it with new one. Loose terminal. “tighten terminal. Motor burn-out. Repair it. Replace it with new one. Damaged magnetic contactor. Repair it. Replace it with new one. Damaged péndant control unit. Repair it. Replace it with new one.2, The hook does not move upward, though UP button is pressed. 2-1, The hook moves downward, when DOWN button is pressed. 2-I-t. For such cause as dust, the limit witch lever keeps working position of FIRST upper limit switch. ‘Remove the cause. Turn the Lmit switch lever back to the normal posi- tion. 2-1-2. Danaged upper limit switch. Repair it. Replace it with new one. 2-1-3. Broken wire to upper limit switch. Ureplace it with new one. 2-1-4. Loose terminal. Lighten terminal. 2-1-5. Danaged magnetic contactor. Repair it. Replace it with mew one. Damaged pendant control unit. Repair it. Replace it with new one. 2-2, The hook does not also move downward, though DOWN button is pressed. 2-2-1, For the cause of wrong wiring, the only second upper limit switch works regardless of the working order from the first upper limit switch to the second one. Uproceed as follows to reset the upper limit switch. i. Turn off the main switch. 2. See our connection @iagram and check UP and DOWN wirings in the pendant control unit. 3. Interchange two wires indicating R and T on the secondary circuit (the hoist side) in che main switch as the following figure shows. Primary eat |®|@O|@ Main switch Secondary circuit $: Grounding line 4. Hold the hook block up and lay it on one side. The limit switch lever will move down, which will release the second upper Limit switch from its working po- sition. 5. Turn on the main switch. 6. While holding up the hook block, inch down the hook block. 7. Turn off the main switch. 2-2-2. Damaged upper limit switch. Repair it. Replace it with new one. 2-2-3. Broken wire to upper limit saitch. UReplace it with new one. 2-2-4, Loose terminal. Lighten terminal. 2-2-5, Damaged magnetic contactor. Repair it. Replace it with new one. -17-2-2-6. Damaged pendant control. 3. Do not interchange wires wit. for UP and DOWN in the Repair it. pendant control unit. Replace it with new one. Otherwise the only. sec- ond upper limit switch works regardless of the 3, The hoist does not troliey, working order from the though such button as WEST, EAST first upper limit switch is pressed. to the seocnd one. When such case arises, the hook block will not move upward nor downward. See the "Troubleshoot= ing, 2-2-1" co reset the upper limit switch. 4, Turn-on the main switch. -* 3-1, Broken wire. ‘Replace it with new one. 3-2. Loose terminal. tighten terminal. 3-3. Motor burn-out. Repair it. 4-2. Reverse winding caused by Replace it with new one. over lowering. Rewind wire rope. aly 3-4, Danaged magnetic contactor- Repair it. - Replace it with new one. 5, Contrary trolley-movements’ (such as WEST, EAST) to function marks 3-5. Damaged pendant control unit. in pendant control unit. Repair it. S-1, Wrong wirings. ‘Proceed = as follows to correct, the wirings. 1. Turn off the main switch. 2. Open the cover of pend- Replace it with new one. 44, Contrary UP and DOWN movements to function marks in pendant control unit. ant control wit. 4-1. Wrong wirings. 3. Interchange two wires Uproceed as follows to indicating 3 and 5 as correct the wirings. the following figure 1. Turn off the main shows. switeh. Common wire, indicating Ror & 2. Interchange two wires indicating R and T on the secondary circuit (the hoist side) in the main switch as the following figure shows. tna [©/0|@ ta 33 Main switch Close the cover of pend- ant control unit. 5. Turn on the main switch. Secondary circuit St Grounding line6, The hook block continues to move upward, though the hook block pushes up Limit svitch lever. 6-1. 6-2. 7-1. 7-2. Damaged upper limit switch. Repair it. Replace it with new one. Loose parts which connect the limit switch lever and the upper init switch. Tighten parts. Abnormal wear of the wire rope. Unsuitable wire rope for the groove. UReplace it with new, right one. Wire rope scratches drum case because of the oblique lifting or the danglingly lifting. Wertically lift. ‘The wire rope does not wind cor- rectly in the groove. at. 8-2. 8-3. Unsuitable wire rope for the groove. LReplace it with new, right one. Kinked wire rope. “Replace it with new one. Oblique lifting or danglingly lifting. vertically lift. Q, The magnetic contactor does not work, though the button is pressed. oe o-4. Broken wire between the pend- ant control unit and the mag~ netic contactor. UReplace- it with new one. Loose terminal. Uighten terminal. Damaged magnetic contactor. Repair it. Replace it with new one. Damaged pendant control unit. Repair it. Replace it with new one. -19- |, The humming of motor without ro~ : 8 tation. + Lower voltage chan the rat~ ing. UEnergize the rated voltage to the hoist. 10-2. Wronger gap of the brake. Proceed as follows for the adjustment. 10-2-1, DC Magnetic Brake. (lift and Lower.) Lf the brake linings (part No. FA 1-16) are exces~ sively worn off until the gap between the stationary core (part No. FA 1-3) and the protection plate for remanence (part No. FA 1-13) reaches the follow ings, the efficiency’ of the braking is reduced. Rated Load Gap 1/2 tf to 3 t£} 1.0 om 5 tf to 30 tf] 1.3 mm | When such casé arises, adjust the gap to be right by the. following proce~ dures. 1, Loosen 3 nuts (part No. FA 1-6) on the side of the brake-lining to narrow the gap dovn to the right one. 2, Tighten up 3 nuts (part No. FA 1-6) on the side of the brake-case~cover to complete the adjust~ ment. Rated Load Right Gap 1/2 t€ to 3 tf] 0.4 mm to 0.6 mm 5 tf to 30 tf} 0.6 mn to 0.9 mmIg the brake linings are worn off very drastically, they must be-replaced with the new ones. Proceed as follows so that the gap is fixed to be right. 1. Put the stationary core (part. No. FA. 1-3) through the pins (part No. FA 1-10) without fixing the spring (part No. FA 1-12), and press it forvard until it reaches the protection plate for remanence (part No. FA 1-13). 2. Adjust the gap to be right with 3 nuts (part No. FA 1-6) on the side of brake-Lining. 3. Remove “the stationary core (part No. FA 1-3). Set the spring (part No. FA 1-12) and also put again the station- ary core. (part No. FA Part No. Description FA 1-16 | Brake Lining FA I~ 3. | Stationary Core FA 1-13. | Protection Plate for Renenance FA 1-10 | Pin FA I- 6 [Nut (with spring washer) FA 1-12 | SpringAdjustment, Loosen the lock nut fixed at the friction-side be~ fore adjustment. Fasten the lock nut fixed at the friction-side after adjustment. Adjust gaps to be uniform at three points. {. When thickness gauge (thickness 0.55 mm) is inserted into clearance (gap) between core and armature, the adjust~ ment is necessary. When thickness gauge (thick- ness 0.35 mm) is not inserted into gap, the adjustment is not nec~ essary. 2. When thickness gauge (thickness 0.55 mm) is inserted into gap, it is to be replaced with one of 0.2 mm thickness and adjust the gep by following method. Turn right (clockwise) the adjusting nut near thickness gauge of 0.2 mm till the position not to leave the gap between thickness gauge and core-amature, and also till thickness gauge being pulled out easily. Be sure, before turning the adjusting nut, to loosen the lock nut which is fixed at the friction~side of outer-disc 3. By same method, adjust each nut in order that gap between core and armature at circumfer- ential three points (near stud bolt) may be uniform. Afcer the uni~ -2- form gaps are obtained, turn counterclockwise the lock nut (been loosened 2.) to fasten the outer-dise. 4. To confirm the proper gap, insert thickness gauge of 0.2 mm thick ness into several points. Structure and Name of Part @ spew #l © o__| sth otf ia © oT sess 6 1. Core 2. Coil 3. Coil Mold Resin 4. Bushing 5. Lead Wire 6. Stud Bole 7. Adjusting Nut 8, Armature 9. Inner-Dise 10. Spline Hub 41, Outer-Dise 12. Spring 13. Lock Nut 10-3. Damaged brake unit. Repair it. Replace it with new one. wVY 11, over-heat of the motor. ll=1. More operation than the spec~ ified rating. “Operate che hoist than the specified rating. less 11-2. More operation than the spec~ ified duty rating. “operate the hoist less than the specified duty rating. 11-3. Lifting the overload. ‘Lift the rated less. load or + Lower voltage than the rat- ing. “Energize the rated voltage to the hoist. 11-5. Excessive inching. “Do not inch excessively. '176. Slow release of the bréke. 11-6-1. Wrong gap of the brake. Cadjust it. See the "Troubleshoot~ ing, 10-2. 1176-2. Damaged brake unit. Repair it. Replace it one. 11-7. Locked brake. with new N-7-1. Wrong gap of the brake. Ladjust ir. See the "Troubleshoot- ing, 10-2." 1177-2. Damaged brake unit. [Repair ic. Replace it with new one. 1-7-3, Broken wire in the magne~ tic brake coil. Repair it. Replace it one. with new V1-7-4. Burn-out of magnetic brake coil, tReplace it one. with new ~22- 11-7-5. Lower than the rating. ‘Energize the rated voltage to the hoist. voltage 12 12-1. Excessive wear of the brake lining. ‘Replace it with new one. See the "Troubleshooting, 10-2. 12-2, Wrong gap of the brake. “adjust ic. See the "Troubleshooting, 10-2 Inefficient braking. 13, Abnormal noise in the gear case. 13-1. No gear ofl. ‘Sufficiently pour the specified gear oil. See the "Lubrication." 13-2. Insufficient gear oil. ‘“Sufficiently pour thé specified gear oil. See the "Lubrication" and “Every Three (3) Maintenance, Oiling." 13-3. Dirty gear oil. “brain it and sufficiently pour the clean and speci- fied gear oil. See the "Lubrication" and “Every Three (3) Month Maintenance, Oiling.” 13-4, Wear of the gear, bush, etc. “Replace it with new one.14, The hoist moves, though the but- ton is not pressed. 14-1. Damaged pendant control unit. Repair it. Replace it with new one. 14-2. Contact-fusion in the mag netic contactor. ‘Replace it with new one. 14-3. Wrong grounding. “correctly © ground the hoist. 15, The trolley wheels run idle or slip. 15-1. Oil, dust, paint on the track. tRenove it. 15-2. All trolley wheels do not contact with the track. ‘ig it is hard that all trolley wheels contact with the track, reasonably load onto the hoist just before securely tightening every’ nut. After checking every con- tact, securely tighten every nut. See the "Installation." = 23 -KAMIUCHI ELECTRIC WORKS, LTD. Head Office §-31, Tagawa 2-chome, Yodogawa-ku, Osaka 532, Japan Tel: 06-301-6751 Fax: 06-308-0389