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Hitachi 2 - 5F-FN Manual
Hitachi Hoist User Manual
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Hitachi 2 - 5F-FN Manual
Hitachi Hoist User Manual
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HITACHI INSTRUCTIONS FOR HANDLING HITACHI ELECTRIC CHAIN HOIST CAUTION—IMPORTANT Before hoist use, all persons who will install, operate or maintain should read this manual thoroughly For safe, dependable and economical performance, follow all instructions and recommendations contained hearin When use hoist in the manner other than those stated in this manual, please contact the nearest Hitachi representative, Its also important to retain this manual for future use WARNING THIS HOIST IS INTENDED FOR INDUSTRIAL USE ONLY AND SHOULD NOT BE USED TO LIFT, SUPPORT OR OTHERWISE TRANSPORT HUMAN CARGO. (TYPE F-FN)— TABLE OF CONTENTS — PAGE 1, SAFE OPERATING PRACTICE 1 2. GENERAL INFORMATION 2.1. REPAIR PARTS ORDERING INFORMATION 3. INSTALLATION so 3.1. ELECTRICAL INSTALLATIONS: 2 3.2 CHAIN CONTAINER INSTALLATION 6 3.3 FUNCTION TESTING, ~~ 6 4. OPERATION 6 4,1 GOOD OPERATING PRACTICES 6 4.2 HANDLING THE LOAD 6 4.3. PROPER SLINGING FOR SAFETY OPERATION™~ “7 5. MAINTENANCE “8 5.1 PREVENTIVE MAINTENANCE SCHEDULE: rrnennnssneinnnnnanininnnnnt “8 5.2 INSPECTION ee 7 8 5.3. MAINTENANCE sencennnnnenenenen 5.4 FUNCTION TESTING 6. TROUBLE SHOOTING 13, 6.1 PROCEDURES ~ 13 7. DISASSEMBLY AND REASSEMBLY ennai z 15 7.1 INSTALLING NEW CHAIN estnnnnninntnennnnnnnsiennneeeie) 8. LIST OF REPAIR PARTS FOR IF 17 9. LIST OF REPAIR PARTS FOR 2-5 F+FN-- 241. SAFE OPERATING PRACTICE The following are recommendations for safe operation of an over head hoist. Failure to heed the following recommendations could endanger the operator and others. Use good common sense at all time Safety is the responsibility of the operator of the equipment You must be competent and attempt to foresee and avoid all hazardous conditions. To be as safe as possible, the hoist must be given proper periodic inspection and preventive maintenance ‘described in this manual and National Safety Codes for overhead hoists. 1. Do not operate hoist unless you are properly trained, phisically fit, and authorized to do so, 2. Do not operate hoist unless you are femili with all controls, warnings and instructions on or attached to the hoist, safe operating practice listed in this bulletin, National Safety Codes, and all pertinent federal, state local regulations before starting operation. Do not allow any unqualified personnel to operate hoist Never lit load beyond the rated capacity appearing on the hoist. Never carry pemonnel on the hook or the load Never lift @ load with the hoist until all personnel are clear. Never use the chain as a sling ‘Stand clear of load when operating the hoist. eeronne Do not transport load over personnel 10. Do not use the chain as @ ground for welding 11. Never touch a welding electrode to the chain. 12. Do not leave @ load suspended in the air for extended or unattended periods. 13. Keep watching the load while operating the hoist. 14. Center hoist unit over the load before lifting. Avoid side pull and end pull 18. Be sure the sling is properly seated in the saddle of the hook. 16, Make sure the load clears neighboring stock piles or machinery before moving 17. Avoid plugging, excessive inching, and quick reversals of load. 18. Avoid swinging of load or hook when traveling the hoist, 19. Check limit devices and braking mechanism daily for proper function. Check daily the chain for improper seating, twisting, kinking, wear, or other defects before operating the hoist. 20. Be sure that the power supply is disconnected before performing maintenance and repair procedure. 21. Do not operate hoist if it is functioning improperly 22. Do not use the limit switch as a means of stopping the loaded hook in the down direction. This is primarily 2 backup device. 23. Do not use hoist in a manner not described in this manual 24. Perform all daly, monthly and yearly inspections as indicated.25. Do not remodel the hoist 26. Donot use hoist in a manner to restrict a free action of lifting devices, such as material cargo guided by rails. 27. Do not use the hoist where itis exposed to rain or water. 2. GENERAL INFORMATION 2.1. REPAIR PARTS ORDERING INFORMATION To insure prompt service, place all parts orders with your local distributor. The following information must accompany all correspondence or replacement parts order. 1. complete data from hoist nameplate (Type, MFG NO. of the hoist, Volt, Phase and Hertz) 2. Part No’s, description and quantity required. 3. when ordering chain or chain container, give additional informations; lift of hoist and no. of falls. 4. correct shipping destination. ‘AUTION] When replacement parts are needed, order only manufacturer's Factory Engineering Parts 3. INSTALLATION 3.1 ELECTRICAL INSTALLATIONS [CAUTION] Before connecting power to the hoist, be sure the power supply corresponds to the hoist rating Check the power supply within plus or minus 10% of rated voltage. (2) CABLES INSTALLATION (1) Insert the plug Insert the plug to the receptacle.(2) instal the Plug-Cover Pushing the part indicated “PUSH” of the Plug-Cover, insert the Plug-Cover to the cover of the heist, ‘Then make sure that the Plug-Cover is fixed firmly. Plug-Cover 9 Hook (3) Finished S The power source cable should _ be fixed by cable stopper, ‘The screw should be screwed own to prevent the wire end ‘coming out ‘The edge of the rubber-cover is not bein put inte the groove of the plug-cover. (0) REMOVAL OF CABLE (1) Removal of Plug-Cover Romovs Plug-Cover following ¢ reverse procedure of assembling. (2) Removal of plug Push open the stopper of Receptacle with a screwdriver{ ), and others. Setting free the projection of Plug from the stopper, pull out Plug, pL Push open the stopper of Receptacle Screwdriver(-) ‘Stopper Projection Receptacle + Don't pull the cable, pull the Plug —3-CHECK HOIST RATING] To determine hoist rating or to change rating on unit equipped with dual voltage connection, remove the cover which have receptacles of the power supply and control cable to expose dual voltage terminals, and also the wiring diagram pasted to the inside of the cover. ‘Voltage setting is determined by location of the wire harness. To change Voltage, move the wires according to the instructions in the wiring diagram, and replace the connector of the Reverse Phase Inspecting Relay (3- phase models only) with the other. Before replacing cover, make sure the wiring and all connections are tight. POWER SUPP! CABLE] For grounding the hoist, the power supply cable includes a grounding conductor (green or green / yellow) By means of this conductor, the hoist should be grounded, furthermore, the suspension system on which the hoist is mounted should be also grounded permanently, CHECK FOR CORRECT PHASING] Incorrect phasing can result of serious damage on poly phase A.C hoist. If the hook does not travel UP when the "UP" button is depresse: |, reverse any two of the three line wires in the main power supply. [CAUTION] Do not rewire the push button3.2 CHAIN CONTAINER INSTALLATION The Chain container used to house, the slack side of the load chain in order to ease operation, is installed on all standard lft models. -SIDE COVER OC CHAIN CONTAINER SAND EY PLATES) oe S| SCREW UP the we ~ ~ PLATE to tne contain | [GP Legt-s®seove | Bs ' =) ibe cover D/ cua éor deh NS _ se a HANGER HOOK q 1 SF Fh 2~5F + FN Fig. 1 Installing Chain Cont er on Electric Chain Hoist [EAUTION] 1 Po not omtana it ofthe hoist by yours —~ In case longer lift than standard is required, contact an authorized Hitachi repair shop. 2. Do not use hoist without @ chain container 3. When inspecting hoist, please check if proper chain container is equipped according to the following table LIFT (m) AND CHAIN CONTAINER, move. [ 3 6 1F D | 2.2.5F-FN E F 3F, FN F 6 | SF FN | G 6 Table 13.3 FUNCTION TESTING {6} Limit Switch Operation Before placing the hoist in operation, check for proper operation of upper and lawer limit switch. Push the UP(DOWN) button, while the hook is moving upward (downward) direction. The hoist should stop immediately. [CAUTION] 2° not operate the hoist ifthe limit switch is not operating property. Do not use the limit switch as 2 means of stopping the hook travel. This is primarily a backup device. (0) Brake Operation (Check for load hook drift with rated load on the hook. If hook does not stop within 25mm when push button is released, it may be necessary to adjust or replace the brake assembly. (See P. 10) 4. OPERATION 4.1 GOOD OPERATING PRACTICES 1. The operator should not engage in any practice which will divert his attention while engaged in operating the hoist 2. Before starting the hoist, the operator should be certain that all personnel are clear 3. Pushbutton, brake and limit switch should be tested by the operator before beginning a shift. If these controls do not operate properly. they should be repaired or replaced before operations are started, 4.2 HANDLING THE LOAD [CAUTION] 00 not exceed the rated load. (a) Atteching load 1. The hoist chain should not be wrapped around the load. 2. The load should be attached to the hook by means of slings or other appropriate devices which should be seated properiy in the saddle of the hook before operation, (b) Moving the toad [WARNING] 00 not use the hoist for liting people and avoid carrying loads over people 1. Before starting to hoist, the chain should not be kinked or twisted, 2. The operator should inch the hoist into engagement with the load, and avoid unnecessary stops and starts 3. The load should not be lifted more than a few inches until itis well balanced on a sling or lifting device.4.3. PROPER SLINGING for SAFETY OPERATION One of serious hazards is dropping of the load caused by improper slinging. All operators of the hoist shall make sure before operations that the slings or other approved devices are seated propery in the saddle of the hook. Please do not neglect the following for your own safety end the safety of others, PROPER SLINGING The safety latch shall be returrned in the original Position after slinging. The slings shall be seated properly in the saddle of the hook recommended IMPROPER SLINGING Belows are examples of misuse of the slings. You must recognize that the slings shall not touch the safety ch in any manner. [WARNING] ': The hook latch is to prevent the slings from coming off and not for loading = 2. Damaged or improperly working hook latch shall be replaced immediately before further use of the hoist5. MAINTENACE 5.1 PREVENTINVE MAINTENANCE SCHEDULE ‘The periods between inspections will vary due to the wide range of duty cycle and operat 19 conditions. The following inspection periods ar bbased on average duty with single shift operation (20-25% on t 180 times “hour starts) under normal envirommental condition: If the hoist is used in heavier applications or under adverse environmental conditions, it should be inspected more frequently [CAUTION] 00 nct operate hoist unt all deficiencies are corrected 5.2. INSPECTION {a} Daily inspection Inspect the following items daily before operating hoist 1, Check pushbutton station, brake and limit switch for improper operation. (See paragraph 3.3) 2. Inspect the hook to ensure that no abnormal wear exists on the slinging section and that hook is not bent to open excessibly. Fig. 2 shows standard dimensions of the mouth opening ow fa.2.si] at | St \* Nonmat-c" | 29 | 33 | 49 | 55. e/ Fig. 2 Hook Dimensions 3, Make sure that bottom hook swivels freely 4. Check link chain for wear, twist or distortion 5. Check for damaged or improperly working hook latch. NOTE; If bent or twisted hook is observed, other load bearing components of hoist or trolley shall be inspected, because bent or twisted hooks indicate overloading or abuse of the nuitDo not operate the hoist if it is functioning improperly or damege is noted. {b} Monthiy inspection Inspect the following items at 30-day intervals 1. All items under daily inspection 2. Chain; If chain binds, jumps or is noizy, check for cleanliness and proper lubrication. If trouble persists, inspect chain for we snd elongation. (See Fig. 3 and 4) Oo g g Tee g _ = (@ ble uve phil a Se 3. Hooks; check for cracks or deformations. Replace hook if the mouth opening is in excess of normal hook Fig. 2) 4. Load and Idler sheaves; sheaves which are worn should be replaced. Worn sheave can greatly reduce the life of load chain. ‘opening or twists from normal plane of hook. (S 5. Electric parts; check for signs of pitting or any deterioration of controts, limit switch and pushbutton 6. Check for loose bolts, screw and nuts. 7. Brake; Check the wear of the brake lining and other parts. ‘When the thickness of lining has reached its limit 10mm, or other parts remarkably has worn, replace those parts by following procedures.Brake Spring Cove Bish 8 Brake Whee! Spring Cover 8 Unc ‘Acjasiment gt UL Acjstment Screw | Lower BM Support A ‘Acusimect Seow | Pake\ TT Sere ‘eM Suppor B ‘3M Suppor 8 Suppo A Fig. 5a Structure of 1F Brake Fig. 5 Structure of 2—5F + FN Brake [CAUTION] : when check the brake, unload land cut the power supoly. (1) Disassemble the brake mechanism with solenoid by removing 4 screws (2) Check worn parts and repiace them if necessary. BM Support 8 Fig, 6a Measurement of (Return the Adjustment Serew by unlocking the Adjustment Screw the Adjustment Lever, Adjustment (Reter to Fig, 6a, 6b) Lever Note :Check the Adjustment Screw for smooth movernent, and apply ‘Adjustment Screw, grease if necessary. th (4) Mount the brake wheels, lining and brake a emectanem Fig. 6b Disengagement of CAUTION] : When mounting the brake mechanism, —__the Adjustment Lever the Brake Lever shall be located _ between the projected parts on the _ Magnetic Brake Disk A oa
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M1130055 [BOLT whox1z0 H 155 |B [812189 [axisesi46—1] FESEESE PEABE, 1__| 820-230 7380~460¥ 16 7901183 [SCREW MSx16 a | 157 2 tse | ¢ | e1aie6 |suapseoi6—3| BASE 2 159 | ¢ | 812646 | s114D70269~1| TBAMINAC BASE 1 2 1 7 ri 5 1 1 2 161 | D 3821145494—1| oP CONNECTOR rer |p | 12061 | sp2co0870—i| conracror MALE B | 812058 | 3B2H45494-3| 6P_ CONNECTOR s _| 812061 | sB2G00870—1| CONTACTOR MALE Ms470077 | SCREW BRUS 8700005 | SPRING WASHER Mé c | 12649 [4B2552708-6| reRMINAL BOAD oP. M7901806 | SCREW WMa~i2 a M7900112 SCREW M6x10 2 D 34258917—2| 2F POWER CABLE ASS'Y c__| 812420 [siicésa3e—| 2F HOUSING PLATE I B | sizare | scozessa7-A [2m ROTOR ASSY 1 FOR P TYPE B 12672 | 3c2z75707-A_| 2FNM ROTOR ASSY L FOR_FN TYPEIm"| cuass| part | peawina «| PART NAME quantity REMARKS 178 | 8 | eize7e |acaz20064—C| TAN HOUSING ASST ee A 17s |__| aiz9st | acsz2ae64-E | 29 HOUSING ASST. 1 [ seovsous, FoR F TYPE 175, B 812673 | 203227607-A | 2FNM HOUSING ASSY 1 20/380-415V50H2, FOR FN TYPE 176 | sigsie | scae6eaai-1 | 2M END BRACKET 1 FOR F TYPE 177 | ¢__| #12674 | sceB750¢97A | 2PNW END BRACKET 1 [FOR AN TYPE 1 3Ms700008 | SPRING WASHER Ma @ [FOR FN MODEL ONLY 178 c 4M11A3542-1| 2F THROUGH BOLT 6 FOR F TYPE Pais | c__[ aizeso | amizasio-1 | 2PNt THROUGH BOLT | For FN TYPE 119 | 180 | © | #12ae2 | 1Asq09027-2] oF COVER B 1 |For F TYPE reo | c | 812790 | sas@72109-A | 2FN COVER B L MODEL ONLY is 7 Z 182 i8s_|_B | a7iios [Litto0ss | WaecoappunR TOR F TPE 185 1112042 | BB620«DDUNR 1 FOR_FN_MODEL_ONLY 186 #36039 [GA409651-4 [© RING 5 6 187 | ¢ | 12459 | sp1z65347-a| CENTRIFUGE, FRAREY | 186 c [e36106 [Ga30«952—a | FLAT SPRING 2 189 | | 836105 |Ga410405—A | MOVABLE PIECE 3 190 [Mas.00008 | C RING(SHAFT) 18 1 131 [Miisooeo | BOLT 10x20 3a Te [aa700009 | SPRING WASHER MIO, 3 1s |e 2H4DA0d1T-1| 2EN SW BASE 1 [isa c 813001 |4H4D79994~1 | 2FN SWITCH BASE 1 195) fars00u78 | SCREW aMexi6 2 196 fw 700100 | PLAIN WASHER 2 aria ite 3K21B7578—1 | CONTACTOR MAATSND 7 198 fu7900239 | SCREW AMSxé 2 199 | a 7 _ 200 M7900101 SCREW AMSXI2 3 Zo1_|_p | #1a689 [sHaD70271—1| F MG SW BASE 1 202 | C_| 871194 [4k2127121-1| CONTACTOR(HMO—1 6) z [203 o Msai0084 [SCREW Max20 3 204 Ms700005 | SPRING WASHER wa 3 205 Me700100 [PLAIN WASHER ma 3 a 206 12077 | 3412415383] CAPACITOR (2#F) 1 FOR OLL MODEL ONLY | 207 7901405 | SCREW Méxi0 2 * soa #12646 | sH14p70270—1| TRANS BASE 1 209 M7900239 | SCREW aMsx8 2 | 210 B 871099 | 245319013~-1| TRANSFORMER 30VA 1 220/380-415V_50Hz 210 B 871144 | 255319014—-1) ’ . a 220-230440-460V_60H2 210 _| B | 812965 [2rss19012—4 : 7 1 nee 210_[ B | 870719 [zusaiso13—2| + 1 | 200/346-aa0vsune 2a1 7 M7900000 SCREW _WM5x8 4 212 | © | esioaa_[syiz708is-1 [me caPaciToRUpr) | ier 2 =2 Sara ro aT ~—|wrs00230 [screw ase 2 218) C__[sre7aa_[ansv76129-1 | BRAKE COVER 1 FOR FN MODEL ONLY 219_| MSA10118 [SCREW Mex 1 [POR PN MODEL ONLY 220 ‘M8700007 [SPRING WASHER Me 4 /FOR FN MODEL ONLY [ 222 M7400006 RIVET 2, 49x48 4 FOR 2.5ton MODEL ONLY on ; 302 c 812472 |3H5Z67372-D [3F UPPER HOOK 1 303~305 [303] p | srora2 |sasp2aaz0-7| ni LATCH 1 309 c 812476 | 4A1F64786-2| 28F HOOK PIN 1 __ oir] [aziaa [onesiaea= [2s Dist, cova i ohio) aac Eta GA443230-2 | SBHPF CHAIN HANGER 2 330] C | 812511 [1H5z09124-B| aF LONER HOOK ASSY 1 333 M1130021 BOLT M8x25 4 _ 343 c 812587 | 4H5Z69200-B] 3F SHEAVE 1 WITH BALL BEARING 344 c 812482 | 3HsF64808-1| 3F SHEAVE COVER oo 349 c 812481 | 4A5N68026-1] 3F SB COVER. TT —29-pant «| peavive «| pant wawe — [quantity] REMARKS 3 [earess [oiriie7 [TRUST EARRING SHOT] 7 co [arzaTe [sasdersra-e | sF Lowe WOOK Toe D aaspaaTes=1 [ATER D i “D 4A4V73724-1 [HOOK SPRING 1 B wiszad 77-1 [HOOK BOLT i LLL FF i B LINK CHAIN (106) 1 [ev 2s05 | SaaTooTaTAAl SF LIMIT SPRING z M5410084 ‘SCREW M4X20 2 = oases toheaanes-2 parr TANCE PW i 5 e1z46e | 4A2K67971-1] F REATNER i B 812409 | 4M4936578-3| U-NUT M4 2 _ Tre TH cuass| pant a] onawine «| part ame — quantity] REMARKS SOT ewer moar aT al a UPPER TOOK SET] [oes S0s[c[ei2se7 | auszers72- | SF UPPER ROOR 1 Tsoxss sos] c 870737 | 4A3P24420-9| BH LATCH i 1 a 504 B 839091 [GA140369-1 | BHPS HOOK SPRIN 1 | | iiescoas7 [SPRING PIN arEsAT_[ 1 508 c 812488 |2H1V24706-A| SF UPPBR HANGER A 1 509 c 12506] B/ SF UPPER HANGER B a sro] C [850081 [Gaauav1s-7 [COLLAR z Sir} e— wir ase feat FowonT-1 [SF Wook PIN i ae c 839666 |Gas43982-2 | STUD BOLT ae 7 ao hwer00012 [SPRING WAS a [site itai10008 [NOT sive 4 = S18 wairsoo71 [son Mi ETOS i 520 Cc ‘812491 [4A2K15539-9| COLLAR 127x54 = 521 Mev00010 [SPRING WASHER 1 522 M4110004 ‘NUT M12 _ 1 525 M7900101 | SCREW M5x12 2 [s27 c 812489 | 4A1F68030-1| 5F SUSPENSION PIN. 1 s30| Cc 812592 | $Z6W69013-C| SF SHFAVE PIN B 1 WITH STOPPERS AND SCREWS: sar] c | 612567 |sitsz69200-8| 5F sHEAVE i Hivini gate weanixe | [saat ce [asorss|Gasiors0-7 | WASHER z 535 Z 812494 [15209126 -Al 5F LOWER HOOK ASS”Y 1 536 hairs0023 — [HOUT We~3s — 537 M8 700008 SPRING WASHER M8 4 - sae 0 [812186 [atsreszea-a] $F SHaPr STOPPER 2 [safc] [oaseszsi-2 | solipr suSeeNson PIN[ a z [see hes00082 —[ SPLIT PIN #=35 z 548 ex00088 SPLIT PIN tvs A aTrew TM) cuass| part a] peawinc «| PART Name | quaNTiTy REMARKS © _[s12075 |Gaaas06-6 | 58H HANGER PIN) TI ¢ GAs432324 | 28HPF COLLAR A 2 c IGA443230-2 | 5BH HANGER 2 ¢_|e12389 [2s 24705-5| sF LOWER HANGER 7 ¢_[ #12591 [4a1reso2s~4] 5F SHPAVE SHAFT 1 ¢__[ 012587 [4is760200-8] 37 SHEAVE 1 [WIT BALL. REARING C_[e124e2 [sisreeeoe-1| 97 SHEAVE COVER z D GAs11292-6 | CaP, PLATE 1 Mz400006 [RIVET 2.4908 a c 4Maio4775-7) NUT M39 i — | 812167 [4A5NG4774-1| s8SB COVER 1 2 Li171208 | THRUST BEARING Sim06| 1 4Me402540-7| SPRING PIN 6x60AW [1 B__| Sresi [auszera7s-c | 38 LOWER HOOK 1 © [813028 _[szewper72-e [LATCH EASY 1 [sessea D aASPA2754-1 | LATCH 1 D GAWTSTEI—1 | WOOK SPRING t D ‘aMs2Az 757-1 | HOOK BOLT 1 Cf as1008 [amesoss66—8 [0 NUT Mo 1 3 I LINK CHAIN (910) 1 | “¢ [812505 |saaTb9747-1[ 5F LIMIT SPRING 1 _ B__[812409 [4a9ae576-3 | U-NUT Ma 2 B__|[812468 |4azke70971-1| F RETAINER i I c __|6a403225-« [2BHPF HANGER PIN H 5410084 | SCREW Max20 2 377 | | 812400 |GA%27687-A | 5F HANGER alecmniea 578 17900333 [BOLT aMexd0 2 579 D 4A5102664~2| SF SHEAVE PIN STOPPER | 2 380 7900113 [SCREW Mext2 42,2.5F » FN AND COMMON BODY OF 3,5F - FNFOOKS FOR 3, 5F + FN
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