KITO CX003 Installation instructions

AS-CX1ZZZ-MGE-00
/005

2
Table of Contents
Safety Precautions................................................................................. 3
Disassembly/reassembly tools and Lubricant................................................. 5
Before Disassembly/reassembly ................................................................ 5
Part Name........................................................................................... 6
Disassembly Procedure........................................................................... 7
Disassembly of Brake ................................................................................. 7
Removal of the Load Chain ........................................................................ 8
Disassembly of Gear................................................................................... 9
Disassembly of Latch................................................................................ 10
Assembly Procedure ............................................................................. 11
Assembly of Gear ..................................................................................... 11
Assembly of Load Chain........................................................................... 13
Assembly of Brake.................................................................................... 14
Bottom Hook Set ...................................................................................... 17
Assembly of Latch .................................................................................... 17
Preoperational Check ............................................................................ 18

3
Person to perform disassembly/reassembly
Disassembly/reassembly shall be performed by a competent person (a person duly authorized by the company
as having expertise on the structure and device of Chain Hoist, or with expertise and appropriate understanding
of the Periodic Inspection Manual and Disassembly/reassembly Manual), or consult with KITO or your dealer.
Disassembly/reassembly in general
This Disassembly/reassembly Manual for Chain Hoist includes important contents to prevent injury to any person
performing disassembly/reassembly, users, other persons and damage to property, and to disassemble/reassemble
the Chain Hoist safely and correctly.
Before performing disassembly/reassembly, be sure to read and follow the Owner’s Manual of Chain Hoist Model
CX003/005 (separate document) since its contents are also important for disassembly/reassembly.
Disassembly/reassembly of Chain Hoist is essential for inspection and repair. Refer to the separate Periodic
Inspection Manual and Troubleshooting to perform disassembly/reassembly correctly.
Safety Precautions
Only competent persons must disassemble/reassemble the Chain Hoist.
Disassembly/reassembly by anyone other than competent persons may result in death or severe injury.
Do not adjust or disassemble the Over Load Limiter (OLL *).
Adjustment or disassembly of OLL may result in death or severe injury.
* A device to prevent an excessive overload, built in Hand Wheel Assembly.
Do not use parts beyond their discard limit or criteria and unauthorized parts for the KITO Chain
Hoist Model CX003/005.
Even if the part is an authorized part for KITO Chain Hoist, it may not be used for a different model.
Use parts correctly in accordance with the Disassembly/reassembly Manual.
Failure to do so may result in death or severe injury.
Do not disassemble/reassemble the Chain Hoist subject to a load.
When disassembling/reassembling a Chain Hoist, place it on a floor and disassemble/reassemble it.
Disassembly/reassembly of a Chain Hoist subject to a load may result in death or severe injury.
Do not lubricate the Friction Plate.
The Friction Plate is of the dry type.
Lubricating the Friction Plate may result in death or severe injury due to insufficient braking.
Prohibited
Prohibited
Prohibited
Prohibited
Do not use grease or oil in areas near a fire or spark.
Failure to do so may result in ignition.
Prohibited
Do not cut, extend or weld the Load Chain.
Failure to do so may result in death or severe injury.
Prohibited
Mandatory

4
When assembling, follow the instructions below.
Failure to follow these instructions may result in injury due to damage to the Chain Hoist or falling parts.
a. Before re-assembly, remove dust and oil on the part to be re-used.
b. When re-assembling, replace the grease with new one.
c. When re-assembling, replace the Snap Rings with new ones.
d. When re-assembling, replace the Split Pin with new one.
e. Fasten bolts and nuts to the specified tightening torque.
If the torque is lower than the specified value, it may cause the loosening of the screw and the Chain Hoist may
be broken.
If the torque is higher, the internal thread will be damaged and the Chain Hoist may be broken.
f. Insert the Snap Ring completely in the groove.
g. When assembling the gear unit, match the gear marks "O" and "V" on each of Gear #2.
h. Assemble the Load Chain (no load side) without torsion.
When assembling the Pawl, follow the instructions below.
Failure to do so may result in an inability to lift loads.
•Hook the Pawl Spring correctly onto the Pawl.
•Engage the Pawl and Ratchet Disc correctly.
When assembling the braking unit, clean the Friction Disc, Friction Plate, Ratchet Disc and Bushing.
Oil, dust or foreign objects on the braking surface may result in death or severe injury, due to insufficient braking.
Mandatory
When assembly is completed, perform a functional test (Preoperational check) to ensure that the
hoist is operating properly.
Failure to do so may result in death or severe injury.
Refer to the Preoperational Check in this manual for details.
Do not disassemble the Hand Wheel Assembly.
Failure to do so may result in death or severe injury.
Prohibited
Do not disassemble the Pawl Shaft.
Failure to do so may result in death or severe injury.
When the Pawl Shaft is loosened, replace the Body Assembly (including the Pawl Shaft).
Prohibited
Set Pawl Spring Assembly properly with two Pawl Springs fitted each other.
Improper combination may result in death or severe injury.
Set the lower part of the Pawl Spring Assembly securely under the step of the Pawl Shaft.
Failure to do so may result in death or severe injury.
Mandatory
Mandatory
Mandatory
Mandatory
Mandatory

5
Disassembly/reassembly tools and Lubricant
Before Disassembly/reassembly
Prepare the following tools and lubricant for disassembly/reassembly.
No. Tool Name Purpose Icon
1 Hexagon wrench 4mm For disassembly/reassembly of Frame A / B, Gear
Case, Wheel Cover
2 Shaft Snap Ring pliers For disassembly/reassembly of Pawl and Cam Guide
3 Hexagon wrench 2.5mm For disassembly/reassembly of End Pin
4 Hexagon wrench 3mm For disassembly/reassembly of Bottom Yoke and
Latch
5 Spanner 7mm, 8mm x 2 For disassembly/reassembly of Bottom Yoke and
Latch
6 Needle-nose pliers For Cam Guide
7Automotive wheel bearing gease
Type 1, Class 2 (JIS K 2220) For oil application except the following No. 8.
8Rust preventive oil Type 2, Class
1 (JIS K 2246) For oiling on the Pawl and Pawl Shaft
9Three Bond 1401, Loctite 241 or
242
For locking of the Set Screw and bolts for the Bottom
Yoke
10 Torque wrench For checking tightening force
- Read this manual thoroughly and perform disassembly/reassembly correctly.
- Consult with KITO when changing the lift.
•Replace the Snap Rings, Split Pin and Grease with fresh supplies when reassembling.
(illustrated in this manual with .)
•Prepare wooden blocks (2 pieces) to stabilize the Body of the Chain Hoist when disassembling/reassembling.
Only competent persons to disassemble/reassemble Chain Hoist.
Disassembly/reassembly by anyone other than a competent person may result in death or severe injury.
Do not use parts beyond their discard limit or criteria and unauthorized parts for the KITO Chain
Hoist Model CX003/005.
Even if the part is an authorized part for KITO Chain Hoist, it may not be used for a different model.
Use parts correctly in accordance with the Disassembly/reassembly Manual.
Failure to do so may result in death or severe injury.
Do not disassemble/reassemble a Chain Hoist subject to a load.
When disassembling/reassembling a Chain Hoist, place it on the floor and disassemble/reassemble it.
Disassembly/reassembly of a Chain Hoist subject to a load may result in death or severe injury.
When assembly is completed, perform a functional test (operational check) to confirm that the
Chain Hoist works correctly.
Failure to do so may result in death or severe injury. Refer to "Operational Check" in this manual for details.
Prohibited
Mandatory
Mandatory
Prohibited
NEW
Torque
Lock
Oil
Grease
3 mm
2.5 mm
4 mm

6
Part Name
Wheel Cover
Hand Chain
Friction Plate
Cam Guide
Hand Wheel Assembly
Ratchet Disc
Bushing
Snap Ring
Pawl
Pawl Spring (Assembly)
Top Hook
Top Hook
Set Latch Body Assembly
Top Pin
Load Sheeve
Frame B
Load Gear
Socket Head Cap Screw
Socket Head Cap
Screw
Conical Lock Washer
Spring Lock Washer
Pinion
Gear #2
Chain Guide
Load Chain
Bottom Yoke
Gear Case Assembly
Socket Head Cap
Screw
Conical Lock
Washer
Friction Disc
Hexagon Socket Set Screw
End Pin
Frame A
Bottom Hook Set
Snap Ring
Bottom Hook
Chain Stopper Link
Warning Tag CE
Latch
Split Pin
Slotted Nut
Chain Pin
Bottom Hook Bottom Hook Set
Hook Latch Asembly
Load Chain
CX005

7
(3) Remove two Friction Plates, Ratchet
Disc, Bushing and Friction Disc from
Pinion. Pinion
Friction Disc
Bushing
Ratchet Disc
Friction Plates
Disassembly Procedure
Disassembly of Brake
1
(2) Remove the Snap Ring and the Cam
Guide, using a tool with a small
tip, such as needle-nose pliers.
Turn the Hand Wheel Assembly
counterclockwise to remove it.
Hand Wheel Assembly
Cam Guide
Snap Ring
Socket Head
Cap Screw
Wheel Cover
Conical Lock Washer
Hand Chain 4 mm
Do not disassemble the Hand Wheel Assembly.
Failure to do so may result in death or severe injury.
Carefully remove the Snap Ring.
Failure to do so may result in injury.
(1) Remove three sets of Socket
Head Cap Screws and Conical
Lock Washers from Wheel Cover.
Remove the Cover and Hand Chain.

8
Removal of the Load Chain
2
(2) Turn the Pinion counterclockwise
and remove the load chain.
(1) Remove the Hexagon Socket Set
Screw and pull out End Pin.
When it is hard to pull out the End
Pin, lightly hit the side of the Gear
Case.
End Pin
Hexagon Socket
Set Screw
2.5 mm
Bottom Hook
Load chain
Pinion
(4) Remove the Snap Ring of the Pawl
Shaft and pull out the Pawl and two
Pawl Springs.
Pawl Spring (2 pcs)
Pawl Shaft
Pawl
Snap Ring
Do not disassemble the Pawl Shaft.
If it is loosened, replace the Body Assembly
(including the Pawl Shaft) with a new one.
Carefully remove the Snap Ring.
Failure to do so may result in injury.
Do not pull the Bottom Hook and Load Chain
excessively.
Failure to do so may entangle the Chain.
(Continued on the following page)

9
Disassembly Procedure (continued from the previous page)
(2) Pull out the Top Pin to remove the
Top Hook Set.
Top Pin
Top Hook Set
(1) Turn the Body as shown in the right
figure. Remove four sets of Socket
Head Cap Screws and Conical Lock
Washers, and then remove the Gear
Case Assembly.
Conical Lock Washer
Gear Case Assembly
Socket Head Cap
Screw
4 mm
Disassembly of Gear
3
(4) Remove two Socket Head Cap
Screws on the lower side, and then
remove the Chain Guide.
(3) Remove two pieces of Gear #2, Pinion and Load Gear.
Load Gear
Pinion
Gear #2
Socket Head Cap Screw
Spring Lock Washer
4 mm
Chain Guide
To facilitate disassembly, place the
hoist Body on wood blocks with
the pinion set between the blocks.
To facilitate disassembly, loosen two Socket Head Cap Screws on the upper side first.

10
Disassembly of the Latch
4
(2) Hold the Latch firmly and remove
the Socket Head Cap Screw from
the fixing hole.
(1) Loosen the Socket Head Cap
Screw fixing Latch and remove the
Hexagon Nut.
Hexagon Nut
Latch
Socket
Head Cap
Screw
3 mm 7 mm
LatchSocket
Head Cap
Screw
Lever Spring
(5) Remove the two Socket Head Cap Screws on the upper side, and then remove Frame B
and Load Sheave.
Socket Head Cap
Screw
Spring Lock Washer
Frame B
4 mm
Load Sheave
Frame A
(6) Remove Frame A on the opposite side.
Holding the Latch securely, remove the
Socket Head Cap Screw.
Failure to do so may mean the Lever Spring bounces
off to cause injury.

11
Assembly Procedure
Load Sheeve
Frame A
Pawl Shaft Body Assembly
Assembly of Gear
1
(1) Apply grease over the entire
circumference of the specified part
of the Load Sheave (arrow in the
figure).
Automotive wheel bearing grease
·Rated load 0.25t : 1.2g
·Rated load 0.5t : 1.5g
Grease
Load Sheave cross section
Whole circumference Whole circumference
Socket Head Cap
Screw
Spring Lock Washer
Frame B
4 mm
(2) Assemble Frame A into the Body
Assembly at the brake side (with
the Pawl Shaft), and then insert
the Load Sheave into the Body
Assembly from the Gear side with
the Load Sheave directed as shown
in the figure "Gear side of the
Body".
(3) Insert Frame B into the Body
Assembly from the Gear side
and fix the upper part of Frame B
temporarily with two sets of Spring
Lock Washers and Socket Head
Cap Screws (M5-25).
* Ensure that the Spring Lock Washers
are fastened to contact the Frame B.
Remove the grease, oil and dust on each part.
Frame A
(5 holes)
Frame B
(7 holes)
Gear side of the Body Assembly
Brake side of the Body Assembly
Gear side of the Body Assembly

12
(5) Insert two sets of Spring Lock
Washers and Socket Head Cap
Screws on the lower side of Frame
A/B and tighten temporarily them,
and then secure all the four screws
in order of ①, ②, ③ and ④ with
the specific torque.
 Ensurethat the Road Sheave
rotatessmoothly.
 Tighteningtorque:7to8N•m
(6) Attach the Load Gear to the Load
Sheave. Apply specified amount of
grease to the specified position of
the Pinion and insert the Pinion in
and out of the Load Sheave a few
times.
Automotive wheel bearing grease
·Rated load 0.25t :0.7g
·Rated load 0.5t :0.9g
Load Gear
Load Sheeve
Pinion
Grease
Gear #2
Socket Head Cap
Screw
Spring Lock Washer
4 mm
Torque
Grease
(7) Apply the grease to Gear #2, and
then assemble two of Gears #2 with
the "O" and "V" marks set as shown
in the bottom figure.
Automotive wheel bearing grease
·Rated load 0.25t :0.2g
·Rated load 0.5t :0.3g
(4) Align the projecting part of the Chain
Guide with the notch of the Body,
and assemble the Chain Guide to
the bottom of the Body Assembly.
Chain Guide
Protrution
and notch
(Continued on the following page)
Gear cross section
Pinion
Gear #2Gear #2

13
Assembly Procedure (continued from the previous page)
(2) Ensure that the Load Chain is not
twisted, kinked or entangled while
inserting the End Link of the no-load
side into the Body Assembly.
Shortening the no-load side chain
can facilitate checks for a twisted,
kinked or entangled link.
(8) Apply grease over the entire
circumference on the Gear #2, the
Load Gear and the Top Pin. Insert
the Top Pin into the hole of the
Body, with the Top Hook Set held as
shown in the right figure.
Automotive wheel bearing grease
Rated load Gear #2, Load gear Top pin
0.25 t 10 g 0.2 g
0.5 t 12 g 0.3 g
(1) Insert the End Link into the load-side
chain slit of the Chain Guide while
directing the welded part outward,
as shown in the right figure.
Next turn the Pinion clockwise until
the End Link comes out of the no-
load side sufficiently.
Assembly of Load Chain
2
(9) As shown in the right figure (check
the nameplate direction), attach
the Gear Case Assembly to the
Body and fix it temporarily with four
sets of Conical Lock Washers and
Socket Head Cap Screws (M5-15)
in the direction shown in the right
figure.
Afterward, secure all the four screws
in order of ①, ②, ③ and ④ with
the specific torque.
Tighteningtorque:7to8N•m
Conical Lock Washer
Gear Case Assembly
Socket Head Cap
Screw
4 mm
Torque
Top Pin
Top Hook Set
Grease
Bottom Hook
Load Chain
End Link
Pinion
Welded part
Welded part End Link
Load side No-load side

14
(1) As shown in the figure, assemble
two Pawl Springs to make Pawl
Spring Assembly. Attach the Pawl
Spring Assembly to the Pawl Shaft
and press the Pawl Spring Assembly
to the bottom of the Pawl Shaft step
in the correct direction, and then
apply rust preventive oil to the Pawl
Spring Assembly.
Rust preventive oil: one drop
Assembly of Brake
3
Pawl Spring
Pawl Spring
Assembly
Hook the arm of
Pawl Spring here.
Oil
(2) Apply rust preventive oil to the Pawl,
set it in the correct direction, and
then hook the Pawl to the arms of
the Pawl Spring.
(3) Insert the End Pin to fix the End Link
at the no-load side, and then apply
a thread locker to the Hexagon
Socket Set Screw and fix the End
Pin with the Socket Set Screw.
End Pin
Hexagon Socket
Set Screw
2.5 mm
Lock
Pawl Spring Assembly
Pawl (applied with oil)
Oil
(Continued on the following page)
Set Pawl Spring Assembly properly
with two Pawl Springs fitted each
other.
Improper combination may result in death or
severe injury.

15
Assembly Procedure (continued from the previous page)
(4) While holding the Pawl outward,
set the Friction Disc, Friction Plate,
Bushing, Ratchet Disc and Friction
Plate in this order, as shown in the
figure.
Ensure that the Ratchet Disc is
properly assembled, and that the
Pawl and Ratchet Disc engage
correctly.
Pawl Ratchet Disc
Pinion
Friction Disc
Bushing
Ratchet Disc
Friction Plates
Snap Ring
NEW
(3) Fix the Pawl with a new Snap Ring.
As shown in the figure, check that
the lower part of the Pawl Spring
comes under the step of the Pawl
Shaft and that the Snap Ring is
firmly installed into the groove of the
Pawl Shaft, and furthermore, that
the Snap Ring can rotate smoothly.
Pawl
Snap Ring
Pawl Shaft
Pawl Spring Assembly
Set the lower part of the Pawl Spring
Assembly securely under the step of
the Pawl Shaft.
Failure to do so may result in death or severe
injury.
•
Ensure that the braking surfaces of
the Friction Disc, Friction Plate and
Ratchet Disc are free of dust. If any is
present, wipe it clean.
•
After assembly check that the lower
part of the Pawl Spring Assembly is
inserted to the position under Pawl
Shaft step.
Failure to do so may result in death or
severe injury.

16
(6) Attach a Hand Chain around the Hand Wheel while directing its welded part outward,
place a Wheel Cover on it, and then fix it with three sets of Conical Lock Washers and
Socket Head Cap Screws (M5-30) with the specific torque in the direction shown in the
figure below.
 Tighteningtorque:7to8N•m
Socket Head
Cap Screw
Wheel Cover
Conical Lock Washer
4 mm
Torque
Hand
Chain
Welded
part
(5) Apply grease to the thread at the
center of the Hand Wheel Assembly,
up to the root of thread.
Attach a Hand Wheel Assembly
to the Friction Disc, and turn it
clockwise. (Assemble the Hand
Wheel Assembly turning until it
clicks.)
Set a Cam Guide to the center of
the gap of Hand Wheel. If the Cam
Guide cannot be inserted, press it
turning clockwise. Check that the
gaps between the Cam Guide and
the Hand Wheel Assembly are as
shown in the figure. Be sure to fix
with a new Snap Ring.
Automotive wheel bearing grease
·Rated load 0.25t :0.3g
·Rated load 0.5t :0.4g
Hand Wheel Assembly
Gap B Gap A
Cam Guide
Snap Ring
≧
Grease
Hand Wheel Assembly
Cam Guide
Snap Ring
NEW
(Continued on the following page)
Ensure that the braking surface of
Hand Wheel Assembly is free of dust. If
there is any, wipe it clean.
Failure to do so may result in death or severe
injury.

17
(1) Set the Load Chain to the bottom
hook assembly and insert the
Chain Pin to the hook assembly.
Tighten with the Slotted Nut, then
insert the Split Pin and bend it.
Assembly Procedure (continued from the previous page)
(2) Attach the other side of the Bottom
Yoke to the previously-assembled
Bottom Yoke, apply a thread locker
to the Socket Head Cap Screws,
and then fix the Bottom Yoke with
Hexagon Nuts and Spring Lock
Washers with the specific torque.
Eusure that the Bottom Hook
rotates lightly.
 Tighteningtorque:2.1to3.1N•m
(1) Set the Load Chain and Bottom
Hook to one side of the Bottom
Yoke.
Bottom Hook Set (without chain)
4
Bottom Yoke
Load Chain
Bottom Hook
Hexagon Nut
Socket Head Cap
Screw
Spring Lock Washer
Bottom Yoke
3 mm
Lock
Torque
7 mm
Assembly of Latch
5
(1) Align the Lever Spring with the hole
of the Hook for the Latch fitting
properly.
Bottom Hook Set
Chain Pin
Load Chain Slotted Nut
Split Pin
8 mm
8 mm
Lever Spring
For CX003
For CX005
Slotted Nut
Split Pin
How to bend the split pin
NEW

18
Preoperational Check
Before use, ensure you check the following when disassembly/reassembly is completed.
(1) Ensure that there is no missing part. If there is any, disassemble/reassemble the hoist again
correctly.
(2) Perform daily check. Refer to the Owner's Manual for details.
(3) Before performing the following operational test under the rated load, ensure to check that
the hoist has no defect when subject to no load.
Preoperational Test
When assembly is completed, check the
operation to confirm that the Chain Hoist
works correctly.
Failure to do so may result in death or severe
injury.
Item Method Discard limit or criteria Action
No load
test
Repeat lifting and
lowering a few times.
•The Chain Hoist should be operated
with a light pulling force.
•The Chain Hoist should have regular
click sounds of Pawl when lifting.
Disassemble the
Chain Hoist to verify
that the hoist is
assembled properly
and the components
are free of defects.
Rated load
test
Lift and lower the rated
load for 20 to 30cm.
Perform the items in
the "Basic function" of
Monthly Inspection.
•The Chain Hoist should have regular
click sounds of Pawl and run smoothly
when lifting.
•The sound should be at a constant level
with no irregular clicks.
•The Chain Hoist should make no sound
when lowering.
•It should be free of a heavy pulling
force.
•It should be free of slip in braking.
(2) Align the Latch with the hole of the
hook for the Latch fitting, and fasten
it with a Socket Head Cap Screw
and a Hexagon Nut.
Ensure that the Latch can move
smoothly.
Hexagon Nut
Latch
Socket Head
Cap Screw
3 mm
7 mm

19
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