KITO EQ series User manual

1
Persons performing 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 the electric chain hoist) or consult KITO.
This Disassembly and Reassembly Manual includes contents to prevent injury to any person performing
disassembly and reassembly, users, and other persons and damage to property, and to disassemble/
reassemble the electric chain hoist safely and correctly.
Before performing disassembly/reassembly, be sure to read and follow this manual as well as the EQ
Series Electric Chain Hoist Owner’s Manual (separate document) since its contents are also important for
disassembly/reassembly.
Disassembly/reassembly of the electric chain hoist is required operations for regular inspection and repair.
Carry out disassembly/reassembly properly in accordance with these manuals.
Safety precaution
EQ Series Electric Chain Hoist (125kg to 1t)
Disassembly and Reassembly Manual
AS No.EQ-1209-MG-01

2
DANGER
■Disassembly and reassembly (general)
Safety Precaution
Safety Precaution
Prohibited
Prohibited
Prohibited
Prohibited
Prohibited
Prohibited
Mandatory
Mandatory
Mandatory
Mandatory
• Do not use gear oil or grease in areas near a re or spark.
Failure to follow this instruction may result in re or severe injury arising from ignition.
•
Carry out the installation or removal work of the electric chain hoist after securing the stable foothold.
Failure to follow this instruction may result in death or severe injury due to falling or dropping.
• Do not cut, extend, or weld the load chain.
Failure to follow this instruction may result in death or severe injury.
• Carry out the installation or removal work of the electric chain hoist after shutting down
the power distribution panel.
Failure to follow this instruction may result in death or severe injury due to an electric shock.
• When reassembly is complete, perform a function check (preoperational check) to make sure
it operates properly.
Failure to follow this instruction may result in death or severe injury.
For details, refer to ‘Periodic Inspection’ in the separated Owner’s Manual.
• Tighten the bolts and nuts with the specied tightening torque.
Failure to follow this instruction may result in death or severe injury.
• Only competent persons must disassemble/reassemble the electric chain hoist.
Disassembly/reassembly by anyone other than competent persons may result in death or severe injury.
• Do not use unauthorized parts for EQ series electric chain hoist.
Even if the part is an authorized part, it may not be used for a different model.
Use parts correctly in accordance with this manual.
Failure to follow this instruction may result in death or severe injury.
• Do not perform disassembly/reassembly during conduction.
Failure to follow this instruction may result in death or severe injury due to an electric shock or
unexpected operation.
• Do not adjust or disassemble the friction clutch.
Failure to follow this instruction may result in death or severe injury.
If adjustment and disassembly are required, contact KITO.
Prohibited
• Do not disassemble/reassemble the electric chain hoist subject to a load.
When disassembling/reassembling an electric chain hoist, place it on a oor and perform them on the workbench.
Failure to follow this instruction may result in death or severe injury.

3
CAUTION
■Before disassembly and reassembly
Safety Precaution
Mandatory
Mandatory
Mandatory
The disassembly and reassembly procedures are described based on the representative model.
Note that components may be slightly different for different capacities.
The specications may be changed without prior notice and may be different from the actual products.
• Only competent persons with expertise and experience must disassemble/reassemble the electric
chain hoist. Alternately, contact the nearest distributor or KITO. Disassembling/reassembling
improperly causes death or severe injury.
Perform disassembly and reassembly in correct procedures as described in the manual.•
Do not extend the load chain.•
Before reassembling the parts such as gear, clean and remove oil and dust on them.•
Especially when a plastic hammer is used, clean them thoroughly so that no chip of the
hammer remains inside.
Prepare anti-loosening (screw lock) for bolts. Apply it to the specied locations.•
Use only authorized parts for replacement.•
Failure to follow these instructions may result in death or severe injury.
• When reassembling, follow the instructions below.
Before reassembly, remove dust and oil on the part to be reused.•
Insert snap rings completely in the groove.•
Assemble the load chain without torsion.•
Failure to follow these instructions may cause bodily injury or loss of property arising from damaged product
or dropped parts.
• When reassembling, replace the following parts with new ones.
Gear oil (type and required amount of oil vary depending on the specication and main body size. •
Refer to page 24.)
Packing•
Grease•
Oil seal•
Snap ring•
O ring•
Liquid gasket•
Failure to follow these instructions may cause bodily injury or loss of property.
NOTE
DANGER

4
Safety Precaution ....................................................................................2
Table of Contents.....................................................................................4
Disassembly and Reassembly Tools.......................................................5
Name of Parts..........................................................................................6
Disassembly Procedure.........................................................................10
1. Removing the outer circumference parts ...................................10
2. Disconnecting the power supply cable and push button cord ....10
3. Removing the internal electrical components............................. 11
4. Disassembling the gear parts.....................................................11
5. Disassembling the load chain circumference.............................12
6. Disassembling the load sheave..................................................13
7. Removing the suspension eye ...................................................13
8. Removing the chain guide..........................................................13
9. Removing the braking resistor....................................................13
10. Disassembling the motor and brake.........................................14
Reassembly Procedure .........................................................................15
1. Assembling
the rotor (when disassembled to the pull rotor) ........15
2. Assembling the stator and rotor..................................................15
3. Assembling the suspension eye .................................................17
4. Assembling the braking resistor and fan cover...........................17
5. Assembling the chain guide assembly .......................................17
6. Assembling the load sheave.......................................................18
7. Installing the load chain..............................................................19
8. Assembling the gear parts..........................................................20
9. Assembling the internal electrical components ..........................21
10. Connecting the power supply cable and push button cord .....22
11. Installing the bottom hook (if removed from the chain).............23
12. Oil lling....................................................................................24
13. Operation check, etc. ...............................................................24
Table of Contents
Table of Contents

5
For disassembly and reassembly, prepare the following tools.
No. Tool name Application Icon
1Wrench
13mm Bolts and nuts
2Hexagon wrench
4mm/5mm/6mm/8mm Socket bolts
3Snap ring pliers S
(Large) (Small) Snap rings (shaft)
4Snap ring pliers R Snap rings (hole)
5Socket wrench 10mm Bottom yokes
6Adjustable wrench Bolts and nuts
7Plastic hammer
8Screwdrivers (+) (-) Screws
9Puller Bearings and fan
10 Vices (2 pcs.) Pull rotor
11 Torque wrench/nut runner
12 Plier Set pin
●Use the following types of grease.
• JIS K2220 Grease type 1 No. 2 for Roller shaft bearing
• Molybdenum disulde lubricant Molytherm No. 2 (Specied brand: SUMICO LUBRICANT)
●Use the following liquid gasket.
• Liquid gasket TB1121 (made by ThreeBond)
●Use the following screw lock.
• ThreeBond 1401 (made by ThreeBond) or its equivalent
●Helpful tools
• Remover: Prepare a remover for bearings (for inner race & outer race) and one for oil seal for precise operation.
• Preparing wooden block (used as sleepers) and wire for guiding lead wires will be helpful.
Disassembly and Reassembly Tools
Disassembly and Reassembly Tools
Torque

6
A16
A17
Name of Parts
A41
A42
A40
A44 A43
A46
A45
A47 A48
A49
A50 A51
A52 A53
A54
A55
A
A
A23 A19
A21
A18
A1
A2
A7
A3
A4
A8
A24
A25
A23
A19
A27
A28
A22
A23
A30
A37
A38 A39
A33
A34
A32
A31
A35 A36
A29
C
B
A26
A6
A5
A9
A10 A12
A11
A13
A14
A15
C
B
Block A
A20
Name of Parts

7
Figure # Part Number Part Name Remark
A1 001 Suspension eye
A2 121 Top pin
A3 033 Machine screw socket bolt For Top pin
A4 5501 Body with stator
A5 238 Ball bearing
A6 137 Set pin S
A7 820 Warning sticker HW
A8 960 Name plate load side E
A9 1223 Friction clutch complete set
A10 244 Oil seal
A11 241 Load sheave
A12 242 Ball bearing
A13 245 Oil seal
A14 243 Ball bearing
A15 207 Snap ring
A16 240 Load gear
A17 208 Snap ring
A18 187 Packing
A19 153 Cable holder
A20 5505 Braking resister assembly
A21 194 Machine screw with spring washer For Braking register
A22 151 Limit switch cord cover
A23 152 Machine screw with spring washer
For Limit switch cord cover, Cable holder
A24 331 Chain guide
A25 1060 Limit switch complete set
A26 333 Limit switch cover
A27 335 Machine screw
A28 165 Machine screw socket bolt For Chain guide
A29 110 Gear case
A30 239 Ball bearing
A31 133 Oil plug
A32 136 Plug packing
A33 810 Name plate OF
A34 815 Name plate SP
A35 167 Machine screw socket bolt For Gear case (shorter)
A36 162 Machine screw socket bolt For Gear case (longer)
A37 116 Packing G
A38 135 Oil plug B
A39 173 Eyebolt packing
A40 107 Fan cover
A41 164 Socket bolt For Fan cover
A42 225 Toothed lock washer For Fan cover
A43 108 Fan
A44 323 Snap ring
A45 106 Motor cover
A46 163 Machine screw socket bolt For Motor cover
A47 209 Ball bearing
A48 5212 Brake drum assembly
A49 214 Brake spring
A50 324 O ring
A51 318 Collar
A52 317 Thrust disc
A53 503 Pull rotor
A54 316 Coned disc spring
A55 5502 Motor shaft with rotor
Name of Parts

8
Block B
㻱㻽㻜㻜㻠㻵㻿
㻱㻽㻜㻜㻡㻵㻿
㻱㻽㻜㻝㻜㻵㻿
㻱㻽㻜㻜㻝㻵㻿
㻱㻽㻜㻜㻟㻵㻿
B28
B27
B22 B24
B23
B21
B25
B26
B38
B34
B30
B29
B13 B12
B14
B15
B18
B20
B19
B37 B1
B5
B3
B4
B6
B9
B8
B7
B36
B40
B11
B10
B16
B17
B12
B41
B33
B32
B31
B35
B39
Name of Parts

9
Figure # Part Number Part Name Remark
B1 2104 Controller cover assembly
B3 161 Socket bolt For Controller cover
B4 224 Toothed lock washer For Controller cover
B5 800 Name plate B
B6 935 Warning sticker E
B7 1571 Inverter assembly
B8 508 HBB board
B9 191 Machine screw with spring washer For Inverter
B10 1011 Bottom hook complete set
B11 002 Hook latch assembly
B12 874 NC load chain
B13 054 Limiting plate For EQ004IS, EQ005IS, EQ010IS
B14 051 Chain spring For EQ004IS, EQ005IS, EQ010IS
B15 055 Spring guide For EQ004IS, EQ005IS, EQ010IS
B16 041 Stopper
B17 1951 Lubricant tube assembly For Load chain
B18 401 Chain container P assembly
B19 166 Socket bolt For Chain container
B20 226 U nut For Chain container
B21 1521 Power supply cable 4C assembly
B22 521 Power supply cable 4C
B23 541 Cable support arm
B24 1542 Cable support 12 assembly
B25 569 Holder A
B26 574 Cable packing
B27 823 Name plate G
B28 542 Machine screw with spring washer For Cable support arm
B29 1557 3 push button cord 5C complete set
B30 557 Push button cord 5C
B31 1561 3 push button switch assembly
B32 565 Warning tag PB
B33 566 Tag holder
B34 569 Holder A
B35 574 Cable packing
B36 535 Cord support (wire stopper)
B37 536 Machine screw with spring washer For Cord support
B38 891 Holder B
B39 892 Holder packing
B40 893 Holder nut
B41 053 Cushion rubber For EQ001IS, EQ003IS
Name of Parts

10
CAUTION
Disassembly Procedure
DANGER
Remove the chain container(1) B18 from the
main body.
Removing the outer circumference parts
1
• Do not disassemble the electric chain hoist while it is being suspended.
Failure to follow this instruction may result in death or severe injury due to dropped parts.
Be sure to place the electric chain hoist on a oor and perform the disassembly on the workbench.
The overall disassembly procedure is shown below. Perform disassembly of only necessary parts.
Prohibited
• When opening the controller cover, support it with your hand and open it slowly and
carefully.
Failure to follow this instruction may cause the controller cover to hit the internal electrical
components, resulting in damage.
Mandatory
2
Disconnecting the power supply cable and push button cord
Remove the controller cover(1) B1 .
Loosen the 4 socket bolts
•B3
and remove the
controller cover.
When disassembling the gear part,(2)
remove the oil plug A31 (for waste oil hole)
and plug packing A32 from the bottom of
the gear case, and then remove gear oil.
Check stain and viscosity of the removed oil.
•
If any metal powder is discovered, perform a
•
careful inspection suspecting abnormal wear of
the gear.
Disassembly Procedure
B19
B18
B20
A38 A39 (for oil hole)
A31 A32 (for waste oil hole)