KITO ER2 Series Installation instructions

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 ER2
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 are required operations for regular inspection and repair.
Carry out disassembly/reassembly properly in accordance with these manuals.
Safety precaution
AS-ER2ZZZ-MGE-00
ER2 Series Electric Chain Hoist (125kg to 5t)
Disassembly and Reassembly Manual

2
 Disassembly and reassembly (general)
Safety precautionDisassembly and reassembly (general)
Safety precaution
Prohibited
Prohibited
Prohibited
Prohibited
Prohibited
Prohibited
Mandatory
Mandatory
• Do not use gear oil or grease in areas near a fire or spark.
Failure to follow this instruction may result in fire or severe injury arising from ignition.
• Carry out the installation or removal work 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 specified tightening torques.
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 sever injury.
•Do not use unauthorized parts for KITO 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 and friction clutch with mechanical brake.
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 floor and perform them on the
workbench.
Failure to follow this instruction may result in death or severe injury.
Danger
Mandatory
Mandatory

3
 Before disassembly and reassembly
Safety precaution Before disassembly and reassembly
Mandatory
Mandatory
Mandatory
•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 specified 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.
• When setting the plate in the gear case, be careful so that your finger won't get caught.
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 specification and main body size.
Refer to page 48.)
• Packing
• Molybdenum disulfide lubricant Molytherm No.2: (specified brand: SUMICO LUBRICANT)
• Oil seal
• Snap ring
• Split pin
• O ring
Failure to follow this instruction may cause bodily injury or loss of property.
The disassembly and reassembly procedures are described based on the representative model. Note that
components may be slightly different for different capacities.
The specifications may be changed without prior notice and may be different from the actual products.
Note
Danger
Caution

4
Safety precaution ....................................................................................2
Table of Contents ....................................................................................4
Disassembly and assembly tool ..............................................................5
Name of parts..........................................................................................6
Disassembly procedure...........................................................................8
1 Removing the outer circumference parts......................................8
2 Removing the controller cover .....................................................9
3 Removing the top hook ..............................................................14
4 Disassembling the gear parts .....................................................15
5 Disassembling the load chain circumference ............................18
6 Disassembling the motor and electromagnetic brake ................19
7 Disassembling the body part ......................................................22
Reassembly procedure .........................................................................24
1 Assembling the body ..................................................................24
2 Assembling the motor and electromagnetic brake .....................27
3 Connecting the motor and body..................................................31
4 Installing the load chain ..............................................................32
5 Assembling the gear parts..........................................................34
6 Installing the top hook.................................................................37
7 Assembling the controller cover..................................................39
8 Installing the bottom hook (if removed from the chain)...............46
9 Oil lling ......................................................................................48
10 Operation check, etc.................................................................49
Table of Contents
Table of Contents

5
For disassembly and reassembly, prepare the following tools.
No. Tool name Application Icon
1Wrench
10mm / 13mm / 17mm / 19mm Bolts and nuts
2Hexagon wrench
4mm / 5mm / 6mm / 8mm / 10mm Socket bolts
3 Snap ring pliers S (Large) (Small) Snap rings (shaft)
4 Snap ring pliers R Snap rings (hole)
5 Socket wrench 10mm Bottom yokes
6Combination pliers Split pins
7Adjustable wrench
8Plastic hammer
9Screwdrivers (+)(-)
10 Puller Bearing, fan, brake, hub
11 Thickness gauge
12 Torque wrench/nut runner
13 Plier Set pin
●Use the following types of grease.
• JIS K2220 Grease type 1 No.2 for Roller shaft bearing
• Molybdenum disulfide lubricant Molytherm No.2 (Specified brand: SUMICO LUBRICANT)
●Helpful tools
• Remover: Prepare a remover for bearings (for inner race & outer race) and one for oil seal for precise operation.
• Preparing two wooden blocks (used as sleepers) and wire for guiding lead wires will be helpful.
Disassembly and assembly tools
Disassembly and assembly tools
Torque

6
Name of parts
Name of parts
Load sheave
Pinion
Rotor
Motor Frame with Stator
Key B
Body
Gear case
Friction clutch Load gear
Top hook
Electromagnetic brake
Brake cover
Fan
Fan cover
Chain Guide A
Chain Guide B
Hub spring
Packing M
Packing B
V ring
Shaft clip
Cushion rubber
Bottom yoke
Bottom hook
Motor shaft
Plate A
(for Top pin)
Oil seal
Controller cover
Packing G
Bearing holder
Top pin
Limit lever pin
Limit lever spring
Limit lever
The structure and names of parts in the
controller cover are shown on the next
page for each model.

7
Name of parts
Single speed type / Dual speed pole change type
Dual speed inverter type (Basic main body B/C type)
Dual speed inverter type (Basic main body D/E/F type)
Inverter
Controller cover
Plate
Limit switch
Packing C
Braking resistor
Name plate
Resistor cover
Interface board
Controller cover
Plate
Limit switch
Packing C
Inverter
Controller cover
Braking resistor
Name plate
Plate
Limit switch Resistor cover
Interface board
Packing C

8
Danger
(1) Remove the protection wire from
the main body, and remove the
push button cord complete set with
plug 8P.
Removing the outer circumference parts
1
(2) Remove the chain container from the main
body.
(2) Remove the power supply cable
assembly with plug 4P and cable
support arm from the main body.
•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 floor and perform the disassembly on the workbench.
Socket
bolt
U nut
Container spring
Chain
container
The overall disassembly procedure is shown below. Perform disassembly of only necessary parts.
Protection
wire
Cable support
Remove the push button
cord before loosening it.
Turn the coupling
counter-clockwise
and pull out.
1
Coupling screw
2
Disassembly procedure
Disassembly procedureRemoving the outer circumference parts
Prohibited
<Plug connection>
Cable Packing
Connector Socket holder
Holder A
Holder A
Holder C (upper side)
Holder C (lower side)
1
2
<Direct connection>
(1) Turn Holder A and remove it from
Holder C.
• Do not pull the cable at this time, as it is still
attached to the inside of the main body.
• Remove the controller cover, disconnect the
connector to which the cable is connected, and
then pull the cable out.

9
(3) When disassembling the gear part, remove
the oil plug (for waste oil hole) and plug
packing 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 or clutch.
Body
Oil plug
(for waste oil hole)
Oil plug
(for oil check window)
Gear case
Oil plug B (for oilhole)
Removing the controller cover
2
(1) Loosen the 4 socket bolts and open the
controller cover.
• If it is difcult to open, hammer the cover side gently with a
plastic hammer, as shown to the right.
(2) Remove the socket bolt (gear case side)
securing the cover belt, and remove the
controller cover from the gear case.
• The controller cover can be removed with the cover belt
attached.
(3) Remove the lead wire and connector
between the panel plate and main body,
and remove the panel plate.
• Loosen the 3 setscrews, and turn the panel plate a little
according to the shape of the fulcrum pin to remove it.
• Make a note of the locations of the lead wire connections
that will be referred to upon reassembly.
•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.
Remove the lead
wire in advance.
Plate screw
Fulcrum pin Panel plate
Controller cover
Socket bolt
(gear case side)
Cover belt
Socket bolt
Controller cover
(To be continued)
Disassembly procedure Removing the controller cover
Single speed type / Dual speed pole change type
Mandatory
Caution

10
(4) Remove the limit switch as required.
• Remove 4 lead wires (connectors) of the limit switch rst.
• Loosen the 3 socket bolts to remove the limit switch
(replace the O ring attached to the shaft with a new part
upon reassembly).
• Be careful when removing the limit switch because it may
be damaged if handled in a wrong way. Socket bolt
Limit switch
O ring
Disassembly procedure (continued)
Dual speed inverter type (Basic main body B/C type)
Socket bolt
Controller cover
Toothed lock washer
(1) Loosen the 4 socket bolts and open the
controller cover.
• If it is difcult to open, hit the cover side gently with a
plastic hammer, as shown to the right.
•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.
•The controller cover is very hot immediately after operation. Wait until about 30 minutes after
operation.
•Do not disassemble the limit switch.
Replace the limit switch as an
assembly. Disassembly causes a
defective operation, and a major
accident may occur.
Prohibited
Mandatory
Disassembly procedureRemoving the controller cover
Danger
Caution

11
Controller cover
Ground line
Braking resistor
lead wire
Pan-head
machine screw
Controller cover
Socket bolt
(gear case side)
Ground line
Cover belt
Plate screw
Fulcrum pin Plate
(2) Remove the connector and ground line
connected to the controller cover.
• To remove the ground line, loosen the pan-head machine
screw of the plate side.
(3) Remove the socket bolt (gear case side)
securing the cover belt, and remove the
controller cover from the gear case.
• The controller cover can be removed with the cover belt
attached.
(4) Remove the lead wire and connector
between the plate, main body, and inverter,
and remove the plate.
• Loosen the 3 Plate screws, and turn the plate a little
according to the shape of the fulcrum pin to remove it.
• Make a note of the locations of the lead wire connections
that will be referred to upon reassembly.
(To be continued)
Disassembly procedure Removing the controller cover

12
Disassembly procedure (continued)
Dual speed inverter type (Basic main body D/E/F type)
Socket bolt
Limit switch
O ring
Controller cover
Socket bolt
Toothed lock washer
Controller cover
Ground line
Pan-head
machine screw
Braking resistor
lead wire
(5) Remove the limit switch as required.
• Remove the connector of the limit switch rst.
• Remove it carefully by holding the connector of the limit
switch side.
• Loosen the 3 socket bolts to remove the limit switch
(replace the O ring attached to the shaft with a new part
upon reassembly).
• Be careful when removing the limit switch because it may
be damaged if handled in a wrong way.
•Do not disassemble the limit switch.
Replace the limit switch as an assembly. Disassembly causes a defective operation, and a
major accident may occur.
(1) Loosen the 4 socket bolts and open the
controller cover.
• If it is difcult to open, hit the cover side gently with a
plastic hammer, as shown to the right.
•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.
•The controller cover is very hot immediately after operation. Wait until about 30 minutes after
operation.
(2) Remove the connector and ground line
connected to the controller cover.
Prohibited
Mandatory
Disassembly procedureRemoving the controller cover
Danger
Caution

13
Controller cover
Socket bolt
(gear case side)
Ground line
Cover belt
Remove the lead
wire in advance
Plate screw
Plate
Pan-head
machine screw
Inverter
Socket bolt
Limit switch
O ring
(3) Remove the socket bolt (gear case side)
securing the cover belt, and remove the
controller cover from the gear case.
• The controller cover can be removed with the cover belt
attached.
(4) Remove the lead wire and connector
between the plate, main body, and inverter,
and remove the plate and inverter.
• Loosen the 3 Plate screws to remove the plate.
• Loosen the 4 pan-head machine screws of the inverter to
remove it.
• Make a note of the locations of the lead wire connections
that will be referred to upon reassembly.
(5) Remove the limit switch as required.
• Remove the connector of the limit switch rst.
• Remove it carefully by holding the connector of the limit
switch side.
• Loosen the 3 socket bolts to remove the limit switch
(replace the O ring attached to the shaft with a new part
upon reassembly).
• Be careful when removing the limit switch because it may
be damaged if handled in a wrong way.
•Do not disassemble the limit switch.
Replace the limit switch as an assembly. Disassembly causes a defective operation, and a
major accident may occur.
Prohibited
(To be continued)
Disassembly procedure Removing the controller cover
Danger

14
Removing the top hook
Remove the top hook first to make it easier to disassemble other parts.
3
(1) Loosen the socket bolt to remove the Plate
A (for Top pin).
(2) Remove the shaft clip in the opposite side.
• Pull up the shaft clip to remove.
• If it is difcult to remove, use the longnose pliers to open
the presser part and slide it upward.
(3) Remove the top pin, and then top hook.
Removing the top hook (Basic main bodies B,
C, D, and E)
Top hook or
Suspender
Socket bolt
Plate A
(for Top pin)
Top pin
Shaft clip Presser
part
Disassembly procedure (continued)
Removing the top hook (Basic main
body F)
• For the double chain type, remove the
load chain rst.
1. Pull out the split pin securing the slotted nut of
the chain pin, and remove the slotted nut.
2. Loosen the chain pin to remove the load chain.
1. Loosen the 2 socket bolts to remove the Plate A
(for Top pin).
2. Loosen the 2 pan-head machine screws to remove
the Plate A (for xing shaft).
3. Pull out Top pin and Fixing shaft.
• If it is difcult to pull out smoothly, remove
Stator on the opposite side, remove Shaft
plug, and use a proper jig to pull out Top pin,
hammering with a Plastic hammer.
• For disassembly of the stator, refer to page
19.
4. Remove the 2 O rings each from the top pin and
Fixing shaft.
5. Remove the hook or Connection yoke.
Load chain
Chain pin
Split pin
Slotted nut
Fixing shaft
plug
Plate A
(for Top pin)
Spring lock
washer
Socket bolt
Plate A (for fixing shaft)
Pan-head machine screw
Top pin
Fixing shaft
O ring
Stator
O ring
Top hook Top hook
(for the double chain type)
Top pin plug
Disassembly procedureRemoving the top hook

15
(2) Loosen the 4 socket bolts (5 for F type).
Hammer the gear case gently with a plastic
hammer to remove it.
• Remove it carefully not to pull the lead wire from the motor
or brake.
• Note that the gear case may come off with the friction
clutch attached to it.
(3) Remove Packing G and set pin.
• Be careful not to scratch the gear case junction face.
• For Friction clutch with mechanical brake specication,
remove Spacer M.
Disassembling the gear parts
4
(1) Remove the friction plug from the gear case
as required.
• For the friction clutch with mechanical brake ("friction
clutch with mechanical brake" hereafter) specication, this
operation is not required.
Friction plug
Slot for removal
Socket bolt
Packing G
Body
Set pin
Another one
exists in the
opposite side,
on the diagonal line.
(To be continued)
Disassembly procedure Disassembling the gear parts
Spacer M
Packing G
Set pins (two locations)
Another one exists in the opposite side,
on the diagonal line.

16
•Do not disassemble the friction clutch or friction clutch with mechanical brake.
Failure to follow this instruction may result in death or severe injury due to a falling load.
Double reduction
• The gear conguration as shown to the right is the double
reduction specication. Perform disassembly in the
following steps.
(4) Remove the wave washer and friction clutch
from the body.
• For the friction clutch with mechanical brake specication,
release the pawl from the ratchet disc to remove the
friction clutch with mechanical brake.
(There is no wave washer.)
Friction clutch
Wave washer
Snap ring
Load gear
Release
Friction clutch with
mechanical brake
(5) Remove the snap ring, and remove the load
gear.
Friction clutch with mechanical brake specication (option)
(6) Remove the snap ring, and remove the pawl spring and pawl from the pawl shaft.
Pawl shaft
Pawl spring
Snap ring
Pawl
•The pawl shaft is fixed to the body with
pawl shaft washer and screw lock. Do
not remove it.
Failure to follow this instruction may
cause the pawl shaft to come off and
result in death or severe injury due to a
dropped load.
Disassembly procedure (continued)
Prohibited
Prohibited
Disassembly procedureDisassembling the gear parts
Danger
Danger

17
Triple reduction
• The gear conguration with Gear B built in as shown
to the right is the triple reduction specication. Perform
disassembly in the following steps.
(4) Remove Gear B from the bearing of the
gear plate.
(5) Remove the set spring and friction clutch
from the body.
• For the friction clutch with mechanical brake specication,
release the pawl from the ratchet disc to remove the
friction clutch with mechanical brake.
(There is no set spring.)
(6) Loosen the 3 socket bolts, and remove the
gear plate from the body.
Gear B
(7) Remove the snap ring, and remove the load
gear.
Friction clutch
Wave washer
Snap ring
Gear holder
plate
Gear B
Friction clutch with
mechanical brake Release
Load gear
Friction clutch with mechanical brake specication (option)
(8) Remove the snap ring, and remove the pawl spring and pawl from the pawl shaft.
Pawl shaft
Pawl spring
Snap ring
Pawl
•The pawl shaft is fixed to the body with
pawl shaft washer and screw lock. Do
not remove it.
If you do, the pawl shaft will come off,
and a major accident such as death
or serious injury may occur due to a
dropped load.
Prohibited
(To be continued)
Disassembly procedure Disassembling the gear parts
Danger

18
(3) Remove the limit lever.
• Remove the limit lever pin, limit lever spring, and then limit
lever.
(4) Loosen the 4 socket bolts, and remove
Chain Guide A from the body.
• Remove the guide roller and roller pin.
(Basic main bodies B and C are not provided with Guide
roller.)
• Be careful not to lose the roller pin of the guide roller
during operation.
Limit lever pin
Limit lever
spring
Limit lever
Chain Guide A
Socket bolt
Guide roller
Roller
pin
Disassembling the load chain circumference
5
(1) Remove the stopper and cushion rubber
from the load chain (no load side).
• For the double chain type, also remove the stopper of the
load side.
(2) Remove the load chain from the body to the
load side.
• Remove the bottom hook as required.
Chain Guide A
Stopper
Cushion rubber
(Remove it in advance.)
Socket bolt
Stopper
Cushion rubber
Disassembly procedure (continued)
Disassembly procedureDisassembling the load chain circumference

19
(1) Loosen the 4 socket bolts, and remove the
fan cover.
Disassembling the motor and electromagnetic brake
6
Socket bolt
Fan cover
(3) Insert the "pawl" part of the puller to the
outer circumference bottom of the fan to
remove the fan.
• Insert it as close to the blade as possible. Be careful not to
damage the fan.
• Use a three-pawl puller for safer operation.
(4) Remove the set pin.
Fan
Puller
Blade
(Remove it
with the
puller.)
Set pin
(2) Remove the snap ring. Snap ring
Fan
Disassembly procedure Disassembling the motor and electromagnetic brake
(To be continued)

20
(5) Remove the brake cover.
• If it is difcult to remove, hammer it gently with a plastic
hammer to remove.
• Be careful not to hammer it too much to cause
deformation.
(6) Remove the brake wiring.
• Hold the male and female bullet terminals to remove it.
• Be careful not to pull the lead wire causing damage in the
connection with the bullet terminal.
(7) Remove the socket bolt (with spring
washer), and remove the brake.
• Make a note of the installation position (lead wire position)
of the electromagnetic brake for easy reassembly.
• Do not disassemble the electromagnetic brake.
Failure to follow this instruction may cause death or sever injury due to a falling load.
Bolts (x3)
Brake
Remove the bullet
terminal in advance.
Make a note of this position.
(8) Check the V ring for any abnormality.
• If the V ring is worn, check for dust entering to the brake.
Disassembly procedure (continued)
Prohibited
Disassembly procedureDisassembling the motor and electromagnetic brake
Danger