KITO RY 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 Wire rope 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 Wire rope hoist safely and correctly.
Disassembling and reassembling the rope hoist is an essential part of periodic inspections and repairs. Refer
to the "RY Series Wire Rope Hoist (10t) Owner's Manual" (separate document) and carry out the procedures
correctly.
Safety Precaution
AS-RYL100-MGE-01
RY Series Wire Rope Hoist (10t)
Disassembly and Reassembly Manual
Low Headroom Type:RYL

2
Safety Precautions
Safety Precautions
Improper use of the hoist may cause serious accidents resulting in death or severe injury such as drop of lifted
load.
Read this Disassembly and Reassembly Manual carefully before installation, operation and maintenance.
Use the product after understanding the product knowledge, safety information and precautions.
This Disassembly and Reassembly Manual classifies the safety information and precautions into three catego-
ries of "DANGER", "WARNING", and "CAUTION".
Also read the instruction manual of the device associated with the hoist (option, crane, etc.), and follow the de-
scribed contents.
Description of Signal Words
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in
death or severe injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or severe injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
Further, the event described in CAUTION may result in serious accident depending on the situation. All
of these items describe important matters. Please follow the instruction.
After reading, please keep this manual at hand for future use by the user.
Description of Safety Symbols
Prohibited
means "Prohibited" or "You must not do".
Prohibited action is shown in the circle or described near the circle with words and figures.
This Disassembly and Reassembly Manual uses as the general prohibition.
Mandatory
means "Mandatory Action" or "You must do".
Required action is shown in the circle or described near the circle with words and figures.
This Disassembly and Reassembly Manual uses as the general instruction.

3
Safety Precautions
■Disassembly and reassembly (general)
DANGER
Prohibited
• Only competent persons must disassemble/reassemble the rope hoist.
Disassembly/reassembly by anyone other than competent persons may result in death or sever injury.
Prohibited
• Do not use unauthorized parts for RY Series Wire Rope 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.
Prohibited
• Do not disassemble/reassemble the rope hoist while it is being suspended.
When disassembling/reassembling the rope hoist, place it on the floor and perform them on the
workbench.
Failure to follow this instruction may result in death or severe injury.
Prohibited
• 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.
Prohibited
• Do not use oil such as gear grease and lubricating oil in areas near a fire or spark.
Failure to follow this instruction may result in fire or severe injury arising from ignition.
Mandatory
• Carry out the installation or removal work of the rope hoist after securing the stable
foothold.
Failure to follow this instruction may result in death or severe injury due to falling or dropping.
Mandatory
• Carry out the installation or removal work of the rope 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.
Mandatory
• 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.
Mandatory
• Tighten the bolts and nuts with the specified tightening torques.
Failure to follow this instruction may result in death or severe injury.

4
Safety Precautions
CAUTION
Mandatory
• 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 wire rope without torsion.
• When closing the control box cover, be careful so that your finger won't get caught.
Failure to follow these instructions may cause loss of property arising from damaged product or dropped
parts.
Mandatory
• When reassembling, replace the following parts with new ones.
• Lubricating oil (The type and amount of oil required will vary depending on the specifications and
size of the unit. Refer to "RY Series Wire Rope Hoist (10t) Owner's Manual" (separate document).)
• Packing and the like
• Oil seal
• Snap ring
• Split pin
• O-ring
• Spring pin
Failure to follow this instruction may cause bodily injury or loss of property.
■Before disassembly and reassembly
DANGER
Mandatory
• Disassembling/reassembling improperly causes death or severe injury. Only
competent persons with expertise and experience must disassemble/reassemble the
rope hoist. Alternatively, contact the nearest distributor or KITO.
(Refer to the back of this manual.)
• Perform disassembly and reassembly in correct procedures as described in the manual.
• 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.
NOTE
The disassembly and reassembly procedures are described based on the representative model. Note that components
may be slightly different for different capacities. In addition, the specifications may be changed without prior notice and
may be different from the actual products.

5
Table of Contents
Table of Contents
Safety Precautions ...........................................................2
Table of Contents .............................................................5
Disassembly and assembly tool .....................................6
Major parts in common....................................................7
Name of parts....................................................................8
Disassembly procedure...................................................9
1.Wire rope .....................................................................................9
2.Hook block .................................................................................13
3.Anchorage .................................................................................15
4.Idle sheave ................................................................................17
5.Rope drum .................................................................................18
6.Lifting motor ...............................................................................23
7.Direct limit switch .......................................................................28
8.Control box ................................................................................30
9.Traversing motor........................................................................36
10.Trolley frame ............................................................................41
Reassembly Procedures................................................45
1.Trolley frame ..............................................................................45
2.Traversing motor........................................................................49
3.Control box ................................................................................55
4.Direct Limit Switch .....................................................................60
5.Lifting motor ...............................................................................63
6.Rope drum .................................................................................69
7.Idle Sheave................................................................................74
8.Anchorage .................................................................................75
9.Hook Block.................................................................................77
10.Installing the Wire Rope...........................................................79

6
Disassemblyandassemblytool
Disassembly and assembly tool
For disassembly and reassembly, prepare the following tools.
No. Tool/jig name Application Icon
1
Wrench
8mm/10mm/13mm/16mm//17mm/18mm/19mm/24m-
m/30mm/36mm
Bolts and nuts
2Hexagon wrench
3mm/5mm/6mm/8mm/10mm/14mm Socket bolts
3Snap ring pliers S Snap rings (shaft)
4Snap ring pliers R Snap rings (hole)
5
Socket wrench
8mm/10mm/13mm/16mm/17mm/18mm/19mm/24mm/30m-
m/36mm
Bolts and nuts
6Combination pliers Split pins
7Plastic hammer Removing pinions
8Screwdrivers (+)(-) Screws
9Puller Ball bearings
10 Monkey wrench Bolts and nuts
11 Torque wrench Setting torque Torque
12 Pliers/Needle nose pliers Set pins
13 Nippers Cutting INSULOK
14 Brush Applying lubricating oil
15 Precision screwdriver (athead) Used for lead wire removal
16 Wood block Used as a sleeper
17 Fiber sling Used when lifting rope drum and the like
18 Chain sling Supporting control box unit and the like
19 Eye type bolt M12 Supporting control box unit and the like
20 Round bar Pinions
21 Pin punch Spring pins
22 Spatula Used when removing lubricating oil
23 Gas burner For thread lock removal
24 Socket bolt (complete thread) [M10x50] Used for gear case removal
25 T wrench Socket bolts
●Use the following types of grease.
• ENEOS: BONNOC M260
• ENEOS: Epinoc AP (N) 2
• MOLY PS Grease No.2 or equivalent (Molybdenum disulde No. 3)
• Molybdenum disulde lubricant Molytherm No. 2
●Helpful tools
• Remover. Preparing remover for bearings (for inner race & outer race) or for oil seal allows easy operation.
• Preparing wire for guiding lead wires will be helpful.

7
Major parts in common
Major parts in common
10t Di󰀨erence
Rail width (mm) 150-350 351-500
Lifting range (mm) 9 12 9 12
Frame A, B, C, and D a
Suspension shaft a b Length
Adjusting bolt a b Length
Drive shaft a b Length
Drum a b a b Length
Support shaft a b a b Length
Limit switch bolt a b a b Length
Drum cover a b a b Length
Counter weight a b a b Length
Beam a b a b Length
Traversing motor a
Hook block a
Wire rope a b a b Structure and length

8
Name of parts
Name of parts
Idle sheave
Guide roller
Adjusting bolt
Suspension shaft
Hook latch
Hook
Upper lower limit switch
Gear box
Rope drum
Motor (for lifting)
Wire rope
Anchorage
Rope guide
Wheel
Direct limit switch
Motor (for traversing)
Counter weight
Control box

Wire rope
9
Disassembly Procedures
Disassembly procedure
DANGER
Prohibited
• Do not disassemble the rope hoist while it is being suspended.
Doing so may result in death or severe injury due to a falling part.
Place it on the floor and perform maintenance on the workbench.
The overall disassembly procedure is shown below. Perform disassembly of only necessary parts.
1.Wire rope
■Removing Wire Rope
(1) Remove the snap ring from the anchorage
shaft supporting the Rope End Fixing Part of
the Main Unit.
Snap ring Anchorage shaft
(2) Pull out the anchorage shaft from inside.
Anchorage shaft
Socket
(3) Remove the socket.
(4) Remove the hex nuts (two locations), and then
the Wire Clip at the rope end.
[19mm]
CAUTION
Mandatory
Your hands may be injured.
Wear gloves and the like. Be careful of
fine splits of element wires at the rope
end while working.
Hex nuts
Wire clip

Disassembly Procedures Wire rope
10
(5) Tap lightly the tip of the cotter, and pull out the
cotter from the socket.
• If it is di󰀩cult to tap the tip of the cotter, put a
athead screwdriver on the cotter as shown in the
gure and tap the screwdriver with a hammer.
Cotter
Flathead screwdriver
Plastic hammer
(6) Remove the Wire Rope from the socket.
Socket
Wire rope
(7) Pull out slowly the Wire Rope from the Hook
Sheave of the Hook Block.
Wire rope
Hook sheave
(8) Pull out slowly the Wire Rope from the Idle
Sheave.
Idle sheave
Wire rope
(9) Pull out slowly the Wire Rope from the other
Hook Sheave of the Hook Block.

Wire rope
11
Disassembly Procedures
(10) Remove the bolt fixing Guide B, and remove
Guide B from Guide C along the Support
Shaft.
(11) Loosen the socket bolt indicated by the
arrow in the figure below. Next, move Guide
A toward the Drum Frame B side until its
Guide Roller does not lie on the wire, and
remove the socket bolt you loosened.
(12) As shown in the figure on the right, rotate
Guide A and Guide C along the Rope Drum
using the Guide Roller as a guide.
(13) Loosen the socket bolt connecting Guide A
to Guide C, and remove Guide A from the
Rope Drum at a position where Guide A has
no interference with the Support Shaft.
(14) As shown in the figure on the right, rotate
Guide A and Guide C along the Rope Drum
with Guide A removed from the Rope Drum.
(15) Remove Guide C from the Rope Drum at a
position where Guide C has no interference
with the Support Shaft.
Loosen the socket bolt
Drum Frame B
side
Gear box side
Guide roller
Rope drum
Guide roller
Socket bolt
Guide A
Support shaft
Guide C
Guide B
Guide C
Shim
Guide A
Structure of Rope
Guide B
Guide C

Disassembly Procedures Wire rope
12
(16) Perform unwinding operation while pulling
the Wire Rope by hand so that the Wire
Rope does not float away from the Rope
Drum. Remove in advance the Wire Rope
to the position of the Rope Clamp as shown
right.
(Fixed state)
(17) Loosen socket bolts and remove Wire
Clamps at three locations to remove the
Wire Rope from the Wire Drum. Remove the
Wire Rope while holding it by hand so as to
prevent the Wire Rope from being removed
suddenly by tension of the Wire Rope.
[6mm]
Socket bolt

Wire rope
13
Disassembly Procedures
2. Hook block
■Removing the hook block
(1) Pull out the spring pin fixing the hook nut and
hook.
Spring pin
Pin punch
Hook nut
(2) Remove the hook nut fixing the hook.
Hook nut
Hook
(3) Remove the thrust bearing from the hook.
Hook
Thrust bearing
(4) Remove the hook from the trunnion hole.
Hook
Trunnion hole
(5) Remove the hex nuts and spring lock washers
fixing the sheave covers A and B.
[30mm]
Hex nut
Sheave cover A
Spring lock
washer
(6) Remove the sheave cover A.

Hook block
14
Disassembly Procedures
(7) Remove the snap ring fixing the sheave
subassembly.
Snap ring
(8) Remove the sheave subassembly from the
trunnion subassembly shaft.
Trunnion subassembly shaft
Sheave
subassembly
(9) Remove the sheave cover B from the trunnion
subassembly. Trunnion subassembly
Sheave cover B
(10) Remove the spring pin from the bracket. Bracket
Spring pin
(11) Remove the parts on the opposite side in the
same way.
Follow the steps from (5) to (10).

Disassembly Procedures Anchorage
15
3. Anchorage
■Removing the anchorage
(1) Remove the socket bolts and spring lock
washers (two locations for each) of the key
plate fixing the shaft of the anchorage, and
remove the key plate.
[5mm]
Shaft
Spring lock
washer
Key plate
Socket bolt
Anchorage
(2) Pull out the shaft of the anchorage from
the hole of the beam A, and remove the
anchorage.
• Make sure to support the anchorage by hand to
prevent it from dropping. Shaft
Beam A
Anchorage
■Disassembling the anchorage
(1) Remove the snap ring fixing the anchorage
shaft.
Snap ring
Anchorage hanger
Anchorage shaft
Socket
(2) Pull out the anchorage shaft from the anchor-
age hanger and socket.
(3) Remove the hex nuts (two locations), and
remove the wire clip at the rope end.
[19mm]
CAUTION
Mandatory
Your hands may be injured.
Wear gloves and the like. Be careful
of fine splits of element wires at the
rope end while working.
Hex nut
Wire clip

Disassembly Procedures Anchorage
16
(4) Hammer the cotter tip gently, and pull out the
cotter from the socket.
• If it is di󰀩cult to tap the tip of the cotter, put a
athead screwdriver on the cotter as shown in the
gure and tap the screwdriver with a hammer.
Cotter
Flathead screwdriver
Plastic hammer
(5) Remove the wire rope from the socket.
Socket
Wire rope

Disassembly Procedures Idle sheave
17
4. Idle sheave
■Removing the idle sheave
(1) Remove the socket bolts (two locations) of
the key plate fixing the sheave support, and
remove the key plate.
[5mm]
Spring lock washer
Sheave support
Key plate
Socket bolt
(2) While supporting the idle sheave to prevent
it from falling, pull the sheave support out
of the hole in beam B and remove the
intermediate sheave.
Sheave support
Beam B
Idle sheave
■Disassembling the idle sheave
(1) Remove the socket bolts and spring lock
washers (two locations for each) fixing the
key plate, and remove the key plate.
[6mm]
Socket bolt
Key plate
Sheave hanger
Sheave
Idle sheave shaft
Collar
Collar
Spring lock
washer
(2) Pull out the idle sheave shaft and remove the
collar and sheave.

Disassembly Procedures Rope drum
18
5. Rope drum
■Removing the lifting motor harness (terminal box side)
(1) Cut the tie that binds the lifting motor
harness. 200V 400V
(2) Remove the round head screws (four
locations each) securing the terminal cover,
and then remove the terminal cover.
(3) Remove the lead wires of the lifting
motor harness shown in Figure A (for 200
V: two each of red, white, and black; for
400V: one each of red, white, and black).
[10mm]
(4) In addition, loosen the round head screw
securing the ground wire (green/yellow)
inside the terminal box, and remove the
ground wire.
(5) Refer to Figure B.
(1) Insert the precision screwdriver (at-
head) into the connector of the lifting
motor brake harness.
(2) Push the precision screwdriver in the
direction of the arrow and remove the
claw that holds the pin in place.
(3) Pull out the lifting motor brake harness.
(6) Refer to Figure A.
(1) Remove the cap from the cable gland.
(2) Pull out the lifting motor harness / lifting
motor brake harness.
(3) Put the cap of the cable gland back on
the cable gland itself.
Cable band
Lifting motor harness
Cable band
Lifting motor harness
Terminal cover
Spring washer
Round head screw
Figure A
Ground wire Ground wire
Lifting motor
harness
Lifting motor
harness
Lifting motor
harness
Lifting motor brake
harness
Cable
gland
Black
White
Red
Red
White
Black
Red
White
Black
200V 400V
Lifting motor brake harness
Precision screwdriver
(athead)
Figure B

Disassembly Procedures Rope drum
19
■Removing the LS harness
(1) Remove the socket bolts, spring lock washers,
and large plain washers (eight locations for
each) installing the drum cover.
[3mm/5mm]
Drum cover
Socket bolt
Spring lock washer
Large plain washer
(2) Cut all the cable bands fixing the LS harness
to the support shaft and mount base.
Cable band
Support shaft
LS harness
LS harness
Cable
band
(3) Remove the wiring cover of the limit switch.
Limit switch
Wiring cover
(4) Loosen the round head screws fixing the lead
wire of the limit switch, and remove the lead wire
from the limit switch.
Round head screw
Lead wire
• When removing the lead wire of the Lower limit
switch, if it cannot be removed due to interference
by the lifting motor, loosen the hex nut xing the
LS tting. Then shift the Lower limit switch to
the position where no interference occurs, and
remove the lead wire.
Hex nut
Lower limit switch
Round head screw

Disassembly Procedures Wire rope
20
(5) Pull out the LS harness from the wiring cover,
and return the wiring cover to the limit switch.
Wiring cover
LS harness
(6) Cut the cable band bundling the DLS
harness and LS harness on the control box
side, and pull out the LS harness from the
suspension shaft.
Cable band
DLS harness
LS harness
(upper limit)
LS harness
(lower limit)
Suspension
shaft
■Removing the rope drum assembly
(1) Put fiber slings around the two support
shafts located on the upper section of the
rope drum assembly, and lift the rope drum
assembly with the crane to the extent that it
will not fall even if the hex bolts are removed,
and then apply tension.
Fiber sling
(2) Remove the hex bolts and spring lock
washers from each of the four locations on
drum frame A and drum frame B.
[24mm]
Hex nut
Spring lock washer
Hex nut
Spring lock washer
(3) Remove the rope drum assembly from the
trolley frame.
Rope drum assembly
Trolley frame
Drum frame A
Drum frame B