KITO TCH Series User manual

OM-TCHZZZ-JP0-00
English
TCH Series Air Hoist (3t-25 t)
Instruction Manual
Hook Suspended Type
TCHH30CS/PS
TCHH60CD/PD
TCHH2PCD/PD
To Customer
-Thank you for purchasing KITOAir Hoist (TCH Series).
-Operators and maintenance engineers are requested to read this manual.
-After reading, please keep this manual at hand for future use.
-This product is designed considering the environment protection. The product
contains none of six hazardous substances specified by European RoHS Directive nor
asbestos.

2
2
Table of Contents
Introduction
3
Operation
24
Disclaimer
3
Operating the Cord and Pendant
26
Restriction on Use
3
Precautions for Operation
29
Warning Indication
4
Maintenance
32
General Matters on Handling and Control
5
Daily Inspection
32
Opening the Package
6
Frequent Inspection
37
Checking the Product
6
Periodic Inspection
41
Checking the Product No.
6
Check Sheet for Daily Inspection
43
Recording the Hook Dimensions
7
Check Sheet for Frequent inspection
44
Checking the Mark on the Load Chain
7
Warranty
45
Product Components
8
Hook Suspended Type
8
Product Specification and
Operational Environment
10
Product Specification 10
Operational Environment 10
Preparations before Daily Work 11
Selecting the Compressor and Removing
the Drain 11
Piping 11
Preparing and Attaching the Air Supply
Hose12
Lubrication 15
Checking the Product Components 16
Attaching the Chain Container 18
Setting the Load Limiter 20
Installing the Product 22
Checking after Installation 23

3
3
Introduction
Thank you for purchasing KITOAir Hoist (TCH Series).
The Air Hoist (TCH Series) is designed and manufactured for the purpose of lifting and lowering a load vertically,
powered by compressed air, within a normal environment.
The instruction manual is intended for the actual operators and maintenance engineers of the air hoist. When using
the air hoist, fully understand the instruction manual together with the instruction manual for the compressor.
Disclaimer
KITO shall not be liable for any damage incurred thereof due to natural disaster such as fire, earth quake and
thunderbolt, conduct by third party, accident, willful conduct or negligence by customer, erroneous use and other
use exceeding the operational condition.
KITO shall not be liable for any incidental damage due to the use or non-use of the product such as loss of
business profit, suspension of business and damage of the lifted load.
KITO shall not be liable for any damage arising from negligence of the contents in the instruction manual and the
use of the product exceeding the scope of its specification.
KITO shall not be liable for any damage arising from the malfunction due to the combination of the product with
other devices in which KITO is not concerned.
KITO shall not be liable to supply the spare parts for the product for which it has been 15 years since the
discontinuation of the product.
Restriction on Use
The product is intended for use only in the region or the country where it was purchased. Due to the differences in
regulations and standards, it is not for use outside of the region or the country where it was purchased.
The product described herein is not designed or manufactured for transporting people. Do not use the product for
that purpose.
The product described herein is designed for the materials handling work such as lifting/lowering and traveling the
load under ordinary operational condition. Do not use the product for the work other than materials handling work.
Do not assemble the product into machinerynot for materials handling, as a part of it.

4
4
Prohibited
Mandatory
DANGER
WARNING
CAUTION
Warning Indication
Improper use of air hoist causes danger such as drop of lifted load. Read this instruction manual carefully before
installation, operation and maintenance. Use the product after understanding the product knowledge, safety
information and precautions.
This instruction manual classifies the safety information and precautions into three categories of “DANGER”,
“WARNING”and “CAUTION”.
Description of Signal Words
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Indicates an imminently hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
Further, the event described in CAUTION may result in serious accident depending on the situation. Both
DANGER and CAUTION describe important contents. Please follow the instruction.
After reading, please keep this manual at hand for future use by the user.
Description of Safety Symbols
Means “Prohibited” or “You must not do”.
Prohibited action is shown in the circle or described near the circle.
This instruction manual uses as the general prohibition.
Means “Mandatory Action” or “You must do”.
Required action is shown in the circle or described near the circle.
This instruction manual uses as the general instruction.

5
5
Prohibited
Prohibited
Mandatory
Mandatory
General Matters on Handling and Control
WARNING
Only the personnel with expertise and know-how should be allowed to disassemble and repair the air
hoist.
Do not modify the product and its accessories.
Failure to comply with these instructions may not only fail to exert the successful functions and
performance of the air hoist, but cause unexpected trouble, resulting in a grave accident.
Understand the contents of the instruction manual sufficiently. Then operate the air hoist.
Use the product according to the instructions on the warning labels or the tags pasted to its different
parts.
Improper use of the air hoist may not only fail to exert its successful functions and performance of the
air hoist, but hinder safe operations, resulting in a grave accident.
CAUTION
When transporting the product, care should be taken not to drag, hit against an object or drop it.
Failure to comply with this instruction not only fail to exert the successful functions and performance of
the air hoist due to damage on or air leak from the air hoist, but cause a grave accident.
Prior to using the air hoist, conduct daily inspection.
Contact our office or our dealer for periodic inspection, repair of the air hoist and maintenance.
Keep regular (frequent and periodic) inspection records.
Failure to comply with inspection and maintenance may not only fail to exert the successful functions
and performance of the air hoist, but cause a grave accident.
NOTE
When discarding the product, disassemble it to an extent that it cannot be reused, and follow the local municipal
ordinance or the rules specified by the business operator.

6
6
Opening the Package
Checking the Product
Make sure that the indications on the package and the packed product coincide with your order.
- Make sure that the code indicated on the package label or the nameplate of the product body conforms to the
ordered product.
- The package includes the following items in addition to the hoist body or hoist body with air trolley.
Instruction manual Test report Load chain grease tube Chain container
(Included only in 3t and 6t)
Make sure that the product has not been deformed or damaged due to vibrations, load shift, etc. during
transportation.
Checking the Product No.
- Enter the product code, serial number, date of purchase and name of the sales shop inscribed on the
nameplate attached to the product in the following table.
* When you ask for repair or order expendable parts, let us know these information as well.
Item
Product information
Product type (Code)
Serial No.
Date of purchase
Name of the sales shop

7
7
Recording the Hook Dimensions
At the time of unpacking, enter the dimension L between the embossed marks of the hook and the hook
thickness dimension H in the following table for maintenance reason.
(These numerical values are used for inspection.)
Dimension
Bottom hook
L
(mm)
H
(mm)
Checking the Marks on the Load Chain
Type marks are indicated on the load chain at equal pitches.
Seeing the following table, check that your product code is compatible with the indicated marks and load chain
size.
Mark pitch
Second mark First mark Second mark
Capacity
Product code
Load Chain size:
diameter (mm)
Mark pitch
First mark
Second mark
Front side
Back side
Front side
Back side
Original Lot
No.4
Manufacturer
Type and
class
Country of
manufacture
3t, 6t
TCHH30CS/PS
TCHH60CD/PD
12.5
12Links
4 digits
KITO
AI-DAT
JAPAN
Capacity
Product code
Load Chain size:
diameter (mm)
Mark pitch
First mark
Second mark
Front side
Back side
Front side
Back side
Original Lot
No.4
Manufacturer
Type and
class
Country of
manufacture
25t
TCHH2PCD/PD
23.5
15Links
T
RUD
3 digits
3 digits

8
8
Bottom hook
End washer
(only with chain container)
Chain down stopper
(only with chain container)
Product Components
Hook Suspended Type
3 t (TCHH30CS/PS)
6 t (TCHH60CD/PD)
Name plate
S shape wire
Handle
Grip
Pendant
Top hook
Reduction Gear
Motor section
Brake section
Lever
Under hook holder
Chain lever
Emergency stop
button
Exhaust outlet
Top hook
Motor section
Exhaust outlet
End washer
(only with chain container)
Chain down stopper
(only with chain container)
Chain
container
Bottom
hook
Under hook holder
Mount section of
the chain end on
the no-load side
Reduction Gear
Mount section of
the chain end on
the load side
Name plate
Chain lever
S shape wire
Emergency stop
button
Lever
Pendant
Handle
Grip
Brake
section

9
9
25 t (TCHH2PCD/PD)
Exhaust outlet
Chain lever
S shape wire
Grip
Handle
Lever
Emergency
stop button
Top hook
Motor section
Chain container
(Option)
Reduction Gear
Brake section
Name plate
Chain end
Under hook block
Bottom hook
Pendant

10
10
Prohibited
Product Specification and Operational Environment
Product Specification
Common specification
Service air pressure: 0.4 to 0.6 MPa (recommended value: 0.6 MPa)
Color: KITO Yellow (Equivalent to Munsell 7.2YR6.5/14.5)
Noise level: 3t, 6t : 84 dB(A), 25t : 84.1 dB(A)
Brake capacity: 500 % or more (when the rated load is applied)
Additional function: Load limiter
(activated between over 100% up to 125% of the capacity at service air pressure of 0.6 MPa).
Hook suspended type (Single unit hoist)
Capacity
Code
Lift
(m)
Operation
method
Load chain
diameter(mm)
xNo. of falls
Speed (m/min)
Air
consumption
(m3/min)
Air inlet
(Rc)
Net
weight
(kg)
During rated
loading
When unloaded
Lifting
Lowering
Lifting
Lowering
3t
TCHH30CS
3
Cord
ø12.5 x 1
5.4
11.6
11.2
6.9
4.3
1
101
3t
TCHH30PS
3
Pendant
ø12.5 x 1
5.4
11.6
11.2
6.9
4.3
1
102
6t
TCHH60CD
3
Cord
ø12.5 x 2
2.7
5.7
5.58
3.48
4.3
1
133
6t
TCHH60PD
3
Pendant
ø12.5 x 2
2.7
5.7
5.58
3.48
4.3
1
134
25t
TCHH2PCD
3
Cord
ø23.5 x 2
1.38
3.0
2.7
2.0
10.8
1 1/2
579
25t
TCHH2PPD
3
Pendant
ø23.5 x 2
1.38
3.0
2.7
2.0
10.8
1 1/2
581
* The performance values in the table above are when the service air pressure is 0.6 MPa and the pendant
hose length is 2 m; the values in the table differ in other cases.
Operational Environment
Installationsite: Indoor
Ambient temperature: -20ºC to 70ºC
Humidity: 85%RH
Operating atmosphere:
Place free from oil mist, corrosive gas, flammable gas, explosive gas, volatile gas and steam.
Do not operate the product in the places exposed to an organic solvent, much powder dust, much acid and
salinity, and direct sunshine.
* When the Product is used in a special environment, consult us.
CAUTION
An air motor lubricant is slightly discharged from the air hoist body because of the structural reason of
the air hoist. Do not use in an environment accepting no oils and fats.
The discharged lubricant may damage your properties or result in an accident affecting the health of
your body such as falling.

11
11
Mandatory
Preparations before Daily Work
Selecting the Compressor and Removing the Drain
Guide for selection
(For max air consumption of each air hoist, see the specifications on Page 12, 13)
(Max air consumption x 10) x No. of units used ≤ Compressor
horsepower
Removing the drain
Internal accumulation of water and oil causes rust and trouble. Before and after daily work, loosen the drain
valve at the lower part of the air tank of the compressor to remove internally accumulated water and oil so as to
use dry clean compressed air. (For details, see the instruction manual for the compressor.)
Piping
See the following piping diagram to connect pipes. The customer is requested to prepare the devices and
materials enclosed by dotted lines in the piping diagram.
The inner diameter of the main and branch pipes must be at least 32 mm for 3t or 6t and at least 50 mm for 25t.
Make sure you use the largest size possible.
If they are smaller or too long, full performancemaynot be exhibited due to pressure loss.
Slope at 1/100 or higher to
allow easy flow of drain
Hose stem
Lubricator Regulator
Filter
Branch
pipe
Main pipe
Compressor
Air supply hose Hose stem Hose stem
Drain
port
(Piping diagram)
CAUTION
Be sure to install an air filter, reducing valve and lubricator (line oiler) near the air hoist.
The air filter, reducing valve and lubricator (line oiler) should be sized larger than the hoses.
Improper air control may not only cause trouble and malfunctioning due to rust, early wear of internal
parts, but lead to bodily injury due to these factors.

12
12
Prohibited
Unit (mm)
Code
TCHH30CS
TCHH30PS
TCHH60CD
TCHH60PD
TCHH2PCD
TCHH2PPD
Hook suspended type
19 or more
38 or more
Use the air filter, regulator and lubricator larger than the hose size.
The pilot type regulator is recommended. If the regulator is not the pilot type, it is recommended to use the
regulator one size above in order to secure the performance.
For handling of the air filter, regulator and lubricator, follow the instructions in the manufacturer’s
instruction manual.
(Recommended air set)
Target product type
Air set
Type
Manufacturer
TCHH30CS/PS
TCHH60CD/PD
Regulator
AR825-14G
SMC
Corporation
Filter
AF800-14
Lubricator
AL800-14
TCHH2PCD/PD
Regulator
AR925-20G
Filter
AF900-20
Lubricator
AL800-14
It is recommended to use the regulator with pressure gauge in order to check the air pressure. Also, use a
mounting bracket as required.
CAUTION
Do not use quick couplers to connect the hoses and pipes.
Failure to comply with this instruction may not only fail to exert the successful functions and
performance of the air hoist, but cause troubles, leading to an unexpected accident.
Preparing and Attaching the Air Supply Hose
Air hose inner diameter
- Check the purchased product type and prepare the hose with inner diameter shown in the table below.
Also, prepare hose bands suitable for the hose used.
(Recommendedair supply hoses)
Product code
Hose inner
diameter
(mm)
Manufacturer
Type
Use pressure
(Mpa)
TCHH30CS/PS
19
The Yokohama Rubber Co., Ltd.
HI-MID OIL SERIES HI-MID38
0-1
TCHH60CD/PD
TCHH2PCD/PD
38.1
The Yokohama Rubber Co., Ltd.
HI-MID OIL SERIES HI-MID38
0-1

13
13
Mandatory
Air hose length
CAUTION
The air supply hose must not be longer than 5 m for 3t or 6t and no longer than 10 m for 25t.
If the hose is too long, a drop in pressure will result in insufficient power. If you need to use a hose that
exceeds the length specified above, make sure its inner diameter is at least 25 mm for 3t or 6t and at least
50 mm for 25t.
Taking account of pressure loss according to the length of the air supply hose, adjust the air pressure
with the regulator and use at the appropriate service air pressure (0.4 to 0.6 MPa; 0.6 MPa
recommended).
Failure to adjust the service air pressure not only fails to exert successful functions and performance of
the air hoist, but obstructs efficient operation.
See the following table for relations between an air flow rate and a pressure drop when the hose is 10 m long.
Capacity
Hose
dimension
(mm)
Hose
inlet
pressure
(MPa)
Free air flow rate through 10-m hose(m3/min)
2.5
3
3.5
4
4.5
6
８
10
12
14
Pressure drop (MPa)
3t,6t
19.0
0.4
0.0353
0.0468
0.0669
0.0874
0.1106
-
-
-
-
-
0.5
0.0294
0.0423
0.0558
0.0729
0.0922
-
-
-
-
-
0.6
0.0253
0.0362
0.0479
0.0624
0.0791
-
-
-
-
-
0.7
0.0221
0.0318
0.0418
0.0547
0.0692
-
-
-
-
-
25.4
0.4
0.0087
0.0126
0.0143
0.0197
0.0249
-
-
-
-
-
0.5
0.0071
0.0105
0.0126
0.0164
0.0208
-
-
-
-
-
0.6
0.0061
0.0090
0.0108
0.0141
0.0179
-
-
-
-
-
0.7
0.0055
0.0080
0.0094
0.0123
0.0156
-
-
-
-
-
25t
38
0.4
-
-
-
-
-
0.0066
0.0117
0.0182
0.0263
0.0358
0.5
-
-
-
-
-
0.0055
0.0097
0.0152
0.0219
0.0298
0.6
-
-
-
-
-
0.0047
0.0084
0.0131
0.0188
0.0256
* When the hose is longer than 10 m, there are proportional relations between the hose length and a pressure loss. If the
hose length is 20 m, for instance, its pressure loss is twice higher than the pressure loss value in the table.
Adjusting the service air pressure
In order to maintain the performanceof the air hoist, supply the appropriate service air pressure (0.4 to 0.6
MPa; 0.6 MPa recommended), taking account of pressure loss in the air supply hose connecting the air
set (regulator, air filter and lubricator) and the air hoist.
Adjusting the pressure loss and service air pressure
Example:When using the TCHH30CS (3t) with the10 m long
air supplyhose
(1) The hose inner diameter is 19 mm according to the table on
Page 12.
(2) The maximum air consumption is 4.3 m3/min. according to
the specification table on Page 10.
(When the table has no relevant air consumption for the maximum air consumptionvalue of the Product, take the
closest higher value.)
(3) The pressure loss is 0.0791 MPa according to the table above, based on the hose inner diameter, hose inlet
pressure (when the regulator’s pressure gauge indicates 0.6 MPa) and air consumption value.
(4) Since the air pressure supplied to the air hoist is reduced only by 0.0791 MPa, the supply pressure is 0.5209
Mpa (=0.6-0.0791). Adjust this reduced pressure portion finely with the regulator so as to obtain the
recommendedvalue of 0.6 MPa.
Note) Check the pressure resistance performance of the regulator and hose to adjust the supplypressure.

14
14
Mandatory
Attaching the Air Hose to the Air Hose Joint
CAUTION
Attach the air supply hose firmly to a hose stem with a hose band.
Loose connection or air leak may not only fail to exert the successful functions and performance, but
detach the hose during operation, coming into contact with the worker and resulting in bodily injury.
3t, 6t TCHH30CS/PS TCHH60CD/PD
(1) Wrap seal tape around the hose nipple, and attach the hose firmly to the air hoist.
(2) Make sure that the main valve of the compressor is closed and that the compressed air path is shut.
(3) Before connecting the hose to the air hoist, apply about 10 drops of lubricant to the connection socket.
Important) Make sure you remove any contaminants from the hose connection joint before attaching the hose!
・Contaminants may cause the connection joint to seize or lead to a malfunction.
(4) Attach the hose stem and nut to the hose, use the hose band to fix the components, and then
securely attach the hose to the air hoist. (The tools for connecting the hose are not included in the
accessories and need to be obtained separately.)
Hose band
Hose nut
Hose stem
Hose nipple
Bushing (1 x 3/4)
Valve
Hose

15
15
Mandatory
25 t (TCHH2PCD/PD)
(1) Wrap seal tape around the hose nipple, and attach the hose firmly to the air hoist.
(2) Make sure that the main valve of the compressor is closed and that the compressed air path is shut.
(3) Before connecting the hose to the air hoist, apply about 20 drops of lubricant to the connection socket.
Important) Make sure you remove any contaminants from the hose connection joint before attaching the hose!
・Contaminants may cause the connection joint to seize or lead to a malfunction.
(4) Attach the hose stem and nut to the hose, use the hose band to fix the components, and then
securely attach the hose to the air hoist. (The tools for connecting the hose are not included in the
accessories and need to be obtained separately.)
Lubrication
CAUTION
(Lubricants)
Be sure to apply a lubricant to the load chain.
If the load chain is no longer properly lubricated after 3,500 cycles for 3t and 6t or after 300
cycles for 25t or any time within those periods, apply the necessary amount of lubricant to the
chain links (chain connections).
If the load chain is not used very frequently at 25t (within 30 cycles per day), you can also
use Castrol Viscogen KL300 manufactured by BP Japan. In that case, lubricate the chain
after every 30 cycles as described above.
For these lubricants, we recommend using the spray type since it is easier to apply.
Make sure that the lubrication rate for the motor is between 10 and 15 drops (0.2 to 0.3 cc)
per minute for 3t or 6t and between 15 and 20 drops (0.3 to 0.4 cc) per minute for 25t with
the lubricator.
When storing the air hoist for a long period or when using it again after long-term storage,
lubricate 2 to 3 cc from the air supply hose joint, perform low-speed operation to accustom,
and then, store or use it again.
Use only the specified lubricants.
Improper lubrication may not only cause trouble and malfunctioning due to rust, early wear of
internal parts, but lead to bodily injury due to these factors.
Capacity
Lubricant
Grade
or Manufacturer
Lubricating spot
Lubrication method
3 t,6 t
EPNOC GREASE AP (N) 0
JX Nippon Oil &
Energy Corporation
Load chain
Direct application
25 t
FRICTTLE2 liquid type
RIX CORPORATION
Load chain
Direct application
3 t,6 t,25 t
Additive turbine oil
ISOVG8 or equivalent
Air motor or Air
Hose Joint section
Lubricator or Direct
application
Hose
Hose band
Hose nut
Hose stem
Hose nipple
Valve

16
16
Checking the Product Components
Checking the chain-down stopper
- Check if the chain-down stopper is properly attached with the bolts (M8) and U-nuts (M8).
Tighten the bolts and U-nuts if they are loose.
Tightening torque = 22 N m
- Make sure that the chain is not twisted in its fixed part and that the welded section of the
vertical link is facing the direction shown in the diagram below.
*Do not attach the part to the horizontal link.
*Attach the part to the vertical link.
Chain down stopper x 2
Hexagon socket head cap screw
M8x 40 x 2 (22 N m)
Spring washer M8 x 2
U-Nut M8 x 2

17
17
Mandatory
Checking the double chain type for twist
WARNING
In the double chain type, a hook block may have passed between chains, twisting them. Before using
the air hoist, check the chains for any twist to use it with no twisted chains.
If used with twisted chains, they may be broken, resulting in a grave accident such as death due to a fall
of the suspended load.

18
18
Attaching the Chain Container
The air hoist body does not come with the chain container attached. Follow the instructions below to attach the
container.
3t and 6t・Canvas Chain Container (See the diagram below.)
・Remove the chain from the mount section of the chain end.
・Attach the end washer and chain-down stopper as shown in the diagram below.
*The chain-down stopper needs to face a particular direction. Confirm that the chain is suspended without any
twists, and attach the chain-down stopper to the vertical link by making sure it faces the direction shown in the
diagram below. If you attach the chain-down stopper to the horizontal link, the chain-down stopper may not
enter the chain container.
・Attach the chain container as shown in the diagram below.
*Be sure to attach the cotter pin.
・Insert the chain end into the chain container without attaching it to the mount section of the chain end.
Flat washer (large diameter) M10
U-Nut M10
Flat washer (large diameter)
M16
Castle nut M16
Mount section
of the chain end
Cotter pin 4 x 40
Chain Container
Flat washer (large diameter) M10
Hexagon socket head cap
screw M10 x 120 (12.5N m)
Flat washer
(large diameter) M16
Hanger bolts M16
(53 N m)
*Do not attach the part to the horizontal link.
*Attach the part to the vertical link.
End washer
Chain down stopper x2
Hexagon socket head cap screw M8 x 40 x2 (22 Nm)
Chain end
U-Nut M8 x 2
Spring washer M8 x 2

19
19
3t and 6t・Steel Chain Container (See the diagram below.)
(1) Shut off the main air supply to the body.
(2) Remove the chain end from its mount section as shown in the diagram. (Do not attach the chain end to the
body when using the chain container.)
(3) Attach the chain container as shown in the diagram.
(4) For the C-type (cord-type) operation method, attach extension pieces R and L to the body chain lever, and
then attach the cord. (This step is not required for the P-type operation method.)
(5) Attach the chain-down stopper at least six links above the chain end as shown in the diagram.
(6) Gradually insert the entire chain into the chain container, starting from the chain end. When doing so, make
sure you insert the chain through the chain insertion section shown in the diagram.
25 t (See the diagram below.)
Attach the chain container as shown in the diagram below.
Insert the entire chain into the chain container.
*Be sure to attach the cotter pin.
*Attach the chain container to the chain end without removing the chain.
Plain washer M10
U-Nut M10
Plain washer M16
Castle nut M16
Cotter pin 4 x 40
Plain washer M10
Hexagon socket head cap screw M10 x 120
plain washer M16
Hanger bolts M16
Hexagon socket head cap screwM8x 20
Plain washer M8
U-Nut M8
U-Nut M8
Spring washer M8
Hexagon socket head cap screw M8x40
Chain container
Chain lever
Extension piece R
Chain insertion
section
Chain end
Extension piece L
Mount section of the chain end
(Not required when the chain
container is attached.)
Chain down stopper
Plain washer M24
Hanger bolts
Cotter pin 5 x 50
Container arm
Castle nut M24
Chain container
6 links above

20
20
Prohibited
Setting the Load Limiter
When the suspended load exceeding the rated load is lifted by mistake, the air hoist is provided with a load limiter
designed to automatically stop lifting operation and inform of an overload. (Except some models) When an overload
is lifted, this load limiter is activated by sensing a pressure increase inside the air motor through its valve and finally
stops lifting. At the time of shipment, the load limiter has been set to be activated within 125% of the rated
load at the air pressure of 0.6 MPa. If there is a difference between your actual service air pressure and the
default pressure (0.6 MPa), there may occur troubles such as “cannot lift the rated load”, “cannot activate the load
limiter even under overload” because of non-conformity between the default pressure sensing point of the load
limiter’s valve and the actual pressure sensing point. Accordingly, it is necessary to readjust the load limiter at
actual service air pressure. The following describes a readjustment procedure.
Readjustment method
Check a setting flow chart on the following page as well.
WARNING
Be careful not to turn the load limiter adjusting screw too many times!
Once the adjusting screw is mounted to the spring, do not turn it more than 17 times.
If you keep turning the adjusting screw, the load limiter will exceed its adjustment capacity
and stop functioning. This may allow the air hoist to lift dangerously excessive loads.
(1) Prepare the rated load.
(2) Set the service air pressure; 0.6 MPa recommended.
(3) 3 t, 6 t:
Loosen the lock nut. (10 mm T wrench)
25 t:
Remove the four hexagon socket head cap screws, remove the cover, and loosen the lock nut. (3 mm hex wrench)
(4) Turn an adjusting screw counterclockwise until it is lightly turned. An internal spring is now disengaged from
the adjusting screw.
(5) Using your fingers, turn the adjusting screw clockwise until it is turned slightly heavily. The adjusting screw is
now engaged with the internal spring.
(6) Lift the rated load slightly to check safety. Next, lift it at full speed.
(7) When this is done, the load limiter is activated to stop lifting automatically.
(8) Turn the adjusting screw once clockwise.
(9) Lift it at full speed.
(10) Repeat Steps (8) and (9) until the load limiter is not activated any more.
(11) Once the load limiter is not activated (not automatically stopping lifting operation) any more by Step (10),
make 3/4 turn of the adjusting screw counterclockwise.
(12) Lift it at full speed.
(13) If the load limiter is activated, make 1/4 turn of the adjusting screw clockwise.
(14) Repeat Steps (12) and (13) until the load limiter is not activated any more.
(15) Once the non-activating point of the load limiter is found, make further 1/4 turn of the adjusting screw from
there clockwise.
(16) Tighten the lock nut to finish adjustment.
(17) 25 t : Use the four hexagon socket head cap screws to attach the cover.
* After tightening, it is recommended to mark the nut so that you can see whether or not it has been
loosened at the time of regular inspection.
3 t, 6 t
25 t
Lock nut
Adjusting screw
Lock nut
Adjusting screw
Cover
Hexagon socket head
cap screw (M5 x 14)