KITO TS Series Operation instructions

OM-TSZZZZ-CEE-01
OWNER’S (OPERATOR’S) MANUAL
AND SAFETY INSTRUCTIONS
FOR KITO PLAIN AND GEARED TROLLEY
TSSERIES
ALWAYS SAVE THIS BOOK FOR FUTURE REFERENCE.
Original Instruction
Issued September 1994. Revised July, 2016 (revision 11)
This instructions describe for connection with manual hoists. In case of connection with electric chain
hoist ER2 series, please refer to the “ER2 electric chain hoist Owner’s Manual”.

CONTENTS
1. DEFINITIONS........................................................................................................................................... 1
2. INTENDED PURPOSE............................................................................................................................. 1
3. BEFORE USE ........................................................................................................................................... 1
3.1 Safety summary ...................................................................................................................................... 1
3.2 Safety instructions................................................................................................................................... 2
4. MAIN SPECIFICATIONS........................................................................................................................ 4
5. INSTALLATION ...................................................................................................................................... 6
5.1 Coupling with manual chain hoists......................................................................................................... 6
5.2 Coupling with electric chain hoists......................................................................................................... 7
5.3 Adjusting trolley width before installation ........................................................................................... 10
5.4 Installation of trolley onto beam........................................................................................................... 10
5.5 Installation of stopper onto traversing beam......................................................................................... 11
5.6 Check points after installation .............................................................................................................. 11
6. OPERATION........................................................................................................................................... 11
6.1 Intended purpose of trolley operation................................................................................................... 11
6.2 Safety working environment................................................................................................................. 11
6.3 Operation .............................................................................................................................................. 11
6.4 Trolley storage...................................................................................................................................... 12
7. INSPECTION.......................................................................................................................................... 12
7.1 Outline .................................................................................................................................................. 12
7.2 Daily inspection.................................................................................................................................... 12
7.3 Periodic inspection................................................................................................................................ 13
8. MAINTENANCE.................................................................................................................................... 16
8.1 Lubrication............................................................................................................................................ 16
8.2 Overhaul and assembly......................................................................................................................... 16
9. BUFFER.................................................................................................................................................. 18
9.1 Buffer.................................................................................................................................................... 18
10. WARRANTY.......................................................................................................................................... 19
11. PARTS LIST ........................................................................................................................................... 20
12. CONTENTS OF EC DECLARATION OF CONFORMITY.................................................................. 25

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1. DEFINITIONS
: Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe
practices.
WLL: Indicates maximum mass (working load limit) which a trolley is designed to support in
general service.
2. INTENDED PURPOSE
This trolley is designed for horizontally transporting loads by hand, through manual or electric hoist under
normal atomospheric conditions of the work place.
3. BEFORE USE
3.1 Safety summary
Danger exists when heavy loads are transported, particularly when the equipment is
not being used properly or is poorly maintained. Becuase accidents and serious injury
could result, special safety precautions apply to the operation, maintenance and
inspection of the KITO plain and geared trolley TS series.
The safety factor of the tolloey is 4:1. The hoist may lift and hold a load more than the
rated loads check that structure for mounting the tolley has sufficient strength.
NEVER use a trolly for transporting people.
NEVER transport loads over or near people.
NEVER transport more than WLL which is shown on the name plate.
ALWAYS let people around you know when a transport is about to begin.
ALWAYS read the operation and safety instructions.
Remember proper handling techniques are the responsibility of the operator. Check all
applicable safety codes, regulations and other applicable laws for further information about
the safe use of your trolley.
More detailed safety information is contained in the following pages. For
additional information, please contact KITO Corporation or your authorized KITO
dealer.
WARNING
CAUTION
WARNING

- 2 -
3.2 Safety instructions
If this trolley is used in conjunction with a hoist, also refer to the hoist manual for additional precautions and
instructions.
3.2.1 Before use
ALWAYS be sure to wear the proper clothing and personal protective equipment when
using and operating the product.
ALWAYS allow the instructed (trained in safety and operation) person to operate the
trolley.
ALWAYS lubricate the trolley regularly (Refer to 8.1).
ALWAYS rig the load properly and carefully.
ALWAYS check the trolley according to the “Daily inspection” (Refer to 7.2)
NEVER use a trolley if the flange width does not fit to the rail.
NEVER connect the hoist to the trolley with improper fittings.
NEVER use a trolley withot a name plate.
3.2.2 While operation
ALWAYS make sure that the load does not get in a way of hand chain.
ALWAYS when any abnormality is observed during the operation, stop the operation
immediately, indicate “FAILURE” and contact with the maintenance engineers.
ALWAYS when inspecting and repairing, be sure to indicate “INSPECTION” and carry out
without lifting a load.
NEVER strike a trolley intentionally to the stopper.
NEVER swing a suspended load.
NEVER weld or cut a load suspended by the trolley.
NEVER allow a trolley to collide with another trolley.
NEVER operate a trolley unless load is centered under the trolley.
3.2.3 After operation
NEVER leave a suspended load unattended.
NEVER throw a trolley.
3.2.4 Maintenance
ALWAYS let the qualified service personnel inspect the trolley periodically (Refer to 7.3).
WARNING

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3.2.5 Others
ALWAYS consult the manufacturer or your dealers if you plan to use a trolley in an
excessively corrosive environment. (Salt water, sea air and/or acid, explosive
environment or other corrosive compounds, etc.).
ALWAYS when not in use of the trolley store it at dry place where appropriate for the
weight and size.
ALWAYS use a trolley within rail slope of 1 degree.
ALWAYS when transferring including handling, and storing the product, carry it out
carefully making sure of the product’s weight and size.
NEVER use a trolley which has been taken out of service until the trolley has been
properly repaired or replaced.
NEVER remove or obscure the warning stickers.

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4. MAIN SPECIFICATIONS
0.5 to 3 t
5 t
For manual chain hoist For electric chain hoist
Rail tread Rail tread
Suspender C
Suspender C
(3t, 5t)
Suspender E,G
Rail tread

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Code/C (1) or. E (2)
WLL
(t)
Rail width adjustability (mm) Min
radius
for
curve
(mm)
Net
Weight
(kg)
Hand chain
folded
length (m)
a
[Max.]
(mm)
Plain
trolley Geared trolley Standard Option
W30 TSP TSG C(1) E(2) C(1) E(2)
TSP005C (E) TSG005C (E) 0.5 50 to 163 164 to 305 1100(3) 4.5 ― ― ― 173 173
TSP010C (E) TSG010C (E) 1 58 to 163 164 to 305 1300(3) 8 12 2.5 3 275 (215) 311
(215)
TSP015C TSG015C 1.5 82 to 163 164 to 305 1500 14 18 2.5 2.5 349 (264) ―
TSP020C (E) TSG020C (E) 2 82 to 204 205 to 305 1500 14 19 3 3 349 (264) 349 (264)
TSP025C (E) TSG025C (E) 2.5 82 to 204 205 to 305 1700 23 27 3 3 359 (280) 359 (280)
TSP030C (E) TSG030C (E) 3 82 to 204 205 to 305 1700 23 27 3 3 359 (280) 359 (280)
TSP050C (E) TSG050C (E) 5 100 to 204 205 to 305 2300 50 56 3.5 3.5 376
(273) 376 (273)
Code/C (1) or E (2)
WLL
(t)
b (mm) d
(mm)
e (mm) f (m) g
(mm) h (mm) k (mm)
ℓ (mm) m
(mm) n (mm) p (mm) q (mm)
Plain
trolley Geared trolley C(1) E(2) C(1) E(2) C(1) E(2) C(1) E(2) C(1) C(1) C(1) C(1)
TSP005C (E) TSG005C (E) 0.5 204 204 182 46 46 2.7 2.7 76 84 22 93 98 26 33 14 14
TSP010C (E) TSG010C (E) 1 309
(249) 345 (249) 236 116 (56) 152 (56) 2.2 2.7 95 112 25 106 — 28 37 18 18
TSP015C TSG015C 1.5 385
(300) ―280 154 (69) — 2.2 — 112 131 32 129 119 32 40 22 22
TSP020C (E) TSG 020C (E) 2 385
(300) 385 (300) 280 154 (69) 154 (69) 2.7 2.7 112 131 32 129 138 32 40 22 22
TSP025C (E) TSG025C (E) 2.5 398
(320) 398 (320) 324 157 (79) 157 (79) 2.7 2.7 134 152 36 144 153 36 44 27 25
TSP030C (E) TSG030C (E) 3 398
(320) 398 (320) 324 157 (79) 157 (79) 2.7 2.7 134 152 36 169 153 40 48 24 30
TSP050C (E) TSG050C (E) 5 401
(297) 401 (297) 400 156 (53) 156 (53) 3.2 3.2 144 178 54 228 171 60 70 33 36
Note: (1) C: For manual chain hoist.
(2) E: For electric chain hoist.
(3) Minimum flange width for curved rail;
(a) 0.5t trolley....................................57 mm
(b) 1t trolly........................................73 mm
(c) 2.5t and 3t trolley.........................89 mm
Remark : 1) Figures in parentheses show the data for plain trolley type.
2) The maximum 300mm rail width are available as option.
3) Net weight is when flange width is in standard range.
4) Dimension “a” is when flange width is adjusted to the maximum of the standard range.
5) Dimension “b” is when flange width is in standard range.
Allowable ambient conditions;
Operation temperature: -40C to +60C: (–20°C to + 40°C for the use with a electric chain hoist)
Operation humidity: 100%
Note:
- Install the trolley at the level where an operator is able to operate the hand chain from the ground level.
- If the adjustment of the bottom of the hand chain between 500 mm and 1000 mm from the ground is
required, consult KITO.
This device was tested according to the required static and dynamic load test provided on the European
standard EN 13157.

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5. INSTALLATION
5.1 Coupling with manual chain hoists
(1) The M3 series hoist can be coupled either in
the hook suspension method (the top hook is
hung from the suspender C as shown in Fig.
5-1), or in the direct coupling method (the hoist
body, with the top hook removed, is directly
coupled to the suspender C as shown in
Fig.5-2).
However the 7.5t and larger capacity M3 series
hoist can only be suspended by the hook
suspension method and the top hook must be
hung from the suspension shaft of the trolley.
The CF series hoist can be suspended with suspender C like Fig.5-3.
(2) The hook suspension method type is best for circumstances when the chain hoist is transferred
frequently.
The direct coupling method is best for circumstances which require as much effective hoisting length as
possible, especially where the height of ceiling is low.
(3) Direct coupling method of M3 series chain hoist.
(a) For 0.5 to 2.5t (Refer to Fig.5-4)
1) Remove the wheel cover nuts and the
spring washers, then remove the wheel
cover.
2) Remove the split pin from the top pin,
then remove the top pin and the top
hook.
3) Mount the suspender C to the hoist
body with the top pin which has been
removed as above. Then insert a new
split pin.
4) Securely bend the split pin as shown in
Fig.5-5
5) Install the wheel cover, as it was before,
with the nuts and the spring washers.
Fig. 5
-
1
TSP+M3CB
Nut
Fig. 5-4 Mounting suspender C
Top hook
Top pin
Split
pin
Fig. 5-5 Split pin bending
Suspender C
Spring washer
Wheel cover
(0.5t to 2.5t)
Split pin
Top pin
Fig. 5
-
2
TSG+M3CB
Fig. 5
-
3
TSP+CF
Nut

- 7 -
(b) For 3 or 5t (Refer to Fig.5-6)
In addition to the procedure stated earlier,
the following steps are also required.
1) Remove the split pin (from the slotted
nut), and then remove the slotted nut,
the chain pin and the load chain from
the top hook.
2) Connect the end of the load chain and
the suspender C with the chain pin, the
slotted nut and a new split pin.
3) Bend securely the split pin.
4) Make sure that no twisting and no
capsizing of the load chain occurs.
5.2 Coupling with electric chain hoists
5.2.1 ES, EF series
The direct coupling method shown in Fig.5-9 should be applied.
(1) Remove the split pin, the slotted nut and the top pin (in the case of double falls of the chain, the top
bolt), and then remove the top hook. (Refer to Fig.5-7).
(2) Mount the suspender E to the hoist body with the top pin (or the top bolt) and the slotted nut which
have been removed as above. Then insert a new split pin and bend it securely as shown in Fig.5-5 on
page 6.
(3) The EF series electric chain hoist can be suspended by the suspender E like Fig.5-10.
F
ig. 5
-
6
Mounting suspender C
Top hook
Top pin
Suspender C
Wheel cover
Spring washer
Nut
Chain pin
Slotted nut
Split pin
(3t to 5t)
F
ig. 5
-
7
Mounting suspender
E
Fig. 5
-
8 Suspender
for double chain
falls hoist
F
ig. 5
-
9
TSG+ES
F
ig. 5
-
10
TSP+EF
Top hook
Top pin
Split pin
Suspender E
Slotted nut
Suspender E for
double falls of chain
Split
pin

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Table 5.1 Adjusting spacers arrangement on suspension shaft
Capacity (t) Parts
Name
Beam flange width (mm)
Plain
trolley
Geared
trolley 50 58 66 74 82 90 91 98 106 113 119 125 131 137 143 144
125kg
250kg
500kg
Thin
spacer Inner23441123341111223445122334011212
Outer 7 4 10 7 5 10 10 8 5 3 9 7 5 11 9 9
Thick
spacer Inner00001111112222222222333333444444
Outer8866644444222000
Fixing
spacer Inner00000000000000000000000000000000
Outer0000000000000000
1t
125kg
250kg
500kg
1t
Thin
spacer Inner 3 4 0 1 2 2 3 3 0 1 0 1 1 2 3 3 4 4 1 1 2 2 3 3 0 0 1 1 1 1
Outer 4 10 7 5 10 10 8 5 3 9 7 5 11 9 9
Thick
spacer Inner 0 0 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4
Outer 866644444222000
Fixing
spacer Inner 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Outer 000000000000000
1.6t
2t
Thin
spacer Inner 2 3 0 0 0 0 1 2 2 3 3 4 0 1 1 2 2 3 3 4 0 1 0 1
Outer 277420642066
Thick
spacer Inner 0 0 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3
Outer 10 8 8 8 8 8 6 6 6 6 4 4
Fixing
spacer Inner 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Outer 000000000000
2.5t
3.2t
Thin
spacer Inner 2 3 3 4 3 4 1 1 2 2 3 3 4 4 1 1 2 2 3 3 4 4 0 1
Outer 9 7 7 12 10 8 6 12 10 8 6 13
Thick
spacer Inner 2 2 2 2 2 2 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 5 5
Outer 888666644442
Fixing
spacer Inner 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Outer 000000000000
5t
Thin
spacer Inner 1 1 2 3 3 3 0 0 1 1 2 2 3 3 3 3
Outer 10 7 6 12 10 8 6 6
Thick
spacer Inner 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1
Outer 6 6 6 4 4 4 4 4
Fixing
spacer Inner 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Outer 0 0 0 0 0 0 0 0
NOTE: 1) Adjustment of trolley width.
Refer to 5.3 on page 10.
Adjust the dimensions by appropriately increasing or decreasing the number of inner or outer adjusting
spacers, without strictly adhering to the number of adjusting spacers shown in the above table.
2) Thick Spacer and Thin Spacer are silver and Fixing Spacer is black.