KITO L5 Owner's Manual And Safety Instructions
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KITO L5 Owner's Manual And Safety Instructions

Chain hoist
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BULLETIN NO. L5-0304-CE-05
Owner's (Operator's) Manual
and

Safety Instructions

Manually Lever Operated
Chain Hoist Model L5
・
WARNING
This equipment must not be installed, operated or
maintained by any person who has not read and
understood all the contents of this manual. Failure to read
and comply with the contents of this manual can result in
serious bodily harm or death, and/or property damage.

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  • Page 1: Safety Instructions

    BULLETIN NO. L5-0304-CE-05 Owner’s (Operator’s) Manual Safety Instructions Manually Lever Operated Chain Hoist Model L5 ・ WARNING This equipment must not be installed, operated or maintained by any person who has not read and understood all the contents of this manual. Failure to read and comply with the contents of this manual can result in serious bodily harm or death, and/or property damage.
  • Page 2 Fill in the following product informaition for identification and future reference to avoid referring to the wrong manual for information or instructions on installation, operation, inspection, maintenace, or parts. Model Code: Serial Number: Date of Purchase: Dealer: Page 2 of 40...

  • Page 3: Table Of Contents

    Table of Contents 1. IMPORTANT INFORMATION AND WARNINGS ..............4 1.1. R ................4 EGARDING NSTRUCTIONS ANUAL 1.2. P ......................4 ROHIBITED RACTICES 2. TECHNICAL INFORMATION ....................7 2.1. S ........................7 PECIFICATIONS 2.2. D ......................... 8 IMENSIONS 3. MOUNTING ..........................9 4.

  • Page 4: Important Information And Warnings

    1. Important Information and Warnings 1.1. Regarding This Instructions Manual This manually lever-operated chain hoist model L5 is designed to lift and lower a load by using manual force, and hold it by using the braking device under normal working conditions, not intended to transport a person.
  • Page 5 ・ WARNING Do not use a deformed or scarred hook. Replace components with new ones authorized by KITO. ・ CAUTION Make sure that the nameplate is readable. Before operation, make sure to perform all inspections given in 5.1 Inspection Classification Use a proper hoist for your purpose, capacity and lift.
  • Page 6 Before lifting, ensure to eliminate load chain slack to avoid a shock load. There are risks of overheating of the braking system during prolonged lowering of loads. If you are considering of the use under such condition, consult KITO. 1.2.4. After operation ・...

  • Page 7: Technical Information

    2. Technical Information 2.1. Specifications 2.1.1. Schematics Top hook Free chain knob Select lever Latch Nameplate Chain pin Anchor screw Grip Connection yoke Load chain Bottom hook Chain stopper link 2.1.2. Operating Conditions and Environment Temperature Range: -40° to +60°C (-40° to +140°F) Humidity: 100% or less, this is not an underwater device.

  • Page 8: Dimensions

    2.2. Dimensions 189.6000 216.6997 112.0000 Up to 3.2 tonnes 6.3 tonnes 189.6000 303.9029 112.0000 9 tonnes Table 2-2 Hoist Dimensions Units: mm Hoist Code LB008 23.5 35.5 LB010 42.5 LB016 42.5 LB025 36.5 LB032 24.5 LB063 LB090 72.5 41.5 Page 8 of 40...

  • Page 9: Mounting

    3. Mounting WARNING Avoid the following when mounting the hoist. Failure to comply with these instructions may result in death or severe injury. NEVER - Ensure that only trained or competent persons install the hoist. - Do not install the hoist within the range of movement of other devices (equipment), such as a trolley.

  • Page 10: Operation

    4. Operation 4.1. Introduction Operating a heavy load may result in hazardous situations. Before operating, read and comply with all of the information in this clause and 1.2 Prohibited Practices. Before operating the hoist, secure the workplace as follows: - Ensure to arrange the workplace to work smoothly. - Ensure to keep a good view to monitor the operation, otherwise arrange watch personnel.

  • Page 11: Load Operation

    4.3. Load Operation 4.3.1. Features Operating the grip with the select lever set to the lifting (‘UP’) or the lowering (‘DN’) position, the hoist performs as follows: - In lifting mode, the tightened mechanical brake rotates as one and supports a load on the pawls when the grip stops.

  • Page 12: Load Signal (As Option)

    4.4. Load Signal (as option) This load signal is designed as an overload detecting device to warn an operator that an excessive load has been applied which could cause a hazardous situation. ・ DANGER Disregarding the overload sign could cause bodily harm or damage to the hoist. Do not lift an overload.

  • Page 13: Inspection

    5. Inspection To maintain continuous and satisfactory operation, a regular inspection procedure must be initiated to replace worn or damaged parts before they become unsafe. 5.1. Inspection Classification Inspection intervals must be determined by the individual application and are based on the type of service to which the hoist will be subjected and the degree of exposure to wear, deterioration or malfunction of the critical components.

  • Page 14: Daily Inspection

    Evaluation and resolution of the results of the frequent inspections shall be made by a designated person so that the hoist is maintained in safe working condition. ・ WARNING Do not use components beyond the stated criteria or KITO-unauthorized ones. Page 14 of 40...
  • Page 15 In addition to the daily inspections, perform the following checks. Table 4-2 Frequent Inspection Methods and Criteria Item Method Criteria Action Put the hoist under a light load and check the following items of “Function - ……” Function – Set the select lever to ‘UP’ and Moving lever forward...
  • Page 16 Item Method Criteria Action Hooks – Visual, Function - Should be held in place on the tip Replace hook Hook Latches of the hook. latch - Should move smoothly. ・ WARNING Do not use the hook with the latch missing. Hooks –...

  • Page 17: Periodic Inspection

    5.4. Periodic Inspection In addition to the frequent inspections, perform the following checks. Table 4-3 Periodic Inspection Methods and Criteria Item Method Criteria Action Chain Pin – Visual, Measure - Significantly deformed pin should Replace. Deformation be discarded. - Should be free of scars or Chain Pin –...
  • Page 18 Item Method Criteria Action Braking System – Measure Should have uniform thickness of A Replace. Bushing Wear dimension. Capacity A dimension (mm) (tonnes) Standard Discard Braking System – Visual Should lubricated that Soak the bushing in Bushing Lubrication Heat with a match flame. lubricant oozes off the surface.
  • Page 19 Item Method Criteria Action Lifting system – Visual Should be free of wear in the Replace Load Sheave pockets or scars on the rising parts. Lifting system – Visual Should not be chipped, unevenly Replace Cogs worn or scarred. Lifting system –...
  • Page 20 Item Method Criteria Action Body – Visual Should free major Replace. Frame A, B deformation or significant scars. Stay Bolts - Should be free of loose caulking. Top Pin Hole - Should be free of cracks on the Pawl Shafts welding parts.
  • Page 21 Item Method Criteria Action Before reuse, reassemble properly the hoist in accordance with 6 Maintenance in this manual Preoperational and perform the following the checks. Checks Checks under No Function, Auditory - The lever should be operated Repair or replace as Load –...

  • Page 22: Maintenance And Storage

    Do not extend the load chain. Remove old grease on the disassembled parts. Replace components with new ones authorized by KITO. To reassemble, apply new grease, and use a new split pin and snap ring. Note: The following symbols in this manual indicate the recommended lubricants.

  • Page 23: Tools

    6.3. Tools To disassemble or reassemble the hoist, prepare for the following tools. Table 5-1 Tools Tools Snap ring pliers Opening a snap ring Socket wrenches 12, 14 mm Slotted nuts Hex keys 4, 5, 10, 12 mm Socket head cap screws Wrenches 10, 12, 13, 14, 17 mm Bolts and nuts Philips screwdriver...

  • Page 24: Components

    6.4. Components Exclusive for 2.5 & 3.2 tonnes Fig. # Part # Part Name Fig. # Part # Part Name Fig. # Part # Part Name 1001 Top Hook Set 116 Load Sheave 223 Select-pawl Spring 1071 Latch Assembly 161 Chain Guide 5211 Lever Assembly 163 Top Pin 162 Stripper...

  • Page 25: Disassembly

    6.5. Disassembly Proceed as follows: 6.5.1. Free Chain Knob Pull out (50) Split pin and remove (49) Slotted nut. – Remove (48) Spring holder, (47) Free chain spring, (45) Free chain knob assembly, (43) Brake – spring and (44) Cam guide from (16) Pinion. 6.5.2.
  • Page 26 Do not apply oil to the friction side WARNING of the female thread. ◯ CAUTION Ensure to clean the friction side of the female thread. ◯ - Apply (G3) grease lightly to the thread of (33) Female thread. - Attach the friction side of (33) Female thread to (29) Brake cover assembly and set (37) Lever assembly on them.
  • Page 27 - Set (52) Load chain to (19) Load sheave as Frame top: Flat Stay bolt shown in the left picture, and attach (20) Chain Top pin hole guide and (21) stripper. Welding part CAUTION ・ ・Keep (53) Chain stopper link in parallel with the frame and set (52) Load chain with its welding part directed outward.
  • Page 28 6.6.6. Gears - For capacity of 2.5 tonnes or more, attach (18) Load gear to the serration part of (19) Load sheave. Shaft Note: Make sure that the load sheave is inserted to the load gear completely. If necessary, use a plastic hammer. - Insert (16) Pinion into (19) Load sheave and arrange the pinion with (17) Gear #2 as shown in the left picture.
  • Page 29 6.6.8. Lever & Body - Attach the lever assembled in 6.6.1 to the previously-assembled bake. ・ Fit the rims of (10) Frame A assembly and (29) Brake cover assembly in right CAUTION direction. - Fit (29) Brake cover assembly and (10) Frame A assembly by screwing (33) Female thread of the lever assembly clockwise to the thread of (16) pinion until making clicking sounds.

  • Page 30: Preoperational Checks

    - Set (43) Brake spring (silver color) into the slot of Slot for spring the back of (45) Free chain knob assembly. Note: As indicated in the left picture, set the end of Slot for cam guide the spring to the rib of the knob. Back of (45) free Set end of spring chain knob assembly...

  • Page 31: Troubleshooting

    If a defect is found in the hoist, stop using it immediately and check the cause of the defect. Read and comply with instructions in this manual and use the hoist properly. Ensure that competent people conduct repairs, otherwise please confirm with your dealer. Replace components with new ones authorized by KITO. Symptom Cause...
  • Page 32 Symptom Cause Remedy Hoist will lift Poor pawl movement caused by faulty pawl Perform periodic overhauls. intermittently spring -The spring is loose or damaged. -Slight irregular Mis-assembly of pawl spring Reassemble it properly and ensure to clicking check click sound of the pawl before reuse. During operation, Poor contact of load sheave and load chain...
  • Page 33 Symptom Cause Remedy Load drops when Mis-assembly of friction plates, i.e. friction Reassemble it properly as shown in the lowering starts. plates at one side as shown in the following following picture and ensure to check hoist picture or one lost functions before reuse.
  • Page 34 Symptom Cause Remedy For load chaiin ・ CAUTION -The load chain is one of critical parts of the hoist. Ensure to maintain the chain carefully including proper handling, good maintenace and inspection. -Replace a chain pin for the load chain replacement. Load chain wear Lack of lubricant Keep the load chain lubricated.
  • Page 35 Symptom Cause Remedy For hooks ・ CAUTION To prevent the hooks from being damaged, handle them properly in accordance with this manual. Stretched hook Overload ・ WARNING Stretched hook -Hook will begin to deform gradually under over double rated load. warns you about overload.

  • Page 36: Warranty

    KITO warrants that KITO’s Products, when shipped, shall be free from defects in workmanship and/or materials under normal use and service and KITO shall, at the election of KITO, repair or replace free of charge any parts or items which are proven to have said defects, provided that all claims for defects under this warranty shall be made in writing immediately upon discovery and, if there is anything within one(1) year from the date of purchase of KITO’s Products by Purchaser and provided,...

  • Page 37: Repair Part List

    9. Repair Part List 9.1. Up to 3.2 tonnes Exclusive for 2.5 & 3.2 tonnes Nos. Capacity (tonnes) Fig. # Part # Part Name Hoist 1001 Top Hook Set L5BA008-1001 L5BA010-1001 L5BA016-1001 L5BA025-1001 L5BA032-1001 1071 Latch Assembly L5BA008-1071 L5BA010-1071 L5BA016-1071 L5BA025-1071 L5BA032-1071 L5BA008-9163...

  • Page 38: Exclusive Parts

    9.2. Exclusive Parts 6.3 tonnes 9 tonnes Note: These basic bodies are the same as 3.2 tonnes. Nos. Capacity Fig. # Part # Part Name (tonnes) Hoist 1001 Top Hook Set L5BA063-1001 L5BA090-1001 2001 Hook Assembly L5BA090-2001 1071 Latch Assembly L5BA063-1071 L5BA090-1071 2011 Top Hook Yoke A &...

  • Page 39: Optional Parts

    9.3. Optional Parts Lever assembly for load signal type ① ② ③ ④ ⑤ Capacity Parts Part (tonnes) Fig.# Part# Name Hoist 5211 Lever Set Y3SS008-5211 Y3SS010-5211 Y3SS016-5211 Y3SS025-5211 Y3SS032-5211 Y3SS063-5211 Y3SS090-5211 Lever 6211 Y3SE008-6211 Y3SE010-6211 Y3SE016-6211 Y3SE025-6211 Y3SE032-6211 Y3SE063-6211 Y3SE090-6211 Assembly Name Plate...

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