KITO ER2 Owner's Manual
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KITO ER2 Owner's Manual

Electric chain hoist
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ER2 Series Electric Chain Hoist
To Customer
• Thank you for purchasing KITO Electric Hoist (ER2).
• 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 Directives nor asbestos.
Owner's Manual
Hook Suspended Type (hoist only) : ER2
Motorized Trolley Type : ER2M
Manual Trolley Type : ER2SP/ER2SG
OM-ER2ZZZ-MGE-00
(125kg to 5t)

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Summary of Contents for KITO ER2

  • Page 1 Motorized Trolley Type : ER2M Manual Trolley Type : ER2SP/ER2SG To Customer • Thank you for purchasing KITO Electric Hoist (ER2). • Operators and maintenance engineers are requested to read this manual. After reading, please keep this manual at hand for future use.
  • Page 2 KITO shall not be liable for any incidental damage due to the use or non-use of the product such as the loss ●...
  • Page 3 ■ Restriction on Use 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 ●...

  • Page 4: Safety Precautions

    Safety Precautions Improper use of electric chain hoist causes danger such as drop of lifted load. Read this Owner’s Manual carefully before installation, operation and maintenance. Use the product after understanding the product knowledge, safety information and precautions. This Owner’s Manual classifies the safety information and precautions into two categories of “DANGER” “WARNING”...
  • Page 5 Mandatory Refer to “Disassembly/Assembly Manual” for disassembling, or contact KITO. (This product uses oil. We prepare MSDS (Materials Safety Data Sheet) for the oil. Contact KITO for it.) • Carry out daily inspection by user. • Carry out inspection (monthly, annual) by maintenance engineer.

  • Page 7: Table Of Contents

    Chapter 1 Handling the Product This chapter describes mainly how to use, assemble and install, and the check after installation. It also describes the daily inspection items before use. ● For Operators and Maintenance Engineers Type and Names of Each Part ............8 Opening the Package ..............11 Product Specification and Operational Environment ....16 How to Use ..................19...

  • Page 8: Type And Names Of Each Part

    Chapter 1 Handling the Product Type and Names of Each Part ■ Hook Suspended Type (ER2) Electric chain hoist dedicated for elevation ● Top Hook Body Electric Chain hoist name plate Chain Container Load Chain Cushion Rubber (Chain spring and end plate for the...
  • Page 9 ■ Motorized Trolley Type (ER2M) Electric Chain Hoist combined with motorized trolley (MR2) for elevation and traveling motion ● Motorized trolley nameplate Connection Box Cable Support Bar Relay Cable Power Cable Electric chain hoist nameplate Chain Container Push Button Load Chain Switch Cord Warning Tag Cushion Rubber...
  • Page 10 Chapter 1 Handling the Product Type and Names of Each Part (continued) ■ Manual Trolley Type (ER2SG/ER2SP) ER2SG : The electric chain hoist equipped with the geared trolley (TSG) enabling fine ● adjustable lateral motion of the load by pulling the hand chain. ER2SP : The electric chain hoist equipped with the plain trolley (TSP) enabling lateral motion by moving the ●...

  • Page 11: Opening The Package

    Opening the Package ■ Checking the Product Make sure that the indication on the package and the product coincide with your order. ● Make sure that the product is not deformed and damaged due to the accident during transportation. ● ■...
  • Page 12 The mass of the hook is Manufacture No. to identify the time of manufacture excluded. and the production lot. 2 SIZE…Body size Ex. Body size C, ER2-C 7 MFG. YEAR…Manufacture year The size of the electric chain hoist body to 8 SERIAL No.
  • Page 13 ■ Nameplate Indication of Motorized Trolley CODE: MR2-010S MFG.YEAR LOT No: SERIAL No: TRAVELING SPEED: 0.333 m/min 50Hz 0.400 m/min 60Hz · · · Capacity Ex. 1t, 500kg The maximum mass of the load that can be imposed on the product.
  • Page 14 Chapter 1 Handling the Product Opening the Package (continued) ■ Nameplate Indication of Manual Trolley · · · Capacity Ex. 1t, 500kg The maximum mass of the load that can be imposed on the product. The mass of the hook is excluded. 2 LOT No.
  • Page 15 • Be sure to check that the Load Chain has "RH-DAT" or "FT-DAT" mark on it and the chain size is appropriate for the ER2 model you are using. (See the following table.) The Load Chain of other models (such as model ES or ER) or different rating cannot be used.

  • Page 16: Product Specification And Operational Environment

    : ER2, single speed 75dB or less (A scale: measured at 1 m away from the Electric chain hoist) : ER2, dual speed VFD model 80dB or less (A scale: measured at 1 m away from the Electric chain hoist)
  • Page 17 ● ISO 4301 specifies the total operating hour (service life) of gears and bearings according to the loading status. For example, the total operating hour (service life) of the mechanism when it is constantly applied with the capacity is 1,600 hours for M5. The total operating hour is 6,300 hours when operated with a medium load. Total operating hour h Loading status* 1600...
  • Page 18 Chapter 1 Handling the Product Product Specification and Operational Environment (continued) ■ Operational Environment Ambient temperature : -20°C — +40°C Gradient of rail : No gradient in travel rail (for the hoist with trolley) Ambient humidity : 85 % or less (no condensation) Explosion-proof construction : Not applicable to the work environment with explosive gases or explosive vapor Non-conforming environment : A place with organic solvent or volatile powder, and a place with a plenty of powder and dust of general substances...

  • Page 19: How To Use

    How to Use ER2 Series Electric Chain Hoist has two models: single speed model and dual speed VFD model. Other than them, such products are provided that can travel/traverse when combined with a trolley or a crane. Their push button switches for operation differ in the size and the operating method.

  • Page 20: Daily Inspection Of Electric Chain Hoist (Hook Suspended Type)

    When replacing with a new nameplate or label is required, please inform KITO of the description in “Record of the Product No." (P17) such as Lot No. and Serial No. Deformation • Check visually.
  • Page 21 ■ Load Chain Item Check method Criteria When failed Elongation of • Check visually • No apparent elongation Refer to Load Chain Pitch (P69) of Chapter 2, Frequent inspection. Abrasion • Check visually • No apparent abrasion Refer to Load Chain of Wire (P69) of Chapter 2, Diameter...
  • Page 22 Chapter 1 Handling the Product How to use (continued) ■ Top Hook/Bottom Hook Item Check method Criteria When failed Opening of • Check visually • No apparent opening of the Hook Carry out the the Hook inspection item of Top and Bottom Hook (P70) of Frequent inspection.
  • Page 23 Item Check method Criteria When failed Movement • Check the Idle Sheave by Replace the bearing of CAUTION of the Idle moving the Idle Sheave. • When checking, wear gloves Sheave and be careful for your finger not to be caught. Mandatory Otherwise it may result in injury.
  • Page 24 Chapter 1 Handling the Product How to use (continued) ■ Push Button Switch Item Check method Criteria When failed Switch body • Check visually • No deformation, damage and no loosened Clean and repair the size screw label or replace with • Label indication of the push button switch can a new label.

  • Page 25: Daily Inspection Of Motorized Trolley (Mr2)

    ■ Daily Inspection of Motorized Trolley (MR2) ■ Appearance Item Check method Criteria When failed Indication of • Check visually • No peel off. Indication can be seen clearly. Clean and repair the Nameplates label or replace with a and Labels new label.

  • Page 26: Daily Inspection Of Manual Trolley (Tsg/Tsp)

    Chapter 1 Handling the Product How to use (continued) ■ Function and Performance ● Check the following item with no load. Item Check method Criteria When failed Operational • Press the push button to • To travel smoothly. No meandering and Refer to Chapter 3 vibration.
  • Page 27 ■ Function and Performance ● Check the following item with no load. Item Check method Criteria When failed Operational • Check the traveling motion • To travel smoothly. No meandering and Carry out Chapter 2 Check of the electric chain hoist by vibration.

  • Page 28: How To Operate The Push Button Switches

    Chapter 1 Handling the Product How to use (continued) ■ How to Operate the Push Button Switches CAUTION • Do not hang the Push Button Switch Cord on other object, or pull the cord strongly. • Do not use the Push Button Switch if its button does not operate smoothly. •...
  • Page 29 ■ 5-Push Button Switch Set 5-Push Button Switch Set is equipped with a lock type emergency stop button (VFD reset button) and lift/lower push buttons. One-step push button switch or two-step push button switch is mounted as Lift/lower push button switches in accordance with the specification of single speed or dual speed VFD specification.
  • Page 30 Chapter 1 Handling the Product How to use (continued) ■ 7-Push Button Switch Set 7-Push Button Switch Set is equipped with a lock type emergency stop button (VFD reset button) and lift/lower push buttons. One-step push button switch or two-step push button switch is mounted as Lift/lower push button switches in accordance with the specification of single speed or dual speed VFD specification.

  • Page 31: Operation

    ■ Operation ■ General DANGER • Do not operate the electric chain hoist in an environment with flammable or explosive gas. The electric chain hoist is not designed as explosion proof specification. • Do not use the electric chain hoist exceeding the ratings (short period rating, Prohibited intermittent rating) of the lifting motor and the maximum start-up frequency.
  • Page 32 Chapter 1 Handling the Product How to use (continued) ■ Lifting/Lowering DANGER • Do not lift more than the capacity. (Fig. E) The capacity is indicated in the nameplate. • Do not operate the electric chain hoist exceeding the lifting height. Prohibited •...
  • Page 33 CAUTION • Do not use the Friction Clutch to measure the weight of a load. The use of the Friction Clutch other than intended purpose may result in injury or property damage. Prohibited • When carrying a lifted load using a lifting magnet or a vacuum chuck, lower the height of the lifted load as low as possible.

  • Page 34: Speed Change Of Dual Speed Vfd Model

    • Only maintenance engineers or the personnel with expertise are allowed to set or change parameters. Wrong parameter settings may result in danger such as defective operation and drop of lifted load. Contact Please contact KITO for consultation. Prohibited Failure to comply with these instructions may result in death or serious injury.

  • Page 35: Precautions After Work

    ■ Precautions After Work CAUTION • Do not store the electric chain hoist at a state of over lifting or over lowering. Failure to comply with these instructions causes bodily injury or loss of property. Prohibited • Store the electric chain hoist with power off. •...

  • Page 36: Work Flow Of Assembling And Installation

    Chapter 1 Handling the Product Work Flow of Assembling and Installation The contents of the work to assemble and install the product by the maintenance engineers and installer are described from this page and after. To eliminate the redo work and for effective assembling and installation, please check the following work flow first and then start assembling and installation work.

  • Page 37: Assembling

    Assembling DANGER • Only maintenance engineers or the personnel with expertise are allowed to assemble and disassemble the electric chain hoist. Assembling or disassembling of the electric chain hoist may result in death or serious injury. Prohibited ■ Assembling Parts to Electric Chain Hoist ■...
  • Page 38 Chapter 1 Handling the Product Assembling (continued) Chain Container Seal ● A seal in the right to indicate the relation between the size of the Load Chain and the lift is attached to the Chain Container. Be sure to check it before installation. Plastic Container ●...
  • Page 39 ● When using the electric chain hoist without the Chain Container, take the following measures. 1) Mount the Stopper at the no-load side of Body size ER2-B/C/D/E the Load Chain. * Number of Links between Chain End Suspender and the Stopper...
  • Page 40 Mandatory Cheking the Gear Oil Amount ● Inspection Hole 1) ER2 Body size B/C/D: Remove the Oil Plug on the Main Body at the opposite Plug side of the Chain Container. ER2 Body size E/F: Remove the Oil Plug Plug...

  • Page 41: Combination With The Trolley

    ■ How to Use the Oil Cap (only for the Friction Clutch with mechanical brake) An Oil Cap is packaged along with the electric chain hoist equipped with built-in Friction Clutch with mechanical brake (option). When installing the hoist, remove the oil plug and attach the Oil Cap instead. When combining the motorized trolley, mount the oil cap to the hoist at a position where the Oil Cap and the frame of the Trolley do not interfere.
  • Page 42 Assembling (continued) ■Combining with the Motorized Trolley CAUTION • When using ER2 series electric chain hoist combined with our old type product, specification needs to be changed. Contact your nearest dealer or KITO. Prohibited ■ Parts replacement of the electric chain hoist The Suspender is attached to the electric chain hoist at shipping.
  • Page 43 ■ Checking the Number of the Assembled Adjusting Spacers and Their Positions When installing a trolley to the beam, the length of the Suspension Shaft (width between frames) must be adjusted in accordance with the rail width. Wrong number of wrong position of Spacers may result in the drop of the electric chain hoist. Insert the correct number of Spacers with correct ratings and for rail width at the correct position, referring to the following table.
  • Page 44 Chapter 1 Handling the Product Assembling (continued) Adjusting spacer arrangement for LOW Head Suspension (Beam flange width 175-305mm) ● Number of Adjusting Spacers Beam flange (in) 6 10 10 11 11 width (mm) 175 178 200 203 215 220 229 232 250 254 257 260 264 267 279 283 286 289 295 298 300 302 305 Parts Name Inner 4+4 4+1 1+1 1+2 4+4 5+0 2+3 3+4 1+1 1+2 4+0 1+1 1+2 2+2 2+3 3+3 1+1 1+2 2+2 2+3 3+0 4+0...
  • Page 45 Adjusting spacer arrangement for Lug Suspension ● Number of Adjusting Spacers Beam flange (in) 2 width (mm) 58 98 100 102 106 110 113 125 127 131 135 137 143 153 155 160 163 170 Parts Name 0 1+0 1+1 1+2 2+2 3+3 0 1+0 1+1 3+3 4+0 4+1 1+1 2+2 2+3 3+0 Thin spacer Thick spacer...
  • Page 46 Spacer, Thick Spacer and a Thick Spacer L. Split pin Thick spacer Thick spacer L 4) Set the Suspender T of ER2 Body size with the Suspension Shaft and the Fixing Shaft. Split pin Shaft Bolt 5) Set the Suspension Shaft with another...
  • Page 47 ■Parts replacement of the Electric Chain Hoist Manual Trolley For Double Chain Type Remove the Top Hook and replace it with a Connection Yoke. Replacing the Top Hook of Body size ER2-B/C/D/E ● 1) Remove the Shaft Retainer Clip using plier. Top Hook 2) Remove Socket Bolt from the Shaft Retainer, and remove the Shaft Retainer.
  • Page 48 Chapter 1 Handling the Product Assembling (continued) ■ Checking the Number of the Assembled Adjusting Spacers and Their Positions When installing a trolley to the beam, the length of the Suspension Shaft (width between frames) must be adjusted in accordance with the rail width. Wrong number of wrong position of Spacers may result in the drop of the electric chain hoist.
  • Page 49 Number of Adjusting Spacers Beam flange (in) 6 10 10 11 11 width (mm) 170 175 178 200 203 215 220 229 232 250 254 257 260 264 267 279 283 286 289 295 298 300 302 305 Parts Inner 3+3 0+0 0+1 1+1 1+2 4+4 4+5 2+3 3+3 4+5 1+1 0+0 0+1 1+1 1+2 2+2 2+3 4+5 1+1 1+2 2+2 3+3 3+4 4+4 4+5 1+5 Thin spacer Outer 3 Inner 2+2 3+3 3+3 3+3 3+3 3+3 3+3 0+0 0+0 0+0 1+1 2+2 2+2 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 3+3 3+3 3+3 3+3 4+3...
  • Page 50 Chapter 1 Handling the Product Assembling (continued) ■ Combination of the Electric Chain Hoist and the Manual Trolley DANGER • Use new split pins. After insertion, bend the pin securely at its both ends. Use of old split pins may result in death or serious injury due to drop. Mandatory 125 kg~2.5 t ●...
  • Page 51 3 t~5 t (For Double Chain type) ● Split pin 1) Fix the Suspension Shaft to the Frame G or the Frame S with a Suspension Shaft Frame S Bolt, a slotted nut and a split pin. • When fixing the Frame G or the Frame S to the Frame G Suspension Shaft, use the hole for standard rail Split pin...

  • Page 52: Checking Power And Power Cable

    • Check that the source voltage satisfies the rated voltage of the electric chain hoist. Failure to comply with this instruction may result in death or serious injury. Mandatory ■ Checking the Power Hook suspendeed Type:ER2 ● Manual trolly type:ER2SP/ER2SG Capacity of fuse and...
  • Page 53 When using the cable of the size other than those described in the table, decide the cable length using the following formula. 1000 Cross section of one core (mm )×Rated voltage (V)×0.02 Permissible length (m) = × 30.8 Rated current (A) Hook suspendeed Type:ER2 ● Manual trolly type:ER2SP/ER2SG (Unit: m) (Unit: m) 230V Class 400V Class PWB Anchor 230/460V Class...

  • Page 54: Connecting Cables

    Chapter 1 Handling the Product Assembling (continued) ■ Connecting Cables NOTE • When clamping a connector, do not use tools. Be sure to clamp it by hand. Excessive tightening of a connector may result in the damage or breakage f plastic thread part. •...
  • Page 55 1) Remove the Holder A mounted to the cable for power supply in the connector Connection Box. socket (4P) of ER2. Tighten the Lock 2) Pass the Power Cable through the Ring securely. Holder A supported by the cable holder and the cable packing.
  • Page 56 Chapter 1 Handling the Product Assembling (continued) ■Manual Trolley Type ■125 kg~5 t Connecting the Power Cable ● 1) Insert the 4-pin plug of the Power Cable to the socket (4P) and tighten the Lock Ring securely. Lock Ring 2) Fix the Power Cable using cable support with a slack.

  • Page 57: Installation

    • Installation (removal) of the electric chain hoist must be carried out by special installer or by personnel with expertise. Consult with the sales shop or KITO for installation, or consign the installation work to special installer or personnel with expertise.

  • Page 58: Installing The Trolley Combined Model

    When the gap between the rail end the wall of the housing is scarce ● CAUTION • Securely support the electric chain hoist Mode ER2 not to tilt. Failure to comply with this instruction causes bodily injury or loss of property. Mandatory...
  • Page 59 ■ Mounting the Stopper Be sure to mount the stoppers at the both ends of the rail to prevent drop. Decide the mounting position in accordance to the size of the wheel. When the customer wants to make the stopper by oneself, refer to the following figures. Beam width Stopper Bolt...
  • Page 60 T-shape Suspender can be applicable to curved rail, however, the application method differs depending on the condition such as radius of curvature. In such case, contact KITO. 1) Mount the wire support bar at the both Rail ends of the rail.

  • Page 61: Check After Installation

    Check after Installation Wrong assembling or installation causes death or serious injury. To prevent such danger check the following. ■ Check items Make sure that the following are satisfied: • No bolt, nut nor split pin is lost. Tightening and assembling are completed. • Protection Wire for Push Button Switch Cord is securely tied to accept and endure the force instead of Push Button Switch Cord when the Push Button Switch Set is drawn.
  • Page 62 Chapter 1 Handling the Product...

  • Page 63: Chapter 2 Inspection

    Chapter 2 Inspection This chapter describes frequent inspection items and periodic inspection items. Refer to Chapter 1 for the “Handling the Product”. Inspection is the first step of safety. Carry out daily inspection, frequent inspection and periodic check. Table of Contents ................64 Safety Precautions ................66 Frequent Inspection ................68 Periodic Inspection ................75...

  • Page 64: Table Of Contents

    Abrasion and flaw of the Load Sheave ………… 81 Push Button Switch, Power Supply …………… 74 Abrasion and flaw of the Idle Sheave ………… 81 (Refer to Electric Chain Hoist (ER2) Frequent Inspection) V ring ……………………………………………… 81 Electrical Equipment ■ Manual Trolley (TS2) Frequent Inspection Electrical Parts ……………………………………...
  • Page 65 Appearance ……………………………………… 86 Abrasion of Wire Diameter …………………… 21 Electrical Equipment and Electric Characteristics … 86 Deformation, Flaw, Entanglement …………… 21 (Refer to Electric Chain Hoist (ER2) Periodic Inspection) Rust, Corrosion ………………………………… 21 Twist ……………………………………………… 21 Function and Performance Lubrication ……………………………………… 21 Operational Check ………………………………...

  • Page 66: Safety Precautions

    KITO electric chain hoist. Prohibited Even if the part is genuine KITO part, it cannot be used for other model. Refer to Disassembly/Assembly Manual (Annex) for the correct use of the part. • Do not adjust or disassemble the Electromagnetic Brake, the Friction Clutch and the Friction Clutch with Mechanical Brake.
  • Page 67 NOTE • When performing the frequent inspection, carry out the daily inspection at the same time. • When performing the periodic inspection, carry out the frequent inspection at the same time. • When detecting any abnormality during inspection due to erroneous use, instruct the operator and user for correct use of the electric chain hoist.

  • Page 68: Frequent Inspection

    • Do not change the VFD parameter. When parameters need to be changed, ask our distributors nearest to the customer or KITO. • Do not carry out the work such as maintenance and inspection within 5 minutes after power off.

  • Page 69: Electric Chain Hoist (Er2) Frequent Inspection

    ● Use the needle head caliper (point caliper) to measure the sum of pitches and wire diameter. ● Apply oil on the Load Chain after inspection. ● Application of lubricant influences on the life of the Load Chain considerably. Use the KITO genuine lubricant or equivalent (industrial lithium grease: consistency No.0) ●...

  • Page 70: Top Hook, Bottom Hook

    Abrasion not to exceed 5% Dimension c • Following tables shows the nominal standard values. Please be aware that these values include tolerance because of forging. ER2 Hook Service Limit (P92) or Criteria Dimension Dimension b (mm) Dimension c (mm) a (mm) Code...

  • Page 71: Peripheral Parts Of The Body Size

    ■ Peripheral parts of the Body size ● Use check stand to check the electric chain hoist from the close point. Item Check method Criteria When failed Chain • Check visually. • To be mounted to the body size securely Replace the Chain Container • No damage, tear, abrasion or deformation...

  • Page 72: Push Button Switch

    Chapter 2 Inspection Frequent Inspection (continued) ■ Push Button Switch Item Check method Criteria When failed Push Button • Check visually and by • No damage, deformation and loosened bolt. Replace the Push Switch Body operation. • Push Button Switches can be operated Button Switch.

  • Page 73: Power Supply

    ■ Power Supply Item Check method Criteria When failed Power Cable • Check visually. • Power Cable to have enough length. Replace the Power • To have no damage Cable. • To be connected securely Cable Hanger • Check visually and by • To have no damage Re-mount the Cable moving by hand.

  • Page 74: Motorized Trolley (Mr2) Frequent Inspection

    Apply oil to gears. (to the gears of wheel) ■ Push Button Switch, Power Supply Carry out the inspection referring to “Frequent Inspection Items” of the electric chain hoist (ER2). (P72, 73) ■ Manual Trolley (TS2) Frequent Inspection ■ Appearance Item...

  • Page 75: Periodic Inspection

    • Do not change the VFD parameters. When parameters need to be changed, ask our distributors nearest to the customer or KITO. • Do not carry out the work such as maintenance and inspection within 5 minutes after power off.

  • Page 76: Electric Chain Hoist (Er2) Periodic Inspection

    Chapter 2 Inspection Periodic Inspection (continued) ■ Electric Chain Hoist (ER2) Periodic Inspection ■ Top Hook, Bottom Hook Item Check method Criteria When failed Number of • Check the number of start • Number of start must not exceed the...

  • Page 77: Chain Spring

    Otherwise it may result in bodily injury or property damage. Service Limit of Chain Spring for Capacity (Do not fall short of the limit value.) Dimensional standard Length of Chain Spring Code Capacity Standard Limit value ER2-015S 1.5t – – ER2-015IS/SD ER2-020L ER2-020IL/LD ER2-020S ER2-020IS/SD ER2-025S 2.5t...

  • Page 78: Chain Pin (Double Type Only)

    Chapter 2 Inspection Periodic Inspection (continued) Item Check method Criteria When failed Chain Pin • Check visually and measure • To have no apparent deformation and flaw. Replace the Chain Pin. (double type with vernier caliper. Service Limit of Chain Pin only) (Do not fall short of the limit value.) Diameter d (mm) Code Standard Limit value...

  • Page 79: Electromagnetic Brake

    Single speed model Dual speed VFD model Pole change model Hub joint Code limit Code limit Code limit (enlarged: top view) (mm) (mm) (mm) Square hub type ER2-001H ER2-001IH ER2-001HD ER2-003S ER2-003IS 0.60 ER2-003SD Brake ER2-005L ER2-005IL ER2-005LD 0.60 ER2-003H ER2-003IH ER2-003HD...

  • Page 80: Driving Mechanism

    Chapter 2 Inspection Periodic Inspection (continued) ■ Driving Mechanism Item Check method Criteria When failed Bearing • Check visually and rotate • T o have no harmful deficiency such as Replace the Bearing. the Bearing by hand. apparent abrasion, flaw and damage. To rotate • Check the operating hours smoothly. with the CH Meter. • The operating hours must not exceed the guidelines for replacement.

  • Page 81: Friction Clutch With Mechanical Brake

    • Service limit of the Load Sheave and Idle Sheave Thickness (Do not fall under the limit) Thickness at purchasing Thickness (mm) Code Capacity (t) Standard Limit ER2-001H/IH/HD 125kg Abrasion and • Disassemble the Load Replace the Idle ER2-003S/IS/SD 250kg flaw of the Sheave and check it visually. Sheave.

  • Page 82: Electrical Equipment

    Chapter 2 Inspection Periodic Inspection (continued) ■ Electrical Equipment Item Check method Criteria When failed Electrical • Remove the Controller • To have no damaged or burnt part. Replace the damaged Parts Cover and check the • To have no loosened bolt. Electrical parts or burnt electrical part.

  • Page 83: Grounding Resistance

    Item Check method Criteria When failed Grounding • Measure the grounding • grounding resistance 100Ω or less Make a grounding Resistance resistance with earth- correctly. DANGER resistance meter. • Turn off the power when measuring the grounding resistance. Mandatory Measuring the grounding resistance without turning off the power may result in death or serious injury due to electric shock.

  • Page 84: Brake

    Chapter 2 Inspection Periodic Inspection (continued) ■ Motorized Trolley (MR2) Periodic Inspection ■ Brake Item Check method Criteria When failed Appearance • Disassemble the Brake and • T o have no deformation, flaw and damage on Replace the Part. check it visually. the Brake Drum and the Motor Cover. • To have no deformation and damage on the Replace the Brake Brake Spring.

  • Page 85: Lifting Shaft

    Item Check method Criteria When failed Lifting Shaft • Check visually. • To have no considerable deformation and Replace the Lifting • Measure the shaft diameter abrasion Shaft. with vernier caliper. • The shaft with obvious deformation reaches at the service limit. Shaft diameter • Abrasion limit of the shaft is 5 % of its diameter respectively.

  • Page 86: Travel Rail

    When failed Appearance • Check the cable surface • The Relay Cable has no deformation or Replace the Relay visually. damage. To be mounted securely. Cable. ■ Electrical Equipment and Electric Characteristics Refer to Electric Chain Hoist (ER2) Periodic Inspection (P82).

  • Page 87: Function And Performance

    ■ Function and Performance DANGER • After completion of the inspection of each part, perform the operational check for correct operation. Neglecting to perform the operational check may result in death or serious injury. Mandatory ● Perform the following inspections with capacity. Item Check method Criteria...

  • Page 88: Manual Trolley (Tsg/Tsp) Periodic Inspection

    Chapter 2 Inspection Periodic Inspection (continued) ■ Manual Trolley (TSG/TSP) Periodic Inspection ■ Body size Components Item Check method Criteria When failed Wheel • Check visually. • To have no considerable deformation Replace the Wheel. • Measure dimensions D and and damage t with vernier caliper.

  • Page 89: Deformation And Abrasion

    Item Check method Criteria When failed Deformation • Check the deformation • T o have no deformation of beam flange such Replace or repair the and Abrasion and abrasion visually and as twist and shear drop Travel Rail. measure them with vernier • To have no exceeding abrasion of rail surface caliper.

  • Page 90: Guidelines For Parts Replacement Based On Indication Of Ch Meter

    Type of gear oil and its amount for one body size Specification Code Gear oil amount (ml) Oil manufacturer Oil type ER2-001H, 001IH, 003S, 003IS,001HD,003SD ER2-003H, 003IH, 005L, 005IL, 005S, 005IS, 003HD,005SD,005HD ER2-010L, 010IL,010SD,010LD Friction Clutch KITO genuine oil KITO genuine oil...

  • Page 91: Guidelines On The Service Life Of Contactor And Its Replacement

    ■ Guidelines on the service life of contactor and its replacement Replace the Contactor in accordance with the following rate of inching and the number of start. Replace the Contactor every five years even if the number of start does not reach at the following. Number of start to replace contactor Every 200,000 Every 500,000...

  • Page 92: Check Of Operating Hours And Number Of Start (Ch Meter)

    Chapter 2 Inspection Periodic Inspection (continued) ■ Guidelines on Bearing Replacement Operating hours to replace parts Every 800 hours Every 1600 hours Every 3200 hours Body size grade M6, 3m – – Parts replacement M5, 2m – Parts replacement – M4, 1Am Parts replacement –...

  • Page 93: Chapter 3 Troubleshooting

    Chapter 3 Troubleshooting This chapter describes the main failure cause and inspection items based on the fault conditions. The repair work (and maintenance work as well) of the electric chain hoist is accompanied with disassembling/assembling work. Refer to the separate “Disassembling/Assembling Manual” for the correct work. ■Guidance on Troubleshooting ............94 ■Safety Precautions ................98 ■Troubleshooting................99...

  • Page 94: Reference

    Chapter 3 Troubleshooting Guidance on Troubleshooting ■ Guidance on Troubleshooting Following table is the summary of the main failure causes based on the failure conditions and their inspection items. Refer to the page of each item for the check method, treatment and the details of countermeasure. • Refer to “Technical Materials”...
  • Page 95 Reference Conditions Main fault contents Check item page Abnormal Popping sound Abrasion of the Load Load Chain noise Chain Abrasion of the Load Load Sheave, Idle Sheave Sheave Sounds strange operating sound Abrasion or breakage of Gears and Joints Gear Deterioration of Bearing Bearing Brake noise...
  • Page 96 Chapter 3 Troubleshooting Guidance on Troubleshooting (continued) ■ Dual Speed VFD Model Reference Conditions Main fault contents Check item page Unable to restart the VFD by resetting with emergency stop Those related to VFD Check the error code of “VFD (the case when the VFD cannot be reset even after cool down) VFD referring to “VFD Manual”...
  • Page 97 Reference Conditions Main fault contents Check item page Does not stop Too long stopping distance Relay failure or melted Relay normally. contact point Too long (or short) stopping distance Abrasion of brake lining Brake Does not stop at the upper/lower limit. Negative phase connection Power Cable of motor lead wires...

  • Page 98: Safety Precautions

    • When replacing the part, be sure to use the genuine part for KITO electric chain hoist ER2, ER2M, ER2SP and ER2SG. Even if the part is the KITO genuine part, the part for different model may not be used. Use the correct part in accordance with separate “Disassembling/Assembling Manual”.

  • Page 99: Troubleshooting

    Troubleshooting Power Symptom Cause Remedy Main factor Countermeasure Electric chain hoist Improper source Measure the voltage of each phase at Faulty power receiving Check the power does not operate. voltage power receiving terminal. facility receiving facility If the source voltage is improper, check regularly.

  • Page 100: Power Cable

    Chapter 3 Troubleshooting Troubleshooting (continued) Power Cable Symptom Cause Remedy Main factor Countermeasure Electric chain hoist Wire breakage Check the conduction, flaw, crimping of Excessive force Support the cable with does not operate. (more than two terminals and soldering of plug. applied on the cable Cable Support Arm wires)

  • Page 101: Motor

    Motor Symptom Cause Remedy Main factor Countermeasure Motor does not Motor coil burning Measure the coil resistance of each Over current due to Operate the electric operate. (two or more phase. Replace the motor when the over voltage or low chain hoist at the rated phases) resistance of all phases are infinity.

  • Page 102: Brake

    Chapter 3 Troubleshooting Troubleshooting (continued) Brake DANGER • Do not adjust/disassemble the Electromagnetic Brake. Adjusting or disassembling the Electromagnetic Brake may result in death or serious injury. Prohibited Symptom Cause Remedy Main factor Countermeasure Electromagnetic Brake coil burning Measure the coil resistance of the Brake Over current due to Operate the electric Brake does not...
  • Page 103 Symptom Cause Remedy Main factor Countermeasure Electromagnetic Rusting When the Brake is rusted shut, replace Wrong assembling of Assemble the brake Brake does not the brake unit as a whole. packings cover packings and V operate. ring securely. Replace the packing if deteriorated.

  • Page 104: Internal Wiring

    Chapter 3 Troubleshooting Troubleshooting (continued) Internal wiring Symptom Cause Remedy Main factor Countermeasure Electric chain hoist Breakage of wire Check the wire. Repair the wire if broken. Vibration, impact Use the electric chain does not operate. hoist avoiding the impact. Lead wire damaged at Be careful not to have assembling...

  • Page 105: Electromagnetic Contactor, Relay

    Electromagnetic Contactor, Relay Symptom Cause Remedy Main factor Countermeasure Electric chain hoist Electromagnetic Operate the contactor manually to check Excessive inching or Do not perform does not stop Contact point the conduction. plugging operation excessive operation. welding, or fusing When the contact point is welded or (consecutive fused, replace the contactor.

  • Page 106: Upper/Lower Limit Switch

    Chapter 3 Troubleshooting Troubleshooting (continued) Upper/Lower Limit Switch Symptom Cause Remedy Main factor Countermeasure Electric chain hoist Contact point fusing Actuate the limit switch manually to Habitual use of the limit Do not use the limit does not operate. check the conduction of the contact switch switch habitually.

  • Page 107: Push Button Switch

    Push Button Switch Symptom Cause Remedy Main factor Countermeasure Electric chain hoist Emergency Stop When the Emergency Stop button is Forgot releasing the Read “How to operate does not operate. button is pressed to Emergency Stop the push button” (P28) pressed and locked, turn it clockwise to (Electromagnetic its end and locked.

  • Page 108: Vfd

    Chapter 3 Troubleshooting Troubleshooting (continued) Symptom Cause Remedy Main factor Countermeasure Electric chain hoist VFD failure Reset the VFD by pressing Emergency VFD failure Check the error code does not operate. Stop button. It the VFD still does not indicated by VFD operate, check it.

  • Page 109: Electric Shock

    (The gear oil for Friction Clutch with Mechanical Brake is different from the standard specification oil.) Mandatory Use of the oil other than KITO genuine oil may result in death or serious injury due to the drop of a lifted load. Leaving the electric...

  • Page 110: Friction Clutch With Mechanical Brake

    (The gear oil for Friction Clutch with Mechanical Mandatory Brake is different from the standard specification oil.) Use of the oil other than KITO genuine oil may result in death or serious injury due to the drop of a lifted load. Secular change...

  • Page 111: Hook

    Hook Symptom Cause Remedy Main factor Countermeasure Widened Hook Deformation of the Replace the Hook if the deformation Over load Use the electric chain opening Hook exceeds the criteria. (See P70.) hoist with a load less than the capacity. Earth lifting Do not carry out earth lifting.
  • Page 112 Chapter 3 Troubleshooting Troubleshooting (continued) Hook (continued) Symptom Cause Remedy Main factor Countermeasure Hook Latch has Deformation of the Replace the Hook if the deformation Over load Use the electric chain come off Hook exceeds the criteria. (See P70.) hoist with a load less than the capacity.

  • Page 113: Load Chain

    Load Chain Symptom Cause Remedy Main factor Countermeasure Twisted Load Chain Capsized Bottom Turn over the Bottom Hook to the original Bottom Hook was When using multi fall Hook position to cancel the capsizing. turned over by one turn model hoist, check during working.
  • Page 114 Store the electric chain hoist exposed to rain hoist indoor or under the roof when not using. Influence of sea water Contact KITO for and chemicals the use in special environment in advance. Use the electric chain hoist correctly within the scope guaranteed by the manufacturer.

  • Page 115: Load Sheave, Idle Sheave

    (The gear oil for Friction Clutch with Mechanical Mandatory Brake is different from the standard specification oil.) Use of the oil other than KITO genuine oil may result in death or serious injury due to the drop of a lifted load. Long hour operation...

  • Page 116: Bearing

    Chapter 3 Troubleshooting Troubleshooting (continued) Bearing Symptom Cause Remedy Main factor Countermeasure Unable to lift a load. Sticking, Breakage Replace the bearing. Use under hot Avoid using under environment or hot environment or excessively frequent use excessively frequent use Strange noise Deterioration Replace the bearing.
  • Page 117 Traveling motion of the Trolley (only for motorized trolley) Symptom Cause Remedy Main factor Countermeasure Wheel unable to rotate Locking of brake Disassemble the motor Ambient conditions, Check regularly. cover. Remove rust and environment stains. Electric system failure (Refer to the items of Electric chain hoist) (Refer to the items of Electric chain hoist) Serpentine motion...
  • Page 118 Chapter 3 Troubleshooting...

  • Page 119: Appendix

    • Wiring Diagram of Dual Speed ER2M ........149 ■ Check Sheet for ER2 Series Electric Chain Hoist Daily inspection ..154 ■ Check Sheet for ER2 Series Electric Chain Hoist Frequent Inspection ..156 ■ Check Sheet for ER2 Series Electric Chain Hoist Periodic Inspection ..158...

  • Page 120: Optional Parts

    C : (103mm) D : (128mm) T-shape Suspender 175 A : (153mm) • Contact KITO when the Travel Rail width exceeds 175 mm. Mounting Suspender Presser ● • When using T-shape Suspender, the suspender presser needs to be mounted to the trolley.
  • Page 121 Standard Standard Low speed High speed Low speed High speed speed speed Chain End ER2-001H ER2-001IH/HD ER2BS9408 Suspender ER2-003S ER2-003H ER2-003IS/SD ER2-003IH/HD Socket Bolt J1BE1-0806528 125kg Lever Nut C2BA100-9074 250kg Socket Bolt J1BE1-0503012 U Nut E2DBX10S9853 Plain Washer J1WD011-00050 Chain End...

  • Page 122: Product Structure And Names Of Each Part

    Appendix Product Structure and Names of Each Part Controller cover The structure inside the controller cover and the names of each part are described below. Top Hook Packing G Shaft retainer clip Gear case Oil seal Friction clutch Load gear Load Sheave Body Shaft retainer plate...
  • Page 123 ■ Single Speed Model (500V Class Dual Speed Panel Model) Controller cover Limit switch Packing C ■ Dual Speed VFD Model (Body size B, C) Panel Inverter Controller cover Braking resistor Limit switch Resistor cover Interface board Packing C Nameplate ■...

  • Page 124: Technical Material

    1.002 1.504 2.004 2.504 3.005 5.014 Lifting Load (t) Note) Above figures are for the standard specification Hook for Electric Chain Hoist ER2. ■ Rated Motor Current ■ Lifting motor (Single speed) (Unit:A) 230V Class 400V Class 230/460V Class 500V Class...
  • Page 125 Capacity Motor Code output 208-230V 415-460V 500V 575V 380– 380– 220–230V output (kW) 415V 440V (kW) 60Hz 50Hz 60Hz 125kg ER2-001IH 250kg ER2-003IS 0.56 1.6/0.9 1.4/0.9 500kg ER2-005IL 250kg ER2-003IH 500kg ER2-005IS 1.8/1.4 1.7/1.4 ER2-010IL ER2-010IS ER2-015IS 3.2/2.2 3.2/2.0 ER2-020IL...

  • Page 126: Specification And Dimensions Of Single Speed Er2

    Appendix Technical Material (continued) ■ Specification and Dimensions of Single Speed ER2 ■ Specification Specification of ER2 Lifting motor Lifting speed (m/min) Load chain Additional Push Button Test Capacity (t) Code Body Standard mass per Intermittent Switch cord Grade Weight...

  • Page 127: Specification And Dimensions Of Single Speed Er2M

    ■ Specification and Dimensions of Single Speed ER2M ■ Specification Specification of ER2 Specification of MR2 Other specification Lifting motor Lifting speed (m/min) Load chain Traveling motor Traveling speed (m/min) Rail Push Button MIinimum Additional Capacity Code Body Standard Switch cord...

  • Page 128: Specification And Dimensions Of Single Speed Er2Sp

    Appendix Technical Material (continued) ■ Specification and Dimensions of Single Speed ER2SP ■ Specification Specification of ER2 Specification of TSP (plain trolley) Specification of ER2SP Lifting motor Lifting speed (m/min) Load chain Hand MIinimum Additional Capacity Push Button Code Body...

  • Page 129: Specification And Dimensions Of Single Speed Er2Sg

    ■ Specification and Dimensions of Single Speed ER2SG ■ Specification Specification of ER2 Specification of TSG (geared trolley) Specification of ER2SG Lifting motor Lifting speed (m/min) Load chain Hand MIinimum Additional Capacity Push Button Code Body Standard Chain Rail Width: B...

  • Page 130: Specification And Dimensions Of Dual Speed Vfd Er2

    Appendix Technical Material (continued) ■ Specification and Dimensions of Dual Speed VFD ER2 ■ Specification Specification of ER2 Lifting motor Lifting speed (m/min) Load chain Push Button Additional Capacity Test Code Body Standard Switch cord Mass mass per Intermittent 50Hz/60Hz...
  • Page 131 ■ Dimensions (mm) Minimum Capacity Code distance between (MFC) (MFC) (MFC) Hooks: C 125kg ER2-001IH 535(564) 276(305) ER2-003IS 250kg ER2-003IH 568(593) ER2-005IL 571(598) 300(325) 271(273) ER2-005IS 568(593) ER2-010IL 614(632) 298(300) 316(332) ER2-010IS 623(639) ER2-015IS 710(737) 372(397) 338(340) 384.5 160.5 137.5...

  • Page 132: Specification And Dimensions Of Dual Speed Vfd Er2M

    Appendix Technical Material (continued) ■ Specification and Dimensions of Dual Speed VFD ER2M ■ Specification Specification of ER2 Lifting motor Lifting speed (m/min) Load chain Capacity Push Button Code Body Standard ER2 series Switch cord Grade 50Hz/60Hz Output Intermittent Wire diameter (mm) ×...
  • Page 133 ■ Dimensions (mm) Other dimensions are the same with those of Single Speed ER2M. (to be continued)

  • Page 134: Conversion Table Between Lift/Travel/Speed

    Appendix Technical Material (continued) ■ Conversion Table between Lift/Travel/Speed (m/s"m/min) Converted Conventional Converted Conventional Converted Conventional Converted Conventional Converted Conventional Converted Conventional value (m/s) value (m/min) value (m/s) value (m/min) value (m/s) value (m/min) value (m/s) value (m/min) value (m/s) value (m/min) value (m/s) value (m/min)

  • Page 135: Clearance Between Trolley And Applicable Rail

    ■ Clearance between Trolley and Applicable Rail ■ Motorized Trolley (Unit:mm) Clearance between trolley and rail I-beam size Single Double × × × × × × × × × 13.8 9.75 × × × × × × × 13.8 9.75 ×...

  • Page 136: Wiring Diagram Of Single Speed Er2/Er2Sp/Er2Sg

    Appendix Technical Material (continued) ■ Wiring Diagram of Single Speed ER2/ER2SP/ER2SG 230V class , 400V class , 500V class (Plug Connection)
  • Page 137 230V class , 400V class , 500V class (Direct Connection) (to be continued)
  • Page 138 Appendix Technical Material (continued) 230/460V class (208-230V) (Plug Connection)
  • Page 139 230/460V class (415-460V) (Plug Connection) (to be continued)

  • Page 140: Wiring Diagram Of Dual Speed Er2

    Appendix Technical Material (continued) ■ Wiring Diagram of Dual Speed ER2 230V class , 400V clas (Plug Connection)
  • Page 141 230V class , 400V clas (Direct Connection) (to be continued)
  • Page 142 Appendix Technical Material (continued) 230/460V class (208-230V) (Plug Connection)
  • Page 143 230/460V class (415-460V) (Plug Connection) (to be continued)
  • Page 144 Appendix Technical Material (continued) 500V class (Plug Connection)

  • Page 145: Wiring Diagram Of Single Speed Er2M

    ■ Wiring Diagram of Single Speed ER2M 230V class , 400V class , 500V class (Plug Connection) (to be continued)
  • Page 146 Appendix Technical Material (continued) 230V class , 400V class , 500V class (Direct Connection)
  • Page 147 230/460V class (208-230V) (Plug Connection) (to be continued)
  • Page 148 Appendix Technical Material (continued) 230/460V class (415-460V) (Plug Connection)

  • Page 149: Wiring Diagram Of Dual Speed Er2M

    ■ Wiring Diagram of Dual Speed ER2M 230V class , 400V class (Plug Connection) (to be continued)
  • Page 150 Appendix Technical Material (continued) 230V class , 400V class (Direct Connection)
  • Page 151 230/460V class (208-230V) (Plug Connection) (to be continued)
  • Page 152 Appendix Technical Material (continued) 230/460V class (415-460V) (Plug Connection)
  • Page 153 500V class (Plug Connection)

  • Page 154: Abrasion Of Wire Diameter

    Appendix Check Sheet for ER2 Series Electric Chain Hoist Daily Inspection Code Capacity Lot No. Your CTRL No. Installation date Location Inspection Certification valid thru Electric Chain Hoist Motorized Trolley Geared Trolley TS2 (TSG) Plain Trolley TS2 (TSP) ■ Electric Chain Hoist ER2 Daily Inspection ■Check result : ○...

  • Page 155: Deformation And Damage Of Each Part

    • When any abnormality is observed during inspection, stop the use of Decide the check items electric chain hoist, indicate “FAILURE”, and contact the maintenance appropriate to the engineer or KITO for repair. environment and operating Mandatory conditions of the customer.

  • Page 156: Check Sheet For Er2 Series Electric Chain Hoist Frequent Inspection

    Appendix Check Sheet for ER2 Series Electric Chain Hoist Frequent Inspection Code Capacity Lot No. Your CTRL No. Installation date Location Inspection Certification valid thru Electric Chain Hoist Motorized Trolley Geared Trolley TS2 (TSG) Plain Trolley TS2 (TSP) ■ Electric Chain Hoist ER2 Frequent Inspection ■Check result : ○...
  • Page 157 Visual inspection To have apparent deformation and damage Oiling Visual inspection To be oiled adequately Refer to check table of electric chain hoist ER2 for electrical parts, push button switch, power feeding and electrical characteristics. Executed by Inspector Checked by Maintenance Engineer ■...

  • Page 158: Check Sheet For Er2 Series Electric Chain Hoist Periodic Inspection

    Appendix Check Sheet for ER2 Series Electric Chain Hoist Periodic Inspection Code Capacity Lot No. Your CTRL No. Installation date Location Inspection Certification valid thru Electric Chain Hoist Motorized Trolley Geared Trolley TS2 (TSG) Plain Trolley TS2 (TSP) ■ Electric Chain Hoist ER2 Periodic Inspection (1/2) ■Check result : ○...
  • Page 159 Use of the product with abnormality may result in death or serious injury. ■ Electric Chain Hoist ER2 Periodic Inspection (2/2) ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, ×Bad, Needs replacement (adjustment)
  • Page 160 To be connected securely without deformation and Appearance Visual inspection damage Refer to check table of electric chain hoist ER2 for electrical parts, push button switch, power feeding and electrical characteristics. Traveling operation Perform inspection of the items on function/performance with a capacity...
  • Page 161 • When any abnormality is observed during inspection, stop the use of Decide the check items electric chain hoist, indicate “FAILURE”, and contact the maintenance appropriate to the engineer or KITO for repair. environment and operating Mandatory conditions of the customer.

  • Page 162: Warranty

    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...
  • Page 164 Global Website: kito.com Utilizing 70% post-consumer recycled paper pulp...

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