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KITO ER Series Owner's Manual And Safety Instructions

Electric chain hoist
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BULLETIN NO. ERM-9806-MC-11
OWNER'S (OPERATOR'S) MANUAL
AND SAFETY INSTRUCTIONS
FOR KITO ELECTRIC CHAIN HOIST
ER
SERIES
125kg through 5t capacity
Approved by CSA
ALWAYS KEEP THIS MANUAL FOR YOUR REFERENCE.

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  • Page 1 BULLETIN NO. ERM-9806-MC-11 OWNER'S (OPERATOR'S) MANUAL AND SAFETY INSTRUCTIONS FOR KITO ELECTRIC CHAIN HOIST SERIES 125kg through 5t capacity Approved by CSA ALWAYS KEEP THIS MANUAL FOR YOUR REFERENCE.

  • Page 2: Table Of Contents

    CONTENTS 1. DEFINITIONS............................1 2. INTENDED PURPOSE........................1 3. BEFORE USE............................1 3.1 Safety summary..........................1 3.2 Safety instructions........................... 2 3.2.1 Before use ..........................2 3.2.2 While operation........................2 3.2.3 After operation ......................... 3 3.2.4 Maintenance ..........................3 3.2.5 Others ............................3 4.
  • Page 3 6. OPERATION ............................31 6.1 Intended purpose of hoist operation....................31 6.2 Safety working environment......................31 6.3 Electric chain hoist.......................... 31 6.4 Electric chain hoist with motorized trolley ..................32 6.4.1 Operation..........................32 6.4.2 Precautions in usage......................... 33 7. MAINTENANCE ..........................34 7.1 Lubrication ............................

  • Page 4: Definitions

    2. INTENDED PURPOSE KITO electric chain hoist is designed for vertically lifting, lowering and horizontally carrying loads by means of switching the pendant push button under normal atmospheric conditions of the workplace.

  • Page 5: Safety Instructions

    ALWAYS use two hoists which each has Capacity equal to or more than the load to be lifted whenever you must use two hoists to lift a load. ALWAYS use KITO original chains or authorized chains. ALWAYS check and keep the surface of the load chain oiled.

  • Page 6: After Operation

    NEVER support a load on the tip of the hook. NEVER contact the load chain over an edge. NEVER weld or cut a load suspended by a hoist. NEVER use the hoist chain as a welding electrode. NEVER operate a hoist if chain jumping or excessive noise occurs. NEVER use the capsized load chain.

  • Page 7: Main Specifications

    5(L) 11.2 34.0 Remarks : (1) Contact KITO or an authorized KITO dealer for information on using the hoist outside the working temperature or humidity range. (2) For dimensions and further details, refer to the latest catalogue. (3) For larger Capacity hoists (7.5t and larger), refer to the ERML-9806-MC manual.

  • Page 8: Mechanical Classification (Grade) And Life

    KITO electric chain hoists ER series are designed for grade 1Am, 2m in the FEM regulations (FEM 9.511) and M4, M5 in the ISO regulations (ISO 4301) shown in Table 4-2. The grades are provided in Table 4-3 to Table 4-6.
  • Page 9 Table 4-3 1Am(FEM) Load spectrum Cubic Average daily Total Load Definitions mean operating operating distribution value time(h) time(h) Mechanisms or parts thereof, usually subject to 2 - 4 6300 k ≦ 0.50 (light) very small loads, seldom to maximum loads. Mechanisms or parts thereof, usually subject to 0.50 ＜...
  • Page 10 Table 4-5 M4(ISO/JIS) Nominal load Total running Total state of loading spectrum Definitions time operating factor / load rate time(h) (Km) ISO; Mechanisms subjected very rarely to the maximum 0.125 load and, normally, to light 6300 loads (light) / 6400 JIS;...
  • Page 11 Table 4-6 M5(ISO/JIS) Nominal load Total running Total state of loading spectrum Definitions time operating factor / load rate time(h) (Km) ISO; Mechanisms subjected very rarely to the maximum 0.125 load and, normally, to light loads 12500 (light) JIS; Use at about 1/3 of rated load usually and at rated load 4 - 8 rarely...

  • Page 12: Special Features

    The hoist is automatically stopped instantly in case of overwinding. (4) Friction clutch The friction clutch mechanism, originally developed by KITO, enables the motor to idle when excessively overloaded or overwinded. Thus the mechanism prevents damage due to overload or overwind. Non-asbestos material is used in the friction clutch.

  • Page 13: Preparation And Checking Before Use

    5. PREPARATION AND CHECKING BEFORE USE 5.1 Assembly of the electric chain hoist - Hook Suspension ALWAYS make sure that the supporting structures and load-attaching device are strong enough to hold the weight of the load and hoist. (1) Attaching the chain container Remark : For large Capacity hoists (7.5t and larger), refer to the ERML-9806-MC manual.
  • Page 14 Remove the chain container P when you put down the hoist on the ground. 2. Chain container Install to the hoist body as shown Fig 5-3. Fig 5-1 Attachment of chain container P with name plate K − 11 −...
  • Page 15 Fig 5-2 Attachment of chain container P with name plate K − 12 −...
  • Page 16 Fig 5-3 Attachment of chain container If a chain container is not used, remove the stopper from the free end of the chain and secure to the 13th, 15th or 25th link from the free end as shown in Fig.5-4. Then attach the end link to the chain guide A with the chain end suspender except the 5t capacity with the end link directly attached to the chain guide A.

  • Page 17: Lubricating The Gear Case

    Recommended oil : Meropa 320 (TEXACO) c) Recommended oil : Meropa 320 (CALTEX) (2) Mechanical brake combined with a friction clutch (option). a) KITO standard oil : Farm Gear B (NIPPON MITSUBISHI OIL) b) Recommended oil : Meropa No.68 (TEXACO) C (-4...

  • Page 18: Lubricating The Load Chain

    Remark : For larger capacity hoists (7.5t and larger), refer to the ERML-9806-MC manual. ER series hoist have double chain fall models for 3t or 5t capacity. Ensure that the bottom hook on the double fall models is not capsized. If it is capsized, restore it to normal and make sure the welds on the chain links are in alignment.

  • Page 19: Assembly Of The Electric Chain Hoist With Motorized Trolley

    5.2 Assembly of the electric chain hoist with motorized trolley For the following four items (1), (2), (3) and (4), refer to the same items in 5.1 "Assembly of the electric chain hoist - Hook Suspension". (1) Attaching the chain container (2) Lubricating the gear case (3) Lubricating the load chain (4) Checking chain alignment...
  • Page 20 Table 5-2 Adjusting spacer arrangement for Low Head Suspension Number of Adjusting Spacers Beam flange (in) 2 width (mm) 58 98 100 102 106 110 113 125 127 131 135 137 143 153 155 160 163 170 175 178 200 203 215 220 229 232 250 254 257 260 264 267 279 283 286 289 295 298 300 302 305 Part Name Inner...
  • Page 21 Table 5-2 Adjusting spacer arrangement for Lug Suspension Number of Adjusting Spacers Beam flange (in) 2 width (mm) 58 98 100 102 106 110 113 125 127 131 135 137 143 153 155 160 163 170 175 178 200 203 215 220 229 232 250 254 257 260 264 267 279 283 286 289 295 298 300 302 305 Part Name Inner...
  • Page 22 Fig. 5-7 Assembling trolley and hoist − 19 −...

  • Page 23: Mounting Trolley To Traversing Rail

    (b) Adjusting trolley width Adjust the trolley width for the following proper clearance referring to Fig.5-8. The proper "A" dimension is measured when both side plates are spread fully outward. The "A" dimension is : Rail flange width (B) + 4 mm approximately If necessary to obtain the above "A"...
  • Page 24 If using two or more trolleys on the same rail, separate them with end stops between every two trolleys. The distance between the end stops depends on the site requirements. Contact KITO or a KITO authorized dealer for help if required.

  • Page 25: Wiring And Installation Of Power Supply

    ALWAYS turn off the power source or breaker switch before wiring to prevent electric shock Remark : For larger Capacity hoists (7.5t and larger), refer to the ERML-9806-MC manual. Have all wiring performed by an authorized electrician or KITO dealer. (1) Checking and changing wiring Check or change wiring of the electric chain hoist and motorized trolley depending on the required voltage.
  • Page 26 Fig.5-11 2. Transformer wiring − 23 −...

  • Page 27: Wiring Of Power Supply Cable

    (2) Wiring of power supply cable ①Remove the switch box cover and switch box packing. ②Install firmly the cable holder to the switch box with screw. ③Connect firmly red, black and blue lead wires of the cable to the terminal plate-16p referring to Fig.5-13. (Be sure to make each number of mark band of the lead wire consistently correspond to each number of the terminal plate) ④The green and yellow stripped lead wire is the ground wire.

  • Page 28: Installation Of Power Supply Cable

    Therefore consult KITO dealer for this matter. Fig.5-14 Installation of power supply cable Consult KITO dealer in case the electrical power supply is by means of any other method (4) Connection of power supply cable to electric power source (a) Connection to electric power switch Three wires of red, black and blue of the power supply cable should be connected to the electric power switch.
  • Page 29 Fig.5-15 Connection of power supply cable to electric power source (b) Fuse and breaker capacity The fuse and breaker should be chosen for each rated capacity shown in the following table for safety. Table 5-3 Capacity of fuse and circuit breaker ①...
  • Page 30 ② ER, ERP, ERG (dual speed type) Motor output Rating Ordinary Minimum size Minimum size graduation of wiring Capacity Lift Fuse(A) Breaker(A) of ground of ammeter wire (kg or t) 220/ 575V 440V 0. 45 125(H),250(S) 500(L) 0.15 250(H),500(S) 1(L) 1(S),1.5(S),2(L) AWG14 2(S),2.5(S),...
  • Page 31 ④ ERM (dual speed type) Motor output Rating Ordinary Minimum size Minimum size graduation of wiring of ground Capacity Lift Travel Fuse(A) Breaker(A) of ammeter wire (kg or t) 220/ 220 440 575 220 440 575 220 440 575 kW HP kW HP 575V 440V 0.45...

  • Page 32: Trial Run

    5.4 Trial run (1) Before proceeding Review the previous sections of the manual to be sure that each step was completed properly and that all parts are attached securely. For example : (a) Whether the electric chain hoist is properly installed to the trolley. (See, Fig.6-7) (b) Whether the stopper of the trolley on the beam is correctly positioned.
  • Page 33 (6) Check the optional emergency stop device function (as option) This device is an option for the electric chain hoist, a standard for electric chain hoist with motorized trolley. While holding down either the button on the push button switch, push the emergency stop button.

  • Page 34: Operation

    (3) The operator must make sure to prevent his hands or other parts of his body from being caught in the moving hoist. 6.3 Electric chain hoist KITO electric chain hoists ER series come in single speed and dual speed models. For an explanation on how to operate the hoists, refer to Table 6-1. Table 6-1 Operation of hoist...

  • Page 35: Electric Chain Hoist With Motorized Trolley

    6.4 Electric chain hoist with motorized trolley 6.4.1 Operation KITO electric chain hoist ER series and motorized trolley MR series both come in single speed and dual speed models. For an explanation on how to operate the hoist, refer to Table 6-2.

  • Page 36: Precautions In Usage

    lifting Refer to Table 6-1. Operation method lowering Traversing The push button switch is a The push button switch is a dual single step push type. The hoist step push type. The first step is will move in the direction of the for low speed and the second EW or NS marks when the step for high speed.

  • Page 37: Maintenance

    7. MAINTENANCE NEVER perform maintenance on the hoist while it is supporting a load. However, this does not apply when checking the brake, friction clutch or limit switch in the periodic inspection. Before performing maintenance, attach tags to the power source and the push button switch reading; "DANGER"...

  • Page 38: Chain Replacement

    7.1.2 Load chain lubrication Refer to 5.1(3) Lubricating the load chain. ALWAYS lubricate load chain once a week, or more frequently, depending on severity of service. ALWAYS lubricate more frequently than normal in corrosive environment (In salt water, sea air and/or acid or other corrosive compounds) 7.2 Chain replacement Observe the procedure below when replacing the chain referring to Fig.7-1.
  • Page 39 Fig. 7-1 Chain replacement − 36 −...

  • Page 40: Inspection

    7.3 inspection 7.3.1 Inspection classification (1) Initial inspection : Prior to initial use, all new, altered or modified hoists shall be inspected by a designated personnel to ensure compliance with the applicable provisions of this manual. (2) Inspection procedure for hoists in regular service is divided into two general classifications based upon the intervals at which inspection should be performed.

  • Page 41: Inspection Record

    7.3.5 Inspection record Dated inspection reports and records should be maintained at time intervals specified in section 7.3.1 (2)(b) and such records are stored where they are available to authorized personnel. 7.3.6 Inspection procedure Remark : For larger Capacity hoists (for ER : 7.5t and larger, ERM : 7.5t and larger), refer to "Inspection procedure"...
  • Page 42 Class Item Inspection method Discard limit/criteria Remedy 3. Limit switch Refer to the name plate AB or AC (written "Upper Limit" or "Upper/Lower Limit") (overwind which is attached on the hoist to make sure which types limit switch are equipped limiting with the hoist.
  • Page 43 Class Item Inspection method Discard limit/criteria Remedy 5. Hook (1) Bottom hook Check visually Shape has not deformed from Replace the deformation what it was at time of purchase. hook with a new one if deformed. (2) Hook latch Move with hand or Free of deformation and damage.
  • Page 44 (2) Periodic inspection Class Item Inspection method Discard limit/criteria Remedy 1. Push button (1) Operation Push buttons in Movement is smooth without Inspect and turn. extreme play and interference. repair it if operation is abnormal. (2) Emergency Stop and reset the The button should operate Inspect and stop function...
  • Page 45 Class Item Inspection method Discard limit/criteria Remedy (2) Grounding Check grounded Grounding resistance should be Ground in point. 100 Ohm or less. compliance with local laws regulations. For the collector type, the Remove trolley-running surface of the insulating beam is free of insulating materials.
  • Page 46 Class Item Inspection method Discard limit/criteria Remedy (3) Quantity of Check visually. Change oil regularly in keeping Provide oil if gear oil and with work frequency. the quantity is contamination insufficient. If oil is badly contaminated, replace it with new oil. Notice : Dispose old oil in accordance...
  • Page 47 Class Item Inspection method Discard limit/criteria Remedy 3. Friction clutch (1) Function Lift up a grounded The motor should rotate. If the motor load. Press the fails to rotate, button and check ask the service from the outside personnel to that the motor inspect.
  • Page 48 Class Item Inspection method Discard limit/criteria Remedy 5. Load chain (1) Abrasion To measure pitch Dimension (P) or (d) shall not If limit with slide calipers: exceed the limits presented in exceeds, ALWAYS ask Measure at the the table below. point that is most the service frequently engaged...
  • Page 49 Class Item Inspection method Discard limit/criteria Remedy (2) Hook wear Measure "b" and NEVER use the hook if dimension Replace with new "c" with slide "b" or "c" becomes less than 90% hook if worn. calipers. of normal. b (mm) c (mm) Capacity (kg or t)
  • Page 50 Class Item Inspection method Discard limit/criteria Remedy (6) Rotation of Turn idle sheave The idle sheave rotates smoothly. Inspect and idle sheave by lifting the load repair if chain up and down, rotation is not as illustrated. smooth. (7) Chain Attachment screws, pins, hangers, Replace with Check visually.
  • Page 51 Class Item Inspection method Discard limit/criteria Remedy 1. Power supply fitting (1) Messenger Check visually. Wire dose not sagexcessively. Tighten to proper wire tension tension. (2) Condition of Check visually. Cable hangers are attached at Replace cable hanger equal intervals so that cable does not defective hangers twist.
  • Page 52 Class Item Inspection method Discard limit/criteria Remedy (5) Side plate Check visually or No obvious deformation must be If damaged deformation with slide calipers, evident. obviously, as necessary. replace it with a new side plate. (6) Suspension Check visually or NEVER use a suspension shaft Replace with new shaft...

  • Page 53: Troubleshooting

    − 50 −...

  • Page 54: Warranty

    (1) "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, in any event.
  • Page 55 3-37-4, Yoyogi, Shibuya-ku, Tokyo 151-0053, Japan Tel. : 03-5371-7341 Fax. : 03-5371-7349 Tlx. : 222-2942 KITO J E-mail : overseas@kito.co.jp URL : http: //www.kito.co.jp CANADA INC. CHAIN HOISTS 309-3815 1ST AVENUE BURNABY, BC V5C 3V6 (604) 291-9955 (604) 294-8855 E-mail info kito.ca URL http: //www.kito.ca/...

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