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

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  • Page 1 OM-ER2ZZZ-KCE-00...

  • Page 2: Table Of Contents

    KITO shall not be liable for any incidental damage due to the use or non-use of the product such as the loss of ●...
  • 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 traveling ●...

  • 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 three categories of “DANGER” “WARNING”...
  • Page 5 Mandatory Refer to “Disassembly/Assembly Manual” for disassembling, or contact KITO. (This product uses oil. We prepare SDS (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: Chapter 1 Handling The Product

    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 2 Inspection 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 Push Button model of rated load 2 t or more) Switch Cord...
  • Page 9 ■ Motorized Trolley Type (ER2M) Electric Chain Hoist combined with motorized trolley (MR2) for elevation and traveling motion ● Motorized trolley 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 2 Inspection 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 load ●...

  • 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 Chapter 2 Inspection Opening the Package (continued) ■ Nameplate and Product Model ■Nameplate Indication of Electric Chain Hoist · · · Capacity Ex. 1t, 500kg 4 Rated Voltage The maximum mass of the load that can be 5 Number of Phase imposed on the product.
  • Page 13 ■ Code of MR2 CODE Capacity Single speed model Dual speed model Standard speed Low speed Standard speed 125kg 250kg MR2-010S MR2-010L MR2-010IS/SD 500kg 1.5t MR2-020S MR2-020L MR2-020IS/SD 2.5t MR2-030S MR2-030L MR2-030IS/SD MR2-050S MR2-050L MR2-050IS/SD (to be continued)
  • Page 14 Chapter 2 Inspection 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 ER2-020S/IS/SD Front side : RH-DAT Front side : Original Lot No. of the ER2-025S/IS/SD 11.2 12 Links Load Chain (4 digits) FT-DAT Back side : KITO ER2-030S/IS/SD 10.2 16 Links Back side : H23 ER2-050S/IS/SD 11.2 12 Links ■ Recording the Product No.

  • Page 16: Product Specification And Operational Environment

    Dual speed VFD model (high speed/low speed) — 30/10 min. Intermittent ratings : ER2 series(63 % of the capacity) : Single speed model — 60 % ED (at 360 rev/h) Dual speed VFD model (high speed/low speed) — 40/20 % ED (120/240 rev/h) : MR2 series(63 % of the capacity) : Single speed model —...
  • 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.
  • Page 18 Chapter 2 Inspection Product Specification and Operational Environment (continued) ■ Operational Environment Ambient temperature : -20°C to +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 : Places exposed to organic solvents : Places with high levels of general or combustible dust in the air...

  • 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: How To Operate The Push Button Switches

    Chapter 2 Inspection 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 21 ■ 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 22 <Memo>...

  • Page 23: 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, intermittent Prohibited rating) of the lifting motor and the maximum start-up frequency.
  • Page 24 Chapter 2 Inspection 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 25 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 26: 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 27: 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 28: Daily Inspection

    When replacing with a new nameplate or label is required, please inform KITO of the description in “Record of the Product No." (P15) such as Lot No. and Serial No. Deformation • Check visually.
  • Page 29 ■ Load Chain Item Check method Criteria When failed Elongation of • Check visually • No apparent elongation Refer to Load Chain (P69) Pitch of Chapter 2, Monthly Inspection. Abrasion • Check visually • No apparent abrasion Refer to Load Chain (P69) of Wire of Chapter 2, Monthly Diameter...
  • Page 30 Chapter 2 Inspection Daily Inspection (continued) ■ Top Hook/Bottom Hook Item Check method Criteria When failed Opening of • Check visually • No apparent opening of the Hook Carry out the inspection the Hook item of Top and Bottom Hook (P70) of Monthly Inspection.
  • Page 31 Item Check method Criteria When failed Movement • Check the Idle Sheave by Replace the bearing of the CAUTION of the Idle moving Idle Sheave. • When checking, wear gloves and Sheave be careful for your finger not to be caught. Mandatory Otherwise it may result in injury.

  • Page 32: Chapter 3 Troubleshooting

    Chapter 2 Inspection Daily Inspection (continued) ■ Push Button Switch Item Check method Criteria When failed Switch body • Check visually • No deformation, damage and no loosened Clean and repair the label screw or replace with a new label. •...

  • Page 33: Motorized Trolley

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

  • Page 34: Manual Trolley

    Chapter 2 Inspection Daily Inspection (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 serpentine motion and Take measures by referring to Chapter vibration.
  • Page 35 ■ 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 serpentine motion and Carry out Chapter 2 Check of the trolley by moving it vibration.

  • Page 36: Work Flow Of Assembling And Installation

    Chapter 2 Inspection 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 DANGER •...
  • Page 38 Chapter 2 Inspection Assembling (continued) Checking the Chain Container ● A sticker that contains the following information is attached to the Chain Container. (See the figure to the right.) Confirm that the information on this sticker matches the specifications of the electric chain hoist on which the Chain Container is to be installed.
  • Page 39 ■ Securing the End of the Load Chain When using the hoist without a Chain Container installed, it is necessary to secure the end of the Load Chain. Refer to page 123 to order the parts required to secure the Load Chain. Use the following procedure to secure the Load Chain to the Chain End Suspender or Chain Guide A.
  • Page 40 Chapter 2 Inspection Assembling (continued) ■ Oiling the Load Chain DANGER • Be sure to apply lubricant on the Load Chain. Do not carry out oiling work in the place near the fire or arc. Otherwise it will result in fire. Mandatory Remove dust and waterdrops attached on the Load Chain and then apply lubricant.

  • 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 2 Inspection 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 Chapter 2 Inspection Assembling (continued) ■ Combination of the Electric Chain Hoist and the Motorized 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~5 t ●...
  • Page 47 ■Combination with the Manual Trolley ■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.
  • Page 48 Chapter 2 Inspection 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 2 Inspection 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 Bolt, a Frame S 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

    Chapter 2 Inspection Assembling (continued) ■ Checking Power and Power Cable DANGER • Check that the rating of the breaker satisfies the specification required by the electric chain hoist. • Check that the source voltage satisfies the rated voltage of the electric chain hoist. •...
  • Page 53 Refer to the following table for the permissible length and the size of the standard Power Cable. 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) =...

  • Page 54: Connecting Cables

    Chapter 2 Inspection Assembling (continued) ■ Connecting Cables NOTE • When tightening a connector, do not use tools. Be sure to tighten it by hand. Excessive tightening of the connector may cause damage to the plastic screw threads or result in cable breakage. •...
  • Page 55 ■Motorized Trolley Type ■125 kg~5 t Connecting the relay cable Connecting the Power Cable ● ● 1) Insert the connector plug (4P) of relay 1) Remove the Holder A mounted to the cable for power supply in the connector Connection Box. socket (4P) of ER2.
  • Page 56 Chapter 2 Inspection 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

    Chapter 2 Inspection Installation (continued) ■ Installing the Trolley Combined Model ■Mounting the Hoist to the Travel Rail 1) Make sure that the dimensions of the Trolley Sling Frame satisfy the size of the rail to which the trolley is installed. 2) Make sure that the rail is set to a level.
  • 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. For the stopper position of the hoist with steel chain container, please refer to the steel chain container installation manual.
  • Page 60 T-shape cable hanger 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 ends Rail 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. •...
  • Page 62 Chapter 1 Handling the Product <Memo>...

  • Page 63: Chapter 2 Inspection

    Chapter 2 Inspection This chapter describes monthly inspection items and annual inspection items. Refer to Chapter 1 for the “Handling the Product”. Inspection is the first step of safety. Carry out daily inspection, monthly inspection and annual inspection.
  • Page 64 Chapter 2 Inspection Table of Contents ■ Safety Precautions ………………………………… 66 ■Monthly Inspection ■ Annual Inspection ■Electric Chain Hoist ■Electric Chain Hoist Load Chain Check of the Operation History Elongation of Pitch ……………………………… 69 Operating Hours and Number of Starts ……… 76 Abrasion of wire diameter ………………………...
  • Page 65 ■ Annual Inspection ■Motorized Trolley Guidelines on the service life of contactor and its replacement … 91 Brake Guidelines on Brake Inspection …………………… 91 Appearance ……………………………………… 84 Guidelines on Gear Parts Replacement ………… 91 Abrasion of Brake Pad …………………………… 84 Guidelines on Motor Shaft Replacement …………...

  • Page 66: Safety Precautions

    DANGER • Disassembly and assembly of the electric chain block must be performed by maintenance engineer. • Do not use the part exceeding the service limit or criteria and the parts other than genuine part for KITO electric chain hoist.
  • Page 67 NOTE • When performing the monthly inspection, carry out the daily inspection at the same time. • When performing the annual inspection, carry out the monthly 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: Monthly 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

    ● 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

    Chapter 2 Inspection Monthly Inspection (continued) ■ Top Hook, Bottom Hook Item Check method Criteria When failed • Check visually and measure Opening Replace the Hook. CAUTION with vernier caliper. • Compare the dimensions of a, b Abrasion of Embossed mark and c with those at purchasing.

  • Page 71: Peripheral Parts Of The Body

    * Especially be careful when the electric chain Container. hoist is used outdoor. • Make sure that the lift of the Load Chain is smaller Contact KITO or than the capacity of the Chain Container. Distributor for the correct chain container.

  • Page 72: Push Button Switch

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

  • Page 73: Power Supply

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

  • Page 74: Motorized Trolley

    Chapter 2 Inspection Monthly Inspection (continued) ■ Motorized Trolley ■ Travel Rail (Recommendation) Item Check method Criteria When failed • Check visually. • To have no apparent deformation and damage Appearance Check items in accordance with “Travel Rail” described in Chapter 2 “Annual Inspection”.

  • Page 75: Annual 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

    Chapter 2 Inspection Annual Inspection (continued) ■ Electric Chain Hoist ■ Check of the Operation History Item Check method Criteria When failed • Check the operating hours • Perform maintenance by referring to “Parts Replacement based on Indication Operating Hours and and number of starts with of CH Meter”.

  • Page 77: Chain Spring

    Item Check method Criteria When failed • Check visually and measure • Check visually to have no apparent setting Chain Replace the Chain the dimensions. (deformation). Spring Spring. CAUTION • The deformation of the Cushion Rubber and the Chain Spring is caused by excessive use of the Friction Clutch and the Limit Mandatory...

  • Page 78: Chain Pin (Double Type Only)

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

  • Page 79: Electromagnetic Brake

    ■ Electromagnetic Brake Item Check method Criteria When failed • Remove the Brake Cover • To have no loosened bolt and screw. Appearance Tighten bolts and and check visually. screws. • To have no flaw and damage. Replace the Electromagnetic Brake. •...

  • Page 80: Electrical Equipment

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

  • Page 81: Grounding Resistance (For Crane Use)

    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. (For crane • Turn off the power when use) measuring the grounding resistance.
  • Page 82 <Memo>...
  • Page 83 <Memo>...

  • Page 84: Motorized Trolley

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

  • Page 85: Suspension Shaft

    Item Check method Criteria When failed • Check visually. • To have no apparent deformation and abrasion Suspension Replace the Shaft Suspension Shaft. • Check visually. • The Suspender must be combined securely Suspender Replace the with the top pin and the Yoke bolt. Suspender.

  • Page 86: Travel Rail (Recommendation)

    Chapter 2 Inspection Annual Inspection (continued) ■ Travel Rail (Recommendation) Item Check method Criteria When failed • Check visually. • To have no attachment of paint, oil and foreign Rail Clean the Travel Rail. matter. Surface • To have no dust and powder due to abrasion Deformation •...

  • Page 87: Function And Performance

    ■ Function and Performance After reassembly, trolley should be operated with no load, checking transverse motion and brake, before applying rated load. When load bearing members or brakes have been replaced, load the trolley with the rated load and check that: Item Check method Criteria...

  • Page 88: Manual Trolley

    Chapter 2 Inspection Annual Inspection (continued) ■ Manual Trolley ■ Body Components Item Check method Criteria When failed Wheel • Check visually. • To have no apparent deformation and damage Replace the Wheel. • Measure dimensions D and The abrasion of the wheel should not be less t with vernier caliper.

  • Page 89: Deformation And Abrasion

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

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

    Oil type ER2-001H, 001IH, 001HD, 003S, 003IS, 003SD ER2-005L, 005IL, 005S, 005IS, ER2-005LD, 005SD ER2-010L, 010IL,010SD,010LD Friction Clutch ER2-010S, 010IS KITO genuine oil KITO genuine oil ER2-015S, 015IS, 015SD, 020L, 020IL, 020LD 1300 ER2-020S, 020IS, 030S, 030IS 1900 ER2-020SD, 030SD 1800...

  • Page 91: Grease Change Cycle

    ■ Guidelines on Needle Bearing (for Idle Sheave) Grease Change Cycle Operating hour for gear oil change Every 200 hrs Every 400 hrs Rate of loading ○ Light A case where the capacity is rarely applied. Usually the hoist is used with a light load. A case where the capacity is applied considerably frequently.

  • Page 92: Guidelines On Motor Shaft Replacement

    Chapter 2 Inspection Parts Replacement based on Indication of the CH Meter (continued) ■ Guidelines on Motor Shaft (with Rotor) Replacement Operating hours to replace parts Every 400 hours Every 800 hours Every 1600 hours Every 3200 hours Body grade M6, 3m –...

  • Page 93: Check Of Operating Hours And Number Of Start

    Check of Operating Hours and Number of Start (CH Meter) ■ Single Speed Model ■CH Meter: Start Times/Operating Hour Display Device Contactor ON/OFF (lowering) times and operating hours(motor energizing hours for lowering × 2) are displayed. Use these values for control of operating condition and maintenance Display on LCD window at inspection and annual inspection.
  • Page 94 Chapter 2 Inspection ■ How to Display the Number of Starts and Operating Hours The following shows the procedure for the operating hours. To display the number of starts, take the following procedure similarly. ● Example: Displaying U7-03 (operating hours). Procedure LED panel 1.
  • Page 95 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”...
  • Page 96 Chapter 2 Inspection 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. •...
  • Page 97 Reference Conditions Main fault contents Check item page Abnormal Popping sound Abrasion of the Load Chain Load Chain noise Abrasion of the Load Sheave Load Sheave, Idle Sheave Strange operating sound Abrasion or breakage of Gear Load Gear, Gear B, Pinion, Motor Shaft Deterioration of Bearing Bearing...
  • Page 98 Chapter 2 Inspection Guidance on Troubleshooting (continued) ■ Dual Speed VFD Model Reference Conditions Main fault contents Check item page Check the error code of Unable to restart the VFD by resetting with emergency stop Those related to VFD “VFD VFD referring to “VFD (the case when the VFD cannot be reset even after cool down) Manual”...
  • Page 99 Reference Conditions Main fault contents Check item page Does not stop Too long stopping distance Relay failure or melted contact point Relay normally. Too long (or short) stopping distance Abrasion of brake lining Brake Does not stop at the upper/lower limit. Negative phase connection of Power Cable motor lead wires...
  • Page 100 • 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 101 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 receiving does not operate. voltage power receiving terminal. facility facility regularly. If the source voltage is improper, check the power receiving facility.
  • Page 102 Chapter 2 Inspection 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 103 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 chain operate. (two or more phase. Replace the motor when the over voltage or low hoist at the rated voltage.
  • Page 104 Chapter 2 Inspection 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 chain Brake does not...
  • Page 105 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 ring operate. securely. Replace the packing if deteriorated.
  • Page 106 Chapter 2 Inspection 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 hoist does not operate. avoiding the impact. Lead wire damaged at Be careful not to have the assembling...
  • Page 107 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 excessive does not stop Contact point the conduction. plugging operation operation. welding, or fusing When the contact point is welded or (consecutive fused, replace the contactor.
  • Page 108 Chapter 2 Inspection 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 switch does not operate. check the conduction of the contact switch habitually.
  • Page 109 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 the does not operate. button is pressed to pressed and locked, turn it clockwise to Emergency Stop push button”...
  • Page 110 Chapter 2 Inspection 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. If the VFD still does not indicated by VFD referring operate, check it.
  • Page 111 (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 112 Mechanical Brake. Friction Clutch Use of oil other than Use KITO genuine oil. the designated oil DANGER • Use KITO genuine gear oil. (The gear oil for Friction Clutch with Mechanical Brake is different from the standard specification Mandatory oil.)
  • Page 113 Hook Symptom Cause Remedy Main factor Countermeasure Widened Hook Deformation of the Replace the Hook if the deformation Over load Use the electric chain hoist opening Hook exceeds the criteria. (See P70.) with a load less than the capacity. Earth lifting Do not carry out earth lifting.
  • Page 114 Chapter 2 Inspection 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 hoist come off Hook exceeds the criteria. (See P70.) with a load less than the capacity.
  • Page 115 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 model Hook position to cancel the capsizing. turned over by one turn hoist, check that the Hook during working.
  • Page 116 Store the electric chain hoist exposed to rain hoist indoor or under the roof when not using. Influence of sea water Contact KITO for the use and chemicals in special environment in advance. Use the electric chain hoist correctly within the scope guaranteed by the manufacturer.
  • Page 117 Load Sheave, Idle Sheave Symptom Cause Remedy Main factor Countermeasure Popping sound Abrasion of sheave Measure the thickness of the crest. Long hour operation Apply lubricant regularly. pocket or flaw by Replace the Sheave if the thickness is without grease, expiry (See P40) the Load Chain out less than the service limit.
  • Page 118 Mechanical Brake is different from the standard specification Mandatory 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 Apply grease regularly.
  • Page 119 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 hot with harmful defects environment or environment or excessively such as significant excessively frequent use frequent use abrasion, deformation, scratches and...
  • Page 120 Chapter 2 Inspection Traveling motion of the Trolley (common for motorized/manual trolley) (continued) Serpentine motion Deterioration of wheel Check if rolling noise Expiry of service life Replace the wheel bearing. bearing sounds when the wheel Abnormal noise is rotating. Unable to travel smoothly (continued) Deformation and Check the abrasion and...
  • Page 121 Appendix This Appendix summarizes the information helpful for the use of KITO electric chain hoist, such as optional parts, technical materials and service network. ■Optional Parts ................122 ■Product Structure and Names of Each Part .......124 ■Technical Material .................126 • Hook Dimensions (for ER2) ............126 •...

  • Page 122: Optional Parts

    C : (103mm) D : (128mm) T-shape cable hanger 175 A : (153mm) • Contact KITO when the Travel Rail width exceeds 175 mm. Cable hanger Pusher ● < Manual Trolley 125 kg to 3 t > < Manual Trolley 5 t >...
  • Page 123 ■ Angle Suspender: Accessory for power feeding Code Angle Hole pitch 50×50 53 mm THLT and THLP 65×65 66 mm 75×75 79 mm < THLT (for intermediate support > < THLP (for Push Button Switch cord > Cable guard Cable guard ■...

  • Page 124: Product Structure And Names Of Each Part

    Chapter 2 Inspection 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...
  • Page 125 ■ 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 126: Technical Material

    Chapter 2 Inspection Technical Material ■ Hook Dimensions (for ER2) Top Hook Bottom Hook ● ● Top Hook (mm) Bottom Hook (mm) Code ER2-001H/IH/HD ER2-003S/IS/SD 35.5 27.0 17.5 23.5 28.0 17.5 35.5 27.0 17.5 23.5 28.0 17.5 ER2-005L/IL/LD ER2-005S/IS/SD ER2-010L/IL/LD 42.5 31.0 22.5...
  • Page 127 ■ Lifting motor (Dual speed) (Unit:A) 230/460V Class 500V Class Motor Capacity Motor Code output 208-230V 415-460V 500V 575V Code output (kW) (kW) 60Hz 50Hz 60Hz 125kg ER2-001IH ER2-001HD 250kg ER2-003IS 0.56 ER2-003SD 0.5/0.13 1.6/0.9 1.4/0.9 ER2-005IL ER2-005LD 500kg ER2-005IS ER2-005SD 0.9/0.23 1.8/1.4...

  • Page 128: Conversion Table Between Lift/Travel/Speed

    Chapter 2 Inspection 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)

  • Page 129: 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 130: Wiring Diagram Of Single Speed Er2/Er2Sp/Er2Sg

    Chapter 2 Inspection Technical Material (continued) ■ Wiring Diagram of Single Speed ER2/ER2SP/ER2SG 575V (Plug Connection)
  • Page 131 220V (Plug Connection) (to be continued)
  • Page 132 Chapter 2 Inspection Technical Material (continued) 440V (Plug Connection)

  • Page 133: Wiring Diagram Of Dual Speed Er2/Er2Sp/Er2Sg

    ■ Wiring Diagram of Dual Speed ER2/ER2SP/ER2SG 220V (Plug Connection) (to be continued)
  • Page 134 Chapter 2 Inspection Technical Material (continued) 440V (Plug Connection)
  • Page 135 575V (Plug Connection) (to be continued)

  • Page 136: Wiring Diagram Of Single Speed Er2M

    Chapter 2 Inspection Technical Material (continued) ■ Wiring Diagram of Single Speed ER2M 575V (Plug Connection)
  • Page 137 220V (Plug Connection) (to be continued)
  • Page 138 Chapter 2 Inspection Technical Material (continued) 440V (Plug Connection)

  • Page 139: Wiring Diagram Of Dual Speed Er2M

    ■ Wiring Diagram of Dual Speed ER2M 220V (Plug Connection) (to be continued)
  • Page 140 Chapter 2 Inspection Technical Material (continued) 440V (Plug Connection)
  • Page 141 575V (Plug Connection)

  • Page 142: Daily Inspection Check Sheet

    Chapter 2 Inspection Daily Inspection Check Sheet 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 ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item...
  • Page 143 ■ Motorized Trolley ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item Check method Criteria Indication of nameplates Check visually To have no peeled off. To be legible clearly. and labels Deformation and To have no apparent deformation and corrosion...

  • Page 144: Monthly Inspection Check Sheet

    Chapter 2 Inspection Monthly Inspection Check Sheet 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 ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item...
  • Page 145 ■ Motorized Trolley ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item Check method Criteria Check the When performing monthly inspection, also perform the Daily inspection execution daily inspection.

  • Page 146: Annual Inspection Check Sheet

    Chapter 2 Inspection Annual Inspection Check Sheet 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 (1/2) ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item...
  • Page 147 ■ Electric Chain Hoist (2/2) ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item Check method Criteria • To have no damaged or burnt part Electrical parts Check visually •...
  • Page 148 Chapter 2 Inspection ■ Motorized Trolley ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item Check method Criteria When performing annual inspection, also perform Daily inspection Check the execution the daily inspection.
  • Page 149 ■ Manual Trolley ■Check result : ○ Good, △ To be replaced (adjusted) next inspection, × Bad, Needs replacement (adjustment) Inspection date/result Category Check item Check method Criteria When performing annual inspection, also perform Daily inspection Check the execution the daily inspection. When performing annual inspection, also perform Monthly inspection Check the execution...
  • Page 150 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...

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Er2-001ihEr2-001hEr2-003sEr2-003isEr2-003sdEr2-005l ... Show all

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