KITO CX003 Istruzioni per l'installazione
AS-CX1ZZZ-MGE-00
/005
2
Table of Contents
Safety Precautions................................................................................. 3
Disassembly/reassembly tools and Lubricant................................................. 5
Before Disassembly/reassembly ................................................................ 5
Part Name........................................................................................... 6
Disassembly Procedure........................................................................... 7
Disassembly of Brake ................................................................................. 7
Removal of the Load Chain ........................................................................ 8
Disassembly of Gear................................................................................... 9
Disassembly of Latch................................................................................ 10
Assembly Procedure ............................................................................. 11
Assembly of Gear ..................................................................................... 11
Assembly of Load Chain........................................................................... 13
Assembly of Brake.................................................................................... 14
Bottom Hook Set ...................................................................................... 17
Assembly of Latch .................................................................................... 17
Preoperational Check ............................................................................ 18
3
Person to perform disassembly/reassembly
Disassembly/reassembly shall be performed by a competent person (a person duly authorized by the company
as having expertise on the structure and device of Chain Hoist, or with expertise and appropriate understanding
of the Periodic Inspection Manual and Disassembly/reassembly Manual), or consult with KITO or your dealer.
Disassembly/reassembly in general
This Disassembly/reassembly Manual for Chain Hoist includes important contents to prevent injury to any person
performing disassembly/reassembly, users, other persons and damage to property, and to disassemble/reassemble
the Chain Hoist safely and correctly.
Before performing disassembly/reassembly, be sure to read and follow the Owner’s Manual of Chain Hoist Model
CX003/005 (separate document) since its contents are also important for disassembly/reassembly.
Disassembly/reassembly of Chain Hoist is essential for inspection and repair. Refer to the separate Periodic
Inspection Manual and Troubleshooting to perform disassembly/reassembly correctly.
Safety Precautions
Only competent persons must disassemble/reassemble the Chain Hoist.
Disassembly/reassembly by anyone other than competent persons may result in death or severe injury.
Do not adjust or disassemble the Over Load Limiter (OLL *).
Adjustment or disassembly of OLL may result in death or severe injury.
* A device to prevent an excessive overload, built in Hand Wheel Assembly.
Do not use parts beyond their discard limit or criteria and unauthorized parts for the KITO Chain
Hoist Model CX003/005.
Even if the part is an authorized part for KITO Chain Hoist, it may not be used for a different model.
Use parts correctly in accordance with the Disassembly/reassembly Manual.
Failure to do so may result in death or severe injury.
Do not disassemble/reassemble the Chain Hoist subject to a load.
When disassembling/reassembling a Chain Hoist, place it on a floor and disassemble/reassemble it.
Disassembly/reassembly of a Chain Hoist subject to a load may result in death or severe injury.
Do not lubricate the Friction Plate.
The Friction Plate is of the dry type.
Lubricating the Friction Plate may result in death or severe injury due to insufficient braking.
Prohibited
Prohibited
Prohibited
Prohibited
Do not use grease or oil in areas near a fire or spark.
Failure to do so may result in ignition.
Prohibited
Do not cut, extend or weld the Load Chain.
Failure to do so may result in death or severe injury.
Prohibited
Mandatory
4
When assembling, follow the instructions below.
Failure to follow these instructions may result in injury due to damage to the Chain Hoist or falling parts.
a. Before re-assembly, remove dust and oil on the part to be re-used.
b. When re-assembling, replace the grease with new one.
c. When re-assembling, replace the Snap Rings with new ones.
d. When re-assembling, replace the Split Pin with new one.
e. Fasten bolts and nuts to the specified tightening torque.
If the torque is lower than the specified value, it may cause the loosening of the screw and the Chain Hoist may
be broken.
If the torque is higher, the internal thread will be damaged and the Chain Hoist may be broken.
f. Insert the Snap Ring completely in the groove.
g. When assembling the gear unit, match the gear marks "O" and "V" on each of Gear #2.
h. Assemble the Load Chain (no load side) without torsion.
When assembling the Pawl, follow the instructions below.
Failure to do so may result in an inability to lift loads.
•Hook the Pawl Spring correctly onto the Pawl.
•Engage the Pawl and Ratchet Disc correctly.
When assembling the braking unit, clean the Friction Disc, Friction Plate, Ratchet Disc and Bushing.
Oil, dust or foreign objects on the braking surface may result in death or severe injury, due to insufficient braking.
Mandatory
When assembly is completed, perform a functional test (Preoperational check) to ensure that the
hoist is operating properly.
Failure to do so may result in death or severe injury.
Refer to the Preoperational Check in this manual for details.
Do not disassemble the Hand Wheel Assembly.
Failure to do so may result in death or severe injury.
Prohibited
Do not disassemble the Pawl Shaft.
Failure to do so may result in death or severe injury.
When the Pawl Shaft is loosened, replace the Body Assembly (including the Pawl Shaft).
Prohibited
Set Pawl Spring Assembly properly with two Pawl Springs fitted each other.
Improper combination may result in death or severe injury.
Set the lower part of the Pawl Spring Assembly securely under the step of the Pawl Shaft.
Failure to do so may result in death or severe injury.
Mandatory
Mandatory
Mandatory
Mandatory
Mandatory
5
Disassembly/reassembly tools and Lubricant
Before Disassembly/reassembly
Prepare the following tools and lubricant for disassembly/reassembly.
No. Tool Name Purpose Icon
1 Hexagon wrench 4mm For disassembly/reassembly of Frame A / B, Gear
Case, Wheel Cover
2 Shaft Snap Ring pliers For disassembly/reassembly of Pawl and Cam Guide
3 Hexagon wrench 2.5mm For disassembly/reassembly of End Pin
4 Hexagon wrench 3mm For disassembly/reassembly of Bottom Yoke and
Latch
5 Spanner 7mm, 8mm x 2 For disassembly/reassembly of Bottom Yoke and
Latch
6 Needle-nose pliers For Cam Guide
7Automotive wheel bearing gease
Type 1, Class 2 (JIS K 2220) For oil application except the following No. 8.
8Rust preventive oil Type 2, Class
1 (JIS K 2246) For oiling on the Pawl and Pawl Shaft
9Three Bond 1401, Loctite 241 or
242
For locking of the Set Screw and bolts for the Bottom
Yoke
10 Torque wrench For checking tightening force
- Read this manual thoroughly and perform disassembly/reassembly correctly.
- Consult with KITO when changing the lift.
•Replace the Snap Rings, Split Pin and Grease with fresh supplies when reassembling.
(illustrated in this manual with .)
•Prepare wooden blocks (2 pieces) to stabilize the Body of the Chain Hoist when disassembling/reassembling.
Only competent persons to disassemble/reassemble Chain Hoist.
Disassembly/reassembly by anyone other than a competent person may result in death or severe injury.
Do not use parts beyond their discard limit or criteria and unauthorized parts for the KITO Chain
Hoist Model CX003/005.
Even if the part is an authorized part for KITO Chain Hoist, it may not be used for a different model.
Use parts correctly in accordance with the Disassembly/reassembly Manual.
Failure to do so may result in death or severe injury.
Do not disassemble/reassemble a Chain Hoist subject to a load.
When disassembling/reassembling a Chain Hoist, place it on the floor and disassemble/reassemble it.
Disassembly/reassembly of a Chain Hoist subject to a load may result in death or severe injury.
When assembly is completed, perform a functional test (operational check) to confirm that the
Chain Hoist works correctly.
Failure to do so may result in death or severe injury. Refer to "Operational Check" in this manual for details.
Prohibited
Mandatory
Mandatory
Prohibited
NEW
Torque
Lock
Oil
Grease
3 mm
2.5 mm
4 mm
6
Part Name
Wheel Cover
Hand Chain
Friction Plate
Cam Guide
Hand Wheel Assembly
Ratchet Disc
Bushing
Snap Ring
Pawl
Pawl Spring (Assembly)
Top Hook
Top Hook
Set Latch Body Assembly
Top Pin
Load Sheeve
Frame B
Load Gear
Socket Head Cap Screw
Socket Head Cap
Screw
Conical Lock Washer
Spring Lock Washer
Pinion
Gear #2
Chain Guide
Load Chain
Bottom Yoke
Gear Case Assembly
Socket Head Cap
Screw
Conical Lock
Washer
Friction Disc
Hexagon Socket Set Screw
End Pin
Frame A
Bottom Hook Set
Snap Ring
Bottom Hook
Chain Stopper Link
Warning Tag CE
Latch
Split Pin
Slotted Nut
Chain Pin
Bottom Hook Bottom Hook Set
Hook Latch Asembly
Load Chain
CX005
7
(3) Remove two Friction Plates, Ratchet
Disc, Bushing and Friction Disc from
Pinion. Pinion
Friction Disc
Bushing
Ratchet Disc
Friction Plates
Disassembly Procedure
Disassembly of Brake
1
(2) Remove the Snap Ring and the Cam
Guide, using a tool with a small
tip, such as needle-nose pliers.
Turn the Hand Wheel Assembly
counterclockwise to remove it.
Hand Wheel Assembly
Cam Guide
Snap Ring
Socket Head
Cap Screw
Wheel Cover
Conical Lock Washer
Hand Chain 4 mm
Do not disassemble the Hand Wheel Assembly.
Failure to do so may result in death or severe injury.
Carefully remove the Snap Ring.
Failure to do so may result in injury.
(1) Remove three sets of Socket
Head Cap Screws and Conical
Lock Washers from Wheel Cover.
Remove the Cover and Hand Chain.
8
Removal of the Load Chain
2
(2) Turn the Pinion counterclockwise
and remove the load chain.
(1) Remove the Hexagon Socket Set
Screw and pull out End Pin.
When it is hard to pull out the End
Pin, lightly hit the side of the Gear
Case.
End Pin
Hexagon Socket
Set Screw
2.5 mm
Bottom Hook
Load chain
Pinion
(4) Remove the Snap Ring of the Pawl
Shaft and pull out the Pawl and two
Pawl Springs.
Pawl Spring (2 pcs)
Pawl Shaft
Pawl
Snap Ring
Do not disassemble the Pawl Shaft.
If it is loosened, replace the Body Assembly
(including the Pawl Shaft) with a new one.
Carefully remove the Snap Ring.
Failure to do so may result in injury.
Do not pull the Bottom Hook and Load Chain
excessively.
Failure to do so may entangle the Chain.
(Continued on the following page)
9
Disassembly Procedure (continued from the previous page)
(2) Pull out the Top Pin to remove the
Top Hook Set.
Top Pin
Top Hook Set
(1) Turn the Body as shown in the right
figure. Remove four sets of Socket
Head Cap Screws and Conical Lock
Washers, and then remove the Gear
Case Assembly.
Conical Lock Washer
Gear Case Assembly
Socket Head Cap
Screw
4 mm
Disassembly of Gear
3
(4) Remove two Socket Head Cap
Screws on the lower side, and then
remove the Chain Guide.
(3) Remove two pieces of Gear #2, Pinion and Load Gear.
Load Gear
Pinion
Gear #2
Socket Head Cap Screw
Spring Lock Washer
4 mm
Chain Guide
To facilitate disassembly, place the
hoist Body on wood blocks with
the pinion set between the blocks.
To facilitate disassembly, loosen two Socket Head Cap Screws on the upper side first.
10
Disassembly of the Latch
4
(2) Hold the Latch firmly and remove
the Socket Head Cap Screw from
the fixing hole.
(1) Loosen the Socket Head Cap
Screw fixing Latch and remove the
Hexagon Nut.
Hexagon Nut
Latch
Socket
Head Cap
Screw
3 mm 7 mm
LatchSocket
Head Cap
Screw
Lever Spring
(5) Remove the two Socket Head Cap Screws on the upper side, and then remove Frame B
and Load Sheave.
Socket Head Cap
Screw
Spring Lock Washer
Frame B
4 mm
Load Sheave
Frame A
(6) Remove Frame A on the opposite side.
Holding the Latch securely, remove the
Socket Head Cap Screw.
Failure to do so may mean the Lever Spring bounces
off to cause injury.
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