Električna Dizalica Proizvođačko en
Električna Dizalica Proizvođačko en
Električna Dizalica Proizvođačko en
Owner's Manual
Hook Suspended Type (hoist only) : ER2
Motorized Trolley Type : ER2M
Manual Trolley Type : ER2SP/ER2SG
To Customer
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This electric hoist ER2 is designed and manufactured for the purpose to lift and lower a load within a normal
work environment. The motorized trolley MR2 and the manual trolley are designed and manufactured for the
purpose to move the lifted load laterally with the combination with the electric hoist.
Movement of a load in a 3D direction such as up/down, forward/backward and right/left is also enabled by
combining with a crane.
This Owner's Manual is intended for those operating the KITO electric hoist ER2 and maintenance engineers
(* pesonnel with expertise).
Other than this manual, Disassembly/Reassembly Manual and Parts List are also available for the maintenance
engineers. Assign the maintenance engineers and use these materials for inspection and repair. Please contact
the nearest distributor or KITO for these materials.
■'LVFODLPHU
● KITO shall not be liable for any damage incurred thereof due to natural disaster such as fire, earth quake
and thunderbolt, conduct by third party, accident, willful conduct or negligence by customer, erroneous use
and other use exceeding the operational condition.
● KITO shall not be liable for any incidental damage due to the use or non-use of the product such as the loss
of business profit, suspension of business and damage of the lifted load.
● KITO shall not be liable for any damage arising from negligence of the contents in the Owner's Manual and
the use of the product exceeding the scope of its specification.
● KITO shall not be liable for any damage arising from the malfunction due to the combination of the product
with other devices in which KITO is not concerned.
● KITO shall be indemnified from any loss of life, bodily injury and property damage due to the use of our
product for which it has passed 10 years since its delivery.
● KITO shall not be liable to supply the spare parts for the product for which it has passed for 15 years since
the discontinue of the product.
2
■
■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 the load under ordinary operational condition. Do not use the product for the work other than
materials handling work.
●● Do not assemble the product into machinery not for materials handling, as a part of it.
■
■Operators
●● Read carefully this Owner’s Manual and the instruction manuals of related products, fully understand their
contents, and the use and operate the product.
●● Be sure to ware the proper clothing and protective equipment when using and operating the product.
■
■Laws and Standards
Carry out installation, inspections, operations, maintenance management in accordance with the laws and
standards of the country and region where the product is used.
An application before installation or a test before beginning usage may be required. Furthermore, the tester
may be required to have specific qualifications. Be sure to check the laws and standards of the corresponding
country and region before using the product.
3
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” and “CAUTION”.
Also read the instruction manual of the device associated with electric chain hoist, and follow the
described contents.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
WARNING injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
CAUTION injury. It may also be used to alert against unsafe practices.
Further, the event described in CAUTION may result in serious accident depending on the situation. Both DANGER and CAUTION
describe important contents. Please follow the instruction.
After reading, please keep this manual at hand for future use by the user.
■
■General Matters on Handling and Control
DANGER
•• This product shall not be disassembled and repaird by personnel other than maintenance engineers.
Other than this manual, Disassembly/Assembly Manual and Parts List are provided for the maintenance engineers.
Perform the disassembling and repair by the maintenance engineer in accordance with these materials for
Prohibited
maintenance.
•• Do not modify the product and its accessories.
Failure to comply with these instructions may result in death or serious injury.
•• Understand the contents of the Owner’s Manual sufficiently. Then operate the Electric chain hoist.
•• Warning label is affixed to each part of the product. Follow the instruction described in the warning label.
Mandatory Failure to comply with these instructions may result in death or serious injury.
4
CAUTION
•• Do not drag or drop the product when carrying.
Otherwise it causes damage or flaw of the electric chain hoist, bodily injury or loss of property due to the drop of the
Prohibited lifted load.
•• When discarding the product, disassemble it not to be used and discard in accordance with the
ordinances of local government or the rules specified by the business entity.
Ask the local government or the relevant section for the details.
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.
•• Keep the record of the inspection.
Failure to comply with these instructions causes bodily injury or loss of property.
■
■General Matters on Handling of Dual Speed VFD Model
The dual speed VFD model electric chain hoist is controlled by VFD for important items related to safety such as
operation, braking and emergency stop. Be sure to follow the safety precautions below as well as the above safety
precautions.
DANGER
•• Do not change parameters.
When parameters need to be changed, ask distributor or KITO.
•• Do not carry out the work such as maintenance and inspection within 5 minutes after power off.
Prohibited
Wait for the completion of discharging of the capacitor inside the VFD.
•• Do not touch the controller cover as it becomes hot during operation.
Do not touch the controller cover until about 30 minutes elapsed after the stop of operation.
•• USE KITO genuine VFD.
The VFD requires the special specification for KITO. Be sure to use genuine VFD.
•• Do not change the connection of the VFD.
When the wires were removed for any reason, connect them again correctly checking the wiring diagram inside the
controller cover.
•• Do not carry out withstand voltage test and insulation resistance measurement of a circuit by megger
while the VFD is connected.
•• Do not turn off the power while operating.
Failure to comply with these instructions may result in death or serious injury and the damage of VFD.
5
6
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.
7
Chapter 1 Handling the Product
■
■Hook Suspended Type (ER2)
●● Electric chain hoist dedicated for elevation
1
Electric Chain hoist
name plate
Hook Suspended Type (ER2)
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
Bottom Yoke
DANGER
•• Warning labels are affixed to each part other than above. Be sure to follow the instructions in the label.
Failure to comply with the contents of the label may result in death or serious injury.
Mandatory
8
Type and Names of Each Part
■
■Motorized Trolley Type (ER2M)
●● Electric Chain Hoist combined with motorized trolley (MR2) for elevation and traveling motion
Motorized trolley
nameplate
Connection Box
Relay Cable
1
Push Button
Load Chain Switch Cord
Warning Tag
Bottom Yoke
Hook latch
Bottom Hook
DANGER
•• Warning labels are affixed to each part other than above. Be sure to follow the instructions in the label.
Failure to comply with the contents of the label can result in serious bodily injury or death.
Mandatory
(to be continued)
9
Chapter 1 Handling the Product
■
■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 manually. For light work.
Plain Trolley (TSP)
Hand Wheel Nameplate
Bumper
Geard Trolley (TSG)
1 Bumper
Manual Trolley Type (ER2SG/ER2SP)
Chain Container
Hand Chain
Load Chain
Cushion Rubber
(Chain Spring and End Plate for the
Push Button Switch Cord model of rated load 2 t or more)
Bottom Yoke
Hook Latch
Warning Tag
Bottom Hook
DANGER
•• Warning labels are affixed to each part other than above. Be sure to follow the instructions in the label.
Failure to comply with the contents of the label can result in serious bodily injury or death.
Mandatory
10
Opening the Package
■
■Checking the Product
■
■Packaging
■■Packaging
For the customer's convenience, the main parts of our product are packaged individually and delivered.
Trolley packaging
Equipped with TSP Plain Trolley
Connection Yoke Power
Cable set Geared Trolley
Combined Model
ER2SP,
ER2SG TSG Geared Trolley
Motorized Trolley
Option Type
(to be continued)
11
Chapter 1 Handling the Product
■
■Nameplate and Product Model
Opening the Package
1 · · · Capacity Ex. 1t, 500kg grade, wire diameter and chain pitch respectively.
The maximum mass of the load that can be 6 LOT No.
imposed on the product. 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.
support the load. Five models of B, C, D, E and F Serial number to indicate the manufacturing sequence
are provided. of the product.
3 GRADE Ex. M4, M5 9 LIFTING SPEED
The grade of an electric chain hoist specified by Single speed model and dual speed VFD model
ISO standard. A guidepost of durability. are provided. Variable speed range and its set
4 CODE…Product model Ex. ER2-005S value are indicated for the dual speed VFD model.
A code to indicate the model No. of the product,
capacity and lifting speed.
5 CHAIN SIZE…Load Chain size
Ex. T-7.7×21.4mm
The alphabet and the figures indicate the JIS
■■Code of ER2
CODE
Capacity Body Size Single speed model Dual speed model
Standard speed Low speed Standard speed Low speed
125kg — (ER2-001H)* — (ER2-001IH/HD)*
ER2-B
250kg ER2-003S (ER2-003H)* ER2-003IS/SD (ER2-003IH/HD)*
500kg ER2-C ER2-005S ER2-005L ER2-005IS/SD ER2-005IL/LD
1t ER2-D ER2-010S ER2-010L ER2-010IS/SD ER2-010IL/LD
1.5t ER2-015S — ER2-015IS/SD
ER2-E
2t ER2-020S ER2-020L ER2-020IS/SD ER2-020IL/LD
2.5t ER2-F ER2-025S — ER2-025IS/SD —
2.8t ER2-028S — ER2-028IS
ER2-E
3t ER2-030S — ER2-030IS/SD —
5t ER2-F ER2-050S — ER2-050IS/SD —
* Hight Speed Type
12
Opening the Package
■■Nameplate Indication of Motorized Trolley
1
2 CODE: MR2-010S MFG.YEAR
1 LOT No:
■■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
1t
1.5t
MR2-020S MR2-020L MR2-020IS/SD
2t
2.5t
2.8t MR2-030S MR2-030L MR2-030IS/SD
3t
5t MR2-050S MR2-050L MR2-050IS/SD
(to be continued)
13
Chapter 1 Handling the Product
1
2
Nameplate and Product Model
14
■
■Checking the Marks
Checking the Marks / Recording the Product No. / Recording the Initial Value
ER2-005L/IL/LD
6.0 20 Links Mark pitch
ER2-005S/IS/SD
ER2-010L/IL/LD
7.7 20 Links
ER2-010S/IS/SD RH-DAT 0000 RH-DAT
■
■Recording the Product No.
●● Fill in the table in the right with
Item Electric chain hoist Motorized trolley Manual trolley
product's Lot No., Serial No.
(described in the product nameplate), Lot No.
date of purchase and the name of the Serial No.
sales shop where you purchased the Date of purchase
product. Name of the sales shop
* When requesting repair or ordering
a chain hoist part, please inform us of these pieces of information together.
■
■Recording the Initial Embossed marks Dimensions when the package was opened
15
Product Specification and Operational Environment
Chapter 1 Handling the Product
■
■Standard Specification
Short time ratings : ER2 series(Capacity 100 %) : Single speed model — 60 min.
Dual speed VFD model (high speed/low speed) — 30/10 min.
: MR2 series(Capacity 100 %) : Single speed model — 30 min.
Dual speed VFD model (high speed/low speed) — 30/10 min.
Intermittent ratings : ER2 series(63 % of the capacity) : S
ingle 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) : S ingle speed model — 40 % ED (at 240 rev/h)
Dual speed VFD model (high speed/low speed) — 27/13 % ED
(78/162 rev/h)
Grade * 1 : ISO-M6, M5 or M4, FEM-3m, 2m or 1Am, ASME-H4
Protection : Hoist IP55, Push button IP65
1 Operation Push button switch operation / 3-Push Button Switch set for hoist only and Manual trolley type / 5- or
7-Push Button Switch set for motorized trolley combined model
Power supply method....Power supply through cabtyre cable
Color...............................KITO Yellow (Equivalent to Munsell 7.2YR6.5/14.5)
Noise level : 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)
Standard Specification
: MR2 85dB or less (A scale: measured at 1 m away from the Electric chain hoist)
Braking capacity : 150% of the capacity or more
Other...............................Power Cable length 5 m/10 m (Standard)
NOTE
•• Operate the electric chain hoist with the rated voltage.
•• Do not use the electric chain hoist exceeding the short time ratings and the intermittent ratings.
* Grade
Code GRADE Code GRADE
Capacity (kg or t)
Single speed Dual speed ISO ASME FEM Dual speed ISO ASME FEM
125 ER2-001H ER2-001HD ER2-001IH
ER2-003H ER2-003HD ER2-003IH
250
ER2-003S ER2-003SD ER2-003IS M6 H4 3m
ER2-005L ER2-005LD ER2-005IL
500 M5 H4 2m
ER2-005S ER2-005SD ER2-005IS
ER2-010L ER2-010IL/LD
1
ER2-010S ER2-010IS/SD
1.5 ER2-015S ER2-015IS/SD
ER2-020L ER2-020IL/LD
2
ER2-020S ER2-020IS/SD
2.5 ER2-025S ER2-025IS/SD
M4 H4 1Am
2.8 ER2-028S ER2-028IS
3 ER2-030S ER2-030IS/SD
5 ER2-050S ER2-050IS/SD
* For 125kg - 500kg dual speed VFD type equipped with friction clutch with mechanical brake, the grade is ISO M5
16 and FEM 2m.
Product Specification and Operational Environment
●● ISO
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*
800 1600 3200 6300 12500 25000
Light M4 M5 M6
Medium M4 M5 M6
Heavy M4 M5 M6
Ultra heavy M4 M5 M6
* Rate of loading
Light : A case where the capacity is rarely applied. Usually the hoist is used with a light load.
Medium : A case where the capacity is applied considerably frequently. Usually the hoist is used with a medium
load. 1
Heavy : A case where the capacity is applied considerably frequently. Usually the hoist is used with a heavy load.
Ultra heavy : A case where the capacity is applied constantly.
Standard Specification
●● ASME HST
Operation time ratings at K=0.65
Unlformly distributed Infrequent
Hoist duty class Typical areas of application work periods work periods
Max. on Max. No. Max. on time from Max. No.
time, min / hr starts / hr cold start, min of starts
Light machine shop fabricating,
service,and maintenance; loads and
H2 7.6 (12.5%) 75 15 100
utilization randomly distributed; capacitys
infrequently handled.
General machine shop fabricating,
H3 assembly, storage, and warehousing; 15 (25%) 150 30 200
loads and utilization randomly distributed.
High volume handing in steel warehouses,
machine shops, fabricationg plants and
mills, and foundries; manual or automatic
H4 30 (50%) 300 30 300
cycling operations in heat treating
and plating; loads at or near capacity
frequently handled.
• The grade symbols are identical to those of ASME HST-1M. (Performance standard for Electric Chain Hoist)
●● FEM
Relation between ISO-and FEM-Denominations
1 Dm 1 Cm 1 Bm 1 Am 2m 3m 4m 5m Average Calculated
Class of
M1 M2 M3 M4 M5 M6 M7 M8 operating total operating
operating
time per day time
time
Class of operation time (in hours) (in hours)
■
■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
: A place with considerable amount of acids and salts
NOTE
When installing the electric chain hoist outdoors or to the place where the hoist is exposed to direct rain, wind and
snow, shade the hoist with roof to protect it from rain, wind and snow.
1
Operational Environment
18
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. Check the product model of the hoist and use it properly.
DANGER
How to Use
•• Do not use the Hook without a Hook Latch or damaged Hook.
•• Do not use the Load Chain with heavy elongation, abrasion or deformation.
•• Do not cut, extend, or weld the Load Chain.
Prohibited •• Do not use the Load Chain with the Bottom Hook without smooth motion.
•• Do not use the Load Chain when its brake does not function securely even without load, or when the
stopping distance is too long.
•• Do not use the product if it moves oppositely to the direction indicated on the push button switch.
Failure to comply with these instructions may result in death or serious injury.
1
•• Carry out daily inspection before operation.
(When any abnormality was found during inspection, turn off the power, indicate “FAILURE" and ask the maintenance
engineer for repair.)
Mandatory •• Check the slinging devices for no abnormality.
Failure to comply with these instructions may result in death or serious injury.
CAUTION
•• Do not use the product with an illegible nameplate or warning label affixed to the body size.
Failure to this instruction may result in the injury or the property damage.
Prohibited
•• When using the product for the first time, affix the labels indicating East, West, North and South on the push
button switches.
•• Check the contents of the work and make sure that the electric chain hoist has proper performance for the load
Mandatory
and lift.
•• Check the contents of the work and operate the electric chain hoist at a place enabling to look out the operating
area without hindrance.
•• When looking out the operating area is difficult, arrange the monitor near the place for safety.
•• Operate the electric chain hoist at a place with firm foothold without danger of falling, stumbling, slipping or
over turning.
•• Before moving the load, warn all the surrounding people.
•• Even if the crane or the electric chain hoist is permanently installed and used for the same purpose repeatedly,
check the contents of the work and make sure that the work does not exceed the capacity on each occasion.
•• Appoint the maintenance engineer or competent personnel among the qualified personnel for operation of
cranes and electric chain hoists. Indicate the name of the personnel on a place with legibility.
•• The maintenance engineers shall check the result of daily inspection.
•• When informed of abnormality of the electric chain hoist, the maintenance engineers shall take immediately
any necessary measures such as prohibition of use and repair.
•• When carrying out inspection and repair, secure the environment for safe work without electric shock and
falling.
Failure to comply with these instructions may result in bodily injury or property damage.
(to be continued)
19
Chapter 1 Handling the Product
■
■Daily Inspection of Electric Chain Hoist (Hook Suspended Type)
DANGER
•• Carry out daily inspection before use.
(When any abnormality was found during inspection, turn off the power, indicate “FAILURE" and ask the maintenance
How to Use
●● Refer to the technical material attached in Appendix (P122) for the structure of the product and the name
of each part.
1 ■■Appearance
Indication of • Check visually. • No peel off. Indication can be seen clearly. Carry out cleaning, repair
nameplates or replace with new
and labels nameplate or label.
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.
Loosened • C
heck visually or using • B
olts, nuts and split pins are fastened Fasten bolts, nuts and
or fallen off tools. securely. split pins securely.
bolts, nuts DANGER
and split pins
•• Even fallen off of a bolt causes
for the body size to drop. Be
sure to check.
Mandatory
Fallen off of a bolt may result in death
or serious injury.
20
■■Load Chain
How to Use
Frequent inspection.
• C
heck visually for no foreign
matter such as attached
sputter.
Rust, • Check visually • No apparent rust and corrosion Replace the Load
Corrosion Chain.
(to be continued)
21
Chapter 1 Handling the Product
Deformation, • Check visually • No apparent deformation, flaw and corrosion Carry out the
Flaw, inspection item of Top
Daily Inspection of Electric Chain Hoist (Hook Suspended Type)
Hook Latch • C
heck visually and check • T he Hook Latch is mounted securely inside Replace the Hook
the movement of the Hook the Hook opening. Latch.
Latch. • No deformation. The Hook Latch moves
smoothly.
DANGER
•• Do not use the Hook without
the Hook Latch.
Use of the Hook without the Hook
Prohibited
Latch may result in death or serious
injury.
Hook • C
heck visually and rotate • N o apparent gap between the Bottom Yoke Replace the Hook.
movement the Hook by hand. and the shank (at the neck).
(Rotation) • The Bottom Yoke rotates in both directions
Neck equally.
• The Bottom Yoke rotates smoothly.
22
Item Check method Criteria When failed
Movement • C
heck 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
How to Use
not to be caught.
Mandatory
Otherwise it may result in injury.
Bottom Yoke • Check visually. • No loosened bolt or nut Attach the Bottom Hook to
the Load Chain securely.
Stopper
(to be continued)
23
Chapter 1 Handling the Product
• Label indication of the push button switch can a new label. Affix the
be seen clearly. label securely.
Check check each operation. • The Electric chain hoist moves in the same “Guidance on
direction as that of the push button operation. Troubleshooting" (P94
• When the operation is stopped, the motor to 97).
stops immediately.
• When the Emergency Stop Button is pressed,
all hoist motions stop.
• When operating other push button while the
Emergency Stop Button is pressed, the hoist
does not start operation.
• When canceling the Emergency Stop Button,
the hoist operates normally.
Brake • P
ress the push button and • W
hen stopping the operation, the Brake is Carry out the inspection in
check the operation of the applied immediately and the Bottom Hook accordance with the items
Brake. shall stop immediately. in Chapter 2 “Periodic
(Guideline: The travel of the Load Chain is inspection" Electromagnetic
within 2 to 3 links.) Brake (P79).
Friction • P
ress the push button and • W
hen lifting, the sound of pawl clicks regularly. Disassemble the
Clutch with check the operation of the (For the friction clutch of standard specification Friction Clutch and to
Mechanical Friction Clutch. makes no pawl sound.) check.
Brake
Limit Switch • P
ress the push button and • W
hen the hoist is operated to the upper or Replace the Limit Switch.
check the operation of the lower limit, the motor automatically stops. Disassemble the actuator
Limit Switch. of the Limit Switch to
clean.
Check for no • P
ress the push button and • No abnormal sounds and vibrations Replace the abnormal
Abnormal check the operation. part.
Sound NOTE Apply oil on the Load
Chain.
Sound is also an important
check point. Always be • No popping sound from the Load Chain. Check the Load Chain.
careful for the noise of the
(Refer to P21.)
electric chain hoist.
24
■
■Daily Inspection of Motorized Trolley (MR2)
■■ Appearance
How to Use
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.
Connection Box
Motor cover
Loosened • C
heck visually or using • B
olts, nuts and split pins are fastened Fasten bolts, nuts and
or fallen off tools. securely. split pins securely.
bolts, nuts DANGER
and split pins
•• Even a drop off of a split pin
may cause of drop of the body
size. Be sure to check it.
Mandatory
Drop off of split pin may result in death
or serious injury.
(to be continued)
25
Chapter 1 Handling the Product
Operational • P
ress the push button to • T o travel smoothly. No meandering and Refer to Chapter 3
Check check the operation. vibration. “Guidance on
• The electric chain hoist moves in the same Troubleshooting" (P94
direction as that of the push button operation. to 97).
• When the operation is stopped, the motor
stops immediately.
• When the Emergency Stop Button is pressed,
1 all hoist motions stop.
• When operating other push button while the
Emergency Stop Button is pressed, the hoist
Daily Inspection of Motorized Trolley (MR2) / Daily Inspection of Manual Trolley (TSG/TSP)
Brake • P
ress the push button to • W
hen the operation is stopped, the Brake is Carry out the inspection
check the operation of the applied and the motor stops immediately. in accordance with the
Brake. items in Chapter 2
“Periodic inspection"
Electromagnetic Brake
(P84).
■
■Daily Inspection of Manual Trolley (TSG/TSP)
■■Appearance
Deformation • Check visually • No apparent deformation and corrosion Replace the deformed
and damage • No apparent deformation on the Frame or damaged part.
of each part
Loosened • C
heck visually or using • B
olts, nuts and split pins are fastened Fasten bolts, nuts and
or fallen off tools. securely. split pins securely.
bolts, nuts DANGER
and split pins
•• Even a drop off of a split pin
may cause of drop of the body
size. Be sure to check it.
Mandatory
Drop off of split pin may result in death
or serious injury.
26
■■Function and Performance
How to Use
Operational • C
heck the traveling motion • T
o travel smoothly. No meandering and Carry out Chapter 2
Check of the electric chain hoist by vibration. "Periodic inspection".
moving it manually.
(to be continued)
27
Chapter 1 Handling the Product
■
■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.
How to Use
•• Do not bundle or tie the cord for the adjustment of its length.
Prohibited
Failure to comply with this instruction causes bodily injury or loss of property.
•• When taking hand off the Push Button Switch after operation, do not throw it. Be careful not to hit other
worker with the Push Button Switch.
•• When starting operation of the hoist after stopping the hoist by pushing the Emergency Stop Button, be
1 Mandatory
sure to confirm there are no hazards around the workplace before releasing the lock of the Emergency
Stop Button and starting operation.
Failure to comply with this instruction causes bodily injury or loss of property.
How to Operate the Push Button Switches
NOTE
If the Electric chain hoist is tripped due to overheat of the VFD, the VFD cannot be reset soon after the trip. Reset the VFD
after a while.
28
■■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. Refer to the operation method
of the corresponding specification.
How to Use
Moving direction of the trolley is expressed as East/West for traveling motion in the operational instruction of the
Push Button Switch Set.
1) Press button to move the 1) Press button to move the trolley to the
trolley to the east. east at low speed.
•• The trolley stops when the 2) Press button further to the end to move
button is released. the trolley to the east at high speed.
•• The trolley stops when the button is released.
1) Press button to move the 1) Press button to move the trolley to the
trolley to the west. west at low speed.
•• The trolley stops when the 2) Press button further to the end to move
button is released. the trolley to the west at high speed.
•• The trolley stops when the button is released.
(to be continued)
29
Chapter 1 Handling the Product
Moving directions of the trolley are expressed as East/West for traveling motion, and North/South for traversal
motion in the operational instruction of the Push Button Switch Set.
●● Emergency Stop Button (VFD Reset Button)
1) Press the Emergency Stop Button deeply when carrying out an emergency stop or
VFD reset.
•• The button is locked at the pressed end.
2) Turn the Emergency Stop Button clockwise to cancel the lock.
1 •• Press-locked button returns to the original position.
* When the electric chain hoist is not used, press the Emergency Stop Button deeply to the end.
●● Operation Button
How to Operate the Push Button Switches
●●Lift/Lower Button
Single Speed Model Dual Speed VFD Model
1) Press button to move the 1) Press button to move the trolley to the
No label for the trolley to the east. east at low speed.
Dual single speed
model •• The trolley stops when the 2) Press button further to the end to move
button is released. the trolley to the east at high speed.
•• The trolley stops when the button is released.
1) Press button to move the 1) Press button to move the trolley to the
trolley to the west. west at low speed.
•• The trolley stops when the 2) Press button further to the end to move
button is released. the trolley to the west at high speed.
•• The trolley stops when the button is released.
●●Traverse Button
Single Speed Model Dual Speed VFD Model
1) Press button to move the 1) Press button to move the trolley to the
trolley to the south. south at low speed.
•• The trolley stops when the 2) Press button further to the end to move
button is released. the trolley to the south at high speed.
•• The trolley stops when the button is released.
1) Press button to move the 1) Press button to move the trolley to the
trolley to the north. north at low speed.
•• The trolley stops when the 2) Press button further to the end to move
button is released. the trolley to the north at high speed.
•• The trolley stops when the button is released.
30
■
■Operation
■■General
DANGER
How to Use
•• 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.
•• Do not use the electric chain hoist by the voltage other than the rated voltage.
•• Do not use the Emergency Stop Button for ordinary stop operation.
•• Do not expose the Load Chain to sparks from welding.
•• Do not contact welding rods or electrodes with the Load Chain.
•• Do not use the Load Chain as the earth for welding work. (Fig. A) A
1
Failure to comply with these instructions may result in death or serious injury.
Operation
•• Follow the operating environment and conditions for the electric chain hoist.
Failure to comply with this instruction may result in death or serious injury.
Mandatory
■■Slinging
DANGER
•• Do not apply a load to the tip of the Bottom Hook or the Hook Latch. (Fig. B)
•• Do not bind a load with the Load Chain directly. (Fig. C)
•• Do not operate the Load Chain while it is in
Prohibited
contact with any sharp edges. (Fig. D)
Failure to comply with these instructions may result in
death or serious injury.
B C D
•• Use the sling appropriate for the weight and shape of a load.
Inappropriate slinging may result in danger such as drop of a lifted load.
•• Carry out the slinging with equal load on slinging devices for stable lifting of a load.
Mandatory
•• Attach the slinging devices securely to a load.
•• Attach the slinging devices to the Bottom Hook correctly.
Failure to comply with these instructions may result in death or serious injury.
(to be continued)
31
Chapter 1 Handling the Product
■■Lifting/Lowering
DANGER
•• Do not lift more than the capacity. (Fig. E)
The capacity is indicated in the nameplate.
How to Use
•• Do not operate the electric chain hoist exceeding the lifting height.
Prohibited
•• Do not dare to lift the structure or any other object supposed to be difficult to lift. over load
•• Do not lift a load at no-load side of the Load Chain.
•• Do not stop the electric chain hoist with the limit switch (over winding prevention device). E
•• Do not use the electric chain hoist when the Friction Clutch (overload prevention
device) is operated to stop winding.
•• Do not lift or lower excessively.
1 •• Do not remove the Chain Spring or the Cushion Rubber to operate the limit switch by
hitting the body size with the Bottom Hook. If such stop operation is repeated, it may
result in breaking of the Load Chain.
•• Do not hit the body size with the End Stopper of the Load Chain to cause the operation
Operation
of the Friction Clutch. If such operation is repeated, it may result in breaking of the Load
Chain.
•• Do not use the body size as a fulcrum. (Fig. F) F
•• Do not swing the lifted load.
•• Do not wind the slack Load Chain with a load in one action to avoid exposing the
Load Chain to shock.
Stop lifting when the Load Chain is stretched tight. Then lift slowly.
•• Do not carry out reverse operation while lifting/lowering a load.
When reversing the motion, stop the electric chain hoist and then reverse the motion.
•• Do not carry out excessively frequent inching.
•• Do not carry out plugging.
When reversing the motion, stop the electric chain hoist and then reverse the motion.
•• When lifting off a load from a pallet, lift the load to avoid exposing to shock,
such as the load falling. (Fig. G) G
•• Do not cause the load to come into contact with the Load Chain.
•• Do not rotate a lifted load. Use the device for rotation.
•• Do not carry out the welding or cutting work on a lifted load.
•• Do not repair or disassemble a lifted load.
When repairing or disassembling an electric chain hoist, ensure that the product is placed down
on the floor and that only maintenance engineers maintain the electric chain hoist.
•• Do not enter beneath a lifted load.
•• Do not hit the Chain Container with a load or slinging devices.
Otherwise the Load Chain in the Chain Container falls out of the bucket to cause injury.
Failure to comply with these instructions may result in death or serious injury.
•• When the limit switch (over winding prevention device) is operated, stop the
lifting work immediately and lower the load.
•• Move the electric chain hoist right above the load and then lift the load. (Do not
Mandatory
lift the load in an inclined direction.) (Fig. H)
•• Do not leave from the operating position while a load is lifted. Watch the lifted load.
Failure to comply with these instructions may result in death or serious injury.
H
32
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
How to Use
•• When carrying a lifted load using a lifting magnet or a vacuum chuck, lower the height of the lifted load
as low as possible.
•• When lifting a load with two electric chain hoists, use the electric chain hoist with the rated lifting
Mandatory
capacity of a single hoist exceeding the load.
•• When lifting a load with two electric chain hoists, use the electric chain hoists of the same model and
capacity and operate the respective electric chain hoist to keep the load lifted or lowered horizontal.
Failure to comply with this instruction causes bodily injury or loss of property. 1
■■Traverse / Travel
Operation
DANGER
•• Do not operate the electric chain hoist underneath the load or transport a load
over people. (Fig. I)
•• Do not operate the electric chain hoist when any person is in the area
Prohibited
where the lifted load moves.
•• Do not allow people to enter into the area where a lifted load moves.
•• Do not ride on a lifted load and do not use the electric chain hoist to
support, lift, or transport people. (Fig. J)
•• Do not strike the stopper or the structure by the body size or the trolley. I J
•• Do not operate or move the electric chain hoist while going backward with a load kept lifted.
Operate the electric chain hoist while looking forward from the back of a load and going ahead.
Failure to comply with these instructions may result in death or serious injury.
CAUTION
•• Do not impede the lifted load with other structure or wiring.
Failure to comply with this instruction causes bodily injury or loss of property.
Prohibited
•• If the Load Chain and the hand chain of the geared trolley are entangled, stop the operation
immediately and reset the entangled chains.
Mandatory Failure to comply with this instruction causes bodily injury or loss of property.
(to be continued)
33
Chapter 1 Handling the Product
■
■Speed Change of Dual Speed VFD Model
You can change the high/low speed of the dual speed VFD model by changing the VFD parameter.
DANGER
•• Only maintenance engineers or the personnel with expertise are allowed to set or change parameters.
How to Use
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.
•• When changing the parameter, set it correctly referring to the VFD Manual.
•• Parameter change requires energizing. Do not touch the energized part.
1 Mandatory Failure to comply with these instructions may result in death or serious injury.
Speed Change of Dual Speed VFD Model / How to Sling the Load Properly / How to Suppress the Swinging of a Load
■
■How to Sling the Load Properly
Do not carry out dangerous hooking as shown below.
■
■How to Suppress the Swinging of a Load
DANGER
•• Do not move the electric chain hoist with a load hung at one side of the Crane Saddle.
Otherwise the load swings and hits a person or object or drops to result in death or serious injury.
Prohibited
Swinging of a load makes it difficult and dangerous to move the trolley. The basics of operation are not to make a
load swing. To do that keep the following instructions.
●● Do not lift a load in an inclined direction.
●● Start slowly when traveling the load.
●● Do not lift suddenly.
Even if you keep the above instructions, the lifted load may swing
at the start and the stop of the electric chain hoist.
Following operation can reduce the swing of the lifted load.
■■Operation
1) Press the Travel Button. (Fig. a)
2) When the trolley starts to move, the lifted load delays a bit. (Fig. b)
3) Release the button a bit before the time when the lifted load
swings to the center position.
4) W
hen the lifted load comes to the position just beneath the electric chain
a b c
hoist, press the button again and continue to travel the load. (Fig. c)
34
■
■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.
How to Use
Prohibited
35
Work Flow of Assembling and Installation
Chapter 1 Handling the Product
Combination with the Motorized Trolley (P42) Combination with the Manual Trolley (P47)
Part replacement of the electric chain hoist Part replacement of the electric chain hoist
Checking the rail width of the motorized Checking the rail width of the manual
trolley trolley
Checking the number and position of Checking the number and position of
adjusting collars adjusting collars
Assembling
Combination of the electric chain hoist and Combination of the electric chain hoist and
the motorized trolley the manual trolley
Mounting the balance weight
Connecting Push Button Switch Set Cord Connecting the Power Cable Connecting Push Button Switch Set Cord
Installation of Hook Suspended Type (hoist only) (P57) Installation of Trolley Combination Model (P58 to 60)
Connecting Power Cable Connecting Power Cable to the power
Installation
36
Assembling
DANGER
•• Only maintenance engineers or the personnel with expertise are allowed to assemble and disassemble the
electric chain hoist.
Assembling
Prohibited Assembling or disassembling of the electric chain hoist may result in death or serious injury.
■
■Assembling Parts to Electric Chain Hoist
■■Preparation for Assembling
• Hang the electric chain hoist body size to facilitate the mounting of the Chain Container.
• Check that the stopper and the cushion rubber are mounted at the link third from the no load side of the Load
1
Chain (the end without the Bottom Hook).
DANGER
•• The each type of Chain Container has the capacity to store the specific amount of the Load Chain. Use
correct capacity of the Chain Container.
When storing the Load Chain of which amount exceeds the capacity of the Chain Container, it may result in death or
Mandatory
serious injury due to the flow over of the Load Chain from the Chain Container or defective operation of the electric
chain hoist.
Improper combination of the Chain Container and the electric chain hoist is very dangerous because of the possibility
of drop of the Chain Container.
The seal to indicate the capacity and lifting height is attached on the Chain Container. Check it before use.
•• If the Chain Container is not assembled correctly, it may result in death or serious injury due to a drop of
the Chain Container or Load Chain, and malfunction of the Electric Chain Hoist.
Refer to the assembling instruction on the page 38 and assemble the Chain Container correctly.
Failure to comply with these instructions causes bodily injury or loss of property.
CAUTION
•• When storing the Load Chain into the Chain Container, put the chain end with no-load side first and
then store the rest of the Load Chain.
Mandatory Failure to comply with these instructions causes bodily injury or loss of property.
(to be continued)
37
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
Assembling
Chain Guide A
1
Edge of the
Container Spring
Container Spring Socket
Bolt U nut
Chain Container
2) Pass a Socket Bolt through all holes of the
Assembling Parts to Electric Chain Hoist
Assembly figure
●● Canvas Container
Socket
1) Pass two Socket Bolts through all Bolt Chain
holes of the Chain Guide A, the Canvas Guide A
Container and the Chain Guide A in this
order to mount the Chain Container.
U nut
38
●● Case without Chain Container
When using the electric chain hoist without the Chain Container, take the following measures.
Assembling
* Number of Links between Chain End Suspender
and the Stopper
Body size Number of Links
B 21
Chain End
C 15 Suspender
D 15
E 15 Chain
F 15 Guide A
*Number of 1
* Tightening torque for the Stopper Bolt: 10 N·m links
Cushion
Cushion
Rubber Stopper
DANGER
•• When using the electric chain hoist, be careful not make the Load Chain at no load side impeded or
entangled.
Mandatory Failure to comply with these instructions may result in death or serious injury.
(to be continued)
39
Chapter 1 Handling the Product
Assembling (continued)
DANGER
•• Be sure to apply lubricant on the Load Chain. Do not carry out oiling work in the place near the fire or
arc.
Assembling
Release all loads from the Load Chain. Apply the lubricant to the
linking portion of the Load Chain that engages the Load Sheave
and the Idle Sheave (hatched area).
After application of the lubricant lift/lower the electric chain hoist
without load to spread the lubricant on the Load Chain.
■■Gear Oil
Inside of the Gear Case is filled with gear oil at the shipping. The level of the oil filled with specified amount comes
to the height of the inspection hole. Check the oil level visually.
DANGER
•• Set the body size to a level and then check the level of gear oil.
When removing the oil plug without leveling the electric chain hoist, the gear oil flows out. It will result in death or serious
Mandatory injury due to fall by slippery floor.
Assembling
DANGER
•• The gear oil for the electric chain hoist with Friction Clutch with mechanical brake is different from that
for the hoist with standard Friction Clutch. Be sure to use the genuine gear oil for the hoist with friction
clutch with mechanical brake.
Mandatory
Use of the gear oil other than the specified oil (including mixed use) will result in death or serious injury due to the drop of
the lifted load.
1
●● When using the electric chain hoist Oil Cap
■
■Combination with the Trolley
* When using the Hook suspended model (Single Unit) “Connection of Power and Power Cable", you can skip the this
section. Please proceed with Page 53.
DANGER
•• Adjust the rail width during assembling and install.
•• Be careful for the Power Cable and Push Button Switch Set Cord are not pulled off or entangled within
the area of traveling area.
Mandatory
Failure to comply with these instructions may result in death or serious injury.
(to be continued)
41
Chapter 1 Handling the Product
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.
Assembling
Prohibited
1 Refer to the following figure to remove the Top Hook and replace the Suspender with the Suspender T.
plier.
Top Hook
2) Remove the Socket Bolt from the Shaft
Retainer, and remove the Shaft Retainer.
Suspender T
3) Remove two Connection Shafts.
Shaft Retainer
Clip
4) Remove the Top Hook and replace it Connection
with the Suspender T. Shaft
Shaft
5) Insert two Connection Shafts into the Retainer
hole of the Body size. Socket
Bolt
6) Mount the Shaft Retainer with Socket
Bolt.
42
■■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
Assembling
following table.
●● Adjusting spacer arrangement for LOW Head Suspension (Beam flange width 58-170mm)
Number of Adjusting Spacers
Beam flange 2 / 2 2 /8 1 7 411/16 511/16
(in) 25/16 5 15 3 31/4 39 /16 37/8 315/16 4 43 /16 45/16 47/16 3 415/16 5 53 /16 55/16 53 /8 55/8 3 6 61/8 65/16 67/16 611/16
width 2 /8 2 /16 4 /4 5 /4
Capacity(t)
64 73 75 90 119 149
Parts
Name
(mm) 58
66 74 76
82
91
98 100 102 106 110 113
120
125 127 131 135 137 143
150
153 155 160 163 170
1
Inner 1+2 2+3 4+4 1+0 1+2 2+3 0 1+0 1+2 2+2 2+3 3+4 4+4 4+1 5+1 2+2 3+3 4+4 4+1 1+1 2+2 2+3 3+0
Thin spacer
Outer 5 3 0 7 5 3 8 7 5 4 3 1 0 3 2 4 2 0 3 6 4 3 5
(to be continued)
43
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 71/16 71/4
(in) 67/8 7 77/8 8 87/16 811/16 9 91/8 97/8 10 101/8 101/4 103/8 101/2 11 111/8 111/4 113/8 115/8 113/4 1113/16 117/8 12
width 71/8 75/16
Capacity(t)
180 184
(mm) 175 178 200 203 215 220 229 232 250 254 257 260 264 267 279 283 286 289 295 298 300 302 305
Assembling
Thick spacer L
Outer 0
Inner 4+4 1+4 1+1 1+2 4+4 1+0 2+3 3+3 4+1 1+1 4+4 4+1 5+1 4+3 2+3 3+3 4+1 1+2 2+2 2+3 3+3 3+4 4+4 4+1 5+1
Combining with the motorized trolley
Thin spacer
Outer 0 3 6 5 0 7 3 2 3 6 0 3 2 1 3 2 3 5 4 3 2 1 0 3 2
Inner 2+2 3+2 0 1+1 1+2 2+2 2+3 3+3 3+4 4+4 4+5
Thick spacer
2 Outer 1 0 9 7 6 5 4 3 2 1 0
Fixing spacer Inner 1+1
Inner 1+1
Thick spacer L
Outer 0
Inner 4+4 1+4 1+1 1+2 4+4 1+0 2+3 3+3 4+1 1+1 4+4 4+1 5+1 4+3 2+3 3+3 4+1 1+2 2+2 2+3 3+3 3+4 4+4 4+1 5+1
Thin spacer
Outer 0 3 6 5 0 7 3 2 3 6 0 3 2 1 3 2 3 5 4 3 2 1 0 3 2
Inner 2+2 3+2 0 1+1 1+2 2+2 2+3 3+3 3+4 4+4 4+5
Thick spacer
3 Outer 1 0 9 7 6 5 4 3 2 1 0
Fixing spacer Inner 1+1
Inner 1+1
Thick spacer L
Outer 0
Inner 4+4 4+1 5+1 4+3 4+4 1+0 2+3 3+4 1+1 1+2 4+4 1+1 1+2 2+2 2+3 3+3 5+1 1+2 2+2 2+3 4+3 4+4 4+0 4+1 5+1
Thin spacer
Outer 0 3 2 1 0 7 3 1 6 5 0 6 5 4 3 2 5 4 3 1 0 4 3 2
Inner 1+1 1+2 2+2 3+3 4+4 5+5 5+6 6+6 6+7
5 Thick spacer
Outer 1 0 10 9 7 5 3 2 1 0
Inner 1+1
Thick spacer L
Outer 0
Remarks) 3) Thin Spacer arrangement example
Side plate S
Suspension shaft
Left side Right side
44
●● Adjusting spacer arrangement for Lug Suspension
Number of Adjusting Spacers
Beam flange 2 1 / 2 2 7 /8 411/16 511/16
(in) 25/16 3 31/4 39 /16 37/8 315/16 4 43 /16 45/16 47/16 3 415/16 5 53 /16 55/16 53 /8 55/8 3 6 61/8 65/16 67/16 611/16
width 25/8 215/16 4 /4 5 /4
Capacity(t)
64 73 75 90 119 149
(mm) 58 82 98 100 102 106 110 113 125 127 131 135 137 143 153 155 160 163 170
Assembling
Parts 66 74 76 91 120 150
Name
0 1+0 1+1 1+2 2+2 3+3 0 1+0 1+1 2+2 3+3 4+0 4+1 1+1 2+2 2+3 3+0
Thin spacer
8 7 6 5 4 2 8 7 6 4 2 4 3 6 4 3 5
5
0 1+1 1+2 2+2 2+3
Thick spacer
5 3 2 1 0
180 184
(to be continued)
45
Chapter 1 Handling the Product
Assembling (continued)
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.
Assembling
Mandatory
●● 125 kg~5 t
Split pin
3) Set the Suspension Shaft with a Thin
Frame G
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 Thin spacer
Thin Spacer, Thick Spacer and Thick Suspension Shaft
Spacer L. Then insert the Suspension Split pin
Shaft into the Frame S. Slotted nut
•• Adjust the Spacers in accordance with the Fixing Shaft Hole A
rail width. (Refer to “Checking the Number of Hole B
the Assembled Adjusting Spacers and their
positions" (P45) for the number of Spacers.) Thick spacer L
Thick spacer
6) Set the Suspension Shaft with a Thick
Spacer. Insert the Shaft Stopper Pin into Shaft Stopper
the Hole A and fix it with a split pin. Thin spacer Pin
•• Insert the Shaft Stopper Pin in the direction that Suspender T of Main Unit
the split pin comes to the left when viewed from Frame S
the front side of the MR2 Connection Box.
Split pin
46
■
■Combination with the Manual Ttrolley
■
■Parts replacement of the Electric Chain Hoist
Manual Trolley For Double Chain Type
Remove the Top Hook and replace it with a Connection
Yoke.
Assembling
●● Replacing the Top Hook of Body size ER2-B/C/D/E
Controller Cover
Socket Bolt
(to be continued)
47
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. Insert the correct number of Spacers with correct ratings and for rail width at the correct position,
referring to the following table.
Assembling
64 73 75 90 119 149
(mm) 50 58 82 98 100 102 106 110 113 125 127 131 135 137 143 153 155 160 163
66 74 76 91 120 150
1
Parts
Inner 2+3 3+4 0+1 1+2 2+2 3+3 0+1 1+2 2+2 2+3 1+1 1+2 2+2 3+3 0+0 0+1 1+1 1+2 2+2 3+3 0+0 0+1 1+1 1+2 2+2
Thin spacer
Outer 4 2 8 6 5 3 8 6 5 4 7 6 5 3 9 8 7 6 5 3 9 8 7 6 5
0.5 Inner 0+0 0+0 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 0+0 0+0 0+0 0+0 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2
Thick spacer
Combination with the Manual Ttrolley
Outer 4 4 2 2 2 2 0 0 0 0 7 7 7 7 5 5 5 5 5 5 3 3 3 3 3
Fixing spacer Inner – – – – – – – – – – 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1
Inner 3+3 0+0 1+1 1+2 2+3 0+0 1+1 1+2 2+2 2+3 3+3 3+4 0+1 1+2 2+2 1+1 1+2 2+2 3+3 0+0 0+1 1+1 1+2 2+2
Thin spacer
Outer 2 8 6 5 3 8 6 5 4 3 2 1 7 5 4 7 6 5 3 9 8 7 6 5
1 Inner 0+0 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 0+0 0+0 0+0 0+0 1+1 1+1 1+1 1+1 1+1
Thick spacer
Outer 6 4 4 4 4 2 2 2 2 2 2 2 0 0 0 5 5 5 5 3 3 3 3 3
Fixing spacer Inner – – – – – – – – – – – – – – – 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1
Inner 2+2 3+4 0+1 1+1 1+2 2+2 2+3 3+3 0+0 1+1 1+2 2+2 2+3 3+3 0+0 1+1 1+2 1+1 1+2 2+2
Thin spacer
Outer 3 0 6 5 4 3 2 1 7 5 4 3 2 1 7 5 4 7 6 5
2 Inner 0+0 0+0 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 0+0 0+0 0+0
Thick spacer
Outer 6 6 4 4 4 4 4 4 2 2 2 2 2 2 0 0 0 11 11 11
Fixing spacer Inner – – – – – – – – – – – – – – – – – 1+1 1+1 1+1
Inner 1+2 3+3 0+0 0+1 1+1 1+2 2+2 2+3 3+4 0+1 1+1 1+2 2+2 2+3 3+4 1+4 1+5 1+1 1+2 2+2
Thin spacer
Outer 7 4 10 9 8 7 6 5 3 9 8 7 6 5 3 5 4 7 6 5
3 Inner 2+2 2+2 3+3 3+3 3+3 3+3 3+3 3+3 3+3 4+4 4+4 4+4 4+4 4+4 4+4 5+4 5+4 0+0 0+0 0+0
Thick spacer
Outer 5 5 3 3 3 3 3 3 3 1 1 1 1 1 1 0 0 11 11 11
Fixing spacer Inner – – – – – – – – – – – – – – – – – 1+1 1+1 1+1
Inner 0+0 0+1 1+1 1+2 2+2 3+3 0+0 0+1 1+1 1+2 2+2 3+3 0+0 0+1 1+2 1+2 2+2
Thin spacer
Outer 8 7 6 5 4 2 8 7 6 5 4 2 8 7 6 5 4
5 Inner 0+0 0+0 0+0 0+0 0+0 0+0 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2
Thick spacer
Outer 5 5 5 5 5 5 3 3 3 3 3 3 1 1 1 1 1
Fixing spacer Inner – – – – – – – – – – – – – – – – –
48
Number of Adjusting Spacers
Beam flange 71/16 71/4
(in) 611/16 67/8 7 1 5 77/8 8 87/16 811/16 9 91/8 97/8 10 101/8 101/4 103/8 101/2 11 111/8 111/4 113/8 115/8 113/4 1113/16 117/8 12
width 7 /8 7 /16
Capacity
180 184
(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 181 185
Assembling
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 9 8 7 6 1 0 4 3 0 7 9 8 7 6 5 4 0 7 6 5 3 2 1 0 3
0.5 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
Thick spacer
Outer 3 1 1 1 1 1 1 7 7 7 5 3 3 3 3 3 3 3 1 1 1 1 1 1 1 0
Fixing spacer Inner 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1
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
1
Outer 3 9 8 7 6 1 0 4 3 0 7 9 8 7 6 5 4 0
Inner 1+1 2+2 2+2 2+2 2+2 2+2 2+2 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
7 6 5 3 2 1 0 3
1
Thick spacer
Outer 3 1 1 1 1 1 1 7 7 7 5 3 3 3 3 3 3 3 1 1 1 1 1 1 1 0
Fixing spacer Inner 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1 1+1
(to be continued)
49
Chapter 1 Handling the Product
Assembling (continued)
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.
Assembling
Mandatory
●● 125 kg~2.5 t
70° or more
Bending the split pin Orientation of Shaft Stopper Pin
50
●● 3 t~5 t (For Double Chain type)
Assembling
Suspension Shaft, use the hole for standard rail
Split pin
width. Use the hole for rail width 175 mm or 190
mm for one stage up rail width. Open the both Slotted
Bolt
ends of the split pin by 70˚ or more. nut
•• Attach the split pin to the right side when
Thick spacer
viewed from the Frame G or the Frame S.
•• Open the both ends of the split pin by 70˚ or Fixing spacer
more.
Bolt
1
2) Set the Suspension Shaft with a Thin Suspension Shaft
Spacer, Thick Spacer and Fixing Spacer. Suspender Fixing spacer
(to be continued)
51
Chapter 1 Handling the Product
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.
Assembling
Failure to comply with this instruction may result in death or serious injury.
Mandatory
1 Code
Wire
size
230V Class
Single Dual
400V Class
Single Dual
(PWB Anchor 415V)
Wire
Single Dual
230/460V Class
Wire
Single Dual
Code
Wire
size
circuit breaker (A)
500V Class
(mm2) (mm2)
size size Single Dual
speed speed speed speed speed speed speed speed
(mm2) (mm2) speed speed
ER2-001H/IH ER2-001H/HD
Checking Power and Power Cable
•• Satisfy the maximum permissible length and core cross section of the Power Cable.
Failure to comply with this instruction causes bodily injury or loss of property.
Mandatory
52
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 (mm2)×Rated voltage (V)×0.02
Permissible length (m) = ×
30.8 Rated current (A)
Assembling
●● Hook
suspendeed Type:ER2
Manual trolly type:ER2SP/ER2SG (Unit: m) (Unit: m)
230V Class 400V Class PWB Anchor 230/460V Class 500V Class
Wire Single speed Dual speed Single speed Dual speed Single Dual
Code size Wire Single speed Dual speed Wire Single speed Dual speed
1
(mm2) 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz size 60Hz 60Hz Code size 50Hz 60Hz 50Hz 60Hz
220-230V 380-415V 380-440V 380-415V 380-440V 415V (mm ) 208-230V 415-460V 208-230V 415-460V
2
(mm2) 500V 575V 500V 575V
ER2-001H/IH ER2-001H/HD
46 59 44 123 171 114 134 124 49 197 46 186 253 253
ER2-003S/IS ER2-003S/SD
(75) (95) (71) (197) (118) (182) (215) (199) (79) (316) (74) (298) (405) (405)
ER2-005L/IL ER2-005L/LD
ER2-003H/IH ER2-003H/HD
ER2-050S/IS 27 24 23 23 23 26 24 71 71 65 66 68 70 69 44 40 41 43
(42) (38) (36) (36) (37) (41) (37) (111) (112) (102) (104) (108) (110) (106) (77) (71) (72) (76)
(Unit: m) (Unit: m)
500V Class 230/460V Class
ER single ER dual ER dual ER single ER single ER dual ER dual ER single
Code Wire MR single MR dual MR single MR dual Code Wire MR single MR dual MR single MR dual
size 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz size 60Hz 60Hz 60Hz 60Hz
(mm2) (mm )2
(to be continued)
53
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.
Assembling
•• To prevent wire breakage and unintentional removal of a connector, tie the protection wire attached to the Push
Button Switch Cord to the body size of the electric chain hoist or the trolley.
Be sure to tie the cord with the body size or the trolley to prevent the wire breakage and removal of connector when the cord is pulled
strongly.
•• Be sure to turn off the power when carrying out the repair work of wire breakage or removal of the connector.
1 ■
■Hook suspended model (hoist only)
■
■125 kg~5 t
Connecting Cables
54
■
■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
Assembling
cable for power supply in the connector Connection Box.
socket (4P) of ER2. Tighten the Lock
Ring securely. 2) Pass the Power Cable through the
Holder A supported by the cable holder
2) Insert the connector plug (8P) of relay and the cable packing.
cable for operation in the connector
3) Insert the Power Cable to the Holder B
socket (8P) of ER2. Tighten the Lock
Ring securely.
of the Connection Box and tighten the
Holder A securely.
1
●● Trolley Type
1) Mount the cable holder, which the Power
Connecting Cables
Cable is passed, to the cable holder arm
using a chain hanging pin B, a slotted nut
and a split pin.
Split pin
Cable holder Slotted nut
●● Connecting the Push Button Switch Cord
1) Insert the connector plug (8P) of Push <Direct-mount Push Button Switch Cord Connection>
Button Switch Cord in the connector socket
(8P). Tighten the Lock Ring securely. Holder nut Plate D
Holder B
●● Direct-mount
Holder A
1) Mount the Holder B, which the Push
Button Switch Cord is passed, to the
plate D using the holder nut.
2) Connect the Push Button Switch Cord to
the terminal panel of the Connection Box.
Assembling (continued)
■
■Manual Trolley Type
■
■125 kg~5 t
■
■Direct connection
1) Connecting the Power Cable 1
Insert the Power Cable into the Holder
C (upper side) of the Connector Socket
holder. Turn the Holder A to connect the
cable securely. 2
56
Installation
DANGER
•• 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.
•• Do not install the electric chain hoist at a place exposed to rain or water always or the place different from
Prohibited
the Operational Environment (P18).
•• Do not install the electric chain hoist in the motion space of other trolley or any other moving equipment (facility).
Installation
•• Do not use the electric chain hoist contacting with other object, or being fixed.
Failure to comply with these instructions may result in death or serious injury.
•• When installing or removing the electric chain hoist, follow the instructions in Owner's Manual.
Travel rail
•• Carry out the work for grounding (earthing) and installation of earth leakage breaker.
•• When the installation is completed, carry out “Check after Installation". (See P61) Trolley
Mandatory
•• Connect the power after all installation works have been completed and just
before the oparation check.
1
•• Mount the stopper at the both ends of the travel rail for trolley. <Fig. A>
•• Make sure that the strength of the structure is sufficient to install the electric chain hoist.
Connecting Power and Power Cable / Installing the Hook suspended Type (hoist only)
Stopper
•• Carry out the installation work after securing the stable hoothold.
•• Before building the electric chain host into part of your own travel
device without using the standard trolley, contact us for information on
A
precautions.
Failure to comply with these instructions may result in death or serious injury.
CAUTION
•• Connect the Power Cable to the power of rated voltage.
Failure to comply with this instruction causes bodily injury or loss of property.
Mandatory
■
■Connecting Power and Power Cable
When connecting the Power Cable to the power, connect the cable in
accordance with the following instructions.
L1 L2 L3
R- S- T-
●● Connect the electric chain hoist to the power through a breaker. phase phas phase
Breaker
White
Black
Black
Red
■
■Installing the Hook Suspended Type (hoist only)
■
■Checking Installation Method and Place
DANGER
•• When using an electric chain hoist suspended (as a single unit) without combination with a trolley,
make sure that the Hook Latch of the Top Hook closes securely.
•• Install the electric chain hoist so that the Top Hook and body can swing freely. (Make sure not to
Mandatory
restrain the Top Hook and body when in use.)
•• Do not install and use the electric chain hoist upside down.
Failure to comply with these instructions may result in death or serious injury.
(to be continued)
57
Chapter 1 Handling the Product
Installation (continued)
■
■Installing the Trolley Combined Model
■
■Mounting the Hoist to the Travel Rail
●● 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
58
■■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.
Installation
d Stopper Beam width
t2
H G
Bolt
K
1
Nuts
(double nuts)
T-shape Suspender
Power Cable
Stopper for
T-shape Suspender
T-shape Suspender
Power Cable
(to be continued)
59
Chapter 1 Handling the Product
Messenger Wire
5) Fix the Power Cable to the Cable Hanger. Connection Box Messenger Wire
Cable hanger
Power Cable
7) Insert the Power Cable into the
Connection Box of MR2 and connect it
to the terminal panel.
•• Connect wires correctly according to the wiring
diagram affixed on the Connection Box.
60
Check after Installation
Wrong assembling or installation causes death or serious injury. To prevent such danger check the following.
■■Operational Check
Carry out the operational check in accordance with Daily inspection (P20).
61
Chapter 1 Handling the Product
62
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
Guidelines for Parts Replacement based on Indication of CH Meter.....90
Check of Operating Hours and Number of Start (CH Meter)............92
63
Chapter 2 Inspection
Table of Contents
■
■Frequent Inspection ■■Periodic Inspection
(Carry out the frequent inspection after check of no (Carry out the periodic inspection after check of no
abnormality in daily inspection items.) abnormality in daily inspection and frequent inspection
■
■Electric Chain Hoist (ER2) Frequent Inspection items.)
Table of Contents
Load Chain ■
■Electric Chain Hoist (ER2) Periodic Inspection
Elongation of Pitch… ……………………………… 69 Top Hook, Bottom Hook
Abrasion of wire diameter… ……………………… 69 Number of start……………………………………… 76
Top Hook, Bottom Hook Peripheral parts of the Body size
Opening and Abrasion of the Hook… …………… 70 Chain Guide A… …………………………………… 76
Deformation, Flaw, Corrosion… ………………… 70 Chain Spring………………………………………… 77
Peripheral parts of the Body size Stopper… …………………………………………… 77
Chain Container… ………………………………… 71 Limit Lever…………………………………………… 77
Chain Pin (double type only)… …………………… 78
2 Electromagnetic Brake
Number of start……………………………………… 71 Connection Yoke D (double type only)…………… 78
Push Button Switch Shaft Retainer Clip… ……………………………… 78
Push Button Switch Body size… ………………… 72 Oil
Push Button Switch Cord… ……………………… 72 Oil Leakage… ……………………………………… 78
Power Supply Oil amount and stain… …………………………… 78
Power Cable………………………………………… 73 Electromagnetic Brake
Cable Hanger… …………………………………… 73 Appearance… ……………………………………… 79
Messenger Wire… ………………………………… 73 Gap…………………………………………………… 79
Function and Performance Hub Joint… ………………………………………… 79
Abnormal Noise… ………………………………… 73 Number of start……………………………………… 79
Driving Mechanism
■
■Motorized Trolley (MR2) Frequent Inspection Bearing… …………………………………………… 80
Load Gear, Gear B, Pinion………………………… 80
Appearance
Friction Clutch… …………………………………… 80
Travel Rail…………………………………………… 74
Friction Clutch with Mechanical Brake…………… 81
Oiling (to the gears of wheel)……………………… 74
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……………………………………… 82
Appearance
Wiring………………………………………………… 82
Combination… ……………………………………… 74
Contamination and attachment of foreign matter… … 82
Travel Rail…………………………………………… 74
VFD…………………………………………………… 82
Oiling (to the gears of wheel)……………………… 74
Electric Characteristics Measurement
Source Voltage……………………………………… 82
Insulation Resistance… …………………………… 82
Grounding Resistance……………………………… 83
Function and Performance
Operational Check… ……………………………… 83
Brake… ……………………………………………… 83
64
■
■Motorized Trolley (MR2) Periodic Inspection ■■Check of Operating Hours and Number of Start
Brake (CH Meter)
Appearance… ……………………………………… 84 CH Meter: Start Times/Operating Hour Display Device… … 92
Abrasion of Brake Pad……………………………… 84
Body size Components
Wheel………………………………………………… 84
Table of Contents
Side Roller…………………………………………… 84
Lifting Shaft… ……………………………………… 85
Suspender…………………………………………… 85
Gear Frame Packing… …………………………… 85 ●Reference
●
Daily inspection is described in Chapter 1 “How
Gears and Motor Shaft… ………………………… 85 to Use the Product”. Refer to the following daily
Travel Rail inspection items and their relevant pages.
Rail Surface… ……………………………………… 86 ■■ Daily Inspection of Electric Chain Hoist (Hook Suspended Type)
Deformation and Abrasion………………………… 86 Appearance
Indication of nameplates and labels… ………… 20
2
Rail Mounting Bolt… ……………………………… 86
Deformation and damage of body size and each part… … 20
Stopper… …………………………………………… 86 Loosened or fallen off bolts, nuts and split pins… … 20
Relay Cable Load Chain
Elongation of Pitch… ……………………………… 21
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… ……………………………… 87 Mark… ……………………………………………… 21
Brake… ……………………………………………… 87 Top Hook / Bottom Hook
Abnormal Noise… ………………………………… 87 Opening of the Hook… …………………………… 22
Abrasion… ………………………………………… 22
Deformation, Flaw, Corrosion… ………………… 22
■■Manual Trolley (TSG/TSP) Periodic Inspection Hook Latch… ……………………………………… 22
Hook movement (Rotation)… …………………… 22
Body size Components Movement of the Idle Sheave… ………………… 23
Wheel………………………………………………… 88 Bottom Yoke………………………………………… 23
Lifting Shaft… ……………………………………… 88 Peripheral parts of the body size
Chain Spring… …………………………………… 23
Suspender…………………………………………… 88
Cushion Rubber… ………………………………… 23
Travel Rail Push Button Switch
Rail Surface… ……………………………………… 88 Switch body size…………………………………… 24
Deformation and Abrasion………………………… 89 Function and Performance
Operational Check… ……………………………… 24
Rail Mounting Bolt… ……………………………… 89 Brake………………………………………………… 24
Stopper… …………………………………………… 89 Friction Clutch with Mechanical Brake… ………… 24
Limit Switch… ……………………………………… 24
Function and Performance
Check for no Abnormal Sound…………………… 24
Operational Check… ……………………………… 89
Daily Inspection of Motorized Trolley (MR2)
Abnormal Noise… ………………………………… 89
Appearance
Indication of Nameplates and Labels… ………… 25
■■Guidelines for Parts Replacement based on Deformation and damage of each part… ……… 25
Loosened or fallen off bolts, nuts and split pins… … 25
Indication of CH Meter
Function and Performance
Guidelines and Precautions on Gear Oil Change Cycle…… 90 Operational Check… ……………………………… 26
Guidelines on the service life of contactor and its replacement…… 91 Brake………………………………………………… 26
Guidelines on Brake Inspection……………………… 91 ■■Daily Inspection of Manual Trolley (TSG/TSP)
Guidelines on Gear Parts Replacement… ………… 91 Appearance
Guidelines on Motor Shaft Replacement…………… 91 Indication of Nameplates and Labels… ………… 26
Deformation and damage of each part… ……… 26
Guidelines on Bearing Replacement… …………… 92 Loosened or fallen off bolts, nuts and split pins… … 26
Guidelines on Hook and Yoke Replacement… …… 92 Function and Performance
Guidelines on V ring Inspection… ………………… 92 Operational Check… ……………………………… 27
65
Chapter 2 Inspection
Safety Precautions
■
■General Matters related to Inspection
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.
Safety Precautions
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.
•• Do not adjust the set nut.
•• When oiling the Friction Clutch and the Friction Clutch with Mechanical Brake, use KITO genuine oil
(manufacturer specified oil).
•• Do not carry out the inspection of electric chain hoist with a lifted load.
•• Do not use the electric chain hoist removing the cushion rubber, the chain spring and the stopper.
•• Turn off the main power when carrying out the inspection.
2 •• When using oils such as gear oil and grease, avoid places with fire or sparks.
Failure to comply with these instructions may result in death or serious injury.
General Matters related to Inspection
•• Put the electric chain hoist on the floor or work bench when performing the repair and disassembling of
the electric chain hoist.
•• Even if each component of the electric chain hoist does not exceed the service limit, replace the part
Mandatory
exceeding the total operating hours derived from the grade indicated on the electric chain hoist and the
load factor.
•• Do not use the electric chain hoist when any abnormality was observed during the inspection. Indicate
“FAILURE” on the hoist and contact with maintenance engineer or KITO for repair.
•• After completion of the inspection (frequent, periodic), perform the functional check and make sure
that the electric chain hoist operates correctly.
•• When performing the functional check, be sure to perform the capacity test after no load test.
Failure to comply with these instructions may result in death or serious injury.
CAUTION
•• Indicate “CHECKING” when performing the inspection.
When a crane is operated erroneously during the inspection, it may result in the accident such as fall-off of parts and
tools and downfall.
Mandatory
•• Wear protection equipment such as protection goggles and gloves depending on the work contents.
Otherwise it may result in the injury due to scattered oil or sharp edge of a part.
•• Pay attention to work method, work procedure and work posture.
If the product or the part is heavy, your hand is caught or your waist is hurt.
Especially be careful for the work on an unstable scaffold such as the work at high lifted place using stepladder.
•• Wear helmet and safety belt when carrying the high lift work.
Otherwise it may result in injury or downfall accident.
•• Remove the oil attached to the product or spilt on the floor.
Otherwise it may result in injury due to drop of the product or overturning.
•• Keep the work area clean when disassembling the product.
Assembling or mixing the part other than genuine part may result in the damage of the product or the accident due to
defective operation.
66
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.
Ex. (1) The flaw on the Chain Guide A hit with the Chain (Cause: lifting incline)
Safety Precautions
(2) The deformation of the Cushion Rubber and the Chain Spring (Cause: excessive use of the limit switch)
67
Chapter 2 Inspection
Frequent Inspection
■
■General Matters on Frequent Inspection
DANGER
•• After completion of the frequent inspection, perform the functional check and make sure that the
electric chain hoist operates correctly.
Frequent Inspection
Neglecting to perform the functional check may result in death or serious injury.
Mandatory
■
■General Matters on Handling the Dual Speed VFD Model
DANGER
•• Do not change the VFD parameter.
When parameters need to be changed, ask our distributors nearest to the customer or KITO.
2 Prohibited
•• Do not carry out the work such as maintenance and inspection within 5 minutes after power off.
Wait for the completion of discharging of the capacitor inside the VFD.
•• Do not touch the controller cover as it becomes hot during operation.
•• Do not touch the controller cover until about 30 minutes elapsed after the stop of operation.
General Matters on Frequent Inspection / General Matters on Handling the Dual Speed VFD Model
NOTE
When performing the frequent inspection, carry out the daily inspection at the same time.
68
■
■Electric Chain Hoist (ER2) Frequent Inspection
■■Load Chain
●●Check the Load Chain after removing the stain on the chain.
●●Use the needle head caliper (point caliper) to measure the sum of pitches and wire diameter.
●●Apply oil on the Load Chain after inspection.
Frequent 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)
●●Release all loads from the Load Chain. Apply the lubricant to the linking portion of the Load Chain that engages the
Load Sheave and the Idle Sheave and the linking portion of the Load Chain.
●● After application of the lubricant lift/lower the electric chain hoist without load to spread the lubricant on the Load Chain.
2 Dimension b
Dimension c
Abrasion not to exceed 5%
• F
ollowing tables shows the nominal standard
Electric Chain Hoist (ER2) Frequent Inspection
Deformation, • Check visually. • No deformation such as bend or twist Replace the Hook.
Flaw, • No deep cut
Corrosion • No loosened bolt or not, or their fall off
• No considerable corrosion
• No attachment of foreign matter such as
sputter
70
■■Peripheral parts of the Body size
●● Use check stand to check the electric chain hoist from the close point.
Frequent Inspection
Container • No damage, tear, abrasion or deformation Container.
• Check no foreign matter inside the Chain Discard the foreign
Container. matter in the Chain
* Especially be careful when the electric chain Container.
hoist is used outdoor.
• Make sure that the lift of the Load Chain
is smaller than the capacity of the Chain
Container.
■■Electromagnetic Brake
(to be continued)
71
Chapter 2 Inspection
size smoothly.
• Emergency Stop Button can be operated and
cancelled.
2 Push Button • Check visually. • P ush Button Switch Cord is securely Tie the Push Button
Switch Cord connected. Switch Cord and the
• The Protection Wire is tied with the body Protection Wire to the
Electric Chain Hoist (ER2) Frequent Inspection
size so that Push Button Switch Cord is not body size properly.
Body size
strained directly even if the Push Button
Switch is pulled.
Protection Wire
• To have no damage Replace the Push
Button Switch Cord.
Push Button
Switch Cord
72
■■Power Supply
Frequent Inspection
• To be connected securely
Cable Hanger • C
heck visually and by • To have no damage Re-mount the Cable
moving by hand. • To move smoothly Hangers for no
• To be mounted at equal interval hindrance to cable
··· Appropriate interval 1.5 m motion.
Messenger Wire
Cable Hanger 2
Power Cable
NOTE
• T
o sound no popping sound from the Load Check the Load Chain.
Sound is also an important Chain (Refer to P69.)
check point. Always be
careful for the noise of the
electric chain hoist.
(to be continued)
73
Chapter 2 Inspection
■
■Motorized Trolley (MR2) Frequent Inspection
■■Appearance
2
Motorized Trolley (MR2) Frequent Inspection / Manual Trolley (TS2) Frequent Inspection
■
■Manual Trolley (TS2) Frequent Inspection
■■Appearance
74
Periodic Inspection
■
■General Matters on Periodic Inspection
DANGER
•• Put the electric chain hoist on the floor or work bench when inspecting the electric chain hoist.
•• After completion of the periodic inspection, perform the functional check and make sure that the
electric chain hoist operates correctly.
Periodic Inspection
Mandatory · Wear insulating gloves when measuring voltage.
· When measuring the electric characteristics (insulation resistance, but except voltage measurement), turn off the
power.
Failure to comply above instructions may result in death or serious injury.
■
■General Matters on Handling the Dual Speed VFD Model
DANGER
•• Do not change the VFD parameters.
When parameters need to be changed, ask our distributors nearest to the customer or KITO.
2
•• Do not carry out the work such as maintenance and inspection within 5 minutes after power off.
Prohibited
Wait for the completion of discharging of the capacitor inside the VFD.
General Matters on Periodic Inspection / General Matters on Handling the Dual Speed VFD Model
•• Do not touch the controller cover as it becomes hot during operation.
•• Do not touch the controller cover until about 30 minutes elapsed after the stop of operation.
•• USE KITO genuine VFD.
The VFD requires the special specification for KITO. Be sure to use genuine VFD.
•• Do not change the connection of the VFD.
When the wires were removed for any reason, connect them again correctly checking the wiring diagram inside the
controller cover.
•• Do not carry out withstand voltage test of a circuit while the VFD is connected.
•• Do not turn off the power while operating.
Failure to comply with these instructions may result in death or serious injury and the damage of VFD.
NOTE
When performing the periodic inspection, carry out the daily inspection at the same time.
●● Disassemble the electric chain hoist and check that it is assembled correctly without abnormal parts.
●● Refer to Appendix “Technical Material” (P122) for the structure of the product and the name of each part.
(to be continued)
75
Chapter 2 Inspection
■
■Electric Chain Hoist (ER2) Periodic Inspection
■■Top Hook, Bottom Hook
start with the CH Meter. guidelines for replacement. (Refer to P92) and Bottom Hook.
76
Item Check method Criteria When failed
Chain Spring • C
heck visually and measure • C
heck visually to have no apparent setting Replace the Chain
the dimensions. (deformation). Spring.
CAUTION
Periodic Inspection
•• The deformation of the Cushion
Rubber and the Chain Spring is
caused by excessive use of the
Mandatory Friction Clutch and the Limit
Switch. Operate the electric
chain hoist properly.
Otherwise it may result in bodily injury
or property damage.
Dimensional standard
not fall short of the limit value.)
Length of Chain Spring
2
Code Capacity
Standard Limit value
ER2-015S
1.5t – –
Stopper
Limit Lever • C
heck visually and by • T
o have no deformation, damage and abrasion Replace the Limit
moving by hand. • To move smoothly Lever.
• To have no stain Disassemble the Limit
Lever and clean.
Limit Lever.
(to be continued)
77
Chapter 2 Inspection
Code
Standard Limit value
Chain Pin 028S/IS
10.8 10.3
030S/IS/SD
050S/IS/SD 12.9 12.3
Connection • M
easure the dimensions a • T he difference between dimensions a (vertical) Replace the
Yoke D and b with vernier caliper. and b (lateral) must be within 0.5 mm. Connection Yoke D.
(double type • To have no apparent deformation and abrasion
only)
2 Deformation
of mounting
a
Chain Pin
Electric Chain Hoist (ER2) Periodic Inspection
■■Oil
Oil amount • C
heck the oil level from • Oil is filled enough close to the oil check hole. Replace the Oil.
and stain the oil check hole. (The
• Check the oil level through the oil cap at the top (shown by an arrow)
position of the oil check hole
for electric chain hoist equipped with the friction clutch with mechanical
depends on the model. See
brake. (Do not open the oil check hole at the side. Or, oil leaks out.) When
P40.)
checking the oil level, insert the check bar into the oil check hole, tilting the
Oil check hole bar slightly, to see the oil level.
• The distance between the hole and the oil level is 75 mm for the body size
B, 100 mm for the body size C/D, 120 mm for the body size E, and 130
mm for the body size F respectively.
78
■■Electromagnetic Brake
Periodic Inspection
• To have no flaw and damage. Replace the
Electromagnetic Brake.
Gap • M
easure the gap with • E
lectromagnetic Brake Gap Limit Replace the
thickness gauge. (not to exceed the limit) Electromagnetic Brake.
DANGER
•• Do not adjust or disassemble
the Electromagnetic Brake.
Adjusting or disassembling the
Prohibited Electromagnetic Brake may result in
death or serious injury.
Hub Joint • Check visually. • To have no apparent deformation and abrasion Replace the Hub and
• Hub spring must be seated. the Electromagnetic
Brake.
Number of • Check the number of start • The number of start must be less than one When the number
start with the CH Meter. million times. of start exceeds one
million times, perform
the inspection in
accordance with
“Guidelines on Brake
Inspection” (P91).
(to be continued)
79
Chapter 2 Inspection
■■Driving Mechanism
Load Gear, • D isassemble the electric • To have no apparent abrasion • Replace the Gear.
Gear B, chain hoist and check the • To have no damage • Replace the Pinion.
Pinion arrowed portion. • Operating hours not to exceed the guidelines • Replace the oil at
• Check the operating hours for replacement the same time.
2 using the CH Meter. (Refer to “Guidelines on Gear Parts
Replacement” (P91).)
Electric Chain Hoist (ER2) Periodic Inspection
Spline
Motor shaft
Rotor
Friction • Check visually • T o have no apparent abrasion, deformation, Replace the Friction
Clutch • Check the operating hours flaw and damage. Clutch.
using the CH Meter. • Pawl must have no apparent deformation and
abrasion.
DANGER
•• Do not adjust or disassemble
the Friction Clutch.
Adjusting and disassembling the
Prohibited Friction Clutch may result in death or
serious injury.
• O
perating hours not to exceed the guidelines
for replacement
(Refer to “Guidelines on Gear Parts
Replacement” (P91).)
80
Item Check method Criteria When failed
Friction • Check visually. • T o have no apparent abrasion, deformation, Replace the Pawl and
Clutch with • Check the operating hours flaw and damage the Friction Clutch with
Mechanical using the CH Meter. • Pawl must have no apparent deformation and Mechanical Brake.
Brake abrasion.
Periodic Inspection
DANGER
•• Do not adjust or disassemble
the Friction Clutch with
Mechanical Brake.
Prohibited
Adjusting and disassembling the
Friction Clutch with Mechanical Brake
may result in death or serious injury.
• O
perating hours not to exceed the guidelines
for replacement 2
(Refer to “Guidelines on Gear Parts Replacement” (P91).)
Abrasion and • D isassemble the Load • T o have no apparent abrasion, deformation Replace the Load
NOTE
Worn portion
If the abrasion is observed on the Load
Sheave, the Load Chain may be worn also.
Refer to the item of Load Chain Abrasion
and check the abrasion.
Thickness • S
ervice limit of the Load Sheave and Idle Sheave
Thickness at (Do not fall under the limit)
purchasing
Thickness (mm)
Code Capacity (t)
Standard Limit
ER2-001H/IH/HD 125kg
Abrasion and • D isassemble the Load ER2-003S/IS/SD 1.5 1.0 Replace the Idle
flaw of the Sheave and check it visually. 250kg Sheave.
ER2-003H/IH/HD
Idle Sheave • Measure the thickness with ER2-005L/IL/LD
500kg 3.0 2.0
vernier caliper. ER2-005S/IS/SD
ER2-010L/IL/LD
Worn portion 1 4.5 3.0
ER2-010S/IS/SD
ER2-015S/IS/SD 1.5
ER2-020L/IL/LD
2
ER2-020S/IS/SD 6.5 4.3
ER2-028S/IS
3
Thickness ER2-030S/IS/SD
Crest
Thickness at ER2-025S/IS/SD 2.5
7.3 4.9
purchasing ER2-050S/IS/SD 5
V ring • Check visually. • To have no deformation and crack Perform the inspection
• Check the operating hours • Operating hour must not exceed 200 hours. items of “Guidelines on
using the CH Meter. V ring Inspection” (P92).
(to be continued)
81
Chapter 2 Inspection
■■Electrical Equipment
• Check the number of start • The number of start must not exceed the part securely.
with the CH Meter. guidelines for replacement (P91). Replace the electrical
part with service life.
Wiring • W
iring must be fixed to the Electrical Parts Connect wirings
securely. securely.
• Connectors must be inserted securely.
and matter.
attachment of
foreign matter
VFD • C
heck the parts with service • E
lectrolytic capacitor: 3000 hours (depending • Replace the VFD.
life on the use)
(see VFD Manual.)
Source • M
easure the voltage with a • T
he source voltage of the rated voltage ± 10 Supply proper voltage.
Voltage circuit tester. % at the receiving terminal must be supplied
when operating with the capacity.
DANGER
•• Be careful of electric shock
when measuring the voltage.
Electric shock may result in death or
Mandatory
serious injury.
Insulation • M
easure the insulation • Insulation resistance must be 5 MΩ or higher. Replace the Body size.
Resistance resistance with megger. DANGER
(Resistance between
energized and non- •• Turn off the power when
energized parts ··· Each measuring the insulation
phase of R(L1), S(L2) and resistance.
Mandatory
T(L3) and the earth wire) Measuring the insulation resistance
without turning off the power may
result in death or serious injury.
82
Item Check method Criteria When failed
Grounding • M
easure the grounding • grounding resistance 100Ω or less Make a grounding
Resistance resistance with earth- DANGER correctly.
resistance meter.
•• Turn off the power when
measuring the grounding
Periodic Inspection
resistance.
Mandatory
Measuring the grounding resistance
without turning off the power may
result in death or serious injury due to
electric shock.
DANGER
2
•• After completion of the inspection of each part, perform the operational check for correct operation.
Brake • O
perate the electric chain • W
hen stopping the operation, the Brake must Disassemble the Brake
hoist with a capacity and be applied immediately and the motor must to check whether it is
then stop it. stop. assembled correctly
and has no abnormal
part.
Up/Down: Stop distance must be 1 % or less
of the traveling distance for one minute.
(to be continued)
83
Chapter 2 Inspection
■
■Motorized Trolley (MR2) Periodic Inspection
■■Brake
• T
o have no deformation and damage on the Replace the Brake
Brake Spring. Spring.
Abrasion of • D
isassemble the Brake and Trolley Brake Service Limit Replace the Motor
Brake Pad measure the abrasion. (Do not fall under the limit.) Cover.
Speed Dimension Standard Limit
Single Speed
Brake Pad B 32.5 31.0
Dual Speed (VFD)
B’ Dual Speed
2
Motor Cover B' 36.8 36.3
(500V Class)
Motorized Trolley (MR2) Periodic Inspection
Brake Drum B
Side Roller • Check visually. • T o have no considerable deformation and damage Replace the Side
• Measure outer diameter of • Abrasion Limit of Side Roller Roller.
the worn part with vernier (Do not fall under the limit.)
caliper. Outer diameter (mm)
Capacity (t)
Outer diameter Standard Limit
125, 250, 500kg 38 37
1 38 37
1.5, 2 43 42
2.5, 3 43 42
5 55 54
84
Item Check method Criteria When failed
Lifting Shaft • Check visually. • T o have no considerable deformation and Replace the Lifting
• Measure the shaft diameter abrasion Shaft.
with vernier caliper. • The shaft with obvious deformation reaches at
Shaft diameter the service limit.
Periodic Inspection
• Abrasion limit of the shaft is 5 % of its diameter
respectively.
Motor shaft
Rotor
(to be continued)
85
Chapter 2 Inspection
■■Travel Rail
Deformation • C
heck 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. • Service limit of B: up to 95 % of the dimension
at purchasing
I-beam H-beam • Service limit of c: up to 90 % of the dimension
2 at purchasing
Motorized Trolley (MR2) Periodic Inspection
t
t
B B
Rail Mounting • Check visually. • To have no loosened bolt or fall-off Tighten the bolts
Bolt securely.
■■Relay Cable
86
■■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.
Periodic Inspection
Mandatory
Brake • O
perate the electric chain • W
hen stopping the operation, the Brake must Disassemble the Brake
hoist with a capacity and be applied immediately and the motor must to check whether the
then stop it. stop. brake is assembled
correctly without
Traveling : Stop distance must be 10 % or less abnormal part.
of the traveling distance for one
minute.
(Without swinging of the load. Except the case
when the load is swinging.)
Abnormal • O
perate the electric chain • To have no irrotating noise Disassemble the
Noise hoist with a capacity and • To sound no howling of motor and scraping electric chain hoist
then stop it. sound of the Brake. to check whether it is
assembled correctly
and has no abnormal
part.
(to be continued)
87
Chapter 2 Inspection
■
■Manual Trolley (TSG/TSP) Periodic Inspection
■■Body size Components
2 • M
easure the outer diameter 2.5t, 3t
H-steel
I-steel
100
98.5
To have no considerable damage or crack
on the contact surface.
with vernier caliper. H-steel
5t 118 112 9.6 6.7
I-steel
Manual Trolley (TSG/TSP) Periodic Inspection
Lifting Shaft • Check visually. • T o have no considerable deformation and Replace the Lifting
• Measure the shaft diameter abrasion Shaft.
with vernier caliper. • The shaft with obvious deformation reaches at
Shaft diameter the service limit.
• A
brasion limit of the shaft and the hole is 5 %
of its diameter respectively.
■■Travel Rail
88
Item Check method Criteria When failed
Deformation • C
heck 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. • Service limit of B: up to 95 % of the dimension
Periodic Inspection
at purchasing
I-beam H-beam
• Service limit of c: up to 90 % of the dimension
at purchasing
t
t
B B
Rail Mounting • Check visually. • To have no loosened bolt or fall-off Tighten the bolts
Bolt securely.
2
Stopper • Check visually. • T
he stoppers must be mounted at the both Tighten the Stoppers.
ends of the Travel Rail securely.
Stopper Stopper
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
Abnormal • T
o make the electric chain • To have no irrotating sound Disassemble the electric
Noise hoist travel with a capacity chain hoist to check whether
it is assembled correctly and
has no abnormal part.
89
Chapter 2 Inspection
Guidelines for Parts Replacement based on Indication of CH Meter
■
■Guidelines and Precautions on Gear Oil Change Cycle
Change the gear oil in accordance with the rate of loading and the operating hours.
●●Change the oil at every five years even if the operating hours do not reach at the following hours.
DANGER
•• Gear oil differs depending on the specification. Use of wrong gear oil may result in the drop of the
lifted load. Be sure to use the designated gear oil.
Mandatory Failure to comply with this instruction may result in death or serious injury.
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 520
ER2-003H, 003IH, 005L, 005IL, 005S, 005IS,
540
003HD,005SD,005HD
ER2-010L, 010IL,010SD,010LD 620
Friction Clutch KITO genuine oil KITO genuine oil
ER2-010S, 010IS 680
ER2-015S, 015IS, 020L, 020IL,015SD,015LD 1300
ER2-020S, 020IS, 028S, 028IS, 030S, 030IS 1900
ER2-025S, 025IS, 050S, 050IS 1900
ER2-001H, 001IH, 003S, 003IS,001HD,003SD 680
ER2-005L, 005IL,005SD 820
ER2-003H, 003IH, 005S, 005IS 900
ER2-010L, 010IL,010SD,010LD 1050
Friction Clutch with
ER2-010S, 010IS 1100 KITO genuine oil KITO genuine oil
Mechanical Brake
ER2-015S, 015IS, 020L, 020IL,015SD,020LD 2000
ER2-020S, 020IS, 028S, 028IS, 030S, 030IS,
2500
030SD
ER2-025S, 025IS, 050S, 050IS,025SD,050SD 2700
* Oil is available in 0.7 L and 1.0 L bottles only.
90
Guidelines for Parts Replacement based on Indication of CH Meter
■
■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 Every 1 million
Rate of inching times times times
Low Normally operating with scarce inching ○
Medium Normally operating with occasional inching ○
High Normally operating with inching at a half times or more ○
NOTE) · F
or single speed model, check the number of start with the CH Meter. (Refer to “Check of Operating Hours and Start Times (CH
Meter)”. (P92))
·F or dual speed VFD model, check the number of start and operating hours with the indicator of the VFD by the maintenance engineer
in accordance with the separate “VFD Manual”.
NOTE
Be sure to use the designated contactor.
2
■
■Guidelines on Brake Inspection
When the number of start reaches at one million times, inspect the brake gap and carry out the following treatment
depending on the condition of the brake gap.
When the number of start reaches at two million times, replace the brake unit as a whole irrespective of the condition
of the brake gap.
■
■Guidelines on Gear Parts Replacement (Load Gear, Gear B,
Pinion, Friction Clutch, Friction Clutch with Mechanical Brake)
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 – –
■
■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 size grade
* Grease needs to be applied on spline part every 800, 1600 and 2400 hours.
(to be continued)
91
Chapter 2 Inspection
Check of Operating Hours and Number of Start
■
■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 – –
■
■Guidelines on Hook and Yoke Replacement
Replace the Hook and Yoke in accordance with the rate of loading and the number of start in the following table.
Number of start to replace parts Every million Every 1.5 million Every 2 million
Rate of loading times times times
A case where the capacity is rarely applied. Usually the hoist is
Light ○
used with a light load.
2 Medium
A case where the capacity is applied considerably frequently.
Usually the hoist is used with a medium load.
○
■
■Guidelines on V ring Inspection
Apply grease MOLITHERM No.2 on the V ring when the operating hours reaches at every 200 hours.
Refer to “Product Structure and Name of Each Part” (P122) for the location of the V ring.
92
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
• Power..............................................................................................99
• Circuit breaker...............................................................................99
• Power Cable.................................................................................100
• Motor.............................................................................................101
• Brake.............................................................................................102
• Internal wiring..............................................................................104
• Transformer..................................................................................104
• Electromagnetic Contactor, Relay.............................................105
• Fuse..............................................................................................105
• Upper/Lower Limit Switch...........................................................106
• Push Button Switch.....................................................................107
• VFD................................................................................................108
• Interface Board............................................................................108
• Braking Resistor..........................................................................108
• Electric shock..............................................................................109
• Friction Clutch.............................................................................109
• Friction Clutch with Mechanical Brake......................................110
• Hook.............................................................................................. 111
• Load Chain...................................................................................113
• Load Sheave, Idle Sheave...........................................................115
• Chain Guide A..............................................................................115
• Gears and Joints..........................................................................115
• Bearing.........................................................................................116
• Traveling motion of the Trolley...................................................116
93
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” (P122) for the product structure and the component name of each part.
■
■Single speed model
Guidance on Troubleshooting
Reference
Conditions Main fault contents Check item
page
Electric chain Sounds no brake Sounds no Improper source voltage Power 99
hoist does not operating sound Electromagnetic Breakage or burning of Circuit breaker 99
operate without contactor operating control circuit Power Cable 100
load sound Faulty electrical part
Internal wiring 102
Electromagnetic Contactor 105
Transformer 104
Fuse 105
Upper/Lower Limit Switch 106
Push Button Switch 107
Sounds contactor Breakage or burning of Motor 101
3 Electromagnetic power circuit, Brake 102
operating sound Faulty motor or brake
Internal wiring 104
Electromagnetic Contactor 105
Guidance on Troubleshooting / Single speed model
94
Reference
Conditions Main fault contents Check item
page
Abnormal Popping sound Abrasion of the Load Load Chain 113
noise Chain
Abrasion of the Load Load Sheave, Idle Sheave 115
Sheave
Guidance on Troubleshooting
Sounds strange operating sound Abrasion or breakage of Gears and Joints 115
Gear
Deterioration of Bearing Bearing 116
Brake noise Sounds when applied Dragging Brake 102
(scraping noise)
Sounds when Abrasion of brake lining Brake 102
released
Friction Clutch with Scraping noise Use of improper oil other Friction Clutch with 110
Mechanical Brake than the designated oil Mechanical Brake
(sounds when
lowering)
Sounds at curved rail (friction noise) Mechanical interference Traveling motion of the 116
of the rail and the wheel Trolley
Unable to
travel
Motorized Trolley/Manual Trolley Slipping wheel
Inclined rail
Traveling motion of the
Trolley
116
3
Pulling a load in an
inclined direction (floating
(to be continued)
95
Chapter 3 Troubleshooting
■
■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”
Guidance on Troubleshooting
Manual”. (annex)
Electric chain Sounds no brake operating sound Improper source voltage Power 99
hoist does not Breakage and burning of Circuit breaker 99
operate without control circuit Power Cable 100
load Faulty electrical part
Internal wiring 104
Transformer 104
Fuse 105
Relay 105
Interface Board 108
VFD 108
Upper/Lower Limit Switch 106
3 Push Button Switch 107
Breakage and burning of Motor 101
power circuit Brake 102
Failure of motor or brake
Dual Speed VFD Model
96
Reference
Conditions Main fault contents Check item
page
Does not stop Too long stopping distance Relay failure or melted Relay 105
normally. contact point
Too long (or short) stopping distance Abrasion of brake lining Brake 102
Guidance on Troubleshooting
Does not stop at the upper/lower limit. Negative phase connection Power Cable 100
of motor lead wires
Wrong connection Internal wiring 104
Push Button Switch 107
Abnormal Popping sound Abrasion of the Load Chain Load Chain 113
noise Abrasion of the Load Sheave Load Sheave, Idle Sheave 115
Sounds strange operating sound Abrasion or breakage of Gear Gears and Joints 115
Deterioration of Bearing Bearing 116
Brake noise Sounds when applied Dragging Brake 102
(scraping noise)
Sounds when released Abrasion of brake lining Brake 102
Friction Clutch with Scraping noise Use of improper oil other Friction Clutch with 110
Mechanical Brake than the designated oil Mechanical Brake
(sounds when lowering)
Sounds at curved rail (friction noise) Mechanical interference Traveling motion of the 116
3
of the rail and the wheel Trolley
Unable to Motorized Trolley/Manual Trolley Slipping wheel Traveling motion of the 116
97
Chapter 3 Troubleshooting
Safety Precautions
■
■General Matters on Failure Cause and Countermeasure
DANGER
•• Do not disassemble or repair the electric chain hoist by the personnel other than maintenance engineer.
“Disassembling/Assembling Manual” and “Parts List” are provided separately for the maintenance. Disassembling
and repair must be performed by the maintenance engineer in accordance with these materials for maintenance.
Prohibited
•• 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”.
Safety Precautions
Failure to comply with this content may result in death or serious injury.
•• When any abnormality is observed during the maintenance (repair) of the electric chain hoist, survey the
cause by the maintenance engineer and carry out the repair.
•• Be sure to keep the following when repairing the electric chain hoist:
Mandatory
•• Be sure to turn off the power.
•• Be sure to indicate “INSPECTION”.
•• Carry out the repair without lifting a load.
•• Be sure to pay attention to the change of the operating sound of electric chain hoist and trolley.
3
The change of operating sound is an important factor to judge the failure.
Failure to comply with this content may result in death or serious injury.
General Matters on Failure Cause and Countermeasure / General Matters on Handling the Dual Speed VFD Model
■
■General Matters on Handling the Dual Speed VFD Model
DANGER
•• 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.
Prohibited
Wait for the completion of discharging of the capacitor inside the VFD.
•• Do not touch the controller cover as it becomes hot during operation.
•• Do not touch the controller cover until about 30 minutes elapsed after the stop of operation.
•• USE KITO genuine VFD.
The VFD requires the special specification for KITO. Be sure to use genuine VFD.
•• Do not change the connection of the VFD.
When the wires were removed for any reason, connect them again correctly checking the wiring diagram inside the
controller cover.
•• Do not carry out withstand voltage test of a circuit while the VFD is connected.
•• Do not turn off the power while operating.
Failure to comply with these instructions may result in death or serious injury and the damage of VFD.
98
Troubleshooting
Power
Troubleshooting
Mandatory serious injury due to electric shock.
(to be continued)
99
Chapter 3 Troubleshooting
Troubleshooting (continued)
Power Cable
vibration impact.
Slow start or unable Insufficient cable Check the cable size for adequacy. Voltage drop due Use the cable with
to start capacity Replace with the proper cable if the to insufficient cable proper capacity. (See
cable capacity is insufficient. capacity P54.)
Electric chain hoist Breakage or
operates but unable burning of one
Refer to the breakage and burning of above items.
to lift a load. (single phase only
phase status)
For single speed Wrong connection Change two wires of power line. Wrong connection Refer to the connection
model, the electric of power line when when assembling diagram and connect
chain hoist operates wiring wires correctly.
in the direction
different to the push
DANGER
button operation •• Do not change the connection at the
(negative phase). Push Button Switch circuit.
* For dual speed The change of circuit at the Push Button Switch
VFD model, refer Prohibited
circuit is very dangerous as the limit switch
to the item of becomes not to function.
VFD.
100
Motor
Troubleshooting
intermittent rating rating. Use the electric
chain hoist within these
ratings.
Excessive inching or Do not perform
plugging operation excessive operation.
(consecutive
impression of start
rush current)
Over current due to
brake dragging
Refer to the items of
Brake. 3
Lead wire breakage Measure the coil resistance of each Lead wire damaged at Assemble with care.
(more than two lead phase. Replace the motor when the assembling
Motor
wires) resistance of all phases are infinity.
Vibration, impact Use the electric chain
hoist avoiding the
impact.
Electric chain hoist Motor coil burning Measure the coil resistance of each Layer short due to Be careful about the
operates but unable (only one phase) phase. Replace the motor when the poor insulation of coil intrusion of foreign
to lift a load. (single resistance of all phases are infinity. (between phases) matter into the motor
phase status) when assembling.
Lead wire breakage Measure the coil resistance of each Lead wire damaged at Be careful not to have
(only in one lead phase. Replace the motor when the assembling the lead wire caught
wire) resistance of all phases are infinity. when assembling.
Vibration, impact Use the electric chain
hoist avoiding the
impact.
(to be continued)
101
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
102
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.
Leaving the electric Operate the electric
chain hoist in an chain hoist regularly.
environment with rich
moisture
Dew condensation Pay attention to the
Troubleshooting
use in an environment
where the ambient
temperature changes
rapidly.
Breakage of rectifier Measure the resistance of the rectifier Over current due to Operate the electric
with circuit tester. over voltage or low chain hoist at the rated
Anode terminal : Negative probe of the voltage voltage.
circuit tester
Excessive inching or Do not perform
Cathode terminal : Positive probe of the
circuit tester (measure
plugging operation
(consecutive
excessive operation.
3
the resistance in kΩ
impression of start
range)
rush current)
When the resistance is almost zero, the
Brake
rectifier is normal. Over current due to Use the electric chain
In other cases, replace the rectifier. over load hoist with a load less
than the capacity.
Operation exceeding Check the short time
short time rating or rating and intermittent
intermittent rating rating. Use the electric
chain hoist within these
ratings.
Over current due to The electric chain hoist
open phase operation cannot lift a load in
open phase operation.
When any abnormality
is observed, stop the
operation immediately
and check the cause of
open phase operation.
Too long (or short) Abrasion of brake Measure the brake gap. If the gap Excessive inching Do not perform
stopping distance lining exceeds the service limit, replace the operation excessive operation.
(stopping distance electromagnetic brake unit as a whole
may change slightly (See P79.)
depending on the
temperature.)
Louder operating Abrasion of brake Measure the brake gap. If the gap Excessive inching Do not perform
sounds lining exceeds the service limit, replace the operation excessive operation.
electromagnetic brake unit as a whole
(See P79.)
(to be continued)
103
Chapter 3 Troubleshooting
Troubleshooting (continued)
Internal wiring
Transformer
104
Electromagnetic Contactor, Relay
Troubleshooting
Over current due to Use the electric chain
over load hoist with a load less
than the capacity.
Electric chain hoist Burnout or Measure the resistance of relay coil or Excessive inching or Do not perform
does not operate. breakage of relay contactor coil. If it is infinity, replace the plugging operation excessive operation.
coil or contactor coil relay or the contactor. (consecutive
impression of start
rush current)
Over voltage Operate the electric
chain hoist with the 3
rated voltage.
Chattering due to low Operate the electric
Fuse
(to be continued)
105
Chapter 3 Troubleshooting
Troubleshooting (continued)
Moving part rusted Check the moving part of the limit switch Leaving the electric Do not leave the
shut (defective such as actuator lever is not stiff. If it is chain hoist for a long electric chain hoist at
return action of the stiff, remove the rust or replace the stiff time at the upper/lower the upper/lower limit.
moving part) part. limit.
Electric chain hoist Contact point Actuate the limit switch manually to Habitual use of the limit Do not use the limit
does not stop at the welding check the conduction of the contact switch switch habitually.
upper/lower limit. points.
Replace the limit switch as a whole when
it does not turn off.
3 Moving part rusted Check the moving part of the limit switch No use for a long time, Check the electric
shut such as actuator lever is not stiff. If it is use in an environment chain hoist regularly.
stiff, remove the rust or replace the stiff with rich moisture
Upper/Lower Limit Switch
part.
Wrong wiring Check the wiring in accordance with Wrong wiring Correct the wiring in
the wiring diagram. Perform the wiring accordance with the
correctly. wiring diagram.
If the wiring of the limit switch is correct,
the cause is in the negative phase
connection. Change two wires of the
power line.
106
Push Button Switch
Emergency Stop
button
Troubleshooting
Faulty switch unit Check the conduction of the contact Vibration, impact Use the electric chain
points. Replace the Push Button Switch if hoist avoiding the
it has no conduction. impact.
Breakage inside the Check that the Push Button Switch Vibration, impact Use the electric chain
switch cord is connected with the switch unit hoist avoiding the
correctly. Repair the cord if it has no impact.
conduction.
Loosened terminal Tighten the screw if loosened Vibration, impact Use the electric chain
screw inside the hoist avoiding the 3
switch unit impact.
Wire breakage of Check the conduction of the Push Button Damage of cable cover Operate the electric
(to be continued)
107
Chapter 3 Troubleshooting
Troubleshooting (continued)
VFD
VFD overheat Stop by overheat preventive function of Operation exceeding Check the short time
the VFD short time rating or rating and intermittent
Motor resumes operation when the VFD intermittent rating rating. Use the electric
is reset by pressing the Emergency Stop chain hoist within these
after cool down. ratings.
Expired service Refer to the “VFD Manual”. Operation exceeding Check the short time
life of the VFD short time rating or rating and intermittent
(capacitor) intermittent rating rating. Use the electric
3 chain hoist within these
ratings.
VFD / Interface Board / Braking Resistor
Interface Board
Braking Resistor
108
Electric shock
Troubleshooting
item of Power Cable
and Push Button
Switch.)
Attachment of Remove the waterdrop, dry the electric Operation by wet hand Do not operate the electric
waterdrop chain hoist and then use it. chain hoist by wet hand.
Friction Clutch
DANGER
3
•• Do not adjust/disassemble the Friction Clutch.
Adjusting or disassembling the Friction Clutch may result in death or serious injury.
Troubleshooting (continued)
Abrasion of Clutch Replace the Friction Clutch with Too many use of the Avoid the over load.
Disk Mechanical Brake. Friction Clutch
Use of oil other than Use KITO genuine oil.
the designated oil
DANGER
•• Use KITO genuine gear oil.
110
Hook
Troubleshooting
Slinging a load at the Sling a load at the
tip of the Hook. center of the Hook
Hook
120 degrees or less
Hook unable to Rusting shut or Swivel the Hook at the neck by hand. If it Insufficient grease Apply grease regularly.
swivel smoothly at corrosion of Bearing is difficult to swivel smoothly, overhaul or application, corrosion Use the sling to avoid
the neck replace the Bearing. due to environment of the dipping of the Hook
use into chemicals.
Damaged Bearing Intrusion of dust Be careful about the
intrusion of foreign
matter into the neck.
(to be continued)
111
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.
Earth lifting Do not carry out earth
lifting.
Be careful not to
impede the Hook
with protruding object
during lifting.
Troubleshooting
112
Load Chain
Troubleshooting
Load Chain is Remove the Chain Guide A and the Load Improper assembling Assemble the electric
twisted inside the Chain, and then reassemble them. chain hoist correctly.
main body of the (See Disassembling/
electric chain hoist. Assembling Manual)
Sudden activation Knot of the Load Check the capacity of the Chain Insufficient capacity of When installing the
of the Friction Chain due to Container (with the nameplate on the the Chain Container electric chain hoist,
Clutch when entanglement in the Chain Container). If insufficient, replace check the lift and 3
lowering Chain Container the Chain Container with a larger the capacity of the
capacity. Chain Container,
and assemble them
Load Chain
correctly.
Sounds the popping Abrasion of the Measure the abrasion of wire diameter. Long hour operation Apply lubricant
sound Load Chain links Replace the Load Chain if it reaches at without grease regularly. (See P40)
the abrasion limit. (See P69) Grease
application portion
Load
(to be continued)
113
Chapter 3 Troubleshooting
Troubleshooting (continued)
Hit flaw on the Load Hit with other object Use the electric chain
Chain surface strongly hoist carefully paying
attention not to impede
with other object.
3 Surface losing lust Rusting and Remove rust and apply oil. Run-out of oil Apply lubricant
and discolored corrosion Replace the Load Chain if the rust and regularly. (See P40)
corrosion is apparent. Grease
application portion
Load Chain
Load
114
Load Sheave, Idle Sheave
Troubleshooting
Pulling a load in an Do not pull a load in an
inclined direction inclined direction.
Chain Guide A
DANGER
•• Use KITO genuine gear oil.
(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.
Troubleshooting (continued)
Bearing
Serpentine motion Abrasion of the side roller Check the abrasion Traveling on curved rail Check regularly.
Troubleshooting
Strange noise or expiry of service life
Abrasion of the Brake Check the abrasion of the Expiry of service life Check regularly.
Pad Brake Pad
Traveling motion of the Trolley (only for motorized trolley) / Traveling motion of the Trolley (only for manual trolley)
117
Chapter 3 Troubleshooting
118
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.................................................................................120
■
■Product Structure and Names of Each Part................................122
■
■Technical Material..........................................................................124
• Hook Dimensions (for ER2)........................................................124
• Table of Lifting Load....................................................................124
• Rated Motor Current....................................................................124
• Specification and Dimensions of Single Speed ER2........................126
• Specification and Dimensions of Single Speed ER2M......................127
• Specification and Dimensions of Single Speed ER2SP....................128
• Specification and Dimensions of Single Speed ER2SG....................129
• Specification and Dimensions of Dual Speed VFD ER2....................130
• Specification and Dimensions of Dual Speed VFD ER2M.................132
• Conversion Table between Lift/Travel/Speed............................134
• Clearance between Trolley and Applicable Rail........................135
• Wiring Diagram of Single Speed ER2/ER2SP/ER2SG..............136
• Wiring Diagram of Dual Speed ER2...........................................140
• Wiring Diagram of Single Speed ER2M.....................................145
• 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
119
Appendix
Optional Parts
■
■Friction Clutch with Mechanical Brake
KITO’s original friction clutch equipped with mechanical brake
■
■Load Bell: Over load alarm
An alarm unit to detect over load
Detection load: 100 to 110 % of the capacity
Alarm sound level: 85 dB or more
automatically.
■
■Bumper: Stopper for Trolley MR2
A shock absorber for collision (special for MR2)
Be sure to use the bumper when the trolley uses urethane wheel.
A ■
■T-shape Suspender: Attachment for power feeding
Code Travel Rail width (mm) Hole pitch
75 A : (53mm)
T-shape Suspender 100 B : (78mm)
100 125 C : (103mm)
150 D : (128mm)
T-shape Suspender 175 175 A : (153mm) A
• Contact KITO when the Travel Rail width exceeds 175 mm. B
C
D
< Manual Trolley 125 kg to 3 t > < Manual Trolley 5 t > < MR2 >
120
■
■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 >
53
66
79
Cable guard Cable guard
■
■Chain End Suspender
Optional Parts
Code
Capac- Single speed Dual speed Part
Part name Part code Note
ity Standard Standard number
speed Low speed High speed speed Low speed High speed
Chain End
ER2-001H ER2-001IH/HD 408 Suspender ER2BS9408
ER2-003S ER2-003H ER2-003IS/SD ER2-003IH/HD 417 Socket Bolt J1BE1-0806528
125kg
418 Lever Nut C2BA100-9074
250kg 396 Socket Bolt J1BE1-0503012
A
397 U Nut E2DBX10S9853
399 Plain Washer J1WD011-00050
Chain End
ER2-005S ER2-005L ER2-005IS/SD ER2-005IL/LD 408 Suspender ER2CS9408
417 Socket Bolt J1BE1-0807528
500kg 418 Lever Nut C2BA100-9074
396 Socket Bolt J1BE1-0604018
397 U Nut E5SE003S9855
399 Plain Washer J1WD011-00060
ER2-009S ER2-009L ER2-009IS ER2-009IL 408 Chain End ER2CS9408
Suspender
980kg
ER2-010S ER2-010L ER2-010IS/SD ER2-010IL/LD 417 Socket Bolt J1BE1-0809012
1t ER2-020C ER2-020IC/CD 418 Lever Nut C2BA100-9074
(2t) 396 Socket Bolt J1BE1-0804013
397 U Nut C2BA100-9074
Chain End
ER2-015S ER2-015IS/SD 408 ER2ES9408
Suspender
1.5t
ER2-016S ER2-020L ER2-016IS ER2-020IL/LD 417 Socket Bolt J1BE1-1010032
1.6t ER2-020S ER2-020IS/SD 418 Lever Nut C2BA200-9074
2t 396 Socket Bolt J1BE1-0804013
397 U Nut C2BA100-9074
Chain End
ER2-025S ER2-025IS/SD 408 Suspender ER1ES9408
417 Socket Bolt J1BE1-1008532
2.5t 418 Lever Nut C2BA200-9074
396 Socket Bolt J1BE1-1006032
397 U Nut C2BA200-9074
2.8t ER2-028S ER2-028IS 417 Socket Bolt J1BE1-1010032
3t ER2-030S ER2-030IS/SD 418 Lever Nut C2BA200-9074 *
3.2t ER2-032S ER2-032IS
ER2-050S ER2-050IS/SD 417 Socket Bolt J1BE1-1008532
5t *
418 Lever Nut C2BA200-9074
* Chain End Suspender is not used for double chain fall type due to the orientation of the chain.
For double chain fall type, attach the terminal chain directly to Chain Guide A.
121
Appendix
Packing G
Gear case
Friction clutch Oil seal
Load gear
Load Sheave
Body
A
Limit lever
Bearing bracket
Bottom Yoke
Key
Bottom Hook
Rotor
Motor shaft
V ring
Packing M
Stator
Hub
Electromagnetic brake
Packing B
Brake cover
Fan
Fan cover
122
■
■Single Speed Model
(500V Class Dual Speed Panel
Model)
Limit switch
Packing C
■
■Dual Speed VFD Model (Body size B, C)
Panel
Inverter
Controller cover
Braking resistor
A
Limit switch Resistor cover
Interface board
Packing C
Nameplate
■
■Dual Speed VFD Model (Body size D, E, F)
Panel
Inverter
Controller cover
Braking resistor
Limit switch
Resistor cover
Interface board
Packing C
Nameplate
123
Appendix
Technical Material
■
■Hook Dimensions (for ER2)
●● Top Hook i ●● Bottom Hook
g
j e
D D
l c
k
j
g
h
Top Hook (mm) Bottom Hook (mm)
Code
D g i j k l D g h j e c
ER2-001H/IH/HD
ER2-003S/IS/SD
ER2-003H/IH/HD
35.5 27.0 17.5 23.5 28.0 17.5 35.5 27.0 17.5 23.5 28.0 17.5
ER2-004L/IL/LD
Technical Material
ER2-004S/IS/SD
ER2-005S/IS/SD
ER2-010L/IL/LD
42.5 31.0 22.5 31.0 36.5 22.5 42.5 31.0 22.5 31.0 36.5 22.5
ER2-010S/IS/SD
ER2-015S/IS/SD 47.5 34.0 26.5 36.5 43.5 26.5
ER2-020L/IL/LD 53.0 39.0 31.5 43.5 51.5 31.5
ER2-020S/IS/SD 53.0 39.0 31.5 43.5 51.5 31.5
ER2-025S/IS/SD 32.5 44.0 52.0 32.5
ER2-028S/IS/SD 60.0 44.0
34.5 47.5 56.0 34.5 60.0 44.0 34.5 47.5 56.0 34.5
ER2-030S/IS/SD
A ER2-050S/IS/SD 63.0 47.0 42.5 56.0 67.0 42.5 63.0 47.0 42.5 56.0 67.0 42.5
■
■Table of Lifting Load
Capacity (t) 125kg 250kg 500kg 1 1.5 2 2.5 3 5
Lifting Load (t) 0.126 0.251 0.501 1.002 1.504 2.004 2.504 3.005 5.014
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
Motor
Capacity
Code output 220–230V 380–415V 380–440V 208-230V 415-460V 500V 575V
(t)
(kW)
50Hz 60Hz 50Hz 60Hz 60Hz 50Hz 60Hz
125kg ER2-001H
250kg ER2-003S 0.56 3.8 3.0 2.5 1.8 3.4 1.7 1.6 1.4
500kg ER2-005L
250kg ER2-003H
500kg ER2-005S 0.9 5.0 4.3 3.4 2.6 4.8 2.5 2.0 1.8
ER2-010L
1
ER2-010S
1.5 ER2-015S 1.8 7.3 8.3 4.8 4.6 8.6 4.2 3.0 3.3
ER2-020L
2
ER2-020S
2.5 ER2-025S
2.8 ER2-028S 3.5 13.3 15.4 8.3 8.7 16.4 7.9 6.0 6.2
3 ER2-030S
5 ER2-050S
Motor Insulation Class B F B B
124
■■Lifting motor (Dual speed) (Unit:A)
Technical Material
2.8 ER2-028IS 3.5 16.2 9.2 17.3 8.3 3.5 6.0/3.7 6.0/3.4
3 ER2-030IS
5 ER2-050IS
Motor Insulation Class B F B B
(to be continued)
125
Appendix
■
■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 Intermittent mass per
Switch cord Output Wire diameter (mm) × Grade Weight Mass (kg)
size lift (m) rating 50Hz 60Hz another 1 m lift
length L (m) (kW) Number of falls (t)
(% ED) (kg)
125kg ER2-001H 14.1 16.9 156kg
B 0.56 4.3×1 27(28) 0.42
ER2-003S 9.1 10.9
250kg 313kg
ER2-003H 0.9 13.4 16.1 37(38)
ER2-005L C 0.56 3.8 4.6 6.0×1 625kg 33(37) 0.81
0.5 M5
ER2-005S 7.3 8.8 613kg 37(38)
0.9
ER2-010L 3.5 3.5 4.2 48(51)
1 D 7.7×1 1.25 1.33
ER2-010S 7.1 8.5 55
3 60
1.5 ER2-015S 1.8 4.5 5.4 1.88 74(79)
ER2-020L E 3.7 4.4 10.2×1 75(81) 2.3
2 2.5
ER2-020S 7.0 8.4 93(92)
2.5 ER2-025S F 5.7 6.8 11.2×1 3.13 106(105) 2.8
M4
2.8 ER2-028S 3.5 4.6 5.5
E 10.2×2 3.75 111 4.7
3 ER2-030S 3.8 4.4 5.3
Technical Material
A
C
D
L
lift
■■Dimensions (mm)
Minimum a b d e f i
Capacity
(t)
Code distance between D g h
Hooks: C (MFC) (MFC) (MFC) (MFC) (MFC) (MFC)
125kg ER2-001H
350 430 478(564) 321(345) 219(305) 259 260(284) 99 93(117)
ER2-003S
250kg
ER2-003H 510(593) 268 27
ER2-005L 370 490 513(599) 348 242(325) 271(273) 283 113 106
0.5
ER2-005S 510(593) 268
ER2-010L 589(632) 298(300)
1 430 550 376 291(332) 335 31 129 118
ER2-010S 598(639) 307
1.5 ER2-015S 510 34
646(738) 308(397) 338(341)
ER2-020L 575 630 427 384.5 160.5 137.5
2
ER2-020S 590 703(782) 347(426) 356 39
2.5 ER2-025S 625 840 736(826) 445 337(427) 399 437.5 173.5 142.5
2.8 ER2-028S
785 703(782) 427 347(426) 356 397 44 216 82
3 ER2-030S 920
5 ER2-050S 850 736(826) 445 337(427) 399 439 47 231.5 84.5
* Dimensions D and f are for the lift of 4 m.
126 * The values in parenthesis ( ) are for friction clutch with mechanical brake type.
■
■Specification and Dimensions of Single Speed ER2M
■■Specification
Specification of ER2 Specification of MR2 Other specification
Capacity Push Button Lifting motor Lifting speed (m/min) Load chain Traveling motor Traveling speed (m/min) Rail MIinimum Additional
Code ER2 Body Standard Switch cord Intermittent Wire diameter Grade MR2 Intermittent Width: Turning mass per
(t) Output Output Mass (kg)
series size lift (m) length L rating 50Hz 60Hz (mm) × series rating 50Hz 60Hz B Radius another 1
(m) (kW) (kW) (mm) (mm) m lift (kg)
(% ED) Number of falls (% ED)
125kg ER2M001H-S/L ER2-001H 14.1 16.9
B 0.56 4.3×1 58(59) 0.42
ER2M003S-S/L ER2-003S 9.1 10.9
250kg
ER2M003H-S/L ER2-003H 0.9 13.4 16.1 58 68(69)
MR2- 800
ER2M005L-S/L ER2-005L C 0.56 3.8 4.6 6.0×1 to 64(67) 0.81
0.5 M5 010S(L) [3500]
ER2M005S-S/L ER2-005S 7.3 8.8 153 68(69)
0.9
ER2M010L-S/L ER2-010L 3.5 3.5 4.2 78(81)
1 D 7.7×1 1.33
ER2M010S-S/L ER2-010S 7.1 8.5 0.4 20 24 85
1.5 ER2M015S-S/L ER2-015S 3 1.8 60 4.5 5.4 40 82 112(117)
MR2- (10) (12) 800
ER2M020L-S/L ER2-020L E 3.7 4.4 10.2×1 to 113(118) 2.3
2 020S(L) [1000]
ER2M020S-S/L ER2-020S 7.0 8.4 178 131(130)
2.5 ER2M025S-S/L ER2-025S F 5.7 6.8 11.2×1 154(153) 2.8
2.8 ER2M028S-S/L ER2-028S 4.6 5.5 M4 MR2- 100 1000
E 3.5 10.2×2 030S(L) 159 4.7
Technical Material
3 ER2M030S-S/L ER2-030S 4.4 5.3 to
3.8 178
MR2-
5 ER2M050S-S/L ER2-050S F 2.9 3.5 11.2×2 0.75 1800 207(205) 5.6
050S(L)
*M ass is for the lift of 4 m.
* The traveling speed values in
parenthesis ( ) are for the low speed.
*T he values in brackets [ ] are for the
minimum turning radius of the value
e B d
in the brackets.
b u e'
*T he mass values in parenthesis
n m ( ) are for friction clutch with
mechanical brake type.
A
k
r
D
L
i
lift
g
t
■■Dimensions (mm)
Capacity Minimum
Code distance between D b d e e' g i j k m n r t u
(t) Hooks: C
125kg ER2M001H-S/L
375 450
ER2M003S-S/L
250kg
ER2M003H-S/L 27
ER2M005L-S/L 395 510 315 220 515 179 95 22 130 205 109 51 31 83
0.5
ER2M005S-S/L
ER2M010L-S/L
1 435 550 31
ER2M010S-S/L
1.5 ER2M015S-S/L 505 34
ER2M020L-S/L 570 630 325 225 520 184 110 27 125 212 118 60 36 76
2
ER2M020S-S/L 585 39
2.5 ER2M025S-S/L 620 830
2.8 ER2M028S-S/L 340 226 521 186 125 29 131 215 132 68 43 70
765 900 44
3 ER2M030S-S/L
5 ER2M050S-S/L 840 910 400 281 528 192 47 140 44 145 233 150 86 54 56
* Dimensions D is for the lift of 4 m.
(to be continued)
127
Appendix
■
■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 ER2 Body Standard Wire diameter Grade TSP Chain Rail Width: Turning mass per
(t) Switch cord Output Intermittent Mass (kg)
series size lift (m) series length: B (mm) Radius another 1 m
length L (m) (kW) rating 50Hz 60Hz (mm) × Number
(% ED) of falls E (m) (mm) lift (kg)
125kg ER2SP001H ER2-001H 14.1 16.9
B 0.56 4.3×1 32(33) 0.42
ER2SP003S ER2-003S 9.1 10.9
250kg
ER2SP003H ER2-003H 0.9 13.4 16.1 TSP005 50 to 102 1100 42(43)
ER2SP005L ER2-005L C 0.56 3.8 4.6 6.0×1 38(42) 0.81
0.5 M5
ER2SP005S ER2-005S 7.3 8.8 42(43)
0.9
ER2SP010L ER2-010L 3.5 3.5 4.2 56(59)
1 7.7×1 TSP010 58 to 127 1300 1.33
ER2SP010S ER2-010S 7.1 8.5 63
3 60
1.5 ER2SP015S ER2-015S D 1.8 4.5 5.4 87(93)
ER2SP020L ER2-020L 3.7 4.4 10.2×1 TSP020 1500 88(94) 2.3
2
ER2SP020S ER2-020S 7.0 8.4 107(106)
82 to 153
2.5 ER2SP025S ER2-025S F 5.7 6.8 11.2×1 130(129) 2.8
M4
2.8 ER2SP028S ER2-028S 3.5 4.6 5.5 TSP030 1700
E 10.2×2 134(133) 4.7
3 ER2SP030S ER2-030S 3.8 4.4 5.3
Technical Material
5 ER2SP050S ER2-050S F 2.9 3.5 11.2×2 TSP050 100 to 178 2300 187(185) 5.6
* Mass is for the lift of 4 m
b a * The mass values in parenthesis
( ) are for friction clutch with
n e B
mechanical brake type.
m
o
k
A
C
D
L
h
i
p
r
j
Lift
■■Dimensions (mm)
Capacity Minimum
Code distance between D a b e g h i j k m n o p q r t
(t) Hooks: C
125kg ER2SP001H
395 470
ER2SP003S
250kg
ER2SP003H 204 182 46 27 82 60 21 76 47.5 84 42 54 38 22
ER2SP005L 415 530
0.5
ER2SP005S
ER2SP010L
1 470 590 249 236 56 31 106 71 28 95 56 112 50 69 50 25
ER2SP010S
10
1.5 ER2SP015S 570 34
ER2SP020L 635 690 300 280 69 127 85 34 112 71 131 63 83 62 32
2
ER2SP020S 650 39
2.5 ER2SP025S 680 890
2.8 ER2SP028S 320 324 79 148 100 36 134 80 152 74 102 68 36
780 44
3 ER2SP030S 910
5 ER2SP050S 840 297 400 53 47 169 118 46 144 81 178 70 104 88 54
* Dimensions D is for the lift of 4 m.
128
■
■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 ER2 Body Standard Wire diameter Grade TSG Chain Rail Width: B Turning mass per
(t) Switch cord Output Intermittent Mass (kg)
series size lift (m) series length: (mm) Radius another 1
length L (m) (kW) rating 50Hz 60Hz (mm) × Number
(% ED) of falls E (m) (mm) m lift (kg)
125kg ER2SG001H ER2-001H 14.1 16.9
B 0.56 4.3×1 41(42) 1.4
ER2SG003S ER2-003S 9.1 10.9
250kg
ER2SG003H ER2-003H 0.9 13.4 16.1 51(52)
ER2SG005L ER2-005L C 0.56 3.8 4.6 6.0×1 TSG010 58 to 127 1300 1.7
0.5 M5 47(50)
ER2SG005S ER2-005S 7.3 8.8
0.9
ER2SG010L ER2-010L 3.5 3.5 4.2 61(64)
1 D 7.7×1 2.3
ER2SG010S ER2-010S 7.1 8.5 2.8 68
3 60
1.5 ER2SG015S ER2-015S 1.8 4.5 5.4 92(98)
ER2SG020L ER2-020L E 3.7 4.4 10.2×1 TSG020 1500 93(99) 3.2
2
ER2SG020S ER2-020S 7.0 8.4 112(111)
82 to 153
2.5 ER2SG025S ER2-025S F 5.7 6.8 11.2×1 135(134) 3.7
M4
2.8 ER2SG028S ER2-028S 3.5 4.6 5.5 TSG030 1700
E 10.2×2 139(138) 5.6
3 ER2SG030S ER2-030S 3.8 4.4 5.3
Technical Material
5 ER2SG050S ER2-050S F 2.9 3.5 11.2×2 TSG050 4.2 · 6.2 100 to 178 2300 194(192) 6.5
A
C
D
E
L
h
i
p
r
j
Lift
■■Dimensions (mm)
Capacity Minimum
Code distance between D a b e g h i j k k' m n o p q r t u
(t) Hooks: C
125kg ER2SG001H
415 490
ER2SG003S
250kg
ER2SG003H 27
ER2SG005L 435 550 345 236 152 106 71 28 95 107 56 112 50 69 50 25
0.5
ER2SG005S
ER2SG010L
1 470 590 31
ER2SG010S
10 183
1.5 ER2SG015S 570 34
ER2SG020L 635 690 385 280 154 127 85 34 112 109 71 131 63 83 62 32
2
ER2SG020S 650 39
2.5 ER2SG025S 680 890
2.8 ER2SG028S 398 324 157 148 100 36 134 115 80 152 74 102 68 36
780 44
3 ER2SG030S 910
5 ER2SG050S 840 401 400 156 47 169 118 46 144 131 81 178 70 104 88 54
* Dimensions D is for the lift of 4 m.
(to be continued)
129
Appendix
■
■Specification and Dimensions of Dual Speed VFD ER2
■■ Specification
Specification of ER2
Push Button Lifting motor Lifting speed (m/min) Load chain Additional
Capacity Test
Code Body Standard Switch cord Intermittent 50Hz/60Hz Wire diameter Grade Weight Mass mass per
(t)
size lift (m) length L Output rating (mm) × Number (kg) another 1 m
(kW) High speed Low speed (t)
(m) (% ED) of falls lift (kg)
INIT. 16.6 2.8
125kg ER2-001IH 156kg
RANGE 16.6 1.4
B 0.56 4.3×1 27(29) 0.42
INIT. 10.8 1.8
ER2-003IS
RANGE 10.8 0.9
250kg 313kg
INIT. 15.7 2.6
ER2-003IH 0.9 M6 36(38)
RANGE 15.7 1.3
INIT. 4.5 0.8 613kg
ER2-005IL C 0.56 6.0×1 32(37) 0.81
RANGE 4.5 0.4 (625kg)
0.5
INIT. 8.5 1.4
ER2-005IS 625kg 36(38)
RANGE 8.5 0.7
0.9
Technical Material
130
■■Dimensions (mm)
Minimum a d e
Capacity
(t)
Code distance between D b f g h i
Hooks: C (MFC) (MFC) (MFC)
125kg ER2-001IH
350 430 535(564) 345 276(305) 259 284 99 117
ER2-003IS
250kg
ER2-003IH 568(593) 268 27
ER2-005IL 370 490 571(598) 348 300(325) 271(273) 283 113 106
0.5
ER2-005IS 568(593) 268
ER2-010IL 614(632) 298(300)
1 430 550 376 316(332) 335 31 129 118
ER2-010IS 623(639) 307
1.5 510 34
ER2-015IS 710(737) 372(397) 338(340)
575 630 427 384.5 160.5 137.5
2
ER2-020IS 590 767(782) 411(426) 356 39
2.5 ER2-025IS 625 840 800(826) 445 401(427) 399 437.5 173.5 142.5
2.8 ER2-028IS
785 767(782) 427 411(426) 356 397 44 216 82
3 ER2-030IS 920
5 ER2-050IS 850 800(826) 445 401(427) 399 439 47 231.5 84.5
* Dimensions D and f are for the lift of 4 m.
* The values in parenthesis ( ) are for
friction clutch with mechanical brake type.
Technical Material
b
f a
h i d e
C
A
D
L
lift
(to be continued)
131
Appendix
A
INIT. 5.3 0.9
2.8 ER2M028IS-IS ER2-028IS 3.5
RANGE 5.3 0.4
E 10.2×2
INIT. 5.2 0.9
3 ER2M030IS-IS ER2-030IS 3.8
RANGE 5.2 0.4
INIT. 3.4 0.6
5 ER2M050IS-IS ER2-050IS F 11.2×2
RANGE 3.4 0.3
125kg ER2M-001IH-IS
59(61) 0.42
ER2M-003IS-IS
250kg
ER2M-003IH-IS 69(71)
800
ER2M005IL-IS MR2-010IS 58 to 153 65(69) 0.81
0.5 [3500]
INIT. 4
ER2M005IS-IS 69(71)
ER2M010IL-IS 78(82)
1 1.33
ER2M010IS-IS 0.4 85(86)
27/13 24
1.5 ER2M015IS-IS 113(120)
800
ER2M020IL-IS MR2-020IS 114(121) 2.3
2 [1000]
ER2M020IS-IS 131(134)
82 to 178
2.5 ER2M025IS-IS 153(159) 2.8
RANGE 2.4
2.8 ER2M028IS-IS MR2-030IS 1000
159(164) 4.7
3 ER2M030IS-IS
e B d
b u e'
n m
k
r
Technical Material
L
lift
i
j
t
A
(to be continued)
133
Appendix
■
■Conversion Table between Lift/Travel/Speed (m/s"m/min)
Converted Conventional Converted Conventional Converted Conventional Converted Conventional Converted Conventional Converted Conventional
p
p
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)
0.067 4.0 0.133 8.0 0.200 12.0 0.267 16.0 0.333 20.0
0.002 0.1 0.068 4.1 0.135 8.1 0.202 12.1 0.268 16.1 0.335 20.1
0.003 0.2 0.070 4.2 0.137 8.2 0.203 12.2 0.270 16.2 0.337 20.2
0.005 0.3 0.072 4.3 0.138 8.3 0.205 12.3 0.272 16.3 0.338 20.3
0.007 0.4 0.073 4.4 0.140 8.4 0.207 12.4 0.273 16.4 0.340 20.4
0.008 0.5 0.075 4.5 0.142 8.5 0.208 12.5 0.275 16.5 0.342 20.5
0.010 0.6 0.077 4.6 0.143 8.6 0.210 12.6 0.277 16.6 0.343 20.6
0.012 0.7 0.078 4.7 0.145 8.7 0.212 12.7 0.278 16.7 0.345 20.7
0.013 0.8 0.080 4.8 0.147 8.8 0.213 12.8 0.280 16.8 0.347 20.8
0.015 0.9 0.082 4.9 0.148 8.9 0.215 12.9 0.282 16.9 0.348 20.9
0.017 1.0 0.083 5.0 0.150 9.0 0.217 13.0 0.283 17.0 0.350 21.0
0.018 1.1 0.085 5.1 0.152 9.1 0.218 13.1 0.285 17.1 0.352 21.1
0.020 1.2 0.087 5.2 0.153 9.2 0.220 13.2 0.287 17.2 0.353 21.2
Technical Material
0.022 1.3 0.088 5.3 0.155 9.3 0.222 13.3 0.288 17.3 0.355 21.3
0.023 1.4 0.090 5.4 0.157 9.4 0.223 13.4 0.290 17.4 0.357 21.4
0.025 1.5 0.092 5.5 0.158 9.5 0.225 13.5 0.292 17.5 0.358 21.5
0.027 1.6 0.093 5.6 0.160 9.6 0.227 13.6 0.293 17.6 0.360 21.6
0.028 1.7 0.095 5.7 0.162 9.7 0.228 13.7 0.295 17.7 0.362 21.7
0.030 1.8 0.097 5.8 0.163 9.8 0.230 13.8 0.297 17.8 0.363 21.8
0.032 1.9 0.098 5.9 0.165 9.9 0.232 13.9 0.298 17.9 0.365 21.9
0.033 2.0 0.100 6.0 0.167 10.0 0.233 14.0 0.300 18.0 0.367 22.0
0.035 2.1 0.102 6.1 0.168 10.1 0.235 14.1 0.302 18.1 0.368 22.1
0.037 2.2 0.103 6.2 0.170 10.2 0.237 14.2 0.303 18.2 0.370 22.2
A 0.038
0.040
2.3
2.4
0.105
0.107
6.3
6.4
0.172
0.173
10.3
10.4
0.238
0.240
14.3
14.4
0.305
0.307
18.3
18.4
0.372
0.373
22.3
22.4
0.042 2.5 0.108 6.5 0.175 10.5 0.242 14.5 0.308 18.5 0.375 22.5
0.043 2.6 0.110 6.6 0.177 10.6 0.243 14.6 0.310 18.6 0.377 22.6
0.045 2.7 0.112 6.7 0.178 10.7 0.245 14.7 0.312 18.7 0.378 22.7
0.047 2.8 0.113 6.8 0.180 10.8 0.247 14.8 0.313 18.8 0.380 22.8
0.048 2.9 0.115 6.9 0.182 10.9 0.248 14.9 0.315 18.9 0.382 22.9
0.050 3.0 0.117 7.0 0.183 11.0 0.250 15.0 0.317 19.0 0.383 23.0
0.052 3.1 0.118 7.1 0.185 11.1 0.252 15.1 0.318 19.1 0.385 23.1
0.053 3.2 0.120 7.2 0.187 11.2 0.253 15.2 0.320 19.2 0.387 23.2
0.055 3.3 0.122 7.3 0.188 11.3 0.255 15.3 0.322 19.3 0.388 23.3
0.057 3.4 0.123 7.4 0.190 11.4 0.257 15.4 0.323 19.4 0.390 23.4
0.058 3.5 0.125 7.5 0.192 11.5 0.258 15.5 0.325 19.5 0.392 23.5
0.060 3.6 0.127 7.6 0.193 11.6 0.260 15.6 0.327 19.6 0.393 23.6
0.062 3.7 0.128 7.7 0.195 11.7 0.262 15.7 0.328 19.7 0.395 23.7
0.063 3.8 0.130 7.8 0.197 11.8 0.263 15.8 0.330 19.8 0.397 23.8
0.065 3.9 0.132 7.9 0.198 11.9 0.265 15.9 0.332 19.9 0.398 23.9
0.400 24.0
0.500 30.0
0.600 36.0
134
■
■Clearance between Trolley and Applicable Rail
■■Motorized Trolley
(Unit:mm)
Clearance between trolley and rail
I-beam size ~3t
~1t ~2t ~5t
Single Double
H B t A B A B A A B A B B
100 75 5 × × × × × × × × ×
125 75 5.5 13.8 9.75 × × × × × × ×
150 75 5.5 13.8 9.75 × × × × × × ×
180 100 6 14.2 22 18.6 19.5 × × × × ×
200 100 7 14.1 21.5 18.6 19 × × × × ×
150 125 8.5 11 33.25 15.4 30.75 × × × × ×
250 125 7.5 12.5 33.75 16.9 31.25 10.6 11.8 28.75 32.4 18.25
250 125 10 5.9 32.5 10.3 30 17.2 18.4 27.5 25.8 17
Technical Material
200 150 9 9.8 45.5 14.3 43 14.5 15.7 40.5 29.7 30 A
300 150 8 12.9 46 17.3 43.5 17.6 18.8 41 32.8 30.5
300 150 10 7.3 45 11.7 42.5 12.0 13.2 40 27.2 29.5
300 150 11.5 3.7 44.25 8.2 41.75 8.5 9.7 39.25 23.7 28.75
350 150 9 10.8 45.5 15.4 43 15.5 16.7 40.5 30.7 30
350 150 12 1.7 44 6.2 41.5 6.4 7.6 39 21.6 28.5
400 150 10 7.8 45 12.2 42.5 12.5 13.7 40 27.7 29.5
400 150 12.5 0.7 43.75 5.1 41.25 5.4 6.6 38.75 20.6 28.25
450 175 11 × × 11.1 54.5 11.4 12.6 52 19.5 41.5
450 175 13 × × 4.5 53.5 4.3 5.5 51 26.6 40.5
600
600
190
190
13
16
×
×
×
×
6.5
×
61
×
6.8
×
8
×
58.5 22.0 48
× 11.9 46.5 A
■■Manual Trolley
(Unit:mm)
Clearance between trolley and rail
I-beam size TSP TSP/TSG
~500kg ~1t ~2t ~3t ~5t
H B t A B A B A B A B A B B
100 75 5 13.3 12.5 21.1 11.0 × × × × × ×
125 75 5.5 10.8 12.25 19.5 10.75 × × × × × ×
150 75 5.5 10.8 12.25 19.5 10.75 × × × × × ×
180 100 6 11.2 24.5 19.9 23 25.6 18.5 × × × ×
200 100 7 11.1 24 19.9 22.5 25.6 18 × × × ×
150 125 8.5 7.9 35.75 16.7 34.25 22.4 29.75 24.1 27.25 × × A
250 125 7.5 9.4 36.25 18.2 34.75 23.9 30.25 25.6 27.75 35.2 20.25
250 125 10 2.9 35 11.6 33.5 17.3 29 19 26.5 28.6 19
200 150 9 6.8 48 15.6 46.5 21.2 42 22.9 39.5 32.5 32
300 150 8 9.8 48.5 18.6 47 24.3 42.5 26 40 35.6 32.5
300 150 10 4.2 47.5 13 46 18.7 41.5 20.4 39 30.5 31.5
300 150 11.5 0.7 46.75 9.5 45.25 15.2 40.75 16.9 38.25 26.4 30.75
350 150 9 7.8 48 16.6 46.5 22.2 42 23.9 39.5 33.5 32
350 150 12 × × 7.5 45 13.1 40.5 14.8 38 24.4 30.5
400 150 10 4.7 47.5 13.5 46 19.2 41.5 20.9 39 30.5 31.5
400 150 12.5 × × 6.4 44.75 12.1 40.25 13.8 37.75 23.4 30.25
450 175 11 3.6 59.5 12.4 58 18.1 53.5 19.7 51 29.3 43.5
450 175 13 × × 5.3 57 11 52.5 12.7 50 22.3 42.5
600 190 13 × × 7.8 64.5 13.5 60 15.2 57.5 24.8 50
600 190 16 × × × × 3.4 58.5 5.1 56 14.7 48.5
(to be continued)
135
Appendix
■
■Wiring Diagram of Single Speed ER2/ER2SP/ER2SG
230V class , 400V class , 500V class (Plug Connection)
Technical Material
136
230V class , 400V class , 500V class (Direct Connection)
Technical Material
A
(to be continued)
137
Appendix
138
230/460V class (415-460V) (Plug Connection)
Technical Material
A
(to be continued)
139
Appendix
■
■Wiring Diagram of Dual Speed ER2
230V class , 400V clas (Plug Connection)
Technical Material
140
230V class , 400V clas (Direct Connection)
Technical Material
A
(to be continued)
141
Appendix
142
230/460V class (415-460V) (Plug Connection)
Technical Material
A
(to be continued)
143
Appendix
144
■
■Wiring Diagram of Single Speed ER2M
230V class , 400V class , 500V class (Plug Connection)
Technical Material
A
(to be continued)
145
Appendix
146
230/460V class (208-230V) (Plug Connection)
Technical Material
A
(to be continued)
147
Appendix
148
■
■Wiring Diagram of Dual Speed ER2M
230V class , 400V class (Plug Connection)
Technical Material
A
(to be continued)
149
Appendix
150
230/460V class (208-230V) (Plug Connection)
Technical Material
A
(to be continued)
151
Appendix
152
500V class (Plug Connection)
Technical Material
A
153
Appendix
Check Sheet for ER2 Series Electric Chain Hoist Daily Inspection
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 ER2
Motorized Trolley MR2
Geared Trolley TS2 (TSG)
Plain Trolley TS2 (TSP)
■
■Electric Chain Hoist ER2 Daily Inspection
■
■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
Visual inspection To have no peeled off. To be legible clearly.
and labels
Appearance
Visual inspection
entanglement entanglement
Rust, corrosion Visual inspection To have no apparent rust and corrosion
To have no twisting due to capsized Bottom Hook of
Twist Visual inspection
double type
Oiling Visual inspection To be oiled adequately
Check of mark Visual inspection To have no error in indication and marked pitch
A Stretched opening
Abrasion
Visual inspection To have no stretched opening
Visual inspection To have no apparent abrasion
Top Hook, Bottom Hook
part
Executed by Inspector
Checked by Maintenance Engineer
154
Check Sheet for ER2 Series Electric Chain Hoist Daily inspection
DANGER NOTE
•• 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.
Use of the product with abnormality may result in death or serious injury.
■
■Motorized Trolley MR2 Daily Inspection
■
■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
Visual inspection To have no peeled off. To be legible clearly.
and labels
Appearance
Traveling
operation
Operational check operation with no
• All operations to stop when Emergency Stop is
load
pressed
• Electric Chain Hoist not to operate when pressing
the push button while Emergency Stop is pressed
• Electric Chain Hoist to operate normally when A
canceling Emergency Stop
Traveling
When stopping the operation, brake to operate
Brake operation with no
securely and motor to stop immediately.
load
Executed by Inspector
Checked by Maintenance Engineer
■
■Manual Trolley TS2 (TSG/TSP) Daily Inspection
■
■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
Visual inspection To have no peeled off. To be legible clearly.
and labels
Appearance
Traveling
Function/
Executed by Inspector
Checked by Maintenance Engineer
155
Appendix
Check Sheet for ER2 Series Electric Chain Hoist Frequent Inspection
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 ER2
Motorized Trolley MR2
Geared Trolley TS2 (TSG)
Plain Trolley TS2 (TSP)
■
■Electric Chain Hoist ER2 Frequent Inspection
■
■Check result : ○ Good, △ To be replaced (adjusted) next inspection, ×Bad, Needs replacement (adjustment)
Inspection date/result
Category Check item Check method Criteria
/ / / / / /
Preceding
inspection
Pitch Sum of pitches for 5 links must not exceed the limit
Load Chain
Elongation of pitch
measurement value.
Abrasion of wire Diameter
Not to exceed the limit value
diameter measurement
Interval between embossed marks not to exceed
Electromagnetic Body size Top Hook, Bottom
A
• To have no breakage, deformation and foreign
Chain container Visual inspection matter
• Lift must be shorter than the length of the
permissible capacity of the chain container
• To be connected securely
• To have no damage
Cable hanger Visual inspection • To move with a small force
• To be mounted at equal spacing
Messenger wire Visual inspection • To have no slack
• To have no humming noise from motor and
performance
Lifting/lowering
Function/
Executed by Inspector
Checked by Maintenance Engineer
156
Check Sheet for ER2 Series Electric Chain Hoist Frequent Inspection
DANGER NOTE
•• 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.
Use of the product with abnormality may result in death or serious injury.
■
■Motorized Trolley MR2 Frequent Inspection
■
■Check result : ○ Good, △ To be replaced (adjusted) next inspection, ×Bad, Needs replacement (adjustment)
Inspection date/result
Category Check item Check method Criteria
/ / / / / /
Preceding
inspection
Combination Shake the hoist Electric chain hoist to swing right and left swiftly
Appearance
Travel rail (guider) 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
■
■Manual Trolley TS2 (TSG/TSP) Frequent Inspection
■
■Check result : ○ Good, △ To be replaced (adjusted) next inspection, ×Bad, Needs replacement (adjustment)
A
Inspection date/result
Category Check item Check method Criteria
/ / / / / /
Combination Shake the hoist Electric chain hoist to swing right and left swiftly
Appearance
Travel rail (guider) Visual inspection To have apparent deformation and damage
Oiling Visual inspection To be oiled adequately
Executed by Inspector
Checked by Maintenance Engineer
157
Appendix
Check Sheet for ER2 Series Electric Chain Hoist Periodic Inspection
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 ER2
Motorized Trolley MR2
Geared Trolley TS2 (TSG)
Plain Trolley TS2 (TSP)
■
■Electric Chain Hoist ER2 Periodic Inspection (1/2)
■
■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 periodic inspection, also perform
Daily inspection
Preceding
inspection
Oil amount and stain Visual inspection • Check the operating hours with CH Meter.
Operating hours not to exceed the guidelines for
oil change.
• To have no loosened bolts and screws
Appearance Visual inspection
• To have no flaw and damage
Electromagnetic brake
158
Check Sheet for ER2 Series Electric Chain Hoist Periodic Inspection
DANGER NOTE
•• 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.
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)
Inspection date/result
Category Check item Check method Criteria
/ / / / / /
• To have no apparent abrasion, flaw and damage
Visual inspection, • To move smoothly
Bearing
Check CH Meter • Operating hours not to exceed the guidelines for
replacement of bearing
• To have no apparent abrasion, deformation and damage
Load gear, Gear B, Visual inspection,
• Operating hours not to exceed the guidelines for
Pinion Check CH Meter
replacement of bearing
• To have no apparent abrasion, deformation and flaw
Visual inspection,
Friction clutch • Operating hours not to exceed the guidelines for
Check CH Meter
replacement of gears
• To have no apparent abrasion, deformation and flaw
Driving unit
Visual inspection/
• The thickness of sheave pocket must not lower the criteria.
• To have no apparent abrasion, deformation and damage
A
• To have no flaw on sheave pocket due to defective
Idle sheave inspection by
engagement
measurement
• The thickness of sheave pocket must not lower the criteria.
• To have no deformation and crack
Visual inspection,
V ring • Apply grease MOLITHERM No.2 on the V ring at
Check CH Meter
brake cover side at 200 hours of operating hours
• To have no damaged or burnt part
Electrical parts Visual inspection • To be mounted securely
• Number of start no to exceed the guidelines for replacement
• Wiring to be fixed to electrical parts securely
Electrical parts
Executed by Inspector
Checked by Maintenance Engineer
(to be continued)
159
Appendix
Check Sheet for ER2 Series Electric Chain Hoist Periodic Inspection
Check Sheet for ER2 Series Electric Chain Hoist Periodic Inspection (continued)
Code Capacity Lot No. Your CTRL No. Installation date Location Inspection Certification valid thru
Electric Chain Hoist ER2
Motorized Trolley MR2
Geared Trolley TS2 (TSG)
Plain Trolley TS2 (TSP)
■
■Motorized Trolley MR2 Periodic Inspection
■
■Check result : ○ Good, △ To be replaced (adjusted) next inspection, ×Bad, Needs replacement (adjustment)
Inspection date/result
Category Check item Check method Criteria
/ / / / / /
Check theWhen performing periodic inspection, also perform
Daily inspection
Preceding
inspection
A Lifting shaft
Visual inspection/ • To have no apparent deformation and damage
inspection by • Abrasion of outer diameter to be less than limit
measurement value
Visual inspection/ • To have no apparent deformation and damage
Suspender inspection by • Abrasion of outer diameter to be less than limit
measurement value
Gear frame packing Visual inspection • To have no damage, breakage and grease leakage.
Gears, motor shaft Visual inspection • To have no apparent abrasion, deformation and damage
• To have no attachment of paint, oil and foreign matter
Rail surface Visual inspection
• To have no dust and powder due to abrasion
Visual inspection/ • To have no deformation of beam flange such as
Travel Rail
Traveling operation
with a capacity • Stopping distance of traveling to be within 10 %
Brake Visual inspection/ of the traveling distance, when no swinging of a
inspection by load
measurement
Traveling operation
with a capacity • To have no irregular rotating noise
Strange noise Visual inspection/ • To have no motor hamming or scraping noise of a
inspection by brake
measurement
Executed by Inspector
Checked by Maintenance Engineer
160
Check Sheet for ER2 Series Electric Chain Hoist Periodic Inspection
DANGER NOTE
•• 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.
Use of the product with abnormality may result in death or serious injury.
■
■Manual Trolley TS2 (TSG/TSP) Periodic Inspection
■
■Check result : ○ Good, △ To be replaced (adjusted) next inspection, ×Bad, Needs replacement (adjustment)
Inspection date/result
Category Check item Check method Criteria
/ / / / / /
Visual inspection/ • To have no apparent deformation and damage
Wheel inspection by • Abrasion of outer diameter to be less than limit
Body size component
measurement value
Visual inspection/ • To have no apparent deformation and damage
Lifting shaft inspection by • Abrasion of outer diameter to be less than limit
measurement value
Visual inspection/ • To have no apparent deformation and damage
Suspender inspection by • Abrasion of outer diameter to be less than limit
measurement value
• To have no attachment of paint, oil and foreign
Rail surface Visual inspection matter
• To have no dust and powder due to abrasion
Visual inspection/ • To have no deformation of beam flange such as
Travel rail
A
To be mounted securely without looseness and
Rail fixing bolt Visual inspection
come-off
To be mounted securely without looseness and
Stopper Visual inspection
come-off at the rail end
Traveling
operation with a Perform inspection of the items on function/
capacity performance of daily inspection with no load, and
Operational check
Function/performance
Visual inspection/ then perform the inspection of the same items with
inspection by a capacity.
measurement
Traveling
operation with a Perform inspection of the items on function/
capacity performance of daily inspection with no load, and
Strange noise
Visual inspection/ then perform the inspection of the same items with
inspection by a capacity.
measurement
Executed by Inspector
Checked by Maintenance Engineer
161
WARRANTY
KITO Corporation (“KITO”) extends the following warranty to the original purchaser
(“Purchaser”) of new products manufactured by KITO (KITO’s Products).
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, if there is anything within a warranty period stated
by your dealer from whom you purchased the products from the date of purchase
of KITO's Products by Purchaser and provided, further, that defective parts or items shall
be kept for examination by KITO or its authorized agents or returned to KITO's factory or
authorized service center upon request by KITO.
2) KITO does not warrant components of products provided by other manufacturers. However
to the extent possible, KITO will assign to Purchaser applicable warranties of such other
manufacturers.
3) Except for the repair or replacement mentioned in (1) above which is KITO's sole liability and
WARRANTY
purchaser’s exclusive remedy under this warranty, KITO shall not be responsible for any
other claims arising out of the purchase and use of KITO’s Products, regardless of whether
Purchaser’s claims are based on breach of contract, tort or other theories, including claims
for any damages whether direct, incidental or consequential.
W 4) This warranty is conditional upon the installation, maintenance and use of KITO’s Products
pursuant to the product manuals prepared in accordance with content instructions by KITO.
This warranty shall not apply to KITO’s Products which have been subject to negligence,
misuse, abuse, misapplication or any improper use or combination or improper fittings,
alignment or maintenance.
5) KITO shall not be responsible for any loss or damage caused by transportation, prolonged or
improper storage or normal wear and tear of KITO’s Products for loss of operating time.
6) This warranty shall not apply to KITO’s Products which have been fitted with or repaired with
parts, components or items not supplied or approved by KITO or which have been modified
or altered.
This warranty is not applicable in Australia. Please refer to your local supplier for warranty
details when this product is purchased in Australia.
162
Global Website: kito.com
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