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AS No.

ER2-0908-MC-00

ER2 Series Electric Chain Hoist (125kg to 5t)

Disassembly and Reassembly Manual

Safety precaution
This Disassembly and Reassembly Manual includes contents to prevent injury to any person performing
disassembly and reassembly, users, and other persons and damage to property, and to disassemble/
reassemble the electric chain hoist safely and correctly.
Before performing disassembly/reassembly, be sure to read and follow this manual as well as the ER2
Series Electric Chain Hoist Owner's Manual (separate document) since its contents are also important for
disassembly/reassembly.
Disassembly/reassembly of the electric chain hoist are required operations for regular inspection and repair.
Carry out disassembly/reassembly properly in accordance with these manuals.

Persons performing disassembly/reassembly


Disassembly/reassembly shall be performed by a competent person (a person duly authorized by the company as having expertise on the structure
and device of the electric chain hoist) or consult KITO.

1
Safety precaution
Disassembly and reassembly (general)
Danger
Safety precaution

• Only competent persons must disassemble/reassemble the electric chain hoist.


Disassembly/reassembly by anyone other than competent persons may result in death or sever injury.
Prohibited

• Do not use unauthorized parts for KITO Electric Chain Hoist.


Even if the part is an authorized part, it may not be used for a different model.
Use parts correctly in accordance with this manual.
Prohibited
Failure to follow this instruction may result in death or severe injury.

• Do not disassemble/reassemble the Electric Chain Hoist subject to a load.


When disassembling/reassembling an electric chain hoist, place it on a floor and perform them on the
workbench.
Disassembly and reassembly (general)

Prohibited
Failure to follow this instruction may result in death or severe injury.

• Do not perform disassembly/reassembly during conduction.


Failure to follow this instruction may result in death or severe injury due to an electric shock or
Prohibited unexpected operation.

• Do not adjust or disassemble the friction clutch and friction clutch with mechanical brake.
Failure to follow this instruction may result in death or severe injury.
Prohibited If adjustment and disassembly are required, contact Kito.

• Do not use gear oil or grease in areas near a fire or spark.


Failure to follow this instruction may result in fire or severe injury arising from ignition.
Prohibited

• Do not cut, extend, or weld the load chain.


Failure to follow this instruction may result in death or severe injury.
Prohibited

• Carry out the installation or removal work after securing the stable foothold.
Failure to follow this instruction may result in death or severe injury due to falling or dropping.
Mandatory

• Carry out the installation or removal work of the electric chain hoist after shutting down the power distribution
panel.

Mandatory Failure to follow this instruction may result in death or severe injury due to an electric shock.

• When reassembly is complete, perform a function check (preoperational check) to make sure it operates properly.
Failure to follow this instruction may result in death or severe injury.
Mandatory For details, refer to 'Periodic Inspection' in the separated Owner's Manual.

• Tighten the bolts and nuts with the specified tightening torques.
Failure to follow this instruction may result in death or severe injury.
Mandatory

2
Caution
• When reassembling, follow the instructions below.

Safety precaution
• Before reassembly, remove dust and oil on the part to be reused.
• Insert snap rings completely in the groove.
Mandatory
• Assemble the load chain without torsion.
• When setting the plate in the gear case, be careful so that your finger won't get caught.
Failure to follow these instructions may cause bodily injury or loss of property arising from damaged
product or dropped parts.

• When reassembling, replace the following parts with new ones.


• Gear oil (type and required amount of oil vary depending on the specification and main body size.
Refer to page 48.)
Mandatory
• Packing
• Molybdenum disulfide lubricant Molytherm No.2: (specified brand: SUMICO LUBRICANT)
• Oil seal

Before disassembly and reassembly


• Snap ring
• Split pin
• O ring
Failure to follow this instruction may cause bodily injury or loss of property.

Before disassembly and reassembly


Danger
• Only competent persons with expertise and experience must disassemble/reassemble the electric chain hoist.
Alternately, contact the nearest distributor or KITO.
Disassembling/reassembling improperly causes death or severe injury.
Mandatory
• Perform disassembly and reassembly in correct procedures as described in the manual.
• Do not extend the load chain.
• Before reassembling the parts such as gear, clean and remove oil and dust on them.
Especially when a plastic hammer is used, clean them thoroughly so that no chip of the hammer
remains inside.
• Prepare anti-loosening (screw lock) for bolts. Apply it to the specified locations.
• Use only authorized parts for replacement.
Failure to follow these instructions may result in death or severe injury.

Note
The disassembly and reassembly procedures are described based on the representative model. Note that
components may be slightly different for different capacities.
The specifications may be changed without prior notice and may be different from the actual products.

3
Table of Contents

Safety precaution ....................................................................................2

Table of Contents ....................................................................................4


Disassembly and assembly tool ..............................................................5
Table of Contents

Name of parts ..........................................................................................6

Disassembly procedure ...........................................................................8


1 Removing the outer circumference parts ......................................8

2 Removing the controller cover .....................................................9


3 Removing the top hook ..............................................................14

4 Disassembling the gear parts .....................................................15

5 Disassembling the load chain circumference ............................18


6 Disassembling the motor and electromagnetic brake ................19

7 Disassembling the body part ......................................................22


Reassembly procedure .........................................................................24
1 Assembling the body ..................................................................24

2 Assembling the motor and electromagnetic brake .....................27


3 Connecting the motor and body .................................................31
4 Installing the load chain ..............................................................32
5 Assembling the gear parts ..........................................................34
6 Installing the top hook .................................................................37

7 Assembling the controller cover ..................................................39

8 Installing the bottom hook (if removed from the chain) ...............45
9 Oil filling ......................................................................................47

10 Operation check, etc. ................................................................48

4
Disassembly and assembly tools
For disassembly and reassembly, prepare the following tools.

No. Tool name Application Icon


Wrench
1 Bolts and nuts
10mm / 13mm / 17mm / 19mm
Hexagon wrench

Disassembly and assembly tools


2 Socket bolts
4mm / 5mm / 6mm / 8mm / 10mm

3 Snap ring pliers S (Large) (Small) Snap rings (shaft)

4 Snap ring pliers R Snap rings (hole)

5 Socket wrench 10mm Bottom yokes

6 Combination pliers Split pins

7 Adjustable wrench

8 Plastic hammer

9 Screwdrivers (+)(-)

10 Puller Bearing, fan, brake, hub

11 Thickness gauge

12 Torque wrench/nut runner Torque

13 Plier Set pin

● Use the following types of grease.


• JIS K2220 Grease type 1 No.2 for Roller shaft bearing
• Molybdenum disulfide lubricant Molytherm No.2 (Specified brand: SUMICO LUBRICANT)

● Helpful tools
• Remover: Prepare a remover for bearings (for inner race & outer race) and one for oil seal for precise operation.
• Preparing two wooden blocks (used as sleepers) and wire for guiding lead wires will be helpful.

5
Name of parts

Controller cover
The structure and names of parts in
the controller cover are shown on the
Top hook next page for each model.

Packing G

Shaft clip

Gear case
Friction clutch Load gear Oil seal

Load sheave
Name of parts

Body

Plate A
(for Top pin) Top pin
Chain Guide B
Chain Guide A
Limit lever pin
Pinion
Limit lever spring

Limit lever
Bearing holder

Cushion rubber
Bottom yoke

Key B
Bottom hook

Rotor

Motor shaft
V ring
Packing M

Motor Frame with Stator


Hub spring
Electromagnetic brake

Packing B

Brake cover
Fan

Fan cover
6
 Single speed type / Dual speed pole change type

Plate

Controller cover

Limit switch

Packing C

 Dual speed inverter type (Basic main body B/C type)

Name of parts
Plate
Inverter

Controller cover

Braking resistor

Limit switch Resistor cover

Interface board

Packing C

Name plate

 Dual speed inverter type (Basic main body D/E/F type)


Plate

Inverter
Controller cover

Braking resistor
Limit switch
Resistor cover

Interface board

Packing C

Name plate
7
Disassembly procedure

Danger
• Do not disassemble the electric chain hoist while it is being suspended.
Failure to follow this instruction may result in death or severe injury due to dropped parts.
Prohibited Be sure to place the electric chain hoist on a floor and perform the disassembly on the workbench.

The overall disassembly procedure is shown below. Perform disassembly of only necessary parts.

Removing the outer circumference parts


1
(1) Remove the protection wire from
the main body, and remove the
Turn the coupling
pushbutton cord complete set with counter-clockwise
plug 8P. and pull out.
Disassembly procedure

Cable support

(2) Remove the power supply cable Protection


wire
assembly with plug 4P and cable
support arm from the main body.
1
Remove the pushbutton
cord before loosening it.
2
Coupling screw

(3) Remove the chain container from the main


body. Container spring
Removing the outer circumference parts

Socket
bolt
U nut
Chain
container

(4) When disassembling the gear part, remove Oil plug B (for oilhole)
the oil plug (for waste oil hole) and plug
Body
packing from the bottom of the gear case,
and then remove gear oil.
• Check stain and viscosity of the removed oil.
• If any metal powder is discovered, perform a careful
inspection suspecting abnormal wear of the gear or clutch. Gear case
Oil plug Oil plug
(for oil check window) (for waste oil hole)

8
Removing the controller cover
2
 Single speed type / Dual speed pole change type
Caution
• When opening the controller cover, support it with your hand and open it slowly and carefully.
Failure to follow this instruction may cause the controller cover to hit the internal electrical
Mandatory components, resulting in damage.

(1) Loosen the 4 socket bolts and open the


controller cover.
• If it is difficult to open, hammer the cover side gently with a
plastic hammer, as shown to the right.

Disassembly procedure
Controller cover

Socket bolt

(2) Remove the socket bolt (gear case side) Controller cover
securing the cover belt, and remove the
controller cover from the gear case. Socket bolt
(gear case side)
• The controller cover can be removed with the cover belt
attached.

Removing the controller cover


Cover belt

(3) Remove the lead wire and connector Panel plate


Fulcrum pin
between the panel plate and main body,
Remove the lea
and remove the panel plate.
wire in advance
• Loosen the 3 setscrews, and turn the panel plate a little
according to the shape of the fulcrum pin to remove it.
• Make a note of the locations of the lead wire connections
that will be referred to upon reassembly.

Plate screw

(To be continued) 9
Disassembly procedure (continued)

(4) Remove the limit switch as required.


• Remove 4 lead wires (connectors) of the limit switch first.
• Loosen the 3 socket bolts to remove the limit switch
(replace the O ring attached to the shaft with a new part
upon reassembly).
• Be careful when removing the limit switch because it may
Socket bolt
be damaged if handled in a wrong way.

O ring Limit switch

Danger
• Do not disassemble the limit switch.
Replace the limit switch as an
Prohibited assembly. Disassembly causes a
defective operation, and a major
accident may occur.
Disassembly procedure

 Dual speed inverter type (Basic main body B/C type)


Caution
• When opening the controller cover, support it with your hand and open it slowly and carefully.
Failure to follow this instruction may cause the controller cover to hit the internal
electrical components, resulting in damage.
Mandatory
• The controller cover is very hot immediately after operation. Wait until about 30 minutes after
operation.

(1) Loosen the 4 socket bolts and open the


Removing the controller cover

controller cover.
• If it is difficult to open, hit the cover side gently with a
plastic hammer, as shown to the right.

Controller cover

Toothed lock washer


Socket bolt

10
(2) Remove the connector and ground line
connected to the controller cover.
• To remove the ground line, loosen the pan-head machine Braking resistor
screw of the plate side. lead wire

Ground line

Pan-head
machine screw

Controller cover

Disassembly procedure
(3) Remove the socket bolt (gear case side) Controller cover
securing the cover belt, and remove the
controller cover from the gear case.
• The controller cover can be removed with the cover belt Socket bolt
attached. (gear case side)

Cover belt

Ground line

Removing the controller cover


(4) Remove the lead wire and connector Fulcrum pin Plate
between the plate, main body, and inverter,
and remove the plate.
• Loosen the 3 Plate screws, and turn the plate a little
according to the shape of the fulcrum pin to remove it.
• Make a note of the locations of the lead wire connections
that will be referred to upon reassembly.

Plate screw

(To be continued) 11
Disassembly procedure (continued)

(5) Remove the limit switch as required.


• Remove the connector of the limit switch first.
• Remove it carefully by holding the connector of the limit
switch side.
• Loosen the 3 socket bolts to remove the limit switch
(replace the O ring attached to the shaft with a new part
upon reassembly).
Socket bolt
• Be careful when removing the limit switch because it may
be damaged if handled in a wrong way.
O ring Limit switch

Danger
• Do not disassemble the limit switch.
Replace the limit switch as an assembly. Disassembly causes a defective operation, and
Prohibited a major accident may occur.
Disassembly procedure

 Dual speed inverter type (Basic main body D/E/F type)


Caution
• When opening the controller cover, support it with your hand and open it slowly and carefully.
Failure to follow this instruction may cause the controller cover to hit the internal electrical
components, resulting in damage.
Mandatory
• The controller cover is very hot immediately after operation. Wait until about 30 minutes after
operation.

(1) Loosen the 4 socket bolts and open the


controller cover.
• If it is difficult to open, hit the cover side gently with a
plastic hammer, as shown to the right.
Removing the controller cover

Controller cover

Toothed lock washer


Socket bolt

(2) Remove the connector and ground line


connected to the controller cover.

Ground line

Pan-head
machine screw

Braking resistor
lead wire

Controller cover

12
(3) Remove the socket bolt (gear case side) Controller cover
securing the cover belt, and remove the
controller cover from the gear case.
• The controller cover can be removed with the cover belt
attached.
Socket bolt
(gear case side)

Cover belt

Ground line

(4) Remove the lead wire and connector Remove the lead
between the plate, main body, and inverter, wire in advance

Disassembly procedure
and remove the plate and inverter.
• Loosen the 3 Plate screws to remove the plate.
• Loosen the 4 pan-head machine screws of the inverter to
remove it.
• Make a note of the locations of the lead wire connections Pan-head
that will be referred to upon reassembly. machine screw

Plate screw
Plate

Inverter

Removing the controller cover


(5) Remove the limit switch as required.
• Remove the connector of the limit switch first.
• Remove it carefully by holding the connector of the limit
switch side.
• Loosen the 3 socket bolts to remove the limit switch
(replace the O ring attached to the shaft with a new part
upon reassembly). Socket bolt
• Be careful when removing the limit switch because it may
be damaged if handled in a wrong way.

O ring Limit switch

Danger
• Do not disassemble the limit switch.
Replace the limit switch as an assembly. Disassembly causes a defective operation, and
Prohibited a major accident may occur.

(To be continued) 13
Disassembly procedure (continued)

Removing the top hook


3 Remove the top hook first to make it easier to disassemble other parts.

 Removing the top hook (Basic main bodies B,


C, D, and E)
7RSKRRNRU 6KDIWFOLS
(1) Loosen the socket bolt to remove the Plate 3UHVVHU
6XVSHQGHU SDUW
A (for Top pin).

7RSSLQ
(2) Remove the shaft clip in the opposite side.
3ODWH$
• Pull up the shaft clip to remove. IRU7RSSLQ
• If it is difficult to remove, use the longnose pliers to open
the presser part and slide it upward.
Disassembly procedure

6RFNHWEROW
(3) Remove the top pin, and then top hook.

 Removing the top hook (Basic main


body F)
7RSKRRN
7RSKRRN
• For the double chain type, remove the IRUWKHGRXEOHFKDLQW\SH
load chain first. 6ORWWHGQXW
1. Pull out the split pin securing the slotted nut of 6SOLWSLQ &KDLQSLQ
the chain pin, and remove the slotted nut.
2. Loosen the chain pin to remove the load chain. 7RSSLQSOXJ
Removing the top hook

)L[LQJVKDIW
SOXJ /RDGFKDLQ
1. Loosen the 2 socket bolts to remove the Plate A
(for Top pin).
2. Loosen the 2 pan-head machine screws to remove the 7RSSLQ
Plate A (for fixing shaft). 2ULQJ 3ODWH$
3. Pull out Top pin and Fixing shaft. IRU7RSSLQ
• If it is difficult to pull out smoothly, remove
6SULQJORFN
Stator on the opposite side, remove Shaft ZDVKHU
plug, and use a proper jig to pull out Top pin,
hammering with a Plastic hammer. 6WDWRU 6RFNHWEROW
• For disassembly of the stator, refer to page
2ULQJ
19.
4. Remove the 2 O rings each from the top pin and )L[LQJVKDIW
Fixing shaft.
3ODWH$ IRUIL[LQJVKDIW
5. Remove the hook or Connection yoke.

3DQKHDGPDFKLQHVFUHZ

14
Disassembling the gear parts
4
(1) Remove the friction plug from the gear case Friction plug
as required.
Slot for removal
• For the friction clutch with mechanical brake ("friction
clutch with mechanical brake" hereafter) specification, this
operation is not required.

(2) Loosen the 4 socket bolts (5 for F type).


Hammer the gear case gently with a plastic

Disassembly procedure
hammer to remove it.
• Remove it carefully not to pull the lead wire from the motor
or brake.
Socket bolt
• Note that the gear case may come off with the friction
clutch attached to it.

Disassembling the gear parts

(3) Remove Packing G and set pin.


• Be careful not to scratch the gear case junction face.
• For Friction clutch with mechanical brake specification,
remove Spacer M.

Packing G
Set pins (two locations)
Another one exists in the opposite side, Body
on the diagonal line.
Set pin
Another one
Spacer M exists in the
opposite side,
on the diagonal line.
Packing G

(To be continued) 15
Disassembly procedure (continued)

Danger
• Do not disassemble the friction clutch or friction clutch with mechanical brake.
Failure to follow this instruction may result in death or severe injury due to a falling load.
Prohibited

 Double reduction
• The gear configuration as shown to the right is the double
reduction specification. Perform disassembly in the
following steps.
Disassembly procedure

(4) Remove the wave washer and friction clutch )ULFWLRQFOXWFKZLWK


5HOHDVH PHFKDQLFDOEUDNH
from the body.
• For the friction clutch with mechanical brake specification,
release the pawl from the ratchet disc to remove the
friction clutch with mechanical brake.
(There is no wave washer.)
:DYHZDVKHU
6QDSULQJ
)ULFWLRQFOXWFK

(5) Remove the snap ring, and remove the load


gear. /RDGJHDU
Disassembling the gear parts

 Friction clutch with mechanical brake specification (option)


(6) Remove the snap ring, and remove the pawl spring and pawl from the pawl shaft.

Pawl shaft
Danger
• The pawl shaft is fixed to the body with Pawl spring
pawl shaft washer and screw lock. Do
Pawl
not remove it.
Prohibited
Failure to follow this instruction may
cause the pawl shaft to come off and
result in death or severe injury due to a
Snap ring
dropped load.

16
Triple reduction
• The gear configuration with Gear B built in as shown Gear B
to the right is the triple reduction specification. Perform
disassembly in the following steps.

(4) Remove Gear B from the bearing of the )ULFWLRQFOXWFKZLWK 5HOHDVH


gear plate. PHFKDQLFDOEUDNH

Disassembly procedure
(5) Remove the set spring and friction clutch
)ULFWLRQFOXWFK *HDU%
from the body.
• For the friction clutch with mechanical brake specification, :DYHZDVKHU
release the pawl from the ratchet disc to remove the *HDUKROGHU
friction clutch with mechanical brake. SODWH
(There is no set spring.)
6QDSULQJ

(6) Loosen the 3 socket bolts, and remove the


gear plate from the body.
/RDGJHDU

(7) Remove the snap ring, and remove the load

Disassembling the gear parts


gear.

 Friction clutch with mechanical brake specification (option)


(8) Remove the snap ring, and remove the pawl spring and pawl from the pawl shaft.

Pawl shaft
Danger
• The pawl shaft is fixed to the body with Pawl spring
pawl shaft washer and screw lock. Do
not remove it. Pawl
Prohibited
If you do, the pawl shaft will come off,
and a major accident such as death
or serious injury may occur due to a
dropped load. Snap ring

(To be continued) 17
Disassembly procedure (continued)

Disassembling the load chain circumference


5
(1) Remove the stopper and cushion rubber
from the load chain (no load side). Cushion rubber
• For the double chain type, also remove the stopper of the
load side.

Socket bolt

Stopper

(2) Remove the load chain from the body to the


load side.
• Remove the bottom hook as required.
Disassembly procedure

Chain Guide A
Stopper
Cushion rubber
(Remove it in advance.)

(3) Remove the limit lever.


• Remove the limit lever pin, limit lever spring, and then limit
lever.
Disassembling the load chain circumference

/LPLWOHYHUSLQ

5ROOHU
SLQ 6RFNHWEROW

(4) Loosen the 4 socket bolts, and remove /LPLWOHYHU


Chain Guide A from the body. VSULQJ
• Remove the guide roller and roller pin.
*XLGHUROOHU
(Basic main bodies B and C are not provided with Guide
roller.) &KDLQ*XLGH$ /LPLWOHYHU
• Be careful not to lose the roller pin of the guide roller
during operation.

18
Disassembling the motor and electromagnetic brake
6
(1) Loosen the 4 socket bolts, and remove the Socket bolt
fan cover. Fan cover

(2) Remove the snap ring. Snap ring

Fan

Disassembly procedure
(3) Insert the "pawl" part of the puller to the
outer circumference bottom of the fan to Puller
remove the fan.
Blade
• Insert it as close to the blade as possible. Be careful not to
damage the fan. Fan

Disassembling the motor and electromagnetic brake


• Use a three-pawl puller for safer operation.
(Remove it
with the
puller.)

(4) Remove the set pin. Set pin

(To be continued) 19
Disassembly procedure (continued)

(5) Remove the brake cover.


• If it is difficult to remove, hammer it gently with a plastic
hammer to remove.
• Be careful not to hammer it too much to cause
deformation.

(6) Remove the brake wiring.


• Hold the male and female bullet terminals to remove it.
• Be careful not to pull the lead wire causing damage in the
connection with the bullet terminal.
Disassembly procedure

(7) Remove the socket bolt (with spring Bolts (x3)


washer), and remove the brake.
• Make a note of the installation position (lead wire position)
Brake Remove the bullet
of the electromagnetic brake for easy reassembly.
terminal in advance.

Make a note of this position.


Disassembling the motor and electromagnetic brake

Danger
• Do not disassemble the electromagnetic brake.
Failure to follow this instruction may cause death or sever injury due to a falling load.
Prohibited

(8) Check the V ring for any abnormality.


• If the V ring is worn, check for dust entering to the brake.

20
(9) Remove the V ring, snap ring, Packing B,
and hub.
• Be careful not to scratch the motor junction face.
• Some models don't have the snap ring (for hub bottom).
• Remove the hub using a puller.
• Spline hub is also available. 9ULQJ

6SULQJV [ 6QDSULQJIRU
KXEWRS

 Spline hub 0RWRUVKDIW +XE


• First, remove the 3 hub springs installed to the spline +XEVSULQJ
hub and store them. )DQLQVWDOODWLRQ
6QDSULQJ
DUHD
.H\
+XELQVWDOODWLRQ
DUHD
.H\VORW

6SOLQHKXE 6QDSULQJIRUKXE
ERWWRP

Disassembly procedure
3DFNLQJ%
Information
There are two types of Spline hubs; one with a
Hub spring and without it. Check the shape of
Spline hub.
Spline hub with Spline hub without
hub spring hub spring

Disassembling the motor and electromagnetic brake


Hub removal

Puller

Hub

(To be continued) 21
Disassembly procedure (continued)

(10) Remove the 4 socket bolts. Hammer the


stator gently with a plastic hammer to Loosen socket
bolts (x4).
remove it from the body.
• Turn it over so that the stator is facing down and the body
is facing up.
• Use a wooden block for easier operation.
• Handle it carefully not to damage the motor lead wire.

Hammer gently
with a plastic
hammer.

(11) Remove Packing M. Packing M


• Be careful not to scratch the motor junction face. Set pins (two locations)
• Remove the set pin. Another one exists
in the opposite side,
on the diagonal line.
Disassembly procedure

(12) Remove the rotor from the stator. Stator


• Be careful not to scratch the stator inner circumference Rotor (Be careful so that the rotor
and rotor outer circumference. (Remove it gently.) does not interfere with
internal winding.)
Disassembling the body part

Disassembling the body part


7
(1) Remove the 3 socket bolts from the body.
Socket Bearing holder
Bolt

22
(2) Place the body sideways. Hammer the
pinion gently to remove the bearing holder
(including the pinion).

Pinion
(Integrated with the bearing
and bearing holder)

(3) Hammer the load sheave gently as shown


in the figure to remove it.
• Hold the load sheave with hands to prevent it from falling.
• For Basic main bodies B and C, Chain Guide B is not
fixed. Be careful not to damage Chain Guide B.

Disassembly procedure
Load sheave

(4) Remove the 4 screws, and remove Chain


Guide B.
• There is no Pan-head machine screw for Basic main
bodies B and C.

Chain
Guide B

Disassembling the body part


Pan-head
machine screw

500kg or less
Chain Guide B

(5) Remove the snap ring as required, and


Snap ring
remove the bearing and oil seal built into
the body.
• If the oil seal is removed, replace it with a new one upon
reassembly.

Bearing

Oil seal

23
Reassembly procedure

Danger
• Do not perform reassembly using parts exceeding application limits.
• For parts to be replaced with new parts upon reassembly, refer to page 3.
• Tighten the bolts and nuts securely with the specified torques.
Mandatory
• Make sure to perform installation and retaining measure (i.e. opening legs) for the split pin.
• Apply oil, grease, and screw lock as instructed.
Failure to follow this instruction may result in death or severe injury.

Assembling the body


1
(1) Mount the snap ring to Housing A of the
Snap ring
body, and press-fit the bearing and then oil
seal. (Apply oil to Housing A in advance.)
• Make sure that the snap ring is fully inserted to the slot.
• Turn over the body, and press-fit the bearing until it
reaches the snap ring.
Insert a new oil seal.
Reassembly procedure


Housing A
• Apply machine oil on the oil seal, and install it so that the
flat part faces the direction as shown in the figure.
• After installation, apply additional oil on the lip
circumference. Bearing

Oil seal

Cross-sectional shape

Snap ring Bearing


Oil

NEW

Housing A

Oil seal
Assembling the body

NEW

(2) Turn over the body, and press-fit the bearing Housing B Bearing
Oil
until it reaches the snap ring. Oil

• Apply oil on all bearings and insert them using a proper jig. Housing A

24
(3) Install the oil seal with machine oil applied
to the load sheave securely.
• Install it fully so that the flat part faces the direction as
shown in the figure.
Bearing
• After installation, apply additional oil on the lip Oil
circumference.
Oil seal
NEW
Oil

Oil

Bearing installation part


Load sheave
(4) Install the bearing to the load sheave.

Oil

(5) Install Chain Guide B to the body securely.


• Use a Pan-head machine screw to install Basic main
bodies D, E, and F.

Reassembly procedure
• Basic main bodies B and C are fastened together with
Chain Guide A, so no Pan-head machine screw is
required.

Chain
Guide B

Pan-head
machine screw
500kg or less
Chain Guide B

Assembling the body


(6) Insert the load sheave to the body.
• Place the body on a wooden block, and insert the load
sheave fully by using a proper jig not to hit the bearing. Be
careful not to scratch the oil seal during operation.
Bearing
• If it is difficult to insert the bearing, hammer it gently with a Oil
plastic hammer.
• For Basic main bodies B and C, Chain Guide B is not
fixed. Be careful not to damage the load sheave and Chain Oil

Guide B.

(To be continued) 25
Reassembly procedure (continued)

(7) Insert the pinion (with the bearing) to the


bearing holder.
• If it is difficult to insert the pinion, hammer it gently with a
plastic hammer. Pinion

Bearing Oil

Bearing holder

(8) Insert the bearing bearer (integrated with Torque


Socket
the pinion) to the body. bolt
Lock

• Make sure there is no gap between the junction faces of


the bearing holder and body. Spline part
• Be careful not to scratch the oil seal with the gear part of Grease

the pinion.
• Apply screw lock on the 3 socket bolts and tighten them. Bearing
holder
• Apply molybdenum disulfide grease Molytherm No.2 lightly
and evenly onto the spline part of the pinion.

Molytherm No.2 : 2g
Tightening torque M5: 8.4 N·m
Reassembly procedure

M6: 10.8 N·m

Danger
• Apply the specified grease on the spline part of the pinion.
Failure to follow this instruction may cause a falling load due to wear or damage of parts
Mandatory and result in death or severe injury.

(9) Install the guide roller to Chain Guide A with


Assembling the body

the roller pin.


• Guide roller is provided for Basic main bodies D, E, and F.

(10) Install Chain Guide A to the body with the 4


socket bolts. Roller Torque
pin Socket bolt
• Tighten the socket bolts at the following torque.
• Chain Guide B is fastened together for Basic main bodies
B and C.

Tightening torque M6: 10.8 N·m


M8: 37.2 N·m Guide roller Chain Guide A

26
Assembling the motor and electromagnetic brake
2
(1) Press-fit the bearings at 2 locations on the
motor shaft.
Snap ring NEW

Key
(For hub Bearing
(2) Install a Snap ring between the key groove (For rotor)
driving)
and Bearing.
• Install it so that the key slot and snap ring opening are in Rotor
the opposite sides.
• Some models do not require any Snap rings.

(3) Install the key to the motor shaft. Bearing


(For rotor)
• Install it fully into the key slot.

(4) Insert the rotor (including the motor shaft) to Rotor Stator
the stator. (Insert it gently.) (Be careful so that the rotor
does not interfere with intern

Reassembly procedure
• Insert it from the tip of the key installation side of the motor
winding.)
shaft, and insert the bearing to the housing inside the
stator.
• When inserting the rotor, be careful not to scratch the
stator winding.

Assembling the motor and electromagnetic brake

(5) Mount the backing plate on the bottom of Brake lead wire
the motor shaft for supporting the rotor, and
make the motor frame upright.
• Draw the 2 lead wires for braking out from the stator upper
opening.

(To be continued) 27
Reassembly procedure (continued)

(6) Install the hub to the motor shaft. Hub installation cross-sectional view
• If it is difficult to insert, hammer it gently with a plastic
hammer. Snap ring Motor Snap Motor
• Press down until the slot to which a snap ring is mounted shaft ring shaft
Hub
is visible. Hub
Snap ring Key Key
(for hub
bottom)
With snap ring Without snap ring
for hub bottom for hub bottom

NEW
(7) Install a snap ring to the hub top. Snap ring
• Make sure that the snap ring rotates smoothly. Install after
positioning the hub.
Use a
cylindrical jig
Hammer it gently
Danger with a plastic
Hub
hammer
• Install the key and snap ring securely.
Failure to follow this instruction may
Mandatory result in death or severe injury.
Reassembly procedure

For Spline hub


• After installing the spline hub to the motor shaft, install Motor shaft Hub spring
the 3 hub springs to the correct positions as shown to the Snap ring
right.

Caution Key slot

• Make sure that the hub spring is Spline hub


Assembling the motor and electromagnetic brake

installed to the spline hub correctly.


• Check the shape of the spline hub.
Mandatory Spline hub
Spline hub with Spline hub without
hub spring hub spring

Failure to follow this instruction may


cause abnormal sound, vibration or
damage of property.

28
(8) Install the electromagnetic brake with the 3       Tighten
Torque with
socket bolts. (three) bolts
• Check the orientation of the electromagnetic brake. Refer
Connect the
Brake bullet terminal
to the position data recorded upon disassembly. (Disassembly after installation
• Check that the lead wire is not too long or too short for is prohibited.) is complete.
connection.
• Perform wire connection properly by referring to the figure.

Tightening torque M6: 10.8 N·m


M8: 37.2 N·m
Spring lock washer : Yes

Align orientation to the position in the note.

(9) Install the V ring. Brake cover side


• Insert the V ring to the motor (pinion) shaft. V ring
• Insert the V ring in the orientation as shown in the figure
until it touches the groove of the motor shaft.
Brake Cross-sectional shape

Reassembly procedure
(10) Install the set pin, and then install the brake Brake cover
cover.
• The center hole will slide against the V ring, so make sure
to apply Molytherm No.2.

Molytherm No.2 : Several grams Assembling the motor and electromagnetic brake
Set pin Packing B
NEW

Grease

Brake cover
(Apply Molytherm No.2
on the contact face
with the V ring before
installing.)

(To be continued) 29
Reassembly procedure (continued)

(11) Install the fan.


• If the fit is hard and it is difficult to install, set a proper jig
and hammer it gently with a plastic hammer.
• Be careful not to hammer the motor shaft or fan directly.
(Use the jig.)

Fan

Motor shaft

(12) Install a snap ring. Snap ring


NEW
Reassembly procedure

Fan

(13) Install the Fan cover to the Stator with the Bolts (x4) Torque

Socket bolt.
Fan cover
• Be careful of the orientation of the fan cover (align it with
the set pin).
Assembling the motor and electromagnetic brake

Tightening torque M5: 4.7 N·m


M6: 7.9 N·m

Align with
2 set pins.
Caution
• When installing the fan cover, observe
the tightening torque value to tighten the
socket bolt.
Mandatory
Failure to follow this instruction may
cause damage or crack of the fan
cover.

30
Connecting the motor and body
3
(1) Install the 2 set pins and Packing M to the
motor. 3DVVWKURXJKWKH
ZLULQJKROHRIWKHERG\

%RG\
(2) Mount the body on the motor. 3DVVWKH
• Mount it so that the Chain Guide A side of the body is in OHDGZLUH &KDLQ*XLGH$
the name plate side of the motor. 3DFNLQJ0
• Be careful so that the lead wire won't get caught between
NEW
the body and stator.
• Fit the spline hole at the pinion bottom to the spline shaft
at the motor shaft tip by rotating the pinion.
• Hammer the motor gently with a plastic hammer to 6WDWRU
connect the motor without any gap.
• Apply screw lock on the 4 socket bolts, and install the
motor and body. 1DPHSODWH
6RFNHWEROWV [
7RUTXH 6HWSLQ
Tightening torque M6 : 10.8 N·m /RFN 3XVKLQDQRWKHURQHLQWKH
RSSRVLWHVLGHRQDGLDJRQDOOLQH

Reassembly procedure
M8 : 34.3 N·m
M10 : 39.2 N·m
M12 : 58.8 N·m

(3) Install the limit lever to Chain Guide A at the


body bottom. /HDGZLUH
• Fit the limit lever to Chain Guide A, insert the lever pin with
the limit lever spring installed, and align it with the hole /LPLWOHYHU
position of Chain Guide A to install it. SLQ

/LPLWOHYHU
Connecting the motor and body
VSULQJ

/LPLWOHYHU

(To be continued) 31
Reassembly procedure (continued)

Installing the load chain


4 Rotate with hand.

(1) Install the load chain so that the welded


Load side
part comes outside of the load sheave. No load side
(insert from the
• Insert it to the main body from the horizontal link (or horizontal link) Draw out chain
vertical link for capacity over 3t) Insert chain.
Chain welded part

(2) Insert the load chain from the load side


(bottom hook side) of Chain Guide A, wind
it up by rotating the load sheave manually to
guide it out to the load chain outlet (no load
side).
• When it engages with the load sheave, tilt the body to the
no load side, and rotate the load sheave manually to guide
Reassembly procedure

the load chain out without getting it entangled. For single chain

For double chain

Installation for the double chain type Rotate


• Insert the load chain from the no load side of with hand.
Chain Guide A, wind it up by rotating the load
sheave manually to guide it out to the load chain No load side
outlet (load side).
Load side (insert from the
Draw out vertical link)
chain Chain welded part
Insert chain.
Installing the load chain

Danger
• Insert the load chain so that the welded part comes outside when it is engaged with the load
sheave.

Mandatory Failure to follow this instruction may cause defective operation or abnormal wear and
result in severe injury due to a falling load.

32
(3) Re-check the orientation of the load chain,
and check for any twist.

(4) Install the stopper and cushion rubber or


chain spring to the 3rd link from the end of
the no load side load chain as they were No load side chain
before disassembly.
Cushion rubber

Stopper

Reassembly procedure
Installing the load chain

(To be continued) 33
Reassembly procedure (continued)

Assembling the gear parts


5
Double reduction

• Mechanical brake specification (option) Pawl shaft


NEW
(1) Insert the pawl spring and pawl to the pawl Pawl spring
shaft, and lock them with a snap ring. (Replace it with
a new part if worn.)
• Check the orientation so that the pawl is in engagement
with the ratchet disc. Pawl

NEW
Snap ring

(1) Insert the load gear to the load sheave, and )LJ$2ULHQWDWLRQRIWKHORDGJHDU
6SOLQH 3LQLRQ )ULFWLRQFOXWFKZLWK
lock it with a new snap ring. %RVVSDUW PHFKDQLFDOEUDNH
%HDULQJVLGH /RDGVKHDYH
• Make sure that the snap ring is inserted fully.
KDVLQGHQWDWLRQ 6QDSULQJ
• For the orientation of the load gear to install it correctly,
refer to Figure A.
/RDG
JHDU
Reassembly procedure

:DYHZDVKVHU
6QDSULQJ
NEW
)ULFWLRQFOXWFK

(2) Install the friction clutch, and mount the


wave washer.
/RDGJHDU

%HDULQJ

3LQLRQ
Assembling the gear parts

Friction clutch with mechanical brake


specification (option)
• Install the friction clutch with mechanical brake while
checking the engagement between the ratchet disc and Rotational direction
pawl. when hoisting
(No wave washer available.)

34
Danger
• Do not adjust the friction clutch or friction clutch with mechanical brake.
Failure to follow this instruction may result in death or severe injury.
Prohibited

Triple reduction
(1) Insert the load gear to the load sheave, and )LJ$2ULHQWDWLRQRIWKHORDGJHDU
6SOLQH 3LQLRQ )ULFWLRQFOXWFKZLWK
lock it with a new snap ring. %RVVSDUW PHFKDQLFDOEUDNH
%HDULQJVLGH /RDGVKHDYH
• For the orientation of the load gear to install it correctly,
KDVLQGHQWDWLRQ 6QDSULQJ
refer to Figure A.

/RDG
JHDU

*HDU% )ULFWLRQFOXWFK
*HDUKROGHUSODWH
:DYH
6RFNHWEROW ZDVKHU
[
(2) Place the set pin to the body, and install the 7RUTXH

gear holder plate with the 3 socket bolts.


6QDSULQJ

Reassembly procedure
Tightening torque M6: 10.8 N·m NEW

M8: 37.2 N·m


Spring lock washer : Yes

/RDGJHDU

(3) Install the friction clutch, and mount the


wave washer.

3LQLRQ

Assembling the gear parts


(4) Insert Gear B to the bearing of the gear
plate.

For the friction clutch with mechanical brake


specification (option), install additional
parts as in the case of the double reduction
specification.
(Refer to the previous page.)

(To be continued) 35
Reassembly procedure (continued)

(3) Press-fit the bearing for the pinion to the Bearing


gear case using a proper jig. Oil seal

Cross-sectional
shape
Bearing
(triple reduction
(4) Install the oil seal to the gear case using a specification
proper jig. only)

(5) Install the friction plug by hammering it with


a plastic hammer.

Friction plug

Torque

Socket bolt (x4)


Install it while
* (x5) for F type hammering
(6) Mount a new Packing G on the body, and around the
install the gear case by hammering it with a pin charging
plastic hammer. part gently.
Lead wire
Reassembly procedure

• At the same time, install the 2 set pins.


• Be careful so that the lead wire won't get caught. Gear case
• Temporarily install the gear case with the 4 socket bolts
(5 for F type), and tighten them sequentially, alternating
diagonally.
• For Friction clutch with mechanical brake specification,
install Spacer M with Packing G between Gear case and NEW

the body.
Packing G
Set pins (two locations) Spacer M
Another one exists
in the opposite side,
on the diagonal line. Set pin (x2)
(Another one exists in the
opposite side, on the
Packing G diagonal line.)
Body
Assembling the gear parts

Tightening torque M6: 10.8 N·m


M8: 37.2 N·m
Toothed lock washer : Yes

(7) Install the limit switch from the gear case


side (inside of the panel plate) (if removed).
• Replace O ring attached to the shaft of the limit switch with
a new one and apply oil to it.
• Align the shaft salient of the limit switch to the notch of the
Install it in advance.
lever pin when inserting it. Torque
• Insert it gently not to scratch the O ring.
• Perform wiring of the limit switch. Socket bolts
(x3)
After installation, move the limit lever manually and check if
it performs follow-up operation.
Oil Limit
NEW
Tightening torque M6: 10.8 N·m Apply oil. switch
Spring lock washer : Yes

36
Installing the top hook
6
Assembling the top hook (Basic main bodies
B, C, D, and E)
Top hook or Shaft clip
(1) Install the top hook by inserting the 2 top Suspender
pins.

Top pin
(2) Install Plate A (for Top pin) with Socket bolt
(1 piece) and Shaft clip on the opposite Plate A
side. (for Top pin)
• Fix and lock the top pin with the plate A (for Top pin) and
shaft clip.
• Push the shaft clip fully until it clicks.

Tightening torque M6: 10.8 N·m


Spring lock washer: Yes Socket bolt
Torque

(3) When connecting to Motorized trolley, install


Suspender instead of Top hook.

Reassembly procedure
Assembling the top hook (Basic main
body F)
(1) Install the 2 O rings to the top pin and fixing Top hook
shaft. Top hook
• Apply Molytherm No.2 around O ring.

Molytherm No.2: Several grams


(2) Install the top hook or suspender while
inserting Top pin. Top pin plug
(3) Install Plate A (for Top pin) with the 2 socket
Fixing shaft
bolts. plug Grease
Tightening torque M6 : 10.8 N·m
Spring lock washer: Yes Top pin
Installing the top hook
(4) Insert the fixing shaft plug.
(5) Install the Plate A (for fixing shaft) with the 2 O ring Plate A
pan-head machine screws. (for Top pin)
Tightening torque M5 : 8.4 N·m Spring lock
(6) Insert the shaft plug and O ring, and fixing washer
shaft plug and O ring to the hole of the top pin Socket
and fixing shaft of the stator side. Stator bolt
If they were removed during disassembly, insert
O ring

them before connecting the motor and body as
Grease
described on page 26.
Fixing shaft
Plate A (for fixing shaft)

Pan-head machine screw

(To be continued) 37
Reassembly procedure (continued)

Double chain
When the reassembly of the top hook of Basic
main body E/F is complete, install the load chain.
(1) Insert Load chain from the load side of Chain
Guide A through Limiting plate, Chain spring,
Bottom hook, and Chain spring in that order.
• Make sure Load chain is not twisted 8th or 7th link
(2) Install Stopper on the specified number of the stopper
link from the Load chain terminal.
• Link number where Stopper is installed Limiting plate
2.8t and 3t: 8th link
Chain spring
4.8t and 5t: 7th link of the load side
(3) Install the load chain to the connection yoke
while inserting the chain pin.
• Check Load chain for any twist.

(4) Tighten the slotted nut to the split pin slot of


the chain pin, and insert the split pin. Cushion
rubber
(5) Bend the split pin to lock.

7RSKRRN
6SOLWSLQ

6ORWWHGQXW
Reassembly procedure

&KDLQSLQ
/RDGFKDLQ

&RQQHFWLRQ\RNH

Danger
Installing the top hook

• Make sure Load chain is not installed with a twist.


Failure to follow this instruction may cause a falling load due to broken load chain or
Prohibited damaged parts, resulting in death or severe injury.

38
Assembling the controller cover
7
 Single speed type
Caution
• Be careful so that your finger won't get caught by the panel plate.

Mandatory

(1) Fix the plate securely with the 3 setscrews. Draw out from
• Align the elongate hole of the plate to the fulcrum pin head the notch of
of the gear case, and rotate it slightly for position it. the plate.
Fulcrum pin

Reassembly procedure
Plate screw

(2) Reconnect the motor lead wire. Connect to


• Check the wire connection by looking at the connecting each terminal. Wiring hole inside
diagram. The connecting diagram is attached on the inside the gear case
of the controller cover.

Assembling the controller cover

From motor

(3) Install the cover belt to the controller cover (if Controller cover
removed).
• Be careful so that the cover suspender faces the direction
as shown in the figure.

Cover belt

Put the yoke in this orientation.

(To be continued) 39
Reassembly procedure (continued)

(4) Install the cover belt to the gear case. Socket bolt
• Pass the cover belt through Controller Cover Packing C. (gear case side) Plain washer
• Tighten the socket bolt while holding the controller cover Controller
with hands. Cover Packing C
Cover belt
* For B type, install the cover belt before fixing Controller
the plate. cover

(5) Install the controller cover with 4 socket


Controller cover
bolts (spring lock washer required). packing C
NEW
Tightening torque M5: 8.4 N·m
M6: 10.8 N·m
Spring lock washer : Yes

Controller cover

Spring lock washer


Reassembly procedure

Socket bolt
Torque

(6) Insert the pushbutton cord plug to the


socket, and install the protection wire to the 6RFNHW
body.
• Install Cable Support L with the protection wire attached to 3XVKEXWWRQ &DEOH
the body with the 2 pan-head machine screws. FRUG VXSSRUW

3XVKLQWKH
FRXSOLQJDQGWXUQ
FORFNZLVH 3URWHFWLRQ
 ZLUH
Assembling the controller cover


(7) Insert the power cable plug to the socket. &RXSOLQJVFUHZ
&DEOHVXSSRUWDUP

7RUTXH

(8) Install the cable support arm to the body 3DQKHDG


PDFKLQH
with the 2 pan-head machine screws.
VFUHZV [

3XVKLQWKHFRXSOLQJ
DQGWXUQFORFNZLVH

(9) Install the chain bucket to the main body.


• For information on how to install various types of buckets, refer to ER2 Series Electric Chain Hoist Owner's Manual (separate
document).

40
 Dual speed inverter type (Basic main body B/C type)
Caution
• Be careful so that your finger won't get caught by the panel plate.

Mandatory

(1) Fix the plate securely with the 3 setscrews. 'UDZRXWIURPWKHQRWFK


• Align the elongate hole of the plate to the fulcrum pin head RIWKHSODWH
of the gear case, and rotate it slightly for position it. 3ODWH
)XOFUXPSLQ

3ODWHVFUHZ

Reassembly procedure
(2) Reconnect the motor lead wire. Connect to
• Check the wire connection by looking at the connecting each terminal. Wiring hole inside
diagram. The connecting diagram is attached on the inside the gear case
of the controller cover.

From motor
Assembling the controller cover

(3) Install the cover belt to the controller cover (if Controller cover
removed).
• Be careful so that the cover suspender faces the direction
as shown in the figure.

Cover belt

Pan-head Ground line


machine screw

(To be continued) 41
Reassembly procedure (continued)

(4) Install the cover belt to the gear case. Socket bolt Torque

• Pass the cover belt through Controller Cover Packing C. (gear case side) Controller cover
• Tighten the socket bolt while holding the controller cover Spring lock packing C
with hands. washer
Plain washer
Tightening torque M6: 10.8 N·m Cover belt
Spring lock washer : Yes
Plain washer : Yes
Controller cover
* For B type, install the cover belt before fixing
the plate.

(5) Connect the wiring to Controller cover


connector, and connect the ground line to
the ground terminal of plate. %UDNLQJUHVLVWRU
OHDGZLUH
Reassembly procedure

*URXQGOLQH

3DQKHDG
PDFKLQHVFUHZ

&RQWUROOHUFRYHU
Assembling the controller cover

(6) Install the controller cover with 4 socket Controller cover


bolts (toothed lock washer required). packing C
Toothed lock
Tightening torque M5: 8.4 N·m washer
M6: 10.8 N·m
Toothed lock washer : Yes

Controller cover

Socket bolt
Torque

42
 Dual speed inverter type (Basic main body D/E/F type)
Caution
• Be careful so that your finger won't get caught by the panel plate.

Mandatory

(1) Fix the plate securely with the 3 setscrews 5HPRYHWKH


and the inverter with the 2 pan-head OHDGZLUH
LQDGYDQFH
machine screws.
• When installing the inverter, be careful so that the lead
wire won't get caught.
3DQKHDG
PDFKLQHVFUHZ

3ODWHVFUHZ
3ODWH

Reassembly procedure
,QYHUWHU

(2) Reconnect the motor lead wire. Connect to


• Check the wire connection by looking at the connecting each terminal. Wiring hole inside
diagram. The connecting diagram is attached on the inside the gear case
of the controller cover.

From motor Assembling the controller cover

(3) Install the cover belt to the controller cover (if Controller cover
removed).
• Be careful so that the cover suspender faces the direction
as shown in the figure.

Cover belt

Pan-head Ground line


machine screw

(To be continued) 43
Reassembly procedure (continued)

(4) Install the cover belt to the gear case. Socket bolt Torque
• Pass the cover belt through Controller Cover Packing C. (gear case side)
• Tighten the socket bolt while holding the controller cover Spring lock
Controller cover
with hands. washer
packing C
Plain washer
Tightening torque M6: 10.8 N·m
Spring lock washer : Yes Cover belt
Plain washer : Yes

* For B type, install the cover belt before fixing Controller cover
the plate.

(5) Connect the wiring to Controller cover


connector, and connect the ground line to
the ground terminal of Plate.
Reassembly procedure

*URXQGOLQH
3DQKHDG
PDFKLQHVFUHZ

%UDNLQJ
UHVLVWRU
OHDGZLUH

&RQWUROOHUFRYHU
Assembling the controller cover

(6) Install the controller cover with 4 socket Controller cover


bolts (toothed lock washer required). packing C

Tightening torque M5: 8.4 N·m


M6: 10.8 N·m
Toothed lock washer : Yes

Controller cover

Toothed lock
washer
Socket bolt
Torque

44
Installing the bottom hook (if removed from the chain)
8
Caution
• Check the load side of the load chain to install the bottom hook.

Mandatory

Installing single type Bottom hook 2t or more


• For 2t or more, pass the limiting plate and chain spring Limiting plate
through before installing the bottom hook.
Chain spring

(1) Apply grease on Thrust bearing. Grease

Apply grease Cushion rubber


(2) Face the smaller internal diameter of Thrust after cleaning
the interior so Nut
bearing to the A side (upper side) of Thrust that no dust
Torque

Lock
Stopper to incorporate it into Hook. exists.
Thrust collar A
(3) Use 2 Thrust Stoppers to pinch the hook Thrust bearing

Reassembly procedure
neck and incorporate Thrust collar A as The smaller internal diameter
to cover the outer circumference of Thrust of Thrust bearing is facing
Secure with Thrust Stopper A side
Stopper A. a double
wrench Assemble after applying
(4) Assemble the incorporated Hook and the grease. Grease

terminal link of Load chain as to nip them Thrust Stopper A


with Bottom yoke.
Details of assembling Thrust bearing

Thrust collar A
(5) Put through a bolt, apply Screw lock before Thrust Stopper A
tightening.
Tightening torque M6: 19.6 N・m Thrust bearing

M8: 34.3 N・m Bottom yoke


M10: 63.7 N・m Smaller internal diameter
M12: 63.7 N・m
Installing the bottom hook
Spring lock washer: Yes

(6) Check if Hook rotates smoothly.

Bigger internal diameter

Danger
• Make sure that Thrust collar A, Thrust Stopper A, and Thrust bearing are incorporated correctly as
shown in the figure above.

Prohibited Failure to follow this instruction may result in death or severe injury due to a falling load.

(To be continued) 45
Reassembly procedure (continued)

Installing double type Bottom hook Fix with Idle sheave


a double spanner
(1) Apply grease to Thrust bearing. Grease

Bottom shaft assemb


(2) Face the smaller internal diameter of Thrust
bearing to the A side (upper side) of Thrust
Stopper to incorporate it into Hook.
(Refer to the details of assembling Thrust Bottom yoke
bearing) Thrust collar A

(3) Use 2 Thrust Stoppers to pinch the hook


Nut
neck and incorporate Thrust collar A as to Torque

cover the outer circumferential of Thrust Lock

Thrust Stopper A
Stopper A. Thrust bearing
(Refer to the details of assembling Thrust The smaller internal d
bearing) of Thrust bearing is fa
Thrust Stopper A side

(4) Apply grease to the Bottom shaft assembly Grease

and Idle sheave assembly.


Reassembly procedure

(5) Incorporate the Bottom shaft assembly


into the incorporated Hook and Idle sheave
assembly as to nip them with Bottom yoke.

(6) Put through a bolt, apply Screw lock before


tightening.
Tightening torque M10: 63.7 N・m
M12: 63.7 N・m
Spring lock washer: Yes

(7) Check if Hook rotates smoothly.


Installing the bottom hook

Danger
• Make sure that Thrust collar A, Thrust Stopper A, and Thrust bearing are incorporated correctly as
shown in the figure above.

Mandatory Failure to follow this instruction may result in death or severe injury due to a falling load.

46
Oil filling
9
Danger
• Use genuine gear oil.
If you inject (or mix) any oil other than genuine oil, a major accident such as death or
Mandatory serious injury may occur due to a dropped load.

(1) Tighten the oil plug (for waste oil hole) with OIL plug B
a new packing securely. (for oilhole)

Oil plug
(for oil check window)
Oil plug
(for waste oil hole)

Reassembly procedure
(2) Inject gear oil from the oil plug B Oil plug B
(for oilhole). oil (for oilhole)
ar
• Inject a proper quantity of oil by referring to the table on Main body Ge Packing
the next page.
Inject oil up to the proximity of the oil plug (for oil check
window).
Packing

Oil plug Packing


(for oil check window)
Oil plug
(for waste oil hole) Oil filling

(3) Place a new packing on the oil plug B (for


oilhole) and tighten it.

Use Kito genuine gear oil. (Refer to the oil


quantity on the next page.)

* The friction clutch with mechanical brake specification has a


sticker that indicates “With mechanical brake" (orange letters
on a black background) to the right side seen from the main
body controller cover.

(To be continued) 47
Reassembly procedure (continued)

Danger
• Use the gear oil that comply with the specifications.
If you use different oil, a major accident such as death or serious injury may occur due to a
Mandatory dropped load.
The types of oil used are different for the friction clutch and friction clutch with mechanical
brake.

Oil types and oil quantity for one unit of main body

Gear oil amount Oil


Specification Code Oil type
(ml) manufacturer

ER2-001H, 001IH, 003S, 003IS, 001HD, 003SD 520


ER2-003H, 003IH, 005L, 005IL, 005S, 005IS, 003HD,
540
005SD, 005HD
ER2-010L, 010IL, 010SD, 010LD, 020C, 020IC, 020CD 620
Friction clutch KITO genuine oil KITO genuine oil
ER2-010S, 010IS 680
ER2-015S, 015IS, 020L, 020IL, 015SD, 015LD 1300
ER2-020S, 020IS, 030S, 030IS 1900
ER2-025S, 025IS, 050S, 050IS 1900
Reassembly procedure

ER2-001H, 001IH, 003S, 003IS, 001HD, 003SD 680


ER2-005L, 005IL, 005SD 820
ER2-003H, 003IH, 005S, 005IS 900
Friction clutch
ER2-010L, 010IL, 010SD, 010LD, 020C, 020IC, 020CD 1050
with mechanical KITO genuine oil KITO genuine oil
ER2-010S, 010IS 1100
brake
ER2-015S, 015IS, 020L, 020IL, 015SD, 020LD 2000
ER2-020S, 020IS, 030S, 030IS, 030SD 2500
ER2-025S, 025IS, 050S, 050IS, 025SD, 050SD 2700

* Do not top up on old oil. Use entirely new oil.


Operation check, etc.

Operation check, etc.


10
After disassembly and reassembly, check the following items.
(1) Check for parts that are left unused in reassembly.
• If any part is left, perform disassembly and reassembly again for correct assembly.

(2) Perform daily inspection.


• For details, refer to "Daily inspection" in ER2 Series Electric Chain Hoist Owner's Manual (separate document).

(3) After checking that no error occurs with no load, perform an operation test with a rated
load.
• For details, refer to "Regular inspection" in ER2 Series Electric Chain Hoist Owner's Manual (separate document).

48
URL. http://www.kito.co.jp