KITO RY Series Instrucciones de instalación

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 Wire rope hoist) or consult KITO.

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 Wire rope hoist safely and correctly.

Disassembling and reassembling the rope hoist is an essential part of periodic inspections and repairs. Refer

to the "RY Series Wire Rope Hoist (10t) Owner's Manual" (separate document) and carry out the procedures

correctly.

Safety Precaution

AS-RYL100-MGE-01

RY Series Wire Rope Hoist (10t)

Disassembly and Reassembly Manual

Low Headroom Type:RYL

Safety Precautions

Improper use of the hoist may cause serious accidents resulting in death or severe injury such as drop of lifted

load.

Read this Disassembly and Reassembly Manual carefully before installation, operation and maintenance.

Use the product after understanding the product knowledge, safety information and precautions.

This Disassembly and Reassembly Manual classifies the safety information and precautions into three catego-

ries of "DANGER", "WARNING", and "CAUTION".

Also read the instruction manual of the device associated with the hoist (option, crane, etc.), and follow the de-

scribed contents.

Description of Signal Words

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in

death or severe injury.

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in

death or severe injury.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.

Further, the event described in CAUTION may result in serious accident depending on the situation. All

of these items describe important matters. Please follow the instruction.

After reading, please keep this manual at hand for future use by the user.

Description of Safety Symbols

Prohibited

means "Prohibited" or "You must not do".

Prohibited action is shown in the circle or described near the circle with words and figures.

This Disassembly and Reassembly Manual uses

as the general prohibition.

Mandatory

means "Mandatory Action" or "You must do".

Required action is shown in the circle or described near the circle with words and figures.

This Disassembly and Reassembly Manual uses

as the general instruction.

Safety Precautions

■Disassembly and reassembly (general)

DANGER

Prohibited

• Only competent persons must disassemble/reassemble the rope hoist.

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

Prohibited

• Do not use unauthorized parts for RY Series Wire Rope 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.

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

Prohibited

• Do not disassemble/reassemble the rope hoist while it is being suspended.

When disassembling/reassembling the rope hoist, place it on the floor and perform them on the

workbench.

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

Prohibited

• 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 unexpected

operation.

Prohibited

• Do not use oil such as gear grease and lubricating oil in areas near a fire or spark.

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

Mandatory

• Carry out the installation or removal work of the rope hoist 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 rope hoist after shutting down the

power distribution panel.

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

Mandatory

• 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.

For details, refer to 'Periodic Inspection' in the separated Owner's Manual.

Mandatory

• Tighten the bolts and nuts with the specified tightening torques.

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

Safety Precautions

CAUTION

Mandatory

• When reassembling, follow the instructions below.

• Before reassembly, remove dust and oil on the part to be reused.

• Insert snap rings completely in the groove.

• Assemble the wire rope without torsion.

• When closing the control box cover, be careful so that your finger won't get caught.

Failure to follow these instructions may cause loss of property arising from damaged product or dropped

parts.

Mandatory

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

• Lubricating oil (The type and amount of oil required will vary depending on the specifications and

size of the unit. Refer to "RY Series Wire Rope Hoist (10t) Owner's Manual" (separate document).)

• Packing and the like

• Oil seal

• Snap ring

• Split pin

• O-ring

• Spring pin

Failure to follow this instruction may cause bodily injury or loss of property.

■Before disassembly and reassembly

DANGER

Mandatory

• Disassembling/reassembling improperly causes death or severe injury. Only

competent persons with expertise and experience must disassemble/reassemble the

rope hoist. Alternatively, contact the nearest distributor or KITO.

(Refer to the back of this manual.)

• Perform disassembly and reassembly in correct procedures as described in the manual.

• 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. In addition, the specifications may be changed without prior notice and

may be different from the actual products.

Table of Contents

Safety Precautions ...........................................................2

Table of Contents .............................................................5

Disassembly and assembly tool .....................................6

Major parts in common....................................................7

Name of parts....................................................................8

Disassembly procedure...................................................9

1.Wire rope .....................................................................................9

2.Hook block .................................................................................13

3.Anchorage .................................................................................15

4.Idle sheave ................................................................................17

5.Rope drum .................................................................................18

6.Lifting motor ...............................................................................23

7.Direct limit switch .......................................................................28

8.Control box ................................................................................30

9.Traversing motor........................................................................36

10.Trolley frame ............................................................................41

Reassembly Procedures................................................45

1.Trolley frame ..............................................................................45

2.Traversing motor........................................................................49

3.Control box ................................................................................55

4.Direct Limit Switch .....................................................................60

5.Lifting motor ...............................................................................63

6.Rope drum .................................................................................69

7.Idle Sheave................................................................................74

8.Anchorage .................................................................................75

9.Hook Block.................................................................................77

10.Installing the Wire Rope...........................................................79

Disassemblyandassemblytool

Disassembly and assembly tool

For disassembly and reassembly, prepare the following tools.

No. Tool/jig name Application Icon

Wrench

8mm/10mm/13mm/16mm//17mm/18mm/19mm/24m-

m/30mm/36mm

Bolts and nuts

2Hexagon wrench

3mm/5mm/6mm/8mm/10mm/14mm Socket bolts

3Snap ring pliers S Snap rings (shaft)

4Snap ring pliers R Snap rings (hole)

Socket wrench

8mm/10mm/13mm/16mm/17mm/18mm/19mm/24mm/30m-

m/36mm

Bolts and nuts

6Combination pliers Split pins

7Plastic hammer Removing pinions

8Screwdrivers (+)(-) Screws

9Puller Ball bearings

10 Monkey wrench Bolts and nuts

11 Torque wrench Setting torque Torque

12 Pliers/Needle nose pliers Set pins

13 Nippers Cutting INSULOK

14 Brush Applying lubricating oil

15 Precision screwdriver (athead) Used for lead wire removal

16 Wood block Used as a sleeper

17 Fiber sling Used when lifting rope drum and the like

18 Chain sling Supporting control box unit and the like

19 Eye type bolt M12 Supporting control box unit and the like

20 Round bar Pinions

21 Pin punch Spring pins

22 Spatula Used when removing lubricating oil

23 Gas burner For thread lock removal

24 Socket bolt (complete thread) [M10x50] Used for gear case removal

25 T wrench Socket bolts

●Use the following types of grease.

• ENEOS: BONNOC M260

• ENEOS: Epinoc AP (N) 2

• MOLY PS Grease No.2 or equivalent (Molybdenum disulde No. 3)

• Molybdenum disulde lubricant Molytherm No. 2

●Helpful tools

• Remover. Preparing remover for bearings (for inner race & outer race) or for oil seal allows easy operation.

• Preparing wire for guiding lead wires will be helpful.

Major parts in common

10t Di󰀨erence

Rail width (mm) 150-350 351-500

Lifting range (mm) 9 12 9 12

Frame A, B, C, and D a

Suspension shaft a b Length

Adjusting bolt a b Length

Drive shaft a b Length

Drum a b a b Length

Support shaft a b a b Length

Limit switch bolt a b a b Length

Drum cover a b a b Length

Counter weight a b a b Length

Beam a b a b Length

Traversing motor a

Hook block a

Wire rope a b a b Structure and length

Name of parts

Idle sheave

Guide roller

Adjusting bolt

Suspension shaft

Hook latch

Hook

Upper lower limit switch

Gear box

Rope drum

Motor (for lifting)

Wire rope

Anchorage

Rope guide

Wheel

Direct limit switch

Motor (for traversing)

Counter weight

Control box

Wire rope

Disassembly Procedures

Disassembly procedure

DANGER

Prohibited

• Do not disassemble the rope hoist while it is being suspended.

Doing so may result in death or severe injury due to a falling part.

Place it on the floor and perform maintenance on the workbench.

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

1.Wire rope

■Removing Wire Rope

(1) Remove the snap ring from the anchorage

shaft supporting the Rope End Fixing Part of

the Main Unit.

Snap ring Anchorage shaft

(2) Pull out the anchorage shaft from inside.

Anchorage shaft

Socket

(3) Remove the socket.

(4) Remove the hex nuts (two locations), and then

the Wire Clip at the rope end.

[19mm]

CAUTION

Mandatory

Your hands may be injured.

Wear gloves and the like. Be careful of

fine splits of element wires at the rope

end while working.

Hex nuts

Wire clip

Disassembly Procedures Wire rope

(5) Tap lightly the tip of the cotter, and pull out the

cotter from the socket.

•

If it is di󰀩cult to tap the tip of the cotter, put a

athead screwdriver on the cotter as shown in the

gure and tap the screwdriver with a hammer.

Cotter

Flathead screwdriver

Plastic hammer

(6) Remove the Wire Rope from the socket.

Socket

Wire rope

(7) Pull out slowly the Wire Rope from the Hook

Sheave of the Hook Block.

Wire rope

Hook sheave

(8) Pull out slowly the Wire Rope from the Idle

Sheave.

Idle sheave

Wire rope

(9) Pull out slowly the Wire Rope from the other

Hook Sheave of the Hook Block.

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