KITO RY Series Installation instructions
1
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
2
Safety Precautions
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.
3
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.
4
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.
5
Table of Contents
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
6
Disassemblyandassemblytool
Disassembly and assembly tool
For disassembly and reassembly, prepare the following tools.
No. Tool/jig name Application Icon
1
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)
5
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 disulde No. 3)
• Molybdenum disulde 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.
7
Major parts in common
Major parts in common
10t Dierence
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
8
Name of parts
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
9
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
10
(5) Tap lightly the tip of the cotter, and pull out the
cotter from the socket.
•
If it is dicult 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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