KITO CX005, CX003 Owners/operators Manual And Safety Instructions
OM-CX1ZZZ-CEE-02
/005
Original Instruction
This equipment should not be installed,operated or
maintained by any person who has not read and
understood all the contents of this manual. Failure to
read and comply with the contents of this manual can
result in serious bodily injury or death, and/or property
damage.
Issued August, 2011. Revised November, 2019 (Revision 05)
Table of Contents
Introduction ........................................................................................................ 2
Intended Purpose .............................................................................................. 2
Safety precautions ............................................................................................ 3
Chapter 1 Operation ......................................................................................... 5
Chapter 2 Inspection ...................................................................................... 17
Chapter 3 Troubleshooting ............................................................................ 33
WARRANTY ...................................................................................................... 40
Introduction
This Instruction Manual is intended for those operating the KITO model CX chain hoist. Separate document;
Disassembly/Reassembly Manual is also available for the relevant person (Note). Please contact KITO or your dealer
for the material.
Note : A person who is authorized by the business entity as having thorough knowledge and expertise on the
structure and devices of a chain hoist, or a person with similar thorough knowledge and expertise and capable of
understanding periodic inspection, and Disassembly/Reassembly Manual.
When these conditions are not satisfied, consult KITO or your dealer, or request maintenance.
Intended Purpose
This manual chain hoist is designed and manufactured to lift and lower a load manually within a normal work
environment. Movement in the horizontal direction is also enabled by combining with a trolley.
- Reproduction of this document, in whole or in part, without prior consent is prohibited.
- This document is subject to change without prior notice.
- This document was prepared with the utmost care. However, the customer is kindly requested to inform us of
any question, error or unclear point included in the document.
2
Safety precautions
Improper use of this manual chain hoist may result in danger, such as falling of the lifted load. Before installation,
operation, maintenance and inspection, be sure to read this manual carefully, comply with its instructions and operate
the product correctly. Prior to operation, all the safety and operating information, and safety precautions must be fully
understood. In this manual, precautions are classified into three categories: "Danger", "Warning" and "Caution". In
addition, read the instruction manuals of the equipment (such as trolley) related to the operation of the manual chain
hoist, and follow the instructions.
Description of signal words
DANGER indicates an imminently hazardous situation, which, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury.
However, even CAUTION situations may result in serious injury or death depending on circumstances.
Ensure all precautions are recognized as important and complied with. After reading this manual, ensure it
remains readily available for users.
Description of safety symbols
Means a "Prohibited" action or a thing "You must not do".
Prohibited
Mandatory
Specific prohibited actions are shown in the safety symbol or described near the same.
Means a "Mandatory Action" or "Do as indicated".
The specific required action is shown in the safety symbol or described near the same.
Disclaimer
- KITO shall not be liable for any damage incurred due to fire, natural disasters such as earthquake and lightning,
actions of a third party, other accidents, intentional or accidental improper operation or misuse by customer, and
operation under conditions exceeding the operating environmental conditions.
- KITO shall not be liable for any incidental damage incurred, due to the use or inability to use this product (loss of
business profit, interruption of business, and damage to the lifted load).
- KITO shall not be liable for any damage incurred due to negligence concerning the instructions in this manual, or
operation under a condition exceeding the range defined in the specifications.
- KITO shall not be liable for any damage arising from malfunction due to the combination of the chain hoist used
with other equipment, unrelated to KITO.
Restricted usage
- The product is intended for use only in the region or the country where it was purchased. Due to the differences in
regulations and standards, it is not for use outside of the region or the country where it was purchased.
- This product is not designed nor manufactured to transport people. Do not use the product to transport people.
- This product is designed and manufactured for the purpose of lifting and lowering a load manually under normal
operating environmental conditions. Do not lift or lower loads using electric power. Movement in a horizontal
direction is enabled by combining with a trolley. Decide on and judge the appropriateness of use in accordance
with the intended purpose of the product design and manufacture.
- Since this chain hoist is used under diverse conditions, the customer should judge whether the product would be
used appropriately by carrying out analysis and tests if necessary. Ensuring the product performance and safety
are the responsibility of the person who judges the appropriateness.
3
Operators
- Before operating the product, read this manual and that of related equipment thoroughly to understand the
contents.
- Be sure to wear the proper clothing and personal protective equipment when using and operating the product.
Handling & Maintenance
Do not handle the chain hoist in any of the following manners.
Handling the chain hoist in the manner described below may result in death or severe injury:
Prohibited
- Only suitably competent persons are allowed to disassemble or repair the chain hoist.
Separate document; Disassembly/Reassembly Manual is provided for such competent persons. Disassembly and repair shall
be carried out in accordance with the document and page 17 to 39.
- Do not enter into any area below a lifted load or moving range thereof. Do not transport a load over people or allow people to
enter into the moving range of a lifted load.
- Do not remodel the product and its accessories.
- Do not adjust or disassemble the Bottom Yoke and Overload Limiter (a device to prevent excessive overload).
Mandatory
Prohibited
Mandatory
Comply with the following instructions when handling the chain hoist.
Failure to comply with these instructions may result in death or severe injury:
- Before operating the product, fully understand the contents of this manual and the caution labels.
- Carry out daily inspection before operation.
- Request the competent person to carry out periodic inspection (monthly, annually), or ask KITO.
- Keep the record of the periodic inspections.
- When not in use of the chain hoist, store it at any place where appropriate for the weight and size.
Do not drag or throw the chain hoist when carrying.
The chain hoist may be broken or damaged and any fall of the lifted load during use may result in injury or physical damage to
property.
Follow the operating environmental conditions (refer to page 11) when using the chain
hoist.
Use of chain hoist beyond the conditions may result in injury or physical damage to property.
4
Mandatory
When discarding the product, disassemble it to ensure it is not reused, and discard in
accordance with locale government regulations and ordinances or the rules defined by
the business entity.
Contact your local government and related division for details.
Refer to Disassembly/Reassembly Manual for how to disassemble the chain hoist, or consult with KITO.
Chapter 1
Operation
Table of Contents
Safety precautions ............................................................................................ 6
Unpacking ........................................................................................................ 10
Main parts......................................................................................................... 10
Specifications .................................................................................................. 11
Operating environmental conditions ............................................................. 11
Installation ........................................................................................................ 11
Preoperational check ...................................................................................... 11
Operation .......................................................................................................... 12
Maintenance and storage ............................................................................... 13
Inspection classification ................................................................................. 14
Daily inspection ............................................................................................... 15
Parts list ........................................................................................................... 16
5
Safety precautions
Mounting
Avoid the following when mounting the chain hoist.
Failure to comply with these instructions may result in death or severe injury:
Prohibited
- Ensure that only trained or competent persons install the chain hoist.
- Do not install the chain hoist within the range of movement of other devices (equipment), such as a trolley.
Mandatory
Mandatory
Comply with the following instructions when installing the chain
hoist.
Failure to comply with these instructions may result in death or severe injury:
- Check that the structure for mounting the chain hoist has sufficient strength.
- Fix the Top Hook to the structure securely.
- Before using the chain hoist with a trolley, read the Instruction Manual of the trolley carefully
and install it by adjusting the rail width.
- Install a stopper at both ends of the traversing rail for the trolley.
Comply with the following instructions when installing the chain
hoist.
Failure to comply with these instructions may result in injury or damage to property:
- Install the chain hoist to avoid impeding the hoist.
- Install the Load Chain with sufficient length for lifting work.
- If the adjustment of the bottom of the hand chain between 500 mm and 1000 mm from the
ground is required, consult KITO.
Traversing rail
Trolley
Stopper
Lift
Before use
Mandatory
Mandatory
6
Before moving the load, warn all the surrounding people.
Failure to comply with these instructions may result in death or severe injury.
Check the following before using the chain hoist.
If a defect is found while checking the chain hoist, stop using it, place a notice indicating "failure/inspection in progress" and request
a competent person to carry out inspection and repair.
Failure to comply with these instructions may result in death or severe injury:
- Carry out daily inspection before operation (refer to page 15).
- Check to see whether there is any defect in the sling.
- Check to use a proper chain hoist for your purpose, capacity and lift.
- Check the work environment to see if the work area is secure to pull the hand chain vertically and to maintain a good view
without any obstacles to monitor the operation.
- Check to see if the footing is secure.
Operation
Do not use the chain hoist in the following manners.
Failure to comply with these instructions may result in death or severe injury.
Prohibited
<General>
<Slinging>
- The Load Chain is exclusively designed for this model of chain hoist. Do not use chains of other models of chain hoist.
Ensure that a competent person replaces the chain with an authorized part for this model, referring to Disassembly/Reassembly
Manual.
- Operate the chain hoist using only manual force.
- Do not leave a lifted load unattended for an extended period.
A
- Do not use a Hook without a Latch.
- Do not apply a load to the tip of the hook or latch.
<Fig. A>
- Do not use the load chain as a sling. <Fig. B>
- Do not operate the load chain while it is in contact with any
sharp edges, e.g. of a steel plate. <Fig. C>
B C
<Lifting>
- Do not lift more than the rated load. <Fig. D>
- Do not cause the load to come into contact with the load or
hand chains.
- Do not lift the load while holding the load chain.
- Do not swing the lifted load.
- Do not use the chain hoist without a straight line present
between the top and bottom hooks relative to the load direction. <Fig. E>
- Do not swing the load when lifting it off the ground. <Fig. F>
- In the situation where the chain hoist is to be used as a sling by connecting it to a crane, be
certain to convey the fact of this intended usage to KITO beforehand to confirm whether this
type of use is possible.
- Do not impede the hand chain with a lifted load or a member of the structure caught on the
chain.
Overload
D
E
F
- Do not use the chain hoist as a fulcrum. <Fig. G>
- When lifting off a load from a pallet, lift the load to avoid
exposing to shock, such as the load falling. <Fig. H>
- Do not lift or lower excessively.
- Before use, confirm the minimum distance between the
hook and load (minimum headroom) and lift in technical
data.
- Do not repeatedly operate the overload limiter (slipping action).
- If the overload limiter is activated, stop the lifting operation immediately and ensure that the chain hoist is in a no load state.
G
(Continued on the following page)
H
7
Operation
Do not use the chain hoist in the following manners.
Failure to comply with these instructions may result in death or severe injury.
Prohibited
<Transportation/Move>
<Post-lifting Work>
(continued from the previous page)
- Do not operate the chain hoist underneath the load or transport a load
over people. <Fig. I>
- Do not ride on a lifted load and do not use the chain hoist to support, lift,
or transport people. <Fig. J>
- Do not strike the stopper of the traversing rail or the structure with the
chain hoist or the trolley.
I J
- Do not execute welding or cutting work on a suspended steel plate.
- Do no use the load chain as the earth for welding work. <Fig. K>
- When repairing or disassembling, ensure that the chain hoist is placed down on the floor and
that only competent persons maintain the chain hoist.
- Ensure that the hand chain is pulled by a single person.
Mandatory
Prohibited
<Abnormality/failure>
- Do not use a damaged chain hoist or one generating abnormal sounds.
- Do not use the chain hoist if one of the following defects is found in the load chain.
Deformation, twists, kinks, flaws, cracks, adhesion of foreign matter, corrosion, and abnormal meshing.
- Heavy elongation or abrasion.
- Do not use the load chain hoist out of order or under repair.
Follow the instructions below when using the chain hoist.
Failure to comply with these instructions may result in death or severe injury:
- If any abnormality is detected during use, immediately stop using of the chain hoist, indicate "failure/repair in progress" and
request a competent person to perform maintenance and repair.
- When the manual force becomes excessive, stop operation immediately.
- Use sling appropriate for the weight and shape of a load. Improper slinging may result in an unsafe situation, such as the falling
of the lifted load.
- When any abnormality is observed during the operation, stop the operation immediately, indicate "FAILURE" and contact with
the maintenance engineers.
- When inspecting and repairing, be sure to indicate "INSPECTION" and carry out without lifting a load.
Do not use the chain hoist in the following manners.
Failure to comply with these instructions may result in death or severe injury:
- Do not operate the chain hoist as the hand chain is tangled or twisted.
- Do not expose the chain hoist to sparks from welding.
- Do not use an overload limiter for measuring the weight of the load.
- Do not apply a load to the hook tip or hook latch.
- Do not impede the lifted load or hand chain with other structures.
- If a load bounces up and down significantly when lowering the load, do not operate the chain hoist until the bouncing reduces.
K
Observe the following instructions when using the chain hoist.
Failure to comply with these instructions may result in death or severe injury:
Mandatory
- Unwind any twists in the load chain before lifting a load.
- If the load and hand chains are entangled or twisted, stop the operation immediately and reset the entangled or twisted chains.
- When lifting a load with two hoists, choose each hoist whose lifting capacity exceeds the load and operate the respective chain
hoist to keep the load lifted horizontal.
- There are risks of overheating of the braking system during prolonged lowering of loads.
If you are considering of the use under such condition, consult KITO.
8
Maintenance inspection / storage
Only competent persons are allowed to carry out maintenance inspection of the chain
hoist.
Mandatory
Mandatory
Failure to comply with these instructions may result in death or serious injury:
- The competent person should carry out maintenance inspection in accordance with page 17 to 39 and Disassembly/
Reassembly Manual.
- Do not cut, extend, or weld the load and hand chains.
- Do not apply oil to the braking part.
Comply with the following instructions when carrying out maintenance inspection and
storing the chain hoist.
Failure to comply with these instructions may result in injury or physical damage to property:
- To avoid misuse of the chain hoist under repair, apply a label indicating "failure/inspection in progress" on the chain hoist.
- When storing the chain hoist, wipe off dust and waterdrop, apply oil to the neck of the hook and load chain and store the hoist
indoors when not used for lifting loads.
- When replacing a part, use only an authorized part for the KITO model CX chain hoist.
Even though the part is an authorized one for KITO chain hoist, it may not be used for different model.
- Wear protection equipment such as protection goggles and gloves depending on the work contents. Especially, wear helmet
and safety belt when carrying the high lift work.
- Pay attention to work method, work procedure and work posture.
- Remove the oil or grease attached to the product or spilt on the floor.And keep the work area clean when disassembling the
product.
9
Unpacking
b
- Check that the information on the box and the product match the details of your order.
- Check to see whether the product has been deformed or damaged by an accident in transit.
- Fill in the blank provided in the right table with the Lot NO. (written
on the nameplate on the product), the date of purchase, and the
name of the store where you purchased the product.
* When requesting repair or ordering a chain hoist part, please
inform us of these pieces of information together.
Lot NO. CX1A-
Date of purchase
Store
- Fill in the spaces provided in the right table with
the distance "a" between embossed marks, the
hook width "b" and the thickness "c" for both the
top and bottom hook. (These figures are referred in
maintenance.)
Main parts
Hook latch
Wheel cover
Body
Hand wheel
Over load limiter (OLL)
built-in
Brake (built into the body)
Embossed mark
a
c
Top
hook
Bottom
hook
Top hook
Nameplate
(rating / warning)
Equipped with OVERLOAD LIMITER
CODE:
LOAD CHAIN:
LOT No: CX1A
SERIAL No:
MFG.YEAR:
Yamanashi 409-3853 Japan
MADE IN JAPAN
Dimensions when new
Dimension a
Dimension b
Dimension c
Dimension a
Dimension b
Dimension c
Rated load
(ex. of CX005)
LOT No.
Model
mm
mm
mm
mm
mm
mm
10
Load chain
Load chain end at no-load side
Hand chain
Warning tag
Load chain
Bottom yoke
Latch
Bottom hook
Minimum
Headroom
Lift
Specifications
Product
code
CX003 0.25 2.5 217 2 147[15] 33.8
CX005 0.5 2.5 260 2.5 187 [19] 42.8
Product
code
CX003 3.2 x 9.0 1 0.313 0.4 2.4
CX005 4.3 x 12.0 1 0.625 0.9 4.5
This device was tested according to the required static and dynamic load test provided on the European standard EN 13157.
Rated load
(t)
Load chain diameter x pitch
Standard lift
(m)
(mm)
Minimum
Headroom (mm)
Chain fall lines
Standard length of the hand
chain double fold (m)
Test Load
(t)
*1: Average hand pull to lift the rated load.
*2: Length of the hand chain necessary to lift a load 1m.
Weight for additional 1m
Pull to lift Load
(N) [kgf]
of lift (kg/m)
*1
Hand chain length
for 1m lifting*2 (m)
Operating environmental conditions
Operating temperature range -40°C to +60°C
Operating humidity range Use the hoist at under 100%RH. This product cannot be used in water.
Standard materials are used.
Materials
Special materials such as sparkless materials and asbestos are not used.
With regard to the environmental load substances, 6 substances defined in the
RoHS directives are not contained in this product.
Mass
(kg)
Do not use the chain hoist in the following environments:
- In an alkaline/acidic atmosphere
- In an organic solvent/explosive atmosphere
Incidentally, when you wish to use the chain hoist in environments other than the aforementioned normal use environments, such as one with a high
salt content, or in an environment where outdoor use in particular is extensive, it may be possible to use the chain hoist by carrying out maintenance
inspection frequently. In such cases, consult with KITO beforehand.
Installation
Read the "Safety precautions : Mounting" on page 6 carefully before use and follow the instructions.
- The safety factor of the chain hoist is 4:1. The hoist may lift and hold a load more than the rated load. Check that the structure for mounting the
chain hoist has sufficient strength.
- Only allow trained or competent persons to install the chain hoist.
- Do not install the chain hoist within the moving range of other devices (equipment), such as a trolley.
- Before using the chain hoist with a trolley, read the Instruction Manual of the trolley carefully and install it by adjusting the rail width.
Install a stopper at both ends of the traversing rail for the trolley.
- If the adjustment of the bottom of the hand chain between 500 mm and 1000 mm from the ground is required, consult KITO.
Note: KITO TS trolley (Models TSP005) can be connected to this hoist. When using the CX003 by connecting to a
trolley, change the capacity on the trolley nameplate to 250kg, corresponding to CX003. For details, contact
KITO.
Preoperational check
Read the "Safety precautions : Mounting" on page 6 and "Safety precautions : Maintenance" on page 9 carefully
before use and follow the instructions.
The user must carry out a daily inspection before operation.
Even if the chain hoist is permanently installed and used for the same purpose repeatedly, check all the works for the
day and check to ensure that it does not exceed the rated load on each occasion.
11
Operation
Read the "Safety precautions" Operation on pages 7 to 9 carefully before use and follow the instructions.
Correct way to lift a load
Hang on the axis of
the hook.
Avoid the dangerous hooking method shown in the following diagrams.
The holding object or
the sling is not hooked
in the correct position.
More than 60 degrees.
The angle is too wide.
60 degrees or less.
The hook latch does
not close.
Operation method
Wheel cover side
The load is applied at
the tip of the hook.
Lowering
When the hand chain on the left,
as viewed from the wheel cover
side, is pulled down (in a DN
direction), the load is lowered.
This product is designed for a rated load to be hoisted by pulling the hand chain with a force shown in the "Pull to lift
load" table below or less. If an excessive load is applied, the overload limiter will operate. In this situation, immediately
stop the operation and lighten the load.
Pull to lift load:
CX003 147 N (15kgf)
CX005 187 N (19kgf)
Lifting
When the hand chain on the right,
as viewed from the wheel cover
side, is pulled down (in an UP
direction), the load is lifted.
12
Overload limiter (OLL)
Do not adjust or disassemble Overload Limiter (OLL).
Failure to comply with these instructions may result in death or serious injury.
This product is equipped with an overload limiter (OLL: a device to prevent an excessive overload) as standard.
An excessive overload via the hand chain activates OLL which slips the hand wheel to prevent damage to the
product.
When OLL operates, the maximum load to the product is approximately 2.4 times of the rated load.
If OLL operates, reduce a load to less than the rated load. Also check that the structure for mounting the chain
hoist (including a trolley) has no damage.
Maintenance and storage
Read the "Safety precautions : Maintenance, inspection/storage" on page 9 carefully after use and follow the
instructions.
Care
- Do not drag or throw the chain hoist when carrying.
- Never apply oil to the braking part.
- Wipe off dust and moisture, and apply oil to the neck of hook and the load chain.
Storage
- When not in use, ensure that it does not encumber other works.
- Store the hoist in a dry area indoors.
- When installing outdoors, cover the hoist to avoid exposure to rain or store in a place with covering against rain.
- Before storing the hoist, pull the hand chain by about 10cm to lower the hook and ensure that the brake is released.
Tool
- To disassemble or reassemble the hoist, prepare for the following tools.
.
No
1 Hexagon wrench 4mm
2 Snap ring pliers For disassembling and reassembling the pawl and cam guide
Hexagon wrench
3
2.5mm
4 Hexagon wrench 3mm For disassembling and reassembling the bottom yoke and hook latch
Tool name Application
For disassembling and reassembling the frames A and B, gear case, and
wheel cover
For disassembling and reassembling the end pin
5 Wrench 7mm For disassembling and reassembling the bottom yoke and hook latch
6 Long nose pliers For the cam guide
7 Torque wrench For checking a tightening force
13
Inspection Classification
To maintain continuous and satisfactory operation, a regular inspection procedure must be initiated to replace worn or
damaged parts before they become unsafe.
INSPECTION Classification
Inspection intervals must be determined by individual application and are based on the type of service to which the hoist will be subjected and the
degree of exposure to wear, deterioration or malfunction of the critical components.
The type of service to which the hoist is subjected can be classified below.
- Normal Service – service that involves operation with randomly distributed loads within the rated load limit, or uniform loads less that 65% of
rated load for not more than 15% of the time.
- Heavy Service – service that involves operation within the rated load limit which exceeds normal service.
- Severe Service – service that involves normal or heavy service with abnormal operating conditions.
The three general classifications are herein designated as DAILY, FREQUENT and PERIODIC, with respective intervals between inspections as
defined below.
DAILY Inspection – visual examinations by the operator or other competent person before daily operation.
FREQUENT Inspection – visual examinations by the competent person with intervals per the following criteria:
- Normal service – monthly
- Heavy service – weekly to monthly
- Severe service – daily to weekly
Records are not required.
PERIODIC Inspection – disassembly/reassembly inspection by the competent person with intervals per the following criteria:
- Normal service – yearly
- Heavy service – semiannually – 6 months
- Severe service – quarterly – 3 months
Records are to be kept for continuing evaluation of the condition of the hoist.
14
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