Owner’s (Operator’s) Manual
and
Safety Instructions Manually Lever Operated
Chain Hoist Model L5

L5 LB Lever Hoist

WARNING
This equipment must 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 harm or death, and/or property damage.
[Only for customers who purchased our chain locks] When using this equipment with the chain lock, read the owner’s manual of the chain lock to correctly use it.
Issued January 2010. Revised July,2022 (revision 08)
Fill in the following product information for identification and future reference to avoid referring to the wrong manual for information or instructions on installation, operation, inspection, maintenance, or parts.
Model Code:
Serial Number:
Date of Purchase:
Dealer:

Important Information and Warnings

1.1. Regarding this instructions manual
This manually lever-operated chain hoist model L5 is designed to lift and lower a load by using manual force, and hold it by using the braking device under normal working conditions, not intended to transport a person.
The following symbols are used in this manual to identify the degree or level of hazard seriousness.
DANGER
This symbol indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury, and property damage.
WARNING
This symbol indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury, and property damage.
CAUTION
This symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property damage.
Even the caution situations may result in serious injury or death depending on conditions.
Therefore, notice should be taken whenever encountering them.
This symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property damage.
Even the caution situations may result in serious injury or death depending on conditions.
Therefore, notice should be taken whenever encountering them.
Always keep this manual in a convenient place for operator’s reference.
1.2. Prohibited practices
1.2.1. General
Improper usage or negligent maintenance of the hoist may result in dangerous situations arising such as a lifted load dropping. Before installing, operating or maintaining, read and comply with both this manual for the safety and operation instructions, and notes for all the equipments.
KITO will not be held liable for any malfunction, lack of performance or accident if the product is being used in conjunction with any other equipment. If the product is to be used for unintended purposes, please confirm with your dealer in advance.
DANGER ◼ Do not use the hoist to support, lift or transport people. ◼ Do not go under a lifted load or its path, and do not move the lifted load over people.
WARNING ◼ Do not lift more than the rated load.
◼ Do not modify the product or its accessories.
CAUTION
◼ Before moving the load, warn all people in the vicinity.
◼ Do not operate the hoist unless the contents of this operating manual and the warning labels are fully understood.
1.2.2. Prior to operation
CAUTION
◼ This manual is intended for the operator who will use the hoist. Prior to operation, all of the safety and operating instructions must be fully understood.
WARNING
◼ Do not use a deformed or scarred hook.
◼ Replace components with new ones authorized by KITO.
CAUTION
◼ Be sure to wear the proper clothing and personal protective equipment when using and operating the product.
◼ Make sure that the nameplate is readable
◼ Before operation, make sure to perform all inspections given in 5.1 Inspection classification
◼ Use a proper hoist for your purpose, capacity and lift.
◼ Ensure to check that the hook latches are not deformed or scarred, and are moving smoothly.
◼ Ensure to check that the brake and free chaining functions properly work.
◼ Ensure to check that the load chain is well-lubricated.
◼ Ensure to avoid welding sparks on the hoist and load chain.
1.2.3. Operation
WARNING ◼ Do not use the hoist with deformed or scarred load chain. ◼ Do not use the load chain as a sling. ◼ Do not use the hoist as a fulcrum. ◼ Do not impede the chain on any surface e.g. a steel plate. ◼ Do not support a load on the tip of the hook. ◼ Do not perform welding or cutting operation on the load being suspended. ◼ Do not use the hoist by stepping on the lever. ◼ Do not extend the lever by attaching a pipe to it.
◼ Do not swing a lifted load.
◼ Do not use the load chain as an earth for welding.
◼ Do not lift excessively until the bottom yoke comes into contact with the hoist body.
◼ Do not lower excessively until the chain stopper comes into contact with the hoist body.
◼ Do not use a damaged hoist or one having abnormal sounds.
◼ Do not use a hoist with a loose lever grip.
◼ Do not leave a lifted load unattended for a long time.
◼ In lowering mode, do not pull the no-load-side chain which could cause a hazardous situation arising the grip revolving.
CAUTION
◼ Ensure to place a load properly on the middle of the hook saddle.
◼ Before lifting, ensure to eliminate load chain slack to avoid a shock load.
◼ There are risks of overheating of the braking system during prolonged lowering of loads.
If you are considering the use under such condition, consult KITO.
◼ 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.
1.2.4. After operation
CAUTION
◼ After operating, ensure to put a load down securely to avoid dropping it.
WARNING
◼ Do not drag or throw the hoist when carrying it. 1.2.5. Inspection and Maintenance
CAUTION
◼ Ensure that competent people periodically conduct inspections and maintenance corresponding to 5 Inspection and 6 Maintenance otherwise please confirm with your dealer.
◼ Indicate “CHECKING” when performing the inspection.
◼ Wear protection equipment such as protection goggles and gloves depending on the work contents.
◼ Pay attention to work method, work procedure and work posture.
◼ Wear helmet and safety belt when carrying the high lift work.
◼ Remove the oil or grease attached to the product or spilt on the floor.
◼ Keep the work area clean when disassembling the product.
WARNING
◼ Do not extend or weld the load chain.
1.2.6. Others
CAUTION
◼ In case of use in special environments such as salt water, seawater, acidic, alkaline or explosive atmospheres, confirm with your dealer in advance.
WARNING
◼ Do not use the hoist which is out of order or under repair.
◼ Do not use the hoist with warning labels or tags missing.

Technical Information

2.1. Specifications
2.1.1. Schematics2.1.2. Operating conditions and environment
Temperature range: -40° to +60°C (-40° to +140°F) Humidity: 100% or less, this is not an underwater device.
Not applicable for explosive atmosphere (No special materials such as sparkless used)
Table 2-1 Hoist Specifications

**Capacity (t)| ****Product Code| ****Standard Lift (m)| Pull to Lift Rated Load (N)(kgf)| Load Chain Diameter x Pitch (mm)| ****Chain Fall Lines| ****Test Load (t)| ****Net Weight (kg)| Weight for Additional One Meter of Lift (kg)*
---|---|---|---|---|---|---|---|---
0.8| LB008| 1.5| 284(29)| 5.6×15.7| 1| 1.2| 5.7| 0.7
1| LB010| 1.5| 353(36)| 1| 1.5| 5.9| 0.7
1.6| LB016| 1.5| 333(34)| 7.1×19.9| 1| 2.4| 8.0| 1.1
2.5| LB025| 1.5| 363(37)| 8.8×24.6| 1| 3.8| 11.2| 1.7
3.2| LB032| 1.5| 363(37)| *** 10×28.0| 1| 4.8| 15.0| 2.3
6.3| LB063| 1.5| 372(38)| 2| 7.9| 26| 4.7
9| LB090| 1.5| 382(39)*| 3| 11.3| 40| 7.0

• This device was tested according to the required static and dynamic load test provided on the European standard EN 13157.
• *marked “Pull to Lift Rated Load” does not comply with the requirement of EN 13157. (5.2.6 Operating effort)

2.2. Dimensions Table 2-2 Hoist Dimensions

Hoist Code| a| b| C| D| e| g| S| t
---|---|---|---|---|---|---|---|---
LB008| 114| 119| 280| 245| 97| 23.5| 35.5| 14
LB010| 114| 119| 300| 245| 97| 29| 42.5| 15
LB016| 159| 126| 335| 265| 100| 32| 42.5| 19
LB025| 173| 150| 375| 265| 102| 36.5| 47| 21
LB032| 190| 159| 395| 415| 112| 39| 50| 24.5
LB063| 190| 217| 540| 415| 112| 50| 60| 34
LB090| 190| 304| 680| 415| 112| 72.5| 85| 41.5

Mounting

WARNING
ALWAYS
Avoid the following when mounting the hoist.
Failure to comply with these instructions may result in death or severe injury.
– Ensure that only trained or competent persons install the hoist.
– Do not install the hoist within the range of movement of other devices (equipment), such as a trolley.
ALWAYS
Comply with the following instructions when installing the hoist.
Failure to comply with these instructions may result in death or severe injury.
– The hoist may lift and hold a load more than the rated load. Check that the structure for mounting the hoist has sufficient strength.
– Fix the Top Hook to the structure securely.
CAUTION
ALWAYS
Comply with the following instructions when installing the hoist.
Failure to comply with these instructions may result in injury or damage to property.
– Install the hoist to avoid impeding the hoist.
– Install the Load Chain with sufficient length for lifting work.

Operation

4.1. Introduction
Operating a heavy load may result in hazardous situations. Before operating, read and comply with all of the information in this clause and 1.2 Prohibited practices.
Before operating the hoist, secure the workplace as follows:
– Ensure to arrange the workplace to work smoothly.
– Ensure to keep a good view to monitor the operation, otherwise arrange watch personnel.
4.2. Free chaining
DANGER
Do not operate the hoist in free chaining mode under a load.
4.2.1. Features
– Free chaining can freely feed the load chain as the brake is released under no load situations.
– Pulling the free chain knob moves the internal spring to release the mechanical brake and to pull the load chain in either direction to its needed length.
4.2.2. How to operate

1. Set the select lever to the neutral (‘N’) position.

2. Pull the free chain knob upwards.

3. In this mode, the load chain can be pulled through the to its required length.
   CAUTION
   Do not pull the load chain suddenly in free chaining mode.
   – Excessive pulling may make a brake and can not feed the chain.
   – In this case, reset the hoist (see 4), make some lowering operations, and then start over.

4. To reset the hoist for load operation, turn the free chain knob clockwise with the load-side chain pulled lightly.
   The knob will come into contact again to operate the hoist with the grip.

When a load under the minimum load for each capacity shown in the following table is applied to the load chain, the brake does not operate.
Do not apply any load to the load chain in free chaining mode, except for the positional adjustment of the load chain by an operator.

130

4.3. Load operation
4.3.1. Features
Operating the grip with the select lever set to the lifting (‘UP’) or the lowering (‘DN’) position, the hoist performs as follows:
– In lifting mode, the tightened mechanical brake rotates as one and supports a load on the pawls when the grip stops.
– In lowering mode, grip operation un-tightens the mechanical brake and lowers the load chain, and when the grip stops, the mechanical brake is tightened and supports the load instantly.
– In lifting and lowering, braking always acts.
4.3.2. How to operate
DANGER
Do not operate the free chain knob in lifting or lowering.
CAUTION
Before operating, make sure that the hoist is out of the free chaining mode and the select lever position meets your operation demands.
The following table shows select lever position and grip operation for lifting and lowering.
Table 3-1 Hoist & Grip Operation

CAUTION
Under no load conditions, in the case that the load chain does not lower against your lowering operation, operate the grip with the load-side chain pulled lightly. (This is a standard manner.)
4.4. Load signal (as option)
This load signal is designed as an overload detecting device to warn an operator that an excessive load has been applied which could cause a hazardous situation.
DANGER
◼ Disregarding the overload sign could cause bodily harm or damage to the hoist. Do not lift an overload. Warn all the people in the vicinity and remove the causes.
CAUTION
◼ Do not leave dust or foreign objects in the load signal.
◼ Disassembling the hoist or changing the signal setting will invalidate your product warranty.
Contact your dealer for disassembly or repair.
◼ Excessive impact on the grip may result in a malfunctioning signal or damage to the components.
◼ Using the hoist recklessly may cause the load signal to work improperly.
4.4.1. Features

– Lifting pull is transmitted to the grip through the spring inside the lever.
– A pull over the designed limit compresses the spring and bends the grip. （in response to 100 to 120 % of the rated capacity）
– Then the color of the signal window on the lever changes to warn the operator of an overload.
– The signal colors are identified as shown in the following table.
Table 3-2 Signal Warning

4.4.2. How to operate

1. Operate the hoist by holding the grip in the middle.

2. The following events of the load signal warn you of an overload.
   – The grip is bent.
   – The lever clicks.
   – The signal window changes from green to red.

3. Stop lifting and lower immediately when an overload is detected.

4. Reset the grip into its straight position (back in place) before operation commences.

5. Reduce the load to less than the rated load.
   Check that the structure for mounting the hoist has no damage.

Inspection

To maintain continuous and satisfactory operation, a regular inspection procedure must be initiated to replace worn or damaged parts before they become unsafe.
5.1. Inspection classification
Inspection intervals must be determined by the 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 – by the operator or other designated people before daily operation.
FREQUENT Inspection – by the operator or other designated people 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 – by a designated people 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.
5.2. Daily inspection
Table 4-1 Daily Inspection Methods and Criteria

Replace.
Function – Lifting| Set the select lever to ‘UP’ and make lifting operation with the load-side chain pulled slightly.| Moving the lever forward and backward should make clicking sounds.| Repair or replace as necessary.
Function – Lowering| Set the select lever to ‘DN’ and make lowering operation with the load-side chain pulled
slightly.| Moving the lever only backward, not forward, should make clicking sounds.| Repair or replace as necessary.
Function – Free Chaining| Set the select lever to ‘N’ and pull the free chain knob upward
into free chaining mode to adjust the chain length.| – The chain should be pulled smoothly.
–  The free chain knob should be easily pulled or reset.| Repair or replace as necessary.
Hooks – Condition| Visual, Function| –  Should be not deformed.
–  Should turn smoothly.| Replace
Hooks – Latches| Visual| Should be not deformed or scarred.| Replace
Load Chain| Visual| –  Should be free of severe rust.
–  Should be coated with lubricant.
– Should not be deformed or scarred.| Replace Clean/Lubricate Replace
Others| Visual| –  Nuts, split pins, grip or screws should not be loose or missing.
–  Hoist should not be scarred or damaged.
–  Chain stopper link at no-load side should not be missing or deformed.
– Bottom hook on multiple chain fall line models should not be capsized.| Replace
Correct all chain irregularities as shown in the following picture.
**** Twisted Chain
Capsized Hook and Chain Double Fall Models

5.3. Frequent Inspection
Evaluation and resolution of the results of the frequent inspections shall be made by a designated
person so that the hoist is maintained in safe working condition.
WARNING Do not use components beyond the stated criteria or KITO- unauthorized ones.
In addition to the daily inspections, perform the following checks.
Table 4-2 Frequent Inspection Methods and Criteria

Put the hoist under a light load and check the following items of “Function – ……”

Function – Lifting| Set the select lever to ‘UP’ and lift the load operation 20 to 30 cm.| Moving the lever forward and backward should make clicking sounds.| Repair or replace as necessary.
---|---|---|---
Function – Lowering| Set the select lever to ‘DN’ and lower the load operation 20 to 30 cm.| Moving the lever only backward, not forward, should make clicking sounds.| Repair or replace as necessary.
Function – Abnormal Sounds| Check auditorily.| Should have no damped clicking or irregular sounds.| Repair or replace as necessary.
Function – Pull| Check function.| Should not be extremely heavy.| Repair or replace as necessary.
Function – Braking| Check function.| Should not slip.| Repair or replace as necessary.
Hooks – Stretch| Measure | Measured when new
(mm)| Discard limit
---|---
a:
b:
c:| Over the measured
5 % or more reduction
5 % or more reduction
Capacity
(tonnes)| a* (mm)| b (mm)| c (mm)
---|---|---|---
Nominal| Standard| Discard| Standard| Discard
0.8| 44| 14| 13.3| 19.6| 18.6
1| 52| 15| 14.3| 21| 20
1.6| 55| 19| 18.1| 25.7| 24.4
2.5| 63| 21| 20| 29| 27.6
3.2| 67| 24.5| 23.3| 31| 29.5
6.3| 90| 34| 32.3| 41| 39
9| 111| 41.5| 39.4| 52| 49.4

Record the following sizes, a, b and c at the time of purchase.
*These values are nominal since the dimensions are not controlled to a tolerance. The measurements at the time of purchase become the reference ones. Subsequent measurements are compared to these references to make determinations about hook deformation/stretch.

Replace
Hooks – Abrasion| Replace
Hooks –Deformation, Scars| Check visually.| –  Should not be significantly twisted or deformed.
–  The shank portions of the hook should be evenly worn.
–  Should have no deep scars.
–  Should have no loose or missing rivets, bolts or nuts.
–  Should have no welding sparks.| Replace
Hooks – Swivel| Check visually, and check function.| The hook should rotate smoothly.| Replace
Item| Method| Criteria| Action
---|---|---|---
Hooks – Hook Latches| Check visually, and check function.| –  Should be held in place on the tip of the hook.
–  Should move smoothly.
WARNING Do not use the hook with the latch missing.| Replace the hook latch.
Hooks – Idle Sheave (bottom hook on double fall hoist)| Check visually, and check function.| WARNING **** Make sure to avoid having your fingers caught.
Should rotate smoothly.
(If not, idle sheave or axle may be deformed or worn.)| Replace the idle sheave and axle.
Hooks – Idle Sheave| Check visually.| Pockets of idle sheave should be free of wear or scars.| Replace the idle sheave and axle.
Load Chain – Wear| Measure| Capacity
(tonnes)| L dimension (mm)| d dimension (mm)
---|---|---
Standard| Discard| Standard| Discard
0.8, 1| 7900%| 81.3| 5.6| 5.1
1.6| 100| 102.9| 7.1| 6.4
2.5| 124| 127.6| 8.8| 7.9
3.2, 6.3, 9| 141| 145.1| 10| 9

Notice: If wear on the load chain is found, make sure to check the load sheave.

Replace
Load Chain – Rust| Check visually.| Should be free of significant rust.
WARNING ** Make sure to lubricate the load chain frequently.| Replace
Load Chain – Deformation, Scars| Check visually.| –  Should be free of deformation (such as twist).
–  Should be free of deep scars or dents.| Replace
Load Chain – Welding Sparks| Check visually.| Should be free of welding sparks.
WARNING ** Make sure to avoid welding sparks on the hoist.| Replace

5.4. Periodic Inspection
In addition to the frequent inspections, perform the following checks.
Table 4-3 Periodic Inspection Methods and Criteria

dimension (mm)
---|---
Standard| Discard
0.8, 1| 6.8| 6.5
1.6| 8.7| 8.3
2.5| 10.8| 10.3
3.2, 6.3, 9| 12.1| 11.5
–  Significantly deformed pin should be discarded.
–  Should be free of scars or deformation on the thread.| Replace
Chain Pin – Wear| Replace
Chain Pin – Rust| Check visually.| Should be free of significant rust.| Replace
Yoke – Hole Deformation| Measure
Check the diameters of the top| | Replace the hook set.
---|---|---|---
pin and chain pin hole.

| ****

Capacity (tonnes)

| Diameter (mm) for|
Chain pin| Top pin
Standard| Discard| Standar

d

| Discard
0.8, 1| 7.1| 7.6| 12.2| 12.7
1.6| 8.9| 9.4| 12.2| 12.7
2.5| 11.0| 11.5| 14.2| 14.7
3.2| 12.3| 12.8| 16.2| 16.7
6.3, 9| 12.3| 12.8| 16.4| 16.9
Braking System –Components| **** Friction plates are made of asbestos free material.
---|---
Braking System – Friction Surface| Check visually.| Should free of scars or gouged flaws on the braking surface.
The braking surface should
not be excessively worn with the tool marks erased and surface lustered.| Replace
Braking System – Friction Plate| Measure
__  | –  Should have uniform thickness. The plate with thinner outer than the inner should be discarded.

–  Should be free of scars or cracks.

| Replace
| Capacity
(tonnes)| Thickness of Friction Plate (mm)
---|---
Standard| Discard
All| 350%| 3
Item| Method| Criteria| Action
---|---|---|---
Braking System – Bushing Wear| Measure| Should have uniform thickness of A dimension.| Capacity (tonnes)| A dimension (mm)
---|---
Standard| Discard
All| 4.0| 3.0
Replace
Braking System – Bushing Lubrication| Check visually.
Heat with a match flame in a short time. **| Should be so lubricated that lubricant oozes off the surface.
WARNING
-Even for repair or assembly, soak the bushing in turbine oil for a day before reuse.-Pay attention to heat of fire around| Soak the bushing in turbine oil for a day.
Braking System – Ratchet Disc| Measure| | Capacity (tonnes)| D dimension (mm)
---|---
Standard| Discard
0.8, 1| 64| 61
1.6
2.5
3.2, 6.3, 9| 74| 71
Replace
Braking System – Pawl| Check visually.| As shown in the left picture, the side of the pawl should not be worn.| Replace
Braking System – Pawl Spring| Check visually.| Should not be deformed or scarred.| Replace
Braking System – Female thread| Check visually.| The cogs should be free of significant deformations.| Replace
Braking System – Rust| Check visually.| All parts should be free of rust.| Replace
Lifting system– Components|
---|---
Item| Method| Criteria| Action
---|---|---|---
Lifting system – Load Sheave| Check visually.| Should be free of wear in the
pockets or scars on the rising parts.| Replace
Lifting system
– Cogs| Check visually.| Should not be chipped, unevenly
worn or scarred.| Replace
Lifting system
– Pinion| Check visually.| A deformed pinion should be
discarded.| Replace
Lifting system
– Lever| Check visually.| Should be free of bends or cracks of
whole lever and loose swaging of
select lever and stud.| Replace
Lifting system
– Select Pawl| Check visually.| As shown in the left picture, the
sides of the pawl should not be
worn.| Replace
Lifting system
– Spring Shaft| Check visually.| Should be free of deformation (suchas bend).| Replace
Lifting system – Select-pawl Spring| Measure | | Capacity
(tonnes)| L dimension
(mm) Minimum
---|---
0.8, 1| 37
1.6
2.5
3.2, 6.3, 9| 42
Replace
Lifting system
–Brake Spring| Measure | | Capacity(tonnes)| L dimension(mm)
Minimum| A angle (°: degree)
---|---|---
Standard| Discard
0.8, 1| 30| 30| 45
1.6
2.5
3.2, 6.3, 9| 30| 25| 40
Replace
Lifting system
–Free Chain Spring| Measure | | Capacity(tonnes)| L dimension (mm)| A angle (°: degree)
---|---|---
Standard| Discard| Standard| Discard
0.8, 1| 66| 59| 180| 165
1.6
2.5
3.2, 6.3, 9| 71| 64| 180| 165
Replace
Item| Method| Criteria| Action**
---|---|---|---
Body – Components| |
Body – Frame A, B Stay Bolts Top Pin Hole Pawl Shafts| Check visually.| – Should be free of major deformation or significant scars.
–  Should be free of loose swaging.
–  Should be free of cracks on the welding parts.
–  The maximum difference between a and b in the picture on previous page should be 0.5 mm.
–  The bearing holes should not be deformed.| Replace
Body – Gear Case| Check visually.| – Should be free of major deformation or significant scars.
–  The bearing holes for the gear #2 and the pinion should not be deformed.| Replace
Body – Top Pin| Measure
| Should be free of significant deformation.

| Capacity
(tonnes)| d dimension (mm)
---|---
Standard12| Discard
0.8, 1| 12| 11.4
1.6
2.5| 14| 13.3
3.2, 6.3, 9| 16| 15.2
Replace
Others – Components| |
---|---|---
Others – Stripper| Check visually.| Should be free of cracks or deformation on the tip.| Replace
Others – Chain Stopper Link| Check visually.| Should not be open or significantly deformed.| Replace
Others – Chain Guide| Check visually.| Should be free of damage or significant deformation.| Replace
Item| Method| Criteria| Action
---|---|---|---
Preoperational Checks| Before reuse, reassemble properly the hoist in accordance with section 6 Maintenance in this manual and perform the following the checks.
Checks under No Load – Lifting| Check function, and check auditorily.
“Set the select lever to ‘UP’ and make lifting operation with the load-side chain pulled slightly.| –  The lever should be operated smoothly.
–  Moving the lever forward and backward should make clicking sounds.| Repair or replace as necessary.
Checks under No Load – Lowering| Check function, and check auditorily.
Set the select lever to ‘DN’ and make lowering operation with the load-side chain pulled slightly.| –  The lever should be operated smoothly.
–  Moving the lever only backward, not forward, should make clicking sounds.| Repair or replace as necessary.
Checks under No Load – Free Chaining| Check function.
Set the select lever to ‘N’ and pull the free chain knob upward into free chaining mode to adjust the chain length.| –  The chain should be pulled smoothly.
–  The free chain knob should be easily pulled or reset.| Repair or replace as necessary.
Checks under the rated load| Check function.
Lift and lower the rated load from 20 to 30 cm. Check the functions in accordance with “Function – ……” of 5.3 Frequent Inspection.| See “Function – ……” of 5.3 Frequent Inspection.| See “Function – ……” of 5.3 Frequent Inspection.

Maintenance and storage

6.1. General
Improper maintenance may result in death or serious injury. Have only a trained or competent person maintain the hoist, or contact your dealer.
CAUTION
◼ Do not drag or throw the hoist when carrying.
◼ Do not use the hoist which is under maintenance.
◼ Remove any dirt or water of the hoist.
◼ Perform all inspections given in 5 Inspection if irregularity of the hoist is found after operation.
◼ Always ensure that lubricant is applied to the load chain, the chain pin, the top pin, the hook necks, the hook latches. Refer to 2.1.1 Schematics.
◼ Load chain – The load chain is one of critical parts of the hoist. Ensure to lubricate the load chain well with rust preventive oil equivalent to ISO VG32.
◼ Others – Lubricate the contacting parts as instructed in the following sections.
Storage
◼ When not in use, ensure that it does not encumber other works.
◼ Before storing the hoist, rotate the lever counterclockwise several times to lower the hook and ensure that the brake is released.
◼ Store the hoist in a dry and clean area.
◼ Do not store the hoist under a load.
◼ When installing outdoors, cover the hoist to avoid exposure to rain or store in a place with covering against rain. When transferring, including handling, and storing the product, carry it out carefully making sure of the product’s weight and size.
6.2. Disassembly, Assembly and Adjustment
WARNING
◼ Perform proper disassembly or assembly in accordance with this manual.
◼ The friction plates are dry ones. Do not lubricate them.
◼ Do not extend the load chain.
◼ Remove old grease of the disassembled parts.
◼ Replace components with new ones authorized by KITO.
◼ To reassemble, apply new grease, and use new split pins and snap rings.
Note: The following symbols in this manual indicate the recommended lubricants.
G1: JIS K2220 general class 1, No.2 grease (EPNOC GREASE AP(N)2, JX Nippon Oil & Energy)
G2: JIS K2246 General Class 1, No.1 (NP-9), Lubricating oil type long-term rust preventive oil (Antirust Terami LN-H, ENEOS）
G3: Moly Speed Grease No. 2 (SUMICO LUBRICANT)
6.3. Tools
To disassemble or reassemble the hoist, prepare for the following tools:
Table 5-1 Tools

| Tools| For

---|---|---
1| Snap ring pliers| Opening a snap ring
2| Socket wrenches 12, 14 mm| Slotted nuts
3| Hex keys 4, 5, 10, 12 mm| Socket head cap screws
4| Wrenches 10, 12, 13, 14, 17 mm| Bolts and nuts
5| Philips screwdriver| Machine screws
6| Pliers| Split pins
7| Soft-face (plastic) hammer|

6.4. Components

Exclusive for 2.5 & 3.2 tonnes6.5. Disassembly
Proceed as follows:
6.5.1. Free Chain Knob
– Pull out (50) Split pin and remove (49) Slotted nut.
– Remove (48) Spring holder, (47) Free chain spring, (45) Free chain knob assembly, (43) Brake spring and (44) Cam guide from (16) Pinion.
6.5.2. Lever
– Remove (31) Domed cap nut and (32) Spring lock washer which fix (29) Brake cover assembly to (10) Frame A assembly, and then remove (29) Brake cover assembly.
– While holding (37) Lever assembly horizontally by hand, turn (33) Female thread counterclockwise and remove the lever assembly from the hoist.
– Remove (42) Hex cap screw and (30) Flange nut, and separate (37) Lever assembly and (29)
Brake cover assembly.
– Remove (33) Female thread from (29) Brake cover assembly.
– Remove (34) Select pawl, (35) Spring shaft and (36) Select-pawl spring from (37) Lever assembly.
6.5.3. Brake
– Remove the parts from (16) Pinion in the following order, (26) Friction plate (one piece), (27) Rachet disc, (28) Bushing, (26) Friction plate (one piece) and (25) Friction disc.
– Remove (24) Snap ring from the pawl shaft with snap ring pliers, and remove (22) Pawl and (23) Pawl spring.
6.5.4. Gears
– Remove (14) Domed cap nut and (15) Spring lock washer, and detach (13) Gear case assembly.
– Remove (17) Gear #2, (16) Pinion, (18) Load gear.
Note: For capacity 1.6 tonnes or less, the load gear and (19) Load sheave are as one, and the load gear will not be detached.
– Pull out (3) Top pin and remove (1) Top hook set.
6.5.5. Load Chain
– Remove (12) Frame B, (20) Chain guide and (21) Stripper.
– Remove (52) Load chain from (19) Load sheave.
– Remove (9) Split pin, (8) Slotted nut and (7) Chain pin from yoke part of (4) Bottom hook set, and remove (52) Load chain.
– Remove (19) Load sheave.
6.6. Assembly
WARNING
◼ Do not reconnect components beyond the stated criteria as a result of inspection.
◼ Ensure to secure the nuts and bolts firmly.
◼ Ensure to secure also the split pins.
Proceed as follows:
6.6.1. Lever– Set the select lever on the lever upper side to ‘N’ position.
– With the select lever pulled in the ‘a’ direction, as shown in the left picture, insert the hex part of the select lever into (34) Select pawl.
– Apply (G1) grease lightly to the pawl of (34) Select pawl.
– Apply (G1) grease lightly to the part of (35) Spring shaft as shown in the above picture.
– Insert (35) Spring shaft into (36) Select-pawl spring and attach them into the spring holder. WARNING
Do not apply oil to the friction side of the female thread.
CAUTION
Ensure to clean the friction side of the female thread.
– Apply (G3) grease lightly to the thread of (33) Female thread.
– Attach the friction side of (33) Female thread to (29) Brake cover assembly and set (37) Lever assembly on them.
– Secure it with (42) Hex cap screw and (30) Flange nut.
6.6.2. Lever Grip
CAUTION
New glue accompanies the lever grip when it is ordered for repair. Read and comply with its instruction manual and remove dirt such as water, oil and rust from the part glue-applied on the lever.
Applying glue
– Make a quick and even application of the glue on the all around the lever assembly as shown in the above picture.
– As instructed below, attach (38) Grip to the lever within 10 seconds after applying the glue. (Note: It will be difficult to attach if the glue dries or hardens.)
Fitting
– Place (38) Grip with its inside boss (rising part) downward.
– Insert the boss of (38) Grip until it completely fits into the boss hole of the lever.
– Tighten the binding screws firmly.
6.6.3. Load Sheave & Chain
– Attach (4) Bottom hook set to (52) Load chain with (8) Slotted nut and (7) Split pin. CAUTION
Use a new split pin.
– Apply (G3) grease to the inner parts of the bearing hole of (10) Frame A Assembly and (19) Load sheave as shown in the left picture.
– Attach (19) Load sheave to (10) Frame A Assembly at the stay-bolt longer side of the frame. Note: Face the side of the load sheave where it has no gear or serration.– Set (52) Load chain to (19) Load sheave as shown in the left picture, and attach (20) Chain guide and (21) stripper.
CAUTION
・Keep (53) Chain stopper link in parallel with the frame and set (52) Load chain with its welding part directed outward.
・Reeve (52) Load chain through (19) Load sheave and (20) Chain guide.
– Apply (G3) grease to the bearing part of (12) Frame B.
‐Make sure of proper fitting before attaching (12) Frame B to the stay bolts.
CAUTION
Make sure to set the flat parts of (10) Frame A Assembly and (12) Frame B in the same position with the holes for the top pin arranged.
6.6.4. Chain stopper link ‐If the no-load side of the load chain is disengaged from the load sheave by free chaining and excessive rewinding, you are exposed to an extremely dangerous state. To avoid this, attach a （53）chain stopper link.
DANGER
‐When attaching the （53）chain stopper link afresh, be sure to use new one and attach it to the second link of the load chain from the no-load side. If attached to the end link, it may be deformed or fractured, failing to prevent disengagement of the load chain.

Product Code| LB008| LB016、LB025、LB032
LB063、LB090
---|---|---
Gap（mm）| 1±1| 2±1

6.6.5. Top Hook – Fit (1) Top hook set between (10) Frame A assembly and (12) Frame B.
– Insert (3) Top pin from the side of (12) Frame B to fasten (1) Top hook set.
6.6.6. Gears – For capacity of 2.5 tonnes or more, attach (18) Load gear to the serration part of (19) Load sheave.
Note: Make sure that the load sheave is inserted to the load gear completely. If necessary, use a plastic hammer.
– Insert (16) Pinion into (19) Load sheave and arrange the pinion with (17) Gear #2 as shown in the left picture.
CAUTION
If ‘0’ mark alignment on two of the gear#2 do not match to the above picture, the gears will not rotate.
– Apply (G1) grease to gear cogs and shafts of e.g. (16) Pinion, (17) Gear #2 and (18) Load gear.
CAUTION
Apply grease good enough to the cogs. (approx. 20 g for 0.8 & 1 t, 30 g for 1.6 & 2.5 t, 60 g for 3.2 t or more)
– Set (13) Gear case assembly over the gears and fix it firmly to the stay bolts with (14) Domed cap nut and (15) Spring lock washer.
CAUTION
Fit the rims of (12) Gear frame B and (13) Gear case in right direction.
6.6.7. Brake
– Apply (G2) grease to the pawl shaft and (22) Pawl.
CAUTION
For (22) Pawl, just coat it with the grease, not too much.
– Fasten two sets of (23) Pawl spring and (22) Pawl with (24) Snap ring.
– While holding two pawls outward, set (25) Friction disc, (26) Friction plate, (28) Bushing, (27) Ratchet disc and (26) Friction plate properly in this order.
CAUTION
◼ Make sure that the pawl spring fits into the pawl.
◼ Make sure that the pawl comes into good contact with the rachet disc.
◼ The friction plates are dry ones. Do not apply oil to them.
◼ Make sure that (28) Bushing has sufficient oil. If the bushing oil is not enough, soak the bushing in turbine oil for a day and wipe extra oil for reuse.
6.6.8. Lever & Body
– Attach the lever assembled in 6.6.1 to the previously-assembled bake.
CAUTION
Fit the rims of (10) Frame A assembly and (29) Brake cover assembly in right direction.
– Fit (29) Brake cover assembly and (10) Frame A assembly by screwing (33) Female thread of the lever assembly clockwise to the thread of (16) pinion until making clicking sounds.
– Fasten (29) Brake cover assembly firmly to the stay bolts with (14) Domed cap nut and (15) Spring lock washer.
CAUTION
To eliminate a clearance in the brake section, perform the following procedures before moving to the next step.

1. Set the select lever to ‘N’ position.
2. Turn (33) Female thread clockwise to tighten the brake lightly with (52) Load chain at the hook side held by hand firmly without (19) Load sheave’s rotation.

Insufficient hold of the chain makes clicking sounds. Even in this case, the clearance is eliminated.
After tightening, make sure that the female thread will not rotate counterclockwise
– To attach (44) Cam guide to (16) Pinion, set a jog of the guide to right a bit from the middle of (33)
Female thread’s jog as shown in the following picture.
– Apply (G3) grease lightly to the side of (44) Cam guide.
CAUTION
– Set (43) Brake spring (silver color) into the slot of the back of (45) Free chain knob assembly.
Note: As indicated in the left picture, set the end of the spring to the rib of the knob.
– Fit the other end of (43) Brake spring to the jog of the female thread.
– Hold the load chain in the hook side firmly to prevent (19) Load sheave from rotating.
– Turn (45) Free chain knob assembly 120° clockwise while pressing it lightly on (33) Female thread.
Note: As the free chain knob turns, the cam parts of (44) Cam guide fit into the slots of the knob to set the knob down.
– With (45) Free chain knob assembly pressed, hook the outward-projecting end of (47) Free chain spring onto the slot at the back of (48) Spring holder, and hook the other end (inward-projecting) of the spring onto the slot of (45) Free chain knob assembly.
– Turn (48) Spring holder 120° counterclockwise while pressing it lightly toward (45) Free chain knob assembly to insert it along the pinion serration.
Note: (47) Free chain spring raises (48) Spring holder. Hold and do not loosen it.
– With (48) Spring holder held, fasten it with (49) Slotted nut and (50) Split pin.
– Set the select lever to ‘N’ position and pull the free chain knob into the free chaining mode. Ensure to perform the free chaining operation.
CAUTION
If the free chaining can not be performed, the hoist has been misassembled.
Ensure to reassemble in accordance with this instruction.
6.7. Preoperational Checks
CAUTION
After assembly, ensure to perform the preoperational checks with the following points before reuse.
– Check defects in appearance, any parts left to be assembled.
– Perform lifting and lowering operation and check the following items.

• Should be free of irregular clicking sounds in lifting or abnormal sounds
• Should be free of heavier pull to lift
• Should be free of brake slipping

– Ensure that the hoist operate properly under no load before checking the hoist under a load.

Troubleshooting

WARNING
◼ If a defect is found in the hoist, stop using it immediately and check the cause of the defect.
◼ Read and comply with instructions in this manual and use the hoist properly.
◼ Ensure that competent people conduct repairs, otherwise please confirm with your dealer.
◼ Replace components with new ones authorized by KITO.

For lifting

CAUTION| Checking sounds from the hoist is a critical inspection. So, note the sounds of the hoist in operation.
-For lifting, moving the lever forward and backward should make clicking sounds.
-For lowering, moving the lever only backward, not forward, should make clicking sounds.
---|---
Hoist will not lift -Slight clicking| Improper assembly of rachet disc, i.e. incorrect contact with the pawl caused by its wrong side fitting.| Reassemble the pawl and rachet disc properly and ensure to check click sounds before reuse.
Hoist will not lift -Not clicking| Faulty pawl contact
-The pawl or pawl shaft stuck with dust or oil caused by long-term negligent maintenance may make poor contact for the pawl and rachet disc.
-Faulty pawl spring may cause this symptom.| Perform periodic overhauls. Faulty contact:
Improper select-lever fitting
-Missing select-pawl spring
-Assembly in wrong direction| Reassemble it properly and ensure to check click sound of the select lever before reuse.

Loose select-pawl spring| Perform periodic overhauls.
Hoist will not lift -Impossible lever operation| Improper assembly of gear #2
-Mis-located ‘0’ mark| Reassemble it properly and ensure to check smooth operation before reuse.
CAUTION Ensure to set the ‘0’ marks of the gear #2 as shown in the following picture.
Symptom| Cause| Remedy
---|---|---
Hoist will lift intermittently

-Slight or irregular clicking

| Poor pawl movement caused by faulty pawl spring.
-The spring is loose or damaged.| Perform periodic overhauls.
Mis-assembly of pawl spring.| Reassemble it properly and ensure to check click sound of the pawl before reuse.
During operation, hoist idles or load drifts| Poor contact of load sheave and load chain caused by improper chain-reeving such as the following picture.| Reassemble it properly and ensure to check proper lifting before reuse.

Hoist will not lift under no load| Mis-assembly of brake spring -Insufficient angle to set the spring will cause a poor braking.| Reassemble it properly.
CAUTION Turn the free chain knob 120° clockwise and set the brake spring.
Hoist will not lift all over the way| Capsized hook| Reset the capsized hook.
Check the chain for any damage.

For lowering

CAUTION

-Faulty braking may cause improper lowering.
-The friction method is a dry one. Do not apply oil to friction surfaces.

Load will not go down| Excessively tightened brake
-The hoist under a load left for a long period.
-A shock during operation.| Set the select lever to ‘DN’ position and reset the brake by lowering with larger pull.
-Brake tightened by rust.| Replace the rusty components and Perform periodic overhauls.
Load drops when lowering starts.| A foreign object between friction surfaces.| Remove the object and clean the surfaces. Replace if the surface is scarred.
Brake slip caused by significant rust.| Replace the rusty component and perform periodic overhauls.
Symptom| Cause| Remedy
---|---|---
Load drops when lowering starts.| Mis-assembly of friction plates, i.e. friction plates at one side as shown in the following picture or one lost.| Reassemble it properly as shown in the following picture and ensure to check hoist functions before reuse.
Cracked friction plate caused by overload.| Replace the friction plate and use the hoist properly within rated capacity.
Load drifts.| A foreign object between friction surfaces.| Remove the object and clean the surfaces.
Replace if the surface is scarred.
Friction plate wear
-Caused by high frequent and long term use.| Perform periodic overhauls.
Load drifts.| Mis-assembly of female thread and cam guide
-Attaching cam guide without tightening female thread may cause an un-tightened brake.| Reassemble it properly.
CAUTION
Secure the female thread firmly before attaching cam guide.

For free chaining

Free chain knob does not rise.| Damaged or deformed friction plate.| Perform periodic overhauls.
---|---|---
Load chain is not pulled in free chain mode.
Note: Not defect| Load chain pulled with free chain knob held.| Pull the load chain without holding the free chain knob.
Load chain pulled with excessive force (brake excessively tightened).| Pull the load chain with smaller force.
CAUTION
This prevents the load from dropping even with unintentional operation to free chain mode.
Mis-assembly of free chain spring
-Twisted with excessive angle.| See the symptom of “Hoist will not lift under no load.”
Load drops when select lever is set in free chain mode.| Mis-assembly of free chain spring
-Poorly tightened brake caused by insufficient twist angle.| See the symptom of “Hoist will not lift under no load.”
Hard to reset the hoist out of free chain mode.| Mis-assembly of free chain spring
-Insufficient twist angle.| Reassemble it properly.
Symptom| Cause| Remedy
---|---|---

For load chain

CAUTION
-The load chain is one of critical parts of the hoist. Ensure to maintain the chain carefully including proper handling, good maintenace and inspection.

-Replace the chain pin for the load chain replacement.

Load chain wear.| Lack of lubricant
-Caused by high frequent and long term use.| Keep the load chain lubricated.
Deformed or scarred load chain.| Twisted load chain caused by mis-assembling.| Reeve the load chain into hoist properly. Replace as needed.
Deformed or scarred load chain.| Capsized hook| Reset the capsized hook. Replace as needed.
Contact with load or an obstacle.| Replace as needed.
Do not use the load chain as a sling.
Extended pitch of load chain caused by overload.| Replace as needed.
WARNING ** Do not lift over the rated capacity.
Rusty load chain.| Lack of lubricant.| Handle and maintain the hoist properly corresponding to your operating conditions.
CAUTION Keep the hoist hooked indoors when out of use.
Exposed to rain.
Exposed to seawater or chemicals.
Broken load chain.| Caused often by a combination of the three symptoms as mentioned above and shock load.| WARNING ** Broken load chain could result in death or serious injury.
Ensure to maintain the chain carefully
including proper handling, good maitenace and inspection.
Symptom| Cause| Remedy
---|---|---

For hooks

CAUTION To prevent the hooks from being damaged, handle them properly in accordance with this manual.

Stretched hook.| Overload
-Hook will begin to deform gradually when the load applied exceeds the double of rated load.| WARNING ** Stretched hook warns you about overload. Do not lift over the rated capacity.
Support on tip of hook.| Support a load in the middle of the hook saddle.
Improper slinging, sling size used to hook, or suspension angle.| -Use a sling suitable for your operation.
-Use the sling with suspension angle of 120 degrees or less.
Bend shank or neck of hook.| Support on tip of hook.| WARNING ** Ensure to support a load in the middle of the hook saddle, otherwise the hook could be damaged.
Twisted hook.| Attaching load chain around load.| Do not use the load chain as a sling.
Broken hook latches.| Hook deformed by overloading.| Perform proper hooking.
Improper sling in size used to hook.
Sling hooked on latch.

Warranty

KITO Corporation (referred to after as KITO) extends the following warranty to the original purchaser (referred to after as Purchaser) of new products manufactured by KITO (KITO’s Products) KITO warrants that KITO’s Products, when shipped, shall be free from defects in workmanship and/or materials under normal use and service and KITO shall, at the election of KITO, repair or replace free of charge any parts or items which are proven to have said defects, provided that all claims for defects under this warranty shall be made in writing immediately upon discovery and, if there is anything within one(1) year from the date of purchase of KITO’s Products by Purchaser and provided, further, that defective parts or items shall be kept for examination by KITO or its authorized agents or returned to KITO’s factory or authorized service center upon request by KITO.
KITO does not warrant components of products provided by other manufacturers. However to the extent possible, KITO will assign to Purchaser applicable warranties of such other manufacturers.
Except for the repair or replacement mentioned above which is KITO’s sole liability and purchaser’s exclusive remedy under this warranty, KITO shall not be responsible for any other claims arising out of the purchase and use of KITO’s Products, regardless of whether Purchaser’s claims are based on breach of contract tort or other theories, including claims for any damages whether direct, indirect incidental or consequential.
This warranty is conditional upon the installation, maintenance and use of KITO’s Products pursuant to the product manuals prepared in accordance with content instructions by KITO. This warranty shall not apply to KITO’s Products which have been subject to negligence, misuse, abuse, misapplication or any improper use or combination or improper fittings, alignment or maintenance.
KITO shall not be responsible for any loss or damage caused by transportation, prolonged or improper storage or normal wear and tear of KITO’s Products or for loss of operating time.
This warranty shall not apply to KITO’s Products which have been fitted with or repaired with parts, components or items not supplied or approved by KITO or which have been modified or altered.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

Parts List

9.1. Up to 3.2 tonnes
Exclusive for 2.5 & 3.2 tonnes9.2. Exclusive Parts
Note: These basic bodies are the same as 3.2 tonnes. 9.3. Optional Parts
Lever assembly for load signal type
1. Four rivets are also supplied to fasten the nameplate.
2. Since Brake Cover Assembly is exclusive for LOAD SIGNAL 0.8 tonne and 1 tonne, their standard Brake
Cover Assembly needs to be exchanged for LOAD SIGNAL installation.

Contents of EC Declaration of Conformity

We, KITO Corporation,
2000 Tsuijiarai, Showa-cho,
Nakakoma-gun, Yamanashi-ken, 409-3853,Japan
declare under our sole responsibility that the products:
Manually lever operated chain hoist in capacity range of 800 kg up to 9 tonnes
LB, model L5
to which this declaration relates is in conformity with the following EC directives and standards.
EC directives:
Machinery Directive
2006/42/EC
Harmonized standards:
EN ISO 12100:2010
Risk assessment and risk reduction
EN 13157:2004+A1:2009
Hand powered lifting equipment,
except for the requirement of “5.2.6 Operating effort”

URL. http://www.kito.com
KITO Europe GmbH
Heerdter Lohweg 93, D-40549 Düsseldorf, Germany
TEL: +49-(0)211-528009-0
FAX: +49-(0)211-528009-59
E-mail: [email protected]
URL: http://www.kito.net
KITO corporation
Tokyo Head office:
SHINJUKU NS Building 9F, 2-4-1, Nishi-Shinjuku, Shinjuku-ku, Tokyo 163-0809, Japan
URL: http://www.kito.com
Head office & Factory:
2000 Tsuijiarai Showa-Cho, Nakakoma-Gun, Yamanashi 409-3853, Japan
URL: http://www.kito.com 

References

• KITO GROUP | Global Site
• KITO GROUP | Global Site
• Home – KITO – Raise your world

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