EFFECTIVE: May 1, 2006
Owner’s Manual
AIR
POWERED
CHAIN HOIST
TCR SERIES
MODEL TCR
10 Ton and 25 Ton Capacity
Code, Lot and Serial Number
WARNING
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.
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Table of Contents
Section
Page Number
1.0
Important Information and Warnings…………………………………………………………………4
1.1
1.2
Terms and Summary
Warning Tags and Labels
2.0
Technical Information…………………………………………………………………………………8
2.1
2.2
2.3
Specifications
Dimensions
Part Names
3.0
Pre-operational Procedures………………………………………………………………………...12
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Air Supply System Requirements
Air Supply Capacity And Regulation
Lubrication
Filtration
Air Dryer
Piping, Hoses And Fittings
Mounting Location
Connecting Hoist to Air Supply
Mounting the Hoist
3.10 Optional Chain Container
3.11 Non-Stationary Application
3.12 Preoperational Checks and Trial Operation
Operation……………………………………………………………………………………………. 19
4.0
4.1
4.2
4.3
4.4
4.5
Introduction
Shall’s and Shall Not’s for Operation
Hoist Controls
Adjusting the Controls
Operation of the Load Limiter
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Section
Page Number
5.0
Inspection………………………………………………………………………….…………………24
5.1
5.2
5.3
5.4
5.5
5.6
5.7
General
Inspection Classification
Frequent Inspection
Periodic Inspection
Occasionally Used Hoists
Inspection Records
Inspection Methods and Criteria
6.0
7.0
Lubrication…………………………………………………………………………………………... 31
6.1
6.2
6.3
Air Hoist Lubrication
Load Chain Lubrication
Hooks and Suspension Components
Maintenance & Handling……………………………………………………………………………32
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Load Limiter
Brake
Load Chain
Pendant
Load Sheave Inspection
Storage
Outdoor Installation
8.0
9.0
9.0
Troubleshooting…………………………………………………………………………………….. 38
Warranty…………………………………………………………………………………………….. 40
Parts Information…………………………………………………………………………………….41
3
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1.0 Important Information and Warnings
1.1
Terms and Summary
This manual provides important information for personnel involved with the installation, operation and maintenance
of this product. Although you may be familiar with this or similar equipment, it is strongly recommended that you read
this manual before installing, operating or maintaining the product.
Danger, Warning, Caution and Notice - Throughout this manual there are steps and procedures that can present
hazardous situations. The following signal words are used to identify the degree or level of hazard seriousness.
DANGER
WARNING
CAUTION
NOTICE
Danger indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury, and property damage.
Warning indicates an imminently hazardous situation which, if not avoided, could result in death or
serious injury, and property damage.
Caution indicates a potentially hazardous situation which, if not avoided, may result minor or
moderate injury or property damage.
Notice is used to notify people of installation, operation, or maintenance information which is
important but not directly hazard-related.
CAUTION
These general instructions deal with the normal installation, operation, and maintenance situations encountered with
the equipment described herein. The instructions should not be interpreted to anticipate every possible contingency
or to anticipate the final system, crane, or configuration that uses this equipment. For systems using the equipment
covered by this manual, the supplier and owner of the system are responsible for the system’s compliance with all
applicable industry standards, and with all applicable federal, state and local regulations/codes.
This manual includes instructions and parts information for a variety of hoist types. Therefore, all instructions and
parts information may not apply to any one type or size of specific hoist. Disregard those portions of the instructions
that do not apply.
Record your hoist’s Code and Serial Number (see Section 3.11.6 and Figure 10-1) on the front cover of this manual
for identification and future reference to avoid referring to the wrong manual for information or instructions on
installation, operation, inspection, maintenance, or parts.
Use only Harrington authorized replacement parts in the service and maintenance of this hoist.
4
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WARNING
Equipment described herein is not designed for and MUST NOT be used for lifting, supporting, or transporting people,
or for lifting or supporting loads over people.
Equipment described herein should not be used in conjunction with other equipment unless necessary and/or
required safety devices applicable to the system, crane, or application are installed by the system designer, system
manufacturer, crane manufacturer, installer, or user.
Modifications to upgrade, rerate, or otherwise alter this equipment shall be authorized only by the original equipment
manufacturer.
Equipment described herein may be used in the design and manufacture of cranes or monorails. Additional
equipment or devices may be required for the crane and monorail to comply with applicable crane design and safety
standards. The crane designer, crane manufacturer, or user is responsible to furnish these additional items for
compliance. Refer to ANSI/ASME B30.17, “Safety Standard for Top-Running Single Girder Cranes”; ANSI/ASME
B30.2 “Safety Standard for Top-Running Double-Girder Cranes”; and ANSI/ASME B30.11 “Safety Standard for
Underhung Cranes and Monorails”.
If a below-the-hook lifting device or sling is used with a hoist, refer to ANSI/ASME B30.9, “Safety Standard for
Slings” or ANSI/ASME B30.20, “Safety Standard for Below-the-Hook Lifting Devices”.
Hoists, trolleys and cranes, used to handle hot molten material may require additional equipment or devices. Refer to
ANSI Z241.2, “Safety Requirements for Melting and Pouring of Metals in the Metalcasting Industry”.
Failure to read and comply with any one of the limitations noted herein can result in serious bodily injury or death,
and/or property damage.
5
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DANGER
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY OF COMPRESSED AIR TO THE
HOIST, AND IN THE CONNECTIONS BETWEEN COMPONENTS.
Before performing ANY maintenance on the equipment, de-energize the supply of compressed air to the
equipment, and lock and tag the supply device in the de-energized position. Refer to ANSI Z244.1, “Personnel
Protection - Lockout/Tagout of Energy Sources.”
Only trained and competent personnel should inspect and repair this equipment.
NOTICE
It is the responsibility of the owner/user to install, inspect, test, maintain, and operate a hoist in accordance with
ANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations. If the hoist is installed as part of a
total lifting system, such as an overhead crane or monorail, it is also the responsibility of the owner/user to comply with
the applicable ANSI/ASME B30 volume that addresses that type of equipment.
It is the responsibility of the owner/user to have all personnel that will install, inspect, test, maintain, and operate a
hoist read the contents of this manual and applicable portions of ANSI/ASME B30.16, “Safety Standard for Overhead
Hoists” and OSHA Regulations. If the hoist is installed as part of a total lifting system, such as an overhead crane, the
applicable ANSI/ASME B30 volume that addresses that type of equipment must also be read by all personnel.
If the hoist owner/user requires additional information, or if any information in the manual is not clear, contact
Harrington or the distributor of the hoist. Do not install, inspect, test, maintain, or operate this hoist unless this
information is fully understood.
A regular schedule of inspection of the hoist in accordance with the requirements of ANSI/ASME B30.16 should be
established and records maintained.
6
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1.2
Warning Tags and Labels
The warning tag illustrated below in Figure 1-1 is supplied with each hoist shipped from the factory. If the tag is not
attached to your hoist (for pendant control, the warning tag is attached to the pendant hose; for the pull cord control, the
warning tag is attached to the up cord), order a tag from your dealer and install it. See parts list in the parts section of
this manual. Read and obey all warnings attached to this hoist. Tag is not shown actual size.
front
back
Figure 1-1 Warning Tag Attached to Air Hoist
7
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2.0 Technical Information
2.1
Specifications
2.1.1 Product Code
2.1.2 Operating Conditions and Environment
Temperature range: +14° to +140°F (-10° to +60°C)
Relative Humidity: 85% or less
Supply Air: 60 to 90 pounds per square inch
Air Consumption: 170 to 220 cubic feet minute
Air Lubrication Requirements: Minimum 10 to 15 drops per minute (2-3 cc/min) of oil
Air Filtration Requirements: Maximum 5 micron air filter or finer
Load Limiter: Adjustable; Factory set to 125% of rated capacity
Table 2-1 Hoist Specifications
Load Chain
Diameter
(mm)
Up/Down
Air Consumption Rates
Push
Standard Button
Weight for
Additional
One Foot
of Lift
Up/Down Speeds
(ft/min @ 90 psi)
Net
Weight
(lbs)
Cap.
(Tons)
Product
Code
Lift
(ft)
Hose
L
(ft)
(cubic ft/min @ 90 psi)
x
Chain Fall
Lines
(lbs)
No Load w/Full Load No Load w/Full Load
10 TCR10000P2
25 TCR25000P2
10 TCR10000C2
25 TCR25000C2
8.8
9.4
8.1
8.7
7.2/5.9
2.1/1.6
7.2/5.9
2.1/1.6
5.1/7.6
1.8/2.2
5.1/7.6
1.8/2.2
220/180 180/210
210/190 170/200
220/180 180/210
210/190 170/200
16 x 2
22 x 2
16 x 2
22 x 2
476
1082
465
3.8
7.0
3.8
7.0
10
10
1074
8
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2.2
Dimensions
Table 2-2 TCR with Pendant Control Dimensions
TCR10000P2
TCR25000P2
Headroom
Cap.
(Tons)
Product
Code
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
(in)
i
j
C
(in)
(in)
(in)
10
25
TCR10000P2
TCR25000P2
35.0
56.7
21.7 18.4
9.7
12.0
1.6
3.1
7.4
6.4
11.0
12.3
2.4
4.9
27.5 18.7 14.3 13.2
TABLE 2-3 TCR WITH CORD CONTROL DIMENSIONS
TCR10000C2
TCR25000C2
Headroom
Cap.
(Tons)
Product
Code
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
(in)
i
j
C
(in)
(in)
(in)
10
25
TCR10000C2
TCR25000C2
35.0
56.7
21.7 18.4
9.7
12.0
1.6
3.1
7.4
6.4
11.0
12.3
2.4
4.9
27.5 18.7 14.3 13.2
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Table 2-4 Top and Bottom Hook Dimension*
Units = inch
Product Code
a
b
c
d
e
f
g
h
TCR10000C/P2 2.8
TCR25000C/P2 4.9
2.4
3.5
2.4
3.9
2.2
3.5
2.4
4.9
2.6
4.9
1.6
7.1
3.1 13.1
*Refer to Section 5.7 for inspection dimensions and limits.
2.3
Part Names
Figure 2-1 Hoist Part Identification Diagrams – 10 Ton TCR10000C2 and TCR10000P2
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Figure 2-2 Hoist Part Identification Diagrams – 25 Ton TCR25000P2 and TCR25000C2
11
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3.0 Preoperational Procedures
3.1 Air Supply System Requirements
NOTICE
3.1.1
3.1.2
3.1.3
Pressure and Flow - Verify that the air supply system has capacity to supply your
air hoist with required pressure and flow. Otherwise the hoist may operate poorly or may fail to
operate. See Section 3.2.
CAUTION
Lubrication - The hoist requires lubrication for proper operation. The oil in the air
supply is the primary source of lubrication to the hoist. Therefore, a dedicated air supply lubricator must
be used with the hoist. Refer to Section 3.3.
CAUTION
Air Quality - Good air quality is essential to prevent damage to your hoist and to
ensure its proper operation. The air must be clean and free of debris such as dirt and rust. Refer to
Section 3.4 for filtration requirements. The air must also be dry; free of moisture and water. Refer to
Section 3.5.
3.2
Air Supply Capacity And Regulation
3.2.1 Capacity - The air supply system must be capable of delivering the required airflow (cfm) to the hoist
inlet port. Without the required airflow the hoist will not operate properly or may not operate at all. See
Section 2.0 for your hoists air consumption requirements. In determining if your system is capable of
supplying the required airflow, consider the following:
ꢀ
ꢀ
ꢀ
Capacity of compressor(s) and tank
Other air consuming equipment
Flow restrictions such as pipes, hoses, valves and fittings
Inadequate capacity will cause a significant drop in pressure when the hoist is operated, and could
cause poor performance or failure to operate.
3.2.2 Regulation - The hoist requires a constant supply of air at a pressure of between 60 and 90 psi. If the
air supply is not regulated or is regulated at a pressure greater than 90 psi, then a regulator must be
used. The regulator may be located anywhere upline of the lubricator in the air supply to the hoist.
3.3
Lubrication
CAUTION
as follows:
3.3.1
The hoist must be supplied with its own lubricator. The lubricator must be located
1) Best location - At the hoist inlet. In this case the lubricator can be either the mist type or drop
type.
2) Second best location - No more than 15 feet away from the hoist, at the same elevation or
above the hoist inlet. In this case the mist type lubricator must be used.
3) Third best location - No more than 15 feet away below the hoist. In this case the mist type
lubricator must be used.
CAUTION
3.3.2
The lubricator must be set to deliver the equivalent of 10 to 15 drops of oil per
minute (2 to 3 cc/minute). The hoist’s exhaust will emit a fine oil mist when properly lubricated.
3.4
Filtration
CAUTION
3.4.1
The air entering the hoist inlet must not contain any particulate greater than 5
microns in size. Therefore, the hoist must have a 5 micron filter in its air supply. The filter must be
upstream of the lubricator.
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3.4.2 The filter servicing the hoist can also service other hoists and air consuming equipment. In this case,
the air filter must be in sized for the total air consumption of the equipment it is servicing.
CAUTION
To prevent corrosion and hoist malfunction, employ an air dryer in the air
supply system to ensure that dry air is supplied to the hoist. If there is moisture in the air supplied to the hoist,
this moisture will cause corrosion on internal hoist components during periods when the hoist is idle leading to
hoist malfunction.
3.5
3.6
Air Dryer -
Piping, Hoses And Fittings
CAUTION
3.6.1
System Configuration - The system should be configured as shown in Figure 3-1.
Since moisture tends to accumulate in compressed air systems, corrosion may result if the system is
not periodically drained.
ꢀ
ꢀ
ꢀ
Arrange for a drain in the air supply piping at the lowest point in the piping, and
Periodically drain the system to remove moisture/water from the system and to prevent corrosion.
Filter, regulator (if equipped), and lubricator must be arranged in the order shown in Figure 3-2.
Figure 3-1 Diagram of Air Supply Configuration (Typical)
Figure 3-2 Typical Air Supply Filter, Regulator and Lubricator.
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NOTICE
3.6.2
Piping - Pipe should be sized to accommodate the hoist airflow requirements.
Table 3-1 gives recommended pipe sizes.
Table 3-1 Air Supply Pipe and Hose Sizes
Diameter of Supply
Pipe
Diameter of Supply
Hose
Model
TCR10000P2
TCR25000C2
TCR10000P2
TCR25000C2
Inside diameter
1.25 inch or larger
Inside diameter
1.0 inch or larger
NOTICE
3.6.3
Hoses - The connection from the air supply system piping to the hoist must be
made with a flexible pressure hose. Due to normal line losses in air supply lines:
ꢀ
ꢀ
Do not use hose smaller than specified in Table 3-1, and
Limit the length of the hose to that specified in Figure 3-3.
If your application exceeds these requirements consult factory.
Figure 3-3 Typical Arrangements of Filter, Regulator and Lubricator and
Maximum Air Supply Hose Lengths
CAUTION
include:
3.6.4
Fittings - Important considerations regarding fittings in the hoist's air supply
ꢀ
When connecting air supply components, remove all dirt or debris from the connecting surfaces of
the hoses, pipes, fittings, or threaded fasteners to prevent contaminants from entering the hoist.
ꢀ
Keep airflow restrictions such as quick disconnect fittings, bends, elbows, and adapters to a
minimum.
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CAUTION
3.6.5
Before connecting the hoist to its air supply line; perform the proper draining and
purging procedures to prevent contaminants or moisture from entering the hoist.
3.7
3.8
Mounting Location
WARNING
3.7.1
Prior to mounting the hoist ensure that the suspension and it supporting structure
are adequate to support the hoist and its loads. If necessary consult a professional that is qualified to
evaluate the adequacy of the suspension location and its supporting structure.
NOTICE
3.7.2
See Section 7.6 for outdoor installation considerations.
Connecting Hoist to Air Supply
WARNING
3.8.1
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY
OF COMPRESSED AIR TO THE HOIST, AND IN THE CONNECTIONS BETWEEN COMPONENTS.
Figure 3-4 Typical Air Supply Connection
3.8.2 Shut off the air supply and stop the airflow completely. Lock out and tag out in accordance with ANSI
Z244.1 “Personnel Protection -Lockout/Tagout of Energy Sources”.
CAUTION
3.8.3
Before connecting the air supply hose to the hoist, always purge the air hose to
clear any debris and water.
3.8.4 Apply approximately 10-15 drops of turbine oil (see approved lubricant under Section 6.0 Lubricants)
into the hose before attaching to the hoist.
3.8.5 Make connections to air supply; reference Figure 3-4. Use a reducing adapter at the hoist valve
section for hose sizes larger than 1 inch.
NOTICE
3.8.6
Where conditions dictate, the installation sequence can be reversed by mounting
the hoist first (Section 3.9) followed by connecting the air supply (Section 3.8).
3.9
Mounting the Hoist
3.9.1 Manual Trolley - Follow instructions in Owner’s Manual provided with the trolley.
3.9.2 Motorized Trolley - Follow instructions in Owner’s Manual provided with the trolley.
3.9.3 Hook Mounted to a Fixed Location - Attach the hoist’s top hook to the fixed suspension point.
WARNING
3.9.4
Ensure that the fixed suspension point rests on the center of the hook’s saddle and
that the hook’s latch is engaged .
15
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3.10 Non-Stationary Application
3.10.1 For applications such as rental fleets or construction sites where the hoist is moved from place-to-
place, a filter and lubricator are still required. Consult factory for recommended methods.
3.10.2 Connections and fittings must be kept clean and care taken to prevent dirt, debris and moisture from
entering the hoist.
3.10.3 Recommended practice for removing the hoist from an installation:
ꢀ
ꢀ
ꢀ
ꢀ
Run the hoist briefly with well lubricated air
Disconnect the air supply line
Inject a small quantity (approximately 20 drops) of oil into the hoist’s inlet port
Plug the inlet port
3.11 Preoperational Checks and Trial Operation
CAUTION
3.11.1
Check for the availability of required operating air pressure of between 60 PSI to
90 PSI at the hoist's inlet port before trying to operate the hoist.
WARNING
3.11.2
Verify that the load chain is not twisted or tangled and that the bottom hook is not
capsized prior to operating the hoist. Correct all chain irregularities before conducting the first hoist
operation. See Figures 3-5 and 3-6.
Figure 3-5 Twist in Load Chain
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Figure 3-6 Capsized Hook and Chain
WARNING
3.11.3
3.11.4
Confirm the adequacy of the rated capacity for all slings, chains,
wire ropes and all other lifting attachments before use. Inspect all load suspension
members for damage prior to use and replace or repair all damaged parts.
WARNING
Verify that the Chain/Limit Levers are operational and can move
freely in both the up and down directions. For reference see Figure 3-7.
Figure 3-7 Limit Switch Components – 10 Ton TCR10000C2 and TCR10000P2
17
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Figure 3-8 Limit Switch Components – 25 Ton TCR25000C2 and TCR25000P2
3.11.5 Measure and record the “K” dimension of all hooks on hoist. See Table 5-6 under Section 5,
“Inspection”. Always use the same side of the hook to measure and record the "K" dimension.
3.11.6 Record the hoist Code Number and Serial Number (from the nameplate on the hoist – see Section 10)
in the space provided on the cover of this manual.
3.11.7 Ensure that the hoist is properly installed to either a fixed point, or trolley, whichever applies.
3.11.8 If hoist is installed on a trolley, ensure that
ꢀ
ꢀ
trolley is properly installed on the beam, and
stops for the trolley are correctly positioned and securely installed on the beam.
3.11.9 Ensure that all nuts, bolts and split (cotter) pins are sufficiently fastened.
3.11.10 For hoists with pendant controls, Ensure that the Pendant Hoses and Strain Relief Chain are properly
attached to the hoist. See Section 7.4.
CAUTION
3.11.11
Check Air Supply - Check air supply before everyday use. Ensure proper air
quality and air pressure.
CAUTION
3.11.12
Check the lubricator for proper function and adequate oil level.
3.11.13 Confirm proper operation.
ꢀ
ꢀ
Before operating read and become familiar with Section 4 - Operation.
Before operating ensure that the hoist (and trolley) meets the Inspection, Testing and Maintenance
requirements of ANSI/ASME B30.16.
ꢀ
Before operating ensure that nothing will interfere with the full range of the hoist’s (and trolley’s)
operation.
3.11.14 Proceed with trial operation to confirm proper operation.
ꢀ
ꢀ
Initially operate slowly under no load in both directions. Verify controls agree with hoist direction.
Perform inspections per Section 5.3, “Frequent Inspections”.
18
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4.0 Operation
4.1 Introduction
DANGER
DO NOT WALK UNDER A SUSPENDED LOAD
WARNING
HOIST OPERATORS SHALL BE REQUIRED TO READ THE OPERATION SECTION OF THIS MANUAL, THE
WARNINGS CONTAINED IN THIS MANUAL, INSTRUCTION AND WARNING LABELS ON THE HOIST OR
LIFTING SYSTEM, AND THE OPERATION SECTIONS OF ANSI/ASME B30.16 and ANSI/ASME B30.10. THE
OPERATOR SHALL ALSO BE REQUIRED TO BE FAMILIAR WITH THE HOIST AND HOIST CONTROLS
BEFORE BEING AUTHORIZED TO OPERATE THE HOIST OR LIFTING SYSTEM.
HOIST OPERATORS SHOULD BE TRAINED IN PROPER RIGGING PROCEDURES FOR THE ATTACHMENT
OF LOADS TO THE HOIST HOOK.
HOIST OPERATORS SHOULD BE TRAINED TO BE AWARE OF POTENTIAL MALFUNCTIONS OF THE
EQUIPMENT THAT REQUIRE ADJUSTMENT OR REPAIR, AND TO BE INSTRUCTED TO STOP OPERATION
IF SUCH MALFUNCTIONS OCCUR, AND TO IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE
ACTION CAN BE TAKEN.
HOIST OPERATORS SHOULD HAVE NORMAL DEPTH PERCEPTION, FIELD OF VISION, REACTION TIME,
MANUAL DEXTERITY, AND COORDINATION.
HOIST OPERATORS SHOULD NOT HAVE A HISTORY OF OR BE PRONE TO SEIZURES, LOSS OF
PHYSICAL CONTROL, PHYSICAL DEFECTS, OR EMOTIONAL INSTABILITY THAT COULD RESULT IN
ACTIONS OF THE OPERATOR BEING A HAZARD TO THE OPERATOR OR TO OTHERS.
HOIST OPERATORS SHOULD NOT OPERATE A HOIST OR LIFTING SYSTEM WHEN UNDER THE
INFLUENCE OF ALCOHOL, DRUGS, OR MEDICATION.
OVERHEAD HOISTS ARE INTENDED ONLY FOR VERTICAL LIFTING SERVICE OF FREELY SUSPENDED
UNGUIDED LOADS. DO NOT USE HOIST FOR LOADS THAT ARE NOT LIFTED VERTICALLY, LOADS THAT
ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED.
NOTICE
• Read ANSI/ASME B30.16 and ANSI/ASME B30.10.
• Read the hoist manufacturer’s Operating and Maintenance Instructions.
• Read all labels attached to equipment.
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The operation of an overhead hoist involves more than activating the hoist’s controls. Per the ANSI/ASME B30
standards, the use of an overhead hoist is subject to certain hazards that cannot be mitigated by engineered features,
but only by the exercise of intelligence, care, common sense, and experience in anticipating the effects and results of
activating the hoist’s controls. Use this guidance in conjunction with other warnings, cautions, and notices in this manual
to govern the operation and use of your overhead hoist.
4.2
Shall’s and Shall Not’s for Operation
WARNING
Improper operation of a hoist can create a potentially hazardous
situation which, if not avoided, could result in death or serious injury,
and substantial property damage. To avoid such a potentially
hazardous situation THE OPERATOR SHALL:
•
•
•
NOT lift more than rated load for the hoist.
springs, shock absorbers, stoppers, striker plates or
limit locks.
NOT operate unless load is centered under hoist.
•
•
•
NOT leave load supported by the hoist unattended
unless specific precautions have been taken.
NOT use damaged hoist or hoist that is not working
properly.
NOT allow the chain, or hook to be used as an
electrical or welding ground.
•
•
•
NOT use hoist with twisted, kinked, damaged, or
worn chain.
NOT allow the chain, or hook to be touched by a
live welding electrode.
NOT use hoist if the bottom hook is capsized
(double fall hoists - see Section 3.11).
•
•
NOT remove or obscure the warnings on the hoist.
NOT use the hoist to lift, support, or transport
people.
Be familiar with operating controls, procedures, and
warnings.
•
•
NOT lift loads over people.
•
•
Make sure the unit is securely attached to a
suitable support before applying load.
NOT apply load unless load chain is properly
seated in the load sheave (and idle sheave for hoist
with two chain falls).
Make sure load slings or other approved single
attachments are properly sized, rigged, and seated
in the hook saddle.
•
•
•
NOT use the hoist in such a way that could result in
shock or impact loads being applied to the hoist.
•
Take up slack carefully - make sure load is
balanced and load-holding action is secure before
continuing.
NOT attempt to lengthen the load chain or repair
damaged load chain.
NOT operate hoist when it is restricted from forming
a straight line from hook to hook in the direction of
loading.
•
•
•
Make sure all persons stay clear of the supported
load.
Protect the hoist’s load chain from weld splatter or
other damaging contaminants.
•
•
•
•
•
NOT use load chain as a sling or wrap load chain
around load.
Report malfunctions or unusual performances
(including unusual noises) of the hoist and remove
the hoist from service until the malfunction or
unusual performance is resolved.
NOT apply the load to the tip of the hook or to the
hook latch.
NOT apply load if binding prevents equal loading
on all load supporting chains.
•
•
•
Make sure hoist limit switches function properly.
Warn personnel before lifting or moving a load.
Warn personnel of an approaching load.
NOT operate beyond the limits of the load chain
travel.
NOT operate hoist with missing/damaged chain
20
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CAUTION
Improper operation of a hoist can create a potentially hazardous
situation which, if not avoided, could result in minor or moderate
injury, or property damage. To avoid such a potentially hazardous
situation THE OPERATOR SHALL:
•
•
•
•
•
Maintain a firm footing or be otherwise secured
when operating the hoist.
•
•
•
•
•
•
Use the hoist manufacturer’s recommended parts
when repairing the unit.
Check brake function by tensioning the hoist prior
to each lift operation.
Lubricate load chain per hoist manufacturer’s
recommendations.
Use hook latches. Latches are to retain slings,
chains, etc. under slack conditions only.
NOT use the hoist load limiting or warning device to
measure load.
Make sure the hook latches are closed and not
supporting any parts of the load.
NOT use limit switches as routine operating stops.
They are emergency devices only.
Make sure the load is free to move and will clear all
obstructions.
NOT allow your attention to be diverted from
operating the hoist.
•
•
Avoid swinging the load or hook.
NOT allow the hoist to be subjected to sharp
contact with other hoists, structures, or objects
through misuse.
Make sure hook travel is in the same direction as
shown on controls.
•
NOT adjust or repair the hoist unless qualified to
perform such adjustments or repairs.
•
Inspect the hoist regularly, replace damaged or
worn parts, and keep appropriate records of
maintenance.
4.3
Hoist Controls
4.3.1 For hoists mounted to motorized trolleys follow the control instruction included in the trolley ‘s Owner’s
Manual.
4.3.2 Pendant Control - When using the pendant control depress the up lever to raise the hoist or the down
lever to lower the hoist as shown in Figure 4-1 below. To stop motion release the lever switches.
Figure 4-1 Pendant Control
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4.3.3 Cord Control - When using a hoist with cord control, pull down on the appropriate colored cord to raise
or lower the hoist. White indicates the raise control and red indicates lowering control. Release the
cords to stop the hoist. Refer to Figure 4-2 below.
Figure 4-2 Cord Control
CAUTION
4.3.4
Make sure the motor completely stops before reversing direction.
4.4
Adjusting the Controls
4.4.1 For pendant control, the speed can be adjusted by the amount the lever is depressed. As shown below
in Figure 4-3, by depressing the lever slightly, you will be able control the hoist’s motions slowly and
with more precision. By depressing the lever further, the speed of the hoist will be increased until the
lever is fully depressed.
4.4.2 For the cord type control, adjust the speed by varying the amount of pull on the cord. Refer to Figure
4-4.
Figure 4-4 Cord Control Speed Adjustment
22
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4.5
Operation of the Load Limiter
4.5.1 If a hoist is used to lift a load that exceeds the hoists rated capacity, the load limiter will cause the hoist
to automatically stop lifting.
4.5.2 If the hoist stops lifting automatically, lower and remove the load from the hoist.
4.5.3 If the load is at or below the hoist’s capacity rating and the hoist stops lifting automatically, the load
limiter may need adjustment.
ꢀ
ꢀ
Check air line pressure to ensure adequate pressure at the hoist.
If pressure is adequate, adjust the load limiter. For load limiter adjustment, refer to Section 7.
23
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5.0 Inspection
5.1
General
5.1.1 The inspection procedure herein is based on ANSI/ASME B30.16. The following definitions are from
ANSI/ASME B30.16 and pertain to the inspection procedure below.
ꢀ
Designated Person - a person selected or assigned as being competent to perform the specific
duties to which he/she is assigned.
ꢀ
Qualified Person - a person who, by possession of a recognized degree or certificate of
professional standing, or who, by extensive knowledge, training, and experience, has successfully
demonstrated the ability to solve or resolve problems relating to the subject matter and work.
ꢀ
Normal Service - that distributed service which involves operation with randomly distributed loads
within the rated load limit, or uniform loads less than 65% of rated load for not more than 25% of
the time.
ꢀ
ꢀ
Heavy Service - that service which involves operation within the rated load limit which exceeds
normal service.
Severe Service - that service which involves normal or heavy service with abnormal operating
conditions.
5.2
Inspection Classification
5.2.1 Initial Inspection - prior to initial use, all new, altered, or modified hoists shall be inspected by a
designated person to ensure compliance with the applicable provisions of this manual.
5.2.2 Inspection Classification - the inspection procedure for hoists in regular service is divided into two
general classifications based upon the intervals at which inspection should be performed. The intervals
in turn are dependent upon the nature of the critical components of the hoist and the degree of their
exposure to wear, deterioration, or malfunction. The two general classifications are herein designated
as FREQUENT and PERIODIC, with respective intervals between inspections as defined below.
5.2.3 FREQUENT Inspection - visual examinations by the operator or other designated personnel with
intervals per the following criteria:
ꢀ
ꢀ
ꢀ
ꢀ
Normal service - monthly
Heavy service - weekly to monthly
Severe service - daily to weekly
Special or infrequent service - as recommended by a qualified person before and after each
occurrence.
5.2.4 PERIODIC Inspection - visual inspection by a designated person with intervals per the following criteria:
ꢀ
ꢀ
ꢀ
ꢀ
Normal service - yearly
Heavy service - semiannually
Severe service - quarterly
Special or infrequent service - as recommended by a qualified person before the first such
occurrence and as directed by the qualified person for any subsequent occurrences.
24
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5.3
Frequent Inspection
5.3.1 Inspections should be made on a FREQUENT basis in accordance with Table 5-1, “Frequent
Inspection.” Included in these FREQUENT Inspections are observations made during operation for
any defects or damage that might appear between Periodic Inspections. Evaluation and resolution of
the results of FREQUENT Inspections shall be made by a designated person such that the hoist is
maintained in safe working condition.
Table 5-1 Frequent Inspection
All functional operating mechanisms for maladjustment and unusual sounds.
Operation of limit switch and associated components
Hoist braking system for proper operation
Hooks in accordance with ANSI/ASME B30.10
Hook latch operation
Load chain in accordance with Section 5.7
Load chain reeving for compliance with Section 3.11 and 7.3
Air valves and components for leakage or damage
5.4
Periodic Inspection
5.4.1 Inspections should be made on a PERIODIC basis in accordance with Table 5-2, “Periodic Inspection.”
Evaluation and resolution of the results of PERIODIC Inspections shall be made by a designated
person such that the hoist is maintained in safe working condition.
5.4.2 For inspections where load suspension parts of the hoist are disassembled, a load test per ANSI/ASME
B30.16 must be performed on the hoist after it is re-assembled and prior to its return to service.
Table 5-2 Periodic Inspection
Requirements of frequent inspection.
Evidence of loose bolts, nuts, or rivets.
Evidence of worn, corroded, cracked, or distorted parts such as load blocks, suspension housing,
chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings and pins.
Evidence of damage to hook retaining nuts or collars and pins, and welds or rivets used to secure
the retaining members.
Evidence of damage or excessive wear of load and idler sheaves.
Evidence of excessive wear on motor vanes or on load brake.
Evidence of damage of supporting structure or trolley, if used.
Function labels on pendant control stations for legibility.
Warning label properly attached to the hoist and legible (see Section 1.2).
End connections of load chain.
25
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5.5
5.6
Occasionally Used Hoists
5.5.1 Hoists that are used infrequently shall be inspected as follows prior to placing in service:
ꢀ
ꢀ
Hoist Idle More Than 1 Month, Less Than 1 Year: Inspect per FREQUENT Inspection criteria of
Section 5.3 above.
Hoist Idle More Than 1 Year: Inspect per PERIODIC Inspection criteria of Section 5.4 above.
Inspection Records
5.6.1 Dated inspection reports and records should be maintained at time intervals corresponding to those
that apply for the hoist’s PERIODIC interval per Section 5.2.4. These records should be stored where
they are available to personnel involved with the inspection, maintenance, or operation of the hoist.
5.6.2 A long range chain inspection program should be established and should include records of
examination of chains removed from service so a relationship can be established between visual
observation and actual condition of the chain.
5.7
Inspection Methods and Criteria
5.7.1 This section covers the inspection of specific items. The list of items in this section is based on those
listed in ANSI/ASME B30.16 for the Frequent and Periodic Inspection. In accordance with ANSI/ASME
B30.16, these inspections are not intended to involve disassembly of the hoist. Rather, disassembly for
further inspection would be required if frequent or periodic inspection results so indicate. Such
disassembly and further inspection should only be performed by a qualified person trained in the
disassembly and re-assembly of the hoist.
Table 5-3 Hoist Inspection Methods and Criteria
Item
Method
Criteria
Action
Functional operating Visual, Auditory
mechanisms.
Mechanisms should be properly adjusted and
should not produce unusual sounds when
operated.
Repair or replace
as required.
Limit Switch
Function
Visual, Function
Function
Visual
Proper operation. Actuation of limit switch should Repair or replace
stop hoist. as required.
Chain Lever/Limit
Lever Assembly
Lever should not be bent or significantly worn and Replace.
should be able to move freely.
Braking System
Braking distance should not exceed
approximately five chain links.
Repair or replace
as required.
Hooks - Surface
Condition
Should be free of significant rust, weld splatter,
deep nicks, or gouges.
Replace.
Hooks - Fretting
wear
Measure
Measure
The “u” dimension should not be less than
minimum value listed in Table 5-6.
Replace.
Replace.
Hooks - Stretch
The “K” dimension should not exceed the
maximum value for replacement from Table 5-6
(See Section 3.11).
26
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Table 5-3 Hoist Inspection Methods and Criteria (continued)
Item
Method
Criteria
Action
Replace.
Hooks - Bent Shank Visual
or Neck
Shank and neck portions of hook should be free
of deformations
Hooks - Yoke
Assembly
Visual
Should be free of significant rust, weld splatter,
nicks, gouges. Holes should not be elongated,
fasteners should not be loose, and there should
be no gap between mating parts.
Clean/Lubricate, or
replace as required.
Hooks - Swivel
Bearing
Visual, Function
Bearing parts and surfaces should not show
significant wear, and should be free of dirt, grime
and deformations. Hook should rotate freely with
no roughness.
Clean/lubricate, or
replace as required.
Hooks - Idle Sheave Visual, Function
and Axle (Bottom
Hook on Double Fall
Hoist)
Pockets of Idle Sheave should be free of
significant wear. Idle Sheave surfaces should be
free of nicks, gouges, dirt and grime. Bearing
parts and surfaces of Idle Sheave and Axle
should not show significant wear. Idle Sheave
should rotate freely with no roughness or
significant free play.
Clean/lubricate, or
replace as required.
Hooks - Hook
Latches
Visual, Function
Latch should not be deformed. Attachment of
latch to hook should not be loose. Latch spring
should not be missing and should not be weak.
Latch movement should not be stiff - when
depressed and released latch should snap
smartly to its closed position.
Replace.
Replace.
Load Chain -
Surface Condition
Visual
Should be free of rust, nicks, gouges, dents, and
weld splatter. Links should not be deformed, and
should not show signs of abrasion. Surfaces
where links bear on one another should be free of
significant wear.
Load Chain - Pitch
Measure
The “L” dimension should not be greater than
maximum value listed in Table 5-7.
Replace, inspect
Load Sheave (and
Idle Sheave for
double fall hoist).
Load Chain -
Lubrication
Visual, Auditory
Visual
Entire surface of each chain link should be coated Clean/lubricate
with lubricant and should be free of dirt and grime. (see Sections 6.0).
Chain should not emit cracking noise when
hoisting a load.
Load Chain -
Reeving
Chain should be reeved properly through Load
Sheave (and Idle Sheave for double fall hoist) -
refer to Section 3.11. Chain, limit locks and
stoppers should be installed properly - refer to
Section 7.3.2.
Reeve/Install chain
properly.
Bolts, Nuts and
Rivets
Visual, Check
with Proper Tool
Bolts, nuts and rivets should not be loose.
Tighten or replace
as required.
27
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Table 5-3 Hoist Inspection Methods and Criteria (continued)
Item
Method
Criteria
Action
Replace
Housing and
Mechanical
Components
Visual, Auditory,
Vibration,
Function
Hoist components including load blocks,
suspension housing, chain attachments, clevises,
yokes, suspension bolts, shafts, gears, bearings,
pins and rollers should be free of cracks,
distortion, significant wear and corrosion.
Evidence of same can be detected visually or via
detection of unusual sounds or vibration during
operation.
Chain Separator
Motor Brake
Visual, Measure
Measure, Visual
The Chain Guide/Side Plate should be free of
cracks, distortion, significant wear and corrosion.
The “L” and "W" dimension should not be greater
than maximum value listed in Table 5-5.
Replace
Replace
Motor brake dimension should be within the
allowable limits of Table 5-4. See Section 7.2 for
gaining access to motor brake. Braking surfaces
should be clean, free of grease/oil and should not
be glazed.
Load Sheave
Visual
Pockets of Load Sheave should be free of
significant wear. See Section 7.5 to gain visual
access to the load sheave.
Replace.
Pendant Control
Levers
Visual,
Function
Depressing and releasing pendant control levers
should cause hoist to operate.
Repair or replace
as necessary.
Pendant - Housing
Visual
Pendant housing should be free of cracks and
mating surfaces of parts should seal without gaps.
Replace.
Pendant - Tubing
Visual, auditory
Tubing to pendant control switches should not be Repair or replace
loose or be leaking air.
as necessary.
Pendant - Labels
Warning Labels
Visual
Visual
Labels denoting functions should be legible.
Replace.
Warning Labels should be affixed to the hoist (see Replace
Section 1.2) and they should be legible.
Hoist Capacity Label Visual
The label that indicates the capacity of the hoist
should be legible and securely attached to the
hoist.
Replace.
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Table 5-4 Brake Disc Dimension
Parts View
Figure No.
Std Dimension
Inch (mm)
Minimum Value for Replacement
Inch (mm)
Hoists
TCR10000C2
TCR10000P2
TCR25000C2
TCR25000P2
T = 0.16 (4.0)
T = 0.10 (2.5)
Table 5-5 Chain Guide/Side Plate Dimensions
Std Dimension
Inch (mm)
Maximum Value for Replacement
Parts View
Figure No.
Hoists
Inch (mm)
L = 1.69 (42.8)
W = 2.48 (63)
L = 2.36 (60)
W = 4.02 (102)
L = 1.57 (40)
W = 2.36 (60)
L = 2.20 (55.8)
W = 3.82 (97)
TCR10000C2
TCR10000P2
146
TCR25000C2
TCR25000P2
161 & 162
29
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Table 5-6 Top Hook & Bottom Hook Dimensions
Dimensions K and U should be measured and recorded below prior to any use when the hook is first placed into service.
Parts View
Figure No.
Recorded Dimension
When New
Maximum/Minimum Value
for Replacement
Hoists
Top Hook K = _______________
Top Hook U = _______________
Bottom Hook K = ____________
Bottom Hook U = ____________
For K if the measured dimension
exceeds 1.05 times the recorded new
dimension, the hook should be
replaced.
TCR10000C2
TCR10000P2
165
180
Top Hook K = _______________
Top Hook U = _______________ less than .9 times the recorded new
Bottom Hook K = ____________
Bottom Hook U = ____________
For U if the measured dimension is
TCR25000C2
TCR25000P2
dimension, the hook should be
replaced.
Table 5-7 Chain Dimensions
“P” Dimension
inch (mm)
“d” Dimension
inch (mm)
Parts View
Figure No.
Product Code
Standard
Discard
Standard
Discard
TCR10000C2
TCR10000P2
182
179
8.86 (225)
9.00 (228.5)
0.63 (16)
0.87 (22)
0.61 (15.5)
TCR25000C2
TCR25000P2
12.99 (330)
13.14 (333.8)
0.85 (21.5)
30
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6.0 Lubrication
6.1
Air Hoist Lubrication
6.1.1 See Section 3.0 for lubrication requirements.
CAUTION
6.1.2
Lubrication to the motor will be provided primarily by the air supply lubricator. The
recommended amount is 10-15 drops/minute (2-3cc/min.). Refer to Table 6-1 below for the approved
lubricant for use with your air hoist.
6.1.3 Additional lubrication to the reduction gears is not necessary. When disassembling the hoist for service
or repair, apply new grease to the gears before reassembling the hoist.
6.2
6.3
Load Chain Lubrication
6.2.1 For longer life, lightly coat the load chain with machine or gear oil. Ensure that the oil is applied to the
bearing surfaces of the load chain links.
6.2.2 The load chain lubrication should be accomplished after cleaning the load chain with acid free cleaning
solution. Use approved lubricant in Table 6-1 or equivalent.
6.2.3 For dusty environments, it is acceptable to substitute a dry lubricant.
Hooks and Suspension Components
6.3.1 Hooks - Bearings should be cleaned and lubricated at least once per year for normal usage. Clean and
lubricate more frequently for heavier usage or severe conditions.
6.3.2 Suspension Pins - Lubricate at least twice per year for normal usage; more frequently for heavier usage
or severe conditions.
Table 6-1 Table of Approved Lubricants
Application
Air motor
Part Location
Lubricator
Lubrication
Turbine Oil
Grade
ISO VG 32-56 or
equivalent
Load chain & pocket
wheel
ISO VG 46-68 or
equivalent
Load chain
Machine or gear oil
Grease
Hook bearings &
suspension pins
Top & bottom hook
sets
National Lubricating
Grease #3
National Lubricating
Grease #2
Gears and Bearings
Gear Section
Grease
31
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7.0 Maintenance and Handling
7.1
Load Limiter
7.1.1 The purpose of the load limiter is to prevent using the hoist in an overload situation. When lifting, the
hoist will stop automatically if the load is above the rated capacity of the hoist.
7.1.2 The adjustment is factory set to actuate at approximately125% of rated capacity (based on supply air
pressure of 90 PSI). Note: the load limiter may need adjustment to compensate for air supply
pressures significantly less than 90 PSI.
Figure 7-1 Load Limiter screw adjustment location
7.1.3 Adjustment Procedure
1) Before proceeding with the load limiter adjustment, note the following:
WARNING
a.
Adjusting the load limiter involves operating the hoist. Personnel involved
in the adjustment procedure should read, understand, and follow Section 4, "Operation".
b. For the adjustment procedure, the hoist should be connected to an air supply (see Section 3.1)
and it should initially be without a load on its hook.
c. Start this procedure with an unloaded hoist. All adjustments to the load limiter should be made
with the load in a resting position so that the load chain is not tensioned.
d. For the adjustment procedure: OUT means the counter-clockwise (CCW) direction, and IN
means the clockwise (CW) direction.
e. The pressure of the air supply at the hoist’s inlet port (acceptable range is 60 to 90 PSI) affects
the performance of your air hoist, including the actuation point of the load limiter. Therefore,
ensure that during the adjustment procedure the air pressure at the hoist's inlet port is the
same as that which the hoist will experience in normal operation. The relationship between air
supply pressure and load limiter actuation is:
ꢀ
For a given load limiter setting, as pressure decreases, the actuation point increases.
f. When the load limiter is adjusted and working properly, the hoist will operate and lift the load a
short distance before the load limiter automatically stops lifting.
2) Refer to Figure 7-1. Loosen the lock nut and slowly turn the adjustment screw OUT until it is loose and
no longer is in contact with the internal load limiter spring – as this occurs the screw should become
easier to turn. Stop turning the screw once it is loose and easier to turn.
3) Turn the adjustment screw IN just enough so that it begins to contact the internal load limiter spring –
as this occurs the screw should become slightly harder to turn.
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4) Put a load equal to the desired actuation point on the hoist's hook (do not exceed 125% of the hoist's
rated capacity). Begin to slowly lift the load, then increase the lifting speed. Return the load to its
resting position so the load chain is not under tension.
5) If the load limiter prevents lifting, turn the adjustment screw IN one full turn.
6) Repeat steps 4 and 5 until the load limiter allows lifting.
7) Turn the adjustment screw OUT ¾ of a turn.
8) Attempt to lift the rated capacity load again, beginning slowly, then increasing the lifting speed.
9) If the load limiter does not allow lifting, then turn the adjustment screw IN ¼ turn.
10) Repeat steps 8 and 9 until the load limiter allows lifting.
11) Turn the adjustment screw IN ¼ turn. Then, while holding the adjustment screw, tighten the lock nut to
secure the setting.
7.2
Brake
7.2.1 For Load Brake setup and adjustment procedure consult factory.
7.2.2 Inspect the brake disc in accordance with Section 5.7, Table 5-3.
7.2.3 The following is the hoist brake inspection procedure. Refer to Figure 7-2.
WARNING
1)
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE
SUPPLY OF COMPRESSED AIR TO THE HOIST, AND IN THE CONNECTIONS BETWEEN
COMPONENTS. Shut off the air supply and stop the airflow completely. Lock out and tag out in
accordance with ANSI Z244.1 “Personnel Protection -Lockout/Tagout of Energy Sources”.
2) Do NOT turn or remove the brake adjustment screw located in the center of the brake cover.
3) Gradually back out all four hex socket cap screws from brake cover to slowly decrease spring
tension of brake piston against brake disc.
4) Remove brake cover from the motor housing top of gear case. Keep brake piston, springs, seals,
etc. together inside the brake cover.
5) Remove brake disc for inspection and measurement. Refer to "Motor Brake" in Table 5-3, "Hoist
Inspection Methods and Criteria".
6) Prior to reassembly, clean all surfaces of debris, dirt and loose paint.
7) Reassemble in reverse order. Torque all mounting hardware evenly during the reassembly
process.
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Figure 7-2 Brake Inspection Diagram
7.3
Load Chain
7.3.1 Lubrication and Cleaning
ꢀ
ꢀ
Clean the chain with an acid-free cleaning solution. The load chain should be kept clean and
lubricated.
Lubrication - Clean and lubricate the load chain per Section 6 at least once every 3 months for
normal usage. Clean and lubricate more frequently for heavier usage or severe conditions.
7.3.2 Replacement
CAUTION
1)
An air supply line must be connected to the hoist in order to perform the
following procedures. The hoist must accessible and must be hanging from the top hook
assembly.
WARNING
2)
3)
Be certain that the replacement chain is obtained from Harrington and is the
exact size, grade and construction as the original chain.
CAUTION
When replacing load chain, check for wear on mating parts, i.e. Load Sheave,
Chain Guides and Idle Sheave, and replace parts if necessary. Remove old chain. Remove hook
set assemblies, limit locks, stoppers and end connections from the chain for reuse on new chain. If
the load chain is being replaced due to damage or wear out, prevent its reuse by destroying the old
chain.
4) Remove the existing Load Chain – Lower the bottom hook assembly until it rests on the ground or
is supported by some other means. Disconnect the no-load and load end of the load chain from
the hoist. Run the hoist in the down direction to remove the chain form the hoist body.
5) Run the hoist in the up or down direction until the load sheave is positioned as shown in Figure 7-3.
6) Without operating the hoist, tie a wire to the end of the new load chain, then thread the wire
through the hoist over the load sheave. Pull the wire so that the load chain enters the hoist
making certain that the first link is a standing link and that its weld is facing away from the
centerline of the hoist.
34
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7) While pulling on the wire, SLOWLY operate hoist in the DOWN direction to thread the load chain
over the load sheave. Make sure the chain feeds smoothly while operating the hoist. If binding
occurs, stop and SLOWLY operate the hoist in the up direction to the back the chain out, then
reorient the load sheave as instructed in step 5 before attempting to reinsert the load chain.
8) Operated the hoist in the down direction until sufficient there is sufficient load chain to reeve the
hoist.
9) Reeve the chain through the bottom hook assembly. Remove the wire from the Load chain and
attach the no-load and load end of the load chain to the hoist. Ensure that chain remains free of
twists.
10) After installation has been completed, perform steps outlined in Section 3.12 "Preoperational
Checks and Trial Operation".
10 Ton TCR10000P2 & TCR10000C2
25 Ton TCR25000P2 & TCR25000C2
Figure 7-3 Diagram showing chain replacement
35
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7.4
Pendant
7.4.1 The following procedure covers the installation of a pendant control station.
1) Attach the strain relief chain and the three hoses to the pendant station.
2) Attach the strain relief chain to the hoist valve body with the socket bolt as shown in Figure 7-4.
3) Attach the three hoists to the fittings on the hoist's valve body. Refer to Figure 7-4 and make sure
the up, down and supply hoses are attached to the correct locations.
NOTICE
4)
When attaching tubes take care not to bend or kink tubing. This will result in
the air flow being restricted and poor response to the pendant controls.
5) Attach the hoist to supply air. Check for leaks and properoperation.
WARNING
6)
The pendant hoses hoist must be connected so that its direction of operation
corresponds to the up-and-down lever on the pendant control; i.e. pushing the up button must
cause the hook to raise. If the hoist does not operate correctly, shut off the air supply to the hoist
and correct the pendant connections.
Figure 7-4 Pendant Hose and Strain Relief Connections
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7.5
7.6
Storage
7.5.1 Whenever the hoist is to be placed into storage, place extra lubricating oil into the air inlet opening and
circulate the air motor before plugging the inlet. Make certain that no debris, dirt or moisture is allowed
to enter the air hoist through air inlet opening during preparations for storage.
7.5.2 The storage location should be clean and dry.
Outdoor Installation
7.6.1 For hoist installations that are outdoors, the hoist should be covered when not in use.
7.6.2 In order to prevent internal corrosion from occurring, the hoist must be operated using proper quality air
at least once per week by raising and lowering the hoist one full cycle. Note: the possibility of corrosion
in the valve section of the hoist increases for areas where salt air and high humidity are present. For
such situations you may need to operate your hoist more often than once per week.
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8.0 Troubleshooting
WARNING
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY OF COMPRESSED AIR TO
THE HOIST, AND IN CONNECTIONS BETWEEN COMPONENTS.
Before performing ANY maintenance on the equipment, de-energize the supply of compressed air to the
equipment, and lock and tag the supply device in the de-energized position. Refer to ANSI Z244.1, “Personnel
Protection - Lockout/Tagout of Energy Sources.”
Only Trained and competent personnel should inspect and repair this equipment.
Table 8-1 Troubleshooting Guide
Symptom
Cause
Remedy
Lack of air pressure or loss of air
supply.
Repair or adjust air supply or filters.
Seizure of Main Spool, Brake Spool,
or Air Motor.
Repair at service facility.
Repair at service facility.
Seizure of brake or brake
mechanism fails to release.
Does not operate
Bending or crimping of pendant
control hose(s)
Correct or repair the bend or crimp in
control hose(s)
Reduce the load to the rated capacity
of hoist.
Hoist is overloaded.
Repair or adjust air supply or filters.
Check for air line obstruction.
Low air pressure at hoist inlet port.
Replace hose or piping sizes with
recommended sizes in Section 3.0.
Air supply hose or piping is too small.
Malfunction of brake.
Repair at service facility.
Bending or crimping of pendant
control hose(s)
Correct or repair the bend or crimp in
control hose(s)
Increase oil in air supply to hoist in
accordance with requirements in
Section 3.0.
Lack of sufficient oil in air supply to
hoist
Lifting speed is slow
Exhaust Silencer clogged
Clean or replace.
Increase air flow capacity of
compressed air system to
requirements in Section 2.0.
Air flow capacity of compressed air
system insufficient
Air motor vanes or bearings worn
Repair at service facility.
Filter the air supply to the hoist in
accordance with the requirements in
Section 3.0.
Air supply to hoist contains dirt or
debris
Lack of air pressure or loss of air
supply.
Repair or adjust air supply or filters.
Adjust Load Limiter. See Section 7.1.
Unable to lift rated load
Improper adjustment of load limiter.
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Table 8-1 Troubleshooting Guide (continued)
Symptom
Cause
Remedy
Pendant control hoses are
terminated to incorrect ports on hoist
body.
Hoist moving in wrong
direction (pendant control)
Connect the control tubes in
accordance with Section 7.4.
Hoist is overloaded.
Reduce load to hoist rated capacity.
Faulty pendant control or control
hose(s)
Repair or replace pendant control or
control hose(s)
Hoist lowers but will not lift
Lack of air pressure or partial loss of
or leakage in air supply.
Repair or adjust air supply or filters.
Inject approx. 20 drops of oil into inlet
port to lubricate the main spool. If
spool still sticks, repair at service
facility.
Main Spool sticking
Hoist continues running after
pendant or cord is released
Valve in Pendant Handle stuck
Brake is not holding.
Repair at service facility
Hoist drifts excessively when
hoist is stopped
Repair brake at service facility.
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9.0 Warranty
Warranty explanation and terms.
All products sold by Harrington Hoists, Inc. are warranted to be free from defects in material and
workmanship from date of shipment by Harrington for the following periods:
Manual Hoists & Trolleys - 2 years
Air and Electric Powered Hoists, Trolleys, and Crane Components - 1 year
Spare / Replacement Parts - 1 year
The product must be used in accordance with manufacturer’s recommendations and must not have
been subject to abuse, lack of maintenance, misuse, negligence, or unauthorized repairs or
alterations.
Should any defect in material or workmanship occur during the above time period in any product,
as determined by Harrington Hoist’s inspection of the product, Harrington Hoists, Inc. agrees, at its
discretion, either to replace (not including installation) or repair the part or product free of charge
and deliver said item F.O.B. Harrington Hoists, Inc. place of business to customer.
Customer must obtain a Return Goods Authorization as directed by Harrington or Harrington’s
published authorized repair center prior to shipping product for warranty evaluation. An explanation
of the complaint must accompany the product. Product must be returned freight prepaid. Upon
repair, the product will be covered for the remainder of the original warranty period. If it is
determined there is no defect, or that the defect resulted from causes not within the scope of
Harrington’s warranty, the customer will be responsible for the costs of returning the product.
Harrington Hoists, Inc. disclaims any and all other warranties of any kind expressed or implied as to
the product’s merchantability or fitness for a particular application. Harrington will not be liable for
death, injuries to persons or property or for incidental, contingent, special or consequential
damages, loss or expense arising in connection with the use or inability whatever, regardless of
whether damage, loss or expense results from any act or failure to act by Harrington, whether
negligent or willful, or from any other reason.
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10.0 Parts Information
A complete parts list is available from Harrington Hoists and is supplied separately with your hoist. The parts list is also
manual).
When ordering Parts, please provide the Hoist code number located on the Hoist nameplate (see fig. below).
Reminder: Per Sections 3.11.6 and 1.1 to aid in ordering Parts and Product Support, record the Hoist code number and
serial number in the space provided on the cover of this manual.
Figure 10-1 TCR Nameplate
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NOTES
42
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NOTES
43
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Harrington Hoists – Western Division
Harrington Hoists, Inc.
401 West End Avenue
Manheim, PA 17545-1703
Phone: 717-665-2000
Toll Free: 800-233-3010
Fax: 717-665-2861
2341 Pomona Rincon Rd. #103
Corona, CA 92880-6973
Phone: 951-279-7100
Toll Free: 800-317-7111
Fax: 951-279-7500
TCROM1025
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