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EFFECTIVE: May 1, 2006
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
W ARN ING
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 Terms and Summary 1.2 Warning Tags and Labels 2.0 Technical Information………………………………………………………………………………… 8 2.1 Specifications 2.2 Dimensions 2.3 Part Names 3.0 Pre-operational Procedures………………………………………………………………………... 12 3.1 Air Supply System Requirements 3.2 Air Supply Capacity And Regulation 3.3 Lubrication 3.4 Filtration 3.5 Air Dryer 3.6 Piping, Hos
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Section Page Number 5.0 Inspection………………………………………………………………………….………………… 24 5.1 General 5.2 Inspection Classification 5.3 Frequent Inspection 5.4 Periodic Inspection 5.5 Occasionally Used Hoists 5.6 Inspection Records 5.7 Inspection Methods and Criteria 6.0 Lubrication…………………………………………………………………………………………... 31 6.1 Air Hoist Lubrication 6.2 Load Chain Lubrication 6.3 Hooks and Suspension Components 7.0 Maintenance & Handling…………………………………………………………………………… 32 7.1
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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 situati
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WA R N IN G 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, rer
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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.
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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
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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% o
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2.2 Dimensions Table 2-2 TCR with Pendant Control Dimensions TCR10000P2 TCR25000P2 Headroom Cap. Product a b d e g h i j C (Tons) Code (in) (in) (in) (in) (in) (in) (in) (in) (in) 10 TCR10000P2 35.0 21.7 18.4 9.7 12.0 1.6 7.4 11.0 2.4 25 TCR25000P2 56.7 27.5 18.7 14.3 13.2 3.1 6.4 12.3 4.9 TABLE 2-3 TCR WITH CORD CONTROL DIMENSIONS TCR10000C2 T
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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 2.4 2.4 2.2 2.4 2.6 1.6 7.1 TCR25000C/P2 4.9 3.5 3.9 3.5 4.9 4.9 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 10
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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 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 3.1.2 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 lubr
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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 3.5 Air Dryer - 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 durin
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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 Diameter of Supply Model Pipe Hose TCR10000P2 TCR25000C2 Inside diameter Inside diameter TCR10000P2 1.25 inch or larger 1.0 inch or larger TCR25000C2 NOTICE 3.6.3 Hoses - The connection from the air supply system piping to the hoist must be made with a flexible pressure hose.
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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 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
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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 Disconnec
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Figure 3-6 Capsized Hook and Chain WARNING 3.11.3 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 3.11.4 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 TCR1
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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
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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.
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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 operat
