Harrington Hoists TCR User Manual
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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
WARNING
This equipment should not be installed, operated o
maintained by any person who has not read and understood
all the contents of this manual. Failure to read and compl
with the contents of this manual can result in serious bodil
injury or death, and/or property damage.
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, Hoses And Fittings
3.7 Mounting Location
3.8 Connecting Hoist to Air Supply
3.9 Mounting the Hoist
3.10 Optional Chain Container
3.11 Non-Stationary Application
3.12 Preoperational Checks and Trial Operation
4.0 Operation……………………………………………………………………………………………. 19
4.1 Introduction
4.2 Shall’s and Shall Not’s for Operation
4.3 Hoist Controls
4.4 Adjusting the Controls
4.5 Operation of the Load Limiter
2
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 Load Limiter
7.2 Brake
7.3 Load Chain
7.4 Pendant
7.5 Load Sheave Inspection
7.6 Storage
7.7 Outdoor Installation
8.0 Troubleshooting…………………………………………………………………………………….. 38
9.0 Warranty…………………………………………………………………………………………….. 40
9.0 Parts Information……………………………………………………………………………………. 41
3
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
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.
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
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.
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WARNING
Equipment described herein is not designed for and MUST NOT
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”.
be used for lifting, supporting, or transporting people,
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.
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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.
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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
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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
Standard
Lift
(ft)
Cap.
(Tons)
Product
Code
Table 2-1 Hoist Specifications
Push
Button
Hose
(ft)
Up/Down Speeds
(ft/min @ 90 psi)
L
No Load w/Full Load No Load w/Full Load
Air Consumption Rates
(cubic ft/min @ 90 psi)
Up/Down
Load Chain
Diameter
(mm)
Chain Fall
Lines
x
Net
Weight
(lbs)
Weight for
Additional
One Foot
of Lift
(lbs)
10 TCR10000P2 8.8 7.2/5.9 5.1/7.6 220/180 180/210 16 x 2 476 3.8
Model
Pendant
25 TCR25000P2
10
9.4 2.1/1.6 1.8/2.2 210/190 170/200 22 x 2 1082 7.0
10 TCR10000C2 8.1 7.2/5.9 5.1/7.6 220/180 180/210 16 x 2 465 3.8
Cord
Model
25 TCR25000C2
10
8.7 2.1/1.6 1.8/2.2 210/190 170/200 22 x 2 1074 7.0
8
2.2 Dimensions
j
j
TCR10000P2 TCR25000P2
Table 2-2 TCR with Pendant Control Dimensions
Cap.
(Tons)
Product
Code
Headroom
C
(in)
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
(in)
(in)
i
(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 TCR25000C2
Cap.
(Tons)
Product
Code
Headroom
C
(in)
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
(in)
(in)
i
(in)
10 TCR10000C2 35.0 21.7 18.4 9.7 12.0 1.6 7.4 11.0 2.4
25 TCR25000C2 56.7 27.5 18.7 14.3 13.2 3.1 6.4 12.3 4.9
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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
TCR25000C/P2
2.8 2.4 2.4 2.2 2.4 2.6 1.6 7.1
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
Figure 2-2 Hoist Part Identification Diagrams – 25 Ton TCR25000P2 and TCR25000C2
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3.0 Preoperational Procedures
3.1 Air Supply System Requirements
3.1.1
3.1.2
3.1.3
NOTICE
air hoist with required pressure and flow. Otherwise the hoist may operate poorly or may fail to
operate. See Section 3.2.
CAUTION
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
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.
Pressure and Flow - Verify that the air supply system has capacity to supply your
Lubrication - The hoist requires lubrication for proper operation. The oil in the air
Air Quality - Good air quality is essential to prevent damage to your hoist and to
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
3.3.1
3.3.2
CAUTION
as follows:
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
minute (2 to 3 cc/minute). The hoist’s exhaust will emit a fine oil mist when properly lubricated.
3.4 Filtration
3.4.1
CAUTION
microns in size. Therefore, the hoist must have a 5 micron filter
upstream of the lubricator.
The hoist must be supplied with its own lubricator. The lubricator must be located
The lubricator must be set to deliver the equivalent of 10 to 15 drops of oil per
The air entering the hoist inlet must not contain any particulate greater than 5
in its air supply. The filter must be
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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.
3.5 Air Dryer -
supply system to ensure that dry air
this moisture will cause corrosion on internal hoist components during periods when the hoist is idle leading to
hoist malfunction.
CAUTION
3.6 Piping, Hoses And Fittings
3.6.1
CAUTION
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.
System Configuration - The system should be configured as shown in Figure 3-1.
To prevent corrosion and hoist malfunction, employ an air dryer in the air
is supplied to the hoist. If there is moisture in the air supplied to the hoist,
Figure 3-1 Diagram of Air Supply Configuration (Typical)
Figure 3-2 Typical Air Supply Filter, Regulator and Lubricator.
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3.6.2
3.6.3
NOTICE
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
Model
Diameter of Supply
Pipe
Diameter of Supply
Hose
TCR10000P2
TCR25000C2
TCR10000P2
Inside diameter
1.25 inch or larger
Inside diameter
1.0 inch or larger
TCR25000C2
NOTICE
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.
3.6.4
Figure 3-3 Typical Arrangements of Filter, Regulator and Lubricator and
Maximum Air Supply Hose Lengths
CAUTION
Fittings - Important considerations regarding fittings in the hoist's air supply
include:
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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