Harrington Hoists TCR User Manual

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

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

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.

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.

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.

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

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)

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

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

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

8.7 2.1/1.6 1.8/2.2 210/190 170/200 22 x 2 1074 7.0

2.2 Dimensions

TCR10000P2 TCR25000P2

Table 2-2 TCR with Pendant Control Dimensions

Cap.

(Tons)

Product

Code

Headroom

(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

(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

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

Figure 2-2 Hoist Part Identification Diagrams – 25 Ton TCR25000P2 and TCR25000C2

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

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.

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.

+ 30 hidden pages