This equipment should not be installed, operated or
injury or deat h, and/or p ropert y d amag e.
AIR
POWERED
CHAIN HOIST
TCR SERIES
¼ Ton through 6 Ton Capacity
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
Table of Contents
Section Page Number
1.0 Important Information and Warnings…… …………………… ………………… ………… …………4
This manual provides impor tant 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, Cauti on and Notic e - 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 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 minoror
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.
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 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
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
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.
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
1.2 Warning Tags and Labels
The warning tag illustrated below in Figure 1-1is 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 1-1Warning Tag Attached to Air Hoist
7
2.0 T echni cal Informati on
Temperature range:
+14° to +140°F (-10° to +60°C)
Relative Humidity:
85% or less
Noise Level:
92 dba maximum @ 1 meter when lifting rated load
Supply Air:
60 to 90 pounds per square inch
Air Consumption:
30 to 90 cubic feet minute
Air Lubrication Requirements:
Minimum 10 to 15 drops per minute (2-3 cc/min) of oil
Figure 2-4Hoist Part Identification Diagrams TCR 1000P2, 1000C2, 2000P2, 2000C2
13
Figure 2-5Hoist Part Identification Diagrams TCR 3000P, 3000C
Figure 2-6Hoist Part Identification Diagrams TCR 6000P2, 6000C2
14
3.0 Preoperational Procedu res
3.1 Air Supply System Requirements
3.1.1
air hoist with required pressure and flow. Otherwise the hoist may operate poorly or may fail to
operate. See Section 3.2.
3.1.2
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.
3.1.3
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
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.
3.3.2
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
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
15
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.
3.6 Piping, Hoses And Fittings
3.6.1
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, reg ulator (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 3-1Diagram of Air Supply Configuration (Typical)
Figure 3-2Typical Air Supply Filter, Regulator and Lubricator.
16
3.6.2
Piping - Pipe should be sized to accommodate the hoist airflow requirements.
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.
Diameter of Supply
Pipe
Inside diameter
0.75 inch or larger
Inside diameter
1.0 inch or larger
Diameter of Supply
Hose
Inside diameter
0.5 inch or larger
Inside diameter
0.75 inch or larger
3.6.4
Figure 3-3Typical Arrangements of Filter, Regulator and Lubricator and
Maximum Air Supply Hose Lengths
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.
17
3.6.5
purging procedures to prevent contaminants or moisture from entering the hoist.
Before connecting the hoist to its air supply line; perform the proper draining and
3.7 Mounting Location
3.7.1
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.
3.7.2
Prior to mounting the hoist ensure that the suspension and it supporting structure
See Section 7.6 for outdoor installation considerations.
3.8 Connecting Hoist to Air Supply
3.8.1
OF COMPRESSED AIR TO THE HOIST, AND IN THE CONNECTIONS BETWEEN COMPONENTS.
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY
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”.
3.8.3
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 1/2 inch.
3.8.6
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.
Figure 3-4Typical Air Supply Connection
Before connecting the air supply hose to the hoist, always purge the air hose to
Where conditions dictate, the installation sequence can be reversed by mounting
18
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 .
3.10 Optional Chain Container
3.10.1 For installation of the optional bag style chain container refer to Figure 3-5below and perform the
following:
Make sure all end stoppers and limit locks are installed correctly. See Sections 3.12 and 7.3.
Torque all fasteners to the values shown.
Feed the chain into the chain container beginning with the free end. Take care to avoid twisting or
tangling the chain.
Do not use the chain container if any parts are damaged or if any fasteners/hardware are missing.
Figure 3-5Optional Chain Container Installation
3.11 Non-Stationary Application
3.11.1 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.
3.11.2 Connections and fittings must be kept clean and care taken to prevent dirt, debris and moisture from
entering the hoist.
3.11.3 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
19
3.12 Preoperational Checks and T rial Oper ation
3.12.1
3.12.2
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.
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 3-6and 3-7.
Figure 3-6Twist in Load Chain
3.12.3
Figure 3-7Capsized Hook and Chain
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.
20
3.12.4
For Models TCR-250P&C, 500P&C, 1000P2&C2, 1000P&C and 2000P2&C2
verify the limit locks are properly installed on the load chain. For reference see Figure 3-8 for hoist
versions 1, A, B and C and Section 7.3.2. For Models TCR-3000P&C and 6000P2&C2 verify that the
chain/limit lever is operational and can move freely in both the up and down directions. For reference
see Figure 3-9.
Versions 1, A and B Version C Only
Figure 3-8 Limit Switch Components
Figure 3-9Limit Switch Components
3.12.5 Measure and record the “K” dimension of all hooks on hoist. See Table 5-6under Section 5,
“Inspection”. Always use the same side of the hook to measure and record the "K" dimension.
3.12.6 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.
21
3.12.7 Ensure that the hoist is properly installed to either a fixed point, or trolley, whichever applies.
3.12.8 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.
3.12.9 Ensure that all nuts, bolts and split (cotter) pins are sufficiently fastened.
3.12.10 For hoists with pendant controls, ensure that the pendant's exterior flexible metal hose is intact and is
properly attached to the hoist. Also ensure that the air tubing and wire cable inside the pendant hose
are properly attached to the hoist. See Section 7.4.
3.12.11
Check Air Supply - Check air supply before everyday use. Ensure proper air
quality and air pressure.
3.12.12
Check the lubricator for proper function and adequate oil level.
3.12.13 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.
3.12.14 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”.
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