Harrington Hoists and Cranes TCR Hoist User Manual

Code Number and Serial Number

EFFECTIVE: October 7, 2010

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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

1.0 Important Information and Warnings

1.1 Terms and Summary

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 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.

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.

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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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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.

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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 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

Air Filtration Requirements:

Maximum 5 micron air filter or finer

Load Limiter:

Adjustable; Factory set to 125% of rated capacity

2.1 Specifications

2.1.1 Product Code

2.1.2 Operating Conditions and Environment

95 dba maximum @ 1 meter when lowering rated load

8

Product

Standard

Lift

Push

Button

Hose

L

Up/Down

Load Chain

Diameter

(mm)

x

Chain Fall

Net

Weight

Weight for

Additional

One Foot

of Lift

Table 2-1 Hoist S pecifi cations

Cap.

(Tons)

Code

1/4 TCR250P 1/2 TCR500P 7.5 68 / 44 37 / 57 63 / 49 48 / 57 6.3 x 1 68 0.6

1 TCR1000P2 7.5 34 / 22 19/ 29 63 / 49 48 / 57 6.3 x 2 78 1.2 1 TCR1000P 7.5 37 / 22 21 / 33 62 / 53 53 / 60 7.1 x 1 77 0.8 2 TCR2000P2 7.5 19 / 11 11 / 16 62 / 53 53 / 60 7.1 x 2 88 1.5

Pendant Model

3 TCR3000P 8.0 18 / 11 10 / 15 90 / 65 71 / 74 11.2 x 1 152 2.0 6 TCR6000P2 8.0 9 / 5 5 / 7 90 / 65 71 / 74 11.2 x 2 198 4.0

1/4 TCR250C 1/2 TCR500C 7.5 68 / 44 37 / 57 63 / 49 48 / 57 6.3 x 1 66 0.6

1 TCR1000C2 7.5 34 / 22 19/ 29 63 / 49 48 / 57 6.3 x 2 76 1.2 1 TCR1000C 7.5 37 / 22 21 / 33 62 / 53 53 / 60 7.1 x 1 75 0.8 2 TCR2000C2 7.5 19 / 11 11 / 16 62 / 53 53 / 60 7.1 x 2 86 1.5

Cord Model

3 TCR3000C 8.0 18 / 11 10 / 15 90 / 65 71 / 74 11.2 x 1 150 2.0 6 TCR6000C2 8.0 9 / 5 5 / 7 90 / 65 71 / 74 11.2 x 2 196 4.0

2.2 Dimensions

(ft)

10

Up/Down Speeds

(ft/min @ 90 psi)

No Load w/Full Load No Load w/Full Load

(ft)

Air Consumption Rates

(cubic ft/min @ 90 psi)

Lines

(lbs)

7.5 68 / 44 52 / 51 63 / 49 48 / 57 6.3 x 1 68 0.6

7.5 68 / 44 52 / 51 63 / 49 48 / 57 6.3 x 1 66 0.6

Table 2-2 Top and Bottom H ook Dimen sion*

Units = inch

Product Code a b c d e f g h

TCR250C/P 1.4 0.9 1.1 0.9 1.6 1.6 1.1 4.2 TCR500C/P 1.4 0.9 1.1 0.9 1.6 1.6 1.1 4.2 TCR1000C/P2 1.4 0.9 1.1 0.9 1.6 1.6 1.1 4.2 TCR1000C/P 1.4 0.9 1.1 0.9 1.6 1.6 1.1 4.2 TCR2000C/P2 1.8 1.2 1.5 1.2 1.8 2.0 1.1 4.9 TCR3000C/P 2.0 1.5 1.7 1.3 2.0 2.4 1.3 5.9 TCR6000C/P2 2.3 1.6 1.9 1.6 2.6 2.8 1.7 6.8

*Refer to Section 5.7 for inspection dimensions and limits.

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Product

Headroom

C

a

b

d

e

g

h

j

Table 2-3 TCR with Pendant Control Dimens ions

Cap.

(Tons)

Code

(in)

i

(in)

1/4 TCR250P 18.2 13.4 6.9 6.1 6.6 1.1 4.9 2.0 1.3 1/2 TCR500P 18.2 13.4 6.9 6.1 6.6 1.1 4.9 2.0 1.3

1 TCR1000P2 20.4 13.4 7.3 6.1 6.6 1.1 5.9 1.5 2.2 1 TCR1000P 18.3 13.4 6.9 6.1 6.6 1.1 4.9 2.0 1.3 2 TCR2000P2 21.8 13.4 7.6 6.1 6.6 1.1 6.0 1.6 2.3 3 TCR3000P 22.2 17.7 8.9 8.0 9.0 1.3 1.9 6.9 1.7 6 TCR6000P2 26.5 17.7 11.1 8.0 9.0 1.7 2.5 2.5 3.4

Single Fall Hoist Double Fall Hoist

Figure 2-1 Pendant Model TCR (See Table 2-3)

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Product

Headroom

C

a

b

d

e

g

h

i

j

k

Table 2-4 TCR with Cor d Contr ol Dime nsions

Cap.

(Tons)

Code

(in)

1/4 TCR250C 18.2 13.4 6.9 6.1 6.6 1.1 4.9 2.0 1.3 8.3 1/2 TCR500C 18.2 13.4 6.9 6.1 6.6 1.1 4.9 2.0 1.3 8.3

1 TCR1000C2 20.4 13.4 7.3 6.1 6.6 1.1 5.9 1.5 2.2 8.3 1 TCR1000C 18.3 13.4 6.9 6.1 6.6 1.1 4.9 2.0 1.3 8.3 2 TCR2000C2 21.8 13.4 7.6 6.1 6.6 1.1 6.0 1.6 2.3 8.3 3 TCR3000C 22.2 17.7 8.9 8.0 9.0 1.3 1.9 6.9 1.7 8.3 6 TCR6000C2 26.5 17.7 11.1 8.0 9.0 1.7 2.5 8.7 3.4 8.3

Single Fall Hoist Double Fall Hoist

Figure 2-2 Cord Model TCR (See Table 2-4)

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2.3 Part Names

Figure 2-3 Hoist Part Identification Diagrams TCR 250P, 250C, 500P, 500C, 1000P, 1000C

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Figure 2-4 Hoist Part Identification Diagrams TCR 1000P2, 1000C2, 2000P2, 2000C2

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Figure 2-5 Hoist Part Identification Diagrams TCR 3000P, 3000C

Figure 2-6 Hoist Part Identification Diagrams TCR 6000P2, 6000C2

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3.0 Preoperational Procedu res

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

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

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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.

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 3-1 Diagram of Air Supply Configuration (Typical)

Figure 3-2 Typical Air Supply Filter, Regulator and Lubricator.

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

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 P ipe and Hose Sizes

Model

TCR250P, 250C, 500P, 500C, 1000P, 1000C TCR1000P2, 1000C2, 2000P2, 2000C2

TCR3000P, 3000C TCR6000P2, 6000C2

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.

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 3-3 Typical 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.

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









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 3-4 Typical 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

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

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 3-5 below 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 3-5 Optional 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 3-6 and 3-7.

Figure 3-6 Twist in Load Chain

3.12.3

Figure 3-7 Capsized 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.

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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 3-9 Limit Switch Components

3.12.5 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.

3.12.6 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.

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

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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4.0 Operation







• Read ANSI/ASME B30.16 and ANSI/ASME B30.10.

4.1 Introduction

DO NOT WALK UNDER A SUSPENDED LOAD

HOIST OPERAT ORS SHALL BE REQUIRED TO READ THE OPER ATION SECTION O F THIS MANUAL, THE WARNINGS CONTAINED IN THIS MANUAL, INSTRUCTION AND WARNING LABELS ON THE HOIST OR LIFTING SYSTEM , AND THE OPERATION SEC TIONS OF ANSI/ASM E B30.16 and ANSI/ASM E 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 ADJ USTMENT OR REPAIR, AND TO BE INSTRUCT ED TO STOP OPER ATION IF SUCH MALFUNCTIONS OCCUR, AND TO IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE ACTION CAN BE TAKEN.

HOIST OPERAT ORS SHOULD HAVE NORMAL DEPTH PER CEPTION, FIELD OF VISION, REACTIO N 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 ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED.

USE HOI ST FOR LOADS THAT ARE NOT LIFTED VER TICALLY, L OADS THAT

• 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 c ertain hazards that cannot be m itigated by engine ered features, but only by the exercise of intelligenc e, care, common sense, and experi ence in anticipating the effec ts 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

Improper operation of a hoist can create a poten tially haz ardous

situation which, if not avoided, could result in death

and substantial property damage. To avoi d such a poten tially

hazardous situation THE OPERATOR SHALL:

• NOT

• NOT operate hoist with missing/damaged chain

lift more than rated load for the hoist. operate unless load is centered under hoist. use damaged hoist or hoist that is not working

properly.

use hoist with twisted, kinked, damaged, or

worn chain.

use hoist if the bottom hook is capsized

(double fall hoists - see Section 3.12).

use the hoist to lift, support, or transport

people.

lift loads over people.

apply load unless load chain is properly seated in the load sheave (and idle sheave for hoist with two chain falls).

use the hoist in such a way that could result in shock or impact loads being applied to the hoist.

attempt to lengthen the load chain or repair damaged load chain.

operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading.

use load chain as a sling or wrap load chain around load.

apply the load to the tip of the hook or to the hook latch.

apply load if binding prevents equal loading on all load supporting chains.

operate beyond the limits of the load chain travel.

springs, shock absorbers, stoppers, striker plates or limit locks.

• NOT unless specific precautions have been taken.

• NOT electrical or welding ground.

• NOT live welding electrode.

• NOT

• Be familiar with operating controls, procedures, and warnings.

• Make sure the unit is securely attached to a suitable support before applying load.

• Make sure load slings or other approved single attachments are properly sized, rigged, and seated in the hook saddle.

• Take up slack carefully - make sure load is balanced and load-holding action is secure before continuing.

• Make sure all persons stay clear of the supported load.

• Protect the hoist’s load chain from weld splatter or other damaging contaminants.

• 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.

• Make sure hoist limit switches function properly.

• Warn personnel before lifting or moving a load.

• Warn personnel of an approaching load.

or serious injury,

leave load supported by the hoist unattended

allow the chain, or hook to be used as an

allow the chain, or hook to be touched by a

remove or obscure the warnings on the hoist.

24



Improper operation of a hoist can create a poten tially haz ardous situation which, if not avoided, could resul t in minor

injury

, or property damage. To avoid such a potentiall y haz ardous

situation THE OPERATOR SHALL:

or moderate

• Maintain a firm footing or be otherwise secured when operating the hoist.

• Check brake funct ion by tensioning the hoist prior to each lift operation.

• Use hook latches. Latches are to retain slings, chains, etc. under slack conditions only.

• Make sure the hook latches are closed and not supporting any parts of the load.

• Make sure the load is free to move and will clear all obstructions.

• Avoid swinging the load or hook.

• Make sure hook travel is in the same direc tion as shown on controls.

• 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.

• Use the hoist manufacturer’s recommended parts when repairing the unit.

• Lubricate load chain per hoist manufacturer’s recommendations.

• NOT use the hoist load limiting or warning device to measure load.

• NOT use limit switches as r outine operating stops. They are emergency devices only.

• NOT allow your attention to be diverted from operating the hoist.

• NOT allow the hoist to be subjected to sharp contact with other hoists, structures, or objects through misuse.

• NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs.

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

25



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

4.3.4

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 By adjusting the set screw in the pendant, the control can be adjusted to suit the user’s needs. Adjusting the screw does not affect the speed of the hoist; it simply changes the feel or stiffness of the lever control. Adjusting the screw sets the position of a small spring plunger and this affects how the plunger interacts with the lever.

 Turning the screw in causes the spring plunger to be in contact with the lever for more of the lever’s

travel, resulting in more stiffness and better feel for finer control of hoist motions.

 Turning the screw out reduces the effect that the spring plunger has on the lever control. This

makes it easier to depress the lever, which is usually preferred for coarse control (more on/off than variable) of hoist motions.

Make sure the motor completely stops before reversing direction.

Figure 4-3 Pendant Control Adjustment

4.4.3 For the cord type control, adjust the speed by varying the amount of pull on the cord. Refer to Figure 4-4.

26

Figure 4-4 Cord Control Speed Adjustment

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.

27

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 specif ic

duties to which he/she is assigned.

 Qualified Person - a person who, by possession of a recognized degree or certificate of

professional standing, or wh o, b y extensive know ledge, t raining, a nd exper ience, has s ucces sfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

 Normal Service - that distrib uted service w hich involves operation with r andom ly distributed loads

within the rated load lim it, or uniform loads less than 65 % of rated load for not mor e than 25% of the time.

 Heavy Service - that service which involves oper ation within the rated load limit which exc eeds

normal service.

 Severe Service - that service which involves nor mal 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.

28

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.

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 3.12 and 7.3

Table 5-1 Frequent Inspec tion

Air valves and components for leakage or damage

5.4 Periodic Inspect ion

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.

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.

Table 5-2 Periodic I nspection

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.

29

5.5 Occasionally U sed Hoi sts

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.

5.6 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 Inspecti on Methods and Cr iteri a

Item Method Criteria Action

Functional operating mechanisms.

Visual, Auditory Mechanisms should be properly adjusted and

should not produce unusual sounds when operated.

Limit Switch Function Proper operation. Actuation of limit switch should

stop hoist.

Chain Lever/Limit Lever Assembly

Visual, Function Lever should not be bent or significantly worn and

should be able to move freely.

Braking System Function Braking distance should not exceed

approximately five chain links.

Hooks - Surface Condition

Visual Should be free of significant rust, weld splatter,

deep nicks, or gouges.

Repair or replace as required.

Replace.

Repair or replace as required.

Replace.

Hooks - Fretting wear

Measure The “u” dimension should not be less than

minimum value listed in Table 5-6.

Hooks - Stretch Measure The “K” di mension should not exceed the

maximum value for replacement from Table 5-6 (See Section 3.12).

30

Replace.

no roughness.

Table 5-3 Hoist Inspecti on Methods and Cr iteri a

Item Method Criteria Action

Hooks - Bent Shank or Neck

Hooks - Yoke Assembly

Hooks - Swivel Bearing

Hooks - Idle Sheave and Axle (Bottom Hook on Double Fall Hoist)

Hooks - Hook Latches

Visual Shank and neck portions of hook should be free

of deformations

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.

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

Visual, Function 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.

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.

Clean/Lubricate, or replace as required.

Clean/lubricate, or replace as required.

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.

Load Chain Lubrication

Visual, Auditory Entire surface of each chain link should be coated

with lubricant and should be free of dirt and grime. Chain should not emit cracking noise when hoisting a load.

Load Chain Reeving

Visual Chain should be reeved properly through Load

Sheave (and Idle Sheave for double fall hoist) refer to Section 3.12. Chain, limit locks and stoppers should be installed properly - refer to

Section 7.3.2.

Chain Container (Optional)

Visual Container should not be damaged. Brackets

should not be deformed or missing

Chain Springs Visual Chain springs should not be deformed or

compressed.

Replace.

Replace, inspect Load Sheave (and Idle Sheave for double fall hoist).

Clean/lubricate (see Sections 6.0).

Reeve/Install chain properly.

Replace

Shock Absorber Visual Should be free of significant deformation. Replace

31

Table 5-3 Hoist Inspecti on Methods and Cr iteri a

Item Method Criteria Action

Chain Container (optional)

Bolts, Nuts and Rivets

Housing and Mechanical Components

Visual Container should not be damaged. Brackets

should not be deformed or missing.

Visual, Check

Bolts, nuts and rivets should not be loose. Tighten or replace

with Proper Tool 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 Visual, Measure The Chain Separator 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.

Motor Brake Measure, Visual 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

as required. Replace

Replace

Replace.

Pendant Control Levers

Pendant - Housing Visual Pendant housing should be free of cracks and

Visual, Function

Depressing and releasing pendant control levers should cause hoist to operate.

Repair or replace as necessary.

Replace.

mating surfaces of parts should seal without gaps.

Pendant - Tubing Visual, auditory Tubing to pendant control switches should not be

loose or be leaking air.

Repair or replace as necessary.

Pendant - Labels Visual Labels denoting functions should be legible. Replace.

Warning Labels Visual 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

Replace. should be legible and securely attached to the hoist.

32

Inch (mm)

Table 5-4 Brake Disc Dimension

Hoists

Parts View

Item No.

Std Dimension

Minimum Value for Replacem ent

TCR250, 500, 1000-2 73 T = 0.31 (8.0) T = 0.29 (7.3) TCR1000, 2000-2 73 T = 0.31 (8.0) T = 0.29 (7.3) TCR3000, 6000-2 73 T = 0.31 (8.0) T = 0.29 (7.3)

Table 5-5 Chain Separ ator Dimens ions

TCR250, 500, 1000-2, 1000, 2000-2

Hoists

Parts View

Item No.

Std Dimension

Inch (mm)

TCR 3000, 6000-2

Maximum Value for Replacement

Inch (mm)

TCR250, 500, 1000-2 97

TCR1000, 2000-2 97

TCR3000, 6000-2 97

L = 0.55 ( 14) W = 0.98 ( 25) L = 0.62 ( 15.8) W = 1.10 ( 28) L = 1.00 ( 25.5) W = 1.85 ( 47)

33

L = 0.67 ( 17) W = 1.08 ( 27.5) L = 0.70 ( 17.8) W = 1.18 ( 30) L = 1.10 ( 28) W = 1.93 ( 49)

Maximum/Minimum Value

Maximum Value for Replacement

Dimensions K and U sho uld be mea sured a nd recor ded belo w pr ior to a ny use when the hook is first placed into service.

Hoists

TCR250, 500, 1000-2

TCR1000, 2000-2

TCR3000, 6000-2

Table 5-6 Top Hook & B ottom Hook Dimens ions

Parts View

Item No.

Recorded Dimension

When New

Top Hook K = _______________ 115 120

Top Hook U = _______________

Bottom Hook K = ____________

Bottom Hook U = ____________

Top Hook K = _______________ 115 120

Top Hook U = _______________

Bottom Hook K = ____________

Bottom Hook U = ____________

Top Hook K = _______________ 115

120

Top Hook U = _______________

Bottom Hook K = ____________

Bottom Hook U = ____________

for Replacement

For K if the measured dimension exceeds 1.05 times the recorded new dimension, the hook should be replaced.

For U if the measured dimension is less than .9 times the recorded new dimension, the hook should be replaced.

Table 5-7 Chain Dimensio ns

Hoists

Parts View

Item No.

Std Nominal Dimension

Inch (mm)

TCR 250, 500, 1000-2 131 Nominal L = 3.76 (95.5) L = 3.82 (96.9) TCR 1000, 2000-2 131 Nominal L = 4.18 (106.2) L = 4.25 (107.8) TCR 3000, 6000-2 131 Nominal L = 5.96 (151.5) L = 6.05 (153.8)

34



6.0 Lubrication

6.1 Air Hoist Lubrication

6.1.1 See Section 3.0 for lubrication requirements.

6.1.2 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.

Lubrication to the motor will be provided primarily by the air supply lubricator. The

6.2 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.

6.3 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 A pproved Lubrica nts

Application Part Location Lubrication Grade

Air motor Lubricator Turbine Oil

ISO VG 32-56 or equivalent

Load chain & pocket wheel

Hook bearings & suspension pins

Gears and Bearings Gear Section Grease

Load chain Machine or gear oil

Top & bottom hook sets

Grease

ISO VG 46-68 or equivalent

National Lubricating Grease #3

National Lubricating Grease #2

35



7.0 Maintenance and H andling

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:

a.

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.

Adjusting the load limiter involves operating the hoist. Personnel involved

36





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.

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 The hoist brake is not adjustable.

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.

Turning the adjustment screw IN 8 full turns or more will disable the load limiter.

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) Gradually back out all four hex socket cap screws (A) from brake cover (B) from gear case (J) to

slowly decrease spring tension (K) of brake piston (D) against brake disc (I).

3) Remove brake cover (B) from top of gear case (J). Keep brake piston (D), springs (K), seals and

piston cover (C) together inside the brake cover. Do not remove cap screws (E). Set parts aside for reassembly.

4) Remove retaining ring (F) on pinion shaft (H) adjacent to brake disc (I).

5) Remove brake disc for inspection and measurement and then the two keys (G) from each side of

pinion shaft (H). 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. Apply a light film of grease to

all "O"-ring seals.

7) Reassemble in reverse order. Keep the small hole on the back of the brake piston (D) aligned

toward the top of the hoist. Torque all mounting hardware evenly during the reassembly process.

37







(Note: figure above represents TCR250-2000 model types, larger model types are

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

1)

following procedures.

2)

exact size, grade and construction as the original chain.

3)

Chain Guides and Idler Wheels, 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.

Figure 7-2 Brake Inspection Diagram

similar and the procedure for inspection is identical.)

An air supply line must be connected to the hoist in order to perform the

Be certain that the replacement chain is obtained from Harrington and is the

When replacing load chain, check for wear on mating parts, i.e. Load Sheave,

38



4)

Invert the hoist such that the chain separator openings are facing up. The chain must be inserted into the chain separator on the no load side opening. This is where the no load end of chain attaches to hoist body. Without inserting the load chain, operate the hoist pendant or cord control to determine which direction the load sheave is rotating in relation to the pendant control function pressed or pulled. Install load chain into the hoist making certain the first link is a standing link and that its weld is facing away from the centerline of the hoist. See Figures

7-3 and 7-4 below.

5)

Model Type Hoist

TCR250P, C TCR500P, C TCR1000P, C

TCR1000P2, C2 TCR2000P2, C2 TCR3000P, C

TCR6000P2, C2

Figure 7-3 Load Chain Installation Diagram

Operate the hoist slowly to catch and pull the chain through the hoist. Make sure the chain feeds smoothly while operating the hoist. If binding occurs, stop and reverse the hoist direction to back the chain out. Reinsert the chain while gradually operating the hoist controls. Continue until sufficient quantity of chain is fed through the hoist.

Table 7-1 Placement of S toppers on Load Chain

Version 1, A & B Version C

Load Side Chain En d No Load Side Chain End Load Side Chain End No Load Side Chain End

None 8 None 10

8 8 8 10 7 8 7 10

None None None None

39



6)

7-1 and the diagram in Figure 7-4.

7) Ensure that chain remains free of twists when attaching dead end(s) of chain and when feeding

chain through bottom hook case (double fall units). Refer to Figures 3-6 and 3-7.

8) After installation has been completed, perform steps outlined in Section 3.12 "Preoperational

Checks and Trial Operation".

Make sure end stoppers and limit locks are installed in accordance with Table

Figure 7-4 Diagram showing chain replacement guide – Versions 1, A & B (See Section 10)

40

Figure 7-4 Diagram showing chain replacement guide – Version C (See Section 10)

41

7.4 Pendant



7.4.1 The following procedure covers the installation of a pendant control station.

1) Put hose, 3 tubes and wire through the bracket hole. See Figure 7-5.

2) Attach the hose to the bracket by installing the retaining nut to the hose fitting.

3) Torque retaining nut to 20 lbf.-ft.

4) Attach the wire cable to the hoist valve body with the screw as shown in Figure 7-6.

5) Torque machine screw to between 30 and 40 in-lbf.

Figure 7-5

Figure 7-6

6) Attach the three tubes to each nipple as shown in Figure 7-7. Red tube for main air, clear tube for lifting and black tube for lowering.

Versions 1 & A

Figure 7-7

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.

42

Versions B & C

7.5 Load Sheave Inspection

7.5.1 Perform this inspection by removing the chain separator and viewing the load sheave while operating

the hoist slowly, with no load, and in accordance with Section 4 “Operation”. Refer to Figure 7-8 and remove the chain separator as follows.

 TCR3000 and TCR6000-2: The chain separator can be removed by removing the shaft retaining

ring from its groove on the limit lever shaft adjacent to the valve section, sliding the limit lever assembly away from the chain separator, and removing the two larger outboard hex socket screws holding the chain separator to the hoist body.

 TCR250 through TCR2000-2: The chain separator can be removed by removing the shaft

retaining ring from its groove on the limit lever shaft adjacent to the valve section, sliding the limit lever assembly away from the chain separator, removing the limit lever from the limit lever shaft, and removing the hex socket screws holding the chain separator to the hoist body.

7.6 Storage

7.6.1 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.

7.6.2 The storage location should be clean and dry.

7.7 Outdoor Installation

7.7.1 For hoist installations that are outdoors, the hoist should be covered when not in use.

7.7.2 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.

Figure 7-8 Chain Separator Removal

43



clogged

Air motor vanes or bearings worn

Repair at service facility.

8.0 Troubleshooting

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

Does not operate

Lifting speed is slow

Lack of air pressure or loss of air supply.

Seizure of Main Spool, Brake Spool, or Air Motor.

Seizure of brake or brake mechanism fails to release.

Bending or crimping of pendant hose or control tubes

Air leak between the two chambers in the Top Cover

Hoist is overloaded.

Low air pressure at hoist inlet port.

Air supply hose or piping is too small. Malfunction of brake. Repair at service facility.

Bending or crimping of pendant hoses or control tubes

Lack of sufficient oil in air supply to hoist

Exhaust Silencer or Nylon Silencer

Repair or adjust air supply or filters.

Repair at service facility.

Repair at service facility. Correct or repair bend or crimp in hose

and/or tubes Correct or repair to eliminate air leak. Reduce the load to the rated capacity

of hoist. Repair or adjust air supply or filters.

Check for air line obstruction. Replace hose or piping sizes with

recommended sizes in Section 3.0.

Correct or repair the bend or crimp in hose and/or control tubes

Increase oil in air supply to hoist in accordance with requirements in

Section 3.0.

Clean or replace.

Air flow capacity of compressed air system insufficient

Air supply to hoist contains dirt or debris

Air leak between the two chambers in the Top Cover

44

Increase air flow capacity of compressed air system to requirements in Section 2.0.

Filter the air supply to the hoist in accordance with the requirements in

Section 3.0.

Correct or repair to eliminate air leak.

Symptom

Cause

Remedy

in the Top Cover

Table 8-1 Troubleshooting Guide

Unable to lift rated load

Hoist moving in wrong direction (pendant control)

Hoist lowers but will not lift

Hoist continues running after pendant or cord is released

Hoist drifts excessively when hoist is stopped

Lack of air pressure or loss of air supply.

Improper adjustment of load limiter. Adjust Load Limiter. See Section 7.1. Air leak between the two chambers

Pendant control tubes are terminated to incorrect ports on hoist body.

Hoist is overloaded. Reduce load to hoist rated capacity. Faulty pendant control or control

tube(s) Lack of air pressure or partial loss of

or leakage in air supply.

Main Spool sticking

Main Spool spring broken Repair at service facility Main Spool leaking Repair at service facility Mis-alignment of Limit Shaft with

Bottom Plate (TCR3000/6000 only) Valve in Pendant Handle stuck Repair at service facility

Brake is not holding. Repair brake at service facility. Motor vanes leaking.

Repair or adjust air supply or filters.

Correct or repair to eliminate air leak. Connect the control tubes in

accordance with Section 7.4.

Repair or replace pendant control or control tube(s)

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.

Loosen Bottom Plate and re-align so that Limit Shaft operates freely.

Replace motor vanes and springs at service facility.

45

9.0 Warranty

Warranty expl anati on a nd ter ms. All products sold by Har ring ton Hoists , Inc. are warr anted to be free fro m defects in material and

workmanship from d ate of shi pment by Harring ton for the foll ow ing periods:

Manual Hoists & Trolleys - 2 years

NER/ER Hoists En han ced Feat ur es Mod els - 3 years

Electric Hoists, Air Hoists & Trolleys, and Crane Components - 1 year

Spare / Replace ment Par ts - 1 year

NER/ER “The Guardian” Electromagnetic Smart Technology Brake - 1 0 y ear s

The product mus t be us ed i n acc ord ance w i th ma nufact ur er’s r ec ommend atio ns and must not hav e been subject t o ab use, l ack o f mai nte nance , misuse, neg li gence, or u n author iz ed re pairs or alterations.

Should any de fect i n m aterial or w orkma nshi p occ ur during t he ab ove t ime peri od i n a ny pr odu ct, as determined by H arri ng ton Hoi st ’s ins pec tion of the pro duc t, H arri ngton H oi sts, Inc . agr ees , at i ts discretion, ei ther to r epl ace ( not inc ludi ng i nst all atio n) or repai r the p art or pr oduc t free of c harg e and deliver s aid it em F .O.B . H arri ngton Hoi sts , Inc . pl ace o f busin ess to c ust omer.

Customer must obtai n a Retur n G oods Aut hori zat ion as di rec ted by Har r ing ton or Harr ing ton’ s published aut horiz ed r epair ce nter prior to shi pping pro duc t for w arr anty ev aluati on. An ex plan atio n of the complai nt m ust acc ompany the pro duc t. Prod uct must be r etur n ed fr eig ht pr epai d. U po n repair, the pr oduc t w ill be cov ere d for the r em ainder o f th e or ig inal w ar ranty p eri od. Replacement parts install ed a fter t he ori gi nal w arr anty perio d w i ll only be el ig ible for r eplac eme nt (n ot i nclu ding installation) for a period o f one year fro m the instal lation da te. If it is determined there is no defect, or that the de fect r es ult ed fr om ca uses not w i thi n the s cop e of Harr ing ton’ s w arrant y, t he cust omer will be respons ible for th e cos ts of re turni ng the prod uct.

Harrington Hoi sts, Inc . d iscl aims any a nd al l o ther w arrant ies of any ki nd ex pres sed or i mpli ed as t o the product’s merch ant ability or fitness for a parti cular appli catio n. Harri ngton wi ll not be liabl e for death, injuri es t o per son s or pr op erty or for i nci dent al, c onti ng ent, s peci al or c ons eque ntial damages, loss or expen se ari sing in co nnecti on w ith the use or in abil ity w hatev er , reg ardles s o f whether damage, los s o r ex pens e res ults fr om a ny ac t or failur e t o act by Har ring ton, w heth er negligent or w il lful, or from any o th er reas on .

46

Numerical digit

"A"

"B"

"C"

Hairpin Cotter

90° Tube Fitting

10.0 Parts List

When ordering Parts, please provide the Hoist code number located on the Hoist nameplate (see fig. below). Reminder: Per Sections 3.12.6 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.

TCR Nameplate

Parts lists for t he TCR Air Hoists are presented in this section and are subdivided for reference in Figures 10-1 through

10-6.

The letters C and P designate "Cord" and "Pendant" controlled hoists. Hoists with 2 parts or falls of load chain have a "2" designator following the model number.

Certain hoists parts in the following parts list are identified by hoist version 1, A, B or C. Use Table 10-1 to determine the hoist version and select the correct hoist part(s).

Table 10-1 Hoist Version Identification C hart

Item Version 1 Version A Version B Version C

Last digit of the Serial Number:

Limit Shaft Attachment Method:

Pendant Hose Connections:

Side Cover Thickness: 1/2" 1/2" 1/2" 7/8"

(ex. BL182)

External

Retaining Ring

Hose Barb

5mm thread

(ex. MD165A)

and Washer

Hose Barb

5mm thread

(ex. DF124B) Hairpin Cotter

and Washer

1/8" pipe thread

(ex. KE189C) Hairpin Cotter

and Washer

90° Tube Fitting 1/8" pipe thread

Chain Springs No No No Yes

47

10.1 Main Body

10.1.1 TCR250 / TCR500 Main Body

48

Figure 10-1 TCR250 / TCR500 Main Body

Figure

Number

Part Number Part Name

28 TCR130406005 PARALLEL PIN 2 35 TCR426224151 ROTOR 1 36 TCR426224161 STATOR 1 37 TCR426224171 F RO NT PLATE 1 38 TCR426224182 REAR PLATE 1 39 TCR426224191 REAR RETAINER 1 40 TCR137102020 VANE 8 41 TCR130802212 VANE SPRING 8 42 9001202 BEARING 1 43 TCR131103004 O-RING 1 44 TCR131103023 O-RING 1 45 9047115 RETAINING RING 1 46 9091283 SOCKET BOLT 3 47 9012511 WASHER 1 48 TCR130402051 KNOCK PIN 1 49 9000102 BEARING 1

49

50 TCR426224200 COUPLING 1 51 TCR426224212 WHEEL HOUSING 1 52 TCR426224220 TOP PIN 1 53 TCR426224230 SPACER 1 54 TCR426261R50 WASHER 1 55 9001204 BEARING 1 56 9000109 BEARING 1 57 9091247 SOCKET BOLT 1 59 9091273 SOCKET BOLT 1 60 TCR426221R50 WASHER 1 61 TCR132108012 SET SCREW 1 62 TCR137309075 BRAND NAME PLATE 1 70 TCR426224401 BRAKE PISTON 1 71 TCR426224410 BRAKE COVER 1 72 TCR426224421 PISTON COVER 1 73 TCR426224430 BRAKE DISC 1 74 TCR130408081 KEY 2 75 TCR130802213 DISC SPRING 6 76 TCR131103002 O-RING 1 77 TCR131101004 O-RING 1

Parts

Per

Hoist

Figure

Number

Part Number Part Name

78 TCR131103055 O-RING 1 79 9091247 SOCKET BOLT 2 80 9091254 SOCKET BOLT 4 81 TCR131117033 O-RING 1 85 TCR426224240 CAGE 1 86 TCR426224250 STAR GEAR 3 87 TCR426224260 PIN 3 88 TCR426224270 T HRUST COLLAR 6 89 TCR426224280 RETAINER 3 90 TCR426224290 PINION 1 91 TCR426224300 LOAD SHEAVE 1 92 TCR426224312 GEAR CASE 1 93 TCR426224322 RING GEAR 1 94 TCR426224330 SPACER (P) 3 95 TCR426221K90 LOCK SCREW 1 96 TCR426224352 CHAIN GUIDE 1 97 TCR426224363 CHAIN SEPARATOR 1

98 TCR426224381 BRAKE TUBE 1 100 9000102 BEARING 2 101 9001201 BEARING 2 102 TCR130170035 NEEDLE BEARING 6 103 TCR131117042 O-RING 1 104 TCR131103055 O-RING 1 105 9047110 RETAINING RING 3 106 9047145 RETAINING RING 1 107 9047115 RETAINING RING 3 108 9047232 RETAINING RING 2 109 TCR130303005 RETAINING RING 1 110 9091247 SOCKET BOLT 4 111 9091271 SOCKET BOLT 3 112 TCR131103036 O-RING 1 115 TCR42622457B TOP HOOK SE T 1

115B TCR426221S30 HOOK LATCH 1 115C TCR130802258 HOOK SPRING 1 115D 9091232 SOCKET BOLT 1 115E E2D853125 U-NUT 1

Parts

Per

Hoist

Figure

Number

Part Number Part Name

119 TCR426224390 END STOPPER 1

120 TCR42622477C BOTTOM HOOK SET 250 1 120A TCR426221S2F BOTTOM HOOK ASSY. 1 120B TCR426221S30 HOOK LATCH 1 120C TCR130802258 HOOK SPRING 1 120D 9091232 SOCKET BOLT 1 120E E2D853125 U-NUT 1 125 TCR130502020 STEEL BALL 8 126 TCR426221S80 BOTTOM HOOK HOLDER 1 127 TCR420846PY0 SWIVEL HOOK PLUG 1 128 TCR426224770 SLEEVE 1 129 TCR426221T20 CHAIN PIN 1 130 TCR130802259 LOCK RING 1

120 TCR426221S2C BOTT OM HOOK SET 500 1 120A TCR426221S2F BOTTOM HOOK ASSY. 1 120B TCR426221S30 HOOK LATCH 1 120C TCR130802258 HOOK SPRING 1 120D 9091232 SOCKET BOLT 1 120E E2D853125 U-NUT 1 125 TCR130502020 STEEL BALL 8 126 TCR426221S80 BOTTOM HOOK HOLDER 1 127 TCR420846PY0 SWIVEL HOOK PLUG 1 128 TCR426224760 SLEEVE 1 129 TCR426221T20 CHAIN PIN 1 130 TCR130802259 LOCK RING 1

131 LCER005C LOAD CHAIN FT

132 TCR426224450 LI MIT LOCK 2

133 TCR136206002 SHOCK ABSORBER 2

136 TCR426224680 E ND BOLT 1

138 9098504 U NUT 1

139* TCR426224C80 LIMIT WASHER* 2 140* TCR130802219 CHAIN SPRING* 2

* Version C hoists only.

Parts

Per

Hoist

TCR250 / TCR500 Main Body

Figure 10-2 TCR1000-2 M ain Bod y

10.1.2 TCR1000-2 Main Body

50

Figure

Hoist

Number

Part Number Part Name

28 TCR130406005 PARALLEL PIN 2 35 TCR426224151 ROTOR 1 36 TCR426224161 STATOR 1 37 TCR426224171 F RO NT PLATE 1 38 TCR426224182 REAR PLATE 1 39 TCR426224191 REAR RETAINER 1 40 TCR137102020 VANE 8 41 TCR130802212 VANE SPRING 8 42 9001202 BEARING 1 43 TCR131103004 O-RING 1 44 TCR131103023 O-RING 1 45 9047115 RETAINING RING 1 46 9091283 SOCKET BOLT 3 47 9012511 WASHER 1 48 TCR130402051 KNOCK PIN 1 49 900902 BALL BEARING 1

51

50 TCR426224200 COUPLING 1 51 TCR426224212 WHEEL HOUSING 1 52 TCR426224220 TOP PIN 1 53 TCR426224230 SPACER 1 54 TCR426261R50 WASHER 1 55 9001204 BEARING 1 56 9000109 BEARING 1 57 9091247 SOCKET BOLT 1 59 9091273 SOCKET BOLT 1 60 TCR426221R50 WASHER 1 61 TCR132108012 SET SCREW 1 62 TCR137309075 BRAND NAME PLATE 1 70 TCR426224401 BRAKE PISTON 1 71 TCR426224410 BRAKE COVER 1 72 TCR426224421 PISTON COVER 1 73 TCR426224430 BRAKE DISC 1 74 TCR130408081 KEY 2 75 TCR130802213 DISC SPRING 6 76 TCR131103002 O-RING 1 77 TCR131101004 O-RING 1

Parts

Per

Figure

Number

Part Number Part Name

78 TCR131103055 O-RING 1 79 9091247 SOCKET BOLT 2 80 9091254 SOCKET BOLT 4 81 TCR131117033 O-RING 1 85 TCR426224240 CAGE 1 86 TCR426224250 STAR GEAR 3 87 TCR426224260 PIN 3 88 TCR426224270 T HRUST COLLAR 6 89 TCR426224280 RETAINER 3 90 TCR426224290 PINION 1 91 TCR426224300 LOAD SHEAVE 1 92 TCR426224312 GEAR CASE 1 93 TCR426224322 RING GEAR 1 94 TCR426224330 SPACER (P) 3 95 TCR426221K90 LOCK SCREW 1 96 TCR426224352 CHAIN GUIDE 1 97 TCR426224363 CHAIN SEPARATOR 1

98 TCR426224381 BRAKE TUBE 1 100 9000102 BEARING 2 101 9001201 BEARING 2 102 TCR130170035 NEEDLE BEARING 6 103 TCR131117042 O-RING 1 104 TCR131103055 O-RING 1 105 9047110 RETAINING RING 3 106 9047145 RETAINING RING 1 107 9047115 RETAINING RING 3 108 9047232 RETAINING RING 2 109 TCR130303005 RETAINING RING 1 110 9091247 SOCKET BOLT 4 111 9091271 SOCKET BOLT 3 112 TCR131103036 O-RING 1 115 TCR42624457H TOP HOOK SET 1

115B TCR426221S30 HOOK LATCH 1 115C TCR130802258 HOOK SPRING 1 115D 9091232 SOCKET BOLT 1 115E E2D853125 U-NUT 1

Parts

Per

Figure

Number

Part Number Part Name

115H TCR426244580 CHAIN PIN 1 115J 9012511 WASHER 1 115K 9098504 U NUT 1

116 TCR426244630 FREE LIMIT LOCK 1 118 TCR426244620 HOLDER 1 119 TCR426224390 END STOPPER 2

120 TCR426244S2C BOTTOM HOOK SET 1 120A TCR426221S2F BOTTOM HOOK ASSY. 1 120B TCR426221S30 HOOK LATCH 1 120C TCR130802258 HOOK SPRING 1 120D 9091232 SOCKET BOLT 1 120E E2D853125 U-NUT 1 121 TCR130172006 NEEDLE BEARING 1 122 TCR131204014 OIL SEAL 2 125 TCR130502020 STEEL BALL 8 126 TCR426244590 BOTTOM YOKE ASSY. 1 127 TCR420846PY0 SWIVEL HOOK PLUG 1 128 TCR420846PW0 OUTER BEARING RACE 1 129 TCR426244600 WHEEL SHAFT 1 130 TCR426241U20 IDLE SHEAVE 1 135 9091253 SOCKET BOLT 2 137 9098504 U NUT 2 139 9047114 RETAINING RING 1

131 LCER005C LOAD CHAIN FT

132 TCR426224450 LI MIT LOCK 1

133 TCR136206002 SHOCK ABSORBER 2

136 TCR426224680 E ND BOLT 2

138 9098504 U NUT 2

139* TCR426224C80 LIMIT WASHER* 1 140* TCR130802219 CHAIN SPRING* 3

* Version C hoists only.

Parts

Per

TCR1000-2 Main Body

10.1.3 TCR1000 Main Body

52

Figure 10-3 TCR1000 Main Body

Figure

Hoist

Number

Part Number Part Name

28 TCR130406005 PARALLEL PIN 2 35 TCR426224151 ROTOR 1 36 TCR426224161 STATOR 1 37 TCR426224171 F RO NT PLATE 1 38 TCR426224182 REAR PLATE 1 39 TCR426224191 REAR RETAINER 1 40 TCR137102020 VANE 8 41 TCR130802212 VANE SPRING 8 42 9001202 BEARING 1 43 TCR131103004 O-RING 1 44 TCR131103023 O-RING 1 45 9047115 RETAINING RING 1 46 9091283 SOCKET BOLT 3 47 9012511 WASHER 1 48 TCR130402051 KNOCK PIN 1 49 9000102 BEARING 1

53

50 TCR426224200 COUPLING 1 51 TCR426224212 WHEEL HOUSING 1 52 TCR426224220 TOP PIN 1 53 TCR426224230 SPACER 1 54 TCR426261R50 WASHER 1 55 9001204 BEARING 1 56 9000109 BEARING 1 57 9091247 SOCKET BOLT 1 59 9091273 SOCKET BOLT 1 60 TCR426221R50 WASHER 1 61 TCR132108012 SET SCREW 1 62 TCR137309075 BRAND NAME PLATE 1 70 TCR426224401 BRAKE PISTON 1 71 TCR426224410 BRAKE COVER 1 72 TCR426224421 PISTON COVER 1 73 TCR426224430 BRAKE DISC 1 74 TCR130408081 KEY 2 75 TCR130802213 DISC SPRING 6 76 TCR131103002 O-RING 1 77 TCR131101004 O-RING 1

Parts

Per

Figure

Number

Part Number Part Name

78 TCR131103055 O-RING 1 79 9091247 SOCKET BOLT 2 80 9091254 SOCKET BOLT 4 81 TCR131117033 O-RING 1 85 TCR426266240 CAGE 1 86 TCR426266250 STAR GEAR 3 87 TCR426266260 PIN 3 88 TCR426266270 T HRUST COLLAR 6 90 TCR426266290 PINION 1 91 TCR426266300 LOAD SHEAVE 1 92 TCR426266310 GEAR CASE 1 93 TCR426266320 RING GEAR 1 95 TCR426266340 DOWEL PIN 4 96 TCR426266351 CHAIN GUIDE 1 97 TCR426266360 CHAIN SEPARATOR 1

98 TCR426224381 BRAKE TUBE 1 100 9000102 BEARING 2 101 9001203 BEARING 2 102 9000101 BEARING 9 103 TCR131117042 O-RING 1 104 TCR131103055 O-RING 1 105 9047112 RETAINING RING 3 106 9047145 RETAINING RING 1 107 9047115 RETAINING RING 3 108 9047232 RETAINING RING 2 109 TCR130303005 RETAINING RING 1 110 9091247 SOCKET BOLT 4 111 9091271 SOCKET BOLT 6 112 9047228 RETAINING RING 6 113 9091225 SOCKET BOLT 6 114 TCR426266640 ADAPTER 1 115 TCR42622457B TOP HOOK SE T 1

115B TCR426221S30 HOOK LATCH 1 115C TCR130802258 HOOK SPRIN G 1 115D 9091232 SOCKET BOLT 1 115E E2D853125 U-NUT 1

Parts

Per

Figure

Number

Part Number Part Name

119 TCR426266390 END STOPPER 1

120 TCR426261S2C BOTTOM HOOK SET 1 120A TCR426221S2F BOTTOM HOOK ASSY. 1 120B TCR426221S30 HOOK LAT CH 1 120C TCR130802258 HOOK SPRING 1 120D 9091232 SOCKET BOLT 1 120E E2D853125 U-NUT 1 125 TCR130502020 STEEL BALL 8 126 TCR426261S80 BOTTOM HOOK HOLDER 1 127 TCR420846PY0 SWIVEL HOOK PLUG 1 128 TCR426266760 SLEEVE 1 129 TCR426261T20 CHAIN PIN 1 130 TCR130802259 LOCK RING 1

131 LCES010 LOAD CHAIN FT

132 TCR426266450 LI MIT LOCK 2

133 TCR136206003 SHOCK ABSORBER 2

136 TCR426224680 E ND BOLT 1

138 9098504 U NUT 1

139* TCR426266C80 LIMIT WASHER* 2 140* TCR130802219 CHAIN SPRING* 2

* Version C hoists only.

Parts

Per

TCR1000 Main Body

Figure 10-4 TCR2000-2 M ain Bod y

10.1.4 TCR2000-2 Main Body

54

Figure

Hoist

Number

Part Number Part Name

28 TCR130406005 PARALLEL PIN 2 35 TCR426224151 ROTOR 1 36 TCR426224161 STATOR 1 37 TCR426224171 F RO NT PLATE 1 38 TCR426224182 REAR PLATE 1 39 TCR426224191 REAR RETAINER 1 40 TCR137102020 VANE 8 41 TCR130802212 VANE SPRING 8 42 9001202 BEARING 1 43 TCR131103004 O-RING 1 44 TCR131103023 O-RING 1 45 9047115 RETAINING RING 1 46 9091283 SOCKET BOLT 3 47 9012511 WASHER 1 48 TCR130402051 KNOCK PIN 1 49 9000102 BEARING 1

55

50 TCR426224200 COUPLING 1 51 TCR426224212 WHEEL HOUSING 1 52 TCR426224220 TOP PIN 1 53 TCR426224230 SPACER 1 54 TCR426261R50 WASHER 1 55 9001204 BEARING 1 56 9000109 BEARING 1 57 9091247 SOCKET BOLT 1 59 9091273 SOCKET BOLT 1 60 TCR426221R50 WASHER 1 61 TCR132108012 SET SCREW 1 62 TCR137309075 BRAND NAME PLATE 1 70 TCR426224401 BRAKE PISTON 1 71 TCR426224410 BRAKE COVER 1 72 TCR426224421 PISTON COVER 1 73 TCR426224430 BRAKE DISC 1 74 TCR130408081 KEY 2 75 TCR130802213 DISC SPRING 6 76 TCR131103002 O-RING 1 77 TCR131101004 O-RING 1

Parts

Per

Figure

Number

Part Number Part Name

78 TCR131103055 O-RING 1 79 9091247 SOCKET BOLT 2 80 9091254 SOCKET BOLT 4 81 TCR131117033 O-RING 1 85 TCR426266240 CAGE 1 86 TCR426266250 STAR GEAR 3 87 TCR426266260 PIN 3 88 TCR426266270 THRUST COLLAR 6 90 TCR426266290 PINION 1 91 TCR426266300 LOAD SHEAVE 1 92 TCR426266310 GEAR CASE 1 93 TCR426266320 RING GEAR 1 95 TCR426266340 DOWEL PIN 4 96 TCR426266351 CHAIN GUIDE 1 97 TCR426266360 CHAIN SEPARATOR 1

98 TCR426224381 BRAKE TUBE 1 100 9000102 BEARING 2 101 9001203 BEARING 2 102 9000101 BEARING 9 103 TCR131117042 O-RING 1 104 TCR131103055 O-RING 1 105 9047112 RET AI NING RING 3 106 9047145 RETAI NING RING 1 107 9047115 RET AI NING RING 3 108 9047232 RET AI NING RING 2 109 TCR130303005 RE T AI NING RING 1 110 9091247 SOCKET BOLT 4 111 9091271 SOCKET BOLT 6 112 9047228 RET AI NING RING 6 113 9091225 SOCKET BOLT 6 114 TCR426266640 ADAPTER 1 115 TCR42628657B HOOK SET 1

115A TCR420645PAA HOOK ASSY. 1 115AB TCR420645P10 HOOK LATCH 1 115AC TCR130802046 HOOK SPRING 1 115AD TCR130603024 SPRING PIN 1

Parts

Per

Figure

Number

Part Number Part N ame

Parts

115F TCR426286570 TOP YOKE ASSY. 1 115G 9091297 SOCKET BOLT 2 115H 9012712 SPRING WASHER 2 115J 9098508 U-NUT 2

117 TCR426286580 CHAIN PIN 1 118 TCR426286630 FREE LIMIT LOCK 1 119 LCES010 LOAD CHAIN FT 120 TCR426286620 HOLDER 1 121 TCR426266390 END STOPPER 2

122 TCR426001PAC BOTTOM HOOK SET 1 122A TCR420645PAA HOOK ASSY. 1 122B TCR420645P10 HOOK LATCH 1 122C TCR130802046 HOOK SPRING 1 122D TCR130603024 SPRING PIN 1 123 TCR420866QG0 BOTTOM YOKE ASSY. 1 124 TCR426001RB0 IDLE SHEAVE 1

125 TCR420866QH0

BOTTOM HOOK

COVER 126 TCR420866Q10 BOTTOM HOOK SHAFT 1 130 9091297 SOCKET BOLT 2 131 9091293 SOCKET BOLT 2 134 9098508 U-NUT 2 137 9012712 SPRING WASHER 2 139 9000606 BEARING 2

127 TCR426266450 LI MIT LOCK 1 128 TCR136206003 SHOCK ABSORBER 2 133 TCR426224680 E ND BOLT 2 135 9098506 U-NUT 1 136 9098504 U NUT 2

138 9012513 WASHER 1 139* TCR426266C80 LIMIT WASHER* 1 140* TCR130802219 CHAIN SPRING* 3

* Version C hoists only.

Per

2

TCR2000-2 Main Body

10.1.5 TCR3000 Main Body

56

Figure 10-5 TCR3000 Main Body

Figure

Hoist

Number

Part Number Part Name

28 TCR130406005 PARALLEL PIN 2 35 TCR426325150 ROTOR 1 36 TCR426325160 STATOR 1 37 TCR426325170 F RO NT PLATE 1 38 TCR426325180 REAR PLATE 1 39 TCR426325190 REAR RETAINER 1 40 TCR137102022 VANE 8 41 TCR130802212 VANE SPRING 8 42 9000103 BEARING 2 43 TCR131103004 O-RING 1 44 TCR131103026 O RING 1 45 9047117 RETAINING RING 1 46 9091288 SOCKET BOLT 3 47 9012511 WASHER 1 48 TCR130402054 KNOCK PIN 1 49 9091269 SOCKET BOLT 4

57

50 TCR426325200 COUPLING 1 51 TCR426325212 WHEEL HOUSING 1 52 TCR426325220 TOP PIN 1 53 TCR426325230 SPACER 1

54 TCR420875MN0

CHAIN END SET

WASHER 55 9000119 BEARING 1 56 9000212 BEARING 1 57 9098516 U NUT 1 58 9012715 SPRING WASHER 1 59 9091274 SOCKET BOLT 1 60 9091269 SOCKET BOLT 2 61 TCR132108020 SET SCREW 1 62 TCR137309075 BRAND NAME PLATE 1 63 TCR426325730 SET PIECE 1 70 TCR426325400 BRAKE PISTON 1 71 TCR426325410 BRAKE COVER 1 72 TCR426325420 PISTON COVER 1 73 TCR426325430 BRAKE DISK 1 74 TCR130408084 KEY 2

Parts

Per

1

Figure

Number

Part Number Part Name

75 TCR130802213 DISC SPRING 6 76 TCR131103008 O-RING 1 77 TCR131101004 O-RING 1 78 TCR131103063 O RING 1 79 9091247 SOCKET BOLT 2 80 9091252 SOCKET BOLT 4 85 TCR426325240 CAGE 1 86 TCR426325250 STAR GEAR 3 87 TCR426325260 PIN 3 88 TCR426325270 THRUST COLLAR 6 90 TCR426325290 PINION 1 91 TCR426325300 LOAD SHEAVE 1 92 TCR426325310 GEAR CASE 1 93 TCR426325320 RING GEAR 1 95 TCR426325340 DOWEL PIN 4 96 TCR426325351 CHAIN GUIDE 1 97 TCR426325360 CHAIN SEPARATOR 1 98 TCR426325380 BRAKE TUBE 1

99 TCR426325371 BOTTOM PLATE 1 100 9000103 BEARING 2 101 9000109 BEARING 2 102 9000104 BEARING 12 103 TCR131103058 O RING 1 104 TCR131103063 O RING 1 105 9047120 RET AI NING RING 3 106 9047160 RET AI NING RING 1 107 9047117 RET AI NING RING 3 108 9047235 RET AI NING RING 2 109 TCR130303005 RE T AI NING RING 1 110 9091247 SOCKET BOLT 12 111 9091284 SOCKET BOLT 4 112 9091271 SOCKET BOLT 2 113 TCR130406028 PARALLEL PIN 2 114 9047245 RET AI NING RING 6

Parts

Per

Figure

Number

Part Number Pa rt Nam e

Parts

Per

115 TCR42632557B TOP H OOK SET 1 115AB TCR420655P10 HOOK LATCH 1 115AC TCR130802046 HOOK SPRING 1 115AD TCR130603024 SPRING PIN 1

120 TCR420875PAD BOTTOM HOOK SET 1 120A TCR420875PAA BOTTOM HOOK ASSY. 1 120B TCR420655P10 HOOK LATCH 1 120C TCR130802046 HOOK SPRING 1 120D TCR130603024 SPRING PIN 1 121 TCR420875PZ1 BOTTOM YOKE ASSY. 1 122 TCR420875PW0 OUTER BEARING RACE 1 123 TCR420875PY0 SWIVEL HOOK PLUG 1 124 TCR131101025 O RING 1 125 TCR130502024 STEEL BALL 10 126 9091275 SOCKET BOLT 2 127 9091278 SOCKET BOLT 2 128 9012711 SPRING WASHER 4 129 9098506 U-NUT 4

131 LCER025C LOAD CHAIN FT

TCR3000 Main Body

10.1.6 TCR6000-2 Main Body

58

Figure 10-6 TCR6000-2 M ain Bod y

Figure

Parts Hoist

Number

Part Number Part Name

Per

28 TCR130406005 PARALLEL PIN 2 35 TCR426325150 ROTOR 1 36 TCR426325160 STATOR 1 37 TCR426325170 F RO NT PLATE 1 38 TCR426325180 REAR PLATE 1 39 TCR426325190 REAR RETAINER 1 40 TCR137102022 VANE 8 41 TCR130802212 VANE SPRING 8 42 9000103 BEARING 2 43 TCR131103004 O-RING 1 44 TCR131103026 O RING 1 45 9047117 RETAINING RING 1 46 9091288 SOCKET BOLT 3 47 9012511 WASHER 1 48 TCR130402054 KNOCK PIN 1 49 9091269 SOCKET BOLT 4

59

50 TCR426325200 COUPLING 1 51 TCR426325212 WHEEL HOUSING 1 52 TCR426325220 TOP PIN 1 53 TCR426325230 SPACER 1

54 TCR420875MN0

CHAIN END SET WASHER

1

55 9000119 BEARING 1 56 9000212 BEARING 1 57 9098516 U NUT 1 58 9012715 SPRING WASHER 1 59 9091274 SOCKET BOLT 1 60 9091269 SOCKET BOLT 2 61 TCR132108020 SET SCREW 1 62 TCR137309075 BRAND NAME PLATE 1 63 TCR426325730 SET PIECE 1 70 TCR426325400 BRAKE PISTON 1 71 TCR426325410 BRAKE COVER 1 72 TCR426325420 PISTON COVER 1 73 TCR426325430 BRAKE DISK 1

Figure

Number

Part Number Part Name

74 TCR130408084 KEY 2 75 TCR130802213 DISC SPRING 6 76 TCR131103008 O-RING 1 77 TCR131101004 O-RING 1 78 TCR131103063 O RING 1 79 9091247 SOCKET BOLT 2 80 9091252 SOCKET BOLT 4 85 TCR426325240 CAGE 1 86 TCR426325250 STAR GEAR 3 87 TCR426325260 PIN 3 88 TCR426325270 T HRUST COLLAR 6 90 TCR426325290 PINION 1 91 TCR426325300 LOAD SHEAVE 1 92 TCR426325310 GEAR CASE 1 93 TCR426325320 RING GEAR 1 95 TCR426325340 DOWEL PIN 4 96 TCR426325351 CHAIN GUIDE 1 97 TCR426325360 CHAIN SEPARATOR 1 98 TCR426325380 BRAKE TUBE 1

99 TCR426325371 BOTTOM PLATE 1 100 9000103 BEARING 2 101 9000109 BEARING 2 102 9000104 BEARING 12 103 TCR131103058 O RING 1 104 TCR131103063 O RING 1 105 9047120 RETAINING RING 3 106 9047160 RETAINING RING 1 107 9047117 RETAINING RING 3 108 9047235 RETAINING RING 2 109 TCR130303005 RETAINING RING 1 110 9091247 SOCKET BOLT 12 111 9091284 SOCKET BOLT 4 112 9091271 SOCKET BOLT 2 114 9047245 RETAINING RING 6

Per

Figure

Number

Part Number Part Name

Per

116 TCR4200HH006 TOP HOOK SET 1 115A TCR420890PAB HOOK ASSY. 1 115B TCR420890P10 HOOK LATCH 1 115C TCR130802046 HOOK SPRING 1 115D TCR130603024 SPRING PIN 1 117 TCR426335690 HOOK ANCHOR 1 120 TCR420890QF0 TOP YOKE ASSY. 1 121 TCR420890JG0 CHAIN PIN 1 125 90912118 SOCKET BOLT 2 126 90912121 SOCKET BOLT 1 128 9098511 U NUT 4 132 9012713 SPRING WASHER 4

115 TCR420890PAC BOTTOM HOOK SET 1 115A TCR420890PAB HOOK ASSY. 1 115B TCR420890P10 HOOK LATCH 1 115C TCR130802046 HOOK SPRING 1 115D TCR130603024 SPRING PIN 1 122 TCR420890RB0 IDLE SHEAVE 1 123 TCR420890QH0 BOTTOM HOOK COVER 2

124 TCR420890QG0

BOTTOM YOKE ASSY. PR.

1 PR

125A 90912118 SOCKET BOLT 2 127 9093155 HEX HEAD BOLT 1 128A 9098511 U NUT 2 129 9093433 HEX NUT 1 132A 9012713 SPRING WASHER 3 134 9000611 BEARING 2

131 LCER025C LOAD CHAIN FT

TCR6000-2 Main Body

10.2 Cord Control Valve Body

60

Figure 10-7 Cord Control Valve Body – Versions 1, A and B Hoists

Part Number

Figure

Number

1 TCR426224012 TCR426325010 MAIN SPOOL 1 2 TCR426224020 BRAKE SPOOL 1 3 TCR426224030 SPOOL RETAINER 4 4 TCR426224040 BRAKE RETAINER 1 5 TCR426224050 BRAKE NUT 1

6

7 TCR426224070 TOP COVER 1

8

9

10 TCR426224100 LIMIT G UID E 1 14 TCR136102160 SIDE PACK ING 2

61

15 TCR426224140 LIMIT LEVER 1 16 TCR130802210 BRAKE SPR ING 2 17 TCR130802211 LIMIT S PR ING 1 18 TCR136102161 VALVE PAC KING 1 19 TCR426224A90 EXHAUST PLA TE 1 20 TCR136102162 TCR136102192 TOP PACKING 1 21 9047219 RETAINING RING 4 22 9047258 RETAINING RING 1 23 9091247 SOCKET BOLT 6 24 9091253 SOCKET BOLT 3 25 9091258 SOCKET BOLT 3 26 9093420 HEX NUT 1 27 9098506 U-NUT 1 29 TCR132306028 SET SCREW 1 30 TCR137402031 NYLON SIL ENC ER 1 31 TCR134902003 HEX SOCKET PIPE PLUG 3 32 TCR130604010 SPRING P IN 2 33 TCR130821418 SPRING 1 34 TCR136102163 UNDER PACKING 1

69* TCR426224110 TCR426325113 CHAIN LEVER* 1

TCR250C TCR500C TCR1000C2 TCR1000C TCR2000C2

TCR426224061 TCR426325060 VALVE BO DY Ve rsion 1 & A TCR426224062 TCR426325061 VALVE BODY Version B

TCR426224081 SIDE COVER (L) Version 1 & A TCR426224082 SIDE COVER (L) Version B TCR426224091 SIDE COVER (R) Version 1 & A TCR426224092 SIDE COVER (R) Version B

TCR3000C TCR6000C2

Part Name

Parts

Per

Hoist

1

Figure

Number

68 TCR426224120 ROLLER SHAFT 1

68A TCR132108016 SET SCREW 1

69 TCR426224130 LIMIT ROLLER 1

69A* TCR426325740 CAM* 1

TCR137309277 NAME PLATE 250 TCR137309276 NAME PLATE 500 TCR137309278 NAME PLATE 1000, 1000-2

134

TCR137309280 NAME PLATE 2000-2

138 AH136602627 HANDLE 1 139 TCR1302CRIMP ROPE CRIMP 2

140** TCR426225461 TCR426326461 LIMIT SHAFT** 1

141 TCR130802215 MAIN SPRING 2 142 TCR426225470 UNDER COVER 1 143 TCR426225540 CORD LEVER 1 144 TCR130802081 S-TYPE WIRE 2

145W 9013101 WHITE CORD (UP) FT***

145R 9013102 RED CORD (DOWN) FT***

146 AH136602625 THROTTLE VALVE GRIP (UP) 1 147 AH136602626 THROTTLE VALVE GRIP (DOWN) 1

148

150 9091250 SOCKET BOLT 1 151 TCR132805010 152 9047110 RETAINING RING 1

153 9047112 RETAINING RING Version 1 1 156 TCR130790012 HAIRPIN CO T TER Ver sio n s A & B 1 157 TCR426325750 WASHER Version A & B 1 165 TCR1350005HH TCR420845DHH HOSE STEM ASSEM BLY 1 180 WTAG7 WARNING TAG 1

* Replacing the one-piece Chain Lever (#67) on 3 and 6 Ton version 1 hoists. Hoist requires figure nu mbers 67 and 69A. ** Replacing limit shaft (#140) on version 1 hoists requires figure numbers 140, 156 and 157 . *** Specify the hoist’s lift or the required cord drop when ordering.

Part Number

TCR250C TCR500C TCR1000C2 TCR1000C TCR2000C2

TCR137309282 NAME PLATE 3000 TCR137309288 NAME PLATE 6000-2

TCR134902003

TCR3000C TCR6000C2

9091301 SET SCREW Versions 1 & A 3

HEX SOCKET PIP E PL UG Ve rsion B

HEX FLAT HEAD MACHINE SCREW

Part Name

Parts

Per

Hoist

1

3

4

Cord Control Valve Body

62

Figure 10-8 Cord Control Valve Body – Version C Hoists

Part Number

Figure

Number

67 TCR426224110 TCR426325113 CHAIN L EVER 1 68 TCR426224120 ROLLER SHAFT 1

68A TCR132108008 SET SCREW 1

69 TCR426224130 LIMIT ROLLER 1

69A TCR426325740 CAM 1

134

138 AH136602627 HANDLE 1 139 TCR1302CRIMP ROPE CRIMP 2 140 TCR426225461 TCR426326461 LIM IT SH AF T 1

63

61

141 TCR130802217 SPRING 2 142 TCR426225470 UNDER COVER 1 143 TCR426225540 CORD LEVER 1 144 TCR130802081 S-TYPE WIRE 2

145W* 9013101 WHITE CORD (UP) FT*

145R* 9013102 RED CORD (DOWN) FT*

146 AH136602625 THROTTLE VAL VE GRI P (UP) 1 147 AH136602626 148 TCR134902003 HEX SOCKET PIPE PLUG 3 149 TCR426224C30 TCR426325C30 MAIN BUSHING 1 150 9091250 SOCK ET BOL T 1 151 TCR132805010 HEX FLAT HEAD MACH. SCREW 4 152 9047110 RETAINING RING 1 156 TCR130790012 HAIRPIN COTT ER 1 157 TCR426325750 WASHER 1 159 TCR134703060 TCR134703070 INLET BUSHING 1 165 TCR1350005HH TCR420845DHH HOSE STEM ASSEMBL Y 1 180 WTAG7 WARNING TAG 1 201 TCR426224013 MAIN SPOOL 1 202 TCR426224021 BRAKE SPOO L 1 203 TCR426224C20 SPOOL CYLINDER 2 204 TCR426224041 BRAKE RETAINER 1 205 TCR426224051 BRAKE NUT 1

TCR250C TCR500C TCR1000C2 TCR1000C TCR2000C2

TCR137309277 TCR137309276 NAME PLATE 500 TCR137309278 NAME PLATE 1000, 1000-2 TCR137309280 NAME PLATE 2000-2

TCR137309282 NAME PLATE 3000 TCR137309288 NAME PLATE 6000-2

TCR3000C TCR6000C2

NAME PLATE 250

THROTTLE VALVE GRIP(DOWN)

Part Name

Parts

Per

Hoist

1

Figure

Number

206 TCR426224063 VALVE BODY 1 207 TCR426224070 TOP COVER 1 208 TCR426224083 SIDE COV ER (L ) 1 209 TCR426224093 SIDE COVER (R) 1 210 TCR426224101 LIMIT GU ID E 1 211 TCR426224C40 BRAKE BUSHING 1 212 TCR426224C50 LIMIT BUSHING 1 213 TCR426224C60 SPOOL PISTON 2 214 TCR426224C70 SPRING SEAT 2 215 TCR426224140 LIMIT LEVER 1 216 TCR130802216 SPRING 1 217 TCR136102164 SIDE PACK ING 2 218 TCR136102161 VALVE PAC KING 1 219 TCR136102162 TCR136102192 TOP PACKING 1 220 TCR136102163 UNDER PACKING 1 221 TCR426224A90 EXHAU ST PLATE 1 222 TCR137402031 NYLON SILEN CER 1 223 9047225 RETAINING RING 1 224 9047258 RETAINING RING 1 225 9091247 SOCK ET BOL T 2 226 9091251 SOCK ET BOL T 4 227 9091254 SOCK ET BOL T 3 228 9091258 SOCK ET BOL T 3 229 9798532 MACHINE SCREW 2 230 TCR132306035 SET SCREW 1 231 TCR134902003 HEX SOCK ET PIPE PLUG 3 232 9093420 HEX NUT 1 233 9098506 U-NUT 1 235 TCR130604010 SPRING PIN 2 236 TCR131103004 O-RING 2 237 TCR131103021 O-RING 2 238 TCR131103022 O-RING 7 239 TCR131103024 O-RING 2 240 TCR131103027 O-RING 2 241 TCR136803032 SCREEN 1

*Specify the hoist's lift or the required pendant drop when ordering.

TCR250C TCR500C TCR1000C2 TCR1000C TCR2000C2

Part Number

TCR3000C TCR6000C2

Part Name

Parts

Per

Hoist

Cord Control Valve Body Cord Control Valve Body

10.3 Pendant Control Valve Body

64

Figure 10-9 Pendant Control Valve Body – Versions 1, A and B Hoists

Part Number

Figure

Number

1 TCR426224012 TCR426325010 MAIN SPOOL 1 2 TCR426224020 BRAKE SPOOL 1 3 TCR426224030 SPOOL RETAINER 4 4 TCR426224040 BRAKE RETAINER 1 5 TCR426224050 BRAKE NUT 1

6

7 TCR426224070 TOP COVER 1

8

9

10 TCR426224100 LIMIT G UID E 1

65

14 TCR136102160 SIDE PACK ING 2 15 TCR426224140 LIMIT LEVER 1 16 TCR130802210 BRAKE SPR ING 2 17 TCR130802211 LIMIT S PR ING 1 18 TCR136102161 VALVE PAC KING 1 19 TCR426224A90 EXHAUST PLA TE 1 20 TCR136102162 TCR136102192 TOP PACKING 1 21 9047219 RETAINING RING 4 22 9047258 RETAINING RING 1 23 9091247 SOCKET BOLT 6 24 9091253 SOCKET BOLT 3 25 9091258 SOCKET BOLT 3 26 9093420 HEX NUT 1 27 9098506 U-NUT 1 29 TCR132306028 SET SCREW 1 30 TCR137402031 NYLON SIL ENC ER 1 31 TCR134902003 HEX SOC KET P IPE PLUG 3 32 TCR130604010 SPRING P IN 2 33 TCR130821418 SPRING 1

TCR250P TCR500P TCR1000P2 TCR1000P TCR2000P2

TCR426224061 TCR426325060 VALVE BO DY Ve rsion 1 & A TCR426224062 TCR426325061 VALVE BODY Ver sion B

TCR426224081 SIDE COVER (L) Version 1 & A TCR426224082 SIDE COVER (L) Version B TCR426224091 SIDE COVER (R) Version 1 & A 1 TCR426224092 SIDE COVER (R) Version B

TCR3000P TCR6000P2

Part Name

Parts

Per

Hoist

1

Figure

Number

34 TCR136102163 UNDER PACKING 1

67* TCR426224110 TCR426325113 CHAIN LE VER* 1

68 TCR426224120 ROLLER SHAFT 1

68A TCR132108016 SET SCREW 1

69 TCR426224130 LIMIT ROLLER 1

69A* TCR426325740 CAM* 1

134

140** TCR426224461 TCR426325461 LIMIT SHAFT** 1

141 TCR130802214 TCR130821123 MAIN SPRING 2 142 TCR426224471 UNDER COVER 1 148 9047110 RETAINING RING 1 149 9047112 RETAINING RING Version 1 1

151 TCR132805010

152 TCR132506012 153 TCR137240020 PENDANT HOSE ASSY. FT***

154 TCR426221E20 HOSE NIPPLE Version 1 & A 3 155 TCR136102094 SEAL WASH ER Version 1 & A 3 156 TCR130790012 HAIR PIN COT TER Ve r sion s A & B 1 157 TCR426325750 WASHER Version A & B 1 158 9013137 90° TUBE FITTING Version B 3 165 TCR1350005HH TCR420845DHH HOSE STEM ASSY. 1 180 WTAG7 WARNING TAG 1

* Replacing the one-piece Chain Lever (#67) on 3 and 6 Ton version 1 hoi sts. Hoist requires figure nu mbers 67 and 69A. ** Replacing limit shaft (#140) on version 1 hoists requires figure numbers 140, 156 and 157 . *** Specify the hoist’s lift or the required pendant drop when ordering.

TCR250P TCR500P TCR1000P2 TCR1000P TCR2000P2

TCR137309277 NAME PLATE 250 TCR137309276 NAME PLATE 500 TCR137309278 NAME PLATE 1000, 1000-2 TCR137309280 NAME PLATE 2000-2

Part Number

TCR3000P TCR6000P2

TCR137309282 NAME PLATE 3000 TCR137309288 NAME PLATE 6000-2

HEX FLAT HEAD MACHINE SCREW

SLOTTED HEAD MACHINE SCREW

Part Name

Parts

Per

Hoist

1

4

2

Cord Control Valve Body

10.3 Pendant Control Valve Body

66

Figure 10-10 Pendant Control Valve Body – Version C Hoists

Part Number

Figure

Number

67 TCR426224110 TCR426325113 CHAIN L EVER 1 68 TCR426224120 ROLLER SHAFT 1

68A TCR132108008 SET SCREW 1

69 TCR426224130 LIMIT ROLLER 1

69A TCR426325740 CAM 1

134

140 TCR426224461 TCR426235461 LIM IT SH AF T 1 141 TCR130802217 SPRING 2

67

142 TCR426224470 UNDER COVER 1 148 9047110 RETAINING RING 149 TCR426224C30 TCR426325C30 MAIN BUSHING 1

151 TCR132805010

152 TCR132506012

153* TCR137240020 PENDANT H OS E A SS EMBL Y FT*

156 TCR130790012 HAIRPIN C OT TER 1 157 TCR426325750 WASHER 1 158 9013137 90 DEGR E E TUB E FIT TING 3 159 TCR134703060 TCR134703070 INLET BUSHING 1 165 TCR1350005HH TCR420845DHH HOSE STEM ASSEMBL Y 1 180 WTAG7 WARNING TAG 1 201 TCR426224013 MAIN SPOOL 1 202 TCR426224021 BRAKE SPOO L 1 203 TCR426224C20 SPOOL CYLINDER 2 204 TCR426224041 BRAKE RETAINER 1 205 TCR426224051 BRAKE NUT 1 206 TCR426224063 VALVE BODY 1 207 TCR426224070 TOP COVER 1

TCR250P TCR500P TCR1000P2 TCR1000P TCR2000P2

TCR137309277 TCR137309276 NAME PLATE 500 TCR137309278 NAME PLATE 1000, 1000-2 TCR137309280 NAME PLATE 2000-2

TCR137309282 NAME PLATE 3000 TCR137309288 NAME PLATE 6000-2

TCR3000P TCR6000P2

NAME PLATE 250

HEX FLAT HEAD MACHINE SCREW

SLOTTED HEAD MACHINE SCREW

Part Name

Parts

Per

Hoist

1

4

1

Figure

Number

208 TCR426224083 SIDE COV ER (L ) 1 209 TCR426224093 SIDE COVER (R) 1 210 TCR426224101 LIMIT GU ID E 1 211 TCR426224C40 BRAKE BUSHING 1 212 TCR426224C50 LIMIT BUSHING 1 213 TCR426224C60 SPOOL PISTON 2 214 TCR426224C70 SPRING SEAT 2 215 TCR426224140 LIMIT LEVER 1 216 TCR130802216 SPRING 1 217 TCR136102164 SIDE PACK ING 2 218 TCR136102161 VALVE PAC KING 1 219 TCR136102162 TCR136102192 TOP PACKING 1 220 TCR136102163 UNDER PACKING 1 221 TCR426224A90 EXHAU ST PLATE 1 222 TCR137402031 NYLON SILEN CER 1 223 9047225 RETAINING RING 1 224 9047258 RETAINING RING 1 225 9091247 SOCK ET BOL T 2 226 9091251 SOCK ET BOL T 4 227 9091254 SOCK ET BOL T 3 228 9091258 SOCK ET BOL T 3 229 9798532 MACHINE SCREW 2 230 TCR132306035 SET SCREW 1 231 TCR134902003 HEX SOCKET PIPE PLUG 3 232 9093420 HEX NUT 1 233 9098506 U-NUT 1 235 TCR130604010 SPRING PIN 2 236 TCR131103004 O-RING 2 237 TCR131103021 O-RING 2 238 TCR131103022 O-RING 7 239 TCR131103024 O-RING 2 240 TCR131103027 O-RING 2 241 TCR136803032 SCREEN 1

*Specify the hoist's lift or the required pendant drop when ordering.

TCR250P TCR500P TCR1000P2 TCR1000P TCR2000P2

Part Number

TCR3000P TCR6000P2

Part Name

Parts

Per

Hoist

Pendant Control Valve Body

Figure

Number

152 TCR132506012 S LO T TE D HEA D MACHINE SCREW 1 154 TCR426221E20 HOSE NIPPLE 3 155 TCR136102094 SEAL WASHER 3

160 TCR42622452D PENDANT HANDLE CP 1 160A TCR426224520 CONTROL HANDLE 1 160B TCR130501004 STEEL BALL 2 160C TCR130802255 PENDANT VALVE SPRING 2 160D TCR426221H30 PENDANT VALVE SEAT 2 160E TCR131103008 O-RING 4

68

160F TCR426224480 CONTROL SPOOL 2 160G TCR426224530 CONTROL BUSH 2 160H TCR426221H60 PUS H ROD 2 160J TCR136602023 VALVE LEVER (U) 1 160K TCR136602024 VALVE LEVER (D) 1 160L TCR130402006 LEVER PI N 1 160M TCR426221H90 BUFFER SLEEVE 2 160N TCR130305007 CIR-CLIP 2 160P TCR130802256 BUFFER SPRI NG 2 160Q TCR426221J20 BUFFER ROD 2 160R TCR132112010 SET SCREW 2 160S TCR426221J40 HANDLE COVER 1 160T TCR132805010 HEX FLAT HEAD MACHINE SCREW 4 160U TCR132105005 SET SCREW 2

Part Number Part Name

Parts

Per

Handle

Pendant Handle

TCR250C

TCR2000-2

Parts

69

TCR500C TCR1000-2 TCR1000

Figure

Number

— 60395 CHAIN CONTAINER ASSY. 1 1 E7SU010S683 CHAIN BAG 1 2 60392 BRACKET A 1 3 60393 BRACKET “B” 1 4 9091271 SOCKET BOLT M8X 16 1 5 9012711 LOCK WASHER M8 1 6 9091248 SOCKET BOLT M6X 14 1 7 9012709 LOCK WASHER M6 1 8 9798533 MACHINE SCREW M5X10 6 9 9098503 LOCK NUT M5 6

Part Number Part Name

Per Hoist

TCR3000 TCR6000-2

Figure

Number

— 60401 CHAIN CONTAINER ASSY. 1 1 E7SU020S683 CHAIN BAG 1 2 60398 BRACKET A 1 3 60399 BRACKET “B” 1 4 9091271 SOCKET BOLT M8X 16 2 5 9012711 LOCK WASHER M8 2 6 9798535 MACHINE SCREW M5X16 8 7 9098503 LOCK NUT M5 8

Part Number Part Name

Per Hoist

Optional Chain Container

NOTES

70

NOTES

71

www.harringtonhoists.com

Harrington Hoists, Inc. Harrington Hoists – Western Division

401 West End Avenue 2341 Pomona R d. #103 Manheim, PA 17 54 5-1703 Corona, CA 928 80-6973 Phone: 717-665-2000 Phone: 951-279-7100 Toll Free: 800-233-3010 Toll Free: 800-317-7111 Fax: 717-665-2861 Fax: 951-279-7500

TCROM

Harrington Hoists and Cranes TCR Hoist User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1.0 Important Information and Warnings…… …………………… ………………… ………… …………4

2.0 Technical Information…………………… …………… ……………… …………… ……………… … 8

3.0 Pre-operational Procedu res……… ………… ……… ……………… …… ……… ……………… ... 15

4.0 Operation……………………………………………………………………………………………. 23

5.0 Inspection……………………………………………………………………………………………. 28

6.0 Lubrication…………………………………………………………………………………………... 35

7.0 Maintenance & Handling……… ……… ………… ………… ……… ………… … ……………… … 36

8.0 Troubleshooting…………………………………………………………………………………….. 44

9.0 Warranty…………………………………………………………………………………………….. 46

10.0 Parts List………………… ……………… …… ……… ……………… …… ……… ……… ………. . 47

1.0 Important Information and Warnings

2.0 T echni cal Informati on

3.0 Preoperational Procedu res

4.0 Operation

5.0 Inspection

6.0 Lubrication

7.0 Maintenance and H andling

8.0 Troubleshooting

9.0 Warranty

10.0 Parts List

10.1 Main Body

10.1.1 TCR250 / TCR500 Main Body

Part Number Part Name

Part Number Part Name

TCR250 / TCR500 Main Body

10.1.2 TCR1000-2 Main Body

Part Number Part Name

Part Number Part Name

TCR1000-2 Main Body

10.1.3 TCR1000 Main Body

Part Number Part Name

Part Number Part Name

10.1.4 TCR2000-2 Main Body

Part Number Part Name

Part Number Part Name

Part Number Part N ame

TCR2000-2 Main Body

10.1.5 TCR3000 Main Body

Part Number Part Name

Part Number Part Name

Part Number Pa rt Nam e

TCR3000 Main Body

10.1.6 TCR6000-2 Main Body

Part Number Part Name

Part Number Part Name

TCR6000-2 Main Body

10.2 Cord Control Valve Body

Cord Control Valve Body

10.3 Pendant Control Valve Body

10.3 Pendant Control Valve Body

Part Number Part Name

Part Number Part Name

Part Number Part Name

NOTES

NOTES

Harrington Hoists, Inc. Harrington Hoists – Western Division