Page 1
Code, Lot and Serial Number
EFFECTIVE: May 1, 2006
This equipment should not be installed, operated or
with the contents of this manual can result in serious bodily
injury or deat h, and/or p ropert y d amag e.
EFFECTIVE: October 13, 2010
CHEETAH
AIR POWERED
CHAIN HOIST
TCS SERIES
¼ Ton, ½ Ton and 1 Ton Capacity
maintained by any person who has not read and understood
all the contents of this manual. Failure to read and comply
Page 2
Table of Contents
Section Page Number
1.0 Important Information and Warnings…… …………………… ………………… ………… …………4
1.1 Terms and Summary
1.2 Warning Tags and Labels
2.0 Technical Information………………………………………………………………………………… 8
2.1 Specifications
2.2 Dimensions
2.3 Part Names
3.0 Pre-operational Procedu res……… ………… ……… ……………… …… ……… ……………… ... .13
3.1 Air Supply System Requirements
3.2 Air Supply Capacity And Regulation
3.3 Lubrication
3.4 Filtration
3.5 Air Dryer
3.6 Piping, Hoses And Fittings
3.7 Mounting Location
3.8 Connecting Hoist to Air Supply
3.9 Mounting the Hoist
3.10 Optional Chain Container
3.11 Non-Stationary Application
3.12 Preoperational Checks and Trial Operation
4.0 Operation……………………………………………………………………………………………. 21
4.1 Introduction
4.2 Shall’s and Shall Not’s for Operation
4.3 Hoist Controls
4.4 Adjusting the Controls
4.5 Speed Adjustment Controls
4.6 Pendant Controllabil ity Adjustment
2
Page 3
Section Page Nu mber
5.0 Inspection………………………………………………………………………….………………… 27
5.1 General
5.2 Inspection Classification
5.3 Frequent Inspection
5.4 Periodic Inspection
5.5 Occasionally Used Hoists
5.6 Inspection Records
5.7 Inspection Methods and Criteria
6.0 Lubrication…………………………………………………………………………………………... 34
6.1 Air Hoist Lubrication
6.2 Load Chain Lubrication
6.3 Hooks and Suspension Components
7.0 Maintenance & Handling……… ……… ………… ………… ……… ………… … ……………… … 36
7.1 Brake
7.2 Load Chain
7.3 Pendant
7.4 Load Sheave Inspection
7.5 Storage
7.6 Outdoor Installation
8.0 Troubleshooting…………………………………………………………………………………….. 42
9.0 Warranty…………………………………………………………………………………………….. 44
10.0 Parts Information………………………… ………… ………………… ………… ………………… . 45
3
Page 4
1.0 Important Information and Warnings
1.1 Terms and Summary
This manual provides impor tant infor mation for personnel involved with the installation, operation and maintenance
of this product. Although you may be familiar with this or similar equipment, it is strongly recommended that you read
this manual before installing, operating or maintaining the product.
Danger, Warning, Caution and Noti ce - 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 (see Section 3.12.6 and Figure 10-1) on the front cover of this manual
for identification and future reference to avoid referring to the wrong manual for information or instructions on
installation, operation, inspection, maintenance, or parts.
Use only Harrington authorized replacement parts in the service and maintenance of this hoist.
4
Page 5
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
ASTM-E-2349, “Standard for Safety Requirements in Metal Casting: Sand Preparation, Molding, and Core Making;
Melting and Pouring; and Cleaning and Finishing”.
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
Page 6
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY OF COMPRESSED AIR TO THE
HOIST, AND IN THE CONNECTIONS BETWEEN COMPONENTS.
Before performing ANY maintenance on the equipment, de-energize the supply of compressed air to the
equipment, and lock and tag the supply device in the de-energized position. Refer to ANSI Z244.1, “Personnel
Protection - Lockout/Tagout of Energy Sources.”
Only trained and competent personnel should inspect and repair this equipment.
It is the responsibility of the owner/user to install, inspect, test, maintain, and operate a hoist in accordance with
ANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations. If the hoist is installed as part of a
total lifting system, such as an overhead crane or monorail, it is also the responsibility of the owner/user to comply with
the applicable ANSI/ASME B30 volume that addresses that type of equipment.
It is the responsibility of the owner/user to have all personnel that will install, inspect, test, maintain, and operate a
hoist read the contents of this manual and applicable portions of ANSI/ASME B30.16, “Safety Standard for Overhead
Hoists” and OSHA Regulations. If the hoist is installed as part of a total lifting system, such as an overhead crane, the
applicable ANSI/ASME B30 volume that addresses that type of equipment must also be read by all personnel.
If the hoist owner/user requires additional information, or if any information in the manual is not clear, contact
Harrington or the distributor of the hoist. Do not install, inspect, test, maintain, or operate this hoist unless this
information is fully understood.
A regular schedule of inspection of the hoist in accordance with the requirements of ANSI/ASME B30.16 should be
established and records maintained.
6
Page 7
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.
Bilingual Version
Figure 1-1 Warni ng Tag A ttached to Hois t
7
Page 8
2.0 T echni cal Informati on
Temperature range:
+14° to +140°F (-10° to +60°C)
Noise Level:
83 dba maximum @ 1 meter when lifting rated load
Supply Air:
60 to 90 psi (0.4 to 0.6 MPa)
Air Lubrication Requirements:
Minimum 10 to 15 drops per minute (2-3 cc/min) of oil
2.1 Specifications
2.1.1 Product Code
2.1.2 Operating Conditions and Environment
Relative Humidity: 85% or less
93 dba maximum @ 1 meter when lowering rated load
Air Consumption: 60 to 75 cfm (1.7 to 2.1 m³/min)
Air Filtration Requirements: Maximum 5 micron air filter or finer
8
Page 9
Cap.
Product
tandard
Lift
Push
Button
L
Up/Down
Load Chain
Diameter
(mm)
x
Chain Fall
Net
Weight
Additional
S
(Tons)
Code
(ft)
1/4 TCS250P
1/2 TCS500P 8.1 108/62 60/108 74/64 60/71 6.3 X 1 42 0.6
1 TCS1000P2 8.1 54/31 30/54 74/64 60/71 6.3 x 2 55 1.2
Pendant Model
10
1/4 TCS250C
1/2 TCS500C 7.3 108/62 60/108 74/64 60/71 6.3 X 1 40 0.6
Cord Model
1 TCS1000C2 7.3 54/31 30/54 74/64 60/71 6.3 x 2 53 1.2
10
Table 2-1 Hoist Specifi cations
Up/Down Speeds
Hose
(ft)
(ft/min @ 90 psi)
No Load w/Full Load N o Load w/Full Loa d
Air Consumpti on Rat es
(cubic ft/min @ 90 psi)
8.1 207/125 121/197 78/67 64/74 6.3 X 1 42 0.6
7.3 207/125 121/197 78/67 64/74 6.3 X 1 40 0.6
Weight for
One foot
(lbs)
Lines
of Lift
(lbs)
9
Page 10
2.2 Dimensions
Product
Headroom
C
a
b
d
e
g
h
i
j
Table 2-2 TCS with Pe ndant Contro l Dimens ions
Single Fall Hoist
Double Fall Hoist
Cap.
(Tons)
Code
(in)
(in)
(in)
(in)
(in)
(in)
(in)
(in)
(in)
1/4 TCS250P 16.3 14.4 6.6 6.3 7.6 1.0 4.4 2.2 1.0
1/2 TCS500P 16.3 14.4 6.6 6.3 7.6 1.0 4.4 2.2 1.0
1 TCS1000P2 17.9 14.4 9.0 6.3 8.0 1.1 6.3 2.8 1.9
10
Page 11
Product
Headroom
C
a
b
d
e
g
h
i
j
TCS250C/P
0.6
0.8
0.6
0.8
1.4
1.3
1.0
2.9
0.6
0.8
0.6
0.8
1.4
1.3
1.0
2.9
TCS1000C2/P2
1.4
0.9
1.1
0.9
1.6
1.6
1.1
4.2
Table 2-3 TCS with Cor d Control Di mensions
Cap.
(Tons)
Single Fall Hoist
Code
(in)
(in)
(in)
(in)
Double Fall Hoist
(in)
(in)
in)
(in)
(in)
1/4 TCS250C 16.3 14.4 8.7 6.3 7.6 1.0 5.3 3.3 1.0
1/2 TCS500C 16.3 14.4 8.7 6.3 7.6 1.0 5.3 3.3 1.0
1 TCS1000C2 17.9 14.4 9.0 6.3 8.0 1.1 6.3 2.8 1.9
Table 2-4 Top and Bottom H ook Dimension*
Units = inch
Product Code a b c d e f g h
TCS500C/P
*Refer to Section 5.7 for inspection dimensions and limits.
11
Page 12
2.3 Part Names
Figure 2-1 Hoist Part Identification Diagrams – TCS250C/P and TCS500C/P
Figure 2-2 Hoist Part Identification Diagrams – TCS1000C2/P2
12
Page 13
3.0 Preoperational Procedures
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
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
13
Page 14
3.4.1
microns in size. Therefore, the hoist must have a 5 micron filter
upstream of the lubricator.
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.
The air entering the hoist inlet must not contain any particulate greater than 5
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, regulator (if equipped), and lubricator must be arranged in the order shown in Figure 3-2.
System Configuration - The system should be configured as shown in Figure 3-1.
in its air supply. The filter must be
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)
14
Page 15
Figure 3-2 Typical Air Supply Filter, Regulator, and Lubricator.
3.6.2
3.6.3
Piping - Pi pe 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 Diameter of Supply Pipe Diameter of Supply Hose
TCS250C/P
TCS500C/P
TCS1000C2/P2
Inside diameter
3/4” or larger
Inside diameter
1/2” or larger
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.
Figure 3-3 Typical Arrangements of Filter, Regulator and Lubricator and
Maximum Air Supply Hose Lengths
3.6.4
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.
15
Page 16
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.
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”.
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY
Figure 3-4 Air Supply Connection to Hoist – Cord or Pendant Models
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”.
3.8.6
the hoist first (Section 3.9) followed be connecting the air supply.
3.9 Mounting the Hoist
3.9.1 Manual Trolley - Follow instructions in Owner’s Manual provided with the trolley.
3.9.2 Hook Mounted to a Fixed Location - Attach the hoist’s top hook to the fixed suspension point.
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
16
Page 17
3.9.3
that the hook’s latch is engaged.
Ensure that the fixed suspension point rests on the center of the hook’s saddle and
3.10 Optional Chain Container
3.10.1 Follow instructions below to install the optional chain container. Refer to Figure 3-5.
1) Attach the metal bracket on top of the chain container to the lower boss on the side of the hoist body
using the M8 Socket Bolt, Washers, Nut and Split Pin provided.
2) Attach the support chain to the upper boss on the side of the hoist body using the M6 Socket Bolt,
Washers, Nut and Split Pin provided.
3) Make sure all fasteners on the chain container and chain attachment points are secure and that the
split pins are sufficiently bent.
4) Feed the Chain into the Chain Container beginning with the no-load end. Take care to avoid twisting or
tangling the Chain.
5)
fasteners/hardware are missing.
Do not use the Chain Container if any parts are damaged or if any
Figure 3-5 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-toplace, 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:
1) Run the hoist briefly with well lubricated air
2) Shut off the air supply to the hoist, bleed off any pressure in the system then disconnect the air supply
line.
17
Page 18
3) Inject a small quantity (approximately 20 drops) of turbine oil (see Section 6.0) into the hoist’s inlet port
4) Plug the inlet port
3.12 Preoperational Checks and T rial Oper ation
3.12.1
90 psi at the hoist's inlet port before trying to operate the hoist.
3.12.2
capsized prior to operating the hoist. Correct all chain irregularities before conducting the first hoist
operation. See Figures 3-6 and 3-7.
Check for the availability of required operating air pressure of between 60 psi to
Verify that the load chain is not twisted or tangled and that the bottom hook is not
Figure 3-6 Twist in Load Chain
Figure 3-7 Capsized Hook and Chain
18
Page 19
3.12.3
3.12.4
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.
Verify that the Chain/Limit Lever is operational and can move freely in both the up
and down directions. For reference see Figure 3-8.
Figure 3-8 Limit Switch Components –
TCS250C/P, TCS500C/P and TCS1000C2/P2
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.
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 Hoses and Strain Relief wire are properly
attached to the hoist. See Section 7.4.
3.12.11
quality and air pressure.
3.12.12
Check Air Supply - Check air supply before everyday use. Ensure proper air
Check the lubricator for proper function and adequate oil level.
19
Page 20
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.
3.12.4 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”.
Make sure hook travel is in the same direction as shown on controls.
20
Page 21
4.0 Operation
ES, LOSS OF
• 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 ATTACH MENT
OF LOADS TO THE HOIST HOOK .
HOIST OPERATORS SHOULD BE TRAINED TO BE AWARE OF POTENTIAL MALFUNCTIONS OF THE
EQUIPMENT T HAT REQUIRE ADJUST MENT OR REP AIR, AND TO BE IN STRUCTED TO STOP OPERAT ION
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 SEIZUR
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 T HAT ARE NOT LI FTED VERTIC ALLY, LOADS T HAT
• Read the hoist manufacturer’s Operating and Maintenance Instructions.
• Read all labels attached to equipment.
21
Page 22
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 eff ects 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 a damaged, malfunctioning or
unusually performing hoist.
operate a hoist until you have thoroughly read
and understood Manufacturer’s Operating and
Maintenance Instructions or Manuals.
• NOT
seated in the load sheave (and idle sheave for hoist
with two chain falls).
• NOT
on all load-supporting chain.
or serious i njury,
apply loa d unless the load chain is properly
apply load if bearing prevents equal loading
• Be familiar with operating controls, procedures, and
warnings.
• NOT
• NOT
• NOT
• NOT
• NOT
• NOT
• NOT
• NOT
• Protect the hoist’s load c hain from weld splatter or
• NOT
• NOT
• NOT appl y the load to the tip of the hook or to the
operate a hoist that has been modified without
the manufacturer’s appr oval or without certification
that it is in conformity with ANSI/ASME B30
volumes.
lift more than rated load for the hoist.
use hoist with twisted, kinked, damaged, or
worn chain.
use the hoist to lift, support, or transport
people.
lift loads over people.
operate a hoist unless all persons are and
remain clear of the supported load.
operate unless load is centered under hoist.
attempt to lengthen the load chain or repair
damaged load chain.
other damaging contaminants.
operate hoist when it is restricted from forming
a straight line from hook to suppor t in the direction
of loading.
use load chain as a sling or wra p load chain
around load.
hook latch.
• NOT
• NOT
• NOT
• NOT
• NOT
• NOT
• NOT
• NOT
• NOT
• Take up slack carefully – make sure load is
• Shut down a hoist that malfunctions or performs
• Make sure hoist limit lever functions properly.
• Warn personnel before lifting or moving a load.
• Warn personnel of an approaching load.
operate beyond the limits of the load chain
travel.
leave load supp orted by th e hoist u nattended
unless specific precautions have been taken.
allow the load chain or hook to be us ed as an
electrical or welding ground.
allow the load chain or hook to be touched by
a live welding electrode.
remove or obscure the warnings on the hoist.
operate a hoist on which the safety placards
or decals are missing or illegible
operate a hoist unless it has been securely
attached to a suitable support.
operate a hoist unless load slings or other
approved single attachments are properly sized,
and seated in the hook saddle.
use the hoist in such a way that could result in
shock or impact loads being applied to the hoist.
balanced and load-holding action is secure bef ore
continuing.
unusually and report such malfunction.
22
Page 23
Improper operation of a hoist can create a potentially hazardous
situation which, if not avoided, could result 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 lever as a routine operating stop. It
is an emergency device 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
23
Page 24
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.
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. Refer to Figure 4-3.
4.4.2 For the cord type control, adjust the speed by varying the amount of pull on the cord. Refer to Figure
4-4.
Figure 4-3 Cord and Pendant Control Speed Adjustment
Figure 4-2 Cord Control
Make sure the motor completely stops before reversing direction.
24
Page 25
4.5 Speed Adjustment Controls
4.5.1 The hoist is equipped with speed adjustment controls. The controls allow the hoist lifting and lowering
speeds to be reduced for those applications requiring slower speeds or better speed control. The
speed adjustment controls are set for the highest speed from the factory. The speed adjustment
controls are located on top of the valve section of the hoist as shown in Figure 4-4.
4.5.2
4.5.3 To reduce the lifting/lowering speeds remove the speed adjustment covers to gain access to the speed
adjustment screws as shown in Figure 4-4. The covers may be plastic or aluminum. Viewed from the
valve side of the hoist, the lowering adjustment screw is on the left and the lifting adjustment screw is
on the right. The lifting and lowering adjustment mechanisms are not connected, allowing separate
adjustments for lifting and lowering speeds.
4.5.4 Referring to Figure 4-4 the hoist is at the highest speed when the screw is in the “vertical” position and
at the lowest speed when in the “horizontal” position. Speed adjustment can be made between these
postions.
The hoist must be stopped when adjusting the lifting and lowering speeds.
Figure 4-4 Speed Adjustment
25
Page 26
4.6 Pendant Controllability Adjustment
4.6.1 The standard pendant hose length is 8.1 feet. For longer pendant hose lengths the speed
controllability from the pendant may be diminished. The reduction in speed control is a result of
pressure loss due to the longer pendant hose. The pendant hose extension adjustment control
provides a screw adjustment method to reduce the air pressure loss to provide normal pendant/hoist
operation. The adjustment screw is set fully open from the factory for normal operation and to allow the
fine feathering feature.
4.6.2 To adjust the pendant air pressure locate the hex nut and hex screw as shown in Figure 4-5. The
adjustment screw on the left is for adjusting the lowering speed and the adjustment screw on the right is
for adjusting the lifting speed.
4.6.3 Adjustment is accomplished by loosening the hex nut with a 2.5mm wrench and turning the hex head
screw clockwise. Once correct operation is obtained securely tighten the hex nut.
4.6.4
If the adjustment screw is tighened too tight the fine feathering feature will be
reduced or lost.
Figure 4-5 Pendant Controllability Adjustment
26
Page 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 pers on selected or assigned as being com petent to perform the specific
Qualified Person - a person who, by possession of a recognized degree or certificate of
Normal Service - that distributed s ervice which in volves operati on with random l y distributed loads
Heavy Service - that service which invol ves operation within the rated load lim it which exceeds
Severe Service - that service which involves norm al or heavy service with abnormal operating
duties to which he/she is assigned.
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.
within the rated load lim it, or uniform loads less than 65 % of rated load for not mor e than 25% of
the time.
normal service.
conditions.
5.2 Inspection Cl assif icat io n
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.
27
Page 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.
28
Page 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 Lever Function Proper operation. Actuation of limit lever 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
Hooks - Fretting
wear
Visual Should be free of significant rust, weld splatter,
deep nicks, or gouges.
Measure The “u” dimension should not be less than
minimum value listed in Table 5-6.
Hooks - Stretch Measure The “K” dimension should not exceed the
maximum value for replacement from Table 5-6
(See Section 3.12).
Repair or replace
as required.
Repair or replace
as required.
Replace.
Repair or replace
as required.
Replace.
Replace.
Replace.
29
Page 30
no roughness.
Table 5-3 Hoist Inspecti on Methods and Cr iteri a (continu ed)
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.
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
and Wire Diameter
Measure The "P" dimension should not be greater than
discard value listed in Table 5-7. The “d"
dimension should not be less than discard 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 should be installed
properly - refer to Section 7.2.
Chain Spring - Visual Chain springs should not be deformed or
compressed.
Bolts, Nuts and
Rivets
Visual, Check
with Proper Tool
Bolts, nuts and rivets should not be loose. Tighten or replace
Replace.
Replace. Inspect
Load Sheave (and
Idle Sheave for
multiple fall hoists).
Clean/lubricate
(see Sections 6.0).
Reeve/Install chain
properly.
Replace
as required.
30
Page 31
Table 5-3 Hoist Inspecti on Methods and Cr iteri a (continu ed)
Item Method Criteria Action
Housing and
Mechanical
Components
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 and 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 7.1 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 7.4 to gain visual
access to the load sheave.
Pendant Control
Levers
Visual,
Function
Depressing and releasing pendant control levers
should cause hoist to operate.
Pendant - Housing Visual Pendant housing should be free of cracks and
mating surfaces of parts should seal without gaps.
Replace
Replace
Replace
Replace.
Repair or replace
as necessary.
Replace.
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.
31
Page 32
Hoists
Inch (mm)
Inch (mm)
TCS250C2/P2
TCS500C2/P2
TCS1000C2/P2
Table 5-4 Brake Disc Dimension
Parts View
Std Dimension
Minimum Value for Replacem ent
Figure No.
152 T = 0.31 (8) T = 0.29 (7.3)
Table 5-5 Chain Separator Dimensions
Hoists
TCS250C2/P2
TCS500C2/P2
TCS1000C2/P2
Parts View
Figure No.
104
Std Dimension
Inch (mm)
L = 0.51 (13)
W = 0.95 (24)
Maximum Value for Replacement
Inch (mm)
L = 0.63 (16)
W = 1.04 (26.5)
32
Page 33
aximum/Minimum Value
Table 5-6 Top Hook & B ottom Hook D imensi ons
Dimensions K and U should be measured and recorded below pr ior to any use when the hook is first placed into service .
Hoists
Parts View
Figure No.
Recorded Dimension
When New
M
for Replacement
TCS250C2/P2
TCS500C2/P2
TCS1000C2/P2
2-1
2-1
2-1
2-1
2-2
2-2
Top Hook K = _______________
Top Hook U = _______________
Bottom Hook K = ____________
Bottom Hook U = ____________
Top Hook K = _______________
Top Hook U = _______________
Bottom Hook K = ____________
Bottom Hook U = ____________
Top Hook K = _______________
Top Hook U = _______________
Bottom Hook K = ____________
Bottom Hook U = ____________
Table 5-7 Chain Dimensio ns
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.
Product Code
TCS250C2/P2
TCS500C2/P2
TCS1000C2/P2
Parts View
Figure No.
114 3.76 (95.5) 3.82 (96.9) 0.25 (6.3) 0.22 (5.7)
“P” Dimension
inch (mm)
Standard Discard Standard Discard
33
“d” Dimension
inch (mm)
Page 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, the load chain should be lubricated.
6.2.2 The load chain lubrication should be accomplished after cleaning the load chain with an acid free
cleaning solution.
6.2.3 Apply Harrington lubricating grease (Part No. ER1BS1951) or an equivalent to industrial general lithium
grease, NLGI No. 0, to the bearing surfaces of the load chain links as indicated by the shaded areas in
Figure 6-2. Also apply the grease to the areas of the load chain (shaded areas in Figure 6-2) that
contact the load sheave. Insure that the grease is applied to the contact areas in the load sheave
pockets.
6.2.4 Machine or gear oil (grade ISO VG 46 or 68 oil or equivalent) may be used as an alternative lubricant
but must be applied more frequently.
Figure 6-2 Chain Grease Application
6.2.5 The chain should be lubricated every 3 months (more frequently for heavier usage or severe
conditions).
6.2.6 For dusty environments, it is acceptable to substitute a dry lubricant.
34
Page 35
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
Load chain & pocket
wheel
Hook bearings &
suspension pins
Gears and Bearings Gear Section Grease
Load chain
Top & bottom hook
sets
Grease, Machine or
gear oil
Grease
ISO VG 32-56 or
equivalent
- HHI Chain Grease
P/N ER1BS1551
- NLGI No. 0
- ISO VG 46-68 or
equivalent
National Lubricating
Grease #3
National Lubricating
Grease #2
35
Page 36
7.0 Maintenance and H andling
7.1 Brake
7.1.1 The hoist brake is not adjustable.
7.1.2 Inspect the brake disc in accordance with Section 5.7, Table 5-4.
7.1.3 The following is the hoist brake inspection procedure. Refer to Figure 7-1.
1)
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 and evenly back out 4 Hex Socket Cap Screws (A) from Brake Cover (B) from Gear
Case (J) to slowly decrease spring tension (C) of Brake Piston (D) against Brake Disc (E).
3) Remove Brake Cover (B), Brake Piston (D), Springs (C), and O-Rings from Gear Case (J). Set
parts aside for reassembly.
4) Remove Brake Disc for inspection and measurement. Refer to "Motor Brake" in Table 5-3, "Hoist
Inspection Methods and Criteria".
5) Prior to reassembly, clean all surfaces of debris, dirt and loose paint. Apply a light film of grease to
all O-Ring seals.
6) Reassemble in reverse order. Torque all mounting hardware evenly during the reassembly
process.
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE
Figure 7-1 Brake Inspection
36
Page 37
7.2 Load Chain
7.2.1 Lubrication and Cleaning – Refer to Section 6.2.
7.2.2 Replacement
1)
following procedures.
7)
exact size, grade and construction as the original chain. The new load chain must have an even
number of links so that the end links are oriented 90° from each other.
8) Remove the Bottom Hook Complete Set and Button Head Screw connecting the no-load end of
the chain to the hoist body. Keep the Bottom Hook Complete Set and Button Head Screw for
reuse on new chain. Carefully operate the hoist in the down direction to remove old chain.
9)
Chain Guides, Bottom Hook Complete Set and replace parts if necessary. If the load chain is
being replaced due to damage or wear out, destroy the old chain to prevent its reuse.
10)
the hoist approximately 30° as shown in Figure 7-2. Insert the chain into the chain separator on
the no-load side opening making certain that the first link is a standing link and that its weld is
facing away from the centerline of the hoist.
11)
Chain and pull it through the hoist. Make sure the chain feeds smoothly while operating the hoist.
If binding occurs, stop and reverse the hoist direction to the back the chain out. Reinsert the chain
again while gradually operating hoist controls. Continue until a sufficient quantity of Chain is fed
through the hoist to attach the Bottom Hook Complete Set.
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,
Invert the hoist such that the chain separator openings are facing up and tilt
Operate the hoist as slowly as possible in the down direction to catch the Load
12) Ensure that of the Chain remains free of twists and attach the no-load end of the chain to the hoist
body with the Flat Washer and Button Head Screw. Reinstall the Bottom Hook Complete Set.
Torque the Button Head Screw to 78 lbf-in. Refer to Figure 7-3 and Figure 7-4.
13) After installation has been completed, perform steps outlined in Section 3.14 "Pre-operational
Checks and Trial Operation".
37
Page 38
Figure 7-2 Load Chain Installation Diagram
Figure 7-3 Single Fall Chain Connections
38
Page 39
7.3 Pendant
7.3.1 The following procedure covers the installation of the Pendant Hose (Parts List Figure Number 360)
and the Pendant Valve. Refer to Figure 7-5.
1) Place boot on the ends of the Pendant Hoses to be attached to the Manifold Block on the hoist.
2) Attach pendant hose to hoist body using the one-piece fittings and screw type clamps (hose bands).
3) Attach pendant hoses to the pendant valve using the 2 piece fittings and crimp type hose clamps (hose
bands). Refer to Figure 7-5 for the correct placement of the Hoses.
4) Attach the Strain Relief wire S-Hook on the Pendant Valve and Manifold Block using the S-Hook.
5) Slide the Boot in to place over the Hose Fittings at the Manifold Block on the hoist.
6)
levers on the Pendant Valve.
Figure 7-4 Double Fall Chain Connections
Operate hoist and make sure the direction of hook travel agrees with the control
39
Page 40
7.4 Load Sheave Inspection
7.4.1 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 7-6 and
remove the chain separator as follows:
1)
procedures.
2) Remove 2 Socket Bolts attaching the Chain Separator to the Wheel Housing and drop the Chain
Separator down.
3) Inspect the Load Sheave. Refer to “Load Sheave” in Table 5-3, “Hoist Inspection Methods and
Criteria”.
4) Reverse the procedure to reassemble the hoist.
An air supply line must be connected to the hoist in order to perform the following
Figure 7-5 Pendant Hose Connections
40
Page 41
7.5 Storage
7.5.1 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.
7.5.2 The storage location should be clean and dry.
7.6 Outdoor Installation
7.6.1 For hoist installations that are outdoors, the hoist should be covered when not in use.
7.6.2 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 7-6 Load Sheave Inspection
41
Page 42
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
Unable to lift rated load
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
control hose(s)
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
control hose(s)
Lack of sufficient oil in air supply to
hoist
Exhaust Silencer clogged Clean or replace.
Air flow capacity of compressed air
system insufficient
Air motor vanes or bearings worn Repair at service facility.
Air supply to hoist contains dirt or
debris
Lack of air pressure or loss of air
supply.
Repair or adjust air supply or filters.
Repair at service facility.
Repair at service facility.
Correct or repair the bend or crimp in
control hose(s)
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
control hose(s)
Increase oil in air supply to hoist in
accordance with requirements in
Section 3.0.
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.
Repair or adjust air supply or filters.
42
Page 43
body.
Table 8-1 Troubleshooting Guide (co ntinued)
Symptom Cause Remedy
Hoist moving in wrong
direction (pendant control)
Pendant control hoses are
terminated to incorrect ports on hoist
Hoist is overloaded. Reduce load to hoist rated capacity.
Faulty pendant control or control
Hoist lowers but will not lift
hose(s)
Lack of air pressure or partial loss of
or leakage in air supply.
Hoist continues running after
Control Valves
pendant or cord is released
Valve in Pendant Handle stuck Repair at service facility
Hoist drifts excessively when
hoist is stopped
Brake is not holding. Repair brake at service facility.
Connect the control tubes in
accordance with Section 7.3.
Repair or replace pendant control or
control hose(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.
43
Page 44
9.0 Warranty
Warranty expl anati on and 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 date of shi pment by Harring ton for the foll ow ing periods:
Manual Hoists, Trolleys, & Beam C lamp s - 2 years
NER/ER Hoists Enhanced Featur es Mod els - 3years
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 - 10 years
The product mus t be us ed i n acc ord ance w i th ma nufact urer’s rec ommend ations an d 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 business to custom er.
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 produc t. Product must be retur ned fr eight prep aid. Upo 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 warranty period wi ll only be elig ible for replac e ment (n ot including
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 turning the produc t.
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 property or for inci dent al, c onti ng ent, spec ial 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 hether
negligent or w il lful, or from any o th er reas on .
44
Page 45
10.0 Parts Information
A complete parts list is available from Harrington Hoists and is supplied separately with your hoist. The parts list is also
available from Harrington's web site (www.harringtonhoists.com) or from any Harrington facility (see back cover of this
manual).
When ordering Parts, please provide the Hoist code number located on the Hoist nameplate (see fig. below).
Reminder: Per Sections 3.11.6 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.
Figure 10-1 TCS Nameplate
The parts list is arranged into the following sections:
Section Page
10.1 Motor, Valve Body and Controls……………………………………….……………………………... 46
10.2 Brake, Gears and Load Suspension Components……………………………………………….…. 48
10.3 Chain Container Assembly……………………………………………...……………………………..50
45
Page 46
10.1 Motor, Valve Body and Controls
Figure 10-1 Motor, Valve Body and Controls
46
Page 47
Motor, Valve Body and Controls
hoist
1
Throttle Valve
2
AH420215VB0
2
Valve Bushing (Up)
1
TCS426230E90
3
Valve Bushing (Down)
1
TCS426230F00
4
Spring Seat
2
TCS426230C70
5
Valve Cap
2
TCS426230A20
6
Valve Body
1
TCS426230060
7
Bush Cap
2
TCS426230A30
8
Piston 2 TCS426230C60
9
Exhaust Plate
1
TCS426230810
10
Silencer (S)
4
TCS137402023
11
Adjust Cap
2
TCS426230A10
12
Inlet Bushing
1
TCR134703070
13
Screen 1 TCR136803032
14
Valve Spring
2
AH130802030
15
Spring 2 TCS130802224
16
Valve Gasket
1
TCS136102165
17
Bushing
2
TCS130219705
18
Socket Bolt
4
9091235
19
Button-Head Screw
2
AH131905010
20
Set Screw
2
TCR132105005
21
O-Ring 2 TCR131103005
22
O-Ring 2 AH131103013
23
O-Ring 4 AH131103016
24
O-Ring 2 AH131103017
25
O-Ring 2 TCS131117023
26
O-Ring 2 AH131118012
27
O-Ring 2 TCS131103011
28
Spring Pin 4 9148101
29
Spring Pin
2
TCR130604010
30
Retaining Ring
2
9047112
31
Retaining Ring
2
9047232
32
Retaining Ring
2
9047225
50
Motor Case
1
TCS426230790
51
Rear Plate
1
TCS426230180
52
Cylinder
1
TCS426230160
53
Rotor 1 TCS426230150
54
Front Plate
1
TCS426230170
55
Vane 8 TCS137102032
56
Lift Spring
8
TCR130802212
57
Limit Sh af t
1
TCS426230460
58
Limit Shaft Bushing
1
TCS426230A40
59
Limit Lever
1
TCS426230140
60
Bearing
2
TCS130128104
61
Roller Shaft
2
TCS426230120
62
Chain Lever
TCS 1000C2/P2
1
TCS426251110
63
Motor Gasket
1
TCS136102166
64
Silencer (M)
1
TCS137402024
65
Bearing 2 9000102
66
Needle Bearing
2
TCS130151210
67
Socket Bolt
3
9091250
68
Socket Bolt
1
90912147
69
Socket Bolt
2
9091248
70
O-Ring 2 TCS131103012
71
O-Ring 1 TCS131103019
72
O-Ring 1 TCS131102009
73
Spring Pin 1 9148152
75
Spring Pin 1 91481169
76
Retaining Ring
1
9047115
77
Retaining Ring
1
9047228
hoist
78
Hair Pin Cotter
1
AH130790008
79
Retaining Ring
4
TCS130303003
450
Brand Nam e Plate
1
AH137309264
Parts
hoist
62
Chain Lever
TCS 250/500
1
TCS426230110
350
Under Cover
1
TCS426233470
352
Socket Bolt
1
9091231
353
Socket Bolt
2
9091229
358
O-Ring 3 TCR131103004
400
S-Type Wire
2
TCR130802081
402
Grip (Wh ite, Up)
1
AH136602625
403
Grip (Red, Down)
1
AH136602626
404
Handle 1 AH136602627
401R
Red Cord (Down)
2
9013102
401W
White Cord (Up)
2
9013101
Parts
hoist
62
Chain Lever
TCS 250/500
1
TCS426351110
300A
Pendant Valve Assembly
1
TCS420226VRD
300
Throttle Valve
2
TCS420218VB0
301
Valve Body
1
TCS420226VR0
302
Bushing
2
TCS420218VF0
303
Lever Pin
1
TCS130402071
304
Lever 2 TCS420218VH0
305
Spring 2 TCS130802220
306
Set Screw
1
TCS132106006
307
O-Ring 2 TCS131109001
308
O-Ring 2 TCR131103008
309
O-Ring 2 TCS131103009
330
Hose Fitting
3
TCS135106302
332
Hose Clam p
3
TCS137501013
335
S-Type Wire
1
TCR130802081
337
Cable Tie - Red
4
TCS137502034
338
Cable Tie - White
2
TCS137502036
339
Cable Tie - Black
2
TCS137502037
350
Under Cover
1
TCS426230470
351
Pendant Air Silencer
1
TCS137402033
352
Socket Bolt
1
9091231
353
Socket Bolt
2
9091229
354
Set Screw
2
TCS132105016
355
Set Screw
1
TCR132105005
356
Flat Head Machine Screw
3
9096566
357
Hex Nut 2 9093417
358
O-Ring 3 TCR131103004
359
Boot 1 AH136608250
360
Pendant Hose
3@FT
9013156
361
Strain Relief Wire
1
9013120
363
Hose Fitting
3
TCS135106301
364
Hose Clam p
3
9013155
365
Socket Bolt
1
9091225
366
Washer 1 9012511
350
Under Cover
1
TCS426230470
358
O-Ring 1 TCR131103004
Figure
Number
Name
Parts
per
Part Number
Figure
Number
Name
Cord Model Only:
Figure
Number
Name
Pendant Model Only:
Figure
Number
Name
Parts
per
per
per
Part Number
Part Number
Part Number
47
Page 48
10.2 Brake, Gears and Load Suspension Components
Figure 10-2 Brake, Gears and Load Suspension Components
48
Page 49
Brake, Gears and Load Suspension Components
Hook
Figure
Number
Name
Parts
per
hoist
Part Number
100 Center Housing 1 TCS426230A00
101 Load Sheave 1 TCS426230A50
102 Coupling 1 TCS426230200
103 Chain Guide 1 TCS426230350
104 Chain Separator 1 TCS426230360
105 Bearing 2 9000508
106 Socket Bolt 4 9091250
107 Set Screw 1 TCS132106006
108 O-Ring 1 TCS131103006
109 O-Ring 1 TCS131103052
110 O-Ring 1 TCS131117043
111 Spring Pin 2 TCS130608060
113 Chain Container Assembly 0 TCSS2623055C
114 Load Chain 0 LCER005NP
150 Brake Cover 1 TCS426230410
151 Brake Piston 1 TCS426230400
152 Brake Disk 1 TCS426230430
153 Disk Spring 6 TCR130802213
TCS 250 1 TCS137301067
Name Plate
154
TCS 500 1 TCS137301063
TCS 1000 1 TCS137301065
155 Socket Bolt 4 9091255
156 Set Screw 1 TCR132105005
157 O-Ring 1 TCS131103052
158 O-Ring 1 TCS131103045
200 Gear Case 1 TCS426230310
201 First Pinion
First Star
202
Gear
TCS 250
TCS 500/1000 TCS426230A60
TCS 250
TCS 500/1000 TCS426230A70
TCS426351A60
1
TCS426351A70
3
203 First Pin 3 TCS426230A80
204 First Ring Gear 1 TCS426230E10
205
Second
Pinion
TCS 250
TCS 500/1000 TCS426230E20
TCS426351E20
1
206 Second Star Gear 3 TCS426230E30
207 Second Pin 3 TCS426230E40
208 Second Ring Gear 1 TCS426230E50
209 Cage 1 TCS426230240
210 Lock Screw 1 TCS426230890
211 Brake Plate 1 TCS426230900
Figure
Number
Name
Parts
per
hoist
Part Number
212 Bearing 2 TCS130113001
213 Bearing 1 TCS130120004
214 Bearing 1 9000105
215 Needle Bearing 3 TCS130131020
216 Needle Bearing 3 TCS130131212
217 Socket Bolt 3 9091250
218 Button Head Screw 1 9738076
219 Washer 3 TCS131307012
220 Washer 1 9012513
221 O-Ring 1 TCS131103006
222 O-Ring 1 TCS131103052
223 Spring Pin 1 9148125
224 Spring Pin 2 9148198
225 Retaining Ring 3 9047112
250 Top Hook Complete Set 1 60913
250A Top Hook Assembly 1 60914
251 Hook Latch 1 AH420620P10
252 Spring Pin 1 TCR130603024
253 Hook Latch Spring 1 TCR130802046
254 Hook End Piece 1 TCS426230570
255 Hex Flat Head Mach. Screw 2 9096542
260
Bottom
Block Set
TCS 250 1 60915
TCS 500 1 60916
260A Bottom Hook Assembly 1 70007
261 Hook Latch 1 AH420620P10
262 Spring Pin 1 TCR130603024
263 Hook Latch Spring 1 TCR130802046
270 Steel Ball 7 TCR130502020
271 Bottom Hook Holder 1 TCS426230800
272 Swivel Hook Plug 1 TCR420846PY0
273 Sleeve
TCS 500 1 TCS426230760
TCS 250 1 TCS426351760
274 Sleeve Pin 1 TCS426230E70
275 Lock Ring 1 TCS130802286
280 Spring 1 TCR130802219
281 Washer 1 TCS426230G20
49
Page 50
TCS 1000 Top Hook Assembly
282 Top Hook Set 1 70003
282A Top Hook Assembly 1 70004
283 Hook Latch 1 TCR426221S30
284 Hook Spring 1 TCR130802258
285 Socket Bolt 1 9091232
286 U Nut 1 E2D853125
287 Hook End Piece 1 TCS426251570
288 Sock et Bolt 2 TCS131706020
289 Hook Joint Bolt 1 TCR426244580
290 Washer 1 9012511
291 U Nut 1 9098504
TCS 1000 Lower Hook Assembly
292 Bottom Hook Set 1 70005
292A Bottom Hook Assembly 1 70006
293 Hook Latch 1 TCR426221S30
294 Hook Spring 1 TCR130802258
295 Socket Bolt 1 9091232
296 U Nut 1 E2D853125
297 Bol t Yo k e Assy. 1 TCS426251590
298 Swivel Hook Out er Race 1 TCR420846PW0
299 Swivel Hook P l ug 1 TCR420846PY0
300 Free Chain Wheel 1 TCS426251F70
301 Bearing 2 TCS130112003
302 St eel Ball 8 TCR130502020
303 Sock et Bolt 2 9091253
304 U Bol t 2 9098504
Brake, Gears and Load Suspension Components
50
Page 51
Figure 10-2 Chain Container Assembly (optional)
Figure
Number
400 Chain Container Assembly 1 TCSS2623055C
401 Socket Bolt 1 9091280
402 Flat Washer 2 9012513
403 Hex Nut 1 9093424
404 Split Pin 1 90094165
405 Socket Bolt 1 9091252
406 Flat Washer 2 9012511
407 Hex Nut 1 9093420
408 Split Pin 1 9009413
409 Load Chain 8 Links LCCF005
410 Socket Bolt 1 9091251
411 Flat Washer 2 9012511
412 Lock Nut 1 9098504
413 Machine Screw 4 9798532
414 Hex Nut 4 9093417
Name
Parts
per
hoist
Part Number
51
Page 52
www.harringtonhoists.com
Harrington Hoists, Inc. Harrington Hoists – Western Division
401 West End Avenue 2341 Pomona Rd. #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
TCSOM
Loading...