Harrington Hoists TCR manual

Owner’s Manual AIR POWERED CHAIN HOIST TCR SERIES MODEL TCR 10 T on and 25 T on Cap acity Code, Lot and Serial Number EFFECTIVE: May 1, 2006 WARN ING This equipment should not be installed, operated o r maintained by any person who has not read and understood all the contents of this manual . Failure to read and compl y with the contents of this [...]

2 T able of Contents S e c t i o n P a g e N u m b e r 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 Spec[...]

3 S e c t i o n P a g e N u m b e r 5.0 Inspection………………………………………………………………………….……… ………… 24 5.1 General 5.2 Inspection Classification 5.3 Frequent Inspection 5.4 Periodic Inspection 5.5 Occasionally Used Hoists 5.6 Inspection R ecords 5.7 Inspection M ethods and Criteria 6.0 Lubri[...]

4 1.0 Impor tant Info r mation and W ar nings 1.1 Terms and Summary This manual provides imp ortant information for personn el involved with the installation, operation and maintenance of this product. Although you may be familiar wit h this or similar equipment, it is strongly reco mmended that you read this manual before in stalling, operating or[...]

5 WA R N I NG Equipment descr ibed herein is not designed for and MUST NOT be used for lifting, sup porting, or transporting pe ople, or for lifting or su pporting loads over peop le. Equipment descri bed herein should not be used i n conj unction with other equipment unl ess necessary and/or required safet y devices applicable to the system, crane[...]

6 DANGER HAZARDOUS AIR PRESSURE IS PRESEN T IN THE HOIS T, IN THE SUPPL Y OF COMPRESSED AIR TO THE HOIST, AND IN THE CO NNECTIONS BETWEE N COMPONENTS. Before performing ANY mai ntenance on the equipm ent, de-energize the supply of compressed air to the equipment, and lock an d tag the supply device in th e de-energized position. Refe r to ANSI Z244[...]

7 1.2 Warning Tags and Labels The warning tag illu strated below in Figure 1-1 is supplie d with each hoist shipped from the fa ctory. If the tag is not attached to your hoist (f or pendant control, the warni ng tag is attached to the pen dant hose; for the pull co rd control, the warning tag is attached to the up cord), ord er a tag from your deal[...]

8 2.0 T echnical Inf or mat ion 2.1 Specifications 2.1.1 Prod uct Code 2.1.2 Operating Condition s and Environment Temperature range: +14° to +140°F (-10 ° to +60°C) Relative Humidity: 85% or less Supply Air: 60 to 90 pounds per square inch Air Consumption: 170 to 220 cu bic feet minute Air Lubrication Re quirements: Minimum 10 to 15 drops p er[...]

9 2.2 Dimensions Table 2-2 TCR with Pendant Control Di mensions TCR10000P2 TCR25000P2 Cap. (Tons) Product Code Headroom C (in) a (in) b (in) d (in) e (in) g (in) h (in) i (in) j (in) 10 TCR10000P2 3 5. 0 21 .7 18 .4 9. 7 12 .0 1. 6 7. 4 1 1. 0 2 .4 25 TCR25000P2 56.7 27.5 18.7 14.3 13.2 3.1 6.4 12.3 4.9 TABLE 2-3 TCR WITH CO RD CONTROL DIME NSIONS [...]

10 Table 2-4 Top and Bo ttom Hook Dimension* Units = inch Product Code a b c d e f g h TCR10000C/ P2 2.8 2.4 2.4 2.2 2.4 2.6 1.6 7.1 TCR25000C/ P2 4.9 3.5 3.9 3.5 4.9 4.9 3.1 13.1 *Refer to Section 5.7 for inspection dimensi ons and limits. 2.3 Part Names Figure 2-1 Hoist Part Ide ntification Diagra ms – 10 Ton TCR10000 C2 and TCR10000 P2[...]

11 Figure 2-2 Hoist Part Ide ntification Diagra ms – 25 Ton TCR25000P2 and TCR25000C2[...]

12 3.0 Preoper ational Procedur es 3.1 Air Supply Sy stem Requirements 3.1.1 NOTICE Pressure and Flow - Verify that the ai r supply sy stem has capacity to su pply your air hoist with required pressure and flow. Otherw ise the hoist may operate poorly or may fail to operate. See Section 3.2 . 3.1.2 CAUTION Lubrication - The hoist requires lubric at[...]

13 3.4.2 The filter servicing th e hoist can also service othe r hoists and air consuming equipment. In this case, the air filter must be in sized for the total air consumption of the equipment it i s servicing. 3.5 Air Dryer - CAUTION To prevent corrosion and hoist m alfunction, employ an air d ryer in the air supply system to ensure that dry air [...]

14 3.6.2 NOTICE Piping - Pipe should be si zed to accommodate the hoist airflo w requirements. Table 3-1 gives re commended pipe si zes. Table 3-1 Air Supply Pipe and Hose Sizes Model Diameter of Supply Pipe Diameter of Supply Hose TCR10000P2 TCR25000C2 TCR10000P2 TCR25000C2 Inside diamet er 1.25 inch or larger Inside diamet er 1.0 inch or larger 3[...]

15 3.6.5 CAUTION Before connecting the hoi st to its air supply line; p erform the proper draini ng and purging procedu res to prevent contaminants or moist ure from entering the h oist. 3.7 Mounting Location 3.7.1 WARNING Prior to mounting th e hoist ensure that the suspension an d it supporting structure are adequate to suppo rt the hoist and its[...]

16 3.10 Non-Stationary Application 3.10.1 For applicatio ns such as rental fleets or co nstruction sites where the hoist i s moved from place-to- place, a filter and lubricator are still requi r ed. Consult factory fo r recommende d meth ods. 3.10.2 Connections and fittin gs must be kept clean an d ca re taken to prevent dirt, debris and moisture f[...]

17 Figure 3-6 Capsized Hoo k and Chain 3.11.3 WARNING Confirm the adequacy of the rated ca pacity 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. 3.11.4 WARNING Verify that the Chain/Limit Lev ers are operational and[...]

18 Figure 3-8 Limit Switch Components – 25 Ton T CR25000C2 and TCR250 00P2 3.11.5 Measure and reco rd the “K” dimension of all hooks on hoist. See Table 5-6 under Section 5 , “Inspection”. Alway s use the same side of the hoo k to measure and record the "K" dimen sion. 3.11.6 Record the hoist Code Number and Serial Number (from [...]

19 4.0 Operation 4.1 Introduction DANGER DO NOT WALK UNDE R A SUSPENDED LOAD WARNING HOIST OPERAT ORS SHAL L BE R EQUIRED TO READ THE OPERATION SECTION OF THIS MANUAL, THE WARNINGS CONTAINE D IN THIS MA NUAL, INSTRUCTION AND WARNIN G LABELS ON THE HOIST OR LIFTING SYSTEM, AND THE OPERATI ON SECTIONS OF ANSI/ASME B30.16 and ANSI/ASME B30.10. THE OPE[...]

20 The operation of an overhead hoist involves more than activating the hoist’s controls. Per the ANSI/ASME B30 standards, the use of a n overhead hoist is subject to certai n hazard s that cannot be mitigated by en gineered features, but only by the exercise of intelligen ce, care, common sense, and experien ce in anticipating the effects and re[...]

21 CAUTION Improper operation of a hoist can create a potentially hazar dous situation which, if not avoided, could result in minor or moderate injury , or property damage. To avoid such a potentially hazardous situation THE OPERATOR SHALL: • Maintain a firm footin g or be otherwise secure d when operating the hoist. • Check brake function by t[...]

22 4.3.3 Cord Control - When using a hoist with co rd contro l, pull down on the app ropriate colored co rd to raise or lower the hoist. White indicates the raise cont rol and red indicates lowerin g control. Release the cords to st op the hoist. Refer to Fi gure 4-2 below. Figure 4-2 Cord Control 4.3.4 CAUTION Make sure t he motor compl etely stop[...]

23 4.5 Operation of the Load Limiter 4.5.1 If a hoist is used to lift a loa d that exceeds the hoi sts 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 lo ad from the hoist. 4.5.3 If the load is at or below th e hoist’s capacity rating a nd th[...]

24 5.0 Inspection 5.1 General 5.1.1 The inspection procedure he rein is bas ed on ANSI/ASME B30.16. The following definitions are from ANSI/ASME B30.16 and pertain to t he inspection proc edure below.  Designated Person - a person selected or a ssigned as being comp etent to perform the specific duties to which he/ she is assigned.  Qualified[...]

25 5.3 Frequent Inspection 5.3.1 Inspections should be made on a FREQUE NT basis in accordance with Table 5-1 , “F requent Inspection.” Included i n these FREQUENT Inspe ctions are observations made during operation for any defects or damage that might appear betwe en Peri odic Inspections. Evaluation and resolution of the results of FRE QUENT [...]

26 5.5 Occasionally Used Hoists 5.5.1 Hoists that are used i nfrequently shall be in spe cted as follows prior to pl acing in servic e:  Hoist Idle More Than 1 Month, Less Than 1 Year : Inspect per FREQUENT Inspection criteria o f Section 5.3 above.  Hoist Idle More Than 1 Year : Inspect per PERIODIC Inspection criteria of Section 5.4 above. [...]

27 Table 5-3 Hoist In spection Methods an d Criteria (continued ) Item Method Criteria Action Hooks - Bent Shank or Neck Visual Shank and neck po rtions of hook shou ld be free of deformations Replace. Hooks - Yok e Assembly Visual Should be free of significant rust, weld splatter, nicks, goug es. Hole s should not be elongated , fasteners sho uld [...]

28 Table 5-3 Hoist In spection Methods an d Criteria (continued ) Item Method Criteria Action Housing and Mechanical Component s Visual, Auditory, Vibration, Function Hoist component s including load blocks, suspension housi ng, chain attachment s, clevises, yokes, suspens ion bolts, shafts , gears, be arings, pins and rolle rs should be free of cr[...]

29 Table 5-4 Brake Disc Dimensi on Hoists Parts View Figure No. Std Dimension Inch (mm) Minimum Value for Replacemen t Inch (mm) TCR10000C2 TCR10000P2 TCR25000C2 TCR25000P2 T = 0.16 (4.0) T = 0.10 (2.5) Table 5-5 Chain Gui de/Side Plate Dimensions Hoists Parts View Figure No. Std Dimension Inch (mm) Maximum Value for Re placement Inch (mm) TCR10000[...]

30 Table 5-6 Top Hook & Bottom Ho ok Dimensions Dimensions K and U should be measured and recorded below prior to any use w hen the hook is first placed into service. Hoists Parts View Figure No. Recorded Dimension When Ne w Maximum/Minimum Value for Replacemen t TCR10000C2 TCR10000P2 165 Top Hook K = ___ ____________ Top Hook U = ___________ _[...]

31 6.0 Lubricat ion 6.1 Air Hoist Lubrication 6.1.1 See Section 3.0 for l ubrication requirement s. 6.1.2 CAUTION Lubrication to the motor will be provided prima rily by the air supp ly lubricator. The recommended am ount is 10 -15 drops/min ute (2-3cc /min.). Refer to Table 6-1 below for the approved lubricant for use with your air hoist. 6.1.3 Ad[...]

32 7.0 Maintenance and Handling 7.1 Load Limiter 7.1.1 The purpose of the load limiter is to prevent using the hoi st in an overload situatio n. When lifting, the hoist will stop automatically if the load is above the rated capacity of the hoi st. 7.1.2 The adjustment is fact ory set to actuate at approximately 125% of rated capacity (based on sup [...]

33 4) Put a load equal to the desired actuation poi nt on the hoist's h ook (do not exceed 125% of the hoist's rated capacity ). Begin to slowly lift the load, then incre ase the lifting speed. Return th e load to its resting position so the l oad chain is not under tensio n. 5) If the load limiter prevents lifting, turn the adjustment sc[...]

34 Figure 7-2 Brake Inspection Diagram 7.3 Load Chain 7.3.1 Lubrication and Cl eaning  Clean the chain with an acid-free cleaning solution. The l oad chain should be ke pt clean and lubricated.  Lubrication - Clean and lubricate the load chai n per Section 6 at least o nce every 3 months for normal usage. Clean and lubricate more frequ ently [...]

35 7) While pulling on the wi re, SLOWLY operate hoist i n the DOWN direction to thread th e load chain over the load sheav e. Make sure the chain feeds smoothly wh ile operating the hoist. If bindi ng occurs, stop and SLOWLY operate the hoist in the up directi on to the back the chain out, then reorient the load sheave as instru cted in step 5 bef[...]

36 7.4 Pendant 7.4.1 The following procedure covers the in stalla tion of a pendant contro l station. 1) Attach the strain relief chain and the th ree hoses to the pendant station. 2) Attach the strain relief chain to t he hoist valve body with the socket bolt as shown in Figure 7-4. 3) Attach the three hoists to the fitting s on the hoist's v[...]

37 7.5 Storage 7.5.1 Whenever the hoist is t o be placed into storage, pla ce extra lubricating oil into the air inlet opening and circulate the ai r motor before plugging th e inlet. Make certain that no deb ris, dirt or moisture is all owed to enter the air hoi st through air inlet openi ng during preparati ons for storage. 7.5.2 The storage loca[...]

38 8.0 T r oubleshooting WARNING HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIS T, IN THE SU PPLY OF COMPRESSED AIR TO THE HOIST, AND IN CONNECTIONS BE TWEEN COMPONENTS. Before performing ANY mai ntenance on the equipm ent, de-energize the supply of compressed air to the equipment, and lock an d tag the supply device in th e de-energized position. R[...]

39 Table 8-1 Troubleshoo ting Guide (continued) Symptom Ca use Remedy Hoist mo ving in wron g direction (pendant control) Pendant control hose s are terminated to incorrect ports on hoist body. Connect the control tube s in accordance with Section 7.4 . Hoist is overlo aded. Reduce load t o hoist rated capacity. Faulty pendant co ntrol or control h[...]

40 9.0 War r anty Warranty explanation and terms. All products sold by Harrington Hois ts, Inc. are warranted to be free from defects in material and workmanship from date of shipment by Harrington for the following periods: Manual Hoists & Trolley s - 2 years Air and Electric Powered Hoists, Tro lley s, and Crane Components - 1 year Spare / Re[...]

41 10.0 Par ts Infor mation A complete parts list i s available from Harrington Hoi sts and is supplied separately with you r hoist. The parts list is also available from Harrington's web site ( www.harringtonhoi sts.com) or from any Harrington facility (see back cover of this manual). When orderin g Parts, please provide the Hoi st code numb [...]

42 NOTES[...]

43 NOTES[...]

www.harringtonhoists.com Harrington Hoists , Inc. Harrington Hoists – Western Division 401 West End Avenue 2341 Pomona Rincon Rd. #103 Manheim, PA 17545-1703 Corona, CA 92880-6973 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 TCROM1025[...]