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Table of Contents

Section

Page Number

5.0

Inspection……………………………………………………………………………………………. 33

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…………………………………………………………………………………………... 40

6.1

Air Hoist Lubrication

6.2

Load Chain Lubrication

6.3

Hooks and Suspension Components

7.0

Maintenance & Handling…………………………………………………………………………… 41

7.1

Load Limiter

7.2

Brake

7.3

Load Chain

7.4

Load Sheave

7.5

Pendant

7.6

Storage

7.7

Outdoor Installation

8.0

Troubleshooting…………………………………………………………………………………….. 49

9.0

Parts List…………………………………………………………………………………………….. 52

10.0

Warranty

Содержание TCR Series

Страница 1: ...l Number BULLETIN NO TCROM 0913 04 This equipment should not be installed operated or maintained by any person who has not read and understood all the contents of this manual Failure to read and compl...

Страница 2: ...irements 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 Hoi...

Страница 3: ...ed Hoists 5 6 Inspection Records 5 7 Inspection Methods and Criteria 6 0 Lubrication 40 6 1 Air Hoist Lubrication 6 2 Load Chain Lubrication 6 3 Hooks and Suspension Components 7 0 Maintenance Handlin...

Страница 4: ...ation operation or maintenance information which is important but not directly hazard related WARNING These general instructions deal with the normal installation operation and maintenance situations...

Страница 5: ...rail 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...

Страница 6: ...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 in...

Страница 7: ...st 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 i...

Страница 8: ...l 92 dba maximum 1 meter when lifting rated load 95 dba maximum 1 meter when lowering rated load Supply Air 60 to 90 pounds per square inch Air Consumption 30 to 90 cubic feet minute Air Lubrication R...

Страница 9: ...6 TCR6000P2 6 8 5 5 7 88 64 67 71 11 2 x 2 198 22 Cord Model TCR250C 10 6 61 45 29 57 35 28 28 32 4 x 1 15 4 TCR500C 6 62 43 33 53 63 49 49 57 6 3 x 1 66 4 1 TCR1000C2 6 31 21 16 26 63 49 49 57 6 3 x...

Страница 10: ...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 TC...

Страница 11: ...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...

Страница 12: ...12 Figure 2 3 Dimensions for Manipulator TCR250 Air Hoist inches...

Страница 13: ...13 2 3 Part Names Figure 2 4 Hoist Part Identification Diagrams TCR500P 500C 1000P 1000C...

Страница 14: ...14 Figure 2 5 Hoist Part Identification Diagrams TCR 1000P2 1000C2 2000P2 2000C2...

Страница 15: ...15 Figure 2 6 Hoist Part Identification Diagrams TCR 3000P 3000C Figure 2 7 Hoist Part Identification Diagrams TCR 6000P2 6000C2...

Страница 16: ...16 Top hook Bottom hook Figure 2 8 Hoist Part Identification Diagrams TCR250C...

Страница 17: ...17 Top hook Bottom hook Figure 2 9 Hoist Part Identification Diagrams TCR250P...

Страница 18: ...18 Top hook Bottom hook Figure 2 10 Hoist Part Identification Diagrams TCR250M...

Страница 19: ...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 p...

Страница 20: ...System Configuration The system should be configured as shown in Figure 3 1 Since moisture tends to accumulate in compressed air systems corrosion may result if the system is not periodically drained...

Страница 21: ...se 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 Arrangeme...

Страница 22: ...agout of Energy Sources 3 8 3 CAUTION Before connecting the air supply hose to the hoist always purge the air hose to clear any debris and water 3 8 4 Apply approximately 10 15 drops of turbine oil se...

Страница 23: ...ers 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 tw...

Страница 24: ...truction 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 ca...

Страница 25: ...e hoist s inlet port before trying to operate the hoist 3 12 2 WARNING Verify that the load chain is not twisted or tangled and that the bottom hook is not capsized prior to operating the hoist Correc...

Страница 26: ...d 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...

Страница 27: ...Section 7 4 3 12 11 CAUTION Check Air Supply Check air supply before everyday use Ensure proper air quality and air pressure 3 12 12 CAUTION Check the lubricator for proper function and adequate oil...

Страница 28: ...RATION IF SUCH MALFUNCTIONS OCCUR AND TO IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE ACTION CAN BE TAKEN HOIST OPERATORS SHOULD HAVE NORMAL DEPTH PERCEPTION FIELD OF VISION REACTION TIME MANUAL...

Страница 29: ...en the load chain or repair damaged load chain NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading NOT use load chain as a sling or wrap...

Страница 30: ...ve and will clear all obstructions Avoid swinging the load or hook Make sure hook travel is in the same direction as shown on controls Inspect the hoist regularly replace damaged or worn parts and kee...

Страница 31: ...or lower the hoist Release the cords to stop the hoist Refer to Figure 4 2 below F Figure 4 2 Cord Control 4 3 3 CAUTION Make sure the motor completely stops before reversing direction 4 4 Adjusting...

Страница 32: ...acity 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 h...

Страница 33: ...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 reg...

Страница 34: ...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...

Страница 35: ...ce 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 s...

Страница 36: ...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 Load Chain Su...

Страница 37: ...d 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 Replace Load Sheave Visual...

Страница 38: ...00 6000 2 T 0 31 8 0 T 0 29 7 3 Table 5 5 Chain Separator Dimensions TCR250 500 1000 2 1000 2000 2 TCR 3000 6000 2 Hoists Std Dimension Inch mm Maximum Value for Replacement Inch mm TCR250 L 0 33 8 5...

Страница 39: ...he recorded new dimension the hook should be replaced TCR500 1000 2 Top Hook K _______________ Top Hook U _______________ Bottom Hook K ____________ Bottom Hook U ____________ TCR1000 2000 2 Top Hook...

Страница 40: ...uld 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 l...

Страница 41: ...o 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...

Страница 42: ...tment screw IN 8 full turns or more will disable the load limiter 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 foll...

Страница 43: ...heavier usage or severe conditions 7 3 2 Replacement 1 CAUTION An air supply line must be connected to the hoist in order to perform the following procedures 2 WARNING Be certain that the replacement...

Страница 44: ...s weld is facing away from the centerline of the hoist See Figures 7 3 and 7 4 below Figure 7 3 Load Chain Installation Diagram 5 CAUTION Operate the hoist slowly to catch and pull the chain through t...

Страница 45: ...hat 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 complet...

Страница 46: ...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...

Страница 47: ...etaining nut to 20 lbf ft Figure 7 6 4 Attach the wire cable to the hoist valve body with the screw as shown in Figure 7 7 5 Torque machine screw to between 30 and 40 in lbf Figure 7 7 6 Attach the 3...

Страница 48: ...2 The storage location should be clean and dry 7 7 Outdoor Installation 7 5 1 For hoist installations that are outdoors the hoist should be covered when not in use 7 5 2 In order to prevent internal...

Страница 49: ...d or tubes Air leak between the two chambers in the Top Cover Correct or repair to eliminate air leak Hoist is overloaded Reduce the load to the rated capacity of hoist Lifting speed is slow Low air p...

Страница 50: ...hoist rated capacity Faulty pendant control or control tube s Repair or replace pendant control or control tube s Lack of air pressure or partial loss of or leakage in air supply Repair or adjust air...

Страница 51: ...Kito Air Hoists Parts List...

Страница 52: ...TCR250 MAIN BODY 52 9 0 Parts List TCR250 Main Body...

Страница 53: ...ve 1 T1CR426205300 116 Gear Case 1 T1CR426205310 117 Ring Gear 1 T1CR426205320 Figure Name Parts Per Hoist Part 118 Lock Screw 1 T1CR426205890 119 Brake Plate 1 T1CR426205900 120 Bearing 2 T1CR1301128...

Страница 54: ...TCR250 VALVE BODY 54 TCR250 Valve Body...

Страница 55: ...ulator Models Only Figure Name Parts Per Hoist Part 6 Valve Body 1 T1CR426206060 20 Valve Spring 1 T1CR130802209 160 Manifold Block 1 T1CR426206941 164 O Ring 2 T1CR131103008 165 Socket Bolt 2 T1CR131...

Страница 56: ...TCR250 MANIPULATOR CONTROL 56 TCR250M Manipulator Control...

Страница 57: ...420215VB0 221 Push Rod 2 T1CR420215VC0 222 O Ring 2 T1CR131118012 223 O Ring 2 T1CR131117013 224 Throttle Valve Body CP 1 T1CR42621597B 225 Lever Pin 1 T1CR130402048 226 Throttle Lever Up 1 T1CR420985...

Страница 58: ...TCR500 MAIN BODY TCR500 Main Body TCR500 Main Body 58...

Страница 59: ...0 LOAD SHEAVE 1 92 T1CR426224312 GEAR CASE 1 93 T1CR426224322 RING GEAR 1 94 T1CR426224330 SPACER P 3 95 T1CR426221K90 LOCK SCREW 1 96 T1CR426224352 CHAIN GUIDE 1 97 T1CR426224363 CHAIN SEPARATOR 1 98...

Страница 60: ...TCR1000 2 Main Body TCR1000 2 Main Body 60...

Страница 61: ...CHAIN SEPARATOR 1 98 T1CR426224381 BRAKE TUBE 1 100 T1CR130104003 BEARING 2 101 T1CR130112808 BEARING 2 102 T1CR130170035 NEEDLE BEARING 6 103 T1CR131117042 O RING 1 104 T1CR131103055 O RING 1 105 T1...

Страница 62: ...TCR1000 Main Body TCR1000 Main Body 62...

Страница 63: ...92 T1CR426266310 GEAR CASE 1 93 T1CR426266320 RING GEAR 1 95 T1CR426266340 DOWEL PIN 4 96 T1CR426266351 CHAIN GUIDE 1 97 T1CR426266360 CHAIN SEPARATOR 1 98 T1CR426224381 BRAKE TUBE 1 100 T1CR130104003...

Страница 64: ...TCR2000 2 Main Body TCR2000 2 Main Body 64...

Страница 65: ...3008 BEARING 2 102 T1CR130104002 BEARING 9 103 T1CR131117042 O RING 1 104 T1CR131103055 O RING 1 105 T1CR130302012 RETAINING RING 3 106 T1CR130302045 RETAINING RING 1 107 T1CR130302015 RETAINING RING...

Страница 66: ...TCR3000 Main Body TCR3000 Main Body 66...

Страница 67: ...ION 1 91 T1CR426325300 LOAD SHEAVE 1 92 T1CR426325310 GEAR CASE 1 93 T1CR426325320 RING GEAR 1 95 T1CR426325340 DOWEL PIN 4 96 T1CR426325351 CHAIN GUIDE 1 97 T1CR426325360 CHAIN SEPARATOR 1 98 T1CR426...

Страница 68: ...TCR6000 2 Main Body TCR6000 2 Main Body 68...

Страница 69: ...AIN GUIDE 1 97 T1CR426325360 CHAIN SEPARATOR 1 98 T1CR426325380 BRAKE TUBE 1 99 T1CR426325371 BOTTOM PLATE 1 100 T1CR130104004 BEARING 2 101 T1CR130104010 BEARING 2 102 T1CR130104005 BEARING 12 103 T1...

Страница 70: ...Cord Control Valve Body Cord Control Valve Body 70...

Страница 71: ...1CR426224C20 SPOOL CYLINDER 2 204 T1CR426224041 BRAKE RETAINER 1 205 T1CR426224051 BRAKE NUT 1 Figure Part Number Part Name Parts Per Hoist TCR500C TCR1000C2 TCR1000C TCR2000C2 TCR3000C TCR6000C2 206...

Страница 72: ...Pendant Control Valve Body 72 Pendant Control Valve Body...

Страница 73: ...E BODY 1 207 T1CR426224070 TOP COVER 1 Figure Part Part Name Parts Per Hoist TCR500P TCR1000P2 TCR1000P TCR2000P2 TCR3000P TCR6000P2 208 T1CR426224083 SIDE COVER L 1 209 T1CR426224093 SIDE COVER R 1 2...

Страница 74: ...R131109001 O RING S 3 HS90 2 308 T1CR131103008 O RING S 10 2 309 T1CR131103009 O RING S 11 2 2 330 T1CR135106302 HOSE JOINT H 2 PT 1 8 7 3 335 T1CR130802081 S TYPE WIRE 1 332 T1CR137501012 HOSE BAND 5...

Страница 75: ...2 160E T1CR131103008 O RING 4 160F T1CR426224480 CONTROL SPOOL 2 160G T1CR426224530 CONTROL BUSH 2 160H T1CR426221H60 PUSH ROD 2 160J T1CR136602023 VALVE LEVER U 1 160K T1CR136602024 VALVE LEVER D 1...

Страница 76: ...00P T1CR426224D5D 1 TCR1000P2 T1CR426224D5D 1 TCR1000P T1CR426266D5D 1 TCR2000P2 T1CR426266D5D 1 TCR3000P T1CR426325D5D 1 TCR6000P2 T1CR426325D5D 1 TCR250C T1CR426205D5D 1 TCR500C T1CR426224D5D 1 TCR1...

Страница 77: ...cted by Kito Canada Inc prior to shipping product for warranty evaluation An explanation of the complaint must accompany the product Product must be returned freight prepaid Upon repair the product wi...

Страница 78: ...Avenue Burnaby BC V5C 3V6 Phone 604 291 9955 Toll Free 1 888 322 KITO Fax 604 294 8855 www kito ca Kito Canada Inc East 6 1750 Courtney Park Drive E Mississauga ON L5T 1W1 Phone 905 405 0905 Toll Fre...

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