KITO TCR Series, Owner'S Manual

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

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

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

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

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

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

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

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

Page 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...

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

Page 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...

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

Page 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...

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

Page 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...

Page 60: ...TCR1000 2 Main Body TCR1000 2 Main Body 60...

Page 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...

Page 62: ...TCR1000 Main Body TCR1000 Main Body 62...

Page 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...

Page 64: ...TCR2000 2 Main Body TCR2000 2 Main Body 64...

Page 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...

Page 66: ...TCR3000 Main Body TCR3000 Main Body 66...

Page 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...

Page 68: ...TCR6000 2 Main Body TCR6000 2 Main Body 68...

Page 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...

Page 70: ...Cord Control Valve Body Cord Control Valve Body 70...

Page 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...

Page 72: ...Pendant Control Valve Body 72 Pendant Control Valve Body...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...