RED ROOSTER TCR-6000/2, User Manual

Page 1: ...AIR HOIST USER MANUAL MODEL TCR 6000 2 ...

Page 2: ......

Page 3: ...IFTING GEAR BELOW THE HOIST 3 4 MOUNTING ON TROLLEYS 3 5 OPERATIONAL BREAKDOWN OR ACCIDENT SECTION 4 MAINTENANCE 4 1 GENERAL 4 2 REPAIRS 4 3 SILENCING 4 4 CHANGING THE SILENCERS 4 5 FITTING OR REPLACING LOAD CHAIN 4 6 TYPES OF CHAIN 4 7 HOIST COMPONENTS AND CHAIN 4 8 SERVICE DATA SECTION 5 LAYING UP THE HOIST SECTION 6 CHAIN COLLECTORS SECTION 7 SPEED LOAD LIMITER ADJUSTMENT 7 1 SPEED ADJUSTMENT 7...

Page 4: ...fy and gives further information on the hoist Notations The following notations are used throughout this manual Failure to follow this instruction may result in a dangerous occurrence or fatal injury Failure to follow this instruction may result in premature wear of the hoist or a component part of the hoist SWL TONNE MODEL CHAIN FALLS WEIGHT KG FULL LOAD LIFTING SPEED M MIN FLR SIZE MINIMUM HOSE ...

Page 5: ... 01651 872101 0121 525 4162 MODEL TCR 6000 2 SERIAL NO SWL 6000 KG DATE OF PURCHASE NAME PLATES The name plate gives important information which must be retained Hoist serial number SWL model air pressure air flow hoist rating chain size speed year of manufacture and the manufacturers name and address ATEX Explosive protection In Europe and several parts of the world the use of non electrical equi...

Page 6: ...ications When used outdoor or offshore hoists should be protected against the weather and examination and maintenance interval should be reduced Our hoists are extremely robust being developed over many years in the harshest of environments and will require little maintenance if kept lubricated on a regular basis Noise levels can be found in the technical specification and as motor lubricating oil...

Page 7: ...installation of an in line air service unit although essential cannot in itself compensate for serious contamination in the air supply When operating the compressor in moist humid or dusty atmospheres seek the advice of your compressor supplier with regard to the fitting of a dryer and filter AIR PRESSURE The hoist is designed to operate best in the pressure range of 5 to 6 bar 72 to 90 p s i The ...

Page 8: ...lows the load to turn without twisting the chain However when repeatedly handling loads with the bottom hook close to the hoist especially when rotation of the load is prevented there is tendency for the chain to attempt to enter the guide at an angle This is particularly pronounced on two fall units If this problem is noticed when doing a trial lift a high quality ball bearing swivel should be mo...

Page 9: ... should be run weekly where the hoist is outside and not protected it should be checked lubricated and run daily The emergency stop button valve operates immediately Upper and lower limit switches levers work satisfactorily Load chains run smoothly over the pocket wheel The load chain should be examined periodically for cracks gouges and wear Chain collectors should be checked for security and cha...

Page 10: ...NSTALLATION INSTRUCTIONS Hook suspension with long chain drops Problem When a long heavy chain is fitted and the raise is pressed with the hoist in an unloaded condition due to the centre line of the hoist having been affected by the weight of chain the upper limit switch may fail to operate In addition the slack load chain may on some modules foul the limit lever arms thus preventing it from retu...

Page 11: ... Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 GETTING STARTED STANDARD HOSE CONNECTION PENDANT CONTROL OR HOIST WITH EXTERNAL EMERGENCY STOP VALVE STANDARD HOSE CONNECTION CORD CONTROL OR HOIST WITH INTERNAL EMERGENCY STOP VALVE ...

Page 12: ...SER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 GETTING STARTED Some hoists are fitted with internal emergency stop valves ...

Page 13: ... Chains used in these areas should be re lubricated on a regular basis NEVER use heavy grease or bitumen based products to lubricate the chain as these will foul the chain guide idler and load wheels and bearings Remove dust and water drops on the Load Chain and then apply lubricant Application of lubrication influences on the life of the Load Chain considerably Apply the lubricant sufficiently AI...

Page 14: ...in the area and make sure the pendant hangs vertically and cannot swing or get blown against anything When there is a longer break in the lifting operation and the load has been landed then the emergency stop button should be actuated so that a positive action is required before the hoist or hoist and trolley can be operated If the hook is still attached to an item then a sign should be attached t...

Page 15: ...s of the weight of the load being lifted Do not use the hoist to lift lower personnel Fig B Only use the hoist to lift a load vertically It is not designed to pull or drag loads without modification and or a lift plan being used for special lifting operations such as cross hauling Fig C Ensure that the load is securely supported by its lifting gear slings shackles etc and that it cannot escape whi...

Page 16: ...e that the load bar and tie bar nut have been secured and the trolley side plates are set parallel to the beam web Ensure that the tie bars are correctly adjusted in the slots with the anti tilt roller close under the beam with enough clearance to allow the trolley to run along the beam 3 5 OPERATIONAL BREAKDOWN OR ACCIDENT If an unloaded hoist stops working then it should be removed from location...

Page 17: ...d Any wear should be measured and checked against section 10 1 BRAKE With a load applied check the brake efficiency If there is any delay in actuation or slippage the brake is defective and the hoist must be thoroughly overhauled before being returned to service HOOKS SWIVELS AND CLAWS Examine hooks for wear deformation refer to chart nicks and gouges Ensure that the hooks swivel smoothly and that...

Page 18: ...the silencers are in the correct order two type S one type F and a further two type S TCR 500 to TCR 15000 5 The silencer section is located on the top of the hoist body on the motor side Remove the three M6 Hex socket cap screws which retain the section and very carefully remove the section taking care not to damage the gasket If damaged the gasket must be replaced as any leak in the gasket will ...

Page 19: ...ercised Always examine the first link of chain after passing it over the load wheel If damaged remove the damaged link s REPLACING EXISTING CHAIN Cut away the centre portion of a link of the old chain to allow a chain diameter to pass through Connect the spare link to the last link of the old chain and the first link of the replacement chain Use the old chain to draw the replacement chain though t...

Page 20: ...N818 7 EN1677 standard TCR 6000 2 STANDARD ATEX PEWAG KITO Nominal diameter 11 2 0 1 0 5 mm 11 2 0 4 0 4 mm Pitch 34 1 0 6 0 00 mm 31 2 0 67 0 00 mm Max dia at weld 12 mm 12 mm Min breaking force 160 kN 160 kN Surface hardness ca400HV101 Grade 80T Grade EN818 7 ISO 3077 EN818 7 ISO 3077 NOTE When supplied new only quality chain from a reputable supplier has been fitted to the hoist Your supplier w...

Page 21: ... CHAIN FITTINGS TCR 6000 2 HOIST PARTS 13 12 1 Link Chain 2 Chain Lever 3 Brake Section 4 Gear Section 5 Upper Hook 6 Hook Safety Latch 7 Motor Section 8 Valve Section 9 Hook Case 10 Hook Safety Latch 11 Lower Hook 12 Cord Lever 13 Cord Control 14 Pendant Control 14 1 2 3 4 5 6 7 8 9 11 10 1 Chain 2 Welding Area 3 Install at 10th Link 4 Chain End Stop 5 Limit Lever 3 4 1 2 5 ...

Page 22: ...m STD T 4mm MIN T 3 5mm Replace if any of the width length and thickness is less than the stated minimums 73 Brake Disc T STD T 8mm MIN T 7 3mm Below minimum for replacement 85 Cage Replace when there is a large or uneven play in the pin hole 86 90 91 93 Star Gear Pinion Wheel Ring Gear Replace if there is a step on the surface of the gear teeth 87 Pin step Replace if there is a step on the surfac...

Page 23: ...W STD L 25 5mm MAX L 28mm STD W 47mm MAX W 49mm Replace if any of the above dimensions exceed maximum wear 115 Hook Dimensions STD L 65mm MAX L 66 3mm STD H 49mm MIN H 47mm Check dimensions as casting size can vary Replace if beyond maximum L or H There is some variation in the H size on hooks so it is best to measure the hook when new and then allow up to 1mm of wear 101 Load Chain 5 links L d ST...

Page 24: ... MONTHS Heavily lubricate the hoist as specified above If the hoist is contaminated with dirt or chemicals wash with a propriety mild solvent or detergent and thoroughly rinse off with fresh water Allow to dry and spray lightly with penetrating fluid Lubricate the load chain limit shafts safety latches and hook swivels Disconnect the air supply and plug the inlet port If required dismantle the cha...

Page 25: ...r either manually or by carefully running out of the hoist checking for snagging The chain should then be run back into the collector by the hoist checking there are no twists in the chain that the bottom hook is not twisted through the chain fall on multi fall blocks Hoists with long drops of chain and heavy loads in the chain collectors will require a secondary suspension point to hold the hoist...

Page 26: ...CR 500 6000 2 TCR 500 6000 2 1 3 2 1 3 2 4 TCR 500 TCR 2000 2 TCR 3000 TCR 6000 2 1 Bolt M8 x 25 1 Bolt M8 x 20 2 Bolt M6 x 16 2 Bolt M8 x 16 3 Bolt M8 x 25 3 Bolt M8 x 25 4 Chain Bag 4 Chain Bag TCR 500 TCR 2000 2 TCR 3000 TCR 6000 2 1 Bolt M8 x 25 1 Bolt M8 x 20 2 Bolt M6 x 16 2 Bolt M8 x 16 3 Bolt M8 x 25 3 Bolt M8 x 25 4 Chain Bucket 4 Chain Bucket ...

Page 27: ...d or a larger capacity hoist installed The load can still be lowered when the load limiter cuts in 7 2 SETTING THE LOAD LIMITER Viewing the hoist from the motor end the load limiter adjusting screw M6 hex is located on the left hand side on the valve cover It is locked in position with an M6 nut Back off the lock nut before commencing adjustment Set the regulator pressure to that which will be use...

Page 28: ...hoses leaking or loose Silencer is clogged Check compressor output against hoist requirements Check air hose size against table Ensure fittings are matched to hose size Replace incorrect items Reduce to 6 bar Fit regulator Check connections of air supply hose and control hoses and connect properly Replace or clean silencer elements improve air quality if necessary Hoist starts but will not stop St...

Page 29: ...FSHORE INSPECTION Arrange to have the hoist examined by a person specifically trained and experienced in the examination of lifting machines This can be done by a Red Rooster engineer or an independent competent person Ensure that the party is operating to a detailed inspection procedure or code of practice SERVICE We would recommend the hoist is returned every 5 years for a full inspection and se...

Page 30: ... or to function by means of friction generation They require periodic inspection and replacement and comprise of the rotor vanes and the brake disc Inadequate lubrication seriously reduces the life expectancy of the vanes 2 Load chain Whilst adequate lubrication of the load chain will reduce friction and thereby limit the wear occurring between the bearing points of adjacent links it will not tota...

Page 31: ...rts SPECIAL INSTRUCTIONS This section of the manual refers to special instructions to special instructions exclusions or warnings about the equipment Several gases such as hydrogen sulphide and ethylene oxide are at the very top of the IIB temperature class and are extremely flammable so you may wish to include them in the higher IIC temperature class This is also relevant for impact sensitive dus...

Page 32: ...PLICATIONS In general most standard Red Rooster hoists can be used for underground mining operations along with the surface buildings and services The equipment is certified for Group I M2 use so must be switched off isolated in the event of an emergency The equipment has to be robust non sparking taking into account the conditions and the handling underground and be built to survive along with ex...

Page 33: ...7 202 161 144 286 385 C CORD CONTROL PE PENDANT MODEL WLL LIFTING SPEED WITH LOAD LIFTING SPEED WITHOUT LOAD LOWERING SPEED WITH LOAD TCR 6000 2 6000 kg 1 4 m min 2 9 m min 2 3 m min AIR CONSUMPTION LIFTING AIR CONSUMPTION LOWERING AIR CONNECTION MINIMUM HOSE DIA TCR 6000 2 33 l sec 43 l sec 1 2 BSP 3 4 HOSE CHAIN FALLS WORKING PRESSURE WEIGHT WITH 3M HOL ADDITIONAL METRE HOL TCR 6000 2 2 6 bar 91...

Page 34: ...34 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 DRAWINGS AND PARTS LISTS ...

Page 35: ...t Ask 1 1 N A Weight 0 Title of Part TCR 6000 2 Date Material Sheet Size A3 GENERAL ASSEMBLY Date Revision Profile Number Replaces Drawing 25 01 2018 Signature Part Number DRG 1368D 12 up to 5 0 05 over 5 up to 30 0 1 over 30 up to 120 0 2 over 120 up to 500 0 25 over 500 up to 1000 0 5 over 1000 1 N10 Tolerances all dimensions are in milimeters unless otherwise specified 14 04 2010 25 01 2018 REV...

Page 36: ...36 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 D01 AH8 REV0 Hoist Body TCR 6000 2 10 10 16 ...

Page 37: ... CASE 1 093 426325320 RING GEAR 1 095 426325340 DOWEL PIN 4 096 426325351 CHAIN GUIDE 1 Fig No Part Number Part Name Parts Per Hoist 097 426325360 CHAIN SEPARATOR 1 098 426325380 BRAKE TUBE 1 099 426325371 BOTTOM PLATE 1 100 130104004 BEARING 6003 2 101 130104010 BEARING 6009 2 102 130104005 BEARING 6004 12 103 131103058 O RING S 115 1 104 131103063 O RING S 135 1 105 130302020 RETAINING RING S 20...

Page 38: ...38 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 D01 AH8 REV0 Pendant Body TCR 6000 2 10 10 16 ...

Page 39: ...C40 BRAKE BUSHING 1 212 426224C50 LIMIT BUSHING 1 213 426224C60 SPOOL PISTON 2 214 426224C70 SPRING SEAT 2 215 426224140 LIMIT LEVER 1 216 130802216 SPRING LEVER 15X59X2 4 1 217 136102164 SIDE PACKING N 2 218 136102161 VALVE PACKING 1 219 136102192 TOP PACKING 1 220 136102163 UNDER PACKING 1 221 137402030 EXHAUST SILENCER 1 222 137402031 NYLON SILENCER 1 223 130301025 RETAINING RING H 25 1 224 130...

Page 40: ... MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 D01 AH8 REV0 Built In Mains Emergency Stop Valve Pendant Body TCR 6000 2 13 05 21 ...

Page 41: ...VE PACKING 1 219 136102192 TOP PACKING 1 220 136102163 UNDER PACKING 1 221 137402030 EXHAUST SILENCER 1 222 137402031 NYLON SILENCER 1 223 130301025 RETAINING RING H 25 1 224 130301058 RETAINING RING H 58 1 225 131706012 HEX SOCKET HEAD CAP SCREW M6X12 2 226 131706025 HEX SOCKET HEAD CAP SCREW M6X25 4 227 131706040 HEX SOCKET HEAD CAP SCREW M6X40 3 228 131706060 HEX SOCKET HEAD CAP SCREW M6X60 3 2...

Page 42: ...42 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 D01 AH8 REV0 Cord Body TCR 6000 2 10 10 16 ...

Page 43: ...083 SIDE COVER L 1 209 426224093 SIDE COVER R 1 210 426224101 LIMIT GUIDE 1 211 426224C40 BRAKE BUSHING 1 212 426224C50 LIMIT BUSHING 1 213 426224C60 SPOOL PISTON 2 214 426224C70 SPRING SEAT 2 215 426224140 LIMIT LEVER 1 216 130802216 SPRING 15X59X2 4 1 217 136102164 SIDE PACKING N 2 218 136102161 VALVE PACKING 1 219 136102192 TOP PACKING 1 220 136102163 UNDER PACKING 1 221 137402030 EXHAUST SILEN...

Page 44: ...3 133 1P M4 NYLOCK 4 4 BIK3206P BS54 E STOP BUTTON 1 5 304P 1 8 TO 6mm BANJO 4 6 P118 90º ELBOW 6mm 2 7 P112 4 WAY JUNCTION 1 8 301P 8mm TO 6 mm CONNECTOR 1 10 BIK 3209 P VALVE PENDANT VALVE 2 11 P087 1 8 TO 6mm PUSH FIT 2 12 TP 2 HOUS 2 STATION HOUSING 1 14 BIK 3209 294 B COVER COVER FOR BIK VALVES 2 15 XAC B LEGEND UP UP LEGEND 1 16 XAC B LEGEND DOWN DOWN LEGEND 1 19 HP7 6mm TUBE 4 24 P116 6mm B...

Page 45: ... BANJO 4 6 P118 90º ELBOW 6mm 2 7 P112 4 WAY JUNCTION 1 8 301P 8mm to 6mm REDUCER 1 10 BIK 3209 P VALVE PENDANT VALVE 2 11 P087 1 8 TO 6mm PUSHFIT 2 12 TP 2 HOUS M 2 STATION PENDANT 1 14 BIK 3209 294 B COVER COVER FOR BIK VALVES 2 15 XAC B LEGEND UP UP LEGEND 1 16 XAC B LEGEND DOWN DOWN LEGEND 1 19 HP7 6mm SMC TUBE 4 20 P245 1 8 TO 6mm BULKHEAD AND NUT 4 21 DRG 2652 01 PLATE 1 22 P071 1 1 8 BSP NI...

Page 46: ...46 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 ACCESSORIES ...

Page 47: ...lves are opened by the control air from the pendant opening the valve allowing full pressure to open the hoist spool valve Valve model SYJA712 01 DUMP VALVES On hoists fitted with 1 4 air hose in place of tubes dump valves are fitted to the control lines to reduce operating delays Valve model DV 0 25 FILTER SILENCING TYPE AMC This ensures clean plant air and reduces noise levels In areas where you...

Page 48: ...48 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 ACCESSORIES ...

Page 49: ...electrical equipment and goods If contamination from purged water is not a problem then automatic drain units should be selected Failure to fit and drain the filter will result in excessive moisture being carried into the hoist valve motor and brake actuator resulting in internal corrosion and premature failure LUBRICATOR UNIT There are two types of lubricator available Oil mist lubricator The pre...

Page 50: ...e to the internal parts 2 Do not use tools on the pressure regulator knob as this may cause damage It must be operated manually MOUNTING ADJUSTMENT CAUTION 1 Be sure to unlock the knob before adjusting the pressure and lock it after setting the pressure Failure to follow this procedure can cause damage to the knob and the outlet pressure may fluctuate Pull the pressure regulator knob up to unlock ...

Page 51: ...51 LOG BOOK Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH8 REV0 LOG BOOK ...

Page 52: ...ontrol function labels HOIST CHAIN Check chain lubrication twisted chains multi fall blocks AIR SET Check oil level indicator SAFETY CATCHES Check operation and for damage NOISE OPERATION Check for any unusual noise and speeds during function tests HOIST OPERATION Check the hoist starts and stops quickly EXTRA CHECKS FOR TROLLEY OPERATION Check movement and control of the trolley TROLLEY MOVEMENT ...

Page 53: ... DAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 AIR HOIST CHECKS HOOK SWIVEL AIR LEAKS AIR SET LUBRICATION SAFETY CATCHES NOISE OPERATION PENDANT OPERATION E STOP CHAIN LUBRICATION CHAIN NUT TWISTED SUPPLY HOSE CHAIN COLLECTOR TROLLEY CHECKS OPERATION NOISE FESTOON SYSTEMS MOVEMENT IF FITTED OPERATOR S NAME 1 2 3 4 COMMENTS INITIALS DATE ...

Page 54: ...TO BE CARRIED OUT MONTHLY IN PRODUCTION OPERATIONS WHERE HEAVILY USED OR IN HARSH WORKING CONDITIONS TO BE CARRIED OUT THREE MONTHLY WHEN THE HOIST IS ONLY USED OCCASIONALLY PLEASE CONTACT RED ROOSTER TO CONFIRM IF MONTHLY OR THREE MONTHLY MAINTENANCE CHECKS ARE REQUIRED IF YOU ARE NOT SURE MONTHLY 3 MONTHLY CHECKS CARRIED OUT AS PER MANUAL NAME DATE ...

Page 55: ...1651 872101 Nauta House Oldmeldrum E sales redroosterlifting com The Meadows Aberdeenshire AB51 0EZ W www redroosterlifting com Depot Unit 26 Kelvin Way T 44 0 121 525 4162 Kelvin Way Trading Estate West Bromwich B70 7TW ...