Harrington TCK Owner's Manual

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Owner’s Manual

EFFECTIVE: April 28, 2020

AIR

POWERED

CHAIN HOIST

TCK SERIES

3 Ton and 6 Ton Capacity

Code Number and Serial Number

WARNING

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 comply with the contents of this manual can result in serious bodily injury or death, and/or property damage.

© Harrington Hoists, Inc.

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 Preoperational Procedures………………………………………………………………………... 12

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……………………………………………………………………………………………. 23

4.1 Introduction

4.2 Shall’s and Shall Not’s for Operation

4.3 Hoist Controls

4.4 Adjusting the Controls

4.5 Operation of the Load Limiter

Section Page Number

5.0 Inspection……………………………………………………………………………………………. 28

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…………………………………………………………………………………………... 36

6.1 Air Hoist Lubrication

6.2 Load Chain Lubrication

6.3 Hooks and Suspension Components

7.0 Maintenance & Handling…………………………………………………………………………… 38

7.1 Load Limiter

7.2 Brake

7.3 Load Chain

7.4 Pendant

7.5 Load Sheave Inspection

7.6 Storage

7.7 Outdoor Installation

8.0 Troubleshooting…………………………………………………………………………………….. 47

9.0 Warranty…………………………………………………………………………………………….. 49

10.0 Parts List…………………………………………………………………………………………….. 50

10.1 Main Body

10.2 Cord Control Valve Body

10.3 Pendant Control Valve Body

10.4 Pendant Handle

1.0 Important Information and Warnings

1.1 Terms and Summary

This manual provides important information 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 Notice - 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

Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury , and property damage.

WARNING

Warning indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury , and property damage.

CAUTION

NOTICE

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.

NOTICE

INTENDED USE OF HOIST/TROLLEY HOIST and Owner’s Manual

The TCK hoists are intended only for vertical lifting service of freely suspended, unguided loads. In addition to lifting service of freely suspended, unguided loads, TCK when coupled with a trolley is to be used to traverse these loads on a single girder beam.

The TCK hoists are not intended to lift greater than rated loads, lift, support or transport people nor lift loads over people.

The TCK hoists are intended to be operated by persons who have read and understood the operation section of the

TCK owner’s manual, all warnings and are familiar with the TCK hoist controls.

CAUTION

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 9 ) 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.

WARNING

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 use d 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

ANSI Z241.2, “Safety Requirements for Melting and Pouring of Metals in the Metalcasting Industry”.

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.

DANGER

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 deenergized position. Refer to ANSI Z244.1, “Personnel

Protection - Lockout/Tagout of Energy Sources.”

Only trained and competent personnel should inspect and repair this equipment.

NOTICE

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.

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.

front back

Figure 1-1 Warning Tag Attached to Hoist

2.0 Technical Information

2.1 Specifications

2.1.1 Product Code

2.1.2 Operating Conditions and Environment

Temperature range: -4° to +158°F (-20° to +70°C)

Relative Humidity: 85% or less

Noise Level: 84 dba maximum @ 1 meter when lifting/lowering rated load

Supply Air: 60 to 90 pounds per square inch

Air Consumption: 30 to 90 cubic feet minute

Air Lubrication Requirements: Minimum 10 to 15 drops per minute (0.2-0.3 cc/min) of oil

Air Filtration Requirements: Maximum 5 micron air filter or finer

Load Limiter: Adjustable; Factory set to 125% of rated capacity

Cap.

(Tons)

Product

Code

TCK3000P

(ft)

Push

Hose or

Table 2-1 Hoist Specifications

Up/Down Speeds

(ft/min @ 90 psi)

Cord

(ft) w/Full Load

Air Consumption Rates

(cubic ft/min @ 90 psi)

No Load w/Full Load

Diameter

(mm)

Chain Fall

Lines

Weight for

Additional

Weight

(lbs)

One Foot of Lift

(lbs)

8.6 37 / 23 18 / 38 148 / 141 124 / 152 12.5 x 1 225 2.3

6 TCK6000P2 8.6 18 / 12 9 / 19 148 / 141 124 / 152 12.5 x 2 295 4.6

3 TCK3000C

6 TCK6000C2

8.2 37 / 23 18 / 38 148 / 141 124 / 152 12.5 x 1

8.2 18 / 12 9 / 19 148 / 141 124 / 152 12.5 x 2

223

293

2.3

4.6

2.2 Dimensions

Table 2-2 TCK with Pendant Control Dimensions

Cap.

(Tons)

Single Fall Hoist Double Fall Hoist

Code

Headroom

Product a

(in) (in)

(in)

(in) e g i j

(in) (in) (in) (in) (in)

3 TCK3000P

6 TCK6000P2

21.1

30.3

22.7

12.4

14.6

10.4

12.2

1.3

1.7

7.4

9.6

4.9

5.0

1.3

3.5

Table 2-3 TCK with Cord Control Dimensions

Cap.

(Tons)

Single Fall Hoist Double Fall Hoist

Headroom

Product

Code

(in)

(in) (in) e g i j

(in) (in) (in) (in) (in)

3 TCK3000C

6 TCK6000C2

21.1

30.3

22.7 12.4 10.4 12.2 1.3

22.7 14.6 10.4 12.2 1.7

7.4

9.6

4.9

5.0

1.3

3.5

Table 2-4 Top and Bottom Hook Dimension*

Units = inch

Product Code

TCK3000

TCK6000 a b c d e f g h

2.0 1.5 1.8 1.3 2.0 2.4 1.3 5.9

2.3 1.6 1.9 1.6 2.6 2.8 1.7 6.8

*Refer to Section 5.7

for inspection dimensions and limits.

2.3 Part Names

Figure 2-1 Hoist Part Identification Diagrams TCK3000

Figure 2-2 Hoist Part Identification Diagrams TCK6000

3.0 Preoperational Procedures

3.1 Air Supply System Requirements

3.1.1

3.1.2

3.1.3

NOTICE

Pressure and Flow – Verify that the air supply system has capacity to supply your air hoist with required pressure and flow. Otherwise the hoist may operate poorly or may fail to operate. See Section 3.2.

CAUTION

Lubrication – The hoist requires lubrication for proper operation. The oil in the air 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.

CAUTION

Air Quality – Good air quality is essential to prevent damage to your hoist and to 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.

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

CAUTION as follows:

3.3.2

The hoist must be supplied with its own lubricator. The lubricator must be located

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.

CAUTION

The lubricator must be set to deliver the equivalent of 10 to 15 drops of oil per minute (0.2-0.3 cc/minute). The hoist’s exhaust will emit a fine oil mist when properly lubricated.

3.4 Filtration

3.4.1

CAUTION

The air entering the hoist inlet must not contain any particulate greater than 5 microns in size. Therefore, the hoist must have a 5 micron filter in its air supply. The filter must be 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 sized for the total air consumption of the equipment it is servicing.

3.5 Air Dryer

3.5.1

CAUTION

To prevent corrosion and hoist malfunction, employ an air dryer in the air supply system to ensure that dry air is supplied to the hoist. If there is moisture in the air supplied to the hoist, 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

CAUTION

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.

◼

Arrange for a drain in the air supply piping at the lowest point in the piping.

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.

Figure 3-1 Diagram of Air Supply Configuration (Typical)

Figure 3-2 Typical Air Supply Filter, Regulator and Lubricator.

3.6.2

NOTICE

Piping – Pipe should be sized to accommodate the hoist airflow requirements.

Table 3-1 gives recommended pipe sizes.

Model

Table 3-1 Air Supply Pipe and Hose Sizes

TCK3000, TCK6000

Diameter of Supply Pipe Diameter of Supply Hose

Inside diameter

1.0 inch or larger

Inside diameter

0.75 inch or larger

3.6.3

NOTICE

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.

The use of “Quick Couplers” is to be avoided. Quick Couplers restrict the air flow that will affect hoist performance.

Figure 3-3 Typical Arrangements of Filter, Regulator and Lubricator and

Maximum Air Supply Hose Lengths

3.6.4

3.6.5

CAUTION include:

Fittings – Important considerations regarding fittings in the hoist's air supply

◼ 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.

CAUTION

Before connecting the hoist to its air supply line; perform the proper draining and purging procedures to prevent contaminants or moisture from entering the hoist.

3.7 Exhaust Control

3.7.1 Some hoist applications require the hoist exhaust to be expelled outside the immediate environment.

To accommodate this need it is possible to extend the hoist exhaust to another area. Figure 3-4 describes the method to extend the hoist exhaust.

Figure 3-4 Extended Hoist Exhaust Installation

3.8 Mounting Location

3.8.1

WARNING

Prior to mounting the hoist ensure that the suspension and its supporting structure 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.

3.8.1 For applications requiring a “Secondary Support” a support attachment location has been provided in the hoist Top Hook Yoke/Hoist Body. Reference Figure 3-5.

TCK3000 TCK6000

Figure 3-5 Hoist “Secondary Support” Configuration

3.8.3

NOTICE

See Section 7.7 for outdoor installation considerations.

3.9 Connecting Hoist to Air Supply

3.9.1

WARNING

HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY

OF COMPRESSED AIR TO THE HOIST, AND IN THE CONNECTIONS BETWEEN COMPONENTS.

Figure 3-6 Typical Air Supply Connection

3.9.2 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”.

3.9.3

CAUTION

Before connecting the air supply hose to the hoist, always purge the air hose to clear any debris and water.

3.9.4 Apply approximately 10-15 drops (0.2-0.3 cc/min) of turbine oil (see approved lubricant under Section

6.0

Lubricants) into the hose before attaching to the hoist.

3.9.5 Make connections to air supply; reference Figure 3-6. Use a reducing adapter at the hoist valve section for hose sizes larger than 3/4 inch NPT.

3.9.6

NOTICE

Where conditions dictate, the installation sequence can be reversed by mounting the hoist first (Section 3.9) followed by connecting the air supply (Section 3.6).

3.10 Mounting the Hoist

3.10.1 Manual Trolley – Follow instructions in Owner’s Manual provided with the trolley.

3.10.2 Motorized Trolley – Follow instructions in Owner’s Manual provided with the trolley.

3.10.3 Hook Mounted to a Fixed Location – Attach the hoist’s top hook to the fixed suspension point.

3.10.4

WARNING

Ensure that the fixed suspension point rests on the center of the hook’s saddle and that the hook’s latch is engaged .

3.11 Optional Chain Container

3.11.1 For installation of the optional bag style chain container refer to Figure 3-7 and perform the following:

◼ Make sure all end stoppers are installed correctly. See Figure 3.7 and section 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 twisting or tangling the chain.

Do not use the chain container if any parts are damaged or if any fasteners/hardware are missing.

Figure 3-7 Optional Chain Container Installation

3.12 Non-Stationary Application

3.12.1 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.

3.12.1 Connections and fittings must be kept clean and care taken to prevent dirt, debris and moisture from entering the hoist.

3.12.2 Recommended practice for removing the hoist from an installation:

◼ Run the hoist briefly with well lubricated air

◼

Disconnect the air supply line

Inject a small quantity (approximately 20 drops) of oil into the hoist’s inlet port

Plug the inlet port

3.13 Preoperational Checks and Trial Operation

3.13.1

CAUTION

Check for the availability of required operating air pressure of between 60 PSI to

90 PSI at the hoist's inlet port before trying to operate the hoist.

3.13.2

WARNING

Verify that the load chain is not twisted or tangled and that the bottom hook is not capsized prior to operating the hoist. Correct all chain irregularities before conducting the first hoist operation. See Figures 3-8 and 3-9.

Figure 3-9 Capsized Hook and Chain

Figure 3-8 Twist in Load Chain

3.13.3

3.13.4

WARNING

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.

WARNING

For Models TCK3000 and TCK6000 verify that the chain/limit lever is operational and can move freely in both the up and down directions. For reference see Figure 3-10.

TCK3000 and TCK6000

Figure 3-10 Limit Switch Components

3.13.5 For Models TCK3000 and TCK6000 verify that the chain/limit lever is operational and can move freely in both the up and down directions.

3.13.6 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.

3.13.7 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.

3.13.8 Ensure that the hoist is properly installed to either a fixed point, or trolley, whichever applies.

3.13.9 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.

3.13.10 Ensure that all nuts, bolts and split (cotter) pins are sufficiently fastened.

3.13.11 For hoists with pendant controls, ensure that the pendant's air tubing and wire cable are properly attached to the hoist. See Section 7.4.

3.13.12

CAUTION

Check Air Supply - Check air supply before everyday use. Ensure proper air quality and air pressure.

3.13.13

CAUTION

Check the lubricator for proper function and adequate oil level.

3.13.14 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 e nsure that nothing will interfere with the full range of the hoist’s (and trolley’s) operation.

3.13.15 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”.

4.0 Operation

4.1 Introduction

DANGER

DO NOT WALK UNDER A SUSPENDED LOAD

WARNING

HOIST OPERATORS SHALL BE REQUIRED TO READ THE OPERATION SECTION OF THIS MANUAL, THE

WARNINGS CONTAINED IN THIS MANUAL, INSTRUCTION AND WARNING LABELS ON THE HOIST OR

LIFTING SYSTEM, AND THE OPERATION SECTIONS OF ANSI/ASME B30.16 and ANSI/ASME 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 ATTACHMENT

OF LOADS TO THE HOIST HOOK.

HOIST OPERATORS SHOULD BE TRAINED TO BE AWARE OF POTENTIAL MALFUNCTIONS OF THE

EQUIPMENT THAT REQUIRE ADJUSTMENT OR REPAIR, AND TO BE INSTRUCTED TO STOP OPERATION

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 DEXTERITY, AND COORDINATION.

HOIST OPERATORS SHOULD NOT HAVE A HISTORY OF OR BE PRONE TO SEIZURES, LOSS OF

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 USE HOIST FOR LOADS THAT ARE NOT LIFTED VERTICALLY, LOADS THAT

ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED.

NOTICE

• Read ANSI/ASME B30.16 and ANSI/ASME B30.10.

• Read the hoist manufacturer’s Operating and Maintenance Instructions.

• Read all labels attached to equipment.

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 certain hazards that cannot be mitigated by engineered features, but only by the exercise of intelligence, care, common sense, and experience in anticipating the effects 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

WARNING

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in death or serious injury, and substantial property damage. To avoid such a potentially hazardous situation THE OPERATOR SHALL:

• NOT operate a damaged, malfunctioning or unusually performing hoist.

• NOT operate a hoist until you have thoroughly read and understood Manufacturer’s Operating and

Maintenance Instructions or Manuals.

• Be familiar with operating controls, procedures, and warnings.

• NOT operate a hoist that has been modified without the manufactur er’s approval or without certification that it is in conformity with ANSI/ASME B30 volumes.

• NOT lift more than rated load for the hoist.

• NOT use hoist with twisted, kinked, damaged, or worn chain.

• NOT use the hoist to lift, support, or transport people.

• NOT lift loads over people.

• NOT operate a hoist unless all persons are and remain clear of the supported load.

• NOT operate unless load is centered under hoist.

• NOT attempt to lengthen the load chain or repair damaged load chain.

• Protect the h oist’s load chain from weld splatter or other damaging contaminants.

• NOT operate hoist when it is restricted from forming a straight line from hook to support in the direction of loading.

• NOT use load chain as a sling or wrap load chain around load.

• NOT apply the load to the tip of the hook or to the hook latch.

• NOT apply load unless the load chain is properly seated in the load sheave (and idle sheave for hoist with two chain falls).

• NOT apply load if bearing prevents equal loading on all load-supporting chain.

• NOT operate beyond the limits of the load chain travel.

• NOT leave load supported by the hoist unattended unless specific precautions have been taken.

• NOT allow the load chain or hook to be used as an electrical or welding ground.

• NOT allow the load chain or hook to be touched by a live welding electrode.

• NOT remove or obscure the warnings on the hoist.

• NOT operate a hoist on which the safety placards or decals are missing or illegible

• NOT operate a hoist unless it has been securely attached to a suitable support.

• NOT operate a hoist unless load slings or other approved single attachments are properly sized, and seated in the hook saddle.

• NOT use the hoist in such a way that could result in shock or impact loads being applied to the hoist.

• Take up slack carefully – make sure load is balanced and load-holding action is secure before continuing.

• Shut down a hoist that malfunctions or performs unusually and report such malfunction.

• Make sure hoist limit lever functions properly.

• Warn personnel before lifting or moving a load.

• Warn personnel of an approaching load.

CAUTION

Improper operation of a hoist can create a potentially hazardous 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 footing or be otherwise secured when operating the hoist.

• Check brake function 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 direction as shown on controls.

• Inspect the hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance.

• 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 Hoist Controls

4.3.1 For hoists mounted to motorized trolleys follow the control instruction included in the trolley’s Owner’s

Manual.

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. To stop motion release the lever switches.

Pendant used with

10mm X 6.3mm Hose Optional E-Stop Pendant used with 10mm X 6.3mm Hose

Figure 4-1 Pendant Control

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

Figure 4-2 Cord Control

CAUTION

Make sure the motor completely stops before reversing direction.

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 w ill 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.

Figure 4-3 Pendant Control Speed Adjustment

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 4-4 Cord Control Speed Adjustment

4.5 Operation of the Load Limiter

4.5.1 If a hoist is used to lift a load that exceeds the hoists 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 load from the hoist.

4.5.3 If the load is at or below the hoist’s capacity rating and the hoist stops lifting automatically, the load limiter may need adjustment.

◼

Check air line pressure to ensure adequate pressure at the hoist.

If pressure is adequate, adjust the load limiter. For load limiter adjustment, refer to Section 7.

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 – person selected or assigned as being competent to perform the specific duties to which he/she is assigned.

◼

Qualified Person – person who, by possession of a recognized degree or certificate of professional standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

Normal Service – that distributed service which involves operation with randomly distributed loads within the rated load limit, or uniform loads less than 65% of rated load for not more than 25% of the time.

Heavy Service – that service which involves operation within the rated load limit which exceeds normal service.

Severe Service – that service which involves normal or heavy service with abnormal operating conditions.

5.2 Inspection Classification

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.

5.3 Frequent Inspection

5.3.1 Inspections should be made on a FREQUENT basis in accordance with Table 51, “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.

Table 5-1 Frequent Inspection

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

Air valves and components for leakage or damage

5.4 Periodic Inspection

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.

Table 5-2 Periodic Inspection

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.

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.

5.5 Occasionally Used Hoists

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.

Hoist Idle More Than 1 Year: Inspect per PERIODIC Inspection criteria of Section 5.4.

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.

Hooks - Surface

Condition

Hooks - Fretting wear

Item

Functional operating mechanisms.

Limit Switch

Chain Lever/Limit

Lever Assembly

Braking System

Hooks - Stretch

Table 5-3 Hoist Inspection Methods and Criteria

Method

Visual, Auditory

Function

Visual, Function

Function

Visual

Measure

Criteria

Mechanisms should be properly adjusted and should not produce unusual sounds when operated.

Proper operation. Actuation of limit switch should stop hoist.

Lever should not be bent or significantly worn and should be able to move freely.

Braking distance should not exceed approximately five chain links.

Should be free of significant rust, weld splatter, deep nicks, or gouges.

The “u” dimension should not be less than minimum value listed in Table 5-6.

Th e “K” dimension should not exceed the maximum value for replacement from Table 5-6

(See Section 3.12).

Action

Repair or replace as required.

Replace.

Repair or replace as required.

Replace.

Hooks - Bent Shank or Neck

Hooks - Yoke

Assembly

Hooks - Swivel

Bearing

Item

Top Hook/Yoke Gap

Hooks - Idle Sheave and Axle (Bottom

Hook on Double Fall

Hoist)

Hooks - Hook

Latches

Load Chain -

Surface Condition

Load Chain - Pitch

Load Chain -

Lubrication

Load Chain -

Reeving

Chain Container

(Optional)

Visual, Function

Visual

Table 5-3 Hoist Inspection Methods and Criteria

Method

Visual

Visual, Function

Measure

Visual, Function

Visual

Measure

Visual, Auditory

Criteria

Shank and neck portions of hook should be free of deformations

Should be free of significant rust, weld splatter, nicks, and gouges. Holes should not be elongated, fasteners should not be loose, and there should be no gap between mating parts.

Bearing parts and surfaces should not show significant wear, and should be free of dirt, grime and deformations. Hook should rotate freely with no roughness.

Gap should not be greater than maximum value listed in Table 5-7.

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.

Action

Replace.

Clean/Lubricate, or replace as required.

Clean/lubricate, or replace as required.

Replace.

Clean/lubricate, or replace as required.

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.

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.

The “P” dimension should not be greater than maximum value listed in Table 5-8.

Replace, inspect

Load Sheave (and

Idle Sheave for double fall hoist).

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.

Clean/lubricate

(see Sections 6.0).

Chain should be reeved properly through Load

Sheave (and Idle Sheave for double fall hoist) - refer to Section 3.13. Chain and stoppers should be installed properly - refer to Section 7.3.2.

Container should not be damaged. Brackets should not be deformed or missing

Replace.

Reeve/Install chain properly.

Replace

Chain Container

(optional)

Bolts, Nuts and

Rivets

Housing and

Mechanical

Components

Pendant Control

Levers

Item

Chain Springs

Chain Separator

Motor Brake

Load Sheave

Pendant - Housing

Pendant - Tubing

Pendant - Labels

Visual, Check with Proper Tool

Visual, Auditory,

Vibration,

Function

Visual

Table 5-3 Hoist Inspection Methods and Criteria

Method

Visual

Visual, Measure

Measure, Visual

Criteria

Chain springs should not be deformed or compressed.

Container should not be damaged. Brackets should not be deformed or missing.

Action

Replace

Bolts, nuts and rivets should not be loose.

Tighten or replace as required.

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.

The Chain Separator should be free of cracks, distortion, significant wear and corrosion. The “L” and "W" dimension should not be greater than maximum value listed in Table 5-5.

Motor brake dimension should 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.

Pockets of Load Sheave should be free of significant wear. See Section 7.5 to gain visual access to the load sheave.

Replace

Replace.

Visual,

Function

Depressing and releasing pendant control levers should cause hoist to operate.

Repair or replace as necessary.

Visual

Visual, auditory

Visual

Pendant housing should be free of cracks and mating surfaces of parts should seal without gaps.

Replace.

Tubing to pendant control switches should not be loose or be leaking air.

Repair or replace as necessary.

Labels denoting functions should be legible. Replace.

Warning Labels Visual

Hoist Capacity Label Visual

Warning Labels should be affixed to the hoist (see

Section 1.2) and they should be legible.

Replace

The label that indicates the capacity of the hoist should be legible and securely attached to the hoist.

Replace.

Table 5-4 Brake Disc Dimensions

Hoists

TCK3000, TCK6000

Std Dimension

Inch (mm)

T = 0.31 (8)

W = 0.10 (2.6)

Minimum Value for Replacement

Inch (mm)

T = 0.29 (7.3)

W = 0.11 (2.8)

Table 5-5 Chain Separator Dimensions

Hoists

TCK3000, TCK6000

Std Dimension

Inch (mm)

L = 1.08 (27.5)

W = 2.01 (51.0)

Maximum Value for Replacement

Inch (mm)

L = 1.16 (29.5)

W = 2.09 (53.0)

Table 5-6 Top Hook & Bottom Hook Dimensions

Dimensions K and U do not have a controlled tolerance; therefore they should be measured and recorded below prior to the hoist being placed into service. The measured K and U values will be the dimensional reference for hook inspection.

Hoists

Parts View

Figure No.

Recorded Dimension

When New

Maximum/Minimum Value for Replacement

TCK3000

2-5

Top Hook K = _______________

Top Hook U = _______________ For K if the measured dimension exceeds 1.05 times the recorded new

Bottom Hook K = ____________

Bottom Hook U = ____________ dimension, the hook should be replaced.

TCK6000

2-6

Top Hook K = _______________

Top Hook U = _______________

Bottom Hook K = ____________

Bottom Hook U = ____________

For U if the measured dimension is less than 0.9 times the recorded new dimension, the hook should be replaced.

Table 5-7 Top Hook/Yoke Gap Wear Limit Dimension

Capacity Code

TCK3000

TCK6000

NOTE: Hook image does not represent actual hook.

Minimum Value for Replacement

Inch (mm)

0.11(7/64) inch/(2.8mm)

0.14(9/64) inch/(3.5mm)

Table 5-8 Chain Wear Dimensions

Capacity Code

TCK3000, TCK6000

“P” Dimension inch (mm)

Standard

7.52 (191)

Discard

“d” Dimension inch (mm)

Standard Discard

7.74 (196.7) 0.49 (12.5) 0.44 (11.3)

Table 5-9 Hook Joint Bolt Dimension

Capacity Code

TCK6000

Wear Limit

Minimum Value for Replacement inch (mm)

0.004 (0.1)

6.0 Lubrication

6.1 Air Hoist Lubrication

6.1.1 See Section 3.0 for lubrication requirements.

6.1.2

CAUTION

Lubrication to the motor will be provided primarily by the air supply lubricator. The recommended amount is 10-15 drops/minute (0.2-0.3 cc/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.

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 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.

Figure 6-2 Chain Grease Application

6.2.4 Machine or gear oil (grade ISO VG 32-56 or equivalent) may be used as an alternative lubricant but must be applied more frequently.

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.

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.

Application

Air motor

Load chain & pocket wheel

Hook bearings & suspension pins

Gears and Bearings

Table 6-1 Table of Approved Lubricants

Part Location Lubrication

Lubricator Turbine Oil

Grade

ISO VG 32-56 or equivalent

Load chain

Top & bottom hook sets

Gear Section

Grease or

Machine/gear oil

Grease

- HHI Chain Grease

P/N ER1BS1551

- NLGI No. 0

- ISO VG 32, 46, 68 or

equivalent

National Lubricating

Grease #3 or equivalent

Shell Gadus S2 V220 2,

Shell Alvania EP Grease

R000, R00, R0, 1, 2 or equivalent

7.0 Maintenance and Handling

7.1 Load Limiter

7.1.1 The purpose of the load limiter is to prevent using the hoist in an overload situation. When lifting, the hoist will stop automatically if the load is above the rated capacity of the hoist.

7.1.2 The adjustment is factory set to actuate at approximately 125% of rated capacity (based on supply air pressure of 90 PSI). Note: the load limiter may need adjustment to compensate for air supply pressures significantly less than 90 PSI.

Figure 7-1 Load Limiter screw adjustment location

7.1.3 Adjustment Procedure

1) Before proceeding with the load limiter adjustment, note the following: a.

WARNING

Adjusting the load limiter involves operating the hoist. Personnel involved in the adjustment procedure should read, understand, and follow Section 4, "Operation". b. For the adjustment procedure, the hoist should be connected to 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 a resting position so that the load chain is not tensioned. d. For the adjustment procedure: OUT means the counter-clockwise (CCW) direction, and IN means the clockwise (CW) direction. e. The pressure of the air supply at the hoist’s inlet port (acceptable range is 60 to 90 PSI) affects the performance of your air hoist, including the actuation point of the load limiter. Therefore, ensure that during the adjustment procedure the air pressure at the hoist's inlet port is the same as that which the hoist will experience in normal operation. The relationship between air supply pressure and load limiter actuation is:

◼ for a given load limiter setting, as pressure decreases, the actuation point increases. f. When the load limiter is adjusted and working properly, the hoist will operate and lift the load a short distance before the load limiter automatically stops lifting.

2) Refer to Figure 7-1. Loosen the lock nut and slowly turn the adjustment screw OUT until it is loose and no longer is in contact with the internal load limiter spring – as this occurs the screw should become easier to turn. Stop turning the screw once it is loose and easier to turn.

Turn the adjustment screw IN just enough so that it begins to contact the internal load limiter spring

– as this occurs the screw should become slightly harder to turn.

4) Put a load equal to the desired actuation point on the hoist's hook (do not exceed 125% of the hoist's rated capacity). Begin to slowly lift the load, and then increase the lifting speed. Return the load to its resting position so the load chain is not under tension.

If the load limiter prevents lifting, turn the adjustment screw IN one full turn.

Repeat steps 4 and 5 until the load limiter allows lifting.

7) Turn the adjustment screw OUT ¾ of a turn.

8) Attempt to lift the rated capacity load again, beginning slowly, and then increasing the lifting speed.

9) If the load limiter does not allow lifting, then turn the adjustment screw IN ¼ turn.

10) Repeat steps 8 and 9 until the load limiter allows lifting.

11) Turn the adjustment screw IN ¼ turn. Then, while holding the adjustment screw, tighten the lock nut to secure the setting.

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, and Table 5-4.

7.2.3 The following is the hoist brake inspection procedure.

WARNING

HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE

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/Tag out of Energy

Sources”.

2) Gradually and evenly back out 4 Hex Socket Cap Screws from Brake Cover as shown in

Figure 7-2.

Figure 7-2 Brake Cover Bolt Removal

Remove the Hex Socket Set Screw from the Brake Cover as shown in Figure 7-3.

Figure 7-3 Hex Socket Set Screw Removal

Remove the Brake Cover, Brake Piston, and Springs from the Gear Case, as shown in Figure

7-4.

Figure 7-4 Brake Internals Removal

Remove the O-ring from the Brake Piston as shown in Figure 7-5. If the Brake Piston has any cracking, it must be replaced.

Figure 7-5 Brake Piston

Remove the Brake Disc, as shown in Figure 7-6. Measure the thickness of the Brake Disc and the width of the center splines according to Table 5-4.

Prior to reassembly, clean all surfaces of debris, dirt and loose paint. Apply a light film of grease to all O-Ring seals.

Reassemble in reverse order. Torque all mounting hardware evenly during the reassembly process.

Figure 7-6 Brake Disc Removal

7.3 Load Chain

7.3.1 Lubrication and Cleaning – Refer to Section 6.2.

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 chain is obtained from Harrington and is the 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.

Remove the Bottom Hook Complete Set, as well as the Chain Set Pin and Split Pin connecting the no-load end of the chain to the hoist body. Keep the Bottom Hook Complete Set, Chain Set Pin, and Split Pin for reuse on new chain. Carefully operate the hoist in the down direction to remove old chain.

CAUTION

When replacing load chain, check for wear on mating parts, i.e. Load Sheave,

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.

CAUTION

Invert the hoist such that the chain separator openings are facing up and tilt the hoist approximately 30° as shown in Figure 7-7. 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.

CAUTION

Operate the hoist as slowly as possible in the down direction to catch the Load

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.

7) 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 7-8 and Figure 7-9.

8) After installation has been completed, perform steps outlined in Section 3.13 "Pre-operational

Checks and Trial Operation".

Figure 7-7 Load Chain Installation Diagram

Figure 7-8 Single Fall Chain Connections

Figure 7-9 Double Fall Chain Connections

7.4 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 7-10.

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 7-10 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.

CAUTION

Operate hoist and make sure the direction of hook travel agrees with the control levers on the Pendant Valve.

Figure 7-10 Pendant Hose Connections

7.5 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 7-11 and remove the chain separator as follows:

CAUTION procedures.

An air supply line must be connected to the hoist in order to perform the following

2) Remove 4 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.

Figure 7-11 Load Sheave Inspection

7.6 Storage

7.6.1 Whenever the hoist is to be placed into storage, place extra lubricating oil (minimum 3cc) 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.

7.6.2 The storage location should be clean and dry.

7.6.3 Care should be take to not damage any of the air hoses, fittings and cords.

7.7 Outdoor Installation

7.7.1 For hoist installations that are outdoors, the hoist MUST BE covered and protected from the weather at all times.

7.7.2 Avoid hoist oxidation by using suitable treatment and lubricating all mechanisms.

7.7.3 Possibility of corrosion on components of the hoist increases for installations where salt air and high humidity are present. The hoist may require more frequent lubrication.

7.7.4 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. Make frequent and regular inspections of the unit's condition and operation.

7.7.5 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.

7.7.6 For hoist installations where temperature variations introduce condensation into the hoist additional inspection and more frequent lubrication may be required.

7.8 Operational Environment

7.8.1 Non-conforming environment

A non-conforming environment is defined as one with any or all of the following.

•

Explosive gases or vapor.

•

Organic solvents or volatile powder

•

Excessive amounts of powder and dust of general substances

•

Excessive amount of acids or salts.

•

Refer to Section 2.1.2 for allowable environmental conditions.

8.0 Troubleshooting

WARNING

HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, IN THE SUPPLY OF COMPRESSED AIR TO

THE HOIST, AND IN CONNECTIONS BETWEEN COMPONENTS.

Protection - Lockout/Tagout of Energy Sources.”

Only Trained and competent personnel should inspect and repair this equipment.

Symptom

Does not operate

Lifting speed is slow

Unable to lift rated load

Table 8-1 Troubleshooting Guide

Cause Remedy

Lack of air pressure or loss of air supply.

Seizure of Main Spool, Brake Spool, or Air Motor.

Repair or adjust air supply or filters.

Repair at service facility.

Seizure of brake or brake mechanism fails to release.

Bending or crimping of pendant hose or control tubes

Repair at service facility.

Hoist is overloaded.

Low air pressure at hoist inlet port.

Correct or repair bend or crimp in hose and/or tubes

Reduce the load to the rated capacity of hoist.

Repair or adjust air supply or filters.

Check for air line obstruction.

Air supply hose or piping is too small.

Replace hose or piping sizes with recommended sizes in Section 3.0.

Repair at service facility. Malfunction of brake.

Bending or crimping of pendant control hoses(s).

Lack of sufficient oil in air supply to hoist

Exhaust Silencer clogged

Air flow capacity of compressed air system insufficient

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.

Clean or replace.

Increase air flow capacity of compressed air system to requirements in Section 2.0.

Air motor vanes or bearings worn

Air supply to hoist contains dirt or debris

Repair at service facility.

Filter the air supply to the hoist in accordance with the requirements in

Section 3.0.

Lack of air pressure or loss of air supply.

Repair or adjust air supply or filters.

Improper adjustment of load limiter. Adjust Load Limiter. See Section 7.1.

Air leak between the two chambers in the Top Cover

Correct or repair to eliminate air leak.

Symptom

Hoist moving in wrong direction (pendant control)

Hoist lowers but will not lift

Hoist continues running after pendant or cord is released

Hoist drifts excessively when hoist is stopped

Table 8-1 Troubleshooting Guide

Cause

Pendant control hoses are terminated to incorrect ports on hoist body.

Remedy

Connect the control hose(s) in accordance with Section 7.4.

Hoist is overloaded.

Faulty pendant control or control tube(s)

Lack of air pressure or partial loss of or leakage in air supply.

Reduce load to hoist rated capacity.

Repair or replace pendant control or control hose(s).

Repair or adjust air supply or filters.

Control Valves

Valve in Pendant Handle stuck

Inject approx. 20 drops of oil into inlet port to lubricate the main spool. If spool still sticks, repair at service facility.

Repair at service facility

Brake is not holding.

Motor vanes leaking.

Repair brake at service facility.

Replace motor vanes and springs at service facility.

9.0 Warranty

Warranty explanation and terms.

All products sold by Harrington Hoists, Inc. are warranted to be free from defects in material and workmanship from date of shipment by Harrington for the following periods:

1 year

– Electric and Air Powered Hoists (excluding (N)ER2 Enhanced Features Models,

EQ / SEQ Hoists), Powered Trolleys, Powered Tiger Track Jibs and Gantries, Crane

Components, Spare / Replacement Parts, Below-the-Hook and Material Handling

Equipment

2 years – Manual Hoists & Trolleys, Beam Clamps

3 years – (N)ER2 Enhanced Features Model Hoists, EQ / SEQ Hoists, RY Wire Rope Trolley

Hoists

5 years – Manual Tiger Track Jibs and Gantries, TNER, EQ / SEQ and RY Pull-Rotor Motor

Brake

10 years – (N)ER2 “The Guardian” Smart Brake

The product must be used in accordance with manufacturer’s recommendations and must not have been subject to abuse, lack of maintenance, misuse, negligence, or unauthorized repairs or alterations.

Should any defect in material or workmanship occur during the above time period in any product, as determined by Harrington Hoist’s inspection of the product, Harrington Hoists, Inc. agrees, at its discretion, either to replace (not including installation) or repair the part or product free of charge and deliver said item F.O.B. Harrington Hoists, Inc. place of business to customer.

Customer must obtain a Return Goods Authorization as directed by Harrington or Harrington’s published repair center 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 will be covered for the remainder of the original warranty period. Replacement parts installed after the original warranty period will only be eligible for replacement (not including installation) for a period of one year from the installation date. If it is determined there is no defect, or that the defect resulted from causes not within the scope of Harrington’s warranty, the customer will be responsible for the costs of returning the product.

Harrington Hoists, Inc. disclaims any and all other warranties of any kind expressed or implied as to the product’s merchantability or fitness for a particular application. Harrington will not be liable for death, injuries to persons or property or for incidental, contingent, special or consequential damages, loss or expense arising in connection with the use or inability whatever, regardless of whether damage, loss or expense results from any act or failure to act by Harrington, whether negligent or willful, or from any other reason.

10.0 Parts List

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 Figure 10-1 below).

Reminder: Per Sections 3.12.6 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 TCK Nameplate

The parts list is arranged into the following sections:

Section Page

10.1 Motor , Valve Body and Controls……………………………………….……………………………...

10.2 Brake, Gears and Load Suspension Components……………………………………………….…. 54

10.3 Chain Container Assembly……………………………………………...……………………………..57

10.4 Hoist Maintenance Kits………………………………………………………………………………...58

The letters C and P designate "Cord" and "Pendant" controlled hoists. Hoists with 2 parts or falls of load chain have a

"-2" designator following the model number.

10.1 Motor, Valve Body and Controls

Figure

Number

Name

Throttle Valve

Valve Bushing (Up)

Valve Bushing (Down)

Spring Seat

Valve Cap

Valve Body

Bushing Cap

Piston

Exhaust Plate

Silencer (SS)

Silencer (SL)

Silencer (F)

Spring (11.4X46X1.4)

Spring (26X32.3X2.6)

Valve Gasket

Bearing (K5B0807)

Hex Socket Head Cap Screw

(M6X65)

Hex Socket Head Cap Screw

(M6X50)

Hex Socket Head Button Screw

(M5X10)

Set Screw (6X6)

Hex Set Screw (M5X5)

O-Ring (S-7)

O- Ring (S-20)

O- Ring (S-30)

O- Ring (S-32)

O- Ring (AS568-115)

O- Ring (AS568113(HS90))

Spring Pin (3X5)

Snap Ring (Ext. S-12)

Snap Ring (Int. H-36)

Retaining Ring (H-40)

Motor Case

Rear Plate

Cylinder

Rotor

Front Plate

Vane

Vane Spring

Limit Spool

Limit Spool Bushing

Limit Retainer (F)

Limit Retainer (B)

Limit Plug

Spring Seat

Spring (13X67X2)

Limit Shaft

Limit Shaft Bushing

Limit Lever

Limit Washer

Roller Shaft

Chain Lever

Motor Gasket

Silencer M CP

Bearing (605ZZ)

Bearing (6010)

Needle Bearing (TA2215Z)

Parts per hoist

Part Number

TCK425806J80

TCK425806E90

TCK425806F00

TCK425806C70

TCK425806A20

TCK425806060

TCK425806A30

TCK425806C60

TCK425806810

TCK137402055

TCK137402056

TCK137402057

TCK130802227

TCK130802228

TCK136102171

TCK130216001

9091259

9091256

TCK131905010

TCS132106006

90005843

TCR131103005

AH131103016

TCR131103024

TCR131103026

TCK131117115

TCK131118113

TCK130603005

TCK130302012

TCK130301036

TCK130301040

TCK425806790

TCK425806180

TCK425806160

TCK425806150

TCK425806170

TCK137102036

TCR130802235

TCK425806J40

TCK425806J30

TCK425806J50

TCK425806J60

TCK425806J70

TCR426307Z50

TCK130802226

TCK425806460

TCK425806A40

TCK425806140

TCK425806J90

TCK425806120

TCK425806110

TCK136102172

TCK425806K0B

9000505

9000510

TCK130132116

Figure

Number

Name

Hex Socket Head Cap Bolt

(M10X 25)

Set Screw Hex (M8X12)

Hex Socket Cap Screw

(M6X50)

Hex Set Screw (M5X5)

Hex Nut (M6)

O-Ring (S-5)

O-Ring (S-20)

O-Ring (S-26)

O-Ring (S-28)

Front Cap O-Ring (S-36)

O-Ring (P-100)

Dust Seal (OS22294)

Spring Pin (5X20)

Spring Pin (5X10)

Spring Pin (3X5)

Retaining Ring (Int. H-32)

Retaining Ring (Int. H-40)

Retaining Ring (Ext. S-50)

Retaining Ring (E-4)

94 Split Pin (2.5X25)

400 Brand Nameplate (HHI)

Cord Model Only:

Figure

Number

Name

300 Inlet Bushing (NPT) CP

301

Hex Socket Head Cap Bolt

(M6X25)

304 O-Ring (S-25)

305 O-Ring (AS568-134)

306 Spring Pin (5X10)

307 Plug

308 Snap Ring (Ext. S-32)

320 Under Cover

336 O-Ring (S-29)

380 S-Type Wire

381W White Cord (Up)

381R Red Cord (Down)

382 Grip (White, Up)

383 Grip (Red, Down)

384 Handle

Pendant Model Only:

Figure

Number

Name

300 Inlet Bushing (NPT) CP

301

Hex Socket Head Cap Bolt

(M6X25)

302 Hex Plug (PT ¾ in.)

303 O-Ring (S-7)

304 O-Ring (S-25)

305 O-Ring (AS568-134)

306 Spring Pin (5X10)

307 Plug

308 Snap Ring (Ext. S-32)

10.1 Motor, Valve Body and Controls

Parts per hoist

Part Number

9091294

TCK131708012

9091256

90005843

TCK134403106

AH131103003

AH131103016

TCR131103021

TCR131103022

TCK131103029

TCK131101068

TCK131246003

TCK130605020

TCK130605010

TCK130603005

TCK130301032

TCK130301040

TCK130302050

TCK130303004

TCK130702125

AH137309264

Parts per hoist

Part Number

TCK425806L0B

9091251

TCK131103020

TCK131117134

TCK130605010

TCK425807K90

TCK130302032

TCK425806470

TCR131103023

TCR130802081

9013101

9013102

AH136602625

AH136602626

AH136602627

Parts per hoist

Part Number

TCK425806L0B

9091251

TCK134902011

TCR131103005

TCK131103020

TCK131117134

TCK130605010

TCK425807K90

TCK130302032

309 Hex Plug (PT1/8 IN.)

320 Under Cover

326 Pilot Silencer

328

Hex Socket Head Cap Bolt

(M5X8)

329 Hex Screw (M5X22)

330 Hex Set Screw (M5X5)

331

Cross Head Flat Machine

Screw (M5X6)

332 Hex Nut (M5)

336 O-Ring (S-29)

339 Boot

350 Pendant Valve Assembly

A Throttle Valve

B Valve Body

C Bushing

D Lever Pin

Lever

Spring

G Set Screw (Hex Skt, M6X6)

H O-Ring, S-3 (HS90)

O-Ring, S-10

O-Ring, S-11.2

Hose Fitting

M Hose Clamp

N S-Type Wire

351 Cable Tie – Red

352 Cable Tie – White

353 Cable Tie

– Black

354 Pendant Hose

355 Strain Relief Wire

356 Hose Fitting

357 Hose Clamp

401 Warning Tag

*Qty: 4 or 6 depending upon hoist type.

TCR134902003

TCK425806470

TCK137402060

9091224

TCK132105022

90005843

TCK132905206

TCK134403205

TCR131103023

AH136608250

TCS420226VRD

TCR420218VB0

TCS420226VR0

TCS420218VF0

TCS130402071

TCS420218VH0

TCS130802220

TCS132106006

TCS131109001

TCR131103008

TCS131103009

TCS135106302

9013155

TCR130802081

TCS137502034

TCS137502036

TCS137502037

TCS137240925

9013120

TCS135106301

9013155

WTAG7

3 @

10.1 Motor, Valve Body and Controls

10.2 Brake, Gears and Load Suspension Components

Figure

Number

Name

110 Center Housing

111 Load Sheave

112 Coupling

113 Chain Guide

114 Chain Separator

115 Hanger Pin

116 Dowel Pin

117 Bearing (6003)

118 Bearing (6211ZZ)

119 Bearing (6014ZZ)

120

Hex Socket Head Cap Screw

(M8X25)

121 Hex Socket Set Screw (M8X6)

122 U-Nut M12

123 Washer M12

124 O-Ring S-7

126 Load Chain

150 Brake Cover

151 Brake Piston

152 Brake Disk

153 Spring (20.5X21.9X2.9)

TCK3000

154 Name Plate

TCK6000

155 Socket Bolt (M6X40)

156 Set Screw

157 O-Ring (AS568-255)

200 Gear Case

201 First Pinion

202 First Star Gear

203 First Pin

204 First Ring Gear

205 Second Pinion

206 Second Star Gear

207 Second Pin

208 Second Ring Gear

209 Third Pinion

210 Third Star Gear

211 Third Pin

212 Third Ring Gear

213 Cage

214 Spacer

215 Brake Plate

216 Chain Set Pin

217 Second Thrust Washer

218 Bearing (6003ZZ)

219 Bearing (6003)

220 Bearing (6909)

221 Bearing (6916)

222 Needle Bearing (TA1620Z)

Parts per hoist

Part Number

TCK425807A00

TCK425807A50

TCK425806200

TCK425807350

TCK425807360

TCK425806220

TCK426325340

9000103

9000611

9000514

9091273

TCK132108006

E2D853125

TCK131307012

TCK131103005

LCER0030NP

TCK425806410

TCK425806400

TCK425806430

TCK130802229

80542

80543

9091254

TCR132105005

TCK131117255

TCK425806310

TCK425806A60

TCK425806A70

TCK425806A80

TCK425806E10

TCK425806E20

TCK425806E30

TCK425806E40

TCK425806E50

TCK425806K20

TCK425806K30

TCK425806K40

TCK425806K50

TCK425806240

TCK425806230

TCK425806900

TCK425806K60

TCK425806K70

9000503

9000103

TCK130113009

TCK130113016

TCK130131621

Figure

Number

Name

223 Needle Bearing (TA1616Z)

224 Needle Bearing (TA1512Z)

225 HSHCS (M10X25)

226 HSHCS (M6X30)

227 Washer (M14)

228 O-Ring (S-7)

229 O-Ring (S-135)

230 O-Ring (S-145)

231 O-Ring (AS568-242)

232 O-Ring (AS568-249)

233 Retaining Ring (S-16)

234 Retaining Ring (S-15)

235 Split Pin (4X25)

Top Hook

250

Top & Bottom

Hook

TCK3000

TCK6000

251

252

253

254

255

266

267

268

Hook Latch

Spring

HSHCS

M4X28

U-Nut M4

Hook End

Piece

256

257

258

259

260

261

262

Hex Flat Head

Mach. Screw

(M6X25)

TCK3000

Hook Joint Bolt TCK6000

HSHCS

(M12X55)

Spring Washer

(M12)

TCK6000

U-Nut M12

Bottom Hook

Hook Latch

Hook Spring

263

HSHCS

(M4X28)

264 U-Nut M4

TCK6000

TCK3000

265

Under Hook

Holder

TCK3000

TCK6000

TCK3000

TCK6000

TCK3000

TCK6000

TCK3000

TCK6000

TCK3000

TCK6000

TCK3000

TCK6000

Swivel Hook

Outer Bearing

Race

Thrust Ring

Swivel Hook

Plug

TCK3000

TCK6000

TCK3000

Steel Ball (3/8) TCK3000

Free Chain

Wheel

TCK6000

Parts per hoist

1 Set

Part Number

TCK130131617

TCK130131513

9091294

9091252

TCK131307014

TCR131103005

TCR131103063

TCK131103065

TCK131117242

TCK131117249

TCK130302016

TCK130302015

130704025

TCK425806E60

TCK425810E60

TCK420655L30

TCK420890L30

TCR130802046

9091232

E2D853125

TCK425806570

TCK425810570

9091251

TCK425810580

90912119

TCK131301012

E2D853125

TCK420875PC1

TCK420655L30

TCR130802046

9091232

E2D853125

TCK425806800

TCK425811801

TCR420875PW0

TCK425810710

TCR420875PY0

TCR130502024

TCK425811F71

Figure

Number

Name

269

270

HSHCS

(M12X45)

Under Hook

Metal Cover

TCK3000

TCK6000

Hex Nut (M12) TCK3000

Thrust Bearing

(6211ZZ)

Spring Washer

(M12)

TCK6000

TCK3000

271

272

Thrust Bearing

(51112)

HSHCS

(M12X60)

273

HSHCS

(M12X100)

274

Spring Washer

(M12)

275 U Nut (M12)

276 Holder Shaft

TCK6000

Parts per hoist

Part Number

90912117

TCK420890QH0

9093433

9000611

9012713

TCK130121112

90912120

90912126

9012713

E2D853125

TCK425811P60

10.2 Brake, Gears and Load Suspension Components

10.3 Chain Container Assembly

Figure 10-3 Chain Container Assembly (Optional)

Figure

Number

Name

125 Chain Container Assembly

Parts per hoist

Part Number

TCK42580655C

10.4 Hoist Maintenance Kits

TCK3000/6000 Air Motor Maintenance Kit No. AH0002010:

Figure

Number

Name

010 Pilot Silencer (SS)

011 Silencer (SL)

012 Silencer (F)

015 Valve Gasket

055 Vane

056 Vane/Lift Spring

070 Air Motor Gasket

071 Silencer M CP

073 Bearing (6010)

085 O-Ring (P-100)

Parts per hoist

TCK3000/6000 Valve Maintenance Kit No. AH0002020:

Figure

Number

Name

022 O-Ring (S-7)

023 O- Ring (S-20)

024 O- Ring (S-30)

025 O- Ring (S-32)

026 O- Ring (AS568-115)

027 O- Ring (AS568-113(HS90))

304 O- Ring (S-25)

305 O- Ring (AS568-134)

336 O- Ring (S-29)

Parts per hoist

TCK3000/6000 Brake Maintenance Kit No. AH0002040:

Figure

Number

Name

157 O-Ring ( AS568-255)

228 O-Ring (S-7)

229 O-Ring (S-135)

230 O-Ring (S-145)

231 O-Ring (AS568-242)

Parts per hoist

Part Number

TCK137402055

TCK137402056

TCK137402057

TCK136102171

TCK137102036

TCR130802235

TCK136102172

TCK425806K0B

TCK130104011

TCK131101068

Part Number

TCR131103005

AH131103016

TCR131103024

TCR131103026

TCK131117115

TCK131118113

TCK131103020

TCK131117134

TCR131103023

Part Number

TCK131117255

TCR131103005

TCR131103063

TCK131103065

TCK131117242

This Page Intentionally Left Blank

Harrington Hoists, Inc.

401 West End Avenue

Manheim, PA 17545

www.harringtonhoists.com

Toll Free: 800-233-3010

Phone: 717-665-2000

Fax: 717-665-2861

TCKOM

Hello! I am an AI chatbot specifically trained to assist you with the Harrington TCK Owner's Manual. I have thoroughly reviewed the document and can help you locate the exact information you need or explain the content in clear and simple terms. Whether you’re looking for guidance on specific features, troubleshooting steps, or general usage, feel free to ask your questions. The more details you provide about your concerns or needs, the more accurately and effectively I can assist you!

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Owner’s Manual

AIR

POWERED

CHAIN HOIST

TCK SERIES

3 Ton and 6 Ton Capacity

WARNING

Table of Contents

Section Page Number

Section Page Number

1.0 Important Information and Warnings

1.1 Terms and Summary

NOTICE

CAUTION

WARNING

DANGER

NOTICE

1.2 Warning Tags and Labels

2.0 Technical Information

2.1 Specifications

2.2 Dimensions

2.3 Part Names

3.0 Preoperational Procedures

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 Exhaust Control

3.8 Mounting Location

3.9 Connecting Hoist to Air Supply

3.10 Mounting the Hoist

3.11 Optional Chain Container

3.12 Non-Stationary Application

3.13 Preoperational Checks and Trial Operation

4.0 Operation

4.1 Introduction

DANGER

WARNING

NOTICE

4.2 Shall’s and Shall Not’s for Operation

WARNING

CAUTION

4.3 Hoist Controls

4.4 Adjusting the Controls

4.5 Operation of the Load Limiter

5.0 Inspection

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

6.1 Air Hoist Lubrication

6.2 Load Chain Lubrication

6.3 Hooks and Suspension Components

7.0 Maintenance and Handling

7.1 Load Limiter

7.2 Brake

7.3 Load Chain

7.4 Pendant

7.5 Load Sheave Inspection

7.6 Storage

7.7 Outdoor Installation

7.8 Operational Environment

8.0

Troubleshooting

WARNING

9.0 Warranty

1 year

– Electric and Air Powered Hoists (excluding (N)ER2 Enhanced Features Models,

EQ / SEQ Hoists), Powered Trolleys, Powered Tiger Track Jibs and Gantries, Crane

Components, Spare / Replacement Parts, Below-the-Hook and Material Handling

Equipment

2 years – Manual Hoists & Trolleys, Beam Clamps

3 years – (N)ER2 Enhanced Features Model Hoists, EQ / SEQ Hoists, RY Wire Rope Trolley

Hoists