KITO TCL Series User manual

Owner’s Manual
LUBRICANTFREE
AIRPOWERED
CHAINHOIST
TCLSERIES
¼, tonne through 1 tonne Capacity
WARNING
Code, Lot and Serial Number
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.
EFFECTIVE: April 1, 2020

2
Table of Contents
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 Pre-operational Procedures………………………………………………………………………....13
3.1 Air Supply System Requirements
3.2 Air Supply Capacity And Regulation
3.3 Lubrication
3.4 Air 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……………………………………………………………………………………………. 24
4.1 Introduction
4.2 Shall’s and Shall Not’s for Operation
4.3 Hoist Controls
4.4 Adjusting the Controls
4.5 Speed Adjustment Controls
4.6 Pendant Controllability Adjustment

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Section Page Number
5.0 Inspection………………………………………………………………………….…………………30
5.1 General
5.2 Inspection Classification
5.3 Preoperation Inspection
5.4 Frequent Inspection
5.5 Periodic Inspection
5.6 Occasionally Used Hoists
5.7 Inspection Records
5.8 Inspection Methods and Criteria
6.0 Lubrication…………………………………………………………………………………………... 38
6.1 Air Hoist Lubrication
6.2 Load Chain Lubrication
6.3 Hooks and Suspension Components
7.0 Maintenance & Handling……………………………………………………………………………40
7.1 Brake
7.2 Load Chain
7.3 Pendant
7.4 Pull Cord
7.5 Load Sheave Inspection
7.6 Storage
7.7 Outdoor Installation
7.8 Operational Environment
8.0 Troubleshooting…………………………………………………………………………………….. 48
9.0 Warranty…………………………………………………………………………………………….. 50
10.0 Parts Information…………………………………………………………………………………….51

4
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 animminently 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
Caution indicates a potentially hazardous situation which, if not avoided, may result minor or
moderate injury or property damage.
NOTICE
Notice is used to notify people of installation, operation, or maintenance information which is
important but not directly hazard-related.
NOTICE
These general instructions dealwith 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, provincial 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 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 KITO authorized replacement parts in the service and maintenance of this hoist.

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!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 shallbe 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 used 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 materialmay require additional equipment or devices. Refer to
ASTM-E-2349, “Standard for Safety Requirements in Metal Casting: Sand Preparation, Molding, and Core Making;
Melting and Pouring; and Cleaning and Finishing”.
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.

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!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 de-energized 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”, OHS 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 tohave 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 OHS Regulations. If the hoist is installed as part of a total lifting system, such as an overhead crane, the
applicable ANSI/ASMEB30 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 KITO 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.

7
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 Air Hoist

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2.0 Technical Information
2.1 Specifications
2.1.1 Product Code
2.1.2 Operating Conditions and Environment
Temperature range:
-10° to +60°C (+14° to +140°F)
Relative Humidity:
85% or less
Noise Level:
83 dba maximum @ 1 meter when lifting rated load
93 dba maximum @ 1 meter when lowering rated load
Supply Air:
60 to 90 psi (0.4 to 0.6 MPa)
Air Consumption:
60 to 75 cfm (1.7 to 2.1 m³/min)
Air Filtration Requirements:
Maximum 5 micron air filter or finer
Air Lubrication Requirements:
Minimum 10 to 15 drops per minute (0.2-0.3 cc/min) of oil

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Table 2-1 Hoist Specifications
Cap.
tonne
Product
Code
Standard
Lift
(ft)
Push
Button
Hose
L
(ft)
Up/Down Speeds
(ft/min @ 90 psi)
Up/Down
Air Consumption Rates
(cubic ft/min @ 90 psi)
Load Chain
Diameter
(mm)
x
Chain Fall
Lines
Net
Weight
(lbs)
Weight for
Additional
One foot
of Lift
(lbs)
No Load
w/Full Load
No Load
w/Full Load
Pendant Model
1/4
TCL250P
10
8.1
151 / 105
85 / 144
64 / 57
57 / 64
6.3 x 1
46
0.6
1/2
TCL500P
10
8.1
79 / 53
43 / 79
64 / 57
57 / 64
6.3 x 1
46
0.6
1
TCL1000P2
10
8.1
39 / 26
21 / 39
64 / 57
57 / 64
6.3 x 2
60
1.2
Cord Model
1/4
TCL250C
10
8.1
151 / 105
85 / 144
64 / 57
57 / 64
6.3 x 1
44
0.6
1/2
TCL500C
10
8.1
79 / 52
43 / 79
64 / 57
57 / 64
6.3 x 1
44
0.6
1
TCL1000C2
10
8.1
39 / 26
21 / 39
64 / 57
57 / 64
6.3 x 2
58
1.2

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2.2 Dimensions
Table 2-2 TCL with Pendant Control Dimensions
Single Fall Hoist
Double Fall Hoist
Cap.
tonne
Product
Code
Headroom
C
(in)
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
(in)
i
(in)
j
(in)
1/4
TCL250P
16.3
14.4
6.6
6.4
8.0
1.0
4.4
2.2
1.0
1/2
TCL500P
16.3
14.4
6.6
6.4
8.0
1.0
4.4
2.2
1.0
1
TCL1000P2
18.0
14.4
9.0
6.4
8.0
1.1
6.3
2.7
1.9

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Table 2-3 TCL with Cord Control Dimensions
Single Fall Hoist
Double Fall Hoist
Cap.
tonne
Product
Code
Headroom
C
(in)
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
in)
i
(in)
j
(in)
1/4
TCL250C
16.3
14.4
8.7
6.4
8.0
1.0
5.3
3.3
1.0
1/2
TCL500C
16.3
14.4
8.7
6.4
8.0
1.0
5.3
3.3
1.0
1
TCL1000C2
18.0
14.4
9.0
6.4
8.0
1.1
6.3
2.7
1.9
Table 2-4 Top and Bottom Hook Dimension*
Units = inch
Product Code
a
b
c
d
e
f
g
h
TCL250C/P
0.6
0.8
0.6
0.8
1.4
1.3
1.0
2.9
TCL500C/P
0.6
0.8
0.6
0.8
1.4
1.3
1.0
2.9
TCL1000C2/P2
1.4
0.9
1.1
0.9
1.6
1.6
1.1
4.2
*Refer to Section 5.7 for inspection dimensions and limits.

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2.3 Part Names
Figure 2-1 Hoist Part Identification Diagrams –TCL250C/P and TCL500C/P
Figure 2-2 Hoist Part Identification Diagrams –TCL1000C2/P2

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3.0 Preoperational Procedures
3.1 Air Supply System Requirements
3.1.1
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.
3.1.2
!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.
3.1.3 This hoist is equipped with a lube-free vane motor that does not require lubrication of the supply air for
operation. However, if the hoist supply air is lubricated, there is no disadvantage. For further
information, see Section 3.2.
3.2 Air Supply Capacity And Regulation
3.2.1 Capacity - The air supply system must be capable of delivering the required airflow volume (cfm) to the
hoist inlet port. Without the required airflow volume 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 notregulated 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 air supply to the hoist (or lubricator if
installed).
3.3 Lubrication
3.3.1
!CAUTION
The TCL hoists do not require supply air lubrication for safe operation; however if
the hoist supply air is lubricated, there is no disadvantage.
3.3.2 If using lubrication, follow the guidelines below for best results. The lubricator must be located as
follows:
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.
3.3.3
!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.

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3.4 Air 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. If using a lubricator,
the filter must be upstream.
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.
3.4.3 It is highly recommended to use a filter with automatic draining capability, to prevent excessive
moisture accumulation.
3.5 Air Dryer -
!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.
◼Arrangefor a drain in the air supply piping at the lowestpoint in the piping, and
◼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)

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Figure 3-2 Typical Air Supply Filter with auto drain, Regulator,
and Lubricator (if included).
3.6.2
NOTICE
Piping - Pipe should be sized to accommodate the hoist airflow requirements.
Table 3-1 gives recommended pipe sizes.
Table 3-1 Air Supply Pipe and Hose Sizes
Model
Diameter of Supply Pipe
Diameter of Supply Hose
TCL250C/P
TCL500C/P
TCL1000C2/P2
Inside diameter
3/4” or larger
Inside diameter
1/2” 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.

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Figure 3-3 Typical Arrangements of Filter, Regulator and Lubricator and
Maximum Air Supply Hose Lengths
3.6.4
!CAUTION
Fittings - Important considerations regarding fittings in the hoist's air supply
include:
◼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.
3.6.5
!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.

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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 it 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.
3.8.2 For applications requiring a “Secondary Restraint” a “hole” has been provided in the hoist Top Hook
Yoke. Reference Figure 3-5.

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Figure 3-5 Hoist “Secondary Restraint” 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.
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”.
Figure 3-6 Air Supply Connection to Hoist –Cord or Pendant Models
3.9.3
!CAUTION
Before connecting the air supply hose to the hoist, always purge the air hose to
clear any debris and water.

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3.9.4 Make connections to air supply; reference Figure 3-6. Use a reducing adapter at the hoist valve
section for hose sizes larger than 1/2”.
3.9.5
NOTICE
Where conditions dictate, the installation sequence can be reversed by
mounting the hoist first followed by connecting the air supply.
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 Follow instructions below to install the optional chain container. Refer to Figure 3-7.
1) Attach the metal bracket on top of the chain container to the lower boss on the side of the hoist body
using the M8 Socket Bolt, Washers, Nut and Split Pin provided.
2) Attach the support chain to the upper boss on the side of the hoist body using the M6 Socket Bolt,
Washers, Nut and Split Pin provided.
3) Make sure all fasteners on the chain container and chain attachment points are secure and that the
split pins are sufficiently bent.
4) Feed the Chain into the Chain Container beginning with the no-load end. Take care to avoid twisting or
tangling the Chain.
5)
!CAUTION
Do not use the Chain Container if any parts are damaged or if any
fasteners/hardware are missing.

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Figure 3-7 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-to-
place, a filter and lubricator are still required. Consult factory for recommended methods.
3.12.2 Connections and fittings must be kept clean and care taken to prevent dirt, debris and moisture from
entering the hoist.
3.12.3 Recommended practice for removing the hoist from an installation:
1) Verify the hoistoperates correctly by running the hoist briefly (with well lubricated air, if desired),
notingany malfunctions or abnormal noises.
2) Shut off the air supply to the hoist, bleed off any pressure in the system then disconnect the air
supply line.
3) Inject a small quantity (approximately 20 drops) of turbine oil (see Section 6.0) into the hoist’s inlet
port
4) 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 load chain irregularities before conducting the first hoist
operation. See Figures 3-8 and 3-9.