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

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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.

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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