KITO TCR Series User manual

Owner’s Manual
AIR
POWERED
CHAINHOIST
TCRSERIES
¼ tonne through 6 tonne Capacity
Code Number and Serial Number
BULLETIN NO. TCROM-0913-04
This equipment should not be installed, operated or
maintained by any person who has not read and understood
all the contents of this manual. Failure to read and comply
with the contents of this manual can result in serious bodily
injury or death, and/or property damage.


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………………………………………………………………………...19
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……………………………………………………………………………………………. 28
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

3
Table of Contents
Section Page Number
5.0 Inspection…………………………………………………………………………………………….33
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…………………………………………………………………………………………... 40
6.1 Air Hoist Lubrication
6.2 Load Chain Lubrication
6.3 Hooks and Suspension Components
7.0 Maintenance & Handling……………………………………………………………………………41
7.1 Load Limiter
7.2 Brake
7.3 Load Chain
7.4 Load Sheave
7.5 Pendant
7.6 Storage
7.7 Outdoor Installation
8.0 Troubleshooting…………………………………………………………………………………….. 49
9.0 Parts List…………………………………………………………………………………………….. 52
10.0 Warranty

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 stronglyrecommended 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 imminentlyhazardous 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.
WARNING!
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 industrystandards, and with all applicable federal, state and local regulations/codes.
This manual includes instructions and parts information for a varietyof hoist types. Therefore, all instructions and
parts information maynot applyto 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.

5
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 necessaryand/or
required safety devices applicable to the system, crane, or application are installed bythe system designer, system
manufacturer, crane manufacturer, installer, or user.
Modifications to upgrade, derate, or otherwise alter this equipment shall be authorized only by the original equipment
manufacturer.
Equipment described herein maybe used in the design and manufacture of cranes or monorails. Additional
equipment or devices maybe 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 material mayrequire 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 anyone of the limitations noted herein can result in serious bodilyinjuryor death,
and/or property damage.

6
DANGER!
HAZARDOUS AIR PRESSURE IS PRESENT IN THE HOIST, INTHE SUPPLY OF COMPRESSED AIR TO THE
HOIST, AND IN THE CONNECTIONS BETWEEN COMPONENTS.
Before performing ANYmaintenance 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!
Itis the responsibilityof the owner/user to install, inspect,test, maintain, and operate a hoistin accordance with
ANSI/ASME B30.16 regulations. If the hoist is installed as part of a totallifting 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 responsibilityof the owner/user to have all personnel that will install, inspect, test,maintain, and operate a
hoist read the contents of this manualand applicable portions of ANSI/ASME B30.16 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 equipmentmust also be read byall personnel.
If thehoist owner/userrequires additionalinformation,or if anyinformationin 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 actualsize.
front back
Figure 1-1 Warning Tag Attached to Air Hoist

8
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:
92 dba maximum @ 1 meter when lifting rated load
95 dba maximum @ 1 meter when lowering rated load
Supply Air:
60 to 90 pounds per square inch
Air Consumption:
30 to 90 cubic feet minute
Air Lubrication Requirements:
Minimum 10 to 15 drops per minute (2-3 cc/min) of oil
Air Filtration Requirements:
Maximum 5 micronair filter or finer
Load Limiter:
Adjustable; Factory set to 125% of rated capacity

9
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
5 ft of Lift
(lbs)
No Load
w/Full Load
No Load
w/Full Load
Pendant Model
¼
TCR250M
6
6
55 / 41
26 / 54
32 / 25
28 / 28
4 x 1
24
---
¼
TCR250P
10
6
55 / 41
27 / 54
32 / 25
25 / 28
4 x 1
19
4
½
TCR500P
6
62 / 43
33 / 53
60 / 49
49 / 57
6.3 x 1
68
4
1
TCR1000P2
6
31 / 21
16/ 26
60 / 49
49 / 57
6.3 x 2
78
8
1
TCR1000P
6
34 / 21
19 / 30
60 / 53
49 / 60
7.1 x 1
75
5
2
TCR2000P2
6
17 / 10
10 / 15
60 / 53
49 / 60
7.1 x 2
88
10
3
TCR3000P
6
17 / 10
9 / 13
88 / 64
67 / 71
11.2 x 1
152
11
6
TCR6000P2
6
8 / 5
5 / 7
88 / 64
67 / 71
11.2 x 2
198
22
Cord Model
¼
TCR250C
10
6
61 / 45
29 / 57
35 / 28
28 / 32
4 x 1
15
4
½
TCR500C
6
62 / 43
33 / 53
63 / 49
49 / 57
6.3 x 1
66
4
1
TCR1000C2
6
31 / 21
16 / 26
63 / 49
49 / 57
6.3 x 2
76
8
1
TCR1000C
6
34 / 21
19 / 30
62 / 53
49 / 60
7.1 x 1
73
5
2
TCR2000C2
6
17 / 10
10 / 15
62 / 53
49 / 60
7.1 x 2
86
10
3
TCR3000C
6
17 / 10
9 / 13
90 / 64
67 / 71
11.2 x 1
150
11
6
TCR6000C2
6
8 / 5
5 / 7
90 / 64
67 / 71
11.2 x 2
196
22
2.2 Dimensions
Table 2-2 Top and Bottom Hook Dimension*
Units = inch
Product Code
a
b
c
d
e
f
g
h
TCR250C/P/M
0.8
0.8
0.6
0.8
1.4
1.7
0.9
2.9
TCR500C/P
1.4
0.9
1.1
0.9
1.6
1.6
1.1
4.2
TCR1000C/P2
1.4
0.9
1.1
0.9
1.6
1.6
1.1
4.2
TCR1000C/P
1.4
0.9
1.1
0.9
1.6
1.6
1.1
4.2
TCR2000C/P2
1.8
1.2
1.5
1.2
1.8
2.0
1.1
4.9
TCR3000C/P
2.0
1.5
1.7
1.3
2.0
2.4
1.3
5.9
TCR6000C/P2
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.

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Table 2-3 TCR with Pendant Control Dimensions
Cap.
(Tons)
Product
Code
Headroom
C
(in)
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
(in)
i
(in)
j
(in)
1/4
TCR250P
12
11.3
4
4.4
6.9
0.9
2.8
1.3
0.7
1/2
TCR500P
18.2
13.4
6.9
6.1
6.6
1.1
4.9
2.0
1.3
1
TCR1000P2
20.4
13.4
7.3
6.1
6.6
1.1
5.9
1.5
2.2
1
TCR1000P
18.3
13.4
6.9
6.1
6.6
1.1
4.9
2.0
1.3
2
TCR2000P2
21.8
13.4
7.6
6.1
6.6
1.1
6.0
1.6
2.3
3
TCR3000P
22.2
17.7
8.9
8.0
9.0
1.3
1.9
6.9
1.7
6
TCR6000P2
26.5
17.7
11.1
8.0
9.0
1.7
2.5
2.5
3.4
Single Fall Hoist Double Fall Hoist
Figure 2-1 Pendant Model TCR (See Table 2-3)

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Table 2-4 TCRwith Cord Control Dimensions
Cap.
(Tons)
Product
Code
Headroom
C
(in)
a
(in)
b
(in)
d
(in)
e
(in)
g
(in)
h
(in)
i
(in)
j
(in)
k
(in)
1/4
TCR250C
12
11.3
4
4.4
6.9
0.9
2.8
1.3
0.7
4
1/2
TCR500C
18.2
13.4
6.9
6.1
6.6
1.1
4.9
2.0
1.3
8.3
1
TCR1000C2
20.4
13.4
7.3
6.1
6.6
1.1
5.9
1.5
2.2
8.3
1
TCR1000C
18.3
13.4
6.9
6.1
6.6
1.1
4.9
2.0
1.3
8.3
2
TCR2000C2
21.8
13.4
7.6
6.1
6.6
1.1
6.0
1.6
2.3
8.3
3
TCR3000C
22.2
17.7
8.9
8.0
9.0
1.3
1.9
6.9
1.7
8.3
6
TCR6000C2
26.5
17.7
11.1
8.0
9.0
1.7
2.5
8.7
3.4
8.3
Single Fall Hoist Double Fall Hoist
Figure 2-2 Cord Model TCR (See Table 2-4)

12
Figure 2-3 Dimensions for Manipulator TCR250 Air Hoist (inches)

13
2.3 Part Names
Figure 2-4 Hoist Part Identification Diagrams TCR500P, 500C, 1000P, 1000C

14
Figure 2-5 Hoist Part Identification Diagrams TCR 1000P2, 1000C2, 2000P2, 2000C2

15
Figure 2-6 Hoist Part Identification Diagrams TCR 3000P, 3000C
Figure 2-7 Hoist Part Identification Diagrams TCR 6000P2, 6000C2

16
Top hook
Bottom hook
Figure 2-8 Hoist Part Identification Diagrams TCR250C

17
Top hook
Bottom hook
Figure 2-9 Hoist Part Identification Diagrams TCR250P

18
Top hook
Bottom hook
Figure 2-10 Hoist Part Identification DiagramsTCR250M

19
3.0 Preoperational Procedures
3.1 Air Supply System Requirements
3.1.1 NOTICE! Pressure and Flow - Verifythat the air supplysystem has capacityto supply your air
hoist with required pressure and flow. Otherwise the hoist may operate poorly or mayfail to operate.
See Section 3.2.
3.1.2 CAUTION! Lubrication - The hoist requires lubrication for proper operation. The oil in the air
supplyis the primary source of lubrication to the hoist. Therefore, a dedicated air supplylubricator must
be used with the hoist. Refer to Section 3.3.
3.1.3 CAUTION! Air Quality - Good air quality is essentialto 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 supplysystem must be capable of delivering the required airflow(cfm) to the hoist
inlet port. Without the required airflow the hoist willnot operate properlyor maynot 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 supplyof air at a pressure of between 60 and 90 psi. If the
airsupplyis notregulated or is regulated ata pressure greater than 90psi,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! The hoist must be supplied with its own lubricator. The lubricatormust 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 awayfrom 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 awaybelow the hoist. In this case the mist type
lubricator must be used.
3.3.2 CAUTION! The lubricator must be set to deliver the equivalent of 10 to 15 drops of oilper minute
(2 to 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 inletmust 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.

20
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 mayresult if the system is
not periodicallydrained.
Arrange for a drain in the air supply piping at the lowest point in the piping, and
Periodicallydrain the system to removemoisture/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 SupplyConfiguration (Typical)
Figure 3-2 Typical Air SupplyFilter, Regulator and Lubricator.