Toku TCR Series User manual

AIR HOIST
TCR-250C
TCR-250DP
TCR-250DPE
TCR-250M
TCR-250ME
TOKU PNEUMATIC PRODUCTS
INSTRUCTION MANUAL
Carefully read all instructions before operating
or servicing any TOKU Products.
TOKU PNEUMATIC CO., LTD.
No.3
18-07
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au
www.air-allied.com.au

1
（１）Introduction
We thank you for your recent purchase of a TOKU CHAIN HOIST
This manual is a guide book which will show you how to use the air chain hoist safely and efficiently.
Please read this manual in its entirety and understand the contents before proceeding to operate the hoist.
Also convey this information to the actual operators of the hoist.
The air chain hoist was designed to operate on compressed air to lift and lower loads. As a result before
operating the hoist it is necessary to also read the instruction manual for the compressor. In addition, for
proper regulations about usage of the hoist, consult the “crane safety regulation standards “
Usage other than the ones written in this manual should be performed with the consideration of safety and
responsibility.
◆With regards to the safety precautions, the following words are used to identify safety messages in the
manual.
WARNING; This word is used on safety messages and labels where a potential
dangerous situation could result in serious injury or death if the hazard is
not avoided.
CAUTION; This word is used in safety messages and on labels for hazards which
couldresult in minor or moderate injury if the hazard is not avoided.
IMPORTANT; This word may indicate hazards whose result could be damage to the
equipment.
◆ Keep this manual handy and read it periodically
◆ If this manual is lost or becomes dirty, ask for a replacement manual from Air & Allied Sales (Pacific) P/L.
◆ If the hoist is not used by one person, please have the new person read this manual before operating the
hoist.
◆ If you transfer the hoist to another source, make sure that you give the manual to the new owner.
※（Designs and Specifications are subject tochange without prior notice）
If you have any questions about the hoist or this instruction manual, please contact Air & Allied Sales (Pacific)
Pty Ltd (see below for contact details).
PLEASE UNDERSTAND THE FOLLOWING POINTS BEFORE READING THIS MANUAL;
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

2
（２）Table of Contents
Page
（１）Introduction ……………………………………………………………………………… １
（２）Table of Contents ……………………………………………………………………… ２
（３）Safety Precautions …………………………………………………………………… ３

（４）Precautions during Operation ……………………………………………………… ５

（５）General Precautions……………………………………………………………… ９

（６）Specifications …………………………………………………………………………１１

（７）Name of Parts ………………………………………………………………………… １１

（８）Accessories …………………………………………………………………………… １４

（９）Before Operation ……………………………………………………………………… １７

（１０）Preparation before Operation …………………………………………………………１８

（１１）How to Operate ………………………………………………………………………２２

（１２）Maintenance and Inspection ………………………………………………………２８

（１３）Troubleshooting ………………………………………………………………… ３０














[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

3
（３）Safety Precautions
WARNING
・When using the chain hoist, obey the safety precautions written in this instruction manual.
WARNING; Obey the safety rules at the job site.
・The people who operate the hoist should be the one who have received instruction to properly
operate the hoist.
・ Obey all rules, safety procedures and operational methods at the job sit
・When using the hoist with other people, make sure your signals during operation are well
discussed before jointly using the hoist.
WARNING; Wear proper clothing and safety protection.
・Wear proper clothing when operating the hoist.
・To protect the body, wear safety items such as a helmet, mask,
safety shoes and gloves. Or if the sound level is high, where ear
plugs.
・Do not wear a tie or loose fit clothing when operating the hoist. They
may get caught in the chain during operation.
WARNING; Safe operation begins with proper posture.
・It is dangerous to operate the hoist when your posture is not in balance. Make sure your footing is
proper and your body is stable when operating the hoist.
WARNING; Attach the hose properly.
・Make sure the hose socket is securely tight using a hose band.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

4
WARNING; Do not modify the hoist.
・Do not remove screws of covers which are on the hoist.
・Do not modify the hoist. This will lead to danger.
The responsibility will be yours if an accident occurs due to these modifications.
CAUTION; Do not use the chain or hook as an earth connection.
・During a weld operation, do not use the chain or hook as an earth connection. This may lead to
the cause of an accident or other damages.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

5
（４）Precautions during Operation
WARNING; Do not depress the pendant lever unnecessarily.
・ Make sure the conditions are correct before operating the hoist. Under poor conditions, the load
may fall onto the floor or the load may fall onto the operator. It is very dangerous.
WARNING; Before operating the hoist, reconfirm the safety issues with
the operators and the personal involved.
・Check the operating position and footing before operating the hoist. Make sure the surrounding
personnel are safe and make sure everyone is aware of the signals when operating the hoist.
WARNING; Check the slings and hook safety claw before using the hoist.
・ Make sure the sling is connected correctly before lifting. Also make sure the hook safety claw is
working correctly. If it is used in poor conditions, this may lead to removal of the sling and the load
may fall.
WARNING; Before using the hoist, make sure the chain is not twisted.
・As shown in the diagram, make sure the chain is not twisted during usage of the hoist.
If the chain is twisted, this will lead to jamming and also possible breakage of the chain.
・Depressing the pendant lever will start
operation of the hoist and releasing will
stop the hoist.
・Pulling the cord will start the hoist and
releasing the hoist will stop the hoist.
twisted
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

6
WARNING; Do not over load the hoist.
・ Before lifting the load, confirm that the load is within the rated load of the hoist.
The hoist or chain may break and the load may fall and this is very dangerous.
WARNING; Make sure the load is
balanced.
・ When using a wire rope or a sling, make sure the load is
balanced before lifting. The load may fall and it is
dangerous.
WARNING; Do not lift / lower suddenly.
・When suddenly lowering the load, this may lead to poor
balance of the load and the load may fall.
WARNING; Do not use the hoist to lift
people.
・The hoist is used to lift loads. Never lift people using the
hoist. This is very dangerous.
WARNING; Do not leave the job site.
・Do not leave the job site when a load is in suspension.
Always lower the load and un-load the load before departing.
WARNING; Do not operate the hoist
under
the load.
・Make sure you are away from the load when operating the
hoist.
It is dangerous if the load falls.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

7
WARNING; Use agreed upon signals when working with a partner.
・ When using the hoist jointly with another person, use signals agreed at the job site and obey them
during a joint operation.
WARNING; Do not touch the hoist, under hook area and chain during
operation of the hoist.
・ It is dangerous if your hand gets caught in these areas.
WARNING; Do not touch the hoist after operation.
・ After operating the hoist, do not touch the hoist. After operation, the hoist may become hot. Please
let the hoist cool before touching.
WARNING; Do not use the limiter to stop the hoist all the time.
・ This mechanism is a safety device. The limiter for over lifting and over lowering will operate
continuously using this device may lead to an accident and it is not recommended to use it
continuously.
CAUTION; Do not pull or use the hoist sideways.
・The hoist was designed to be used in the vertical direction. Using the hoist in the horizontal
direction is not recommended and may result in an accident or premature wear of parts.
CAUTION; Do not suddenly change the direction of the hoist.
・ Suddenly changing the direction of the hoist will shock certain areas of the hoist and may cause
breakage of parts or lead to an accident.
CAUTION; Do not pull on the pendant hose or cords when trying to
move the hoist.
・This will lead to damage to the hose and may cause the hoist to malfunction.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

8
IMPORTANT; Avoid operating the hoist with no load for extended
periods.
・This may lead to damage to the internal parts of the motor or premature wear of these parts.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

9
（５）General Precautions
CAUTION; Keeping the area tidy is the first step to safety.
・Keeping the job site tidy is the first step to a safe environment. Keep the facility clean and neat at
all times.
WARNING; Do not allow unauthorized staff near the hoist area.
・Do not allow unauthorized staff near the hoist area.
Especially children.
WARNING; Difficult operations will lead to accidents.
・Do not use the hoist for operations over its capacity. These operations may lead to damage of the
hoist and should be avoided.
WARNING; Stop operating the hoist if trouble is detected.
・When operating the hoist if trouble is found, immediately stop operating the hoist and inspect or
repair.
WARNING; Handle the hoist with care.
・Do not drop or hit the hoist externally. This will lead to cracks and damage to the hoist. Also, do
not stamp or engrave information directly onto the hoist. If a crack develops, and air is leaking
through the crack, do not operate the hoist.
IMPORTANT; Good Maintenance will extend the life of your hoist.
・Keep a good maintenance program for the hoist and keep it clean
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

10
WARNING; Periodic inspection of the hoist is the basics to safety.
・Periodic inspection of the hoist will allow your hoist to operate smoothly and safely.
Referring to the crane safety standards, daily and monthly inspection programs should be
performed.
CAUTION; For inspection or repair of the hoist, consult your dealer.
・Contact your dealer for repairs or inspections of the hoist. When parts are needed to be changed,
use only genuine TOKU parts.
CAUTION; Storage must be considered carefully.
・Store the hoist away from children in a dry area. When storing the hoist for a longer period of time,
to prevent internal rust, apply 3 cc of lubrication into the air hose and operate the hoist for 3-4 sec.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

11
（６）Specifications
１．Operation Conditions
①Operating Air pressure： 0.4 MPa～0.6MPa ≪ ≫Recommended 0.6MPa
②Operating Ambient Temp. range： -10℃～60℃ ≪ ℃≫Recommended 20
③Operating location： Inside
④Applications： For vertical lifting loads
２．Specifications
Model Operating
type
Capacity
kg
Air
Pressure
MPa
(kgf/cm2)
Lifting Speed
with rated load
m/min
Air cons.
m3/min
Std.
Lift
m
Air
Inlet
Weight
(inc. chain)
kg
TCR-250C Code
250 0.4～0.6
（4～6）
9 0.8 3
3/8
7
TCR-250DP Pendant 8.1 0.7 3 8.6
TCR-250M,ME Pendant 8 0.7 2 11
※Lifting speed is measured at 0.6 Mpa with rated load. 2 meters pendant hose is used for DP type.
※DPE type is 3 kg heavier than DP type. The other values are the same.
※ Above speed is subject to change depending on weigh of load, air pressure, length of pendant
hose and air hoses.
（７）Name of Parts
TCR-250C
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

12
TCR-250DP
TCR-250DPE
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

13
TCR-250M, ME
TCR
-
250ME
TCR
-
250M
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

14
（８）Accessories
1． Code Assembling （TCR-250C）
Assemble the code as shown in diagram below.
２．Pendant hose assembling (TCR-250DP)
Mount boot on urethane hoses at first. Connect each hoses as shown in the diagram below. Then fit the
boot. Assemble pendant chain to both pendant and air hoist.
Make sure that all the hose are connected properly.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

15
３．Pendant hose assembling (TCR-250DPE)
４．Coil hose assembling TCR-250M,ME
Attach tubes and Hose Support as shown in the diagram below.
Make sure to attach each tube securely to correct part.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

16
５．Chain installation
・Suspend air hoist to check and learn how to operate them in slow speed.
・Attach steel wire to the end of chain and lead them through chain passage.
・Pulling the steel wire, slowly operate air hoist and install chain
WARNING：
・ When connecting chain end to air hoist, or when leading chain through hook case, make sure
that the chain is not twisted. Otherwise the chain will break and may result in injury.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

17
（９）Before Operation
１． Piping
CAUTION; Always install air filter, regulator and lubricator (Line Oiler)
near the hoist.
・The operating air pressure is 0.4～0.6Mpa ≪Recommended 0.6MPa≫
Operating at air pressures above 0.4～0.6Mpa will effect the durability, performance and safety of the
hoist. As a result, it is important to consider the pressure for the air compressor, volume and piping
aspects to operate the hoist at its best level.
※ Please note the air pressures stated above are actual operating air pressures and not the air
pressure when the hoist is not operating, which is normally slightly lower. As a result, always check
the air pressure when the air hoist is operating.
２． Checking the operating air pressure
CAUTION; Maintain the correct air pressure.
・The operating air pressure is 0.4～0.6Mpa ≪Recommended 0.6MPa≫
Operating at air pressures above 0.4～0.6Mpa will affect the durability, performance and safety of the
hoist. As a result, it is important to consider the pressure for the air compressor, volume and piping
aspects to operate the hoist at its best level.
 Please note the air pressures stated above are actual operating air pressures and not the air
pressure when the hoist is not operating, which is normally slightly lower. As a result, always check
the air pressure when the air hoist is operating.
３． Lubrication
WARNING: Maintain correct lubrication.
・The lubricator (line oiler) in the air line will supply lubrication to the air motor.
Oil supply should be 10～15 drops/min. (0.2 - 0.3 cc)
・For the lifting chain, please apply industrial general-purpose lithium grease to the chain link (the part
each link is in touch). If air maintenance is not performed properly, this will lead to rust, malfunctioning
and premature wear of the internal parts, and this may result in personal injury.
・Lubrication to the reduction gears is not needed on a daily basis. Grease up when the hoist is
disassembled.
Lubrication
Type Grade Location Method
Turbine Oil ISO VG32～56
Or equivalent
Air Motor Line Oiler
Chain
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

18
（１０）Preparation before Operation
・Selection of the compressor and drain removal
・Method of selection; ( Air Consumption for each hoist is shown on Page 11)
( Air consumption × 10 ) × Hoist Quantity  Compressor Horse Power
・Method of drain removal
Rust will develop leading to the cause of trouble if the drain is not removed from the compressor.
Remove the drain at the bottom of the air tank on your compressor. Remove excess water and oil.
Supply clean dry air to the hoist. (Refer to the compressor manual for details）
１． Air hose
Prepare collect hoses for air hoist
TCR-250C
Internal diameter
9.5mm or larger
TCR-250DP
TCR-250M
CAUTION： We recommend to keep the hose length within 10 meters.
・ When the hose length exceeds 10 meters, choose larger hose in order to minimize the pressure
loss.
IMPORTANT： Always clean up connecting part before connecting.
・ Foreign material causes troubles.
２． Piping
Refer to the diagram below for piping or installation. The main and secondary pipes should be larger
than the air hoist hose size. It the main or secondary pipe is smaller in diameter or too long, you will
experience pressure drop and this will reduce the performance of your hoist.
Secondary pipe
Drain outlet
Filter
Compressor
Filter
To allow the pipe to drain add
a 1/100 or greater slope to
the pipe.
Main Pipe
Oiler
To Air Hoist
Regulator
Drain outlet
Air outlet
Proper Piping Drawing
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

19
３． Check the strength of the beam before installing the hoist.
WARNING： Before installing the hoist to the beam make sure the safety
factor is met.
・ Before installing the Air hoist to the beam, make sure the rated load for the beam exceeds the
rated load for the air hoist with the proper safety factor. If the rated load of the beam does not
exceed the rated load of the air hoist, please do not install the air hoist to this location.
４． Installation of Air Hoist
① Attach code or tubes as shown in diagram on page 14 and 15.
② Insert hose until it reaches to hex part of hose nipple.
Secure it by hose band.
③ Apply Turbine oil (ISO VG32-56) 10 drops to hose nipple for first lubrication.
④ Attach hose nipple to air hose securely.
⑤ Mount air hoist onto beam.
WARNING： Make sure the upper hook is assembled correctly.
・ Make sure the upper hook is assembled to the recommended material and also make sure the
hook safety claw is securely locked.
[email protected]
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au