TCR Operation and Parts

BULLETIN NO.
TCR-0210-PC-03
Owner’s Manual
AIR
POWERED
CHAIN HOIST
TCR SERIES
¼ tonne through 6 tonne 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.
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
2
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
3
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! 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 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 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.
4
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, derate, 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 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 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.
5
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 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 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 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.
6
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
7
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 micron air filter or finer
Load Limiter: Adjustable; Factory set to 125% of rated capacity
8
Table 2-1 Hoist Specifications
Up/Down Load Chain
Push Up/Down Speeds
Air Consumption Rates Diameter Weight for
Standard Button (ft/min @ 90 psi) Net
Cap. Product (cubic ft/min @ 90 psi) (mm) Additional
Lift Hose Weight
(tonne) Code x 5 ft of Lift
(ft) L (lbs)
No Load w/Full Load No Load w/Full Load Chain Fall (lbs)
(ft)
Lines
¼ TCR250M 6 6 54 / 42 41 / 47 31 / 26 28 / 27 4x1 24 ---
¼ TCR250P 6 55 / 43 42 / 48 31 / 26 28 / 27 4x1 16 4
½ TCR500P 6 68 / 44 37 / 57 63 / 49 48 / 57 6.3 x 1 68 4
Pendant Model
1 TCR1000P2 6 34 / 22 19/ 29 63 / 49 48 / 57 6.3 x 2 76 8

1 TCR1000P 10 6 37 / 22 21 / 33 62 / 53 53 / 60 7.1 x 1 74 5
2 TCR2000P2 6 19 / 11 11 / 16 62 / 53 53 / 60 7.1 x 2 87 10
3 TCR3000P 6 18 / 11 10 / 15 90 / 65 71 / 74 11.2 x 1 151 11
6 TCR6000P2 6 9/5 5/7 90 / 65 71 / 74 11.2 x 2 197 22
¼ TCR250C 6 61 / 45 47 / 51 34 / 28 32 / 30 4x1 17 4
½ TCR500C 6 68 / 44 37 / 57 63 / 49 48 / 57 6.3 x 1 68 4
Cord Model
1 TCR1000C2 6 34 / 22 19/ 29 63 / 49 48 / 57 6.3 x 2 76 8

1 TCR1000C 10 6 37 / 22 21 / 33 62 / 53 53 / 60 7.1 x 1 74 5
2 TCR2000C2 6 19 / 11 11 / 16 62 / 53 53 / 60 7.1 x 2 87 10
3 TCR3000C 6 18 / 11 10 / 15 90 / 65 71 / 74 11.2 x 1 151 11
6 TCR6000C2 6 9/5 5/7 90 / 65 71 / 74 11.2 x 2 197 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.
9
Table 2-3 TCR with Pendant Control Dimensions
Headroom
Cap. Product a b d e g h i j
C
(Tons) Code (in) (in) (in) (in) (in) (in) (in) (in)
(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)
10
Table 2-4 TCR with Cord Control Dimensions
Headroom
Cap. Product a b d e g h i j k
C
(Tons) Code (in) (in) (in) (in) (in) (in) (in) (in) (in)
(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)
11
Figure 2-3 Dimensions for Manipulator TCR250 Air Hoist (inches)
12
2.3 Part Names
Figure 2-4 Hoist Part Identification Diagrams TCR500P, 500C, 1000P, 1000C
13
Figure 2-5 Hoist Part Identification Diagrams TCR 1000P2, 1000C2, 2000P2, 2000C2
14
Figure 2-6 Hoist Part Identification Diagrams TCR 3000P, 3000C
Figure 2-7 Hoist Part Identification Diagrams TCR 6000P2, 6000C2
15
T op ho o k
B o tto m h o o k
Figure 2-8 Hoist Part Identification Diagrams TCR250C
16
Top hook
B o tto m h o o k
Figure 2-9 Hoist Part Identification Diagrams TCR250P
17
Top hook
B o tto m h o o k
Figure 2-10 Hoist Part Identification Diagrams TCR250M
18
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! 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.
3.1.3 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! The hoist must be supplied with its own lubricator. 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.
3.3.2 CAUTION! The lubricator must be set to deliver the equivalent of 10 to 15 drops of oil per 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 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.
19
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.
 Arrange for a drain in the air supply piping at the lowest point 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)
Figure 3-2 Typical Air Supply Filter, Regulator and Lubricator.
20
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
Diameter of Supply Diameter of Supply

Model
Pipe Hose
TCR250P, 250C, 500P, 500C, 1000P, 1000C Inside diameter Inside diameter
TCR1000P2, 1000C2, 2000P2, 2000C2 0.75 inch or larger 0.5 inch or larger
TCR3000P, 3000C Inside diameter Inside diameter
TCR6000P2, 6000C2 1.0 inch or larger 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.
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.
21
3.7 Mounting Location
3.7.1 CAUTION! 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.
3.7.2 NOTICE! See Section 7.6 for outdoor installation considerations.
3.8 Connecting Hoist to Air Supply

3.8.1 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 3-4 Typical Air Supply Connection
3.8.2 Shut off the air supply and stop the airflow completely. Perform Lockout /Tagout in accordance with
ANSI Z244.1 “Personnel Protection -Lockout/Tagout of Energy Sources”.
3.8.3 CAUTION! Before connecting the air supply hose to the hoist, always purge the air hose to clear
any debris and water.
3.8.4 Apply approximately 10-15 drops of turbine oil (see approved lubricant under Section 6.0 Lubricants)
into the hose before attaching to the hoist.
3.8.5 Make connections to air supply; reference Figure 3-4. Use a reducing adapter at the hoist valve
section for hose sizes larger than 1/2 inch.
3.8.6 CAUTION! Where conditions dictate, the installation sequence can be reversed by mounting the
hoist first (Section 3.9) followed by connecting the air supply (Section 3.8).
3.9 Mounting the Hoist
3.9.1 Manual Trolley - Follow instructions in Owner’s Manual provided with the trolley.
3.9.2 Hook Mounted to a Fixed Location - Attach the hoist’s top hook to the fixed suspension point.
3.9.3 NOTICE! Ensure that the fixed suspension point rests on the center of the hook’s saddle and
that the hook’s latch is engaged .
22
3.10 Optional Chain Container
3.10.1 For installation of the optional bag style chain container refer to Figure 3-5 below and perform the
following:
 Make sure all end stoppers and limit locks are installed correctly. See Sections 3.12 and 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 3-5 Optional Chain Container Installation
23
Method of Setting The Chain Basket For TCR250
 Put the basket arm into the housing front and fix them securely with the arm holder using bolts and nuts
as it is shown below.
 Set the chain basket on the basket arm as it is shown below.
3.11 Non-Stationary Application

3.11.1 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.
3.11.2 Connections and fittings must be kept clean and care taken to prevent dirt, debris and moisture from
entering the hoist.
3.11.3 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
24
3.12 Preoperational Checks and Trial Operation
3.12.1 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.
3.12.2 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 3-6 and 3-7.
Figure 3-6 Twist in Load Chain
Figure 3-7 Capsized Hook and Chain
25
3.12.3 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.
3.12.4 WARNING! For Models TCR500P&C, 1000P2&C2, 1000P&C and 2000P2&C2 verify the limit
locks are properly installed on the load chain. For reference see Figure 3-8 for hoist versions 1, A, B
and C and Section 7.3.2. For Models TCR-3000P&C and 6000P2&C2 verify that the chain/limit lever is
operational and can move freely in both the up and down directions. For reference see Figure 3-9.
Versions 1, A and B Version C Only

Figure 3-8 Limit Switch Components
Figure 3-9 Limit Switch Components
3.12.5 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.
3.12.6 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.
26
3.12.7 Ensure that the hoist is properly installed to either a fixed point, or trolley, whichever applies.
3.12.8 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.
3.12.9 Ensure that all nuts, bolts and split (cotter) pins are sufficiently fastened.
3.12.10 For hoists with pendant controls, ensure that the pendant's flexible hose is intact and is properly
attached to the hoist. Also ensure that the wire cable is properly attached to the hoist.
See Section 7.4.
3.12.11 CAUTION! Check Air Supply - Check air supply before everyday use. Ensure proper air quality
and air pressure.
3.12.12 CAUTION! Check the lubricator for proper function and adequate oil level.
3.12.13 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 ensure that nothing will interfere with the full range of the hoist’s (and trolley’s)
operation.
3.12.14 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”.
27
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.
28
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 lift more than rated load for the hoist. springs, shock absorbers, stoppers, striker plates or
limit locks.
• NOT operate unless load is centered under hoist.
• NOT leave load supported by the hoist unattended
• NOT use damaged hoist or hoist that is not working
unless specific precautions have been taken.
properly.
• NOT allow the chain, or hook to be used as an
• NOT use hoist with twisted, kinked, damaged, or
electrical or welding ground.
worn chain.
• NOT allow the chain, or hook to be touched by a
• NOT use hoist if the bottom hook is capsized
live welding electrode.
(double fall hoists - see Section 3.12).
• NOT remove or obscure the warnings on the hoist.
• NOT use the hoist to lift, support, or transport
people. • Be familiar with operating controls, procedures, and
warnings.
• NOT lift loads over people.
• Make sure the unit is securely attached to a
• NOT apply load unless load chain is properly
suitable support before applying load.
seated in the load sheave (and idle sheave for hoist
with two chain falls). • Make sure load slings or other approved single
attachments are properly sized, rigged, and seated
• NOT use the hoist in such a way that could result in
in the hook saddle.
shock or impact loads being applied to the hoist.
• Take up slack carefully - make sure load is
• NOT attempt to lengthen the load chain or repair
balanced and load-holding action is secure before
damaged load chain.
continuing.
• NOT operate hoist when it is restricted from forming
• Make sure all persons stay clear of the supported
a straight line from hook to hook in the direction of
load.
loading.
• Protect the hoist’s load chain from weld splatter or
• NOT use load chain as a sling or wrap load chain
other damaging contaminants.
around load.
• Report malfunctions or unusual performances
• NOT apply the load to the tip of the hook or to the
(including unusual noises) of the hoist and remove
hook latch.
the hoist from service until the malfunction or
• NOT apply load if binding prevents equal loading unusual performance is resolved.
on all load supporting chains.
• Make sure hoist limit switches function properly.
• NOT operate beyond the limits of the load chain
• Warn personnel before lifting or moving a load.
travel.
• Warn personnel of an approaching load.
• NOT operate hoist with missing/damaged chain
29
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 • Use the hoist manufacturer’s recommended parts
when operating the hoist. when repairing the unit.
• Check brake function by tensioning the hoist prior • Lubricate load chain per hoist manufacturer’s
to each lift operation. recommendations.
• Use hook latches. Latches are to retain slings, • NOT use the hoist load limiting or warning device to
chains, etc. under slack conditions only. measure load.
• Make sure the hook latches are closed and not • NOT use limit switches as routine operating stops.
supporting any parts of the load. They are emergency devices only.
• Make sure the load is free to move and will clear all • NOT allow your attention to be diverted from
obstructions. operating the hoist.
• Avoid swinging the load or hook. • NOT allow the hoist to be subjected to sharp
contact with other hoists, structures, or objects
• Make sure hook travel is in the same direction as
through misuse.
shown on controls.
• NOT adjust or repair the hoist unless qualified to
• Inspect the hoist regularly, replace damaged or
perform such adjustments or repairs.
worn parts, and keep appropriate records of
maintenance.
30
4.3 Hoist Controls
4.3.1 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 below. To stop motion release the lever switches.
Figure 4-1 Pendant Control
4.3.2 Cord Control - When using a hoist with cord control, pull down on the appropriate cord to raise or lower
the hoist. Release the cords to stop the hoist. Refer to Figure 4-2 below.
Figure 4-2 Cord Control
4.3.3 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 will 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.
4.4.2 By adjusting the set screw in the pendant, the control can be adjusted to suit the user’s needs.
Adjusting the screw does not affect the speed of the hoist; it simply changes the feel or stiffness of the
31
lever control. Adjusting the screw sets the position of a small spring plunger and this affects how the
plunger interacts with the lever.
 Turning the screw in causes the spring plunger to be in contact with the lever for more of the lever’s
travel, resulting in more stiffness and better feel for finer control of hoist motions.
 Turning the screw out reduces the effect that the spring plunger has on the lever control. This
makes it easier to depress the lever, which is usually preferred for coarse control (more on/off than
variable) of hoist motions.
Figure 4-3 Pendant Control Adjustment
4.4.3 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
32
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 - a person selected or assigned as being competent to perform the specific
duties to which he/she is assigned.
 Qualified Person - a 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.
33
5.3 Frequent Inspection
5.3.1 Inspections should be made on a FREQUENT basis in accordance with Table 5-1, “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.
34
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 above.
 Hoist Idle More Than 1 Year: Inspect per PERIODIC Inspection criteria of Section 5.4 above.
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.
Table 5-3 Hoist Inspection Methods and Criteria
Item Method Criteria Action

Functional operating Visual, Auditory Mechanisms should be properly adjusted and Repair or replace
mechanisms. should not produce unusual sounds when as required.
operated.
Limit Switch Function Proper operation. Actuation of limit switch should Repair or replace
stop hoist. as required.
Chain Lever/Limit Visual, Function Lever should not be bent or significantly worn and Replace.
Lever Assembly should be able to move freely.
Braking System Function Braking distance should not exceed Repair or replace
approximately five chain links. as required.
Hooks - Surface Visual Should be free of significant rust, weld splatter, Replace.
Condition deep nicks, or gouges.
Hooks - Fretting Measure The “u” dimension should not be less than Replace.
wear minimum value listed in Table 5-6.
Hooks - Stretch Measure The “K” dimension should not exceed the Replace.
maximum value for replacement from Table 5-6
(See Section 3.12).
35

Hooks - Bent Shank Visual Shank and neck portions of hook should be free Replace.
or Neck of deformations
Hooks - Yoke Visual Should be free of significant rust, weld splatter, Clean/Lubricate, or
Assembly nicks, gouges. Holes should not be elongated, replace as required.
fasteners should not be loose, and there should
be no gap between mating parts.
Hooks - Swivel Visual, Function Bearing parts and surfaces should not show Clean/lubricate, or
Bearing significant wear, and should be free of dirt, grime replace as required.
and deformations. Hook should rotate freely with
no roughness.
Hooks - Idle Sheave Visual, Function Pockets of Idle Sheave should be free of Clean/lubricate, or
and Axle (Bottom significant wear. Idle Sheave surfaces should be replace as required.
Hook on Double Fall free of nicks, gouges, dirt and grime. Bearing
Hoist) 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.
Hooks - Hook Visual, Function Latch should not be deformed. Attachment of Replace.
Latches 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.
Load Chain - Visual Should be free of rust, nicks, gouges, dents and Replace.
Surface Condition 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.
Load Chain - Pitch Measure The “L” dimension should not be greater than Replace, inspect
maximum value listed in Table 5-7. Load Sheave (and
Idle Sheave for
double fall hoist).
Load Chain - Visual, Auditory Entire surface of each chain link should be coated Clean/lubricate
Lubrication with lubricant and should be free of dirt and grime. (see Sections 6.0).
Chain should not emit cracking noise when
hoisting a load.
Load Chain - Visual Chain should be reeved properly through Load Reeve/Install chain
Reeving Sheave (and Idle Sheave for double fall hoist) - properly.
refer to Section 3.12. Chain, limit locks and
stoppers should be installed properly - refer to
Section 7.3.2.
Chain Springs Visual Chain springs should not be deformed or Replace
compressed.
Shock Absorber Visual Should be free of significant deformation. Replace
Chain Container Visual Container should not be damaged. Brackets Replace
(optional) should not be deformed or missing.
36

Bolts, Nuts and Visual, Check Bolts, nuts and rivets should not be loose. Tighten or replace
Rivets with Proper Tool as required.
Housing and Visual, Auditory, Hoist components including load blocks, Replace
Mechanical Vibration, suspension housing, chain attachments, clevises,
Components Function 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.
Chain Separator Visual, Measure The Chain Separator should be free of cracks, Replace
distortion, significant wear and corrosion. The “L”
and "W" dimension should not be greater than
maximum value listed in Table 5-5.
Motor Brake Measure, Visual Motor brake dimension should be within the Replace
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.
Load Sheave Visual Pockets of Load Sheave should be free of Replace.
significant wear. See Section 7.5 to gain visual
access to the load sheave.
Pendant Control Visual, Depressing and releasing pendant control levers Repair or replace
Levers should cause hoist to operate. as necessary.
Function
Pendant - Housing Visual Pendant housing should be free of cracks and Replace.
mating surfaces of parts should seal without gaps.
Pendant - Tubing Visual, auditory Tubing to pendant control switches should not be Repair or replace
loose or be leaking air. as necessary.
Pendant - Labels Visual Labels denoting functions should be legible. Replace.
Warning Labels Visual Warning Labels should be affixed to the hoist (see Replace
Section 1.2) and they should be legible.
Hoist Capacity Label Visual The label that indicates the capacity of the hoist Replace.
should be legible and securely attached to the
hoist.
37
Table 5-4 Brake Disc Dimension
Std Dimension Minimum Value for Replacement

Hoists
Inch (mm) Inch (mm)
TCR250 T = 0.31 (8.0) T = 0.29 (7.3)
TCR500, 1000-2 T = 0.31 (8.0) T = 0.29 (7.3)
TCR1000, 2000-2 T = 0.31 (8.0) T = 0.29 (7.3)
TCR3000, 6000-2 T = 0.31 (8.0) T = 0.29 (7.3)
Table 5-5 Chain Separator Dimensions
TCR250, 500, 1000-2, 1000, 2000-2 TCR 3000, 6000-2

Std Dimension Maximum Value for Replacement
Hoists
Inch (mm) Inch (mm)
L =0.33 (8.5) L = 0.41 (10.5)
TCR250
W = 0.61 (15.5) W = 0.69 (17.5)
L = 0.55 ( 14) L = 0.67 ( 17)
TCR500, 1000-2
W = 0.98 ( 25) W = 1.08 ( 27.5)
L = 0.62 ( 15.8) L = 0.70 ( 17.8)
TCR1000, 2000-2
W = 1.10 ( 28) W = 1.18 ( 30)
L = 1.00 ( 25.5) L = 1.10 ( 28)
TCR3000, 6000-2
W = 1.85 ( 47) W = 1.93 ( 49)
38
Table 5-6 Top Hook & Bottom Hook Dimensions
Dimensions K and U should be measured and recorded below prior to any use when the hook is first placed into service.
Maximum/Minimum Value
Hoists Recorded Dimension When New
for Replacement
Top Hook K = _______________
Top Hook U = _______________
TCR250
Bottom Hook K = ____________
Bottom Hook U = ____________
Top Hook K = _______________ For K if the measured dimension
Top Hook U = _______________ exceeds 1.05 times the recorded new
TCR500, 1000-2 dimension, the hook should be
Bottom Hook K = ____________
replaced.
Bottom Hook U = ____________
Top Hook K = _______________ For U if the measured dimension is
Top Hook U = _______________ less than .9 times the recorded new
TCR1000, 2000-2
Bottom Hook K = ____________ dimension, the hook should be
Bottom Hook U = ____________ replaced.
Top Hook K = _______________
Top Hook U = _______________
TCR3000, 6000-2
Bottom Hook K = ____________
Bottom Hook U = ____________
Table 5-7 Chain Dimensions
Maximum Value for Replacement

Hoists Std Nominal Dimension Inch (mm)
Inch (mm)
TCR250 Nominal L = 2.38 (60.5) L = 2.43 (61.7)
TCR 500, 1000-2 Nominal L = 3.76 (95.5) L = 3.82 (96.9)
TCR 1000, 2000-2 Nominal L = 4.18 (106.2) L = 4.25 (107.8)
TCR 3000, 6000-2 Nominal L = 5.96 (151.5) L = 6.05 (153.8)
39
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 (2-3cc/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, lightly coat the load chain with machine or gear oil. Ensure that the oil is applied to the
bearing surfaces of the load chain links.
6.2.2 The load chain lubrication should be accomplished after cleaning the load chain with acid free cleaning
solution. Use approved lubricant in Table 6-1 or equivalent.
6.2.3 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.
Table 6-1 Table of Approved Lubricants
Application Part Location Lubrication Grade

ISO VG 32-56 or
Air motor Lubricator Turbine Oil
equivalent
Load chain & pocket ISO VG 46-68 or
Load chain Machine or gear oil
wheel equivalent
Hook bearings & Top & bottom hook National Lubricating

Grease
suspension pins sets Grease #3
National Lubricating
Gears and Bearings Gear Section Grease
Grease #2
40
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 approximately125% 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.
41
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.
3) 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, then increase the lifting speed. Return the load
to its resting position so the load chain is not under tension.
5) If the load limiter prevents lifting, turn the adjustment screw IN one full turn.
6) 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, 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.
NOTICE! Turning the adjustment screw IN 8 full turns or more will disable the load limiter.
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.
7.2.3 The following is the hoist brake inspection procedure. Refer to Figure 7-2.
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. 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”.
2) Gradually back out all four hex socket cap screws (A) from brake cover (B) from gear case (J) to
slowly decrease spring tension (K) of brake piston (D) against brake disc (I).
3) Remove brake cover (B) from top of gear case (J). Keep brake piston (D), springs (K), seals and
piston cover (C) together inside the brake cover. Do not remove cap screws (E). Set parts aside
for reassembly.
4) Remove retaining ring (F) on pinion shaft (H) adjacent to brake disc (I).
5) Remove brake disc for inspection and measurement and then the two keys (G) from each side of
pinion shaft (H). Refer to "Motor Brake" in Table 5-3, "Hoist Inspection Methods and Criteria".
6) Prior to reassembly, clean all surfaces of debris, dirt and loose paint. Apply a light film of grease to
all "O"-ring seals.
7) Reassemble in reverse order. Keep the small hole on the back of the brake piston (D) aligned
toward the top of the hoist. Torque all mounting hardware evenly during the reassembly process.
42
Figure 7-2 Brake Inspection Diagram
(Note: Figure above represents TCR250-2000 model types, larger model types are
similar and the procedure for inspection is identical.)
7.3 Load Chain

7.3.1 Lubrication and Cleaning
 Clean the chain with an acid-free cleaning solution. The load chain should be kept clean and
lubricated.
 Lubrication - Clean and lubricate the load chain per Section 6 at least once every 3 months for
normal usage. Clean and lubricate more frequently for heavier usage or severe conditions.
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 Kito and is the exact size,
grade and construction as the original chain.
3) CAUTION! When replacing load chain, check for wear on mating parts, i.e. Load Sheave,
Chain Guides and Idler Wheels, and replace parts if necessary. Remove old chain. Remove hook
set assemblies, limit locks, stoppers and end connections from the chain for reuse on new chain. If
the load chain is being replaced due to damage or wear, prevent its reuse by destroying the old
chain.
43
4) CAUTION! Invert the hoist such that the chain separator openings are facing up. The chain
must be inserted into the chain separator on the no load side opening. This is where the no load
end of chain attaches to hoist body. Without inserting the load chain, operate the hoist pendant or
cord control to determine which direction the load sheave is rotating in relation to the pendant
control function pressed or pulled. Install load chain into the hoist making certain the first link is a
standing link and that its weld is facing away from the centerline of the hoist. See Figures 7-3 and
7-4 below.
Figure 7-3 Load Chain Installation Diagram
5) CAUTION! Operate the hoist slowly to catch and pull the chain through the hoist. Make sure
the chain feeds smoothly while operating the hoist. If binding occurs, stop and reverse the hoist
direction to back the chain out. Reinsert the chain while gradually operating the hoist controls.
Continue until sufficient quantity of chain is fed through the hoist.
Table 7-1 Placement of Stoppers from end of Load Chain
Model Type Hoist

Load Side No Load Side
TCR500P, C
TCR1000P, C None 10 links
TCR1000P2, C2 8 links 10 links
TCR2000P2, C2 7 links 10 links
TCR250P, C
None None
TCR3000P, C
TCR6000P2, C2
44
6) WARNING! Make sure end stoppers and limit locks are installed in accordance with
Table 7-1 and the diagram in Figure 7-4.
7) Ensure that chain remains free of twists when attaching dead end(s) of chain and when feeding
chain through bottom hook case (double fall units). Refer to Figures 3-6 and 3-7.
8) After installation has been completed, perform steps outlined in Section 3.12 "Preoperational
Checks and Trial Operation".
Figure 7-4 Diagram showing chain replacement guide
45
7.4 Load Sheave Inspection
7.5.1 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 7-8 and
remove the chain separator as follows.
 TCR3000 and TCR6000-2: The chain separator can be removed by removing the shaft retaining
ring from its groove on the limit lever shaft adjacent to the valve section, sliding the limit lever
assembly away from the chain separator, and removing the two larger outboard hex socket screws
holding the chain separator to the hoist body.
 TCR500 through TCR2000-2: The chain separator can be removed by removing the shaft
retaining ring from its groove on the limit lever shaft adjacent to the valve section, sliding the limit
lever assembly away from the chain separator, removing the limit lever from the limit lever shaft,
and removing the hex socket screws holding the chain separator to the hoist body.
Figure 7-5 Chain Separator Removal
46
7.5 Pendant
7.3.1 The following procedure covers the installation of a pendant control station.
1) Put 3 red tubes and wire through the bracket hole. See Figure 7-6.
2) Attach the hose to the bracket by installing the retaining nut to the fitting.
3) Torque retaining nut to 20 lbf.-ft.
Figure 7-6
4) Attach the wire cable to the hoist valve body with the screw as shown in Figure 7-7.
5) Torque machine screw to between 30 and 40 in-lbf.
Figure 7-7
6) Attach the 3 red tubes to each nipple as shown in Figure 7-8. Main air supply, lifting and
lowering.
Figure 7-8
NOTICE! When attaching the tubes take care not to bend or kink tubing. This will result in the air flow
being restricted and poor response to the pendant controls.
47
Figure 7-9 Hose Pendant Connections For TCR250P
7.6 Storage
7.4.1 Whenever the hoist is to be placed into storage, place extra lubricating oil 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.
7.4.2 The storage location should be clean and dry.
7.7 Outdoor Installation
7.5.1 For hoist installations that are outdoors, the hoist should be covered when not in use.
7.5.2 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. 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.
48
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.
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.
Table 8-1 Troubleshooting Guide

Symptom Cause Remedy
Lack of air pressure or loss of air
Repair or adjust air supply or filters.
supply.
Seizure of Main Spool, Brake Spool,
Repair at service facility.
or Air Motor.
Seizure of brake or brake
Repair at service facility.
mechanism fails to release.
Does not operate
Bending or crimping of pendant hose Correct or repair bend or crimp in hose
or control tubes and/or tubes
Air leak between the two chambers
Correct or repair to eliminate air leak.
in the Top Cover
Reduce the load to the rated capacity
Hoist is overloaded.
of hoist.
Low air pressure at hoist inlet port.
Check for air line obstruction.
Replace hose or piping sizes with
Air supply hose or piping is too small.
recommended sizes in Section 3.0.
Malfunction of brake. Repair at service facility.
Bending or crimping of pendant Correct or repair the bend or crimp in
hoses or control tubes hose and/or control tubes
Increase oil in air supply to hoist in
Lack of sufficient oil in air supply to
accordance with requirements in
Lifting speed is slow hoist
Section 3.0.
Exhaust Silencer or Nylon Silencer
Clean or replace.
clogged
Increase air flow capacity of
Air flow capacity of compressed air
compressed air system to
system insufficient
requirements in Section 2.0.
Air motor vanes or bearings worn Repair at service facility.
Filter the air supply to the hoist in
Air supply to hoist contains dirt or
accordance with the requirements in
debris
Section 3.0.
49
Table 8-1 Troubleshooting Guide
Symptom Cause Remedy
Lifting speed is slow Correct or repair to eliminate air leak.
in the Top Cover
Lack of air pressure or loss of air
supply.
Unable to lift rated load Improper adjustment of load limiter. Adjust Load Limiter. See Section 7.1.
Correct or repair to eliminate air leak.
in the Top Cover
Hoist moving in wrong Pendant control tubes are terminated Connect the control tubes in
direction (pendant control) to incorrect ports on hoist body. accordance with Section 7.4.
Hoist is overloaded. Reduce load to hoist rated capacity.
Faulty pendant control or control Repair or replace pendant control or
Hoist lowers but will not lift tube(s) control tube(s)
Lack of air pressure or partial loss of
or leakage in air supply.
Inject approx. 20 drops of oil into inlet
port to lubricate the main spool. If
Main Spool sticking
spool still sticks, repair at service
facility.
Hoist continues running after Main Spool spring broken Repair at service facility
pendant or cord is released
Main Spool leaking Repair at service facility
Mis-alignment of Limit Shaft with Loosen Bottom Plate and re-align so
Bottom Plate (TCR3000/6000 only) that Limit Shaft operates freely.
Valve in Pendant Handle stuck Repair at service facility
Brake is not holding. Repair brake at service facility.
Hoist drifts excessively when
hoist is stopped Replace motor vanes and springs at
Motor vanes leaking.
service facility.
50
Kito
Air Hoists
Parts List
TCR250 MAIN BODY
9.0 Parts List
TCR250 Main Body
52
TCR250 MAIN BODY
Parts Parts
Figure # Name Per Part # Figure # Name Per Part #
Hoist Hoist
50 Motor Case 1 T1CR426205790 118 Lock Screw 1 T1CR426205890
51 Rear Plate 1 T1CR426205180 119 Brake Plate 1 T1CR426205900
52 Cylinder 1 T1CR426205160 120 Bearing 2 T1CR130112806
53 Rotor 1 T1CR426205150 121 Bearing 2 T1CR130113003
54 Front Plate 1 T1CR426205170 122 Needle Bearing 6 T1CR130170013
55 Vane 6 T1CR137102018 123 O-Ring 1 T1CR131103047
56 Knock Pin 1 T1CR130402049 124 O-Ring 1 T1CR131103004
57 Bearing 2 T1CR130113003 125 Socket Bolt 3 T1CR131705014
58 O-Ring 1 T1CR131103044 126 Retaining Ring 1 T1CR130302025
59 Socket Bolt 3 T1CR131705014 127 Retaining Ring 3 T1CR130302012
60 Retaining Ring 1 T1CR130302012 128 Retaining Ring 2 T1CR130301024
70 Brake Cover 1 T1CR426205410 129 Spring Pin 1 T1CR130603006
71 Brake Piston 1 T1CR426205400 140 Top Hook Complete Set 1 T1CR42620557C
72 Brake Disk 1 T1CR426205430 140A Top Hook Assy. 1 T1CR420810PAA
73 Key 1 T1CR130408079 140B Hook Latch 1 T1CR420620P10
74 Brake Spring 6 T1CR130802207 140C Spring Pin 1 T1CR130603024
75 O-Ring 1 T1CR131103047 140D Latch Spring 1 T1CR130802046
76 O-Ring 1 T1CR131103042 141 Top Yoke Pair 1 T1CR426205570
77 Socket Bolt 2 T1CR131705030 148 Hex Flat Head Machine Screw 2 T1CR132805018
78 Set Screw 1 T1CR132104005 Bottom Hook Complete Set –
142 1 T1CR42620593C
500 lbs
Wheel Housing –
1 T1CR426205210
Cord and Pendant Models 142A Bottom Hook Assy. 1 T1CR42620593A
90
Wheel Housing – 142B Hook Latch 1 T1CR420620P10
1 T1CR426215210
Manipulator Model
142C Spring Pin 1 T1CR130603024
91 Chain Guide 1 T1CR426205350
142D Latch Spring 1 T1CR130802046
92 Chain Separator 1 T1CR136610025
143 Bottom Yoke Pair – 500 lbs 1 T1CR426205800
93 Spacer 1 T1CR426205230
144 Hook Thrust Plate Pair 1 T1CR426205910
94 Bearing 1 T1CR130116005
145 Thrust Bearing 1 T1CR130121103
95 Bearing 1 T1CR130113010
146 O-Ring 1 T1CR131103017
96 O-Ring 2 T1CR131103004
147 Socket Bolt 2 T1CR131706018
97 O-Ring 1 T1CR131102006
152 Spring Washer 2 T1CR131310006
98 Spring Pin 2 T1CR130606045
149 Button Head Screw 1 T1CR131905010
150 Washer 1 T1CR131305005
101 Load Chain FT KED040
170 Brand Name Plate 1 T1CR137309264
110 Cage 1 T1CR426205240
171 Name Plate – T1CR250 1 T1CR137309262
111 Star Gear 3 T1CR426205250
172 Logo Name Plate 1 T1CR137309269
112 Pin 3 T1CR426205260
238 O-Ring – Manipulator Model Only 1 T1CR131101015
113 Thrust Collar 6 T1CR426205270
114 Pinion 1 T1CR426205290
115 Load Sheave 1 T1CR426205300
116 Gear Case 1 T1CR426205310
117 Ring Gear 1 T1CR426205320
53
TCR250 VALVE BODY
TCR250 Valve Body
54
TCR250 VALVE BODY
Parts Cord Model Only:

Figure # Name Per Part #
Parts
Hoist
Figure # Name Per Part #
1 Main Spool 1 T1CR426205010 Hoist
2 Valve Bush 1 T1CR426205780 6 Valve Body 1 T1CR426205060
3 Shuttle 1 T1CR426205870 20 Valve Spring 1 T1CR130802208
4 Valve Seat R 1 T1CR426205830 34 Hex Socket Pipe Plug 1 T1CR134902003
5 Valve Seat L 1 T1CR426205840
160 S-Type Wire 2 T1CR130802081
7 Side Cover 2 T1CR426205080
161W White Cord (Down) FT T1CR138001015WH
8 Valve Pin 1 T1CR426205850
161W White Cord (Up) FT T1CR138001015WH
9 Limit Lever 1 T1CR426205140
163 Grip W 1 T1CR136602625
10 Limit Guide 1 T1CR426205100
11 Limit Shaft 1 T1CR426205460 164 Grip R 1 T1CR136602626
12 Chain Lever 1 T1CR426205110 165 Handle 1 T1CR136602627
13 Stopper 1 T1CR426205860
14 Under Cover 1 T1CR426205470 Pendant Model Only:
15 Exhaust Plate 1 T1CR426205810 Parts
16 Valve Packing 1 T1CR136102151 Figure # Name Per Part #
17 Under Packing 1 T1CR136102153 Hoist
18 Silencer S 4 T1CR137402022 Pendant Hose Assy.
153 1 T1CR137240520
(Three hoses)
19 Silencer F 1 T1CR137402021
21 Bumper 2 T1CR136406025 155 Cord Chain FT E3S626
22 Protector 1 T1CR426205880 156 Eye Bolt 1 T1CR131756050
23 O-Ring 2 T1CR131117004 157 Eye Bolt 1 T1CR131756030
24 O-Ring 2 T1CR131103003 158 Split Ring A/R T1CR130802093
25 O-Ring 4 T1CR131103014 159 S-Type Wire 2 T1CR130802081
26 O-Ring 2 T1CR131103016 161 Boot 2 T1CR136608250
27 Socket Bolt 1 T1CR131704030 163 Hose 3@FT T1CR137240923
169 Warning Tag 1 E2R567-001H
162 Hose Fittings 6 T1CR137291310
167 Pendant Valve CP 1 T1CR420215VBC
31 Hex Flat Head Mach Screw 6 T1CR132804010
167A Throttle Valve 2 T1CR420215VB0
32 Set Screw 2 T1CR132110008
33 Set Screw 3 T1CR132104005 167B Push Rod 2 T1CR420215VC0
35 Washer 1 T1CR131309008 167C O-Ring 2 T1CR131118012

36 Washer 1 T1CR131305005 167D O-Ring 2 T1CR131117013
37 Retaining Ring 2 T1CR130301022 167E Pendant Valve Body CP 1 T1CR420215VRB
38 Hair Pin Cotter 1 T1CR130790008 167EA Pendant Valve Body 1 T1CR420215VR0
39 Parallel Pin 3 T1CR130406017 167EB Bushing 2 T1CR420214VF0
40 Spring Pin 1 T1CR130602112 167F O-Ring 2 T1CR131103016
170 Hose Stem 1 T1CR134803040 167G Spring Pin 2 T1CR130604132
171 Inlet Bushing w/Screen 1 T1CR134703050
167H Pendant Valve Lever 2 T1CR420210VH0
Pendant and Manipulator Models Only: 167J Valve Spring 2 T1CR130802030
Parts 167K Pendant Valve Cap 2 T1CR420214V10
Figure # Name Per Part # 167L O-Ring 2 T1CR131103022
Hoist
167M E-Ring 2 T1CR130303004
6 Valve Body 1 T1CR426206060
20 Valve Spring 1 T1CR130802209
160 Manifold Block 1 T1CR426206941
164 O-Ring 2 T1CR131103008
55
TCR250 MANIPULATOR CONTROL
TCR250M Manipulator Control
56
TCR250 MANIPULATOR CONTROL
Parts Parts
Figure # Name Per Part # Figure # Name Per Part #
Hoist Hoist
12M Chain Basket CP 1 T1CR42621592C 290 Shield 1 T1CR426215B20
17 Bucket Arm Assembly (pair) 1 pr. T1CR426205920 291 Hex Socket Pipe Plug 2 T1CR134901006
18 Arm Holder 2 T1CR426205820 292 Manipulator Warning Tag 1 T1CR137304071
19 Bolt 1 T1CR131605016
20 U-Nut 2 T1CR134501005
21 Washer 1 T1CR131305005
22 Chain Basket 1 E2D1831
200 Hose Arm 1 T1CR426215960
201 Hanger Half 4 T1CR426215B30
202 Coil Hose – Std. 6.5 ft lift 1 T1CR137202018
203 Rubber Bushing 2 T1CR136608252
204 Hose Support 1 T1CR136608253
205 Tube Fitting 1 T1CR137289310
206 Tube Fitting 5 T1CR137290310
220 Throttle Valve 2 T1CR420215VB0
221 Push Rod 2 T1CR420215VC0
222 O-Ring 2 T1CR131118012
223 O-Ring 2 T1CR131117013
224 Throttle Valve Body CP 1 T1CR42621597B
225 Lever Pin 1 T1CR130402048
226 Throttle Lever Up 1 T1CR420985UY0
227 Throttle Lever Down 1 T1CR420985UZ0
228 Valve Spring 2 T1CR130802221
229 Spring Seat 2 T1CR426215B00
230 O-Ring 2 T1CR131103016
231 Retaining Ring 2 T1CR130301024
234 Grip 1 T1CR136608140
241 Retaining Ring 2 T1CR130303004
232 Rotary Joint 1 T1CR426215B40
233 Hook Protector 1 T1CR136201200
236 Rubber Bushing 1 T1CR136608251
237 O-Ring 8 T1CR131103013
238 O-Ring 1 T1CR131101015
57
TCR500 Main Body
TCR500 Main Body
TCR500 MAIN BODY
58
Figure Parts Figure Parts Figure Parts
Part # Part Name Part # Part Name Part # Part Name
# Per # Per # Per
28 T1CR130406005 PARALLEL PIN Hoist

2 78 T1CR131103055 O-RING Hoist
1 119 T1CR426224390 END STOPPER Hoist
1
35 T1CR426224151 ROTOR 1 79 T1CR131706012 SOCKET BOLT 2 120 T1CR426221S2C BOTTOM HOOK SET 500 1
36 T1CR426224161 STATOR 1 80 T1CR131706040 SOCKET BOLT 4 120A T1CR426221S2F BOTTOM HOOK ASSY. 1
37 T1CR426224171 FRONT PLATE 1 81 T1CR131117033 O-RING 1 120B T1CR426221S30 HOOK LATCH 1
38 T1CR426224182 REAR PLATE 1 85 T1CR426224240 CAGE 1 120C T1CR130802258 HOOK SPRING 1
39 T1CR426224191 REAR RETAINER 1 86 T1CR426224250 STAR GEAR 3 120D T1CR131705035 SOCKET BOLT 1
40 T1CR137102020 VANE 8 87 T1CR426224260 PIN 3 120E T1CR134501005 U-NUT 1
41 T1CR130802212 VANE SPRING 8 88 T1CR426224270 THRUST COLLAR 6 125 T1CR130502020 STEEL BALL 8
42 T1CR130113002 BEARING 1 89 T1CR426224280 RETAINER 3 126 T1CR426221S80 BOTTOM HOOK HOLDER 1
43 T1CR131103004 O-RING 1 90 T1CR426224290 PINION 1 127 T1CR420846PY0 SWIVEL HOOK PLUG 1
44 T1CR131103023 O-RING 1 91 T1CR426224300 LOAD SHEAVE 1 128 T1CR426224760 SLEEVE 1
45 T1CR130302015 RETAINING RING 1 92 T1CR426224312 GEAR CASE 1 129 T1CR426221T20 CHAIN PIN 1
46 T1CR131708075 SOCKET BOLT 3 93 T1CR426224322 RING GEAR 1 130 T1CR130802259 LOCK RING 1
47 T1CR131307006 WASHER 1 94 T1CR426224330 SPACER (P) 3 131 KER063 LOAD CHAIN FT
48 T1CR130402051 KNOCK PIN 1 95 T1CR426221K90 LOCK SCREW 1 132 T1CR426224450 LIMIT LOCK 2
49 T1CR130104003 BEARING 1 96 T1CR426224352 CHAIN GUIDE 1 133 T1CR136206002 SHOCK ABSORBER 2
50 T1CR426224200 COUPLING 1 97 T1CR426224363 CHAIN SEPARATOR 1 136 T1CR426224680 END BOLT 1
51 T1CR426224212 WHEEL HOUSING 1 98 T1CR426224381 BRAKE TUBE 1 138 T1CR134501006 U NUT 1
59
52 T1CR426224220 TOP PIN 1 100 T1CR130104003 BEARING 2 139 T1CR426224C80 LIMIT WASHER 2
53 T1CR426224230 SPACER 1 101 T1CR130112808 BEARING 2 140 T1CR130802219 CHAIN SPRING 2
54 T1CR426261R50 WASHER 1 102 T1CR130170035 NEEDLE BEARING 6
55 T1CR130113015 BEARING 1 103 T1CR131117042 O-RING 1
56 T1CR130104010 BEARING 1 104 T1CR131103055 O-RING 1
57 T1CR131706012 SOCKET BOLT 1 105 T1CR130302010 RETAINING RING 3
60 T1CR426221R50 WASHER 1 107 T1CR130302015 RETAINING RING 3
61 T1CR132108012 SET SCREW 1 108 T1CR130301032 RETAINING RING 2
62 T1CR137309075 BRAND NAME PLATE 1 109 T1CR130303005 RETAINING RING 1
70 T1CR426224401 BRAKE PISTON 1 110 T1CR131706012 SOCKET BOLT 4
71 T1CR426224410 BRAKE COVER 1 111 T1CR131708016 SOCKET BOLT 3
72 T1CR426224421 PISTON COVER 1 112 T1CR131103036 O-RING 1
73 T1CR426224430 BRAKE DISC 1 115 T1CR42622457B TOP HOOK SET 1
74 T1CR130408081 KEY 2 115B T1CR426221S30 HOOK LATCH 1
TCR500 Main Body

75 T1CR130802213 DISC SPRING 6 115C T1CR130802258 HOOK SPRING 1
76 T1CR131103002 O-RING 1 115D T1CR131705035 SOCKET BOLT 1
77 T1CR131101004 O-RING 1 115E T1CR134501005 U-NUT 1
TCR1000-2 Main Body
TCR1000-2 Main Body
60
Parts Parts Parts
Figure Figure Figure
Part # Part Name Per Part # Part Name Per Part # Part Name Per
# # #
Hoist Hoist Hoist
28 T1CR130406005 PARALLEL PIN 2 78 T1CR131103055 O-RING 1 115H T1CR426244580 CHAIN PIN 1

35 T1CR426224151 ROTOR 1 79 T1CR131706012 SOCKET BOLT 2 115J T1CR131307006 WASHER 1
36 T1CR426224161 STATOR 1 80 T1CR131706040 SOCKET BOLT 4 115K T1CR134501006 U NUT 1
37 T1CR426224171 FRONT PLATE 1 81 T1CR131117033 O-RING 1 116 T1CR426244630 FREE LIMIT LOCK 1
38 T1CR426224182 REAR PLATE 1 85 T1CR426224240 CAGE 1 118 T1CR426244620 HOLDER 1
39 T1CR426224191 REAR RETAINER 1 86 T1CR426224250 STAR GEAR 3 119 T1CR426224390 END STOPPER 2
40 T1CR137102020 VANE 8 87 T1CR426224260 PIN 3 120 T1CR426244S2C BOTTOM HOOK SET 1
41 T1CR130802212 VANE SPRING 8 88 T1CR426224270 THRUST COLLAR 6 120A T1CR426221S2F BOTTOM HOOK ASSY. 1
42 T1CR130113002 BEARING 1 89 T1CR426224280 RETAINER 3 120B T1CR426221S30 HOOK LATCH 1
43 T1CR131103004 O-RING 1 90 T1CR426224290 PINION 1 120C T1CR130802258 HOOK SPRING 1
44 T1CR131103023 O-RING 1 91 T1CR426224300 LOAD SHEAVE 1 120D T1CR131705035 SOCKET BOLT 1
45 T1CR130302015 RETAINING RING 1 92 T1CR426224312 GEAR CASE 1 120E T1CR134501005 U-NUT 1
46 T1CR131708075 SOCKET BOLT 3 93 T1CR426224322 RING GEAR 1 121 T1CR130172006 NEEDLE BEARING 1
47 T1CR131307006 WASHER 1 94 T1CR426224330 SPACER (P) 3 122 T1CR131204014 OIL SEAL 2
48 T1CR130402051 KNOCK PIN 1 95 T1CR426221K90 LOCK SCREW 1 125 T1CR130502020 STEEL BALL 8
49 T1CR130104003 BALL BEARING 1 96 T1CR426224352 CHAIN GUIDE 1 126 T1CR426244590 BOTTOM YOKE ASSY. 1
50 T1CR426224200 COUPLING 1 97 T1CR426224363 CHAIN SEPARATOR 1 127 T1CR420846PY0 SWIVEL HOOK PLUG 1
61
51 T1CR426224212 WHEEL HOUSING 1 98 T1CR426224381 BRAKE TUBE 1 128 T1CR420846PW0 OUTER BEARING RACE 1
52 T1CR426224220 TOP PIN 1 100 T1CR130104003 BEARING 2 129 T1CR426244600 WHEEL SHAFT 1
53 T1CR426224230 SPACER 1 101 T1CR130112808 BEARING 2 130 T1CR426241U20 IDLE SHEAVE 1
54 T1CR426261R50 WASHER 1 102 T1CR130170035 NEEDLE BEARING 6 135 T1CR131706035 SOCKET BOLT 2
55 T1CR130113015 BEARING 1 103 T1CR131117042 O-RING 1 137 T1CR134501006 U NUT 2
56 T1CR130104010 BEARING 1 104 T1CR131103055 O-RING 1 139 T1CR130302014 RETAINING RING 1
57 T1CR131706012 SOCKET BOLT 1 105 T1CR130302010 RETAINING RING 3 131 KER063 LOAD CHAIN FT
59 T1CR131708025 SOCKET BOLT 1 106 T1CR130302045 RETAINING RING 1 132 T1CR426224450 LIMIT LOCK 1
60 T1CR426221R50 WASHER 1 107 T1CR130302015 RETAINING RING 3 133 T1CR136206002 SHOCK ABSORBER 2
61 T1CR132108012 SET SCREW 1 108 T1CR130301032 RETAINING RING 2 136 T1CR426224680 END BOLT 2
62 T1CR137309075 BRAND NAME PLATE 1 109 T1CR130303005 RETAINING RING 1 138 T1CR134501006 U NUT 2
70 T1CR426224401 BRAKE PISTON 1 110 T1CR131706012 SOCKET BOLT 4 139 T1CR426224C80 LIMIT WASHER 1
71 T1CR426224410 BRAKE COVER 1 111 T1CR131708016 SOCKET BOLT 3 140 T1CR130802219 CHAIN SPRING 3
72 T1CR426224421 PISTON COVER 1 112 T1CR131103036 O-RING 1
73 T1CR426224430 BRAKE DISC 1 115 T1CR42622457B TOP HOOK SET 1
TCR1000-2 Main Body

74 T1CR130408081 KEY 2 115B T1CR426221S30 HOOK LATCH 1
75 T1CR130802213 DISC SPRING 6 115C T1CR130802258 HOOK SPRING 1
76 T1CR131103002 O-RING 1 115D T1CR131705035 SOCKET BOLT 1
TCR1000 Main Body
TCR1000 Main Body
62
Parts Parts Parts
# # #
Hoist Hoist Hoist
28 T1CR130406005 PARALLEL PIN 2 79 T1CR131706012 SOCKET BOLT 2 119 T1CR426266390 END STOPPER 1
35 T1CR426224151 ROTOR 1 80 T1CR131706040 SOCKET BOLT 4 120 T1CR426261S2C BOTTOM HOOK SET 1
36 T1CR426224161 STATOR 1 81 T1CR131117033 O-RING 1 120A T1CR426221S2F BOTTOM HOOK ASSY. 1
37 T1CR426224171 FRONT PLATE 1 85 T1CR426266240 CAGE 1 120B T1CR426221S30 HOOK LATCH 1
38 T1CR426224182 REAR PLATE 1 86 T1CR426266250 STAR GEAR 3 120C T1CR130802258 HOOK SPRING 1
39 T1CR426224191 REAR RETAINER 1 87 T1CR426266260 PIN 3 120D T1CR131705035 SOCKET BOLT 1
40 T1CR137102020 VANE 8 88 T1CR426266270 THRUST COLLAR 6 120E T1CR134501005 U-NUT 1
41 T1CR130802212 VANE SPRING 8 90 T1CR426266290 PINION 1 125 T1CR130502020 STEEL BALL 8
42 T1CR130113002 BEARING 1 91 T1CR426266300 LOAD SHEAVE 1 126 T1CR426261S80 BOTTOM HOOK HOLDER 1
43 T1CR131103004 O-RING 1 92 T1CR426266310 GEAR CASE 1 127 T1CR420846PY0 SWIVEL HOOK PLUG 1
44 T1CR131103023 O-RING 1 93 T1CR426266320 RING GEAR 1 128 T1CR426266760 SLEEVE 1
45 T1CR130302015 RETAINING RING 1 95 T1CR426266340 DOWEL PIN 4 129 T1CR426261T20 CHAIN PIN 1
46 T1CR131708075 SOCKET BOLT 3 96 T1CR426266351 CHAIN GUIDE 1 130 T1CR130802259 LOCK RING 1
47 T1CR131307006 WASHER 1 97 T1CR426266360 CHAIN SEPARATOR 1 131 KER071 LOAD CHAIN FT
48 T1CR130402051 KNOCK PIN 1 98 T1CR426224381 BRAKE TUBE 1 132 T1CR426266450 LIMIT LOCK 2
49 T1CR130104003 BEARING 1 100 T1CR130104003 BEARING 2 133 T1CR136206003 SHOCK ABSORBER 2
50 T1CR426224200 COUPLING 1 101 T1CR130113008 BEARING 2 136 T1CR426224680 END BOLT 1
63
51 T1CR426224212 WHEEL HOUSING 1 102 T1CR130104002 BEARING 9 138 T1CR134501006 U NUT 1

52 T1CR426224220 TOP PIN 1 103 T1CR131117042 O-RING 1 139 T1CR426266C80 LIMIT WASHER 2
53 T1CR426224230 SPACER 1 104 T1CR131103055 O-RING 1 140 T1CR130802219 CHAIN SPRING 2
54 T1CR426261R50 WASHER 1 105 T1CR130302012 RETAINING RING 3
55 T1CR130113015 BEARING 1 106 T1CR130302045 RETAINING RING 1
56 T1CR130104010 BEARING 1 107 T1CR130302015 RETAINING RING 3
60 T1CR426221R50 WASHER 1 110 T1CR131706012 SOCKET BOLT 4
61 T1CR132108012 SET SCREW 1 111 T1CR131708016 SOCKET BOLT 6
71 T1CR426224410 BRAKE COVER 1 114 T1CR426266640 ADAPTER 1
72 T1CR426224421 PISTON COVER 1 115 T1CR42622457B TOP HOOK SET 1
73 T1CR426224430 BRAKE DISC 1 115B T1CR426221S30 HOOK LATCH 1
74 T1CR130408081 KEY 2 115C T1CR130802258 HOOK SPRING 1
75 T1CR130802213 DISC SPRING 6 115D T1CR131705035 SOCKET BOLT 1
TCR1000 Main Body

77 T1CR131101004 O-RING 1
78 T1CR131103055 O-RING 1
TCR2000-2 Main Body
TCR2000-2 Main Body
64
Parts Parts Parts
# # #
Hoist Hoist Hoist
28 T1CR130406005 PARALLEL PIN 2 78 T1CR131103055 O-RING 1 115F T1CR426286570 TOP YOKE ASSY. 1
35 T1CR426224151 ROTOR 1 79 T1CR131706012 SOCKET BOLT 2 115G T1CR131710040 SOCKET BOLT 2
36 T1CR426224161 STATOR 1 80 T1CR131706040 SOCKET BOLT 4 115H T1CR131301010 SPRING WASHER 2
37 T1CR426224171 FRONT PLATE 1 81 T1CR131117033 O-RING 1 115J T1CR134501010 U-NUT 2
38 T1CR426224182 REAR PLATE 1 85 T1CR426266240 CAGE 1 117 T1CR426286580 CHAIN PIN 1
39 T1CR426224191 REAR RETAINER 1 86 T1CR426266250 STAR GEAR 3 118 T1CR426286630 FREE LIMIT LOCK 1
40 T1CR137102020 VANE 8 87 T1CR426266260 PIN 3 119 KER071 LOAD CHAIN FT
41 T1CR130802212 VANE SPRING 8 88 T1CR426266270 THRUST COLLAR 6 120 T1CR426286620 HOLDER 1
42 T1CR130113002 BEARING 1 90 T1CR426266290 PINION 1 121 T1CR426266390 END STOPPER 2
43 T1CR131103004 O-RING 1 91 T1CR426266300 LOAD SHEAVE 1 122 T1CR426001PAG BOTTOM HOOK SET 1
44 T1CR131103023 O-RING 1 92 T1CR426266310 GEAR CASE 1 122A T1CR420645PAA HOOK ASSY. 1
45 T1CR130302015 RETAINING RING 1 93 T1CR426266320 RING GEAR 1 122B T1CR420645P10 HOOK LATCH 1
46 T1CR131708075 SOCKET BOLT 3 95 T1CR426266340 DOWEL PIN 4 122C T1CR130802046 HOOK SPRING 1
47 T1CR131307006 WASHER 1 96 T1CR426266351 CHAIN GUIDE 1 122D T1CR130603024 SPRING PIN 1
48 T1CR130402051 KNOCK PIN 1 97 T1CR426266360 CHAIN SEPARATOR 1 123 T1CR426286590 BOTTOM YOKE ASSY. 1
49 T1CR130104003 BEARING 1 98 T1CR426224381 BRAKE TUBE 1 124 T1CR426001RB0 IDLE SHEAVE 1
50 T1CR426224200 COUPLING 1 100 T1CR130104003 BEARING 2 125 T1CR420866QH0 BOTTOM HOOK COVER 2
65
51 T1CR426224212 WHEEL HOUSING 1 101 T1CR130113008 BEARING 2 126 T1CR420866Q10 BOTTOM HOOK SHAFT 1
52 T1CR426224220 TOP PIN 1 102 T1CR130104002 BEARING 9 130 T1CR131710045 SOCKET BOLT 2
53 T1CR426224230 SPACER 1 103 T1CR131117042 O-RING 1 131 T1CR131710020 SOCKET BOLT 2
54 T1CR426261R50 WASHER 1 104 T1CR131103055 O-RING 1 134 T1CR134501010 U-NUT 2
55 T1CR130113015 BEARING 1 105 T1CR130302012 RETAINING RING 3 137 T1CR131301010 SPRING WASHER 2
56 T1CR130104010 BEARING 1 106 T1CR130302045 RETAINING RING 1 139 T1CR130109007 BEARING 2
57 T1CR131706012 SOCKET BOLT 1 107 T1CR130302015 RETAINING RING 3 127 T1CR426266450 LIMIT LOCK 1
59 T1CR131708025 SOCKET BOLT 1 108 T1CR130301032 RETAINING RING 2 128 T1CR136206003 SHOCK ABSORBER 2
60 T1CR426221R50 WASHER 1 109 T1CR130303005 RETAINING RING 1 133 T1CR426224680 END BOLT 2
61 T1CR132108012 SET SCREW 1 110 T1CR131706012 SOCKET BOLT 4 135 T1CR134501008 U-NUT 1
62 T1CR137309075 BRAND NAME PLATE 1 111 T1CR131708016 SOCKET BOLT 6 136 T1CR134501006 U NUT 2
70 T1CR426224401 BRAKE PISTON 1 112 T1CR130301028 RETAINING RING 6 138 T1CR131307008 WASHER 1
71 T1CR426224410 BRAKE COVER 1 113 T1CR131705010 SOCKET BOLT 6 139 T1CR426266C80 LIMIT WASHER 1
72 T1CR426224421 PISTON COVER 1 114 T1CR426266640 ADAPTER 1 140 T1CR130802219 CHAIN SPRING 3
73 T1CR426224430 BRAKE DISC 1 115 T1CR42628657F HOOK SET 1 170 T1CR426286710 THRUST RING 1
74 T1CR130408081 KEY 2 115A T1CR420645PAA HOOK ASSY. 1 171 T1CR130121108 THRUST BEARING<51108> 1
TCR2000-2 Main Body

75 T1CR130802213 DISC SPRING 6 115AB T1CR420645P10 HOOK LATCH 1
76 T1CR131103002 O-RING 1 115AC T1CR130802046 HOOK SPRING 1
77 T1CR131101004 O-RING 1 115AD T1CR130603024 SPRING PIN 1
TCR3000 Main Body
TCR3000 Main Body
66
Parts Parts Parts
# # #
Hoist Hoist Hoist
28 T1CR130406005 PARALLEL PIN 2 75 T1CR130802213 DISC SPRING 6 115 T1CR42632557B TOP HOOK SET 1
35 T1CR426325150 ROTOR 1 76 T1CR131103008 O-RING 1 115AB T1CR420655P10 HOOK LATCH 1
36 T1CR426325160 STATOR 1 77 T1CR131101004 O-RING 1 115AC T1CR130802046 HOOK SPRING 1
37 T1CR426325170 FRONT PLATE 1 78 T1CR131103063 O RING 1 115AD T1CR130603024 SPRING PIN 1
38 T1CR426325180 REAR PLATE 1 79 T1CR131706012 SOCKET BOLT 2 120 T1CR420875PAD BOTTOM HOOK SET 1
39 T1CR426325190 REAR RETAINER 1 80 T1CR131706030 SOCKET BOLT 4 120A T1CR420875PAA BOTTOM HOOK ASSY. 1
40 T1CR137102022 VANE 8 85 T1CR426325240 CAGE 1 120B T1CR420655P10 HOOK LATCH 1
41 T1CR130802212 VANE SPRING 8 86 T1CR426325250 STAR GEAR 3 120C T1CR130802046 HOOK SPRING 1
42 T1CR130104004 BEARING 2 87 T1CR426325260 PIN 3 120D T1CR130603024 SPRING PIN 1
43 T1CR131103004 O-RING 1 88 T1CR426325270 THRUST COLLAR 6 121 T1CR420875PZ1 BOTTOM YOKE ASSY. 1
44 T1CR131103026 O RING 1 90 T1CR426325290 PINION 1 122 T1CR420875PW0 OUTER BEARING RACE 1
45 T1CR130302017 RETAINING RING 1 91 T1CR426325300 LOAD SHEAVE 1 123 T1CR420875PY0 SWIVEL HOOK PLUG 1
46 T1CR131708105 SOCKET BOLT 3 92 T1CR426325310 GEAR CASE 1 124 T1CR131101025 O RING 1
47 T1CR131307006 WASHER 1 93 T1CR426325320 RING GEAR 1 125 T1CR130502024 STEEL BALL 10
48 T1CR130402054 KNOCK PIN 1 95 T1CR426325340 DOWEL PIN 4 126 T1CR131708035 SOCKET BOLT 2
49 T1CR131708012 SOCKET BOLT 4 96 T1CR426325351 CHAIN GUIDE 1 127 T1CR131708050 SOCKET BOLT 2
50 T1CR426325200 COUPLING 1 97 T1CR426325360 CHAIN SEPARATOR 1 128 T1CR131301008 SPRING WASHER 4
67
51 T1CR426325212 WHEEL HOUSING 1 98 T1CR426325380 BRAKE TUBE 1 129 T1CR134501008 U-NUT 4

52 T1CR426325220 TOP PIN 1 99 T1CR426325371 BOTTOM PLATE 1 131 KER112 LOAD CHAIN FT
53 T1CR426325230 SPACER 1 100 T1CR130104004 BEARING 2
54 T1CR420875MN0 CHAIN END SET 1 101 T1CR130104010 BEARING 2
55 T1CR130104019 WASHER
BEARING 1 102 T1CR130104005 BEARING 12
56 T1CR130107013 BEARING 1 103 T1CR131103058 O RING 1
57 T1CR134501016 U NUT 1 104 T1CR131103063 O RING 1
58 T1CR131301016 SPRING WASHER 1 105 T1CR130302020 RETAINING RING 3
63 T1CR426325730 SET PIECE 1 110 T1CR131706012 SOCKET BOLT 12
72 T1CR426325420 PISTON COVER 1 113 T1CR130406028 PARALLEL PIN 2
TCR3000 Main Body

73 T1CR426325430 BRAKE DISK 1 114 T1CR130301042 RETAINING RING 6
74 T1CR130408084 KEY 2
TCR6000-2 Main Body
TCR6000-2 Main Body
68
Parts Parts Parts
# # #
Hoist Hoist Hoist
28 T1CR130406005 PARALLEL PIN 2 75 T1CR130802213 DISC SPRING 6 116 T1CR4200HH006 TOP HOOK SET 1
35 T1CR426325150 ROTOR 1 76 T1CR131103008 O-RING 1 115A T1CR420890PAB HOOK ASSY. 1
36 T1CR426325160 STATOR 1 77 T1CR131101004 O-RING 1 115B T1CR420890P10 HOOK LATCH 1
37 T1CR426325170 FRONT PLATE 1 78 T1CR131103063 O RING 1 115C T1CR130802046 HOOK SPRING 1
38 T1CR426325180 REAR PLATE 1 79 T1CR131706012 SOCKET BOLT 2 115D T1CR130603024 SPRING PIN 1
39 T1CR426325190 REAR RETAINER 1 80 T1CR131706030 SOCKET BOLT 4 117 T1CR426335690 HOOK ANCHOR 1
40 T1CR137102022 VANE 8 85 T1CR426325240 CAGE 1 120 T1CR420890QF0 TOP YOKE ASSY. 1
41 T1CR130802212 VANE SPRING 8 86 T1CR426325250 STAR GEAR 3 121 T1CR420890JG0 CHAIN PIN 1
42 T1CR130104004 BEARING 2 87 T1CR426325260 PIN 3 125 T1CR131712055 SOCKET BOLT 4
43 T1CR131103004 O-RING 1 88 T1CR426325270 THRUST COLLAR 6 126 T1CR131712065 SOCKET BOLT 1
44 T1CR131103026 O RING 1 90 T1CR426325290 PINION 1 128 T1CR134501012 U NUT 6
45 T1CR130302017 RETAINING RING 1 91 T1CR426325300 LOAD SHEAVE 1 132 T1CR131301012 SPRING WASHER 7
46 T1CR131708105 SOCKET BOLT 3 92 T1CR426325310 GEAR CASE 1 115 T1CR420890PAC BOTTOM HOOK SET 1
47 T1CR131307006 WASHER 1 93 T1CR426325320 RING GEAR 1 115A T1CR420890PAB HOOK ASSY. 1
48 T1CR130402054 KNOCK PIN 1 95 T1CR426325340 DOWEL PIN 4 115B T1CR420890P10 HOOK LATCH 1
49 T1CR131708012 SOCKET BOLT 4 96 T1CR426325351 CHAIN GUIDE 1 115C T1CR130802046 HOOK SPRING 1
115D T1CR130603024 SPRING PIN 1
69
50 T1CR426325200 COUPLING 1 97 T1CR426325360 CHAIN SEPARATOR 1

51 T1CR426325212 WHEEL HOUSING 1 98 T1CR426325380 BRAKE TUBE 1 118 T1CR426335710 THRUST RING 1
52 T1CR426325220 TOP PIN 1 99 T1CR426325371 BOTTOM PLATE 1 119 T1CR130121111 THRUST BEARING<51111> 1
53 T1CR426325230 SPACER 1 100 T1CR130104004 BEARING 2 122 T1CR420890RB0 IDLE SHEAVE 1

123 T1CR420890QH0 BOTTOM HOOK COVER 2
54 T1CR420875MN0 CHAIN END SET 1 101 T1CR130104010 BEARING 2
124 T1CR426335590 BOTTOM YOKE ASSY. 1
55 T1CR130104019 WASHER
BEARING 1 102 T1CR130104005 BEARING 12
127 T1CR131612090 HEX HEAD BOLT 1
56 T1CR130107013 BEARING 1 103 T1CR131103058 O RING 1
128 T1CR134501012 U NUT 6
57 T1CR134501016 U NUT 1 104 T1CR131103063 O RING 1
129 T1CR134401012 HEX NUT 1
58 T1CR131301016 SPRING WASHER 1 105 T1CR130302020 RETAINING RING 3
132 T1CR131301012 SPRING WASHER 7
134 T1CR130109012 BEARING 2
131 KER112 LOAD CHAIN FT
63 T1CR426325730 SET PIECE 1 110 T1CR131706012 SOCKET BOLT 12
TCR6000-2 Main Body

72 T1CR426325420 PISTON COVER 1 114 T1CR130301042 RETAINING RING 6
73 T1CR426325430 BRAKE DISK 1
74 T1CR130408084 KEY 2
Cord Control Valve Body
70
Part # Part #
TCR500C Parts TCR500C Parts
Figure Figure
TCR1000C2 TCR3000C Part Name Per TCR1000C2 TCR3000C Part Name Per
# #
TCR1000C TCR6000C2 Hoist TCR1000C TCR6000C2 Hoist
TCR2000C2 TCR2000C2
67 T1CR426224110 T1CR426325113 CHAIN LEVER 1 205 T1CR426224051 BRAKE NUT 1
68 T1CR426224120 ROLLER SHAFT 1 206 T1CR426224063 VALVE BODY 1
68A T1CR132108008 SET SCREW 1 207 T1CR426224070 TOP COVER 1
69 T1CR426224130 LIMIT ROLLER 1 208 T1CR426224083 SIDE COVER (L) 1
69A T1CR426325740 CAM 1 209 T1CR426224093 SIDE COVER (R) 1
T1CR137309076 NAME PLATE 500 210 T1CR426224101 LIMIT GUIDE 1
T1CR137309078 NAME PLATE 1000, 1000-2 211 T1CR426224C40 BRAKE BUSHING 1
134 T1CR137309079 NAME PLATE 2000-2 1 212 T1CR426224C50 LIMIT BUSHING 1

213 T1CR426224C60 SPOOL PISTON 2
T1CR137309082 NAME PLATE 3000
214 T1CR426224C70 SPRING SEAT 2
T1CR137309088 NAME PLATE 6000-2
215 T1CR426224140 LIMIT LEVER 1
139 T1CR130802081 ROPE CRIMP 2
216 T1CR130802216 SPRING 1
140 T1CR426225460 T1CR426326461 LIMIT SHAFT 1
217 T1CR136102164 SIDE PACKING 2
141 T1CR130802218 SPRING 2
218 T1CR136102161 VALVE PACKING 1
142 T1CR426225470 UNDER COVER 1
219 T1CR136102162 T1CR136102192 TOP PACKING 1
143 T1CR426225540 CORD LEVER 1
220 T1CR136102163 UNDER PACKING 1
144 T1CR130802081 S-TYPE WIRE 2 221 T1CR426224A90 EXHAUST PLATE 1
71
145W* T1CR138001015WH WHITE CORD (UP) FT* 222 T1CR137402031 NYLON SILENCER 1
145W* T1CR138001015WH WHITE CORD (DOWN) FT* 223 T1CR130301025 RETAINING RING 1
148 T1CR134902003 HEX SOCKET PIPE PLUG 3 224 T1CR130301058 RETAINING RING 1
149 T1CR426224C30 T1CR426325C30 MAIN BUSHING 1 225 T1CR131706012 SOCKET BOLT 2
150 T1CR131706018 SOCKET BOLT 1 226 T1CR131706025 SOCKET BOLT 4
151 T1CR132805010 HEX FLAT HEAD MACH. SCREW 4 227 T1CR131706040 SOCKET BOLT 3
152 T1CR130302010 RETAINING RING 1 228 T1CR131706060 SOCKET BOLT 3
156 T1CR130790012 HAIRPIN COTTER 1 229 T1CR132405008 MACHINE SCREW 2
157 T1CR426325750 WASHER 1 230 T1CR132306035 SET SCREW 1
159 T1CR134703060 T1CR134703070 INLET BUSHING 1 231 T1CR134902003 HEX SOCKET PIPE PLUG 3
165 T1CR135000500 T1CR420845DA0 HOSE STEM ASSEMBLY 1 232 T1CR134403006 HEX NUT 1
180 E2R567-001H WARNING TAG 1 233 T1CR134501008 U-NUT 1
190 T1CR136602625 GRIP (W) 1 235 T1CR130604010 SPRING PIN 2
191 T1CR136602626 GRIP (R) 1 236 T1CR131103004 O-RING 2
237 T1CR131103021 O-RING 2
192 T1CR136602627 HANDLE 1

238 T1CR131103022 O-RING 7
201 T1CR426224013 MAIN SPOOL 1
239 T1CR131103024 O-RING 2
202 T1CR426224021 BRAKE SPOOL 1
240 T1CR131103027 O-RING 2
203 T1CR426224C20 SPOOL CYLINDER 2
241 T1CR136803032 SCREEN 1
204 T1CR426224041 BRAKE RETAINER 1
*Specify the hoist's lift or the required pendant drop when ordering.
Pendant Control Valve Body
72
Part # Part #
TCR500P Parts TCR500P Parts
Figure Figure
TCR1000P2 TCR3000P Part Name Per TCR1000P2 TCR3000P Part Name Per
# #
TCR1000P TCR6000P2 Hoist TCR1000P TCR6000P2 Hoist
TCR2000P2 TCR2000P2
67 T1CR426224110 T1CR426325113 CHAIN LEVER 1 208 T1CR426224083 SIDE COVER (L) 1
68 T1CR426224120 ROLLER SHAFT 1 209 T1CR426224093 SIDE COVER (R) 1
68A T1CR132108008 SET SCREW 1 210 T1CR426224101 LIMIT GUIDE 1
69 T1CR426224130 LIMIT ROLLER 1 211 T1CR426224C40 BRAKE BUSHING 1
212 T1CR426224C50 LIMIT BUSHING 1
69A T1CR426325740 CAM 1
213 T1CR426224C60 SPOOL PISTON 2
T1CR137309076 NAME PLATE 500
214 T1CR426224C70 SPRING SEAT 2
134 T1CR137309078 NAME PLATE 1000, 1000-2 1
215 T1CR426224140 LIMIT LEVER 1
T1CR137309079 NAME PLATE 2000-2 216 T1CR130802216 SPRING 1
T1CR137309082 NAME PLATE 3000 217 T1CR136102164 SIDE PACKING 2
T1CR137309088 NAME PLATE 6000-2 218 T1CR136102161 VALVE PACKING 1
140 T1CR426224461 T1CR426325461 LIMIT SHAFT 1 219 T1CR136102162 T1CR136102192 TOP PACKING 1
141 T1CR130802217 SPRING 2 220 T1CR136102163 UNDER PACKING 1
142 T1CR426224470 UNDER COVER 1 221 T1CR426224A90 EXHAUST PLATE 1
222 T1CR137402031 NYLON SILENCER 1
73
148 T1CR130302010 RETAINING RING

223 T1CR130301025 RETAINING RING 1
149 T1CR426224C30 T1CR426325C30 MAIN BUSHING 1
224 T1CR130301058 RETAINING RING 1
HEX FLAT HEAD MACHINE
151 T1CR132805010 4 225 T1CR131706012 SOCKET BOLT 2
SCREW
226 T1CR131706025 SOCKET BOLT 4
SLOTTED HEAD MACHINE
152 T1CR132506012 1 227 T1CR131706040 SOCKET BOLT 3
SCREW
156 T1CR130790012 HAIRPIN COTTER 1 228 T1CR131706060 SOCKET BOLT 3
229 T1CR132405008 MACHINE SCREW 2
157 T1CR426325750 WASHER 1
230 T1CR132306035 SET SCREW 1
158 T1CR137285010 90 DEGREE TUBE FITTING 3
231 T1CR134902003 HEX SOCKET PIPE PLUG 3
159 T1CR134703060 T1CR134703070 INLET BUSHING 1
232 T1CR134403006 HEX NUT 1
165 T1CR135000500 T1CR420845DA0 HOSE STEM ASSEMBLY 1
233 T1CR134501008 U-NUT 1
180 E2R567-001H WARNING TAG 1 235 T1CR130604010 SPRING PIN 2
201 T1CR426224013 MAIN SPOOL 1 236 T1CR131103004 O-RING 2
202 T1CR426224021 BRAKE SPOOL 1 237 T1CR131103021 O-RING 2
203 T1CR426224C20 SPOOL CYLINDER 2 238 T1CR131103022 O-RING 7
204 T1CR426224041 BRAKE RETAINER 1 239 T1CR131103024 O-RING 2

205 T1CR426224051 BRAKE NUT 1 240 T1CR131103027 O-RING 2
241 T1CR136803032 SCREEN 1
206 T1CR426224063 VALVE BODY 1
207 T1CR426224070 TOP COVER 1
Pendant Handle
Parts
Figure
Part Number Part Name Per
Number
Handle
T1CR420226VRD PENDANT VALVE ASSEMBLY 1

300 T1CR420218VB0 THROTTLE VALVE 2
301 T1CR420226VR0 VALVE BODY 1
302 T1CR420218VF0 BUSHING 2
303 T1CR130402071 LEVER PIN 1
304 T1CR420218VH0 LEVER 2
305 T1CR130802220 SPRING 6X14X0.6 2
306 T1CR132106006 SET SCREW M6X6 1
307 T1CR131109001 O-RING S-3 (HS90) 2
308 T1CR131103008 O-RING S-10 2
74
309 T1CR131103009 O-RING S-11.2 2

330 T1CR135106302 HOSE JOINT H-2 PT 1/8-7 3
332 T1CR137501012 HOSE BAND 8.8~10.5 3
335 T1CR130802081 S-TYPE WIRE 1
360* T1CR137240926 POLYURETHANE HOSE HR-6R 2.1M 3
363 T1CR135106303 HOSE JOINT GHJL-0107 (HOIST) 3 Pendant Handle – Current Version
361 T1CR230708005 WIRE CABLE 1
365 T1CR135111022 CONNECTOR EBG2022BK (HOIST) 1
**Pendant Assembly applies to hoists beginning with serial number 8G _ _ _ _and beyond.
Parts
Pendant Handle
Figure
Part # Part Name Per
#
Handle
152 T1CR132506012 SLOTTED HEAD MACHINE SCREW 1

160 T1CR42622452D PENDANT HANDLE CP 1
154 T1CR426221E20 HOSE NIPPLE 3
153 T1CR137240020 PENDANT HOSE ASSEMBLY FT
155 T1CR136102094 SEAL WASHER 3
160A T1CR426224520 CONTROL HANDLE 1
160B T1CR130501004 STEEL BALL 2
160C T1CR130802255 PENDANT VALVE SPRING 2
160D T1CR426221H30 PENDANT VALVE SEAT 2
70
75
160E T1CR131103008 O-RING 4

160F T1CR426224480 CONTROL SPOOL 2
160G T1CR426224530 CONTROL BUSH 2
160H T1CR426221H60 PUSH ROD 2
160J T1CR136602023 VALVE LEVER (U) 1
160K T1CR136602024 VALVE LEVER (D) 1
160L T1CR130402006 LEVER PIN 1
160M T1CR426221H90 BUFFER SLEEVE 2
160N T1CR130305007 CIR-CLIP 2
160P T1CR130802256 BUFFER SPRING 2
160Q T1CR426221J20 BUFFER ROD 2
160R T1CR132112010 SET SCREW 2
160S T1CR426221J40 HANDLE COVER 1 Pendant Handle - Old Version
160T T1CR132805010 HEX FLAT HEAD MACHINE SCREW 4
160U T1CR132105005 SET SCREW 2
This page intentionally left blank
10.0 Warranty
Warranty Policy and Procedures

Kito Corporation (“Kito”) extends the following warranty to the original purchaser (“Purchaser”)
of new products manufactured by “Kito” (Kito’s Products).
1. “Kito” warrants that Kito’s Products, when shipped, shall be free from defects in
workmanship and/or materials under normal use and service and “Kito” shall, at the
election of “Kito”, repair or replace free of charge any parts or items which are proven to
have said defects, provided that all claims for defects under this warranty shall be made
in writing immediately upon discovery and, in any event, within one (1) year from the
date of purchase of Kito’s Products by “Purchaser” and provided, further, that defective
parts or items shall be kept for examination by “Kito” or its authorized agents or returned
to Kito’s factory or authorized service center upon request by “Kito”.
2. “Kito” does not warrant components of products provided by other manufacturers.

However, to the extent possible, “Kito” will assign to “Purchaser” applicable warranties
of such other manufacturers.
3. Except for the repair or replacement mentioned in (1) above which is “Kito”’s sole
liability and purchaser’s exclusive remedy under this warranty, “Kito” shall not be
responsible for any other claims arising out of the purchase and use of Kito’s Products,
regardless of whether “purchaser”’s claims are based on breach of contract, tort or other
theories’ including claims for any damages whether direct, indirect, incidental or
consequential.
4. This warranty is conditional upon the installation, maintenance and use of Kito’s
Products pursuant to the product manuals prepared in accordance with content
instructions by “Kito”. This warranty shall not apply to Kito’s Products which have been
subject to negligence, misuse, abuse, misapplication or any improper use or
combination or improper fittings, alignment or maintenance.
5. “Kito” shall not be responsible for any loss or damage caused by transportation,
prolonged or improper storage or normal wear and tear of Kito’s products or for loss of
operating time.
6. This warranty shall not apply to Kito’s Products which have been fitted with or repaired
with parts, components or items not supplied or approved by “Kito” or which have been
modified or altered.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,

INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR A PARTICULAR PURPOSE.
WEBSITE : www.kito.ca
E-MAIL : info@kito.ca
TOLL FREE: 1-888-322-KITO (5486)
Kito Canada Inc. West Kito Canada Inc. East

309-3815 1st Avenue 36-2400 Lucknow Drive
Burnaby, BC V5C 3V6 Mississauga, ON L5S 1T9
Phone: 604-291-9955 Phone: 905-405-0905
Fax: 604-294-8855 Fax: 905-405-0906

TCR Operation and Parts

Uploaded by

Copyright:

Available Formats

TCR Operation and Parts

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TCR Operation and Parts

Uploaded by

Copyright:

Available Formats

BULLETIN NO.

Code Number and Serial Number

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

2.3 Part Names

3.0 Pre-operational Procedures………………………………………………………………………... 19

3.1 Air Supply System Requirements

3.2 Air Supply Capacity And Regulation

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

4.2 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

5.2 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

6.1 Air Hoist Lubrication

6.2 Load Chain Lubrication

6.3 Hooks and Suspension Components

7.0 Maintenance & Handling…………………………………………………………………………… 41

7.1 Load Limiter

7.3 Load Chain

7.4 Load Sheave

7.7 Outdoor Installation

9.0 Parts List…………………………………………………………………………………………….. 52

1.1 Terms and Summary

Figure 1-1 Warning Tag Attached to Air Hoist

2.1.1 Product Code

2.1.2 Operating Conditions and Environment

Temperature range: -10° to +60°C (+14° to +140°F)

1 TCR1000P2 6 34 / 22 19/ 29 63 / 49 48 / 57 6.3 x 2 76 8

1 TCR1000C2 6 34 / 22 19/ 29 63 / 49 48 / 57 6.3 x 2 76 8

1/4 TCR250P 12 11.3 4 4.4 6.9 0.9 2.8 1.3 0.7

Single Fall Hoist Double Fall Hoist

Figure 2-1 Pendant Model TCR (See Table 2-3)

1/4 TCR250C 12 11.3 4 4.4 6.9 0.9 2.8 1.3 0.7 4

Single Fall Hoist Double Fall Hoist

Figure 2-2 Cord Model TCR (See Table 2-4)

Figure 2-7 Hoist Part Identification Diagrams TCR 6000P2, 6000C2

Figure 2-8 Hoist Part Identification Diagrams TCR250C

Figure 2-9 Hoist Part Identification Diagrams TCR250P

Figure 2-10 Hoist Part Identification Diagrams TCR250M

3.1 Air Supply System Requirements

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

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