Toku TCR Series Instruction Manual
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Toku TCR Series Instruction Manual

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AIR HOIST
TCR-series
TOKU PNEUMATIC PRODUCTS
TCR-250C
TCR-250DP
TCR-250DPE
www.air-allied.com.au
TCR-250M
TCR-250ME
M A N U A L
INSTRUCTION MANUAL
This manual is a guidebook which will show you how to use
the air chain hoist safely and efficiently.
Read this manual thoroughly before starting to use air hoist.
This manual shall be accessible at all time.
TOKU PNEUMATIC CO., LTD
No.5
21-07
sales@air-allied.com.au
Air & Allied Sales (Pacific) Pty Ltd
www.air-allied.com.au

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  • Page 1 This manual is a guidebook which will show you how to use the air chain hoist safely and efficiently. Read this manual thoroughly before starting to use air hoist. This manual shall be accessible at all time. TOKU PNEUMATIC CO., LTD No.5 21-07 sales@air-allied.com.au Air &...
  • Page 2 sales@air-allied.com.au Air & Allied Sales (Pacific) Pty Ltd www.air-allied.com.au...

  • Page 3: Introduction

    （１） INTRODUCTION We thank you for your recent purchase of a TOKU AIR HOIST This manual is a guidebook which will show you how to use the air chain hoist safely and efficiently. Please read this manual in its entirety and understand the contents before proceeding to operate the hoist. Also, convey this information to the actual operators of the hoist.

  • Page 4: Table Of Contents

    （２） Table of Contents Page ・・・・・・・・・・・・・・・・・・・・・・・・・・ Introduction ・・・・・・・・・・・・・・・・・・・・・・・・・・ Table of Contents ・・・・・・・・・・・・・・・・・・・・・・・・・・ Safety Precautions ・・・・・・・・・・・・・・・・・・・・・・・・・・ Precautions during operation ・・・・・・・・・・・・・・・・・・・・・・・・・・ Specifications ・・・・・・・・・・・・・・・・・・・・・・・・・・ Name of parts ・・・・・・・・・・・・・・・・・・・・・・・・・・ Preparation before operation ・・・・・・・・・・・・・・・・・・・・・・・・・・ Before Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・ How to operate (10) ・・・・・・・・・・・・・・・・・・・・・・・・・・ Maintenance and inspection (11) ・・・・・・・・・・・・・・・・・・・・・・・・・・...

  • Page 5: Safety Precautions

    （３） Safety Precautions WARNING When using the hoist, obey the safety precautions written in this instruction manual. WARNING ; Obey the safety rules at the job site. ・The people who operate the hoist should be the one who have received instruction to properly operate the hoist.
  • Page 6 Contact your dealer for repairs or inspections of the hoist. When parts are needed to be changed, use only genuine TOKU parts. Non-genuine parts are not certified their strength and durability. That may cause fatal accidents, and it is very dangerous.

  • Page 7: Precautions During Operation

    （４） Precautions during operation WARNING ; Installation of hoist must be performed by trained personnel Installation of the hoist must be performed by trained personnel only. If installation is not performed properly this may lead to an accident with personal and is very dangerous. WARNING ;...
  • Page 8 WARNING ; Before using the hoist, make sure the chain is not twisted. As shown in the diagram, make sure the chain is not twisted during usage of the hoist. Otherwise chain may break and can cause accidents. twist WARNING ;...
  • Page 9 WARNING ; Make sure the load is balanced. When using a wire rope or a sling, make sure the load is balanced before lifting. The load may fall and it is dangerous. WARNING ; Do not lift or lower suddenly. When suddenly lowering the load, this may lead to poor balance of the load and the load may fall.
  • Page 10 WARNING ; Use one hoist for one load. When lifting one load by more than 2 hoists, imbalanced of stress applied to single hoist. WARNING ; Lubrication to the chain. Always lubricate lift chain. If there is no oil on the chain, chain will be worn out quickly. This may lead to dropping of the load and personal injury due to breaking of the chain and it is very dangerous.
  • Page 11 CAUTION ; Make sure the correct air pressure is used with the hoist. ・Operating air pressure is 0.4-0.6 MPa ≪Recommended air pressure 0.6 MPa≫ Operating at air pressures above 0.4-0.6 MPa will affect the durability, performance and safety of the hoist.

  • Page 12: Specifications

    （５） Specifications １． Operating conditions ① Operating Air pressure： 0.4 MPa-0.6 MPa ≪Recommended 0.6MPa≫ ② Operating Ambient Temp. range： -10℃ to 60℃ ≪Recommended 20℃≫ ③ Operating location： Inside ④ Applications： For vertical lifting loads ２． Specifications LIFTING WITH LIFTING STANDARD WEIGHT MINIMUM FULL LOAD...

  • Page 13: Name Of Parts

    （６） Name of parts TCR-250C TCR-250DP sales@air-allied.com.au Air & Allied Sales (Pacific) Pty Ltd www.air-allied.com.au...
  • Page 14 TCR-250DPE TCR-250M/ME sales@air-allied.com.au Air & Allied Sales (Pacific) Pty Ltd www.air-allied.com.au...

  • Page 15: Preparation Before Operation

    （７） Preparation before operation １．Preparation of the compressor and drain removal ・Method of selection; (Air consumption of each model is shown in the chapter “Specification”.) ( Air consumption × 10 ) × Hoist Quantity ≦ Compressor Horse Power ・Method of drain removal; Rust will develop leading to the cause of trouble if the drain is not removed from the compressor.
  • Page 16 ３．Preparation of the Air Hose CAUTION ; Do not use Quick Coupler for connection. Quick Coupler restricts air flow too much. This leads to significant degradation of the hoist performance and to trouble on brake part. Do not use quick coupling to connect hose and piping. ・Size of Hose;...
  • Page 17 ５．Installation of chain basket (See the drawing shown below) Standard：TCR-250M/ME Option：TCR-250C/DP/DPE ・Install the chain basket as shown in the drawing below. ※ Make sure that bolts and nuts do not loosen when touching Bucket Arm. TCR-250C TCR-250DP TCR-250DPE TCR-250M TCR-250ME sales@air-allied.com.au Air &...
  • Page 18 ６．Installation of Pendant (TCR-250DP) ・Install the pendant as shown in the drawing below. ・Make sure each urethane hose is connected to the correct port. ７．Installation of Pendant (TCR-250DPE) ・Install the pendant as shown in the drawing below. ・Make sure each urethane hose is connected to the correct port. ・Fasten the hose band tightly.
  • Page 19 ８．Installation of Cord (TCR-250C) ・Install the Cord as shown in the drawing below. ９．Installation of Coil hose (TCR-250M/ME) ・Install the tubes and the hose support as shown in the drawing below. ・Make sure to insert the tube until the end. ・Make sure each tubes are connected to the correct port.
  • Page 20 １０． Installation of air hoist ① Hang up the hoist. ② Install the upper hook to the supporting beam. WARNING ; Make sure the upper hook is assembled correctly. Make sure the upper hook is assembled to the recommended material and also make sure the hook safety claw is securely locked.

  • Page 21: Before Operation

    （８） Before Operation １．Check operating air pressure CAUTION ; Maintain the correct air pressure. ・Operating air pressure is 0.4-0.6 MPa ≪Recommended air pressure 0.6 MPa≫ Operating at air pressures above 0.4-0.6 MPa will affect the durability, performance and safety of the hoist.
  • Page 22 ３．Test operation WARNING ; Before actual operation, check for abnormal operation or sounds. Operate the hoist with no load up and down at low speed. Check for abnormal operation or sounds. If abnormal operation or sounds are found, stop operation and return the unit for inspection to your service center.
  • Page 23 TCR-250M/ME ６．Check the sling equipment WARNING ; Check the sling chain and wire rope. Before using the slings and wire ropes, make sure they are rated correctly to use for the job, and also make sure they are not damaged in any way. If the hoist is operated with abnormally, this may lead to dropping of the load and may lead to personal injury.

  • Page 24: How To Operate

    （９） How to operate １. How to start and stop the Hoist TCR-250C（Cord） Pull the cord to operate. Release to stop. TCR-250DP/DPE/M/ME （Pendant） Press the lever to operate. Release to stop. TCR-250M/ME TCR-250DP TCR-250DPE sales@air-allied.com.au Air & Allied Sales (Pacific) Pty Ltd www.air-allied.com.au...
  • Page 25 ２. Speed Adjustment ・TCR-250DP/DPE/M/ME For the pendant type, the more you depress the lever, the faster the hoist will operate. As shown in the diagram below, if you depress the lever a small amount the speed will be slow. Slow Fast ・TCR-250C For the cord type, the more you pull the cord, the faster the hoist will operate.
  • Page 26 ３. Lifting and lowering the load ① Put a wire rope or a chain sling onto the load. ② Put the wire rope of chain sling onto the swivel hook. ③ Make sure that the hook safety claw is locked and secured. Hook Safety Claw 〇...
  • Page 27 ５. Special function (TCR-250M/ME) ① Handle-Under hook distance adjustment. The handle of TCR-250M/ME can be attached to link chain. This enables to fix the under hook onto handle, or set the under hook free. By fixing the under hook onto handle, one-handed operation is available when the sling is flexible like wires.
  • Page 28 ② Handle conversion The handle can convert for right handed and left handed. Instruction WARNING Before converting, always shut off the main air (pressurized air from air compressor). Loosen all of the 6 bolts on backside of handle and remove valve body with grip. Make sure all of the 8 O-rings are fixed in grooves as shown in the diagram.

  • Page 29: Maintenance And Inspection

    （１０） Maintenance and inspection WARNING ; Inspect the Air Hoist regularly. To operate the hoist safely, it is necessary to obey the crane safety regulations and also perform daily inspections, monthly inspections and annual inspections. If the hoist is not inspected on a regular basis this may lead to damage to the hoist and result in personal injury ★DAILY INSPECTION １．Air pressure and oil...
  • Page 30 ★MONTHLY INSPECTION（shall be carried out more depending on working frequency） １．Chain (Rust, elongation and damage) Inspect the chain according to “Maintenance Chart”. If it exceeds the limits, stop using and replace. ２．Brake Make sure that the brake is working properly. If the load should slip down, stop using and contact the dealer or distributor to repair the hoist.
  • Page 31 Maintenance Chart Part Dimension Criteria Service Limit ・If chain is badly oxidized, replace it. ・If chain is badly damaged, replace ・If the dimension exceeds following Chain limits, replace the chain. Diameter 4.2mm-3.8mm 5 link length 60mm-61.5mm ・If the length L is larger than Mark Brand new dimension brand-new dimension, replace it.

  • Page 32: How To Install Chain

    If the chain is twisted and assembled, the chain will break and may result in personal injury. ① Use TOKU genuine chain. ② Suspend the hoist and attach a wire to the end of the chain. (Smaller wire is easier) ③...

  • Page 33: Trouble Shooting

    When the air hoist needs to be disassembled or repaired, please contact Air & Allied Sales (Pacific) P/L for your local authorised service center. Use genuine Toku parts to make sure the strength and durability of the parts are correct, if imitation parts are used this may lead to personal injury and is dangerous.
  • Page 34 sales@air-allied.com.au Air & Allied Sales (Pacific) Pty Ltd www.air-allied.com.au...
  • Page 35 sales@air-allied.com.au Air & Allied Sales (Pacific) Pty Ltd www.air-allied.com.au...
  • Page 36 Customer Memo Record information such as the distributor name, model number and serial number. It will be of good use when you bring the unit in for servicing. Date of Purchase Distributor Information Model Serial Number This is a high precision manufactured product. As a result if the unit does not work Operate properly do not attempt to repair the unit.

This manual is also suitable for:

Tcr-250cTcr-250dpTcr-250dpeTcr-250mTcr-250me

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