KITO Harrington RYU030A25HDD Owner's Manual
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KITO Harrington RYU030A25HDD Owner's Manual

Electric wire rope hoist and trolley 3 ton and 5 ton capacity
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EFFECTIVE: May 8, 2019

ELECTRIC
WIRE ROPE
HOIST and TROLLEY
RY SERIES
3 Ton and 5 Ton Capacity
Hoist Code and Serial Number

This equipment should not be installed, operated or
maintained by any person who has not read and
understood all the contents of this manual. Failure to read
and comply with the contents of this manual can result in
serious bodily injury or death, and/or property damage.
© Harrington Hoists, Inc.
All Rights Reserved

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Summary of Contents for KITO Harrington RYU030A25HDD

  • Page 1 EFFECTIVE: May 8, 2019  ELECTRIC WIRE ROPE HOIST and TROLLEY RY SERIES 3 Ton and 5 Ton Capacity Hoist Code and Serial Number  This equipment should not be installed, operated or maintained by any person who has not read and understood all the contents of this manual.

  • Page 2: Table Of Contents

    Table of Contents Section Page Number Important Information and Warnings…………………………………………….……………………. 4 Terms and Summary Warning Tags and Labels Technical Information …………………………….…………………………………………………… 10 Specifications Dimensions Part Names Pre-operational Procedures……………………………………………………………………….….. 16 General Information Handling Mounting Location Assembly, Adjustments and Mounting Block Operated Limit Switch (BLS) Adjustment Electrical Connections Pendant Installation Hoist Variable Frequency Drive (VFD) Setup...
  • Page 3 Section Page Number Inspection……………………………………………………………………………………………….. 48 General Inspection Classification Frequent Inspection Periodic Inspection Occasionally Used Hoists and Trolleys Inspection Records Inspection Methods and Criteria Maintenance & Handling………………………………………………………………………….…… 61 Count/Hour Meter Lubrication Lubrication – Hoist Gearbox Hoist Motor Brake Trolley Brake Adjustment Wire Rope, Reeving and Adjustment Storage Outdoor Installation...

  • Page 4: Important Information And Warnings

    Important Information and Warnings 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.
  • Page 5  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.
  • Page 6  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.
  • Page 7  HAZARDOUS VOLTAGES ARE PRESENT IN THE CONTROL BOX, OTHER ELECTRICAL COMPONENTS, AND CONNECTIONS BETWEEN THESE COMPONENTS. Before performing ANY mechanical or electrical maintenance on the equipment, de-energize (disconnect) the main switch supplying power to the equipment; and lock and tag the main switch in the de-energized position. Refer to ANSI Z244.1, “Personnel Protection –...
  • Page 8  It is the responsibility of the owner/user to install, inspect, test, maintain, and operate a trolley hoist in accordance with ANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, "National Electric Code". If the trolley 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.

  • Page 9: Warning Tags And Labels

    Warning Tag and Labels The warning tag illustrated below in Figure 1-1 is supplied with each RY hoist and trolley hoist shipped from the factory. If the tag is not attached to the pendant cord for your hoist/trolley, order a tag from your dealer and install it.

  • Page 10: Technical Information

    Technical Information  NOTE: Throughout this section the symbol “ “ is used as a place holder for the trolley hoist voltage. The available trolley hoist voltages are listed in Section 2.1.1 that follows. Specifications 2.1.1 Product Code: 2.1.2 Operating Conditions and Environment Temperature Range: -4°...
  • Page 11 Table 2-2 Ultra-Low Headroom Trolley Hoists Hoist Specifications Lifting Motor 3 Phase - 50/60Hz Lifting Speed Rated Current Reeving Rope Lift Capacity (ft/min) (amps) Product Code (Parts/ Dia. (Ton) (ft.) Output reeving) (mm) Initial (Hp) Load @208-230V/ @415- 460V/ High/Low High 60Hz 60Hz...

  • Page 12: Dimensions

    Dimensions Table 2-4 Ultra-Low Headroom Trolley Hoist Dimensions Flange Dimensions (in) Range Capacity Lift Product Code (Tons) (ft) (in) 32.4- 4.92- 23.6 13.78 RYU030A25HDD 36.3 27.8 29.5- 13.79- 23.6 19.68 22.8 7.3 14.1 17.4 13.5 4.9 7.3 13.7 6.7 8.5 32.4- 4.92- less...
  • Page 13 Table 2-7 Hook Dimension* Units = inch Capacity Product Code (Tons) (in) (in) (in) (in) (in) (in) (in) (in) RYU030A25HDD RYU030A33HDD RYU050B25HDD RYU050B33HDD Notes: *Refer to Section 5, Table 5-6 for inspection dimensions and limits. Table 2-8 Reaction Forces at Rated Load Ultra-Low Headroom Monorail Trolley Flange Range Capacity...
  • Page 14 Table 2-9 Trolley Wheel Dimensions φD Capacity Product Code (Tons) (in) (in) RYU030A25HDD 0.79 3.86 RYU030A33HDD RYU050B25HDD 0.79 3.86 RYU050B33HDD...

  • Page 15: Part Names

    Part Names Figure 2-1 RY Part Names...

  • Page 16: Pre-Operational Procedures

    Pre-operational Procedures General Information 3.1.1 When the RY trolley hoist is incorporated into lifting systems utilizing other equipment, follow and complete all pre-operational procedures and instructions provided with the equipment. Special wiring considerations must also be taken to complete the integration of the RY trolley hoist into the system.

  • Page 17: Mounting Location

    Figure 3-3 Sling Lifting Method Mounting Location  3.3.1 Prior to mounting the RY trolley hoist ensure that the wire rope has not loosened on the wire rope drum. Due to vibration or other impacts during transportation of the product, the wire rope wound on the Rope Drum may be loosened.

  • Page 18: Assembly, Adjustments And Mounting

     3.3.5 See Section 6.8 for outdoor installation considerations. Assembly, Adjustments and Mounting  When installing the trolley hoist on a beam, ALWAYS raise the hoist into position with the trolley assembled together and securely attached to a pallet/skid. Raise the trolley hoist with a forklift, lifting platform, or other similar means.
  • Page 19 5) To adjust the flange width of the trolley, loosen the Socket Bolt located on the underside of the “adjustment side” of the Trolley Frame on each as shown in Figure 3-7 and Figure 3-8. To widen the flange width: Loosen the adjusting nut on the outer side of the trolley frame (adjustment side) and tighten the nut on the inner side of the trolley frame (adjustment side) shown in Figures 3-8.
  • Page 20 7) If the end of the runway beam is not accessible, the trolley flange width will need to be opened up to allow the Trolley Hoist to fit around the beam. (See Section 3.4.1 Step 5 for proper procedure to widen flange width.) 8) Once the hoist is in position with the beam flange wheel running surface, the trolley flange can be made narrowed to accommodate the respective beam flange width.
  • Page 21 Note: A (trolley plate spacing) = B (beam flange width) + 2 inches (inc. 5/64 in/2mm space between each trolley wheel and guide roller) Figure 3-10 Trolley Flange Adjustment Example...

  • Page 22: Block Operated Limit Switch (Bls) Adjustment

    Block Operated Limit Switch (BLS) Adjustment The BLS must be adjusted to where the Hoist and the Hook Block do not interfere with each other. The BLS operates when the Upper/Lower Limit Switch does not function due to failure, improper setting, or abnormal operation.

  • Page 23: Electrical Connections

    Electrical Connections  3.6.1 If the Trolley hoist was supplied without a Power Supply Cable. The installer must use a UL List power supply cable Type SJ, SJT, SO, SOO, SOOW, ST, STO or of a type at least equally servicable for the particular application. Rated 90C, 600V minimum. Refer to total AMP draw and NEC®...

  • Page 24: Pendant Installation

    Cable the ground wire will be either Green with Yellow stripe or solid Green. It should always be connected to a suitable ground connection. Do not paint the trolley wheel running surfaces of the beam as this can affect grounding. 9) Replace the Control Cover.
  • Page 25 Figure 3-13 Pendant Terminal Block Location Figure 3-14 Pendant Terminal Connection Figure 3-15 Pendant Strain Relief Attachment...

  • Page 26: Hoist Variable Frequency Drive (Vfd) Setup

    Hoist Variable Frequency Drive (VFD) Setup The hoist Lifting/Lowering VFD is located in the Trolley Hoist Control Box as shown in Figure 3-16. Figure 3-16 VFD Locations  3.8.1 To avoid a shock hazard, DO NOT perform ANY mechanical or electrical maintenance on the dual speed (VFD control) trolley or hoist within 5 minutes of de-energizing (disconnecting) the trolley or hoist.
  • Page 27 Figure 3-17 VFD Keypad/Display Interface 3.8.8 When power is supplied to the hoist the VFD LED operator display will illuminate as shown Table 3-1. Table 3-1 LED Operator Display 3.8.9 During operation the data display will exhibit illuminating or blinking data as shown in Figure 3- Figure 3-18 Illuminating/Blinking Display...
  • Page 28 3.8.10 The digital display uses a seven segment character to form the specific charaters used in the display. Table 3-2 shows the corresponding digital characters to its English eqivalent. Table 3-2 Digital Character Key 3.8.11 The LED Lamp display provides hoist status. Table 3-3 shows some of the status displays. Table 3-3 LED Lamp Display 3.8.12 The Run Lamp display provides hoist “RUN”...
  • Page 29 Table 3-4 Run Lamp 3.8.13 All of the hoists have speed/frequency ranges that can be customized to a specific application. Refer to Table 3-5 for specific hoist speed/frequency ranges. To set custom speeds for an application, follow the procedure listed in Table 3-6 and refer to the speed/frequency Table 3-7. Table 3-5 Hoist Speed and VFD Frequency Ranges 200V = 208 –...
  • Page 30 Table 3-6 Hoist VFD Speed/Frequency Change Procedure   Each dual speed hoist model has a range of available speeds/frequencies (upper and lower limits). Any value outside the range listed in Table 3-5 for your specific hoist is strictly prohibited. ...
  • Page 31 Table 3-7 Additional Speed Settings - Lifting Lifting Speed Frequency – Hz ft/min 3 Ton - 230V 3 Ton - 460V 5 Ton - 230V 5 Ton – 460V Factory Low Setting 10.1 10.2 10.0 11.3 11.3 11.0 11.2 12.4 12.4 12.1 12.3...

  • Page 32: Light-Load High Speed Function

    3.8.14 “Hbb” will appear on the dual speed unit’s VFD display when the Emergency Stop Button is depressed. Turn the Emergency Stop Button clockwise to unlock the controls and allow hoist operation. Light-Load High Speed Function  3.9.1 All RY hoists come equipped with the “Light-Load High Speed Function”. At loads 25% or less than rated load, it allows the hoist to operate in the lifting and lowering direction 1.5 times faster than the standard high speed.

  • Page 33: Hoist Load Limiter (Ll) Adjustment

    3.10 Hoist Load Limiter (LL) Adjustment The RY hoist is equipped with a load limiting device. The LL is adjusted from the factory to activate at 110% to 125% of the rated RY capacity. Change the parameters of the VFD in the Control Box if the LL should be inactivated for the load test or changes and fine-tuning of the activation load are necessary.
  • Page 34 Table 3-9 Load Limiter Setting Values  • Follow the procedure described below to properly perform settings. The range of values (upper and lower limits) that can be set depends on the model. Values that are not included in this range cannot be registered.
  • Page 35 Table 3-11 Load Limiter Inactivation Setting Values 200V = 208 – 230V/400V = 415 – 460V LL Inactivation Settings 200V 400V Capacity Product Code S1-38 S1-41 S1-38 S1-41 High High Speed Speed Speed Speed RYU030A RYU050B 8. Press to confirm the new setting. 9.

  • Page 36: Trolley Variable Frequency Drive (Vfd) Setup

    3.11 Trolley Variable Frequency Drive (VFD) Setup The trolley traversing VFD is located in the Trolley Hoist Control Box as shown in Figure 3-19. Figure 3-19 Trolley Hoist Control Box  3.11.1 To avoid a shock hazard, DO NOT perform ANY mechanical or electrical maintenance on the dual speed (or VFD control) trolley or hoist within 5 minutes of de-energizing (disconnecting) the trolley or hoist.
  • Page 37 Table 3-13 Trolley VFD Speed/Frequency Change Procedure   Each dual speed trolley has a range of available speeds/frequencies (upper and lower limits). Any value outside the range listed in Table 3-11 for your specific trolley is strictly prohibited.  Speeds must be set such as Low [d1-01] and High [d1-02].
  • Page 38 Table 3-14 Additional Speed Settings - Traversing Traversing Speed Frequency – Hz ft/min 10.0 Factory Low Setting 11.0 11.9 12.8 13.7 14.6 15.6 16.5 17.4 18.3 22.9 27.4 32.0 36.6 41.1 45.7 50.3 54.9 60.0 Factory High Setting 3.11.6 All dual speed trolleys have a acceleration/deceleration time parameter range that can be customized to a specific application.
  • Page 39 Table 3-16 Trolley VFD Variable Parameter Setup Procedure   Each dual speed trolley model has a range of available speeds/frequencies (upper and lower limits) and acceleration/deceleration time parameters.  The VFD deceleration/acceleration time within the frequency range (0 to 120 Hz) is actually used by setting the deceleration/accelation time at 120 Hz.

  • Page 40: Hoist Upper And Lower Limit Switch (Ulls) Setup

    3.12 Hoist Upper and Lower Limit Switch (ULLS) Setup The Upper/Lower Limit Switch (ULLS) can automatically stop the Hook Block at preset locations (at two (2) upper-limit and lower-limit points) without requiring a positioning operation (such as “inching”) by the pendant. 3.12.1 Factory Settings 1) The factory set positions of the Upper/Lower Limit Switch are as shown Table 3-17.
  • Page 41 Table 3-18 Setting the Upper and Lower Limit Switches   Do NOT adjust the BLS with wet hands. Failure to comply with this instruction can lead to electric shock, which may seriously affect the operator.  Do NOT set the Upper Limit Switch of the Hook Block to a position higher than the lever of the BLS.
  • Page 42 Figure 3-20 Hoist Upper and Lower Limit Switch (ULLS)

  • Page 43: Pre-Operational Checks And Trial Operation

    3.13 Pre-operational Checks and Trial Operation 3.13.1 Refer to the trolley hoist’s nameplate and record the Product Code, and Serial Numbers in the space provided on the cover of this manual. 3.13.2 Perform pre-operational checks for the trolley hoist:  ...

  • Page 44: Operation

    Operation Introduction  DO NOT WALK UNDER A SUSPENDED LOAD  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.

  • Page 45: Shall's And Shall Not's For Operation

    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.
  • Page 46  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 •...

  • Page 47: Hoist And Trolley Controls

    Hoist and Trolley Controls 4.3.1 Emergency Stop Button – Press the Emergency Stop Button to perform an emergency stop and lock-out of hoist motion controls or to reset the VFD as shown in Figure 4-1. Turn the Emergency Stop Button clockwise to unlock the controls and allow hoist operation. “Hbb” will appear on the dual speed unit’s VFD display when the Emergency Stop Button is depressed.

  • Page 48: Inspection

    Inspection 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 by the employer or employer’s representative as being competent to perform the specific duties.

  • Page 49: Frequent Inspection

    5.2.4 PERIODIC Inspection – visual inspection by a designated person with intervals per the following criteria: Table 5-2 Periodic Inspection Intervals Service Hoist and Trolley Interval Rope Inspection Interval Normal Yearly Service 1) At Least monthly (per OSHA), AND Heavy 2) Determined by a qualified person and based Semiannually Service...

  • Page 50: Occasionally Used Hoists And Trolleys

    5.4.2 For inspections where load suspension parts of the hoist/trolley are disassembled, a load test per ANSI/ASME B30.16 must be performed on the hoist/trolley after it is re-assembled and prior to its return to service. Table 5-4 Periodic Inspection Requirements of frequent inspection. Evidence of loose bolts, nuts, or rivets.

  • Page 51: Inspection Records

    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/trolley.
  • Page 52 Table 5-5 Hoist and Trolley Inspection Methods and Criteria Item Method Criteria Action Hook Block – Visual, Function Bearing parts and surfaces should not show Clean/lubricate, or Swivel Bearing significant wear, and should be free of dirt, grime replace as required. and deformations.
  • Page 53 Table 5-5 Hoist and Trolley Inspection Methods and Criteria Item Method Criteria Action  The full length of the Wire Rope must be inspected for rope diameter, broken strands or wires, and condition. The rope must be free of load for testing to detect any broken wires when bending the rope by hand (especially by radius of rope sheeve).
  • Page 54 Table 5-5 Hoist and Trolley Inspection Methods and Criteria Item Method Criteria Action  Run the hoist into the highest and lowest Wire Rope - Visual Replace as hook positions without load. Twisting required.  If any twisting is detected , untwist the rope immediately.
  • Page 55 Table 5-6 Bottom Hook Dimensions “k” Measured When New: _____________________ *These values are nominal since the dimension is not controlled to a tolerance. The “k” dimension should be measured with the hook is new- this becomes a reference measurement. Subsequent measurements are compared to this reference measurement in order to determine hook deformation/stretch.
  • Page 56 Table 5-7 Wire Rope Wear Dimensions • The ratio of broken wires in a single strand must be less than 10%. • Measure a part of the rope with significant abrasion and check that the diameter “d” is not reduced by 7% or more. •...
  • Page 57 Table 5-8 Various shapes that require the wire rope to be replaced.
  • Page 58 Table 5-9 Hoist Motor Brake  Brake must be properly adjusted before measuring "A". See Section 6.4 "A" Dimension – inch (mm) Capacity Code Standard Discard RY030, RY050 0.82 (20.9) 0.76 (19.4) Table 5-10 Rope Sheave Dimensions • The abrasion of the groove (A) must not exceed 15% of the wire rope diameter.
  • Page 59 Table 5-11 Wheel Dimensions • The dimension “D” must not be reduced to below the limit value due to abrasion of the running surface. • The difference (ellipticity) in the running surface diameter must not exceed 0.0394 in. (1mm). • The dimension “A”...
  • Page 60 Table 5-12 Travel Motor Brake Brake Torque, Default Settings Trolley Motor Output HP (kW) Brake Torque, T (%) Adjusting Bolt Height, A in. (mm) 0.34 (0.25) 0.47 (12) 0.54 (0.4) 0.43 (11) Brake Dimensions Applicable Product Motor ØD (in./mm) Code Output (in./mm) Standard...

  • Page 61: Maintenance & Handling

    Maintenance and Handling Count/Hour Meter A count/hour function is included in all RY trolley hoists as one of the VFD parameters. Below are maintenance recommendations based on the number of starts and hours of operation accessed through the VFD. 6.1.1 Number of Starts/Hours of operation -.
  • Page 62 6.1.2 Hoist Motor Gear Grease – The C/H Meter can be used in conjunction with the average load lifted by the hoist to estimate when the gear grease should be changed. Refer to Table 6-3. Table 6-3 Criteria for Recommended Gear Grease Oil Replacement Loading During Normal Operation Change Gear Oil After: (hours)

  • Page 63: Lubrication

    Lubrication 6.2.1 Wire Rope:  For proper performance the Wire Rope must be maintained in a clean and well lubricated condition.  The rope should be lubricated every 3 months (more frequently for heavier usage or severe conditions).  To lubricate the rope, first remove any dirt, grime, moisture or other accumulations of contaminates. Then coat the Wire Rope with the grease specified in Table 6-6.
  • Page 64 Table 6-6 – Guidelines on Timing of Replacement or Application of Lubricants Specified Timings of Lubricant Lubricant Quantity Part Replacement/Application Brand (Hrs) 3 Ton 5 Ton Nippon Oil Hoist Gear Box 2500g 1600 Epinoc AP (N) 0 Trolley Gear Box Wheel Gear/Idle Gear Nippon Oil, Epinoc AP (N) 2...

  • Page 65: Lubrication - Hoist Gearbox

    Lubrication – Hoist Gearbox  6.3.1 DO NOT use any grease or quantity other than that listed in Table 6-6. New trolley hoists are prefilled with the correct type and amount of grease. There is no need to check before installation, but if at any time the grease is found to be insufficient at an inspection, additional must be added at the Filler Opening, after removing the vent (air breather) as shown in Figure 6-1 and Figure 6-2.
  • Page 66 6.4.3 Motor Brake Unit Removal - Adjustment and inspection of the motor brake requires removal of the motor brake unit from the hoist as an assembly. Refer to Figure 6-6. Remove the four Fan Cover bolts (A), Fan Cover (B), Fan snap ring (C), and Fan washer (D). Pull the Fan (E) off the motor shaft using a wheel puller if necessary.
  • Page 67 Table 6-9 Motor Brake Gap Brake Gap (G) Capacity Code inch (mm) 0.032 (0.8) RY030, RY050...

  • Page 68: Trolley Brake Adjustment

    6.4.5 Brake Lining Inspection –The brake lining is designed for a long life and should provide years of trouble-free service. If the brake lining is being inspected due to excessive load drift during operation (see Section 5.7), disassemble the motor brake and inspect all motor brake parts. Braking surfaces should be clean, free of grease/oil and should not be glazed.
  • Page 69 Figure 6-7 Trolley Motor Brake Adjustment Table 6-10 Trolley Brake Torque Adjustment 1) Loosen the Locknut with a 28mm hex wrench. 2) Loosen the Adjusting Bolt with a 10mm hex drive. Determine the correct Adjusting Bolt height, Dimension A, using the Motor Brake tables on the right.
  • Page 70 6.6.3 After commissioning a new wire rope hoist, or after replacing the Wire Rope, the Wire Rope of multi-fall hoists may twist. This can be seen from the bottom hook block turning, particularly when unloaded.  Twisting in the Wire Rope affects safety and service life. Remove any twists! 6.6.4 Regularly inspect the Wire Rope for twisting and follow the procedure in Section 6.6.6 “Wire Rope Installation/Rope Guide Installation and other corresponding Wire Rope sections.
  • Page 71 Figure 6-17 Figure 6-15 Figure 6-16 10) Remove both Socket Bolts holding Rope Guide B (part with the Support Shaft “guide”) to Rope Guide A. Then move Rope Guide B away from Rope Guide A as shown in Figure 6-18. 11) Referencing Figure 6-19, loosen the other Socket Bolt indicated by the arrow and move Rope Guide A toward the Back Frame side to the position where the Rope Guide A Support Shaft Guide does not contact the Wire Rope.
  • Page 72 12) Move Rope Guide A to a position where it does not interfere with the Support Shaft by the procedure shown in Figure 6-20. Figure 6-20 13) As shown in Figure 6-21, unreeve or remove the Wire Rope from the drum manually by carefully pulling the Wire Rope off the Drum.
  • Page 73 6.6.6 Wire Rope Installation/Rope Guide Installation  The hoist must be properly powered and operational in order to perform the following procedures.  When replacing Wire Rope, check for wear on mating parts, i.e. Drum, Sheaves, Hook Block Sheaves, and replace if necessary. ...
  • Page 74 7) Press the “UP” button on the Pendant and slowly begin lifting, rotating the Drum and winding the Wire Rope tightly onto the Drum for about 120 degrees to the next Wire Rope Clamp location. While keeping the Wire Rope tightly on the Drum, install the second Wire Rope Clamp. Reference Figures 6-25, 6-26 and 6-27.
  • Page 75 Figure 6-29 Figure 6-28 Figure 6-30 Figure 6-31 15) Referring to Figure 6-32, adjust the position of the Rope Guide so that the guide of the Rope Guide A contacts with the last wind of the Wire Rope on the Rope Drum. After the adjustment is finished, tighten the Socket Bolt indicated by the arrow to a torque value of approximately 53 lbf-inch (6 N*m) to fasten the Rope Guide onto the Rope Drum.
  • Page 76 Figure 6-32 16) Hook the Rope Guide B on the Support Shaft as shown in Figure 6-33 and fasten the Rope Guide B with the Socket Bolts. Pay special attention to attach the Rope Guide B so that the Wire Rope comes out from the gap between Rope Guide A and Rope Guide B.
  • Page 77 Figure 6-34 18) Then thread the Wire Rope through the return Sheave on the hoist (see Figure 6-35), then back down through the other Sheave on Bottom Hook Block (see Figure 3-36). Figure 6-35 Figure 6-36 Figure 6-37 19) Insert the end of the Wire Rope into the Terminal being careful to pass through the side not having an arc shape indicated by “R”...
  • Page 78 Figure 6-38 Figure 6-39  Make certain the wire rope is tight against the Terminal Wedge in the Terminal. 21) Attach the Wire Rope Clamp approximately 4 times the Wire Rope diameter from the Terminal as shown in Figure 6-40 and fully tighten the nuts to a torque value of approximately 80 lbf-inch (9 N*m). Do NOT clamp the free end of the rope to the load bearing rope fall (the rope between the Terminal and the Bottom Hook Block) see Figure 6-41.

  • Page 79: Storage

    Figure 6-42 Figure 6-43 Storage 6.7.1 The storage location should be clean and dry. 6.7.2 Care should be taken to not damage any of the electrical power cords or fittings. Outdoor Installations 6.8.1 For trolley hoist installations that are outdoors, the trolley hoist shall be covered and protected from the weather at all times.

  • Page 80: Troubleshooting

    Troubleshooting General Troubleshooting 7.1.1 For electrical connections and schematics, refer to the drawing inside the control box or drawing 81700 available from Harrington Hoists.  HAZARDOUS VOLTAGES ARE PRESENT IN THE HOIST AND IN CONNECTIONS BETWEEN COMPONENTS. Before performing ANY maintenance on the equipment, de-energize the supply of electricity to the equipment, and lock and tag the supply device in the de-energized position.
  • Page 81 Table 7-1 Troubleshooting Guide Symptom Cause Remedy Brake does not Check motor brake adjustment for proper clearance. release . Replace brake if needed. Check fault codes (Reference Section 7.2). Reset VFD by pressing Faulty Hoist VFD the Emergency Stop Button on pendant. Replace as needed. Emergency Stop “Hbb”...
  • Page 82 Table 7-1 Troubleshooting Guide Symptom Cause Remedy Brake does not Check motor brake adjustment for proper clearance. release . Replace brake if needed. Check fault codes (Reference Section 7.2). Reset VFD by pressing Faulty Hoist VFD the Emergency Stop Button on pendant. Replace as needed. Emergency Stop “Hbb”...
  • Page 83 Table 7-1 Troubleshooting Guide Symptom Cause Remedy Brake does not Check motor brake adjustment for proper clearance. release . Replace brake if needed. Check fault codes (Reference Section 7.2). Reset VFD by pressing Faulty Hoist VFD the Emergency Stop Button on pendant. Replace as needed. Emergency Stop “Hbb”...
  • Page 84 Table 7-1 Troubleshooting Guide Symptom Cause Remedy Brake does not Check motor brake adjustment for proper clearance. release . Replace brake if needed. Check fault codes (Reference Section 7.2). Reset VFD by pressing Faulty Hoist VFD the Emergency Stop Button on pendant. Replace as needed. Emergency Stop “Hbb”...

  • Page 85: Vfd Troubleshooting

    VFD Troubleshooting 7.2.1 If the VFD or motor runs irregularly, check the alarm/error on the LED display. Details of the types of alarms and errors shown in Table 7-2 and are as follows: • Error • Minor Failure/Warning • Operation Error Table 7-2 Types of Alarms and Errors Display Display...
  • Page 86 Table 7-3 "Error" Type Summary LED Display Name Control error CPF03 EEPROM failure CPF06 EEPROM data error CPF07 Terminal board communication error CPF08 EEPROM serial communication error CPF11 RAM error CPF12 Flash memory error CPF13 Watchdog error CPF14 Control circuit error CPF16 Clock error CPF17...
  • Page 87 Table 7-4 "Minor Failure/ Warning Error" Type Summary LED Display Name Forward/reverse command simultaneous input EF1 to EF7 External error (Input terminal S1 to S7) Inputting a safety signal Current warning Heat sink overheat Main circuit overvoltage CrST Reset during driving command input Main circuit low voltage Table 7-5 "Operation Error"...
  • Page 88 Table 7-7 "Error" Display Details and Remedies (Continued) LED Display Error name EEPROM serial communication error CPF08 Failure with the EEPROM Cause Measure Failure between the terminal board and -Turn off the power supply of the VFD, and re-connect the control circuit control board terminal.
  • Page 89 Table 7-7 "Error" Display Details and Remedies (Continued) LED Display Error name Ground fault The ground-fault current exceeded about 50% of the inverter rated output current in the VFD output side Cause Measure Check the insulating resistance of the motor Motor burnout or insulation degradation occurred.
  • Page 90 Table 7-7 "Error" Display Details and Remedies (Continued) LED Display Error name Heat sink overheat The heat sink temperature of the VFD exceeded the setting value (90 to 100°C, or approximately 195 to 210°F) Heat sink overheat The heat sink temperature of the VFD exceeded 100 to 110 Cause Measure Check the ambient temperature.
  • Page 91 Table 7-7 "Error" Display Details and Remedies (Continued) LED Display Error name Main circuit overvoltage The main circuit DC voltage exceeded the overvoltage detection level. 208-230V: Approximately 410V 415-460V: Approximately 820V A ground fault of the motor occurred. Check the power cable, relay terminal, and motor terminal box of the (A ground-fault current is charging motor.
  • Page 92 Table 7-7 "Error" Display Details and Remedies (Continued) LED Display Error name Internal damping transistor error Operation of the damping transistor is erroneous. Cause Measure The damping transistor is broken. Turn on/off the power supply to check if an error occurs. -If the error occurs in succession, replace the VFD.
  • Page 93 Table 7-7 "Minor Failure/ Warning Error" Display Details and Remedies (Continued) LED Display Error name In-rush prevention circuit error Failure of the in-rush prevention circuit occurred. Turn on/off the power supply to check if an error occurs. ⇒ If the error Cause Measure Failure of the contactor of the in-rush...
  • Page 94 Table 7-8 "Minor Failure/ Warning" Display Details and Remedies (Continued) LED display Minor failure name Heat sink overheat The VFD heat sink temperature exceeded the setting value (90 to 100°C) (that varies depending on the VFD capacity) Cause Measure ⇒ Use it at an ambient temperature of 40oC or lower. Check the ambient temperature.
  • Page 95 Table 7-8 "Minor Failure/ Warning" Display Details and Remedies (Continued) LED display Minor failure name Main circuit low voltage The following states occurred when no driving command is inputted (when ⇒The inrush current suppression contactor inside the VFD was released. the VFD is not operating).

  • Page 96: Vfd Error Rest And Restart

    VFD Error Reset and Restart 7.3.1 Error reset - When an error occurred, restart the VFD after removing the cause of the error. To restart the VFD, turn on/off the emergency stop button. If the VFD is not reset, (1) Turn it on/off several times. (2) If the VFD is too hot, cool it down before resetting.

  • Page 97: Vfd Monitoring, Error Trace And Error History

    VFD Monitoring, Error Trace and Error History 7.4.1 The monitor parameter (U parameter) shows parameters that can be monitored in the drive mode: • U1 – State Monitor, Table 7-10 • U2 – Error Trace, Table 7-11 and 7-12 • U3 –...
  • Page 98 Table 7-11 U2 Error Trace Name Description Current error Checks the details of the current U2-01 error. Past error Checks the details of the error that U2-02 occurred immediately before the past error. Frequency command Displays the frequency command U2-03 upon an error value when the "past error"...
  • Page 99 Table 7-13 U3 Error History Name Description Details of the Displays the details of the previous U3-01 previous error error Details of the error 2 Displays the details of the error 2 U3-02 errors before errors before lays the details of the error Details of the error Disp U3-03...

  • Page 100: Warranty

    Warranty All products sold by Harrington Hoists, Inc. are warranted to be free from defects in material and workmanship from date of shipment by Harrington for the following periods: 1 year – Electric and Air Powered Hoists (excluding (N)ER2 Enhanced Features Models, EQ / SEQ Hoists), Powered Trolleys, Powered Tiger Track Jibs and Gantries, Crane Components, Spare / Replacement Parts, Below-the-Hook and Material Handling Equipment...

  • Page 101: Parts List

    Parts List When ordering P arts, please provide the hoist product code and serial number located on the hoist nameplate (see fig. below). Reminder: Per Sections 1.1 and 3.9. 1 to aid in ordering Parts and P roduct Support, record the hoist product number and serial number in the space provided on the cover of this manual.

  • Page 102: Hoist Gearbox Parts

    Hoist Gearbox Parts Figure 9-1-1 Hoist Gearbox Parts Figure Part Name RYU030 RYU050 Hoist Gear Box Assembl y – 208-230V R-1ALBH-4701 R-1BLBH-4501 Gear Box Assembl y – 415-460V R-1ALBH-4501 Capa ci ty Label 80673 80674 Terminal Cover – 208-230V R-1ALBC-9071 Terminal Cover –...

  • Page 103: Rope Drum Parts

    Rope Drum Parts Figure 9-2 Rope Drum Parts Parts Figure Part Name RYU030 RYU050 Hoist Rope Drum Assembl y – 25 ft. Li ft R-1ALCH-1101 Rope Drum Assembl y – 33 ft. Li ft R-1ALCH-1201 Wi re Rope – 25 ft. Li ft 83352 Wi re Rope –...

  • Page 104: Trolley Frame Parts

    Trolley Frame Parts Figure 9-3 Trolley Frame Parts...
  • Page 105 9.3 Trolley Frame Parts Parts Figure RYU030 RYU050 Part Name Hoist Wheel A Assembl y R-1ALDC-6036 Wheel B Assembl y R-1ALDC-6041 Snap Ring T3G106075 Wheel Cover A R-1ALDC-9053 Socket Bol t 9091519 Spring Lock 9016604 Washer Plain Washer 9015623 Wheel Cover B R-1ALDC-9054 Guide Roller R-1ALDC-6061...

  • Page 106: Hook Block Parts

    Hook Block Parts Figure 9-4 Hook Block Parts Parts Figure Part Name RYU030 RYU050 Hoist Hook Block R-1ALEC-1001 R-1BLEC-1001 Assembl y Shea ve Assembl y R-1ALEC-5001 Hook Assembl y R-1ALEC-6014 R-1BLEC-6014 Hook La tch SR-1ALEC-6015 SR-1BLEC-6015 Assembl y Shea ve Cover A R-1ALEC-9020 Shea ve Cover B R-1ALEC-9021...

  • Page 107: Rope Anchorage Parts

    9.5 Rope Anchorage Parts Figure 9-5 Rope Anchorage Parts Figure Parts Per Part Name RYU030 RYU050 Hoist Rope Anchorage Assembl y R-1ALFH-1001...

  • Page 108: Rope Guide Parts

    Rope Guide Parts Figure 9-6 Rope Guide Parts Parts Per Figure No. Part Name RYU030 RYU050 Hoist Rope Guide Assembl y R-1ALGH-1001 (i ncludes all Ha rdwa re)

  • Page 109: Idle Sheave Parts

    9.7 Idle Sheave Parts Figure 9-7 Idle Sheave Parts Parts Figure Part Name RYU030 RYU050 Hoist Idle Shea ve Assembl y R-1ALHH-1001 Shea ve Assembl y R-1ALEC-5001 Spring Lock Washer 9016604 Socket Bol t 9091504...

  • Page 110: Lifting Limit Switch (Ulls) Parts

    9.8 Lifting Limit Switch (ULLS) Parts Figure 9-8 Lifting Limit Switch (ULLS) Parts Parts Per Figure No. Part Name RYU030 RYU050 Hoist Limi t Swi tch R-1ALIJ-9001 Socket Bol t 9091510 Spring Lock Washer 9016602...

  • Page 111: Block Operated Limit Switch (Bls) Parts

    9.9 Block Operated Limit Switch (BLS) Parts Figure 9-9 Block Operated Limit Switch (BLS) Parts Parts Figure Part Name RYU030 RYU050 Hoist Di rect Li mit Swi tch Assembl y R-1BLJH-1001 Limi t Swi tch R-1ALIJ-9001 Socket Bol t 9091510 Spring Lock Washer 9016602 Fi xi ng Bol t...

  • Page 112: Hoist Motor Parts Parts

    9.10 Hoist Motor Parts Figure 9-10 Hoist Motor Parts...
  • Page 113 9.10 Hoist Motor Parts Parts Figure RYU030 RYU050 Part Name Hoist Lifti ng Motor Assembl y – 208- R-1BLMH-1201 R-1CLMH-1201 230V Lifti ng Motor Assembl y – 415- R-1BLMH-1401 R-1CLMH-1401 460V Motor Cover Assembl y R-1ALMJ-5021 R-1CLMJ-5021 Fa n R-1ALMC-9024 R-1CLMC-9024 Bra ke Drum Assembl y ER1ES52123...

  • Page 114: Trolley Motor Parts

    9.11 Trolley Motor Parts Figure 9-11 Trolley Motor Parts...
  • Page 115 9.11 Trolley Motor Parts Figure Parts Part Name RYU030 RYU050 Hoist Tra versing Motor Assembl y – 208- R-1BLNH-1001 230V Tra versing Motor Assembl y – 415- R-1BLNH-1101 460V Ball Bea ring 9000705 Snap Ring J1SR000-00062 Snap Ring 9047125 Socket Bol t 9091518 Ball Bea ring 9000602...

  • Page 116: Control Panel/Box Parts

    9.12 Control Panel/Box Parts Figure 9-12 Control Panel/Box Parts...
  • Page 117 9.12 Control Panel/Box Parts Figure Parts Part Name RYU030 RYU050 Hoist Pa cki ng R-1ALPC-9009 Ma chine Screw w/ Spring Lock Washer J1AP2-5001212 Washer 9016507 Ha nger Wi re R-1ALPC-9012 Lifti ng Inverter – VFD – 208-230V INV675E11 INV61QE11 Lifti ng Inverter – VFD – 415-460V INV655Y11 INV61QY11 Round Head Screw...
  • Page 118 9.12 Control Panel/Box Parts Figure Parts Part Name RYU030 RYU050 Hoist Cable Gland – Flat Cable Control FC816C 208-230V Cable Gland – Lifting Motor – 208-230V R-1ALPC-9088 Control Side Cable Gland – Lifting Motor – 208-230V R-1ALPC-9088 Gearbox Side Cable Gland – Lifting Motor – 415-460V R-1ALPC-9085 Control Side Cable Gland –...
  • Page 119 This Page Intentionally Left Blank...
  • Page 120 Harrington Hoists, Inc. Toll Free: 800-233-3010 401 West End Avenue www.harringtonhoists.com Phone: 717-665-2000 Manheim, PA 17545 Fax: 717-665-2861 © Harrington Hoists, Inc., All Rights Reserved RYOM-ENG...

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