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Harrington ER Series Repair Manual

Electric chain hoist
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EDOC0202
REV. 0
EFFECTIVE: September 23, 2002
Repair Manual
ELECTRIC
CHAIN HOIST
ER and NER
SERIES
1/8 Ton through 20 Ton Capacity
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.

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  • Page 1 EDOC0202 REV. 0 EFFECTIVE: September 23, 2002 Repair Manual ELECTRIC CHAIN HOIST ER and NER SERIES 1/8 Ton through 20 Ton Capacity 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.
  • Page 2 Table of Contents Section Page Number Important Information and Warnings …………………………………………………………..4 Terms and Summary Warning Tags and Labels ER and NER Repair Manual Information. .………………………………………….…………. . 8 Purpose Difference Between the ER and NER Design Concept Tools Required Instructional Sequence Hoist Disassembly Procedure ……………………………………………………….

  • Page 3: Table Of Contents

    Troubleshooting/Repair Appendix A – Inspection Methods, Criteria and Wear Measurements Appendix B – Inspection Methods, Criteria and Wear Measurements for Large Capacity (N)ER Appendix C – Electrical Troubleshooting Guide and Wiring Diagrams Appendix D – Harrington Hoists, Inc. Contact Information...
  • Page 4 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. Use only Harrington authorized replacement parts in the service and maintenance of this hoist.
  • Page 5 Z241.2, “Safety Requirements for Melting and Pouring of Metals in the Metalcasting Industry”. Electrical equipment described herein is designed and built in compliance with Harrington's interpretation of ANSI/NFPA 70, “National Electrical Code”. The system designer, system manufacturer, crane designer, crane manufacturer, installer, or user is responsible to assure that the installation and associated wiring of these electrical components is in compliance with ANSI/NFPA 70, and all applicable Federal, State and Local Codes.
  • Page 6 If the hoist owner/user requires additional information, or if any information in the manual is not clear, contact Harrington or the distributor of the hoist. Do not install, inspect, test, maintain, or operate this hoist unless this information is fully understood.
  • Page 7 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’s pendant cord, order a tag from your dealer and install it. Read and obey all warnings attached to this hoist.
  • Page 8 2.0 ER and NER Repair Manual Information Purpose The purpose of this manual is to provide disassembly and assembly instructions for the ER/NER family of hoists 1/8 through 20 Ton. It is also intended to act as a diagnostic guide for troubleshooting various hoist problems and provide applicable solutions.

  • Page 9: Reassembly, Controls Unit

    Harrington Authorized Repair Center. (You can contact Harrington for a list of official repair centers. See Appendix D to this manual to find a repair center nearest you.)
  • Page 10 When reassembling the hoist, the following parts must be replaced with new: - GEAR OIL - PACKING - OIL SEALS - SNAP RINGS - SPLIT PINS - O-RINGS • Use thread-locking adhesive when re-installing bolts where indicated. • Always use Harrington genuine parts for replacement.
  • Page 11 3.0 Hoist Disassembly Outer Part Removal DANGER Hazardous voltages are present in the control box, other electrical components, and connections between these components. Only trained and competent personnel should inspect and repair this equipment. A) De-energize (disconnect) the main switch supplying power to the equipment, and lock and tag the main switch in the de-energized position.
  • Page 12 D) Remove plug 5P (5 pin connector) of the push button cable assembly. E) When the hoist is used without a chain container, the free end of the chain is attached to the hoist body as shown in Figure to the right. Remove the no load end of the chain from Chain Guide A by detaching the End Wire or End Suspender installed on the hoist.
  • Page 13 Disassembly of the Controls Unit CAUTION Never disassemble the electric chain hoist while it is suspended. Only perform disassembly and assembly repair work while the hoist is supported on a stable and level work surface. A) PLACE HOIST ON WORKBENCH SO THAT THE CONTROLS SECTION IS ON TOP.
  • Page 14 F) On the under side of the controls plate, remove lead-wires of the motor from the terminal strip. For convenience, group wires removed from each terminal together and mark with the terminal strip identification to prevent misconnecting wiring during reassembly. Several models will have wiring passing through to the front side of the plate.
  • Page 15 3.3 Disassembly of the Gear Case and Gear Parts A) Swing the electrical controls plate open, remove the two screws retaining plate A. B) Using pliers, pull out the connection shaft and the fixing shaft to disconnect the top hook assembly or connection yoke from the hoist.
  • Page 16 D) For NER, remove the friction plug, oil seal and nut cover from the gear case. (Do not remove oil seal, unless it is to be replaced.) Remove the socket bolts connecting the gear case to the body. Tap the controls section lightly with a plastic or rubber mallet to release it from the body section.
  • Page 17 H) For three gear hoists, remove the ball bearing, needle bearing and gear B assembly with bearing. Remove socket bolt and spring washer from gear plate and remove gear plate.
  • Page 18 DANGER Do not attempt to adjust the friction clutch assembly or mechanical friction assembly. If you think an adjustment is needed, contact Harrington. K) Remove the snap ring from the body and remove the pawl and the pawl spring.
  • Page 19 3.4 Disassembly of the Chain Guide and Load Chain A) Remove the stopper, and the cushion rubber or the chain spring from the no load side of the load chain. B) Pull out the load chain from the body. Pulling the chain out of the body from the load side.
  • Page 20 3.5 Disassembly of the Motor A) Turn the hoist over so that fan cover is facing up. Remove the socket bolts to detach the fan cover from the motor frame. NOTICE Setting the hoist up on wooden blocks will accommodate the gear shaft, which extends out past the body.
  • Page 21 D) Remove the key (small square metal insert that keeps the fan in line with the motor) and the “O” ring. E) Remove the socket bolts on the motor cover assembly. F) Using a plastic or rubber mallet and a screwdriver tap the cover evenly on each side to release the motor brake assembly from the motor frame.
  • Page 22 H) Remove the socket bolts and loosen the motor frame/stator assembly by lightly tapping the base of the assembly with a plastic or rubber mallet. To separate, pry gently at the square notch on the side of the body. Pull off the motor frame/stator assembly from the body.
  • Page 23 3.6 Disassembly of the Body A) Remove the snap ring retaining the pinion to the body. B) Pull out the pinion together with the bearing by lightly tapping the pinion from the direction of the gear case with a plastic or rubber mallet. C) Remove the socket bolts to detach the bearing holder from the body.
  • Page 24 D) Remove the load sheave together with the bearing and the oil seal by lightly tapping in the same direction as the pinion. E) Remove the snap ring and take out all bearings and oil seals from the body. F) Remove the screws to take out chain guide B.
  • Page 25 3.7 Disassembly of the Motor Brake A) Flatten the claw of the lock washer using a small screwdriver. B) Loosen nut by lightly tapping a notch on the nut with a screwdriver and mallet. Remove the nut by turning. NOTICE Pushing down on the motor brake cover releases the spring tension making the nut easier to remove.
  • Page 26 D) Clamp the pull-rotor and the rotor together with two vises to remove the thrust disc. E) Remove the pull rotor and the coned disc spring CAUTION Inspect all parts referring to Appendix A for wear measurements and criteria before reassembly.
  • Page 27 4.0 Hoist Reassembly Reassembly of the Motor Brake DANGER If any part is judged to be outside of discard criteria during the check, do not use it for reassembly. - Fasten bolts and nuts properly. - Ensure that all split pins are installed properly. CAUTION Make sure that the brake gap is inspected and adjusted.
  • Page 28 E) Tighten the nut until the break gap (a gap between the pull rotor and the brake drum) becomes the equal to the value specified in the Appendix A, Table 6-3. Confirm the gap with a feeler gauge. F) After confirmed, bend up the claw of the lock washer into the notch of the nut.
  • Page 29 B) Prepare the bearing for the mechanical brake gear set or friction clutch set into the body section. C) Put a new oil seal on the bearing, and insert them into the body section from the gear-case side using a properly sized ball bearing or oil seal driver.
  • Page 30 F) Put the pinion assembly (includes bearing) on the bearing holder and insert by lightly tapping with a plastic or rubber mallet. G) Using a snap ring pliers, install a new snap ring with its sharp edge up (away from bearing). Check the snap ring fit.
  • Page 31 Mount the motor frame/stator assembly on to the body section such that the Harrington nameplate is located on the top hook side. Make sure the set pin is already installed. B) Apply thread-locking adhesive to the socket bolts that connect the motor frame/stator assembly to the body section and tighten the socket bolts.
  • Page 32 E) Slide the key into the motor shaft of the motor brake assembly. F) Align the notch in the fan with the key on the motor shaft and press the fan onto the shaft. If the fit is too tight, lightly tap the place indicated in the figure with a plastic or rubber mallet to install the fan.
  • Page 33 Reassembly of the Load Chain A) Reinstall the guide roller and the roller pin on the chain guide A. B) Reinstall the limit lever S (an upper limit switch type) or the limit lever assembly (an upper/ lower limit type) on the chain guide A (AL). C) Install the socket bolts to connect the chain guide A to the body.
  • Page 34 I) The quantity and location of the chain components 1/8 to 3 Ton Upper Limit Switch Only including cushion rubbers, chain springs and striker plates depend on the hoist model, capacity and limits switches. Never operate the hoist with incorrect, missing or damaged chain components.
  • Page 35 M) For 8 to 20 Ton hoists without a chain container, the free end of the chain is attached to the hoist body as shown in Figure at right. Connect the “no load” end 8 to 20 Ton Stopper and End Connections of the chain to Chain Guide A with an End Wire or End Suspender and the pre-installed socket bolt and lock nut.
  • Page 36 • PRECAUTIONS FOR ASSEMBLING DOUBLE FALL TYPE LOAD CHAIN (5 – 20 TON) A) For hoist capacities 5-20 Ton, insert the load chain from the no load side. Also, insert a vertical link first into the chain guide. B) For placement of the chain spring, stopper, and cushion rubber or chain spring see Owner’s Manual 1/8 –...
  • Page 37 Reassembly of the Gear Case and Gear Parts A) Flip the hoist body such that the fan side is down. Insert the load gear on to the load sheave and attach with a new snap ring with its sharp edge up. B) Ensure that the snap ring is properly seated in the groove.
  • Page 38 B) Pre-assemble the mechanical brake with friction clutch complete set (composed of the gear, brake holder, ratchet, friction clutch assembly, thrust disc, and thrust collar). After confirming the engagement of the ratchet wheel and pawl, connect them together. C) Install the friction clutch assembly and attach the set spring (This step is not necessary for mechanical brake with friction clutch type) D) For NER, insert new oil seal into the gear case...
  • Page 39 F) Place a new gear case packing and assemble the gear case by lightly tapping with a plastic or rubber mallet. Make sure that the set pin is already installed. CAUTION Prevent pinching lead-wires while connecting the gear case to the body. G) Hand tighten socket bolts to connect the gear case to the body section, and then tighten bolts in a diagonal sequential manner.
  • Page 40 Reassembly of the Controls Unit A) Reconnect lead-wires of the motor. B) Check the wiring using the wiring diagram listed in Appendices or Owner’ Manual. C) Close the plate and secure the plate screws. D) Hook the cover suspender C connected to the controller cover onto the cover suspender A and B connected to the gear case.
  • Page 41 § Acceptable equivalent: Meropa 320 (CALTEX) ER Gear Oil § Harrington standard: Antoil super B (NIPPON OIL) § Acceptable equivalent: Meropa No.68 (TEXACO) CAUTION The ER (with mechanical load brake/friction clutch) uses different gear oil than the NER (with friction clutch).

  • Page 42: Principle Of Operation

    Electrical Troubleshooting Procedure WARNING HAZARDOUS VOLTAGES ARE PRESENT IN THE HOIST AND IN CONNECTIONS BETWEEN COMPONENTS. Before performing ANY troubleshooting on the equipment, de-energize the supply of electricity 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.”...

  • Page 43: Additional Tools Required

    Figure 5-1 Count/Hour Meter 5.3.1 Contactor Use The C/H Meter can be used in conjunction with the amount of hoist “jogging” to estimate when the contactor(s) should be replaced. “Jogging” is defined as short or quick hoist operations required to position the load hook.

  • Page 44: Troubleshooting/Repair

    Troubleshooting/Repair 5.5.1 Lower/Lift Direction Notice WARNING The hoist must be connected to the power source so that its direction of operation corresponds to the up-and-down commands issued from the pendant control; i.e. pushing the up button must cause the hoist to lift the load. If the hoist does not operate correctly, shut off and before proceeding, ensure that the electrical supply for the hoist or trolley has been de-energized (disconnected).
  • Page 45 DANGER Hazardous voltages are present in the control box, other electrical components, and connections between these components. Only trained and competent personnel should inspect and repair this equipment. B) Before proceeding, ensure proper lock out and tag out procedures in accordance with ANSI Z244.1 “Personnel Protection -Lockout/Tagout of Energy Sources”...
  • Page 46 3) Check Contactor(s) NOTICE Taking a reading from line to ground will not yield the proper voltage reading due to the use of phase converters or deltas. Only measure line to line. B) Power On – High Voltage. With the hoist powered ON check the voltage on the contactor.
  • Page 47 4) Check Transformer A) De-energize (disconnect) the main switch supplying power to the equipment, and lock and tag the main switch in the de-energized position. B) Verify that the transformer fuse is not open. Transformer A) Isolate or disconnect the transformer. Using the VOM verify the continuity of the primary and the secondary transformer windings.
  • Page 48 6) Check the Motor Windings (Current Draw). With the hoist powered ON measure the current draw at the motor connections on the terminal strip using the clamp type ammeter (amp clamp). Ensure that the current measurements match those listed on the data plate, which is on the outside of the hoist.
  • Page 49 8) Check Limit Switch(es) A) Power On Method – While operating the hoist in the lifting direction, push up on the load side of the limit switch. The hoist should stop lifting. B) If there is an optional lower limit switch, operate the hoist in the lowering direction, push up on the no- load side the limit switch.
  • Page 50 10) Check Hoist Motor A) Motor Winding Resistance Value. Using the VOM, the resistance measurement between terminals U1, V1 and W1 should be the equal. B) Motor Voltage (+/-10% Range). Check the motor voltage across terminals U1, V1 and W1 to ensure that each phase measures within 10% of the voltage listed on the data plate on the outside of the hoist.
  • Page 51 12) Check Hoist Motor Thermal Overload A) The thermal overload is a normally closed switch. The switch opens when there is an overload condition. B) With the hoist power OFF measure the continuity between plug terminals 1 and 1B. C) Plug terminal 1 is located at the hinged panel by the hoist contactors.
  • Page 52 5.5.4 Wiring Diagram – Select the appropriate wiring diagram in Appendix C 5.5.5 Troubleshooting Guide – See Appendix C...

  • Page 53: Appendix A - Inspection Methods, Criteria And Wear Measurements

    Appendix A • Inspection Methods, Criteria and Wear Measurements • For 1/8 Ton through 5 Ton Capacity • Section references are to the Owner’s Manual, Electric Chain Hoist, ER and NER Series Table 5-3 Hoist Inspection Methods and Criteria Item Method Criteria Action...
  • Page 54 Table 5-3 Hoist Inspection Methods and Criteria Item Method Criteria Action 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.
  • Page 55 Table 5-3 Hoist Inspection Methods and Criteria Item Method Criteria Action Load Sheave Visual Pockets of Load Sheave should be free of Replace. significant wear. Cushion Rubber Visual Should be free of significant deformation. Replace. Chain Springs Visual Chain springs should be not be deformed or Replace.
  • Page 56 Table 5-4 Top Hook & Bottom Hook Dimensions “k” Measured When New: Top: _________________________ Bottom: ______________________ *Nominal "u" Dimension "t" Dimension "k" inch (mm) inch (mm) Capacity Code Dimension Standard Discard Standard Discard inch (mm) 001H, 003S, 003H, 1.65 (42) 0.93 (23.5) 0.83 (21) 0.69 (17.5)
  • Page 57 Table 5-5 Chain Wear Dimensions “P” Dimension “d” Dimension inch (mm) inch (mm) Capacity Code Standard Discard Standard Discard 001H, 003S, 2.97 (75.5) 3.02 (76.6) 0.22 (5.0) 0.18 (4.5) 003H, 005L, 005S 3.76 (95.5) 3.82 (96.9) 0.25 (6.3) 0.22 (5.7) 010L, 010S 4.76 (121.0) 4.91 (124.6)
  • Page 58 Table 5-6 Motor Brake Wear Dimensions NOTICE Brake must be properly adjusted before measuring "A". See Section 6.3 "A" Dimension - inch (mm) Capacity Code Single Speed Dual Speed Standard Discard Standard Discard 001H, 003S, 005L 0.67 (17) 0.61 (15.5) 0.67 (17) 0.61 (15.5) 003H, 005S, 010L...
  • Page 59 Table 6-3 Motor Brake Gap Brake Gap (G) Capacity Code inch (mm) 001H, 003S, 005L, 003H, 005S, 0.020 (0.5) 010L, 010S, 015S, 020L 020S, 025S, 030L, 030S, 050L 0.032 (0.8) Figure 6-3 Chain Replacement Appendix A...
  • Page 60 Chain Spring Measurements WARNING The chain spring gets compressed over time and if not replaced will result in damage to the hoist body form motor drift. NOTICE For the 001H, 003S, 005L 003H, 010L, 015S -single and dual speed hoists with just the upper limit switch there are No Springs. Chain Spring Dimensions Chain Capacity Code...
  • Page 61 Appendix B • Inspection Methods, Criteria and Wear Measurements • For 8 Ton through 20 Ton Capacity NOTICE The information listed in this section is intended to supplement Appendix A. Section references are made to the Owner’s Manual, Electric Chain Hoist ER and NER Series Table 5-3 Hoist Inspection Methods and Criteria...
  • Page 62 Table 5-4 Top Hook & Bottom Hook Dimensions “k” Measured When New: Top: _________________________ Bottom: ______________________ *Nominal "u" Dimension "t" Dimension "k" inch (mm) inch (mm) Capacity Code Dimension Standard Discard Standard Discard inch (mm) 080S, 100L, 100S 4.72(120) 2.87(73) 2.60(66) 1.89(48) 1.69(43)
  • Page 63 Table 5-5 Chain Wear Dimensions “P” Dimension “d” Dimension inch (mm) inch (mm) Capacity Code Standard Discard Standard Discard 080S, 100L, 100S, 6.75 (171.5) 6.85 (174.1) 0.44 (11.2) 0.40 (10.1) 150S, 200S Table 5-6 Motor Brake Wear Dimensions NOTICE Brake must be properly adjusted before measuring "A". Section 6.3 of EROM "A"...
  • Page 64 Table 6-3 Motor Brake Gap Brake Gap (G) Capacity Code inch (mm) 080S, 100L, 100S, 150S, 200S 0.032 (0.8) Figure 6-4 Chain Replacement for 100S, 150S, 200S Appendix B...
  • Page 65 Chain Spring Measurements WARNING The chain spring gets compressed over time and if not replaced will result in damage to the hoist body from motor drift. Chain Spring Dimensions Chain Diameter inch (mm) inch (mm) inch (mm) inch (mm) Capacity Code Inch (mm) Single Speed with Upper/Lower Limit Switch (standard) 080S, 100L,...
  • Page 66 Appendix C • Electrical Trouble shooting Guide and Wiring Diagram. Table 7-1 Troubleshooting Guide Symptom Cause Remedy Power supply Switch 2 of the 3 power supply cord wires at the power reversed phased source. Hoist moving in wrong direction Improper electrical Refer to wiring diagram and check all connections.
  • Page 67 Table 7-1 Troubleshooting Guide Symptom Cause Remedy Hoist overloaded Reduce load to within rated capacity of hoist. Determine cause of low voltage and bring to within plus or Low voltage in hoist's minus 10% of the voltage specified on the motor nameplate. power supply The voltage should be measure at the hoist contactor.
  • Page 68 Table 7-1 Troubleshooting Guide Symptom Cause Remedy Excessive load Reduce load to within rated capacity of hoist. Excessive duty cycle Reduce frequency of lifts. Wrong voltage or Check voltage and frequency of power supply against the frequency rating on the nameplate on the motor. Motor or brake overheating Brake drags...
  • Page 69 Single Speed Wiring diagram 1/8 Ton – 5 Ton Capacity § Consult factory for 8 – 20 Ton hoist wiring information. Appendix C...
  • Page 70 § Dual Speed Wiring Diagram 1/8 Ton – 5 Ton Capacity Consult factory for 8 – 20 Ton hoist wiring information. Appendix C...
  • Page 71 Harrington Hoists, Inc. Harrington Hoists – Western Division 401 West End Avenue 2341 Pomona Rincon Rd. #103 Manheim, PA 17545-1703 Corona, CA 92880-6973 Phone: 717-665-2000 Phone: 909-279-7100 Toll Free: 800-233-3010 Toll Free: 800-317-7111 Fax: 717-665-2861 Fax: 909-279-7500 ERRM...

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