Harrington ER Series Repair Manual Download Page 1 | Manualshive

Page: 1 / 71

Harrington ER Series Repair Manual Download Page 1

Repair Manual

ELECTRIC

CHAIN HOIST

ER and NER

SERIES

1/8 Ton through 20 Ton Capacity

EDOC0202

REV. 0

EFFECTIVE: September 23, 2002

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.

1
2
3
...
»

Summary of Contents for ER Series

Page 1: ...FECTIVE September 23 2002 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...

Page 2: ...nstructional Sequence 3 0 Hoist Disassembly Procedure 11 3 1 Outer Part Removal 3 2 Disassembly Controls Unit 3 3 Disassembly Gear Case and Gear Parts 3 4 Disassembly Chain Guide and Load Chain 3 5 Di...

Page 3: ...nciple of Operation 5 2 Design Concept 5 3 Count Hour Meter C H 5 4 Additional Tools Required 5 5 Troubleshooting Repair Appendix A Inspection Methods Criteria and Wear Measurements Appendix B Inspect...

Page 4: ...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 CAUTIO...

Page 5: ...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 t...

Page 6: ...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...

Page 7: ...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: ...trical components such as the transformer limit switch s and motor contactors 2 Gear Case This section consists of the gear system A mechanical brake with friction clutch ER only 3 Body This section c...

Page 9: ...t 4 8 Checking Operation 5 0 Electrical Troubleshooting Appendix A Inspection Methods Criteria and Wear Measurements Appendix B Inspection Methods Criteria and Wear Measurements for Large Capacity App...

Page 10: ...chain Remove dirt and contamination from disassembled parts such as gears When reassembling the hoist the following parts must be replaced with new GEAR OIL PACKING OIL SEALS SNAP RINGS SPLIT PINS O...

Page 11: ...energize disconnect the main switch supplying power to the equipment and lock and tag the main switch in the de energized position B Remove plug 4P 4 pin Connector of the power supply cable complete...

Page 12: ...the no load end of the chain from Chain Guide A by detaching the End Wire or End Suspender installed on the hoist For 5 ton hoist remove the no load end of the chain directly from Chain Guide A if Ch...

Page 13: ...TOP B Loosen and remove socket bolts and open the controller cover If necessary loosen the cover by tapping it lightly with a plastic or rubber mallet CAUTION Although the controller cover can be susp...

Page 14: ...ark 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 Disconnect and mark these wi...

Page 15: ...hoist CAUTION Once the Shafts are removed the hook and yokes will fall from the hoist C For the ER Remove the socket bolts and tap the controls case lightly with a plastic or rubber mallet to remove t...

Page 16: ...CE Take precautions to prevent damage to the gasket during removal of the controls section If damaged the gasket must be replaced with a new gasket during reassembly Also lift off the controls section...

Page 17: ...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: ...ction clutch assembly rotate it NOTICE Thrust disc can be removed with needle nose pliers J Remove the ratchet the brake collar and the gear by rotating the assembly DANGER Do not attempt to adjust th...

Page 19: ...e the split pin and pull out the limit lever pin from the lever coupling D Remove the limit lever pin the lever coupling and the limit lever collar from the limit lever S an upper limit switch type or...

Page 20: ...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 B Remove the snap ring and fan washer C Remove fan If fan d...

Page 21: ...tor brake assembly from the motor frame Pry gently under the recesses the tabs to free the cover assembly G Remove rotor and brake assembly NOTICE For convenient removal rotate the motor cover tabs so...

Page 22: ...n the side of the body Pull off the motor frame stator assembly from the body CAUTION Take precautions to prevent damaging the lead wires of the motor stator while pulling the unit off of the body sec...

Page 23: ...ng 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 socke...

Page 24: ...ave 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 t...

Page 25: ...ch 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 Then remove the lock wash...

Page 26: ...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 Replac...

Page 27: ...and brake drum assembly on to the rotor assembly C Assemble the four coned disc springs M and add them make sure of their direction to the rotor assembly D Install collar M and the motor cover assembl...

Page 28: ...nut slightly in tightening direction so that the claw gets into the nearest notch CAUTION If the gap becomes 0 047 1 2mm or larger for those models with a proper gap of 0 020 0 5 mm and 0 059 1 5 mm f...

Page 29: ...circumference of the lip Using snap ring pliers insert a new snap ring with its sharp edge up away from bearing Check the snap ring fit Make sure that the snap ring is properly seated in the groove D...

Page 30: ...the snap ring fit Make sure that the snap ring is properly seated in the groove H Apply a thin and uniform layer of liquid sealant on the surface of the bearing holder that contacts the body Install t...

Page 31: ...e 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 C Apply liquid...

Page 32: ...ure with a plastic or rubber mallet to install the fan G Insert the fan washer and using snap ring pliers install a new snap ring with its sharp edge up Check the snap ring fit Make sure that the snap...

Page 33: ...an upper lower limit switch reinstall the split pin and reinsert the limit lever pin in the lever coupling F Set up the load chain for installation such that the welded side of the chain link runs on...

Page 34: ...ther information on installing the stopper and cushion rubber or chain spring refer to section 3 2 in the Owner s Manual for specific instructions applicable to your hoist 5 Ton Upper Limit Switch Onl...

Page 35: ...optional canvas chain container is used install it on the hoist body as shown in the figures to the right In this case the free end of the chain is not attached to the hoist body and the chain stopper...

Page 36: ...chain spring stopper and cushion rubber or chain spring see Owner s Manual 1 8 5 Ton 8 20 Ton Section 3 2 C Pass the chain spring to the top of the bottom hook D Connect the load side chain end to th...

Page 37: ...its sharp edge up B Ensure that the snap ring is properly seated in the groove FOR ER ONLY A Insert the pawl spring and pawl onto the pawl shaft Make sure that the pawl spring is inserted into the res...

Page 38: ...This step is not necessary for mechanical brake with friction clutch type D For NER insert new oil seal into the gear case and press it into the gear case After assembly apply machine oil on the enti...

Page 39: ...y 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...

Page 40: ...cable to the socket 4P and connect the power supply cable to the cable holder H Reinstall the chain container on to the body if the hoist was equipped with one Or install load chain end wire or end su...

Page 41: ...alent Meropa No 68 TEXACO CAUTION The ER with mechanical load brake friction clutch uses different gear oil than the NER with friction clutch DO NOT use any oil or quantity other than that specified W...

Page 42: ...the hoist through the power supply cord to the contactor and the transformer The contactors are used to control the hoist and or trolley operation The transformer lowers and converts the voltage to 11...

Page 43: ...ing Normal Operation Rating Approximate Jogging Frequency Change Contactor After Starts Low Jogging is rare 1 000 000 Medium During 25 of operations lifts 500 000 High During 50 or more of operations...

Page 44: ...in accordance with ANSI Z244 1 Personnel Protection Lockout Tagout of Energy Sources 2 Disconnect and switch any two of the three input power leads at the power source to correct the hoist s motor ph...

Page 45: ...normally if the incoming power is not present on all three 3 conductors which is a condition called single phasing 2 Check Power Supply Cord Continuity Measurement A Check the power supply SO cord co...

Page 46: ...agraph 5 5 3 1 C Contactor Coil Verifiy that the contactor coil is not damaged or open by measuring the resistance between A1 and A2 on both coils It should not be an open circuit Contactor A Power Of...

Page 47: ...nnect all wiring reenergize all circuits and check the voltage on the secondary low voltage side of the transformer It should measure 10 of rated voltage C Check for improper electrical connections by...

Page 48: ...f the amount of motion that the conductors within the SO Cord encounter Over time the conductors may become brittle and break Using the VOM check the continuity of the pendant cable conductors Remove...

Page 49: ...switch terminals A and B Push the limit lever UP the VOM should measure an open circuit and in the DOWN direction a closed circuit B If there is an optional lower limit switch place the VOM probes ac...

Page 50: ...ithin 10 of the voltage listed on the data plate on the outside of the hoist If the voltage varies more than 10 of the rated value the hoist may not function normally A hoist will not function normall...

Page 51: ...d and the continuity test performed If there is no thermal overload and the thermal overload switch measures open the switch should be replaced E Perform the continuity test and corrections until the...

Page 52: ...52 5 5 4 Wiring Diagram Select the appropriate wiring diagram in Appendix C 5 5 5 Troubleshooting Guide See Appendix C...

Page 53: ...value listed in Table 5 4 Replace Hooks Stretch Measure The k dimension should not be greater than 1 15 times that measured and recorded at the time of purchase See Section 3 6 If recorded k values a...

Page 54: ...properly through Load Sheave and Idle Sheave for double fall hoist refer to Section 6 4 Chain Chain Springs Cushion Rubbers Striker Plates and Stoppers should be installed properly refer to Section 3...

Page 55: ...pair or replace as necessary Pendant Housing Visual Pendant housing should be free of cracks and mating surfaces of parts should seal without gaps Replace Pendant Wiring Visual Wire connections to swi...

Page 56: ...79 20 015S 2 36 60 1 44 36 5 1 30 33 1 04 26 5 0 94 24 020L 020S 2 46 62 5 1 57 40 1 42 36 1 14 29 1 02 26 025S 2 72 69 43 5 1 71 1 54 39 1 24 31 5 1 10 28 030L 030S 2 95 75 1 87 47 5 1 69 43 1 36 34...

Page 57: ...dard 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 0 31 8 0 0 28 7 2 015S 020L 020S 5 96 151 5 6 05 153 8...

Page 58: ...ction 6 3 A Dimension inch mm Single Speed Dual Speed Capacity Code Standard Discard Standard Discard 001H 003S 005L 0 67 17 0 61 15 5 0 67 17 0 61 15 5 003H 005S 010L 0 85 21 5 0 79 20 0 85 21 5 0 79...

Page 59: ...Appendix A 59 Table 6 3 Motor Brake Gap Capacity Code Brake Gap G inch mm 001H 003S 005L 003H 005S 010L 010S 015S 020L 0 020 0 5 020S 025S 030L 030S 050L 0 032 0 8 Figure 6 3 Chain Replacement...

Page 60: ...7 015S 0 39 10 1 59 40 5 3 35 85 2 95 7 5 0 22 5 5 020L 0 39 10 1 59 40 5 2 76 70 0 26 6 5 0 18 4 5 020S 0 39 10 1 59 40 5 3 35 85 2 95 7 5 0 22 5 5 025S 0 44 11 2 1 77 45 2 95 75 0 26 6 5 0 18 4 5 03...

Page 61: ...e The P dimension should not be greater than maximum value listed in Table 5 5 The d dimension should not be less than minimum value listed in Table 5 5 Replace Inspect Load and Idle Sheaves Load Chai...

Page 62: ...100L 100S 4 72 120 2 87 73 2 60 66 1 89 48 1 69 43 150S 5 04 128 3 43 87 3 07 78 2 36 60 2 13 54 200S 5 57 141 5 3 92 99 5 3 54 90 2 76 70 2 48 63 These values are nominal since the dimension is not c...

Page 63: ...S 100L 100S 150S 200S 6 75 171 5 6 85 174 1 0 44 11 2 0 40 10 1 Table 5 6 Motor Brake Wear Dimensions NOTICE Brake must be properly adjusted before measuring A See Section 6 3 of EROM A Dimension inch...

Page 64: ...Appendix B 64 Table 6 3 Motor Brake Gap Capacity Code Brake Gap G inch mm 080S 100L 100S 150S 200S 0 032 0 8 Figure 6 4 Chain Replacement for 100S 150S 200S...

Page 65: ...om motor drift Chain Spring Dimensions Capacity Code Chain Diameter Inch mm a inch mm b inch mm c inch mm d inch mm Single Speed with Upper Lower Limit Switch standard 080S 100L 100S 150S 200S 0 44 11...

Page 66: ...ndant Check motor brake adjustment for proper clearance Brake does not release Check voltage and frequency of power supply against the rating on the nameplate of the motor Faulty magnetic contactor Ch...

Page 67: ...Check electrical connections Replace or repair as needed Faulty friction clutch Repair by a qualified person trained in the repair of hoists and proper friction clutch adjustment procedures Replace a...

Page 68: ...requency of hoist operation must be reduced to avoid overheating of the motor Special provisions should be made to ventilate the hoist or otherwise shield it from the heat Collectors making poor conta...

Page 69: ...Appendix C 69 Single Speed Wiring diagram 1 8 Ton 5 Ton Capacity Consult factory for 8 20 Ton hoist wiring information...

Page 70: ...Appendix C 70 Dual Speed Wiring Diagram 1 8 Ton 5 Ton Capacity Consult factory for 8 20 Ton hoist wiring information...

Page 71: ...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 3...

Reviews:

No comments