Harrington Hoists and Cranes ER1 User Manual
EFFECTIVE: February 2, 2004
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Owner's Manual
SUPPLEMENT
ELECTRIC
CHAIN HOIST
ER and NER
SERIES
8 Ton through 20 Ton Capacity
4.7 HP MOTOR VERSION
Code, Lot and Serial Number
WARNING
This equipment should not be installed, operated o
maintained by any person who has not read and understood
all the contents of this manual. Failure to read and compl
with the contents of this manual can result in serious bodil
injury or death, and/or property damage.
IMPORTANT INFORMATION ON HOW TO USE THIS MANUAL
This OWNER’S MANUAL SUPPLEMENT is intended for use in combination with the “Owner’s Manual for
Electric Chain Hoist ER and NER Series 1/8 through 5 Ton Capacity”. Refer to the Table of Contents below to
determine the location(s) of information pertaining to your hoist. References to the “Owner’s Manual for Electric Chain
Hoist ER and NER Series 1/8 through 5 Ton Capacity” will be designated by the use of the acronym “EROM”.
Table of Contents
Section Page Number/Location
1.0 Important Information and Warnings……...………………...………………………………………. EROM
1.1 Terms and Summary EROM
1.2 Warning Tags and Labels EROM
2.0 Technical Information………………………………………………………………………….…..………...4
2.1 Specifications 4
2.2 Dimensions 5
3.0 Preoperational Procedures …………………………………………………………………………………6
3.1 Fill Gear Box with Oil 6
3.2 Chain 6
3.3 Mounting Location 8
3.4 Mounting the Hoist 9
3.5 Electrical Connections 9
3.6 Preoperational Checks and Trial Operation 12
4.0 Operation…………………………………………………………………………………………..….. EROM
4.1 Introduction EROM
4.2 Shall’s and Shall Not’s for Operation EROM
4.3 Hoist Controls EROM
2
Section Page Number/Location
5.0 Inspection……………………………….………………………………….…………..…….. 13 and EROM
5.1 General EROM
5.2 Inspection Classification EROM
5.3 Frequent Inspection EROM
5.4 Periodic Inspection EROM
5.5 Occasionally Used Hoists EROM
5.6 Inspection Records EROM
5.7 Inspection Methods and Criteria 13 and EROM
6.0 Maintenance & Handling……………………………………………………….…………….16 and EROM
6.1 Count/Hour Meter EROM
6.2 Lubrication 16 and EROM
6.3 Motor Brake 16 and EROM
6.4 Load Chain 16 and EROM
6.5 Friction Clutch and Mechanical Load Brake with Friction Clutch EROM
6.6 Storage EROM
6.7 Outdoor Installation EROM
7.0 Troubleshooting ………………………………………………………………………………….……EROM
8.0 Material Safety Data Sheets……………………………………..……..…….………………………EROM
8.1 ER Model Gear Box Oil EROM
8.2 ER Model Load Chain Grease EROM
9.0 Warranty………………………………………………………………………………………………. EROM
10.0 Parts List……………………………………………………………………………………………………. 20
3
2.0 Technical Information
2.1 Specifications
2.1.1 Product Code
2.1.2 8 through 20 ton hoists are available in one standard specification:
• Dual Speed Motor
• Mechanical Load Brake/Friction Clutch Combination
• Count/Hour Meter
• Upper/Lower Limit Switch
2.1.3 Operating Conditions and Environment
Temperature range: -4° to +104°F (-20° to +40°C)
Relative Humidity: 85% or less
Enclosure Rating: Hoist Meets IP 55, Pendant Meets IP65
Supply Voltage: Standard 208-230/460V-3-60, Optional 575V-3-60, Special Voltages Available
Hoist Speed: Single Dual
ASME Duty Classification: H4 H4
Intermittent Duty Rating:
60% ED 40%/20% ED
360 starts/hour 120/240 starts/hour
Short Time Duty Rating: 60 min. 30/10 min.
Table 2-1 Hoist Specifications
Motor
Capacity
(Ton)
8 ER080S 8 11.2 x 3 439 5.9
10 ER100L 597
10 ER100L-LG
10 ER100S 12 11.2 x 4 683
15 ER150S 8 11.2 x 6 897 12.1
Single Speed
20 ER200S 6
8 ER080SD 8/3 11.2 x 3 485 5.9
10 ER100LD 642
10 ER100LD-LG
10 ER100SD 12/4
15 ER150SD 8/3 11.2 x 6 985 12.1
Dual Speed
20 ER200SD 6/2
Product
Code
Lifting
Speed
(ft/min)
6
6/2
Output
(hp)
4.7 18.3 9.2
4.7 x 2 18.3 x 2 9.2 x 2
4.7/1.6 19.6/9.4 9.8/4.7
4.7/1.6x2 19.6/9.4 x 2 9.8/4.7 x 2
Current Draw
(amps)
208V or
230V
460V
Load Chain
Wire Diameter
(mm) x Chain
Fall Lines
11.2 x 4
11.2 x 8
11.2 x 4
11.2 x 8
Load
Sheave
Pockets
4
4
Weight
(lbs.)
1065 16.1
1153 16.1
Net
496
542
772
Weight for
One Addnl.
FT. of Lift
(lbs.)
8.1
8.1
4
2.2 Dimensions
ER080S
Table 2-2 Hoist Dimensions
Head-
Product
Code
ER080S ~ 42.0 8.7 23.8 11.3 7.5
ER100L 52.6 9.2 39.4 20.4
ER100L-LG
ER100S 52.6 9.2 34.2
ER150S 60.6 41.3 3.1
SINGLE SPEED
ER200S 65.0
ER080SD ~ 42.0 8.7 23.8 11.3 7.5
ER100LD 52.6 9.2 39.4 20.4
ER100LD-LG
ER100SD 52.6 9.2 34.2
DUAL
SPEED
ER150SD 60.6 41.3 3.1
ER200SD 65.0
*The "L" dimensions are based on the standard lift of 10 feet.
~Hoist available lug mount only. Dimension C (headroom) and L are to the
center of the lug hole.
room:
(in)
39.7 8.7 28.0
39.7 8.7
L*
C
(ft)a(in)b(in)d(in)e(in)g(in)h(in)i(in)
30.9
10.5
32.2
33.5
10.5
49.1
28.0
49.1
15.5 15.5
16.8
15.5
16.8
2.4
3.4
2.4
3.4
14.0
8.9
14.0
8.9
Table 2-3 Hook Dimensions*
Capacity Code
080S
100L, 100S T & B 3.3 2.2 2.9 1.9 3.3 2.4
150S
T = Top Hook
B = Bottom Hook
Units = in.
*Refer to EROM Section 5.7 for inspection dimensions and limits.
200S
Hookabcdeg
B 3.3 2.2 2.9 1.9 3.3 2.4
T & B 4.1 2.8 3.4 2.4 3.9 3.1
T & B 4.6 3.3 3.9 2.8 4.3 3.4
5
3.0 Preoperational Procedures
3.1 Fill Gear Box with Oil
3.1.1
3.1.2 For a new hoist the correct quantity and type of oil is supplied with the hoist in separate containers.
3.1.3 Refer to Section 6.2 of the EROM when replacing the gear oil or checking the gear oil level.
Table 3-1 Amount of Gear Oil
Capacity
Code
080S, 100L 3.17 3.0
100S, 150S,
200S
CAUTION
Remove the fill plug from the top of the hoist and connect the flexible pour tube to the oil container.
Pour in all of the oil from the separate containers, then replace the fill plug.
Quarts Liters
6.34
(3.17 per
hoist body)
DO NOT use any oil or quantity other than that listed below.
6.0
(3.0 per
hoist body)
Figure 3-1 Oil Plug Locations
3.2 Chain
3.2.1 The quantity and location of the chain components including chain springs and stoppers depends on
3.2.2 When the hoist is used without a chain container, the free end of the chain is attached to the hoist body
ER Gear Oil:
§ Harrington standard: Antoil super B (NIPPON OIL)
§ Acceptable equivalent: Meropa No.68 (TEXACO)
the hoist model and capacity. Never operate the hoist with incorrect, missing or damaged chain
components. Refer to the hoist's nameplate, Table 3-2, and Figure 3-2 and ensure that all chain
components are in the correct location and properly installed.
as shown in Figure 3-2. Connect the “no load” end of the chain to Chain Guide A and the pre-installed
socket bolt and lock nut. Make sure the chain remains free of twists and the chain Stopper is installed
on the correct link. Refer to Table 3-2 for proper placement of Stopper.
6
Figure 3-2 Chain Component Arrangement
Table 3-2 Chain Stopper Placement
Capacity Code Without Chain Container With Chain Container
080S, 100L, 100S,
150S, 200S
th
9
link from the free end 3rd link from the free end
3.2.3 When the optional canvas chain container(s) is used, unfold it fully and install it on the hoist body(ies)
as shown in Figure 3-3. In this case the free end of the chain is not attached to the hoist body and the
chain stopper is installed on the third link from the free end. To place the chain into the chain
container(s), feed the chain into the chain container(s) beginning with the free end. Take care to avoid
twisting or tangling the chain. NEVER put all the chain into the container(s) at once. Lumped or
twisted chain may activate the down limit switch and stop the hoist during lowering.
3.2.4
CAUTION
Each chain container indicates the maximum length of the load chain that can be
stored in the container. The amount of chain the container must hold is equal to the lift on the hoist.
DO NOT use a chain container with a storage capacity less than the lift length on the hoist. If all of the
chain can not be stored in the container, the limit switch will not operate properly.
7
Figure 3-3 Installation of Chain Container
3.2.5 When using an optional steel chain container, refer to the instructions and/or assembly drawing(s)
provided with the container for correct assembly and attachment.
3.2.6
3.2.7 Lubricate the entire length of the load chain with the supplied tube(s) of grease per the instructions in
WARNING
Make sure the bottom hook is not capsized. See Figures 3-4. Correct all chain irregularities before
conducting the first hoist operation.
Section 6.2.1.
3.3 Mounting Location
Verify that the load chain is not twisted or tangled prior to operating the hoist.
Figure 3-4 Capsized Hook and Chain
3.3.1
WARNING
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.
Prior to mounting the hoist ensure that the suspension and the supporting
8
3.3.2
NOTICE
3.4 Mounting the Hoist
3.4.1 Manual Trolley - Follow instructions in Owner’s Manual provided with the trolley.
3.4.2 Motorized Trolley - Follow instructions in Owner’s Manual provided with the trolley.
3.4.3 Hook Mounted to a Fixed Location - Attach the hoist’s top hook to the fixed suspension point.
3.4.4 Lug Mounted ER080S and ER100L-LG – To maintain proper balance when the hoist is not loaded, it
is necessary to install a stabilizing shaft to prevent the hoist from pivoting on the main support shaft.
Refer to Table 2-2 for the size and location of the main support and stablizing holes in the hoist’s top
suspension plates.
See Section 6.7 of the EROM for outdoor installation considerations.
3.4.5
WARNING
that the hook’s latch is engaged.
3.5 Electrical Connections
3.5.1
3.5.2
3.5.3 This instruction applies to installations where the hoist is installed hook mounted to a fixed suspension
CAUTION
DANGER
been de-energized (disconnected). Lock out and tag out in accordance with ANSI Z244.1 “Personnel
Protection -Lockout/Tagout of Energy Sources”.
point or installed on a manual trolley. In this case the hoist is controlled by a pendant with two push
buttons – one for raising and one for lowering. Refer to the appropriate trolley Owner’s Manual if the
hoist is installed on a motorized trolley.
Pendant Cord
The Pendant Cord connects to the hoist via a 5-pin (5P) Plug and Socket. Make this connection as
follows:
§ Refer to Figure 3-5 or 3-6 depending on the Product Code.
§ For ER080S and ER100L - Insert the 5P Plug into the 5P Socket on the hoist body and hand
tighten the Screw Coupling. Install the strain relief cable to the bottom of the hoist body.
§ For ER100S, ER150S and ER200S - Insert the 5P Plug into the 5P Socket on the switch box
and hand tighten the Screw Coupling. Install the strain relief cable onto the cord strain relief
stopper located at the 5P socket.
Ensure that the fixed suspension point rests on the center of the hook’s saddle and
Ensure that the voltage of the electric power supply is proper for the hoist or trolley.
Before proceeding, ensure that the electrical supply for the hoist or trolley has
Power Supply Cable - Hoist Connection
The Power Supply Cable connects to the hoist via a 4-pin (4P) plug and socket or a direct fitting
depending on the product code. Make this connection as follows:
§ Refer to Figure 3-5 or 3-6 depending on the product code.
§ For ER080S and ER100L insert the 4P plug of the Power Supply Cable into the 4P Socket on
the hoist and hand tighten the screw coupling.
§ For ER100S, ER150S, and ER200S – The power supply cable should be pre-installed to the
switch box and properly connected.
§ Install the Cable Support Arm (pre-installed on the Power Supply Cable) on to the Socket
Holder or Switch Box depending on the product code. Use the pre-installed Machine Screws
and Lock Washers.
§ Use care to avoid twisting or kinking the Power Supply Cable.
9
Figure 3-5 Pendant and Power Supply Cable Connections
for ER080S and ER100L
Figure 3-6 Pendant and Power Supply Cable Connections
for ER100S, ER150S and ER200S
10
Figure 3-7 Power Supply Cable Festooning and Guide Wire Location
Power Supply Cable - Installation
If the hoist is hook mounted to a fixed support ensure that the Power Supply Cable is properly
installed and supported between the hoist and the electrical power supply.
If the hoist is installed on a manual trolley, then the Power Supply Cable must be installed along
the beam that the trolley runs on. For curved beams a special cable suspension system will be
needed, and this instruction does not apply. For straight beams install the Power Supply Cable as
follows:
§ Refer to Figure 3-7.
§ Install the Cable Hangers on to the Power Supply Cable spacing them every 5 feet.
§ Install a Guide Wire system parallel to the Bridge Beam. Pass the Guide Wire through the
Cable Hangers and the Wire Guide.
§ Make sure the Guide Wire is properly tensioned and the Power Supply Cable is not twisted or
kinked.
3.5.4 Connection to Electrical Power Source - The red, white, and black wires of the Power Supply Cable
should be connected to an Electric Power Disconnect Switch or Circuit Breaker. This connection
should be made so that the hoist is phased properly. Refer to Section 3.6.11 for instructions on how to
check for correct power supply phase connection.
3.5.5 Fuse/Breaker Capacity -The hoist's power supply should be equipped with overcurrent protection such
as fuses, which should be selected for 110% to 120% of total listed full load amperage, and should be
dual element time-delay fuses. Refer to the motor nameplate(s) for the full load amperage draw.
3.5.6
DANGER
shock hazard when touching any part of the hoist or trolley. In the Power Supply 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.
Grounding - An improper or insufficient ground connection creates an electrical
11
3.6 Preoperational Checks and Trial Operation
3.6.1 Refer to the hoist’s nameplate and record the hoist's Code, Lot and Serial Number in the space
provided on the cover of this manual.
3.6.2
3.6.3
3.6.4 Measure and record the “k” dimension of all hooks on hoist. See Table 5-4 under Section 5
3.6.5 Ensure that the hoist is properly installed to either a fixed point, or trolley, whichever applies.
3.6.6 If hoist is installed on a trolley, ensure that
3.6.7 Ensure that all nuts, bolts and split pins (cotter pins) are sufficiently fastened.
3.6.8 Pull down on the Pendant and ensure that the Cord Strain Relief Cable takes the force, not the
3.6.9
3.6.10 Confirm proper operation.
WARNING
other lifting attachments before use. Inspect all load suspension members for damage prior to use and
replace or repair all damaged parts.
WARNING
Section 3.2 of this manual.
“Inspection”, of this manual.
§ trolley is properly installed on the beam, and
§ stops for the trolley are correctly positioned and securely installed on the beam.
Pendant Cord.
CAUTION
the rated value, electrical devices may not function normally.
Confirm the adequacy of the rated capacity for all slings, chains, wire ropes and all
Verify and correct all chain irregularities prior to operating the hoist. Refer to
Check supply voltage before everyday use. If the voltage varies more than 10% of
§ Before operating read and become familiar with Section 4 – Operation in the EROM.
§ 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.
3.6.11 Proceed with trial operation to confirm proper operation.
§ Verify that the controls agree with hoist direction. Make sure that depression of the up button lifts
the load chain and depression of the down button lowers the load chain hook. If the load chain
does not move in the correct direction when the push buttons are pushed, the power supply is
phased incorrectly. In this case, turn off the power source or breaker switch then reverse any two of
the three wires at the power source. The hook will then move in accordance with the directions of
the push button.
§ Perform inspections per Section 5.2, “Frequent Inspections” in the EROM.
12
5.0 Inspection
NOTICE
Use this table in conjunction with Table 5-3 of the EROM. The entries in this table replace in their entirety
Item Method Criteria Action
Hooks - Fretting
wear
Hooks - Stretch Measure The "k" dimension should not be greater than
The information listed in this section is intended to supplement Section 5.7 of the EROM.
Table 5-3 Hoist Inspection Methods and Criteria
the corresponding entries in Table 5-3 of the EROM.
Measure The "u" and "t" dimensions should not be less
than discard value listed in Table 5-4
1.15 times that measured and recorded at the
time of purchase (See Section 3.6). If recorded
"k" values are not available for hooks when new,
use nominal "k" values from Table 5-4.
Replace.
Replace.
Load Chain - Pitch
and Wire Diameter
Load Chain –
Reeving and
Evening
Measure 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.
Visual Chain should be reeved properly through Load
and Idle Sheaves - refer to Section 6.4. Chain,
Chain Springs, Stoppers, and Chain Pin should
be installed properly - refer to Section 3.2. For
double body hoists, chain should be evenly
distributed – equal length of chain in each chain
container or equal lengths of chain on no-load
side of each hoist body.
Replace. Inspect
Load and Idle
Sheaves.
Reeve/Install chain
properly.
Lower hook until
lower limit switch is
activated on both
hoist bodies.
13
Table 5-3 Hoist Inspection Methods and Criteria
Use this table in conjunction with Table 5-3 of the EROM. The entries in this table replace in their entirety
the corresponding entries in Table 5-3 of the EROM.
Item Method Criteria Action
Motor Brake Measure, Visual Motor brake gap should be adjusted to the
distance shown in Table 6-3 before measuring
the brake wear. Brake lining dimension “A”
should not be less than discard value listed in
Table 5-6. Refer to Section 6.3 of the EROM for
gaining access to motor brake and for adjustment
and inspection procedures. Braking surfaces
should be clean, free of grease/oil and should not
be glazed.
Table 5-4 Top Hook & Bottom Hook Dimensions
“k” Measured When New:
Top: _________________________
Adjust, Repair or
Replace as
required.
Bottom: ______________________
Capacity Code
080S, 100L, 100S
150S
200S
Nominal "k"
Dimension*
inch (mm)
4.72(120) 2.87(73) 2.60(66) 1.89(48) 1.69(43)
5.04(128) 3.43(87) 3.07(78) 2.36(60) 2.13(54)
5.57(141.5) 3.92(99.5) 3.54(90) 2.76(70) 2.48(63)
"u" Dimension
inch (mm)
Standard Discard Standard Discard
"t" Dimension
inch (mm)
* These values are nominal since the dimension is not controlled to a tolerance. The "k"
dimension should be measured when the hook is new - this becomes a reference measurement.
Subsequent measurements are compared to this reference to make determinations about hook
deformation/stretch. See Section 5.7 of EROM, “Hooks - Stretch”.
14
Table 5-5 Chain Wear Dimensions
Capacity Code
080S, 100L, 100S,
150S, 200S
“P” Dimension
inch (mm)
Standard Discard Standard Discard
6.75 (171.5) 6.85 (174.1) 0.44 (11.2) 0.40 (10.1)
“d” Dimension
inch (mm)
Table 5-6 Motor Brake Wear Dimensions
NOTICE
Capacity Code
080S, 100L, 100S, 150S, 200S
Brake must be properly adjusted before measuring "A".
See Section 6.3 of EROM
"A" Dimension - inch (mm)
Single Speed Dual Speed
Standard Discard Standard Discard
0.83 (21) 0.77 (19.5) 1.54 (39) 1.48 (37.5)
15
6.0 Maintenance and Handling
6.2 Lubrication
6.2.1 Load Chain
§ Refer to 6.2.1 of the EROM.
6.2.2 Hooks and Suspension Components:
§ Refer to 6.2.2 of the EROM.
6.2.3 Gear Box:
§ Refer to 6.2.3 of the EROM except use the following table for checking oil level.
Table 6-3 Criteria for Checking Hoist Gear Oil Level
Capacity Code
080S, 100L, 100S, 0150S,
200S
Oil Level (Hoist at level position)
Min Max
1“ below bottom
edge of check hole
Even with bottom
edge of check hole.
6.3 Motor Brake - Use the table below in conjunction with Section 6.3 of the EROM. This table replaces
Table 6-3 of the EROM.
Table 6-3 Motor Brake Gap
6.4 Load Chain
6.4.1 Lubrication and Cleaning – refer to Section 6.2 of EROM.
6.4.2 Load Chain Replacement for ER080S and ER100L:
Capacity Code
080S, 100L, 100S, 150S, 200S
Brake Gap (G)
inch (mm)
0.032 (0.8)
16
1)
CAUTION
following procedures.
The hoist must be properly powered and operational in order to perform the
2)
3)
4) For hoists without a chain container, remove the socket bolt, lock nut, and attach the no-load side of the
5) Remove the Stopper and Chain Spring from the no-load side of the chain for reuse on the new chain.
6) Using an open link, attach the new chain to the end link of the old chain on the no-load side. The end
7) Operate the hoist down to move the new chain though the hoist body. Stop when a sufficient amount
8) Complete reeving as follows:
9) Remove the Snap Ring and Chain Pin that attach the old chain to the chain holder for use on the new
10) Connect the end link of the new chain to the chain holder with the Chain Pin and Snap Ring. Ensure
WARNING
size, grade and construction as the original chain. The new load chain must have an odd number of
links so that both its end links have the same orientation. If the load chain is being replaced due to
damage or wear out, destroy the old chain to prevent its reuse.
CAUTION
Chain Guides and Idle Sheaves, and replace parts if necessary.
chain to Chain Guide A.
Inspect and replace any damaged or worn parts.
link of the new load chain should be connected so that the welded portions of the load chain's standing
links are oriented to the outside as they pass over the Load Sheave. Refer to Figure 6-3.
of new chain is accumulated on the load side.
• For ER080S pull down on Part
Secure the new chain at Part
chain from running back through the idle sheaves. Remove the open link attaching the new chain
to the old chain.
• For ER100L pull up on Part
Secure the new chain at Part
running back through the idle sheaves. Remove the open link attaching the new chain to the old
chain.
chain. Inspect and replace any damaged or worn parts.
that the chain remains free of twists. Attach the remaining chain components to the chain referring to
Section 3.2 for the proper locations. For hoists without a chain container, attach the no-load side of the
chain to Chain Guide A with the socket bolt, and lock nut. See Figure 3-2.
Be certain that the replacement chain is obtained from Harrington and is the exact
When replacing load chain, check for wear on mating parts, i.e. Load Sheave,
until new chain is fed through the upper and lower idle sheaves.
directly below the upper suspension plates to prevent the new
until the new chain is fed through the upper and lower idle sheaves.
directly above the lower idle sheave to prevent the new chain from
11)
12) After installation has been completed, perform steps outlined in Section 3.6 "Preoperational Checks
WARNING
3.2.
and Trial Operation".
Make sure the Stopper and Chain Springs are properly installed. Refer to Section
17
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