Harrington Hoists and Cranes Static Dynamic Hoist Load Tester User Manual
Effective: October 25, 2005
OWNER'S (OPERATOR'S) MANUAL
FOR
HARRINGTON
STATIC & DYNAMIC
LOAD TESTER
Model SHLT/DHLT
BEFORE USING THIS PRODUCT:
ALWAYS READ OWNER'S MANUAL
ALWAYS SAVE THIS BOOK FOR FUTURE REFERENCE
TABLE OF CONTENTS
1. ASSEMBLY INSTRUCTIONS FOR LOAD TESTER FRAME ........................... 3
1.1 Frame Assembly ........................................................................................ 3
1.2 Assembly of Static Option.......................................................................... 9
1.3 Assembly of Dynamic Option ................................................................... 10
2. SEQUENCE OF OPERATIONS FOR STATIC HOIST LOAD TESTER.......... 11
2.1 Load Testing a Manually Operated Hoist................................................. 11
3. SEQUENCE OF OPERATIONS FOR DYNAMIC HOIST LOAD TESTER...... 13
3.1 Load Testing an Electric Operated Hoist ................................................. 13
3.2 Load Testing a Manually Operated Hoist................................................. 15
3.3 Trouble Shooting Tips.............................................................................. 16
4. PARTS LIST ................................................................................................... 19
4.1 Step Assembly (50767) ........................................................................... 19
4.2 Winch Assembly ...................................................................................... 20
4.3 Trolley Beam Assembly (50973) .............................................................. 21
4.4 Link Support (50614) ............................................................................... 22
4.5 Electro-Hydraulic Base Assy. for Dynamic Option................................... 23
4.6 English/Metric Tester Frame Assembly ................................................... 24
4.7 English/Metric Tester Assembly - Static Option ....................................... 27
4.8 English/Metric Tester Assembly - Dynamic Option .................................. 28
4.9 Electrical Components and Wiring Subassembly - Dynamic Option ....... 31
2
1. ASSEMBLY INSTRUCTIONS FOR LOAD TESTER FRAME
Note: Please refer to drawing 50979 on page 26 entitled English/Metric Tester Frame
Assembly. This portion of the assembly instructions is identical for either static or
dynamic options.
Recommended Equipment:
Forklift or hoist with a minimum capacity of one ton, various hand tools and two quali
fied assembly personnel.
Note: Please review this entire portion of the assembly instructions prior to beginning the
assembly of the hoist tester frame. Follow the steps listed below for assembly of your
hoist tester frame.
1.1 Frame Assembly
Step 1: Assembly of the hoist tester base item 5 on drawing 50979, page 26.
a.) Locate all component parts for the base assembly and orient them according to
Figure #1.
Note: Be sure that the support beam 4 with the front support holes is oriented
on support angle B 1 as shown in Figure #1.
b.) Secure the entire assembly by using eight (8) M16x65mm long bolts, item 16 ,
eight (8) M16 lock washer, item 18 , and eight (8) M16x20 nuts, item 19 , as
shown on drawing 50979.
c.) Make certain that these fasteners are tight by applying 187 foot-lb of force using
a torque wrench.
d.) Install two plain caster, item 30 , and two (2) swivel casters, item 31 , to the
frame using sixteen (16) 1/2x13x1 1/4" long bolts, item 26 , sixteen (16) 1/2"
diameter flat washer, item 28 , sixteen (16) 1/2" diameter lock washers, item
27 , and sixteen (16) 1/2-13 nuts, item 29 , as shown on drawing 50979.
Note: The swivel casters are located on the front or narrow portions of the base.
After tightening all fasteners lock the brakes on the swivel casters to prepare for
the remainder of the assembly.
3
Figure 1
Limit Switch Holes
Front Support Holes
Step 2: Assembly of the lower beam, Figure #2, and the vertical column, Figure #3. Examine
drawing #50979 for correct orientation of the lower beam, Figure #2, the vertical
column, Figure #3 and the base assembly Figure #1.
Attachment Holes for
Vertical Column
Cylinder
Mount
Figure 3
Front
5 Ton
10 Ton
Figure 2
4"
Concrete
Floor
Attachment
Pin Hole
Attachment
Angle
4
a.) Remove the lower beam assembly, Figure #2, from the shipping crate using a
forklift or bridge crane.
b.) Locate the lower beam assembly securely on heavy blocks to allow approxi
mately 4" of clearance between the bottom of the lower beam and a smooth flat
surface preferably a concrete floor, as shown in Figure #2.
c.) Select three long pins, item 7 , and one orange colored size 1 1/4" master link,
item 10 , and one yellow colored size 1" master link, item 9 . Also select six (6)
M8x60mm long bolts, item 32 , and six (6) M8 lock nuts, item 33, all shown on
drawing 50979. Insert two (2) of the long pins in the pin holes labeled 5 ton and
10 ton, sliding them partially through the lower beam. Place the orange 1 1/4"
master link on the pin at the 10 ton location and the yellow 1" master link on the
pin at the 5 ton location. Now slide the pins the remainder of the way through
the lower beam and secure them by placing the M8x60mm long bolt with lock nut
at each end of the two pins, as shown in section A-A on drawing 50979.
d.) Remove the vertical column, Figure #3 from the shipping crate using a forklift,
trolley/hoist, or bridgecrane.
e.) Orient the vertical column in a vertical position with the attachment pin hole at
the bottom and the attachment angle in a position pointing toward the front of the
lower beam. See Figures 2 and 3.
f.) Lift the vertical column high enough to clear the lower beam and center the
attachment pin hole in the vertical column directly above the attachment hole for
the vertical column in the lower beam.
g.) Lower the vertical column down between the two horizontally oriented channels
of the lower beam and align attachment holes between the beam and the
column.
h.) Slide the third long pin, item 7 , drawing 50979 through the attachment holes
coupling the beam and column together. Install M8x60mm long bolts, item 32 ,
and 8 lock nuts, item 33 , as shown in section A-A on drawing 50979.
i.) Slide two pieces of 2"x6"x18" long wood through the opening between the rear of
the vertical column and the rear of the lower beam allowing them to bottom on
the floor and extend vertically upward along the column. See Figure #4 below.
These blocks of wood will prevent the lower beam from rotating about the attachment pin.
Figure 4
Vertical Column
2"x6"x18" long wood
Lower Cylinder Pin Hole
4"x4"x25" long wood
Lower Beam Assembly
5
Step 3: Assembly of vertical column, Figure #3, and lower beam, Figure #2, to base assem-
bly, Figure #1.
a.) Lift the coupled vertical column and lower beam assembly by attaching to verti
cal column. Lift high enough to clear the base assembly and move directly over
the base assembly.
b.) Lower the vertical column and lower beam until the outriggers, Figure #5, can be
attached to the base and vertical column.
c.) Before installing the outriggers place the six (6) M20x46x100 bolts, item 13 , with
six (6) 3/4" flat washers, item 54 , through the holes on the rear flange of the
vertical column. These bolts will be used to attach the cylinder mount during a
later step in the assembly instruction. These bolts must be placed with the
threads pointing toward the rear of the load tester and must be inserted prior to
the installation of the outriggers to avoid interference.
d.) Fix both outriggers into position using four (4) M16x65mm long bolts, item 16 ,
pushing through the lower attachment holes of the outriggers and through the
attachment holes on the base. Secure the outriggers by placing M16 "U"
washer, item 34 , and M16 nuts, item 19 , as shown on drawing 50979. Do not
tighten these nuts until the remainder of the attachment bolts have been placed
in the upper holes of the outriggers.
e.) Align the upper holes of the outriggers and the vertical column attachment holes
by using a drift punch until the four (4) M16x65mm long bolts, item 16 , have
been placed through the alignment holes at the top of the outrigger shown in
drawing 50979. Secure the four (4) bolts with M16 flat washers, item 17 , lock
washer, item 18 , and nuts, item 19 .
f.) Make certain that all M16 fasteners are tight by applying 187 foot-lb of force
using a torque wrench.
Top Attachment
Holes
Bottom Attachment
Holes
Figure 5
6
Step 4: Assembly of top beam, Figure #6, to vertical column, Figure #3.
a.) Remove the upper beam, Figure #6, from the shipping crate using a forklift or
bridgecrane.
b.) Lift the upper beam, Figure #6, to the top of the vertical column and couple them
by inserting six (6) M20x75mm long bolts, item 13 , six (6) M20 lock washer, item
14 , and six (6) M20x2.5 nuts, item 15 , as shown on drawing 50979. Also insert
six (6) M16x65mm long bolts, item 16 , six (6) M16 "U" washers, item 34 , six (6)
M16 lock washers, item 18 , and six (6) M16x2.0 nuts, item 19 , shown on draw
ing 50979.
c.) Make certain that all fasteners are tight by applying 187 foot-lb to the M16 fas-
teners and 367 foot-lb to the M20 fasteners, using a torque wrench.
Figure 6
Pin Holes
Step 5: Assembly of master links, item 9 and 10 , to the upper beam as shown on drawing
50979.
a.) Select the two (2) remaining short pins, item 7 , and the one (1) remaining
orange colored size 1 1/4" master link, item 10 , and the yellow colored size 1"
master link, item 9 .
b.) Insert the two (2) short pins into the pin holes and slide them partially through
the top beam.
c.) Place one (1) orange size 1 1/4" master link on the pin closest to the vertical
column and labeled 10 ton and place the yellow size 1" master link farthest away
from the vertical column and labeled 5 ton. Now slide the pins the remainder of
the way through the top beam and secure them by placing one (1) M8x60mm
long bolt, item 32 , and an M8 lock nut, item 33 , at each end of both pins as
shown in section A-A drawing 50979.
7
Step 6: Assembly of cylinder mount, Figure #7, to vertical column, Figure #3 as shown on
drawing 50979.
a.) Remove the cylinder mount from the shipping crate using a forklift or
bridgecrane.
b.) Select six (6) M20 "I" taper washers, item 12 , six (6) 3/4" flat washers, item
54 , and twelve (12) M20x2.5 nuts, item 15 .
c.) Lower the cylinder mount and carefully align and slide over the six (6) M20 bolts
protruding through the vertical column. The cylinder mount must be oriented so
that the cylinder pin hole is located at the bottom rear corner of the cylinder
mount.
d.) Now place the six (6) M20 "I" taper washers, the six (6) 3/4" flat washers, and
the six (6) M20 nuts respectively on the bolts. Make certain the nuts are tight by
applying 367 foot-lb of force using a torque wrench. Now place one (1) each
M20 nut in addition to the existing nuts and torque to ensure that the fasteners
will remain secure during operation of the test stand. See drawing 50979 for
details and orientation.
Figure 7
Upper Cylinder
Pin Hole
Step 7: Assembly of winch to tester frame. See assembly on page 20 and drawing 50979
page 26.
a.) Select the components as shown on the winch assembly drawing page 20.
b.) Assemble the RH and LH pulley mounts, items 1 and 4 page 20, and pulleys
with components, items 6 , 7 , and 9 , prior to attaching them to the tester
frame. Be sure the mounting holes are oriented correctly as shown in the assembly drawing page 20. The ends of the frame with two (2) mounting holes
are located to the front of the tester and the ends with the single mounting holes
to the rear. Place all three (3) pulleys, pulley spacers, and pulley bushings in
position and attach by using three (3) M12x70mm long bolts, item 50 , three (3)
M12 lock washers, item 47 , and three (3) M12x1.75 nuts, item 46 , as shown on
assembly drawing 50979. Do not tighten nuts until after attaching to the tester
frame.
8
c.) Attach front and rear mounting brackets, items 2 and 3 on winch assembly
page 20, to the tester frame in their respective positions. See also drawing
50979 page 26, items 20 and 21 for correct placement.
d.) Assemble pulley mounts and pulleys to frame by using two (2) M10x40mm long
bolts, item 42 , two (2) M10 lock washers, item 43 , and two (2) M10x1.5 nuts,
item 44 . Tighten all fasteners located on this pulley mount.
e.) Attach the winch, item 5 , on page 20, to the tester by placing it on top of the
cylinder mount as shown on drawing 50979 page 26. Use four (4) M10x40mm
long bolts, item 42 , four (4) M10 lock washers, item 43 , and four (4) M10x1.5
nuts, item 44 , to secure winch to load tester frame.
This completes the assembly of the frame for your hoist load tester. Please refer to section
1.2 if you have the static option or section 1.3 if you have the dynamic option.
1.2 Assembly of static hydraulic cylinder assembly to the tester frame assembly
a.) Remove the static hydraulic cylinder assembly, item 12 on drawing 50979-1,
from the shipping crate with a forklift or crane.
b.) Select two (2) "U" bolt assemblies, item 22 , from the hardware packet.
c.) Lower the winch cable and attach it to the 1" master link in the lower beam
assembly. Raise the winch which will lift the lower beam until the 2"x6"x18" long
wood can be removed from between the rear of the lower beam and the vertical
column.
d.) Remove the lower pin from the cylinder (end opposite the rod end) and tilt the
upper yoke away from the rear of the vertical column and gently slide the lower
yoke over the lower beam cylinder mount, (see Figure #2 page 4 and 27). Lower
the cylinder assembly until the holes in the yoke of the cylinder and the lower
beam cylinder mount align. Insert the lower pin and replace the fixing clip to
secure the lower yoke to the hoist tester frame. Now tilt the rod end of the cylin
der forward adjusting the lower beam by raising or lowering the winch until the
rod end holes align with the upper cylinder pin hole of the cylinder mount. Insert
the upper pin and replace the fixing clip to secure the upper yoke to the cylinder
mount.
e.) Attach the pressure gauge to the appropriate location using the "U" bolt assem-
blies, item 22 , as shown on drawing 50979-1.
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1.3 Assembly of dynamic hydraulic system to hoist load tester frame, drawing 50924
a.) Remove dynamic hydraulic system from the shipping crate using a forklift or
crane.
b.) Select the dynamic option hardware packet, the front support, item 4 , and the
DHLT stand cover, item 6 page 23.
c.) Attach the front support, item 4 , as shown on drawing 50924 to the base as
sembly of the load tester frame using two (2) M12x40mm long bolts, item 18 ,
two (2) M12 "U" taper washers, item 19 , two (2) M12 lock washers, item 20 ,
and two (2) M12x1.75 nuts, item 21 , as shown on drawing 50924. Tighten
securely before proceeding to the next step.
d.) Lower the dynamic hydraulic system assembly orienting the accumulator end
according to drawing 50924. Fasten the system by inserting two (2) M12x40mm
long bolts, item 18 , through the rear mounting holes in the pump base and
through the holes in the mounting angle, item 6 , at the rear of the tester base ,
see Figure #1 and drawing 50924. Secure by placing two (2) M12 lock washers,
item 20 , and two (2) M12x1.75 nuts, item 21 , onto the M12 bolts, item 18 , and
tighten.
e.) Refer to parts "c" and "d" of section 1.2 for installation of cylinder assembly.
f.) Attach the pressure gauge/adjusting valve to the appropriate location using two
(2) M10x75 long bolts, item 25 , two (2) M10 lock washers, item 12 , and two (2)
M10x1.5 nuts, item 13 , as shown on drawing 50924 page 23.
g.) Attach the lower arm limit switch assembly, item 39 , to the base of the test stand
using two (2) M8x20 socket head cap screws, item 40 , and two (2) M8 lock
washer, item 16 , as shown on drawing 50924 page 30. Set the cam roller of
the limit switch so it will activate the limit switch as the lower beam assembly is
lifted and before the cylinder is fully extended. The measurement of the length
of the rod that is extended when the limit switch is activated is approximately
4 1/2".
h.) Attach the electrical enclosure, item 5 , to the mounting bracket on the vertical
column using four (4) 1/4-20x1 1/4" long bolts, item 6 , four (4) 1/4" flat washers,
item 7 , and four (4) 1/4-20 nuts, item 8 , as shown on drawing 50924.
i.) Remove plug with red tag from pump oil tank and replace with vented cap.
This completes the assembly of the dynamic option of your hoist load tester. Please
refer to the operation instructions for initial set up and operation of your tester.
10
2. SEQUENCE OF OPERATIONS FOR STATIC HOIST LOAD TESTER
IMPROPER test stand use could result in death or serious injury.
To avoid these hazards:
NEVER overload unit.
ALWAYS operate, inspect and maintain this test stand with
operator safety as a goal.
ALWAYS read owner's manual and safety instructions prior to
use.
2.1 The following is a suggested procedure for load testing a manually operated
hoist.
Step 1: If the hoist tester is mounted on casters,
insure that the caster pivot and rolling locks
are engaged.
Step 2: Always use the winch to lift heavy units into place.
Step 3: Using the hoist tester winch and hoist tester step, suspend a 1/4 to 5 ton hoist
from front top link (yellow, size 1) or 6 to 10 ton hoist from the rear top link
(orange, size 1 1/4).
Step 4: Engage the bottom hook through the corresponding master link on the lower
beam assembly and remove the slack from the load chain.
Step 5: Review the calibration chart and locate the pressure setting that corresponds
to the rated capacity of the hoist being tested.
11
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