Page 1
EFFECTIVE: November 1, 2013
Code, Lot 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.
THEATRICAL
CHAIN HOIST
TNER
SERIES
1/2 Ton through 2 Ton Capacity
Page 2
Table of Contents
Section Page Number
1.0 Important Information and Warnings ……… ………………… …………… ……………… ……………… 4
1.1 Terms and Summary
1.2 Warning Tags and Labels
2.0 Technical Information…………………… ………… ………………… …………… …………… .…………. 8
2.1 Specifications
2.2 Dimensions
3.0 Preoperational Procedures ………………………………………………………………………………10
3.1 Gearbox
3.2 Chain
3.3 Mounting Location
3.4 Mounting the Hoist
3.5 Electrical Connections
3.6 Preoperational Checks and Trial Operation
4.0 Operation ……………………… …………… ……… ……… …………… …… ………… …………… ….. . 16
4.1 Introduction
4.2 Shall’s and Shall Not’s for Operation
4.3 Hoist Controls
5.0 Inspection ……………………… ………………………………………………………………………….. 19
5.1 General
5.2 Inspection Classification
5.3 Frequent Inspection
5.4 Periodic Inspection
5.5 Occasionally Used Hoists
5.6 Inspection Records
5.7 Inspection Methods and Criteria
2
Page 3
Section Page Number
6.0 Maintenance & Handling …………………………………………………………………………………. 26
6.1 Lubrication – Load Chain, Hooks and Gearbox
6.2 Motor Brake
6.3 Load Chain
6.4 Friction Clutch
6.5 Storage
6.6 Outdoor Installation
7.0 Troubleshooting …………………………………………………………………………………………… 32
8.0 Warranty ………………………… …………… …… ………… …………… …… ………… ……… ……… 35
9.0 Parts List …………………………………………………………………………………………………… 37 Appendix A: Wiring Diagram ……………………… …...…………… …………………………………………… 53 Appendix B: CE Decla ration o f Con formi ty………… ……………… …… ……… ….…………………………… 54
3
Page 4
1.0 Important Information and Warnings
1.1 Terms and Summary
This manual provides importa nt informa tion 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.
Danger, Warning, Caution a nd Notice
Throughout this manual there are steps and procedures that can present hazardous situations. The following signal
words are used to identify the degree or level of hazard seriousness.
Danger indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury, and property damage.
Warning indicates an imminently hazardous situation which, if not avoided, could result in death or
serious injury, and property damage.
Caution indicates a potentially hazardous situation which, if not avoided, may result minor or
moderate injury or property damage.
Notice is used to notify people of installation, operation, or maintenance information which is
important but not directly hazard-related.
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.
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.
Record your hoist’s Code, Lot and Serial Number on the front cover of this manual for identification and future
reference to avoid referring to the wrong manual for information or instructions on installation, operation, inspection,
maintenance, or parts.
Use only Harrington authorized replacement parts in the service and maintenance of this hoist.
4
Page 5
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.
Modifications to upgrade, rerate, or otherwise alter this equipment shall be authorized only by the original equipment
manufacturer.
Equipment described herein may be used in the design and manufacture of cranes or monorails. Additional
equipment or devices may be required for the crane and monorail to comply with applicable crane design and
safety standards. The crane designer, crane manufacturer, or user is responsible to furnish these additional items
for compliance. Refer to ANSI/ASME B30.17, “Safety 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-the-hook lifting device or sling is used with a hoist, refer to ANSI/ASME B30.9, “Safety Standard for
Slings” or ANSI/ASME B30.20, “Safety Standard for Below-the-Hook Lifting Devices”.
Hoists and cranes, used to handle hot molten material may require additional equipment or devices. Refer to ANSI
Z241.2, “Safety Requirements for Melting and Pouring of Metals in the Metal Casting 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.
Failure to read and comply with any one of the limitations noted herein can result in serious bodily injury or death,
and/or property damage.
5
Page 6
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; as well as lock and tag the main switch in the de-energized position.
Refer to ANSI Z244.1, “Personnel Protection – Lockout/Tagout of Energy Sources”.
Only trained and competent personnel should inspect and repair this equipment.
It is the responsibility of the owner/user to install, inspect, test, maintain, and operate a hoist in accordance with
ANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, National
Electric Code. If the 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.
It is the responsibility of the owner/user to have all personnel that will install, inspect, test, maintain, and operate a
hoist read the contents of this manual and applicable portions of ANSI/ASME B30.16, “Safety Standard for
Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, “National Electric Code”. If the hoist is installed as part
of a total lifting system, such as an overhead crane, the applicable ANSI/ASME B30 volume that addresses that
type of equipment must also be read by all personnel.
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.
A regular schedule of inspection of the hoist in accordance with the requirements of ANSI/ASME B30.16 should be
established and records maintained.
6
Page 7
1.2 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 or hoist’s pendant cord, order a tag from your dealer and install it. Read and obey all
warnings attached to this hoist. Tag is not shown actual size.
Front Back
Figure 1-1 Warning Tag
7
Page 8
Temperature range:
-4° to +104°F (-20° to +40°C)
Humidity:
85% or less
Noise Level:
85 dB or less (A scale: measured 1 meter away from electric chain hoist)
Enclosure Rating:
Hoist Meets IP55, Optional Pendant Meets NEMA 4X
Supply Voltage:
Single Speed Standard: Reconnectable 208/230 & 460V-3-60
Lines
2.0 T echni cal Informati on
2.1 Specifications
2.1.1 Product Code
2.1.2 Operating Conditions and Environment
Hoist Duty Rating:
Intermittent Duty Rating:
Short Time Duty Rating:
Table 2-1 Hoist Specifications
Capacity
(Ton)
Product
Code
Lifting
Speed
(ft/min)
Output
(Hp)
Single Speed
ISO M3; ASME H3
25% ED
150 starts per hour
30 min.
Motor Load
Current Draw
(amps)
208V or
230V
460V
Chain
Wire
Diameter
(mm) x
Chain Fall
Load
Sheave
Pockets
Net Weight
with 60 Feet
of Lift
(lbs)
Weight
for One
Addnl.
FT. of
Lift
(lbs)
1/2 TNER005L
1 TNER010L
2 TNER020L 8 8.0 x 2
16
0.65
1.3
4.2 2.1
7.1 3.6
8
6.3 x 1
8.0 x 1
99
4
135
209
0.57
0.93
1.9
Page 9
Table 2-2 Hook Dimension*
2.2 Dimensions
Figure 2-2 Hoist Dimensions (See Table 2-3)
Capacity Code Hook a b c d e g
005L
010L
020L
*Refer to Section 5.7 for inspection dimensions and limits.
C 1.1 0.7 0.9 0.7 1.4 0.9
B 1.0 0.6 0.9 0.6 1.7 1.1
C 1.4 0.9 1.2 0.9 1.7 1.2
B 1.2 0.8 1.0 0.8 1.9 1.3
C 1.9 1.1 1.6 1.1 2.0 1.5
B 1.6 1.0 1.3 1.0 2.1 1.6
Table 2-3 Hoist Dimensions
Minimum
Product
Code
Headroom
C
L*
(ft) a (in) b (in)
d
(in)
(in)
TNER005L 13.2 2.5 18.7 14.2 9.6 9.2 0.9 3.9 4.0 35.4
TNER010L 16.1 2.5
TNER020L 22.8 2.5 1.6 48.8
20.0 15.0 10.2 9.8
*The hoist is supplied with 2.5 feet of power supply cable and 2.5 feet of pendant cord.
A pendant is optional.
C = Chain Hook
B = Body Hook
Units = inch
e
(in)
g
(in)
1.2
h
(in)
4.1 4.7
(in)
i
D
(in)
37.0
9
Page 10
Figure 3-1
3.0 Preoperational Proc edures
3.1 Gearbox
3.1.1 The gearbox is filled with the correct amount of grease at the time of shipment.
3.1.2 Refer to Section 6.3 when replacing the gear grease.
3.1.3 Gear grease for TNER is Sumiplex L-Mo No.1 (Part No. SA1BS1855). 1 oz (30 milliliter) of grease is
used to lubricate the gears.
3.2 Chain
3.2.1 The chain components include Ball Stopper, Chain Coupling, Cha in C lip and Chain Container
Assembly. Never operate the hoist with incorrect, missing, or damaged chain components. Ensure
that all chain components are in the correct location and properly installed as shown in Figure 3-1.
Chain Components Arrangement
3.2.2 The Ball Stopper must be installed at least 40 inches away from the no load end of the chain.
Tightening torque for the Ball Stopper Bolt is 10 N-m (7 lb-ft).
3.2.3 The Chain Coupling and the Chain Clip are installed at the no load end of the chain.
3.2.4 Canvas Chain Container - fully unfold and install it on the hoist body as shown in Figure 3-2. Be sure to
mount the chain container in the orientation where the hook guard is away from the hoist body as
shown in Figure 3.1. The no load end of the chain is attached to the chain container bracket by the
Chain Clip as shown in Figure 3.1. To place the chain into the chain container, feed the no load end of
the chain into the container gradually. Take care to avoid twisting or tangling the chain. NEVER put all
the chain into the container at once.
10
Page 11
Figure 3-2
3.2.5
3.2.6
Operating this hoist without the correct Harrington chain container may create a
potentially harzardous situation. To avoid this potentially hazardous situation, always operate this hoist
with the correct chain container installed.
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 cannot be stored in the container, the limit switch will not operate properly.
Attachment of Chain Container to Hoist Body
11
Page 12
Figure 3-3
3.2.7
Verify that the load chain is not twisted or tangled prior to operating the hoist.
Make sure the chain hook on 2 Ton double fall models is not capsized. See Figures 3-3 and 3-4.
Correct all chain irregularities before conducting the first hoist operation.
Figure 3-4 Capsized Hook and Chain –Double Fall Models
3.3 Mounting Location
3.3.1
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.
Twist in Load Chain – 2 Ton Double Fall Models
Prior to mounting the hoist ensure that the suspension and the supporting
3.3.2
See Section 6.6 for outdoor installation considerations.
12
Page 13
Figure 3-5
3.4 Mounting the Hoist
3.4.1 Hook Mounted to a Fixed Location - Attach the hoist’s hook to the fixed suspension point.
3.4.2 The hoist may be mounted by the chain hook or the body hook to a fixed suspension point.
3.4.3
that the hook’s latch is engaged.
3.5 Electrical Connection s
3.5.1
and/or injury. This hoist is reconnectable and is equipped with a quick voltage change device. Check
to make sure the power source matches the voltage configuration of the hoist before supplying power
to the hoist.
3.5.2 The hoist is equipped with a quick voltage changer inside the controller cover. To configure the hoist to
proper voltage configuration, connect the plug from the terminal block to one of the plugs from the
contactor marked with the desired voltage configuration.
Ensure that the fixed suspension point rests on the center of the hook’s saddle and
Supplying this hoist with the incorrect power source can lead to serious damage
Voltage Changer
3.5.3
hoist. Use of such devices may cause the motor brake and other electrical components to malfunction.
3.5.4
energized (disconnected). Lock out and tag out in accordance with ANSI Z244.1 “Personnel Protection
-Lockout/Tagout of Energy Sources”.
3.5.5 The hoist is supplied with 2.5 feet of power supply cable and 2.5 feet of control cable in a standard
configuration. Power supply cable and control cable are directly wired into the hoist.
3.5.6 A pendant is optional. In a case where an optional pendant is used, the hoist is controlled by a pendant
with two push buttons – one for raising and one for lowering.
3.5.7 Ensure that the power supply cable and the control cord are supported by the Cable Support Assembly
and connected to the Socket Holder as shown in Figure 3-6. Use care to avoid twisting or kinking the
cables.
Do NOT apply electronic soft-start control or voltage varying controls to the TNER
Before proceeding, ensure that the electrical supply for the hoist has been de-
13
Page 14
Figure 3-6
Cable Support Assembly
3.5.8 Connection to Electrical Power Source - The red, blue 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 3.6.10 for instructions on how to
check for correct power supply phase connection.
3.5.9 Fuse/Breaker Capacity -The hoist's power supply should be equipped with current overload 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 for the full load amperage
draw.
3.5.10
Grounding - An improper or insufficient ground connection creates an electrical
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.
14
Page 15
3.6 Preoperation al Ch ecks an d T ria l Op eratio n
3.6.1
other lifting attachments before use. Inspect all load suspension members for damage prior to use and
replace or repair all damaged parts.
3.6.2
Section 3.2.
3.6.3 Measure and record the “k” dimension of all hooks on hoist. See Table 5-4 under Section 5,
“Inspection”.
3.6.4 Record the hoist's Code, Lot and Serial Number (from the name plate on the hoist) in the space
provided on the cover of this manual.
3.6.5 Ensure that the hoist is properly installed to a fixed point.
3.6.6 Ensure that all nuts, bolts and split pins (cotter pins) are sufficiently fastened.
3.6.7 If applicable, pull down on the Pendant and ensure that the Cord Strain Relief Cable takes the force,
not the Pendant Cord.
3.6.8
the rated value, electrical devices may not function normally.
3.6.9 Confirm proper operation.
Before operating read and become familiar with Section 4 - Operation.
Before operating ensure that the hoist (and trolley) meets the Inspection, Testing and Maintenance
requirements of ANSI/ASME B30.16.
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 ensure that nothing will interfere with the full range of the hoist’s operation.
3.6.10
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 hook. If the hoist does not operate correctly, shut off and
lockout /tagout the main power source to the hoist. Disconnect and switch any two of the three input
power leads at the power source to correct the hoist’s motor phasing.
The hoist must be connected to the power source such that its direction of
15
Page 16
NSTRUCTION AND WARNING LABELS ON THE HOIST OR
HAVE A HISTORY OF OR BE PRONE TO SEIZURES, LOSS OF
OVERHEAD HOISTS ARE INTENDED ONLY FOR VERTICAL LIFTING SERVICE OF FREELY SUSPENDED
• Read ANSI/ASME B30.16 and ANSI/ASME B30.10.
4.0 Operation
4.1 Introduction
DO NOT WALK UNDER A SUSPENDED LOAD
HOIST OPERAT ORS SHALL BE REQUIRED TO READ THE O PERATION SECTION O F THIS MANUAL, THE
WARNINGS CONTAINED IN THIS MANUAL, I
LIFTING SYST EM, AND THE OPERATION SECTIONS OF ANSI/ASM E B30.16 and ANSI/ASM E 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.
HOIST OPERATORS SHOULD BE TRAINED IN PROPER RIGGING PROCEDURES FOR THE ATTACHMENT
OF LOADS TO THE HOIST HOOK .
HOIST OPERATORS SHOULD BE TRAINED TO BE AWARE OF POTENTIAL MALFUNCTIONS OF THE
EQUIPMENT THAT REQUIRE ADJUSTMENT OR REPAIR, AND TO BE IN STRUCT ED TO STOP OPERAT ION
IF SUCH MALFUNCTIONS OCCUR, AND TO IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE
ACTION CAN BE TAKEN.
HOIST OPERAT ORS SHOULD HAVE NORMAL DEPTH PER CEPTION, FIELD OF VISION, REACTI ON TIME,
MANUAL DEXTERITY, AND COORDINATION.
HOIST OPERATORS SHOULD NOT
PHYSICAL CONTROL, PHYSICAL DEFECTS, OR EMOTIONAL INSTABILITY THAT COULD RESULT IN
ACTIONS OF THE OPERATOR BEING A HAZARD TO THE OPERATOR OR TO OTHERS.
HOIST OPERATORS SHOULD NOT OPERATE A HOIST OR LIFTING SYSTEM WHEN UNDER THE
INFLUENCE OF ALCOHOL, DRUGS, OR MEDICATION.
UNGUIDED LOADS. DO NOT USE HO IST FOR LOADS T HAT ARE NOT LIFTED VERT ICALLY, LOAD S THAT
ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED.
• Read the hoist manufacturer’s Operating and Maintenance Instructions.
• Read all labels attached to equipment.
16
Page 17
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. Use this guidance in conjunction with other warnings, cautions, and notices in this manual
to govern the operation and use of your overhead hoist.
4.2 Shall’s and Shall Not’s for Operation
Improper operation of a hoist can create a poten tially hazardous si tuation w hich, if
not avoided, could result in death
To avoid such a potentially hazardous si tuation THE OPERA TOR SHALL:
• NOT operate a damaged, malfunctioning or
unusually performing hoist.
or serious injury, and substantial property damage.
• NOT apply load unless th e load chain is properly
seated in its grooves.
• NOT operate a hoist until you have thoroughly read
and understood Manufacturer’s Operating and
Maintenance Instructions or Manuals.
• Be familiar with operating controls, procedures, and
warnings.
• NOT operate a hoist that has been modified without
the manufacturer’s appr oval or without certification
that it is in conformity with ANSI/ASME B30
volumes.
• NOT lift more than rated load for the hoist.
• NOT use hoist with twisted, kinked, damaged, or
worn load chain.
• NOT use the hoist to lift, support, or transport
people.
• NOT lift loads over people.
• NOT operate a hoist unless all persons are and
remain clear of the supported load.
• NOT operate unless load is centered under hoist.
• NOT attempt to lengthen the load chain or repair
damaged load chain.
• Protect the hoist’s load chain from weld splatter or
other damaging contaminants.
• NOT operate hoist when it is restricted from forming
a straight line from hook to support in the direction
of loading.
• NOT use load chain as a sling or wrap load c hain
around load.
• NOT apply the load to the tip of the hook or to the
hook latch.
• NOT apply load if bearing prevents equal loading
on all load-supporting chain.
• NOT operate beyond the limits of the load chain
travel.
• NOT leave load supported by the h oist unattended
unless specific precautions have been taken.
• NOT allow the load chain or hook to be used as an
electrical or welding ground.
• NOT allow the load chain or hook to be touched by
a live welding electrode.
• NOT remove or obscure the warnings on the hoist.
• NOT operate a hoist on which the safet y placards
or decals are missing or illegible
• NOT operate a hoist unless it has been securely
attached to a suitable support.
• NOT operate a hoist unless load slings or other
approved single attachments are properly sized,
and seated in the hook saddle.
• NOT u se the hoist in such a way that could result in
shock or impact loads being applied to the hoist.
• Take up slack carefully – make sure load is
balanced and load-holding action is secure bef ore
continuing.
• Shut down a hoist that malfunctions or performs
unusually and report such malfunction.
• Make sure hoist limit switches function properly.
• Warn personnel before lifting or moving a load.
• Warn personnel of an approaching load.
17
Page 18
Improper operation of a hoist can create a poten tially hazardous si tuation
which, if not avoided, could result i n minor
or moderate injury, or
property damage. To avoid such a po tentially haz ardous si tuation THE
OPERATOR SHALL:
• Maintain a firm footing or be otherwise secured
when operating the hoist.
• Check brake function by tensioning the hoist pr ior
to each lift operation.
• Use hook latches. Latches are to retain slings,
chains, etc. under slack conditions only.
• Make sure the hook latches are closed and not
supporting any parts of the load.
• Make sure the load is free to move and will clear all
obstructions.
• Av oid swinging the load or hook.
• Make sure hook travel is in the same direction as
shown on controls.
• Inspect the hoist regularly, replace damaged or
worn parts, and keep appropriate records of
maintenance.
4.3 Hoist Controls
4.3.1 Emergency Stop Button – Press the
Emergency Stop Button to perform an
emergency stop and lock-out of hoist
motion controls. Turn the Emergency
Stop Button clockwise to unlock the
controls and allow hoist operation.
• Use the hoist manufacturer’s recommended parts
when repairing the unit.
• Lubricate load chain per hoist manufacturer’s
recommendations.
• NOT use the hoist load limiting or warning device to
measure load.
• NOT use limit switches as r outine operating stops .
They are emergency devices only.
• NOT allow your attention to be diverted from
operating the hoist.
• NOT allow the hoist to be subjected to sharp
contact with other hoists, structures, or objects
through misuse.
• NOT adjust or repair the hoist unless qualified to
perform such adjustments or repairs.
4.3.2 When using the pendant control
4.3.3
depress the UP button to raise the
hoist load chain/hook or the DOWN
button to lower the hoist load
chain/hook as shown in Figure 4-1.
To stop motion release the buttons.
Make sure the
motor completely stops before
reversing direction.
Figure 4-1 Push Button Pendant Control
18
Page 19
5.0 Inspection
5.1 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 as being competent to perform the specific duties
to which he/she is assigned.
Qualified Person – a person who, by possession of a recognized degree or certificate of professional
standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject matter and work.
Normal Service – that distributed service which involves operation with randomly distributed loads
within the rated load limit, or uniform loads less than 65% of rated load for not more than 25% of the
time.
Heavy Service – that service which involves operation within the rated load limit which exceeds normal
service.
Severe Service – that service which involves normal or heavy service with abnormal operating
conditions.
5.2 In spect ion Cla ssif icat ion
5.2.1 Initial Inspection – prior to initial use, all new, altered, or modified hoists shall be inspected by a
designated person to ensure compliance with the applicable provisions of this manual.
5.2.2 Inspection Classification – the inspection procedure for hoists in regular service is divided into two
general classifications based upon the intervals at which inspection should be performed. The intervals
in turn are dependent upon the nature of the critical components of the hoist and the degree of their
exposure to wear, deterioration, or malfunction. The two general classifications are herein designated
as FREQUENT and PERIODIC, with respective intervals between inspections as defined below.
5.2.3 FREQUENT Inspection – visual examinations by the operator or other designated personnel with
intervals per the following criteria:
Normal service – monthly
Heavy service – weekly to monthly
Severe service – daily to weekly
Special or infrequent service – as recommended by a qualified person before and after each
occurrence.
5.2.4 PERIODIC Inspection – visual inspection by a designated person with intervals per the following
criteria:
Normal service – yearly
Heavy service – semiannually
Severe service – quarterly
Special or infrequent service – as recommended by a qualified person before the first such
occurrence and as directed by the qualified person for any subsequent occurrences.
19
Page 20
5.3 Frequent Inspection
5.3.1 Inspections should be made on a FREQUENT basis in accordance with Table 5-1, “Frequent Inspection.”
Included in these FREQUENT Inspections are observations made during operation for any defects or
damage that might appear between Periodic Inspections. Evaluation and resolution of the results of
FREQUENT Inspections shall be made by a designated person such that the hoist is maintained in safe
working condition.
All functional operating mechanisms for maladjustment and unusual sounds.
Operation of limit switch and associated components
Hoist braking system for proper operation
Hooks in accordance with ANSI/ASME B30.10
Hook latch operation
Load chain in accordance with Section 5.7
Load chain reeving for compliance with Section 3.2 and 6.3
Table 5-1 Frequent Inspection
5.4 Periodic Inspect ion
5.4.1 Inspections should be made on a PERIODIC basis in accordance with Table 5-2, “Periodic Inspection.”
Evaluation and resolution of the results of PERIODIC Inspections shall be made by a designated person
such that the hoist is maintained in safe working condition.
5.4.2 For inspections where load suspension parts of the hoist are disassembled, a load test per ANSI/ASME
B30.16 must be performed on the hoist after it is re-assembled and prior to its return to service.
Requirements of frequent inspection.
Evidence of loose bolts, nuts, or rivets.
Evidence of worn, corroded, cracked, or distorted parts such as load blocks, suspension housing,
chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings, pins and rollers.
Evidence of damage to hook retaining nuts or collars and pins, and welds or rivets used to secure
the retaining members.
Evidence of damage or excessive wear of load and idler sheaves.
Evidence of excessive wear on motor or load brake.
Electrical apparatus for signs of pitting or any deterioration of visible controller contacts.
Evidence of damage of supporting structure or trolley, if used.
Table 5-2 Periodic Inspection
Function labels on pendant control stations for legibility.
Warning label properly attached to the hoist and legible (see Section 1.2).
End connections of load chain.
20
Page 21
5.5 Occasionally U sed Hoi sts
5.5.1 Hoists that are used infrequently shall be inspected as follows prior to placing in service:
Hoist Idle More Than 1 Month, Less Than 1 Year: Inspect per FREQUENT Inspection criteria in
Section 5.3.
Hoist Idle More Than 1 Year: Inspect per PERIODIC Inspection criteria in Section 5.4.
5.6 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.
5.6.2 A long range chain inspection program should be established and should include records of examination of
chains removed from service so a relationship can be established between visual observation and actual
condition of the chain.
5.7 Inspection Methods and Criteria
5.7.1 This section covers the inspection of specific items. The list of items in this section is based on those listed
in ANSI/ASME B30.16 for the Frequent and Periodic Inspection. In accordance with ANSI/ASME B30.16,
these inspections are not intended to involve disassembly of the hoist. Rather, disassembly for further
inspection would be required if frequent or periodic inspection results so indicate. Such disassembly and
further inspection should only be performed by a qualified person trained in the disassembly and reassembly of the hoist.
Table 5-3 Hoist Inspection Methods and Cr iteri a
Item Method Criteria Action
Functional operating
mechanisms.
Limit Switch Function Proper operation. Actuation of limit switch should
Limit Lever
Assembly
Braking System
Operation
Hooks - Surface
Condition
Hooks - Fretting
wear
Hooks - Stretch Measure The "k" dimension should not be greater than
Visual, Auditory Mechanisms should be properly adjusted and
should not produce unusual sounds when
operated.
stop hoist.
Visual, Function Lever should not be bent or significantly worn and
should be able to move freely.
Function Braking distance with rated capacity should not
exceed 3% of the lifting speed (approximately two
chain links).
Visual Should be free of significant rust, weld splatter,
deep nicks, or gouges.
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.
Repair or replace
as required.
Repair or replace
as required.
Replace.
Repair or replace
as required.
Replace.
Replace.
Replace.
Hooks - Bent Shank
or Neck
Visual Shank and neck portions of hook should be free
of deformations.
21
Replace.
Page 22
Table 5-3 Hoist Inspection Methods and Cr iteri a
Item Method Criteria Action
Hooks - Yoke
Assembly
Hooks - Swivel
Bearing
Hooks - Idle Sheave
and Axle (Bottom
Hook on Double Fall
Hoist)
Hooks - Hook
Latches
Load Chain Surface Condition
Visual Should be free of significant rust, weld splatter,
nicks, gouges. Holes should not be elongated,
fasteners should not be loose, and there should
be no gap between mating parts.
Visual, Function Bearing parts and surfaces should not show
significant wear, and should be free of dirt, grime
and deformations. Hook should rotate freely with
no roughness.
Visual, Function Pockets of Idle Sheave should be free of
significant wear. Idle Sheave surfaces should be
free of nicks, gouges, dirt and grime. Bearing
parts and surfaces of Idle Sheave and Axle
should not show significant wear. Idle Sheave
should rotate freely with no roughness or
significant free play.
Visual, Function Latch should not be deformed. Attachment of
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.
Visual Should be free of rust, nicks, gouges, dents and
weld splatter. Links should not be deformed, and
should not show signs of abrasion. Surfaces
where links bear on one another should be free of
significant wear.
Tighten or replace
as required.
Clean/lubricate, or
replace as required.
Clean/lubricate, or
replace as required.
Replace.
Replace.
Load Chain - Pitch
and Wire Diameter
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.
Load Chain Lubrication
Visual, Auditory Entire surface of each chain link should be coated
with lubricant and should be free of dirt and grime.
Chain should not emit cracking noise when
hoisting a load.
Load Chain Reeving
Visual Chain should be reeved properly through Load
Sheave (and Idle Sheave for double fall hoist) refer to Section 6.3. Chain, Chain Coupling,
Chain Clip and Ball Stopper should be installed
properly - refer to Section 3.2 .
Chain Container Visual Container should not be damaged. Brackets
should not be deformed or missing.
Housing and
Mechanical
Components
Visual, Auditory,
Vibration,
Function
Hoist components including load blocks,
suspension housing, chain attachments, clevises,
yokes, suspension bolts, shafts, gears, bearings,
pins and rollers should be free of cracks,
distortion, significant wear and corrosion.
Evidence of same can be detected visually or via
detection of unusual sounds or vibration during
operation.
Replace. Inspect
Load Sheave (and
Idle Sheave for
double fall hoist).
Clean/lubricate
(see Section 6.0).
Reeve/Install chain
properly.
Replace.
Replace.
22
Page 23
Table 5-3 Hoist Inspection Methods and Cr iteri a
Item Method Criteria Action
Bolts, Nuts and
Rivets
Visual, Check
with Proper Tool
Bolts, nuts and rivets should not be loose. Tighten or replace
Motor Brake Measure, Visual Motor brake gap should be adjusted to the
distance shown in Table 6-1 before measuring
the brake wear. Brake lining dimension “A”
should not be less than discard value listed in
Table 5-6. Refer to Section 6.2 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.
Contactor Contacts Visual Contacts should be free of significant pitting or
deterioration.
Load Sheave Visual Pockets of Load Sheave should be free of
significant wear.
Pendant – Switches
(Optional)
Function Depressing and releasing push-buttons should
make and break contacts in switch contact block
and result in corresponding electrical continuity or
open circuit. Push-buttons should be interlocked
either mechanically or electrically to prevent
simultaneous energization of circuits for opposing
motions (e.g. up and down).
Pendant - Housing
(Optional)
Visual Pendant housing should be free of cracks and
mating surfaces of parts should seal without gaps.
as required.
Adjust, Repair or
Replace as
required.
Replace.
Replace.
Repair or replace
as necessary.
Replace.
Pendant - Wiring
(Optional)
Pendant - Cord Visual, Electrical
Visual Wire connections to switches in pendant should
not be loose or damaged.
Surface of cord should be free from nicks,
Continuity
gouges, and abrasions. Each conductor in cord
should have 100% electrical continuity even when
cord is flexed back-and-forth. Pendant Cord
Strain Relief Cable should absorb all of the load
associated with forces applied to the pendant.
Pendant - Labels Visual Labels denoting functions should be legible. Replace.
Warning Labels Visual Warning Labels should be affixed to the hoist (see
Section 1.2) and they should be legible.
Hoist Capacity Label Visual The label that indicates the capacity of the hoist
should be legible and securely attached to the
hoist.
Tighten or repair
Replace.
Replace.
Replace.
23
Page 24
Table 5-4 Chain Hook & Bottom Hook Dimensions
“k” Measured When New:
Chain: ________________________
Body: ________________________
C = Chain Hook
B = Body Hook
Capacity Code
005L
010L
020L
Nominal "k"
Dimension*
inch (mm)
C
B 1.92 (48.8) 0.86 (21.8) 0.77 (19. 6) 0.63 (16 .0) 0.57 (14.4)
C
B 2.22 (56.3) 1.04 (26.5) 0.94 (23. 9) 0.77 (19 .5) 0.69 (17.6)
C
B 2.52 (64.1) 1.32 (33.5) 1.19 (30. 2) 0.96 (24 .3) 0.86 (21.9)
1.65 (42) 0.93 (23.5) 0.83 (21) 0.69 (17.5) 0.63 (16)
1.97 (50) 1.22 (31) 1.10 (28) 0.89 (22.5) 0.79 (20)
2.46 (62.5) 1.57 (40) 1.42 (36) 1.14 (29) 1.02 (26)
"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, “Hooks - Stretch”.
Table 5-5 Chain Wear Dimensions
“P” Dimension
Capacity Code
Standard Discard Standard Discard
005L 3.76 (95.5) 3.82 (96.9) 0.25 (6.3) 0.22 (5.7)
010L, 020L 4.76 (121.0 ) 4.91 (124.6) 0.31 (8.0) 0.28 (7.2)
inch (mm)
“d” Dimension
inch (mm)
24
Page 25
Table 5-6 Motor Brake Wear Dimensions
Brake must be properly adjusted before measuring "A". See Section 6.3
Capacity Code
005L
010L, 020L
Standard Discard
0.67 (17) 0.61 (15.5)
0.85 (21.5) 0.79 (20)
"A" Dimension - inch ( mm)
25
Page 26
6.0 Maintenance and Handling
6.1 Lubrication
6.1.1 Load Chain
For longer life, the load chain should be lubricated.
The load chain lubrication should be accomplished after cleaning the load chain with an acid free
cleaning solution.
Apply Harrington lubricating grease (Part No. ER1BS1951) or an equivalent to industrial general lithium
grease, NLGI No. 0, to the bearing surfaces of the load chain links as indicated by the shaded areas in
Figure 6-1. Also apply the grease to the areas of the load chain (shaded areas in Figure 6-1) that
contact the load sheave. Insure that the grease is applied to the contact areas in the load sheave
pockets.
Machine or gear oil (grade ISO VG 46 or 68 oil or equivalent) may be used as an alternative lubricant
but must be applied more frequently.
Figure 6-1 Chain Grease Application
The chain should be lubricated every 3 months (more frequently for heavier usage or severe
conditions).
For dusty environments, it is acceptable to substitute a dry lubricant.
6.1.2 Hooks and Suspension Components:
Hooks - Bearings should be cleaned and lubricated at least once per year for normal usage. Clean and
lubricate more frequently for heavier usage or severe conditions.
Suspension Pins - Lubricate at least twice per year for normal usage; more frequently for heavier usage
or severe conditions.
Idle Sheave Bearing - Bearings should be cleaned and lubricated at least twice per year for normal
usage. Clean and lubricate more frequently for heavier usage or severe conditions.
26
Page 27
6.1.3 Gear Box:
may prevent the friction clutch from working properly and may affect the ability of the hoist to hold the
load. Refer to Section 3.1 for the correct grease and quantity.
If experiencing abnormal noise or unusual gearbox operation, have the gearbox serviced by a qualified
individual.
Always replace the gearbox grease when servicing the gearbox.
6.2 Motor Brake
6.2.1 To keep your hoist working in optimum condition and prevent possible down time, it is recommended to
check your motor brake lining and adjustment at regular intervals.
6.2.2 Motor Brake Unit Removal - Adjustment and inspection of the motor brake requires removal of the motor
brake unit from the hoist as an assembly.
1)
To keep the load chain from moving secure it by tying together the load and no-load sides directly under the
hoist using a cord or wire.
2) Refer to Figure 6-3.
3) Remove the four Frame Cover Bolts (A), Frame Cover (B), Nut (C), Lock Washer (D), and Spacer (E).
Using an incorrect type/grade of gearbox grease or the wrong quantity of grease
Dispose of the used grease in accordance with local regulations.
Before proceeding disconnect the power supply and make sure the hoist is unloaded.
4) Remove the four Motor Cover Assembly bolts (F) and carefully pull the motor brake unit (G) out of the hoist.
Figure 6-2 Motor Brake
27
Page 28
6.2.3 Brake Gap (G) - The Brake Gap should be measured between the Brake Drum and Pull Rotor. Adjustment
of the Brake Gap is accomplished by turning the Adjustment Nut in the center of the Motor Cover as shown
in the figure with Table 6-1. Do this as follows:
5) Bend the tab of the Lock Washer away from the Adjusting Nut so that the Adjusting Nut can be rotated.
6) Using a spanner wrench and a feeler gauge, rotate the Adjusting Nut to attain the proper Brake Gap per
Table 6-1.
7) After the Brake Gap is set, secure the Adjusting Nut by bending one of the tabs of the Lock Washer into a
slot in the Adjusting Nut. If necessary rotate the Adjusting Nut clockwise (tightening) to line up the tab with
the slot.
8) If the proper brake adjustment cannot be achieved, disassemble the motor brake and inspect all motor
brake parts. Replace the Brake Drum and/or Motor Cover if necessary.
28
Page 29
Table 6-1 Motor Brake Gap
6.2.4 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 chain 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. Replace the Brake Drum and/or Motor Cover if necessary. For
normal inspections, the Brake Lining and Motor Cover wear should be measured as follows.
1) Adjust the Brake Gap per Section 6.2.3 before measuring the Brake Lining and Motor Cover wear.
2) Refer to Table 5-6.
3) Measure the distance "A" using calipers and a straight edge. Place the straight edge across the edge of the
motor cover and measure from the straight edge to the face of the Pull Rotor.
4) Compare the measurement with the values listed in Table 5-6. Replace the Brake Drum and/or Motor
Cover if the "A" measurement is smaller than the discard limit.
6.2.5 Motor Brake Unit Installation - After the brake is properly adjusted and inspected, carefully replace the
motor brake unit back into the hoist. Be sure to reseal the Motor Cover to motor frame surface using a
small bead of liquid (hi-temperature) sealant. Refer to Section 6.2.2 and reassemble the parts in reverse
order of removal.
6.3 Load Chain
Brake Gap (G)
inch (mm)
0.020 (0.5)
6.3.1 Lubrication and Cleaning – refer to Section 6.1.
6.3.2 Load Chain Replacement:
1)
The hoist must be properly powered and operational in order to perform the following
procedures.
6.3.3
Be certain that the replacement chain is obtained from Harrington and is the exact size,
grade and construction as the original chain. The new load chain must have an odd number of links so that
29
Page 30
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.
1)
When replacing load chain, check for wear on mating parts, i.e. Load Sheave, Chain
Guides and Idle Sheaves, and replace parts if necessary.
2) Remove all chain components including the Chain Hook Set Assembly, Ball Stoppers, Chain Pin, Chain
Coupling and Chain Clip from the chain for reuse on new chain. Inspect and replace any damaged or worn
parts.
3) Using a C-link, attach the new chain to the end link of the old chain on the no-load side. The end 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 sheave. Refer to Figure 6-3.
4) Operate the hoist down to move the chain though the hoist body. Stop when a sufficient amount of new
chain is accumulated on the load side.
5) Single fall hoists - Attach the chain components (step 4 above) to the chain. Refer to Section 3.2 for the
proper locations.
6) Double falls (020L) - Feed the end link on the load side of the new chain through the required chain
components (step 4 above) and the bottom hook’s Idle Sheave. Attach the remaining chain components to
the chain referring to Section 3.2 for the proper locations. Connect the end link to the top connection yoke
with the chain pin, slotted nut and cotter pin. Ensure that chain remains free of twists. Refer to Figures 3-3
and 3-4.
7)
Make sure Ball Stopper, Chain Coupling and Chain Clip are properly installed. Refer to
Section 3.2.
8) After installation has been completed, perform steps outlined in Section 3.6 "Preoperational Checks and
Trial Operation".
Figure 6-3 Chain Replacement
30
Page 31
6.4 Friction Clutch
6.4.1 Friction Clutch – If abnormal operation or slippage occurs do NOT attempt to disassemble or adjust the
Friction Clutch. Replace the worn or malfunctioning Friction Clutch as an assembly with a new, factory
adjusted part.
6.5 Storage
6.5.1 The storage location should be clean and dry.
6.6 Outdoor Installation
6.6.1 For hoist installations that are outdoors, the hoist should be covered when not in use.
6.6.2 Possibility of corrosion on components of the hoist increases for installations where salt air and high
humidity are present. Make frequent and regular inspections of the unit's condition and operation.
31
Page 32
7.0 Troubleshooting
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.”
Only Trained and competent personnel should inspect and repair this equipment.
Table 7-1 Troubleshooting Guide
Symptom Cause Remedy
Hoist moving in wrong
direction
Hoist will not operate
Power supply reversed
phased
Improper electrical
connections
Loss of power
Wrong voltage or
frequency
Hoist overload
Motor overheated and
thermal overload
protector has tripped
Improper, loose, or
broken wire in hoist
electrical system
Brake does not
release
Faulty magnetic
contactor
Defect in control
transformer
Switch 2 of the 3 power supply cord wires at the power source.
Refer to wiring diagram and check all connections.
Check circuit breakers, switches, fuses and connections on power
lines/cable.
Check voltage and frequency of power supply against the rating
on the nameplate of the motor.
Reduce load to within rated capacity of hoist.
See Trouble Shooting Problem "Motor or brake overheating".
Shut off power supply, check wiring connections on hoist control
panel and inside push-button pendant.
Check motor brake adjustment for proper clearance.
Check coil for open or short circuit. Check all connections in the
control circuit. Check for open contactors. Replace as needed.
Check transformer coil for signs of overheating. Disconnect
transformer and check for open winding.
Motor burned out
Replace motor frame/stator, shaft/rotor, and any other damaged
parts.
32
Page 33
Table 7-1 Troubleshooting Guide
Symptom Cause Remedy
Hoist lifts but will not
lower
Hoist lowers but will
not lift
Down circuit open
Broken conductor in
pendant cord
Faulty magnetic
contactors
Faulty switch in
pendant
Hoist overloaded Reduce load to within rated capacity of hoist.
Low voltage in hoist's
power supply
Up circuit open
Broken conductor in
pendant cord
Faulty magnetic
contactor
Faulty switch in
pendant
Check circuit for loose connections. Check down side of limit
switch for malfunction.
Check the continuity for each conductor in the cable. If one is
broken, replace entire cable.
Check coils for open or short circuit. Check all connections on
motor circuit. Check for burned contacts. Replace as needed.
Check electrical continuity. Check electrical connections.
Replace or repair as needed.
Determine cause of low voltage and bring to within plus or minus
10% of the voltage specified on the motor nameplate. The
voltage should be measured at the hoist contactor.
Check circuit for loose connections. Check up side of limit switch
for malfunction.
Check the continuity of each conductor in the cable. If one is
broken, replace entire cable.
Check coils for open or short circuit. Check all connections on
motor circuit. Check for burned contacts. Replace as needed.
Check electrical continuity. Check electrical connections.
Replace or repair as needed.
Hoist will not lift rated
load or does not have
the proper lifting speed
Load drifts excessively
when hoist is stopped
Faulty friction clutch Replace.
Hoist overloaded Reduce load to within rated capacity.
Low voltage in hoist's
power supply
Brake drags Check motor brake adjustment for proper clearance.
Faulty friction clutch Replace.
Motor brake not
holding
Determine cause of low voltage and bring to within plus or minus
10% of voltage specified on the motor nameplate. The voltage
should be measured at the hoist contactor.
Clean and inspect brake lining. Check brake adjustment for
proper clearance.
33
Page 34
Contactor contacts
arcing
Table 7-1 Troubleshooting Guide
Symptom Cause Remedy
Excessive lo ad Reduce load to within rated capacity of hoist.
Excessive duty cycle Reduce frequency of lifts.
Motor or brake
overheating
Hoist operates
intermittently
Wrong voltage or
frequency
Brake drags Check brake adjustment for proper clearance.
Extreme external
heating
Collectors making poor
contact
Loose connection in
circuit
Broken conductor in
Pendant Cord
Check voltage and frequency of power supply against the rating
on the nameplate on the motor.
Above an ambient temperature of 140°F, the frequency 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.
Check movement of spring loaded arm, weak spring, connections,
and shoe. Replace as needed.
Check for burned contacts. Replace as needed.
Check all wires and terminals for bad connections. Replace as
needed.
Check for intermittent continuity in each conductor the Pendant
Cord. Replace entire Pendant Cord if continuity is not constant.
34
Page 35
8.0 Warranty
Warranty expl anati on a nd ter ms.
All products sol d by Har r ing ton Hois ts , Inc. are w arr anted to be free fro m defects in material and
workmanship from date of shi pment by Harring ton for the foll ow ing periods:
Manual Hoist s & T rolle y s – 2 years
NER/ER Hoists Enhanced Features Models – 3 Years
NER/ER, TNER, SNER and ED Electric Hoists, Air Hoists & Trolleys, Crane Components – 1 year
Spare / Replacement Parts – 1 year
NER/ER Enhanced Feature DC Current Brake – 10 years
TNER Pull-Rotor Motor Brake – 5 y ears
The product mus t be us ed i n acc ord ance w i th ma nufact ur er’s r ec ommend atio ns and mus t not have
been subject t o ab use, l ack o f mai nte nance , misuse, neg li gence, or u n author iz ed re pairs or
alterations.
Should any de fect i n m aterial or w orkma nshi p occ ur during t he ab ove t ime peri od i n a ny pr odu ct,
as determined by H arri ng ton Hoi st ’s ins pec tion of the pro duc t, H arri ngton H oi sts, Inc . agr ees , at i ts
discretion, ei ther to r epl ace ( not inc ludi ng i nst all atio n) or repai r the p art or pr oduc t free of c harg e
and deliver s aid it em F .O.B . H arri ngton Hoi sts , Inc . pl ace of busin ess to c ustom er.
Customer must obtai n a Retur n G oods Aut hori zat ion as di rec ted by Har r ing ton or Harr ing ton’ s
published repai r c ent er pr ior to shi ppi ng prod uct for w arr anty eval uati on. An expl anati on of t he
complaint mus t acc omp any th e pr odu ct. Pro duct m ust be r etur ned freight prepai d. U po n re pair ,
the product w ill be cov er ed for the r em ain der of the ori gi nal w arr anty per i od. I f i t is deter mi ned
there is no de fect , or that the de fect r esul ted fr om ca uses not w i thin t he sc ope of H arr ingt on’s
warranty, the c ust omer w ill be responsible for th e cos ts of re turni ng the prod uct.
Harrington Hoi sts, Inc . d iscl aims any a nd al l o ther w arrant ies of any ki nd ex pres sed or i mpli ed as t o
the product’s merch ant ability or fitness for a parti cular appli catio n. Harri ngton wi ll not be liabl e for
death, injuri es t o per son s or pr op erty or for i nci dent al, c onti ng ent, s peci al or c ons eque ntial
damages, loss or expen se ari sing in co nnecti on w ith the use or in abil ity w hatev er , reg ardles s o f
whether damage, los s o r ex pens e res ults fr om a ny ac t or failur e t o act b y Har ring ton, w heth er
negligent or w il lful, or from any o th er reas on .
35
Page 36
This Page Intentionally Left Blank
36
Page 37
9.0 Parts List
ER/NER Series Nameplate
37
When ordering Parts, please provide the Hoist code number, lot number and serial number located on the Hoist nameplate (see fig. below).
Reminder: Per sections 1.1 and 3.6.4 to aid in ordering Parts and Product Support, record the Hoist code number, lot number and serial number in the space
provided on the cover of this manual.
The parts list is arranged into the following sections:
Section
9.1 Housing and Motor Parts……………………………………………….…………………………….. 38
9.2 Gearing Parts…………………………………………………………………………………………... 42
9.3 Hook Parts………………………………………………………………….………………………….. 44
9.4 Chaining Parts…………………………………………………………...…………………………….. 46
9.5 Electric Parts…………………………………………………………….……………………………... 48
9.6 Power Supply and Pendant Parts……………………………………...…………………………….. 50
In the column "Parts Per Hoist" a designator is used for parts that apply only to a particular model or option. Refer to Section 2 for hoist model numbers and
additional descriptions. The designators are:
Page 38
9.1 Housing and Motor Parts
38
Figure 9-1 Housing and Motor Parts
Page 39
Figure
9.1 Housing and Motor Parts
Part Name
No.
1
Frame Cover
2 Socket Bolt 4 9091233
3 Toothed Lock Washer 4 9679708
8 Nut 1 ES217005S
9 Lock Washer 1 ES218005S
10 Spacer 1 SA1BL9313 ES216S005
11 Motor Cover As sembly 1 ER1BS2106 ER1CS2106
12 Socket Bolt 4 9091251 9091273
13 Spring Washer 4 9012709 9012711
14 Collar M 1 ES192005S
15 Coned Disc Spring M 4 E3S191005S
16 Brake Drum Assembly 1 ER1BS5212 ER1CS5212
17 Brake Spring 1 ES214003 ES214005S
18 Thrust Collar 1 ES506003 ES506005S
19 Thrust Disc 2 ES505003 ES505005S
39
20 Pull Rotor 1 ES503003 ES503005S
21 Coned Disc Spring 1 ES504003 ES504005S
22 Motor Shaft w ith Rotor 1 SA1BL5502 SA1CL5502
Parts Per
Hoist
1 SA1BL9207 SA1CL9207
005L 010L 020L
Page 40
9.1 Housing and Motor Parts
Figure
40
No.
24
25 Socket Bolt 4 90912138 9091275
26 Set Pin S 2 ES120003 ES120010S
27 Packing M 1 ER1BS9118 ER1CS9118
28 Body B 1 SA1BL9101 SA1CL9101
30 Oil Plug 2 E3S111003
31 Plug Packing 2 E3S112003
32 Set Pin S 2 ES1200035
33 Packing G 1 ER1BS9116 ER1CS9116
35 Gear Case F 1 SA1BL9103 SA1CL9103
36 Socket Bolt 4 9091259
37 Toothed Lock Washer 4 9679709
38 Name Plate SP 1 SA1DHM05I9B6 SA1DHM10I9B6 SA1DHM20I9B6
39 Oil Plug B 2 SA1BS9135
40 Eyebolt Packing 1 ES127005S
42 Bending Washer 1 SA1BS9983
43 Spring Pin 1 E3S129005S
44 Handle 2 SA1CL9963
45 Socket Bolt 4 9091250
48 Packing C 1 ER1BS9117 ER1CS9117
50 Socket Bolt 4 9091238 9091239
51 Toothed Lock Washer 4 9679708
52 Name Plate B 1 SA1CHM05L9A3 SA1CHM10L9A3
53
55 Grease Warning Label 1 80470
56
57 TNER Logo Label 1 80483
58 BGV-D8 Logo Label 1 80486
59 CE Mark Label 1 80487
60 Controller Cover 1 SA1BL9104 SA1CL9104
61 Wiring Diagram 1 EWE4A00H1
Part Name
Motor Frame with Stator
208-230/460V-3-60
Warning Sticker E
(Disconnect Power)
Voltage Changer Warning
Label
Parts Per
Hoist
1 SA1DHM05L5A1 SA1DHM010L5A1
1 ER2CS9936
1 80485
005L 010L 020L
Page 41
41
This Page Intentionally Left Blank
Page 42
9.2 Gearing Parts
42
Figure 9-2 Gearing Parts
Page 43
Parts Per
10.2 Gearing Parts
9.2 Gearing Parts
Figure
43
No.
1 Bearing Holder 1 ER1CS9110
2 Socket Bolt 3 90912133
3 Snap Ring 1 9047262 9047262
4 Collar B 1 ER1BS9111
5 Pinion Assembly 1 ER1BS5220 SA1CL5220
6 Oil Seal 1 ES221003 ES221010S
7 Ball Bearing 1 9000907 9000909
8 Load Sheave 1 ER1BL9241
9 Oil Seal 1 ES232005S ES232005S
10 Ball Bearing 1 9000907
11 Snap Ring 1 9047262 9047262
12 Load Gear 1 ER1BL9240
13 Snap Ring 1 9047130 9047135
14 Ball Bearing 1 9001001 9001101
15 Ball Bearing 1 9000301 9000204
16 Friction Clutch Set 1 SA1BL1626 SA1CL1626
17 Wavy Washer 1 E1DBX20S9311
18 Oil Seal 1 ES221005S E6F235003S
19 Friction Plug 1 ER1BS9235 ER1CS9235
20 Nameplate FP 1 ER1BS9892
21 Set Pin S 2 ES120003
22 Gear Plate 1 ER1CL9261
23 Spring Washer 3 9012709
24 Socket Bolt 3 90912138
25 Ball Bearing 2 9000900
26 Gear B As sembly 1 SA1CL5262
Part Name
Hoist
005L 010L 020L
ER1CL9241
ER1CS9240
Page 44
9.3 Hook Parts
44
Figure 9-3 Hook Parts
Page 45
Figure
9.3 Hook Parts
No.
2 Chain Clip 1 SA1BS9422
3 Suspender D 1 SA1CR9030
5 Yoke Bolt 1 SA1CR9032
6 Slotted Nut 1
7 Split Pin 1 9009436
8 Body Hook Complete Assembly 1 SA1BS1001 SA1CS1001 SA1CR1001
9 Hook Latch Assembly 1 CF071010 CF071015 CF071030
10 Chain Pin 1 M2041010
11 Slotted Nut 1 M2049010
12 Split Pin 1 9009412
13 Connection Sha ft 1 ER1BS9121 ER1CS9121
14 O Ring 2 9013306 9013309
15 Plate A 1 ER1BS9123
16 Machine Screw w/ Spring Washer 2 J1AP25001212
18 Fixing Shaft Assembly 1 ER1BS1122 ER1CS1122
19 O Ring 2 9013305
20 Shaft Plug 1 ER1BS9128 ER1CS9128
45
22 Machine Screw 1 9798543
26 Chain Hoo k Co mple te A ssem bly 1 SA1BL1011
28 Hook Latch Assembly 1 ER1BS1002 ER1DS1002 ER1ES1002
29 Thru st Co llar A 1 ES026003 ES026010L
30 Hook St opper 2 ES027003 ES027010L
31 Thrust Bearing 1 ES022003 ES022010L
32 Bottom Shaft Assembly 1 ER2DR6023
33 Idle Sheave Assembly 1 27SH010S1103
34 Bottom Yoke Assembly 1 SA1CR2015
35 Bolt 2 90931215
36 Spring Washer 2 9012711
37 Nut 2 9093424
38 Name Plate C 1 M3805030
39 Ball Stopper Set 1 SA1CS9041 SA1CL9041
Load Chain (Nickel Pla ted D IN) 1 LCER005NP-DIN LCER010NP-DIN
40
Load Chain (Blac k)* 1 LCER005C LCER010C
41 Chain Cou pling 1 P2HC0051121
42 Socket Bolt w/ Spring Washer 2 J1BG10602020 J1BG10602525
Part Name
Parts Per
Hoist
005L 010L 020L
SA1CL1011 SA1CR1011
ES088020L
*The black load chain is optional. The hoist will not have CE Conformance with the bla ck chain installed.
Page 46
9.4 Chaining Parts
46
Figure 9-4 Chaining Parts
Page 47
Fig No Part Name
Parts Per
Hoist
9.4 Chaining Parts
005L 010L 020L
1 Chain Guide A 1 SA1BL9331 SA1CL1331
3 Guide Roller 1 ER1DS9333
4 Roller Pin 1 ER1CS9334
5 Limit Lever S 1 SA1BL9337 SA1CL9337
24 Chain Guide B 1 ER1BL9332 ER1CL9332
11 Mach. Screw w/ Spring Washer 4 J1AP25001212
12 Socket Bolt 4 J1BG10602525 J1BG10603535
14 Limit Lever Pin Assembly 1 SA1BS1338 SA1CS1338
17 Split Pin 1 9009410
Chain Container Assembly (S)
18
Chain Container Assembly (M) SA1BS6405 (100f t) SA1BS6405 (65ft) SA1BS6405 (32ft)
Chain Container Assembly (L) SA1BS6406 (120ft) SA1BS6406 (60ft)
21 Body Plate 1 SA1BL9961 SA1CL9961
22 Socket Bolt 1 9091262 9091263
23 Flat Washer 2 9012511
47
24 Spring Washer 1 9012709
25 Nut 1 9093420
26 Socket Bolt 1 9091286
27 Spring Washer 1 9012711
28 Nut 1 9093424
29 Chain Guide C 1 SA1BS9962 SA1CL9962
30 Socket Bolt 2 9091262 9091286
31 Spring Washer 2 9012709 9012711
32 Nut 2 9093420 9093424
1
SA1BS6404 (49ft) SA1BS6404 (32ft) SA1BS6404 (16ft)
Page 48
9.5 Electric Parts
48
Figure 9-5 Electric Parts
Page 49
Fig No Part Name
Parts Per
49
1 Limit Switch Assembly 1 ER1BS1551
2 Socket Bolt 3 9091247
3 Spring Washer 3 9012709
4 Plate Assembly 1 SA1DHM05L5A2 SA1DHM10L5A2
5 Transformer 3 TRF62M611
6 Machine Screw 2 MS555010
7 Terminal Plate 1 ECP1309AD
8 Mach. Screw w/ Spring Washer 2 J1AW24001010
9 E-Stop Contactor 1 MGC14306C
10 Mach. Screw w/Spring Washer 2 MS556010
11 Electromagnetic Contactor 1 MGC23406C
12 Machine Screw 2 J1AP24001212
13 Plate Screw 2 (3) ER1BS9445
14 Fuse 1 ECP91FZ06
15 Fuse Holder 1 ECP92FZAA
16 Mach. Screw w /Spring Washer 1 E2D667125
17 Mach. Screw w /Spring Washer 2 MS555010
*Quantities in “()” are for 010L and 020L hoists.
18 Lead Wire Assembly 1 SA1DHM05L9A2 SA1CHM10L9A2
Hoist
005L 010L 020L
Page 50
10.5 Electric Parts 9.6 Power Supply and Pendant Parts
50 50
Figure 9-6 Power Supply and Pendant Parts
Page 51
9.6 Power Supply and Pendant Parts
51
Fig No Part Name
1 Socket Holder Assembly 1 SA1CL1511
2 Socket Holder 1 SA1CL9511
3 Holder B 2 ECP5924AB
4 Holder Packing 2 ECP5924AC
5 Holder Nut 2 ECP5924AD
6 Machine Screw w/ Spring Washer 2 J1AP26001212
7 Socket Holder Packing 1 ER1BS9512
8 Machine Screw w/ Spring Washer 4 MS561010
9 Cable Support Arm 1 SA1BS9541
10 Cable Support 1 E4YS0059822
11 Cable Support Pin B 1 E3ES0029541
12 Spli t Pin 1 9009402
Power Supply Cable 4C Complete
13
Assembly
14 Pow er Supply Cable 4C ft 14/4
15 Cable Packing 1 ECP6916AA
16 Holder A 1 ECP5924AA
17 Control Cord Co mplete Assembly 1 8050295
18 Control Cord ft 16/4P
19 Cable Packing 1 ECP6912AA
20 Holder A 1 ECP5924AA
Power Supply Cable 4C Complete
21
Assembly with Hubbell Connector
(HBL2431)
Control Cord Complete Assembly with
22
Hubbell Connector (HBL2433)
23 Pendant with Cord Co mplete Assembly 1 8049895
24 Pendant Cord 1 16/4P
25 Pendant As sembly 1 9012877
26 Warning Tag 1 WTAG7
Parts Per
Hoist
1 8050095
1 8049695
1 8049595
005L 010L 020L
Page 52
This Page Intentionally Left Blank
52
Page 53
Appendix A: Wiring Diagram
53
Page 54
EC DECLARATION OF CONFORMITY
Appendix B: CE Dec laration o f Conformity
We, Harrington Hoists, Inc.,
401 West End Ave.,
Manheim, PA 17 545, US A
declare under our sole responsibility that the products:
Electric chain hoist TNER
for use with or without the relev ant serial trolleys in c apacity range o f 1/2 ton up to 2 ton,
to which this declaration relates is in conformity with the following EC directives and standards.
EC directives:
Machinery Directive 2006/42/EC
EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC
Harmonized standards:
EN ISO 12100: 2010 Risk assessment and risk reduction
EN 14492-2: 2006 Power driven hoists
EN 818-7: 2002+A 1: 200 8 Short link chain for lifting purposes
EN ISO 13850: 2006 Emergency stop
EN 60204-1: 2006 Electrical equipment of machines
EN 60204-32: 2008 Electrical equipment of machines
EN 61000-6-4: 2007 Electromagnetic compatibility - Emission
EN 61000-6-2: 2005 Electromagnetic compatibility - Immunity
National standards:
FEM 9.511: 1986 Classification of mechanisms
FEM 9.683: 1995 Section of lifting and travel motors
BGV-D8: 1980 Winch, Hoist and pulling device
VPLT.SR2.0: 2005 Codes of practice for event techno logy
54
Page 55
This Page Intentionally Left Blank
55
Page 56
www.harringtonhoists.com
Harrington Hoists, Inc. Harrington Hoists – Western Division
401 West End Avenue 2341 Pomona Rd. #103
Manheim, PA 17545-1703 Corona, CA 92880-6973
Phone: 717-665-2000 Phone: 951-279-7100
Toll Free: 800-233-3010 Toll Free: 800-317-7111
Fax: 717-665-2861 Fax: 951-279-7500
TNEROM
Loading...