HARRINGTON ED525DSA ED Series Electric Chain Hoist Owner’s Manual

: June 5, 2024
: HARRINGTON

Table of Contents

ED525DSA ED Series Electric Chain Hoist
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ED525DSA ED Series Electric Chain Hoist

EFFECTIVE: November 8, 2021

ELECTRIC CHAIN HOIST
ED SERIES EDV
250 through 1000 Lb. Capacity
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.

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

2.3 Part Names

3.0 Pre-operational Procedures ……………………………………………………………………………… 14

3.1 Fill Gear Box with Oil

3.2 Chain

3.3 Load Chain Lubrication

3.4 Chain Container

3.5 Mounting Location

3.6 Mounting the Hoist

3.7 Electrical Connections

3.8 Mini Trolley Installation

3.9 Pre-operational Checks and Trial Operation

4.0 Operation ………………………………………………………………………………………………….. 21

4.1 Introduction

4.2 Shall’s and Shall Not’s for Operation

4.3 Hoist Controls

4.4 Electric Chain Hoist with Trolley

4.5 Lifting Speed Adjustment Using Potentiometer

2

Section

Page Number

5.0 Inspection ………………………………………………………………………………………………….. 26

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

6.0 Maintenance & Handling …………………………………………………………………………………. 33

6.1 Lubrication

6.2 Load Chain

6.3 Mechanical Load Brake with Friction Clutch

6.4 Fuses

6.5 Storage

6.6 Outdoor Installation

7.0 Troubleshooting …………………………………………………………………………………………… 36

8.0 Warranty …………………………………………………………………………………………………… 39

9.0 Parts List …………………………………………………………………………………………………… 40

3

1.0 Important Information and Warnings

1.1 Terms and Summary

This manual provides important information 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 and 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 (see Section 9) 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

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 Metalcasting Industry”.
Electrical equipment described herein is designed and built in compliance with Harrington’s interpretation of ANSI/NFPA 70, “National Electrical Code”. The system designer, system manufacturer, crane designer, crane manufacturer, installer, or user is responsible to assure that the installation and associated wiring of these electrical components is in compliance with ANSI/NFPA 70, and all applicable Federal, State and Local Codes.
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

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; and 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

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’s pendant cord or cylinder control, 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 Attached to Hoist

7

2.0 Technical Information 2.1 Specifications
2.1.1 Product Code

2.1.2 Features and General Specifications

Push Button Pendant Control Standard Weight/Size Light weight and compact size, easy to install, move, or store
Double Braking System A Weston style load brake and a regenerative brake Low Headroom Die cast aluminum body provides low headroom, perfect for tight quarters
Upper Limit Switch Standard

Over-Travel Protection
Smooth Operation
Corrosion Resistant Load Chain Chain Container

Friction clutch integrated with load brake and engineered to protect the hoist from overwinding
Gears are immersed in an oil bath and have deep groove ball and needle bearings to support rotating components
Nickel-plated, heat treated alloy chain for long life
Standard

2.0.1

Operating Conditions and Environment

Temperature range: Humidity:
Noise Level:
Enclosure Rating:
Supply Voltage: ASME Duty Classification:

-4° to +104°F (-20° to +40°C)

85% or less
83 dB or less (A scale: measured 1 meter away from electric chain hoist)

Hoist Body

IP54

Push Button Pendant

IP65

Standard 120V-1-60

H2

8

Table 2-1 Hoist Specifications

Cap. (lbs.)

Product Code

Lifting Speed (ft/min)

Lifting Speed (maximum, ft/min)

Load Chain Wire
Diameter (mm) x Chain Fall Lines

Load Sheave Pockets

Standard Lift (ft)

Push Button Cord L
(ft)

Motor Output
(HP)

Intermittent Duty Rating

Duty Rating % ED

Max. Start Freq.
(Times/Hr)

Short Time Duty Rating (min)

Rated Current at 120V (amps)

250 ED250V

16

26

4

0.4

20

120

10

6

350 ED350V

16

44

4.0 x 1

0.8

30

180

20

10

8

500 ED500V

16

44

5

0.8

30

180

20

10

1000 ED1000V

8

22

4.0 x 2

0.8

30

180

20

10

2.2 Dimensions

Table 2-2 Hoist Dimensions

Cap. (lbs)

Headroom C (in)

a (in)

d (in)

e (in)

f (in)

g (in)

h (in)

i (in)

j (in)

k (in)

Net Weight
(lbs)

Weight for Additional One
Foot of Lift (lbs)

250

12.4

14.6 7.4 7.2 8.1

4.9 3.1

13.4

24

350

13.0

16.9 8.1

8.8

8.6

1.0

5.3

3.3

1.0 14.3

33

0.26

500

13.0

16.9 8.1 8.8 8.6

5.3 3.3

14.3

33

1000

20.5

16.9 8.1 8.8 9.0 1.1 6.1 2.9

17.9

46

0.49

Figure 2-1 Hoist Dimensions ED250V, ED350V, ED500V (See Table 2-2)

Figure 2-2 Hoist Dimensions ED1000V (See Table 2-2)

9

Figure 2-3 ET525 Mini Trolley (See Tables 2-4 and 2-5)

Maximum Capacity
(lbs.)
500

Table 2-4 Mini Trolley Dimensions

Product Code

Beam Flange Width Minimum Radius

Range, B (in)

for Curve(in)

Net Weight (lbs.)

ET525

1.97 3.94

23.6

4.0

Approximate Shipping Weight (lbs.)
5.0

Table 2-5 Mini Trolley Headroom

Capacity (lbs.)

Headroom C (in.)

250

10.5

350 11.1
500

10

Capacity (lbs.)
250 to 500
1000

Table 2-6 ED Hook Dimensions*

Hook

a (in)

b (in)

c (in)

d (in)

e (in)

f (in)

g (in)

Top

0.8 0.3 0.7 0.3 1.3 1.2 1.0

Bottom 0.8 0.5 0.7 0.5 1.4 1.4 1.0

Top

1.1 0.7 0.9 0.7 1.4 1.2 1.1

Bottom 1.1 0.7 0.9 0.7 1.4 1.4 1.1 *See Table 5-5 in for discard dimensions.

Cap. Product

(lbs)

Code

Table 2-7 ED Chain Dimensions

d

a

b

P

(in) (in) (in) (in)

250 to 1000

(All Models)

0.16

0.20

0.53

0.48

11

2.3 Part Names
Figure 2-4 ED250V, ED350V, and ED500V Part Names 12

Figure 2-4 ED1000V Part Names 13

3.0 Pre-operational Procedures

3.1 Fill Gear Box with Oil

3.1.1

Use only Harrington ED brand oil. The oil is specially blended and should be

purchased from Harrington. Refer to parts list for part number.

3.1.2 For a new hoist the correct quantity and type of oil is pre-supplied in the gearbox.

3.1.3 Refer to Section 6.1 when replacing the gear oil or checking the gear oil level.

Table 3-1 Amount of Gear Oil Capacity Code quarts liters

250

0.28 0.27

350

500

0.37 0.35

1000

Figure 3-1 Oil Plug Locations

3.2 Chain

3.2.1

The quantity and location of the chain components including Cushion Rubbers, Washers and Stopper Assemblies depend on the hoist model, 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.

Table 3-2 Chain Stopper Placement

Capacity Code

Load Side

250, 350, 500, 1000

Adjacent to bottom yoke

No Load Side Last link

14

ED250V, ED350V, ED500V

ED1000V

Figure 3-2 Chain Component Arrangement

3.3 Load Chain Lubrication

3.3.1 Always lubricate load chain weekly, or more frequently, depending on severity of service.

3.3.2

Always make sure to apply ISO VG 46 or 48 or equivalent machine oil. Insufficient

oil lubrication will accelerate Load Chain wear.

15

3.4 Chain Container

3.4.1 Follow the instructions below to install the Chain Container. Refer to Figure 3-3.

Feed the Load Chain into the Chain Container beginning with the no-load end. Take care to avoid twisting or tangling the Load Chain.
Attach the Chain Container to the Chain Guide (1) with the Socket Bolt (2) and the U-Nut (3).
Attach the Split Pin (4) to prevent the U-Nut (3) from backing off.
Bend the Split Pin ends 90o or more.

Do not use the Chain Container if any parts are damaged or if any

fasteners/hardware are missing.

Figure 3-3 Chain Container Installation

3.5 Mounting Location

3.5.1

Prior to mounting the hoist ensure that the suspension and the supporting
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.

3.5.2

See Section 6.6 for outdoor installation considerations

3.6 Mounting the Hoist

3.6.1 ET525 Mini Trolley Refer to Section 3.8 for installation instructions

3.6.2 Manual Trolley – Follow instructions in Owner’s Manual provided with the trolley.

3.6.3 Hook Mounted to a Fixed Location – Attach the hoist’s top hook to the fixed suspension point.

3.6.4

Ensure that the fixed suspension point rests on the center of the hook’s saddle and

the hook’s latch is engaged.

3.7 Electrical Connections

3.7.1

Ensure that the voltage of the electric power supply is proper for the hoist or trolley.

16

3.7.2 3.7.3

Before proceeding, ensure that the electrical supply for the hoist or trolley has
been de-energized (disconnected). Lock out and tag out in accordance with ANSI Z244.1 “Personnel Protection -Lockout/Tagout of Energy Sources”.

This instruction applies to installations where the hoist is installed hook mounted to a fixed suspension 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.

Pendant Cord

The Pendant Cord is hard wired to the hoist. Make this connection as follows:

1.) Single Speed Adjustable Models (EDV) Refer to Figure 3-4. The Push Button Cord is factory installed onto the hoist body. Attach the Strain Relief Wire (2) to Cable Support L (1).

2.)

Short circuit and electric shock may result if the Push Button Cord is

pulled when the Strain Relief Wire is not connected to the hoist body. ALWAYS make sure

that the Strain Relief Wire is properly attached to the hoist body.

3.)

To avoid wear between the Load Chain and the Chain Guide, straighten

Load Chain before fitting the Coiled Cord to the Chain Container.

4.)

To avoid damaging the Coiled Cord, attach the Chain Container so that

the Wire Tie faces up and away from the Load Chain

Figure 3-4 Diagram for Pendant Type Push Button Cord Installation
Power Supply Cable Hoist Connection A 14-gauge Power Supply Cable is supplied with hoist.
When the power source is far away and an extension supply cable is required,
an adequate gauge size.
Power Supply Cable – Installation 17

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 host 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:
Install a Guide Wire System parallel to the beam.
For a manual trolley the Guide Wire should be positioned slightly outside the hoist’s Cable Support.

3.7.4 Connection to Electrical Power Source – The white and black wires of the Power Supply Cable should be connected to an Electric Power Disconnect Switch or Circuit Breaker.

3.7.5

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 for the full load amperage draw.

3.7.6

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. Do not paint the trolley wheel running surfaces of the beam as this can affect grounding.

3.8 Mini Trolley Installation

3.8.1 Mini Trolley – Follow instructions below to install the trolley. Refer to Figure 3-6.

Remove the Top Hook Assembly from the hoist.
Refer to Table 3-3 for placement of Adjusting Spacers for the flange width “B” of the traversing beam. The position of Adjusting Spacers differs with flange width. If the beam flange width is not listed in Table 3-3, use the next size smaller and make adjustments in accordance with step 3. Use all 32 Adjusting Spacers provided.

Flange Width
(in)
2 2 5/16 2 1/2 2 11/16 2 13/16
3 3 1/4 3 5/16 3 9/16 3 11/16 3 7/8 3 15/16

Table 3.3 Quantity and Position of Trolley Spacers

Outside Left Frame
8 6 6 5 5 4 3 3 2 1 0 0

Number of spacers

Inside Left Frame

Inside Yoke

Inside Right Frame

6

4

6

7

4

8

4

8

4

9

4

9

10

4

10

11

4

11

4

11

12

4

12

4

13

4

14

4

14

Outside Right Frame 8 7 6 6 5 4 3 3 2 2 1 0

Refer to Figure 3-6 and assemble the Trolley Frames, Adjusting Spacers and Socket Bolts onto the Top Yoke. Install and hand tighten the Hex Nuts on the Socket Bolts. Verify that dimension “A” is approximately 0.12 – 0.16 in (3-4mm) greater than “B” (flange width). If “A” does not fall within the
18

specified range, move Adjusting Spacers from the inside of the Trolley Frame to the outside or from the outside to the inside as necessary to obtain the proper “A” dimension, irrespective of the numbers in Table 3-3.

Install the trolley and hoist onto traversing beam using one of the following 2 methods:

Preferred Method Sliding adjusted the trolley connected with hoist onto the traversing beam from the beam end is the most convenient and recommended method. If the trolley can be mounted from the end of the beam then: Remove the trolley end-stop from the beam and set the trolley on the beam from the end. Securely re-install the trolley end stop on the beam.

Optional Method If the trolley cannot be mounted from the end of the beam, loosen the Hex Nuts and spread the trolley Frames. Lift the trolley and hoist onto the beam from below. Push the trolley frames together, adjust the spacing as in accordance with Step 3 and hand tighten the hex Nuts.

Check for contact between all four Trolley Wheels and the rail surface. Shift the Trolley Frame until all Trolley Wheels rest on the rail surface. Tighten the Hex Nuts and install the two (2) U-Nuts onto the Socket Bolts tighten against the Hex Nuts. Install the Split Pins onto the Socket Bolts and bend securely.

Incorrect number of Adjusting Spacers may cause the trolley to not move or to

drop. To avoid these hazards, always make sure to use all 32 spacers and confirm that A – B = 0.12 –

0.16 in (3-4mm).

To prevent the trolley from dropping, firmly fasten the Socket Bolt, Nut and U-Nut.

Insert Split Pin and bend the ends 90 degrees or more.

Figure 3-6 Mini Trolley Installation

3.8.2

For all trolley suspended electric chain hosts, rail stops must be installed at each
end of the rail. Failure to install rail stops will allow the hoist and trolley to fall off the end of the rail and thus cause and accident that could resutt in injury and/ or property damage. The stops must be positioned so as to not exert impact force on the electric chain hoist frame or trolley wheels. They must contact the ends of the trolley side frames.

19

3.9 Pre-operational Checks and Trial Operation

3.9.1

Confirm the adequacy of the rated capacity for all slings, chains, wire ropes and all
other lifting attachments before use. Inspect all load suspension members for damage prior to use and replace or repair all damaged parts.

3.9.2

Verify and correct all chain irregularities prior to operating the hoist. For reference

see Section 3.2.

3.9.3 Measure and record the “k” dimension of all hooks on hoist. See Table 5-5 under Section 5, “Inspection”.

3.9.4 Record the hoist’s Code, Lot and Serial Number (from the name plate on the hoist; see Section 9) in the space provided on the cover of this manual.

3.9.5 Ensure that the hoist is properly installed to either a fixed point, or trolley, whichever applies

3.9.6 If hoist is installed on a trolley, ensure that

trolley is properly installed on the beam, and

stops for the trolley are correctly positioned and securely installed on the beam.

3.9.7 Ensure that all nuts, bolts and split pins (cotter pins) are sufficiently fastened.

3.9.8 Pull down on the Pendant and ensure that the Cord Strain Relief Cable takes the force, not the Pendant Cord.

3.9.9

Check supply voltage before everyday use. If the voltage varies more than 10% of

the rated value, electrical devices may not function normally.

3.9.10 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.

Before operating ensure that nothing will interfere with the full range of the hoist’s (and trolley’s) operation.

20

4.0 Operation

4.1 Introduction

DO NOT WALK UNDER A SUSPENDED LOAD

HOIST OPERATORS SHALL BE REQUIRED TO READ THE OPERATION SECTION OF THIS MANUAL, THE WARNINGS CONTAINED IN THIS MANUAL, INSTRUCTION AND WARNING LABELS ON THE HOIST OR LIFTING SYSTEM, AND THE OPERATION SECTIONS OF ANSI/ASME B30.16 and ANSI/ASME 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 INSTRUCTED TO STOP OPERATION IF SUCH MALFUNCTIONS OCCUR, AND TO IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE ACTION CAN BE TAKEN.
HOIST OPERATORS SHOULD HAVE NORMAL DEPTH PERCEPTION, FIELD OF VISION, REACTION TIME, MANUAL DEXTERITY, AND COORDINATION.
HOIST OPERATORS SHOULD NOT HAVE A HISTORY OF OR BE PRONE TO SEIZURES, LOSS OF 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.
OVERHEAD HOISTS ARE INTENDED ONLY FOR VERTICAL LIFTING SERVICE OF FREELY SUSPENDED UNGUIDED LOADS. DO NOT USE HOIST FOR LOADS THAT ARE NOT LIFTED VERTICALLY, LOADS THAT ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED.

· Read ANSI/ASME B30.16 and ANSI/ASME B30.10. · Read the hoist manufacturer’s Operating and Maintenance Instructions. · Read all labels attached to equipment.
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.
21

4.2 Shall’s and Shall Not’s for Operation

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in death or serious injury,
and substantial property damage. To avoid such a potentially hazardous situation THE OPERATOR SHALL:

· NOT lift more than rated load for the hoist.
· NOT operate unless load is centered under hoist.
· NOT use damaged hoist or hoist that is not working properly.
· NOT use hoist with twisted, kinked, damaged, or worn chain.
· NOT use the hoist to lift, support, or transport people.
· NOT lift loads over people.
· NOT apply load unless load chain is properly seated in the load sheave (and idle sheave for hoist with two chain falls).
· NOT use the hoist in such a way that could result in shock or impact loads being applied to the hoist.
· NOT attempt to lengthen the load chain or repair damaged load chain.
· NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading.
· NOT use load chain as a sling or wrap load chain around load.
· NOT apply the load to the tip of the hook or to the hook latch.
· NOT apply load if binding prevents equal loading on all load-supporting chains.
· NOT operate beyond the limits of the load chain travel.
· NOT operate hoist with missing/damaged cushion rubbers, stoppers or washers.

· NOT leave load supported by the hoist unattended unless specific precautions have been taken.
· NOT allow the chain, or hook to be used as an electrical or welding ground.
· NOT allow the 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 safety placards or decals are missing or illegible.
· Be familiar with operating controls, procedures, and warnings.
· Make sure the unit is securely attached to a suitable support before applying load.
· Make sure load slings or other approved single attachments are properly sized, rigged, and seated in the hook saddle.
· Take up slack carefully – make sure load is balanced and load-holding action is secure before continuing.
· Make sure all persons stay clear of the supported load.
· Protect the hoist’s load chain from weld splatter or other damaging contaminants.
· Report Malfunctions or unusual performances (including unusual noises) of the hoist and remove the hoist from service until the malfunction or unusual performance is resolved.
· Make sure hoist limit switches function properly.
· Warn personnel before lifting or moving a load.
· Warn personnel of an approaching load.

22

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in minor or moderate injury, or property damage. To avoid such a potentially hazardous
situation THE OPERATOR SHALL:
· Maintain a firm footing or be otherwise secured when operating the hoist.
· Check brake function by tensioning the hoist prior 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.
· Avoid 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. · 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 routine 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.
23

4.3 Hoist Controls

4.3.1 Pendant Control When using the pendant control depress the up button to raise the hoist or the down button to lower the hoist as shown in Figure 4-1 below. To stop motion release the buttons.

4.3.2

Make sure the motor completely stops before reversing direction.

Figure 4-1 Push Button Pendant Control

4.4 Electric Chain Hoist with Trolley

4.4.1 To operate the electric chain hoist with trolley, move it horizontally by either pushing the lifted load or the Load Chain.

4.4.2

Never pull the coiled cord, pendant or pendant cord. Pulling the coiled cord,
pendant or the pendant cord may disconnect cord wires. Disconnected wire(s) may cause a short circuit in the hoist body or any surrounding conductor, giving the operator electric shock.

4.4.3

Always move the hoist horizontally by grasping the cylinder grip or pushing the

load.

24

4.5 Lifting Speed Adjustment Using Potentiometer

4.5.1

Always disconnect power to the hoist before making any lifting speed
adjustments. When making multiple lifting speed adjustments, be sure to disconnect power before each adjustment. Failure to do so may result in electrical shock.

4.5.2 EDV model hoists are equipped with adjustable speed control using a variable resistor (potentiometer) located under the control cover (as seen in Figure 4-2).

4.5.3

Using a small flathead screwdriver, engage the slotted potentiometer dial and rotate the potentiometer dial to make adjustments to the lifting speed. To achieve the slowest lifting speed, rotate the potentiometer dial fully clockwise to its limit. To achieve the fastest lifting speed, rotate the potentiometer dial fully counterclockwise to its limit. Intermediate lifting speeds can be achieved with dial adjustments between the upper and lower limits of the potentiometer.

Figure 4-2 Lifting Speed Adjustment

25

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 Inspection Classification

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.

26

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.

Table 5-1 Frequent Inspection 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

5.4 Periodic Inspection

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.

Table 5-2 Periodic Inspection 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. 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.

27

5.5 Occasionally Used Hoists

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 re-assembly of the hoist.

Item
Functional operating mechanisms.
Limit Switch (model ED3) Braking System Operation Hooks – Surface Condition Hooks – Fretting wear
Hooks – Stretch
Hooks – Bent Shank or Neck
Hooks – Yoke Assembly

Table 5-3 Hoist Inspection Methods and Criteria

Method

Criteria

Visual, Auditory

Mechanisms should be properly adjusted and should not produce unusual sounds when operated.

Function

Proper operation. Actuation of limit switch should stop hoist.

Function

Braking distance with rated capacity should not exceed approximately five 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 5-5

Measure

The “k” dimension should not exceed the measured value for discard from Table 5-5 (See Section 3.9).

Visual

Shank and neck portions of hook should be free of deformations.

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.

Action Repair or replace as required. Repair or replace as required. Repair or replace as required. Replace.
Replace.
Replace.
Replace.
Tighten or replace as required.

28

Item
Hooks – Swivel Bearing
Hooks – Hook Latches
Cylinder Hook Chuck – Ball Guide (DA Model)
Load Chain Surface Condition
Load Chain – Pitch and Wire Diameter
Load Chain Lubrication
Load Chain Reeving
Chain Container (optional)
Housing and Mechanical Components
Bolts, Nuts and Rivets Motor Brushes
Contactor Contacts

Table 5-3 Hoist Inspection Methods and Criteria

Method

Criteria

Action

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.

Clean/lubricate, or replace as required.

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.

Replace.

Visual, Function

Ball Guide should not be worn or deformed. Ball Guide should interact properly with the Spring Collar to retain the hook shank.

Replace.

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.

Replace.

Measure

The “P” dimension should not be greater than maximum value listed in Table 5-6. The “d” dimension should not be less than minimum value listed in Table 5-6.

Replace. Inspect Load Sheave by qualified person.

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.

Clean/lubricate (see Section 6.1).

Visual

Chain should be reeved properly through Load Sheave – refer to Section 6.2. Chain, Cushion Rubbers, Washers and Stoppers should be installed properly

Reeve/Install chain properly.

Visual

Container should not be damaged. Brackets should not be deformed or missing.

Replace

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.

Visual, Check with Proper Tool

Bolts, nuts and rivets should not be loose.

Tighten or replace as required.

Measure, Visual

The “F” dimension should not be less than minimum value listed in Table 5-4.

Replace.

Visual

Contacts should be free of significant pitting or deterioration

Replace.

29

Table 5-3 Hoist Inspection Methods and Criteria

Item

Method

Criteria

Action

Cushion Rubber

Visual

Should be free of significant deformation.

Replace.

Pendant – Switches 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).

Repair or replace as necessary.

Pendant – Housing Visual

Pendant housing should be free of cracks and mating surfaces of parts should seal without gaps.

Replace.

Pendant – Wiring Visual

Wire connections to switches in pendant should not be loose or damaged.

Tighten or repair

Pendant – Cord

Visual, Electrical Continuity

Surface of cord should be free from nicks, 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 the entire load associated with forces applied to the pendant.

Replace.

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.

Replace.

Hoist Capacity Label Visual

The label that indicates the capacity of the hoist should be legible and securely attached to the hoist.

Replace.

Table 5-4 Motor Brush Dimensions

Capacity (lbs)
250 to 1000

“F” Dimension inch (mm) Discard
0.31(8.0)

30

Table 5-5 Top Hook & Bottom Hook Dimensions
“k” Measured When New: Top: _____ Bottom:

Capacity (lbs)
250 to 500

Hook Bottom
Top

*Nominal “k” Dimension inch (mm)
1.73(44).
1.77(45)

“u” Dimension inch (mm)

Standard

Discard

0.67(17)

0.60(15.3)

0.67(17)

0.60(15.3)

“t” Dimension inch (mm)

Standard

Discard

0.48(12.1)

0.43(10.9)

0.28(7.0)

0.25(6.3)

1000

Bottom Top

1.65(42) 1.77(45)

0.93(23.5) 0.67(17)

0.88(22.3) 0.60(15.3)

0.69(17.5) 0.28(7.0)

0.65(16.6) 0.25(6.3)

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 5-6 Chain Wear Dimensions

Capacity (lbs)
250 to 1000

“P” Dimension inch (mm)

Standard

Discard

2.38 (60.5)

2.43 (61.7)

“d” Dimension Wear Limit Inch (mm)

Standard

Discard

0.16 (4.0)

0.13 (3.3)

31

Item Functional operating mechanisms.
Mechanical Components
Side Plates Bolts, Nuts, Snap Rings, and Split Pins Track Wheel Tread and Flange
Suspension Bolts
Warning Labels
Trolley Capacity Label

Table 5-7 Mini Trolley Inspection Methods and Criteria

Method

Criteria

Visual, Auditory

Mechanisms should be properly adjusted and should not produce unusual sounds when operated.

Visual, Auditory, Vibration, Function

Trolley components including, suspension shafts, track wheels, track wheel axles, suspension bolts, shafts, bearings and pins 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.

Visual

Must be free of significant deformation

Visual, Check

Bolts, nuts, snap rings and split pins should not be

with Proper Tool loose.

Visual, Measure

Diameter of the tread surface and the thickness of the wheel flange should not be less than the discard value shown in Table 5-8.

Visual, Measure

Suspension bolts should not be bent. Diameter should not be worn by 10% or more.

Visual

Warning Labels should be affixed to the pendant cord (see Section 1.2) and they should be legible.

Visual

The label that indicates the capacity of the trolley should be legible and securely attached to the trolley.

Action Repair or replace as required.
Replace.
Replace. Tighten or replace as required. Replace. Replace. Replace. Replace.

Table 5-8 Mini Trolley Wear Dimensions

“D” Dimension inch (mm)
Standard Discard
1.57 (40) 1.50 (38)

“t” Dimension inch (mm)
Standard Discard
0.32 (8) 0.21 (5.33)

32

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

6.1.2 6.1.3

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.

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.

Gear Box:

Not using Harrington ED oil or the wrong quantity of oil 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 quantity.

Change gear oil at least once every 5 years. The oil should be changed more frequently depending on the hoist’s usage and operating environment.

To change the gear oil, remove both fill and drain plugs and allow the old oil drain completely. Replace the drain plug and refill the gear case with the correct quantity of new oil or until the oil level is even with the bottom of the oil check hole. Refer to Figure 3-1.

Dispose of the used oil in accordance with local regulations.

33

6.2 Load Chain

6.2.1 Lubrication and Cleaning refer to Section 6.1.

6.2.2 Load Chain Replacement:

The hoist must be properly powered and operational in order to perform the

following procedures.

Be certain that the replacement Load 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 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.

When replacing load chain, check for wear on mating parts, i.e. Load Sheave,

Chain Guides and Idle Sheaves, and replace parts if necessary.

Remove all chain components including the Bottom Hook Set Assembly, Stoppers, Cushion Rubbers, Washers and Chain Pin from the chain for reuse on new chain. Inspect and replace any damaged or worn parts.
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 6-1.
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.
Attach the chain components (step 4 above) to the chain. Refer to Section 3.2 for the proper locations.

Make sure Stoppers, Cushion Rubbers, Washers and Split Pins are properly

installed.

After installation has been completed, perform steps outlined in Section 3.8 “Pre-operational Checks and Trial Operation”.

6.3 Mechanical Load Brake with Friction Clutch

6.3.1

Mechanical Load Brake with Friction Clutch If abnormal operation or slippage occurs do NOT attempt to disassemble or adjust the Mechanical Load Brake with Friction Clutch. Replace the worn or malfunctioning Mechanical Load Brake with Friction Clutch as an assembly with a new, factory adjusted part.

34

Figure 6-1 Chain Replacement

6.4 Fuses
6.4.1 Spare fuses are attached inside the controller cover (the capacity/nameplate side). The fuse sizes are shown in the Table 6-1.

Table 6-1 Fuse Size

Capacity (lbs)

Main Fuse Rating
(Amps)

250

10

350

525

15

1000

6.4.2 In addition, current model DS and DA units have a second smaller fuse (5 x 20mm) rated at 0.1 AMPS.
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. 35

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.

Symptom Hoist will not operate
Hoist lifts but will not lower

Table 7-1 Troubleshooting Guide

Cause

Remedy

Loss of power
Wrong voltage or frequency Hoist overload Improper, loose, or broken wire in hoist electrical system Faulty magnetic contactor
Motor burned out
Fuses burned out
Brush wear
Down circuit open
Broken conductor in pendant cord Faulty magnetic contactors Faulty switch in pendant

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.
Shut off power supply, check wiring connections on hoist control panel and inside push-button pendant.
Check coil for open or short circuit. Check all connections in the control circuit. Check for open contacts. Replace as needed.
Replace motor frame/stator, shaft/rotor, and any other damaged parts.
Replace fuses.
Inspect both motor brushes per Table 5-4 and replace if necessary.
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.

36

Symptom
Hoist lowers but will not lift
Hoist will not lift rated load or does not have the proper lifting speed
Load drifts excessively when hoist is stopped

Table 7-1 Troubleshooting Guide

Cause

Remedy

Hoist overloaded

Reduce load to within rated capacity of hoist.

Low voltage in hoist’s power supply

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 measure at the hoist contactor.

Up circuit open

Check circuit for loose connections. Check up side of limit switch for malfunction.

Broken conductor in pendant cord

Check the continuity of each conductor in the cable. If one is broken, replace entire cable.

Faulty magnetic contactor

Check coils for open or short circuit. Check all connections on motor circuit. Check for burned contacts. Replace as needed.

Faulty switch in pendant

Check electrical continuity. Check electrical connections. Replace or repair as needed.

Faulty friction clutch

Repair by a qualified person trained in the repair of hoists and proper friction clutch adjustment procedures. Replace as needed.

Hoist overloaded

Reduce load to within rated capacity.

Low voltage in hoist’s power supply

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.

Faulty friction clutch

If abnormal operation or slippage occurs do NOT attempt to disassemble or adjust the Mechanical Load Brake with Friction Clutch. Replace the worn or malfunctioning Mechanical Load Brake with Friction Clutch as an assembly with a new, factory adjusted part.

Mechanical Load brake not holding

Replace as needed.

Improper gear oil

Replace oil with the correct Harrington ED gear oil.

Motor demagnetized

Motor demagnetizing is generally caused from using the hoist beyond it’s duty rating. Replace stator assembly and reduce usage to comply with the duty rating stated in Table 2-1.

Dynamic brake resistor burned out

Check resistance and replace if necessary.

37

Symptom
Hoist operates intermittently
DA Model – Hook drops out of cylinder chuck Actuation of Limit Switch does not stop hoist

Table 7-1 Troubleshooting Guide

Cause

Remedy

Collectors making poor Check movement of spring loaded arm, weak spring, connections,

contact

and shoe. Replace as needed.

Contactor contacts arcing

Check for burned contacts. Replace as needed.

Loose connection in circuit

Check all wires and terminals for bad connections. Replace as needed.

Broken conductor in Pendant Cord

Check for intermittent continuity in each conductor the Pendant Cord. Replace entire Pendant Cord if continuity is not constant.

Worn or deformed Ball Check Ball Guide Tube for excessive wear or deformation.

Guide Tube

Replace as needed.

Limit switch defective
Bent or worn lever; Lever should move freely.

Repair or replace as required. Repair or replace as required.

38

8.0 Warranty
All products sold by Harrington Hoists, Inc. are warranted to be free from defects in material and workmanship from date of shipment by Harrington for the following periods:
1 year Electric and Air Powered Hoists (excluding (N)ER2 Enhanced Features Models and EQ/SEQ Models ), Powered Trolleys, Powered Tiger Track Jibs and Gantries, Crane Components, Below the Hook Devices, Spare / Replacement Parts
2 years Manual Hoists & Trolleys, Beam Clamps 3 years (N)ER2 Enhanced Features Hoists, EQ/SEQ Hoists, and RY Hoists 5 years Manual Tiger Track Jibs and Gantries, TNER, EQ/SEQ, and RY Hoist Motor Brakes 10 years (N)ER2 “The Guardian” Smart Brake
The product must be used in accordance with manufacturer’s recommendations and must not have been subject to abuse, lack of maintenance, misuse, negligence, or unauthorized repairs or alterations.
Should any defect in material or workmanship occur during the above time period in any product, as determined by Harrington Hoist’s inspection of the product, Harrington Hoists, Inc. agrees, at its discretion, either to replace (not including installation) or repair the part or product free of charge and deliver said item F.O.B. Harrington Hoists, Inc. place of business to customer.
Customer must obtain a Return Goods Authorization as directed by Harrington or Harrington’s published repair center prior to shipping product for warranty evaluation. An explanation of the complaint must accompany the product. Product must be returned freight prepaid. Upon repair, the product will be covered for the remainder of the original warranty period. Replacement parts installed after the original warranty period will only be eligible for replacement (not including installation) for a period of one year from the installation date. If it is determined there is no defect, or that the defect resulted from causes not within the scope of Harrington’s warranty, the customer will be responsible for the costs of returning the product.
Harrington Hoists, Inc. disclaims any and all other warranties of any kind expressed or implied as to the product’s merchantability or fitness for a particular application. Harrington will not be liable for death, injuries to persons or property or for incidental, contingent, special or consequential damages, loss or expense arising in connection with the use or inability whatever, regardless of whether damage, loss or expense results from any act or failure to act by Harrington, whether negligent or willful, or from any other reason.
39

9.0 Parts List
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 3.9.4 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.

EDV Nameplate

The parts list is arranged into the following sections:

Section

Page

9.1 Housing, Motor, and Gearing Parts……………………………………………………………………….42

9.2 ED1000V Additional Parts………………………………………………………………………………….46

9.3 Power Supply and Pendant Parts ………………………………………………………………………..48

9.4 Electric Parts ………………………………………………………………………………………………..50

9.5 Mini Trolley Parts………………………………………………………………………………. …………..52

40

Pendant Parts

This Page Intentionally Left Blank

41

9.1 Housing, Motor, and Gearing Parts
FIGURE 9-1 HOUSING, MOTOR, AND GEARING PARTS 42

Fig. No. Part Name
1 Top Hook Assembly 2 Hook Latch Assembly 3 Top Yoke Complete Set 4 Top Pin Assembly 5 Bottom Hook Comp. Set 6 Latch Assembly. B 7 Chain Pin 8 Slotted Nut 9 Split Pin
10 Body
11 Top Pin E 12 Shaft Stopper 13 Socket Bolt w/ Spring Washer 14 Oil Plug 15 Plug Packing 16 Pawl Pin 17 Pawl Spring 18 Pawl 19 Snap Ring 20 Set Pin 21 Chain Guide 22 Socket Bolt w/ Spring Washer 24 Cushion Rubber 25 Stopper 26 Socket Bolt w/ Spring Washer 27 Lever Nut 28 Gear Oil
Chain Container 10 ft max lift 29 Chain Container 20 ft max lift (10 ft. for
ED1000V)
30 Socket Bolt BP 31 U Nut 32 Split Pin

9.1 Housing, Motor, and Gearing Parts

Parts Per Hoist
1 1 1 2 1 1 1 1 1

Capacity (lbs.)

250

350

500

E2D1001125 L41071008 E2D1011125 M3041010 E2D1021125 CF071005 E2D041125 E2D049125
9009402

1 E3DBX10S9101

E3DBX24S9101

1

E2D117125

1

2

1

2

E2D117350 E2D118350 E2D072350 E3S111003 E3S112003 E2D269125 E2D270125 L4155015 L4188015 CF083020

1 E3DBX10S9401

E3DBX24S9401

2

E2D451125

2

E3DBX10S9046

1

E1DBX10S9045

1

E2D086125

1

E2D087125

1

E2D90B125

E2D90B350

1

E2D1831125

1000

1

E2D1835125

1

E2D854125

1

E2D853125

1

9009402

43

9.1 Housing, Motor, and Gear Parts

Fig. No. Part Name

33 Motor Complete Set for 120V, 50/60 Hz

34 Armature Assembly for 120V, 50/60 Hz

35 Stator Assembly

36 Motor Cover

37 Motor Flange

38 Lid Assembly

39 Carbon Brush

40 Name Plate M

42 Socket Bolt w/ Spring Washer

43 Oil Seal

44 Needle Roller Bearing

45 Ball Bearing

46 Gear #2 Assembly

47 Ball Bearing

48 Oil Seal

49

Friction Clutch Assembly (Including Load Sheave)

50 Set Spring

51 Oil Seal

52 Gear Cast Packing

53 Gear Case

54 Socket Bolt w/ Spring Washer

55 Controller Cover

Parts Per Hoist
1 1 1 1 1 2 2 1 4 1 1 2 1 1 1

Capacity (lbs.)

250

350

500

E2D1501P125

E2D1501P350

7023001

E2D5508P350

E2D5507P125

E2D5507P350

(Part of armature assembly)

E2D509P350

E2D506P125

E2D506P350

E2D1510P125

E2D1510P350

E2D502P125

E2D502P350

E2D802P250

E2D802P350

J1BG20602222 (M6 x 22mm)

E2D221125

E2D222125

9000100

E2D1223250

E2D1223525

E2D238125

E2D238350

E2D236125

E2D236350

1

E2D5234400

E2D5234525

1

E2D311125

E2D311350

1

E2D239125

E2D239350

1

E2D125125

E2D125350

1

E2D105125

E2D105350

4

E2D152125

1

E2D104125

E2D104350

1000

56 Name Plate B

1

57 Controller Cover Packing

1

58 Machine Screw w/ Spring Washer

3

59 Load Chain

Ft.

60 Warning Seal EO

1

61 Warning Seal EE

1

62 Warning Seal EF

1

80580 E2D109125

80581

80582

E2D109350 MS554010 LCED125NP E2D865125 E2D866125 E2D867125

80583

44

Pendant Parts

This Page Intentionally Left Blank

45

9.2 ED1000V ADDITIONAL PARTS

1050 ADD

FIGURE 9-2 ED1000V ADDITIONAL PARTS

46

9.2 ED1000V Additional Parts

Fig. No.

Part Name

5

Connection Yoke Complete Set

6 Top Hook assembly

7 Hook Latch assembly

8 Connection Yoke

9 Top Pin, L

10 Slotted nut

11 Split Pin

15 Joint Yoke

16 Protection Pad

17 18 19 20 21 22 23

Truss Head Machine Screw Washer U nut Chain pin Slotted nut Split pin Bottom Hook Complete Set

24 Bottom Hook Assembly

25 Hook Latch Assembly

26 Bottom Yoke Assembly

27 Bottom Yoke

28 Bolt

29 Spring Lock Washer

30 Nut

31 Bottom Shaft Assembly

32 Idle Sheave Assembly

33 Thrust Collar A

34 35 36 37 38 49 50

Hook Stopper
Thrust Bearing Name Plate C Chain Spring Washer Warning Seal E (Finger protection) Nameplate M (Motor Nameplate)

Parts Per Hoist
1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1
1
1
1
2
2
2
2
1
1
1
2 1 1 1 1 1 1

Capacity (lbs.) 1000
E3DBX48S1470 E3DBX48S6460
CF071005 E3DBX48S9470
ES006005L L3183008 9009403 E3DBX48S9580 E3DBX48S9592
J1AG25003535 9012510 9098503
E2D041125 E2D041125
9009402 —
83056
ER2CS1002
E3DBX48S2485
E3DBX48S9485
9093307
9012709 9093420
E3DBX48S6489
E3DBX48S6487
ES026003
ES027003 ES022003 E3DBX48S9597 E3DBX48S9590 E3DBX489591 E3DBX48S9599 E3DHX48S9802

47

9.3 Pow er Supply and Pendant Parts
FIGURE 9-3 POWER SUPPLY AND PENDANT PARTS 48

9.3 Pow er Supply and Pendant Parts

Fig. No. Part Name
1 Power Supply Cable 3C Complete Set 2 Power Supply Cable 3C 3 Cable Holder C 4 Cable Packing C8 5 Machine Screw w/ Spring Washer 6 Cable Clamp E8 7 Machine Screw w/ Spring Washer 8 Cable Clamp E8 10 Machine Screw w/ Spring Washer 11 Cable Support L 12 Machine Screw w/ Spring Washer 21 Push Button Cord 3C Complete Set 22 Push Button Cord 3C 23 Cable Holder C 24 Cable Packing C8 25 Push Button Switch S Assembly 26 Cord Chain Pin 27 Split Pin 28 Lock-Belt 29 Fixing Sleeve 30 Machine Screw w/ Spring Washer 84 Warning Seal EO 85 Warning Seal EE 86 Warning Seal EF 87 Warning Tag LD 88 Chain Stopper Link 90 Limit switch 91 Socket Bolt w/ Spring Washer

Parts Per Hoist
1 1 1 1 3 1 2 1 2 1 2 1 FT 1 1 1 1 1 3 1 3 1 1 1 1 1 1 2

250 E2D1607P125 E3DBX10S1411

Capacity (lbs.)

350

500

E2D1521125

16/3

E2D537125

E2D524125

MS554010

E2D541125

MS556010