Harrington ER Series Operating instructions

Repair Manual
ELECTRIC
CHAIN HOIST
ER and NER
SERIES
1/8 Ton through 20 Ton Capacity
EDOC0202
REV. 0
EFFECTIVE: September 23, 2002
WARNING
This equipment should not be installed, operated o
r
maintained by any person who has not read and understood
all the contents of this manual. Failure to read and compl
y
with the contents of this manual can result in serious bodil
y
in
j
ur
y
or death, and/or
p
ro
p
ert
y
dama
g
e.

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 ER and NER Repair Manual Information. .………………………………………….…………. . 8
2.1 Purpose
2.2 Difference Between the ER and NER
2.3 Design Concept
2.4 Tools Required
2.5 Instructional Sequence
3.0 Hoist Disassembly Procedure ………………………………………………………. . . . . . . . . 11
3.1 Outer Part Removal
3.2 Disassembly, Controls Unit
3.3 Disassembly, Gear Case and Gear Parts
3.4 Disassembly, Chain Guide and Load Chain
3.5 Disassembly, Motor
3.6 Disassembly, Body
3.7 Disassembly, Motor Brake
4.0 Hoist Reassembly Procedure ………………………………………………………. . . . . . . . . 27
4.1 Reassembly, Motor Brake
4.2 Reassembly, Partial Chain Guide
4.3 Reassembly, Body
4.4 Reassembly, Motor
4.5 Reassembly, Load Chain
4.6 Reassembly, Gear Case and Gear Parts

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Table of Contents
Section Page Number
4.0 Hoist Reassembly Procedure, Continued …………………………………………. . . . . . . . . 27
4.7 Reassembly, Controls Unit
4.8 Checking Hoist Operation
5.0 Electrical Troubleshooting . . . .………………………………………………………. . . . . . . . . 42
5.1 Principle of Operation
5.2 Design Concept
5.3 Count/Hour Meter (C/H)
5.4 Additional Tools Required
5.5 Troubleshooting/Repair
Appendix A – Inspection Methods, Criteria and Wear Measurements
Appendix B – Inspection Methods, Criteria and Wear Measurements for Large Capacity (N)ER
Appendix C – Electrical Troubleshooting Guide and Wiring Diagrams
Appendix D – Harrington Hoists, Inc. Contact Information

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1.0 Important Information and Warnings
1.1 Terms and Summary
This manual provides important information for personnel involved with the repair of this product. Although
you may be familiar with this or similar equipment, it is strongly recommended that you read this manual before
repairing or operating 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 Danger indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury, and property damage.
WARNING Warning indicates an imminently hazardous situation which, if not avoided, could result in
death or serious injury, and property damage.
CAUTION Caution indicates a potentially hazardous situation which, if not avoided, may result minor
or moderate injury or property damage.
NOTICE Notice is used to notify people of installation, operation, or maintenance information which
is important but not directly hazard-related.
CAUTION
These general instructions deal with the normal repair, 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.
Use only Harrington authorized replacement parts in the service and maintenance of this hoist.

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WARNING
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.

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DANGER
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.
NOTICE
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.

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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, 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

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2.0 ER and NER Repair Manual Information
2.1 Purpose
The purpose of this manual is to provide disassembly and assembly instructions for the ER/NER family of hoists
1/8 through 20 Ton. It is also intended to act as a diagnostic guide for troubleshooting various hoist problems
and provide applicable solutions. Instructions provided are generic and intended to apply to all sizes of hoists
covered by this document.
2.2 Difference between the ER and NER
The NER has a friction clutch mechanism that provides over winding protection. The ER has a
mechanical load brake/friction clutch combination and an electronic count/hour meter in the control circuit.
The ER has a vented oil plug where as the NER has a solid vent plug. Finally, a brake label is placed on
the ER.
2.3 Design Concept
The ER/NER hoist is a modular design consisting of four primary parts.
1. Controls Section- This section houses the electrical components such as the transformer, limit
switch(s) and motor contactors.
2. Gear Case - This section consists of the gear system. A mechanical brake with friction clutch (ER
only).
3. Body - This section consists of the chain guide, load chain, load sheave and suspension hooks.
4. Motor and Fan Cover - This section consists of the motor frame with stator, motor shaft with rotor,
pull rotor, rotor, thrust disc, motor brake spring, brake drum, and fan.
This concept allows any ER/NER model to be disassembled and repaired according to specific requirements of
the repair job. For a complete list of parts and an exploded view- see the ER/NER owners manuals.
2.4 Tools Required
•¼” and 3/8” drive metric socket sets
•metric Allen wrenches
•metric Hex bit sockets
•#1, 2, & 3 Philips screwdrivers
•Medium and Large Flat blade screwdrivers
•Needle nose pliers
•Small snap ring pliers internal/external
•6” adjustable wrench
•Feeler Gages (0.010-0.080” range)
•Sm. Plastic or Rubber Mallet
•Small 2 arm wheel/pulley remover
•Bearing puller
•Electrical tape
•Safety glasses
•Vise or 2 clamps
•Ball bearing and oil seal drivers (to install
seals/bearings)

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2.5 Instructional Sequence
3.0 Hoist Disassembly
3.1 Removal of outer parts.
3.2 Disassembly, Controls unit.
3.3 Disassembly, Gear Case and Gear Parts.
3.4 Disassembly, Chain Guide and Load Chain.
3.5 Disassembly, Motor.
3.6 Disassembly, Body.
3.7 Disassembly, Motor Brake.
4.0 Hoist Reassembly
4.1 Reassembly, Motor Brake
4.2 Reassembly, Partial Chain Guide.
4.3 Reassembly, Body.
4.4 Reassembly, Motor.
4.5 Reassembly, Load Chain.
4.6 Reassembly, Gear Case and Gear Parts.
4.7 Reassembly, Controls Unit.
4.8 Checking Operation.
5.0 Electrical Troubleshooting
Appendix A- Inspection Methods, Criteria, and Wear
Measurements.
Appendix B- Inspection Methods, Criteria, and Wear
Measurements for Large Capacity.
Appendix C- Electrical Criteria and Wiring Diagram
Appendix D- Harrington Hoists, Inc. Contact
Information
Figure 1 - Hoist Sections
DANGER Improper disassembly/assembly may cause a serious accident. Disassembly/ assembly should be
conducted by a qualified and well-experienced service technician, otherwise please contact a Harrington Authorized
Repair Center. (You can contact Harrington for a list of official repair centers. See Appendix D to this manual to find a
repair center nearest you.)

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NOTICE
•Perform disassembly and assembly procedures in accordance with this manual.
•Never connect additional links to the load chain.
•Remove dirt and contamination from disassembled parts such as gears.
•When reassembling the hoist, the following parts must be replaced with new:
- GEAR OIL - PACKING - OIL SEALS
- SNAP RINGS - SPLIT PINS - O-RINGS
•Use thread-locking adhesive when re-installing bolts where indicated.
•Always use Harrington genuine parts for replacement.

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3.0 Hoist Disassembly
3.1 Outer Part Removal
DANGER Hazardous voltages are present
in the control box, other electrical components, and
connections between these components.
Only trained and competent personnel should inspect
and repair this equipment.
A) De-energize (disconnect) the main switch
supplying power to the equipment, and lock and tag
the main switch in the de-energized position.
B) Remove plug 4P (4 pin Connector) of the power
supply cable complete set.
NOTICE The 4P and 5P plugs are quick
disconnects; therefore, just loosen the threaded
nut on the connector and pull connector from hoist.
C) Remove the cable support wire from the body
by removing the machine screw attaching the
cable support to the hoist.

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D) Remove plug 5P (5 pin connector) of the push
button cable assembly.
E) When the hoist is used without a chain container,
the free end of the chain is attached to the hoist body
as shown in Figure to the right. Remove the no load
end of the chain from Chain Guide A by detaching the
End Wire or End Suspender installed on the hoist.
For 5 ton hoist, remove the no load end of the chain
directly from Chain Guide A if Chain Guide A is
notched to accept the chain.
F) If a chain container is installed, remove the chain
container from the body.
G) Drain the gear oil by removing the oil plug and plug
packing from the bottom of the gear case.

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3.2 Disassembly of the Controls Unit
CAUTION Never disassemble the electric
chain hoist while it is suspended. Only perform
disassembly and assembly repair work while the hoist
is supported on a stable and level work surface.
A) PLACE HOIST ON WORKBENCH SO THAT
THE CONTROLS SECTION IS ON TOP.
B) Loosen and remove socket bolts and open the
controller cover. If necessary, loosen the cover by
tapping it lightly with a plastic or rubber mallet.
CAUTION Although the controller cover
can be suspended, the cover may fall off of the
hoist if there is a loose suspension hook.
C) Detach the cover suspender C from suspender
by unscrewing the two retaining hooks.
D) Remove lead-wires of the motor from terminal
plate.
E) Loosen and remove plate screws and to enable
plate to swing out on hinge.

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F) On the under side of the controls plate, remove
lead-wires of the motor from the terminal strip. For
convenience, group wires removed from each
terminal together and mark with the terminal strip
identification to prevent misconnecting wiring
during reassembly. Several models will have
wiring passing through to the front side of the
plate. Disconnect and mark these wires, too.
G) Make sure all motor leads are clear of the plate
and tape the wires together so that they pass
through the body sections without chaffing or
scraping the wires.

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3.3 Disassembly of the Gear Case and Gear Parts
A) Swing the electrical controls plate open,
remove the two screws retaining plate A.
B) Using pliers, pull out the connection shaft
and the fixing shaft to disconnect the top hook
assembly or connection yoke from the hoist.
CAUTION Once the Shafts are
removed the hook and yokes will fall from the
hoist.
C) For the ER - Remove the socket bolts and
tap the controls case lightly with a plastic or
rubber mallet to remove the body section.
NOTICE Take precautions to
prevent damage to the gasket during removal
of the controls section. If damaged, the gasket
must be replaced with a new gasket during
reassembly. Also, lift off the controls section
carefully to prevent damaging motor wiring.

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D) For NER, remove the friction plug, oil seal
and nut cover from the gear case. (Do not
remove oil seal, unless it is to be replaced.)
Remove the socket bolts connecting the gear
case to the body. Tap the controls section
lightly with a plastic or rubber mallet to release
it from the body section.
NOTICE Take precautions to
prevent damage to the gasket during
removal of the controls section. If
damaged, the gasket must be replaced
with a new gasket during reassembly.
Also, lift off the controls section carefully
to prevent damaging motor wiring.
E)
§For ER -Lift out the complete friction
clutch set
§For NER -Remove the wavy washer,
then pull out the complete friction clutch
set.
F) Pull out the load gear bearing from the gear
case using a bearing remover.
G) Remove the snap ring to pull out the load
gear.

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H) For three gear hoists, remove the ball
bearing, needle bearing and gear B assembly
with bearing. Remove socket bolt and spring
washer from gear plate and remove gear plate.

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FOR ER ONLY – MECHANICAL BRAKE WITH FRICTION CLUTCH DISASSEMBLY
I) Remove the thrust disc and the thrust collar from
the mechanical brake with friction clutch complete
set. To pull out the friction clutch assembly rotate
it.
NOTICE Thrust disc can be removed
with needle nose pliers.
J) Remove the ratchet, the brake collar, and the
gear by rotating the assembly.
DANGER Do not attempt to adjust the
friction clutch assembly or mechanical friction
assembly. If you think an adjustment is needed,
contact Harrington.
K) Remove the snap ring from the body and
remove the pawl and the pawl spring.

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3.4 Disassembly of the Chain Guide and Load Chain
A) Remove the stopper, and the cushion rubber or
the chain spring from the no load side of the load
chain.
B) Pull out the load chain from the body. Pulling the
chain out of the body from the load side.
C) If hoist is equipped with upper limit or an upper/
lower limit switch remove the split pin and pull out the
limit lever pin from the lever coupling.
D) Remove the limit lever pin, the lever coupling, and
the limit lever collar from the limit lever S (an upper
limit switch type) or the limit lever assembly (an upper/
lower limit switch type).
E) Remove the limit lever S (an upper limit switch
type) or the limit lever assembly (an upper/ lower limit
type) from the chain guide A (AL).
F) Remove the socket bolts to detach the chain guide
A from the body.
G) Remove the guide roller and the roller pin from the
chain guide.

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3.5 Disassembly of the Motor
A) Turn the hoist over so that fan cover is facing up.
Remove the socket bolts to detach the fan cover from
the motor frame.
NOTICE Setting the hoist up on wooden
blocks will accommodate the gear shaft, which
extends out past the body.
B) Remove the snap ring and fan washer.
C) Remove fan. If fan does not come off easily, use a
pulley remover. Insert the "arms" of the pulley-
remover into the holes in the fan to remove it.