sanyuan ER3 Series Quick start guide

SAN YUAN CHAIN HOIST CORP.
Professional Design & Manufacturer

1
Thank you for your wise choice of our distinguished electric hoist.
For your better understanding of the performance of this model,
Operational safety and inspection, please read carefully and keep this
manual in a safe place.
CONTENTS
Section Page
Index 1
Product Features 2-12
Product Features 2-23
Introduction 4
Specifications 5
Cautions in Operation 6
Check List for Periodic Inspection 7
Item inspection and Maintenance 8
Item inspection and Maintenance 9
Regular Inspection 9
Regular Inspection 10
Check List for Periodic Inspection 11
Malfunctions and Solutions 12
Electric Schematic Diagram 2-113
Electric Schematic Diagram 2-214
Explosion Chart 3-115
Explosion Chart 3-216
Explosion Chart 3-317
Parts List 2-118
Parts List 2-219
Motor Trolley Structure 20
Motor Trolley Prats List 21

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Current Driven Electromagnec Brake External motor fan
Thermal Protector
Chain Guide
Die-Cast Aluminum
IP55 Enclosure
Friction Clutch
Grind Helical Gears
Rubber Cushion Buffer
Absolute Safety Hook
ER3 Type Features 2-1
STANDARD COMPONENT -
1CHAIN CONTAINER
1 PUSH BUTTON
CHAIN LENGTH - STANDARD 3M
Patent No. US D846827 S
TW D187828

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ER3 Type Features 2-2

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INTRODUCTION
1. Connected in series to a motor circuit, a Current Driven
Electromagnetic Brake does not release unless the motor is
energized. This concurrent drive increases safety of the circuit
compared to separate circuits for the motor and the brake.
2. Uniquely-structured Chain Guide for smooth chain-feeding.
3. Tough body is made by Die-Cast Aluminum to keep dimension
precision & outlook smooth..
4. External motor fan.
5. Thermal Protector Sensor overheating to shut off the current.
6. Friction Clutch Emergency overload protection to slip the force from
the motor when subjected to an excessive load over the rated
capacity. It is not easily compromised with changes in the
surrounding temperature. In the case of irregular loading, this
operates in advance to prevent the hoist body or load chain from
being damaged.
7. Grind Helical Gears reduces operating noise.
8. IP55 Enclosure Dust-protected and jet protected.
9. Absolute Safety Hook Equipped with a bearing & characterized by
gradual elongation, not sudden breakage under overload conditions.
The notched latch for firm contact improves resistance against lateral
force.
10. Rubber Cushion Buffer.

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Type ER3-003S ER3-005L ER3-010L ER3-015S ER3-020L ER3-020S ER3-025S ER3-030S ER3-050S
Cap (Ton) 250Kg 500Kg 11.5 222.5 35
Test Load %125 %
Rating %ED 60 %
Lift (m) 3
Lifting Speed
(M/min)
50HZ 13.4 7.3 3.5 4.5 3.7 75.7 52.9
60HZ 16.1 4.6 4.2 5.4 4.4 8.4 6.8 63.5
Lifting Motor (Kw) 1111.8 1.8 1.8 43.75 4
Load Chain (mm)X Fa;;s Φ5 X 1 Φ6.3 X 1 Φ7.1 X 1 Φ10 X 1 Φ10 X 1 Φ10 X 1 Φ11.2 X 1 Φ11.2 X 1 Φ11.2 X 2
Diameter
(mm)
C350 370 430 510 575 590 625 785 850
a219 242 291 308 308 347 337 347 337
b259 271 298 338 338 356 399 356 399
d99 113 129 129 129 160.5 173.5 216 231.5
e93 106 118 118 118 137.5 142.5 82 84.5
Specifications
Single Speed Hoist Dimensions
Patent No. US D846827 S
TW D187828

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CAUTIONS IN OPERATION AND MAINTENANCE
An electric hoist has been used as a safe and convenient machine to save time and la-
bor in operation. Before use, however, careful attention must be paid to operational
safety and inspection procedures. Therefore, before operating this electric hoist, please
read the following instructions and follow correct operational methods. Otherwise, it will
not perform properly as is expected.
(A) Before the installation, please ensure the delivery to have the exact specifications
as you had purchased. This machine has been subjected to strict inspection before
delivery
ex-work. In case of any trouble caused during the handling process, please contact
your local distributor or service station. We shall provide best services to meet your
satisfaction.
(B) Items to be inspected before operation :
1. Mount the hoist in position. Make sure to secure the power cords and control cables,
so as to avoid poor electrical connection.
2. For the wiring system, this machine must be grounded（green wire）to avoid slight
leakage caused by static charge.
3. Depress the button switch when the machine runs in idle and check if the UP （↑）
and DOWN （↓） operation is consistent with the switch indication.
4. The surface of chain（Wire ROPE）must be kept clean and oiled, to avoid the chain
（Wire ROPE）from interwinding.
5. To store the chain, lower the chain to the lower limit, mount the chain bag onto the
hoist, then, put the chain into the chain container.
6. Check the correct operation of the limit switch for upper and lower limits and brake
stop
device.
(C) CAUTIONS FOR THE USE OF ELECTRICAL HOIST
1. For the sake of safety, do not apply a load in excess of the rated load.
2. Ensure if the load is tightly fastened?
3. Before applying the load, the chain（Wire ROPE）must be straightened to buffer the
impact.

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4. The center of gravity of the load should be hoisted. Never operate unbalanced hoist-
ing. For inclined hoisting by the electric hoist, the inclination should be kept within
15°.
（If possible, try to avoid inclined hoisting.）
5. During the hoisting of load, allow no person to stay below or nearby the load, to avoid any
injury.
6. To move the electric hoist with a load, do not pull the control cable in a transverse direction,
so as to avoid the electric cable from being broken.
7. Make sure to depress the switch to the full limit. NEVER operate abrupt positive then reverse
rotation or inch movement.
8. During hoisting, try to keep the hook from reaching the upper and lower limits, so to minimize
the wear of the Clutch lining.
9. A stop device must be fitted when the transverse pulley reaches the terminal of l-beam, so to
avoid the hoist from damage or slipping off the end.
10. For outdoor use of electric hoist, keep the hoist from direct sunshine, rain and wind. There
should be a proper shelter (such as rain resistant hood, etc.)
11. There is a stop button on the lower hook to prevent the steel cable from escaping. Therefore,
make sure the cable is in the correct position on the lower hook and keep the safety angle
within 60°. (See diagram)
(D) Routine and regular inspection items of electrical hoist :
To ensure the proper performance of this machine and extend its service life, please make
the following routine checks.
D-1 Routine inspection items:
1. Depress the button switch and let the hoist run idle, check if the upward and downward oper-
ation are normal?
2. Is the hoist operation smooth? Is there abnormal noise when it is with load?
3. Check if the chain is oiled or damaged?

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4. Is the brake operation normal when the winding is stopped?
5. Is the lower hook wassily rotating?
D-2 Regular inspection items:
1. Inspection of LINK chain
LINK chain is the most important part of the electrical chain hoist, which is made of special alloy
steel with heat treatment. The purpose is to withstand wear and tension. In case the surface is
dried and rusted, it will cause interwoven chains which may break. Therefore, the surface must
be oiled frequently (use normal lubricating oil). In case the chain is deformed, cracked,
elongated, worn, in excess of the following standards, new parts must be replaced:
2. Inspection of gear:
a. Regular replacement of lubricating oil in the gearbox.
b. Check if the gear surface is cracked or worn.
3. Inspection of hook:
a. In case of abnormal deformation, damage or breakage at the opening of the hook, it must
be replaced with new.
b. In case the wear extent of the hook is in excess of 10%, it must be replaced with a new
part.
4. Inspection of pushbutton switch:
a. Are the inner and outer screws of the pushbutton switch loosened? Is the electric wire
damaged?
b. Is there foreign substance between the contact points? Are the contact points abnormally
worn?
Cap (Ton) Dimensions (mm)
dp
2/1 6.3 19.1
17.1 21
1.5、210 30
2.5、2.8、3
11.2 34
511.2 34
Cap (Ton) Dimensions (mm)
ABCDEF
2/1 28 34.2 31 21.6 24.5 18
130 37 35 26 29 23
1.5、240 46 45 31 41 31
2.8、3
49 59 52 32 46 32
552 62 67 45 60 45

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5. Inspection of main unit:
a. Is the wiring system in the main unit secured? Is the electric wire aged or damaged?
b. Are the inner or outer screws of the main unit loosened?
c. Is the panel or casing of the main unit deformed?
6. Inspection of main unit:
a. Is the wiring system in the main unit secured? Is the electric wire aged or dam-
aged?
b. Are the inner or outer screws of the main unit loosened?
c. Is the panel or casing of the main unit deformed?
CAUTIONS FOR THE USE OF ELECTRICAL HOIST
Our electrical hoist is a heavy-duty motor hoist with high frequency.
To operate, please follow the points below:
A. Inspection of brake:
1. Check the wear and oil all parts.
2. When the load stops, the sliping distance of load is too large.
3. When the electromagnetic iron attracts, it produces abnormal noise. In case of any of
the above, please make proper adjustment or replace new parts.
B. Item inspection
1. If you would use the hoist CONTINUALLY for a longer period of time, for example,
more than SIX (6) HOURS, you must inspect it monthly so that you can be aware of
when would be the time to change new parts to be.
2. The intervals of the item inspection may be determined according to real condition of
use and work classification. Moreover, you should check it according to the environ-
ment which it exposed to and the rate of key parts ageing. Periodic inspection such as
daily, monthly, quarterly
checking are always encouraged by SAN YUAN as you may be free from risk.
◆Daily inspection: Before or during daily use, user or technical staff may inspect it
visually.

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2-1 Regular Inspection
Project Method Standard of Judgement Solution
Label Warning
Mark Inspect visually Stick correctly clean and clearly read Change
Control
Pendant
Push stop button without load Hoist stops, rotates at the right side; after
pushing the stop button, hoist runs Change
Push start button without load Bottom hook could lift and land Repair or change
Brake Lift and land 2 or 3 times
without load Check the Brake effect is good or not Repair or change
Up & Down
position limit
Operate the hook into the limit
position without load
When touches the down position limit, the
electric motor should stop, but could work in
a reverse direction
Repair or change
Lifting chain Inspect visually Surface with lubricate grease without defor-
mation, without crackle
Clean. Lubricate it;
or change it if
necessary
Hook Inspect functions visually Without deformation, and it could move, slide,
and rotate freely Change
Position limit
spring Inspect visually Without deformation Change

11
2-2 Check List for Periodic Inspection
Project Method Standard of Judgement Solution
Control
pendant Push button to STOP function Is the push button stable?
No problem? Repair
Power plant Measure by voltmeter ± 10% rated voltage Check the power
plant and wire
Hoist frame Inspect visually Not broken and cracked Change
Screw Inspect visually Screw should not be loosen or missing Kindly fasten the
screw
Abnormal
condition of
operation
Lifting and landing operation
with small capacity load
Users should not be able to hear abnormal
sound from hoist machine or lifting motor Repair
Gear oil Inspect visually Should be in accordance with the frequency
of use
Add gear oil or
use new oil
Brake
Lifting, landing, stopping
operation within its
rated-capacity load
Stop when landing, the down slide speed
cannot over 1% of lifting speed Repair
Position limit
switch
Lift to the limit position with
rated-capacity load
Hoist could stop, could move reversely; the
spring has certain flexibility Repair or change
Lifting chain
deformation Inspect visually without deformation (such as distortion) without deeper scratch and indent Change
Lifting chain
welding scar Inspect visually Warning: without welding scar Change
Lifting clan rust Inspect visually Warning: without obvious rust; lubricate the
lifting chain with grease Change
Hook
deformation Inspect visually
Without obvious deformation and crack;
without deeper cracks; screw and bolt should
be well tightened; without welding scar
Change
Hook rotation Inspect visually Hook should rotate normally Change
Hook Inspect visually
Inspect the overall condition Hook tab should be in the hook tip Change
Basal plate
Inspect visually
Inspection the overall
condition
▪Should work normally
WARNING Please do NOT use the hoist if
the hook tab is missing
Change

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C. Malfunctions and Solutions
Malfunctions Causes Solution
The hoist unable to operate
when it is switched on
Wire disconnected or power off due to
plug loosened
Check and fasten all the wire connection
points
Electrical parts were damaged Replace with new electrical parts
After switched off, the load
dropped while braked
Dust or oil in the brake disc Clean the disc
Severe abrasion of disc Replace with new disc
Chain runs with strange noise
The chain was not well-lubricated Lubricate chain by oil or grease
Load-guider broken Change a new load-guider
Leakage of electricity
The electricity was not well-earthed Ensure the earthed connection
High humidity Use dehumidifier to eliminate the problem
Too much dust in the electrical parts Clean the electrical parts
Skid when lifting the load Load limit is flexible Screw down the load limiter
Hook extension
Maintain the load with hook tip Maintain the load at the middle section
of hook
The chain sling of load is not correct Use a correct chain sling

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ER3 Electric Schematic Diagram 2-1

14
ER3 Electric Schematic Diagram 2-2

15
ER3 Type Explosion Chart 3-1

16
ER3 Type Explosion Chart 3-2

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ER3 Type Explosion Chart 3-3

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No. Part Name Specicaon Qty No. Part Name Specicaon Qty
1Gear box 141 Brake back cover gasket 1
2Electrical board suspension bolt 142 Brake back cover 1
2Electrical box weight 143 fan OD 185 1
4Clutch nut cover 144 Electrical box cover 1
5Electrical box packing 145 Chain bag F 1
646 Electrical cover - counterweight 1
747 Electrical box side cover is tight 1
8Oil plug M12 248 Hanger keyboard - large 1
9Lower hook 249 Hexagon socket bolt + spring washer M8-25L 3
10 50 Hook 1
11 Cotter pin d3-25L 151 Hanger keyboard - small 1
12 Oil plug M16 152 Cross bolt + spring washer M5-12L 2
13 Lower hook F 153 Cross bolt + spring washer M6-12L 2
14 Oil seal TC-30X42X7 154 Hook positioning pin D10-L63 1
15 Limit switch group 155 Motor housing 1
16 Safety stop + stop spring 256 Ball Bearings - Japan 6206ZZ 1
17 Hex bolt + spring washer M12-40L 257 Motor shaft 1
18 Limit rod F 158 Motor turn 1
19 Limit rod spring 159 Bearing - Japan 6304ZZ 1
20 Limit rocker 160 Shaft ring S50 1
21 61 Bearing - Japan 6303ZZ 1
22 62 Shaft ring S25 2
23 Cross bolt + spring washer M6-12L 363 Shaft ring S30 1
24 Motor packing 164 Motor nameplate 1
25 Brake coil holder 165 Spring pin D9 2
26 Lower hook spring 166 Fan cover F 1
27 Brake plate 167 Nameplate 1
28 Brake floor 168 Hexagon socket head bolt + spring
washer M6-50L 4
29 Brake spacer 369 Hexagon socket head bolt + spring
washer M12-40L 4
30 Brake order 170 Guide wheel 1
31 Rubber crash pad 271 Chain
32 Rubber crash pad 672 Hexagon socket head bolt + spring
washer M6-45L 4
33 Brake teeth 173 Oil seal TC-35X45X8 1
34 Chain anti-collision iron piece 274 Oil seal SC-25X37X7 1
35 Hanger - large d12 175 Bearing - Japan 6206ZZ 1
36 Brake fixing bolt spring washer M8-45L 676 Three small teeth 1
37 O ring d=9x1.6 277 Disc spring 2
38 O ring d=18x2.2 278 Two large teeth 1
39 Hanger - large D22 179 Clutch pressure plate 2
40 Hexagon socket bolt spring washer M8-25L 280 Clutch bushing 1
ER3 Parts List 2-1

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No. Part Name Specicaon Qty No. Part Name Specicaon Qty
81 Disc nut cover 1121 Electromagnetic contactor 1
82 1122 Hexagon socket head cap + nut +
spring washer M10-90L 1
83 Clutch oil seal sleeve 1123 Chain bag iron piece A
84 Clutch lock nut 1124 Chain bag iron piece B
85 Three large teeth 1125 Chain bag box
86 Ball Bearing / Roller Bearing NU1010 6010ZZ 1126 Hexagon socket bolt + serrated gasket M8-85L 1
87 F main body 1127
88 Lower chain guide 1128 Cross bolt + spring washer M6-25L 1
89 Spring pin D11 2129 Chain end stop F 2
90 Hole buckle R80 1130 Hexagon socket bolt + spring washer M8-40L 3
91 Oil seal TC-58X80X9 1
92 Bearing housing 1
94 Ball bearing - no shell 6405 1
95 Gear box is tight 1
96 Small roller axle d8-52L 1
97 Small wheel F 2
98 Hexagon socket bolt + spring washer M8-30L 4
99 Spring pin D11 2
100 a large tooth 1
101 Shaft ring S40 1
102 Ball bearing 6203ZZ 1
103 Hook plate 1
104 Ball bearing 6202ZZ 1
105 Motor bearing 1
106 Hexagon socket head cap + nut +
spring washer M6-20L 3
107
108 a small tooth 1
109 Motor coupling 1
110 Ball bearing 6015ZZ
112 V-type shaft seal VA-22 1
113 a large tooth 1
114 Two small teeth 1
115 Spring pin D15 2
116 Electrical board F 1
118 Electrical board F 1
119 Main electromagnetic switch 1
120
ER3 Parts List 2-1