R&M LM Manuel

This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

INSTALLATION AND

MAINTENANCE MANUAL

LM STEPLESS CHAIN HOIST

LOADMATE

LM05 STEPLESS CHAIN HOIST

English

STD-R-KHA-F-CQD-ENG

LoadMate

LM05

STEPLESS I&M/EN/11.

.2010

2/71

This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

THIS PAGE INTENTIONALLY LEFT BLANK

LoadMate

LM05

STEPLESS I&M/EN/11.

.2010

3/71

This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

mCAUTION: Read the instructions supplied with the product before installation and

commissioning.

mCAUTION: Keep the instructions in a safe place for future reference.

Table of contents

1 INTRODUCTION ........................................................................................................................................5

1.1 Contact Information...............................................................................................................................5

1.2 Warranty................................................................................................................................................5

1.3 Disclaimer .............................................................................................................................................5

1.4 Safety ....................................................................................................................................................6

1.5 Placards and Instructions......................................................................................................................8

2 INSTALLATION..........................................................................................................................................9

2.1 General .................................................................................................................................................9

2.2 Lubrication.............................................................................................................................................9

2.3 Mounting ............................................................................................................................................ 10

2.4 Load Hook Throat Opening................................................................................................................ 10

2.5 Electrical Connection ......................................................................................................................... 11

2.6 Connection ......................................................................................................................................... 13

3 INITIAL START-UP ................................................................................................................................. 14

3.1 General .............................................................................................................................................. 14

3.2 Correcting the Direction of Hook Travel............................................................................................. 14

3.3 Operational Checks – No Load.......................................................................................................... 15

3.4 Operational Checks – With Load ....................................................................................................... 15

4 HOIST OPERATION................................................................................................................................ 16

5 LOW HEADROOM TROLLEY ................................................................................................................ 17

5.1 Description – Technical Characteristics (low headroom trolley)........................................................ 17

5.1.1 Technical Characteristics .......................................................................................................... 17

5.1.2 Environmental Data................................................................................................................... 18

5.1.3 Optional equipment ................................................................................................................... 18

6 SWIVEL TROLLEY ................................................................................................................................. 19

6.1 Description – Technical Characteristics (swiveling trolley to 3.2 tons) .............................................. 19

6.1.1 Technical Characteristics .......................................................................................................... 19

6.2 Installation of Swivel Trolley............................................................................................................... 20

6.3 Electric Swivel Trolley ........................................................................................................................ 21

6.3.1 Swiveling trolley (3.2 tons) ........................................................................................................ 22

6.3.2 Swiveling trolley (3.2 to 5.0 tons) (NOT LOCALLY AVAILABLE) ............................................. 22

6.3.3 Procedure to adjust swivel trolley guide rollers......................................................................... 23

7 MAINTENANCE ...................................................................................................................................... 24

7.1 Basic Hoist Construction.................................................................................................................... 24

7.2 Motor / Body....................................................................................................................................... 25

7.3 Hoist Motor Brake and Load-Limiting Device .................................................................................... 25

7.3.1 Slip Clutch Operation ................................................................................................................ 25

7.3.2 Slip Clutch Adjustment after Installation.................................................................................... 27

7.4 Load Chain......................................................................................................................................... 28

7.4.1 General...................................................................................................................................... 28

7.4.2 Maintenance Inspection ............................................................................................................ 28

7.4.3 Load Chain Specifications (see Figure 11) ............................................................................... 30

7.4.4 Removing the Load Chain......................................................................................................... 30

7.4.5 Installing the Load Chain........................................................................................................... 31

7.5 Fall Stop Assembly ............................................................................................................................ 33

7.5.1 General...................................................................................................................................... 33

7.5.2 Removing fall stop (Figure 13) .................................................................................................. 33

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This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

7.5.3 Fall Stop Installation (Figure 13) ............................................................................................... 33

7.6 Chain Container ................................................................................................................................. 34

7.6.1 Removing Chain Container (Figure 14) .................................................................................... 34

7.6.2 Installing Chain Container (Figure 14) ...................................................................................... 34

7.7 Vinyl Chain Bag (optional) ................................................................................................................. 35

7.7.1 Installing Vinyl Chain Bag (Figure 15)....................................................................................... 35

7.8 Limit Switches .................................................................................................................................... 36

7.8.1 Upper and Lower Gear Limit Switch ......................................................................................... 36

7.9 Hooks ................................................................................................................................................. 37

7.9.1 General...................................................................................................................................... 37

7.9.2 Inspection .................................................................................................................................. 38

7.9.3 Hook Dimensions and Specifications........................................................................................ 38

7.9.4 Top Hook ................................................................................................................................... 39

7.10 Control Changes and Fuses.......................................................................................................... 40

7.10.1 Control Circuit Fuses................................................................................................................. 40

7.11 Printed Circuit Board (Stepless) .................................................................................................... 41

7.12 Three Phase – Wiring Diagram – Stepless Hoist - 460 volts – Power Circuit............................ 43

7.13 Three Phase – Wiring Diagram – Stepless Hoist - 460 volts – Control Circuit .......................... 44

7.14 Wiring Diagram – 3 Button – Push Button.................................................................................... 45

7.15 Wiring Diagram – 5 Button – Push Button..................................................................................... 46

7.16 Wiring Diagram – 7 Button – Push Button..................................................................................... 47

8 PREVENTATIVE MAINTENANCE.......................................................................................................... 48

8.1 Maintenance and Inspection Table.................................................................................................... 48

8.2 Lubrication.......................................................................................................................................... 49

8.3 Recommended technical support for various spare parts ................................................................. 50

8.4 Screw Tightening Torque (lb-ft) Specifications .................................................................................. 50

8.5 Troubleshooting ................................................................................................................................. 51

9 PARTS ILLUSTRATION ......................................................................................................................... 52

9.1 Hoist Body – Three Phase Power Supply.......................................................................................... 52

9.2 Mechanism / Brake (Stepless)........................................................................................................... 54

9.3 Lifting Assembly................................................................................................................................. 56

9.4 Controls (Stepless) ............................................................................................................................ 58

9.5 Adjust Limit Switch (Stepless)............................................................................................................ 59

9.6 Low Headroom Trolley....................................................................................................................... 60

9.6.1 Low Headroom Trolley (Drive Components)............................................................................. 60

9.6.2 Low Headroom Trolley (Suspension Components) .................................................................. 62

9.7 Electric trolley (Swiveling trolley 0 to 3.2 Tons (3200 Kg)) ................................................................ 64

9.8 Push Button Assembly – Horizontal Pairs of Buttons ........................................................................ 66

9.9 Pushbutton Assembly – Horizontal Pairs of Buttons ......................................................................... 67

9.10 Push Button Assembly – Vertical Pairs of Buttons (Option).......................................................... 68

9.11 Push Button Assembly – Vertical Buttons (Option) ....................................................................... 70

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LM05

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This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

1 INTRODUCTION

1.1 Contact Information

Please do not hesitate to use the following contact information in the event that you may need assistance:

R&M MATERIALS HANDLING, INC.

4501 Gateway Boulevard

Springfield, OH 45502

General Telephone: 937 - 328-5100

Toll Free Telephone (US): 800 - 955-9967

General Fax: 937 - 325-5319

Parts Department Fax (US): 800 - 955-5162

Parts Dept. Fax (other): 937 - 328-5162

Website: www.rmhoist.com

1.2 Warranty

All sales are subject to the R&M Materials Handling, Inc. Standard Terms and Conditions of Sale (Revision

101707), a copy of which is available at www.rmhoist.com or upon request from R&M Materials Handling,

Inc. customer service/sales representatives and the terms of which are incorporated as if fully rewritten

herein.

1.3 Disclaimer

This Manual has been prepared by R&M MATERIALS HANDLING, INC. to provide information and

suggestions for hoist installation, maintenance, and inspection personnel. This manual should be used in

conjunction with the LoadMate® Electric Chain Hoist Operator’s Manual to teach safe operating practices

to all personnel associated with hoist operations and maintenance.

It is NOT intended that the recommendations in this manual take precedence over existing plant safety rules

and regulations or OSHA regulations. However, a thorough study of the following information should

provide a better understanding of proper installation, maintenance, and inspection procedures that are to be

followed in order to afford a greater margin of safety for people and machinery in the area of hoist

operations.

It must be recognized that this is a manual of recommendations for the Hoist Installation, Maintenance, and

Inspection personnel and its use is permissive not mandatory. It is the responsibility of the hoist owner to

make personnel aware of all federal, state, and local codes and regulations. The owner is responsible for

providing instruction and insuring that certain installation, maintenance, and inspection personnel are

properly trained.

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LM05

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This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

1.4 Safety

Read and understand this manual before using the hoist.

Important issues to remember during installation, operation, maintenance, and inspection are provided at the

hoist control stations, at various locations on the hoist, in this manual, and in the LoadMate® Electric Chain

Hoist Operator’s Manual.These issues are indicated by DANGER, WARNING, or CAUTION instructions

or placards that alert personnel to potential hazards, proper operation, load limitations, and more.

DANGER: Indicates an imminently hazardous situation, which, if not avoided, will result in death or

serious injury.

WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death or

serious injury.

CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in minor or

moderate injury. It may also be used to alert against unsafe practices.

Taking precedence over any specific rule, however, is the most important rule of all:

“USE COMMON SENSE”

It is a responsibility of the hoist owner / user to establish programs to:

1. Train and designate hoist operators, and

2. Train and designate hoist inspectors / maintenance personnel.

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LM05

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.2010

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This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

The words SHALL and SHOULD are used throughout this manual in accordance with definitions in the

ASME B30 standards as follows:

SHALL indicates a rule is mandatory and must be followed.

SHOULD indicates a rule is a recommendation, the advisability of which depends on the facts

in each situation.

Hoist operation, hoist inspection, and hoist maintenance personnel training programs should be based on

requirements in accordance with the latest edition of:

ASME B30.16 Safety Standard for Overhead Hoists ( Underhung )

Such training should also provide information for compliance with any Federal, State, or Local Code

requirements, and existing plant safety rules and regulations.

If an overhead hoist is installed as part of an overhead crane or monorail system, training programs should

also include requirements in accordance with the latest editions, as applicable, of:

•ASME B30.2 Safety Standard for Overhead and Gantry Cranes, Top Running Bridge,

Single or Multiple Girder, Top Running Trolley Hoist

•ASME B30.11 Safety Standard for Monorails and Underhung Cranes

•ASME B30.17 Safety Standard for Overhead and Gantry Cranes, Top Running Bridge,

Single Girder, Underhung Hoist.

LoadMate

LM05

STEPLESS I&M/EN/11.

.2010

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This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

NOTICE:







It is a responsibility of the owner / user to install, inspect, test, maintain, and operate a

hoist in accordance with the ASME B30.16 Safety Standard, OSHA Regulations, and

ANSI / NFPA 70, National Electric Code. If the hoist is installed as part of a total lifting

system, it is also the responsibility of the owner / user to comply with the applicable

ASME B30 volume that addresses other types of equipment used in the system.





Further, it is the responsibility of the owner / user to require that all personnel who will

install, inspect, test, maintain, and operate a hoist read the contents of this manual,

LoadMate® Electric Chain Hoist Operator’s Manual, ASME B30.16 Safety Standards for

Overhead Hoists (Underhung), OSHA Regulations, and ANSI / NFPA 70, National

Electric Code. If the hoist is installed as part of a total lifting system, all personnel

must also read the applicable ASME B30 volume that addresses other types of

equipment used in the system.

DANGER: Failure to read and comply with any one of the limitations noted in this manual

can result in product failure, serious bodily injury or death, and / or property damage.

R&M Materials Handling, Inc. has no direct involvement or control over the hoist’s operation and

application. Conforming to good safety practices is the responsibility of the owner, the user, and its

operating personnel.

Only those Authorized and Qualified Personnel who have shown that they have read and have understood

this manual and the LoadMate® Electric Chain Hoist Operator’s Manual should be permitted to operate

the hoist.

The owner / user SHALL insure that all Operators read and understand the LoadMate® Electric Chain

Hoist Operator’s Manual prior to operating the hoist.

1.5 Placards and Instructions

READ and OBEY all Danger, Warning, Caution, and Operating Instructions on the hoist and in this manual

and LoadMate® Electric Chain Hoist Operator’s Manual.Make sure that all placards are in place and

legible.

Failure to comply with safety precautions in this manual and on the hoist is a safety violation that may result

in serious injury, death, or property damage.

LoadMate

LM05

STEPLESS I&M/EN/11.

.2010

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This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

2 INSTALLATION

DANGER: Before installing, removing, inspection, or performing any maintenance on a

hoist, the main switch shall be de-energized. Lock and tag the main switch in the de-

energized position in accordance with ANSI Z244.1. Follow other maintenance procedures

outlined in this manual and ASME B30.16.

2.1 General





NOTE: Install the breather on the upper part of the hoist.

Prior to installation, the unit shall be checked thoroughly for damage during shipment or handling at the job

site.

Each complete electric chain hoist is load tested at the factory at 125% of the nameplate-rated capacity.

All hoists are designed for the type of mounting specified by the purchaser. The adequacy of the supporting

members (monorail beams, cranes, hangers, supports, framing, etc.) is the responsibility of user / owner and

shall be determined or verified by qualified personnel.

Read the instructions contained in this manual and the LoadMate® Electric Chain Hoist Operator’s

Manual as well as any other related manuals. Observe the warning tags attached to the unit before the

installation is started.

2.2 Lubrication

The hoist gear case comes completely pre-lubricated with grease.

Note: Open trolley wheel gearing has not been greased at the factory. See the trolley manual for proper

gear lubricant to use before installing hoist.

The load chain requires lubrication prior to first use. Chain lubricant is included with shipment of each new

chain hoist.

LoadMate

LM05

STEPLESS I&M/EN/11.

.2010

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This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

2.3 Mounting

Below are three types of mounting:

1. Hook Mounted

2. Base Mounted

3. Coupling Mounted

4. Trolley Mounted – NOT SHOWN – is accomplished via a Hook or Trolley Coupling to the Trolley

Assembly.

Figure 1. Mounting Types

For all trolley-mounted hoists, refer to appropriate trolley manual for trolley installation instructions.

After a trolley-mounted hoist has been assembled to a beam, check for balance. Each trolley-mounted hoist

is balanced at the factory for “as shipped” condition. Any auxiliary devices (radio control, lights, hose reels,

etc.) furnished and mounted by “others” may require additional counterweight. Hoists must hang straight

without a load or there will be a noticeable “kick” when a load is applied to hook. An unbalanced hoist /

trolley may result in damage to equipment.

2.4 Load Hook Throat Opening

mCAUTION: ANSI B30.16-1998 recommends that the throat opening of a load hook be measured

and recorded prior to putting a hoist into service and that a gage be made to provide a quick

visual inspection for a bent hook as required during routine inspections. Record this

information before initial start-up. See Section 7.9 for more detailed hook information.

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