R&m Loadmate lm 01 User manual

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.

OPERATOR’S MANUAL

ELECTRIC CHAIN HOIST

LOADMATE

LM1-LM05-LM10-LM16/20/25

English

STD-R-KHA-F-CQD-ENG

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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

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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

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 ........................................................................................................................................ 3

1.1 Contact Information................................................................................................................................... 3

1.2 Disclaimer of Warranty.............................................................................................................................. 3

1.3 Disclaimer of Liability ................................................................................................................................ 3

1.4 Indemnity .................................................................................................................................................. 4

2 SCOPE AND PURPOSE ............................................................................................................................ 5

2.1 Scope ........................................................................................................................................................ 5

2.2 Purpose..................................................................................................................................................... 5

2.3 Installation and Maintenance Manual ....................................................................................................... 5

3 SAFETY ..................................................................................................................................................... 6

3.1 Training Requirements.............................................................................................................................. 6

3.2 Introduction to Safety ................................................................................................................................ 7

3.3 Owner / User / Operator Responsibilities ................................................................................................. 8

3.4 Recommended Operator Qualifications.................................................................................................. 10

4 ELECTRIC CHAIN HOIST CONSTRUCTION........................................................................................... 11

4.1 General Hoist Construction..................................................................................................................... 11

4.2 Lifting Medium......................................................................................................................................... 11

4.3 Power for Operation................................................................................................................................ 11

4.4 Suspension Types .................................................................................................................................. 12

4.5 Directional Travel of Overhead Hoists .................................................................................................... 14

4.6 Principal Parts of an Electric Chain Hoist ............................................................................................... 16

5 SAFE OPERATING PRACTICES............................................................................................................. 24

5.1 Before Each Shift or The First Time the Hoist is Used Each Shift ......................................................... 24

5.2 Before Operating A Hoist and Applying a Load...................................................................................... 27

5.3 Moving the Load ..................................................................................................................................... 29

5.4 Parking the Load..................................................................................................................................... 30

5.5 Hoist Limit Devices ................................................................................................................................. 31

5.6 General Recommendations .................................................................................................................... 31

5.7 Recommended General Do Not’s........................................................................................................... 32

5.8 Operator Hand Signals ........................................................................................................................... 33

6 APPENDIX – A – DEFINITIONS OF ELECTRIC CHAIN HOIST TERMS.................................................. 34

7 APPENDIX – B – REFERENCES............................................................................................................. 37

8 APPENDIX – C – RECOMMENDED PRACTICES – ELECTRIC POWERED HOISTS............................. 39

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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

1 INTRODUCTION

1.1 Contact Information

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 Disclaimer of Warranty

R&M Materials Handling, Inc. makes no warranties whatsoever in connection with this manual. R&M

Materials Handling, Inc. specifically disclaims all implied warranties of merchantability or of fitness for

particular purpose. No warranties (express, implied, or statutory) are made in connection with this manual.

1.3 Disclaimer of Liability

User specifically understands and agrees that R&M Materials Handling, Inc.,its successors, assigns, officers,

agents, employees and members shall not be liable in tort and in contract – whether based on warranty,

negligence, strict liability, or any other theory of liability – for any action or failure to act in respect to the

recommended operation or inspection or other characteristics of anything covered in this manual. By using or

otherwise employing this manual, it is the user’s intent and understanding to absolve and protect R&M

Materials Handling, Inc.,its successors, assigns, officers, agents, employees and members from any and all

tort, contract, or other liability.

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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

1.4 Indemnity

By referring to, or otherwise employing this manual the user agrees to defend, protect, indemnify, and hold R&M

Materials Handling, Inc., its successors, assigns, officers, agents, employees and member harmless of, from

and against all claims, losses, expenses, damages and liabilities, direct, incidental or consequential, arising from

use of this manual including loss or profits and reasonable counsel fees, which may arise out of the use or

alleged use of such manual, it being the intent of this provision and of the user to absolve and protect R&M

Materials Handling, Inc., its successors, assigns, officers, agents, employees and members from any and all

loss relating in any way to this manual including those resulting from their own negligence.

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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

2 SCOPE AND PURPOSE

2.1 Scope

This Manual has been prepared by R&M Materials Handling, Inc. to provide recommendations for safe

operation of LoadMate® Series Electric Chain Hoists with warnings against specific hazards so as to avoid

personal injury and/or damage to property.

2.2 Purpose

It is the purpose of this manual to promote the adoption and use of uniform and effective safe operating

practices for hoist operators. This manual also provides a ready reference for training, evaluation, and review of

LoadMate® Series Electric Chain Hoist operating practices that are designed to assist in the prevention of

personal injury and / or damage to property.

2.3 Installation and Maintenance Manual

The ELECTRIC CHAIN HOIST OPERATOR’S MANUAL and the ELECTRIC CHAIN HOIST INSTALLATION

AND MAINTENANCE MANUAL are both provided with each LoadMate® Series Electric Chain Hoist. Both

manuals are shipped with each unit from the factory. Both manuals SHALL be read prior to installation and

operation in order to provide a safe environment and ensure the proper care and maintenance of the product

provided by R&M Materials Handling, Inc.

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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

3 SAFETY

3.1 Training Requirements

LoadMate® Series Electric Chain Hoist operator, inspector, and 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 programs should also provide information for compliance with any Federal, State, or Local Code

requirements, existing plant safety rules and regulations, and LoadMate® Series Electric Chain Hoist

Operator’s Manual and the appropriate LoadMate®Installation and Maintenance Manual.

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 edition, 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.

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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

3.2 Introduction to 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.

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

ASME B30 standards as follows:

SHALL indicates that a rule is mandatory and must be followed.

SHOULD indicates that a rule is a recommendation, the advisability of which

depends on the facts in each situation.

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

“USE COMMON SENSE”

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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

3.3 Owner / User / Operator Responsibilities

READand OBEY all DANGER, WARNING, CAUTION, and OPERATION INSTRUCTIONS on the hoist and in

this 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

product failure, serious injury, death, or property damage.





NOTE: It is important that warning, control marking, and other safety labels and signs are present

on the hoist and that the information on the label or sign is legible.

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

the Installation and Maintenance Manual furnished by R&M Materials Handling, Inc. can result in

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

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

The hoist manufacturer has no direct involvement or control over the hoist’s operation and application.

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

TRAIN and designate hoist operators, and

TRAIN and designate hoist inspection and maintenance personnel

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

that they understand the proper operation of the hoist should be authorized to operate and/or repair the hoist.







NOTE: 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.

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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

WARNING: Before installing, removing, inspecting 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 the Installation and Maintenance Manual furnished by R&M Materials Handling,

Inc., and ASME B30.16.

mWARNING: Failure to properly ground the hoist presents the danger of electric shock.

mWARNING: An improper or insufficient ground connection creates an electrical shock hazard

when touching any part of the hoist or trolley.

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3.4 Recommended Operator Qualifications

HOIST OPERATORS SHALL:

Be required to read this manual (Electric Chain Hoist Operator’s Manual).

Be required to read the warnings in Installation and Maintenance Manual supplied with hoist.

Be required to read the instructions and warning labels on the hoist.

Be required to read the operating section of ASME B30.16.

Be required to be familiar with the hoist controls before being authorized to operate the

hoist.

Be trained in proper rigging procedures to be followed in the attachment of loads to

the hoist load hook.

Be trained and be familiar with any below-the-hook devices that may be used in

lifting of loads.

Be trained to be aware of potential malfunctions of the hoist that may require adjustment

or repair.

Be instructed to stop operation if 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 for the work to be performed.

NOT be subject 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

others.

NOT operate a hoist when under the influence of alcohol or drugs.

NOT operate a hoist when under the influence of medication that could result in actions

of the operator being a hazard to the operator or others.

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4 ELECTRIC CHAIN HOIST CONSTRUCTION

4.1 General Hoist Construction

Overhead hoists are defined in the ANSI / ASME standards as a machinery unit that is used for vertical lifting

service involving material handling of freely suspended (unguided) loads. Overhead hoists are a basic and

versatile piece of equipment used in manufacturing, warehousing, construction, and numerous other

applications to aid workers in the handling and moving of loads.

Overhead hoists are available in various types of configurations and constructions. Overhead hoist types are

usually referred to using the terms that define a specific configuration and construction.

The following are three areas that further define the hoist type.

4.2 Lifting Medium

Lifting medium defines the type of component used to transmit and cause vertical motion of the hoist load hook

or hoist load block. Chain is a lifting medium. The LoadMate® Series Electric Chain Hoist uses welded link

load chain.

Welded Link Load Chain

Welded link load chain consists of a series of interwoven formed and welded links. The links fit pockets

of the hoist load sprocket that transmits motion to the load chain. The load sprocket may also be called

load wheel, load sheave, pocket wheel, chain wheel, or lift wheel. Welded link load chain sizes are

stated as the diameter of the wire used to form the link, i.e. 3.1mm, 4.8mm, 6.8mm, etc. Welded link

load chain is designed and manufactured to specific dimension and material strength requirements for a

specific hoist. Welded link load chain is not interchangeable between different manufacturers’ hoists;

and is not interchangeable with welded link lifting chain used for other purposes such as chain slings

and securing the load. Only original equipment welded link load chain, as supplied by R&M Materials

Handling, Inc., shall be used on any LoadMate® Series Electric Chain Hoist.

4.3 Power for Operation

Power for operation defines the type of power used to operate the hoisting motion. The electric chain

hoist uses electrical power to run an electric motor that provides the motion for lifting and lowering the

load.

DANGER: ON ELECTRIC POWERED HOISTS, HAZARDOUS VOLTAGES ARE PRESENT IN

THE CONTROL BOX, OTHER ELECTRICAL COMPONENTS, AND CONNECTIONS

BETWEEN THESE COMPONENTS.

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Electric Power

The hoisting motion (lifting or lowering) of an electric powered hoist is initiated when the operator grasps

and activates a control device. The control device has push buttons that energize, through a series of

contractors and other electrical components, an electric motor. The electric motor transmits power

through the hoist gearing to the hoist load chain sprocket; thereby, lifting or lowering the hoist load hook.

Lifting is accomplished by actuating the lifting control; and lowering is accomplished by actuating the

lowering control. The controls could be marked: LIFT/LOWER; UP/DOWN; RAISE/LOWER; or a

combination of such markings. Hoist lifting and lowering controls are usually pushbuttons mounted in a

pendant control enclosure suspended from the hoist; or levers or switches mounted in a remote radio-

control transmitter. Pendant control enclosures, radio-control transmitters, or other control means could

also be permanently mounted on the building structure or cab of an overhead crane depending on the

application.

The control device used to lift and lower hoist motion may also contain controls for other motions or

functions. Such controls include: trolley travel, overhead crane travel, power on/off, emergency stop,

motions associated with below-the-hook lifting devices, and other special functions associated with a

specific application. Examples of such control markings may include, but are not limited to, EAST /

WEST; RIGHT / LEFT; OPEN / CLOSE; START / STOP; etc.

4.4 Suspension Types

Suspension defines the type of mounting or method used to mount or suspend the hoist. Common suspension

types include hook mounted and trolley mounted. Other types of suspension may be designed to meet specific

application requirements.

When the above various types of configurations or constructions are considered, some of the names used to

refer to overhead hoists include: hook mounted electric chain hoists, lug mounted electric chain hoists, push

trolley mounted electric chain hoists, motor driven trolley mounted chain hoists, etc.

Hook Mounted

Hook mounted hoists have a top hook on the hoist frame or body that can be used to suspend the hoist

from the clevis or suspension pin of a trolley; or a fixed suspension device, that will accept the hook,

mounted on a beam or the structural framework of a building.

Lug Mounted

Lug mounted hoists have a lug mounting attached to the top of the hoist frame, or a lug mounting

attached as an integral part of the hoist frame. Lug mounted hoists are available in all hoist types. Lug

mountings are used to suspend the hoist from a trolley, or a fixed suspension device mounted on a

beam or the structural framework by the use of suspension pin(s) or stud(s).

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Trolley Mounted

Trolley mounted hoists are hook mounted or lug mounted hoists suspended from a trolley; or a hoist

having an integral trolley as part of the hoist frame, that allows travel motion on the lower flange of a

monorail beam, or the lower flange of the bridge beam of an overhead crane.

Trolleys allow traverse motion of the hoist unit, and load being handled, by traveling: on the lower flange

of a monorail beam; on the lower flange of a bridge beam of an overhead crane; or on top of the bridge

beams of an overhead crane. Hoist trolleys are available in several types depending on the method

used to obtain travel motion. Trolley types include:

Plain (Push) Trolleys

Plain type trolley motion is obtained by pulling or pushing the load or by some other means,

such as the strain relief of a pendant control, suspended from the trolley or hoist. Plain type

trolleys are recommended where trolley motion is infrequent or relatively short. Because of the

force required to manually operate this type of trolley, it is recommended that the use of plain

trolleys be limited to a maximum capacity load of 3 tons or 3000 kg, and that the elevation of the

beam where the trolley is suspended be not more than 20 feet or 6 m above the operating floor

level.

Hand Chain Operated (Hand Geared) Trolleys

Hand geared trolley motion is achieved by grasping and pulling a continuous hand chain that is

connected to the trolley. Hand chain consists of a series of interwoven formed welded or un-

welded links according to the design specifications of the hand chain. The hand chain links fit

pockets of the trolley hand chain wheel, or sprocket. As the operator pulls the hand chain, the

hand chain wheel turns and transmits power through gearing to the trolley wheels. Pulling the

hand chain in one direction will cause the trolley to travel in the opposite direction. Hand chain

manually operated trolleys provide excellent load spotting ability.

Electric Powered (Motorized) Trolleys

Motorized trolley motion is achieved by activating a control device in the same manner as

described under electric powered hoists. The control device used to lift and lower hoist motion

may also contain controls for trolley travel. Recommendations for use of electric powered are

based on frequency of operation, distance of travel, capacity of load, height of beam, and type

or size of load being handled.

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4.5 Directional Travel of Overhead Hoists

Hoist motion is the vertical travel motion direction of the hoist load hook. The hoist operator should be familiar

with the hoist (or crane) controls and understand what type of motion will occur when any one of the control

devices is activated. The controls SHALL be marked, and all markings SHALL be legible. The daily inspection

that is required to be performed by the operator at the start of each shift or at the time the hoist is first used

during each shift, SHOULD include a check that all motions agree with control device markings.

Overhead hoists have one axis of directional travel. This is:



THE HOISTING OR VERTICAL TRAVEL DIRECTION OF THE LOAD HOOK

When overhead hoists are trolley suspended, the trolley hoist unit has two axes of directional travel. These

include:



THE HOISTING OR VERTICAL TRAVEL DIRECTION OF THE LOAD HOOK



THE TRAVERSE TRAVEL DIRECTION OF THE TROLLEY (INCLUDING THE HOIST UNIT)

When trolley suspended overhead hoists are used on an overhead crane, the crane, including the trolley hoist

unit has three axes of directional travel. These include:



THE HOISTING OR VERTICAL TRAVEL DIRECTION OF THE LOAD HOOK



THE TRAVERSE TRAVEL DIRECTION OF THE TROLLEY (INCLUDING THE HOIST UNIT)

•THE TRAVERSE TRAVEL DIRECTION OF THE BRIDGE (INCLUDING THE TROLLEY AND HOIST

UNIT)

Some hoists or cranes may have power-operated rotating hooks, power-operated below-the-hook lifting devices,

or other power-operated accessories that result in additional axes of directional travel.

If more than one hoist or trolley hoist unit is used on an overhead crane, each hoist or trolley hoist SHALL have

an identification mark on it or its load block, and these markings SHALL also appear on the controllers used by

the operator.

For example, if a crane has two trolley hoist units, one trolley hoist unit shall be marked “1” (or some other

designation) on the trolley hoist or load block, and the other trolley hoist unit shall be marked “2” (or some other

designation) on the trolley hoist or load block.

The markings on the trolley hoists are to be visible to the operator and any signal person used in rigging the

load. The controllers for trolley hoist 1 must be marked “1” (or other designation used on the trolley hoist), and

the controllers for trolley hoist 2 must be marked “2” (or other designation used on the trolley hoist).

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All motions of multi-speed powered hoists should be started in the slowest speed available for that motion, and

then the speed should be increased until the desired speed is obtained. At the beginning of hoisting motion, the

load should be lifted only a few inches and stopped to check the holding brake before continuing with the lift.

The hoist should be brought directly over the load before rigging the load to the hoist load hook. Failure to

center the hoist over the load could cause the load to swing when it is lifted, or could cause side pulls or other

forces to be transferred into the crane. Slack should be taken out of the chains, and slings, if used, before

attempting to lift the load.

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4.6 Principal Parts of an Electric Chain Hoist

Hoist operators should be familiar with the parts of a hoist and have a thorough knowledge of hoist control

device functions.

Figure 1. Parts of an Electric Chain Hoist

1 - LOAD BLOCK ASSEMBLY (2-FALL SHOWN)

2 - LOAD CHAIN

3 - ELECTRICAL CONTROL ENCLOSURE

4 - TOP HOOK

5 - HOIST GEAR BOX ASSEMBLY

6 - CHAIN CONTAINER & HARDWARE

7 - HOIST BODY / MOTOR

8 - LOAD HOOK SAFETY LATCH

9 – FASTENER FOR CHAIN CONTAINER

10 – PIN / BOLT FOR CHAIN CONTAINER

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Trolley Assemblies

Figure 2. Plain (Push) Trolley

Figure 3. Hand Geared Trolley

BASIC ELECTRIC CHAIN HOIST

PLAIN TROLLEY ASSEMBLY

CRANE BEAM OR MONORAIL

HAND GEARED TROLLEY ASSEMBLY

BASIC ELECTRIC CHAIN HOIST

HAND CHAIN DRIVE WHEEL

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Figure 4. Motorized Trolley Assembly

BASIC ELECTRIC CHAIN HOIST

MOTORIZED TROLLEY ASSEMBLY

CRANE BEAM OR MONORAIL

TROLLEY DRIVE MOTOR

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