R&M LOADMATE LM 16 Installation and operating instructions

` ®R&M Materials Handling, Inc LoadMate®Chain Hoist
Springfield, Ohio USA LM16-20-25 Manual
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April 1, 2005 LM16-20-25-I&M MANUAL-2005-0
LoadMate®
LM16 / 20 / 25 ELECTRIC CHAIN HOIST
L
LM M20 25
LM16
INSTALLATION & MAINTENANCE INSTRUCTIONS
JOB NO. : ______________
SERIAL NO. : ______________
(RECORD HOIST SERIAL NUMBER FOR FUTURE REFERENCE)

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TABLE OF CONTENTS
1INTRODUCTION......................................................................................................1
1.1 Contact Information.......................................................................................................1
1.2 Warranty........................................................................................................................1
1.3 Disclaimer......................................................................................................................1
1.4 Safety............................................................................................................................2
1.5 Placards and Instructions..............................................................................................4
2INSTALLATION........................................................................................................5
2.1 General..........................................................................................................................5
2.2 Chain Container Installation..........................................................................................5
2.3 Lubrication.....................................................................................................................5
2.4 Mounting........................................................................................................................6
2.5 Load Hook Throat Opening...........................................................................................6
2.6 Electrical Connection ....................................................................................................6
2.7 Three Phase Power Connections..................................................................................7
3INITIAL START-UP..................................................................................................8
3.1 General..........................................................................................................................8
3.2 Correcting the Direction of Hook Travel........................................................................8
3.3 Operational Checks – No Load.....................................................................................8
3.4 Operational Checks – With Load...................................................................................9
4HOIST OPERATION..............................................................................................10
5MAINTENANCE.....................................................................................................12
5.1 Construction................................................................................................................12
5.2 Hoist Motor and Brake Assembly................................................................................13
5.3 Torque Limiter (Refer to Figure 5.4)............................................................................17
5.4 Load Chain..................................................................................................................18
5.5 Maintenance Inspection ..............................................................................................18
5.6 Load Chain Specifications (see Figure 5.5) ................................................................20
5.7 Removing the Load Chain...........................................................................................20
5.8 Installing the Load Chain.............................................................................................21
5.9 Fall Stop Assembly (Refer to Figure 5.8)....................................................................22
5.10 Chain Container ..........................................................................................................23
5.11 Upper and Lower Travel Safety Limit Switch ..............................................................24
5.12 Upper and Lower Rotary Travel Limit Switch..............................................................24
5.13 Hooks..........................................................................................................................25
5.14 Hook Inspection ..........................................................................................................25
5.15 Hook Dimensions........................................................................................................26
5.16 Top Hook.....................................................................................................................27
5.17 Controls.......................................................................................................................28
5.18 Two Speed – Three Phase – 208 / 230 / 460 Volt – Power Circuit.............................30
5.19 Two Speed – Three Phase – 208 / 230 / 460 Volt – Control Circuit............................31
5.20 Two Speed – Three Phase – 208 / 230 / 460 Volt – Push Button...............................32
5.21 Two Speed – Three Phase – 575 Volt – Power Circuit...............................................33
5.22 Two Speed – Three Phase – 575 Volt – Control Circuit..............................................34
5.23 Two Speed – Three Phase – 575 Volt – Push Button.................................................35
6PREVENTATIVE MAINTENANCE.........................................................................37
6.1 Maintenance and Inspection Table .............................................................................37

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6.2 Lubrication...................................................................................................................38
6.3 Recommended Technical Support for Various spare parts.........................................39
6.4 Screw Tightening Torque (lb-ft) Specification .............................................................39
6.5 Troubleshooting ..........................................................................................................40
7PARTS ILLUSTRATIONS......................................................................................41
7.1 Basic Hoist Assembly..................................................................................................41
7.2 Hoist Gearbox Components........................................................................................43
7.3 C16 / C20 / C25 Hoist Motor & Brake Assembly.....................................................45
7.4 Lifting Assembly – C16 Only.......................................................................................47
7.5 Lifting Assembly – C20/25 Only..................................................................................49
7.6 C16 / C20 / C25 Electrical Control Assembly..............................................................51
7.7 Push Button Assembly –Vertical Pairs of Buttons.......................................................53

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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 Dept. 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
and Product Warranty. Copies are available upon request from R&M MATERIALS HANDLING, INC. and
are expressly incorporated by reference hereto. The documents are also available from the above
website.
1.3 Disclaimer
This Manual has been prepared by R&M MATERIALS HANDLING, INC. to provide information and
suggestions for personnel performing installation, maintenance, and inspection procedures on this electric
chain hoist. 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 personnel performing installation,
maintenance, and inspection procedures and its use is permissive not mandatory. It is the responsibility of
the hoist owner/user to make personnel aware of all federal, state, and local codes and regulations. The
owner/user is responsible for providing instruction and insuring that certain installation, maintenance, and
inspection personnel are properly trained.

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1.4 Safety
The Safety Alert Symbol is used in this manual to indicate hazards and to alert the reader to information
that should be known, understood, and followed in order to avoid DEATH or SERIOUS INJURY.
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, which 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:
Train and designate hoist operators, and
Train and designate hoist inspectors / maintenance personnel.
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.

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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
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.
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 it’s
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.

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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.

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2 INSTALLATION
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
Prior to installation, the unit shall be checked thoroughly for damage during shipment or handling at the job
site.
At the factory, each complete electric chain hoist is load tested 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 Chain Container Installation
REMOVE SMALL CHAIN CONNECTING CHAIN CONTAINER TO HOIST BODY. THIS CHAIN IS TO
BE USED ONLY DURING INSTALLATION AND THEN MUST BE REMOVED.
Due to the weight of the chain and chain container on all Models LM16 / 20 / 25, the chain container is
attached to hoist body with a LIGHT DUTY chain to facilitate removing hoist and chain container from
packing container for assembly of chain container to hoist body.
2.3 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.

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2.4 Mounting
Below are three types of mounting: 1) Hook Mounted
2) Base Mounted
3) Coupling Mounted
4) Trolley Mounted – NOT SHOWN
FIGURE 2.1
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.
2.5 Load Hook Throat Opening
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 5.20 for
more detailed hook information.
2.6 Electrical Connection
The user / owner must provide the main power supply hardware (cable, conductor bar, fuses, disconnect
switch, etc.).
Make sure that the power supply voltage is the same as that shown on hoist serial plate / nameplate.
Make sure that fuses and other current overload devices are in place to protect the power supply. Make
sure that power cable or conductors have sufficient capacity to maintain the hoist supply voltage by ±5
percent of nominal voltage under all operating conditions. Poor voltage regulation may cause motor
overheating or sluggishness, and chattering / inoperative motor brake(s) and controls. Do not use power
supply cables with solid conductors.

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2.7 Three Phase Power Connections
PS
PBTR
FIGURE 2.2
PS – Power supply
TR – Trolley connection
PB – Pushbutton connection
1. Remove the control enclosure cover.
2. Insert the power supply cable through the cable gland or connector (PS).
3. Connect phases L1, L2, L3, and ground (PE) to terminal strip. Refer to the wiring diagram.
4. Tighten the terminal screws
5. Tighten the cable gland or connector to secure the cable.
6. Connect the pushbutton assembly to plug connector X23 (PB).
7. Connect the motorized trolley plug connector X24 (TR) (optional).
8. Close the control enclosure cover.

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3 INITIAL START-UP
Before connecting power to hoist, check all “motion” buttons on pendant control assembly to
make sure that they operate freely without binding or sticking. Check pendant cable and strain
relief connection to ensure that they are not damaged.
3.1 General
Initial start-up procedures are as follows:
• Read all attached WARNING tags and placards affixed to hoist.
• Oil load chain generously over entire length of chain.
• Make sure that load chain is not twisted. If so, untwist load chain before using.
• Make sure fall stop is placed at least 6” [150 mm] from last chain link on free end.
• Install chain container.
• If furnished, make sure that trolley wheels have proper spacing in relation to beam flange. See
appropriate trolley manual for details.
• Check direction of hook travel to make certain that it corresponds to respective control button that is
depressed. That is, does hook travel “UP” when UP BUTTON is depressed? If OK, go to section
3.3. If not, proceed to section 3.2 for correcting direction of travel.
3.2 Correcting the Direction of Hook Travel
DO NOT change control leads in pushbutton enclosure or at motor relays. DO NOT change
nameplates on pushbutton assembly. The upper/lower safety limit switch is wired in series with
“UP” control circuit as furnished from factory. Changing pushbutton control leads or nameplates
will prevent the upper safety travel limit switch from functioning properly.
Reversing any two power leads of a three-phase AC motor will reverse the direction of rotation.
• Reverse any two leads of a three-phase power at the main power source or at motor connections.
Do not change internal wiring of hoist.
• After changing two of the main power leads, recheck direction of rotation. Press “UP” button only. If
hook travel goes in “UP” direction, proceed to section 3.3. If not, redo section 3.2.
3.3 Operational Checks – No Load
• Check hoist motor brake function. Run empty load block up or down to check that load block does not
drift more than 1.0 inch [25mm]. If so, adjust brake as described in Section 5.3 of this manual.
• Run empty load block down to check that fall stop (located on free end of load chain) makes proper
contact with upper / lower travel safety limit switch and that limit switch functions properly.
• Run empty load block up to check that load block makes proper contact with upper / lower travel
safety limit switch and that limit switch functions properly.
• Run empty load block up and down several times while checking for proper tracking of load chain.

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3.4 Operational Checks – With Load
• After completion of no-load operational tests, the user /owner should perform a full load test even
though each complete hoist is load tested at factory.
• Lift a near capacity load about one (1) foot [30cm] above floor level. Check that the brake holds load.
Also, check stopping capability of brake when lifting to a stop and lowering to a stop.
• Move trolley the full length of monorail or crane beam. Check for any binding of trolley wheels on
flange and/or interference at splice joints, hanger connections / bolts, etc.
• Check contact with stops. Contact with stops SHALL only be made with trolley bumpers. Stops that
are designed to make contact with wheels SHALL NOT be used.

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4 HOIST OPERATION
BEFORE PROCEDING WITH THE NORMAL OPERATION OF THIS HOIST, THE OPERATOR/(S)
SHALL BE TRAINED IN ACCORDANCE WITH THE LoadMate®Electric Chain Hoist Operator’s
Manual AS SUPPLIED WITH THIS HOIST.
FAILURE TO READ AND COMPLY WITH ANY ONE OF THE LIMITATIONS NOTED IN THIS MANUAL
AND THE LoadMate®Electric Chain Hoist Operator’s Manual FURNISHED WITH THIS HOIST CAN
RESULT IN PRODUCT FAILURE, SERIOUS BODILY INJURY OR DEATH, AND / OR PROPERTY
DAMAGE.
REFER TO SECTION 1.0 OF THIS MANUAL FOR CONTACT INFORMATION IF YOU NEED ANY
ADDITIONAL ASSISTANCE.

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5 MAINTENANCE
5.1 Construction
FIGURE 5.1
1. TOP HOOK
2. HOIST MOTOR
3. GEAR CASE & GEARING
4. LOAD BLOCK ASSEMBLY
5. CHAIN CONTAINER
6. CHAIN SPROCKET
7. CONTROLS & ENCLOSURE
1
2
3
4
6
7
5
P 25010

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5.2 Hoist Motor and Brake Assembly
The hoist motors are designed to provide dependable hoisting service. The standard motors are enclosed
for IP55 protection against normal hazards of dust and moisture. The motor bearings are sealed and do
not require further greasing.
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.
FIGURE 5.2
1. Hex head cap screw – three (3)
2. Brake and fan cover
3. Fan lock collar
4. Fan
5. Motor mounting bolt / threaded rod – three (3)
6. Hoist motor
7. Hex head cap screw – three (3)
8. Motor brake assembly
9. Friction rotor
10. Snap ring

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11. Brake hub
Remove Hoist Motor and Brake Assembly (refer to Figure 5.2)
1. Remove load from load block assembly.
2. Raise load block assembly to hoist body. Allow slack in chain to permit tying up bottom block
assembly to remove weight of bottom block assembly from load chain.
3. Remove and lockout power to the hoist.
4. Remove three-sided branding cover.
5. Remove three (3) screws (item 1) and take off Brake and Fan Cover (item 2).
6. Remove brake coil leads from terminals inside hoist electrical control enclosure.
7. Loosen brake cable gland on electrical control enclosure and pull out brake cable.
8. Remove hoist motor leads from K25 and K10 contactors located in hoist electrical control
enclosure.
9. Loosen motor cable gland on electrical control enclosure and pull out motor leads.
10. Remove screws and remove electrical control enclosure from hoist motor.
11. Remove screw and remove mounting bracket from hoist motor.
12. Remove three lock nuts from threaded rods (item 5) and pull hoist motor and brake assembly out
away from gearbox.
Installing Hoist Motor and Brake Assembly (refer to Figure 5.2)
1. Mount hoist motor to gearbox making sure hoist motor is positioned properly. Push hoist motor
into gearbox until tight and threaded rods (item 5) are through end flange of hoist motor.
2. Use lock nuts to draw hoist motor in place against the gearbox. Tighten lock nuts evenly as the
hoist motor moves into place.
3. Mount brackets to hoist motor and tighten socket head cap screw.
4. Mount electrical control enclosure to hoist motor and tighten four (4) screws.
5. Insert hoist motor cable through motor cable gland on electrical control enclosure and reconnect
motor leads to K25 and K10 contactors. Tighten hoist motor cable gland.
6. Insert hoist motor brake leads through brake cable gland on electrical control enclosure and
reconnect hoist motor brake leads. Tighten hoist motor brake cable gland.
7. Recheck tightness of lock nuts holding hoist motor.
8. Mount end cap and tighten socket head cap screws. (Do not over-tighten.)
9. Replace three-sided branding panel.
10. Untie the load block assembly.
11. Unlock power and turn on.
12. Press “UP” button and check for proper phase rotation. If not correct, turn off power and change
position of two of the three power leads that were just reconnected.
13. If direction is correct, perform a no-load check and then a full load check per section 3.3 and 3.4
respectively.

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Hoist Motor Brake
The hoist motor brake is a D.C. electromagnetic disc brake and does not require adjustment. The brake
brings the load to a smooth and quick stop and holds the load when the hoist motor is not energized. An
energized coil releases the hoist motor brake and permits the raising and lowering of the load.
FIGURE 5.3
1. Brake Spring
2. Brake Armature Plate
3. Friction Rotor
4. Brake Hub
5. Brake Adjusting Rod
6. Brake Mounting Screw
7. Screw
8. Wear Plate
AIR GAP
SNAP RING
REPLACED
WITH LOCK
COLLAR
7
8

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NOTE: MAXIMUM ALLOWABLE GAP IS 0.5mm or 0.020 inches. Remove round plastic dust cap on the
side of the brake assembly. Turn off power to hoist, insert gage pin of proper diameter to check
motor brake gap. Recommend that a gage pin set be available with increments of 0.001” ranging
from 0.015” to 0.020”.
Gap may be measured periodically to predict replacement based upon frequency of use. Replace
the friction rotor when the gap reaches the maximum allowable dimension.
Removing Hoist Motor Brake (Refer to Figures 5.2 and 5.3)
1. Remove load from load block assembly.
2. Raise load block assembly to hoist body. Allow slack in chain to permit tying up bottom block
assembly to remove weight of bottom block assembly from load chain.
3. Remove and lockout power to the hoist.
4. Remove three-sided branding cover.
5. Remove three (3) screws (item 1- figure 5.2) and take off Brake and Fan Cover (item 2-figure 5.2).
6. Remove lock collar (see Figure 5.3) and remove fan. If needed, use two screwdrivers under hub
to pry fan loose.
7. Remove second retaining ring and pull out spacer.
8. Remove brake coil leads from terminals inside hoist electrical control enclosure.
9. Loosen brake cable gland and pull out brake cable as necessary.
10. Remove three (3) screws – Figure 5.3 - from brake magnetic assembly. Remove brake magnetic
assembly.
11. Remove motor brake friction rotor – item 3 – Figure 5.3.
12. Remove three (3) screws – item 7 – Figure 5.3 and remove wear plate item 8 – Figure 5.3.
Installing Hoist Motor Brake (Refer to Figures 5.2 and 5.3)
1. Check the voltage of the motor brake assembly. It must match the voltage of the motor.
2. Attach wear plate – item 8 – Figure 5.3 to hoist motor end flange and tighten three (3) screws item
7 – Figure 5.3 to recommended tightening torque – 6.6 lb-ft [9Nm].
3. Slide friction rotor (item 3 – Figure 5.3) onto brake hub (item 4 – Figure 5.3).
4. Mount magnetic brake assembly (item 1 – Figure 5.3) and tighten three (3) screws (item 6 –
Figure 5.3) to recommended tightening torque – 6.6 lb-ft [9 Nm].
5. Insert spacer and install snap ring into groove just above spacer.
6. Mount fan (item 4 – Figure 5.2) and install lock collar just above fan hub.
7. Insert motor brake leads through brake cable gland on electrical control enclosure and reconnect
motor brake leads. Tighten motor cable gland.
8. Mount end cap and tighten three screws. (Do not over-tighten.)
9. Replace branding cover.
10. Turn on power.
11. Free the bottom block and make certain load chain is not twisted
12. Perform no-load test and load test per Sections 3.3 and 3.4 respectively.