R&m Loadmate lm 16 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.

INSTALLATION AND

MAINTENANCE MANUAL

LM CHAIN HOIST

LOADMATE

LM16 - LM20 – LM25

English

STD-R-KHA-F-CQD-ENG

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THIS PAGE INTENTIONALLY LEFT BLANK

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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 Chain Container Installation ................................................................................................................. 9

2.3 Lubrication ............................................................................................................................................ 9

2.4 Mounting ............................................................................................................................................. 10

2.5 Load Hook Throat Opening ................................................................................................................ 10

2.6 Electrical Connection .......................................................................................................................... 11

2.7 Three Phase Power Connections....................................................................................................... 12

3 INITIAL START-UP.................................................................................................................................. 13

3.1 General ............................................................................................................................................... 13

3.2 Correcting the Direction of Hook Travel ............................................................................................. 13

3.3 Operational Checks – No Load .......................................................................................................... 14

3.4 Operational Checks – With Load........................................................................................................ 14

4 HOIST OPERATION ................................................................................................................................ 15

5 SWIVEL TROLLEY .................................................................................................................................. 16

5.1 Description – Technical Characteristics (swiveling trolley to 3.2 tons)............................................... 16

5.1.1 Technical Characteristics........................................................................................................... 16

5.2 Installation of Swivel Trolley ............................................................................................................... 17

5.3 Electric Swivel Trolley......................................................................................................................... 18

5.3.1 Swiveling trolley (3.2 tons) ......................................................................................................... 19

5.3.2 Swiveling trolley (3.2 to 5.0 tons) (NOT LOCALLY AVAILABLE) .............................................. 19

5.3.3 Procedure to adjust swivel trolley guide rollers.......................................................................... 20

6 MAINTENANCE ....................................................................................................................................... 21

6.1 Basic Hoist Construction .................................................................................................................... 21

6.2 Hoist Motor and Brake Assembly ....................................................................................................... 22

6.2.1 Replacement Criteria for Motor Brakes ..................................................................................... 25

6.3 Torque Limiter (Refer to Figure 11) .................................................................................................... 27

6.4 Load Chain ......................................................................................................................................... 28

6.5 Maintenance Inspection...................................................................................................................... 28

6.6 Load Chain Specifications (see Figure 12) ........................................................................................ 30

6.7 Removing the Load Chain .................................................................................................................. 30

6.8 Installing the Load Chain .................................................................................................................... 31

6.9 Fall Stop Assembly (Refer to Figure 14) ............................................................................................ 33

6.10 Chain Container ............................................................................................................................. 34

6.11 Upper and Lower Travel Safety Limit Switch ................................................................................. 35

6.12 Upper and Lower Rotary Travel Limit Switch................................................................................. 36

6.13 Hooks ............................................................................................................................................. 37

6.14 Hook Inspection.............................................................................................................................. 38

6.15 Hook Dimensions ........................................................................................................................... 39

6.16 Top Hook ........................................................................................................................................ 40

6.17 Controls .......................................................................................................................................... 41

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6.18 Two Speed – Three Phase – 208 / 230 / 460 Volt – Power Circuit ............................................... 43

6.19 Two Speed – Three Phase – 208 / 230 / 460 Volt – Control Circuit .............................................. 44

6.20 Two Speed – Three Phase – 575 Volt – Power Circuit.................................................................. 45

6.21 Two Speed – Three Phase – 575 Volt – Control Circuit ................................................................ 46

6.22 Wiring Diagram – 3 Button – Push Button ..................................................................................... 47

6.23 Wiring Diagram – 5 Button – Push Button ..................................................................................... 48

6.24 Wiring Diagram – 7 Button – Push Button ..................................................................................... 49

7 PREVENTATIVE MAINTENANCE .......................................................................................................... 50

7.1 Maintenance and Inspection Table..................................................................................................... 50

7.2 Lubrication .......................................................................................................................................... 51

7.3 Recommended Technical Support for Various Spare Parts .............................................................. 52

7.4 Screw Tightening Torque (lb-ft) Specifications................................................................................... 52

7.5 Troubleshooting .................................................................................................................................. 53

8 PARTS ILLUSTRATIONS........................................................................................................................ 54

8.1 Hoist Gearbox Components ............................................................................................................... 54

8.2 C16 / C20 / C25 Hoist Motor & Brake Assembly............................................................................ 56

8.3 Lifting Assembly – C16 Only .............................................................................................................. 58

8.4 Lifting Assembly – C20/25 Only ......................................................................................................... 60

8.5 C16 / C20 / C25 Electrical Control Assembly..................................................................................... 62

8.6 Double Brake (Option) C16 / C20 / C25 ............................................................................................. 64

8.7 Electric trolley (Swiveling trolley 0 to 3.2 Tons (3200 Kg)) ................................................................. 66

8.8 Push Button Assembly – Horizontal Pairs of Buttons......................................................................... 68

8.9 Push Button Assembly – Horizontal Pairs of Buttons........................................................................ 69

8.10 Push Button Assembly – Vertical Pairs of Buttons (Option) .......................................................... 70

8.11 Push Button Assembly – Vertical Buttons (Option)........................................................................ 72

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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 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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1.4 Safety





NOTE: 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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The words SHALLand 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.

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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.

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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

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 Chain Container Installation

mCAUTION: 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 LM 16 / 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 – 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.

2.5 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.

mCAUTION: Record this information before initial start-up. See Section 6.13-15 for more

detailed hook information.

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2.6 Electrical Connection

The user / owner must provide the main power supply hardware (cable, conductor bar, fuses, disconnect

switch, etc.).

mCAUTION: Make sure that the power supply voltage is the same as that shown on hoist serial

plate / nameplate.

mCAUTION: Make sure that fuses and other current overload devices are in place to protect the

power supply.

mCAUTION: 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.

mCAUTION: Do not use power supply cables with solid conductors.

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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2.7 Three Phase Power Connections

Figure 2. Three Phase Control Box Power Connections

PBTR

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

WARNING: 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

WARNING: 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 connections to motor.

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.

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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 6.3 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.

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

WARNING: BEFORE PROCEEDING 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.

mWARNING: 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.

mWARNING: REFER TO SECTION 1.0 OF THIS MANUAL FOR CONTACT INFORMATION IF

ADDITIONAL ASSISTANCE IS NEEDED.

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5 SWIVEL TROLLEY

5.1 Description – Technical Characteristics (swiveling trolley to 3.2

tons)







NOTE: The trolley you have just purchased must be used only with the nominal load indicated on the

rating plate.







NOTE: The trolley’s service life will depend on the level of duty, the average operating time, the

number of starts and the maintenance applied to it.

5.1.1 Technical Characteristics

Type 1 Type 2

30 Hz

≤1000 kg

100 Hz

>1000 kg

Fem Class H4 H4

IP IP55 IP55

Insulation class F F

Duty factor 40% 40%

Operating temperature -10°C, +40°C -10°C, +40°C

Power supply frequency 60 Hz 60 Hz

Standard speed 20/5 m/min 80/20 fpm 20/5 m/min 80/20 fpm

Default acceleration time (Deceleration time) 2.5 s 2.5 s

Thermal protection for motor Option Option

Thermal protection for frequency converter Std. Std.

Noise level 70 db 70 db

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5.2 Installation of Swivel Trolley

The service life of the trolley depends upon the way it is installed. The instructions in this manual must be

followed carefully for the installation, use and maintenance of the hoist. Any use contrary to these

instructions can be dangerous. Do not use hoist until this manual has been fully read and understood.

Always keep this manual near the hoist, available to the operator and the person in charge of maintenance.

Make sure that the safety rules are followed (harness, clearance of work areas, posting of instructions to be

followed in the area, etc.).

The Trolley can be mounted on any type of standard profile (see: setting of the flange width).







NOTE: Check the width of the runaway rail and adapt the spacing of the flanges of the trolley as

indicated by the tables.

Make sure:

That the profile is secured.

That the profile is suitable to the loads to be supported.

That the dimensions are compatible with the trolley that is to be installed.

That the electrical characteristics of the mains network conform to those of the motor.

Carry out:

1 – Disassembly of the trolley:

Remove the side plate on the counterweight side.

Position the trolley on the beam.

Refit the side plate.

(see: Tightening torques)

2 – Without disassembly of the trolley:

Install the trolley on the profile, by the end.

Fit the travel limit stops (not provided) at the end of the runway.

Check that the nuts are correctly tightened.

(see: Tightening torques)

After these checks, perform the following test with care:

1. Drive in one direction with the slow speed for a few seconds.

2. Accelerate up to the high speed and keep the high speed for 5-10 seconds.

3. Follow the same procedure in the other direction.

4. If the trolley drives in the wrong direction, swap the cables (blue and white) of the motor or the wires on

D1 and D2.

5. Check the function of the slow down and end limit switches.

R&M Materials Handling, Inc. | 4501 Gateway Boulevard, Springfield, Ohio 45502 | PH: 1-937-525-5100 | FAX: 1-937-325-5319

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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.

Figure 3. Drive wheel and idler wheel/side plates

Adjust drive wheel and idler wheel/side plates as shown above.

5.3 Electric Swivel Trolley

Figure 4. Electric swivel trolley

Table 1. Electric swivel trolley

HOIST TYPE SWIVELING

TROLLEY

TYPE

CAPACITY NUMBER OF

WHEELS

WHEEL

DIAMETER

MOTOR TYPE

C05 SWIV32 0 – 1 ton 4 100 2 x TMU 1 (35

Hz)

C10 SWIV32 0 – 2 tons 4 100 2 x TMU 2 (100

Hz)

C16-20-25 SWIV32 0 – 3.2 tons 4 100 2 x TMU 2 (100

Hz)

R&M Materials Handling, Inc. | 4501 Gateway Boulevard, Springfield, Ohio 45502 | PH: 1-937-525-5100 | FAX: 1-937-325-5319

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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.

5.3.1Swiveling trolley (3.2 tons)

Figure 5. Swiveling trolley (3.2 tons)

- CAPACITY MAX 3.2 TONS (3200 KG)

- RAY OF CURVE MINI 2.6 FEET

5.3.2 Swiveling trolley (3.2 to 5.0 tons) (NOT LOCALLY AVAILABLE)

Figure 6. Swiveling trolley (3.2 to 5.0 tons)

- CAPACITY MAX 3.2 TO 5 TONS (3200 TO 5000 KG)

- RAY OF CURVE MINI 3.9 FEET

R&M Materials Handling, Inc. | 4501 Gateway Boulevard, Springfield, Ohio 45502 | PH: 1-937-525-5100 | FAX: 1-937-325-5319

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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.