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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. Copyright 2020 © R&M Materials Handling Inc. All rights reserved.

4.2

Main Functions

4.2.1

Hoisting function

Main components of electrical chain hoist hoisting function

Pos.

Part

1

Main power board

2

Main contactor

3

Hoisting gear

4

Motor board

5

Hoisting brake (single brake in the example)

6

Friction torque limiter

7

Hoisting motor

8

Sprocket wheel

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Summary of Contents for LK10C022200

Page 1: ...016024179900103001 0 101106635 PS16792 10 1 2020 English Original instructions OWNER S MANUAL FOR CHAIN HOIST LK10C022200 101106635 1911 012 JB_Updated 01602417990010 0 ORD 01 10 2020 ...

Page 2: ... stop 11 2 5 Owner s Responsibilities 12 2 5 1 General Safety Issues 12 2 5 2 Hoisting machinery designed working period DWP 14 2 5 3 How to assess hoisting machinery designed working period 14 2 6 Intended use of the product 15 2 6 1 Duty group 16 2 7 Operating environment 17 2 8 Safety during installation 18 2 9 Safety during Usage 20 2 10 Safety during maintenance 20 2 10 1 Lockout Tagout Proce...

Page 3: ...er Set Up 61 7 3 4 Operational checks with controller enabled 63 7 4 Movements 65 7 4 1 Motor Control Methods 65 7 4 2 Lifting and Lowering Motions 66 7 5 Load Handling 67 7 5 1 Traveling movements 75 7 6 Load Control 77 7 7 Safety procedure after using the hoist 78 7 8 Hand Signals and Other Methods of Communication 78 8 MAINTENANCE 80 8 1 Why You Must Care About Maintenance 80 8 2 Service Person...

Page 4: ... altered or otherwise employed in any manner whatsoever without the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved APPENDIX DESIGNED WORKING PERIOD DWP CALCULATION 109 ANNEX ANSI HAND SIGNALS 112 APPENDIX RECONNECTABLE HOIST 113 APPENDIX REPLACING THE CONTROL VOLTAGE FUSE 115 11 CERTIFICATES 116 11 1 Load chain 116 11 2 Lower hoo...

Page 5: ...etime This manual is not intended as a substitute for proper training but provides recommendations and methods for safe and efficient operation and maintenance The equipment s owner must ensure that operators are properly trained prior to operation and at all times comply with all of the applicable and prevailing safety and other standards rules and regulations Read also the safety instructions 1 ...

Page 6: ...R OTHERWISE INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE 1 6 Manual Use Every person exposed to the manufacturer s equipment must prior to OPERATING SERVICING AND OR MAINTAINING SUCH PRODUCTS read and understand the contents of this manual and strictly adhere AND CONFORM THEIR CONDUCT WITH AND TO THE INFORMATION RECOMMENDATIONS AND warn...

Page 7: ... this product To prevent environmental risks during use please follow instructions for safe lubricant handling and disposal of waste material Proper use and maintenance improves environmental performance of this product 1 7 1 Lifecycle Environmental Impacts The lifecycle stages are production of materials components and energy transportation to factory equipment manufacturing and assembly transpor...

Page 8: ... and momentarily pressing the direction control Main isolation switch The main isolation switch is the power switch that the operator should normally use to turn power off or on Chain hoist A machine for lifting and lowering the load Inspection Looking for defects and checking the operation of the controls limiting and inspecting devices without loading the product An inpection is much more than a...

Page 9: ...mity to the product may be required to wear Personal Protective Equipment PPE Various types of PPE are available and must be selected according to the requirements of the working environment Some examples of different types of PPE are Typical PPE A Hard hat B Hearing protection C Gloves D Safety shoes E Safety goggles F Face mask G Flashlight for use in case of power failure H Overalls Appropriate...

Page 10: ...ent falls If the product does not have dedicated fixing points for fall protection it is the owner s responsibility to make sure that there are suitable fixing points in the building structure If ladders must be used personnel must practice setting and securing the ladders before using them for actual work A typical fall protection program may include Documented and established site policies and p...

Page 11: ...less he or she knows the location of the main isolation switch CAUTION Avoid turning off the main isolation switch during load movement Sudden loss of power may cause the load to swing and cause serious damage to the product personnel or load When the main isolation switch is turned on after being placed in the off position the set up procedure must be followed before the product can be used 2 4 E...

Page 12: ... service personnel and visitors that no one must ever venture underneath the load for any reason This rule must be respected at all times 2 Maintain the lighting Owners SHALL ensure that there is adequate lighting in good working order at the operating site so that the equipment can be operated safely and efficiently at all times 3 Maintain walkways and service platforms Owners SHALL ensure that t...

Page 13: ...g order 8 Fire safety Owners SHALL ensure that personnel are prepared in case of fire and that the correct fire fighting equipment is available and maintained 9 First Aid Owners SHALL ensure that in accordance with local regulations personnel are prepared in case of accidents and that a suitable first aid kit is available and maintained 10 Emergency Stop devices Owners SHALL ensure that they and t...

Page 14: ...nt DWP The DWP is the period in which provided the equipment has been used and maintained in line with the original expectations the equipment can be safely operated DWP Designed Working Period PGO Predicted General Overhaul AGO Actual General Overhaul T Time In practice the lifetime of the equipment can vary due to changes in the environment and usage of the equipment For safety in accordance wit...

Page 15: ...ct to be used to pull or drag a load sideways Side pulling accelerates hoisting machinery wear The load must always be lifted clear of the ground before performing traveling movements DANGER DO NOT ALLOW THE EQUIPMENT TO BE USED FOR LIFTING PERSONNEL UNLESS THE MANUFACTURER OR MANUFACTURER S REPRESENTATIVE HAS DECLARED IN WRITING THAT IT MAY BE USED FOR THIS PURPOSE Modifying the equipment without...

Page 16: ...duty group that it has been designed for By doing so the product should reach the original predicted lifetime WARNING Do not allow the product to be used outside the limits of the specified duty group Doing so raises the risk of mechanical failure and can shorten the product s lifetime DANGER EXCEEDING THE PRODUCT S SPECIFIED DUTY GROUP COMBINED WITH THE LACK OF MAINTENANCE CAN LEAD TO A RISK OF A...

Page 17: ...ufacturer Solutions are available to enable the product to work in a wide range of operating environments If the product that is designed for general use would be used in exceptional ambient conditions or for handling dangerous substances consult the manufacturer or the manufacturer s representative Notice for example that molten metal is considered a dangerous substance Examples of exceptional am...

Page 18: ...and equipment The owner must ensure that tools and equipment are available for installation in accordance with the sales contract Lifting equipment manlifters and test loads may be required Hand lines securely attached to the building structure should be used for lifting or lowering materials and tools Use proper safety equipment to prevent objects from falling when working in high places 5 Allow ...

Page 19: ...mental and space requirements Ensure that the operating environment and space reserved for the product in the operating location is suitable for all functions of the product 12 Check for dimensional conformance Before installation and prior to commissioning check that the supplied parts conform to the drawings instructions parts lists and structural measurements Discuss any non conformance with th...

Page 20: ...cautions NOTICE Safe access to the product is the owner s responsibility CAUTION Use experienced service personnel authorized by the manufacturer of the product for servicing the product The person servicing the product must be competent for the task and must be familiar with the servicing and inspection instructions CAUTION After a collision or overload situation inspection and repair operations ...

Page 21: ...6 Turn controllers off All controllers must be placed in the off position before starting maintenance 7 Verify that power is completely disconnected Measure between the phases and between each phase and ground to ensure that power is completely disconnected from the product 8 Lockout Tagout The equipment power source must be locked out and tagged out when necessary in accordance with local regulat...

Page 22: ...e Check that components are cool before working on them 2 10 1 Lockout Tagout Procedure During installation inspection and maintenance lockout tagout procedures must be followed in accordance with local regulations and the documented site lockout tagout policy The owner must ensure that the operators are fully aware of the applicable lockout tagout practices Lockout tagout procedures are primarily...

Page 23: ...s which generate noise Hoisting machinery Trolley bridge or other moving structures associated with the hoist Typically when the operating location is more than 5m from the hoist and associated moving components the average combined noise pressure level due to the hoist and its associated components will not exceed 70 dB A at the operating location The noise pressure level rises as the operator mo...

Page 24: ...l number A unique product identification number 5 Bar code Bar code of the serial number 6 Protection class Protection class type for enclosures explosive atmosphere markings hoist safety standard 7 Certification type CE or EX marking depending on the hoist configuration 8 Certification type CSA or EX marking depending on the hoist configuration 9 Designation of series or type Product type code 10...

Page 25: ...d 22 Rated input of traveling motor Rated input of current to the traveling motor in amperes 23 Power of traveling motor Power output of the traveling motor 24 Electrical information Rated input in main voltage control voltage frequency number of phases 1 or 3 phases 25 Fuse Rating of the fuse for the main power supply 26 Manufacturing date Manufacturing day month year 27 Manufacturer Name and ful...

Page 26: ...rotection class type for enclosures explosive atmosphere markings hoist safety standard 7 Certification type CE or EX marking depending on the hoist configuration 8 Certification type CSA or EX marking depending on the hoist configuration 9 Designation of series or type Product type code 10 Hoist duty class Hoist duty class according to standards 11 Load Maximum load that can be lifted with the pr...

Page 27: ...ltage control voltage frequency number of phases 1 or 3 phases 25 Fuse Rating of the fuse for the main power supply 26 Manufacturing date Manufacturing day month year 27 Manufacturer Name and full address of the manufacturer 28 Manufacturer reference Sales order number 29 Fault current information Suitable for use on a circuit capable of delivering not more than 5 kA RMS symmetrical amperes SCCR 5...

Page 28: ...e Product identification data B Bar code sticker Product order references 1 Motor type code Exact model of the product 2 Motor number Unique number which identifies the unit 3 Input Acceptable main voltage range and frequency of the power source that the product can be connected to 4 Output Voltage range the product is able to provide at a specified output capacity 5 Phases Number of phases of the...

Page 29: ...t 2020 R M Materials Handling Inc All rights reserved 3 3 Manufacturer Manufacturer R M Materials Handling Inc 4501 Gateway Boulevard 45502 SPRINGFIELD OH USA Address Note For further information about the product operational training or servicing please contact the closest representative of the manufacturer 3 4 Standards and directives This state of the art product has been designed and manufactu...

Page 30: ...nsent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 4 CONSTRUCTION 4 1 Identifying key parts of the hoist Pos Part Description 1 Hoisting machinery Equipment composed of hoist frame hoisting motor gear and brake 2 Hook Composed of hook and hook block 3 Suspension hook The upper hook with which hook suspended hoist is fixed to its support structure 4 Ch...

Page 31: ...yright 2020 R M Materials Handling Inc All rights reserved Pos Part Description 1 Hoisting machinery Composed of hoist frame hoisting motor gear and brake 2 Hook Composed of hook and hook block 3 Traveling machinery Composed of traveling motor gear and brake 4 Electrical cubicle for trolley movement Electrical control system for trolley drive 5 Trolley Composed of trolley frame and traveling wheel...

Page 32: ...herwise employed in any manner whatsoever without the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 4 2 Main Functions 4 2 1 Hoisting function Main components of electrical chain hoist hoisting function Pos Part 1 Main power board 2 Main contactor 3 Hoisting gear 4 Motor board 5 Hoisting brake single brake in the example 6 Frict...

Page 33: ... screw 2 Gear 3 Chain sprocket 4 Motor 5 Friction torque limiter 6 Brake 7 Motor torque 8 Brake torque Motor torque path The motor 4 rotates the axle which makes the hoisting gear 2 helical steps turn The gear transfers the motor power over the chain sprocket 3 to the hoisting chain which then moves according to the selected direction up or down The assembly includes a friction torque limiter 5 th...

Page 34: ...ment in the event of a malfunction or another emergency situation Using the emergency stop button e g as a hoisting limit to stop the hoisting motion can cause the load to swing unexpectedly 4 2 1 Traveling function Pos Part 1 Motor 2 Wheel 3 Electric panel 4 Traveling gear 5 Trolley Operation of the traveling function When the relevant button is activated on the controller the trolley travels hor...

Page 35: ...fore the main brake For more information about the secondary brake see chapter Checking the brake lining Upper and lower mechanical limit switch The mechanical limit switches are adjusted to prevent the hook from moving too high or low which may cause damages When the chain stop touches the limit switches it is activated which stops the hook movement The upper limit switch stops the upward hook mo...

Page 36: ...anner whatsoever without the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 4 3 1 Safety Signs Safety signs inform the operator about potential hazards and also about special features concerning the product s operation Failure to avoid dangers identified by these signs can result in death or serious injury Sign Description Locati...

Page 37: ...tructions in chapter Safety first Installation procedure requires special skills qualified personnel and tools e g the clutch adjustment tool ChainQ and chain inserting tool to ensure safe and reliable operation of the product Installation work shall be carried out only by authorized service personnel or an experienced service technician authorized by the product s manufacturer Note For the use of...

Page 38: ...f not contact your supplier To remove the hoist from the box first remove the temporary transport supports The chain bucket is not fixed to the hoist during transportation so lift the hoist and the chain bucket from the box simultaneously Note that the chain connects the bucket and the hoist IMPORTANT If the hoist is used in outdoor conditions drill a D10 mm sized hole to the bottom of the chain b...

Page 39: ...ore lifting the hoist 5 1 2 Lifting the hoist Evaluating the weight of the hoist It is important to know the weight of the hoist before starting to lift it so that you can select an appropriate lifting device for the task and prevent overloading The weight of the hoist can often be found from the packing list the technical documents or the hoist data plate Auxiliary lifting device The hoist is usu...

Page 40: ...whatsoever without the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved WARNING Never attempt to lift a load before ensuring that it weighs less than the maximum permitted load of the auxiliary lifting devices Overloading can damage the auxiliary lifting devices Lifting points Hook or eye suspended models Motorized trolley or push ...

Page 41: ...wer supply must be OFF and locked before making any electrical connections The lockout tagout procedures must be followed in accordance with the local regulations See chapter Lockout tagout procedure DANGER GROUNDING AN IMPROPER OR INSUFFICIENT GROUND CONNECTION CREATES AN ELECTRICAL SHOCK HAZARD WHEN TOUCHING ANY PART OF THE HOIST OR TROLLEY IN THE POWER SUPPLY CABLE THE GROUND WIRE WILL BE EITHE...

Page 42: ...rights reserved 5 2 1 Installing pendant cable 1 2 Remove the four screws that hold the cover plate in place Leave the cover plate hanging from the strip 3 4 Disconnect the power supply plug from the power supply socket Slide the power cable assembly out It is put back in place later when the main power is connected power plug connected to power socket 5 6 If the pendant is not already pre assembl...

Page 43: ... socket Open the cable gland and peel the wires off from the length needed 3 4 Cut the cable to selected length and peel the wires Tighten the cable gland 1 and shorten the retaining wire 2 Make sure that the retaining wire is shorter than the cable 3 so that the cable itself will not be disconnected accidentally 5 Connect the wires to the socket Carry out the following procedures before connectin...

Page 44: ... plug 3 phase hoists Pay attention to the order of the wires to ensure the correct phase sequence Connect the power control board PCB connectors L1 L2 L3 with the phases 1 2 3 according to the correct phase sequence 1 phase hoists Connect the power control board PCB connector with the phase L according to the information given in the sticker for the 4 pole plug N N L GND N neutral L phase GND grou...

Page 45: ... and commissioning of the hoist The equipment shall not be used before proper commissioning The commissioning procedure requires special skills and tools to ensure safe and reliable operation of the equipment Commissioning shall be carried out only by authorized service personnel or an experienced service technician authorized by the manufacturer or manufacturer s representative Before commissioni...

Page 46: ...ion commission and maintenance lockout tagout procedures must be followed in accordance with local regulations and the documented site lockout tagout policy See chapter Lockout Tagout procedure 1 Ensure that there are no hazards from loose items Items which are not properly secured to the product such as tools or detached components could move or fall accidentally with potentially serious conseque...

Page 47: ... Tightening torques 4 Electrical connections With the product disconnect OFF check the proper electrical grounding of the product Check that the connections of electrical devices comply with the wiring diagrams and meet local requirements In particular check connections that affect the safety and controlling of the equipment Check the condition of wiring and connections 5 Chain Check that the chai...

Page 48: ...he express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved DANGER AN IMPROPER OR INSUFFICIENT GROUND CONNECTION CREATES AN ELECTRICAL SHOCK HAZARD WHEN TOUCHING ANY PART OF THE HOIST OR TROLLEY IN THE POWER SUPPLY CABLE THE GROUNDING WIRE IS EITHER GREEN WITH YELLOW STRIPE OR SOLID GREEN IT SHOULD ALWAYS BE CONNECTED TO A SUITABLE GROUND ...

Page 49: ...e purpose The load falls down if the lifting device fails WARNING Never use a damaged lifting device Carefully inspect lifting devices before using them The load falls down if the lifting device fails WARNING Only use the lifting devices in accordance with the manufacturer s instructions WARNING Never lift a load that is heavier than the rated capacity of the lifting device and never use an overlo...

Page 50: ...s not cause any disturbance to other radio controlled equipment Check the functionality of the push buttons joysticks and switches Check that all motions occur to the correct direction Make sure that desired functions occur when operating the push button joystick or switch Check that the hook movement corresponds to the controller direction by driving the hook carefully in down direction If the ho...

Page 51: ...on adjust the limits according to the instructions given in chapter Limit switch If the limits cannot be adjusted the rotating geared limit switch needs to be replaced Functional description of the rotating geared limit switch 2 step rotating geared limit switch The 2 step geared limit switch works together with the internal controls as an adjustable upper and lower stop limit 4 step rotating gear...

Page 52: ...Inc All rights reserved CAUTION Any defects or abnormalities which are detected during the commissioning must be investigated and corrected in accordance with the instructions relevant to the component in question 8 Trolley Run the trolley at least 3 5 times over the whole length of the girder Check that the trolley moves smoothly Check that the wheelbase of the trolley is correctly adjusted 9 Bra...

Page 53: ...e hoists Check the motor current at each phase during the hoisting motion with the rated capacity The current should be in balance in all phases and it may not exceed the ratings for the motor Check the current with both hoisting speeds 1 phase hoists Check the motor current during the hoisting motion with the rated capacity The current may not exceed the ratings for the motor 5 Running temperatur...

Page 54: ...o third parties altered or otherwise employed in any manner whatsoever without the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved NOTICE Local requirements may demand other commissioning testing to be performed before the product can be used Make sure all the local requirements are fulfilled All optional features must be tested b...

Page 55: ...Check that all tools and materials used during installation are removed from the hoist and the track 3 User training Ensure that the hoist operator and supervision personnel are aware of the need for user training The authorized service organization of the hoist manufacturer can arrange user training by separate agreement 4 Handover documents Check the documents delivered with the hoist Check that...

Page 56: ...nsibility of the owner and the equipment s operating personnel Only those Authorized Personnel and Qualified Personnel who can demonstrate that they have read and understood this manual and that they understand the proper operation and maintenance of the product should be permitted to work with it Failure to adhere to the instructions and warnings provided in this manual can result in serious inju...

Page 57: ...s SHALL be familiar with proper rigging procedures 10 Operators SHALL carry out daily inspections 11 Always follow the local regulations Operators SHALL NOT 1 Operators SHALL NOT operate the equipment when under the influence of alcohol or drugs Alcohol and drugs can impair judgment and thereby cause a hazard 2 Operators SHALL NOT operate the equipment when under medication which may cause a hazar...

Page 58: ...he equipment will accelerate up to the maximum speed Note If you press a pushbutton for example hoist UP while the opposite direction pushbutton is pressed for example hoist DOWN the lifting device will not change direction Note Sudden speed changes increase wear on motors and brakes and can cause an overtemperature in the motor s 7 2 2 Controller The layout of controls may vary from product to pr...

Page 59: ...ret 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 Copyright 2020 R M Materials Handling Inc All rights reserved WARNING Operating a product with an abnormal condition or malfunction can result in serious injury or death or serious damage to the product ...

Page 60: ...3 Visually check to see if there are any oil leaks from the product 4 Visually check the chains for any deformation damage or twists Check the chain for cleanness and correct lubrication according to the instructions given in chapter Lubrication 5 Inspect the load hook for nicks gouges deformation of the throat opening wear on the saddle or load bearing point and twisting Also check that the hook ...

Page 61: ...he emergency stop button pressed down check that the product does not move when the direction control pushbuttons are pressed This verifies that the emergency stop button is working properly 3 Control devices without power Check for smooth mechanical operation of each pushbutton joystick or safety switch on the controller 7 3 3 Controller Set Up WARNING Never release the emergency stop button and ...

Page 62: ...y 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 Copyright 2020 R M Materials Handling Inc All rights reserved 4 Energize the product by pressing the start pushbutton if available Now the controller is ready for operational checks ...

Page 63: ...horns gongs bells sirens beacons strobe lights are working correctly before using the hoist 2 Control devices with power Starting at low speed check that movements correspond to the controller labels Check that the brakes operate in all directions and that the speed increases as it should do in relation to the control 3 Noise Listen for unusual noises 4 Limit switch Upper and lower mechanical limi...

Page 64: ...ing to operate the hoist Checking the operation of the limit switch First check the operation of the limit switch For instructions on how to check the operation of the limit switch refer to chapter Test run without load Adjusting the limit switch After checking the operation of the limit switch adjust the upper and lower limits according to the instructions given in chapter Limit switch If the lim...

Page 65: ...e underneath or near the load could cause death or serious injury NOTICE Do not deliberately use mechanical limit switches to stop the motion Always stop the motion before reaching the mechanical end limits by using the control devices on the controller NOTICE If the product malfunctions during use push the emergency stop button and contact the supervisor Note Motors get hot when they are running ...

Page 66: ...nding to the force applied to the direction control The motor moves at its slowest speed when the control is partially pushed and at its maximum speed when the control is fully pushed The motor stops moving when the pushbutton is released Trolley 7 4 2 Lifting and Lowering Motions Before lifting After securely attaching the load to the lifting device the hoist must be correctly positioned and atta...

Page 67: ... load The hook slings and harnesses must be positioned so that the pulling force of the product lies on the load s center of gravity so that the load is balanced When the operator begins to hoist a load he or she shall check that it is properly balanced before lifting it high off the ground If the load is not balanced lower it down and adjust the lifting point 1 Lifting centrally balanced loads Th...

Page 68: ... cause the trolley or hoist to jump NOTICE Avoid shock loading the product Shock loading the product could damage the product or the load CAUTION After a shock load do not use the equipment before the authorized service personnel or an experienced service technician that is authorized by the manufacturer or manufacturer s representative has determined that the equipment is safe to use The usage of...

Page 69: ...erved Load handling 1 To avoid damaging the hook lifting devices must only be positioned on the load bearing surface of the hook That is the lowest point of the hook 2 Ensure that the hook safety latches are closed Check that the safety latch is not subjected to any force by the load 3 The weight of the load must be centered on the center line of the hook forging so that the load does not bend the...

Page 70: ...out the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 5 The hoist must be positioned directly above perpendicular to the load so that there are no side pulling forces The jib arm is liable to swing towards a load which is not situated directly under the hoist 6 Do not drag the load along the ground NOTICE Never drag loads or pul...

Page 71: ...at it does not collide with anything or fall from the lifting device NOTICE Never add any load to a hook that is already loaded NOTICE Do not always drive the hook up to the highest or down to the lowest position It is not recommended to use the mechanical limit switches as operational end stops This can cause damages and lead to dangerous situations or accidents NOTICE Do not drive the hook up to...

Page 72: ...tten consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 1 Ensure that everything is ready for lifting 2 If the hoist has a horn push the horn pushbutton to warn people nearby that a load is about to be moved 3 Gently push the UP pushbutton to slowly take up the slack from the chains or sling before lifting the load from the ground 4 Continue to push...

Page 73: ...ights reserved 6 Release the UP pushbutton gently when the load is at the desired height Do not raise the load higher than is needed to avoid colliding with objects NOTICE Do not raise the load higher than necessary to avoid colliding with objects on the ground during movements Lowering 1 Ensure that the landing area is clear of people and obstacles WARNING When operating the hoist make sure that ...

Page 74: ... M Materials Handling Inc All rights reserved 2 If the hoist has a horn push the horn pushbutton to warn people nearby that a load is about to be moved 3 Push the DOWN pushbutton to lower the load 4 Decrease the lowering speed by gradually releasing the DOWN pushbutton when the load is approaching the ground 5 Fully release the DOWN pushbutton when there is slack in the lifting device but before t...

Page 75: ...ents of the trolley End stops are fitted to the runway of the trolley to limit travel of the trolley respectively Bumpers are fitted to absorb the impact if the trolley runs into the end stops NOTICE Stops and bumpers are intended for the emergency use only Do not use buffers and stops as operational means to stop the traveling motion during normal operations Manual push trolley 1 Move the trolley...

Page 76: ...ay cause hazardous situation or injuries Trolley movements Two speed contactor control With contactor control an automatic electric brake activates as soon as the direction control is released In some cases this fast deceleration could cause the load to swing The operator can reduce brake wear and load swing by accurately judging where the trolley will stop so that the brake is not applied more of...

Page 77: ...l the load at all times to prevent uncontrolled movements such as load swing or rotation If the load has a tendency to rotate or swing a third person can guide the load with a tag line provided that it is safe to do so Guiding or steadying loads by hand Guide and steady the load by controlling it with your hands WARNING Never PULL on the load or chain Only move the trolley by PUSHING on the load h...

Page 78: ...ad height is recommended 3 If applicable park the jib arm so that it does not obstruct the movement of other hoists for example 4 Engage the emergency stop button 5 Turn off power to the hoist 6 Check the hoist for any visible damages 7 Report all observed defects and abnormalities in equipment or operation to the foreman and to the next operator WARNING Always remove the product from service imme...

Page 79: ...gnals Other standards for hand signals exist The operator must be trained in the use of appropriate hand signals A copy of the hand signals should be displayed at the operator s station and anywhere else where it could be useful Special operations may require additional hand signals Special signals must be agreed upon and understood before hoisting It should not be possible to confuse special sign...

Page 80: ...actions excluding the daily actions performed by operators must be done by service personnel who are authorized by the manufacturer or manufacturer s representative The owner shall ensure that replacement parts and materials meet the specifications defined by the product manufacturer WARNING Do not modify the product without the manufacturer s permission Any modifications to the product structures...

Page 81: ... 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 Copyright 2020 R M Materials Handling Inc All rights reserved ...

Page 82: ... the product s manufacturer or manufacturer s representative 8 3 Inspections The operator owner of a product shall carry out regular inspections to ensure the safe operation The product s owner shall also keep record of the inspections and findings Periodic inspections must be carried out by authorized service personnel or experienced service technician authorized by the product s manufacturer or ...

Page 83: ...ry working shift and the monthly inspections as well as the following inspections General Component Objective Suspension part Check the suspension part for nicks gouges deformations or wear 8 3 4 Annual inspections The annual inspection items include the same check ups as the daily see chapter Checks to be done before every working shift monthly and quarterly inspections as well as the following i...

Page 84: ... operation of the motors Brakes Check the operation and wearing of the brake For instructions on how to check the brake wear refer to chapter Checking brake lining Mechanical component Component Objective Reference Chain sprocket Check the condition of the chain sprocket With two fall hoists also check the return sprocket For instructions on how to replace the return sprocket see Replacing return ...

Page 85: ...control electrics and brake remove the end cover as follows 1 2 Unscrew the four screws of the end cover and remove the cover Leave it hanging from the strip Locate the brake check hole in the brake assembly 3 4 Measure the depth of the check hole gap with a caliper Compare the measured value with the maximum allowed value for the brake wear given in the brake sticker Note The brake measurement va...

Page 86: ...itten consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved Secondary brake double brake option The secondary brake located in the double brake assembly that is available as an optional feature works only as a back up brake for the main brake It will be the functional brake only if the main brake is damaged in a way that it cannot hold the load If the ...

Page 87: ...sting tools Note The static value of the factory setting is 1 3 1 5 x the nominal load The value depends on the hoisting speed Once the hoist has been in use the linings set and the static loading is reduced Note To adjust the friction torque limiter it is recommended to use the chain force measuring device for example the ChainQ tool Nevertheless it is possible to use loads as well for the adjust...

Page 88: ...decrease the torque Note Make sure not to over tighten the adjustment screw since this can damage the springs of the torque limiter After the adjustment lock the adjustment screw with the locking nut by turning the pipe key counter clockwise and then remove the tools Turn on the power to the hoist 1 Hook the original test load and check that it can be lifted with both the slow and fast speed 2 Hoo...

Page 89: ...ed by the product s manufacturer See the lubricant tables for more information Use only fresh oils greases Do not mix up different kinds of grease The information about the safe handling risks and handling as waste of each chemical is described in the Safety Data Sheet that is available from manufacturer of the lubricant Note The equipment can have a synthetic lubricant as a factory installed lubr...

Page 90: ... without the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 7 The specified lubrication periods apply in favorable conditions and normal use More frequent lubrication is recommended in more demanding conditions and in heavy use 8 Trolley Verify that the gear teeth of the open gear transmission are entirely lubricated Note Do not ...

Page 91: ...starts immediately after taking the hoist into use Lubricate the chain carefully before taking the hoist into use for the first time Lubricating the chain The target of the chain lubrication is to have enough lubricant between the chain links The lubricant grease or oil must be applied on the contact surfaces between the chain links Make sure that you add the new layer of lubrication always on a c...

Page 92: ...hain drive of the hoist reduces drastically Failing to maintain the chain can result in a failure of the chain Check the proper and sufficient lubrication of the chain visually between the chain links Well lubricated Completely dry and damaged Figure 4 Checking the chain lubrication Lubrication intervals of the chain Defining the required maintenance interval for the chain depends on the use of th...

Page 93: ...is based on use of the hoist as an industrial indoor application under conditions where there are no external particles and where the hoist is in continuous use with full load Nbr of chain sprockets 1 2 3 4 Chain reeving 1 fall 2 falls 1 fall LH2 3 falls 2 fall LH2 4 falls Example hoist construction Oil cycles 1 6000 3000 2000 1500 Grease cycles 1 12000 6000 4000 3000 1 Cycle One work cycle from p...

Page 94: ...Copyright 2020 R M Materials Handling Inc All rights reserved 8 6 Lubrication charts Pos Component Intervals 1 Secondary output shaft traveling transmission Annual 2 Hoisting transmission Lubricated for the designed working period of the product 3 Traveling wheel bearings Lubricated for the designed working period of the product 4 Chain From 1 week up to a year depending on the usage Return sprock...

Page 95: ...lable as an option Food safety lubricant grease Installation Trade name and number Quantity l pt Factory installed Klübersynth UH1 14 151 7 5 0 16 2 Hoisting transmission gear Lubricated with oil Lubrication will last for the design working period of the hoist Installation Trade name and number Quantity Factory installed Dexron III Lubricated for the design working period of the hoist NOTE If you ...

Page 96: ...inimum of one week to one year depending on the use of the hoist If the chain is dry clean it before lubrication to avoid dust accumulation and damaging the sprockets and chain guides Standard Grease lubricant Installation Trade name and number Quantity Lubricate before 1st run Renolit LZR 000 As required Available as an option Oil lubricant Installation Trade name and number Quantity Lubricate be...

Page 97: ...ts have to be replaced or repaired according to the instructions given by the manufacturer Only authorized service personnel or an experienced service technician who is authorized by the manufacturer or the manufacturer s representative may conduct a General Overhaul service The data and the information about conditions based on which the General Overhaul should be performed can be provided for a ...

Page 98: ...proved when an expert engineer has entered the conditions for further utilization into the test and inspection booklet Completion of the general overhaul must be confirmed in the test and inspection booklet and a further period of utilization in accordance with FEM 9 755 must be entered INSPECTION AND MAINTENANCE SCHEDULE Action Chapter s Before first run Before every working shift With every annu...

Page 99: ...product to use after long period out of service Note Carry out these actions also if the product has been exposed to extreme weather conditions For storing conditions see the Appendix Transportation and storing the product When taking the product into use after a long period out of service do the checks according to the instructions in chapter Checks to be done before every working shift Before re...

Page 100: ...controls must be placed in the OFF position safety switches must be opened and the main isolator switch must be turned off The product must be electrically isolated before dismantling commences Make sure that all personnel involved are aware that the product will be dismantled before dismantling commences The owner must prevent unauthorized persons and bystanders from walking on or below the work ...

Page 101: ...e of manufacturer s proposals for adequate waste handling methods NOTICE Use always licensed recycling companies 1 Metals should be recycled 2 Electronics and electromechanical components should be collected separately and recycled Some electrical parts may be treated as hazardous waste e g standard fluorescent lamps contain mercury 3 Batteries and other energy storage components may contain hazar...

Page 102: ...l rights reserved 10 TECHNICAL DATA 10 1 Technical features The basic technical specifications can be found on the hoist s data plate 10 2 Tightening torques The recommended tightening torques for steel are presented in the following table Bolt size Tightening torques Strength 8 8 Nm Ft lb M4 2 7 2 0 M5 5 4 4 0 M6 10 6 8 M8 23 17 0 M10 45 33 0 M12 77 56 6 M14 125 92 M16 190 140 M18 275 202 M20 385...

Page 103: ...es between links for wear Replace a chain with excessively pitted corroded nicked gouged twisted or worn links with a factory approved chain 2 Measuring the link thickness d Measure the dimension d at several points of the chain and calculate the dimension dm dm d1 d2 2 0 9 dn dn Nominal t Pitch Criteria Chain size d t 4x11 5x14 7x20 9x27 11 3x31 dn 4 5 7 9 11 3 dm max mm in 3 6 0 142 4 5 0 177 6 ...

Page 104: ...e chain guide and the chain sprocket should also be checked and these should be replaced if necessary For instructions on how replace the return sprocket see appendix Replacing the return sprocket for 2 fall bottom hook Note If a single link is defective in any way whatsoever the chain must be replaced CAUTION Do not assume that a load chain is safe because it measures below the replacement points...

Page 105: ... the chain 1 2 Detach the chain bucket Remove the endstop by pulling out the rubber 3 and opening the clutch 1 2 3 4 Open the hook block and remove the chain Remove the chain from the hoist by driving the motor 5 6 Feed the new chain to the hoist Fix the chain to the chain tool and feed it through the chain guide Fix the hook block make sure that the chain is fixed to the hook block with the pin T...

Page 106: ...t twisted or opened more than 10 degrees from the plane of the unbent hook which could cause the hook latch to bypass the hook tip WARNING If the hook is twisted or has an excessive throat opening it indicates an abuse or an overloading of the hoist In that case inspect also the other load bearing components of the hoist for damage 2 Measuring the bottom hook opening a2 If the maximum dimension of...

Page 107: ... chapter Adjusting the friction torque limiter The braking path1 is more than 10 cm 3 9 in The brake lining is worn Measure the brake lining wear and replace the brake components if necessary For instructions on how to measure the brake wear see chapter Checking the brake lining The traveling2 or hoisting direction does not correspond to the direction indicated on the controller3 The power supply ...

Page 108: ...porting products is prohibited if your alertness or working ability is impaired for example by medication illness or injury The load must be securely fastened during transportation During loading and transportation the product package shall be orientated in the same way as when it was received from the manufacturer Inverting the product could cause lubricants to leak Storage Instructions The produ...

Page 109: ...N the average number of work cycles per hour cycles h T the average daily working time h V the maximum hoisting speed m min as shown on the data plate Use the following formula to calculate Ti the motor operating hours total lifting time per inspection interval 60 2 V J T N H Ti For example if we use J 180 days H 5 m N 20 cycles h T 12 h V 5 m min 1440 60 5 180 12 20 5 2 i T Step 2 Calculate the a...

Page 110: ...lculate Si hours Select the value of X from the table below i mi i T K X S Product Value of X With counter and log book 1 2 With log book 1 4 Without counter log book or CMS 1 5 Record the value of Si in the log book This value will be needed for the future DWP calculations For example if we use X 1 2 Kmi 0 124 and Ti 1440 272 214 1440 124 0 2 1 i S Step 4 Calculate the actual duration of service ...

Page 111: ... S The two final columns on the same row will tell you the remaining DWP and the estimated remaining service life Hoist operating group marked on hoist s rating plate DWP Estimated remaining service life years M3 1Bm M4 1Am M5 2m M6 3m M7 4m M8 5m Actual duration of service S h 0 0 0 0 0 0 100 10 40 80 160 320 630 1250 90 9 80 160 320 640 1260 2500 80 8 120 240 480 960 1890 3750 70 7 160 320 640 1...

Page 112: ...iption ANSI hand signal Hoist With forearm vertical and forefinger pointing up move hand in a small horizontal circle Lower With arm extended downward forefinger pointing down move hand in a small horizontal circle Trolley travel Palm up fingers closed thumb pointing in direction of motion jerk hand horizontally Bridge travel Arm extended forward hand open and slightly raised make pushing motion i...

Page 113: ...All rights reserved APPENDIX RECONNECTABLE HOIST Only qualified personnel is allowed to do the reconnecting of the hoist CAUTION When reconnecting the hoist to a different voltage than previously the sticker attached to the product indicating the voltage used shall be changed accordingly Power board Turn the switches to correct positions according to the main supply voltage used Voltage V Switch p...

Page 114: ...ret 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 Copyright 2020 R M Materials Handling Inc All rights reserved Brake connection Add the brake leads to correct plugs The upper plug on the board is for the 460 V and the lower plug for the 208 V and 230 V ...

Page 115: ...s fuse Check the fuse for burn marks If burn marks can be found this is an indicator that fuse is blown Replace the fuse Check the filament If the filament is inconstant this is an indicator that the fuse is blown Replace the fuse If the filament is constant and there no burn marks on the fuse the fuse is in good condition Ceramic fuse If a ceramic fuse is used use a continuity checker or a multim...

Page 116: ...aterials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 11 CERTIFICATES 11 1 Load chain Order N 01602417990010 0 ORD TECHNICAL CHARACTERISTICS Hoist type Chain type Standard Diameter d pitch t 7 20 mm K05 only if high hoisting speed 16 24 4 11 mm Class T Grade HEOG80 Maximum working stress 159 4 N mm Standard EN 818 7 Markings 6 x t H16T Maximum working load M3 1250 kg ...

Page 117: ...thout the express written consent of R M Materials Handling Inc Copyright 2020 R M Materials Handling Inc All rights reserved 11 2 Lower hook Order N 01602417990010 0 ORD DIMENSIONS DIN Dimensions mm M a1 a2 a3 b1 b2 e1 h1 h2 t1 t2 05 08 20 20 43 48 32 36 49 54 29 35 24 29 105 116 37 44 31 37 39 43 14 5 14 5 Note the a2 dimensions is the free space with the hook latch TECHNICAL CHARACTERISTICS Sta...

Page 118: ...levard 45502 SPRINGFIELD OH USA Name and address of the person authorized to compile the technical file Loïc Bernard 2 Boulevard de l Industrie 28500 VERNOUILLET FRANCE The manufacturer declares that the Product description Electric Chain Hoist Serial number 101106635 Manufacturer s reference Customer s reference 1911 012 JB_Updated is in conformity with the relevant provisions of the Machinery Di...

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