Sistemas de Levantamiento de Cargas

LoadMate Chain Hoist
LM5 Manual
Revision 3
R&M Materials Handling, Inc

Springfield, Ohio USA
: 800 955-9967
web: www.rmhoist.com
R&M LOADMATE CHAIN HOIST
XC
01
51
P0
LM 5
3PH 208/230/460/575V
INSTALLATION, OPERATION AND MAINTENANCE

INSTRUCTIONS
JOB NO.
NO. :
SERIAL NO.
NO. :
(RECORD HOIST SERIAL NUMBER FOR FUTURE REFERENCE)
08/22/01
Bulletin: RM-LM5-MAN-1999-3-ENG.doc
TABLE OF CONTENTS
Section
Page
Table of Contents..................................................................................................... i
Foreword .................................................................................................................. iii
Standard Guarantee and Warranty................................................................. iii
Guarantee on Purchased Items....................................................................... iv
How to Order Repair Parts Correctly ............................................................ iv
Minimum Charges ......................................................................................... iv
Return of Parts ............................................................................................... iv
Claims for Damage in Shipment.................................................................... iv
1. Installation
General........................................................................................................... 1-1
Mounting........................................................................................................ 1-2
Lubrication..................................................................................................... 1-2
Load Hook Throat Opening ........................................................................... 1-3
Power Connections ........................................................................................ 1-3
2. Initial Start-Up
Proper Hook Motion (Hoist Motor Rotation) ................................................ 2-1
Proper Trolley Motion ................................................................................... 2-2
Mounting the Chain Container ...................................................................... 2-2
No Load Operational Checks......................................................................... 2-3
Torque Limiter ............................................................................................... 2-3
Upper Hook/Trolley Assembly...................................................................... 2-3
Load/Run Test................................................................................................ 2-4
3. Safe Operation Practices
General........................................................................................................... 3-1
Dos and Donts (Safe Operation of Hoist) ................................................... 3-1
4. Operation/Maintenance
Typical Construction...................................................................................... 4-1
Motors............................................................................................................ 4-2
Brake/Torque Limiting Device ...................................................................... 4-2
Operation............................................................................................ 4-2
Adjustment of the Limiter.................................................................. 4-3
Adjustment of the Brake .................................................................... 4-4
Frame ............................................................................................................. 4-5
Load Chain..................................................................................................... 4-5
Load Chain Installation.................................................................................. 4-6
Removal of the Chain ........................................................................ 4-7
Replacement of the Chain .................................................................. 4-7
Fall Stop Assembly........................................................................................ 4-9

Bottom Block, Load Wheel and Suspension Hook ....................................... 4-9
Hook Specification............................................................................. 4-10
Suspension Hook ............................................................................... 4-11
Measurement of the Wear on the Suspension and Lifting Hook ....... 4-11
Controls/Enclosure......................................................................................... 4-12
Printed Circuit Boards ................................................................................... 4-14
Circuit Diagrams............................................................................................ 4-18
Pendant Station .............................................................................................. 4-20
5. Preventative Maintenance
Maintenance Table......................................................................................... 5-1
Lubricants ...................................................................................................... 5-2
Spare Parts Replacement Table ..................................................................... 5-2
Screw Tightening Torques ............................................................................. 5-2
Troubleshooting ............................................................................................. 5-3
6. Spare Parts Identification
ii
FOREWORD
This manual has been prepared to acquaint you of the procedures necessary for the installation,
operation, and maintenance of the hoist you have purchased.
Proper installation is important to the ultimate performance of this equipment. Careful study of
and adherence to the instructions will help ensure safe, dependable operation. It is also
recommended that you keep this manual readily accessible to operators as well as maintenance
and safety personnel.
Information in this manual is subject to change without notice.
Standard Guarantee and Warranty
R&M Materials Handling, Inc., hereinafter called the Company, will repair or replace, at its
option, equipment or parts with defects in material and/or workmanship identified within two
years from shipment from R&M for electric chain hoists. Should a problem develop, contact the
factory or authorized repair center for written authorization to inspect, repair, or replace.
The Warranty Administrator will provide a written Return Goods Authorization (RGA) for return
of the equipment. All equipment shall be returned freight prepaid to the factory or authorized
repair center; the RGA number should be clearly indicated. If the problem is covered under
warranty, the equipment will be repaired or replaced and returned freight prepaid. If inspection
reveals that the problem is not warranty related, the purchaser will be provided a quotation for
repairs. If no purchase order is provided for repairs, the equipment will be returned freight collect.
The purchaser is responsible for removal and installation. In event that replacement parts are
issued for warranty related field repairs, parts will be invoiced at net value; original parts must be
returned (freight collect) for failure evaluation. If evaluation reveals a warranty situation, a credit
will be issued against the replacement parts invoice.
This warranty does not cover failure due to normal operating wear and tear. All products shall be
regularly maintained and operated in accordance to the equipments Installation, Operation and
Instruction manual. The original warranty period is not renewed or extended by repair work or
parts supplied after the original ship date.
This warranty does not cover damage due to abuse from side pulling of load, excessive jogging,
eccentric loading, chemical exposure not specified in order, damage resulting from an accident, or
damage resulting from improper storage or handling prior to placing the equipment in service.
Failure of equipment to meet published performance specifications due to abnormal operating
conditions beyond R&Ms knowledge or control shall not be considered defective workmanship
and/or material unless R&Ms examination discloses such a defect. Correction of such defects
shall constitute fulfillment of this warranty.
This warranty is void if parts or materials used in the repair or maintenance or R&Ms equipment
are not supplied or approved by R&M. Any modification or change made by the Purchaser
without R&Ms written approval will void the warranty.
iii
How to Order Repair Parts Correctly

The Parts Catalog section of this manual covers replacement parts required for your R&M
Materials Handling, Inc. hoist. To ensure prompt service, each repair parts order must contain the
following information:
1. Hoist serial number (affixed to hoist)
2. Capacity
3. Reference number from spare parts identification sheet
4. Quantity
5. Description
6. Voltage, phase, cycles
7. Correct shipping destination.
The Serial Number of your hoist will be found on the nameplate affixed to the hoist. Without this
serial number we cannot be sure of sending you correct parts, so always mention the serial
number for parts, service, etc.
All verbal orders must be immediately followed up with a written confirmation since the
company cannot assume responsibility for the correctness of the verbal message.
R&M Materials Handling, Inc. spare parts are available locally in major industrial areas. Contact
our Customer Service Department should you desire the name and address of the Authorized
Stocking Parts Distributor for your area.
Minimum Charges
All orders for repair parts are subject to a minimum charge.
Claims for Damage in Shipment
All shipments are carefully inspected and are delivered to the carrier in good order. Upon receipt
of shipment caution should be exercised so that there is no loss or damage. If damage has
occurred, refuse to accept the shipment until the carrier makes the proper notation to that effect.
In the event of concealed loss or damage, notify the carrier immediately. By following these
suggestions you will encounter less difficulty collecting your claim.
iv

: 800 955-9967

LM5 Manual
Revision 3
Before proceeding with the installation, operation or maintenance of the hoist it is important that
the installation, operating, and maintenance personnel read this bulletin carefully in order to
ensure the safe and efficient use of the hoist.
Also, it is strongly recommended that the personnel responsible for the operation, inspection, and
servicing of this hoist, read and follow the Safety Standard ANSI B30.16-1993 (or current
revised edition). This standard covers Overhead Hoists (under-hung) as promulgated by the
American National Standards Institute and is published by the American Society of Mechanical
Engineers. Copies of this publication are available from the Society at United Engineering
Center, 345 East 47th St., New York, NY 10017.
If any instructions are unclear, contact the manufacturer or distributor of the hoist before
attempting to install or use the hoist.
IMPORTANT
Electrical wiring diagrams are included with this manual. Also, if an
optional push or motorized trolley has been purchased, a manual has
been included for it.
If these items are missing, contact the manufacturer or distributor
before attempting to install or use the hoist.
Manufactured by:
R&M Materials Handling, Inc.

4501 Gateway Boulevard
Springfield, OH 45502
Tel. 937-328-5100
Fax 937-325-5319
Visit our website: www.rmhoist.com
08/22/01
Bulletin: RM-LM5-MAN-1999-3-ENG.doc

: 800 955-9967

LM5 Spare Parts
Revision 3
Index of Exploded Illustrations and Parts Lists

HOIST BODY ..................................................................................................................2
GEAR MECHANISM & VERSION 1 BRAKE ...................................................................4
GEAR MECHANISM & VERSION 2A BRAKE ................................................................6
GEAR MECHANISM & VERSION 2B BRAKE ................................................................8
LIFTING ASSEMBLY ....................................................................................................10
CONTROLS ..................................................................................................................12
PUSHBUTTON..............................................................................................................14
UPPER & LOWER LIMIT SWITCH ...............................................................................16
08/22/01
RM-LM5-SPARE-1999-3-ENG.doc

: 800 955-9967

LM5 Spare Parts
Revision 3
Hoist Body
08/22/01

: 800 955-9967

LM5 Spare Parts
Revision 3
Hoist Body
Item
1
2
3
4
6
7
8
9
10
11
12
13
15
16
17
18
19
19
19
19
19
19
08/22/01
Part Number
2229943
2229942
2219996
2219995
2219961
8380202
2210004
2218002
2219962
2219960
2218004
2406879001
2213309001
2213309002
2213309003
2213309007
2213309008
2213309009
Description
Hoist body
Stator
Trolley coupling set-perpend. push
Trolley coupling set-parallel push
Suspension hook set
Dowel pin
M8 Screw
Suspension hook set
Motor endcap & hardware set
Motor endcap
M6 Screw
Cap
O-ring 2 x 120-NB70
Brake end cap
Seal ring
Brake endcap with counterweight
Cable gromet
Suspension kit for pendant
Control enclosure
Body branding label set
Self adhesive load plate - 1/4 ton
Self adhesive load plate - 1 ton
Self adhesive load plate - 250 kg
Self adhesive load plate - 1000kg
Comments
Qty
1
parallel for TDU

perpend. for TDU
Perpendicular
1
1
1
2
1
1
1
1
13
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
Parallel

: 800 955-9967

LM5 Spare Parts
Revision 3
Gear Mechanism & Version 1 Brake
Version 1 brake is not interchangeable with Version 2 brake. Version 1 brake is obsolete, but selected
spare parts are available.
08/22/01

: 800 955-9967

LM5 Spare Parts
Revision 3

Item
1
2
3
3
4
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25
25
26
27
28
29
30
31
32
33
Part Number
2211500
2215000
2215001
2214001
2219983
2210500
2210520
2210503
2210510
2210503
2219982
2211000
2211012
2211013
2211018
2211014
2211015
34
34
35
08/22/01
Description
Self locking nut
Gear input shaft set
Rotor assembly
Rotor assembly
Bearing
Chain sprocket set assembled
Sprocket equipment
Bearing
Bushing
Bushing
Planetary gear assembly, 2nd step
Planet carrier
Brass washer
Self lubricating bushing
Planet wheel
Retaining ring
Pinion 2nd step
Planetary gear assembly, 1st step
Planet carrier
Planet wheel
Pinion 1st step
Metal sealing ring set
Circlip
O-ring
Bearing
Complete brake & slip clutch assy
Screw
Friction and anchor disk
Slip clutch friction disk assembly
Lipseal
Brake pressure disk
Brake cap
Brake spring
Coil assembly
Slip clutch spring set (1Bm)
Slip clutch spring set (2m)
Limiter spring
Limiter spring
Washer
Comments
Two speed
Single speed
16 fpm
32 fpm
=22+23+24
380-480V
200-240V
500-575V
=1+34+34+34+37+35+1
=1+34+34+34+37+35+1
Qty
2
1
1
1
1
1
1
1
1
1
1
1
1
3
3
6
1
1
1
3
3
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Gear Mechanism & Version 2a Brake
Version 2a brake has been replaced by Version 2b brake, which are interchangeable. Version 2 brake is
not interchangeable with Version 1 brake.
08/22/01

: 800 955-9967

LM5 Spare Parts
Revision 3

Item
1
2
3
3
4
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25
25
26
27
27b
28
29
30
31
32
33
33
33
34
35
36
08/22/01
Part Number
2211501
2215000
2215001
2214001
2219983
2210500
2210520
2210503
2210510
2210503
2219984
2211070
2211071
2211018
2211020
2211026
2211021
2211023
2211024
2211025
2211016
2211022
Description
Self locking nut
Rotor assembly
Rotor assembly
Bearing
Sprocket equipment
Bearing
Bushing
Bushing
Planet carrier
Brass washer
Planet wheel
Retaining ring
Pinion 2nd step
Planet carrier
Planet wheel
Pinion 1st step
Circlip
O-ring
Bearing
Screw
Screw
Adjustment nut
Lipseal
Brake pressure disk
Anchor disk
Brake spring
Coil assembly 190Vdc
Slip clutch spring set
Washer
Limiter spring
Friction disk
Comments
Two speed
Single speed
16 fpm
32 fpm
=21+22+23+24
380-480V
200-240V
500-575V
=8+28+29
200-240V
380-480V
500-600V
=1+34+34+34+37+35+1
Qty
2
1
1
1
1
1
1
1
1
1
1
1
1
3
3
6
1
1
1
3
3
1
1
1
1
1
1
1
1
1
3
3
3
1
1
1
1
1
1
1
1
1
3
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Gear Mechanism & Version 2b Brake
08/22/01

: 800 955-9967

LM5 Spare Parts
Revision 3
Gear Mechanism & Brake Version 2b

Item
2a1
2a2
2a3
2a3
2a3
2a4
2a5
2b1
2b2
2b2
2b3
2b4
2c1
2c2
2c3
2c4
2d1
2d2
2d3
2d3
2d3
2d6
08/22/01
Part Number
2210503
2211016
2215000
2215001
2215055
8384702
2211018
300077
2210500
2210520
8262501
2211020
2210510
2211501
2214001
8182543
8381806
833706
2211081
2211080
2211082
8552528
Description
Comments
Pinion
Limiter spring set
2 speed rotor assembly
1 speed rotor assembly-1800 rpm
O-ring 2 x 47-NB70
Clutch disc set-number 2
Circlip 47 x 1.75
Planetary gear assy-2nd reduction
Retaining ring
Planetary gear assy-1st reduction
Gear input shaft
Chain sprocket assy
Metal seal ring
Lip seal
Ball bearing
Coil assembly 190VDC
Sprocket tube
Two speed
Single speed
Single speed
16 fpm
32 fpm
380-480V
200-240V
500-600V
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Lifting Assembly
08/22/01
10

: 800 955-9967

LM5 Spare Parts
Revision 3
Lifting Assembly
Item
1
2
3
4
5
5
5
5
6
7
8
9
Part Number
2214011
2214014
2214013
10
10a
11
12
13
14
14
14
14
14
14
14
16
17
18
19
20
20a
21
21
21
21
21
21
22
23
2212011
001512
2219999
2249985
2249986
2249987
2211050
2219997
2213308001
2213308002
2213308003
2213308006
2213308008
2213308009
2213308010
2219998
2214003
2217004
001515
2213308014
2213308004
2213308005
2213308015
2213308011
2213308012
2213500
2211045
2213523
24
25
26
27
28
29
08/22/01
Description
Upper chain guide
Lower chain guide assy
Rubber plate set
Screw
Chain bucket (25ft) & hardware
Suspension pin
Slack fall stop assembly
Split pin
Hook block complete-1 fall
Hook assembly-1 fall
Safety latch (1 fall)
Shaft
Screw
Self locking nut
Idler sprocket assembly
Shaft
Load chain 4.8 x 12.5
Screw
Chain fitting tooling
Chain anchor assembly
Screw + washer
Dowel
Chain anchor
Fixing plate
Washer
Split pin
11
Comments
=2+3+4+4+13+23
=5+6+28+29
=5+6+28+29
=5+6+28+29
=5+6+28+29
=8
=10+11+12+13+14+15+
16
1 fall
1 fall
1 fall
1 fall
1 fall
1 fall
1 fall
2 fall
2 fall
2 fall
2 fall
2 fall
2 fall
=24+25+26+27
Qty
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
2
2
2
2
2
2
ar
1
1
1
4
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Controls
08/22/01
12

: 800 955-9967

LM5 Spare Parts
Revision 3
Controls
Item
1
2
2
3
3
3
4
5
6
7
Part Number
2219963
7383020
2219092
2213017
2213018
2213016
8090411
2249946
2249982
9
10
11
12
13a
13
14
15
16
17
18
7285039
2219808
833130
2219814
2213001
2218000
08/22/01
Description
Control box base & hardware
Ground PE terminal board
Hour counter
PC board 208/230/460V/60Hz/110V
PC board 208/230/460V/60Hz/110V
PC board 575V/60Hz/110V
Screw
Stop nut
Screw
Female connector + wire harness
Plastic screw
Plug set for trolley
Plug set for power supply
Plug
Screw
Cable gland set
Fuse
Closing plate set
Closing plate
Screw
Nut
Counterweight
Control box cover, cwt. & screw
Screw
Pendant suspension set
13
Comments
=1+5+6
Two speed
Single speed
Two speed
Pushbutton
pendant
=16+17+18
Qty
1
1
1
1
1
1
5
4
4
1
2
1
1
1
2
1
1
1
1
4
4
1
1
4
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Pushbutton
08/22/01
14

: 800 955-9967

LM5 Spare Parts
Revision 3
Pushbutton
Item
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
7
7
7
08/22/01
Part Number
2309673010
2309673015
2309673020
2309674010
2309674015
2309674020
2309675010
2309675015
2309675020
2309675010
2309675015
2309675020
2218000
2219812
2212752001
2212753001
RPC1612
2212932011
2212932012
2212932032
2212932033
Description
E-stop, SS Hoist pendant assy
E-stop, TS Hoist pendant assy
E-stop, SS Hoist, TS Trolley pendant
E-stop, TS Hoist, TS Trolley pendant
Upper suspension kit
Plug kit
Strain relief cable
Suspension unit
Electrical cable
E-stop, SS Hoist pushbutton assy
E-stop, TS Hoist pushbutton assy
E-stop, SS Hoist, TS Trolley pushbutton
E-stop, TS Hoist, TS Trolley pushbutton
15
Comments
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Upper & Lower Limit Switch
Item
1
2
3
4
5
6
08/22/01
Part Number
2213059
2219002
2219003
Description
Complete limit switch
Switch plate
Switch set
M8 x 25 screw
Cable gland
Spring plate
Spring
Comments
=1+2+3+4+5+6
1 fall/2 fall
1 fall/2 fall
16
Qty
1
1
1
1
1
2/3
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LM5 Manual
: 800 955-9967
Revision 3
SECTION 1
INSTALLATION
1
Figure 1-1
1- Hoist body/motor
2- Gears
3- Brake/limiter/housing
assembly
4- Chain sprocket with
output shaft
5- Chain guide
6- 1-fall hook block
7- 2-fall hook block
8- Chain container
9- Electrical control panel
IMPORTANT
Hoists/trolleys are designed for lifting and transporting of material
only. Under no conditions or circumstances, either during initial
installation or in regular use, are hoists to be used for lifting or
transporting of personnel. Never lift or transport a load until all
personnel are clear and do not transport any load over personnel.
General
Each complete electric chain hoist is load tested at the factory at 125% of nameplate rated capacity,
and it is shipped assembled.
All hoists/trolleys 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 the user and shall be determined by qualified personnel.
08/22/01
1-1
RM-LM5-MAN-1999-3-ENG


LM5 Manual
: 800 955-9967
Revision 3
Prior to installation, the unit shall be checked thoroughly for damage during shipment or handling at
the job site. Particular attention shall be taken to make sure that the load chain and limit switch
mechanism has not been damaged by improper use of forklifts or sling chains.
Read the instructions contained in this manual and observe the warning tags attached before
installation is started.
WARNING
Before installing the hoist, make certain that the main power switch
supplying power to the hoist/crane is in the open position.
Mounting
Before installing trolley mounted hoists, rail stops must be installed for open-ended beams. These
stops must be positioned such that the trolley bumpers absorb impact forces only. Do not allow
trolley wheels to impact rail stops.
When for use on standard mill rolled S or WF sections or patented monorail beam, the clearance
between wheel flange and rail with hoist/trolley centered on beam must be no more than 1/16 on
each side, 1/8 total. See trolley manual for additional mounting instructions before operating hoist.
If this trolley manual is missing, contact factory.
After trolley mounted hoists have been hung on the beam, check for balance. Each electric chain
hoist is balanced at the factory for the as shipped condition. Any auxiliary devices (control boxes,
cable reels, etc.) furnished and mounted by customer may require the addition of counter-weight.
Hoists must hang straight without a load or there will be a noticeable kick when a load is applied to
the hook. Unbalanced hoist/trolley may result in damage to the equipment.
Lubrication
The hoist gear reducer is lifetime lubricated and needs no regular checking or maintenance.
Note: Trolley open wheel gearing has not been greased at the factory. See trolley manual for proper
lubricant to add before hoist and trolley is installed on the monorail.
Make sure the load chain is free from contamination or dirt and adequately lubricated with SAE 80
grade oil. Bottom block must hang straight and load chain must be free of kinks or twists.
Load Hook Throat Opening
ANSI B30.16-1993 recommends that the throat opening of the load hook be measured and recorded
prior to putting the hoist into service and that a gage be made to provide a quick visual inspection
for a bent hook as required by monthly inspections. See Section 4.
08/22/01
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LM5 Manual
: 800 955-9967
Revision 3
Power Connections
Make sure that power supply voltage is the same as that shown on the hoist nameplate and that fuses
or other current overload devices are provided to protect the power supply. The power
source/conductors must have sufficient capacity to maintain the voltage at the hoist at 10% of the
nominal voltage under all operating conditions. Standard nominal voltages are 230/460/575. Poor
voltage maintenance can cause motor overheating or sluggishness, and chattering or inoperative
motor brakes and controls.
A wiring diagram is included in this manual showing the identification of the power lead
connections. Refer to wiring diagram prior to start up and/or any electrical work. If drawing has
been misplaced you may obtain one from the factory upon request with the serial number of the unit.
CAUTION
It is recommended that a power disconnect be installed no more than 30
feet from the hoist.
Make sure the power source disconnect is off and locked in open
position while making connections.
Make sure all collectors, if furnished, are compatible and properly lined
up and make good contact with conductor bars on rail.
The customer must supply the power cable; the fuses and the main disconnect switch.
Figure 1-2
PS: Power supply connection
TR: Trolley power and control connection
PB: Push button connection
Connection:
1. Remove the control box cover.
2. Insert the cable (PS) into the box through the PG cable gland. Cable gland accepts a
cable diameter of 8-15mm.
3. Connect phases L1, L2, L3 to K10, and the ground wire to the terminal board (2).
4. Check that the terminals are correctly tightened, even unused terminals.
5. Tighten the power round cable PG gland.
6. Reinstall the control box cover. (Do not over-tighten cover screws.)
7. Check the hoist operation
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Note: This electric chain hoist is furnished with motor and control circuit protection as standard,
which in the Companys interpretation, meet the requirements of the National Electrical Code in
effect at time of shipment from the factory. The protective devices required for the power feed are
outlined in Article 610 of the NEC and are the responsibility of the user. It is recommended that the
user for compliance requirements review this article.
Follow National, State and Local Codes when providing electrical service to the hoist.
Only a qualified electrician shall make all electrical connections.
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SECTION 2
INITIAL START-UP
WARNING
Before connecting the hoist to the power supply, check all
motion buttons in push button station to ensure that none bind
or stick in any position. Check pendant cable and supporting
strain relief wires to ensure they that are not damaged.
Once power has been supplied to the hoist, several important no-load checks must be made.
Proper Hook Motion (Hoist Motor Rotation)
Since direction of rotation of any three-phase AC motor can be reversed by reversing any two of
the three lines feeding the motor, it is important that the direction of motion is correct with
respect to the button being depressed.
To check/correct hook motion (motor rotation), carefully inch the up button and observe hook
motion. If hook does not travel up, stop and open the power source disconnect.
WARNING
Do not attempt to reverse hoist motion by changing control leads
in the push button or at the contactor, and do not change the
nameplate on the P/B. The pilot circuit limit switch is in series
with the UP control circuit wiring as furnished from the factory.
Changing the push button control leads or nameplates will
prevent the limit switch from functioning properly.
IMPORTANT
Do not run the hoist with the DOWN button if direction is
reversed. To correct the direction of the hook block travel,
reverse any two leads supplying power to the hoist, at the main
power source or at the lead in connections to the hoist. Do not
change the internal wiring of the hoist.
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Proper Trolley Motion

If it is necessary to change the direction of the trolley motion with respect to the P/B markings,
change any two power leads at the load side of the trolley contactor only.
Note:
If TDU is used the rotation direction cannot be changed by changing the power leads.
See TDU manual.
CAUTION
Do not reverse main power leads for trolley motion correction. This
would also cause a reversal of hoist motion, with resulting hazards at
limit switch as listed above.
Mounting the Chain Container
Install chain container on hoist as described in the installation instructions below.
REMOVAL:
1. Remove the cotter pin (5) from the end
of the pin (3).
2. Pull the pin out from its hole; support
the chain container (2) at the same time.
3. Remove the container.
INSTALLATION:
1. Insert the chain into the container and
position the container on the guide (1).
2. Fit the pin through the hole of container
and guide.
3. Attach the cotter pin and split its ends
apart to secure it.
Note: The electric chain hoist must always
be transported with chain container loose.
Note: The chain container must be used for
effective operation of the limit of travel.
Figure 2-1
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No Load Operational Checks

Check the hoist motor brake function.
Run the empty hook block up or down to check that the hook drift does not exceed more than
1 inch (25mm). If so adjust the brake as described in Section 4, Operation/Maintenance.
Run the empty hook block down to check that the slack fall stop on the free end of the chain
(inside the chain container) makes proper contact with the limit switch and that the limit
switch functions correctly.
Run the empty hook block up to check that the load block makes proper contact with the limit
switch and that the limit switch functions properly.
Run the empty hook block up and down several times while checking for proper tracking of
the load chain.
Torque Limiter
The electric chain hoist is equipped with a torque-limiting device to help protect against the
damage from attempts to lift an over-capacity load. This device is not intended as a measuring
device and shall not be used as such. The device is adjusted at the factory for the designed load
capacity of the hoist. Sound operating practices shall be followed to avoid attempts to lift overcapacity loads.
Upper Hook/Trolley Assembly
The mounting position of the upper hook or coupling to the hoist is important for maintaining
proper hoist balance. The mounting position of the upper hook or trolley is illustrated in Figure 410 in SECTION 4.
Load/Run Test
While each complete hoist is load tested at the factory, the user should perform a full load test
after installation of the hoist and completion of no load operational tests.
Lift a near capacity load about 1 foot (30cm) above floor level and check that the brake holds the
load. Also, check the holding capability of the brake when lifting/lowering and stopping the load.
Run the trolley the full length of the monorail or crane and check for binding of the trolley wheels
on the rail and/or interference at splice joints, hanger connections/bolts, etc.
Check the contact with the rail stops. Contact with the rail stops shall be made with the trolley
bumpers only. Rail stops that are designed to make contact with wheels must be not be used.
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SECTION 3
SAFE OPERATING PRACTICES
General
There is no one single factor that is more important for minimizing the possibility of personal
injury to the operator and those working in the area, or damage to property, equipment, or
material, than being familiar with the equipment and using Safe Operating Practices.
Hoist/trolleys are designed for lifting and transporting of material only. Under no circumstances,
either during initial installation or in any other use, shall the hoist be used for lifting or
transporting personnel.
No operator shall be permitted to use the equipment if he is not familiar with its operation, is not
physically and mentally fit, or has not been schooled in safe operating practices. The misuse of
hoists can lead to certain hazards which cannot be protected against by mechanical means;
hazards which can only be avoided by the exercise of intelligence, care, and common sense.
Safe Operating Practices also include a program of periodic inspection and preventative
maintenance (see Section 5). Part of the operators training shall be an awareness of potential
malfunctions/hazards requiring adjustments or repairs, and bringing these to the attention of
supervision for corrective action.
Supervision and management also have an important role to play in any safety program. They
must ensure that a maintenance schedule is adhered to. Also that the equipment provided for the
operators is suitable for the job intended without violation of any of the rules covering safe
operating practices and good common sense.
The Safe Operating Practices shown are taken in part from the following publications:
American National Standard Institute (ANSI)
Safety Standards for Cranes, Derricks, Hoists
ANSI B30.2 - Overhead and Gantry Cranes
ANSI B30.16 - Overhead Hoists
Dos and Donts (Safe Operation of Hoists)
The following are Dos and Donts for safe operation of overhead hoist. Taking precedence over
any specific rule listed here, however, is the most important rule of all: USE COMMON
SENSE. A few minutes spent reading these rules can make an operator aware of dangerous
practices to avoid and precautions to take for his own safety and the safety of others. Frequent
examinations and periodic inspections of the equipment as well as a conscientious observance of
safety rules may save lives as well as time and money.
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DOS - HOISTS
1.
READ and follow manufacturers Instruction, Installation and Maintenance manuals. When
repairing or maintaining a hoist use only manufacturers recommended parts and materials.
2.
READ and follow all instruction and warning information on, or attached to the hoist.
3.
REMOVE the hoist from service and thoroughly inspect and repair, as necessary, if unusual
performance or visual defects (such as peculiar noise, jerky operation, travel in wrong
direction, or obviously damaged parts) are noticed.
4.
ESTABLISH a regular schedule of inspection and maintain records for all hoists with special
attention given to hooks, load chains, brakes, and limit switches. See SECTION 5.
5.
CHECK operation of brakes for excessive drift.
6.
MAKE SURE you never lift loads over people.
7.
CHECK for damaged hooks and load chains.
8.
KEEP load chain clean and well lubricated.
9.
CHECK the load chain for improper seating, twisting, kinking, wear, or other defects before
operating the hoists.
10. MAKE SURE a load clears neighboring stockpiles, machinery, or other obstructions when
raising, lowering, or traveling the load.
11. CENTER hoist over the load before operating.
12. AVOID swinging of load or load hook when traveling the hoist.
13. BE SURE the load attachment is properly seated in the saddle of the hook. Balance load
properly before handling. Avoid hook tip loading.
14. PULL in a straight line, so that hoist body or load chain is angled around an object.
15. TAKE up slack slowly.
16. KNOW the hand signals for hoisting, cross travel, and crane travel if working with caboperated hoists or cranes. Operators should accept the signals of only those persons
authorized to give them.
17. KEEP load chain clear from any objects.
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DONTS - HOISTS
1.
NEVER lift or transport a load until all personnel are clear and do not transport the load over
personnel.
2.
DO NOT allow any unqualified personnel to operate hoist.
3.
NEVER pick up a load beyond the capacity rating appearing on the hoist. Overloading can be
caused by jerking as well as by static overload.
NEVER carry personnel on the hook or the load.
5.
DO NOT operate hoist if you are not physically fit.
6.
DO NOT operate hoist to extreme limits of chain travel without first checking for proper
limit switch action.
7.
AVOID sharp contact between two hoists or between hoist and end stops.
8.
DO NOT tamper with or adjust any parts of the hoist unless specifically authorized to do so.
9.
NEVER use the load chain as a sling.
10. DO NOT divert attention from load while operating hoist.

11. NEVER leave a suspended load unattended.
12. DO NOT use limit switch(es) for normal operating stop(s). These are safety devices only and
shall be checked on a regular basis for proper operation.
13. NEVER operate any hoist that has an inherent or suspected mechanical or electrical defect.
14. DO NOT use load chain as ground for welding. NEVER touch a live welding electrode to the
load chain. Isolate load hook to prevent grounding.
15. DO NOT jog controls unnecessarily. Hoist motors are generally high torque, high slip types.
Each start causes an inrush of current greater than the running current and leads to overheating and heat failure, or burnout, if continued to excess.
16. NEVER place hands on moving load chain or near moving chain pinch points.
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SECTION 4
OPERATION/MAINTENANCE
Typical Construction
While each electric chain hoist may have some slight variations in design/arrangement, all hoists
have same basic elements.
1. Motor - basic drive package.
2. Chain Sprocket - moves the load chain to lift and lower the load
3. Gear case Assembly - couples the motor to the chain sprocket
4. Brake/Torque Limiting Device - to stop and hold the load as well as to help prevent lifting of
excessive loads which may damage the hoist.
5. Frame - basic structural components that support the load to be handled.
6. Bottom Block and Load Wheel - includes bottom block and chain sprocket.
7. Load Chain - load chain and end connections for picking up the load.
8. Controls/Enclosures - devices for supplying power to motor and reversing direction of the
motor.
The following details the operation/maintenance instructions for each basic element. In Figure 4.1
the basic components inside the frame and the basic kinematics are shown.
Figure 4-1
1.
2.
3.
4.
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Motor
Chain sprocket
Gear
Brake/limiter
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Motors
The hoist motors are designed to provide dependable hoisting service. The standard motors are
enclosed for protection against normal hazards of dust and moisture. The bearings are sealed and
lifetime lubricated and they do not require greasing.
Brake/Torque Limiting Device
The hoist brake is a D.C. disc type. The function of the hoist brake is to minimize hook drift by
bringing the motor to a quick and smooth stop, and to hold loads suspended from the hook with
the power off.
In addition to the hoist brake the hoist is furnished with a torque-limiting device, integral with the
hoist brake. The torque-limiting device helps prevent the lifting of excessive loads, which may
damage the hoist.
In Figure 4-2 the construction of hoist brake/torque limiting device is shown.
10
6
Air gap
1
5
8
X
2
9
Figure 4-2
Operation
The parts of the limiter and the brake disc are mounted on the gear input shaft (1). Other brake
parts are mounted to the brake housing.
The spring (2) keeps the limiter (3) and the brake discs (4) plated together and defines the
maximum torque that can be transferred through the limiter.
The nut (5) maintains the assembly on the gear-input shaft.
When the coil (6) is energized, during lifting or lowering, it moves against the anchor disc (7),
which is fixed to the brake housing by an attachment screw (10) (there is an air gap for this
purpose). The discs (3 and 4), that are connected together by the friction of the limiter, turn freely,
transmitting the movement to the pinion (8).
Braking occurs when the coil is no longer energized and the spring (9) drives back coil (6).
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Adjustment of the Limiter (Refer to Figure 4-3)
WARNING
When adjusting the limiter make sure that the main power switch applying
current to the hoist is in open and locked position. When testing the limiter
function, be sure not to touch any rotating parts. Before pressing the control
button on the pendant station, check the adjusting nut is clear of any items
such as tools.
1.
2.
3.
4.
Hook a load of 1.25 times the nominal load onto the hoist.
Remove the brake end cap and the seal.
Raise the load at slow and fast speed.
Turn the adjusting nut (5) in the required direction.
Turn the nut clockwise to increase the torque.
Turn the nut counterclockwise to decrease the torque.
WARNING
When decreasing the torque, make sure that there is no load connected to the
load block. Failure to remove load from the load block before performing this
procedure may result in personal injury.
5. Repeat steps 3 and 4 until the load can barely be lifted at fast speed. The limiter is now
adjusted.
CAUTION
The limiter will generate heat whenever it is slipping and while as a result of
this a massive clutch plate will absorb most of this heat. When the clutch
plate becomes too hot, adjusting the limiter maybe difficult due to unstable
behavior of friction surfaces. If this happens let the limiter cool down for a
while and then readjust the limiter.
6. Fit the brake end cap and seal.
7. Check, at fast speed, the lifting of a nominal load.
WARNING
Never adjust the torque limiter to allow lifting of more than the maximum
capacity shown on the hoist. Failure to adhere to this restriction may result in
personal injury or property damage.
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11
10
6
Air gap
7
5
Figure 4-3
Adjustment of the Brake (Refer to Figure 4-3)
The maximum air gap of the brake is 0.022". If this value has been reached or will be exceeded
before next inspection, the brake must be adjusted.
WARNING
When adjusting the brake make sure that the main power switch applying
current to the hoist is in open and locked position and remove the load from
the hook. When testing the brake function, be sure not to touch moving and
rotating parts. Before pressing the control button on the pendant station,
check that the adjusting nut is clear of any misplaced items such as tools.
1. Remove the brake end cap and the seal.
2. Measure the air gap between the anchor disc (7) and the outer ring of the coil with a feeler
gauge. Measure the air gap at least at 3 different points around the coil.
3. Set the air gap to 0.008 +0.002.
4. Slightly open the three screws, (10) so that the adjustment nut (11) still touches to the brake
housing. Turn the adjustment nut (11) counterclockwise to reduce the air gap. Turning the
adjustment nut clockwise increases the air gap.
5. Check the air gap after the adjusting the brake and make sure that the three screws, (10) are
properly tightened to the Torque Specification in SECTION 5.
6. Check the brake function and adjustment:
7. Run the load chain up and down several times without a load to test the function of the brake.
Then, lift a near-capacity load about 1 foot above the floor level and check that the brake
holds the load.
8. Reinstall the seal and the brake end cap.
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Frame
The frame is constructed of aluminum and, unless damaged from abuse (impact with another
hoist or building structure), requires no maintenance. Any hoist with a frame that is no longer
serviceable for any reason should be referred to the factory for replacement/repair.
Load Chain
CAUTION
A hoist shall never be used if the load chain shows any evidence of mechanical
damage or excessive wear.
The replacement load chain must be of exact size and quality to the original load chain that was
furnished with the hoist from the factory.
Improper load chain storage or installation procedure can render the load chain unusable prior to
the first lift.
Load chain inspection shall be conducted weekly by a designated person using good judgment in
evaluating the remaining service life. Any deterioration of the load chain resulting in appreciable
loss of the original strength, such as situations described below, shall be noted and evaluated. A
monthly inspection shall include a written record, dated and signed by the inspector.
Main items to record regularly:
1. Poor lubrication of load chain.
2. Worn outside or inside chain.
3. Crushing, kinking, or signs of distortion.
4. Reduction of original diameter more than 10%.
At regular intervals, check the chain for wear. If any of the links show cracks or signs of
distortion, the chain must be replaced immediately.
WARNING
Also during inspections evaluate those sections which are
normally hidden, such as sections which pass over equal load
wheels.
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Load Chain Installation

Chain Specification:
Chain type:
Diameter (d) / pitch (t):
Class:
Grade:
Maximum working stress:
Hardened surface:
Thickness:
Standard:
Marking (10 x t):
Maximum working load, 1 fall:
Breaking load:
Maximum breaking stress:
Total breaking elongation:
Weight for 100 links:
Revision 3
Load chain
Standard
0.189 (4.8 mm) /0.492 (12.5 mm)
DAT
H8S or HE G80 RAS
19,652 lbs/in2 (135.5 N/mm2)
580 or 700 HV (Vickers Hardness)
0.0039 (0.1 mm) to 0.0079 (0.2 mm)
DIN 5684 - 8
1 or 16
H 8 S or A 8
1100 lbs. (500 kg)
6519.50 lbfs (29 kN)
116,030 lbs/in2 (800 N/mm2)
>10% min.
1.5 lbs. (0.680 kg)
Figure 4-4
Measuring the wear on the chain
This shall be done by measuring the dimensions, at several points of the chain, of one link (d) and
(t), and over 11 links (11 t).
Maximum wear allowed:
Minimum link thickness allowed (d):
Maximum pitch allowed (t):
Maximum length allowed (11 t):
0.1693 (4.30 mm)

0.5157 (13.10 mm)
5.5216 (140.25 mm)
If these limits are exceeded, the chain must be replaced immediately. In this case, the wear on
the guide chain and chain sprocket shall also be checked and they shall be replaced if necessary. If
a single link is defective in any way, the whole chain must be replaced.
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Removal of the Load Chain

1-fall chain:
1. Remove the load from the hook.
2. Disassemble the hook block.
3. Drive the chain into the chain container.
4. Remove the chain container and unscrew and remove the lower chain guide.
2-fall chain:
1. Raise the hook block to about 12 (30 cm) from the hoist body.
2. Remove the chain container.
3. Carefully remove the anchor of the load chain from the hoist body.
4. Disassemble the chain pin and the chain from the anchor.
5. Remove the 2-fall hook block, without disassembling it, letting the chain run through it.
6. Let the rest of the chain slide through the chain sprocket.
Replacement of the Load Chain
The load chain should always be installed using the flexible plastic insertion tool (1 in Fig 4-5).
Use of these tool helps ensures that the load chain is installed correctly. Support the chain during
installation to prevent the insertion tool from distortion.
Figure 4-5
1-fall chain:
1. Insert the last chain link onto the small plastic hook of the insertion tool.
2. Insert the other side of the tool in the sprocket as shown in Figure 4-5.
3. Place the load chain on the chain sprocket so the chain link welds are toward the pocket as
shown in Figure 4-6.
4. Raise the chain at slow speed so that the tool and the chain come out the other side of the
sprocket.
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Figure 4-6
Note: The weld (1) of the vertical chain links shall be towards the chain sprocket
2-fall chain:
1. Insert the last chain link in the small plastic hook of the insertion tool.
2. Insert the other side of the tool up through the sprocket, entering the chain container
side.
3. Run the hoist at slow speed so that the tool and the chain come out the other side of the
sprocket. Continue until about 20 (50 cm) of chain becomes available.
4. Put the chain through the idler sprocket, taking care not to twist the chain
5. Remove the limit switch by removing the two screws.
6. Remove the chain anchor from the hoist body.
7. Disassemble the chain pin from the anchor.
8. Insert the chain end to anchor and place the chain pin into its place to fix the chain.
9. Reattach the chain anchor to the hoist body. Properly tighten bolts according to Torque
Specification, SECTION 5.
10. Reinstall the limit switch to the chain guide. Properly tighten screws according to
Torque Specification, SECTION 5.
Run the load chain up and down a few times without load and make sure the load chain is not
twisted. Lubricate the load chain.
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Fall Stop Assembly
1
2
6''
Figure 4-7
REMOVAL:
1. Remove the cotter pin.
2. Slide the ring up from the stop.
3. Remove the stop.
4. Slide the ring off the load chain.
REPLACEMENT:
1. Slide the ring onto the free end of the load chain.
2. Properly position the two halves of the stop around the chain (Figure 4-7), locating it
approximately six inches from the free end of the load chain.
3. Insert the tube around the stop.
4. Insert the cotter pin through the stop.
Note: Make sure that the stop is correctly fitted to the chain as illustrated in Figure 4-7. The
locking tube shall be turned towards the hoist.
Bottom Block, Load Wheel and Suspension Hook
Load wheels showing evidence of scored grooves or broken/cracked flanges or sharp edges
generated from wear, shall be replaced. Worn load wheels can greatly reduce the life of the load
chain.
Check hooks for deformation or cracks. Hooks having a throat opening more than 115% of
normal, or more than 10-degree twist from the plane of the unbent hook, must be replaced. See
Figure 4-8 below.
Figure 4-8
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Due to many types and sizes of hooks that can be furnished and specified by the user, it is
recommended that the user measure the actual throat opening of the hook as originally furnished
and record it on the above sketch and retain for a permanent record. This record can then be used
for determining when the hook must be replaced due to deformation or excessive throat opening.
Note: Any hook that is twisted or has a throat opening in excess of normal indicates abuse or
overloading of the unit. Other load bearing components shall be checked for damage.
Safety latches shall be replaced if bent or broken to the extent that they no longer provide proper
closure of the throat opening of the hook.
CAUTION
Repairing hooks by welding or reshaping is strictly forbidden.
Hook Specification
Load
capacity
(lbs.)
353
551
705
1102
1389
2205
Test
load
(lbs.)
705
1102
1411
2205
2778
4409
No Minimum Marking
offalls ruin load
Class
(lbs.)
1 1764
012T
1 3472
012T
1-2 3527 012T/025 T
1-2 5512 012T/025 T
2 8752
025T
2 11023
025T
M
0.551
0.551
0.551
0.630
0.630
0.630
a1
1.181
1.181
1.181
1.417
1.417
1.417
a2
0.787
0.787
0.787
1.024
1.024
1.024
a3
1.339
1.339
1.339
1.614
1.614
1.614
b1
0.748
0.748
0.748
0.866
0.866
0.866
Dimensions
(inch)
b2
e1
0.591 3.268
0.591 3.268
0.591 3.268
0.748 3.780
0.748 3.780
0.748 3.780
h1
0.866
0.866
0.866
1.102
1.102
1.102
h2
0.748
0.748
0.748
0.945
0.945
0.945
t1
1.260
1.260
1.260
1.496
1.496
1.496
Figure 4-9
Mark: ISO 2766
DIN model number: 15401
DIN 15400 class: T
DIN 15401 material: 35 CD 4
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t2
0.394
0.394
0.394
0.512
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Suspension Hook
Removal:
1. Remove the attaching screw and the locking plate.
2. Slide the two connection pins out of their holes and remove the hook.
Replacement:
1. Check if the suspension is to be done for the 1-fall (1/1) or for the 2-fall (2/1) hoist. The
hook is asymmetrical so that by turning the hook half a turn the correct position can be
selected.
2. Attach the hook into the slot at the hoist body so that the hook neck and the ball of the
hook are in the same line of the correct fall marking at the hoist body (see fig 4-10).
Figure 4-10
Measurement of the Wear on the Suspension and Lifting Hooks
The wear on the suspension and lifting hooks (dimension a2 - see fig 4-9) shall be checked
regularly.
Damaged safety latches shall be replaced immediately.
If the maximum dimension (a2) is greater than the initial dimension by more than 15%, the hook
shall be replaced immediately.
Class:
a2, max. allowed:
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0.905 (23 mm)
025
1.181 (30 mm)
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Controls/Enclosure
WARNING
Before removing or checking any electrical component, ensure
that the power supply is shut off and the power disconnect switch
is locked in open position.
Standard basic control components consist of the following:
1. Printed Circuit Board - control transformer and contactors are soldered to a circuit board.
2. Push Button Station
3. Motor Thermal Protection - pilot circuit contact that opens the hoisting circuit if motor overheats.
Note: The number, size and quantity of control devices vary considerably, depending on the
number and types of motors and the many control options that are available. Refer to
wiring diagram for specific details on power/control devices.
No specific rules can be given as to the frequency of replacement of electrical devices.
Deterioration of electrical components is directly related to the heat generated (over time) in
contactor coils and transformers, and the arcing of contactors when the motor circuit is opened
(starts/stops).
Figure 4-11
Minimum cable sections:
Power supply: AWG 16 (1.50 mm2)
Auxiliary current:AWG 18 (0.75 mm2)
Control box/hoist:
AWG 18 (1.00 mm2)
Fuses: T 400 mA
T 400 mA
Figure 4-12
08/22/01
4-12


LM5 Manual
: 800 955-9967
Revision 3
Controls
The single speed electric chain hoist is available for a power supply of 208, 230 or 460 volts, but
not for 575 volts. The two-speed electric chain hoist, on the other hand, is available for a power
supply of 208, 230, 460 or 575 volts.
The single speed electric chain hoist, furnished without a TDU motorized trolley, is voltage
reconnectable for 208/230/460 volts. See the appropriate single speed hoist wiring diagrams for
the required connection changes.
To convert a single speed hoist from 230 to 208 volts, the connection changes include:
Disabling fuse (F100) and connecting fuse (F101) for control transformer (T100).
To convert a single speed chain hoist from 230 (208) volts to 460 volts, the connection
changes include:
Checking that fuse (F100) is being used for control transformer (T100).
Reconnecting primary line connections to control transformer.
Reconnecting hoist motor leads.
Reconnecting hoist motor brake.
The single speed electric chain hoist, furnished with a TDU motorized trolley, is voltage
reconnectable for 208, 230 and 460 volts, but the TDU requires a transformer change to convert
to another voltage. The transformer for the TDU is mounted on the trolley side plate. For the
required connection changes, see the appropriate single speed hoist wiring diagrams in the hoist
manual, and the TDU wiring diagram in the TDU manual.
Chain hoists with two-speed hoist motion are not voltage reconnectable.
Hoist Circuit Diagram-Standard
Hoist circuit (wiring) diagrams shown in figure 4-17 through 4-20 are standard for electric chain
hoist used on most monorail applications.
Hoist Circuit Diagram-Modular Crane
Hoist circuit diagram for an electric chain hoist that is used on a modular crane is slightly
different from standard. On modular cranes, the bridge transformer supplies the control voltage
for the hoist/trolley controls and the pushbutton pendant is mounted from the crane.
08/22/01
4-13


LM5 Manual
: 800 955-9967
Revision 3
Printed Circuit Boards

TWO SPEED HOIST: 208V/230V/460V (see also figure 4-17)
Figure 4-13
HOIST SUPPLY
L1
L2
L3
BRAKE n
BRAKE +
1U
2U
1V
2V
1W
2W
hoist supply
hoist supply
hoist supply
_ brake
+brake
motor supply
motor supply
motor supply
motor supply
motor supply
motor supply
GROUND WIRES
ground terminal, 4 connections
(see also figure 4-11)
PE
motor
PE
p.c. board (K10)
PE
trolley connection
PE
power supply
08/22/01
PRINTED CIRCUIT BOARD

TAG STRIP X1
Terminal No:
X24 plug
A
11
12
13
14
15
Trolley
Control Voltage
SD: low speed
F: high speed
D2: left
D1: right
Pin No:
1
2
3
4
5
X23 plug
B
1
2
3
4
5
6
7
8
9
Push button
common
hoist up
hoist down
hoist fast
emergency stop
trolley fwd
trolley rev
trolley fast
-
4-14
Pin No:
1
2
3
4
5
6
7
8
C Protections
30-31 Thermal protection
20-21 Uupper limit switch
22-23 Lower limit switch
K10 Emergency stop
contactor
K21 Hoist UP contactor
K22 Hoist DOWN contactor
K25 Hoist FAST contactor
T100 Control Transformer
F100 Fuse 400 mA, with
230V and 460V
F101 Fuse 400mA, with 208V


LM5 Manual
: 800 955-9967
Revision 3
TWO SPEED HOIST: 575V (see also figure 4-17)
Figure 4-13
HOIST SUPPLY
L1
L2
L3
BRAKE n
BRAKE +
1U
2U
1V
2V
1W
2W
hoist supply
hoist supply
hoist supply
_ brake
+brake
motor supply
motor supply
motor supply
motor supply
motor supply
motor supply
GROUND WIRES
PE
motor
PE
p.c. board (K10)
PE
trolley connection
PE
power supply
08/22/01

TAG STRIP X1
Terminal No:
X24 plug
A
11
12
13
14
15
Trolley
Control Voltage
SD: low speed
F: high speed
D2: left
D1: right
Pin No:
1
2
3
4
5
X23 plug
B
1
2
3
4
5
6
7
8
9
Push button
common
hoist up
hoist down
hoist fast
emergency stop
trolley fwd
trolley rev
trolley fast
-
4-15
C Protections
30-31 Tthermal protection
20-21 Upper limit switch
22-23 Lower limit switch
K10 Emergency stop
contactor
K21 Hoist UP contactor
K22 Hoist DOWN contactor
K25 Hoist FAST contactor
T100 Control Transformer
F100 Fuse 400 mA
Pin No:
1
2
3
4
5
6
7
8


LM5 Manual
: 800 955-9967
Revision 3
SINGLE SPEED HOIST: 208V/230V (see also figure 4-18)
Figure 4-14
HOIST SUPPLY
L1
L2
L3
hoist supply
hoist supply
hoist supply
Terminal X7 _ brake
BRAKE +
+brake
T1-T9
motor supply
GROUND WIRES
PE
motor
PE
p.c. board (K10)
PE
trolley connection
PE
power supply
08/22/01

TAG STRIP X1
Terminal No:
X24 plug
A
11
12
13
14
15
Trolley
Control Voltage
SD: low speed
F: high speed
D2: left
D1: right
Pin No:
1
2
3
4
5
B
1
2
3
4
5
6
7
8
9
Push button
common
hoist up
hoist down
hoist fast
emergency stop
trolley fwd
trolley rev
trolley fast
-
Pin No:
1
2
3
4
5
6
7
8
X23 plug
4-16
C
30-31
20-21
22-23
K10
K21
K22
T100
F100
F101
Protections
Thermal protection
Upper limit switch
Lower limit switch
Emergency stop
contactor
Hoist UP contactor
Hoist DOWN contactor
Control Transformer
Fuse 400 mA with 230V
Fuse 400mA with 208V


LM5 Manual
: 800 955-9967
Revision 3
SINGLE SPEED HOIST: 460V (see also figure 4-19)
Figure 4-15
HOIST SUPPLY
L1
L2
L3
BRAKEBRAKE +
T1-T9
hoist supply
hoist supply
hoist supply
_ brake
+brake
motor supply
GROUND WIRES
Terminal X5
PE
motor
PE
p.c. board (K10)
PE
trolley connection
PE
power supply
08/22/01

TAG STRIP X1
Terminal No:
X24 plug
A
11
12
13
14
15
Trolley
Control Voltage
SD: low speed
F: high speed
D2: left
D1: right
Pin No:
1
2
3
4
5
X23 plug
B
1
2
3
4
5
6
7
8
9
Push button
common
hoist up
hoist down
hoist fast
emergency stop
trolley fwd
trolley rev
trolley fast
-
4-17
C
30-31
20-21
22-23
K10
K21
K22
T100
F100
Protections
Thermal protection
Upper limit switch
Lower limit switch
Emergency stop
contactor
Hoist UP contactor
Hoist DOWN contactor
Control Transformer
Fuse 400 mA
Pin No:
1
2
3
4
5
6
7
8


LM5 Manual
: 800 955-9967
Revision 3
C05 Hoist Circuit Diagram-Standard

TWO SPEED HOIST: 208V/230V/460V
Figure 4-17
TWO SPEED HOIST: 575V
Figure 4-18
08/22/01
4-18


LM5 Manual
: 800 955-9967
Revision 3
C05 Hoist Circuit Diagram-Standard

SINGLE SPEED HOIST: 208V/230V
Figure 4-19
SINGLE SPEED HOIST: 460V
Figure 4-20
08/22/01
4-19


LM5 Manual
: 800 955-9967
Revision 3
C05 Hoist Circuit Diagram-QL Modular Crane

SINGLE SPEED HOIST: (208V) 230V
Figure 4-21
08/22/01
4-20


LM5 Manual
: 800 955-9967
Revision 3

SINGLE SPEED HOIST: 460V
Figure 4-22
08/22/01
4-21


LM5 Manual
: 800 955-9967
Revision 3

TWO SPEED HOIST: (208V) 230/460V
Figure 4-23
08/22/01
4-22


LM5 Manual
: 800 955-9967
Revision 3

TWO SPEED HOIST: 575V
Figure 4-24
08/22/01
4-23


LM5 Manual
: 800 955-9967
Revision 3
Bridge Panel Circuit Diagram-QL Modular Crane
Figure 4-25
08/22/01
4-24


LM5 Manual
: 800 955-9967
Revision 3
Pendant Station
2 speeds 1 speed 2 speedsEmergency
LIFTING TRAVEL TRAVEL
stop
08/22/01
4-25


LM5 Manual
: 800 955-9967
Revision 3
SECTION 5
PREVENTATIVE MAINTENANCE
Maintenance table
Interval
Qualification of the
customers personnel
Brake operation for holding and releasing
Daily
Operator
Visual inspection of the load chain
Daily
Operator
Suspension of the pendant station
Daily
Operator
Cleanliness and lubrication of the chain
Monthly
Operator
Torque limiter operation
Monthly
Operator
Measure for wear on the chain
Every 3 months
Operator
Measure for wear on the hooks
Every 3 months
Operator
Tightness of the load block screws & nuts
Every 3 months
Operator
Check the suspension hook/coupling locking plate screws
Every 3 months
Operator
Adjustment of the limiter and hoist brake
3 to 6 months
Qualified mechanic
Lubrication of open wheel gearing
3 to 6 months
Qualified mechanic
Tightness of wire terminal screws and terminal connections
Semi-annually
Qualified mechanic
Lubrication of the load block idler sprocket
Annually
Operator
Tightness of all screws to Screw Tightening Torque

Specifications and check for signs of corrosion.
Annually
Qualified mechanic
Clean motor cooling fins
Annually
Qualified mechanic
Lubrication of the gears
Lubricated for life
Check
CAUTION! These intervals shall be shortened if the hoist is used heavily with maximum
loads or in extreme ambient conditions.
Figure 5-1
08/22/01
5-1


LM5 Manual
: 800 955-9967
Revision 3
Lubricants
Lubrication point
Chain
Idler sprocket
slide bearing + bearing
Gears
Specifications
Oil or liquid grease
Possible brands
Chain lubricating fluid (Ceplattyn or similar)
EP-90
Aral : Aralub FK 2
BP : BP Energrease LS - EP 2
Esso : Unirex N2
Mobil : Mobilgrease HP
Shell : Shell Alvanio EP Grease 2
DEA : Paragon EP 2
Fuchs : Renolit Duraplex EP 2
Mobil: Mobilith SHC 007
Grease (without MoS2)

KP 2 (DIN 51 502)
Soap-based lithium
Approx. drip point + 500F
Worked penetration 509-563F
Operating temperature
- 4F - +266F
NLGI Class 00
Synthetic hydrocarbon liquid with
lithiumcomplex soap
Approx. Drip point +550 F
Worked penetration 415-420F
Operating temperature -55 - +390 F
Quantity
As required
As required
0.11 lbs.
Open Wheel Gearing: EP1 Mobilux or equivalent.
Spare Parts Replacement Table

Spare part
Upper chain guide
Output shaft
PG cable gland
Gear input shaft + adjusting nuts
Motor end cap
Gearing (1st/2nd stage)
Brake cap/end cap sealing
Other seals and O-rings
Brake-limiter
Brake end cap
Lower chain guide
Rubber buffer
Electric box
PC-board
Plugs
Chain
Chain bucket
Slack fall stop
Suspension hook
Hook block (1/1; 2/1)
Control box
To be replaced by
Authorized manufacturer personnel
Customer
Customer
Customer
Customer
Customer
Customer
Customer
Customer
Customer
Customer
Qualification of the personnel

Qualified electrician & mechanic
Qualified electrician
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Qualified mechanic
Once a part has been replaced, check the operation of the hoist.
Screw Tightening Torque (lb. ft) Specification

M5
M6
M8
M10
M12
Standard screws
18
35
61
Self-tapping screws
15
30
53
08/22/01
5-2


LM5 Manual
: 800 955-9967
Revision 3
Troubleshooting
Problem
Possible Cause
Possible Solution
Hoist does not lift or lower load
Emergency stop button is activated
Deactivate button
Blown fuse
Replace the fuse
Pendant plug pin pushed out
Reinstall plug pin
Contactor terminal screws loose
Tighten screws
Mainline switch shut off
Turn switch on
Overload condition
Reduce load
Worn load chain and torque limiter

prevents lifting.
Replace load chain
Torque limiter worn or incorrectly

adjusted
Replace torque limiter wear items or

properly adjust torque limiter
Brake not releasing
Check brake coil resistance.
Hoist does not lift load
Check air gap setting. Adjust if

necessary.
Check rectifier output voltage.
Brake drift more than 4 inches
(100mm)
Brake lining worn
Adjust brake air gap setting and

replace wear items as necessary.
Travel direction does not correspond

to that indicated on push button
Power supply incorrectly connected
See SECTION 2
Abnormal noises while lifting or

lowering
Load chain and its components are

not lubricated
Lubricate load chain.
Load chain is worn
Replace chain
Sprocket or chain guide is worn
Replace sprocket or chain guide
Idler sprocket is worn
Replace idler sprocket
A supply phase is missing
Connect the three phases
Twist in load chain
Remove twist.
08/22/01
5-3

: 800 955-9967

LM5 Spare Parts
Revision 3
Index of Exploded Illustrations and Parts Lists

HOIST BODY ..................................................................................................................2
GEAR MECHANISM & VERSION 1 BRAKE ...................................................................4
GEAR MECHANISM & VERSION 2A BRAKE ................................................................6
GEAR MECHANISM & VERSION 2B BRAKE ................................................................8
LIFTING ASSEMBLY ....................................................................................................10
CONTROLS ..................................................................................................................12
PUSHBUTTON..............................................................................................................14
UPPER & LOWER LIMIT SWITCH ...............................................................................16
09/27/01

: 800 955-9967

LM5 Spare Parts
Revision 3
Hoist Body
09/27/01

: 800 955-9967

LM5 Spare Parts
Revision 3
Hoist Body
Item
1
2
3
4
6
7
8
9
10
11
12
13
15
16
17
18
19
19
19
19
19
19
09/27/01
Part Number
2229943
2229942
2219996
2219995
2219961
8380202
2210004
2218002
2219962
2219960
2218004
2406879001
2213309001
2213309002
2213309003
2213309007
2213309008
2213309009
Description
Hoist body
Stator
Trolley coupling set-perpend. push
Trolley coupling set-parallel push
Suspension hook set
Dowel pin
M8 Screw
Suspension hook set
Motor endcap & hardware set
Motor endcap
M6 Screw
Cap
O-ring 2 x 120-NB70
Brake end cap
Seal ring
Brake endcap with counterweight
Cable gromet
Suspension kit for pendant
Control enclosure
Body branding label set
Self adhesive load plate - 1000kg
Comments
Qty
1
parallel for TDU

perpend. for TDU
Perpendicular
1
1
1
2
1
1
1
1
13
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
Parallel

: 800 955-9967

LM5 Spare Parts
Revision 3
Version 1 brake is not interchangeable with Version 2 brake. Version 1 brake is obsolete, but selected
spare parts are available.
09/27/01

: 800 955-9967

LM5 Spare Parts
Revision 3

Item
1
2
3
3
4
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25
25
26
27
28
29
30
31
32
33
Part Number
2211500
2215000
2215001
2214001
2219983
2210500
2210520
2210503
2210510
2210503
2219982
2211000
2211012
2211013
2211018
2211014
2211015
34
34
35
09/27/01
Description
Self locking nut
Rotor assembly
Rotor assembly
Bearing
Sprocket equipment
Bearing
Bushing
Bushing
Planet carrier
Brass washer
Planet wheel
Retaining ring
Pinion 2nd step
Planet carrier
Planet wheel
Pinion 1st step
Circlip
O-ring
Bearing
Screw
Friction and anchor disk
Lipseal
Brake pressure disk
Brake cap
Brake spring
Coil assembly
Slip clutch spring set (1Bm)
Slip clutch spring set (2m)
Limiter spring
Limiter spring
Washer
Comments
Two speed
Single speed
16 fpm
32 fpm
=22+23+24
380-480V
200-240V
500-575V
=1+34+34+34+37+35+1
=1+34+34+34+37+35+1
Qty
2
1
1
1
1
1
1
1
1
1
1
1
1
3
3
6
1
1
1
3
3
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Version 2a brake has been replaced by Version 2b brake, which are interchangeable. Version 2 brake is
not interchangeable with Version 1 brake.
09/27/01

: 800 955-9967

LM5 Spare Parts
Revision 3

Item
1
2
3
3
4
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25
25
26
27
27b
28
29
30
31
32
33
33
33
34
35
36
09/27/01
Part Number
2211501
2215000
2215001
2214001
2219983
2210500
2210520
2210503
2210510
2210503
2219984
2211070
2211071
2211018
2211020
2211026
2211021
2211023
2211024
2211025
2211016
2211022
Description
Self locking nut
Rotor assembly
Rotor assembly
Bearing
Sprocket equipment
Bearing
Bushing
Bushing
Planet carrier
Brass washer
Planet wheel
Retaining ring
Pinion 2nd step
Planet carrier
Planet wheel
Pinion 1st step
Circlip
O-ring
Bearing
Screw
Screw
Adjustment nut
Lipseal
Brake pressure disk
Anchor disk
Brake spring
Slip clutch spring set
Washer
Limiter spring
Friction disk
Comments
Two speed
Single speed
16 fpm
32 fpm
=21+22+23+24
380-480V
200-240V
500-575V
=8+28+29
200-240V
380-480V
500-600V
=1+34+34+34+37+35+1
Qty
2
1
1
1
1
1
1
1
1
1
1
1
1
3
3
6
1
1
1
3
3
1
1
1
1
1
1
1
1
1
3
3
3
1
1
1
1
1
1
1
1
1
3
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Gear Mechanism & Version 2b Brake
09/27/01

: 800 955-9967

LM5 Spare Parts
Revision 3
Gear Mechanism & Brake Version 2b

Item
2a1
2a2
2a3
2a3
2a3
2a4
2a5
2b1
2b2
2b2
2b3
2b4
2c1
2c2
2c3
2c4
2d1
2d2
2d3
2d3
2d3
2d6
09/27/01
Part Number
2210503
2211016
2215000
2215001
2215055
8384702
2211018
300077
2210500
2210520
8262501
2211020
2210510
2211501
2214001
8182543
8381806
833706
2211081
2211080
2211082
8552528
Description
Comments
Pinion
Limiter spring set
2 speed rotor assembly
O-ring 2 x 47-NB70
Circlip 47 x 1.75
Retaining ring
Planetary gear assy-1st reduction
Gear input shaft
Chain sprocket assy
Metal seal ring
Lip seal
Ball bearing
Sprocket tube
Two speed
Single speed
Single speed
16 fpm
32 fpm
380-480V
200-240V
500-600V
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Lifting Assembly
09/27/01
10

: 800 955-9967

LM5 Spare Parts
Revision 3
Lifting Assembly
Item
1
2
3
4
5
5
5
5
6
7
8
9
Part Number
2214011
2214014
2214013
10
10a
11
12
13
14
14
14
14
14
14
14
16
17
18
19
20
20a
21
21
21
21
21
21
22
23
2212011
001512
2219999
2249985
2249986
2249987
2211050
2219997
2213308001
2213308002
2213308003
2213308006
2213308008
2213308009
2213308010
2219998
2214003
2217004
001515
2213308014
2213308004
2213308005
2213308015
2213308011
2213308012
2213500
2211045
2213523
24
25
26
27
28
29
09/27/01
Description
Upper chain guide
Lower chain guide assy
Rubber plate set
Screw
Suspension pin
Slack fall stop assembly
Split pin
Shaft
Screw
Self locking nut
Idler sprocket assembly
Shaft
Load chain 4.8 x 12.5
Screw
Chain fitting tooling
Chain anchor assembly
Screw + washer
Dowel
Chain anchor
Fixing plate
Washer
Split pin
11
Comments
=2+3+4+4+13+23
=5+6+28+29
=5+6+28+29
=5+6+28+29
=5+6+28+29
=8
=10+11+12+13+14+15+
16
1 fall
1 fall
1 fall
1 fall
1 fall
1 fall
1 fall
2 fall
2 fall
2 fall
2 fall
2 fall
2 fall
=24+25+26+27
Qty
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
2
2
2
2
2
2
ar
1
1
1
4
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Controls
09/27/01
12

: 800 955-9967

LM5 Spare Parts
Revision 3
Controls
Item
1
2
2
3
3
3
4
5
6
7
Part Number
2219963
7383020
2219092
2213017
2213018
2213016
8090411
2249946
2249982
9
10
11
12
13a
13
14
15
16
17
18
7285039
2219808
833130
2219814
2213001
2218000
09/27/01
Description
Control box base & hardware
Ground PE terminal board
Hour counter
PC board 208/230/460V/60Hz/110V
PC board 208/230/460V/60Hz/110V
PC board 575V/60Hz/110V
Screw
Stop nut
Screw
Female connector + wire harness
Plastic screw
Plug set for trolley
Plug set for power supply
Plug
Screw
Cable gland set
Fuse
Closing plate set
Closing plate
Screw
Nut
Counterweight
Control box cover, cwt. & screw
Screw
Pendant suspension set
13
Comments
=1+5+6
Two speed
Single speed
Two speed
Pushbutton
pendant
=16+17+18
Qty
1
1
1
1
1
1
5
4
4
1
2
1
1
1
2
1
1
1
1
4
4
1
1
4
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Pushbutton
09/27/01
14

: 800 955-9967

LM5 Spare Parts
Revision 3
Pushbutton
Item
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
7
7
7
09/27/01
Part Number
2309673010
2309673015
2309673020
2309674010
2309674015
2309674020
2309675010
2309675015
2309675020
2309675010
2309675015
2309675020
2218000
2219812
2212752001
2212753001
RPC1612
2212932011
2212932012
2212932032
2212932033
Description
Upper suspension kit
Plug kit
Strain relief cable
Suspension unit
Electrical cable
E-stop, SS Hoist pushbutton assy
E-stop, TS Hoist pushbutton assy
E-stop, SS Hoist, TS Trolley pushbutton
E-stop, TS Hoist, TS Trolley pushbutton
15
Comments
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
10 ft hoist lift
15 ft hoist lift
20 ft hoist lift
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

: 800 955-9967

LM5 Spare Parts
Revision 3
Upper & Lower Limit Switch
Item
1
2
3
4
5
6
09/27/01
Part Number
2213059
2219002
2219003
Description
Complete limit switch
Switch plate
Switch set
M8 x 25 screw
Cable gland
Spring plate
Spring
Comments
=1+2+3+4+5+6
1 fall/2 fall
1 fall/2 fall
16
Qty
1
1
1
1
1
2/3
2/3

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