STAGEMAKER SM1, SM5, SM10, SM16/20/25 Concert Electric Chain Hoist Operator's Manual

®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
STAGEMAKER®
CONCERT ELECTRIC CHAIN HOISTS
MODELS: SM1 - SM5 - SM10 - SM16/20/25
OPERATOR’S
MANUAL
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
THIS PAGE TO REMAIN BLANK
September 19, 2005
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R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
TABLE OF CONTENTS
1
INTRODUCTION ...............................................................................................................................................1
1.1
1.2
1.3
1.4
2
SCOPE AND PURPOSE.....................................................................................................................................2
2.1
2.2
2.3
3
TRAINING REQUIREMENTS .................................................................................................................3
INTRODUCTION TO SAFETY ................................................................................................................3
OWNER / USER / OPERATOR RESPONSIBILITIES ..................................................................................4
ELECTRIC CHAIN HOIST CONSTRUCTION .............................................................................................7
4.1
4.2
4.3
4.4
4.5
4.6
5
SCOPE ..............................................................................................................................................2
PURPOSE ..........................................................................................................................................2
INSTALLATION AND MAINTENANCE MANUAL.........................................................................................2
SAFETY................................................................................................................................................................3
3.1
3.2
3.3
4
CONTACT INFORMATION ....................................................................................................................1
DISCLAIMER OF WARRANTY ...............................................................................................................1
DISCLAIMER OF LIABILITY ...................................................................................................................1
INDEMNITY ........................................................................................................................................1
GENERAL HOIST CONSTRUCTION .......................................................................................................7
LIFTING MEDIUM ................................................................................................................................7
POWER FOR OPERATION ...................................................................................................................7
SUSPENSION TYPES ..........................................................................................................................8
DIRECTIONAL TRAVEL OF OVERHEAD HOISTS .....................................................................................9
PRINCIPAL PARTS OF AN ELECTRIC CHAIN HOIST ..............................................................................11
SAFE OPERATING PRACTICES ..................................................................................................................19
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
BEFORE EACH SHIFT OR THE FIRST TIME THE HOIST IS USED EACH SHIFT ........................................20
BEFORE OPERATING A HOIST AND APPLYING A LOAD .......................................................................22
MOVING THE LOAD ..........................................................................................................................24
PARKING THE LOAD .........................................................................................................................25
HOIST LIMIT DEVICES ......................................................................................................................25
GENERAL RECOMMENDATIONS ........................................................................................................26
RECOMMENDED GENERAL DO NOT’S ...............................................................................................26
OPERATOR HAND SIGNALS ..............................................................................................................27
6
APPENDIX – A – DEFINITIONS OF ELECTRIC CHAIN HOIST TERMS.............................................28
7
APPENDIX – B – REFERENCES ...................................................................................................................30
8
APPENDIX – C – RECOMMENDED PRACTICES – ELECTRIC POWERED HOISTS ......................32
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STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
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www.rmhoist.com
1
1.1
September 2005
INTRODUCTION
Contact Information
R&M MATERIALS HANDLING, INC.
4501 Gateway Boulevard
Springfield, OH 45502
1.2
General Telephone:
Toll Free Telephone (US):
937 - 328-5100
800 - 955-9967
General Fax:
Parts Dept. Fax (US):
Parts Dept. Fax (other):
937 - 325-5319
800 - 955-5162
937 - 328-5162
Website:
www.rmhoist.com
Disclaimer of Warranty
R&M MATERIALS HANDLING, INC. MAKES NO WARRANTIES WHATSOEVER IN CONNECTION
WITH THIS MANUAL. R&M MATERIALS HAINDLING, INC. SPECIFICALLY DISCLAIMS ALL IMPLIED
WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE. NO
WARRANTIES (EXPRESS, IMPLIED, OR STATUTORY ARE MADE IN CONNECTION WITH THIS
MANUAL).
1.3
Disclaimer of Liability
USER SPECIFICALLY UNDERSTANDS AND AGREES THAT R&M MATERIALS HANDLING, INC., ITS
SUCCESSORS, ASSIGNS, OFFICERS, AGENTS, EMPLOYEES AND MEMBERS SHALL NOT BE
LIABLE IN TORT AND IN CONTRACT – WHETHER BASED ON WARRANTY, NEGLIGENCE, STRICT
LIABILITY, OR ANY OTHER THEORY OF LIABILITY – FOR ANY ACTION OR FAILURE TO ACT IN
RESPECT TO THE RECOMMENDED OPERATION OR INSPECTION OR OTHER
CHARACTERISTICS OF ANYTHING COVERED IN THIS MANUAL. BY USING OR OTHERWISE
EMPLOYING THIS MANUAL, IT IS THE USER’S INTENT AND UNDERSTANDING TO ABSOLVE AND
PROTECT R&M MATERIALS HANDLING, INC., ITS SUCCESSORS, ASSIGNS, OFFICERS, AGENTS,
EMPLOYEES AND MEMBERS FROM ANY AND ALL TORT, CONTRACT, OR OTHER LIABILITY.
1.4
Indemnity
BY REFERRING TO, OR OTHERWISE EMPLOYING THIS MANUAL THE USER AGREES TO
DEFEND, PROTECT, INDEMNIFY, AND HOLD R&M MATERIALS HANDLING, INC., ITS
SUCCESSORS, ASSIGNS, OFFICERS, AGENTS, EMPLOYEES AND MEMBERS HARMLESS OF,
FROM AND AGAINST ALL CLAIMS, LOSSES, EXPENSES, DAMAGES AND LIABILITIES, DIRECT,
INCIDENTAL OR CONSEQUENTIAL, ARISING FROM USE OF THIS MANUAL INCLUDING LOSS OR
PROFITS AND REASONABLE COUNSEL FEES, WHICH MAY ARISE OUT OF THE USE OR
ALLEGED USE OF SUCH MANUAL, IT BEING THE INTENT OF THIS PROVISION AND OF THE
USER TO ABSOLVE AND PROTECT R&M MATERIALS HANDLING, INC., ITS SUCCESSORS,
ASSIGNS, OFFICERS, AGENTS, EMPLOYEES AND MEMBERS FROM ANY AND ALL LOSS
RELATING IN ANY WAY TO THIS MANUAL INCLUDING THOSE RESULTING FROM THEIR OWN
NEGLIGENCE.
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2.1
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
September 2005
SCOPE AND PURPOSE
Scope
This Manual has been prepared by R&M Materials Handling, Inc. to provide recommendations for safe
®
operation of STAGEMAKER COMPACT Concert Hoists with warnings against specific hazards so
as to avoid personal injury and/or damage to property.
2.2
Purpose
It is the purpose of this manual to promote the adoption and use of uniform and effective safe operating
practices for hoist operators. This manual also provides a ready reference for training, evaluation, and
®
review of STAGEMAKER COMPACT Concert Hoist operating practices that are designed to assist
in the prevention of personal injury and / or damage to property.
2.3
Installation and Maintenance Manual
The CONCERT ELECTRIC CHAIN HOIST OPERATOR’S MANUAL and the specific CONCERT
ELECTRIC CHAIN HOIST INSTALLATION AND MAINTENANCE MANUAL are both provided with each
®
STAGEMAKER COMPACT Concert Hoist. Both manuals are shipped with each unit from the
factory. Both manuals SHALL be read prior to installation and operation in order to provide a safe
environment and insure the proper care and maintenance of the product provided by R&M Materials
Handling, Inc.
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STAGEMAKER® COMPACT Concert Hoist
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3.1
September 2005
SAFETY
Training Requirements
®
STAGEMAKER COMPACT Concert Hoist operator, inspector, and maintenance personnel training
programs should be based on requirements in accordance with the latest edition of:
ASME B30.16 Safety Standard for Overhead Hoists (Underhung)
Such training programs should also provide information for compliance with any Federal, State, or Local
®
Code requirements, existing facilities safety rules and regulations, and STAGEMAKER COMPACT
®
Concert Hoists Operator’s Manual and the appropriate STAGEMAKER Installation and Maintenance
Manual. If an overhead hoist is installed as part of an overhead crane or monorail system, training
programs should also include requirements in accordance with the latest edition, as applicable, of:
ASME B30.11 Safety Standard for Monorails and Underhung Cranes
ASME B30.17 Safety Standard for Overhead and Gantry Cranes, Top Running Bridge,
Single Girder, Underhung Hoist
3.2
Introduction to Safety
The above Safety Alert Symbol is used in this manual to indicate hazards and to alert the reader to
information that should be known, understood, and followed in order to avoid DEATH or SERIOUS
INJURY.
Read and understand this manual before using the hoist.
Important issues to remember during operation are provided at the hoist control stations, at various
locations on the hoist, in this manual, and the ELECTRIC CHAIN HOIST INSTALLATION AND
MAINTENANCE MANUAL by DANGER, WARNING, or CAUTION instructions or placards, that alerts
personnel to potential hazards, proper operation, load limitations, and more.
Indicates an imminently hazardous situation, which if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation, which if not avoided, could result in death or serious injury.
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STAGEMAKER® COMPACT Concert Hoist
R&M Materials Handling, Inc
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Operator’s Manual
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September 2005
Indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
The words SHALL and SHOULD are used throughout this manual in accordance with the definitions in
the ASME B30 standards as follows:
SHALL
indicates that a rule is mandatory and must be followed.
SHOULD
indicates that a rule is a recommendation, the advisability of which
depends on the facts in each situation.
Taking precedence over any specific rule, however, is the most important rule of all:
“USE COMMON SENSE.”
3.3
Owner / User / Operator Responsibilities
READ and OBEY all DANGER, WARNING, CAUTION, and OPERATION INSTRUCTIONS on the hoist
and in this manual. Make sure that all placards are in place and legible.
Failure to comply with safety precautions in this manual and on the hoist is a safety violation that may
result in product failure, serious injury, death, or property damage.
NOTICE
It is important that warning, control marking, and other safety labels and signs are present on the hoist
and that the information on the label or sign is legible.
Failure to read and comply with any one of the limitations noted in this manual and the Installation and
Maintenance Manual furnished by R&M Materials Handling, Inc. can result in product failure, serious
bodily injury or death, and/or property damage.
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R&M Materials Handling, Inc
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September 2005
Conforming to good safety practices is the responsibility of the owner, the user, and its operating
personnel. The hoist manufacturer has no direct involvement or control over the hoist’s operation and
application.
It is a responsibility of the hoist owner / user to establish programs to:
TRAIN and designate hoist operators, and
TRAIN and designate hoist inspection and maintenance personnel
Only those Qualified Personnel who have shown that they have read and have understood this manual
and that they understand the proper operation of the hoist should be authorized to operate and/or repair
the hoist.
NOTICE
It is a responsibility of the owner / user to install, inspect, test, maintain, and operate a hoist in
accordance with the ASME B30.16 Safety Standard, OSHA Regulations, and ANSI/NFPA 70, National
Electrical Code. If the hoist is installed as part of a total lifting system, it is also the responsibility of the
owner / user to comply with the applicable ASME B30 volume that addresses other types of equipment
used in the system.
Further, it is the responsibility of the owner / user to require that all personnel that will install, inspect,
test, maintain, and operate a hoist read the contents of the Instruction and Maintenance Manual
furnished by R&M Materials Handling, Inc., ASME B30.16 Safety Standard for Overhead Hoists
(Underhung), OSHA Regulations, and ANSI/NFPA 70, National Electrical Code. If the hoist is installed
as part of a total lifting system, all personnel must also read the applicable ASME B30 volume that
addresses other types of equipment used in the system.
Before installing, removing, inspecting, or performing any maintenance on a hoist; the main switch shall
be de-energized. Lock and tag the main switch in the de-energized position in accordance with ANSI
Z244.1. Follow other maintenance procedures outlined in the Installation and Maintenance Manual
furnished by R&M Materials Handling, Inc. and ASME B30.16.
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STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
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September 2005
Recommended Operator Qualifications
HOIST OPERATORS SHALL:
Be required to read this manual (Operator’s Manual).
Be required to read the warnings in Installation and Maintenance Manual supplied with
hoist.
Be required to read the instructions and warning labels on the hoist.
Be required to read the operating section of ASME B30.16.
Be required to be familiar with the hoist controls before being authorized to operate the
hoist.
Be trained in proper rigging procedures to be followed in the attachment of loads to
the hoist load hook.
Be trained and be familiar with any below-the-hook devices that may be used in
lifting of loads.
Be trained to be aware of potential malfunctions of the hoist that may require adjustment
or repair.
Be instructed to stop operation, if malfunctions occur, and to immediately advise the
supervisor so corrective action can be taken.
HOIST OPERATORS SHOULD:
Have normal depth perception, field of vision, reaction time, manual dexterity, and
coordination for the work to be performed.
NOT be subject to seizures, loss of physical control, physical defects, or emotional
instability that could result in actions of the operator being a hazard to the operator or
others.
NOT operate a hoist when under the influence of alcohol or drugs.
NOT operate a hoist when under the influence of medication that could result in actions
of the operator being a hazard to the operator or others.
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R&M Materials Handling, Inc
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STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
4
4.1
September 2005
ELECTRIC CHAIN HOIST CONSTRUCTION
General Hoist Construction
Overhead hoists are defined in the ANSI / ASME standards as a machinery unit that is used for vertical
lifting service involving material handling of freely suspended (unguided) loads. Overhead hoists are a
basic and versatile piece of equipment used in manufacturing, warehousing, construction, and numerous
other applications to aid workers in the handling and moving of loads.
Overhead hoists are available in various types of configurations and constructions. Overhead hoist
types are usually referred to using the terms that define a specific configuration and construction.
The following are three areas that further define the hoist type.
4.2
Lifting Medium
Lifting medium defines the type of component used to transmit and cause vertical motion of the hoist
®
load hook, hoist body, or hoist load block. Chain is a lifting medium. STAGEMAKER COMPACT
Concert Hoists uses welded link load chain.
Welded Link Load Chain
Welded link load chain consists of a series of interwoven formed and welded links. The links fit
pockets of the hoist load sprocket that transmits motion to the load chain. The load sprocket
may also be called load wheel, load sheave, pocket wheel, chain wheel, or lift wheel. Welded
link load chain sizes are stated as the diameter of the wire used to form the link, i.e. 3.1mm,
4.8mm, 6.8mm, etc. Welded link load chain is designed and manufactured to specific dimension
and material strength requirements for a specific hoist. Welded link load chain is not
interchangeable between different manufacturers’ hoists; and is not interchangeable with
welded link lifting chain used for other purposes such as chain slings and securing the load.
Only original equipment welded link load chain, as supplied by R&M Materials Handling, Inc.,
®
shall be used on any STAGEMAKER COMPACT Concert Hoist.
4.3
Power for Operation
Power for operation defines the type of power used to operate the hoisting motion. The electric chain
hoist uses electrical power to run an electric motor that provides the motion for lifting and lowering the
load.
ON ELECTRIC POWERED HOISTS, HAZARDOUS VOLTAGES ARE PRESENT IN THE
CONTROL BOX, OTHER ELECTRICAL COMPONENTS, AND CONNECTIONS BETWEEN
THESE COMPONENTS.
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STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
September 2005
Electric Power
The hoisting motion (lifting or lowering) of an electric powered hoist is initiated when the operator grasps
and activates a control device. The control device has push buttons that energize, through a series of
contractors and other electrical components, an electric motor. The electric motor transmits power
through the hoist gearing to the hoist load chain sprocket. Thereby, lifting or lowering the hoist load
hook. Lifting is accomplished by actuating the lifting control; and lowering is accomplished by activating
the lowering control. The controls could be marked: LIFT/LOWER; UP/DOWN; RAISE/LOWER; or a
combination of such markings.
Hoist lifting and lowering controls are usually pushbuttons mounted in a pendant control enclosure
suspended from the hoist, levers or switches mounted in a remote radio-control transmitter and/or a
control console. Control consoles, pendant control enclosures, radio-control transmitters, or other
control means could also be permanently mounted on the building structure depending on the
application.
The control device used to lift and lower hoist motion may also contain controls for other motions or
functions. Such controls include: trolley travel, overhead crane travel, power on/off, emergency stop,
motions associated with below-the-hook lifting devices, and other special functions associated with a
specific application. Examples of such control markings may include, but are not limited to, EAST /
WEST; RIGHT / LEFT; OPEN / CLOSE; START / STOP; etc.
Suspension Types
Suspension defines the type of mounting or method used to mount or suspend the hoist. Common
suspension types include hook mounted and trolley mounted. Other types of suspension may be
designed to meet specific application requirements.
When the above various types of configurations or constructions are considered, some of the names
used to refer to overhead hoists include: hook mounted electric chain hoists; lug mounted electric chain
hoists; push trolley mounted electric chain hoists; motor driven trolley mounted chain hoists; etc.
Hook Mounted
Hook mounted hoists have a body hook on the hoist body that can be used to suspend the hoist
from the clevis or suspension pin of a trolley; or a fixed suspension device, that will accept the
hook, mounted on a beam or the structural framework of a building.
Lug Mounted
Lug mounted hoists have a lug mounting attached to the top of the hoist frame, or a lug
mounting attached as an integral part of the hoist frame. Lug mounted hoists are available in all
hoist types. Lug mountings are used to suspend the hoist from a trolley, or a fixed suspension
device mounted on a beam or the structural framework by the use of suspension pin(s) or
stud(s).
Trolley Mounted
Trolley mounted hoists are hook mounted or lug mounted hoists suspended from a trolley; or a
hoist having an integral trolley as part of the hoist frame, that allows travel motion on the lower
flange of a monorail beam, or the lower flange of the bridge beam of an overhead crane.
Trolleys allow traverse motion of the hoist unit, and load being handled, by traveling: on the
lower flange of a monorail beam; on the lower flange of a bridge beam of an overhead crane; or
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STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
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September 2005
on top of the bridge beams of an overhead crane. Hoist trolleys are available in several types
depending on the method used to obtain travel motion. Trolley types include:
Plain (Push) Trolleys
Plain type trolley motion is obtained by pulling or pushing the load or by some other
means, such as the strain relief of a pendant control, suspended from the trolley or hoist.
Plain type trolleys are recommended where trolley motion is infrequent or relatively
short. Because of the force required to manually operate this type of trolley, it is
recommended that the use of plain trolleys be limited to a maximum capacity load of 3
tons or 3000 kg, and that the elevation of the beam where the trolley is suspended be
not more than 20 feet or 6 meters above the operating floor level.
Hand Chain Operated (Hand Geared) Trolleys
Hand geared trolley motion is achieved by grasping and pulling a continuous hand chain
that is connected to the trolley. Hand chain consists of a series of interwoven formed
welded or un-welded links according to the design specifications of the hand chain. The
hand chain links fits pockets of the trolley hand chain wheel, or sprocket. As the
operator pulls the hand chain, the hand chain wheel turns and transmits power through
gearing to the trolley wheels. Pulling the hand chain in one direction will cause the
trolley to travel in the opposite direction. Hand chain manually operated trolleys provide
excellent load spotting ability.
Electric Powered (Motorized) Trolleys
Motorized trolley motion is achieved by activating a control device in the same manner
as described under electric powered hoists. The control device used to lift and lower
hoist motion may also contain controls for trolley travel. Recommendations for use of
electric powered are based on frequency of operation, distance of travel, capacity of
load, height of beam, and type or size of load being handled.
4.4
Directional Travel of Overhead Hoists
Hoist motion is the vertical travel motion direction of the hoist load hook. The hoist operator should be
familiar with the hoist (or crane) controls and understand what type of motion will occur when any one of
the control devices is activated. The controls SHALL be marked, and all markings SHALL be legible. A
routine inspection, required to be performed by the operator prior to the hoist being used each day,
SHOULD include a check that all motions agree with control device markings.
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September 2005
Overhead hoists have one axis of directional travel. This is:
•
THE HOISTING OR VERTICAL TRAVEL DIRECTION OF LOAD HOOK OR HOIST BODY
When overhead hoists are trolley suspended, the trolley hoist unit has two axes of directional travel.
These include:
•
THE HOISTING OR VERTICAL TRAVEL DIRECTION OF THE LOAD HOOK / BODY.
•
THE TRAVERSE TRAVEL DIRECTION OF THE TROLLEY (INCLUDING HOIST UNIT)
When trolley suspended overhead hoists are used on an overhead crane, the crane, including the trolley
hoist unit has three axes of directional travel. These include:
•
THE HOISTING OR VERTICAL TRAVEL DIRECTION OF THE LOAD HOOK
•
THE TRAVERSE TRAVEL DIRECTION OF THE TROLLEY (INCLUDING THE HOIST UNIT)
•
THE TRAVERSE TRAVEL DIRECTION OF THE BRIDGE (INCLUDING THE TROLLEY AND
HOIST UNIT)
Some hoists or cranes may have power-operated rotating hooks, power-operated below-the-hook lifting
devices, or other power-operated accessories that result in additional axes of directional travel.
If more than one hoist or trolley hoist unit is used on an overhead crane, each hoist or trolley hoist
SHALL have an identification mark on it or its load block, and these markings SHALL also appear on
the controllers used by the operator.
For example, if a crane has two trolley hoist units, one trolley hoist unit shall be marked “1” (or some
other designation) on the trolley hoist or load block, and the other trolley hoist unit shall be marked “2”
(or some other designation) on the trolley hoist or load block.
The markings on the trolley hoists are to be visible to the operator and any signal person used in rigging
the load. The controllers for trolley hoist 1 must be marked “1” (or other designation used on the trolley
hoist), and the controllers for trolley hoist 2 must be marked “2” (or other designation used on the trolley
hoist).
All motions of multi-speed powered hoists should be started in the slowest speed available for that
motion, and then the speed should be increased until the desired speed is obtained. At the beginning of
hoisting motion, the load should be lifted only a few inches and stopped to check the holding brake
before continuing with the lift.
The hoist should be brought directly over the load before rigging the load to the hoist load hook. Failure
to center the hoist over the load could cause the load to swing when it is lifted, or could cause side pulls
or other forces to be transferred into the crane. Slack should be taken out of the chains, and slings, if
used, before attempting to lift the load.
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STAGEMAKER® COMPACT Concert Hoist
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4.5
September 2005
Principal Parts of an Electric Chain Hoist
Hoist operators should be familiar with the parts of a hoist and have a thorough knowledge of hoist
control device functions.
INVERTED POSITION
NORMAL POSITION
Figure 4.1
1 - HOOK BLOCK ASSEMBY (NORMAL SUSPENSION 2-FALL SHOWN)
2 - LOAD CHAIN
3 - ELECTRICAL CONTROL ENCLOSURE
4 - BODY HOOK
5 - HOIST GEAR BOX ASSEMBLY
6 - CHAIN CONTAINER & HARDWARE
7 - HOIST BODY / MOTOR
8 - LOAD HOOK SAFETY LATCH
9 - FASTENER FOR CHAIN CONTAINER
10 - PIN / BOLT FOR CHAIN CONTAINER
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STAGEMAKER® OP MAN 2005-
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STAGEMAKER® COMPACT Concert Hoist
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Operator’s Manual
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September 2005
Trolley Assemblies
Plain (Push) Trolley
CRANE BEAM OR MONORAIL
PLAIN TROLLEY ASSEMBLY
BASIC ELECTRIC CHAIN HOIST
Hand Geared Trolley
CRANE BEAM OR MONORAIL
HAND GEARED TROLLEY ASSEMBLY
HAND CHAIN DRIVE WHEEL
BASIC ELECTRIC CHAIN HOIST
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STAGEMAKER® OP MAN 2005-
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September 2005
Motorized Trolley Assembly
CRANE BEAM OR MONORAIL
MOTORIZED TROLLEY ASSEMBLY
TROLLEY DRIVE MOTOR
BASIC ELECTRIC CHAIN HOIST
Pistol Grip “Pickle” Pushbutton Controller
SINGLE PAIR –
UP / DOWN
PUSH BUTTONS
September 19, 2005
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OPTIONAL TWIST LOCK
CONNECTOR
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STAGEMAKER® OP MAN 2005-
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STAGEMAKER® COMPACT Concert Hoist
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September 2005
Push Button Control Assembly - Complete
8
Figure 4.2
1 – COMPLETE P/B ASSEMBLY
2 – UPPER RESTRAINT ATTACHMENT
3 – P/B CABLE PLUG ASSEMBLY
4 – RESTRAINT CABLE
5 – LOWER RESTRAINT ATTACHMENT
6 – P/B ELECTRIC CONTROLS CABLE
7 – P/B CONTROL ENCLOSURE ASSEMBLY
8 – OPERATOR’S WARNING TAG
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STAGEMAKER® OP MAN 2005-
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R&M Materials Handling, Inc
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STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
The following pushbutton controllers are examples of several variations that may be encountered with
®
the STAGEMAKER COMPACT Concert Hoists. The operator must become familiar with the location
and function of each button. Any hoist operator who is not familiar with a given installation SHALL
operate the controller (WITH NO LOAD ATTACHED) to become familiar with the response of pressing
each button and the relative movement of the hook block / body within the surroundings of the hoist
installation.
The markings on each of the pairs of motion control buttons may vary in format due to purchaser
specifications. The hoist operator SHALL review the markings on each of the buttons and verify that the
symbol represents the motion depicted on the button. For example, verify that the button with “UP”
symbol actually activates the “UP” motion when depressed. Also, verify if the button activates a single
speed motion or multiple speed motion. The button must be depressed slowly until fully depressed.
Multi-speed buttons usually have distinct “steps” that can be felt during the full range of movement of the
button.
THE HOIST OPERATOR SHALL INSPECT AND VERIFY THAT THE CONTROLLER BUTTONS ARE
LABELED AND ACTUALLY PERFORM THE MOTION INDICATED. IF THE MOTION LABELS ARE
MISSING OR THE ACTIVATED BUTTON IS DIFFERENT FROM THE MOTION LABEL ON THE
BUTTON, THE HOIST OPERATOR SHALL STOP IMMEDIATELY AND NOTIFY THE SUPERVISOR.
IN CASE OF AN EMERGENCY, PRESS THE “RED” EMERGENCY STOP BUTTON TO DE-ENERGIZE
ALL THE ELECTRICALLY DRIVEN MOTIONS CONTROLLED BY THE PUSHBUTTON CONTROL
ASSEMBLY. ONCE THE “RED” EMERGENCY STOP BUTTON HAS BEEN DEPRESSED, THE
BUTTON WILL REMAINED DEPRESSED IN A LOCKED DOWN MODE UNTIL ROTATED AND
RELEASED.
September 19, 2005
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
Pushbutton Controller – Vertical Pairs (Multiple)
EMERGENCY STOP BUTTON (RED)
PRESS TO STOP ALL ELECTRICALLY
CONTROLLED MOTIONS
BLANK – NOT IN USE
HOISTING MOTION “UP” & “DOWN”
TROLLEY MOTION (OPTIONAL) “LEFT”& “RIGHT”
BRIDGE MOTION (OPTIONAL) “FORWARD” & “REVERSE”
September 19, 2005
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
Pushbutton Controller – Horizontal Pairs (Multiple)
BLANK – NOT IN USE
EMERGENCY STOP BUTTON (RED)
PRESS TO STOP ALL ELECTRICALLLY
CONTROLLED MOTIONS
HOISTING MOTION “UP” & “DOWN”
TROLLEY MOTION (OPTIONAL) “LEFT”& “RIGHT”
Pushbutton Label Symbols
Columns A, B, C, and D represent sets of symbols. In order to meet local requirements, the purchaser
specifies a particular set of symbols.
Rows 1, 2, and 3 represent the pairs of buttons for a particular button. For example, row 1 represents
the pair of buttons for the hoisting motion, row 2 represents the pair of buttons for the trolley motion
(optional), and row 3 represents the pair of buttons for the bridge motion (optional).
The control enclosure assembly will vary in the total number of buttons depending on the motions
controlled.
September 19, 2005
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
Below is a system arrangement with hoists, connection cables, and a control console.
MOTO
0
MOTO
0
MOTO
0
MOTO
0
MOTO
MOTO
MOTO
MOTO
STA
MAR
C
September 19, 2005
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18
STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
5
September 2005
SAFE OPERATING PRACTICES
The operation of an electric chain hoist can be categorized by the various sequential parts of a particular
cycle of use. The typical sub-sections are:
•
•
•
•
BEFORE EACH SHIFT or THE FIRST TIME THE HOIST IS USED EACH SHIFT
BEFORE OPERATING A HOIST AND APPLYING A LOAD
MOVING THE LOAD
PARKING THE LOAD
Taking precedence over any specific rule, however is the most important rule of all:
“USE COMMON SENSE.”
HOIST OPERATORS SHOULD READ THIS MANUAL AND THE WARNINGS CONTAINED IN THIS
MANUAL; INSTRUCTION AND WARNING LABELS ON THE HOIST; AND THE OPERATION
SECTION OF ASME B30.16. HOIST OPERATORS ARE TO BE FAMILIAR WITH THE HOIST AND
HOIST CONTROLS BEFORE BEING AUTHORIZED TO OPERATE THE HOIST.
HOIST OPERATORS ARE TO BE FAMILIAR WITH PROPER RIGGING PROCEDURES TO BE
FOLLOWED IN THE ATTACHMENT OF LOADS TO THE HOIST HOOK.
HOIST OPERATORS MUST BE AWARE OF POTENTIAL MALFUNCTIONS OF THE EQUIPMENT
THAT REQUIRE ADJUSTMENT OR REPAIR, AND STOP THE OPERATION IF SUCH
MALFUNCTIONS OCCUR, AND IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE
ACTION CAN BE TAKEN.
HOIST OPERATORS ARE NOT TO OPERATE A HOIST WHEN UNDER THE INFLUENCE OF
ALCOHOL OR DRUGS; OR UNDER THE INFLUENCE OF MEDICATION THAT COULD RESULT IN
ACTIONS BY THE OPERATOR THAT MAY CAUSE A HAZARD TO THE OPERATOR OR OTHERS.
HOISTS ARE INTENDED ONLY FOR VERTICAL LIFTING SERVICE OF FREELY SUSPENDED
UNGUIDED LOADS; AND ARE NOT INTENDED TO LIFT LOADS THAT ARE NOT LIFTED
VERTICALLY, LOADS THAT ARE NOT FREELY-SUSPENDED, OR LOADS THAT ARE GUIDED. IF
SUCH CONDITIONS EXIST, THE OPERATOR SHOULD CONTACT THE SUPERVISOR FOR
INSTRUCTIONS OR THE MANUFACTURER OF THE HOIST.
DO NOT LIFT PERSONNEL OR LOADS OVER PEOPLE.
September 19, 2005
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STAGEMAKER® OP MAN 2005-
®
5.1
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
Before Each Shift or The First Time the Hoist is Used Each Shift
September 2005
Operation of an overhead electric powered chain hoist involves more than operating the controls of the
hoist. The operator must consider and anticipate the motions and actions that will occur as a result of
operating the controls. In accordance with the requirements of ASME B30.16, the hoist operator should
perform daily (pre-start) inspections at the start of each shift, or at the time the hoist is first used during
each shift. The daily inspection is a visual and audible examination of the hoist. Records of the daily
inspection are not required except as required by the hoist owner/user.
Daily inspection items that should be performed by the operator at the start of each shift, or at the time
the hoist is first used during the shift, include the below items:
ITEM
INSPECTION CHECK POINTS
Tagged Hoist
Check that hoist is not tagged with an out-of-order sign.
Control Devices
Check that all travel motions agree with control device markings.
When checking hoist travel motion, always use “UP” control first.
Brakes
Check that all travel motions do not have excessive drift and that
stopping distances are normal.
Hook
Check for hook latch presence and that it operates properly.
Load Chain
Check for nicks, gouges, and any type of deformation or damage to the
chain. Check for lubrication of load chain.
Reeving
Check that load chain is properly reeved, that load chain is not kinked or
twisted, and that load chain parts are not twisted about each other.
Limit Devices
Check that the primary upper limit device stops lifting motion of the
hoist load block at the upper limit of travel.
If furnished, check that the lower limit device stops lowering motion of
hoist load block at lower limit of travel.
Oil Leakage
Check for any sign of oil or grease leakage on the hoist and on floor
area beneath hoist.
Unusual Sounds
Check for any unusual sounds from hoist and hoist mechanism while
operating the hoist.
Warning & Safety Labels
Check that warning and other safety labels are not missing and that
they are legible.
It is Recommended That the Operator:
SHALL
perform a daily inspection. Refer to the above INSPECTION CHECK POINTS.
SHALL
visually inspect load chain for nicks, gouges, any type of deformation or damage, and
check load chain for proper lubrication.
SHALL
visually inspect hooks for nicks, gouges, deformed throat opening worn saddle or load
bearing point, and twisting.
September 19, 2005
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20
STAGEMAKER® OP MAN 2005-
®
SHALL
STAGEMAKER® COMPACT Concert Hoist
R&M Materials Handling, Inc
Springfield, Ohio USA
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
visually inspect hook latches for proper operation or damage that does not allow
proper operation.
SHALL
test operation of the primary upper limit device of the hoisting motion.
SHALL
report to supervisor if warning label or labels are missing or illegible.
SHALL
report to supervisor any damage or malfunctions.
SHALL NOT
operate hoist if any damage or malfunctions exist.
SHALL NOT
operate hoist if it is tagged with an out-or-order sign.
IF ANY DAMAGE OR MALFUNCTIONS ARE NOTED IN THE DAILY INSPECTION ITEMS, THE
OPERATOR SHALL NOT OPERATE THE HOIST, AND SHALL IMMEDIATELY ADVISE THE
SUPERVISOR SO CORRECTIVE ACTION CAN BE TAKEN. IF THE HOIST IS TAGGED WITH AN
OUT-OF-ORDER SIGN, THE OPERATOR SHALL NOT OPERATE THE HOIST.
HOIST OPERATORS SHOULD BE AWARE OF MALFUNCTIONS OF THE EQUIPMENT THAT COULD
OCCUR DURING OPERATION, AND SHOULD IMMEDIATELY STOP OPERATION IF SUCH
MALFUNCTIONS OCCUR, AND SHOULD IMMEDIATELY ADVISE THE SUPERVISOR SO
CORRECTIVE ACTION CAN BE TAKEN.
IF CORRECTIVE ACTION HAS NOT BEEN COMPLETED BY THE END OF THE SHIFT, THE
OPERATOR SHALL ADVISE THE OPERATOR OR OPERATORS ON THE NEXT SHIFT THAT
CORRECTIVE ACTION IS REQUIRED ON THE HOIST AND VERIFY THAT THE HOIST IS TAGGED
WITH AN OUT-OF-ORDER SIGN.
NOTICE
THE HOIST OPERATOR SHALL NOT PERFORM FREQUENT OR PERIODIC INSPECTIONS, OR
PERFORM MAINTENANCE ON A HOIST UNLESS THE OPERATOR HAS BEEN TRAINED TO
PERFORM SUCH INSPECTIONS OR MAINTENANCE, AND IS DESIGNATED BY THE HOST
OWNER/USER TO PERFORM SUCH INSPECTIONS OR MAINTENANCE.
September 19, 2005
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
Before Operating a Hoist and Applying a Load
5.2
September 2005
•
Bring the hoist directly over the load.
•
Lower the load hook / body so it can be attached directly to the load, the slings, or any other
devise used to rig the load. The load, sling(s), or other lifting device should be fully seated in the
saddle or bowl of the hook. Verify that the hook latch is operational and closes the throat
opening of the hook. Make sure that the hook latch is not supporting any part of the load or the
slings or device used to attach the load to the hook. Verify that the weight of the load to be lifted
does not exceed the rated load capacity of the hoist.
•
Slack should be taken out of the hoisting chain(s) and slings, if used, before attempting to lift the
load.
•
The load should be lifted only a few inches and stopped to check:
o That the load is properly balanced;
o That slings, if used, are properly positioned;
o That load or sling is seated in the saddle, base, or bowl of the hook; and
o That the hoist brake stops and holds the load before continuing with the lift.
If a particular motion (hoisting motion / trolley motion / bridge motion) has multiple speeds, always start
the motion with the slowest speed and then increase speed until the desired speed is obtained. Some
multiple-speed hoists may have other features that affect the lifting motion and the operator should
®
become familiar with the operation of such features. Refer to the STAGEMAKER COMPACT
Concert Hoists Installation and Maintenance Manual furnished with the hoist.
The operator must verify that all personnel are clear of the load and the path of the load, and that the
load will clear all obstacles before lowering or landing a load. When lowering the load, if an electric
chain hoist has multiple travel speeds, the lowering speed should be decreased to the slowest travel
speed before stopping or landing the load. Place blocks under the load (“block load”) before landing if
slings or other lifting devices must be removed from under the landed load.
A load should never be left suspended and unattended unless specific precautions have been instituted
and are in place to prevent the load from inadvertently lowering. Guards or barriers are to be utilized on
the floor to prevent people from entering the area affected by the suspended load. When the hoist is not
in use, the empty load hook / body hook should be raised and positioned above head level for storage.
Seven feet or greater above floor level is recommended.
It is Recommended that the Operator:
SHALL
be familiar with all operating controls of the hoist.
SHALL
be familiar with this Electric Chain Hoist Operator’s Manual provided by R&M Materials
Handling, Inc., instruction and WARNING labels on the hoist, and the OPERATION
section of ASME B30.16.
SHALL
be familiar with the operations to be performed.
SHALL NOT
operate hoist if any damage or malfunctions exist.
SHALL
report to the supervisor any damage or malfunctions.
SHALL NOT
operate hoist if it is tagged with an out-of-order sign.
SHALL
center hoist over load.
September 19, 2005
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22
STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
SHALL NOT
operate a hook mounted hoist when the hoist is restricted from forming a straight line
from top hook to load hook in the direction of loading.
SHALL NOT
use the load chain as a sling to wrap around the load.
SHALL
attach the load to the hook by suitable means such as slings or lifting devices.
SHALL
verify that the size of the attachment part of the sling or other lifting device to be used is
compatible with the size of the hoist hook.
SHALL
verify that the capacity of the attachment part of the sling or other lifting device to be
used is compatible with the capacity of the hoist and the weight of the load to be lifted.
SHALL
only attach loads to the hoist that do not exceed the rated load capacity of the hoist.
SHALL
verify that the attachment part of the sling or other lifting device is properly seated in the
base, bowl, or saddle of the hook.
SHALL
verify that the hook latch operates properly and that the hook latch properly bridges and
closes the hook throat opening.
SHALL
verify that the latch of the hoist hook will not support any part of the load.
SHALL
verify that the load or any part of the load will not be applied to and/or not supported by
the tip or point of the hook.
SHALL
verify that load will be properly balanced when it is lifted.
SHALL
verify that side loads will not be applied to the hoist when the load is lifted.
SHALL
verify that load chain is not kinked or twisted, and that load chain parts are not twisted
about each other.
SHALL
verify that hoist load chain is properly seated in the chain sprockets.
SHALL NOT
use the hoist load limiting device or load warning device (if provided) to measure the
load to be lifted.
SHALL
notify personnel in the area that a load will be lifted and verify that all personnel are clear
of the load.
SHALL
verify that when the load is lifted, it will clear all material, machinery, or other
obstructions in the area.
September 19, 2005
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23
STAGEMAKER® OP MAN 2005-
®
5.3
STAGEMAKER® COMPACT Concert Hoist
R&M Materials Handling, Inc
Springfield, Ohio USA
Operator’s Manual
: 800-955-9967
www.rmhoist.com
Moving the Load
September 2005
DO NOT LIFT PERSONNEL.
DO NOT LIFT LOADS OVER PEOPLE
NOTICE
HOISTS ARE INTENDED ONLY FOR VERTICAL LIFTING SERVICE OF FREELY SUSPENDED,
UNGUIDED LOADS. DO NOT USE A HOIST TO LIFT LOADS THAT ARE NOT LIFTED
VERTICALLY, LOADS THAT ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED. IF
SUCH CONDITIONS EXIST, THE OPERATOR SHOULD CONTACT THE SUPERVISOR FOR
INSTRUCTIONS.
When trolleys are used with a hoist, trolley motion is the traverse travel motion direction of the trolley
hoist unit. Control device markings for this motion should be as stated in the HOIST TYPES section of
this manual. Regardless of the marking designation used, the operator should be fully aware of the
direction of trolley motion that will occur when the control device is activated.
If a load is to be lifted with the hoist hook before moving the trolley, refer to the HOIST MOTION section
of this manual. If a powered trolley has multiple travel speeds, always start motion with the slowest
speed and then increase speed until the desired speed is obtained. Motorized trolleys may have
electronic devices that provide controlled acceleration of the motor and offer a soft or controlled start.
When bringing the trolley to a stop, if a powered trolley has multiple or variable travel speeds, it is
recommended that the travel speed be decreased to the slowest speed before stopping the trolley to
minimize load swing.
It is Recommended that the Operator:
SHALL NOT
engage in any activity that will divert the attention of the operator.
SHALL NOT
lift, lower, or transport a load with the hoist until the operator and all other personnel are
clear of the load and the path of the load.
SHALL
verify that the load and hoist will clear all obstacles before moving
or rotating the load.
SHALL
avoid moving loads over personnel.
SHALL NOT
lift, lower, or transport personnel by means of the hoist, trolley, hoist hook,
or load.
SHALL
slowly inch the load hook into engagement with the load to eliminate load chain slack
and minimize impact loading the hoist.
SHALL
avoid unnecessary inching and quick reversals of direction.
September 19, 2005
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24
STAGEMAKER® OP MAN 2005-
®
SHALL
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
only lift the load a few inches to verify that the load is properly balanced before
continuing with the lift.
SHALL
only lift the load a few inches to verify that the hoist braking system is
functioning properly before continuing with the lift.
SHALL
avoid swinging of the load or hoist load hook when the trolley
(if applicable) or hoist is traveling.
SHALL
avoid sharp contact between trolleys or between trolley and stops
(if applicable).
SHALL NOT
use the hoist load limiting device or load warning device (if provided)
to measure the load to be lifted.
SHALL NOT
use hoist limit devices as a normal means of stopping the hoist.
SHALL NOT
use the slip clutch as a normal means of stopping the hoist
SHALL NOT
permit continuous contact between the hoist body and the load block / slack fall stop.
5.4
Parking the Load
It is Recommended that the Operator:
SHALL NOT
lower a load with the hoist until the operator and all other personnel are
clear of the load and the path of the load.
SHALL
verify that the load will clear all obstacles before lowering the load.
SHALL
block loads before landing if slings or other lifting devices must be
removed from under the landed load.
SHALL
exercise care when removing a sling from under a landed and blocked load.
SHALL NOT
leave a suspended load unattended unless specific precautions to prevent
the load from inadvertent lowering have been instituted and are in place.
SHALL
position the hoist load block and load hook / body above head level for storage when
the hoist is not in use. Seven feet or greater above floor level is recommended.
Hoist Limit Devices
Powered hoists must be equipped with an upper limit device that will prevent the hoist from exceeding
the upper limit of travel. Depending on the shape or size of the load being lifted, it may be impossible for
some part of the load to come into contact with some part of the hoist, trolley, crane, or building structure
before the hoist/load block activates the slip clutch or reaches the upper limit of travel. The operator
must consider this possibility when it is required to lift the load to a level of close proximity to the hoist.
Powered hoists may have additional travel limit devices depending on the specific purchase
specifications of the hoist. However, in such cases, the upper limit device that is activated to stop the
upper limit of travel is considered the primary upper limit device.
September 19, 2005
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25
STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
Operation of the primary upper limit device, on powered hoists, is one of the items the hoist operator
must check during the daily inspection to be performed at the start of each shift, or at the time the hoist
is first used during each shift.
The primary limit device that controls the upper limit of travel is an emergency device only. It shall not
be used as an operational means to stop travel during normal operations.
5.5
General Recommendations
It is Recommended that the Operator:
SHALL
know hand signals used for hoist and crane operations if a signal person is used
in the operation, and accept signals of only persons authorized to give hand signals.
SHALL
obey a stop signal regardless who gives it.
SHALL NOT
adjust or repair a hoist unless qualified and authorized to perform maintenance.
SHALL NOT
use the hoist limiting device or load warning device (if provided) to measure
the load to be lifted.
5.6
Recommended General Do Not’s
It is Recommended that the Operator:
DO NOT
operate a hoist that is damaged or has any actual or suspected mechanical
or electrical malfunction.
DO NOT
attempt to lengthen load chain or repair damaged load chain.
DO NOT
use the load chain, any part of the hoist, or the load block and hook as a ground for
welding.
DO NOT
allow a welding electrode to be touched to the load chain or load hook.
DO NOT
remove or obscure any instructions, warnings or warning labels on the hoist.
DO NOT
walk under a suspended load or allow other personnel to walk under
a suspended load.
DO NOT
perform or allow any other person to perform ANY work on a suspended
load that requires a worker to be positioned under the suspended load.
September 19, 2005
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
: 800-955-9967
www.rmhoist.com
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
September 2005
DO NOT WALK UNDER A SUSPENDED LOAD.
DO NOT PERFORM ANY WORK ON A SUSPENDED LOAD THAT REQUIRES A WORKER TO BE
POSITIONED UNDER THE SUSPENDED LOAD.
IF IT IS ESSENTIAL THAT A WORKER BE POSITINED UNDER A SUSPENDED LOAD TO
PERFORM WORK ON THE SUSPENDED LOAD; SUCH WORK SHALL NOT BE STARTED OR
PERFORMED UNTIL OTHER AUXILIARY SUPPORTING MEANS ARE PLACED UNDER THE
SUSPENDED LOAD. FAILURE TO USE OTHER AUXILIARY SUPPORTING MEANS COULD
RESULT IN SERIOUS BODILY INJURY OR DEATH, AND/OR PROPERTY DAMAGE.
5.7
Operator Hand Signals
Hoist operators are normally involved in rigging the load, attaching the load to the hoist, and other tasks
related to the load for which they have skills in addition to those required for operation of the hoist.
Therefore, in addition to the specific information required to operate the hoist, hoist operators should be
familiar with rigging procedures and practices. In many applications, a single hoist may be operated by
several workers as part of their regular job responsibility.
In some instances, when a hoist is used on an overhead crane or when a hoist is used as a component
in a larger material handling system, other persons, such as a signal person, in addition to the hoist
operator, may be involved. Operations that involve an operator (either hoist or crane) and a signal
person (normally the rigging or hookup person) require hand signals between the signal person and the
hoist or crane operator unless voice communication, such as telephone, radio, or an equivalent method,
is used. Where hand signals are used, the operator must be familiar with and understand hand signals,
and must respond to hand signals from the designated signal person except to obey a stop signal
regardless who gives it. When voice communication between the signal person and the operator is
used, a dedicated channel is required in order to eliminate any commands from other personnel in the
area that could be confusing the operator.
Refer to standard hand signals, as shown in ASME B30.2, for use in overhead hoist, and overhead
crane and gantry crane operations. A copy of the standard hand signals should be posted where the
application requires both an operator and a signal person. Special hoist or crane operations may require
the use of additional hand signals or modifications of the standard hand signals. When special signals
are required, they should be documented by the crane owner / user, and agreed upon, and understood,
by the signal person and hoist or crane operator. Special signals should not conflict with standard
signals.
Operators, rigging personal, signal persons, and maintenance personnel SHALL be required to know
the location and operation of the main power supply disconnect all hoists (and cranes, if applicable) in
the area.
NOTE: Do not release operators and users from the responsibility of obtaining, reading, and fully
®
understanding the strict execution and observation of ALL procedures in the STAGEMAKER
COMPACT Concert Hoist OPERATOR’S MANUAL. This will better qualify personnel to operate the
hoist in a safe manner.
___________________________________________________________________________________
_____
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
6
September 2005
APPENDIX – A – DEFINITIONS OF ELECTRIC CHAIN HOIST TERMS
below-the-hook lifting devices – Devices that are not normally reeved onto the hoist chain,
such as hook-on buckets, magnets, grabs, and other supplemental devices used for ease of handling
certain types of loads. The weight of these devices is to be considered part of the load to be lifted.
block loads – An action that facilitates the removal of slings or other lifting devices from under the
load, accomplished by bringing the load to rest on wood, metal, or other spacers between the floor and
load.
brake – A device, other than a motor, used for retarding or stopping motion by friction or power means.
brake, holding – A friction brake for a hoist that is automatically applied and prevents motion when
power to the brake is de-energized.
chain, hand – The chain grasped by a person to apply force required for the lifting / lowering and or
traversing motion.
chain, welded link – A chain consisting of a series of interwoven links formed and welded.
designated person – A person selected or assigned by the employer or the employer’s
representative as being competent to perform specific duties.
hand chain wheel – See wheel, hand chain.
hoist – A machinery unit that is used for lifting or lowering a freely suspended (unguided) load.
lifting devices – Devices that are not normally reeved onto the hoist chain, such as hook-on buckets,
magnets, grabs, and other supplemental devices used for ease of handling certain types of loads. The
weight of these devices is to be considered part of the load to be lifted.
limit device – A device that is operated by some part or motion of power driven hoist to limit motion.
limit device, primary upper – See primary upper- limit device.
load – The total superimposed weight on the hoist or hook.
load, rated – The maximum load for which a hoist is designated by the manufacturer or a qualified
person.
hook block – The assembly of hook or shackle, swivel, bearing, sheaves, sprockets, pins, and frame
suspended by the hoisting load chain. This shall include any appurtenances reeved in the hoisting load
chain.
load chain – See chain, load.
load suspension parts – The load suspension parts of the hoist are the means of suspension
(hook or lug), the structure or housing which supports the load sprocket, the load sprocket, the load
chain, the sprockets, and the load block or hook.
September 19, 2005
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
September 2005
normal operating conditions – Conditions during which a hoist is performing functions within the
scope of the original design.
overload – Any load greater than the rated load.
parts (lines or falls) – Number of lines of chain supporting the hook block or hook.
pendant station – Controls suspended from the hoist for operating the unit from the floor.
primary upper-limit device – The primary upper-limit device is the first limit device that will be
activated to control the upper limit of travel of the load block or hoist body when a hoist is equipped with
more than one upper-limit device.
qualified person – A person who, by possession of a recognized degree in an applicable field or a
certificate of professional standing, or who by extensive knowledge, training, and experience, has
successfully demonstrated the ability to solve or resolve problems relating to the subject matter and
work.
rated load – See load, rated.
reeving – A system in which chain travels around sprockets.
side pull – The component of the hoist pull, acting horizontally, when the hoist lines with hooks inline
are not operated vertically.
slack fall stop – A device used to prevent the slack end of load chain from inadvertently being
lowered out of the load sprocket.
sprocket, load – A hoist component that transmits motion to the load chain. This component is
sometimes called load wheel, load sheave, pocket wheel, or chain wheel.
switch – A device for making, breaking, or changing the connections in an electric or pneumatic circuit
(valve).
trolley – A machine unit that travels on a monorail track or crane bridge girder.
trolley hoist – A hoist and trolley unit consisting of a hoist suspended from or mounted to a trolley, or
a hoist with an integral trolley.
welded link chain – See chain, welded link.
wheel, hand chain – A wheel with formed pockets on its periphery to allow torque to be transmitted
when a force is applied to the hand chain.
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STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
: 800-955-9967
www.rmhoist.com
7
September 2005
APPENDIX – B – REFERENCES
NOTE: The current edition date of a listed document or standard, in effect at the time of publication of
this manual, is shown. It is recommended that the reader refer to the latest edition.
HMI Hoist Operator’s Manual
HMI Recommended Practices – Electric And Air Powered Hoists
HMI Consensus of the NEC
Publisher:
Hoist Manufacturers Institute
8720 Red Oak Blvd., Suite 201
Charlotte, NC 28217
ASME HST-1-1999 Performance Standard for Electric Chain Hoists
ASME B30.2-1996 Safety Standard, Overhead and Gantry Cranes (Top Running Bridge, Single or
Multiple Girder, Top Running Trolley Hoist)
ASME B30.9-1996 Safety Standard, Slings
ASME B30.10-1999 Safety Standard, Hooks
ASME B30.11-1998 Safety Standard, Monorails and Underhung Cranes
ASME B30.16-1998 Safety Standard, Overhead Hoists (Underhung)
ASME B30.20-1999 Safety Standard, Below-the-Hook Lifting Devices
The American Society of Mechanical Engineers
Three Park Avenue
New York, NY 10016-5990
CMAA Specification No. 70, Revised 1999 Specification for Top Running Bridge and Gantry Type
Multiple Girder Electric Overhead Traveling Cranes
CMAA Specification No. 74, Revised 1999 Specifications for Top Running & Under Running Single
Girder Electric Overhead Traveling Cranes Utilizing Under Running Trolley Hoist
CMAA Crane Operators Manual
Publisher:
Crane Manufacturers Association of America, Inc.
8720 Red Oak Blvd., Suite 201
Charlotte, NC 28217
ANSI/MMA MH27.1-1996 Specifications for Patented Track Underhung Cranes and Monorail Systems
MMA MH27.2-1997 Specifications for Enclosed Track Underhung Cranes and Monorail Systems
Publisher:
September 19, 2005
0.doc
Monorail Manufacturers Association, Inc.
8720 Red Oak Blvd., Suite 201
Charlotte, NC 28217
30
STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
STAGEMAKER® COMPACT Concert Hoist
: 800-955-9967
www.rmhoist.com
NFPA 70-1999 National Electrical Code
Publisher:
Operator’s Manual
September 2005
National Fire Protection Association
Battermarch Park
Quincy, MA 02269
ANSI Z244.1-1982(R1993) Safety Requirements for the Lockout / Tagout of Energy Sources
Publisher:
September 19, 2005
0.doc
American National Standards Institute
11 West 42nd Street
New York, NY 10036
31
STAGEMAKER® OP MAN 2005-
®
R&M Materials Handling, Inc
Springfield, Ohio USA
: 800-955-9967
www.rmhoist.com
8
STAGEMAKER® COMPACT Concert Hoist
Operator’s Manual
September 2005
APPENDIX – C – RECOMMENDED PRACTICES – ELECTRIC POWERED
HOISTS
RECOMMENDED PRACTICES - ELECTRIC POWERED HOISTS
Because R&M Materials Handling, Inc. has no direct control over the hoist and its operation,
conformance with good safety practice is the responsibility of the user and operating personnel.
ANSI/ASME B30.16 has been used as a guide in preparing this list of SHALL’s and SHALL NOT’s.
Ask your supervisor for a copy. Each is identified according to ANSI / NEMA Z535.4 with either the
signal word CAUTION or WARNING to indicate the degree of seriousness
WARNING
CAUTION
Improper operation of a hoist can create a potentially hazardous
situation, which, if not avoided, could result in death or serious
injury. To avoid such a potentially hazardous situation, the
operator SHALL:
1. NOT operate a damaged, malfunctioning or unusually
performing hoist.
2. NOT operate the hoist until you have thoroughly read and
understand the Operator’s Manual and the Installation and
Maintenance Manual provided with this hoist.
3. NOT operate a hoist that has been modified without the
manufacturer’s approval or without certification that it is in
conformity with ANSI/AMSE B30 volumes.
4. NOT lift more than rated load for the hoist.
5. NOT use hoist with twisted, kinked, damaged, or worn load
chain.
6. NOT use the hoist to lift, support, or transport people.
7. NOT lift loads over people.
8. NOT operate a hoist unless all persons are and remain
clear of the supported load.
9. NOT operate unless load is centered under hoist.
10. NOT attempt to lengthen the chain or repair damaged load
chain.
11. Protect the hoist’s chain from weld splatter or other
damaging contaminants.
12. NOT operate hoist when it is restricted from forming a
straight line from hook-to-hook in the direction of loading.
13. NOT use load chain as a sling, wrap load chain around
load.
14. NOT apply the load to the tip of the hook or to the hook
latch.
15. NOT apply load unless load chain is properly seated in the
chain wheel(s) or sprocket(s).
16. NOT apply load if bearing prevents equal loading on all load
supporting chains.
17. NOT operate beyond the limits of the load chain travel.
18. NOT leave load supported by the hoist unattended unless
specific precautions have been taken.
19. NOT allow the load chain or hook to be used as an
electrical or welding ground.
20. NOT allow the load chain or hook to be touched by a live
welding electrode.
21. NOT remove or obscure the warnings on the hoist.
22. NOT operate a hoist on which the safety placards or decals
are missing or illegible.
23. NOT operate a hoist unless it has been securely attached
to a suitable support.
24. NOT operate a hoist unless load slings or other approved
single attachments are properly sized and seated in the
hook saddle.
25. Take up slack carefully – make sure load is balanced and
load holding action is secure before continuing.
26. Shut down a hoist that malfunctions or performs unusually
and report such malfunctions.
27. Make sure hoist limit switches function properly.
28. Warn personnel of an approaching load.
Improper operation of a hoist can create a potentially hazardous
situation, which, if not avoided, could result in minor or moderate
injury. To avoid such a potentially hazardous situation, the
operator SHALL:
1. Maintain a firm footing or be otherwise secured when
operating the hoist.
2. Check brake function by tensioning the hoist prior to each
lift operation.
3. Use hook latches. Latches are to retain slings, chains, etc.
under slack conditions only.
4. Make sure the hook latches are closed and not supporting
any parts of the load.
5. Make sure the load is free to move and will clear all
obstructions.
6. Avoid swinging the load or hook.
7. Make sure hook travel is in the same direction as shown on
the controls.
8. Inspect the hoist regularly, replace damaged or worn parts,
and keep appropriate records or maintenance.
9. Use the hoist manufacturer’s recommended parts when
repairing the unit.
10. Lubricate load chain per Installation and Maintenance
Manual supplied with the hoist.
11. NOT use the hoist load limiting or warning device to
measure load.
12. NOT use limit switches as routine operating stops unless
allowed by manufacturer. They are emergency devices
only.
13. NOT allow your attention to be diverted from operating the
hoist.
14. NOT allow the hoist to be subjected to sharp contact with
other hoists, structures, or objects through misuse.
15. NOT adjust or repair the hoist unless qualified to perform
such adjustments or repairs.
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DISCLAIMER
Under no circumstances does R&M Materials Handling, Inc.
assume any liability for the use of these voluntary
recommendations, and no warranty whatsoever is made in
connection with them. The recommendations do not take
precedence over existing plant/site safety rules and regulations,
and OSHA regulations. It is the user’s intent to absolve and
protect R&M Materials Handling, Inc. from any and all liability, in
tort or otherwise.
STAGEMAKER® OP MAN 2005-