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Technical Manual
R&M Materials Handling, Inc
Springfield, Ohio USA
: 800 955-9967
web:
www.rmhoist.com
STAGEMAKER
STAGEMAKER
STAGEMAKER
STAGEMAKER
INSTALLATION, OPERATION AND MAINTENANCE
INSTALLATION, OPERATION AND MAINTENANCE
INSTALLATION, OPERATION AND MAINTENANCE
INSTALLATION, OPERATION AND MAINTENANCE
JOB
JOB NO
JOB
JOB
SERIAL NO. : . : . : . :
SERIAL NO
SERIAL NO
SERIAL NO
(RECORD HOIST SERIAL NUMBER FOR FUTURE REFERENCE)
08/14/02
® ® ® ®
COMPACT Concert
COMPACT
COMPACT
COMPACT
SM5
INSTRUCTIONS
INSTRUCTIONS
INSTRUCTIONS
INSTRUCTIONS
NO. : . : . : . :
NO
NO
®
STAGEMAKER
COMPACT Concert Hoist
Concert Hoist
Concert
Concert
Bulletin: RM-SM5-MAN-2001-1-ENG.doc
SM5 Manual
Revision 1
Hoist
Hoist
Hoist
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Summary of Contents for R&M STAGEMAKER COMPACT SM5
- Page 1 ® R&M Materials Handling, Inc STAGEMAKER COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com ® ® ® ® STAGEMAKER STAGEMAKER STAGEMAKER STAGEMAKER COMPACT COMPACT Concert COMPACT COMPACT Concert Concert Hoist Concert Hoist Hoist Hoist INSTALLATION, OPERATION AND MAINTENANCE INSTALLATION, OPERATION AND MAINTENANCE...
- Page 2 ® R&M Materials Handling, Inc STAGEMAKER COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Before proceeding with the installation, operation or maintenance of the hoist it is important that installation, operating and maintenance personnel read this bulletin carefully in order to ensure the safe and efficient use of the hoist.
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Page 3: Table Of Contents
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com TABLE OF CONTENTS Section Page Table of Contents .....................i Foreword ........................iii Warranty......................iii Parts & Service....................iii Claims for Damage in Shipment ..............iii 1. - Page 4 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Upper & Lower Limit Switch.................4-11 Rotary Limit Switch ..................4-12 Controls ......................4-13 AFC Board ..................4-13 PC Board Controls ................4-14 Hoist Circuit Diagram - Standard............4-14 Control Panel....................4-15 Circuit Diagram....................4-19 5.
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Page 5: Foreword
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com FOREWORD This manual has been prepared to acquaint you with the procedures necessary for the installation, operation and maintenance of the hoist you have purchased. Proper installation is important for the performance of your equipment. -
Page 6: Installation
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com SECTION 1 INSTALLATION Figure 1-1 1- Hoist body/motor 5- Chain guide assembly 2- Gears 6- 1-fall hook block 3- Brake/limiter/housing 7- 2-fall hook block assembly 8- Chain container... -
Page 7: General
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com General Each complete electric chain hoist is load tested in accordance to ANSI B30.16 at the factory at 125% of nameplate rated capacity, and is usually shipped assembled, unless otherwise stated on order inquiry. -
Page 8: Mounting
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Mounting The hoist body should be mounted from its suspension hook allowing the body to move in the direction of the load chain pull and to hang in a straight line between the suspension hook and load block during hoisting. - Page 9 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com The customer must supply power cable, power distribution set, installation fusing and main disconnect switch. Figure 1-2 Power supply connection for hoist configuration A Combined power and controls for hoist configuration C or configuration D Controls, hoist configuration B1 or configuration B2 Trolley connection, if motorized trolley is supplied, for hoist configuration B1 only.
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Page 10: Initial Start-Up
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com SECTION 2 INITIAL START-UP WARNING Before connecting the hoist to the power supply, check all “motion” buttons or selector switches on your controller or push button station to ensure that none of them bind or stick in any position. -
Page 11: No Load Operational Checks
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com No Load Operational Checks ü Check the hoist motor brake function. ü Run the empty hook block up or down to check that the hook drift does not exceed more than 1 inch (25mm). -
Page 12: Safe Operation Practices
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 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. - Page 13 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com DO’S - HOISTS 1. READ and follow manufacturer’s Instruction, Installation and Maintenance manuals. When repairing or maintaining a hoist use only manufacturer’s recommended parts and materials. 2.
- Page 14 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com DON’TS - HOISTS 1. NEVER lift or transport a load until all personnel are clear and do not transport the load over personnel, unless additional safety precautions are taken.
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Page 15: Operation/Maintenance
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 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. -
Page 16: Motors
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 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 regreasing. -
Page 17: Adjustment Of The Limiter
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Adjustment of the Limiter (Refer to Figure 4-3) WARNING Make sure that the main switch supplying power to the hoist is in the opened and locked position before adjusting the torque-limiter. -
Page 18: Adjustment Of The Brake
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Air gap Figure 4-3 Adjustment of the Brake (Refer to Figure 4-3) The maximum air gap of the brake is 0.022"[0.55mm]. If this value has been reached or will be exceeded before next inspection, the brake must be adjusted. -
Page 19: Frame (Hoist Body)
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Frame (Hoist Body) The frame (hoist body) 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. -
Page 20: Load Chain Replacement
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Load Chain Replacement Chain Specification: Load chain Chain type: Standard Diameter (d) x Pitch (t): 0.189 x 0.492” (4.8 x 12.5 mm) Class: Grade: H8S or HE G80 RAS... -
Page 21: Load Chain Removal
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Load Chain Removal 1-fall chain 1. Remove the load from the hook. 2. Disassemble the hook block. 3. Drive the chain into the chain container. 4. - Page 22 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 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.
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Page 23: Fall Stop Assembly
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Fall Stop Assembly Figure 4-7 REMOVAL: 1. Remove the cotter pin. 2. Slide the ring up from the stop. 3. Remove the stop. 4. -
Page 24: Hook Specification
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 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. -
Page 25: Suspension Hook
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 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. -
Page 26: Rotary Limit Switch
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Rotary Limit Switch The rotary limit switch is an adjustable type and provides over-travel protection for the upper and lower limits of hoist travel. The limit switch is a control circuit type. Limit switches are not available for hoist configuration A - direct (full line voltage) control. -
Page 27: Controls
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Controls 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. -
Page 28: Hoist Circuit Diagram-Standard
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 2. PC Board - control transformer and contactors are soldered to a circuit board. PC Board is furnished on the hoist for configuration B1, B2 or C. A special PC Board is furnished on the hoist for configuration D. - Page 29 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com (Hoist configuration B1 or B2) TWO SPEED HOIST: 208V/230V or 460V Figure 4-13 HOIST SUPPLY PRINTED CIRCUIT BOARD C Protections TAG STRIP X1 hoist supply 30-31 Thermal prot.
- Page 30 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com (Hoist configuration B1 or B2) SINGLE SPEED HOIST: 208V/230V Figure 4-14 HOIST SUPPLY PRINTED CIRCUIT BOARD C Protections TAG STRIP X1 30-31 Thermal F291 hoist supply Terminal No:...
- Page 31 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com (Hoist configuration B1 or B2) SINGLE SPEED HOIST: 460V Figure 4-15 HOIST SUPPLY PRINTED CIRCUIT BOARD C Protections TAG STRIP X1 30-31 Thermals F291 hoist supply Terminal No:...
- Page 32 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com (Hoist configuration D) SINGLE SPEED HOIST Configuration D hoists are equipped with a multi connector, which are wired as follows: PLUG PIN N°...
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Page 33: Circuit Diagram
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Hoist Circuit Diagram-Standard (Hoist configuration A) SINGLE SPEED HOIST: 208V / 230V 08/14/02 RM-SM5-MAN-2001-1-ENG... - Page 34 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Hoist Circuit Diagram-Standard (Hoist configuration B1 or B2) TWO SPEED HOIST: 208V/230V or 460V 08/14/02 RM-SM5-MAN-2001-1-ENG...
- Page 35 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Hoist Circuit Diagram-Standard (Hoist configuration B1 or B2) SINGLE SPEED HOIST: 208V/230V (Hoist configuration B1 or B2) SINGLE SPEED HOIST: 460V 08/14/02 RM-SM5-MAN-2001-1-ENG...
- Page 36 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Hoist Circuit Diagram (Hoist configuration D) 08/14/02 RM-SM5-MAN-2001-1-ENG...
- Page 37 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Hoist Circuit Diagram (Hoist configuration D) Test facility 08/14/02 RM-SM5-MAN-2001-1-ENG...
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Page 38: Preventative Maintenance
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com SECTION 5 PREVENTATIVE MAINTENANCE Maintenance table Qualification of the Check Interval customer’s personnel Brake operation for holding and releasing Daily Operator Visual inspection of the load chain Daily... -
Page 39: Lubricants
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com Lubricants Lubrication point Specifications Possible brands Quantity Chain Oil or liquid grease Chain lubricating fluid (Ceplattyn or similar) As required EP-90 Idler sprocket Grease (without MoS2) -
Page 40: Troubleshooting
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Manual : 800 955-9967 Revision 1 web: www.rmhoist.com 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... - Page 41 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Index of Exploded Illustrations and Parts Lists HOIST BODY ........................2 GEAR MECHANISM & VERSION 2A BRAKE ..............4 GEAR MECHANISM & VERSION 2B BRAKE ..............6 LIFTING ASSEMBLY ......................8 CONTROLS ........................10 UPPER &...
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Page 42: Hoist Body
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Hoist Body 08/14/02 RM-SM5-SPARE-2001-1-ENG.doc... - Page 43 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Hoist Body Item Item Item Item Part Number Part Number Part Number Part Number Description Description Description Description Comments Comments Comments Comments...
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Page 44: Gear Mechanism & Version 2A Brake
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Gear Mechanism & Brake (Brake version 2A) 08/14/02 RM-SM5-SPARE-2001-1-ENG.doc... - Page 45 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Gear Mechanism & Brake (Brake version 2A) Item Item Item Item Part Number Part Number Part Number Part Number Description Description Description...
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Page 46: Gear Mechanism & Version 2B Brake
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Gear Mechanism & Brake (Brake version 2B) 08/14/02 RM-SM5-SPARE-2001-1-ENG.doc... - Page 47 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Gear Mechanism & Brake (Brake version 2B) Item Item Part Number Part Number Description Description Comments Comments Item Item Part Number Part Number Description...
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Page 48: Lifting Assembly
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Lifting Assembly 08/14/02 RM-SM5-SPARE-2001-1-ENG.doc... - Page 49 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Lifting Assembly Item Item Item Item Part Number Part Number Part Number Part Number Description Description Description Description Comments Comments Comments Comments...
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Page 50: Controls
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Controls 08/14/02 RM-SM5-SPARE-2001-1-ENG.doc... - Page 51 R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Controls Item Item Item Item Part Number Part Number Part Number Part Number Description Description Description Description Comments Comments Comments Comments =1+6+5...
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Page 52: Upper & Lower Limit Switch
R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist Springfield, Ohio USA SM5 Spare Parts : 800 955-9967 Revision 1 web: www.rmhoist.com Upper & Lower Limit Switch for Upright position (Configuration B1 only) Attention: Attention: Attention: Attention: The limit switch, when furnished, is installed in place of the rubber buffer. Use screws 6x30mm. Item Item Part Number...