LIM SO Number: ####

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SHOP TEST PROCEDURE & REPORT

DYNAMIC, VARIABLE LOAD TEST
REV0:

PROJECT: LIM Project ####

[customer name] – Mobile Torque Tube Gate Hoists
[customer location]

LOCATION: Lemke Industrial Machine LLC

Finishing Shop
143454 Cty. Hwy. NN
Marathon, WI.

CONTACT: Cody D. Lemke

715-846-0162
clemke@lemkeindustrial.com

DEFINITIONS:
Raise Action = Completely raising the gate from the closed to open position.
Lower Action = Completely lowering the gate from the open to closed position.
Cycle = Complete gate raise action immediately followed by a complete gate lower action.
Test Factor = Test fixture bearing coefficient of friction. Less than 2% load adjustment.
Nominal Lift = Normal, everyday lift of 51,500 lbF. / 25.75 Tons (59,010 ft*lbF.).
That equates to 12.88 Tons per load cell / chain during Nominal Lift.
Alarm Lift = Torque Limit 1 set at this lift: 64,400 lbF. / 32.2 Tons (73,800 ft*lbF.).
That equates to 16.1 Tons per load cell / chain during Alarm Lift.
Maximum Lift = Torque Limit 2 set at this lift: 80,000 lbF. / 40.0 Tons (91,670 ft*lbF.).
That equates to 20.0 Tons per load cell / chain during Maximum Lift.
Travel Speed = Approximately 2 FPM.
Unit = Drive unit, or brake motor-reducer assembly.

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 LIM SO Number: ####

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SYNOPSIS:
Safety is important during shop load tests. Witnesses should follow LIM’s instructions for safety, including but
not limited to wearing safety glasses, standing in the correct location during the shop load test, and never
reaching/leaning over equipment while it is connected to power. Do not stand closer than 15 feet from the hoist
during shop load testing and never stand between the hoist and the loading equipment. Avoid equipment pinch
points at all times and do not wear loose clothing, jewelry, untied shoes, etc. Be aware of your surroundings at all
times, including but not limited to overhead conditions. Do not walk through the shop while on your cellphones or
reviewing paperwork (including this packet); head must be up at all times while commuting through LIM facilities.
Ear protection and steel-toed shoes are optional but recommended.

□ Confirm you have read the safety statement above by checking this box and signing below.

Print Name: ____________________ Sign Name: ____________________ Date: / /

LIM will perform a witnessed shop test prior to hoist delivery. The test will demonstrate hoist drive operation, all
local control features including limit switch functionality / interlocking, required consecutive cycles / run time,
required loads, hold points, travel speed, and mobile cart drive operation. Hoist drive operation will be performed
while the hoist is fastened to LIM’s 200 TON hydraulic loading fixture. The loading fixture is capable of
variable, dynamic loading which accurately demonstrates field conditions. The load can be gradually
increased while the hoist is lifting or lowering, and the load is monitored via calibrated load cells. This allows
“Torque Limit 1” and “Torque Limit 2” to be set with increased accuracy. Cart drive operation will be
performed on rails within LIM’s finishing and testing facility. Pictures and videos will be taken of key
demonstrations.

An official from each party in attendance is to sign the ‘master’ test report after completion of the shop load test.
LCRA has the right to determine which parties are required to sign the ‘master’ test report.

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 LIM SO Number: ####

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SHOP TEST LAYOUT (EXAMPLE):

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 LIM SO Number: ####

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LOCAL PUSHBUTTON STATION: (strobes not shown) (see control manufacturer drawings)

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 LIM SO Number: ####

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DYNAMIC, VARIABLE LOAD TEST: (pictures & videos to be taken at each step, as practical)

HOIST SERIAL NUMBER: _____________________________________________________________________

1. Pre-Test Check

Voltage: (460V) ________ V □ Pass □ Fail __________________

Amperage: (40A<)________ A □ Pass □ Fail __________________

Cracks, blowholes or breaks in castings or other parts: □ Pass □ Fail __________________

Damage to electrical insulation: □ Pass □ Fail __________________

Misalignment of machinery: □ Pass □ Fail __________________

Weld cracks or damage: □ Pass □ Fail __________________

Lube oil and seal leakage: □ Pass □ Fail __________________

Extensive blisters, bare spots, rust, or scaling of finish: □ Pass □ Fail __________________

2. With LOCAL OPERATION Selected

2.1. Meter Check:

Gate Position Indication – A: ___________ ft.

2.2. Operate through [10] consecutive Cycles at Normal Lift:

□ Pass □ Fail

2.2.1. Pilot Light Check, Normal Load, Hold & Travel Speed during Raise Action:

□ “Gate Raising”

Chain Load: ___________ TONS Load Hold: □ Pass □ Fail

Travel Speed: ___________

Voltage: __________ V Amperage: ___________ A (29.8 FLA per Motor)

Excessive noise: □ Pass □ Fail __________________

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Excessive heat: □ Pass □ Fail _________________

Sticking or binding of moving parts: □ Pass □ Fail __________________

2.2.2. Torque Limit 1 Interruption at Alarm Load, & Hold:

Chain Load at Torque Limit Trip: ___________ TONS □ Pass □ Fail _______________

Load Hold: □ Pass □ Fail

2.2.3. Torque Limit 2 Interruption at Maximum Load, & Hold:

Bypass Function: □ Pass □ Fail ________________

Chain Load at Torque Limit Trip: ___________ TONS □ Pass □ Fail _______________

Load Hold: □ Pass □ Fail

2.2.4. Observe & Record Gate Position Indicator during Raise Action:

Reading at 1 Linear Foot: ___________ 10 Linear Feet: ___________

2.2.5. E-Stop Interruption:

□ Pass □ Fail

2.2.6. Upper Travel Limit Interruption :

□ Pass □ Fail □ “Upper Limit Reached”

2.2.7. Pilot Light Check, Normal Load, Hold & Travel Speed during Lower Action:

□ “Gate Lowering”

Chain Load: ___________ TONS Load Hold: □ Pass □ Fail

Travel Speed: ___________

Voltage: __________ V Amperage: ___________ A (29.8 FLA per Motor)

Excessive noise: □ Pass □ Fail __________________

Excessive heat: □ Pass □ Fail _________________

Sticking or binding of moving parts: □ Pass □ Fail __________________

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2.2.8. Alarm Load Hold:

Chain Load: ___________ TONS

Load Hold: □ Pass □ Fail

2.2.9. Maximum Load Hold:

Bypass Function: □ Pass □ Fail ________________

Chain Load: ___________ TONS

Load Hold: □ Pass □ Fail

2.2.10. Observe & Record Gate Position Indicator during Lower Action:

Reading at 10 Linear Feet: ___________ 1 Linear Foot: ___________

2.2.11. E-Stop Interruption:

□ Pass □ Fail

2.2.12. Lower Travel Limit Interruption:

□ Pass □ Fail

3. Remote Selection Interruption:

□ Pass □ Fail

4. Off Selection Interruption:

□ Pass □ Fail

5. Hoist Auxiliary Drive Operational Check

5.1 .Electrical/Manual Operation selection lever functions:

□ Pass □ Fail

5.2.Manual handwheel removes and adapter connects:

□ Pass □ Fail

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5.3.System aligns using adjustable feet, and socket connects:

□ Pass □ Fail

5.4.Time to raise gate 10 feet: ___________

5.5.Generator provides sufficient power with 85 foot power cable:

Voltage at hoist: ___________V □ Pass □ Fail

5.6.Electrical/Manual Operation selection lever auto-engages when hoist is electrically operated:

□ Pass □ Fail

6. With Mobile Hoist on Rails and TRAVEL OPERATION Selected

6.1. Operate in both directions [5] times on 40 foot rail:

□ Pass □ Fail _____________________________________________________________

6.2. Braking and accurate alignment of Catch Pin:

□ Pass □ Fail _____________________________________________________________

7. Post-Test Check

Cracks, blowholes or breaks in castings or other parts: □ Pass □ Fail __________________

Damage to electrical insulation: □ Pass □ Fail __________________

Misalignment of machinery: □ Pass □ Fail __________________

Weld cracks or damage: □ Pass □ Fail __________________

Lube oil and seal leakage: □ Pass □ Fail __________________

Extensive blisters, bare spots, rust, or scaling of finish: □ Pass □ Fail __________________

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8. General Notes & Observations

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TEST WITNESS RECORD:

Name: _______________________________ Company _____________________________________

Signature: ____________________________ Date: ____________________

Name: _______________________________ Company _____________________________________

Signature: ____________________________ Date: ____________________

Name: _______________________________ Company _____________________________________

Signature: ____________________________ Date: ____________________

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