CM Lodestar XL Operating, Maintenance And Parts Manual

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Page 1

OPERAT I N G ,

MAINTENANC E

& PA R T S

MANUAL

ELECT R I C

CHAIN HOIST

Manual No. 652-E

Before installing hoist, fill in the information below. Refer to the hoist identification plate.

Model No. __________________

Serial No. __________________

Purchase Date ______________

Voltage ____________________

Rated Capacity______________

52756

XXLL

Rated capacities 2 through 7½ tons/ 2000 through 7500 kg

Follow all instructions and warnings for inspecting, maintaining and operating this hoist.

The use of any hoist presents some risk of personal injury or property damage. That risk is greatly increased if proper instructions and warnings are not followed. Before using this hoist, each operator should become thoroughly familiar with all warnings, instructions and recommendations in this manual.

Retain this manual for future reference and use.

Forward this manual to operator. Failure to operate equipment as directed in manual may cause injury.

Page 2

CM®XL HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA

As a CM

XL Hoist user, you are assured of reliable repair and parts services through a network of Master Parts Depots and Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.

Below is a list of the Master Parts Depots in the United States and Canada. To quickly obtain the name of the U.S. Service Center located nearest you, call 314-869-7200 | FAX: 314-869-7226. In the following list, the Canadian Service Centers are indicated.

UNITED STATES MASTER PARTS DEPOT

CANADIAN SERVICE CENTERS

MISSOURI

Distributed by Tri-State Equipment Company Inc. Email: sales@tsoverheadcrane.com Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

COLUMBUS McKINNON, LTD. 10311-174th Street

Edmonton,

Alberta T5S 1H1

Page 3

SAFETY PRECAUTIONS

Each CM

Lodes tar XL Electric Hoist is built in accordance wit h the spe cific ation s conta ined he rein an d at the ti me of manuf actur e compl ied wit h our interpretation of applicable sections of the *A meric an Soci ety of Me chani cal Eng ineer s Stand ard B30 .16 “Overhead Hoists,” the National Electrical Co de (ANS I/NFPA 70) a nd the Oc cupat ional S afety a nd Healt h Act. Since OHSA states the N ation al Elec trica l Code ap plies t o all ele ctric h oists , insta llers a re requ ired to p ro vide cu rrent o verload protection and grounding on the bran ch circ uit sec tion in k eepin g with th e code. Ch eck eac h insta llati on for co mplia nce with the application, operation and maintenance sect ions of t hese ar ticle s.

The safety laws for elevators, lifting of people and for dumbwaiters specify construction details that are not incorporated in Lodes tar XL hoists. For such applications, re fer to th e requi remen ts of app licab le stat e and loc al code s, and th e Ameri can National Safety Code for elevators, dumb waite rs, esc alato rs and mo ving wa lks (AS ME A17. 1). Col umbus McKin non Cor porat ion cannot be responsible for applications other th an thos e for whi ch CM equ ipmen t is inte nded.

* Copies of this Standard can be obtained from ASME Order Department, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300, U.S.A.

THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED WITH THE EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR CM

LODESTAR XL HOIST.

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 malfunction.

27. Make sure hoist limit switches function properly.

28. Warn personnel of an approaching load.

1. Not operate a damaged, malfunctioning or unusually performing hoist.

2. Not

operate the hoist until you have thoroughly read and understood this Operating, Maintenance and Parts Manual.

3. Not

operate a hoist which has been modified.

4. Not lift more than the 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 load chain or repair damaged load chain.

11. Protect the hoist’s load 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, or wrap load or 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 sproket(s).

16. Not

apply load if bearing prevents equal loading on all

load 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.

WARNING

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:

WARNING

Usage of hoists that do not involve lifting of the load on the lower hook or using hoists in the inverted position without special precaution may cause an accident resulting in injury and/or property damage.

TO AVOID INJURY:

Consult Factory for information concerning using hoists in these applications.

CAUTION

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 slackconditions 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 of maintenance.

9. Use the hoist manufacturer’s recommended parts when repairing the unit.

10. Lubricate load chain per instructions in this manual.

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 when operating 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.

Page 4

iii

Page 5

ITEM PAGE NO. MASTER PARTS DEPOTS AND SERVICE CENTERS .

SAFETY PRECAUTIONS . . . . . . . . . . . . . ii

HOIST SAFETY IS UP TO YOU. . . . . . . . iii

GENERAL INFORMATION

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 2

REPAIR/REPLACEMENT POLICY . . . . . . 3

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION

UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INSTALLING THE SUSPENSION

HOOK SUSPENSIONS . . . . . . . . . . . . . . . . . . 4

LUG SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . 6

MOUNTING TROLLEY ON HOIST. . . . . . 6

INSTALLING TROLLEY SUSPENDED

HOIST ON BEAM

. . . . . . . . . . . . . . . . . . . . .7

INSTALLING BREATHER . . . . . . . . . . . . . . . . 8

POWER SUPPLY SYSTEM . . . . . . . . . . . . . . . 8

ELECTRICAL CONNECTIONS

SINGLE SPEED DUAL VOLTAGE HOISTS (AND MOTOR DRIVEN TROLLEYS) . 9

ALL HOISTS. . . . . . . . . . . . . . . . . . . . . . . . . 9

CHECKING FOR TWIST IN LOAD CHAIN . 10 CHECKING FOR ADEQUATE VOLTAGE . . 10

CHECKING LIMIT SWITCH OPERATION . . . 10

CHAIN CONTAINER. . . . . . . . . . . . . . . . . . . . 10

CONTROL CORD . . . . . . . . . . . . . . . . . . . . . . . 10

OPERATING INSTRUCTIONS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ALL HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

HOIST WITH PLAIN TROLLEY . . . . . . . . . . . . 11

HOIST WITH GEARED TROLLEY . . . . . . . . . . 11

HOIST WITH MOTOR DRIVEN TROLLEY . . 11

SAFETY PROCEDURES. . . . . . . . . . . . . . . . . . . 11

ITEM PAGE NO. MAINTENANCE

INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FREQUENT INSPECTIONS . . . . . . . . . . . . . . 12

PERIODIC INSPECTIONS . . . . . . . . . . . . . . . 12

HOOK INSPECTION . . . . . . . . . . . . . . . . . . . 12

LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 13

PROTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 13

LUBRICATION

HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TROLLEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ADJUSTMENTS

HOIST BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 15

LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . 16

TROLLEY BRAKE . . . . . . . . . . . . . . . . . . . 17

RECOMMENDED SPARE PARTS. . . . . . . 18

PREVENTIVE MAINTENANCE . . . . . . . . . 18

TROUBLE SHOOTING

ALL HOISTS. . . . . . . . . . . . . . . . . . . . . . . . 19

TWO SPEED HOISTS . . . . . . . . . . . . . . . . . 22

MOTOR DRIVEN TROLLEY . . . . . . . . . . . . 23

ELECTRICAL DATA . . . . . . . . . . . . . . . . . 24, 25

WIRING DIAGRAMS . . . . . . . . . . . . . . . 26, 28

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 29

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 29

REMOVAL AND REPLACEMENT OF LOAD CHAIN29 REEVING LOAD CHAIN

3,4 AND 5 TON DOUBLE REEVED UNITS . . 30 5,6 AND 71/2 TON TRIPLE REEVED UNITS . 31

CUTTING CHAINS. . . . . . . . . . . . . . . . . . . . . . 31

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

REPAIR PARTS

ORDERING INSTRUCTIONS. . . . . . . . . . . . 32

EXPLODED VIEWS AND PARTS LISTS. . 33-48

FOREWORD

This manual contains important information to help you properly install, operate and maintain your hoist for maximum performance, economy and safety.

Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating procedures and by carrying out the recommended preventative maintenance suggestions, you will experience long, dependable and safe service. After you have completely familiarized yourself with the contents of this manual, we recommend that you carefully file it for future reference.

The information herein is directed to the proper use, care and maintenance of the hoist and does not comprise a handbook on the broad subject of rigging. Rigging can be defined as the process of lifting or moving heavy loads using hoist and other mechanical equipment. Skill acquired through specialized experience and study is essential to safe rigging operations. For rigging information, we recommend consulting a standard textbook on the subject.

TABLE OF CONTENTS

Page 6

SPECIFICATIONS

The CM®LODESTAR XL Electric Chain Hoist is a highly versatile material handling device that can be used to lift loads that are within its rated load capacity. Single and Two speed units with rated loads up to 7½ tons (7500 kg.) are available. The hoist can be supplied with a single hook suspension up to 6 ton (6000 kg.) capacity or suspended from a plain, geared or motor driven trolley. The standard lift is 10 feet and longer lifts can be provided on a per order basis.

The standard features of the CM

LODESTAR XL Electric

Chain Hoist include:

• Hardened, alloy steel, oblique lay liftwheel provides constant chain speed and reduces chain wear.

• Hoistaloy

load chain for long and dependable

service.

• Lightweight cast aluminum frame and covers.

• Surface hardened, alloy steel, helical gears running in an oil bath provide smooth and quiet operation.

• Protector that prevents lifting an excessive overload.

• Single or two speed hoist duty motor equipped with thermal protection.

• Low voltage control circuit. 115 volt is standard. 24 or 48 volt control circuits are also available.

• Hardened, forged steel hooks equipped with latch.

TABLE 1—SPECIFICATIONS

LODESTAR XL ELECTRIC CHAIN HOISTS

TONS 2 3 4 & 5 5 5 6 7½

RATED LOAD Kg. 2000 3000 4000 & 5000 5000 5000 6000 7500

*LIFTING SPEEDS AVAILABLE:

FPM 18 24 30 9 12 15.2 6 8 6 8 10 6 10

SINGLE SPEEDS

MPM 5.5 7.3 9.1 2.7 3.6 4.6 1.8 2.4 1.8 2.4 3.0 1.8 3.0

FPM 6 /18 8 / 24 3/9 4/12 2/6 2.7/8 2/6 2.7/8 2/6

TWO SPEEDS N/A N/A N/A N/A

MPM

1.8 / 5.5 2.4 / 7.3 .9/2.7 1.2 / 3.6 .6 / 1.8 .8 / 2.4 .6/1.8 .8/2.4 .6/1.8

FEET 127 139 71 60 65 106 42 46 42 46 71 42 71

MAXIMUM LIFT

METERS 39 42 22 19 21 32 13 14 13 14 22 13 22

REEVING OF LOAD CHAIN SINGLE DOUBLE TRIPLE

MINIMUM HEADROOM

HOOK SUSPENDED—IN. (mm) 25 (635) 35.31 (897) 36.18 (919) N/A

TROLLEY SUSPENDED—IN. (mm) 28.69 (729) 33 (841) 33.38 (848) 34.25 (870) 34.25 (870)

RANGE OF TROLLEY ADJUSTABILITY 6 X 12.5

TO 8 X 18.4#TO 20 X 66.0

“S” BEAMS 15 X 42.9

IN. 3.33 TO 5.50 4.00 TO 6.250

FLANGE WIDTH

mm 84.5 TO 139.7 101.6 TO 158.8

STANDARD MOTOR DRIVEN TROLLEY 65 (19.8) OR TRAVEL SPEED—FPM (MPM) 100 (30.4) 50 (15.2)

**APPROX. NET WEIGHT—LBS. (Kg.)

HOOK SUSPENDED 368 (167) 442 (200) 442 (200) 474 (215) WITH PLAIN TROLLEY 428 (194) 497 (225) 597 (271) 629 (285) WITH GEARED TROLLEY 473 (215) 512 (232) 607 (275) 639 (290) WITH MOTOR DRIVEN TROLLEY 483 (219) 582 (264) 632 (287) 664 (301)

*Lifting speeds are based on 60 Hertz power supply. When operating on 50 Hertz, lifting speeds will be 5/6 of those listed. **Weights are for single speed hoist with 10 ft. (3 M) lift. For two speed hoists, add 10 pounds (4.5 Kg.).

GENERAL INFORMATION

• Oversize reversing and speed selecting contactors for long, trouble free service.

• Hoist duty, A.C. motor brake plus regenerative braking.

• Weatherproof, CM 2 or 4 direction control station.

•Shielded, lifetime lubricated ball bearings at all rotating points. Open bearings are used in gear case.

• Voltage conversion board on single speed, dual voltage units.

• Three stage gear reduction.

• Upper and lower screw type limit switches.

CM®LODESTAR XL Hoist with Motor Driven Trolley

Page 7

REPAIR/REPLACEMENT POLICY

All Lodestar XL Electric Chain Hoists are thoroughly inspected and performance tested prior to shipment. If any properly maintained hoist develops a performance problem due to a material or workmanship defect, as verified by factory, repair or replacement of the unit will be made to the original purchaser without charge. This repair/replacement policy applies only to LODESTAR XL Hoists installed, maintained and operated as outlined in this manual, and specifically excludes parts subject to normal wear, abuse, improper installation, improper or inadequate maintenance, hostile environmental effects and unauthorized repairs/modifications.

We reserve the right to change materials or design if, in our opinion, such changes will improve our product. Abuse, repair by an unauthorized person, or use of non-factory replacement parts voids the guarantee and could lead to dangerous operation. For full Terms of Sale, see Sales Order Acknowledgement. Also, refer to the back cover for Limitations of Warranties, Remedies and Damages, and Indemnification and Safe Operation.

ACCESSORIES

HOOK SUSPENSIONS

Hook suspensions are available for suspending 2 through 6 ton hoist from a trolley with a single load bar or for suspending the hoist from a fixed

structure.

LUG SUSPENSIONS

Lug suspensions are required to suspend the LODESTAR XL Electric Hoist from plain, geared or motor driven trolleys described below. When the hoist is to be suspended from a plain, geared or motor driven trolley, the lug suspension is attached to the hoist prior to shipment.

LUG SUSPENSION

PLAIN TROLLEYS

These are manual push type trolleys designed for use with the LODESTAR XL Electric Hoist. The trolley is adjustable to operate on a range of American Standard ‘S’ beams and flat flanged beams. The plain trolley is mounted on hoist prior to shipment.

PLAIN TROLLEY

GEARED TROLLEYS

The geared trolley is similar to the plain trolley except it is moved by the means of a hand chain. The hand chain rotates a pinion that drives gears attached to trolley wheels and moves trolley along the beam. The geared trolley is mounted on the hoist prior to shipment.

MOTOR DRIVEN TROLLEYS

The motor driven trolley is similar to geared trolley except the hand chain wheel is replaced with a gear reducer and an electric motor. The motor is energized by a reversing contactor mounted inside the hoist and it is controlled by push buttons located in the pendant control station. A variety of single and two speed trolley travel speeds are available and the motor driven trolley is mounted on hoist prior to shipment.

2 ton

3-6 ton

HOOK SUSPENSION

Page 8

CHAIN CONTAINER

This accessory is used to hold the slack chain and it is supplied complete with mounting hardware and instructions. The chain container is recommended for those applications where the slack chain will interfere with the load or drag on the floor as may be the case with double and triple reeved units. Chain containers are shipped separately and can be furnished for units already in use.

LATCHLOK®HOOKS

Latchlok hooks are available to replace the standard upper or lower latch type hooks (2-6 ton only). The unique design of the Latchlok hook assures that it will stay locked until the operator releases it by depressing the release button. It will not open accidentally—even if the load chain goes slack. Once opened, it can be shut with one hand or the weight of the load when it is lifted. Latchlok hooks can be supplied with the hoist or it can be provided in kit form for hoists already in service.

LATCHLOK

HOOK

INSTALLATION

UNPACKING

After opening the carton, carefully inspect the hoist, suspension, trolley and chain container for damage that may have occurred during shipment. If there is damage, refer to the packing slip envelope.

Make sure that the power supply to which the hoist is to be connected is the same as that shown on the identification plate located on the bottom of the hoist. For single speed, dual voltage hoists, refer to instructions on page 8.

INSTALLING SUSPENSION

A. HOOK SUSPENSIONS

For hook suspended 2 through 6 ton units, the suspension is shipped separately and it must be attached to the hoist as follows:

1. 2 THROUGH 6 TON. Supplied with the hook suspen-

sion is a counterweight that must be attached to the motor cover using the two long screws provided. Remove and discard corresponding motor cover screws. Place counterweight on motor cover and secure it using the two longer screws. Tighten these screws to a seating torque of 16 pound feet (22 NM).

WARNING

Operating a unit with obvious external damage may cause load to drop and that may result in personal injury and/or property damage.

TO AVOID INJURY:

Carefully check unit for external damage prior to installation.

MAKING SURE THE HOIST WILL OPERATE ON THE POWER SUPPLY SYSTEM

INSPECT FOR SHIPPING DAMAGE

MOTOR DRIVEN TROLLEY

Page 9

c. After the hook is in the desired position, slide the

suspension adapter into cavity on top of hoist and secure it using the suspension adapter screw from the kit. Tighten screw to a seating torque of 16 pound feet (22 NM).

NOTE: INSTALL BREATHER IN MAIN HOUSING AFTER HOOK SUSPENSION IS ASSEMBLED TO HOIST. SEE PAGE 8.

3. 3, 4 and 5 Ton Double Reeved and 5 and 6 Ton Triple Reeved Units. As shipped from the factory, the

hook is rigid with the plane of the hook parallel to long axis of hoist. The hook can be changed to swivel type or the plane of the hook can be changed to perpendicular to the long axis of the hoist as follows:

a. If a swivel type hook is required, remove and discard

keeper plate screw and keeper plate. Then using a hammer, drive the hook nut pin into nut so that the end of the pin is flush with side of the nut.

b. If it is necessary to position the hook so that the

plane of the hook is perpendicular to long axis of hoist, first convert to a swivel type hook as described above but do not discard the keeper plate and screw. Turn hook 90 degrees and insert loose pin (packed with the suspension) into a hole in the hook nut. Loosely reassemble keeper plate to suspension adapter so that the hook is free to swivel approximately 45 degrees in either direction. The hook will be made rigid after suspension is attached to the hoist.

Attach the “XL” label, from the kit, to counterweight in the recess provided for same.

2. 2 Ton Single Reeved Units. As shipped from the facto ry, the hook is rigid with the plane of the hook parallel to the long axis of the hoist. The hook can be changed to swivel type or the plane of the hook can be changed to perpendicular to the long axis of the hoist as follows:

a. If a swivel type hook is required, use a 1/4 inch

(6.4 mm) drift, and working through the hole in the side of the suspension adapter, drive the hook nut pin into the nut so that it is flush with the side of the nut. Discard the loose pin packed with the suspension.

b. If it is necessary to position the hook so that the

plane of the hook is perpendicular to the long axis of hoist, first convert to a swivel type hook as described above. Rotate the hook 90 degrees and slide the loose pin (packed with the suspension) through the hole in the side of the suspension adapter and engage the hole in the hook nut.

CHANGING

POSITION OF

HOOK

TO CONVERT

TO SWIVEL

TYPE HOOK

MOUNTING THE

COUNTERWEIGHT

INSTALLING

HOOK

SUSPENSION

2 TON UNIT

TO CONVERT TO

SWIVEL TYPE

HOOK

DRIFT

COUNTERWEIGHT

Page 10

c. Slide the suspension adapter into cavity on top

of hoist. Install dead end bolt and thread it by hand to engage the dead end block (3, 4 and 5 ton double reeved units) or idler sheave hanger (5 and 6 ton units). Then tighten dead end bolt to a seating torque of 120 pound feet (160NM).

If the hook is to be perpendicular to long axis of hoist per step b above, rotate the hook to that position and firmly tighten the keeper plate screw while making sure the loose pin engages the slot in keeper plate.

NOTE: INSTALL BREATHER IN MAIN HOUSING

AFTER HOOK SUSPENSION IS ASSEMBLED TO HOIST. SEE PAGE 8.

B. LUG SUSPENSIONS

The following instructions are provided to cover installing the lug suspension after the hoist has been reassembled following inspection and/or repair. On hoists shipped from factory, the lug suspension is installed prior to mounting the trolley.

1. 2 Ton Single Reeved Units. Slide the suspension adapter into the cavity on top of hoist and secure it using the suspension adapter screw. Tighten the screw to a seating torqueof16 pound feet (22 NM).

INSTALLING LUG SUS-

PENSION—2 TON UNITS

INSTALLING

HOOK

SUSPENSION

3, 4, 5, & 6 TON

CHANGING

POSITION OF

HOOK

2. 3, 4 And 5 Ton Double Reeved And 5, 6 And 7½ Ton Triple Reeved Units. Slide the suspension adapter into cavity on top of hoist. Install dead end bolt and thread it by hand to engage the dead end block (3, 4 and 5 ton double reeved units) or idler sheave hanger (5, 6 and 7 1/2 ton triple reeved units). Then tighten the dead end bolt to a seating torque of 120 pound feet (160 NM).

INSTALLING LUG

SUSPENSION—3, 4,

5, 6 AND 7 1/2 TON

MOUNTING TROLLEY ON HOIST

The following instructions are provided to cover mounting plain, geared and motor driven trolleys after the hoist has been reassembled following inspection and/or repair. On units shipped from factory, these trolleys are mounted on the hoists.

1. Measure actual width of the beam flange on which the trolley is to operate. To determine proper trolley side frame spacing to assure that adequate wheel clearance is provided, the distance between the beam flange and the inside face of the trackwheel flange (approximately 1/8 to 3/16 inch on straight runway beams, 3/16 to 1/4 inch on curved beams for 2 ton units. See Figure 2) and (1/4 inch for straight runway beams, 3/8 inch on curved beams for 3-7 1/2 ton units. See Figure 1).

2. Use Table 2 to determine proper spacing for 2 ton units. On 3-7 1/2 ton capacity units, proper spacing is obtained by varying the number of spacer washers (furnished with trolley) that are installed on the suspension pins.

WARNING

Using other than factory supplied suspension adapter screw or dead end bolt to attach suspension adapter to hoist may cause the screw or bolt to break and allow the hoist and load to fall.

TO AVOID INJURY:

Use only the factory supplied suspension adapter screw or dead end bolt and tighten these to the seating torque specified above.

MOUNTING

TROLLEY ON

HOIST

HANDWHEEL OR TROLLEY MOTOR GEARED OR MOTOR DRIVEN TROLLEY ONLY

Dead End Bolt

Page 11

3. For 2 ton units, assemble a slotted nut to one end of each suspension bolt and secure it using a cotter pin. Spread legs of cotter pin to keep it in place. Using Table 2 as a reference for washer spacing, assemble side frames and bolts and washers together as shown below. Do not install remaining cotter pins at this time. These are to be installed after the trolley is mounted on the beam.

For 3-7½ ton units, temporarily assemble trolley to hoist using 3 or 4 washers at each end of suspension pins, between side plates and suspension lug. Tighten pin nuts for accurate check of spacing. Measure the distance between the inside faces of the trackwheel flanges and compare to the dimension required. Remove trolley side plates and add or remove an equal number of inside spacer washers as required to obtain proper distance between wheels. When spacing is correct, install all remaining spacer washers on the outside ends of each suspension pin and secure the pins with lockwashers and hex nut (See Note Below). The nuts should not be completely tightened until after hoist and trolley are mounted onto beam.

NOTE: It is very important that all spacer

washers that come with the trolley be used. Install remaining spacer washers equally on outside ends of each suspension pin.

4. On geared and motor driven trolleys, make sure the handwheel or motor is on loose end/chain container side of the hoist.

INSTALLING TROLLEY SUSPENDED HOIST ON BEAM

Stops must be positioned to contact the trolley side frames and not exert impact force on the hoist.

Trolleys are mounted on the hoist prior to shipment and side frames are positioned for the nominal beam flange specified on the order. However, due to variations in beam flange widths, actual beam flange width should be measured to determine the exact distribution of the spacer washers. See Mounting Trolley On Hoist Section.

WARNING

Operating the trolley on a beam that has no rail stops may allow the trolley to fall off the end of the beam.

TO AVOID INJURY:

Install rail stops at each end of the beam on which the trolley is to operate.

WARNING

If washer spacing recommendations are not followed, trolley may fall from beam.

TO AVOID INJURY:

Measure the actual beam flange on which the trolley is to operate and use Table 2 to determine the arrangement of the spacer washers for that flange width.

NOTE: USE OF OTHER THAN SUPPLIED SPACER WASHERS

MAY CAUSE IMPROPER TRACKWHEEL SPACING.

Table 2. Trolley Spacer Washer Arrangement

ABCD

3-3/8 (85.7) 13 0013 3-5/8 (92.0) 11 2211 3-7/8 (98.4) 10 349

4 (101.6) 9449

Standard 4-1/8 (104.7) 8558

Trolleys 4-5/8 (117.4) 58 85

5 (127.0) 3 10 10 3 5-1/8 (130.1) 3 10 11 2 5-1/4 (133.3) 2 11 12 1 5-1/2 (139.7) 0 13 13 0 5-5/8 (142.9) 12 1112

6 (152.4) 10 3310 6-1/4 (158.7) 9458 6-3/8 (161.9) 8567

Special 7 (177.8) 4994

Trolleys 7-1/8 (181.0) 3 10 10 3

7-1/4 (184.1) 3 10 11 2 7-3/8 (187.3) 2 11 12 1 7-1/2 (190.5) 1 12 12 1 7-5/8 (193.7) 0 13 13 0

* Minimum Beam

Radius ft.(M) 4’-0”(1.22)

*Dimension applies to minimum S-beam and will

vary with larger S-beams

Flange Width in.(mm)

2 Ton

No. of Washers

Figure 2.

Figure 1.

QUANTITY OF OUTSIDE WASHERS SHOULD BE EQUAL

-BOTH SIDES

QUANTITY OF INSIDE WASHERS SHOULD BE EQUAL

-BOTH SIDES

Page 12

POWER SUPPLY SYSTEM

To insure proper operation, to avoid damage to hoist and electrical system and to reduce the risk of electric shock or fire, the branch circuit supplying power to the hoist must:

1. Have ample capacity to prevent excess voltage drop during starting and operation (refer to “Checking for Adequate Voltage at Hoist”See Pg. 10). When determining the size of branch circuit components and conductors, special consideration should be given to the starting current-amps (approximately three times that shown on the hoist identification plate) and the length of the conductors. As a minimum, the system should be rated for 20 amps and it should have #12AWG, or larger, wiring.

2. Be in accordance with the National Electrical Code (ANSI/NFPA-70) and applicable National, State and Local Codes.

3. Effectively ground the hoist in accordance with National Electrical Code and other applicable codes. Proper grounding provides a path of least resistance for electric current to reduce the risk of electric shock. The power cord of the hoist includes a green wire for grounding the hoist to the external power supply system. If grounding is to be through the trolley trackwheels, each section of the runway must be grounded to the building ground system using metal to metal connections.

4. Include slow blow type fuses or inverse trip time circuit breakers to permit the hoist to start and accelerate load.

5. Include a disconnecting means capable of being locked in the “open” position.

Before installing geared or motor driven trolleys (2 ton only) on the beam, lubricate the trackwheel gears and pinion with Texaco Novatex #2 or equivalent heavy cup grease.

On open end beams, remove rail stops, lift hoist/trolley into position and slide the hoist/trolley assembly onto beam flange. Reinstall the rail stops.

On closed end beams, loosen the suspension bolt nuts on one side of trolley and slide one side frame out far enough to clear the beam flange. Lift hoist/trolley assembly up so that trackwheels are riding on beam flange. Draw side frames together by tightening the suspension bolt nuts snugly.

Be sure to install cotter pins through slotted nuts and hole in suspension bolts and spread legs of cotter pins to secure on 2 ton units. For 3-7 1/2 ton units, be sure lockwashers are positioned properly on the suspension pins and completely tightened.

On geared trolleys, the bottom of the hand chain loop is normally located two feet (0.6M) above the floor. If it is desired to change this, find the unwelded link and open it by spreading with a chisel or twist one end with a wrench while holding the other end in a vise or another wrench. Remove an even number of links (2,4,6, etc.) as necessary to shorten the chain or add an even number of links to lengthen the chain (when lengthening the chain, another open link will be required and this can be made from a welded link by cutting through weld with a hacksaw). Make certain that the chain is not twisted–then re-install and close open links.

NOTE: AFTER THE UNIT IS CONNECTED TO THE POWER

SUPPLY SYSTEM (SEE BELOW), SUSPEND A CAPACITY LOAD FROM THE HOIST AND OPERATE THE TROLLEY OVER THE ENTIRE LENGTH OF THE RUNWAY OR MONORAIL SYSTEM TO BE SURE THAT THE ADJUSTMENTS AND OPERATION IS SATISFACTORY. ON SYSTEMS WITH CURVES, THE EDGES OF THE RAIL AT THE CURVED SECTIONS SHOULD BE KEPT LIGHTLY LUBRICATED WITH GREASE.

WARNING

An excessively worn beam flange may fail and allow the trolley to fall from the beam.

TO AVOID INJURY:

Periodically inspect the beam flange for wear. Replace beam if flange is worn.

INSTALLING BREATHER

After the hook suspension is assembled to the hoist or after the hoist and trolley are mounted on the beam, remove the upper plug from the main housing (652-110) and install the breather (from small envelope attached to the power cord). Failure to install the breather could damage oil seals and thus cause oil leaks.

INSTALL

BREATHER

WARNING

Failure to properly ground the hoist presents the danger of electric shock.

TO AVOID INJURY:

Permanently ground the hoist as instructed in this manual.

TYPICAL POWER SUPPLY SYSTEM

Page 13

NOTE: IN THIS MANUAL, NOMINAL VOLTAGES ARE

USED WHEN REFERRING TO POWER SUPPLY SYSTEMS. HOWEVER, WITH NO MODIFICATION, THE XL HOIST WILL OPERATE ON A

RANGE OF VOLTAGES AS INDICATED BELOW:

NOMINAL VOLTAGE HERTZ

VOLTAGE RANGE

230 208-240 60 460 440-480 60 220 200-240 50 380 365-395 50 415 400-430 50 575 550-575 60

WARNING

Failure to provide a proper power supply system for the hoist may cause hoist damage and offers the potential for a fire.

TO AVOID INJURY:

Provide the hoist with a 20 amp, minimum, overcurrent protected power supply system per the National Electrical Code (ANSI/NFPA 70) and applicable local codes as instructed in this manual.

ELECTRICAL CONNECTIONS

SINGLE SPEED, DUAL VOLTAGE HOISTS (AND MOTOR DRIVEN TROLLEYS)

Unless ordered on a special basis, single speed dual voltage (230/460-3-60, 220/380-3-50 and 220/415-3-50) hoists are factory wired to operate on 460-3-60 (or 380-3-50 or 415-3-50). However, a conversion terminal board is provided to easily and quickly change from 460 to 230 (or 380 to 220 or 415 to 220) volt operation. The conversion terminal board is located adjacent to the reversing contactor at motor end of hoist. If necessary, change voltage connections before connecting hoist to power supply system as follows:

1. Remove the motor cover (652-182). On units with hook suspension, it will be necessary to remove the counterweight (652-219) before removing motor cover.

2. Shift all eight wires from row of terminals marked “460” (or 380 or 415) to row of terminals marked “230” (or 220).

CONVERSION TERMINAL BOARD MOVE ALL 8 WIRES TO CONVERT FROM 460 TO 230 (380 TO 220, 415 TO 220) VOLT OPERATION

HOIST VOLTAGE

CONVERSION

3. Reassemble motor cover (and counterweight if so equipped) to hoist frame.

4. Mark the tag attached to power cord to indicate that the hoist has been converted to operate on 230 (or 220) volts and restamp hoist identification plate accordingly.

If the hoist is suspended from a single speed motor driven trolley, it will also be necessary to change the trolley motor connections. To do this, remove the cover from the terminal box mounted on the side of the trolley motor and reconnect the trolley motor wires attached to the terminal board as shown below:

ALL HOISTS

After making sure that the hoist (and motor driven trolley) are wired to operate on the power supply system, you are now ready to connect hoist power cord to the power supply. Since these are three phase units, the hoist motor can rotate in either direction depending on how it is connected to the power supply. Therefore, direction of hook movement must be checked during the original installation and each time the hoist is moved to a new location.

Always disconnect the hoist from the power supply system or de-energize the power supply system and follow proper Lockout/Tagout procedures when working (connecting or disconnecting) with the hoist electrical connections. Serious damage will result if the hook is run to upper or

lower limit of lift with hook moving in a direction opposite to that indicated by the control station. Connect hoist power cord to the power supply and check hook movement as follows:

1. Move the manual disconnect switch handle to the “OFF” position.

2. Connect the WHITE-PURPLE, RED AND BLACK wires of hoist power cord to load side of disconnect switch. Connect the GREEN wire of hoist power cord to power supply ground.

TROLLEY VOLTAGE CONVERSION

(Connections shown are for 208-240 volt operation)

WARNING

FAILURE TO FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES MAY PRESENT THE DANGER OF ELECTRICAL SHOCK.

TO AVOID INJURY:

DISCONNECT POWER AND LOCKOUT/TAGOUT DISCONNECTING MEANS BEFORE REMOVING COVER OR SERVICING THIS EQUIPMENT.

(2 TON ONLY)

Page 14

3. Move the manual disconnect switch handle to the “ON” position.

4. Depress the  (up) control. If the hook moves in the up direction, the hoist is ready for operation. If the hook lowers, move the disconnect switch handle to the “OFF” position and interchange the BLACK and RED leads at the disconnect switch. Move the disconnect switch handle to the “ON” position and the hoist is now ready for operation.

NOTE: DO NOT CHANGE INTERNAL WIRING OF

HOIST OR CONTROL STATION TO REVERSE HOOK DIRECTION. THE HOIST AND CONTROL STATION WIRING WAS INSPECTED AND TESTED FOR PROPER OPERATION AT THE FACTORY. CHANGING THIS WIRING WILL CAUSE IMPROPER OPERATION AND SERIOUS DAMAGE.

Also, do not force the Protector to compensate for improperly adjusted limit switches or reverse voltage phasing.

CHECKING FOR TWIST IN LOAD CHAIN

3, 4 And 5 Ton Double Reeved Units

The best way to check for this condition is to run the lower hook, without a load, up to within about 2 feet (0.6M) of hoist. If the dead end of chain has been properly installed, a twist can occur only if the lower hook block has been capsized between the strands of chain. Reverse capsize to remove twist.

5,6 And 7 1/2 Ton Triple Reeved Units

On these models, the load chain is dead ended on top of the lower hook block. If chain has been properly installed, the only way a twist can occur is if the lower hook block has been capsized between the strands of chain. If this has occurred, two strands of chain will be wrapped around each other and to remove twist, reverse the capsize.

CHECKING FOR ADEQUATE VOLTAGE AT HOIST

The hoist must be supplied with adequate electrical power for proper operation and to reduce problems that may result from insufficient power (low voltage). These include:

• Noisy hoist operation due to brake and/or contactor chatter.

• Heating of the hoist motor and other internal components as well as heating of wires and connectors in the circuit feeding the hoist.

• Failure of the hoist to lift the load due to motor stalling.

• Blowing fuses or tripping circuit breakers.

For proper operation and to avoid these low voltage problems, voltage (measured at the end of the 2.5 foot (.9 M) power cord while lifting rated load) should be as follows:

WARNING

Allowing the hook block to run into the bottom of the hoist when raising a load or allowing the chain to become taut between the loose end screw and the frame when lowering a load may break the chain and allow the load to drop.

TO AVOID INJURY:

Do not allow the hook block to contact the bottom of the hoist or the loose end chain to become taut.

NOMINAL MINIMUM * MIN. VOLTAGE

POWER OPERATING AT INSTANT SUPPLY VOLTAGE OF START

208-3-60 187 172 220-3-50 198 182 230-3-60 207 190 380-3-50 365 336 415-3-50 399 367 460-3-60 414 380

* The drop in voltage upon energizing the hoist should not be below the value listed.

Remember, operation with low voltage can void the Repair/Replacement policy. When in doubt about any of the electrical requirements for the power supply system, consult a qualified electrician.

CHECKING LIMIT SWITCH OPERATION

1. Press the  (Up) control and raise the lower hook

until the top of the hook block is about one foot (0.3M) below hoist.

2. Cautiously continue raising the hook until upper limit switch stops upward motion. At this point, the top of the hook block should be 3 inches (76 mm) below bottom of the hoist.

3. If adjustment is necessary, see page 16.

4. Press (Down) control and cautiously lower hook until lower limit switch stops the downward motion. From 10 to 12 chain links should be between the loose end link and the opening for the chain in bottom of hoist. If adjustment is necessary, see page 16.

CHAIN CONTAINER

If a chain container is to be used, attach it to the hoist frame and place chain in container per instructions provided with the chain container kit. After the chain container is installed, follow the instructions on page 16 to reset upper limit switch so uppermost point of hook travel is just below the bottom of the chain container.

UNDER NO CIRCUMSTANCES SHOULD THE HOOK BLOCK OR LOAD BE PERMITTED TO COME IN CONTACT WITH THE CHAIN CONTAINER. IF CONTACT IS MADE, THE FUNCTION OF THE CHAIN CONTAINER CAN BE INTERFERED WITH, THE CONTAINER MAY BE DAMAGED AND IT COULD FALL OFF OF THE HOIST.

CONTROL CORD

Unless ordered on a special basis, the hoist is supplied with a control cord that will position the control station approximately 4 feet (1.2M) above the lower hook when it is at the lower limit of lift. If this places the control station too close to the floor, a “control cord alteration kit” (Key No. 627-474, Part Number 28642) can be obtained from factory for shortening the length of the control cord.

WARNING

Allowing the hook block to run into the bottom of hoist when raising a load or allowing the chain to become taut between the loose end screw and the frame when lowering a load may break the chain and allow the load to drop.

TO AVOID INJURY:

Do not allow the hook block to contact the bottom of hoist or the loose end chain to become taut.

Page 15

WARNING

Tying knots or loops to shorten the drop of the control station will make the strain relief ineffective and the internal conductors of the cord may break.

TO AVOID INJURY:

Shorten the control cord using the control cord alteration kit and the instructions provided with the kit.

OPERATING INSTRUCTIONS

GENERAL

1. The Protector is designed to allow the first reduction gear to slip on an excessive overload. An overload is indicated when the hoist will not raise the load. Also, some clutching noise may be heard if the hoist is loaded beyond rated capacity. Should this occur, immediately release the (Up) control to stop operation of the hoist. At this point, the load should be reduced to the rated hoist capacity or the hoist should be replaced with one of the proper capacity. When the excessive load is removed, normal hoist operation is automatically restored.

CAUTION: THE PROTECTOR IS SUSCEPTIBLE TO OVER

HEATING AND WEAR WHEN SLIPPED FOR EXTENDED PERIODS. UNDER NO CIRCUMSTANCE SHOULD THE PROTECTOR BE ALLOWED TO SLIP FOR MORE THAN A FEW SECONDS.

Due to the above, a hoist equipped with a Protector is not recommended for use in any application where there is a possibility of adding to an already suspended load to the point of overload. This includes *dumbwaiter installations, containers that are loaded in mid-air, etc.

*Refer to limitations on Page ii concerning dumbwaiter applications.

Also, if a XL Hoist with a Protector is used at unusual xtremes of ambient temperatures, above 150°F (65°C) or below 15° F (-9°C) changes in lubricant properties may

permit the hoist to raise larger loads than under normal operating conditions and presents possibility of damage or injury.

2. All hoists are equipped with an adjustable screw limit switch, which automatically stops the hook at any predetermined point when either hoisting or lowering.

3. The control station used on two speed hoists is similar to single speed unit, except that either of two definite speeds may be selected by the operator in both hoisting and lowering. Each control when partially depressed provides SLOW speed and when fully depressed gives FAST speed. Partial release of control returns hoist to slow speed, while complete release allows hoist to stop. Rated lifting speeds are shown on hoist identification plate. SLOW speed is intended as a means of carefully controlling or “spotting” the load, although the hoist may be operated solely at this speed if desired. It is not necessary to operate in the SLOW speed position as the hoist will pick up a capacity load at FAST speed from a standing start. In other words, it is not necessary to hesitate at the slow position when moving control from STOP and FAST position or vice versa.

4. If material being handled must be immersed in water, pickling baths, any liquid, dusty or loose solids, use a sling chain of ample length so that the hook is always above the surface. Bearings in the hook block are shielded only against ordinary atmospheric conditions.

5. Read operation section of American National Standard ASME B30.16.

ALL HOISTS

1. Before picking up a load, check to see that the hoist is directly overhead.

2. WHEN APPLYING A LOAD, IT SHOULD BE DIRECTLY UNDER HOIST OR TROLLEY. AVOID OFF-CENTER LOADING OF ANY KIND.

3. Take up a slack load chain carefully and start load easily to avoid shock and jerking of hoist load chain. If there is any evidence of overloading, immediately lower the load and remove the excess load.

4. Do not allow the load to swing or twist while hoisting.

5. Do not allow the load to bear against the hook latch.

HOIST WITH PLAIN TROLLEY

This unit should be moved by pushing on the suspended load or by pulling the empty hook. However, the unit can also be moved by pulling on the control station since an internal steel cable extends the length of the control cord and is anchored to the hoist and to the control station.

HOIST WITH GEARED TROLLEY

This unit should be moved by means of the pendant hand chain. Pull on the chain farthest from end toward which the unit is to travel.

HOIST WITH MOTOR DRIVEN TROLLEY

This unit should be moved by operating the controls marked < FORWARD and > REVERSE in control station. Anticipate the stopping point and allow trolley to coast to a smooth stop. Reversing or “plugging” to stop trolley causes overheating of motor and swaying of load.

SAFETY PROCEDURES

For safety precautions and a list of Do’s and Do Not’s for safe operation of hoists, refer to page ii.

1. When preparing to lift a load, be sure that attachments to hook are firmly seated in hook saddle. Avoid off center loading of any kind, especially loading on the point of hook.

2. When lifting, raise load only enough to clear the floor or support and check to be sure that the attachments to the hook and load are firmly seated. Continue lift only after you are assured the load is free of all obstructions.

3. Do not load hoist beyond the rated load shown on hoist identification plate and capacity labels. Overload can cause immediate failure of some loadcarrying part or create a defect causing subsequent failure at less than rated load. When in doubt, use the next larger capacity of XL Hoist.

Page 16

4. Do not use this or any other overhead materials handling equipment for lifting persons.

5. Stand clear of all loads and avoid moving a load over the heads of other personnel. Warn personnel of your intention to move a load in their area.

6. Do not leave load suspended in air unattended.

7. Permit only qualified personnel to operate unit.

8. Do not wrap the load chain around the load and hook onto itself as a choker chain. Doing this will result in: a. The loss of the swivel effect of the hook which

could mean twisted chain and a jammed lift

wheel.

b. The upper limit switch is by-passed and the load

could hit the hoist.

c. The chain could be damaged at the hook.

9. On double and triple reeved hoists, check for twists in the load chain. A twist can occur if the lower hook block has been capsized between the strands of chain. Reverse the capsize to remove the twist.

10. Do not allow the load to bear against the hook latch. The latch is to help maintain the hook in position while the chain is slack before taking up slack chain.

11. Take up a slack load chain carefully and start load eas ily to avoid shock and jerking of hoist load chain. If there is any evidence of overloading, immediately lower the load and remove the excess load.

12. Do not allow the load to swing or twist while hoisting.

13. Never operate the hoist when flammable materials or vapors are present. Electrical devices produce arcs or sparks that can cause a fire or explosion.

14. STAY ALERT! Watch what you are doing and use common sense. Do not use the hoist when you are tired, distracted or under the influence of drugs, alcohol or medication causing diminished control.

INSPECTION

To maintain continuous and satisfactory operation, a regular inspection procedure must be initiated to replace worn or damaged parts before they become unsafe. Inspection intervals must be determined by the individual application and are based on the type of service to which the hoist will be subjected and degree of exposure to wear, deterioration or malfunction of the critical components.

WARNING

Allowing the load to bear against the hook latch and/or hook tip can result in loss of load.

TO AVOID INJURY:

Do not allow the load to bear against the hook latch and/or hook tip. Apply load to hook bowl or saddle

MAINTENANCE

The type of service to which the hoist is subjected can be classified as “Normal,” “Heavy,” or “Severe.” Normal Service: Involves operation with randomly distributed loads within rated load limit, or uniform loads less than 65 percent of rated load for not more than 25 percent of the time.

Heavy Service: Involves operating the hoist within rated load limit which exceeds normal service.

Severe Service: Normal or heavy service with abnormal operating conditions.

Two classes of inspection—Frequent and Periodic— must be performed.

FREQUENT INSPECTIONS: These inspections are visu-

al examinations by the operator or other designated personnel. Records of such inspections are not required. The frequent inspections are to be performed monthly for normal service, weekly to monthly for heavy service, and daily to weekly for severe service, and they should include those items listed in Table 3.

PERIODIC INSPECTIONS: These inspections are visual

inspections of external conditions by an appointed person. Records of periodic inspections are to be kept for continuing evaluation of the condition of the hoist. Periodic inspections are to be performed yearly for normal service, semi-annually for heavy service and quarterly for severe service, and they are to include those items listed in Table 4.

CAUTION: ANY DEFICIENCIES ARE TO BE CORRECTED

BEFORE THE HOIST IS RETURNED TO SERVICE. ALSO, THE EXTERNAL CONDITIONS MAY SHOW THE NEED FOR DISASSEMBLY TO PERMIT A MORE DETAILED INSPECTION, WHICH, IN TURN, MAY REQUIRE THE USE OF NONDESTRUCTIVE TYPE TESTING.

HOOK INSPECTION

Hooks damaged from chemicals, deformations or cracks, or that have more than a 10° twist from the hook’s unbent plane, excessive opening or seat wear must be replaced. Also, hooks that are opened and allow the latch to not engage the tip must be replaced. Any hook that is twisted or has excessive throat opening indicates abuse or overloading of the unit. Inspect other load sustaining parts for damage.

On latch type hooks, check to make sure that the latch is not damaged or bent and that it operates properly with sufficient spring pressure to keep the latch tightly against the tip of the hook and allow latch to spring back to tip when released. If latch does not operate properly, it should be replaced. See below to determine when the hook must be replaced.

Page 17

Replace Hook

When Opening

Is Greater

Than

1 1/2 IN.

38.1 mm

2 3/8 IN.

60.3 mm

CAPACITY

(TONS)

3,4,5,6 AND 7 ½

LATCH TYPE HOOK (Upper and Lower) TO MEASURE OPENING, DEPRESS LATCH AGAINST HOOK BODY AS SHOWN.

*UPPER HOOK NOT AVAIL ABLE

FOR 7 1/2 TON

Replace Hook

When Opening

Or Seat are:

CAPACITY

(TONS)

3,4,5, and 6

LATCHLOCK® TYPE HOOK (UPPER AND LOWER)

“A” Max.

1/2 IN.

63.5 mm

15/16 IN.

74.6 mm

“B” Mn.

1/8 IN.

28.5mm

13/32 IN.

35.7mm

Hook Inspection

MEASURE

OPENING

“A”

“B” Max.

LOAD CHAIN

Cleaning and Inspection

First clean load chain with a non-acid or non-caustic type solvent. Then slack the chain and make a link-by-link inspection for nicks, gouges, twisted links and excessive wear or stretching. Chain exhibiting wear should be checked throughout its entire length and replaced if worn beyond serviceable limits.

Checking For Load Chain Wear

Slack the portion of the chain that normally passes over the liftwheel. Examine the interlink area for the point of maximum wear (polishing). Measure and record the stock diameter at this point of the link. Then measure stock diameter in the same area on a link that does not pass over the liftwheel (use the link adjacent to the loose end link for this purpose). Compare these two measurements. If the stock diameter of the worn link is 0.010 inches (0.254mm), or greater, less than the stock diameter of the unworn link, the chain must be replaced.

Note that worn chain can be an indication of worn hoist components. For this reason, the hoist’s chain guides, hook blocks and liftwheel should be examined for wear and replaced as necessary when replacing worn chain.

Also, these chains are specially heat treated and hardened and should never be repaired.

WARNING

Using other than factory supplied load chain may cause the chain to jam in the hoist and/or allow the chain to break and the load to drop.

TO AVOID INJURY:

Due to size requirements and physical properties, use only Hoistaloy

load chain in the XL Hoists.

IMPORTANT: DO NOT USE REPLACED CHAIN FOR OTHER PURPOSES SUCH AS LIFTING OR PULLING. LOAD CHAIN MAY BREAK SUDDENLY WITHOUT VISUAL DEFORMATION. FOR THIS REASON, CUT REPLACED CHAIN INTO SHORT LENGTHS TO PREVENT USE AFTER DISPOSAL.

PROTECTOR™

The Protector should operate for the normal life of hoist without service. The device has been calibrated at the factory for a specific capacity/gear ratio of XL Hoist. It is not adjustable and it is not interchangeable with other capacities/gear ratios.

XL Hoist with Motor Driven

Trolley

Page 18

Table 3. Minimum Frequent Inspections

TYPE OF SERVICE

ITEM

Normal

Heavy

Severe

a) Brake for evidence of slippage. b) Control functions for proper operation. c) Hooks for damage, cracks, twists, excessive throat opening. latch engagement

and latch operation–see page 13.

d) Load chain for adequate lubrication, as well as for signs of wear, damaged links

or foreign matter–see page 15.

e) Load chain for proper reeving and twists.

Daily

to Weekly

Weekly

to Monthly

Monthly

Table 4. Minimum Periodic Inspections

ITEM

Normal

Heavy

Severe

TYPE OF SERVICE

a) All items listed in Table 3 for frequent inspections. b) External evidence of loose screws, bolts or nuts. c) External evidence of worn, corroded, cracked or distorted hook block, gears,

bearings, dead end block, dead end pin, dead end bolt and suspension components.

d) External evidence of damage to hook retaining nut and pin. Also check the

upper suspension adapter making sure it is fully seated in the hoist frame and that suspension adapter screw or dead end bolt is tight.

e) External evidence of damage or excessive wear of the liftwheel and hook block

sheave chain pockets. Widening and deepening of the pockets may cause the chain to lift-up in the pocket and result in binding between liftwheel and chain guide or between the sheave and hook block. Also, check the chain guide for wear or burring where the chain enters the hoist. Severely worn or damaged parts should be replaced.

f) External evidence of excessive wear of brake parts, and brake adjustment—see

page 15.

g) External evidence of pitting or any deterioration of contactor contacts. Check

the operation of the control station making sure the buttons operate freely and do not stick in either position.

h) Inspect the electrical cords and cables and control station enclosure for damaged

insulation.

i) Inspect trolley trackwheels for external wear on tread and flange and for wear

on internal bearing surfaces as evidenced by a looseness on the stud. Suspension components for damage, cracks, wear and operation. Also check suspension adapter screw or dead end bolt for proper tightness—(see pages 4, 5,and 6).

j) Inspect the loose end link, loose end screw, dead end block on double reeved

units and dead end plate on triple reeved units. Replace worn or distorted parts.

k) Inspect the hook for excess free play or rotation. Replace worn parts as evidenced

by excess free play or rotation.

l) Inspect for oil leaks at the gasket on either side of intermediate plate. Tighten

the screws used to attach the main housing and brake housing to intermediate plate. If leak persists, disassemble hoist (see page 27) and replace gaskets.

m) Inspect inside of motor and brake housings for presence of oil. Oil in motor

housing may be excess chain lubricant or a leaking seal. Wipe out oil and monitor. If leak persists, replace seal (652-122 or 652-132). Oil in brake housing is due

to leaking seal. Replace seal (652-122 or 652-134). n) Check motor bolts for damage and replace if bent, cracked or damaged. o) Inspect all splines for signs of wear and deterioration. Replace splined parts if

worn or damaged.

Yearly

Every 6 Months

Every 3 Months

Page 19

LUBRICATION

NOTE: TO ASSURE EXTRA LONG LIFE AND TOP PERFOR-

MANCE, BE SURE TO LUBRICATE THE VARIOUS PARTS OF THE XL HOIST USING THE LUBRICANTS SPECIFIED BELOW. IF DESIRED, THESE LUBRCANTS MAY BE PURCHASED FROM THE FACTORY.

HOIST LUBRICATION

Gears. Check oil level in gear housing at least once a

month, maintaining it at the bottom of oil level hole in main housing (652-110).

Drain housing every 2-3 years and refill with one gallon (3.86 liters) of gear oil Amoco 85W-140.

CAUTION: THE PROTECTOR IS TO OPERATE IN THE

ABOVE MENTIONED OIL. DO NOT USE ANY OTHER TYPE OF LUBRICANT OR THE PROTECTOR WILL NOT OPERATE PROPERLY AND PARTS COULD BE DAMAGED.

The limit switch gears are of molded nylon and require no lubrication. Apply a light film of machine oil to the limit switch shaft threads at least once a year.

Chain Guides, Liftwheel & Sheave Wheels.

When the hoist is disassembled for inspection and/or repair, the chain guides, sheave wheels (on multi-reeved units) and liftwheel must be lubricated with Lubriplate Bar and Chain Oil 10-R (Fiske Bros. Refining Co.) prior to reassembly. Apply sufficient lubricant to obtain natural runoff and full coverage.

Load Chain. Keep chain lubricated with a small amount of lubricant. This will greatly increase the life of load chain. Do not allow the chain to run dry.

Keep it clean and lubricate at regular intervals with Lubriplate Bar and Chain Oil 10-R (Fiske Bros. Refining Co.) or equal lubricant. Normally, weekly lubrication and cleaning is satisfactory, but under hot and dirty conditions, it may be necessary to clean the chain at least once a day and lubricate it several times between cleanings. When lubricating the chain, apply sufficient lubricant to obtain natural runoff and full coverage.

WARNING

The lubricants used in and recommended for the XL Hoist may contain hazardous materials that mandate specific handling and disposal procedures.

TO AVOID CONTACT AND CONTAMINATION:

Handle and dispose of lubricants only as directed in applicable material safety data sheets and in accordance with applicable local, state and federal regulations.

WARNING

Used motor oils contain known carcinogenic materials.

TO AVOID HEALTH PROBLEMS:

Never use used motor oils as a chain lubricant. Only use Lubriplate Bar and Chain Oil 10-R as a lubricant for the load chain.

Bearings. All bearings except the lower hook thrust bearings are pre-lubricated or are in an oil bath and need no lubrication. The lower hook thrust bearing should be lubricated at least once a month with heavy duty machine oil.

Miscellaneous. If unit is disassembled, splines inside coupling (652-103) should be coated with an EP type grease (such as Evans Products Co. Anti-Scoring Extreme Pressure Lub. No. 3) before reassembly.

TROLLEY LUBRICATION

Trackwheel bearings are pre-lubricated and require no lubrication. Geared Trolley. Once a month lubricate trackwheel

gears with Texaco Novatex No. 2 or an equivalent heavy cup grease or graphite grease.

Every six months lubricate handwheel shaft bearings in 3-in-1 machine oil.

Motor Driven Trolley. Once a month lubricate trackwheel gears with Texaco Novatex No. 2 or an equivalent heavy cup grease or graphite grease.

For 2 ton trolleys, the motor bearings and reduction gears require no additional lubrication. However, if gears are disassembled, upon reassembly use Texaco Novatex No. 1 or an equivalent medium cup grease.

For 3-7 1/2 ton trolleys, the right angle worm gear reducer oil should be changed after the first 100 hours of operation, then after every 2500 hours of normal service. When replacing oil due to repairs or service, use Mobil SHC-626 or equal, for each oil change.

ADJUSTMENTS

HOIST BRAKE

The correct air gap between armature and field when brake is not energized, is 0.025 inch (.63 mm) and need not be adjusted until the gap reaches 0.045 inch (1.14 mm).

To adjust the brake, proceed as follows:

1. Disconnect hoist from power supply.

2. Remove brake end cover.

3. Before adjusting the gap, back off the brake nuts and examine friction linings and friction surfaces for wear, scoring or warpage (min.thk. .188). Also check shading coils to be sure they are in place and not broken. A missing or broken shading coil will cause the brake to be noisy when hoist is operated. Any of these symptoms indicate the need for replacement of parts.

4. Turn brake nuts clockwise gaging the air gap on each side and at both ends of the armature.

5. Replace cover, reconnect the power and check operation.

HOIST BRAKE

ADJUSTMENT

Page 20

LIMIT SWITCHES

If limit switch operation has been checked as described on page 10 and is not operating correctly or is not automatically stopping the hook at a desired position, proceed as follows:

1. Disconnect hoist from power supply.

2. Remove brake end cover.

3. The positions of upper and lower limit switches are indicated on the fiber insulator.

4. Loosen the screws to permit guide plate to be moved out of engagement with the traveling nuts.

5. Reconnect hoist to power supply

6. Run hook to the desired upper or lower position, cautiously operating the hoist without load.

7. Disconnect hoist from power supply.

8. Moving one travel nut toward the other increases hook travel and away from the other decreases the travel. To adjust the upper limit, turn the nut nearest the switch indicated as “Upper Limit Switch”. To adjust the lower limit, turn the nut nearest the switch marked “Lower Limit Switch”. Turn the desired nut until it just breaks the limit switch contacts. An audible click will he heard as the switch opens. Continue to rotate the nut toward the switch an additional two full teeth.

9. Reposition the guide plate in the next slot and securely tighten screws.

10. Reconnect hoist to power supply and check the stopping point of the hook by first moving the hook about 10 inches (254 mm) away from the desired stopping point. Then move the hook towards the desired stopping point by jogging cautiously until the limit switch stops the motion. If the stopping point is not the desired position, repeat the above instructions.

11. Double check the adjustment by moving the hook about 2 feet (610 mm) from the desired stopping point and then run the hook into the limit with the control held in the fully depressed position.

12. Fine adjustment of the screw limits setting may be obtained by inverting the guide plate. The offset on the plate gives adjustments equivalent to 1/2 notch (see Table below). When inverting the plate, it may be necessary to use the notch adjacent to the one used in the preliminary setting.

LIMIT SWITCHES

1. Limit switch sub-assy 4 Guide Plate

2. Limit switch shaft 5. Screws

3. Traveling nuts

HOOK TRAVEL PER NOTCH OF

LIMIT SWITCH NUT

* At 60 Hertz. For 50 Hertz speeds are 5/6 of those listed. Fast speeds are listed for two speed units.

RATED

LOAD

TONS

(Kg.)

*LIFT

SPEED

FPM

(MPM)

MAX.

LIFT

FT. (M)

HOOK

TRAVEL

PER NOTCH IN.(mm)

2 (2000) 18 (5.5) 127 (39) 1.10 (27.9)

2 (2000) 1 24 (7.3) 139 (42) 1.27 (32.3)

2 (2000) 30 (9.1) 212 (65) 0.63 (16.0)

3 (3000) 9 (2.7) 60 (18) 0.55 (14.0)

3 (3000) 12 (3.6) 65 (20) 0.64 (16.1)

3 (3000) 15.2 (4.6) 106 (32) 0.93 (23.6)

4 (4000) 9 (2.7) 60 (18) 0.55 (14.0)

4 (4000) 2 12 (3.6) 65 (20) 0.64 (16.1)

4 (4000) 15.2 (4.6) 106 (32) 0.93 (23.6)

5 (5000) 9 (2.7) 60 (18) 0.55 (14.0)

5 (5000) 12 (3.6) 65 (20) 0.64 (16.1)

5 (5000) 15.2 (4.6) 106 (32) 0.93 (23.6)

5 (5000) 6(1.8) 42 (13) 0.37 (9.3)

5 (5000) 8(2.4) 46 (14) 0.42 (10.8)

6 (6000) 6 (1.8) 42 (13) 0.37 (9.3)

6 (6000) 3 8 (2.4) 46 (14) 0.42 (10.8)

6 (6000) 10 (3.0) 71 (22) 0.63 (16.0)

7½ (7500) 6 (1.8) 42 (13) 0.37 (9.3)

7½ (7500) 10 (3.0) 71 (22) 0.63 (16.0)

PARTS

CHAIN

(REEVING)

Page 21

TROLLEY BRAKE (2 TON UNIT)

(Optional Accessory)

The stopping distance of the Motor Driven Trolley equipped with an electric brake can be increased or decreased by adjusting the brake pressure. To increase brake pressure, and thereby decrease stopping distance, move the brake spacer washers progressively from the nut side of the brake field plate to the spring side. To decrease the stopping distance, move the washers in an opposite manner. Both studs must have the same number of washers on the spring side of the brake field plate.

The correct air gap between armature and field, when the brake is not energized, is 0.025 inch (.63 mm) and need not be adjusted until the gap reaches 0.045 inch (1.14 mm).

To adjust the air gap or brake pressure, proceed as follows:

1. Disconnect hoist from power supply.

2. Remove brake cover.

3. Before adjusting air gap or brake pressure:

a. Back off the brake nuts and examine friction lin-

ings and friction surfaces for excessive wear, scoring or warpage.

b. Check shading coils to be sure they are in place

and not broken. A missing or broken shading coil will cause the brake to be noisy when trolley is operated.

Any of these symptoms indicate the need for replacement of parts.

4. If brake pressure is to be adjusted, move brake spacer washers to the desired side of the brake field plate to increase or decrease pressure as indicated above.

5. After spacer washers are positioned, turn brake nuts clockwise gaging the air gap at both ends.

6. Replace brake cover, reconnect the power and check operation. If the stopping distance of the trolley is not as desired, repeat the above.

TROLLEY BRAKE

ADJUSTMENT

TROLLEY BRAKE (3 THUR 7½ TON UNITS)

(Optional Accessory)

The brake can be ordered with the trolley or it is available in kit form for installation on a unit in the field. To order a brake kit for an existing unit, order brake kit Key No. 29 and indicate the serial number of the trolley on which it is to be installed and the voltage on which the trolley operates.

ADJUSTMENT

The motor brake should be checked periodically for wear of the friction discs and/or proper adjustment of the solenoid air gap. Refer to Figure 1. Normal lining wear will cause the solenoid lever (8) to move away from the solenoid frame (79) and thus increase the air gap and trolley stopping time.

When the air gap reaches approximately 11/16” the brake should be adjusted. To adjust the air gap of the brake, proceed as follows:

1. De-energize the power supply to trolley.

2. Remove both access covers to expose brake.

3. Depress the plunger (13) towards the solenoid frame until spring pressure is felt.

4. Hold the plunger firmly in the position and measure the air gap between the mating (ground) surfaces of the solenoid (79) and the solenoid plunger (29).

5. To adjust, turn both wear adjustment screws (10) equal amounts clockwise until the air gap measures 13/32”.

Replacement of Friction Disc (Refer to Exploded View Drawing, Page 47)

1. De-energize the power supply to the trolley and remove the motor/brake assembly from the gear reducer. Remove housing (3) from the brake.

2. Remove the entire support plate assembly by unscrewing 3 screws (32). Remove the stationary disc (11) and worn friction disc (12). Install the new friction disc, making sure that the two stablizing springs are at 90° in the recessed portion of the squared hole in the friction disc, with the prongs pointing into the brake. Place the stationary disc on the friction disc and re-assemble the entire support plate assembly engages the guide pins of the end plate.

3. Remove both access covers (5) from the housing (1) and slide the housing with its shaft assembly on to the mounting studs. Be sure the housing is assembled with access windows above the horizontal centerline. Rotate shaft to engage key into the hub keyway.

4. Re-assemble the motor/brake assembly to the gear reducer using the four nuts and lockwashers.

5. Adjust air gap per above instructions (ADJUSTMENTS).

6. Re-energize power supply and operate trolley a few times to make sure air gap is correct and then replace access covers (5).

Page 22

RECOMMENDED SPARE PARTS

To insure continued service of the XL Hoist, the following is a list of parts that are recommended to be kept on hand at all times to replace parts that have worn or failed. Parts applicable to your unit should be stocked.

Key No. Part Name Qty. for Each

Hoist in Service

652-120 Limit Switch Assembly 1 652-130 Brake Coil 1 652-131 Brake Friction Disc 2 652-135 Transformer 1 627-563 Control Station Parts Kit 1

(2 Direction Station)

627-565 Control Station Switch Kit 1

(2 Direction Station)

635-155 Control Station Switch Kit 1

(4 Direction Station) 652-136 Hoist Reversing Contactor 1 652-137 Speed Selecting Contactor 1

(2 Speed Hoists Only) 652-138 Trolley Reversing Contactor 1 652-236 Trolley Speed Selector 1

(2 Speed Trolley Only)

Refer to page 32 for ordering instructions and the parts list for part numbers.

PREVENTIVE MAINTENANCE

In addition to the inspection procedure on page 12, a preventive maintenance program should be established to prolong the useful life of the hoist and maintain its reliability and continued safe use. The program should include the periodic and frequent inspections with particular attention being paid to the lubrication of the various components using the recommended lubricants (see page 15).

Replacement of Coil (Refer to Figure 1 on page 17 and Exploded View Drawing on page 48).

1. De-energize the power supply to the trolley and remove the motor/brake assembly from the gear

reducer.

2. Remove housing (3) from the brake and disconnect the

coil wires from the cord.

3. Insert screw driver between support plate (126, Fig.1)

and the top of lever arm (17, Fig.1). Wedge these apart and remove bearing pin (26, Fig.1) and solenoid lever (8, Fig.1) with link (13, Fig.1) and plunger (29, Fig.1).

4. Remove plunger guide screw (84, Fig.1) and both

plunger guides (82, Fig.1). Slide old coil sideways out of the frame (79, Fig.1). If coil is difficult to move, tap lightly with a soft hammer.

5. Install new coil in the same relative position as the old

coil and replace the plunge guides (82, Fig.1) and screw (84 and 84W, Fig.1).

6. Re-assemble follwing Step 3 in reverse order.

7. Re-connect the coil leads to the brake coil. Slide hous

ing and shaft assembly onto mounting studs, rotating shaft to engage key into hub keyway. Be sure the access covers are above the horizontal centerline.

8. Re-assemble motor/brake assembly to gear reducer

using the four nuts and lockwashers.

9. Adjust air gap per above instructions (ADJUSTMENT).

10. Re-energize power supply and operate trolley a few

times to make sure air gap is correct and then replace access covers.

Page 23

TROUBLE SHOOTING

1. Hook does not respond to the control station.

A) No voltage at hoist—mainline or

branch circuit switch open; branch line fuse blown or circuit breaker tripped.

B) Phase failure (single phasing)—

open circuit, grounded or faulty connection in one line of supply system, hoist wiring, reversing contactor, motor leads or windings.

C) Upper or lower limit switch has

opened the motor circuit.

D) Open control circuit—motor ther-

mal switch open; shorted or open winding in transformer, reversing contactor coil or speed selecting contactor coil; loose connection or broken wire in circuit; mechanical binding in contactor; control station contacts not closing or opening.

E) Wrong voltage or frequency.

F) Low voltage.

G) Brake not releasing—open or shorted

coil winding; armature binding.

H) Excessive load.

A) Close switch, replace fuse or

reset breaker.

B) Check for electrical continuity and

repair or replace defective part.

C) Press the “other” control and

the hook should respond. Adjust limit switches as described on page 15.

D) Check electrical continuity thru

thermal switch. If it is open, allow motor to cool. Should this not correct the trouble, check electrical continuity of other parts and repair or replace defective part.

E) Use the voltage and frequency

indicated on hoist identification plate. For three phase dual voltage unit, make sure the connections at the conversion and trolley terminal boards are the proper voltage as described on page 8.

F) Check for low voltage condition

as described on page 10.

G) Check electrical continuity and

connections. Check that correct coil has been installed. The coil for dual voltage unit operates at 230 volts when the hoist is connected for either 230 volt or 460 volt operation. Check brake adjustment as described on page

15.

H) Reduce loading to the capacity

limit of hoist as indicated on the identification plate.

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

ALL HOISTS

Page 24

2. Hook moves in the

wrong direction.

3. Hook lowers but

will not raise.

4. Hook raises but

will not lower.

5. Hook lowers when

hoisting control is operated.

6. Hook does not

stop promptly.

7. Hoist operates

sluggishly.

A) Wiring connections reversed at

either the control station or terminal board.

B) Phase reversal.

A) Excessive load.

B) Open hoisting circuit—open or

shorted winding in reversing contactor coil or speed selecting contactor coil; loose connection or broken wire in circuit; control station contacts not making; upper limit switch contacts open.

C) Phase failure.

A) Open lowering circuit—open or

shorted winding in reversing contactor coil or speed selecting contactor coil; loose connection or broken wire in circuit; control station contacts not making; lower limit switch contacts open.

A) Phase failure.

A) Brake slipping.

B) Excessive load.

C) Protector slipping.

A) Excessive load.

B) Low voltage.

C) Phase failure or unbalanced cur-

rent in phases.

D) Brake dragging.

A) Check connections with the

wiring diagram.

B) Refer to installation instructions

on page 9 (all hoists).

A) See Item 1H.

B) See Item 1D. Also check opera-

tion of limit switch as described on page 10.

C) See Item 1B.

A) Check electrical continuity and

repair or replace defective part. Check operation of limit switch operation as described on page

10.

A) See Item 1B.

A) Check brake adjustment as

described on page 15.

B) See Item 1H.

C) If Protector is not functioning

properly, it should be replaced.

A) See Item 1H.

B) Check for low voltage condi-

tion as described on page 10.

C) See Item 1B.

D) Check brake adjustment as

described on page 15.

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

Page 25

8. Motor overheats.

9. Hook fails to stop at either or both ends of travel.

10. Hook stopping point varies.

A) Excessive Load.

B) Low Voltage.

C) Extreme external heating.

D) Frequent starting or reversing.

E) Phase failure or unbalanced current

in the phase.

F) Brake dragging.

A) Limit switches not opening circuits.

B) Shaft not rotating.

C) Traveling nuts not moving along

shaft—guide plate loose; shaft or nut threads damaged.

A) Limit switch not holding adjustment.

B) Brake not holding.

A) See Item 1H.

B) Check for low voltage condition

as described on page 10.

C) Above an ambient temperature

of 104°F. (40°C.), the frequency of hoist operation must be limited to avoid overheating of motor. Special provisions should be made to ventilate the space of shield the hoist from radiation.

D) Avoid excessive inching, jogging

or plugging. This type of operation drastically shortens the motor and contactor life and causes excessive brake wear.

E) See Item 1B.

F) Check brake adjustment as

described on page 15.

A) Check switch connections, elec-

trical continuity and mechanical operation. Check the switch adjustment as described on page 10. Check for a pinched wire.

B) Check for damaged gears.

C) Tighten guide plate screws.

Replace damaged part.

A) See Item 9.

B) Check the brake adjustment as

described on page 15.

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

Page 26

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

11. Hoist will not operate at slow speed in either direction.

12. Hoist will not operate at fast speed in either direction.

13. Hook will not raise at slow speed.

14. Hook will not lower at slow speed.

15. Hook will not raise at fast speed.

16. Hook will not lower at fast speed.

17. Hook moves in proper direction at one speed—wrong direction at other speed.

A) Open Circuit.

B) Phase failure.

A) Open circuit.

B) Open speed selection circuit.

C) Phase failure.

A) Excessive load.

B) Phase failure.

C) Open circuit.

D) Brake not releasing.

A) Phase failure.

B) Open circuit.

C) Brake not releasing.

A) Excessive load.

B) Phase failure.

C) Brake not releasing.

A) Phase reversal.

B) Brake not releasing.

A) Phase reversal.

A) Open or shorted motor wind-

ing, loose or broken wire in circuit, speed selecting contactor stuck in opposite speed mode. Replace motor, repair wire and/or replace speed selecting contactor.

B) See Item 1B.

A) See Item 11A.

B) Open or shorted winding in

speed selecting contactor coil. Loose connection or broken wire in circuit. Mechanical binding in contactor. Control station contacts not making or opening. Replace speed selecting contactor; repair connection, replace contactor or control station.

C) See Item 1B.

A) See Item 1H.

B) See Item 1B.

C) See Item 11A.

D) See Item 1G.

A) See Item 1B.

B) See Item 11A.

C) See Item 1G.

A) See Item 1H.

B) See Item 1B.

C) See Item 1G.

A) See Item 1B.

B) See Item 1G.

A) Wiring reconnected improperly.

Interchange two leads of motor winding that are out of phase at the speed selecting contactor.

TWO SPEED HOISTS

Page 27

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

MOTOR DRIVEN TROLLEY

18) Trolley does not

operate in either direction.

19) Trolley operates in

one direction only.

20) Trolley operates

sluggishly.

21) Trolley motor

overheats.

A) No voltage at motor.

B) Phase failure.

C) Open control circuit.

D) Low voltage.

E) Wrong voltage or frequency.

A) Open control circuit.

A) Excessive load.

B) Low voltage.

C) Unbalanced current in the phases.

D) Brake dragging.

A) Open circuit, grounded or faulty

connection in hoist wiring.

B) See Item 1B.

C) See Item 1D.

D) See Item 1F.

E) See Item 1E.

A) See Item 1D.

A) See Item 1H.

B) See Item 1F.

C) See Item 1B.

D) Check electrical continuity and

connections. Check that the correct coil has been installed. The coil for dual voltage units operate on 230 volts when the trolley is connected for either 230 or 460 volt operation. Check brake adjustment as described on page 17.

A) See Item 8.

Page 28

Open circuits in the coils of electrical components may be detected by isolating the coil and checking for continuity with an ohmmeter or with the unit in series with a light or bell circuit.

Shorted turns are indicated by a current draw substantially above normal (connect ammeter in series with suspected element and impose normal voltage) or D.C.

resistance substantially below normal. The current method is recommended for coils with very low D.C. resistance.

Motor current draw in the stator should be measured with the rotor in place and running. Brake, relay and contactor coil current should be measured with the core iron in operating position.

COILS

HOIST REVERSING

CONTACTOR COILS

HOIST SPEED SELECTING

CONTACTOR COILS

TROLLEY REVERSING

CONTACTOR COILS

HOIST BRAKE COILS

TROLLEY BRAKE COILS

TROLLEY SPEED

SELECTOR

VOLTAGE

115

48 24

115

48 24

115

48 24

**220-240

380-480

575

**220-2 40

380-480

575

**220-2 40

380-480 (2 Ton)

575

115

48 24

CURRENT DRAW

(AMPS) AT 60 HERTZ

0.09

0.46

0.49

0.11

0.25 N/A

0.17

0.30

1.00

1.39

0.86

0.39

0.27

0.16

0.09

0.20

0.08

0.06

0.09

0.20

0.47

*D.C. RESISTANCE

(OHMS)

88.4

3.6

3.7

86.8

14.4 N/A

117.3

18.2

4.7

2.4

9.3

14.9

22.8

89.4

143.3

200.00

31.9

8.6

ELECTRICAL DATA

TO DETECT OPEN AND SHORT CIRCUITS IN ELECTRICAL COMPONENTS

TRANSFORMERS (652-135)

VOLTS

PRIMARY SECONDARY

208-240/380-480 110-120 208-240/380-480 24

220/380/440 48

550/575 110-120

*D.C. RESISTANCE (OHMS)-LEADS

16-17 18-19 16-18 16-19 R-R B-B

43.3 48.1 -- -- 7.8 --

41.2 46.1 -- -- 0.4 --

21.9 -- 58.4 71.9 1.4 --

-- -- -- -- 7.6 145.5

Page 29

HOIST MOTORS (652-162)

VOLTS-PHASE H.P.

-HERTZ (KW)

230/460-3-60 3.5 (2.7) 220/380-3-50 3.5 (2.7) 220/415-3-50 3.5 (2.7) 230/460-3-60 5.7 (4.3)

220/380-3-50 5.7 (4.3) 220/415-3-50 5.7 (4.3)

230-3-60 1.2/3.5

(.9/2.7)

220-3-50 1.2/3.5

(.9/2.7)

460-3-60 1.2/3.5

(.9/2.7)

380-3-50 1.2/3.5

(.9/2.7)

415-3-50 1.2/3.5

(.9/2.7) 575-3-60 3.5 (2.7) 575-3-60 1.2/3.5

(.9/2.7)

CURRENT (AMPS)

STARTING FULL LOAD

18.4/6.4 11.5/5.8

13.6/6.4 11.9/5.9

13.6/6.4 11.9/5.8

23.2/8.0 14.5/7.3

17.0/8.0 14.9/7.4

17.0/8.0 14.9/7.3

49.2/40.8 12.3/10.2

36.4/26.2 13.0/11.4

25.6/20.4 6.4/5.1

16.8/14.3 6.7/5.7

9.5 3.8

14.5/11.3 5.8/4.5

*D.C. RESISTANCE (OHMS)-LEADS

1-2 1-2 11-12 1-3 1-3 11-13 2-3 2-3 12-13

4.4 – –

2.8 _ _

2.8 – –

_ 3.0 1.9

– 3.0 1.9

– 10.8 6.3

6.9 – -

– 15.8 9.9

TROLLEY MOTORS (670-407)

*D.C. RESISTANCE (OHMS)-LEADS

VOLTS HP RPM FULL LOAD T1-T4 T7-T8 T1-T2 T11-T12

(3 PHASE) (KW) (SYN.) CURRENT (AMPS) T2-T5 T7-T9 T1-T3 T11-T13

AT 60 HERTZ AT 60 HERTZ T3-T6 T8-T9 T2-T3 T12-T13

208-240/380-480 .5 (.38) 1200 1.95/.98 15.9 31.2 –– 208-240/380-480 .5 (.38) 600 3.75/1.88 14 28 ––

550-575 .5 (.38) 1200 0.70 ––101.2 – 550-575 .5 (.38) 600 1.80 ––86.3 – 208-240 .25/.50(.19/.38) 600/1200 3.00/2.60 ––25.0 27.1 380-480 .25/.50(.19/.38) 600/1200 1.30/1.10 ––105.9 106.9 208-240 .25/.50(.19/.38) 900/1800 4.5/8.1 -- -- 17.3 30.6 380-480 .25/.50(.19/.38) 900/1800 .8/.7 ––67.3 123.4 550-575 .25/.50(.19/.38) 900/1800 .6/.7 ––123.0 187.5

*Resistance values are nominal and may vary from component to component.

**On dual voltage units (230/460-3-60, 220/380-3-50 and 220/415-3-60), brake coil operates on 230 (220) volts.

TROLLEY MOTORS (BET-3001)

VOLTS H.P. RPM FULL

(3 PHASE) (KW) (SYN) CURRENT (AMPS)

AT 60 HERTZ AT 60 HERTZ

208-240/380/480 .25 (.19) 1800 1.35/.65

208-240/380-480 .5 (.38) 1800 .37

550-575 .25 (.19) 1800 2.0/1.0

550-575 .5 (.38) 1800 .80

D.C. RESISTANCE (OHMS)-LEADS

230 VOLT 460 VOLT 575 VOLT

CT1-CT2 CT1-CT2 CT1-CT2 CT2-CT3 CT2-CT3 CT2-CT3 CT1-CT3 CT1-CT3 CT1-CT3

19.7 78.9 --

10.3 41.2 --

-- -- 132.3

-- -- 66.2

Page 30

TYPICAL WIRING DIAGRAMS

Wiring diagrams shown are representative. Consult wiring diagram in hoist or furnished

with unit.

SINGLE SPEED - HOIST ONLY

2 TON - SINGLE SPEED HOIST WITH TROLLEY

Page 31

TWO SPEED - HOIST ONLY

2 TON - TWO SPEED HOIST WITH TROLLEY

Page 32

3-7½ TON - SINGLE SPEED HOIST WITH TROLLEY

3-7½ TON

2 SPEED HOIST WITH SINGLE SPEED TROLLEY

Page 33

DISASSEMBLY

Refer to pages 30 through 40 for exploded view and parts list. The following are general guide lines for disassembling the XL Hoist. Prior to disassembly:

1. Operate the hoist in the “down” direction until the lower limit is reached. Remove the brake end cover (652-181) and disengage the limit switch guide plate from the traveling nuts (see page 15). Remove the chain container or remove the loose end screw (652-

256) and washers (652-257 and 652-258).

2. Carefully run the chain out of the hoist. On 3 and 4 ton units, the chain will remain suspended from the dead end block (652-204).

3. Disconnect the hoist from the power supply system and Lockout/Tagout disconnecting means.

4. Drain the oil from the hoist.

5. Remove the hoist from its support (hook suspended units) or remove the hoist and trolley from the beam. Remove the trolley from the hoist.

These guide lines cover the disassembly of the major mechanical components; not covered is the removal of obvious items such as hardware and seals. While disassembling the hoist, care should be taken so as to not damage the seals. Seals should be inspected for nicks or damage that could cause oil leaks. Damaged seals should be replaced prior to reassembly.

1. Remove brake end cover (652-181).

2. Remove the brake assembly (652-161) and brake hub (652-142).

3. Remove the entire limit switch assembly and the limit switch worm (652-146).

4. Remove the motor end cover (652-182) and the complete motor (652-162). Coupling (652-103) should remain on motor shaft.

5. On the 2, 3 and 4 ton units, remove chain plate (652-178). On the 5 and 6 ton units,remove the idler wheel housing (652-211) with idler wheel and bearings.

6. *Remove the brake housing (652-108) and gasket (652-118).

7. Remove the drive shaft and pinion (652-112).

8. Remove the Protector (652-160).

9. *Remove the intermediate plate (652-109) from the

main housing (652-110) and remove gasket (652-

118).

10. Remove the limit switch gear (652-149) from the limit switch input shaft (652-104) and remove the shaft from the intermediate plate.

11. Remove the second gear (652-159) from third reduction pinion and shaft (652-106) and remove the third reduction pinion and shaft from the main housing (652-110).

12. Remove the liftwheel gear (652-105) from the lift wheel (652-111).

13. Remove the motor housing (652-107) from the main housing (652-110).

14. Remove the chain stripper (652-114) and chain guide (652-113).

15. On the 3, 4, and 5 ton (Double Reeved) units,

remove the dead end block (652-204) and chain.

16. Remove the liftwheel (652-111) from the main housing.

*Slots are provided in intermediate plate (652-109) to

aid in the removal of screws.

REASSEMBLY

The reassembly of the hoist is, basically, the reverse of the above disassembly sequence. However, during reassembly:

1. If new seals are installed, make sure the lip of the seal is on the oil side.

2. Apply a light coat of gear oil to lips of all seals and surfaces of shafts that pass thru the seals.

3. Carefully slide the shafts through the seals.

4. The frame screws used to attach the motor and gear housings to the main frame should be tightened to a seating torque of 21 pound feet (28 NM).

5. Lubricate, especially the splines, as specified on page 14.

6. Make sure that “this side out” embossed on the liftwheel gear is visible when the gear is assembled to the liftwheel.

7. Place the load chain (with welds down and towards liftwheel. See illustration on page 27) over the liftwheel before attaching the motor housing to the main frame. After assembly reeve chain per page 27.

8. Follow instructions starting on page 4 when reinstalling the unit.

9. After installation, test the unit as indicated on page 29.

REMOVAL AND REPLACEMENT OF LOAD CHAIN

Hoist load chain can be removed and installed using one of the following methods. Method 1 is recommended if only the load chain is replaced. Method 2 is recommended when the entire hoist is disassembled for repair and /or inspection.

WARNING

Working in or near exposed energized electrical equipment presents the danger of electrical shock.

TO AVOID INJURY:

DISCONNECT POWER AND LOCKOUT/TAGOUT DISCONNECTING MEANS BEFORE REMOVING COVER OR SERVICING THIS HOIST.

USE ONLY STAR (H) GRADE LOAD CHAIN AND FACTORY REPLACEMENT PARTS. USE OF OTHER CHAIN AND PARTS MAY BE DANGEROUS AND VOIDS FACTORY WARRANTY.

WARNING

USE OF COMMERCIAL OR OTHER MANUFACTURERS’ CHAIN AND PARTS TO REPAIR XL HOISTS MAY CAUSE LOAD LOSS.

TO AVOID INJURY:

Use only factory supplied replacement load chain and parts. Chain and parts may look alike, but factory chain and parts are made of specific material or processed to achieve specific properties.

Star and 2-digit year code

Page 34

METHOD 1

1. Disconnect the hoist from the power supply system.

2. Remove the motor end cover (652-182). On units with book suspension, remove the counterweight (652-219) prior to removing the motor cover.

3. Disengage the limit switch guide plate from the traveling nuts (see page 15).

4. Remove the chain container or remove the loose end of the chain from the hoist frame.

5. Using the procedures described on page 28 for cutting load chain, cut a portion out of the last loose end link to form a coupling link. The portion removed should be centered on the weld and be 1/2 inch (13mm) long. Remove burrs from cut edges.

6. Using the coupling link, attach the new chain to the old chain. Carefully check the welds on the new chain and make sure they are positioned the same as the old chain. The new chain must enter the hoist so that the welds are down and towards the lift wheel. See illustration below. Failure to properly position the chain will cause the chain to jam between the liftwheel and chain guide.

7. Re-energize power supply and carefully operate hoist in the “down” direction until approximately 6 feet (2 M) of the new chain is hanging free on the dead end side.

8. ON SINGLE REEVED UNITS, remove the hook block from the old chain, remove the coupling link, discard the old chain and attach the hook block to the new chain. ON DOUBLE REEVED UNITS, the hoist must be removed from the trolley before reeving the replacement load chain. For hook suspended units, the hook must be positioned so that the dead end bolt can be removed. If necessary, rotate hook approximately 45 degrees following the instructions on page 5. Now remove the chain plate and allow it and the dead end block spacer (652-253) to slide down the chain. Working through the cavity in the bottom of the hoist, hold the dead end block while loosening the dead end bolt. Remove the dead end block and remove the dead end pin. Remove the coupling link, pull the old chain out of the hook block and discard the old chain. Reeve the new load chain as described below. After reeving, mount trolley on hoist or reposition hook, if necessary, per installation instructions starting on page 4. ON TRIPLE REEVED UNITS, remove the dead end plate from the top of the hook block. Remove the dead end pin and remove the old chain from the dead end plate. Remove the coupling link, pull the old chain out of the hook block and idler sheave housing. Reeve the new load chain as described below.

9. Remount the chain container or reattach the loose end of the new chain to the hoist.

10 Reset upper and lower limit switches per page 15.

METHOD 2

1. Completely disassemble the hoist as described on page 26.

2. Prior to reassembly, inspect the liftwheel, chain guides and stripper for wear. If these parts are worn or damaged, they could cause premature wear of the chain. Replace worn or damaged parts.

3. Place chain on liftwheel with welds down and towards liftwheel as shown below. Welds must engage the relief machined in the bottom of the liftwheel pockets. If the chain is not properly placed

on the liftwheel, it will not be possible to install the chain guide. After making sure the chain is correctly installed on the liftwheel, continue to assemble the hoist.

4. On single reeved units, remove the hook block from the old chain and attach it to the new chain. On double and triple reeved units, reeve the new chain as described below.

5. Install the unit following the installation instructions starting on page 4.

6. Remount the chain container or reattach the loose end of the new chain to the hoist frame.

7. Reset upper and lower limit switches per page 15.

REEVING LOAD CHAIN

3, 4 AND 5 TON DOUBLE REEVED UNITS

The following instructions assume that the trolley has been removed from the hoist or the upper hook has been positioned to provide access to the dead end bolt and that there is 6 feet (2 m) of chain hanging free on the dead end side of the hoist. Based on these, reeve the load chain as follows:

1. Slide the suspension adapter into the hoist frame, if has moved out of position or if it was removed.

2. Install the dead end bolt.

3. Attach a soft wire to the end of the chain. Feed the wire around the hook block sheave. MAKING SURE THERE ARE NO TWISTS, pull the chain thru the hook block.

4. Feed the chain thru the square opening in the chain plate and then thru the dead end block spacer.

5. Attach the last link of chain to dead end block using the dead end pin.

6. MAKING SURE THERE ARE NO TWISTS IN THE CHAIN, slide the dead end block into the cavity in hoist frame. Turn the dead end bolt by hand to thread it into the dead end block. Then tighten dead end bolt to a seating torque of 120 pound feet (160 NM).

7. Slide the chain plate and spacer up the chain and attach the chain plate to the hoist frame.

8. Retrace the chain and make sure there are no twists. If there are twists, start over.

INSTALL LOAD

CHAIN PROPERLY

ON LIFTWHEEL

WARNING

Improper installation (reeving) of load chain can result in dropped load.

TO AVOID INJURY:

Properly reeve load chain per the following instructions.

Page 35

HOOK SUSPENSION SHOWN LUG SUSPENSION SIMILAR

REEVING LOAD CHAIN

3,4 AND 5 TON HOISTS

REEVING LOAD CHAIN 5,6 AND 7 1/2 TON HOISTS

5, 6 AND 7 1/2 TON TRIPLE REEVED UNITS

The following instructions assume that the idler wheel housing assembly has been attached to the suspension adapter and hoist frame, there is 6 feet (2 M) of chain hanging free on the dead end side of the hoist and the hoist is suspended from the trolley or permanent support.

Based on these, reeve the load chain as follows:

1. Attach a soft wire to the end of the chain. Feed the wire around the hook block sheave. MAKING SURE THERE ARE NO TWISTS IN THE CHAIN, pull the chain thru the hook block.

2. Feed the soft wire into the outboard side of the idler wheel housing and around the idler wheel. MAKING SURE THERE ARE NO TWISTS IN THE CHAIN, pull the chain over the idler wheel.

3. Remove the wire from the end of the chain and route chain down to the hook block. MAKING SURE THERE ARE NO TWISTS IN THE CHAIN, insert the last link of the chain into the slot in the dead end plate. Secure the chain using the dead end pin and attach the dead end plate to top of hook block. Tighten the dead end plate screws to a seating torque of 120 pound feet (160 NM).

4. Retrace chain and make sure there are no twists. If there are twists, start over.

CUTTING CHAINS

Hoistaloyload chain is hardened and it is difficult to cut. The following methods are recommended when cutting a length of new chain from stock or cutting off worn chain. Always wear eye protection when cutting chain.

1. Use a grinder and nick the link on both sides (see below), then secure the link in a vise and break off with a hammer.

2. Use a 7 inch ( 177 mm) minimum diameter by 1/8 inch ( 3.1 mm) thick abrasive wheel (or type recommended by wheel supplier) that will clear adjacent links.

3. Use a bolt cutter (See below) similar to the H.K. Porter No. 0590MTC with special cutter jaws for cutting hardened chain. Jaws should be 1 inch (25.4 mm) long.

Cutting Chain by Nicking

Cutting Chain with a Bolt Cutter

HOOK SUSPENSION SHOWN. LUG SUSPENSION SIMILAR

GRINDER NICKS

Page 36

TESTING

Before using, all altered, repaired or used hoists that have not been operated for the previous 12 months shall be tested by the user for proper operation. First, test the unit without a load and then with a light load of 50 pounds (23 kg) times the number of load supporting parts of load chain to be sure that the hoist operates properly and that the brake holds the load when control is released. Next test with a load of *125% of rated capacity. In addition hoists in which load sustaining parts have been replaced should be tested with *125% of rated capacity by or under the direction of an appointed person and written report prepared for record purposes. After this test, check that the Protector functions. If the Protector permits lifting a load in excess of 180% of rated load, it should be replaced.

NOTE: For additional information on inspection

and testing, refer to American National Standard ASME B30.16 “Overhead Hoists” obtainable from The American Society of Mechanical Engineers, 345 East 47th Street, New York, NY 10017 U.S.A.

*If the Protector prevents lifting of a load of 125% of rated capacity, reduce load to rated capacity.

ORDERING INSTRUCTIONS

The following information must accompany all correspondence and orders for replacement parts:

1. Hoist rated load from identification plate.

2. Serial number of the hoist stamped below identification plate.

3. Voltage, Phase, Hertz from identification plate.

4. Length of lift.

5. Key number part from parts list.

6. Number of parts required.

7. Part name from parts list.

8. Part number from the parts list.

If trolley replacement parts are ordered, also include the type and capacity of the trolley.

WARNING

Cutting Chain Can Produce Flying Particles.

TO AVOID INJURY:

• Wear Eye Protection

• Provide A Shield Over Chain To Prevent Flying Objects

WARNING

Using “commercial” or other manufacturer’s parts to repair the XL Hoists may cause load loss.

TO AVOID INJURY:

Use only factory supplied replacement parts. Parts may look alike but factory original parts are made of specific materials or processed to achieve specific properties.

REPAIR PARTS

NOTE: WHEN ORDERING REPLACEMENT PARTS, IT IS

RECOMMENDED THAT CONSIDERATION BE GIVEN TO THE NEED FOR ALSO ORDERING SUCH ITEMS AS GASKETS, FASTENERS, INSULATORS, SEALS, ETC. THESE ITEMS MAY BE DAMAGED OR LOST DURING DISASSEMBLY OR JUST UNFIT FOR FUTURE USE BECAUSE OF DETERIORATION FROM AGE OR SERVICE.

Page 37

KEY NO. NO. REQ’D PART NAME PART NUMBER

652-100 2 BRAKE HUB SNAP RING 35764 652-101 1 2ND GEAR SNAP RING 36763 652-102 1 2ND PINION SNAP RING 45766 652-103 1 MOTOR SHAFT COUPLING FOR:

2, 3, 4, 5 AND 6 TON 52018 5 TON (15 FPM UNITS) AND 52078

7 1/2 TON (TRIPLE REEVED) 652-104 1 LIMIT SWITCH INPUT SHAFT 52019 652-105 1 LIFTWHEEL GEAR FOR:

2, 3, 4, 5 AND 6 TON 52021

5 TON (15 FPM) AND 52076

7 1/2 TON (10 FPM) 652-106 1 3RD REDUCTION PINION AND SHAFT FOR:

2, 3, 4, 5 AND 6 TON 52026

5 TON (15 FPM UNITS) AND 52075

7 1/2 TON (10 FPM) 652-107 1 MOTOR HOUSING ASSEMBLY (See note 1) 52631 652-108 1 BRAKE HOUSING ASSEMBLY (See note 2) 52632 652-109 1 INTERMEDIATE PLATE ASSEMBLY (See note 3) 52633 652-110 1 MAIN HOUSING ASSEMBLY (See note 4) 52630 652-111 1 LIFTWHEEL 52033 652-112 1 DRIVE SHAFT AND PINION FOR:

2, 3, 4, 5 AND 6 TON 52036

5 TON (DOUBLE REEVED) AND 52079

7 1/2 TON (TRIPLE REEVED) 652-113 1 CHAIN GUIDE 52041 652-114 1 CHAIN STRIPPER 52055 652-115 1 LIMIT SWITCH SHAFT ASSEMBLY 36623 652-116 1 MOUNTING BRACKET 52704 652-117 1 CONTACTOR MOUNTING PLATE 52706 652-118 2 MAIN HOUSING GASKET 52709 652-119 1 LIMIT SWITCH SPRING 52742 652-120 1 LIMIT SWITCH ASSEMBLY 52609 652-121 1 BREATHER 70726 652-122 2 DRIVE SHAFT SEAL 80401 652-123 2 DRIVE SHAFT BEARING 80402 652-124 1 2ND REDUCTION PINION 80403

BEARING - INBOARD 52-125 1 2ND REDUCTION PINION 88429

BEARING - OUTBOARD 652-126 1 3RD REDUCTION PINION 80408

BEARING - OUTBOARD 652-127 3 CHAIN GUIDE PIN 80410 652-128 1 LIFTWHEEL BEARING - MOTOR END 80411 652-129 1 LIFTWHEEL SEAL - GEAR END 80412 652-130 1 *BRAKE COIL: (See note 5)

208-240 VOLT 68877

380-480 VOLT 68878

550-575 VOLT 68879 652-131 2 BRAKE FRICTION DISC 70652 652-132 1 LIFTWHEEL SEAL - INBOARD 80415 652-133 1 LIFTWHEEL GEAR SNAP RING 80416 652-134 1 LIMIT SWITCH INPUT SHAFT SEAL 80417 652-135 1 TRANSFORMER :

208-240/380-480 VOLT 68810

PRIMARY, 115 VOLT SECONDARY

208-240/380-480 VOLT 70793 CON’T. PRIMARY, 48 VOLT SECONDARY

KEY NO. NO. REQ’D PART NAME PART NUMBER

652-135 1 208-240/380-480 VOLT 68811

PRIMARY, 24 VOLT SECONDARY 550-575 VOLT PRIMARY, 68786 115 VOLT SECONDARY

652-136 1 HOIST REVERSING CONTACTOR WITH :

115 VOLT COILS 52749 48 VOLT COILS 52751 24 VOLT COILS 52750

652-137 1 SPEED SELECTING CONTACTOR WITH :

115 VOLT COIL 70805 48 VOLT COIL 70806 24 VOLT COIL 70781

652-138 1 TROLLEY REVERSING CONTACTOR WITH :

115 VOLT COILS 28835 48 VOLT COILS 28846

24 VOLT COILS 28837 652-139 -- LINE CONNECTOR-SPECIFY NO REQ’D. 982158 652-140 4 MOTOR BOLT 80429 652-141 2 LIMIT SWITCH INPUT SHAFT BEARING 88437 652-142 1 BRAKE HUB 68367 652-143 1 LIFTWHEEL BEARING - GEAR END 80413 652-144 1 3RD REDUCTION PINION BEARING - 88500

INBOARD 652-145 15 FRAME SCREW 987289 652-146 1 LIMIT SWITCH WORM 35756 652-147 1 LIMIT SWITCH WORM PIN 983766 652-148 1 LIMIT SWITCH GEAR PIN 983768 652-149 1 LIMIT SWITCH GEAR FOR :

6, 9, 10, 15.2, 18, 30, 2/6, 3/9 AND 6/18 FPM 52720

8, 12, 24, 8/2.7, 4/12 AND 8/24 FPM 52713 652-150 2 FRAME PLUG (1”) 989074 652-151 1 GROUND SCREW 982686 652-152 2 LIMIT SWITCH SHAFT BEARING 35751 652-153 2 LIM. SW. SHAFT BEARING SCREW 983643 652-154 1 LIMIT SWITCH GUIDE PLATE 28714 652-155 2 LIMIT SWITCH GUIDE PLATE SCREW 983614 652-156 2 FRAME PLUG (3/4”) 989055 652-157 1 POWER CORD 51108 652-158 1 POWER CORD CONNECTOR 983979 652-159 1 2ND GEAR FOR :

6, 9, 10, 15.2, 18, 30, 2/6, 3/9 AND 6/18 FPM 52043

8, 12, 24, 2.7/8, 4/12, AND 8/24 FPM 52024 652-160 1 PROTECTOR ASSEMBLY FOR :

CAPACITY SPEED

(TONS) (FPM)

2 18 AND 6/18 52613 2 24 AND 8/24 52614 2 30 52626 3 9 AND 3/9 52628 3 12 AND 4/12 52613 3 15 AND 5/15 52665 4 9 AND 3/9 52613 4 12 AND 4/12 52614 4 15 52626 5 6 AND 2/6 52627 5 8 AND 2.7/8 52613 5 9 AND 9/3 52665 5 12 52626

CON’T 5 15.2 52661

XL Electric Chain Hoist Parts List

Page 38

KEY NO. NO. REQ’D PART NAME PART NUMBER

652-160 1 PROTECTOR ASSEMBLY FOR: Con’t:

6 6 AND 2/6 52613 6 8 AND 2.7/8 52614

6 10 52626 7 1/2 6 AND 2/6 52665 7 1/2 10 52661

652-161 1 ELECTRIC BRAKE COMPLETE:

208-240/380-480 VOLT, ONE SPEED 52606 208-240 VOLT, TWO SPEED 52606 380-480 VOLT, TWO SPEED 52611 550-575 VOLT, SINGLE AND TWO SPEED 52612 FOR: 5 TON (DOUBLE REEVED) 52660 AND 7 1/2 TON (TRIPLE REEVED) 208-240/380-480 VOLT, SINGLE SPEED

652-162 1 MOTOR (ROTOR WITH BEARINGS,

STATOR AND END BELL) FOR : 208-240/380-480 VOLT, SINGLE SPEED 52710 208-240 VOLT, TWO SPEED 52711 380-480 VOLT, TWO SPEED 52712 550-575 VOLT, SINGLE SPEED 52730 550-575 VOLT, TWO SPEED 52754 FOR: 5 TON (DOUBLE REEVED) 52812 AND 7 1/2 TON (TRIPLE REEVED) 208-240/380-480 VOLT, SINGLE SPEED

652-163 -- LOAD CHAIN - SPECIFY LENGTH REQ’.D

BURNISHED IN OIL 85885 ZINC 85886

652-164 1 WIRING HARNESS FOR :

SINGLE SPEED 51109

TWO SPEED 51110 652-165 2 CONTACTOR MOUNTING PLATE SCREW 983747 652-166 1 CONVERSION T.B. BRACKET 52705 652-167 2 BRACKET ATTACHING SCREW 982683 652-168 1 CONVERSION TERMINAL BOARD 28828 652-169 1 CONVERSION T.B. INSULATOR 27776 652-170 3 CONVERSION T.B. SCREW 987847 652-171 3 CONVERSION T.B. SCREW L.W. 987873 652-172 - JUMPERS -

FOR SINGLE SPEED: 3-51111, 4-51112,

AND 3-51113 JUMPERS REQ’D.

FOR TWO SPEED: 4-51111, 6-51112,

AND 2-51114 JUMPERS REQ’D. 652-173 3 TRANSFORMER SCREW 987859 652-174 3 TRANSFORMER SCREW L.W. 987873 652-175 1 LOWER HOOK WITH LATCH ---

LATCH TYPE :

2 TON 35612

3, 4, 5, 6 AND 7 1/2 TON 52651

LOWER HOOK --- LATCHLOK TYPE :

2-TON 36681

3, 4, 5 AND 6 TON 52625

3-6 TON LOWER LATCHLOK KIT 5264 652-176 1 HALF LINK 52017

652-177 2 HOOK BLOCK :

2 TON 52025

3 AND 4 TON 52049

5, 6 AND 7 1/2 TON 52069 652-178 1 CHAIN PLATE :

2 TON 52046C

3 AND 4 TON 52048C 652-179 - HOOK BLOCK SCREW :

2 TON - 4 REQ’D. 982369

3 AND 4 TON - 4 REQ’D. 80423

5, 6 AND 7 1/2 TON - 2 REQ’D. 80423 652-180 2 CHAIN PLATE OR IDLER HOUSING SCREW 987288

KEY NO. NO. REQ’D PART NAME PART NUMBER

652-181 1 BRAKE END COVER 52028C 652-182 1 MOTOR END COVER 52031C 652-183 1 IDENTIFICATION PLATE:

LODESTAR XL 70728

652-184 4 BRAKE END COVER SCREW 80409 652-185 4 I.D. PLATE DRIVE SCREW 988271 652-186 2 WARNING LABEL, ELECTRICAL 24842 652-187 1 LIFTWHEEL GEAR BEARING 80414 652-188 1 2ND REDUCTION PINION FOR :

6, 9, 10, 15.2, 18, 30, 2/6, 3/9 AND 6/18 FPM 52044 8, 12, 24, 2.7/8, 4/12 AND 8/24 FPM 52023

652-189 1 CAPACITY LABEL FOR :

2 TON 52714 3 TON 52724 4 TON 52716 5 TON 52726 6 TON 52728 7 1/2 TON 52757

652-190 1 WARNING LABEL FOR :

2 TON 52715 3 TON 52725 4 TON 52717 5 TON 52727 6 TON 52729

7 1/2 TON 52785 652-191 1 COIL RETAINER STRAP 35704 652-192 1 BRAKE BASE PLATE 52607 652-193 1 BRAKE FIELD PLATE 59634 652-194 3 BRAKE SPRING FOR:

2, 3, 4, 5 AND 6 TON 68818

5 TON (DOUBLE REEVED) AND 52811

7 1/2 TON (TRIPLE REEVED) 652-195 1 BRAKE INTERMEDIATE PLATE 68820 652-196 1 BRAKE ARMATURE 70657 652-197 3 BRAKE NUT 982448 652-198 4 MOTOR COVER SCREW 80409 652-199 2 SPEED SELECTOR SCREW 982706 652-200 1 HOOK NUT OR COLLAR FOR :

2 TON 35369

3, 4, 5, 6 AND 7 1/2 TON 52047 652-201 1 HOOK NUT OR COLLAR PIN FOR :

2 TON 45946

3, 4, 5, 6 AND 7 1/2 TON 80418 652-202 1 LOWER HOOK THRUST BEARING FOR :

2 TON 88505

3, 4, 5, 6 AND 7 1/2 TON 80421 652-203 1 SHEAVE WHEEL 52050 652-204 1 DEAD END BLOCK 52051 652-205 1 DEAD END PIN 52057 652-206 2 SHEAVE WHEEL BEARING 80422 652-207 1 DEAD END BOLT 80424

3, 4, 5, 6 AND 7 1/2 TON 652-208 2 HOOK BLOCK CAPACITY LABEL FOR :

3 TON 52738

4 TON 52739

5 TON 52740

6 TON 52741

7 1/2 TON 52786 652-209 4 CAPACITY LABEL DRIVE SCREW 988271 652-210 1 DEAD END PLATE 52068 652-211 1 IDLER WHEEL HOUSING 52053C

Page 39

KEY NO. NO. REQ’D PART NAME PART NUMBER

652-212 1 IDLER WHEEL 52054 652-213 1 ANCHOR PIN 52058 652-214 2 IDLER WHEEL BEARING 80425 652-215 6 DEAD END PLATE SCREW 52074 652-216 1 LATCH KIT FOR:

2 TON 45663 3, 4, 5, 6 AND 7½ TON 52701

652-217 1 SUSPENSION ADAPTER FOR :

2 TON 52022 3, 4, 5 AND 6 TON 52035

652-218 1 UPPER HOOK NUT FOR :

2 TON 52045

3, 4, 5 AND 6 TON 52047 652-219 1 COUNTERWEIGHT 52061 652-220 1 UPPER HOOK, LATCH TYPE, FOR :

2 TON 52608

3, 4, 5 AND 6 TON 52651

UPPER HOOK, LATCHLOK TYPE FOR :

2 TON 52624

3, 4, 5 AND 6 TON 52625 652-221 1 HOOK NUT PIN 80418 652-222 1 ANTI-ROTATION PIN FOR :

2 TON 80419

3, 4, 5 AND 6 TON 80420 652-223 2 COUNTERWEIGHT SCREW 80428 652-224 1 SUSPENSION SCREW ( 2 TON ONLY) 987208 652-225 1 ANTI-ROTATION PLATE 52708 652-226 1 ANTI-ROTATION PLATE SCREW 982371 652-227 1 UPPER HOOK SUSPENSION, LATCH TYPE

COMPLETE (SEE NOTE 6) :

2 TON 5254

3, 4, 5 AND 6 TON 5255 652-228 2 LIMIT SWITCH BRACKET SCREW 982708 652-229 2 LIMIT SWITCH BRACKET SCREW L.W. 982226 652-230 1 LIMIT SWITCH BRACKET 35032 652-231 1 LIM. SW. ASSEMBLY ATTACH. SCREW 983614 652-232 1 DRAIN PLUG 989050 652-233 1 2ND REDUCTION PINION SNAP RING FOR:

6, 9, 10, 15.2, 18, 30, 2/6, 3/9, AND 6/18 FPM UNITS ONLY. 45766

KEY NO. NO. REQ’D PART NAME PART NUMBER

652-234 1 TROLLEY CONTACTOR BRACKET 52722 652-235 1 TROLLEY SPEED SELECTOR INSULATOR 52723 652-236 1 TROLLEY SPEED SELECTOR WITH:

115 VOLT COIL 28806 48 VOLT 28848

24 VOLT COIL 28829 652-237 2 TRO. CONTACTOR BRACKET SCREW 25862 652-238 2 TRO. SPEED SELECTOR SCREW 25859 652-239 2 TROLLEY CONTACTOR SCREW 25866 652-240 1 TERMINAL INSULATOR 35881 652-241 -- TROLLEY CONTACTOR JUMPERS: --

3-51661 JUMPER AND 1-51699 JUMPER 652-242 3 TROLLEY CONTACTOR TO SPEED 51661

SELECTOR JUMPER 652-243 1 HOIST CONTACTOR TO TROLLEY 51118

CONTACTOR HARNESS 652-244 4 BRAKE ATTACHING SCREW 946801 652-245 2 LODESTAR XL LABEL 52760

652-246 1 CONTROL CORD ATTACHING SCREW 982688 652-247 1 CONTROL CORD ATTACH. SCREW L. W. 982226 652-248 1 CONTROL CORD ATTACH. SCREW WASHER 927835 652-249 1 WARNING TAG 81704 652-250 1 CONTROL CORD ASSEMBLY FOR:

SINGLE SPEED HOIST WITH 10 FT. LIFT 28450

TWO SPEED HOIST WITH 10 FT. LIFT 36584

SINGLE OR TWO SPEED HOIST WITH 51711

10 FT. LIFT AND MOTOR DRIVEN TROLLEY

(FOR OTHER LIFTS CONTACT CM) 652-251 2 END COVER GASKET

(WEATHER PROOF UNITS ONLY) 52759 652-252 2 CONTACTOR MOUNTING SCREW 982686 652-253 1 DEAD END BLOCK SPACER 52064 652-254 1 CONV. T.B. LABEL--LONG 52721 652-255 1 TROLLEY CORD HOLE PLUG 989052 652-256 1 LOOSE END SCREW 982667 652-257 1 LOOSE END SCREW WASHER 987898 652-258 1 LOOSE END SCREW WASHER 45915 652-259 1 CONV. T.B. LABEL--SHORT 52762 652-261 1 CONTROL GROMMET 27891 652-262 1 ROTOR BEARING -OUTBOARD 83692 652-263 1 ROTOR BEARING -INBOARD 83689

Notes:

1. Includes 652-128

2. Includes 652-122, 652-123, 652-125, 652-134, and 652-141.

3. Includes 652-122, 652-123, 652-124, 652-126, 652-132, 652-141, and 652-187.

4. Includes Dowel Pins, 652-129, 652-143, and 652-144.

5. Dual Voltage (208-240/440-480, 220/380 and 220/415) units use 230 volt brake coil part number 68877.

6. If complete Latchlok Type Hook Suspension is Required, Contact Factory.

Part number for Packaged Lubricants Used in the XL Electric Chain Hoists

(Refer to page 15 for Lubrication Instructions)

Lubricant

Usage

Hoist Gears

Splines

Load Chain

Limit Switch

Shaft Threads

Lower Hook

Thrust Bearing

Trolley

Trackwheel Bearings and Gears

Trolley Gears

Type of

Lubricant

Grease Oils

(Amoco 85W-140)

*Grease

Oil

*Oil

Grease (Novatex #2)

Grease (Novatex #1)

Part Numbers and Packaged

Quantity of Lubricants

52776 for 1 Gal. Can

EP Type Grease - Obtain Locally

28608 for 1 Pint Can 28619 for 1 Gal. Can

“3 in 1” or Light Machining

Oil - Obtain Locally

Heavy Machine Oil

Obtain Locally

28632 for 4 lb. Can 28610 for 1 lb. Can

28613 for 4 lb. Can 28612 for 1 lb. Can

*These lubricants are not furnished by in Packaged Quantities. When ordering lubricants, specify the type of lubricant, part number and packaged quantity required. Touch-up Paints for Lodestar XL Electric Chain Hoists and 2 Ton Trolley Order: (1) case (12-12 oz. Aerosol Cans) of Orange Touch-up paint Part Number 84190.

Touch-up Paints for 3-7½ Ton Trolleys order: (1) case (12-12 oz. Aerosol Cans) of Black Touch-up Paint Part Number 84189. Touch-up paint is only available in case quantities. Note: When painting Hoists or Trolley, also order warning labels, identification labels, etc. that may be coating during painting.

Page 40

1 MOTOR & GEARBOX ASS’Y (LESS POWER CORD) BET-3000 11 MOTOR (INCLUDES REF. NO.2 BET-3001 21 MOTOR KEY (3/16 X 3/16 X 1 1/4”) BET-3002

1 GEAR BOX ASS’Y - COMPLETE BET-3003 31 ELECTRICAL WARNING LABEL 24842 41 POWER CONNECTOR LOCKNUT 989771 54 LOCKWASHER BET-3006 64 HEX HEAD BOLT (3/8-16 X 7/8) BET-3007 71 POWER CORD 51120 8 WIRE NUT 983812 91 POWER CORD CONNECTOR 89926

10 1 WEATHERPROOF 0-RING 983967

11 LINE CONNECTOR 982158

SPECIFY

QTY.

SPECIFY

QTY.

REF. NO. NO. REQ’D

PART DESCRIPTION

PART NUMBER

3-7 1/2 TON

3 THRU 7½ TON MOTOR AND GEAR BOX ASSEMBLY

TROLLEY BRAKE (OPTIONAL)

*SEE PAGE 47 FOR TROLLEY BRAKE ASSEMBLY

Page 41

•For control station and control station parts see pages 45 and 46

*SEE ALSO 652-219 COUNTER WEIGHT IF ORDERING HOOK SUSPENSION PARTS SEPARATELY.

Page 42

39 40

2 TON

ANTI-TIPPING BRACKET KIT 670-464

Page 43

KEY NO. NO. REQ’D PART NAME PART NUMBER

2 TON

670-320 2 REQ’D. PLAIN SIDE FRAME FOR:

FOR PLAIN 3.25” TO 5.50” FLANGE (82.6 to 139.7 mm.) 59614

TROLLEYS 5.51” TO 7.63” FLANGE (139.9 to 193.8 mm.) 58617

1 REQ’D. FOR 3.25” TO 5.50” FLANGE (82.6 to 139.7 mm.) 52152

GEARED AND FOR USE WITH ANTI-TIPPING ROLLER

MOTOR DRIVEN

TROLLEYS

670-321 1 HANDWHEEL BRACKET WITH BUSHINGS 59616

670-322 2 HANDWHEEL BUSHING 58727

670-323 3 HANDWHEEL BRACKET SCREW L.W. 945853

670-324 3 HANDWHEEL BRACKET SCREW 987061

670-325 1 HANDWHEEL SHAFT 58504

670-326 1 HANDWHEEL KEY 59967

670-327 1 HANDWHEEL 33143

670-328 1 OR 2 TRACKWHEEL PINION OR HANDWHEEL 986270

SHAFT NUT L.W.

670-329 1 OR 2 TRACKWHEEL PINION OR HANDWHEEL 988095

SHAFT NUT

670-330 1 HANDCHAIN GUIDE 58152

670-331 1 CHAIN GUIDE SCREW 987065

670-332 1 CHAIN GUIDE SCREW WASHER 986224

670-333 1 CHAIN GUIDE SCREW L.W. 945853

670-334 1 CHAIN GUIDE SCREW NUT 945822

670-335 — HAND CHAIN - SPECIFY LENGTH REQ’D. 619022

670-336 1 HAND CHAIN CONNECTING LINK 945491

670-337 — TRACKWHEEL PINION SPACER 987963

WASHER-SPECIFY NO. REQ’D.

670-338 1 TRACKWHEEL PINION SHAFT 58450

670-339 1 or 2 TRACKWHEEL PINION SPACER -- 58456

SPECIFY NO. REQ’D.

670-341 2 PINION SHAFT BEARING 88438

670-342 1 INTERMEDIATE SHAFT BEARING -- 88437

SIDE FRAME END

670-343 1

INTERMEDIATE SHAFT BEARING --MOTOR END

88436

670-344 1 DRIVEN GEAR 58451

670-345 1 INTERMEDIATE PINION 58452

670-346 1 INTERMEDIATE GEAR FOR :

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

58453

50 FPM TROLLEYS (15.2 MPM) 58407

100 FPM TROLLEY (30.4 MPM) 58407

35/65 FPM TROLLEYS (10.7/ 19.8 MPM) 58453

25/50 FPM TROLLEYS (7.6/ 15.2 MPM) 58453

Con’t.

50/100 FPM TROLLEY (15.2/ 30.4 MPM) 58453

2 TON

Plain, Geared and Motor

Driven Trolleys Parts List.

Part Number

Key No. No. Req’d Part Name 2 TON

652-186 2 WARNING LABEL, ELECTRICAL 24842

652-300 1 TROLLEY POWER CORD 51117

652-301 1 HOIST SUSPENSION ADAPTER 52059

652-302 1

SUSPENSION ADAPTER SCREW / DEAD END BOLT

987208

652-303 1 “CM” LABEL 25779

670-304 2 SUSPENSION BOLT FOR :

3.25” TO 5.50” FLANGE (82.6 to 139.7 mm) 58503

5.51” TO 7.63” FLANGE (139.9 to 193.8 mm) 59350

670-305 4 SUSPENSION BOLT NUT 958818

670-306 4 SUSPENSION BOLT NUT COTTER PIN 988368

670-307 — SPACER WASHER - SPECIFY NO. REQ’D. 958726

670-308 4 TRACKWHEEL WITH BEARING CUP :

CROWNED TREAD 58162

670-309 8 TRACKWHEEL BEARING CUP 88521

670-310 8 TRACKWHEEL BEARING CONE 88525

670-311 8 TRACKWHEEL BEARING SHIELD 68918

670-312 4 TRACKWHEEL STUD 58459

670-313 4 TRACKWHEEL STUD COLLAR 58484

670-314 4 TRACKWHEEL STUD NUT 982613

670-315 2 TRACKWHEEL GEAR FOR :

GEARED TROLLEY 58548

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

58548

50 FPM TROLLEYS (15.2 MPM) 58548

100 FPM TROLLEY (30.4 MPM) 58548

35/65 FPM TROLLEYS (10.7/ 19.8 MPM) 58548

25/50 FPM TROLLEYS (7.6/ 15.2 MPM) 58548

50/100 FPM TROLLEY(15.2/ 30.4 MPM) 58548

670-316 4 TRACKWHEEL GEAR PIN 983503

670-317 1 TRACKWHEEL GEAR PINION FOR:

GEARED TROLLEY 58505

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

58505

50 FPM TROLLEYS (15.2 MPM) 58505

100 FPM TROLLEY (30.4 MPM) 58505

35/65 FPM TROLLEYS (10.7/ 19.8 MPM) 58505

25/50 FPM TROLLEYS (7.6/ 15.2 MPM) 58487

50/100 FPM TROLLEYS (15.2/ 30.4 MPM) 58505

670-318 1 TRACKWHEEL PINION KEY 85546

670-319 1 GEARED SIDE FRAME FOR :

3.25” TO 5.50” FLANGE (82.6 to 139.7 mm) 59615

5.51” TO 7.63” FLANGE (139.9 to 193.8 mm) 58618

41 42

Page 44

KEY NO. NO. REQ’D PART NAME PART NUMBER

2 TON

670-378 1 POWER CORD CONNECTOR 89926

670-380 1 TERMINAL BOX GASKET 59991

670-407 1 TROLLEY MOTOR (REFER TO MOTOR

NAMEPLATE) :

.5 HP, 600 RPM, 230/460 V. 57766

.5 HP, 600 RPM, 575 V. 57782

.5 HP, 1200 RPM, 230/460 V. 68916

.5 HP, 1200 RPM, 575 V. 57771

.25/.5 HP, 600/1200 RPM, 230 V. 57273

.25/.5 HP, 600/1200 RPM, 460 V. 57274

.25/.5 HP, 900/1800 RPM, 230 V. 57778

.25/.5 HP, 900/1800 RPM, 460 V. 57779

.25/.5 HP, 900/1800 RPM, 575 V. 57783

670-420 1 TROLLEY BRAKE (INCLUDES 670-421,

670-422, 670-423, AND 670-425 THROUGH

670-431) FOR :

230/460 V. SINGLE SPEED AND 230 V. 59692

TWO SPEED TROLLEYS

460 V. TWO SPEED TROLLEYS 59694

575 V. SINGLE AND

TWO SPEED TROLLEYS 59693

670-421 1 BRAKE BASE PLATE 28668

670-422 1 FRICTION DISC 27677

670-423 1 BRAKE ARMATURE 28678

670-425 1 BRAKE COIL FOR:

230/460V. SINGLE SPEED AND 51518

230 V. TWO SPEED TROLLEYS

460 V. TWO SPEED TROLLEYS 51519

575 V. SINGLE AND TWO

SPEED TROLLEYS 51520

670-426 1 BRAKE COIL RETAINER STRAP 57753

670-427 1 BRAKE FIELD 28677

670-428 2 BRAKE SPRING 68750

670-429 10 BRAKE SPACER WASHER 954807

670-430 2 BRAKE STUD NUT 945840

670-431 2 SHADING COIL 54831

670-462 1 WARNING LABEL 936984

670-463 1 CAPACITY LABEL 957928

670-464 1 ANTI-TIPPING ROLLER KIT 52813

KEY NO. NO. REQ’D PART NAME PART NUMBER

2 TON

670-347 1 MOTOR PINION FOR :

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

54356

50 FPM TROLLEYS (15.2 MPM) 58406

100 FPM TROLLEYS (30.4 MPM) 58406

35/65 FPM TROLLEYS (10.7/ 19.8 MPM) 54356

25/50 FPM TROLLEYS (7.6/ 15.2 MPM) 54356

50/100 FPM TROLLEYS (15.2/ 30.4 MPM) 54356

670-348 1 MOTOR PINION PIN 988263

670-349 1 DRIVEN GEAR KEY 989096

670-350 2 PINION BEARING SPACER 58456

670-351 1 INTERMEDIATE BEARING SPACER 58728

670-352 1 INTERMEDIATE PINION NUT 988146

670-353 1 INTERMEDIATE PINION NUT L.W. 986266

670-354 1 GEAR HOUSING 70064

670-355 1 GEAR HOUSING GASKET 58729

670-356 4 GEAR HOUSING SCREW 987019

670-357 4 GEAR HOUSING SCREW L.W. 945851

670-358 1 MOTOR END BELL GASKET - 58730

670-359 1 BRAKE HUB 59363

670-360 1 BRAKE HUB SNAP RING 27766

670-361 2 BRAKE ATTACHING SCREW 982708

670-362 2 BRAKE ATTACHING SCREW L.W. 982226

670-363 2 MOTOR COVER GASKET - 68756

WEATHERPROOF UNITS ONLY

670-364 1 BRAKE COVER 58161

670-365 3 BRAKE COVER SCREW 968752

670-366 3 BRAKE COVER SCREW L.W. FOR :

NON-WEATHERPROOF UNITS 940802

WEATHERPROOF UNITS 982251

670-367 1 MOTOR END COVER 68751

670-368 3 MOTOR END COVER SCREW 982717

670-369 3 MOTOR END COVER SCREW L.W. FOR :

NON-WEATHER PROOF UNITS 982226

WEATHERPROOF UNITS 982251

670-370 1 TERMINAL BOX AND COVER 58120

670-372 1 TERMINAL BOARD 68837

670-373 1 TERMINAL BOX SCREW 927930

670-374 1 TERMINAL BOX SCREW L.W. 982226

670-375 2 TERMINAL BOARD SPACER 68776

670-376 2 TERMINAL BOX AND BOARD SCREW 982695

670-377 2 TERMINAL BOX AND BOARD SCREW L.W. 986290

Page 45

3 THRU 7½ TON

PLAIN, GEARED AND MOTOR DRIVEN

TROLLEYS

EXPLODED VIEW

ANTI-TIPPING

BRACKET KIT

Page 46

12SIDE PLATE ASSEMBLY FOR:

4” TO 61/4” FLG. AND PATENTED TRACK 700T-1400 700T-1700 BET-2800 700T-1501 700T-1801 BET-3801 6 3/8” TO 8

5/8” FLG. 700T-1402 700T-1701 BET-2801 700T-1504 700T-1803 BET-3803

8 3/4” TO 11” FLG. 700T-1404 700T-1702 BET-2802 700T-1507 700T-1805 BET-3805 28BALL BEARING 700T-1406 700T-1703 BET-2803 700T-1514 700T-1811 BET-3811 34RETAINING RING 700T-1407 700T-1704 BET-2804 700T-1516 700T-1813 BET-3813 42*TRACKWHEEL-PLAIN

STANDARD 700T-1408 700T-1705 BET-2805 700T-1518 700T-1815 BET-3815

PATENTED TRACK 700T-1409 700T-1706 BET-2806 700T-1520 -- BET-3817

SPARK RESISTANT 700T-1410 700T-1707 -- 700T-1521 700T-1818 -52TRACKWHEEL-GEARED

STANDARD -- 700T-1708 BET-2807 -- 700T-1820 BET-3818

PATENTED TRACK -- 700T-1709 BET-2808 -- -- BET-3820

SPARK RESISTANT -- 700T-1710 -- -- 700T-1823 -- 64RETAINING RING 700T-1411 700T-1711 BET-2809 700T-1523 700T-1825 BET-3821 71PINION -- 700T-1719 BET-2810 -- 700T-1846 BET-3823 81PINION KEY -- 700T-1720 BET-2811 -- 700T-1847 BET-3824 92**RETAINING RING -- 700T-1718 BET-2812 -- 700T-1845 BET-3825 10 4 HEX CAP SCREW -- 700T-1721 BET-2813 -- 700T-1848 BET-3826 11 4 SELF LOCKING NUT -- 700T-1725 BET-2814 -- 700T-1853 BET-3828 12 4 HEX JAM NUT 700T-1412 700T-1712 BET-2815 700T-1526 700T-1828 BET-3830 13 4 LOCKWASHER 700T-1414 700T-1713 BET-2816 700T-1529 700T-1831 BET-3833 14 40 SPACER WASHERS 700T-1416 700T-1714 BET-2817 700T-1532 700T-1834 BET-3836 15 2 SUSPENSION PIN FOR:

4” TO 6 1/4” FLG. AND PATENTED TRACK 700T-1418 700T-1715 BET-2818 700T-1535 700T-1837 BET-3839

6 3/8” TO 8 5/8” FLG. 700T-1420 700T-1716 BET-2819 700T-1537 700T-1839 BET-3841

8 3/4” TO 11” FLG. 700T-1422 700T-1717 BET-2820 700T-1539 700T-1841 BET-3843 16 2 BUSHING -- 700T-1723 -- -- 700T-1851 -17 1 PLATE AND TUBE ASSEMBLY -- 700T-1724 -- -- 700T-1852 -18 2 RETAINING RING -- 700T-1722 -- -- 700T-1850 -19 1 HANDWHEEL SHAFT -- 700T-1726 -- -- 700T-1854 -20 1 HANDWHEEL SHAFT KEY -- 700T-1727 -- -- 700T-1856 -21 2 WASHER -- 700T-1728 -- -- 700T-1857 -22 2 CHAIN GUIDE

8 5/8” O.D. HAND CHAIN WHEEL -- 700T-1729 -- -- -- --

11 5/8” O.D. HAND CHAIN WHEEL -- 700T-1730 -- -- 700T-1858 -23 1 HAND CHAIN WHEEL

8 5/8” OUTSIDE DIAMETER -- 700T-1731 -- -- -- --

11 5/8” OUTSIDE DIAMETER -- 700T-1732 -- -- 700T-1860 -24 1 SUSPENSION ADAPTER 52784 52787 25 1 SUSPENSION ADAPTER SCREW 80430 80430 26 1 WARNING LABEL -- 936986 -- 936986 27 1 TROLLEY CAPACITY LABEL 52764 52765 28 1 WARNING LABEL 936984 936984 29 1 ANTI-TIPPING ROLLER KIT 44927630 44927660 *** AS HAND CHAIN (NOT SHOWN)

REQ’D STANDARD -- 700T-1733 -- -- 700T-1862 --

SPARK RESISTANT -- 700T-1734 -- -- 700T-1863 --

* TOTAL QUANTITY OF 4 EACH REQUIRED FOR PLAIN TYPE TROLLEYS.

** TOTAL QUANTITY OF 1 EACH REQUIRED FOR 3 TON TROLLEYS.

*** SPECIFY LENGTH OF HAND CHAIN REQUIRED. STANDARD LENGTH EQUALS TWO TIMES HOIST LIFT PLUS 2’-6”.

. PART NUMBER

3 TON 4-7 1/2 TON

PLAIN GEARED MOTOR PLAIN GEARED MOTOR

DRIVEN DRIVEN

REF. NO.

NO.

REQ’D

PART DESCRIPTION

Page 47

Single Speed Hoist Control Station

Key No. Part Name Qty. Code

627-250 Standard Control Cord Assembly 1 See page 35 627-551 Control Station Grommet 1 58278 627-552 Control Station (Includes 627-551 thru 627-567) 1 58272 627-563 Control Station Hardware Kit w/gasket 1 58275 627-565 Control Station 1-speed Insert 1 58255 627-566 Control Station Warning Label Kit (Includes Exterior Labels) 1 57276 627-567 Contol Station Button Label Kit 1 58277

Page 48

Two Speed Hoist Control Station

Key No. Part Name Qty. Code

627-250 Standard Control Cord Assembly 1 See Page 35 627-551 Control Station Grommet 1 58278 627-552 Control Station (Included 627-551 Thru 627-567) 1 58273 627-563 Control Station Hardware Kit w/gasket 1 58275 627-565 Control Station 2-speed Insert 1 58256 627-566 Control Station Warning Label Kit (Includes Exterior Labels) 1 57276 627-567 Contol Station Button Label Kit 1 58277

Page 49

4 DIRECTIONAL CONTROL STATION PARTS LIST

4 Directional Control Station

Key No. Part Name Qty. Code

627-451 Standard Control Cord Assembly 1 See Page 35 627-551 Control Station Grommet 1 58278 635-156 Control Station (Includes 627-551 Thru 627-567) 1 58220 CM

627-553

Control Station Housing Kit (Includes Housing, Boots, Collar, Gasket & Hardware)

1 58288

627-563 Control Station Hardware Kit w/gasket 1 58279 627-565

Control Station 1-Speed Insert 1 58522

Control Station 2-Speed Insert 1 58256 627-566 Control Station Warning Label Kit 1 57276 627-567 Contol Station Button Label Kit 1 58277

Page 50

3 THRU 7½ TON TROLLEY MOTOR BRAKE EXPLODED VIEW

Key No. No. Req’d Part Name Part Number

11 Brake Cord 51074

21 Coupler Brake Shaft KIt (includes Shaft, Bearing,Snap Ring, Retainer Ring and Key) 31 Housing 44 Mounting Stud with Nut 52 Access Cover -Plain 6- Access Cover Screw (Specify No. Req’d.) 72 *Access Cover Gasket 81 *Drain Plug

91 *Housing To End Plate Gasket 10 2 *Gasket-Each End Of Brake 11 1 Stationary Disc 12 1 Friction Disc Kit (Includes 3 Discs With Stabilizer Spring-Only One Disc Req’d.Per Brake) 13 1 Hub Kit (Included Hub And Set Screws) 14 1 End Plate Assembly 15 1 Plug-External Lead Hole 16 1 Bearing 17 1 Solenoid Lever 18 1 Retaining Ring 19 2 Spacer 20 2 Torque Adjusting Screw 21 2 Wear Adjusting Screw 22 2 Pressure Spring 23 1 Lever Arm And Stop Nut Assembly 24 1 Bearing Pin 25 1 Support Plate And Stop Nut Assembly 26 1 Pivot Pin 27 1 Solenoid Kit (Includes Plunger, Link, Frame Link Screw, Link Nut And Mounting Screws) 28 1 Coil Kit (Includes Coil, Plunger Guides, Guide Screw and Locwashers) 29 1 Motor Brake Kit (Includes Complete Brake Assembly, Brake Cord, Connector Wire Nuts

9598 for 220, 230

and Installation Instructions) 380 & 460 Volt Brake 30 1 Brake Cord Connector 83968 31 4 Wire Nut 982473 32 3 Brake Attaching Screw Contact Factory 33 1 **Access Cover With Manual Release Knob Contact Factory

Contact Factory

For

Part Numbers

Brake

Components

Key Numbers

2 Thru 28, 32 And 33

* For Weatherproof Units-Not Shown **Not Shown

Page 51

NOTES

Page 52

Note: When ordering parts, always furnish Hoist Model and Serial Number, Motor Horsepower, Voltage, Phase, Frequency and Rated Capacity of hoist on which the parts are to be used. For the location of the nearest Master Parts Depot, see the list located on the inside front cover.

Distributed by Tri-State Equipment Company Inc.

Email: sales@tsoverheadcrane.com

Web: www.tsoverheadcrane.com

PH: 314-869-7200 | FAX: 314-869-7226

LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES

THE WARRANTY STATED BELOW IS GIVEN IN PLACE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR OTHERWISE, NO PROMISE OR AFFIRMATION OF FACT MADE BY ANY AGENT OR REPRESENTATIVE OF SELLER SHALL CONSTITUTE A WARRANTY BY SELLER OR GIVE RISE TO ANY LIABILITY OR OBLIGATION.

Seller warrants that on the date of delivery to carrier the goods are free from defects in workmanship and materials.

SELLER’S SOLE OBLIGATION IN THE EVENT OF BREACH OF WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR OTHERWISE WITH RESPECT TO GOODS SOLD SHALL BE EXCLUSIVELY LIMITED TO REPAIR OR REPLACEMENT, F.O.B. SELLER’S POINT OF SHIPMENT, OF ANY PARTS WHICH SELLER DETERMINES TO HAVE BEEN DEFECTIVE or if Seller determines that such repair or replacement is not feasible, to a refund of the purchase price upon return of the goods to Seller.

Any action against Seller for breach of warranty, negligence or otherwise, must be commenced within one year after such cause of action accrues.

NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE GOODS SHALL BE VALID OR ENFORCEABLE UNLESS BUYER’S WRITTEN NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE YEAR FROM THE DATE OF SHIPMENT. Seller shall not be liable for any damage, injury or loss arising out of the use of the goods if, prior to such damage, injury or loss, such goods are (1) damaged or misused following Seller’s delivery to carrier; (2) not maintained, inspected, or used in compliance with applicable law and Seller’s written instructions and recommendations; or (3) installed, repaired, altered

or modified without compliance with such law, instructions or recommendations. UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES AS THOSE TERMS ARE DEFINED IN SECTION 2-715 OF THE UNIFORM COMMERCIAL CODE.

INDEMNIFICATION AND SAFE OPERATION Buyer shall comply with and require its employees to comply with directions set forth in instructions and manuals furnished by Seller and shall use and require its employees to follow such instructions and manuals and to use reasonable care in the use and maintenance of the goods. Buyer shall not remove or permit anyone to remove any warning or instruction signs on the goods. In the event of personal injury or damage to property or business arising from the use of the goods, Buyer shall within 48 hours thereafter give Seller written notice of such injury or damage. Buyer shall cooperate with Seller in investigating any such injury or damage and in the defense of any claims arising therefrom.

If Buyer fails to comply with this section or if any injury or damage is caused, in whole or in part, by Buyer’s failure to comply with applicable federal or state safety requirements, Buyer shall indemnify and hold Seller harmless against any claims, loss or expense for injury or damage arising from the use of the goods.

WARNING

Alterations or modifications of equipment and use of non-factory repair parts can lead to dangerous operation and injury.

TO AVOID INJURY:

•

Do not alter or modify equipment

•

Do use only factory provided replacement parts.

CM Lodestar XL Operating, Maintenance And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual