CM Shopstar Operating, Maintenance & Parts Manual
OPERATING, MAINTENANCE
& PARTS MANUAL
ELECTRIC CHAIN HOIST
SHOPSTAR
SLC SERIES
SHOPHOIST
SLM SERIES
Before installing hoist, fill in the information below.
Model Number
Serial No.
Purchase Date
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 the hoist operator. Failure to operate
equipment as directed in manual may cause injury.
Columbus McKinnon Corporation
205 Crosspoint Parkway
Getzville, NY 14068
P/N 192047138 Rev AA November 2017
CM HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
As a CM Hoist and Trolley 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 efciently. To quickly obtain the name of the Master Parts Depot or Service
Center located nearest you, call (800) 888-0985. Fax: (716) 689-5644.
LAS PIEZAS Y REPARACIONES DE LOS POLIPASTOS DE CM
ESTÁN ASEGURADAS EN ESTADOS UNIDOS Y CANADÁ
Como usuario de un polipasto y carro de CM le aseguramos cualquier reparación o la disponibilidad de cualquier pieza de repuesto a
través de una red de almacenes de piezas de repuesto y centros de servicio situados estratégicamente en Estados Unidos y Canadá. Estas
instalaciones se han seleccionado en base a su capacidad demostrada en la reparación de equipos y suminstro de piezas de repuesto de
forma rápida y ecaz. Para obtener la dirección del almacén de piezas de repuesto o del centro de servicio más cercano, llame al teléfono
(800) 888-0985. Fax: (716) 689-5644 (sólo en Estados Unidos y Canadá).
LE SERVICE DE RÉPARATION ET DE PIÈCES POUR PALANS CM
EST DISPONIBLE AUX ÉTATS-UNIS ET AU CANADA
Soyez assurés qu'en temps d'utilisateur de palan et treuil CM, d'un service de réparation et de pièces able par l'entremise d'un réseau de
Centres de service et de Dépôts de pièces maîtresses qui sont stratégiquement situés aux États-Unis et au Canada. Ces établissements ont
été sélectionnés sur une base de leur habileté démontrée à s'occuper promptement et efcacement des besoins de réparation de pièces.
Appelez le (800) 888-0985, Fax: (716) 689-5644 pour obtenir rapidement le nom du dépôt de pièces maîtresses ou du centre de service situé
le plus près.
2
P/N 192047138 Rev AA November 2017
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:
a. NOT operate a damaged, malfunctioning or unusually
performing hoist.
b. NOT operate the hoist until you have thoroughly read and
understood this Operating, Maintenance and Parts Manual.
c. NOT operate a hoist which has been modied.
d. NOT lift more than rated load for the hoist.
e. NOT use hoist with twisted, kinked, damaged, or worn load
chain.
f. NOT use the hoist to lift, support, or transport people.
g. NOT lift loads over people.
h. NOT operate a hoist unless all persons are and remain clear
of the supported load.
i. NOT operate unless load is centered under hoist.
j. NOT attempt to lengthen the load chain or repair damaged
load chain.
k. Protect the hoist’s load chain from weld splatter or other
damaging contaminants.
l. NOT operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
m. NOT use load chain as a sling, or wrap chain around load.
n. NOT apply the load to the tip of the hook or to the hook
latch.
o. NOT apply the load unless load chain is properly seated in
the chain wheel(s) or sprocket(s).
p. NOT apply load if bearing prevents equal loading on all load
supporting chains.
q. NOT operate beyond the limits of the load chain travel.
r. NOT leave load supported by the hoist unattended unless
specic precautions have been taken.
s. NOT allow the load chain or hook to be used as an electrical
or welding ground.
t. NOT allow the load chain or hook to be touched by a live
welding electrode.
u. NOT remove or obscure the warnings on the hoist.
v. NOT operate a hoist on which the safety placards or decals
are missing or illegible.
w. NOT operate a hoist unless it has been securely attached to
a suitable support.
x. NOT operate a hoist unless load slings or other approved
single attachments are properly sized and seated in the
hook saddle.
y. Take up slack carefully - make sure load is balanced and
load holding action is secure before continuing.
z. Shut down a hoist that malfunctions or performs unusually
and report such malfunction.
aa. Make sure hoist limit switches function properly.
ab. Warn personnel of an approaching load.
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result
in minor or moderate injury. To avoid such a potentially
hazardous situation, THE OPERATOR SHALL:
a. Maintain rm footing or be otherwise secured
when operating the hoist.
b. Check brake function by tensioning the hoist prior
to each lift operation.
c. Use hook latches. Latches are to retain slings, chains, etc.
under slack conditions only.
d. Make sure the hook latches are closed and not supporting
any parts of the load.
e. Make sure the load is free to move and will clear
all obstructions.
f. Avoid swinging the load or hook.
g. Make sure hook travel is in the same direction as shown
on the controls.
h. Inspect the hoist regularly, replace damaged or worn parts,
and keep appropriate records of maintenance.
i. Use factory parts when repairing the unit.
j. Lubricate load chain per hoist manufacturer’s
recommendations.
k. NOT use the hoist’s overload limiting clutch to measure
load.
l. NOT use limit switches as routine operating stops.
They are emergency devices only.
m. NOT allow your attention to be diverted from operating
the hoist.
n. NOT allow the hoist to be subjected to sharp contact with
other hoists, structures, or objects through misuse.
o. NOT adjust or repair the hoist unless qualied to perform
such adjustments or repairs.
SAFETY PRECAUTIONS
Each Shopstar Electric Hoist is built in accordance with the
specications contained herein and at the time of manufacture
complied with our interpretation of applicable sections of the National
Electrical Code (ANSI/NFPA 70). Installers are required to provide
current overload protection and grounding in keeping with the code.
Check each installation for compliance with the applicable sections of
the code as well as the National, State and Local Codes that may apply
to the installation. In addition, safety code requirements associated
with the operation of a hoist in the inverted (theatrical) position (chain
port up), as with any mechanical equipment, vary depending upon
locality. Therefore, before installing the hoist, the user should consult
his insurance company and/or local authority to see if a deviation is
required to permit the use of the hoist in this particular application.
The safety laws for elevators, lifting of people and for dumbwaiters
specify construction details that are not incorporated into
the hoists. For such applications, refer to the requirements of
applicable state and local codes, and the American National Safety
Code for elevators, dumbwaiters, escalators and moving walks
(ASME A17.1). We cannot be responsible for applications other
than those for which the equipment is intended.
* Copies of this standard can be obtained from ASME Order Department,
22 Law Drive, PO Box 2300, Faireld, NJ 07007- 2300, U.S.A.,
www.asme.org, 800-843-2763.
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 SHOPSTAR HOIST.
3
P/N 192047138 Rev AA November 2017
HOIST SAFETY IS UP TO YOU...
DO NOT LIFT MORE THAN RATED LOAD.
CHOOSE THE RIGHT HOIST FOR THE JOB...
Choose a hoist with the capacity for
the job. Know the capacities of your
hoists and the weight of your loads.
Then match them.
The application, the size and type
of load, the attachments to be used
and the period of use must also be
taken into consideration in selecting
the right hoist for the job.
Remember, the hoist was
designed to ease our burden and
carelessness not only endangers the
operator, but in many cases, a valuable load.
DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST.
DO NOT OPERATE WITH TWISTED, KINKED, OR DAMAGED CHAIN.
INSPECT
All hoists should be visually inspected
before use, in addition to regular, periodic
maintenance inspections.
Inspect hoists for operations warning notices
and legibility.
Deciencies should be noted and brought to the attention of
supervisors. Be sure defective hoists are tagged and taken out
of service until repairs are made.
Under no circumstances should you operate a malfunctioning hoist.
Check for gouged, twisted,
distorted links and foreign material.
Do not operate hoists with twisted,
kinked, or damaged chain links.
Load chain should be properly
lubricated.
Hooks that are bent, worn, or whose
openings are enlarged beyond
normal throat opening should not
be used. If latch does not engage
throat opening of hook, hoist should
be taken out of service.
Chains should be checked for
deposits of foreign material which
may be carried into the hoist
mechanism.
Check brake for evidence of slippage under load.
DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD ARE
IN A STRAIGHT LINE.
DO NOT USE LOAD CHAIN AS A SLING.
USE HOIST PROPERLY
Be sure hoist is solidly held in the uppermost part of the support
hook arc.
Be sure hoist and load are in a straight line.
Do not pull at an angle.
Be sure load is hooked securely. Do not tip load the hook. Do not
load hook latch. Hook latch is to prevent detachment of load under
slack chain conditions only.
Do not use load chain as a sling. Such usage damages the chain
and lower hook.
Do not operate with hoist head resting against any object. Lift the
load gently. Do not jerk it.
DO NOT LIFT PEOPLE OR LOADS OVER PEOPLE
LIFT PROPERLY
Do not lift co-workers with a
hoist.
Make sure everyone is clear of
the load when you lift.
Do not remove or obscure
operational warning notices.
MAINTAIN PROPERLY
CLEANING
Hoists should be kept clean and free of dust, dirt, moisture, etc.,
which will in any way affect the operation or safety of the equipment.
LUBRICATION
Chain should be properly lubricated.
AFTER REPAIRS
Carefully operate the hoist
before returning it to full service.
VIOLATIONS OF ANY OF THE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL INJURY TO THE OPERATOR
OR NEARBY PERSONNEL BY NATURE OF RELEASED LOAD OR BROKEN HOIST COMPONENTS.
4
P/N 192047138 Rev AA November 2017
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 preventive 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 le 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 dened as the process of lifting and moving heavy loads using hoists 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
Master Parts Depots And Service Centers ........................................ 2
Safety Precautions ............................................................................. 3
Foreword ........................................................................................... 5
SPECIFICATIONS
Electric Chain Hoists .......................................................................... 6
Repair/Replacement Policy ................................................................ 6
Accessories ........................................................................................ 7
INSTALLATION
Unpacking .......................................................................................... 8
Mounting the Hoist ............................................................................. 8
Power Supply System ........................................................................ 8
Three Phase Hoists ............................................................................ 9
Checking for Adequate Voltage at Hoist ............................................ 9
OPERATION
General ............................................................................................. 10
MAINTENANCE
Inspection ......................................................................................... 11
Preventive Maintenance ................................................................... 11
Inspection Table ............................................................................... 12
Hook Inspection ............................................................................... 13
Hook Replacement Criteria .............................................................. 13
Inspecting The Load Chain .............................................................. 13
Lubrication ........................................................................................ 14
Electric Brake ................................................................................... 15
TROUBLESHOOTING
General ............................................................................................. 16
ELECTRICAL DATA
Open or Short Circuit in Electrical Components .............................. 17
WIRING
General ............................................................................................. 19
DISASSEMBLY-ASSEMBLY
General ............................................................................................. 23
Load Chain Removal/Installation...................................................... 23
Cutting Chain ................................................................................... 24
Testing .............................................................................................. 24
Repair Parts List ............................................................................... 25
ORDERING INSTRUCTIONS
General ............................................................................................. 25
RECOMMENDED SPARE PARTS
General ............................................................................................. 25
LIST OF TABLES
TABLE DESCRIPTION PAGE
1 Specications .................................................................... 6
2 Nominal Voltage ................................................................. 9
3 Start-up Voltage ................................................................. 9
4a-b Adequate Power Supply .................................................... 9
5 Electrical Data for Components ....................................... 18
6 Torque Settings ................................................................ 23
LIST OF ILLUSTRATIONS
FIG. DESCRIPTION PAGE
1 Chain Container ................................................................. 7
2 Latchlok Hook .................................................................... 7
3 632 Trolley .......................................................................... 7
4 UT Trolley ........................................................................... 7
5 CM Rocket Universal Pendant Control .............................. 7
6 Single Phase Systems ....................................................... 8
7 Three Phase Systems ........................................................ 8
8 Nameplate ......................................................................... 9
9 Hoist Components ............................................................. 9
10 Hook Inspection ...............................................................13
11 Chain Inspection .............................................................. 14
12 Chain Wear Areas ............................................................ 14
13 Chain Identication .......................................................... 14
14 Brake Field Assembly ...................................................... 15
15 Drive Shaft Assembly.......................................................15
16 Brake Assembly ............................................................... 15
17 110-1-50, 115-1-60 Hoists
without Contactor (Orange Control Station) .................... 19
18 110-1-50, 115-1-60 Hoists
with Contactor (Black Control Station) ............................ 19
19 220-1-50, 230-1-60 Hoists
with Contactor (Black Control Station) ............................ 20
20 220-3-50, 230-3-60 Hoists
with Contactor (Black Control Station) ............................ 20
21 380-3-50, 415-3-50, 460-3-60 Hoists
with Contactor (Black Control Station) ............................ 21
22 230-3-60, 400-3-50 PCB
(Printed Circuit Board) Unit .............................................. 21
23 575-3-60 Hoists with Contactor
(Black Control Station) ..................................................... 22
24 Main Frame ...................................................................... 23
25 Stator Installation ............................................................. 23
26 Chaining Hoist ................................................................. 23
27 Chaining Diagram ............................................................ 24
28 Chain Stop ....................................................................... 24
29 Cutting Chain by Nicking ................................................. 24
30 Cutting Chain with a Bold Cutter ..................................... 24
5
P/N 192047138 Rev AA November 2017
SPECIFICATIONS
Standard features of the Electric Chain Hoist include:
• Alloy steel, oblique lay liftwheel that provides constant chain
speed and reduces chain wear.
• Hoistaloy® load chain for long and dependable service.
• Grease lubricated, hardened spur gears provide smooth and
quiet operation.
• Thermally protected, hoist duty motor.
• Forged steel upper and lower hooks with latch.
• ProtectorTM that prevents lifting dangerous overloads.
• D.C. disc type motor brake plus regenerative braking.
• 10 foot (3 M) lift. Longer lifts can be supplied on a per order basis.
• 6 foot (1.8 M) power cord with three prong plug for grounding on
115-1-50/60 units. 6 foot (1.8 M) power cord with provisions for
grounding is standard on 220-1-50 and three phase units.
• Rugged NEMA 4 (weatherproof) control station is suspended
on a TYPE SO cord six feet (2.8 M) below the bottom of the
hoist. Longer cords can be provided on a per order basis.
• Lightweight die cast aluminum frames and covers.
• Ball or needle bearings at all rotating points.
• Compact, yet rugged, design provides minimum headroom
and long, trouble-free service
• 220-1-50, 380 to 460-3-50/60, 220 to 240-3-50/60 and 575-3-60
units available. Lift speeds are based on 60 hertz power supply.
For 50 hertz power supply lift speeds will be 5/6 of those indicated.
• Speeds and capacities based on Table 1, below.
• UL and cUL listed.
• Lifetime Warranty.
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 the hoist operator. Failure to operate the
equipment as directed in the manual may cause injury. Before
putting hoist into service, ll in the information below. Refer to the
hoist identication plate.
REPAIR/REPLACEMENT POLICY
All Electric Chain Hoists are inspected and performance
tested prior to shipment. If any properly maintained hoist
develops a performance problem, due to a material or
workmanship defect, as veried by the factory, repair or
replacement of the unit will be made to the original purchaser
without charge. This repair/replacement policy applies only to
Shopstar Hoists installed, maintained and operated as outlined
in this manual, and specically excludes hoists subject to normal
wear, abuse, improper installation, improper or inadequate
maintenance, hostile environmental effects and unauthorized
repairs/modications.
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.
All Shopstar Electric Chain Hoists are backed with a lifetime
warranty. Refer to the back cover for details and limitations.
Alterations or modication of hoist 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 replacement parts.
Model Number
Serial No.
Purchase Date
Voltage
Rated Load
Table 1 - Specifications
Lift
fpm
6
8 fpm
12
fpm
13.3
fpm
16
fpm
250 lb x x x
300 lb x x x x
500 lb x x x x x
550 lb x
600 lb x x
1000 lb x x x
20
fpm
24
fpm
40
fpm
6
P/N 192047138 Rev AA November 2017
Figure 1 - Chain Container
Figure 2 - Latchlok Hook
Figure 5 - CM® Rocket™ Universal Pendant Control
ACCESSORIES
HOOK SUSPENSIONS
Swivel and rigid type hook suspensions are available for all Shopstar
Electric Hoists. However, swivel type hook suspensions are normally
recommended for most applications.
CHAIN CONTAINER
This accessory item (Figure 1) is used to hold the slack chain
and it is supplied with mounting hardware and instructions.
Chain containers are recommended for those applications where
slack chain will interfere with the load or drag on the oor as may
more often be the case with the double-reeved units (500, 600,
1,000lb - 226, 272, and 453kg). Chain containers are shipped
separately and can be furnished for units already in service.
Figure 3 - 632 Trolley
Figure 4 - UT Trolley
LATCHLOK
®
HOOKS
CM’s Latchlok hooks are available (Figure 2) to replace the standard
upper and lower hooks used on the Shopstar Electric Hoists.
CM SERIES 632 TROLLEY
This lightweight, yet, rugged, manual push type trolley (Figure 3)
is designed to t a wide range of monorail beams and negotiate
tight curves. Provides mobility of your hoist.
CM UNIVERSAL (UT) TROLLEY
The CM Universal Trolley (UT) is designed to t virtually all
Columbus McKinnon powered chain hoists up to 3 ton capacities.
The rugged UT is available as a convertible plain unit, a geared unit
ideal for precise hoist positioning, and a motorized unit that’s perfect
for applications requiring high cycling and long distance hoist travel.
CM® ROCKET™ UNIVERSAL PENDANT CONTROL
The CM Rocket Pendant Control is engineered for maximum
operator comfort, while delivering the precision control your
application demands.
7
P/N 192047138 Rev AA November 2017
INSTALLATION
UNPACKING
After opening the carton, carefully inspect the hoist frame, cords,
hooks, chain and control station 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 identication plate
located on bottom of hoist.
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.
MOUNTING THE HOIST
Hang the hoist from its intended support. The structure used to
support the hoist must have sufcient strength to withstand several
times the load imposed. If in doubt consult a registered engineer
and local building codes.
Suspending the hoist from an inadequate support may allow the
hoist and load to fall and cause injury and/or property damage.
TO AVOID INJURY:
Make sure the attachment point has sufcient strength to hold
several times the hoist and its rated load. Using the upper hook,
hang the hoist from the support. Be sure hoist is solidly held
in the uppermost part of the hook arc and the latch is tightly
against the hook tip.
POWER SUPPLY SYSTEM
(Refer to Figure 6 or 7). To insure proper operation, to avoid damage
to hoist and electrical system and to reduce the risk of electric shock
or re, the branch circuit supplying power to the hoist must:
1. Have ample capacity to prevent excessive voltage drop during
starting and operation (refer to Figure 8). 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 identication plate) and the length of the conductors.
As a minimum, the system should be rated for 15 amps and
it should have #16 AWG, 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-yellow wire for grounding the hoist to the external
power supply system. Be sure that the receptacle opening that
receives the longest prong is properly grounded. 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.
Failure to properly ground the hoist presents the danger of
electric shock.
TO AVOID INJURY:
Permanently ground the hoist as instructed in this manual.
To reduce the risk of electric shock or injury, use indoors only.
Manual
Disconnect
Switch
Black
White
Ground
Thermal
Overload
Relay
Receptacle Rated for 15 amp Minimum (220-1-50 units do
not include Power Cord Plug). Wire Blue and Brown Wires to
Fuses or Circuit Breakers and Green-Yellow Wire to Ground.
Slow Blow Fuses or
Inverse Time Circuit
Breakers
Blue
Hoist Power
Cord
Brown
Green-Yellow
Figure 6 - Single Phase Systems
Manual
Disconnect
Switch
L1
L2
L3
Ground
Incoming Power
Must be per National Electrical Code and These Devices are
to be Supplied by the User.
Slow Blow Fuses or
Inverse Time Circuit
Breakers
Hoist Power
Cord
Black
Grey
Brown
Green-Yellow
Figure 7 - Three Phase Systems
Failure to provide a proper power supply system for the hoist may
cause hoist damage and offers the potential for a re.
TO AVOID INJURY:
Provide the hoist with a 15 amp, minimum, overcurrent protected
power supply per the National Electrical Code (ANSI/NFPA 70) and
applicable local codes as instructed in this manual.
8
P/N 192047138 Rev AA November 2017
Figure 8 - Nameplate
UPPER HOOK
LOOSE END OF CHAIN
CHAIN STOP
LOWER HOOK
POWER
CORD
CONTROL STATION
Note
In this manual, nominal voltages are used when referring to power
supply systems. However, with no modication, the Shopstar
Hoist will operate on a range of voltages as indicated below:
Table 2 - Nominal Voltage
NOMINAL
VOLTAGE
VOLTAGE
RANGE
HERTZ
TRADITIONAL
CONTACTOR
230 208-240 60 AVAILABLE AVAILABLE
460 440-480 60 AVAILABLE NOT AVAILABLE
220 200-240 50 AVAILABLE AVAILABLE
380 365-395 50 AVAILABLE AVAILABLE
415 400-415 50 AVAILABLE AVAILABLE
430 415-430 50 AVAILABLE NOT AVAILABLE
575 550-600 60 AVAILABLE NOT AVAILABLE
THREE PHASE HOISTS
Since the motor in a three phase hoist can rotate in either direction,
depending on the manner in which it is connected to the power
supply, the direction of hook movement must be checked during
the original installation and each time hoist is moved to a new
location as follows:
1. Move the manual disconnect switch handle to the
“OFF” position.
2. Connect the BROWN, GREY AND BLACK wires of hoist
power cord to load side of disconnect switch. Connect
the GREEN-YELLOW wire of hoist power cord to power
supply ground.
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 BROWN leads at the disconnect
switch. Move the disconnect switch handle to the “ON”
position and the hoist is now ready for operation.
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 insufcient
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.
• Dimming of lights or slowing of motors connected to the
same circuit.
PRINTED
CIRCUIT BOARD
Figure 9 - Hoist Components
For proper operation and to avoid these low voltage problems,
voltage (measured at end of the power cord while lifting rated load)
should be as the following chart indicates.
Table 3 - Start-up Voltage
NOMINAL MINIMUM * MIN. VOLTAGE
POWER OPERATING AT INSTANT
SUPPLY VOLTAGE OF START
115-1-50/60 108
220-1-50 198
208-3-60 187
220-3-50 198
230-3-60 207
380-3-50 365
415-3-50 399
460-3-60 414
575-3-60 518
*The drop in voltage upon energizing the hoist should not be below the value listed.
Low voltage can also be caused by using an undersize extension
cord to supply power to the hoist. The following charts should be
used to determine the size wires in the extension cord in order to
minimize the voltage drop between the power source and the hoist.
115-1-50/60 units with contactor, 220-1-50 units and three phase
units (hoists with black control station)
Table 4a - Adequate Power Supply
MAXIMUM LENGTH OF EXTENSION CORD
Wire Size Single Phase Hoist Three Phase Hoist
#16 A.W.G. 135 ft (40m) 245 ft (73m)
#14 A.W.G. 220 ft (66m) 395 ft (120m)
#12 A.W.G. 354 ft (107m) 630 ft (192m)
115-1-50/60 units without contactor (hoists with orange control station)
Table 4b - Adequate Power Supply
LENGTH OF CONTROL
CORD ft(m)
MAXIMUM LENGTH OF EXTENSION CORD
BASED ON SIZE OF WIRE
#16 AWG #14 AWG #12 AWG
1.0 to 10.0 (0.3 to 3.0) 105ft (32m) 170ft (51m) 270ft (82m)
11.1 to 20.0 (3.1 to 6.0) 75ft (22m) 120ft (36m) 190ft (58m)
21.1 to 30.0 (6.1 to 9.0) 45ft (14m) 70ft (21m) 110ft (33m)
31.1 to 40.0 (9.1 to 12.0) 15ft (4.5m) 20ft (6m) 35ft (11m)
After the hoist is suspended from its support and you have made
sure the power supply complies with the above, the hoist is ready
for operation.
On the Double units, cut and discard the ties used to hold the two
strands of chain together. With no load on the lower hook, depress
the UP button in the control station and raise the lower hook
until it is about 2 feet below the bottom of the hoist. Check both
strands of chains for twists. Twists occur if the lower hook block
has been capsized between the strands of chain during packing,
shipment and/or handling. Reverse the capsize to remove twists.
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P/N 192047138 Rev AA November 2017
OPERATING INSTRUCTIONS
The hoist is equipped with a Protector™ that is designed to
allow the rst gear to slip on an excessive overload. An overload
is indicated when the hoist speed slows down, it raises the load in
a jerky manner or it will not lift the load at all. Also, some clutching
noise may be heard if the hoist is loaded beyond rated capacity.
Should this occur, immediately release the UP button to stop the
operation of the hoist. At this point, the load should be reduced to
the rated 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.
The Protector™ is susceptible to overheating 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, the hoist 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. Also, if the
hoist is used at unusual extremes of ambient temperatures, above
150º F (65ºC). or below 15ºF (-9ºC)., changes in lubricant properties
may permit the hoist to raise larger loads than under normal
operating conditions and present possibility of damage or injury.
On units without contactor (hoists with orange control station)
it is necessary to stop the hoist before changing direction.
Therefore, when lowering a load, the push button in the control
station must be released momentarily before the UP button is
depressed to raise the load. If this is not done, the hoist will
continue to operate in the down direction while the UP push
button is depressed, and it will continue to lower the load until
the control push button is released. As a result, the direction
must not be reversed quickly (plug reversed).
There are no electrical switches to stop the operation of the hoist
at the upper and lower limits of lift. As a result, it is necessary to
release the push button in the control station to stop the hoist
components from damage. However, continued, prolonged or
repeated slipping of the Protector will damage the Protector and
cause overheating of the internal hoist components.
Allowing the hook block to run into the hoist when raising a load or
allowing the chain stop to run into the hoist when lowering a load
may break the chain and allow the load to drop.
TO AVOID INJURY:
Do not allow the hook block or the chain stop to contact the hoist frame.
Hoist operation is controlled by depressing the control station push
buttons. Depressing the UP push button will move the load hook
toward the hoist head; depressing the DOWN push button will move
the load hook away from the hoist head.
The UP and DOWN buttons are momentary type and the hoist will
operate in the selected direction as long as the button is held in the
depressed position. Release the push button and the hoist will stop.
It is preferred that the load always be tied off with auxiliary chains or
cables before access to the area beneath the load is permitted. As
an alternative, the system may be designed such that malfunction or
failure of one hoist’s load bearing components does not cause load
loss and/or overloading of any other hoists in the system. Note that
in such a system, hoist performance and function must be monitored
visually or with the use of load cells. Check the supporting structure
to which the load hook is to be attached. Make sure the attachment
point as well as the structure have sufcient strength to withstand
several times the load imposed. If in doubt, consult a registered
engineer and local building codes.
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P/N 192047138 Rev AA November 2017
Attaching the load hook to an inadequate support may allow the
hoist and load to fall and cause injury and/or property damage.
TO AVOID INJURY:
Make sure the structure and the load hook attachment point have
sufcient strength to hold several times the hoist and rated load.
1. When preparing to lift a load, be sure that the attachments to
the load hook are rmly seated in hook saddle. Avoid off center
loading of any kind, especially loading on the point of the hook.
2. When lifting, raise the load only enough to clear the oor or
support and check to be sure that the attachments to the
hook and load are rmly seated. Continue lift only after you are
assured the load is free of all obstructions.
3. Do not load the hoist beyond the rated capacity shown on the
brake end cover. Overloading can cause immediate failure of
some load-carrying part or create a defect causing subsequent
failure at less than rated capacity. When in doubt, use the next
larger capacity of hoist.
4. Do not use this or any other overhead materials
handling equipment for lifting persons or allow people
on unsecured load.
5. Stand clear of all loads and avoid moving a load over heads
of other personnel. Warn personnel of your intention to move
a load in their area. Do not leave unsecured load over people.
6. Do not leave the load suspended in the air unattended.
7. Permit only qualied personnel to operate unit.
8. Do not wrap the load chain around the supporting structure and
hook onto itself as a choker chain. Doing this will result in:
1. The loss of the swivel effect of the load hook which could
mean twisted chain and a jammed liftwheel.
2. The chain could be damaged at the load hook.
9. On the Double-reeved hoists, check for twists in the load chain.
A twist can occur if the lower block has been capsized between
the strands of chain. Reverse the capsize to remove twist.
10. Do not allow a 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 the slack chain.
11. Take up a slack load chain carefully and start load easily to
avoid shock and jerking of hoist 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 ammable materials or vapors
are present. Electrical devices produce arcs or sparks that can
cause a re 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 inuence of drugs, alcohol or medication causing
diminished control.
TO AVOID INJURY:
DO NOT Lift more than rated load.
DO NOT Operate with twisted, kinked or damaged chain.
DO NOT Operate damaged or malfunctioning hoist
DO NOT Lift people, loads over people, allow people on
unsecured load or leave unsecured load over people.
DO NOT Operate hoist when load hook is not centered overhoist.
DO NOT Permit load hook block to contact hoist frame or
chain container.
DO Replace damaged or malfunctioning hook latch.
DO Keep load chain well oiled.
DO Read ASME B30.16 Safety Code for Hoist and appropriate
operating instructions.
MAINTENANCE
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. The type of service to
which the hoist is subjected can be classied as “Severe”, “Normal”,
or “Stand by Service” per ANSI E1.6-2.
Severe Service: Hoist operates in excess of 200 days a year.
Normal Service: Hoist operates 200 or fewer days a year but
more than 25.
Stand by Service: Hoist operates 25 or fewer days per year
but at least once per year.
Two classes of inspection - frequent and periodic – must
be performed.
Frequent Inspections: Visual examination shall be performed by
a competent person following the items listed in the inspection table
Records of such inspections are recommended.
Periodic Inspections: Inspection shall be performed by a qualied
person following the items listed in inspection table. Records of
this inspection shall be recorded and retained for a minimum of 36
months after the hoist is taken out of service.
Lifting and lowering functions shall be tested under no-load
conditions. (Testing through complete rated lift length is
not required). Brake(s) operation shall be tested under
no-load conditions.
Any deciencies found during inspections 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.
PREVENTIVE MAINTENANCE
In addition to the above inspection procedure, 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).
Note
To perform some of the periodic inspections, it is necessary to
partially disassemble the hoist. Refer to Disassembly - Assembly
starting on page 23.
Any deciencies noted must be corrected before the hoist is
returned to service. Also, the external conditions may show the
need for more detailed inspection which, in turn, may require the
use of nondestructive-type testing.
Any parts that are deemed unserviceable are to be replaced with
new parts before the unit is returned to service. It is very important
that the unserviceable parts be destroyed to prevent possible future
use as a repair item and properly disposed of.
Allowing a load to bear against the hook latch and/or hook tip can
result in loss of load.
TO AVOID INJURY:
Do not allow a load to bear against the hook latch and/or hook tip.
Apply load to hook bowl or saddle only
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P/N 192047138 Rev AA November 2017
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