CM-ET Lodestar User Manual

83877

EENNTTEERRTTAAIINNMMEENNTT

®

Manual No. E627

Operating, Maintenance &

PPaarrttss MMaannuuaall

11//44 TToo 22 TToonn

225500 KKgg.. TToo 22000000 KKgg..

Columbus McKinnon Corporation

CM Entertainment Division

140 John James Audubon Parkway

Amherst, New York 14228-1197

1-800-888-0985
1-716-689-5400

cmrigging.com

®

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 APARTICULAR PURPOSE, OR
OTHERWISE, NO PROMISE OR AFFIRMATION OF FACT MADE
BY ANY AGENT OR REPRESENTATIVE OF SELLER SHALL
CONSTITUTE AWARRANTY 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 EVENTOF BREACH OF
WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR OTHER­WISE WITH RESPECT TO GOODS SOLD SHALL BE EXCLUSIVE­LYLIMITED TO REPAIR OR REPLACEMENT, F.O.B. SELLER’S
POINT OF SHIPMENT, OFANY 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 occurs.

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 SHALLSELLER BE LIABLE FOR
INCIDENTALOR 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.

®

V

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WARNING

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

TO AVOID INJURY:

• Do not alter or modify equipment.

• Do use only CM replacement parts.

Columbus McKinnon Corporation

CM Entertainment Division

140 John James Audubon Parkway

Amherst, New York 14228-1197

1-800-888-0985
1-716-689-5400

Fax [phone]

cmrigging.com

© 2006 Columbus McKinnon Corp. 8/06 Printed in USA

All Columbus McKinnon (CM®) Lodestar 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 CM, repair or replacement of the unit
will be made to the original purchaser without charge. This
repair/replacement policy applies only to Lodestar 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-CM
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.

GENERAL INFORMATION

CM HOIST PARTS AND SERVICES ARE AVAILABLE WORLD WIDE

As a CM 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 World Wide. 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 and Entertainment Hoist Service Stations. To quickly obtain the name of the U.S. Service Center located near­est you, call [phone]. Fax: [phone].

ARGENTINA

IFAN RENIERI Y CIA SA.
Aristobulo Del Valle 1933/43
(1295) Buenos Aires,
Argentina

UPSTAGE, S.A.
Warnes 2351
(1427) Capital Federal
Buenos Aires, Argentina

AUSTRIA

Tüchler GmbH
Rennbahnweg 78
Vienna 1220
Austria
(43)-1-400-10-23
Fax [phone]

AUSTRALIA

PWB ANCHOR
441 Grimshaw Street
Bundoora Victoria,
Australia 3083
(61)-39-467-2933
Fax [phone]

BRASIL

HABITASUL S.A. COMERCIO
EXTERI
157-Sala 1302

90.010.030
Porto Alegre-RS-Brasil

ROSCO DO BRASIL
Rua Antonio De Barros #827
Cep 03401-000
Sao Paulo, Brasil

BOLIVIA

SONILUM ILUMINACION Y
SONIDO
Tucuman 20 (6 Este) Equipetrol
Santa Cruz De La Sierra
Bolivia

CHINA

HANGZHOU, LILA LIFT./LASH. CO.
Zhijiang Hi-Tech Zone
Hangzhou, Zhejiang, 310053
P.R. Of China
(86)-571-8669-6946
Fax [phone]

ENGLAND

TOMCAT UK Ltd.
Unit 2, Skiddaw Rd
Croft Business Park
Bromborough, Wirral CH62 3RB
United Kingdom
(44)-151-482-3100
Fax [phone]

FRANCE

SONOSS
Avenue De La Rotonde
Sac Postal 9
59465 Lomme, France
Lomme (Cedex)
(33)-3-20-00-92-10
Fax [phone]

GERMANY

LMP LICHTTECHNIK
Gildestrasse 55
49477 Ibbenburen, Germany

PFAFF SILBERBLAU
Postfach 102229
Augsburg 86012, Germany

HOAC HANDELS GMBH
Pferdsweide 39C
Nordrhein-Westfalen, Deutschla
Mores, Germany 47441
(49)-2841-90-828-28
Fax [phone]

ISRAEL

GILON SUPPLY (1946) LTD
21, Frug St.
Tel-Aviv, 63417, Israel

ITALY

Litec Srl
Via Venier 52
30020 Macron (Ve)
Italy
(39)-041-596-0000
Fax [phone]

JAPAN

KATSUYAMA KIKAI LTD
104-18 Honjounishi 2
Chome, Higashiosaka,
Osaka, 578-0965
Japan
(81)-6-6747-6390
Fax [phone]

SHIMIZU OCTO INC
1-4-1 Shimoochiai, Shinjuku-Ku
Tokyo 161-0033
Japan
(81)-0-3-3360-7743
Fax [phone]

MEXICO

COLUMBUS McKINNON
De Mexico S.A. De C.V.
Venustiano Carranza #301
Santiago Tianguistenco
C.P. 52600, Mexico

NETHERLANDS

Louis Reyners B.V.
Symon Spiersweg 13A
Postbus 2118
1500 GC Zaandam
Netherlands
(31)-75-650-4750
Fax [phone]

SINGAPORE

CSP PRODUCTIONS (PTE) LTD
No 3 Upper Aljunied Link 05-04
Joo Seng Warehouse Tower B
Singapore 367902
(65)-6283-0220
Fax [phone]

CALIFORNIA

OTTO SYSTEMS, INC.
12010 Bloomfield Ave.
Sante Fe Springs, CA 90670
562/462-1612 or 800/596-7392
Fax [phone]
or

7656 Las Positas Road
Livemore, CA 94551
925/245-8800 or 800/508-6886

Fax [phone]
STAGE RIGGING

2690 Middlefield Road, Unit F
Redwood City, CA 94063
650/299-1189
Fax [phone]

FLORDIA

NATIONAL PRODUCTIONS SERVICES
9561 Satellite Blvd.
Orlando, FL 32837
407/857-6446
Fax [phone]

GEORGIA

ATLANTA RIGGING SYSTEMS
1270 Tacoma Dr.
Atlanta, GA 30318
404/355-4370
Fax [phone]

ACE INDUSTRIES, INC.
6295 McDonough Drive
Norcross, GA 30093
770/441-0898 or 800/733-2231
Fax [phone]

ILLINOIS

REED RIGGING
2309 S. Keeler Ave.
Chicago IL 60623
773/521-7333
Fax [phone]

INDIANA

HORNER ELECTRIC COMPANY, INC.
1521 East Washington Street
Indianapolis, IN 46201
317/639-4261
Fax [phone]

IOWA

VMI HOIST & CRANE SERVICES
901 17th Street NE
Cedar Rapids, IA 52406
319/365-4662
Fax [phone]

LOUISIANA

BEERMAN PRECISION, INC.
4206 Howard Ave.
New Orleans, LA 70125
504/486-9391
Fax [phone]

MASSACHUSETTS

ABEL DISTRIBUTORS, INC.
50 Parker Street, Unit 2
Newburyport, MA 01950
978/463-0700

Fax [phone]

MISSOURI

INDEPENDENT ELECTRIC MACHINERY
4425 Oliver Street
Kansas City, MO 66106
913/362-1155
Fax [phone]

NEVADA

SILVER STATE WIRE ROPE
5380 S. Valley View Blvd.
Suite A
Las Vegas, NV 89118
702/597-2010
Fax [phone]

TOMCAT USA, INC
4020 Ali Baba Lane
Bldg. D. Suite A
Las Vegas, NV 89118
702/798-6200
Fax [phone]

NEW JERSEY

SHUPPER-BRICKLE EQUIPMENT CO.
2394 Route 130, Suite C
Dayton, NJ 08810
732/438-3888
Fax [phone]

NEW YORK

VOLLAND ELECTRIC EQUIPMENT CO.
75 Innsbruck Drive
Buffalo, NY 14227
716/656-9900
Fax [phone]

NORTH CAROLINA

TEAM SESCO
2225 Freedom Drive
Charlotte, NC 28208
704/372-4832 or 800/487-3726
Fax [phone]

OHIO

MAZZELLA LIFTING TECHNOLOGIES
21000 Aerospace Parkway
Cleveland, OH 44142
440/239-5700 or 800/362-4601
Fax [phone]

PENNSYLVANIA

AMICK ASSOCIATES, INC.
11 Sycamore Street
Carnegie, PA 15106-0529
412/429-1212 or 800/445-9456
Fax [phone]

RAM MOTORS & CONTROLS, INC.
5460-B Pottsville Pike
Leesport, PA 19533
610/916-8000 or 877/916-8018
Fax [phone]

MOUNTAIN PRODUCTIONS
80 New Fredrick St.
Wilkes-Barre, PA 18702
570/826-5566 or 800/733-5553
Fax [phone]

TEXAS

ABEL EQUIPMENT CO., INC.
3710 Cavalier Drive
Garland, TX 75042
972/272-7706
Fax [phone]

HYDRAULIC EQUIPMENT SERVICES,
INC.
1021 North San Jacinto Street
Houston, TX 77002
713/228-9601
Fax [phone]

SHIMIZU INTERNATIONAL PRO­DUCTION SERVICES, INC.
1500 East Belt Line Road
Carrollton, TX. 75006

TOMCAT USA
2160 Commerce Dr
Midland TX 79703
432/694-7070
Fax [phone]

WISCONSIN

TRESTER HOIST & EQUIPMENT, INC.
W136 N4863 Campbell Drive
Menomonee Falls, WI 53051
262/790-0700 or 800/234-6098
Fax [phone]

ALBERTA

BENNETT & EMMOTT, LTD.
18131 118th Avenue
Edmonton, Alberta T5S 1M8
403/454-9000
Fax [phone]

CHRISTIE LITES
2610 3rd Avenue
Calagary, AB T2A 2L5
403/243-2688
Fax [phone]

MASTER PARTS DEPOT

i

“ENTERTAINMENT HOIST”

SERVICE STATIONS

“ENTERTAINMENT HOIST”

SERVICE STATIONS

ALBERTA

**COLUMBUS McKINNON, LTD.
10311-174th Street
Edmonton, Alberta T5S 1H1
800/263-1997
Fax [phone]

BRITISH COLUMBIA

FLECK BROTHERS, LTD.
4084 McConnel Court
Burnaby, British Columbia V5A 3N7

CHRISTIE LITES
3686 Bainbridge Ave.
Burnaby, BC V5C 5A9
604/255-9943
Fax [phone]

STUDIO CITY RENTALS
2050 Alfa Avenue
Burnaby, BC V5C 5A9
604/291-9414
Fax [phone]

MANITOBA

KING’S ELECTRIC MOTORS, INC.
633 Tyne Avenue
Winnipeg, Manitoba R2L 1J5
204/663-5332
Fax [phone]

NOVA SCOTIA

*W & A MOIR
95 Ilsley Ave.
Burnside Park, Nova Scotia B3B 1L5
902/468-7720
Fax [phone]

ONTARIO

CHRISTIE LITES
102-15 North Queen St.
Toronto, ON M8Z 6C1
416/644-1010
Fax [phone]

PRG LIGHTING
2480 Tedlo St.
Mississaua, ON L5A 3V3
905/270-9050
Fax [phone]

*R & W HOIST REPAIR, LTD.
790 Redwood Square
Units 5, 6, & 7
Oakville, Ontario L6L 6N3
905/825-5500
Fax [phone]

STUDIO CITY RENTALS
75 Commissioner St.
Toronto, ON M5A 1A6
416/465-6434
Fax [phone]

*TORONTO ELECTRIC HOIST SALES & SERVICE
9 CoDeco Court
North York, Ontario M3A 1A1
416/386-0820
Fax [phone]

*MASLACK SUPPLY, LTD.
488 Falconbridge Road
Sudbury, Ontario P3A 4S4
705/566-1270
Fax [phone]

*COLUMBUS McKINNON, LTD.
P.O. Box 1106
10 Brook Road, North
Cobourg, Ontario K9A 4W5
905/372-0153
Fax [phone]

QUEBEC

*HERCULES SLING & CABLE
3800 TransCanada Highway
Pointe-Claire, Quebec H9R 1B1
514/428-5511

514/48631-5511

Fax [phone]
*LEGER PALANS ET OUTILLAGES, INC.

7995-17th Ave.
Montreal, Quebec H1Z 3R2
514/376-3050
Fax [phone]

SOLOTECH
4820 4th Avenue
Montreal, QC H1Y 2T8
514/526-7725
Fax [phone]

**ARE ALSO MASTER PARTS DEPOTS

**MASTER PARTS DEPOT ONLY

“ENTERTAINMENT HOIST”

SERVICE STATIONS

“ENTERTAINMENT HOIST”

SERVICE STATIONS

1. NOT lift people.

2. NOT allow people on unsecured load without fall protection.

3. NOT exceed rated capacity of hoist.

4. NOT remove or obscure any capacity or warning label.

5. Check the supporting structure. The connection between the
load hook and structure. The load itself and the connection between
the hoist support and the load for their ability to withstand the loads
imposed with an adequate design factor.

6. Tie off the load 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 use of load cells.

7. Read hoist manual and special instructions before installing and
operating the hoist.

Successful Theatrical Hoist Operation Requires the following actions:

At the loose end, maintain a minimum of 24 inches of chain freely
hanging over the side of hoist.

Keep load chain well lubricated using Lubriplate® 10R Bar and
Chain oil.

Do make sure hoist is phased properly and chain travel limits
function properly.

If a chain container is used, inspect before each use for damaged,
loose hardware and water drainage provisions. Make certain container
attachment hardware has an adequate design factor of a minimum of
5 to 1. Also, make sure chain container is of sufficient capacity: chain
chain in fully loaded container shall not exceed 75% of container
height.

1. Maintain a firm footing or be otherwise secured when operating
the hoist.

2. Check brake function by tensioning the hoist prior to each lift
operation.

3. Use hook latches. Latches are to retain slings, chains, etc. under
slack conditions only.

4. Make sure the hook latches are closed and not supporting any
parts of the load.

5. Make sure the load is free to move and will clear all obstructions.

6. Avoid swinging the load or hook.

7. Make sure hook travel is in the same direction as shown on the
controls.

8. Inspect the hoist regularly, replace damaged or worn parts, and
keep appropriate records of maintenance.

9. Use CM 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. 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.

SAFETY PRECAUTIONS

Each Entertainment-Lodestar Electric Hoist is built in accordance with the specifications contained herein and at the time of
manufacture complied with our interpretation of applicable sections of the *American Society of Mechanical Engineers Code
B30.16 “Overhead Hoists”, the National Electrical Code (ANSI/NFP A70), the Occupational Safety and Health Act, British Health
Safety Executives, TUV and CE Directive. Since OSHA states the National Electrical Code applies to all electric hoists,
installers are required to provide current overload protection and grounding on the branch circuit section in keeping with the
code. Check each installation for compliance with the application, operation and maintenance sections of these articles.

The safety laws for elevators, lifting of people and for dumbwaiters specify construction details that are not incorporated in CM
industrial 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). Columbus McKinnon
Corporation cannot be responsible for applications other than those for which CM equipment is intended.

*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
LODESTAR HOIST.

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WWAARRNNIINNGG

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.

WWAARRNNIINNGG

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:

CCAAUUTTIIOONN

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:

ii

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CCAAUUTTIIOONN

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TABLE OF CONTENTS

Master Parts Depots And Service Centers . . . . . . . . . .i

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Information

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CM Repair/Replacement policy . . . . . . .(Back Page)

Accessories

Hook Suspensions . . . . . . . . . . . . . . . . . . . . . . . . .3

Latchlok Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Installation

Unpacking Information . . . . . . . . . . . . . . . . . . . . . .3

Installing Suspension . . . . . . . . . . . . . . . . . . . . . . .3

Attaching Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . .4

Power Supply and Electrical Connections . . . . . . . . . .5

Operating Instructions

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Operating Instruction-Hoist . . . . . . . . . . . . . . . . . . .7

Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .7

Inspection

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Frequent Inspections . . . . . . . . . . . . . . . . . . . . . . . .8

Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . .8

Preventative Maintenance . . . . . . . . . . . . . . . . . . . .8

Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Maintenance

Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Hoist Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .11

Adjustments

Electric Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . .12

Recommended Spare Parts . . . . . . . . . . . . . . . . . .13

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .15-16

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . .17-20

Assembly Instructions

Hook Suspension . . . . . . . . . . . . . . . . . . . . . . . . .21

Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Lower Hook Block Pin . . . . . . . . . . . . . . . . . . . . . .22

Removal and Installation of Load Chain . . . . . . . .23

Cutting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . .24

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-42

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-46

LIST OF TABLES

Table Title Page

1 Lodestar Electric Chain Hoist Specs. . . . . .2

2 Recommended Seating Torques for

Suspension Adapter Screws . . . . . . . . .4

4 Minimum Frequent Inspections . . . . . . . . . .9

5 Minimum Periodic Inspections . . . . . . . . . .9

6 Limit Switches . . . . . . . . . . . . . . . . . . . . .13

7 Electrical Data . . . . . . . . . . . . . . . . . . . . .14

8 Troubleshooting . . . . . . . . . . . . . . . . . .15,16

LIST OF ILLUSTRATIONS

Figure Table Page

1 Hook Suspensions . . . . . . . . . . . . . . . . . . .3

2 Upper or Lower Latchlok Hook . . . . . . . . . .3

7 Attaching Load Chain . . . . . . . . . . . . . . . . .4

8 Contact Block . . . . . . . . . . . . . . . . . . . . . . .4

12 Voltage Change Board . . . . . . . . . . . . . . . .5

13 Locations of Components . . . . . . . . . . . . . .5

14 Hook Inspection . . . . . . . . . . . . . . . . . . . .10

15 Chain Wear areas . . . . . . . . . . . . . . . . . . .10

16 Chain Inspection . . . . . . . . . . . . . . . . . . . .10

17 Chain Embossing . . . . . . . . . . . . . . . . . . .10

18 Limit Switches Models B, C & F . . . . . . . . .12

18A Rotatable Limit Switches Models B, C & F 12

19 Limit Switches Models J, L, R, LL & RR . . . .12

19A Rotatable Limit Switch J, L , R, LL& RR .12-13

20 Typical Wiring Diagrams . . . . . . . . . . .17-20

21 Swivel Hook Suspensions . . . . . . . . . . . .21

22 Non-Circular Gearing . . . . . . . . . . . . . . . .22

23 Cutting Chain By Nicking . . . . . . . . . . . . .24

24 Cutting Chain With ABolt Cutter . . . . . . . .24

25 Exploded View-

Components . . . . . . . . . . . . . . . . . 25-42

FORWARD

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 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 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.

1

SSPPEECCIIFFIICCAATTIIOONNSS
The Lodestar Electric Chain Hoist is a highly versatile materi­als handling device that can be used to lift loads that are
within its rated capacity. The mechanical features of these
hoists include an alloy liftwheel, Load Protector, hardened
steel chain guides, hardened steel load chain, hardened steel
gear train, life-time lubrication, forged steel hooks, and light­weight aluminum frame. The electrical features included
hoist-duty motor, rugged hoist brake, magnetic reversing con­tactor and voltage conversion board (dual voltage units).

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

MMooddeell NNuummbbeerr

__________________________________

SSeerriiaall NNuummbbee

r ____________________________________

PPuurrcchhaassee DDaattee

__________________________________

VVoollttaaggee

__________________________________________

RRaatteedd LLooaadd

______________________________________

Table 1. Specifications

Entertainment-Lodestar Electric Chain Hoists

Maximum
Capacity

(Tons)

Model

*Lifting

Speed

Per Min.

(Feet)

*Lifting

Speed

Per Min.

(M)

Motor

H.P.

Motor

K.W.

Shortest
Distance
Between

Hooks

(Inches)

Shortest
Distance
Between

Hooks

(mm)

Net

Weight

(Lbs.)

Net

Weight

(Kg.)

Single Speed 230/460-3-60 or 220/380-3-50

or 220/415-3-50

1/4 B 16 4.88 1/4

.186

14-1/4

362.0 57 25.8

1/4
1/2

C
F

32
16

9.75

4.88

1/2
1/2

.372
.372

14-1/4
14-1/4

362.0

362.0

65
64

29.5

29.0

1/2

1
2

J
L
R

32
16

8

9.75

4.88

2.44

1
1
1

.746
.746
.746

15-9/16
15-9/16

22-1/2

395.3

395.3

571.5

115
117
136

52.2

53.1

61.7

Single Speed 230/460-3-60 or 220/380-3-50

or 220/415-3-50

1 LL 32 9.75 2 1.49 15-9/16 395.3 121 54.9
2 RR 16 4.88 2 1.49 22-13/16 579.4 136 61.7

*Lifting and travel speeds listed are for 60 Hertz units. For
50 Hertz units, these speeds will be 5/6 of those listed.

2

HOOK SUSPENSIONS

Swivel and rigid type hook suspensions (see Figure 1) are
available for all Lodestar Electric Hoists. However, swivel
type hook suspensions are normally recommended for most
applications.

UNPACKING INFORMATION

When received, the hoist should be carefully inspected for
damage which may have occurred during shipment or han­dling. Check the hoist frame for dents or cracks, the external
cords for damaged or cut insulation, the control station for cut
or damaged enclosure, and inspect the load chain for nicks
and gouges. If shipping damage has occurred, refer to the
packing list envelope on the carton for claim procedure.

Before using the hoist, make sure the voltage change board
(Key# 627-1013) is connected for the intended power supply
the hoist is to be operated.

NOTE: To assure long life and top performance, be sure
to follow the load chain lubricating instructions on page

11.

INSTALLING THE SUSPENSION

A. Single Reeved Units:

Remove the hook suspension from its carton and the two
suspension screws. Place the suspension assembly into the
recess on top of the hoist so that the adapter body follows the
contour of the hoist. Insert the suspension screws through
the holes in the adapter and hand thread these into the self
locking nuts enclosed in the hoist. The screws will turn freely
into the nuts until the last 1/4” (6.35 mm) of travel, during
which the resistance of the nut locking collar will be encoun­tered. Securely tighten the screws to the recommended seat­ing torque (see Table 2) using a 12 point socket (½” (13mm)
socket) which fits the head of the screw.

LATCHLOK®HOOKS

CM’s Latchlok hooks (see Figure 2) are available to replace
the standard upper and lower hooks used on the Lodestar
Electric Hoists.

B. Double Reeved Units:

Remove the hook suspension from its carton and the two
suspension screws, dead end pin, washer and cotter pin. It
should be noted that the suspension includes a dead end bolt
and block for supporting the dead end of the load chain as
shown in Figure 7.

Place the suspension assembly into the recess on top of the
hoist. The dead end block should project through the bottom
of the hoist with the pin hole and slot aligned to the under­side of the hoist as shown in Figure 7. If these are not
aligned as shown, lift the head of the bolt from the hex
recess in the adapter and turn the bolt and block assembly
and reseat the bolt head to obtain the proper alignment. Do
not change the position of the dead end block on the bolt to
attain this alignment.

Check the position of the pin hole in the dead end block to
make sure it has not been disturbed from its factory setting.
The distance from the top of the pin hole to the bottom of the
hoist should not exceed 7/16” (1 1.11 mm) for the Models R and
RR. If the distance is not correct, adjust the position of the
dead end block to obtain the proper distance (see Page 21).

INSTALLATION

ACCESSORIES

Figure 1. Hook Suspensions

Figure 2. Upper or Lower Latchlok

®

Hook

3

CCAAUUTTIIOONN

USE OF IMPACT TOOLS (ELECTRIC OR PNEUMATIC)
MAY CAUSE PREMATURE FAILURE OF ATTACHING
HARDWARE.

V

!!

Now, insert the suspension screws through the holes in the
adapter and hand thread these into the self locking nuts
enclosed in the hoist frame. The screws will turn freely into
the nut until the last 1/4” (6.35mm) of travel during which
the resistance of the nut locking collar will be encountered.
Securely tighten the screws to the recommended seating
torque (see Table 2) using a 12 point socket which fits the
head of the screw.

The dead end of the load chain is temporarily positioned (a
few links from the end) by a wire tie. Do not remove this tie
before attaching the chain to the dead end block. (See Fig.7).

Table 2. Recommended Seating Torques For Suspension

Adapter Screws

ATTACHING LOAD CHAIN

The Model R & RR are shipped with the dead end of the load
chain temporarily connected to the bottom of the hoist by a
wire tie (1) as shown in Figure 7. The clip is located a few links
from the end of the chain, and it should not be removed until
the chain is to be attached to the dead end block (2). To attach
the chain to the dead end block, proceed as follows:

1. Suspend the hoist from an adequate support.

2. The hoist is shipped with the dead end of the load chain
temporarily positioned a few links from the end by a light
wire clip (1) as shown in Figure 7. Do not remove this clip
until the chain is secured.

3. Remove the clip (1) by inserting a screw driver blade
through a chain link and levering against the bottom of
the hoist. Slide the contact block up the chain until it is
against the bottom of the hoist and the dead end block is
projecting through the square opening in the bottom of
the block. Insert the last link of the load chain, making
sure there are no twists between the hook block and the
dead end block, into the dead end block. Push the
contact block up slightly and secure the load chain to the
dead end block using the dead end pin, washer and
cotter pin furnished with the suspension. The dead end
pin also supports the contact block (See Figure 8).

4. Do not remove the wire ties from the load chain at this
time.

Models No’s Screw Size

Recommended

Seating Torque

B, C & F 3/8”-16UNC-2A

40.7 to 61.0 Nm
(30 to 45 lb. ft.)

J, L, R, LL & RR 1/2”-20UNF-2A

54.2 to 108.5 Nm
(40 to 80 lb. ft.)

1. Wire Clip 7. Chain guide

2. Dead end block

8. Loose end link

3. Suspension assembly 9. Liftwheel

4. Suspension self-locking nut 10. Gear housing

5. Dead end bolt 11. Loose end screw
and lockwasher

6. Load Chain

(Do not order parts by these numbers. See parts list).

WWAARRNNIINNGG

Using other than CM supplied high strength suspension
screws to attach the suspension adapter to the hoist may
cause the screws to break and allow the hoist and load to
fall.

TO AVOID INJURY:

Use only the CM supplied suspension screws to attach the
suspension to the hoist and hand torque these screws to
the recommended seating torque as specified above.

DO NOT apply any type of lubricant to the threads of these
screws. Lubricating the threads will reduce the effort to seat
the screws and as a result, tightening the screws to the above
recommended torque may break the screw, damage the sus­pension adapter, strip the nuts and/or damage the hoist
frame.

V

!!

Figure 7. Attaching Load Chain Models R and RR

4

3

5

6

Dead

End

2

Contact

Block

Removed For

Clarity

4

8

Loose

End

11

10

9

Contact

Block

Figure 8. Contact Block Used On Models R & RR.

CCAAUUTTIIOONN

USE OF IMPACT TOOLS (ELECTRIC OR PNEUMATIC)
MAY CAUSE PREMATURE FAILURE OF ATTACHING
HARDWARE.

V

!!

7

POWER SUPPLY AND
ELECTRICAL CONNECTIONS

The hoist should be connected to a branch circuit which com­plies with the requirements of the National Electrical Code
and applicable local codes.

It is recommended, especially for a single phase hoist with a
one horsepower motor (.746 Kilowatts), that a line of ade­quate capacity be run directly from the power supply to the
hoist to prevent having problems with low voltage and circuit
overloads.

For grounding of the hoist, the power cord includes a ground­ing conductor (green yellow, G-Y). Before connecting the
hoist to the power supply, check that the power to be used
agrees with the position of voltage change plug on the volt­age change board. The nominal hoist voltage rating corre­sponding to the voltage range given on hoist identification
plate is:

THREE PHASE HOIST

Unless ordered on a special basis, all single speed dual volt­age (230/460-3-60, 220/380-3-50 and 220/415-3-50) hoists
are factory arranged to operate on 460-3-60 (or 380-3-50 or
415-3-50). However, a voltage change board is provided to
easily and quickly change from 460 to 230 (or 380 to 220 or
415 to 220) volt operation. The voltage change board shown
in Figure 12 is located in the hoist as shown in Figure 13.

Voltage change board is located under back frame cover
(1) for Models B, C & F and under motor housing cover
(2) for Models J, L, R, LL and RR.

The voltage change board is color coded to indicate high and
low volt connections. Connecting the 9 and 12 pin plugs into
the “Red” voltage change board recepticles will connect the
hoist for high voltage (380-3-50, 415-3-50 or 460-3-60). To
change the hoist voltage to low voltage (208-3-60, 220-3-50 or
230-3-60) simply remove the 9 and 12 pin plugs from the
“Red” recepticles and insert same into the “White” recepticles
located on the voltage change board.
Be sure to make a notation of the new hoist voltage on the tag
attached to the power cord.

PROPER PHASING

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 prior to each usage.

NOTE: Serious damage can result if the hook is run to
the upper or lower limit of travel with the hook operating
in a direction opposite to that indicated by the control sta­tion. Therefore, proceed as follows:

1. Make temporary connections at the power supply.

2. Operate

(UP) control momentarily. If hook raises,

connections are correct and can be made permanent.

3. If hook lowers, it is necessary to change direction by inter
changing the Blue lead and the Black lead of hoist power
cord at power supply. Under no circumstances should the
internal wiring of the control device or hoist be changed to
reverse hook direction. The wiring is inspected and tested
before leaving the factory.

SINGLE SPEED UNITS

Low

Range Nominal

Volts

High

Range Nominal

Volts

380-415

400

220-240 230 440-460 460

5

Figure 12. Voltage Change Board

Figure 13. Location of Components

2

1

HIGH
VOLTAGE (RED)

LOW
VOLTAGE
(WHITE)

Do not force the Lodestar Protector to compensate for
improperly adjusted limit switches or reverse voltagephasing.

CHECKING FOR TWIST IN LOAD CHAIN Models R, RR

The best way to check for this condition is to run the lower
hook, without a load, up to within about 2 feet (.61 Meters) of
hoist. If the dead end of the 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.

CHECKING FOR ADEQUATE VOLTAGE AT HOIST

The hoist must be supplied with adequate electrical power in
order to operate properly. For proper operation, the voltage,
(measured at the hoist end of the standard power cord with
the hoist operating in the , up direction with full load) must
be as indicated in the table below.

SIGNS OF INADEQUATE ELECTRICAL POWER
(LOW VOLTAGE) ARE:

• Noisy hoist operations due to brake and/or contactor

chattering.

• Dimming of lights or slowing of motors connected to

the same circuit.

• Heating of the hoist motor and other internal compo-

nents as well as heating of the wires and connectors
in the circuit feeding the hoists.

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

• Blowing of fuses or tripping of circuit breakers.

To avoid these low voltage problems, the hoist must be con­nected to an electrical power supply system that complies
with the National Electrical Code and applicable local codes.
This system must also provide (slow blow fuses or inverse­time type circuit breakers) and provisions for grounding the
hoist.

Low voltage may also be caused by using an undersized
cord and/or connectors to supply power to the hoist. The fol­lowing chart 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.

Remember, operation with low voltage can void the CM
repair/replacement policy. When in doubt about any of the
electrical requirements, consult a qualified electrician.

WWAARRNNIINNGG

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.

TTOO AAVVOOIIDD IINNJJUURRYY::

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

V

!!

NOMINAL

CURRENT

MINIMUM
RUNNING
VOLTAGE

MINIMUM

STARTING

VOLTAGE

230-3-60 187 ­460-3-60 396 ­220-3-50 198 ­380-3-50 365 ­415-3-50 399 -

6

WWAARRNNIINNGG

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

TTOO AAVVOOIIDD IINNJJUURRYY::

Permanently ground the hoist as instructed in this manual.

V

!!

LENGTH

OF

EXTENSION

CORD

THREE
PHASE

HOISTS

MINIMUM

WIRE SIZE

UP TO 50 FEET #16 AWG

(1.6 mm)

80 FEET

(24.4 M)

#16 AWG

(1.6 mm)

120 FEET

(36.7 M)

#14 AWG

(2.0 mm)

200 FEET

(61.0 M)

#14 AWG

(2.0 mm)

300 FEET

(91.4 M)

#12 AWG

(2.7 mm)

For runs beyond 300 Feet contact factory.

WWAARRNNIINNGG

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

TTOO AAVVOOIIDD IINNJJUURRYY::

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

V

!!

WWAARRNNIINNGG

TTOO AAVVOOIIDD IINNJJUURRYY::

Always disconnect the power cord from the power supply
system and lockout/tagout disconnecting means before
servicing the hoist. Working in or near exposed energized
electrical equipment presents the the danger of electric
shock.

CHECKING LIMIT SWITCH OPERATION IF HOIST IS
EQUIPPED

Operate hoist over the entire length of its rated lift, checking
upper and lower limit switches for correct operation as follows:

1. Press (UP) control and raise the lower hook until
top of hook block is about one foot (.30 M) below the
hoist.

2. Cautiously continue raising the hook until the upper
limit switch stops the upward motion. The upper limit
switch is set at the factory to stop the hook block 6
inches (152 mm) from the bottom of all hoists.

3. If adjustment is necessary, see page 12.

4. Press (DOWN) control and cautiously lower hook
until lower limit switch stops the downward motion.
Maintain a minimum of 24” (610 mm) of chain freely
hanging over the side of the hoist.

5. If adjustment is necessary, see page 12.

NOTE: If the hoist is equipped with a chain
container/bag, reset the upper and lower limit
switches as indicated on page 12.

Under no condition should the hook block or load
be permitted to come in contact with the chain
container/bag. If contact is made, the function of
the chain container can be interfered with and its
fasterners imperiled.
NOTE:

When chain bag is filled to capacity the
bag must be no more than 75% filled.

GENERAL

1. The Protector is designed to allow the intermediate 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 the 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 overheating
and wear when slipped for extended periods. Under no
circumstance should the clutch 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 (*see below) installa­tions, containers that are loaded in mid-air, etc.

(*) Refer to limitations on Page ii concerning dumbwaiter
applications.

Also, if a Lodestar Hoist with a Protector is used at unusual
extremes of ambient temperatures, above 66°C (150

0

F), or
below -9°C (15°F), 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. With hoists that are equipped with an adjustable screw

limit switch, the limit switch will automatically stop the
hook at any predetermined point when either hoisting or
lowering.

OPERATING INSTRUCTIONS
HOIST

1. Check to ensure that the load point is in line with the hoist

head.

2. WHEN APPLYING A LOAD, IT MUST BE DIRECTLY

IN LINE WITH HOIST. 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 and/or attachments to bear against

the hook latch.

SAFETY PROCEDURES

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

1. When preparing to lift a load, be sure that the attachments

to the 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 the 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 capacity shown on

hoist identification plate or on the hoist motor housing
cover, Models B, C & F and on hoist back frame cover,
Models J, L, R, LL & RR. Overload 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 CM

Lodestar Hoist.

4. Do not use this or any other overhead materials handling

equipment for lifting persons.

5. Warn personnel of your intention to lift a load in the area.

Tie off the load with auxiliary chains or cables before
access to the area beneath the load is permitted.

6. Permit only competent personnel to operate unit.

7. 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

result in twisted chain and a jammed lift wheel.

b. The upper limit switch, if so equipped, is by-passed

and the load could hit the hoist.

c. The chain could be damaged at the hook.

8. Before lifting load, check for twists in the load chain. Atwist

can occur if the lower hook block has been capsized
between the strands of chain. Reverse the capsize to

remove twist.

WWAARRNNIINNGG

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.

TTOO AAVVOOIIDD IINNJJUURRYY::

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

V

!!

OPERATING INSTRUCTIONS

7

9. On single reeved chain hoist used in conjuction with head
blocks and ground support systems. Check for twists
between the hoist and head block. Twisted load can result
in a jammed liftwheel.

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.

1 1.T ake up a slack load chain carefully and st art 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.

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.STAYALERT! 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.

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 the degree of exposure to wear, deterioration or mal­function of the critical components.

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 the 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 the 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 visual 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 4.

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 5.

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.

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 11).

HOOK INSPECTION

Hooks damaged from chemicals, deformations or cracks, or
that have more than a 10

o

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, hook block screws, load pins and
hook block bodies 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 the latch to spring back to the tip when
released. If the latch does not operate properly, it should be
replaced. See Figure 14 to determine when the hook must be
replaced.

WWAARRNNIINNGG

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

TTOO AAVVOOIIDD IINNJJUURRYY::

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

V

!!

INSPECTION

8

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 10.

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

matter - see page 10.

e) Load chain for proper reeving and twists.

Table 5. Minimum Periodic Inspections

TYPE OF SERVICE

ITEM

Normal Heavy Severe

a) All items listed in Table 4 for frequent inspections.
b) External evidence of loose screws, bolts or nuts.
c) External evidence of worn, corroded, cracked or distorted hook block, suspension screws,

gears, bearings and dead end block and chain pin.

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

sion adapter making sure it is fully seated in the hoist frame and that both screws are 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 guides 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 11.
g) External evidence of pitting or any deterioration of contactor contacts. Check the opera-

tion 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 screws for proper

tightness - see page 4.
j) Inspect the loose end link, loose end screw and dead end block on double reeved units.

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

evidenced by excess free play or rotation.
l) Inspect for signs of lubricant leaks at the gasket between the gear housing and back

frame. tighten screws holding back frame to gear housing. If leak persists, repack housing

and gears with grease and install a new gasket.

Monthly

Weekly

to Monthly

Daily

to Weekly

Yearly

Every 6 Months

Every 3 Months

Table 4. Minimum Frequent Inspections

9

LOAD CHAIN

Chain should feed smoothly into and away from the hoist or
hook block. If chain binds, jumps or is noisy, first clean and
lubricate it (see below). If trouble persists, inspect chain and
mating parts for wear, distortion or other damage.

Chain Inspection

First Clean chain with a non-caustic/non-acid type solvent and
make a link by link inspection for nicks, gouges, twisted links,
weld splatter, corrosion pits, striations (minute parallel lines),
cracks in weld areas, wear and stretching. Chain with any one
of these defects must be replaced.

Slack the portion if the chain that normally passes over the lift­wheel. Examine the interlink area for the point of maximum
wear (polishing, see Figure 15). 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 (0.254 mm), or more, less than the
stock diameter of the unworn link, the chain must be replace.

On double reeved units, repeat this examination of the chain
that passes through the hook block.

Also check chain for stretch using a vernier caliper as shown
in Figure 16. Select an unused, unstretched section of chain
(usually at the lose end) and measure and record the length
over 11 chain links (pitches). Measure and record the same
length on a worn section of the chain. Obtain the amount of
stretch and wear by subtracting the measurement of the worn
section. If the result (amount of stretch and wear) is greater
than 0.145 inch (3.7mm), the chain must be replaced.

Use only a “Knife-edge” caliper to eliminate possibility of false
reading by not measuring full pitch length.

Note that worn chain can be an indication of worn hoist com­ponents. For this reason, the hoist’s chain guide, hook block
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.

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IMPORT ANT:

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.

10

Figure 14. Hook Inspection

MEASURE

OPENING

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

LATCHLOCK®TYPE HOOK
(UPPER AND LOWER)

“A”

“B” Max.

Models

Replace Hooks
When Opening

is Greater

Than

B, C AND F

1 3/16 (30.2mm)

J, L, AND LL

1 5/16 (33.3mm)

R AND RR

1 1/2 (38.1mm)

Models

Replace Hook

When Opening

or Seat are:

B, C, F, J, L, AND LL

“A” Max “B” Max

1 31/64 in.

(37.7mm)

2 1/32 in.

(51.6mm)

R AND RR

1 59/64 in.

(48.8mm)

27/32 in.

(21.4mm)

Figure 15. Chain Wear Areas

WWAARRNNIINNGG

Use of commerical or other manufactures’ chain and parts
to repair Lodestar Hoists may cause load loss.

TTOO AAVVOOIIDD IINNJJUURRYY::

Use only factory supplied replacement load chain and parts.
Chain and parts may look alike, but factory original chain
and parts are made of specific materials or processed to
achieve specific properties. See Figure 17.

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Figure 17. Chain Embossing

Figure 16. Chain Inspection

PROTECTOR

The Protector should operate for the normal life of the hoist
without service. The device has been lubricated and calibrated
at the factory for a specific model of hoist and is not adjustable
or interchangeable with other models. For proper overload pro­tection, be sure before installing a Protector that it is correct for
the unit. The spring washer of the Protector had been color
coded at the factory as follows:

HOIST LUBRICATION
GEARS

NOTE: To assure extra long life and top performance, be

sure to lubricate the various parts of the Lodestar Hoist
using the lubricants specified below. If desired, these
lubricants may be purchased from CM. Refer to page 29
for information on ordering the lubricants.

• The Protector should operate for the normal life of the
hoist without service. The device has been lubricated and
calibrated at the factory for a specific model of Lodestar
Hoist and is not adjustable or interchangeable with other
models.

CAUTION: The Protector is to be used with “Century
Lubricants HB-1 1 #3” grease. Do not use any other grease
or the Protector will not operate properly and parts could
be damaged.

The gears and Protector (627-327 and 627-328) are packed at
assembly with grease and should not need to be renewed
unless the gears have been removed from the housing and
degreased.

CAUTION: Never degrease the Protector or attempt to
disassemble this device. Degreasing the Protector may
damage parts and using a device that has been degreased
may cause erratic, inconsistent operation. If the Protector
has been degreased, it must be replaced by a factory
calibrated device.

If the gears are removed from the housing, wipe the excess
grease off the outside surfaces of the Protector with a soft cloth
and degrease the remaining gears and housings. Upon
reassembly, add 7 oz. of the above grease to gears and hous­ing. Also, coat the spline on the end of the drive shaft (627-311)
with a Molydisulphide lubricant such as “Super Herculon”.

For Models LL, and RR, see page 22 for special gearing align­ment instructions.

• 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 (627-220, page 28) at least once a year.

BEARINGS

• All bearings and bushings, except the lower hook thrust

bearing, are pre-lubricated and require no lubrication.
The lower hook thrust bearing should be lubricated at
least once a month.

CHAIN GUIDES, LIFTWHEELAND LOWER SHEAVE WHEEL

• When the hoist is disassembled for inspection and/or

repair, the chain guides, lower sheave wheel (on double

chain units) and liftwheel must be lubricated with . . . .

Lubriplate Bar and Chain Oil 10-R (Fiske Bros. Refining
Co. or equivalent) prior to reassembly. The lubricant must
be applied in sufficient quantity to obtain natural runoff and
full coverage of these parts.

LOAD CHAIN

Asmall amount of lubricant 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 10-4 (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 run-off and full coverage, especially in the interlink
area.

ELECTRIC BRAKE ASSEMBLY

The correct air gap between armature and field, when brake
is not energized, is 0.025 inch (.635mm) and need not be
adjusted until the gap reaches 0.045 inch (1.143mm). When
checking brake gap, always reset to .025 inch (.635 mm).

To adjust the brake, proceed as follows:

1. Disconnect hoist from power supply.

2. Remove back frame cover, see figure 13

3. Before adjusting the gap: a) back off the stud nuts

and examine friction linings and friction surfaces for
excessive wear (min. thickness .188 inch, 4.78mm),
scoring or 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 hoist is operated. Any of these
symptoms indicate the need for replacement parts.

MAINTENANCE

WWAARRNNIINNGG

Used motor oils contain known carcinogenic materials.

TTOO AAVVOOIIDD HHEEAALLTTHH PPRROOBBLLEEMMSS::

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.

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11

WWAARRNNIINNGG

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

TTOO AAVVOOIIDD CCOONNTTAACCTT AANNDD CCOONNTTAAMMIINNAATTIIOONN::

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

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Models Protector Color Code No. of Teeth on

Gear

B White 63

C, F Orange 63

J Red 71

L, R Green 92

LL, RR Yellow 92

WWAARRNNIINNGG

DO NOT REMOVE PROTECTOR SNAP RING

Removing the snap ring on the Protector assembly will
allow the parts to spring apart. Personal injury may occur.

TTOO AAVVOOIIDD IINNJJUURRYY::

Do not attempt to disassemble the Protector.

V

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