CMWORKS Lodestar Parts Manual

Operating, Maintenance & Parts Manual

Rated Loads 1/8 To 3 Tonnes

125 Kg To 3000 Kg

Follow all instructions and warning 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 using the hoist, fill in the information below. Refer to the hoist identification plate.

Model Number

Serial Number

Purchase Date

Voltage

Rated Load

Electric Chain

00001996 (REV AB) 627NH

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

PARTS FOR YOUR HOIST ARE AVAILABLE FROM YOUR LOCAL AUTHORIZED REPAIR STATION. FOR THE NAME

OF THE NEAREST PARTS OR SERVICE CENTER, VISIT OUR WEB SITE WWW.CMWORKS.COM

OR CALL OUR CUSTOMER SERVICE DEPARTMENT.

SAFETY PRECAUTIONS

Each 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/NFPA 70) and the Occupational Safety and Health Act. 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 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). 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

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.

Consult Columbus McKinnon for information concerning

using hoists in these applications.

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in death tially hazardous situation, the operator shall:

1. NOT operate a damaged, malfunctioning or unusually

performing hoist.

2. NOT operate the hoist until you have thoroughly read and

understood this Operating, Maintenance and Parts Manual.

3. NOT operate a hoist which has been modified.

4. NOT lift more than rated load for the hoist.

5. NOT use hoist with twisted, kinked, damaged, or worn

load chain.

6. NOT use the hoist to lift, support, or transport people.

7. NOT lift loads over people.

8. NOT operate a hoist unless all persons are and remain

clear of the supported load.

9. NOT operate unless load is centered under hoist.

10.NOT attempt to lengthen the load chain or repair dam-

aged load chain.

11.Protect the hoist’s load chain from weld splatter or other damaging contaminants.

12.NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading.

13.NOT use load chain as a sling, or wrap load chain around load.

14.NOT apply the load to the tip of the hook or to the hook latch.

15.NOT apply the load unless load chain is properly seated in the chain wheel(s) or sprocket(s).

16.NOT apply load if bearing prevents equal loading on all load supporting chains.

17.NOT operate beyond the limits of the load chain travel.

18.NOT leave load supported by the hoist unattended unless specific precautions have been taken.

19.NOT allow the load chain or hook to be used as an electrical or welding ground.

20.NOT allow the load chain or hook to be touched by a live welding electrode.

OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED

WITH THE EQUIPMENT BEFORE

ATTEMPTING TO OPERATE YOUR LODESTAR HOIST.

WARNING

TO AVOID INJURY:

WARNING

or serious injury. To avoid such a poten-

21.NOT remove or obscure the warnings on the hoist.

22.NOT operate a hoist on which the safety placards or de-

cals are missing or illegible.

23.NOT operate a hoist unless it has been securely attached

to a suitable support.

24.NOT operate a hoist unless load slings or other approved

single attachments are properly sized and seated in the hook saddle.

25.Take up slack carefully - make sure load is balanced and load holding action is secure before continuing.

26.Shut down a hoist that malfunctions or performs unusually and report such malfunction.

27.Make sure hoist limit switches function properly.

28.Warn personnel of an approaching load.

CAUTION

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. To avoid such a potentially hazardous situation, the operator shall:

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

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

3. Use hook latches. Latches are to retain slings, chains, etc. under 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 the hoist manufacturer’s recommended parts when repairing the unit.

10.Lubricate load chain per hoist manufacturer’s recommendations.

11.NOT use the hoist load limiting or warning device to measure load.

12.NOT use limit switches as routine operating stops unless allowed by manufacturer. They are emergency devices only.

13.NOT allow your attention to be diverted from operating the 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.

HOIST SAFETY IS UP TO YOU...

Know the capacities of your hoists and the weight of your loads. Then match them.

CHOOSE THE RIGHT HOIST FOR THE JOB...

Choose a hoist with a capacity for the job.

The application, the size and type of load,

fore use, in addition to regular, periodic maintenance inspections.

tices and legibility.

to the attention of supervisors. Be sure defective hoists are tagged and taken out of

INSPECT

All hoists should be visually inspected be-

Inspect hoists for operational warning no-

Deficiencies should be noted and brought

WARNING

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

WARNING

service until repairs are made.

Under no circumstances should you oper-

ate a malfunctioning hoist.

Check chain for gouged, twisted, distorted links and foreign material. Do not operate hoists with twisted, kinked or damaged chain.

Load chain should be properly lubricated.

Hooks that are bent, worn or whose open-

WARNING

– DO NOT LIFT MORE THAN RATED LOAD.

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.

ings are enlarged beyond normal throat opening should not be used. If latch does not engage throat opening of hook, hoist should be taken out service.

Check for misphasing – hook travel should

correspond to control direction.

– DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD

ARE IN A STRAIGHT LINE.

– DO NOT USE LOAD CHAIN AS A SLING.

3 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.

4 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.

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.

WARNING

Do not use load chain as a sling. Such usage damages the chain and lower hook.

– DO NOT LIFT PEOPLE OR LOADS

OVER PEOPLE.

and free of dust, dirt, moisture, etc., which will in any way affect the operation or safety of the equipment.

lubricated.

hoist before returning it to full service.

MAINTAIN PROPERLY

CLEANING: Hoists should be kept clean

LUBRICATION: Chain should be properly

AFTER REPAIRS: Carefully operate the

Do not operate with hoist head resting against any object. Lift the load gently. Do not jerk it.

VIOLATION OF ANY OF THESE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL INJURY TO THE OPERATOR OR NEARBY PERSONNEL BY RELEASED LOAD OR BROKEN HOIST COMPONENTS.

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 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.

TABLE OF CONTENTS

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

General Information

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

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

Accessories

Hook Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . .9

Lug Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Series 635 Low Headroom Trolley . . . . . . . . . . . . . .9

Series 635 Motor Driven Trolley . . . . . . . . . . . . . . . .9

Latchlok Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Installation

Unpacking Information . . . . . . . . . . . . . . . . . . . . . .10

Installing Suspension . . . . . . . . . . . . . . . . . . . .10-11

Recommended Torques . . . . . . . . . . . . . . . . . . . . .11

Attaching Load Chain . . . . . . . . . . . . . . . . . . . . . . .12

Installing Series 635 Low Headroom Trolley . . . . .12-13

Power Supply and Electrical Connections . . . . . . . . . .14

Operating Instructions

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Operating Instruction-Hoist . . . . . . . . . . . . . . . .16-17

Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . .17

Inspection

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Frequent Inspections . . . . . . . . . . . . . . . . . . . .18-19

Periodic Inspections . . . . . . . . . . . . . . . . . . . . .18-19

Preventative Maintenance . . . . . . . . . . . . . . . . . . .18

Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Maintenance

Load-limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Hoist Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .21

Trolley Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .21

Adjustments

Electric Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . .23-24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .25-27

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . .28-29

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . .30-72

Assembly Instructions

Hook or Lug Suspensions . . . . . . . . . . . . . . . . . . .73

Lower Hook Block Pin . . . . . . . . . . . . . . . . . . . . . .73

Removal and Installation of Load Chain . . . . . .73-74

Cutting Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .75

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76-137

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Recommended Spare Parts . . . . . . . . . . . . . . . . . . .138

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

LIST OF TABLES

Table Title Page

1 Lodestar Electric Chain Hoist Specs. . . . . . 6-8

2 Recommended Torques . . . . . . . . . . . . . . . . 11

3 Series 635 Trolley Side Frame Spacing . . . . .13

4 Minimum Frequent Inspections . . . . . . . . . . . .19

5 Minimum Periodic Inspections . . . . . . . . . . . .19

6 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . .22

7 Troubleshooting . . . . . . . . . . . . . . . . . . . . .25-27

8 Electrical Data . . . . . . . . . . . . . . . . . . . . . .28-29

LIST OF ILLUSTRATIONS

Figure Table Page

1 Hook Suspensions . . . . . . . . . . . . . . . . . . . . . .9

2 Lug Suspensions . . . . . . . . . . . . . . . . . . . . . . .9

3 Series 635 Low Headroom Trolley . . . . . . . . . .9

4 Series 635 Motor Driven Trolley . . . . . . . . . . . .9

5 Upper or Lower Latchlok Hook . . . . . . . . . . . . .9

6 Chain Container . . . . . . . . . . . . . . . . . . . . . . . .9

7 Attaching Load Chain . . . . . . . . . . . . . . . . . . .11

8 Contact Block . . . . . . . . . . . . . . . . . . . . . . . . .12

9 Series 635 Low Headroom Trolley . . . . . . . . .12

10 1/8 to 2 Ton Hoist to Trolley Assembly . . . . . .13

11 3 Ton Hoist to Trolley Assembly . . . . . . . . . . .13

12 Voltage Change Board . . . . . . . . . . . . . . . . . .14

13 Locations of Components . . . . . . . . . . . . . . . .14

14 Hook Inspection . . . . . . . . . . . . . . . . . . . . . . .18

15 Chain Wear areas . . . . . . . . . . . . . . . . . . . . .20

16 Gaging Load Chain Wear . . . . . . . . . . . . . . . .20

17 Chain Inspection . . . . . . . . . . . . . . . . . . . . . .20

18 Limit Switches Models, V1 Models . . . . . . . . .23

18A Rotatable Limit Switches, V1 Models . . . . . . . . .23

19 Limit Switches, V2 Models . . . . . . . . . . . . . . .23

19A Rotatable Limit Switch, V2 Models . . . . . . . . .23

20 Typical Wiring Diagrams . . . . . . . . . . . . . .30-72

21 Swivel Hook Suspensions . . . . . . . . . . . . . . .73

22 Chain Embossing . . . . . . . . . . . . . . . . . . . . . .73

23A Cutting Chain By Nicking . . . . . . . . . . . . . . . .75

23B Cutting Chain With A Bolt Cutter . . . . . . . . . . .75

GENERAL INFORMATION

SPECIFICATIONS

The Lodestar Electric Chain Hoist is a highly versatile materials handling device that can be used to lift loads that are within rated capacity. The mechanical features of these hoists include an alloy steel lift wheel, Load Limiter, hardened steel chain guides, hardened steel gear train, life-time lubrication, forged steel hooks and lightweight aluminum frame. The electrical features include hoist-duty motor, rugged hoist brake, magnetic reversing contactor and voltage conversion board (dual voltage units). The hoist is available with hook or lug suspensions that are supplied separately. Table 1 summarizes the Lodestar Electric Chain Hoist models and the Series 635 Trolleys available. It should be noted that standard single speed hoists are available with 10 (3M), 15 (4.6M) and 20 (6.1M) foot lifts and the standard lift for two speeds hoists is10 feet. However, hoists with longer lifts are available on a special, per order basis.

Table 1.a. Specifications

Lodestar Electric Chain Hoists

Single Speed 115-1-60

Model

Load Capacity

Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m

A 1/8 125 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

AA 1/8 125 60 18.3 50.0 15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87

B 1/4 250 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 C 1/4 250 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 E 1/2 500 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74 F 1/2 500 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

J 1/2 500 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87 H 1 1000 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74 L 1 1000 16 4.9 13.3 4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40 R 2 2000 8 2.4 6.7 2.0 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RT 3 3000 5.3 1.6 4.4 1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20

Lifting Speed

60Hz units

Lifting Speed

50Hz units

CM REPAIR/REPLACEMENT POLICY

All Columbus McKinnon (CM®) Lodestar Electric Chain Hoists are i nspe c t e d an d per f o r m ance t este d prio r 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.

Chain

Falls

Chain Size

Chain Weight

per length of lift

Lodestar Electric Chain Hoists

Single Speed 115-1-60

Model

Shortest Distance

Between Hooks

in mm HP kW HP kW lb kg

A 16.9 429 0.25 0.19 0.21 0.16 54 72 32.8

AA 19.9 505 0.50 0.37 0.42 0.31 54 76 34.3

B 16.9 429 0.25 0.19 0.21 0.16 54 73 33.1 C 16.9 429 0.50 0.37 0.42 0.31 54 75 34.2 E 21.6 549 0.25 0.19 0.21 0.16 54 78 31.8

F 16.9 429 0.50 0.37 0.42 0.31 54 76 34.5

J 18.1 460 1.00 0.75 0.83 0.62 54 127 57.5 H 21.6 549 0.50 0.37 0.42 0.31 54 81 36.7

L 18.1 460 1.00 0.75 0.83 0.62 54 125 56.7 R 25.8 655 1.00 0.75 0.83 0.62 54 148 67.1

RT 32.1 815 1.00 0.75 0.83 0.62 54 166 75.4

Motor Power

60Hz

Motor Power

50Hz

Rating

Net Weight 10’ lift less

upper suspension

Table 1.b.Specifications, cont’d

Single Speed 230/460-3-60 or 220/380-3-50 or 220/415-3-50

Lodestar Electric Chain Hoists

Model

Load Capacity

Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m

A 1/8 125 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

AA 1/8 125 60 18.3 50.0 15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87

B 1/4 250 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

C 1/4 250 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

E 1/2 500 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74

F 1/2 500 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

J 1/2 500 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87

JJ 1/2 500 64 19.5 53.3 16.3 1 .312 x .8583 7.92 x 21.8 0.94 1.40

H 1 1000 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74

L 1 1000 16 4.9 13.3 4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

LL 1 1000 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

R 2 2000 8 2.4 6.7 2.0 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RR 2 2000 16 4.9 13.3 4.1 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RT 3 3000 5.3 1.6 4.4 1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20

RRT 3 3000 10.7 3.3 8.9 2.7 3 .312 x .8583 7.92 x 21.8 1.88 2.80

Lifting Speed

60 Hz units

Lifting Speed

50Hz units

Chain

Falls

Chain Size

Chain Weight

per length of lift

Lodestar Electric Chain Hoists

Single Speed 230/460-3-60 or 220/380-3-50 or 220/415-3-50

Model

Shortest Distance

Between Hooks

Motor Power

60Hz

Motor Power

50Hz

Rating

Net Weight 10’ lift less

upper suspension

in mm HP kW HP kW lb kg

A 16.9 429 0.25 0.19 0.21 0.16 54 70 31.9

AA 19.9 505 0.50 0.37 0.42 0.31 54 73 32.9

B 16.9 429 0.25 0.19 0.21 0.16 54 71 32.2

C 16.9 429 0.50 0.37 0.42 0.31 54 72 32.8

E 21.6 549 0.25 0.19 0.21 0.16 54 76 30.9

F 16.9 429 0.50 0.37 0.42 0.31 54 73 33.1

J 18.1 460 1.00 0.75 0.83 0.62 54 121 54.7

JJ 18.1 460 2.00 1.49 1.67 1.24 54 127 57.5

H 21.6 549 0.50 0.37 0.42 0.31 54 78 35.4

L 18.1 460 1.00 0.75 0.83 0.62 54 119 53.9

LL 18.1 460 2.00 1.49 1.67 1.24 54 127 57.6

R 25.8 655 1.00 0.75 0.83 0.62 54 142 64.4

RR 25.8 655 2.00 1.49 1.67 1.24 54 150 68.0

RT 32.1 815 1.00 0.75 0.83 0.62 54 160 72.7

RRT 32.1 815 2.00 1.49 1.67 1.24 54 173 78.4

Table 1.c. Specifications, cont’d

Two Speed 230-3-60 or 460-3-60 or 575-3-60 or 220-3-50 or 380-3-50 or 415-3-50 or 550-3-50

Lodestar Electric Chain Hoists

Model

Load Capacity

Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m

A-2 1/8 125 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

AA-2 1/8 125 20/60 6.1/18.3 16.7/50 5.1/15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87

B-2 1/4 250 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

C-2 1/4 250 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

E-2 1/2 500 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .250 x .7445 6.35 x 18.9 1.17 1.74

F-2 1/2 500 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

J-2 1/2 500 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87

JJ-2 1/2 500 21.3/64 6.5/19.5 17.8/53.3 5.4/16.3 1 .312 x .8583 7.92 x 21.8 0.94 1.40

H-2 1 1000 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2

L-2 1 1000 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

LL-2 1 1000 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

R-2 2 2000 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RR-2 2 2000 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RT-2 3 3000 1.8/5.3 0.5/1.6 1.5/4.4 0.5/1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20

RRT-2 3 3000 3.6/10.7 1.1/3.3 3/8.9 0.9/2.7 3 .312 x .8583 7.92 x 21.8 1.88 2.80

Lifting Speed

60Hz units

Lifting Speed

50Hz units

Chain

Falls

Chain Size

.250 x .7445

Chain Weight

per length of lift

6.35 x 18.9 1.17 1.74

Lodestar Electric Chain Hoists

Two Speed 230-3-60 or 460-3-60 or 575-3-60 or 220-3-50 or 380-3-50 or 415-3-50 or 550-3-50

Capacity

Tons

(kg)

Model

Shortest Distance

Between Hooks

Motor Power

60Hz

Motor Power

50Hz

Rating

Net Weight 10’ lift less

upper suspension

in mm HP kW HP kW lb kg

A-2 16.9 429 0.25 0.19 0.21 0.16 54 76 34.6

AA-2 19.9 505 0.50 0.37 0.42 0.31 54 78 35.2

B-2 16.9 429 0.25 0.19 0.21 0.16 54 77 34.9

C-2 16.9 429 0.50 0.37 0.42 0.31 54 77 35.1

E-2 21.6 549 0.25 0.19 0.21 0.16 54 82 33.6

F-2 16.9 429 0.50 0.37 0.42 0.31 54 78 35.4

J-2 18.1 460 1.00 0.75 0.83 0.62 54 133 60.2

JJ-2 18.1 460 2.00 1.49 1.67 1.24 54 135 61.1

H-2 21.6 549 0.50 0.37 0.42 0.31 54 83 37.6

L-2 18.1 460 1.00 0.75 0.83 0.62 54 131 59.4

LL-2 18.1 460 2.00 1.49 1.67 1.24 54 135 57.6

R-2 25.8 655 1.00 0.75 0.83 0.62 54 154 61.2

RR-2 25.8 655 2.00 1.49 1.67 1.24 54 158 69.8

RT-2 32.1 815 1.00 0.75 0.83 0.62 54 172 71.6

RRT-2 32.1 815 2.00 1.49 1.67 1.24 54 181 82.1

Table 1.d. Specifications, cont’d

Series 635 Low Headroom Trolleys

For Use

With

Models

Adj. For

STD

S-Beams

Depth In. (mm)

Tread

Dia. of

Wheels

In. (mm)

Min. Rad.

Curve

In. (mm)

Capacity

Tons

(kg)

Table 1.e. Specifications, cont’d

Series 635 Motor Driven Trolleys

For Use

With

Models

*Travel

Speed

FPM

(MPM)

Motor

H.P.

(kW)

Adj. For

STD

S-Beams

Depth In.(mm)

Min.

Rad.

Curve

In.(mm)

= to 1

(125 to 2000)

2 (2000)

3 (3000)

A thru LL-2

R thru RR-2

RT thru RRT-2

4 - 15 (102 - 381)

6 - 18 (152 - 457)

8 - 15 (203 - 381)

3= (79.4)

4< (120.6)

4 (101.6)

24 (610)

30 (762)

= to 2

(125 to 2000)

3 (3000)

A thru RR-2

RT thru RRT-2

75 (23)

; (.19)

6 - 15 (152 - 381)

30 (762)

ACCESSORIES

Hook Suspensions

Swivel and rigid type hook suspensions (see Figure 1) are available for all Lodestar Electric Hoists. However, rigid type hook suspensions are normally recommended for most application. The hook suspensions are intended for suspending the hoist from a trolley which has a single load bar (such as

CM’s

Series 632 and 633 Trolleys) or for suspending the

hoist from a fixed structure.

Figure 1. Hook Suspensions

Lug Suspension

Lug suspensions (see Figure 2) are available for all Lodestar Electric Hoists. These are rigid type suspensions wherein the lug shown replaces the hook (Figure 1) in the suspension adapter. The Lug suspensions are required for suspending the hoist from the Series 635 Low Headroom and Motor Driven Trolleys described next.

Figure 4. Series 635 Motor Driven Trolley

Series 635 Motor Driven Trolley

The motor driven trolleys (see Figure 4) are self-contained and supplied complete with independent controls and wiring, including a four directional control station. A rigid lug suspension (see Figure 2) is required to suspend the hoist from the Motor Driven Trolley. The hoist and trolley are joined electrically by connecting the hoist control and power cords (supplied) into the hoist or trolley. The trolley is adjustable for operation on a range of American Standard “S” beams as indicated in Table 1 and it will also operate on flat flanged beams.

Latchlok

Hooks

CM’s Latchlok hooks (see Figure 5) are available to replace the standard upper and lower hooks used on the Lodestar Electric Hoists.

Figure 2. Lug Suspensions

Series 635 Low Headroom Trolley

These are manual push type trolleys (see Figure 3) designed for use with the Lodestar Electric Chain Hoists. A rigid lug suspension (see Figure 2) is required to suspend the hoist from the trolley. The trolley is adjustable for operation on a range of American Standard “S” beams as indicated in Table 1, and it will also operate on flat flanged beams.

Figure 3. Series 635 Low Headroom Trolley

Figure 5. Upper or Lower Latchlok®Hook Figure 5. Latchlok

Hook

Chain Container

This accessory (see Figure 6) is used to hold slack chain and it is supplied complete with mounting hardware and instructions. The chain container is recommended for those applications where the slack chain would interfere with the load or drag on the floor as may be the case with double or triple reeved units. Chain containers can be furnished for units already in use.

Figure 6. Chain Container

INSTALLATION

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 installing the hoist, make sure that the power supply to which it will be connected is the same as that shown on the nameplate located on the side of the hoist.

NOTE: See Electrical Installation instructions

INSTALLING THE SUSPENSION

A. Single Reeved Units:

Remove the hook suspension and (2) suspension screws from the packaging. Place the suspension assembly into the recess on top of the hoist so that the adaptor body follows the contour of the hoist. Insert the suspension screws through the holes in the adapter and hand thread these into the selflocking nuts enclosed in the hoist. .

CAUTION

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

Securely tighten the screws to the recommended seating torque (see Table 2) using a 12 point socket: 3/8" for Models A, B, C, & F and 1/2 " for Models J-LL.

B. Double Reeved Units:

Remove the hook suspension,(2) suspension screws, (1) dead end pin, (1) washer, and (1) cotter pin from the packaging. 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 1/4" (6.35mm) for Models E,E-2, H, H-2 and 7/16" (11.11mm) for Models R, R-2, RR, RR-2. If the distance is not correct, adjust the position of the dead end block to obtain the proper distance (see fig. 21, p 73.)

enclosed in the hoist frame. Securely tighten the screws to the recommended seating torque (see Table 2) using a 12 point socket: 3/8" for Models E & H and 1/2" for Models R & RR.

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)

C. Triple Reeved Units:

These hoists have a sheave hanger which is loosely connected to the top of the frame by a thin metal plate for shipping purposes. To attach the suspension, support the sheave hanger from the underside of the hoist and remove the nut and seat from the sheave stud. Remove and discard the shipping plate and retain the sheave stud nut and seat since they will be reused later.

Remove the suspension assembly from the carton and the two suspension screws. Place the suspension assembly over the sheave stud and into the recess on top of the hoist.

Insert the suspension screws through the holes in the suspension adapter and hand thread these into the selflocking nut enclosed in the hoist. Securely tighten the screws to the recommended seating torque (see Table 2) using a 12 point, 1/2" socket.

After the suspension assembly is installed, secure the sheave stud to the suspension adapter using the round slotted nut and seat that were formerly used to attach the shipping plate to top of the hoist frame. Place the seat over the stud with the flat side down and then rotate the seat so that there is clearance between the seat and the suspension lug or hook. Assemble the nut to the stud and turn the nut by hand until the nut seats in the seat and the sheave hanger is snug in the frame. Then back off the nut until the hole in the stud is in line with one of the slots in the nut. Using a hammer, drive the retaining pin (packed with the suspension assembly) into the hole in the sheave stud until the end of the pin is flush with the edge of the nut.

WARNING

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.

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 in tables 2a and 2b. 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.

TO AVOID INJURY:

Now, insert the suspension screws through the holes in the adapter and hand thread these into the self-locking nuts























Figure 7. Attaching Load Chain Double Reeved Models

1. Dead end block 7. Lift-wheel

2. Suspension assembly 8. Motor housing

3. Suspension self-locking nut 9. Loose end screw

4. Dead end bolt 10. Loose end link

5. Dead end link 11. Loose end

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

Table 2.a. Recommended Torques: V1 Models A-H

*Recommended

Fastener

Brake End

cover

Motor End

cover

Brake Attaching

Screw

Power Cord

Strain Relief Nut

Motor Housing/

Gear Housing/

Back Frame

Lower Hook Block

Screws -

Doubled Reeved

Suspension

Adapter Screws

Lift-Wheel

Locking Nut 1"-12 Hex Nut

Reversing

Contactor

Connecting

Screws-1ø

Reversing

Contactor

Connecting

Screws-3ø

Fastener

Description Tool Required

1/4-20 Slotted Fillister

Head Screw

1/4-20 Slotted Fillister

Head Screw

1/4-20 Slotted Fillister

Head Screw

1/4-20 Hex Nut

1/4"-20 Socket Head

Cap Screw

1/4"-20 Socket Head

Cap Screw

3/8"-16-12

Point Cap Screw

Terminal

Clamp Screw

Terminal

Clamp Screw

Slotted Blade Screw Driver

7/16" - 6 or 12

Point Socket

3/16" Hex Driver 7.9 - 8.3 10.7 - 11.3

3/16" Hex Driver 5.0 - 5.8 6.8 - 7.9

3/8 "

12 Point Socket

1-1/2" - 6 or 12

Point Socket

Phillips No.2 or

3/16" Slotted Head

Screw Driver

Phillips No.2 or

3/16" Slotted Head

Screw Driver

Seating Torque

ft-lbf N-m

4.0 - 5.0 5.4 - 6.8

4.2 - 5.0 5.6 - 6.8

1.7 - 2.0 2.3 - 2.7

35.0 - 45.0 47.5 - 61.0

55.0 - 60.0 74.6 - 81.3

0.6 - 1.0 0.8 - 1.3

Table 2.b. Recommended Torques: V2 Models J-RRT

*Recommended

Fastener

Brake End

cover

Motor End

cover

Brake Attaching

Screw

Brake Hex Stud

Power Cord

Strain Relief Nut

Motor Housing/

Gear Housing/

Back Frame

Lower Hook Block

Screws -

Doubled Reeved

Suspension

Adapter Screws

Lift-Wheel

Locking Nut 1-1/8"-12 Hex Nut

Reversing

Contactor

Connecting

Screws-1ø

Reversing

Contactor

Connecting

Screws-3ø

Stator Mounting

Screws

Fastener

Description Tool Required

1/4-20 Slotted Fillister

Head Screw

1/4-20 Slotted Fillister

Head Screw

1/4-20 Slotted Fillister

Head Screw

1/2" Hex w/ 5/16 -18

Threaded End

1/4-20 Slotted Rd.

Head Screw

5/16"-18 Socket Head

Cap Screw

5/16"-18 Socket Head

Cap Screw

1/2"-20-12

Point Cap Screw

Terminal

Clamp

Screw

Terminal

Clamp

Screw

1/4"- 20 Hex Cap

Screw

Slotted Blade

Screw Driver

Slotted Blade

Screw Driver

Slotted Blade

Screw Driver

1/2" Open-End

Wrench

Slotted Blade

Screw Driver

1/4" Hex Driver 14.2 - 15.0 19.2 - 20.3

1/4" Hex Driver 10.0 - 11.3 13.6 - 15.3

1/2 "

12 Point Socket

1-11/16" - 6 or 12

Point Socket

Phillips No.2

Phillips No.2 or

3/16" Slotted Head

Screw Driver

7/16" - 6 or 12

Point Socket

Seating Torque

ft-lbf N-m

4.0 - 5.0 5.4 - 6.8

4.2 - 5.0 5.6 - 6.8

1.7 - 2.0 2.3 - 2.7

70.0 - 80.0 94.9 -108.5

85.0 - 90.0 115 .2 -1 2 2.0

1.3 1.7

0.6 - 1.0 0.8 - 1.3

4.2 - 5.0 5.8 - 6.8

* All torque values are for clean, dry fasteners. DO NOT apply oil or any other lubricant to the fastner threads.

ATTACHING LOAD CHAIN

To attach the chain to the dead end block on Models E, E-2, H, H-2, R, R-2 and RR-2, proceed as follows:

1. Suspend the hoist from an adequate support.

2. On Models E, E-2, H and H-2, insert the last link of the load chain into the dead end block (2) and secure it with the dead end pin, washer and cotter pin furnished with the suspension. Ensure there are no twists in the chain.

3. On Models R, R-2, RR and RR-2, 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)

INSTALLING THE SERIES 635 LOW HEADROOM TROLLEY (See Figure 9)

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

Install rail stops at each end of the beam on which the trolley

is to operate.

WARNING

TO AVOID INJURY:

Figure 8. Contact Block Used on Models R, R-2, RR and RR-2

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

After the suspension is installed, hoists with a hook suspension can be suspended from its permanent support and then connected to the power supply system (refer to page 14). For hoists with a lug suspension that are to be suspended from a Series 635 Low Headroom Trolley, attach the hoist to the trolley per the following instructions.

Figure 9. Series 635 Low Headroom Trolley: 1 and 2 Ton (1000 and 2000 kg)

Trolley Shown - 3 Ton (3000 kg) Similar.

For hoists with a lug suspension that are to be suspended from a Series 635 Motor Driven Trolley, attach the hoist to the trolley, wire the hoist and trolley together and connect the trolley to the power supply system per the instructions supplied with the trolley.

The stops must be positioned so as to not exert impact force on the hoist frame or trolley wheels. They must contact the ends of the trolley side frames.

It is recommended that the trolley be mounted on the beam prior to attaching the hoist to the trolley. Before attempting to mount the trolley on the beam, measure the actual width of the beam flange on which the trolley is to operate. Using the measurement and Table 3, determine the arrangement of the spacer washers. Loosely assemble the side frames, load bracket, spacer washers and nuts on the suspension bolts as shown in Table 3.

Table 3. Series 635 Low Headroom Trolley Side Frame Spacing

Standard Load Bracket

3 7/16” Wide

“X”

Side Frame

Suspension Bolt

Load Bracket

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

Measure the actual beam flange on which the trolley is to operate and use Table 3 to determine the arrangement of the spacer wash-

ers for that flange width.

Suspenison Bolt Nuts

WARNING

TO AVOID INJURY:

1 Ton Capacity

Flange

Width

2 5/8 10 0 0 10

3 3/8 8 2 2 8 3 5/8 7 3 3 7

4 5/8 4 6 6 4

5 1/4 2 8 8 2 5 5/8 1 9 9 1

Flange

Width

6 1/4 5 6 6 4

No. of Spacers

A B C D

3 9 1 1 9

4 6 4 4 6

5 3 7 7 3

Standard Load Bracket

5 7/16” Wide

1 Ton Capacity

No. of Spacers

A B C D

6 6 5 5 5

7 2 9 9 1

*Dimension applies to minimum S-Beam and will vary with larger S-Beams..

Note: Due to the variations in beam flange widths, it is suggested that the beam flange width be measured to determine the exact distribution of spacer washers. The distance between trackwheel flanges (dimension “X”) should be 1/8 to 3/16 inch (3.18 to

4.77 mm) greater than the beam flange width for straight runway beams, and 3/16 to 1/4 inch (4.77 to

6.35 mm) greater than the beam flange width if runway system includes sharp curves. Also, the use of other than CM supplied washers may result in trackwheel to beam flange variations and thus Table 3 will not apply.

Standard Load Bracket

4 3/16” Wide

2 Ton Capacity

Flange

Width

3 3/8 8 0 0 8 3 5/8 7 1 1 7

4 5/8 4 4 4 4

5 1/4 3 5 6 2 5 5/8 2 6 7 1

Flange

Width

6 1/4 8 2 1 8

7 1/8 5 5 5 4 7 1/4 4 6 5 5 7 7/8 2 8 8 1

No. of Spacers

A B C D

4 6 2 2 6

5 3 5 5 3

6 0 8 8 0

Standard Load Bracket

6 11/16” Wide 2 Ton Capacity

No. of Spacers

A B C D

7 5 5 4 5

8 1 9 8 1

Standard Load Bracket

4 13/16” Wide 3 Ton Capacity

Flange

Width

4 5/8 5 3 3 4

5 1/4 3 5 5 2 5 5/8 3 5 6 1

Flange

Width

6 1/4 6 3 2 6

7 1/8 3 6 5 3

No. of Spacers

A B C D

4 6 1 1 7

5 4 4 4 3

Standard Load Bracket

3 7/16” Wide

1 Ton Capacity

No. of Spacers

A B C D

6 7 2 2 6

7 4 5 5 3

On the 3 ton (3000 kg) trolley (refer to Figure 11), drive one retaining pin into the hole on one end of the lug pin. Raise the hoist into position so that the lug is between the legs of the shackle. Align the holes in the shackle and lug. Insert the lug pin in the aligned holes and secure the lug pin by driving the remaining retaining pin into the hole in the lug pin. Make certain that the shackle pin is properly seating in the load bracket by manipluating the hoist and checking for freedom of movement (swinging) in both planes and all four directions.

Note that the shackle pin should be retained and centered in the shackle by the retainers.

On the 1/8 to 2-ton (125 to 2000 kg) trolleys, assemble the suspension lug on hoist to the trolley on beam as shown in Figure 10. The lug is inserted in the trolley load bracket and retained by the vertical load bar pin. A socket head cap screw and lockwasher are used to keep the in place.

For the 3-ton (3000 kg) trolley, a shackle and pin assembly consisting of a pin retained in a central position by retainers is packed loose with the suspension. Insert this assembly into the opening in the top of the load bracket with the legs of the shackle down. Position the shackle pin in the groove provided for the same in the load bracket making sure it is centered between the suspension bolts.

Now install the trolley on the beam by sliding one side frame out far enough to allow all the trackwheels to clear the beam flange. Lift the trolley up so that the trackwheels are riding on the beam, draw the side frames together and tighten the nuts snugly. Insert the cotter pins through the slotted nuts and holes in the supension bolts and spread the legs of the cotter pins to secure.

Figure 10. 1/8 to 2 Ton (125 to 2000 kg) Hoist to Trolley Assembly

Figure 11. 3 Ton (3000 kg) Hoist to Trolley Assembly

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 (1) horsepower motor (.75 Kilowatts), that a line with adequate capacity be run directly from the power supply to the hoist to prevent problems with low voltage and circuit overloads.

For grounding of the hoist, the power cord includes a gounding 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 correspo nding to the voltage range given on hoist identification plate is:

SINGLE SPEED UNITS TWO SPEED UNITS

Range Nominal Range Nominal

110-120 115 -- -208-240 230 208-240 230 440-480 460 440-480 460 550-575 575 550-575 575

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 380-350 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.

HIGH VOLTAGE (RED)

LOW VOLTAGE (WHITE)

Figure 12. Voltage Change Board

Figure 13. Location of Components

Voltage conversion board is located under back frame cover (1) for Models A-H and under motor housing cover (2) for Models J-RRT.

The voltage change board is color coded to indicate high and low voltage connections. Connecting the 9 and 12 pin plugs into the “Red” voltage change board receptacles 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 (208-360, 220-3-50 or 230-3-60) simply remove the 9 and 12 pin plugs from the “Red” receptacles and insert same into the “White” receptacles 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.

POWER 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 connecions 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 Grey lead and the Black lead of hoist 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.

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

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.

Do not allow the hook block to contact the bottom of the

hoist or the loose end chain to become taut.

CHECKING FOR TWIST IN LOAD CHAIN Models E,H, E-2, H-2,R, RR, R-2, RR-2

WARNING

TO AVOID INJURY:

WARNING

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

TO AVOID INJURY:

Permanently ground the hoist as instructed in this manual.

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 inverse-time type circuit breakers) and provisions for grounding the hoist.

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.

Models RT, RT-2, RRT and RRT-2

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

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.

MINIMUM

NOMINAL

VOLTAGE

115-1-60 104 98 230-1-60 207 196 230-3-60 187 460-3-60 396 -

575-3-60 495 -

220-3-50 198 380-3-50 365 415-3-50 399 -

550-3-50 495 -

RUNNING

VOLTAGE

MINIMUM STARTING

VOLTAGE

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.

SINGLE

LENGTH

EXTENSION

CORD

UP TO

50 FEET

80 FEET (24.4 M)

120 FEET

(36.7 M)

200 FEET

(61.0 M)

For runs beyond 200 Feet contact factory.

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

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

PHASE

HOISTS

MINIMUM

WIRE SIZE

#14 AWG

#12 AWG

#10 AWG

Contact Factory

WARNING

TO AVOID INJURY:

THREE PHASE

HOIST

MINIMUM

WIRE SIZE

#16 AWG

#14 AWG

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 components 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.

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.

WARNING

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

TO AVOID INJURY:

DISCONNECT POWER AND LOCKOUT/TAGOUT DISCONNECTING MEANS BEFORE REMOVING COVER OR

SERVICING THIS EQUIPMENT.

CHECKING LIMIT SWITCH OPERATION IF HOIST IS EQUIPPED

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.

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

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

1. Press top of hook block is about one foot (305 mm) 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 3 inches (76.2 mm) from bottom of the hoist on all units with standard 10 foot (3m) lift except Models AA and AA-2. Factory setting is 6 inches (152.4 mm) for these models and for all other models equipped with chain for lifts longer than 10 feet (3m).

3. If adjustment is necessary, see page 23.

4. Press  (DOWN) control and cautiously lower hook

until lower limit switch stops the downward motion From 7 to 11 chain links (depending on hoist model) should be between the loose end link and the hoist entry. See Figures 7 and 8.

5. If adjustment is necessary, see page 23.

NOTE: If the hoist is equipped with a chain container/bag, reset the upper and lower limit switches as indicated on page 23.

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.

CONTROL CORD

Unless ordered on a special basis, the hoist is supplied with a control cord that will position the control station approximately 4 feet above the lower hook when it is at the lower limit of the lift. If this places the control station too close to the floor, a “control cord alteration kit” (Part Number 28642) can be obtained from CM for shortening the length of the control cord.

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

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

WARNING

TO AVOID INJURY:

(UP) control and raise the lower hook until

WARNING

TO AVOID INJURY:

OPERATING INSTRUCTIONS

GENERAL

1. The Load-limiter is designed 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 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 Load-limiter 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 Load-limiter 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 3 concerning dumbwaiter applications.

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

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

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

HOIST

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

directly overhead.

2. WHEN APPLYING A LOAD, IT SHOULD BE DIRECTLY

UNDER HOIST OR TROLLEY. AVOID OFF CENTER LOADING OF ANY KIND.

3. Take up a slack load chain carefully and start load easily

to avoid shock and jerking of hoist load chain. If there is any evidence of overloading, immediately lower the load and remove the excess load.

4. DO NOT allow the load to swing or twist while hoisting.

5. DO NOT allow the load to bear against the hook latch.

(UP) control to stop the operation of

HOIST WITH LOW HEADROOM TROLLEY

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

HOIST WITH MOTOR DRIVEN TROLLEY

This unit should be moved by operating the controls marked  (Forward) and (Reverse) in control station. Unless altered by the erector, depressing (Forward) control will move the hoist toward motor housing end. Anticipate the stopping point and allow trolley to coast to a smooth stop. Reversing or “plugging” to stop trolley causes overheating of motor and swaying of load.

SAFE OPERATING INSTRUCTIONS AND PROCEDURES

For safety precautions and a list of Do’s and Do Not’s for safe operation of hoists, refer to page 3.

1. Permit only competent personnel to operate unit.

2. 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.

3. DO NOT allow the load to bear against the hook latch. The latch is to help maintain the hook in position while the chain is slack before taking up slack chain.

11. Take up a slack load chain carefully and start load 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.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.

13. DO NOT allow the load to swing or twist while hoisting.

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

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

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

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.

4. 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.

5. Before lifting load, check for twists in the load chain. On double and triple reeved units, a twist can occur if the lower hook block has been capsized between the strands of chain. Reverse the capsize to remove twist.

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

7. DO NOT leave the load suspended in the air unattended.

8. DO NOT use this or any other overhead materials handling

equipment for lifting persons.

9. DO NOT load hoist beyond the rated capacity shown on ID plate. When in doubt, use the next larger capacity CM Lodestar Hoist.

10.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.

WARNING

TO AVOID INJURY:

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 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 or constant exposure to the elements of nature.

Two classes of inspection - frequent and periodic - must be performed.

Frequent Inspections: These inspections are visual exami-

nations 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.

CAUTION: Any deficiencies found during inspections are to be corrected before the hoist is returned to service. Also, the external conditions may show the need for disasembly to permit a more detailed inspection, which, in turn, may require the use of nondestructive type testing

PREVENTATIVE 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 127).

HOOK INSPECTION

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

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.

LATCH TYPE HOOK (Upper and Lower) TO MEASURE OPENING,

MEASURE

OPENING

DEPRESS LATCH AGAINST HOOK BODY AS SHOWN.

Models

A, A-2, AA, AA-2, B, B-2, C, C-2, F AND F-2

E, E-2, H, H-2, J, J-2, JJ, JJ-2, L, L-2, LL AND LL-2 R, R-2, RR AND RR-2, RT, RT-2, RRT AND RRT-2

Figure 14. Hook Inspection

Replace Hooks When

Opening is Greater Than

1 3/16 (30.2 mm)

1 5/16 (33.3mm)

1 1/2 (38.1 mm)

“A” Max.

“B” Max.

Models

A, A-2, AA, AA-2, B, B-2, C, C-2, E, E-2, F, F-2, H, H-2, J, J-2, JJ, JJ-2, L, L-2, LL, LL-2

R, R-2, RR, RR-2

RT, RT-2, RRT AND RRT-2

LATCHLOK®HOOK

(Upper and Lower)

Replace Hook

When Opening or Seat are:

“A” Max. “B” Min.

1 31/64 in.

(37.7mm)

1 59/64 in.

(48.8mm)

2 1/2 in

(63.5mm)

21/32 in.

(16.7mm)

27/32 in.

(21.4mm)

1 1/8 in

(28.6mm)

TYPE OF SERVICE

Normal Heavy Severe

Monthly

Weekly

to Monthly

Daily

to Weekly

Table 4. Minimum Frequent Inspections

ITEM

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 18.

d) Load chain for adequate lubrication, as well as for signs of wear, damaged links or foreign matter - see page 20.

e) Load chain for proper reeving and twists.

Table 5. Minimum Periodic Inspections

TYPE OF SERVICE

Normal Heavy Severe

Yearly

Every 6 Months

Every 3 Months

ITEM

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 suspension 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 AC brake adjustment - see page 22.

g) External evidence of pitting or any deterioration of contactor contacts. Check the operation of the control station making sure the buttons operate freely and do not stick in either position.

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

i) Inspect trolley trackwheels for external wear on tread and flange and for wear on internal bearing surfaces as evidenced by a looseness on the stud. Suspension components for damage, cracks, wear and operation. Also check suspension adapter screws for proper tightness - see page 11.

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.

m) On the Models RT, RT-2, RRT and RRT-2:

1. Inspect shackle and lug pins for wear. Replace if worn.

2. Check dead end screw in lower hook black for wear and tighteness*.

3. Check shackle pin for proper seating in groove of load bracket.

4. Inspect cloverleaf plate on bottom of sheave hanger for wear or burring. Replace if worn.

5. Inspect sheave stud nut and seat for wear. Replace if worn or damaged.

*When tightening the special, dead end socket head screw, it should be held firmly in place and torqued from the nut end only to avoid damage to the screw and/or dead end chain link (Refer to step J on page 45).

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

Models

A thru H

A-2 thru H-2

J thru RRT

J-2 thru RRT-2

Dia. of

Chain Stock

0.250"

(6.35mm)

0.312"

(7.9mm)

No. of Links

to Gage

Max. Gage Length

Allowable Used Chain

14 13/16" (376 mm)

18 7/8"

(479 mm)

Figure 17. Chain Embossing

Use only Star (*) grade load chain and original replacement parts. Use of other chain and parts may be dangerous and voids factory warranty.

Figure 15. Chain Wear Areas

Gaging Load Chain Wear

To determine if load chain should be continued in service, check gage lengths as indicated in Figure 16. Chain worn beyond length indicated, nicked, gouged or twisted should be replaced before returning hoist to service. Chain should be clean, free of twists and pulled taut before measuring.

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

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

IMPORTANT:

Do not use replaced chain for other purposes such as lifting or pulling. Load chain may break suddenly without visual deformation. For this reason, cut replaced chain into short lengths to prevent use after disposal.

USE OF COMMERICAL OR OTHER MANUFACTURER’S CHAIN AND PARTS TO REPAIR CM HOISTS MAY CAUSE LOAD LOSS.

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

WARNING

TO AVOID INJURY:

Figure 16. Gaging Load Chain Wear

MAINTENANCE

LOAD-LIMITER

The Load-limiter should operate for the normal life of the hoist without service. The device has been calibrated at the factory for a specific model of hoist. For proper overload protection, be sure before installing a Load-limiter that it is correct for the unit.

Models

A,A-2,B,B-2, E, E-2

AA,AA-2, C, C-2, F, F-2,

H, H-2

J, J-2, L, L-2, R, R-2,

RT, RT-2

JJ. JJ-2, LL, LL-2, RR

RR-2, RRT, RRT-2

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

TO AVOID CONTACT AND CONTAMINATION:

Handle and dispose of lubricants only as directed

in applicable material safety data sheets and in accordance with applicable local, state and federal regulations.

HOIST LUBRICATION

Load-Limiter Part Number

00000240

00000241 241

00000242

00000243

WARNING

Load-Limiter ID

(marked on

Load-limiter)

240

242

243

CHAIN GUIDES, LIFTWHEEL AND 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

A small 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.

Used motor oils contain known carcinogenic materials.

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.

WARNING

TO AVOID HEALTH PROBLEMS:

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 on page 85. If desired, these lubricants may be purchased from CM. Refer to page 85 for information on ordering the lubricants.

The gearbox is packed at assembly with grease and should not need to be renewed unless the gears have been removed from the housing and degreased.

If the gears are removed from the housing, wipe the excess grease off with a soft cloth and degrease the gears and housings. Upon reassembly, add grease (see page 85) to gears and housing. V1 hoists require 8 fl. oz. of grease. V2 hoists require 15 fl. oz. of grease.

Also, coat the spline on the end of the drive shaft with a Molydisulphide lubricant such as “Super Herculon”.

• The limit switch gears are of molded nylon and require no lubrication.

• Apply a light film of machine oil to the limit switch shaft threads at least once a year.

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.

TROLLEY LUBRICATION

Low Headroom Trolley

• CM trackwheel bearings are pre-lubricated and require no lubrication.

EXTERIOR FINISH

The exterior surfaces of the hoist and trolleys have a durable, scratch resistant baked powder coating. Normally, the exterior surfaces can be cleaned by wiping with a cloth. However, if the finish is damaged, compatible touch-up paint can be purchased from CM. Refer to page138 for information on ordering the paint.

SOLID STATE REVERSE SWITCH

(115-1-60/230-1-60 Units Only)

Above an ambient temperature of 104°F. (40° C.), the frequency of hoist operation should be limited to avoid overheating the solid state reverse switch. Even at temperatures less than 104° F. (40° C.), high duty cycle, frequent starting or reversing, excessive inching, jogging or plugging may overheat the solid state reverse switch. Overheating the switch will cause it to malfunction, and this in turn will overheat the motor and/or damage the solid state reverse switch.

If allowed to cool, the solid state switch will return to normal operation. However, before returning the hoist to service, the following procedure should be used to determine if the switch has been damaged.

1. De-energize the power system supplying the hoist

and remove the solid state reverse switch.

2. Connect the solid state reverse switch to a 115-1-60/230-1-60 light circuit as shown below.

3. Close the switch to energize the 115-1-60/230-1-60 power supply. The light bulb will illuminate if the solid state reverse switch is not damaged. If the bulb fails to illuminate, the switch is damaged and must be replaced.

4. Turn the 115-1-60/230-1-60 power off and remove the solid state reverse switch from the test circuit.

Reinstall the solid state reverse switch in the hoist and re-connect it using the wiring diagram supplied with the hoist. Re-energize the power system supplying the hoist and test for proper operation. Also, ventilate the space around the hoist and/or reduce duty cycle, excessive starting, excessive plugging to reduce future malifunctions of the solid state reverse due to overheating.

JUMPER

Solid State Reverse Switch

Switch

115V, 25W Light Bulb

BRAKE ADJUSTMENTS

DC ELECTRIC BRAKE ASSEMBLY

The correct air gap between field and armature is .008-.018 in (0.2-0.45 mm) for models A through H and .008-,020 in (0.2-

0.5 mm) for models J through RRT. The DC brake is not adjustable. As the friction material wears, the brake gap increases. If the maximum air gap is reached, a new friction disc/rotor should be installed.

AC 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.

4. Turn adjusting nuts clockwise gaging the air gap at both ends.

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

Table 6a. Limit Switches

Hook Travel w/44TPI Shaft (Standard)

Model

A, A-2, C, C-2 63.1 207 53.1 2.09 38.1 1.50

AA, AA-2 118.3 388 99.6 3.92 50.8 2.00

B, B-2, F, F-2 32.1 105 27.0 1.06 38.1 1.50

E, E-2, H, H-2 16.0 53 13.5 0.53 44.5 1.75 L, L-2 38.8 127 30.4 1.20 38.1 1.50

JJ, JJ-2 149.0 489 116.8 4.60 63.5 2.50 J, J-2, LL, LL-2 75.9 249 59.5 2.34 38.1 1.50 8 R, R-2 19.4 64 15.2 0.60 63.5 2.50 8 RR, RR-2 37.9 124 29.7 1.17 63.5 2.50 8 RT, RT-2 12.9 42 10.1 0.40 63.5 2.50 8 RRT, RRT-2 25.3 83 19.8 0.78 63.5 2.50 8

Max Length of Lift Hook Travel, per Notch

m ft mm in mm in

A B

Links

6 8

Table 6b. Extended Lift Limit Switches

Hook Travel w/56TPI Shaft Hook Travel w/64TPI Shaft

Model

A, A-2, C, C-2 80.3 263 41.7 1.64 91.8 AA, AA-2 150.6 494 78.2 3.08 172.1

B, B-2, F, F-2 40.8 134 21.2 0.84 46.6 E, E-2. H. H-2 20.4 67 10.6 0.42 23.3 L, L-2 49.4 162 23.9 0.94 56.4 JJ, JJ-2 189.7 622 91.8 3.61 216.8 J, J-2, LL, LL-2 96.6 317 46.7 1.84 110.4 362 40.9 1.61

R, R-2 24.7 81 11.9 0.47 28.2 93 10.4 0.41 RR, RR-2 48.3 158 23.4 0.92 55.2 181 20.4 0.80 RT, RT-2 16.5 54 8.0 0.31 18.8 62 7.0 0.27 RRT, RRT-2 32.2 106 15.6 0.61 36.8 121 13.6 0.54

Max Length of Lift Hook Travel, per Notch Max Length of Lift Hook Travel, per Notch

m ft mm in m ft mm in

301 565

153

77 185 711

36.6 1.44

68.5 2.70

18.6 0.73

9.3 0.37

20.9 0.82

80.3 3.16

LIMIT SWITCH ADJUSTMENTS

If limit switch operation has been checked as described on page 16 and is not operating correctly or is not automatically stopping the hook at a desired position, proceed as follows:

1. Disconnect hoist from power supply.

2. Remove back frame cover, see Figure 13.

3. The identification of upper and lower limit switches

are indicated on the fiber insulator.

4. Loosen the 2 screws or spring back the rotatable

guide to disengage the travel nut

6. Reconnect hoist to power supply.

7. Run hooktothe desired upper position,cautiously operating the hoist without a load.

8. Disconnect hoist from power supply.

9. Moving one travel nut toward the other increases hook travel and away from the other decreases the travel. . Now, turn the nut nearest the switch indicated as the “ UPPER LIMIT SWITCH” until it just breaks the limit switch contacts, cautious not to allow the movement of the other travel nut, if previously set. An audible click will be heard as the switch opens.

Continue to rotate the nut toward the switch an additonal one full tooth.

3 2

Figure 18. Limit Switches, V1 Models

1. Limit switch sub-assy 4. Guide plate

2. Limit switch shaft 5. Screws

3. Travelling nuts

Figure 19. Limit Switches, V2 Models

1. Limit switch sub-assy 4. Guide plate

2. Limit switch shaft 5. Screws

3. Traveling nuts

Figure 18A. Rotatable Limit Switches, V1 Models

SETTING UPPER LIMIT SWITCH

After completing steps1 thru 4

5. Refer to table 6 -The "A" Dimensions given are the minimum distance that should be set between the top at hook block and the bottom of the hoist.

CAUTION: THE “A” DIMENSIONS SHOWN IN TABLE 6 ARE THE MINIMUM ALLOWED FOR SAFE OPERATION AND SHOULD NOT BE REDUCED.

Figure 19A. Rotatable Limit Switches, V2 Models

10.Securely reposition the guide plate in the slot

11.Reconnect hoist to power supply and check the stopping point of hook by first lowering the hook about 2 feet (61 cm), then raise the hook by jogging cautiously until the upper limit switch stops upward motion. The stopping point of hook should be the desired upper position. If not, repeat the above instructions.

12.Double check setting by lowering the hook about 2 feet (61 cm) and then run the hook into the upper limit with (UP) control held depressed.

13.Fine adjustment of the upper limit setting may be obtained by inverting the stationary guide plate in Step

10. (Not available with the rotatable guide plate.) The offset on the plate gives adjustments equivalent to1/2 notch, see Table 6 for the “Hook Travel Per Notch of Limit

Switch Nut”. When inverting the plate, it may be necessary to use the notch adjacent to the one used in the preliminary setting.

SETTING LOWER LIMIT SWITCH

After completing steps1 thru 4

5. Refer toTable 6 -The “B” dimensions given are the minimum length of loose end chain left on the load side of the lift wheel when the hook is positioned at the lowest allowable hook position.

CAUTION: THE “B” DIMENSIONS SHOWN IN TABLE 6 ARE THE MINIMUM ALLOWED FOR SAFE OPERATIONS AND SHOULD NOT BE REDUCED.

6. Reconnect hoist to power supply.

7. Run hook to the desired lower position, cautiously operating the hoist without a load.

CONVERTING LIMIT SWITCH GUIDES

1. Disconnect the hoist from the power supply system.

2. Refer to the exploded views and remove the back frame . cover from the hoist.

3. Remove and discard the limit switch guide plate - retaining the 2 screws.

4. Refer to Figure 18A and 19A and assemble the limit switch guide plate to the limit switch bracket. Secure using the 2 screws.

8. Disconnect hoist from power supply.

9. Moving one travel nut toward the other increases hook travel and away from the other decreases hook travel. Now, turn the nut nearest the switch indicated as the “LOWER LIMIT SWITCH” until it just breaks the limit switch contacts, cautious not to allow the movement of the other travel nut if previously set. An audible click will be heard as the switch opens.

Continue to rotate the nut toward the switch an additional one full tooth.

10.Securely reposition the guide plate in the slot.

11.Reconnect hoist to power supply and check the stopping point of hook by first raising the hook about 2 feet (61cm ) then lower the hook by jogging cautiously until the lower limit switch stops downward motion. The stopping point of the hook should be the desired lower position, if not repeat the above instructions.

12.Double check setting by raising the hook about 2 feet (61 cm) and then run the hook into the lower limit with (DOWN) control held depressed.

13. Fine adjustment of the lower limit setting may be

obtained by inverting the stationary guide plate in Step

10. (Not available with the rotatable guide plate). The plate offset on the plate gives adjustments equivalent to 1/2 notch, see Table 6 for the “Hook Travel per Notch of Limit Switch Nut”. When inverting the plate, it may be necessary to use the notch adjacent to the one used in the preliminary setting.

Table 7.

TROUBLE SHOOTING

All Hoists

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

1. Hook does not respond to the control station or control device

A.) No voltage at hoist-main line or branch circuit switch open; branch line fuse blown or circuit breaker tripped.

B.) Phase failure (single phasing, three phase unit only)-open circuit, grounded or faulty connection in one line of supply system, hoist wiring, reversing contactor, motor leads or windings.

C.) Upper or lower limit switch has opened the control circuit.

D.) Open control circuit-open or shorted winding in transformer, reversing contactor coil or loose connection or broken wire in circuit;mechanical binding in contactor control station contacts not closing or opening.

E.) Wrong voltage or frequency.

A.) Close switch, replace fuse or reset breaker.

B.) Check for electical continuity and repair or replace defective part.

C.) Press the “other” control and the hook should respond. Adjust limit switches as described on page 23.

D.) Check electrical continuity and repair or replace defective part.

E.) Use the voltage and frequency indicated on hoist identification plate. For three phase dual voltage unit, make sure the connections at the voltage change board are the proper voltage as described on page 14.

2.) Hook moves in wrong

direction.

3.) Hook lowers but will not

raise.

F.) Low Voltage.

G.) Brake not releasing-open or shorted coil winding; armature binding.

H.) Excessive load.

A.) Wiring connections reversed at either the control station or terminal board (single phase unit only).

B.) Failure of the motor reversing switch to effect dynamic braking at time of reversal (single phase unit only).

C.) Phase reversal (three phase unit only).

A.) Excessive load. A.) See item 1H.

B.) Open hoisting circuit-open or shorted winding in reversing contactor coil loose connection or broken wire in circuit; control station contacts not making; upper limit switch contacts open.

C.) Phase failure (three phase unit only). C.) See item 1B.

F.) Correct low voltage condition as described on page 14.

G.) Check electrical continutiy and connections. Check that correct coil has been installed. The coil for three phase dual voltage unit operates at 230 volts when the hoist is connected for either 230 volt or 460 volt operation. Check brake adjustment as described on page 22.

H.) Reduce loading to the capacity limit of hoist as indicated on the identifcation plate.

A.) Check connections with the wiring diagram.

B.) Check connections to switch. Replace a

damaged or faulty capacitor

C.) Refer to installation instructions on page 14

B.) Check electrical continuity and repair or replace defective part. Check operation of limit switch as described on page 16.

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

4.) Hook raises but will not lower.

Table 7 (cont.)

A.) Open lowering circuit-open or shorted winding in reversing contactor coil, loose connection or broken wire in circuit; control station contacts not making; lower limit switch contacts open.

A.) Check electrical continuity and repair or replace defective part. Check operation of limit switch as described on page 15-16.

5.) Hook lowers when hoisting control is operated.

6.) Hook does not stop promptly.

7.) Hoist operates sluggishly.

8.) Motor overheats.

B.) Motor reversing switch not operating (single phase unit only).

A.) Phase failure (three phase unit only). A.) See item 1B.

|B.) Phase reversal (three phase unit only). B.) Refer to installation instruction on page 14.

A.) Brake slipping.

B.) Excessive load. B.) See item 1H.

A.) Excessive load. A.) See item 1H.

B.) Low voltage. B.) Correct low voltage condition as described

C.) Phase failure or unbalanced current in the phases (three phase unit only).

D.) Brake dragging. D.) Check brake adjustment as described on

A.) Low voltage. A.) Correct low voltage condition as described

B.) Excessive load. B.) See item 1H. C.) Extreme external heating. C.) Above an ambient temperature of 40°C.

B.) See items 2B and 3C.

A.) Check brake adjustment as described on page 22.

on page 15.

C.) See item 1B.

page 22.

on page 15.

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

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

10.) Hook stopping point varies.

D.) Frequent starting or reversing. D.) Avoid excessive inching, jogging or

E.) Phase failure or unbalanced current in the phase (three phase unit only).

F.) Brake dragging.

G.) 115-1-60 Units: Solid state reverse switch exposed to excessive temperature or the switch is damaged.

A.) Limit switches not opening circuits. A.) Check switch connections, electrical

B.) Limit Switch Shaft not rotating. B.) Check for damaged Limit Switch gears.

C.) Traveling nuts not moving along shaft guide plate loose; shaft or nut threads damaged.

A.) Limit switch not holding adjustment. A.) See item 9.

B.) Brake not holding. B.) Check the brake adjustment as described

C.) Binding of Limit Switch Shaft. C.) Check Limit Switch Bearing for proper

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

E.) See item 1B.

F.) Check brake adjustment as described on page 22.

G.) See page 21.

continuity and mechanical operation. Check the switch adjustment as described on page 15-16.

C.) Tighten guide plate screws. Replace damaged part.

on page 22.

seating.

TROUBLE PROBABLE CAUSE CHECK AND REMEDY

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

12.) Hoist will not operate at

fast speed in either directio n.

13.) Hook will not raise at

slow speed.

14.) Hook will not lower at

slow speed.

15.) Hook will not raise at

fast speed.

16.) Hook will not lower at

fast speed.

17.) Hook moves in proper

direction at one speed wrong direction at other speed.

Table 7 (cont.)

Two Speed Hoist

A.) Open Circuit. A.) Open or shorted motor winding, loose or

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

B.) Phase Failure. B.) See item 1B.

A.) Open Circuit. A.) See Item 11A.

B.) Open speed selecting circuit. B.) Open or shorted winding in speed selecting

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

C.) Phase Failure. C.) See Item 1B.

A.) Excessive load. A.) See item 1H.

B.) Phase Failure. B.) See Item 1B.

C.) Open Circuit. C.) See item 11A.

D.) Brake not releasing. D.) See Item 1G.

A.) Phase Failure. A.) See item 1B.

B.) Open Circuit. B.) See item 11A.

C.) Brake not releasing. C.) See Item 1G.

A.) Excessive load. A.) See item 1H.

B.) Phase Failure. B.) See Item 1B.

C.) Brake not releasing. C.) See Item 1G.

A.) Phase Failure. A.) See Item 1B.

B.) Brake not releasing. B.) See Item 1G.

A.) Phase reversal. A.) Wiring reconnected improperly. Interchange

two leads of motor winding that is out of phase at the speed selecting relay.

ELECTRICAL DATA

TO DETECT OPEN AND SHORT CIRCUITS IN ELECRICAL COMPONENTS

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

Shorted turns are indicated by a current draw substantially above normal (connect ammeter in series with suspected element and impose normal voltage) or D.C. resistance substantially below normal. The current method is recommend for coils with very low D.C. resistance.

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

Table 8. Electrical Data for Hoist Components

TRANSFORMER

VOLTAGE

230/460 to 115

230/380 to 48

220/415 to 24

575 to 115

MODELS

A thru H-2

JJ thru RRT-2

SPEED SELECTOR

LEADS

X2 to X1 H2 to H1 H3 to H4

X2 to X1 H4 to H1

CONTACTOR OR

COIL VOLTAGE

115

48 24

115

48 24

NOMINAL

CURRENT

(AMPS)

0.04

0.09

0.19

0.07

0.17

0.33

*D.C.

RESISTANCE

(OHMS)

27.9

99.0

111.8

5.2

99.0

112.6

1.3

100.4

114.9

28.4

329.1

*D.C.

RESISTANCE

(OHMS)

297.5

56.3

14.9

126.6

25.1

6.4

MODELS

A, AA, B, C, E

F and H

A thru H-2 **230 .17 23.1

A-2 thru H-2 460 .20 92.3

A, A-2, AA, AA-2, B,

B-2, C, C-2, E, E-2, F,

F-2, H, H-2

J, L, R, RT 115 1.25 1.1

J, J-2, L, L-2, LL-2, R,

R-2, RT, RT-2

JJ, JJ-2, LL, LL-2,

RR, RR-2, RRT,

RRT-2

J-2, L-2, R-2, RT-2 460 .25 18.7

JJ-2, LL-2, RR-2,

RRT-2

J, J-2, L, L-2, LL-2, R,

R-2, RT, RT-2

JJ, JJ-2, LL, LL-2,

RR, RR-2, RRT,

RRT-2

AC BRAKE

COIL

VOLTAGE

115 .51 5.8

575 .14 140.0

**230 .46 4.6

**230 1.7 2.2

460 1.5 8.9

575 .50 38.5

575 1.70 14.2

NOMINAL

CURRENT

(AMPS)

RESISTANCE

(OHMS)

*D.C.

MODELS

A, AA, B, C, E

F and H

A thru H-2 205 0.122 1681

A-2 thru H-2 255 0.098 2601

J, JJ, L, LL, R, RR,

RT, RRT

J thru RRT-2 205 0.161 1273

J thru RRT-2 255 0.118 2167

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

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

DC BRAKE

COIL

VOLTAGE

103 0.243 424.4

103 0.311 331.5

NOMINAL CURRENT

(AMPS)

*D.C.

RESISTANCE

(OHMS)

Volts-

Models

A,B,E 110-1-50

A,B,E 115-1-60

A,B,E 220-1-50

A,B,E 230-1-60

AA,C,F,H 110-1-50

AA,C,F,H 115-1-60

A,B,E 220-1-50

A,B,E 230-1-60

A,B,E

AA,C,F,H

A-2, B-2,

E-2

A-2, AA-2,

B-2, C-2, E-2, F-2,

H-2

Phase

Hertz

230/460-3-60

220/380-3-50 1.4/0.7

220/415-3-50 1.4/0.7

575-3-60 0.5

550-3-50 0.6

230/460-3-60

220/380-3-50 2.1/1.0

220/415-3-50 2.1/1.0

575-3-60 0.8

550-3-50 0.9

230-3-60

220-3-50 1.9/2.1

230-3-60

220-3-50 2.1/2.4

460-3-60 1.0/1.0

380-3-50 1.2/1.2

415-3-50 1.2/1.2

575-3-60 .8/.85

550-3-50 .8/.85

H.P.

(kW)

1/4

(.19)

1/4

(.19)

1/4

(.19)

1/4

(.19)

1/2

(.37)

1/2

(.37)

1/2

(.37)

1/2

(.37)

1/4

(.19

1/2

(.37)

.08/.25

(.06/.19)

.15/.5

(.12/.37)

Full Load

Current (Amps)

3.2

4.6

1.6

2.3

6.4

7.2

3.2

3.6

1.4/0.7

1.8/0.9

1.6/1.6

1.8/2.0

Leads

1 - 2 3 - 4 5 - 8 1 - 2 3 - 4 5 - 8

1 - 2 3 - 4 5 - 8 1 - 2 3 - 4 5 - 8 1 - 2 3 - 4 5 - 8 1 - 2 3 - 4 5 - 8 1 - 2 3 - 4 5 - 8 1 - 2 3 - 4 5 - 8

3 - 6 2 - 5 1 - 4

8 - 9 8 - 7 9 - 7

1 - 2 2 - 3 1 - 3

3 - 6 2 - 5 1 - 4

8 - 9 8 - 7 9 - 7

1 - 2 2 - 3 1 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

Table 8. (cont.)

*D.C.

Resistance

(Ohms)

7.2

5.8

4.3

4.9

7.2

5.8

4.3

4.9

2.7

3.5

1.9

3.6

2.7

3.5

1.9

3.6

14.8

29.5

98.2

7.8

15.6

48.3

17.5

42.5

13.5

25.0

63.0

104.0

99.1

156.0

Models

J,L,R,RT

JJ,LL,RR,

RRT

J-2,L-2,R-2,

RT-2

J-2,L-2,R-2,

RT-2

VoltsPhase

Hertz

110-1-50

115-1-60 9.8

220-1-50

230-1-60 4.9

230/460-3-60

220/380-3-50 3.6/1.8

220/415-3-50 3.6/1.8

575-3-60

550-3-50 1.8

230/460-3-60

220/380-3-50 6.4/3.3

220/415-3-50

575-3-60

550-3-50

230-3-60

220-3-50 3.2/4.7

460-3-60 1.5/2.4

380-3-50 1.6/2.4

415-3-50 1.6/2.4

575-3-60 1.1/1.9

550-3-50 1.3/2.1

230-3-60

220-3-50 6.6/9.5

460-3-60 3.3/5.1

380-3-50 3.0/5.0

415-3-60 3.0/5.0

575-3-60 2.3/3.5

550-3-50 2.5/3.7

(.25/.75)

(.50/1.5)

H.P.

(kW)

(.75)

(1.5)

.33/1

.67/2

Full Load

Current (Amps)

11.6 1 - 2

5.8

3.0/1.5

1.5

5.8/2.9

6.4/3.3

3.2

3.5

3.4/5.0

5.8/8.8

Leads

3 - 4 5 - 8

1 - 2 3 - 4 5 - 8

3 - 6 2 - 5 1 - 4 8 - 9 8 - 7 9 - 7

1 - 2 2 - 3 1 - 3

3 - 6 2 - 5 1 - 4 8 - 9 8 - 7 9 - 7

1 - 2 2 - 3 1 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

12 - 3 11 - 3

11 - 12

1 - 2 1 - 3 2 - 3

*D.C.

Resistance

(Ohms)

1.1

1.3

1.1

1.3

4.7

9.4

29.6

2.2

9.4

14.8

7.7

19.4

29.9

29.4

29.0

80.2

80.1

82.2

42.9

40.1

53.2

125.7

125.8

125.2

3.2

3.1

3.3

14.1

14.0

11.4

11.3

55.2

55.4

55.3

17.0

17.1

17.2

84.1

84.0

83.6

REFERENCE WIRING DIAGRAMS

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