CM 635 Series User manual

perating, Maintenance
& Parts Manual
CCaappaacciittiieess
11//88 -- 22 aanndd 33--TToonnss
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tr ro ol ll le ey y. .
The use of any hoist and trolley presents some risk of
personal injury or property damage. That risk is great-
ly increased if proper instructions and warnings are
not followed. Before using this trolley, 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.
MMooddeell NNuummbbeerr________________________________________________________________________________
SSeerriiaall NNuummbbeerr________________________________________________________________________________
PPuurrcchhaassee DDaattee________________________________________________________________________________
VVoollttaaggee____________________________________________________________________________________________
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MMoottoorr DDrriivveenn TTrroolllleeyy
M t r Driven Tr lley
83875 Manual o. 635-J
COLUMBUS McKI O CORPORATIO
I DUSTRIAL PRODUCTS DIVISIO
140 JOH JAMES AUDUBO PARKWAY
AMHERST, EW YORK 14228-1197
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

i
CM H IST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
As a CM Hoist user, you are assured of reliable repair and parts services through a network of Master Parts Depots and
Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the
basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.
Below is a list of the Master Parts Depots in the United States and Canada. To quickly obtain the name of the U.S. Service
Center located nearest you, call [phone]. Fax: [phone]. n the following list, the Canadian Service Centers are
indicated.
UNI ED S A ES MAS ER PAR S DEPO CANADIAN SERVICE CEN ERS
CALIFORNIA
OTTO SYSTEMS, I C.
12010 Bloomfield Ave.
Sante Fe Springs, CA 90670
562/462-1612 or 800/596-7392
Fax [phone]
or
7656 Las Positas Road
Livemore, CA 94551
925/245-8800
Fax [phone]
GEORGIA
ACE I DUSTRIES, I C.
6295 McDonough Drive
orcross, GA 30093
770/441-0898 or 800/733-2231
Fax [phone]
INDIANA
HOR ER ELECTRIC COMPA Y, I C.
1521 East Washington Street
Indianapolis, I 46201
317/639-4261
Fax [phone]
IOWA
VMI HOIST & CRA E SERVICES
901 17th Street E
Cedar Rapids, IA 52406
319/365-4662
Fax [phone]
KANSAS
I DEPE DE T ELECTRIC MACHI ERY
4425 Oliver Street
Kansas City, KS 66106
913/362-1155
Fax [phone]
LOUISIANA
BEERMA PRECISIO , I C.
4206 Howard Ave.
ew Orleans, LA 70125
504/486-9391
Fax [phone]
MASSACHUSETTS
ABEL DISTRIBUTORS, I C.
50 Parker Street, Unit 2
ewburyport, MA 01950
978/463-0700
Fax [phone]
NEW JERSEY
SHUPPER-BRICKLE EQUIPME T CO.
2394 Route 130, Suite C
Dayton, J 08810
732/438-3888
Fax [phone]
NEW YORK
VOLLA D ELECTRIC EQUIPME T CO.
75 Innsbruck Drive
Buffalo, Y 14227
716/656-9900
Fax [phone]
NORTH CAROLINA
TEAM SESCO
2225 Freedom Drive
Charlotte, C 28208
704/372-4832 or 800/487-3726
Fax [phone]
OHIO
MAZZELLA LIFTI G TECH OLOGIES
21000 Aerospace Parkway
Cleveland, OH 44142
440/239-5700 or 800/362-4601
Fax [phone]
PENNSYLVANIA
AMICK ASSOCIATES, I C.
11 Sycamore Street
Carnegie, PA 15106-0529
412/429-1212 or 800/445-9456
Fax [phone]
RAM MOTORS & CO TROLS, I C.
5460-B Pottsville Pike
Leesport, PA 19533
610/916-8000 or 877/916-8018
Fax [phone]
TEXAS
ABEL EQUIPME T CO., I C.
3710 Cavalier Drive
Garland, TX 75042
972/272-7706
Fax [phone]
HYDRAULIC EQUIPME T SERVICES, I C.
1021 orth San Jacinto Street
Houston, TX 77002
713/228-9601
Fax [phone]
WISCONSIN
TRESTER HOIST & EQUIPME T, I C.
W136 4863 Campbell Drive
Menomonee Falls, WI 53051
262/790-0700 or 800/234-6098
Fax [phone]
ALBERTA
BE ETT & EMMOTT, LTD.
18131 118th Avenue
Edmonton, Alberta T5S 1M8
403/454-9000
Fax [phone]
**COLUMBUS McKI O , LTD.
10311-174th Street
Edmonton, Alberta T5S 1H1
800/263-1997
Fax [phone]
BRITISH COLUMBIA
FLECK BROTHERS, LTD.
4084 McConnel Court
Burnaby, British Columbia V5A 3 7
MANITOBA
KI G’S ELECTRIC MOTORS, I C.
633 Tyne Avenue
Winnipeg, Manitoba R2L 1J5
204/663-5332
Fax [phone]
NOVA SCOTIA
*W & A MOIR
95 Ilsley Ave.
Burnside Park, ova Scotia B3B 1L5
902/468-7720
Fax [phone]
ONTARIO
*R & W HOIST REPAIR, LTD.
790 Redwood Square
Units 5, 6, & 7
Oakville, Ontario L6L 6 3
905/825-5500
Fax [phone]
*TORO TO ELECTRIC HOIST
SALES & SERVICE
9 CoDeco Court
orth York, Ontario M3A 1A1
416/386-0820
Fax [phone]
*MASLACK SUPPLY, LTD.
488 Falconbridge Road
Sudbury, Ontario P3A 4S4
705/566-1270
Fax [phone]
*COLUMBUS McKI O , LTD.
P.O. Box 1106
10 Brook Road, orth
Cobourg, Ontario K9A 4W5
905/372-0153
Fax [phone]
QUEBEC
*HERCULES SLI G & CABLE
3800 TransCanada Highway
Pointe-Claire, Quebec H9R 1B1
514/428-5511
514/48631-5511
Fax [phone]
*LEGER PALA S ET OUTILLAGES, I C.
7995-17th Ave.
Montreal, Quebec H1Z 3R2
514/376-3050
Fax [phone]
**ARE ALSO MASTER PARTS DEPOTS
**MASTER PARTS DEPOT O LY
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

SAFETY PRECAUTI NS
Each Series 635 Motor Driven Trolley is built in accordance with the specifications contained herein and at the time of manufac-
ture complied with our interpretation of applicable sections of the *American Society of Mechanical Engineers Code B30.11
“Monorail Systems and Underhung Cranes,” the National Electrical Code (ANS /NFPA 70) and the Occupational Safety and
Health Act. Since OSHA states the National Electrical Code applies to all electrical installations and utilization equipment,
installers are required to provide current overload protection and grounding in keeping with the code. Check each installation for
compliance with the application, operation and maintenance sections of these articles.
After you have completely familiarized yourself with the contents of this manual, we recommend that you carefully file it for future
reference.
*Copies of this standard can be obtained from ASME Order Department, 22 Law Drive, Box 2300, Fairfield, J 07007-2300, U.S.A.
ii
1. mmediately after installation, operate trolley (according
to the Operating and Safety Procedures as follows) with a
capacity load over the entire length of runway or monorail
system to be sure that all adjustments and operations are
satisfactory.
2. Rail stops must be installed for all trolleys operating on
open end beams. These stops must be positioned such
that impact forces are absorbed by the trolley side
frames only.
3. When preparing to lift a load, be sure that the attach-
ments to the hook are firmly seated in hook saddle. Avoid
off-center loading of any kind, especially loading on the
point of hook.
4. When lifting, raise the load only enough to clear the floor
or support and check to be sure that the attachments to
hook and load are firmly seated. Continue lift only after
you are assured the load is free of all obstructions.
5. When applying a load, it should be directly under the
trolley. Avoid off-center loading of any kind.
6. Take up a slack load chain carefully and start lifting load
slowly to avoid shock and jerking of hoist load chain. f
there is any evidence of overloading, immediately lower
the load and remove the excess load.
7. DO OT allow the load to swing or twist while hoisting.
8. 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.
9. DO OT load trolley beyond the rated capacity.
Overload can cause immediate failure of load carrying
parts or cause damage resulting in future failure at less
than rated capacity.
10. DO OT use this or any other overhead materials han-
dling equipment for lifting or transporting people.
11.Stand clear of all loads and avoid moving a load over the
heads of other people. Warn people of your intention to
move a load in their area.
12. DO OT leave the load suspended in the air unattended.
13. DO OT wrap the load chain around the load and hook
onto itself as a choker chain.
Doing this will result in the following:
(a) Operation of the upper limit switch is bypassed and
the load could hit the hoist.
(b) The loss of the swivel effect of the hook which could
mean twisted chain and a jammed liftwheel.
(c) The chain could be damaged at the hook.
14.Permit only qualified personnel to operate unit.
!
WARNING
Improper operation of a trolley can create a potentially
hazardous situation which, if not avoided, could result in
death or serious injury. To avoid such a potentially hazardous
situation, the operator shall follow these operating and safety
procedures.
L
!
PERATING AND SAFETY PR CEDURES
The following are operating and safety procedures for safe operation of the Series 635 Motor Driven Trolley. Taking precedence
over any specific rules listed here, however, is the most important rule of all, USE COMMON SENSE. A few minutes spent reading
these rules can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety
of others. Frequent examinations and periodic inspections of the equipment as well as a conscientious observance of safety rules
may save lives as well as time and money.
L
!
LL
!!
THIS SYMBOL POI TS OUT IMPORTA T SAFETY I STRUCTIO S WHICH IF OT FOLLOWED
COULD E DA GER THE PERSO AL SAFETY A D/OR PROPERTY OF YOURSELF A D OTHERS.
READ A D FOLLOW ALL I STRUCTIO S I THIS MA UAL A D A Y PROVIDED WITH THE
EQUIPME T BEFORE ATTEMPTI G TO OPERATE YOUR SERIES 635 MOTOR DRIVE TROLLEY.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

iii
N TES
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

1
F REW RD
This manual contains important information to help you properly install, operate and maintain the Series 635 Motor Driven Trolley
for maximum performance, economy and safety.
Please study its contents thoroughly before putting your trolley 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.
TABLE F C NTENTS
PAGE
SAFETY PRECAUTIO S
Operating and Safety Procedures . . . . . . . . . . . . . . . . . .ii
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GE ERAL I FORMATIO
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CM Repair/Replacement Policy . . . . . . . . . . . . . . . . . . . .2
I STALLATIO
Unpacking nformation . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Trolley to Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Hoist to Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Electrical nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Trolley Motor Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trolley Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hoist Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hoist Control Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Three-Phase Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATI G I STRUCTIO S
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
I SPECTIO
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
MAI TE A CE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Motor Brake (Optional Equipment) . . . . . . . . . . . . . . . . . .7
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Replacement of Friction Disc . . . . . . . . . . . . . . . . . . .7
Replacement of Coils . . . . . . . . . . . . . . . . . . . . . . . . .7
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . .8
TROUBLESHOOTI G
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cause and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
REPLACEME T PARTS
Ordering nstructions . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Control Stations and Parts List . . . . . . . . . . . . . . . . . . . .12
Trolley Components and Parts List . . . . . . . . . . . . . . . . .13
Control Box Components and Parts List . . . . . . . . . .14-15
Motor and Gear Reducer
Components and Parts List . . . . . . . . . . . . . . . . . . .17
Motor Brake
Components and Parts List . . . . . . . . . . . . . . . . . . .18
LIST F TABLES
TABLE PAGE
1Series 635 Trolley Specifications . . . . . . . . . . . . . . . . . . .2
2Washer Spacing Charts . . . . . . . . . . . . . . . . . . . . . . . . . .3
3Electrical Data for Trolley Components . . . . . . . . . . . . . .8
LIST F ILLUSTRATI NS
FIGURE PAGE
1Trolley to Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2Hoist to Trolley (1/8 – 2-Ton) Assembly . . . . . . . . . . . . . .4
3Hoist to Trolley (3-Ton) Assembly . . . . . . . . . . . . . . . . . . .4
4Hoist and Trolley – General Arrangement . . . . . . . . . . . .4
5Hoist Power Cord Connections – Single-Phase . . . . . . . .5
6Hoist Power Cord Connections – Three-Phase . . . . . . . .5
7Connections for Proper Trolley and Hook Travel . . . . . . .6
8Motor Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .7
9Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
10 Trolley Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
11 Control Stations Exploded Views . . . . . . . . . . . . . . . . . .12
12 Trolley Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . .13
13 Control Box Exploded View . . . . . . . . . . . . . . . . . . . . . .14
14 Motor and Hub City Type
Gear Reducer Exploded View . . . . . . . . . . . . . . . . . . . .16
15 Motor and Peerless-Winsmith Type
Gear Reducer Exploded View . . . . . . . . . . . . . . . . . . . .17
16 Motor Brake Exploded View . . . . . . . . . . . . . . . . . . . . . .18
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

2
GENERAL INF RMATI N
SPECIFICATI NS
The Series 635 Motor Driven Trolleys are designed for use
with the Lodestar, and Valustar Electric Chain Hoists. The trol-
leys are available in two capacities: 1/8 through 2-Tons and
3-Tons. These trolleys are similar except for the sizes of the
load carrying members.
The trolleys have rugged steel side plates, hardened steel
axles, steel suspension bolts, cast iron load bracket from
which the hoist is suspended and hardened cast iron wheels
that are suitable for operation on sloped or flat flanged
beams. Hardened steel gears are attached to two track-
wheels and driven by a right angle worm gear reducer. The
worm and gear of the gear reducer operate in an oil bath.
A weatherproof motor drives the gear reducer.
The control box contains a reversing contactor, terminal
boards and a transformer (as required). A four-button control
station is suspended from the control box. An electric brake,
which fits between the motor and gear reducer, is available
as optional equipment.
Table 1 provides the general specifications for the trolley. t
should be noted that the table indicates that the standard travel
speed is 75 FPM. However, other travel speeds are available.
CM REPAIR/REPLACEMENT P LICY
All Columbus McKinnon (CM) Series 635 Motor Driven
Trolleys are inspected and performance tested prior to ship-
ment. f any properly maintained Series 635 Motor Driven
Trolley develops a performance problem, within 1 (one) year
of shipment, due to a material or workmanship defect, as ver-
ified by CM, repair or replacement of the unit will be made to
the original purchaser without charge. This
repair/replacement policy applies only to Series 635 Motor
Driven Trolleys installed, maintained and operated as out-
lined 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 replace-
ment 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.
INSTALLATI N
UNPACKING INF RMATI N
After removing the trolley from the shipping carton, carefully
inspect the external condition of the cords, control box, gear
reducer, motor brake (if equipped with same) and motor for
damage that may have occurred during shipment and han-
dling. Check to make sure all parts (trolley side frame assem-
bly with control box, trolley side frame with gear reducer and
motor, load bracket, suspension bolts, spacer washer, cotter
pins and nuts) are furnished. Also, before attempting to
install the trolley, make sure that the power supply indicated
on the labels attached to the control box is the same as the
power supply on which the unit is to operate.
INSTALLATI N
The hoist, trolley and lug suspension for suspending the hoist
from the trolley are packed separately. Assemble the lug sus-
pension to the hoist according to the instructions furnished
with the suspension and/or the instructions in the manual fur-
nished with the hoist.
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.
Trolley to Beam
t 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
this measurement, determine the arrangement of the spac-
er washers using Figure 1 and Table 2. Chart A of Table 2
shows the washer arrangement for the 1/8 – 2-Ton trolley,
while Chart B provides data for the 3-Ton trolley. Loosely
assemble the side frames, load bracket, spacer washers
and nuts on the suspension bolts as shown in Figure 1.
WARNING
Operating the trolley on a beam that has no rail stops may
allow the trolley to fall off the end of beam.
T AV ID INJURY:
Install rail stops at each end of the beam on which the trolley
is to operate.
Series 635 Motor Driven Trolley Specifications
FOR USE RAVEL AADDJJUUSSTTMMEENNTT FFOORR SSTTDD.. SS BBEEAAMMSSMINIMUM APPROX.
DC CAPACI Y WI H POWER SPEED MO OR DEP H FLANGE RADIUS SHIPPING
CODE CODE ( ONS) MODELS SUPPLY* (FPM) H.P. (IN.) WID H (IN.) CURVE (IN.) WEIGH
3670 63670 1/8 A 115-1-60 6 3-3/8 103
3671 63671 to thru 230-3-60 75 1/4 thru thru 30 112
3672 63672 2 RR 460-3-60 15 5-5/8 112
9577 69577 115-1-60 64 130
9578 69578 3 RT-RRT 230-3-60 75 1/4 thru thru 30 130
9579 69579 460-3-60 15 5-5/8 130
Table 1
*Trolleys are also available for operation on 573-3-60 and 220/380-3-50 power supply systems.
LL
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For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

For the 3-Ton trolley, (refer to Figure 3), a shackle and pin
assembly (627-729) consisting of a pin retained in a central
position by retainers is packed loose with the suspension.
nsert this assembly into the opening in the top of the load
bracket (635-13) with the legs of the shackle down. Position
the shackle pin in the groove provided for same in the load
bracket making sure it is centered between the suspension
bolts.
Now install the trolley (1/8 – 2-Ton or 3-Ton) on the beam by
sliding one side frame out far enough to allow the trackwheels
to clear the beam flange. Lift the trolley up so that the track-
wheels are riding on the beam and draw the side frames
together and tighten the nuts snugly. Do not overtighten the
nuts. nsert the cotter pins through the slotted nuts and holes
in the suspension bolts and spread the legs of the cotter pins
to secure.
IMPORTANT: After the trolley is installed on the beam,
remove the hex socket lug from the to of the gear
reducer and re lace same with the breather acked
loose with the trolley or remove the small brass nail
rojecting from the side of the gear reducer. This ro-
vides a vent for the gear reducer and failure to install
the breather may cause the seals to leak.
WARNING
If CM’s washer spacing recommendations are not followed,
trolley may fall from beam.
T AV ID INJURY:
Measure the actual beam flange on which the trolley is to
operate and use Table 2 to determine the arrangement of the
spacer washers for that flange width.
3
Washer Spacing Chart
Table 2
Chart B. 3-Ton Trolley
Standard Bracket (4-13/16" Wide)
Flange NNUUMMBBEERR OOFF SSPPAACCEERR WWAASSHHEERRSS
Width (in.) ABCD
4 13 140
4-5/8 9360
5 7470
5-1/4 5580
5-1/2 4590
5-5/8 3690
Special Load Bracket (6-7/16" Wide)
Flange NNUUMMBBEERR OOFF SSPPAACCEERR WWAASSHHEERRSS
Width (in.) ABCD
5-5/8 13 140
6 11 250
6-1/4 9360
6-3/8 8460
7 4590
7-1/4 3690
Special Load Bracket (6-7/16" Wide)
Flange NNUUMMBBEERR OOFF SSPPAACCEERR WWAASSHHEERRSS
Width (in.) ABCD
7-1/2” 13 140
7-7/8” 11 250
8-1/8” 9360
8 1/4” 8460
8-7/8” 4590
9-1/8” 3690
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Chart A. 1/8 – 2-Ton Trolley
Standard Bracket (4-3/16" Wide)
Flange NNUUMMBBEERR OOFF SSPPAACCEERR WWAASSHHEERRSS
Width (in.) ABCD
3-3/8 14 250
3-5/8 12 360
3-7/8 11 370
4 10 470
4-1/8 9480
4-5/8 6690
54710 0
5-1/8 3711 0
5-1/4 2811 0
5-1/2 1812 0
5-5/8 0912 0
Special Load Bracket (6-11/16" Wide)
Flange NNUUMMBBEERR OOFF SSPPAACCEERR WWAASSHHEERRSS
Width (in.) ABCD
5-5/8” 16 140
6” 14 250
6-1/4” 13 250
6-3/8” 12 360
6-1/2” 11 370
6-7/8” 9480
7” 8580
7-1/4” 7490
7-3/8” 6590
7-1/2” 5610 0
7-7/8” 3810 0
8” 2811 0
8-1/4” 1911 0
8-3/8” 0912 0
Figure 1. Trolley to Beam Installation
D
C
B
ALOAD
BRACKET
WIDTH
X
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 greater than the beam flange width for straight
runway beams, and 3/16 to 1/4 inch 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 2 will
not apply.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Hoist to Trolley
On the 1/8 – 2-Ton trolley, assemble the suspension lug (on
hoist) to the trolley (on beam) as shown in Figure 2. The lug
is inserted in the trolley load bracket and retained by the sus-
pension lug pin. A socket head cap screw and lockwasher
are used to keep the pin in place. This assembly must be
made with the hoist mounted parallel to the beam and the
control cord to the right when facing the trolley control box.
Figure 2. 1/8 – 2-Ton Hoist to Trolley Assembly
On the 3-Ton trolley, drive one retaining pin into the hole on
one end of the lug pin (627-730). Raise the hoist into position
so that the lug (627-728) is between the legs of the shackle.
Align the holes in the shackle and lug. nsert 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 (627-729) is properly seated in the load bracket
by manipulating the hoist and checking for freedom of move-
ment (swinging) in both planes and all four
directions.
Figure 3. 3-Ton Hoist to Trolley Assembly
ote that the shackle pin should be retained and centered in the shackle
with retainers.
Figure 4. Hoist and Trolley General Arrangement
Electrical Installation
The trolley electrical connections must be completed as
shown in Figure 4. Power to the trolley and hoist should be
furnished from a compatible source through a disconnect
device. Overcurrent protection and proper grounding means
should be accomplished in accordance with the “National
Electrical Code” and local codes if applicable. Power should
be disconnected when making or changing connections.
A Field Wiring Kit 635-198 (part number 36666 for units with
4-button control station) is furnished containing the neces-
sary material to complete the trolley electrical connections.
Diagrams show connections to be made within trolley control
box for standard units. For special units, see wiring diagram
supplied with unit.
Trolley Motor Cord
nsert Trolley Motor Cord into control box (see Figure 4).
Connections for the Trolley Motor Cord are shown in Figures
5 and 6. The cord should be brought over the top of the hoist
and clamped to the control box mounting bracket (see
Figure 4). The cord between the motor and clamp must be
tight enough to prevent it from rubbing against the beam.
Trolley Power Cord
The short power cord furnished is for use with a collector and
bus system. t should be discarded if a cable is to supply the
trolley. Terminals for use on the trolley end of the supply
cable are furnished in the Field Wiring Kit. Connections to the
trolley are shown in Figures 5 and 6. The box connector must
be made tight on the cable, and if necessary, a separate
strain relief provided to prevent any stress on the terminals.
4
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Shackle Pin
Retainers
627-729
Shackle
Assembly
627-728
Lug
627-730
Lug Pin
Trolley
Power
Trolley Motor
Cord
Short Hoist
Power Cord
Short Hoist
Control Cord
Bridge
Control
Cord (6 Button
Station Only)
CM Type 4
Directional
Control Station
4 or 6 Button
Control Station
WARNING
An excessively worn beam flange may fail and allow the
trolley to fall from the beam.
T AV ID INJURY:
Periodically inspect the beam flange for wear. Replace beam if
flange is worn.
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Suspension Lug
on Hoist
Hoist
Suspension
Lug Pin
Load Bracket
on Trolley
Trolley
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Hoist Power Cord
The trolley is supplied with a short hoist power cord connect-
ed into the power circuit of the trolley – refer to Figure 4. As a
result, it is necessary to remove the power cord (if supplied –
see note on page 6) from the hoist. To do this, remove the
back frame cover (Lodestar and Valustar Hoists) from the
hoist and remove and discard the power cord from the hoist.
Then connect the short hoist power cord attached to the trol-
ley to the hoist power circuit according to the wiring diagram
furnished with the hoist. The trolley is also supplied with a
short hoist control cord, and it should be connected to the
hoist control circuit, as indicated below (see Hoist Control
Cord) before the back frame cover (Lodestar and Valustar
Hoists) is reassembled to the hoist frame.
Control Station
The standard trolleys for use with Lodestar and Valustar
Hoists are supplied with a four directional control station.
Unless ordered special, the control station is suspended
from the trolley control box by a cord that is approximately
16' – 3" long. f this is too long for your application, the cord
should be shortened so that the control station is suspended
approximately four feet above the operating floor.
To shorten the cord, measure the distance the control station
is to be raised. Disconnect the trolley from the power supply
system. Remove the cover from the control station and dis-
connect the conductors of the control cord from the various
terminals. For cords with the internal type strain relief, discon-
nect the strain relief loop from the control station housing and
retain the strain relief screw, washer and the terminal block
WARNING
Tying knots or loops to shorten the drop of the control station
will make the strain relief ineffective and the internal conduc-
tors of the cord may break.
T AV ID PR BLEMS:
Shorten the control cord per the following instructions.
tab. For cords with the external, chain strain relief, discon-
nect the chain from the control station by twisting open the
link. Measuring from the end of the longest conductor, cut-off
the cord the distance the control is to be raised. Using the
cut-off piece of cord as an example, prepare the end of the
shortened cord. For cords with the internal type strain relief,
prepare the strain relief loop as shown below.
ote: Conductors not shown for clarity.
Be sure to firmly squeeze the clamp sleeve (from the field
wiring kit) using a vise or very large pliers to secure the loop
end and insulate the clamp sleeve using the rubber sleeve
from the cut-off piece of cord.
For units with external chain strain relief, cut-off the chain the
distance the control station is to be raised.
Slide the prepared cord thru the grommet or box connector
on top of the control station. Using the wiring diagram sup-
plied with the trolley, connect the conductors of the control
cord to the various terminals. For units with the internal type
strain relief, attach the loop to the control station housing
using the screw washer and the terminal block tab. For units
with external type chain strain relief, attach the chain to the
control station by re-closing the link. On these units, also
firmly tighten the top ring of the box connector to seal the
opening between the cord and the grommet.
5
Figure 5. Hoist Power Cord Connections: Single-Phase Figure 6. Hoist Power Cord Connections: Three-Phase
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Cord Clamp Sleeve
11/32
25/16
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Re-attach the cover to the control station. Energize the
power supply system and test the trolley and hoist for
proper operation.
NOTE: The four-directional control station can only
be used with a hoist that has a reversing contactor. If
the trolley and hoist is shi ed direct from the facto-
ry, the hoist may not be equi ed with the normal
ower cord or control station and cord assembly. As
a result, these items will not have to be removed as
indicated and the short hoist ower and control cord
on the hoist can be wired directly into the trolley.
Use the wiring diagram su lied with the trolley for
making the connections.
Hoist Control Cord
t is necessary to remove the control station (if supplied – see
note above) from the hoist since the trolley is supplied with a
short hoist control cord. Remove the control station and con-
trol cord assembly from the hoist. Connect the short hoist
control cord from the trolley to the hoist control circuit follow-
ing the wiring diagram supplied with the hoist. After this is
completed, re-assemble the Back Frame Cover to the hoist
frame.
The single-phase units are now ready for operation. However,
on the three-phase units, the direction of trolley and hook
travel must be checked (as indicated below) before the unit
is put into service.
Figure 7. Connections for Proper Hook and Trolley Travel.
Three-Phase Units
A three-phase motor can rotate in either direction depending
on its connection to the power supply. Therefore, the direc-
tion of trolley and hook travel relative to the selected indicat-
ed direction must be checked before the unit is put in ser-
vice. f the hoist is incorrectly phased, the limit switches are
ineffective and serious damage can result. Refer to hoist
manual. The trolley should be checked out first, then the
hoist. See Figure 7.
PERATING INSTRUCTI NS
After the trolley and hook travel directions are correct, operate
the trolley (according to the operating and safety procedures
– see page ii) with a capacity load over the entire length of
the runway or monorail system to be sure that all adjustments
and operations are satisfactory.
The hoist/trolley combination is not ready for service and it
should be moved forward 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.
INSPECTI N
To maintain continuous and satisfactory operation, a regular
periodic inspection procedure must be initiated so that worn
or damaged parts can be replaced before they become
unsafe. The frequency of inspection must be determined by
the individual application.
The following list gives an inspection procedure for normal
usage under normal conditions. When the unit is subjected
to heavy usage or dusty, gritty, moist or other adverse atmos-
pheric conditions, shorter time periods must be assigned.
nspection must be made of all parts for unusual wear, corro-
sion or damage in addition to those specifically mentioned in
the list below.
t is suggested that the unit be inspected monthly for wear
damage and corrosion effects to all parts with particular
attention to the following:
1. Tightness of all fasteners including trackwheel stud nuts
and suspension bolt nuts.
2. Contactor and control station for burnt or pitted contacts
and loose or corroded terminals.
3. Cables and leads for broken wires, loose or corroded
terminals, also damaged insulation.
4. Terminal board for loose or corroded connections.
5. Trackwheels for wear of tread and flange and for bearing
wear as indicated by excessive looseness of wheel on stud.
6. Trackwheel gear, pinion and pinion bearing for wear.
7. On the 1/8 – 2-Ton trolley, check suspension lug, load
bracket, suspension adapter and suspension lug pin for
excess wear by manipulating hoist and visually inspect-
ing suspension parts.
8. On the 3-Ton trolleys, check shackle pin for proper seat-
ing in groove of load bracket.
Manipulate hoist and check for freedom of movement (swing-
ing) in both planes and all four directions. Also examine
the shackle, shackle pin, suspension lug pin retaining pins,
sheave stud and suspension adapter for excess wear by
manipulating hoist and visually inspecting suspension parts.
9. Collector or power supply system for damage, wear
corrosion and proper operation.
10.On trolleys equipped with the optional motor brake, check
for friction disc wear and proper adjustment of the sole-
noid air gap.
6
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MAINTENANCE
Once a month lubricate trackwheel gear and pinion with
Texaco Novatex #2 or an equivalent heavy cup grease or
graphite grease.
Motor gear box oil must be changed after the first 100 hours
of operation, then every six months or 2500 hours of normal
service, whichever comes first. Use 1/2 pint of Mobile SHC-
626 or equal lubricant, for each oil change.
All other trolley parts and lubricated for life at the factory.
IMPORTANT: Refer to manual acked with the hoist
for the ins ection and maintenance of the hoist.
M T R BRAKE ( PTI NAL EQUIPMENT)
A motor brake is available as optional equipment. The brake
can be ordered with the trolley or it is available in kit form for
installation on a unit in the field. To order a brake kit for an
existing unit, order brake kit Key No. 635-287 and indicate
the serial number of the trolley on which it is to be installed
and the voltage on which the trolley operates.
Figure 8. Motor Brake Adjustment.
Adjustment
The motor brake should be checked periodically for wear of
the friction discs and/or proper adjustment of the solenoid air
gap. Refer to Figure 8. Normal lining wear will cause the
solenoid lever (8) to move away from the solenoid frame (79)
and thus increase the air gap and trolley stopping time.
When the gap reaches approximately 11/16" the brake
should be adjusted. To adjust the brake, de-energize the
power supply to the trolley.
Remove both access covers to expose the brake. Depress
the plunger (13) towards the solenoid frame until spring pres-
WARNING
The lubricants used in and recommended for the Series 635
Motor Driven Trolley may contain hazardous materials that
mandate specific handling and disposal procedures.
T AV ID C NTACT AND C NTAMINATI N:
Handle and dispose of lubricants only as directed in applicable
material safety data sheets and in accordance with applicable
local, state and federal regulations.
sure is felt. Hold the plunger firmly in this position and mea-
sure the air gap between the mating (ground) surfaces of the
solenoid (79) and the solenoid plunger (29). To adjust, turn
both wear adjustment screws (10) equal amounts clockwise
until the air gap measures 13/32".
REPLACEMENT F FRICTI N DISC
(Refer to Figure 16, page 18)
1. De-energize the power supply to the trolley and remove
the motor/brake assembly from the gear reducer. Remove
housing (635-261) from the brake.
2. Remove the entire support plate assembly by unscrewing
three (3) screws (635-294). Remove the stationary disc
(635-269) and worn friction disc (635-270). nstall the new
friction disc, making sure that the two stabilizing springs
are at 90° in the recessed portion of the square hole in
the friction disc, with the prongs pointing into the brake.
Place the stationary disc on the friction disc and re-
assemble the entire support plate assembly engages the
guide pins of the end plate.
3. Remove both access covers (635-263) from the housing
(635-261) and slide the housing with its shaft assembly
onto the mounting studs. Be sure the housing is assem-
bled with the access windows above the horizontal cen-
terline. Rotate shaft to engage key into the hub keyway.
4. Re-assemble the motor/brake assembly to the gear
reducer using the four nuts and lockwashers.
5. Adjust air gap per above instructions(adjustment).
6. Re-energize power supply and operate trolley a few times
to make sure air gap is correct and then replace access
covers (635-263).
REPLACEMENT F C IL
(Refer to Figure 8 on this page and Figure 15 on page 17)
1. De-energize the power supply to the trolley and remove
the motor/brake assembly from the gear reducer.
2. Remove housing (635-261) from the brake and discon-
nect the coil lead wires from brake cord.
3. nsert screwdriver between support plate (126) and the
top of lever arm (17). Wedge these apart and remove
bearing pin (26) and solenoid lever (8) with link (13) and
plunger (29).
4. Remove plunger guide screw (84) and both plunger
guides (82). Slide old coil sideways out of frame (79). f
coil is difficult to move, tap lightly with a soft hammer.
5. nstall new coil in the same relative position as the old coil
and replace the plunger guides (82) and screws (84, 84W).
6. Re-assemble following Step 3 in reverse order.
7. Re-connect the coil leads to the brake cord. Slide hous-
ing and shaft assembly onto mounting studs, rotating
shaft to engage key into hub keyway. Be sure the access
covers are above the horizontal centerline.
WARNING
Working in or near exposed energized electrical equipment
presents the danger of electric shock.
T AV ID INJURY:
DISCO ECT POWER A D LOCKOUT/TAGOUT DISCO ECTI G
MEA S BEFORE REMOVI G COVER OR SERVICI G THIS
EQUIPME T.
7
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8. Re-assemble motor/brake assembly to gear reducer
using the four nuts and lockwashers.
9. Adjust air gap per above instructions (Adjustment).
10.Re-energize power supply and operate trolley a few times
to make sure air gap is correct and then replace access
covers.
REC MMENDED SPARE PARTS
To insure continued operation of the Series 635 Motor Driven
Trolleys, the following is a list of parts that are recommended
to be kept on hand at all times to replace parts that have
worn or failed:
Qty. for each
Key No. Part Name rolley in Service
635-45 Transformer 1
(3-phase units only)
635-126 Contactor 1
635-156 Control Station
635-286 Coil Kit 1
(for units equipped
with brake)
Refer to page 11 for ordering information and the parts lists
for the part numbers.
TR UBLESH TING
ELECTRICAL DATA
To detect open and short circuits in electrical components,
use the following procedure.
OPE CIRCUITS in the coils of electrical components may
be detected by isolating the coil and checking for continuity
with an ohmmeter or with the component in series with a light
or bell circuit.
SHORTED TUR S are indicated by a current draw substan-
tially above normal (connect ammeter in series with suspected
element and impose normal voltage) or D.C. resistance sub-
stantially below normal. The current method is recommended
for coils with very low D.C. resistance
MOTOR CURRE T should be measured with the motor run-
ning under full load with rated voltage applied.
CO TACTOR COIL CURRE T should be measured with
the contactor armature (contacts) closed and full voltage on
the coil.
8
Electrical Data for Trolley Components
Table 3
TRANSF RMER
D.C. Resistance
Voltage Leads (Ohms)
230/460 H4 to H3 150
To H1 to H2 150
115 X1 to X2 21
M T RS
Voltage-Phase Full Load D.C. Resistance
Hertz Current (Amps.) Leads (Ohms)
115-1-60/50 3.4/4.2 1 - 3 3.3
2 - 3 3.1
230/460-3-60 1.3/.65 1 - 4 15.3
2 - 5 15.3
3 - 6 15.3
7 - 8 30.5
7 - 9 30.5
8 - 9 30.5
220/380-3-50 1.7/.85 1 - 4 15.3
2 - 5 15.3
3 - 6 15.3
7 - 8 30.5
7 - 9 30.5
8 - 9 30.5
575-3-60 .52 1 - 2 95.0
1 - 3 95.0
2 - 3 95.0
C NTACT R C IL
Voltage Current D.C. Resistance
Hertz (Amps) (Ohms)
120-60 0.10 150
110-50 0.12 210
115-60/50 .124/.140 132
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9
Figure 9. Typical Wiring Diagrams. Wiring Diagrams shown are representative. Consult diagram attached to contactor or furnished with unit.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

10
A. No voltage at trolley
B. Phase failure (single-phasing)
C. Open control circuit
D. Wrong voltage or frequency
E. Low voltage
F. Excessive load
A. Main line or branch circuit switch open; branch line fuse blown or circuit breaker
tripped. Close, replace or reset.
Check for grounded or open connection in supply lines or current collectors.
B. Open circuit, grounded or open connection in one line of supply system, collec-
tors, hoist wiring, reversing contactor, motor leads or windings.
Check for electrical continuity.
C. Open or shorted windings in transformer or reversing contactor coil; loose con-
nection or broken wire in circuit; mechanical binding in contactor; control station
contacts not making.
D. The voltage and frequency must be the same as shown on trolley control box.
E. Voltage at the motor must be above the minimum with the unit in operation:
UNIT RATING INI U VOLTAGE
110-120/1/60 99
208-240/3/60 187
440-480/3/60 396
220/3/50 198
380/3/50 342
575/3/60 517
F. Reduce loading to the capacity limit of trolley.
1. Trolley does not operate in either direction.
––– Probable Cause –––
––– Remedy –––
TR UBLE SH TING
A. Open control circuit A. See tem 1c.
2. Trolley operates in one direction only.
A. Excessive load
B. Low voltage
C. Worn or dirty rails
A. See tem 1f.
B. See tem 1e.
C. Clean rails, inspect for worn spots.
3. Trolley operates sluggishly.
A. Excessive load
B. Low voltage
C. Extreme external heating
A. See tem 1f.
B. See tem 1e.
C. Above an ambient temperature of 104°F., the frequency of trolley operation must
be limited to avoid overheating of motor. Special provision should be made to ven-
tilate the space or shield the trolley from heat radiation.
Excessive inching, jogging or plugging should be avoided since this type of oper-
ation will drastically shorten the life of motor and contactor.
See tem 1b.
4. Motor overheats.
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REPLACEMENT PARTS
RDERING INSTRUCTI NS
The following information must accompany all correspon-
dence or orders for replacement parts:
1. Serial number – this is stamped on the side frame above
the motor mounting, as shown below.
2. Voltage, Phase, Hertz – see the labels located next to the
power cord and on the inside of the control box cover.
When ordering motor parts, give the motor name plate data
in addition to the above.
For parts orders also specify:
1. Quantity desired.
2. Key number or part.
3. Part name.
4. Part number.
Parts should be ordered from CM’s authorized Master Parts
Depots conveniently located throughout the United States
and Canada. Refer to page i of this manual to locate the
Master Parts Depot nearest you.
NOTE: When ordering re lacement arts, it is rec-
ommended that consideration be given to the need
for also ordering such items as bearings, contacts,
fasteners, etc. These items may be damaged or lost
during disassembly or just unfit for future use
because of deterioration from age or service.
WARNING
Using “commercial” or other manufacturer’s parts to repair the
Series 635 Motor Driven Trolley may cause load loss.
T AV ID INJURY:
Use only CM supplied replacement parts. Parts may look alike,
but CM parts are made of specific materials or processed to
achieve specific properties.
11
Figure 10. Trolley Arrangement
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See Figure 11
See Figure 13
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12
Figure 11. Control Station Exploded View.
CM®4 DIRECTI NAL C NTR L STATI N PARTS LIST
Figure 11
Key No. Part Name No. Req’ . Part No.
635-21 Warning Tag 1 81704
635-141 Control Cord Complete 1
( Specify Length Required.)
8 Conductors, 16'-3" 51708
All others Contact Factory
Consists of (1) Control Cord and (1) Warning Tag
635-144 Chain Clip at Control Box 1
8 Conductors 68704
10 Conductors 57817
635-146 Control Station Support Chain – 621431
( Specify Length Required.)
635-147 Cable Clip ( Specify Number Required.) 1 20744
635-148 Support Chain Attaching Link 2 59883
635-155 Control Station nserts
1-Speed nserts 1 58255
2-Speed nserts 1 58256
635-156 Control Station Complete
4 Button Control Station 1 58220CM
6-Button Control Station 1 58252
635-551 Control Station Grommet 1 58278
635-553 Control Station Housing Kit
( ncludes Housing, Boots, Collar
Gasket & Hardware) 1 58388
635-563 Control Station Hardware Kit
w/Gaskets 1 58279
635-566 Control Station Warning Label Kit 1 57276
635-567 Control Station Button Label Kit 1 58277
*Refer to parts list on page 15
for information on these parts
6-Button Control Station-
Individual components not
available for repair
Multifunction
Control Stations
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13
Figure 12. Trolley Exploded View.
TR LLEY C MP NENTS PARTS LIST
Part No. Part No.
Key No. Part Name No. Req’ . 1/8 – 2-Ton 3-Ton
635-1* Side Frame – Plain Side 1
(Does not include wheels)
3-3/8” thru 5 5/8” Flange Range 35680 -
5-5/8” thru 8 3/8” Flange Range 35680 -
4” thru 5 5/8” Flange Range - 36696
5-5/8” thru 7-1/4” Flange Range - 36696
7-1/2” thru 9-1/8” Flange Range - 35682
635-2* Side Frame – Geared Side
(Does not include wheels)
3-3/8” thru 5-5/8” Flange Range 1 35690 -
5-5/8” thru 8-3/8” Flange Range 35690 -
4” thru 5-5/8” Flange Range - 36696
5-5/8” thru 7-1/4” Flange Range - 36696
7-1/2” thru 9-1/8” Flange Range - 35665
635-3 Motor Shaft Bearing 1 82055 82055
635-4 Trackwheel Plain 2 39002 39002
635-5 Trackwheel with Gear 2 35642 35642
635-6 Trackwheel Bearing 4 82113 82113
635-7 Trackwheel Stud – 2 36361 36361
Plain Wheel
635-8 Trackwheel Stud – 2 36362 36362
Geared Wheel
635-9 Trackwheel Washer – Steel 4 81014 81014
635-10 Trackwheel Washer – Oilite 4 82046 82046
635-11 Trackwheel Stud Lockwasher 4 987926 987926
635-12 Trackwheel Stud Nut 4 988155 988155
Part No. Part No.
Key No. Part Name No. Req’ . 1/8 – 2-Ton 3-Ton
635-13 Load Bracket- (F.R.= Flange Range) 1
3-3/8” thru 5-5/8” F.R. (4-3/16" wide) 35033 –
5-5/8” thru 8-3/8”F.R. (6-11/16” wide) 35043 –
4” thru 5-5/8” F. R. (4-13/16” wide) – 36012
5-5/8” thru 7-1/4” F.R. (6-7/16” wide) -- 36021
7-1/2” thru 9-1/8” F.R. 6-7/16” wide) -- 36021
635-14 Suspension Lug Pin 1
2-7/8" long 35413 –
3-3/4" long 35400 –
635-15 Suspension Lug Pin 1 983547 –
Screw Washer
635-16 Suspension Lug Pin Screw 1
3/4" long 982433 –
1-1/2" long 987209 –
635-17 Suspension Bolt-(F.R.=Flange Range) 2
3-3/8” thru 5-5/8” F.R. 1" dia. x 10-23/32" long 35446 –
5-5/8” thru 8-3/8”F.R. 1-1/4" dia. x 11-15/32" long 35430
4” thru 5-5/8” F. R. 1" dia. x 13-1/4" long 36358
5-5/8” thru 7-1/4” F.R. 1-1/4" dia. x 12-31/32" long – 36380
7-1/2” thru 9-1/8” F.R. 1-1/4" dia. x 15-15/32" long – 35187
635-18 Spacer Washer
42 981012 –
36 – 936827
635-19 Suspension Bolt Nut 4 958818 945835
635-20 Suspension Bolt Cotter Pin 4 988368 988382
635-22 Warning Label 1 936984 936984
* For Trolleys with standard ranges of adjustment and without trolley guards.
For all others, contact CM for side frame part numbers.
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14
Figure 13. Control Box Exploded View.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

15
C NTR L B X C MP NENTS PARTS LIST
Part No.
Key No. Part Name No. Req’ . 1/8 – 2-Ton, 3-Ton
Part No.
Key No. Part Name No. Req’ . 1/8 – 2-Ton, 3-Ton
635-26 Control Box & Brackets w/ Cover 1
and Cover Mounting Screws
Units w/o Main Line Contactor 36801
Units w/ Main Line Contactor 36248
635-29 Control Box Mounting Screw 4 982693
635-30 C.M. Nameplate 1 935899 936828
(1/8 – 2-Ton) (3-Ton)
635-31 Wiring Diagram 1 Contact CM
635-32 Current Label 2
115-1-60 935884
230-3-60 935885
460-3-60 935886
220-3-50 935887
380-3-50 935888
Blank 935889
635-33 Strain Relief Screw 1 982695
635-34 Strain Relief Screw Washer 2 954802
635-35 Cable Clamp 1 27833
635-36 Cable Clamp Screw Washer 1 954802
635-37 Cable Clamp Screw 1 982688
635-38 Power Cord (Specify Length) 1
Single-Phase 51436
Three-Phase 51434
Units w/ Main Line Contactor See pg. 15
635-39 Power Cord Connector 1
Single-Phase 89926
Three-Phase 89916
635-40 Power Cord Connector Locknut 1 989771
635-43 Hoist Power Cord Connector 1 89916
635-44 Hoist Power Cord Connector Locknut 1 989771
635-45 Transformer (See Units with Main Line Contactor) 1
230-3-60 & 460-3-60 Trolleys (115 V. ctrl.) 36412
220-3-50 & 380-3-50 Trolleys (48 V. ctrl.) 36413
230, 220, 380 & 460 Trolleys (24 V. ctrl.) 35809
575-3-60 Trolleys (115 V. ctrl.) 35807
115-1-60 Trolleys (48 V. ctrl.) 36753
115-1-60 Trolleys (24 V. ctrl.) 35810
635-46 Transformer Mounting Screw 2 982686
635-47 Terminal Board 1 35880
635-48 Terminal Board Mounting Screw 2
Single-Phase 982684
Three-Phase 982537
635-49 Terminal Board Mounting Screw Nut 2 988101
635-50 Control Cord Connector 2
8 Conductors 983979
10 Conductors 83982
635-51 Control Cord Connector Locknut 1
8 Conductors 989772
10 Conductors 989773
635-53 Contactor Mounting Screw & Lockwasher -
Screw 2 957854
Lockwasher 2 957855
635-54 Jumper – (No. Req’d.) followed by Part No.
Single-Phase (2)35382, (1)35386, (1)35388, (1)35387
Three-Phase (1)35376, (1)35377, (1)35378, (1)35387,
(1)35386, (1) 35388
635-55 Jumper (Between Coil Terminals) 1 51487
635-58 Term. Bd. Nut 2 982484
635-59 Term. Bd. Motor Cable 2 28719
635-61* Cover Gasket 1 35941
635-65 Motor Cable Connector 1 89916
635-66* Motor Cable Connector “O” Ring 1 983967
635-67 Motor Cable Connector Locknut 1 989771
635-68* Power Cord Connector “O” Ring 1 983967
635-69* Hoist Power Cord Connector “O” Ring 1 983967
635-70* Control Cord Connector “O” Ring 1
8 Conductors 983963
10 Conductors 984901
635-71* Control Box Plug Screw 2
Single-Phase 982686
Three-Phase 982683
635-72* Gasket Cement 1 986913
635-76 Hoist Control Cord Connector 1 89926
635-77* Hoist Control Cord Connector “O” Ring 1 983967
635-78 Hoist Control Cord Connector Locknut 1 989771
635-79~Bridge Control Cord (Specify Length Required) 1 89683
635-80~Bridge Control Cord Connector 1 83980
635-81*~ Bridge Control Cord Connector “O” Ring 1 983963
635-82~Bridge Control Cord Connector Locknut 1 989772
635-83~Cable Clamp Screw Nut 1 982514
635-84~Cable Clamp 1 27833
635-85~Cable Clamp Screw Washer 1 954802
635-86~Cable Clamp Screw 1 982688
635-87 Label (For Wiring Diagram) 1 968996
635-88 Connector Washer (Control Box Part No. 36801) 1 987177
635-126†Contactor
115 V. Coils (Three Phase) 1 24799
48 V. Coils (Three Phase) 1 24797
24 V. Coils (Three Phase) 1 28860
115 V. Coils 1 28553
48 V. Coils 1 28545
24 V. Coils 1 28552
635-197‡Field Wiring Kit (2-Button Control Station) 1 36665
635-198‡Field Wiring Kit (4-Button Control Station) 1 36666
635-217 Ground Screw 3 958805
635-218 Ground Screw Lockwasher 3 987873
635-223 Short Hoist Power Cord 1
Single-Phase Lodestar 27759
Three-Phase Lodestar 28546
Valustar Contact CM
635-224 Short Hoist Control Cord 1
Lodestar (Single Phase) 51131
Lodestar (Three Phase) 51130
Valustar Contact CM
635-300 Line Connector (Specify Number Required) – 982158
635-304 Brake Cord Connector Locknut 1 989771
635-305* Brake Cord Connector “O” Ring 1 983967
635-306 Brake Cord Connector 1 89916
UNITS WITH MAIN LINE CONTACTOR
Key No. Part Name No. Req’ . Part No.
635-45 Transformer W/Fuse 1
230 Volt & 460 Volt (115 V. Control) 68659
575 Volt (115 V. Control) 68658
For Others Contact CM
635-38 Power Cord 1
Single-Phase 51201
Three-Phase 51203
‡Main Line Contactor
(115 Volt) 3-Phase 1 36947
(48 Volt) 3-Phase 1 35248
(24 Volt) 3 Phase 1 35249
(115 Volt) 1-Phase 1 28904
(48 Volt) 1-Phase 1 28903
(24 Volt) 1-Phase 1 28902
‡Main Line Contactor Screw 2 987277
‡Main Line Contactor Screw L.W. 2 957844
‡Transformer Spacer 4 68759
‡Transformer Mfg. Screw 4 959200
‡Transformer Screw L.W. 4 987873
*For weatherproof units only
~For use with 6-Button Control Stations
†ndividual components not available for repairs
‡Not shown
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

635-329 Shaft, Output 1 Contact CM
635-330 Worm, ntegral 1 Contact CM
635-331 Gear, Worm 1 Contact CM
635-332 Cup, Bearing 2 Contact CM
635-333 Cone, Bearing 2 Contact CM
635-334 Bearing, Ball 1 Contact CM
635-335 Washer 1 Contact CM
635-336 Screw, Hex Cap (1/4 NC x 5/8-GR5) 4 Contact CM
635-337 Screw, Hex Cap (1/4 NC x 7/8-GR5) 4 Contact CM
635-338 Screw, Hex Cap (1/4 NC x 1/2-GR5) 8 Contact CM
635-339 Screw, Hex Cap (3/8 NC x 1-GR5) 4 Contact CM
635-340 Washer, Locking (3/8) 4 Contact CM
635-341 Kit, Repair ( ncludes 635-342 thru 635-351) 1 Contact CM
635-342* Seal, mput Shaft 1 Contact CM
635-343* Seal, Output Shaft 1 Contact CM
635-344* Key, P&W (3/16 Sq. x 1") 1 Contact CM
635-345* Key, P&W (3/16 Sq. x 1-3/8") 1 Contact CM
635-346* Ring, Retaining 1 Contact CM
635-347* Ring, Retaining 1 Contact CM
635-348* Gasket, nput Cap 12 Contact CM
635-349* Gasket, Output Cap 12 Contact CM
635-350* Plug, Pipe, Socket (1/8 NPT) 4 Contact CM
635-351* Plug, Vented 1 Contact CM
635-352 Cap, Closed 1 Contact CM
16
Figure 14. Motor and Hub City Type Gear Reducer Exploded View.
Key No. Part Name No. Req’ . Part No.
635-89 Gear Reducer Mtg. Screw 4 927764
635-90 Gear Reducer Screw L.W. 4 982226
635-91 Pinion Washer 1 982263
635-92 Pinion 1 35429
635-93 Pinion Key 2 85546
635-94 Pinion Retaining Ring 1 82680
635-95 Motor Cable Assembly 1
Single-Phase 36500
Three-Phase 51440
635-96 Motor Cable Connector 1
Single-Phase 83969
Three-Phase 83968
635-97 Connector Lockout 1 989771
635-288 Motor – Complete 1
( ndividual Components not available for repairs)
115-1-60 36925
230/460-3-60 and 220/380-3-50 36924
575-3-60 36926
635-289 Gear Reducer – Complete 1
75 F.P.M. Trolleys (10:1) 36204
30 F.P.M. Trolleys (25:1) 36205
635-290 Motor Shaft Key 1 85554
635-291 Motor
Attaching Screw 4 987005
and Lockwasher 4 987919
635-325 Housing 1 Contact CM
635-326 Cap, Output 2 Contact CM
635-327 Cap, Closed nput 1 Contact CM
635-328 Flange, Motor 1 Contact CM
Key No. Part Name No. Req’ . Part No.
M T R AND HUB CITY TYPE GEAR REDUCER PARTS LIST
* These tems are only available in Repair Kit Form. Order “Kit, Repair, Key No. 635-341”.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com