CM Lodestar A User manual

P/N: 83874 (REV. 627-T) September 2016
Before installing hoist, fill in the information below.
Antes de instalar el polipasto, rellene los datos siguientes.
Enregistrez les informations suivantes avant de faire l'installation.
Rated Load / Carga Nominal / Charge nominale
Serial No. / N° de Serie / No. de Ser.
Purchase Date / Fecha de Compra / Date d'achat
CAPACITIES:
1/8 – 3 TONS
(125 – 3000 kg)
Follow all instructions and warnings
for inspecting, maintaining and
operating this hoist.
The use of any hoist presents some risk
of personal injury or property damage. That
risk is greatly increased if proper instructions
and warnings are not followed. Before using
this hoist, each operator should become
thoroughly familiar with all warnings,
instructions and recommendations
in this manual. Retain this manual for
future reference and use.
Forward this manual to operator.
Failure to operate equipment as
directed in manual may cause injury.
CAPACIDADES DE CARGA:
1/8 – 3 TONELADAS
(125 – 3000 kg)
Siga todas las instrucciones y
advertencias para inspeccionar,
mantener y operar este polipasto.
El uso de cualquier polipasto presenta
algunos riesgos de daños a las personas o a
las cosas. Este riesgo se ve incrementado si
no se siguen correctamente las instrucciones
y advertencias. Antes de usar el polipasto
el operario debería estar familiarizado con
todas las advertencias, instrucciones y
recomendaciones de este manual. Guarde
este manual para futuras consultas.
Entregue este manual al operario. Si el
equipo no se maneja tal y como se
recomienda en el presente manual, es
posible que se produzcan situaciones
de peligro que pueden resultar en
daños personales.
CHARGES NOMINALES:
1/8 – 3 TONNES
(125 – 3000 kg)
Veuillez vous conformer à toutes les
instructions et avertissements d'inspection,
d'entretien et d'opération de ce palan.
L'utilisation de tout appareil de levage
comporte des risques de blessures ou
de dégâts matériels. Ces risques sont
de beaucoup accrus si les instructions
et avertissements ne sont pas suivis.
Tours les opérateurs devraient se
familiariser complètement avec toutes
les recommandations instructions et
avertissements de ce manuel avant d'utiliser
ce palan. Conservez ce manuel pour
utilisation et référence future.
Remettre ce manuel à l'opérateur.
L'utilisation de cet équipement contrairement
aux directives de ce manuel peut causer
des blessures.
ELECTRIC CHAIN HOIST
POLIPASTO ELÉCTRICO DE CADENA
PALAN ÉLECTRIQUE À CHAÎNE
OPERATING, MAINTENANCE
& PARTS MANUAL
MANUAL DE FUNCIONAMIENTO,
MANTENIMIENTO Y PIEZAS
MANUEL D'ENTRETIEN,
D'OPÉRATION ET DE PIÈCES

P/N: 83874 (REV. 627-T) September 2016

1P/N: 83874 (REV. 627-T) September 2016
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ENGLISH
CM HOIST PARTS AND SERVICES ARE AVAILABLE
IN THE UNITED STATES AND IN CANADA
As a CM Hoist and Trolley user you are assured of reliable repair and parts services through a network of Master Parts Depots and Service Centers
that are strategically located in the United States and Canada. These facilities have been selected on the basis of their demonstrated ability to handle
all parts and repair requirements promptly and efciently. To quickly obtain the name of the Master Parts Depot or Service Center located nearest you,
call [phone]. Fax: [phone].
LAS PIEZAS Y REPARACIONES DE LOS POLIPASTOS DE CM ESTÁN
ASEGURADAS EN ESTADOS UNIDOS Y CANADÁ
Como usuario de un polipasto y carro de CM le aseguramos cualquier reparación o la disponibilidad de cualquier pieza de repuesto a través de una
red de almacenes de piezas de repuesto y centros de servicio situados estratégicamente en Estados Unidos y Canadá. Estas instalaciones se han
seleccionado en base a su capacidad demostrada en la reparación de equipos y suminstro de piezas de repuesto de forma rápida y ecaz. Para obtener
la dirección del almacén de piezas de repuesto o del centro de servicio más cercano, llame al teléfono [phone]. Fax: [phone] (sólo en
Estados Unidos y Canadá).
LE SERVICE DE RÉPARATION ET DE PIÈCES POUR PALANS CM EST
DISPONIBLE AUX ÉTATS-UNIS ET AU CANADA
Soyez assurés qu'en temps d'utilisateur de palan et treuil CM, d'un service de réparation et de pièces able par l'entremise d'un réseau de Centres de
service et de Dépôts de pièces maîtresses qui sont stratégiquement situés aux États-Unis et au Canada. Ces établissements ont été sélectionnés sur
une base de leur habileté démontrée à s'occuper promptement et efcacement des besoins de réparation de pièces. Composez le [phone],
télécopieur: [phone] pour obtenir rapidement le nom du dépôt de pièces maîtresses ou du centre de service situé le plus près.

2P/N: 83874 (REV. 627-T) September 2016
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ENGLISH
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.
Improper operation of a hoist can create a potentially hazardous
situation which, if not avoided, could result in death or serious
injury. To avoid such a potentially hazardous situation, the
operator shall:
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
damaged load chain.
11. Protect the hoist’s load chain from weld splatter
or other damaging contaminants.
12. NOT operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
13. NOT use load chain as a sling, or wrap load 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.
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.
Usage of hoists that do not involve lifting of the load on the
lower hook or using hoists in the inverted position without special
precaution may cause an accident resulting in injury and/or
property damage.
TO AVOID INJURY:
Consult Columbus McKinnon for information concerning using
hoists in these applications.
21. NOT remove or obscure the warnings on the hoist.
22. NOT operate a hoist on which the safety placards or decals
are missing or illegible.
23. NOT operate a hoist unless it has been securely attached to
a suitable support.
24. NOT operate a hoist unless load slings or other approved single
attachments are properly sized and seated in the hook saddle.
25. Take up slack carefully - make sure load is balanced and
load holding action is secure before continuing.
26. Shut down a hoist that malfunctions or performs unusually
and report such malfunction.
27. Make sure hoist limit switches function properly.
28. Warn personnel of an approaching load.

3P/N: 83874 (REV. 627-T) September 2016
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HOIST SAFETY IS UP TO YOU...
CHOOSE THE RIGHT HOIST FOR
THE JOB...
Choose a hoist with the capacity for the job.
Know the capacities of your hoists and the
weight of your loads.
Then match them.
The application, the size and type of load,
the attachments to be used and the period
of use must also be taken into consideration
in selecting the right hoist for the job.
Remember, the hoist was designed to ease
our burden and carelessness not only endangers
the operator, but in many cases, a valuable load.
INSPECT
All hoists should be visually inspected before
use, in addition to regular, periodic maintenance
inspections.
Inspect hoists for operations warning notices
and legibility.
Deficiencies should be noted and brought to the
attention of supervisors. Be sure defective hoists
are tagged and taken out of service until repairs are made.
Under no circumstances should you operate a malfunctioning hoist.
Check for gouged, twisted, distorted links
and foreign material. Do not operate hoists
with twisted, kinked, or damaged chain links.
Load chain should be properly lubricated.
Hooks that are bent, worn, or whose
openings are enlarged beyond normal throat
opening should not be used. If latch does not
engage throat opening of hook, hoist should
be taken out of service.
Chains should be checked for deposits of
foreign material which may be carried into
the hoist mechanism.
Check brake for evidence of slippage
under load.
DO NOT LIFT MORE THAN RATED LOAD.
DO OPERATE WITH MANUAL POWER ONLY (ONE OPERATOR)
DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST.
DO NOT OPERATE WITH TWISTED, KINKED, OR DAMAGED CHAIN.
DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD ARE
IN A STRAIGHT LINE.
DO NOT USE LOAD CHAIN AS A SLING.
USE HOIST PROPERLY
Be sure hoist is solidly held in the uppermost
part of the support hook arc.
Be sure hoist and load are in a straight line.
Do not pull at an angle.
Be sure load is hooked securely. Do not tip load
the hook. Do not load hook latch. Hook latch
is to prevent detachment of load under slack
chain conditions only.
Do not operate with hoist head resting against
any object. Lift the load gently. Do not jerk it.
PRACTICE CAUTION ALWAYS
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.
OPERATOR SERVICE
CLEANING
Hoists should be kept clean and free of dust, dirt, moisture, etc.,
which will in any way affect the operation or safety of the equipment.
LUBRICATION
Chain should be properly lubricated.
AFTER REPAIRS
Carefully operate the hoist before returning it to full service.
DO NOT LIFT PEOPLE OR LOADS OVER PEOPLE
VIOLATIONS OF ANY OF THE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL INJURY TO THE OPERATOR
OR NEARBY PERSONNEL BY NATURE OF RELEASED LOAD OR BROKEN HOIST COMPONENTS.

4P/N: 83874 (REV. 627-T) September 2016
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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 information, we
recommended consulting a standard textbook on the subject.
TABLE OF CONTENTS
SAFETY PRECAUTIONS
Master Parts Depots And Service Centers ........................................ 1
Safety Precautions ............................................................................. 2
Hoist Safety is Up To You................................................................... 3
Foreword ............................................................................................ 4
GENERAL INFORMATION
Specifications..................................................................................... 5
CM Repair/Replacement Policy ......................................................... 5
ACCESSORIES
Hook Suspensions ............................................................................. 6
Lug Suspensions................................................................................ 6
Series 635 Low Headroom Trolleys.................................................... 6
Series 635 Motor Driven Trolleys........................................................ 6
Latchlok Hooks .................................................................................. 7
Chain Container.................................................................................. 7
INSTALLATION
Unpacking Information....................................................................... 7
Installing Suspension ......................................................................7-8
Attaching Load Chain......................................................................8-9
Installing Series 635 Low Headroom Trolley .................................9-10
Power Supply and Electrical Connections ..................................10-11
Checking for Twists in Load Chain................................................... 11
Checking for Adequate Voltage at Hoist .....................................11-12
Control Cord..................................................................................... 12
OPERATING INSTRUCTIONS
General............................................................................................. 13
Operating Instruction-Hoist.............................................................. 13
Hoist with Low Headroom Trolley..................................................... 13
Hoist with Motor Driven Trolley ........................................................ 13
Safety Procedures ............................................................................ 13
INSPECTION
Procedures ....................................................................................... 14
Frequent Inspections...................................................................14-15
Periodic Inspections....................................................................14-15
Preventive Maintenance................................................................... 14
Hook Inspection ............................................................................... 14
Load Chain ....................................................................................... 16
Protector........................................................................................... 16
MAINTENANCE
Hoist Lubrication .............................................................................. 17
Trolley Lubrication ............................................................................ 17
Exterior Finish................................................................................... 17
Solid State Reverse Switch.............................................................. 17
Adjustments
Electric Brake ................................................................................... 18
Limit Switches .............................................................................18-19
Troubleshooting...........................................................................20-21
Electrical Data .............................................................................23-24
Typical Wiring Diagrams..............................................................25-47
ASSEMBLY INSTRUCTIONS
Hook or Lug Suspension.................................................................. 48
Weatherproof Hoists......................................................................... 48
Gearing............................................................................................. 48
Fasteners.......................................................................................... 48
Lower Hook Block Pin...................................................................... 48
Removal and Installation of Load Chain......................................48-49
Cutting Chains.................................................................................. 50
Testing .............................................................................................. 50
REPLACEMENT PARTS
Ordering Instructions........................................................................ 51
Parts List and Exploded Views....................................................52-90
Recommended Spare Parts............................................................. 90
LIST OF TABLES
TABLE DESCRIPTION PAGE
1 Lodestar Electric Chain Hoist and
Series 635 Trolley Specifications .............................................. 5
2 Recommended Seating Torques for
Suspension Adapter Screws..................................................... 8
3 Series 635 Low Headroom
Side Frame Spacing.................................................................. 9
4 Minimum Frequent Inspections .............................................. 15
5 Minimum Periodic Inspections................................................ 15
6 Limit Switches......................................................................... 19
7 Troubleshooting .................................................................20-21
8 Electrical Data....................................................................22-23
LIST OF ILLUSTRATIONS
FIG. DESCRIPTION PAGE
1 Hook Suspensions.................................................................... 6
2 Lug Suspensions ...................................................................... 6
3 Series 635 Low Headroom Trolley ............................................ 6
4 Series 635 Motor Driven Trolley................................................ 6
5 Upper or Lower Latchlok Hook................................................. 7
6 Chain Container ........................................................................ 7
7 Attaching Load Chain ............................................................... 7
8 Contact Block ........................................................................... 8
9 Series 635 Low Headroom Trolley ............................................ 9
10 1/8 To 2 Ton (125kg To 2000 kg)
Hoist To Trolley Assembly ....................................................... 10
11 3 Ton (3000kg) Hoist To Trolley Assembly............................... 10
12 Voltage Conversion Terminal Board........................................ 10
13 Location of Components ........................................................ 11
14 Hook Inspection...................................................................... 16
15 Gaging Load Chain ................................................................. 16
16 Limit Switches Models A Thru H-2 ......................................... 18
17 Limit Switches Models J Thru RRT-2.................................18-19
18 Typical Wiring Diagrams.....................................................24-47
19 Hook Suspensions.................................................................. 48
20 Non-Circular Gearing.............................................................. 48
22 Cutting Chain With A Bolt Cutter ............................................ 50
23 Hoist Frame Componets....................................................54-55
24 Hoist Upper Suspension Components ..............................56-57
24 Hoist Lower Hook Components ........................................58-59
25 Control End Components ..................................................60-61
26 Brake Components............................................................62-63
27 Limit Switch Components..................................................64-65
28 Gearing Components.........................................................66-67
27 Liftwheel Components.......................................................68-69
28 Motor End Components ....................................................70-71
29 Contactor Plate Assemblies...............................................72-84
30 Control Station Components .............................................85-87
28 Trolley Components ...........................................................88-89

5P/N: 83874 (REV. 627-T) September 2016
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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 Protector, 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 is 10 feet.
However, hoists with longer lifts are available on a special, per order
basis.
CM REPAIR/REPLACEMENT POLICY
All Columbus McKinnon (CM®) Lodestar Electric Chain Hoists are
inspected and performance tested prior to shipment. If any properly
maintained hoist develops a performance problem due to a material
or workmanship defect, as 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.
TABLE 1. SPECIFICATIONS
A. Lodestar electric chain hoists
Maximum
Capacity
Ton (kg) Model
Lifting
Speed Per
Min.
Ft. (m)
Motor
H.P. (kW)
Shortest
Distance
Between Hooks
in. (mm)
Net Weight
lbs. (kg)
Single Speed 115-1-60
1/8 (125) A 32 (9.8) 1/4 (.19) 14¼ (362) 53 (24)
1/8 (125) AA 60 (18.4) 1/2 (.37) 14¼ (362) 64 (29)
1/4 (250) B 16 (4.9) 1/4 (.19) 14¼ (362) 57 (26)
1/4 ((250g) C 32 (9.8) 1/2 (.37) 14¼ (362) 65 (29.5)
1/2 (500) E 8 (2.4) 1/4 (.19) 17 1/8 (454) 68 (31)
1/2 (500) F 16 (4.9) 1/2 (.37) 14 ¼ (362) 64 (29)
1/2 (500) J 32 (9.8) 1 (.75) 15 9/16 (395) 115 (52.3)
1 (1000) H 8 (2.4) 1/2 (.37) 17 7/8 (454) 75 (34)
1 (1000) L 16 (4.9) 1 (.75) 15 9/16 (395) 117 (53.2)
2 (2000) R 8 (2.4) 1 (.75) 22½ (572) 136 (61.8)
3 (3000) RT 5.5 (1.9) 1 (.75) 25 (635) 161(73.2)
Single Speed 230/460-3-60 or 220/380-3-50 or 220/415-3-50
1/8 (125) A 32 (9.8) 1/4 (.19) 14¼ 67 (30.5)
1/8 (125) AA 60 (18.4) 1/2 (.37) 14¼ 74 (33.6)
1/4 (250) B 16 (4.9) 1/4 (.19) 14¼ 68 (31)
1/4 (250) C 32 (9.8) 1/2 (.37) 14¼ 74 (33.6)
1/2 (500) E 8 (2.4) 1/4 (.19) 17 7/8 79 (36)
1/2 (500) F 16 (4.9) 1/2 (.37) 14¼ 74 (33.6)
1/2 (500) J 32 (9.8) 1 (.75) 15 9/16 113 (51.4)
1/2 (500) JJ 64 (19.6) 2 (1.50) 15 9/16 120 (54.5)
1(1000) H 8 (2.4) 1/2 (.37) 17 7/8 85 (38.6)
1 (1000) L 16 (4.9) 1 (.75) 15 9/16 114 (51.8)
1 (1000) LL 32 (9.8) 2 (1.50) 15 9/16 121 (55)
2 (2000) R 8 (2.4) 1 (.75) 22½ 134 (61)
2 (2000) RR 16 (4.9) 2 (1.50) 22 13/16 136 (61.8)
3 (3000) RT 5.5 (1.9) 1 (.75) 25 161 (73.2)
3 (3000) RRT 11 (3.8) 2 (1.50) 25 161 (73.2)
Maximum
Capacity
Ton (kg) Model Lifting Speed
Per Min.
Ft. (m)
Motor
H.P.
(kW)
Shortest
Distance
Between Hooks
in. (mm)
Net Weight
lbs. (kg)
Two Speed 230-3-60 or 460-3-60 or 220-3-50 or 380-3-50 or 415-3-50
1/8 (125) A-2 10/32 (3.1/9.8) ¼ (.19) 14¼ (362) 69 (31.3)
1/8 (125) AA-2 20/60 (6.1/18.3) ½ (.37) 14¼ (362) 76 (34.5)
**1/4 (250) B-2 5/16 (1.5/4.9) ¼ (.19) 14¼ (362) 70 (31.8)
1/4 (250) C-2 10/32 (3.1/9.8) ½ (.37) 4¼ (362) 176 (34.5)
**1/2 (500) E-2 2.5/8 (.76/2.4) ¼ (.19) 17 7/8 (454) 81 (36.8)
1/2 (500) F-2 5/16 (1.5/4.9) ½ (.37) 14¼ (362) 76 (34.5)
1/2 (500) J-2 10/32 (3.1/9.8) 1 (.75) 15 9/16 (395) 115 (52.3)
1/2 (500) JJ-2 21/64 (6.4/19.5) 2 (1.50) 15 9/16 (395) 125 (56.3)
1 (1000) H-2 2.5/8 (.76/2.4) ½ (.37) 17 7/8 (454) 87 (39.5)
1 (1000) L-2 5/16 (1.5/4.9) 1 (.75) 15 9/16 (395) 116 (52.7)
1 (1000) LL-2 10/32 (3.1/9.8) 2 (1.50) 15 9/16 (395) 126 (57.3)
2 (2000) R-2 2.5/8 (.76/2.4) 1 (.75) 22½ (572) 136 (61.8)
2 (2000) RR-2 5/16 (1.5/4.9) 2 (1.50) 22 13/16 (579) 143 (65)
3 (3000) RT-2 1.75/5.5 (.53/1.68) 1 (.75) 25 (635) 175 (79.5)
3 (3000) RRT-2 3.5/11 (1.1/3.4) 2 (1.50) 25 (635) 177 (80.5)
B. Series 635 Low Headroom Trolleys
Capacity
Tons (kg)
For Use
with
Models
Adj. for STD S-Beams
Depth In. (mm)
Tread Dia.
of Wheels
In. (mm)
Min. Rad.
Curve In.
(mm)
1/8 to 1 (125
to 1000) A thru LL-2 4 thru 15 (102 thru 381) 3 1/8 (79.4) 24 (609)
2 (2000) R thru RR-2 6 thru 18 (152 thru 457) 4 3/4 (120.6) 24 (609)
3 (3000) RT thru RRT-2 8 thru 15 (203 thru 381) 4 (101.6) 30 (762)
C. Series 635 Motor Driven Trolleys
Capacity
Tons (kg)
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)
1/8 to 2 (125
to 2000) A thru RR-2 75 (23) ¼ (.19) 6 thru 15 (152 thru 381) 30 (762)
3 (3000) RT thru
RRT-2 75 (23) ¼ (.19) 6 thru 15 (152 thru 381) 30 (762)
*Lifting and travel speed listed are for 60 Hertz units. For 50 Hertz units,
theses speeds will be 5/6 of those listed.
**A 1/2 H.P. (.37 kW) motor furnished on 380-3-50, 415-3-50 and 460-3-60 volt units.

6P/N: 83874 (REV. 627-T) September 2016
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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 2. Lug Suspensions
Figure 3. Series 635 Low Headroom Trolley
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 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.

7P/N: 83874 (REV. 627-T) September 2016
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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 5. Upper or Lower 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 damaged
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: To assure long life and top performance, be sure to follow
the load chain lubricating instructions on page 15.
INSTALLING THE SUSPENSION
A. Single Reeved Units:
Remove the hook or lug suspension from its carton and the two
suspension screws. Place the suspension assembly into the recess
on top of the hoist so that the adapter body follows the contour
of the hoist. Insert the suspension screws through the holes in the
adapter and hand thread these into the self locking nuts enclosed
in the hoist. The screws will turn freely into the nuts until the last
1/4” (6.35mm) of travel, during which the resistance of the nut
locking collar will be encountered. Securely tighten the screws to the
recommended seating torque (see Table 2) using a 12 point socket
which fits the head of the screw.
B. Double Reeved Units:
Remove the hook or lug suspension from its carton and the two
suspension screws, dead end pin, washer and cotter pin. It should be
noted that a Double Reeved suspension includes a dead end bolt and
block for supporting the dead end of the chain as shown if 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 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” (6.35 mm) for Models E, E-2, H and H-2 and 7/16”
for the Models R, R-2, RR and RR-2. If the distance is not correct,
adjust the position of the dead end block to obtain the proper
distance (see Page 48).
Figure 7. Attaching Load Chain (Models E, H, E-2 and H-2
illustrated) (Models R, RR, R-2 and RR-2 similar)
1. Dead End Block
2. Suspension Assembly
3. Suspension Self-Locking Nut
4. Dead End Bolt
5. Load Chain
6. Chain Guide
7. Loose End Link
8. Liftwheel
9. Gear Housing
10. Loose End Screw and Lockwasher
(Do not order parts by these numbers. See parts list.)

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Now, insert the suspension screws through the holes in the adapter
and hand thread these into the self-locking nuts enclosed in the
hoist frame. These screws will turn freely into the nut until the last
1/4” (6.35 mm) of travel during which the resistance of the nut
locking collar will be encountered. Securely tighten the screws to the
recommended seating torque (see Table 2) using a 12 point socket
which fits the head of the screw.
To rotate the hook 90°, proceed as follows: NOTE: On the rigid
hook suspensions for Models A through RR-2, if it is necessary
to rotate the hook 90°, from its factory set position, one of the
suspension screws becomes captive and a socket cannot be
used to tighten this screw.
1. Using a hammer and drift, drive the pin out of the
square hook collar.
2. Remove the square collar from the hook shank.
3. Place a hi-collar type lockwasher (this lockwasher is not
supplied with the suspension assembly) under the head of one
of the suspension screws. Insert this assembly into the hole in
the suspension adapter and rotate the hook 90° to make this
screw captive.
4. Re-assemble the square collar to the hook shank using the
drive pin previously removed.
5. Follow the instructions above, except tighten the captive screw
to the recommended seating torque (see Table 2) using a 12
point box type wrench.
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 self-locking nut enclosed
in the hoist. The screws will turn freely into the nuts until the last
1/4” (6.35 mm) of travel, during which the resistance of the nut
locking collar will be encountered. Securely tighten the screws to the
recommended seating torque (see Table 2) using a 12 point socket
which fits the head of the screw.
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.
TABLE 2. RECOMMENDED SEATING TORQUES
FOR SUSPENSION ADAPTER SCREWS
Model No's Screw Size Recommended
Seating Torque
A thru H-2 3/8”-16 UNC-2A 30 to 45 lb. ft.
J thru RRT-2 1/2”-20 UNF-2A 40 to 80 lb. ft.
Using other than CM supplied high strength suspension screws to
attach the suspension adapter to the hoist may cause the screws
to break and allow the hoist and load to fall.
TO AVOID INJURY:
Use only the CM supplied suspension screws to attach
the suspension to the hoist and torque these screws to the
recommended seating torque as specified above.
Also, 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 (Table
2) recommended torque may break the screw, damage the
suspension adapter, strip the nuts and/or damage the hoist frame.
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.
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)
Figure 8. Contact Block Used on Models R, R-2, RR and RR-2
INSTALLATION (CONTINUED)