CM Lodestar A User manual

Before installing hoist, fill in the information below.
Model Number
Serial No.
Purchase Date
Voltage
Rated Load
RATED LOADS 1/8 TO 3 TONNES
125 KG TO 3000 KG
Follow all instructions and warning for inspecting,
maintaining and operating this hoist.
The use of any hoist presents some risk of personal injury
or property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using
this hoist, each operator should become thoroughly familiar
with all warnings, instructions and recommendations in this
manual. Retain this manual for future reference and use.
Forward this manual to operator. Failure to operate equipment
as directed in manual may cause injury.
ELECTRIC CHAIN HOIST
OPERATING, MAINTENANCE
& PARTS MANUAL
P/N: 00001996 (REV AC) 627NH October 2014
Distributed by Ergonomic Partners
[email protected]
www.ErgonomicPartners.com
Tel: [phone]

200001996 (REV AC) 627NH October 2014
CM HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
PARTS FOR YOUR HOIST ARE AVAILABLE FROM YOUR LOCAL AUTHORIZED REPAIR STATION.

300001996 (REV AC) 627NH October 2014
SAFETY PRECAUTIONS
Each Lodestar Electric Hoist is built in accordance with the
specifications contained herein and at the time of manufacture
complied with our interpretation of applicable sections of the
*American Society of Mechanical Engineers Code B30.16 “Overhead
Hoists,” the National Electrical Code (ANSI/NFPA 70) and the
Occupational Safety and Health Act. Since OSHA states the National
Electrical Code applies to all electric hoists, installers are required
to provide current overload protection and grounding [on the branch
circuit section] in keeping with the code. Check each installation
for compliance with the application, operation and maintenance
sections of these articles.
The safety laws for elevators, lifting of people and for dumbwaiters
specify construction details that are not incorporated into the
hoists. For such applications, refer to the requirements of applicable
state and local codes, and the American National Safety Code
for elevators, dumbwaiters, escalators and moving walks (ASME
A17.1). Columbus McKinnon Corporation cannot be responsible for
applications other than those for which CM equipment is intended.
*Copies of this standard can be obtained from ASME Order
Department, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300,
U.S.A.
THIS SYMBOL POINTS OUT IMPORTANT SAFETY
INSTRUCTIONS WHICH IF NOT FOLLOWED COULD
ENDANGER THE PERSONAL SAFETY AND/OR
PROPERTY OF YOURSELF AND OTHERS. READ AND
FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND
ANY PROVIDED WITH THE EQUIPMENT BEFORE
ATTEMPTING TO OPERATE YOUR LODESTAR HOIST.
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.
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.
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.
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.

400001996 (REV AC) 627NH October 2014
DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD ARE
IN A STRAIGHT LINE.
DO NOT USE LOAD CHAIN AS A SLING.
USE HOIST PROPERLY
Be sure hoist is solidly held in the uppermost part of the support
hook arc.
Be sure hoist and load are in a straight line.
Do not pull at an angle.
Be sure load is hooked securely. Do not tip load the hook. Do not
load hook latch. Hook latch is to prevent detachment of load under
slack chain conditions only.
Do not use load chain as a sling. Such usage damages the chain
and lower hook.
Do not operate with hoist head resting against any object. Lift the
load gently. Do not jerk it.
DO NOT LIFT PEOPLE OR LOADS OVER PEOPLE
LIFT PROPERLY
Do not lift co-workers with a
hoist.
Make sure everyone is clear of
the load when you lift.
Do not remove or obscure
operational warning notices.
MAINTAIN PROPERLY
CLEANING
Hoists should be kept clean and free of dust, dirt, moisture, etc.,
which will in any way affect the operation or safety of the equipment.
LUBRICATION
Chain should be properly lubricated.
AFTER REPAIRS
Carefully operate the hoist
before returning it to full service.
HOIST SAFETY IS UP TO YOU...
DO NOT LIFT MORE THAN RATED LOAD.
CHOOSE THE RIGHT HOIST FOR THE JOB...
Choose a hoist with the capacity for
the job. Know the capacities of your
hoists and the weight of your loads.
Then match them.
The application, the size and type
of load, the attachments to be used
and the period of use must also be
taken into consideration in selecting
the right hoist for the job.
Remember, the hoist was
designed to ease our burden and
carelessness not only endangers the
operator, but in many cases, a valuable load.
DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST.
DO NOT OPERATE WITH TWISTED, KINKED, OR DAMAGED CHAIN.
INSPECT
All hoists should be visually inspected before
use, in addition to regular, periodic maintenance
inspections.
Inspect hoists for operations warning notices and
legibility.
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.
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.

500001996 (REV AC) 627NH October 2014
TABLE OF CONTENTS
Safety Precautions..........................................................................3-4
Foreword............................................................................................5
General Information
Specifications.......................................................................6-8
CM Repair/Replacement policy........................................6, 95
Accessories
Hook Suspensions..................................................................9
Lug Suspension ......................................................................9
Latchlok Hooks.......................................................................9
Chain Container ......................................................................9
Installation
Unpacking Information..........................................................10
Installing Suspension.......................................................10-12
Recommended Torques...................................................11-12
Attaching Load Chain............................................................13
Power Supply and Electrical Connections.......................14-15
Operating Instructions
General..................................................................................16
Operating Instruction-Hoist..............................................16-17
Safety Procedures.................................................................17
Inspection
Inspection..............................................................................18
Frequent Inspections .......................................................18-19
Periodic Inspections.........................................................18-19
Preventative Maintenance.....................................................18
Hook Inspection....................................................................18
Load Chain............................................................................20
Maintenance
Load-limiter...........................................................................21
Hoist Lubrication...................................................................21
Trolley Lubrication.................................................................21
Adjustments
Electric Brake........................................................................22
Limit Switches..................................................................23-24
Troubleshooting................................................................25-28
Electrical Data..................................................................29-30
Typical Wiring Diagrams...................................................31-46
Assembly Instructions
Hook or Lug Suspensions.....................................................47
Lower Hook Block Pin...........................................................47
Removal and Installation of Load Chain..........................47-48
Cutting Chain........................................................................49
Testing...................................................................................49
Ordering Instructions........................................................................49
Parts List .....................................................................................50-93
Main Assembly.................................................................50-59
Gearbox Assembly...........................................................60-65
Upper Suspension ...........................................................66-70
Lower Hook......................................................................71-72
Brake................................................................................73-74
Control Cord and Station.................................................75-76
Contactor Plates ..............................................................77-91
Chain Containers.........................................................................92-93
Lubricants.........................................................................................94
Recommended Spare Parts.............................................................94
LIST OF TABLES
Table Title ............................................................................Page
1 Lodestar Electric Chain Hoist Specs.............................6-8
2 Recommended Torques.............................................11-12
4 Minimum Frequent Inspections......................................19
5 Minimum Periodic Inspections .......................................19
6 Limit Switches.................................................................22
7 Troubleshooting.........................................................25-28
8 Electrical Data............................................................29-30
LIST OF ILLUSTRATIONS
Figure Table............................................................................Page
1 Hook Suspensions............................................................9
2 Lug Suspensions..............................................................9
3 Series 635 Low Headroom Trolley....................................9
4 Series 635 Motor Driven Trolley........................................9
5 Upper or Lower Latchlok Hook.........................................9
6 Chain Container................................................................9
7 Attaching Load Chain.....................................................11
8 Contact Block.................................................................13
12 Voltage Change Board....................................................14
13 Locations of Components ..............................................14
14 Hook Inspection..............................................................18
15 Chain Wear areas............................................................20
16 Gaging Load Chain Wear................................................20
17 Chain Embossing............................................................20
18 Limit Switches Models, Models A–H..............................23
18A Rotatable Limit Switches, Models A–H ......................... 23
19 Limit Switches, Models J–RRT.......................................23
19A Rotatable Limit Switch, Models J–RRT ..........................23
20 Typical Wiring Diagrams ............................................31-46
21 Hook Suspensions..........................................................47
22A Cutting Chain By Nicking................................................49
22B Cutting Chain With A Bolt Cutter....................................49
FOREWORD
This manual contains important information to help you properly install, operate and maintain your hoist for maximum performance, economy
and safety.
Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating procedures and by carrying out
the recommended preventive maintenance suggestions, you will experience long, dependable and safe service. After you have completely
familiarized yourself with the contents of this manual, we recommend that you carefully file it for future reference.
The information herein is directed to the proper use, care and maintenance of the hoist and does not comprise a handbook on the broad
subject of rigging.
Rigging can be defined as the process of lifting and moving heavy loads using hoists and other mechanical equipment. Skill acquired through
specialized experience and study is essential to safe rigging operations. For rigging information, we recommend consulting a standard
textbook on the subject.

600001996 (REV AC) 627NH October 2014
GENERAL INFORMATION
SPECIFICATIONS
The Lodestar Electric Chain Hoist is a highly versatile materials
handling device that can be used to lift loads that are within rated
capacity. The mechanical features of these hoists include an alloy
steel lift wheel, Load Limiter, hardened steel chain guides, hardened
steel gear train, life-time lubrication, forged steel hooks and
lightweight aluminum frame. The electrical features include hoist-
duty motor, rugged hoist brake, magnetic reversing contactor and
voltage conversion board (dual voltage units). The hoist is available
with hook or lug suspensions that are supplied separately. Table 1
summarizes the Lodestar Electric Chain Hoist models and the Series
635 Trolleys available. It should be noted that standard single speed
hoists are available with 10 (3M), 15 (4.6M) and 20 (6.1M) foot lifts
and the standard lift for two speeds hoists is10 feet. However, hoists
with longer lifts are available on a special, per order basis.
SPECIFICATIONS
Table 1.a.
Lodestar Electric Chain Hoists
Single Speed 115-1-60
Model Load Capacity Lifting Speed
60Hz units Lifting Speed 50Hz units Chain Falls Chain Size Chain Weight per length
of lift
Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m
A 1/8 125 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
AA 1/8 125 60 18.3 50.0 15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87
B 1/4 250 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
C 1/4 250 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
E 1/2 500 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74
F 1/2 500 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
J 1/2 500 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87
H 1 1000 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74
L 1 1000 16 4.9 13.3 4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40
R 2 2000 8 2.4 6.7 2.0 2 .312 x .8583 7.92 x 21.8 1.88 2.80
RT 3 3000 5.3 1.6 4.4 1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20
Lodestar Electric Chain Hoists
Single Speed 115-1-60
Model Shortest Distance
Between Hooks Motor Power 60Hz Motor Power 50Hz IP Rating Net Weight 10’ lift less upper suspension
in mm HP kW HP kW lb kg
A 16.9 429 0.25 0.19 0.21 0.16 54 72 32.8
AA 19.9 505 0.50 0.37 0.42 0.31 54 76 34.3
B 16.9 429 0.25 0.19 0.21 0.16 54 73 33.1
C 16.9 429 0.50 0.37 0.42 0.31 54 75 34.2
E 21.6 549 0.25 0.19 0.21 0.16 54 78 31.8
F 16.9 429 0.50 0.37 0.42 0.31 54 76 34.5
J 18.1 460 1.00 0.75 0.83 0.62 54 127 57.5
H 21.6 549 0.50 0.37 0.42 0.31 54 81 36.7
L 18.1 460 1.00 0.75 0.83 0.62 54 125 56.7
R 25.8 655 1.00 0.75 0.83 0.62 54 148 67.1
RT 32.1 815 1.00 0.75 0.83 0.62 54 166 75.4
CM REPAIR/REPLACEMENT POLICY
All Columbus McKinnon (CM®) Lodestar Electric Chain Hoists are
inspected and per formance tested pr ior 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.

700001996 (REV AC) 627NH October 2014
SPECIFICATIONS (CONT.)
Table 1.b.
Lodestar Electric Chain Hoists
Single Speed 230/460-3-60 or 220/380-3-50 or 220/415-3-50
Model Load Capacity Lifting Speed
60Hz units Lifting Speed 50Hz units Chain Falls Chain Size Chain Weight per length
of lift
Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m
A 1/8 125 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
AA 1/8 125 60 18.3 50.0 15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87
B 1/4 250 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
C 1/4 250 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
E 1/2 500 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74
F 1/2 500 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
J 1/2 500 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87
JJ 1/2 500 64 19.5 53.3 16.3 1 .312 x .8583 7.92 x 21.8 0.94 1.40
H 1 1000 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74
L 1 1000 16 4.9 13.3 4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40
LL 1 1000 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40
R 2 2000 8 2.4 6.7 2.0 2 .312 x .8583 7.92 x 21.8 1.88 2.80
RR 2 2000 16 4.9 13.3 4.1 2 .312 x .8583 7.92 x 21.8 1.88 2.80
RRS 2 2000 16 4.9 13.3 4.1 1 .394 x 1.18 10 x 30 1.45 2.16
RT 3 3000 5.3 1.6 4.4 1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20
RRT 3 3000 10.7 3.3 8.9 2.7 3 .312 x .8583 7.92 x 21.8 1.88 2.80
Lodestar Electric Chain Hoists
Single Speed 230/460-3-60 or 220/380-3-50 or 220/415-3-50
Model Shortest Distance
Between Hooks Motor Power 60Hz Motor Power 50Hz IP Rating Net Weight 10’ lift less upper suspension
in mm HP kW HP kW lb kg
A 16.9 429 0.25 0.19 0.21 0.16 54 70 31.9
AA 19.9 505 0.50 0.37 0.42 0.31 54 73 32.9
B 16.9 429 0.25 0.19 0.21 0.16 54 71 32.2
C 16.9 429 0.50 0.37 0.42 0.31 54 72 32.8
E 21.6 549 0.25 0.19 0.21 0.16 54 76 30.9
F 16.9 429 0.50 0.37 0.42 0.31 54 73 33.1
J 18.1 460 1.00 0.75 0.83 0.62 54 121 54.7
JJ 18.1 460 2.00 1.49 1.67 1.24 54 127 57.5
H 21.6 549 0.50 0.37 0.42 0.31 54 78 35.4
L 18.1 460 1.00 0.75 0.83 0.62 54 119 53.9
LL 18.1 460 2.00 1.49 1.67 1.24 54 127 57.6
R 25.8 655 1.00 0.75 0.83 0.62 54 142 64.4
RR 25.8 655 2.00 1.49 1.67 1.24 54 150 68.0
RRS 24.8 630 2.00 1.49 1.67 1.24 54 164 74.4
RT 32.1 815 1.00 0.75 0.83 0.62 54 160 72.7
RRT 32.1 815 2.00 1.49 1.67 1.24 54 173 78.4

800001996 (REV AC) 627NH October 2014
SPECIFICATIONS (CONT.)
Table 1.c.
Lodestar Electric Chain Hoists
Two Speed 230-3-60 or 460-3-60 or 575-3-60 or 220-3-50 or 380-3-50 or 415-3-50 or 550-3-50
Model Load Capacity Lifting Speed
60Hz units Lifting Speed 50Hz units Chain Falls Chain Size Chain Weight per length
of lift
Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m
A-2 1/8 125 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
AA-2 1/8 125 20/60 6.1/18.3 16.7/50 5.1/15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87
B-2 1/4 250 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
C-2 1/4 250 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
E-2 1/2 500 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .250 x .7445 6.35 x 18.9 1.17 1.74
F-2 1/2 500 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87
J-2 1/2 500 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87
JJ-2 1/2 500 21.3/64 6.5/19.5 17.8/53.3 5.4/16.3 1 .312 x .8583 7.92 x 21.8 0.94 1.40
H-2 1 1000 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .250 x .7445 6.35 x 18.9 1.17 1.74
L-2 1 1000 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40
LL-2 1 1000 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40
R-2 2 2000 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .312 x .8583 7.92 x 21.8 1.88 2.80
RR-2 2 2000 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 2 .312 x .8583 7.92 x 21.8 1.88 2.80
RT-2 3 3000 1.8/5.3 0.5/1.6 1.5/4.4 0.5/1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20
RRT-2 3 3000 3.6/10.7 1.1/3.3 3/8.9 0.9/2.7 3 .312 x .8583 7.92 x 21.8 1.88 2.80
Lodestar Electric Chain Hoists
Two Speed 230-3-60 or 460-3-60 or 575-3-60 or 220-3-50 or 380-3-50 or 415-3-50 or 550-3-50
Model Shortest Distance
Between Hooks Motor Power 60Hz Motor Power 50Hz IP Rating Net Weight 10’ lift less upper suspension
in mm HP kW HP kW lb kg
A-2 16.9 429 0.25 0.19 0.21 0.16 54 76 34.6
AA-2 19.9 505 0.50 0.37 0.42 0.31 54 78 35.2
B-2 16.9 429 0.25 0.19 0.21 0.16 54 77 34.9
C-2 16.9 429 0.50 0.37 0.42 0.31 54 77 35.1
E-2 21.6 549 0.25 0.19 0.21 0.16 54 82 33.6
F-2 16.9 429 0.50 0.37 0.42 0.31 54 78 35.4
J-2 18.1 460 1.00 0.75 0.83 0.62 54 133 60.2
JJ-2 18.1 460 2.00 1.49 1.67 1.24 54 135 61.1
H-2 21.6 549 0.50 0.37 0.42 0.31 54 83 37.6
L-2 18.1 460 1.00 0.75 0.83 0.62 54 131 59.4
LL-2 18.1 460 2.00 1.49 1.67 1.24 54 135 57.6
R-2 25.8 655 1.00 0.75 0.83 0.62 54 154 61.2
RR-2 25.8 655 2.00 1.49 1.67 1.24 54 158 69.8
RT-2 32.1 815 1.00 0.75 0.83 0.62 54 172 71.6
RRT-2 32.1 815 2.00 1.49 1.67 1.24 54 181 82.1
RRT 32.1 815 2.00 1.49 1.67 1.24 54 173 78.4

900001996 (REV AC) 627NH October 2014
ACCESORIES
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®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, Motor Driven,
Universal Trolleys described next.
Figure 2. Lug Suspensions
SERIES 635 LOW HEADROOM TROLLEY
These are manual push
type trolleys (see Figure 3)
designed for use with the
Lodestar Electric Chain
Hoists. A rigid lug suspension
(see Figure 2) is required to
suspend the hoist from the
trolley. The trolley is adjustable
for operation on a range of
American Standard “S” beams
and it will also operate on flat
flanged beams.
Figure 3. Series 635 Low
Headroom Trolley
Figure 4. Series 635 Motor Driven Trolley
UNIVERSAL TROLLEY
The UTM Universal Trolley are supplied complete with
independent controls, wiring and a four directional control
station. These trolleys are adaptable to a wide variety of
CMCO hoist products when used in conjunction with the
appropriate hoist suspension. Trolley is adjustable for
operation on American Standard 'S' beams and will also
operate on flat flanged beams.
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 and it
will also operate on flat flanged beams.
LATCHLOK®HOOKS
CM Latchlok hooks (see Figure 5)
are available to replace the standard
upper and lower hooks used on the
Lodestar Electric Hoists.
Figure 5. Latchlok®Hook
CHAIN CONTAINER
This accessory (see Figure 6) is used to hold slack chain
and it is supplied complete with mounting hardware and
instructions. The chain container is recommended for those
applications where the slack chain would interfere with the
load or drag on the floor as may be the case with double or
triple reeved units. Chain containers can be furnished for
units already in use.
Figure 6. Chain Container

10 00001996 (REV AC) 627NH October 2014
INSTALLATION
UNPACKING INFORMATION
When received, the hoist should be carefully inspected
for damage which may have occurred during shipment or
handling. Check the hoist frame for dents or cracks, the
external cords for damaged or cut insulation, the control
station for cut or damaged enclosure, and inspect the
load chain for nicks and gouges. If shipping damage has
occurred, refer to the packing list envelope on the carton for
claim procedure.
Before installing the hoist, make sure that the power supply
to which it will be connected is the same as that shown on
the nameplate located on the side of the hoist.
NOTE: See Electrical Installation instructions
INSTALLING THE SUSPENSION
A. Single Reeved Units:
For Models A,B,C,F, J, JJ, L, & LL:
Remove the hook suspension and (2) suspension screws
from the packaging. Place the suspension assembly into the
recess on top of the hoist so that the adaptor body follows
the contour of the hoist. Insert the suspension screws
through the holes in the adapter and hand thread these into
the self-locking nuts enclosed in the hoist.
Securely tighten the screws to the recommended seating
torque (see Table 2) using a 12 point socket: 3/8" for Models
A, B, C, & F and 1/2" for Models J-LL.
For Model RRS:
Remove the hook suspension, screw and locknut from
the packaging. Slide the suspension assembly into the
channel in the top of the hoist. Insert the locknut into the
hex recess on the side of the suspension riser, insert the
screw through opposite side and hand thread the screw
into the self-locking nut.
Securely tighten the screw to the recommended torque (see
table 2), using a 3/16" hex bit socket.
Use of impact tools (electric or pneumatic) may cause premature failure
of attaching hardware.
B. Double Reeved Units:
Remove the hook suspension,(2) suspension screws,
(1) dead end pin, (1) washer, and (1) cotter pin from the
packaging. It should be noted that the suspension includes a
dead end bolt and block for supporting the dead end of the
load chain as shown in Figure 7.
Place the suspension assembly into the recess on top of
the hoist. The dead end block should project through the
bottom of the hoist with the pin hole and slot aligned to the
underside of the hoist as shown in Figure 7. If these are
not aligned as shown, lift the head of the bolt from the hex
recess in the adapter and turn the bolt and block assembly
and reseat the bolt head to obtain the proper alignment. Do
not change the position of the dead end block on the bolt to
attain this alignment.
Check the position of the pin hole in the dead end block to
make sure it has not been disturbed from its factory setting.
The distance from the top of the pin hole to the bottom of the
hoist should not exceed 1/4" (6.35mm) for Models E,E-2, H,
H-2 and 7/16" (11.11mm) for Models R, R-2, RR, RR-2. If the
distance is not correct, adjust the position of the dead end
block to obtain the proper distance (see fig. 21, p 73.)
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. Securely tighten the screws to
the recommended seating torque (see Table 2) using a 12
point socket: 3/8" for Models E & H and 1/2" for Models R &
RR.
The dead end of the load chain is temporarily positioned ( a
few links from the end) by a wire tie. Do not remove this tie
before attaching the chain to the dead end block. (See Fig. 7)
C. Triple Reeved Units:
These hoists have a sheave hanger which is loosely
connected to the top of the frame by a thin metal plate for
shipping purposes. To attach the suspension, support the
sheave hanger from the underside of the hoist and remove
the nut and seat from the sheave stud. Remove and discard
the shipping plate and retain the sheave stud nut and seat
since they will be reused later.
Remove the suspension assembly from the carton and the
two suspension screws. Place the suspension assembly over
the sheave stud and into the recess on top of the hoist. Insert
the suspension screws through the holes in the suspension
adapter and hand thread these into the self-locking nut
enclosed in the hoist. Securely tighten the screws to the
recommended seating torque (see Table 2) using a 12 point,
1/2" socket.
After the suspension assembly is installed, secure the sheave
stud to the suspension adapter using the round slotted nut
and seat that were formerly used to attach the shipping plate
to top of the hoist frame. Place the seat over the stud with
the flat side down and then rotate the seat so that there is
clearance between the seat and the suspension lug or hook.
Assemble the nut to the stud and turn the nut by hand until
the nut seats in the seat and the sheave hanger is snug in
the frame. Then back off the nut until the hole in the stud is
in line with one of the slots in the nut. Using a hammer, drive
the retaining pin (packed with the suspension assembly) into
the hole in the sheave stud until the end of the pin is flush
with the edge of the nut.
Using other than CM supplied high strength suspension screws to
attach the suspension adapter to the hoist may cause the screws to
break and allow the hoist and load to fall.
TO AVOID INJURY:
Use only the CM supplied suspension screws to attach the
suspension to the hoist and hand torque these screws to the
recommended seating torque as specified in tables 2a and 2b. DO
NOT apply any type of lubricant to the threads of these screws.
Lubricating the threads will reduce the effort to seat the screws
and as a result, tightening the screws to the above recommended
torque may break the screw,damage the suspension adapter, strip
the nuts and/or damage the hoist frame.
SUSPENSION BOLT SHOULD BE REPLACED ANY TIME
THE SUSPENSION IS REMOVED FROM THE HOIST

11 00001996 (REV AC) 627NH October 2014
Figure 7. Attaching Load Chain Double Reeved Models
1. Dead end block 7. Lift-wheel
2. Suspension assembly 8. Motor housing
3. Suspension self-locking nut 9. Loose end screw
4. Dead end bolt 10. Loose end link
5. Dead end link 11. Loose end
6. Chain guide
(Do not order parts by these numbers. See parts list)
3
2
4
7
11
9
8
10
1
5
6
Table 2a. Torque Specification: All Models
Fastener Fastener Description Tool Required *Recommended Seating Torque
ft-lbf N-m
Brake End cover 1/4-20 Slotted Fillister Head Screw Slotted Blade Screw Driver 4.0 - 5.0 5.4 - 6.8
Motor End Cover 1/4-20 Slotted Fillister Head Screw Slotted Blade Screw Driver 4.0 - 5.0 5.4 - 6.8
Reversing contactor Connecting Screws-1ø Terminal Clamp Screw Phillips no.2 or 3/16” slotted head screwdriver 0.6 - 1.0 0.8 - 1.3
Reversing contactor Connecting Screws-3ø Terminal Clamp Screw Phillips no.2 or 3/16” slotted head screwdriver 0.6 - 1.0 0.8 - 1.3
Limit Switch Guide Screws #10-24 Slotted Fillister Head Screw Slotted Blade Screw Driver 1.7 - 2.1 2.3 - 2.8
1/4-20 Button Head Screw for
MiscellaneousApplications 1/4-20 Button Head Socket Cap Screw 5/32" Hex Driver 4.2 - 5.0 5.6 - 6.8
Table 2b. Torque Specification: Models A-H
Fastener Screw Size Tool Required *Recommended Seating Torque
ft-lbf N-m
Motor Housing / Gear Housing / Back Frame
Screws 1/4"-20 Socket Head Cap Screw 3/16" Hex Driver 7.9 - 8.3 10.7 - 11.3
Lift-Wheel Nut 1"-12 Hex Nut 1-1/2" - 6 or 12 Point Socket 55.0 - 60.0 74.6 - 81.3
BrakeAttaching Screws 1/4-20 Slotted Fillister Head Screw Slotted Blade Screw Driver 4.2 - 5.0 5.6 - 6.8
BrakeArmature Mounting Screws M5 Socket Head Cap Screw 4mm Hex Driver 4.0 - 4.7 5.4 - 6.4
Contactor Plate Mounting Nuts 1/4-20 Hex Nut 7/16" - 6 or 12 Point Socket 2.0 - 2.5 2.7 - 3.4
SuspensionAdapter Screws 3/8"-16 - 12-Point Cap Screw 3/8" - 12 Point Socket 35.0 - 45.0 47.5 - 61.0
"Lower Hook Block Screws-Double Reeved" 1/4"-20 Socket Head Cap Screw 3/16" Hex Driver 5.0 - 5.8 6.8 - 7.9
Loose End Screw 1/4"-20 Hex Cap Screw 7/16" - 6 or 12 Point Socket 4.2 - 5.0 5.6 - 6.8
Chain Stop Screw 1/4"-20 Socket Head Cap Screw 3/16" Hex Driver 5.0 - 5.8 6.8 - 7.9

12 00001996 (REV AC) 627NH October 2014
Table 2c. Torque Specification: Models J-RR, RT, RRT
Fastener Screw Size Tool Required *Recommended Seating Torque
ft-lbf N-m
Motor Housing / Gear Housing /
Back Frame Screws 5/16"-18 Socket Head Cap Screw 1/4" Hex Driver 14.2 - 15.0 19.2 - 20.3
Lift-Wheel Nut 1-1/8"-12 Hex Nut 1-11/16" - 6 or 12 Point Socket 85.0 - 90.0 115.2 - 122.0
BrakeAttaching Screw 5/16-18 Slotted Fillister Head Screw Slotted Blade Screw Driver 4.2 - 5.0 5.6 - 6.8
BrakeArmature Mounting Screws M6 Socket Head Cap Screw 5mm Hex Driver 7.1 - 7.9 9.6 - 10.7
Stator Mounting Screws 1/4"-20 Hex Cap Screw 7/16" - 6 or 12 Point Socket 4.2 - 5.0 5.6 - 6.8
SuspensionAdapter Screws 1/2"-20 12-Point Cap Screw 1/2" - 12 Point Socket 70.0 - 80.0 94.9 - 108.5
Lower Hook Block Screws
-Double Reeved 5/16"-18 Socket Head Cap Screw 1/4" Hex Driver 10.0 - 11.3 13.6 - 15.3
Loose End Screw 5/16"-18 Hex Cap Screw 1/2" - 6 or 12 Point Socket 8.0 - 10.0 10.8 - 13.6
Chain Stop Screw 1/4"-20 Socket Head Cap Screw 3/16" Hex Driver 5.0 - 5.8 6.8 - 7.9
Table 2d. Torque Specification: Model RRS
Fastener Screw Size Tool Required *Recommended Seating Torque
ft-lbf N-m
Main Frame/Intermediate Frame/Back Frame
Screws 5/16"-18 Socket Head Cap Screw 1/4" Hex Driver 14.2 - 15.0 19.2 - 20.3
3rd Pinion Nut 1-1/8"-12 Hex Nut 1-11/16" - 6 or 12 Point Socket 85.0 - 90.0 115.2 - 122.0
Chain Chute Pin Set ScrewTorque 1/2-13 Hex Recess Set Screw 1/4" Hex Driver 11.7 - 13.3 15.8 - 18.1
BrakeAttaching Screw 5/16-18 Slotted Fillister Head Screw Slotted Blade Screw Driver 4.2 - 5.0 5.6 - 6.8
BrakeArmature Mounting Screws M6 Socket Head Cap Screw 5mm Hex Driver 7.1 - 7.9 9.6 - 10.7
Stator Mounting Screws 1/4"-20 Hex Cap Screw 7/16" - 6 or 12 Point Socket 4.2 - 5.0 5.6 - 6.8
Suspension Retainer Screw 1/4"-20 Socket Head Cap Screw 3/16" Hex Driver 4.2 - 5.0 5.6 - 6.8
Chain Container Bracket Mounting Screws 9/16"-18 Hex Cap Screw 7/16" Hex Driver 20.0 - 50.0 27.1 - 67.8
Chain Stop Screws 5/16"-18 Socket Head Cap Screw 1/4" Hex Driver 10.0 - 13.0 13.6 - 17.6
*AllTorque values are for clean,dry fasteners. DO NOT apply oil or any other lubricant to the fastener threads

13 00001996 (REV AC) 627NH October 2014
ATTACHING LOAD CHAIN
RRS & Single.
1. Suspend the hoist from an adequate support.
2. If replacing existing chain, remove chain block kit from
loose end of chain by removing the two (2) screws
from opposing sides of the block. Remove lower hook
assembly by removing the pin holding the chain into the
assembly.
3. Using the connecting link, attach new chain to end of
starter chain (existing chain if replacing) and feed through
chain guides and over liftwheel. Feed enough chain
through to be able to attach the chain block kit to the
loose end of the chain by assembling the screws and
nuts into the appropriate slots and tightening securely.
4. Attach the lower hook assembly to the appropriate end
of the chain, by inserting the end link of the chain into the
block, and securing the link with the pin.
Triple Reeve
1. Suspend the hoist from an adequate support.
2. If replacing existing chain, disconnect “loose end” of
chain by removing the screw holding loose end link in
place on side of hoist frame. Remove dead end of chain
by removing the pin holding dead end link into lower
hook assembly block.
3. Using a connecting link, attach new chain to the “loose
end” of starter chain (existing chain if replacing) and
guide through lower hook block, through upper sheave
hanger and over sheave wheel, through center hole
of plate, and to dead end (center) slot on lower hook
assembly. Make certain load chain is free from twists and
binds.
4. Place dead end link into dead end slot, and insert pin.
Attach loose end link to frame of hoist, using the provided
screw. Tighten all fasteners securely.
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 (1) and secure it with
the dead end pin, washer and cotter pin furnished with
the suspension. Ensure there are no twists in the chain.
3. On Models R, R-2, RR and RR-2, slide the contact block
up the chain until it is against the bottom of the hoist
and the dead end block is projecting through the square
opening in the bottom of the block. Insert the last link of
the load chain, making sure there are no twists between
the hook block and the dead end block, into the dead
end block. Push the contact block up slightly and secure
the load chain to the dead end block using the dead end
pin, washer and cotter pin furnished with the suspension.
The dead end pin also supports the contact block (See
Figure 8)
Figure 8. Contact Block Used on Models R, R-2, RR and RR-2
Do not remove the plastic ties from the load chain at this
time. After the suspension is installed, hoists with a hook
suspension can be suspended from its permanent support
and then connected to the power supply system (refer to
page 14). For hoists with a lug suspension that are to be
suspended from a Series 635 Low Headroom Trolley, attach
the hoist to the trolley per the following instructions.

14 00001996 (REV AC) 627NH October 2014
POWER SUPPLY AND ELECTRICAL
CONNECTIONS
The hoist should be connected to a branch circuit which
complies with the requirements of the National Electrical
Code and applicable local codes.
It is recommended, especially for a single phase hoist with
a (1) horsepower motor (.75 Kilowatts), that a line with
adequate capacity be run directly from the power supply to
the hoist to prevent problems with low voltage and circuit
overloads.
For grounding of the hoist, the power cord includes a
grounding conductor (green yellow, G-Y). Before connecting
the hoist to the power supply, check that the power to
be used agrees with the position of voltage change plug
on the voltage change board. The nominal hoist voltage
rating corresponding to the voltage range given on hoist
identification plate is:
Single Speed Units Two Speed Units
Range Nominal Range Nominal
110-120 115 -- --
208-240 230 208-240 230
440-480 460 440-480 460
550-575 575 550-575 575
THREE PHASE HOIST
Unless ordered on a special basis, all single speed/dual
voltage (230/460-3-60, 220/380-3-50 and 220/415-3-50)
hoists are factory arranged to operate on 460-3-60 (or
380-3- 50 or 415-3-50). However, a voltage change board
is provided to easily and quickly change from 460 to 230 (or
380 to 220 or 415 to 220) volt operation. The voltage change
board shown in Figure 12 is located in the hoist as shown in
Figure 13.
Figure 12. Voltage Change Board
Figure 13. Location of Components
Voltage conversion board is located under back frame
cover (1) for Models A-H and under motor housing cover
(2) for Models J-RRT.
The voltage change board is color coded to indicate high
and low voltage connections. Connecting the 9 and 12 pin
plugs into the “Red” voltage change board receptacles will
connect the hoist for high voltage (380-3-50, 415-3-50 or
460-3-60). To change the hoist voltage to low voltage (208-3-
60, 220-3-50 or 230-3-60) simply remove the 9 and 12 pin
plugs from the “Red” receptacles and insert same into the
“White” receptacles located on the voltage change board. Be
sure to make a notation of the new hoist voltage on the tag
attached to the power cord.
POWER PHASING
Since the motor in a three phase hoist can rotate in either
direction, depending on the manner in which it is connected
to the power supply, the direction of hook movement must
be checked prior to each usage.
NOTE: Serious damage can result if the hook is run to the
upper or lower limit of travel with the hook operating in a
direction opposite to that indicated by the control station.
Therefore, proceed as follows:
1. Make temporary connections at the power supply.
2. Operate (UP) control momentarily. If hook raises,
connections are correct and can be made permanent.
3. If hook lowers, it is necessary to change direction by
inter-changing the Grey lead and the Black lead of hoist
power supply. Under no circumstances should the
internal wiring of the control device or hoist be changed
to reverse hook direction. The wiring is inspected and
tested before leaving the factory.
Do not force the Lodestar Load-limiter to compensate
for improperly adjusted limit switches or reverse voltage
phasing.

15 00001996 (REV AC) 627NH October 2014
Allowing the hook block to run into the bottom of the hoist when raising
a load or allowing the chain to become taut between the loose end
screw and the frame when lowering a load may break the chain and
allow the load to drop.
TO AVOID INJURY:
Do not allow the hook block to contact the bottom of the hoist or
the loose end chain to become taut.
CHECKING FOR TWIST IN LOAD CHAIN
MODELS E,H, E-2, H-2,R, RR, R-2, RR-2
The best way to check for this condition is to run the lower
hook, without a load, up to within about 2 feet (.61 meters)
of hoist. If the dead end of the chain has been properly
installed, a twist can occur only if the lower hook block
has been capsized between the strands of chain. Reverse
capsize to remove twist.
Models RT, RT-2, RRT and RRT-2
On these models, the load chain is dead ended on top of the
lower hook block. If the chain has been properly installed,
the only way a twist can occur is if the lower hook block
has been capsized between the strands of chain. If this has
occurred, two strands of chain will be wrapped around each
other and to remove this, reverse the capsize.
CHECKING FOR ADEQUATE VOLTAGE AT HOIST
The hoist must be supplied with adequate electrical power in
order to operate properly. For proper operation, the voltage,
(measured at the hoist end of the standard power cord with
the hoist operating in the, up direction with full load) must be
as indicated in the table below.
Nominal Voltage Minumum
Running Voltage Minimum Starting Voltage
115-1-60 104 98
230-1-60 207 196
230-3-60 187 -
460-3-60 396 -
575-3-60 495 -
220-3-50 198 -
380-3-50 365 -
415-3-50 399 -
550-3-50 495 -
SIGNS OF INADEQUATE ELECTRICAL POWER
(LOW VOLTAGE) ARE:
• Noisy hoist operations due to brake and/or
contactor chattering.
• Dimming of lights or slowing of motors connected
to the same circuit.
• Heating of the hoist motor and other internal
components as well as heating of the wires and
connectors in the circuit feeding the hoists.
• Failure of the hoist to lift the load due to motor stalling.
• Blowing of fuses or tripping of circuit breakers.
Failure to properly ground the hoist presents the danger of
electric shock.
TO AVOID INJURY:
Permanently ground the hoist as instructed in this manual.
To avoid these low voltage problems, the hoist must be
connected to an electrical power supply system that
complies with the National Electrical Code and applicable
local codes. This system must also provide (slow blow fuses
or inverse-time type circuit breakers) and provisions for
grounding the hoist.
Low voltage may also be caused by using an undersized
cord and/or connectors to supply power to the hoist. The
following chart should be used to determine the size wires
in the extension cord in order to minimize the voltage drop
between the power source and the hoist.
Length of
Extension Cord Single Phase Hoists Three Phase Hoist
Minimum Wire Size Minimum Wire Size
Up to 50 Feet #14 AWG #16 AWG
80 FEET (24.4 M) #12AWG #16 AWG
120 FEET (36.7 M) #10AWG #14AWG
200 FEET (61.0 M) Contact Factory #14AWG
For runs beyond 200 Feet contact factory.
Failure to provide a proper power supply system for the hoist may cause
hoist damage and offers the potential for a fire.
TO AVOID INJURY:
Provide each hoist with a 20 amp, minimum, overcurrent
protected power supply system per the National Electrical Code
and applicable local codes as instructed in this manual.
Remember, operation with low voltage can void the CM
repair/replacement policy. When in doubt about any of the
electrical requirements, consult a qualified electrician.
Working in or near exposed energized electrical equipment presents the
danger of electric shock.
TO AVOID INJURY:
DISCONNECT POWER AND LOCKOUT/TAGOUT
DISCONNECTING MEANS BEFORE REMOVING COVER OR
SERVICING THIS EQUIPMENT.

16 00001996 (REV AC) 627NH October 2014
CHECKING LIMIT SWITCH OPERATION IF
HOIST IS EQUIPPED
With hoists that are equipped with an adjustable screw limit
switch, the limit switch will automatically stop the hook at
any predetermined point when either hoisting or lowering.
Allowing the hook block to run into the bottom of the hoist when raising
a load or allowing the chain to become taut between the loose end
screw and the frame when lowering a load may break the chain and
allow the load to drop.
Do not allow the hook block to contact the bottom of the
hoist or the loose end chain to become taut.
Operate hoist over the entire length of its rated lift, checking
upper and lower limit switches for correct operation as
follows:
1. Press(UP) control and raise the lower hook until top of
hook block is about one foot (305 mm) below the hoist.
2. Cautiously continue raising the hook until the upper limit
switch stops the upward motion. The upper limit switch
is set at the factory to stop the hook block 3 inches (76.2
mm) from bottom of the hoist on all units with standard
10 foot (3m) lift except Models AA and AA-2. Factory
setting is 6 inches (152.4 mm) for these models and for all
other models equipped with chain for lifts longer than 10
feet (3m).
3. If adjustment is necessary, see page 23.
4. Press (DOWN) control and cautiously lower hook until
lower limit switch stops the downward motion From
7 to 11 chain links (depending on hoist model) should
be between the loose end link and the hoist entry. See
Figures 7 and 8.
5. If adjustment is necessary, see page 23.
NOTE: If the hoist is equipped with a chain container/
bag, reset the upper and lower limit switches as
indicated on page 23.
Under no condition should the hook block or load
be permitted to come in contact with the chain
container/bag. If contact is made, the function of
the chain container can be interfered with and its
fasterners imperiled.
NOTE: When chain bag is filled to capacity the bag
must be no more than 75% filled.
CONTROL CORD
Unless ordered on a special basis, the hoist is supplied
with a control cord that will position the control station
approximately 4 feet above the lower hook when it is at the
lower limit of the lift. If this places the control station too
close to the floor, a “control cord alteration kit” (Part Number
28642) can be obtained from CM for shortening the length of
the control cord.
Tying knots or loops to shorten the drop of the control station will make the
strain relief ineffective and the internal conductors of the cord may break
TO AVOID INJURY:
Shorten the control cord using the control cord alteration kit
and the instructions provided with the kit.
OPERATING INSTRUCTIONS
GENERAL
1. The Load-limiter is designed to slip on an excessive
overload. An overload is indicated when the hoist will not
raise the load. Also, some clutching noise may be heard
if the hoist is loaded beyond rated capacity. Should this
occur, immediately release the (UP) control to stop the
operation of the hoist. At this point, the load should be
reduced to the rated hoist capacity or the hoist should
be replaced with one of the proper capacity. When the
excessive load is removed, normal hoist operation is
automatically restored.
CAUTION: The Load-limiter is susceptible to
overheating and wear when slipped for extended
periods. Under no circumstance should the clutch be
allowed to slip for more than a few seconds.
It is not recommended for use in any application where
there is a possibility of adding to an already suspended
load to the point of overload. This includes dumbwaiter
(*see below) installations, containers that are loaded in
mid-air, etc.
(*) Refer to limitations on Page 3 concerning dumbwaiter
applications.
2. All hoists are equipped with an adjustable screw limit
switch, which automatically stops the hook at any
predetermined point when either hoisting or lowering.
3. The control station used on two speed hoists is similar
to single speed unit, except that either of two definite
speeds may be selected by the operator in both hoisting
and lowering. Each control when partially depressed
provide SLOW speed and when fully depressed gives
FAST speed. Partial release of control returns hoist to
slow speed, while complete release allows hoist to stop.
Rated lifting speeds are shown on hoist identification
plate. SLOW speed is intended as a means of carefully
controlling or “spotting” the load, although the hoist
may be operated solely at this speed if desired. It is not
necessary to operate in the SLOW speed position as the
hoist will pick up a capacity load at FAST speed from
a standing start. In other words, it is not necessary to
hesitate at the slow position when moving control from
STOP to FAST position or vice versa.
4. If material being handled must be immersed in water,
pickling baths, any liquid, dusty or loose solids, use a
sling chain of ample length so that the hook is always
above the surface. Bearings in the hook block are
shielded only against ordinary atmospheric conditions.
HOIST
1. Before picking up a load, check to see that the hoist is
directly overhead.
2. WHEN APPLYING A LOAD, IT SHOULD BE DIRECTLY
UNDER HOIST OR TROLLEY. AVOID OFF CENTER
LOADING OF ANY KIND.
3. Take up a slack load chain carefully and start load easily
to avoid shock and jerking of hoist load chain. If there is
any evidence of overloading, immediately lower the load
and remove the excess load.
4. DO NOT allow the load to swing or twist while hoisting.
5. DO NOT allow the load to bear against the hook latch.

17 00001996 (REV AC) 627NH October 2014
HOIST WITH LOW HEADROOM TROLLEY
This unit should be moved by pushing on the suspended
load or by pulling the empty hook. However, the unit can also
be moved by pulling on the control station since an internal
steel cable extends the length of the control cord and is
anchored to the hoist and to the control station.
HOIST WITH MOTOR DRIVEN TROLLEY
This unit should be moved by operating the controls marked
(Forward) and (Reverse) in control station. Unless altered by
the erector, depressing (Forward) control will move the hoist
toward motor housing end. Anticipate the stopping point
and allow trolley to coast to a smooth stop. Reversing or
“plugging” to stop trolley causes overheating of motor and
swaying of load.
SAFE OPERATING INSTRUCTIONS AND
PROCEDURES
For safety precautions and a list of Do’s and Do Not’s for
safe operation of hoists, refer to page 3.
1. Permit only competent personnel to operate unit.
2. When preparing to lift a load, be sure that the
attachments to the hook are firmly seated in hook saddle.
Avoid off center loading of any kind, especially loading on
the point of hook.
3. DO NOT allow the load to bear against the hook latch.
The latch is to help maintain the hook in position while the
chain is slack before taking up slack chain.
Allowing the load to bear against the hook latch and/or hook tip can
result in loss of load.
TO AVOID INJURY:
Do not allow the load and/or attachments to bear against
the hook latch and/or hook tip. Apply load to hook bowl or
saddle only.
4. DO NOT wrap the load chain around the load and hook
onto itself as a choker chain.
Doing this will result in:
a. The loss of the swivel effect of the hook
which could result in twisted chain and a
jammed lift wheel.
b. The upper limit switch, if so equipped, is
by-passed and the load could hit the hoist.
c. The chain could be damaged at the hook.
5. Before lifting load, check for twists in the load chain.
On double and triple reeved units, a twist can occur if
the lower hook block has been capsized between the
strands of chain. Reverse the capsize to remove twist.
6. Stand clear of all loads and avoid moving a load over
the heads of other personnel. Warn personnel of your
intentions to move a load in their area.
7. DO NOT leave the load suspended in the air unattended.
8. DO NOT use this or any other overhead materials
handling equipment for lifting persons.
9. DO NOT load hoist beyond the rated capacity shown on
ID plate. When in doubt, use the next larger capacity CM
Lodestar Hoist.
10.Warn personnel of your intention to lift a load in the area.
Tie off the load with auxiliary chains or cables before
access to the area beneath the load is permitted.
11.Take up a slack load chain carefully and start load easily
to avoid shock and jerking of hoist load chain. If there is
any evidence of overloading, immediately lower the load
and remove the excess load.
12.When lifting, raise the load only enough to clear the floor
or support and check to be sure that the attachments
to the hook and load are firmly seated. Continue lift only
after you are assured the load is free of all obstructions.
13.DO NOT allow the load to swing or twist while hoisting.
14.Never operate the hoist when flammable materials or
vapors are present. Electrical devices produce arcs or
sparks that can cause a fire or explosion.
15.STAY ALERT! Watch what you are doing and use
common sense. Do not use the hoist when you are tired,
distracted or under the influence of drugs, alcohol or
medication causing diminished control.

18 00001996 (REV AC) 627NH October 2014
INSPECTION
To maintain continuous and satisfactory operation, a regular
inspection procedure must be initiated to replace worn or
damaged parts before they become unsafe. Inspection intervals
must be determined by the individual application and are based
on the type of service to which the hoist will be subjected.
The type of service to which the hoist is subjected can be
classified as “Normal”, “Heavy”, or “Severe”.
Normal Service:
Involves operation with randomly distributed loads within
the rated load limit, or uniform loads less than 65 percent of
rated load for not more than 25 percent of the time.
Heavy Service:
Involves operating the hoist within the rated load limit which
exceeds normal service.
Severe Service:
Normal or heavy service with abnormal operating conditions
or constant exposure to the elements of nature.
Two classes of inspection - frequent and periodic - must
be performed.
Frequent Inspections:
These inspections are visual examinations by the operator or
other designated personnel. Records of such inspections are
not required. The frequent inspections are to be performed
monthly for normal service, weekly to monthly for heavy
service, and daily to weekly for severe service, and they
should include those items listed in Table 4.
Periodic Inspections:
These inspections are visual inspections of external
conditions by an appointed person. Records of periodic
inspections are to be kept for continuing evaluation of the
condition of the hoist.
Periodic inspections are to be performed yearly for normal
service, semi-annually for heavy service and quarterly for severe
service, and they are to include those items listed in Table 5.
CAUTION: Any deficiencies found during inspections are to
be corrected before the hoist is returned to service. Also,
the external conditions may show the need for disassembly
to permit a more detailed inspection, which, in turn, may
require the use of nondestructive type testing
PREVENTATIVE MAINTENANCE
In addition to the above inspection procedure, a preventive
maintenance program should be established to prolong
the useful life of the hoist and maintain its reliability and
continued safe use. The program should include the periodic
and frequent inspections with particular attention being
paid to the lubrication of the various components using the
recommended lubricants (see page 127).
SUSPENSION INSPECTION CRITERIA
BRACKETS - Replace any bracelets found to be cracked or distorted.
BOLTS - If the suspension is removed for any reason, including
inspection, the suspension bolts should be replaced.
NYLON THREAD LOCKING NUTS - It is not necessary to replace
the nylon thread locking nuts each time the suspension bolts are
replaced as long as new bolts with the locking patch are being used.
It is recommend that the nylon thread locking nuts are replaced each
time the hoist is torn down to allow these nuts to be replaced.
HOOK REMOVE CRITERIA
Based on B30-10 Hooks shall be removed from service if
damage such as the following is visible and shall only be
returned to service when approved by a qualified person:
a. Missing or illegible rated load identification or illegible
hook manufacturers’ identification or secondary
manufacturer’s identification.
b. Excessive pitting or corrosion.
c. Cracks, nicks, or gouges.
d. Wear--any wear exceeding 10% of the original section
dimension of the hook or its load pin.
e. Deformation--any visibly apparent bend or twist from the
plane of the unbent hook.
f. Throat opening-any distortion causing an increase in the
throat opening of 5% not to exceed ¼” (6mm).
g. Inability to lock - any self-locking hook that does
no lock.
h. Inoperative latch any damaged latch or malfunctioning
latch that does not close the hook’s throat.
i. Thread wear, damage, or corrosion.
j. Evidence of excessive heat exposure or
unauthorized welding.
k. Evidence of unauthorized alterations such as drilling,
machining, grinding, or other modifications.
Figure 14. Hook Inspection
Models Latch Type Hook Latchlok®Hook
"A" Max "B" Min "A" Max "B" Min
A,A-2,AA,AA-2,
B,B-2,C, C-2,F
AND F-2
1.19"
(30.2mm) .91" (23.1mm) 1.48" (37.7mm) .75" (18.8mm)
E,E-2,H, H-2,
J,J-2,JJ, JJ-2,
L,L-2,LL AND
LL-2
1.31"
(33.3mm) 1.08" (27.5mm) 1.48" (37.7mm) .75" (18.8mm)
R,R-2,RR,RR-2
AND RRS 1.50" (38.1 mm) 1.43" (36.2mm) 1.92" (48.8mm) .94" (23.9mm)
RT,RT-2,RRT
AND RRT-2 1.50"
(38.1 mm) 1.43" (36.2mm) 2.50" (63.5mm) 1.19" (23.9mm)
"A" MAX.
A
A
"B" MIN
"A" MAX
B
B
"B" MIN
Section A-A Section B-B

19 00001996 (REV AC) 627NH October 2014
Table 4. Minimum Frequent Inspections
TYPE OF SERVICE ITEM
Normal Heavy Severe
Monthly
Weekly to Monthly
Daily to Weekly
a) Brake for evidence of slippage.
b) Control functions for proper operation.
c) Hooks for damage, cracks, twists, excessive throat opening, latch engagement and latch
operation - see page 18.
d) Load chain for adequate lubrication, as well as for signs of wear, damaged links or foreign matter
- see page 20.
e) Load chain for proper reeving and twists.
Table 5. Minimum Periodic Inspections
TYPE OF SERVICE ITEM
Normal Heavy Severe a) All items listed in Table 4 for frequent inspections.
Yearly
Every 6 Months Every 3 Months
b) External evidence of loose screws, bolts or nuts.
c) External evidence of worn, corroded, cracked or distorted hook block, suspension screws,gears,
bearings and dead end block and chain pin.
d) External evidence of damage to hook retaining nut and pin. Also check the upper suspension
adapter making sure it is fully seated in the hoist frame and that both screws are tight.
e) External evidence of damage or excessive wear of the liftwheel and hook block sheave chain
pockets. Widening and deepening of the pockets may cause the chain to lift-up in the pocket
and result in binding between liftwheel and chain guides or between the sheave and hook block.
Also, check the chain guide for wear or burring where the chain enters the hoist. Severely worn
or damaged parts should be replaced.
f) External evidence of excessive wear of brake parts, and AC brake adjustment - see page 22.
g) External evidence of pitting or any deterioration of contactor contacts. Check the operation of
the control station making sure the buttons operate freely and do not stick in either position.
h) Inspect the electrical cords and cables and control station enclosure for damaged insulation.
i) Inspect trolley trackwheels for external wear on tread and flange and for wear on internal bearing
surfaces as evidenced by a looseness on the stud. Suspension components for damage, cracks,
wear and operation. Also check suspension adapter screws for proper tightness - see page 11.
j) Inspect the loose end link, loose end screw and dead end block on double reeved units. Replace
worn or distorted parts.
k) Inspect the suspension lug or hook for excess free play or rotation. Replace worn parts as
evidenced by excess free play or rotation.
l) Inspect for signs of lubricant leaks at the gasket between the gear housing and back frame.
tighten screws holding back frame to gear housing. If leak persists, repack housing and gears
with grease and install a new gasket.
m) On the Models RT, RT-2, RRT and RRT-2:
1. Inspect shackle and lug pins for wear. Replace if worn.
2. Check dead end screw in lower hook black for wear and tightness*.
3. Check shackle pin for proper seating in groove of load bracket.
4. Inspect cloverleaf plate on bottom of sheave hanger for wear or burring. Replace if worn.
5. Inspect sheave stud nut and seat for wear. Replace if worn or damaged.
*When tightening the special, dead end socket head screw, it should be held firmly in place and torqued from the nut end only to avoid damage to the
screw and/or dead end chain link (Refer to step J on page 45).

20 00001996 (REV AC) 627NH October 2014
INSPECTING THE LOAD CHAIN:
The chain must be inspected at regular intervals, with
a minimum of once annually. As the frequency of use
increases, the time intervals between inspections must be
reduced. During inspection, the chain must be examined
along their entire length, including the hidden parts. If the
lifting equipment is frequently used with a constant lifting
distance or in other words the switch from upward to
downward often takes place in the same area, a particularly
thorough inspection and lubrication is required in that area.
Worn chain can be an indication of worn hoist components.
For this reason, the hoist’s chain guides, hook blocks
and liftwheel (sprocket) should be examined for wear and
replaced as necessary when replacing chain.
1. Check to see if chain is dirty or poorly lubricated.
2. Clean the chain with a non-caustic/non-acid type solvent
and make a link by link inspection for wear or cracks in
the links, twisted or deformed links. Chain with any one
of these defects must be replaced.
3. Slack the portion of the chain that normally passes over
the lift-wheel (sprocket) or idler sprocket on multi-reeved
hoist. Examine the chain links for wear ( see figure 15).
If the wire diameter anywhere on the link measures less
than 90% of the nominal wire diameter, the chain must
be replaced.
Figure 15. Chain Wear Areas
Models P D
A,A-2,AA,AA-2, B, B-2,
C,C-2, F, F-2,E,E-2,H
and H-2 .745" (18.9mm) .250" (6.3mm)
J,J-2, JJ, J-2,L,L-2, LL,
LL-2,R, R-2, RR,RR-2,RT,
RT-2, RRT, and RRT-2 .858" (21.8mm) .312" (7.9mm)
RRS 1.18 (30.0mm) .394" (10.0mm)
Figure 16. Gaging Load Chain Wear
4. Based upon ASME B30.16, 2012 chain should also
be checked for elongation. Select an unworn, un-
stretched length of the chain (at the slack end for
example).Suspend the chain vertically under tension
and using a knife blade caliper type gauge, measure the
outside length of any convenient number of links, 11 is
recommended. Measure the same number of links in the
used sections and calculate the percentage in increased
length. The chain should be replaced if the length of the
used portion is more than 2% longer than the unused
portion of the chain. Also, if the pitch of any individual
link has elongated by more than 5%,the chain should
be replaced.
Figure 17. Chain Embossing
Use only Star (*) grade load chain and original
replacement parts. Use of other chain and parts may be
dangerous and voids factory warranty.
IMPORTANT: Do not use replaced chain for other purposes
such as lifting or pulling. Load chain may break suddenly
without visual deformation. For this reason, cut replaced
chain into short lengths to prevent use after disposal.
Use of commercial or other manufacturer’s chain and parts to
repair CM hoists may cause load loss.
TO AVOID INJURY:
Use only CM supplied replacement load chain and parts. Chain
and parts may look alike, but CM chain and parts are made of
specific material or processed to achieve specific properties.
P = Nominal Pitch
D = Nominal Wire Diameter