CM Lodestar D8 PLUS Installation and operating instructions

P/N: 192070212 (REV AA) December 2019
Before installing the D8 Plus hoist, fill in the information below.
Model Number
Serial No.
Purchase Date
Voltage
Rated Load
RATED LOADS 1/2 TO 2 TONNES
500 KG TO 2000 KG
WARNING
Follow the instructions and warnings of the
OPERATING, MAINTENANCE & PARTS manual
and all of the instructions contained in this
ADDENDUM in order to assemble, commission
and integrate the hoist.
The use of any D8 Plus hoist presents some risk
of personal injury or property damage, and that
risk is greatly increased if the proper commissioning
and integration instructions and warnings are
not followed.
Before using this D8 Plus hoist, each operator
should become thoroughly familiar with all warnings,
instructions and recommendations in this ADDENDUM.
Retain these instructions for future reference and use.
Forward these safety instructions to the operator.
Failure to operate the equipment as directed in
these safety instructions may cause injury.
SAFETY INSTRUCTIONS AND GUIDELINES
ELECTRIC CHAIN HOIST
ADDENDUM
D8 PLUS - SQ P2 10:2018

2P/N: 192070212 (REV AA) December 2019
CM HOIST PARTS AND SERVICES ARE AVAILABLE IN EUROPE,
IN THE UNITED STATES AND IN CANADA
PARTS FOR YOUR HOIST ARE AVAILABLE FROM YOUR LOCAL AUTHORIZED DISTRIBUTOR.
FOR THE NAME OF THE NEAREST PARTS OR SERVICE CENTER, VISIT OUR WEBSITE WWW.CMWORKS.COM
OR CALL OUR CUSTOMER SERVICE DEPARTMENT AT 1-8Z00-888-0985.

3P/N: 192070212 (REV AA) December 2019
D8 Plus hoists are not designed to lift, lower or move loads
with the presence of people in the hazard zone.
D8 Plus hoists are not designed to move people or lift performers
unless a dedicated risk assessment made by a qualied person
states otherwise.
FOREWORD
This addendum contains important information to help you properly assemble, commission and integrate your D8 Plus hoist for correct
performance and safety lifting operations. Please study its contents thoroughly before putting your D8 Plus hoist into service.
By practicing correct operating procedures and by carrying out the recommended preventive maintenance suggestions, you will be able
to claim presumption of compliance with the requirements as stated in the SQ P2 10:2018 German standard. After you have completely
familiarised yourself with the contents of this addendum, we recommend that you carefully le it for future reference.
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED
COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOUR SELF AND OTHERS.
INTENDED USE
Lodestar D8 Plus chain hoist can be used to lift loads during the setup process with the hazard zone clear of people, and are
hoists that are allowed to keep the load suspended above people without the need of a secondary suspension being installed.
These electric chain hoists are designed with specic provisions in mind and are be tted with supplementary
safety-related elements to ensure an increased level of safety.
Lodestar D8 Plus chain hoists can be used in the following modes:
A) ASYNCHRONOUS GROUP TRAVEL
Lifting operation of a group that occurs after a common start without mutual dependence or inuence of the individual
electric chain hoists by the control. The asynchronous group travel can occur with or without a group shut down.
B) PATH SYNCHRONOUS GROUP TRAVEL
Lifting of a group in which all electric chain hoists in the group cover an equally long stroke at the same speed and at the same time.
TABLE OF CONTENTS
Foreword ........................................................................................... 3
Intended Use ..................................................................................... 3
Risk Assessment ............................................................................... 4
Risk Assessment Before Use ....................................................... 4
Risk Assessment Before Each Use .............................................. 4
Integration ......................................................................................... 4
Site Conditions ............................................................................. 4
Load Chain ................................................................................... 4
Competent Person ....................................................................... 4
Commissioning.................................................................................. 4
Operators ..................................................................................... 4
Control System.................................................................................. 5
Safety Functions........................................................................... 5
Other Requirements ..................................................................... 5
Maintenance...................................................................................... 5
Inspections ........................................................................................ 5
Periodic Inspections..................................................................... 5
Brake Test Provisions ................................................................... 6
Documentation.................................................................................. 7
Sample Handover Report............................................................. 7
Sample Test Report...................................................................... 8

4P/N: 192070212 (REV AA) December 2019
RISK ASSESSMENT
Before using a Lodestar D8 Plus chain hoist and the associated
work equipment, the user must assess the hazards to be expected
(risk assessment), and describe and implement the necessary and
suitable protective measures.
The presence of a CE marking on the Lodestar D8 Plus chain
hoist does not release the user from the obligation to carry out a
risk assessment.
The risk assessment must include all allocated hazards that can
occur when using the Lodestar D8 Plus electric chain hoist.
These risks include not only those that can arise from the electric
chain hoists themselves, but also those that can affect the working
environment (e.g. weather conditions when used outdoors).
RISK ASSESSMENT BEFORE USE
The risk assessment must be drafted before the selection
and integration of the Lodestar D8 Plus electric chain hoists.
The risk assessment may only be carried out by competent persons.
An expert must be commissioned if the user does not possess
the appropriate knowledge.
The risk assessment must be documented in writing.
RISK ASSESSMENT BEFORE EACH USE
Individual application-related (scenic motion) risk assessments
MUST be carried out due to the large number of possible uses the
Lodestar D8 Plus chain hoist can be utilised for in event technology.
Elements to be considered:
- Mechanical risks.
- Electrical risks.
- Risk due to the working environment conditions.
- Danger from physical stress and work severity.
- Risks due to the lack of organisation.
Circumstances to be considered:
- Presence of persons under loads.
- Type of loads to be lifted.
- Emergency or hazardous situations.
- Competence and experience of users.
- Time frame.
The risk assessment should take place during the
planning phase and must be documented in writing.
When using electric chain hoists in event technology, risks due to
the use of technical protective measures can only be minimised
to a limited extent in individual cases. In such cases, electric
chain hoists can only be used with special care.
INTEGRATION
Before integrating Lodestar D8 Plus chain hoist and the chosen
work equipment, the following points must be considered:
SITE CONDITIONS
The condition of the on-site attachment points must be visually
checked, and the load-bearing capacity of the attachment points
must be ascertained based on the operator documentation
and information.
LOAD CHAIN
- Electric chain hoists are to be mounted so that the chain does
not rest on anything and cannot run in at an angle. In particular,
the fastening of a load (e.g. truss construction) on several electric
chain hoists must not cause any slack run in of the chain.
- The chain of an electric chain must be able to run safely
into the chain container.
- It must be ensured that the chain can freely run in
and out without obstacles even when unloaded.
- When using double reeve electric chain hoists, make sure
that the chain strands are not twisted.
These integration guidelines are in addition to the safety
guidelines present in the Lodestar D8 Plus user manual!
COMPETENT PERSON
- The competence or qualication of those involved in planning,
construction and dismantling the machinery operation depends
on the degree of risk and the output of the risk assessment.
- As general guideline, a competent person is a person with
sufcient practical and theoretical knowledge and experience
to carry out the person’s duties, and who is aware of the limits
of the person’s competency, expertise and knowledge.
COMMISSIONING
The Lodestar D8 Plus electric chain hoist may be used to hold
loads over persons without a secondary safety component.
For the “at rest” state, the operating coefcients of all elements of
the electric chain hoist located in the power ow must be known
and must be dimensioned for at least twice the load capacity of
the D8 Plus electric chain hoist.
The Lodestar D8 Plus electric chain hoist is equipped with a direct-
acting hoisting force limiter (slipping clutch), but it must not be used
for the protection against overload. Lodestar D8 Plus electric chain
hoists may be supplied with additional safety features such as, for
example, indirectly acting lifting force limiters (e.g. load cells, load
pins), limit switches and encoders.
The requirements of such safety-related devices is the consequence
of the risk assessment being carried out by the user.
As a general rule, a load cell system should be used as an overload
device, every time a Lodestar D8 Plus system is installed.
Load monitoring and measurement is ALWAYS required if there
is the possibility to overload a load-bearing element.
OPERATORS
- The operator must always be able to see the lifting operation of a
Lodestar D8 Plus electric chain hoist and its load throughout the
entire travel distance. If this is not possible, suitable measures for
monitoring the lifting process must be dened and implemented.
- If several electric chain hoists are used to lift a shared load with
more than one control, it must be ensured that the lifting process
is triggered over a common command device and that the lifting
process can be interrupted by a common emergency stop.
- The operator should perform the lifting operation based
on the output of the risk assessment.

5P/N: 192070212 (REV AA) December 2019
CONTROL SYSTEM
Lodestar D8 Plus chain hoist can be integrated with a control
system which must full the electrical and functional safety
requirements as follows:
- They should be tted with control devices designed to
perform a single operation.
- They should have indicators visible from the operator’s position.
- They should be tted with safety-related switches or functions
in order to permit local and remote operation of the machinery.
- They can initiate a movement only by means of pushing
a DEADMAN button.
- They cannot restart automatically after trippage;
even if the DEADMAN button is kept pressed.
- They should be designed NOT to function in automatic mode.
- They should be tted with a control device equipped with a
means to bring it to a safe stop (DEADMAN) and an E-STOP push
button to perform a Category 1 or Category 0 Emergency Stop.
- They should be tted with Restart prevention after an E-STOP.
- The Lodestar D8 Plus chain hoist’s safe stop shall have priority
over the Start controls, and the E-STOP system shall have
priority over the Lodestar D8 Plus safe stop.
- They should remove the energy supplied from the actuators
and perform a Category 0 or 1 Stop when the E-STOP is
activated, or keep the stop condition monitored.
- They should be tted with wrong direction detection.
- The power supply should be protected by MCB and RCD.
- They should have an Emergency Stop safety function that
cannot be overridden by other operating modes.
- The power plug should be rated to the machine’s capacity.
- The circuit breaker rated to the machine’s current limit
must be in place in the controller.
- RCD of at least 30mA must be in place as part of the
installation’s electrical supply.
- If the phase sequence of the supply voltage is incorrect:
no hazardous state is possible, no damage to the machine
is possible or a protective measure is in place.
- Other electrical and control system requirements as
60204-1 and 60204-32 must be fullled.
- The technical le should Include an electrical assessment
as per the LV directive; including, but not only, EN 60204-1
and 60204-32.
SAFETY FUNCTIONS
- When using more than one Lodestar D8 Plus chain hoist together,
a group shut down (group halt) is a necessary safety condition.
- An automatic overload cut-off is required if the operator
response is insufcient to prevent a risk condition.
NOTE: Current absorption cannot be used as load
monitoring system.
OTHER REQUIREMENTS
- The drives and brakes of the Lodestar D8 Plus electric chain
hoist must be de-energised when people are in the danger zone.
- If more than one emergency stop button is present,
each individual emergency stop button must be able
interrupt the lifting operation of all electric chain hoists.
These commissioning and control system guidelines are
in addition to the safety guidelines present in the Lodestar
D8 Plus user manual!
MAINTENANCE
Lodestar D8 Plus maintenance and inspections should
be carried out following the instructions present in the
Lodestar D8 Plus user manual.
However, the following provisions should be considered
in addition to the manufacturer’s guidelines:
- DGUV regulation 17/18 “Event presentation and production
facilities for scenic representation”
- DGUV regulation 115-002 “”Event presentation and production
facilities for scenic representation”
- DGUV Principles 315-390 “Principles for testing mechanical
equipment in stages and studios”
- DGUV regulation 54/55 “Winches, hoists and towing equipment”
- DGUV regulation 3/4 “Electrical installations and equipment”
- DIN 56950-1 “Event technology - Mechanical engineering
equipment - Part 1: Safety requirements and testing”.
- DIN 56950-5 “Event technology - Mechanical engineering
equipment - Part 5: Safety requirements for electric chain
hoist systems”
- Operational risk assessment for the electric chain hoist
INSPECTIONS
According to the Operational Safety Ordinance, the user must
ensure that a qualied person tests the electric chain hoist because
the safety depends on the installation conditions before the rst use.
The inspection includes:
a) control of the assembly or installation and the safe
operation of the electric chain hoists,
b) the timely detection of damages,
c) determining whether the safety measures taken are effective.
Inspection contents that have been tested and documented
as part of a Conformity Assessment procedure do not need
to be rechecked.
The inspection must take place before each start-up after assembly.
PERIODIC INSPECTIONS
- The user must also ensure that the Lodestar D8 Plus electric
chain hoist is inspected at least every four years by authorised
experts (test experts) in accordance with DGUV regulation 17/18.
- In addition, there may be further test criteria as a result of
the DGUV provisions and regulations and the state of the art.
- The electrical and mechanical safety of the electric chain
hoist must be assessed during the periodic inspection.
- Additional documents may be required regarding the testing of
electric chain hoists / electric chain hoist systems after assembly,
for example:
a) Technical drawings (e.g. of the load system)
b) Bill of materials
c) Load plans
d) Static calculations
- A qualied person must inspect the Lodestar D8 Plus electric
chain hoist at the place of use after each assembly or installation
of the systems components and document the inspection.
- The user must immediately submit the Lodestar D8 Plus chain
hoist that is affected by the revisions or exceptional occurrences
which have harmful effects on their safety, and which may
endanger persons for an extraordinary inspection by an
authorised expert (verier).

6P/N: 192070212 (REV AA) December 2019
- Revisions requiring inspection are, for example:
a) Change in load capacity
b) Replacement of safety devices (brakes)
c) Changes to the control system
- Exceptional events may in particular be:
a) Malfunctions
b) Prolonged periods of non-use of electric chain hoists
c) Natural events
BRAKE TEST PROVISIONS
The part number for the brake tester is 192070166.
Please follow the steps below in order to properly
conduct the brake test.
Test the Primary Brake
1. Remove the power to the hoist and the power to
the brake test box.
2. Open the cover.
3. Identify the brake connectors.
4. Unplug the Brake 2 connector from the distribution block.
Note: Brake 1 is the primary brake and is located closer
to the hoist body.
5. Ensure that the Brake 1 connector is still plugged
into the distribution block.
6. Connect the test lead from the brake test box to
the Brake 2 connector.
7. Ensure that none of the cables are untied or loose.
8. Make sure that the area around the hoist is clear
and segregated.
9. Plug the power to the hoist and the power to the test box.
Make sure that the area around the hoist is clear and segregated!
10. Press and hold the test box button to conrm that
Brake 2 is lifting (open and free).
11. While holding the text box button, perform a movement
to lift the load.
12. Conrm that Brake 1 is able to stop the load on its own.
Test The Secondary Brake
13. Lower the load to the ground.
14. Remove the power from the test box and hoist.
15. Plug Brake 2 back into the distribution block.
16. Unplug the Brake 1 connector from the distribution block.
17. Ensure that the Brake 2 connector is still plugged into
the distribution block.
18. Connect the test lead from the brake test box to
the Brake 1 connector.
19. Ensure that none of the cables are untied or loose.
20. Make sure that the area around the hoist is
clear and segregated.
21. Plug the power back into the hoist and test box.
22. Press and hold the test box button to conrm that
Brake 1 is lifting (open and free).
23. While holding the test box button, perform a movement
to lift the test load.
24. Conrm that Brake 2 is able to stop the load on its own.
25. Plug Brake 1 back into the distribution block.
26. Use cable tidies to prevent cables from being
unplugged or moved.
27. Close the cover.
28. Test the movement of the hoist and cabling.
Record the brake test in the periodic test checklist for the electric
chain hoist as per the example on page 9 of this addendum.
The power supply must have an overcurrent protector
device rated to the hoist maximum current and an RCD!

7P/N: 192070212 (REV AA) December 2019
SAMPLE - HANDOVER REPORT
Declaration of the compliant assembly and operational handover of electric chain hoists
Installation site:
CONTRACTOR
Name:
Surname:
Person responsible:
CLIENT
Name:
Surname:
Person responsible:
The contractor hereby conrms to the client that all Lodestar D8 Plus electric chain hoists installed
by them former comply with the applicable regulations and recognized technical rules.
The required user information and proofs were provided.
Comments:
Date
Date
Signature Contractor
Signature Client
DOCUMENTATION
- Prior to each assembly, the Lodestar D8 Plus electric chain hoist
and all equipment required for operation (e.g. slings, load handler,
control system, cabling) must be visually inspected.
- The user must ensure that the results of the tests
are recorded and kept for the entire period of use.
- The documentation of the inspection must provide
at least the following information:
a) Identication of the electric chain hoist.
b) Type of inspection.
c) Date and place of the inspection.
d) Test basis.
e) Scope of testing.
f) Result of the test.
g) Evaluation of identied defects.
h) Statements for further operation.
i) Date of the next inspection.
l) Name and signature of the person qualied for the inspection.
- Records can also be kept in electronic form. If electric chain
hoists are used at different locations, proof of the performance
of the last inspection must be provided so that it can be
inspected at the place of use.
- A summary of all documents relevant to the inspection is
appropriate to illustrate the complete history of an electric
chain hoist.
- The proof of the tests can be supplemented by test labels.

8P/N: 192070212 (REV AA) December 2019
SAMPLE -TEST REPORT - CHECKLIST PERIODIC TEST OF AN ELECTRIC CHAIN HOIST
CLIENT / OPERATOR NEXT INSPECTION DATE
MANUFACTURER TYPE
SERIAL NUMBER YEAR OF MANUFACTURING
LOAD CAPACITY LIFTING SPEED
LIFTING HEIGHT CHAIN REEVES
LOAD CHAIN TEST REGULATION
INSPECTION BOOK
AVAILABLE
OPERATION MODE
(CLIMBING / NOT CLIMBING)
TEST STEPS
FAULTS
COMMENT / MEASURE / MEASURED VALUES
YES NO
INSPECTION DOCUMENT
Operating instructions, test certicates,
test reports, EU declaration of conformity
GENERAL VISUAL INSPECTION
Housing, form, screw connection, nameplate, leaks, traces
of wear, load details, cable glands, connection cables, etc.
ELECTRICAL TEST
See DGUV regulation 3 / DIN VDE 0701-0702
SPECIFIC CHECKS (MANUFACTURER’S SPECIFICATIONS)
Chain container
Chain guide / sprocket wheel
Load chain / chain lubrication
Hook harness / hook block
Connection cable / control cable
Electrical connections / terminal points
Seals and gaskets
Brake / brakes
Transportion handles
FUNCTIONAL TESTS
Noise emission
Brake function / load test
Rated capacity limiter / load test
Limit switch
[NO - YES] SAFETY CONCERNS | FURTHER TEST IS NEEDED [NO - YES] | INSPECTION REQUIRED [NO - YES]
NOTES / COMMENTS
Date Test Inspector Signature

9P/N: 192070212 (REV AA) December 2019
NOTES

10 P/N: 192070212 (REV AA) December 2019
NOTES

11 P/N: 192070212 (REV AA) December 2019
NOTES

P/N: 192070212 (REV AA) December 2019
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04.2019 45
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