CM LODESTAR NH User manual

Electric C ain
®
Operating, Maintenance & Parts Manual
Rated Loads 1/8 To 3 Tonnes
125 Kg To 3000 Kg
00001996 (REV AB) 627 H
Follow all instructions and warning for
inspecting, maintaining and operating
this hoist.
The use of any hoist presents some risk of personal injury or
property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using this
hoist, each operator should become thoroughly familiar with all
warnings, instructions, and recommendations in this manual.
Retain this manual for future reference and use.
Forward this manual to the hoist operator.
Failure to operate the equipment as directed in the manual
may cause injury.
Before using the hoist, fill in the information below.
Refer to the hoist identification plate.
Model umber
Serial umber
Purchase Date
Voltage
Rated Load

2
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 STATIO . FOR THE AME
OF THE EAREST PARTS OR SERVICE CE TER, VISIT OUR WEB SITE WWW.CMWORKS.COM
OR CALL OUR CUSTOMER SERVICE DEPARTME T.

3
SAFETY PRECAUTIONS
Each Lodestar Electric Hoist is built in accordance with the specifications contained herein and at the time of manufacture com-
plied 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 main-
tenance 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 re-
sponsible 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, N 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.
1. NOT operate a damaged, malfunctioning or unusually
performing hoist.
2. NOT operate the hoist until you have thoroughly read and
understood this Operating, Maintenance and Parts Manual.
3. NOT operate a hoist which has been modified.
4. NOT lift more than rated load for the hoist.
5. NOT use hoist with twisted, kinked, damaged, or worn
load chain.
6. NOT use the hoist to lift, support, or transport people.
7. NOT lift loads over people.
8. NOT operate a hoist unless all persons are and remain
clear of the supported load.
9. NOT operate unless load is centered under hoist.
10. NOT attempt to lengthen the load chain or repair dam-
aged load chain.
11.Protect the hoist’s load chain from weld splatter or other
damaging contaminants.
12. NOT operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
13. NOT use load chain as a sling, or wrap load chain
around load.
14. NOT apply the load to the tip of the hook or to the hook
latch.
15. NOT apply the load unless load chain is properly seated
in the chain wheel(s) or sprocket(s).
16. NOT apply load if bearing prevents equal loading on all
load supporting chains.
17. NOT operate beyond the limits of the load chain travel.
18. NOT leave load supported by the hoist unattended un-
less specific precautions have been taken.
19. NOT allow the load chain or hook to be used as an elec-
trical 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 de-
cals are missing or illegible.
23. NOT operate a hoist unless it has been securely attached
to a suitable support.
24. NOT operate a hoist unless load slings or other approved
single attachments are properly sized and seated in the
hook saddle.
25.Take up slack carefully - make sure load is balanced and
load holding action is secure before continuing.
26.Shut down a hoist that malfunctions or performs unusually
and report such malfunction.
27.Make sure hoist limit switches function properly.
28.Warn personnel of an approaching load.
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.
WARNING
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could re-
sult in death or serious injury. To avoid such a poten-
tially hazardous situation, the operator shall:
CAUTION
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could re-
sult in minor or moderate injury. To avoid such a po-
tentially hazardous situation, the
operator shall:
WARNING
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.
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1 CHOOSE THE RIGHT HOIST FOR THE OB...
Choose a hoist with a 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 en-
dangers the operator, but in many cases, a
valuable load.
VIOLATION OF ANY OF THESE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL IN URY TO THE OPER-
ATOR OR NEARBY PERSONNEL BY RELEASED LOAD OR BROKEN HOIST COMPONENTS.
– DO NOT LIFT MORE THAN RATED LOAD.
WARNING
2 INSPECT
– DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST.
– DO NOT OPERATE WITH TWISTED, KINKED OR DAMAGED
CHAIN.
3 USE HOIST PROPERLY
Be sure hoist is solidly held in the
uppermost part of the support
hook arc.
Be sure hoist and load are in a
straight line. Do not pull at an
angle.
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 PULL AT AN ANGLE. BE SURE HOIST AND LOAD
ARE IN A STRAIGHT LINE.
– DO NOT USE LOAD CHAIN AS A SLING.
4 LIFT PROPERLY
Do not lift co-workers with a hoist.
Make sure everyone is clear of the load
when you lift.
Do not remove or obscure operational
warning notices.
5 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.
– DO NOT LIFT PEOPLE OR LOADS
OVER PEOPLE.
HOIST SAFETY IS UP TO YOU...
All hoists should be visually inspected be-
fore use, in addition to regular, periodic
maintenance inspections.
Inspect hoists for operational warning no-
tices and legibility.
Deficiencies should be noted and brought
to the attention of supervisors. Be sure de-
fective hoists are tagged and taken out of
service until repairs are made.
Under no circumstances should you oper-
ate a malfunctioning hoist.
Check chain for gouged, twisted, distorted
links and foreign material. Do not operate
hoists with twisted, kinked or damaged chain.
Load chain should be properly lubricated.
Hooks that are bent, worn or whose open-
ings are enlarged beyond normal throat
opening should not be used. If latch does
not engage throat opening of hook, hoist
should be taken out service.
Check for misphasing – hook travel should
correspond to control direction.
WARNING
WARNING
WARNING
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4

TABLE OF CONTENTS
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General Information
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
CM Repair/Replacement policy . . . . . . .(Back Page)
Accessories
Hook Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . .9
Lug Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Series 635 Low Headroom Trolley . . . . . . . . . . . . . .9
Series 635 Motor Driven Trolley . . . . . . . . . . . . . . . .9
Latchlok Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installation
Unpacking Information . . . . . . . . . . . . . . . . . . . . . .10
Installing Suspension . . . . . . . . . . . . . . . . . . . .10-11
Recommended Torques . . . . . . . . . . . . . . . . . . . . .11
Attaching Load Chain . . . . . . . . . . . . . . . . . . . . . . .12
Installing Series 635 Low Headroom Trolley . . . . .12-13
Power Supply and Electrical Connections . . . . . . . . . .14
Operating Instructions
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Operating Instruction-Hoist . . . . . . . . . . . . . . . .16-17
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . .17
Inspection
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Frequent Inspections . . . . . . . . . . . . . . . . . . . .18-19
Periodic Inspections . . . . . . . . . . . . . . . . . . . . .18-19
Preventative Maintenance . . . . . . . . . . . . . . . . . . .18
Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Maintenance
Load-limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Hoist Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .21
Trolley Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .21
Adjustments
Electric Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . .23-24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .25-27
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . .28-29
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . .30-72
Assembly Instructions
Hook or Lug Suspensions . . . . . . . . . . . . . . . . . . .73
Lower Hook Block Pin . . . . . . . . . . . . . . . . . . . . . .73
Removal and Installation of Load Chain . . . . . .73-74
Cutting Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .75
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76-137
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Recommended Spare Parts . . . . . . . . . . . . . . . . . . .138
otes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
LIST OF TABLES
Table Title Page
1 Lodestar Electric Chain Hoist Specs. . . . . . 6-8
2 Recommended Torques . . . . . . . . . . . . . . . . 11
3 Series 635 Trolley Side Frame Spacing . . . . .13
4 Minimum Frequent Inspections . . . . . . . . . . . .19
5 Minimum Periodic Inspections . . . . . . . . . . . .19
6 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . .22
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . .25-27
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . .28-29
LIST OF ILLUSTRATIONS
Figure Table Page
1 Hook Suspensions . . . . . . . . . . . . . . . . . . . . . .9
2 Lug Suspensions . . . . . . . . . . . . . . . . . . . . . . .9
3 Series 635 Low Headroom Trolley . . . . . . . . . .9
4 Series 635 Motor Driven Trolley . . . . . . . . . . . .9
5 Upper or Lower Latchlok Hook . . . . . . . . . . . . .9
6 Chain Container . . . . . . . . . . . . . . . . . . . . . . . .9
7 Attaching Load Chain . . . . . . . . . . . . . . . . . . .11
8 Contact Block . . . . . . . . . . . . . . . . . . . . . . . . .12
9 Series 635 Low Headroom Trolley . . . . . . . . .12
10 1/8 to 2 Ton Hoist to Trolley Assembly . . . . . .13
11 3 Ton Hoist to Trolley Assembly . . . . . . . . . . .13
12 Voltage Change Board . . . . . . . . . . . . . . . . . .14
13 Locations of Components . . . . . . . . . . . . . . . .14
14 Hook Inspection . . . . . . . . . . . . . . . . . . . . . . .18
15 Chain Wear areas . . . . . . . . . . . . . . . . . . . . .20
16 Gaging Load Chain Wear . . . . . . . . . . . . . . . .20
17 Chain Inspection . . . . . . . . . . . . . . . . . . . . . .20
18 Limit Switches Models, V1 Models . . . . . . . . .23
18A Rotatable Limit Switches, V1 Models . . . . . . . . .23
19 Limit Switches, V2 Models . . . . . . . . . . . . . . .23
19A Rotatable Limit Switch, V2 Models . . . . . . . . .23
20 Typical Wiring Diagrams . . . . . . . . . . . . . .30-72
21 Swivel Hook Suspensions . . . . . . . . . . . . . . .73
22 Chain Embossing . . . . . . . . . . . . . . . . . . . . . .73
23A Cutting Chain By icking . . . . . . . . . . . . . . . .75
23B Cutting Chain With A Bolt Cutter . . . . . . . . . . .75
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.
FOREWORD
5

6
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.
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 replace-
ment parts voids the guarantee and could lead to dangerous
operation. For full Terms of Sale, see Sales Order Acknowl-
edgement. Also, refer to the back cover for Limitations of
Warranties, Remedies and Damages, and Indemnification
and Safe Operation.
GENERAL INFORMATION
Table 1.a. Specifications
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

7
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
60 Hz 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
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
RT 32.1 815 1.00 0.75 0.83 0.62 54 160 72.7
RRT 32.1 815 2.00 1.49 1.67 1.24 54 173 78.4
Table 1.b.Specifications, cont’d

8
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
Table 1.c. Specifications, cont’d
Table 1.d. Specifications, cont’d
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)
= to 1
(125 to 2000)
2 (2000)
3 (3000)
A thru LL-2
R thru RR-2
RT thru RRT-2
4 - 15 (102 - 381)
6 - 18 (152 - 457)
8 - 15 (203 - 381)
3=(79.4)
4< (120.6)
4 (101.6)
24 (610)
24 (610)
30 (762)
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)
= to 2
(125 to 2000)
3 (3000)
A thru RR-2
RT thru RRT-2
75 (23)
75 (23)
;(.19)
;(.19)
6 - 15 (152 - 381)
6 - 15 (152 - 381)
30 (762)
30 (762)
Table 1.e. Specifications, cont’d

9
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 appli-
cation. 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.
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.
Series 635 Low Headroom Trolley
These are manual push type trolleys (see Figure 3) designed
for use with the Lodestar Electric Chain Hoists. A rigid lug
suspension (see Figure 2) is required to suspend the hoist
from the trolley. The trolley is adjustable for operation on a
range of American Standard “S” beams as indicated in
Table 1, and it will also operate on flat flanged beams.
Figure 3. Series 635 Low Headroom Trolley
ACCESSORIES
Figure 4. Series 635 Motor Driven Trolley
Series 635 Motor Driven Trolley
The motor driven trolleys (see Figure 4) are self-contained
and supplied complete with independent controls and wiring,
including a four directional control station. A rigid lug suspension
(see Figure 2) is required to suspend the hoist from the Motor
Driven Trolley. The hoist and trolley are joined electrically by
connecting the hoist control and power cords (supplied) into
the hoist or trolley. The trolley is adjustable for operation on a
range of American Standard “S” beams as indicated in Table
1 and it will also operate on flat flanged beams.
Latchlok®Hooks
CM’s Latchlok hooks (see Figure 5) are available to replace
the standard upper and lower hooks used on the Lodestar
Electric Hoists.
Figure 5. Upper or Lower Latchlok®Hook
Figure 5. Latchlok® Hook
Chain Container
This accessory (see Figure 6) is used to hold slack chain
and it is supplied complete with mounting hardware and
instructions. The chain container is recommended for those
applications where the slack chain would interfere with the
load or drag on the floor as may be the case with double or
triple reeved units. Chain containers can be furnished for
units already in use.
Figure 6. Chain Container
Figure 1. Hook Suspensions
Figure 2. Lug Suspensions

INSTALLATION
UNPACKING INFORMATION
When received, the hoist should be carefully inspected for
damage which may have occurred during shipment or han-
dling. Check the hoist frame for dents or cracks, the external
cords for damaged or cut insulation, the control station for cut
or damaged enclosure, and inspect the load chain for nicks
and gouges. If shipping damage has occurred, refer to the
packing list envelope on the carton for claim procedure.
Before installing the hoist, make sure that the power supply to
which it will be connected is the same as that shown on the
nameplate located on the side of the hoist.
NOTE: See Electrical Installation instructions
INSTALLING THE SUSPENSION
A. Single Reeved Units:
Remove the hook suspension and (2) suspension screws
from the packaging. Place the suspension assembly into the
recess on top of the hoist so that the adaptor body follows the
contour of the hoist. Insert the suspension screws through
the holes in the adapter and hand thread these into the 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.
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.
USE OF IMPACT TOOLS (ELECTRIC OR PNEUMATIC)
MAY CAUSE PREMATURE FAILURE OF ATTACHING
HARDWARE.
!CAUTION
WARNING
!
Using other than CM supplied high strength suspension
screws to attach the suspension adapter to the hoist may
cause the screws to break and allow the hoist and load to fall.
TO AVOID IN URY:
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.
10












Figure 7. Attaching Load Chain Double Reeved Models
Fastener Fastener
Description Tool Required
*Recommended
Seating Torque
ft-lbf -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
Brake Attaching
Screws1/4-20 Slotted Fillister
Head Screw
Slotted Blade
Screw Driver 4.2 - 5.0 5.6 - 6.8
Power Cord
Strain Relief ut 1/4-20 Hex ut
7/16" - 6 or 12
Point Socket 1.7 - 2.0 2.3 - 2.7
Motor Housing/
Gear Housing/
Back Frame
1/4"-20 Socket Head
Cap Screw
3/16" Hex Driver 7.9 - 8.3 10.7 - 11.3
Lower Hook Block
Screws -
Doubled Reeved 1/4"-20 Socket Head
Cap Screw
3/16" Hex Driver 5.0 - 5.8 6.8 - 7.9
Suspension
Adapter Screws
3/8"-16-12
Point Cap Screw
3/8 "
12 Point Socket 35.0 - 45.0 47.5 - 61.0
Lift-Wheel
Locking ut 1"-12 Hex ut
1-1/2" - 6 or 12
Point Socket 55.0 - 60.0 74.6 - 81.3
Reversing
Contactor
Connecting
Screws-1ø
Terminal
Clamp
Screw
Phillips o.2 or
3/16" Slotted Head
Screw Driver 0.6 - 1.0 0.8 - 1.3
Reversing
Contactor
Connecting
Screws-3ø
Terminal
Clamp
Screw
Phillips o.2 or
3/16" Slotted Head
Screw Driver
0.6 - 1.0 0.8 - 1.3
Fastener Fastener
Description Tool Required
*Recommended
Seating Torque
ft-lbf -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
Brake Attaching
Screws
1/4-20 Slotted Fillister
Head Screw
Slotted Blade
Screw Driver 4.2 - 5.0 5.6 - 6.8
Brake Hex Stud 1/2" Hex w/ 5/16 -18
Threaded End
1/2" Open-End
Wrench 4.2 - 5.0 5.6 - 6.8
Power Cord
Strain Relief ut
1/4-20 Slotted Rd.
Head Screw
Slotted Blade
Screw Driver 1.7 - 2.0 2.3 - 2.7
Motor Housing/
Gear Housing/
Back Frame
5/16"-18 Socket Head
Cap Screw
1/4" Hex Driver 14.2 - 15.0 19.2 - 20.3
Lower Hook Block
Screws -
Doubled Reeved 5/16"-18 Socket Head
Cap Screw
1/4" Hex Driver 10.0 - 11.3 13.6 - 15.3
Suspension
Adapter Screws
1/2"-20-12
Point Cap Screw
1/2 "
12 Point Socket 70.0 - 80.0 94.9-108.5
Lift-Wheel
Locking ut 1-1/8"-12 Hex ut
1-11/16" - 6 or 12
Point Socket 85.0 - 90.0 11 5. 2 -1 2 2.0
Reversing
Contactor
Connecting
Screws-1ø
Terminal
Clamp
Screw Phillips o.2 1.3 1.7
Reversing
Contactor
Connecting
Screws-3ø
Terminal
Clamp
Screw
Phillips o.2 or
3/16" Slotted Head
Screw Driver
0.6 - 1.0 0.8 - 1.3
Stator Mounting
Screws 1/4"- 20 Hex Cap
Screw
7/16" - 6 or 12
Point Socket 4.2 - 5.0 5.8 - 6.8
Table 2.a. Recommended Torques: V1 Models A-H
Table 2.b. Recommended Torques: V2 Models -RRT
* All torque values are for clean, dry fasteners. DO NOT apply oil or any other
lubricant to the fastner threads.
11
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)

INSTALLING THE SERIES 635 LOW HEADROOM
TROLLEY (See Figure 9)
.
Figure 9. Series 635 Low Headroom Trolley: 1 and 2 Ton (1000 and 2000 kg)
Trolley Shown - 3 Ton (3000 kg) Similar.
For hoists with a lug suspension that are to be suspended
from a Series 635 Motor Driven Trolley, attach the hoist to the
trolley, wire the hoist and trolley together and connect the
trolley to the power supply system per the instructions sup-
plied with the trolley.
The stops must be positioned so as to not exert impact force
on the hoist frame or trolley wheels. They must contact the
ends of the trolley side frames.
It is recommended that the trolley be mounted on the beam
prior to attaching the hoist to the trolley. Before attempting
to mount the trolley on the beam, measure the actual width
of the beam flange on which the trolley is to operate. Using
the measurement and Table 3, determine the arrangement of
the spacer washers. Loosely assemble the side frames, load
bracket, spacer washers and nuts on the suspension bolts as
shown in Table 3.
ATTACHING LOAD CHAIN
To attach the chain to the dead end block on Models E, E-2,
H, H-2, R, R-2 and RR-2, proceed as follows:
1. Suspend the hoist from an adequate support.
2. On Models E, E-2, H and H-2, insert the last link of the
load chain into the dead end block (2) and secure it with
the dead end pin, washer and cotter pin furnished with
the suspension. Ensure there are no twists in the chain.
3. On Models R, R-2, RR and RR-2, slide the contact block
up the chain until it is against the bottom of the hoist and
the dead end block is projecting through the square
opening in the bottom of the block. Insert the last link of the
load chain, making sure there are no twists between the
hook block and the dead end block, into the dead end
block. Push the contact block up slightly and secure the
load chain to the dead end block using the dead end pin,
washer and cotter pin furnished with the suspension. The
dead end pin also supports the contact block (See Figure 8)
Figure 8. Contact Block Used on Models R, R-2, RR and RR-2
4. Do not remove the plastic ties from the load chain at this
time.
After the suspension is installed, hoists with a hook suspen-
sion 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.
Operating the trolley on a beam that has no rail stops may
allow the trolley to fall off the end of beam.
TO AVOID IN URY:
Install rail stops at each end of the beam on which the trolley
is to operate.
WARNING
!
12

On the 3 ton (3000 kg) trolley (refer to Figure 11), drive one
retaining pin into the hole on one end of the lug pin. Raise the
hoist into position so that the lug is between the legs of the
shackle. Align the holes in the shackle and lug. Insert the lug
pin in the aligned holes and secure the lug pin by driving the
remaining retaining pin into the hole in the lug pin. Make
certain that the shackle pin is properly seating in the load
bracket by manipluating the hoist and checking for freedom
of movement (swinging) in both planes and all four directions.
Note that the shackle pin should be retained and centered in
the shackle by the retainers.
Figure 10. 1/8 to 2 Ton (125 to 2000 kg) Hoist to Trolley Assembly
Figure 11. 3 Ton (3000 kg) Hoist to Trolley Assembly
Note: Due to the variations in beam flange widths,
it is suggested that the beam flange width be meas-
ured to determine the exact distribution of spacer
washers. The distance between trackwheel flanges
(dimension “X”) should be 1/8 to 3/16 inch (3.18 to
4.77 mm) greater than the beam flange width for
straight runway beams, and 3/16 to 1/4 inch (4.77 to
6.35 mm) greater than the beam flange width if run-
way system includes sharp curves. Also, the use of
other than CM supplied washers may result in track-
wheel to beam flange variations and thus Table 3
will not apply.
On the 1/8 to 2-ton (125 to 2000 kg) trolleys, assemble the
suspension lug on hoist to the trolley on beam as shown in
Figure 10. The lug is inserted in the trolley load bracket and
retained by the vertical load bar pin. A socket head cap
screw and lockwasher are used to keep the in place.
For the 3-ton (3000 kg) trolley, a shackle and pin assembly
consisting of a pin retained in a central position by retainers
is packed loose with the suspension. Insert this assembly into
the opening in the top of the load bracket with the legs of the
shackle down. Position the shackle pin in the groove provided
for the same in the load bracket making sure it is centered
between the suspension bolts.
Now install the trolley on the beam by sliding one side frame
out far enough to allow all the trackwheels to clear the beam
flange. Lift the trolley up so that the trackwheels are riding
on the beam, draw the side frames together and tighten the
nuts snugly. Insert the cotter pins through the slotted nuts and
holes in the supension bolts and spread the legs of the cotter
pins to secure.
Table 3. Series 635 Low Headroom Trolley Side Frame Spacing
*Dimension applies to minimum S-Beam and will vary with larger S-Beams..
“X”
B
ACD
Side
Frame
Suspension
Bolt
Load
Bracket
Suspenison
Bolt Nuts
Standard Load Bracket
3 /16” Wide
1 Ton Capacity
Flange
Width
No. of Spacers
A B C D
2 5/8 10 0 0 10
3 9 1 1 9
3 3/8 8 2 2 8
3 5/8 3 3
4 6 4 4 6
4 5/8 4 6 6 4
5 3 3
5 1/4 2 8 8 2
5 5/8 1 9 9 1
Standard Load Bracket
4 3/16” Wide
2 Ton Capacity
Flange
Width
No. of Spacers
A B C D
3 3/8 8 0 0 8
3 5/8 1 1
4 6 2 2 6
4 5/8 4 4 4 4
5 3 5 5 3
5 1/4 3 5 6 2
5 5/8 2 6 1
6 0 8 8 0
Standard Load Bracket
4 13/16” Wide
3 Ton Capacity
Flange
Width
No. of Spacers
A B C D
4 6 1 1
4 5/8 5 3 3 4
5 4443
5 1/4 3 5 5 2
5 5/8 3 5 6 1
Standard Load Bracket
5 /16” Wide
1 Ton Capacity
Flange
Width
No. of Spacers
A B C D
6 6 5 5 5
6 1/4 5 6 6 4
2 9 9 1
Standard Load Bracket
6 11/16” Wide
2 Ton Capacity
Flange
Width
No. of Spacers
A B C D
6 1/4 8 2 1 8
5 5 4 5
1/8 5 5 5 4
1/4 4 6 5 5
/8 2 8 8 1
8 1 9 8 1
Standard Load Bracket
3 /16” Wide
1 Ton Capacity
Flange
Width
No. of Spacers
A B C D
6 2 2 6
6 1/4 6 3 2 6
4 5 5 3
1/8 3 6 5 3
If CM’s washer spacing recommendations are not followed, trolley
may fall from beam.
TO AVOID IN URY:
Measure the actual beam flange on which the trolley is to operate
and use Table 3 to determine the arrangement of the spacer wash-
ers for that flange width.
WARNING
!
13

POWER SUPPLY AND ELECTRICAL CONNECTIONS
The hoist should be connected to a branch circuit which
complies with the requirements of the National Electrical
Code and applicable local codes.
It is recommended, especially for a single phase hoist
with a (1) horsepower motor (.75 Kilowatts), that a line with
adequate capacity be run directly from the power supply
to the hoist to prevent problems with low voltage and circuit
overloads.
For grounding of the hoist, the power cord includes a
gounding conductor (green yellow, G-Y). Before connecting
the hoist to the power supply, check that the power to be
used agrees with the position of voltage change plug on the
voltage change board. The nominal hoist voltage rating
corresponding to the voltage range given on hoist
identification plate is:
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.
Voltage conversion board is located under back frame
cover (1) for Models A-H and under motor housing
cover (2) for Models -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 connecions at the power supply.
2, Operate (UP) control momentarily. If hook raises,
connections are correct and can be made permanent.
3. If hook lowers, it is necessary to change direction by
inter-changing the Grey lead and the Black lead of hoist
power supply. Under no circumstances should the internal
wiring of the control device or hoist be changed to
reverse hook direction. The wiring is inspected and
tested before leaving the factory.
Do not force the Lodestar Load-limiter to compensate for
improperly adjusted limit switches or reverse voltage phasing.
Figure 12. Voltage Change Board
Figure 13. Location of Components
HIGH
VOLTAGE (RED)
LOW
VOLTAGE
(WHITE)
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
14

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 cap-
size 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 volt-
age, (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.
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.
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.
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.
NOMINAL
VOLTAGE
MINIMUM
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 -
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)
#12 AWG #16 AWG
120 FEET
(36.7 M)
#10 AWG #14 AWG
200 FEET
(61.0 M)
Contact
Factory
#14 AWG
For runs beyon 200 Feet contact factory.
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 IN URY:
Do not allow the hook block to contact the bottom of the
hoist or the loose end chain to become taut.
WARNING
!
Failure to properly ground the hoist presents the danger of
electric shock.
TO AVOID IN URY:
Permanently ground the hoist as instructed in this manual.
WARNING
!
Failure to provide a proper power supply system for the hoist
may cause hoist damage and offers the potential for a fire.
TO AVOID IN URY:
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
WARNING
!
WARNING
Work ng n or near exposed energ zed electr cal equ pment
presents the danger of electr c shock.
TO AVOID INJURY:
DISCONNECT POWER AND LOCKOUT/TAGOUT
DISCONNECTING MEANS BEFORE REMOVING COVER OR
SERVICING THIS EQUIPMENT.
15

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.
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 equippe with a chain
container/bag, reset the upper an lower limit
switches as in icate on page 23.
Un er no con ition shoul the hook block or loa
be permitte to come in contact with the chain
container/bag. If contact is ma e, the function of
the chain container can be interfere with an its
fasterners imperile .
NOTE: When chain bag is fille to capacity the
bag must be no more than 75% fille .
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.
OPERATING INSTRUCTIONS
GENERAL
1. The Load-limiter is designed to slip on an excessive over-
load. 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.
Due to the above, a hoist equipped with a Load-limiter is not
recommended for use in any application where there is a
possibility of adding to an already suspended load to the
point of overload. This includes dumbwaiter (*see below)
installations, containers that are loaded in mid-air, etc.
(*) Refer to limitations on Page 3 concerning dumbwaiter
applications.
2. All hoists are equipped with an adjustable screw limit
switch, which automatically stops the hook at any pre-
determined point when either hoisting or lowering.
3. The control station used on two speed hoists is similar to
single speed unit, except that either of two definite
speeds may be selected by the operator in both hoisting
and lowering. Each control when partially depressed
provide SLOW speed and when fully depressed gives
FAST speed. Partial release of control returns hoist to
slow speed, while complete release allows hoist to stop.
Rated lifting speeds are shown on hoist identification
plate. SLOW speed is intended as a means of carefully
controlling or “spotting” the load, although the hoist may
be operated solely at this speed if desired. It is not
necessary to operate in the SLOW speed position as the
hoist will pick up a capacity load at FAST speed from a
standing start. In other words, it is not necessary to
hesitate at the slow position when moving control from
STOP to FAST position or vice versa.
4. If material being handled must be immersed in water,
pickling baths, any liquid, dusty or loose solids, use a
sling chain of ample length so that the hook is always
above the surface. Bearings in the hook block are
shielded only against ordinary atmospheric conditions.
HOIST
1. Before picking up a load, check to see that the hoist is
directly overhead.
2. WHEN APPLYING A LOAD, IT SHOULD BE DIRECTLY
UNDER HOIST OR TROLLEY. AVOID OFF CENTER
LOADING OF ANY KIND.
3. Take up a slack load chain carefully and start load easily
to avoid shock and jerking of hoist load chain. If there is
any evidence of overloading, immediately lower the load
and remove the excess load.
4. DO NOT allow the load to swing or twist while hoisting.
5. DO NOT allow the load to bear against the hook latch.
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 IN URY:
Do not allow the hook block to contact the bottom of the
hoist or the loose end chain to become taut.
WARNING
!
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 IN URY:
Shorten the control cord using the control cord alteration kit
and the instructions provided with the kit.
WARNING
!
16

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.
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.
Allowing the load to bear against the hook latch and/or
hook tip can result in loss of load.
TO AVOID IN URY:
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.
WARNING
!
17

INSPECTION
To maintain continuous and satisfactory operation, a regular
inspection procedure must be initiated to replace worn or
damaged parts before they become unsafe. Inspection
intervals must be determined by the individual application
and are based on the type of service to which the hoist will
be subjected.
The type of service to which the hoist is subjected can be
classified as “Normal”, “Heavy”, or “Severe”.
Normal Service: Involves operation with randomly distributed
loads within the rated load limit, or uniform loads less than
65 percent of rated load for not more than 25 percent of the time.
Heavy Service: Involves operating the hoist within the rated
load limit which exceeds normal service.
Severe Service: Normal or heavy service with abnormal
operating conditions or constant exposure to the elements
of nature.
Two classes of inspection - frequent and periodic - must
be performed.
Frequent Inspections: These inspections are visual exami-
nations by the operator or other designated personnel.
Records of such inspections are not required. The frequent
inspections are to be performed monthly for normal service,
weekly to monthly for heavy service, and daily to weekly for
severe service, and they should include those items listed in
Table 4.
Periodic Inspections: These inspections are visual
inspections of external conditions by an appointed person.
Records of periodic inspections are to be kept for continuing
evaluation of the condition of the hoist.
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
disasembly to permit a more detailed inspection, which,
in turn, may require the use of nondestructive type testing
PREVENTATIVE MAINTENANCE
In addition to the above inspection procedure, a preventive
maintenance program should be established to prolong the
useful life of the hoist and maintain its reliability and continued
safe use. The program should include the periodic and
frequent inspections with particular attention being paid to
the lubrication of the various components using the recom-
mended lubricants (see page 127).
HOOK INSPECTION
Hooks damaged from chemicals, deformations or cracks,
or that have more than a 10° twist from the hook’s unbent
plane, excessive opening or seat wear must be replaced.
Also, hooks that are opened and allow the latch to not
engage the tip must be replaced. Any hook that is twisted
or has excessive throat opening indicates abuse or over-
loading of the unit. Inspect other load sustaining parts, hook
block screws, load pins and hook block bodies for damage.
On latch type hooks, check to make sure that the latch is
not damaged or bent and that it operates properly with
suffcient spring pressure to keep the latch tightly against
the tip of the hook and allow the latch to spring back to the
tip when released. If the latch does not operate properly, it
should be replaced. See Figure 14 to determine when the
hook must be replaced.
MEASURE
OPE I G
“A” Max.
“B” Max.
LATCH TYPE HOOK
(Upper and Lower)
TO MEASURE OPENING,
DEPRESS LATCH AGAINST
HOOK BODY AS SHOWN.
Models Replace Hooks When
Opening is Greater Than
A, A-2, AA, AA-2, B, B-2,
C, C-2, F AND F-2 1 3/16 (30.2 mm)
E, E-2, H, H-2, , -2, , -2,
L, L-2, LL AND LL-2 1 5/16 (33.3mm)
R, R-2, RR AND RR-2,
RT, RT-2, RRT AND RRT-2 1 1/2 (38.1 mm)
Models
Replace Hook
When Opening or Seat are:
“A” Max. “B” Min.
A, A-2, AA, AA-2, B, B-2, C, C-2,
E, E-2, F, F-2, H, H-2, , -2, ,
-2, L, L-2, LL, LL-2
1 31/64 in.
(37.7mm)
21/32 in.
(16.7mm)
R, R-2, RR, RR-2 1 59/64 in.
(48.8mm)
27/32 in.
(21.4mm)
RT, RT-2, RRT AND RRT-2 2 1/2 in
(63.5mm)
1 1/8 in
(28.6mm)
Figure 14. Hook Inspection
LATCHLOK®HOOK
(Upper and Lower)
18

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

LOAD CHAIN
Chain should feed smoothly into and away from the hoist
or hook block. If chain binds, jumps or is noisy, first clean and
lubricate it (see below). If trouble persists, inspect chain and
mating parts for wear, distortion or other damage.
Chain Inspection
First Clean chain with a non-caustic/non-acid type solvent and
make a link by link inspection for nicks, gouges, twisted links,
weld splatter, corrosion pits, striations (minute parallel lines),
cracks in weld areas, wear and stretching. Chain with any one
of these defects must be replaced.
Slack the portion of the chain that normally passes over the lift-
wheel. Examine the interlink area for the point of maximum wear
(polishing, see Figure 15). Measure and record the stock diameter
at this point of the link. Then measure stock diameter in the same
area on a link that does not pass over the liftwheel (use the link
adjacent to the loose end link for this purpose). Compare these
two measurements. If the stock diameter of the worn link is 0.010
inches (0.254 mm), or more, less than the stock diameter of the
unworn link, the chain must be replaced.
On double reeved units, repeat this examination of the chain
that passes through the hook block.
Gaging Load Chain Wear
To determine if load chain should be continued in service,
check gage lengths as indicated in Figure 16. Chain worn
beyond length indicated, nicked, gouged or twisted should
be replaced before returning hoist to service. Chain should
be clean, free of twists and pulled taut before measuring.
Note that worn chain can be an indication of worn hoist
components. For this reason, the hoist’s chain guides, hook
blocks and liftwheel should be examined for wear and
replaced as necessary when replacing worn chain.
Also, these chains are specially heat treated and hardened
and should never be repaired.
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 with-
out visual deformation. For this reason, cut replaced chain
into short lengths to prevent use after disposal.
Figure 15. Chain Wear Areas
Figure 17. Chain Embossing
Models Dia. of
Chain Stock
No. of Links
to Gage
Max. Gage Length
Allo able Used Chain
A thru H
A-2 thru H-2
0.250"
(6.35mm) 19 14 13/16" (376 mm)
J thru RRT
J-2 thru RRT-2
0.312"
(7.9mm) 21 18 7/8" (479 mm)
Figure 16. Gaging Load Chain Wear
20
USE OF COMMERICAL OR OTHER MANUFACTURER’S
CHAIN AND PARTS TO REPAIR CM HOISTS MAY CAUSE
LOAD LOSS.
TO AVOID IN URY:
Use only CM supplied replacement load chain and parts.Chain
and parts may look alike, but CM chain and parts are made of
specific material or processed to achieve specific properties.
WARNING
!