CM Lodestar XL User manual

SOLUTIONS
OPERATING,
MAINTENANCE &
PARTS MANUAL
ELECTRIC
CHAIN HOIST
Rated capacities 2 through 6 tons/
2000 through 6000 kg
Follow all instructions and warnings for
inspecting, maintaining and operating this hoist.
The use of any hoist presents some risk of personal
injury or property damage. That risk is greatly
increased if proper instructions and warnings are not
followed. Before using this hoist, each operator
should become thoroughly familiar with all warnings,
instructions and recommendations in this manual.
Retain this manual for future reference and use.
Forward this manual to operator.
Failure to operate equipment as directed
in manual may cause injury.
Manual No. 652-B
Before installing hoist, fill in the
information below. Refer to the
hoist identification plate.
Model no. __________________
Serial no. ___________________
Purchase date ______________
Voltage _____________________
Rated capacity ______________
®
52756
®

CM HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
As a CM Hoist user, you are assured of reliable repair and parts services through a network of Master Parts Depots and
Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the
basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.
Below is a list of the Master Parts Depots in the United States and Canada. To quickly obtain the name of the U.S. Service
Center located nearest you, call [phone]. Fax: [phone]. In the following list, the Canadian Service Centers
are indicated.
UNITED STATES
MASTER PARTS DEPOT
CALIFORNIA
OTTO SYSTEMS, INC.
12010 Bloomfield Ave.
Santa Fe Springs, CA 90670
562/462-1612, 800-596-7392
Fax [phone]
or
2439 Verna Court
San Leandro, CA 94577
510/667-3730, 800-508-6886
Fax [phone]
COLORADO
MATERIALS HANDLING EQUIPMENT CO.
1740 W. 13th Ave.
Denver, CO 80204
303/573-5333, 800-873-5333
Fax [phone]
FLORIDA
TAMPA ARMATURE WORKS, INC.
440 South 78th Street
Tampa, FL 33619
813/621-5661, 800-333-9449
Fax [phone]
GEORGIA
ACE INDUSTRIES, INC.
6295 McDonough Drive
Norcross, GA 30093
770/441-0898, 800-733-2231
Fax [phone]
ILLINOIS
TORRANCE ELECTRIC COMPANY
415-31st. Ave.
Rock Island, IL 61204
309/786-7777, 800-747-8374
Fax [phone]
INDIANA
HORNER ELECTRIC COMPANY, INC.
1521 East Washington St.
Indianapolis, IN 46201
317/ 639-4261
Fax [phone]
LOUISIANA
BEERMAN PRECISION, INC.
4206 Howard Avenue
New Orleans, LA 70125
504/486-9391
Fax [phone]
MASSACHUSETTS
ABEL DISTRIBUTORS, INC.
70 Flagship Drive
N. Andover, MA 01845
978/975-8234
Fax [phone]
MICHIGAN
GAYLORD HOIST SALES & SERVICE
34471 Industrial Road
Livonia, MI 48150
313/261-1910
Fax [phone]
MISSOURI
INDEPENDENT ELECTRIC MACHINERY
310 West 20th Street
Kansas City, MO 64108
816/471-2610
Fax [phone]
NEW YORK
VOLLAND ELECTRIC EQUIPMENT CO.
75 Innsbruck Drive
Buffalo, NY 14227
716/656-9900
Fax [phone], 8899
NORTH CAROLINA
SOUTHERN ELECTRIC SERVICE CO., INC.
2225 Freedom Drive
Charlotte, NC 28208
704/372-4832, 800-487-3726
Fax [phone]
OHIO
MAZZELLA WIRE ROPE & SLING COMPANY
14600 Brookpark Road
Cleveland, OH 44135
216/362-4600, 800-362-4601
Fax [phone]
PENNSYLVANIA
AMICK ASSOCIATES, INC.
11 Sycamore Street
Carnegie, PA 15106-0529
412/429-1212, 800-445-9456
Fax [phone]
RAM MOTORS AND CONTROLS, INC.
Route 61
Leesport, PA 19533
610/916-3939, 800-999-8183
Fax [phone]
TEXAS
ABEL EQUIPMENT CO., INC.
3710 Cavalier Drive
Garland, TX 75042
972/272-7706
Fax [phone]
HYDRAULIC EQUIPMENT SERVICE, INC.
1021 North San Jacinto St.
Houston, TX 77002
713/228-9601 or 713/228-8117 (purchasing)
Fax [phone]
WASHINGTON
UNITED ELECTRIC MOTORS
308 9th Ave. North
Seattle, WA 98109
206/624-0044
Fax [phone]
WISCONSIN
TRESTER HOIST & EQUIPMENT, INC.
4465 North 124th St.,Unit C
Brookfield, WI 53005
414/790-0700, 800-234-6098
Fax [phone]
CANADIAN
SERVICE CENTERS
ALBERTA
**COLUMBUS McKINNON, LTD.
10311-174th Street
Edmonton, Alberta T8H 1N3
NOVA SCOTIA
*W & A MOIR
95 Ilsley Ave.
Dartmouth, Nova Scotia B3B 1L5
902/468-7720
Fax [phone]
ONTARIO
*R & W HOIST REPAIR, LTD.
790 Redwood Square
Units 5, 6, & 7
Oakville, Ontario L6L 6N3
905/825-5500
Fax [phone]
*TORONTO ELECTRIC HOIST
SALES & SERVICE
72 Crockford Blvd.
Scarborough, Ontario M1R 3C4
416/755-7716
Fax [phone]
*MASLACK SUPPLY, LTD.
488 Falconbridge Road
Sudbury, Ontario P3A 4S4
705/566-1270
Fax [phone]
*COLUMBUS MCKINNON, LTD.
P.O. Box 1106
10 Brook Road, North
Cobourg, Ontario K9A 4W5
905/372-0153
Fax [phone]
QUEBEC
*HERCULES SLING & CABLE
2525 Louis A. Amos
Lachine, Quebec H8T 1C3
514/631-5511
Fax [phone]
*LEGER HOIST EQUIPMENT CO.
7995-17th Ave.
Montreal, Quebec H1Z 3R2
514/376-3050
Fax [phone]
* ARE ALSO MASTER PARTS DEPOTS
** MASTER PARTS DEPOT ONLY
i

SAFETY PRECAUTIONS
Each Lodestar XL 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 Standard B30.16
“Overhead Hoists,” the National Electrical Code (ANSI/NFPA 70) and the Occupational Safety and Health Act. Since OHSA
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 appli-
cation, 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 in
CM industrial 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 The American Society of Mechanical Engineers, 345 East 47th Street,New
York, NY 10017, U.S.A.
ii
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.
DO’S AND DO NOT’S
Safe Operation of Hoists
The following are Do’s and Do Not’s for safe operation of
overhead hoists. Taking precedence over any specific rule
listed here, however, is the most important rule of all—USE
COMMON SENSE. A few minutes spent reading these
rules can make an operator aware of dangerous practices
to avoid and precautions to take for his own safety and the
safety of others. Frequent examinations and periodic
inspections of the equipment as well as conscientious
observance of safety rules may save lives as well as time
and money.
12. DO warn personnel of an approaching load.
13. DO protect load chain from weld spatter or other damaging
contaminants.
14. DO promptly report any malfunction, unusual performance or
damage of the hoist.
15. DO inspect hoist regularly, replace damaged or worn parts,
and keep appropriate records of maintenance.
16. DO use CM’s replacement parts when repairing the hoist.
17. DO use hook latches whenever possible.
18. DO apply lubricant to the load chain as recommended in
this manual.
19. DO NOT lift more than rated load.
20. DO NOT use the hoist load limiting device to measure the
load.
21. DO NOT use damaged hoist or hoist that is not working
correctly.
22. DO NOT use the hoist with twisted, kinked, damaged or worn
chain.
23. DO NOT lift a load unless chain is properly seated in chain
wheel(s).
24. DO NOT use load chain as a sling or wrap chain around the
load.
25. DO NOT lift a load if any binding prevents equal loading on
all supporting chains.
26. DO NOT apply the load to the tip of the hook.
27. DO NOT operate unless load is centered under hoist.
28. DO NOT allow your attention to be diverted from operating
the hoist.
29. DO NOT operate the hoist beyond limits of chain travel.
30. DO NOT use limit switches as routine operating stops. They
are emergency devices only.
31. DO NOT use hoist to lift, support or transport people.
32. DO NOT leave a suspended load unattended unless specific
precautions have been taken.
33. DO NOT allow sharp contact between two hoists or between
hoist and obstructions.
34. DO NOT allow the chain or hook to be used as a ground for
welding.
35. DO NOT allow the chain or hook to be touched by a live
welding electrode.
36. DO NOT remove or obscure the warnings on the hoist.
37. DO NOT adjust or repair a hoist unless qualified to perform
hoist maintenance.
38. DO NOT attempt to lengthen the chain or repair damaged
chain.
1. DO read ASME B30.16 Safety Standard for Overhead Hoists
and this manual thoroughly.
2. DO be familiar with hoist operating controls, procedures and
warnings.
3. DO make sure hook travel is in the same direction as shown
on controls.
4. DO make sure that the hoist limit switches function properly.
5. DO maintain firm footing when operating hoist.
6. DO make sure that load slings or other approved single
attachments are properly sized and seated in the hook
saddle.
7. DO make sure that the hook latch, if used, is closed and not
supporting any part of the load.
8. DO make sure that load is free to move and will clear all
obstuctions.
9. DO take up slack carefully, check load balance, lift a few
inches and check load holding action before continuing.
10. DO avoid swinging of load or load hook.
11. DO make sure that all persons stay clear of the suspended
load.
WARNING To Avoid Injury:
!
!
!
WARNING
Usage of hoists that do not involve lifting of the load on the lower
hook or using hoists in the inverted poistion without special pre-
caution 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.
!

iii
Hoist safety is up to you ...
.1AWARNING - DO NOT UFT MORE THAN RATED LOAD. I
1CHOOSE THE RIGHT
HOIST FOR
THE JOB ...
Choo ... hOlst with tne cap.cily for tho job . Know !he
ca!>'Iclll •• of Y "'" 1IO<0"'JI<l 1"- w"gM 01 you< lOadS.
The" milch Ihem .
TM IPl>li c'l iOll, Ihe I I" and typo!
0 1 lead. tn, aUac""",nl. 10 be "s,
ed Ind tn, PMI O<I 01 uM muS! aloo
be , • • .." inlO conti_ . ,i "" in
..leeti .... l,.. right l'I<H.t lor ,.... job.
AWARNING
2 INSPECT
.oJ1 hOi". OhO IM De ';S""lIy In·
" ",""led t>eIOie use. In addition
10 fO'Qu ' .r. Deriodic mlm'."ane l
InS_flori s
Inspect hOll'S far opefl"""S
wI ,n lng notices and legil>ilily.
Delicienel
•• Should be ro<>1e<1
Ind bloughl 10 ,.... an ",, ' lon of
, "peM la ... Be O u'" <lel..,tl ...
holil' .'.'egged Ir.c! , .. .." "'"
01 seMce un!ll ,ePI'" I r' m _.
AWARNING
3 USE HOIST
PROPERLY
e• •"IO no lO! I. lOIic1 ly
h" d in 'h , " pp er mos,
plr ' ollr>o! IuppO r! 1I0OI<
Ire.
AWARNING
4
00 110' lili co · w", . ...
w ,, ~ • hOi" .
Make . ", . e•• 'YO'" i.
clu ' ot ''''' l oa d ... """
,0" t,11.
00 no! ,em",. or
obscu'e OQOI'a, j onal
w. ,nlng no'le ••.
00 NOT OPERATE DAMAGED OR MALFUN CTIONING HOIST
DO NOT OPERATE WITH TWISTED, KINKED OR DAMAGED CHAIN.
UnCle' no clrcum.,.nc .. ""0<1 10
you operl,e j mall ~""'inn,"Il
"ol.!.
Check c~ a ln ! ", gouge<!. ''' 'S! e<!.
<f is .",i e<l Hnk. Ir>d !o'e,gn
ml 'er l" . Do 1101 O_"i . fIOi s1I
.. I'~ ' ... .. ,e<! • • 'nke<!",
damage<! link•.
Lold Cnl'n ShO uld tle ~o~"~
' '' bl iCIUK'
Hoo •• ,h l l II. tlen •. wo,"" 0'
"'fIOs. OP8"lng •• 'e 0<1" '0 ""
tleVond IIOIm l' 'hroa, ope ning
l"oul d 1101 tle u""d . II Il ' ch 00e .
ne l .ngage ln,o l ' open ing 01
hOOk. fIO,st snould tMI ' "k .... ou,
of "" ,';01 .
Check to, mispl1 .. lng~l>OOk
1< ... , . fIOu'd oor ,~ .pond to con ·
1<01 di,ec'ion .
Carel~lIr ch...,. limil
. .. IICh ., Io ,lfIOuT. 'ood CI "
'fIOutd be .1. "" ne T10 dlmage
I.... fIOl.,
DO NOT PULL AT AN ANGLE . BE SURE HOIST
AND LOAD ARE IN A STRAIGHT LINE.
DO NOT USE LOAD CHAIN AS A SLING .
80 Ou ,. 00'" Inc lOad
.re In •• ,,"ight lino. Do
nel 1>\111 II In I ngle .
S. lu,a 10. <1 il "'>oke<!
"" "'tir. 00 ne. lip load
,'''' "'>ok. 00 ne! loa"
nODI< Ilicn . HODI< '"tcn is
'0 p' .... n! "a"ohm a n' 01
load unde' "ack enlln
OOnd ll ,on . only
00 no l " •• load c" ", n
.. I .' ing. Sveh U I'~
,, " mIO"'r>o! chl in I nd
m•••• '" . 'Im l, . .. ,Ten
"'''i ng ino ff ee" ... .
DO NOT LIFT PEOPLE
OR LOAOS OVER
PEOPLE . 5
Cl EANING
H "'S TS snould be .ePI Cleo " .nd
It "" 01 Ou" . d"1. mo,slu, e, e,c ..
w h,ch w,11 In an ~ .. ay altee . 'f><
opOf.tton", .a l el~ 01 II,..
eQ "'pmen!
lUBRICATION
ChI'" Shoul d be P'O P<l"~
lubliCOIO<l
AFlER REPAIRS
Care !ully opo,. te th. no,",
be f ore re' u,n ing it '0 !ull ...... ' e.
F\emerntMI' ,n. "oi1l was d •• igned
10 ..... OU' bu'~ Ir>d
c "., ••• ". •• no. only otnOl"OOro
, '''' operaT",. M In mln~ CI "" S.'
," l ull>4 . lOa<! .
00 no TOPO"IO .. II"
...,;., M.d ",,; ng
'g o,ns ' on~ ob,oc' un
tna 'oad ~ft1 l j 00 no,
,.,. 11.
VIOLATION OF ANY OF THE WAANINGS LISTED MAY RESULT IN SERIOUS PER SONAL INJURY
TO
THE OPERATOR OR NEARBY PERSONNEL BY RELEASED LOAD OR BROKEN
HOIST
COMPONENTS .

1
ITEM PAGE NO.
MASTER PARTS DEPOTS AND SERVICE CENTERS . . i
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . ii
HOIST SAFETY IS UP TO YOU. . . . . . . . . . . . . . . . . . . iii
GENERAL INFORMATION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2
CM REPAIR/REPLACEMENT POLICY . . . . . . . . . . 3
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION
UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING THE SUSPENSION
HOOK SUSPENSIONS . . . . . . . . . . . . . . . . . . 4
LUG SUSPENSIONS . . . . . . . . . . . . . . . . . . . . 6
MOUNTING TROLLEY ON HOIST . . . . . . . . . . . . . 6
INSTALLING TROLLEY SUSPENDED
HOIST ON BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLING BREATHER . . . . . . . . . . . . . . . . . . . . 8
POWER SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . 8
ELECTRICAL CONNECTIONS
SINGLE SPEED DUAL VOLTAGE
HOISTS (AND MOTOR DRIVEN TROLLEYS) . 8
ALL HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECKING FOR TWIST IN LOAD CHAIN . . . . 9
CHECKING FOR ADEQUATE VOLTAGE . . . . 10
CHECKING LIMIT SWITCH OPERATION . . . . . . . 10
CHAIN CONTAINER . . . . . . . . . . . . . . . . . . . . . . . 10
CONTROL CORD. . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATING INSTRUCTIONS
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ALL HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HOIST WITH PLAIN TROLLEY . . . . . . . . . . . . . . . 11
HOIST WITH GEARED TROLLEY. . . . . . . . . . . . . 11
HOIST WITH MOTOR DRIVEN TROLLEY. . . . . . . 11
SAFETY PROCEDURES. . . . . . . . . . . . . . . . . . . . 11
ITEM PAGE NO.
MAINTENANCE
INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FREQUENT INSPECTIONS. . . . . . . . . . . . . . 12
PERIODIC INSPECTIONS . . . . . . . . . . . . . . . 12
HOOK INSPECTION . . . . . . . . . . . . . . . . . . . 12
LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 14
PROTECTOR. . . . . . . . . . . . . . . . . . . . . . . . . 14
LUBRICATION
HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TROLLEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENTS
HOIST BRAKE. . . . . . . . . . . . . . . . . . . . . . . . 15
LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . . . 15
TROLLEY BRAKE . . . . . . . . . . . . . . . . . . . . . 16
RECOMMENDED SPARE PARTS. . . . . . . . . . . . . 16
PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . 16
TROUBLE SHOOTING
ALL HOISTS. . . . . . . . . . . . . . . . . . . . . . . . . . 17
TWO SPEED HOISTS . . . . . . . . . . . . . . . . . . 20
MOTOR DRIVEN TROLLEY. . . . . . . . . . . . . . 21
ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . 22
WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . 24, 25
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL AND REPLACEMENT OF LOAD CHAIN. . . . 26
REEVING LOAD CHAIN
3 AND 4 TON DOUBLE REEVED UNITS . . . . 27
5 AND 6 TON TRIPLE REEVED UNITS . . . . . 28
CUTTING CHAINS . . . . . . . . . . . . . . . . . . . . . . . . 28
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REPAIR PARTS
ODERING INSTRUCTIONS . . . . . . . . . . . . . . . . . 29
EXPLODED VIEWS AND PARTS LISTS . . . . . 30-40
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 preventative 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 or moving heavy loads using hoist 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.
TABLE OF CONTENTS

SPECIFICATIONS
The Lodestar XL Electric Chain Hoist is a highly versatile
material handling device that can be used to lift loads that
are within its rated load capacity. Single and two speed
units with rated loads up to 6 tons (6000 Kg.) are available.
The hoist can be supplied with a single hook suspension or
suspended from plain, geared or motor driven trolley. The
standard lift is 10 feet and longer lifts can be provided on a
per order basis.
The standard features of the CM Lodestar XL Electric Chain
Hoist include:
• Hardened, alloy steel, oblique lay liftwheel provides
constant chain speed and reduces chain wear.
• CM’s Hoistaloy®load chain for long and dependable
service.
• Lightweight cast aluminum frame and covers.
• Surface hardened, alloy steel, helical gears running
in an oil bath provide smooth and quiet operation.
• Protector that prevents lifting an excessive overload.
• Single or two speed hoist duty motor equipped with
thermal protection.
• Low voltage control circuit. 115 volt is standard.
24 or 48 volt control circuits are also available.
• Hardened, forged steel hooks equipped with latch.
• Oversize reversing and speed selecting contactors for
long, trouble free service.
• Hoist duty, A.C. motor brake plus regenerative
braking.
2
RATED LOAD
TONS 2 3 and 4 5 and 6
Kg. 2000 3000 and 4000 5000 and 6000
*LIFTING SPEEDS AVAILABLE:
FPM 18 24 9 12 6 8
SINGLE SPEEDS MPM 5.5 7.3 2.7 3.6 1.8 2.4
FPM 6 / 18 8 / 24 3 / 9 4 / 12 2 / 6 2.7 / 8
TWO SPEEDS MPM 1.8 / 5.5 2.4 / 7.3 .9 / 2.7 1.2 / 3.6 .6 / 1.8 .8 / 2.4
FEET 127 139 63 70 42 46
MAXIMUM LIFT METERS 39 42 19 21 13 14
REEVING OF LOAD CHAIN SINGLE DOUBLE TRIPLE
MIN. HEADROOM
HOOK SUSPENDED—IN. (mm) 25 (635) 35.31 (897) 36.18 (919)
TROLLEY SUSPENDED—IN. (mm) 28.69 (729) 33.13 (841) 34.00 (864)
RANGE OF TROLLEY ADJUSTABILITY
“S” BEAMS 6 X 12.5 TO 15 X 42.9 12 X 31.8 TO 20 X 65.4
IN. 3.33 TO 5.50 5.00 TO 6.25
FLANGE WIDTH mm 84.5 TO 139.7 127.0 TO 158.8
STANDARD MOTOR DRIVEN TROLLEY 65 (19.8) OR
TRAVEL SPEED—FPM (MPM) 100 (30.4) 50 (15.2)
**APPROX. MET WEIGHT—LBS. (Kg.)
HOOK SUSPENDED 368 (167) 442 (200) 474 (215)
WITH PLAIN TROLLEY 428 (194) 593 (269) 602 (273)
WITH GEARED TROLLEY 473 (215) 638 (289) 647 (294)
WITH MOTOR DRIVEN TROLLEY 483 (219) 658 (298) 667 (303)
*Lifting speeds are based on 60 Hertz power supply. When operating on 50 Hertz, lifting speeds will be 5/6 of those listed.
**Weights are for single speed hoist with 10 ft. (3 M) lift. For two speed hoists, add 10 pounds (4.5 Kg.).
TABLE 1—SPECIFICATIONS
LODESTAR XL ELECTRIC CHAIN HOISTS
GENERAL INFORMATION
• Weatherproof, CM snap action 2 or 4 direction control
station.
• Shielded, lifetime lubricated ball bearings at all
rotating points. Open bearings are used in gear
case.
• Voltage conversion board on single speed, dual
voltage units.
• Three stage gear reduction.
• Upper and lower screw type limit switches.
Lodestar XL
Hoist with
Motor Driven
Trolley

CM REPAIR/REPLACEMENT
POLICY
All Columbus McKinnon (CM) Lodestar XL Electric Chain
Hoists are thoroughly 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 manu-
al, and specifically excludes parts subject to normal wear,
abuse, improper installation, improper or inadequate main-
tenance, 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.
ACCESSORIES
HOOK SUSPENSIONS
Hook suspensions are available for suspending the hoist
from a trolley with a single load bar (such as CM’s Series
639 trolleys) or for suspending the hoist from a fixed struc-
ture.
LUG SUSPENSIONS
Lug suspensions are required to suspend the Lodestar XL
Electric Hoist from plain, geared or motor driven trolleys
described below. When the hoist is to be suspended from a
plain, geared or motor driven trolley, the lug suspension is
attached to the hoist prior to shipment.
LUG SUSPENSION 3
PLAIN TROLLEYS
These are manual push type trolleys designed for use with
the Lodestar XL Electric Hoist. The trolley is adjustable to
operate on a range of American Standard ‘S’ beams and
flat flanged beams. The plain trolley is mounted on hoist
prior to shipment.
PLAIN TROLLEY
GEARED TROLLEYS
The geared trolley is similar to the plain trolley except it is
moved by the means of a hand chain. The hand chain
rotates a pinion that drives gears attached to trolley wheels
and moves trolley along the beam. The geared trolley is
mounted on the hoist prior to shipment.
GEARED TROLLEY
MOTOR DRIVEN TROLLEYS
The motor driven trolley is similar to geared trolley except
the hand chain wheel is replaced with a gear reducer and
an electric motor. The motor is energized by a reversing
contactor mounted inside the hoist and it is controlled by
push buttons located in the pendant control station. A vari-
ety of single and two speed trolley travel speeds are avail-
able and the motor driven trolley is mounted on hoist prior
to shipment.
2 ton 3-6 ton
HOOK SUSPENSION

CHAIN CONTAINER
This accessory is used to hold the slack chain and it is
supplied complete with mounting hardware and instruc-
tions. The chain container is recommended for those
applications where the slack chain will interfere with the
load or drag on the floor as may be the case with double
and triple reeved units. Chain containers are shipped sep-
arately and can be furnished for units already in use.
CHAIN CONTAINER
4
LATCHLOK® HOOKS
CM’s Latchlok hooks are available to replace the standard
upper or lower latch type hooks. The unique design of the
Latchlok hook assures that it will stay locked until the
operator releases it by depressing the release button. It
will not open accidentally—even if the load chain goes
slack. Once opened, it can be shut with one hand or the
weight of the load when it is lifted. Latchlok hooks can be
supplied with the hoist or it can be provided in kit form for
hoists already in service.
LATCHLOK®HOOK
INSTALLATION
UNPACKING
After opening the carton, carefully inspect the hoist, sus-
pension, trolley and chain container for damage that may
have occurred during shipment. If there is damage, refer
to the packing slip envelope.
Make sure that the power supply to which the hoist is to be
connected is the same as that shown on the identification
plate located on the bottom of the hoist. For single speed,
dual voltage hoists, refer to instructions on page 8.
INSTALLING SUSPENSION
A. HOOK SUSPENSIONS
For hook suspended units, the suspension is shipped sep-
arately and it must be attached to the hoist as follows:
1. ALL UNITS. Supplied with the hook suspension is a
counterweight that must be attached to the motor
cover using the two long screws provided. Remove
and discard corresponding motor cover screws. Place
counterweight on motor cover and secure it using the
two longer screws. Tighten these screws to a seating
torque of 16 pound feet. (22 NM)
WARNING
Operating a unit with obvious external damage may
cause load to drop and that may result in personal injury
and/or property damage.
TO AVOID INJURY:
Carefully check unit for external damage prior to installa-
tion.
!
MAKING SURE THE
HOIST WILL OPER-
ATE ON THE POWER
SUPPLY SYSTEM
INSPECT FOR SHIP-
PING DAMAGE
MOTOR DRIVEN TROLLEY

c. After the hook is in the desired position, slide the
suspension adapter into cavity on top of hoist and
secure it using the suspension adapter screw from
the kit. Tighten screw to a seating torque of 16
pound feet (22 NM).
NOTE: INSTALL BREATHER IN MAIN HOUSING AFTER
HOOK SUSPENSION IS ASSEMBLED TO HOIST. SEE
PAGE 8.
3. 3 and 4 Ton Double Reeved and 5 and 6 Ton Triple
Reeved Units. As shipped from the factory, the hook
is rigid with the plane of the hook parallel to long axis
of hoist. The hook can be changed to swivel type or
the plane of the hook can be changed to perpendicular
to the long axis of the hoist as follows:
a. If a swivel type hook is required, remove and discard
keeper plate screw and keeper plate. Then using a
hammer drive the hook nut pin into nut so that the end
of the pin is flush with side of the nut.
b. If it is necessary to position the hook so that the plane
of the hook is perpendicular to long axis of hoist, first
convert to a swivel type hook as described above but
do not discard the keeper plate and screw. Turn hook
90 degrees and insert loose pin (packed with the sus-
pension) into a hole in the hook nut. Loosely
reassemble keeper plate to suspension adapter so
that the hook is free to swivel approximately 45
degrees in either direction. The hook will be made rigid
after suspension is attached to the hoist.
Attach the “Lodestar XL” label, from the kit, to counter-
weight in the recess provided for same.
2. 2 Ton Single Reeved Units. As shipped from the fac-
tory, the hook is rigid with the plane of the hook parallel
to the long axis of the hoist. The hook can be changed to
swivel type or the plane of the hook can be changed to
perpendicular to the long axis of the hoist as follows:
a. If a swivel type hook is required, use a 1/4 inch (6.4
mm) drift, and working through the hole in the side of
the suspension adapter, drive the hook nut pin into the
nut so that it is flush with the side of the nut. Discard
the loose pin packed with the suspension.
b. If it is necessary to position the hook so that the plane
of the hook is perpendicular to the long axis of hoist,
first convert to a swivel type hook as described above.
Rotate the hook 90 degrees and slide the loose pin
(packed with the suspension) through the hole in the
side of the suspension adapter and engage the hole
in the hook nut.
5
CHANGING
POSITION OF
HOOK
TO CONVERT
TO SWIVEL
TYPE HOOK
MOUNTING THE
COUNTERWEIGHT
INSTALLING
HOOK
SUSPENSION
2 TON UNIT
TO CONVERT TO
SWIVEL TYPE
HOOK
DRIFT

c. Slide the suspension adapter into cavity on top of
hoist. Install dead end bolt and thread it by hand
to engage the dead end block (3 and 4 ton units)
or idler sheave hanger (5 and 6 ton units). Then
tighten dead end bolt to a seating torque of 120
pound feet (160 NM).
If the hook is to be perpendicular to long axis of hoist per
step b above, rotate the hook to that position and firmly
tighten the keeper plate screw while making sure the loose
pin engages the slot in keeper plate.
NOTE: INSTALL BREATHER IN MAIN HOUSING AFTER
HOOK SUSPENSION IS ASSEMBLED TO HOIST. SEE
PAGE 8.
B. LUG SUSPENSIONS
The following instructions are provided to cover installing
the lug suspension after the hoist has been reassembled
following inspection and/or repair. On hoists shipped from
CM, the lug suspension is installed prior to mounting the
trolley.1. 2 Ton Single Reeved Units. Slide the suspen-
sion adapter into the cavity on top of hoist and
secure it using the suspension adapter screw.
Tighten the screw to a seating torque of 16 pound
feet (22 NM).
6
INSTALLING LUG SUS-
PENSION—2 TON
UNITS
INSTALLING
HOOK
SUSPENSION
3, 4, 5, & 6 TON
UNIT
CHANGING
POSITION OF
HOOK
2. 3 And 4 Ton Double Reeved And 5 And 6 Ton
Triple Reeved Units. Slide the suspension
adapter into cavity on top of hoist. Install dead
end bolt and thread it by hand to engage the dead
end block (3 and 4 ton units) or idler sheave
hanger (5 and 6 ton units). Then tighten the dead
end bolt to a seating torque of 120 pound feet
(160 NM).
INSTALLING LUG
SUSPENSION—3,
4, 5 AND 6 TON
MOUNTING TROLLEY ON HOIST
The following instructions are provided to cover mounting
plain, geared and motor driven trolleys after the hoist has
been reassembled following inspection and/or repair. On
units shipped from CM, these trolleys are mounted on the
hoists.1. Measure actual width of the beam flange on which
the trolley is to operate. Using this measurement
and Table 2, determine arrangement of spacer
washers.
2. Assemble a slotted nut to one end of each sus-
pension bolt and secure it using a cotter pin
(spread legs of cotter pin to keep it in place).
3. Mount trolley side frame assemblies to lug sus-
pension on hoist as shown below. On geared and
motor driven trolleys, make sure the handwheel or
motor is on side opposite the loose end/chain
container side of the hoist. Also, do not install
remaining cotter pins at this time. These are to be
installed after the trolley is mounted on the beam.
On motor driven trolleys, use the wiring diagram
provided and make the nesessary electrical con-
nections.
WARNING
Using other than CM supplied suspension adapter screw
or dead end bolt to attach suspension adapter to hoist
may cause the screw or bolt to break and allow the hoist
and load to fall.
TO AVOID INJURY:
Use only the CM supplied suspension adapter screw or
dead end bolt and tighten these to the seating torque
specified above.
!
MOUNTING
TROLLEY ON
HOIST
HANDWHEEL OR TROLLEY
MOTOR GEARED OR MOTOR
DRIVEN TROLLEY ONLY
Dead End Bolt

ABCDABCD
3-3/8 (85.7) 13 0 0 13
3-5/8 (92.0) 11 2 2 11
3-7/8 (98.4) 10 3 4 9 Special Trolleys
4 (101.6) 9 4 4 9 11 0 0 11
Standard 4-1/8 (104.7) 8 5 5 8 10 1 0 11
Trolleys 4-5/8 (117.4) 5 8 8 5 7 4 4 7
5 (127.0) 3 10 10 3 11 0 0 11
5-1/8 (130.1) 3 10 11 2 11 0 1 10
5-1/4 (133.3) 2 11 12 1 10 1 1 10
5-1/2 (139.7) 0 13 13 0 8 3 3 8
5-5/8 (142.9) 12 1 1 12 7 4 4 7
6 (152.4) 10 3 3 10 3 8 7 4
6-1/4 (158.7) 9 4 5 8 3 8 8 3
6-3/8 (161.9) 8 5 6 7 11 0 0 11
Special 7 (177.8) 4 9 9 4 6 5 5 6
Trolleys 7-1/8 (181.0) 3 10 10 3 6 5 4 7
7-1/4 (184.1) 3 10 11 2 6 5 5 6
7-3/8 (187.3) 2 11 12 1 5 6 6 5
7-1/2 (190.5) 1 12 12 1 4 7 7 4
7-5/8 (193.7) 0 13 13 0 3 8 8 3
* Minimum Beam
Radius ft.(M) 4’-0”(1.22) 5’-6”(1.68)
*Dimension applies to minimum S-beam and will vary with larger S-
beams
Before installing geared or motor driven trolleys on the
beam, lubricate the trackwheel gears and pinion with
Texaco Novatex #2 or equivalent heavy cup grease.
On open end beams, remove rail stops, lift hoist/trolley into
position and slide the hoist/trolley assembly onto beam
flange. Reinstall the rail stops.
On closed end beams, loosen the suspension bolt nuts on
one side of trolley and slide one side frame out far enough
to clear the beam flange. Lift hoist/trolley assembly up so
that trackwheels are riding on beam flange. Draw side
frames together by tightening the suspension bolt nuts
snugly.
7
Be sure to install cotter pins through slotted nuts and hole
in suspension bolts and spread legs of cotter pins to
secure.
On geared trolleys, the bottom of the hand chain loop is
normally located two feet (0.6M) above the floor. If it is
desired to change this, find the unwelded link and open it
by spreading with a chisel or twist one end with a wrench
while holding the other end in a vise or another wrench.
Remove an even number of links ( 2,4,6, etc.) as neces-
sary to shorten the chain or add an even number of links to
lengthen the chain (when lengthing the chain, another open
link will be required and this can be made from a welded
link by cutting through weld with a hacksaw). Make certain
that the chain is not twisted–then re-install and close open
links.
NOTE: AFTER THE UNIT IS CONNECTED TO THE
POWER SUPPLY SYSTEM (SEE BELOW), SUSPEND A
CAPACITY LOAD FROM THE HOIST AND OPERATE
THE TROLLEY OVER THE ENTIRE LENGTH OF THE
RUNWAY OR MONORAIL SYSTEM TO BE SURE THAT
THE ADJUSTMENTS AND OPERATION IS SATISFACTO-
RY. ON SYSTEMS WITH CURVES, THE EDGES OF THE
RAIL AT THE CURVED SECTIONS SHOULD BE KEPT
LIGHTLY LUBRICATED WITH GREASE.
INSTALLING TROLLEY
SUSPENDED HOIST ON BEAM
Stops must be positioned to contact the trolley side frames
and not exert impact force on the hoist.
Trolleys are mounted on the hoist prior to shipment and
side frames are positioned for the nominal beam flange
specified on the order. However, due to variations in beam
flange widths, actual beam flange width should be mea-
sured to determine the exact distribution of the spacer
washers. Refer to Table 2.
On all trolleys, the distance between trackwheel flanges
(dimension “x”) should be 1/8 to 3/16 inch (3.17 to 4.77
mm) greater than the flange width for straight runways,
and 3/16 to 1/4 inch (4.77 to 6.35 mm) greater than the
flange width if the runway includes sharp curves. If dimen-
sion “x” is not as specified, rearrange the spacer washers.
Make sure the number of spacer washers at “B” and “C”
are the same or differ by one spacer washer maximum.
WARNING
Operating the trolley on a beam that has no rail stops
may allow the trolley to fall off the end of the beam.
TO AVOID INJURY:
Install rail stops at each end of the beam on which the
trolley is to operate.
WARNING
If CM’s washer spacing recommendations are not fol-
lowed, trolley may fall from beam.
TO AVOID INJURY:
Measure the actual beam flange on which the trolley is to
operate and use Table 2 to determine the arrangement of
the spacer washers for that flange width.
NOTE: USE OF OTHER THAN CM SUPPLIED SPACER
WASHERS MAY CAUSE IMPROPER TRACKWHEEL
SPACING AND THUS TABLE 2 WILL NOT APPLY.
!
!
CAUTION: On the 3 through 6 ton trolleys, there must
be a minimum of 3 washers at locations “A” and “D”.
Flange
Width
in.(mm)
2 Ton 3 Thru 6 Ton
No. of Washers No. of Washers
Table 2. Trolley Spacer Washer Arrangement

INSTALLING BREATHER
After the hook suspension is assembled to the hoist or
after the hoist and trolley are mounted on the beam,
remove the upper plug from the main housing (652-110)
and install the breather (from small envelope attached to
the power cord). Failure to install the breather could dam-
age oil seals and thus cause oil leaks.
POWER SUPPLY SYSTEM
To insure proper operation, to avoid damage to hoist and
electrical system and to reduce the risk of electric shock or
fire, the branch circuit supplying power to the hoist must:
1. Have ample capacity to prevent excess voltage
drop during starting and operation (refer to
“Checking for Adequate Voltage at Hoist” below).
When determining the size of branch circuit com-
ponents and conductors,special consideration
should be given to the starting current-amps
(approximately three times that shown on the
hoist identification plate) and the length of the
conductors. As a minimum, the system should be
rated for 20 amps and it should have #12AWG, or
larger, wiring.
2. Be in accordance with the National Electrical
Code (ANSI/NFPA-70) and applicable National,
State and Local Codes.
3. Effectively ground the hoist in accordance with
National Electrical Code and other applicable
codes. Proper grounding provides a path of least
resistance for electric current to reduce the risk of
electric shock.
The power cord of the hoist includes a green wire
for grounding the hoist to the external power sup-
ply system. If grounding is to be through the trol-
ley trackwheels, each section of the runway must
be grounded to the building ground system using
metal to metal connections.
4. Include slow blow type fuses or inverse trip time
circuit breakers to permit the hoist to start and
accelerate load.
8
WARNING
An excessively worn beam flange may fail and allow the
trolley to fall from the beam.
TO AVOID INJURY:
Periodically inspect the beam flange for wear. Replace
beam if flange is worn.
!
NOTE: IN THIS MANUAL, NOMINAL VOLTAGES ARE
USED WHEN REFERRING TO POWER SUPPLY SYS-
TEMS. HOWEVER, WITH NO MODIFICATION, THE
LODESTAR XL HOIST WILL OPERATE ON A RANGE OF
VOLTAGES AS INDICATED BELOW:
NOMINAL VOLTAGE HERTZ
VOLTAGE RANGE
230 208-240 60
460 440-480 60
220 200-240 50
380 365-395 50
415 400-430 50
575 550-575 60
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 INJURY:
Provide the hoist with a 20 amp, minimum, overcurrent
protected power supply system per the National Electrical
Code (ANSI/NFPA 70) and applicable local codes as
instructed in this manual.
!
ELECTRICAL CONNECTIONS
SINGLE SPEED, DUAL VOLTAGE HOISTS (AND MOTOR
DRIVEN TROLLEYS)
Unless ordered on a special basis, single speed dual volt-
age (230/460-3-60, 220/380-3-50 and 220/415-3-50) hoists
are factory wired to operate on 460-3-60 (or 380-3-50 or
415-3-50). However, a conversion terminal board is provid-
ed to easily and quickly change from 460 to 230 (or 380 to
220 or 415 to 220) volt operation. The conversion terminal
board is located adjacent to the reversing contactor at motor
end of hoist. If necessary, change voltage connections
before connecting hoist to power supply system as follows:
INSTALL
BREATHER
TYPICAL POWER
SUPPLY SYSTEM
WARNING
Failure to properly ground the hoist presents the danger
of electric shock.
TO AVOID INJURY:
Permanently ground the hoist as instructed in this manu-
al.
5. Include a disconnecting means capable of being
locked in the “open” position.

9
Lockout/Tagout procedures when working (connecting or
disconnecting) with the hoist electrical connections.
Serious damage will result if the hook is run to upper or
lower limit of lift with hook moving in a direction opposite to
that indicated by the control station. Connect hoist power
cord to the power supply and check hook movement as fol-
lows:
1. Move the manual disconnect switch handle to the
“OFF” position.
2. Connect the WHITE-PURPLE, RED AND BLACK
wires of hoist power cord to load side of disconnect
switch. Connect the GREEN wire of hoist power cord
to power supply ground.
3. Move the manual disconnect switch handle to the
“ON” position.
4. Depress the <(up) control. If the hook moves in the
up direction, the hoist is ready for operation. If the
hook lowers, move the disconnect switch handle to the
“OFF” position and interchange the BLACK and RED
leads at the disconnect switch. Move the disconnect
switch handle to the “ON” position and the hoist is now
ready for operation.
NOTE: DO NOT CHANGE INTERNAL WIRING OF
HOIST OR CONTROL STATION TO REVERSE HOOK
DIRECTION. THE HOIST AND CONTROL STATION
WIRING WAS INSPECTED AND TESTED FOR PROPER
OPERATION AT THE FACTORY. CHANGING THIS
WIRING WILL CAUSE IMPROPER OPERATION AND
SERIOUS DAMAGE.
Also, do not force the Lodestar Protector to compensate
for improperly adjusted limit switches or reverse voltage
phasing.
CHECKING FOR TWIST IN LOAD CHAIN
3 and 4 Ton Units
The best way to check for this condition is to run the lower
hook, without a load, up to within about 2 feet (0.6M) of
hoist. If the dead end of 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.
WARNING
FAILURE TO FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES
MAY PRESENT THE DANGER OF ELECTRICAL SHOCK
TO AVOID INJURY:
DISCONNECT POWER AND LOCKOUT/TAGOUT DISCONNECTING
MEANS BEFORE REMOVING COVER OR SERVICING THIS EQUIP-
MENT.
WARNING
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 lower-
ing 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.
!
3. Reassemble motor cover (and counterweight if so
equipped) to hoist frame.
4. Mark the tag attached to power cord to indicate
that the hoist has been converted to operate on
230 (or 220) volts and restamp hoist identification
plate accordingly.
If the hoist is suspended from a single speed motor driven
trolley, it will also be necessary to change the trolley motor
connections. To do this, remove the cover from the terminal
box mounted on the side the trolley motor and reconnect
the trolley motor wires attached to the terminal board as
shown below:
ALL HOISTS
After making sure that the hoist (and motor driven trolley)
are wired to operate on the power supply system, you are
now ready to connect hoist power cord to the power supply.
Since these are three phase units, the hoist motor can
rotate in either direction depending on how it is connected
to the power supply. Therefore, direction of hook movement
must be checked during the original installation and each
time the hoist is moved to a new location.
Always disconnect the hoist from the power supply system
or de-energize the power supply system and follow proper
CONVERSION TERMINAL BOARD
MOVE ALL 8 WIRES TO CONVERT FROM 460 TO 230
(380 TO 220, 415 TO 220) VOLT OPERATION
HOIST VOLTAGE
CONVERSION
TROLLEY VOLTAGE CONVERSION
(Connections shown are for 208-240 volt operation)
1. Remove the motor cover (652-182). On units with
hook suspension, it will be necessary to remove the coun-
terweight (652-219) before removing motor cover.
2. Shift all eight wires from row of terminals marked
“460” (or 380 or 415) to row of terminals marked “230” (or
220).

10
lower limit switch stops the downward motion From 10 to
12 chain links should be between the loose end link and
the opening for the chain in bottom of hoist. If adjustment
is necessary, see page 15.
CHAIN CONTAINER
If a chain container is to be used, attach it to the hoist
frame and place chain in container per instructions pro-
vided with the chain container kit. After the chain contain-
er is installed, follow the instructions on page 15 to reset
upper limit switch so uppermost point of hook travel is just
below the bottom of the chain container.
UNDER NO CIRCUMSTANCES SHOULD THE HOOK
BLOCK OR LOAD BE PERMITTED TO COME IN CON-
TACT WITH THE CHAIN CONTAINER. IF CONTACT IS
MADE, THE FUNCTION OF THE CHAIN CONTAINER
CAN BE INTERFERED WITH, THE CONTAINER MAY
BE DAMAGED AND IT COULD FALL OFF OF THE
HOIST.
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 (1.2M) above the lower hook when it
is at the lower limit of lift. If this places the control station
too close to the floor, a “control cord alteration kit” (Key
No. 627-474, Part Number 28642) can be obtained from
CM for shortening the length of the control cord.
WARNING
Tying knots or loops to shorten the drop of the control
station will make the strain relief ineffective and the inter-
nal 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 Protector is designed to allow the first reduction
gear to slip on an excessive overload. An overload is indi-
cated 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 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 capaci-
ty. When the excessive load is removed, normal hoist
operation is automatically restored.
CAUTION: THE PROTECTOR IS SUSCEPTIBLE TO
OVERHEATING AND WEAR WHEN SLIPPED FOR
EXTENDED PERIODS. UNDER NO CIRCUMSTANCE
SHOULD THE PROTECTOR BE ALLOWED TO SLIP
FOR MORE THAN A FEW SECONDS.
Due to the above, a hoist equipped with a Protector 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 installations,
containers that are loaded in mid-air, etc.
*Refer to limitations on Page ii concerning dumbwaiter
applications.
Also, if a Lodestar XL Hoist with a Protector is used at
5 and 6 Ton Units
On these models, the load chain is dead ended on top of
the lower hook block. If 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 twist, reverse the capsize.
CHECKING FOR ADEQUATE VOLTAGE AT HOIST
The hoist must be supplied with adequate electrical power
for proper operation and to reduce problems that may
result from insufficient power (low voltage). These include:
• Noisy hoist operation due to brake and/or contactor
chatter.
• Heating of the hoist motor and other internal compo-
nents as well as heating of wires and connectors in
the circuit feeding the hoist.
• Failure of the hoist to lift the load due to motor
stalling.
• Blowing fuses or tripping circuit breakers.
For proper operation and to avoid these low voltage prob-
lems, voltage (measured at the end of the 2.5 foot (.9 M)
power cord while lifting rated load) should be as follows:
NOMINAL MINIMUM * MIN. VOLTAGE
POWER OPERATING AT INSTANT
SUPPLY VOLTAGE OF START
208-3-60 187 172
220-3-50 198 182
230-3-60 207 190
380-3-50 365 336
415-3-50 399 367
460-3-60 414 380
* The drop in voltage upon energizing the hoist should not
be below the value listed.
Remember, operation with low voltage can void the CM
Repair/Replacement policy. When in doubt about any of
the electrical requirements for the power supply system,
consult a qualified electrician.
CHECKING LIMIT SWITCH OPERATION
1. Press the <(Up) control and raise the lower hook until
the top of the hook block is about one foot (0.3M) below
hoist.
2. Cautiously continue raising the hook until upper limit
switch stops upward motion. At this point, the top of the
hook block should be 3 inches (76 mm) below bottom of
the hoist.
3. If adjustment is necessary, see page 15.
4. Press :(Down) control and cautiously lower hook until
WARNING
Allowing the hook block to run into the bottom of hoist
when raising a load or allowing the chain to become taut
between the loose end screw and the frame when lower-
ing 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 hoist
or the loose end chain to become taut.
!

11
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.
SAFETY PROCEDURES
For safety precautions and a list of do’s and do not’s for
safe operation of hoists, refer to page ii.
1.When preparing to lift a load, be sure that attachments to
hook are firmly seated in hook saddle. Avoid off center
loading of any kind, especially loading on the point of hook.
2.When lifting, raise 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.
3.Do not load hoist beyond the rated load shown on hoist
identification plate and capacity labels. Overload can
cause immediate failure of some load-carrying part or cre-
ate a defect causing subsequent failure at less than rated
load. When in doubt, use the next larger capacity of CM
Lodestar XL Hoist.
4.Do not use this or any other overhead materials handling
equipment for lifting persons.
5.Stand clear of all loads and avoid moving a load over the
heads of other personnel. Warn personnel of your intention
to move a load in their area.
6.Do not leave load suspended in air unattended.
7.Permit only qualified personnel to operate unit.
8.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 mean twisted chain and a jammed liftwheel.
b.The upper limit switch is by-passed and the load
could hit the hoist.
c.The chain could be damaged at the hook.
9.On double and triple reeved hoists, check for twists in the
load chain. A twist can occur if the lower hook block has
been capsized between the strands of chain. Reverse the
capsize to remove the twist.
10.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.
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.Do not allow the load to swing or twist while hoisting.
13.Never operate the hoist when flammable materials or
WARNING
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 to bear against the hook latch
and/or hook tip. Apply load to hook bowl or saddle only.
!
unusual extremes of ambient temperatures, above 150
degrees F (65 degrees C) or below 15 degrees F (-9
degrees C) changes in lubricant properties may permit the
hoist to raise larger loads than under normal operating
conditions and presents possibility of damage or injury.
2.All hoists are equipped with an adjustable screw limit
switch, which automatically stops the hook at any prede-
termined 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 low-
ering. Each control when partially depressed provides
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 control-
ling or “spotting” the load, although the hoist may be oper-
ated 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 and FAST posi-
tion 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.
5.Read operation section of American National Standard
ASME B30.16.
ALL HOISTS
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.
HOIST WITH PLAIN 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 GEARED TROLLEY
This unit should be moved by means of the pendant hand
chain. Pull on the chain farthest from end toward which
the unit is to travel.
HOIST WITH MOTOR DRIVEN TROLLEY
This unit should be moved by operating the controls
marked =FORWARD and >REVERSE in control station.

12
vapors are present. Electrical devices produce arcs or
sparks that can cause a fire or explosion.
14.STAY ALERT! Watch what you are doing and use com-
mon sense. Do not use the hoist when you are tired, dis-
tracted or under the influence of drugs, alcohol or medica-
tion causing diminished control.
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 and degree of exposure to wear, deterioration
or malfunction of the critical components.
The type of service to which the hoist is subjected can be
classified as “Normal,” “Heavy,” or “Severe.”
Normal Service: Involves operation with randomly distrib-
uted loads within 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 rated
load limit which exceeds normal service.
Severe Service: Normal or heavy service with abnormal
operating conditions.
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 3.
PERIODIC INSPECTIONS: These inspections are visual
inspections of external conditions by an appointed person.
Records of periodic inspections are to be kept for continu-
ing evaluation of the condition of the hoist. Periodic inspec-
tions 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 4.
CAUTION: ANY DEFICIENCIES ARE TO BE CORRECT-
ED 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 TEST-
ING.
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 for
damage.
Replace Hookd
When Opening
Is Greater
Than
1 1/2 IN.
38.1 mm
2 3/8 IN.
60.3 mm
CAPACITY
(TONS)
2
3,4,5, and 6
LATCH TYPE HOOK
(Upper and Lower)
TO MEASURE OPENING,
DEPRESS LATCH
AGAINST HOOK
BODY AS SHOWN.
Replace Hookd
When Opening
Or Seat are:
CAPACITY
(TONS)
2
3,4,5, and 6
LATCHLOCK® TYPE HOOK
(UPPER AND LOWER)
“A” Max.
2 1/2 IN.
63.5 mm
2 15/16 IN.
74.6 mm
“B” Mn.
1 1/8 IN.
28.5mm
113/32 IN.
35.7mm
Hook Inspection
MEASURE
OPENING
“A” Max.
“B” Max.
MAINTENANCE
Trackwheel Gears
Trolley Terminal
Box
Motor
Cover
(652-182)
Control Station
Brake Cover
(652-181)
Trolley Brake
(optional)
Lodestar XL
Hoist with Motor
Driven Trolley
On latch type hooks, check to make sure that the latch is
not damaged or bent and that it operates properly with suf-
ficient spring pressure to keep the latch tightly against the
tip of the hook and allow latch to spring back to tip when
released. If latch does not operate properly, it should be
replaced. See below to determine when the hook must be
replaced.

Table 3. Minimum Frequent Inspections
Table 4. Minimum Periodic Inspections
TYPE OF SERVICE ITEM
ITEM
Normal
Normal Heavy
Heavy Severe
Severe
TYPE OF SERVICE
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 12.
d) Load chain for adequate lubrication, as well as for signs of wear, damaged links or
foreign matter–see page 14.
e) Load chain for proper reeving and twists.
a) All items listed in Table 3 for frequent inspections.
b) External evidence of loose screws, bolts or nuts.
c) External evidence of worn, corroded, cracked or distorted hook block, gears, bear-
ings, dead end block, dead end pin, dead end bolt and suspension components.
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 suspen-
sion adapter screw or dead end bolt is 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 guide 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 brake adjustment—see
page 15.
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 screw or dead end bolt for proper tightness—(see pages 4, 5,and 6).
j) Inspect the loose end link, loose end screw, dead end block on double reeved units
and dead end plate on triple reeved units. Replace worn or distorted parts.
k) Inspect the hook for excess free play or rotation. Replace worn parts as evidenced
by excess free play or rotation.
l) Inspect for oil leaks at the gasket on either side of intermediate plate. Tighten the
screws used to attach the main housing and brake housing to intermediate plate. If
leak persists, disassemble hoist (see page 26) and replace gaskets.
m) Inspect inside of motor and brake housings for presence of oil. Oil in motor housing
may be excess chain lubricant or a leaking seal. Wipe out oil and monitor. If leak
persists, replace seal (652-122 or 652-132). Oil in brake housing is due to leaking
seal. Replace seal (652-122 or 652-134).
n) Check motor bolts for damage and replace if bent, cracked or damaged.
o) Inspect all splines for signs of wear and deteriation. Replace splined parts if worn or
damaged.
Yearly
Every 6 Months
Every 3 Months Daily
to Weekly
Weekly
to Monthly
Monthly
13

14
LOAD CHAIN
Cleaning and Inspection
First clean load chain with a non-acid or non-caustic type
solvent. Then slack the chain and make a link-by-link
inspection for nicks, gouges, twisted links and excessive
wear or stretching. Chain exhibiting wear should be
checked throughout its entire length and replaced if worn
beyond serviceable limits.
Checking For Load Chain Wear
Slack the portion of the chain that normally passes over the
liftwheel. Examine the interlink area for the point of maxi-
mum wear (polishing). Measure and record the stock diam-
eter at this point of the link. Then measure stock diameter
in the same area on a link that does not pass over the lift-
wheel (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 (0.254mm), or
greater, less than the stock diameter of the unworn link, the
chain must be replaced.
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.
IMPORTANT:
DO NOT USE REPLACED CHAIN FOR OTHER PURPOS-
ES 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.
PROTECTOR
The Protector should operate for the normal life of hoist
without service. The device has been calibrated at the fac-
tory for a specific capacity/gear ratio of Lodestar XL Hoist.
It is not adjustable and it is not interchangeable with other
capacities/gear ratios.
WARNING
Using other than CM supplied load chain may cause the
chain to jam in the hoist and/or allow the chain to break
and the load to drop.
TO AVOID INJURY:
Due to size requirements and physical properties, use
only CM Hoistaloy®load chain in the Lodestar XL Hoists.
!
LUBRICATION
NOTE: TO ASSURE EXTRA LONG LIFE AND TOP PER-
FORMANCE, BE SURE TO LUBRICATE THE VARIOUS
PARTS OF THE LODESTAR XL HOIST USING THE
LUBRICANTS SPECIFIED BELOW. IF DESIRED, THESE
LUBRICANTS MAY BE PURCHASED FROM CM.
HOIST LUBRICATION
Gears. Check oil level in gear housing at least once a
month, maintaining it at the bottom of oil level hole in main
housing (652-110).
Drain housing every 2-3 years and refill with one gallon
(3.86 liters) of gear oil Amoco 85W-140.
CAUTION: THE PROTECTOR IS TO OPERATE IN THE
ABOVE MENTIONED OIL. DO NOT USE ANY OTHER
TYPE OF LUBRICANT OR THE PROTECTOR WILL NOT
OPERATE PROPERLY AND PARTS COULD BE DAM-
AGED.
The limit switch gears are of molded nylon and require no
lubrication. Apply a light film of machine oil to the limit
switch shaft threads at least once a year.
Chain Guides, Liftwheel & Sheave Wheels.
When the hoist is disassembled for inspection and/or
repair, the chain guides, sheave wheels (on multi-reeved
units) and liftwheel must be lubricated with Lubriplate, Bar
and Chain Oil 10-R (Fiske Bros. Refining Co.) prior to
reassembly. Apply sufficient lubricant to obtain natural
runoff and full coverage.
Load Chain. Keep chain lubricated with a small amount of
lubricant. This will greatly increase the life of load chain.
Do not allow the chain to run dry.
Keep it clean and lubricate at regular intervals with
Lubriplate, Bar and Chain Oil 10-R (Fiske Bros. Refining
Co.) or equal lubricant. Normally, weekly lubrication and
cleaning is satisfactory, but under hot and dirty conditions, it
may be necessary to clean the chain at least once a day
and lubricate it several times between cleanings. When
lubricating the chain, apply sufficient lubricant to obtain nat-
ural runoff and full coverage.
WARNING
The lubricants used in and recommended for the Lodestar
XL Hoist may contain hazardous materials that mandate spe-
cific handling and disposal procedures.
TO AVOID CONTACT AND CONTAMINATION:
Handle and dispose of lubricants only as directed in
applicable material safety data sheets and in accordance
with applicable local, state and federal regulations.
!
WARNING
Used motor oils contain unknown carcinogenic materials.
TO AVOID HEALTH PROBLEMS:
Never use used motor oils as a chain lubricant. Only use
Lubriplate Bar and Chain Oil 10-R as a lubricant for the
load chain.
!
Bearings. All bearings except the lower hook thrust bear-
ings are pre-lubricated or are in an oil bath and need no
lubrication. The lower hook thrust bearing should be lubri-
cated at least once a month with heavy duty machine oil.
Miscellaneous. If unit is disassembled, splines inside cou-
pling (652-103) should be coated with an EP type grease
(such as Evans Products Co. Anti-Scoring Extreme
Pressure Lub. No. 3) before reassembly.
TROLLEY LUBRICATION
Trackwheel bearings are pre-lubricated and require no lubri-
cation.

15
Geared Trolley. Once a month lubricate trackwheel gears
with Texaco Novatex No. 2 or an equivalent heavy cup
grease or graphite grease.
Every six months lubricate handwheel shaft bearings in 3-
in-1 machine oil.
Motor Driven Trolley. Once a month lubricate trackwheel
gears with Texaco Novatex No. 2 or an equivalent heavy
cup grease or graphite grease.
The motor bearings and reduction gears require no addi-
tional lubrication. However, if gears are disassembled,
upon reassembly use Texaco Novatex No. 1 or an equiva-
lent medium cup grease.
ADJUSTMENTS
HOIST BRAKE
The correct air gap between armature and field when brake
is not energized, is 0.025 inch (.63 mm) and need not be
adjusted until the gap reaches 0.045 inch (1.14 mm).
To adjust the brake, proceed as follows:
1. Disconnect hoist from power supply.
2. Remove brake end cover.
3. Before adjusting the gap, back off the brake nuts and
examine friction linings and friction surfaces for wear,
scoring or warpage (min.thk. .188). Also check shading
coils to be sure they are in place and not broken. A
missing or broken shading coil will cause the brake to
be noisy when hoist is operated. Any of these symtoms
indcate the need for replacement of parts.
4. Turn brake nuts clockwise gaging the air gap on each
side and at both ends of the armature.
5. Replace cover, reconnect the power and check oper-
ation
LIMIT SWITCHES
If limit switch operation has been checked as described on
page 10 and is not operating correctly or is not automatical-
ly stopping the hook at a desired position, proceed as fol-
lows:
1. Disconnect hoist from power supply.
2. Remove brake end cover.
3. The positions of upper and lower limit switches are
indicated on the fiber insulator.
4. Loosen the screws to permit guide plate to be moved
out of engagement with the traveling nuts.
1
4
3
2
5
LIMIT SWITCHES
1. Limit switch sub-assy 4. Guide plate
2. Limit switch shaft 5. Screws
3. Traveling nuts
5. Reconnect hoist to power supply
6. Run hook to the desired upper or lower position, cau-
tiously operating the hoist without load.
7. Disconnect hoist from power supply.
8. Moving one travel nut toward the other increases
hook travel and away from the other decreases the
travel. To adjust the upper limit, turn the nut nearest
the switch indicated as “Upper Limit Switch”. To
adjust the lower limit, turn the nut nearest the switch
marked “Lower Limit Switch”. Turn the desired nut
until it just breaks the limit switch contacts. An audi-
ble click will he heard as the switch opens. Continue
to rotate the nut toward the switch an additional two
full teeth.
9. Reposition the guide plate in the next slot and secure-
ly tighten screws.
10. Reconnect hoist to power supply and check the stop-
ping point of the hook by first moving the hook about
10 inches (254 mm) away from the desired stopping
point. Then move the hook towards the desired stop-
ping point by jogging cautiously until the limit switch
stops the motion. If the stopping point is not the
desired position, repeat the above instructions.
11. Double check the adjustment by moving the hook
about 2 feet (610 mm) from the desired stopping point
and then run the hook into the limit with the control
held in the fully depressed position.
12. Fine adjustment of the screw limits setting may be
obtained by inverting the guide plate. The offset on
the plate gives adjustments equivalent to 1/2 notch
(see Table below). When inverting the plate, it may
be necessary to use the notch adjacent to the one
used in the preliminary setting.
HOIST BRAKE
ADJUSTMENT

16
TROLLEY BRAKE
(Optional Accessory)
The stopping distance of the Motor Driven Trolley equipped
with an electric brake can be increased or decreased by
adjusting the brake pressure. To increase brake pressure,
and thereby decrease stopping distance, move the brake
spacer washers progressively from the nut side of the
brake field plate to the spring side. To decrease the stop-
ping distance, move the washers in an opposite manner.
Both studs must have the same number of washers on the
spring side of the brake field plate.
The correct air gap between armature and field, when the
brake is not energized, is 0.025 inch (.63 mm) and need
not be adjusted until the gap reaches 0.045 inch (1.14
mm).
To adjust the air gap or brake pressure, proceed as follows:
1. Disconnect hoist from power supply.
2. Remove brake cover.
3. Before adjusting air gap or brake pressure:
a. Back off the brake nuts and examine friction lin-
ings and friction surfaces for excessive wear,
scoring or warpage.
b. Check shading coils to be sure they are in place
and not broken. A missing or broken shading coil
will cause the brake to be noisy when trolley is
operated.
Any of these symptoms indicate the need for
replacement of parts.
4. If brake pressure is to be adjusted, move brake spacer
washers to the desired side of the brake field plate to
increase or decrease pressure as indicated above.
5. After spacer washers are positioned, turn brake nuts
clockwise gaging the air gap at both ends.
6. Replace brake cover, reconnect the power and check
operation. If the stopping distance of the trolley is not
as desired, repeat the above.
HOOK TRAVEL PER NOTCH OF
LIMIT SWITCH NUT
* At 60 Hertz. For 50 Hertz speeds are 5/6 of those
listed. Fast speeds are listed for two speed units.
RATED
LOAD
TONS
(Kg.)
*LIFT
SPEED
FPM
(MPM)
MAX.
LIFT
FT. (M)
HOOK
TRAVEL
PER
NOTCH
IN. (mm)
2 (2000) 18 (5.5) 127 (39) 1.10 (27.9)
2 (2000) 24 (7.3) 139 (42) 1.27 (32.3)
3 (3000) 9 (2.7) 63 (19) 0.55 (14.0)
3 (3000) 12 (3.6) 70 (21) 0.64 (16.1)
4 (4000) 9 (2.7) 63 (19) 0.55 (14.0)
4 (4000) 12 (3.6) 70 (21) 0.64 (16.1)
5 (5000) 6 (1.8) 42 (13) 0.37 (9.3)
5 (5000) 8 (2.4) 46 (14) 0.42 (10.8)
6 (6000) 6 (1.8) 42 (13) 0.37 (9.3)
6 (6000) 8 (2.4) 46 (14) 0.42 (10.8)
RECOMMENDED SPARE
PARTS
To insure continued service of the Lodestar XL Hoist,
the following is a list of parts that are recommended
to be kept on hand at all times to replace parts that
have worn or failed. Parts applicable to your unit
should be stocked.
Key No. Part NameQty. for Each
Hoist in Service
652-120 Limit Switch Assembly 1
652-130 Brake Coil 1
652-131 Brake Friction Disc 2
652-135 Transformer 1
627-563 Control Station Parts Kit 1
(2 Direction Station)
627-565 Control Station Switch Kit 1
(2 Direction Station)
635-155 Control Station Switch Kit 1
(4 Direction Station)
652-136 Hoist Reversing Contactor 1
652-137 Speed Selecting Contactor 1
(2 Speed Hoists Only)
652-138 Trolley Reversing Contactor 1
652-236 Trolley Speed Selector 1
(2 Speed Trolley Only)
Refer to page 29 for ordering instructions and the
parts list for part numbers.
PREVENTIVE MAINTENANCE
In addition to the inspection procedure on page 12, a
preventive maintenance program should be estab-
lished to prolong the useful life of the hoist and main-
tain its reliability and continued safe use. The pro-
gram should include the periodic and frequent
inspections with particular attention being paid to the
lubrication of the various components using the rec-
ommended lubricants (see page 14).
TROLLEY BRAKE
ADJUSTMENT