CM Lodestar XL User manual

OPERATING,
MAINTENANCE
& PARTS
MANUAL
ELECTRIC
CHAIN HOIST
Manual No. 652-
Before installing hoist, fill in
the information below. Refer
to the hoist identification
plate.
Model No. __________________
Serial No. __________________
Purchase Date ______________
Voltage ____________________
Rated Capacity______________
52756
XXLL
Rated capacities 2 through 7½ tons/
2000 through 7500 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.
®

CM®XL HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
As a CM® XL 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 314-869-7200 | FAX: [phone]. In the following list, the Canadian Service Centers are
indicated.
i
UNITED STATES MASTER PARTS DEPOT CANADIAN SERVICE CENTERS
MISSOURI
Distributed by Tri-State Equipment Company Inc.
Email: [email protected]
Web: www.tsoverheadcrane.com
PH: 314-869-7200 | FAX: [phone]
COLUMBUS McKINNON, LTD.
10311-174th Street dmonton,
Alberta T5S 1H1

SAFETY PRECAUTIONS
ach CM® Lodestar XL lectric 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 ngineers
Standard B30.16 “Overhead Hoists,” the National lectrical Code (ANSI/NFPA 70) and the Occupational Safety and
Health Act. Since OHSA states the National lectrical Code applies to all electric hoists, installers are required to pro-
vide current overload protection and grounding on the branch circuit section in keeping with the code. Check each
installation for compliance with the application, operation and maintenance sections of these articles.
The safety laws for elevators, lifting of people and for dumbwaiters specify construction details that are not incorporated in
Lodestar XL 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 (ASM 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 ASM Order Department, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300, 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 CM®LODESTAR XL HOIST.
19. Not allow the load chain or hook to be used as an electrical or
welding ground.
20. Not allow the load chain or hook to be touched by a live
welding electrode.
21. Not remove or obscure the warnings on the hoist.
22. Not operate a hoist on which the safety placards or decals are
missing or illegible.
23. Not operate a hoist unless it has been securely attached to a
suitable support.
24. Not operate a hoist unless load slings or other approved single
attachments are properly sized and seated in the hook saddle.
25. Take up slack carefully - make sure load is balanced and load
holding action is secure before continuing.
26. Shut down a hoist that malfunctions or performs unusually and
report such malfunction.
27. Make sure hoist limit switches function properly.
28. Warn personnel of an approaching load.
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 the 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 or chain
around load.
14. Not apply the load to the tip of the hook or to the
hook latch.
15. Not apply load unless load chain is properly seated in
the chain wheel(s) or sproket(s).
16. Not apply load if bearing prevents equal loading on all
load chains.
17. Not operate beyond the limits of the load chain travel.
18. Not leave load supported by the hoist unattended
unless specific precautions have been taken.
WARNING
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could
result in death or serious injury. To avoid such a
potentially hazardous situation, the operator shall:
!
!
!
WARNING
Usage of hoists that do not involve lifting of the load
on the lower hook or using hoists in the inverted posi-
tion without special precaution may cause an accident
resulting in injury and/or property damage.
TO AVOID IN URY:
Consult Factory for information concerning using hoists in
these applications.
!
iii
CAUTION
Improper operation of a hoist can create a potentially haz-
ardous situation which, if not avoided, could result in minor
or moderate injury. To avoid such a potentially hazardous
situation, the operator shall:
!
1. Maintain a firm footing or be otherwise secured when operating
the hoist.
2. Check brake function by tensioning the hoist prior to each lift
operation.
3. Use hook latches. Latches are to retain slings, chains, etc. under
slackconditions 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 instructions in this manual.
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 when operating 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.

iii

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
REPAIR/REPLACEMENT POLICY . . . . . . 3
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION
UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING THE SUSPENSION
HOOK SUSP NSIONS . . . . . . . . . . . . . . . . . . 4
LUG SUSP NSIONS . . . . . . . . . . . . . . . . . . . . . 6
MOUNTING TROLLEY ON HOIST. . . . . . 6
INSTALLING TROLLEY SUSPENDED
HOIST ON BEAM. . . . . . . . . . . . . . . . . . . . .7
INSTALLING BREATHER . . . . . . . . . . . . . . . . 8
POWER SUPPLY SYSTEM . . . . . . . . . . . . . . . 8
ELECTRICAL CONNECTIONS
SINGL SP D DUAL VOLTAG
HOISTS (AND MOTOR DRIV N TROLL YS) . 9
ALL HOISTS. . . . . . . . . . . . . . . . . . . . . . . . . 9
CH CKING FOR TWIST IN LOAD CHAIN . 10
CH CKING FOR AD QUAT VOLTAG . . 10
CHECKING LIMIT SWITCH OPERATION . . . 10
CHAIN CONTAINER. . . . . . . . . . . . . . . . . . . . 10
CONTROL CORD . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATING INSTRUCTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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
FR QU NT INSP CTIONS . . . . . . . . . . . . . . 12
P RIODIC INSP CTIONS . . . . . . . . . . . . . . . 12
HOOK INSP CTION . . . . . . . . . . . . . . . . . . . 12
LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 13
PROT CTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LUBRICATION
HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TROLL Y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AD USTMENTS
HOIST BRAK . . . . . . . . . . . . . . . . . . . . . . . . 15
LIMIT SWITCH S. . . . . . . . . . . . . . . . . . . . 16
TROLL Y BRAK . . . . . . . . . . . . . . . . . . . 17
RECOMMENDED SPARE PARTS . . . . . . . 18
PREVENTIVE MAINTENANCE . . . . . . . . . 18
TROUBLE SHOOTING
ALL HOISTS. . . . . . . . . . . . . . . . . . . . . . . . 19
TWO SP D HOISTS. . . . . . . . . . . . . . . . . 22
MOTOR DRIV N TROLL Y. . . . . . . . . . . . 23
ELECTRICAL DATA . . . . . . . . . . . . . . . . . 24, 25
WIRING DIAGRAMS . . . . . . . . . . . . . . . 26, 28
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 29
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL AND REPLACEMENT OF LOAD CHAIN29
REEVING LOAD CHAIN
3,4 AND 5 TON DOUBL R V D UNITS . . 30
5,6 AND 71/2 TON TRIPL R V D UNITS . 31
CUTTING CHAINS. . . . . . . . . . . . . . . . . . . . . . 31
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REPAIR PARTS
ORDERING INSTRUCTIONS. . . . . . . . . . . . 32
EXPLODED VIEWS AND PARTS LISTS. . 33-48
FOREWORD
This manual contains important information to help you properly install, operate and maintain your hoist for maxi-
mum performance, economy and safety.
Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating proce-
dures and by carrying out the recommended preventative maintenance suggestions, you will experience long, depend-
able and safe service. After you have completely familiarized yourself with the contents of this manual, we recom-
mend 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 CM®LOD STAR XL lectric 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 7½ tons
(7500 kg.) are
available. The hoist can be supplied with a single hook
suspension up to 6 ton (6000 kg.) capacity or suspended
from a plain, geared or motor driven trolley. The stan-
dard lift is 10 feet and longer lifts can be provided on a
per order basis.
The standard features of the CM® LOD STAR XL lectric
Chain Hoist include:
• Hardened, alloy steel, oblique lay liftwheel pro-
vides constant chain speed and reduces chain wear.
• Hoistaloy®load chain for long and dependable
service.
• Lightweight cast aluminum frame and covers.
• Surface hardened, alloy steel, helical gears run-
ning 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.
2
TABLE 1—SPECIFICATIONS
LODESTAR XL ELECTRIC CHAIN HOISTS
TONS 2 3 4 & 5 5 5 6 7½
RATED LOAD Kg. 2000 3000 4000 & 5000 5000 5000 6000 7500
*LIFTING SPEEDS AVAILABLE:
FPM 18 24 30 9 12 15.2 6 8 6 8 10 6 10
SINGLE SPEEDS
MPM 5.5 7.3 9.1 2.7 3.6 4.6 1.8 2.4 1.8 2.4 3.0 1.8 3.0
FPM 6 /18 8 / 24 3/9 4/12 2/6 2.7/8 2/6 2.7/8 2/6
TWO SPEEDS N/A N/A N/A N/A
MPM 1.8 / 5.5 2.4 / 7.3 .9/2.7 1.2 / 3.6 .6 / 1.8 .8 / 2.4 .6/1.8 .8/2.4 .6/1.8
FEET 127 139 71 60 65 106 42 46 42 46 71 42 71
MAXIMUM LIFT
METERS 39 42 22 19 21 32 13 14 13 14 22 13 22
REEVING OF LOAD CHAIN SINGLE DOUBLE TRIPLE
MINIMUM HEADROOM
HOOK SUSPENDED—IN. (mm) 25 (635) 35.31 (897) 36.18 (919) N/A
TROLLEY SUSPENDED—IN. (mm) 28.69 (729) 33 (841) 33.38 (848) 34.25 (870) 34.25 (870)
RANGE OF TROLLEY AD USTABILITY 6 X 12.5 #TO 8 X 18.4#TO 20 X 66.0#
“S” BEAMS 15 X 42.9#
IN. 3.33 TO 5.50 4.00 TO 6.250
FLANGE WIDTH
mm 84.5 TO 139.7 101.6 TO 158.8
STANDARD MOTOR DRIVEN TROLLEY 65 (19.8) OR
TRAVEL SPEED—FPM (MPM) 100 (30.4) 50 (15.2)
**APPROX. NET WEIGHT—LBS. (Kg.)
HOOK SUSPENDED 368 (167) 442 (200) 442 (200) 474 (215)
WITH PLAIN TROLLEY 428 (194) 497 (225) 597 (271) 629 (285)
WITH GEARED TROLLEY 473 (215) 512 (232) 607 (275) 639 (290)
WITH MOTOR DRIVEN TROLLEY 483 (219) 582 (264) 632 (287) 664 (301)
*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.).
GENERAL INFORMATION
• Oversize reversing and speed selecting contactors
for long, trouble free service.
• Hoist duty, A.C. motor brake plus regenerative braking.
• Weatherproof, CM 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.
CM®LODESTAR
XL Hoist with
Motor Driven
Trolley

REPAIR/REPLACEMENT POLICY
All Lodestar XL lectric Chain Hoists are thoroughly inspect-
ed and performance tested prior to shipment. If any proper-
ly maintained hoist develops a performance problem due to
a material or workmanship defect, as verified by factory,
repair or replacement of the unit will be made to the origi-
nal purchaser without charge. This repair/replacement poli-
cy applies only to LOD STAR XL 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-factory
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 2 through 6
ton hoist from a trolley with a single load bar or for sus-
pending the hoist from a fixed structure.
3
LUG SUSPENSIONS
Lug suspensions are required to suspend the LOD STAR XL
lectric 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
PLAIN TROLLEYS
These are manual push type trolleys designed for use with
the LOD STAR XL lectric 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.
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
variety of single and two speed trolley travel speeds are
available 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
instructions. 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 separately and can be furnished for units
already in use.
LATCHLOK®HOOKS
Latchlok hooks are available to replace the standard
upper or lower latch type hooks (2-6 ton only). 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,
suspension, 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 iden-
tification 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 2 through 6 ton units, the suspension is
shipped separately and it must be attached to the hoist
as follows:
1. 2 THROUGH 6 TON. Supplied with the hook suspen-
sion 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 IN URY:
Carefully check unit for external damage prior to
installation.
!
MAKING SUR TH
HOIST WILL OP RAT
ON TH POW R SUPPLY
SYST M
INSP CT FOR SHIPPING
DAMAG
MOTOR DRIVEN TROLLEY
4

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, 4 and 5 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 per-
pendicular 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 suspension) 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 “XL” label, from the kit, to counterweight in
the recess provided for same.
2. 2 Ton Single Reeved Units. As shipped from the facto
ry, 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 CONV RT
TO SWIV L
TYP HOOK
MOUNTING TH
COUNT RW IGHT
INSTALLING
HOOK
SUSP NSION
2 TON UNIT
TO CONV RT TO
SWIV L TYP
HOOK
DRIFT
COU TERWEIGHT

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, 4 and 5
ton double reeved units) or idler sheave hanger
(5 and 6 ton units). Then tighten dead end bolt
to a seating torque of 120 pound feet (160NM).
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 factory, the lug suspension is
installed prior to mounting the trolley.
1. 2 Ton Single Reeved Units. Slide the suspension
adapter into the cavity on top of hoist and secure it
using the suspension adapter screw. Tighten the
screw to a seating torqueof16 pound feet (22 NM).
INSTALLING LUG SUS-
P NSION—2 TON UNITS
INSTALLING
HOOK
SUSP NSION
3, 4, 5, & 6 TON
CHANGING
POSITION OF
HOOK
2. 3, 4 And 5 Ton Double Reeved And 5, 6 And 7½
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, 4 and 5 ton double reeved units) or idler
sheave hanger (5, 6 and 7 1/2 ton triple reeved
units). Then tighten the dead end bolt to a seating
torque of 120 pound feet (160 NM).
INSTALLING LUG
SUSP NSION—3, 4,
5, 6 AND 7 1/2 TON
MOUNTING TROLLEY ON HOIST
The following instructions are provided to cover mount-
ing plain, geared and motor driven trolleys after the
hoist has been reassembled following inspection and/or
repair. On units shipped from factory, these trolleys are
mounted on the hoists.
1. Measure actual width of the beam flange on which
the trolley is to operate. To determine proper trolley
side frame spacing to assure that adequate wheel
clearance is provided, the distance between the
beam flange and the inside face of the trackwheel
flange (approximately 1/8 to 3/16 inch on straight
runway beams, 3/16 to 1/4 inch on curved beams for
2 ton units. See Figure 2) and (1/4 inch for straight
runway beams, 3/8 inch on curved beams for 3-7 1/2
ton units. See Figure 1).
2. Use Table 2 to determine proper spacing for 2 ton
units. On 3-7 1/2 ton capacity units, proper spacing is
obtained by varying the number of spacer washers
(furnished with trolley) that are installed on the sus-
pension pins.
WARNING
Using other than factory 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 IN URY:
Use only the factory supplied suspension adapter
screw or dead end bolt and tighten these to the seat-
ing torque specified above.
!
MOUNTING
TROLL Y ON
HOIST
HANDWH L OR TROLL Y
MOTOR G AR D OR MOTOR
DRIV N TROLL Y ONLY
Dead End Bolt
6