Lodestar CM Hoist User manual

Operating, Maintenance
& Parts Manual
83874 627-T
®
Electric Chain
Rated Loads
1/8 through 3-Tons
125 kg through 3000 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 the hoist operator.
Failure to operate the equipment as directed in the
manual may cause injury.
Before using the hoist, fill in the information below.
Refer to the hoist identification plate.
Model Number ____________________________
Serial Number ____________________________
Purchase Date ____________________________
Voltage __________________________________
Rated Load ______________________________

i
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 CANADIAN SERVICE CENTERS
CALIFORNIA
OTTO SYSTE S, INC.
12010 Bloomfield Ave.
Sante Fe Springs, CA 90670
562/462-1612 or 800/596-7392
Fax [phone]
or
7656 Las Positas Road
Livemore, CA 94551
925/245-8800 or 800/508-6886
Fax [phone]
GEORGIA
ACE INDUSTRIES, INC.
6295 cDonough Drive
Norcross, GA 30093
770/441-0898 or 800/733-2231
Fax [phone]
ILLINOIS
JOHN SAKASH CO PANY, INC.
700 Walnut Street
Elmhurst, IL 60126
630/833-3940
Fax [phone]
INDIANA
HORNER ELECTRIC CO PANY, INC.
1521 East Washington Street
Indianapolis, IN 46201
317/639-4261
Fax [phone]
IOWA
V HOIST & CRANE SERVICES
PO Box 440
450 Highway 151
Walford, IA 52351
319/846-6040
Fax [phone]
KANSAS
INDEPENDENT ELECTRIC ACHINERY
4425 Oliver Street
Kansas City, KS 66106
913/362-1155 or 800/833-2610
Fax [phone]
LOUISIANA
BEER AN PRECISION, INC.
PO Box 6018
etairie, LA 70009
504/207-6000
Fax [phone]
MASSACHUSETTS
ABEL DISTRIBUTORS, INC.
50 Parker Street, Unit 2
Newburyport, A 01950
978/463-0700
Fax [phone]
NEW JERSEY
SHUPPER-BRICKLE EQUIP ENT CO.
PO Box 803
2394 Route 130, Suite C
Dayton, NJ 08810
732/438-3888
Fax [phone]
NEW YORK
VOLLAND ELECTRIC EQUIP ENT CO.
75 Innsbruck Drive
Buffalo, NY 14227
716/656-9900
Fax [phone]
NORTH CAROLINA
TEA SESCO
PO Box 667489
2225 Freedom Drive
Charlotte, NC 28208
704/372-4832 or 800/487-3726
Fax [phone]
OHIO
AZZELLA LIFTING TECHNOLOGIES
21000 Aerospace Parkway
Cleveland, OH 44142
440/239-5700 or 800/362-4601
Fax [phone]
PENNSYLVANIA
A ICK ASSOCIATES, INC.
11 Sycamore Street
Carnegie, PA 15106-0529
412/429-1212 or 800/445-9456
Fax [phone]
RA OTORS & CONTROLS, INC.
5460-B Pottsville Pike, Docks 8-11
PO Box 748
Leesport, PA 19533
610/916-8000
Fax [phone]
SOUTH CAROLINA
ENGINEERED SYSTE S INC.
1121 Duncan-Reidville Road
Duncan, SC 29334
864/879-7438 or 800/879-7438
Fax [phone]
TEXAS
ABEL EQUIP ENT CO., INC.
3710 Cavalier Drive
Garland, TX 75042
972/272-7706
Fax [phone]
HYDRAULIC EQUIP ENT SERVICES, INC.
1021 North San Jacinto Street
Houston, TX 77002
713/228-9601
Fax [phone]
WISCONSIN
TRESTER HOIST & EQUIP ENT, INC.
W136 N4863 Campbell Drive
Suite #4
enomonee Falls, WI 53051
262/790-0700 or 800/234-6098
Fax [phone]
ALBERTA
BENNETT & E OTT, LTD.
18131 118th Avenue
Edmonton, Alberta T5S 1 8
403/454-9000
Fax [phone]
**COLU BUS cKINNON, LTD.
10311-174th Street
Edmonton, Alberta T5S 1H1
800/263-1997
Fax [phone]
BRITISH COLUMBIA
FLECK BROTHERS, LTD.
4084 cConnel Court
Burnaby, British Columbia V5A 3N7
MANITOBA
KING’S ELECTRIC OTORS, INC.
633 Tyne Avenue
Winnipeg, anitoba R2L 1J5
204/663-5332
Fax [phone]
NOVA SCOTIA
*W & A OIR
95 Ilsley Ave.
Burnside Park, 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
9 CoDeco Court
North York, Ontario 3A 1A1
416/386-0820
Fax [phone]
* ASLACK SUPPLY, LTD.
488 Falconbridge Road
Sudbury, Ontario P3A 4S4
705/566-1270
Fax [phone]
*COLU BUS cKINNON, LTD.
P.O. Box 1106
10 Brook Road, North
Cobourg, Ontario K9A 4W5
905/372-0153
Fax [phone]
QUEBEC
*HERCULES SLING & CABLE
3800 TransCanada Highway
Pointe-Claire, Quebec H9R 1B1
514/428-5511
514/48631-5511
Fax [phone]
*LEGER PALANS ET OUTILLAGES, INC.
7995-17th Ave.
ontreal, Quebec H1Z 3R2
514/376-3050
Fax [phone]
**ARE ALSO ASTER PARTS DEPOTS
** ASTER PARTS DEPOT ONLY

SAFETY PRECAUTIONS
Each Lodestar Electric Hoist is built in accordance with the specifications contained herein and at the time of manufacture com-
plied with our interpretation of applicable sections of the *American Society of Mechanical Engineers Code B30.16 “Overhead
Hoists,” the National Electrical Code (ANSI/NFPA 70) and the Occupational Safety and Health Act. Since OSHA states the
National Electrical Code applies to all electric hoists, installers are required to provide current overload protection and grounding
[on the branch circuit section] in keeping with the code. Check each installation for compliance with the application, operation
and maintenance sections of these articles.
The safety laws for elevators, lifting of people and for dumbwaiters specify construction details that are not incorporated into the
hoists. For such applications, refer to the requirements of applicable state and local codes, and the American National Safety
Code for elevators, dumbwaiters, escalators and moving walks (ASME A17.1). Columbus McKinnon Corporation cannot be
responsible for applications other than those for which CM equipment is intended.
*Copies of this standard can be obtained from AS E 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 LODESTAR HOIST.
1. NOT operate a damaged, malfunctioning or unusually
performing hoist.
2. NOT operate the hoist until you have thoroughly read
and understood this Operating, Maintenance and Parts
Manual.
3. NOT operate a hoist which has been modified.
4. NOT lift more than rated load for the hoist.
5. NOT use hoist with twisted, kinked, damaged, or worn
load chain.
6. NOT use the hoist to lift, support, or transport people.
7. NOT lift loads over people.
8. NOT operate a hoist unless all persons are and remain
clear of the supported load.
9. NOT operate unless load is centered under hoist.
10. NOT attempt to lengthen the load chain or repair dam-
aged load chain.
11.Protect the hoist’s load chain from weld splatter or other
damaging contaminants.
12. NOT operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
13. NOT use load chain as a sling, or wrap load chain
around load.
14. NOT apply the load to the tip of the hook or to the hook
latch.
15. NOT apply the load unless load chain is properly seated
in the chain wheel(s) or sprocket(s).
16. NOT apply load if bearing prevents equal loading on all
load supporting chains.
17. NOT operate beyond the limits of the load chain travel.
18. NOT leave load supported by the hoist unattended
unless specific precautions have been taken.
19. NOT allow the load chain or hook to be used as an elec-
trical or welding ground.
20. NOT allow the load chain or hook to be touched by a
live welding electrode.
21. NOT remove or obscure the warnings on the hoist.
22. NOT operate a hoist on which the safety placards or
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. Maintain a firm footing or be otherwise secured when
operating the hoist.
2. Check brake function by tensioning the hoist prior to
each lift operation.
3. Use hook latches. Latches are to retain slings, chains,
etc. under slack conditions only.
4. Make sure the hook latches are closed and not support-
ing any parts of the load.
5. Make sure the load is free to move and will clear all
obstructions.
6. Avoid swinging the load or hook.
7. Make sure hook travel is in the same direction as shown
on the controls.
8. Inspect the hoist regularly, replace damaged or worn
parts, and keep appropriate records of maintenance.
9. Use the hoist manufacturer’s recommended parts when
repairing the unit.
10.Lubricate load chain per hoist manufacturer’s
recommendations.
11. NOT use the hoist load limiting or warning device to
measure load.
12. NOT use limit switches as routine operating stops unless
allowed by manufacturer. They are emergency devices
only.
13. NOT allow your attention to be diverted from operating
the hoist.
14. NOT allow the hoist to be subjected to sharp contact
with other hoists, structures, or objects through misuse.
15. NOT adjust or repair the hoist unless qualified to per-
form such adjustments or repairs.
L
L
!
!
WARNING
Improper operation of a hoist can create a potentially haz-
ardous situation which, if not avoided, could result in death or
serious injury. To avoid such a potentially hazardous situation,
the operator shall:
L
!
!
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 situa-
tion, the operator shall:
L!L!
L
L
!
!
WARNING
Usage of hoists that do not involve lifting of the load on the
lower hook or using hoists in the inverted position without
special precaution may cause an accident resulting in injury
and/or property damage.
TO AVOID IN URY:
Consult Columbus cKinnon for information concerning
using hoists in these applications.

iii
1 CHOOSE THE RIGHT HOIST FOR THE JOB...
Choose a hoist with a capacity for the job.
now the capacities of your hoists and the
weight of your loads. Then match them.
The application, the size and type of load,
the attachments to be used and the period of
use must also be taken into consideration in
selecting the right hoist for the job.
Remember the hoist was designed to ease
our burden and carelessness not only
endangers the operator, but in many cases,
a valuable load.
VIOLATION OF ANY OF THESE WARNINGS LISTED AY RESULT IN SERIOUS PERSONAL INJURY TO THE
OPERATOR OR NEARBY PERSONNEL BY RELEASED LOAD OR BROKEN HOIST CO PONENTS.
–DO NOT LIFT ORE THAN RATED LOAD.
L
!
!
WARNING
2 INSPECT
–DO NOT OPERATE DA AGED OR ALFUNCTIONING HOIST.
–DO NOT OPERATE WITH TWISTED, KINKED OR DA AGED
CHAIN.
3 USE HOIST PROPERLY
Be sure hoist is solidly held in
the uppermost part of the support
hook arc.
Be sure hoist and load are in a
straight line. Do not pull at an
angle.
Be sure load is hooked securely.
Do not tip load the hook. Do not
load hook latch. Hook latch is to
prevent detachment of load under
slack chain conditions only.
Do not use load chain as a sling.
Such usage damages the chain
and lower hook.
Do not operate with hoist head
resting against any object. Lift the
load gently. Do not jerk it.
–DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD
ARE IN A STRAIGHT LINE.
4 LIFT PROPERLY
Do not lift co-workers with a hoist.
Make sure everyone is clear of the load
when you lift.
Do not remove or obscure operational
warning notices.
5 AINTAIN PROPERLY
CLEANING: Hoists should be kept clean
and free of dust, dirt, moisture, etc., which
will in any way affect the operation or safe-
ty of the equipment.
LUBRICATION: Chain should be properly
lubricated.
AFTER REPAIRS: Carefully operate the
hoist before returning it to full service.
–DO NOT LIFT PEOPLE OR LOADS
OVER PEOPLE.
HOIST SAFETY IS UP TO YOU...
All hoists should be visually inspected
before use, in addition to regular, periodic
maintenance inspections.
Inspect hoists for operational warning
notices and legibility.
Deficiencies should be noted and brought
to the attention of supervisors. Be sure
defective hoists are tagged and taken out of
service until repairs are made.
Under no circumstances should you oper-
ate a malfunctioning hoist.
Check chain for gouged, twisted, distorted
links and foreign material. Do not operate
hoists with twisted, kinked or damaged chain.
Load chain should be properly lubricated.
Hooks that are bent, worn or whose open-
ings are enlarged beyond normal throat
opening should not be used. If latch does not
engage throat opening of hook, hoist should
be taken out service.
Check for misphasing – hook travel should
correspond to control direction.
L
!
!
WARNING
L
!
!
WARNING
L
!
!
WARNING

1
FOREWORD
This manual contains important information to help you properly install, operate and maintain your hoist for maximum performance,
economy and safety.
Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating procedures and by
carrying out the recommended preventive maintenance suggestions, you will experience long, dependable and safe service.
After you have completely familiarized yourself with the contents of this manual, we recommend that you carefully file it for future
reference.
The information herein is directed to the proper use, care and maintenance of the hoist and does not comprise a handbook on
the broad subject of rigging. Rigging can be defined as the process of lifting and moving heavy loads using hoists and other
information, we recommended consulting a standard textbook on the subject.
SAFETY PRECAUTIONS
Master Parts Depots And Service Centers . . . . . . . . . . . .i
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Hoist Safety is Up To You . . . . . . . . . . . . . . . . . . . . . . . . .iii
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL INFOR ATION
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CM Repair/Replacement Policy . . . . . . . . . . . . . . . . . . . .2
ACCESSORIES
Hook Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Lug Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Series 635 Low Headroom Trolleys . . . . . . . . . . . . . . . . .3
Series 635 Motor Driven Trolleys . . . . . . . . . . . . . . . . . . .3
Latchlok Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INSTALLATION
Unpacking Information . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Installing Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Attaching Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Installing Series 635 Low Headroom Trolley . . . . . . . . .6-7
Power Supply and Electrical Connections . . . . . . . . .8-16
OPERATING INSTRUCTIONS
eneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operating Instruction-Hoist . . . . . . . . . . . . . . . . . . . . . . .11
Hoist with Low Headroom Trolley . . . . . . . . . . . . . . . . . .11
Hoist with Motor Driven Trolley . . . . . . . . . . . . . . . . . . . .11
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
INSPECTION
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Frequent Inspections . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .12
Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
AINTENANCE
Hoist Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Trolley Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Exterior Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Solid State Reverse Switch . . . . . . . . . . . . . . . . . . . . . . .15
AAddjjuussttmmeennttss
Electric Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . .18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . .24-47
ASSE BLY INSTRUCTIONS
Hook or Lug Suspension . . . . . . . . . . . . . . . . . . . . . . . .48
Weatherproof Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
earing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Lower Hook Block Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Removal and Installation of Load Chain . . . . . . . . . . . .49
Cutting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
REPLACE ENT PARTS
Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Parts List and Exploded Views . . . . . . . . . . . . . . . . .51-91
LIST OF TABLES
1Lodestar Electric Chain Hoist and
Series 635 Trolley Specifications . . . . . . . . . . . . . . . .2
2Recommended Seating Torques for
Suspension Adapter Screws . . . . . . . . . . . . . . . . . . .5
3Series 635 Low Headroom
Side Frame Spacing . . . . . . . . . . . . . . . . . . . . . . . . . .7
4Minimum Frequent Inspections . . . . . . . . . . . . . . . . . . .13
5Minimum Periodic Inspections . . . . . . . . . . . . . . . . . . . .13
6Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
7Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21
8Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
LIST OF ILLUSTRATIONS
1Hook Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2Lug Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3Series 635 Low Headroom Trolley . . . . . . . . . . . . . . . . . .3
4Series 635 Motor Driven Trolley . . . . . . . . . . . . . . . . . . . .3
5Upper or Lower Latchlok Hook . . . . . . . . . . . . . . . . . . . .4
6Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
7Attaching Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
8Contact Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
9Series 635 Low Headroom Trolley . . . . . . . . . . . . . . . . . .6
10 1/8 To 2 Ton (125kg To 2000 kg) Hoist To Trolley Assembly . .7
11 3 Ton (3000kg) Hoist To Trolley Assembly . . . . . . . . . . . .7
12 Voltage Conversion Terminal Board . . . . . . . . . . . . . . . . .8
13 Location of Components . . . . . . . . . . . . . . . . . . . . . . . . . .9
14 Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
15 aging Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
16 Limit Switches Models A Thru H-2 . . . . . . . . . . . . . . . . .17
17 Limit Switches Models J Thru RRT-2 . . . . . . . . . . . . . . .17
18 Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . .24-47
19 Hook Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
20 Non-Circular earing . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
22 Cutting Chain With A Bolt Cutter . . . . . . . . . . . . . . . . . . .30
23 Hoist Frame Componets . . . . . . . . . . . . . . . . . . . . . . .54-55
24 Hoist Upper Suspension Components . . . . . . . . . . . .56-57
24 Hoist Lower Hook Components . . . . . . . . . . . . . . . . .58-59
25 Control End Components . . . . . . . . . . . . . . . . . . . . . .60-65
26 earing Components . . . . . . . . . . . . . . . . . . . . . . . . .66-67
27 Liftwheel Components . . . . . . . . . . . . . . . . . . . . . . .68-69
28 Motor End Components . . . . . . . . . . . . . . . . . . . . . .70-71
29 Contactor Plate Assemblies . . . . . . . . . . . . . . . . . . .72-84
30 Control Station Components . . . . . . . . . . . . . . . . . .86-88
28 Trolley Components . . . . . . . . . . . . . . . . . . . . . . . . . .90-91
TABLE OF CONTENTS
PAGE PAGE

2
SPECIFICATIONS
The Lodestar Electric Chain Hoist is a highly versatile materials
handling device that can be used to lift loads that are within
rated capacity. The mechanical features of these hoists
include an alloy steel lift wheel, Load Protector, hardened
steel chain guides, hardened steel gear train, life-time lubri-
cation, forged steel hooks and lightweight aluminum frame.
The electrical features include hoist-duty motor, rugged hoist
brake, magnetic reversing contactor and voltage conversion
board (dual voltage units). The hoist is available with hook or
lug suspensions that are supplied separately. Table 1 summa-
rizes the Lodestar Electric Chain Hoist models and the Series
635 Trolleys available. It should be noted that standard single
speed hoists are available with 10 (3M), 15 (4.6M) and 20
(6.1M) foot lifts and the standard lift for two speeds hoists is
10 feet. However, hoists with longer lifts are available on a
special, per order basis.
CM REPAIR/REPLACEMENT POLICY
All Columbus McKinnon (CM®) Lodestar Electric Chain
Hoists are inspected and performance tested prior to ship-
ment. If any properly maintained hoist develops a perfor-
mance 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.
Table 1. Specifications
A. Lodestar Electric Chain Hoists
Maximum
Capacity
Tons (kg)
Model
Lifting
Speed
Per Min.
Feet (m)
Motor
H.P
(kW).
Shortest
Distance
Between
Hooks
Inches (mm)
Net
Weight
Lbs. (kg)
Single Speed 115-1-60
1/8 (125)
1/8 (125)
1/4 (250)
A
AA
B
32 (9.8)
60 (18.4)
16 (4.9)
1/4 (.19)
1/2 (.37)
1/4 (.19)
14¼ (362)
14¼ (362)
14¼ (362)
53 (24)
64 (29)
57 (26)
1/4 ((250g)
1/2 (500)
1/2 (500)
C
E
F
32 (9.8)
8 (2.4)
16 (4.9)
1/2 (.37)
1/4 (.19)
1/2 (.37)
14¼ (362)
17 1/8 (454)
14 ¼ (362)
65 (29.5)
68 (31)
64 (29)
1/2 (500)
1 (1000)
1 (1000)
2 (2000)
J
H
L
R
32 (9.8)
8 (2.4)
16 (4.9)
8 (2.4)
1 (.75)
1/2 (.37)
1 (.75)
1 (.75)
15 9/16 (395)
17 7/8 (454)
15 9/16 (395)
22½ (572)
115 (52.3)
75 (34)
117 (53.2)
136 (61.8)
3 (3000) RT 5.5 (1.9) 1 (.75) 25 (635) 161(73.2)
Single Speed 230/460-3-60 or 220/380-3-50
or 220/415-3-50
1/8 (125)
1/8 (125)
1/4 (250)
A
AA
B
32 (9.8)
60 (18.4)
16 (4.9)
1/4 (.19)
1/2 (.37)
1/4 (.19)
14¼
14¼
14¼
67 (30.5)
74 (33.6)
68 (31)
1/4 (250)
1/2 (500)
1/2 (500)
C
E
F
32 (9.8)
8 (2.4)
16 (4.9)
1/2 (.37)
1/4 (.19)
1/2 (.37)
14¼
17 7/8
14¼
74 (33.6)
79 (36)
74 (33.6)
1/2 (500)
1/2 (500)
1(1000)
J
JJ
H
32 (9.8)
64 (19.6)
8 (2.4)
1 (.75)
2 (1.50)
1/2 (.37)
15 9/16
15 9/16
17 7/8
113 (51.4)
120 (54.5)
85 (38.6)
1 (1000)
1 (1000)
2 (2000)
L
LL
R
16 (4.9)
32 (9.8)
8 (2.4)
1 (.75)
2 (1.50)
1 (.75)
15 9/16
15 9/16
22½
114 (51.8)
121 (55)
134 (61)
2 (2000)
3 (3000)
3 (3000)
RR
RT
RRT
16 (4.9)
5.5 (1.9)
11 (3.8)
2 (1.50)
1 (.75)
2 (1.50)
2213/16
25
25
136 (61.8)
161 (73.2)
161 (73.2)
**LLiiffttiinngg aanndd ttrraavveell ssppeeeedd lliisstteedd aarree ffoorr 6600 HHeerrttzz uunniittss.. FFoorr 5500 HHeerrttzz uunniittss,,
tthheesseess ssppeeeeddss wwiillll bbee 55//66 ooff tthhoossee lliisstteedd..
****AA 1//22 HH..PP.. ((..3377 kkWW)) mmoottoorr ffuurrnniisshheedd oonn 338800--33--5500,, 441155--33--5500 aanndd 446600--33--6600
vvoolltt uunniittss..
Maximum
Capacity
Tons (kg)
Model
*Lifting
Speed
Per Min.
Feet (m)
Motor
H.P.
(kW)
Shortest
Distance
Between
Hooks
Inches (mm)
Net
Weight
Lbs. (kg)
Two Speed 230-3-60 or 460-3-60 or 220-3-50
or 380-3-50 or 415-3-50
1/8 (125)
1/8 (125)
**1/4 (250)
A-2
AA-2
B-2
10/32 (3.1/9.8)
20/60 (6.1/18.3)
5/16 (1.5/4.9)
¼ (.19)
½ (.37)
¼ (.19)
14¼ (362)
14¼ (362)
14¼ (362)
69 (31.3)
76 (34.5)
70 (31.8)
1/4 (250)
**1/2 (500)
1/2 (500)
C-2
E-2
F-2
10/32 (3.1/9.8)
2.5/8 (.76/2.4)
5/16 (1.5/4.9)
½ (.37)
¼ (.19)
½ (.37)
14¼ (362)
17 7/8 (454)
14¼ (362)
76 (34.5)
81 (36.8)
76 (34.5)
1/2 (500)
1/2 (500)
1 (1000)
J-2
JJ-2
H-2
10/32 (3.1/9.8)
21/64 (6.4/19.5)
2.5/8 (.76/2.4)
1 (.75)
2 (1.50)
½ (.37)
15 9/16 (395)
15 9/16 (395)
17 7/8 (454)
115 (52.3)
125 (56.3)
87 (39.5)
1 (1000)
1 (1000)
2 (2000)
L-2
LL-2
R-2
5/16 (1.5/4.9)
10/32 (3.1/9.8)
2.5/8 (.76/2.4)
1 (.75)
2 (1.50)
1 (.75)
15 9/16 (395)
15 9/16 (395)
22½ (572)
116 (52.7)
126 (57.3)
136 (61.8)
2 (2000)
3 (3000)
3 (3000)
RR-2
RT-2
RRT-2
5/16 (1.5/4.9)
1.75/5.5 (.53/1.68)
3.5/11 (1.1/3.4)
2 (1.50)
1 (.75)
2 (1.50)
22 13/16 (579)
25 (635)
25 (635)
143 (65)
175 (79.5)
177 (80.5)
B. Series 635 Low Headroom Trolleys
Capacity
Tons (kg)
For Use
With
Models
Adj. For
STD
S-Beams
Depth In.(mm)
Tread
Dia. of
Wheels
In.(mm)
Min.
Rad.
Curve
In. (mm)
1/8 to 1 (125 to 1000)
2 (2000)
3 (3000)
A thru LL-2
R thru RR-2
RT thru RRT-2
4 thru 15 (102 thru 381)
6 thru 18 (152 thru 457)
8 thru 15 (203 thru 381)
3 1/8 (79.4)
4 3/4 (120.6)
4 (101.6)
24 (609)
24 (609)
30 (762)
C. Series 635 otor Driven Trolleys
Capacity
Tons (kg)
For Use
With
Models
*Travel
Speed
FPM
(MPM)
Motor
H.P.
(kW)
Adj. For
STD
S-Beams
Depth In. (mm)
Min.
Rad.
Curve
(In.)
1/8 to 2 (125 to 2000)
3 (3000)
A thru RR-2
RT thru RRT-2
75 (23)
75 (23)
¼ (.19)
¼ (.19)
6 thru 15 (152 thru 381)
6 thru 15 (152 thru 381)
30 (762)
30 (762)
GENERAL INFORMATION

3
HOOK SUSPENSIONS
Swivel and rigid type hook suspensions (see Figure 1) are
available for all Lodestar Electric Hoists. However, rigid type
hook suspensions are normally recommended for most appli-
cation. The hook suspensions are intended for suspending
the hoist from a trolley which has a single load bar (such as
CM’s®Series 632 and 633 Trolleys) or for suspending the
hoist from a fixed structure.
Figure 1. Hook Suspensions
LUG SUSPENSION
Lug suspensions (see Figure 2) are available for all Lodestar
Electric Hoists. These are rigid type suspensions wherein the
lug shown replaces the hook (Figure 1) in the suspension
adapter. The Lug suspensions are required for suspending
the hoist from the Series 635 Low Headroom and Motor
Driven Trolleys described next.
Figure 2. Lug Suspensions
Figure 3. Series 635 Low Headroom Trolley
Series 635 Low
Headroom Trolley
These are manual push type trolleys (see Figure 3) designed
for use with the Lodestar Electric Chain Hoists. A rigid lug
suspension (see Figure 2) is required to suspend the hoist
from the trolley. The trolley is adjustable for operation on a
range of American Standard “S” beams as indicated in
Table 1, and it will also operate on flat flanged beams.
Figure 4. Series 635 otor Driven Trolley
Series 635 Motor Driven Trolley
The motor driven trolleys (see Figure 4) are self-contained
and supplied complete with independent controls and wiring,
including a four directional control station. A rigid lug sus-
pension (see Figure 2) is required to suspend the hoist from
the Motor Driven Trolley. The hoist and trolley are joined elec-
trically by connecting the hoist control and power cords (sup-
plied) into the hoist or trolley. The trolley is adjustable for
operation on a range of American Standard “S” beams as
indicated in Table 1, and it will also operate on flat flanged
beams.
ACCESSORIES

LATCHLOK®HOOKS
CM’s Latchlok hooks (see Figure 5) are available to replace
the standard upper and lower hooks used on the Lodestar
Electric Hoists.
Figure 5. Upper or Lower Latchlok®Hook
UNPACKING INFORMATION
When received, the hoist should be carefully inspected for
damage which may have occurred during shipment or han-
dling. Check the hoist frame for dents or cracks, the external
cords for damaged or cut insulation, the control station for
cut or damaged enclosure, and inspect the load chain for
nicks and gouges. If shipping damaged has occurred, refer
to the packing list envelope on the carton for claim proce-
dure.
Before installing the hoist, make sure that the power supply
to which it will be connected is the same as that shown on
the nameplate located on the side of the hoist.
NOTE: To assur long lif and top p rformanc , b sur to
follow th load chain lubricating instructions on pag 15.
INSTALLING THE SUSPENSION
A. Single Reeved Units.
Remove the hook or lug suspension from its carton and the
two suspension screws. Place the suspension assembly into
the recess on top of the hoist so that the adapter body fol-
lows the contour of the hoist. Insert the suspension screws
through the holes in the adapter and hand thread these into
the self locking nuts enclosed in the hoist. The screws will
turn freely into the nuts until the last 1/4” (6.35mm) of travel,
during which the resistance of the nut locking collar will be
encountered. Securley tighten the screws to the recommed-
ed seating torque (see Table 2) using a 12 point socket
which fits the head of the screw.
B. Doubl R v d Units:
Remove the hook or lug suspension from its carton and the
two suspension screws, dead end pin, washer and cotter
pin. It should be noted that a Double Reeved suspension
includes a dead end bolt and block for supporting the dead
end of the chain as shown if Figure 7.
Place the suspension assembly into the recess on top of the
hoist. The dead end block should project through the bottom
of the hoist with the pin hole and slot aligned to the under-
side of the hoist as shown in Figure 7. If these are not
aligned as shown, lift the head of the bolt and block assem-
bly and reseat the bolt head to obtain the proper alignment.
Do not change the position of the dead end block on the bolt
to attain this alignment.
Check the position of the pin hole in the dead end block to
make sure it has not been disturbed from its factory setting.
The distance from the top of the pin hole to the bottom of the
hoist should not exceed 1/4” (6.35 mm) for Models E, E-2, H
and H-2 and 7/16” for the Models R, R-2, RR and RR-2. If the
distance is not correct, adjust the position of the dead end
block to obtain the proper distance (see Page 48).
4
CHAIN CONTAINER
This accessory (see Figure 6) is used to hold slack chain
and it is supplied complete with mounting hardware and
instructions. The chain container is recommended for those
applications where the slack chain would interfere with the
load or drag on the floor as may be the case with double or
triple reeved units. Chain containers can be furnished for
units already in use.
Figure 6. Chain Container
INSTALLATION

5
Figure 7. Attaching Load Chain
(Models E, H, E-2 and H-2 illustrated)
(Models R, RR, R-2 and RR-2 similar)
11.. DDeeaadd EEnndd BBlloocckk77.. LLoooossee EEnndd LLiinnkk
22.. SSuussppeennssiioonn AAsssseemmbbllyy88.. LLiiffttwwhheeeell
33.. SSuussppeennssiioonn SSeellff--LLoocckkiinngg NNuutt99.. eeaarr HHoouussiinngg
44.. DDeeaadd EEnndd BBoolltt1100.. LLoooossee EEnndd SSccrreeww
55.. LLooaadd CChhaaiinnaanndd LLoocckkwwaasshheerr
66.. CChhaaiinn uuiiddee
((DDoo nnoott oorrddeerr ppaarrttss bbyy tthheessee nnuummbbeerrss.. SSeeee ppaarrttss lliisstt..))
Now, insert the suspension screws through the holes in the
adapter and hand thread these into the self-locking nuts
enclosed in the hoist frame. These screws will turn freely into
the nut until the last 1/4” (6.35 mm) of travel during which the
resistance of the nut locking collar will be encountered.
Securley tighten the screws to the recommended seating
torque (see Table 2) using a 12 point socket which fits the
head of the screw.
To rotate the hook 90°, proceed as follows:
NOTE: On the rigid hook suspensions for Models
A through RR-2, if it is necessary to rotate the
hook 90°, from its factory set position, one of
the suspension screws becomes captive and a
socket cannot be used to tighten this screw.
1. Using a hammer and drift, drive the pin out of the
square hook collar.
2. Remove the square collar from the hook shank.
3. Place a hi-collar type lockwasher (this lockwasher
is not supplied with the suspension assembly)
under the head of one of the suspension screws.
Insert this assembly into the hole in the suspenison
adapter and rotate the hook 90° to make this screw
captive.
4. Re-assemble the square collar to the hook shank
using the drive pin previously removed.
5. Follow the instructions above, except tighten the
captive screw to the recommended seating torque
(see Table 2) using a 12 point box type wrench.
C. Triple Reeved Units:
These hoists have a sheave hanger which is loosely con-
nected to the top of the frame by a thin metal plate for ship-
ping purposes. To attach the suspension, support the
sheave hanger from the underside of the hoist and remove
the nut and seat from the sheave stud. Remove and disgard
the shipping plate and retain the sheave stud nut and seat
since they will be reused later.
Remove the suspension assembly from the carton and the
two suspension screws. Place the suspension assembly
over the sheave stud and into the recess on top of the hoist.
Insert the suspension screws through the holes in the sus-
pension adapter and hand thread these into the self-locking
nut enclosed in the hoist. The screws will turn freely into the
nuts until the last 1/4” (6.35 mm) of travel, during which the
resistance of the nut locking collar will be encountered.
Securely tighten the screws to the recommended seating
torque (see Table 2) using a 12 point socket which fits the
head of the screw.
After the suspension assembly is installed, secure the
sheave stud to the suspension adapter using the round slot-
ted nut and seat that were formerly used to attach the ship-
ping plate to top of the hoist frame. Place the seat over the
stud with the flat side down and then rotate the seat so that
there is clearance between the seat and the suspension lug
or hook. Assemble the nut to the stud and turn the nut by
hand until the nut seats in the seat and the sheave hanger is
snug in the frame. Then back off the nut until the hole in the
stud is in line with one of the slots in the nut. Using a ham-
mer, drive the retaining pin (packed with the suspension
assembly) into the hole in the sheave stud until the end of
the pin is flush with the edge of the nut.
Tabl 2. R comm nd d S ating Torqu s For Susp nsion
Adapt r Scr ws
MODEL NO’S SCREW SIZE
RECOMMENDED
SEATING TOR UE
A thru H-2 3/8”-16 UNC-2A 30 to 45 lb. ft.
J thru RRT-2 1/2”-20 UNF-2A 40 to 80 lb. ft.
L
!
WARNING
Using other than C supplied high strength suspension
screws to attach the suspension adapter to the hoist may
cause the screws to break and allow the hoist and load to fall.
TO AVOID IN URY:
Use only the C supplied suspension screws to attach the
suspension to the hoist and torque these screws to the recom-
mended seating torque as specified above.
1
28
9
10
7
3
4
56

CCAAUUTTIIOONN::
Also, do not apply any type of lubricant to the threads of
these screws. Lubricating the threads will reduce the effort to
seat the screws and as a result, tightening the screws to the
(Table 2) recommended torque may break the screw, dam-
age the suspension adapter, strip the nuts and/or damage
the hoist frame.
ATTACHING LOAD CHAIN
To attach the chain to the dead end block on Models E, E-2,
H, H-2, R, R-2 and RR-2, proceed as follows:
1. Suspend the hoist from an adequate support.
2. On Models E, E-2, H and H-2, insert the last link of the
load chain into the dead end block (2) and secure it with
the dead end pin, washer and cotter pin furnished with
the suspension.
3. On Models R, R-2, RR and RR-2, slide the contact block
up the chain until it is against the bottom of the hoist and
the dead end block is projecting through the square
opening in the bottom of the block. Insert the last link of
the load chain, making sure there are no twists between
the hook block and the dead end block, into the dead
end block. Push the contact block up slightly and secure
the load chain to the dead end block using the dead end
pin, washer and cotter pin furnished with the suspension.
The dead end pin also supports the contact block (See
Figure 8)
Figure 8. Contact Block Used on odels R, R-2, RR and RR-2
4. Do not remove the plastic ties from the load chain at this
time.
After the suspension is installed, hoists with a hook suspen-
sion can be suspended from its permanent support and then
connected to the power supply system (refer to page 8). For
hoists with a lug suspension that are to be suspended from a
Series 635 Low Headroom Trolley, attach the hoist to the trol-
ley per the following instructions.
INSTALLING THE SERIES 635 LOW
HEADROOM TROLLEY (See Figure 9)
.
Figure 9. Series 635 Low Headroom Trolley: 1 and 2 Ton (1000 and 2000
kg) Trolley Shown- 3 Ton (3000 kg) Similar.
For hoists with a lug suspension that are to be suspended
from a Series 635 Motor Driven Trolley, attach the hoist to the
trolley, wire the hoist and trolley together and connect the
trolley to the power supply system per the instructions
supplied with the trolley.
The stops must be positioned so as to not exert impact force
on the hoist frame or trolley wheels. They must contact the
ends of the trolley side frames.
It is recommended that the trolley be mounted on the beam
prior to attaching the hoist to the trolley. Before attempting to
mount the trolley on the beam, measure the actual width of
the beam flange on which the trolley is to operate. Using the
measurement and Table 3, determine the arrangement of the
spacer washers. Loosely assemble the side frames, load
bracket, spacer washers and nuts on the suspension bolts
as shown in Table 3.
L
!
WARNING
Operating the trolley on a beam that has no rail stops may
allow the trolley to fall off the end of beam.
TO AVOID IN URY:
Install rail stops at each end of the beam on which the trolley
is to operate.
6