Valustar CM 624 R User manual

Operating, Maintenance
& Parts Manual
24761
Electric Chain
Rated Loads
1/4 through 2-Tons
250 through 2000 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 ________________________________________
TM
624-R

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.
CALIFORNIA
OTTO SYSTEMS, INC.
12010 Bloomfield Ave.
Santa Fe Springs, CA 90670
562/462-1612 or 800/596-7392
Fax [phone]
or
7656 Las Positas Road
Livermore, CA 94551
[phone]
Fax [phone]
COLORADO
MATERIALS HANDLING EQUIPMENT CO.
1740 W. 13th Ave.
Denver, CO 80204
303/573-5333
Fax [phone]
GEORGIA
ACE INDUSTRIES, INC.
6295 McDonough Drive
Norcross, GA 30093
770/441-0898 or 800-733-2231
Fax [phone]
ILLINOIS
CM CHICAGO PARTS& SERVICE
10321 Werch Drive
Woodridge, IL 60517
877/511-3170
Fax [phone]
INDIANA
HORNER ELECTRIC COMPANY, INC.
1521 East Washington Street
Indianapolis, IN 46201
317/639-4261
Fax [phone]
IOWA
VMI HOIST & CRANE SERVICES
901 17th Street NE
Cedar Rapids, IA 52406
319/365-4662
Fax [phone]
KANSAS
INDEPENDENT ELECTRIC MACHINERY
4425 Oliver Street
Kansas City, KS 66106
913/362-1155
Fax [phone]
LOUISIANA
BEERMAN PRECISION, INC.
4206 Howard Avenue
New Orleans, LA 70125
504/486-9391
Fax [phone]
MASSACHUSETTS
ABEL DISTRIBUTORS, INC.
50 Parker Street, Unit 2
Newburyport, MA 01950
978/463-0700
Fax [phone]
NEW JERSY
SHUPPER-BRICKLE EQUIPMENT CO.
2394 Route 130, Suite C
Dayton, NJ 08810
732/438-3888
Fax [phone]
NEW YORK
VOLLAND ELECTRIC EQUIPMENT CO.
75 Innsbruck Drive
Buffalo, NY 14227
716/656-9900
Fax [phone]
NORTH CAROLINA
TEAM SESCO
2225 Freedom Drive
Charlotte, NC 28208
704/372-4832 or 800/487-3726
Fax [phone]
OHIO
MAZZELLA LIFTING TECHNOLOGIES
21000 Aerospace Parkway
Cleveland, OH 44142
440/239-5700 or 800/362-4601
Fax [phone]
PENNSYLVANIA
AMICK ASSOCIATES, INC.
11 Sycamore Street
Carnegie, PA 15106-0529
412/429-1212 or 800/445-9456
Fax [phone]
RAM MOTORS & CONTROLS, INC.
5460-B Pottsville Pike
Leesport, PA 19533
610/916-8000 or 877/916-8018
Fax [phone]
TEXAS
ABEL EQUIPMENT CO., INC.
3710 Cavalier Drive
Garland, TX 75042
972/272-7706
Fax [phone]
HYDRAULIC EQUIPMENT SERVICES, INC.
1021 North San Jacinto Street
Houston, TX 77002
713/228-9601
Fax [phone]
WISCONSIN
TRESTER HOIST & EQUIPMENT, INC.
W136 N4863 Campbell Drive
Menomonee Falls, WI 53051
262/790-0700 or 800/234-6098
Fax [phone]
ALBERTA
BENNETT & EMMOTT, LTD.
18131 118TH Avenue
Edmonton, Alberta T5S 1MB
403/454-9000
Fax [phone]
**COLUMBUS McKINNON, LTD.
10311-174th Street
Edmonton, Alberta T5S 1H1
800/263-1997
Fax [phone]
BRITISH COLUMBIA
FLECK BROTHERS, LTD.
4084 McConnel Court
Burnaby, British Columbia V5A 3N7
604/420-3535
Fax [phone]
MANITOBA
KING’S ELECTRIC MOTORS, INC.
633 Tyne Avenue
Winnipeg, Manitoba R2L 1J5
204/663-5332
Fax [phone]
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
9 Codeco Court
North York, Ontario M3A 1A1
416/386-0820
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
3800 Transcanada Highway
Pointe-Claire, Quebec H9R 1B1
514/428-5511
Fax [phone]
*LEGER PALANS ET OUTILLAGES,INC.
7995-17th Ave.
Montreal, Quebec H1Z 3R2
514/376-3050
Fax [phone]
* ARE ALSO MASTER PARTS DEPOTS
** MASTER PARTS DEPOT ONLY
UNITED STATES MASTER PARTS DEPOT CANADIAN SERVICE CENTERS

SAFETY PRECAUTIONS
Each Valustar 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 ASME 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 VALUSTAR 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 (without
the manufacturer’s approval or without certification that it
is in conformity with ANSI/AMSE B30 volumes).
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.
V
!!
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:
V
!!
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:
V!V!

iii
1 CHOOSE THE RIGHT HOIST FOR THE JOB...
Choose a hoist with a capacity for the job.
Know the capacities of your hoists and the
weight of your loads. Then match them.
The application, the size and type of load,
the attachments to be used and the period of
use must also be taken into consideration in
selecting the right hoist for the job.
Remember the hoist was designed to ease
our burden and carelessness not only
endangers the operator, but in many cases,
a valuable load.
VIOLATION OF ANY OF THESE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL INJURY TO THE
OPERATOR OR NEARBY PERSONNEL BY RELEASED LOAD OR BROKEN HOIST COMPONENTS.
–DO NOT LIFT MORE THAN RATED LOAD.
V
!!
WARNING
2 INSPECT
–DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST.
–DO NOT OPERATE WITH TWISTED, KINKED OR DAMAGED
CHAIN.
3 USE HOIST PROPERLY
Be sure hoist is solidly held in
the uppermost part of the support
hook arc.
Be sure hoist and load are in a
straight line. Do not pull at an
angle.
Be sure load is hooked securely.
Do not tip load the hook. Do not
load hook latch. Hook latch is to
prevent detachment of load under
slack chain conditions only.
Do not use load chain as a sling.
Such usage damages the chain
and lower hook.
Do not operate with hoist head
resting against any object. Lift the
load gently. Do not jerk it.
–DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD
ARE IN A STRAIGHT LINE.
4 LIFT PROPERLY
Do not lift co-workers with a hoist.
Make sure everyone is clear of the load
when you lift.
Do not remove or obscure operational
warning notices.
5 MAINTAIN PROPERLY
CLEANING: Hoists should be kept clean
and free of dust, dirt, moisture, etc., which
will in any way affect the operation or 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.
V
!!
WARNING
V
!!
WARNING
V
!!
WARNING

1
FOREWORD
This manual contains important information to help you properly install, operate and maintain your hoist for maximum perfor-
mance, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i
Do’s and Do Not’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Hoist Safety is Up To You . . . . . . . . . . . . . . . . . . . . . . . . .iii
Foreward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL INFORMATION
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CM Repair/Replacement Policy . . . . . . . . . . . . . . . . . . . .2
ACCESSORIES
Series 635 Low Headroom Trolley . . . . . . . . . . . . . . . . . .3
Series 635 Motor Driven Trolley . . . . . . . . . . . . . . . . . . . .3
Rigid Lug Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
INSTALLATION
Unpacking Information . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Attaching Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Attaching Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Installing Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Series 635 Low Headroom Trolley . . . . . . . . . . . . . . .4
Series 635 Motor Driven Trolley . . . . . . . . . . . . . . . . .6
Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Power Supply and Electrical Connections . . . . . . . . . . . .6
Three-Phase Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Checking for Adequate Voltage at Hoists . . . . . . . . .7
Checking for Twist in Load Chain . . . . . . . . . . . . . . . .8
OPERATING INSTRUCTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hoist with Low Headroom Trolley . . . . . . . . . . . . . . . . . . .9
Hoist with Motor Driven Trolley . . . . . . . . . . . . . . . . . . . . .9
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
INSPECTION
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Frequent Inspections . . . . . . . . . . . . . . . . . . . . . . . . . .9,10
Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . .9,10
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .9
Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
MAINTENANCE
Hoist Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Electric Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . .12
Exterior Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . .12
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
ASSEMBLY
Hook or Lug Suspension . . . . . . . . . . . . . . . . . . . . . . . .16
Centrifugal Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Lower Hook Block Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Removal and Installation of Load Chain . . . . . . . . . . . .17
Cutting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
REPLACEMENT PARTS
Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Parts List and Exploded Views . . . . . . . . . . . . . . . . .19-25
LIST OF TABLES
1Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2Trolley Side Frame Spacing . . . . . . . . . . . . . . . . . . . . . . .7
3Min. Frequent Inspections . . . . . . . . . . . . . . . . . . . . . . .10
4Min. Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . .10
5Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
LIST OF ILLUSTRATIONS
1Series 635 Low Headroom Trolley . . . . . . . . . . . . . . . . . .3
2Series 635 Motor Driven Trolley . . . . . . . . . . . . . . . . . . . .3
3Rigid Lug Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5Suspension Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .4
6Load Chain Attachment . . . . . . . . . . . . . . . . . . . . . . . . . .5
7Series 635 Low Headroom Trolley . . . . . . . . . . . . . . . . . .6
8Attaching Hoist to Trolley . . . . . . . . . . . . . . . . . . . . . . . . .6
9Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
10 Gaging Load Chain Wear . . . . . . . . . . . . . . . . . . . . . . . .11
11 Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . .15
12 Hook Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
13 Centrifugal Mechanism Assembly . . . . . . . . . . . . . . . . .16
14 Cutting Chain by Nicking . . . . . . . . . . . . . . . . . . . . . . . .18
15 Cutting Chain with Bolt Cutter . . . . . . . . . . . . . . . . . . . .18
16 Exploded View, Control Station . . . . . . . . . . . . . . . . . . . .22
17 Exploded View, Hoist . . . . . . . . . . . . . . . . . . . . . . . . .23-24
18 Exploded View, Series 635 Low Headroom Trolley . . . . .25
TABLE OF CONTENTS
PAGE PAGE

2
GENERAL INFORMATION
SPECIFICATIONS
The Valustar 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, overload device (Protector),
hardened steel chain guides, simple two stage gear reduc-
tion, lifetime lubrication, forged steel hooks and lightweight
aluminum frames. The electrical features include hoist-duty
motor, magnetic reversing contactor, rugged control station,
heavy-duty motor brake and control transformer (3 phase
units). Hoists are supplied with a rigid upper hook suspension
as standard. Table 1 summarizes the hoist’s specifications.
CM REPAIR/REPLACEMENT POLICY
All Columbus McKinnon (CM) Valustar Electric Chain Hoists
are inspected and performance tested prior to shipment. If
any properly maintained hoist develops a performance prob-
lem, within 1 (one) year of shipment, due to a material or
workmanship defect, as verified by CM, repair or replace-
ment of the unit will be made to the original purchaser with-
out charge. This repair/replacement policy applies only to
Valustar Hoists installed, maintained and operated as out-
lined in this manual, and specifically excludes parts subject
to normal wear, abuse, improper installation, improper or
inadequate maintenance, hostile environmental effects and
unauthorized repairs/modifications.
We reserve the right to change materials or design if, in our
opinion, such changes will improve our product. Abuse,
repair by an unauthorized person, or use of non-CM replace-
ment parts voids the guarantee and could lead to dangerous
operation. For full Terms of Sale, see Sales Order
Acknowledgement. Also, refer to the back cover for
Limitations of Warranties, Remedies and Damages, and
Indemnification and Safe Operation.
Valustar Electric Chain Hoist Specifications
DC MAX. CAP. LIFTING SPEED MOTOR MIN. HOOK POWER SUPPLY NET WEIGHT
CODE CODE MODEL (TONS) F.P.M. H.P. DISTANCE VOLTS/PHASE/HERTZ (POUNDS)
2401 62401 WB 1/4 16 1/4 16-1/2" 115-1-60 51
2402 62402 WB 1/4 16 1/4 16-1/2" 230/460-3-60 61
2413 62413 WE 1/2 8 1/4 19-7/8" 230/460-3-60 72
2412 62412 WE 1/2 8 1/4 19-7/8" 115-1-60 62
2403 62403 WF 1/2 16 1/2 16-1/2" 115-1-60 53
2404 62404 WF 1/2 16 1/2 16-1/2" 230/460-3-60 68
2405 62405 WH 1 8 1/2 19-7/8" 115-1-60 69
2406 62406 WH 1 8 1/2 19-7/8" 230/460-3-60 78
2414 62414 WJ 1/2 32 1 17-5/8" 230/460-3-60 105
2407 62407 WL 1 16 1 17-5/8" 115-1-60 109
2408 62408 WL 1 16 1 17-5/8" 230/460-3-60 106
2409 62409 WR 2 8 1 24-1/2" 115-1-60 129
2410 62410 WR 2 8 1 24-1/2" 230/460-3-60 126
Series 635 Low Headroom Trolley Specifications
MAX. CAP. TREAD DIA. OF MIN. RADIUS
(TONS) FOR USE WITH MODELS ADJUSTABLE FOR S-BEAMS WHEELS (IN.) CURVE (IN.)
1/4 to 1 WB, WE, WF, WH, WJ, WL 4" X 7.7# TO 15" X 50# 3-1/8 24
2 WR 6" X 12.5# TO 18" X 54.7# 4-3/4 24
Series 635 Motor-Driven Trolley Specifications
MAX. CAP. POWER TRAVEL MOTOR ADJUSTABLE MIN. RADIUS
(TONS) FOR USE WITH MODELS SUPPLY SPEED (FPM) H.P. FOR S-BEAMS CURVE (IN.)
1/4 to 2 WB, WE, WF, WH, WJ, 115-1-60 75 1/4 6" x 12.5" 30
WL, WR 230-3-60 thru
or 460-3-60 15" x 50#
Table 1

3
ACCESSORIES
Series 635 Low Headroom Trolley
These are manual push type trolleys designed for use with
the Valustar Electric Chain Hoists, and a rigid lug suspension
is required to attach the hoist to the trolley (see Figure 1).
The trolley is adjustable to operate on a range of American
Standard beams as indicated in Table 1, and it will also
operate on flat flanged beams.
Figure 1. Series 635 Low Headroom Trolley
Series 635 Motor Driven Trolley
The motor driven trolley is self-contained and supplied com-
plete with controls and wiring, ready for attachment to any of
the Valustar Electric Hoists (see Figure 2). A rigid lug sus-
pension is required to attach the hoist to the trolley, and
complete instructions are provided to electrically and
mechanically attach the hoist to the trolley. The trolley is
adjustable to operate on a range of American Standard
beams as indicated in Table 1, and it will operate on flat
flanged beams.
Figure 2. Series 635 Motor Driven Trolley
Rigid Lug Suspension
This suspension is required for attaching the hoist to the Low
Headroom or Motor Driven Trolley (see Figure 3). It must be
ordered separately with the hoist model and trolley type
specified.
Figure 3. Rigid Lug Suspension
Chain Container
This accessory is used to hold the slack chain, and it is sup-
plied complete with mounting hardware and mounting
instructions. The chain container is recommended for those
applications where the slack chain would interfere with the
load. Chain containers can be furnished for units already in
use. When ordering, specify hoist model and lift.
Figure 4. Chain Container
INSTALLATION
UNPACKING INFORMATION
When received, the hoist should be carefully inspected for
damage which may have occurred during shipment or han-
dling. Check the hoist frame for dents or cracks, the external
cords for damaged or cut insulation, the control station for
cut or damaged enclosure, and inspect the load chain for
nicks and gouges. If shipping damage has occurred, refer to
the packing list envelope on the carton for claim procedure.
Before installing the hoist, make sure that the power supply
to which it will be connected is the same as that shown on
the nameplate located on the side of the hoist.
Note: To assure extra long life and top performance,
be sure to follow the load chain lubricating instruc-
tions on Page 12.

Figure 5. Suspension Assemblies
1. Lug type (single reeved adapter) for use with Low
Headroom Trolley and Motor Driven Trolley.
2. Swivel hook type (double-reeved adapter).
3. Rigid Hook Type (single-reeved adapter).
4. 12 point suspension screws.
(Do not order parts by these numbers. See parts list.)
ATTACHING SUSPENSION
1. Remove the hook suspension from the carton and the two,
12 point suspension screws from the bag, see Figure 5.
The suspension for a double chain hoist (Models WE, WH
and WR) includes a dead end bolt and block for support-
ing the dead end of the load chain as shown in Figure 5.
2. Place the suspension in the recess on top of hoist. On
double chain hoist, the dead end block should project
through the bottom of hoist with the pin hole and slot
aligned to the underside of hoist as shown in Figure 6. It
may be necessary to lift the bolt head from the hex
recess in the suspension adapter, turn and reseat it, to
obtain this alignment. DO NOT CHANGE THE POSITION
OF THE DEAD END BLOCK ON THE BOLT. The pin hole
should clear the hoist frame by not more than 1/4" on
Models WE and WH and 7/16" on Model WR.
3. Insert the screws through the adapter and engage the self-
locking nuts enclosed in the hoist. Screws will enter the
nuts freely except for the last 1/4" of travel during which the
resistance of the nut locking collar will be encountered.
4. Securely tighten the screws to the recommended seating
torque specified in the table below, using a 12 point sock-
et which fits the head of the screw.
Recommended
Model No. Screw Size Seating Torque
WB, WE, WF 3/8-16 UNC-3A 30-45 Lb. Ft.
and WH
WJ, WL, 1/2-20 UNF-3A 40-80 Lb. Ft.
and WR
V
!
WARNING
Using other than CM supplied high strength suspension
screws to attach the suspension adapter to the hoist may
cause the screws to break and allow the hoist and load to fall.
TO AVOID INJURY:
Use only the CM supplied suspension screws to attach the
suspension to the hoist and torque these screws to the recom-
mended seating torque as specified above.
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
above recommended torque may break the screw, damage
the suspension adapter, strip the nuts and/or damage the
hoist frame.
ATTACHING LOAD CHAIN
Models WE, WH and WR
1. Suspend the hoist from an adequate support.
2. The hoist is shipped with the dead end of the load chain
temporarily positioned a few links from the end by a plas-
tic tie (1) as shown in Figure 6. Do not remove this plastic
tie until the chain is secured.
3. On Models WE and WH, 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. Remove the plastic tie (1) by cutting with a
pair of electrical pliers.
On Model WR, remove the plastic tie (1) by cutting with a
pair of electrical pliers. 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.
4. Do not remove the ties from the load chain until after the
hoist is suspended from its permanent support or tract
system. Now, suspend the hoist from its permanent sup-
port or tract system. If the hoist is to be hung from a Low
Headroom Trolley or a Motor Driven Trolley, refer to the
trolley installation instructions.
INSTALLING ACCESSORIES
Series 635 Low Headroom Trolley
(See Figure 7)
To attach the hoist to the trolley a lug suspension (Figure 3) is
required. The trolley and lug suspension are packed sepa-
rately, and the hook suspension that is packed with the hoist
may be discarded. To install the lug suspension, follow the
instructions for attaching the suspension on this page.
To adjust the trolley to fit the beam properly, proceed as follows:
1. Arrange the side frames, load bracket, spacer washers
and nuts on the suspension bolts according to Figure 7
and Table 2. Do not assemble cotter pins to the bolts.
Note: special trolleys shown in chart require
special suspension bolts.
2. The number of spacers as given in Table 2 is nominally
correct, however, due to the variation in size encountered
on structural steel sections, it will be necessary in some
cases to vary the number used. Therefore, the distance
V
!
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 INJURY:
Install rail stops at each end of the beam on which the trolley
is to operate.
4

5
Figure 6. Load Chain Attachment

between the trolley trackwheel flanges and the beam
flange width should be measured to determine the exact
distribution of the spacer washers. The number of spacer
washers between side frames and load bracket should
be the same or differ only by one spacer to keep the hoist
hook centered under the beam.
Figure 7. Series 635 Low Headroom Trolley
Note: Due to the variations in beam flange
widths, it is suggested that the beam flange
width be measured to determine the exact distri-
bution of spacer washers. The distance between
trackwheel flanges (dimension “X”) should be
1/8 to 3/16 inch greater than the beam flange
width for straight runway beams, and 3/16 to 1/4
inch greater than the beam flange width if run-
way system includes sharp curves. Also, the use
of other than CM supplied washers may result in
trackwheel to beam flange variations and thus
Table 2 will not apply.
3. Install the trolley on beam by sliding one side of frame out
far enough to allow the trackwheels to clear the beam
flange.
4. Draw the side frames together and assemble cotter pins.
5. With the trolley mounted on the beam, attach the hoist by
inserting the suspension lug into the trolley load bracket
and inserting the suspension pin through the load bracket
and suspension lug as shown in Figure 8. Secure the pin
using the socket head cap screw and lockwasher.
6. Thread the socket head cap screw and lockwasher into
load bracket and tighten securely.
7. Now, refer to “Power Supply and Electrical Connections”
on this page and complete the hoist installation procedure.
8. Then with a capacity load on hoist, operate trolley over
the entire length of runway or monorail system to be sure
that the adjustment and operation is satisfactory. On sys-
tems with curves, keep the rail edges at the curved sec-
tions lightly greased.
V
!!
WARNING
If CM’s washer spacing recommendations are not followed,
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.
Figure 8. Attaching Hoist to Trolley
Series 635 Motor Driven Trolley
To attach the hoist to the trolley, a lug suspension (Figure 3)
is required. The trolley and lug suspension are packed sepa-
rately, and the hook suspension that is packed with the hoist
may be discarded. To install the lug suspension, follow the
instructions for attaching the suspension on page 4. The
Motor Driven Trolley must be assembled and wired to the
hoist by the user per the manual packed with the trolley.
Chain Container
For installation instruction, refer to instruction sheet packed
with the chain container.
POWER SUPPLY AND ELECTRICAL
CONNECTIONS
All Hoists
The hoist should be connected to a branch circuit which
complies with the requirements of the National Electrical
Code and applicable local codes.
It is recommended, especially for a single phase hoist with a
one horsepower motor, that a line of adequate capacity be
run directly from the power supply to the hoist to prevent
having problems with low voltage and circuit overloads.
For grounding of the hoist, the power cord includes a
grounding conductor (green wire). On a standard single
phase unit this cord is equipped with a three-prong plug. Be
sure that the receptacle opening which receives the longest
prong is properly grounded. Furthermore, the suspension
system on which the hoist is mounted should also be perma-
nently grounded.
Before connecting the hoist to the power supply, check that
the power to be used agrees with that shown on the hoist
identification label. In addition, for a three phase, dual volt-
age unit, check the voltage shown on the tag attached to
power cord.
V
!!
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.
6

The nominal hoist voltage rating corresponding to the voltage
range given on hoist identification label is:
SINGLE SPEED UNITS
Range Nominal Volts
110-120 115
220-240 230
440-480 460
Three Phase Hoists
Changing the voltage connections on a single speed, three
phase dual voltage unit is easily accomplished by following
the instructions on the wiring diagram provided with the hoist.
Since the motor in a three phase hoist can rotate in either
direction, depending on the manner in which it is connected
to the power supply, the direction of hook movement must be
checked during the original installation and each time hoist is
moved to a new location.
1. Make temporary connections at the power supply.
2. Operate (UP) control in control station momentarily. If
hook raises, connections are correct and can be made
permanent.
3. If hook lowers, it is necessary to change direction by
interchanging the Red Lead and the Black Lead of the
hoist power cord at power supply. Under no circum-
stances should the internal wiring of control station or
hoist be changed to reverse hook direction. The wiring is
inspected and tested at the factory.
¶
Checking for Adequate Voltage at Hoist
The hoist must be supplied with adequate electrical power in
order to operate properly. For proper operation, the voltage,
(measured at the end of the hoist power cord) must be as
indicated in the table below:
NOMINAL MINIMUM MINIMUM
POWER RUNNING STARTING
SUPPLY VOLTAGE VOLTAGE
115-1-60 104 98
230-3-60 198 –
460-3-60 396 –
Signs of Inadequate Electrical Power (Low Voltage) are:
• Noisy hoist operations due to brake and/or contactor
chattering.
• Dimming of lights or slowing of motors connected to the
same circuit.
• Heating of the hoist motor and other internal components,
as well as heating of the wires and connectors in the cir-
cuit feeding the hoists.
• Failure of the hoist to lift the load due to motor stalling.
• Blowing of fuses or tripping of circuit breakers.
V
!!
WARNING
Allowing the hook block to run into the bottom of the hoist
when raising a load or allowing the loose end block to run into
the bottom of the hoist when lowering a load may break the
chain and allow the load to drop.
TO AVOID INJURY:
Do not allow the hook block or the loose end block to contact
the bottom of the hoist.
7
1-TON CAPACITY 2-TON CAPACITY
Trolley Side Frame Spacing NO. OF SPACERS NO. OF SPACERS
FLANGE ABCD ABCD
WIDTH
2-5/8 10 0 0 10
3 9119
3-3/8 8228 8008
3-5/8 7337 7117
STANDARD 4 6446 6226
TROLLEYS 4-5/8 4664 4444
5 3773 3553
5-1/4 2882 3562
5-1/2 1982 2671
5-5/8 1991 1771
6 0880
6 5554
6-1/4 4663 8218
7 0991 5545
SPECIAL 7-1/8 5554
TROLLEYS 7-1/4 4654
7-7/8 2881
8 1981
Table 2
Minimum Beam Radius 24" for all capacities. Dimension applies to minimum S-Beam and will vary with larger S-Beams.
“X”
B
ACD

To avoid these low voltage problems, the hoist must be con-
nected to an electrical power supply system that complies
with the National Electrical Code and applicable local codes.
This system must also be rated for a minimum of 20 amps
and it must have #14 AWG or larger wiring, a disconnecting
means, overcurrent protection (slow blow fuses or inverse-time
type circuit breakers) and provisions for grounding the hoist.
Low voltage can also be caused by using an undersize
extension cord to supply power to the hoist. The following
chart should be used to determine the size wires in the
extension cord in order to minimize the voltage drop between
the power source and the hoist.
LENGTH OF SINGLE-PHASE THREE-PHASE
EXTENSION HOISTS HOISTS
CORD MIN. WIRE SIZE MIN. WIRE SIZE
Up to 50 feet #14 AWG #16 AWG
80 feet #12 AWG #16 AWG
120 feet #10 AWG #14 AWG
Remember, operation with low voltage can void the CM
repair/replacement policy. When in doubt about any of the
electrical requirements, consult a qualified electrician.
Note: Always disconnect the power from the power
supply system and lockout/tagout disconnecting
means before servicing the hoist.
Checking for Twist in Load Chain
Models WE, WH and WR
The best way to check for this condition is to run the lower
hook, without a load, up to within about 2” of hoist. If the
dead-end of the chain has been properly installed, a twist
can occur only if the lower hook block has been capsized
between the strands of chain. Reverse capsize to remove
twist.
V
!!
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 pro-
tected power supply system per the National Electrical Code
and applicable local codes as instructed in this manual.
V
!!
WARNING
Failure to properly ground the hoist presents the danger of
electric shock.
TO AVOID INJURY:
Permanently ground the hoist as instructed in this manual.
OPERATING INSTRUCTIONS
GENERAL
The hoist is equipped with a Protector™ that is designed to
allow the intermediate gear to slip on an excessive overload.
An overload is indicated when the hoist will not raise the
load. Also, some clutching noise may be heard if the hoist is
loaded beyond rated capacity. Should this occur, immediate-
ly release the up control to stop the operation of the hoist.
At this point, the load should be reduced to the rated hoist
capacity or the hoist should be replaced with one of the
proper capacity. When the excessive load is removed, nor-
mal hoist operation is automatically restored.
CAUTION: The Protector™ is susceptible to over-
heating and wear when slipped for extended peri-
ods. Under no circumstance should the clutch be
allowed to slip for more than a few seconds.
Due to the above, the hoist 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 installation (refer to limitations dis-
cussed in Safety Precautions on Page ii), containers that are
loaded in mid-air, etc. Also, if the hoist is used at unusual
extremes of ambient temperatures, above 150°F. or below
15°F., changes in lubricant properties may permit the hoist to
raise larger loads than under normal operating conditions
and present possibility of damage or injury.
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There are no electrical switches to stop the operation of the
hoist at the upper and lower limits of the lift. As a result, it is
necessary to release the rocker in the control station to stop
the hoist before the hook block or loose end block contacts
the bottom of the hoist frame. If the hook block or loose end
block contacts the hoist frame, the Protector™ will function to
stop the hoisting or lowering operation and protect the hoist
components from damage. However, continued, prolonged
or repeated slipping of the Protector™ will damage the
Protector™ and cause overheating of the internal hoist com-
ponents.
HOIST
1. Before picking up a load, check to see that the hoist is
directly overhead.
2. WHEN APPLYING A LOAD, IT SHOULD BE DIRECTLY
UNDER HOIST OR TROLLEY. AVOID OFF CENTER
LOADING OF ANY KIND.
3. Take up a slack load chain carefully and start load easily
to avoid shock and jerking of hoist load chain. If there is
any evidence of overloading, immediately lower the load
and remove the excess load.
4. DO NOT allow the load to swing or twist while hoisting.
5. DO NOT allow the load to bear against the hook latch.
¶
¶
¶
8
WWAARRNNIINNGG
Working in or near exposed energized electrical equipment
presents the danger of electrical shock.
TTOOAAVVOOIIDDIINNJJUURRYY
Disconnect power and lockout/tagout disconnecting means
before removing cover or servicing this equipment.

HOIST WITH LOW HEADROOM TROLLEY
This unit should be moved by pushing on the suspended
load or by pulling the empty hook. However, the unit can also
be moved by pulling on the control station since an internal
steel cable extends the length of the control cord and is
anchored to the hoist and to the control station.
HOIST WITH MOTOR DRIVEN TROLLEY
This unit should be moved by operating the controls marked
¶(Forward) and (Reverse) in control station. Unless altered
by the erector, depressing ¶(Forward) control will move the
hoist toward motor housing end. Anticipate the stopping
point and allow trolley to coast to a smooth stop. Reversing
or “plugging” to stop trolley causes overheating of motor and
swaying of load.
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 the attachments to
the hook are firmly seated in hook saddle. Avoid off center
loading of any kind, especially loading on the point of hook.
2. When lifting, raise the load only enough to clear the floor
or support and check to be sure that the attachments to
the hook and load are firmly seated. Continue to lift only
after you are assured the load is free of all obstructions.
3. DO NOT load hoist beyond the rated capacity shown on
hoist identification plate or on the hoist motor housing
cover or hoist back frame cover. Overload can cause
immediate failure of some load-carrying part or create a
defect causing subsequent failure at less than rated
capacity. When in doubt, use the next larger capacity of
CM Valustar Hoist.
4. DO NOT use this or any other overhead materials han-
dling 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 inten-
tion to move a load in their area.
6. DO NOT leave the load suspended in the 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 a twisted chain and a jammed lift wheel.
b. The chain could be damaged at the hook.
9. On two part-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 cap-
size to remove 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.
V
!!
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.
¶
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.
INSPECTION
PROCEDURES
To maintain continuous and satisfactory operation, a regular
inspection procedure must be initiated to replace worn or
damaged parts before they become unsafe. Inspection inter-
vals must be determined by the individual application and
are based on the type of service to which the hoist will be
subjected and the degree of exposure to wear, deterioration
or malfunction of the critical components.
The type of service which the hoist is subjected can be clas-
sified as “NORMAL,” “HEAVY,” “SEVERE.”
NORMAL SERVICE: Involves operation with randomly
distributed loads within the rated load limit, or uniform
loads less than 65 percent of rated load for not more than
25 percent of the time.
HEAVY SERVICE: Involves operating the hoist within the
rated load limit which exceeds normal service.
SEVERE SERVICE: Is 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 person-
nel. Records of such inspections are not required. The
frequent inspections are to be performed monthly for nor-
mal 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 per-
son. Records of periodic inspections are to be kept for
continuing evaluation of the condition of the hoist.
Periodic inspections are to be performed yearly for nor-
mal service, semi-annually for heavy service and quarter-
ly for severe service, and they are to include those items
listed in Table 4.
CAUTION: Any deficiencies are to be corrected
before the hoist is returned to service. Also, the
external conditions may show the need for disas-
sembly to permit a more detailed inspection, which,
in turn, may require the use of non-destructive type
testing.
Preventive Maintenance
In addition to the above inspection procedure, a preventive
maintenance program should be established to prolong the
useful life of the hoist and maintain its reliability and continued
safe use. The program should include periodic and frequent
inspections with particular attention being paid to the lubrica-
tion of the various components using the recommended lubri-
cants (see page 12).
9

10
Minimum Frequent Inspections
Type of Service Item
Normal Heavy Severe
a) Brake for evidence of slippage.
b) Control functions for proper operation.
c) Hooks for damage, cracks, twists, excessive throat opening, latch
engagement and latch operation – see page 11.
d) Load chain for adequate lubrication, as well as for signs of wear,
damaged links or foreign matter – see page 11.
e) Load chain for proper reeving and twists.
Table 3
Yearly Weekly
to
Yearly
Daily
to
Weekly
Minimum Periodic Inspections
Type of Service Item
Normal Heavy Severe
a) All items listed in Table 3 for frequent inspections.
b) External evidence of loose screws, bolts or nuts.
c) External external evidence of worn, corroded, cracked or distorted
hook block, suspension bolts, gears, bearings, loose end chain, stop
block, loose end block and pins, and dead end block and pin
(double reeved units).
d) External evidence of damage to hook retaining nut or collar and pin.
Also check the upper suspension adapter making sure it is fully seat-
ed in the hoist frame and retighten the screws to the recommended
seating torque (see page 4). If a condition of loose screws persists,
replace the self-locking nuts in the frame.
e) External evidence of damage or excessive wear of the liftwheel and
hook block sheave (double reeved units) chain pockets. Widening
and deepening of the pockets may cause the chain to lift-up in the
pocket and result in binding between liftwheel and chain guides or
between the sheave and hook block (double reeved units).
Also, check the chain guides for wear or burring where the chain
enters the hoist.
Severely worn or damaged parts should be replaced.
f) External evidence of excessive wear or brake parts and brake
adjustment – see page 12.
g) External evidence of pitting or any deterioration of contactor contacts.
h) Inspect the electrical cords and cables for damaged insulation.
i) Inspect trolley trackwheels for external wear on tread and flange,
and for wear on internal bearings surfaces as evidenced by a loose-
ness on the stud.
Table 4
Yearly Every
Six
Months
Every
Three
Months

Models Replace Hook When Opening is
Greater Than
WB, WF 1-3/16
WE, WH, WJ & WR 1-5/16
WR 1-1/2
Figure 9. Hook Inspection
Hook Inspection
Hooks damaged from chemicals, deformations or cracks, or
that have more than a 10° twist from the hook’s unbent plane
or 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 exces-
sive throat opening indicates abuse or overloading of the
unit. Inspect other load sustaining parts for damage.
On latch type hooks, check to make sure that the latch is not
damaged or bent and that it operates properly with sufficient
spring pressure to keep the latch tightly against the tip of the
hook and allow the latch to spring back to the tip when
released. If the latch does not operate properly, it should be
replaced. See Figure 9 to determine when the hook must be
replaced.
Protector™
The Protector™ should operate for the normal life of the hoist
without service. The device has been lubricated and calibrat-
ed at the factory for a specific model of hoist and is not
adjustable or interchangeable with other models. For proper
overload protection be sure before installing a Protector™
that it is correct for the unit. The spring washer of the
Protector™ has been color coded at the factory as follows:
Models Protector™ Color Code
WB, WE White
WE, WH Orange
WJ Red
WL, WR Green
LOAD CHAIN
Clean and Inspection
First clean the load chain with a non-acid or non-caustic type
solvent, then slack the chain and make a link-by-link inspec-
V
!!
WARNING
Removing the snap ring on the Protector™ assembly will
allow the parts to spring apart.
TO AVOID INJURY:
Do not attempt to disassemble the Protector™.
tion for nicks, gouges, twisted links, stretching and excessive
wear. In particular, observe the bearing surface between
links, and if any of these conditions exist, the load chain must
be replaced. Chain should be gaged throughout its entire
length and replaced if beyond serviceable limits.
To determine if load chain should be continued in service,
check gage lengths as indicated in Figure 10. Chain worn
beyond length indicated, nicked, gouged or twisted should
be replaced before returning hoist to service. Chain should
be clean, free of twists and pulled taut before measuring. In
cases where the wear is localized and not beyond service-
able limits, it is sometimes possible to reverse the load chain,
end for end, and allow a new section to take the wear.
Removal and installation of the load chain is covered in sub-
sequent paragraphs.
To aid in gaging load chain wear, a chain gage can be
obtained from CM. This can be obtained by ordering Chain
Gage Part No. 3191.
CAUTION: Before installing new load chain, the unit
must be disassembled to allow inspection for dam-
age or wear and replacement, if required, of mating
parts (liftwheel, chain guides, motor and gear hous-
ings).
Figure 10. Gaging Load Chain Wear
Dia. of No. of Links Max. Gage Length
Models Chain Stock to Gage Allowable
Used Chain
WE, WB, 0.250" 19 14-13/16"
WF & WH
WJ, WL, 0.312" 21 18-7/8"
and WR
When installing new load chain or mating parts, refer to
Lubrication on page 12.
IMPORTANT: Do not use replaced chain for other
purposes such as lifting or pulling. Load chain may
break suddenly without visual deformation. For this
reason, cut worn chain into short lengths to prevent
use after disposal.
V
!!
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 CM Valustar Hoists.
11
MEASURE
OPENING
LATCH TYPE HOOK
(Upper and Lower)
TO MEASURE OPENING,
DEPRESS LATCH
AGAINST HOOK BODY
AS SHOWN

MAINTENANCE
HOIST LUBRICATION
NOTE: To assure extra long life and top perfor-
mance, be sure to lubricate the various parts of the
Valustar Hoist using the lubricants specified below.
If desired, these lubricants may be purchased from
CM. Refer to page 22 for information on ordering the
lubricants.
Gears
The Protector™ should operate for the normal life of the hoist
without service. The device has been lubricated and calibrat-
ed at the factory for a specific model of hoist and is not
adjustable or interchangeable.
CAUTION: The Protector™ is to be used with
“Century Lubricants HB-11, #3” grease. Use of any
other grease will damage Protector™ parts or cause
improper operation.
The gears and Protector™ are factory greased and should
not need to be renewed unless the gears have been
removed from the housing and degreased.
CAUTION: Never degrease or attempt to disassem-
ble the Protector™. Degreasing may damage parts
or cause erratic, inconsistent operation. If the
Protector™ has been degreased, it must be replaced
by a factory calibrated device.
If the gears are removed from the housing, wipe the excess
grease off the outside Protector™ surfaces with a soft cloth
and degrease the remaining gears and housings. Upon
reassembly, add 7 oz. of above grease to gears and hous-
ing. Also, coat the spline on the end of the drive shaft with a
molydisulphide lubricant such as “Super Herculon.”
Bearings
All bearings and bushings except the lower hook thrust bear-
ing are prelubricated and require no lubrication. Lubricate
the lower hook thrust bearing at least once a month, using a
heavy cup grease.
Chain Guides, Liftwheel & Lower Sheave Wheel
When the hoist is disassembled for inspection and/or repair,
the chain guides, lower sheave wheel (on double chain 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 run-off and full coverage.
Load Chain
A small amount of lubricant will greatly increase the life of load
chain. Do not allow the chain to run dry. Keep it clean and lubri-
cate 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
V
!!
WARNING
The lubricants used in and recommended for the Valustar
Hoist may contain hazardous materials that mandate specific
handling and disposal procedures.
TO AVOID CONTACT AND CONTAMINATION:
Handle and dispose of lubricants only as directed in applica-
ble material safety data sheets and in accordance with applica-
ble local, state and federal regulations.
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 natural
run-off and full coverage.
Low Headroom Trolley
CM trackwheel bearings are pre-lubricated and require no lubrica-
tion.
ELECTRIC BRAKE ADJUSTMENT
The correct air gap between armature and field, when brake is not
energized, is 0.035 inch and need not be adjusted until the gap
reaches 0.075 inches. To adjust the brake, proceed as follows:
1. Disconnect hoist from power supply.
2. Remove back frame cover.
3. Before adjusting the gap:
a) back off the stud nuts and examine friction linings and friction
surfaces for excessive wear, scoring or warpage.
b) check shading coils to be sure they are in place and not bro-
ken. A missing or broken shading coil will cause noisy brake
operation.
These symptoms indicate the need for parts replacement.
4. Turn adjusting nuts clockwise gaging the air gap at both ends.
5. Replace cover, reconnect the power and check operation.
EXTERIOR FINISH
The exterior surfaces of the hoist and trolleys have a durable, scratch
resistant baked powder coating. Normally, the exterior surfaces can
be cleaned by wiping with a cloth. However, if the finish is damaged,
compatible touch-up paint can be purchased from CM. Refer to
page 22 for information on ordering the paint.
RECOMMENDED SPARE PARTS
To insure continued service of the Valustar 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:
Qty. for each
Key No. Part Name Hoist in Service
624-197 Brake Friction Disc
Models WB & WE 1
All Other Models 2
624-199 Brake Coil 1
624-213 Capacitor
(115-1-60 Units Only) 1
624-215 Cut-Out Switch
(115-1-60 Units Only) 1
624-216 Contactor 1
624-218 Transformer
(Three-phase Units Only) 1
624-306 Control Station Parts Kit 1
624-307 Control Station Switch Kit 1
624-778 Solid State Reverse Switch 1
Refer to Page 21 for ordering information and parts list for the part
numbers.
V
!!
WARNING
Used motor oils contain known 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.
12

13
A. No voltage at hoist – main line or branch circuit switch open; branch line fuse
blown or circuit breaker tripped.
B. Phase failure (single-phasing, three-phase unit only) – open circuit, grounded or
faulty connection in one line of supply system, hoist wiring, reversing contactor,
motor leads or windings.
C. Open control circuit – open or shorted winding in transformer or reversing
contactor coil; loose connection or broken wire in circuit; mechanical binding in
contactor; control station contacts not closing or opening
D. Wrong voltage or frequency.
E. Low voltage.
F. Brake not releasing – open or shorted coil winding; armature binding.
G. Excessive load.
A. Close switch, replace fuse or reset breaker.
B. Correct power supply system. Check for electrical continuity and repair or replace
defective part.
C. Check electrical continuity and repair or replace defective part.
D. Use the voltage and frequency indicated on hoist identification label.
E. Correct low voltage condition as described on page 7.
F. Check electrical continuity and connections. Check that correct coil has been
installed. The coil for three phase dual voltage unit operates at 230 volts when the
hoist is connected for either 230 volt or 460 volt operation. Check brake adjust-
ment (page 12).
G. Reduce load to the capacity limit of hoist as indicated on the hoist identification
label.
1. Hook does not respond to control station.
A. Wiring connections reversed at the control station.
B. Failure of the motor cut-out switch to effect dynamic braking at time of reversal
(single-phase units only).
C. Phase reversal (three-phase units only).
A. Use wiring diagram and check wiring connections.
B. Check connections to switch. Replace damaged switch or faulty capacitor.
C. Refer to installation instructions page 7.
2. Hook moves in wrong direction.
A. Excessive load.
B. Open hoisting circuit – open or shorted winding in reversing contactor coil; loose
connection or broken wire in circuit; control station contacts are not making.
C. Motor cut-out device not operating. (single-phase units only).
D. Phase failure (three-phase units only).
A. See item 1G.
B. Check electrical continuity and repair or replace defective part.
C. Check the switch connections and actuating bar and contact for sticking or dam-
age. Check centrifugal mechanism for loose or damaged components. Replace
defective parts.
D. See item 1B.
3. Hook lowers but will not raise.
A. Open lowering circuit – open or shorted winding in reversing contactor coil; loose
connections or broken wire in circuit; control station contacts not making.
B. Motor cut-out switch not operating (single-phase units only).
A. Check electrical continuity and repair or replace defective part.
B. See item 3C.
4. Hook raises but will not lower.
A. Phase failure (three-phase units only). A. See item 1B.
5. Hook lowers when hoisting control is operated.
A. Excessive load.
B. Low voltage.
C. Phase failure or unbalanced current in phases (three-phase units only).
D. Brake dragging.
A. See item 1G.
B. Correct low voltage condition as described on page 7.
C. See item 1B.
D. Check brake adjustment as described on page 12.
7. Hoist operates sluggishly.
A. Excessive load.
B. Low voltage.
C Extreme external heat.
D. Frequent starting or reversing.
E. Phase failure or unbalanced current in the phases (three-phase units only).
F. Brake dragging.
G. Motor cut-out device not opening start winding circuit (single-phase units only).
A. See item 1G.
B. Correct low voltage condition as described on page 7.
C. Above an ambient temperature of 104°F (40°C), the frequency of hoist operation
must be limited to avoid overheating the motor. Special provisions should be made
to ventilate the space or shield the hoist from radiant heat.
D Avoid excessive inching, jogging or reversing. This type of operation drastically
shortens the motor and contactor life and causes excessive brake wear.
E. See item 1B.
F. Check brake adjustment as described on page 12.
G. See Item 3C.
8. Motor overheats.
A. Shaft not rotating. A. Check for damaged gears.
9. Hook fails to stop either or both.
––– Probable Cause –––
––– Remedy–––
TROUBLE SHOOTING
A. Brake slipping.
B. Excessive load.
A. Check brake adjustment as described on page 12.
B. See item 1G.
6. Hook does not stop promptly.

ELECTRICAL DATA
To Detect Open and Short Circuits in
Electrical Components
Open circuits in the coils of electrical components may be
detected by isolating the coil and checking for continuity with
an ohmmeter or with the unit in series with a light or bell circuit.
Shorted turns are indicated by a current draw substantially
above normal (connect ammeter in series with suspected
element and impose normal voltage) or D.C. resistance sub-
stantially below normal. The current method is recommended
for coils with very low D.C. resistance.
Motor current draw in the stator should be measured with the
rotor in place and running. Brake, relay and contactor coil
current should be measured with the core iron in operating
position.
14
Electrical Data for Hoist Components
MOTORS
Voltage Full Load *D.C.
Phase Current Resistance
Models & Hertz H.P. (Amps) Leads (Ohms)
WB, WE 115-1-60 1/4 4.6 5 TO 8 (START) 4.9
T1 to T2 4.3
T3 to T4 4.3
WB, WE 230/460 1/4 1.4/.70 1 to 4 14.8
3-60 2 to 5 14.8
3 to 6 14.8
7 to 8 29.5
7 to 9 29.5
8 to 9 29.5
WF, WH 115-1-60 1/2 7.2 5 to 8 (START) 3.7
T1 to T2 3.8
T3 to T4 3.8
WF, WH 230/460 1/2 1.8/.90 1 to 4 7.8
3-60 2 to 5 7.8
3 to 6 7.8
7 to 8 15.6
7 to 9 15.6
8 to 9 15.6
WL, WR 115-1-60 1 9.8 5 to 8 (START) 1.3
T1 to T2 1.1
T3 to T4 1.1
WJ, WL, WR 230/460 1 3/1.5 1 to 4 4.7
3-60 2 to 5 4.7
3 to 6 4.7
7 to 8 9.4
7 to 9 9.4
8 to 9 9.4
*Resistance values listed are nominal and they may vary slightly from component to component.
**On dual-voltage units connected for 460 volts, brake coils operate on 230 volts.
Table 5
TRANSFORMER
D.C. Resistance
Voltage Leads (Ohms)*
230/480 Secondary:
TO 115 Blue-tan to Blue 19.5
Primary: .
Red-black 87.5
to Red-blue
Primary:
White-red to 99.0
White-green
CONTACTOR
Models Coil Normal D.C. Resistance
Voltage (Volts) Current (Amps) (Ohms)*
WB, WE,
WF & WH 120 .04 297.5
WJ, WL,
and WR 120 .04 297.5
BRAKE COIL
Rated Nominal Current D.C. Resistance
Voltage (Amps) at Rated Voltage (Ohms)*
115 0.5 6.2
230** 0.25 24.7

15
Figure 11. Typical Wiring Diagrams. Wiring Diagrams shown are representative. Consult diagram in Hoist or furnished with unit.
SINGLE PHASE-TYPE ‘T’ CONTACTOR
110-120 VOLT SINGLE PHASE-TYPE ‘T’ CONTACTOR 110-120 VOLT
THREE PHASE
230/460-3-60
220/380-415-3-50
MODELS WB, WE, WF &
WH
THREE PHASE
230/460-3-60
220/380-415-3-50
MODELS WJ, WL & WR

16
ASSEMBLY
HOOK OR LUG SUSPENSION
Models WE, WH, and WR
Assemble the dead end bolt and block through the suspen-
sion adapter, as shown in Figure 12.
Figure 12. Hook Suspension
CENTRIFUGAL MECHANISM
Centrifugal mechanism (624-212) is furnished in kit form
which contains the centrifugal mechanism, spacers and an
Instruction Sheet. The Instruction Sheet provides complete
details on the installation of replacement mechanism.
To install the replacement mechanism, a press-on tool as shown
in Figure 13 will be required. The press-on tool is not included in
the kit, however, it may be ordered from CM – order centrifugal
mechanism press-on tool part number 28598.
When installing the replacement centrifugal mechanism, the
spacer is placed between the rotor shaft shoulder and the cen-
trifugal mechanism as shown in Figure 13. Using a slow-acting
press, apply pressure to the press-on tool and press the mech-
anism onto the shaft until it sets against the spacer. To prevent
damaging the mechanism and/or spacer, the force applied to
the press-on tool press the mechanism onto the shaft should
not exceed 3000 pounds.
FASTENERS
Models WE, WB, WF and WH, tighten motor housing cover
screws (624-106) to where they have a minimum breakaway
torque of 48 pound inch.
Models WJ, WL and WR tighten motor thru bolts (624-140) to
where they have a minimum breakaway torque of 50 pound
inch.
The liftwheel gear nut (624-139) should be tightened to a seat-
ing torque of 85 pound feet.
LOWER HOOK BLOCK PIN
When removing or installing the lower hook chain block pin
(624-764), care must be taken so as to prevent damaging the
pin and/or hook block. These pins are tapered groove pins and,
as a result, they can only be removed in one direction. To
remove the pin, a V-Block, drift and hammer (or slow acting
press) are required. The drift should be the same diameter as
the pin (5/16" diameter for Models WB, WE, and WF and 3/8"
diameter for Models WJ and WL) and it should be placed on
Figure 13. Centrifugal Mechanism Assembly