Specifications

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 INFORMATION
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
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
MAINTENANCE
Hoist Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Trolley Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Exterior Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Solid State Reverse Switch . . . . . . . . . . . . . . . . . . . . . . .15
AAddjjuussttmmeennttss
El
ectric Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . .18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . .24-47
ASSEMBLY INSTRUCTIONS
Hook or Lug Suspension . . . . . . . . . . . . . . . . . . . . . . . .48
Weatherproof Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Lower Hook Block Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Removal and Installation of Load Chain . . . . . . . . . . . .49
Cutting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
REPLACEMENT PARTS
Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Parts List and Exploded Views . . . . . . . . . . . . . . . . .51-91
LIST OF TABLES
1 Lodestar Electric Chain Hoist and
Series 635 Trolley Specifications . . . . . . . . . . . . . . . .2
2 Recommended Seating Torques for
Suspension Adapter Screws . . . . . . . . . . . . . . . . . . .5
3 Series 635 Low Headroom
Side Frame Spacing . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 Minimum Frequent Inspections . . . . . . . . . . . . . . . . . . .13
5 Minimum Periodic Inspections . . . . . . . . . . . . . . . . . . . .13
6 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
LIST OF ILLUSTRATIONS
1 Hook Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Lug Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3 Series 635 Low Headroom Trolley . . . . . . . . . . . . . . . . . .3
4 Series 635 Motor Driven Trolley . . . . . . . . . . . . . . . . . . . .3
5 Upper or Lower Latchlok Hook . . . . . . . . . . . . . . . . . . . .4
6 Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
7 Attaching Load Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
8 Contact Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
9 Series 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 Gaging 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 Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Gearing 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
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