Att 7 - AS890 VLFD OM Manual.pdf

INTERNATIONAL DOOR INC.

DIRECTORY

OVERHEAD HOIST-UP FABRIC “PARTHENON” DOOR

JOB# 12-ID-2100

MANUFACTURER CONTRACTOR

International Door, Inc. HASKELL Architects & Engineers 8001 Ronda Drive 111 Riverside Avenue Canton, Michigan 48187 Jacksonville, FL 32202 Tel: 734-459-3000

John Kaounas-President Michael R. McCarthy- Project Manager Devar Sateesh-Chief Engineer

Architect HASKELL Architects & Engineers 111 Riverside Avenue Jacksonville, FL 32202

SUPPLIER AND SOURCE OF REPLACEMENT PRODUCT PARTS

International Door, Inc.

8001 Ronda Drive.

Canton, MI 48187

734-459-3000 George Kaounas- Parts Manager

INTERNATIONAL DOOR, INC.

SAFETY PRECAUTIONS

OVERHEAD HOIST-UP FABRIC”PARTHENON” DOOR

JOB #12-ID-2100

Doors should be operated only by authorized trained Personnel. Before doors are opened or closed, operating personnel should ascertain that there are no obstructions, vehicles or personnel in the path of the doors.

FASTENERS ALL STRUCTURAL CONNECTIONS MECHANICAL HARDWARE AND WIREROPE

CLAMPS MUST BE INSPECTED, TIGHTENED OR REPLACED AS REQUIRED AT THREE MONTH

INTERVALS

All maintenance work must be performed by Trained Personnel.

All electrical maintenance and trouble-shooting must be performed by a qualified electrician.

CAUTION

EXERCISE CAUTION WHEN INSPECTING ELECTRICAL COMPONENTS.

Job# 12-ID-2100

OPERATING INSTRUCTIONS

SAFETY PRECAUTIONS:

Door should be operated only by authorized trained personnel. Before Door is opened or closed, operating personnel should ascertain that there are no obstructions, vehicles or personnel in the path of the door.

ELECTRICAL SEQUENCE OF OPERATION:

MULLIONS are electrically interlocked with DOORS. MULLIONS CANNOT BE RAISED while DOORS are in CLOSED position and DOORS CANNOT BE OPERATED while Mullions are RAISED.

NOTE: ALL SIX DOORS IN EACH MODULE WILL BE OPERATED INDIVIDUALLY

FROM MASTER CONTROLLERS MOUNTED INSIDE THE BUILDING ON EAST

WALL FOR EACH MODULE.A KEYED “OPEN” SWITCH MOUNTED OUTSIDE THE

BUILDING ON NORTH SIDE (MODULE “A”) TO OPEN DOOR#1 OF MODULE “A”

ONLY FOR FIRE MARSHALL. DIAGNOSTIC PANELS WITH INDICATING LIGHTS

TO SHOW THE STATUS OF DOOR POSITIONS ARE LOCATED ON EAST WALL

FO EACH MODULE NEXT TO MASTER CONTROL PANELS.

INITIAL POSITION:

ALLMULLIONS ARE LOWERED (VERTICAL POSITION) AND MULION PINS ARE

EXTENDED INTO THE MULION KEEPER PIT, AND ALL SIX DOORS ARE IN

CLOSED POSITION.

TO OPERATE DOORS FROM EITHER “MASTERCONTROLLER”

1. Press Momentarily” OPEN” of a particular door Push button door starts to open and stops in full open position when all “OPEN LIMIT “switches are tripped.

2. Press and HOLD MULLION “HORIZONTAL” BUTTON. Mullion Pin retracts and after a time delay, Mullion will start to go up and come to full horizontal position and stops when horizontal limit switch “MU-HLS”is tripped.

3. Press and HOLD MULLION “VERTICAL” BUTTON. Mullion will start to come down and come to full vertical position and stops when vertical limit switch “MU-VLS”is tripped after a time delay the mullion pin extends and engage inside the mullion keeper pit

OPERATING INSTRUCTIONS (CON’D)

4. Press and HOLD” CLOSE” of a particular Push button, door Starts to close and stops in full closed position when “CLOSE LIMIT” Switch is tripped. Releasing the “CLOSE” Push button stops door in any position.

5. While closing if “A SLACK CABLE “Condition occurs at any one side, the close limit switch for that side trips and cut off power to that side motor only.

6. If either of the motor windings reaches maximum temperature of 310 degree or burn out, then both motors stops and door becomes inoperable.

7. Momentary pressure on the “STOP” Push button will stop the door in any position during the opening or closing cycle

8. While CLOSING or OPENING the door if bottom truss becomes out of level during the open or close cycle the Tilt Switch will stop and start the motors to keep bottom truss level.

EXERCISE CAUTION WHEN OPERATING ELECTRICAL

COMPONENT

SPARE PARTS LIST

FOR

HOIST-UP FABRIC “PARTHENON” DOOR OPERATOR

#SK9072.1-132S/4 245.76:1RATIO

Experience proves that with proper maintenance (except for rubber weather-stripping and electrical components) replacement parts for International Door, Inc. products are usually not required for normal wear and aging. However, the list of recommended spare parts shows those major items which might need to be replaced to maintain door operation.

I.D.I. recommends that most components be stocked to facilitate quick repair and provide a model to maintenance personnel as to what the assembly is. Please contact the factory for current pricing and delivery schedule.

Part Number Part Description

Unit Qty.PER/

DOOR

Sugg.

Stock

Unit Price

A10-M1

Geared Motor w/ Brake,Shaft extn thru brake 7.5HP, 460 V, 3PH, 60 Hz, 1750 RPM 245.76:1 ratio 30 FT- LB Nord Brake w/ themostat protection 2 2

A10- M4&M3

Chain Coupling (W/ Chain) 3 5/8"" Dia. Bore - Gearbox Shaft 3" Dia. Bore - Drum Shaft 2 2

A10-M2 Two bolt Flanged Bearings For 3" Dia Shaft 4 2 A10- M7 Lifting Cable 3/4" dia(6x37) w/ftg.x 80'-0" 2 2

M1 1000KG CHAIN HOIST -Loadstar#3525CF 6 2 M2 Load arrestor-Tractel#75399-80ft 6 2

OVERHEAD HOIST-UP FABRIC ”PARTHENON” DOOR

MAINTENANCE & LUBRICATION INSTRUCTIONS

Inspection, maintenance and lubrication should be performed every fall. Doors operated more than 15 times a day should be serviced every three months. Doors require limit switch adjustments. All maintenance work must be performed by trained personnel.

FASTENERS ALL STRUCTURAL CONNECTIONS MECHANICAL HARDWARE AND

WIREROPE CLAMPS MUST BE INSPECTED, TIGHTENED OR REPLACED AS

REQUIRED AT THREE MONTH INTERVALS

MOTOR OPERATOR:

A. Check oil in Gearbox. Drain, flush and replace oil when required. Use Mobil SHC-626 synthetic oil or equal.

B. Drum Support Bearings - Lubricate with all purpose chassis lube at grease fittings.

C. Chain Coupling - Lubricate lightly with SAE 10W oil.

D. Motor - Lifetime lubricated, routine maintenance not required.

E. Magnetic Brake - Routine maintenance not required. As brake wears and decreases in thickness, the air gap will increase. While checking the air gap, measure the gap around the socket screws.

1. Loosen the socket head cap screw that attaches the brake to the motor end bell.

2. Depending if the air gap needs to be increased/ decreased, turn the adjusting nut accordingly. A quarter or half turn is usually sufficient for adjusting purposes.

3. After adjusting the nut, tighten the socket head cap screw back onto the brake

4. Measure the air gap for spacing. Repeat process to achieve recommended setting.

Refer attached brake instruction manual for details.

F. Lifting Cables- Visually inspects at the motor operators and cable winding drums very frequently (EVERY TWO WEEKS) for frying or damages. Replace if there is any indication of damage to cables.

Every 6 months cables clamps and cables should be visible inspected for cable slippage and torque mark movement on cable clamp nuts. Torque cable clamps nuts to 130 foot pounds every 6 months

MAINTENANCE & LUBRICATION INSTRUCTIONS (CON’D)

G. Deflector roller- Lifetime lubricated & sealed bearings, routine maintenance not required H. Idler Roller- - Lifetime lubricated & sealed bearings, routine maintenance not required

I. Fabric Panel- No maintenance required. Visually inspect for any tears or holes. Use patching kit to repair

J. Safety arrestor & wind lock- Lubricate lightly the sliding surfaces with SAE 10W oil.

Inspect compression springs for proper operation. Replace if necessary.

K. Door guide roller assembly- No maintenance required. Sealed bearings.

L. Mullion Pin Actuators: Actuators are factory Lubricated. Generally not required any further lubrication or maintenance. Actuators should be visually inspected periodically for signs of wear and damage and promptly repaired.

Actuators should be operated at least once annually to assure proper operation.

WEATHER –STRIPPING

A. Inspect for tears and replaces as required.

ELECTRICAL MAINTENANCE:

A. Visually inspect all controls. Run door through a complete cycle and check operation of all components.

B. Limit switch and brake were adjusted at time of installation for a smooth and quick stop, and should not require further adjustment. Inspect for broken parts and replace as required.

C. Visible inspection of the Over travel light mounted on the mullion, if on replace or adjust the open limit switch

EXERCISE CAUTION WHEN INSPECTING ELECTRICAL COMPONENTS.

OPERATION, MAINTENANCE & SPARE PARTS

OVERHEAD HOIST-UP FABRIC “PARTHENON”DOOR

PROJECT:

MV-22 NEW RIVER

AVIATION COMPLEX P-683 &P-687

Marine Core Air Station (MCAS) New River, North Carolina

CONTRACTOR

HASKELL Architects & Engineers 111 Riverside Avenue Jacksonville, FL 32202

ARCHITECTS

HASKELL Architects & Engineers

111 Riverside Avenue Jacksonville, FL 32202

INTERNATIONAL DOOR JOB#: 12-ID-2100

Designed & Manufactured By:

International Door, Inc.

8001 Ronda Drive Canton, Michigan 48187

1-800-231-9521

(734) 459-3000

Fax (734) 459-8962 www.international-door.com

ELECTRICAL SPARE PARTS

PUSH BUTTON TYPE CONTROLS

This list provides the items which may need to be replaced over time. However, this list may not include all electrical items included in your door. Please contact the factory for current pricing and delivery schedules for these or other items.

DESCRIPTION PART# UNIT

QTY.

SUGG.

STOCK

Disconnect Switch EC16 1 Reversing Starter EC1 1 Control Transformer 460V-120V(300 VA) Chain Hoist Control Box Transformer 460v-24v 50va

EC32-300

EC32-100

OPEN-CLOSE Limit Switches

OPEN-CLOSE –STOP Push buttons w/ contacts Key Switch

EC-OLS/CLS

EC-PB

EC-KEYSW

Overload Relay E1-OLD’S 3 3 Fuse (Primary) EC34 4 4 Fuse (Control) EC33 2 2 Indicating lights (green) EC8 10 10

Main Fuses EC35 6 6 120V Relay with socket-8 PIN EC-REL-8 2 2 120V Relay with socket-11 PIN EC-REL-11 4 2 12V Relay with sockets 24 V Relay (DPDT) Master Controller Relays Tilt Switch

E1-R E1-24R

E1-MR-700

ELS-DR-2-05-1

“PARTHENON” HOIST-UP FABRIC DOORS

IDI Job# 12-ID-2100

IMPORTANT OPERATING INSTRUCTIONS

SAFETY PRECAUTIONS:

Door should be operated only by authorized trained personnel. Before door is opened or closed, operating personnel should ascertain that there are no obstructions, vehicles or personnel in the path of the door.

During door “OPENING “cycle, if the door operator notices the bottom beam going up noticeably “out of level”, from one end to other, operator must stop the door operation immediately by pressing the “STOP” push button.

CAUTION:- If door operation is allowed to continue, the out of level condition will gradually increase as door is going up and ultimately the door will miss the open limit switch actuating rods and become “two-blocked”(jammed) into the header causing major damage to the door system.

Operator should follow the procedure listed below to correct the out of level condition.

A. Push and “HOLD CLOSE” push button until “LOW end of door closes fully and trip the lifting cable slack limit switch. so that a slack cable condition occurs

B. Turn the control panel disconnect to “OFF” position.

C. Release the Motor brake on the HIGH end side of the operator.

D. Rotate the shaft extension thru the brake with a socket wrench to lower the door bottom beam until the slack cable limit switch is tripped and a slack cable condition is occurred.

E. Check the slackness of the cable on both sides at the slack cable limit switch located near the operator to make sure they are equal. If they are not equal adjust the slackness as follows

1) Release the motor brake on the side that needs adjustment

2) Rotate the shaft extension thru the brake with socket wrench until desired slackness is achieved.

A. Turn the control panel disconnect to “ON” position.

B. Resume “OPEN “ cycle operation

CAUTION;- EXERCISE CAUTION WHEN INSPECTING &

OPERATINELECTRICAL COMPONENTS

DS

Text Box

DS

Text Box

OF MOTOR BRAKE ONLY

eng3 Project5 eng3 Pencil

Pencil

Load arrestor – Suspended type

BLOCMAT™ " S "

réf. : T-2153 GB rév. n° : 2 date : 06/08 page : 1/1

TECHNICAL

DATA SHEET

FUNCTION :

This range with 500, 800 and 1000 kg W.L.L has been designed to be suspended to a structure through a rectangular fixing plate.

DESCRIPTION AND PRINCIPLE OF USE :

The " S " type is composed of :

• An automatic fall arrest device.

• A rope reeling drum.

• A reliable rectangular fixing plate.

A centrifugal device continuously monitors the speed at which the wire rope passes through the fall arrest device and automatically triggers the closing of the jaw on the wire rope as soon as the speed exceeds a given threshold. The brake jaw grips over a large contact area, causing no damage to the wire rope.

A drilled fixing plate allows the complete system to be anchored to support steel profiles or concrete plates. The fall arrest device and the reeling drum are fixed to this fixing plate.

• The structure where the BLOCMAT™ is anchored to shall be dimensioned to support a vertical force equal to 8 times the nominal load.

• Fall arrest speed 18 m/min.

• Use M20 bolts to installe fixing bracket on structure

ADVANTAGES :

• Minimum free fall height (< 100 mm).

• Fall is stopped gradually.

• Fall arrest device can be reset by simple action to the lever.

• Operation can be tested at any time by closing the jaw manually through the emergency button.

• No need to recondition the device after fall arrest.

CHARACTERISTICS :

C

A

B

E

W.L.L.

kg ø of wire rope mm

Wire rope length m

Weight kg

Dimension"A" mm

Dimension"B" mm

Dimension"C" mm

Dimension"E" mm

500 6,5 15 29 715 500 190 300

500 6,5 25 40 715 580 190 400

800 8,3 10 35 753 580 190 400

800 8,3 20 43 753 580 190 400

1000 9,5 8 35 753 580 190 400

1000 9,5 12 42 753 580 190 400

Load arrestor – Floor mounted type

BLOCMAT™ " S.I "

réf. : T-2154 GB rév. n° : 02 date : 06/08 page : 1/1

TECHNICAL

DATA SHEET

FUNCTION :

The BLOCMAT™ " S.I " range has been designed to secure suspen-ded loads. Three Working Load Limit are available 500/800 and 1000

kg. This range shall be fixed in a floor mounted position and used with an upper return sheave.

DESCRIPTION AND PRINCIPLE OF USE :

The " S.I " type is composed of :

• An automatic fall arrest device.

• A rope reeling drum.

• A reliable rectangular fixing plate.

A centrifugal device continuously monitors the speed at which the wire rope passes through the fall arrest device and automatically triggers the closing of the jaw on the wire rope as soon as the speed exceeds a given threshold. The brake jaw grips over a large contact area, cau-sing no damage to the wire rope.

A drilled plate allows the complete system to be anchored to floor mounted support steel profiles or concrete plates. The fall arrest devi-ce and the reeling drum are mounted to this fixing plate.

• The structure where the BLOCMAT™ is anchored to shall be dimensioned to support a vertical force equal to 8 times the nominal load.

• Fall arrest speed 18 m/min.

• Use M20 bolts to installe fixing bracket on structure

ADVANTAGES :

• Minimum free fall height (< 100 mm).

• Fall is stopped gradually.

• Operation can be tested at any time by closing the jaw manually through the emergency button.

• No need to recondition the device after fall arrest.

CHARACTERISTICS :

C

A

B

E

W.L.L.

kg ø of wire rope mm

Wire rope length m

Weight kg

Dimension"A" mm

Dimension"B" mm

Dimension"C" mm

Dimension"E" mm

500 6,5 15 29 715 550 190 300

500 6,5 25 39 715 640 190 400

800 8,3 10 31 753 550 190 300

800 8,3 15 36 753 640 190 400

800 8,3 25 45 753 640 190 400

1000 9,5 10 36 753 640 190 400

1000 9,5 25 47 753 640 190 400 blocmat™

M/S/SI/SIP

rectractable load arrestor anticaídas de cargas de retracción automática anticaduta per carichi a richiamo automatico antiquedas de cargas com chamada automática

Operation and maintenance manual Original manual

Manual de empleo y mantenimiento Traducción del manual original

GB

ES

Istruzioni d’uso e manutenzione Traduzione del manuale originale

Instruções de uso e manutenção Tradução do manual original

PT

IT

2006/42/CE

English

Español

Italiano

Português eng3 earaser3

CONTENTS Page

General warning 2

1.Functions and description 3

2. Installation 3

3. Inspection before use 4

4. Operation 4

5. Storage 4

6. Maintenance and repair 4

7. Warnings against hazardous operations 5

8. Labelling 6

Pictures A, B

Always concerned to improve the quality of its products, the TRACTEL® Group reserves the right to modify the specifications of the equip-ment described in this manual. The companies of the TRACTEL® group and their agents or dis-tributors will supply on request descriptive docu-mentations on the full range of TRACTEL® pro-ducts : lifting and pulling machines,permanent and temporary access equipment, safety devices, electronic load indicators, accessories such as blocks, hooks , slings, ground anchors, etc…

The network is able to supply an after sales and regular maintenance service. Should you have any quiries or require technical assistance, please do not hesitate to contact us.

1. Before using the load arrestor, it is essential that users read this manual and comply with its instructions, in order to ensure safe and effective operation. This manual must be kept and made available to all users. Additional copies can be supplied on request.

2. The blocmat™ load arrestor from TRACTEL® is a safety device, designed to secure a load in the event of a fall. Never use a blocmat™ load arrestor to secure people from falling.

3. Always check that the load weight does not exceed the Working Load Limit of the blocmat™.

4. Before using this load arrestor, it is essential that users are trained in its use.

5. Never use a blocmat™ which is not in apparent good order. IT IS RECOMMENDED THAT A VISUAL CHECK IS CARRIED OUT BEFORE EACH USE. Return any blocmat™ which is dama-ged in any way to TRACTEL® or its distributor.

6. TRACTEL® S.A.S accepts no responsability for the consequence of dismantling a blocmat™ or any modification not made under its control, in particular in the event of the replacement of original parts with parts from another source.

7. The blocmat™ as described in this manual shall be EXCLUSIVELY used to secure load, any other application is prohibited.

8. The blocmat™ shall be tested in fall arrest operation before use (refer to § 3).

9. The blocmat™ as described in this manual shall not be used in explosive or chemical environ-ment. (For specific applications, consult us).

GENERAL WARNING! !

SPECIAL APPLICATIONS

For any special applications, please do not hesitate to contact TRACTEL® S.A.S.

For Belgium and Luxembourg, contact TRACTEL® Benelux

GB

1. FUNCTIONS AND DESCRIPTION

The blocmat™ range has been designed to secure suspended loads. The range is composed of various Working Load Limit (500/800/1000 kg) and different rope lengths.

According to the applications, the blocmat™ can be suspended to structures, floor mounted used with return sheave or integrated into aluminium truss for show business applications.

(The operation of the blocmat™ on horizontal position is prohibited).

The blocmat™ load arrestor is composed of :

• An automatic fall arrest device with centrifugal action.

• An automatic rope reeling drum.

• An anchor system to structure.

The blocmat™ automatically stops a load in the event of fall. The blocmat™ is attached to a support structure, the load moving up and down on a vertical axis. (Fig. 1)

The load is connected to the load arrestor by a wire rope, whose length is adjusted automatically by a retracting spring which activates a reeling drum on which the rope is wound.

A centrifugal device continously monitors the speed at which the wire rope passes through the fall arrest device and automatically triggers the closing of the jaw on the wire rope as soon as the speed exceeds a given threshold (about 18 m/min.) The brake jaw grips over a large contact area, cau-sing no damage to the wire rope. The distance to stop the fall is inferior to 10 cm.

The blocmat™ is available in various configurations :

• The "M" type to be integrated into an aluminium square truss (show business applications).

• The "S.I.P." type to be used with aluminium triangular truss (show business applications).

• The "S" type to be suspended to structure.

• The "S.I." type as floor mounted version tobe used together with a return sheave. (The anchor point of the return sheave shall withstand with the force generated by a fall arrest – refer to § 2).

(Fig. 2).

2. INSTALLATION

Whatever the type, the blocmat™ shall always be anchored on a vertical axis to the load.

The blocmat™ shall always be connected to the support structure through the fixing plate or bracket supplied with the device.

Use M20 bolts to installe fixing bracket on structure. (Fig. 3)

THE ANCHOR POINT BETWEEN THE BLOCMAT™ AND THE SUPPORT STRUCTU-

RE SHALL HAVE A RESISTANCE AT LEAST EQUAL TO 8 TIMES THE NOMINAL

LOAD.

3. INSPECTION BEFORE USE

Before using the blocmat™, we recommend you to ckeck that :

• The wire rope is correctly engaged and move freely through the fall arrestor.

• The wire rope is correctly positioned on the reeling drum.

• The centrifugal device works correctly by acting the emergency stop located on the side of the load arrestor (reset by simple action to the lever).

• The blocmat™ is correctly anchored to the support (refer § 2).

• The hook on the wire rope is correctly positioned on the load and the anchor point between the hook and the load has the suitable resistance in case of fall arrest (refer §2).

• The wire rope is not twisted

4. OPERATION

Prior to use the blocmat™, make sure that the anchor points of the blocmat™ to the support structu-re and the load have the necessary resistance (refer § 2).

When load moves up and down, the wire rope shall move freely through the fall arrestor. The length of the rope is adjusted automatically by the retracting spring of the reeling drum on which the rope is wound.

In the event of fall, the centrifugal device will detect the overspeed action and close the jaw on the wire rope in order to stop the fall of the load.

After fall arrest the blocmat™ can be reset by simple action to the lever. PRIOR TO DO THAT, YOU

MUST FIND OUT THE REASONS OF THE FALL OF THE LOAD AND SECURE IT AGAIN

BEFORE RESETTING THE BLOCMAT™.

NEVER LET THE WIRE ROPE MOVES UP FREELY WHEN RELEASING THE HOOK

FROM THE LOAD. HOLD THE HOOK UNTIL THE ROPE HAS BEEN COMPLETLY

REWOUND ON THE REELING DRUM

5. STORAGE

The blocmat™ fall arrestor must be stored in a location sheltered from adverse weather conditions, and kept at a temperature of between – 10° C to + 60° C.

6. MAINTENANCE AND REPAIR

The blocmat™ shall be regularly maintained by the user. In addition to the inspections described in § 3, the following maintenance operations should be performed once a week :

• Check that the wire rope is in a good condition (this check is compulsory in case of fall arrest).

• Check the anchor points between the blocmat™ the support structure and the load.

• Check that the wire rope moves freely through the fall arrestor.

• Check that the wire rope winds and unwinds freely on the reeling drum.

• Check that the hook and the safety catch are in a good condition of use.

In case of you notice a disfunction of the device, The blocmat™ shall be returned to TRACTEL® or to an approved repair shop. The wire rope has specific characteristics to be used with our fall arres-tor. You must not use another type of rope.

7. WARNINGS AGAINST HAZARDOUS OPERATIONS

Warnings against hazardous operations have been described in the preceding sections, however, we would draw your attention to certain operations which are dangerous :

• DO NOT USE the blocmat™ load arrestor as a fall arrest equipment for people. Those people-should have their own protection equipment.

• DO NOT USE the blocmat™ above its Working Load Limit.

• DO NOT USE the blocmat™ for any other application than the Load fall arrest.

• DO NOT ANCHOR the blocmat™ to a structure having a resistance inferior to the value given in § 2

• DO NOT ANCHOR the blocmat™ with a connecting part other than the one supplied with the device.

• NEVER USE the wire rope as a sling on the load.

• NEVER USE an anchor point to the load having a resistance inferior to the value given in § 2.

• NEVER USE a hook which is not the one supplied with the blocmat™.

• NEVER USE a hook the safety catch of which is damaged or missing.

• NEVER USE a wire rope which is not the one supplied with the blocmat™.

• NEVER USE the blocmat™ with a wire rope which is damaged or worn.

• NEVER USE the blocmat™ with the position lever which has been forced to "open" position.

8. LABELLING

Every blocmat™ is delivered with a label indicating :

• The type and the code number.

• The Working Load Limit.

• The maxi length of the wire rope.

• The serial number and the year of manufacture.

• The name and the adress of the manufacturer.

Pencil eng3 Pencil eng3 Pencil eng3 Pencil eng3 Pencil

E le c tr ic C h a in

Operating, Maintenance & Parts Manual Rated Loads 1/8 To 3 Tonnes

125 Kg To 3000 Kg

00001996 (REV AB) 627NH

Follow all instructions and warning 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 eng3 earaser3 eng3 earaser3 eng3 earaser3 eng3 Project5

CM HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA

PARTS FOR YOUR HOIST ARE AVAILABLE FROM YOUR LOCAL AUTHORIZED REPAIR STATION. FOR THE NAME

OF THE NEAREST PARTS OR SERVICE CENTER, VISIT OUR WEB SITE WWW.CMWORKS.COM

OR CALL OUR CUSTOMER SERVICE DEPARTMENT.

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 main-tenance 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 re-sponsible 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.

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 un-less 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 de-cals 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 supporting any parts of the load.

5. Make sure the load is free to move and will clear all obstructions.

6. Avoid swinging the load or hook.

7. Make sure hook travel is in the same direction as shown on the controls.

8. Inspect the hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance.

9. Use the hoist manufacturer’s recommended parts when repairing the unit.

10.Lubricate load chain per 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 perform such adjustments or repairs.

WARNING

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could re-sult in death or serious injury. To avoid such a poten-tially hazardous situation, the operator shall:

CAUTION

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could re-sult in minor or moderate injury. To avoid such a po-tentially hazardous situation, the operator shall:

WARNING

Usage of hoists that do not involve lifting of the load on the lower hook or using hoists in the inverted position without special precaution may cause an accident resulting in injury and/or property damage.

TO AVOID INJURY:

Consult Columbus McKinnon for information concerning using hoists in these applications.

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 en-dangers the operator, but in many cases, a valuable load.

VIOLATION OF ANY OF THESE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL INJURY TO THE OPER-

ATOR OR NEARBY PERSONNEL BY RELEASED LOAD OR BROKEN HOIST COMPONENTS.

–DO NOT LIFT MORE THAN RATED LOAD.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.

–DO NOT USE LOAD CHAIN AS A SLING.

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 safety 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 be-fore use, in addition to regular, periodic maintenance inspections.

Inspect hoists for operational warning no-tices and legibility.

Deficiencies should be noted and brought to the attention of supervisors. Be sure de-fective 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.

WARNING

WARNING

WARNING!

TABLE OF CONTENTS

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Foreword

General Information Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 CM Repair/Replacement policy . . . . . . .(Back Page)

Accessories Hook Suspensions Lug Suspension Series 635 Low Headroom Trolley Series 635 Motor Driven Trolley Latchlok Hooks Chain Container

Installation Unpacking Information Installing Suspension . . . . . . . . . . . . . . . . . . . .10-11 Recommended Torques Attaching Load Chain Installing Series 635 Low Headroom Trolley . . . . .12-13 Power Supply and Electrical Connections

Operating Instructions General Operating Instruction-Hoist . . . . . . . . . . . . . . . .16-17 Safety Procedures

Inspection Inspection Frequent Inspections . . . . . . . . . . . . . . . . . . . .18-19 Periodic Inspections . . . . . . . . . . . . . . . . . . . . .18-19 Preventative Maintenance Hook Inspection Load Chain

Maintenance Load-limiter Hoist Lubrication Trolley Lubrication Adjustments Electric Brake Limit Switches . . . . . . . . . . . . . . . . . . . . . . . .23-24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .25-27 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . .28-29 Typical Wiring Diagrams . . . . . . . . . . . . . . . . . .30-72

Assembly Instructions Hook or Lug Suspensions Lower Hook Block Pin Removal and Installation of Load Chain . . . . . .73-74 Cutting Chain Testing

Ordering Instructions Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76-137 Lubricants Recommended Spare Parts Notes

LIST OF TABLES

Table Title Page 1 Lodestar Electric Chain Hoist Specs. . . . . . 6-8 2 Recommended Torques 3 Series 635 Trolley Side Frame Spacing 4 Minimum Frequent Inspections 5 Minimum Periodic Inspections 6 Limit Switches 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . .25-27 8 Electrical Data . . . . . . . . . . . . . . . . . . . . . .28-29

LIST OF ILLUSTRATIONS

Figure Table Page 1 Hook Suspensions 2 Lug Suspensions 3 Series 635 Low Headroom Trolley 4 Series 635 Motor Driven Trolley 5 Upper or Lower Latchlok Hook 6 Chain Container 7 Attaching Load Chain 8 Contact Block 9 Series 635 Low Headroom Trolley 10 1/8 to 2 Ton Hoist to Trolley Assembly 11 3 Ton Hoist to Trolley Assembly 12 Voltage Change Board 13 Locations of Components 14 Hook Inspection 15 Chain Wear areas 16 Gaging Load Chain Wear 17 Chain Inspection 18 Limit Switches Models, V1 Models 18A Rotatable Limit Switches, V1 Models 19 Limit Switches, V2 Models 19A Rotatable Limit Switch, V2 Models 20 Typical Wiring Diagrams . . . . . . . . . . . . . .30-72 21 Swivel Hook Suspensions 22 Chain Embossing 23A Cutting Chain By Nicking 23B Cutting Chain With A Bolt Cutter

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 mechanical equipment. Skill acquired through specialized experience and study is essential to safe rigging operations. For rigging information, we recommend consulting a standard textbook on the subject.

FOREWORD

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 Limiter, hardened steel chain guides, hardened steel gear train, life-time lubrication, 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 summarizes 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 is10 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 per formance tested pr ior to shipment. If any properly maintained hoist develops a performance problem due to a material or workmanship defect, as verified by CM®, repair or replacement of the unit will be made to the original purchaser without charge. This repair/replacement policy applies only to Lodestar Hoists installed, maintained and operated as outlined in this 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 Acknowl-edgement. Also, refer to the back cover for Limitations of Warranties, Remedies and Damages, and Indemnification and Safe Operation.

GENERAL INFORMATION

Table 1.a. Specifications

Lodestar Electric Chain Hoists Single Speed 115-1-60

Model Load Capacity

Lifting Speed 60Hz units

Lifting Speed 50Hz units Chain

Falls Chain Size

Chain Weight per length of lift

Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m

A 1/8 125 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 AA 1/8 125 60 18.3 50.0 15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87 B 1/4 250 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 C 1/4 250 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 E 1/2 500 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74 F 1/2 500 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 J 1/2 500 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87 H 1 1000 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74 L 1 1000 16 4.9 13.3 4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40 R 2 2000 8 2.4 6.7 2.0 2 .312 x .8583 7.92 x 21.8 1.88 2.80 RT 3 3000 5.3 1.6 4.4 1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20

Lodestar Electric Chain Hoists Single Speed 115-1-60

Model Shortest Distance Between Hooks

Motor Power 60Hz

Motor Power 50Hz

IP

Rating

Net Weight 10’ lift less upper suspension in mm HP kW HP kW lb kg

A 16.9 429 0.25 0.19 0.21 0.16 54 72 32.8

AA 19.9 505 0.50 0.37 0.42 0.31 54 76 34.3

B 16.9 429 0.25 0.19 0.21 0.16 54 73 33.1 C 16.9 429 0.50 0.37 0.42 0.31 54 75 34.2 E 21.6 549 0.25 0.19 0.21 0.16 54 78 31.8 F 16.9 429 0.50 0.37 0.42 0.31 54 76 34.5 J 18.1 460 1.00 0.75 0.83 0.62 54 127 57.5 H 21.6 549 0.50 0.37 0.42 0.31 54 81 36.7 L 18.1 460 1.00 0.75 0.83 0.62 54 125 56.7 R 25.8 655 1.00 0.75 0.83 0.62 54 148 67.1

RT 32.1 815 1.00 0.75 0.83 0.62 54 166 75.4

Lodestar Electric Chain Hoists Single Speed 230/460-3-60 or 220/380-3-50 or 220/415-3-50

Model Load Capacity Lifting Speed 60 Hz units

Lifting Speed 50Hz units Chain

Falls Chain Size

Chain Weight per length of lift

Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m

A 1/8 125 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 AA 1/8 125 60 18.3 50.0 15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87

B 1/4 250 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

C 1/4 250 32 9.8 26.7 8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

E 1/2 500 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74

F 1/2 500 16 4.9 13.3 4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

J 1/2 500 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87

JJ 1/2 500 64 19.5 53.3 16.3 1 .312 x .8583 7.92 x 21.8 0.94 1.40

H 1 1000 8 2.4 6.7 2.0 2 .250 x .7445 6.35 x 18.9 1.17 1.74

L 1 1000 16 4.9 13.3 4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

LL 1 1000 32 9.8 26.7 8.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

R 2 2000 8 2.4 6.7 2.0 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RR 2 2000 16 4.9 13.3 4.1 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RT 3 3000 5.3 1.6 4.4 1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20

RRT 3 3000 10.7 3.3 8.9 2.7 3 .312 x .8583 7.92 x 21.8 1.88 2.80

Lodestar Electric Chain Hoists Single Speed 230/460-3-60 or 220/380-3-50 or 220/415-3-50

Model Shortest Distance Between Hooks

Motor Power 60Hz

Motor Power 50Hz

IP

Rating

Net Weight 10’ lift less upper suspension in mm HP kW HP kW lb kg A 16.9 429 0.25 0.19 0.21 0.16 54 70 31.9

AA 19.9 505 0.50 0.37 0.42 0.31 54 73 32.9

B 16.9 429 0.25 0.19 0.21 0.16 54 71 32.2

C 16.9 429 0.50 0.37 0.42 0.31 54 72 32.8

E 21.6 549 0.25 0.19 0.21 0.16 54 76 30.9

F 16.9 429 0.50 0.37 0.42 0.31 54 73 33.1

J 18.1 460 1.00 0.75 0.83 0.62 54 121 54.7

JJ 18.1 460 2.00 1.49 1.67 1.24 54 127 57.5

H 21.6 549 0.50 0.37 0.42 0.31 54 78 35.4

L 18.1 460 1.00 0.75 0.83 0.62 54 119 53.9

LL 18.1 460 2.00 1.49 1.67 1.24 54 127 57.6

R 25.8 655 1.00 0.75 0.83 0.62 54 142 64.4

RR 25.8 655 2.00 1.49 1.67 1.24 54 150 68.0

RT 32.1 815 1.00 0.75 0.83 0.62 54 160 72.7

RRT 32.1 815 2.00 1.49 1.67 1.24 54 173 78.4

Table 1.b.Specifications, cont’d

Lodestar Electric Chain Hoists Two Speed 230-3-60 or 460-3-60 or 575-3-60 or 220-3-50 or 380-3-50 or 415-3-50 or 550-3-50

Model Load Capacity

Lifting Speed 60Hz units

Lifting Speed 50Hz units Chain

Falls Chain Size

Chain Weight per length of lift

Tonne kg ft/min m/min ft/min m/min in x in mm x mm lb/ft kg/m

A-2 1/8 125 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87 AA-2 1/8 125 20/60 6.1/18.3 16.7/50 5.1/15.2 1 .250 x .7445 6.35 x 18.9 0.585 0.87

B-2 1/4 250 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

C-2 1/4 250 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

E-2 1/2 500 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .250 x .7445 6.35 x 18.9 1.17 1.74

F-2 1/2 500 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .250 x .7445 6.35 x 18.9 0.585 0.87

J-2 1/2 500 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .312 x .8583 7.92 x 21.8 0.585 0.87

JJ-2 1/2 500 21.3/64 6.5/19.5 17.8/53.3 5.4/16.3 1 .312 x .8583 7.92 x 21.8 0.94 1.40

H-2 1 1000 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .250 x .7445 6.35 x 18.9 1.17 1.74

L-2 1 1000 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

LL-2 1 1000 10.7/32 3.3/9.8 8.9/26.7 2.7/8.1 1 .312 x .8583 7.92 x 21.8 0.94 1.40

R-2 2 2000 2.7/8 0.8/2.4 2.2/6.7 0.7/2 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RR-2 2 2000 5.3/16 1.6/4.9 4.4/13.3 1.4/4.1 2 .312 x .8583 7.92 x 21.8 1.88 2.80

RT-2 3 3000 1.8/5.3 0.5/1.6 1.5/4.4 0.5/1.4 3 .312 x .8583 7.92 x 21.8 2.82 4.20

RRT-2 3 3000 3.6/10.7 1.1/3.3 3/8.9 0.9/2.7 3 .312 x .8583 7.92 x 21.8 1.88 2.80

Lodestar Electric Chain Hoists Two Speed 230-3-60 or 460-3-60 or 575-3-60 or 220-3-50 or 380-3-50 or 415-3-50 or 550-3-50

Model Shortest Distance Between Hooks

Motor Power 60Hz

Motor Power 50Hz

IP

Rating

Net Weight 10’ lift less upper suspension in mm HP kW HP kW lb kg A-2 16.9 429 0.25 0.19 0.21 0.16 54 76 34.6

AA-2 19.9 505 0.50 0.37 0.42 0.31 54 78 35.2

B-2 16.9 429 0.25 0.19 0.21 0.16 54 77 34.9

C-2 16.9 429 0.50 0.37 0.42 0.31 54 77 35.1

E-2 21.6 549 0.25 0.19 0.21 0.16 54 82 33.6

F-2 16.9 429 0.50 0.37 0.42 0.31 54 78 35.4

J-2 18.1 460 1.00 0.75 0.83 0.62 54 133 60.2

JJ-2 18.1 460 2.00 1.49 1.67 1.24 54 135 61.1

H-2 21.6 549 0.50 0.37 0.42 0.31 54 83 37.6

L-2 18.1 460 1.00 0.75 0.83 0.62 54 131 59.4

LL-2 18.1 460 2.00 1.49 1.67 1.24 54 135 57.6

R-2 25.8 655 1.00 0.75 0.83 0.62 54 154 61.2

RR-2 25.8 655 2.00 1.49 1.67 1.24 54 158 69.8

RT-2 32.1 815 1.00 0.75 0.83 0.62 54 172 71.6

RRT-2 32.1 815 2.00 1.49 1.67 1.24 54 181 82.1

Table 1.c. Specifications, cont’d

Table 1.d. Specifications, cont’d

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)

= to 1 (125 to 2000)

2 (2000)

3 (3000)

A thru LL-2

R thru RR-2

RT thru RRT-2

4 - 15 (102 - 381)

6 - 18 (152 - 457)

8 - 15 (203 - 381)

3= (79.4)

4< (120.6)

4 (101.6)

24 (610)

24 (610)

30 (762)

Series 635 Motor 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.(mm)

= to 2 (125 to 2000)

3 (3000)

A thru RR-2

RT thru RRT-2

75 (23)

75 (23)

; (.19)

; (.19)

6 - 15 (152 - 381)

6 - 15 (152 - 381)

30 (762)

30 (762)

Table 1.e. Specifications, cont’d

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.

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.

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 3. Series 635 Low Headroom Trolley

ACCESSORIES

Figure 4. Series 635 Motor 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 suspension (see Figure 2) is required to suspend the hoist from the Motor Driven Trolley. The hoist and trolley are joined electrically by connecting the hoist control and power cords (supplied) 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.

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 Figure 5. Latchlok® Hook

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

Figure 1. Hook Suspensions

Figure 2. Lug Suspensions

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: See Electrical Installation instructions

INSTALLING THE SUSPENSION

A. Single Reeved Units:

Remove the hook suspension and (2) suspension screws from the packaging. Place the suspension assembly into the recess on top of the hoist so that the…