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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.
TABLE OF CONTENTS
Master Parts Depots And Service Centers ........................................ 1
Safety Precautions ............................................................................. 2
Hoist Safety is Up To You ................................................................... 3
Foreword ............................................................................................ 4
Specifications ..................................................................................... 5
CM Repair/Replacement Policy ......................................................... 5
Hook Suspensions ............................................................................. 6
Lug Suspensions ................................................................................ 6
Series 635 Low Headroom Trolleys .................................................... 6
Series 635 Motor Driven Trolleys ........................................................ 6
Latchlok Hooks .................................................................................. 7
Chain Container .................................................................................. 7
Unpacking Information ....................................................................... 7
Installing Suspension ......................................................................7-8
Attaching Load Chain ......................................................................8-9
Installing Series 635 Low Headroom Trolley .................................9-10
Power Supply and Electrical Connections ..................................10-11
Checking for Twists in Load Chain ................................................... 11
Checking for Adequate Voltage at Hoist .....................................11-12
Control Cord ..................................................................................... 12
General ............................................................................................. 13
Operating Instruction-Hoist .............................................................. 13
Hoist with Low Headroom Trolley..................................................... 13
Hoist with Motor Driven Trolley ........................................................ 13
Safety Procedures ............................................................................ 13
Procedures ....................................................................................... 14
Frequent Inspections ...................................................................14-15
Periodic Inspections ....................................................................14-15
Preventive Maintenance ................................................................... 14
Hook Inspection ............................................................................... 14
Load Chain ....................................................................................... 16
Protector ........................................................................................... 16
Hoist Lubrication .............................................................................. 17
Trolley Lubrication ............................................................................ 17
Exterior Finish ................................................................................... 17
Solid State Reverse Switch .............................................................. 17
Electric Brake ................................................................................... 18
Limit Switches .............................................................................18-19
Troubleshooting ...........................................................................20-21
Electrical Data .............................................................................23-24
Typical Wiring Diagrams ..............................................................25-47
Hook or Lug Suspension .................................................................. 48
Weatherproof Hoists ......................................................................... 48
Gearing ............................................................................................. 48
Fasteners .......................................................................................... 48
Lower Hook Block Pin ...................................................................... 48
Removal and Installation of Load Chain......................................48-49
Cutting Chains .................................................................................. 50
Testing .............................................................................................. 50
REPLACEMENT PARTS
Ordering Instructions ........................................................................ 51
Parts List and Exploded Views ....................................................52-90
Recommended Spare Parts ............................................................. 90
LIST OF TABLES
TABLE
DESCRIPTION
1 Lodestar Electric Chain Hoist and
Series 635 Trolley Specifications .............................................. 5
2 Recommended Seating Torques for
Suspension Adapter Screws ..................................................... 8
Side Frame Spacing.................................................................. 9
4 Minimum Frequent Inspections .............................................. 15
5 Minimum Periodic Inspections................................................ 15
6 Limit Switches ......................................................................... 19
7 Troubleshooting .................................................................20-21
8 Electrical Data ....................................................................22-23
LIST OF ILLUSTRATIONS
FIG.
DESCRIPTION
1 Hook Suspensions .................................................................... 6
2 Lug Suspensions ...................................................................... 6
3 Series 635 Low Headroom Trolley ............................................ 6
4 Series 635 Motor Driven Trolley ................................................ 6
5 Upper or Lower Latchlok Hook ................................................. 7
6 Chain Container ........................................................................ 7
7 Attaching Load Chain ............................................................... 7
8 Contact Block ........................................................................... 8
9 Series 635 Low Headroom Trolley ............................................ 9
10 1/8 To 2 Ton (125kg To 2000 kg)
Hoist To Trolley Assembly ....................................................... 10
11 3 Ton (3000kg) Hoist To Trolley Assembly............................... 10
12 Voltage Conversion Terminal Board ........................................ 10
13 Location of Components ........................................................ 11
14 Hook Inspection ...................................................................... 16
15 Gaging Load Chain ................................................................. 16
16 Limit Switches Models A Thru H-2 ......................................... 18
17 Limit Switches Models J Thru RRT-2 .................................18-19
18 Typical Wiring Diagrams.....................................................24-47
19 Hook Suspensions .................................................................. 48
20 Non-Circular Gearing .............................................................. 48
22 Cutting Chain With A Bolt Cutter ............................................ 50
23 Hoist Frame Componets ....................................................54-55
24 Hoist Upper Suspension Components ..............................56-57
24 Hoist Lower Hook Components ........................................58-59
25 Control End Components ..................................................60-61
26 Brake Components ............................................................62-63
27 Limit Switch Components ..................................................64-65
28 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 .............................................85-87
28 Trolley Components ...........................................................88-89
4
(ENGLISH)
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P/N: 83874 (REV. 627-T) September 2016
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