CM Lodestar A Operating, Maintenance & Parts Manual Download Page 106

Page: 106 / 128

P/N: 10001609 (REV AB) 627NH

December 2014

V1 CONTACTOR PLATE ASSEMBLIES

ITEM NO.

PART NUMBER

DESCRIPTION

QTY

28968

AFD BRACKET

38953

VFD G+MINI, 1/2 HP

38954

VFD 3/4HP 460V

70246

RECTIFIER

70274

INSULATOR, RECTIFIER

28969

BRAKE RELAY BRACKET

35928

MAINLINE CONTACTOR

957854

SCREW #6-32 NC-2 X 5/8" ROUND

987378

SCREW #8-32 UNC-2A X 1/2"

00000535

SURGE SUPPRESSOR

982233

ALTECH DIN SERIES SINGLE WIRE

982234

ALTECH DIN SERIES SINGLE WIRE

27771

TRANSFORMER

11782704

CONNECTOR PUSHWIRE ORANGE

982158

LINE CONNECTOR

27686

JUMPER (G-Y)

00001729

JUMPER (R7)

20940

GROUND LABEL

28086

JUMPER (T)

28087

JUMPER (T)

28090

JUMPER (T)

NOT SHOWN

00001558

V1 230V VFD WIRING HARNESS

00001557

V1 460V VFD WIRING HARNESS

NOT SHOWN

10001109

THERMAL CONDUCTIVE PASTE

AS REQ'D

V1 CONTACTOR PLATE ASSEMBLIES

ITEM NO.

PART NUMBER

DESCRIPTION

QTY.

28968

AFD BRACKET

38953

VFD G+MINI, 1/2 HP

38954

VFD 3/4HP 460V

70246

RECTIFIER

70274

INSULATOR, RECTIFIER

28969

BRAKE RELAY BRACKET

35928

MAINLINE CONTACTOR

957854

SCREW #6-32 NC-2 X 5/8" ROUND

987378

SCREW #8-32 UNC-2A X 1/2"

00000535

SURGE SUPPRESSOR

982233

ALTECH DIN SERIES SINGLE WIRE

982234

ALTECH DIN SERIES SINGLE WIRE

27771

TRANSFORMER

11782704

CONNECTOR PUSHWIRE ORANGE

982158

LINE CONNECTOR

27686

JUMPER (G-Y)

00001729

JUMPER (R7)

20940

GROUND LABEL

28086

JUMPER (T)

28087

JUMPER (T)

28090

JUMPER (T)

NOT SHOWN

00001558

V1 230V VFD WIRING HARNESS

00001557

V1 460V VFD WIRING HARNESS

NOT SHOWN

10001109

THERMAL CONDUCTIVE PASTE AS REQ'D

HOIST BRAKE END

HOIST MOTOR END

Summary of Contents for Lodestar A

Page 1: ...creased 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 operator Failure to operate equipment as directed in manual may cause injury ELECTRIC CHAIN HOIST OPERATING MAINTENANCE PARTS MANU...

Page 2: ...2 00001996 REV AC 627NH October 2014 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 ...

Page 3: ...or repair damaged 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...

Page 4: ...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 DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST DO NOT OPERATE WITH...

Page 5: ...T OF ILLUSTRATIONS Figure Table Page 1 Hook Suspensions 9 2 Lug Suspensions 9 3 Series 635 Low Headroom Trolley 9 4 Series 635 Motor Driven Trolley 9 5 Upper or Lower Latchlok Hook 9 6 Chain Container 9 7 Attaching Load Chain 11 8 Contact Block 13 12 Voltage Change Board 14 13 Locations of Components 14 14 Hook Inspection 18 15 Chain Wear areas 20 16 Gaging Load Chain Wear 20 17 Chain Embossing 20...

Page 6: ...8 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 ...

Page 7: ...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 RRS 2 2000 16 4 9 13 3 4 1 1 394 x 1 18 10 x 30 1 45 2 16 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 Shorte...

Page 8: ...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 Ele...

Page 9: ... UTM Universal Trolley are supplied complete with independent controls wiring and a four directional control station These trolleys are adaptable to a wide variety of CMCO hoist products when used in conjunction with the appropriate hoist suspension Trolley is adjustable for operation on American Standard S beams and will also operate on flat flanged beams SERIES 635 MOTOR DRIVEN TROLLEY The motor...

Page 10: ... 2 H H 2 and 7 16 11 11mm for Models R R 2 RR RR 2 If the distance is not correct adjust the position of the dead end block to obtain the proper distance see fig 21 p 73 Now insert the suspension screws through the holes in the adapter and hand thread these into the self locking nuts enclosed in the hoist frame Securely tighten the screws to the recommended seating torque see Table 2 using a 12 po...

Page 11: ...Guide Screws 10 24 Slotted Fillister Head Screw Slotted Blade Screw Driver 1 7 2 1 2 3 2 8 1 4 20 Button Head Screw for Miscellaneous Applications 1 4 20 Button Head Socket Cap Screw 5 32 Hex Driver 4 2 5 0 5 6 6 8 Table 2b Torque Specification Models A H Fastener Screw Size Tool Required Recommended Seating Torque ft lbf N m Motor Housing Gear Housing Back Frame Screws 1 4 20 Socket Head Cap Scre...

Page 12: ...ew 1 4 20 Socket Head Cap Screw 3 16 Hex Driver 5 0 5 8 6 8 7 9 Table 2d Torque Specification Model RRS Fastener Screw Size Tool Required Recommended Seating Torque ft lbf N m Main Frame Intermediate Frame Back Frame Screws 5 16 18 Socket Head Cap Screw 1 4 Hex Driver 14 2 15 0 19 2 20 3 3rd Pinion Nut 1 1 8 12 Hex Nut 1 11 16 6 or 12 Point Socket 85 0 90 0 115 2 122 0 Chain Chute Pin Set Screw To...

Page 13: ...y Make certain load chain is free from twists and binds 4 Place dead end link into dead end slot and insert pin Attach loose end link to frame of hoist using the provided screw Tighten all fasteners securely To attach the chain to the dead end block on Models E E 2 H H 2 R R 2 and RR 2 proceed as follows 1 Suspend the hoist from an adequate support 2 On Models E E 2 H and H 2 insert the last link ...

Page 14: ...e conversion board is located under back frame cover 1 for Models A H and under motor housing cover 2 for Models J RRT The voltage change board is color coded to indicate high and low voltage connections Connecting the 9 and 12 pin plugs into the Red voltage change board receptacles will connect the hoist for high voltage 380 3 50 415 3 50 or 460 3 60 To change the hoist voltage to low voltage 208...

Page 15: ...owing 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 circuit feeding the hoists Failure of the hoist to lift the load due to motor stalling Blowing of fuses or tripping of circuit breakers Failure to properly ground the hoist presents the danger of electric shock TO AVOID INJURY Permanently grou...

Page 16: ... the kit OPERATING INSTRUCTIONS GENERAL 1 The Load limiter is designed 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 immediately release the UP control to stop the operation of the hoist At this point the load should be reduced to the rated hoist ...

Page 17: ...vel effect of the hook which could result in twisted chain and a jammed lift wheel b The upper limit switch if so equipped is by passed and the load could hit the hoist c The chain could be damaged at the hook 5 Before lifting load check for twists in the load chain On double and triple reeved units a twist can occur if the lower hook block has been capsized between the strands of chain Reverse th...

Page 18: ...o prolong the useful life of the hoist and maintain its reliability and continued safe use The program should include the periodic and frequent inspections with particular attention being paid to the lubrication of the various components using the recommended lubricants see page 127 SUSPENSION INSPECTION CRITERIA BRACKETS Replace any bracelets found to be cracked or distorted BOLTS If the suspensi...

Page 19: ...brake parts and AC brake adjustment see page 22 g External evidence of pitting or any deterioration of contactor contacts Check the operation of the control station making sure the buttons operate freely and do not stick in either position h Inspect the electrical cords and cables and control station enclosure for damaged insulation i Inspect trolley trackwheels for external wear on tread and flan...

Page 20: ...A 2 AA AA 2 B B 2 C C 2 F F 2 E E 2 H and H 2 745 18 9mm 250 6 3mm J J 2 JJ J 2 L L 2 LL LL 2 R R 2 RR RR 2 RT RT 2 RRT and RRT 2 858 21 8mm 312 7 9mm RRS 1 18 30 0mm 394 10 0mm Figure 16 Gaging Load Chain Wear 4 Based upon ASME B30 16 2012 chain should also be checked for elongation Select an unworn un stretched length of the chain at the slack end for example Suspend the chain vertically under t...

Page 21: ... the lower hook thrust bearing are pre lubricated and require no lubrication The lower hook thrust bearing should be lubricated at least once a month CHAIN GUIDES LIFTWHEEL AND 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 Ref...

Page 22: ... and armature is 008 018 in 0 2 0 45 mm for models A through H and 008 020 in 0 2 0 5 mm for models J through RRT The DC brake is not adjustable As the friction material wears the brake gap increases If the maximum air gap is reached a new friction disc rotor should be installed Table 6a Limit Switches Model Hook Travel w 44 T P I Shaft Standard Hook Travel w 56 T P I Shaft Standard Hook Travel w ...

Page 23: ...SHOULD NOT BE REDUCED 6 Reconnect hoist to power supply 7 Run hook to the desired upper position cautiously operating the hoist without a load 8 Disconnect hoist from power supply 9 Moving one travel nut toward the other increases hook travel and away from the other decreases the travel Now turn the nut nearest the switch indicated as the UPPER LIMIT SWITCH until it just breaks the limit switch co...

Page 24: ...ks the limit switch contacts cautious not to allow the movement of the other travel nut if previously set An audible click will be heard as the switch opens Continue to rotate the nut toward the switch an additional one full tooth 10 Securely reposition the guide plate in the slot 11 Reconnect hoist to power supply and check the stopping point of hook by first raising the hook about 2 feet 61 cm t...

Page 25: ...defective part E Wrong voltage or frequency E Use the voltage and frequency indicated on hoist identification plate For three phase dual voltage unit make sure the connections at the voltage change board are the proper voltage as described on page 14 F Low Voltage F Correct low voltage condition as described on page 14 G Brake not releasing open or shorted coil winding armature binding G Check ele...

Page 26: ...cuit control station contacts not making lower limit switch contacts open A Check electrical continuity and repair or replace defective part Check operation of limit switch as described on page 15 16 B Motor reversing switch not operating single phase unit only B See items 2B and 3C 5 Hook lowers when hoisting control is operated A Phase failure three phase unit only A See item 1B B Phase reversal...

Page 27: ...the phase three phase unit only E See item 1B F Brake dragging F Check brake adjustment as described on page 22 G 115 1 60 Units Solid state reverse switch exposed to excessive temperature or the switch is damaged G See page 21 9 Hook fails to stop at either or both ends of travel A Limit switches not opening circuits A Check switch connections electrical continuity and mechanical operation Check ...

Page 28: ...ntacts not making or opening Replace speed selector repair connection replace contactor or control station C Phase Failure C See Item 1B 13 Hook will not raise at slow speed A Excessive load A See item 1H B Phase Failure B See Item 1B C Open Circuit C See item 11A D Brake not releasing D See Item 1G 14 Hook will not lower at slow speed A Phase Failure A See item 1B B Open Circuit B See item 11A C ...

Page 29: ...sition Table 8 Electrical Data for Hoist Components Transformer Voltage Leads D C RESISTANCE OHMS 230 460 to 115 X2 to X1 H2 to H1 H3 to H4 27 9 99 0 111 8 230 380 to 48 X2 to X1 H2 to H1 H3 to H4 5 2 99 0 112 6 220 415 to 24 X2 to X1 H2 to H1 H3 to H4 1 3 100 4 114 9 575 to 115 X2 to X1 H4 to H1 28 4 329 1 Models CONTACTOR OR SPEED SELECTOR COIL VOLTAGE NOMINAL CURRENT AMPS D C RESISTANCE OHMS A ...

Page 30: ...60 1 0 1 0 12 3 11 3 11 12 1 2 1 3 2 3 63 0 63 0 63 0 104 0 104 0 104 0 380 3 50 1 2 1 2 415 3 50 1 2 1 2 575 3 60 8 85 12 3 11 3 11 12 1 2 1 3 2 3 99 1 99 1 99 1 550 3 50 8 85 156 0 156 0 156 0 J L R RT 110 1 50 1 75 11 6 1 2 3 4 5 8 1 1 1 1 1 3 115 1 60 9 8 MOdels Volts Phase Hertz H P kW Full Load Current Amps Leads D C Resistance Ohms J L R RT 220 1 50 1 75 5 8 1 2 3 4 5 8 1 1 1 1 1 3 230 1 60...

Page 31: ...31 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 32: ...32 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 33: ...33 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 34: ...34 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 35: ...35 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 36: ...36 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 37: ...37 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 38: ...38 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 39: ...39 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 40: ...40 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 41: ...41 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 42: ...42 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 43: ...43 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 44: ...44 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 45: ...45 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 46: ...46 00001996 REV AC 627NH October 2014 REFERENCE WIRING DIAGRAMS ...

Page 47: ...ck each end of the hole in the lower hook chain block and determine which end is the largest Place the chain in the slot of the chain block and insert the chain block with the large hole on top into the hook block body Align the holes in the hook block body with the hole in the chain block and insert the small end of the pin in the hole Push the pin in by hand until it stops and then use a hammer ...

Page 48: ...ow entire length of lift check with CM for modification if necessary l For triple reeved models run the hoist UP until only 4 feet 1 2 m of chain remains on the dead end side This will minimize the chance of introducing a twist between the hook block and hoist Allow the chain to hang free to remove twists Using a wire as a starter insert the chain upstanding link first into lower hook block upstan...

Page 49: ...ed capacity by or under the direction of an appointed person and written report prepared for record purposes After this test check that the Load limiter functions If Load limiter prevents lifting of a load of 125 of rated capacity reduce load to rated capacity and continue test NOTE For additional information on inspection and testing refer to Code B30 16 Overhead Hoists obtainable from ASME Order...

Page 50: ... MODELS A A 2 AA AA 2 B B 2 C C 2 E E 2 F F 2 H H 2 63 65 62 35 66 7 64 37 39 6 30 40 33 40 1 15 4 5 2 1 19 18 34 10 43 14 36 12 13 38 31 34 42 16 41 49 46 47 45 44 50 51 52 53 55 54 57 14a 14c 61 48 14b A 27 DETAIL A 22 28 20 25 26 21 27 ...

Page 51: ...00000464 00000464 00000464 00000464 00000464 00000464 STATOR 575V 2 SPEED 00000470 N A 00000470 00000470 00000470 00000470 5 STATOR PIN 983541 1 6 MOTOR COVER GASKET 27847 1 7 ROTOR ASSEMBLY 50HZ 1Ø 00000261 00000261 00000261 00000261 00000261 00000261 1 ROTOR ASSEMBLY 60HZ 1Ø 00000265 00000261 00000265 00000261 00000265 00000261 ROTOR ASSEMBLY 3Ø 00000264 00000260 00000264 00000260 00000264 00000...

Page 52: ...V SECONDARY 00000586T 1 TRANSFORMER 48V SECONDARY 00000587T TRANSFORMER 120V SECONDARY 00000588T 38 LOCK WASHER 982226 2 39 TRANSFORMER MOUNTING SCREW 982688 2 40 UPPER SUSPENSION ASSEMBLY SEE SUSPENSION SECTION 1 40 1 SUSPENSION BOLT 987554 2 41 HARNESS 110 115V 1 50 60 110 115V CON TROL 00001516 1 HARNESS 110 115V 1 50 60 24 48V CONTROL 00001517 HARNESS 220 230V 1 50 60 00001522 HARNESS 220 230 ...

Page 53: ... 52 LOCK WASHER 982226 1 53 LOOSE END SCREW 927764 1 54 LOWER HOOK BLOCK ASSEMBLY SEE LOWER HOOK BLOCK SECTION 1 55 CHAIN STOP KIT 24015K 1 56 EMPTY 57 LOAD CHAIN 85944 ZINC PLATED AS REQ D 85889 BURNISHED AND OILED 85965 ZINC PHOSPHATE PLATED 85915 NICKEL PLATED 85952 STAINLESS STEEL FOR USE IN CLEAN ROOM HOIST ONLY 58 60 EMPTY 61 ELECTRICAL WARNING LABEL 24842 2 62 ROHS LABEL 00000782 1 63 ELECT...

Page 54: ...8 31 30 11 14 10 3 2 36 40 1 40 1 32 16 14c 31 1 34 35 35 34 9 15 6 18 49 48 47 46 45 44 41 58 59 60 69 50 51 53 52 56 14a 61 63 65 66 64 43 33 62 57 31 4 14b 28 24 27 20 21 23 24 32 29 26 DETAIL A 27 25 MODELS J J 2 JJ JJ 2 L L 2 LL LL 2 R R 2 RR RR 2 RT RT 2 RRT RRT 2 ...

Page 55: ...2226 4 9 MOTOR MOUNTING SCREW 1Ø 87377 4 MOTOR MOUNTING SCREW 230 460V 3 60 OR 575V 3 60 87377 87336 87377 87336 87377 87336 87377 87336 MOTOR MOUNTING SCREW 2 SPEED 87336 10 CONTACTOR PLATE ASSEMBLY SEE SEE CONTACTOR PLATE SECTION 1 11 CONTACTOR PLATE MOUNTING SCREW 983656 3 12 EMPTY 13 EMPTY 14 BRAKE ASSEMBLY SEE BRAKE SECTION 1 14a BRAKE HUB SPACER SEE BRAKE SECTION 0 2 14b BRAKE HUB SEE BRAKE ...

Page 56: ...CREW RETAINER 00001747 6 36 BACK FRAME COVER SCREW 968752 4 37 39 EMPTY 40 UPPER SUSPENSION ASSEMBLY SEE SUSPENSION SECTION 1 40 1 SUSPENSION BOLT 36849 2 41 HARNESS 110 115V 1 50 60 110 115V CONTROL 00001530 1 HARNESS 110 115V 1 50 60 24 48V CONTROL 00001523 HARNESS 220 230V 1 50 60 00001523 HARNESS 220 230 380 415 460V 3 50 60 00001531 HARNESS 550 575V 3 50 60 00001534 HARNESS 220 230V 1 50 60 2...

Page 57: ... 57 LOAD CHAIN 85949 ZINC PLATED AS REQ D 85979 BURNISHED AND OILED 85966 ZINC PHOSPHATE PLATED 85916 NICKEL PLATED 58 SOLID STATE REVERSE SWITCH 35499 1 59 SOLID STATE REVERSE SWITCH MTG CLAMP 27275 1 60 SOLID STATE REVERSE SWITCH MTG CLAMP SCREW 982873 1 61 ELECTRICAL WARNING LABEL 24842 2 62 ROHS LABEL 00000782 1 63 ELECTRICAL INFORMATION LABEL 24846 1 64 BILINGUAL WARNING LABEL 27248 1 65 MANU...

Page 58: ...96 REV AC 627NH October 2014 MODEL RRS 53 36 34 9 16 45 33 44 35 30 41 10 11 3 6 38 40 39 2 1 51 52 47 46 55 54 57 32 14a 14b 8 15 14 18 31 35 37 34 14c A 20 32 49 50 49 50 21 DETAIL A 23 24 28 27 25 26 29 24 23 ...

Page 59: ...ACKET S A 36827 1 26 LIMIT SWITCH BRACKET SCREWS 983656 2 27 LIMIT SWITCH GUIDE PLATE 28714 1 28 LIMIT SWITCH GUIDE PLATE MOUNTING SCREWS 983614 2 29 TERMINAL STRIP S A 230 460V 3ø 00001734 1 TERMINAL STRIP S A 575V 3ø 00001735 30 MOTOR COVER 36025C 1 31 BACK FRAME COVER 36008C 1 32 BACK FRAME COVER PINS 983784 4 33 MOTOR COVER SCREW 987553 2 34 WASHER 982251 6 35 SCREW RETAINER 00001747 6 36 BACK...

Page 60: ...C 627NH October 2014 MODELS A A 2 AA AA 2 B B 2 C C 2 E E 2 F F 2 H H 2 1 19 1 3 1 22 1 14 1 23 1 12 1 10 1 4 1 11 1 1 1 2 1 2 1 4 1 7 1 6 1 9 1 5 1 9 1 20 1 21 1 24 1 15 1 16 1 4 1 4 1 18 1 25 1 13 1 12 ASSEMBLED VIEW ...

Page 61: ...GEAR HOUSING SUB ASSY 00000503C 00000503C 00000502C 00000503C 00000502C 1 CLEAN ROOM GEAR HOUSING SUB ASSY 00000503W 00000503W 00000502W 00000503W 00000502W 1 12 LOCK WASHER 940802 7 1 13 GEAR HOUSING SCREW 28830 4 1 14 LIFTWHEEL GEAR 00000160 45TEETH 00000159 36TEETH 00000161 59TEETH 00000160 45TEETH 00000161 59TEETH 1 1 15 LOCK WASHER 00000199 1 1 16 LIFTWHEEL NUT 00000198 1 1 17 EMPTY 1 18 GEAR...

Page 62: ...7NH October 2014 J J 2 JJ JJ 2 L L 2 LL LL 2 R R 2 RR RR 2 RT RT 2 RRT RRT 2 1 9 1 10 1 1 1 2 1 3 1 2 1 4 1 4 1 5 1 6 1 7 1 13 1 9 1 11 1 15 1 16 1 4 1 19 1 4 1 18 1 21 1 20 1 14 1 22 1 23 1 12 1 25 1 24 1 12 ASSEMBLED VIEW ...

Page 63: ...000507C 00000508C 00000507C 00000512C 00000512C 1 1 12 LOCK WASHER 940830 8 1 13 GEAR HOUSING SCREW 982682 8 1 14 LIFEWHEEL GEAR 00000163 66 TEETH 00000162 42 TEETH 00000163 66 TEETH 00000163 66 TEETH 00000163 66 TEETH 1 1 15 LOCK WASHER 986276 1 1 16 LIFTWHEEL NUT 35773 1 1 17 ALIGNMENT BUSHING 35768 2 1 18 GEAR HOUSING GASKET 00000192 1 1 19 INTERMEDIATE SHAFT SUB ASSY 00000146 47 TEETH 8 TEETH ...

Page 64: ... 00001996 REV AC 627NH October 2014 RRS GEARBOX 1 2 1 10 1 6 1 13 1 7 1 15 1 23 1 25 INNER RACE 1 24 1 6 1 1 1 3 1 4 1 5 1 12 1 10 1 11 1 14 1 9 1 16 1 17 1 21 1 22 1 19 1 20 1 18 1 17 1 8 ASSEMBLED VIEW ...

Page 65: ...NG EXTERNAL 10001107 1 1 9 SPRING PIN 983784 4 1 1 GASKET GEAR HOUSING V2 00000192 2 1 11 INT FRAME SUB ASSY ORANGE 10001009C 1 1 12 SCREW 982682 5 1 13 GEAR 42 TEETH 00000162 1 1 14 WASHER LOCK EXT TOOTH 986276 1 1 15 NUT 35773 1 1 16 SHAFT SUB ASSY 10T 92T 10001011 1 1 17 DOWEL BACK FRAME 35768 2 1 18 DRIVE SHAFT 10T 10001012 1 1 19 V2 BACK FRAME S A ORANGE 00000510C 1 1 20 SCREW 80409 4 1 21 LO...

Page 66: ... 1 6 1 2 1 1 4 1 2 1 11 1 1 1 11 1 6 1 5 1 10 1 9 1 7 1 8 1 3 1 2 1 1 15 1 14 1 11 1 2 1 13 1 12 1 17 3 2 6 2 5 2 4 2 2 2 3 2 1 2 8 1 1 2 9 2 10 1 4 1 5 2 1 16 1 2 7 1 9 1 10 1 2 1 6 1 11 1 11 1 4 1 5 1 8 1 7 1 1 SWIVEL HOOK ASSEMBLY RIGID HOOK ASSEMBLY TRIPLE REEVED LUG ASSEMBLY UPPER SUSPENSIONS LUG ASSEMBLY ...

Page 67: ...1 2 1 LATCH KIT 45661 45661 45662 45663 45663 1 3 THRUST WASHER FOR SWIVEL SUSPENSIONS ONLY 27786 45930 45930 45918 1 1 4 UPPER HOOK COLLAR FOR SWIVEL SUSPENSIONS 27350 45385 35042 35041 36352 1 UPPER HOOK COLLAR FOR RIGID HOOK AND LUG SUSPENSIONS 27372 27373 35458 35426 36360 1 5 SPRING PIN 27805 45941 983764 983762 983762 1 1 6 DEAD END BOLT 89508 35957 1 1 7 DEAD END BLOCK 27397 35418 1 1 8 DEA...

Page 68: ...NH October 2014 UPPER SUSPENSIONS MODEL RRS 1 1 1 2 1 1 2 1 5 1 4 1 3 SWIVEL HOOK ASSEMBLY 1 2 1 4 1 5 1 1 LUG ASSEMBLY 1 1 1 4 1 5 1 2 1 1 2 RIGID HOOK ASSEMBLY 1 32 1 31 1 2 1 1 1 4 1 5 1 30 UNIVERSAL TROLLEY LUG ASSEMBLY ...

Page 69: ...UNIVERSAL TROLLEY CROSS MOUNT 10001104X 1 1 SUSPENSION ADAPTER 10001050B 1 1 2 UPPER HOOK SUB ASSEMBLY LATCH TYPE 35616B 1 UPPER HOOK SUB ASSEMBLY LATCHLOK TYPE 36680 SUSPENSION LUG FOR LOW HEADROOM OR MOTOR DRIVEN TROLLEY 35457 SUSPENSION LUG FOR UNIVERSAL TROLLEY 00002508 1 2 1 LATCH KIT 45663 1 1 3 THRUST WASHER FOR SWIVEL SUSPENSIONS ONLY 35426 1 1 4 UPPER HOOK COLLAR FOR SWIVEL SUSPENSIONS 35...

Page 70: ...g Part Number 1 UT 1 TON SUSPENSION KIT PARALLEL MOUNT ONLY 1 2292NHUT 2 UT 1 TON SUSPENSION KIT CROSS MOUNT ONLY 1 2292NHUTC 3 UT 1 TON SUSPENSION KIT CROSS OR PARALLEL 2 29923NHUT 4 UT 2 TON SUSPENSION KIT CROSS OR PARALLEL 1 3677NHUT 5 UT 2 TON SUSPENSION KIT CROSS OR PARALLEL 2 3668NHUT 6 UT 3 TON SUSPENSION KIT CROSS OR PARALLEL 3 9561NHUT ...

Page 71: ...K WITH LATCH 28686 35611 35612B 1 LATCHLOK TYPE HOOK 28604 28604 36681 1 1 1 LATCH KIT 45661 45662 45663 1 1 2 LOWER HOOK BODY 45401B 35370 45399B 1 1 3 LOWER HOOK WASHER 945921 945921 N A 1 1 4 LOWER HOOK THRUST BEARING 88485 88485 88505 1 1 5 LOWER HOOK NUT 982526 982526 35369 1 1 6 LOWER HOOK NUT PIN 983772 983772 45946 1 1 7 LOWER HOOK CHAIN BLOCK 28007 35026 10001054 1 1 8 LOWER HOOK CHAIN BL...

Page 72: ...35369 1 1 1 4 LOWER HOOK NUT 36352 1 1 1 5 LOWER HOOK PIN 45941 45946 983762 1 1 2 HOOK BLOCK ORDER IN PAIRS 00000271B 00000276B 36010B 2 1 3 HOOK BLOCK SHEAVE 00000273 00000274 36351 1 1 4 HOOK BLOCK SHEAVE BEARING 88429 83674 83670 2 1 5 HOOK BLOCK SCREW LONG 982066 982374 2 1 6 HOOK BLOCK SCREW SHORT 986191 982370 1 1 7 HOOK BLOCK LOCK WASHER 940802 940830 3 1 8 HOOK BLOCK NUT 982514 982445 3 1...

Page 73: ...0 205VDC 10001245 550 575 3 50 60 255VDC ITEM NO PART NUMBER DESCRIPTION QTY 1 SEE TABLE V1 LODESTAR SIZE 8 1 1 1 10001252 V1 LODESTAR SIZE 8 ROTOR 1 1 2 10001251 V1 LODESTAR SIZE 8 FRICTION PLATE 1 2 00001430 V1 LODESTAR SIZE 8 HUB 1 3 00001432 HUB SPACER V1 DC BRAKE 1 4 982708 SCREW 1 4 20 X 75 SL FIL HD 2 5 940802 LOCK WASHER 1 4 x 109 X 062 2 6 10409710 ROTOR CLIP RETAINING RING 1 1 1 3 1 1 2 ...

Page 74: ...5 3 50 60 255VDC JJ JJ 2 LL LL 2 RR RR 2 RRS RRT RRT 2 10001249 00001429 220 230 3 50 60 380 415 480 3 50 60 205VDC 10001250 00001429 550 575 3 50 60 255VDC ITEM NO PART NUMBER DESCRIPTION QTY 1 SEE TABLE V2 LODESTAR SIZE 10 BRAKE 1 1 1 10001253 V2 LODESTAR SIZE 10 ROTOR 1 1 2 00001437 V2 LODESTAR FRICTION PLATE 1 2 00001433 HUB SPACER V2 DC INTORQ BRAKE 1 3 00001431 V2 LODESTAR SIZE 10 HUB 1 4 98...

Page 75: ... AND CONTROL CORD FOR 15 FOOT LIFT 23606616 STATION ASSEMBLY AND CONTROL CORD FOR 20 FOOT LIFT 1 1 58272 2 BUTTON CONTROL STATION 1 1 1 1 58278 GROMMET 1 1 1 2 58275 HARDWARE KIT 1 1 1 3 58255 1 SPEED INSERT 1 1 1 4 58276 WARNING LABEL KIT 1 1 1 5 58277 BUTTON LABEL KIT 1 1 2 29353 CONTROL CORD 10 FOOT LIFT 1 29353 15 CONTROL CORD 15 FOOT LIFT 29353 20 CONTROL CORD 20 FOOT LIFT 1 1 4 1 1 3 1 1 2 1...

Page 76: ...D CONTROL CORD FOR 15 FOOT LIFT 29348 20 STATION ASSEMBLY AND CONTROL CORD FOR 20 FOOT LIFT 1 1 58273 2 BUTTON CONTROL STATION 1 1 1 1 58278 GROMMET 1 1 1 2 58275 HARDWARE KIT 1 1 1 3 58256 2 SPEED INSERT 1 1 1 4 58276 WARNING LABEL KIT 1 1 1 5 58277 BUTTON LABEL KIT 1 1 2 29349 CONTROL CORD 10 FOOT LIFT 1 29349 15 CONTROL CORD 15 FOOT LIFT 29349 20 CONTROL CORD 20 FOOT LIFT 1 1 4 1 1 4 1 1 2 1 1 ...

Page 77: ...CARTRIDGE 1 1 9 00000393 FUSE 5MM X 20MM 500MA 1 1 10 27716 CAPACITOR 1 1 11 29910 CAPACITOR CAP 1 1 12 27910 CAPACITOR MOUNTING BRACKET 2 1 13 982696 SCREW 10 32 UNF 2A X 3 8 LG 4 1 14 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 15 27189 JUMPER G Y 16 AWG 1 1 16 20940 GROUND LABEL 1 1 17 27925 SOLID STATE SWITCH CAP 1 1 18 27257 REVERSE SWITCH 1 1 19 51845 JUMPER 2 1 20 27156 JUMPER R14 1 1 21 29911 JUM...

Page 78: ...DGE 1 1 9 00000393 FUSE 5MM X 20MM 500MA 1 1 10 27716 CAPACITOR 1 1 11 29910 CAPACITOR CAP 1 1 12 27910 CAPACITOR MOUNTING BRACKET 2 1 13 982696 SCREW 10 32 UNF 2A X 3 8 LG 4 1 14 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 15 27189 JUMPER G Y 16 AWG 1 1 16 20940 GROUND LABEL 1 1 17 27925 SOLID STATE SWITCH CAP 1 1 18 27257 REVERSE SWITCH 1 1 19 51847 JUMPER 8 1 20 51845 JUMPER 2 1 21 27156 JUMPER R14 1 ...

Page 79: ...CARTRIDGE 1 1 6 10001233 VOLTAGE CHANGE BOARD 1 1 8 987862 SCREW 8 32UNC 2A X 1 1 1 9 982686 SCREW 10 32 UNF 2A X 3 8 SL 2 1 10 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 11 957854 SCREW 6 32 NC 2 X 5 8 ROUND 1 1 12 987873 LOCK WASHER 10 ASA MEDIUM 2 1 13 51847 Jumper 14 AWG Black 5 1 14 20940 GROUND LABEL 1 1 15 00000393 FUSE 5MM X 20MM 500MA 1 1 16 31633 CONTACTOR PLATE 1 1 17 27189 JUMPER G Y 16 AWG ...

Page 80: ...0000393 FUSE 5MM X 20MM 500MA 1 1 10 27189 JUMPER G Y 16 AWG 1 1 11 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 12 20940 GROUND LABEL 1 1 13 51847 JUMPER 6 1 14 00001503 JUMPER B2 1 1 15 SEE TABLE CONTACTOR 1 1 16 51845 JUMPER 1 1 17 27609 JUMPER 1 1 18 27610 JUMPER 1 1 19 SEE TABLE REVERSING CONTACTOR 1 1 20 00001502 JUMPER B1 1 1 21 00001506 TERMINAL STRIP 2 1 22 70246 RECTIFIER 1 1 23 70274 RECTIFIER ...

Page 81: ...SCREW 10 32 UNF 2A X 3 8 SL 2 1 9 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 10 51847 JUMPER 5 1 11 20940 GROUND LABEL 1 1 12 27189 JUMPER G Y 16 AWG 1 1 13 00001502 JUMPER B1 1 1 14 00001503 JUMPER B2 1 1 15 29019 TERMINAL STRIP CARTRIDGE 1 1 16 00000393 FUSE 5MM X 20MM 500MA 1 1 17 00001551 RECTIFIER 1 1 18 957854 ROUND HEAD MACHINE SCREW 1 1 19 00001506 TERMINAL STRIP 2 1 20 00001507 TERMINAL STRIP P...

Page 82: ...1 1 16 29035 JUMPER R4 1 1 17 00000758 JUMPER V2 1 PHASE R9 1 1 18 29036 JUMPER R2 1 1 19 29037 JUMPER R3 1 1 20 00000755 JUMPER V2 1 PHASE R7 1 1 21 00000757 JUMPER V2 1 PHASE R6 1 1 22 70274 RECTIFIER INSULATOR 1 1 23 70246 RECTIFIER 1 1 24 957854 ROUND HEAD MACHINE SCREW 1 1 25 982470 HEX HEAD MACHINE NUT 1 1 26 29014 TERMINAL STRIP 3 1 27 29047 TERMINAL STRIP BRIDGE 1 1 28 00000535 SURGE SUPPR...

Page 83: ...93 FUSE 5MM X 20MM 500MA 1 1 11 29014 TERMINAL STRIP 6 1 12 29047 TERMINAL STRIP BRIDGE 2 1 13 35279 START CAPACITOR 1 1 14 35278 CAPACITOR RUN 1 1 15 35268 CLAMP 2 1 16 982873 MACHINE SCREW PAN HEAD 6 1 17 35285 RUN CAPACITOR INSULATOR 1 1 18 SEE TABLE TRANSFORMER V2 110 115 PRIMARY 1 1 19 25861 SCREW 1 4 20 UNC 2A X 3 8 HEX 2 1 20 20940 GROUND LABEL 1 1 21 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 22...

Page 84: ... 1 1 10 00000393 FUSE 5MM X 20MM 500MA 1 1 11 29014 TERMINAL STRIP 7 1 12 29047 TERMINAL STRIP BRIDGE 3 1 13 35279 START CAPACITOR 1 1 14 35278 CAPACITOR RUN 1 1 15 35268 CLAMP 2 1 16 987873 LOCK WASHER 10 ASA MEDIUM 2 1 17 35285 RUN CAPACITOR INSULATOR 1 1 18 SEE TABLE TRANSFORMER V2 230 460 PRIMARY 1 1 19 25861 SCREW 1 4 20 UNC 2A X 3 8 HEX 2 1 20 20940 GROUND LABEL 1 1 21 987827 SCREW 1 4 20 UN...

Page 85: ...TRIP COVER SEGMENT 1 1 8 29019 FUSIBLE TERMINAL STRIP 1 1 9 SEE TABLE REVERSING CONTACTOR 1 1 10 27672 VOLTAGE CHANGE BOARD 1 1 12 987862 SCREW 8 32UNC 2A X 1 1 1 13 20940 GROUND LABEL 1 1 14 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 15 987873 LOCK WASHER 10 ASA MEDIUM 2 1 16 51847 JUMPER 1 1 17 00000393 FUSE 5MM X 20MM 500MA 1 1 18 982686 SCREW 10 32 UNF 2A X 3 8 SL 2 1 19 27189 JUMPER G Y 16 AWG 1 1 ...

Page 86: ...USIBLE TERMINAL STRIP 1 1 9 29019 TERMINAL STRIP CARTRIDGE 1 1 10 00000393 FUSE 5MM X 20MM 500MA 1 1 12 27189 JUMPER G Y 16 AWG 1 1 13 20940 GROUND LABEL JUMPER G Y 16 AWG 1 1 14 51847 JUMPER 3 1 15 SEE TABLE TRANSFORMER V2 575V PRIMARY 1 1 16 25861 SCREW 1 4 20 UNC 2A X 3 8 HEX 2 1 17 29014 TERMINAL STRIP 2 1 18 00001505 SURGE SUPPRESSOR 1 1 19 00001551 RECTIFIER 1 1 20 957854 ROUND HEAD MACHINE ...

Page 87: ...TERMINAL STRIP COVER SEGMENT 1 1 8 29018 FUSIBLE TERMINAL STRIP 1 1 9 29019 TERMINAL STRIP CARTRIDGE 1 1 10 00000393 FUSE 5MM X 20MM 500MA 1 1 11 29047 TERMINAL STRIP BRIDGE 2 1 12 SEE TABLE CONTACTOR 1 1 13 SEE TABLE TRANSFORMER V2 230 460 1 1 14 25861 SCREW 1 4 20 UNC 2A X 3 8 HEX 2 1 15 987827 W 1 4 20 UNC 2A X 1 2 1 1 16 20940 GROUND LABEL 1 1 17 51847 JUMPER 3 1 18 27652 JUMPER R4 1 1 19 2765...

Page 88: ...3 TERMINAL STRIP END CLAMP 4 1 7 00000398 TERMINAL STRIP COVER SEGMENT 1 1 8 29018 FUSIBLE TERMINAL STRIP 1 1 9 29019 TERMINAL STRIP CARTRIDGE 1 1 10 00000393 FUSE 5MM X 20MM 500MA 1 1 11 SEE TABLE TRANSFORMER V2 230 460 1 1 12 25861 SCREW 1 4 20 UNC 2A X 3 8 HEX 2 1 13 20940 GROUND LABEL 1 1 14 51847 JUMPER 3 1 15 27652 JUMPER W5 1 1 16 27657 JUMPER R4 1 1 17 27736 JUMPER R5 1 1 18 SEE TABLE REVE...

Page 89: ...M 3 1 6 909J13 TERMINAL STRIP END CLAMP 4 1 7 00000398 TERMINAL STRIP COVER SEGMENT 1 1 8 29019 TERMINAL STRIP CARTRIDGE 1 1 9 00000393 FUSE 5MM X 20MM 500MA 1 1 10 29018 FUSIBLE TERMINAL STRIP 1 1 11 SEE TABLE CONTACTOR 1 1 12 SEE TABLE TRANSFORMER V2 230 460 1 1 13 25861 SCREW 1 4 20 UNC 2A X 3 8 HEX 2 1 14 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 15 20940 GROUND LABEL 1 1 16 51847 JUMPER 3 1 17 276...

Page 90: ...AL STRIP CARTRIDGE 1 1 9 SEE TABLE REVERSING CONTACTOR 1 1 10 957844 LOCK WASHER 1 1 11 10001233 VOLTAGE CHANGE BOARD 1 1 12 987862 SCREW 8 32UNC 2A X 1 1 1 13 987873 LOCK WASHER 10 ASA MEDIUM 2 1 14 982686 SCREW 10 32 UNF 2A X 3 8 SL 2 1 15 51847 JUMPER 1 1 16 20940 GROUND LABEL 1 1 17 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 18 00000393 FUSE 5MM X 20MM 500MA 1 1 19 00001733 HARNESS V2 CONTACTOR 1 1 ...

Page 91: ...9 29019 TERMINAL STRIP CARTRIDGE 1 1 10 00000393 FUSE 5MM X 20MM 500MA 1 1 11 987827 SCREW 1 4 20 UNC 2A X 1 2 1 1 12 982226 LOCK WASHER 1 4 X 109 X 062 1 1 13 27189 JUMPER G Y 16 AWG 1 1 14 20940 GROUND LABEL 1 1 15 51847 JUMPER 3 1 16 SEE TABLE TRANSFORMER V2 575V PRIMARY 1 1 17 25861 SCREW 1 4 20 UNC 2A X 3 8 HEX 2 1 18 29014 TERMINAL STRIP 2 1 19 00001505 SURGE SUPPRESSOR 1 1 20 00001551 RECTI...

Page 92: ...40 50 70 60 90 30 45 20 30 48 2458 3818PNH ITEM NO PART NUMBER DESCRIPTION QTY 1 CHAIN CONTAINER BUCKET BAG 1 24650 CHAIN CONTAINER KIT 5 DIAMETER CONSIST OF THE BELOW ITEMS 1 2 UPPER BRACKET 1 3 LOWER BRACKET 1 4 PIN CLEVIS 1 5 COTTER PIN 1 16 X 3 4 LG 1 6 ADAPTER V2 FOR MODELS J THRU RRT 2 1 7 SCREW HEAD RETAINER 1 8A HHCS 5 16 18 UNC 2A X 1 USE ONLY ON HOIST WITH SERIAL BEGINNING WITH NL MODELS...

Page 93: ...ONTAINER BUCKET LENGTH VS LIFT Lift in Feet Canvas Container Kit 30 10001563 55 10001564 80 10001565 105 10001566 130 10001567 Item Description Metal Kit Part Qty Canvas Kit Part Qty 1 CHAIN CONTAINER BRACKET SEE TABLE FOR PART NUMBER BASED ON LIFT 1 SEE TABLE FOR PART NUMBER BASED ON LIFT 1 2 WASHER 2 2 3 SOCHET HEAD CAP SCREW 2 2 4 QUICK LINK 2 2 5 CHAIN CONTAINER 1 1 6 CHAIN CONTAINER RAMP 1 7 ...

Page 94: ...labels identification labels etc that may be coated during painting RECOMMENDED SPARE PARTS To insure continued service of the Lodestar 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 of failed Part Description Models A H Models J RRT Model RRS Qty Required for Each Hoist Limit Switch Kit 31631 31636 excludes RRS 31636 1 S...

Page 95: ...95 00001996 REV AC 627NH October 2014 NOTES ...

Page 96: ...RPOSE IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD PARTY WITH RESPECT TO ANY GOOD WHETHER IN CONTRACT TORT OR OTHER THEORY OF LAW FOR LOSS OF PROFITS OR LOSS OF USE OR FOR ANY INCIDENTAL CONSEQUENTIAL SPECIAL DIRECT OR INDIRECT DAMAGES HOWSOEVER CAUSED B Upon Buyer s submission of a claim as provided above and its substantiation Seller shall at its option either i repair or replace its...

Page 97: ...hat 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 operator Failure to operate equipment as directed in manual may cause injury Electric Chain HOIST Variable F...

Page 98: ...s 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...

Page 99: ...the Electromotive adjustable frequency drives are to be connected to 220 volt 3 phase 50 hertz 208 240 volt 3 phase 60 hertz 380 415 volt 3 phase 50 hertz or 440 480 volt 3 phase 60 hertz power supply Before connecting the hoist to the power supply check that the power to be used agrees with that shown on the hoist identification plate Hoists with drives are not dual voltage The hoist should be co...

Page 100: ...the button to the intermediate position for second speed operation and fully depress the button for fast speed operation The hoist speed gradually increases to the next speed point d 2 step infinitely variable control Partially depress the up or down push button and the speed of the hoist will gradually increase to the slow speed point Fully depress the button and the speed of the hoist will gradu...

Page 101: ...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 13 Never operate the hoist when flammable materials or vapors are present Electrical devices produce arcs or sparks that can cause a fire or explosion 14 STAY ALERT Watch what you are doing and use common sense Do not us...

Page 102: ...6 P N 10001609 REV AB 627NH December 2014 WIRING DIAGRAM LODESTAR MODELS A H 380 480 VOLT 3 PHASE WITH VARIABLE SPEED DRIVE ...

Page 103: ...7 P N 10001609 REV AB 627NH December 2014 WIRING DIAGRAM LODESTAR MODELS A H 208 230 VOLT 3 PHASE WITH VARIABLE SPEED DRIVE ...

Page 104: ...8 P N 10001609 REV AB 627NH December 2014 WIRING DIAGRAM LODESTAR MODELS J THRU RRT 440 480 VOLT 3 PHASE WITH VARIABLE SPEED DRIVE ...

Page 105: ...9 P N 10001609 REV AB 627NH December 2014 WIRING DIAGRAM LODESTAR MODELS J THRU RRT 208 230 VOLT 3 PHASE WITH VARIABLE SPEED DRIVE ...

Page 106: ...1 460V VFD WIRING HARNESS 1 NOT SHOWN 10001109 THERMAL CONDUCTIVE PASTE AS REQ D V1 CONTACTOR PLATE ASSEMBLIES ITEM NO PART NUMBER DESCRIPTION QTY 1 28968 AFD BRACKET 1 2 38953 VFD G MINI 1 2 HP 1 38954 VFD 3 4HP 460V 1 3 70246 RECTIFIER 1 4 70274 INSULATOR RECTIFIER 1 5 28969 BRAKE RELAY BRACKET 1 6 35928 MAINLINE CONTACTOR 1 7 957854 SCREW 6 32 NC 2 X 5 8 ROUND 3 8 987378 SCREW 8 32 UNC 2A X 1 2...

Page 107: ...NOT SHOWN 00001556 WIRING HARNESS V2 CE 1 NOT SHOWN 10001109 THERMAL CONDUCTIVE PASTE AS REQ D V2 AND RRS CONTACTOR PLATE ASSEMBLIES ITEM NO PART NUMBER DESCRIPTION QTY 1 10001056 RRS VFD CONTROLS BRACKET 1 00000339 V2 VFD CONTROLS BRACKET 1 2 38955 VFD 1HP 230V 1 38956 VFD 1HP 406V 1 38957 VFD 2HP230V 1 38992 VFD 5HP 460V 1 3 35928 BRAKE CONTACTOR 1 4 00000535 SURGE SUPPRESSOR 230V 2 00001505 SUR...

Page 108: ...8731 GROMMET BUNA N 9307K38 1 7 87325 SCREW 1 4 20 X 6 5 SL FIL HD 3 8 982251 WASHER 252 ID X 19 WALL 3 ITEM NO PART NUMBER DESCRIPTION QTY 1 R E V O C 5 2 0 7 2 1 2 28958 DYNAMIC BRAKING RESISTOR 250 OHM 1 28959 DYNAMIC BRAKING RESISTOR 500 OHM 1 3 982537 SLOTTED ROUND HEAD SCREW 8 32 2 2 R E H S A W K C O L 4 4 8 7 5 9 4 5 982472 NUT 8 32 UNC 2B 11 32 X 1 8 2 6 28731 GROMMET BUNA N 9307K38 1 7 8...

Page 109: ...4NH WARNING LABEL 2 10 982472 NUT 8 32 UNC 2B 11 32 X 1 8 2 11 957844 LOCKWASHER 2 ITEM NO PART NUMBER DESCRIPTION QTY 1 35262 CVR BACK FRAME MOD J THRU RRT 1 2 968752 SCREW BRAKE COVER 4 3 982251 WASHER 252 ID X 19 WALL 4 4 28731 GROMMET 1 4ID X 3 16 PANEL THK 1 4 G U L P E L O H 4 7 5 0 0 0 0 0 5 6 28960 DYNAMIC BRAKING RESISTOR 150 OHMS 1 28961 DYNAMIC BRAKING RESISTOR 250 OHMS 1 7 982537 SLOTT...

Page 110: ...MBLY AND CONTROL CORD FOR 15 FOOT LIFT 28081 STATION ASSEMBLY AND CONTROL CORD FOR 20 FOOT LIFT 1 1 58296 2 BUTTON CONTROL STATION 1 1 1 1 58278 GROMMET 1 1 1 2 58275 HARDWARE KIT 1 1 1 3 57803 1 SPEED INSERT 1 1 1 4 58276 WARNING LABEL KIT 1 1 1 5 58277 BUTTON LABEL KIT 1 1 2 28076 CONTROL CORD 10 FOOT LIFT 1 28077 CONTROL CORD 15 FOOT LIFT 28078 CONTROL CORD 20 FOOT LIFT 1 1 4 1 1 3 1 1 2 1 1 1 ...

Page 111: ...e the drive s application is entered into the drive by using the functional LEDs This information is stored into the drive s memory Keypad Functions The keypad has a 5 digit LED display Both numeric and alpha numeric data can appear on the display Indicators and keys on the keypad are described below Note The STOP key is always active and will cause any run command to come to an immediate stop ...

Page 112: ...g digit of a parameter setting 6 Down Arrow Key Scrolls down to select next parameter group or parameter settings It also decreases the value of the blinking digit of a parameter setting 7 STOP Ley Stops the drive by initiating a base block STOP command Note Stop priority circuit 8 ENTER Key Selects modes or parameters Displays each parameter s set value By pressing this key again the set value is...

Page 113: ...ganized by function group that determine how the drive functions These parameters are programmed in the drive s software as measurable values or options both of which will be referred to in this manual as settings While some of these parameters are associated with one setting others are tied to a number of possible settings The IMPULSE G Mini is configured for a specific hoist or trolley If you fi...

Page 114: ...Monitor parameters These are monitor only functions the operator cannot change the displayed value Accessible during run command See pages 18 thru 21 for complete listing of all monitor parameters Parameter Programming Selects or reads data using parameter settings Data is displayed by pressing the ENTER key and can be changed by pressing the up arrow or down arrow keys Any changes can be saved by...

Page 115: ...4 Control method Displays the value of A01 02 U01 05 Motor Speed Motor Speed OLV only U01 06 Output Voltage Inverter Output Voltage Reference V U01 07 DC Bus Voltage DC Bus Voltage Measured V U01 08 Output Power Inverter Output Power Calculated HP U01 09 Motor Torque Motor Torque OLV only U01 10 Input Terminal Status Input Terminal Status U01 10 U01 11 Output Terminal Status Output Terminal Status...

Page 116: ...the pulse train input RP Frequency Fault Trace U02 01 Current Fault Displays Current fault U02 02 Last Fault Displays last fault detected U02 03 Frequency Reference Fault Frequency reference when fault was detected Hz U02 04 Output Frequency Fault Output frequency when fault was detected Hz U02 05 Output Current Fault Output current when fault was detected A U02 06 Motor Speed Fault OLV Only Motor...

Page 117: ... Fault Message 10 Displays tenth most recent fault U03 11 Elapsed Time 1 Elapsed time of most recent fault U03 12 Elapsed Time 2 Elapsed time of second most recent fault U03 13 Elapsed Time 3 Elapsed time of third most recent fault U03 14 Elapsed Time 4 Elapsed time of fourth most recent fault U03 15 Elapsed Time 5 Elapsed time of fifth most recent fault U03 16 Elapsed Time 6 Elapsed time of sixth...

Page 118: ...ction Level U04 18 Frequency Reference Source Selection U04 19 Frequency Reference Memobus U04 20 Output Frequency Reference decimal U04 21 Run Command Selection Results U04 22 Memobus Communication Reference U04 23 Not Used Motor Control Monitor U06 01 Motor Secondary Current lq U06 02 Motor Excitation Current ld U06 03 ASR Input U06 04 ASR Output U06 05 Output Voltage Reference Vq U06 06 Output ...

Page 119: ...nds 1 set 0 0 to 6000 0 3 sets 8 parameters are independently adjustable Braking torque 150 or more with dynamic braking Motor overload protection UL recognized electronic thermal overload relay field programmable Overcurrent protection level 200 of drive rated current Circuit protection Ground fault and blown fuse protection Overvoltage protection level Approximately 410VDC 230V Class 820VDC 460V...

Page 120: ...variable speed control can be configured The IMPULSE G Mini has two ways in which infinitely variable control can be configured 2 Step Infinitely Variable and 3 Step Infinitely Variable control Sample timing diagrams for both methods are given Note Above figures shown with stopping method set for immediate stop as in hoist applications the frequency output is immediately set to zero and the hoist ...

Page 121: ...0 Sec B05 02 Deceleration Time 3 0 Sec B01 01 First Speed 10 Hz B01 03 Maximum Speed 60 Hz A01 04 03 3 step infinitely variable B05 01 Acceleration Time 3 0 Sec B05 02 Deceleration Time 3 0 Sec B01 01 First Speed 10 Hz B01 03 Maximum Speed 60 Hz A01 04 04 NOTE 1 Standard factory setting for control is 3 Step Infinitely Variable 2 B01 01 B05 01 and B05 02 can be accessed and changed using the user ...

Page 122: ...tune 2 Check motor parameters COF Current Offset Fault The drive automatically adjusts the current offset the calculated value exceeded the allowable setting range 1 Press reset 2 Check brake 3 Check brake contact CPF02 A D Conversion Error An A D conversion error occurred 1 Cycle power to drive 2 Ensure that the control board terminals and wiring are shielded from electrical noise 3 Check resista...

Page 123: ...ions for input terminal S6 U01 10 EF7 External Fault 7 External fault occurs on Terminal S7 1 Check constant H01 07 for proper programming 2 Check the conditions for input terminal S7 U01 10 GF Ground Fault Ground Fault Current shorted to ground exceeded 50 of rated current in output side of the drive Setting L08 09 to 1 enable ground fault detection in models 2025 and 4014 or larger 1 Disconnect ...

Page 124: ...rameter s to appropriate settings 3 Set A01 05 5550 OPE07 Analog Selection Multi Function Analog Input Setting Fault Set values other than 00 and 0F are duplicated 1 Check setting for H03 02 and H03 10 Verify that the same value is not used twice OPE08 Terminal Selection Parameter error A parameter has been changed that is not available in the present control method 1 Undo the last parameter chang...

Page 125: ...eck settings 2 Check motor coupling UV Flashing DC Bus Undervolt Undervoltage Fault Undervoltage status occurs for more than 2 sec during STOP Input voltage drops below 190V DC or less for 230V AC class 380V DC or less for 460V AC class 1 Check the power source wiring 2 Replace and bad branch fuses 3 Check collector system UV1 DC Bus Undervolt Undervoltage 1 Fault Undervoltage status occurs for mo...

Page 126: ...proper use Any corrective maintenance performed by anyone other than the Company during the warranty period shall void the warranty Company shall not be liable for damages of any kind from any cause whatsoever beyond the price of the defective Company supplied items involved Company shall not be liable for economic loss property damage or other consequential damages or physical injury sustained by...

Page 127: ...31 P N 10001609 REV AB 627NH December 2014 Notes ...

Page 128: ... 2014 Columbus McKinnon Corporation All Rights Reserved P N 10001609 REV AB 627NH 12 14 BJB Distributed by Ergonomic Partners Sales ErgonomicPartners com 314 884 8884 www ErgonomicPartners com ...

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