Lodestar CM Hoist Operating Manual Download Page 94

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Figure 27. 1 and 2 Ton Series 635 Low Headroom Trolley Exploded View

SERIES 635 LOW HEADROOM TROLLEY PARTS LIST

Key No. Part Name

No. Req’d.

Part Number

1 Ton

2 Ton

1 Ton

2 Ton

627-330 TrackWheel

35774

50762

627-336 TrackWheel Stud Nut

982520

948804

627-337 Suspension Bolt (Special

Alloy Special Alloy Steel Bolt)
*9 5/32” Long

35450

**10¼” Long

35407

†

10” Long

35445

††

12 1/16” Long

35414

627-338 Trolley Spacer Washers

* 0.165” Thick

35782

**0.125” Thick

958822

†

0.165” Thick

35783

††

0.125” Thick

988039

627-339 Suspension Bolt Nut

948803

958818

627-340 Suspension Bolt Nut

Cotter Pin

988343

988368

627-342 ***Side Frame, Plain Side,

w/o Trolley Guards

35640

35654

***Side Frame, Plain Side,

Trolley Guards

35635

35636

627-379 ***Side Frame, I.D., Plate

Side, w/o Trolley Guards

35640

35654

***Side Frame, I.D., Plate

Side, Trolley Guards

35635

35636

627-380 Load Bracket

* 3 7/16” Wide

35019

**5 13/32” Wide

35024

†

4 3/16” Wide

35033

††

6 11/16” Wide

35043

Key No. Part Name

No. Req’d.

Part Number

1 Ton

2 Ton

1 Ton

2 Ton

627-381 Vertical Load Bar Pin

(Special Alloy Steel Pin)

*2 11/16” Long

35371

**2 7/8” Long

35413

†

3 3/4” Long

35400

627-382 Vertical Load Bar Pin Screw

* ½” Long

982383

**1¼” Long

982386

†

3/4” Long

982433

††

1½” Long

987209

627-383 Vertical Load Bar Pin

Screw L.W.

983548

983547

627-384 TrackWheel Stud Nut L.W.

987923

987924

627-386 Identification Label

36916

36917

627-389 TrackWheel Washer

987903

627-395 Warning Label

936984

* These items are for the 1-Ton Trolley for operation on 2.66" thru 5.64" flange

widths.

** These items are for the 1-Ton Trolley for operation on over 5.64" thru 7.00" flange

widths.

*** If side frame is equipped with spacer block, contact factory.

†

These items are for the 2-Ton Trolley for operation on 3.33" thru 6.00" flange
widths.

††

These items are for the 2-Ton Trolley for operation on over 6.00" thru 8.25" flange
widths.

Summary of Contents for CM Hoist

Page 1: ...st 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 op...

Page 2: ...AM SESCO PO Box 667489 2225 Freedom Drive Charlotte NC 28208 704 372 4832 or 800 487 3726 Fax 704 358 1098 OHIO MAZZELLA LIFTING TECHNOLOGIES 21000 Aerospace Parkway Cleveland OH 44142 440 239 5700 or...

Page 3: ...eyond the limits of the load chain travel 18 NOT leave load supported by the hoist unattended unless specific precautions have been taken 19 NOT allow the load chain or hook to be used as an elec tric...

Page 4: ...gently Do not jerk it DO NOT PULL AT AN ANGLE BE SURE HOIST AND LOAD ARE IN A STRAIGHT LINE 4 LIFT PROPERLY Do not lift co workers with a hoist Make sure everyone is clear of the load when you lift Do...

Page 5: ...Lubrication 15 Trolley Lubrication 15 Exterior Finish 15 Solid State Reverse Switch 15 A Ad dj ju us st tm me en nt ts s Electric Brake 16 Limit Switches 16 17 Recommended Spare Parts 18 Troubleshoot...

Page 6: ...454 15 9 16 395 22 572 115 52 3 75 34 117 53 2 136 61 8 3 3000 RT 5 5 1 9 1 75 25 635 161 73 2 Single Speed 230 460 3 60 or 220 380 3 50 or 220 415 3 50 1 8 125 1 8 125 1 4 250 A AA B 32 9 8 60 18 4...

Page 7: ...rolley 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 susp...

Page 8: ...s to the recommed ed seating torque see Table 2 using a 12 point socket which fits the head of the screw B Double Reeved Units Remove the hook or lug suspension from its carton and the two suspension...

Page 9: ...ave hanger which is loosely con nected to the top of the frame by a thin metal plate for ship ping purposes To attach the suspension support the sheave hanger from the underside of the hoist and remov...

Page 10: ...me After the suspension is installed hoists with a hook suspen sion can be suspended from its permanent support and then connected to the power supply system refer to page 8 For hoists with a lug susp...

Page 11: ...URY Measure the actual beam flange on which the trolley is to operate and use Table 3 to determine the arrangement of the spacer washers for that flange width On the 3 ton 3000 kg trolley refer to Fig...

Page 12: ...rees with that shown on the hoist identification plate In addition for a three phase dual volt age unit check the voltage shown on the tag attached to the power cord Figure 12 Voltage Conversion Board...

Page 13: ...e es s o or r r re ev ve er rs se e v vo ol lt ta ag ge e p ph ha as si in ng g CHECKING FOR TWIST IN LOAD CHAIN Models E H E 2 H 2 R RR R 2 and RR 2 The best way to check for this condition is to run...

Page 14: ...g is 6 inches 152 4 mm for these models and for all other mod els equipped with chain for lifts longer than 10 feet 3 M 3 If adjustment is necessary see page 17 4 Press DOWN control and cautiously low...

Page 15: ...directly overhead 2 WHEN APPLYING A LOAD IT SHOULD BE DIRECTLY UNDER HOIST OR TROLLEY AVOID OFF CENTER LOADING OF ANY KIND 3 Take up a slack load chain carefully and start load easily to avoid shock...

Page 16: ...and daily to weekly for severe service and they should include those items listed in Table 4 PERIODIC INSPECTIONS These inspections are visual inspections of external conditions by an appointed perso...

Page 17: ...ng 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 c...

Page 18: ...ic model of Lodestar Hoist and is not to adjustable or interchangeable with other mod els For proper overload protection be sure before installing a Protector that it is correct for the unit The edge...

Page 19: ...ID CONTACT AND CONTAMINATION Handle and dispose of lubricants only as directed in applica ble material safety data sheets and in accordance with applic able local state and federal regulations Chain G...

Page 20: ...d nuts and examine friction linings and friction surfaces for excessive wear min thickness 188 inches 4 78 mm scoring or warpage b Check shading coils to be sure they are in place and not broken A mis...

Page 21: ...H until it just breaks the limit switch contacts An audible click will be heard as the switch opens Continue to rotate the nut toward the switch an additional one full tooth 10 Reposition the guide pl...

Page 22: ...arts that are recommended to be kept on hand at all times to replace parts that have worn or failed Refer to Pages 51 through 85 for ordering information and parts list for the part numbers T TA AB BL...

Page 23: ...are the proper voltage as described on page 8 F Low Voltage F Correct low voltage condition as described on page 9 G Brake not releasing open or shorted coil winding armature binding G Check electrica...

Page 24: ...voltage condition as described on page 9 C Extreme external heating C Above an ambient temperature of 40 C 104 F the frequency of hoist operation must be limited to avoid overheating of motor Special...

Page 25: ...ing 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 F...

Page 26: ...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 CONTACTOROR SPEEDSELECTOR COIL VOLTAGE NOMINAL CURR...

Page 27: ...ts Phase Hertz H P kW Full Load Current Amps Leads D C Resistance Ohms J L R RT 115 1 60 1 75 9 8 T1 to T2 run 1 1 T3 to T4 run T5 to T8 start 1 3 J L R RT 230 1 60 1 75 4 9 T1 to T2 run 1 1 T3 to T4...

Page 28: ...24 WIRING DIAGRAMS MODELS A AA B C E F H 110 115 1 50 60 VOLT...

Page 29: ...25 WIRING DIAGRAMS MODELS A AA B C E F H 220 230 1 50 60 VOLT...

Page 30: ...26 WIRING DIAGRAMS MODELS A AA B C E F H 220 230 3 50 60 OR 380 415 460 3 50 60 VOLT...

Page 31: ...27 WIRING DIAGRAMS MODELS A AA B C E F H 220 230 3 50 60 OR 380 415 460 3 50 60 VOLT CSA UNITS...

Page 32: ...28 WIRING DIAGRAMS MODELS A 2 AA 2 B 2 C 2 E 2 F 2 H 2 220 230 3 50 60 VOLT...

Page 33: ...29 WIRING DIAGRAMS MODELS A 2 AA 2 B 2 C 2 E 2 F 2 H 2 220 230 3 50 60 VOLT CSA UNITS...

Page 34: ...30 WIRING DIAGRAMS MODELS A 2 AA 2 B 2 C 2 E 2 F 2 H 2 380 415 460 3 50 60 VOLT...

Page 35: ...31 WIRING DIAGRAMS MODELS A 2 AA 2 B 2 C 2 E 2 F 2 H 2 380 415 460 3 50 60 VOLT CSA UNITS...

Page 36: ...32 WIRING DIAGRAMS MODELS A AA B C E F H 550 575 3 50 60 VOLT...

Page 37: ...33 WIRING DIAGRAMS MODELS A AA B C E F H 550 575 3 50 60 VOLT CSA UNITS...

Page 38: ...34 WIRING DIAGRAMS MODELS A 2 AA 2 B 2 C 2 E 2 F 2 H 2 550 575 3 50 60 VOLT...

Page 39: ...35 WIRING DIAGRAMS MODELS A 2 AA 2 B 2 C 2 E 2 F 2 H 2 550 575 3 50 60 VOLT CSA UNITS...

Page 40: ...36 WIRING DIAGRAMS MODELS J L R RT 110 115 1 50 60 VOLT...

Page 41: ...37 WIRING DIAGRAMS MODELS J L R RT 220 230 1 50 60 VOLT...

Page 42: ...38 WIRING DIAGRAMS MODELS J JJ L LL R RR RT RRT 220 230 3 50 OR 380 415 460 3 50 60 VOLT...

Page 43: ...39 WIRING DIAGRAMS MODELS J JJ L LL R RR RT RRT 220 230 3 50 60 OR 380 415 460 3 50 60 VOLT CSA UNITS...

Page 44: ...40 WIRING DIAGRAMS MODELS J 2 JJ 2 L 2 LL 2 R 2 RR 2 RT 2 RRT 2 220 230 3 50 60 VOLT...

Page 45: ...41 WIRING DIAGRAMS MODELS J 2 JJ 2 L 2 LL 2 R 2 RR 2 RT 2 RRT 2 220 230 3 50 50 VOLT CSA UNITS...

Page 46: ...42 WIRING DIAGRAMS MODELS J 2 JJ 2 L 2 LL 2 R 2 RR 2 RT 2 RRT 2 380 415 460 3 50 60 VOLT...

Page 47: ...43 WIRING DIAGRAMS MODELS J 2 JJ 2 L 2 LL 2 R 2 RR 2 RT 2 RRT 2 380 415 460 3 50 60 VOLT CSA UNITS...

Page 48: ...44 WIRING DIAGRAMS MODELS J JJ L LL R RR RT RRT 550 575 3 50 60 VOLT...

Page 49: ...45 WIRING DIAGRAMS MODELS J JJ L LL R RR RT RRT 550 575 3 50 60 VOLT CSA UNITS...

Page 50: ...46 WIRING DIAGRAMS MODELS J 2 JJ 2 L 2 LL 2 R 2 RR 2 RT 2 RRT 2 550 575 3 50 60 VOLT...

Page 51: ...47 WIRING DIAGRAMS MODELS J 2 JJ 2 L 2 LL 2 R 2 RR 2 RT 2 RRT 2 550 575 3 50 60 VOLT CSA UNITS...

Page 52: ...akaway torque Models J thru RRT 2 tighten limit switch attaching screws 627 220 brake attaching screws 627 253 and hexago nal brake stud 627 265 to where they have a minimum breakaway torque of 50 pou...

Page 53: ...of links This will prevent twist in chain To simplify handling when reassembling the hoist a short undamaged piece of the old chain may be used as a starter chain Position this piece of chain in exac...

Page 54: ...eter by 1 8 3 175 mm thick abrasive wheel or type recommended by wheel supplier that will clear adjacent links 2 Use a bolt cutter Figure 22 similar to the H K Porter No 0590MTC with special cutter ja...

Page 55: ...87002 60 HZ 286010 50 HZ A B and E 575 3 60 27658 51520 27653 286004 287009 230 460 27659 51518 286004 287006 220 1 50 230 1 60 27656 51517 286005 286007 60 HZ 286009 50 HZ 110 1 50 115 1 60 27656 515...

Page 56: ...uantities N No ot te e W Wh he en n p pa ai in nt ti in ng g H Ho oi is st ts s o or r T Tr ro ol ll le ey ys s a al ls so o o or rd de er r w wa ar rn ni in ng g l la ab be el ls s i id de en nt ti i...

Page 57: ...53 Notes...

Page 58: ...54 HOIST FRAME COMPONENTS GENERAL LAYOUT Models A A 2 AA AA 2 B B 2 C C 2 E E 2 F F 2 H H 2 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 59: ...n 27238 A A 2 AA AA 2 B B 2 C C 2 F F 2 28009B No Req d 1 1 8 2 2 1 1 1 1 1 1 1 1 As Req d As Req d 1 1 Part Name Motor Housing Cover Gasket Weatherproof Units Only Back Frame Cover Gasket Weatherproo...

Page 60: ...56 LODESTAR HOIST UPPER SUSPENSION 627 700 COMPLETE SWIVEL HOOK SUSPENSION 627 720 COMPLETE LUG SUSPENSION 627 710 COMPLETE RIGID HOOK SUSPENSION TRIPLE REEVED SUSPENSION SHEAVE HANGER...

Page 61: ...Hook Suspension Only Upper Hook Collar Nut Swivel Hook Suspension Only Upper Hook or Suspension Lug Pin Special Alloy Steel Specify for Rigid or Swivel Type Suspension Rigid Hook Suspension Includes 6...

Page 62: ...58 LODESTAR LOWER HOOK BLOCK ASSEMBLY...

Page 63: ...27 772 Lower Hook Thrust Bearing 1 88485 88478 88485 88505 88505 627 773 Lower Hook Collar 1 27359 35478 627 774 Lower Hook Pin 1 983772 45941 983772 45946 983762 627 775 Lower Hook Chain Block 1 2800...

Page 64: ...60 LODESTAR HOIST CONTROL END COMPONENTS Models A A 2 AA B B 2 C C 2 E E 2 F F 2 H H 2 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 Control and Power Cords...

Page 65: ...Screw Brake Stud Nut Hex Brake Stud Spring Hex Brake Stud Spring Washer Hex Brake Stud Hex Brake Stud Lockwasher Control Cord Attaching Screw Control Cord Attaching Screw Washer Control Cord Attaching...

Page 66: ...62 Lodestar Hoist Brake Components Models A A 2 AA B B 2 C C 2 E E 2 F F 2 H H 2 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 67: ...Coded Blue 35716 Color Coded Yellow for Models J J 2 L 2 R R 2 RT and RT 2 35717 Color Coded Green for Models JJ JJ 2 LL LL 2 RR RR 2 RRT and RRT 2 627 256 Brake Field Sub Assembly 1 28677 Includes 6...

Page 68: ...64 LODESTAR HOIST LIMIT SWITCH COMPONENTS Models A A 2 AA AA 2 B B 2 C C 2 E E 2 F F 2 H H 2 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 69: ...Gear 1 27714 35753 627 220B Limit Switch Shaft 44 thread 1 70399 36373 Limit Switch Shaft 56 thread 27307 36317 Limit Switch Shaft 64 thread 27251 36321 627 220C Travel Nut 44 thread 2 70053 70053 Tr...

Page 70: ...66 LODESTAR HOIST GEARING COMPONENTS Models A A 2 AA AA 2 B B 2 C C 2 E E 2 F F 2 H H 2 Models J JJ JJ 2 L LL LL 2 R RR RR 2 RT RT 2 RRT RRT 2...

Page 71: ...Drive Shaft and Pinion Bearing Spacer 1 27710 627 314 Brake Hub 1 27852 1 1 2 lg for Models AA AA 2 C C 2 F F 2 H H 2 27851 2 1 32 lg for Models A A 2 B B 2 E E 2 35744 627 315 Brake Hub Snap Ring 1 2...

Page 72: ...68 LODESTAR HOIST LIFTWHEEL COMPONENTS Models A A 2 AA AA 2 B B 2 C C 2 F F 2 E E 2 H H 2 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 73: ...35421 627 307 Liftwheel Bearing Gear End 1 88429 82002 627 308 Liftwheel Bearing Motor End 1 88429 83669 627 740 Loose End Screw 1 927764 987210 627 741 Loose End Screw Lockwasher 1 982226 945851 627...

Page 74: ...70 LODESTAR HOIST MOTOR END COMPONENTS Models A A 2 AA AA 2 B B 2 C C 2 E E 2 F F 2 H H 2 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 75: ...5Volt Primary with 24Volt Secondary w Thermal Cutout for CSA use code 28999 V1 Single Phase Units 220 230 1 50 60 220 230 Volt Primary with 115 Volt Secondary code 27771 220 230 Volt Primary with 48 V...

Page 76: ...1 29312 627 1053 Din Rail Mounting Bracket Screw 2 982686 627 1054 Din Rail Mounting Bracket Screw Lockwasher 2 987873 627 1057 Capacitor Mounting Bracket or Solid State Reversing Switch Mounting Bra...

Page 77: ...1 29312 627 1053 Din Rail Mounting Bracket Screw 2 982686 627 1054 Din Rail Mounting Bracket Screw Lockwasher 2 987873 627 1055 Ground Screw 1 987827 627 1057 Capacitor Mounting Bracket or Solid State...

Page 78: ...t 1 29312 627 1053 Din Rail Mounting Bracket Screw 2 982686 627 1054 Din Rail Mounting Bracket Screw Lockwasher 2 987873 627 1055 Ground Screw 1 987827 627 1057 Capacitor Mounting Bracket or Solid Sta...

Page 79: ...14 Voltage Change Board Insulator 1 27685 627 1050 Terminal Strip 1 29014 627 1051 Terminal Strip End Clamp 2 29015 627 1052 Din Rail Mounting Bracket 1 29312 627 1053 Din Rail Mounting Bracket Screw...

Page 80: ...1 Contactor Mounting Plate 1 31633 627 1003A Ground Label 1 20940 627 1050 Terminal Strip 1 29014 627 1051 Terminal Strip End Clamp 2 29015 627 1052 Din Rail Mounting Bracket 1 29312 627 1053 Din Rail...

Page 81: ...e 1 31633 627 1003A Ground Label 1 20940 627 1050 Terminal Strip 1 29014 627 1051 Terminal Strip End Clamp 2 29015 627 1052 Din Rail Mounting Bracket 1 29312 627 1053 Din Rail Mounting Bracket Screw 2...

Page 82: ...Coil 27138 48 Volt Coil 27139 24 Volt Coil 627 1001 Contactor Mounting Plate 1 29013 627 1003A Ground Label 1 20940 627 1051 Terminal Strip End Clamp 2 29015 627 1052 Din Rail Mounting Bracket 1 2900...

Page 83: ...t Coil 27104 48 Volt Coil 27105 24 Volt Coil 627 1001 Contactor Mounting Plate 1 29013 627 1003A Ground Label 1 20940 627 1051 Terminal Strip End Clamp 2 29015 627 1052 Din Rail Mounting Bracket 1 290...

Page 84: ...7 1012 Conversion Board Mounting Screw 1 987862 627 1013 Conversion Board 1 27672 627 1014 Conversion Board Insulator 1 27685 627 1050 Terminal Strip 3 29014 627 1051 Terminal Strip End Clamp 4 29015...

Page 85: ...627 800 Hoist Speed Selecting Contactor 1 28870 115 Volt Coil 28871 48 Volt Coil 28878 24 volt Coil 627 1001 Contactor Mounting Plate 1 29013 627 1003A Ground Label 1 20940 627 1050 Terminal Strip 3...

Page 86: ...eed Selecting Contactor 1 28870 115 Volt Coil 28871 48 Volt Coil 28878 24 Volt Coil 627 1001 Contactor Mounting Plate 1 29013 627 1003A Ground Label 1 20940 627 1050 Terminal Strip 3 29014 627 1051 Te...

Page 87: ...1 24799 115 Volt Coil 24797 48 Volt Coil 28860 24 Volt Coil 627 1001 Contactor Mounting Plate 1 29013 627 1003A Ground Label 1 20940 627 1050 Terminal Strip 1 29014 627 1051 Terminal Strip End Clamp 4...

Page 88: ...Selecting Contactor 1 28870 115 Volt Coil 28871 48 Volt Coil 28878 24 Volt Coil 627 1001 Contactor Mounting Plate 1 29013 627 1003A Ground Label 1 20940 627 1050 Terminal Strip 1 29014 627 1051 Termi...

Page 89: ...85 NOTES...

Page 90: ...for CSA Units 627 451 Standard Control Cord Assembly 1 29350 for 10 Lift 29351 for 15 Lift 29352 for 20 Lift 29353 for 10 Lift for CSA Units 627 551 Control Station Grommet 1 58278 627 552 Control Sta...

Page 91: ...Cord and Station Assembly 1 29337 for 10 Lift 29348 for 10 Lift for CSA Units 627 451 Standard Control Cord Assembly 1 29354 for 10 Lift 29349 for 10 Lift for CSA Units 627 551 Control Station Gromme...

Page 92: ...2 Control Station Includes 627 551 Thru 627 567 1 58220 CM 627 553 Control Station Housing Kit Includes Housing Boots Collar Gasket Hardware 1 58288 627 563 Control Station Hardware Kit w gasket 1 582...

Page 93: ...89 NOTES...

Page 94: ...olley Guards 2 2 35635 35636 627 380 Load Bracket 1 1 3 7 16 Wide 35019 5 13 32 Wide 35024 4 3 16 Wide 35033 6 11 16 Wide 35043 Key No Part Name No Req d Part Number 1 Ton 2 Ton 1 Ton 2 Ton 627 381 Ve...

Page 95: ...TrackWheel Washer Steel 81014 635 10 4 TrackWheel Washer Oilite 82046 635 11 4 TrackWheel Stud Lockwasher 987926 635 12 4 TrackWheel Stud Nut 988155 635 13 1 Load Bracket Specify Width 36012 4 13 16...

Page 96: ...er s delivery to car rier 2 not maintained inspected or used in compliance with applicable law and Seller s written instructions and recommenda tions or 3 installed repaired altered or modified withou...

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