O P E R AT I N G ,

MAINTENANCE
& PA R T S
MANUAL

ELECTRIC
CHAIN HOIST

Before installing hoist, fill in

the information below. Refer
to the hoist identification
plate.
Model No. __________________
Serial No. __________________
Purchase Date ______________

XL
Rated capacities 2 through 7 tons/
2000 through 7500 kg
Follow all instructions and warnings 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.

Voltage ____________________
Rated Capacity______________

52756

Forward this manual to operator.

Failure to operate equipment as directed
in manual may cause injury.

Manual No. 652-E

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

As a CM XL Hoist user, you are assured of reliable repair and parts services through a network of Master Parts Depots
and Service Centers that are strategically located in the United States and Canada. These facilities have been selected on
the basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.
Below is a list of the Master Parts Depots in the United States and Canada. To quickly obtain the name of the U.S. Service
Center located nearest you, call (800) 888-0985. Fax: (716) 689-5644. In the following list, the Canadian Service Centers
are indicated.

UNITED STATES MASTER PARTS DEPOT

CALIFORNIA
OTTO SYSTEMS, INC.
12010 Bloomfield Ave.
Sante Fe Springs, CA 90670
562/462-1612 or 800/596-7392
Fax 562/462-1617
or
7656 Las Positas Road
Livemore, CA 94551
925/245-8800 or 800/508-6886
Fax 925/245-8804
GEORGIA
ACE INDUSTRIES, INC.
6295 McDonough Drive
Norcross, GA 30093
770/441-0898 or 800/733-2231
Fax 800/628-3648
ILLINOIS
JOHN SAKASH COMPANY, INC.
700 Walnut Street
Elmhurst, IL 60126
630/833-3940
Fax 630/833-9830
INDIANA
HORNER ELECTRIC COMPANY, INC.
1521 East Washington Street
Indianapolis, IN 46201
317/639-4261
Fax 317/639-4342
IOWA
VM HOIST & CRANE SERVICES
P.O. Box 440
450 Highway 151
Walford, IA 52351
319/846-6040
Fax 319/846-6045
KANSAS
INDEPENDENT ELECTRIC MACHINERY
4425 Oliver Street
Kansas City, KS 66106
913/362-1155 or 800/833-2610
Fax 913/904-3330
LOUISIANA
BEERMAN PRECISION, INC.
P.O. Box 6018
Metairie, LA 70009
504/207-6000
Fax 504/207-6044
MASSACHUSETTS
ABEL DISTRIBUTORS, INC.
50 Parker Street, Unit 2
Newburyport, MA 01950
978/463-0700
Fax 978/463-5200
NEW JERSEY
SHUPPER-BRICKLE EQUIPMENT CO.
P.O. Box 803
2394 Route 130, Suite C
Dayton, NJ 08810
732/438-3888
Fax 732/438-3889

CANADIAN SERVICE CENTERS

NEW YORK
VOLLAND ELECTRIC EQUIPMENT CO.
75 Innsbruck Drive
Buffalo, NY 14227
716/656-9900
Fax 716/656-8899

ALBERTA
BENNETT & EMMOTT, LTD.
18131 118th Avenue
Edmonton, Alberta T5S 1M8
403/454-9000
Fax 403/454-8990

NORTH CAROLINA
TEAM SESCO
P.O. Box 667489 28266
2225 Freedom Drive
Charlotte, NC 28208
704/372-4832 or 800/487-3726
Fax 704/358-1098

**COLUMBUS McKINNON, LTD.

10311-174th Street
Edmonton, Alberta T5S 1H1
800/263-1997
Fax 403/486-6160

OHIO
MAZZELLA LIFTING TECHNOLOGIES
21000 Aerospace Parkway
Cleveland, OH 44142-1072
440/239-7000 or 800/362-4601
Fax 440/239-7010
PENNSYLVANIA
AMICK ASSOCIATES, INC.
11 Sycamore Street
P.O. Box 529
Carnegie, PA 15106-0529
412/429-1212 or 800/445-9456
Fax 412/429-0191
RAM MOTORS & CONTROLS, INC.
5460-B Pottsville Pike, Docka 8-11
P.O. Box 748
Leesport, PA 19533
610/916-8000
Fax 610/916-7957
SOUTH CAROLINA
ENGINEERED SYSTEMS, INC.
1121 Duncan-Reidville Road
Duncan, SC 29334
864/879-7438 or 800/879-7438
Fax 864/879-6428
TEXAS
ABEL EQUIPMENT CO., INC.
3710 Cavalier Drive
Garland, TX 75042
972/272-7706
Fax 972/272-6955
HYDRAULIC EQUIPMENT SERVICES, INC.
1021 North San Jacinto Street
Houston, TX 77002
713/228-9601
Fax 713/228-0931
WISCONSIN
TRESTER HOIST & EQUIPMENT, INC.
W136 N4863 Campbell Drive
Suite #4
Menomonee Falls, WI 53051
262/790-0700 or 800/234-6098
Fax 262/790-1009

BRITISH COLUMBIA
FLECK BROTHERS, LTD.
4084 McConnel Court
Burnaby, British Columbia V5A 3N7
MANITOBA
KINGS ELECTRIC MOTORS, INC.
633 Tyne Avenue
Winnipeg, Manitoba R2L 1J5
204/663-5332
Fax 204/663-4059
NOVA SCOTIA
*W & A MOIR
95 Ilsley Ave.
Burnside Park, Nova Scotia B3B 1L5
902/468-7720
Fax 902/468-3777
ONTARIO
*R & W HOIST REPAIR, LTD.
790 Redwood Square
Units 5, 6, & 7
Oakville, Ontario L6L 6N3
905/825-5500
Fax 905/825-5315
*TORONTO ELECTRIC HOIST
SALES & SERVICE
9 CoDeco Court
North York, Ontario M3A 1A1
416/386-0820
Fax 416/386-0821
*MASLACK SUPPLY, LTD.
488 Falconbridge Road
Sudbury, Ontario P3A 4S4
705/566-1270
Fax 705/566-4208
*COLUMBUS McKINNON, LTD.
P.O. Box 1106
10 Brook Road, North
Cobourg, Ontario K9A 4W5
905/372-0153
Fax 905/372-3078
QUEBEC
*HERCULES SLING & CABLE
3800 TransCanada Highway
Pointe-Claire, Quebec H9R 1B1
514/428-5511514/48631-5511
Fax 514/428-5555
*LEGER PALANS ET OUTILLAGES, INC.
7995-17th Ave.
Montreal, Quebec H1Z 3R2
514/376-3050
Fax 514/376-0657
**ARE ALSO MASTER PARTS DEPOTS
**MASTER PARTS DEPOT ONLY

SAFETY PRECAUTIONS

Each CM Lodestar XL Electric Hoist is built in accordance with the specifications contained herein and at the time of
manufacture complied with our interpretation of applicable sections of the *American Society of Mechanical Engineers
Standard B30.16 Overhead Hoists, the National Electrical Code (ANSI/NFPA 70) and the Occupational Safety and
Health Act. Since OHSA 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 maintenance sections of these articles.
The safety laws for elevators, lifting of people and for dumbwaiters specify construction details that are not incorporated in
Lodestar XL 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 responsible 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 CM LODESTAR XL HOIST.

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 Factory for information concerning using hoists in
these applications.

WARNING

Improper operation of a hoist can create a potentially

hazardous situation which, if not avoided, could
result in death or serious injury. To avoid such a
potentially hazardous situation, the operator shall:
1.
2.

3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Not operate a damaged, malfunctioning or unusually

performing hoist.
Not operate the hoist until you have thoroughly read
and understood this Operating, Maintenance and Parts
Manual.
Not operate a hoist which has been modified.
Not lift more than the rated load for the hoist.
Not use hoist with twisted, kinked, damaged or worn
load chain.
Not use the hoist to lift, support, or transport people.
Not lift loads over people.
Not operate a hoist unless all persons are and
remain clear of the supported load.
Not operate unless load is centered under hoist.
Not attempt to lengthen the load chain or repair damaged load chain.
Protect the hoists load chain from weld splatter or
other damaging contaminants.
Not operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
Not use load chain as a sling, or wrap load or chain
around load.
Not apply the load to the tip of the hook or to the
hook latch.
Not apply load unless load chain is properly seated in
the chain wheel(s) or sproket(s).
Not apply load if bearing prevents equal loading on all
load chains.
Not operate beyond the limits of the load chain travel.
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 electrical 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 decals 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.

CAUTION

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in minor
or moderate injury. To avoid such a potentially hazardous
situation, the operator shall:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Maintain a firm footing or be otherwise secured when operating

the hoist.
Check brake function by tensioning the hoist prior to each lift
operation.
Use hook latches. Latches are to retain slings, chains, etc. under
slackconditions only.
Make sure the hook latches are closed and not supporting any
parts of the load.
Make sure the load is free to move and will clear all obstructions.
Avoid swinging the load or hook.
Make sure hook travel is in the same direction as shown on the
controls.
Inspect the hoist regularly, replace damaged or worn parts, and
keep appropriate records of maintenance.
Use the hoist manufacturers recommended parts when repairing
the unit.
Lubricate load chain per instructions in this manual.
Not use the hoist load limiting or warning device to measure load.
Not use limit switches as routine operating stops unless allowed by
manufacturer. They are emergency devices only.
Not allow your attention to be diverted when operating hoist.
Not allow the hoist to be subjected to sharp contact with other
hoists, structures, or objects through misuse.
Not adjust or repair the hoist unless qualified to perform such
adjustments or repairs.

ii

iii

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 preventative 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 or moving heavy loads
using hoist 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.

TABLE OF CONTENTS
ITEM
PAGE NO.
MASTER PARTS DEPOTS AND SERVICE CENTERS . i
SAFETY PRECAUTIONS . . . . . . . . . . . . . ii
HOIST SAFETY IS UP TO YOU. . . . . . . . iii
GENERAL INFORMATION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 2
REPAIR/REPLACEMENT POLICY . . . . . . 3
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION
UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING THE SUSPENSION
HOOK SUSPENSIONS . . . . . . . . . . . . . . . . . . 4
LUG SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . 6
MOUNTING TROLLEY ON HOIST. . . . . . 6

INSTALLING TROLLEY SUSPENDED

HOIST ON BEAM. . . . . . . . . . . . . . . . . . . . .7
INSTALLING BREATHER . . . . . . . . . . . . . . . . 8
POWER SUPPLY SYSTEM . . . . . . . . . . . . . . . 8
ELECTRICAL CONNECTIONS
SINGLE SPEED DUAL VOLTAGE
HOISTS (AND MOTOR DRIVEN TROLLEYS) . 9
ALL HOISTS. . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECKING FOR TWIST IN LOAD CHAIN . 10
CHECKING FOR ADEQUATE VOLTAGE . . 10
CHECKING LIMIT SWITCH OPERATION . . . 10
CHAIN CONTAINER . . . . . . . . . . . . . . . . . . . . 10
CONTROL CORD . . . . . . . . . . . . . . . . . . . . . . . 10

OPERATING INSTRUCTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ALL HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HOIST WITH PLAIN TROLLEY . . . . . . . . . . . . 11
HOIST WITH GEARED TROLLEY . . . . . . . . . . 11
HOIST WITH MOTOR DRIVEN TROLLEY . . 11
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . 11

ITEM
MAINTENANCE

PAGE NO.

INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FREQUENT INSPECTIONS . . . . . . . . . . . . . . 12
PERIODIC INSPECTIONS . . . . . . . . . . . . . . . 12
HOOK INSPECTION . . . . . . . . . . . . . . . . . . . 12
LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 13
PROTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 13

LUBRICATION
HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TROLLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ADJUSTMENTS
HOIST BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 15
LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . 16
TROLLEY BRAKE . . . . . . . . . . . . . . . . . . . 17
RECOMMENDED SPARE PARTS . . . . . . . 18
PREVENTIVE MAINTENANCE . . . . . . . . . 18

TROUBLE SHOOTING
ALL HOISTS. . . . . . . . . . . . . . . . . . . . . . . . 19
TWO SPEED HOISTS . . . . . . . . . . . . . . . . . 22
MOTOR DRIVEN TROLLEY. . . . . . . . . . . . 23
ELECTRICAL DATA . . . . . . . . . . . . . . . . . 24, 25
WIRING DIAGRAMS . . . . . . . . . . . . . . . 26, 28
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 29
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL AND REPLACEMENT OF LOAD CHAIN 29

REEVING LOAD CHAIN

3,4 AND 5 TON DOUBLE REEVED UNITS . . 30
5,6 AND 71/2 TON TRIPLE REEVED UNITS . 31
CUTTING CHAINS. . . . . . . . . . . . . . . . . . . . . . 31
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

REPAIR PARTS
ORDERING INSTRUCTIONS . . . . . . . . . . . . 32
EXPLODED VIEWS AND PARTS LISTS. . 33-48

GENERAL INFORMATION
SPECIFICATIONS

The CM LODESTAR XL Electric Chain Hoist is a highly

versatile material handling device that can be used to
lift loads that are within its rated load capacity. Single
and Two speed units with rated loads up to 7 tons
(7500 kg.) are
available. The hoist can be supplied with a single hook
suspension up to 6 ton (6000 kg.) capacity or suspended
from a plain, geared or motor driven trolley. The standard lift is 10 feet and longer lifts can be provided on a
per order basis.

Oversize reversing and speed selecting contactors

for long, trouble free service.
Hoist duty, A.C. motor brake plus regenerative braking.
Weatherproof, CM 2 or 4 direction control station.
Shielded, lifetime lubricated ball bearings at all rotating
points. Open bearings are used in gear case.
Voltage conversion board on single speed, dual voltage units.
Three stage gear reduction.
Upper and lower screw type limit switches.

The standard features of the CM LODESTAR XL Electric

Chain Hoist include:

Hardened, alloy steel, oblique lay liftwheel provides constant chain speed and reduces chain wear.
Hoistaloy load chain for long and dependable
service.
Lightweight cast aluminum frame and covers.
Surface hardened, alloy steel, helical gears running in an oil bath provide smooth and quiet
operation.
Protector that prevents lifting an excessive overload.
Single or two speed hoist duty motor equipped
with thermal protection.
Low voltage control circuit. 115 volt is standard.
24 or 48 volt control circuits are also available.
Hardened, forged steel hooks equipped with latch.

CM LODESTAR
XL Hoist with
Motor Driven
Trolley

TABLE 1SPECIFICATIONS
LODESTAR XL ELECTRIC CHAIN HOISTS
RATED LOAD

TONS
Kg.

*LIFTING SPEEDS AVAILABLE:

2
2000

3
3000

4&5
4000 & 5000

5
5000

5
5000

6
6000

7
7500

FPM

18

24

30

12

15.2

10

10

MPM

5.5

7.3

9.1

2.7

3.6

4.6

1.8

2.4

1.8

2.4

3.0

1.8

3.0

2.7/8

2/6

2.7/8

SINGLE SPEEDS
FPM

6 /18

8 / 24

MPM

1.8 / 5.5

2.4 / 7.3

FEET

127

139

METERS

39

42

TWO SPEEDS

3/9

4/12

.9/2.7

1.2 / 3.6

71

60

65

106

42

46

42

46

71

42

71

22

19

21

32

13

14

13

14

22

13

22

N/A

2/6
N/A

2/6
N/A

.6 / 1.8

.8 / 2.4 .6/1.8 .8/2.4

N/A
.6/1.8

MAXIMUM LIFT
REEVING OF LOAD CHAIN

SINGLE

MINIMUM HEADROOM
HOOK SUSPENDEDIN. (mm)
TROLLEY SUSPENDEDIN. (mm)
RANGE OF TROLLEY ADJUSTABILITY
S BEAMS

25 (635)
28.69 (729)

DOUBLE

TRIPLE

35.31 (897)

36.18 (919)

33 (841) 33.38 (848) 34.25 (870)

6 X 12.5 # TO
15 X 42.9#

34.25 (870)

8 X 18.4# TO 20 X 66.0#

IN.

3.33 TO 5.50

4.00 TO 6.250

mm

84.5 TO 139.7

101.6 TO 158.8

FLANGE WIDTH
STANDARD MOTOR DRIVEN TROLLEY
TRAVEL SPEEDFPM (MPM)

65 (19.8) OR
100 (30.4)

**APPROX. NET WEIGHTLBS. (Kg.)

HOOK SUSPENDED
WITH PLAIN TROLLEY
WITH GEARED TROLLEY
WITH MOTOR DRIVEN TROLLEY

368 (167)
428 (194)
473 (215)
483 (219)

50 (15.2)

442 (200)
497 (225)
512 (232)
582 (264)

442 (200)
597 (271)
607 (275)
632 (287)

474 (215)
629 (285)
639 (290)
664 (301)

*Lifting speeds are based on 60 Hertz power supply. When operating on 50 Hertz, lifting speeds will be 5/6 of those listed.
**Weights are for single speed hoist with 10 ft. (3 M) lift. For two speed hoists, add 10 pounds (4.5 Kg.).

N/A

REPAIR/REPLACEMENT POLICY
All Lodestar XL Electric Chain Hoists are thoroughly inspected and performance tested prior to shipment. If any properly maintained hoist develops a performance problem due to
a material or workmanship defect, as verified by factory,
repair or replacement of the unit will be made to the original purchaser without charge. This repair/replacement policy applies only to LODESTAR XL 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-factory
replacement parts voids the guarantee and could lead to
dangerous operation. For full Terms of Sale, see Sales Order
Acknowledgement. Also, refer to the back cover for
Limitations of Warranties, Remedies and Damages, and
Indemnification and Safe Operation.

ACCESSORIES

LUG SUSPENSIONS
Lug suspensions are required to suspend the LODESTAR XL
Electric Hoist from plain, geared or motor driven trolleys
described below. When the hoist is to be suspended from a
plain, geared or motor driven trolley, the lug suspension is
attached to the hoist prior to shipment.

LUG SUSPENSION

PLAIN TROLLEYS
These are manual push type trolleys designed for use with
the LODESTAR XL Electric Hoist. The trolley is adjustable to
operate on a range of American Standard S beams and
flat flanged beams. The plain trolley is mounted on hoist
prior to shipment.

HOOK SUSPENSIONS
Hook suspensions are available for suspending 2 through 6
ton hoist from a trolley with a single load bar or for suspending the hoist from a fixed structure.

PLAIN TROLLEY

2 ton

3-6 ton
HOOK SUSPENSION

GEARED TROLLEYS
The geared trolley is similar to the plain trolley except it is
moved by the means of a hand chain. The hand chain
rotates a pinion that drives gears attached to trolley wheels
and moves trolley along the beam. The geared trolley is
mounted on the hoist prior to shipment.

MOTOR DRIVEN TROLLEYS

The motor driven trolley is similar to geared trolley except
the hand chain wheel is replaced with a gear reducer and
an electric motor. The motor is energized by a reversing
contactor mounted inside the hoist and it is controlled by
push buttons located in the pendant control station. A
variety of single and two speed trolley travel speeds are
available and the motor driven trolley is mounted on hoist
prior to shipment.

INSTALLATION
UNPACKING
After opening the carton, carefully inspect the hoist,
suspension, trolley and chain container for damage that
may have occurred during shipment. If there is damage,
refer to the packing slip envelope.

INSPECT FOR SHIPPING

DAMAGE
MOTOR DRIVEN TROLLEY

CHAIN CONTAINER
This accessory is used to hold the slack chain and it is
supplied complete with mounting hardware and
instructions. The chain container is recommended for
those applications where the slack chain will interfere
with the load or drag on the floor as may be the case
with double and triple reeved units. Chain containers
are shipped separately and can be furnished for units
already in use.

WARNING

Operating a unit with obvious external damage may

cause load to drop and that may result in personal
injury and/or property damage.
TO AVOID INJURY:
Carefully check unit for external damage prior to
installation.
Make sure that the power supply to which the hoist is
to be connected is the same as that shown on the identification plate located on the bottom of the hoist. For
single speed, dual voltage hoists, refer to instructions
on page 8.

LATCHLOK HOOKS
Latchlok hooks are available to replace the standard
upper or lower latch type hooks (2-6 ton only). The
unique design of the Latchlok hook assures that it will
stay locked until the operator releases it by depressing
the release button. It will not open accidentallyeven if the
load chain goes slack. Once opened, it can be shut with
one hand or the weight of the load when it is lifted.
Latchlok hooks can be supplied with the hoist or it can
be provided in kit form for hoists already in service.

MAKING SURE THE

HOIST WILL OPERATE
ON THE POWER SUPPLY
SYSTEM

INSTALLING SUSPENSION
A. HOOK SUSPENSIONS
For hook suspended 2 through 6 ton units, the suspension is
shipped separately and it must be attached to the hoist
as follows:

LATCHLOK HOOK

1. 2 THROUGH 6 TON. Supplied with the hook suspension is a counterweight that must be attached to the
motor cover using the two long screws provided.
Remove and discard corresponding motor cover
screws. Place counterweight on motor cover and
secure it using the two longer screws. Tighten these
screws to a seating torque of 16 pound feet (22 NM).

c. After the hook is in the desired position, slide the

suspension adapter into cavity on top of hoist and
secure it using the suspension adapter screw from
the kit. Tighten screw to a seating torque of 16
pound feet (22 NM).
COUNTERWEIGHT

INSTALLING
HOOK
SUSPENSION
2 TON UNIT
MOUNTING THE
COUNTERWEIGHT

Attach the XL label, from the kit, to counterweight in

the recess provided for same.
2. 2 Ton Single Reeved Units. As shipped from the facto
ry, the hook is rigid with the plane of the hook parallel
to the long axis of the hoist. The hook can be changed
to swivel type or the plane of the hook can be changed
to perpendicular to the long axis of the hoist as follows:
a.

If a swivel type hook is required, use a 1/4 inch

(6.4 mm) drift, and working through the hole
in the side of the suspension adapter, drive the
hook nut pin into the nut so that it is flush
with the side of the nut. Discard the loose pin
packed with the suspension.

NOTE: INSTALL BREATHER IN MAIN HOUSING

AFTER HOOK SUSPENSION IS ASSEMBLED TO HOIST.
SEE PAGE 8.
3. 3, 4 and 5 Ton Double Reeved and 5 and 6 Ton
Triple Reeved Units. As shipped from the factory, the
hook is rigid with the plane of the hook parallel to
long axis of hoist. The hook can be changed to swivel
type or the plane of the hook can be changed to perpendicular to the long axis of the hoist as follows:

TO CONVERT TO
SWIVEL TYPE
HOOK

TO CONVERT
TO SWIVEL
TYPE HOOK

DRIFT
b.

If it is necessary to position the hook so that the

plane of the hook is perpendicular to the long
axis of hoist, first convert to a swivel type hook as
described above. Rotate the hook 90 degrees and
slide the loose pin (packed with the suspension)
through the hole in the side of the suspension
adapter and engage the hole in the hook nut.

CHANGING
POSITION OF
HOOK

a.

If a swivel type hook is required, remove and discard

keeper plate screw and keeper plate. Then using a
hammer, drive the hook nut pin into nut so that
the end of the pin is flush with side of the nut.

b.

If it is necessary to position the hook so that the

plane of the hook is perpendicular to long axis of
hoist, first convert to a swivel type hook as
described above but do not discard the keeper
plate and screw. Turn hook 90 degrees and insert
loose pin (packed with the suspension) into a hole
in the hook nut. Loosely reassemble keeper plate
to suspension adapter so that the hook is free to
swivel approximately 45 degrees in either direction.
The hook will be made rigid after suspension is attached
to the hoist.

CHANGING
POSITION OF
HOOK

2. 3, 4 And 5 Ton Double Reeved And 5, 6 And 7

Ton Triple Reeved Units. Slide the suspension
adapter into cavity on top of hoist. Install dead end
bolt and thread it by hand to engage the dead end
block (3, 4 and 5 ton double reeved units) or idler
sheave hanger (5, 6 and 7 1/2 ton triple reeved
units). Then tighten the dead end bolt to a seating
torque of 120 pound feet (160 NM).
INSTALLING LUG
SUSPENSION3, 4,
5, 6 AND 7 1/2 TON

Dead End Bolt

c. Slide the suspension adapter into cavity on top

of hoist. Install dead end bolt and thread it by
hand to engage the dead end block (3, 4 and 5
ton double reeved units) or idler sheave hanger
(5 and 6 ton units). Then tighten dead end bolt
to a seating torque of 120 pound feet (160NM).

! WARNING

INSTALLING
HOOK
SUSPENSION
3, 4, 5, & 6 TON

Using other than factory supplied suspension adapter

screw or dead end bolt to attach suspension adapter
to hoist may cause the screw or bolt to break and
allow the hoist and load to fall.

TO AVOID INJURY:
Use only the factory supplied suspension adapter
screw or dead end bolt and tighten these to the seating torque specified above.

MOUNTING TROLLEY ON HOIST

If the hook is to be perpendicular to long axis of hoist

per step b above, rotate the hook to that position and
firmly tighten the keeper plate screw while making sure
the loose pin engages the slot in keeper plate.
NOTE: INSTALL BREATHER IN MAIN HOUSING
AFTER HOOK SUSPENSION IS ASSEMBLED TO
HOIST. SEE PAGE 8.

B. LUG SUSPENSIONS
The following instructions are provided to cover
installing the lug suspension after the hoist has been
reassembled following inspection and/or repair. On
hoists shipped from factory, the lug suspension is
installed prior to mounting the trolley.
1. 2 Ton Single Reeved Units. Slide the suspension
adapter into the cavity on top of hoist and secure it
using the suspension adapter screw. Tighten the
screw to a seating torque of 16 pound feet (22 NM).

INSTALLING LUG SUSPENSION2 TON UNITS

The following instructions are provided to cover mounting plain, geared and motor driven trolleys after the
hoist has been reassembled following inspection and/or
repair. On units shipped from factory, these trolleys are
mounted on the hoists.
1. Measure actual width of the beam flange on which
the trolley is to operate. To determine proper trolley
side frame spacing to assure that adequate wheel
clearance is provided, the distance between the
beam flange and the inside face of the trackwheel
flange (approximately 1/8 to 3/16 inch on straight
runway beams, 3/16 to 1/4 inch on curved beams for
2 ton units. See Figure 2) and (1/4 inch for straight
runway beams, 3/8 inch on curved beams for 3-7 1/2
ton units. See Figure 1).
2. Use Table 2 to determine proper spacing for 2 ton
units. On 3-7 1/2 ton capacity units, proper spacing is
obtained by varying the number of spacer washers
(furnished with trolley) that are installed on the suspension pins.
MOUNTING
TROLLEY ON
HOIST

HANDWHEEL OR TROLLEY
MOTOR GEARED OR MOTOR
DRIVEN TROLLEY ONLY

3. For 2 ton units, assemble a slotted nut to one

end of each suspension bolt and secure it using a
cotter pin. Spread legs of cotter pin to keep it in
place. Using Table 2 as a reference for washer
spacing, assemble side frames and bolts and
washers together as shown below. Do not install
remaining cotter pins at this time. These are to
be installed after the trolley is mounted on the
beam.
For 3-7 ton units, temporarily assemble trolley to
hoist using 3 or 4 washers at each end of suspension
pins, between side plates and suspension lug. Tighten
pin nuts for accurate check of spacing. Measure the
distance between the inside faces of the trackwheel
flanges and compare to the dimension required.
Remove trolley side plates and add or remove an
equal number of inside spacer washers as required to
obtain proper distance between wheels. When spacing is correct, install all remaining spacer washers on
the outside ends of each suspension pin and secure
the pins with lockwashers and hex nut (See Note
Below). The nuts should not be completely tightened
until after hoist and trolley are mounted onto beam.

QUANTITY OF
INSIDE WASHERS
SHOULD BE EQUAL
-BOTH SIDES

QUANTITY OF
OUTSIDE WASHERS
SHOULD BE EQUAL
-BOTH SIDES

Figure 1.

NOTE: It is very important that all spacer

washers that come with the trolley be
used. Install remaining spacer washers
equally on outside ends of each
suspension pin.
4. On geared and motor driven trolleys, make sure
the handwheel or motor is on loose end/chain
container side of the hoist.

INSTALLING TROLLEY SUSPENDED HOIST ON

BEAM
!

WARNING

Operating the trolley on a beam that has no rail stops

may allow the trolley to fall off the end of the beam.

TO AVOID INJURY:
Install rail stops at each end of the beam on which
the trolley is to operate.
Stops must be positioned to contact the trolley side
frames and not exert impact force on the hoist.
Trolleys are mounted on the hoist prior to shipment and side
frames are positioned for the nominal beam flange specified
on the order. However, due to variations in beam flange
widths, actual beam flange width should be measured to
determine the exact distribution of the spacer washers. See
Mounting Trolley On Hoist Section.

WARNING

If washer spacing recommendations are not followed, trolley may fall from beam.

TO AVOID INJURY:
Measure the actual beam flange on which the trolley
is to operate and use Table 2 to determine the
arrangement of the spacer washers for that flange
width.
NOTE: USE OF OTHER THAN SUPPLIED SPACER WASHERS
MAY CAUSE IMPROPER TRACKWHEEL SPACING.

Figure 2.

Table 2. Trolley Spacer Washer Arrangement

Flange
Width
in.(mm)
3-3/8 (85.7)
3-5/8 (92.0)
3-7/8 (98.4)
4 (101.6)
Standard
4-1/8 (104.7)
Trolleys
4-5/8 (117.4)
5 (127.0)
5-1/8 (130.1)
5-1/4 (133.3)
5-1/2 (139.7)
5-5/8 (142.9)
6 (152.4)
6-1/4 (158.7)
6-3/8 (161.9)
Special
7 (177.8)
Trolleys
7-1/8 (181.0)
7-1/4 (184.1)
7-3/8 (187.3)
7-1/2 (190.5)
7-5/8 (193.7)
* Minimum Beam
Radius ft.(M)

2 Ton
No. of Washers
A
13
11
10
9
8
5
3
3
2
0
12
10
9
8
4
3
3
2
1
0

B
0
2
3
4
5
8
10
10
11
13
1
3
4
5
9
10
10
11
12
13

C
0
2
4
4
5
8
10
11
12
13
1
3
5
6
9
10
11
12
12
13

D
13
11
9
9
8
5
3
2
1
0
12
10
8
7
4
3
2
1
1
0

4-0(1.22)

*Dimension applies to minimum S-beam and will

vary with larger S-beams

Before installing geared or motor driven trolleys (2 ton

only) on the beam, lubricate the trackwheel gears and
pinion with Texaco Novatex #2 or equivalent heavy cup
grease.
On open end beams, remove rail stops, lift hoist/trolley
into position and slide the hoist/trolley assembly onto
beam flange. Reinstall the rail stops.
On closed end beams, loosen the suspension bolt nuts
on one side of trolley and slide one side frame out far
enough to clear the beam flange. Lift hoist/trolley
assembly up so that trackwheels are riding on beam
flange. Draw side frames together by tightening the suspension bolt nuts snugly.
Be sure to install cotter pins through slotted nuts and
hole in suspension bolts and spread legs of cotter pins to
secure on 2 ton units. For 3-7 1/2 ton units, be sure lockwashers are positioned properly on the suspension pins
and completely tightened.
On geared trolleys, the bottom of the hand chain loop is
normally located two feet (0.6M) above the floor. If it is
desired to change this, find the unwelded link and open
it by spreading with a chisel or twist one end with a
wrench while holding the other end in a vise or another
wrench. Remove an even number of links (2,4,6, etc.) as
necessary to shorten the chain or add an even number
of links to lengthen the chain (when lengthening the
chain, another open link will be required and this can be
made from a welded link by cutting through weld with
a hacksaw). Make certain that the chain is not twistedthen re-install and close open links.
NOTE:

AFTER THE UNIT IS CONNECTED TO THE POWER

SUPPLY SYSTEM (SEE BELOW), SUSPEND A
CAPACITY LOAD FROM THE HOIST AND OPERATE
THE TROLLEY OVER THE ENTIRE LENGTH OF THE
RUNWAY OR MONORAIL SYSTEM TO BE SURE
THAT THE ADJUSTMENTS AND OPERATION IS
SATISFACTORY. ON SYSTEMS WITH CURVES, THE
EDGES OF THE RAIL AT THE CURVED SECTIONS
SHOULD BE KEPT LIGHTLY LUBRICATED WITH
GREASE.

! WARNING
An excessively worn beam flange may fail and allow
the trolley to fall from the beam.

TO AVOID INJURY:
Periodically inspect the beam flange for wear. Replace
beam if flange is worn.

POWER SUPPLY SYSTEM

To insure proper operation, to avoid damage to
hoist and electrical system and to reduce the risk of
electric shock or fire, the branch circuit supplying
power to the hoist must:
1. Have ample capacity to prevent excess voltage
drop during starting and operation (refer to
Checking for Adequate Voltage at HoistSee
Pg. 10). When determining the size of branch
circuit components and conductors, special consideration should be given to the starting current-amps (approximately three times that
shown on the hoist identification plate) and the
length of the conductors. As a minimum, the
system should be rated for 20 amps and it
should have #12AWG, or larger, wiring.
2. Be in accordance with the National Electrical
Code (ANSI/NFPA-70) and applicable National,
State and Local Codes.
3. Effectively ground the hoist in accordance with
National Electrical Code and other applicable
codes. Proper grounding provides a path of least
resistance for electric current to reduce the risk
of electric shock. The power cord of the hoist
includes a green wire for grounding the hoist to
the external power supply system. If grounding is
to be through the trolley trackwheels, each section of the runway must be grounded to the
building ground system using metal to metal
connections.
4. Include slow blow type fuses or inverse trip time
circuit breakers to permit the hoist to start and
accelerate load.
5. Include a disconnecting means capable of being
locked in the open position.

! WARNING
Failure to properly ground the hoist presents the danger of
electric shock.
TO AVOID INJURY:
Permanently ground the hoist as instructed in this manual.

INSTALLING BREATHER
After the hook suspension is assembled to the hoist or after
the hoist and trolley are mounted on the beam, remove the
upper plug from the main housing (652-110) and install the
breather (from small envelope attached to the power cord).
Failure to install the breather could damage oil seals and thus
cause oil leaks.
INSTALL
BREATHER

TYPICAL POWER
SUPPLY SYSTEM

! WARNING
Failure to provide a proper power supply system for
the hoist may cause hoist damage and offers the
potential for a fire.
TO AVOID INJURY:
Provide the hoist with a 20 amp, minimum, overcurrent
protected power supply system per the National
Electrical Code (ANSI/NFPA 70) and applicable local
codes as instructed in this manual.
NOTE: IN THIS MANUAL, NOMINAL VOLTAGES ARE
USED WHEN REFERRING TO POWER SUPPLY
SYSTEMS. HOWEVER, WITH NO MODIFICATION, THE XL HOIST WILL OPERATE ON A
RANGE OF VOLTAGES AS INDICATED BELOW:

NOMINAL
VOLTAGE
230
460
220
380
415
575

VOLTAGE
RANGE
208-240
440-480
200-240
365-395
400-430
550-575

3. Reassemble motor cover (and counterweight if so

equipped) to hoist frame.
4. Mark the tag attached to power cord to indicate
that the hoist has been converted to operate on 230
(or 220) volts and restamp hoist identification plate
accordingly.
If the hoist is suspended from a single speed motor driven trolley, it will also be necessary to change the trolley motor
connections. To do this, remove the cover from the terminal box mounted on the side of the trolley motor and
reconnect the trolley motor wires attached to the terminal
board as shown below:

(2 TON ONLY)

HERTZ
60
60
50
50
50
60

ELECTRICAL CONNECTIONS
SINGLE SPEED, DUAL VOLTAGE HOISTS (AND
MOTOR DRIVEN TROLLEYS)
Unless ordered on a special basis, single speed dual voltage
(230/460-3-60, 220/380-3-50 and 220/415-3-50) hoists are factory
wired to operate on 460-3-60 (or 380-3-50 or 415-3-50).
However, a conversion terminal board is provided to easily and
quickly change from 460 to 230 (or 380 to 220 or 415 to 220)
volt operation. The conversion terminal board is located adjacent
to the reversing contactor at motor end of hoist. If necessary,
change voltage connections before connecting hoist to power
supply system as follows:
1. Remove the motor cover (652-182). On units with
hook suspension, it will be necessary to remove the
counterweight (652-219) before removing motor
cover.
2. Shift all eight wires from row of terminals marked
460 (or 380 or 415) to row of terminals marked
230 (or 220).
HOIST VOLTAGE
CONVERSION

TROLLEY VOLTAGE CONVERSION

(Connections shown are for 208-240 volt operation)

ALL HOISTS
After making sure that the hoist (and motor driven trolley) are wired to operate on the power supply system,
you are now ready to connect hoist power cord to the
power supply. Since these are three phase units, the
hoist motor can rotate in either direction depending on
how it is connected to the power supply. Therefore,
direction of hook movement must be checked during the
original installation and each time the hoist is moved to
a new location.
Always disconnect the hoist from the power supply system or
de-energize the power supply system and follow proper
Lockout/Tagout procedures when working (connecting
or disconnecting) with the hoist electrical connections.
Serious damage will result if the hook is run to upper or

WARNING
FAILURE TO FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES
MAY PRESENT THE DANGER OF ELECTRICAL SHOCK.

TO AVOID INJURY:
DISCONNECT POWER AND LOCKOUT/TAGOUT DISCONNECTING MEANS BEFORE REMOVING COVER OR SERVICING THIS
EQUIPMENT.

lower limit of lift with hook moving in a direction opposite to that indicated by the control station. Connect
hoist power cord to the power supply and check hook
movement as follows:
1. Move the manual disconnect switch handle to the
OFF position.
CONVERSION TERMINAL BOARD
MOVE ALL 8 WIRES TO CONVERT FROM 460 TO 230
(380 TO 220, 415 TO 220) VOLT OPERATION

2. Connect the WHITE-PURPLE, RED AND BLACK wires

of hoist power cord to load side of disconnect switch.
Connect the GREEN wire of hoist power cord to
power supply ground.
9

3. Move the manual disconnect switch handle to the

ON position.

4. Depress the
(up) control. If the hook moves in the

up direction, the hoist is ready for operation. If the
hook lowers, move the disconnect switch handle to
the OFF position and interchange the BLACK and
RED leads at the disconnect switch. Move the disconnect switch handle to the ON position and the
hoist is now ready for operation.

! WARNING
Allowing the hook block to run into the bottom of
the hoist when raising a load or allowing the chain to
become taut between the loose end screw and the
frame when lowering a load may break the chain and
allow the load to drop.
TO AVOID INJURY:
Do not allow the hook block to contact the bottom of
the hoist or the loose end chain to become taut.
NOTE: DO NOT CHANGE INTERNAL WIRING OF
HOIST OR CONTROL STATION TO REVERSE
HOOK DIRECTION. THE HOIST AND CONTROL
STATION WIRING WAS INSPECTED AND TESTED FOR PROPER OPERATION AT THE FACTORY.
CHANGING THIS WIRING WILL CAUSE IMPROPER OPERATION AND SERIOUS DAMAGE.
Also, do not force the Protector to compensate for improperly
adjusted limit switches or reverse voltage phasing.

CHECKING FOR TWIST IN LOAD CHAIN

3, 4 And 5 Ton Double Reeved Units

The best way to check for this condition is to run the

lower hook, without a load, up to within about 2 feet
(0.6M) of hoist. If the dead end of chain has been properly installed, a twist can occur only if the lower hook block
has been capsized between the strands of chain. Reverse
capsize to remove twist.
5,6 And 7 1/2 Ton Triple Reeved Units

NOMINAL
POWER
SUPPLY

MINIMUM
OPERATING
VOLTAGE

* MIN. VOLTAGE
AT INSTANT
OF START

208-3-60
220-3-50
230-3-60
380-3-50
415-3-50
460-3-60

187
198
207
365
399
414

172
182
190
336
367
380

* The drop in voltage upon energizing the hoist should

not be below the value listed.
Remember, operation with low voltage can void the
Repair/Replacement policy. When in doubt about any of
the electrical requirements for the power supply system,
consult a qualified electrician.

CHECKING LIMIT SWITCH OPERATION

1. Press the
(Up) control and raise the lower hook

until the top of the hook block is about one foot
(0.3M) below hoist.
2. Cautiously continue raising the hook until upper
limit switch stops upward motion. At this point, the
top of the hook block should be 3 inches (76 mm)
below bottom of the hoist.
3. If adjustment is necessary, see page 16.
4. Press  (Down) control and cautiously lower hook until
lower limit switch stops the downward motion. From
10 to 12 chain links should be between the loose end
link and the opening for the chain in bottom of hoist.
If adjustment is necessary, see page 16.

! WARNING
Allowing the hook block to run into the bottom of
hoist when raising a load or allowing the chain to
become taut between the loose end screw and the
frame when lowering a load may break the chain and
allow the load to drop.
TO AVOID INJURY:
Do not allow the hook block to contact the bottom of
hoist or the loose end chain to become taut.

On these models, the load chain is dead ended on top of

the lower hook block. If chain has been properly installed,
the only way a twist can occur is if the lower hook block
has been capsized between the strands of chain. If this
has occurred, two strands of chain will be wrapped
CHAIN CONTAINER
around each other and to remove twist, reverse the capIf a chain container is to be used, attach it to the hoist
size.
frame and place chain in container per instructions provided with the chain container kit. After the chain container
CHECKING FOR ADEQUATE VOLTAGE AT HOIST
is installed, follow the instructions on page 16 to reset
The hoist must be supplied with adequate electrical
power for proper operation and to reduce problems that upper limit switch so uppermost point of hook travel is
just below the bottom of the chain container.
may result from insufficient power (low voltage). These
include:
UNDER NO CIRCUMSTANCES SHOULD THE HOOK
Noisy hoist operation due to brake and/or contactor
BLOCK OR LOAD BE PERMITTED TO COME IN CONchatter.
TACT WITH THE CHAIN CONTAINER. IF CONTACT IS
Heating of the hoist motor and other internal
MADE, THE FUNCTION OF THE CHAIN CONTAINER CAN
components as well as heating of wires and conBE INTERFERED WITH, THE CONTAINER MAY BE DAMnectors in the circuit feeding the hoist.
AGED AND IT COULD FALL OFF OF THE HOIST.
Failure of the hoist to lift the load due to motor
stalling.
CONTROL CORD
Blowing fuses or tripping circuit breakers.
Unless ordered on a special basis, the hoist is supplied
with a control cord that will position the control station
For proper operation and to avoid these low voltage
approximately 4 feet (1.2M) above the lower hook when
problems, voltage (measured at the end of the 2.5 foot
it is at the lower limit of lift. If this places the control sta(.9 M) power cord while lifting rated load) should be as
tion too close to the floor, a control cord alteration kit
follows:
(Key No. 627-474, Part Number 28642) can be obtained
from factory for shortening the length of the control
10
cord.

! WARNING
Tying knots or loops to shorten the drop of the control station will make the strain relief ineffective and the
internal conductors of the cord may break.
TO AVOID INJURY:
Shorten the control cord using the control cord alteration kit and the instructions provided with the kit.

OPERATING INSTRUCTIONS

4. If material being handled must be immersed in

water, pickling baths, any liquid, dusty or loose
solids, use a sling chain of ample length so that the
hook is always above the surface. Bearings in the
hook block are shielded only against ordinary atmospheric conditions.
5. Read operation section of American National
Standard ASME B30.16.

ALL HOISTS
1. Before picking up a load, check to see that the hoist
is directly overhead.

GENERAL

1. The Protector is designed to allow the first reduction gear 2. WHEN APPLYING A LOAD, IT SHOULD BE DIRECTLY
UNDER HOIST OR TROLLEY. AVOID OFF-CENTER
to slip on an excessive overload. An overload is indicated
LOADING OF ANY KIND.
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) 3. Take up a slack load chain carefully and start load
easily to avoid shock and jerking of hoist load
control to stop operation of the hoist. At this point, the
chain. If there is any evidence of overloading,
load should be reduced to the rated hoist capacity or the
immediately lower the load and remove the excess
hoist should be replaced with one of the proper capacity.
load.
When the excessive load is removed, normal hoist operation is automatically restored.
4. Do not allow the load to swing or twist while hoisting.
CAUTION: THE PROTECTOR IS SUSCEPTIBLE TO OVER
5. Do not allow the load to bear against the hook latch.
HEATING AND WEAR WHEN SLIPPED FOR
EXTENDED PERIODS. UNDER NO CIRCUMHOIST WITH PLAIN TROLLEY
STANCE SHOULD THE PROTECTOR BE
This unit should be moved by pushing on the suspended load
ALLOWED TO SLIP FOR MORE THAN A FEW
or by pulling the empty hook. However, the unit can also be
SECONDS.
moved by pulling on the control station since an internal steel
cable extends the length of the control cord and is anchored to
Due to the above, a hoist equipped with a Protector is not the hoist and to the control station.
recommended for use in any application where there is a
possibility of adding to an already suspended load to the
HOIST WITH GEARED TROLLEY
point of overload. This includes *dumbwaiter installations, This unit should be moved by means of the pendant
containers that are loaded in mid-air, etc.
hand chain. Pull on the chain farthest from end toward
which the unit is to travel.
*Refer to limitations on Page ii concerning dumbwaiter applications.
Also, if a XL Hoist with a Protector is used at unusual
xtremes of ambient temperatures, above 150F (65C) or
below 15 F (-9C) changes in lubricant properties may
permit the hoist to raise larger loads than under normal
operating conditions and presents possibility of damage
or injury.
2. All hoists are equipped with an adjustable screw
limit switch, which automatically stops the hook at
any predetermined point when either hoisting or lowering.

HOIST WITH MOTOR DRIVEN TROLLEY

This unit should be moved by operating the controls
marked < FORWARD and > REVERSE in control station.
Anticipate the stopping point and allow trolley to coast
to a smooth stop. Reversing or plugging to stop trolley
causes overheating of motor and swaying of load.

SAFETY PROCEDURES
For safety precautions and a list of Dos and Do Nots for
safe operation of hoists, refer to page ii.

3. The control station used on two speed hoists is similar to 1. When preparing to lift a load, be sure that attachments to hook are firmly seated in hook saddle.
single speed unit, except that either of two definite
Avoid off center loading of any kind, especially
speeds may be selected by the operator in both
loading on the point of hook.
hoisting and lowering. Each control when partially
depressed provides SLOW speed and when fully
2. When lifting, raise load only enough to clear the
depressed gives FAST speed. Partial release of confloor or support and check to be sure that the
trol returns hoist to slow speed, while complete
attachments to the hook and load are firmly seated.
release allows hoist to stop. Rated lifting speeds are
Continue lift only after you are assured the load is
shown on hoist identification plate. SLOW speed is
free of all obstructions.
intended as a means of carefully controlling or
spotting the load, although the hoist may be
3. Do not load hoist beyond the rated load shown on
operated solely at this speed if desired. It is not nechoist identification plate and capacity labels.
essary to operate in the SLOW speed position as the
Overload can cause immediate failure of some loadhoist will pick up a capacity load at FAST speed
carrying part or create a defect causing subsequent
from a standing start. In other words, it is not necfailure at less than rated load. When in doubt, use
essary to hesitate at the slow position when moving
the next larger capacity of XL Hoist.
control from STOP and FAST position or vice versa.

11

4. Do not use this or any other overhead materials handling equipment for lifting persons.
5. Stand clear of all loads and avoid moving a load over
the heads of other personnel. Warn personnel of
your intention to move a load in their area.
6. Do not leave load suspended in air unattended.
7. Permit only qualified personnel to operate unit.
8. Do not wrap the load chain around the load and
hook onto itself as a choker chain.
Doing this will result in:
a. The loss of the swivel effect of the hook which
could mean twisted chain and a jammed lift
wheel.
b. The upper limit switch is by-passed and the load
could hit the hoist.
c. The chain could be damaged at the hook.
9. On double and triple reeved hoists, check for twists
in the load chain. A twist can occur if the lower
hook block has been capsized between the strands
of chain. Reverse the capsize to remove the twist.
10. Do not allow the load to bear against the hook
latch. The latch is to help maintain the hook in position while the chain is slack before taking up slack chain.

! WARNING
Allowing the load to bear against the hook latch
and/or hook tip can result in loss of load.
TO AVOID INJURY:
Do not allow the load to bear against the hook latch
and/or hook tip. Apply load to hook bowl or saddle
11. Take up a slack load chain carefully and start load eas
ily to avoid shock and 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 use the hoist when you are
tired, distracted or under the influence of drugs,
alcohol or medication causing diminished control.

MAINTENANCE
INSPECTION
To maintain continuous and satisfactory operation, a
regular inspection procedure must be initiated to
replace worn or damaged parts before they become
unsafe. Inspection intervals must be determined by the
individual application and are based on the type of service to which the hoist will be subjected and degree of
exposure to wear, deterioration or malfunction of the
critical components.

12

The type of service to which the hoist is subjected can be

classified as Normal, Heavy, or Severe.
Normal Service: Involves operation with randomly distributed loads within rated load limit, or uniform loads less
than 65 percent of rated load for not more than 25 percent of the time.
Heavy Service: Involves operating the hoist within rated
load limit which exceeds normal service.
Severe Service: Normal or heavy service with abnormal
operating conditions.
Two classes of inspectionFrequent and Periodic
must be performed.

FREQUENT INSPECTIONS: These inspections are visual examinations by the operator or other designated personnel. Records of such inspections are not required. The
frequent inspections are to be performed monthly for
normal service, weekly to monthly for heavy service, and
daily to weekly for severe service, and they should
include those items listed in Table 3.
PERIODIC INSPECTIONS: These inspections are visual
inspections of external conditions by an appointed person. Records of periodic inspections are to be kept for
continuing evaluation of the condition of the hoist.
Periodic inspections are to be performed yearly for normal service, semi-annually for heavy service and quarterly
for severe service, and they are to include those items
listed in Table 4.
CAUTION: ANY DEFICIENCIES ARE TO BE CORRECTED
BEFORE THE HOIST IS RETURNED TO SERVICE. ALSO, THE EXTERNAL CONDITIONS
MAY SHOW THE NEED FOR DISASSEMBLY
TO PERMIT A MORE DETAILED INSPECTION,
WHICH, IN TURN, MAY REQUIRE THE USE
OF NONDESTRUCTIVE TYPE TESTING.

HOOK INSPECTION
Hooks damaged from chemicals, deformations or cracks,
or that have more than a 10 twist from the hooks
unbent plane, excessive opening or seat wear must be
replaced. Also, hooks that are opened and allow the
latch to not engage the tip must be replaced. Any hook
that is twisted or has excessive throat opening indicates
abuse or overloading of the unit. Inspect other load sustaining parts for damage.
On latch type hooks, check to make sure that the latch is
not damaged or bent and that it operates properly with
sufficient spring pressure to keep the latch tightly
against the tip of the hook and allow latch to spring
back to tip when released. If latch does not operate
properly, it should be replaced. See below to determine
when the hook must be replaced.

LOAD CHAIN

LATCH TYPE HOOK

(Upper and Lower)
TO MEASURE OPENING,
DEPRESS LATCH AGAINST
HOOK BODY AS SHOWN.

E
UR
AS ING
E
N
M PE
O

*UPPER HOOK NOT AVAIL ABLE

FOR 7 1/2 TON

CAPACITY
(TONS)

Replace Hook
When Opening
Is Greater
Than

1 1/2 IN.
38.1 mm

3,4,5,6 AND 7

2 3/8 IN.
60.3 mm

LATCHLOCK TYPE HOOK

(UPPER AND LOWER)
A

B Max.

CAPACITY
(TONS)
2
3,4,5, and 6

Replace Hook
When Opening
Or Seat are:

A Max.
2 1/2 IN.
63.5 mm

B Mn.
1 1/8 IN.
28.5mm

2 15/16 IN.
74.6 mm

1 13/32 IN.
35.7mm

Hook Inspection

Cleaning and Inspection

First clean load chain with a non-acid or non-caustic type
solvent. Then slack the chain and make a link-by-link
inspection for nicks, gouges, twisted links and excessive
wear or stretching. Chain exhibiting wear should be
checked throughout its entire length and replaced if
worn beyond serviceable limits.
Checking For Load Chain Wear
Slack the portion of the chain that normally passes over
the liftwheel. Examine the interlink area for the point of
maximum wear (polishing). Measure and record the stock
diameter at this point of the link. Then measure stock
diameter in the same area on a link that does not pass
over the liftwheel (use the link adjacent to the loose end
link for this purpose). Compare these two measurements.
If the stock diameter of the worn link is 0.010 inches
(0.254mm), or greater, less than the stock diameter of
the unworn link, the chain must be replaced.
Note that worn chain can be an indication of worn hoist
components. For this reason, the hoists chain guides,
hook blocks and liftwheel should be examined for wear
and replaced as necessary when replacing worn chain.
Also, these chains are specially heat treated and hardened and should never be repaired.

! WARNING
Using other than factory supplied load chain may
cause the chain to jam in the hoist and/or allow the
chain to break and the load to drop.
TO AVOID INJURY:
Due to size requirements and physical properties, use
only Hoistaloy load chain in the XL Hoists.

IMPORTANT:
DO NOT USE REPLACED CHAIN FOR OTHER PURPOSES SUCH AS LIFTING OR PULLING. LOAD CHAIN MAY
BREAK SUDDENLY WITHOUT VISUAL DEFORMATION.
FOR THIS REASON, CUT REPLACED CHAIN INTO
SHORT LENGTHS TO PREVENT USE AFTER DISPOSAL.

PROTECTOR
The Protector should operate for the normal life of hoist
without service. The device has been calibrated at the
factory for a specific capacity/gear ratio of XL Hoist. It is
not adjustable and it is not interchangeable with other
capacities/gear ratios.

XL Hoist with
Motor Driven
Trolley

13

Table 3. Minimum Frequent Inspections

ITEM

TYPE OF SERVICE

Monthly

Severe
a)
b)
c)

Daily
to Weekly

Heavy

Weekly
to Monthly

Normal

d)
e)

Brake for evidence of slippage.

Control functions for proper operation.
Hooks for damage, cracks, twists, excessive throat opening. latch engagement
and latch operationsee page 13.
Load chain for adequate lubrication, as well as for signs of wear, damaged links
or foreign mattersee page 15.
Load chain for proper reeving and twists.

Table 4. Minimum Periodic Inspections

TYPE OF SERVICE
Normal

Heavy

ITEM

Severe
a)
b)
c)
d)

e)

f)

Every 3 Months

Every 6 Months

Yearly

g)

h)
i)

j)
k)
l)

m)

n)
o)

14

All items listed in Table 3 for frequent inspections.

External evidence of loose screws, bolts or nuts.
External evidence of worn, corroded, cracked or distorted hook block, gears,
bearings, dead end block, dead end pin, dead end bolt and suspension components.
External evidence of damage to hook retaining nut and pin. Also check the
upper suspension adapter making sure it is fully seated in the hoist frame and
that suspension adapter screw or dead end bolt is tight.
External evidence of damage or excessive wear of the liftwheel and hook block
sheave chain pockets. Widening and deepening of the pockets may cause the
chain to lift-up in the pocket and result in binding between liftwheel and chain
guide or between the sheave and hook block. Also, check the chain guide for
wear or burring where the chain enters the hoist. Severely worn or damaged
parts should be replaced.
External evidence of excessive wear of brake parts, and brake adjustmentsee
page 15.
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.
Inspect the electrical cords and cables and control station enclosure for damaged
insulation.
Inspect trolley trackwheels for external wear on tread and flange and for wear
on internal bearing surfaces as evidenced by a looseness on the stud.
Suspension components for damage, cracks, wear and operation. Also check suspension adapter screw or dead end bolt for proper tightness(see pages 4,
5,and 6).
Inspect the loose end link, loose end screw, dead end block on double reeved
units and dead end plate on triple reeved units. Replace worn or distorted parts.
Inspect the hook for excess free play or rotation. Replace worn parts as evidenced
by excess free play or rotation.
Inspect for oil leaks at the gasket on either side of intermediate plate. Tighten
the screws used to attach the main housing and brake housing to intermediate
plate. If leak persists, disassemble hoist (see page 27) and replace gaskets.
Inspect inside of motor and brake housings for presence of oil. Oil in motor
housing may be excess chain lubricant or a leaking seal. Wipe out oil and monitor. If leak persists, replace seal (652-122 or 652-132). Oil in brake housing is due
to leaking seal. Replace seal (652-122 or 652-134).
Check motor bolts for damage and replace if bent, cracked or damaged.
Inspect all splines for signs of wear and deterioration. Replace splined parts if
worn or damaged.

LUBRICATION

! WARNING
The lubricants used in and recommended for the XL Hoist
may contain hazardous materials that mandate specific handling and disposal procedures.

TO AVOID CONTACT AND CONTAMINATION:

Handle and dispose of lubricants only as directed in applicable
material safety data sheets and in accordance with applicable
local, state and federal regulations.

Bearings. All bearings except the lower hook thrust

bearings are pre-lubricated or are in an oil bath and
need no lubrication. The lower hook thrust bearing
should be lubricated at least once a month with heavy
duty machine oil.
Miscellaneous. If unit is disassembled, splines inside
coupling (652-103) should be coated with an EP type
grease (such as Evans Products Co. Anti-Scoring Extreme
Pressure Lub. No. 3) before reassembly.

TROLLEY LUBRICATION
Trackwheel bearings are pre-lubricated and require no lubrication.
Geared Trolley. Once a month lubricate trackwheel
gears with Texaco Novatex No. 2 or an equivalent heavy
cup grease or graphite grease.

NOTE: TO ASSURE EXTRA LONG LIFE AND TOP PERFORMANCE, BE SURE TO LUBRICATE THE VARIOUS
PARTS OF THE XL HOIST USING THE LUBRICANTS
SPECIFIED BELOW. IF DESIRED, THESE LUBRCANTS Every six months lubricate handwheel shaft bearings in
3-in-1 machine oil.
MAY BE PURCHASED FROM THE FACTORY.

HOIST LUBRICATION
Gears. Check oil level in gear housing at least once a
month, maintaining it at the bottom of oil level hole in
main housing (652-110).

Motor Driven Trolley. Once a month lubricate trackwheel gears with Texaco Novatex No. 2 or an equivalent
heavy cup grease or graphite grease.

Drain housing every 2-3 years and refill with one gallon
(3.86 liters) of gear oil Amoco 85W-140.

For 2 ton trolleys, the motor bearings and reduction gears

require no additional lubrication. However, if gears are disassembled, upon reassembly use Texaco Novatex No. 1 or an
equivalent medium cup grease.

CAUTION: THE PROTECTOR IS TO OPERATE IN THE

ABOVE MENTIONED OIL. DO NOT USE ANY
OTHER TYPE OF LUBRICANT OR THE
PROTECTOR WILL NOT OPERATE PROPERLY
AND PARTS COULD BE DAMAGED.

For 3-7 1/2 ton trolleys, the right angle worm gear reducer oil
should be changed after the first 100 hours of operation, then
after every 2500 hours of normal service. When replacing oil
due to repairs or service, use Mobil SHC-626 or equal, for
each oil change.

ADJUSTMENTS

The limit switch gears are of molded nylon and require no HOIST BRAKE
lubrication. Apply a light film of machine oil to the limit
The correct air gap between armature and field when brake is
switch shaft threads at least once a year.
not energized, is 0.025 inch (.63 mm) and need not be adjusted
until the gap reaches 0.045 inch (1.14 mm).
Chain Guides, Liftwheel & Sheave Wheels.
When the hoist is disassembled for inspection and/or
To adjust the brake, proceed as follows:
repair, the chain guides, sheave wheels (on multi-reeved
1. Disconnect hoist from power supply.
units) and liftwheel must be lubricated with Lubriplate Bar 2. Remove brake end cover.
and Chain Oil 10-R (Fiske Bros. Refining Co.) prior to
3. Before adjusting the gap, back off the brake nuts
reassembly. Apply sufficient lubricant to obtain natural
and examine friction linings and friction surfaces for
runoff and full coverage.
wear, scoring or warpage (min.thk. .188). Also check
shading coils to be sure they are in place and not
Load Chain. Keep chain lubricated with a small amount
broken. A missing or broken shading coil will cause
of lubricant. This will greatly increase the life of load
the brake to be noisy when hoist is operated. Any of
chain. Do not allow the chain to run dry.
these symptoms indicate the need for replacement of
parts.
Keep it clean and lubricate at regular intervals with
4. Turn brake nuts clockwise gaging the air gap on
Lubriplate Bar and Chain Oil 10-R (Fiske Bros. Refining
each side and at both ends of the armature.
Co.) or equal lubricant. Normally, weekly lubrication and
5. Replace cover, reconnect the power and check operation.
cleaning is satisfactory, but under hot and dirty conditions,
it may be necessary to clean the chain at least once a day
and lubricate it several times between cleanings. When
lubricating the chain, apply sufficient lubricant to obtain
natural runoff and full coverage.

! WARNING
Used motor oils contain known carcinogenic materials.
TO AVOID HEALTH PROBLEMS:
Never use used motor oils as a chain lubricant. Only
use Lubriplate Bar and Chain Oil 10-R as a lubricant
for the load chain.
HOIST BRAKE
ADJUSTMENT

15

LIMIT SWITCHES
If limit switch operation has been checked as described
on page 10 and is not operating correctly or is not automatically stopping the hook at a desired position, proceed as follows:
1. Disconnect hoist from power supply.
2. Remove brake end cover.
3. The positions of upper and lower limit switches are
indicated on the fiber insulator.
4. Loosen the screws to permit guide plate to be moved
out of engagement with the traveling nuts.

5. Reconnect hoist to power supply

6. Run hook to the desired upper or lower position,

cautiously operating the hoist without load.
7. Disconnect hoist from power supply.
8. Moving one travel nut toward the other increases
hook travel and away from the other decreases the
travel. To adjust the upper limit, turn the nut nearest
the switch indicated as Upper Limit Switch. To adjust
the lower limit, turn the nut nearest the switch marked
Lower Limit Switch. Turn the desired nut until it
just breaks the limit switch contacts. An audible click
will he heard as the switch opens. Continue to
rotate the nut toward the switch an additional two
full teeth.
9. Reposition the guide plate in the next slot and
securely tighten screws.
10. Reconnect hoist to power supply and check the stopping point of the hook by first moving the hook
about 10 inches (254 mm) away from the desired
stopping point. Then move the hook towards the
desired stopping point by jogging cautiously until
the limit switch stops the motion. If the stopping
point is not the desired position, repeat the above
instructions.
11. Double check the adjustment by moving the hook
about 2 feet (610 mm) from the desired stopping
point and then run the hook into the limit with the
control held in the fully depressed position.
12. Fine adjustment of the screw limits setting may be
obtained by inverting the guide plate. The offset on
the plate gives adjustments equivalent to 1/2 notch
(see Table below). When inverting the plate, it may
be necessary to use the notch adjacent to the one
used in the preliminary setting.

LIMIT SWITCHES
1. Limit switch sub-assy
4 Guide Plate
2. Limit switch shaft
5. Screws
3. Traveling nuts

HOOK TRAVEL PER NOTCH OF

LIMIT SWITCH NUT
PARTS
RATED
OF
LOAD
CHAIN
TONS
(REEVING)
(Kg.)
2 (2000)

18 (5.5)

127 (39)

1.10 (27.9)

24 (7.3)

139 (42)

1.27 (32.3)

2 (2000)

30 (9.1)

212 (65)

0.63 (16.0)

3 (3000)

9 (2.7)

60 (18)

0.55 (14.0)

3 (3000)

12 (3.6)

65 (20)

0.64 (16.1)

3 (3000)

15.2 (4.6)

106 (32)

0.93 (23.6)

4 (4000)

9 (2.7)

60 (18)

0.55 (14.0)

2 (2000)

4 (4000)

12 (3.6)

65 (20)

0.64 (16.1)

4 (4000)

15.2 (4.6)

106 (32)

0.93 (23.6)

5 (5000)

9 (2.7)

60 (18)

0.55 (14.0)

5 (5000)

12 (3.6)

65 (20)

0.64 (16.1)

5 (5000)

15.2 (4.6)

106 (32)

0.93 (23.6)

5 (5000)

6(1.8)

42 (13)

0.37 (9.3)

5 (5000)

8(2.4)

46 (14)

0.42 (10.8)

6 (6000)

6 (1.8)

42 (13)

0.37 (9.3)

6 (6000)

8 (2.4)

46 (14)

0.42 (10.8)

10 (3.0)

71 (22)

0.63 (16.0)

7 (7500)

6 (1.8)

42 (13)

0.37 (9.3)

7 (7500)

10 (3.0)

71 (22)

0.63 (16.0)

6 (6000)

16

HOOK
*LIFT
MAX. TRAVEL
SPEED
LIFT
PER
FPM
FT. (M) NOTCH
(MPM)
IN.(mm)

* At 60 Hertz. For 50 Hertz speeds are 5/6 of those listed.

Fast speeds are listed for two speed units.

TROLLEY BRAKE (2 TON UNIT)

(Optional Accessory)
The stopping distance of the Motor Driven Trolley
equipped with an electric brake can be increased or
decreased by adjusting the brake pressure. To increase
brake pressure, and thereby decrease stopping distance,
move the brake spacer washers progressively from the nut
side of the brake field plate to the spring side. To
decrease the stopping distance, move the washers in an
opposite manner. Both studs must have the same number
of washers on the spring side of the brake field plate.
The correct air gap between armature and field, when
the brake is not energized, is 0.025 inch (.63 mm) and
need not be adjusted until the gap reaches 0.045 inch
(1.14 mm).
To
1.
2.
3.

adjust the air gap or brake pressure, proceed as follows:

Disconnect hoist from power supply.
Remove brake cover.
Before adjusting air gap or brake pressure:
a.
b.

4.
5.
6.

Back off the brake nuts and examine friction linings and friction surfaces for excessive wear, scoring or warpage.
Check shading coils to be sure they are in place
and not broken. A missing or broken shading coil
will cause the brake to be noisy when trolley is
operated.

ADJUSTMENT
The motor brake should be checked periodically for wear of
the friction discs and/or proper adjustment of the solenoid
air gap. Refer to Figure 1. Normal lining wear will cause the
solenoid lever (8) to move away from the solenoid frame
(79) and thus increase the air gap and trolley stopping time.

When the air gap reaches approximately 11/16 the brake

should be adjusted. To adjust the air gap of the brake, proceed as follows:
Any of these symptoms indicate the need for
1. De-energize the power supply to trolley.
replacement of parts.
2. Remove both access covers to expose brake.
If brake pressure is to be adjusted, move brake spacer 3. Depress the plunger (13) towards the solenoid frame
until spring pressure is felt.
washers to the desired side of the brake field plate to
increase or decrease pressure as indicated above.
4. Hold the plunger firmly in the position and measure
After spacer washers are positioned, turn brake nuts
the air gap between the mating (ground) surfaces of
clockwise gaging the air gap at both ends.
the solenoid (79) and the solenoid plunger (29).
Replace brake cover, reconnect the power and check 5. To adjust, turn both wear adjustment screws (10) equal
operation. If the stopping distance of the trolley is
amounts clockwise until the air gap measures 13/32.
not as desired, repeat the above.

Replacement of Friction Disc

(Refer to Exploded View Drawing, Page 47)

TROLLEY BRAKE
ADJUSTMENT

TROLLEY BRAKE (3 THUR 7 TON UNITS)

(Optional Accessory)
The brake can be ordered with the trolley or it is available in kit form for installation on a unit in the field. To
order a brake kit for an existing unit, order brake kit
Key No. 29 and indicate the serial number of the trolley
on which it is to be installed and the voltage on which
the trolley operates.

1. De-energize the power supply to the trolley and remove

the motor/brake assembly from the gear reducer.
Remove housing (3) from the brake.
2. Remove the entire support plate assembly by unscrewing 3 screws (32). Remove the stationary disc (11) and
worn friction disc (12). Install the new friction disc, making sure that the two stablizing springs are at 90 in
the recessed portion of the squared hole in the friction
disc, with the prongs pointing into the brake. Place the
stationary disc on the friction disc and re-assemble the
entire support plate assembly engages the guide pins
of the end plate.
3. Remove both access covers (5) from the housing (1) and
slide the housing with its shaft assembly on to the
mounting studs. Be sure the housing is assembled with
access windows above the horizontal centerline. Rotate
shaft to engage key into the hub keyway.
4. Re-assemble the motor/brake assembly to the gear
reducer using the four nuts and lockwashers.
5. Adjust air gap per above instructions (ADJUSTMENTS).
6. Re-energize power supply and operate trolley a few
times to make sure air gap is correct and then replace
access covers (5).

17

Replacement of Coil
(Refer to Figure 1 on page 17 and Exploded
View Drawing on page 48).
1.

2.

3.

4.

De-energize the power supply to the trolley and

remove the motor/brake assembly from the gear
reducer.
Remove housing (3) from the brake and disconnect the
coil wires from the cord.
Insert screw driver between support plate (126, Fig.1)
and the top of lever arm (17, Fig.1). Wedge these apart
and remove bearing pin (26, Fig.1) and solenoid lever
(8, Fig.1) with link (13, Fig.1) and plunger (29, Fig.1).
Remove plunger guide screw (84, Fig.1) and both
plunger guides (82, Fig.1). Slide old coil sideways out of
the frame (79, Fig.1). If coil is difficult to move, tap
lightly with a soft hammer.

To insure continued service of the XL 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 or failed. Parts applicable to your
unit should be stocked.
Key No.

Part Name

652-120
652-130
652-131
652-135
627-563

Limit Switch Assembly

Brake Coil
Brake Friction Disc
Transformer
Control Station Parts Kit
(2 Direction Station)
Control Station Switch Kit
(2 Direction Station)
Control Station Switch Kit
(4 Direction Station)
Hoist Reversing Contactor
Speed Selecting Contactor
(2 Speed Hoists Only)
Trolley Reversing Contactor
Trolley Speed Selector
(2 Speed Trolley Only)

627-565
635-155
652-136
652-137

Qty. for Each

Hoist in Service
1
1
2
1
1
1
1
1
1

5.

Install new coil in the same relative position as the old

coil and replace the plunge guides (82, Fig.1) and screw
(84 and 84W, Fig.1).

6.

Re-assemble follwing Step 3 in reverse order.

Refer to page 32 for ordering instructions and the

parts list for part numbers.

7.

Re-connect the coil leads to the brake coil. Slide hous

ing and shaft assembly onto mounting studs, rotating
shaft to engage key into hub keyway. Be sure the
access covers are above the horizontal centerline.

PREVENTIVE MAINTENANCE

8.

Re-assemble motor/brake assembly to gear reducer

using the four nuts and lockwashers.

9.

Adjust air gap per above instructions (ADJUSTMENT).

10. Re-energize power supply and operate trolley a few

times to make sure air gap is correct and then replace
access covers.

18

RECOMMENDED SPARE PARTS

652-138
652-236

1
1

In addition to the inspection procedure on page

12, a preventive maintenance program should be
established to 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 15).

TROUBLE SHOOTING

TROUBLE

PROBABLE CAUSE

CHECK AND REMEDY

ALL HOISTS
1.

Hook does not

respond to the
control station.

A) No voltage at hoistmainline or
branch circuit switch open; branch
line fuse blown or circuit breaker
tripped.

A) Close switch, replace fuse or

reset breaker.

B)

Phase failure (single phasing)

open circuit, grounded or faulty
connection in one line of supply
system, hoist wiring, reversing contactor, motor leads or windings.

B) Check for electrical continuity and

repair or replace defective part.

C)

Upper or lower limit switch has

opened the motor circuit.

C) Press the other control and

the hook should respond. Adjust
limit switches as described on
page 15.

D) Open control circuitmotor therD) Check electrical continuity thru

mal switch open; shorted or open
thermal switch. If it is open,
winding in transformer, reversing
allow motor to cool. Should this
contactor coil or speed selecting
not correct the trouble, check
contactor coil; loose connection or
electrical continuity of other
broken wire in circuit; mechanical
parts and repair or replace
binding in contactor; control stadefective part.
tion contacts not closing or opening.
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 conversion and trolley terminal boards are the
proper voltage as described on
page 8.

F)

Low voltage.

F) Check for low voltage condition

as described on page 10.

G) Brake not releasingopen or shorted G) Check electrical continuity and

connections. Check that correct
coil winding; armature binding.
coil has been installed. The coil
for dual voltage unit operates at
230 volts when the hoist is connected for either 230 volt or 460
volt operation. Check brake
adjustment as described on page
15.
H) Excessive load.

H) Reduce loading to the capacity

limit of hoist as indicated on the
identification plate.

19

TROUBLE

PROBABLE CAUSE

2. Hook moves in the

wrong direction.

A) Wiring connections reversed at

either the control station or
terminal board.

A) Check connections with the

wiring diagram.

B)

B)

3. Hook lowers but

will not raise.

Phase reversal.

Refer to installation instructions

on page 9 (all hoists).

A) Excessive load.

A) See Item 1H.

B)

Open hoisting circuitopen or

shorted winding in reversing contactor coil or speed selecting contactor coil; loose connection or
broken wire in circuit; control station contacts not making; upper
limit switch contacts open.

B)

See Item 1D. Also check operation of limit switch as described

on page 10.

C)

Phase failure.

C)

See Item 1B.

4. Hook raises but

will not lower.

A) Open lowering circuitopen or

shorted winding in reversing contactor coil or speed selecting contactor coil; loose connection or
broken wire in circuit; 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
operation as described on page
10.

5. Hook lowers when

hoisting control is
operated.

A) Phase failure.

A) See Item 1B.

6. Hook does not

stop promptly.

A) Brake slipping.

A) Check brake adjustment as

described on page 15.

B)

Excessive load.

B)

See Item 1H.

C)

Protector slipping.

C)

If Protector is not functioning

properly, it should be replaced.

7. Hoist operates
sluggishly.

A) Excessive load.

A) See Item 1H.

B)

Low voltage.

B)

Check for low voltage condition as described on page 10.

C)

Phase failure or unbalanced current in phases.

C)

See Item 1B.

D) Brake dragging.

20

CHECK AND REMEDY

D) Check brake adjustment as

described on page 15.

TROUBLE
8. Motor overheats.

9. Hook fails to stop

at either or both
ends of travel.

10. Hook stopping

point varies.

PROBABLE CAUSE

CHECK AND REMEDY

A) Excessive Load.

A) See Item 1H.

B)

Low Voltage.

B)

Check for low voltage condition

as described on page 10.

C)

Extreme external heating.

C)

Above an ambient temperature

of 104F. (40C.), the frequency
of hoist operation must be limited to avoid overheating of
motor. Special provisions
should be made to ventilate
the space of shield the hoist
from radiation.

D) Frequent starting or reversing.

D) Avoid excessive inching, jogging

or plugging. This type of operation drastically shortens the
motor and contactor life and
causes excessive brake wear.

E)

Phase failure or unbalanced current

in the phase.

E)

See Item 1B.

F)

Brake dragging.

F)

Check brake adjustment as

described on page 15.

A) Limit switches not opening circuits.

A) Check switch connections, electrical continuity and mechanical operation. Check the switch
adjustment as described on
page 10. Check for a pinched
wire.

B)

Shaft not rotating.

B)

Check for damaged gears.

C)

Traveling nuts not moving along

shaftguide plate loose; shaft or
nut threads damaged.

C)

Tighten guide plate screws.

Replace damaged part.

A) Limit switch not holding adjustment.

A) See Item 9.

B)

B)

Brake not holding.

Check the brake adjustment as

described on page 15.

21

TROUBLE

PROBABLE CAUSE

CHECK AND REMEDY

TWO SPEED HOISTS

11. Hoist will not operate at slow speed in
either direction.

12. Hoist will not operate at fast speed in

either direction.

13. Hook will not raise

at slow speed.

14. Hook will not lower

at slow speed.

15. Hook will not raise

at fast speed.

16. Hook will not lower

at fast speed.

17. Hook moves in

proper direction at
one speedwrong
direction at other
speed.

22

A) Open Circuit.

A) Open or shorted motor winding, loose or broken wire in

circuit, speed selecting contactor stuck in opposite speed
mode. Replace motor, repair
wire and/or replace speed
selecting contactor.

B)

B)

Phase failure.

See Item 1B.

A) Open circuit.

A) See Item 11A.

B)

Open speed selection circuit.

B)

Open or shorted winding in

speed selecting contactor coil.
Loose connection or broken
wire in circuit. Mechanical
binding in contactor. Control
station contacts not making or
opening. Replace speed selecting
contactor; repair connection,
replace contactor or control
station.

C)

Phase failure.

C)

See Item 1B.

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.

A) Phase failure.

A) See Item 1B.

B)

Open circuit.

B)

See Item 11A.

C)

Brake not releasing.

C)

See Item 1G.

A) Excessive load.

A) See Item 1H.

B)

Phase failure.

B)

See Item 1B.

C)

Brake not releasing.

C)

See Item 1G.

A) Phase reversal.

A) See Item 1B.

B)

B)

Brake not releasing.

A) Phase reversal.

See Item 1G.

A) Wiring reconnected improperly.

Interchange two leads of
motor winding that are out of
phase at the speed selecting
contactor.

TROUBLE

PROBABLE CAUSE

CHECK AND REMEDY

MOTOR DRIVEN TROLLEY

18) Trolley does not
operate in either
direction.

A) No voltage at motor.

A) Open circuit, grounded or faulty

connection in hoist wiring.

B) Phase failure.

B) See Item 1B.

C) Open control circuit.

C) See Item 1D.

D) Low voltage.

D) See Item 1F.

E) Wrong voltage or frequency.

E) See Item 1E.

19) Trolley operates in

one direction only.

A) Open control circuit.

A) See Item 1D.

20) Trolley operates

sluggishly.

A) Excessive load.

A) See Item 1H.

B) Low voltage.

B) See Item 1F.

C) Unbalanced current in the phases.

C) See Item 1B.

D) Brake dragging.

D) Check electrical continuity and

connections. Check that the correct coil has been installed. The
coil for dual voltage units operate on 230 volts when the trolley is connected for either 230
or 460 volt operation. Check
brake adjustment as described
on page 17.

21) Trolley motor

overheats.

A) See Item 8.

23

ELECTRICAL DATA
TO DETECT OPEN AND SHORT CIRCUITS
IN ELECTRICAL COMPONENTS

Open circuits in the coils of electrical components may

be detected by isolating the coil and checking for continuity with an ohmmeter or with the unit in series with a
light or bell circuit.
Shorted turns are indicated by a current draw substantially above normal (connect ammeter in series with suspected element and impose normal voltage) or D.C.

Motor current draw in the stator should be measured

with the rotor in place and running. Brake, relay and
contactor coil current should be measured with the core
iron in operating position.

COILS

VOLTAGE

CURRENT DRAW
(AMPS) AT 60 HERTZ

*D.C. RESISTANCE
(OHMS)

HOIST REVERSING
CONTACTOR COILS

115
48
24

0.09
0.46
0.49

88.4
3.6
3.7

HOIST SPEED SELECTING

CONTACTOR COILS

115
48
24

0.11
0.25
N/A

86.8
14.4
N/A

TROLLEY REVERSING
CONTACTOR COILS

115
48
24

0.17
0.30
1.00

117.3
18.2
4.7

HOIST BRAKE COILS

**220-240
380-480
575

1.39
0.86
0.39

2.4
9.3
14.9

**220-240
380-480
575
**220-240
380-480 (2 Ton)
575

0.27
0.16
0.09

22.8
89.4
143.3

0.20
0.08
0.06

----

115
48
24

0.09
0.20
0.47

200.00
31.9
8.6

TROLLEY BRAKE COILS

TROLLEY SPEED
SELECTOR

TRANSFORMERS (652-135)
VOLTS
PRIMARY
SECONDARY

208-240/380-480
208-240/380-480
220/380/440
550/575
24

resistance substantially below normal. The current

method is recommended for coils with very low D.C.
resistance.

110-120
24
48
110-120

*D.C. RESISTANCE (OHMS)-LEADS

16-17
43.3
41.2
21.9
--

18-19
48.1
46.1
---

16-18
--58.4
--

16-19
--71.9
--

R-R
7.8
0.4
1.4
7.6

B-B
---145.5

HOIST MOTORS (652-162)

VOLTS-PHASE
-HERTZ

H.P.
(KW)

230/460-3-60
220/380-3-50
220/415-3-50
230/460-3-60
220/380-3-50
220/415-3-50
230-3-60

3.5 (2.7)
3.5 (2.7)
3.5 (2.7)
5.7 (4.3)
5.7 (4.3)
5.7 (4.3)
1.2/3.5
(.9/2.7)
1.2/3.5
(.9/2.7)
1.2/3.5
(.9/2.7)
1.2/3.5
(.9/2.7)
1.2/3.5
(.9/2.7)
3.5 (2.7)
1.2/3.5
(.9/2.7)

220-3-50
460-3-60
380-3-50
415-3-50
575-3-60
575-3-60

*D.C. RESISTANCE (OHMS)-LEADS

CURRENT (AMPS)
STARTING

FULL LOAD

1-2
1-3
2-3

1-2
1-3
2-3

11-12
11-13
12-13

18.4/6.4
13.6/6.4
13.6/6.4
23.2/8.0
17.0/8.0

11.5/5.8
11.9/5.9
11.9/5.8
14.5/7.3
14.9/7.4

4.4
4.4
4.4
2.8
2.8

_
_

_
_

17.0/8.0

14.9/7.3

2.8

49.2/40.8

12.3/10.2

3.0

1.9

36.4/26.2

13.0/11.4

3.0

1.9

25.6/20.4

6.4/5.1

10.8

6.3

16.8/14.3

6.7/5.7

10.8

6.3

16.8/14.3

6.7/5.7

10.8

6.3

9.5

3.8

6.9

14.5/11.3

5.8/4.5

15.8

9.9

TROLLEY MOTORS (670-407)

*D.C. RESISTANCE (OHMS)-LEADS

VOLTS
(3 PHASE)

HP
(KW)

RPM
(SYN.)
AT 60 HERTZ

FULL LOAD
CURRENT (AMPS)
AT 60 HERTZ

T1-T4
T2-T5
T3-T6

T7-T8
T7-T9
T8-T9

T1-T2
T1-T3
T2-T3

T11-T12
T11-T13
T12-T13

208-240/380-480
208-240/380-480
550-575
550-575
208-240
380-480
208-240
380-480
550-575

.5 (.38)
.5 (.38)
.5 (.38)
.5 (.38)
.25/.50(.19/.38)
.25/.50(.19/.38)
.25/.50(.19/.38)
.25/.50(.19/.38)
.25/.50(.19/.38)

1200
600
1200
600
600/1200
600/1200
900/1800
900/1800
900/1800

1.95/.98
3.75/1.88
0.70
1.80
3.00/2.60
1.30/1.10
4.5/8.1
.8/.7
.6/.7

15.9
14

31.2
28

101.2
86.3
25.0
105.9
17.3
67.3
123.0

27.1
106.9
30.6
123.4
187.5

TROLLEY MOTORS (BET-3001)

VOLTS
(3 PHASE)

H.P.
(KW)

RPM
FULL
(SYN)
CURRENT (AMPS)
AT 60 HERTZ
AT 60 HERTZ

D.C. RESISTANCE (OHMS)-LEADS

230 VOLT
460 VOLT
575 VOLT
CT1-CT2
CT2-CT3
CT1-CT3

CT1-CT2
CT2-CT3
CT1-CT3

CT1-CT2
CT2-CT3
CT1-CT3

208-240/380/480 .25 (.19)

1800

1.35/.65

19.7

78.9

--

208-240/380-480

.5 (.38)

1800

.37

10.3

41.2

--

550-575

.25 (.19)

1800

2.0/1.0

--

--

132.3

550-575

.5 (.38)

1800

.80

--

--

66.2

*Resistance values are nominal and may vary from component to component.
**On dual voltage units (230/460-3-60, 220/380-3-50 and 220/415-3-60), brake coil operates on 230 (220) volts.

25

TYPICAL WIRING DIAGRAMS

Wiring diagrams shown are representative. Consult wiring diagram in hoist or furnished
with unit.

SINGLE SPEED - HOIST ONLY

26

2 TON - SINGLE SPEED HOIST WITH TROLLEY

TWO SPEED - HOIST ONLY

2 TON - TWO SPEED HOIST WITH TROLLEY

27

3-7 TON - SINGLE SPEED HOIST WITH TROLLEY

3-7 TON
2 SPEED HOIST WITH SINGLE SPEED TROLLEY
28

DISASSEMBLY
Refer to pages 30 through 40 for exploded view and
parts list. The following are general guide lines for disassembling the XL Hoist. Prior to disassembly:
1. Operate the hoist in the down direction until the
lower limit is reached. Remove the brake end cover
(652-181) and disengage the limit switch guide plate
from the traveling nuts (see page 15). Remove the
chain container or remove the loose end screw (652256) and washers (652-257 and 652-258).
2. Carefully run the chain out of the hoist. On 3 and 4
ton units, the chain will remain suspended from the
dead end block (652-204).
3. Disconnect the hoist from the power supply system
and Lockout/Tagout disconnecting means.

WARNING
Working in or near exposed energized electrical
equipment presents the danger of electrical shock.
TO AVOID INJURY:
DISCONNECT POWER AND LOCKOUT/TAGOUT DISCONNECTING MEANS BEFORE REMOVING COVER
OR SERVICING THIS HOIST.
4. Drain the oil from the hoist.
5. Remove the hoist from its support (hook suspended
units) or remove the hoist and trolley from the beam.
Remove the trolley from the hoist.

14. Remove the chain stripper (652-114) and chain

guide (652-113).
15. On the 3, 4, and 5 ton (Double Reeved) units,
remove the dead end block (652-204) and chain.
16. Remove the liftwheel (652-111) from the main housing.
*Slots are provided in intermediate plate (652-109) to
aid in the removal of screws.

REASSEMBLY
The reassembly of the hoist is, basically, the reverse of
the above disassembly sequence. However, during
reassembly:
1.
2.
3.
4.
5.
6.
7.

If new seals are installed, make sure the lip of the

seal is on the oil side.
Apply a light coat of gear oil to lips of all seals and
surfaces of shafts that pass thru the seals.
Carefully slide the shafts through the seals.
The frame screws used to attach the motor and gear
housings to the main frame should be tightened to
a seating torque of 21 pound feet (28 NM).
Lubricate, especially the splines, as specified on page 14.
Make sure that this side out embossed on the liftwheel gear is visible when the gear is assembled to
the liftwheel.
Place the load chain (with welds down and towards
liftwheel. See illustration on page 27) over the liftwheel before attaching the motor housing to the
main frame. After assembly reeve chain per page 27.
Follow instructions starting on page 4 when reinstalling the unit.
After installation, test the unit as indicated on page 29.

These guide lines cover the disassembly of the major

mechanical components; not covered is the removal of
obvious items such as hardware and seals. While disassembling the hoist, care should be taken so as to not
damage the seals. Seals should be inspected for nicks or
damage that could cause oil leaks. Damaged seals
should be replaced prior to reassembly.

8.

1. Remove brake end cover (652-181).

2. Remove the brake assembly (652-161) and brake hub
(652-142).
3. Remove the entire limit switch assembly and the limit
switch worm (652-146).
4. Remove the motor end cover (652-182) and the complete motor (652-162). Coupling (652-103) should
remain on motor shaft.
5. On the 2, 3 and 4 ton units, remove chain plate
(652-178). On the 5 and 6 ton units,remove the idler
wheel housing (652-211) with idler wheel and bearings.
6. *Remove the brake housing (652-108) and gasket (652-118).
7. Remove the drive shaft and pinion (652-112).
8. Remove the Protector (652-160).
9. *Remove the intermediate plate (652-109) from the
main housing (652-110) and remove gasket (652118).
10. Remove the limit switch gear (652-149) from the
limit switch input shaft (652-104) and remove the
shaft from the intermediate plate.
11. Remove the second gear (652-159) from third reduction pinion and shaft (652-106) and remove the third
reduction pinion and shaft from the main housing
(652-110).
12. Remove the liftwheel gear (652-105) from the lift
wheel (652-111).
13. Remove the motor housing (652-107) from the main
housing (652-110).

USE ONLY STAR (H) GRADE LOAD CHAIN AND

FACTORY REPLACEMENT PARTS. USE OF OTHER
CHAIN AND PARTS MAY BE DANGEROUS AND
VOIDS FACTORY WARRANTY.

9.

REMOVAL AND REPLACEMENT OF LOAD CHAIN

Star and 2-digit

year code

WARNING

USE OF COMMERCIAL OR OTHER MANUFACTURERS

CHAIN AND PARTS TO REPAIR XL HOISTS MAY
CAUSE LOAD LOSS.

TO AVOID INJURY:
Use only factory supplied replacement load chain
and parts. Chain and parts may look alike, but
factory chain and parts are made of specific material or processed to achieve specific properties.

Hoist load chain can be removed and installed using one

of the following methods. Method 1 is recommended if
only the load chain is replaced. Method 2 is recommended
when the entire hoist is disassembled for repair and /or
inspection.

29

METHOD 1
1. Disconnect the hoist from the power supply system.
2. Remove the motor end cover (652-182). On units
with book suspension, remove the counterweight
(652-219) prior to removing the motor cover.
3. Disengage the limit switch guide plate from the
traveling nuts (see page 15).
4. Remove the chain container or remove the loose
end of the chain from the hoist frame.
5. Using the procedures described on page 28 for cutting load chain, cut a portion out of the last loose
end link to form a coupling link. The portion
removed should be centered on the weld and be 1/2
inch (13mm) long. Remove burrs from cut edges.
6. Using the coupling link, attach the new chain to the
old chain. Carefully check the welds on the new
chain and make sure they are positioned the same
as the old chain. The new chain must enter the hoist
so that the welds are down and towards the lift
wheel. See illustration below. Failure to properly
position the chain will cause the chain to jam
between the liftwheel and chain guide.
7. Re-energize power supply and carefully operate
hoist in the down direction until approximately 6
feet (2 M) of the new chain is hanging free on the
dead end side.
8. ON SINGLE REEVED UNITS, remove the hook block
from the old chain, remove the coupling link, discard the old chain and attach the hook block to the
new chain. ON DOUBLE REEVED UNITS, the hoist
must be removed from the trolley before reeving
the replacement load chain. For hook suspended
units, the hook must be positioned so that the dead
end bolt can be removed. If necessary, rotate hook
approximately 45 degrees following the instructions
on page 5. Now remove the chain plate and allow it
and the dead end block spacer (652-253) to slide
down the chain. Working through the cavity in
the bottom of the hoist, hold the dead end block
while loosening the dead end bolt. Remove the
dead end block and remove the dead end pin.
Remove the coupling link, pull the old chain out of
the hook block and discard the old chain. Reeve the
new load chain as described below. After reeving,
mount trolley on hoist or reposition hook, if necessary, per installation instructions starting on page 4.
ON TRIPLE REEVED UNITS, remove the dead end
plate from the top of the hook block. Remove the
dead end pin and remove the old chain from the
dead end plate. Remove the coupling link, pull the
old chain out of the hook block and idler sheave
housing. Reeve the new load chain as described
below.
9. Remount the chain container or reattach the loose
end of the new chain to the hoist.
10 Reset upper and lower limit switches per page 15.
METHOD 2
1. Completely disassemble the hoist as described on
page 26.
2. Prior to reassembly, inspect the liftwheel, chain
guides and stripper for wear. If these parts are worn
or damaged, they could cause premature wear of
the chain. Replace worn or damaged parts.
3. Place chain on liftwheel with welds down and
towards liftwheel as shown below. Welds must
engage the relief machined in the bottom of the
liftwheel pockets. If the chain is not properly placed

30

4.

on the liftwheel, it will not be possible to install the

chain guide. After making sure the chain is correctly
installed on the liftwheel, continue to assemble the
hoist.
On single reeved units, remove the hook block from
the old chain and attach it to the new chain. On
double and triple reeved units, reeve the new chain
as described below.

INSTALL LOAD
CHAIN PROPERLY
ON LIFTWHEEL
5.
6.
7.

Install the unit following the installation instructions

starting on page 4.
Remount the chain container or reattach the loose
end of the new chain to the hoist frame.
Reset upper and lower limit switches per page 15.

! WARNING
Improper installation (reeving) of load chain can
result in dropped load.
TO AVOID INJURY:
Properly reeve load chain per the following instructions.

REEVING LOAD CHAIN

3, 4 AND 5 TON DOUBLE REEVED UNITS
The following instructions assume that the trolley has
been removed from the hoist or the upper hook has been
positioned to provide access to the dead end bolt and
that there is 6 feet (2 m) of chain hanging free on the
dead end side of the hoist. Based on these, reeve the load
chain as follows:
1.
2.
3.

4.
5.
6.

7.
8.

Slide the suspension adapter into the hoist frame, if

has moved out of position or if it was removed.
Install the dead end bolt.
Attach a soft wire to the end of the chain. Feed the
wire around the hook block sheave. MAKING SURE
THERE ARE NO TWISTS, pull the chain thru the hook
block.
Feed the chain thru the square opening in the chain
plate and then thru the dead end block spacer.
Attach the last link of chain to dead end block using
the dead end pin.
MAKING SURE THERE ARE NO TWISTS IN THE
CHAIN, slide the dead end block into the cavity in
hoist frame. Turn the dead end bolt by hand to
thread it into the dead end block. Then tighten
dead end bolt to a seating torque of 120 pound feet
(160 NM).
Slide the chain plate and spacer up the chain and
attach the chain plate to the hoist frame.
Retrace the chain and make sure there are no twists.
If there are twists, start over.

REEVING LOAD CHAIN

3,4 AND 5 TON HOISTS
HOOK SUSPENSION SHOWN LUG SUSPENSION SIMILAR

5, 6 AND 7 1/2 TON TRIPLE REEVED UNITS

The following instructions assume that the idler wheel
housing assembly has been attached to the suspension
adapter and hoist frame, there is 6 feet (2 M) of chain
hanging free on the dead end side of the hoist and the
hoist is suspended from the trolley or permanent support.

REEVING LOAD CHAIN

5,6 AND 7 1/2 TON HOISTS
HOOK SUSPENSION SHOWN. LUG SUSPENSION SIMILAR
Hoistaloy load chain is hardened and it is difficult to
cut. The following methods are recommended when cutting a
length of new chain from stock or cutting off worn chain.
Always wear eye protection when cutting chain.
1. Use a grinder and nick the link on both sides (see
below), then secure the link in a vise and break off
with a hammer.

CUTTING CHAINS

Based on these, reeve the load chain as follows:

1. Attach a soft wire to the end of the chain. Feed the
wire around the hook block sheave. MAKING SURE
THERE ARE NO TWISTS IN THE CHAIN, pull the chain
thru the hook block.
2. Feed the soft wire into the outboard side of the idler
wheel housing and around the idler wheel. MAKING
SURE THERE ARE NO TWISTS IN THE CHAIN, pull the
chain over the idler wheel.
3. Remove the wire from the end of the chain and
route chain down to the hook block. MAKING SURE
THERE ARE NO TWISTS IN THE CHAIN, insert the last
link of the chain into the slot in the dead end plate.
Secure the chain using the dead end pin and attach
the dead end plate to top of hook block. Tighten the
dead end plate screws to a seating torque of 120
pound feet (160 NM).

GRINDER
NICKS

Cutting Chain by Nicking

2. Use a 7 inch ( 177 mm) minimum diameter by 1/8

inch ( 3.1 mm) thick abrasive wheel (or type recommended by wheel supplier) that will clear adjacent
links.
3. Use a bolt cutter (See below) similar to the H.K.
Porter No. 0590MTC with special cutter jaws for cutting
hardened chain. Jaws should be 1 inch (25.4 mm) long.

4. Retrace chain and make sure there are no twists. If

there are twists, start over.

Cutting Chain with a Bolt Cutter

31

! WARNING
Cutting Chain Can Produce Flying Particles.

TO AVOID INJURY:
Wear Eye Protection
Provide A Shield Over Chain To Prevent Flying
Objects

TESTING
Before using, all altered, repaired or used hoists that
have not been operated for the previous 12 months shall
be tested by the user for proper operation. First, test the
unit without a load and then with a light load of 50
pounds (23 kg) times the number of load supporting
parts of load chain to be sure that the hoist operates
properly and that the brake holds the load when control
is released. Next test with a load of *125% of rated
capacity. In addition hoists in which load sustaining parts
have been replaced should be tested with *125% of
rated capacity by or under the direction of an appointed
person and written report prepared for record purposes.
After this test, check that the Protector functions. If the
Protector permits lifting a load in excess of 180% of
rated load, it should be replaced.
NOTE: For additional information on inspection
and testing, refer to American National
Standard ASME B30.16 Overhead Hoists
obtainable from The American Society of
Mechanical Engineers, 345 East 47th Street,
New York, NY 10017 U.S.A.
*If the Protector prevents lifting of a load of 125% of
rated capacity, reduce load to rated capacity.

REPAIR PARTS
ORDERING INSTRUCTIONS
The following information must accompany all correspondence and orders for replacement parts:
1. Hoist rated load from identification plate.
2. Serial number of the hoist stamped below identification plate.
3. Voltage, Phase, Hertz from identification plate.
4. Length of lift.
5. Key number part from parts list.
6. Number of parts required.
7. Part name from parts list.
8. Part number from the parts list.
If trolley replacement parts are ordered, also include the
type and capacity of the trolley.

32

NOTE: WHEN ORDERING REPLACEMENT PARTS, IT IS

RECOMMENDED THAT CONSIDERATION BE
GIVEN TO THE NEED FOR ALSO ORDERING
SUCH ITEMS AS GASKETS, FASTENERS, INSULATORS, SEALS, ETC. THESE ITEMS MAY BE
DAMAGED OR LOST DURING DISASSEMBLY
OR JUST UNFIT FOR FUTURE USE BECAUSE OF
DETERIORATION FROM AGE OR SERVICE.

! WARNING
Using commercial or other manufacturers parts to
repair the XL Hoists may cause load loss.
TO AVOID INJURY:
Use only factory supplied replacement parts. Parts may
look alike but factory original parts are made of specific materials or processed to achieve specific properties.

XL Electric Chain Hoist Parts List

KEY NO. NO. REQD
652-100
2
652-101
1
652-102
1
652-103
1

652-104
652-105

652-106

652-107
652-108
652-109
652-110
652-111
652-112

1
1

1
1
1
1
1
1

652-113
652-114
652-115
652-116
652-117
652-118
652-119
652-120
652-121
652-122
652-123
652-124

1
1
1
1
1
2
1
1
1
2
2
1

52-125

652-126

652-127
652-128
652-129
652-130

3
1
1
1

652-131
652-132
652-133
652-134
652-135

CONT.

2
1
1
1
1

PART NAME
BRAKE HUB SNAP RING
2ND GEAR SNAP RING
2ND PINION SNAP RING
MOTOR SHAFT COUPLING FOR:
2, 3, 4, 5 AND 6 TON
5 TON (15 FPM UNITS) AND
7 1/2 TON (TRIPLE REEVED)
LIMIT SWITCH INPUT SHAFT
LIFTWHEEL GEAR FOR:
2, 3, 4, 5 AND 6 TON
5 TON (15 FPM) AND
7 1/2 TON (10 FPM)
3RD REDUCTION PINION AND SHAFT FOR:
2, 3, 4, 5 AND 6 TON
5 TON (15 FPM UNITS) AND
7 1/2 TON (10 FPM)
MOTOR HOUSING ASSEMBLY (See note 1)
BRAKE HOUSING ASSEMBLY (See note 2)
INTERMEDIATE PLATE ASSEMBLY (See note 3)
MAIN HOUSING ASSEMBLY (See note 4)
LIFTWHEEL
DRIVE SHAFT AND PINION FOR:
2, 3, 4, 5 AND 6 TON
5 TON (DOUBLE REEVED) AND
7 1/2 TON (TRIPLE REEVED)
CHAIN GUIDE
CHAIN STRIPPER
LIMIT SWITCH SHAFT ASSEMBLY
MOUNTING BRACKET
CONTACTOR MOUNTING PLATE
MAIN HOUSING GASKET
LIMIT SWITCH SPRING
LIMIT SWITCH ASSEMBLY
BREATHER
DRIVE SHAFT SEAL
DRIVE SHAFT BEARING
2ND REDUCTION PINION
BEARING - INBOARD
2ND REDUCTION PINION
BEARING - OUTBOARD
3RD REDUCTION PINION
BEARING - OUTBOARD
CHAIN GUIDE PIN
LIFTWHEEL BEARING - MOTOR END
LIFTWHEEL SEAL - GEAR END
*BRAKE COIL: (See note 5)
208-240 VOLT
380-480 VOLT
550-575 VOLT
BRAKE FRICTION DISC
LIFTWHEEL SEAL - INBOARD
LIFTWHEEL GEAR SNAP RING
LIMIT SWITCH INPUT SHAFT SEAL
TRANSFORMER :
208-240/380-480 VOLT
PRIMARY, 115 VOLT SECONDARY
208-240/380-480 VOLT
PRIMARY, 48 VOLT SECONDARY

PART NUMBER
35764
36763
45766
52018
52078

KEY NO. NO. REQD

652-135
1

652-136

52019
652-137

52021
52076
652-138

52026
52075
52631
52632
52633
52630
52033
52036
52079
52041
52055
36623
52704
52706
52709
52742
52609
70726
80401
80402
80403
88429

652-139
652-140
652-141
652-142
652-143
652-144

-4
2
1
1
1

652-145
652-146
652-147
652-148
652-149

15
1
1
1
1

652-150
652-151
652-152
652-153
652-154
652-155
652-156
652-157
652-158
652-159

2
1
2
2
1
2
2
1
1
1

80408
80410
80411
80412

652-160

68877
68878
68879
70652
80415
80416
80417
68810
70793
CONT

PART NAME
208-240/380-480 VOLT
PRIMARY, 24 VOLT SECONDARY
550-575 VOLT PRIMARY,
115 VOLT SECONDARY
HOIST REVERSING CONTACTOR WITH :
115 VOLT COILS
48 VOLT COILS
24 VOLT COILS
SPEED SELECTING CONTACTOR WITH :
115 VOLT COIL
48 VOLT COIL
24 VOLT COIL
TROLLEY REVERSING CONTACTOR WITH :
115 VOLT COILS
48 VOLT COILS
24 VOLT COILS
LINE CONNECTOR-SPECIFY NO REQD.
MOTOR BOLT
LIMIT SWITCH INPUT SHAFT BEARING
BRAKE HUB
LIFTWHEEL BEARING - GEAR END
3RD REDUCTION PINION BEARING INBOARD
FRAME SCREW
LIMIT SWITCH WORM
LIMIT SWITCH WORM PIN
LIMIT SWITCH GEAR PIN
LIMIT SWITCH GEAR FOR :
6, 9, 10, 15.2, 18, 30, 2/6, 3/9 AND 6/18 FPM
8, 12, 24, 8/2.7, 4/12 AND 8/24 FPM
FRAME PLUG (1)
GROUND SCREW
LIMIT SWITCH SHAFT BEARING
LIM. SW. SHAFT BEARING SCREW
LIMIT SWITCH GUIDE PLATE
LIMIT SWITCH GUIDE PLATE SCREW
FRAME PLUG (3/4)
POWER CORD
POWER CORD CONNECTOR
2ND GEAR FOR :
6, 9, 10, 15.2, 18, 30, 2/6, 3/9 AND 6/18 FPM
8, 12, 24, 2.7/8, 4/12, AND 8/24 FPM
PROTECTOR ASSEMBLY FOR :
CAPACITY
SPEED
(TONS)
(FPM)
2
18 AND 6/18
2
24 AND 8/24
2
30
3
9 AND 3/9
3
12 AND 4/12
3
15 AND 5/15
4
9 AND 3/9
4
12 AND 4/12
4
15
5
6 AND 2/6
5
8 AND 2.7/8
5
9 AND 9/3
5
12
5
15.2

PART NUMBER
68811
68786

52749
52751
52750
70805
70806
70781
28835
28846
28837
982158
80429
88437
68367
80413
88500
987289
35756
983766
983768
52720
52713
989074
982686
35751
983643
28714
983614
989055
51108
983979
52043
52024

52613
52614
52626
52628
52613
52665
52613
52614
52626
52627
52613
52665
52626
52661

33

KEY NO. NO. REQD

652-160
1

652-161

652-162

652-163

652-164

652-165
652-166
652-167
652-168
652-169
652-170
652-171
652-172

652-173
652-174
652-175

652-176
652-177

652-178

652-179

--

2
1
2
1
1
3
3
-

3
3
1

1
2

34
652-180

PART NAME
PROTECTOR ASSEMBLY FOR: Cont:
6
6 AND 2/6
6
8 AND 2.7/8
6
10
7 1/2
6 AND 2/6
7 1/2
10
ELECTRIC BRAKE COMPLETE:
208-240/380-480 VOLT, ONE SPEED
208-240 VOLT, TWO SPEED
380-480 VOLT, TWO SPEED
550-575 VOLT, SINGLE AND TWO SPEED
FOR: 5 TON (DOUBLE REEVED)
AND 7 1/2 TON (TRIPLE REEVED)
208-240/380-480 VOLT, SINGLE SPEED
MOTOR (ROTOR WITH BEARINGS,
STATOR AND END BELL) FOR :
208-240/380-480 VOLT, SINGLE SPEED
208-240 VOLT, TWO SPEED
380-480 VOLT, TWO SPEED
550-575 VOLT, SINGLE SPEED
550-575 VOLT, TWO SPEED
FOR: 5 TON (DOUBLE REEVED)
AND 7 1/2 TON (TRIPLE REEVED)
208-240/380-480 VOLT, SINGLE SPEED
LOAD CHAIN - SPECIFY LENGTH REQ.D
BURNISHED IN OIL
ZINC
WIRING HARNESS FOR :
SINGLE SPEED
TWO SPEED
CONTACTOR MOUNTING PLATE SCREW
CONVERSION T.B. BRACKET
BRACKET ATTACHING SCREW
CONVERSION TERMINAL BOARD
CONVERSION T.B. INSULATOR
CONVERSION T.B. SCREW
CONVERSION T.B. SCREW L.W.
JUMPERS
FOR SINGLE SPEED: 3-51111, 4-51112,
AND 3-51113 JUMPERS REQD.
FOR TWO SPEED: 4-51111, 6-51112,
AND 2-51114 JUMPERS REQD.
TRANSFORMER SCREW
TRANSFORMER SCREW L.W.
LOWER HOOK WITH LATCH --LATCH TYPE :
2 TON
3, 4, 5, 6 AND 7 1/2 TON
LOWER HOOK --- LATCHLOK TYPE :
2-TON
3, 4, 5 AND 6 TON
3-6 TON LOWER LATCHLOK KIT
HALF LINK
HOOK BLOCK :
2 TON
3 AND 4 TON
5, 6 AND 7 1/2 TON
CHAIN PLATE :
2 TON
3 AND 4 TON
HOOK BLOCK SCREW :
2 TON - 4 REQD.
3 AND 4 TON - 4 REQD.
5, 6 AND 7 1/2 TON - 2 REQD.
CHAIN PLATE OR IDLER HOUSING SCREW

PART NUMBER
52613
52614
52626
52665
52661
52606
52606
52611
52612
52660

KEY NO. NO. REQD

652-181
1
652-182
1
652-183
1

652-184
652-185
652-186
652-187
652-188

652-189

52710
52711
52712
52730
52754
52812

652-190

4
4
2
1
1

85885
85886
51109
51110
983747
52705
982683
28828
27776
987847
987873
-

987859
987873

652-191
652-192
652-193
652-194

652-195
652-196
652-197
652-198
652-199
652-200

652-201

652-202

1
1
1
3

1
1
3
4
2
1

35612
52651
36681
52625
5264
52017
52025
52049
52069

652-203
652-204
652-205
652-206
652-207

1
1
1
2
1

652-208

52046C
52048C
982369
80423
80423
987288

652-209
652-210
652-211

4
1
1

PART NAME
BRAKE END COVER
MOTOR END COVER
IDENTIFICATION PLATE:
LODESTAR XL
BRAKE END COVER SCREW
I.D. PLATE DRIVE SCREW
WARNING LABEL, ELECTRICAL
LIFTWHEEL GEAR BEARING
2ND REDUCTION PINION FOR :
6, 9, 10, 15.2, 18, 30, 2/6, 3/9 AND 6/18 FPM
8, 12, 24, 2.7/8, 4/12 AND 8/24 FPM
CAPACITY LABEL FOR :
2 TON
3 TON
4 TON
5 TON
6 TON
7 1/2 TON
WARNING LABEL FOR :
2 TON
3 TON
4 TON
5 TON
6 TON
7 1/2 TON
COIL RETAINER STRAP
BRAKE BASE PLATE
BRAKE FIELD PLATE
BRAKE SPRING FOR:
2, 3, 4, 5 AND 6 TON
5 TON (DOUBLE REEVED) AND
7 1/2 TON (TRIPLE REEVED)
BRAKE INTERMEDIATE PLATE
BRAKE ARMATURE
BRAKE NUT
MOTOR COVER SCREW
SPEED SELECTOR SCREW
HOOK NUT OR COLLAR FOR :
2 TON
3, 4, 5, 6 AND 7 1/2 TON
HOOK NUT OR COLLAR PIN FOR :
2 TON
3, 4, 5, 6 AND 7 1/2 TON
LOWER HOOK THRUST BEARING FOR :
2 TON
3, 4, 5, 6 AND 7 1/2 TON
SHEAVE WHEEL
DEAD END BLOCK
DEAD END PIN
SHEAVE WHEEL BEARING
DEAD END BOLT
3, 4, 5, 6 AND 7 1/2 TON
HOOK BLOCK CAPACITY LABEL FOR :
3 TON
4 TON
5 TON
6 TON
7 1/2 TON
CAPACITY LABEL DRIVE SCREW
DEAD END PLATE
IDLER WHEEL HOUSING

PART NUMBER
52028C
52031C
70728
80409
988271
24842
80414
52044
52023
52714
52724
52716
52726
52728
52757
52715
52725
52717
52727
52729
52785
35704
52607
59634
68818
52811
68820
70657
982448
80409
982706
35369
52047
45946
80418
88505
80421
52050
52051
52057
80422
80424

52738
52739
52740
52741
52786
988271
52068
52053C

KEY NO. NO. REQD

PART NAME

652-212
652-213
652-214
652-215
652-216

IDLER WHEEL
ANCHOR PIN
IDLER WHEEL BEARING
DEAD END PLATE SCREW
LATCH KIT FOR:
2 TON
3, 4, 5, 6 AND 7 TON
SUSPENSION ADAPTER FOR :
2 TON
3, 4, 5 AND 6 TON
UPPER HOOK NUT FOR :
2 TON
3, 4, 5 AND 6 TON
COUNTERWEIGHT
UPPER HOOK, LATCH TYPE, FOR :
2 TON
3, 4, 5 AND 6 TON
UPPER HOOK, LATCHLOK TYPE FOR :
2 TON
3, 4, 5 AND 6 TON
HOOK NUT PIN
ANTI-ROTATION PIN FOR :
2 TON
3, 4, 5 AND 6 TON
COUNTERWEIGHT SCREW
SUSPENSION SCREW ( 2 TON ONLY)
ANTI-ROTATION PLATE
ANTI-ROTATION PLATE SCREW
UPPER HOOK SUSPENSION, LATCH TYPE
COMPLETE (SEE NOTE 6) :
2 TON
3, 4, 5 AND 6 TON
LIMIT SWITCH BRACKET SCREW
LIMIT SWITCH BRACKET SCREW L.W.
LIMIT SWITCH BRACKET
LIM. SW. ASSEMBLY ATTACH. SCREW
DRAIN PLUG
2ND REDUCTION PINION SNAP RING FOR:
6, 9, 10, 15.2, 18, 30, 2/6, 3/9, AND 6/18 FPM UNITS ONLY.

652-217

652-218

652-219
652-220

652-221
652-222

652-223
652-224
652-225
652-226
652-227

652-228
652-229
652-230
652-231
652-232
652-233

1
1
2
6
1

1
1

1
1

2
1
1
1
1

2
2
1
1
1
1

PART NUMBER
52054
52058
80425
52074
45663
52701
52022
52035
52045
52047
52061
52608
52651
52624
52625
80418
80419
80420
80428
987208
52708
982371

5254
5255
982708
982226
35032
983614
989050
45766

Notes:
1. Includes 652-128
2. Includes 652-122, 652-123, 652-125, 652-134, and 652-141.
3. Includes 652-122, 652-123, 652-124, 652-126, 652-132, 652-141, and 652-187.
4. Includes Dowel Pins, 652-129, 652-143, and 652-144.
5. Dual Voltage (208-240/440-480, 220/380 and 220/415) units use 230 volt brake coil part
number 68877.
6. If complete Latchlok Type Hook Suspension is Required, Contact Factory.

KEY NO. NO. REQD

PART NAME

652-234
652-235
652-236

TROLLEY CONTACTOR BRACKET

TROLLEY SPEED SELECTOR INSULATOR
TROLLEY SPEED SELECTOR WITH:
115 VOLT COIL
48 VOLT
24 VOLT COIL
TRO. CONTACTOR BRACKET SCREW
TRO. SPEED SELECTOR SCREW
TROLLEY CONTACTOR SCREW
TERMINAL INSULATOR
TROLLEY CONTACTOR JUMPERS:
3-51661 JUMPER AND 1-51699 JUMPER
TROLLEY CONTACTOR TO SPEED
SELECTOR JUMPER
HOIST CONTACTOR TO TROLLEY
CONTACTOR HARNESS
BRAKE ATTACHING SCREW
LODESTAR XL LABEL

1
1
1

652-237
652-238
652-239
652-240
652-241

2
2
2
1
--

652-242

652-243

652-244
652-245

4
2

652-246
652-247
652-248
652-249
652-250

1
1
1
1
1

652-251

652-252
652-253
652-254
652-255
652-256
652-257
652-258
652-259
652-261
652-262
652-263

2
1
1
1
1
1
1
1
1
1
1

PART NUMBER

CONTROL CORD ATTACHING SCREW

CONTROL CORD ATTACH. SCREW L. W.
CONTROL CORD ATTACH. SCREW WASHER
WARNING TAG
CONTROL CORD ASSEMBLY FOR:
SINGLE SPEED HOIST WITH 10 FT. LIFT
TWO SPEED HOIST WITH 10 FT. LIFT
SINGLE OR TWO SPEED HOIST WITH
10 FT. LIFT AND MOTOR DRIVEN TROLLEY
(FOR OTHER LIFTS CONTACT CM)
END COVER GASKET
(WEATHER PROOF UNITS ONLY)
CONTACTOR MOUNTING SCREW
DEAD END BLOCK SPACER
CONV. T.B. LABEL--LONG
TROLLEY CORD HOLE PLUG
LOOSE END SCREW
LOOSE END SCREW WASHER
LOOSE END SCREW WASHER
CONV. T.B. LABEL--SHORT
CONTROL GROMMET
ROTOR BEARING -OUTBOARD
ROTOR BEARING -INBOARD

52722
52723
28806
28848
28829
25862
25859
25866
35881
-51661
51118
946801
52760
982688
982226
927835
81704
28450
36584
51711

52759
982686
52064
52721
989052
982667
987898
45915
52762
27891
83692
83689

Part number for Packaged Lubricants Used in the XL Electric Chain Hoists
(Refer to page 15 for Lubrication Instructions)
Type of
Lubricant
Grease Oils
(Amoco 85W-140)

Part Numbers and Packaged

Quantity of Lubricants

Splines

*Grease

EP Type Grease - Obtain Locally

Load Chain

Oil

28608 for 1 Pint Can

28619 for 1 Gal. Can

Limit Switch
Shaft Threads

*Oil

3 in 1 or Light Machining
Oil - Obtain Locally

Lower Hook
Thrust Bearing

*Oil

Heavy Machine Oil

Obtain Locally

Trolley
Trackwheel Bearings and Gears

Grease (Novatex #2)

28632 for 4 lb. Can

28610 for 1 lb. Can

Trolley Gears

Grease (Novatex #1)

28613 for 4 lb. Can

28612 for 1 lb. Can

Lubricant
Usage
Hoist Gears

52776 for 1 Gal. Can

*These lubricants are not furnished by in Packaged Quantities.

When ordering lubricants, specify the type of lubricant, part number and packaged quantity required.
Touch-up Paints for Lodestar XL Electric Chain Hoists and 2 Ton Trolley Order: (1) case (12-12 oz. Aerosol Cans) of Orange Touch-up paint Part
Number 84190.
Touch-up Paints for 3-7 Ton Trolleys order: (1) case (12-12 oz. Aerosol Cans) of Black Touch-up Paint Part Number 84189.
Touch-up paint is only available in case quantities.
Note: When painting Hoists or Trolley, also order warning labels, identification labels, etc. that may be coating during painting.

35

3 THRU 7 TON MOTOR AND GEAR BOX ASSEMBLY

TROLLEY BRAKE
(OPTIONAL)

*SEE PAGE 47 FOR TROLLEY BRAKE ASSEMBLY

REF. NO.
NO. REQD

1
2
3
4
5
6
7
8
9
10
11
36

1
1
1
1
1
1
4
4
1
SPECIFY
QTY.

1
1
SPECIFY
QTY.

PART DESCRIPTION
MOTOR & GEARBOX ASSY (LESS POWER CORD)
MOTOR (INCLUDES REF. NO.2
MOTOR KEY (3/16 X 3/16 X 1 1/4)
GEAR BOX ASSY - COMPLETE
ELECTRICAL WARNING LABEL
POWER CONNECTOR LOCKNUT
LOCKWASHER
HEX HEAD BOLT (3/8-16 X 7/8)
POWER CORD
WIRE NUT
POWER CORD CONNECTOR
WEATHERPROOF 0-RING
LINE CONNECTOR

PART NUMBER
3-7 1/2 TON

BET-3000
BET-3001
BET-3002
BET-3003
24842
989771
BET-3006
BET-3007
51120
983812
89926
983967
982158

*SEE ALSO 652-219 COUNTER

WEIGHT IF ORDERING HOOK SUSPENSION PARTS SEPARATELY.

For control station and control station parts see pages 45 and 46

37

38

ANTI-TIPPING
BRACKET KIT
670-464

2 TON

39

40

2 TON
Plain, Geared and Motor
Driven Trolleys Parts List.

KEY NO.

No. Reqd

Part Name

2 TON

652-186

WARNING LABEL, ELECTRICAL

24842

652-300

TROLLEY POWER CORD

51117

652-301

HOIST SUSPENSION ADAPTER

52059

652-302

SUSPENSION ADAPTER SCREW / DEAD END BOLT

987208

652-303

CM LABEL

25779

670-304

SUSPENSION BOLT FOR :

3.25 TO 5.50 FLANGE (82.6 to 139.7 mm)

58503

5.51 TO 7.63 FLANGE (139.9 to 193.8 mm)

59350

670-305

SUSPENSION BOLT NUT

958818

670-306

SUSPENSION BOLT NUT COTTER PIN

988368

670-307

SPACER WASHER - SPECIFY NO. REQD.

958726

670-308

TRACKWHEEL WITH BEARING CUP :

CROWNED TREAD

58162

670-309

TRACKWHEEL BEARING CUP

88521

670-310

TRACKWHEEL BEARING CONE

88525

670-311

TRACKWHEEL BEARING SHIELD

68918

670-312

TRACKWHEEL STUD

58459

670-313

TRACKWHEEL STUD COLLAR

58484

670-314

TRACKWHEEL STUD NUT

982613

670-315

TRACKWHEEL GEAR FOR :

GEARED TROLLEY

58548

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

58548

50 FPM TROLLEYS (15.2 MPM)

58548

100 FPM TROLLEY (30.4 MPM)

58548

35/65 FPM TROLLEYS (10.7/ 19.8 MPM)

58548

25/50 FPM TROLLEYS (7.6/ 15.2 MPM)

58548

50/100 FPM TROLLEY(15.2/ 30.4 MPM)

58548

670-316

TRACKWHEEL GEAR PIN

983503

670-317

TRACKWHEEL GEAR PINION FOR:

GEARED TROLLEY

58505

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

58505

50 FPM TROLLEYS (15.2 MPM)

58505

100 FPM TROLLEY (30.4 MPM)

58505

35/65 FPM TROLLEYS (10.7/ 19.8 MPM)

58505

25/50 FPM TROLLEYS (7.6/ 15.2 MPM)

58487
58505
85546

670-318

50/100 FPM TROLLEYS (15.2/ 30.4 MPM)

TRACKWHEEL PINION KEY

670-319

GEARED SIDE FRAME FOR :

PART NAME

PART NUMBER
2 TON

Part Number
Key No.

NO. REQD

3.25 TO 5.50 FLANGE (82.6 to 139.7 mm)

59615

5.51 TO 7.63 FLANGE (139.9 to 193.8 mm)

58618

670-320

2 REQD.

PLAIN SIDE FRAME FOR:

FOR PLAIN

3.25 TO 5.50 FLANGE (82.6 to 139.7 mm.)

59614

TROLLEYS

5.51 TO 7.63 FLANGE (139.9 to 193.8 mm.)

58617

1 REQD. FOR

3.25 TO 5.50 FLANGE (82.6 to 139.7 mm.)

52152

GEARED AND

FOR USE WITH ANTI-TIPPING ROLLER

MOTOR DRIVEN
TROLLEYS
670-321

HANDWHEEL BRACKET WITH BUSHINGS

59616

670-322

HANDWHEEL BUSHING

58727

670-323

HANDWHEEL BRACKET SCREW L.W.

945853

670-324

HANDWHEEL BRACKET SCREW

987061

670-325

HANDWHEEL SHAFT

58504

670-326

HANDWHEEL KEY

59967

670-327

670-328

1 OR 2

HANDWHEEL

33143

TRACKWHEEL PINION OR HANDWHEEL

986270

SHAFT NUT L.W.

670-329

1 OR 2

TRACKWHEEL PINION OR HANDWHEEL

988095

SHAFT NUT
670-330

HANDCHAIN GUIDE

58152

670-331
670-332

CHAIN GUIDE SCREW

987065

CHAIN GUIDE SCREW WASHER

986224

670-333

CHAIN GUIDE SCREW L.W.

945853

670-334

CHAIN GUIDE SCREW NUT

945822

670-335

HAND CHAIN - SPECIFY LENGTH REQD.

619022

670-336

HAND CHAIN CONNECTING LINK

945491

670-337

TRACKWHEEL PINION SPACER

987963

WASHER-SPECIFY NO. REQD.

670-338

670-339

1 or 2

TRACKWHEEL PINION SHAFT

58450

TRACKWHEEL PINION SPACER --

58456

SPECIFY NO. REQD.

670-341

PINION SHAFT BEARING

88438

670-342

INTERMEDIATE SHAFT BEARING --

88437

SIDE FRAME END

670-343

INTERMEDIATE SHAFT BEARING --MOTOR END

88436

670-344

DRIVEN GEAR

58451

670-345

INTERMEDIATE PINION

58452

670-346

INTERMEDIATE GEAR FOR :

Cont.

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

58453

50 FPM TROLLEYS (15.2 MPM)

58407

100 FPM TROLLEY (30.4 MPM)

58407

35/65 FPM TROLLEYS (10.7/ 19.8 MPM)

58453

25/50 FPM TROLLEYS (7.6/ 15.2 MPM)

58453

50/100 FPM TROLLEY (15.2/ 30.4 MPM)

58453

41

KEY NO.

NO. REQD

PART NAME

PART NUMBER

KEY NO.

NO. REQD

PART NAME

2 TON
670-347

MOTOR PINION FOR :

2 TON
670-378

POWER CORD CONNECTOR

89926
59991

35 AND 65 FPM TROLLEYS (10.7 and 19.8 MPM)

54356

670-380

TERMINAL BOX GASKET

50 FPM TROLLEYS (15.2 MPM)

58406

670-407

TROLLEY MOTOR (REFER TO MOTOR

100 FPM TROLLEYS (30.4 MPM)

58406

NAMEPLATE) :

35/65 FPM TROLLEYS (10.7/ 19.8 MPM)

54356

.5 HP, 600 RPM, 230/460 V.

57766

25/50 FPM TROLLEYS (7.6/ 15.2 MPM)

54356

.5 HP, 600 RPM, 575 V.

57782

50/100 FPM TROLLEYS (15.2/ 30.4 MPM)

54356

.5 HP, 1200 RPM, 230/460 V.

68916

670-348

MOTOR PINION PIN

988263

.5 HP, 1200 RPM, 575 V.

57771

670-349

DRIVEN GEAR KEY

989096

.25/.5 HP, 600/1200 RPM, 230 V.

57273

670-350

PINION BEARING SPACER

58456

.25/.5 HP, 600/1200 RPM, 460 V.

57274

670-351

INTERMEDIATE BEARING SPACER

58728

.25/.5 HP, 900/1800 RPM, 230 V.

57778

670-352

INTERMEDIATE PINION NUT

988146

.25/.5 HP, 900/1800 RPM, 460 V.

57779

670-353

INTERMEDIATE PINION NUT L.W.

986266

.25/.5 HP, 900/1800 RPM, 575 V.

57783

670-354

GEAR HOUSING

70064

670-355

GEAR HOUSING GASKET

58729

670-422, 670-423, AND 670-425 THROUGH

670-356

GEAR HOUSING SCREW

987019

670-431) FOR :

670-357

GEAR HOUSING SCREW L.W.

945851

230/460 V. SINGLE SPEED AND 230 V.

670-358

MOTOR END BELL GASKET -

58730

TWO SPEED TROLLEYS

670-359

BRAKE HUB

59363

460 V. TWO SPEED TROLLEYS

670-360

BRAKE HUB SNAP RING

27766

575 V. SINGLE AND

670-361

BRAKE ATTACHING SCREW

982708

TWO SPEED TROLLEYS

59693

670-362

BRAKE ATTACHING SCREW L.W.

982226

670-421

BRAKE BASE PLATE

28668

670-363

MOTOR COVER GASKET -

68756

670-422

FRICTION DISC

27677

670-423

BRAKE ARMATURE

28678

670-425

BRAKE COIL FOR:

WEATHERPROOF UNITS ONLY

670-364

BRAKE COVER

58161

670-365

BRAKE COVER SCREW

968752

670-366

BRAKE COVER SCREW L.W. FOR :

670-367

42

PART NUMBER

670-420

TROLLEY BRAKE (INCLUDES 670-421,

230/460V. SINGLE SPEED AND

59692
59694

51518

230 V. TWO SPEED TROLLEYS

NON-WEATHERPROOF UNITS

940802

460 V. TWO SPEED TROLLEYS

WEATHERPROOF UNITS

982251

575 V. SINGLE AND TWO

MOTOR END COVER

68751

SPEED TROLLEYS

51520

982717

670-368

MOTOR END COVER SCREW

670-369

MOTOR END COVER SCREW L.W. FOR :

51519

670-426

BRAKE COIL RETAINER STRAP

57753

670-427

BRAKE FIELD

28677

NON-WEATHER PROOF UNITS

982226

670-428

BRAKE SPRING

68750

WEATHERPROOF UNITS

982251

670-429

10

BRAKE SPACER WASHER

954807

670-370

TERMINAL BOX AND COVER

58120

670-430

BRAKE STUD NUT

945840

670-372

TERMINAL BOARD

68837

670-431

SHADING COIL

54831

670-373

TERMINAL BOX SCREW

927930

670-462

WARNING LABEL

936984

670-374

TERMINAL BOX SCREW L.W.

982226

670-463

CAPACITY LABEL

957928

670-375

TERMINAL BOARD SPACER

68776

670-464

ANTI-TIPPING ROLLER KIT

52813

670-376

TERMINAL BOX AND BOARD SCREW

982695

670-377

TERMINAL BOX AND BOARD SCREW L.W.

986290

43

ANTI-TIPPING
BRACKET KIT

3 THRU 7 TON
PLAIN, GEARED AND MOTOR DRIVEN
TROLLEYS
EXPLODED VIEW

29

.
REF. NO.
NO. REQD

2
3
4

8
4
2

6
7
8
9
10
11
12
13
14
15

16
17
18
19
20
21
22

23

24
25
26
27
28
29
***

44

4
1
1
2
4
4
4
4
40
2

2
1
2
1
1
2
2

1
1
1
1
1
1
AS
REQD

PART DESCRIPTION

SIDE PLATE ASSEMBLY FOR:

4 TO 61/4 FLG. AND PATENTED TRACK
6 3/8 TO 8 5/8 FLG.
8 3/4 TO 11 FLG.
BALL BEARING
RETAINING RING
*TRACKWHEEL-PLAIN
STANDARD
PATENTED TRACK
SPARK RESISTANT
TRACKWHEEL-GEARED
STANDARD
PATENTED TRACK
SPARK RESISTANT
RETAINING RING
PINION
PINION KEY
**RETAINING RING
HEX CAP SCREW
SELF LOCKING NUT
HEX JAM NUT
LOCKWASHER
SPACER WASHERS
SUSPENSION PIN FOR:
4 TO 6 1/4 FLG. AND PATENTED TRACK
6 3/8 TO 8 5/8 FLG.
8 3/4 TO 11 FLG.
BUSHING
PLATE AND TUBE ASSEMBLY
RETAINING RING
HANDWHEEL SHAFT
HANDWHEEL SHAFT KEY
WASHER
CHAIN GUIDE
8 5/8 O.D. HAND CHAIN WHEEL
11 5/8 O.D. HAND CHAIN WHEEL
HAND CHAIN WHEEL
8 5/8 OUTSIDE DIAMETER
11 5/8 OUTSIDE DIAMETER
SUSPENSION ADAPTER
SUSPENSION ADAPTER SCREW
WARNING LABEL
TROLLEY CAPACITY LABEL
WARNING LABEL
ANTI-TIPPING ROLLER KIT
HAND CHAIN (NOT SHOWN)
STANDARD
SPARK RESISTANT

PART NUMBER
4-7 1/2 TON

3 TON
PLAIN

GEARED MOTOR PLAIN

DRIVEN

GEARED

700T-1400
700T-1402
700T-1404
700T-1406
700T-1407

700T-1700
700T-1701
700T-1702
700T-1703
700T-1704

700T-1801
700T-1803
700T-1805
700T-1811
700T-1813

BET-2800
BET-2801
BET-2802
BET-2803
BET-2804

700T-1501
700T-1504
700T-1507
700T-1514
700T-1516

MOTOR
DRIVEN

BET-3801
BET-3803
BET-3805
BET-3811
BET-3813

700T-1408 700T-1705 BET-2805

700T-1409 700T-1706 BET-2806
700T-1410 700T-1707
--

700T-1518 700T-1815 BET-3815

700T-1520
-BET-3817
700T-1521 700T-1818
--

---700T-1411
-----700T-1412
700T-1414
700T-1416

700T-1708
700T-1709
700T-1710
700T-1711
700T-1719
700T-1720
700T-1718
700T-1721
700T-1725
700T-1712
700T-1713
700T-1714

BET-2807
BET-2808
-BET-2809
BET-2810
BET-2811
BET-2812
BET-2813
BET-2814
BET-2815
BET-2816
BET-2817

---700T-1523
-----700T-1526
700T-1529
700T-1532

700T-1820
-700T-1823
700T-1825
700T-1846
700T-1847
700T-1845
700T-1848
700T-1853
700T-1828
700T-1831
700T-1834

700T-1418
700T-1420
700T-1422
-------

700T-1715 BET-2818
700T-1716 BET-2819
700T-1717 BET-2820
700T-1723
-700T-1724
-700T-1722
-700T-1726
-700T-1727
-700T-1728
--

700T-1535
700T-1537
700T-1539
-------

700T-1837 BET-3839
700T-1839 BET-3841
700T-1841 BET-3843
700T-1851
-700T-1852
-700T-1850
-700T-1854
-700T-1856
-700T-1857
--

BET-3818
BET-3820
-BET-3821
BET-3823
BET-3824
BET-3825
BET-3826
BET-3828
BET-3830
BET-3833
BET-3836

---

700T-1729
700T-1730

---

---

-700T-1858

---

700T-1731
-700T-1732
-52784
80430
936986
52764
936984
44927630

---

--700T-1860
-52787
80430
936986
52765
936984
44927660

--

---

700T-1733
700T-1734

---

--

---

700T-1862
700T-1863

* TOTAL QUANTITY OF 4 EACH REQUIRED FOR PLAIN TYPE TROLLEYS.

** TOTAL QUANTITY OF 1 EACH REQUIRED FOR 3 TON TROLLEYS.
*** SPECIFY LENGTH OF HAND CHAIN REQUIRED. STANDARD LENGTH EQUALS TWO TIMES HOIST LIFT PLUS 2-6.

---

---

Single Speed Hoist Control Station

Key No.

Part Name

Qty.

Code

627-250

Standard Control Cord Assembly

See page 35

627-551

Control Station Grommet

58278

627-552

Control Station (Includes 627-551 thru 627-567)

58272

627-563

Control Station Hardware Kit w/gasket

58275

627-565

Control Station 1-speed Insert

58255

627-566

Control Station Warning Label Kit (Includes Exterior Labels)

57276

627-567

Contol Station Button Label Kit

58277

45

Two Speed Hoist Control Station

46

Key No.

Part Name

Qty.

Code

627-250

Standard Control Cord Assembly

See Page 35

627-551

Control Station Grommet

58278

627-552

Control Station (Included 627-551 Thru 627-567)

58273

627-563

Control Station Hardware Kit w/gasket

58275

627-565

Control Station 2-speed Insert

58256

627-566

Control Station Warning Label Kit (Includes Exterior Labels)

57276

627-567

Contol Station Button Label Kit

58277

4 DIRECTIONAL CONTROL STATION PARTS LIST

4 Directional Control Station

Key No.

Part Name

Qty.

Code

627-451

Standard Control Cord Assembly

See Page 35

627-551

Control Station Grommet

58278

635-156

Control Station (Includes 627-551 Thru 627-567)

58220 CM

627-553

Control Station Housing Kit (Includes Housing, Boots,

Collar, Gasket & Hardware)

58288

Control Station Hardware Kit w/gasket

Control Station 1-Speed Insert
Control Station 2-Speed Insert

1
1
1

58279
58522
58256

627-566

Control Station Warning Label Kit

57276

627-567

Contol Station Button Label Kit

58277

627-563
627-565

47

3 THRU 7 TON TROLLEY MOTOR BRAKE EXPLODED VIEW

30

3
4

1
5
14
31
12

13

6
2
11

15
12

17

32

26

16
19

21
25
19

18

24

23

28

27
28

22
20

Key No. No. Reqd

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

1
1
1
4
2
2
1
1
2
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1

30
31
32
33

1
4
3
1

Part Name

* For Weatherproof Units-Not Shown

48

Part Number

Brake Cord
Coupler Brake Shaft KIt (includes Shaft, Bearing,Snap Ring, Retainer Ring and Key)
Housing
Mounting Stud with Nut
Access Cover -Plain
Access Cover Screw (Specify No. Reqd.)
*Access Cover Gasket
*Drain Plug
*Housing To End Plate Gasket
*Gasket-Each End Of Brake
Stationary Disc
Friction Disc Kit (Includes 3 Discs With Stabilizer Spring-Only One Disc Reqd.Per Brake)
Hub Kit (Included Hub And Set Screws)
End Plate Assembly
Plug-External Lead Hole
Bearing
Solenoid Lever
Retaining Ring
Spacer
Torque Adjusting Screw
Wear Adjusting Screw
Pressure Spring
Lever Arm And Stop Nut Assembly
Bearing Pin
Support Plate And Stop Nut Assembly
Pivot Pin
Solenoid Kit (Includes Plunger, Link, Frame Link Screw, Link Nut And Mounting Screws)
Coil Kit (Includes Coil, Plunger Guides, Guide Screw and Locwashers)
Motor Brake Kit (Includes Complete Brake Assembly, Brake Cord, Connector Wire Nuts
and Installation Instructions)
Brake Cord Connector
Wire Nut
Brake Attaching Screw
**Access Cover With Manual Release Knob
**Not Shown

51074

Contact Factory
For
Part Numbers
Of
Brake
Components
Key Numbers
2 Thru 28,
32 And 33

9598 for 220, 230

380 & 460 Volt Brake

83968
982473
Contact Factory
Contact Factory

NOTES

49

Note: When ordering parts, always furnish Hoist Model and Serial Number,
Motor Horsepower, Voltage, Phase, Frequency and Rated Capacity of hoist on
which the parts are to be used.
For the location of the nearest Master Parts Depot, see the list located on the
inside front cover.

LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES

THE WARRANTY STATED BELOW IS GIVEN IN PLACE OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR
OTHERWISE, NO PROMISE OR AFFIRMATION OF FACT MADE
BY ANY AGENT OR REPRESENTATIVE OF SELLER SHALL CONSTITUTE A WARRANTY BY SELLER OR GIVE RISE TO ANY LIABILITY OR OBLIGATION.
Seller warrants that on the date of delivery to carrier the
goods are free from defects in workmanship and materials.
SELLERS SOLE OBLIGATION IN THE EVENT OF BREACH OF
WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR OTHERWISE WITH RESPECT TO GOODS SOLD SHALL BE EXCLUSIVELY
LIMITED TO REPAIR OR REPLACEMENT, F.O.B. SELLERS POINT
OF SHIPMENT, OF ANY PARTS WHICH SELLER DETERMINES TO
HAVE BEEN DEFECTIVE or if Seller determines that such repair
or replacement is not feasible, to a refund of the purchase
price upon return of the goods to Seller.
Any action against Seller for breach of warranty, negligence
or otherwise, must be commenced within one year after such
cause of action accrues.
NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE GOODS
SHALL BE VALID OR ENFORCEABLE UNLESS BUYERS WRITTEN
NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE YEAR
FROM THE DATE OF SHIPMENT.
Seller shall not be liable for any damage, injury or loss arising
out of the use of the goods if, prior to such damage, injury or
loss, such goods are (1) damaged or misused following Sellers
delivery to carrier; (2) not maintained, inspected, or used in
compliance with applicable law and Sellers written instructions and recommendations; or (3) installed, repaired, altered

or modified without compliance with such law, instructions or

recommendations.
UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES AS THOSE
TERMS ARE DEFINED IN SECTION 2-715 OF THE UNIFORM
COMMERCIAL CODE.
INDEMNIFICATION AND SAFE OPERATION
Buyer shall comply with and require its employees to comply
with directions set forth in instructions and manuals furnished by Seller and shall use and require its employees to
follow such instructions and manuals and to use reasonable
care in the use and maintenance of the goods. Buyer shall
not remove or permit anyone to remove any warning or
instruction signs on the goods. In the event of personal injury
or damage to property or business arising from the use of the
goods, Buyer shall within 48 hours thereafter give Seller written notice of such injury or damage. Buyer shall cooperate
with Seller in investigating any such injury or damage and in
the defense of any claims arising therefrom.
If Buyer fails to comply with this section or if any injury or
damage is caused, in whole or in part, by Buyers failure to
comply with applicable federal or state safety requirements,
Buyer shall indemnify and hold Seller harmless against any
claims, loss or expense for injury or damage arising from the
use of the goods.

! WARNING
Alterations or modifications of equipment and use of
non-factory repair parts can lead to dangerous operation and injury.
TO AVOID INJURY:
Do not alter or modify equipment
Do use only factory provided replacement parts.

Columbus McKinnon Corporation

140 John James Audubon Parkway
Amherst, New York 14228-1197
Phone: (800) 888-0985
Fax: (716) 689-5644
2008 Columbus McKinnon Corp.

Printed in USA