Operating, Maintenance &

Parts Manual

Electric Chain ®

Capacities
250 lbs (113 kg) 300 lbs (136 kg)
500 lbs (226 kg) 600 lbs (272 kg)
1,000 lbs (453 kg)

F ollow 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.
Forward this manual to the hoist operator.
Failure to operate the equipment as directed in the manual
may cause injury.
Should you have any questions or have problems with this
product, please call the number located on the inside front
cover.

Before using the hoist, fill in the information below. Model

and serial numbers are stamped into the aluminum hoist
housing.

Model Number

Serial Number

Purchase Date

Columbus McKinnon Corporation

Industrial Products Division
140 John James Audubon Parkway
Amherst, New York 14228-1197

20800 Manual No. 620-M (Pending)

 Note: When ordering parts, always furnish Rated Load, Voltage, Phase, Hertz and Serial
Number of hoist on which the parts are to be used.
For the location of the nearest Repair Station, 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 recommendations.

OTHER WARRANTIES, EXPRESS OR IMPLIED, OF UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES AS
OR OTHERWISE, NO PROMISE OR AFFIRMATION OF FACT THOSE TERMS ARE DEFINED IN SECTION 2-715 OF THE
MADE BY ANY AGENT OR REPRESENTATIVE OF SELLER UNIFORM COMMERCIAL CODE.
SHALL CONSTITUTE A WARRANTY BY SELLER OR GIVE RISE
TO ANY LIABILITY OR OBLIGATION. INDEMNIFICATION AND SAFE OPERATION
Buyer shall comply with and require its employees to comply with
Seller warrants that on the date of delivery to carrier the goods
directions set forth in instructions and manuals furnished by
are free from defects in workmanship and materials.
Seller and shall use and require its employees to follow such
instructions and manuals and to use reasonable care in the use
SELLER’S SOLE OBLIGATION IN THE EVENT OF BREACH OF
and maintenance of the goods. Buyer shall not remove or permit
WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR
anyone to remove any warning or instruction signs on the goods.
OTHERWISE WITH RESPECT TO GOODS SOLD SHALL BE
In the event of personal injury or damage to property or business
EXCLUSIVELY LIMITED TO REPAIR OR REPLACEMENT,
arising from the use of the goods, Buyer shall within 48 hours
F.O.B. SELLER’S POINT OF SHIPMENT, OF ANY PARTS
thereafter give Seller written notice of such injury or damage.
WHICH SELLER DETERMINES TO HAVE BEEN DEFECTIVE
Buyer shall cooperate with Seller in investigating any such injury
or if Seller determines that such repair or replacement is not
or damage and in the defense of any claims arising therefrom.
feasible, to a refund of the purchase price upon return of the
goods to Seller.
If Buyer fails to comply with this section or if any injury or
damage is caused, in whole or in part, by Buyer’s failure to
Any action against Seller for breach of warranty, negligence or
comply with applicable federal or state safety requirements,
otherwise, must be commenced within one year after such cause
Buyer shall indemnify and hold Seller harmless against any
of action occurs.
claims, loss or expense for injury or damage arising from the use
of the goods.
NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE
GOODS SHALL BE VALID OR ENFORCEABLE UNLESS
BUYER’S 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 Seller’s
delivery to carrier; (2) not maintained, inspected, or used in
compliance with applicable law and Seller’s written instructions
and recommendations; or (3) installed, repaired, altered or
modified without compliance with such law, instructions or

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 replacement parts.

Columbus McKinnon Corporation • Industrial Products Division • 140 John James Audubon Parkway
Amherst, New York 14228-1197 • 1-800-888-0985 • Fax 716-689-5644
2011 Columbus McKinnon Corp. Printed in U.S.A. 03/11
 CM HOIST PARTS AND SERVICE ARE AVAILABLE IN THE UNITED STATES AND IN CANADA

As a CM 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 Unites 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 CANADIAN SERVICE CENTERS

CALIFORNIA NEW YORK ALBERTA

OTTO SYSTEMS, INC. VOLLAND ELECTRIC EQUIPMENT CO. BENNETT & EMMOTT, LTD.
12010 Bloomfield Ave. 75 Innsbruck Drive 18131 118th Avenue
Sante Fe Springs, CA 90670 Buffalo, NY 14227 Edmonton, Alberta T5S 1M8
562/462-1612 or 800/596-7392 716/656-9900 403/454-9000
Fax 562/462-1617 Fax 716/656-8898/8899 Fax 403/454-8990
or
7656 Las Positas Road NORTH CAROLINA **COLUMBUS McKINNON, LTD.
Livemore, CA 94551 TEAM SESCO 10311-174th Street
925/245-8800 or 800/508-6886 PO Box 667489 Edmonton, Alberta T5S 1H1
Fax 925/245-8804 2225 Freedom Drive 800/263-1997
Charlotte, NC 28208 Fax 403/486-6160
GEORGIA 704/372-4832 or 800/487-3726
ACE INDUSTRIES, INC. Fax 704/358-1098 BRITISH COLUMBIA
6295 McDonough Drive FLECK BROTHERS, LTD.
Norcross, GA 30093 OHIO 4084 McConnel Court
770/441-0898 or 800/733-2231 MAZZELLA LIFTING TECHNOLOGIES Burnaby, British Columbia V5A 3N7
Fax 800/628-3648 21000 Aerospace Parkway
Cleveland, OH 44142 MANITOBA
ILLINOIS 440/239-5700 or 800/362-4601 KING’S ELECTRIC MOTORS, INC.
JOHN SAKASH COMPANY, INC. Fax 440/239-7010 633 Tyne Avenue
700 Walnut Street Winnipeg, Manitoba R2L 1J5
Elmhurst, IL 60126 PENNSYLVANIA 204/663-5332
630/833-3940 AMICK ASSOCIATES, INC. Fax 204/663-4059
Fax 630/833-9830 11 Sycamore Street
Carnegie, PA 15106-0529 NOVA SCOTIA
INDIANA 412/429-1212 or 800/445-9456 *W & A MOIR
HORNER ELECTRIC COMPANY, INC. Fax 412/429-0191 95 Ilsley Ave.
1521 East Washington Street Burnside Park, Nova Scotia B3B 1L5
Indianapolis, IN 46201 RAM MOTORS & CONTROLS, INC. 902/468-7720
317/639-4261 5460-B Pottsville Pike, Docks 8-11 Fax 902/468-3777
Fax 317/639-4342 PO Box 748
Leesport, PA 19533 ONTARIO
IOWA 610/916-8000 *R & W HOIST REPAIR, LTD.
VM HOIST & CRANE SERVICES Fax 610/916-7957 790 Redwood Square
PO Box 440 Units 5, 6, & 7
450 Highway 151 SOUTH CAROLINA Oakville, Ontario L6L 6N3
Walford, IA 52351 ENGINEERED SYSTEMS INC. 905/825-5500
319/846-6040 1121 Duncan-Reidville Road Fax 905/825-5315
Fax 319/846-6045 Duncan, SC 29334
864/879-7438 or 800/879-7438 *TORONTO ELECTRIC HOIST
KANSAS Fax 864/879-6428 SALES & SERVICE
INDEPENDENT ELECTRIC MACHINERY 9 CoDeco Court
4425 Oliver Street TEXAS North York, Ontario M3A 1A1
Kansas City, KS 66106 ABEL EQUIPMENT CO., INC. 416/386-0820
913/362-1155 or 800/833-2610 3710 Cavalier Drive Fax 416/386-0821
Fax 913/904-3330 Garland, TX 75042
972/272-7706 *MASLACK SUPPLY, LTD.
LOUISIANA Fax 972/272-6955 488 Falconbridge Road
BEERMAN PRECISION, INC. Sudbury, Ontario P3A 4S4
PO Box 6018 HYDRAULIC EQUIPMENT SERVICES, INC. 705/566-1270
Metairie, LA 70009 1021 North San Jacinto Street Fax 705/566-4208
504/207-6000 Houston, TX 77002
Fax 504/207-6044 713/228-9601 *COLUMBUS McKINNON, LTD.
Fax 713/228-0931 P.O. Box 1106
MASSACHUSETTS 10 Brook Road, North
ABEL DISTRIBUTORS, INC. WISCONSIN Cobourg, Ontario K9A 4W5
50 Parker Street, Unit 2 TRESTER HOIST & EQUIPMENT, INC. 905/372-0153
Newburyport, MA 01950 W136 N4863 Campbell Drive Fax 905/372-3078
978/463-0700 Suite #4
Fax 978/463-5200 Menomonee Falls, WI 53051 QUEBEC
262/790-0700 or 800/234-6098 *HERCULES SLING & CABLE
NEW JERSEY Fax 262/790-1009 3800 TransCanada Highway
SHUPPER-BRICKLE EQUIPMENT CO. Pointe-Claire, Quebec H9R 1B1
PO Box 803 514/428-5511514/48631-5511
2394 Route 130, Suite C Fax 514/428-5555
Dayton, NJ 08810
732/438-3888 *LEGER PALANS ET OUTILLAGES, INC.
Fax 732/438-3889 7995-17th Ave.
Montreal, Quebec H1Z 3R2
514/376-3050
Fax 514/376-0657

**ARE ALSO MASTER PARTS DEPOTS

**MASTER PARTS DEPOT ONLY

i
 SAFETY PRECAUTIONS
Each Shopstar Electric Chain Hoist is built in accordance with the 22. NOT operate a hoist on which the safety placards or decals
specifications contained herein and at the time of manufacture are missing or illegible.
complies with our interpretation of applicable sections of 23. NOT operate a hoist unless it has been securely attached to
*American Society of Mechanical Engineers Code (ASME) a suitable support.
B30.16 “Overhead Hoists,” the National Electrical Code
(ANSI/NFPA 70) and the Occupational Safety and Health Act 24. NOT operate a hoist unless load slings or other approved
(OSHA). Since OSHA states the National Electrical Code applies single attachments are properly sized and seated in the hook
to all electric hoists, installers are required to provide current saddle.
overload protection and grounding on the branch circuit section 25. Take up slack carefully - make sure load is balanced and
in keeping with the code. Check each installation for compliance load holding action is secure before continuing.
with the application, operation and maintenance sections of these 26. Shut down a hoist that malfunctions or performs unusually
articles. and report such malfunction.
*Copies of this Standard can be obtained from ASME Order 27. Make sure hoist limit switches function properly.
Department, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300, 28. Warn personnel of an approaching load.
U.S.A.

Improper operation of a hoist can create a potentially Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result hazardous situation which, if not avoided, could result
in death or serious injury. To avoid such a potentially in minor or moderate injury. To avoid such a potentially
hazardous situation, THE OPERATOR SHALL: hazardous situation, THE OPERATOR SHALL:

1. NOT operate a damaged, malfunctioning or unusually 1. Maintain firm footing or be otherwise secured when operating
performing hoist. the hoist.
2. NOT operate the hoist until you have thoroughly read and 2. Check brake function by tensioning the hoist prior to each
understood this Operating, Maintenance and Parts Manual. lift operation.
3. NOT operate a hoist which has been modified without the 3. Use hook latches. Latches are to retain slings, chains, etc.
manufacturer’s approval or without certification that it is in under slack conditions only.
conformity with ANSI/AMSE B30 volumes. 4. Make sure the hook latches are closed and not supporting
4. NOT lift more than rated load for the hoist. any parts of the load.
5. NOT use hoist with twisted, kinked, damaged, or worn load 5. Make sure the load is free to move and will clear all
chain. obstructions.
6. NOT use the hoist to lift, support, or transport people. 6. Avoid swinging the load or hook.
7. NOT lift loads over people. 7. Make sure hook travel is in the same direction as shown on
the controls.
8. NOT operate a hoist unless all persons are and remain clear
of the supported load. 8. Inspect the hoist regularly, replace damaged or worn parts,
and keep appropriate records of maintenance.
9. NOT operate unless load is centered under hoist.
9. Use Shopstar recommended parts when repairing the unit.
10. NOT attempt to lengthen the load chain or repair damaged
load chain. 10. Lubricate load chain per hoist manufacturer’s
recommendations.
11. Protect the hoist’s load chain from weld splatter or other
damaging contaminants. 11. NOT use the hoist’s overload limiting clutch to measure load.
12. NOT operate hoist when it is restricted from forming a 12. NOT use limit switches as routine operating stops. They are
straight line from hook to hook in the direction of loading. emergency devices only.
13. NOT use load chain as a sling, or wrap chain around load. 13. NOT allow your attention to be diverted from operating
the hoist.
14. NOT apply the load to the tip of the hook or to the hook
latch. 14. NOT allow the hoist to be subjected to sharp contact with
other hoists, structures, or objects through misuse.
15. NOT apply load unless load chain is properly seated in the
chain sprocket(s). 15. NOT adjust or repair the hoist unless qualified to perform
such adjustments or repairs.
16. NOT apply load if bearing prevents equal loading on all load
supporting chains.
17. NOT operate beyond the limits of the load chain travel.
18. NOT leave load supported by the hoist unattended 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.

ii
iii
 Figure 1A

REPAIR/REPLACEMENT POLICY
SPECIFICATIONS ®
All Columbus McKinnon (CM ) ShopStar Electric Chain
Hoists are inspected and performance tested prior to
The ShopStar Electric Chain Hoist is a highly versatile shipment. If any properly maintained hoist develops a
materials handling device that can be used to lift loads that
are within its rated load capacity. It is available in five load performance problem, due to a material or workmanship
ratings: 250, 300, 500, 600 and 1,000 pounds (113,136, 226, defect, as verified by CM, repair or replacement of the unit
272 and 453 kg). will be made to the original purchaser without charge. This
repair/replacement policy applies only to ShopStar Hoists
Standard features of the ShopStar Electric Chain Hoist installed, maintained and operated as outlined in this
include: manual, and specifically excludes hoists subject to normal
• Alloy steel, oblique lay liftwheel that provides constant wear, abuse, improper installation, improper or inadequate
chain speed and reduces chain wear. maintenance, hostile environmental effects and unauthorized
• Hoistaloy® load chain for long and dependable service. repairs/modifications.
• Grease lubricated, hardened spur gears provide smooth
and quiet operation.
• Thermally protected, hoist duty motor.
• Forged steel upper and lower hooks with latch. Alterations or modification of hoist and use of non-original repair
• ProtectorTM that prevents lifting dangerous overloads. parts can lead to dangerous operation and injury.
• D.C. disc type motor brake plus regenerative braking. TO AVOID INJURY:
• Do not alter or modify equipment.
• 10 foot (3 M) lift. Longer lifts can be supplied on a per • Do use only original replacement parts.
order basis.
• 6 foot (1.8 M) power cord with three prong plug for
grounding on 115-1-50/60 units. 6 foot (1.8 M) power cord We reserve the right to change materials or design if, in our
with provisions for grounding is standard on 220-1-50 and opinion, such changes will improve our product. Abuse,
three phase units. repair by an unauthorized person, or use of non-CM
• Rugged NEMA 4 (weatherproof) control station is replacement parts voids the guarantee and could lead to
suspended on a TYPE SO cord six feet (2.8 M) below the dangerous operation. For full Terms of Sale, see Sales Order
bottom of the hoist. Longer cords can be provided on a Acknowledgment. Also, refer to the back cover for
per order basis. Limitations of Warranties, Remedies and Damages, and
• Lightweight die cast aluminum frames and covers. Indemnification and Safe Operation.
• Ball or needle bearings at all rotating points.
• Compact, yet rugged, design provides minimum ACCESSORIES
headroom and long, trouble-free service. Chain Container
• 6 fpm (1.8 m/min) lift speed available on 1000 lbs (453 kg)
units. This accessory item (Figure 1A) is used to hold the slack
• 8 fpm (2.4 m/min) lift speed available on 500-600-1000 lbs chain and it is supplied with mounting hardware and
(226, 272 and 453 kg) units. instructions. Chain containers are recommended for those
• 12 fpm (3.6 m/min) lift speeds available on 500-600- applications where slack chain will interfere with the load or
1000 lbs (226, 272 and 453 kg) units. drag on the floor as may more often be the case with the
• 16 fpm (4.9 m/min) lift speeds available on 250-300- (500, 600 and 1,000 lbs., 226, 272 and 453 kg., Double
500 lbs (113, 136 and 226 kg) units. Reeved units). Chain containers are shipped separately and
• 20 fpm (6.1 m/min) lift speeds available on 500-600 lbs can be furnished for units already in service.
(226 and 272 kg) units.
CM Series 632CMCMies 63
• 24 fpm (7.3 m/min) lift speeds available on 250-300-
500 lbs (113, 136 and 226 kg) units. This lightweight, yet rugged, manual push type trolley (Figure
• 40 fpm (12.2 m/min) lift speeds available on 250-300 lbs 2A, pg 2) is designed to fit a wide range of monorail beams
(113 and 136 kg) units. and negotiate tight curves. Provides mobility for your
• 220-1-50, 380 to 460-3-50/60, 220 to 240-3-50/60 and ShopStar Hoist.
575-3-60 units available. Lift speeds are based on 60
hertz power supply. For 50 hertz power supply lift speeds
will be 5/6 of those indicated.
• UL and cUL listed.
• Lifetime Warranty.

1
 Claim Procedure

Figure 2A Figure 2B

2. Be in accordance with the National Electrical Code

INSTALLATION (ANSI/NFPA-70) and applicable National, State and Local
Codes.
UNPACKING 3. Effectively ground the hoist in accordance with National
After opening the carton (Figure 2B) , carefully inspect the Electrical Code and other applicable codes. Proper
hoist frame, cords, hooks, chain and control station for grounding provides a path of least resistance for electric
damage that may have occurred during shipment. If there is current to reduce the risk of electric shock. The power
damage, refer to the packing slip envelope. cord of the hoist includes a green-yellow wire for
grounding the hoist to the external power supply system.
On the standard 115-1-60 units, the power cord is
equipped with a three prong plug. Be sure that the
receptacle opening that receives the longest prong is
Operating a unit with obvious external damage may cause load to
drop and that may result in personal injury and/or property properly grounded. If grounding is to be through the
damage. trolley trackwheels, each section of the runway must be
TO AVOID INJURY: grounded to the building ground system using metal to
Carefully check unit for external damage prior to installation. metal connections.
Make sure that the power supply (Figure 3A) to which the
hoist is to be connected is the same as that shown on the
identification plate located on bottom of hoist.
Failure to properly ground the hoist presents the danger of electric
MOUNTING THE HOIST shock.
Hang the hoist from its intended support. The structure used TO AVOID INJURY:
Permanently ground the hoist as instructed in this manual.
to support the hoist must have sufficient strength to
withstand several times the load imposed. If in doubt consult
4. Include slow blow type fuses or inverse trip time circuit
a registered engineer and local building codes.
breakers to permit the hoist to start and accelerate load.
5. Include a disconnecting means capable of being locked
in the “open” position.
Suspending the hoist from an inadequate support may allow the
hoist and load to fall and cause injury and/or property damage.
TO AVOID INJURY:
Make sure the structure has sufficient strength to hold several Failure to provide a proper power supply system for the hoist may
times the hoist and its rated load. Using the upper hook, hang the cause hoist damage and offers the potential for a fire.
hoist from the support. Be sure hoist is solidly held in the TO AVOID INJURY:
uppermost part of the hook arc and the latch is tightly against the Provide the hoist with a 15 amp, minimum, overcurrent protected
hook tip. power supply per the National Electrical Code (ANSI/NFPA 70)
and applicable local codes as instructed in this manual.
POWER SUPPLY SYSTEM
NOTE: IN THIS MANUAL, NOMINAL VOLTAGES ARE
USED WHEN REFERRING TO POWER SUPPLY
(Refer to Figure 4A or 4B on page 4.) To insure proper

SYSTEMS. HOWEVER, WITH NO MODIFICATION, THE

operation, to avoid damage to hoist and electrical system

SHOPSTAR HOIST WILL OPERATE ON A RANGE OF

and to reduce the risk of electric shock or fire, the branch

VOLTAGES AS INDICATED BELOW:

circuit supplying power to the hoist must:
1. Have ample capacity to prevent excessive voltage drop
during starting and operation (refer to “Checking for NOMINAL VOLTAGE HERTZ
Adequate Voltage at Hoist” on page 3). When determining VOLTAGE RANGE
the size of branch circuit components and conductors,
230 208-240 60
special consideration should be given to the starting
current-amps (approximately three times that shown on 460 440-480 60
the hoist identification plate) and the length of the 220 200-240 50
conductors. As a minimum, the system should be rated for 380 365-395 50
15 amps and it should have #16 AWG, or larger, wiring.
415 400-430 50
575 550-600 60

2
 Upper Hook

ShopStar

Loose End of
Power Cord Chain
Same Name Chain Stop
plate

Control
Station

Power supply Making sure the hoist will operate on Lower Hook
the power supply system

Figure 3A Figure 3B

NOMINAL MINIMUM * MIN. VOLTAGE

POWER OPERATING AT INSTANT
Three Phase Hoists
Since the motor in a three phase hoist can rotate in either SUPPLY VOLTAGE OF START
direction, depending on the manner in which it is connected
to the power supply, the direction of hook movement must 115-1-50/60 108 103
be checked during the original installation and each time 220-1-50 198 182
hoist is moved to a new location as follows: 208-3-60 187 172
1. Move the manual disconnect switch handle to the “OFF” 220-3-50 198 182
position. 230-3-60 207 190
2. Connect the BROWN, GREY AND BLACK wires of hoist 380-3-50 365 336
power cord to load side of disconnect switch. Connect the 415-3-50 399 367
GREEN-YELLOW wire of hoist power cord to power supply
ground. 460-3-60 414 380
3. Move the manual disconnect switch handle to the “ON” 575-3-60 518 506
position.
4. Depress the
(up) control. If the hook moves in the up
For proper operation and to avoid these low voltage
problems, voltage (measured at end of the power cord while
direction, the hoist is ready for operation. If the hook lifting rated load) should be as the above chart indicates.

*The drop in voltage upon energizing the hoist should

lowers, move the disconnect switch handle to the “OFF”

not be below the value listed.

position and interchange the BLACK and BROWN leads
at the disconnect switch. Move the disconnect switch
handle to the “ON” position and the hoist is now ready for
operation. Low voltage can also be caused by using an undersized
extension cord to supply power to the hoist. The following
charts should be used to determine the size wires in the
extension cord in order to minimize the voltage drop
Allowing the hook block to run into the bottom of the hoist when between the power source and the hoist.

115-1-50/60 units without contactor (hoists with orange

raising a load or allowing the chain stop to run into the bottom of

control station)
the hoist when lowering a load may break the chain and allow the
load to drop.

LENGTH MAXIMUM LENGTH

TO AVOID INJURY:

OF CONTROL OF EXTENSION CORD BASED

Do not allow the hook block or the chain stop to contact the
bottom of the hoist.
CORD ON SIZE OF WIRE
ft(M) #16 AWG #14 AWG #12 AWG
Checking for Adequate Voltage at Hoist
The hoist must be supplied with adequate electrical power 1.0 to 10.0 105 ft 170 ft 270 ft
for proper operation and to reduce problems that may result (0.3 to 3.0) (32 M) (51 M) (82 M)
from insufficient power (low voltage). These include:
10.1 to 20.0 75 ft 120 ft 190 ft
• Noisy hoist operation due to brake and/or contactor (3.1 to 6.0) (22 M) (36 M) (58 M)
chatter. 20.1 to 30.0 45 ft 70 ft 110 ft
• Heating of the hoist motor and other internal components (6.1 to 9.0) (14 M) (21 M) (33 M)
as well as heating of wires and connectors in the circuit 30.1 to 40.0 15 ft 20 ft 35 ft
feeding the hoist. (9.1 to 12.0) (4.5 M) (6 M) (11 M)
115-1-50/60 units with contactor, 220-1-50 and three
• Failure of the hoist to lift the load due to motor stalling.

phase units (hoists with black control station)

• Blowing fuses or tripping circuit breakers.

MAXIMUM LENGTH OF EXTENSION CORD

• Dimming of lights or slowing of motors connected to the
same circuit.
Wire Size Single Three
Phase Hoist Phase Hoist
#16 AWG 135 feet(40 M) 245 feet(73 M)
#14 AWG 220 feet(66 M) 395 feet(120 M)
#12 AWG 354 feet(107 M) 630 feet(192 M)

3
 Single Phase Systems Three Phase Systems
* Manual * Slow Blow Fuses
Disconnect or Inverse Time
Switch Circuit Breakers
L1 Black
Black

Incoming
Hoist Power L2

Power
Grey
Cord
White L3 Brown

Ground Green-Yellow
Ground Blue Brown

Hoist Power Cord

* Thermal
Overload * Manual Disconnect
Relay Green-Yellow Switch * Slow Blow Fuses
* Must be per National Electrical or Inverse Time
Code and These Devices are to be Circuit Breakers
Supplied by the User.
*Receptacle Rated for 15 Amps Minimum. (220-1-50 Units Do Not Include Power Cord
Plug) Wire Blue and Brown Wires to Fuses or Circuit Breakers and Green-Yellow Wire to
Ground.
Figure 4A Figure 4B

After the hoist is suspended from its support and you have the “UP” button is depressed to raise the load. If this is not
made sure the power supply complies with the requirements done, the hoist will continue to operate in the down direction
on the previous page, the hoist is ready for operation. while the “UP” push button is depressed, and it will continue
to lower the load until the control push button is released. As
On the (500, 600 and 1,000 lbs., 226, 272 and 453 kg., a result, the direction must not be reversed quickly (plug
Double Reeved units), cut and discard the ties used to hold reversed).
the two strands of chain together. With no load on the lower
hook, depress the “UP” button in the control station and There are no electrical switches to stop the operation of the
raise the lower hook until it is about 2 feet below the bottom hoist at the upper and lower limits of lift. As a result, it is
of the hoist. Check both strands of chains for twists. Twists necessary to release the push button in the control station to
occur if the lower hook block has been capsized between stop the hoist before the hook block or chain stop contacts
the strands of chain during packing, shipment and/or the bottom of the hoist frame. If the hook block or chain stop
handling. Reverse the capsize to remove twists. contacts the hoist frame, the Protector™ will function to stop
the hoisting or lowering operation and protect the hoist
CHAIN CONTAINER components from damage. However, continued, prolonged
or repeated slipping of the Protector™ will damage the
If the chain container is to be used, attach it to the hoist per
Protector™ and cause overheating of the internal hoist
the instructions provided.
components.

OPERATING INSTRUCTIONS
The hoist is equipped with a Protector™ that is designed to Allowing the hook block to run into the hoist when raising a load or
allowing the chain stop to run into the hoist when lowering a load
allow the first gear to slip on an excessive overload. An may break the chain and allow the load to drop.
overload is indicated when the hoist speed slows down, it
TO AVOID INJURY:
raises the load in a jerky manner or it will not lift the load at Do not allow the hook block or the chain stop to contact the hoist
all. Also, some clutching noise may be heard if the hoist is frame.
loaded beyond rated capacity. Should this occur, immediately
release the “UP” button to stop the operation of the hoist. At Hoist operation is controlled by depressing the control
this point, the load should be reduced to the rated capacity station push buttons. (Refer to Figure 5A) Depressing the
or the hoist should be replaced with one of the proper “UP” push button will move the load hook toward the hoist;
capacity. When the excessive load is removed, normal hoist depressing the “DOWN” push button will move the load
operation is automatically restored. hook away from the hoist.

CAUTION: The Protector™ is susceptible to overheating

and wear when slipped for extended periods. Under no
The “UP” and “DOWN” buttons are momentary type and the

circumstance should the Protector be allowed to slip for

hoist will operate in the selected direction as long as the

more than a few seconds.

button is held in the depressed position. Release the push
button and the hoist will stop.
1. When preparing to lift a load, be sure that the attach-
Due to the above, the hoist is not recommended for use in
ments to the hook are firmly seated in hook saddle.
any application where there is a possibility of adding to an
Avoid off center loading of any kind, especially loading
already suspended load to the point of overload. This
on the point of the hook.
includes dumbwaiter installations, containers that are loaded
in mid-air, etc. Also, if the hoist is used at unusual extremes 2. When lifting, raise the load only enough to clear the floor
of ambient temperatures, above 150º F (65ºC), or below 15ºF or support and check to be sure that the attachments to
(-9ºC), changes in lubricant properties may permit the hoist the hook and load are firmly seated. Continue lift only
to raise larger loads than under normal operating conditions after you are assured the load is free of all obstructions.
and present possibility of damage or injury. 3. Do not load the hoist beyond the rated capacity shown
on the brake end cover. Overloading can cause
On units without contactor (hoists with orange control immediate failure of some load-carrying parts or create
station) it is necessary to stop the hoist before changing a defect causing subsequent failure at less than rated
direction. Therefore, when lowering a load, the push button capacity. When in doubt, use the next larger capacity of
in the control station must be released momentarily before the ShopStar Hoist.

4
 Orange 10°
Black Station MAX.
Station for for Hoists
Hoists With
Without Contactor
Contactor

Control Station
Replace
Depress to Move Hook When
Load Hook Towards Opening is
Hoist Greater
UP
Than 1 1/8”
Depress to Move (28.5mm)
DOWN Load Hook Away
From Hoist Twisted Normal
Do Not Use Ok To Use

Figure 5A Figure 5B

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
TO AVOID INJURY:
heads of other personnel. Warn personnel of your -DO NOT Lift more than rated load.
intention to move a load in their area. -DO NOT Operate with twisted, kinked or damaged chain.
6. Do not leave the load suspended in the air unattended. -DO NOT Operate damaged or malfunctioning hoist.
7. Permit only qualified personnel to operate unit. -DO NOT Lift people or loads over people.
8. Do not wrap the load chain around the load and hook -DO NOT Operate hoist when load is not centered under hoist.
onto itself as a choker chain. -DO NOT Permit lower hook block to contact hoist frame or
chain container.
Doing this will result in: -DO Replace damaged or malfunctioning hook latch.
a. The loss of the swivel effect of the hook which -DO Keep load chain well oiled.
could mean twisted chain and a jammed liftwheel. -DO READ ASME B30.16 Safety Code for Hoist and appropriate
operating instructions.
b. The chain could be damaged at the hook.
9. On the (500, 600 and 1,000 lbs., 226, 272 and 453 kg.,
Double Reeved) hoists, check for twists in the load
chain. A twist can occur if the lower block has been
MAINTENANCE
capsized between the strands of chain. Reverse the
capsize to remove twist. INSPECTION
10. Do not allow a load to bear against the hook latch. The To maintain continuous and satisfactory operation, a regular
latch is to help maintain the hook in position while the inspection procedure must be initiated so that worn or
chain is slack before taking up the slack chain. damaged parts can be replaced before they become
unsafe. The intervals of inspection must be determined by
the individual application and are based upon the type of
service to which the hoist will be subjected. The inspection
of hoists is divided into two general classifications
Allowing a load to bear against the hook latch and/or hook tip can designated as “frequent” and “periodic”.
result in loss of load.
TO AVOID INJURY: Frequent Inspections
Do not allow a load to bear against the hook latch and/or hook tip.
Apply load to hook bowl or saddle only. These inspections are usually visual examinations by the
operator or other designated personnel. Frequent
11. Take up a slack load chain carefully and start load inspections are to be performed daily or monthly and shall
easily to avoid shock and jerking of hoist chain. If there include the following items:
is any evidence of overloading, immediately lower the a. Operate the hoist, with no load, and check for visual signs
load and remove the excess load. or abnormal noises which could indicate a potential
12. Do not allow the load to swing or twist while hoisting. problem - daily.
13. Never operate the hoist when flammable materials or b. Brake for evidence of slippage - daily.
vapors are present. Electrical devices produce arcs or c. Chain for lubricant, wear, damaged links or foreign
sparks that can cause a fire or explosion. material - daily (see below).
14. STAY ALERT! Watch what you are doing and use d. Hooks for damage, cracks, twist, latch engagement and
common sense. Do not use the hoist when you are tired, latch operation - daily (see below).
distracted or under the influence of drugs, alcohol or
medication causing diminished control. Any deficiencies must be corrected before the hoist is
returned to service.
Periodic Inspections
These are visual inspections by an appointed person who
records apparent external conditions to provide a basis for
continuing evaluation. Periodic inspections are to be
performed semi-annually and they should include the
following:

5
 .157 Inches Vernier Caliper
(4 mm) Diameter Weld

Wear in These
Areas

Measure 11
Pitches
One
Pitch

Figure 6A Figure 6B

a. All items listed under frequent inspections. On latch type hooks, check to make sure that the latch is not
b. External evidence of loose screws. damaged or bent and that it operates properly with sufficient
spring pressure to keep the latch tightly against the tip of the
c. External evidence of worn, corroded, cracked or distorted
hook and allow the latch to spring back to the tip when
hook block, gears, bearings, chain stop and hook retainer.
released. If the latch does not operate properly. It should be
d. External evidence of damage or excessive wear of the replaced. See Figure 5B, pg. 5 to determine when the hook
liftwheel or sheave (double reeved unit). Widening and must be replaced.
deepening of pockets may cause chain to lift-up in the
pockets and cause binding between liftwheel and chain LOAD CHAIN
guide or between lower sheave and hook block. Check
chain guide for wear or burring where the chain enters the Chain should feed smoothly into and away from the hoist or
hoist. Severely worn or damaged parts should be hook block (500, 600 and 1,000 lbs., 226, 272 and 453 kg.,
replaced. Double Reeved) units. If chain binds, jumps or is noisy, first
clean and lubricate it (see below). If trouble persists, inspect
e. External evidence of excessive wear of brake parts - see
chain and mating parts for wear, distortion or other damage.
page 8.
f. Check the control station push buttons to make sure they Chain Inspection
operate freely and spring back when released. First clean chain with a non-caustic/non-acid type solvent
g. Check power cord, control cord and control station for and make a link by link inspection for nicks, gouges, twisted
damaged insulation. links, weld spatter, corrosion pits, sitriations (minute parallel
h. Check for pitting and any deterioration of contactor lines), cracks in weld areas, wear and stretching. Chain with
contacts (hoists with black control station). any one of these defects must be replaced.
i. Check the chain pin or dead end pin and chain stop for
Slack the portion of the chain that normally passes over the
wear and cracks.
liftwheel. Examine the interlink area for the point of maximum
j. Check for lubricant leaks at gasket between main frame wear (polishing, see Figure 6A). Measure and record the
and gear housing. Tighten gear housing screws to stop stock diameter at this point of the link. Then measure stock
leak. If leak persists, replace gasket. diameter in the same area on a link that does not pass over
k. Inspect splines on first pinion shaft and motor coupling for the liftwheel (use the link adjacent to the loose end link for
signs of wear or deterioration. Replace splined parts if this purpose). Compare these two measurements. If the
worn or damaged. stock diameter of the worn link is 0.010 inches (0.254mm),
NOTE: To perform some of the periodic inspections, it is
or more, less than the stock diameter of the unworn link, the
necessary to partially disassemble the hoist. Refer to
chain must be replaced.
Disassembly - Assembly starting on page 12. On the (500, 600 and 1,000 lbs., 226, 272 and 453 kg.,
Double Reeved) units, repeat this examination of the chain
Any deficiencies noted must be corrected before the hoist is that passes through the hook block.
returned to service. Also, the external conditions may show
the need for more detailed inspection which, in turn, may Also check chain for stretch using a vernier caliper as
require the use of nondestructive-type testing. shown in Figure 6B. Select an unused, unstretched section
of chain (usually at the loose end) and measure and record
Any parts that are deemed unserviceable are to be replaced the length over 11 chain links (pitches). Measure and record
with new parts before the unit is returned to service. It is very the same length on a worn section of chain. Obtain the
important that the unserviceable parts be destroyed to amount of stretch and wear by subtracting the measurement
prevent possible future use as a repair item and properly of the unworn section from the measurement of the worn
disposed of. section. If the result (amount of stretch and wear) is greater
Hook Inspection than 0.145 inch (3.7 mm), the chain must be replaced.
Hooks damaged from chemicals, deformations or cracks or Use only a “Knife-edge” caliper to eliminate possibility of
that have more than a 10° twist from the plane of the unbent false reading by not measuring full pitch length.
hook or excessive opening must be replaced.
Note that worn chain can be an indication of worn hoist
Any hook that is twisted or has excessive throat opening components. For this reason, the hoist’s chain guide, hook
indicates abuse or overloading of the unit. Other load- block and liftwheel should be examined for wear and

6 damage.
sustaining components of the hoist should be inspected for replaced as necessary when replacing worn chain.
 Use only Star (*) grade load chain and original
replacement parts. Use of other chain and parts may
be dangerous and voids factory warranty.

Figure 7A Figure 7B

NOTE: To assure extra long life and top performance, be

sure to lubricate the various parts of the ShopStar using
Also, these chains are specially heat treated and hardened

the lubricants specified below. If desired, these

and should never be repaired.

lubricants may be purchased from CM. Refer to page 18

for information on ordering the lubricants.
Use of commercial or other manufactures’ chain and parts to Gears
repair ShopStar Hoists may cause load loss. • The Protector™ (620-111) should operate for the normal
TO AVOID INJURY: life of the hoist without service. The device has been
Use only factory supplied replacement load chain and parts. lubricated and calibrated by CM and should not be
Chain and parts may look alike, but factory original chain and adjusted.
parts are made of specific materials or processed to achieve
CAUTION: The Protector is to be used with “Century
specific properties. See Figure 7A.
IMPORTANT: Do not use replaced chain for other Lubricants HB-11, #3” grease. Do not use any other
purposes such as lifting or pulling. Load chain may grease or the Protector will not operate properly and
break suddenly without visual deformation. For this parts could be damaged.
reason, cut replaced chain into short lengths to prevent
use after disposal. The gears and Protector are packed at assembly with
Chain Lubrication grease and should not need to be renewed unless the gears
have been removed from the housing and degreased.

CAUTION: Never degrease the Protector or attempt to

A small amount of lubricant will greatly increase the life of

disassemble this device. Degreasing the Protector may

load chain. Do not allow the chain to run dry. Keep it clean

damage parts and using a device that has been

and lubricate at regular intervals with Lubriplate® Bar and

degreased may cause erratic, inconsistent operation. If

Chain Oil 10-R (Fiske Bros. Refining Co.) or equal lubricant.

the Protector has been degreased, it must be replaced

Normally, weekly lubrication and cleaning is satisfactory, but

by a CM calibrated device.
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.
If the gears are removed from the housing, wipe the excess
grease off the outside surfaces of the Protector™ with a soft
cloth and degrease the remaining gears and housings.
Upon reassmbly, add 2 oz. of the above grease to gears
Used motor oils contain known carcinogenic materials. and housing. Also, coat the spline on the end of the first
TO AVOID HEALTH PROBLEMS: pinion and shaft (620-131) with a Molydisulphide lubricant
Never use used motor oils as a chain lubricant. Only use such as Moly-Duolube 67 (Hercules Packing Co.).
Lubriplate® Bar and Chain Oil 10-R as a lubricant for the
load chain. Bearings
Rotor bearings (620-102 and 620-103) are pre-lubricated
When lubricating the chain, apply sufficient lubricant to and require no lubrication. Needle bearings (620-109, 620-
obtain natural run-off and full coverage, especially in the 114, 620-115, 620-128 and 620-164) are packed at
interlink area. assembly with grease and should not need to be
relubricated. However, if the housings (620-113 and 620-
LUBRICATION 107), liftwheel (620-127) or sheave wheel (620-162) have
Refer to Exploded View and Parts List pages 14 thru 18. been degreased, these bearings should be greased using
“Century Lubricants HB-11, #3” grease.
Seals
When reassembling the unit, wipe the inside surface of the
The lubricants used in and recommended for the ShopStar may
contain hazardous materials that mandate specific handling and seals (620-108 and 620-130) with “Century Lubricants HB-11
disposal procedures.. #3” grease.
TO AVOID CONTACT AND CONTAMINATION: Hook Block
Handle and dispose of lubricants only as directed in applicable
material safety data sheets and in accordance with applicable If the hook blocks are disassembled for inspection
local, state and federal regulations. purposes, wipe the grease from the hook knob and the hook

7
 Figure 8A Figure 8B

knob cavities in the hook blocks. At reassembly, coat the 2. Refer to Figure 8B and assemble the brake. Depress and
underside of the hook knob and the knob bearing surfaces hold the field assembly (620-122), while installing the four
of cavities in the hook blocks with Molykote BR-2-S (Dow brake screws through the brake parts and mount the
Corning Corp.) grease or equivalent. brake on the gear housing (620-113). Tighten the four
brake screws (620-124) to 25 in.lb. (2.8 NM).
Chain Guide, Liftwheel and Sheave Wheel
• When the hoist is disassembled for inspection and/or
repair, the chain guide, stripper, sheave wheel (on double PROTECTOR
chain unit) and liftwheel must be lubricated with
The Protector™ should operate for the normal life of the hoist
Lubriplate® Bar and Chain Oil 10-R (Fiske Bros. Refining
without service. The device has been lubricated and
Co.) prior to reassembly. The lubricant must be applied in
calibrated and it should not be adjusted. If the Protector™ is
sufficient quantity to obtain natural runoff and full
not operating properly (see testing on page 13), it must be
coverage of these parts.
replaced with a properly calibrated unit from the factory.
Load Chain
PREVENTATIVE MAINTENANCE
Refer to page 7 for lubrication of the load chain.
A preventative maintenance program should be established
Exterior Finish to prolong the useful life of the hoist and maintain its reliability
The exterior surface of the hoist has a durable, scratch and continued safe use. The program should include the
resistant baked powder coating. Normally, the exterior periodic and frequent inspections with particular attention
surfaces can be cleaned by wiping with a cloth. being paid to the lubrication of the various components using
the recommended lubricants (see page 18).
ELECTRIC BRAKE RECOMMENDED SPARE PARTS
The brake is non-adjustable with a nominal .004 inch (0.102 To insure continued service of the ShopStar, the following
mm) air gap and the brake disc must be replaced when the is a list of parts that are recommended to be kept on hand
air gap reaches .012 inch (0.305 mm). The brake spacer at all times to replace parts that have worn or failed. Parts
should be no more than .012 inch (0.305 mm) thicker than applicable to your hoist should be stocked.
Key Qty. Per Key Qty. Per
the combined thickness of the brake disc and armature
Part Name Part Name
plate. Refer to Figure 7B, pg. 7. No. Hoist No. Hoist
Brake Field
620-122 1 620-117 Brake Disc 1
To inspect the brake gap, disconnect the hoist from power Assembly
Control Station
and remove brake end cover (620-132).
620-186 1 620-110 Cut-Out Device 1
(orange)
Reversing
620-106 Capacitor 1 620-178 1
Contactor
620-181 Transformer 1 Control Station
624-306 1
Failure to follow proper lockout/tagout procedures may present the
danger of electrical shock.
624-232 Control Station 1 Parts Kit
TO AVOID INJURY:
Disconnect power and lockout/tagout disconnecting means before
removing cover or servicing this equipment. Refer to page 13 for ordering instructions and the Parts List
for part numbers.
1. Refer to Figure 8B and disassemble the brake. Depress
and hold the field assembly (620-122) while removing the
four brake screws (620-124). The field assembly is under
spring pressure and will spring-out if not held.
Examine the base plate (620-116), brake disc (620-117)
and armature (620-118) for excessive wear, scoring or
warpage. Make sure the brake disc is not glazed, the coil
firmly fixed in the field (620-122) and the brake spring
(620-123) is not damaged. Worn, scored, warped, glazed
or damaged parts should be replaced before preceding.

8
TROUBLE SHOOTING Failure to follow proper lockout/tagout procedures may present the
danger of electrical shock.
Always disconnect unit from the power supply system before TO AVOID INJURY:
Disconnect power and lockout/tagout disconnecting means before
removing hoist covers or the back cover of control station. removing cover or servicing this equipment.

––– Probable Cause ––– ––– Remedy–––

1. Hook does not respond to control station.

A. No voltage at hoist. A. Check for blown fuse or tripped circuit breaker or open disconnect switch in main
line or branch circuit. Replace fuse, reset circuit breaker or close switch.
B. Open control circuit due to loose connections or broken wires in circuit; motor B. Check electrical continuity through motor thermal protector. If it is open, allow
thermal protector open; control station contacts not closing; open or shorted motor to cool. If this does not correct the trouble, use wiring diagram to check
winding in transformer; transformer thermal cut-out open; mechanical binding in electrical continuity of wiring, transformer, contactor and control station contacts.
contactor; open or shorted winding in contactor coil. Repair wiring or replace defective part.
C. Wrong voltage or frequency. C. Make sure that the power supply to hoist is the same as that shown on the
identification plate on buttom of hoist.
D. Low voltage. D. Check power supply system to make sure it complies with the requirements listed
under “power supply system” starting on page 2.
E. Brake not releasing due to open or shorted coil, defective diodes or brake disc E. Check coil continuity, diodes (see page 10) and connections. Make sure brake
binding. disc slides freely on brake driver and brake spring is not broken. Replace coil
(brake field), repair connections, remove burrs from brake driver so that brake disc
slides freely and/or replace brake spring.
F. Excessive load. F. Reduce load to capacity limit as indicated on identification and capacity labels on
hoist.
G. Phase failure (single phasing-three phase units only) - open circuit, grounded or G. Check for electrical continuity and repair or replace defective part.
faulty connection in one line of power supply system, hoist wiring, contactor, motor
leads or windings.

2. Hook moves in wrong direction.

A. Wiring connections reversed in control station or hoist. A. Use wiring diagram and check wiring connections.

B. Failure of cut-out device (single phase units only) to effect dynamic braking at time B. Check connections to cut-out device. Replace damaged device or faulty
of reversal. capacitor.
C. Phase Reversal (three phase units only). C. See “Three Phase Hoists” on page 3.

3. Hook lowers but will not raise.

A. Excessive load. A. See item 1F.

B. Hoisting circuit is OPEN due to loose connections or broken wires in circuit; control B. Use wiring diagram to check electrical continuity of wiring and control station
contacts. Repair wiring or replace defective part.
station contacts are not making; open or shorted winding in contactor coil. C. Check cut-out device and connections to same. See page 10. Repair connections
C. Motor cut-out device not operating. (single phase units only). and/or replace cut-out device.
D. Phase failure (three phase units only). D. See item 1G.

4. Hook raises but will not lower.

A. Lowering circuit is OPEN due to loose connections or broken wires; control station A. See item 1B.
contacts not closing; open or shorted winding in contactor coil.
B. Motor cut-out device not operating (single phase units only). B. See item 3C.
C. Phase reversal (three phase units only). C. See item 2C.
D. Phase failure (three phase units only). D. See item 1G.

5. Hook does not stop promptly.

A. Brake slipping. A. Check electric brake (see page 8), especially the brake disc for wear or glazing
and make sure brake spring is not broken. Replace worn or glazed brake disc or
replace brake spring.
B. Excessive load. B. See item 1F.

6. Hoist operates sluggishly.

A. Excessive load. A. See item 1F.

B. Low voltage. B. See item 1D.
C. Brake dragging. C. Check electric brake (see page 8). Check to make sure brake disc is free to move
on brake driver. Check for warped or bent brake disc and base plate. Free-up
brake disc by removing burrs on driver. Replace warped armature base plate or
brake disc.
D. Phase failure or unbalanced current in phases (three phase units only). D. See item 1G.

7. Motor overheats (Hoist will not operate in up or down direction - motor thermal protector open).

A. Excessive load. A. See item 1F.

B. Low voltage. B. See item 1D.
C Extreme external heat. C. Above an ambient temperature of 104°F (40°C), the frequency of hoist operation
must be limited to avoid overheating the motor. Special provisions should be
made to ventilate the space around the hoist and shield it from radiant heat.
D. Frequent starting or reversing. D Avoid excessive inching, jogging and reversing. This type of operation drastically
shortens motor cut-out device, capacitor, control station and contactor contact life
and causes excessive brake wear.
E. Brake dragging. E. See item 6C.
F. Motor cut-out device not opening start winding circuit (single phase units only). F. See item 3C.
G. Phase failure or unbalanced current in phases (three phase units only). G. See item 1G.

8. Hook fails to stop in either direction.

A. Brake not closing or ineffective. A. Check electric brake (see page 8), and armature for binding, broken brake spring,
first pinion shaft broke, brake driver worn, brake disc worn. Correct binding of
armature; replace broken or worn parts.

9. Hook lowers when “UP” button is depressed.

9
A. Phase reversal (three phase units only). A. See item 2C.
 Coils
ELECTRICAL DATA Voltage Current Nominal D.C.
Draw (Amps) Resistance (Ohms)
Open or Short Circuit in Electrical Components Contactor 115 0.02 765
Open circuits in electrical components may be detected by Coils 48 0.2 98.4
isolating the component and checking for continuity using Brake *115 - *272
an ohmmeter. Short circuits are indicated by D.C. resistance Field **220 - 1120
substantially below the nominal D.C. resistance. Motor ***280 - 1608
current draw should be measured at the end of the power Cut-out 115 0.1 Terminals 3 to 4: 0.3
cord while the hoist is raising rated load. Check cut-out Device
device (on single phase units only) by measuring coil *To measure 115 volt brake coil resistance, carefully cut and
resistance (terminals 3 and 4) and making sure the contact peel back the shrink tubing on the brake coil leads to
(terminals 2 and 4) is open. expose the diodes. Trace the leads from the coil to the
diodes. Connect the ohmmeter leads at the coil side of the
Electrical Data for Components diodes (refer to the wiring diagram) and measure the
Stators resistance. If coil is ok, reinsulate the brake coil leads and
Volts-Phase-Hertz Full Load Current Nominal D.C.
diodes using electrical tape. Diodes are checked by
(Amps) Resistance
connecting the ohmmeter to the ends of the brake coil
(Ohms)
leads, checking for an open or short circuit, reversing the
connections to the ohmmeter and again checking for an
110 to 120-1-50/60 2.7 Yellow to Red: 7.7 open or short circuit. If there is an indication of an open or
Blue to Black: 6.2 short circuit with the original and reversed connections,
220-1-50 1.1 Yellow to Red: 27.7 diodes are defective and the brake field (620-122), which
Blue to Black: 24.2 includes the diodes, must be replaced. Usable diodes are
220-3-50 1.1 White to Red: 26.8 indicated by continuity with the original connections and an
230-3-60 0.6 White to Black: 26.8 open circuit when the connections are reversed or, an open
Red to Black: 26.8 circuit with the original connection and continuity with
reversed connections.
380-3-50 0.63 White to Red: 72.6
415-3-50 0.58 White to Black: 72.6 **220 volt brake coil is used on 220-1-50, 220-3-50/60 and,
460-3-60 0.88 Red to Black: 72.6 380-3-50, 415-3-50 and 460-3-60 hoists.
575-3-60 0.4 White to Red: 140.0 ***280 volt brake is used on 575-3-60 hoists.
White to Black: 140.0
Red to Black: 140.0

Transformers
Primary 220/380v. 230/460v. 460v. 575v. 575v.
Secondary 48v. 115v. 48v. 115v. 48v.
Leads Nominal D.C. Resistance (ohms)
Black to Purple 11.7 71.0 11.9 73 98
White to Red 228.0 224.0
White to Yellow 614.0 902.0 - - -
Red to Yellow 384.0 682.0 - - -
White to Orange - - 916.0 1100 1100

WIRING DIAGRAMS
THE FOLLOWING WIRING DIAGRAMS ARE REPRESENTATIVE. FOR ACTUAL WIRING DIAGRAM, REFER TO THE DIAGRAM
SUPPLIED WITH THE HOIST. NOTE: FOR 575-3-60 UNITS, REFER TO WIRING DIAGRAM SUPPLIED WITH HOISTS.

115-1-50/60
HOISTS WITHOUT
CONTACTOR
(Orange Control
Station)

10
 115-1-60
HOISTS WITH
CONTACTOR
(Black Control
Station)

WIRING DIAGRAM
115-1-60

220-1-50
HOISTS WITH
CONTACTOR
(Black Control
Station)

220-3-50
230-3-60
HOISTS WITH
CONTACTOR
(Black Control
Station)

380-3-50
415-3-50
460-3-60
HOISTS WITH
CONTACTOR
(Black Control
Station)

11
 Pin Retainer
Plate

Cut-Out
Device

Main
Frame
Wire
Slot Welds
Down and
Jumpers “2” Towards
and “Cap” Main Frame Liftwheel

Figure 12A Figure 12B Figure 12C

assembled to the main frame (620-107). On single

DISASSEMBLY-ASSEMBLY phase units slide jumpers “2” and “CAP” through the
wire slot in the main frame. Route these wires around
the rotor bearing boss in the main frame as shown in
When disassembling and assembling the ShopStar Hoist, Figure 12A. Attach the brown and blue stator leads and
refer to the exploded view and the parts list on pages 14 “2” jumper to cut-out device (refer to wiring diagram).
thru 18. These show the proper relationship of the parts, the Slide the cut-out device into the cavity as shown. Push
names of the parts and the required quantities of the parts. the cut-out device down until it sets on the main frame.
In addition, please observe the following: Place the capacitor on top of the cut-out device and
1. Needle bearings are pressed into the gear housing attach “CAP” jumper and the yellow stator lead to it. Re-
(620-113), main frame (620-107), liftwheel (620-127) route jumpers “2” and “CAP”, if necessary to make sure
and lower sheave wheel (620-162). Unless they are to they clear the rotor bearing boss as shown in Figure
be replaced, do not attempt to remove these bearings. 12A. On all units slide stator leads through wire slot.
Align the slots in the stator shell with the threaded holes
2. A liftwheel seal (620-108) is pressed into the main frame in the main frame, as shown in Figure 12B. With the
(620-107) and a seal (620-130) is pressed into the end leads down, slide the stator into the main frame. Slide
of the liftwheel shaft (620-148). Be careful that these the rotor, large bearing first, into stator. Place the rotor
seals are not cut or damaged during disassembly and thrust washer (620-104) on top of the exposed rotor
reassembly. bearing and then assemble the motor end cover (620-
3. Refer to page 8 for disassembly, inspection and 105) to the main frame. Using wiring diagram, complete
reassembly of the brake. the wiring at the brake end of the unit.
4. Do not attempt to disassemble the Protector™ - refer to 10. Properly install the upper hook as shown in Figure 13A,
page 8. then slide the hook retainer (620-139) into the cavity on
top of the hoist and secure it using hook retainer screw
5. Refer to page 7 for lubrication instructions. (620-140). Tighten screw to a seating torque of 10 in.
6. See next section for load chain removal and installation. lbs. (1.1 NM).
7. Tighten the various screws as follows: 11. After reassembly, test the unit per instructions on page 13.

KEY-NO. PART NAME SEATING TORQUE

LB. IN. NM LOAD CHAIN REMOVAL/INSTALLATION
620-126 Pin Retainer Plate Screw 25 2.8 1. If unit has a chain container, remove it from the chain
620-154 Motor Cover Screw 25 2.8 guide.
620-134 Gear Housing Screw 25 2.8 2. Remove the chain stop (620-146). Depress “DOWN”
button and run chain out of hoist.
620-133 Brake End Cover Screw 25 2.8 3. Feed a short length of soft wire through the opening
620-168 Dead End Plate Screw 125 14.1 between the chain guide (620-141), and stripper (620-
620-140 Hook Retainer Screw 10 1.1 143) until it comes out of the hoist. Attach “new” chain to
620-157 Hook Block Screw end of the wire which is in the center of the hoist.
500, 600 and 1000 lbs Position the chain so that the welds will be down and
towards the liftwheel as shown above in Figure 12C.
(226, 272 and 453 kg)
4. Jog the “UP” push button while pulling on the free end
(Double Reeved) units 125 14.1 of wire until the chain comes out of the hoist. Remove
250, 300 and 500 lbs the wire and attach the chain stop as shown in Figure
(113, 136 and 226 kg) 13B. On units with chain container, place chain stop
(Single Reeved) units 50 5.6 and loose end of chain in chain container. Attach chain
620-152 Power Cord Ground Screw 20 2.2 container to chain guide.
8. When removing the stator (620-100), first remove the 5. On the single-chained units, remove the hook block
brake end cover (620-132). Disconnect stator leads from the old chain and attach it to the new chain by
from the wiring or contactor. At the other end, remove reusing the chain pin (620-158).
the motor end cover (620-105). On single phase units,
use an insulated screw driver to short between the bare On the double-chained units:
terminals of the capacitor to discharge it. A spark may • Remove dead end plate (620-160) from hoist.
be produced. Disconnect wiring to the capacitor and
then remove the capacitor. Remove the cut-out device • Remove dead end pin (620-161) from the last link of
(620-110) and disconnect the wires from it. Remove the chain and pull chain out of dead end plate.
rotor assembly (620-101) and thrust washer (620-104).
Then slide the stator out of the main frame (620-107).
• Pull old chain out of hook block and disassemble the hook
9. To install the stator refer to Figure 12A and make sure block.
that the pin retainer plate (620-125) has been
• Make sure the new chain is not twisted and wrap the

12
 Hook Opening Hook
Away From Opening
Loose End Towards
Loose End

ShopStar ShopStar

Loose Loose
End End

Figure 13A Figure 13B

chain around the sheave wheel (620-162) with welds without a load and then with a light load of 50 pounds (23
down and towards the sheave wheel. kg) times the number of load supporting parts of load chain
• Reassemble hook block and pull the new chain through to be sure that the hoist operates properly and that the brake
the hook block. holds the load when control is released. Next test with a load
of *125% of rated capacity. In addition hoists in which load
• Slide the dead end plate over the last link and secure it sustaining parts have been replaced should be tested with
using the dead end pin. *125% of rated capacity by or under the direction of an
• Making sure the chain is not twisted between the hook appointed person and a written report prepared for record
block and hoist, attach the dead end plate to the purposes. After this test, check the Protector™ functions. If
stripper (620-143). the Protector™ permits lifting a load in excess of 200% of
• Retrace the new chain and check for twists. If chain is rated load, it should be replaced.
twisted, start over.
*If the Protector™ prevents lifting of a load of 125% of rated
capacity, reduce load to rated capacity.
IMPORTANT: Do not use “old” chain for other purposes NOTE: For additional
such as lifting or pulling. Load chain may break REPAIR PARTS information on
suddenly without visual deformation. For this reason, inspection and testing,
cut the “old” chain into short lengths to prevent use refer to ASME B30.16 “Overhead Hoists” obtainable from
after disposal. ASME Order Department, 22 Law Drive, Box 2300,
Fairfield, NJ 07007-2300, U.S.A.
CUTTING CHAIN
Hoistaloy® load chain is ORDERING INSTRUCTIONS
hardened and it is difficult The following information must accompany all
to cut. The following correspondence and orders for replacement parts:
methods are recommended
when cutting a length of 1. Hoist rated load from identification plate.
new chain from stock or
cutting off worn chain. Always wear eye protection when 2. Serial number of the hoist stamped below identification
cutting chain. plate.
1. Use a grinder and nick the link on both sides (see right), 3. Voltage, Phase, Hertz from identification plate.
then secure the link in a
vise and break off with a 4. Length of lift.
hammer.
2. Use a 7”(177 mm) 5. Key number of part from parts list.
minimum diameter by
1/8" (3.1 mm) thick abrasive wheel (or type 6. Number of parts required.
recommended by wheel supplier) that will clear adjacent
links. 7. Part name from parts list.

8. Part number from the parts list.

NOTE: When ordering replacement parts, it is recom-

mended that consideration be given to the need for
also ordering such items as gaskets, fasteners, seals,
Cutting chain can produce flying particles.
etc. These items may be damaged or lost during
disassembly or just unfit for future use because of
TO AVOID HEALTH PROBLEMS:

deterioration from age or service.

• Wear eye protection.
• Place a shield over chain to prevent flying objects.

3. Use a bolt cutter (see right) with special cutter jaws for
cutting hardened chain. Jaws should be 1 inch (25.4 mm)
long.
Using “commercial” or other manufacturer’s parts to repair the
TESTING ShopStar Hoist may cause load loss.
Before using, all altered, repaired or used hoists that have TO AVOID INJURY:
Use only factory supplied replacement parts. Parts may look alike
not been operated for the previous 12 months must be but factory original parts are made of specific materials or
tested by the user for proper operation. First, test the unit processed to achieve specific properties.

13
 NOTES

14
 CONTROL STATION (ORANGE) FOR USE ON
115-1-50/60 HOISTS WITHOUT CONTACTOR
NOTE: Individual components are not available for
repairs


 

 





PARTS LIST
No.
KEY NO. PART NAME REQ’D. PART NUMBER
 
 
620-186 Control station 1 24807
with retainer,
screws and
grommet

Control Station (Black) for use on 115-1-50/60

hoists with contactor, 220-1-50 and three
phase units.

CONTROL STATION
Key No. Part Name No. Req’d Part No.
624-232 Control Station (Includes 1 36900B
624-301 thru 624-307)
624-252 Warning Label (Electrical) 1 24842
624-253 Manufacturer Label 1 28470
624-301 Control Station Grommet 1 36989
624-302 Control Station Housing 1 36998B
624-303 Gasket 1 36986
624-304 Control Station Button 1 36988
Assembly
624-306 Control Station Parts Kit 1 36939
624-307 Contact Assembly (Includes 1 36987
624-304)
624-308 Warning Label 1 24845

19
 NOTES

20