CMTrolley-635MDTmanual

CMTrolley-635MDTmanual
Operating , Maintenance
and Parts Man ual
Series 635 Motor
Driven Trolley
Capacities: % • 2 and 3 Tons
CAUTIO N - IMPORTA NT
fOll OW AU INSTRUCTIONS "NO WARWINGS IN INSPfCTING,
M"' .UJIIING AND OPERATING TillS TROLLEY.
The use , 11"f hO~\ Ind trolll, "n,nlt ..... 'iJl< of p,,*,..llnjury
or prop,ny dim. g•. Thot .ilk il grl.tI, i.,,".nd il pr.por inllfuc,
til .' Ind w. r. ings ,ro not r,Uowl d. B,Io," ulin g th i. uolloy, IIch
uN' I hlUld b... ml thorlughl, f. .. il .II with 1M war.inp. iIIsuuCl;"',
1M ..,o", ..",dl lio .. hi" ''''
RETA'" TillS MAIIUAL FOR FUT URE REFERENCE AIIO USE.
fORWARD THIS MANUAL TO OPERATOR. fAILURE TO OPERATE EQUIPMENT AS DIRECTED IN MANUAL MAY CAUSE INJURY,
PRINTED
I~
U.S .... .
C Coko'nDuo MCl\jmoo Corporation II/ge
alll1S
"
2.5Ml%o
Instruction Sheet No . 635·H
Pri ce: $8.00
SAFETY PRECAUTIONS
AII9t you have completely t~ri:ed
M ufti 'e~ .
roursett with the con_
of ttOs n'IIIn>aI . ..... ecoo ' . 'lo!nCllI'Ial )'QU ClIft!...., ~ .. ~ k><
•~ oI lhi1 &tanc\••d ma~ be obtained from the American $odeI)' 01 Mechanical ErogmeelS. 22 Uw on.e, P,O. 80. 2300.
Faolield. N.J . 0 7007·2300, U,S.A.
,
,
FOLLOWED COULD ENDANGER TH E PERSONAL SAFETY ANOiO.'~'; ,'~O~iPEATY OF
A
,
OPERATING AND SAFETY
PROCEDURES
The following."
Op8faling and safety procedU'H 101' $81e ope<alion of the series 635
Motor Driven Trolley. Talting precedenc. over
any specific: rules listlld here . how9ver, i$ the
most important .ule of all , USE COMMON
SeNSE . A few minutes spelll read ing these fules
can
m a~e
an ope rator awa re of dangerous prlO-
tlces 10 avoid and precautions to lake lor his
own safety and the safety 01 othe,s. Frequ enl
examinations and Pflriodic inspections 01 the
equipment as well as a conscienliOUS ob$&!'.
vance 01 ,afety rules may $ave liv. s as _II as
time and money.
1. Immediately .ftflf installation. opel'ate trolley
(aecording to tile operating and $alely pr0cedures as follows) with a capacity lOad over
the eroti.. length of ruroway or moroo<ail
Sy$lem to be stJ'e that aI adjustmerotl and
operation! "e satislactory.
2. Aailltops must
~
installed lor alt trolleys
operating on open erod beams . These stops
must be posit ioned SUCh that impact lorces
are absorbed by the trol ley side Irames only .
3. When preparing to lilt a load. be su re that
the attachments to the hook are l irmly
seated In hook $addle. Avoid off center
loading of any kind. especially Ioadir>g on the
pOint of hook .
4 . When lilting. ralse the load only enoogh to
clear the lloor Of $Upport and check to be
sure that the .nachme<1ts 10 hook and load
are lirmly "ated . Continue lift oroly .ft.... you
are ustJred the lOad is Iree 01 att
obstruction, .
S. When applying a load, it should be directly
under the troll ey. Avoid off center IQadirog 01
,
any kind .
,"
A
6. Take up a slack lOad chain caretully and star!
lilting load slowly 10 .void shock arod larking 01
hoiSl load chain . 1\ there Is .roy evidlroc. of
overloading. immediately lower the 10-.:1 and
rflmove the ElJ(cess load.
7. Do not allow the load to swing
or
twist while
hoisting.
8. Anticipate the stopping point and allow trol lfly to
coast 10 a smooth stop. Reve rsing or '·plugging ··
to stop trolley causes ove,hflatlng 01 moto, and
swaying 01 load.
9. Do
not load trolley beyond the rated capacity.
Overload ean cause immediate I.llure of load
carrying parts or cause damage resulting in
future fa ilurE! al tess than ..ted capacity.
10. Do not use this
01 any DIller overhead mate<ials
handling equipment lor lilting 01 u.rospor!ing
-.
II . Stand clEla< 01 all lOads and , vo;(! moving a load
ove r the heads 01 other people. Warn people 01
your intention to move a load in thei' area.
12.00 not leave IhE!load susperodtd in the air
unaUE!nded .
13. Do root wrap the load chain . round the load and
hook onto itsell as a ch(lker chain .
Doing this will r8$uh in the lollOwing:
(a) Operation of the upper lim~ sw~ch is
bypassed and the load could hi! the hoiSl.
(b) The loss 01 the swivel efleel 01 th' hook
whieh could mearo twisted chain and a
jammed tillwhool.
(e) TIle chair> could
be damaged "t the hook.
14. Permit oroly qualili&d perSOl1",1 to operate unit.
~.~ =i;;~-:~==~~~-----------------------------~-
Flgu'. 14
Moto< Wid Our
Reducer E.pIOded VI_
Motor And Peerless-Winsmlth
CONTACT eM
FOA PART
NUMBER OF
GEAR
REOUCER
COMPONENTS
KEY NUMBERS
635-400 Thru 615 430
"
•
o. ,
o.
,
635-206
Motor Brake Parts List
.,
,
,
,
&35·260
535·261
635-262
635·263
•
635-264
635-265
Couple< 8,31<.., Shaft Kit (includes Shalt. Bearing .
Snap Ring, Retainer Ring and Key)
Housing
Mounting Stud With Nut
,
,
635 -272
635·273
635·274
535·275
• Drain PI,,\!
• Housing To End Plate Gasket
• Gasl<el - Each End Of B rake
Fricti"" DiS(: Kit (Indlldes 3 Discs With Stabilizer
S~i"ll'
Onl)' 000 Disc Required Per Brake)
Hub M (Includes Hub And Sel Screws)
End Plat", A$sembl1
PlU9-External Lead Hole
Bea,jr>g
SoIoooid l<M>r
&35-277
,
535-278
2
Torque Adjusting Screw
,
,
,
,
Wear Adjusting Screw
635-280
635·261
635-282
l ever Arm And Slop Nut Ass&mbly
Bearing Pin
,
Solenoid Kil (iocludes I'1unger, Link . Frame Link
535-287
,
,
,
635·292
,
635·284
635·285
635 ·286
535-293
535·294
635·353
t
,
,
,
Of
Brake
Components
Key Numbers
635·260 Thru
635-286, 635-294
And 635-353
Pressure 5pfing
Support Plate And Slop Nul Assembly
635·263
,,,
Spacer
,
635·279
Contact e M
Part Numbers
Stationary Disc
R81aining Ring
635·276
tw. Aeq'd.)
• Access Cover Gasket
,
,
,
,
,
,
635·271
5 1074
Access Cover Screw (Sp&ci/)I
635 ·270
635-268
Brake Cord
Access Cover . Plain
635·269
635-267
Pan Nu mber
2
,
,
,
,
635·266
Pa rt lilme
Pivot Pin
Screw. U nk
NuI-""::1
M<)Urt1i~
Screws)
Coi1 Kit (Includes Coil . Plunger Guides .
Guide Screw and Lockwuher)
Motor Brake Kit (iocludes Complete Brake
ASSOOlt>/y. Brake Cord. Conn&cto< Wire Nuis aoo
Installation InstrVClions)
Brake Cord Connector
Wir" Nul
I
• For Weatholrproot Unils • Not Shown
9597 For 115 Volt Bra~e.
9598 For 220. 230. 380
Aoo 460 Volt Brake
~962473
Brake Anaching Screw
Con1act CM
•• Acee .. Cover With Manual Aeleas. Knob
Con1act CM
•• Nor Shown
()
•
•
63S-281
Rgure 15
Motor Brake Exploded View
..,-
C~
e3S43~
( m -340
14
635-89
831-.138
I r:635-3'9
L~
_
[ --0
.~
e.3S4320J~
~.2
Motor And Hub City Type Gear Reducer Parts List
CONTACT eM
FOR PART
NUMBERS OF
GEAR
REDUCER
COMPONENTS
KEY NUMBERS
535·325 Thru 635-352
Control Box Conponents Parts List
Refer To Figure 13
..
~ .,
~
.....
~~
Separate Parts List For
Units With Main Line Contactor
..... Ro<! ••.
,
,
,
,
,
,
,
,
,
,
•
•
•
,"". ... $1,_
,... ,OF ... ZlO I _
1,.. ,,· " ..
_
-~
'''"'(SOr!oIo_'
.""
(1_-"
_ l ... e.. ......
"•••47 I'" V. Co'!
1rIo ~
l ... C<In!aro:Jo<
_ liNe..
s-. l.w.
I'
p."N...I...
'." 110....
T,_'
"
..
..
-
1,.,..1 " ... ""D. s-.
r'on. _Se< .... l.W.
~w
.,~
.,"
-
"'''73
"
Control Box Components Parts list
Refer To Figure 13
,
635-26
J
635·38
635-87
,CJ,
635-71
.J"
635 ·30
635·26
635·61
635·52
~,
.
r
~635.76
635·53
1
.
63S--a
63s.5S
."'''~
,,~~
,~
~::::::,~
c-
'-
@-63S.76
&
635.77
\
-
'"
I
.
,..,..., 63S·62 -t§l
~. ~r/ 635.a1 ...e
635·(7
N
~..
1'.
<
635.
635·300
224
I
k-\
63s.soB
,
635-(( .-(§l
635.69 - &
635.43 ~
J
JM
635.223 - 1
Figure 13
Control Box Exploded View
635·4
63s-5
> - 635.2.
3 Ton
T ro~ . ~
Sid.
Fram •• • how n 'fo·l Ton
Troll. y Sid.
From.. • ' •
• imil. ,.
, ,/"635.13
' -- 6' 35·17
Figur e 12
Tro lley Exploded View
Trolley Components Parts list
""'•..
"
ranges
side frame part numbers.
t
."...
..
635-154
-635-21
CM 4 Directional Control Station
~
Parts List
Control Cord, Chain
Strain Relief and
Related Parts
Not.: For key number, not
listed-see paget 16 & 17
Type SBP 5 and 6
Button Control
Station-I ndivid ual
components not
available for repair
Multifunction
Control Station
"
gIVe<> 10 100 need to replace O1he, items: beari ngs.
~onlacts . laslene~. elc. Ilems thai may be damaged or Iosl
REPLACEMENT PARTS
ORDERING INSTRUCTIONS
during disassembly 01 just unm for tuture 0$(1 because of
detarionl:1ion from alle or service.
The folklwing information must accompMy a"
cor raspor;clence 01 ,epair parts orde<s.
f ) Se<ial Numt>er- This is stamped on the sid .. trame
PM. should be Ofdered from CM's authorized Maste, Parts
abo." the mOtor mounting , as shown below.
2), Voltag .... Pr.8U. Hert:-5oo the labels located ooxl10
Ihe f>O .... er oord and on the inside 01 the control box
cove,.
wtIIm ordering m(>lor pMS. give the molor name plate data
in addition 10 the abov" .
For parts orders also specify:
1) Ouantity desired
3 ) PM ""me
2) Key numoo; 0/ part
4) PM numbe,
Whe n ord&ring ,eplacement parts, consideration shocld be
Depots corwooi',lnlly located throughout the United Stales
and Canada. Aole< 10 lhe tlack
"'this manual to
•
k>cal the Ma slef
A
.xw",
,
PM 0 epol ""arest vou.
WARNING
Using ·oorrmercial • or olher manu1aClu rer'S parts 10
repair Ihe Series 635 MOIOr Driven Trolley may cause
load loss.
TO AVOID INJURY:
Order all replacement parts 110m CM. SOme parts may
look alike but ollen CM parts are made 01 specnic
materials 01 processed 10 achieve specnic properties.
TROLLEY
COMPONENTS
See FIgUre 11
,
CONTROL BOX
COMPONENTS
SeeFlg ",e'2
CONTROL STATION
COMPONENTS
S... Flgu,e 13
Figu re 10. Trolley Arrangement
"
SERIAL NUMBER
LOCATION
, _ _ _ _ _T~.:::
ble 4. TroubleshootinQ and Remedial Action
IF
1. Trolley does not
ope<ate 10 eilt\&r
direction
C AUSE MAY BE
REMEDY
al No voltage at trolley
Maln ~oo Of branch circu~ switch open; branch
line fuse blown Of cifaJ~ br&ak(lr hipped. Close,
replace. or fe-set.
I
b) PhaM iallura
(Si. phasing)
Check for grounded or open 0I)IWI8I;!i0n In
SI4lP'Y lines or CUmlnt coIIecIors.
Open cir.::uft. grouOOed or open com>llClion In
one line 01 supply system. collectors, holst
wiring, rev&fSing contacIOf, motor leaJ, or
wir>eings.
Check lor a'ac\11caI continuity.
Open or shorted wlrdngs In transfonTMt< or
reversing COIltactor coil: loose connectlQn or
broken wire In clrcuit;mechanieal binding In
contactor: control station switch contacts nol
making .
d) Wrong vo~aoe or
lrequ&ncy
el Low
vo~ge
Tha VQ/Iagoe and rrequency must be the same as
shown on trOlley control box.
Voltage at the motor must be above the
minimum with the unit In operation:
UN IT RATING
2. nch), op&IatH in
one direc;t;oo only
3. T,"('ayope<ates
MINIM UM VOLTAGE
110-12011160
208-24OJ316O
440-480l'3I60
22013150
99
187
396
198
38OJ3I5O
57513160
342
517
I) Exceulve load
Reduce loading 10 the cBpadty limll ollrOlley
') Open control circuh
See Item Ie.
a,
b)
Ex~1oad
See Item 11.
low~
See Item
18.
sluggishly
e) Worn or dirty rails
Clean ralls. '''Apecllor worn spotS.
See Item 11.
See Item
18.
Above an &",OeOU IempeI8tur8 m,a.'F., 1M
frequency of trdB~' operation must be lIm~ecIlO
avoid ovem esting 01 moIOr_ Special provtaIon
sh<>uItI be miOde 10 ventilate the space or IlhIekI
the trolley tmm heal r~
EXOIISIiive il'"dling. jogging or pIugoglng should
be avaoided sino9 this type 01 operation will
draslically shonen the HIe 01 moIor and
conlaclor.
See Item lb.
"
Wiring dlagl1lms shown are Alpr.Hntalive. Consult diagram attached
to contractor bo. cov. r or h... nlshed with unit.
":'
'..
--
•
--~
-
• ",-=-'
- -1:-,..
.
-- --~
--" - . _...
.-.-
Figure 9, Wiring Diagrams
TROUBLESHOOTING
ELECTRICAL DATA
TO detect open and short circuits in electrica l com·
ponents use the following procedure.
Open circuits in the coils of e lectrical com ponents
may be detecte<1 by isolating the coil and checking
lor continuity with an ohmmeter or with the component in series with a light or bel l cirCuit.
Shorted turns are indicated by a cu rrent draw
substantially above normal (connect ammeter in
series with suspected element and impose normal
voltage) Of D.C. res istance substant ially below nor·
mal . The current method is recommended lor coils
with very low D.C. res istance.
Moto, current should be measured with the motor
running under iuli load with rated voltage applied.
Conlactor coil cu rrent should 00 measured with the
contactor armature (contacts) closed and tull
voltage on the coil.
Table 3 • Electrical Data For Trolley Components
Motors
Voltage-Phase
H.m
Full L.oad
Current (Amps.)
115-1-60150
3.4/4.2
230/460-3-60
1.31.65
2201380-3·50
.52
•
Volta e
230/460
to
"5
Tl-T3
T2·T3
Tt-T4
T2-T5
T3-T6
T7-T8
T7-T9
T8-T9
Tt·T4
T2-T5
T3·T6
T7-T8
T7-T9
T8-T9
Tl·T2
Tt-T3
T2-T3
1.7/.85
575-3-60
Leads
D.C. RfI$lstance
(Ohma)
3.3
3'
15.3
15.3
15.3
30.5
30.5
30.5
15.3
15.3
15.3
30.5
30.5
30.5
95.0
95.0
95.0
T rans f ormer
L.eads
Red to White R&d
Black to Red Blue
Blue to Blue Tan
D.c·l~eall=}ance
Ohma
"0
"0
"
Co nt8(:lor Coil
.
Vottage
H,m
~urre:;
Am s.
D .C.(~eslstance
Ohms
120-60
110-SO
115-60/50
0.10
0.12
.124/.140
"0
"0
'"
9
ADJUSTMENT
The molor brake should be checked periodically tor
wear of the friction discs andlor proper adjustmenl of the
solenoid air gap. Refer to Figure 8. Normal lining wear
witt cause the solenoid lever (8) to move away from the
solenoid frame (79) and thus increase the air gap and
lrottey stopping time,
When the gap reaches approximately l1 11S" the brake
should be adjusted. To adjust the brake, de-energize the
power supplttht
y 0 e ro ll ey.
/.&
WARNING
High electrical potenlial exists within the trolley con·
trol box and COnlact with the wiring terminals win
cause serious electrical shock and injury,
TO AVOID INJURY;
Always de-energize the power supply system feeding the trolley betore removing the control box cover,
4.
Re-assemble the motorlbrake assembly 10 the gear
reducer uSinQ the four nulS and lockwashers,
5.
Adjusl air gap per above instructions (adjuslment),
6.
Re·ene rgize power supply arid operate tro ll ey a
lew limes 10 make su re air gap is correct and then
replace access covers (635·263).
Replacement o f COli
(Refer to Figure 8 on page 7 and Figure 15 on page
19).
1. De·energize the power supply to the tro lley and
remove the molorlbrake assembly from the gear
reducer.
2, Remove housing (635·261) from the brake and dis·
connect the oo~lead wires lrom brake cord,
3.
Remove both access covers to expose the brake.
4. Remove plunger guide screw (84) and bolh plunger
ides (82). Slide old oo~ sideways out of Irame
Oepress the plunger (13) towards the solenoid frame unti l
9) . If oo~ is difficutt to move, tap lightly with a soil
spring pressure is felt. Hold the plunger firmly in this position
ammer.
and measure the air gap between the matinQ (ground)
5. Inslall new coil in the same relative POs~ion as the
surfaces of the solenoid (79) arid the solenoid plunger (29),
old coil and replace the plunger guides (82) and
To adjusl , lurn bolh wear adjustment screws (1 0) equal
screw (84 and84W) .
amounlS clockwise unlit the air 9ap measu res 13132".
6. Re·assemble following Step 3 in reverse order.
~
Replacement 01 Friction Disc
(Refer to Fillure 15 page 19)
t . De -energize the power supply 10 the trolley and remove
the motorlbrake assembly from the Qear reducer,
Remove hOUSing (635-261) from the brake
I~igh
/.&
WARNING
,.
8. Re·assemble motorlbrake assembly to gear reducer
using Ihe four nuts and lockwashers.
9.
Adjust air gap per above instructions (Adjuslment),
elect rical potential BxislS wflhin the trolley con·
tro l bo~ and contac! with the wiring terminals witt
cause serious ele<:trical shock and injury.
to. Re·energize power supply and operate trolley a few
times to make sure air gap is correCl and then
replace access covers.
TO AVOID INJURY:
Always de -energize the power supply system feed·
ing the trolley belO re removing the control box cover.
RECO MMENDED SPARE PARTS
Remove the entlfe support plale assembly by
unscrewing 3 screws (635·294), Remove th e stationary
disc (635 ·269) and worn Irictio n disc (635-270), Install
the new friclion disc. making sure Ihalthe two stabilizing
springs are at 90' in the recessed portion 01 the square
hole in the friction disc, with the prongs poinli"9 inlo the
brake. Place Ihe stationary disc on Ihe friction disc and
'e-asse mble the entire suppol1 plate assembly engages
the guide pins of the end plale.
3. Remove both access covers (635·263) from the
housing (635·261) and slide the housing with its
shalt assembly on to the mounting studs. Be sure
Ihe housing is assembled w~h the access windows
above the horizontal centerline. Rotate shalt 10
engage key into the hub keyway ,
2.
,
To ensu re continued ope ration ollhe Series 635 Motor
Driven Trolleys, the following is a list of parts Ihat are
recommended to be kepi on hand at al l times 10 repla~
parts that have worn or fai led :
KEY NO.
635·45
OTY.FOR
PART NAME
T,~nsform Q r
(3 phase
EACH TROLLEY
IN SERVICE
1
unils only)
635·126
635·156
635-286
Contac-to,
Control Slation
(for units
equippoiod with l>rake)
Coi l l(~
1
t
1
Reier to page 12 tor ordering information and the parts
lisls lor the pan numbers.
OPERATING INSTRUCTIONS
8.
After the trolley and hook travel direclions are
correct. ope rate the trol ley (according to the
operating and safety procedures-see page i)
with a capac ity load over the entire length of the
runway or monorail syste m to be su re that all
adjustments and operations are satisfactory.
The hoistJtro lley combination is not ready for
service and it shou ld be moved by operaling
the conlrols marked . (FORWARD) and
• (REVERSE) in conlrol stati on. Unless
altered by the erector. d!lpressing • (FOR·
WARD) control will move the hoist loward
mOtor housin'g end , A ntic ipate the stopping
point and allow trolley to coast to a smooth
stop . Revers ing or " p lugging" to stop trolley
causes overhealing of motor and swaying 01
load.
INSPECTION
To maintain continuous and satisfactory operation. a
regula r period ic inspection procedure must be
initiated so that worn or damaged parts can be
replaced before they become unsafe. The Irequency
of inspection must be determ ined by the individual
application.
The following list gives an inspection procedure for
normal usage under normal oond ijions, When Ihe unit
is subjected to heavy usage or dusty. gritty, moiSI or
othe r adverse atmospheric conditions, Shorter time
periods must be assigned , Inspection must be made
of all parts for unusual wear. corrosio n or damage in
add ition to those specifically mentioned in Ihe list
below.
On the 3 Ton trotleys, check shackle pin for
proper seating in groove of load bracket.
Manipulate hoist and check for freedom of
movement (swinging) in both planes and all four
directions. Also examine the shackke. shaCkle pin .
suspension lug pin reta ining pins, sheave
stud and suspension adapter for excess wear by
manipulating hoist and visuall y specting
suspenSion parts.
9.
Collector or powe r supply system for damage .
wea r co rrosion and proper operation.
10, On trolleys equipped with Ihe optional motor
brake, check for frictio n disc wear and proper
adjustment of the SOlenoid air gap.
MAINTENANCE
Once a month lubricate trackwheel gea r and pinion
with Texaco Novatex #2 or an equivalent heavy cup
grease or graphite grease.
Motor gear box oil must be changed after the firs! t OO hou rs
01 operation . then every six months or 2500 hours of normal
service. whici1eve r comes first. Use fl2 pint of Mobile SHe·
626 or equal lubricanl, for each oil change,
AI other tRllley parts are iJbricated for I~e at the fadory.
11 is suggested that the unit be inspected month ly lor
wear damage and corlOs ion effects to all parts with
particular attention to the following:
I . T'ghtness 01 all fasteners including trackwhee l
stud nuts and suspension bolt nuts.
2.
Contactor and oontrOI station for burnt or pitted
contacts and loose or corroded te rminals,
3. Cables and leads fo r broken wires . loose or
corroded terminalS. also damaged insu lation.
4,
Term inal board for loose or corroded
connections.
5.
Trackwhee ls for wear of tread and flange and lor
bearing wear as indicated by excessive
looseness of whee l on stoo .
hoist
/lois!.
Motor Brake (Optional Equ ipment)
A motor brake is available as optional equipment.
The brake can be ordered with the trolley or it is
available in kit form for insta llation on a Un il in the
lie ld. To order a brake kit lor an existing unit, order
brake kit Key No 635· 287 and indicate the ser ial
number 01 the trolley on wh ich it is to be install ed and
the voltage on which the Irolley operates,
6. Trackwhee l gea r, pinion and pinion bearing for
wear.
7. On the 1/8·2 Ton \(o ll ey , check suspenS ion lug,
load bracket, suspenS ion adapter and
suspension lug pin for excess wea r by
manipulating hoi st and visua ll y inspecting
suspension parts.
Figure 8. Motor Brake Adjust ment
;
A
WARNING
I ~Ying knoIs or loops 10 shorten the drop 01 the con·
trol $lation will make the SHain reIieI ineI'ect~ arw;l
the inlemal conduclors at the cord may break.
TO AVOIO PROBLEMS:
Shorten the oomrol cord per the lolowing insInx:lions.
.
TO shor1en the cord, measure the dIStance \t1e control
51811011 is 10 be raise<!, Disconnect !he lToIley from the
pow" su~y system . Remove the cove r from the
control stalion and dis.oonnect lhe wnduC101S of lhe
control cord trom the va rious terminals. For cords
with the internal type strain relief, discon nect the
stra in re li e1loop from the cont,oI station hou sing and
retain the strain re lief screw, washer and the term inal
block tab. For cords with the external. chain strain
ralie! . disconnect lhe chain from the COIllrol station by
twisting open the ~nk . Measuring from the end of the
IonpHt conductor. CUI·off the cord the distance !he
control is 10 be laiS«! . Using the CUI·ott pie« 01 cord
as an example, prepare the end !little shof\ened
cord . For COId$ W!\t1lhe internal type strain rehef.
prepare the strain reliet loop as shown below.
~
NOTE: The four directional control station can
only be used with a holst that has a reversing
contactor.
If the trolley and hols t shlp".a direct from the
factory, the hoist may not be Klulpped with the
normal power cord or" control station and
cord assembly. As a resul" these Items will
not have to be removed as Indicated and the
short hOist power and control cord on the
hoist can be wired directr. lnto the 'rotley. Use
the wiring diagram suppt ed with the trolley lor
making the connections.
Holst Contro, Cord
It is necessary to remove the contro l station (il
supplied-see note above) Irom the hoist since the
trolley is supplied with a Short hoist control cord.
A&mOve the control station and control cord
assembly from the ho<st. Connect the short hoist
control cord from the trolley to the holst cont.oI circuit
loIIowing the wiring diagram supplied with the hoist.
AIle< this is completed, ,,·assemble the End Cover or
Back frame COIfeI' to the hOist frame.
The single phase units are now ready 100' Opera~on.
Howeve<, on the three phast units. the drrection of
trolley and hook travel must be cheekad (as ifldicated
below) before the unit is pu1 into se"';08.
-- -- - - - -
- -- ---- -
tKlTE : Conch..c.o.~ HoI Show For Clanry
Be su.e to lirmly squeeze the damp sleeve (Irom the
lield WIfing 1\11) using a vise Of very la.ge pli e.s to
secu.e the loop end and insulate the clamp sleeve
using the rubber slee~ I.om the cut·off piece 01cord.
For units; with external chain strain 'eliel, cut·off the
cha in the distance the control station is to be raiSed.
Slide the prepared cord thru the gromm et or box
connector on top 01 the cont,oI station. l/$ing the
wiring diag.am suppl ied with the trolley, connect the
conductors 01the C(lntrot cord to the various
terminals, For un~s with the iflternal type strain relief.
anach the loop to the control station housing using
the screw washer and the te<minal block tab. FOO'
units with e~temal type chain strain retiet attach the
ctIarn to the control station by ,,·cIosing the link . On
these units. also ,irmly tighten the top ring 01 the box
COf'Vlector 10 seal the opening belwf!en the cord and
the grommet
Ae·auach the cover \0 the control station. Energize
the power suppl y system and test the trolley and hoist
lor proper operation.
,
" OlsrPOW E~
Figure 7. Connections l or Proper Hook and
Trolley Travel.
Three Phase Units
A three phase motor can .otste in either dirlldion
depending on its conneclion to th e powe' supply.
Therefore. the direction 01 trolley and hook travel
retat;"'e to the selected ir6cated direction mUllI be
checked before the und i$ put in service. It the hoist is
incorrectly phased, the limit $wilehes are iflettective
and serious damage can resuh. Retff to hoist
manual. The troley shoukl be chtd<ed out lirs\' then
the hoist See Figure 7.
..........
o
CORI)
CORD
HOIST
CONTRO L CORD
".
-. "
o
} HOIST
FWD.} TROLLEY
~,
AEV.
ON.
,~ .
~
,~ O : FWD. } BR IDGE
:':.~~: REV.
(CRAN E)
-_.
4 OR 6 BUTTON TYPE H
'-
CO N1RDL STATION
Figure 4. HOist and TrOlley
General Arrangement
Trolley Motor Cord
Insert Trolley Motor Cord into centrol box. see Figure
4, Connections for I he Troll ey MOlor Cord are shown
in Figures 5 and 6 . The cord shou ld be brOught over
the top of the hoist and clampM to Ihe w nlfol box
mounting bracket, see Figure 4. The cord between
the motor and clamp musl be tight enough to prevent
it from rubbirlg against Ihe beam.
Trolley Power Cord
The shon power cord furnished is lor use with a
collector and bus system . II shou ld be discarded if a
cable is to supp ly the trolley . Termina ls for use on the
trolley end of the supply cabte are furn ished in the
"Field Wiring Kit: Connections to the troltey a re
shown in Figures 5 and 6. The box connector must
De made tight on the cabte, and if necessary , a
separate strain retief provided to prevent any stress
on the te rminats.
Holst Power Co rd
The troltey is suppli ed with a Short hoisl powe r cord
connected inlO the power circuit of the trolley- refer
to Figure 4. As a result. it is necessary to remove the
power cord (if suppli ed- see note on page 6) from
the hoist. To do this. remove the end cover (Techsta r
Hoists) Or back frame cover (Lodesta r and Valu$tar
Hoists) from the hoisl and remove and discard the
power cord from the hoist Then connect the short
hoist power cord attached 10 the trolley to the hoist
power circuit accordi"9 IO the wiring diagram
furnished with the hoist. The trolley is also supplied
with a short hoist control cord , and il shouk:i be
connected to the hoist control circu ~. as indicated
be low (see Hoist ContrOl Cord) before the end cover
(Tachsta') or back frame cover (Lodestar and
Valustar Hoists) is reassembled to the hoist frame.
ContrOl Statio n
The standard troll eys for use with Lodestar and
Valustar Hoists are suppli ed with a four d irectional
co ntrol stalion.
Un less ordered special , the cont rol station is
suspendoo from the trolley control box by a cord thai
is approx imately 16' - 3- long . If this is too 10"9 for
your application , the cord should be shortened so that
the control station is suspended approximately fou r
feet above the operating floo r.
TROLLEY POWER
CO RO
L
TERM 80. 2
R
••
OP
~~:~ci POWER
Y
•
•
~
L_t=·~==t=~TROLLEY MOTOR CORD
Figure 5. Hoist Power Cor d Connections
- Single Phase
Figure 6. Holst Power Co rd Connections
- Thre-e Phase
Figure 2. 1/8-2 Ton Holst to Trolley Assembly
Figure 1 . Trolley to Beam Installation
Holst to Trolley
On .... 118-2 Ton o~. a . ... m".., tllo ... pension lug lonl>oi. Q'"
' ' 'IWI
"'" troky Ion beam) • •
in F'II'J'" 2. The lug i. i n _ in
,,~ ~_, load bracl<et a rid '011"-<1 by t"- . ".pon""" lug ph "
soc1<et "-ad cap . cmw and locI:wa_ 0 .. u,"<I" k<>o>p Ihe pin in
pilloe. Tro .... ombly "'"<t be m_ wi1h ..... !>ciS! ",,,,,,,,18<1 1"',;01 .
10110 ..., bOam arw:Ilhe "",,001 oor<! Ie Ihe rigI1t """'" facir>g the
...-
••,
,
trQI"1 oonuol bo>,
,
••
00 ..... 3 TOfIl'OIoy. dn"" <>nO . . taininy pin ifllO tI>t ""'" on 0..
.nd 01 ."., lug pin 1627-730). Rai... Ihe !>cist in", ~ .iaion so thot
the lug 1627·72a) is betw .. n tI>o leg. 01 tI>o .flackJo, AIilIn the
hole. in the shocklo ond lug. "'se,,"" log pin in tI>o d gned 001 ...
aoo
tie lug pin b)' m,,;"11 Ill. """an,,!! rellinO">g pin into
110 holo in !he lug pin. Mak& ""","n that tho .hadda pin 1627, nil)
is pr<I!H>ri)< .... tOO in 11>0 10"; bracl<el b)" "'a"l"'latinv tho 001<1 and
~ I« ,,_
01 mowmIlnllswingOo>g) in be., plane. a nd
"'",
.«....
011 Iocr d~"" .
SHAC~LE PIN
,@
RETAINERS~ '
,
,
•
,,•
,•
•
•
••
•
•
Figu re 3. 3 Ton Holst to Trolley Assembly
NO" !hoI I"" . 1Iad<le pin . _
...<1\10 wi1h ret .... ' ..
be """iood and _
.. red in tho-
EleClticallnsta liation
The !cOley oIeol t i e o l _ . mu<t be complo1<>d ••• _
in
F~'. Po_ 10 tI>o troIoy and MOst .hooId be furnished ~"'" a
compo,\>I& sour,,"
OseoM<l<t <:Io>vice. ()Yorcu"''''t pro_
t<I<:tioo and p'ope' groonding moan . should be ."""",pIi.ho-d in
.0<0fd3ne<> wif> tie "N.lion.. ~I<!co-i<al CodtJ" 0.0 IocoI ood<!. ~
oppIOoabio. Pow .. should be <Ii"""",""", when mol<inlI or ohl<>g'
ing """",octioo •. A F>eI<I WOing Kit 6$·1~ (part .."'>I.... 36666
101 "",IS wi"" ootton oon ~oI '\:Olio") is tvtni,l>oO containinll the
"'''''gO •
ne«l"aty
Chart B. 3 Ton Trolley
Table 2. Washer Spacing CharI
4
"'aMi" 10 eomfJl<l'" lho troley ole<oOcal oonne<t""s.
DiaIl' ,""'1> show oonnoctioos 10 be m&de wilron "oIloy oonl'oI box
Io",.n<bcd ""'10. For special units . .." wi~ Ollgfom s"WOod
with ""it.
INSTALLATION
UNPACKING INFORMATION
After removing the trolley from lhe sh ipping car·
ton, carefu lly inspectlhe eXlernal condition of
the cords, cont rol box, gea r reduce r. motor brake
(if equipped with same) and motor for damage
that may have occurred during shipment and
handling. Check to make sure all pa rts (trol ley
side fram e assembly wilh control box, trolley side
frame with gear reducer and motor. load bracket.
suspension bolts, spacer washer. cOHer pins and
nuts) are furn iShed . Also. before al1empting 10 instalilhe trol ley . make sure lhat the power supply
ind icated on Ihe labels a!tached 10 the contro l
box is Ihe same as Ihe power supply On which
lhe unil is 10 OpBrate.
INST ALLA nON
The hoist, trolley and lug suspension for
susper>d ing Ihe hoist from the trol ley are packed
sepa rately. Assemb le the lug suspens ion to the
hoist acco rding to the instructions furn ished wilh
the suspens ion and/or the instructions in the
manuallurnished with the hoisl .
A
WARNING
Operating the trolley on a beam that has flO rail
stops may allow the trot ley to fall oft the end of
Ihe beam.
TO AVOID INJURY,
Insta ll rail stops at eaCh end of the beam on
which the uolley is to operate.
The stopS must be positioned so as to not exert
impact torce on the hoist frame O{ uolley wheels .
They must COnlaet Ihe ends of the trolley side
frames.
Trolley to Beam
It is recommend ed that the troltey be mounted
on the beam prior to attaching the hoist to the
trol ley. Before auempting to mount the trolley on
the beam . measure the actual width of the beam
fla nge on whiCh the trolley is to operate, Using
this measurement determi ne the arrangement of
the spacer washers using Figure I and Table 2_
Chan A of Table 2 shows the washer arrangement lo r the 118-2 Ton trolley whi le chan B pro·
vides data lor the 3 Ton trolley, loosely assem·
ble Ihe side Irames. load brac ket . spacer
washers and nUIS o n the suspension bo lts as
shown in Figure 1.
A
WARNING
HeM', w3_ .pac;ng .-eoortYJ>erKio'on. are
~oIlc, may 1001I.-om beam.
r>OI
"""'0<1,
TO AVOIO INJURY:
OCI"oI ow.m Io~ on " hOol> I"" uoley i,1O
OPO"IO O<><:l u. e T3"o1& 2 10 delO""" ' I"
01 the
.pooo< wa,her> !of 111., ~~ width_
Mo~.",e ~
"'""9<'""""
Due to the variations in beam flange widths. it is
suggested that the beam lIange width be
measured to determine the exact d istribution of
spacer washers. The distance between
trackwhee l lIanges (dimension ··X") shou ld be
1/8 to 3/16 inch greater than the beam flange
width lor straight runway beams. and 3/16 to 1/4
inc h g reater than the beam flange width il runway system incl!.ldes sharp curves_ Also. the use
of other than CM supplied washers may resu lt in
trackwheel to beam Hange va riations and thus
Tab le 2 wi ll not apply_
For the 3 Ton trolley, (reler to Figure 3). a
shack le and pin assembly (627·729) consisting 01
a pin retained in a central position by retainers is
packed loose with the suspenS ion. Insen th is
assembly into the opening' in the top of the load
bracket (635-13) wilh the tegs 01 the shaCkle
down. Pos ition the shackle pin in the groove pro·
vided for same in the load bracket making sure it
is centered between the suspension txlfts.
Now install the trol ley (118-2 Ton Or 3 Ton) on
the beam by sliding one side frame out far
enough to allow the trackwheels to clear the
beam flange_ Lilt the trol ley up so that the
Irac kwhee lS are riding on the beam and draw the
side Irames togethe r and tighten the nuts snugly.
Do not over1ighten the nuts_ Insert the C<ltter
pins through the slolled nuts and holes in the
suspenSion bolts and spread the legs of the cal·
ter pins to secu re.
IMPORTANT
After the trolley Is Installed on the beam, remove
the hex sockel plug from Ihe lap of the gear
reducer and replace same with the breather
paCked loose with the trolley or remove Ihe small
brass nail projecting from the side of the gear
reducer. This provides II vent for fhe gear reducer
and failure 10 Instell the breather may cause the
seals to lellk.
GENERAL INFORMATION
eM REPAIR/REPLACEMENT
POLICY
SPECIFICATIONS
The Series 63S MOlor Driven Trollevs are des;gned
fOf use ""Ilk the LodISIa', Valustar and Teehstar
Electric Chain HQisIS. The troDeys are available in two
capiK:ities: 118 through 2 Tons and 3 Tons. These
trolleys are s.mila. except for the sizes ot the load
ca rrying members.
A.U COlumbus McKinnon (eM) Series 635 Motor
Driven Trolleys ale thoroughly inspected and
performance tested prior to shipmel1l. II any properly
maintained Series 635 Motor OrivtIn Trolley develops
a performance problem dv a to a material or
worl<manship dalect. as verified by e M or an
authorized service stat;OI1. repair or replaceme nt 01
the un it wi ll be made to th e original purchaser without
cha'ge. This repair/reptacement
applies OI1 ly to
Selies 635 Motors Driven TrOlley!! Jnstall&d .
maintained and operated as outlined in this manual .
and spedlitaly excludes parts sul:ljK1. to abuse.
irrpoper inStaialion. irrpoper or inadequate
maintenance . hostile environmental e"~, and
unauthorized repaWs/modi1ications. and normal wear .
The troll eys have rug ged sleel side plates. ha rdened
steel axlts, sleel suspension oollS. cast iron load
bracket from which the hoist is suspended and
hardened caSt i'on wheels that are suitable tor
operati on on sIop8d Of flat flanged beams. Hardeoed
steel gears are attached to two trackwhee!s and
driven by a hardened steel pinion. The pinion is
driven by a right angle worm gear .educe<. 11'1* worm
a nd gear at the gear 'educer operate in an oil bath . A
weatherproot moIOI dMies the gear reducer.
P'O!icy
The control box contains a reYersing conlilctOf.
terminal boards and a lJanslormer (as required) . A
four buttOfl <X)f1l101 statioo is suspended from the
control box. An eleettic bfake . which fits between the
molor and gear ,ed~er. is available as optional
equ;pmem.
WfJ r&Serve the right to ehange materials or design il .
in our opinion. such charlgH will Irrpova our
product. Abuse. l epair b)I an lII"Iautllorized per$0I1. or
use 01 non·eM replacem&r1t parts voids the
~uara ntee and could lead to dangerl)US I)peratil)n.
For lull Terms 01 Sale. see Sa las Order
Acknowledgement. Also. rete, to the baek cove r lor
Limitations of Warranties. Remedies and Damages
and , Indemnification and Safe Operation.
Table t provides the general specificat ions lOr the
trolley. It ~ould be noted that the table indicates that
the standard uavel speed is 75 FPM . However. other
travel speeds are avaitable.
Table 1. Trolley Specificatio;:
n.::.
s~_~_
s. BMml
Min imum
Flln;.
9578
9579
69578
69579
'Trol~.
2
,
RT-RRT
....,..,
230-3·60
75
,
75
,
""""
'"
""ru '" "
Irl "10 en il able lor operallon on 573-3-&1 Ind 2201380-3-50 poWir aupply systems.
'"
''''
'"
FOREWORD
This maoual col'l1ains imponanl in101Tflalion to
you properly instal, operate and maintailllhe Series 635 MoIor
~
Driven Trolley lor max imum pel100nance, economy and salety.
Please study its c:onIents thoroughly !:'7.~= the !rolley into operation. By practiCing (X)IYect operal.-.g
procedures and by carrying out the r
preWintallYII maintenance suggeSlior\s. you willi be assuflld 01
dependable seNice.
A copy of this IIWIUal is pad<ed ~h each Series 635 MOIor Driven Trolley .
Table of Contents
PAGE NO .
........................
" ,"
--- .. --
........... .
.... -.- ...... .... ,", .................................. .
"
Tab le 1
Table 2
Table 3
Table 4
Figure 1
Figure 2
Figure 3
Figure 4
I
Trolley Specifications ... ,..... ,""" ........................................................ ,.,"'" ".""" ...................... __ ... 2
Washer Spacing Charts .. .... ,', ...................................................................................................... .4
Electrical Data fo r Trolley Components ................................................... ..................................... 9
TroubleshootirIQ and Remedial Action ........................................................................................ 11
List ollilustratlons
Tro}ley to Seam......................•••..................................................................................................... 4
Holsl to Trolley 1118. 2 Too) Assembly ........................................................................................... .4
Ho!sl to TrolleY (3 Too) Assembly .................................................................................................. 4
HoIS! and TroBeY - General Arrangement ..........................................•••••..................................... 5
EJgure 5 HoiS! Power Cofd Connections - Single Phase ............................................................................5
Figure 6 HoiS! Power Cord Connections - Tlvee Phase ............................................................................5
Figure 7 Connections lor Proper Trolley and Hook Travel .........................••••.............................................6
Figure 8
Motor 8f ake Adjustment ................................................................................................................7
Figure 9 Wiring Diagrams ..........................................................................................................................10
Figure 10 Trolley Amlngement ....................................................................................................................12
Figure 11 Control Stations Exploded Views ................................................................................................13
Figure 12 Trolley Exploded View ............................................................................................................ .... 14
Figure 13 Control Box Exploded View ................................................ ,.,.,., ........................................ __ ... ",.15
Figure 14 Motor and Gear Redooer Exploded View........... """", .. ___ ............................................ ,, ' 8 and 21
Figure 15 Motor Brake Exploded View ........................... _.................. ," "" "' ", ....................................... ...... 19
CM HOIST PARTS AND SERVICES ARe: AVAIU..~ IN THE UNITED STAT,"S AND IN CANADA
As • eM Hoo$I _ . you are assured 01 reliable reparr and parts &e<vices ihrOugh a ,oelwcwk 01 Maslll< ParIS Depots and
Setvce CenIetS \hal are suategrca."iDcaled"'!he United Stales and Canada. These tacililres have _
seIeC1ed on II-..
oasOl 01 \I'IeJr de'''O''lraled abdily 10 ............ parlS arid r_" requnemerlls promplly and eII~.
UNAtI~ N
' E ~ ~ ICE tENTERS
'"
LID.
EDIRPMENT CO.
ro.
,
• AAE .l.LSO MASTER PAATS DEPOTS
•• MASTER FAATS DEPOT ~L~
& SlRVlCl
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