Owners Manual

External Drive Latching Unit

Models: 422, 512, 522

CHM Industries
Fort Worth, Texas 76179
682-286-0046 ph

Content: Packing List

Assembly Instructions
Operating Instructions
Troubleshooting
Assembly Prints

Note: A portable (external) drive motor unit must be ordered separately for the External
Drive units. Only one portable drive unit is required for any number of CHM High Mast
Service Hoists. The portable drive can be moved from pole to pole as needed.

Caution: Ring and arm assembly supporting fixtures cannot be reoriented on the pole. To
assure proper fixture aiming, make sure an anchor bolt circle template is used to install
anchor bolts in each foundation in the orientation specified for that particular pole.

WARNING: DANGEROUS VOLTAGES EXIST WITHIN THESE UNITS AND ALL PRECAUTIONS
USUALLY OBSERVED IN HANDLING HIGH VOLTAGE EQUIPMENT SHOULD BE OBSEREVED.
MAKE CERTAIN POWER IS OFF BEFORE STARTING INSTALLATION OR BEFORE ATTEMPTING
ANY MAINTENANCE.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection to installation, operations and maintenance. Should further information be de-
sired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter
should be referred to Carolina High Mast.

1
Table of Contents

PACKING LIST

ASSEMBLY INSTRUCTIONS HIGH MAST POLE AND SERVICE HOIST 3

Variations in pole protection …………………………………………………….……………………. 4

Pole preparation ……………………………………………………………………………………….. 5

Service hoist layout and preparation ………………………………………………………………... 6

Mounting the head frame assembly ……………………………………………………………….… 6

Installing hoist cables .…………………………………………………………….……………...…… 8

Installing safety chain………………………………………………………………………...……..…. 10

Raising the pole………………………………………………………………………………...………. 10

Wiring the base……………………………………………………………………………………...….. 11

Assembly with luminaries………………………………………………………………………...……. 11

Ring alignment………………………………………………………………………………...………... 13

Completing the installation…………………………………………………………………...………... 13

OPERATING INSTRUCTIONS

Set up for operation……….. …………………………………………………….……………………. 14

Lowering the ring……………………………………………………………………………………….. 14

Lighting equipment lowered ring…... ………………………………………………………………... 15

Raising the ring …………………….. ……………………………………………………………….… 15

Finishing the service .…………………………………………………………….……………...…….. 15

TROUBLESHOOTING AND LUBRICATION

Un-hanging latches……………………………..………………………………….……………………. 16

Lubrication…... ….……………………………………………………………………………………….. 16

Miscellaneous

Prints for record and prints for approval……..………………………………….……………………. 16

Renewal parts ….……………………………………………………………………………………….. 16

Assembly prints

Index……………….……….. …………………………………………………….……………………. 17

2
Packing List

Cover Assembly:
1. Head Cover
2. Head Frame Assembly
3. Hoist and Power Cable
4. Transition Assembly
5. Pre-wired Support Ring

Hardware Pack:
1. Locking-type Plug and Power Cable Clamps
2. Three (3) Strand Vices
3. Plug Protector
4. (3) Split washers
5. (3) Indicator flags
6. Instructions
7. (3) Split tennis balls
8. Springs

Fixture Mounting Arms with Mounting Hardware (per fixture):

1. (1) 1/2-13 Bolt, Locknut, and Spacer; 3.75 inches long
2. (2) 1/2-13 Bolt, Locknut, and Washer ; 1.75 inches long

Winch Plate Assembly

1. Pole plate with pre-wound winch and circuit breaker box assembly*
2. (3) Studs with six (6) nuts and lock washer

*NOTE: Contractor is to provide bushing for connection to breaker box in pole.

Safety Chains**
1. (1) Chain assemblies

**NOTE: Safety chain is an option to the High Mast System. Your device may not include these
Items.

Assembly Prints:
Representational prints of basic models. Parts and assembly options are available upon request
from the factory.

3
Assembly Instructions -
High Mast Pole and Service Hoist

Variations in Pole Protection

As the support ring and luminaires are lowered and

raised, they can be blown against the pole causing
damage to pole, ring and luminaires. Consequently,
four methods of pole protection are offered on the
CHM Service Hoist– BUMPER TYPE, ROLLER
TYPE, SPRING ARM TYPE. All units will have at
least one method of pole protection. The following
assembly instructions are written with reference to the
spring arm system as this is the most complicated
method to assemble. The three variations are de-
scribed below.

Figure 2: Roller type

Roller Type: This type provides rollers fixed to

the inside of the ring. This enables the ring to roll
when in contact with the pole.

Figure 1: Bumper type

Bumper Type: This type is simply an extruded rub-

ber strip that lines the inside of the ring. It provides a
buffer between the pole and the ring and protects
from impacts and friction as the ring is lowered and
raised. Figure 3: Spring Arm Type

Spring Arm Type: This type provides three roll-

ers on spring loaded arms that limit the lateral
motion of the ring by maintaining contact to the
pole shaft. The spring loaded arms absorb shock
when bumping does occur.

4
NOTE: In the MOUNTING THE HEAD FRAME
ASSEMBLY section, the instructions and illustra-
tions refer to the Three Roller– Arm System. If you
have a bumper or roller type ring, ignore the refer-
ence to “pulling the arms open” when placing the
support ring on the pole. Simply slide the ring onto
the top of the pole.
Pole Preparation
CAUTION: To avoid problems and complica-
tions in the rigging of the cables, it is impor-
tant that the pole be assembled according to
these instructions.
1. The Pole section should be laid out on blocks,
elevating them above the ground, to prevent dirt
and other contaminates from washing into pole,
cribbage or horses are required to support the
sections so that the top end will be at least 5 feet
(1.5 meters) above the ground, as shown in Fig-
ure 5. The top end must be clear of obstructions
for at least five feet to permit installation of equip-
ment. Sections should be placed in order of
matching piece marks. The top of each section
should be marked with a pencil, crayon, or piece
of tape a measured distance (12 inches/305mm)
beyond the minimum overlapping distance for the
section above it-1 1/2 diameters minimum overlap.
This mark will be used as a reference to deter-
mine how far the pole sections are overlapping
(Figure 6).
NOTE: Be certain that there are no projections,
sharp burrs or dirt in the telescoping sections of
the pole
BASE SECTION TOP SECTION
SUPPORTS
Figure 5: Supporting pole sections for
assembly
Come along device
BASE SECTION
Top view
Base plate
Figure 7: Choker cable and come along method
Min. Slip
12 IN. (1.5 x top Dia. of male shaft)
Mark beyond
overlap
Male shaft Female shaft
1/32 IN. max gap
Figure 6: Mark reference line
2. All sections should be properly aligned and then
forced together until the average gap between over-
lapping sections is 1/32 inch (0.79mm) or less.
Measure the distance from the pencil, crayon, or
tape mark to the edge of the overlapped section to
verify that the sections are completely together
(Figure 6).
3. Forcing together can be done by several meth-
ods. The preferred method is by using a pair of jack-
ing devices such as come-alongs (Figure 7) or hy-
draulic jacking devices (Figure 8). One end of each
jack is attached to the base plate or to the ends of a
steel bar across the bottom of the base plate. The
other end of each jack is attached to a steel bar
(backed by wood to avoid damage to the pole)
across the open end of the section being tightened.
Proper alignment is maintained by even pull from
both jacks. Jamming results from uneven rate of
pull; straighten by pulling opposite jack.
NOTE: Telescoping should be done section by sec-
tion starting at the base.
Another way to force sections together is to use a
bulldozer or loader pushing axially against the end of
the pole toward a fixed barrier such as an abutment
or truck tailgate. JOINT LUBRTICATION SUCH AS
5 ft LIQUID SOAP OR DETERGENT SHOULD BE
USED, NOT OIL OR HEAVY GREASE. Weathering
steel poles will not weather evenly at joints where oil
or grease has been used. Dirt and dust will collect
on galvanized poles.
Choker cable
TOP SECTION
Note:
Come alongs should be 180 Deg. apart.
5
 Steel plate Stud assembly

Base plate
Nut
Wood block
Lock washer

Base section Top section Winch plate

Lock washer

Jack

Figure 8: Hydraulic jack method Pole plate

CAUTION: When jacking pole joints together, come-
alongs or jacks must be 180° apart.
4. Lay the pole with the hand hole facing straight up.
Support the pole so that the top end is about five feet off
the ground and the pole is not bowed (Figure 9).
Hand hole,
(Facing up)
5 ft
Figure 9: Supported assembled pole
Nut
Figure 10: Winch plate connection
Mounting the Head Frame Assembly
1. While pulling the roller arms open (on roller–
arm models only), place the support ring assem-
bly on the pole. The roller-arms should be toward
the bottom of the pole, and the latch shafts
should project toward the top of the pole. The
junction box should be on the same side of the
pole as the hand hole, i.e., facing up (Figure 11).
On scrub ring and caster ring models without
roller arms, simply lift the ring over the top plate
with the junction box on the same side of the
pole as the hand hole.

Junction box,
Strand vice same side as
hand hole
Service Hoist Layout and Preparation
Top end
1. Remove high mast assembly from the package. Place of pole
the pole plate and winch assembly at the base of the pole
and the head frame and ring at the top of the pole.

2. A light rope or electrician's “fish line” should be strung Ring

assembly
through the pole. It is easier to push the fish line starting at
the tope of the pole. The fish line will be used to pull the Pull back spring arm
Latch/guide
To clear pole top
cable through the pole. shaft

3. Insert the three 1/2 inch (13mm) studs into the holes in
the support plate welded inside the pole base. Using lock
washers and nuts, tighten each stud securely to the plate Figure 11: Ring assembly installation
(Figure 10). There will be no stud in the hole at the position
behind the circuit breaker box on the pole plate. 2. Remove the cover from the head assembly by
removing the connecting bolts. Place the head
4. Slide the pole through the hole in the pole base plate assembly near the top of the pole and set the
and into position on the three studs. Use lock washers and dome head cover out of the way (Figure 12).
nuts to secure the pole plate to the support plate (Figure
10). It may be necessary to remove the winch from the pole Cover fastener Cover
plate if the hole in the base plate is too small. If so, after the
pole plate has been mounted in the pole, then the winch
may be remounted to the plate through the pole hand hole.

CAUTION: If winch is removed during installation, it Head frame

must be securely refastened to the pole plate by torqu-
ing the bolts to 50 foot-pounds.
Figure 12: Head frame assembly
3. Keep cables separate and in their proper posi-
tions. Uncoil hoist cables hand over hand straight
away from the

6
head frame in the direction from which they
come out of the head frame center hole Top of pole
(Figure 13 & 14).

IMPORTANT: To layout power and hoist ca-

bles, always unroll the coils. Do not uncoil by
pulling from the side of the coil as this will Cord pulley
cause twisting and kinking that may result in
cable damage and cause improper operation.

NOT CORRECT CORRECT Head frame

Support
assembly

Ring assembly

Grade

Hoist cable pulley

Figure 15:
Do not pull out Unroll

Figure 13: Cable roll out Head frame

Hoist cable

Head frame
Transition
assembly
Fish line

Figure 16: Transition assembly with fish line

5. While holding the head frame assembly in posi-

tion as in Figure 15, pull the fish line at the pole base
and insert the transition assembly into the top end of
Figure 14: Hoist cable as packaged at shop the pole. Be sure cables are not crossed or
kinked.

6. While pulling the fish line (to avoid slack in the

4. Balance the head frame assembly on its edge
with the latch cams facing the top of the pole and
the power cable sheaves turned upward (Figure
15). Pull the transition assembly toward the pole.
Uncoil the power cable and remove any tape or
labels from it. Tape the “fish line”, that was strung
through the pole, securely to the transition assem-
bly (Figure 16).
cables), pick up the head frame and match to top
plate, connect with bolts. (Figure 17). The head
frame should be turned so that the power cable
sheaves are on the top side corresponding to the
position of the junction box on the support ring and
the hand hole in the pole base. Tighten the connect-
ing bolts. (Figure 18)

7
 Pole top plate Head frame
assembly

Transition
assembly

Power
cable
Transition
assembly

Ring
assembly

Locate swivel
2 ft above
Winch center line
Support

Figure 17: Installing the head frame assembly

Head frame Winch

Pole top plate
Figure 19: Transition assy. to winch connection

Installing Hoist Cables

1. Insert the end of the hoist cable through its latch

cam, latch shaft, and support ring (Figure 20).

2. Place one ring suspension spring, one spring

plunger and one spring plug over the end of each
cable guide (Figure 21).
Bolt assembly
(4 required)

Figure 18: Fastening the head frame

Cable keeper

7. Pull the transition assembly to a point in the

base of the pole where it is accessible through Head frame
the hand hole and just above the winch (Figure
19). Remove the fish line. While allowing no
slack in the winch cable, loosen the swivel at- Hoist cable
Latch cam
tached to the winch cable from its tied-down
position and attach it to the bail of the transition
assembly using the swivel pin and cotter key. At Latch shaft
Ring
the head frame assembly, pull the four cables assembly
Indicator flags
as the winch is unwound until the swivel is two
feet above the center of the winch drum.
Suspension
spring

Plunger

Strand vise Support washer

Cable clamp

Figure 20: Hoist cable thru device

8
 Hoist cable 8. At the head frame assembly, feed the main
power cable through the two cable clamps in
Ring assembly the ring flange (Figure 23). Leave 10 inches
(254mm) of slack in the cable and tighten the
Suspension spring clamps.

Plunger

Support washer

Strand vice

Cable clamp

Figure 21: Hoist cable thru spring/strand vice assembly

3. Remove any tape from the ends of the hoist cable

before inserting them into the strand vices, and be
sure the cables are not frayed. Place a strand vice on
each of the three cables. (Figure 21).
Figure 23: Main power cable attachment
4. Place a split washer around each of the hoist cables
and slide them down over the top of the latch shafts so
that they rest on the upper latch pin. Use a small
amount of tape to secure the washers temporarily to 9. Pull the main power cable until it extends 20
the latch shafts (Figure 22). The split washers prevent inches below the bottom of the junction-box. Re-
the device from latching during the pole erecting. move the junction-box cover. Feed the power cable
end through the cable connector and into the junc-
tion box (Figure 23). Wire the power cable to the
terminal strips per the wiring diagram.
Latch cam
10. After making sure that all cables are properly
seated in their sheaves, remount the head cover
Split washer
onto the head frame assembly using the (6) con-
necting bolts.

Latch shaft
Fastener,
6 places
Figure 21: Split washer placement
Dome cover

5. While pulling the cable through the strand vice, lift

the ring toward the head frame and insert the taped
slit washer into the cam. Pull as much slack as pos-
Head frame
sible through the vice.

6. Begin to tighten the hoist cables and compress

the suspension springs by turning the hand crank on
Figure 24: Dome cover to head frame
the winch. Continue to tighten the cables until they
are tight enough to hold the ring in place against the
head frame.
11. Tie two light ropes to the support ring, 180°
7. Using about two feet of cable and cable clamp. apart. One tied at a point near the junction box.
form a loop at the bedroom of each strand vice and
cut off excess cable (Figure 21).

9
Their lengths must be at least the length of the
pole. This will be used to pull on the ring in case
the weight of the power cord and cable impairs
the lowering of the relatively lightweight mount-
ing ring. Transition assembly

12. String the pre-wired distribution wires Safety chain

through each mounting arm and then bolt the
arm to the support ring using the hardware sup-
plied (Figure 25). When tightening the three (2)
1/2-13 bolts that hold the arms on, torque each
of the three (2) nuts to 60 foot-pounds.

Ring assembly

S.S. fasteners

Tenon assembly

Figure 25: Mounting the tenon

Figure 26: Safety Chain

Installing Optional Safety Chain

NOTE: Safety chains are optional on High Mast
Systems. Consult your specification and order to
verify that you have purchased the safety cable
option. If you have not, ignore this section of the
instructions.
2. AFTER ERECTING THE POLE AND COMPLETING THE
INSTALLATION (see the next two sections), the safety chain
must be installed and adjusted. First, latch the device. Then
attach the snap hook to the transition bail and connect the
other end of the safety cable to the safety chain.

1. Luminaire support rings can be secured at the
base of the pole with optional safety chain. This
option is provided as a redundant safety feature
in case the latches and hoist cable fail. If a safety
chain is used, attach one end of the chain to the
attachment provision inside the pole shaft and
the other end to the transition assembly. (Figure
26)
3. Loosen the two (2) saddle cable clamps on the cable. Pull
the free end of the cable through the clamps until the cable
is snug. Tighten the clamps to 40 foot-pounds.
4. Make sure the hook can be removed from the ring. If not,
loosen the clamps and adjust.
5. Cut off or tape excess cable.

Raising the Pole

CAUTION: Do not use the lowering device cables to

tether to pole.

1. Erect the pole in the normal manner. Either lash joints

securely together to prevent slipping apart (come-alongs
with tight cable lashings can be used), or use a tethering
cable to the base of the pole as shown in Figure 27.

10
 Assembly with Luminaires

CAUTION: Ring and arm assembly support-

ing fixtures cannot be reoriented on the pole
DO NOT USE after installation. For proper fixture aiming,
SERVICE HOIST follow instructions carefully.
CABLES TO TETHER
THE POLE
1. Follow specific OPERATING INSTURCI-
TONS (FOUND IN THIS BOOKLET) and lower
the support ring. Read the operating instructions
fully before lowering. Start with step 2 of operat-
ing instructions because latches are not yet
functional.

CAUTION: Latches are not yet functional

because split washers are still in place.

2. During Lowering, pull on the rope that was

Figure 26: Raising the pole
attached to the ring if necessary. Stop when the
rollers are within 2 feet (0.6 meters) of the top of
2. Level the pole carefully. This can be done in any the hand hole. For models without roller– arms
one of three ways: (1) Turn one of the leveling nuts (scrub rings or caster rings), stop the ring about
on the anchor bolts down to approximately 1/2 inch 3 to 3 1/2 feet above hand hole (Figure 28).
(13mm) from the bottom edge of the nut to the top After the ring is down, remove the split washers
surface of the concrete base. Rest a 3 or 4 foot. (.9 or and discard them.
1.2 meter) level on top of this (2) Sight the pole along
a plump line from two locations 90° apart and at least
1 pole height away from the pole. (3) Use a transit to
shoot from two positions 90° apart.

3. If the installation is being done during the heat of

the day in sunlight, the first approach for leveling is Ring assembly
the best. The other two approaches can only be done
properly in the early or late hours of the day, because
in sunlight the pole may curve away from the sun due
to the temperature differences from one side of the
pole to the other side.

4. Secure the Anchor bolts.

3 to 3.5 ft
Wiring the Base

1. Wire the circuit breaker to achieve the appropriate

circuit.

NOTE: The contractor is to provide a bushing for con- Hand hole

nection to the circuit breaker box in pole.

2. Energize and test the circuit to the load side of the

circuit breaker at the pigtail connector.

3. CHECK CABLES:
SHINE A SPOTLIGHT UP THE INSIDE OF THE
POLE AND INSPECT THE CABLES. IF THEY ARE Figure 27: Ring distance from hand hole
TWISTED (WHICH HAPPENS WHEN CALBES ARE
PULLED INTO THE POLE), REMOVE THE TWIST
BY HOLDING THE SWIVEL AND ROTATING THE
TRANSITION ASSEMBLY. THIS SHOULD BE DONE
WITHOUT A LOAD ON THE RING, THAT IS. BE-
FORE THE LUMINAIRES ARE MOUNTED.

11
2. Install indicator flags in the unlatched posi-
tion, as in Figure 29. Be certain reflective tape
side of flag is down and screws are tight.

Ring assembly
(flange)

Flag unlatched position

Is tangent to ring flange
Figure 29: Indicator flag (unlatched position)

3. Follow manufacturer’s instructions for each specific

luminaire and Pole to mount and wire the high mast
luminaires or floodlights on the arms. Use counter-
weights to balance out unequally loaded arms.

CAUTION: Do not exceed the maximum number of Reference drawing: Ring with tenons
fixtures per pole, as recommended by the fixture
manufacturer (Table 1, 2, and 3). When determining
totals, count each counterweight as a fixture.

Table 1: Typical ring tenon position configurations Table 2: Typical tenon types

Ring Tenon Spacing

Straight tenon
configuration positions (deg.)

3 120

J-box T-tenon

4 90

Straight tenon with flange

Tenon
position

5 72

T-tenon with flange

6 60

12
4. Make sure the arms are equally spaced around the
ring to balance the load on the ring.
5. When the luminaires are mounted to the arms,
check for vertical and horizontal alignment. See in-
structions packed with luminaire for mounting and
alignment details.
6. Test the lighting circuit by following OPERATING
INSTRUCTIONS, Testing Lighting Equipment on the
Lowered Ring Section.
WARNING: THIS IS NOT A LOAD- RATED DEVICE.
DO NOT ATTEMPT TO MAKE AND BREAK THE
CIRCUIT WITH THE PLUG AND RECEPTACLE.
Leveling the ring (square with the head frame)
IMPORTANT: This step must be completed cor-
rectly for lowering device to operate properly.
1. For smooth operation during raising and lowering,
the ring will need to be aligned with the top plate. This
should be done after the pole is standing and the ring
has been lowered and the luminaires and counter-
weights installed. Be certain that the split washer used
for rigging have been removed and discarded.
2. Remove the three split balls from the Hardware
Pack (Figure 30). Each ball will have a small slot. Push
the balls onto the hoist cable carefully until the cable is
in the center of the ball. Slide the three balls up the
hoist cable about two feet (0.6 meters) above the ring
(Figure 31).
Figure 30: Spit leveling ball
Head frame at
Top of pole
Ball location
after ring is
raised
Ball, placed while
ring is in lowered
18 in. at each position (3 Plcs.)
hoist cable
Figure 31: Ball placement oh hoist cables
13
3. Raise the ring until all three balls touch the three
latch cams. See OPERATING INSTRUCTIONS, rais-
ing the ring section, for instructions on using the port-
able drive unit to raise the ring. After the balls reach
the latch cams, cautiously raise the ring a few more
inches to make sure the balls are in the same plane as
the head plate.
CAUTION: Do not allow the latch shafts to contact
the latch cams at this point.
4. Lower the ring back to maintenance level. Measure
from the top of the ring to the bottom of the balls to
determine which cable has the shortest distance to the
ring. raise the other two points on the ring to the same
length thereby putting them in the same plane. This
can be done by tapping the bottom of the strand vise
with a hammer or by releasing the grip of the vise us-
ing a screwdriver through a slot in the side of the
strand vise. Dimension “A” in Figure 32 should be the
same for all three hoist cables.
Hoist cables,
3 places
Leveled ring
A
Strand vice
Ring in
Lowered position Uneven ring
Figure 32: Leveling the ring
5. Recheck the measurements from the balls to the
top of the ring. Realign if necessary. Remove the
balls and discard.
6. This procedure aligns the ring with the top plate
and is not intended to be a leveling operation for the
ring. Proper alignment with the top plate is necessary
for smooth operation.
Completing the Installation
CAUTION: Before raising the ring, check each
latch to be sure that the latch indicator flags are
in the unlatched position as shown in Figure 29. If
not, rotate them manually.
1.Raise the ring to the top of the pole as described in
OPERATING INSTRUCTIONS, Raising the Ring.
2. Attach optional safety cables, if used (see IN-
STALLING OPTIONAL SAFETY CABLE section for
specific instructions).
3. When ring is initially raised with a full load of
luminaires and latched at the top of the pole, the
transition assembly, hoist cables and power cable
may rotate and twist a few rotations because the
wire cables are new. This twist must be removed
by hand rotation of the transition assembly until the
hoist cables and power cable are hanging
STRAIGHT. Use a high-power light source to visu-
ally check cables. The cables should be under a
small amount of tension to prevent damage from
contact with the pole in high wind conditions.
Operating Instructions
WARNING: ANYONE WHO INTENDS TO OPER-
ATE THIS EQUIPMENT SHOULD READ COM-
PLETLEY AND UNDERSTAND FULLY THESE
OPERATING INSTRUCTIONS.
The Carolina High Mast service hoist is to be power
operated only with the Carolina High Mast Portable
Drive Unit. BE SURE THE INPUT RATING for your
device unit assembly is MATCHED TO THE VOLT-
AGE OF THE DISTRIBUTION SYSTEM at this
installation.
Set Up for Operation
1. Remove the hand hole cover.
2. Turn OFF the circuit breaker. Unhook the op-
tional safety cable, if installed.
3. Lift the portable drive unit to the hand hole and
insert the drive support arm into the support tube.
Slide the unit until the slots in the drive shaft fully
engaging the pins on the winch drive shaft (Figure
33). Drop the retaining pin through holes in the
support tube and support arm to lock them to-
gether.
Transition assy.
Main power plug
Main power supply
Receiver hitch
Portable Drive
Unit (PDU)
Remote control
Transformer
Main power
Supply input
Supply to
PDU
Figure 33: Portable drive unit
4. Disconnect and remove the main power receptacle
from the circuit breaker box in the pole base. Remove
the portable drive unit.
5. Pull at the electrical cable through the transition plated
to be sure there is no slack. If necessary, adjust the posi-
tion of the power cable clamp so that it is 8 to 10 inches
(203 to 254mm) below the hole in the transition assembly
6. Connect the plug of the power cable to the main power
receptacle on the circuit breaker box and close the circuit
breaker.
7. Install the handhold cover.
WARNING: THIS IS NOT A LOAD-RATED DEVICE. DO
NOT ATTEMPT TO MAKE AND BREAK THE CIRCUIT
WITH THE PLUG AND RECEPTACLE.
4. If an auxiliary transformer is required, connect the main
power receptacle to the plug on the transformer, and the
motor power plug to the transformer receptacle. If there is
no need for a transformer, connect the main power recep-
tacle directly to the motor power plug (Figure 33).
5. Place all excess length of main power receptacle cable
down behind the pole mounting plate.
6. Turn ON the circuit breaker.
Lowering the Ring
WARNING: IT IS IMPORTANT TO STAND CLEAR OF
THE POLE WHILE RAISING AND LOWERING THE
RING. THE REMOTE CONTROL SWITCH HAS BEEN
PORVIDED FOR THIS PURPOSE. NEVER STAND UN-
DER THE RING ASSEMBLY WHEN RAISING OR LOW-
ERING.
CAUTION: Do not lower the ring too far. The rollers
should be at least two and a half feet above the top of
the hand hole. For units without roller– arms (using
bumper type or roller type), stop the ring about 3 to 3
and a half feet above the hand hole (Figure 28). If the
ring appears to hesitate and then drop several inches
as it nears the bottom of the pole, some twisting may
have occurred in the cables. Stop the decent of the
ring. Raise it about five feet, then proceed with lower-
ing it.
CAUTION: When lowering the ring BEFORE luminaires
are installed, latches are not yet functional; start with
Step 2 of operating instruction.
1. Turn the remote control switch to FOR and raise the ring
until the indicator flags rotate 45°. Release the switch to the
14
OFF position. All three latch indictors should have
rotated 45° and should appear as shown in Figure 34
(In transition) when viewed from the ground.
Unlatched In transition
position at 45 deg.
Figure 34: Latch indicators (as viewed from below)
2. Turn the remote control switch to REV. As the ring
is lowered, the three latch indicator will align with the
ring as shown in Figure 34 (Unlatched). The
unlatched ring will descend the pole supported by
the cables. If all three latch indicators are not tan-
gent then the unit is still latched. See the TROUBLE-
SHOOTING section, Un-hanging Latches.
3. Release the remote control switch to the OFF
position when the device reaches the desired work-
ing height.
Testing Lighting Equipment on the Lowered
Ring
WARNING: THIS IS NOT A LOAD-RATED DE-
VICE. DO NOT ATTEMPT TO MAKE AND BREAK
THE CIRCUIT WITH THE PLUG AND RECEPTA-
CLE.
1.Turn OFF the circuit breaker.
2. If the main power receptacle on the pigtail from
the circuit breaker box is connected to the trans-
former or to the motor power supply cable, discon-
nect it. Connect the main power receptacle to the
inlet plug of the junction box on the support ring,
after removing the plug protector.
3. Turn ON the circuit breaker to test the luminaires.
Allow about 20 minutes from warm-up, then visually
check all luminaires for proper lamp functioning.
4. After completing test, turn OFF the circuit
breaker .
5. Disconnect the main power receptacle from the
junction box and reconnect it to the transformer box
or to the motor power supply cable, as applicable.
Replace and secure the plug protector.
6. Turn ON the circuit breaker.
15
Raising the Ring
WARNING: IT IS IMPORTANT STAND CLEAR
OF THE POLE WHILE RAISING AND LOWER-
ING THE RING.
1.Verify that all three latches are in the unlatched
position, as shown in Figure 28. If not, rotate
them manually.
2. Lubricate the Latch Pins with a coat of white
lithium grease.
3. Turn the remote control switch to FOR position
and raise the ring until it is near the head frame
assembly, and the transition assembly can be
reached through the hand hole. Stop the ring and
inspect the cables with a spotlight. Use a mirror
for small hand holes if necessary. I the cables
are twisted, remove the twist by rotating the tran-
sition assembly. Turn the remote control switch
to the FOR position and raise the ring until indi-
cator flags rotate 45°. Release the switch to the
OFF position.
4. All three indicator flags will have rotated 45° as
shown in Figure 34 (in transition). Turn the re-
mote switch to REV position. Release it to OFF
as soon as the three latch indicators have turned
to positions shown in Figure 35 which indicate
that the latches are in the latched position. If all
three latches are not in the latched position, see
TROUBLESHOOTING section, Un-hanging
Latches.
Latched
position
Figure 35: Latch indicators (as viewed from below)
CAUTION: Allow only a slight amount of slack
in the winch cable. Once the cable shows any
slack, the latches carry all the ring load, as
intended. DO NOT UNWIND EXCESS SLACK
from the winch as loops of cable may become
entangled on the winch drum and damage the
cable, resulting in reduced cable life.
Finishing the Servicing
1. Turn OFF the circuit breaker. Disconnect the
main power receptacle from the transformer plug
or from the motor power plug.
2. If used, reconnect the optional safety cable to the
transition assembly (see Installing the Optional Safety
Cable section of the installation instructions).
3. Connect the main power plug to the main power re-
ceptacle. Turn ON the circuit breaker. Place all
Troubleshooting and Lubrication
Un-hanging Latches
NOTE: If properly operated according to these in-
structions, it is unlikely that any latch will get out of
sequence and “hang up”. The design of the latches,
suspension springs, and drive unit act together to
assure latching a wide range of support ring load-
ing. If a “hand up” occurs, it can be worked out as
follows:
1. Raise the ring very slowly by a succession of short
“ON” intervals in the FOR position. Watch the sets of
latch indicators until the first set appears to have rotated
45° a bit sooner than the other two. Do not continue to
raise the ring. The full torque of the limiter is not used.
2. Drop the ring slowly while observing if all three latch
shafts drop from the lock plate. If all three latches are
now unlatched, continue to lower the ring or go to Step 3
as required. If the ring is still “hung”, do not lower the
ring further. Repeat steps 1 and 2. It may be necessary
to operate the first two latches to obtain a sequence that
will free all three.
3. Raise the ring fully until the indicator flag rotate 45°.
Release the switch to the OFF position. All three latch
indicators should now have rotated 45° as shown in
Figure 34.
Miscellaneous
Prints for Record and Prints for Approval
Assembly prints in this book are identified with draw-
ing numbers. They are suitable for use as “Prints for
Record” or “Prints for Approval” for a standard lower-
ing device. Drawings indicate all the necessary part
to make up a standard lowering device model.
There are many options available from factory repre-
sentatives. When a non-standard model is required,
these requirements should be discussed prior
16
excess cable down behind the pole plate assembly.
4. Remove the retaining pin from the support tube
and drive support arm and remove the portable drive
unit.
5. Replace the hand hole cover.
4. Turn the remote control switch to the REV position.
Release it to the OFF as soon as all three latch indica-
tors have turned to the latched position, as shown in
Figure 35.
Lubrication
Winch: The winch is lubricated and sealed at the fac-
tory and needs no further lubrication. It should give
many years of service without attention.
Latch Pins: Lubricate with a coating of white lithium
grease at each service interval.
Aircraft Cable. The winch and hoist cables come from
the manufacturer with a very light coating of lubricant.
This lubricant is desirable and should not be removed.
The winch cable should be checked for wear and cor-
rosion and cleaned with a soft, absorbent cloth, then
re-lubricated with a good quality acid-free grease on a
regular service interval. In normal environments the
service should be performed every five years or at re-
lamping intervals. In highly corrosive environments the
cable should be serviced every two years or at re-
lamping intervals.
CAUTION: If during inspection, it is found that
there are more than 12 broken wires in one lay of
the cord, the cable should be replaced.
to “Prints for Record”.
Renewal Parts
Contact the factory for renewal parts. Use the as-
sembly prints in this instructions book for an accu-
rate description of part names.