Beruflich Dokumente
Kultur Dokumente
CHM Industries
Fort Worth, Texas 76179
682-286-0046 ph
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
Ring alignment………………………………………………………………………………...………... 13
OPERATING INSTRUCTIONS
Un-hanging latches……………………………..………………………………….……………………. 16
Lubrication…... ….……………………………………………………………………………………….. 16
Miscellaneous
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
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
4
NOTE: In the MOUNTING THE HEAD FRAME
Min. Slip
ASSEMBLY section, the instructions and illustra- 12 IN. (1.5 x top Dia. of male shaft)
tions refer to the Three Roller– Arm System. If you Mark beyond
overlap
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 Male shaft Female shaft
the top of the pole.
1/32 IN. max gap
Pole Preparation
Figure 6: Mark reference line
CAUTION: To avoid problems and complica-
tions in the rigging of the cables, it is impor-
2. All sections should be properly aligned and then
tant that the pole be assembled according to
forced together until the average gap between over-
these instructions.
lapping sections is 1/32 inch (0.79mm) or less.
Measure the distance from the pencil, crayon, or
1. The Pole section should be laid out on blocks, tape mark to the edge of the overlapped section to
elevating them above the ground, to prevent dirt verify that the sections are completely together
and other contaminates from washing into pole, (Figure 6).
cribbage or horses are required to support the
sections so that the top end will be at least 5 feet 3. Forcing together can be done by several meth-
(1.5 meters) above the ground, as shown in Fig- ods. The preferred method is by using a pair of jack-
ure 5. The top end must be clear of obstructions ing devices such as come-alongs (Figure 7) or hy-
for at least five feet to permit installation of equip- draulic jacking devices (Figure 8). One end of each
ment. Sections should be placed in order of jack is attached to the base plate or to the ends of a
matching piece marks. The top of each section steel bar across the bottom of the base plate. The
should be marked with a pencil, crayon, or piece other end of each jack is attached to a steel bar
of tape a measured distance (12 inches/305mm) (backed by wood to avoid damage to the pole)
beyond the minimum overlapping distance for the across the open end of the section being tightened.
section above it-1 1/2 diameters minimum overlap. Proper alignment is maintained by even pull from
This mark will be used as a reference to deter- both jacks. Jamming results from uneven rate of
mine how far the pole sections are overlapping pull; straighten by pulling opposite jack.
(Figure 6).
NOTE: Telescoping should be done section by sec-
NOTE: Be certain that there are no projections, tion starting at the base.
sharp burrs or dirt in the telescoping sections of
the pole Another way to force sections together is to use a
bulldozer or loader pushing axially against the end of
BASE SECTION TOP SECTION
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
SUPPORTS
on galvanized poles.
Figure 5: Supporting pole sections for
assembly
Top view
Note:
Base plate
Come alongs should be 180 Deg. apart.
5
Steel plate Stud assembly
Base plate
Nut
Wood block
Lock washer
Lock washer
Jack
Nut
CAUTION: When jacking pole joints together, come-
Figure 10: Winch plate connection
alongs or jacks must be 180° apart.
Mounting the Head Frame Assembly
4. Lay the pole with the hand hole facing straight up.
Support the pole so that the top end is about five feet off
1. While pulling the roller arms open (on roller–
the ground and the pole is not bowed (Figure 9).
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
Hand hole, should project toward the top of the pole. The
(Facing up)
junction box should be on the same side of the
5 ft
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
Figure 9: Supported assembled pole 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.
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.
6
head frame in the direction from which they
come out of the head frame center hole Top of pole
(Figure 13 & 14).
Support
assembly
Ring assembly
Grade
Hoist cable
Head frame
Transition
assembly
Fish line
7
Pole top plate Head frame
assembly
Transition
assembly
Power
cable
Transition
assembly
Ring
assembly
Locate swivel
2 ft above
Winch center line
Support
Plunger
Cable clamp
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
Latch shaft
Fastener,
6 places
Figure 21: Split washer placement
Dome cover
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
Ring assembly
S.S. fasteners
Tenon assembly
NOTE: Safety chains are optional on High Mast 2. AFTER ERECTING THE POLE AND COMPLETING THE
Systems. Consult your specification and order to INSTALLATION (see the next two sections), the safety chain
verify that you have purchased the safety cable must be installed and adjusted. First, latch the device. Then
option. If you have not, ignore this section of the attach the snap hook to the transition bail and connect the
instructions. other end of the safety cable to the safety chain.
1. Luminaire support rings can be secured at the 3. Loosen the two (2) saddle cable clamps on the cable. Pull
base of the pole with optional safety chain. This the free end of the cable through the clamps until the cable
option is provided as a redundant safety feature is snug. Tighten the clamps to 40 foot-pounds.
in case the latches and hoist cable fail. If a safety
chain is used, attach one end of the chain to the 4. Make sure the hook can be removed from the ring. If not,
attachment provision inside the pole shaft and loosen the clamps and adjust.
the other end to the transition assembly. (Figure
26) 5. Cut off or tape excess cable.
10
Assembly with Luminaires
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)
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
3 120
J-box T-tenon
4 90
5 72
12
4. Make sure the arms are equally spaced around the 3. Raise the ring until all three balls touch the three
ring to balance the load on the ring. latch cams. See OPERATING INSTRUCTIONS, rais-
ing the ring section, for instructions on using the port-
5. When the luminaires are mounted to the arms, able drive unit to raise the ring. After the balls reach
check for vertical and horizontal alignment. See in- the latch cams, cautiously raise the ring a few more
structions packed with luminaire for mounting and inches to make sure the balls are in the same plane as
alignment details. the head plate.
6. Test the lighting circuit by following OPERATING CAUTION: Do not allow the latch shafts to contact
INSTRUCTIONS, Testing Lighting Equipment on the the latch cams at this point.
Lowered Ring Section.
4. Lower the ring back to maintenance level. Measure
WARNING: THIS IS NOT A LOAD- RATED DEVICE. from the top of the ring to the bottom of the balls to
DO NOT ATTEMPT TO MAKE AND BREAK THE determine which cable has the shortest distance to the
CIRCUIT WITH THE PLUG AND RECEPTACLE. ring. raise the other two points on the ring to the same
length thereby putting them in the same plane. This
Leveling the ring (square with the head frame) can be done by tapping the bottom of the strand vise
with a hammer or by releasing the grip of the vise us-
IMPORTANT: This step must be completed cor- ing a screwdriver through a slot in the side of the
rectly for lowering device to operate properly. strand vise. Dimension “A” in Figure 32 should be the
same for all three hoist cables.
1. For smooth operation during raising and lowering,
the ring will need to be aligned with the top plate. This Hoist cables,
should be done after the pole is standing and the ring 3 places
has been lowered and the luminaires and counter-
weights installed. Be certain that the split washer used Leveled ring
A
for rigging have been removed and discarded.
Figure 30: Spit leveling ball 5. Recheck the measurements from the balls to the
top of the ring. Realign if necessary. Remove the
balls and discard.
Head frame at
Top of pole
6. This procedure aligns the ring with the top plate
and is not intended to be a leveling operation for the
Ball location ring. Proper alignment with the top plate is necessary
after ring is for smooth operation.
raised
Ball, placed while
ring is in lowered Completing the Installation
18 in. at each position (3 Plcs.)
hoist cable
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.
13
3. When ring is initially raised with a full load of 4. Disconnect and remove the main power receptacle
luminaires and latched at the top of the pole, the from the circuit breaker box in the pole base. Remove
transition assembly, hoist cables and power cable the portable drive unit.
may rotate and twist a few rotations because the
wire cables are new. This twist must be removed 5. Pull at the electrical cable through the transition plated
by hand rotation of the transition assembly until the to be sure there is no slack. If necessary, adjust the posi-
hoist cables and power cable are hanging tion of the power cable clamp so that it is 8 to 10 inches
STRAIGHT. Use a high-power light source to visu- (203 to 254mm) below the hole in the transition assembly
ally check cables. The cables should be under a
small amount of tension to prevent damage from 6. Connect the plug of the power cable to the main power
contact with the pole in high wind conditions. receptacle on the circuit breaker box and close the circuit
breaker.
3. Lift the portable drive unit to the hand hole and Lowering the Ring
insert the drive support arm into the support tube.
Slide the unit until the slots in the drive shaft fully WARNING: IT IS IMPORTANT TO STAND CLEAR OF
engaging the pins on the winch drive shaft (Figure THE POLE WHILE RAISING AND LOWERING THE
33). Drop the retaining pin through holes in the RING. THE REMOTE CONTROL SWITCH HAS BEEN
support tube and support arm to lock them to- PORVIDED FOR THIS PURPOSE. NEVER STAND UN-
gether. DER THE RING ASSEMBLY WHEN RAISING OR LOW-
Transition assy. ERING.
Main power plug 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
Main power supply bumper type or roller type), stop the ring about 3 to 3
and a half feet above the hand hole (Figure 28). If the
Receiver hitch ring appears to hesitate and then drop several inches
Portable Drive
as it nears the bottom of the pole, some twisting may
Unit (PDU) have occurred in the cables. Stop the decent of the
ring. Raise it about five feet, then proceed with lower-
Remote control ing it.
Supply to 1. Turn the remote control switch to FOR and raise the ring
PDU
until the indicator flags rotate 45°. Release the switch to the
Figure 33: Portable drive unit
14
OFF position. All three latch indictors should have Raising the Ring
rotated 45° and should appear as shown in Figure 34
(In transition) when viewed from the ground. WARNING: IT IS IMPORTANT STAND CLEAR
OF THE POLE WHILE RAISING AND LOWER-
ING THE RING.
5. Disconnect the main power receptacle from the Finishing the Servicing
junction box and reconnect it to the transformer box
or to the motor power supply cable, as applicable. 1. Turn OFF the circuit breaker. Disconnect the
Replace and secure the plug protector. main power receptacle from the transformer plug
or from the motor power plug.
6. Turn ON the circuit breaker.
15
2. If used, reconnect the optional safety cable to the excess cable down behind the pole plate assembly.
transition assembly (see Installing the Optional Safety
Cable section of the installation instructions). 4. Remove the retaining pin from the support tube
and drive support arm and remove the portable drive
3. Connect the main power plug to the main power re- unit.
ceptacle. Turn ON the circuit breaker. Place all
5. Replace the hand hole cover.
Un-hanging Latches 4. Turn the remote control switch to the REV position.
Release it to the OFF as soon as all three latch indica-
NOTE: If properly operated according to these in- tors have turned to the latched position, as shown in
structions, it is unlikely that any latch will get out of Figure 35.
sequence and “hang up”. The design of the latches,
suspension springs, and drive unit act together to Lubrication
assure latching a wide range of support ring load-
ing. If a “hand up” occurs, it can be worked out as Winch: The winch is lubricated and sealed at the fac-
follows: tory and needs no further lubrication. It should give
many years of service without attention.
1. Raise the ring very slowly by a succession of short
“ON” intervals in the FOR position. Watch the sets of Latch Pins: Lubricate with a coating of white lithium
latch indicators until the first set appears to have rotated grease at each service interval.
45° a bit sooner than the other two. Do not continue to
raise the ring. The full torque of the limiter is not used. Aircraft Cable. The winch and hoist cables come from
the manufacturer with a very light coating of lubricant.
2. Drop the ring slowly while observing if all three latch This lubricant is desirable and should not be removed.
shafts drop from the lock plate. If all three latches are The winch cable should be checked for wear and cor-
now unlatched, continue to lower the ring or go to Step 3 rosion and cleaned with a soft, absorbent cloth, then
as required. If the ring is still “hung”, do not lower the re-lubricated with a good quality acid-free grease on a
ring further. Repeat steps 1 and 2. It may be necessary regular service interval. In normal environments the
to operate the first two latches to obtain a sequence that service should be performed every five years or at re-
will free all three. lamping intervals. In highly corrosive environments the
cable should be serviced every two years or at re-
3. Raise the ring fully until the indicator flag rotate 45°. lamping intervals.
Release the switch to the OFF position. All three latch
indicators should now have rotated 45° as shown in CAUTION: If during inspection, it is found that
Figure 34. there are more than 12 broken wires in one lay of
the cord, the cable should be replaced.
Miscellaneous
Prints for Record and Prints for Approval to “Prints for Record”.
Assembly prints in this book are identified with draw- Renewal Parts
ing numbers. They are suitable for use as “Prints for
Record” or “Prints for Approval” for a standard lower- Contact the factory for renewal parts. Use the as-
ing device. Drawings indicate all the necessary part sembly prints in this instructions book for an accu-
to make up a standard lowering device model. rate description of part names.
16