ProStar Maintenance Manual
Contents
1. Avoid swinging the load or hook Make sure hook travel is in the same direction as shown on the controls 8 Inspect the hoist regularly replace damaged or worn parts and keep appropriate records of maintenance Use factory parts when repairing the unit 0 Lubricate load chain per instructions in this manual NOT use the hoist load limiting or warning device to measure load 12 NOT use limit devices as routine operating stops unless allowed by manufacturer They are emergency devices only 13 NOT allow your attention to be diverted from operating the hoist 14 NOT allow the hoist to be subjected to sharp contact with other hoists structures or objects through misuse 15 NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs TABLE OF CONTENTS Safety Precautions Specifications Installation Operating Instructions Maintenance i L a Electrical Data Disassembly Assembly Repair a Exploded View Replacement Parts List EP Figure 1A SPECIFICATIONS The Prostar Electric Chain Hoist is a highly versatile materials handling device that can be used to lift loads that are within its rated load capacity It is available in five load ratings 250 300 500 600 and 1 000 pounds2. Using commercial or other manufacturer s parts to repair Prostar Hoists may cause load loss TO AVOID INJURY Use only factory supplied replacement parts Parts may look alike but our parts are made of specific materials or processed to achieve specific properties 14 15 624 252 CONTROL STATION Key No Part Name 2 af af a a E a a 624 232 Control Station Includes 624 301 thru 624 307 624 252 Warning Label Electrical 24 253 Manufacturer Label 624 301 Control Station Grommet 624 302 24 303 624 304 24842 Control Station Housing Gasket Control Station Button Assembly 624 306 624 307 1 Control Station Parts Kit 1 Contact Assembly Includes 1 624 304 Warning Label BR wo Control Station Black for use on 115 1 50 60 hoists with contactor 220 1 50 and three phase units 620 176 624 306 T 624 302 n a 0 0 E 624 303 624 307 624 304 KM 624 301 36988 36987 1 24845 624 253 620 181 620 177 620 180 620 184 dm 620 137 620 105 620 154 620 140 620 138 one 620 1 See page 13 for 620 139 Upper Hook Installation 620 100 Snn 5 620 178 620 179 620 125 620 110 620 187 620 188 620 112 A ape 620 112 620 109 620 104 620 182 620 114 620 101 620 103 620 185 W T EON 620 126 620
3. 9 After positioning secure load by using auxiliary cables and or chains 10 On the Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg hoists check for twists in the load chain A twist can occur if the lower block has been capsized between the strands of chain Reverse the capsize to remove twist 11 Do not allow a load to bear against the hook latch The latch is to help maintain the hook in position while the chain is slack before taking up the slack chain 12 Take up a slack load chain carefully and start load easily to avoid shock and jerking of hoist chain If there is any evidence of overloading immediately lower the load and remove the excess load 13 not allow the load to swing or twist while hoisting 14 Never operate the hoist when flammable materials or vapors are present Electrical devices produce arcs or sparks that can cause a fire or explosion 15 STAY ALERT Watch what you are doing and use common sense Do not use the hoist when you are tired distracted or under the influence of drugs alcohol or medication causing diminished control a WARNING TO AVOID INJURY DO NOT Lift more than rated load DO NOT Operate with twisted kinked or damaged chain DO NOT Operate damaged or malfunctioning hoist DO NOT Lift people loads over people allow people on unsecured load or leave unsecured load over people DO NOT Operate hoist when load hook is not centere
4. above in Figure 12C Jog the UP push button while pulling on the free end of wire until the chain comes out of the hoist Remove the wire and attach the chain stop as shown in Figure 13B On units with chain container place chain stop and loose end of chain in chain container Attach chain container to chain guide On the 250 300 and 500 Ibs single reeved 113 136 and 226 kg units remove the hook block from the old chain and attach it to the new chain by reusing the chain pin 620 158 On the 500 600 and 1000 Ibs 226 272 and 453 kg units Remove dead end plate 620 160 from hoist Remove dead end pin 620 161 from the last link of chain and pull chain out of dead end plate Pull old chain out of hook block and disassemble the hook block Make sure the new chain is not twisted and wrap the chain around the sheave wheel 620 162 with welds down and towards the sheave wheel Reassemble hook block and pull the new chain through the hook block Single Reeved Double Reeved i cS Chain Stop Screw 6 Links N Chain Stop of Chain Loose y n End o n End of iL Chain ich Chain Hook 8 Opening Opening 3 Towards Away From Loose End Loose End HOU ae Figure 13B Slide the dead end plate over the last link and secure it using the dead end pin Making sure the chain is not twisted between the hook bloc
5. 166 2 AJ oS 620 107 620 167 620 135 9 620 134 X a 620 150 gt lt a 620 132 620 130 620 148 620 149 620 170 620 173 620 131 620 149 620 122 620 115 620 190 620 142 gt 620 171 cA 620 146 620 162 em S r SAAR 620 156 620 197 620 189 _ 620 133 1 620 163 620 169 620 165 RS 620 160 620 156 6 mem 620 176 620 168 S i m 620 144 hl WP 620 138 620 151 620 159 620 196 620 157 624 232 a peer ae Double Chained Units 620 156 Lower Hook Block 620 159 PROSTAR ELECTRIC Single Chained Units Lower Hook Block 16 CHAIN HOIST EXPLODED VIEW 17 PROSTAR ELECTRIC HOIST PARTS LIST Stator 115 1 50 60 Hoists 620 100 0 4 6 380 3 50 415 3 50 and 460 3 60 Hoists First Pinion and Shaft 575 3 60 Hoists 620 131 10 Tooth 1 Contact 620 101 Rotor Assembly Includes 620 102 and 620 103 1 20651 12 Tooth 1 E otor Assem ant EX MESE UH 620 132 Brake End Cover 20345 620 102 Rotor Bearing Outboard 88487 Brake End Cover Screw 620 103 Rotor Bearing Inboard 88486 620 133 Hoists without contactor 920715 620 104 Rotor Thrust Washer 20727 Hoists with contactor 3 20808 620 105 Motor End Cover 20321 620 134 Gear Housing Screw 920718 620 106 Capacitor Frame dn ES 115 1 50 60 Hoists 1 Hook Includes 620 138 220 1 50 Hoist 1 20785 Hook Latch Kit Cut Out Device Load Chain Specify Lift or Length Required 85988 115 1 50 60 Hoi
6. Figure 7A If the stock diameter of the worn link is 0 010 inches 0 254mm or more less than the stock diameter of the unworn link the chain must be replaced On the Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg units repeat this examination of the chain that passes through the hook block Also check chain for stretch using a vernier caliper as shown in Figure 6B Select an unused unstretched section of chain usually at the loose end and measure and record the length over 11 chain links pitches Measure and record the same length on a worn section of chain Obtain the amount of stretch and wear by subtracting the measurement of the unworn section from the measurement of the worn section If the result amount of stretch and wear is greater than 0 145 inch 3 7mm the chain must be replaced Figure 7B When lubricating the chain apply sufficient lubricant to obtain natural run off and full coverage especially in the interlink area a WARNING Used motor oils contain known carcinogenic materials TO AVOID HEALTH PROBLEMS Never use used motor oils as a chain lubricant Only use Lubriplate Bar and Chain Oil 10 R as a lubricant for the load chain a WARNING LUBRICATION Refer to Exploded View and Parts List pages 15 through 19 Use of commercial or other manufactures chain and parts to repair hoists may cause load loss WARNING TO AVOID INJURY Use only
7. and limitations WARNING Alterations or modification of hoist and use of non factory repair parts can lead to dangerous operation and injury TO AVOID INJURY Do not alter or modify equipment Do use only factory replacement parts ACCESSORIES Chain Container This accessory item Figure 1A is used to hold the slack chain and it is supplied with mounting hardware and instructions Chain containers are recommended for those applications where slack chain will interfere with the load or drag on the floor as may more often be the case with the Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg units Chain containers are shipped separately and can be furnished for units already in service Latchlok Hooks Latchlok Hooks Figure 1B are available to replace the standard lower latch type hooks The unique design of the Latchlok Hook assures that it will stay locked until the operator releases it by depressing the release button It will not open accidentally even if the load chain goes slack Once opened it can be shut with one hand or the weight of the load when it is lifted Latchlok Hooks can be supplied with the hoist or they can be provided in kit form for hoists already in service Claim Procedure Figure 2A BC Series Beam Clamps The beam clamps are ideal as anchors for rigging applications Figure 2A The BC series clamps can be adjusted to fit a wide ran
8. be lubricated with Lubriplate Bar and Chain Oil 10 R Fiske Bros Refining Co prior to reassembly The lubricant must be applied in sufficient quantity to obtain natural runoff and full coverage of these parts Load Chain Refer to page 7 for lubrication of the load chain Exterior Finish The exterior surface of the hoist has a durable scratch resistant baked powder coating Normally the exterior surfaces can be cleaned by wiping with a cloth However if the finish is damaged compatible touch up paint can be purchased from the factory Refer to page 19 for information on ordering the paint ELECTRIC BRAKE The brake is non adjustable with a nominal 004 inch 0 102 mm air gap and the brake disc must be replaced when the air gap reaches 012 inch 0 305 mm The brake spacer Figure 8B should be no more than 012 inch 0 305 mm thicker than the combined thickness of the brake disc and armature plate Refer to Figure 7B page 8 A wARNING Failure to follow proper lockout tagout procedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment To inspect the brake gap disconnect the hoist from power and remove brake end cover 620 132 1 Refer to Figure 8B and disassemble the brake Depress and hold the field assembly 620 122 while removing the four brake screws 620 124 The f
9. factory supplied replacement load chain and parts Chain and parts may look alike but our chain and parts are made of specific materials or processed to achieve specific properties The lubricants used in and recommended for the Prostar Hoist may contain hazardous materials that mandate specific handling and disposal procedures Use only a Knife edge caliper to eliminate possibility of false reading by not measuring full pitch length Note that worn chain can be an indication of worn hoist components For this reason the hoist s chain guide hook block and liftwheel should be examined for wear and replaced as necessary when replacing worn chain Also these chains are specially heat treated and hardened and should never be repaired IMPORTANT Do not use replaced chain for other purposes such as lifting or pulling Load chain may break suddenly without visual deformation For this reason cut replaced chain into short lengths to prevent use after disposal Chain Lubrication A small amount of lubricant will greatly increase the life of load chain Do not allow the chain to run dry Keep it clean and lubricate at regular intervals with Lubriplate Bar and Chain Oil 10 R Fiske Bros Refining Co or equal lubricant Normally weekly lubrication and cleaning is satisfactory but under hot and dirty conditions it may be necessary to clean the chain at least once a day and lubricate it several times between cleaning
10. up or down direction motor thermal protector open A Excessive load A See item 1F B Low voltage B Seeitem 1D C Extreme external heat C Above an ambient temperature of 104 F 40 C the frequency of hoist operation must be limited to avoid overheating the motor Special provisions should be made to ventilate the space around the hoist and shield it from radiant heat D Frequent starting or reversing D Avoid excessive inching jogging and reversing This type of operation drastically shortens motor cut out device capacitor control station and contactor contact life and causes excessive brake wear E Brake dragging E Seeitem 6C Motor cut out device not opening start winding circuit single phase units only See item 3C G Phase failure or unbalanced current in phases three phase units only G See Item 1G 8 Hook fails to stop in either direction A Brake not closing or ineffective A Check electric brake see page 9 and armature for binding broken brake spring first pinion shaft broke brake driver worn brake disc worn Correct binding of armature replace broken or worn parts 9 Hook lowers when up button is depressed A Phase reversal three phase units only A Seeltem 2C 10 11 RECOMMENDED SPARE PARTS To insure continued service of the Prostar Hoist the following is a list of parts that are recommended to be kept on hand at all times to replace parts that have worn or failed P
11. 113 136 226 272 and 453 kg Standard features of the Prostar Electric Chain Hoist include Alloy steel oblique lay liftwheel that provides constant chain speed and reduces chain wear Hoistaloy load chain for long and dependable service Grease lubricated hardened spur gears provide smooth and quiet operation Thermally protected hoist duty motor Forged steel upper and lower hooks with latch e Protector that prevents lifting dangerous overloads D C disc type motor brake plus regenerative braking e Standard Less Chain Unit Longer lifts can be supplied on a per order basis foot 9 M power cord with provisions for grounding is standard on 115 50 60 220 1 50 and three phase units foot 9M is standard for all control cords Longer cords can be provided on a per order basis Lightweight die cast aluminum frames and covers Ball or needle bearings at all rotating points Compact yet rugged design provides minimum headroom and long trouble free service e 1 8 m min lift speed available 1000 Ibs 453 kg units e 8 fom 2 4 m min lift speed available on 500 600 1000 Ibs 226 272 and 453 kg units e 12 fom 3 6 m min lift speeds available on 500 600 1000 Ibs 226 272 and 453 kg units 16 fpm 4 9 m min lift speeds available on 250 300 500 Ibs 113 136 and 226 kg units 20 fpm 6 1 m min lift speeds available on 500 600 Ibs 226 and 272 kg uni
12. 185 Contactor Jumper Specify No Req d 20332 620 174 Gasket 20755 Voltage Suppressor Control Cord Assembly 620 187 230 3 50 60 380 3 50 and 460 3 60 Hoists 1 20861 includes cord strain relief and warning tag 575 3 60 Hoists 1 20869 For Black Control Station and 620 176 10 ft lift 1 620 188 Gound Jumper 20641 15 ft lift 1 620 189 Chain Guide Screw 987859 20 ft lift 1 620 190 Chain Guide Spacer 20812 For other lifts contact factory 620 191 Warning Label 20765 1 Contactor includes power jumpers 620 193 Brake Spacer 0723 620 178 115 VAC Coils 20814 Hook Block Screw Lockwasher Double Chained 40802 48 VAC Coils 1 20787 620 196 2 Hook Block Screw Lockwasher Single Chained 2 983544 620 197 Warning Label 4884 1 1 1 600 Ibs 1 115 Volt Secondary 230 460 primary 1 1 Part Number for Packaged Lubricants Used in the Prostar Hoist Refer to Page 8 for Lubrication Instructions Part Numbers and Lubricant Type Packaged Quantity Usage Lubricant of Lubricants Grease Hoist Gears Century Lubricants HB 11 43 Spline on end Oil Graphite Mixture First Pinion Hercules Packing Co and Shaft Moly Duolube 67 Oil Load Chain Fiske Bros Lubriplate Bar and Chain Oil 10R Grease Lower Hook Knob Dow Corning Molykote BR 2 S When ordering lubricants specify the type of lubricant part number and packaged quantity required Touch up Paints for Prostar Hoist Order 1 case 12 12 oz Aerosol Cans of
13. 40 0 Transformers Primary _ 220 880v 230 460v 460v 575v 575v Secondary 48v 115v 48 115v 48v Leads Nominal D C Resistance ohms Black to Purple 11 7 71 0 11 9 73 98 White to Red 228 0 224 0 White to Yellow 614 0 902 0 Red to Yellow 384 0 6820 White to Orange 916 0 1100 1100 Coils Voltage Current Nominal D C Draw Amps Resistance Ohms Contactor 115 0 02 765 Coils 48 0 2 98 4 Brake 115 272 Field 220 1120 280 1608 Cut out 115 0 1 Terminals 3 to 4 0 3 Device to measure 115 volt brake coil resistance carefully cut and peel back the shrink tubing on the brake coil leads to expose the diodes Trace the leads from the coil to the diodes Connect the ohmmeter leads at the coil side of the diodes refer to the wiring diagram and measure the resistance If coil is ok reinsulate the brake coil leads and diodes using electrical tape Diodes are checked by connecting the ohmmeter to the ends of the brake coil leads checking for an open or short circuit reversing the connections to the ohmmeter and again checking for an open or short circuit If there is an indication of an open or Short circuit with the original and reversed connections diodes are defective and the brake field 620 122 which includes the diodes must be replaced Usable diodes are indicated by continuity with the original connections and an open circuit when the connections are reversed
14. Black Touch up paint Part Numbe Touch up paints are only available in case quantities NOTE When painting hoists also order warning labels etc that may be coated during painting 19 28605 for 1 2 Ib Can 28616 for 1 Ib Can 28617 for 4 Ib Can 40628 for 1 Pint Can 28608 for 1 Pint Can 28619 for 1 Gal Can 28606 for 1 2 Ib Can 28618 for 1 Ib Can r 84189 NOTES 20
15. Columbus McKinnon Entertainment Division Operating Maintenance amp Parts Manual Follow all instructions and warnings for inspecting maintaining and operating this hoist The use of any hoist presents some risk of personal injury or property damage That risk is greatly increased if proper instructions and warnings are not followed Before using this hoist each operator should become thoroughly familiar with all warnings instructions and recommendations in this manual Retain this manual for future reference and use Forward this manual to the hoist operator Failure to operate the equipment as directed in the manual may cause injury Before using the hoist fill in the information below Capacity Serial No Voltage Purchase Date Capacities 250 Ib 113 Kg 300 Ib 136 Kg 500 Ib 226 Kg 600 Ib 272 Kg 1 000 Ib 453 Kg 20875 Revision P620 G LIFETIME WARRANTY This warranty does not apply where deterioration is caused by normal wear abuse improper or inadequate power supply improper or inadequate maintenance eccentric or side loading overloading chemical or abrasive actions excessive heat unauthorized modifications or repairs or use of non Columbus McKinnon Corporation repair parts EXCEPT AS STATED HEREIN COLUMBUS MCKINNON CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABLILITY AND FITNESS FOR A PARTICULAR PURPOSE Ever
16. NOMINAL MINIMUM MIN VOLTAGE POWER OPERATING AT INSTANT SUPPLY VOLTAGE OF START 115 1 50 60 108 103 220 1 50 198 182 208 3 60 187 172 220 3 50 198 182 230 3 60 207 190 380 3 50 365 336 415 3 50 399 367 460 3 60 414 380 575 3 60 518 506 The drop in voltage upon energizing the hoist should not be below the value listed Low voltage can also be caused by using an undersize extension cord to supply power to the hoist The following charts should be used to determine the size wires in the extension cord in order to minimize the voltage drop between the power source and the hoist 115 1 50 60 units with contactor 220 1 50 units and three phase units hoists with black control station MAXIMUM LENGTH OF EXTENSION CORD Wire Size Single Three Phase Hoist Phase Hoist 16 A W G 135 feet 40 M 245 feet 73 M 14 AWG 220 feet 66 M 395 feet 120 M 12 A W G 354 feet 107 M 630 feet 192 M After the hoist is suspended from its support and you have made sure the power supply complies with the above the hoist is ready for operation On the Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg units cut and discard the ties used to hold the two strands of chain together With no load on the lower hook depress the UP button in the control station and raise the lower hook until it is about 2 feet below the bottom of the hoist Check both strands of chains for twists Twists occur if the lower hook block ha
17. Plate Screw 125 14 1 620 140 Hook Retainer Screw 10 1 1 620 157 Hook Block Screw Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg 125 14 1 Single reeved 250 300 and 500 Ibs 113 136 and 226 kg 50 5 6 620 152 Power Cord Ground Screw 20 2 2 8 When removing the stator 620 100 first remove the brake end cover 620 132 Disconnect stator leads from the wiring or contactor At the other end remove the motor end cover 620 105 On single phase units use an insulated screw driver to short between the bare terminals of the capacitor to discharge it A spark may be produced Disconnect wiring to the capacitor and then remove the capacitor Remove the cut out device 620 110 and disconnect the wires from it Remove the rotor assembly 620 101 and thrust washer 620 104 Then slide the stator out of the main frame 620 107 9 sure that the pin retainer plate 620 125 has been assembled to the main frame 620 107 On single phase units slide jumpers 2 and CAP through the To install the stator Refer to dos 12 A and make 10 11 Figure 12C wire slot in the main frame Route these wires around the rotor bearing boss in the main frame as shown in Figure 12A Attach the brown and blue stator leads and 2 jumper to cut out device refer to wiring diagram Slide the cut out device into the cavity as Shown Push the cut out device down until it sets on the main frame Place the capacitor on top o
18. TO AVOID CONTACT AND CONTAMINATION Handle and dispose of lubricants only as directed in applicable material safety data sheets and in accordance with applicable local state and federal regulations NOTE To assure extra long life and top performance be sure to lubricate the various parts of the Prostar Hoist using the lubricants specified below If desired these lubricants may be purchased from the factory Refer to page 19 for information on ordering the lubricants Gears e The Protector 620 111 should operate for the normal life of the hoist without service The device has been lubricated and calibrated by the factory and should not be adjusted CAUTION The Protector is to be used with Century Lubricants HB 11 3 grease Do not use any other grease or the Protector will not operate properly and parts could be damaged The gears and Protector are packed at assembly with grease and should not need to be renewed unless the gears have been removed from the housing and degreased CAUTION Never degrease the Protector or attempt to disassemble this device Degreasing the Protector may damage parts and using a device that has been degreased may cause erratic inconsistent operation If the Protector has been degreased it must be replaced by a factory calibrated device Drive Shaft 627 131 Brake Disc 627 117 Brake Assembly Figure 8A If the gears are remo
19. Y Make sure the attachment point has sufficient strength to hold several times the hoist and its rated load Figure 2B POWER SUPPLY SYSTEM Refer to Figure 4A or 4B on page 5 To insure proper operation to avoid damage to hoist and electrical system and to reduce the risk of electric shock or fire the branch circuit supplying power to the hoist must 1 Have ample capacity to prevent excessive voltage drop during starting and operation refer to Checking for Adequate Voltage at Hoist on page 4 When determining the size of branch circuit components and conductors special consideration should be given to the starting current amps approximately three times that shown on the hoist identification plate and the length of the conductors As a minimum the system should be rated for 15 amps and it should have 16 AWG or larger wiring 2 Be in accordance with the National Electrical Code ANSI NFPA 70 and applicable National State and Local Codes 3 Effectively ground the hoist in accordance with National Electrical Code and other applicable codes Proper grounding provides a path of least resistance for electric current to reduce the risk of electric shock The power cord of the hoist includes a green yellow wire for grounding the hoist to the external power supply system Be sure that the receptacle opening that receives the longest prong is properly grounded If grounding is to be through the trolley trackwhe
20. ad to hook bowl or saddle only 1 When preparing to lift a load be sure that the attach ments to the load hook are firmly seated in hook saddle Avoid off center loading of any kind especially loading on the point of the hook 2 When lifting raise the load only enough to clear the floor or support and check to be sure that the attachments to the hook and load are firmly seated Continue lift only after you are assured the load is free of all obstructions 3 Do notload the hoist beyond the rated capacity shown on the brake end cover Overloading can cause immediate failure of some load carrying part or create a defect causing subsequent failure at less than rated capacity When in doubt use the next larger capacity of hoist 4 Do not use this or any other overhead materials handling equipment for lifting persons or allow people on unsecured load 5 Stand clear of all loads and avoid moving a load over heads of other personnel Warn personnel of your intention to move a load in their area Do not leave unsecured load over people 6 Donotleave the load suspended in the air unattended Permit only qualified personnel to operate unit 8 Do not wrap the load chain around the supporting structure and hook onto itself as a choker chain Doing this will result in a loss of the swivel effect of the load hook which could mean twisted chain and a jammed liftwheel b The chain could be damaged at the load hook
21. ardous situation which if not avoided could result in death or serious injury To avoid such a potentially hazardous situation the operator shall Ay CAUTION 1 Oo RO ONO 11 12 13 14 15 16 17 18 19 20 24 NOT operate hoist on which the safety placards 23 24 25 26 NOT operate a damaged malfunctioning or unusually performing hoist NOT operate the hoist until you have thoroughly read and understood this Operating Maintenance and Parts Manual NOT operate a hoist which has been modified NOT lift more than rated load for the hoist NOT use hoist with twisted kinked damaged or worn load chain NOT use the hoist to lift support or transport people NOT lift loads over people NOT operate a hoist unless all persons are and remain clear of the supported load NOT operate unless load is centered under hoist NOT attempt to lengthen the load chain or repair damaged load chain Protect the hoist s load chain from weld splatter or other damaging contaminants NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading NOT use load chain as a sling or wrap load chain around load NOT apply load to the tip of the hook or to the hook latch NOT apply the load unless load chain is properly seated in the chain wheel s or sprocket s NOT apply load if bearing prevents equal loading on all load sup
22. arts applicable to your hoist should be stocked KEY PART QTY KEY PART QTY NO NAME PER HOIST NO NAME PER HOIST 620 122 BRAKE FIELD ASSEM 620 117 BRAKE DISC 1 620 106 CAPACITOR 620 110 CUT OUT 1 DEVICE 620 181 TRANSFORMER 620 178 REVERSING 1 CONTACTOR 624 232 CONTROL STATION 624 306 CONTROL STATION 1 PARTS KIT Refer to page 14 for ordering instructions and the Parts List for part numbers ELECTRICAL DATA OPEN OR SHORT CIRCUIT IN ELECTRICAL COMPONENTS Open circuits in electrical components may be detected by isolating the component and checking for continuity using an ohmmeter Short circuits are indicated by D C resistance substantially below the nominal D C resistance Motor current draw should be measured at the end of the power cord while the hoist is raising rated load Check cut out device on single phase units only by measuring coil resistance terminals 3 and 4 and making sure the contact terminals 2 and 4 is open ELECTRICAL DATA FOR COMPONENTS Stators Volts Phase Hertz Full Load Current Nominal D C Amps Resistance Ohms 110 to 120 1 50 60 2 7 Yellow to Red 7 7 Blue to Black 6 2 220 1 50 1 1 Yellow to Red 27 7 Blue to Black 24 2 220 3 50 1 1 White to Red 26 8 230 3 60 0 6 White to Black 26 8 Red to Black 26 8 380 3 50 0 63 White to Red 72 6 415 3 50 0 58 White to Black 72 6 460 3 60 0 88 Red to Black 72 6 575 3 60 0 4 White to Red 140 0 White to Black 140 0 Red to Black 1
23. ble chained 1 620 161 Dead End Pin Double chained 1 20720 620 162 Sheave Wheel w 620 164 Double chained 0652 620 163 Wheel Shaft Double chained 0318 620 164 Sheave Wheel Bearing Double chained 88641 eel an ear Assem prn 12000 Iba y 620 165 Sheave Wheel Thrust Washer Double chained 2 88639 8 fpm 500 600 amp 1 000 Ibs 620 166 Jumper 2 1 20610 rm i m u A 12 fpm 500 Ibs 620 167 Jumper Cap 620 127 12 fpm 600 amp 1000 Ibs 16 fpm 250 300 amp 500 Ibs 20 fpm 500 amp 600 Ibs 24 fpm 250 300 amp 500 Ibs 40 fpm 250 amp 300 Ibs 20609 620 168 Dead End Plate Screw Double chained 73715 18 PROSTAR ELECTRIC HOIST PARTS LIST Key Part Name No Part Key Part N No Part Number Req d Number Number ar mame Req d Number 620 168 Dead End Plate Screw Double chained 73715 620 179 Components Board Outboard 20777 Capacity Warning Label 620 180 Components Board Inboard 20778 620 169 250 Ibs Transformer 300 Ibs 48 Volt Secondary 220 380 primary 500 Ibs 48 Volt Secondary 460 primary 1 000 Ibs 115 Volt Secondary 575 primary 48 Volt Secondary 575 primary 620 170 I D Label Contact Factory 620 182 Diode Assembly 20789 620 171 Warning Label 2 1 24842 620 183 Control Cord Plug 20780 620 172 Prostar Label 20764 620 184 Power Cord Plug 20781 620 173 Wire Nut specify No Req d 920756 620
24. d over hoist DO NOT Permit load hook block to contact hoist frame or chain container DO Replace damaged or malfunctioning hook latch DO Keep load chain well oiled INSPECTION To maintain continuous and satisfactory operation a regular inspection procedure must be initiated so that worn or damaged parts can be replaced before they become unsafe The intervals of inspection must be determined by the individual application and are based upon the type of service to which the hoist will be subjected The inspection of hoists is divided into two general classifications designated as frequent and periodic 157 Inches 4 mm Diameter Weld Wear in These Areas Vernier Caliper Measure 11 Pitches Pitch Figure 6A Frequent Inspections These inspections are usually visual examinations by the operator or other designated personnel Frequent inspections are to be performed daily or monthly and shall include the following items a Operate the hoist with no load and check for visual signs or abnormal noises which could indicate a potential problem daily b Brake for evidence of slippage daily c Chain for lubricant wear damaged links or foreign material daily see below d Hooks for damage cracks twist latch engagement and latch operation daily see below Any deficiencies must be corrected before the hoist is returned to service Periodic Ins
25. ed capacity or the hoist should be replaced with one of the proper capacity When the excessive load is removed normal hoist operation is automatically restored CAUTION The Protector is susceptible to overheating and wear when slipped for extended periods Under no circumstance should the Protector be allowed to slip for more than a few seconds Due to the above the hoist is not recommended for use in any application where there is a possibility of adding to an already suspended load to the point of overload This includes dumbwaiter installations containers that are loaded in mid air etc Also if the hoist is used at unusual extremes of ambient temperatures above 150 F 65 C or below 15 F 9 C changes in lubricant properties may permit the hoist to raise larger loads than under normal operating conditions and present possibility of damage or injury On units without contactor hoists with orange control station it is necessary to stop the hoist before changing direction Therefore when lowering a load the push button in the control station must be released momentarily before the UP button is depressed to raise the load If this is not done the hoist will continue to operate in the down direction while the UP push button is depressed and it will continue to lower the load until the control push button is released As a result the direction must not be reversed quickly plug reversed There are no electrical switc
26. els each section of the runway must be grounded to the building ground system using metal to metal connections 4 Include slow blow type fuses or inverse trip time circuit breakers to permit the hoist to start and accelerate load a WARNING Failure to properly ground the hoist presents the danger of electric shock TO AVOID INJURY Permanently ground the hoist as instructed in this manual 5 Include a disconnecting means capable of being locked in the open position A CAUTION To Reduce the Risk of Electric Shock or Injury Use Indoors Only Name plate Making sure the hoist will operate on Power suppl PPY the power supply system m Control Station Mounting Hook Figure 3A NOTE IN THIS MANUAL NOMINAL VOLTAGES ARE USED WHEN REFERRING TO POWER SUPPLY SYSTEMS HOWEVER WITH NO MODIFICATION THE PROSTAR HOIST WILL OPERATE ON A RANGE OF VOLTAGES AS INDICATED BELOW NOMINAL VOLTAGE HERTZ VOLTAGE RANGE 230 208 240 60 460 440 480 60 220 200 240 50 380 365 395 50 415 400 430 50 575 550 600 60 Three Phase Hoists Since the motor in a three phase hoist can rotate in either direction depending on the manner in which it is connected to the power supply the direction of hook movement must be checked during the original installation and each time hoist is moved to a new location as follows 1 Move the manual d
27. f the cut out device and attach CAP jumper and the yellow stator lead to it Re route jumpers 2 and CAP if necessary to make sure they clear the rotor bearing boss as shown in Figure 12 On all units slide stator leads through wire slot Align the slots in the stator shell with the threaded holes in the main frame as shown in Figure 12B With the leads down slide the stator into the main frame Slide the rotor large bearing first into stator Place the rotor thrust washer 620 104 on top of the exposed rotor bearing and then assemble the motor end cover 620 105 to the main frame Using wiring diagram complete the wiring at the brake end of the unit Properly install the upper hook as shown in Figure 13A then slide the hook retainer 620 139 into the cavity on top of the hoist and secure it using hook retainer screw 620 140 Tighten screw to a seating torque of 10 in Ibs 1 1 NM After reassembly test the unit per instructions on page 14 LOAD CHAIN REMOVAL INSTALLATION 1 2 3 If unit has chain container remove it from the chain guide Remove the chain stop 620 146 Depress DOWN button and run chain out of hoist Feed a short length of soft wire through the opening in the chain guide stripper 620 192 until it comes out of the hoist Attach new chain to end of the wire which is in the center of the hoist Position the chain so that the welds will be down and towards the liftwheel as shown
28. ge of beam sizes The lightweight and compact design makes the beam clamps ideal for repeated set ups and tear downs Entertainment Rigging Products Refer to sales Bulletin No EPD 10B for additional rigging products that can be used in the entertainment industry UNPACKING After opening the carton Figure 2B carefully inspect the hoist frame cords hooks chain and control station for damage that may have occurred during shipment If there is damage refer to the packing slip envelope Make sure that the power supply Figure 3A to which the hoist is to be connected is the same as that shown on the identification plate located on bottom of hoist a WARNING Operating a unit with obvious external damage may cause load to drop and that may result in personal injury and or property damage TO AVOID INJURY Carefully check unit for external damage prior to installation MOUNTING THE HOIST Attach the hoist to the truss structure to be lifted using the mounting hook Figure 3B Be sure that the attachment point is held in the lowermost part of the hook arc and the latch is tightly against the hook tip Also the attachment point must have sufficient strength to withstand several times the load imposed If in doubt consult a registered engineer and local building codes WARNING An inadequate attachment point may allow the hoist and load to fall and cause injury and or property damage TO AVOID INJUR
29. he area beneath the load is permitted As an alternative the system may be designed such that malfunction or failure of one hoist s load bearing components does not cause load loss and or overloading of any other hoists in the system Note that in such a system hoist performance and function must be monitored visually or with the use of load cells Check the supporting structure to which the load hook is to be attached Make sure the attachment point as well as the structure have sufficient strength to withstand several times the load imposed If in doubt consult a registered engineer and local building codes Black Station A for Hoists With Contactor 10 Control Station Bee Depress to Move p Load Hook Towards m Hoist Head Opening is Depress to Move Greater Load Hook Away Than 1 1 8 From Hoist Head Twisted Normal 28 5 mm Do Not Use Ok To Use Figure 5A Figure 5B Attaching the load hook to an inadequate support may allow the hoist and load to fall and cause injury and or property damage Allowing a load to bear against the hook latch and or hook tip can result in loss of load TO AVOID INJURY Make sure the structure and the load hook attachment point have sufficient strength to hold several times the hoist and rated load TO AVOID INJURY Do not allow a load to bear against the hook latch and or hook tip Apply lo
30. he back cover of control station Probable Cause WARNING Failure to follow proper lockout tagout procedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment Remedy 1 Hook does not respond to control station A No voltage at hoist A Check for blown fuse or tripped circuit breaker or open disconnect switch in main line or branch circuit Replace fuse reset circuit breaker or close switch B Open control circuit due to loose connections or broken wires in circuit motor B Check electrical continuity thru motor thermal protector If it is open allow motor to thermal protector open control station contacts not closing open or shorted cool If this does not correct the trouble use wiring diagram to check electrical winding in transformer transformer thermal cut out open mechanical binding in continuity of wiring transformer contactor and control station contacts Repair contactor open or shorted winding in contactor coil wiring or replace defective part C Wrong voltage or frequency C Make sure that the power supply to hoist is the same as that shown on identification plate on button of hoist D Low voltage D Check power supply system to make sure it co
31. hes to stop the operation of the hoist at the upper and lower limits of lift As a result it is necessary to release the push button in the control station to stop the hoist before the hook block or chain stop contacts the bottom of the hoist frame If the hook block or chain stop contacts the hoist frame the Protector will function to stop the hoisting or lowering operation and protect the hoist Figure 4B components from damage However continued prolonged or repeated slipping of the Protector will damage the Protector and cause overheating of the internal hoist components WARNING Allowing the hook block to run into the hoist when raising a load or allowing the chain stop to run into the hoist when lowering a load may break the chain and allow the load to drop TO AVOID INJURY Do not allow the hook block or the chain stop to contact the hoist frame Hoist operation is controlled by depressing the control station push buttons Refer to Figure 5A pg 6 Depressing the UP push button will move the load hook toward the hoist head depressing the DOWN push button will move the load hook away from the hoist head The UP and DOWN buttons are momentary type and the hoist will operate in the selected direction as long as the button is held in the depressed position Release the push button and the hoist will stop It is preferred that the load always be tied off with auxiliary chains or cables before access to t
32. ield assembly is under spring pressure and will spring out if not held Examine the base plate 620 116 brake disc 620 117 and armature 620 118 for excessive wear scoring Or warpage Make sure the brake disc is not glazed the coil firmly fixed in the field 620 122 and the brake spring 620 123 is not damaged Worn scored warped glazed or damaged parts should be replaced before preceding 2 Refer to Figure 8B and assemble the brake Depress and hold the field assembly 620 122 while installing the four brake screws through the brake parts and mount the brake on the gear housing 620 113 Tighten the four brake screws 620 124 to 25 in Ib 2 8 NM PROTECTOR The Protector should operate for the normal life of the hoist without service The device has been lubricated and calibrated and it should not be adjusted If the Protector is not operating properly see testing on page 14 it must be replaced with a properly calibrated unit from the factory PREVENTATIVE MAINTENANCE A preventative maintenance program should be established to prolong the useful life of the hoist and maintain its reliability and continued safe use The program should include the periodic and frequent inspections with particular attention being paid to the lubrication of the various components using the recommended lubricants see page 19 TROUBLE SHOOTING Always disconnect unit from the power supply system before removing hoist covers or t
33. ion shaft and motor coupling for signs of wear or deterioration Replace splined parts if worn or damaged Figure 6B NOTE To perform some of the periodic inspections it is necessary to partially disassemble the hoist Refer to Disassembly Assembly starting on page 13 Any deficiencies noted must be corrected before the hoist is returned to service Also the external conditions may show the need for more detailed inspection which in turn may require the use of nondestructive type testing Any parts that are deemed unserviceable are to be replaced with new parts before the unit is returned to service It is very important that the unserviceable parts be destroyed to prevent possible future use as a repair item and properly disposed of Hook Inspection Hooks damaged from chemicals deformations or cracks or that have more than a 10 twist from the plane of the unbent hook or excessive opening must be replaced Any hook that is twisted or has excessive throat opening indicates abuse or overloading of the unit Other load sustaining components of the hoist should be inspected for damage On latch type hooks check to make sure that the latch is not damaged or bent and that it operates properly with sufficient spring pressure to keep the latch tightly against the tip of the hook and allow the latch to spring back to the tip when released If the latch does not operate properly It should be replaced See Figure 5B Pg 6 t
34. isconnect switch handle to the OFF position 2 Connect the BROWN GREY AND BLACK wires of hoist power cord to load side of disconnect switch Connect the GREEN YELLOW wire of hoist power cord to power supply ground 3 Move the manual disconnect switch handle to the ON position 4 Depress the f up control If the hook moves in the up direction the hoist is ready for operation If the hook lowers move the disconnect switch handle to the OFF position and interchange the BLACK and BROWN leads at the disconnect switch Move the disconnect switch handle to the ON position and the hoist is now ready for operation Checking for Adequate Voltage at Hoist The hoist must be supplied with adequate electrical power for proper operation and to reduce problems that may result from insufficient power low voltage These include Noisy hoist operation due to brake and or contactor chatter Heating of the hoist motor and other internal components as well as heating of wires and connectors in the circuit feeding the hoist Failure of the hoist to lift the load due to motor stalling Blowing fuses or tripping circuit breakers Dimming of lights or slowing of motors connected to the same circuit Figure 3B For proper operation and to avoid these low voltage problems voltage measured at end of the power cord while lifting rated load should be as the following chart indicates
35. k and hoist attach the dead end plate to the chain guide stripper 620 192 e Retrace the new chain and check for twists If chain is twisted start over IMPORTANT Do not use old chain for other purposes such as lifting or pulling Load chain may break suddenly without visual deformation For this reason cut the old chain into short lengths to prevent use after disposal CUTTING CHAIN Hoistaloy load chain is hardened and it is difficult to cut The following methods are recommended when cutting a length of new Lees chain from stock cutting off worn chain Always wear eye protection when cutting chain 1 Use a grinder and nick the link on both sides see right then secure the link in a vise and break off with a hammer 2 Use a 7 177 mm minimum diameter by 1 8 d 3 1 mm thick abrasive wheel or type recommended by wheel supplier that will clear adjacent links a WARNING Cutting chain can produce flying particles TO AVOID HEALTH PROBLEMS Wear eye protection Place a shield over chain to prevent flying objects 3 Use a bolt cutter see right with special cutter jaws for cutting hardened chain Jaws should be 1 inch 25 4 mm long TESTING Before using all altered repaired or used hoists that have not been operated for the previous 12 months must be tested by the user for proper operation First test the unit without a load and then with a light load of 50 p
36. mplies with the requirements listed under power supply system starting on page 3 E Brake not releasing due to open or shorted coil defective diodes or brake disc E Check coil continuity diodes see page11 and connections Make sure brake binding disc slides freely on brake driver and brake spring is not broken Replace coil brake field repair connections remove burrs from brake driver so that brake disc slides freely and or replace brake spring Excessive load E Reduce load to capacity limit as indicated on identification and capacity labels on hoist G Phase failure single phasing three phase units only open circuit grounded or G Check for electrical continuity and repair or replace defective part faulty connection in one line of power supply system hoist wiring contactor motor leads or windings 2 Hook moves in wrong direction A Wiring connections reversed in control station or hoist A Use wiring diagram and check wiring connections device single phase units only to effect dynamic braking at time B Check connections to cut out device Replace damaged device or faulty capacitor C Phase reversal three phase units only C See Three Phase Hoists on page 4 3 Hook lowers but will not raise A Excessive load A See item IF Hoisting circuit is OPEN due to loose connections or broken wire in circuit control B EE EM ue Eis freie of wiring and control station station contacts are n
37. o determine when the hook must be replaced LOAD CHAIN Chain should feed smoothly into and away from the hoist or hook block Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg units If chain binds jumps or is noisy first clean and lubricate it see below If trouble persists inspect chain and mating parts for wear distortion or other damage Chain Inspection First clean chain with a non caustic non acid type solvent and make a link by link inspection for nicks gouges twisted links weld spatter corrosion pits striations minute parallel lines cracks in weld areas wear and stretching Chain with any one of these defects must be replaced Slack the portion of the chain that normally passes over the liftwheel Examine the interlink area for the point of maximum wear polishing see Figure 6A Measure and record the Stock diameter at this point of the link Then measure stock diameter in the same area on a link that does not pass over the liftwheel use the link adjacent to the loose end link for this purpose Compare these two measurements Star and 2 digit 3 digit year code date code Use only Star H grade load chain and factory replacement parts Use of other chain and parts may be dangerous and voids factory warranty Brake Assembly Brake Base Plate Brake Field Assembly IncludesCoil T Gap First Pinion Brake Amature Shaft Brake Spring Brake Driver Brake Disc
38. ode Check each installation for compliance with the applicable sections of the code as well as the National State and Local Codes that may apply to the installation In addition safety code requirements associated with the operation of a hoist in the inverted theatrical position chain port up as with any mechanical equipment vary depending upon locality Therefore before installing the hoist the user should consult his insurance company and or local authority to see if a deviation is required to permit the use of the hoist in this particular application The safety laws for elevators lifting of people and for dumbwaiters specify construction details that are not incorporated into the hoists For such applications refer to the requirements of applicable state and local codes and the American National Safety Code for elevators dumbwaiters escalators and moving walks ASME A17 1 We cannot be responsible for applications other than those for which the equipment is intended THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND OR PROPERTY OF YOURSELF AND OTHERS READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED WITH THE EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR PROSTAR HOIST A WARNING A 27 Make sure hoist limit devices function properly 28 Warn personnel of an approaching load Improper operation of a hoist can create a potentially haz
39. ol Station 12 13 Pin Retainer Jumpers 2 and Cap Main Frame Figure 12A Figure 12B DISASSEMBLY ASSEMBLY When disassembling and assembling the Prostar Hoist refer to the exploded view and the parts list on pages 15 through 17 These show the proper relationship of the parts the names of the parts and the required quantities of the parts In addition please observe the following 15 Needle bearings pressed into the gear housing 620 113 main frame 620 107 liftwheel 620 127 and lower sheave wheel 620 162 Unless they are to be replaced do not attempt to remove these bearings 2 A liftwheel seal 620 108 is pressed into the main frame 620 107 and a seal 620 130 is pressed into the end of the liftwheel shaft 620 148 Be careful that these seals are not cut or damaged during disassembly and reassembly 3 Refer to page 8 for disassembly inspection reassembly and adjustment of the brake 4 Do not attempt to disassemble the Protector refer to page 9 5 Refer to page 8 for lubrication instructions 6 See next section for load chain removal and installation 7 Tighten the various screws as follows KEY NO PART NAME SEATING TORQUE LB IN NM 620 126 Pin Retainer Plate Screw 25 28 620 154 Motor Cover Screw 25 2 8 620 134 Gear Housing Screw 25 2 8 620 133 Brake End Cover Screw 25 2 8 620 168 Dead End
40. or an open circuit with the original connection and continuity with reversed connections 220 volt brake coil is used on 220 1 50 220 3 50 60 380 3 50 415 3 50 and 460 3 60 hoists 280 volt brake is used on 575 3 60 hoists Wiring Diagrams THE FOLLOWING WIRING DIAGRAMS ARE REPRESENTATIVE FOR ACTUAL WIRING DIAGRAM REFER TO THE DIAGRAM SUPPLIED WITH THE HOIST NOTE FOR 575 3 60 UNITS REFER TO WIRING B BLACK Y YELLOW CONNECTION r MECHANICAL 1 INTERLOCK Lam O TERMINAL CONTROL CORD MOTOR CAPACITOR ew lI STATION Xcur our DEVICE PROSTAR HOIST WIRING DIAGRAM 115 1 50 60 B 20843 P PURPLE B BLACK Y YELLOW BR BROWN BL BLUE G GREEN R RED W WHITE CONNECTION Lp MECHANCAL INTERLOCK X onu TERMINAL X CUT OUT DEVICE MIU CONTROL STATION TRANSFORMER THERMAL CUTOUT HOIST PROSTAR HOIST WIRING DIAGRAM 220 1 50 33 B 20844 8 21 98 DIAGRAM SUPPLIED WITH HOISTS 115 1 50 60 HOISTS WITH CONTACTOR Black Control Station 220 1 50 HOISTS WITH CONTACTOR Black Control Station 220 3 50 230 3 60 HOISTS WITH CONTACTOR Black Control Station 380 3 50 415 3 50 460 3 60 HOISTS WITH CONTACTOR Black Contr
41. ot making open or shorted winding in contactor coil C Check cut out device and connections to same See page 11 Repair connections C Motor cut out device not operating single phase units only and or replace cut out device D Phase failure three phase units only D See item 1G 4 Hook raises but will not lower A Lowering circuit is OPEN due to loose connections or broken wire control station A See item contacts not closing open or shorted winding in contactor coil B Motor cut out device not operating single phase units only B See item 3C C Phase reversal three phase units only C Seeitem 2C D Phase failure three phase units only D Seeitem 1G 5 Hook does not stop promptly A Brake slipping A Check electric brake see page 9 especially the brake disc for wear or glazing and make sure brake spring is not broken Replace worn or glazed brake disc or replace brake spring B Excessive load B Seeitem 1F 6 Hoist operates sluggishly A Excessive load A See item 1F B Low voltage B Seeitem 1D C Brake dragging C Check electric brake see page 9 Check to make sure brake disc is free to move on brake driver Check for warped or bent brake disc and base plate Free up brake disc by removing burrs on driver Replace warped armature base plate or brake disc D Phase failure or unbalanced current in phases three phase units only D Seeitem 1G 7 Motor overheats Hoist will not operate in
42. ounds 23 kg times the number of load supporting parts of load chain to be sure that the hoist operates properly and that the brake holds the load when control is released Next test with a load of 125 of rated capacity In addition hoists in which load sustaining parts have been replaced should be tested with 125 of rated capacity by or under the direction of an appointed person and written report prepared for record purposes After this test check that the Protector functions If the Protector permits lifting a load in excess of 20096 of rated load it should be replaced If the Protector prevents lifting of a load of 125 of rated capacity reduce load to rated capacity REPAIR PARTS ORDERING INSTRUCTIONS The following information must accompany all correspondence and orders for replacement parts 1 Hoist rated load from identification plate 2 Serial number of the hoist stamped below identification plate 3 Voltage Phase Hertz from identification plate 4 Length of lift 5 Key number of part from parts list 6 Number of parts required 7 Part name from parts list 8 Part number from the parts list NOTE When ordering replacement parts it is recom mended that consideration be given to the need for also ordering such items as gaskets fasteners seals etc These items may be damaged or lost during disassembly or just unfit for future use because of deterioration from age or service WARNING
43. pections There are visual inspections by an appointed person who records apparent external conditions to provide a basis for continuing evaluation Periodic inspections are to be performed semi annually and they should include the following All items listed under frequent inspections b External evidence of loose screws c External evidence of worn corroded cracked or distorted hook block gears bearings chain stop and hook retainer d External evidence of damage or excessive wear of the liftwheel or sheave double reeved unit Widening and deepening of pockets may cause chain to lift up in the pockets and cause binding between liftwheel and chain guide or between lower sheave and hook block Check chain guide for wear or burring where the chain enters the hoist Severely worn or damaged parts should be replaced e External evidence of excessive wear of brake parts see page 9 f Check the control station push buttons to make sure they operate freely and spring back when released g Check power cord control cord and control station for damaged insulation h Check for pitting and any deterioration of contactor contacts hoists with black control station i Check the chain pin or dead end pin and chain stop for wear and cracks j Check for lubricant leaks at gasket between main frame and gear housing Tighten gear housing screws to stop leak If leak persists replace gasket k Inspect splines on first pin
44. porting chains NOT operate beyond the limits of the load chain travel NOT leave load supported by the hoist unattended unless specific precautions have been taken NOT allow the load chain or hook to be used as an electrical or welding ground NOT allow the load chain or hook to be touched by a live welding electrode NOT remove or obscure the warnings on the hoist decals are missing or illegible NOT operate a hoist unless it has been securely attached to a suitable support NOT operate a hoist unless load slings or other approved single attachments are properly sized and seated in the hook saddle Take up slack carefully make sure load is balanced and load holding action is secure before continuing Shut down a hoist that malfunctions or performs unusually and report such malfunction Improper operation of a hoist can create a potentially hazardous situation which if not avoided could result in death or serious injury To avoid such a potentially hazardous situation the operator shall Trouble Shooting 1 Maintain a firm footing or be otherwise secured when operating the hoist 2 Check brake function by tensioning the hoist prior to each lift operation 3 Use hook latches Latches are to retain slings chains etc under slack conditions only 4 Make sure the hook latches are closed and not supporting any parts of the load 5 Make sure the load is free to move and will clear all obstructions
45. s been capsized between the strands of chain during packing shipment and or handling Reverse the capsize to remove twists Single Phase Systems Manual Slow Blow Fuses Disconnect or Inverse Time Switch Circuit Breakers Black T Holst Power 1 1 Ground Therma Overload Relay Green Yellow 207 Receptacle Rated for 15 Amps Minimum 220 1 50 units do not include Power Cord Plug Wire Blue and Brown Wires to Fuses or Circuit Breakers and Green Yellow Wire to Ground Three Phase Systems 1 1 L1 1 Black Bg 2 rz 52 13 be amp Groun i Green Yellow Hoist Power Cord Manual Disconnect Switch Must be per National Electrical Code and These Devices are to be Supplied by the User Slow Blow Fuses or Inverse Time Circuit Breakers Figure 4A CHAIN CONTAINER If the chain container is to be used attach it to the hoist per the instructions provided OPERATING INSTRUCTIONS The hoist is equipped with a Protector that is designed to allow the first gear to slip on an excessive overload An overload is indicated when the hoist speed slows down it raises the load in a jerky manner or it will not lift the load at all Also some clutching noise may be heard if the hoist is loaded beyond rated capacity Should this occur immediately release the UP button to stop the operation of the hoist At this point the load should be reduced to the rat
46. sts Loose End Ring 220 1 50 Hoists 1 20786 Chain Stop Sure Stop Protector Assembly 6 fom 1 000 Ibs 1000 bs 12 fom 500 lbs 12 fpm 600 lbs 12 fom 1000 Ibs Power Cord 16 fpm 250 amp 300 165 115 1 50 60 Hoists with contactor 1 20516 16 fom 500 Ibs 620 151 220 1 50 Hoists 20 fpm 500 Ibs 220 3 50 60 380 3 50 415 3 50 1 20501 20 fpm 600 Ib s 460 3 60 and 575 3 60 Hoists 24 fpm 250 amp 300 Ibs 620 152 Power Cord Ground Screw 982877 50015 Control Station and Cord Assembly 4 n amm Includes control station cord warning tag pm 2 and upper grommet S 620 112 Protector Thrust Washer Black Control Station for 620 113 Gear Housing Includes 620 114 and 620 115 10 ft lift 20642 15 ft lift 20643 88640 20351 620 114 Protector Bearing Gear Housing Side 88636 20 ft lift 1 20644 620 115 First Pinion Bearing 8635 For other lifts contact CM 5 620 116 Brake Base Plate 0419 620 154 Motor Cover Screw 920719 y Hook Block Single Chained 20995 1 1 620 156 2 620 118 Brake Armature 20420 Hook Block Double Chained 2 20739 Brake Field Includes Brake Coil 620 157 Hook Block Screw Single Chained 2 920730 115 1 50 60 Hoists 1 Hook Block Screw Double Chained 2 920724 620 122 220 1 50 220 3 50 60 380 3 50 415 3 50 1 2 1 1 23030 and 460 3 60 Hoists 620 159 Hook Includes 620 138 575 3 60 Hoists Lalenlek Hook 620 123 Spring 620 160 Dead End Plate Dou
47. ts 24 fpm 7 3 m min lift speeds available on 250 300 500 Ibs 113 136 and 226 kg units 40 fpm 12 2 m min lift speeds available on 250 300 Ibs 113 and 136 kg units 220 1 50 380 to 460 3 50 60 220 to 240 3 50 60 and 575 3 60 units available Lift speeds are based on 60 hertz power supply For 50 hertz power supply lift speeds will be 5 6 of those indicated UL and cUL listed Lifetime Warranty Figure 1B REPAIR REPLACEMENT POLICY All Prostar Electric Chain Hoists are inspected and performance tested prior to shipment If any properly maintained hoist develops a performance problem due to a material or workmanship defect as verified by the factory repair or replacement of the unit will be made to the original purchaser without charge This repair replacement policy applies only to Prostar Hoists installed maintained and operated as outlined in this manual and specifically excludes hoists subject to normal wear abuse improper installation improper or inadequate maintenance hostile environmental effects and unauthorized repairs modifications We reserve the right to change materials or design if in our opinion such changes will improve our product Abuse repair by an unauthorized person or use of non factory replacement parts voids the guarantee and could lead to dangerous operation All Prostar Electric Chain Hoists are backed with a lifetime warranty Refer to the back cover for details
48. ved from the housing wipe the excess grease off the outside surfaces of the Protector with a soft cloth and degrease the remaining gears and housings Upon reassembly add 2 oz of the above grease to gears and housing Also coat the spline on the end of the first pinion and shaft 620 131 with a Molydisulphide lubricant such as Moly Duolube 67 Hercules Packing Co Bearings Rotor bearings 620 102 and 620 103 are pre lubricated and require no lubrication Needle bearings 620 109 620 114 620 115 620 128 and 620 164 are packed at assembly with grease and should not need to be relubricated However if the housings 620 113 and 620 107 liftwheel 620 127 or sheave wheel 620 162 have been degreased these bearings should be greased using Century Lubricants HB 11 3 grease Seals When reassembling the unit wipe the inside surface of the seals 620 108 and 620 130 with Century Lubricants HB 11 43 grease Hook Block If the hook blocks are disassembled for inspection purposes wipe the grease from the hook knob and the hook knob cavities in the hook blocks At reassembly coat the underside of the hook knob and the knob bearing surfaces of cavities in the hook blocks with Molykote BR 2 S Dow Corning Corp grease or equivalent Chain Guide Liftwheel and Sheave Wheel When the hoist is disassembled for inspection and or repair the chain guide stripper sheave wheel on double chain unit and liftwheel must
49. y Columbus McKinnon Corporation hoist is thoroughly inspected and performance tested prior to shipment from the factory If any properly installed maintained and operated hoist as outlined in the applicable accompanying Columbus McKinnon hoist manual develops a performance problem due to defective materials or workmanship as verified by Columbus McKinnon Corporation repair or replacement of the hoist will be made to the original purchaser without charge and the hoist will be returned transportation prepaid AWARNING Alterations or modifications of equipment and use of non factory repair parts can lead to dangerous operation and injury TO AVOID INJURY Do not alter or modify equipment Do not use equipment to lift support or otherwise transport people L Do not suspend unattended loads over people COFFING HOISTS P Country Club Road 140 John James Audubon Parkway P O Box 779 Amherst New York 14228 1197 Wadesboro North Carolina 28170 Phone 800 888 0985 Phone 800 477 5003 Fax 800 210 9480 Fax 800 374 6853 2008CM Printed in USA 12 08 SAFETY PRECAUTIONS Each Prostar Electric Hoist is built in accordance with the specifications contained herein and at the time of manufacture complied with our interpretation of applicable sections of the National Electrical Code ANSI NFPA 70 Installers are required to provide current overload protection and grounding in keeping with the c
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