PROSTAR Columbus McKinnon Entertainment Division Operating, Maintenance & 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.
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 code. 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.
Figure 1A Figure 1B SPECIFICATIONS REPAIR/REPLACEMENT POLICY 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 six load ratings. 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.
Claim Procedure Figure 2A Figure 2B 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 range of beam sizes. The lightweight and compact design makes the beam clamps ideal for repeated set-ups and tear-downs. POWER SUPPLY SYSTEM Entertainment Rigging Products Refer to sales Bulletin No. EPD-10B for additional rigging products that can be used in the entertainment industry.
Load Hook Name plate Same Chain Stop Loose End of Chain Power supply Making sure the hoist will operate on the power supply system Figure 3A Control Station Mounting Hook Figure 3B NOTE: IN THIS MANUAL, NOMINAL VOLTAGES ARE USED WHEN REFERRING TO POWER SUPPLY SYSTEMS.
Single Phase Systems Three Phase Systems * Slow Blow Fuses or Inverse Time Circuit Breakers Hoist Power Cord Black White Ground Blue L1 Incoming Power * Manual Disconnect Switch L2 L3 Ground Black Grey Brown Green-Yellow Brown Hoist Power Cord * Thermal Overload Relay Green-Yellow *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.
10° MAX. Black Station for Hoists With Contactor Control Station Depress to Move Load Hook Towards Hoist Head Depress to Move Load Hook Away From Hoist Head Figure 5A Attaching the load hook to an inadequate support may allow the hoist and load to fall and cause injury and/or property damage. TO AVOID INJURY: Make sure the structure and the load hook attachment point have sufficient strength to hold several times the hoist and rated load. 1.
.157 Inches (4 mm) Diameter Vernier Caliper Weld Wear in These Areas Measure 11 Pitches One 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.
Brake Assembly Brake Base Plate First Pinion Shaft Use only Star (H) grade load chain and factory replacement parts. Use of other chain and parts may be dangerous and voids factory warranty. Gap Brake Field AssemblyIncludes Coil Brake Armature Brake Spring Brake Driver Brake Disc Figure 7A Figure 7B 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.
Figure 8A Figure 8B If the gears are removed from the housing, wipe the excess grease off the outside surfaces of the Protector with a soft cloth and degrease the remaining gears and housings. Upon 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.). should be no more than .012 inch (0.
TROUBLE SHOOTING Always disconnect unit from the power supply system before removing hoist covers or the back cover of control station. ––– Probable Cause ––– 1. Hook does not respond to control station. A. No voltage at hoist. B. C.
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. Parts applicable to your hoist should be stocked. KEY. NO. 620-122 620-106 PART QTY. NAME PER HOIST BRAKE FIELD ASSEM. 1 CAPACITOR 1 620-181 TRANSFORMER 1 624-232 CONTROL STATION 1 KEY NO.
Wiring Diagrams THE FOLLOWING WIRING DIAGRAMS ARE REPRESENTATIVE. FOR ACTUAL WIRING DIAGRAM, REFER TO THE DIAGRAM SUPPLIED WITH THE HOIST. NOTE: FOR 575-3-60 UNITS, REFER TO WIRING DIAGRAM SUPPLIED WITH HOISTS.
Wiring Diagrams THE FOLLOWING WIRING DIAGRAMS ARE REPRESENTATIVE. FOR ACTUAL WIRING DIAGRAM, REFER TO THE DIAGRAM SUPPLIED WITH THE HOIST. NOTE: FOR 575-3-60 UNITS, REFER TO WIRING DIAGRAM SUPPLIED WITH HOISTS.
NOTES 14
Welds Down and Towards Liftwheel Pin Retainer Plate Cut-Out Device Main Frame Wire Slot 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: 1. 2. 3. 4. 5. 6. 7.
Single Reeved Loose End of Chain Hook Opening Towards Loose End Double-Reeved Loose End of Chain Hook Opening Away From Loose End Figure 13A • 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 block and hoist, attach the dead end plate to the chain guide/stripper (620-192). • Retrace the new chain and check for twists. If chain is twisted, start over.
CONTROL STATION Key No. 624-232 Part Name 624-252 Control Station (Includes 624-301 thru 624-307) Warning Label (Electrical) 624-301 Control Station Grommet 624-253 624-302 624-303 624-304 624-306 624-307 624-308 Manufacturer Label Control Station Housing Gasket Control Station Button Assembly No. Req’d Part No.
PROSTAR MAIN ASSEMBLY 18
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PROSTAR ELECTRIC HOIST PARTS LIST KEY NUMBER PART NAME Stator 115-1-50/60 Hoists 220-1-50 Hoists 620-100 220-3-50/60 Hoists 380-3-50, 415-3-50 and 460-3-60 Hoists 575-3-60 Hoists 620-101 Rotor Assembly (Includes 620-102 and 620-103) 620-102 Rotor Bearing, Outboard 620-103 Rotor Bearing, Inboard 620-104 Rotor Thrust Washer 620-105 Motor End Cover 620-106 Capacitor 115-1-50/60 Hoists 220-1-50 Hoist 620-107 Main Frame (Includes 620-108 and 620-109) 620-108 Liftwheel Seal 620-109 Protector Bearing, Main F
PROSTAR ELECTRIC HOIST PARTS LIST Part Name Key Number No. Part Req’d Number 620-168 Dead End Plate Screw, (Double chained) 2 Capacity Warning Label 250 lbs.(113Kg) 300 lbs.(136Kg) 500 lbs.(226Kg) 620-169 550 lbs.(250Kg) 600 lbs.(272Kg) 1,000 lbs. (453Kg) 1,100 lbs. 1 1 1 1 1 1 1 620-170 I.D. Label 1 620-171 Warning Label 2 620-173 Wire Nut (not shown, specify No.
LIFETIME WARRANTY Every Columbus McKinnon Corporation hoist is thoroughly inspected and performance tested prior to shipment from the factory.
