CM-ET Prostar - Manual (Page 16)

15
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. Needle bearings are 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. (N M)
620-126 Pin Retainer Plate Screw 25 2.8
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 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 lbs
(226, 272 and 453 kg) 125 14.1
Single-reeved, 250, 300 and
500 lbs (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. To install the stator, (Refer to Figure 12 A) and make
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
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 of 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
12A. 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.
10. 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.
lbs. (1.1 NM).
11. After reassembly, test the unit per instructions on page 14.
LOAD CHAIN REMOVAL/INSTALLATION
1. If unit has a chain container, remove it from the chain
guide.
2. Remove the chain stop (620-146). Depress DOWN
button and run chain out of hoist.
3. 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
above in Figure 12C.
4. 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.
5. On the 250, 300 and 500 lbs (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 lbs (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.
Figure 12A Figure 12B Figure 12C
Main Frame
Welds
Down and
Towards
Liftwheel
Wire
Slot
Pin Retainer
Plate
Cut-Out
Device
Main
Frame
Jumpers “2”
and “Cap”
DISASSEMBLY-ASSEMBLY