INSTALLATION, OPERATING,

& MAINTENANCE MANUAL

ELECTRIC CHAIN HOIST

Before installing hoist, fill in the information below.

Model Number
Serial No.
Purchase Date

WARNING
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
equipment as directed in manual may cause injury.
Columbus McKinnon Corporation
205 Crosspoint Parkway
Getzville, NY 14068

P/N 192045152 Rev AC December 2023

 CM HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND CANADA

PARTS FOR YOUR HOIST ARE AVAILABLE FROM YOUR LOCAL AUTHORIZED REPAIR STATION. FOR THE
NAME OF THE NEAREST PARTS OR SERVICE CENTER, VISIT OUR WEB SITE WWW.CMWORKS.COM OR
CALL OUR CUSTOMER SERVICE DEPARTMENT AT 800-888-0985.

AN ELECTRONIC COPY OF THIS MANUAL AND THE CM HOIST PARTS AND SERVICES LIST IS AVAILABLE AT:

http://www.cm-et.com/products.aspx?id=23221

WARNING
Follow all instructions and warning for inspecting,
maintaining and operating this hoist.

2
P/N 192045152 Rev AC December 2023
Improper operation of a hoist can create a potentially Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result in hazardous situation which, if not avoided, could result
death or serious injury. To avoid such a potentially hazardous in minor or moderate injury. To avoid such a potentially
situation, THE OPERATOR SHALL: hazardous situation, THE OPERATOR SHALL:
a. NOT operate a damaged, malfunctioning or unusually a. Maintain firm footing or be otherwise secured
performing hoist. when operating the hoist.
b. NOT operate the hoist until you have thoroughly read and b. Check brake function by tensioning the hoist prior
understood this Operating, Maintenance and Parts Manual. to each lift operation.
c. NOT operate a hoist which has been modified. c. Use hook latches. Latches are to retain slings, chains, etc.
under slack conditions only.
d. NOT lift more than rated load for the hoist.
d. Make sure the hook latches are closed and not supporting
e. NOT use hoist with twisted, kinked, damaged, or worn load any parts of the load.
chain.
e. Make sure the load is free to move and will clear
f. NOT use the hoist to lift, support, or transport people. all obstructions.
g. NOT lift loads over people. f. Avoid swinging the load or hook.
h. NOT operate a hoist unless all persons are and remain clear g. Make sure hook travel is in the same direction as shown
of the supported load. on the controls.
i. NOT operate unless load is centered under hoist. h. Inspect the hoist regularly, replace damaged or worn parts,
j. NOT attempt to lengthen the load chain or repair damaged and keep appropriate records of maintenance.
load chain. i. Use factory parts when repairing the unit.
k. Protect the hoist’s load chain from weld splatter or other j. Lubricate load chain per hoist manufacturer’s
damaging contaminants. recommendations.
l. NOT operate hoist when it is restricted from forming a k. NOT use the hoist’s overload limiting clutch to measure
straight line from hook to hook in the direction of loading. load.
m. NOT use load chain as a sling, or wrap chain around load. l. NOT use limit switches as routine operating stops.
n. NOT apply the load to the tip of the hook or to the hook They are emergency devices only.
latch. m. NOT allow your attention to be diverted from operating
o. NOT apply the load unless load chain is properly seated in the hoist.
the chain wheel(s) or sprocket(s). n. NOT allow the hoist to be subjected to sharp contact with
p. NOT apply load if bearing prevents equal loading on all load other hoists, structures, or objects through misuse.
supporting chains. o. NOT adjust or repair the hoist unless qualified to perform
q. NOT operate beyond the limits of the load chain travel. such adjustments or repairs.
r. NOT leave load supported by the hoist unattended unless
specific precautions have been taken.
s. NOT allow the load chain or hook to be used as an electrical
or welding ground.
SAFETY PRECAUTIONS
t. NOT allow the load chain or hook to be touched by a live
welding electrode. Each Prostar Electric Hoist is built in accordance with the specifications
u. NOT remove or obscure the warnings on the hoist. contained herein and at the time of manufacture complied with our
interpretation of applicable sections of the National Electrical Code
v. NOT operate a hoist on which the safety placards or decals (ANSI/NFPA 70). Installers are required to provide current overload
are missing or illegible. protection and grounding in keeping with the code. Check each
w. NOT operate a hoist unless it has been securely attached to installation for compliance with the applicable sections of the code
a suitable support. as well as the National, State and Local Codes that may apply to the
installation. In addition, safety code requirements associated with
x. NOT operate a hoist unless load slings or other approved the operation of a hoist in the inverted (theatrical) position (chain
single attachments are properly sized and seated in the port up), as with any mechanical equipment, vary depending upon
hook saddle. locality. Therefore, before installing the hoist, the user should consult
y. Take up slack carefully - make sure load is balanced and his insurance company and/or local authority to see if a deviation is
load holding action is secure before continuing. required to permit the use of the hoist in this particular application.

z. Shut down a hoist that malfunctions or performs unusually The safety laws for elevators, lifting of people and for dumbwaiters
and report such malfunction. specify construction details that are not incorporated into
the hoists. For such applications, refer to the requirements of
aa. Make sure hoist limit switches function properly. applicable state and local codes, and the American National Safety
ab. Warn personnel of an approaching load. 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.
*Copies of this standard can be obtained from ASME Order Department,
22 Law Drive, PO Box 2300, Fairfield, NJ 07007- 2300, U.S.A.,
www.asme.org, 800-843-2763.
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.

3
P/N 192045152 Rev AC December 2023
HOIST SAFETY IS UP TO YOU...

DO NOT LIFT MORE THAN RATED LOAD. DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD ARE
IN A STRAIGHT LINE.
CHOOSE THE RIGHT HOIST FOR THE JOB...
DO NOT USE LOAD CHAIN AS A SLING.
Choose a hoist with the capacity for
the job. Know the capacities of your
hoists and the weight of your loads.
USE HOIST PROPERLY
Then match them. Be sure hoist is solidly held in the uppermost part of the support
hook arc.
The application, the size and type
of load, the attachments to be used Be sure hoist and load are in a straight line.
and the period of use must also be Do not pull at an angle.
taken into consideration in selecting
the right hoist for the job. Be sure load is hooked securely. Do not tip load the hook. Do not
load hook latch. Hook latch is to prevent detachment of load under
Remember, the hoist was slack chain conditions only.
designed to ease our burden and
carelessness not only endangers the Do not use load chain as a sling. Such usage damages the chain
operator, but in many cases, a valuable load. and lower hook.
Do not operate with hoist head resting against any object. Lift the
load gently. Do not jerk it.

DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST.

DO NOT OPERATE WITH TWISTED, KINKED, OR DAMAGED CHAIN.

INSPECT
All hoists should be visually inspected before
use, in addition to regular, periodic maintenance
inspections.
Inspect hoists for operations warning notices and
legibility.
DO NOT LIFT PEOPLE OR LOADS OVER PEOPLE
Deficiencies should be noted and brought to the attention of
supervisors. Be sure defective hoists are tagged and taken out of
service until repairs are made. LIFT PROPERLY
Under no circumstances should you operate a malfunctioning hoist. Do not lift co-workers with a
hoist.
Check for gouged, twisted,
distorted links and foreign material. Make sure everyone is clear of
Do not operate hoists with twisted, the load when you lift.
kinked, or damaged chain links.
Do not remove or obscure
Load chain should be properly operational warning notices.
lubricated.
Hooks that are bent, worn, or whose MAINTAIN PROPERLY
openings are enlarged beyond CLEANING
normal throat opening should not
be used. If latch does not engage Hoists should be kept clean and free of dust, dirt, moisture, etc.,
throat opening of hook, hoist should which will in any way affect the operation or safety of the equipment.
be taken out of service.
LUBRICATION
Chains should be checked for
deposits of foreign material which Chain should be properly lubricated.
may be carried into the hoist AFTER REPAIRS
mechanism.
Carefully operate the hoist
Check brake for evidence of slippage under load. before returning it to full service.

VIOLATIONS OF ANY OF THE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL INJURY TO THE OPERATOR
OR NEARBY PERSONNEL BY NATURE OF RELEASED LOAD OR BROKEN HOIST COMPONENTS.

4
P/N 192045152 Rev AC December 2023
FOREWORD
This manual contains important information to help you properly install, operate and maintain your hoist for maximum performance,
economy and safety.
Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating procedures and by carrying
out the recommended preventive maintenance suggestions, you will experience long, dependable and safe service. After you have
completely familiarized yourself with the contents of this manual, we recommend that you carefully file it for future reference.
The information herein is directed to the proper installation, use, care and maintenance of the hoist and does not comprise a handbook
on the broad subject of rigging.
Rigging can be defined as the process of lifting and moving heavy loads using hoists and other mechanical equipment. Skill acquired
through specialized experience and study is essential to safe rigging operations. For rigging information, we recommend consulting a
standard textbook on the subject.

TABLE OF CONTENTS LIST OF TABLES

Master Parts Depots And Service Centers���������������������������������������� 2
TABLE DESCRIPTION PAGE
Safety Precautions����������������������������������������������������������������������������� 3
1 Specifications�������������������������������������������������������������������� 6
Foreword ������������������������������������������������������������������������������������������� 5
2 Nominal Voltage����������������������������������������������������������������� 8
3 Start-up Voltage����������������������������������������������������������������� 8
SPECIFICATIONS
4 Adequate Power Supply���������������������������������������������������� 8
Prostar Electric Chain Hoists������������������������������������������������������������� 6
5 Inspection Table ............................................................... 11
Repair/Replacement Policy���������������������������������������������������������������� 6
6 Electrical Data for Components��������������������������������������� 17
Accessories���������������������������������������������������������������������������������������� 6
7 Torque Settings���������������������������������������������������������������� 18
INSTALLATION
Unpacking������������������������������������������������������������������������������������������ 7 LIST OF ILLUSTRATIONS
Mounting the Hoist����������������������������������������������������������������������������� 7
FIG. DESCRIPTION PAGE
Power Supply System������������������������������������������������������������������������ 7
1 Chain Container����������������������������������������������������������������� 6
Three Phase Hoists���������������������������������������������������������������������������� 8
2 Latchlok Hook�������������������������������������������������������������������� 6
Checking for Adequate Voltage at Hoist�������������������������������������������� 8
3 Single Phase Systems������������������������������������������������������� 7
4 Three Phase Systems�������������������������������������������������������� 7
OPERATION
5 Nameplate������������������������������������������������������������������������� 8
General����������������������������������������������������������������������������������������������� 9
6 Hoist Components������������������������������������������������������������� 8
7 Hook Inspection��������������������������������������������������������������� 12
MAINTENANCE
8 Chain Inspection�������������������������������������������������������������� 13
Inspection����������������������������������������������������������������������������������������� 10
9 Chain Wear Areas������������������������������������������������������������ 13
Preventive Maintenance������������������������������������������������������������������� 10
10 Chain Identification���������������������������������������������������������� 13
Inspection Table������������������������������������������������������������������������������� 11
11 Brake Field Assembly������������������������������������������������������ 14
Hook Inspection������������������������������������������������������������������������������� 12
12 Drive Shaft Assembly������������������������������������������������������ 14
Hook Replacement Criteria�������������������������������������������������������������� 12
13 Brake Assembly��������������������������������������������������������������� 14
Inspecting The Load Chain�������������������������������������������������������������� 12
14 Main Frame���������������������������������������������������������������������� 18
Lubrication���������������������������������������������������������������������������������������� 13
15 Stator Installation������������������������������������������������������������� 18
Electric Brake����������������������������������������������������������������������������������� 14
16 Chaining Hoist����������������������������������������������������������������� 18
17 Chaining Diagram������������������������������������������������������������ 19
TROUBLESHOOTING
18 Chain Stop����������������������������������������������������������������������� 19
General��������������������������������������������������������������������������������������������� 15
19 Cutting Chain by Nicking������������������������������������������������� 19
20 Cutting Chain with a Bolt Cutter�������������������������������������� 19
ELECTRICAL DATA
Open or Short Circuit in Electrical Components������������������������������ 17

DISASSEMBLY-ASSEMBLY
General��������������������������������������������������������������������������������������������� 18
Load Chain Removal/Installation����������������������������������������������������� 18
Cutting Chain����������������������������������������������������������������������������������� 18
Testing���������������������������������������������������������������������������������������������� 19

5
P/N 192045152 Rev AC December 2023
 Figure 2 – Latchlok Hook

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
Figure 1 – Chain Container 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
SPECIFICATIONS or inadequate maintenance, hostile environmental effects and
unauthorized repairs/modifications.
The Prostar Electric Chain Hoist is a highly versatile materials
handling device that can be used to lift loads that are within its rated We reserve the right to change materials or design if, in our opinion,
capacity. The mechanical features of these hoists include an alloy such changes will improve our product. Abuse, repair by an
liftwheel, load-limiter, hardened steel chain guides, hardened steel unauthorized person, or use of non-factory replacement parts voids
load chain, hardened steel gear train, life-time lubrication, forged the guarantee and could lead to dangerous operation. All Prostar
steel hooks, and lightweight aluminum frame. The electrical features Electric Chain Hoists are backed with a lifetime warranty. Refer to
included hoist-duty motor, rugged hoist brake, magnetic reversing the back cover for details and limitations.
contactor and voltage conversion board (dual voltage units).
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 Alterations or modification of hoist and use of non-factory repair
and warnings are not followed. Before using this hoist, each operator parts can lead to dangerous operation and injury.
should become thoroughly familiar with all warnings, instructions, TO AVOID INJURY:
and recommendations in this manual.
Retain this manual for future reference and use. • Do not alter or modify equipment.
• Do use only factory replacement parts.
Forward this manual to the hoist operator. Failure to operate the
equipment as directed in the manual may cause injury. Before
putting hoist into service, fill in the information below. Refer to the ACCESSORIES
hoist identification plate.
HOOK SUSPENSIONS
Model Number
Swivel and rigid type hook suspensions are available for all Prostar
Serial No. Electric Hoists. However, swivel type hook suspensions are normally
recommended for most applications.
Purchase Date
Voltage LATCHLOK®HOOKS
Rated Load CM’s Latchlok hooks are available (Figure 2) to replace the standard
upper and lower hooks used on the Prostar Electric Hoists.
Table 1 – Specifications
BC SERIES BEAM CLAMPS
6 12 13.3 16 20 24 40
Lift 8 fpm The beam clamps are ideal as anchors for rigging applications. The
fpm fpm fpm fpm fpm fpm fpm
BC series clamps can be adjusted to fit a wide range of beam sizes.
250 lb x x x The lightweight and compact design makes the beam clamps ideal
300 lb x x x for repeated set-ups and tear-downs.
500 lb x x x x x
550 lb x x x
600 lb x x x ENTERTAINMENT RIGGING PRODUCTS
1000 lb x x x Refer to sales Bulletin No. EPD-10B for additional rigging products
1100 lb x x x that can be used in the entertainment industry.
PROSTAR ELECTRIC CHAIN HOISTS
CHAIN CONTAINER
220-1-50, 380 to 460-3-50/60, 220 to 240-3-50/60 & 575-3-60. Lift
speeds are based on 60 hertz power supply. For 50 hertz power If the chain container (Figure 1) is to be used, attach it to the hoist
supply lift speeds will be 5/6 of those indicated. per the instructions provided.

6
P/N 192045152 Rev AC December 2023
INSTALLATION
UNPACKING
Failure to properly ground the hoist presents the danger of electric
After opening the carton, carefully inspect the hoist frame, cords, shock.
hooks, chain and control station for damage that may have occurred
during shipment. If there is damage, refer to the packing slip TO AVOID INJURY:
envelope. Permanently ground the hoist as instructed in this manual.
Make sure that the power supply to which the hoist is to be
connected is the same as that shown on the identification plate
located on bottom of hoist.

To reduce the risk of electric shock or injury, use indoors only.

Operating a unit with obvious external damage may cause load to Slow Blow Fuses or
Manual
drop and that may result in personal injury and/or property damage. Disconnect Inverse Time Circuit
Switch Breakers
TO AVOID INJURY:
Black Hoist Power
Carefully check unit for external damage prior to installation. Cord
White
MOUNTING THE HOIST Brown
Ground Blue
Attach the hoist to the truss/structure to be lifted using the mounting
hook. 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 Thermal
times the load imposed. If in doubt, consult a registered engineer Overload
Relay
and local building codes. Green-Yellow

Receptacle Rated for 15 amp 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.

An inadequate attachment point may allow the hoist and load to fall Figure 3 – Single Phase Systems
and cause injury and/or property damage.
TO AVOID INJURY: Manual Slow Blow Fuses or
Make sure the attachment point has sufficient strength to hold Disconnect Inverse Time Circuit
Switch Breakers Hoist Power
several times the hoist and its rated load.
Cord

POWER SUPPLY SYSTEM L1

Incoming Power

Black

(Refer to Figure 3 or 4). To insure proper operation, to avoid damage L2 Grey

to hoist and electrical system and to reduce the risk of electric shock L3 Brown
or fire, the branch circuit supplying power to the hoist must:
Ground Green-Yellow
1. Have ample capacity to prevent excessive voltage drop during
starting and operation (refer to Figure 5). 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 Must be per National Electrical Code and These Devices are
minimum, the system should be rated for 15 amps and it should to be Supplied by the User.
have #16 AWG, or larger, wiring.
2. Be in accordance with the National Electrical Code (ANSI/NFPA Figure 4 – Three Phase Systems
70), Canadian Electric Code (CEC/C22.1), and other 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 trackwheels, 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.
5. Include a disconnecting means capable of being locked in the
“open” position.

7
P/N 192045152 Rev AC December 2023
Figure 5 – Nameplate Figure 6 – Hoist Components

For proper operation and to avoid these low voltage problems,

Note voltage (measured at end of the power cord while lifting rated load)
should be as the following chart indicates.
In this manual, nominal voltages are used when referring to power
supply systems. However, with no modification, the Prostar Hoist Table 3 – Start-up Voltage
will operate on a range of voltages as indicated below:
NOMINAL MINIMUM * MIN. VOLTAGE
POWER OPERATING AT INSTANT
Table 2 – Nominal Voltage SUPPLY VOLTAGE OF START
115-1-50/60 108
NOMINAL VOLTAGE TRADITIONAL PRINTED
HERTZ 220-1-50 198
VOLTAGE RANGE CONTACTOR CIRCUIT BOARD
208-3-60 187
230 208-240 60 AVAILABLE AVAILABLE 220-3-50 198
460 440-480 60 AVAILABLE NOT AVAILABLE 230-3-60 207
220 200-240 50 AVAILABLE AVAILABLE 380-3-50 365
380 365-395 50 AVAILABLE AVAILABLE 415-3-50 399
415 400-415 50 AVAILABLE AVAILABLE 460-3-60 414
430 415-430 50 AVAILABLE NOT AVAILABLE 575-3-60 518
575 550-600 60 AVAILABLE NOT AVAILABLE *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
THREE PHASE HOISTS cord to supply power to the hoist. The following charts should be
Since the motor in a three phase hoist can rotate in either direction, used to determine the size wires in the extension cord in order to
depending on the manner in which it is connected to the power minimize the voltage drop between the power source and the hoist.
supply, the direction of hook movement must be checked during the 115-1-50/60 units with contactor, 220-1-50 units and three phase
original installation and each time hoist is moved to a new location units (hoists with black control station)
as follows:
Table 4 – Adequate Power Supply
1. Move the manual disconnect switch handle to the “OFF” position.
2. Connect the BROWN, GREY AND BLACK wires of hoist power
MAXIMUM LENGTH OF EXTENSION CORD
cord to load side of disconnect switch. Connect the GREEN-
YELLOW wire of hoist power cord to power supply ground.
Wire Size Single Phase Hoist Three Phase Hoist
3. Move the manual disconnect switch handle to the “ON” position.
#16 A.W.G. 135 feet(40 m) 245 feet(73 m)
4. Depress the (up) control. If the hook moves in the up direction,
the hoist is ready for operation. If the hook lowers, move #14 A.W.G. 220 feet(66 m) 395 feet(120 m)
the disconnect switch handle to the “OFF” position and #12 A.W.G. 354 feet(107 m) 630 feet(192 m)
interchange the BLACK and BROWN leads at the disconnect
switch. Move the disconnect switch handle to the “ON” After the hoist is suspended from its support and you have made
position and the hoist is now ready for operation. sure the power supply complies with the above, the hoist is ready for
operation.
CHECKING FOR ADEQUATE VOLTAGE AT HOIST On the Double units, cut and discard the ties used to hold the two
The hoist must be supplied with adequate electrical power for proper strands of chain together. With no load on the lower hook, depress
operation and to reduce problems that may result from insufficient the UP button in the control station and raise the lower hook until it
power (low voltage). These include: is about 2 feet below the bottom of the hoist. Check both strands
of chains for twists. Twists occur if the lower hook block has been
• Noisy hoist operation due to brake and/or contactor chatter. capsized between the strands of chain during packing, shipment
• Heating of the hoist motor and other internal components as well and/or handling. Reverse the capsize to remove twists.
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.

8
P/N 192045152 Rev AC December 2023
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 Attaching the load hook to an inadequate support may allow the
jerky manner or it will not lift the load at all. Also, some clutching hoist and load to fall and cause injury and/or property damage.
noise may be heard if the hoist is loaded beyond rated capacity. TO AVOID INJURY:
Should this occur, immediately release the UP button to stop the
operation of the hoist. At this point, the load should be reduced Make sure the structure and the load hook attachment point have
to the rated capacity or the hoist should be replaced with one of the sufficient strength to hold several times the hoist and rated load.
proper capacity. When the excessive load is removed, normal hoist 1. When preparing to lift a load, be sure that the attach-ments to
operation is automatically restored. 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
The Protector™ is susceptible to overheating and wear when slipped hook and load are firmly seated. Continue lift only after you
for extended periods. Under no circumstance should the Protector are assured the load is free of all obstructions.
be allowed to slip for more than a few seconds. 3. Do not load the hoist beyond the rated capacity shown
on the brake end cover. Overloading can cause immediate
Due to the above, the hoist is not recommended for use in any failure of some load-carrying part or create a defect causing
application where there is a possibility of adding to an already subsequent failure at less than rated capacity. When in doubt,
suspended load to the point of overload. This includes dumbwaiter use the next larger capacity of hoist.
installations, containers that are loaded in mid-air, etc. Also, if the
hoist is used at unusual extremes of ambient temperatures, above 4. Do not use this or any other overhead materials handling
150º F (65ºC). or below 15ºF (-9ºC)., changes in lubricant properties equipment for lifting persons or allow people on unsecured
may permit the hoist to raise larger loads than under normal load.
operating conditions and present possibility of damage or injury. 5. Stand clear of all loads and avoid moving a load over heads
On units without contactor (hoists with orange control station) of other personnel. Warn personnel of your intention to move
it is necessary to stop the hoist before changing direction. a load in their area. Do not leave unsecured load over people.
Therefore, when lowering a load, the push button in the control 6. Do not leave the load suspended in the air unattended.
station must be released momentarily before the UP button is
depressed to raise the load. If this is not done, the hoist will 7. Permit only qualified personnel to operate unit.
continue to operate in the down direction while the UP push 8. Do not wrap the load chain around the supporting structure
button is depressed, and it will continue to lower the load until and hook onto itself as a choker chain. Doing this will result in:
the control push button is released. As a result, the direction
must not be reversed quickly (plug reversed). 1. The loss of the swivel effect of the load hook which could
mean twisted chain and a jammed liftwheel.
There are no electrical switches to stop the operation of the hoist
at the upper and lower limits of lift. As a result, it is necessary to 2. The chain could be damaged at the load hook.
release the push button in the control station to stop the hoist 9. After positioning, secure load by using auxiliary cables
components from damage. However, continued, prolonged or and/or chains.
repeated slipping of the Protector will damage the Protector and
cause overheating of the internal hoist components. 10. On the Double-reeved 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
Allowing the hook block to run into the hoist when raising a load before taking up the slack chain.
or allowing the chain stop to run into the hoist when lowering a load
may break the chain and allow the load to drop. 12. Take up a slack load chain carefully and start load easily
to avoid shock and jerking of hoist chain. If there is any
TO AVOID INJURY: evidence of overloading, immediately lower the load
Do not allow the hook block or the chain stop to contact the hoist frame. and remove the excess load.
13. Do not allow the load to swing or twist while hoisting.
Hoist operation is controlled by depressing the control station push
buttons. Depressing the UP push button will move the load hook 14. Never operate the hoist when flammable materials or vapors
toward the hoist head; depressing the DOWN push button will move are present. Electrical devices produce arcs or sparks that
the load hook away from the hoist head. can cause a fire or explosion.
The UP and DOWN buttons are momentary type and the hoist will 15. STAY ALERT! Watch what you are doing and use common
operate in the selected direction as long as the button is held in the sense. Do not use the hoist when you are tired, distracted
depressed position. Release the push button and the hoist will stop. or under the influence of drugs, alcohol or medication causing
diminished control.
It is preferred that the load always be tied off with auxiliary chains
or cables before access to the 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. TO AVOID INJURY:
Note that in such a system, hoist performance and function must
be monitored visually or with the use of load cells. Check the DO NOT Lift more than rated load.
supporting structure to which the load hook is to be attached.
Make sure the attachment point as well as the structure have DO NOT Operate with twisted, kinked or damaged chain.
sufficient strength to withstand several times the load imposed. DO NOT Operate damaged or malfunctioning hoist
If in doubt, consult a registered engineer and local building codes. 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 centered overhoist.
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.

9
P/N 192045152 Rev AC December 2023
MAINTENANCE
INSPECTION
To maintain continuous and satisfactory operation, a regular
inspection procedure must be initiated to replace worn or damaged
parts before they become unsafe. Inspection intervals must be
determined by the individual application and are based on the type
of service to which the hoist will be subjected. The type of service
to which the hoist is subjected can be classified as “Severe”,
“Normal”, or “Stand by Service” per ANSI E1.6-2.
Severe Service: Hoist operates in excess of 200 days a year.
Normal Service: Hoist operates 200 or fewer days a year
but more than 25.
Stand by Service: Hoist operates 25 or fewer days per year
but at least once per year.
Two classes of inspection — frequent and periodic — must be
performed.
Frequent Inspections: Visual examination shall be performed by a
competent person following the items listed in the inspection table
Records of such inspections are recommended.
Periodic Inspections: Inspection shall be performed by a qualified
person following the items listed in inspection table. Records of
this inspection shall be recorded and retained for a minimum of 36
months after the hoist is taken out of service.
Lifting and lowering functions shall be tested under no-load conditions.
(Testing through complete rated lift length is not required). Brake(s)
operation shall be tested under no-load conditions.

Any deficiencies found during inspections are to be corrected

before the hoist is returned to service. Also, the external
conditions may show the need for disassembly to permit a
more detailed inspection, which, in turn, may require the use of
nondestructive type testing.

PREVENTIVE MAINTENANCE
In addition to the above inspection procedure, a preventive
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 14).

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.

10
P/N 192045152 Rev AC December 2023
 Table 5 – Inspection Table

Service Classifications

ITEM
Out of
Severe Normal Stand By Rental
Frequent Inspections

Service

Hoist braking system for proper operation.

Hooks and attachment hardware for correct assembly,

damage, cracks, twists, excessive throat openings, latch
Weekly to Monthly

Prior to Next Use

engagement, and latch operation.
Every 3 Months

or Rental
Monthly

Load chain for adequate lubrication, signs of wear, damaged

links, corrosion, or foreign matter.

Load chain for proper reeving and twists.

Limit switches for function, if equipped

All items listed in Inspection Table for frequent inspections.

Evidence of loose screws, bolts or nuts.

Prior to Reintroduction into Service

Evidence of worn, corroded, cracked or distorted hook block

body, suspension screws, gears, bearings, chain dead end
and chain pin.

Evidence of damage or excessive wear of the lift wheel and

hook block sheave chain pockets.

Link by link inspection of the chain for evidence of excessive

interlink wear and damage.
Periodic Inspections

Every 3 Months

Evidence of chain guide wear or damage where the chain

enters the hoist.
Yearly

Yearly

Yearly

Evidence of excessive wear and/or damage of brake parts.

Proper brake adjustment.

If the hoist is equipped with a reversing contactor, inspect

contactors for functionality and free operation of the interlock.

Electrical cords, grommets, connectors, cables, and control

station enclosure (if applicable) for damage or wear.

Check bearings for excessive wear or damage.

Suspension components for damage, cracks, wear and

correct operation.

Evidence of lubricant leakage.

11
P/N 192045152 Rev AC December 2023
HOOK INSPECTION INSPECTING THE LOAD CHAIN
Hooks damaged from chemicals, deformations or cracks, or any The chain must be inspected at regular intervals, with a minimum of
visibly apparent bend or twist from the plane of the unbent hook, once annually. As the frequency of use increases, the time Intervals
excessive opening or seat wear must be replaced. Also, hooks between inspections must be reduced. During inspection, the chain
that are opened and allow the latch to not engage the tip must be link must be examined along their entire length, including the hidden
replaced. Any hook that is twisted or has excessive throat opening parts. If the lifting equipment is frequently used with a constant lifting
indicates abuse or overloading of the unit. Inspect other load distance or in other words the switch from upward to downward
sustaining parts, hook block screws, load pins and hook block often takes place in the same area, a particularly thorough
bodies for damage. inspection and lubrication is required in that area. Worn chain can
also be an indication of worn hoist components. For this reason, the
On latch type hooks, check to make sure that the latch is not hoist’s chain guides, hook blocks and liftwheel (sprocket) should be
damaged or bent and that it operates properly with sufficient spring examined for wear and replaced as necessary when replacing chain.
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 1. Check to see if chain is dirty or poorly lubricated.
does not operate properly, it should be replaced. See Figure 5 to
determine when the hook must be replaced. 2. Clean the chain with a non-caustic/non-acid type solvent
and make a link by link inspection for wear or cracks in the
Suspension bolts should be replaced any time the suspension is links, twisted or deformed links. Chain with any one of these
removed from the hoist. defects must be replaced.
3. Slack the portion of the chain that normally passes over
HOOK REPLACEMENT CRITERIA the lift-wheel (sprocket) or idler sprocket on multi-reeved
Based on ASME B30.10, hooks shall be removed from service hoist. Examine the chain links for wear. If the wire diameter
if damage such as the following is visible and shall only be returned anywhere on the link measures less than 90% of the nominal
to service when approved by a qualified person: wire diameter, the chain must be replaced.

1. Missing or illegible rated load identification or illegible hook 4. Based upon ASME B30.16, should also be checked for
manufacturers’ identification or secondary manufacturer’s elongation. Select an unworn, un-stretched length of the
identification. chain (at the slack end for example). Suspend the chain
vertically under tension and using a knife blade caliper
2. Excessive pitting or corrosion. Cracks, nicks, or gouges. type gauge, measure the outside length of any convenient
3. Wear—any wear exceeding 10% of the original section number of links, 11 is recommended. Measure the same
dimension of the hook or its load pin. number of links in the used sections and calculate the
percentage in increased length. The chain should be
4. Deformation—any visibly apparent bend or twist from the plane replaced if the length of the used portion is more than 1.5%
of the unbent hook. longer than the unused portion of the chain. Also, if the pitch
of any individual link has elongated by more than 5%, the
5. Throat opening-any distortion causing an increase in the throat
chain should be replaced.
opening of 5% not to exceed 1/4” (6mm).
6. Inability to lock—any self-locking hook that does no lock.
7. Inoperative latch, any damaged latch or malfunctioning latch
that does not close the hook’s throat.
8. Thread wear, damage, or corrosion.
9. Evidence of excessive heat exposure or unauthorized welding.
10. Evidence of unauthorized alterations such as drilling,
machining, grinding, or other modifications.

Figure 7 – Hook Inspection

Latch Type Hook Latchlok® Hook

“A” Max “B” Min “A” Max “B” Min

1.19” (30.2mm) .91” (23.1mm) 1.48” (37.7mm) .75” (18.8mm)

1.31” (33.3mm) 1.08” (27.5mm) 1.48” (37.7mm) .75” (18.8mm)

1.50” (38.1mm) 1.43” (36.2mm) 1.92” (48.8mm) .94” (23.9mm)

12
P/N 192045152 Rev AC December 2023
 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.
Figure 8 – Chain Inspection
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.
When lubricating the chain, apply sufficient lubricant to obtain
natural run-off and full coverage, especially in the interlink area.

Used motor oils contain known carcinogenic materials.

TO AVOID HEALTH INJURIES

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.

Figure 9 – Chain Wear Areas LUBRICATION

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. Contact customer service for more information.

The lubricants used in and recommended for the Prostar Hoist may
contain hazardous materials that mandate specific handling and
disposal procedures.
TO AVOID CONTACT AND CONTAMINATION:
Handle and dispose of lubricants only as directed in applicable
Use only Star (H) grade load chain and factory replacement material safety data sheets and in accordance with applicable
parts. Use of other chain and parts may be dangerous and local, state and federal regulations.
voids factory warranty.

Figure 10 – Chain Identification Part Number for Packaged Lubricants used

on the Prostar Electric Chain Hoists
Use only Star (*) grade load chain and original replacement parts.
Use of other chain and parts may be dangerous and voids factory Part Numbers and Packaged
warranty. Lubricant Usage Type of Lubricant
Quantity of Lubricants
IMPORTANT: Do not use replaced chain for other purposes such Hoist Gears Grease (Special) 28605
as lifting or pulling. Load chain may break suddenly without visual Lower Hook Thrust Heavy Machine Oil obtain
deformation. For this reason, cut replaced chain into short lengths to *Oil
prevent use after disposal. Bearing locally
*These oils are not furnished by CM in Packaged Quantities. When ordering lubricants, specify
the type of lubricant, part number and packages quantity required.

GEARS
Use of commercial or other manufactures’ chain and parts to repair The Protector (620-111) should operate for the normal life of the
hoists may cause load loss. hoist without service. The device has been lubricated and calibrated
TO AVOID INJURY: by the factory and should not be adjusted.
Use only 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.

13
P/N 192045152 Rev AC December 2023
 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
The Protector™ is to be used with “Century Lubricants HB-11, liftwheel must be lubricated with Lubriplate® Bar and Chain Oil 10-R
#3” grease. Do not use any other grease or the Protector will not (Fiske Bros. Refining Co.) prior to reassembly. The lubricant must be
operate properly and parts could be damaged. applied in sufficient quantity to obtain natural runoff
and full coverage of these parts.

The gears and Protector are packed at assembly with grease and LOAD CHAIN
should not need to be renewed unless the gears have been removed Refer to page 14 for lubrication of the load chain.
from the housing and degreased.
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,
Never degrease the Protector™ or attempt to disassemble this
compatible touch-up paint can be purchased from the factory.
device. Degreasing the Protector may damage parts and using a
Refer to page 19 for information on ordering the paint.
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. ELECTRIC BRAKE
The brake is non-adjustable with a nominal .004 inch (0.102 mm) air
Brake Assembly
gap and the brake disc must be replaced when the air gap reaches
Gap
.012 inch (0.305 mm). The brake spacer should be no more than
Brake Base Plate .012 inch (0.305 mm) thicker than the combined thickness of the
Brake Field brake disc and armature plate. Refer to Figure 13.
Assembly-
Includes Coil

First Pinion Brake Armature

Shaft
Brake Spring

Brake Driver

Brake Disc

Figure 11 – Brake Field Assembly

Figure 13 – Brake Assembly

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.
Figure 12 – Drive Shaft Assembly
To inspect the brake gap, disconnect the hoist from power and
remove brake end cover.
If the gears are removed from the housing, wipe the excess grease
off the outside surfaces of the Protector with a soft cloth and 1. Refer to Figure 13 and disassemble the brake. Depress and
degrease the remaining gears and housings. Upon reassembly, hold the field assembly while removing the four brake screws.
add 2 oz. of the above grease to gears and housing. Also, coat the The field assembly is under spring pressure and will spring-out
spline on the end of the first pinion and shaft with a Molydisulphide if not held. Examine the base plate, brake disc) and armature
lubricant such as Moly-Duolube 67 (Hercules Packing Co. for excessive wear, scoring or warpage. Make sure the brake
disc is not glazed, the coil firmly fixed in the field) and the
brake spring is not damaged. Worn, scored, warped,
BEARINGS glazed or damaged parts should be replaced before preceding.
Rotor bearings are pre-lubricated and require no lubrication. Needle 2. Refer to Figure 13 and assemble the brake. Depress and hold
bearings) are packed at assembly with grease and should not need the field assembly while installing the four brake screws through
to be relubricated. However, if the housings, liftwheel or sheave the brake parts and mount the brake on the gear housing.
wheel have been degreased, these bearings should be greased Tighten the four brake screws to 25 in.lb.
using “Century Lubricants HB-11, #3” grease.
PROTECTOR™
SEALS The Protector should operate for the normal life of the hoist without
When reassembling the unit, wipe the inside surface of the seals service. The device has been lubricated and calibrated and it should
with “Century Lubricants HB-11, #3” grease. not be adjusted. If the Protector is not operating properly (see
testing on page 19), it must be replaced with a properly calibrated
unit from the factory.
HOOK BLOCK
If the hook blocks are disassembled for inspection purposes, wipe PREVENTATIVE MAINTENANCE
the grease from the hook knob and the hook knob cavities in the
hook blocks. At reassembly, coat the underside of the hook knob A preventative maintenance program should be established to
and the knob bearing surfaces of cavities in the hook blocks with prolong the useful life of the hoist and maintain its reliability and
Molykote BR-2-S (Dow Corning Corp.) grease or equivalent. continued safe use. The program should include the periodic and
frequent inspections with particular attention being paid to the
lubrication schedule on page 11.

14
P/N 192045152 Rev AC December 2023
TROUBLESHOOTING CHART
Always disconnect unit from the power supply system before removing hoist covers or the back cover of control station.

Symptom Possible Cause(s) Corrective Action

1. Hook does not respond to the control A.) No voltage at hoist-main line or branch circuit switch open; A.) C
 heck for blown fuse or tripped circuit breaker
station branch line fuse blown or circuit breaker tripped. 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 B.) Check electrical continuity thru motor thermal
in circuit; motor thermal protector open; control station contacts protector. If it is open, allow motor to cool. If this
not closing; open or Shorted winding in transformer; transformer does not correct the trouble, use wiring diagram to
thermal cut-out open; mechanical binding in contactor; check electrical continuity of wiring, transformer,
open or shorted winding in contactor coil or blown Printed contactor and control station contacts. Repair
Circuit Board fuse. wiring or replace defective part. Check Printed
Circuit Board fuse & replace if needed.
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
complies with the requirements listed under
“power supply system” starting on page 7.
E.) Brake not releasing due to open or shorted coil, defective diodes E.)Check coil continuity, diodes and connections.
or brake disc binding. Make sure brake 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.
F.) Excessive load. F.) 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, G.) Check for electrical continuity and repair
grounded or faulty connection in one line of power supply system, or replace defective part.
hoist wiring, contactor, motor leads or windings.
2.) Hook moves in the wrong direction. A.) Wiring connections reversed in control station or hoist. A.)Use wiring diagram and check wiring connections.

B.) Failure of cut-out device (single phase units only) to effect B.) Check connections to cut-out device. Replace
dynamic braking at time of reversal. damaged device or faulty capacitor
C.) Phase reversal (three phase unit only). C.) See “Three Phase Hoists.”
3.) Hook lowers but will not raise. A.) Excessive load. A.) S ee item 1F.
B.) Hoisting circuit is OPEN due to loose connections or broken B.) Use wiring diagram to check electrical continuity
wire in circuit; control station contacts are not making; open or of wiring and control station contacts. Repair wiring
shorted winding in contactor coil. or replace defective part.
C.) Motor cut-out device not operating. (single phase units only). C.) Check cut-out device and connections to same.
Repair connections 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 A.) S ee item 1B.
wire; control station contacts not closing; open or shorted
winding in contactor coil.
B.) Motor reversing switch not operating (single phase unit only). B.) See item 3C
C.) Phase reversal (three phase units only). C.) See item 2C
D.) Phase failure (three phase units only). D.) See item 1G.
5.) Hook does not stop promptly. A.) Brake slipping. A.) Check electric brake, 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.) See item 1F.

15
P/N 192045152 Rev AC December 2023
 Symptom Possible Cause(s) Corrective Action
6.) Hoist operates sluggishly. A.) Excessive load. A.) S ee item 1F.
B.) Low voltage. B.) See item 1D.
C.) Phase failure or unbalanced current in the phases C.) See item 1G.
(three phase unit only).
D.) Brake dragging. D.) Check electric brake. 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.
7.) Hoist operates sluggishly. A.Excessive load. A.) S ee item 1F.
B.) Low voltage. B.) See item 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.)See item 6C.
F.) Motor cut-out device not opening start winding circuit (single F.) See item 3C.
phase units only).
G.) Phase failure or unbalanced current in phases (three phase units G.) See Item 1G.
only).
8. Hook fails to stop in either direction. A.) Brake not closing or ineffective. A.)Check electric brake, 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 A.) Phase reversal (three phase units only). A.) See Item 2C.
depressed.

16
P/N 192045152 Rev AC December 2023
 Table 6 – Electrical Data for Components

Strators
Failure to follow proper lockout/tagout procedures may present the
danger of electrical shock. Nominal DC
Volts-Phase-Hertz Full Load Current (amp)
TO AVOID INJURY: Resistance (ohm)
Disconnect power and lockout/tagout disconnecting means before 110 to Yellow to Red: 7.7
removing cover or servicing this equipment. 2.7
120-1-50/60 Blue to Black: 6.2

Yellow to Red: 27.7 Blue

ELECTRICAL DATA 220-1-50 1.1
to Black: 24.2

OPEN OR SHORT CIRCUIT IN ELECTRICAL 220-3-50 1.1 White to Red: 26.8 White
to Black: 26.8
COMPONENTS 230-3-60 0.6 Red to Black: 26.8
Open circuits in electrical components may be detected by isolating
the component and checking for continuity using an ohmmeter. 380-3-50 0.63
Short circuits are indicated by DC resistance substantially below White to Red: 72.6
the nominal DC resistance. Motor current draw should be measured 415-3-50 0.58 White to Black: 72.6
at the end of the power cord while the hoist is raising rated load. Red to Black: 72.6
Check cut-out device (on single phase units only) by measuring coil 460-3-60 0.88
resistance (terminals 3 and 4) and making sure the contact (terminals
2 and 4) is open.
White to Red: 140.0 White
575-3-60 0.4 to Black: 140.0 Red to
Black: 140.0

Transformers

Primary 220/380v. 230/460v. 460v. 575v. 575v.

Secondary 48v. 115v. 48v. 115v. 48v.

Leads Nominal DC Resistance (ohm)

Black to Purple 71.0 11.9 73 98

White to Red 228.0 224.0

White to Yellow 614.0 902.0

Red to Yellow 384.0 682.0

White to Orange 916.0 1100 1100

Coils
Voltage Nominal DC
Item Current Draw (amp)
(V) Resistance (ohm)
115 0.02 765
Contactor Coils
48 0.2 98.4
*115 272
Brake Field **220 1120
***280 1608
Cut-out Device 0.1 Terminals 3 to 4: 0.3

*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,
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 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.

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P/N 192045152 Rev AC December 2023
DISASSEMBLY-ASSEMBLY
When disassembling and assembling the Prostar Hoist, refer to the Pin Retainer Plate
exploded view and the parts list at the web link on page 2 of this
manual. . 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, main
frame, liftwheel and lower sheave wheel. Unless they are to be
replaced, do not attempt to remove these bearings.
2. A liftwheel seal is pressed into the main frame and a seal
is pressed into the end of the liftwheel shaft. Be careful that Wire
Slot
these seals are not cut or damaged during disassembly
and reassembly.

Figure 15 – Stator Installation

9. To install the stator, (Refer to Figure 15) and make sure that the
pin retainer plate has been assembled to the main frame.
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 15. 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 15. On all units slide
stator leads through wire slot. Align the slots in the stator shell
Figure 14 – Main Frame with the threaded holes in the main frame, as shown in Figure 14.
With the leads down, slide the stator into the main frame. Slide
3. Refer to page 14 for disassembly, inspection, reassembly the rotor, large bearing first, into stator. Place the rotor thrust
and adjustment of the brake. washer on top of the exposed rotor bearing and then assemble
the motor end cover to the main frame. Using wiring diagram,
4. Do not attempt to disassemble the Protector™ — complete the wiring at the brake end of the unit.
refer to page 14.
10. Properly install the upper hook as shown in Figure 17, then
5. Refer to page 13 for lubrication instructions. slide the hook retainer into the cavity on top of the hoist and
6. See next section for load chain removal and installation. secure it using hook retainer screw. Tighten screw to a seating
torque of 10 in. lbs. (1.1 NM).
7. Tighten the various screws as follows:
Table 7 – Torque Settings LOAD CHAIN REMOVAL/INSTALLATION
Seating 1. If unit has a chain container, remove it from the chain guide.
Part Name Torque (N·m)
lb·in 2. Remove the chain stop. Depress DOWN button and run chain
Pin Retainer Plate Screw 25 2.8 out of hoist.
Motor Cover Screw 25 2.8
Gear Housing Screw 25 2.8
Brake End Cover Screw 25 2.8
Dead End Plate Screw 125 14.1
Hook Retainer Screw 10 1.1
Hook Block Screw, Double-reeved, 500,
125 14.1
600 and 1,000 lb (226, 272 and 453 kg)
Hook Block Screw, Single-reeved, 250,
50 5.6
300 and 500 lb (113, 136 and 226 kg)
Power Cord Ground Screw 20 2.2

8. When removing the stator , first remove the brake end cover.
Disconnect stator leads from the wiring or contactor. At the
other end, remove the motor end cover. 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 and disconnect the
wires from it. Remove the rotor assembly and thrust washer.
Then slide the stator out of the main frame.
Figure 16 – Chaining Hoist

18
P/N 192045152 Rev AC December 2023
 3. Feed a short length of soft wire through the opening in the • Making sure the chain is not twisted between the hook block
chain guide/stripper until it comes out of the hoist. Attach and hoist, attach the dead end plate to the chain guide/stripper.
“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 • Retrace the new chain and check for twists. If chain is twisted,
and towards the liftwheel as shown above in Figure 16. start over.
4. Jog the UP push button while pulling on the free end of wire IMPORTANT: Do not use “old” chain for other purposes such as
until the chain comes out of the hoist. Remove the wire lifting or pulling. Load chain may break suddenly without visual
and attach the chain stop as shown in Figure 18. On units deformation. For this reason, cut the “old” chain into short lengths
with chain container, place chain stop and loose end of chain to prevent use after disposal.
in chain container. Attach chain container to chain guide.
5. On the 250, 300 and 500 lbs (single reeved), (113, 136 and 226 CUTTING CHAIN
kg) units, remove the hook block from the old chain and attach
it to the new chain by reusing the chain pin. On the 500, 600
and 1000 lbs (226, 272 and 453 kg) units:
• Remove dead end plate from hoist.
• Remove dead end pin 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 with welds down and towards the Figure 19 – Cutting Chain by Nicking
sheave wheel. Hoistaloy® load chain is hardened and it is difficult to cut.
• Reassemble hook block and pull the new chain through the The following methods are recommended when cutting a length
hook block. of new chain from stock or cutting off worn chain. Always wear
eye protection when cutting chain.
• Slide the dead end plate over the last link and secure it using the
1. Use a grinder and nick the link on both sides (see right),
dead end pin. then secure the link in a vise and break off with a hammer.
2. Use a 7” (177 mm) minimum diameter by 1/8” (3.1 mm)
thick abrasive wheel (or type recommended by wheel supplier)
that will clear adjacent links.

Figure 20 – Cutting Chain with a Bolt Cutter

Figure 17 – Chaining Diagram 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 pounds (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 200% 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.

Figure 18 – Chain Stop

19
P/N 192045152 Rev AC December 2023
 WARRANTY
LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES

INDEMNIFICATION AND SAFE OPERATION C. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD
PARTY WITH RESPECT TO ANY GOOD OR REPLACEMENT PART,
Buyer shall comply with and require its employees to comply with directions WHETHER IN CONTRACT, TORT OR OTHER THEORY OF LAW, FOR
set forth in instructions and manuals furnished by Seller and shall use LOSS OF PROFITS OR LOSS OF USE, OR FOR ANY INCIDENTAL,
and require its employees to follow such instructions and manuals and to CONSEQUENTIAL, SPECIAL, DIRECT OR INDIRECT DAMAGES,
use reasonable care in the use and maintenance of the Goods and any HOWSOEVER CAUSED. SELLER’S MAXIMUM LIABILITY TO BUYER
Replacement Parts. Buyer shall not remove or permit anyone to remove WITH RESPECT TO THE GOODS OR ANY REPLACEMENT PART
any warning or instruction signs on the Goods or Replacement Parts. In SHALL IN NO EVENT EXCEED THE PRICE PAID BY BUYER FOR THE
the event of personal injury or damage to property or business arising from GOODS OR REPLACEMENT PART THAT ARE THE SUBJECT OF THE
the use of the Goods or Replacement Parts, Buyer shall within 48 hours APPLICABLE CLAIM.
thereafter give Seller written notice of such injury or damage. Buyer shall
cooperate with Seller in investigating any such injury or damage and in the D. Seller shall not be liable for any damage, injury or loss arising out of the
defense of any claims arising therefrom. use of the Goods or any Replacement Part if, prior to such damage, injury
or loss, such Goods or Replacement Parts are: (1) damaged or misused
If Buyer fails to comply with this section or if any injury or damage is following Seller’s delivery to the carrier; (2) not maintained, inspected, or
caused, in whole or in part, by Buyer’s failure to comply with applicable used in compliance with applicable law and Seller’s written instructions
federal or state laws, rules or regulations safety requirements, Buyer shall and recommendations; or (3) installed, repaired, altered or modified (a) with
indemnify and hold Seller harmless against any claims, loss or expense for any part or accessory other than those supplied by Seller or (b) without
injury or damage arising from the use of the Goods and/or Replacement compliance with such laws, instructions or recommendations.
Parts.
E. This warranty is limited and provided only to the original end user. Each
CMCO Warranty (HOISTS) Good and Replacement Part must be registered within sixty (60)
days of receipt of each product to establish eligibility. Please register
A. Columbus McKinnon Corporation (“Seller”) warrants to the original end at www.cmworks.com/hoist-warranty-registration or submit registration
user (“Buyer”) that, for a period of one (1) year from the date of Seller’s card via US mail.
delivery of the goods (collectively, the “Goods”) to the carrier, the Goods
will be free from defects in workmanship and materials. . In addition, F. A
 ny action against Seller for breach of warranty, negligence or otherwise
Seller warrants to Buyer that, for a period of one (1) year from the date in connection with the electrical components of any Good must be
of their delivery by Seller to the carrier, any aftermarket or replacement commenced by Buyer within one (1) year after: (a) the date any alleged
parts, accessories or components purchased by Buyer with respect to claim accrues; or (b) the date of delivery of the Goods to Buyer,
any Goods (collectively, “Replacement Parts”) will be free from defects in whichever is earlier. Any action against Seller for breach of warranty,
workmanship and materials. negligence or otherwise in connection with the mechanical components
of any Good must be commenced by Buyer within one (1) year after the
B.IN THE EVENT OF ANY BREACH OF ANY SUCH WARRANTY, SELLER’S date any alleged claim accrues. . Any action against Seller for breach of
SOLE OBLIGATION SHALL BE EXCLUSIVELY LIMITED TO, AT THE warranty, negligence or otherwise in connection with any Replacement
OPTION OF SELLER, REPAIR OR REPLACEMENT, F.O.B. SELLER’S Part must be commenced by Buyer within one (1) year after: (y) the date
POINT OF SHIPMENT, OF ANY GOODS OR REPLACEMENT PARTS any alleged claim accrues; or (z) the date of delivery of the Replacement
THAT SELLER DETERMINES TO HAVE BEEN DEFECTIVE OR, IF SELLER Part to Buyer, whichever is earlier.
DETERMINES THAT SUCH REPAIR OR REPLACEMENT IS NOT FEASIBLE,
TO A REFUND OF THE PURCHASE PRICE UPON RETURN OF THE G. This warranty is contingent upon Buyer’s proper maintenance and
OR REPLACEMENT PARTS TO SELLER. NO CLAIM AGAINST SELLER care of the Goods and/or Replacement Parts, and does not extend to
FOR ANY BREACH OF (i) SUCH WARRANTY WITH RESPECT TO THE normal wear and tear. Seller reserves the right, at its option, to void this
ELECTRICAL COMPONENTS OF ANY GOOD OR ANY REPLACEMENT warranty in the event of Buyer’s use with the Goods and/or Replacement
PARTS, SHALL BE VALID OR ENFORCEABLE UNLESS BUYER’S Parts of parts or accessories other than those supplied by Seller.
WRITTEN NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE
(1) YEAR FROM THE DATE OF SELLER’S DELIVERY TO THE CARRIER
AND (ii) SUCH WARRANTY WITH RESPECT TO THE MECHANICAL
COMPONENTS OF ANY GOOD SHALL BE VALID OR ENFORCEABLE
UNLESS BUYER’S WRITTEN NOTICE THEREOF IS RECEIVED BY SELLER
WITHIN ONE (1) YEAR FROM THE DATE THE DATE ANY ALLEGED Alterations or modifications of equipment and use of nonfactory
CLAIM ACCRUES. EXCEPT FOR THE WARRANTIES SET FORTH repair parts can lead to dangerous operation and injury.
ABOVE, SELLER MAKES NO OTHER WARRANTIES WITH RESPECT TO
THE GOODS OR ANY REPLACEMENT PARTS, WHETHER EXPRESSED TO AVOID INJURY:
OR IMPLIED, INCLUDING ANY WARRANTIES OF MERCHANTABILITY, • Do not alter or modify equipment.
FITNESS FOR A PARTICULAR PURPOSE, QUALITY AND/OR THOSE
ARISING BY STATUTE OR OTHERWISE BY LAW OR FROM ANY
• Do use only factory replacement parts.
COURSE OF DEALING OR USE OF TRADE, ALL OF WHICH ARE HEREBY
EXPRESSLY DISCLAIMED.

www.cmco.com
P/N 192045152 Rev AC December 2023
© 2023 Columbus McKinnon Corporation. All Rights Reserved.