Figure 13. CUTTING LOAD CHAIN REMOVAL AND INSTALLATION OF LOAD CHAIN Hoist load chain can be installed by any one of several  methods.    The  first  method  is  recommended when  replacing  severely  worn  load  chain  and  requires disassembling  the  hoist.    Method  2  does  not  require hoist   disassembly,   whereas   Method   3   requires   only partial disassembly. NOTE:  When installing load chain in Models E, H,  R,  RR,  E-2,  H-2,  R-2  and  RR-2  by  either  of  the "starter chain" methods, two loose end connecting links S-743 must be used. Method #1 a) Disconnect hoist from power supply. b) Remove  back  frame  cover  and  disengage  the limit  switch  guide  plate  from  the  traveling  nuts, see page 16. c) Detach   loose   end   of   load   chain   from   hoist frame,   see   Figure   2.      Also   on   single   chain models,  detach  the  lower  hook  block  from  the load chain. On double chain models E, H, R, RR, E-2, H-2, R-2  and  RR-2,  unfasten  the  dead  end  side  of load chain. d) Continue  to  disassemble  the  hoist  and  inspect the  liftwheel,  chain  guides,  motor  housing  and gear  housing  which  if  worn  or  damaged  could cause early failure of the new chain.  Parts can be easily identified by referring to pages 29 and 31. e) If  the  liftwheel  pockets,  in  particular  the  ends, are     worn     or     scored     excessively,     replace liftwheel.  If  chain  guides  and  housing  are  worn or cracked, these parts should also be replaced. f) Reassemble   hoist   with   the   new   load   chain inserted  over  the  liftwheel.    Position  chain  with the weld on upstanding links away from liftwheel and leave only one foot of chain hanging free on loose end side.  Make sure the last chain link is an upstanding link and on double chain models that the new load chain has an even number of links.    This  will  help  prevent  resulting  twist  in chain. To   simplify   handling   when   reassembling   the hoist, a short undamaged piece of the old chain may be used as a "starter chain".  Position this piece  of  chain  in  exactly  the  same  manner  as explained    above    for    the    "new    chain"    and complete the reassembly of the hoist. 15 g) Attach the loose end link to chain and connect it to  the  hoist  frame  with  the  loose  end  screw, washer   and   lockwasher,   see   Figure   2.      BE SURE THERE IS NO TWIST. If a starter chain is used, the loose end link (two links   required   for   double   chain   models)   can serve  as  a  temporary  coupling  link  to  connect together  the  starter  chain  in  the  hoist  and  the new  load  chain  to  be  installed.    Then,  under power,  reeve  the  new  load  chain  through  the liftwheel area, replacing the starter chain in unit. Run  enough  chain  through  to  attach  loose  end link to hoist frame. CAUTION:      For   double   chain   models,   be   sure   to disconnect one of the loose end links from load chain before attaching to hoist frame. h) For  single  chain  models,  attach  the  hook  block to load chain and proceed to step m. For  double  chain  models,  run  the  hoist  r  (UP) until  only  3  feet  in  chain  remains  on  (lead  end side.        This    will    minimize    the    chance    of introducing   a   twist   between   hook   block   and hoist. Replace chain with CM "Star" load chain of the appropriate  size,  embossed  with  *  on  side  of barrels at intervals of approximately 19 inches. i) Allow the chain to hang free to remove twists. j) Using  a  wire  as  a  starter,  insert  the  chain,  flat link first, into lower hook block (upstanding links will have weld toward sheave) and pull through. k) Insert   last   link   into   slot   in   dead   end   block making sure that no twist exists in the reeving at any point. l) Assemble  dead  end  pin,  washer  and  cotter  pin as shown in Figure 2. m) Adjust  limit  switches  as  described  on  page  16 and 17.  If the new load chain is longer than old, check  to  be  sure  limit  switch  will  allow  for  new length of lift.  In the event maximum adjustment does  not  allow  entire  length  of  lift,  check  with the factory for modification necessary. Do  not  allow  hook  block  to  hit  hoist  nor  allow load  chain  to  become  taut  between  loose  end screw  and  frame  or  else  serious  damage  will result.  If hook block should inadvertently hit the hoist   the   hoist   frames,   load   chain   and   hook block  should  be  inspected  for  damage  before further use. Method #2 Treat  the  old  load  chain  in  hoist  as  a  "starter chain" and proceed with Steps la, b, c and f thru m above. Method #3 a) First proceed with Steps la, b, c above. b) Then, carefully run the load chain out of hoist. c) Disconnect hoist from power supply. d) Remove the electric brake assembly. 'e) Rotate the brake hub by hand, at the same time feeding the load chain into and through liftwheel area  with  hoist  upside  down  or  using  a  wire  to pull the load chain up onto liftwheel.