Rated Load Model Catalog Number Hook Suspension Lug Suspension ¼ Ton Standard Spark Resistant 8260 8260SR 8301 8301SR ½ Ton Standard Spark Resistant 8261 8261SR 8302 8302SR 1 Ton Standard Spark Resistant 8262 8262SR 8303 8303SR 1½ Ton Standard Spark Resistant 8259 8259SR 8300 8300SR 2 Ton (1 Load Chain) Standard Spark Resistant 8263 8263SR 8304 8304SR 2 Ton (2 Load Chains) Standard Spark Resistant 8258 8258SR 8299 8299SR 3 Ton Standard Spark Resistant 8264 8264SR 8305 8305SR 4 Ton Standard Spark Resistant 8265 8265SR 8306 8306SR 5 Ton Standard Spark Resistant 8266 8266SR 8307 8307SR 6 Ton Standard Spark Resistant 8267 8267SR 8308 8308SR January, 2007 Copyright 2007, YaleLift-Tech, division of Columbus Mckinnon Corporation Part No. 113534-89 USA HAND CHAIN HOISTS OPERATION, SERVICE AND PARTS MANUAL
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RatedLoad Model
Catalog Number
Hook Suspension Lug Suspension
¼ TonStandard
Spark Resistant8260
8260SR8301
8301SR
½ TonStandard
Spark Resistant8261
8261SR8302
8302SR
1 TonStandard
Spark Resistant8262
8262SR8303
8303SR
1½ TonStandard
Spark Resistant8259
8259SR8300
8300SR
2 Ton(1 Load Chain)
StandardSpark Resistant
82638263SR
83048304SR
2 Ton(2 Load Chains)
StandardSpark Resistant
82588258SR
82998299SR
3 TonStandard
Spark Resistant8264
8264SR8305
8305SR
4 TonStandard
Spark Resistant8265
8265SR8306
8306SR
5 TonStandard
Spark Resistant8266
8266SR8307
8307SR
6 TonStandard
Spark Resistant8267
8267SR8308
8308SR
January, 2007 Copyright 2007, Yale�Lift-Tech, division of Columbus Mckinnon Corporation Part No. 113534-89
USAHAND CHAIN
HOISTS
OPERATION, SERVICE AND PARTS MANUAL
Page 2
FOREWORDThis book is written to assist in installation, operation,maintenance and service for BUDGIT USA hand chain hoists.Study its contents thoroughly before attempting operation. Byapplying correct operating procedures and practicing the helpfulmaintenance suggestions, you will be assured optimumperformance and service.
It will likely be a long time before you will need the repair andparts information included, so file this book for future reference.
THE INFORMATION CONTAINED IN THIS MANUAL IS FORINFORMATIONAL PURPOSES ONLY AND LIFT-TECHINTERNATIONAL DOES NOT WARRANT OR OTHERWISEGUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHINGOTHER THAN THE COMPONENTS THAT LIFT-TECHMANUFACTURES AND ASSUMES NO LEGALRESPONSIBILITY (INCLUDING, BUT NOT LIMITED TOCONSEQUENTIAL DAMAGES) FOR INFORMATIONCONTAINED IN THIS MANUAL.
INFORMATION CONTAINED IN THIS MANUAL IS SUBJECTTO CHANGE WITHOUT NOTICE.
INDEXSection Page
I GENERAL DESCRIPTION .............................................. 2II INSTALLATION ................................................................ 2III OPERATION .................................................................... 3IV LUBRICATION ................................................................. 4V MAINTENANCE ............................................................... 4VI TROUBLESHOOTING ..................................................... 6VII DISASSEMBLY & REASSEMBLY ................................... 7VIII SPECIAL LOAD REGULATOR INFORMATION ........... 11IX PARTS LISTS ................................................................ 12X CHAIN CONTAINERS ................................................... 29
SECTION I - GENERAL DESCRIPTION1-1. The BUDGIT USA hand chain hoist is a precision builtspur geared hoist designed as a manually operated liftingmechanism for any type of lifting operation (other than lifting orlowering persons) within the rated load of the chain hoist.Operation is by endless hand chain.
This equipment is not designed or suitable as a powersource for lifting or lowering persons.
WARNING
1-2. This book contains installation, operation, service and partsinformation for 1/4,1/2,1,1-1/2,2,3,4,5 and 6 ton rated chainhoists. Two models of each rating for hook suspension hoistsare included; the standard hoist and the spark resistant hoist.Also included are a number of models of lug suspension hoists.All hooks have hook latches as standard. The catalog numberand model number of each hoist is found on the nameplate onthe hoist frame. When ordering parts, always give the catalogand model number of the hoist.
1-3. All BUDGIT USA hand chain hoists are equipped with aLoad Regulator which is designed to help guard againstexcessive overloads. The 1/4,1/2 and 1 ton hoists are similarto each other. Differences that occur are due to load rating andin general affect hook and chain size. The 1-1/2 and singleload chain 2 ton hoists, while similar to each other, differ fromthe other hoists in internal gearing as well as hook and chain
size. The two load chain 2 ton hoist is internally similar to the 1ton hoist differing in parts of chain and hook size. The 3, 4, 5and 6 ton hoists are internally similar to the 1-1/2 and singleload chain 2 ton hoists differing in parts of chain and hooksize. Hoist frames are aluminum alloy. For all models exceptspark resistant models; load chains are welded link type ofspecial calibrated pitch and are heat treated low alloy steel;hand chains are welded link type and are of steel; and hooksare forged steel.
1-4. Spark resistant hoists have components and finishesintended for service in certain hazardous environments.
1-5. On the lug suspension hoist model the top hook has beenreplaced by a suspension lug which allows this hoist to beused with BUDGIT rigid mount I-beam trolleys. The 1 ton hoistrequires a special push trolley; Catalog Number 905409.
1-6. Hoists with a letter suffix of B, C, D, E, For G to thecatalog number have lifts of 10 feet, 12 feet, 15 feet, 20 feet,25 feet and 30 feet respectively. Standard lift is 8 feet.
SECTION II - INSTALLATION2-1. Install the chain hoist by connecting the upper hook totrolley or support (support must have sufficient strength tosupport weight of chain hoist plus applied load). Make surehook latch is closed before using hoist.
Do not suspend chain hoist from tip of hook.
WARNING
2-2. If hand chain is of improper length (chain should hangabout 2'-6" above floor) modify its length following instructionsbelow (two wrenches may be used in place of a wrench and avise):
a. Insert split connecting link in a vise so that three-quartersof the link is above the top of the vise jaws as shown inFigure 2-1.
Figure 2-1.
b. Place wrench on top part of link, tighten jaws. Then twistlink open wide enough to insert ends of chain to be joined.See Figure 2-2.
Figure 2-2.
Page 3
c. Insert ends of chain on open link, make sure there is notwist in the chain.
Figure 2-3.
d. Place wrench on top part of link, tighten jaws and twistback until link is closed.
2-3. For installation of a trolley hoist, follow the instructionsgiven in the trolley literature.
SECTION III - OPERATION
3-1. GENERAL.A BUDGIT USA hand chain hoist is an extremely versatiletool and will perform any number of load handling jobs whenoperated properly and its features are used to advantage.Operation is easy, once you have become acquainted with itsconvenient controls and their functions. Always practice hoistsafety by applying the rules shown in the safety chart on theinside of the back cover.
3-2. TO RAISE LOAD HOOK.While facing the hand chain wheel cover side of the hoist (thiseliminates reaching over the load), pull down on the right handchain to raise the load hook.
3-3. TO LOWER LOAD HOOK.While facing the hand chain wheel cover side of the hoist, pulldown on the left hand chain to lower the load hook.
3-4. OPERATING PRECAUTIONS.Safe operation of an overhead hoist is the operator'sresponsibility. Listed below are some basic rules that can makean operator aware of dangerous practices to avoid andprecautions to take for his own safety and the safety of others.Observance of these rules in addition to frequent examinationsand periodic inspection of the equipment may save injury topersonnel and damage to equipment. Also, see illustratedoperating rules on the inside of the back cover of this manual.
This equipment is not designed or suitable as a powersource for lifting or lowering persons.
WARNING
DO make sure that load slings or other approved singleattachments are properly sized and seated in the hooksaddle.
DO make sure the hook latch is closed and notsupporting any part of the load.
DO make sure that load is free to move and will clearall obstructions.
DO take up slack carefully, check load balance, lift afew inches, and check load holding action beforecontinuing.
DO make sure all persons stay clear of the suspendedload.
DO avoid swinging of load or load hook.
DO protect load chain from weld spatter or otherdamaging contaminants.
DO promptly report any malfunction, unusualperformance, or damage, of the hoist.
DO inspect hoist regularly, replace damaged or wornparts, and keep appropriate records of maintenance.
DO use the hoist manufacturer's recommended partswhen repairing a hoist.
DO use hook latches.
DO apply lubricant to load chain as recommended.
DO NOT lift more than rated load.
DO NOT use the hoist load limiting device to measurethe load.
DO NOT use damaged hoist or hoist that is notworking correctly.
DO NOT use hoist with twisted, kinked, damaged, orworn chain.
DO NOT lift a load unless chain is properly seated inchain wheel(s) or sprocket(s).
DO NOT use load chain as a sling or wrap load chainaround the load.
DO NOT lift a load if any binding prevents equalloading on all supporting chains.
DO NOT apply the load to the tip of the hook.
DO NOT operate unless load is centered under hoist.
DO NOT operate hoist with other than manual power.
DO NOT permit more than one operator to pull on asingle hand chain at one time.
DO NOT allow your attention to be diverted fromoperating the hoist.
DO NOT operate hoist beyond limits of load chaintravel.
DO NOT use hoist to lift, support, or transport people.
DO NOT lift loads over people.
DO NOT leave a suspended load unattended unlessspecific precautions have been taken.
DO NOT allow sharp contact between two hoists orbetween hoist and obstructions.
DO NOT allow the chain or hook to be used as aground for welding.
DO NOT allow the chain or hook to be touched by alive welding electrode.
DO NOT remove or obscure the warnings on the hoist.
DO read ANSI B30.16 Safety Standard for OverheadHoists and the Operation, Service and Parts Manual.
DO be familiar with hoist operating controls, procedures,and warnings.
DO make sure the hoist suspension hook is securelyattached to a suitable support.
DO maintain firm footing or be otherwise secured whenoperating hoist.
WARNING
Page 4
Do Not Oil Load Brake. It is extremely important theload brake friction surfaces be kept free of any oilfilm, so do not apply oil internally.
WARNING
3-5. LOAD REGULATOR.A BUDGIT USA hand chain hoist should not be overloaded;however, if the hoist is subjected to excessive overload theLoad Regulator unit will allow the hand chain to move withoutincreasing the load on the hoist. When this condition occurs,the hoist will continue to support the overload; however, theoverload must be released as soon as possible.
DO NOT adjust or repair a hoist unless qualified toperform hoist maintenance.
DO NOT attempt to lengthen the load chain or repairdamaged load chain.
The user is also here warned that overloading of thehoist can take place by means other than applying ahigh hand chain force. Proper rigging and observanceof the rules listed here can help avoid such externalcauses of overload. Use good common sense andjudgment at all times.
Never operate hoist with hooks that have opened up.See Figure 5-3.
The supporting structure or anchoring means musthave a load rating at least equal to that of the hoist.
Hoist must not be used in locations that will not allowoperator movement to be free of the load.
Before using the hoist, the operator shall be certainthat all personnel in the area are clear of the load.
The Load Regulator clutch can be affected byenvironmental conditions, use and wear to the pointthat is may not operate correctly. Regulator inspection,maintenance and testing is required. See Section VIII.
WARNING
SECTION IV - LUBRICATION
4-1. LUBRICATION OF INTERNAL PARTS.All internal operating parts of the BUDGIT USA hand chainhoist that require lubrication are prelubricated at time ofassembly by the factory. Periodic greasing only isrecommended, and intervals are dependent upon type ofservice. See Section V - Maintenance.
4-2. LUBRICATION OF EXTERNAL PARTS.a. Load chain should always be protected from wear with alightfilm of bar and chain oil, especially when subjected to damp orcorrosive atmospheres.
b. Lubricate lower hooks at the swivel point with bar and chainoil periodically, as required. Lubricate upper hooks with a fewdrops of bar and chain oil.
SECTION V - MAINTENANCE
5-1. GENERAL.The following are preventive maintenance steps which shouldbe performed periodically as operating conditions demand.Under most conditions, a yearly maintenance inspection isadequate. The entire hoist should be dismantled and its partsinspected for damage or wear and replaced as necessary. Atreassembly, the hoist should be relubricated as outlined inparagraph 7-14. If the hoist has been subjected to extremelyadverse conditions, such as excessive dirt or moisture, a morefrequent maintenance inspection should be made. Visuallycheck hoist after each use.
5-2. LOAD BRAKE.If load brake shows a tendency to slip or drag, remove brakeparts, as outlined in paragraph 7-5, and inspect brake frictionsurfaces for signs of damage, wear, dirt, or an oil film. Contactsurfaces of brake flange, ratchet wheel and nut must be free ofexcessive scoring and clean. Faces of friction washers shouldbe lightly wire brushed and buffed. Replace any worn parts.Load brake pawl should also be checked for signs of wear ordamage.
NoteBe sure to keep brake friction surfaces free of oil atreassembly. Lubricate per paragraph 7-14.b.
5-3. LOAD CHAIN.BUDGIT USA hand chain hoist link type load chain is made ofextremely tough, hard surfaced, low alloy steel. However, itshould be inspected regularly for wear (see Figure 5-1), rust orcorrosion. Examine visually for gouges, nicks, weld splatter,corrosion or distorted links. Slacken chain and check bearingsurfaces between links for wear. Case hardness of chain isabout .010" to .015" deep. Chain must be replaced before thecase is worn thru. Also check chain for elongation using avernier caliper (see Figure 5-2). Chain with excessively pitted,corroded, nicked, gouged, twisted or worn links, should bereplaced using factory approved chain. Never weld or attemptto repair coil load chain.
NoteOn spark resistant models, coil load chains are stainlesssteel and must be inspected for wear and lubricatedmore frequently than the standard low alloy heat treatedload chain.
Figure 5-1. Check Chain Wear at BearingSurfaces Between Links
Page 5
Figure 5-2. Checking Coil Chain Using Vernier Caliper
Do not assume that load chain is safe because it measuresbelow replacement points given herein. Other factors, suchas those mentioned in visual checks above, may renderchain unsafe or ready for replacement long beforeelongation replacement is necessary.
CAUTION
When replacing coil load chain, use only factoryapproved chain conforming to factory specificationsfor material, hardness, strength and link dimensions.Chain not conforming to BUDGIT hoist specificationsmay be dangerous as it will not fit in the load sprocketand chain guide correctly, causing damage to hoist,and it will wear prematurely, deform and eventuallybreak.
WARNINGFigure 5-3. Upper Hook Opening
USE ONLY A "KNIFE-EDGE" CALIPER TO ELIMINATEPOSSIBILITY OF FALSE READING BY NOT MEASURINGFULL PITCH LENGTH.
HoistReplace Chain If Measurement
is Greater Than
¼ & ½ Ton 5-13/16"
1 & 2 (2 load chains) Ton 5-11/16"
1½, 2 (1 load chain)& 3 thru 6 Ton
8-1/16"
5-4. HOOKS.Inspect both hooks regularly for evidence of overloading ordamage. Check for proper hook opening, Figure 5-3. If hook isopened beyond the given dimension, replace immediately. Ifhooks are damaged, dismantle hoist and inspect all partsthoroughly. Refer to Section VII for hook removal and installationinstructions.
5-5. TESTING.Regular testing of the hoist is required. See Section VIII.
Hoist Hook
Hook Throat Opening
NormalOpening
Replace Hook IfOpening is Greater than
¼ & ½ Ton¼, ½ & 1 Ton
UpperLower
1-1/8" 1-9/32"
1 & 2 (2 load chains) Ton1½ & 2 Ton
UpperLower
1-1/4" 1-7/16"
1½ & 2 (1 load chain) Ton Upper 1-3/8" 1-9/16"
3 & 4 Ton (except SR)3 Ton
4 Ton (except SR)
UpperLowerLower
1-1/2" 1-23/32"
3 & 4 Ton SR5 & 6 Ton (except SR)
4 Ton SR5 & 6 Ton (except SR)
UpperUpperLowerLower
1-7/8" 2-5/32"
5 & 6 Ton SR5 & 6 Ton SR
UpperLower
2-1/4" 2-9/16"
Hooks, upper or lower, damaged from chemicals,deformation or cracks or having more than 15 percentin excess of normal throat opening or more than 10degrees twist from the plane of the unbent hook, oropened, allowing the hook latch to bypass hook tipMUST BE REPLACED.
Any hook that is twisted or has excessive throatopening, indicates abuse or overloading of the hoist.Other load bearing components of the hoist should beinspected for damage.
WARNING
12394
Page 6
2. Load brake slips and chain hoist willnot support load.
SECTION Vl - TROUBLE SHOOTING
Trouble Probable Cause Remedy
(Continued on following page)
a. Brake friction surfaces coated withexcessive oil or friction washers glazed.
b. Brake parts worn or damaged.
c. Load chain reeved incorrectly.
d. Brake pawl hangs up.
a. Reduce load to within rated hoistcapacity. Hoist should be dismantledand thoroughly inspected for additionaldamage from overloading.
b. Check chain for bent or twisted links,gouges or nicks. Check for wear betweenlinks and gauge chain per paragraph 5-3.Replace if necessary.
c. Clean chain by tumble polishing or cleanwith solvent. Lubricate per Para. 4-2.
d. Clean and inspect sprocket. Replace ifnecessary.
e. Rereeve chain hoist keeping chain freeof twist.
1. Hoist is hard to operate in hoistingdirection.
a. Hoist is overloaded.
b. Load chain is damaged, worn, elongated orbinding between load chain sprocket andguide.
c. Load chain dry, rusty, corroded or dirty withforeign material adhering to chain.
d. Load chain sprocket worn or clogged withforeign material.
e. Chain twisted.
a. Remove and disassemble brake. Clean andbuff surfaces. Install brake. Lubricate perSection 7-14.b before reassembly.
b. Refer to a. above. Replace if scoredexcessively.
c. Remove damaged gears and install newgears. Hoist should be dismantled andthoroughly inspected for additionaldamage from overloading.
d. See items 1.b., 1.c., and 1.d.
a. Remove and disassemble brake. Cleanand buff friction washers or install newwashers. Lubricate per Section 7-14.b.before reassembly.
b. Remove brake parts. Inspect brake parts.Replace worn or damaged parts.
c. Remove load chain and install correctly.(See Figure 7-8.)
d. Check brake pawl engagement andbrake pawl spring.
3. Load brake drags, hard to lowerload. (Hand chain is hard to pull.)
4. Chain hoist works erratically. a. Remove load chain. Install chaincorrectly. (See Figure 7-8.)
b. Remove load brake parts. Inspect parts.Replace damaged parts.
c. Replace frame.
d. Remove interference.
e. Clean and lubricate hand chain.
a. Dirty or corroded internal parts.
b. Brake friction surfaces scored.
c. Load gearing damaged from overloading.
d. Chain binding.
a. Load chain incorrectly installed.
b. Load brake pawl or ratchet teeth wornor damaged
c. Frame cracked or mutilated.
d. Hand chain rubbing on cover.
e. Hand chain hanging up in hand wheel.
a. Replace opened hooks. Hoist should bedismantled and thoroughly inspected foradditional damage from overloading.
5. Hooks opened. a. Chain hoist overloaded.
6. Frame damaged. a. Load chain hoist only to rated capacity.Replace damaged frame. Hoist should bedismantled and thoroughly inspected foradditional damage from overloading.
b. Replace damaged frame.
c. Operate chain hoist properly. Replacedamaged frame.
a. Hoist subjected to overloading.
b. Load chain run too far through chain blockframe.
c. Chain hoist subjected to extreme angularor side pulls, causing chain to bind.
Page 7
6. Frame damaged. (continued) d. Chain hoist damaged by dropping or d. Disassemble chain hoist. Inspect chainthrowing. hoist. Replace damaged parts and
assemble chain hoist. Whenever theframe shows evidence of damage frommisuse or rough handling, the hoistshould be completely dismantled, allparts inspected and damaged or wornparts replaced, as outlined in SectionVII. Always apply the safety rules shownon the inside of the back cover whenusing BUDGITUSA hand chain hoist.
7. Clutch slipping excessively. a. Hoist is overloaded. a. Reduce load to within rated hoistcapacity. Hoist should be dismantledand thoroughly inspected for additionaldamage from overloading.
b. Internal binding. b. See item 6.d.
c. Load brake locked up. c. See item 2.a.
d. Clutch worn. d. Replace clutch.
SECTION Vl - TROUBLE SHOOTING (continued)
Trouble Probable Cause Remedy
Figure 7-1. Lower Hook Connection
SECTION VII - DISASSEMBLY & REASSEMBLY
7-2. GENERAL.The following disassembly procedure applies to all hoists exceptas specifically noted. A complete tear down procedure is given;however, when servicing specific parts, only a partial tear downmay be required.
7-3. REMOVAL OF LOAD CHAIN.a. To remove hook from end of load chain on single load chainhoists, remove snap ring at top of sleeve, slide sleeve frombody halves and separate parts. See Figure 7-1.
12406
b. Remove hex socket head cap screw holding tail end of loadchain to hoist frame.
c. Run load chain out of hoist by pulling on hand chain inlowering direction.
d. On two load chain 2 ton hoists, remove chain connection pinat upper hook bracket (see Figure 9-3a) and pull chain thrulower block; then follow steps b and c above.
e. On 3 and 4 ton hoists, remove one roll pin from chainanchor pin at upper hook bracket and remove chain anchorpin. See Figure 9-4. Pull chain thru lower block and then followsteps b and c above.
f. On 5 and 6 ton hoists, remove one retaining ring from chainanchor pin at lower block and remove chain anchor pin. SeeFigure 9-5. Pull chain thru upper hook assembly and lowerblock and then follow steps b and c above.
7-4. REMOVAL OF HAND CHAIN AND HAND CHAIN WHEEL.a. If load chain has not been removed per paragraph 7-3,operate hoist in lowering direction.
b. Open split connecting link in hand chain (see paragraph 2-2) and pull hand chain from hoist.
c. Remove four hex socket button head cap screws holdinghand chain wheel cover and lift off cover.
d. A self-locking nut on the end of the pinion shaft secures thehand chain wheel. Remove nut, flat washer, brake stop andhand chain wheel.
e. No disassembly of the hand chain wheel is to be attempted.The hand chain wheel contains the Load Regulator which ispreset at the factory. Any adjustment should be undertakenonly by an authorized BUDGIT repair station.
7-5. REMOVAL OF LOAD BRAKE PARTS.a. Pull two friction washers and brake ratchet off shaft of brakeflange while holding brake pawl open. See Figure 7-5.
b. Remove brake pawl spring. To remove pawl, take retainingring off end of pawl pin and remove washer and pawl. Noterelationship of spring retainer plate (if present) to stop in frame.Slide spacer washer and spring retainer plate (where theyoccur) off pawl pin.
c. Unscrewing the load brake flange (counterclockwise) fromthe pinion shaft, will require extra effort. The easiest way is;after removal of the sprocket gear on 1/4, 1/2, 1 and two loadchain 2 ton models (see paragraph 7-6) or the intermediategear on 1-1/2, single load chain 2, and 3 thru 6 ton models(see paragraph 7-7), turn the pinion counterclockwise with a 6
Page 8
Figure 7-2. Removing Load Brake Flange
12504
7-6. REMOVAL OF GEARING (1/4,1/2, 1 and Two Load Chain2 Ton Models).a. Unscrew four hex socket button head cap screws holdinggearcase cover and remove cover.
b. Lift out sprocket gear with integral chain sprocket (load chainmust have been previously removed from hoist).
or 12 point 17 mm hex socket on a flex handle or ratchet andhold the load brake flange with a face spanner resting againstthe brake pawl pin (see Figure 7-2). If it becomes necessary toremove the load brake flange without removing any gearing,hold load brake flange with face spanner and turn pinion shaftwith a 6" or larger crescent wrench fitted over the flat surfaceunder the end thread on the pinion shaft.
d. Do not remove pawl pin unless damaged, requiringreplacement. A self-locking hex nut secures the pawl pin to theframe. This is accessible in the opening in the frame near theupper hook nut (or lug mounting nut). See Figure 7-4.
Note
Do not remove two bushings from their bores in theframe unless they show evidence of wear or damageand require replacement.
c. Remove retaining ring from pinion shaft (on hand wheel sideof frame) and tap out pinion shaft. See Figure 7-3. Ball bearingshould come out with pinion shaft.
Note
Do not remove needle roller bearing from frame unlessit is worn or damaged and replacement is required.
Figure 7-3. Removing Pinion Shaft
d. Pull chain guide out of frame.
7-7. REMOVAL OF GEARING (All Other Models).a. Unscrew six hex socket button head cap screws holdinggearcase cover and remove cover.
b. Lift out intermediate pinion with intermediate gear attachedand with a washer on each end. To separate intermediate gearfrom pinion, press gear off shaft. A woodruff key joins the two.
Note
Do not remove needle roller bearings from frame unlessthey are worn or damaged and require replacement.
c. Remove pinion shaft as outlined in paragraph 7-6.c.
d. Lift out sprocket gear with integral chain sprocket (load chainmust have been previously removed from hoist).
Note
Do not remove needle roller bearings from frame unlessthey are worn or damaged and require replacement.
e. Pull chain guide out of frame.
7-8. REMOVAL OF UPPER HOOK (Hook SuspensionModels).a. Align grooved pin in hook nut with opening in frame anddrive out pin with drift punch. Use drift punch to hold nut whilehook is being unscrewed.
b. Unscrew and remove hook, nut and washer.
Note
Keep hook and nut together as they are drilled atassembly and are not interchangeable.
7-9. REMOVAL OF SUSPENSION LUG (Lug SuspensionModels).a. For 1/4,1/2,1,1-1/2 and single load chain 2 ton hoists, holdnuts with wrench and unscrew two flat head cap screws (hexhead cap screws on 1-1 /2 and single load chain 2 ton models)to remove suspension lug.
Page 9
b. For two load chain 2 ton, 3 and 4 ton hoists, align groovedpin in upper block bolt with opening in frame and drive out pinwith a drift punch. Use drift punch to hold nut while bolt isbeing unscrewed. Unscrew and remove bolt, nut and washer.
Note
Keep bolt and nut together as they are drilled at assemblyand are not interchangeable.
c. For 5 and 6 ton hoists, hold self-locking nuts while unscrewingbolts.
7-10. DISASSEMBLY OF LOWER BLOCKS (3 Thru 6 TonHoists).a. Remove spring pin in sprocket shaft; then remove sprocketshaft, sprocket, bearings and washers.
b. Remove cotter pin in hook nut; hold nut and unscrew hook;remove nut, thrust bearing and thrust washer.
7-11. REASSEMBLY.
7-12. GENERAL.The procedure to be followed for reassembly is in reverseorder of the disassembly steps outlined above. There are;however, certain precautionary steps that must be taken, asoutlined in paragraphs 7-13 thru 7-21 below.
7-13. CLEANING AND INSPECTION OF PARTS.a. Before assembly, all parts should be thoroughly cleanedand inspected to determine their serviceability. Do not washshielded ball bearing (from pinion shaft) out with solvent. Also,hand chain wheel, which contains Load Regulator, should notbe degreased.
b. Grease should be evident at joint between chain wheel andload brake nut and also chain wheel and regulator collar ofLoad Regulator. If not, test hoist per Section VIII to assuregrease has not been baked or washed out by environmentalconditions.
c. Replace parts that are excessively worn or damaged.
7-14. LUBRICATION OF PARTS.a. Lubricate upper and lower hooks with bar and chain oil.Apply on hook shanks and surfaces between hook, frame,washer and nut on upper hooks. Apply on hook shanks andbody halves on lower hooks. Lubricate hook bearings withMOLYKOTE BR2 Plus grease (by Dow Corning) or equal.
b. Lubricate gearing with MOLYKOTE BR2 Plus grease or equal.Apply same grease to sprocket bearing surfaces and apply alight film of this grease to sprocket bushings or bearings. On1½ and 2 ton models, do the same for intermediate gear andpinion. Apply BR2 Plus grease to pinion bearing surfaces andapply a film of this grease to the pinion needle bearing.Lubricate load brake pawl with a small amount of BR2 Plusgrease at support pin and ratchet engagement tip. While makingsure that the load brake friction surfaces do not becomegreased, lubricate the ratchet inner bearing surfaces. Forlubrication of the load brake threads, apply a small amount ofBR2 Plus grease on the leading internal threads of the loadbrake nut which is part of the hand chain wheel assembly.When the hand chain wheel is assembled to the pinion shaftany excess grease will be brought to the end of the pinionshaft where it can be wiped off.
It is extremely important that load brake frictionsurfaces be kept dry, as an oily film may causeslippage, thereby permitting a load to drop.
WARNING
c. Load chain should be lubricated with a light film of bar andchain oil. It is important that the bearing surfaces between thelinks are lubricated. Note Figure 5-1.
7-15. INSTALLING SUSPENSION LUG (Lug SuspensionModels).a. For 1/4, 1/2 and 1 ton models, the flat head hex socket capscrews fastening the suspension lug to the hoist frame mustbe torqued to 70 to 80 foot-pounds.
b. The hex head cap screws for the 1-1/2, single load chain 2,5 and 6 ton models must be torqued to 195 to 205 foot-pounds.The self-locking plastic material in the nuts must be undamagedand resilient.
c. On two load chain 2, 3 and 4 ton models (round nut withpin), be certain original nut is used. The nut side with thegreater distance to the center of the hole on the 2 ton modelshould face the top of hoist. See Figure 7-4.
7-16. INSTALLING UPPER HOOKS (Hook SuspensionModels).When installing upper hook, be certain original nut is used.The nut side with the greater distance to the center of the holeshould face the hook. See Figure 7-4.
Figure 7-4. Installing Upper Hook and Nut
7-17. INSTALLING GEARING.a. Before gearing is installed, be certain chain guide is properlyseated in hoist frame.
b. Press ball bearing, if required, onto pinion shaft beforeinstalling pinion shaft.
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Make sure the brake pawl spring is properly seated.
CAUTION
c. Install hand wheel on pinion shaft. Turn clockwise thru severalclicks of brake pawl to bring brake friction surfaces into contactbefore brake stop (see paragraph 7-18.d, for installation), flatwasher and nut are installed. Lube should be in hand chainwheel threads so that excess is wiped out, not in.
Figure 7-5. Installing Load Brake Pawl
c. On 1-1/2, single load chain 2 and 3 thru 6 ton models, pressintermediate gear onto intermediate pinion shaft (with woodruffkey in place) before installing in frame. Also, remember toreplace the washers on each end of shaft.
7-18. INSTALLING LOAD BRAKE PARTS.a. The threads between the pinion shaft and brake flange areto be clean and dry. Pretreat these threads only with LOCTITEPrimer 'T'. Apply LOCTITE 680 to shaft threads 3/16" fromthread relief (the inside edge). Set pinion shaft in hoist frameand lock with retaining ring. Assemble brake flange to pinionshaft. Torque flange to 25 foot-pounds.
b. After the load brake flange is in place, the order of assemblyis; friction washer, then ratchet, then second friction washer.On the 1/4 and 1/2 ton models only, the friction washers are ofdifferent diameters. The large diameter friction washer goes onfirst, followed by the ratchet and then the smaller diameterfriction washer. On the other models the light colored wovenfriction washer goes on first, followed by the ratchet and thenthe dark colored molded friction washer. The brake pawl andspring are then installed. The brake pawl spring has a closedend. On 1/4 and 1/2 ton hoist models, the open end must beinstalled to the pawl. On other models, the closed end must beinstalled to the pawl. The open end of the spring on 1 and twoload chain 2 ton models goes against the adapter assembly.See Figure 7-5.
Figure 7-6. Brake Stop Position for 1/4 and 1/2 Ton Models
d. Install brake stop in position shown in Figure 7-6 for 1/4 and1/2 ton models or in position shown in Figure 7-7 for othermodels.
Figure 7-7. Brake Stop Position for Other Models
e. To facilitate installation of the load chain, delay replacinghand chain and hand chain wheel cover until after load chainhas been installed.
7-19. INSTALLING LOAD CHAIN
Figure 7-8. Installing Load Chain
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When installing load chain, it is possible to feed it intothe wrong side of hoist, which will result in a reversedhoist action and the load brake will not function.
WARNING
a. Lay hoist on workbench. By rotating hand chain wheel, runload chain thru hoist. The first link into the hoist from the loadside must be a horizontal link (into a horizontal pocket) so thatthe tail chain will be in the proper position for fastening to thehoist frame. Be sure the welded side of the chain links face upso they do not enter the vertical slots of the sprocket. Makesure chain is not twisted. See Figure 7-8.
b. Attach tail end of load chain to hoist frame. On the 1-1/2,single load chain 2 and 3 thru 6 ton models only, there is awasher under the head of the hex socket head cap screwsecuring the chain.
c. On the two load chain 2 and 3 thru 6 ton models, reeve thehoist in accordance with Figure 7-9. Make sure there is notwist in the chain.
Figure 7-9. Reeving for 2 thru 6 Ton Models
d. Anchor the end of the chain as shown in the proper parts listillustration. In order that the last link falls in the correct positionto be anchored, the chain must have an even number of links.
7-20. ASSEMBLY OF LOWER BLOCK.When installing sleeve on single load chain hoists, be certainlarge chamfer in one end is positioned as noted in Figure 7-1.
21. ASSEMBLY OF HAND CHAIN WHEEL COVER AHANDCHAIN.a. Replace hand chain wheel cover and secure with four hexsocket button head cap screws.
b. Feed hand chain over hand chain wheel keeping chain weldsfacing away from wheel. Make sure chain is not twisted. Connectends of hand chain with open split connecting link. Twistconnecting link closed.
c. Lubricate hand chain with a light, rust preventative oil.
d. Check operation of hoist and test in accordance withparagraph 8-2.
SECTION Vlll - SPECIAL LOAD REGULATORINFORMATION
8-1. GENERAL.a. BUDGIT USA hand chain hoists are equipped with a LoadRegulator in the hand chain wheel which is designed to helpguard against excessive overloads.
b. The Load Regulator is preset at the factory. If a BUDGITchain hoist is subjected to excessive overload, the LoadRegulator unit will allow the hand chain to move withoutincreasing the load on the hoist. When this condition occurs,the hoist will continue to support the overload; however, theoverload must be released as soon as possible.
c. Testing of the BUDGIT chain hoist in accordance withparagraph 8-2 is necessary at regular intervals which shouldbe determined by amount and conditions of use.
8-2. TEST PROCEDURE.a. Suspend hoist from an overhead structure capable ofsupporting several times the rated load of the hoist. Positionhoist so that all parts of hoist and test load, when suspendedon load hook, are free of obstructions and can hang in astraight line. Attach the load hook to a test load equal to therated load of the hoist. Operate hand chain to lift the load. Ifslippage occurs and rated load cannot be lifted, the LoadRegulator requires adjustment or replacement. Adjustmentshould be attempted only by an authorized BUDGIT repairstation.
b. If hoist operates properly with rated load on hook, it shouldnext be tested with a load equal to two times rated load. Withthis overload attached to the load hook, complete slippageshould occur. If hand chain wheel does not slip, the LoadRegulator requires adjustment or replacement. Adjustmentshould be attempted only by an authorized BUDGIT repairstation.
c. For Load Regulator adjustment, the complete hoist must bereturned to an authorized BUDGIT repair station. Alternatively,a new hand chain wheel containing the Load Regulator maybe obtained from an authorized BUDGIT repair station.
IMPORTANT
After completion of reassembly and before being placedin service, the BUDGIT USA hand chain hoist should betested with rated load to ensure safe operation.
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SECTION lX - PARTS LIST
Figure 9-1. 1/4 and 1/2 Ton Models
12497B
1 Label - Capacity1/4 Ton BCH-101 BCH-101 BCH-101 21/2 Ton BCH-102 BCH-102 BCH-102 2
* Not available as individual parts.** Round up to next full foot of length.� Drill .078" diameter holes thru frame when replacing metal tacks.�� Drill .159" diameter hole 3/16" deep when replacing metal tack.
Figure 9-3. 1½ and Single Load Chain 2 Ton Models (continued)
* Not available as individual parts.� Drill .078" diameter holes thru frame when replacing metal tacks.� Quantities for trolley hoists only: Ref. No. 13 2 Req'd
* Not available as individual parts.** Round up to next full foot of length.�� Drill .116" diameter hole 7/16" deep when replacing metal tack.��� Drill .078" diameter holes thru frame when replacing metal tacks.
10-2. INSTALLATION INSTRUCTIONS.The BUDGIT chain container is easily installed by followingthe instructions below.
a. Operate hoist so that load hook is in its low position. Thisshortens the loop at the tail end of the load chain so that it willnot interfere during installation of the container. It also allowsthe chain to correctly feed into the container when installationis complete.
b. Remove small parts from shipping bag (packaged withcontainer).
c. Remove hex socket head screw (and washer on 1-1/2, singleload chain 2, and 3 thru 6 ton models only) attaching tail endof load chain to hoist, save screw and allow chain to hangstraight down.
d. Hold chain container bracket onto hoist and fasten tounderside of hoist with hex head screw. Connection to side ofhoist is then to be in the following order: bracket, load chain,and the original hex socket head screw (and washer on 1-1/2,single load chain 2, and 3 thru 6 ton models only). See Figure10-1.
SECTION X - CHAIN CONTAINERS
10-1. GENERAL.
The BUDGIT chain containers listed below are designed to fitthe BUDGIT USA hand chain hoists in this manual only. Otherhoists require different chain containers. All parts required forcorrect installation are packaged with the container assembly.
Figure 10-1. Chain Container Bracket
HoistRatedLoad
Standard Container Spark Resistant Container
LiftCapacity
CatalogNumber
LiftCapacity
CatalogNumber
1/4 &1/2 Ton
15’ 902741 --- ---
25’ 902742 20’ 902760
40 902743 35’ 902761
1 Ton
10’ 902741 --- ---
20’ 902742 15’ 902760
30’ 902743 25’ 902761
1½ & 2*Ton
15' 902750 10' 902765
30' 902751 25' 902766
2** Ton10' 902742 8' 902760
15' 902743 12' 902761
3 & 4Ton
8' 902750 --- ---
15' 902751 12' 902766
5 & 6Ton
10' 902751 8' 902766
* Single Load Chain** Two Load Chain
Tail end of load chain must be connected to assure chaindoes not run out of hoist during lowering.
CAUTION
e. Attach hinged end of container to bracket. The hinge pin is abolt with a self-locking nut.
f. Open, if not already open, split link (see paragraph 2-2) andconnect one end of support chain to hole in chain container.See Figure 10-2. Twist link closed. Do not run load into bottomof container.
Figure 10-1. Chain Container Bracket
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g. Open split link (see paragraph 2-2) and connect loose endof support chain to open hole in outstanding leg of chaincontainer bracket. See Figure 10-3. Twist link closed.
Container must hang parallel to load chain. A tiltedcontainer will cause piling of chain with possible damageto hoist. If necessary, adjust container support chain. Donot run load into bottom of container.
CAUTION
Figure 10-3. Complete Installation
Notes
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A. Seller warrants that its products and parts, when shipped, and itswork (including installation, construction and start-up), whenperformed, will meet applicable specifications, will be of good qualityand will be free from defects in material and workmanship. All claimsfor defective products or parts under this warranty must be made inwriting immediately upon discovery and in any event, within one (1)year from shipment of the applicable item unless Seller specificallyassumes installation, construction or start-up responsibility. All claimsfor defective products or parts when Seller specifically assumesinstallation, construction or start-up responsibility and all claims fordefective work must be made in writing immediately upon discoveryand in any event, within one (1) year from completion of the applicablework by Seller, provided; however, all claims for defective productsand parts made in writing no later than eighteen (18) months aftershipment. Defective items must be held for Seller’s inspection andreturned to the original f.o.b. point upon request. THE ‘FOREGOINGIS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIESWHATSOEVER, EXPRESS, IMPLIED AND STATUTORY,INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS.
WARRANTYWARRANTY AND LIMITATION OF REMEDY AND LIABILITY
B. Upon Buyer’s submission of a claim as provided above and itssubstantiation, Seller shall at its option either (i) repair or replace itsproduct, part or work at either the original f.o.b. point of delivery or atSeller’s authorized service station nearest Buyer or (ii) refund anequitable portion of the purchase price.
C. This warranty is contingent upon Buyer’s proper maintenance andcare of Seller’s products, and does not extend to normal wear andtear. Seller reserves the right to void warranty in event of Buyer’suse of inappropriate materials in the course of repair or maintenance,or if Seller’s products have been dismantled prior to submission toSeller for warranty inspection.
D. The foregoing is Seller’s only obligation and Buyer’s exclusiveremedy for breach of warranty and is Buyer’s exclusive remedyhereunder by way of breach of contract, tort, strict liability or otherwise.In no event shall Buyer be entitled to or Seller liable for incidental orconsequential damages. Any action for breach of this agreementmust be commenced within one (1) year after the cause of actionhas accrued.
Recommended Spare Partsfor Your Budgit USA Hand Chain Hoist
Certain parts of your hoist will, in time, require replacement under normal wear conditions.It is suggested that the following parts be purchased for your hoist as spares for future use.
Note: When ordering parts always furnish Model and Catalog Number of Hoist and lift of hoist onwhich the parts are to be used.
Parts for your hoist are available from your local authorized BUDGIT repair station.For the location of your nearest repair station, write:
A. Seller warrants that its products and parts, when shipped, and itswork (including installation, construction and start-up), whenperformed, will meet applicable specifications, will be of good qualityand will be free from defects in material and workmanship. All claimsfor defective products or parts under this warranty must be made inwriting immediately upon discovery and in any event, within one (1)year from shipment of the applicable item unless Seller specificallyassumes installation, construction or start-up responsibility. All claimsfor defective products or parts when Seller specifically assumesinstallation, construction or start-up responsibility and all claims fordefective work must be made in writing immediately upon discoveryand in any event, within one (1) year from completion of the applicablework by Seller, provided; however, all claims for defective productsand parts made in writing no later than eighteen (18) months aftershipment. Defective items must be held for Seller’s inspection andreturned to the original f.o.b. point upon request. THE ‘FOREGOINGIS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIESWHATSOEVER, EXPRESS, IMPLIED AND STATUTORY,INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS.
WARRANTYWARRANTY AND LIMITATION OF REMEDY AND LIABILITY
B. Upon Buyer’s submission of a claim as provided above and itssubstantiation, Seller shall at its option either (i) repair or replace itsproduct, part or work at either the original f.o.b. point of delivery or atSeller’s authorized service station nearest Buyer or (ii) refund anequitable portion of the purchase price.
C. This warranty is contingent upon Buyer’s proper maintenance andcare of Seller’s products, and does not extend to normal wear andtear. Seller reserves the right to void warranty in event of Buyer’suse of inappropriate materials in the course of repair or maintenance,or if Seller’s products have been dismantled prior to submission toSeller for warranty inspection.
D. The foregoing is Seller’s only obligation and Buyer’s exclusiveremedy for breach of warranty and is Buyer’s exclusive remedyhereunder by way of breach of contract, tort, strict liability or otherwise.In no event shall Buyer be entitled to or Seller liable for incidental orconsequential damages. Any action for breach of this warranty mustbe commenced within one (1) year after the cause of action hasaccrued.
Recommended Spare Partsfor Your Budgit USA Hand Chain Hoist
Certain parts of your hoist will, in time, require replacement under normal wear conditions.It is suggested that the following parts be purchased for your hoist as spares for future use.
Note: When ordering parts always furnish Model and Catalog Number of Hoist and lift of hoist onwhich the parts are to be used.
Parts for your hoist are available from your local authorized BUDGIT repair station.For the location of your nearest repair station, write: