USA HAND CHAIN HOISTS - BudgitHoist

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.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.WARNINGThe 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.SECTION IV - LUBRICATION4-1. 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.SECTION V - MAINTENANCE5-1. 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.WARNINGDo Not Oil Load Brake. It is extremely important theload brake friction surfaces be kept free of any oilfilm, so do not apply oil internally.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.Figure 5-1. Check Chain Wear at BearingSurfaces Between LinksPage 4

USE ONLY A "KNIFE-EDGE" CALIPER TO ELIMINATEPOSSIBILITY OF FALSE READING BY NOT MEASURINGFULL PITCH LENGTH.HoistReplace Chain If Measurementis Greater Than¼ & ½ Ton5-13/16"1 & 2 (2 load chains) Ton5-11/16"1½, 2 (1 load chain)& 3 thru 6 Ton8-1/16"Figure 5-2. Checking Coil Chain Using Vernier CaliperCAUTIONDo 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.12394Hook Throat OpeningHoist¼ & ½ Ton¼, ½ & 1 TonNormalReplace Hook IfHook Opening Opening is Greater thanUpperLower1-1/8"1-9/32"1 & 2 (2 load chains) Ton Upper1½ & 2 TonLower1-1/4"1-7/16"1½ & 2 (1 load chain) Ton Upper1-3/8"1-9/16"3 & 4 Ton (except SR)3 Ton4 Ton (except SR)UpperLowerLower1-1/2"1-23/32"3 & 4 Ton SR5 & 6 Ton (except SR)4 Ton SR5 & 6 Ton (except SR)UpperUpperLowerLower1-7/8"2-5/32"5 & 6 Ton SR5 & 6 Ton SRUpperLower2-1/4"2-9/16"Figure 5-3. Upper Hook OpeningWARNINGWhen 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.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.WARNINGHooks, 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.5-5. TESTING.Regular testing of the hoist is required. See Section VIII.Page 5

SECTION Vl - TROUBLE SHOOTINGTroubleProbable CauseRemedya. Hoist is overloaded.a. Reduce load to within rated hoistcapacity. Hoist should be dismantledand thoroughly inspected for additionaldamage from overloading.b. Load chain is damaged, worn, elongated orbinding between load chain sprocket andguide.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. Load chain dry, rusty, corroded or dirty withforeign material adhering to chain.c. Clean chain by tumble polishing or cleanwith solvent. Lubricate per Para. 4-2.d. Load chain sprocket worn or clogged withforeign material.d. Clean and inspect sprocket. Replace ifnecessary.e. Chain twisted.e. Rereeve chain hoist keeping chain freeof twist.a. Brake friction surfaces coated withexcessive oil or friction washers glazed.a. Remove and disassemble brake. Cleanand buff friction washers or install newwashers. Lubricate per Section 7-14.b.before reassembly.b. Brake parts worn or damaged.b. Remove brake parts. Inspect brake parts.Replace worn or damaged parts.c. Load chain reeved incorrectly.c. Remove load chain and install correctly.(See Figure 7-8.)d. Brake pawl hangs up.d. Check brake pawl engagement andbrake pawl spring.a. Dirty or corroded internal parts.a. Remove and disassemble brake. Clean andbuff surfaces. Install brake. Lubricate perSection 7-14.b before reassembly.b. Brake friction surfaces scored.b. Refer to a. above. Replace if scoredexcessively.c. Load gearing damaged from overloading.c. Remove damaged gears and install newgears. Hoist should be dismantled andthoroughly inspected for additionaldamage from overloading.d. Chain binding.d. See items 1.b., 1.c., and 1.d.a. Load chain incorrectly installed.a. Remove load chain. Install chaincorrectly. (See Figure 7-8.)b. Load brake pawl or ratchet teeth wornor damagedb. Remove load brake parts. Inspect parts.Replace damaged parts.c. Frame cracked or mutilated.c. Replace frame.d. Hand chain rubbing on cover.d. Remove interference.e. Hand chain hanging up in hand wheel.e. Clean and lubricate hand chain.5. Hooks opened.a. Chain hoist overloaded.a. Replace opened hooks. Hoist should bedismantled and thoroughly inspected foradditional damage from overloading.6. Frame damaged.a. Hoist subjected to overloading.a. Load chain hoist only to rated capacity.Replace damaged frame. Hoist should bedismantled and thoroughly inspected foradditional damage from overloading.1. Hoist is hard to operate in hoistingdirection.2. Load brake slips and chain hoist willnot support load.3. Load brake drags, hard to lowerload. (Hand chain is hard to pull.)4. Chain hoist works erratically.b. Load chain run too far through chain blockframe.c. Chain hoist subjected to extreme angularor side pulls, causing chain to bind.b. Replace damaged frame.c. Operate chain hoist properly. Replacedamaged frame.(Continued on following page)Page 6

SECTION Vl - TROUBLE SHOOTING (continued)TroubleProbable CauseRemedy6. Frame damaged. (continued)d. Chain hoist damaged by dropping orthrowing.d. Disassemble chain hoist. Inspect chainhoist. Replace damaged parts andassemble 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 BUDGIT USA 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 VII - DISASSEMBLY & REASSEMBLY7-2. 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.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 22) 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 7-5.12406Figure 7-1. Lower Hook Connectionb. 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.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 6Page 7

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.Figure 7-3. Removing Pinion Shaftd. 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.NoteDo 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).12504Figure 7-2. Removing Load Brake Flange7-6. 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).NoteDo 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.NoteDo not remove needle roller bearing from frame unlessit is worn or damaged and replacement is required.Page 8NoteDo 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.NoteKeep 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.

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.NoteKeep 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.WARNINGIt is extremely important that load brake frictionsurfaces be kept dry, as an oily film may causeslippage, thereby permitting a load to drop.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.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.Figure 7-4. Installing Upper Hook and Nut7-17. 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.Page 9

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.

DO NOT operate hoist with other than manual power. DO NOT permit more than one operator to pull on a single hand chain at one time. DO NOT allow your attention to be diverted from operating the hoist. DO NOT operate hoist beyond limits of load chain travel. DO NOT use hoist to lift, sup