Distributed by Tri-State Equipment Company Inc

Transcription

1 Distributed by Tri-State Equipment Company Inc BUDGIT INSTRUCTIONS AND PARTS LIST BUDGIT USA RIGID MOUNT I-BEAM AND PATENTED TRACK TROLLEYS (PUSH & HAND GEARED - / THRU 6 TON RATED LOADS) GENERAL BUDGIT USA Rigid Mount Trolleys are designed especially for use with BUDGIT USA Hand Chain Hoists. They attach directly to suspension lugs of lug mounted model hoists. Trolleys are shipped partially disassembled to make it unnecessary to take them apart before mounting with a hoist. This also makes it easier to properly adjust the trolleys to fit the particular beams on which they are to operate. Trolleys must be correctly fitted to properly support the rated load. Your new BUDGIT USA Rigid Mount Trolley can be assembled to your BUDGIT USA Hand Chain Hoist, and the complete unit then installed on its monorail beam with a minimum of effort by following the directions given herein. Ton Rated Load Push Type Trolley 036 Patented track trolleys are designed to operate on patented track with a 3-/" wide flange. Distributed by Tri-State Equipment Company Inc. sales@tsoverheadcrane.com Web: PH: FAX: THE INFORMATION CONTAINED IN THIS MANUAL IS FOR INFORMATIONAL PURPOSES ONLY AND LIFT-TECH DOES NOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT LIFT-TECH MANUFACTURES AND ASSUMES NO LEGAL RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED IN THIS MANUAL. Ton Rated Load Hand Geared Trolley 038 Figure ASSEMBLY OF TROLLEY TO HOIST Place hoist on workbench, suspension lug facing up, and proceed as follows:. If trolley is a hand geared type rated 3 tons or less, make certain that proper size anti-tilt roller is installed on inside of one side plate before assembling trolley to hoist. Two rollers are provided with each hand geared trolley to accommodate the full range of beam sizes that trolley is designed for. If the trolley is to operate on an I-beam smaller than 0", remove the smaller roller and substitute the larger roller, which is shipped loose. For other than standard I-beams, measure beam flange thickness and allow not less than /6" clearance between roller and bottom of beam flange. July, 00. Before attaching trolley to hoist, first determine proper spacing of trolley side plates to provide adequate wheel clearance (approximately /8") on both sides of I-beam, between inside faces of wheel flanges and edges of bottom beam flange. Proper spacing is obtained by varying number of spacer washers, (furnished with trolley) which are installed on suspension cross pins, between suspension lug and trolley side plates. 3. Due to manufacturing tolerances, I-beams having the same size designation may vary in the width of their flanges. This makes it impossible to prescribe the specific number of spacer washers required between trolley side plates and lug for any particular beam size. As a result the following procedure should be followed: Copyright 00, Yale Lift-Tech division of Columbus McKinnon Corporation Distributed by Tri-State Equipment Company Inc. sales@tsoverheadcrane.com Web: PH: FAX: Part No

2 . Measure exact width of bottom beam flange and add /" to this dimension. This is the required distance between inside faces of wheel flanges to obtain proper operating clearance, as indicated in Figure. OPERATING PRECAUTIONS DO NOT load trolley beyond rated load. DO NOT subject trolley to side loads. Always center trolley over load when hoisting. DO NOT ram trolley into end stops, other trolleys, or any obstruction on beam. Improper and careless operation can result in a hazardous condition for operator and load. ALWAYS be sure load is clear of obstruction before traversing load and trolley. DO NOT stand and DO NOT cause or allow others to stand or get under any load the trolley is supporting. DO keep clear, and make sure others keep clear, of any load the trolley is supporting. WARNING 07A Figure. Sectional View of Trolley Showing Proper Wheel and Washer Spacing These trolleys are not designed nor intended to be used to support or transport people or for supporting or transporting loads over people. 5. An equal number of washers must be removed or added at each end of lug (inside side plates) as required to obtain proper wheel spacing determined in Step. When spacing is correct, remaining spacer washers are to be installed in equal numbers on outside ends of cross pins. Install lock-washers and tighten hex nuts. Note: It is important that all the spacer washers that come with trolley be used. SUSPENDING TROLLEY AND HOIST The hoist and trolley may be installed on I-beams by one of two methods. If the trolley can be slipped directly over end of beam it need not be partially disassembled. If this is impossible, remove hex nuts, lockwashers, outer spacer washers and one side plate from one side of trolley and reassemble on beam. CAUTION Make certain lockwashers are in place on cross pins and hex nuts are tight. Recheck clearance dimensions between wheel flanges and beam flanges. MAINTENANCE AND LUBRICATION. BUDGIT USA Rigid Mount Trolleys are built to give long service, but should be inspected periodically for evidence of damage or wear, particularly when subjected to unusually severe operating conditions.. Lubrication requirements: a. Where wheel axles have lubrication fittings apply light grease a minimum of every six months; more often if required. b. Other wheel bearings are permanently lubricated and require no additional lubricant. c. Drive wheel gears are to be lubricated with an open type gear grease which is heavy, plastic, extreme pressure and tacky; such as MOBILTAC 75 or equal. REPLACEMENT PARTS The following parts lists and illustrations cover standard model BUDGIT USA Rigid Mount Trolleys. Typical units are used as the basis for the exploded parts illustrations; therefore, certain variations may occur from the parts information given. For this reason always give the catalog number and model number. WARNING If trolley is mounted on an open-end beam, end stops must be installed to prevent trolley from running off the end of the beam, resulting in injury to operator and others, including danger to life and limb and damages to load and other property. The numbers assigned to the parts of our various assemblies in our parts list are not the part numbers used in manufacturing the part. They are identification numbers, that when given with the trolley model number, permit us to identify, select or manufacture and ship the correct part needed for any trolley. Distributed by Tri-State Equipment Company Inc. sales@tsoverheadcrane.com Page

3 Notes

4 067B To enable us to expedite your parts order, always give Catalog Number, Model Number and Capacity, found on trolley nameplate. Figure 3. Push Type Rigid Mount Trolley Assembly - (½,, ½, & 3 Ton Rated Loads) Ton ½ & Ton Ref. No / Ton Part Number Part Number 3 Ton Part No. Qty. I-beam Qty. Pat. Trk. Qty. I-beam Qty. Pat. Trk. Qty. Part No. Qty. BT-00 BT-003 BT-005 BT-008 BT-0 BT-0 BT-07 BT-09 BT-0 BT-03 BT-00 BT-00 BT-066 BT-0 BT-05 BT-07 BT-09 BT-0 BT-0 BT-05 BT-35 BT-3 5 BT-006 BT-066 BT-05 BT-006 BT-05 BT-055 BT-0 BT-056 BT-057 BT-07 BT-08 BT-058 BT-059 BT-06 BT-06 BT-063 BT BT-007 BT-00 BT-03 BT-06 BT-08 BT-00 BT-0 BT-05 BT-06 BT-07 BT-08 BT-05 - BT-053 BT-05 BT-08 BT-00 BT-0 BT-05 BT-06 BT-07 BT-08 BT-058 BT-060 BT-06 BT-06 BT-06 BT BT-03 - BT-033 BT-03 BT-035 BT-036 BT-037 BT-038 BT-039 BT-07 BT-08 0 Description Nut - Hex Lockwasher - Spring Type Plate Assembly - Side Washer - Spacer, Wheel Wheel & Axle Assembly Plate - Side (drilled for nameplate) Nut - Hex, Cross Pin Lockwasher - Spring Type Washer - Spacer, Cross Pin Pin - Cross, Suspension Bumper Lockwasher - Spring Type Nut - Hex, Thin Plate Assembly - Side Roller - Anti-tilt Ring - Snap Washer - Spacer, Wheel Axle Ring - Retaining Bearing - Ball Wheel Ring - Retaining Distributed by Tri-State Equipment Company Inc. sales@tsoverheadcrane.com Page

5 To enable us to expedite your parts order, always give Catalog Number, Model Number and Capacity, found on trolley nameplate. 683 Figure. Push Type Rigid Mount Trolley Assembly - (, 5 & 6 Ton Rated Load) Ref. Part Number Qty. No. Ton 5 & 6 Ton Description Req d Plate Assembly - Side BT T-500 For " to 6-/" Flange Widths and Patented Track BT-0 700T-503 For 6-3/8" to 8-5/8" Flange Widths BT-0 700T-506 For 8-3/" to " Flange Widths BT T-5 Bearing - Ball 8 3 BT-0 700T-56 Ring - Retaining Wheel - Plain BT T-58 Standard BT T-50 Patented Track BT T-5 Spark Resistant 5 BT T-53 Ring - Retaining 6 BT T-55 Nut - Hex Jam 7 BT-0 700T-58 Lockwasher 8 BT- 700T-53 Washer - Spacer 0 9 Pin - Suspension BT- 700T-53 For " to 6-/" Flange Widths and Patented Track BT-3 700T-536 For 6-3/8" to 8-5/8" Flange Widths BT- 700T 538 For 8-3/" to " Flange Widths Distributed by Tri-State Equipment Company Inc. sales@tsoverheadcrane.com Page 5

6 068B To enable us to expedite your parts order, always give Catalog Number, Model Number and Capacity, found on trolley nameplate. Figure 5. Hand Geared Rigid Mount Trolley Assembly - (, ½, & 3 Ton Rated Loads) Ton Ref. No. Part Number ½ & Ton 3 Ton I-beam Qty. Pat. Trk. Qty. Part No. Qty. Part No. Qty. Description * BT-0 BT-0 BT-03 BT-05 BT-66 BT-08 BT-0 BT- BT-3 BT- BT-6 BT-7 BT-8 BT-9 BT-0 BT-0 BT-03 BT-05 BT-67 BT-0 BT-68 BT- BT-6 BT-7 BT-8 BT-0 BT-0 BT-0 BT-06 BT-07 BT-09 BT-0 BT- BT-3 BT-5 BT-6 BT-7 BT-0 BT-0 BT-0 BT- BT- BT- BT-5 BT-6 BT-8 BT-6 BT-7 BT-0 BT-0 Nut - Hex, Jam Lockwasher - Spring Type Bumper Plate Assembly - Side Washer - Spacer, Plain Wheel Wheel & Axle Assembly - Plain Pinion & Shaft Assembly Wheel & Axle Assembly - Geared Spacer Washer - Geared Wheel Plate & Tube Assembly (Incl. Ref. ) Bushing - Pinion Shaft Key - Woodruff Lockwasher - Spring Type Nut - Hex Page 6

7 Figure 5. Hand Geared Rigid Mount Trolley Assembly - (continued) Ton Ref. No. Part Number ½ & Ton 3 Ton I-beam Qty. Pat. Trk. Qty. Part No. Qty. Part No. Qty. Description ** BT- BT- BT-3 BT- BT-5 BT-7 BT-9 BT-3 BT-3 BT-35 BT-37 BT as req'd BT- BT- BT-3 BT- BT-5 BT-7 BT-9 BT-3 BT-3 BT-35 BT-60 BT-6 BT-6 BT-63 BT-6 BT-60 BT-6 BT-6 BT-65 BT-6 BT-37 BT as req'd BT- BT- BT-3 BT- BT-6 BT-8 BT-30 BT-3 BT-33 BT-3 BT-36 BT-37 BT-38 as req'd BT- BT- BT-3 BT- BT-5 BT-5 BT-53 BT-55 BT-3 BT-36 BT-37 BT-38 0 as req'd Wheel - Hand Chain Washer - Spacer Ring - Retaining, External Guide - Chain Wheel Nut - Hex Lockwasher - Spring Type Washer, Spacer Bushing, Machinery (not shown) Pin - Cross, Suspension Ring - Snap Roller - Anti-tilt Spacer Ring - Retaining Bearing - Ball Wheel - Geared Axle Spacer Ring - Retaining Bearing - Ball Wheel - Plain Axle Chain, Hand (not shown) Link - Open (not shown) * On ½ & -ton model, wheel shaft nuts on hand wheel side only are special self-locking nuts. Lockwashers are not required. ** Specify length of hand chain required. Length equal two times hoist lift plus one foot. Notes Page 7

8 To enable us to expedite your parts order, always give Catalog Number, Model Number and Capacity, found on trolley nameplate. 686 Figure 6. Hand Geared Rigid Mount Trolley Assembly - (, 5 &6 Ton Rated Load) Ref. Part Number Qty. No. Ton 5 & 6 Ton Description Req d Plate Assembly - Side BT T-800 For " to 6-/" Flange Widths and Patented Track BT T-80 For 6-3/8" to 8-5/8" Flange Widths BT T-80 For 8-3/" to " Flange Widths BT T-8 Bearing - Ball 8 3 BT T-83 Ring - Retaining Wheel - Plain BT T-85 Standard BT T-87 Patented Track BT T-88 Spark Resistant 5 Wheel - Geared BT T-80 Standard BT T-8 Patented Track BT T-83 Spark Resistant 6 BT-6 700T-85 Ring - Retaining 7 BT-6 700T-87 Nut - Hex Jam 8 BT T-830 Lockwasher 9 BT-6 700T-833 Washer - Spacer 0 Page 8

9 Figure 6. Hand Geared Rigid Mount Trolley Assembly - (continued) Ref. Part Number Qty. No. Ton 5 & 6 Ton Description Req d 0 Pin - Suspension BT T-836 For " to 6-/" Flange Widths and Patented Track BT T-838 For 6-3/8" to 8-5/8" Flange Widths BT T-80 For 8-3/" to " Flange Widths BT T-85 Ring - Retaining BT T-86 Pinion 3 BT T-87 Key - Pinion BT-6 700T-88 Screw - Hex Cap 5 BT-6 700T-850 Ring - Retaining 6 BT T-85 Bushing 7 BT-6 700T-85 Plate and Tube Assembly 8 BT T-853 Nut - Self-locking 9 BT T-85 Shaft - Hand Chain Wheel 0 BT T-856 Key - Hand Chain Wheel BT T-857 Washer Guide - Chain BT T-858 For 8-5/8" O.D. Hand Chain Wheel BT T-859 For -5/8" O.D. Hand Chain Wheel 3 Wheel - Hand Chain BT T /8" Outside Diameter BT T-86-5/8" Outside Diameter * Chain - Hand (not shown) BT T-86 Standard As req'd. BT T-863 Spark Resistant As req'd. BT T-86 Link - Open (not shown) * Specify length of hand chain required. Standard length equals two times hoist lift plus '-6". Notes Page 9

10 Notes

11 Notes

12 Recommended Spare Parts for Your Budgit Trolley Certain parts of your trolley will, in time, require replacement under normal wear conditions. It is suggested that the following parts be purchased for your trolley as spares for future use. Set of Wheels Pinion (Hand Geared Trolley Only) Note: When ordering parts always furnish Model Number of Trolley. Parts for your trolley are available from your local authorized BUDGIT/TUGIT repair station. For the location of your nearest repair station, write or phone: YaleŸLift-Tech P.O. Box 769 Muskegon, MI Phone: Fax: WARRANTY WARRANTY AND LIMITATION OF REMEDY AND LIABILITY A. Seller warrants that its products and parts, when shipped, and its work (including installation, construction and start-up), when performed, will meet applicable specifications, will be of good quality and will be free from defects in material and workmanship. All claims for defective products or parts under this warranty must be made in writing immediately upon discovery and in any event, within one () year from shipment of the applicable item unless Seller specifically assumes installation, construction or start-up responsibility. All claims for defective products or parts when Seller specifically assumes installation, construction or start-up responsibility and all claims for defective work must be made in writing immediately upon discovery and in any event, within one () year from completion of the applicable work by Seller, provided; however, all claims for defective products and parts made in writing no later than eighteen (8) months after shipment. Defective items must be held for Seller s inspection and returned to the original f.o.b. point upon request. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. B. Upon Buyer s submission of a claim as provided above and its substantiation, Seller shall at its option either (i) repair or replace its product, part or work at either the original f.o.b. point of delivery or at Seller s authorized service station nearest Buyer or (ii) refund an equitable portion of the purchase price. C. This warranty is contingent upon Buyer s proper maintenance and care of Seller s products, and does not extend to normal wear and tear. Seller reserves the right to void warranty in event of Buyer s use of inappropriate materials in the course of repair or maintenance, or if Seller s products have been dismantled prior to submission to Seller for warranty inspection. D. The foregoing is Seller s only obligation and Buyer s exclusive remedy for breach of warranty and is Buyer s exclusive remedy hereunder by way of breach of contract, tort, strict liability or otherwise. In no event shall Buyer be entitled to or Seller liable for incidental or consequential damages. Any action for breach of this agreement must be commenced within one () year after the cause of action has accrued. Distributed by Tri-State Equipment Company Inc. sales@tsoverheadcrane.com

13 Distributed by Tri-State Equipment Company Inc OPERATION, SERVICE AND PARTS MANUAL USA HAND CHAIN HOISTS Rated Load ¼ Ton ½ Ton Ton ½ Ton Ton ( Load Chain) Ton ( Load Chains) 3 Ton Ton 5 Ton 6 Ton Model Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Standard Spark Resistant Hook Suspension SR 86 86SR 86 86SR SR SR SR 86 86SR SR SR SR Catalog Number Lug Suspension SR SR SR SR SR SR SR SR SR SR January, 007 Copyright 007, YaleŸLift-Tech, division of Columbus Mckinnon Corporation Part No

14 FOREWORD This book is written to assist in installation, operation, maintenance and service for BUDGIT USA hand chain hoists. Study its contents thoroughly before attempting operation. By applying correct operating procedures and practicing the helpful maintenance suggestions, you will be assured optimum performance and service. It will likely be a long time before you will need the repair and parts information included, so file this book for future reference. THE INFORMATION CONTAINED IN THIS MANUAL IS FOR INFORMATIONAL PURPOSES ONLY AND LIFT-TECH INTERNATIONAL DOES NOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT LIFT-TECH MANUFACTURES AND ASSUMES NO LEGAL RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED IN THIS MANUAL. INFORMATION CONTAINED IN THIS MANUAL IS SUBJECT TO CHANGE WITHOUT NOTICE. INDEX Section Page I GENERAL DESCRIPTION... II INSTALLATION... III OPERATION... 3 IV LUBRICATION... V MAINTENANCE... VI TROUBLESHOOTING... 6 VII DISASSEMBLY & REASSEMBLY... 7 VIII SPECIAL LOAD REGULATOR INFORMATION... IX PARTS LISTS... X CHAIN CONTAINERS... 9 SECTION I - GENERAL DESCRIPTION -. The BUDGIT USA hand chain hoist is a precision built spur geared hoist designed as a manually operated lifting mechanism for any type of lifting operation (other than lifting or lowering persons) within the rated load of the chain hoist. Operation is by endless hand chain. size. The two load chain ton hoist is internally similar to the ton hoist differing in parts of chain and hook size. The 3,, 5 and 6 ton hoists are internally similar to the -/ and single load chain ton hoists differing in parts of chain and hook size. Hoist frames are aluminum alloy. For all models except spark resistant models; load chains are welded link type of special calibrated pitch and are heat treated low alloy steel; hand chains are welded link type and are of steel; and hooks are forged steel. -. Spark resistant hoists have components and finishes intended for service in certain hazardous environments. -5. On the lug suspension hoist model the top hook has been replaced by a suspension lug which allows this hoist to be used with BUDGIT rigid mount I-beam trolleys. The ton hoist requires a special push trolley; Catalog Number Hoists with a letter suffix of B, C, D, E, For G to the catalog number have lifts of 0 feet, feet, 5 feet, 0 feet, 5 feet and 30 feet respectively. Standard lift is 8 feet. SECTION II - INSTALLATION -. Install the chain hoist by connecting the upper hook to trolley or support (support must have sufficient strength to support weight of chain hoist plus applied load). Make sure hook latch is closed before using hoist. WARNING Do not suspend chain hoist from tip of hook. -. If hand chain is of improper length (chain should hang about '-6" above floor) modify its length following instructions below (two wrenches may be used in place of a wrench and a vise): a. Insert split connecting link in a vise so that three-quarters of the link is above the top of the vise jaws as shown in Figure -. WARNING This equipment is not designed or suitable as a power source for lifting or lowering persons. -. This book contains installation, operation, service and parts information for /,/,,-/,,3,,5 and 6 ton rated chain hoists. Two models of each rating for hook suspension hoists are 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 number and model number of each hoist is found on the nameplate on the hoist frame. When ordering parts, always give the catalog and model number of the hoist. -3. All BUDGIT USA hand chain hoists are equipped with a Load Regulator which is designed to help guard against excessive overloads. The /,/ and ton hoists are similar to each other. Differences that occur are due to load rating and in general affect hook and chain size. The -/ and single load chain ton hoists, while similar to each other, differ from the other hoists in internal gearing as well as hook and chain Figure -. b. Place wrench on top part of link, tighten jaws. Then twist link open wide enough to insert ends of chain to be joined. See Figure -. Figure -. Page

15 c. Insert ends of chain on open link, make sure there is no twist in the chain. Figure -3. d. Place wrench on top part of link, tighten jaws and twist back until link is closed. -3. For installation of a trolley hoist, follow the instructions given in the trolley literature. SECTION III - OPERATION 3-. GENERAL. A BUDGIT USA hand chain hoist is an extremely versatile tool and will perform any number of load handling jobs when operated properly and its features are used to advantage. Operation is easy, once you have become acquainted with its convenient controls and their functions. Always practice hoist safety by applying the rules shown in the safety chart on the inside of the back cover. WARNING This equipment is not designed or suitable as a power source for lifting or lowering persons. 3-. TO RAISE LOAD HOOK. While facing the hand chain wheel cover side of the hoist (this eliminates reaching over the load), pull down on the right hand chain to raise the load hook TO LOWER LOAD HOOK. While facing the hand chain wheel cover side of the hoist, pull down on the left hand chain to lower the load hook. 3-. OPERATING PRECAUTIONS. Safe operation of an overhead hoist is the operator's responsibility. Listed below are some basic rules that can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others. Observance of these rules in addition to frequent examinations and periodic inspection of the equipment may save injury to personnel and damage to equipment. Also, see illustrated operating rules on the inside of the back cover of this manual. WARNING DO read ANSI B30.6 Safety Standard for Overhead Hoists 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 securely attached to a suitable support. DO maintain firm footing or be otherwise secured when operating hoist. DO make sure that load slings or other approved single attachments are properly sized and seated in the hook saddle. DO make sure the hook latch is closed and not supporting any part of the load. DO make sure that load is free to move and will clear all obstructions. DO take up slack carefully, check load balance, lift a few inches, and check load holding action before continuing. DO make sure all persons stay clear of the suspended load. DO avoid swinging of load or load hook. DO protect load chain from weld spatter or other damaging contaminants. DO promptly report any malfunction, unusual performance, or damage, of the hoist. DO inspect hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance. DO use the hoist manufacturer's recommended parts when 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 measure the load. DO NOT use damaged hoist or hoist that is not working correctly. DO NOT use hoist with twisted, kinked, damaged, or worn chain. DO NOT lift a load unless chain is properly seated in chain wheel(s) or sprocket(s). DO NOT use load chain as a sling or wrap load chain around the load. DO NOT lift a load if any binding prevents equal loading 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 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, support, or transport people. DO NOT lift loads over people. DO NOT leave a suspended load unattended unless specific precautions have been taken. DO NOT allow sharp contact between two hoists or between hoist and obstructions. DO NOT allow the chain or hook to be used as a ground for welding. DO NOT allow the chain or hook to be touched by a live welding electrode. DO NOT remove or obscure the warnings on the hoist. Page 3

16 DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance. DO NOT attempt to lengthen the load chain or repair damaged load chain. The user is also here warned that overloading of the hoist can take place by means other than applying a high hand chain force. Proper rigging and observance of the rules listed here can help avoid such external causes of overload. Use good common sense and judgment at all times. Never operate hoist with hooks that have opened up. See Figure 5-3. The supporting structure or anchoring means must have a load rating at least equal to that of the hoist. Hoist must not be used in locations that will not allow operator movement to be free of the load. Before using the hoist, the operator shall be certain that all personnel in the area are clear of the load LOAD REGULATOR. A BUDGIT USA hand chain hoist should not be overloaded; however, if the hoist is subjected to excessive overload the Load Regulator unit will allow the hand chain to move without increasing the load on the hoist. When this condition occurs, the hoist will continue to support the overload; however, the overload must be released as soon as possible. WARNING The Load Regulator clutch can be affected by environmental conditions, use and wear to the point that is may not operate correctly. Regulator inspection, maintenance and testing is required. See Section VIII. SECTION IV - LUBRICATION -. LUBRICATION OF INTERNAL PARTS. All internal operating parts of the BUDGIT USA hand chain hoist that require lubrication are prelubricated at time of assembly by the factory. Periodic greasing only is recommended, and intervals are dependent upon type of service. See Section V - Maintenance. SECTION V - MAINTENANCE 5-. GENERAL. The following are preventive maintenance steps which should be performed periodically as operating conditions demand. Under most conditions, a yearly maintenance inspection is adequate. The entire hoist should be dismantled and its parts inspected for damage or wear and replaced as necessary. At reassembly, the hoist should be relubricated as outlined in paragraph 7-. If the hoist has been subjected to extremely adverse conditions, such as excessive dirt or moisture, a more frequent maintenance inspection should be made. Visually check hoist after each use. 5-. LOAD BRAKE. If load brake shows a tendency to slip or drag, remove brake parts, as outlined in paragraph 7-5, and inspect brake friction surfaces for signs of damage, wear, dirt, or an oil film. Contact surfaces of brake flange, ratchet wheel and nut must be free of excessive scoring and clean. Faces of friction washers should be lightly wire brushed and buffed. Replace any worn parts. Load brake pawl should also be checked for signs of wear or damage. Note Be sure to keep brake friction surfaces free of oil at reassembly. Lubricate per paragraph 7-.b LOAD CHAIN. BUDGIT USA hand chain hoist link type load chain is made of extremely tough, hard surfaced, low alloy steel. However, it should be inspected regularly for wear (see Figure 5-), rust or corrosion. Examine visually for gouges, nicks, weld splatter, corrosion or distorted links. Slacken chain and check bearing surfaces between links for wear. Case hardness of chain is about.00" to.05" deep. Chain must be replaced before the case is worn thru. Also check chain for elongation using a vernier caliper (see Figure 5-). Chain with excessively pitted, corroded, nicked, gouged, twisted or worn links, should be replaced using factory approved chain. Never weld or attempt to repair coil load chain. Note On spark resistant models, coil load chains are stainless steel and must be inspected for wear and lubricated more frequently than the standard low alloy heat treated load chain. WARNING Do Not Oil Load Brake. It is extremely important the load brake friction surfaces be kept free of any oil film, so do not apply oil internally. -. LUBRICATION OF EXTERNAL PARTS. a. Load chain should always be protected from wear with alight film of bar and chain oil, especially when subjected to damp or corrosive atmospheres. b. Lubricate lower hooks at the swivel point with bar and chain oil periodically, as required. Lubricate upper hooks with a few drops of bar and chain oil. Figure 5-. Check Chain Wear at Bearing Surfaces Between Links Page

17 USE ONLY A "KNIFE-EDGE" CALIPER TO ELIMINATE POSSIBILITY OF FALSE READING BY NOT MEASURING FULL PITCH LENGTH. Replace Chain If Measurement Hoist is Greater Than ¼ & ½ Ton 5-3/6" & ( load chains) Ton 5-/6" ½, ( load chain) & 3 thru 6 Ton 8-/6" Figure 5-. Checking Coil Chain Using Vernier Caliper CAUTION Do not assume that load chain is safe because it measures below replacement points given herein. Other factors, such as those mentioned in visual checks above, may render chain unsafe or ready for replacement long before elongation replacement is necessary. WARNING When replacing coil load chain, use only factory approved chain conforming to factory specifications for material, hardness, strength and link dimensions. Chain not conforming to BUDGIT hoist specifications may be dangerous as it will not fit in the load sprocket and chain guide correctly, causing damage to hoist, and it will wear prematurely, deform and eventually break. 5-. HOOKS. Inspect both hooks regularly for evidence of overloading or damage. Check for proper hook opening, Figure 5-3. If hook is opened beyond the given dimension, replace immediately. If hooks are damaged, dismantle hoist and inspect all parts thoroughly. Refer to Section VII for hook removal and installation instructions. Hook Throat Opening Hoist Hook Normal Opening Replace Hook If Opening is Greater than ¼ & ½ Ton Upper ¼, ½ & Ton Lower -/8" -9/3" & ( load chains) Ton Upper ½ & Ton Lower -/" -7/6" ½ & ( load chain) Ton Upper -3/8" -9/6" 3 & Ton (except SR) 3 Ton Ton (except SR) 3 & Ton SR 5 & 6 Ton (except SR) Ton SR 5 & 6 Ton (except SR) 5 & 6 Ton SR 5 & 6 Ton SR Upper Lower Lower Upper Upper Lower Lower Upper Lower -/" -3/3" -7/8" -5/3" -/" -9/6" Figure 5-3. Upper Hook Opening WARNING Hooks, upper or lower, damaged from chemicals, deformation or cracks or having more than 5 percent in excess of normal throat opening or more than 0 degrees twist from the plane of the unbent hook, or opened, allowing the hook latch to bypass hook tip MUST BE REPLACED. Any hook that is twisted or has excessive throat opening, indicates abuse or overloading of the hoist. Other load bearing components of the hoist should be inspected for damage TESTING. Regular testing of the hoist is required. See Section VIII. 39 Page 5

18 SECTION Vl - TROUBLE SHOOTING Trouble Probable Cause Remedy. Hoist is hard to operate in hoisting direction.. Load brake slips and chain hoist will not support load. 3. Load brake drags, hard to lower load. (Hand chain is hard to pull.) a. Hoist is overloaded. b. Load chain is damaged, worn, elongated or binding between load chain sprocket and guide. c. Load chain dry, rusty, corroded or dirty with foreign material adhering to chain. d. Load chain sprocket worn or clogged with foreign material. e. Chain twisted. a. Brake friction surfaces coated with excessive oil or friction washers glazed. b. Brake parts worn or damaged. c. Load chain reeved incorrectly. d. Brake pawl hangs up. a. Dirty or corroded internal parts. b. Brake friction surfaces scored. c. Load gearing damaged from overloading. d. Chain binding. a. Reduce load to within rated hoist capacity. Hoist should be dismantled and thoroughly inspected for additional damage from overloading. b. Check chain for bent or twisted links, gouges or nicks. Check for wear between links and gauge chain per paragraph 5-3. Replace if necessary. c. Clean chain by tumble polishing or clean with solvent. Lubricate per Para. -. d. Clean and inspect sprocket. Replace if necessary. e. Rereeve chain hoist keeping chain free of twist. a. Remove and disassemble brake. Clean and buff friction washers or install new washers. Lubricate per Section 7-.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 and brake pawl spring. a. Remove and disassemble brake. Clean and buff surfaces. Install brake. Lubricate per Section 7-.b before reassembly. b. Refer to a. above. Replace if scored excessively. c. Remove damaged gears and install new gears. Hoist should be dismantled and thoroughly inspected for additional damage from overloading. d. See items.b.,.c., and.d.. Chain hoist works erratically. a. Load chain incorrectly installed. a. Remove load chain. Install chain correctly. (See Figure 7-8.) b. Load brake pawl or ratchet teeth worn or damaged c. Frame cracked or mutilated. d. Hand chain rubbing on cover. e. Hand chain hanging up in hand wheel. b. Remove load brake parts. Inspect parts. Replace damaged parts. c. Replace frame. d. Remove interference. e. Clean and lubricate hand chain. 5. Hooks opened. a. Chain hoist overloaded. a. Replace opened hooks. Hoist should be dismantled and thoroughly inspected for additional damage from overloading. 6. Frame damaged. a. Hoist subjected to overloading. a. Load chain hoist only to rated capacity. Replace damaged frame. Hoist should be b. Load chain run too far through chain block dismantled and thoroughly inspected for frame. additional damage from overloading. c. Chain hoist subjected to extreme angular or side pulls, causing chain to bind. b. Replace damaged frame. c. Operate chain hoist properly. Replace damaged frame. Page 6 (Continued on following page)

19 SECTION Vl - TROUBLE SHOOTING (continued) Trouble Probable Cause Remedy 6. Frame damaged. (continued) d. Chain hoist damaged by dropping or d. Disassemble chain hoist. Inspect chain throwing. hoist. Replace damaged parts and assemble chain hoist. Whenever the frame shows evidence of damage from misuse or rough handling, the hoist should be completely dismantled, all parts inspected and damaged or worn parts replaced, as outlined in Section VII. Always apply the safety rules shown on the inside of the back cover when using BUDGIT USA hand chain hoist. 7. Clutch slipping excessively. a. Hoist is overloaded. a. Reduce load to within rated hoist capacity. Hoist should be dismantled and thoroughly inspected for additional damage from overloading. b. Internal binding. b. See item 6.d. c. Load brake locked up. c. See item.a. d. Clutch worn. d. Replace clutch. SECTION VII - DISASSEMBLY & REASSEMBLY 7-. GENERAL. The following disassembly procedure applies to all hoists except as specifically noted. A complete tear down procedure is given; however, when servicing specific parts, only a partial tear down may be required REMOVAL OF LOAD CHAIN. a. To remove hook from end of load chain on single load chain hoists, remove snap ring at top of sleeve, slide sleeve from body halves and separate parts. See Figure 7-. e. On 3 and ton hoists, remove one roll pin from chain anchor pin at upper hook bracket and remove chain anchor pin. See Figure 9-. Pull chain thru lower block and then follow steps b and c above. f. On 5 and 6 ton hoists, remove one retaining ring from chain anchor pin at lower block and remove chain anchor pin. See Figure 9-5. Pull chain thru upper hook assembly and lower block and then follow steps b and c above. 7-. 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 - ) and pull hand chain from hoist. c. Remove four hex socket button head cap screws holding hand chain wheel cover and lift off cover. d. A self-locking nut on the end of the pinion shaft secures the hand chain wheel. Remove nut, flat washer, brake stop and hand chain wheel. e. No disassembly of the hand chain wheel is to be attempted. The hand chain wheel contains the Load Regulator which is preset at the factory. Any adjustment should be undertaken only by an authorized BUDGIT repair station. 06 Figure 7-. Lower Hook Connection b. Remove hex socket head cap screw holding tail end of load chain to hoist frame. c. Run load chain out of hoist by pulling on hand chain in lowering direction. d. On two load chain ton hoists, remove chain connection pin at upper hook bracket (see Figure 9-3a) and pull chain thru lower block; then follow steps b and c above REMOVAL OF LOAD BRAKE PARTS. a. Pull two friction washers and brake ratchet off shaft of brake flange while holding brake pawl open. See Figure 7-5. b. Remove brake pawl spring. To remove pawl, take retaining ring off end of pawl pin and remove washer and pawl. Note relationship of spring retainer plate (if present) to stop in frame. Slide spacer washer and spring retainer plate (where they occur) off pawl pin. c. Unscrewing the load brake flange (counterclockwise) from the pinion shaft, will require extra effort. The easiest way is; after removal of the sprocket gear on /, /, and two load chain ton models (see paragraph 7-6) or the intermediate gear on -/, single load chain, and 3 thru 6 ton models (see paragraph 7-7), turn the pinion counterclockwise with a 6 Page 7

20 or point 7 mm hex socket on a flex handle or ratchet and hold the load brake flange with a face spanner resting against the brake pawl pin (see Figure 7-). If it becomes necessary to remove the load brake flange without removing any gearing, hold load brake flange with face spanner and turn pinion shaft with a 6" or larger crescent wrench fitted over the flat surface under the end thread on the pinion shaft. d. Do not remove pawl pin unless damaged, requiring replacement. A self-locking hex nut secures the pawl pin to the frame. This is accessible in the opening in the frame near the upper hook nut (or lug mounting nut). See Figure 7-. Figure 7-3. Removing Pinion Shaft d. Pull chain guide out of frame REMOVAL OF GEARING (All Other Models). a. Unscrew six hex socket button head cap screws holding gearcase cover and remove cover. b. Lift out intermediate pinion with intermediate gear attached and with a washer on each end. To separate intermediate gear from pinion, press gear off shaft. A woodruff key joins the two. Note Do not remove needle roller bearings from frame unless they are worn or damaged and require replacement. c. Remove pinion shaft as outlined in paragraph 7-6.c. 50 Figure 7-. Removing Load Brake Flange 7-6. REMOVAL OF GEARING (/,/, and Two Load Chain Ton Models). a. Unscrew four hex socket button head cap screws holding gearcase cover and remove cover. b. Lift out sprocket gear with integral chain sprocket (load chain must have been previously removed from hoist). Note Do not remove two bushings from their bores in the frame unless they show evidence of wear or damage and require replacement. c. Remove retaining ring from pinion shaft (on hand wheel side of frame) and tap out pinion shaft. See Figure 7-3. Ball bearing should come out with pinion shaft. Note Do not remove needle roller bearing from frame unless it is worn or damaged and replacement is required. d. Lift out sprocket gear with integral chain sprocket (load chain must have been previously removed from hoist). Note Do not remove needle roller bearings from frame unless they are worn or damaged and require replacement. e. Pull chain guide out of frame REMOVAL OF UPPER HOOK (Hook Suspension Models). a. Align grooved pin in hook nut with opening in frame and drive out pin with drift punch. Use drift punch to hold nut while hook is being unscrewed. b. Unscrew and remove hook, nut and washer. Note Keep hook and nut together as they are drilled at assembly and are not interchangeable REMOVAL OF SUSPENSION LUG (Lug Suspension Models). a. For /,/,,-/ and single load chain ton hoists, hold nuts with wrench and unscrew two flat head cap screws (hex head cap screws on - / and single load chain ton models) to remove suspension lug. Page 8

21 b. For two load chain ton, 3 and ton hoists, align grooved pin in upper block bolt with opening in frame and drive out pin with a drift punch. Use drift punch to hold nut while bolt is being unscrewed. Unscrew and remove bolt, nut and washer. Note Keep bolt and nut together as they are drilled at assembly and are not interchangeable. c. For 5 and 6 ton hoists, hold self-locking nuts while unscrewing bolts DISASSEMBLY OF LOWER BLOCKS (3 Thru 6 Ton Hoists). a. Remove spring pin in sprocket shaft; then remove sprocket shaft, sprocket, bearings and washers. b. Remove cotter pin in hook nut; hold nut and unscrew hook; remove nut, thrust bearing and thrust washer. 7-. REASSEMBLY. 7-. GENERAL. The procedure to be followed for reassembly is in reverse order of the disassembly steps outlined above. There are; however, certain precautionary steps that must be taken, as outlined in paragraphs 7-3 thru 7- below CLEANING AND INSPECTION OF PARTS. a. Before assembly, all parts should be thoroughly cleaned and inspected to determine their serviceability. Do not wash shielded ball bearing (from pinion shaft) out with solvent. Also, hand chain wheel, which contains Load Regulator, should not be degreased. WARNING It is extremely important that load brake friction surfaces be kept dry, as an oily film may cause slippage, thereby permitting a load to drop. c. Load chain should be lubricated with a light film of bar and chain oil. It is important that the bearing surfaces between the links are lubricated. Note Figure INSTALLING SUSPENSION LUG (Lug Suspension Models). a. For /, / and ton models, the flat head hex socket cap screws fastening the suspension lug to the hoist frame must be torqued to 70 to 80 foot-pounds. b. The hex head cap screws for the -/, single load chain, 5 and 6 ton models must be torqued to 95 to 05 foot-pounds. The self-locking plastic material in the nuts must be undamaged and resilient. c. On two load chain, 3 and ton models (round nut with pin), be certain original nut is used. The nut side with the greater distance to the center of the hole on the ton model should face the top of hoist. See Figure INSTALLING UPPER HOOKS (Hook Suspension Models). When installing upper hook, be certain original nut is used. The nut side with the greater distance to the center of the hole should face the hook. See Figure 7-. b. Grease should be evident at joint between chain wheel and load brake nut and also chain wheel and regulator collar of Load Regulator. If not, test hoist per Section VIII to assure grease has not been baked or washed out by environmental conditions. c. Replace parts that are excessively worn or damaged. 7-. 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 and body halves on lower hooks. Lubricate hook bearings with MOLYKOTE BR Plus grease (by Dow Corning) or equal. b. Lubricate gearing with MOLYKOTE BR Plus grease or equal. Apply same grease to sprocket bearing surfaces and apply a light film of this grease to sprocket bushings or bearings. On ½ and ton models, do the same for intermediate gear and pinion. Apply BR Plus grease to pinion bearing surfaces and apply a film of this grease to the pinion needle bearing. Lubricate load brake pawl with a small amount of BR Plus grease at support pin and ratchet engagement tip. While making sure that the load brake friction surfaces do not become greased, lubricate the ratchet inner bearing surfaces. For lubrication of the load brake threads, apply a small amount of BR Plus grease on the leading internal threads of the load brake nut which is part of the hand chain wheel assembly. When the hand chain wheel is assembled to the pinion shaft any excess grease will be brought to the end of the pinion shaft where it can be wiped off. Figure 7-. Installing Upper Hook and Nut 7-7. INSTALLING GEARING. a. Before gearing is installed, be certain chain guide is properly seated in hoist frame. b. Press ball bearing, if required, onto pinion shaft before installing pinion shaft. Page 9

22 c. On -/, single load chain and 3 thru 6 ton models, press intermediate gear onto intermediate pinion shaft (with woodruff key in place) before installing in frame. Also, remember to replace the washers on each end of shaft INSTALLING LOAD BRAKE PARTS. a. The threads between the pinion shaft and brake flange are to be clean and dry. Pretreat these threads only with LOCTITE Primer 'T'. Apply LOCTITE 680 to shaft threads 3/6" from thread relief (the inside edge). Set pinion shaft in hoist frame and lock with retaining ring. Assemble brake flange to pinion shaft. Torque flange to 5 foot-pounds. b. After the load brake flange is in place, the order of assembly is; friction washer, then ratchet, then second friction washer. On the / and / ton models only, the friction washers are of different diameters. The large diameter friction washer goes on first, followed by the ratchet and then the smaller diameter friction washer. On the other models the light colored woven friction washer goes on first, followed by the ratchet and then the dark colored molded friction washer. The brake pawl and spring are then installed. The brake pawl spring has a closed end. On / and / ton hoist models, the open end must be installed to the pawl. On other models, the closed end must be installed to the pawl. The open end of the spring on and two load chain ton models goes against the adapter assembly. See Figure 7-5. Figure 7-6. Brake Stop Position for / and / Ton Models d. Install brake stop in position shown in Figure 7-6 for / and / ton models or in position shown in Figure 7-7 for other models. CAUTION Make sure the brake pawl spring is properly seated. Figure 7-7. Brake Stop Position for Other Models e. To facilitate installation of the load chain, delay replacing hand chain and hand chain wheel cover until after load chain has been installed INSTALLING LOAD CHAIN Figure 7-5. Installing Load Brake Pawl c. Install hand wheel on pinion shaft. Turn clockwise thru several clicks of brake pawl to bring brake friction surfaces into contact before brake stop (see paragraph 7-8.d, for installation), flat washer and nut are installed. Lube should be in hand chain wheel threads so that excess is wiped out, not in. Figure 7-8. Installing Load Chain Page 0

23 WARNING When installing load chain, it is possible to feed it into the wrong side of hoist, which will result in a reversed hoist action and the load brake will not function. a. Lay hoist on workbench. By rotating hand chain wheel, run load chain thru hoist. The first link into the hoist from the load side must be a horizontal link (into a horizontal pocket) so that the tail chain will be in the proper position for fastening to the hoist frame. Be sure the welded side of the chain links face up so they do not enter the vertical slots of the sprocket. Make sure chain is not twisted. See Figure 7-8. b. Attach tail end of load chain to hoist frame. On the -/, single load chain and 3 thru 6 ton models only, there is a washer under the head of the hex socket head cap screw securing the chain. c. On the two load chain and 3 thru 6 ton models, reeve the hoist in accordance with Figure 7-9. Make sure there is no twist in the chain.. ASSEMBLY OF HAND CHAIN WHEEL COVER AHAND CHAIN. a. Replace hand chain wheel cover and secure with four hex socket button head cap screws. b. Feed hand chain over hand chain wheel keeping chain welds facing away from wheel. Make sure chain is not twisted. Connect ends of hand chain with open split connecting link. Twist connecting link closed. c. Lubricate hand chain with a light, rust preventative oil. d. Check operation of hoist and test in accordance with paragraph 8-. IMPORTANT After completion of reassembly and before being placed in service, the BUDGIT USA hand chain hoist should be tested with rated load to ensure safe operation. SECTION Vlll - SPECIAL LOAD REGULATOR INFORMATION 8-. GENERAL. a. BUDGIT USA hand chain hoists are equipped with a Load Regulator in the hand chain wheel which is designed to help guard against excessive overloads. b. The Load Regulator is preset at the factory. If a BUDGIT chain hoist is subjected to excessive overload, the Load Regulator unit will allow the hand chain to move without increasing the load on the hoist. When this condition occurs, the hoist will continue to support the overload; however, the overload must be released as soon as possible. c. Testing of the BUDGIT chain hoist in accordance with paragraph 8- is necessary at regular intervals which should be determined by amount and conditions of use. 8-. TEST PROCEDURE. a. Suspend hoist from an overhead structure capable of supporting several times the rated load of the hoist. Position hoist so that all parts of hoist and test load, when suspended on load hook, are free of obstructions and can hang in a straight line. Attach the load hook to a test load equal to the rated load of the hoist. Operate hand chain to lift the load. If slippage occurs and rated load cannot be lifted, the Load Regulator requires adjustment or replacement. Adjustment should be attempted only by an authorized BUDGIT repair station. Figure 7-9. Reeving for thru 6 Ton Models d. Anchor the end of the chain as shown in the proper parts list illustration. In order that the last link falls in the correct position to be anchored, the chain must have an even number of links ASSEMBLY OF LOWER BLOCK. When installing sleeve on single load chain hoists, be certain large chamfer in one end is positioned as noted in Figure 7-. b. If hoist operates properly with rated load on hook, it should next be tested with a load equal to two times rated load. With this overload attached to the load hook, complete slippage should occur. If hand chain wheel does not slip, the Load Regulator requires adjustment or replacement. Adjustment should be attempted only by an authorized BUDGIT repair station. c. For Load Regulator adjustment, the complete hoist must be returned to an authorized BUDGIT repair station. Alternatively, a new hand chain wheel containing the Load Regulator may be obtained from an authorized BUDGIT repair station. Page