Budgit Electric Hoist Operation, Service & Parts Manual

OPERATION, SERVICE & PARTS MANUAL
Printed in U.S.A.
April, 2010
©2010, Budgit Hoists division of Columbus McKinnon Corporation
Part No. 113535-30
FOREWORD
This book contains important information to help you install, operate,
maintain and service your new Electric Hoist. We recommend that you
study its content thorough­ly before putting your hoist into use. Then,
through proper installation, application of correct operating procedures,
and by practicing the recommended maintenance sugges­tions you will be
assured maximum lifting service from the hoist.
The “Accident Prevention Manual for Industrial Operations’ (8th Edition)
by the National Safety Council states:
Complete inspection, maintenance and overhaul service is available for
Budgit Electric Hoists at Authorized Repair Stations. All are staffed by
qualified factory-trained service men; have authorized testing equipment;
and stock a com­plete inventory of factory approved Budgit replacement
parts.
From a safety standpoint, one factor is paramount: conduct all lifting
operations in such a manner that if there were an equipment failure,
no personnel would be injured. This means keep out from under raised
loads!”
Complete replacement parts information is given in Section IX. It will likely
be a long time before parts infor­mation is needed, therefore, after you
completely familiar­ize yourself with operation and preventive maintenance
procedures, we suggest that this instruction and parts man­ual be carefully
filed for future reference.
“Employees who work near cranes or assist in hooking on or arranging
loads should be instructed to keep out from under loads. Supervisors
should watch closely to see that this rule is strictly followed.
THE INFORMATION CONTAINED IN THIS MANUAL IS FOR
INFORMATIONAL PURPOSES ONLY AND BUDGIT HOISTS DOES NOT
WARRANT OR OTHERWISE GUAR­ANTEE (IMPLIEDLY OR EXPRESSLY)
ANYTHING OTHER THAN THE COMPONENTS THAT BUDGIT
MANUFACTURES AND ASSUMES NO LEGAL RESPONSIBILITY
(INCLUD­ING, BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES)
FOR INFORMATION CONTAINED IN THIS MANUAL.
Notice: Use only factory approved Budgit replacement parts, available
from Authorized Repair Stations or Budgit Hoist Distributors.
INDEX
SECTION I
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
GENERAL DESCRIPTION
Page
1-1 General .................................................................................................................................................................................. 3
1-2 Hoist Service Classification . ................................................................................................................................................. 3
1-3 Basic Construction ................................................................................................................................................................ 3
1-4 Differences Between Models and Sizes . .............................................................................................................................. 4
1-5 MAN-GUARD Overload Clutch ............................................................................................................................................ 4
SECTION II
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
INSTALLATION
2-1 General .................................................................................................................................................................................. 4
2-2 Installation ............................................................................................................................................................................. 4
2-3 Pre-Installation Checks ......................................................................................................................................................... 5
2-4 Connecting Hoist to Electrical Service . ................................................................................................................................ 5
2-5 Electronic Adjustable Limit Switch . ...................................................................................................................................... 5
SECTION III
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
OPERATION
3-1 General.................................................................................................................................................................................... 6
3-2 Operating Hoist ..................................................................................................................................................................... 6
3-3 Pulling and Rotating Hoist and Load .................................................................................................................................... 6
3-4 Upper and Lower Limit Stops................................................................................................................................................ 6
3-5 MAN-GUARD Overload Clutch Operations . ........................................................................................................................ 7
3-6 Operating Precautions . ......................................................................................................................................................... 7
SECTION IV
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
LUBRICATION
4-1 General .................................................................................................................................................................................. 9
4-2 Change Gear Case Oil .......................................................................................................................................................... 9
4-3 Lubricate Load Chain ............................................................................................................................................................ 9
4-4 Lubricate Upper Hook and Lower Block Assembly ............................................................................................................. 9
4-5 Lubricate Limit Lever Control Shaft and Gears .................................................................................................................... 9
SECTION V
Paragraph
Paragraph
Paragraph
Paragraph
MAINTENANCE
5-1 General ...................................................................................................................................................................................... 9
5-2 Thirty-Day Inspection ................................................................................................................................................................ 9
5-3 Six-Month Inspection .............................................................................................................................................................. 12
5-4 Inspection 5000 Hour or Five Year ......................................................................................................................................... 12
SECTION VI
TROUBLE SHOOTING CHART ................................................................................................................................................13-14
SECTION VII
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
DISASSEMBLY AND REASSEMBLY
7-1 General ................................................................................................................................................................................ 14
7-2 Disassembly of Hoist Into Subassemblies . ........................................................................................................................ 15
7-3 Rebuild of Hoist Frame, Sprocket Gear, Sprocket Shaft and Chain Guide ....................................................................... 17
7-4 Rebuild of Load Brake and Overload Clutch Assembly ..................................................................................................... 20
7-4a Overload Clutch without Load Brake .................................................................................................................................. 21
7-5 Rebuild of Lower Block and Load Chain Assembly ........................................................................................................... 21
7-6 Rebuild of Electrical Controls and Gear Case Cover Subassembly . ................................................................................. 23
7-7 Rebuild of Push Button Station and Conductor Cable Assembly . .................................................................................... 23
7-8 Rebuild of Contactor Assembly (Push Button Models) ...................................................................................................... 24
7-9 Rebuild of Single Phase Motor Assembly .......................................................................................................................... 24
7-10 Rebuild of Three Phase Motor Assembly ........................................................................................................................... 24
7-11 Reassembly of Hoist From Subassemblies ........................................................................................................................ 24
7-12 Testing Hoist ........................................................................................................................................................................ 31
7-13 Test Procedure For Checking Operation of Overload Clutch ............................................................................................. 31
SECTION IX
REPLACEMENT PARTS ...........................................................................................................................................................32-36
Notice: Information contained in this book is subject to change without notice.
Page Figure 1-1. Cutaway View Of Typical Budgit Electric Hoist
SECTION I - GENERAL DESCRIPTION
1-1. GENERAL. Budgit Portable Electric Hoists are precision
built chain type hoists ranging in six rated load sizes from 1/4
ton through 3 tons with various lifting speeds and electrical
power supplies. In addition to the capacities, there are model
variations with hook or lug type suspension, and single or two
speed. In addition to standard models, there are four rated load
sizes of Budgit Electric Hoists ranging from 1/4 ton through 2
tons suitable for plating hoist service with various lifting speeds
and electri­cal power.
1-2. HOIST SERVICE CLASSIFICATION
a. Budgit electric hoists at the time of manufacture comply
with our interpretation of applicable sections of ANSI B30.16
“Overhead Hoists”, National Electric Code ANSI/ NFPA 70 and
Occupational Safety and Health Act, 1992.
b. OSHA places the burden of compliance for hoist installa­tions
on the user. The user must install the equipment in accordance
with the National Electric Code ANSI/NFPA 70 as well as other
federal, state and local regulations which apply to the installation
and application in your particular area.
WARNING
Equipment covered herein is not designed or suitable
as a power source for lifting or lowering persons. Do
not use as an elevator.
c. These hoists meet ANSI/ASME HST-1M “Performance
Standard for Electric Chain Hoists” hoist duty class ratings as
outlined in the sales bulletin.
1-3. BASIC CONSTRUCTION. All sizes and models of these
Budgit Electric Hoists are of the same basic designs, having
many common and interchangeable parts. They consist prima­rily
of an aluminum alloy frame and gear case cover which houses
the gear train. An electric driving motor and external motor
brake are mounted on the rear of the frame, Electrical control
components are mounted on front of the gear case cover and
encased by aluminum alloy end cover. An upper hook or lug
bracket for suspending the hoist is attached to the top of the
frame. A high strength low alloy coil load chain with lower block
assembly is employed to raise and lower loads. Hoist operation
is controlled by a pendant push button station.
Page 1-4. DIFFERENCES BETWEEN MODELS AND SIZES. The main
differences between hoist models are in the service classification,
type of load chain and the suspension employed. These are
described in paragraphs (a) through (c ), below. The differences
between sizes of hoists are in the number of gear reductions
used and the reeving of the load chain. Two-reduction gearing
is used for 1/4 through 1/2 ton rated load hoists; three-reduction
gearing for 1, 2 and 3 ton rated hoists. On 1/4 through 1 ton
rated load hoists, the load chain is single reeved (one part of
chain); on 2 ton rated loads, the chain is double reeved (two
parts of chain); on three ton rated loads, the chain is triple reeved
(three parts of chain).
a. Coil type chain is full-flexing electric welded link chain. It is
especially designed for use in Budgit Electric Hoists and only
factory approved chain of the correct size, pitch, hardness, and
strength can be used with these hoists.
b. Suspension differences include a conventional hook type
mounting and a lug type mounting. Hook suspension allows
portability permitting hoist to be easily moved from job to job.
Lug suspension permits hoist to be rigidly mounted to overhead
structure or attached to Budgit Rigid Mount Trolleys, affording
unusual headroom advantage.
c. Some hoists are adaptations of standard model hoists to
permit use in some mildly corrosive atmospheres, high ambient
temperatures and high duty cycle operation. They are available
in either hook or lug suspension. Construction variations from
standard models are as follows:
(1) Load chain is zinc plated for corrosion resistance.
(2) All exposed aluminum parts are prime painted with corrosion resistant paint.
(3) Aluminum castings are specially treated.
1-5. MAN-GUARD OVERLOAD CLUTCH. Budgit Electric Hoists
having a MAN-GUARD label on the sides of the electrical
compartment cover are equipped with an overload clutch that
is designed to help guard against excessive overloads. It is a
cone-friction clutch that connects the first reduction gear to
the clutch pinion shaft. A belleville disc spring provides clutch
pressure between the gear and its cone shaped gear cen­ter. An
excessive overload causes the gear to rotate without turning the
gear center and pinion shaft. See paragraph 3-5 for operation.
WARNING
THE MAN-GUARD OVERLOAD CLUTCH IS A
PROTECTIVE DEVICE THAT WILL PERMIT OPERATION
OF YOUR HOIST WITHIN ITS RATED LOAD AND WILL
PREVENT LIFTING OF EXCESSIVE OVERLOADS
WHICH CAN CAUSE PERMANENT DEFORMATION OR
WEAKENING OF A PROPERLY MAINTAINED HOIST
AND/OR ITS SUSPENSION.
2-2. INSTALLATION.
NOTICE
Lubricate load chain before operating hoist. See paragraph
4.3
a. On hook suspended hoists, select a suitable overhead support
in area hoist is to be used (one capable of holding weight of
hoist and its rated load) and hang up hoist. Be certain upper
hook is firmly seated in center of hook saddle. Upper hook is
equipped with a spring type hook latch; it may be necessary
to remove latch to attach hook to support. Replace latch after
hoist is installed.
b. On lug suspended hoists, select a suitable overhead sup­port
in area hoist is to be used (one capable of holding weight of
hoist and its rated load). Mount hoist using through bolts, of
appropriate size, to fit mounting holes in suspension lug at top
of hoist frame. (See table below.) The structure used to suspend
hoist must be of sufficient strength to withstand reasonable
forces to which hoist and support may be sub­jected. Hoist must
be aligned with load to avoid side pulls.
c. On lug suspended hoists, the suspension lug is factory
oriented to cross mount the hoist. This is the recommended
orientation. To rotate the lug 90° for parallel mounting, follow
instructions below:
(1) On 1/4 through 1 ton hoists, remove the two screws securing
the anti-rotation bracket and remove the bracket. Rotate the
suspension lug in 90° increments. Reinstall the anti-rotation
bracket and secure with two screws and lock washers.
(2) On 2 ton hoists, remove hex socket head screw in lower
lock plate. Remove lower lock plate. Rotate suspension lug to
selected position and replace lock plate and hex socket head
screw.
(3) On 3 ton hoists, the hanger bracket must first be removed
from the hoist to provide access to suspension nut per Section
VII, par. 7-2. a. (4) and figures 7-2 and 7-3. To remove lug bolt,
follow instructions in Section VII, par. 7-3. b. (3). With bolt
removed lift lug from hanger and reposition as desired. The lug is
located and prevented from turning by integral lugs on adjacent
surfaces of the lug and the hanger. Reinstall suspen­sion bolt,
spherical washers and nut. Align hole in nut and suspension
bolt. Reassemble hanger bracket to hoist.
d. On rigid mount trolley suspended hoists, the trolley side plates
must be properly spaced so trolley will fit I-beam on which hoist
will operate. Adjustment for various I-beam sizes is accomplished
by rearrangement of spacer washers on through bolts which
connect trolley side plates to suspen­sion lug on hoist. Refer to
instruction sheet furnished with Budgit Rigid Mount Trolleys for
complete instructions.
SUSPENSION LUG BOLT SIZES AND SPACING
SECTION II - INSTALLATION
2-1. GENERAL. Budgit Electric Hoists are completely lubricat­ed
and load tested under their own power before being shipped
from the factory. To place hoist in service, attach to suitable
overhead suspension (par. 2-2) in area to be used; make preinstallation check (par. 2-3); and connect to the proper power
supply (par 2-4).
Page Hoist
Rated Load
(tons)
Bolt Diameter
(in)
Distance
Between Holes
(in)
1/4, 1/2 &1
5/8
3-1/8
2
1
5
3
1-1/4
6
2-3. PRE-INSTALLATION CHECK.
Check Oil Level (Fig. 4-1). The gear case has been filled with oil,
to the proper level at the factory. However, the oil level should
be checked before hoist is operated. Remove pipe plug from oil
filler on side of hoist frame. Replace with supplied oil hole cover.
Check oil level by removing oil level plug (side of frame). Observe
if oil level is even with bottom of tapped hole. If it is not, add oil,
as specified in paragraph 4-2c. Also check load chain. Be sure
it is properly lubricated. See para. 4-3.
Check Limit Stops:
Paddle limit equipped. Make sure the actuator on the tail chain
side is securely pinned to the proper link. (See chart on page 30).
On single part hoists, make sure steel actuator is pinned to the
first chain link above the lower block. Multiple part reeved hoists
do not have an actuator on the lower block side.
Electronic limit switch equipped. Make sure the stop on the
tail chain side is securely fastened to the proper link. (See chart
on page 30). There is no stop on the lower block side.
2-4. CONNECTING HOIST TO ELECTRICAL SERVICE.
a. All hoists are equipped with a flexible power cable extend­
ing from the hoist. A grounding type male plug or permanent
connection in an outlet box may be used for connecting hoist
to power supply. See table (fig. 2-1) for branch circuit con­ductor
sizes.
AWG Wire Size
H.P.
1/4
Power Supply
1
2½
#14
#12
115-1-60
80
130
210
230-1-60
230
330
835
200, 230-3-60
465
740 1180
460, 575-3-60
1/2
#16
#10
#8
#6
330
WARNING
The green wire provided in the power supply cable is
a grounding wire and must be connected to a proper
ground. (Follow local code requirements and/or National
Electrical Code Article 250).
c. Dual voltage hoists with reconnectable 230/460 volts, 3 phase,
60 hertz are (unless otherwise specified on customer’s order)
shipped from factory pre-connected for operation on 460 volts.
If hoist is to be operated on 230 volts convert wiring by changing
connections on terminal board. With hoist disconnected from
power source, remove electrical compartment cover and
reconnect terminal board leads. Refer to Wiring Diagram.
d. Dual voltage hoists with reconnectable 115/230 volts, 1
phase, 60 hertz are (unless otherwise specified on customer’s
order) shipped from factory pre-connected for operation on
230 volts. If hoists are to be operated on 115 volts convert
wiring by changing connections on terminal board. With hoist
disconnected from power source, remove electrical compartment
cover and reconnect terminal board leads. Also refer to Wiring
Diagram.
WARNING
On electrically operated hoists it is possible to have
"Reverse Phasing" causing the lower block to raise
when the down button is depressed. When this
condition exists, the block operated limit switches will
not function properly. Serious damage to the hoist can
occur with resulting hazard to operator and load. Hoists
must be properly phased each time they are installed
or moved to a new power source, or when service is
performed on mainline (power source).
e. To properly phase the hoist follow these steps:
1440 2390
(1) Temporarily connect hoist to power source.
115-1-60
45
75
120
190
310
230-1-60
195
305
490
775 1235
200, 230-3-60
280
450
715 1135
460, 575-3-60
860 1440
115-1-60
*
45
75
120
190
230-1-60
120
190
300
475
720
200, 230-3-60
180
290
460
730
460, 575-3-60
560
900
200, 230-3-60
60
100
150
250
460, 575-3-60
260
420
490
300
*Do not use
Figure 2-1. Branch Circuit Conductor Size. Maximum length in
feet for wire size based on horsepower and power supply. Wire
size for entire length of branch circuit and permanent wiring to
main feeder. Power supply measured at hoist, while running and
with normal load, must not vary more than ±5% of voltage on
motor nameplate.
b. Follow local & National Electrical Codes when providing
electrical service to hoist. Connect power wires in accor­dance
with appropriate wiring diagram. Power supply must be the
same voltage, frequency and phase as specified on the hoist
nameplate.
(2) Operate “h” button briefly to determine direction of travel.
(3) If hook raises, phase is correct and temporary connec­tions should be made permanent.
(4)IF HOOK LOWERS, HOIST IS “REVERSE PHASED”
AND MUST BE CORRECTED BY INTERCHANGING
A N Y T W O L E A D S AT P O W E R S O U R C E
CONNECTION. DO NOT CHANGE INTERNAL
WIRING OF HOIST.
f. For connecting hoist to a motor driven trolley, refer to
instructions furnished in trolley manual.
2-5. ELECTRONIC ADJUSTABLE LIMIT SWITCH (if equipped).
The limit switch arrangement consists of two sensors which
protrude into the gear case at the sprocket gear, and a control
module. The control module has two buttons for programming
set points, an UP and DOWN green LED, and a red ALERT
LED.
The electronic adjustable limit switch is factory set to the extreme
upper and lower limits to allow for testing. The limits may be
left as they are, or can be reset according to the following
procedure:
When power is first applied to the hoist, one or both of the green
LED's should be on, and the red ALERT light should be off. The
hoist will operate between the points set at the factory. If red
ALERT light is on and both green lights are off, the hoist will not
operate, the limits need to be set.
Page SECTION III - OPERATION
To set limits:
(1) Press both SET buttons simultaneously. Both green LED's
should come on, and the red ALERT LED should flash. Hoist can
now be operated through full range of lift.
(2) Raise or lower hook to desired set point. It does not matter
whether upper or lower limit is set first. Press the set button that
corresponds to UP if the upper limit is to be set first, or DOWN
if the lower limit is to be set first. The corresponding green LED
should go out.
(3) Move hook to desired upper limit if the lower limit was
previously set, or to the lower limit if the upper limit was
previously set. The LED corresponding to the limit just set will
come back on, indicating the hoist is no longer at that limit. Press
the set button that corresponds to UP if the upper limit is being
set, or DOWN if the lower limit is being set. The corresponding
green LED should go out. The red ALERT light should also go
out.
(4) The upper and lower limits are now set. Operate the hoist
to confirm the settings are at the desired limits.
Tips for setting limits:
For the initial setting, both limits must be set. If one setting is
more critical, that one should be set first. For example, if the
position at the lower limit is more important that the position at
the upper limit, the lower limit should be set first.
Once the upper and lower limits are set, they can be changed
without having to do both if the new limit is within the previously
set limits. For example, if the lower limit is set too low, stop the
hook at the desired position and press the DOWN set button.
The hook will now stop at the new limit.
3-1. GENERAL. Operation of Budgit Electric Hoists are con­trolled
by a push button station suspended from the hoist electrical
compartment. The station has a built-in mechanical interlock to
prevent depressing both buttons simultaneously.
3-2. OPERATING HOIST.
a. Depress push button marked “h” to raise load.
b. Depress push button marked “i” to lower loads.
c. Jogging the push buttons will give “hairline” load move­ment.
The quickness of the depressing motion will determine the
amount of movement. Excessive use of this “jogging” feature will
cause premature burning of contact points, motor overheating,
and rapid motor brake wear.
3-3. PULLING AND ROTATING HOIST AND LOAD.
a. The push button station conductor cable has a built-in strain
cable suitable for pulling trolley suspended hoists when not
loaded. Do not use for pulling bridge cranes. Push on load or
load chain or use a hand geared or motor driven type trolley to
traverse loaded hoists.
b. To rotate hoist and load, push on one corner of load. The
lower hook will pivot through 360 degrees to permit load to be
swung to the desired position. The upper hook (hook suspen­sion
models) is also designed to rotate so that side pulls will swing
hoist to face load, thus reducing side thrust.
When positioning the hook to set a limit, stop the hook in
the same manner as it is likely to be stopped during normal
operation. If it is likely that the limit will be reached when the
hoist is traveling at full speed, then position the hook by pressing
the pushbutton and releasing when the hook is at the desired
position, without jogs. If jogs are used to position the hook for
setting the limit, the hook may drift past the limit if tripped at
full speed.
Note: The limit switch has a setting increment of 1/4
revolution of the sprocket gear. This applies when setting
the limits. The hoist may stop up to a maximum of 1-1/2
inches before the desired position for 5/16 chain, or 1-1/4
inches for 1/4" chain. Once set, the hoist will repeatedly
stop at the same location.
11925A
Figure 3-1a. Limit Lever Being Tripped By Actuator
Above Lower Block on Single Line Hoist (paddle limit)
3-4 UPPER AND LOWER LIMITS. Budgit Electric Hoists are
equipped with either a paddle type limit switch, operated by
the lower block in the up direction and an actuator attached to
the chain in the lowering direction, or an electronic limit switch
which relies on proximity switches mounted in the gear case
cover. Refer to the appropriate section below:
Figure 2-2.
Page 3-4a. UPPER AND LOWER LIMIT STOPS (paddle limit). A lower
block and chain operated limit stop is provided to guard against
overtravel of load in either raising or lowering direction, which
can cause damage to hoist. When highest position is reached
a limit actuator on the load chain, above the lower block, trips
the limit lever (fig. 3-1a). When lowest position is reached, a
limit actuator on the tail end of load chain trips the limit lever
(fig. 3-1b). The limit lever is connected to a limit switch that
automatically stops the hoist motor. This is intended as a safety
device and is not to be used on a routine basis to stop travel of
lower block or shut off hoist.
Figure 3-1d. Chain Stop Contacting
Stop Shoe Tail Chain End of Load Chain
(electronic limit switch)
Figure 3-1b. Limit Lever Being Tripped By Actuator on
Tail End of a Load Chain (paddle limit)
3-4b. UPPER AND LOWER LIMIT STOPS (electronic limit switch).
Upper and lower limit stops are provided to guard against
overtravel of load in either raising or lowering direction, which
can cause damage to hoist. When highest position is reached,
the lower block will cause the overload clutch to slip (fig. 3-1c).
When the lowest block position is reached, the tail chain stop
will cause the overload clutch to slip (fig. 3-1d). Limit stops are
intended as safety devices and are not to be used on a routine
basis to stop block travel. Lowering full rated capacity load at full
rated speed into the limit stop is an especially severe condition
and must be avoided at all times.
3-5. OVERLOAD CLUTCH OPERATION. The overload clutch
is factory preset at assembly so that the hoist will lift its full
rated load but will refuse to lift overloads within a range of
150 percent rated load to 200 percent rated load. If the load
to be lifted exceeds the clutch factory setting, the motor will
continue to run and will rotate the clutch gear with­out lifting the
load. Whenever this occurs, immediately release the “h” push
button to prevent overheating of the clutch friction surfaces and
motor, and reduce the load to rated hoist capacity. Should it
be impractical to reduce the load, replace the hoist with one of
suitable rated capacity.
NOTE: Always know load to be lifted. Budgit Hoists does not
recommend lifting loads greater than the rated load of your
hoist.
3-6. OPERATING PRECAUTIONS.
WARNING
Equipment covered herein is not designed or suitable
as a power source for lifting or lowering persons. Do
not use as an elevator.
Safe operation of an overhead hoist is the operator’s respon­
sibility. Following 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.
Figure 3-1c. Lower Block Contacting
Stop Shoe at Upper Limit of Travel
(electronic limit switch)
Page a. DO read ANSI B30.16 Safety Standard for Overhead Hoists
and the Operation, Service and Parts Manual
ac. DO NOT use limit switches as routine operating stops.
They are emergency de­vices only.
b. DO be familiar with hoist operating controls, pro­cedures
and warnings.
ad. DO NOT use hoist to lift, support or transport people.
c. DO make sure hook travel is in the same direction as
shown on controls.
d. DO make sure hoist limit switches function properly.
e. DO maintain firm footing when operating hoist.
f. DO make sure that load slings or other approved single
attachments are properly sized and seated in the hook
saddle.
g. DO make sure that the hook latch, is closed and not
supporting any part of the load.
h. DO make sure that load is free to move and will clear all
obstructions.
i. DO take up slack carefully, check load balance, lift a few
inches and check load holding action before continuing.
j. DO avoid swinging of load or load hook.
k. DO make sure that all persons stay clear of the suspended
load.
I. DO warn personnel of an approaching load.
m. DO protect load chain from weld splatter or other
damaging contaminants.
n. DO promptly report any malfunction, unusual performance,
or damage of the hoist.
ae. DO NOT lift loads over people.
af. DO NOT leave a suspended load unattended unless
specific precautions have been taken.
ag. DO NOT allow sharp contact between two hoists or
between hoist and obstructions.
ah. DO NOT allow the chain or hook to be used as a ground
for welding.
ai. DO NOT allow the chain or hook to be touched by a live
welding electrode.
aj. DO NOT remove or obscure the warnings on the hoist.
ak. DO NOT adjust or repair a hoist unless qualified to
perform hoist maintenance.
al. DO NOT attempt to lengthen the load chain or repair
damaged load chain.
am. DO NOT allow personnel not physically fit or properly
qualified to operate the hoist.
an. DO NOT operate hoist unless upper and lower limit
switch stops are operating properly.
ao. DO always be sure there is no twist in coil load chain. On
2 & 3 ton coil chain hoists, check to see that lower block is
not capsized between strands of chain.
o. DO inspect hoist regularly, replace damaged or worn
parts, and keep appropriate records of maintenance.
ap. DO avoid operating hoist when hook is not centered
under hoist. Be sure that hoist trolley or other support
mechanism is correctly positioned for handling the load
before lifting.
p. DO use the hoist manufacturer’s recommended parts
when repairing a hoist.
aq. DO operate hoist within recommended duty cycle and
do not “jog” unnecessarily.
q. DO use hook latches wherever possible.
ar. DO conduct regular visual inspections for signs of
damage or wear.
r. DO apply lubricant to load chain as recommended. DO NOT
lift more than rated load.
s. DO NOT use the hoist load limiting device to mea­sure
the load.
t. DO NOT use damaged hoist or hoist that is not working
correctly.
u. DO NOT use the hoist with twisted, kinked, dam­aged or
worn chain.
v. DO NOT lift a load unless chain is properly seated in chain
wheel(s) or sprocket(s).
w. DO NOT use load chain as a sling or wrap chain around
the load.
x. DO NOT lift a load if any binding prevents equal loading
on all supporting chains.
y. DO NOT apply the load to the tip of the hook.
z. DO NOT operate unless load is centered under hoist.
aa. DO NOT allow your attention to be diverted from
operating the hoist.
ab. DO NOT operate the hoist beyond limits of load chain
travel.
Page as. DO NOT operate hoist with hooks that have opened up.
See Figures 5-5 and 5-6.
at. DO provide supporting structure or anchoring means that
has a load rating at least equal to that of the hoist.
au. DO NOT use hoists in locations that will not allow
operator movement to be free of the load.
av. DO when starting to lift or pull, move the load a few
inches at which time the hoist should be checked for proper
load holding action. The operation shall be con­tinued only
after the operator is assured that the hoist is operating
properly.
aw. DO NOT leave a loaded hoist unattended at the end of
a work shift or for extended periods during the work shift.
Where operations are such that this condition cannot be
avoided the operator must be assured that the condition
does not create a hazard to personnel or property.
ax. DO use common sense and best judgement whenever
operating a hoist. Observe American National Standard
Safety standard, ANSI B30.16, latest issue.
SECTION IV - LUBRICATION
4-1. GENERAL. The lubrication services outlined in para­graphs
4-2 through 4-5 should be performed at regular intervals
to maintain top hoist performance and insure long life. The
frequency for lubrication services will depend on the type of
hoisting service that hoist is subjected to and should coincide
with periodic preventive maintenance inspection. See Section
V-Maintenance.
4-2. CHANGE GEAR CASE OIL (Fig. 4-1).
a. Remove drain plug from bottom of hoist frame and drain oil
from gear case. Replace plug.
b. Remove oil level plug from side of hoist.
c. Refill gearcase through oil filler to proper level (bottom of oil
level plug hole) using Automatic Transmission Fluid - DEXRON
Type. This is an all-weather oil available from all major oil
companies. 1-1/2 pints of oil are required.
d. Reinstall oil level plug and breather.
4-3. LUBRICATE LOAD CHAIN. A small amount of lubricant will
greatly increase load chain life, therefore, chain should not be
allowed to run without lubricant. Chain should be cleaned and
lubricated as directed in paragraph a below. User should set up
a regular schedule for chain lubrication after observing operating
con­ditions for a few days. Use Bar and Chain Oil (LUBRIPLATE
or equal) on load chain.
4-4. LUBRICATE UPPER HOOK AND LOWER BLOCK
ASSEMBLY.
a. Apply a few drops of Bar and Chain Oil on shank of upper
hook where it enters frame.
b. Apply a few drops of Bar and Chain Oil on shank of lower
hook where it enters lower block. Hook rotation bearing may
be removed for cleaning and re-lubricating if necessary. See
section 7-5.
c. On lower block assemblies of 2 and 3 ton capacity hoists, also
apply heavy duty lithium soap grease with EP additives through
pressure fitting in end of sprocket pin to lubricate bearing in
chain sprocket.
d. On 3 ton model lubricate sprocket in hanger bracket with
a few drops of Bar and Chain Oil in hole provided in center of
sprocket hub.
4-5. LUBRICATE LIMIT LEVER CONTROL SHAFT AND
GEARS.
Apply a few drops of Bar and Chain Oil on limit lever shaft at
bearing points.
WARNING
Before performing any internal work on hoist, be certain
power is shut off. Lock main service switch in the open
position.
SECTION V - MAINTENANCE
5-1. GENERAL. Preventive maintenance services required
on Budgit Electric Hoists are for the most part, simple peri­
odic inspection procedures to determine condition of hoist
components. Below are suggested inspection procedures, based
on daily average hoist usage.
5-2. THIRTY-DAY INSPECTION. Hoist may be left suspended.
a. Inspect Load Chain.
(1) Operate hoist under load and observe operation of chain
over sprocket in both directions of chain travel. Chain should
feed smoothly into and away from the sprocket. If chain binds,
jumps or is noisy, first see that it is clean and properly lubricated.
If trouble persists, inspect chain as outlined below.
10077L
Figure 4-1. Location of Oil Filler and Plugs
a. Coil Chain. Under ordinary conditions only weekly atten­tion will
be necessary. Under hot and dirty conditions it may be necessary
to clean chain at least once a day and lubricate it several times
between cleanings. Thoroughly clean chain with an oil solvent
and re-lubricate by coating it lightly with oil. Make sure that
lubricant coats wear surfaces between links. Zinc plated load
chain should be cleaned and lubricated daily.
Figure 5-1. Check Chain Wear at Bearing
Surfaces Between Links
(2) Coil Type Load Chain. Clean chain for inspection. Examine
visually for gouges, nicks, weld spatter, corrosion or distorted
links. Slacken chain and check bearing surfaces between links
Page for wear, fig. 5-1. Greatest wear will often occur at sprocket at
high or low point of lift, particularly when hoist is subjected to
repetitive lifting cycles. Case hardness of chain is about 015"
deep. Chain must be replaced before the case is worn through.
Also check chain for elongation using a vernier caliper (fig. 52). Select an unworn, unstretched section of chain (usually at
slack or tail end) and measure and record the length over the
number of chain links (pitches) indicated in figure 5-2. Measure
and record the same length of a worn section in the load side
of the chain. Obtain the amount of wear by subtracting the
measurement of the unworn section from the measurement of
the worn section. If the result (amount of wear) is greater than
the amount specified in the “ALLOW­ABLE CHAIN WEAR” table,
the chain has elongated beyond the maximum allowable length
and must be replaced. Chain with excessively pitted, corroded,
nicked, gouged, twisted or worn links should be replaced using
only factory approved chain. Never weld or attempt to repair
coil chain.
hoist frame and removing limit actuator. New chain is then run
into hoist as old chain is run out. Use open “C” links, figures 5-3
and 5-4, for attaching chains. Links must be iden­tical in size to
hoist chain - 1/4" wire size with .745" pitch length for 1/4 through
1/2 ton models, 5/16" wire size with .858" pitch for 1 through
3 ton models. Be certain that all welds on links of replacement
chain face away from center of load sprocket.
Figure 5-3. Open "C" Link for Removing and
Installing Coil Load Chain
Figure 5-2. Check Coil Chain Using Vernier Caliper
ALLOWABLE CHAIN WEAR - ELONGATION
Hoist
Rated Load
(tons)
Chain Size
(wire dia.)
No. of
Pitches
to Measure
Maximum
Wear Limit
1/4 & 1/2
1/4"
13
.145"
1 thru 3
5/16"
11
.142"
WARNING
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
To avoid serious personal injury from a dropped load
caused by chain breakage, when replacing coil load
chain, use only factory approved chain conforming
to Budgit hoist specifications for material, hardness,
strength and link dimensions. Chain not conforming
to factory Specifications may be dangerous as it will
not fit in the load sprocket and chain guide correctly,
causing serious internal damage to hoist and it will wear
prematurely, deform and eventually break.
(3) Removing and Replacing Coil Load Chain.
(a) Replacement Coil load chain is installed by attaching it to
tail end of old chain, after disconnecting old chain from side of
Page 10
Figure 5-4. Installing Coil Load Chain Using Two
"C" Links (1/4, 1/2 & 1 ton hoists)
(b) Remove lower block assembly and actuator from old chain
and attach them to replacement chain at end which was just run
through hoist. Install limit actuator (as noted below) on other end
of chain and anchor chain to side of hoist frame.
NOTICE
Use one or two "C" links to orient chain for chain anchor
screw. Position first link of new chain to be flat against
hoist housing without twisting the chain.
NOTE: See table on page 30 for location of tail chain
limit stop.
On 2 ton double reeved models, also connect opposite end of
chain (from lower block) to load chain anchor inside of frame.
On 3 ton triple reeved models, the opposite end of the chain is
attached to the lower block connecting link.
NOTE: In the event the old chain is to be removed from
hoist and reinstalled, a short length of chain (about 18"
long) must be run into hoist when the old chain is removed.
This short length can then be used in the same manner as
shown in paragraph 5-2. a.(3). Be sure to use the proper
number of open “C” links in order to correctly position
end link on tail end of chain to fit anchor at side of hoist
frame.
NOTICE
To avoid serious internal damage to hoist, when installing
coil load chain do not attempt to hand feed chain into
hoist, or use a piece of wire in place of the method
described herein. To do so may result in serious internal
damage to hoist, as coil chain links must be properly
seated in chain sprocket before chain is run into hoist.
Install chain only as described in this manual.
CAUTION
Keep fingers clear of chain sprocket when replacing
load chain.
(4) Check connection of chain to lower block on 1/4 through
1 and 3 ton hoists. Replace parts showing evidence of dam­age,
twisting or elongation.
Hook Throat Opening
Hoist
Rated Load
(tons)
Normal
Opening
1/4 & 1/2
1-1/8
1-1/4
1
1-1/4
1-7/16
2
1-3/8
1-9/16
3
1-1/2
1-11/16
Replace Hook if Opening
is Greater Than
(2) On 2 through 3 ton hoists, check sprockets and bearings
in lower block for freedom of movement and signs of dam­age.
Lubricate if necessary. Replace damaged parts.
(3) Check hook latches. Replace damaged or bent latches or
broken springs.
WARNING
Hooks, upper or lower, damaged from chemicals,
deformation or cracks or having more than 15 percent
in excess of normal throat opening or more that 10
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. (See Section V. Par. 5-2. d. (2) below).
(5) Check connection of chain to anchor inside hoist
frame on double-reeved, 2-ton hoists. Replace parts showing
evi­dence of damage, twisting or elongation. (Also see Sec. VII,
par. 7-2. a. (2)).
(6) Lubricate load chain before using hoist. See paragraph 4-3,
Section IV.
b. Inspect Lower Block.
(1) Check for bent or distorted hook. If hook is opened beyond
the dimension given in figure 5-5, it must be replaced. Also check
to see that hook swivels and is free to pivot. Lubricate these
points if necessary.
Hook Throat Opening
Hoist
Rated Load
(tons)
Normal
Opening
1/4 & 1/2
1-1/8
1-1/4
1
1-1/4
1-7/16
2
1-3/8
1-9/16
3
1-1/2
1-11/16
Replace Hook if Opening
is Greater Than
Figure 5-6. Upper Hook Opening
(Shown with latch removed for clarity.)
Figure 5-5. Lower Hook Opening
(Shown with latch removed for clarity.)
Page 11
c. Inspect Upper Suspension.
b. Relubricate Load Chain. See Section IV, paragraph 4-3.
(1) On hook suspended models, check for bent or distorted
hook. If hook is opened beyond the dimension given in figure
5-6, it must be replaced. Also check to see that hook pivots.
Lubricate if necessary.
c. Lubricate Upper Hook and Lower Block. See Section IV,
paragraph 4-4.
(2) On lug suspended models, check condition of suspen­sion
lug. Replace lug if damaged or cracked. Check to see that lock
plate is in place on lug and screw holding it is tight. (All capacities
see figure 7-20).
(3) On 2-ton hoists, check to see that upper lock plate securing
hook or lug bushing is in place and screws holding it are tight.
Lubricate hook shank.
(4) Check hook latch. Replace damaged or broken parts.
(5) Inspect threaded upper suspension bushing. Verify keeper is
in place against flat of suspension bushing, and securing screw
and lock washer are in place and tight.
d. Inspect Motor, Frame and Electrical Compartment
Cover.
(1) Check to see that bolts securing motor to frame are tight.
Also check for any visible damage to motor, such as a cracked
end bell or dented stator housing. Replace damaged parts.
(2) Check hoist frame for signs of visible damage. If frame
shows evidence of fracture, the hoist should be disassembled
and inspected for further signs of damage from possible
overloading. Replace damaged parts.
(3) Check for possible damage to electrical compartment cover.
Be sure screws holding cover are tight.
e. Check Oil Level. Remove oil level plug (fig. 4-1). If oil
level is not even with bottom of tapped hole, add Automatic
Transmission Fluid, DEXRON Type, to bring to proper level.
5-3. SIX-MONTH INSPECTION OR 500-750 HOURS OF
OPERATION. Hoist may be left suspended. Same as thirty day
inspection plus the following:
a. Inspect Electrical Controls. Shut off power supply to hoist
and remove electrical compartment cover from hoist. Use caution
as some covers contain counterweights. Two speed hoists
with a 2-1/4 horsepower motor have an externally mounted
counterweight at the electrical compartment cover.
(1) Check all wiring and terminals. Insulation should be sound
and terminals securely crimped to wires. Terminal screws should
be tight and plug-type terminals completely mated. Replace
terminals or wires as necessary.
(2) Check control circuit transformer for evidence of over­
heating. Replace if necessary.
(3) Check limit switch to see that wires are securely attached
and mounting screws are tight.
(4) Check contactor solenoid coils and replace coils if they
show evidence of overheating.
(5) Check control cable wire strain reliever to see that it is
in good condition and securely attached to gear case cover.
Replace rubber strain reliever grommets if damaged.
a. Change Gear Case Oil. See Section IV, paragraph 4-2.
Page 12
5-4. INSPECTION: 5000 HOURS “ON” TIME OR 5 YEARS
ELAPSED TIME. Hoist must be removed from overhead
suspension.
a. Disassemble Hoist into Subassemblies. Follow proce­dure
outlined in Section VII, paragraph 7-2.
b. Motor shaft oil seal, sprocket shaft bearing, seal and all
gaskets should be replaced.
c. Inspect Load Brake and Overload Clutch. Disassemble load
brake (if equipped) and clutch assembly as outlined in paragraph
7-4. Friction discs should be discarded and replaced with new
discs. Check load brake friction surfaces on flange, ratchet
assembly and gear clutch cone. Replace parts if badly scored
or worn. Check condition of pawl and ratchet assembly. If pawl,
ratchet teeth or pawl spring are broken, damaged or badly worn,
replace complete assembly. Check contact faces of load brake
cam and gear clutch cone. Brake gear and pinion teeth should
be inspected for wear or broken teeth. Clean parts thoroughly
with an oil solvent before reassembly.
NOTE: The overload clutch assembly should not be
disassembled as it is preset at the factory to provide proper
clutch pressure for a specific hoist capacity range. If there
is evidence of the clutch slipping or wear or damage to
the clutch compo­nents, the complete clutch assembly
should be replaced or sent to an authorized Budgit Hoist
Repair Station to be rebuilt and properly adjusted to factory
specifications.
d. Inspect Sprocket and Intermediate Gears.
(1) On 1 through 3 ton hoists, check condition of gear teeth on
intermediate gear and pinion shaft assembly. Replace worn or
damaged parts.
(2) Check condition of pockets on chain sprocket (all
capacities). Replace worn or damaged parts.
e. Inspect Motor Brake. Check braking surfaces for wear and
scoring. Replace badly worn or scored parts. Check spring studs
and guide pins to make sure they are not bent or loose. Check
coil shock mounts for deterioration and damage. Check air gap
adjustment. (See 7-11c)
f. Reassemble and Test Hoist. Reassemble hoist from
subassemblies following procedure outlined in paragraph 7-11.
After assembly is complete, test hoist as outlined in paragraphs
7-12 and 7-13.
SECTION Vl - TROUBLE SHOOTING
Trouble
Probable Cause
Remedy
6-1. Hoist Will Not Operate.
a. No power to hoist.
a. Check switches, circuit breakers and connections in power supply lines. Check power collectors.
b. Wrong voltage.
b. Check voltage required on motor data plate against power supply.
c. No control voltage.
c. Check transformer fuse. If blown, check for grounding and/or short in the pushbutton station. Check the transformer coil for signs of overheating. Replace transformer if burned out. Verify the transformer secondary is the same voltage as the coils to which it is connected.
d. Loose or broken wire
connections in hoist electrical
system.
d. Shut off power supply, remove electrical
cover from hoist and check wiring connections
Also check connections in push button station and limit switches.
e. Contactor assembly not
functioning.
e. Check for burned out solenoid coil. See that
the necessary jumper wires are properly installed.
f. Replace burned out parts.
f. Starting switch burned out
(single phase motor).
g. Motor burned out.
g. Replace motor. On single-phase motors the starting switch may be burned out.
h. Adjust electronic Limit Switch. See section 2-5.
h. Electronic Limit Switch
not set.
6-2. Hook Moves in Wrong Direction.
a. Reverse phasing on three-
phase hoists.
a. Interchange any two of the three power supply line leads. Do not change green ground lead. Refer to Section II, par. 2-4.
b. Hoist wired wrong.
b. Check wiring connections with appropriate wiring diagram.
c. Check for correct starting switch part
number and function. Replace if necessary.
c. Starting switch not working
correctly (single phase motor).
6-3. Hook Will Raise But Not Lower.
a. "DOWN" electrical circuit
open.
a. Check for loose connections. See that necessary jumper wires are properly installed on contactor. Check limit switch condition and electrical connections.
b. Contactor assembly not
functioning.
b. See that necessary jumper wires are properly installed. Verify that the contactor armatures are free to move. If binding occurs replace contactor. Check for burned out contactor coils.
c. Push Button Inoperative.
c. Check push button contacts and wires.
d. Load Brake locked up and
overload clutch slipping.
d. Consult Authorized Budgit Hoist Repair Station.
6-4. Hook Will Lower But Not Raise
(continued on next page).
a. Excessive load, causing
overload clutch to slip.
a. Reduce loading to rated load of hoist, as
shown on nameplate.
b. Overload clutch out of
adjustment.
b. Test hoist and replace clutch if hoist will not lift rated load.
c. "UP" electrical circuit open.
c. Check for loose connections. See that necessary jumper wires are properly installed on contactor. Check limit switch condition
and electrical connections.
Page 13
SECTION Vl - TROUBLE SHOOTING (Continued)
Trouble
Probable Cause
Remedy
6-4. Hook Will Lower But Not Raise
d. Contactor assembly not
(continued).
functioning.
d. See that necessary jumper wires are properly installed. Verify that the contactor armatures are free to move. If binding occurs replace contactor. Check for burned out contactor coils.
e. Check push button contacts and wires.
e. Push button inoperative.
6-5. Hoist Will Not Lift Rated Load.
a. Low voltage
a. See that power supply is same voltage listed on motor data plate. Check size of power supply lines. Refer to fig. 2-1.
b. Remove and replace clutch assembly. Refer
to Section IV, par. 7-2 and 7-4.
b. Overload clutch out of
adjustment.
c. Motor brake not releasing.
c. Check brake components. Refer to Section VII, par 7-2.d, 7-2.e.
6-6. Excessive Drift When Stopping.
a. Excessive load.
a. Reduce loading to rated load, shown on nameplate.
b. Motor brake not holding.
b. Check brake components. Refer to Section VII, par. 7-2.d.
c. Adjust air gap. Refer to Section VII, par.
7-11.c.
c. Motor brake not setting due
to insufficient plunger air gap.
d. Load brake not holding.
d. Remove load brake and inspect parts. Refer to Section V, par. 5-4.
6-7. Hoist motor overheats.
a. Excessive load.
a. Reduce loading to rated load of hoist, shown on nameplate
b. Excessive duty-cycle.
b. Reduce frequency of lift.
c. Excessive "jogging."
c. Reduce frequency of jogs.
d. Wrong voltage.
d. Check voltage rating on motor data plate against power supply.
e. Starting switch on single-
phase motors not opening
starting winding.
e. Refer to Section VII, par. 7-9.b. (3) (b).
Inspect Switch.
f. Damaged motor or worn
bearings in motor or hoist frame.
f. Disassemble hoist and inspect for worn or
damaged parts.
g. Motor brake not releasing.
SECTION VII - DISASSEMBLY AND
REASSEMBLY
7-1. GENERAL.
a. The following disassembly and reassembly instructions apply
to all standard models in the line of Budgit Electric Hoists
equipped with MAN-GUARD overload clutch. Where needed,
variations to instructions are provided to cover differences
between models (suspensions, rated load sizes and motor
voltage ratings), with applicable models specifically noted.
b. A complete teardown procedure is given, however, if only
certain parts require repair or replacement, a partial teardown
may be performed using the applicable portions of the
instructions.
c. For easier handling during disassembly, the following
disassembly steps may, where conditions permit, be completed
Page 14
g. Check brake components. Refer to Section VII, par. 7-2.d.
before hoist is removed from its overhead suspension or
disconnected from its power supply: Remove chain container,
if hoist is so equipped; remove lower block and load chain
assembly, following procedure outlined in paragraph 7-2. a.
Drain and discard gear case oil, by removing plug at bottom
of frame.
d. These hoists contain precision machined parts and should
be handled with care at disassembly and at reassembly. When
removing or installing parts with press fits, be careful to apply
pressure evenly. On ball bearings, apply pressure to face of
inner or outer race, whichever is adjacent to mating part. This
will avoid damage to bearing races from brinelling by pressing
through bearing balls. Apply a thin film of sealant to parts having
a press fit when they are installed.
7-2. DISASSEMBLY OF HOIST INTO SUBASSEMBLIES.
a. Removal of Lower Block and Load Chain Sub­assembly.
(1) On models with single-reeved load chains (1/4 through 1
ton rated loads) disconnect tail end of load chain from anchor
at side of frame. Remove fillister head screw holding end link
to frame. Remove grooved pin from the limit actuator and pull
it off end of chain. With hoist connected to power supply, run
chain out of hoist by operating in “lowering” direction. (See note
following paragraph (2) below and note in Sec. V, par. 5-2. a. (3)
for inserting short length of chain.)
(2) On models with double-reeved load chains (2 ton hoists)
disconnect tail end of load chain from anchor at side of hoist
frame and remove limit actuator as in (1) above, run chain out
of hoist by operating it in “lowering” direction, and disconnect
opposite end of load chain from anchor inside hoist frame. To
disconnect this end of chain, remove cotter pin from end of
anchor pin, press pin from anchor and withdraw chain. The drive
pin securing threaded end of anchor in upper block assembly (at
top of frame) must be removed in order to rotate the anchor.
NOTE: If hoist is inoperative and not equipped with a
load brake, chain can be pulled through by hand by first
manually releasing motor brake. If hoist is equipped with a
load brake it will be necessary to wait until after load brake
is removed (paragraph. c., below), then the chain can be
pulled through the hoist by hand.
(3) On triple-reeved 3 ton hoists, remove retain­ing ring and
connecting link pin as shown in figures 7-30 and 7-31. Remove
connecting link with chain from lower block.
Figure 7-3. Removing 3 Ton Hanger Bracket from Hoist Frame
To remove connecting link from chain, take out cotter key and
push anchor pin from connecting link. Chain can now be pulled
through hanger bracket and lower block. Unfasten tail chain
from hoist frame, remove limit actuator, and if power is avail­able,
operate hoist in lowering direction to remove chain. (See note in
Sec. V, par. 5-2. a. (3) for inserting short length of chain). If hoist
is inoperative see note below but be sure to install short length
of chain into hoist before removing load chain.
NOTE: If hoist is inoperative and not equipped with a load
brake, chain can be pulled through by hand by first manually
releasing motor brake. If hoist is equipped with a load brake it
will be necessary to remove load brake (paragraph. c, below)
so chain can be pulled through the hoist by hand.
(4) To remove 3 ton hanger bracket from hoist, remove
retaining ring and connecting rod pin (see fig. 7-2). Rotate hoist
approximately 45° (see fig. 7-3) and hanger will slip free from
hoist frame.
b. Removal of Electrical Compartment Cover, Electri­cal
Controls and Gear Case Subassembly.
(1) Disconnect hoist from power source. Remove three cover
retaining screws and lift off cover (fig. 9-1). Cover screws have
retaining rings which hold them in cover. Use caution as some
covers contain counterweights. Two speed hoists with a 2-1/4
horsepower motor have an externally mounted counterweight at
the electrical compartment cover.
Figure 7-2. 3 Ton Hanger Bracket Connection Pin Removed
(2) Disconnect push button conductor cable leads at plug-in
type connectors that can be pulled apart. Remove screw and
washer securing strain reliever (fig. 9-8) and pull the cable and
grommet from its slot in gear case cover.
(3) Disconnect power supply flexible cable leads from terminals
of contactor. Remove screw attaching ground leads to gear case
cover and pull flexible cable and grommet from slot in cover.
(4) Disconnect motor leads from electrical control units.
Number of leads depends on type of motor. (See wiring diagrams
in accompanying this manual).
(5) Remove eight hex socket head screws and lockwashers
securing gear case cover to hoist frame. Pry gear case cover
off hoist frame using screw driver at special notches provided
at opposite corners of cover (fig. 7-4). Discard gear case cover
gasket.
Page 15
10314
Figure 7-7. Removing Load Brake and Clutch Assembly
(1/4 & 1/2 Ton Hoists)
10311
Figure 7-4. Prying Gear Case Cover from Hoist Frame
No Figure 7-5.
Figure 7-6. Gear Case Cover with Electrical
Controls Removed from Frame
Figure 7-7a.
c. Removal of Load Brake and Clutch Assembly and
Intermediate Gear Subassembly.
(2) On 1 through 3 ton hoists, pull load brake or clutch assembly
and intermediate gear assembly, including the thrust washers for
each unit, from hoist frame (fig. 7-8).
(1) On 1/4 through 1/2 ton hoists, pull load brake/clutch
assembly if equipped or overload clutch assembly and the
shaft washers from inside hoist frame (fig. 7-7). Caution:
Grease-retained bearing has 36 rollers (all capacities) and may
be reinstalled unless rollers are broken or missing or cup is
damaged.
Page 16
10315A
Figure 7-8. Removing Load Brake and Clutch and
Intermediate Gear Subassemblies (1 through 3 Ton Hoists)
Figure 7-9. Removing Motor Assembly
7-3. REBUILD OF HOIST FRAME, SPROCKET GEAR, SPROCKET
SHAFT AND CHAIN GUIDE.
a. Disassembly of Sprocket Gear, Shaft and Chain Guide.
(1) Remove retaining ring from end of sprocket shaft and pull
off sprocket gear using a common puller (fig. 7-10). Remove
Woodruff key from shaft.
Figure 7-8a.
d. Removal of Motor Brake.
10322
(1) Remove acorn nuts holding brake cover and remove brake
cover (fig. 7-11).
(2) Disconnect wire nuts on brake coil leads.
(3) Remove brake mounting plate screws (fig. 7-11) and lift
brake assembly off to gain access to the motor mounting
bolts.
e. Removal of Motor Assembly.
(1) Place hoist frame on wood blocks to protect intergral gear
on motor shaft. Loosen four motor mounting bolts and lift motor
assembly from frame (fig. 7-9). Guide motor leads through wire
passage to avoid damage.
Figure 7-10. Pulling Sprocket Gear from Sprocket
Shaft using Common Puller
(2) Unscrew four fillister head machine screws securing
sprocket bearing retaining plate and remove plate (fig. 7-11).
Remove and discard ring gasket from groove around bearing.
Page 17
10323
Figure 7-11. View of Sprocket Bearing Retaining Plate
(3) Remove "C" clips holding chain guide pins in place. Pull
guide pins out from motor side of frame. (Fig 7-13)
10326
Figure 7-14. Removing Sprocket Shaft and Front Bearing
NOTE: Do not remove oil seal, ball bearings, and needle
bearings from their bores in the frame unless they show
evidence of wear or damage and require replacement.
When replacing rear sprocket ball bear­ing pack bearing
1/2 full with NLGI No. 2 grease.
10327
Figure 7-15. Chain Guide Being Removed from Frame
as Sprocket Shaft is Lifted Out
Figure 7-13. Removing Chain Guide Support Pins
(4) Remove sprocket shaft and front ball bearings assembly
from frame by lifting up on end of shaft while prying up on
sprocket as illustrated in figure 7-14. The chain guide will need
to be repositioned in frame as sprocket shaft is raised to allow
the sprocket to pass through hole of guide (fig. 7-15).
Page 18
b. Disassembly of Upper Hook. (Hook Suspension Models)
(1) On 1/4 through 1 ton models, remove screw securing
suspension bushing keeper. Unscrew suspension bushing from
frame to remove hook.
drive grooved pin through hook nut until it hits hanger pocket.
Remove drift far enough to hold nut from turning and unscrew
hook from nut. Thrust washer will fall free.
(4) To remove connecting rod (fig 7-2) on 3 ton hoist, remove
screw securing suspension bushing keeper. Unscrew suspension
bushing to remove connecting rod from frame.
Figure 7-18. Removing Upper Hook and Hook Nut
from Hoist Frame (1/4 through 1 Ton Models)
(2) On 2 ton models, unscrew two hex socket head screws
holding suspension bushing lock assembly to upper block (fig.
7-19) and remove lock. Unscrew suspension bushing from block
to remove hook. To disassemble block from frame, remove screw
securing suspension bushing keeper. Remove drive pin securing
threaded end of chain anchor in block and unscrew anchor.
Unscrew suspension bushing to remove block.
Figure 7-20. Removing Suspension Lug
(1/4 through 1 Ton Models)
c. Disassembly of Suspension Lug (Lug Suspension
Models).
(1) On 1/4 through 1 ton models, remove two screws securing
anti-rotation bracket and remove bracket. Remove screw
securing suspension bushing keeper, and remove keeper.
Remove suspension lug using an extra thin 1-1/4" open end
wrench to unscrew suspension bushing from frame. (See fig.
7-20).
(2) On 2 ton models, remove three hex socket head screws
securing the two lock plates to block at top of frame and pull
out locks. Remove suspension lug, using an extra thin 1-1 /4"
open end wrench to unscrew suspension bushing from block.
Instructions for removing block from frame are given in para­graph
b. (2).
NOTE: The suspension lug is not to be further disassembled,
as nut securing suspension bolt and bushing to lug is
permanently secured in place at the factory. Only the
suspension lug assembly is available for replacement.
Figure 7-19. View of Upper Hook Assembled
to Hoist Frame (2 Ton Models)
NOTE: Hook and bushing assembly is not to be further
disassembled as nut securing bushing to hook shank
is welded in place at the factory. Only the assembly is
available for replacement.
(3) On 3 ton models, remove retaining ring from connecting rod
pin and push connecting rod pin through bracket and connecting
rod, releasing hanger (see fig. 7-2). Raise hanger above hoist
frame to provide access to hook nut. Rotate hook until grooved
pin in nut is visible from end of hanger frame. Using a drift punch,
(3) On 3 ton models lug bolt is removed in same manner as
hook. See paragraph 7-3. b. (3).
d. Reassembly.
(1) Before assembly, all parts should be thoroughly cleaned
and inspected to determine their serviceability. Replace parts
that are excessively worn or damaged.
(2) Reassemble suspension hook or lug, chain guide, sprocket
shaft and sprocket gear to frame following a reverse procedure
of the disassembly steps listed in paragraphs (a.) through (c.),
above. If ball bearing is to be reinstalled on sprocket be certain
to position it so that the seal side of bearing faces out, away from
sprocket. To help prevent oil seepage, apply sealant on O.D. of
sprocket bearing and in seat for the ring gasket.
Page 19
7-4. REBUILD OF LOAD BRAKE AND OVERLOAD CLUTCH
ASSEMBLY. (If hoist is equipped with overload clutch less load
brake, see 7-4A.)
a. Disassembly.
(1) Place load brake and clutch assembly, flange up, in a vise
equipped with brass or copper jaw plates to protect pinion gear
teeth. Remove snap ring of load brake shaft (fig. 7-21).
10333
10335
Figure 7-23. Removing Pawl and Ratchet Assembly
from Load Brake Shaft
Figure 7-21. Removing Snap Ring from Load Brake Shaft
(3) Remove load brake gear and overload clutch assembly
from output pinion shaft. Pull the spring from its recess in clutch
cone (fig. 7-24) but do not further disassemble gear and clutch
assembly. See “NOTE” below.
NOTE: Disassembly of the load brake gear and overload
clutch assembly (fig. 7-24) is not recom­mended. Clutch
pressure is preset by the factory at assembly to provide
the correct torque to allow the clutch to refuse loads
within a specified range (150% of rated load to 200%
rated load). It is sug­gested whenever there is a need to
repair or read­just the gear and clutch assembly that it be
sent to an authorized Budgit Hoist Repair Station where
adequate tools, fixtures and appropriate test equipment
is available.
11927
10334
Figure 7-22. View Showing Load Brake Flange Removed
(2) Using a puller tool, remove brake flange from shaft. A groove
is provided around outer diameter for this purpose. See figure
7-22. Remove key from shaft and lift off 2 friction discs, and the
pawl and ratchet assembly (fig. 7-23).
Page 20
Figure 7-24. Load Brake Gear and Overload Clutch
Assembly Removed from Load Brake Shaft
Showing Brake Spring Installed in Clutch Cone
10610
Figure 7-24a.
(4) The load brake pawl and ratchet is a riveted assembly and
is not to be disassembled.
b. Reassembly.
(1) Before assembly, all parts should be cleaned and in­spected
to determine their serviceability. Replace parts that are worn or
damaged.
(2) Reassemble load brake parts following a reverse proce­dure
of the disassembly steps listed above, observing the assembly
steps (3) through (6) below.
(3) Before installing spring in its recess in center of clutch cone
(fig. 7-24) apply a good grade of ball bearing grease to inside of
recess. Spring must be positioned exactly as illus­trated, abutted
against pin.
(4) When installing pawl and ratchet assembly on load brake
shaft, be certain that teeth on ratchet face are in the same
direction as shown in fig. 7-23. The ratchet assembly should
rotate freely when turned counterclockwise and the pawl should
engage ratchet teeth when unit is turned clockwise.
(5) When installing brake flange position it with chamfer facing
friction disc, figure 7-22.
(6) The brake spring must be pre-loaded at assembly to a
torque of from 6 to 10 lb. ft. when used with yellow (color code)
spring and a torque of 10 to 14 lb. ft. when used with plain (no
color code) spring. (See Section IX for proper spring). This is
accomplished using a plumber’s strap wrench to wind (rotate)
load brake gear to set up spring (fig. 7-25) while pressing brake
flange into place using an arbor press. Clamp pinion end of shaft
into a portable vice to keep brake from rotating in press. Use
brass or copper jaw plates on vise to protect pinion gear teeth.
Wind gear counterclockwise (view­ing brake from flange end) with
strap wrench and press down on flange until snap ring groove in
shaft is exposed allowing snap ring to be installed. Use extreme
care not to over wind spring as yield will result and final spring
torque will be reduced. Do not wind gear beyond point necessary
to install snap ring in groove.
Figure 7-25. Winding Load Brake Gear
Using a Strap Wrench to Set Up Load Brake Spring
7-4A. OVERLOAD CLUTCH WITHOUT LOAD BRAKE.
Disassembly of the clutch gear and overload clutch assembly
(fig 7-24a) is not recommended. Clutch pressure is preset at the
factory at assembly to provide the correct torque to allow the
clutch to refuse loads within a specified range (150% of rated
load to 200% rated load). It is suggested whenever there is a
need to repair or readjust the overload clutch assembly that
it be sent to an authorized Budgit Hoist Repair Station where
adequate tools, fixtures, and appropriate test equipment is
available.
7-5. REBUILD OF LOWER BLOCK AND LOAD CHAIN
ASSEMBLY.
a. Disassembly (1/4 through 1-ton, single reeved models).
(1) Separate load chain from lower block assembly. Drive out
small roll pin securing lower block pin in lower block yoke and
push lower block pin from yoke to release chain.
(2) Drive grooved pin from limit actuator and pull actuator from
end of chain.
(3) Lower blocks are of a pinned construction, permitting
replacement of body, thrust bearing, or hook and nut assembly.
To disassemble, drive spring pin from hook nut (fig. 7-26). With
pin removed, hold hook nut from turning with drift punch and
rotate hook to unscrew it from nut.
Page 21
11868
10337A
Figure 7-28. Removing Sprocket Pin Lock on
2 through 5 Ton Lower Block Assembly
Figure 7-26. Removing Roll Pin Securing Hook Nut
to Hook Shank
(4) Separate hook, bearing shield, needle bearings and two
thrust washers from body. Hook and nut are drilled at assembly
and are replaced only as an assembly.
b. Disassembly (2-ton, double reeved models).
(1) Remove fillister head screw securing center guide in top of
lower block body and lift out guide (fig. 7-27) and sprocket pin
lock (fig. 7-28). Press sprocket pin from body and pull out chain,
sprocket and washer (fig. 7-29). Do not remove bushing type
bearing from sprocket or pressure lube fitting from sprocket pin
unless replacement is necessary.
10338A
Figure 7-29. Removing Coil Chain and Sprocket on
2 through 5 Ton Lower Block Assembly (Link Chain Model)
(2) To disassemble hook and nut, drive groove pin from hook
nut with drift punch. With pin removed, hold hook nut from
turning with drift punch and rotate hook to unscrew it from nut.
Separate hook, nut, bearing shield, needle bearing and two thrust
washers from body. Hook and nut are drilled at assembly and
are replaced only as an assembly.
c. Disassembly (3-ton, triple reeved models).
10336A
Figure 7-27. Removing Chain Center Guide from
2 through 5 Ton Lower Block Assembly
Page 22
(1) Remove chain sprocket from lower block following
procedure for 2-ton link chain models described in paragraph
7-5. b. (2) above.
(2) To disconnect end of chain anchored to lower block, remove
retaining ring from pin bore (fig. 7-30). Push connect­ing link pin
from bore by pressing through hole provided in opposite side of
block (fig. 7-31). Chain connecting link is now free and can be
further disassembled for inspection.
7-6. REBUILD OF ELECTRICAL CONTROLS AND GEAR CASE
COVER SUBASSEMBLY.
a. Disassembly.
(1) Disconnect two limit switch leads from contactor. Also, if
hoist has a transformer, disconnect transformer leads at the
contactor or terminal board.
(2) Remove reconnectable terminal board if so equipped.
(3) Remove two screws and lift transformer from gear case
cover if hoist is so equipped.
11752A
(4) Remove two screws attaching contactor assembly to cover
and lift off contactor. Refer to paragraph 7-8 for instruc­tions for
rebuild of contactor assembly.
(5) Remove two hex socket head screws and lockwashers
securing limit switch assembly to gear case cover and pull limit
switch assembly and control shaft from cover.
(6) Loosen two nuts and screws holding limit switches to
retainer bracket and remove.
Figure 7-30. Removing Retaining Ring from Bore of
Connecting Link Pin - 3 Ton Lower Block Assembly
(7) Remove self-locking nut from end of control shaft and pull
off washer, switch activator, centering lever, spring, spacer tube,
retainer bracket and washer.
NOTE: Do not remove needle bearings from gear case
cover unless they show evidence of wear or damage and
require replacement.
b. Reassembly.
(1) Before assembly, all parts should be thoroughly cleaned
and inspected to determine their serviceability. Replace parts
that are worn or damaged.
(2) Reassemble parts to gear case cover in reverse of the
disassembly steps above. Ends of centering spring must strad­
dle centering levers. Lubricate contact segments of limit switch
with small amount of graphite grease.
7-7. REBUILD OF PUSH BUTTON STATION AND CON­
DUCTOR CABLE ASSEMBLY.
11752B
Figure 7-31. Removing Connecting Link Pin from 3 Ton
Lower Block Assembly
a. Disassembly.
(1) Remove seven pan head machine screws and
lockwashers from back of push button station and lift off rear
cover.
(2) Loosen three terminal screws and remove strain cable
screw, lockwasher and plain washer.
(3) To remove hook from lower block body, first drive grooved
pin from hook nut. Then hold nut from turning using drift punch
and rotate hook to unscrew it from nut. Separate hook, shroud
and thrust washer from body. Note that bearing surface of
washer faces nut.
(4) To remove chain sprocket from upper suspension hanger,
first remove hanger as outlined in paragraph 7-2. a. (4). With
hanger removed, push sprocket pin from hanger and sprocket.
NOTE: Sprocket pin must be removed toward side having small
anti-rotation pin slot in hanger.
d. Reassembly of Lower Blocks.
(1) Clean, inspect and replace worn or damaged parts.
(3) Remove two pan head machine screws and lockwashers
from housing cap and remove cap, grommet and cable
assembly.
(4) Remove two pan head screws, contact assembly and
button assembly.
b. Reassembly.
(1) Before assembly, all parts should be thoroughly cleaned and
inspected to determine their serviceability. Replace all parts that
are worn or damaged.
(2) Reassemble push button station and conductor cable
following a reverse procedure of the disassembly steps listed
above.
(2) Lubricate and reassemble following a reverse procedure
of the disassembly steps above.
Page 23
NOTE: Do not attempt to shorten or lengthen push button
conductor cable. Odd length conductor cable assemblies
for other than standard 10 ft. lift hoists can be procured
from the factory.
7-8. REBUILD OF CONTACTOR ASSEMBLY.
a. General. Wear or damage to contactor parts requires
replacement of complete contactor assembly.
7-9. REBUILD OF SINGLE PHASE MOTOR ASSEMBLY.
a. Disassembly.
(1) To inspect capacitor, remove two cover mounting screws
and lift off capacitor cover. Do not disconnect wires at capac­itor
unless capacitor must be replaced.
(2) Remove external retaining ring from end of shaft and press
shaft out of bearing in end bell.
(3) Remove motor end bell from stator assembly. If neces­sary
loosen it by tapping with soft mallet.
(4) Remove internal retaining ring from bearing bore in end bell
and press out bearing assembly.
b. Reassembly.
(1) Before assembly, all parts should be cleaned and in­spected
to determine their serviceability. Replace all parts that are worn
or damaged.
(2) Reassemble motor following a reverse procedure of the
disassembly steps listed above.
(3) After reinstalling hoist motor, connect hoist to power supply
and carefully complete both checks (a) and (b) below:
(a) To check direction of rotation, briefly operate “h“ button.
If hook lowers, interchange motor lead ‘T1" with “T4” at the
contactor or controller. Hook must raise when the “h“ push
button is operated.
(b) To check the starting winding switch, connect ammeter
(minimum 10 ampere) to motor lead “T5”. Amperes must drop to
zero in approximately one second when operating hoist in both
“h“ and “i“ directions. If ampere reading does not drop to zero,
interchange motor leads “T7” and “T8”. If, after above checks
were made with motor having been run in both directions, the
ammeter reading still does not return to zero, the motor switch
is not functioning properly and should be replaced.
b. Reassembly.
(1) Before assembly, all parts should be cleaned and in­spected
to determine their serviceability. Replace all parts that are worn
or damaged.
(2) Reassemble motor following a reverse procedure of the
disassembly steps listed above.
7-11. REASSEMBLY OF HOIST FROM SUBASSEMBLIES.
a. General. The procedure to be followed to reassemble the
hoist from subassemblies is in reverse order of the disassembly
steps outlined in paragraph 7-2. Listed below are special
assembly precautions which should be observed to assure
proper assembly.
NOTE: Grease retained bearings (see Section VII, par. 7-2.
c. (1) and fig. 7-7) have loose rollers. When reassembling
hoist, make certain the correct number of rollers are held
in roller cup with grease before assembling load brake
shaft to hoist.
b. Assembly of Load Brake Thrust Washers. When rein­stalling
load brake assembly be certain thrust washers are properly
installed at both ends of load brake shaft, as noted below.
(1) A bronze thrust washer with a lug on one side belongs on
pinion end of shaft and must be installed so that its lug engages
the special slot located on spotface surrounding bearing bore
inside hoist frame or gearcase cover. Use heavy grease to hold
washer in proper position in frame or cover (depending upon
hoist capacity) during assembly.
(2) A 5/8" I.D. steel thrust washer is to be installed on the brake
flange end (end opposite pinion) of load brake assembly.
c. Motor Brake. Check brake adjustment after first 30 days of
service and regularly thereafter during the six-month inspection
procedure.
Installation and Service Instructions for 54,000 Series
(rev. A) Manual Adjust Brakes.
WARNING
Do not change circuit wiring. Severe damage and
malfunction of hoist may result.
7-10. REBUILD OF THREE PHASE MOTOR ASSEMBLY.
a. Disassembly.
(1) Pull four motor mounting bolts from motor and separate
stator assembly from the end bell and rotor shaft assembly.
(2) Remove external retaining ring from end of motor shaft and
press shaft from bearing in end bell.
(3) Remove internal retaining ring from bearing bore in end bell
and press out bearing assembly.
Page 24
Important - Please read these instructions carefully before
installing, operating, or servicing. Failure to comply with these
instructions could cause injury to personnel and/or damage to
property if the brake is installed or operated incorrectly.
Caution
1. Installation and servicing must be made in compliance with
all local safety codes including Occupational Safety and Health
Act (OSHA). All wiring and electrical connections must comply
with the National Electric Code (NEC) and local electric codes
in effect.
2. To prevent an electrical hazard, disconnect power source
before working on the brake. Lock disconnect in the off position
and tag to prevent accidental application of power.
General Description - This series brake is spring set, electrically
released. These brakes will contain one or two friction discs
driven by a hub mounted on the motor.
Operating Principle - When the brake coil is energized the
lever arm retracts the spring force from the disc pack, allowing
the friction disc to rotate with the hub and motor shaft. When
power is removed the lever arm pushes down on the stationary
disc and friction discs. The hub is held from rotating, and the
load is held in place.
3. Be certain power source conforms to the requirements
specified on the brake nameplate.
4. Be careful when touching the exterior of an operating brake.
Allow sufficient time for brake to cool before disassembly.
Surfaces may be hot enough to be painful or cause injury.
5. Do not operate brake with housing removed. All moving parts
should be guarded.
6. After usage, the brake interior will contain burnt and degraded
friction material dust. This dust must be removed before servicing
or adjusting the brake.
DO NOT BLOW OFF DUST using an air hose. It is important to
avoid dispersing dust into the air or inhaling it, as this may be
dangerous to your health.
a) Wear a filtered mask or a respirator while removing dust from the inside of a brake.
b)Use a vacuum cleaner or a soft brush to remove dust from the
brake. When brushing, avoid causing the dust to become airborne. Collect the dust in a container, such as a bag, which
can be sealed off.
WARNING
Do not release brake if there is a suspended load on
the hoist hook.
Manually releasing the brake will allow a suspended
load to fall, possibly causing damage, injury or
death.
Weight of load chain may be sufficient to cause entire
chain to run through hoist if brake is released. Be sure
chain is secured.
Always be certain any suspended load (which includes
below the hook devices or attachments) are removed
before servicing, adjusting or removing brake.
If chain is moved causing rotation of the sprocket
without the electronic limit switch powered, check
upper and lower limit settings before resuming normal
operation.
NOTES
Page 25
Brake Mounting Procedure
j Place hub on motor shaft.
Loctite 680 to set screws.
k Apply
Tighten set screws on motor shaft.
78 lb-in
l Remove brake housing and gasket.
friction disc with splined hub and slide
m Align
brake against motor face.
n Insert mounting screws and tighten.
coil leadwires to power supply. Refer
o Connect
to nameplate for voltage rating.*
Caution: Keep wiring away from pinch points
and moving components.
15-20 lb-in
p Replace brake housing and tighten to 8 lb-in.
Clockwise
Page 26
Air Gap Adjustment
Friction Disc Replacement
Brake air gaps are factory adjusted to .100”. As friction discs
wear the air gap will increase. When the gap reaches .200” it will
need to be readjusted to .100”.
Friction disc(s) should be replaced when the wear area is
3/32" thick or less.
1. Loosen jam nut (10N).
1. Remove the two brake mounting screws and lift the brake assembly from the hub / motor.
2. Turn adjusting screw (10) CW until .100” gap is reached (see Fig. 1).
2. Remove the two support bracket screws (35), and lift the brake and solenoid assembly (3) off the brake.
3. Retighten jamb nut.
3. Lift the lever arm (17) forward and slide the friction disc(s) out of the brake assembly.
4. Check air gap again.
Air Gap
4. Insert new friction disc(s) under the stationary disc (5). If brake has two friction discs align the center spline holes with each other.
g f
5. Align the brake and friction disc assembly on the hub (16) and slide onto the motor. Insert and tighten the two brake mounting screws (15-20 lb-ft).
6. Reposition the support bracket assembly (3) on the brake,
and retighten the two support bracket screws (35), (52 lb-in).
Note: Air gap readjustment will be required after disc
replacment.
Adjust
Screw
Jam Nut (10N)
Fig. 1
4
3
Torque Adjustment
35
The brake is factory set for nominal rated torque. No further
adjustment to increase torque may be made. The approximate
compressed torque spring height is shown below. Torque
reduction may not exceed 1 full turn in the CCW direction (1.5 lbft brake cannot be reduced). Note that the spring measurement
for the 6 lb-ft spring is from inside the shoulder washer.
Brake Torque
(lb-ft)
Length "L"
(in.)
Max Torque Reduction
(ccw turn of torque nut)
%
Reduction
1.5
1.102
0
0
3
.954
1
15
6
1.286
1
25
17
5
Coil Replacement
1. Remove the two support bracket screws (35), and lift the bracket and solenoid assembly (3) off the brake.
2. Remove the plunger guide (140) from the inside of the coil.
1-1/2 and 3 lb-ft
3. Remove the thru-bolt (160) from the leadwire side of the coil by backing off the lock-nut (210). Slide the bolt, shock mount pads and flat washer out of the way.
4. Remove the coil (12) from the solenoid frame (79) by pushing down on the coil locking tab on the side opposite the leadwires. Push the coil out of the frame.
6 lb-ft
5. Insert the new coil into the solenoid frame in reverse of the steps of removal. Insert the new plunger guide (140) into the coil, locking tabs first.
6. Position a shock mount pad (150) on both sides of the solenoid mounting bracket, and reinsert the thru-bolt (160) through the shock pads and bracket.
7. Slide a flat washer (170) over the bolt, and tighten the locknut down until the shock pads begin to flatten.
Page 27
8. Position the solenoid and bracket assembly (3) over the plunger (29) and slide into place. Tighten the bracket mounting screws (35) to 52 in-lb.
9. Position the solenoid and bracket assembly (3) over the plunger (29) and slide into place. Tighten the bracket mounting screws (35) to 50 in-lb.
9.Reassemble brake motor by following steps 5-7 of the brake
mounting procedure.
10.Reassemble brake to motor by following steps 5-8 of the brake mounting procedure.
140
79
17
12
29S
h
29
29N
210
35
3
170
150
160
Solenoid Replacement
1. Remove the two support bracket screws (35), and lift the bracket assembly (3) off the brake.
2. Remove the plunger guide (140) from the inside of the coil.
3. Remove both thru-bolts (160) from the solenoid assembly (79).
4. Remove the coil (12) from the solenoid frame (79) by pushing down on the coil locking tab on the side opposite the leadwires. Push the coil out of the frame.
5. Insert the coil into the new solenoid frame in reverse of the steps of removal. Insert the new plunger guide (140) into the coil, locking tab first.
6. Position the new shock mount pad (150) on both sides of the solenoid mounting bracket, and reinsert the tap-bolts (160) through the shock pads and bracket.
7. Slide the flat washers (170) over the bolt, and tighten the locknut down until the shock pads begin to flatten.
8.Remove the plunger nut (29N) and screw (29S), and lift
plunger (29) from lever arm (17). Install the new plunger to the
lever arm using the new screw and nut provided. Tighten to 40 in-lb.
Page 28
29
29N
TROUBLESHOOTING
Coil Failure
Supply Voltage Cause
Excessive Wear/Overheating
Supply Voltage Correction
Line voltage >110% of coil rating
Reduce voltage or replace with
proper rated coil
Excessive voltage drop during
inrush time
Increase current rating of power
supply
Wiring Cause
Wiring Correction
Leadwires interfering with plunger
pull-in
Reroute wiring away from plunger
and other moving components
Coil leadwire shorted to ground
Replace coil or leadwire and
protect with wire sleeving
Solenoid Assembly Cause
Solenoid Assembly Correction
Plunger not seating flush against
solenoid frame
Loosen solenoid mounting nuts
and reposition frame to allow full
face contact
Excessive solenoid/plunger wear
at mating surface
Replace solenoid assembly
Broken shading coils
Replace solenoid assembly
Worn Parts Cause
Worn Parts Correction
Air Gap Cause
Low solenoid air gap
Cycle Rate Cause
Air Gap Correction
Reset air gap (refer to Air Gap
Adjustment)
Cycle Rate Correction
Brake "jogging" exceeding coil
cycle rate
Reduce cycle rate or consider
alternate control method
Thermal capacity is being
exceeded
Reduce cycle rate, use alternate
control method or increase brake
size
Alignment Cause
Alignment Correction
Brake endplate not concentric to
motor C-Face
Motor resister must be within
.004" on concentricity
Motor shaft runout is excessive
Must be within .002"; runout;
consult motor manufacturer
Worn Parts Cause
Worn Parts Correction
Friction disc excessively worn
(disc can wear to 1/2 original
thickness or .093")
Replace friction discs
Endplate, stationary disc or
pressure plate warped
Replaced warped or worn
component
Excessive wear of solenoid link
bolt
Replace link bolt; also inspect
plunger thru-hole for elongation
Linkages worn
Replace all worn components
Plunger guide worn down
and interfering with plunger
movement
Replace guide
Motor shaft endfloat excessive
Endfloat must not exceed .020";
consult motor manufacturer
Application Cause
Application Correction
Hub Cause
Hub Correction
Machinery cycle rate is exceeding Reduce brake cycle rate or use
brake rating
alternate control method
Burr on hub interfering with disc
"float"
File off burr
High ambient temperature
(>110º F) and thermal load
exceeding coil insulation rating
Use Class H rated coil and/or find
alternate method of cooling brake
Set screw backed out and
interfering with disc
Retighten set screw; use Loctite®
680 to help secure
Brake coil wired with windings
of an inverter motor or other
voltage/current limiting device
Wire coil to dedicated power
source with instantaneous coil
rated voltage
Miscellaneous Cause
Miscellaneous Correction
Miscellaneous
Miscellaneous
Wiring is restricting disc pack
movement
Reroute wiring
Wrong or over tightened torque
springs
Replace with proper spring or
refer to installation section for
proper spring height
Excessive stop time
(2 seconds or greater)
Increase brake size/torque or use
alternate control method
Excessive air gap
Reset, refer to Airgap Adjustment
High Ambient termperature
(in excess of 110°F)
Reduce cycle rate or use alternate
method of cooling
d. Assembly of Load Chain.
NOTE: Coil chain must be installed so welds on vertical
links face away from the load sprocket.
(1) Install load chain over sprocket before load brake assembly
is installed. Insert anchor end of chain (end opposite lower block
on single reeved models) into chain guide opening on far side of
hoist (viewing frame from anchor screw side). Rotate sprocket
gear by hand counterclockwise as chain is fed into opening.
When sufficient chain has been run into hoist to reach anchor
position, plus a slack loop, install limit stop on anchor end of
load chain (see (2)) and attach end of chain to frame with special
fillister head screw. Be certain chain is not twisted.
NOTE: The spring clip connecting link must be attached to
anchor end of roller load chain before chain is run into hoist.
Failure to do so may result in damage to chain or hoist.
(2) When installing limit stop on anchor end of load chain attach
it at link. See Figure 3-1b.
Page 29
Two Piece Chain Stop (electronic limit switch)
Chain Size
Number of Chain
Links From End
1/4" Wire Dia.
12 Links (9½")
5/16" Wire Dia.
10 Links (9")
If the hoist loses power during operation, the upper and lower
limits will have shifted and need to be reset. The distance
between limits will remain the same, but the entire range will have
shifted up or down accordingly. Operation of the electronic limit
switch is to be checked daily per ASTM/ANSI.B30.16.
g. Lubricate Hoist. Lubricate hoist as outlined in Section IV.
Paddle Limit Switch
1/4" Wire Dia.
8 Links
5/16" Wire Dia.
8 Links
e. Wiring Hook-Up. Before installing hoist, connect wiring
to electrical controls in accordance with applicable wiring
diagram. Wires are coded and/or numbered to agree with wiring
diagrams.
f. Proximity Switch Replacement/Adjustment. The proximity
switches are adjusted at the factory to have a gap of 1-2mm
between the end of the sensor and the face of the sprocket
gear. If the sprocket and/or sprocket gear are not being replaced,
there should be no need to adjust the proximity switches. If the
sprocket gear or sprocket have been replaced, or a proximity
switch needs replacing, use the following procedure:
(1) The proximity switch needs to be set with an air gap of 1-2mm
between the sensor end and the face of the sprocket gear. With
the proximity switch removed, use a flashlight to look through
the mounting hole to verify that a gear surface is directly below
the mounting hole.
CAUTION
Failure to line the proximity switch up with a gear surface could
result in the proximity switch being inserted too far. This will
result in damage to the proximity switch and possibly gear case
cover if the hoist is operated.
Figure 7-32.
(2) Thread the proximity switch in until it bottoms out on the gear
face. Do not over tighten. Back out one full turn. This will leave
a gap of approximately 1mm.
(3) Tighten lock nut to secure proximity switch.
Proximity switches are equipped with a red LED that lights when
it is sensing the presence of metal. An optional method for
setting the proximity switch air gap would be to use a proximity
sensor tester suitable for use with a 15v proximity switch. This
is connected directly to the proximity switch, and lights the LED
when a surface is sensed.
WARNING
If the hoist loses power during operation or if chain
is moved causing rotation of the sprocket without the
electronic limit switch powered the limits may have
shifted. Check upper and lower limit settings before
resuming normal operation.
The hoist electronic limit switch requires power while the chain
is in motion to maintain the limits at the desired position. If the
gearing rotates while power is removed from the unit, the limits
will have to be reset. A common example of a situation causing
such gear movement would be during replacement of the motor
or brake.
Page 30
Figure 7-33.
7-12. TESTING HOIST.
a. General. After completion of reassembly and before plac­ing
hoist in service, hoist should be tested to insure safe operation.
To test: suspend hoist from an overhead supporting member of
sufficient strength to carry twice rated load; connect to a power
supply of the specified voltage (see data plate attached to
motor); and perform the following checks and adjustments.
(1) Operate hoist to raise load. When control is released, hoist
should instantaneously stop and hold load at that level.
(2) Operate hoist to lower load a short distance, then release
control. Hoist should stop instantaneously and hold load at that
level.
(3) If hoist does not stop or hold load refer to Section VI.
b. Check For Correct Control Operation. Refer to Sec­tion II,
paragraph 2-4. d, under “Warning.”
7-13. TEST PROCEDURE FOR CHECKING OPERATION OF
OVERLOAD CLUTCH.
c. Check Upper and Lower Limit Stop Operation (paddle
limit). To determine if upper and lower limit stop functions
properly, make the following checks while operating hoist with
push button control and actuating the limit lever by hand:
a. General. The overload clutch must be tested using known
weights. The following prerequisites (par. (1) through (4)) must
be strictly observed in performing this test.
(1) Depress “h” push button and with chain running in raise
direction, pull down on end of limit lever at tail chain side of hoist
(left side facing cover end). The “UP” limit switch should cut off
power, causing the hoist to stop.
(1) A qualified person shall determine before testing, that all
structures supporting the hoist are adequately strong to with­
stand the test load of 200 percent of rated hoist load, whether
hoist is tested in installed position or moved to a designated test
facility.
(2) Depress “i” push button and with chain running in lowering
direction, push up on same end of limit lever. The “DOWN” limit
switch should cut off power, causing the hoist to stop.
(2) Loads used for testing must be accurately known.
(3) If hoist does not stop in both travel directions, check
for improper wiring. Refer to par. 6-2 and appropriate wiring
diagram. If wiring is correct, check to see that limit switch is
correctly installed.
(4) Provide adequate and proper rigging to insure test loads
are securely attached, properly balanced, and will lift level.
(4) As a final check, operate hoist (no load) in the lowering
direction and allow tail chain limit actuator to trip limit lever.
Hook should stop. Repeat check in hoisting direction and allow
lower block to trip limit lever. Hook should stop.
d. Check Upper and Lower Limit Stop Operation (electronic
limit switch). To determine if upper and lower limit stop functions
properly, make the following checks while operating hoist with
push button control and actuating the limit lever by hand:
(1) Press up push button and verify operation of electronic limit
switch upper limit. Reset as necessary.
(2) Press down push button and verify operation of electronic
limit switch lower limit. Reset as necessary.
(3) If hoist does not stop at one or both of the set limits, check
for improper wiring. Refer to paragraph 6-2 and appropriate
wiring diagram. If wiring is correct, check to see that proximity
switches are correctly installed and sensing properly, paragraph
7-11.f.
(3) Test shall be made only by a qualified operator thor­oughly
familiar with the hoist and the purpose of the test.
b. Test Procedure. With the above prerequisites satisfied and
hoist properly connected to electrical power, proceed with the
test as follows:
(1) Using a known load equal to rated load of hoist, operate
hoist to lift load. Raise load high enough to be certain the entire
load is freely suspended. Clutch should not slip at rated load.
If hoist does not lift rated load, clutch requires adjust­ment. Refer
to Section V, par. 5-4. c.
(2) Increase load to 200 percent rated load and operate hoist
to lift the load. Clutch must slip, causing the hoist to refuse
to lift the load. If hoist lifts this overload, the overload clutch is
out-of-adjustment and must be readjusted. Refer to Section V,
par. 5-4. c.
(3) If clutch slips as required in step (2) above, continue to run
hoist (clutch slipping-hoist refusing to lift load) for five (5) cycles
of one (1) second each.
(4) Remove excess weight to return the load to rated hoist load.
Lift rated load one final time to be certain that the clutch does
not slip and that the hoist lifts the rated load.
e. Check Hoist With Rated Load. Attach rated load to lower
hook and check hoist operation. If hoist does not lift rated load,
refer to par. 7-13.
WARNING
DO NOT LIFT MORE THAN RATED LOAD EXCEPT FOR TEST PURPOSES
NOTICE
THIS EQUIPMENT MUST BE EFFECTIVELY GROUNDED ACCORDING TO THE NATIONAL ELECTRIC
CODE, ARTICLE 250, 610-61 AND OTHER APPLICABLE CODES.
Page 31
SECTION IX - REPLACEMENT PARTS
This section contains complete replacement parts infor­mation
for your new Budgit Electric Hoist. The parts are grouped and
illustrated in exploded view photos to per­mit easy identification.
Each part in an illustration is keyed by reference number to a
corresponding parts table. In the table will be found the BH part
number, description and quantity required.
authorized testing equipment; and stock a complete inventory
of genuine replacement parts.
NOTICE: Information herein is subject to change without
notice. Parts must be ordered from an Authorized Budgit
Repair Station or from a Budgit Hoist Distributor.
When ordering replacement parts it will be necessary that
you include, with your order, the BH part number of parts
required, plus, hoist catalog number and model number, which
will be found on the hoist nameplate attached to hoist. For
motors, complete motor nameplate data is required. Complete
inspection, maintenance and over­haul service is available for
Budgit Electric Hoists at any of the Authorized Repair Stations.
All are staffed by qualified factory-trained servicemen; have
The numbers assigned to the parts of our various
assemblies in our parts lists are not the part num­bers
used in manufacturing the part. They are identification
numbers, that when given with the hoist serial number,
permit us to identify, select or manufacture, and ship
the correct part needed for any hoist.
INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS
Figure No.
Title
Page
9-1
Frame and External Parts . ......................................................................................................................... 33-35
9-2
Upper Suspension, Load Chain and Lower Block Parts (2 ton Hoists) .................................................... 36-37
9-3
Upper Suspension, Load Chain and Lower Block Parts (3 ton Hoists) .................................................... 38-39
9-4
2 and 3 Ton Lower Block Assembly ............................................................................................................... 40
9-5
Gearing and Load Brake Parts (1/4 and 1/2 Ton Hoists) . ......................................................................... 41-42
9-6
Gearing and Load Brake Parts (1 through 3 Ton Hoists) . ......................................................................... 43-44
9-7a
Electrical Control Units (Three Phase Single Speed Hoists, Paddle Limit)................................................ 45-46
9-7b
Electrical Control Units (Three Phase Single Speed Hoists, Electronic Limit Switch)................................ 47-48
9-8a
Electrical Control Units (Two Speed Hoists Only, Paddle Limit) ................................................................ 49-50
9-8b
Electrical Control Units (Two Speed Hoists Only, Electronic Limit Switch)................................................ 51-52
9-9a
Electrical Control Units (Single Phase Hoists, Paddle Limit) ..................................................................... 53-54
9-9b
Electrical Control Units (Single Phase Hoists, Electronic Limit Switch)...................................................... 55-56
9-10
Limit Lever and Switch Parts........................................................................................................................... 57
9-11
Push Button Station and Conductor Cable Assembly (Single Speed Hoists) . .............................................. 58
9-12
Push Button Station and Conductor Cable Assembly (Two Speed Hoists Only) . ......................................... 59
9-13
Single Phase Motor Assembly ........................................................................................................................ 60
9-14
Three Phase Motor Assembly .................................................................................................................... 61-62
9-15
Hoist Motor Brake............................................................................................................................................ 63
ELECTRICAL CONTROL UNITS (Three phase Single Speed
Hoists, Electronic Limit Switch)
Page 32
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
or
Figure 9-1. FRAME AND EXTERNAL PARTS
Standard and Plating Service Hoists
(Except 2 through 3 Ton Model Upper Suspension, Load Chain and Lower Block)
Ref.
No.
Part
Number
Description
1
BH4007A
Hook Assembly-Upper with Latch (Includes Item 51) (Thru 1 ton)
BH-5027
Hook Assembly-Upper with Latch (Includes Item 51) (Thru 1 ton) Plated
This reference number is not used in the figure
2
——
3
***
Frame Assembly 4
BH-5009
Pin-Support, chain guide
5
BH-4008
Retaining Clip, Chain Guide Pin
6
BH-1007
Gasket-Gearcase
7
***
Cover Assembly-Gearcase
8
BH-1010
Cable Assembly-Flexible, 5' (Incl. Items 9 & 10)
115 volt, 1 phase, 60 hertz hoists
230 volt, 1 phase, 60 hertz hoists
200/230/460/575 volt, 3 phase, 60 hertz hoists
9
BH-1096
Grommet-Flexible Cable-3 phase
Grommet-Flexible Cable-1 phase
10
BH-1014
Clamp-Flexible Cable
11
Cover-Electrical Compartment
BH-1168 Without internal counterweight
BH-1169 With internal counterweight
Capacity Label (Not Shown)
Qty.
Req’d
1*
1*
1
2
2
1
1
1
1
1
1
1
1
1
1
1
(Continued on following page)
Page 33
Figure 9-1. FRAME AND EXTERNAL PARTS - Continued
Ref.
No.
Part
Number
Description
Qty.
Req’d
11a
BH-1190 1/4 Ton
BH-1191 1/2 Ton
BH-1192 1 Ton
BH-1193 2 Ton
BH-1194 3 Ton
12
BH-1020
Screw-Fillister Head Machine
3
13
BH-1021
Hi-Collar Helical Spring Lock Washer (1/4)
3
14
BH-1022
Ring-Retaining
8
15
BH-1023
Regular Helical Spring Lock Washer (#10 Pltd.)
8
16
BH-1024
Hex Socket Head Cap Screw (#10-24 x 3/4)
2
17
BH-1025
Grooved Pin (Type D 1/8 x 1/2 Pltd.)
1
18
BH-1026
Grommet-(Motor Driven Trolley Models)-Not Shown
2
19
BH-1027
Dowel Pin (3/8 x 3/4)
2
20
BH-1028
Hex Socket Pipe Plug (1/8)
1
21
BH-5023
Suspension Bushing Keeper
1
22
BH-4016
Lock Washer
1
23
BH-4017
Hex Socket Cap Screw
24
Guide Assembly-Coil Load Chain
1
BH-1031 1/4 & 1/2 ton Hoists
BH-1032 1 through 3 ton Hoists
25
***
Chain Assembly-Coil, load
1*
BH-1033 1/4" Dia.-1/4 & 1/2 ton Hoists
BH-1034 5/16" Dia.-1 ton Hoists
BH-1080 1/4" Dia.-1/4 & 1/2 ton Hoists - Zinc Plated
BH-1086 5/16" Dia.-1 ton Hoists - Zinc Plated
26
BH-5020
Stop Shoe (Electronic Limit Equipped Only)
1
27
BH-5021
Support Pin
1
28
BH-5022
Retaining Ring
1
This reference number is not used in the figure
29
——
30
Block Assembly-Lower, (Incl. items 32 through 39)
1*
BH-5028 For 1/4 ton Hoists
BH-1035 For 1/4 ton Hoists Plated
BH-1035A For 1/2 ton Hoists
BH-5029 For 1/2 ton Hoists Plated
BH-5046 For 1 ton Hoists
BH-5030 For 1 ton Hoists Plated
Note: Lower block assemblies do not include attaching pins.
Order separately.
This reference number is not used in the figure
31
——
32
Body-Lower Block
1*
BH-1174 1/4 ton Hoists
BH-5031 1/4 ton Hoists Plated
BH-1174A 1/2 ton Hoists
BH-5032 1/2 ton Hoists Plated
BH-1175 1 ton Hoists
BH-5033 1 ton Hoists Plated
33
Hook, Nut and Latch Assembly-Lower Block
1
BH-5047 1/4 thru 1 ton Hoists
BH-5034 1/4 thru 1 ton Hoists Plated
34
Latch Kit-Hook, lower
1
BH-5035 1/4 thru 1 ton Hoists
35
BH-1178
Washer-Thrust, needle bearing
2
36
BH-1179
Bearing Assembly-Needle, thrust
1
37
BH-1180
Shield-Bearing
1
38
BH-1181
Grooved Pin (Type F 5/32 x 1-1/8 Pltd.)
1
39
**
Nut-Hook
1
40
Pin-Connecting, lower block
1
BH-1037 1/4 and 1/2 ton Hoists
BH-1038 1 ton Hoists
(Continued on following page)
Page 34
Figure 9-1. FRAME AND EXTERNAL PARTS - Continued
Ref.
No.
Part
Number
Description
Qty.
Req’d
41
BH-1045
Slotted Spring Pin (3/32 x 3/4 Pltd.)
1
42-44
——
These reference numbers are not used in the figure
45
BH-5048
Hex Flange Screw, Self-Locking
1
This reference number is not used in the figure
46
——
47
Limit Stop (Paddle Limit Switch)
2
BH-1098 1/4" Coil Chain
BH-1099 5/16" Coil Chain
48
BH-1184
Grooved Pin (Limit Stop BH-1098) (Type F 7/32 x 2 Pltd.)
2
BH-1185
Grooved Pin (Limit Stop BH-1099) (Type F 1/4 x 2 Pltd.)
2
49
——
This reference number is not used in the figure
50
BH-4010
Filler Assembly-Oil
1
51
BH-1183
Latch Kit-Hook (upper) 1/4 through 1 ton
1
52-53
——
These reference numbers are not used in the figure
54
BH-5025
Lug Suspension Assembly
1*
The following items are for two speed hoists with 2-1/4 horsepower motor only:
55-57
——
These reference numbers are not used in the figure
58
BH-1158
Insert-Coil
3
59
Support Stud
BH-1159 Top
2
BH-1160 Bottom
1
60
BH-1161
Counterweight
1
61
BH-1162
Plain Washer (Type W 1/4 Pltd.)
3
62
BH-1163
Heavy Hex Self-Locking Nut (1/4 - 20)
3
63
Capacity Label
1
BH-1164 1 Ton
BH-1165 2 Ton
BH-1166 3 Ton
65
Chain Stop Assembly (Electronic Limit Switch)
BH-5010 For 5/16" Coil Chain
1
BH-5011 For 1/4" Coil Chain
1
* Refer to Figure 9-2 for 2 Ton Model Upper Suspension, Load Chain and Lower Block Parts.
Refer to Figure 9-3 for 3 Ton Model Upper Suspension, Load Chain and Lower Block Parts.
** Hook and suspension bolt nuts are not serviced separately. They are available only with hook or bolt as assemblies.
*** For frame assembly or gearcase cover assembly, please consult factory. Be sure to have serial number available.
REPLACEMENT CHAIN
Type Chain
Coil (1/4" Dia.)
Coil (5/16" Dia.)
Coil (1/4" Dia. Zinc Plate)
Coil (5/16" Dia. Zinc Plate)
Bulk
BH-1066
BH-1069
BH-1083
BH-1093
Page 35
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
or
10251B
Figure 9-2. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS
(2 Ton Hoists)
Page 36
Figure 9-2. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS - Continued
Ref.
No.
Part
Number
Description
1
905422
Bracket Assembly Kit- Lug Suspension
(Coil Chain Model Only. Includes Items 6, 8 and 9).
2
BH-1102
Hook Assembly-Upper (Includes Items 5, 6, 7 and 20).
BH-5036
Hook Assembly-Upper (Includes Items 5, 6, 7 and 20) Plated
3
BH-1030
Grooved Pin (Type F 3/16 x 1-1/4 Pltd.)
4
Block Assembly-Upper
BH-4013 Coil Chain Models, Includes Items 3, 10, 11, 14, 16, 19 and 21
5
BH-1106
Lock Assembly-Suspension Bushing
6
BH-1107
Regular Helical Spring Lock Washer (#10 Pltd.)
7
BH-1108
Hex, Socket Head Cap Screw (#10-24 x 1/2)
8
BH-1109
Hex, Socket Head Cap Screw (#10-24 x 3/8)
9
BH-1061
Plate - Lock (Coil Chain Lug Suspension Models Only)
10
*
Lug Suspension Stud
11
*
Anchor - Coil Load Chain
14
BH-1111
Cotter Pin (3/32 x 3/4)
16
BH-1113
Pin-Coil Chain Anchor
17
(See Fig. 9-4) Block Assembly-Lower
18**
BH-1114
Chain Assembly
BH-1115
Chain Assembly (Zinc Plated)
19
*
Suspension Bushing
20
BH-2213
Latch Kit-Hook
21
BH-4012
Spacer Washer
22
BH-5010
Chain Stop (Electronic Limit Switch)
23
BH-1099
Actuator (Paddle Limit Switch)
24
BH-5023
Suspension Bushing Keeper
25
BH-4016
Lock Washer
26
BH-4017
Hex Socket Head Cap Screw
27
BH-5020
Stop Shoe (Electronic Limit Equipped)
28
BH-5021
Support Pin
29
BH-5022
Snap Ring
30
BH-1185
Grooved Pin (Type F 1/4 x 2 Pltd.)
Qty.
Req’d
1
1
2
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* Not available as individual parts. Order upper block assembly, Item 4.
** Load Chain Assemblies listed are for hoists with standard 10 ft. lists. Bulk chain is available in 1 ft. increments and 50 ft. lengths as follows:
Type Chain
50' Lengths
Bulk
Link (5/16" Dia.)
Link (5/16" Dia. Zinc Plate)
Not Available
Not Available
BH-1069
BH-1093
Page 37
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
or
11757B
Figure 9-3. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS
(3 Ton Hoists)
Page 38
Figure 9-3. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS - Continued
Ref.
No.
Part
Number
Description
1
BH-1131
Suspension Pin and Nut Assembly
2
BH-1132
Spherical Washer
3
905424
Suspension Lug Kit
(Includes Items 1, 2, 4 and 26)
4
BH-1134
Pin - Grooved (Type A 3/16 x 2 Pltd.)
5
BH-1135
Hook/Latch and Nut (Includes Item 6)
BH-5037
Hook/Latch and Nut (Includes Item 6) Plated
6
BH-2214
Latch Kit, Hook
7
BH-2217
Washer, Thrust
8
BH-1138
Hanger
9
BH-4018
Connecting Rod Assembly
10
BH-5023
Suspension Bushing Keeper
11
BH-4016
Lock Washer
12
BH-1142
Pin, Connection
13
BH-1143
Ring, Retaining
14
BH-1144
Sprocket & Bushing Assembly (Includes Item 15)
15
BH-1145
Bushing
16
BH-5019
Pin, Sprocket
17
BH-1147
Grooved Pin (Type A 3/16 x 3/8 Pltd.)
18
BH-1148
Chain Assembly, Coil Load
BH-5045
Chain Assembly, Coil Load Plated
19
BH-5020
Stop Shoe (Electronic Limit Equipped)
20
BH-5021
Support Pin
21
BH-5022
Snap Ring
24
See Fig. 9-4
Block Assembly, Lower, Coil Chain
25
BH-2210
Washer, Thrust
26
BH-1154
Washer
27
BH-5010
Chain Stop Assembly (Electronic Limit Equipped)
28
BH-1099
Actuator (Paddle Limit Equipped)
29
BH-1185
Grooved Pin (Type F 1/4 x 2 Pltd.)
30
BH-4017
Hex Socket Head Cap Screw
Qty.
Req’d
1
1 Pr.
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
2
1
1
2
NOTICE
Always insist on factory approved Budgit Hoist replacement parts when servicing this equipment. Parts are
available from your local Authorized Repair Station.
NOTES
Page 39
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
12444A
Figure 9-4. 2 and 3 TON LOWER BLOCK ASSEMBLIES
Ref.
Part
No.
Number
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
18
19
20
21
BH-2219
BH-5038
BH-2218
BH-5039
BH-2202
BH-5042
BH-2203
BH-2204
BH-2205
BH-2206
BH-2207
BH-2208
BH-2210
BH-2211
BH-5040
BH-2212
BH-5044
BH-2213
BH-2214
BH-2215
BH-2216
BH-2217
BH-2220
BH-5043
BH-2221
BH-2222
BH-2223
BH-2224
BH-2225
BH-5041
Page 40
Description
Block Assembly-Lower Complete
Block Assembly-Lower Complete Plated
Block Assembly-Lower Complete
Block Assembly-Lower Complete Plated
Guide-Center
Guide-Center Anodized
Lock-Sprocket Pin
Sprocket-Coil Chain
Bushing-Sprocket
Screw-Fillister Head, Self locking
Pin-Sprocket
Fitting-Hydraulic Drive
Washer, Thrust
Body Assembly-Lower Block
Body Assembly-Lower Block Anodized
Hook/Latch and Nut (Includes Items 12, 13 and 15)
Hook/Latch and Nut (Includes Items 12, 13 and 15) Plated
Latch Kit, Hook
Latch Kit, Hook
Pin, Grooved
Shroud
Washer, Thrust
Hook/Latch and Nut (Includes Items 12 and 17)
Hook/Latch and Nut (Includes Items 12 and 17) Plated
Pin, Grooved
Shield, Bearing
Bearing Assembly-Needle, Thrust
Washer, Thrust
Body-Lower Block
Body-Lower Block Anodized
Quantity Required
2 Ton
3 Ton
1
1
—
—
1
1
1
1
1
1
1
1
1
—
—
—
—
1
—
—
—
—
1
1
1
1
1
2
1
1
—
—
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
—
1
1
1
1
—
—
—
—
—
—
—
—
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
11898
Figure 9-5. GEARING AND LOAD BRAKE PARTS (1/4 and 1/2 Ton Hoists)
Ref.
No.
Part
Number
Description
Qty.
Req’d
1
BH-1201
Seal-Oil, motor shaft
1
2
BH-1202
Bearing Assembly-Ball, motor shaft
1
3
BH-1203
Ring-Retaining, Internal
1
4
BH-1237
Bearing Assembly-Needle, 11/16" I.D. (36 rollers, grease retained)
1
5
BH-1205
Bearing-Thrust, bronze
1
6
BH-1206
Washer-Thrust, 11/16" I. D. (Used with 14 tooth Pinion Load Brake
Shaft-13H-1207 below)
1
7
Shaft & Integral Pinion-load brake,
BH-1207 14 teeth
1
BH-1208 23 teeth
BH-1209 36 teeth
8
BH-1210
Key-Woodruff
2
9
BH-1239
Retainer-Spring, load brake
1
10
BH-1212
Spring-load brake (Plain-no color code)
1
BH-1213
Spring-load brake (Yellow color code)
1
11
BH-1214
Pin-Grooved
2
12
BH-1216
Cam-load brake
1
13
Gear & Clutch Assembly-load brake
1
BH-1240 For use with 1/4 H.P. Motor
BH-1241 For use with 1 /2 H.P. Motor
BH-1242 For use with 1 H.P. Motor
14
BH-1218
Disc-Friction, load brake
2
15
BH-1238
Bushing—Ratchet
2
16
BH-1219
Flange—load brake
1
17
BH-1220
Bearing Assembly-Needle, 5/8" I.D.
1
18
BH-1221
Washer-Thrust, 5/8" I.D.
1
19
BH-1222
Ring-Snap, brake flange
1
20
BH-1223
Pawl & Ratchet Assembly-load brake (includes item 15)
1
21
BH-1224
Ring-Snap, sprocket gear
1
22
Gear-Sprocket
BH-1225 74 teeth
1
BH-1226 65 teeth
BH-1227 52 teeth
(Continued on following page)
Page 41
Figure 9-5. GEARING AND LOAD BRAKE PARTS - Continued
Ref.
No.
23
24
25
27
28
30
31
32
33
34
35**
Part
Number
Description
BH-1059
Screw Hex Socket Head Cap
BH-1229
Lockwasher- Spring Type
BH-1230
Plate - Retainer, Sprocket Bearing
BH-1232
Bearing Assembly- Ball, Sprocket
BH-1318
Ball Bearing On Later Model Hoists
BH-1311
Sprocket-Coil Chain (1/4" Dia. Wire)
BH-1235
Bearing Assembly - Ball, Sprocket
BH-1236
Key - Woodruff
BH-1315
O-Ring
BH-1316
Seal Disk
BH-1317
Seal - Oil
BH-4019
Clutch Assembly - 1/4 hp
BH-4020 1/2 hp
BH-4021 1 hp
**This gear and clutch assembly should not be field disassembled.
Replace assembly only as clutch pressure is preset at factory based on hoist capacity and motor H.P.
Replaces items 9-16 on non-load brake equipped models
NOTES
Page 42
Qty.
Req’d
4
4
1
1
1
1
1
1
1
1
1
1
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
11899
Figure 9-6. GEARING AND LOAD BRAKE PARTS (1 thru 3 Ton Hoists)
Ref.
No.
Part
Number
Description
Qty.
Req’d
1
BH-1201
Seal-Oil, motor shaft
1
2
BH-1202
Bearing Assembly-Ball, motor shaft
1
3
BH-1203
Ring-Retaining, Internal
1
4
BH-1220
Bearing Assembly-Needle, 5/8" I.D.
2
5
BH-1221
Washer-Thrust, 5/8" I.D.
2
6
BH-1222
Ring-Snap, brake flange
1
7
BH-1219
Flange-Load Brake
1
8
BH-1218
Disc-Friction, load brake
2
9
BH-1223
Pawl and Ratchet Assembly-Load Brake (includes item 15)
1
10
BH-1238
Bushing-Ratchet
1
11
Gear and Clutch Assembly-Load Brake
1
BH-1241 For use with 1 /2 H.P. Motor
BH-1242 For use with 1 and 2-1/2 H.P. Motors
12
BH-1212
Spring-Load Brake (Plain-no color code)
1
13
BH-1216
Cam-Load Brake
1
14
BH-1239
Retainer-Spring, Load Brake
1
15
BH-1210
Key-Woodruff
2
16
Shaft and Integral Pinion-Load Brake
1
BH-1207 14 teeth
BH-1208 23 teeth
17***
BH-1206
Washer-Thrust, 11/16" I.D.
2
18
BH-1205
Bearing-Thrust, bronze
1
19
BH-1204
Bearing Assembly-Needle, 11 /16" I.D.
1
20
BH-1214
Pin-Grooved
2
21
BH-1224
Ring-Snap, intermediate gear
1
22
Gear-Intermediate
1
BH-1225 74 teeth
BH-1226 65 teeth
23
BH-1236
Key-Woodruff
1
24
BH-1304
Shaft and Integral Pinion-Intermediate
1
25
BH-1237
Bearing Assembly-Needle, 11/16" I.D.
1
26
BH-1305
Ring-Snap, sprocket gear
1
27
BH-1306
Gear-Sprocket
1
This reference number is not used in the figure
28
——
29
BH-1228
Screw-Fillister Head Machine
4
(Continued on following page)
Page 43
Figure 9-6. GEARING AND LOAD BRAKE PARTS - Continued
Ref.
No.
Part
Number
Description
Qty.
Req’d
30
BH-1229
Lockwasher - Spring Type
4
31
BH-1230
Plate - Retainer, Sprocket Bearing
1
32
—— This reference number is not used in the figure
33
BH-1232
Bearing Assembly - Ball, Sprocket
1
BH-1318
Ball Bearing On Later Model Hoists
1
34
BH-1308
Key -Woodruff, Sprocket
1
35
Sprocket - Coil Chain
BH-1311 1/4" Dia. Wire
1
BH-1312 5/16" Dia. Wire
1
36
——
This reference number is not used in the figure
37
BH-1235
Bearing Assembly - Ball, Sprocket
1
38
BH-1315
O-Ring
1
39
BH-1316
Seal Disk
1
40
BH-1317
Seal - Oil
1
41**
BH-4020
Clutch Assembly 1/2
BH-4021
Clutch Assembly 1 & 2-1/2
** This gear and clutch assembly should not be field disassembled.
Replace assembly only as clutch pressure is preset at factory based on hoist capacity and motor H.P.
Ref. No. 41 is replaced by Ref. Nos. 7 thru 14 on non-load brake equipped hoists.
*** Ref. No. 17 occurs next to Ref. No. 16 for 14 tooth pinion shaft only.
NOTES
Page 44
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900J
Figure 9-7a. ELECTRICAL CONTROL UNITS (Three phase Single Speed Hoists, Paddle Limit)
Ref.
No.
Part
Number
Description
Qty.
Req’d
Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
1
BH-3800 Three Phase 24V Control
BH-3801 Three Phase 115V Control
1
BH-3802
Mounting Plate - Contactor
1
2
BH-2155
Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8)
5
3
Contactor Assembly
1
BH-3803 Three Phase 24V Control
BH-3804 Three Phase 115V Control
4
BH-2189
Pan Head Self Tapping Screw (#8-32 x 1/2)
2
5
——
This reference number is not used in the figure
This reference number is not used in the figure
2
6
——
7
See Fig. 9-11 Limit Switch and Shaft Assembly
1
8
Transformer
1
BH-2166 Three Phase 208V/24V
BH-3805 Three Phase 230V/460V/24V
BH-2168 Three Phase 575V/24V
BH-2169 Three Phase 208V/115V
BH-3806 Three Phase 230V/460V/115V
BH-2172 Three Phase 575V/115V
(Continued on following page)
Page 45
Figure 9-7a. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
Part
Number
Description
Qty.
Req’d
9
BH-2173
Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8)
1
10
BH-2174
Plain Washer (Type N 1/4)
2
11
BH-2175
Grommet
1
12
See Fig. 9-12 Push Button Station and Conductor Cable Assembly
1
13
Fuse, Fuse Holder and Wire Assembly
1
BH-2176 3A/250V
1
BH-2177 1/2A/250V
Fuse Only
1
BH-2178 3A/250V Rating
BH-2179 1/2A/250V Rating
14
BH-3807
Block-Terminal
1
15
BH-2181
Spacer-Terminal Block
2
16
BH-2182
Regular Helical Spring Lock Washer (#8 Pltd.)
2
17
BH-3808
Round Head Machine Screw (#8-32 x 1 Pltd.)
2
This reference number is not used in the figure
18
——
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 46
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
20
23 24
19
25
22
21
11900J
Figure 9-7b. ELECTRICAL CONTROL UNITS (Three phase Single Speed Hoists, Electronic Limit Switch)
Ref.
No.
Part
Number
Description
Qty.
Req’d
Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
1
BH-3800 Three Phase 24V Control
BH-3801 Three Phase 115V Control
1
BH-3802
Mounting Plate - Contactor
1
2
BH-2155
Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8)
5
3
Contactor Assembly
1
BH-3803 Three Phase 24V Control
BH-3804 Three Phase 115V Control
4
BH-2189
Pan Head Self Tapping Screw (#8-32 x 1/2)
2
8
Transformer
1
BH-2166 Three Phase 208V/24V
BH-3805 Three Phase 230V/460V/24V
BH-2168 Three Phase 575V/24V
BH-2169 Three Phase 208V/115V
BH-3806 Three Phase 230V/460V/115V
BH-2172 Three Phase 575V/115V
9
BH-2173
Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8)
1
10
BH-2174
Plain Washer (Type N 1/4)
2
11
BH-2175
Grommet
1
12
See Fig. 9-12 Push Button Station and Conductor Cable Assembly
1
13
Fuse, Fuse Holder and Wire Assembly
1
BH-2176 3A/250V
1
BH-2177 1/2A/250V
Fuse Only
1
BH-2178 3A/250V Rating
BH-2179 1/2A/250V Rating
(Continued on following page)
Page 47
Figure 9-7b. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
14
15
16
17
19
20
21
22
23
24
25
Part
Number
Description
BH-3807
BH-2181
BH-2182
BH-3808
BH-4022
BH-4023
BH-2189
BH-2155
BH-4024
BH-4025
BH-4026
Block-Terminal
Spacer-Terminal Block
Regular Helical Spring Lock Washer (#8 Pltd.)
Round Head Machine Screw (#8-32 x 1 Pltd.)
Electronic Limit Switch Controller
Controller Mounting Bracket
Self Tapping Screws
Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8)
Proximity Sensor
Jam Nut-Plated - 7/16-20
Spacer Washer - Proximity Sensor
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 48
Qty.
Req’d
1
2
2
2
1
1
2
2
2
2
1
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900K
Figure 9-8a. ELECTRICAL CONTROL UNITS (Two Speed Hoists Only, Paddle Limit)
Ref.
No.
Part
Number
Description
Qty.
Req’d
Contractor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
1
BH-3800 Three Phase 24V Control
BH-3801 Three Phase 115V Control
1
BH-3802
Mounting Plate - Contactor
1
2
BH-2155
Sems Round Head Machine Screw with External Lock
Washer (#10-24 x 3/8)
5
3
Contactor Assembly
1
BH-3803 Three Phase 24V Control
BH-3804 Three Phase 115V Control
4
BH-2189
Pan Head Self Tapping Screw (#8-32 x 1/2)
2
5
BH-2161
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
2
6
BH-2162
Regular Helical Spring Lock Washer (#10 Pltd.)
2
7
See Fig. 9-11 Limit Switch and Shaft Assembly
1
8
Transformer
1
BH-2166 Three Phase 208V/24V
BH-2164 Three Phase 230V/24V
BH-2167 Three Phase 460V/24V
BH-2168 Three Phase 575V/24V
BH-2169 Three Phase 208/115V
BH-2170 Three Phase 230V/115V
BH-2171 Three Phase 460V/115V
BH-2172 Three Phase 575V/115V
9
BH-2173
Sems Round Head Machine Screw with External Lock
Washer (1/4-20 x 5/8)
1
10
BH-2174
Plain Washer (Type N 1/4)
2
11
See Fig. 9-13 Push Button Station and Conductor Cable Assembly
1
(Continued on following page)
Page 49
Figure 9-8a. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
Part
Number
Description
Qty.
Req’d
12
Fuse, Fuse Holder and Wire Assembly
1
BH-2176 3A/250V
BH-2177 1/2A/250V
Fuse Only
1
BH-2178 3A/250V Rating
BH-2179 1/2A/250V Rating
Contactor and Mounting Plate Assembly (Includes
Ref. Nos. 13, 15 and 16)
1
BH-3809 Three Phase 24V Control
BH-3810 Three Phase 115V Control
13
BH-3811
Mounting Plate - Contactor
1
14
BH-2193
Sems Round Head Machine Screw with External Lock
Washer (#8-32 x 1/2)
2
15
Contactor Assembly
1
BH-3812 Three Phase 24V Control
BH-3813 Three Phase 115V Control
16
BH-2199
Pan Head Self Tapping Screw (#8-32 x 3/8)
2
17
BH-1422
Flanged Sleeve Bearing
1
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 50
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
20
23 24
25
19
22
21
11900K
Figure 9-8b. ELECTRICAL CONTROL UNITS (Two Speed Hoists Only, Electronic Limit Switch)
Ref.
No.
Part
Number
Description
Qty.
Req’d
Contractor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
1
BH-3800 Three Phase 24V Control
BH-3801 Three Phase 115V Control
1
BH-3802
Mounting Plate - Contactor
1
2
BH-2155
Sems Round Head Machine Screw with External Lock
Washer (#10-24 x 3/8)
5
3
Contactor Assembly
1
BH-3803 Three Phase 24V Control
BH-3804 Three Phase 115V Control
4
BH-2189
Pan Head Self Tapping Screw (#8-32 x 1/2)
2
8
Transformer
1
BH-2166 Three Phase 208V/24V
BH-2164 Three Phase 230V/24V
BH-2167 Three Phase 460V/24V
BH-2168 Three Phase 575V/24V
BH-2169 Three Phase 208/115V
BH-2170 Three Phase 230V/115V
BH-2171 Three Phase 460V/115V
BH-2172 Three Phase 575V/115V
9
BH-2173
Sems Round Head Machine Screw with External Lock
Washer (1/4-20 x 5/8)
1
10
BH-2174
Plain Washer (Type N 1/4)
2
11
See Fig. 9-13 Push Button Station and Conductor Cable Assembly
1
(Continued on following page)
Page 51
Figure 9-8b. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
Part
Number
Description
12
Fuse, Fuse Holder and Wire Assembly
BH-2176 3A/250V
BH-2177 1/2A/250V
Fuse Only
BH-2178 3A/250V Rating
BH-2179 1/2A/250V Rating
Contactor and Mounting Plate Assembly (Includes
Ref. Nos. 13, 15 and 16)
BH-3809 Three Phase 24V Control
BH-3810 Three Phase 115V Control
13
BH-3811
Mounting Plate - Contactor
14
BH-2193
Sems Round Head Machine Screw with External Lock
Washer (#8-32 x 1/2)
15
Contactor Assembly
BH-3812 Three Phase 24V Control
BH-3813 Three Phase 115V Control
16
BH-2199
Pan Head Self Tapping Screw (#8-32 x 3/8)
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 52
Qty.
Req’d
1
1
1
1
2
1
2
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900J
Figure 9-9a. ELECTRICAL CONTROL UNITS (Single Phase Hoists, Paddle Limit)
Ref.
No.
Part
Number
Description
Qty.
Req’d
Contractor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
1
1/4, 1/2 & 1 HP
BH-3800 Single Phase 24V Control
BH-3801 Single Phase 115V Control
BH-3814 2-1/4 HP Only
Single Phase 24V Control
BH-3815 Single Phase 115V Control
1
BH-3802
Mounting Plate - Contactor
1
2
BH-2155
Sems Round Head Machine Screw with External Lock
Washer (#10-24 x 3/8)
4
3
Contactor Assembly
1
1/4, 1/2 & 1 HP
BH-3803 Single Phase 24V Control
BH-3804 Single Phase 115V Control
BH-3816 2-1/4 HP Only
Single Phase 24V Control
BH-3817 Single Phase 115V Control
4
BH-2189
Pan Head Self Tapping Screw (#8-32 x 1/2)
2
5
BH-2161
Hex Socket Head Cap screw (#10-24 x 3/8 Pltd.)
2
6
BH-2162
Regular Helical Spring Lock Washer (#10 Pltd.)
2
7
See Fig. 9-11 Limit Switch and Shaft Assembly
1
8
Transformer
1
BH-3818 Single Phase 115V/230V/24V
BH-3819 Single Phase 115V/230V/115V
9
BH-2173
Sems Round Head Machine Screw with External Lock
Washer (1/4-20 x 5/8)
1
(Continued on following page)
Page 53
Figure 9-9a. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
Part
Number
Description
Qty.
Req’d
10
BH-2174
Plain Washer (Type N 1/4)
2
11
BH-2175
Grommet
1
12
See Fig. 9-12 Push Button Station and Conductor Cable Assembly
1
13
Fuse, Fuse Holder and Wire Assembly
1
BH-2176 3A/250V
BH-2177 1/2A/250V
Fuse Only
1
BH-2178 3A/250V Rating
BH-2179 1/2A/250V Rating
14
BH-3807
Block-Terminal
1
15
BH-2181
Spacer-Terminal Block
2
16
BH-2182
Regular Helical Spring Lock Washer (#8 Pltd.)
2
17
BH-3820
Pan Head Self Tapping Screw (#8-32 x 5/8 Pltd.)
2
18
BH-1422
Flanged Sleeve Bearing
1
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 54
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
20
23 24
19
25
22
21
11900J
Figure 9-9b. ELECTRICAL CONTROL UNITS (Single Phase Hoists, Electronic Limit Switch)
Ref.
No.
Part
Number
Description
Qty.
Req’d
Contractor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
1
1/4, 1/2 & 1 HP
BH-3800 Single Phase 24V Control
BH-3801 Single Phase 115V Control
BH-3814 2-1/4 HP Only
Single Phase 24V Control
BH-3815 Single Phase 115V Control
1
BH-3802
Mounting Plate - Contactor
1
2
BH-2155
Sems Round Head Machine Screw with External Lock
Washer (#10-24 x 3/8)
4
3
Contactor Assembly
1
1/4, 1/2 & 1 HP
BH-3803 Single Phase 24V Control
BH-3804 Single Phase 115V Control
BH-3816 2-1/4 HP Only
Single Phase 24V Control
BH-3817 Single Phase 115V Control
4
BH-2189
Pan Head Self Tapping Screw (#8-32 x 1/2)
2
8
Transformer
1
BH-3818 Single Phase 115V/230V/24V
BH-3819 Single Phase 115V/230V/115V
9
BH-2173
Sems Round Head Machine Screw with External Lock
Washer (1/4-20 x 5/8)
1
10
BH-2174
Plain Washer (Type N 1/4)
2
11
BH-2175
Grommet
1
12
See Fig. 9-12 Push Button Station and Conductor Cable Assembly
1
(Continued on following page)
Page 55
Figure 9-9b. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
Part
Number
Description
13
Fuse, Fuse Holder and Wire Assembly
BH-2176 3A/250V
BH-2177 1/2A/250V
Fuse Only
BH-2178 3A/250V Rating
BH-2179 1/2A/250V Rating
14
BH-3807
Block-Terminal
15
BH-2181
Spacer-Terminal Block
16
BH-2182
Regular Helical Spring Lock Washer (#8 Pltd.)
17
BH-3820
Pan Head Self Tapping Screw (#8-32 x 5/8 Pltd.)
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 56
Qty.
Req’d
1
1
1
2
2
2
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
11901A
Figure 9-10. LIMIT LEVER AND SWITCH PARTS (If Equipped)
Ref.
No.
Part
Number
Description
BH-1850
1
BH-1851
2
BH-1852
3
BH-1853
4
BH-1854
5
BH-1855
6
BH-1856
7
BH-1857
8
BH-1858
9
BH-1859
10
BH-1860
11
BH-1861
12
BH-1862
13
BH-1863
14
BH-1864
15
BH-1865
16
BH-1866
17
BH-1867
18
BH-1868
19
BH-1869
20
BH-1870
Qty.
Req’d
Limit Switch and Shaft Assembly (Includes
Ref. Nos. 1 thru 14 and 17 and 18)
1
Light Hex Self-locking Nut (#4-40 Pltd.)
2
Retainer
1
Insulation
2
Limit Switch-Upper
1
Limit Switch-Lower
1
Insulation
1
Plate-Cover
1
Round Head Machine Screw (#40-40 x 1-1/8 Pltd.)
2
Light Thin Hex Self-locking Nut (#10-24 Pltd.)
1
Plain Washer (#10 Pltd.)
1
Switch Actuator
1
Centering Lever
1
Spring-Control
1
Spacer
1
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
2
Regular Helical Spring Lock Washer (#10 Pltd.)
2
Plain Washer (Type N 5/16 Pltd.)
1
Control Shaft
1
Key-Woodruff
1
Limit Lever
1
Page 57
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
12763
Figure 9-11. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY (Single Speed Hoists)
Ref.
No.
Part
Number
Description
BH-3401
BH-3402
1
*
2
*
3
*
4
BH-3403
5
*
6
BH-3404
7
BH-3405
8
*
9
*
10
*
11
*
12
*
13
*
14
BH-3406
15
*
16
BH-3407
17
BH-3408
Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 17)
1
Push Button Station (Includes Ref. Nos. 1 thru 15)
1
Type 1 Pan Head Machine Screw (M3.5 x 0.6 x 12 Pltd.)
7
Lockwasher (M 3.5 Pltd.)
7
Rear Cover
1
Gasket
1
Type l Pan Head Thread Cutting Screw (M 4 x 15 Pltd.)
2
Contact Assembly
1
Button Assembly
1
Type 1 Pan Head Machine Screw (M 6 x 1 x 12 Pltd.)
1
Lockwasher (M 6 Pltd.)
1
Plain Washer (M 6 Pltd.)
1
Type 1 Pan Head Machine Screw (M 3.5 x 1 x 14 Pltd.)
2
Lockwasher (M 3.5 Pltd.)
2
Housing Cap
1
Grommet
1
Housing
1
Conductor Cable Assembly
1
Plastic Warning Tag
1
* Not available separately. Order Push Button Station.
Page 58
Qty.
Req’d
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
12721A
Figure 9-12. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY
(Two Speed Hoists Only)
Ref.
No.
Part
Number
Description
Qty.
Req’d
BH-4027
Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 30)
1
1
BH-1981
Grommet
1
2
BH-1982
Conductor Cable
1
3
BH-1971
Operator Warning Label
1
BH-4029
Push Button Station (Includes Ref. Nos. 12 thru 30)
1
4
BH-4030
Control Station Grommet
1
5
*
Control Station Hardware
4
6
*
Control Station Housing
4
7
BH-3403
Gasket
1
8
BH-4028
Button and Control Assembly
1
Contact Block
2
Contact Block
2
* Not available separately. Order Push Button Station.
** Not available separately. Order Push Button Assembly.
Page 59
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
12724B
Figure 9-13. SINGLE PHASE MOTOR ASSEMBLY
Ref.
No.
Part
Number
Description
Primer
Motor Assembly (Includes Ref. Nos. 1 thru 12)
BH-4031 1/4 Horsepower - Yellow Powercoat
BH-4034
BH-4032 1/2 Horsepower - Yellow Powercoat
BH-4035
BH-4033 1 Horsepower - Yellow Powercoat
BH-4036
BH-3903 2-1/4 Horsepower
1
*
Bell - End
2
*
Ring - Retaining
3
*
Bearing - Ball
4
*
Ring - Retaining
5
BH-3908
Key - Brake
6
*
Rotor and Shaft Assembly
7
*
Stator Assembly
8
Bolt - Motor Mounting
BH-3909 1/4 Horsepower
BH-3910 1/2 Horsepower
BH-3911 1 Horsepower
9
Capacitor Assembly
BH-3913 1/4 Horsepower
BH-3914 1/2 Horsepower
BH-3915 1 Horsepower
10
Cover
For Ref. No. 9
* 1/4 Horsepower
* 1/2 Horsepower
* 1 Horsepower
BH-3919 For Ref. No. 12
11
BH-3920
Slotted Hex Head Self Tapping Screw (#8-32 x 5/16)
12
Solid State Switch Assembly
BH-3921 1/4, 1/2 & 1 Horsepower
* Furnished only as part of motor assembly.
Page 60
Qty.
Req’d
1
1
1
1
1
1
1
1
4
1
1
2
1
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
12724
Figure 9-14. THREE PHASE MOTOR ASSEMBLY
Ref.
No.
Part
Number
Description
Primer
Motor Assembly (Includes Ref. Nos. 1 thru 8)
1/4 Horsepower (1 Speed) - Yellow Powercoat
BH-4037 200 Volt
BH-4050
BH-4038 230/460 Volt
BH-4051
BH-4039 575 Volt
BH-4052
1/2 Horsepower (1 Speed) - Yellow Powercoat
BH-4053 200 Volt
BH-4056
BH-4054 230/460 Volt
BH-4057
BH-4055 575 Volt
BH-4058
1 Horsepower (1 Speed) - Yellow Powercoat
BH-4059 200 Volt
BH-4062
BH-4060 230/460 Volt
BH-4063
BH-4061 575 Volt
BH-4064
2-1/2 Horsepower (1 Speed) - Yellow Powercoat
BH-4065 200 Volt
BH-4068
BH-4066 230/460 Volt
BH-4069
BH-4067 575 Volt
BH-4070
1/2-1/6 Horsepower (2 Speed) - Yellow Powercoat
BH-4071 200 Volt
BH-4075
BH-4072 230 Volt
BH-4076
BH-4073 460 Volt
BH-4077
BH-4074 575 Volt
BH-4078
1-1/3 Horsepower (2 Speed) - Yellow Powercoat
BH-4079 200 Volt
BH-4083
BH-4080 230 Volt
BH-4084
BH-4081 460 Volt
BH-4085
BH-4082 575 Volt
BH-4086
2-1/4 - 3/4 Horsepower (2 Speed) - Yellow Powercoat
BH-4087 200 Volt
BH-4091
BH-4088 230 Volt
BH-4092
BH-4089 460 Volt
BH-4093
BH-4090 575 Volt
BH-4094
1 Bell - End
* 1 Speed - 1/4, 1/2 and 1 HP
* 1 Speed - 2-1/2 HP
* 2 Speed
Qty.
Req’d
1
1
(Continued on following page)
Page 61
Figure 9-14. THREE PHASE MOTOR ASSEMBLY - Continued
Ref.
No.
Part
Number
Description
Qty.
Req’d
2
Ring - Retaining
1
* 1 Speed- 1/4, 1/2 and 1 HP
* 1 Speed - 2-1/2 HP
* 2 Speed
3
Bearing - Ball
1
BH-3312 1 Speed - 1/4, 1/2 and 1 HP
BH-2915 1 Speed - 2-1/2 HP
BH-2915 2 Speed
4
Ring - Retaining
1
* 1 Speed - 1/4, 1/2 and 1 HP
* 1 Speed - 2-1/2 HP
* 2 Speed
5
Key - Brake
1
BH-3314 1 Speed - 1/4,1/2 and 1 HP
BH-2917 1 Speed - 2-1/2 HP
BH-2917 2 Speed
6
*
Rotor and Shaft Assembly
1
7
*
Stator Assembly
1
8
Bolt - Motor Mounting
4
BH-3315 1 Speed - 1/4, 1/2 and 1 HP
BH-2954 1 Speed - 2-1/2 HP
BH-2942 2 Speed
* Furnished only as part of motor assembly.
NOTES
Page 62
Solenoid Kit
Coil
Kit
Figure 9-15. HOIST MOTOR BRAKE
Part No.
BH-4040
BH-4041
BH-4042
Motor HP
Motor RPM
1/4
1800
BH-4043
BH-4044
BH-4045
1/2
BH-4046
BH-4047
BH-4048
Brake Torque
ft. - lbs.
Voltage
115/230 1Ø
230/460
575
Coil Kit
BH-4097
BH-4095
BH-4096
1800
115/230 1Ø
230/460
575
BH-5000
BH-4098
BH-4099
3
1
1800
115/230 1Ø
230/460
575
BH-5003
BH-5001
BH-5002
6
BH-4043
BH-4044
BH-4045
1
3600
115/230 1Ø
230/460
575
BH-5000
BH-4098
BH-4099
3
BH-4046
BH-4047
BH-4048
2-1/4
2-1/2
3600
115/230 1Ø
230/460
575
BH-5003
BH-5001
BH-5002
6
Ref. No.
4
Part No.
Description
BH-5004
BH-5005
BH-5006
BH-5007
BH-5008
Solenoid Kit
Friction Disc (1½ & 3 ft. lbs. use 1 disc - 6 ft. lbs. use 2 discs)
Brake Hub (not shown)
Brake Cover - Yellow Power Coat (not shown)
Brake Cover - Primer (not shown)
1-1/2
Page 63
Recommended Spare Parts for Your Budgit Hoists
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.
Set of Gaskets
Contactor
Set of Bearings
Transformer Fuse
Set of Oil Seals
Limit Lever
Lower Block Assembly
Limit Switch Assembly
Load Chain
Set of Brake Discs for Load Brake
Set of Brake Discs for Motor Brake
Push Button Station & Cable Assembly
Transformer
Note: When ordering parts always furnish Model and Catalog Number of Hoist and lift of hoist on which the
parts are to be used.
Parts for your hoist are available from your local authorized Budgit Hoists repair station.
For the location of your nearest repair station, write:
Phone: (800) 888-0985 • Fax: (800) 689-5644
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 (1)
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 (1) year from completion of the applicable work by Seller,
provided; however, all claims for defective products and parts must
be made in writing no later than eighteen (18) 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 warranty must be commenced
within one (1) year after the cause of action has accrued.
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