BRADEN CH150A Series, Installation Maintenance And Service Manual

Page 1: ...T INSTALLATION MAINTENANCE AND SERVICE MANUAL LIT2222 R1 6 2005 Printed in U S A PACRWINCH DIVISION P O BOX 547 BROKEN ARROW OK U S A 74013 PHONE 918 251 8511 FAX 918 259 1575 www paccarwinch com Copy...

Page 2: ...RECORDS AND RETENTION 16 OIL SAMPLING AND ANALYSIS 17 BRAKE TEST PROCEDURE 18 AUXILIARY BRAKE TEST PROCEDURE 19 EMERGENCY LOWERING PROCEDURE 20 PERSONNEL HANDLING 22 TROUBLE SHOOTING 23 EXPLODED VIEW...

Page 3: ...h service paccar com for the latest available information MODEL NUMBER AND SERIAL NUMBER When requesting information for your Braden hoist always refer to the model code and serial number The serial n...

Page 4: ...proval of PACCAR Winch Engineering 14 See recommended hydraulic oil and gear lubricant 15 Keep your hydraulic system clean and free from contamination at all times 16 Use the correct anchor for the wi...

Page 5: ...ved from the electrical path to ground if the load rigging or wire rope comes in contact with or within proximity to an electrically charged conductor 30 Before operating the hoist be sure ALL safety...

Page 6: ...onents 1 Brake valve assembly 2 Hydraulic motor The brake valve is basically a counterbalance valve It contains a check valve to allow free flow of oil to the motor in the hoisting direction and a pil...

Page 7: ...e figure 6 When the hoist is powered in the lowering direction the motor cannot rotate until there is sufficient pilot pressure to open the brake valve See figures 3 4 The stat ic friction brake will...

Page 8: ...d Sprag Cams Permits free shaft rotation while hoisting Hoisting Figure 6 Static Friction Brake Applied Load attempts to rotate shaft in opposite direction Brake clutch locks sun gear shaft to frictio...

Page 9: ...rt trouble and reduce the length of warm up periods A high viscosity index will minimize changes in viscosity with corresponding changes in tempera ture Maximum cold weather start up viscosity should...

Page 10: ...ermine the proper wedge size It is important that the wire rope have the proper ten sioning when it is installed on the drum When the wire rope is first installed you should operate the hoist with lig...

Page 11: ...of boom extension Allow the load to stabilize and then watch for any sign of downward movement or cable drum rota tion The hoist static brake should hold the load in place without allowing any downwa...

Page 12: ...680 1 1 8 7 12 790 590 1290 970 1 8 14 640 7 12 1120 835 910 485 1460 1820 1360 1 3 8 6 12 1460 1095 2385 1790 1 1 4 3160 2370 RECOMMENDED FASTENER TORQUE Bolt Dia Inches Thds Per Inch Bolt Dia Inche...

Page 13: ...12 PRE USE DAILY INSPECTION QUARTERLY INSPECTION SEMI ANNUAL INSPECTION ANNUAL INSPECTION TEAR DOWN INSPECTION IDLED Not used for 3 months REQUIRED BEFORE PLACED IN SERVICE QO REQUIRED BEFORE PLACED I...

Page 14: ...nd lowering under no load several times to prime all the hoist hydraulic lines with warmed oil and to circulate lubricant through the planetary gear sets Quarterly Inspection Every three 3 months or m...

Page 15: ...revision for gear oil recommendations The gear oil should be changed whenever the ambient temperature changes significantly indicating that an oil of a different viscosity range would be more appropri...

Page 16: ...d All seals and O rings should be replaced at this time Any deficiencies including but not limited to those above shall be corrected immediately All of the following operations MUST be performed BEFOR...

Page 17: ...oil supplier for other equivalent oils if required i Texaco Mobil Exxon Shell Meropa 150 Meropa 220 Mobilgear 629 Spartan EP 150 Omala 150 Mobilgear 630 Spartan EP 220 Omala 220 Chevron Gear Compounds...

Page 18: ...rate representation of the oil condition After taking the sam ple check the oil level and add new oil as required Refer to page 16 of this manual for gear lubricant rec ommendations Analysis General G...

Page 19: ...ost 18 Relative position of the needle valve to other components and fittings on the winch motor and counterbalance valve Brake Test Procedure for API designated hoists NOTE Brake test to be performed...

Page 20: ...Plug the end of the hose and leave the brake release port fitting open to atmosphere 2 With the hydraulic power unit HPU running move the directional control valve handle slowly to the full open hois...

Page 21: ...MUST be repaired or replaced 5 Connect a hand pump to the opening in the tee 6 Operate the hand pump up to about 1 000 psi 6 900 kPa A suspended load will slowly come down Releasing the pressure on t...

Page 22: ...ng retainer cap and tap the spool back into the closed position with a hammer and punch Install the spool and spring retainer caps and proceed with the emer gency load lowering If the main spool was s...

Page 23: ...ning signal and a boom angle and length indicator Two blocking occurs when the load block or hook assembly comes in contact with the upper block or point sheave assembly and often results in damage to...

Page 24: ...cs 4 The auxiliary ABS brake may not be releasing due to a defective brake cylinder seal Remove the pilot hose and fitting from the brake valve then use a 5 32 in hex wrench to remove the pilot orific...

Page 25: ...Service for further information Check the ABS brake release pilot pres sure as follows A Install an accurate 0 2000 PSI 0 13 800 kPa pressure gauge to the ABS release line between the hose and port f...

Page 26: ...n brake will not hold due to worn or damaged brake discs 3 The over running brake clutch may be slipping 4 Same as A5 Same as B2 Same as A3 Improper planetary gear oil can cause the brake clutch to sl...

Page 27: ...g the pressure 3 Compare the pressure gauge reading to the hoist specifications Adjust the relief valve as needed NOTE If the pressure does not increase in proportion to the adjustment the relief valv...

Page 28: ...the rated load 1 Same as D2 2 Hydraulic oil flow to motor may be too low 3 Control lever possibly being moved too quickly 4 Same as A4 5 Same as A5 6 Same as A6 Same as D2 Same as E2 Controls should...

Page 29: ...remain closer together and maintain a more even layer If wire rope of incor rect lay is used the coils will spread apart each time the load is removed When hoisting is resumed the wire rope tends to...

Page 30: ...EXPLODED VIEW 29 For part numbers refer to the Material List for your hoist...

Page 31: ...Gear 1 13 Thrust Washer 1 15 Thrust Washer 1 16 Bearing 2 17 O Ring 1 18 Seal 1 22 Primary Sun Gear 1 23 Cable Drum Closure 1 24 Motor End Plate 1 25 Capscrew 20 26 Lockwasher 8 26 Lockwasher 20 27 C...

Page 32: ...the tie plates HOIST DISASSEMBLY A typical hoist with a 01 cable drum and auxiliary brake assembly weighs approximately 1 400 lbs 635 kg Ensure your lifting equipment is of ade quate capacity Attempt...

Page 33: ...outer races of the brake clutch assembly at this time with a metal marking pen or other means to aid reassembly later 10 Remove the brake plate spacer and the stack of brake discs from the brake cylin...

Page 34: ...e with a soft hammer to break it free Remove and dis card the outer o ring and inner seal Inspect the bearing for wear or damage 14 Remove the ring gear adapter from the end of the ring gear 15 Remove...

Page 35: ...de of non flam mable safety solvent Use the proper personal protec tive equipment such as rubber gloves safety glasses etc Thoroughly inspect all parts for excessive wear nicks scratches and other dam...

Page 36: ...ace any defective parts 5 Turn the brake cylinder over with the large end fac ing up Remove the retaining ring and the brake pis ton plate 6 Push the brake piston down toward the table Turn the brake...

Page 37: ...on is placed squarely into the bore and press into the piston bore Be careful not to cut or pinch the seals 5 Install the eight 8 belleville springs onto the spring guide The first spring should rest...

Page 38: ...e retaining ring into the groove in the piston 11 Connect a hand pump with a 0 2000 PSI 0 13 800 kPa pressure gauge to the brake release port fit ting Apply 1000 PSI 6 900 kPa and let the assem bly st...

Page 39: ...unusual wear or deformation particularly on the cage separator bars Any damage that will impair the bearing cage s abil ity to separate retain and properly guide the rollers is cause for replacement 5...

Page 40: ...acking out of position while in service 3 Drive the spiral pin into place The pin should be installed so that approximately half of the length of the pin is inserted into the gear shaft Once in place...

Page 41: ...be well defined with visible oil grooves The splines should be uniform and square ended If they are worn to a point they should be replaced 8 Inspect the steel brake plates in the same manner as the...

Page 42: ...the seals NOTE To aid assembly use two 2 13 UNC bolts with large washers inserted into housing bolt holes located 180 apart Using two 2 heel bars inserted under the washers apply even pressure to bot...

Page 43: ...ect as described in step 3 6 Closely inspect the bore of the outer race for wear scratches indentions or discoloration Any abnor mality is reason for replacement All brake clutch parts should be thoro...

Page 44: ...e retaining ring is fully seated in the groove 5 Slide the inner race through the sprag clutch The inner race will have to be rotated in the free wheeling direction to start it into the sprag clutch I...

Page 45: ...fully installed when the outer surface is located flush to the drum face 6 Turn the drum over and place it onto the brake shaft Be careful while lowering the drum into position to keep from damaging t...

Page 46: ...in 1 6 mm thick thrust race installs against the carrier followed by the needle bearing and the 092 in 2 3 mm thick thrust race 12 Install the ring gear adapter hub end facing up meshing the adapter w...

Page 47: ...h a single brake plate on top of the stack If installing new friction discs be sure to soak them in new oil before installation 19 Install the brake plate spacer on top of the brake stack 20 Measure t...

Page 48: ...of the hoist assembly 27 Lubricate the motor o ring and install it over the motor pilot DO NOT use standard capscrews to install the tie plates The SPECIAL shoulder bolts are used as locating dowels f...

Page 49: ...ts may have steel tubing instead of hoses 30 After the assembly is completed check all fasteners and fittings for tightness or proper torque as required Ensure all hoses follow correct routing procedu...

Page 50: ...ome installa tions have the brake release hose connected direct ly to the motor instead of to the manifold block as shown above In these cases disconnect the brake release hose from the motor 2 Before...

Page 51: ...the original capscrews and tighten to recommended torque 10 Connect the motor case drain hose to the motor case drain port NOTE On two speed motors the case drain and shift drain ports should be conn...

Page 52: ...ck up Ring 1 18 O Ring 1 19 Pipe Plug 1 20 Check Spring 1 21 Shim as req d 22 Spring Seat 1 19 4 20 11 19 10 12 2 1 14 19 4 5 15 18 17 16 21 3 13 14 6 7 8 22 0 11 19 10 1 1 2 inch brake valves built a...

Page 53: ...spool plug and carefully remove the spool assembly Remove the damper piston from the spool The piston will come out of the spool slowly because of a partial vacuum formed between the two Use extreme...

Page 54: ...as shown It is important that each back up ring is on the correct side of its O ring Take care not to cut the O rings during assembly Let the spool and piston set for ten 10 minutes before installing...

Page 55: ...60o F pounds sq in PSI X 6 895 kilopascals kPa kilopascals kPa X 0 145 pounds sq in PSI pounds sq in PSI X 0 0703 kilograms sq cm kg cm2 kilograms sq cm kg cm2 X 14 22 pounds sq in PSI pounds sq in P...