Paccar Winch BRADEN H20R, Installation Maintenance And Service Manual

Page 1: ...0R Recovery Winch INSTALLATION MAINTENANCE AND SERVICE MANUAL LIT2223 R1 3 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 ...

Page 2: ...RECOMMENDED FASTENER TORQUE 7 WIRE ROPE INSTALLATION 8 PREVENTIVE MAINTENANCE 9 RECOMMENDED PLANETARY HOIST GEAR OIL 11 TROUBLESHOOTING 12 DISASSEMBLY OF WINCH 15 PLANET CARRIER SERVICE 17 BRAKE CYLINDER SERVICE 19 BRAKE CLUTCH SERVICE 22 WINCH ASSEMBLY 24 CROSS SECTION DRAWING AND PARTS KEY 26 METRIC CONVERSION TABLE 30 1 ...

Page 3: ...upport Department via phone at 918 251 8511 from 08 00 to 16 30 hours CST Monday through Friday via fax at 918 259 1575 or via email at winch service paccar com for the latest available information Serial Numbers and Model Numbers are stamped into a data plate located on the tie plate Always refer to the Serial Number and Model Number when request ing information or service parts EXPLANATION OF MO...

Page 4: ... to handle wire rope when the hook end is not free Keep all parts of body and clothing clear of cable rollers cable entry area of fairleads sheaves and winch drum 10 When winding wire rope on the winch drum never attempt to maintain tension by allowing wire rope to slip through hands Always use Hand Over Hand technique 11 Never use wire rope with broken strands Replace wire rope 12 Do not weld on ...

Page 5: ... DESCRIPTION The dual brake system consists of a dynamic brake sys tem and a static brake system The dynamic brake system has two operating compo nents 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 pilot operated spring loaded spool valve that blocks the f...

Page 6: ...ag cams to instantly roll upward and firmly lock the shaft to the fully engaged friction brake Figure 6 When the winch is powered in reverse to lower the load the motor cannot rotate until sufficient pilot pres sure is present to open the brake valve Figures 3 4 The friction brake within the winch will completely release at a pressure lower than that required to open the brake valve The extent to ...

Page 7: ...must be externally drained directly to the reservoir to avoid motor shaft seal failure 5 The winch must be mounted perpendicular to an imaginary line from the center of the winch to the first sheave to ensure even spooling Make certain the fleet angle is between and 1 degrees 6 The winch directional control valve must be a three position four way valve with a motor spool such that when the valve i...

Page 8: ...0 35 80 110 80 150 110 110 55 75 150 115 210 160 14 20 13 20 12 18 11 18 265 200 Torque LB FT Grade 5 Grade 8 380 280 7 8 9 14 420 325 600 450 3 4 10 16 680 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 Q Bolt Dia Inches Thds Per Inch Bolt Dia Inches Thds Per Inch 1 1 2 6 12 1940 To convert lb ft to kg m multiply lb ft va...

Page 9: ...ximately 500 lb 227 kg to the wire rope as the new wire rope is wound onto the cable drum The set screw anchor system is designed for use only with 9 16 5 8 in 14 16 mm wire rope WIRE ROPE INSTALLATION The set screw wire rope anchor system is not capa ble of supporting the rated load Always MAINTAIN a minimum of five wraps of wire rope on the cable drum If the wire rope is fully reeled out the wir...

Page 10: ...e maintenance program in effect A record of written dated and signed inspections load tests maintenance and repairs or modifications must be kept readily available in an appropriate location for a minimum of five years Inspections procedures for hoists are divided into five general categories based upon the hoist usage or duty cycle which in turn determines different appropriate intervals for insp...

Page 11: ...eral times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear train Semi Annual Inspection every six months Must include but is not limited to the following inspec tions performed by a qualified technician 1 Perform the Pre Use inspection 2 Take a lubricant sample as described later in this section and analyze it for wear metals content cor rect v...

Page 12: ...rtan EP 150 Omala 150 Mobilgear 630 Spartan EP 220 Omala 220 Chevron Gear Compounds EP 150 Gear Compounds EP 220 9 2002 PREVAILING AMBIENT TEMPERATURE oF 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF EXXON SPARTAN EP220 OR EQUIVALENT AGMA 5 EP ISO VG 220 EXXON SPARTAN EP150 OR EQUIVALENT AGMA 4 EP ISO VG 150 SYNTHETIC OR EQUIVALENT oC 40 30 20 10 0 10 20 30 40 50 oC NOTE SHADED TEMPE...

Page 13: ...on Assemble valve using new seal rings on CB valve cartridge Install an accurate 0 1000 PSI 0 6900 kPa test gauge in the brake release hose With no load on the hoist slow ly move the control lever into the lowering position and record the pressure when the drum begins to turn in the lowering direction The static brake will release at approximate ly 350 PSI 2415 kPa and the CB valve should open at ...

Page 14: ...e heat 2 System relief valve may be set too low Relief valve needs adjustment or repair 3 Be certain hydraulic system temperature is not more than 180 F 82 C Excessive hydraulic oil temperatures increase motor and pump internal leakage and reduce performance 4 Winch line pull rating is based on 1st layer of wire rope 5 Rigging and sheaves not operating effi ciently Reinforce mounting surface If ne...

Page 15: ...es not spool smoothly on the drum 1 The winch may be mounted too close to the main sheave causing the fleet angle to be more than 1 1 2 degrees 2 The winch may not be mounted perpendi cular to an imaginary line between the center of the cable drum and the first sheave 3 Could possibly be using the wrong lay rope There is a distinct advantage in applying rope of the proper direction of lay When the...

Page 16: ...linder to the hoist end bracket Install two 13 in eye bolts into the motor mounting holes and lift the brake cylinder out of the hoist end brack et Be careful to avoid damaging the seal surfaces of the brake cylinder Refer to Brake Cylinder Service for additional information 7 Remove the capscrews that secure the two tie plates to the hoist end brackets and remove the tie plates and the motor end ...

Page 17: ...t ed from steel bar Refer to Planet Carrier Service for additional information 12 Lift the cable drum off of the drum bearing support and end bracket Remove the seal and drum bear ing as required Thoroughly clean and inspect the ring gear machined into the inside surface of the drum for nicks spalling or excessive wear Replace the drum if the gear wear is more than 015 in 0 4 mm when compared to a...

Page 18: ...material displacement or abnormal wear the bearing should be replaced Likewise the cage should be inspected for unusual wear or deforma tion particularly the cage bars If there is any dam age that will impair the cage s ability to separate retain and guide the rollers properly the bearing should be replaced The thrust washer contact areas should be free from any surface irregularities that may cau...

Page 19: ...ace Always use NEW roll pins When prop erly positioned 50 of the roll pin will engage the planet gear shaft and 50 will remain in the planet carrier 4 Note that the roll pin is slightly recessed in the car rier when properly installed With a center punch stake the carrier next to the pin hole as shown This will distort the hole so the pin will not back out Repeat these steps for each of the three ...

Page 20: ...Make certain the brake release oil port is clean The opening of the port must have a slight chamfer to prevent cutting the seal It is a good practice to smooth the edge of the port with emory cloth 2 Check the oil seal and bearing surfaces on the out side of the brake cylinder for damage wear or rust Replace cylinder as required 3 Place the friction discs on a flat surface and check for distortion...

Page 21: ...nd measure the clearance in three places between the motor support and pressure plate The average gap must measure between 153 in 4 mm maxi mum and 080 in 2 mm minimum If the gap exceeds the maximum limit there may be too many brake discs in the stack up or the discs are distorted If the gap is less than the minimum there are too few discs in the stack up or the discs are worn If the number of dis...

Page 22: ...and pump with accurate 0 2000 psi 0 13 800 kPa gauge and shut off valve to this fitting Apply 1000 psi 6 900 kPa to the brake Close shut off valve and let stand for five 5 minutes If there is any loss of pressure in five 5 minutes the brake cylinder should be disassembled for inspec tion of the sealing surfaces and brake piston 2 WHILE PRESSURE IS APPLIED AND THE BRAKE RELEASED install the brake c...

Page 23: ...fur ther disassembly If disassembly is necessary remove the bushing according to the procedure covered in Step No three 3 All brake clutch assembly parts should be thoroughly cleaned and inspected before assembly ASSEMBLY 1 Press a sprag bushing into the outer race using a mechanical or hydraulic press A flat plate of approximately the same diameter as the bushing flange outside diameter should be...

Page 24: ...ion to start it through the sprag clutch If the inner race will not go through the bushings the bushings have probably been dam aged and should be replaced 6 Turn the assembly over with the snap ring down Install the second retainer and snap ring Make cer tain the snap ring is seated in the groove properly 7 This is a completed brake clutch assembly ARN ING Be certain the snap ring is seated in th...

Page 25: ...f the closure 6 Lubricate the o ring and drum opening with light grease or gear oil and install the drum closure with the seal side facing away from the gear train 7 Place the motor end bracket onto the drum and install the two tie plates that connect the drum bear ing support end bracket to the motor end bracket Start all capscrews and tighten just hand tight at this time 8 Lubricate the pilot di...

Page 26: ...l the hoses that connect the brake valve and motor to the brake cylinder After the winch assem bly is complete check all fasteners and fittings for proper torque Care must be taken to assure the primary thrust plate remains properly located in its counterbore when the motor is installed for the first time or is being reinstalled on the winch It is possible for the primary thrust plate to drop out ...

Page 27: ...26 BRADEN H20R 05559 COMPONENTS ...

Page 28: ...sher 33 1 Support End Plate 38 1 Bearing Support 39 1 Cable Drum 40 1 Drum Closure 41 44 Lockwasher 1 2 Z 42 24 Capscrew 1 2 13 X 1 1 2 G8 Z 43 1 Primary Sun Gear 44 1 Thrust Washer 45 1 O Ring 46 1 Seal 59 1 Output Sun Gear 60 1 Adapter 62 1 Seal 63 1 Bearing Support 64 2 Retaining Ring 65 1 O Ring 67 1 Torque Shaft 68 1 End Cover 69 20 Capscrew 1 2 13 X 1 1 4 G8 Z 70 1 Vent Plug 72 1 Bearing 73 ...

Page 29: ...g BRAKE CYLINDER ASSEMBLY NOTE Drawing shows 6 friction and 7 steel discs The parts list below is correct 7 friction and 8 steel ITEM QTY DESCRIPTION 1 1 Brake Cylinder 2 1 Motor Support 3 8 Steel Disc 4 7 Friction Disc 5 1 Seal 6 1 Backup Ring 7 1 Pressure Plate 8 1 Spacer 9 12 Spring 11 1 O Ring 12 1 Backup Ring 13 1 Spring Spacer 16 4 Lockwasher 1 2 Z 17 4 Capscrew 1 2 13 X 2 G8 Z ...

Page 30: ...anet Gear 12 3 Primary Planet Gear Shaft 13 3 Roller Bearing 14 6 Thrust Washer 15 3 Spirol Pin 37 1 Thrust Washer ITEM QTY DESCRIPTION 15 3 Spirol Pin 16 1 Output Planet Carrier 17 3 Output Planet Gear 18 3 Output Planet Gear Shaft 19 6 Roller Bearing 20 3 Bearing Spacer 21 6 Thrust Washer 38 1 Thrust Washer ...

Page 31: ...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 PSI X 0 069 bars bars X 14 5 pounds sq in PSI inches H2O 60 o F X 0 2488 kilopascals kPa kilopascals kPa X 4 0193 inches H2O 60 o F bars X 100 kilopascals kPa kilopascals kPa X 0 01 bars horsepower hp X...