Paccar BRADEN PD10B Series, Installation Maintenance And Service Manual

Page 1: ...ch hoist and drive information on the Internet Most publications and specification sheets are available for downloading WRITE HOIST SERIAL NUMBER BELOW First 2 numbers indicate year manufactured For serial number location see page 3 Hydraulic Hoist Series PD10 75B PD10 77B PD15 75B PD15 77B INSTALLATION MAINTENANCE AND SERVICE MANUAL PD10 75B 77B PD15 75B 77B ...

Page 2: ...Wire and Braided Rope Installation 9 Preventive Maintenance 10 Recommended Oil Change Information 10 Troubleshooting 12 Hoist Disassembly 16 List of Components 18 Exploded view Drawing 19 Planet Carrier Service 20 Motor Support Brake Cylinder Service 22 Brake Clutch Service 26 Hoist Assembly 28 Brake Valve Service 32 Reversing Direction of Drum Rotation 34 ...

Page 3: ...details or attachments different from your hoist Some components have been removed for illustrative purposes Drawings in this manual represent a typical unit sold through our distribu tion channels Some hoists particularly those sold directly to original equipment manufacturers OEM may differ in appearance and options Refer to the following PACCAR Winch publications for related information LIT2688...

Page 4: ...try area of fairleads and hoist drum 10 When winding wire rope on the hoist drum never attempt to maintain tension by allowing wire rope to slip through hands Always use the hand over hand technique 11 Never use wire rope with broken strands Replace wire rope 12 Do not weld on any part of the hoist 13 Use recommended hydraulic oil and gear lubricant 14 Keep hydraulic system clean and free from con...

Page 5: ...they will drive the ring gear drum DUAL BRAKE SYSTEM DESCRIPTION The dual brake system consists of a dynamic brake system and a static brake system The dynamic brake system has two operating components 1 Brake valve assembly 2 Hydraulic motor The brake valve is basically a counterbalance valve with good metering characteristics It contains a check valve to allow free flow of oil to the motor in th...

Page 6: ...ly engaged friction brake Figure 5 When the hoist is powered in reverse to lower the load the motor cannot rotate until sufficient pilot pressure is pres ent to open the brake valve Figures 2 and 3 The friction brake within the hoist will completely release at a pressure lower than that required to open the brake valve The extent to which the brake valve opens will determine the amount of oil that...

Page 7: ...ng support until vent plug is positioned correctly and bolt holes are aligned C Evenly tighten bolts to recommended torque 5 Hydraulic lines and components that operate the hoist must be of sufficient size to assure minimum back pres sure at the hoist motor ports The hydraulic back pressure measured at the motor work ports must be less than 100 PSI 690 kPa at full operating flow Back pressure in e...

Page 8: ...scosity at 104 F 40 C and viscosity index of 100 or greater will give good results under normal temperature conditions The use of an oil having a high viscosity index will minimize cold start trouble and reduce the length of warm up periods A high viscosity index will minimize changes in viscosity with corresponding changes in temperature Maximum cold weather start up viscosity should not ex ceed ...

Page 9: ...tall the wedge then pull the slack out of the wire rope The wedge will slip into the pocket and secure the wire rope into the drum The early style anchor wedge is designed to ac commodate several different sizes of wire rope You may an chor 7 16 and 1 2 inch 11 and 13 mm wire rope by insert ing the wedge large end first Anchor 9 16 and 5 8 inch 14 and 16 mm wire rope by inserting the wedge small e...

Page 10: ...n of this manual Rec ommended Planetary Gear Oil 2 OIL CHANGE The gear oil should be changed after the first 100 hours of operation then every 1 000 operating hours or six months whichever occurs first Gear oil must be changed to remove wear particles that impede the reliable and safe operation of the brake clutch and erode bearings gears and seals Failure to change gear oil at these suggested min...

Page 11: ...SASSEMBLY page 16 and PLANET CARRIER SERVICE page 20 of this service manual B Brake Cylinder Refer to MOTOR SUPPORT BRAKE CYLINDER SERVICE pages 22 and 23 C Brake Clutch Refer to BRAKE CLUTCH SERVICE page 26 9 RECOMMENDED PLANETARY GEAR OIL Use of the proper planetary gear oil is essential to reliable and safe operation of the brake clutch and obtaining long gear train life For simplicity BRADEN h...

Page 12: ...ately 020 inch Clean and install pilot orifice tightly in the brake valve 2 Check brake cylinder seal as follows a Disconnect the swivel tee from the brake release port Connect a hand pump with accurate 0 2 000 PSI gauge and shut off valve to the 4 JIC fitting in the brake release port b Apply 1 000 PSI 6 900 kPa to the brake Close shut off valve and let stand for five minutes c If there is any lo...

Page 13: ...the reservoir Be sure control valve and plumbing is properly sized to hoist motor 3 Oil analysis may indicate contami nation has worn motor shaft and seal Thoroughly flush entire hydraulic sys tem and install new filters and oil In stall new motor seal C The brake will not hold a load with the control lever in neutral 1 Excessive system back pressure acting on the brake release port 2 Friction bra...

Page 14: ... as follows a Install an accurate 0 4000 PSI 27 580 kPa gauge into the inlet port of the brake valve b Apply a stall pull load on the hoist while monitoring pressure c Compare gauge reading to hoist spec ifications Adjust relief valve as required NOTE If pressure does not increase in proportion to adjustment relief valve may be contaminated or worn out In either case the relief valve may require d...

Page 15: ...g the fleet angle to be more than 1 1 2 degrees 2 The hoist may not be mounted perpendicular 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 direc tion of lay When the load is slacked off the several coils on the drum will stay closer together and maintain an eve...

Page 16: ... drain hole in the drum with a hole in the support side plate before removing the hoses and mounting bolts Af ter the hoist is removed from its mounting thoroughly clean the outside surfaces To drain the oil install a short piece of one inch pipe in the larger threads of the drain hole If necessary insert a bar into the anchor pocket and manually rotate the drum in the direction to hoist a load un...

Page 17: ...oists remove the lip seal remove the motor end side plate and continue with Step 9 9 Remove the lip seal by using a bearing puller or two heel type pry bars placed between a wooden block on the pri mary planet carrier and the drum closure Pry upward Remove and discard the O ring from the outside of the drum closure 10 Remove the bearing from inside of closure 11 Remove the primary sun gear and thr...

Page 18: ...ll parts in this kit will be used on any one winch indicates part in seal kit ITEM NO DESCRIPTION PART NO QTY 2 Bearing support 110956 1 5 Sight gauge 25958 1 6 Relief valve 7 1 2 to 15 PSI 18062 1 7 Oil seal 24109 1 8 Ball bearing 24110 1 9 Retaining ring external 70575 1 10 Cable drum 111088 1 12 Washer 100859 38 14 Drain plug 32411 1 O ring for item no 14 23950 1 15 Cable wedge 40130 1 16 Outpu...

Page 19: ...information Please contact PACCAR Winch for help with nonstandard or OEM specific assemblies BRADEN PD15 75B COMPONENTS 2 1 11 4 26 10 13 12 ADDITIONAL REFERENCE PUBLICATION For related drawings and complete list of parts please refer to LIT2688 Parts List for BRADEN Hydraulic Hoist Series PD10 75B 77B and PD15 75B 77B winches ...

Page 20: ...material displace ment or abnormal wear the bearing should be replaced Likewise the cage should be inspected for unusual wear or deformation particularly the cage bars If there is any damage that will impair the cage s ability to separate re tain 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 21: ...le in the carrier with the hole in the planet gear shaft and drive the roll pin into place Always use NEW roll pins 4 Note that the roll pin is recessed approximately 1 16 inch 06 mm in the carrier 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 planet gears ...

Page 22: ...y clean and inspect all parts at this time Check brake piston sealing surfaces on brake cylinder and motor support Be sure brake release port is free of contamination 2 Check oil seal and bearing surfaces on brake cylinder for damage or wear 3 Place friction brake disc on flat surface and check for distortion with a straight edge Friction material should appear even across entire surface with groo...

Page 23: ...y by placing motor support on workbench with motor mounting surface down Install new O ring and backup ring as shown 2 Insert first a steel brake disc followed by a friction brake disc Then alternate steel and friction discs until seven friction discs and eight steel discs have been installed 3 Finish with a steel brake disc on top NOTE It is a good practice to pre lubricate the discs in hydraulic...

Page 24: ... plate into brake cylinder followed by the piston backup ring 9 Install the small brake release O ring into the groove us ing petroleum jelly 10 Apply petroleum jelly to the entire sealing surface of the brake cylinder and to the piston seal Align the brake re lease port of the motor support to that of the brake cylin der Lower the motor support into the brake cylinder be careful to avoid damaging...

Page 25: ...n five minutes the brake cylinder should be disassembled for inspection of the sealing surfaces and brake piston 2 WHILE PRESSURE IS APPLIED AND THE BRAKE RE LEASED install the brake clutch assembly in the brake pack short end of the inner race toward motor Turn the clutch back and forth as you align the outer race splines with the brake disc splines 3 Release the pressure on the brake cylinder th...

Page 26: ...ed for further disassembly If disassembly is necessary remove the bushing according to the procedure covered in Step 3 All brake clutch assembly parts should be thor oughly cleaned and inspected before assembly ASSEMBLY 1 Press a sprag bushing into the outer race using a me chanical or hydraulic press A flat plate of approximately the same diameter as the bushing flange outside diameter should be ...

Page 27: ... rection to start it through the sprag clutch If the inner race will not go through the bushings the bushings have probably been damaged and should be replaced 6 Turn the assembly over with the snap ring down Install the second retainer and snap ring Make certain the snap ring is seated in the groove properly 7 This is a completed brake clutch assembly Be certain the snap ring is seated in the gro...

Page 28: ...to fasten side plates to the base plate DO NOT use standard capscrews in their place CAUTION CAUTION Make certain the snap ring is installed on the bearing sup port This snap ring will keep the output planet carrier cor rectly positioned in the hoist Gear train damage may oc cur if this snap ring is omitted CAUTION Be sure the vent plug is located above the horizontal cen terline for the intended ...

Page 29: ...all with spring side of the seal toward bearing using a flat plate to avoid distortion 7 Install the output sun gear and thrust washer into output planet carrier 8 Install the output planet carrier into the drum while meshing the planet gears with the ring gear and the planet housing with the bearing support 9 Install the primary sun gear and thrust washer into the primary planet carrier 10 Instal...

Page 30: ...oward motor When installed correctly the inner race should turn free ly in the opposite direction the drum turns to pull wire rope in An easy way to check the rotation is to hold the outer race in one hand and rotate the inner race If the clutch free wheels in the wrong direction disassem ble the clutch and reverse the inner race Refer to Brake Clutch Service for additional information Be certain ...

Page 31: ...Note that the Primary Sun Gear and the entire Brake Clutch Assembly have moved to the right toward the hydraulic motor 22 Engage the motor shaft with the brake clutch inner race and lower motor into place Tighten capscrews to recommended torque 23 Install the hoses that connect the manifold and brake valve to the brake cylinder 24 After the hoist assembly is complete check all capscrews and fittin...

Page 32: ... spring free length Replace spring if less than 1 15 16 inches 49 2 mm long 4 Remove spool plug and carefully remove spool assembly NSS Not sold separately Included in brake O ring kit No 61567 PARTS IN 81712 BRAKE VALVE ITEM NO DESCRIPTION PART NO QTY 1 Break valve housing NSS 1 2 Valve spring retainer 24424 1 3 Spring retainer 24183 1 4 Plug 22450 1 5 Spool NSS 1 6 Damper piston NSS 1 7 O ring 2...

Page 33: ...e open ASSEMBLY 1 Install new O rings on the plug and spring retainers 2 Install new O rings and backup rings on the spool and damper piston 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 damper piston set for ten minutes before installing them in their respective bores This will allow the O ri...

Page 34: ...ort Lowering Port Motor Brake Valve M M Manifold Block 1 Remove the four capscrews securing the brake valve to the motor Remove the four capscrews se curing the manifold block to the motor Dis connect the motor case drain hose at the motor NOTE Some installations have the brake release hose connected directly to the motor instead of to the mani fold block In this case disconnect the brake release ...

Page 35: ...n port NOTE On two speed motors the case drain and shift drain should be connected directly to tank DO NOT use the drain connection on the brake valve 11 If your hoist had the brake release hose connected direct ly to the motor the original motor port must be plugged and the hose connected to the motor pressure port near the manifold block lowering port 12 Operate the hoist slowly in both directio...

Page 36: ...Hg 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 h...