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SERIES PD12C PD15B PD17A HYDRAULIC HOIST

1. MAX DESIGN GEAR MOTOR DRUM ROTATION BASE OPTION DRUM RATING SERIES RATIO SIZE OPTION PD DESIGNATES POWER DRUM 12 DESIGNATES 12 000 LB APPROXIMATE FIRST LAYER LINE PULL C DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES 29 DESIGNATES TOTAL GEAR REDUCTION OTHER RATIOS INCLUDE 21 41 59 34 ETC 064 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN REV DECIMAL POINT ELIMINATED EXAMPLE 064 6 4 CU IN REV 02 DESIGNATES THE DRUM OPTION OTHER DRUMS INCLUDE 01 04 05 23G ETC U DESIGNATES UNDERWOUND CABLE DRUM OPTIONAL L DESIGNATES LEFT HAND BASE OPTIONAL BLANK IS STANDARD RIGHT HAND BASE 1 PERMITS TESTING AND INSPECTION PER API 2C FOR OFFSHORE CRANES OPTIONAL GENERAL SAFETY RECOMMENDATIONS Safety and informational callouts used in this manual include WARNING A WARNING This emblem is used to warn against hazards and unsafe practice which COULD result in severe personal injury or death if proper procedures are not followed NCAUTION CAUTION This emblem is used to warn against potential or unsafe practices which COULD result in personal injury and product or property damage if proper procedures are not followed Safety for operators and ground personnel is of prime concern Always take the necessary precautions to ensure safety to others as well as yourself To ensure safety the prime mover and hoist must be operated with care and concern by the operator for the equipment and a thorough knowledge o
2. 17 Install the hoses that connect the manifold and brake valve to the brake cylinder 18 After the hoist assembly is complete check all cap screws and fittings to make certain they have been tightened correctly Refill the hoist with the recommended oil listed under Preventive Maintenance and install the oil level plug BRAKE VALVE SERVICE mun A N DRAIN PORT f SAE 4 ORB 7 16 20 THD The BRADEN brake valve is a reliable hydraulic valve with internal components manufactured to close toler ances Due to the close tolerances and mating of com ponents the valve housing spool piston and check poppet are not available as replacement parts Before disassembling the brake valve be sure you have conducted all applicable troubleshooting operations and are certain the brake valve is causing the malfunction Thoroughly clean the outside surfaces of the valve and work in a clean dust free area as cleanliness is of utmost importance when servicing hydraulic components DISASSEMBLY 0 1 Remove the pilot orifice from the brake release BR port using a 5 32 in Allen wrench 32 BRAKE VALVE ASSEMBLY DESCRIPTION Valve Housing NSS Check Valve Retainer NSS Spring Retainer NSS Plug NSS Spool NSS Damper Piston NSS O Ring Check Valve Poppet NSS Pilot Orifice Check Valve Spring Spool Spring O Rin
3. Use stainless steel shim stock as required FLEET ANGLE 1 27 MIN 11 27 MAX VENT PLUG ABOVE CENTERLINE 4 The vent plug must always be located above the hori zontal centerline If the hoist is mounted on a pivoting surface be sure vent plug remains above the centerline in all positions If necessary reposition bearing support and vent plug as follows A Remove bearing support bolts B Rotate bearing 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 pressure 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 excess of 100 PSI 690 kPa will shorten motor shaft seal life and partially release the load hold ing brake The standard hoist is supplied with the gear motor internally drained and connected the drain by pass port on the Braden brake valve If high back pres sures are encountered the motor should be externally drained directly to the reservoir and the DRAIN port on the brake valve capped All piston motors MUST be drained directly to the reservoir The piston motor case drain port must NEVER be exposed to more than 42 PSI 290 kPa shaft seal damage will occur 6 The hoist should be mounted perpendicu
4. rotate the bearing support or planet gears to engage the bearing support with the output planet carrier Install and hand tighten the bearing support capscrews Stand hoist on bearing support end and visually check to verify the primary thrust plate is properly positioned Refer to caution and drawings in step 16 Install the primary sun gear and proceed to step 11 to complete hoist assembly Tighten bearing support capscrews to recommended torque after motor is installed NCAUTION Hoists with a three piece fabricated base use spe cial shoulder capscrews to fasten side plates to the base plate DO NOT use standard capscrews in their place PD12C PD15B PD17A NCAUTION A Make certain the snap ring is installed on the bearing support This snap ring will keep the output planet carrier correctly positioned in the hoist Gear train damage may occur if this snap ring is omitted 1 Place hoist base on side with bearing support end up 2 Install a new bearing in the drum if replacement is necessary Apply a non hardening sealant on the out side diameter of the new seal Install the spring side of the seal next to the bearing then press into the drum using a flat plate to avoid distortion Be sure drain plug is installed securely 3 Center the drum in the opening of the base Lubri cate the bearing support with petroleum jelly or gear oil and install in base and drum 28 NCAUTION Be sure the
5. 024 X 1 0567 X 0 2642 X 0 06102 X 0 03531 X 35 315 X 0 03381 X 0 03527 X 2 2046 X 0 001102 X 1 1023 X 0 000984 X 0 2961 X 0 145 X 14 22 X 14 5 X 4 0193 X 0 01 X 8 851 X 0 7376 X 7 233 X 0 6214 X 3 281 X 3 281 Fahrenheit 1 8 X C 32 COMMON METRIC PREFIXES 1 000 000 0r 10 1 000 or 10 100 or 10 100 10 39 inches feet ft miles mi inches sq in feet sq ft inches cu in quarts qts gallon gal inches cu in feet cu ft feet cu ft fluid ounce fl oz ounces oz pounds Ibs tons 2000 Ibs tons 2000 Ibs tons long 2240 Ibs inches Hg 60 F pounds sq in PSI pounds sq in PSI pounds sq in PSI inches 60 F bars horsepower hp ft Ibs min pound inches in Ibs pound feet ft Ibs pound feet ft Ibs miles hour m h feet second ft sec feet minute ft min 0 10r10 7 0 01 or 10 0 001 or 10 0 000 0010r10 FOR BEST RESULTS ALWAYS USE GENUINE BRADEN PARTS Copyright 2008 PACCAR Winch Division All Rights Reserved
6. Connect a hand pump with accurate 0 2000 psi gauge and shut off valve to the 4 J I C fitting in the brake release port TROUBLE A The hoist will not lower the load or not lower the load smoothly Cil leaks from vent plug C The brake will not hold a load with the control lever in neutral PROBABLE CAUSE 1 Friction brake will not release as a result of damaged brake discs 1 Same as A2 2 Motor seal may be defective as a result of high system back pres sure or contaminated oil 1 Excessive system back pressure acting on the brake release port 2 Friction brake will not hold due to worn or damaged brake discs 3 Brake clutch is slipping REMEDY A Apply 1000 PSI 6 900 kPa to the brake Close shut off valve and let stand for five 5 minutes B If there is any loss of pressure in five 5 minutes the brake cylin der should be disassembled for in spection of the sealing surfaces and replacement of the seals Refer to Motor Support Brake Cylinder Ser vice Disassemble brake to inspect brake discs Check stack up height as described in Motor Support Brake Cylinder Service Same as A2 System back pressure must not ex ceed 150 PSI 1 035 kPa Inspect hydraulic system for a restriction in the return line from the control valve to the reservoir Be sure control valve and plumbing is properly sized to hoist motor Oil analysis may indicate contami nation has
7. VALVE Zh h tar LL Lil Oil having 150 to 330 SUS 30 60 cSt viscosity at 104 F 40 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 pe riods A high viscosity index will minimize changes in viscosity with corresponding changes in temperature Maximum cold weather start up viscosity should not exceed 5000 SUS 1000cSt with a pour point at least 20 F 11 lower than the minimum temperature Under continuous operating conditions the temperature of the oil at any point in the system must not exceed 180 82 Optimum oil temperature is generally con sidered to be 120 140 F 49 60 In general terms for continuous operation at ambient temperatures between 50 and 110 F 10 to 43 C use ISO 46 for continuous operation between 10 and 90 F 12 to 32 use ISO 32 for applications colder than 10 F 12 C contact the BRADEN Service Depart ment The use of multi viscosity oils is generally not recommended 8 The hydraulic oil filter should have a 10 micron nomi nal rating and be full flow type and meet the require ments of the hydraulic pump manufacturer RECOMMENDED FASTENER TORQUE Higher or lower torques for special applications will be specified such as the use of spanner nuts nuts on shaft ends jam nuts and where distortion of p
8. cable is wrapped onto the drum or drawn through guide rollers 24 Deadman controls which automatically shut off power to the hoist whenever the operator leaves his station should be installed whenever practicable 25 Never allow anyone to stand under a suspended load 26 Avoid sudden shock loads or attempting to jerk load free This type of operation may cause heavy loads in excess of rated capacity which may result in failure of cable and hoist THEORY OF OPERATION DESCRIPTION OF HOIST The hoist has four basic component parts 1 Hoist base 2 Hydraulic motor and brake valve 3 Brake cylinder and motor support 4 Drum assembly The drum assembly consists of three basic assem blies 1 Drum with integral ring gear 2 Output planetary gear set 3 Primary planetary gear set The hydraulic motor is bolted to the motor support which in turn is bolted to the brake cylinder and the base The motor end of the drum running on a ball bearing is supported by the brake cylinder The other end of the drum runs on a ball bearing on the support bolted to the base The ring gear for both planetary sets is machined into the drum s inside surface HOIST OPERATION The hydraulic motor drives the sun gear of the primary planetary gear set through the splined inner race of the overrunning brake clutch When driven by the sun gear the primary planet gears walk around the ring gear in the drum and drive the primary planet car
9. clutch with the short end of the inner race toward the motor 8 Install a new O ring on the motor pilot Rotate the motor 180 from its original position and install it onto the hoist Install and tighten motor capscrews to rec ommended torque 9 Install new O rings in the brake valve and manifold block Attach the brake valve and manifold block to the motor using the original capscrews and tighten to rec ommended 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 should be connected directly to tank DO NOT use the drain connection on the brake valve See TWO SPEED MOTOR CASE DRAIN PLUMBING for additional information 11 If your hoist had the brake release hose connected directly 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 directions and check for oil leaks and or unusual sounds The hoist should operate smoothly in both directions Refer to WIRE AND BRAIDED ROPE INSTALLATION and properly install rope onto the hoist drum 13 Before returning the hoist to full service a light load should be lifted and held three feet 1 meter off the ground to be sure the static brake is functioning prop erly The hoist should also be able to slowly lower the load a smooth and controlled manner If the hoist does
10. groove NOT necessary on PD17A due to stepped design A WARNING A Be certain the snap ring is seated in the groove in the splined bore of the inner race This snap ring will keep the brake clutch assembly correctly positioned in the center of the friction brake pack Binding of the brake or brake failure may occur if this snap ring is omitted 5 Slide the inner race through the bushings and sprag clutch the race will have to be rotated in the free wheeling direction 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 27 HOIST ASSEMBLY NOTE PD15B HOISTS ONLY The drum closure will not fit through the opening in the base For hoists with a three piece base first assemble the bearing support side plate 91 to the base plate 90 Go to step 1 and follow the assembly procedure Install the motor end side plate and tie bar s after installing the drum closure in step 10 For hoists with a one piece cast base use the following assembly procedure With the drum horizontal install the output planet carrier assembly output sun gear 34 thrust washer 43 primary planet carrier assembly thrust washer 31 and drum closure Apply a light coat of grease to the thrust washer to hold them in position Position the drum in the base and install the bearing support Refer to step 3 for two caution statements You may have to
11. not perform either of these functions refer to TROUBLESHOOTING for additional information PD17 ROTATION INDICATION PROXIMITY SENSOR Early PD17A models have a rotation indicator proximity sensor and hub between the motor and the hoist If the sensor is removed or replaced use the following procedure for adjustment and testing Refer to the drawing below for item numbers Install a new O ring item 108 onto motor pilot Install sensor hub item 123 onto motor shaft positioning the sensor hub so that one of the lobes will be directly under the sensor port Install the motor onto the hoist Install capscrews and lockwashers items 101 amp 102 securing the motor to motor adapter NCAUTION If sensor hub is not correctly positioned with a lobe directly under the sensor port proper adjustment may not be possible and severe damage to the sensor and internal hoist components may result Install flatwasher item 121 and O ring item 122 onto new sensor item 120 Apply a small amount of silicone sealant to the threads just below the washer and O ring DO NOT apply sealant to the end of the sensor or to the threads of the sensor port where it could be pushed into the hoist Install the sensor into the motor adapter until it contacts the sensor hub Back sensor out of the port 2 complete turns Attach wire harness to sensor to verify proper sensor operation IT IS NOT necessary to operate the hoist motor If sensor light is on hold
12. position of the motor in relation to the hoist since it will be rotated 180 when reinstalled Remove the capscrews securing the motor to the hoist and care fully remove the motor 3 Remove the brake clutch assembly from the motor support 4 Remove the snap ring and sprag bushing retainer from one end only of the brake clutch assembly 5 Pull the inner race out Examine the race for scor ing wear or indentations caused by the sprag cams If the inner race is not completely smooth the assembly should be replaced 6 Turn the sprag assembly around and slide the inner race with 1 snap ring and bushing retainer through the bushings and sprag clutch the race will have to be rotated in the free wheeling direction to start it through the sprag clutch Install the remaining bushing retainer and snap ring Make certain the snap ring is properly seated in the groove WARNING Be certain the snap ring is seated in the groove the splined bore of the inner race This snap ring will keep the brake clutch assembly correctly positioned in the center of the friction brake pack Binding of the brake or brake failure may occur if this snap ring is omitted 35 7 Before installing the brake clutch be sure the inner race turns free in the opposite direction the drum will turn to haul in wire rope An easy way to check the rotation is to hold the outer race in one hand and rotate the inner race Install the brake
13. vent plug is located above the horizontal centerline for the intended application Oil leakage may occur if vent is positioned incorrectly 4 Tighten the bearing support capscrews to the recom mended torque 5 Stand hoist on bearing support end Install the output sun gear and thrust washer into output planet carrier m pu 6 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 7 Install the primary sun gear and thrust washer into the primary planet carrier 29 8 Install the primary planet carrier meshing the planet gears with the ring gear and the planet housing with the output sun gear 9 Install a new bearing in the drum closure as required Use sealant on the outside surface of the oil seal In stall with spring side of the seal toward bearing using a flat plate to avoid distortion Install a new O ring in the groove on the O D of the drum closure 10 Lubricate the O ring and drum opening with petro leum jelly or gear oil and install the drum closure into the drum 11 Lubricate the pilot oil seal and bearing surfaces of the brake cylinder and carefully install brake cylinder into base and drum Locate the brake release port to ward the lower rear corner of the base Tighten brake cylinder capscrews to recommended torque 12 Install the brake clutch assembly
14. with the short end of the inner race toward 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 disas semble the clutch and reverse the inner race Refer to Brake Clutch Service for additional information WARNING A Be certain the snap ring is seated in the groove in the splined bore of the inner race This snap ring will keep the brake clutch assembly correctly positioned in the center of the friction brake pack Binding of the brake or brake failure may occur if this snap ring is omitted 30 13 If the brake discs are misaligned preventing the installation of the clutch then with a hand pump ap ply 750 1000 psi to the brake release port The brake discs will move freely with the brake released permit ting alignment of the discs brake clutch and input sun gear 14 Install the hoses and fittings to the brake cylinder release port 15 Install a new O ring on the motor pilot then lubricate with petroleum jelly or gear oil NOTE The following caution DOES NOT apply to PD17A hoists Proceed to step 16 NCAUTION 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 re
15. worn motor shaft and seal Thoroughly flush entire hy draulic system and install new filters and oil Install new motor seal The same as Remedy 2 of Trouble B2 Same as Remedy 3 of Trouble A3 Improper planetary gear oil may cause the brake clutch to slip Drain old gear oil and flush hoist with sol vent Thoroughly drain solvent and refill hoist with recommended plan etary gear oil listed in Preventive Maintenance Brake clutch may be damaged or worn Disassemble and inspect brake clutch as described in Brake Clutch Service TROUBLE D The hoist will not hoist the rated load E The hoist runs hot PROBABLE CAUSE 1 The hoist may be mounted on an uneven or flexible surface which causes distortion of the hoist base and binding of the gear train Bind ing in the gear train will absorb horsepower needed to hoist the rated load and cause heat 2 System relief valve may be set too low Relief valve needs adjust ment or repair 3 Be certain hydraulic system tem perature is not more than 180 de grees F Excessive hydraulic oil temperatures increase motor inter nal leakage and reduce motor per formance 4 Hoist line pull rating is based on 1st layer of wire rope 5 Rigging and sheaves not operat ing efficiently 1 Same as D1 2 Be certain that the hydraulic sys tem temperature is not more than 180 degrees F Excessive hydrau lic oil temperatures may be caused by A
16. 8 X 1 3558 X 1383 X 0 11298 X 0 3048 X 0 3048 Celsius 0 556 METRIC CONVERSION TABLE English to Metric millimeters mm meters m kilometers km millimeters mm meters m liters I liters I liters I centimeters cc liters I meters m millileters ml grams 9 kilograms kg kilograms kg metric tons t kilograms kg kilopascals kPa kilopascals kPa Metric to English LINEAR AREA millimeters mm meters m kilometers km millimeters mm meters m VOLUME liters 1 liters 1 liters 1 centimeters3 cc liters 1 meters3 m3 milliliters ml MASS grams 9 kilograms kg kilograms kg metric tons t kilograms kg PRESSURE kilograms sq cm kg cm bars kilopascals kPa kilopascals kPa kilowatts kW watts W newton meters N m newton meters N m kilopascals kPa kilopascals kPa kilograms sq cm kg cm2 bars kilopascals kPa kilopascals kPa POWER kilowatts KW watts W TORQUE kilograms meter kg m meter second m s meter minute m min newton meters N m newton meters N m kilogram meter kg m VELOCITY kilometers hour km hr kilometers hour km hr meters second m s meters minute m min TEMPERATURE F 32 X 0 3937 X 3 281 X 0 6214 X 0 000155 X 10 764 X 61
17. BRADEN SERIES PD12C PD15B PD1 HYDRAULIC HOIST INSTALLATION MAINTENANCE AND SERVICE MANUAL PACCAR WINCH DIVISION P O Box 547 Broken Arrow Oklahom 251 918 250 m Table of Contents GENERAL SAFETY RECOMMENDATIONS idea 4 TAEORY OF OPERATION 5 AOIS HINS ode bus un ld EEE RECOMMENDED FAS TENER TORQUE 9 WIRE AND BRAIDED ROPE INSTALLATION 9 TWO SPEED MOTOR CASE DRAIN PLUMBING cionis 10 PREVENTIVE MAIN 10 RECOMMENDED OIL CHANGE INFORMATION noa hona ttn c 11 TROUBLE SHOOTING pr 12 HOISTBISASSEMBLEY a ere meee oer p MEE ELE 16 EXPLODED VIEW DRAWING AND PARTS KEY sescccieticnccatudrcnataninctansaedaunoncntie 18 19 PLANET CARRIER SERVIGE 20 MOTOR SUPPORT BRAKE 22 BRAKE CLUTCH SERVICE 26 OIS TASSEMBLY eH ne 28 BRAKE VALVE SERVIGE dado A ETRE 32 REVERSING DIRECTION OF DRUM RO TATION roce turiitate tutte aerem 34 PD17A ROTATION INDICATION PROXIMITY SENSOR 36 FOREWORD Read
18. If disassembly is necessary remove the bushing ac cording to the procedure covered in Step No three 3 All brake clutch assembly parts should be thoroughly cleaned and inspected before assembly A WARNING A The polished surfaces of the races and sprag cams must be perfectly smooth to insure positive engage ment of the clutch The slightest defect may reduce brake clutch effectiveness which may lead to loss of load control and result in property damage personal injury or death It is generally recommended to re place the entire brake clutch assembly if any compo nent is defective ASSEMBLY 1 Press a sprag bushing into the outer race using a mechanical or hydraulic press A flat plate of approxi mately the same diameter as the bushing flange out side diameter should be placed between the press and bushing during assembly to protect the bushing Be certain the bushing flange is against the shoulder in the outer race 6 Turn the assembly over with the snap ring down In stall the second retainer and snap ring Make certain the snap ring is seated in the groove properly 2 Turn the assembly over and install the sprag clutch in the bore of the outer race 3 Press the remaining bushing into the race Again make sure the bushing is against the shoulder 4 Next install a sprag bushing retainer then a snap ring on the inner race Be sure the snap ring is seated in the snap ring
19. Plugged heat exchanger B Too low or too high oil level in hy draulic reservoir C Same as D2 REMEDY Reinforce mounting surface If necessary use shim stock to level hoist Refer to Hoist Installation First loosen then evenly retighten all hoist mounting bolts to recom mended torque Check relief pressure 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 specifications Adjust relief valve as required NOTE f pressure does not in crease in proportion to adjustment relief valve may be contaminated or worn out In either case the relief valve may require disassembly or replacement Same as remedies for Trouble D1 amp D2 Same as remedies for Trouble E2 Refer to hoist performance charts for additional information Perform rigging service as recom mended by crane manufacturer Same as remedies for Trouble D1 Thoroughly clean exterior and flush interior Fill drain to proper level Same remedies as D2 TROUBLE E The hoist runs hot F Hoist chatters while raising rated load G The wire rope does not spool smoothly on the drum PROBABLE CAUSE D Hydraulic pump not operating efficiently 3 Excessively worn or damaged internal hoist parts 1 Same as D2 2 Hydraulic oil flow to motor may be too
20. The mounting plane of the base may be rotated in any position around this SRO ORO ROT EOI RIOR m SEE 2522555 gt otag oleg oleh d ox AQ os ISSEY BEI IIS INES SSS SREY ORR OP ROG LR OPK ROOK RIP K ROP BIRR SOR IMR ROO ES RE SM xS SSS 5 574 m SS SSS iS R SISS SX RNN N S NS SS ANUS SS SRE N X SO NY S QV SS SN SS NS SSS XN IN XS X M SX S SSS eM SS SS SS SS S SS SS SS SS SS NS SSS BS NOSE SS ES X SS X X BRS X X SN Se S SS EN 2 Because of the design of the mounting base the di rection of line pull should only be as shown in the above illustration Line pulls in any other direction must be ap proved by BRADEN Engineering 3 When mounting the hoist use all eight 8 mount ing holes and grade 8 capscrews and nuts Tighten to recommended torque It is important that the hoist is mounted on a surface that will not flex when in use and cause binding of the gear train Binding in the gear train will result in acceler ated wear and heat Also be sure the hoist is mounted on a flat surface If necessary use shim stock to insure the mounting surface is flat within 0 020 in 0 5 mm
21. age s ability to separate retain and guide the roll ers properly the bearing should be replaced The thrust washer contact areas should be free from any surface irregularities that may cause abrasions or friction The gears and shafts should be inspected for abnormal wear or pitting Replace if necessary ASSEMBLY 1 Place the output planet carrier on workbench with splined coupling side down Install output thrust plate in center of carrier NCAUTION PD17A hoists have an internal retaining ring to hold the thrust plate into the carrier This retaining ring MUST be properly installed and fully seated before the planet gears are installed 2 Insert two 2 bearings and a bearing spacer into a gear with the spacer between the bearings Place a thrust washer on each side of the gear and position in a carrier opening Slide the shaft through the carrier thrust washer bearing gear sub assembly and remain ing thrust washer Be careful to avoid damaging thrust washers when installing planet shafts 3 Carefully align the pin hole in the carrier with the hole in the planet gear shaft and drive the roll pin into place Always use NEW roll pins When properly positioned 50 of the roll pin will engage the planet gear shaft and 5096 will remain in the planet carrier 4 Note that the roll pin is slightly recessed in the carrier when properly installed With a center punch stake the carrier next to the pin hole as s
22. arts or gaskets is critical Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut Avoid using thread lubricants such as anti seize compound as the applied torque may vary by 10 4095 de pending upon the product used Torque LB FT N m Torque LB FT N m Bolt Thread Grade 5 Diam per Diam per 20 12 10 EUM 200 380 280 28 Hh e 16 5 16 359 271 515 380 5 16 18 17 13 24 18 420 325 600 450 24 23 17 33 24 569 441 813 610 3 8 16 31 23 45 35 1 8 640 485 910 680 24 42 31 61 47 14 868 658 1234 922 6 14 50 35 70 50 118 Y 790 590 1290 970 20 68 47 95 68 12 1071 800 1749 1315 12 13 75 55 110 80 11 4 T 1120 835 1820 1360 20 102 75 149 108 12 1518 1132 2468 1817 9 16 12 110 80 150 110 13 8 6 1460 1095 2385 1790 18 149 108 203 149 12 1979 1485 3234 2427 5 8 11 150 115 210 160 14 2 6 1940 1460 3160 2370 18 203 156 285 217 12 2360 1979 4284 3214 To convert LB FT to Kg m multiply LB FT value by 0 1383 Bee WIRE AND BRAIDED ROPE INSTALLATION ANCHORING WIRE ROPE ANCHORING BRAIDED ROPE 7A Va 11 13 mm wire rope Insert large end first 9 1 1 in braided rope 25 28 mm SS 7 404 16 5 e 14 16 mm wire Insert small end first Early Style Wire Rope Take the
23. atic Brake c Motor Brake Valve To Tank Control Valve Low Medium High Pressure Pressure Pressure Figure 2 LOWERING 1 Static Brake nu Motor Brake Valve V 1 y WiN pump Z C77 Control Valve lt To Tank Low Medium High Pressure Pressure Pressure Figure 3 LOWERING 2 Static Brake um lt nu Brake Valve To Tank A Pump 2 Control Valve Low Medium High Pressure Pressure Pressure The static brake is released by the brake valve pilot pressure at a pressure lower than that required to open the pilot operated spool valve This sequence assures that dynamic braking takes place in the brake valve and that little if any heat is absorbed by the friction brake The friction brake is a load holding brake only and has nothing to do with dynamic braking or rate of descent of a load The overrunning brake clutch is splined to the primary sun gear shaft between the motor and the primary sun gear It will allow this shaft to turn freely in the direction to raise a load and lock up to force the brake discs to turn with the sha
24. brake disc then alternate steel and friction discs until seven 7 friction and eight 8 steel discs have been installed Finish with a steel brake disc on top NOTE It is a good practice to pre lubricate the discs in hydraulic oil prior to assembly 23 4 Install the remaining brake spacer on top of the last steel brake disc This is the only spacer used with lobed discs 5 To check brake stack height place pressure plate on top of brake spacer Hold pressure plate down firmly by hand and measure clearance in three places between motor support and pressure plate Average gap must measure between 153 in 4 mm maximum and 080 in 2 mm minimum If the gap exceeds the maximum limit there are too many brake discs in stack up or the discs are distorted If the gap is less than the minimum there are too few discs in stack up or the discs are worn out When stack height is correct remove pressure plate and continue assembly 6 Lubricate the brake piston seal and motor support sealing surface with petroleum jelly or hydraulic oil In stall new piston seal to motor support seal lip down 24 OLDER STYLE BRAKE CYLINDER 7 Install brake springs into brake cylinder NEW STYLE BRAKE CYLINDER 7A When using the new style brake cylinder without milled spring pockets install the spring spacer then the brake springs WARNING Always use the mold
25. bute to intermittent brake clutch slippage Make certain that the gear oil viscosity used in your hoist is correct for your prevailing ambient temperature Failure to use the proper type and viscosity of planetary gear oil may contribute to brake clutch slippage which could result in property damage severe personal injury or death Refer to Recommended Planetary Gear Oil for additional information 3 VENT PLUG The vent plug is located in the drum support as shown It is very important to keep this vent clean and unobstructed Whenever gear oil is changed remove vent plug clean in solvent and reinstall Do not paint over the vent or replace with a solid plug 4 HYDRAULIC SYSTEM The original filter element should be replaced after the first fifty 50 hours of operation then every 500 operating hours or three 3 months or in accor dance with the equipment manufacturer s recommen dations 5 WIRE ROPE Inspect entire length of wire rope according to wire rope manufacturers recommendations 6 MOUNTING BOLTS Tighten all hoist base mounting bolts to recom mended torque after the first one hundred 100 hours of operation then every 1000 operating hours or six 6 months whichever occurs first WARNING A Failure to properly warm up the hoist particularly un der low ambient temperature conditions may result in temporary brake slippage due to high back pres sures attempting to release the brake which could r
26. e approximate Refer to Oil Level earlier in this section If a hoist ever exhibits any sign of erratic operation or load control difficulties i e load creeping or chattering appropriate troubleshooting tests and repairs should be performed immediately Continued operation in this manner may result in property damage serious personal injury or death TROUBLE A The hoist will not lower the load or not lower the load smoothly PROBABLE CAUSE 1 The problem could be a plugged or loose pilot orifice The pilot ori fice is a small pipe plug with a hole drilled through it located behind the pilot port fitting on the brake valve If it becomes plugged it will prevent the pilot pressure from the mani fold from opening the brake valve If it becomes loose it will allow an unregulated amount of oil in to op erate the brake valve which cause erratic brake valve operation 2 The friction brake may not be releasing as a result of a defective brake cylinder seal NOTE If the brake cylinder seal is defective you will usually find oil leaking from the hoist vent plug REMEDY Remove the pilot hose and fitting from the brake valve then use a 5 32 inch Allen wrench to remove the pilot orifice The diameter of the orifice is approximately 020 inches Clean and install the pilot orifice tightly in the brake valve Check brake cylinder seal as fol lows A Disconnect the swivel tee from the brake release port
27. e piston 25 2 WHILE PRESSURE IS APPLIED AND THE BRAKE RELEASED 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 then re move the brake clutch assembly The brake cylinder assembly is now complete and ready to be installed in the hoist BRAKE CLUTCH SERVICE DISASSEMBLY 1 Remove the snap ring and sprag bushing retainer from one end only NOTE The brake clutch on PD17A hoists use a stepped inner race which eliminates one retaining ring and bushing retainer The larger end of the inner race is toward the motor 2 Pull the inner race out Examine the race for scoring wear or indentations caused by the sprag cams 3 Use a screwdriver and mallet to remove the sprag bushing from one end of the outer race There are four special cut outs in the bushing for this purpose Be careful not to damage the bushing inside surface If a bushing s inside surface is damaged or shows wear replace it 26 4 Next slide the sprag clutch out inspect the sprag clutch closely for abnormal wear cracks pitting or cor rosion Check small clips for breakage or bright spots the signs of excessive wear Unless the outer race or remaining sprag bushing is damaged or shows exces sive wear there is no need for further disassembly
28. ed spring spacer with the new brake cylinder The brake springs must be properly positioned by the spring spacer Failure to install the spring spacer may allow the springs to contact each other and become damaged This could result in loss of load control property damage injury or death 8 Install pressure plate into brake cylinder followed by the piston back up ring The close fitting piston back up ring may be depressed slightly to one side to lodge the back up ring in the brake cylinder bore and temporarily hold the pressure plate and springs in place while you lower the brake cylinder over the motor support 9 Apply petroleum jelly to the entire sealing surface of the brake cylinder and to the piston seal Install the brake cylinder over the motor support being careful to avoid damaging the piston seal or motor support O ring A press may be necessary to avoid cocking the brake cylinder during installation 10 Install motor support capscrews and evenly tighten to recommended torque BRAKE CYLINDER PRESSURE TEST 1 Install the 4 J I C fitting into the brake release port Connect a hand 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 inspection of the sealing surfaces and brak
29. erew Hose Assembl Hose Assembly 12 inch Cable Drum Closure Adapter straight Elbow 1 1 Ball Bearing 66 1 Elbow Oil Seal 68 1 O Oil Seal 69 1 Reducer elbow ICapserew y O Capscrew Thrust Washer Hydraulic Motor Motor Support 90 1 Base Plate Side Plate bearing support end Output Sun Gear Side Plate motor end Washer o 1 1 Washer Tie Bar Output Thrust Plate 96 24 Capscrew 99 1 Spring Spacer PD17A hoists use an internal retaining ring item 16 not shown to hold item 38 into the output planet carrier Retaining ring item 30 is not used on PD17A hoists PLANET CARRIER SERVICE OUTPUT PLANET CARRIER DISASSEMBLY 1 Remove the planet gears by driving the roll pins into the center of the planet shafts 2 Use a punch to drive the roll pins from the planet shafts Do not reuse the roll pins 20 3 Now you can remove the planet shafts bearings spacer thrust washers and gears Thoroughly clean all parts and inspect for damage and wear The bearing rollers should not exhibit any irregularities If the roll ers show any sign of spalling corrosion discoloration material displacement or abnormal wear the bearing should be replaced Likewise the cage should be in spected for unusual wear or deformation particularly the cage bars If there is any damage that will impair the c
30. esult in property damage severe personal injury or death 7 WARM UP PROCEDURES A warm up procedure is recommended at each start up and is essential at ambient temperatures below 40 F 4 C The prime mover should be run at its lowest recommended RPM with the hydraulic hoist control valve in neutral allowing sufficient time to warm up the system The hoist should then be operated at low speeds raise and lower several times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear sets 8 INSPECTION A Bearings and Gears Refer to DISASSEMBLY OF Hoist page 15 and PLANET CARRIER SERVICE page 20 B Brake Cylinder Refer to MOTOR SUPPORT BRAKE CYLINDER SERVICE pages 22 and 23 C Brake Clutch Refer to BRAKE CLUTCH SERVICE page 26 WARNING A Failure to use the proper type and viscosity of plan etary gear oil may contribute to intermittent brake clutch slippage which could result in property dam age severe personal injury or death Some gear lu bricants contain large amounts of EP extreme pres sure and anti friction additives which may contribute to brake clutch slippage and damage to brake friction discs or seals Oil viscosity with regard to ambient temperature is also critical to reliable brake clutch operation Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake clutch slippage Make certain that the gear o
31. f the machine s performance capabilities The following recommendations are offered as a general safety guide Local rules and regulations will also apply 1 Be certain equipment boom sheave blocks pen dants etc is either lowered to the ground or blocked securely before servicing adjusting or re pairing hoist 2 Be sure personnel are clear of work area BEFORE operating hoist 3 Read all warning and caution tag information provid ed for safe operation and service of hoist 4 Inspect rigging and hoist at the beginning of each work shift Defects should be corrected immediate ly 5 Keep equipment in good operating condition Perform scheduled servicing and adjustments listed in the Preventive Maintenance section of this manual 6 An equipment warm up procedure is recommended for all start ups and essential at ambient tempera tures below 40 F 4 C Refer to Warm up Proce dure listed in the Preventive Maintenance section of this manual 7 Operate hoist line speeds to match job conditions 8 Leather gloves should be used when handling wire rope 9 Never attempt 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 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 Hand Over Hand technique 11 Never use w
32. following minimum service intervals are speci fied for operating hours of the prime mover 1 OIL LEVEL The gear oil level should be checked every 500 operating hours or three 3 months whichever occurs first To check the oil level remove the large plug locat OP ed in the center of the drum support The oil should be level with the bottom of this opening or approximately half way up in a sight glass This is extremely impor tant due to the accelerated wear that can be caused by insufficient lubricating oil in the hoist If addi tional oil in needed refer to Recommended Planetary Gear Oil 2 OIL CHANGE The gear oil should be changed after the first one hundred 100 hours of operation then every 1 000 operating hours or six 6 months whichever occurs first The 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 minimum intervals may contribute to intermittent brake slippage which could result in property damage severe personal injury or death The gear oil should also be changed whenever the ambient temperature changes significantly and an oil from a different temperature range would be more appropriate Oil viscosity with regard to ambient tem perature is critical to reliable brake clutch operation Our tests indicate that excessively heavy or thick gear oil may contri
33. free end of the wire rope and insert it through the small opening of the anchor pocket Loop the wire rope and push the free end about half of the way back through the pocket Install 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 accommodate several dif ferent sizes of wire rope You may anchor 7 16 and 1 2 in 11 amp 13 mm wire rope by inserting the wedge large end first Anchor 9 16 and 5 8 in 14 amp 16 mm wire rope by inserting the wedge small end first CORRECT INSTALLATION Drive from this side 1 Wedge and wire rope fully seated in pocket Figure 7 Figure 8 A special wedge is used to anchor 1 and 1 1 8 in 25 amp 28 m braided synthetic rope The installation proce dure is the same as for anchoring wire rope INCORRECT INSTALLATION 1 Wedge pulled dl too far through MI anchor pocket TWO SPEED MOTOR CASE DRAIN PLUMBING Some hoists with two speed gear motors may have been installed with the motor case drain connected to the drain port of the brake valve This system may result 1 in accelerated motor shaft seal wear and leakage The following modification should be made to the motor hy draulic piping to prevent this type of seal damage 1 Remove the motor case drain
34. ft in the direction to lower a load Refer to figures 4 and 5 The hydraulic cylinder when pressurized will release the spring pressure on the brake discs allowing the brake discs to turn freely Dual Brake System Operation When hoisting a load the brake clutch which connects the motor shaft to the primary sun gear allows free rota tion The sprag cams lay over and permit the inner race to turn free of the outer race Figure 4 The friction brake remains fully engaged The hoist in raising a load is not affected by any braking action Figure 1 When the lifting operation is stopped the load attempts to turn the primary sun gear in the opposite direction This reversed input causes the sprag cams to instantly roll upward and firmly lock the shaft to the fully 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 present to open the brake valve Figures 2 amp 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 can flow through it and the speed at which the load will be lowered Increasing the flow of oil to the motor will cause the pressure to rise and the opening in the brake valve to enlarge speeding up the descent of the load Decreasing this flow causes the pressure
35. g O Ring O Ring ack up Ring ack up Ring Check Ball 1 4 in Check Ball Spring Elbow Fitting 22 Shim A R NSS NOT SERVICED SEPARATELY REPLACE COMPLETE VALVE ASSEMBLY ITEM a jajaja fo fa 4 l l fe fe fe fo oo of E Zaa fee Jk fae Pee Ip Je lt 2 Remove the elbow fitting motor drain check ball and spring 3 Remove the spool spring retainer and spool spring Check spring free length Replace spring if less than 1 15 16 in 49 2 mm long 4 Remove spool plug and carefully remove spool as sembly 5 Remove the damper piston from the spool The pis ton will come out slowly because of a partial vacuum formed as it is removed Use extreme care to avoid damaging the polished surfaces of the piston or spool 6 Remove the check valve spring retainer spring and check valve poppet Check spring free length Replace spring if less than 1 1 2 in 38 1 mm long CLEAN AND INSPECT 1 Discard all O rings and back up rings Clean all parts in solvent and blow dry Inspect polished surfaces of spool and damper piston for damage that may cause binding or leakage Inspect spool bore in valve hous ing for damage or scoring Inspect check valve seat in valve housing and check valve poppet If the spools bores or valves are damaged the entire valve must be replaced as these parts are not serviced separately 2 Inspect the 020 inch 5 mm orifice in the end of the spool and the pi
36. hose from the Q brake valve drain port and install plug Item 1 into the valve port Remove the hose from the case drain port elbow Item 4 2 Install a new case drain hose Item 2 onto x i the motor case drain elbow Item 4 RM i 3 Install the tee adapter Item 3 into the two 2 speed motor shift valve drain port identified by long end cap 4 Install the new motor case drain hose Item 2 onto the tee adapter 5 Install a case drain hose for the tee directly to the reservoir Minimum hose size is 6 ITEM DESCRIPTION PART st 3 8 in 9 5 mm Maximum drain line back Plug 4 ORB 25663 pressure is 100 PSI 690 kPa measured at p Hose 17 in OAL the motor case drain port 4 JIC Svl 4 Hose 1 8 NPT ml Tee 4 ORB Branch 4 JIC Run 29078 PREVENTIVE MAINTENANCE A regular program of preventive maintenance for your planetary hoist is strongly recommended to minimize the need for emergency servicing and promote safe reliable hoist operation Field experience supported by engineering tests indicate the three 3 service procedures listed below are the MOST critical to safe reliable hoist operation and must be observed Regular Gear Oil Changes every 1000 hours or six 6 months Use of Proper Gear Oil recommended type for prevailing ambient temperature Periodic disassembly and inspection of all wear items The
37. hown This will dis tort the hole so the pin will not back out Repeat these steps for each of the three planet gears 21 PRIMARY PLANET CARRIER 1 To service the primary planet carrier the steps are the same as for the output carrier except there is only one bearing for each gear and no bearing spacer MOTOR SUPPORT BRAKE CYLINDER SERVICE NOTE Starting mid year 1996 Braden changed the steel brake separator discs from a splined tooth design to a lobed design This required a change to the motor support and brake cylinder and the addition of a spring spacer A hoist with the lobed discs can be identified by a machined groove on the outside diameter of the motor support When replacing steel brake discs the motor support or brake cylinder care must be taken to properly identify the correct parts Splined discs will re main available as spare parts New lobed steel brake separator plates and motor sup port Note groove on outside diameter of motor sup port Although most photos in this section show splined discs all procedures are the same except where specifically 3 Remove the brake springs noted CLEAN AND INSPECT DISASSEMBLY 1 After removing the motor support and brake clutch 1 Thoroughly clean and inspect all parts at this time assembly continue brake cylinder disassembly by re Check brake piston sealing surfaces on brake cylinder moving the spacers friction brake discs and steel brake motor
38. il viscos ity used in your hoist is correct for your prevailing ambient temperature 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 has listed one 1 read ily available product in each temperature range which has been tested and found to meet our specifications RECOMMENDED PLANETARY GEAR OIL F 40 30 20 10 0 PREVAILING AMBIENT TEMPERATURE 10 20 30 40 50 60 70 80 90 100 110 120 130 F MOBILGEAR 600 XP 220 OR EQUIVALENT AGMA 5 EP ISO VG 220 MOBILGEAR 600 XP 150 OR EQUIVALENT AGMA 4 EP ISO VG 150 MOBILGEAR SHC 150 SYNTHETIC OR EQUIVALENT 40 30 20 10 0 10 20 CRANES SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING 30 40 50 C li NOTE SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS OFFSHORE Planetary hoists are factory filled with Mobilgear 600 XP 150 or equivalent Consult your oil supplier for other equivalent oils if required Jew Mobilgear 600 XP 150 Omala 150 Gear Compounds EP 150 Meropa 150 Mobilgear 600 XP 220 Omala 220 Gear Compounds EP 220 Meropa 220 OIL CAPACITIES PD12C PD15B 01 02 amp 22 DRUM 6 PINTS 2 8 L PD12C PD15B 04 05 amp 23G DRUM 7 PINTS 3 3 L PD17A 14 PINTS 6 6 L TROUBLESHOOTING WARNING A NOTE Capacities ar
39. in stalled on the hoist It is possible for the primary thrust plate to drop out of its counterbore and become wedged between the planet gears and the planet car rier If the hoist is operated with the primary thrust plate wedged between primary gears and the planet carrier or with a thrust washer out of position severe damage to internal hoist components could result AN SS PES SS SS SIE SS Lh dada M I 2 2 NS Dn 7 vA Ly LNG CLN X LAN SASS LS NN 2 Ps ws A 1e MEASURE THIS DISTANCE Measure the distance from the motor mounting surface to the inner brake race With all components properly installed this distance should be 11 16 in 17 5 mm to 3 4 in 19 1 mm If this distance is less than 9 16 in 14 3 mm the primary spacer may be positioned as shown below and should be checked CA WWA S aly pp M S dtc AN N Al W774 BN 7 i A JAN l iu 2 PRIMARY THRUST PLATE SS YY BRAKE CLUTCH INNER BRAKE RACE The Primary Thrust Plate is shown wedged between the planet gears and the planet carrier Note that the Pri mary Sun Gear and the entire Brake Clutch Assembly have moved to the right toward the hydraulic motor 16 Engage the motor shaft with the brake clutch inner race and lower motor into place Tighten capscrews to recommended torque 31
40. ire 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 contami nation at all times 15 Use correct anchor for wire rope and pocket in drum 16 Do not use knots to secure or attach wire rope 17 The BRADEN designed wire rope anchors are ca pable of supporting the rated load when installed properly For additional safety ALWAYS maintain a minimum of five 5 wraps of wire rope on the drum 18 Never attempt to clean oil or perform any mainte nance on a machine with the engine or prime mover running unless instructed to do so in this manual 19 Never operate hoist controls unless you are prop erly positioned at the operators station and you are sure personnel are clear of the work area 20 Assure that personnel who are responsible for hand signals are clearly visible and that the signals to be used are thoroughly understood by everyone 21 Ground personnel should stay in view of the opera tor and clear of hoist drum Do not allow ground per sonnel near hoist line under tension A safe distance of atleast 1 1 2 times the length of the cable should be maintained 22 Do not exceed the maximum pressure PSI kPa or flow GPM LPM stated in the hoist specifica tions 23 Install guarding to prevent personnel from get ting any part of body or clothing caught at a point where the
41. lar to an imaginary line from the center of the drum to the first sheave to insure even spooling Make certain the fleet angle does not exceed 1 1 2 degrees TO LOAD OR FIRST SHEAVE HOIST ASSEMBLY W BRAKE VALVE amp STATIC BRAKE BRAKE VALVE HOIST BRAKE BR OBR L CONTROL VALVE PUMP Li Lid A WARNING A DO NOT use a control valve with any detents or latching mechanism that would hold the control valve in an actuated or running position when the operator releases the control handle Use of the wrong type of control valve could lead to unintentional operation of the hoist which could result in property damage personal injury or death The directional control valve must be a three position four way valve without detents and with a spring cen tered motor spool such that the valve returns to the centered position whenever the handle is released and both work ports are open to tank open center open port 7 High quality hydraulic oil is essential for satisfactory performance and long hydraulic system component life WINCH ASSEMBLY W BRAKE VALVE amp STATIC BRAKE TWAI LI P is E d o eg BRAKE den VALVE WINCH BRAKE 9 BR pa O M L A el R a LL E 2 SPEED SELECTOR CONTROL VALVE
42. lot orifice to be certain they are open 33 ASSEMBLY 1 Install new O rings on the plug and spring retainers 2 Install new O rings and back up 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 in stalling them in their respective bores This will allow the O rings to return to their original size after being stretched 3 Lubricate the spool and damper piston O rings with hydraulic oil Carefully install the damper piston into the spool 4 Lubricate the spool bore and spool O rings with hydraulic oil Carefully install the spool into the valve housing Always install the spool from the plug end as shown to minimize the possibility of damaging the O ring Install the plug spool spring and spring retainer 5 Install the check valve poppet spring and check valve spring retainer 6 Install the motor drain check ball spring and elbow fitting 7 Install the pilot orifice into the valve housing 8 The brake valve is complete and ready to be installed on hoist motor REVERSING DIRECTION OF DRUM ROTATION Motor Case Drain N O OY DRN Brake M Lowering Valve Motor Port BR 1 Hoisting Port Brake Release Circuit Manifold Block Moto
43. low 3 Controls being operated too quickly 1 The hoist may be mounted too close to the main sheave caus ing 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 direction of lay When the load is slacked off the several coils on the drum will stay closer to gether and maintain an even layer If rope of improper lay is used the coils will spread apart each time the load is removed Then when winding is resumed the rope has a tendency to criss cross and overlap on the drum The result is apt to be a flattened and crushed rope 4 The hoist may have been over loaded causing permanent set in the wire rope REMEDY Same as remedies for Trouble D2 Prime mover low on horsepower or R P M Tune adjust prime mover Check suction line for damage If pump is belt driven belts are slip ping Replace tighten belts Pump worn Replace pump Disassemble hoist to inspect re place worn parts Same as remedies for Trouble D2 Same as remedies for Trouble E2 Conduct operator training as re quired Check mounting distance and fleet angle Reposition hoist as required Refer to Hoist Installation Consult wire rope manufacturer for recommendation of wire rope that bes
44. ounting bolts After the hoist is removed from its mounting thor oughly clean the outside surfaces To drain the oil in stall a short piece of 1 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 until the drain holes are aligned 2 Use a 5 16 inch Allen wrench to remove the drain plug through the pipe 3 Begin disassembly by removing the oil level plug or sight glass and standing the hoist on the bearing support end Tag and remove the hydraulic hoses that connect the brake valve and manifold to the brake cylinder 4 Remove the capscrews securing the motor and lift the motor off the hoist Remove and discard the O ring installed on the pilot of the motor 5 Tag and remove the hoses and fittings from the brake cylinder release port 6 Remove the brake clutch assembly from the motor support Refer to Brake Clutch Service for additional information 7 Remove the motor support capscrews and install two 2 capscrews and a short piece of chain into the motor mounting bolt holes Using the chain as a handle lift the motor support out of the brake cylinder being care ful to avoid damaging the sealing surfaces Remove and discard the O ring and back up ring from the motor support Refer to Motor Support Brake Oylinder Ser vice for additional information Note the location of the brake release po
45. r Case Drain DRN Brake M Lowering Valve Motor Port X O O Hoisting Port Brake Release Circuit In order to change the direction of rotation and brake operation 2 components must be changed on the hoist First the motor must be made to rotate in the opposite direction This is done by exchanging positions of the brake valve and manifold block on the motor Secondly the brake clutch assembly must be made effective for the opposite direction of rotation This is done by reversing the inner race of the brake clutch assembly Figures A and B above show typical PD12C motor installations Note that the only difference between the two drawings is the motor is rotated 180 the belly of the motor moves to the opposite side If the motor shaft rotates clockwise in figure A when the hoisting port is pressurized it will rotate counterclockwise in figure B 1 Remove the four capscrews securing the brake valve to the motor Remove the four capscrews securing the manifold block to the motor Disconnect 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 manifold block In this case disconnect the brake release hose at the motor port Stand hoist up on drum support with the motor end up and secure in this position 2 Before removing the motor it is a good idea to note or mark the
46. rier The primary planet carrier drives the output planet sun gear which in turn drives the output planet gears The output planet carrier is splined to the bearing sup port and cannot rotate Therefore as the output planet gears are driven by the sun gear 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 compo nents 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 the hoist ing direction and a pilot operated spring loaded spool valve that blocks the flow of oil out of the motor when the control valve is placed in neutral When the control valve is placed in the lowering position the spool valve remains closed until sufficient pilot pressure is applied to the end of the spool to shift it against spring pres sure and open a passage After the spool valve cracks open the pilot pressure becomes flow dependent and modulates the spool valve opening which controls the lowering speed Refer to figures 1 2 and 3 Figures 1 2 and 3 The static brake system has three operating compo nents 1 Spring Applied Multiple Friction Disc Static Brake 2 Overrunning Brake Clutch Assembly 3 Hydraulic Piston and Cylinder Figure 1 HOISTING St
47. rt in relation to hoist prior to removing the brake cylinder 8 Remove the brake cylinder capscrews and install two 2 capscrews and a short piece of chain into the mo tor support mounting bolt holes Using the chain as a handle lift the brake cylinder out of the drum and base being careful to avoid damaging the sealing or bearing surfaces Refer to Motor Support Brake Cylinder Ser vice for additional information For PD15B hoists the drum closure cannot be re moved through the opening in the base If your hoist has a one piece cast base remove the bearing sup port as described in step 15 and remove the drum from the base Then proceed with steps 9 thru 14 If your hoist has a three piece base remove the motor end side plate and continue with step 9 9 Using two heel type pry bars placed between the pri mary planet carrier and the drum closure pry upward to remove the drum closure Remove and discard the O ring from the outside of the drum closure Some drum closures have 3 8 16 tapped lifting eye holes that may be used in place of the heel bars 10 Remove the seal and bearing from inside of clo sure 11 Remove the primary sun gear and thrust washer from the primary planet carrier 12 Remove the primary planet carrier from the drum Refer to Planet Carrier Service for additional informa tion 15 Stand hoist on motor end with bearing support up then remove eight 8 bearing support capscrew
48. s and bearing support being careful to avoid damaging the sealing or bearing surfaces 16 Slide drum out of base onto a work bench and re move seal and bearing from support end 17 Thoroughly clean and inspect drum and base Check ring gear machined into inside surface of drum teeth for nicks spalling or excessive wear Replace if wear is greater than 0 015 in 0 4 mm when compared to unworn area of teeth 13 Remove the output sun gear and thrust washer from the output planet carrier 14 Remove the output planet carrier from the drum Refer to Planet Carrier Service for additional informa tion BRADEN PD12C 15B17A COMPONENTS ITEM DESCRIPTION ITEM DESCRIPTION Brake Cylinder Pressure Plate Plug Hex Head Piston Back up Ring Plug Flush Piston Seal Thrust Washer Vent Plug 6 7 jFrconDisc 7 8 jBrakeDic 11 3 Primary Planet Gear Brake Race Inner wo Primary Planet Carrier Brake Race Outer 12 3 Primary Planet Gear Shaft 13 3 Roller Bearing Sprag Bushing Retainer 14 6 __ Thrust Washer Retaining Ring 15 6 jSproPin 55 Sprage Clutch Output Planet Carrier 55 Retaining Ring Output Planet Gear Cable Clamp Output Planet Gear Shaft 19 6 Roller Bearing Bearing Spacer Manifold 58 2 4 21 6 Thrust Washer 61 62 63 4 Capscrew Cable Drum 6 60 4 Capscrew 0 Caps
49. sensor from turning and tighten jam nut against motor adapter If light is off or blinks intermittently adjust sensor inward toward sensor hub until light remains on then tighten jam nut 120 121 SS MM y AAN S Ik ZA THIS PAGE INTENTIONALLY LEFT BLANK THIS PAGE INTENTIONALLY LEFT BLANK 38 inches in feet ft miles mi inches sq in feet sq ft inches cu in quarts qts gallons gal inches cu in feet cu ft feet cu ft fluid ounce fl oz ounces oz pounds Ibs tons 2000 Ibs tons 2000 Ibs tons long 2240 165 inches Hg 60 F pounds sq in PSI pounds sq in PSI pounds sq in PSI inches 60 F bars horsepower hp ft Ibs min pound inches in Ibs pound feet ft Ibs pound feet ft Ibs miles hour m h feet second ft sec feet minute ft min X 25 4 X 0 3048 X 1 6093 X 645 15 X 0 0929 X 0 01639 X 0 94635 X 3 7854 X 16 39 X 28 317 X 0 02832 X 29 57 X 28 35 X 0 4536 X 907 18 X 0 90718 X 1013 05 X 3600 X 6 895 X 0 0703 X 0 069 X 0 2488 X 100 X 0 746 X 0 0226 X 0 1129
50. support Be sure brake release port is free discs of contamination 2 Remove the piston back up ring and pressure 2 Check oil seal and bearing surfaces on brake cylin plate der for damage or wear 22 ASSEMBLY NCAUTION Failure to replace brake springs as a set may result in uneven brake application pressure and repeated brake spring failure 1 Begin assembly by placing motor support on work bench with motor mounting surface down Install new O ring and back up ring as shown 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 groove pattern visible Replace friction disc if splines are worn to a point disc is distorted friction material is worn uneven ly or groove pattern is worn away 4 Place steel brake disc on flat surface and check for distortion with a straight edge Check surface for signs of material transfer or heat Replace steel disc if splines are worn to a point disc is distorted or heat discolored 2 Install a brake spacer into the motor support NOT REQUIRED WITH LOBED DISCS 5 Check brake spring free length minimum free length is 1 3 16 in 30 2 mm Check springs for any sign of cracking or failure If a brake spring must be replaced for any reason then ALL brake springs must be replaced 3 Insert first a steel brake disc against the spacer fol lowed by a friction
51. t suits your application Replace wire rope and conduct operator rigger training as required DISASSEMBLY OF HOIST SERVICE PRECAUTIONS Before any part is removed from the hoist all service instructions should be read and understood e Work in a clean dust free area as cleanliness is of utmost importance when servicing hydraulic equipment Inspect all replacement parts prior to installation to detect any damage which might have occurred in ship ment e Use only genuine BRADEN replacement parts for optimum results Never reuse expendable parts such as oil seals and O rings Inspect all machined surfaces for excessive wear or damage before reassembly operations are begun Lubricate all O rings and oil seals with gear oil prior to installation Use a sealing compound on the outside surface of oil seals and a light coat of thread sealing compound on pipe threads Avoid getting thread compound inside parts or passages which conduct oil e Thoroughly clean all parts in a good grade of non flammable safety solvent Wear protective clothing as re quired After troubleshooting the hoist and its hydraulic system as covered in the Troubleshooting section and the prob lem is determined to be in the hoist use the following procedure to disassemble the hoist 1 Remove the wire rope from the cable drum and align the drain hole in the drum with a hole in the support side plate before removing the hoses and m
52. this entire publication and retain it for future reference If you have any questions regarding your Braden Planetary Hoist or this publication call the Braden Service Depart ment at 1 918 251 8511 08 00 1630 hours CT Monday through Friday The minimum service intervals specified are for operating hours of the prime mover The following service instructions have been prepared to provide assembly disassembly and maintenance informa tion for the BRADEN Model PD12C PD15B and PD17A series hoist It is suggested that before doing any work on these units all assembly and disassembly instructions should be read and understood Some pictures in this manual may show details or attachments that are different from your hoist Also some compo nents have been removed for illustrative purposes Illustrations and pictures in this manual are of a typical unit sold through our distribution channels Some hoists particularly those sold directly to original equipment manufacturers OEM may differ in appearance and options Whenever a question arises regarding your BRADEN HOIST please contact BRADEN Service Department for the latest available information Serial Numbers and Model Numbers are located to the left hand side of the hydraulic motor stamped into the base Always refer to the Serial Number and Model Number when requesting information or ser vice parts EXPLANATION OF MODEL NUMBER PD 12 C 29 064 02 U L 1 nC D E ML RD I L
53. to lower and the opening in the brake valve to decrease thus slowing the descent of the load When the control valve is shifted to neutral the pres sure will drop and the brake valve will close stopping the load The friction brake will engage and hold the load after the brake valve has closed When lowering a load very slowly for precise position ing no oil flow actually occurs through the hoist motor The pressure will build up to a point where the brake will release sufficiently to allow the load to rotate the motor through its own internal leakage This feature results in a very slow speed and extremely accurate positioning The friction brake receives very little wear in the lower ing operation All of the heat generated by the lowering and stopping of a load is absorbed by the hydraulic oil where it can be readily dissipated Figure 4 Sprag Cams Static Friction Brake Applied z B Permits free shaft rotation while hoisting Figure 5 Sprag Cams Load attempts to rotate shaft in opposite direction Brake clutch locks sun gear shaft to friction brake HOIST INSTALLATION 1 The hoist should be mounted with the centerline of the drum in a horizontal position

SERIES PD12C PD15B PD17A HYDRAULIC HOIST

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