BRADEN - Winches, Inc.
Contents
1. Il o H BACK UP RING P 5 6 O RING BACK UP RING 1 Install new O rings and back up rings on the spool and damper pistons as shown t is important that each 38 T m 1 1 2 in valve AT back up ring is on the correct side of its O ring Take care not to cut the O rings during assembly Let the spool and piston set for ten 10 minutes before installing them into the brake valve housing This will allow the O rings to return to their original size after being stretched Install new O rings on the plug and spool retainers 1 1 4 in valve 1 1 2 in valve Lubricate the spool and damper piston O rings with hydraulic oil Carefully install the damper piston into the spool Carefully install the spool into the valve housing On either valve always install the spool into the valve body from the plug end so the O ring enters the bore first On the 1 1 4 inch valve install the spool spring and spring retainer On the 1 1 2 inch valve install the spring seat spool spring damper piston extension and spring retainer Install the check valve poppet spring and check valve retainer Install the motor drain check ball spring and fitting On the 1 1 4 inch valve only install the pilot orifice into the BR port of the valve housing The brake valve is now completely assembled and ready to be installed on the winch motor METRIC CONVERSION TABLE English to Metr2. Low Pressure Medium Pressure High Pressure The static brake is released by the brake valve pilot pres sure at a pressure lower than that required to open the pilot operated spool valve This sequence assures that dynam ic 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 noth ing to do with dynamic braking or rate of descent of a load The 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 shaft in the direction to lower a load Figures 5 and 6 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 rotation The sprag cams lay over and permit the inner race to turn free of the outer race Figure 5 The friction brake remains fully engaged The winch in raising a load is not affected by any braking action Figure 2 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 fu
3. Rigging and sheaves not operat ing efficiently Same as D1 Be certain that the hydraulic sys tem temperature is not more than 180 degrees F Excessive hydraulic oil temperatures may be caused by Plugged heat exchanger Too low or too high oil level in hydraulic reservoir Same as D2 Hydraulic pump not operating effi ciently Excessively worn or damaged internal winch parts 13 REMEDY Apply a stall pull load on the winch while monitoring pressure Compare gauge reading to winch specifications 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 disassembly or replacement Same as remedies for Trouble D1 amp D2 Same as remedies for Trouble E2 Refer to winch 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 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 slipping Replace tighten belts Pump worn Replace pump Disassemble winch to inspect replace worn parts TROUBLE F Winch chatters while raising rated load G The wire rope does
4. C 40 30 20 10 0 20 30 40 50 C TROUBLE SHOOTING A WARNING A If a winch ever exhibits any sign of erratic operation or load control difficulties i e load creeping or chattering appro priate troubleshooting tests and repairs should be performed immediately Continued operation in this manner may result in property damage serious personal injury or death TROUBLE The winch will not lower the load or not lower the load smoothly 3 PROBABLE CAUSE 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 manifold from opening the brake valve If it becomes loose it will allow an unregulated amount of oil in to operate the brake valve which cause erratic brake valve opera tion The friction brake may not be releasing as a result of a defec tive brake cylinder seal NOTE If the brake cylinder seal is defective you will usually find oil leaking from the winch vent plug Friction brake will not release as a result of damaged brake discs 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 brak
5. S e NT Hi lil Iii M HYY U Wt EE IM TEN Hil W I EIL BU ALI ELT LAUS AIA 6 Turn the assembly over with the snap ring down VAAN Install the second retainer and snap ring Make cer 2 Turn the assembly over and install the sprag clutch in tain the snap ring is seated in the groove properly 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 groove 7 This is a completed brake clutch assembly 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 28 HOIST ASSEMBLY 1 2 Clean all parts before reassembling The first step is to lay the support end plate down with the bearing support up Lubricate
6. 0 000 001 or 10 Copyright 2005 PACCAR Winch Division All rights reserved
7. The thrust washer contact areas should be free from any surface irregularity that causes excessive abrasion or friction Finally the shafts and carrier should be checked where there is roller or thrust washer contact The same surface and material conditions that are detri mental to the life of the bearing and thrust washer also apply to the contact areas on the shaft and carrier If the hoist was disassembled only to replace damaged seals after a short period of service it is not necessary to replace the bearings Experience and common sense along with a good inspection will determine if they can be used again Always coat O rings bearings bushings and the rub ber parts of seals with oil or grease during assembly Use a sealing compound on the outside diameter of seals and a light coat of thread sealing compound or sealing tape on pipe fittings and plugs Be careful not to get this compound or tape inside parts and pas sages which conduct oil BRAKE CLUTCH SERVICE DISASSEMBLY M MI TM A I Ih HA We 1 Remove the snap ring and sprag bushing retainer from one end only 2 Pull the inner race out Examine the race for scoring wear or indentations caused by the sprag cams If the inner race is not completely smooth the entire brake clutch assembly must be replaced 3 Use a screwdriver and mallet to remove the sprag bushing from one end of the o
8. P WINCH BRAKE zb BRAKE BR VALVE M T WINCH BRAKE Y go DR ODR 2 LLLI sy SELECTOR CONTROL Le SN PUMP CN PUMP H Ll I RECOMMENDED BOLT TORQUE The general purpose torque shown in the chart applies to SAE Grade 5 bolts studs and standard steel full thick and high nuts 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 parts or gaskets is critical Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut Bolt Dia Thds per Torque LB FT Bolt Dia Thds per Torque LB FT Inches Inch Inches Inch 200 325 485 PREVENTIVE MAINTENANCE Aregular program of preventive maintenance for your planetary winch is strongly recommended to minimize the need for emergency servicing and promote safe reliable winch operation Field experience supported by engineering tests indicate the three 3 service procedures listed below are the MOST critical to safe reliable winch 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 Annual Disassembly and Inspection of All Wear Items in compliance with American National Standards Institute ANSI specification B30 5c 1987
9. absorbed by the hydraulic oil where it can be readily dissipated Figure 5 Static Friction Brake Applied Sprag Cams Permits free iN shaft rotation Sl while hoisting Figure 6 Static Friction Brake Applied Sprag Cams LAAN Stopped 7 S Holding d N Po Load attempts to rotate shaft in opposite direction Brake clutch locks sun gear shaft to friction brake INSTALLATION GENERAL REQUIREMENTS 1 The hoist should be mounted with the centerline of the drum in a horizontal position The mounting plane can be rotated to any position around this centerline 2 When mounting the hoist use at least grade five bolts and nuts and use both mounting holes in each end gate 3 Itis important that the hoist be mounted on a surface that will not flex when the hoist is in use since this could bind the working parts of the hoist Also be sure the hoist is mounted on a flat sur face If necessary use shim stock to insure proper mounting The mounting surface should be flat within or 020 inches 4 Hydraulic lines and components that operate the hoist should be of sufficient size to assure minimum back pressure at the hoist The motor manufacturer recommends
10. and American Petroleum Institute API recommended practice RP 2D section 3 The following minimum service intervals are specified for operating hours of the prime mover Oil Level Plug 1 Oil Level The gear oil level should be checked every 500 oper ating hours or three 3 months whichever occurs first To check the oil level remove the plug located in the drum support The oil should be level with the bottom of this opening If additional oil in needed refer to Recommended Planetary Gear Oil 2 Oil Change The gear oil should be changed after the first one hun dred 100 hours of operation then every 1 000 oper ating 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 person al 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 vis cosity with regard to ambient temperature is critical to reliable brake clutch operation Our tests indicate that excessively heavy or thick gear oil may contribute to intermit tent brake clutch slippage Make certain that the gear oil vis cosi
11. connected to the 1 8 NPTF elbow in the top of the assembly Apply 1000 psi and let the unit set for 5 minutes If the gauge does not register a pressure drop it means you have installed the O rings and backup rings correctly OUTPUT PLANET CARRIER SERVICE 3 1 Drive the three 3 spiral pins into the center of the planet gear shafts JA N NSSE haft two 2 thrust wash 2 Remove one 1 planet gear s ers two 2 roller bearings and one 1 planet gear 5 from each of three 3 locations in the carrier The CH150A C2H150A CH175A and C2H175A also have a bearing spacer between each pair of bearings that has to be removed 24 To disassemble the primary planet carrier assembly the steps are the same as for the output planet carrier assembly except there is only one bearing for each gear Also the primary carrier has a thrust washer inside that can be removed after the planet gears are removed If the rollers show any sign of spalling corrosion dis coloration material displacement 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 retain and guide the rollers properly the bearing should be replaced The thrust washer contact areas should be free from any surface irregularities that cause exces sive abrasion or fri
12. output planet carrier assembly except there is only one bearing for each gear Also the thrust washer must be installed inside the carrier on the hub end before the planet gears are installed 25 CLEAN AND INSPECT Thoroughly clean all of the parts in a good grade of cleaning solvent one that is not flammable not toxic and will not cause skin rashes If necessary use rub ber gloves Inspect all parts for wear nicks scratches and damage that would render them unusable If a part is question able it is better to replace it rather than take a chance on premature failure when the hoist is placed back in service Always replace O rings seals and spiral pins Sometimes it is permissible to reuse bearings and bushings it depends on how much use they have had At regular service intervals the cage and roller bearing assemblies and thrust washers in the planet carrier assemblies should be inspected to insure beyond any doubt that they will function properly when re installed The rollers should not exhibit any surface irregularities If the rollers show any sign of spalling corrosion dis coloration material displacement or abnormal wear the bearings 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 retain and guide the rollers properly the bearing should be replaced 26
13. rs 29 REVERSING DIRECTION OF DRUM ROTATION 34 BRAKE VALVE SERVICE 2154592535499 Eee die ta beta Se ted 36 METRIC CONVERSIONS aider eere Ra pied Se AES Ke 39 FOREWORD Read this entire publication and retain it for future reference The following service instructions have been prepared to provide assembly disassembly and maintenance information for the BRADEN Model CH series winch It is suggested that before doing any work on these units all assembly and disas sembly instructions should be read and understood Some pictures in this manual may show details or attachments that are different from your winch Also some components have been removed for illustrative purposes Continuing product improvement may cause changes in your winch which are not included in this manual Whenever a question arises regarding your BRADEN Winch or this manual please contact BRADEN Service Department at 1 918 251 8511 08 00 16 30 hours CST Monday through Friday for the latest available information MODEL NUMBER AND SERIAL NUMBER MODEL NUMBER AND SERIAL NUMBER When information on a hoist is needed always refer to the model number and serial number Both are located on the top of the motor side end plate as indicated above EXPLANATION OF MODEL NUMBER CH 150 A 23 090 01 G 1 eL cH ub zl cq cM cq CONSTRUCTION MAX DESIGN GEAR MOTOR DRUM DRUM OPTION HOIST RATING MODEL RATIO SIZE SIZE OPTION CH DE
14. the sealing and bearing lands on the bearing support NOTE If the bearing support was removed from the end plate reinstall it with eight 8 capscrews and lock washers making certain two 2 large holes in the end plate line up with the cutouts in the bearing support Install a new bearing in the drum if replacement is nec essary making certain to press it against the shoulder in the bottom of the bearing bore Coat the outside diameter of the new seal with a good grade of sealant Turn the spring side of the seal next to the bearing and press the seal into the seal bore leaving it flush with the surface shown 29 3 Turn the drum over and set it down on the bearing support Be careful not to damage the seal when low ering the drum onto the bearing support 4 Lower the output planet carrier assembly into the drum making certain that the teeth on the carrier mesh with the teeth in the drum 5 Install the ring gear The ring gear teeth must mesh with the output planet gears un 9 Install the ring gear adapter hub end up meshing the 6 Install the output sun gear and the thrust washer adapter with the ring gear Center the thrust washer on the output carrier so the primary carrier pilot can be installed in it 10 Install a new bearing in the drum closure if replace ment is necessary making certain to press it against the shoulder in the bottom of the bearing bore Coat HIE the outside dia
15. 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 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 recommended torque 10 Connect the motor case drain hose to the motor case drain port NOTE On two speed motors the case drain and shift drain ports should be connnected directly to tank DO NOT use the drain connection on the brake valve Se TWO SPEED MOTOR CASE DRAIN PLUMBING for additional information 1 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 pres sure port near the manifold block lowering port 12 Operate the winch slowly in both directions and check for oil leaks and or unusual sounds The hoist should operate smoothly in both directions Refer to WIRE ROPE INSTALLATION and properly install wire rope onto the winch drum 13 Before returning the hoist to full service a light load should be lifted and held a few feet off the ground to be sure the static brake is functioning properly The winch should also be able to slowly lower the load
16. 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 exceed 5000 SUS with a pour point at least 20 F lower than the mini mum temperature Under continuous operating conditions the temperature of the oil at any point in the system must not exceed 180 120 140 F is generally considered optimum In general terms for continuous operation at ambient tempera tures between 50 and 110 F use SAE 20W for continuous operation between 10 and 90 F use SAE 10W for applications colder than 10 F contact the BRADEN Service Department The use of multi viscosity oils is generally not recom mended WIRE ROPE INSTALLATION A WARNING A THE CABLE ANCHORS ALONE ON HOISTS ARE NOT DESIGNED TO HOLD RATED LOADS Winch loads applied directly to the wire rope anchor may cause the wire rope to pull free and result in the sudden loss of load control and cause property damage personal injury or death A minimum of 3 wraps of wire rope must be left on the drum barrel to achieve rated load The wedge and anchor pocket must be clean and dry The end of the wire rope being anchored to the drum must be clean and dry and not frayed Anything on the end of the wire rope to keep it from fraying i e tape or wire must not be in contact with the wedge when the installation is com plete Consult the wire rope manufacturer on the proper t
17. BRADEN 2ND GENERATION CH SERIES PLANETARY HOISTS CH150A CH175A CH185A CH230A C2H150A C2H175A C2H185A C2H230A INSTALLATION MAINTENANCE AND SERVICE MANUAL R WINCH DIVISION P O BOX 547 BROKEN ARROW OK U S A 74013 PHONE 918 251 8511 FAX 918 259 1575 www paccarwinch com TABLE OF CONTENTS FOREWORD ee bb ELE Ud tds tbe es ES 2 GENERAL SAFETY RECOMMENDATIONS 3 BASIG OPERATION crr Babb baa soe eae 4 HOIST INSTALLATION 5325 ott slide tote ee ESSAY he tlt Ut 6 WIRE ROPE INSTALLATION ees ei ERRARE AG wie eee 6 WIRE WEDGES 7 ETEBERADEIC GIRGULDEIS eee eet eas 8 RECOMMENDED BOLT TORQUES 8 PREVENTIVE MAINTENANCE 22224005 6REXx RR nm xe 9 RECOMMENDED GEAR OIL 5c pa USERS is beg eee YR 10 TROUBLE SHOOTING Sy eens wees 11 HOIST DISASSEMBLY 2 50 ede bees ye sev ee Ouse n Ses 15 EXPLODED VIEW DRAWING AND PARTS KEY 18 BRAKE CYLINDER SERVICE AND ASSEMBLY 21 BRAKE CYLINDER TESTING uoi x ket uk ERE ER ERES 23 PLANET CARRIER SERVICE AND ASSEMBLY 24 BRAKE CLUTCH SERVICE REED MEA ESI 27 HOISTASSEMBEY ue clos eo quem Saag ioa e tee ee ek o to e
18. BearingSpacer 3 64 BalBeaing 1 65 BalBeaing 1 66 BrakeDisc 10 67 FrictionDisc 9 69 1 ee pe 71 CableAnchorWedge 1 qe iLipgs o oon f ug 73 Brake Plate Spacer 1 74 RetainingRing 76 PipeNiple 100 Bearing Race 092 thick 1 101 ThrustBearing 102 Bearing Race 063 thick 1 122 HydraulicMotor 1 128 BrakeVave 1 124 ORing 5 0 1 125 ORing 2 J t 126 Capscrew 4 127 ElbowFitting 90 1 128 HoseAssembly 1 429 W 1 sn 130 ElbowFitting 90 1 131 HoseAssemby 1 132 1 133 NeedeVave 1 138a ElbowFitting 90 1 134 Fitingy aa 137 1 139 ElbowFitting 90 1 140 WamingTag 142 Lockwasher 4 143 Capscrew 4 a e e ej e e A gt e e gt e e e je j e BRAKE CYLINDER ASSEMBLY Install the eight 8 belleville springs over the spring 1 Lubricate O rings and backup rings with oil and install guide The first one should rest against the snap ring them on the brake piston The concave surface of the on the spring guide with the concave side facing the backdrop ring must be next to the O ring Let the snap ring The second spring should be installed with assembly set for 10 minutes in order fo
19. SIGNATES CONSTRUCTION HOIST C2H DESIGNATES TWO SPEED 150 DESIGNATES 15 000 LB FIRST LAYER LINE PULL A DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES 23 DESIGNATES TOTAL GEAR REDUCTION 090 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN REV DECIMAL POINT ELIMINATED EXAMPLE 090 9 0 CU IN REV 01 DESIGNATES THE DRUM OPTION G DESIGNATES OTHER DRUM OPTIONS G GROOVED M MACHINED P RATCHET AND PAWL U UNDERWOUND 1 PERMITS TESTING AND INSPECTION PRE API2C FOR OFFSHORE CRANES 10 11 12 13 14 15 GENERAL SAFETY RECOMMENDATIONS Be certain equipment boom sheave blocks pen dants etc is either lowered to the ground or blocked securely before servicing adjusting or repairing winch Be sure personnel are clear of work area BEFORE operating winch Read all warning and caution tag information provided for safe operation and service of winch Inspect rigging and winch at the beginning of each work shift Defects should be corrected immediately Keep equipment in good operating condition Perform scheduled servicing and adjustments listed in the Preventive Maintenance section of this manual An equipment warm up procedure is recommended for all start ups and essential at ambient temperatures below 40 F Refer to Warm up Procedure listed in the Preventive Maintenance section of this manual Do not exceed the maximum pressure PSI or flow GPM stated in the winch specifications Oper
20. ascals kPa kilograms sq cm kg cm bars kilopascals kPa kilopascals kPa kilopascals kPa kilopascals kPa kilograms sq cm kg cm2 bars kilopascals kPa kilopascals kPa POWER kilowatts KW watts W kilowatts KW watts W TORQUE 0 11298 1 3558 1383 newton meters newton meters kilograms meter kg m newton meters N m newton meters N m kilogram meter kg m VELOCITY 0 11298 0 3048 0 3048 kilometers hour km hr meter second m s meter minute m min kilometers hour km hr meters second m s meters minute m min TEMPERATURE Celsius 0 556 F 32 Fahrenheit 1 8 C 32 COMMON METRIC PREFIXES 1 000 000 or 106 1 000 or 10 100 or 10 10or10 deci centi milli micro 0 000155 feet sq ft inches in feet ft miles mi inches sq in inches cu in quarts qts gallon gal inches cu in feet cu ft feet cu ft fluid ounce fl oz ounces 07 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 HO 60 F bars horsepower hp ft lbs 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 1 or 10 0 01 or 10 0 001 or 10
21. ate winch line speeds to match job conditions Leather gloves should be used when handling wire rope Never attempt to handle wire rope when the hook end is not free 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 Never use wire rope with broken strands wire rope Replace Do not weld on any part of the winch Use recommended hydraulic oil and gear lubricant Keep hydraulic system clean and free from contamina tion at all times 16 17 18 Use correct anchor for wire rope and pocket in drum Do not use knots to secure or attach wire rope The BRADEN designed wire rope anchors are capable 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 Safety and informational callouts used in this manual include 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 A CAUTION A 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 BASIC OPERATION DESCRIPTION OF HOIST The hoist is made up of the following sub assemblies Hydraulic motor and brak
22. ck pressure must not exceed 150 psi 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 winch motor Oil analysis may indicate contam ination has worn motor shaft and seal Thoroughly flush entire hydraulic 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 winch with solvent Thoroughly drain solvent and refill winch with rec ommended planetary gear oil list ed in Preventive Maintenance Brake clutch may be damaged or worn Disassemble and inspect brake clutch as described in Brake Clutch Service Reinforce mounting surface If necessary use shim stock to level winch Refer to Winch Installation First loosen then evenly retight en all winch mounting bolts to recommended torque Check relief pressure as follows Install an accurate 0 4000 psi gauge into the inlet port of the brake valve TROUBLE TROUBLE D CONTINUED FROM PREVIOUS PAGE E The winch runs hot PROBABLE CAUSE Be certain hydraulic system tem perature is not more than 180 degrees F Excessive hydraulic oil temperatures increase motor internal leakage and reduce motor performance Winch line pull rating is based on 15 layer of wire
23. ction The gears should be inspect ed for abnormal wear or pitting Replace if necessary LN S ly S e HEN ba EN N eS BN Use a punch to drive the spiral pins out of the planet gear shafts The same surface and material conditions that are detrimental to the life of the bearings and thrust washers also apply to the contact areas on the shafts and carrier OUTPUT PLANET CARRIER ASSEMBLY d 1 Insert two bearings into gear when assembling the output planet carrier assembly for a CH150A vM C2H150A CH175A or C2H175A install a bearing spacer between the two bearings Place a thrust 3 Drive a spiral pin into place Note that it is slightly washer on each side of the gear and install it in a car recessed in the carrier when it is in the proper position rier opening Slide a shaft through the carrier thrust Use a center punch to dent the carrier next to the hole washers bearings and gear as shown This will distort the hole so the pin will not work itself out Repeat these steps for each of the three planet gears 2 Align the hole in the carrier and shaft so a spiral pin can be installed Always use new 3 16 4 spiral pins when assembling these carriers Use spiral pins because they are much stronger than roll pins This is how the output planet carrier should look after you assemble it To assemble the primary planet carrier assembly the steps are the same as for the
24. drain plug in the drum with the hole in the support end plate before removing the hoses and mounting bolts After the hoist is removed from its mounting clean the outside surfaces Begin the disassembly by standing the hoist on the end opposite the motor Tag and remove the hydraulic hoses that connect the brake valve and the motor manifold in the case of a two speed motor to the brake release port 2 To drain the oil screw a short piece of 1 pipe into the e Remove the four 4 capscrews and lockwashers larger threads OF te drainnole securing the motor and lift the motor off the hoist Remove and discard the O ring installed on the out side of the motor pilot 3 Use a 3 8 drive extension to remove the drain plug through the pipe If the drain holes were not aligned before the hoist was removed from its mounting the oil can be drained through the fill vent plug in the bearing support by turning the hoist up on the bearing support end 6 Remove the sixteen 16 capscrews and lockwashers 20 in the CH185A and C2H185A models from the two 2 tie plates and remove the plates 15 IU ai A 2 ye Q C NUN ds Ded Sh bee a 11 Remove the brake plate spacer and brake and friction discs 8 Remove the eight 8 capscrews and lockwashers from the motor adapter and remove the motor adapter Remove and discard the O ring that was under the m
25. e cylinder seal as fol lows Disconnect the swivel tee from the brake release port 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 Apply 1000 psi 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 cylin der should be disassembled for inspection of the sealing surfaces and replacement of the seals Refer to Motor Support Brake Cylinder Service Disassemble brake to inspect brake discs Check stack up height as described in Motor Support Brake Cylinder Service TROUBLE B Oil leaks from vent plug C The brake will not hold a load with the control lever in neutral D The winch will not hoist the rated load PROBABLE CAUSE 1 Same as A2 2 Motor seal may be defective as a 1 result of high system back pres sure or contaminated oil Excessive system back pressure acting on the brake release port Friction brake will not hold due to worn or damaged brake discs Brake clutch is slipping The winch may be mounted on an uneven or flexible surface which causes distortion of the winch base and binding of the gear train Binding in the gear train will absorb horsepower needed to hoist the rated load and cause heat System relief valve may be set too low Relief valve needs adjustment or repair REMEDY Same as A2 System ba
26. e valve Drum drum closure ball bearings and oil seals Support end plate and bearing support Motor end plate and motor adapter Tie plates Brake clutch assembly Brake cylinder assembly and multiple disc brake parts Primary planetary reducer Secondary planetary reducer 0 Ring gear and adapter THEORY OF OPERATION The primary sun gear being coupled to the hydraulic motor by the inner race of the brake clutch assembly turns with the motor As the primary sun gear turns the primary plan et gears which are meshed with the primary sun gear and ring gear walk around the stationary ring gear causing the primary carrier to turn in the same direction as the motor shaft but at a reduced speed The primary carrier is meshed with the output sun gear which therefore turns in the same direction and at the same speed as the primary carrier The output sun gear causes the output planet gears to walk around the ring gear turning the output carrier and drum in the same direction as the primary carrier but at a further reduced speed 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 It con tains a check valve to allow free flow of oil to the motor in the hoisting direction and a pilot opera
27. gear When installed correctly the outer race should turn freely in the same direction as the drum turns to spool wire rope out For most Braden assemblies this will be clockwise as viewed from the motor end M 17 Measure the brake stack up as shown The measure TITS ment should be a minimum of 3 16 from the top of the 41111 a brake plate spacer to the top of the brake cylinder If 14 Before installing the brake discs and friction discs the measurement is less than 3 16 remove the brake check their condition Both kinds of discs should be plate spacer and add a brake disc to the top of the flat and their teeth should not be pointed The friction brake package Replace the brake plate spacer and discs should have groove in the friction material repeat procedure Do not exceed an overall height of Replace discs if necessary ve 31 21 Install the tie plates next Position the plates so that the curved part is toward the top of the hoist and curv 18 Install the motor end plate and then the brake cylinder ing away from the drum Install the sixteen 16 cap nipple using a good grade of thread sealant screws and lockwashers twenty for CH185A and C2H185A ae 19 Lubricate the o ring and install it on the outside of the brake cylinder Push it down until it s resting against the motor end plate 22 Install the tee and hydraulic hoses at this time Use a good grade
28. ic 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 07 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 lbs 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 Metric to English LINEAR 25 4 0 3048 1 6093 millimeters mm meters m kilometers km millimeters mm meters m kilometers km AREA 645 15 0 0929 millimeters mm meters m millimeters meters m 10 764 VOLUME 0 01639 0 94635 3 7854 16 39 28 317 0 02832 29 57 liters I liters I liters I centimeters cc liters I meters m millileters ml 61 024 1 0567 0 2642 0 06102 0 03531 35 315 0 03381 liters liters liters I centimeters3 cc liters 1 meters3 m3 milliliters ml MASS 28 35 0 4536 907 18 0 90718 1013 05 grams g kilograms kg kilograms kg metric tons t kilograms kg 0 03527 2 2046 0 001102 1 1023 0 000984 grams g kilograms kg kilograms kg metric tons t kilograms kg PRESSURE kilopascals kPa kilop
29. in a controlled manner If the winch does not perform either of these functions refer to TROUBLE SHOOT ING FOR ADDITIONAL INFORMATION 35 BRAKE VALVE SERVICE Standard Braden second generation CH series hoists are supplied with one of two types of brake valves Both are reliable hydraulic valves with internal componentsmanu factured to close tolerances Due to these close toler ances several individual parts are not available as replacement parts and are noted in the following parts lists as NSS Not Serviced Separately Before disassembling the brake valve be sure you have conducted all applicable trouble shooting operations and are certain the brake valve is causing the malfuntion 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 1 1 4 INCH BRAKE VALVE O Ring Pilot Orifice 1 1 1 2 INCH BRAKE VALVE 20 11 10 19 1 2 Check Valve Retainer NSS 5 SpringRetainer NSS 5 5 sons Damper pistons 7 Damper Piston Extension 2 Check Valve Poppet NSS Checea aum EN 5 5 28 EM 9 20 QTY Check Valve Spring Main Piston Spring Back up Ring Back up Ring Pipe Plug Check Spring Shm as rea NEED Spring Seat 1 1 1 2 inch b
30. lease Circuit In order to change the direction of drum rotation 2 things 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 driection of rotation This is done by reversing the brake clutch Figures A and B above show typical 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 in figure A rotates clockwise when the hoisting port is pressurized the motor shaft in figure B will rotate counterclockwise 1 Stand the hoist up on the motor support with the motor up and secure in this position Remove the four y screws 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 as shown above In these cases disconnect the brake release hose from the motor 2 Before removing the motor it is a good idea to mark the position of the motor in relation to the hoist since it will be rotatled 1809 when re installed Remove the capscrews securing the motor to
31. lly engaged friction brake Figure 6 When the winch 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 3 amp 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 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 winch 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 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 pressure 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 positioning no oil flow actually occurs through the winch motor The pres sure will build up to a point where the brake will release suf ficiently 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 lowering operation All of the heat generated by the lowering and stopping of a load is
32. meter of the new seal with a good 7 Install the primary planet carrier assembly in the ring grade of sealant Turn the spring side of the seal gear meshing the planet gears with the ring gear The toward the bearing and press the seal into the seal hub goes down engaging the output sun gear Be bore leaving it flush with the surface shown Lubricate sure the pilot enters the thrust washer the new O ring and install it on the drum closure Lubricate the large diameter on the closure and install the closure in the drum 8 Install thrust bearing and two race as shown The thin ner thrust race 063 thick goes next to the planet car rier and the thicker thrust race 092 thick goes next to the ring gear adapter The needle thrust bearing of course goes between the two races Not all units have this design revision using the thrust washer see Parts Breakdown for details 11 Install the primary sun gear meshing its teeth with the primary planet gears 30 15 Install the brake discs Start with a brake disc and end with a brake disc Alternate brake and friction discs eC until there are nine 9 of the friction discs and ten 10 12 Install the brake cylinder assembly over the primary of the brake discs sun gear making certain the brake cylinder engages the ring gear adapter teeth A 16 Install thi brake plate spacer on top of the brake discs 13 Install the brake clutch assembly over the primary sun
33. not spool smooth ly on the drum PROBABLE CAUSE Same as D2 Hydraulic oil flow to motor may be too low Controls being operated too quickly The winch may be mounted too close to the main sheave caus ing the fleet angle to be more than 17 degrees The winch may not be mounted perpendicular to an imaginary line between the center of the cable drum and the first sheave 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 together 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 The winch may have been over loaded causing permanent set in the wire rope REMEDY Same as remedies for Trouble D2 Same as remedies for Trouble E2 Conduct operator training as required Check mounting distance and fleet angle Reposition winch as required Refer to Winch Installation Consult wire rope manufacturer for recommendation of wire rope that best suits your application Replace wire rope and conduct operator rigger X training as required DISASSEMBLY PROCEDURE FOR HOIST 1 Remove the wire rope from the hoist drum and align 4 the
34. of thread sealant being careful not to get it in the hydraulic lines as it could block an orifice in the brake valve The long hose should point to the right as viewed from the motor end 20 Install the motor adapter with eight 8 special 23 Lubricate and install a new O ring around the pilot on BRADEN capscrews and lockwashers the motor 32 24 Engage the motor shaft in the brake clutch assembly inner race and lower the motor into place Install four 26 After the hoist assembly is complete check all cap dy capscrews andiloclrashers screws and fittings to make certain they have been tightened correctly Refill the hoist with the recom mended oil listed under maintenance suggestions 25 Install the hydraulic hoses as shown then tighten Continued on illustration no 26 33 REVERSING DIRECTION OF DRUM ROTATION This procedure applies in general terms to standard hoists with Commercial Intertech gear motors For information concerning hoists with other types of motors consult the BRADEN Service Department at the phone number listed in the FOREWORD section of this manual lt lt Motor Case Drain Motor Case Drain Lowering X Port Lowering Port Hydraulic Hyd Mot s ydraulic Valve otor M B Motor M Br M Manifold Block Hoisting Hoisting Port Port Brake Release Circuit Brake Re
35. ones shown to make removal Inspect the bearing in the end of drum If replacement easier Refer to the section on disassembly of the out is necessary use a bearing driver to remove the bear put planet carrier assembly ing 21 Lift the drum off the support end plate 23 Check the bearing support sealing surface for nicks and burrs It is not necessary to remove the bearing support from the support end plate unless it has been damaged 18 BRAKE CYLINDER SERVICE 1 Turn the brake cylinder on end with the large end down Use the special compression tool or a shop press to compress the backup plate in order to remove the retaining ring A CAUTION A CAUTION Make certain that the threaded rod of the compression tool fully engages the lower plate Ifa press is used be careful not to damage any parts by applying too much pressure Remove the retaining ring with snap ring pliers Be careful to not let the pliers slip out of the retaining ring Release the compression tool by holding the threaded rod stationary while backing off the nut 2 Remove the spring guide The backup plate belleville springs and spring guide will come out together Closely inspect the spring guide for damage that might prevent the springs from moving freely in an axial direction Also inspect the springs for cracks and material displacement Replace any defective parts 3 Turn the brake cylinder on end with the large end up Remove the spi
36. operate the hoist with light to moder for the last three wraps Correct Installation Drive from this side Wedge and wire rope fully seated in pocket Figure 8 Figure 7 Incorrect Installations nt 2 through anchor pocket fully seated i 4 Dead end of wire rope and or wedge may interfere with proper spooling Figure 9 Wedge may be too small Figure 10 0 Wire rope not tight against wedge Wedge may be too large WIRE ROPE WEDGE PART NUMBERS WINCH MODEL WEDGE PART NO CH150A C2H150A CH185A C2H185A 24493 for 7 16 thru 5 8 in 11 16 mm 24494 3 4 thru 1 in 19 25 mm CH230A and C2H230A 24493 for 7 16 thru 5 8 in 11 16 mm 24494 3 4 thru 1 in 19 25 mm CH175A and C2H175A 24492 for 7 16 in thru 7 8 in 11 22 mm Standard Anchor HYDRAULIC CIRCUITS SINGLE SPEED CIRCUIT 2 SPEED CIRCUIT WINCH ASSEMBLY W BRAKE VALVE WINCH ASSEMBLY amp STATIC BRAKE WIBRAKE VALVE BRAKE gt lt VALVE T
37. otor adapter 12 Remove the brake cylinder assembly and place it a clean dry surface so as not to damage the splines Refer to the section on disassembly of the brake cylin der assembly 9 Remove the brake cylinder nipple then remove the motor end plate Es E N SS Ow 10 Remove the brake clutch assembly from the brake cylinder Refer to the section on disassembly of MEET the brake clutch assembly 13 Next remove the primary sun gear 16 14 Remove the cable drum closure by using two 2 cap screws from the motor adapter and a short piece of chain Lift the closure out of the drum Remove and 17 Remove the primary planet carrier assembly Refer to discard the O ring and the seal Inspect the bearing the section on disassembly of the primary planet carri for wear If replacement is necessary use a bearing er assembly driver to remove the bearing m lt mn iua ZR LL A T S 18 Remove the thrust bearing that was under the primary planet carrier assembly then remove the output sun 15 Lift out the ring gear adapter gear s 19 Lift out the ring gear Inspect the gear for abnormal wear or pitting 17 ae X IF AL E 20 Remove the output planet carrier assembly You can 22 Turn the drum over and remove and discard the seal make hooks like the
38. ould then be operated at low speeds forward and reverse several times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear sets A WARNING A Failure to properly warm up the winch particularly under low ambient temperature conditions may result in temporary brake slippage due to high back pres sures attempting to release the brake which could result in property damage severe personal injury or death 8 Recommended Planetary Gear Oil Field experience supported by extensive engineering tests indicates the use of the proper planetary gear oil is essential to reliable and safe operation of the brake clutch and obtaining long gear train life A WARNING A Failure to use the proper type and viscosity of plane tary gear oil may contribute to intermittent brake clutch slippage which could result in property damage severe personal injury or death Some gear lubricants contain large amounts of EP extreme pressure 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 oil viscosity used in your winch is correct for your prevailing ambient tempera ture For simplicity BRADEN ha
39. r the O rings its convex side facing the snap ring Alternate the and backup rings to return to their original shape remaining six 6 springs until all eight 8 are in place 2 Here are the backup rings and O rings installed cor rectly The backup rings must be to the outside of the O rings 6 Next place the backup plate over the spring guide so that it rests on the top spring Then insert the spring 3 Lubricate the outside of the piston with oil or grease guide springs and backup plate into the brake cylin der 4 With the brake cylinder resting on its large end insert the piston into the brake cylinder Be careful not to cut the O rings or backup rings 22 que Al fT igi INS Use a press or the special compression tool to com press the springs Make certain the threaded portion of the compression tool fully engages the lower plate Install the retaining ring using snap ring pliers Be careful to not let the pliers slip out of the retaining ring After making certain the retaining ring is in place release the compression tool slowly holding the threaded portion of the tool stationary while backing off the nut CUPUHCERDEDASC ji Turn the assembly over and place the brake piston plate over the brake piston Install the spiral retaining ring in the groove in the brake piston 23 Now pressure check the brake cylinder assembly with the hand pump
40. rake valves built after mid March 1997 contain a spring seat item 22 between the spool spring and the spool This provides a slightly larger more uniform area for the spring to seat against the spool The result is increased spring service life and improved repeatability of pressure flow modulation over the full compression range of the spring 1 2 3 4 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 The spring retainer has been modified to allow for the additional thickness of the spring seat and a groove machined into the hex end cap serves as a visual indica tion that the valve contains the new spring seat The spring seat improvement may be added to earlier brake valves by installing kit Part Number 62805 Items 3 7 13 14 and 22 are included in the kit We recommend that this kit be installed whenever the brake valve is removed for inspection or service 1 1 4 in valve It is always a good practice to check the initial opening or cracking pressure of the brake valve whenever the hoist is serviced or inspected Refer to Braden Service Bulletin 527 for complete brake valve test and adjustment proce dures DISASSEMBLY 1 1 2 in valve 3 Remove the spool spring retainer and spool spring Remove the spool plug and carefully remove the spool assembly Remove the damper piston from the spool The piston will come out of the spool slowly because of a partial vacuum formed between the two U
41. ral retaining ring and lift out the brake piston plate Turn the brake cylinder over and pull the piston out Remove and discard the O rings Inspect the backup rings for nicks or cuts and replace if necessary Be careful not to damage the O ring groove surfaces Inspect the brake cylinder for nicks and scratches on the O ring sealing area Check the internal splines for notches that might prevent the brake discs from sliding freely Be careful not to damage the O ring sealing surfaces SECOND GENERATION CH SERIES EXPLODED VIEW AND PARTS KEY rae These items NOT SERVICED SEPARATELY s Entire brake clutch assembly must be Mum replaced Two Speed Motor 1 option Refer to BRADEN Second Generation CH Series Material List Publication 11 18 for part numbers 20 2 BrakeCyinder 1 3 4 6 Belleville Spring Snap Ring Snap Ring 29 ThrustWasher 6 29 ThrustWasher 37 ThrustWasher 6 38 RollerBearing 6 8 Bearing Support Capscrew Q WA SA Single Speed Motor A 1 option eed 21 44 ReducerBushing 1 45 Reliefvave 1 46 SightGlass 1 46 PipePug 1 48 MotrEndPlate 1 50 ORng 54 RingGearAdaper 1 55 PrmaySunGea 1 56 CableDrumClosue 1 57 OuputSunGear 1 58 ThrustWasher 1 59 CabeDum 60 Capscrew 16 61 TePat 2 62
42. reatment of the dead end of the wire rope Some rope manufacturers recommend when using rotation resistant wire rope that the rope end be seized welded or brazed before inserting the wire rope into the wedge socket to pre vent core slippage or loss of rope lay Take the free end of the wire rope and insert it through the small opening on the cable drum Loop the wire rope and push the free end about 3 4 of the way back through the pocket Install the wedge as shown in figure 7 then pull the slack out of the wire rope The dead end of the rope needs to extend slightly beyond the end of the wedge as shown in figure 8 Using a hammer and brass drift drive the wedge as deep into the pocket as possible to ensure it is fully seated and no further movement is detected Applying a load on the wire rope will also help seat the wedge in the pocket Check to ensure the wedge does not protrude from either end of the pocket causing it to interfere with proper spool ing of wire rope onto the drum see figures 9 amp 10 If there is interference or the wedge does not seat firmly contact the Braden Product Support Department at 918 251 8511 to determine the proper wedge size It is important that the wire rope have the proper tensioning ate loads with reeving that let s you place these loads when it is installed the drum When the wire rope is first block and the drum with all the rope off the drum except installed you should
43. s listed one 1 readily avail able product in each temperature range which has been tested and found to meet our specifications This is not to say that other lubricant brands would not per form equally as well If the following lubricant brands are not available in your area make certain your lubricant vendor supplies you with oil that is equivalent to those products listed below BRADEN planetary winches are factory filled with Texaco Meropa 150 or equivalent API GL 2 3 gear oil 9 Inspection In compliance with ANSI specification number B30 5c1987 and API Recommended Practice RP 2D section 3 we recommend that the winch be disassem bled for a thorough inspection of all wear items every 2 000 hours of operation or twelve 12 months whichever occurs first A Bearings and Gears Refer to DISASSEMBLY OF WINCH item17 on page 19 and PLANET CARRIER SERVICE item 3 on page 20 B Brake Cylinder Refer to MOTOR SUPPORT BRAKE CYLINDER SERVICE Clean and Inspect pages 22 and 23 C Brake Clutch Refer to BRAKE CLUTCH SERVICE item 4 on page 26 RECOMMENDED GEAR OIL PREVAILING AMBIENT TEMPERATURE F 40 30 20 10 0 10 20 30 40 60 70 80 90 100 110 120 130 F TEXACO MEROPA 220 OR EQUIVALENT API GL 2 3 TEXACO MEROPA 150 OR EQUIVALENT API GL 2 3 MOBIL SHC 630 NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS OFFSHORE CRANES SYNTHETIC SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING
44. se extreme care to avoid damaging the polished surfaces of either piece 1 On the 1 1 4 inch valve only remove the pilot orifice from the brake release BR port using a 5 32 inch Allen wrench 1 1 4 in valve 1 1 4 in valve 1 1 2 in valve 1 1 2 in valve 5 mm tr 4 Remove the check valve spring retainer spring and 2 Remove the fitting motor drain check ball and spring check valve poppet 37 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 9 bores or valves are damaged the entire brake valve must be replaced Check the free length of main pis ton spring For the 1 1 4 inch valve replace if less than 1 15 16 in 49 2 mm long For the 1 1 2 inch valve replace if less than 3 7 16 in 87 3 mm long Check the free length of the check valve spring Replace if less than 1 1 2 in 38 1 mm long 1 1 4 in valve 1 1 2 in valve 2 Inspect the 0 020 inch 0 5 mm orifice in the end of the spool to be certain it is open On the 1 1 4 in valve also inspect the pilot orifice to be certain it is open 3 ASSEMBLY O RING 1 1 4 in valve z TN V Ul MI coro
45. ted 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 pressure 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 See figures 2 3 and 4 The static brake system has three operating components 1 Spring Applied Multiple Friction Disc Static Brake 2 Brake Clutch Assembly 3 Hydraulic Piston and Cylinder Figure 2 al Static Motor Brake Brake JWW Ls Valve Tank Pump p Z Control Valve Low Pressure Medium Pressure High Pressure lt Figure 3 Static Brake To Brake Valve Pump ra Bru umm 3 Z 7 Low Pressure Medium Pressure High Pressure Figure 4 lt Static 212 S A To Brake 12222 Valve
46. that the back pressure not exceed 100 psi for maximum motor seal life 150 psi is the maximum allowable back pressure The standard CH150A CH175A CH185A CH230A C2H150A C2H175A C2H185A and C2H230A hoists are supplied with the motor internally drained If high back pressures are encountered the motor can be drained directly to tank to improve motor seal life To insure adequate static brake load holding ability back pressure on the hoist should not exceed 200 psi For pressures exceeding 200 psi consult Braden Engineering 5 Make certain that the hoist drum is centered behind the first sheave and the fleet angle does not exceed 1 72 degrees The hoist should also be mounted perpendicular to an imaginary line from the center of the drum to the first sheave to insure even spooling 6 The hoist directional control valve must be a three position four way valve with a motor spool such that when the valve is in the center position both work ports are opened directly to tank 7 The hydraulic oil filter should have a 10 micron nominal rating and be a full flow type 8 High quality hydraulic oil is essential for satisfactory performance and long hydraulic system component life Oil having 150 to 330 SUS viscosity at 100 F 38 C and vis cosity index of 100 or greater will give good results under normal temperature conditions The use of an oil having a high viscosi ty index will minimize cold start trouble and reduce the length of
47. the hoist and careful N ly remove the motor Remove the snap ring and sprag bushing retainer from one end only of the brake clutch assembly 3 Remove the brake clutch assembly from the hoist Carefully inspect the splines on both ends of the inner 3 a f they are the same the entire brake clutch assembly can be turned over and re installed in the hoist Before installing the brake clutch be sure AN the inner race turns free in the same direction the NS FX drum will turn to haul in wire rope An easy way to v check the rotation is to hold the outer race in hand 5 Pull the inner race out Examine the race for scoring and rotate the inner race Proceed to step 8 wear or indentations caused by the sprag cams If the b If the splines in each end of the inner are not inner race is not completely smooth the entire brake the same proceed to step 4 clutch assembly must be replaced 34 6 Turn the sprag assembly around and slide the inner race with 1 snap ring and bushing retainer through the bushing and sprag clutch the race will have to be ratated in the free wheeling direction to start it through the sprag clutch Install the remaining bushing retain er and snap ring Make sure the snap ring is properly seated in the groove 7 Install the brake clutch assembly into the hoist Before installing the brake clutch be sure the inner race turns free in the same direction the drum will turn
48. ty used in your winch 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 person al 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 unob structed 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 oper ating hours or three 3 months or in accordance with the equipment manufacturer s recommendations 5 Wire Rope Inspect entire length of wire rope according to wire rope manufacturers recommendations 6 Mounting Bolts Tighten all winch base mounting bolts to recommended torque after the first one hundred 100 hours of operation then every 1000 operating hours or six 6 months whichever occurs first 7 Warm up Procedures Awarm 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 winch control valve in neutral allowing sufficient time to warm up the system The winch sh
49. uter 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 27 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 If disassembly is necessary remove the bushing accord ing 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 could result in prop erty damage severe personal injury or death It is generally recommended to replace the entire brake clutch assembly if any component 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
Download Pdf Manuals
Related Search