RW300A - Winches, Inc.
Contents
1. 7 Valve ZU ZU mm Tank 2 gt 2 2 2 2 Valve Low Pressure Medium Pressure High Pressure Figure 4 Static Brake Brake igen Valve Pump Control Valve 9 Low Pressure Medium Pressure High 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 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 mo2. Pula uy quietus 24 CROSS SECTION DRAWING AND PARTS KEY 26 METRIC CONVERSION TABLE 30 FOREWORD Read this entire publication and retain it for future reference 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 infor mation for the Braden Model RW300A It is suggested that before doing any work on this unit all assembly and disassembly instructions should be read and understood Some illustrations in this manual may show details or attachments that are different from your winch Also some components have been removed for illustrative purposes Whenever a question arises regarding your winch or this manual please contact the Braden Technical Support Department via phone at 918 251 8511 from 08 00 to 16 30 hours CT Monday through Friday via fax at 918 259 1575 or via email at winch service paccar com for the latest available information Model Number Serial Number OLLEVEL SIGHT GLASS The winch serial number and model number are stamped into a data plate located on the drum bearing support end bracket The serial number is steel stamped into the top of the motor end support plate Always refer to the serial number and model number when requesting information or service parts
3. SKK KKK RR KKK KRY RRR KKK KKK OOOI RRR KKK KKK KKK KKK KR KKK KKK II NNN IN III I PRK KOK NNN KKK KKK KR ORK Sis 394040505005 46504640 RRS LKE lt 556550550605 KKK KKK KK RS n e 222 25525506 n 555 225052 gt KK 55 R OOOO 555 XX The winch must be mounted with the centerline of the drum in a horizontal position Due to the design of the winch base group the cable departure angle must only be in the shaded area as shown When mounting the winch use all four mounting holes with 1 25 in grade 8 capscrews hardened washers and nuts tightened to recommended torque The winch must be mounted to a flat rigid surface that will not flex when the winch is in use causing binding in the gear train Binding in the winch gear train will result in accelerated wear of internal com ponents reduced hoisting capacity and heat If nec essary use shim stock under the winch mounting pads to ensure the surface is flat within 0 020 in 0 5 mm The vent plug installed in the brake cylinder must always be located above the horizontal centerline If the winch is mounted on a pivoting surface be sure the vent plug remains above centerline Hydraulic lines and components that operate the winch should be of sufficient si
4. 19 Brake Cylinder Pressure Test 1 Connect a hydraulic hand pump with an accurate gauge and shut off valve to the brake release port of the motor support Apply 500 psi 3 450 kPa to the brake Close the shut off valve and let stand for five 5 minutes If there is any loss of pressure the brake cylinder should be disassembled for inspec tion of the sealing surfaces and O rings WHILE PRESSURE IS APPLIED AND THE BRAKE 8 Set the spring stop 52 on the spring and install the IS RELEASED install the brake clutch assembly spring compressor tool or move the assembly to a brake hub Rotate the clutch back and forth to align press Be sure the step on the compressor tool is the splines in all brake discs When the brake clutch squarely seated on the spring stop has engaged all the discs release the pressure on the brake cylinder and remove the brake clutch ACAUTION The brake spring must be compressed approximate ly 4 inches 10 cm and has a compressed force of approximately 1 500 680 Extreme care should be observed while completing this step to avoid sudden release of the spring DO NOT stand directly in front of the spring while it is being com pressed 9 Slowly compress the spring until the spring stop is slightly below the retaining ring groove in the brake cylinder Install the retaining ring 57 NOTE The holes in the ends of the retaining ring are slightly tapered The smaller end of
5. m m m VENT lL LOWERING PORT SAE 12 ORB 1 1 16 12 EXPLANATION OF MODEL NUMBER RW 300 A 69 V 086 050 B S dq T T T WINCH MAX DESIGN GEAR PISTON MOTOR BRAKE OPTION RATING MODEL RATIO MOTOR SIZE RW REDUCER DRIVE WINCH 300 DESIGNATES APPROXIMATE PEAK TORQUE X 1000 Ib in A DESIGNATES DESIGN SERIES 69 DESIGNATES GEAR REDUCTION RATIO 1 V DESIGNATES PISTON MOTOR VARIABLE DISPLACEMENT 086 050 DESIGNATES MOTOR DISPLACEMENT IN CUBIC INCH REVOLUTION LOW RANGE HIGH RANGE B DESIGNATES UNIT EQUIPPED WITH INTERNAL BRAKE S DESIGNATES SPECIAL GENERAL SAFETY RECOMMENDATIONS Safety and informational callouts used in this manual include AWARNINGA A CAUTION WARNING This emblem is used to warn against CAUTION This emblem is used to warn against hazards and unsafe practice which COULD result in potential or unsafe practices which COULD result in severe personal injury or death if proper procedures personal injury and product or property damage if are not followed 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 winch must be operated with care and concern by the operator for the equipment and a thorough knowledge of the machine s performance capabilities The following recommendations are offered as a general safety guide Local r
6. DUAL BRAKE SYSTEM DESCRIPTION The dual brake system consists of a dynamic brake sys tem and a static brake system The dynamic brake system has two operating compo nents 1 Brake valve assembly 2 Hydraulic motor The brake valve is basically a counterbalance valve It contains a check valve to allow free flow of oil to the motor in the hoisting direction and a pilot operated spring loaded spool valve that blocks the flow of oil out of the motor when the control valve is placed in neutral When the control valve is placed in the lowering posi tion 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 Figures 2 3 amp 4 show a simplified version of the brake valve for illustrative purposes The static brake system has three operating compo nents 1 Spring Applied Multiple Friction Disc Static Brake 2 Brake Clutch Assembly 3 Hydraulic Piston and Cylinder Figure 2 Static Motor Brake Brake Valve Tank Pump Z ZZ Cx Control Valve Low Pressure Medium Pressure High Pressure Figure 3 Static Brake
7. 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 METRIC CONVERSION TABLE Metric to English LINEAR millimeters mm meters m kilometers km 25 4 0 3048 1 6093 millimeters mm meters m kilometers km AREA millimeters mm meters m 645 15 0 0929 0 000155 10 764 millimeters mm meters m VOLUME 0 01639 0 94635 3 7854 16 39 28 317 0 02832 29 57 61 024 1 0567 0 2642 0 06102 0 03531 35 315 0 03381 liters liters liters liters liters liters l centimeters centimeters3 cc liters liters 1 meters m meters3 m3 millileters ml milliliters ml MASS grams g kilograms kg kilograms kg metric tons t kilograms kg 28 35 0 4536 907 18 0 90718 1013 05 0 03527 2 2046 0 001102 1 1023 0 000984 grams g kilograms kg kilograms kg metric tons t kilograms kg PRESSURE kilopascals kPa kilopascals kPa kilograms sq cm kg cm2 bars kilopascals kPa kilopascals kPa 3600 6 895 0 0703 0 069 bars 0 2488 kilopascals kPa 100 kilopascals kPa kilopascals k
8. 80 NAMEPLATE 1 83 85 87 88 96 sipEPLATEMOTOR 71 98 TENSION ROLLER ASSY 04893 WINCH 1 99 CAPSCREW 1 2 X 1 1 2 G8 SPECIAL 16 HYDRAULIC MOTOR SUB ASSEMBLY FOR WINCH ASSEMBLY 04893 amp 05051 MOTOR HYDRAULIC 05051 WINCH TH MOTOR HYDRAULIC 04893 WINCH ADAPTER 4 4 ORB 04893 WINCH 119 ELBOW 44 JIC 4 ORB 05051 WINCH 27 69 G OO amp amp 9 9 HYDRAULIC MOTOR SUB ASSEMBLY FOR WINCH ASSEMBLY 05435 5 CAPSCREW 1 2 NC X 1 1 2 G8Z 6 6 CAPSCREW 1 2 NC X 4 1 2 G8 Z 2 NEEDLE VALVE PLUG 4 ORB CAPSCREW 1 2 NC X 5 1 2 G8 ADAPTER NIPPLE ELBOW 28 TENSION ROLLER ASSEMBLY 04893 WINCH ONLY 1 NOT ALL PARTS ARE SHOWN 2 TENSIONSPRING 1 TENSION ROLLER SHAFT 1 TENSION ARM SHAFT 1 WASHER TINCH 8 ROLLER BUSHING 2 5 16 2 LOCKWASHER 5 16 ROLLER 3 1 6 8 9 j ROLERRODEND 71 ROLLER 19 C C 1 29 English to Metric 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 2 pounds Ibs
9. B Oil leaks from vent plug PROBABLE CAUSE 1 The problem could be a plugged internal orifice or leaking cartridge body seal ring on the counter balance valve If a small piece of contamination entered the count er balance CB valve cartridge it may be restricting the hydraulic signal to open the valve The pressure may be going too high or the smooth action of the CB valve may be impaired If the cartridge body seals are leaking the pilot signal pressure may be lost or the oil flow that the CB valve is modulating is able to return to tank without the proper control allowing the load to lower too early or too quickly The friction brake may not be releasing as a result of a defective brake cylinder seal NOTE If the brake cylinder seal is defec tive you will usually find oil leaking from the winch vent plug Friction brake will not release as a result of damaged brake discs Same as A2 Motor seal may be defective as a result of high back pressure or contaminated oil REMEDY Remove the counter balance cartridge from the valve body and inspect condition of body seal rings Disassemble valve body and flush with clean solvent to remove contamination Assemble valve using new seal rings on CB valve cartridge Install an accurate 0 1000 PSI 0 6900 kPa test gauge in the brake release hose With no load on the hoist slow ly move the control lever into the lowering position and record the pressure when
10. BRADEN RW300A INSTALLATION MAINTENANCE AND SERVICE MANUAL PACCAR pivisioN P O BOX 547 BROKEN ARROW U S A 74013 i Copyright 2005 PACCAR Winch Division PHONE 918 251 8511 FAX 918 259 1575 Printed in U S A All rights reserved www paccarwinch com TABLE OF CONTENTS FOREWORD 22 525 siqaq es pee ead 2 GENERAL SAFETY RECOMMENDATIONS 3 THEORY OF OPERATION 35 32 12 m e ER eee RESES pa i 4 WINCH INSTALLATION 1 iiu Tam br dieing uhi eo er ES 6 SPECIFICATIONS rerin Sete shat ee eth Bee age ass 7 RECOMMENDED FASTENER TORQUE 7 WIRE ROPE INSTALLATION 8 PREVENTIVE MAINTENANCE 9 RECOMMENDED PLANETARY HOIST GEAR OIL 11 SPECIAL TOOLS Ses wa e diam ae 12 TROUBLESHOOTING ouk Cre 13 DISASSEMBLY 16 BRAKE CYLINDER SERVICE 18 BRAKE CLUTCH ASSEMBLY SERVICE 21 PLANET CARRIER SERVICE 22 WINGCH ASSE BLY
11. loads in excess of rated capacity which may result 13 Use recommended hydraulic oil and gear lubricant of cable and winch THEORY OF OPERATION DESCRIPTION OF WINCH The winch has four basic component parts 1 Winch base 2 Hydraulic motor and brake valve 3 Brake cylinder and motor support 4 Drum assembly The drum assembly consists of four basic assemblies 1 Drum with integral ring gear 2 Output planetary gear set 3 Secondary planetary gear set 4 Primary planetary gear set The hydraulic motor is bolted to the brake cylinder and the base The motor end of the drum running on dual tapered bearings is supported by the brake cylinder The other end of the drum runs on a spherical bearing on the support bolted to the base The ring gear for the planetary sets is machined into the drum s inside sur face WINCH OPERATION The hydraulic motor drives the sun gear of the primary planetary gear set through the splined inner race of the 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 carrier The primary planet carrier drives the secondary sun gear The secondary planet gears drive the secondary planet carrier which drives the output sun gear The output planet carrier is splined to the brake cylinder and cannot rotate Therefore as the output planet gears are driven by the sun gear they will drive the ring gear drum
12. Remove and discard both sets of piston O rings and backup rings 27 28 30 31 5 Turn the assembly over to access the brake plates Remove the retaining ring 62 Remove the spacer plate 61 steel separator discs and friction discs 25 26 Thoroughly clean and inspect all parts paying close attention to the sealing surfaces of the brake piston Place each friction disc on a flat surface and check for distortion with a straight edge Friction material should appear even across the entire surface and the groove pattern should be visible Replace fric tion discs if splines are worn to a point disc is dis torted friction material is worn unevenly or groove pattern is no longer visible Place each steel brake plate on a flat surface and check for distortion with a straight edge Check surface for signs of material transfer or heat Replace steel discs if splines are worn to a point disc is distorted or heat discolored Check the brake release passage to be sure it is clean and completely open Inspect both sets of large tapered roller bearings 35 36 56 57 for signs of damage or excessive wear The bearing rollers should not exhibit any irregularities If the rollers show any sign of spalling 3 Install the spacer plate 61 on top of the last friction corrosion discoloration material displacement or disc abnormal wear the bearing should be replaced Likewise the cage should be inspected for wear or deformati
13. end of the planet pin If this method is not successful the roll pin must be sheared by driving or pressing the planet pin out of the carrier A piece of pipe or tubing long enough to hold the planet pin may be used to support the car rier while each pin is removed Adequately support the assembly and drive or press out one planet pin shearing the roll pin Slide the planet gear 19 out of the carrier and remove the bearing cones Clean and inspect the bearing cups in each end of the gear If they are determined to be in serviceable condition no further disassembly is required If the bearings need to be replaced remove the bearing cups spacer and internal retaining ring from the bore of the planet gear Repeat steps 1 2 and 3 for each planet gear Thoroughly clean all parts and inspect for damage and wear The bearings should be examined for any signs of spalling corrosion discoloration mate rial displacement or abnormal wear The bearing cages should be inspected for wear or deformation If any of these conditions are found the bearing should be replaced Gears should be inspected for abnormal wear or pitting and replaced as necessary Inspect all machined surfaces and bearing bores for signs of damage or excessive wear NOTE Steps 5 through 8 are necessary only if the planet gear bearings are being replaced 22 5 Install a retaining ring 21 in the bore of a planet gear Be sure it is completely se
14. the drum begins to turn in the lowering direction The static brake will release at approximate ly 300 PSI 2070 kPa and the CB valve should open at approximately 1050 PSI 7240 kPa Check brake cylinder seal as follows A 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 fitting in the brake release port B Apply 1000 psi to the brake Close shut off valve and let stand for five 5 minutes C If there is any loss of pressure in five 5 minutes the brake cylinder should be disas sembled 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 Same as A2 Motor case drain back pressure must not exceed 40 psi 275 kPa Inspect hydraulic system for a restriction in the return line to the reservoir Be sure plumbing is properly sized to winch motor Oil analysis may indicate contamination has worn motor shaft and seal Thoroughly flush entire hydraulic system and install new filters and oil Install new motor seal TROUBLE 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 Excessive system back pressure acting on the brake release port Friction
15. A piece of pipe or tub ing long enough to hold the planet pin may be used to support the carrier while each pin is removed Adequately support the assembly and drive or press out one planet pin shearing the roll pin Slide the planet gear out of the carrier and remove the thrust washers and loose roller bearings Repeat steps 1 and 2 for each planet gear Remove the retaining ring holding the sun gear in the planet carrier and remove the sun gear 23 Thoroughly clean all parts and inspect for damage and wear The bearing rollers should be examined for any signs of spalling corrosion discoloration material displacement or abnormal wear If any of these conditions are found the rollers should be replaced Gears should be inspected for abnormal wear or pitting and replaced as necessary Inspect all machined surfaces and bearing bores for signs of damage or excessive wear Engage the sun gear with the splines on the planet carrier and install the retaining onto the sun gear Liberally coat the bore of a planet gear with a good grade of oil soluble grease Set a thrust washer on a clean flat work surface Set the planet gear on the thrust washer with the bore the gear centered over the washer Install a row of loose rollers around the bore of the gear using additional grease as required to hold them in place Set another thrust washer on top of the rollers and slide the gear and bearing assembly into plac
16. Check the oil level monthly if no external oil leaks are detected 2 Check the hydraulic fittings and hoses for leaks chaffing deterioration or excessive corrosion and repair as required 3 Visually inspect for corroded loose or missing fas teners and tighten or replace as required 4 Inspect the entire length of wire rope and rigging as recommended by the wire rope and rigging manu facturer 5 Inspect all safety devices such as anti two blocking switches and limit switches and repair as required 6 Awarm up procedure is recommended at each start up and is essential at ambient temperatures below 40 F 4 C The engine should be run at low RPM with the hoist control valve in neutral allowing suffi cient time to warm up the hydraulic system The hoist should then be operated without a load at low speeds raise then lower several times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear train A WARNING A Failure to properly warm up the hoist particularly under low ambient conditions may result in tempo rary brake slippage due to thick gear oil in the brake clutch assembly or hydraulic system back pressure attempting to release the brake which could result in property damage injury or death Semi Annual Inspection every six months Must include but is not limited to the following inspec tions performed by a qualified technician 1 Perform the Pre Use in
17. Pa kilopascals kPa kilograms sq cm kg cm POWER kilowatts KW watts W 0 746 0 0226 kilowatts KW watts W TORQUE newton meters N m newton meters N m kilogram meter kg m 0 11298 1 3558 1383 newton meters N m newton meters N m kilograms meter kg m VELOCITY kilometers hour km hr meter second m s meter minute m min 0 11298 0 3048 0 3048 kilometers hour km hr meters second m s meters minute m min TEMPERATURE Celsius 0 556 F 32 1 8 X C 32 COMMON METRIC PREFIXES 1 000 000 or 10 1 000 or 10 100 or 10 10 or 10 deci centi milli micro 30 inches in 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 2 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 H O 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 102 0 001 or 10 0 000 001 or 10
18. 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 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 flat tened and crushed rope The winch may have been overloaded causing permanent set in the wire rope REMEDY Same as remedies for Trouble D1 Thoroughly clean exterior and flush interior Fill drain to proper level Same as remedies for Trouble D2 Engine low on horsepower or R P M Tune adjust prime mover Check suction line for damage Pump worn Replace pump Disassemble winch to inspect replace worn parts 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 recom mendation of wire rope that best suits your application Replace wire rope and conduct operator rig ger training as required DISASSEMBLY OF WINCH See cross section illustration on page 26 and parts key for re
19. ated in the groove Install a bearing spacer 20 into the bore of the planet gear Be sure the step on the spacer is toward the retaining ring Install a bearing cup 22 into each end of the gear The cups should firmly contact the spacer Repeat steps 5 6 and 7 for each planet gear 9 Install a bearing cone 23 into each end of a planet gear and slide the gear and bearings into the planet carrier aligning the bearing bores with the planet pin bore 10 Install a planet pin through the planet carrier and bearings aligning the hole in the pin with the roll pin hole in the carrier Drive a new roll pin 24 into place in the carrier NOTE Always use NEW roll pins 11 The roll pin should be slightly recessed in the carri er when properly installed Use a punch to stake the carrier next to the pin hole so the pin will not back out when the unit is in operation 12 Repeat steps 9 10 11 for each planet gear PRIMARY AND SECOND STAGE PLANET CARRIERS 1 preferred method of removing the planet is to first remove the roll pin This can usually be done by using a punch or small pry bar to drive or push the roll pin out of the planet carrier Access to the roll pin is gained through a drilled hole in the end of the planet pin If this method is not successful the roll pin must be sheared by driving or pressing the planet pin out of the carrier
20. 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 Be certain hydraulic system temperature is not more than 180 F 82 C Excessive hydraulic oil temperatures increase motor and pump internal leakage and reduce performance 4 Winch line pull rating is based on 1st layer of wire rope Rigging and sheaves not operating effi ciently 14 REMEDY System back pressure must not exceed 100 psi 690 kPa Inspect hydraulic system for restriction in the circuit from the motor to the reservoir 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 recommended planetary gear oil listed 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 retighten all winch mounting bolts to recommended torque Check relie
21. cle manufacturer the hydraulic oil filter should have a 10 micron rating SPECIFICATIONS Unit weight without wire rope approximate 1370 Ib 621 kg Gear Ratio uso Edad eu Cauda peur cw did Cable Drum Dimensions Barrel Diameter 15 25 in 387 mm Flange Diameter 20 0 in 508 mm Barrel Length 13 5 in 343 mm Cable Storage Capacity dae 1 2 7 8 in 22 mm 65 ft 19 8 m 137 ft 41 8 m Gear Oil Capasso ei nee 15 pints 7 1 liters RECOMMENDED FASTENER TORQUE Higher and lower torque values 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 Avoid using thread lubricants as the applied torque may vary by 10 40 depending upon product used Torque LB FT Torque LB FT Bolt Dia Thds Grade5 Grade8 Inch Inches Dry u ERES a ERES e o N N AR N 99 PES 11 N E 5 a o 2 20 28 18 24 16 24 14 20 13 20 12 18 11 18 N 5 8 150 convert Ib ft to kg m multiply ft value by 0 1383 WIRE ROPE INSTALLATION Prepare the end of the wire rope as recommended by the
22. d alcohol to the large o rings and place them in the seal seat in the housings Apply denatured alcohol to the o ring again and evenly push the lapped metal face seal into the o ring You may need the assistance of another technician to help push the metal face seal into place Do not use punches or metal tools directly on the seal surface as the lapped surface is easily damaged Install bearing cone 36 onto the brake cylinder and new bearing cups 35 56 into the drum ring gear Place the brake cylinder on the workbench with the motor side down Apply a light coat of oil to the metal face seals and to the bearing cones and cups Place the drum ring gear onto the brake cylinder The face seals will hold the two components slight ly apart Install bearing cone 57 onto the brake cylinder Use a brass punch to gently start the bearing onto the brake cylinder journal Note Fabricate the bearing compression tool shown in the Tools section of this manual Using the bearing compression tool or large frame hydraulic press press the bearing cone down into the bearing cup Make certain the bearing cone is fully seated in the cup Remove any burs or nicks from the split rings and install the split rings into the groove in the brake cylinder The two halves of the split ring must be centered in the groove The count 24 er bore in the output planet carrier holds the split rings in the groove The split rings must be centered for t
23. d firmly raise then lower the test load the full height of the boom mast as available Increase the load and repeat the test If no problems are found the winch may be placed into service If any malfunction is detected the winch must be removed from service until the problem is corrected and the winch passes the lift tests Make a permanent record of the winch repairs that include the date of repair what was wrong before the repair what was done what parts were used the test performed and the name of the technician s RW300A COMPONENTS 9 G9 89 89 89 22 E 09 CE E 99 Q9 99 82 89 2 ED 8 SSPESSSSOQOOGKOOOOOOOOOOOHOHOOOOOOHWW 26 RW300A 04893 05051 amp 05435 PARTS KEY Description Qty 6 PRIMARY PLANET 3 1 8 WAsHER THRUST j 6 ROLLER 10 GEAR PRIMARY PLANET 11 SPIROL 12 17 WASHER THRUST 6 22 BEARING CUP 6 22 BEARINGCONE 6 25 FRICTION DISC 26 BRAKE DISC 27 BACK UP RING 28 O RING 29 PIPE PLUG 3 1 43 1 44 1 45 1 46 1 47 1 1 60 GEAR RING 1 RING INTERNAL RETAINING CARRIER FINAL PLANET GEAR FINAL SUN 65 RING SPLIT 66 WASHER THRUST 67 EXTERNAL RETAINING 68 CARRIER SECONDARY PLANET 1 69 o RING Description Qty
24. e in the planet carrier Align the gear with one of the planet pin bores in the carrier and install a planet pin Align the hole in the pin with the hole in the car rier and install a new roll pin NOTE Always use NEW pins The roll pin should be slightly recessed in the carri er when properly installed Use a punch to stake the carrier next to the pin hole so the pin will not back out when the unit is in operation 10 Repeat steps 5 through 9 for the remaining planet gears 1 WINCH ASSEMBLY The following procedure should be used to assemble the complete winch It assumes all the sub assemblies have been properly serviced as described earlier in this manual Install the motor end bracket 96 onto the fully assembled brake cylinder Install the 12 capscrews and lockwashers 82 83 only snug at this time They will be tightened to recommended torque after both end brackets have been installed If the lapped metal face seal assembly 33 is being replaced install one half of the seal in the brake cylinder and the other half in the drum ring gear The old seal is simply pried out of position Thoroughly clean the seal seat areas Note Handle the new seals with great care The smooth metal contact surfaces must remain perfect ly flat and free of dents or nicks for the seal to oper ate leak free Alcohol acts as a lubricant for rubber If alcohol in not available a light coating of oil may be used Apply denature
25. eated release the pressure from the hand pump then remove the hand pump 25 16 Install new o rings onto the motor pilot adapter 39 40 41 and install the adapter into the brake cylin der Install the motor sub assembly onto the winch Install and tighten capscrews and lockwashers 78 79 to 380 lb ft 515 N m torque Install the brake release signal hose from the lowering port of the motor to the brake release port on the brake cylin der 17 Fill winch to the oil level port or the centerline of the assembly with recommended gear oil Refer to Recommended Gear Oil in the Specifications section of this manual Note Whenever a winch has been repaired it should be tested on a test tower or tested on the original equip ment The following test procedure is offered as a sug gestion only equipment specifications will dictate the test required the 1 Install the winch as recommended Installation section of this manual Install wire rope as recommended by the wire rope supplier If unknown make certain first layer the most important is tightly packed onto the cable drum and maintain approximately 500 Ib 226 kg tension load on all layers of wire rope Rope off a secure test area for test lift Make certain no personnel will be under a suspended load Lift a test load of approximately 2500 pounds 1134 kg approximately 3 feet 1 meter and return the con trols to neutral hold If the load is hel
26. f pressure as follows A Install an accurate gauge into the inlet port of the brake valve B Apply a stall pull load on the winch while monitoring pressure C Compare gauge reading to winch specifi cations Adjust relief valve as required NOTE If pressure does not increase in pro portion 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 addi tional information Perform rigging service as recommended by rig manufacturer TROUBLE E The winch runs hot F Winch chatters raising rated load while G The wire rope does not spool smoothly on the drum PROBABLE CAUSE Same as D1 Be certain that the hydraulic system tem perature is not more than 180 F 82 C 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 efficiently Excessively worn or damaged internal winch parts 1 Same as D2 2 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 causing the fleet angle to be more than 1 1 2 degrees The winch may not be mounted perpendi cular to
27. ference 1 Remove the wire rope from the cable drum and rotate the drum until the fill drain plug is at the bot tom six o clock position Remove the drain plug and capture the gear oil in a suitable container Recycle or dispose of used oil in an environmentally respon sible manner Install the drain plug Label the hydraulic hoses as they are removed from the hoist motor Install plugs in the open hoses and motor ports to reduce entrainment of dirt in the open port A The RW300 hoist weighs approximately 1370 Ibs 621 kg Use adequate lifting equipment Remove the hoist mounting fasteners and lift the hoist from the mount Begin disassembly by placing the hoist on a stable work surface with the motor end facing up Secure the hoist in this position to prevent it from falling and causing injury Remove the hose that connects the brake valve to the brake release port Remove the fasteners secur ing the motor to the brake cylinder assembly Lift the motor straight up to disengage the motor shaft from the brake clutch assembly Remove the brake clutch assembly brake hub 42 from the brake cylinder The input sun gear 2 can not be removed at this time A WARNING A DO NOT attempt to remove the large retaining ring at this time It is holding the static brake spring in compression Removing this retaining ring at this time could result in property damage personal injury or death 16 6 Remo
28. he planet carrier to install over the brake cylin der splines Install two 72 13 eye bolts into the output planet car rier With a hoist install the output planet carrier into the drum ring gear Rotate each gear to align the teeth as you lower the carrier Rotate the carrier to align the carrier with the brake cylinder splines When aligned the carrier will drop down onto the splines and capture the split rings Install thrust washer 66 onto the second stage planet assembly with output sun gear A light coat of oil soluble grease should be used to hold it in place during assembly Slide the planet assembly into the ring gear and engage the output sun gear with the output planet gears The second stage planet gears should now be at least 1 8 inch 3 mm below the top of the teeth cut into the drum ring gear If they are above the ring gear teeth the unit is not properly assembled to this point Either the thrust washer 66 is improperly positioned or the output planet carrier is not fully engaged onto the brake cylinder possibly caused by the split ring not being fully seated Remove the second stage plan et assembly and or the output planet assembly to determine and correct the cause of the problem before proceeding Install thrust washer 70 onto the primary planet assembly with second stage sun gear A light coat of oil soluble grease should be used to hold it in place during assembly Install the primary planet assembl
29. ic operation and or unusual noise the hoist must be taken out of service until it is inspected and serviced by a qualified techni cian Continued operation of a hoist with a defect in a critical component may lead to loss of load control property damage injury or death A record of written dated and signed inspections load tests maintenance and repairs or modifications must be kept readily available in an appropriate location for a minimum of five years PRE USE DAILY USAGE INSPECTION CATEGORY IDLED Not used for 3 months REQUIRED BEFORE PLACED IN SERVICE REQUIRED INFREQUENT USAGE less than ten hours per month MODERATE USAGE 10 50 hours per month REQUIRED REQUIRED SEVERE USAGE 200 hours per month REQUIRED or 50 of lifts exceed 75 rated capacity HEAVY USAGE 50 200 hours per month SEMI ANNUAL INSPECTION REQUIRED BEFORE PLACED IN SERVICE REQUIRED REQUIRED REQUIRED REQUIRED QUARTERLY 3 months Inspection procedures for hoists are divided into five general categories based upon the hoist usage or duty cycle which in turn determines different appropriate intervals for inspections The usage categories must be assigned by the hoist user owner on a consistent unit by unit basis The five hoist usage categories are as fol lows Idled The hoist has not been used for three months Infrequent Usage The hoist is used less than ten hours per month based on a three m
30. injury or death entire sprag clutch assembly must be replaced if any component is defective 21 Apply a light coat of winch lubricant to all compo nents as they are assembled Install the roller bear ing 58 into the outer race 42 Install spacer 47 on top of roller bearing Install the sprag clutch assembly 46 NOTE The sprag assembly con sists of three parts two u shaped bronze spacers and a cam assembly The bronze spacers are installed with their open end toward the cam assem bly one spacer on each side Rotate the cam assembly while gently pushing it into the outer race Before installing the inner race 50 be sure the internal retaining ring 49 is installed and fully seat ed Slide the inner race through the sprag clutch the race will have to be rotated in the freewheeling direction to start it into the clutch Be sure the inner race turns freely in the same direction determined before the unit was disassembled If it turns freely in the opposite direction the sprag clutch has been installed backwards and must be reversed Install spacers 44 45 and retaining ring 43 PLANET CARRIER SERVICE OUTPUT PLANET CARRIER 1 The preferred method of removing the planet pin 18 is to first remove the roll pin 24 This can usu ally be done by using a punch or small pry bar to drive or push the roll pin out of the planet carrier 63 Access to the roll pin is gained through drilled hole in the
31. n Plug tion Remove the plug and capture the gear oil in a suitable container Recycle or dispose of used oil in an environmentally responsible manner While the oil is draining collect oil from mid stream for oil x analysis A gt N y 2 Rotate drum to place the drain fill plug at the 3 o clock position Fill winch to the level plug with rec ommended oil Oil fill capacity is 15 pints 7 1 liters Install plug securely after refilling gear cavity m to to 3 Remove the vent relief plug located in the brake cylinder above the motor Clean the vent relief plug in solvent and reinstall Do not paint over the plug Drum seal leaks will result if the relief vent hole is restricted RECOMMENDED PLANETARY HOIST GEAR OIL WARNING Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slip page 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 or 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 i
32. n your hoist is correct for your prevailing ambient temperature PREVAILING AMBIENT TEMPERATURE 40 30 20 10 0 11 20 30 40 50 60 70 80 90 100 110 120 130 F 5 220 OR EQUIVALENT 5 ISO VG 220 EXXON SPARTAN EP150 OR EQUIVALENT AGMA 4 EP ISO VG 150 MOBILGEAR SHC 150 or 220 SYNTHETIC OR EQUIVALENT C 40 30 20 10 0 10 20 30 40 50 C H NOTE SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS OFFSHORE CRANES SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING Texaco Meropa 150 previously used as factory fill may no longer be widely available due to current market conditions As of mid year 2002 planetary hoists are factory filled with Exxon Spartan EP150 or equivalent The chart below relates the Texaco products to 4 currently available oils Consult your oil supplier for other equivalent oils if required Meropa 150 Spartan EP 150 Mobilgear 629 Omala 150 Gear Compounds EP 150 Meropa 220 Spartan EP 220 Mobilgear 630 Omala 220 Gear Compounds EP 220 9 2002 11 SPECIAL TOOLS 2 each 13 eye bolt 2 each 10 eye bolt NOTE The first two items below are required only if NOTE If a press is available with at least 5 the motor support is separated from the ring inches of travel only part A shown gear The other tools are required to service below is required center hole not the brake assembly required If a press is not a
33. nd will last many years and may often be reused if the mating surfaces are still smooth with no scoring Inspect the ring gear teeth for pitting and wear If the wear is greater than 015 in 4 mm when com pared to the unworn area of teeth the ring gear should be replaced Inspect the thrust washers for scoring and wear Replace the thrust washers if Scoring appears excessive BRAKE CYLINDER SERVICE Fabricate the spring compressor tool as illustrated in the Tools section of this manual DISASSEMBLY 1 Install the spring compressor tool as show If a hydraulic press is available only part A of the tool is required Tighten the nut above part A or apply hydraulic pressure to slightly compress the spring and relieve load on the retaining ring 53 Carefully remove the retaining ring until spring pressure is completely released spring travel is approximately 4 inches 10 cm Remove the compressor tool 3 Remove the spring stop 52 spring 55 and piston stop 32 from the brake cylinder 18 4 Remove the brake piston 59
34. on If there is any damage that would impair the cage s ability to separate retain and guide the rollers properly the bearing should be replaced Carefully inspect both halves of the metal face seal between the motor support brake cylinder and the ring gear If the metal contact faces show signs of excessive wear or mechanical damage or the rub ber rings brittle or damaged the seal should be replaced 4 Install the retaining ring NN Turn the assembly over 62 with the motor end up and be sure all brake plates ASSEMBLY are stacked squarely against the spacer plate BACKUP RING O RING BACKUP RING 5 Install new O rings and backup rings 27 28 30 31 1 Set the motor support brake cylinder on a bench with into the brake cylinder as shown It is VERY impor the motor end down tant to position the O rings and backup rings as shown above to prevent brake cylinder leakage C 2 Starting with a steel disc alternately install a steel then a friction disc until eight 8 of each type disc 6 Lightly lubricate the sealing surfaces of the brake pis have been installed ending with a friction disc It is ton 59 and install it into the brake cylinder until it advisable to lightly lubricate the brake discs with oil touches the brake discs that will be used in the winch prior to assembly 7 Install the piston stop 32 and the brake spring 55
35. onth average Moderate Usage Hoist used 10 50 hours per month based on a three month average Heavy Usage Hoist used 50 200 hours per month Severe Duty Hoist is operated more than 200 hours per month OR where 50 of the lifts exceed 75 of the Braden rated capacity for the hoist The following chart lists the inspections that are required for each type of usage category ANNUAL INSPECTION TEAR DOWN INSPECTION REQUIRED IF MAINTENANCE amp REPAIR HISTORY UNKNOWN 5 YEARS 3 YEARS IF NOT SUBJECT TO FULL INSPECTION PROGRAM REQUIRED 4 YEARS 2 YEARS IF NOT SUBJECT TO FULL INSPECTION PROGRAM REQUIRED 3 YEARS 1 5 YEARS IF NOT SUBJECT TO FULL INSPECTION PROGRAM REQUIRED SEMI ANNUALLY 6 months REQUIRED SEMI ANNUALLY 6 months Pre Use or Daily Inspection Must include but is not limited to the following inspec tions that will be performed prior to placing the hoist into service and then as necessary during extended opera tion This inspection must be performed by a qualified technician HOIST gt ANCHOR TO ACCEPT 7 8 WIRE B OIL FILL amp DRAIN SAE 8 1 B 3 4 16 THRD B OIL FILLDRAIN EE ACCESS HOLE 1 Check for external oil leaks and repair as necessary This is extremely important due to the accelerated wear that will result from insufficient lubricating oil in the hoist
36. over pattern Install the drum bearing support end bracket assembly onto the drum assembly For added safe ty remove two of the drum bearing support cap screws 89 and replace them with two 5 8 11 eye bolts so that a hoist may be used to lift the drum flange After the end bracket is installed remove the eye bolts and install the drum bearing support cap screws 89 snugly at this time Install the tie plates 101 onto the end brackets with capscrews and lockwashers 99 100 Only hand tighten the capscrews at this time Place assembled winch onto a flat surface and evenly tighten the tie plate capscrews 99 to 105 lb ft 142 N m torque Tighten the motor end bracket capscrews 82 to 600 lb ft 814 N m torque in an alternating cross over pattern Tighten the drum bearing support capscrews 89 to 210 ft 285 N m torque Turn the winch up on end with the motor end up Secure the winch in this position so that it does not fall over Install the brake release hose adapter into the brake release port Attach a hand pump to the adapter and apply approximately 500 PSI 3450 kPa to release the brake Install the brake clutch assembly brake hub into the brake cylinder You must align all of the brake discs and the input sun gear splines The brake clutch assembly should bottom out with the input sun gear against the snap ring in the inside diameter of the inner brake race After the brake clutch assembly is fully s
37. proximately 125 Ib 57 kg With a hoist lift the output planet carrier out of the drum ring gear Use a long pry bar or chisel to separate the ends of the split ring 65 then remove both halves from the brake cylinder The bearing cone 57 is a snug fit on the brake cylinder and will have to be pressed off Place a stack of shop towels onto the work bench to provide padding when the bearing drops off of the brake cylinder Turn the drum ring gear assembly over with the motor end up and centered over the stack of shop towels 17 14 15 16 Remove the twelve capscrews lockwashers 82 83 that secure the motor end bracket 96 to the brake cylinder 34 Install three 7 8 9 jack screws 6 inches long evenly spaced into the end bracket mounting bolt holes Apply general purpose grease to the threads to reduce friction Evenly tighten the jack screws against the drum ring gear flange to push the brake cylinder out of the drum ring gear and separate the bearings When the two pieces have separated you will hear the bearing cone drop off the brake cylinder journal onto the pile of shop towels Install two 34 10 eye bolts into the brake cylinder motor mounting holes and lift the brake cylinder out of the drum ring gear Be very careful to avoid dam aging the drum seals One half of the lapped metal surface seal is installed on the brake cylinder the other half is on the drum ring gear This seal is very durable a
38. sed 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 Static Friction Brake Applied Figure 5 Sprag Cams Permits free shaft rotation p while hoisting Figure 6 Static Friction Brake Applied Sprag Cams Load attempts to rotate shaft in opposite direction Brake clutch locks sun gear shaft to friction brake WINCH INSTALLATION 55 0 R 55 1 Ko 0 lt R KS 190 lt RS 90 Ko KS lt lt KS Ko KS 90 e Ke cO OK SERS KKK ERROR KKK KH LER RR Qao KKK KKK ERE RRR OK KE SRK KK RRR KKK SERRE SKK E SKK EK RRR NI EEE EE REE RRR EERE RK KKK KKK RRRS RIRIS EISS ERROR KK KKK RK LEBER KKK ROKK KKK HHO ERR RRR RRR KKK KKK KKK YISI
39. spection 2 Take a lubricant sample as described later in this section and analyze it for wear metals content cor rect viscosity lubricant deterioration moisture and other contaminants If the oil sample contains a high amount of metallic particles the hoist must be taken out of service to undergo a tear down inspection Note Oil analysis cannot detect nor warn against a fatigue failure 3 Perform a brake test as described later in this sec tion 4 Inspect tighten all hoist mounting fasteners to rec ommended torque 5 Service the hydraulic system oil and filters as recom mended by the vehicle manufacturer Annual Inspection Must include but not limited to the following inspections that must be performed by a qualified technician 1 Perform the Pre Use and Semi Annual inspections 2 Change hoist gear cavity lubricating oil after an oil sample has been taken as described later in this section Refill the hoist to the proper level with rec ommended lubricant Refer to Recommended Planetary Hoist Gear Oil later in this section for more information On new hoists change gear oil after the first 50 operating hours then every 500 1000 operating hours or annually depending upon hoist usage as shown on Page 9 Oil change instructions 1 The fill drain plug is located on the end of the drum flange away from the motor Rotate drum barrel to place the fill drain plug at the bottom 6 o clock posi Oil Fill Drai
40. stood by everyone tures below 40 F 4 C Refer to Warm up 19 Ground personnel should stay in view of the opera Procedure listed in the Preventive Maintenance tor and clear of winch drum Do not allow ground section of this manual personnel near winch line under tension Operate winch line speeds to match job conditions 20 Do not exceed the maximum pressure PSI kPa or 8 Leather gloves should be used when handling wire flow GPM LPM stated in the winch specifications rope 21 Install guarding to prevent personnel from getting 9 Never attempt to handle wire rope when the hook any part of body or clothing caught at a point where end is not free Keep all parts of body and clothing the cable is wrapped onto the drum or drawn clear of cable rollers cable entry area of fairleads through guide rollers sheaves and winch drum 22 Deadman controls which automatically shut off 10 When winding wire rope on the winch drum never power to the winch whenever the operator leaves attempt to maintain tension by allowing wire rope to his station should be installed whenever practica slip through hands Always use Hand Over Hand ble technique 23 Never allow anyone to stand under a suspended 11 Never use wire rope with broken strands Replace load wire rope 24 Avoid sudden shock loads or attempting to jerk 12 Do not weld on any part of the winch load free This type of operation may cause heavy
41. the hole MUST be installed away from the spring stop or toward the motor to prevent the ring from slipping off the pliers when installed or removed sure the retaining ring is completely seated in its groove and slowly release the spring compressor until the force of the spring is held by the retaining ring Remove the spring compressor tool 20 BRAKE CLUTCH ASSEMBLY SERVICE Before disassembling the brake clutch make note of the freewheeling direction of the inner brake race 50 Hold the outer race 42 and try to turn the inner race in both directions It should turn free of the outer race one direction only If the inner race will not turn freely in either direction or turns freely in both directions the sprag clutch assembly has been damaged and must be replaced 1 Remove the retaining ring 43 All other internal parts can now be removed including the sprag assembly 46 and the roller bearing 58 2 Thoroughly clean all parts in solvent and inspect for signs of wear and or damage Inspect the sprag clutch and roller bearing closely for abnormal wear cracks pitting or corrosion Check small clips for breakage or bright spots the signs of excessive wear A WARNING The polished surfaces of the inner and outer races must be perfectly smooth to insure positive engage ment of the clutch The slightest defect may reduce sprag clutch effectiveness which could result in property damage personal
42. tor 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 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 fully engaged friction brake Figure 6 When the winch is powered in reverse to lower the load the motor cannot rotate until sufficient pilot pres sure is present to open the brake valve Figures 3 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 low ered 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 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 clo
43. ules and regulations will also apply 1 Be certain equipment boom mast sheave blocks 14 Keep hydraulic system clean and free from contam pendants etc is either lowered to the ground or ination at all times blocked securely before servicing adjusting Or 15 Use correct anchor method for wire and pock repairing winch etin drum Do not use knots to secure or attach 2 Be sure personnel are clear of work area BEFORE wire rope For additional safety ALWAYS maintain operating winch a minimum of five 5 wraps of wire rope on the 3 Read all warning and caution tag information provid drum ed for safe operation and service of winch 16 Never attempt to clean oil or perform any mainte 4 Inspect rigging and winch at the beginning of each nance on a machine with the engine or prime mover work shift Defects should be corrected immediately running unless instructed to do so in this manual 5 Keep equipment in good operating condition 17 Never operate winch controls unless you are prop Perform scheduled servicing and adjustments listed erly positioned at the operators station and you are in the Preventive Maintenance section of this man sure personnel are clear of the work area ual 18 Assure that personnel who are responsible for hand 6 An equipment warm up procedure is recommended signals are clearly visible and that the signals to be for all start ups and essential at ambient tempera used are thoroughly under
44. vailable all parts shown and listed below are 3 each 7 8 9NC x 6 inch long capscrews required A ratcheting internal snap ring pliers capable 1 each 1 8 NC threaded rod 14 inches long of handling an N5000 700 snap ring 1 each 1 8 NC nuts 1 each 1 inch plain washer All units use a single coil spring to apply the internal brake The following spring compres sor must be fabricated and is strongly recom mended pe 6 00 2 00 6 5 37 1 I I 1 1 06 1 X 1 06 0 38 0 75 950 T lt 1 00 Z 1 inch 8 NC 2 00 ALL THREAD B7 WELD E 4 2 14 00 8 50 10 00 4 P 0 75 4 00 WELD 12 TROUBLESHOOTING A WARNING If a hoist ever exhibits any sign of erratic operation or load control difficulties load creeping down or chatter ing appropriate troubleshooting tests and repairs must be performed immediately Continued operation of a hoist with a defect may result in property damage injury or death TROUBLE A The hoist will not lower the load or not lower the load smoothly
45. ve the brake release hose adapter from the brake release port to prevent damage Remove the motor pilot adapter 40 from the brake cylinder With a suitable hoist turn the hoist over with the motor end down Remove the capscrews and lock washers 99 100 that retain the tie plates 101 to the end brackets 96 97 Remove the drum bear ing support and end bracket assembly from the cable drum Remove the 16 socket head capscrews and lock washers 12 13 from the drum flange end 5 With a plastic face mallet unseat the drum flange end 5 from the drum ring gear 60 Remove the drum flange end from the drum ring gear mmm UIT HUM 9 Remove the primary sun gear 2 from the primary planet carrier assembly 71 10 Remove the primary planet carrier 71 and second ary sun gear assembly from the drum ring gear If the thrust washer 70 between the primary and secondary planet carriers stayed on the secondary planet carrier remove it and set it aside with the pri mary planet carrier 11 12 13 Remove the secondary planet carrier assembly 68 from the drum ring gear The output sun gear 64 will come out with the secondary sun gear If the thrust washer 66 stayed on the output planet car rier remove it and set aside with the secondary plan et carrier Install two 13 thread eyebolts into the two tapped holes in the output planet carrier 63 The output planet carrier weighs ap
46. wire rope manufacturer Insert the free end of the wire rope through the opening in the drum flange Push the wire rope into the anchor pocket until the end of the wire rope is even with the outer edge of the pocket Install the clamp plate onto the drum flange with the thin end of the clamp wedge toward the dead end of the wire rope Apply a light load of approximately 500 Ib 227 kg to the wire rope as the new wire rope is wound onto the cable drum The anchor system is designed for use only with 7 8 in 22mm wire rope WARNING The clamp plate wire rope anchor system is not capa ble of supporting the rated load Always MAINTAIN a minimum of five wraps of wire rope on the cable drum If the wire rope is fully reeled out the wire rope may slip out of the drum causing a loss of load con trol which may result in property damage injury or death We suggest that the last 5 6 wraps of wire rope be painted bright red to serve as a visual warn ing 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 The user of Braden products is responsible for hoist inspection testing and mainte nance with frequency dependent upon the severity of the hoist duty cycle and thoroughness of the preventive maintenance program in effect WARNING Any time a hoist exhibits errat
47. y onto the second stage planet assembly engaging the second stage sun gear with the sec ond stage planet gears Visually check to be sure the thrust washer is properly positioned Install the primary sun gear 2 through the center of the primary planet assembly Press a new bearing 88 if required into the drum flange Use a flat steel plate that is slightly smaller OD than the drum bearing as a pressure plate to press the new drum bearing into the drum flange bore until it is fully seated at the bottom Apply non hardening sealant to the outside diameter of a new drum seal then install the new seal into the drum flange Use a flat steel plate as a driver and press the new seal into the drum flange until it is even with the outside edge of the drum flange A In the following step the drum flange primary ring gear may suddenly drop onto the drum ring gear when all primary planet gear teeth are aligned with those in the flange DO NOT work with your fingers between the drum flange and the drum ring gear 10 11 12 13 14 15 Carefully set the drum flange 5 onto the drum ring gear engaging the primary planet gears with the ring gear teeth machined into the inside surface Turn the drum flange to align the bolt holes with those in the drum ring gear and install the 16 cap screws and lockwashers 12 13 Tighten the cap screws 12 to 210 lb ft 285 N m torque in alternating cross
48. ze to assure minimum back pressure at the winch The motor must be externally drained directly to the reservoir to avoid motor shaft seal failure gt o 0 le P 72 First sheave or load The winch must be mounted perpendicular to an imaginary line from the center of the winch to the first sheave to ensure even spooling Make certain the fleet angle is between gt and 1 1 degrees WINCH ASSEMBLY W BRAKE VALVE pda amp STATIC BRAKE BRAKE VALVE WINCH BRAKE BR gt CASE DRAIN CONTROL VALVE 7 _ L The winch 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 open to tank often called open center open port High quality hydraulic oil is essential for satisfactory performance and long hydraulic component life Make certain the hydraulic oil used is the proper vis cosity for your starting ambient temperature Typically the maximum cold weather start up viscos ity should not exceed 5000 SUS with a pour point 20 F 11 C lower than the minimum anticipated temperature Under continuous operating conditions the oil tem perature should not exceed 180 F 82 C Optimum oil temperature is 120 140 F 49 60 C Unless oth erwise specified by the vehi
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