BRADEN CH400B Installation Maintenance And Service Manual

Planetary hoist

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INSTALLATION, MAINTENANCE,

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LIT2419 R4

April 2017

Printe d in USA

CH400B

PLANETARY HOIST

AND SERVICE MANUAL

WRITE HOIST SERIAL NUMBER BELOW

First 2 numbers indicate

year manufactured

For serial number location see page 3

CH400B

Table of Contents

Summary of Contents for BRADEN CH400B

Page 1 CH400B CH400B PLANETARY HOIST INSTALLATION, MAINTENANCE, AND SERVICE MANUAL WRITE HOIST SERIAL NUMBER BELOW First 2 numbers indicate year manufactured For serial number location see page 3 Visit our Web site at www.paccarwinch.com for the most comprehensive collection of winch, hoist, and drive information on the Internet.
Page 2: Table Of Contents
TABLE OF CONTENTS Foreword ........................3 Model and Serial Number Location ................3 Explanation of Model Number ..................3 Glossary ........................4 General Safety Recommendations................5 Theory of Operation.....................6 Hoist Installation ......................8 3-piece Cable Anchor Installation ................9 Hydraulic Circuits.......................10 Preventive Maintenance .................... 11 Weights, Oil Capacities, and Special Tools ...............13 Recommended Planetary Gear Oil................13 Troubleshooting ......................14 Service Precautions....................17...
Page 3: Foreword
The following service instructions have been prepared to provide assembly, disassembly, and maintenance informa- tion for the BRADEN Model CH330/CH400A series winch. It is suggested that before performing any work on these units, all assembly and disassembly instructions should be read and understood.
Page 4: Glossary
GLOSSARY Brake Valve — A hydraulic counterbalance valve is usually bolted to the hoist port of the hydraulic motor. It allows oil to flow freely through the motor in the hoisting direction. When oil pressure tries to rotate the motor in the lowering direction, the brake valve blocks the flow of oil out of the motor until the internal static brake is released.
Page 5: General Safety Recommendations
The following recommendations are offered as a general safety guide. Local rules and regulations will also apply. 18. The BRADEN designed wire rope anchors are not intended to support the rated load. ALWAYS maintain a minimum of Failure to obey the following safety recommendations may five wraps of wire rope on the drum.
Page 6: Theory Of Operation
THEORY OF OPERATION DESCRIPTION OF HOIST Figure 2 The hoist is made up of the following sub-assemblies and Static Brake parts: Motor 1. Hydraulic motor, brake valve and motor adapter 2. Drum and drum support assembly 3. Motor end support Brake Valve 4.
Page 7 When the hoist is powered in the pay-out or lowering di- Figure 4 Sprag Cams rection, the motor cannot rotate until sufficient lowering pressure is present to release the brake and open the Static Friction Brake Applied brake valve. See Figures 2 and 3. The friction brake will completely release at a pressure lower than that required to open the brake valve.
Page 8: Hoist Installation
(32°C) use SAE 10W; for applications colder than 10°F erated wear and heat. Also, the mounting surface should (-12°C), contact the BRADEN Service Department. The be flat with +/- 0.020 inch. If necessary, install shims un- use of multiviscosity oils is generally not recommended.
Page 9: 3-Piece Cable Anchor Installation
WIRE ROPE INSTALLATION 01 AND 02 DRUM – ANCHOR Figure 1 Remove both sheet metal covers from the end bracket Remove both sheet metal covers from the end bracket of of the winch. Pull the end of the cable through the the hoist.
Page 10: Hydraulic Circuits
HYDRAULIC CIRCUITS SINGLE-SPEED CIRCUIT 2-SPEED CIRCUIT WINCH ASSEMBLY WINCH ASSEMBLY W/BRAKE VALVE W/BRAKE VALVE & STATIC BRAKE & STATIC BRAKE BRAKE VALVE WINCH BRAKE BRAKE VALVE WINCH BRAKE HOIST LOWER HOIST CONTROL LOWER VALVE 2-SPEED SELECTOR VALVE CONTROL VALVE PUMP CUSTOMER PUMP SUPPLIED...
Page 11: Preventive Maintenance
PREVENTIVE MAINTENANCE A regular program of preventive maintenance for your 2. Oil Change planetary hoist is strongly recommended to minimize the The gear oil should be changed after the first 100 hours need for emergency servicing and promote safe, reliable of operation, then every 1,000 operating hours or six hoist operation.
Page 12 The gear oil should also be changed whenever the am- 8. Recommended Planetary Gear Oil bient temperature changes significantly and an oil from Field experience, supported by extensive engineering a different temperature range would be more appropri- tests, indicates the use of the proper planetary gear oil ate.
Page 13: Weights, Oil Capacities, And Special Tools
Snap-On P/N IMD242A For simplicity, BRADEN has listed one readily available 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 perform equally as well.
Page 14: Troubleshooting
TROUBLESHOOTING WARNING CAUTION If a hoist exhibits any sign of erratic operation or load- control difficulties (such as load creeping or chattering), appropriate troubleshooting tests and repairs should be performed immediately. Continued operation in this manner may result in property damage, serious person- al injury, or death.
Page 15 TROUBLE PROBABLE CAUSE REMEDY The brake will not hold a 1. Excessive system back pressure acting Same as remedy for Trouble B2. load with the control lever on the brake release port. in neutral. 2. Friction brake will not hold due to worn Same as remedy for Trouble A2.
Page 16 TROUBLE PROBABLE CAUSE REMEDY The hoist runs hot. 1. Same as D1. Same as remedies for Trouble D1. 2. Be certain that the hydraulic system temperature is not more than 180°F (82°C). Excessive hydraulic oil tem- peratures may be caused by: A.
Page 17: Service Precautions
Before beginning to disassemble the hoist or drive Use only genuine BRADEN replacement parts for opti- gearbox, remove the wire rope, drain the oil and clean mum results. Never reuse expendable parts such as O- the outside surfaces to avoid contaminating gears and rings and oil seals.
Page 18: Hoist Disassembly
HOIST DISASSEMBLY from the end brackets. Install four large C-clamps around the drum support end bracket (Item 2) and the drum flange. This will prevent the end bracket and The hoist weighs 2900 to 3900 pounds (1315 to 1770 drum from separating when the motor end bracket and kg) depending on model.
Page 19 6. Remove the hex-head capscrews and lockwashers (Items 30 and 22) that secure the gearbox to the hoist drum. The hoist drive weighs 565 pounds (256 kg). Ensure the hoist and rigging are rated for this weight. Using a hoist or rigging with insufficient rating may result per- sonal injury or death.
Page 20: Hoist Assembly
HOIST ASSEMBLY NOTE: Apply Loctite Marine Grade Antiseize compound 7. Set the side-plate with outer hub installed and the to all external fasteners before installation. These fasten- drum side facing up on a surface capable of support- ers are items 8, 9, 12, 23, and 30 shown in the main com- ing assembled hoist weight (up to 4000 pounds or ponents drawing, and the motor flange capscrew.
Page 21: Drum Support End Bracket Service
16. Install a new O-ring on the hydraulic motor pilot for an SAE C flange motor, or in the motor adapter for the SAE D flange motor. Install the hydraulic motor onto the motor adapter engaging the motor splines with the overrunning clutch inner race. Install the four capscrews and lockwashers which secure the motor to the motor adapter.
Page 22: Hoist Drive Service
HOIST DRIVE SERVICE Item No Description Item No Description THRUST BUTTON O-RING PRIMARY SUN GEAR MOTOR ADAPTER INTERMEDIATE SUN GEAR RETAINING RING WASHER, THRUST BEARING CARRIER COVER SHAFT CAPSCREW FINAL SUN GEAR LOCKWASHER RING GEAR LOCKWASHER CAPSCREW CAPSCREW PRIMARY CARRIER ASSY ADAPTER, LONG INTERMEDIATE CARRIER ASSY LIP SEAL...
Page 23 SAE D Motor Adapter DISASSEMBLY 7. Place 5/16 NC eyebolts 180 degrees apart in the ring gear tapped holes and carefully lift the ring gear off of The hoist drive weighs 565 pounds (256 kg). Ensure the brake cylinder. Lift straight up using an overhead the hoist and rigging are rated for this weight.
Page 24 Thoroughly clean all parts and inspect for damage. In- 7. Set the brake cylinder assembly on the workbench spect all machined surfaces for irregular wear. Inspect with the motor end down. Place spacer blocks under the ring gear and planet gear teeth for nicks, pitting, and the brake cylinder so the overrunning clutch inner race any signs of wear.
Page 25: Brake Cylinder Service
3. There are 7 friction discs (25) and 8 steel brake discs 1. Use a special compressor tool to compress the springs. (26) in the standard CH400B brake, but units with SPL If a hydraulic press is available, only part A of the spring (special) in the model number may have a different compressor tool is required.
Page 26 Brake Cylinder Pressure Test Connect a hydraulic hand pump with an accurate gauge and shut-off valve to the brake release port. Apply 500 PSI (3,450 kPa) to the brake. Close the shut-off valve and let stand for five minutes. If there is any loss of pressure, the brake cylinder should be disassembled for inspection of the sealing surfaces and O-rings.
Page 27: Overrunning Clutch Service
The clutch MUST be re-assem- Shown below are the two types of clutch assemblies used bled correctly for proper hoist operation. in CH400B hoists. The drawings show each type properly assembled for standard rotation. The polished surfaces of the inner and outer race and the overrunning cams must be perfectly smooth to en- sure positive engagement of the clutch.
Page 28: Primary Planet Carrier Service
PRIMARY PLANET CARRIER SERVICE the bearing rollers should be replaced. The thrust DISASSEMBLY washer contact areas should be free from any surface irregularities that may cause abrasion or friction. The planet gears (10) and planet pins (6) should be inspect- ed for abnormal wear or pitting.
Page 29: Intermediate Planet Carrier Service
INTERMEDIATE PLANET CARRIER SERVICE DISASSEMBLY ASSEMBLY The loose roller bearings can be difficult to keep in place during assembly. This procedure attempts to simplify this. 1. Clean and inspect parts as described in step 4 of the disassembly procedure. 2. Place planet gear (15) on clean workbench. Install a thrust washer (17) and retaining ring (21) in one side of the planet gear.
Page 30: Final Planet Carrier Service
FINAL PLANET CARRIER SERVICE DISASSEMBLY ASSEMBLY The loose roller bearings can be difficult to keep in place during assembly. This procedure attempts to simplify this. 1. Clean and inspect parts as described in step 4 of the disassembly procedure. 2. Ensure thrust spacer (66) is installed in the planet car- rier (22) before installing the gears on the planet carrier posts.
Page 31: Brake Valve Service
BRAKE VALVE SERVICE BRADEN CH400B hoist is supplied with one of two BRADEN brake valves, depending on the hydraulic mo- tor used. Both are reliable hydraulic valves with internal components manufactured to close tolerances. Because of these close tolerances, several individual parts are not available as replacement parts and are noted in the fol- lowing parts list as NSS (not serviced separately).
Page 32 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 number 527 for complete brake valve test and adjustment procedures.
Page 33 binding or leakage. Inspect spool bore in valve hous- 2. Install new O-rings and backup rings on the spool and ing for damage or scoring. Inspect check valve seat in damper pistons as shown. It is important that each valve housing and check valve poppet. If the spools, backup ring is on the correct side of its O-ring.
Page 34: Recommended Fastener Torque
RECOMMENDED FASTENER 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.
Page 35: Metric Conversion Chart
METRIC CONVERSION TABLE English to Metric Metric to English LINEAR inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.03937 = inches (in.) feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.) miles (mi.) X 1.6093 = kilometers (km) kilometers (km)