Paccar Braden BP200 Installation Maintenance And Service Manual
  1. Manuals
  2. Brands
  3. Paccar Manuals
  4. Winches
  5. Braden BP200
  6. Installation maintenance and service manual
Paccar Braden BP200 Installation Maintenance And Service Manual

Paccar Braden BP200 Installation Maintenance And Service Manual

Hydraulic planetary underground pulling winch
Hide thumbs
Table of Contents

Advertisement

Quick Links

HYDRAULIC PLANETARY
UNDERGROUND PULLING
INSTALLATION, MAINTENANCE, AND SERVICE MANUAL
LIT2754 PB303 R3
November 2018
Printed in USA
BRADEN
BP200
WINCH
PACCAR Winch
800 East Dallas Street
Broken Arrow, OK 74012
www.paccarwinch.com
Copyright 2018 PACCAR Inc.
All rights reserved

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Braden BP200 and is the answer not in the manual?

Questions and answers

Related Manuals for Paccar Braden BP200

Summary of Contents for Paccar Braden BP200

  • Page 1 BRADEN BP200 HYDRAULIC PLANETARY UNDERGROUND PULLING WINCH INSTALLATION, MAINTENANCE, AND SERVICE MANUAL PACCAR Winch 800 East Dallas Street LIT2754 PB303 R3 Broken Arrow, OK 74012 Copyright 2018 PACCAR Inc. November 2018 Printed in USA www.paccarwinch.com All rights reserved...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS FOREWORD ..............2 MODEL AND SERIAL NUMBER LOCATION .

  • Page 3: Foreword

    FOREWORD The following service instructions have been prepared to provide assembly, disassembly and maintenance infor- mation for the BRADEN Model BP200 series winch. It is suggested that before doing any work on these units, all assembly and disassembly instructions should be read and understood. Some pictures in this manual may show details or attachments that are different from your winch.

  • Page 4: General Safety Recommendations

    Engaged” indicator light to make sure it is illuminat- ed before beginning a lift or pull. The clutch must 1. The BRADEN BP200 is neither designed nor intended be in its fully engaged position before this light will for use or application to equipment used in the lifting illuminate.

  • Page 5: Basic Operation

    BASIC OPERATION DESCRIPTION OF WINCH engaged by spring pressure, and the drum drag brake is not applied. The BRADEN BP200 winch consists of the following BASIC WINCH OPERATION sub-assemblies: The winch is built with a solid hub between the input 1.

  • Page 6: Installation

    winch is equipped with an electrical switch that will light LEVEL WIND the red “WINCH DISENGAGED” lamp on the freespool The BP200 winch is equipped with a level wind system panel whenever the drum is disengaged from the drive to ensure smooth even spooling of wire rope onto the train.

  • Page 7: Hydraulic Circuits

    HYDRAULIC CONTROLS Free Spool Circuit Drag Brake Circuit Route Rod End Port Back to Tank to Contain Oil Should a Seal Fail Freespool Valve 150 PSI Min 150 PSI Min. (Solenoid or Manual) 250 PSI Max 250 PSI Max. 500 PSI Max. Hydraulic Inlet Hydraulic Inlet Lever Operated Master Cylinder...
  • Page 8 end of the wire rope to keep it from fraying (i.e. tape or Using a hammer and brass drift, drive the wedge as deep wire) must not be in contact with the wedge when the into the pocket as possible to ensure it is fully seated and installation is complete.

  • Page 9: Dimensional Drawings And Specifications

    opening toward the diamond screw. Disengage the dia- the previous page for additional information. When mond screw by rotating the lever on the chain case, 90 o spooling cable onto the drum, the roller bracket should toward the front of the winch. Using the handwheel on lag behind where the rope is laying onto the drum by 1/2 the motor end of the winch, turn the diamond screw in the of a rope diameter.

  • Page 11: Winch Operation

    WINCH OPERATION The following warnings are basic to safe winch operation. Please read them completely and follow them each time your BP200 winch is operated. CAUTION WARNING CAUTION WARNING A partially engaged drum clutch may “jump out” of Ground personnel must stay in view of the operator engagement causing a sudden loss of load control and clear of the load and winch drum.

  • Page 12: Capstan Use

    CAPSTAN USE Braden has two types of capstans available. One is a quick disconnect bayonet type, the other is a bolt-on style. CAUTION WARNING Before installing a bayonet type capstan, make certain the spring is properly located in the bore. The spring holds the capstan in the lock position on the extension shaft.

  • Page 13: Preventive Maintenance

    PREVENTIVE MAINTENANCE A regular program of preventive maintenance for your relief valve to ensure proper performance and com- Braden BP200 winch will minimize the need for emer- ponent protection. gency servicing and promote long life and trouble-free Service the hydraulic system filters/strainers as rec- service.

  • Page 14: Recommended Gear Oil

    Wire Rope Mounting Bolts Inspect the entire length of wire rope according to the Tighten all winch base mounting bolts to recommended wire rope manufacturer’s recommendations. torque after the first one hundred (100) hours of opera- tion, then every 1,000 operating hours, or six (6) months, whichever occurs first.

  • Page 15: Identification Of Major External Winch Components

    IDENTIFICATION OF MAJOR EXTERNAL WINCH COMPONENTS 1. Hydraulic Motor 10. Vent Plug 2. Brake Valve Block and Cartridges 11. Cable Anchor Pocket 3. Drum Drag Brake Cylinders (2) 12. Chain Case for Level Wind Mechanism 4. Diamond Screw Handwheel 13. Extension Shaft 5.

  • Page 16: Trouble Shooting

    TROUBLE SHOOTING CAUTION WARNING If a winch ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping or chattering) appropriate troubleshooting tests and repairs should be performed immediately. Continued operation in this manner may result in property damage, serious personal injury or death. REMEDY TROUBLE PROBABLE CAUSE...
  • Page 17 REMEDY TROUBLE PROBABLE CAUSE The brake will not hold a load with Excessive system back pres- The same as B2. the control lever in neutral. sure acting on the brake release port. Same as A2. Friction brake will not hold due to worn or damaged brake discs.
  • Page 18 PROBABLE CAUSE REMEDY TROUBLE Same as remedies for Trouble D1. The winch runs hot. Same as D1. Be certain that the hydraulic system temperature is not more than 180 degrees F. Excessive hydraulic oil temperatures may be caused by: Thoroughly clean exterior and flush Plugged heat exchanger.
  • Page 19 PROBABLE CAUSE REMEDY TROUBLE F Continued The levelwind ratio does not Verify levelwind ratio is correct for match the cable being used. the size cable being used. When winch is shifted into freespool, Insufficient pressure at the Check pressure at freespool port. winch continues to operate normally.

  • Page 20: Changing Extension Shaft Length

    CHANGING EXTENSION SHAFT LENGTH Extension shafts are available as 46 in., 47 in., and 50 in. lengths. (from centerline of drum to end of shaft). The extension shaft is connected to the winch with a coupling that has two (2) sets of holes in it, 2 inches apart. This allows the 46 in.
  • Page 21 Place a suitable container under the chain case drain Remove the two (2) socket head capscrews from the plug and remove the plug to drain the oil. Remove the bearing/seal carrier and remove the carrier from the vent and reducer bushing from the chain case and clean winch.
  • Page 22 Remove all three sprockets and chains. Thoroughly Apply a light coat of winch oil to the outside of the clean and inspect any parts that will be re-used for signs freespool piston and install it into the chain case cover. of damage and/or excessive wear.

  • Page 23: Change From Overwind To Underwind

    an open circuit. If your winch is air controlled, connect an air source to the freespool pressure port next to the switch. If your winch is hydraulically contrtolled, connect a hydraulic hand pump with an accurate gauge to the pressure port. Apply 90 - 150 psi (621 - 1,030 kPa) of air, or 150 - 250 psi (1,030 - 1,720 kPa) of hydraulic pressure.

  • Page 24: Servicing The Diamond Screw Level Wind

    SERVICING THE DIAMOND SCREW LEVEL WIND Routine preventive maintenance will greatly extend the life of components of the levelwind system. It is important to keep the two smooth slide bars clean and rust free. They should be wiped clean and lightly oiled before and after each use.

  • Page 25: Replacing The Drag Brake Discs

    Clean the diamond screw and slide tubes and lightly lubricate their entire lengths. Slide the carrier assembly onto the slide bars and engage the pawl with the dia- mond screw. Lightly lubricate the sealing surfaces of the diamond screw and the handwheel shaft. Install the support bracket onto the winch, being careful not to damage the seal as it engages the diamond screw.

  • Page 26: Servicing The Gear Train, Brake And Drum

    SERVICING THE WINCH GEAR TRAIN, BRAKE AND DRUM Drain the oil from the winch drum and chain case as Remove the brake cylinder nipple and the seven (7) cap- described in “PREVENTIVE MAINTENANCE”, on page screws and lockwashers holding the diamond screw 12.
  • Page 27 Remove thrust bearing and two races. Remove the brake cylinder assembly, and place it on a clean, dry surface so as not to damage the splines. Refer to “BRAKE CYLINDER SERVICE” for additional informa- tion.. Remove the primary planet carrier assembly. Refer to “PRIMARY PLANET CARRIER SERVICE”...
  • Page 28 Remove the output planet carrier assembly. You can Lift the drum off the chain case end plate. make hooks like the ones shown to make removal easi- er. Refer to “OUTPUT PLANET CARRIER SERVICE” for more information. Freespool gear and pull tube The drum bearing and seal in the chain case end brack- et can now be removed.

  • Page 29: Brake Cylinder Service

    BRAKE CYLINDER SERVICE Disassembly All thread or capscrew Tube or socket Retaining Ring Turn the brake cylinder on end with the large end up. Remove the spiral retaining ring and lift out the brake piston plate. The static brake in the BP200 winch is applied by eight (8) belleville springs.
  • Page 30 Assembly Install the eight (8) belleville springs over the spring Lubricate O-rings and backup rings with oil and install guide. The first one should rest against the snap ring on them on the brake piston. The concave surface of the the spring guide, with the concave side facing the snap backdup ring must be next to the O-ring.
  • Page 31 All thread or capscrew Tube or socket Retaining Ring Pressure check the brake cylinder assembly by connect- ing a hand pump with an accurate 0-2,000 psi (0- Use a press or the compression tool shown above to 13,800 kPa) gauge and shut-off valve to the brake compress the springs until the backup plate is just below release port in the top of the assembly.

  • Page 32: Planet Carrier Service

    PLANET CARRIER SERVICE Disassembly NOTE: The illustrations show the output carrier assem- bly. Follow the same steps to service the primary carri- er. The only difference is that the primary planet gears have only one bearing, and no bearing spacer. Use a punch to drive the spirol pins out of the planet gear shafts.
  • Page 33 Assembly Install the thrust washer into the planet carrier. Insert two bearings and a spacer into a planet gear (one bear- ing and no spacer for the primary carrier gears). Place a thrust washer on each side of the gear and install it in a carrier opening.

  • Page 34: Assembling The Winch Gear Train, Brake And Drum

    ASSEMBLING THE WINCH GEAR TRAIN, BRAKE AND DRUM Before beginning to assemble the winch, all bearings should be cleaned, inspected and replaced as required. All seals should be replaced. Use a good grade non- hardening sealing compound on the outside diameter of seals and a light coat of thread sealing compound or sealing tape on pipe fittings and plugs.
  • Page 35 Install the output sun gear and the thrust washer. Install the ring gear adapter, hub end up, meshing the Center the thrust washer on the output carrier so the pri- adapter with the ring gear. mary carrier pilot can be installed through it. Install a new bearing in the drum closure if replacement is necessary, making certain to press it against the shoulder in the bottom of the bearing bore.
  • Page 36 Before installing the brake discs and friction discs, check their condition. Both types of discs should be flat and their teeth should not be pointed. The friction discs should have a clearly visible groove pattern in the fric- tion material. Replace discs if necessary. Install the brake cylinder assembly over the primary sun gear, making certain the brake cylinder engages the ring gear adapter teeth.
  • Page 37 Measure the brake stack-up as shown. The measure- ment should be a minimum of 0.1875 in. (4.75 mm) from the top of the brake plate spacer to the top of the brake cylinder. If the measurement is less than this, remove Install the motor adapter with eight (8) capscrews and the brake plate spacer and add a steel brake disc to the lockwashers.

  • Page 38: Brake Valve And Cartridge Information

    Add 5 quarts (4.73 L) of oil to the winch drum through (approx. 9 quarts - 8.5L). the pull tube. Refer to “CONVERSION PARTS FOR After the winch is installed, be sure the drum rotates in LEVEL WIND DRIVE” and install the sprockets, chain, the correct direction to pay-out and haul-in cable as indi- freespool parts, extension shaft and diamond screw dis- cated at the operators station.

  • Page 39: Parts Key

    BRADEN BP200B PARTS KEY For Part Numbers, refer to Material List, Publication PB-304 1 0 1 1 0 2 1 0 0 DRUM AND INTERNAL GEARS Item Description Qty. Item Description Qty. O-Ring Brake Cylinder Backup Ring Brake Piston Backup Ring Brake Piston Plate Street Elbow Backup Plate...
  • Page 40 Item Description Qty. Item Description Qty. Thrust Washer Steel Brake Disc Output Planet Carrier Seal Output Planet Gear Bearing Output Planet Gear Shaft Cable Wedge (1/2 - 3/4 in.) Thrust Washer Retaining Ring Roller Bearing Oil Drain Plug (not shown) Spirol Pin Tie Plate Output Sun Gear...
  • Page 41 FREESPOOL GEARS Item Description Qty. Carrier Extension Retaining Ring Thrust Washer Freespool Coupling Pull Tube Bushing ROLLER ASSEMBLY Item Description Qty. Roller Bracket Bushing Fixed Roller Shaft Fixed Roller Horizontal Roller Shaft Horizontal Roller Retaining Ring Moving Roller Moving Roller Shaft Bushing Roller Tension Spring Capscrew (3/8 NC X 3/4 G5)
  • Page 42 200 199 196 195 104 96 DIAMOND SCREW DRIVE, Item Description Qty. FREESPOOL AND CAPSTAN Retaining Ring Roll Pin Set Screw Item Description Qty. Diamond Screw Lockwasher (5/16) Driven Sprocket Bearing Cup Bushing Bearing Cone Retaining Ring Seal Dual Sprocket Retaining Ring Bushing Guide Bar...
  • Page 43 Item Description Qty. Item Description Qty. Torque Tube Assy. W/bushing Retaining Ring Torque Tube Bushing (N.S.) O-Ring Capstan Shaft Backup Ring Coupling Thrust Washer Seal Retaining Ring Bearing Drive Sprocket O-Ring Extension Shaft Backup Ring Chain Case End Bracket Freespool Spring Thrust Washer Freespool Piston Drive Chain...
  • Page 44 MOTOR ASSEMBLY Item Description Qty. Hydraulic Motor O-Ring O-Ring Brake Valve Block 172 173 Capscrew (5/16 NC X 2 1/2 G8) Counterbalance Cartridge The Following Items Not Shown on the Drawing Capscrew (1/2 NC X 1 1/4 G5) Lockwasher (1/2) Washer (1/2) Motor Gasket Brake Release Hose...

  • Page 45: Recommended Bolt Torque

    RECOMMENDED BOLT TORQUE Higher or lower torques for special applications will be specified such as the use of spanner nuts, nuts on shaft ends, jam nuts and where distortion of 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. Torque (LB-FT) Torque (LB-FT) Bolt Dia.

  • Page 47: Metric Conversion Table

    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)
  • Page 48 PACCAR Winch LIT2754 PB303 R3 800 East Dallas Street November 2018 Broken Arrow, OK 74012 Copyright 2018 PACCAR Inc. Printed in USA www.paccarwinch.com All rights reserved...

Table of Contents

Save PDF