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BRADEN CH150A Series Installation Maintenance And Service Manual

With auxiliary brake planetary hoist
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CH150A/CH230A
PLANETARY HOIST
INSTALLATION, MAINTENANCE AND SERVICE MANUAL
LIT2222 R1
6/2005
Printed in U.S.A.
Copyright 2005 PACCAR Winch Division. All rights reserved.
BRADEN
w/Auxiliary Brake
PACR
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE (918) 251-8511 FAX (918) 259-1575
www.paccarwinch.com
WINCH DIVISION

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  • Page 1 BRADEN CH150A/CH230A w/Auxiliary Brake PLANETARY HOIST INSTALLATION, MAINTENANCE AND SERVICE MANUAL PACR WINCH DIVISION P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013 LIT2222 R1 PHONE (918) 251-8511 FAX (918) 259-1575 6/2005 www.paccarwinch.com Printed in U.S.A. Copyright 2005 PACCAR Winch Division. All rights reserved.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS FOREWORD ........... .2 GENERAL SAFETY RECOMMENDATIONS .

  • Page 3: Foreword

    The information in this manual has been prepared to provide assistance with safe installation, operation and serv- icing of your new Braden planetary hoist. It is strongly recommended that you read and understand this entire man- ual before installing and operating your hoist.

  • Page 4: General Safety Recommendations

    Perform scheduled servicing and adjustments defined in the "Preventive Maintenance" section of 18. The Braden designed wire rope anchors are NOT this manual. designed to support the full rated load. ALWAYS maintain a minimum of five (5) wraps of wire rope on 6.

  • Page 5: Special Tools

    This type of operation may cause heavy If there is any question regarding the safety recommen- loads in excess of rated capacity, which may result dations, or the safe operation of your Braden hoist, in failure of the wire rope, hoist or crane structure. please...

  • Page 6: Basic Operation

    BASIC OPERATION DESCRIPTION OF HOIST the pilot operated spool valve. This sequence assures that dynamic braking takes place within the brake valve, The hoist is made up of the following sub-assemblies: and that little, if any, heat is absorbed by the static fric- 1.
  • Page 7 the brake. For extremely light loads (such as in empty Figure 4 hook conditions), some slight scrubbing of the auxiliary Motor Static brake plates may occur. The fully applied static brake Brake has no effect on the hoist during lifting operations. When the lifting operation is stopped, the load attempts Brake to turn the primary sun gear in the opposite direction.
  • Page 8 Static Friction Brake Applied Figure 5 Figure 6 Static Friction Brake Applied Sprag Sprag Cams Cams Hoisting Stopped, Holding Load Permits free shaft rotation while hoisting Load attempts to rotate shaft in opposite direction. Brake clutch locks sun gear shaft to friction brake.

  • Page 9: Hoist Installation

    SAE 10W; for applications colder than 10°F (-12°C), contact the tion whenever the handle is released, and both work ports BRADEN Product Support Department. The use of multi-vis- are opened to tank (open center, open port). cosity oils is generally not recommended.
  • Page 10 Using a hammer and brass drift, drive the wedge as seat firmly, contact the Braden Product Support deep into the pocket as possible to ensure it is fully Department at 918-251-8511 to determine the proper seated and no further movement is detected. Applying wedge size.

  • Page 11: Hoist Operation

    Braden Gearmatic Product Support Department at 918-251-8511, 8:00 am to 16:30 pm CST, Monday through Friday.

  • Page 12: Hydraulic Circuits

    The user of any Braden hoist product is responsible for hoist inspections, testing, operator training and the main- tenance procedures defined below, with the frequency being dependent upon the severity of the hoist duty cycle and the thoroughness of the maintenance program.
  • Page 13 Field experience, supported by engineering testing, indicates the three service procedures listed below are most crucial to safe, reliable hoist operation and MUST be observed. • Regular gear oil changes • Use of proper gear oil - recommended type for prevailing ambient temperatures, and additives used •...
  • Page 14 Use only the recommended type of lubricant. Refer injury or death. to page 16 of this manual and Braden Service Bulletin 503 (latest revision) for gear oil recommen- dations. Quarterly Inspection: OIL FILL &...
  • Page 15 2. Change the hoist gear oil, after an oil sample has been taken. Refer to page 16 of this manual and Braden Service Bulletin 503 (latest revision) for gear oil recommendations. The gear oil must be changed to remove the wear particles that impede safe and reliable operation of the brake clutch, and erode bearings and seals.

  • Page 16: Tear Down Inspection

    Recommendations For Personnel Handling Hoists Hoist Model No.: _______________________________ Hoist Serial No.: _______________________________ Date of Inspection: _______________________________ Work Order/Job No:_______________________________ Inspector’s Name: _______________________________ For a copy of recommendations call or write: BRADEN PO Box 547, Broken Arrow, OK, 74012, USA (918) 251-8511...

  • Page 17: Recommended Gear Oil

    Make certain that the gear oil viscosity used in your hoist is correct for your pre- vailing ambient temperature. For simplicity, BRADEN has listed available products in each temperature range that have been tested and found to meet our specifications. This is not to say that other lubricant brands would not perform equally as well.

  • Page 18: Oil Sampling And Analysis

    OIL SAMPLING AND ANALYSIS Proper oil sampling, and analysis of the sample, is a Analysis vital part of a comprehensive preventive maintenance General Guidelines program. Information obtained from oil analysis is best (After approximately 250 hours of operation) utilized in conjunction with a regular preventive mainte- nance program.

  • Page 19: Brake Test Procedure

    BRAKE TEST PROCEDURE (For Internal Spring-Applied Load Holding Brake) All BRADEN hoists employ a spring-applied, hydrauli- Hoists ordered for personnel handling cranes will also cally released, multiple disc brake inside the hoist hous- have a needle valve installed in the brake release line ing.

  • Page 20: Auxiliary Brake Test Procedure

    AUXILIARY BRAKE TEST PROCEDURE NOTE: Brake test to be performed with no load on the hoist. The weight of the wire rope, hook block and over- 3. Increase the engine speed, if necessary, to bring the haul ball or hook weights are acceptable. system pressure up to the relief valve setting.

  • Page 21: Emergency Lowering Procedure

    EMERGENCY LOWERING PROCEDURES For Units Employing Only the Internal Spring-Applied Load Holding Brake Do not touch the motor, brake valve or standpipe while lowering a load. They may become hot enough An emergency load lowering condition exists when a to cause burns. load is suspended and the hydraulic power supply to the hoist has been disabled for some reason.
  • Page 22 the hand-pump, slowly apply pressure to observe if there is any movement of the suspended load. If the load begins to lower, there may be a gear train fail- The stand-pipe must be kept full of oil. Attempting to ure in the hoist. The load may be lowered by control- lower a load with no oil in the motor or with a brake ling the pressure to the ABS port;...

  • Page 23: Personnel Handling

    In these situations, all safety precautions must be strictly adhered to. BRADEN recommends adherence to the latest revision of API 2D (RP 2D) and/or ANSI/ASME standard B30.5 and/or OSHA and/or other applicable standards for your application.

  • Page 24: Trouble Shooting

    TROUBLE SHOOTING If a hoist ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping or chattering), appropriate trouble shooting tests should be performed immediately. Continued operation in this manner may result in property damage, serious personal injury or death. REMEDY TROUBLE PROBABLE CAUSE...
  • Page 25 TROUBLE REMEDY PROBABLE CAUSE “A” ROUBLE CONTINUED FROM REVIOUS C. Apply 800 PSI (5,500 kPa) to the ABS release port. Check the cable drum to determine if it spins freely. If it does not, slowly increase the pressure until the drum is free. DO NOT exceed 1,200 PSI (8,300 kPa) in this port.
  • Page 26 TROUBLE REMEDY PROBABLE CAUSE Oil leaks from the vent 1. Same as A2. Same as A2. plug. 2. The hydraulic motor shaft seal may be System back pressure must not exceed defective as a result of high system 150 PSI (1,035 kPa). Inspect the back pressure contaminated...
  • Page 27 TROUBLE REMEDY PROBABLE CAUSE “D” ROUBLE CONTINUED FROM REVIOUS 2. The system relief valve may be set too Check the relief valve pressure, as fol- low. The relief valve may need adjust- lows: ment, repair or replacement. 1. Install an accurate 0-4000 PSI (0- 27,600 kPa) pressure gauge into the inlet port of the brake valve.
  • Page 28 TROUBLE REMEDY PROBABLE CAUSE “E” ROUBLE CONTINUED FROM REVIOUS D.Hydraulic pump not operating effi- Prime mover low on horsepower or ciently. RPM. Tune or adjust prime mover as required. Check suction line for damage. Repair as needed. If pump is belt driven, ensure belts are tensioned properly and not slipping.
  • Page 29 TROUBLE REMEDY PROBABLE CAUSE The wire rope does not 1. The hoist may be installed too close to Check the mounting distance and fleet spool smoothly on the the main sheave, increasing the fleet angle. Reposition the hoist as needed. cable drum.

  • Page 30: Exploded View And Parts Key

    EXPLODED VIEW For part numbers, refer to the Material List for your hoist.
  • Page 31 PARTS KEY ITEM NO. DESCRIPTION QTY. Sprag Clutch Assembly Brake Cylinder Assembly Primary Planet Carrier Assembly Output Planet Carrier Assembly Motor Assembly Auxiliary Brake Assembly Capscrew Auxiliary Brake Shaft Oil Level Sight Gauge Vent/Relief Plug Oil Seal Support End Plate Tie Plate (with holes for valve block) Cable Drum Closure Output Sun Gear...

  • Page 32: Hoist Disassembly

    5. Remove the capscrews and washers from the tie plates, and remove the tie plates. BRADEN recommends that the motor ONLY be removed from a hoist positioned on end as described above. A thrust washer located behind the input sun...
  • Page 33 9. Remove the over-running brake clutch assembly. Refer to "Brake Clutch Assembly" section for further information. NOTE: It may be helpful to mark the outboard end 6. Remove the hydraulic fitting from the brake cylinder of the inner and outer races of the brake clutch nipple.
  • Page 34 12. Remove the primary sun gear. 15. Remove the thrust bearing set from the planet car- rier. 13. Remove the cable drum closure. Install two (2) short ½-13 UNC bolts through a short length of chain, or insert two (2) ½-13 UNC eyebolts in to the puller holes.
  • Page 35 21. Turn the cable drum over and remove and discard the oil seal. Inspect the drum bearing for abnormal 18. Carefully lift the ring gear out of the drum. Inspect wear or damage. Replace as needed. the ring gear for abnormal wear, pitting or other damage.

  • Page 36: Brake Cylinder Service And Assembly

    BRAKE CYLINDER SERVICE 5. Turn the brake cylinder over, with the large end fac- 1. Place the brake cylinder assembly on a stable work ing up. Remove the retaining ring and the brake pis- surface with the large end down. Use the spring ton plate.
  • Page 37 BRAKE CYLINDER ASSEMBLY Back-up Rings O-Rings 5. Install the eight (8) belleville springs onto the spring guide. The first spring should rest against the snap 1. Lubricate the o-rings and back-up rings with clean ring on the spring guide, with the concave side oil and install them onto the brake piston.
  • Page 38 CAUTION Make certain that the threaded rod of the compres- sion tool is fully engaged into the lower plate. If a press is used, be careful to apply only as much pres- sure as required to allow removal of the retaining ring.

  • Page 39: Planet Carrier Service And Assembly

    PLANET CARRIER SERVICE 4. Inspect the roller bearings closely for wear or dam- age. Inspect the bearing rollers for spalling, corro- sion, discoloration, displaced material or abnormal wear. Inspect the bearing cage for unusual wear or deformation, particularly on the cage separator bars. Any damage that will impair the bearing cage's abil- ity to separate, retain and properly guide the rollers is cause for replacement.
  • Page 40 PLANET CARRIER ASSEMBLY 2. Using a small punch, align the holes in the shaft and carrier and insert a NEW spirol pin the carrier. NOTE: ALWAYS use new spirol pins when a carrier has been disassembled for any reason. Use of exist- ing pins can lead to improper fit and the pin backing out of position while in service.

  • Page 41: Auxiliary Brake Service And Assembly

    AUXILIARY BRAKE SERVICE 1. Carefully turn the auxiliary brake assembly over and place it with the end cover facing upward. Use the proper precautions to keep from damaging the bear- The brake piston weighs approximately 78 lbs (35 ing and seal surfaces at the end of the brake hous- kg).
  • Page 42 1. Place the brake housing into a supporting structure 9. Using 3/8-16 UNC eyebolts inserted in the lifting with the large end facing up. The supporting struc- holes, lower the piston into the brake housing. ture can be the motor end of the cable drum, the hoist ring gear, or other square-cut tubular structure that will allow the housing to clear the work surface The brake piston weighs approximately 78 lbs (35...

  • Page 43: Brake Clutch Service And Assembly

    BRAKE CLUTCH SERVICE 1. Remove the retaining ring and sprag bushing retain- 4. Remove the sprag bearing from the outer race. er from one end only. Inspect the sprag closely for abnormal wear, discol- oration, cracks, pitting or corrosion. Check the retainer clips between the cams for excessive wear, as seen by broken or missing clips, or bright spots on the outer face.
  • Page 44 BRAKE CLUTCH ASSEMBLY 5. Slide the inner race through the sprag clutch. The inner race will have to be rotated in the free- wheeling direction to start it into the sprag clutch. If the inner race will not go through the bushings, the bushings may have been damaged and may need replaced.

  • Page 45: Hoist Assembly

    HOIST ASSEMBLY 1. Clean all parts before reassembling. 5. If necessary, install the bearing into the cable drum bore, ensuring that it is fully seated against the shoulder in the bottom of the bore. Apply sealing compound to the outside diameter of the oil seal. Turn the spring side of the seal toward the bearing and press the seal into bore by applying constant, even pressure.
  • Page 46 8. Install the ring gear over the planet carrier assem- 12. Install the ring gear adapter, hub end facing up, bly. The ring gear teeth must mesh with the planet meshing the adapter with the ring gear teeth. gears. Ensure that the end with the deepest splines is installed over the planet carrier.
  • Page 47 16. Install the brake cylinder assembly over the primary 19. Install the brake plate spacer on top of the brake sun gear, making certain the splines on the brake stack. cylinder engage the ring gear adapter splines. 20. Measure the stack-up height of the brake stack 17.
  • Page 48 24. Install the motor adapter over the brake cylinder using the SPECIAL BRADEN capscrews and wash- ers. Torque to 110 lb-ft (150 N-m). DO NOT use standard capscrews to secure the motor adapter to the end plate.
  • Page 49 Refer to the oil specifications in required. Ensure all hoses follow correct routing "Preventive Maintenance" section of this manual, procedures and none are kinked or twisted. and the latest printing of BRADEN Service Bulletin 503.

  • Page 50: 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.
  • Page 51 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 connected directly to tank. DO NOT use the drain connection on the brake valve. See “TWO SPEED MOTOR CASE DRAIN PLUMBING”...

  • Page 52: Brake Valve Service

    BRAKE VALVE SERVICE This CH Series hoist is supplied with our Braden 1-1/2” ITEM DESCRIPTION QTY. brake valve. It is a reliable hydraulic valve with internal Valve Housing (NSS) components manufactured to close tolerances. Due to Check Valve Retainer (NSS)
  • Page 53 DISASSEMBLY 1. Remove the fitting, motor drain check ball and 3. Remove the check valve spring retainer, spring and spring. check valve poppet. 2. Remove the spool spring retainer and spool spring. Remove the spool plug and carefully remove the spool assembly.
  • Page 54 CLEAN AND INSPECT 1. Discard all O-rings and back-up rings. Clean all 2. Install new O-rings on the plug and spool retain- parts in solvent and blow dry. Inspect polished sur- ers. faces of spool and damper piston for damage that may cause binding or leakage.

  • Page 55: Metric Conversions

    METRIC CONVERSION TABLE English to Metric Metric to English LINEAR inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = 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)

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Ch230a series

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