Table of Contents
Summary of Contents for Paccar Winch BRADEN PD21A Series
- Page 1 BRADEN PD21A PLANETARY HOIST INSTALLATION, MAINTENANCE AND SERVICE MANUAL PACR WINCH DIVISION P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013 LIT2158 R2 PHONE (918) 251-8511 FAX (918) 259-1575 9/2007 www.paccarwinch.com Printed in U.S.A.
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Page 2: Table Of Contents
TABLE OF CONTENTS FOREWORD ............2 MODEL &... -
Page 3: Foreword
FOREWORD The following service instructions have been prepared to provide assembly, disassembly and maintenance infor- mation for the BRADEN Model PD21A series hoist. 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 hoist. -
Page 4: Glossary Of Terms
GLOSSARY OF TERMS 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 low- ering 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
28. Whenever possible, install the hoist in a location 13. Do not weld on any part of the hoist without that is not immediately adjacent to a “normal” oper- approval from PACCAR Winch Engineering. ator’s station. 14. Use recommended hydraulic oil and gear lubricant. - Page 6 30. Before operating the hoist, be sure ALL safety pro- If there is any question regarding the preceding safety cedures for the equipment or vehicle the hoist is recommendations, or the safe operation of your hoist, mounted on are properly followed and/or in place. please contact the Braden Product Support Department at 1-918-251-8511, Monday through Friday from 0800 to 1630 hours, CST, by fax at (918) 259-1575, or via the...
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Page 7: Basic Operation
BASIC OPERATION DESCRIPTION OF HOIST The PD21A hoist is made up of the following sub- assemblies: 1. Hydraulic motor and brake valve 2. Brake cylinder and brake clutch assembly Figure 2 3. Hoist base components Static 4. Hoist drum and gear train Motor Brake (Refer to illustration on page 8) - Page 8 The static brake is released by the brake valve pilot rotate the motor through its own internal leakage. This pressure at a pressure lower than that required to open feature results in a very slow speed and extremely the pilot operated spool valve. This sequence assures accurate positioning.
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Page 9: Exploded View Of Major Components
PD21A COMPONENTS Support End Bracket Detail Drum & Gear Train Base Components Motor & Brake Cylinder & Brake Valve Brake Clutch... -
Page 10: Installation
INSTALLATION GENERAL REQUIREMENTS 1. The hoist must be mounted with the centerline of the drum in a horizontal position. The mounting plane can be rotated to any position around this centerline, providing the vent DO NOT use a control valve with any detents or latching plug is positioned above the oil level. - Page 11 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.
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Page 12: Hoist Operation
HOIST OPERATION The following warnings and instructions are basic to safe hoist operation. Please read them carefully and follow them each time your hoist is operated. These instructions are provided in addition to any information furnished by the Original Equipment Manufacturer. Equipment operators should be completely familiar with the overall opera- tion of the piece of equipment on which the hoist is mounted (i.e. -
Page 13: Hydraulic Circuit
TYPICAL HYDRAULIC CIRCUIT NOTE: The hydraulic circuit shown below is representative of typical Braden hoists. Options and accessory equip- ment may result in changes to the circuit shown. If there are any questions regarding the hydraulic circuit, refer to information supplied by the original equipment manufacturer, or contact the Braden Product Support Department at the number given in the Foreword of this manual. -
Page 14: Preventive Maintenance
PREVENTIVE MAINTENANCE A regular program of preventive maintenance for your RPM with the hydraulic hoist control in neutral allow- planetary hoist is required to minimize the need for ing sufficient time to warm up the system. The hoist emergency servicing and promote safe, reliable hoist should then be operated at low speeds, hoisting and operation. -
Page 15: Recommended Gear Oil
The gear oil should be changed whenever the ambi- To change the gear oil, slowly rotate the drum until ent temperature changes significantly and an oil the oil drain plug is aligned with the lower oil port from a different viscosity range would be more access hole. -
Page 16: Oil Sampling And Analysis
Tear-down Inspection Any deficiency must be corrected immediately. Any hoist that has not been subjected to regular oil Before placing the hoist back in service, the rebuilt hoist sample analysis should undergo a tear-down inspection must be pull tested to the rated load of the hoist with a every 24 months. -
Page 17: Troubleshooting
TROUBLESHOOTING The following troubleshooting section is provided as a general guide. You may also need to contact the Original Equipment Manufacturer (OEM) for additional information. If a hoist exhibits any sign of: - Erratic operation such as poor load control, load creeping down or chattering. - Unusual noise. - Page 18 TROUBLE PROBABLE CAUSE REMEDY 1. Same as A2. Oil leaks from vent plug. Same as A2. 2. Motor seal may be defective as a Case drain back pressure must result of high back pressure in not exceed 70 psi (480 kPa). the motor case drain circuit or Inspect hydraulic system for a contaminated oil.
- Page 19 TROUBLE PROBABLE CAUSE REMEDY “D” C B. Apply a stall pull load on the hoist ROUBLE ONTINUED while monitoring pressure. REVIOUS C. Compare gauge reading to hoist specifications. Adjust relief valve as required. NOTE: If pressure does not increase in proportion to adjust- ment, relief valve may be con- taminated or worn out.
- Page 20 TROUBLE PROBABLE CAUSE REMEDY 1. Same as D2. Same as remedies for Trouble D2. Hoist “chatters” or surges while rais- ing rated load. 2. Hydraulic oil flow to motor may be Same as remedies for Trouble E2. too low. Conduct operator training as required. 3.
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Page 21: Disassembly Procedure
DISASSEMBLY PROCEDURE 1. Remove the wire rope from the drum and wind onto 9. Grasp the input sun gear shaft and lift the input a cable reel as recommended by the wire rope man- planetary carrier assembly from the drum. ufacturer. -
Page 22: Planetary Carrier Service
PLANETARY CARRIER SERVICE Disassembly Assembly 1. With a pin-punch, drive the spirol pins into the plan- 1. Place the planetary carrier on a clean work surface et gear shafts until the spirol pins clear the planetary with the splined collar facing up. carrier. - Page 23 Output Planet Carrier Assembly Item Description Quantity Output Planetary Carrier Output Planet Gear Output Planet Gear Shaft Thrust Washer Bearing Rollers Spirol Pin Bearing Spacer Item Description Quantity Primary Planetary Carrier Primary Planet Gear Primary Planet Gear Shaft Thrust Washer Bearing Rollers Spirol Pin Output Sun Gear...
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Page 24: Over-Running Clutch Service
OVER-RUNNING CLUTCH SERVICE to carefully tap the remaining bearing (44) out of the outer race (42). The over-running clutch (46) may be removed from the inner race. Closely inspect the polished surfaces of the over-running clutch cams and the races. Check for wear, scoring, pitting or heat discoloration. -
Page 25: Brake Cylinder Service
BRAKE CYLINDER SERVICE Item Description Quantitiy Brake Cylinder Housing Motor Adapter Steel Separator Discs Friction Discs Piston Seal Piston Back-up Ring Pressure Plate Brake Plate Spacer Brake Spring Spring Spacer O'ring Back-up Ring O'ring Capscrew Lockwasher Expansion Plug Disassembly Clean and Inspect CAUTION The motor adapter is under spring tension from the brake springs. - Page 26 material must appear even across the entire surface 5. Measure the brake spring free length. The minimum with a groove pattern visible. Replace the friction free-length is 1 7/16 in. (36.5 mm). Inspect the discs if the splines are worn to a point, the disc is springs for any signs of cracking or fatigue.
- Page 27 NOTE: The close fitting piston backup ring (6) may BRAKE CYLINDER PRESSURE TEST be depressed slightly to one side to lodge it in the 1. Install a -6 ORB fitting into the brake release port on brake cylinder bore and temporarily hold the pres- the motor adapter.
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Page 28: Hoist Assembly
HOIST ASSEMBLY (Refer to illustration on page 8) 1. Thoroughly clean the machined surfaces of the cast the drum, you may have installed the primary thrust base (61). Make sure the tapped holes, end plate pad upside down and the gear train must be and bottom mounting surfaces are free of paint and removed to check this condition. -
Page 29: Motor Group Illustrations
13. Turn the two jam nuts on the rotation sensor (144) bly, from the brake valve and motor lowering port to produce an installed length of the threads of 1.21 manifold to the brake release port on the brake in. (30.7 mm) measured from the bottom of the sen- cylinder. -
Page 30: Brake Valve Service
BRAKE VALVE SERVICE The BRADEN brake valve is a reliable hydraulic valve with internal components manufactured to close tolerances. Due to the close tolerances and mating of components, the valve housing, spool, piston and check poppet are not available as replacement parts. Before disassembling the brake valve, be sure you have conducted all applicable troubleshooting operations and are certain the brake valve is causing the malfunction. - Page 31 2. Install new o-rings and back-up rings on the spool and damper piston as shown. It is important that each back-up ring is on the correct side of its o-ring. Take care not to cut the o-rings during assembly. Let the spool and damper piston set for ten minutes before installing them in their respective bores.