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3

GENERAL SAFETY
RECOMMENDATIONS

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 hoist 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 rules and regulations will

also apply.
1. Read all warning tag information and become familiar

with all controls before operating hoist.

2. Never  attempt  to  clean,  oil  or  perform  any  mainte-

nance on a machine with the engine running, unless
instructed to do so in the service manual.

3. Never operate hoist controls unless you are properly

seated  at  the  operators  station  on  the  prime  mover
and  you  are  sure  personnel  are  clear  of  the  work
area.

4. Assure that personnel who are responsible for hand

signals  are  clearly  visible  and  that  the  signals  to  be
used are thoroughly understood by everyone.

5. Ground  personnel  should  stay  in  view  of  the  prime

mover operator and clear of hoist drum.  Do not allow
ground  personnel  near  hoist  line  under  tension.    A
safe distance of at least 1

½

 times the working length

of the cable should be maintained.

6. On  machines  having  hydraulically,  mechanically

and/or  cable  controlled  equipment,  be  certain  the
equipment is either lowered to the ground or blocked
securely  before  servicing,  adjusting  and/or  repairing
the  hoist.    Always  apply  the  prime  mover  parking
brakes and lower equipment before dismounting the
prime mover.

7. Inspect  rigging,  hoist  and  hydraulic  hoses  at  the

beginning  of  each  work  shift.    Defects  must  be  cor-
rected before operating hoist.

8. Keep  equipment  in  good  operating  condition.

Perform  scheduled  servicing  and  adjustments  listed
in  the            "Preventive  Maintenance"  section  of  this
manual.

9. An  equipment  warm-up  procedure  is  recommended

for all start-ups and is essential at ambient tempera-
tures            below  +40ºF  (4.4ºC).    Refer  to  "Warm-up
Procedure"  listed  in  the  "Preventive  Maintenance"
section of this manual.

10.  Be sure of equipment stability before operating hoist.

11. The  winches  described  herein  are  neither  designed

nor intended for use or application to equipment used
in  the  lifting  or  moving  of  persons  unless  specially
equipped  from  the  factory.    Refer  to  preventative
maintenance section for more information.

12. Do not exceed the maximum pressure (PSI/ kPa) or

flow (GPM/ LPH) stated in the hoist specifications.

13. Operate hoist line speeds to match job conditions.

14. Never  handle  the  cable  when  hook  end  is  free  and

wear protective gloves when handling wire rope.

15. When  winding  hoist  cable  on  the  hoist  drum,  never

attempt to maintain tension by allowing hoist cable to
slip  through  hands.    Always  use  "hand-over-hand"
technique.

16. Follow wire rope manufacturer’s guidelines and appli-

cable standards (such as ASME and API) for rigging
and inspecting wire rope.

17. Do not weld on any part of the hoist.

18. Use recommended hydraulic oil and gear lubricant. 

19. Keep hydraulic system clean and free from contami-

nation at all times.

20. Use correct size cable anchor for cable and pocket in

hoist drum.

21. The BRADEN wire rope anchors are capable of sup-

porting  the  rated  load  when  installed  properly.    For
additional safety, ALWAYS maintain a minimum of five
(5) wraps of wire rope on the drum.

FAILURE TO OBEY THE FOLLOWING SAFETY REC-
OMMENDATIONS  MAY RESULT IN  PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.

Summary of Contents for BRADEN Gearmatic BG6A

Page 1: ...BG6A BG6B HYDRAULIC PLANETARY HOIST PACRWINCH DIVISION P O BOX 547 BROKEN ARROW OK U S A 74013 PHONE 918 251 8511 FAX 918 259 1575 www paccarwinch com LIT2286 R2 5 2010 Printed in U S A Copyright 201...

Page 2: ......

Page 3: ...E CLUTCH SERVICE 22 23 PLANET CARRIER SERVICE 24 25 HOIST ASSEMBLY 26 29 REVERSING DIRECTION OF DRUM ROTATION 30 FASTENER TORQUE CHART 32 METRIC CONVERSION TABLE 33 Safety informational callout s used...

Page 4: ...259 1575 Provide the complete hoist model number and serial number when making inquiries The model and serial num bers are stamped into the data plate attached to the base to the left of the hydraulic...

Page 5: ...t the beginning of each work shift Defects must be cor rected before operating hoist 8 Keep equipment in good operating condition Perform scheduled servicing and adjustments listed in the Preventive M...

Page 6: ...7 88 LOWER PORT SAE 16 ORB 1 5 16 12 ORB 1 57 4 12 A HOIST PORT SAE 16 ORB 1 5 16 12 THD MOTOR A B 020 20 06 3 81 029 20 56 4 06 039 21 01 4 32 6 25 12 50 1 75 LOWERING PORT SAE 10 ORB 7 8 14 THD 62 1...

Page 7: ...4 THD 62 15 28 8 00 63 3 75 15 00 6 63 87 MOTOR A B 020 20 58 4 07 029 21 08 4 32 039 21 08 4 32 A B 656 4 Holes 4 04 15 91 3 78 3 75 6 63 14 56 15 00 63 15 28 88 1 22 10 26 8 00 67 7 28 7 84 HOIST PO...

Page 8: ...tem The dynamic brake system has two operating compo nents 1 Brake valve assembly 2 Hydraulic motor The brake valve is basically a counterbalance valve with improved metering It contains a check valve...

Page 9: ...l sufficient pilot pressure is present to open the brake valve The friction brake with in the hoist will completely release at a pressure lower than that required to open the brake valve The extent to...

Page 10: ...in temperature Maximum cold weather start up viscosity should not exceed 5 000 SUS with a pour point at least 20o F 7oC lower than the minimum ambient temperature Under continuous operating conditions...

Page 11: ...d an oil from a different temperature range would be more appropriate Oil viscosity with regard to ambient temperature is critical to reliable brake operation Make certain that the gear oil viscosity...

Page 12: ...ompounds EP 220 PREVAILING AMBIENT TEMPERATURE oF 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF AGMA 5 EP ISO VG 220 AGMA 4 EP ISO VG 150 SYNTHETIC OR EQUIVALENT oC 40 30 20 10 0 10 20 3...

Page 13: ...Install a pressure gauge in the haul in port and apply a stall pull on the hoist If pressure is low increase relief valve setting until recommended pressure is obtained NOTE If pressure does not incr...

Page 14: ...m up procedure in Preventive Maintenance section Same remedy for F1 D Brake will not hold when control valve is returned to neutral after lifting a load 1 Excessive system back pressure acting on the...

Page 15: ...rator training as required Remove oil level plug and check oil level Fill to proper level See Hoist Installation section for control valve specifica tions G The hoist runs hot 1 Same as A 5 2 Be certa...

Page 16: ...7 OIL SEAL 1 28 BALL BEARING 2 29 SNAP RING 1 31 O RING 1 32 OIL SEAL 1 33 LOCKWASHER 6 34 CAPSCREW 6 ITEM DESCRIPTION QTY 49 16166 8 PLUG 1 51 DRIVE SCREW 4 53 LOCKWASHER 6 54 CAPSCREW 6 55 CABLE WED...

Page 17: ...AP RING 1 372 SNAP RING 1 400 OUTPUT PLANET CARRIER ASY 1 406 OUTPUT PLANET CARRIER 1 407 OUTPUT PLANET GEAR 3 408 OUTPUT PLANET GEAR SHAFT 3 409 ROLLER BEARING 6 410 BEARING SPACER 3 411 THRUST BEARI...

Page 18: ...assembling hoist HOIST DISASSEMBLY 1 Disconnect all hoses and fittings at the hoist 2 Stand the hoist on the bearing support plate Remove the brake release tube assembly 59 between the brake valve blo...

Page 19: ...drum for nicks spalling or excessive wear Replace the drum if wear is greater than 0 015 in 0 4 mm when compared to unworn area of teeth 2 Install new bearings in the drum if replacement is nec essary...

Page 20: ...eparator plates and motor sup port Note groove on outside diameter of motor support Although most photos in this section show splined discs all procedures are the same except where specifically noted...

Page 21: ...eplace steel disc if splines are worn to a point disc is distorted or heat discolored 5 Check brake spring free length minimum free length is 15 16 in 23 8 mm Check springs for any sign of cracking or...

Page 22: ...must rise above uppermost flange 080 in 2 mm maximum and 000 in 00 mm If the gap exceeds the maximum limit there are too many brake discs in stack up or the discs are distorted If the gap is less tha...

Page 23: ...0 psi 0 13 800 kPa gauge and shut off valve to this fitting Apply 1000 psi 6 900 kPa to the brake Close shut off valve and let stand for five 5 minutes If there is any loss of pressure in five 5 minut...

Page 24: ...assembly If disassembly is necessary remove the bushing according to the procedure covered in Step No three 3 All brake clutch assembly parts should be thoroughly cleaned and inspected before assem bl...

Page 25: ...t it through the sprag clutch If the inner race will not go through the bushings the bushings have probably been damaged and should be replaced 6 Turn the assembly over with the snap ring down Install...

Page 26: ...terial displacement or abnormal wear the bearing should be replaced Likewise the cage should be inspected for unusual wear or deformation particularly the cage bars If there is any damage that will im...

Page 27: ...ce Always use NEW roll pins When properly posi tioned 50 of the roll pin will engage the planet gear shaft and 50 will remain in the planet carrier 4 Note that the roll pin is slightly recessed in the...

Page 28: ...ith petroleum jelly or gear oil and install in base and drum 4 Tighten the bearing support capscrews to the recom mended torque 5 Stand hoist on bearing support end Install the output sun gear and thr...

Page 29: ...quired Use sealant on the outside surface of the oil seal Install with spring side of the seal toward bearing using a flat plate to avoid distortion Install a new O ring in the groove on the O D of th...

Page 30: ...i to the brake release port The brake discs will move freely with the brake released 14 Install the hoses and fittings to the brake cylinder release port 15 Install a new O ring on the motor pilot the...

Page 31: ...brake and close the shut off valve Let the brake stand for five 5 minutes If there is any loss of pressure the brake pack should be disassembled for inspection of the sealing surfaces and the brake p...

Page 32: ...y smooth the assembly should be replaced 30 REVERSING DIRECTION OF DRUM ROTATION Motor Case Drain Brake Release Circuit Brake Release Circuit Hoisting Port Motor Case Drain Motor Brake Valve M Lowerin...

Page 33: ...he original capscrews and tighten to recommended torque 10 Connect the motor case drain hose to the motor case drain port 11 If your winch had the brake release hose connected directly to the motor th...

Page 34: ...void using thread lubricants as the applied torque may vary by 10 40 depending upon product used Dry Lubed Dry Lubed Dry Lubed Dry Lubed Torque LB FT Grade 5 Grade 8 1 4 20 28 5 16 3 8 18 24 16 24 7 1...

Page 35: ...Hg 60o F pounds sq in PSI X 6 895 kilopascals kPa kilopascals kPa X 0 145 pounds sq in PSI pounds sq in PSI X 0 0703 kilograms sq cm kg cm2 kilograms sq cm kg cm2 X 14 22 pounds sq in PSI pounds sq i...

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