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THEORY OF OPERATION

DESCRIPTION OF HOIST

The hoist has four basic component parts:

1. Hoist base
2. Hydraulic motor group
3. Brake cylinder and motor adapter
4. Cable drum with gear train

The hydraulic motor is bolted to the motor support which
in turn is bolted to the brake cylinder and the base. The
motor end of the drum, running on a ball bearing, is sup-
ported by the brake cylinder. The other end of the drum
runs on a ball bearing on the support bolted to the base.
The ring gear for the planetary gear train is machined into
the drum’s inside surface.

HOIST OPERATION

The  hydraulic  motor  drives  the  sun  gear  of  the  primary
planetary  gear  set  through  the  splined  inner  race  of  the
brake  clutch.  When  driven  by  the  sun  gear,  the  primary
planet  gears  walk  around  the  ring  gear  in  the  drum  and
drive the primary planet carrier.

The  primary  planet  carrier  drives  the  output  planet  sun
gear  which,  in  turn  drives  the  output  planet  gears.  The
output planet carrier is splined to the bearing support and
cannot rotate. Therefore, as the output planet gears are
driven by the sun gear, they will drive the ring gear/drum.

NOTE

The special order 07 (7:1) gear ratio has only one

planetary gear set

Dual Brake System – Description

The dual brake system consists of a dynamic brake sys-
tem and a static brake system.
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 to allow free
flow of oil to the motor in the hoisting direction and a pilot
operated, spring-loaded spool valve that blocks the flow of
oil  out  of  the  motor  when  the  control  valve  is  placed  in
neutral. When the control valve is placed in the lowering
position,  the  spool  valve  remains  closed  until  sufficient
pilot pressure is applied to the end of the spool to shift it
against  spring  pressure  and  open  a  passage.  After  the
spool valve cracks open, the pilot pressure becomes flow-
dependent and modulates the spool valve opening which
controls the lowering speed.

The static brake system has three operating components:

1. Spring Applied, Multiple Friction Disc Static Brake
2. Brake Clutch Assembly
3. Hydraulic Piston and Cylinder

NOTE

Some special order models have a solid hub for

brake effective both directions.

The static brake is released by the brake valve pilot pres-
sure  at  a  pressure  lower  than  that  required  to  open  the
pilot  operated  spool  valve.  This  sequence  assures  that
dynamic braking takes place in the brake valve and that
little, if any, heat is absorbed by the friction brake.

6

Winch Brake

Brake

Valve

Pump

Control

Valve

Winch Assembly

W/Brake Valve

& Static Brake

DR

BR

HYDRAULIC CIRCUIT

PUMP

CONTROL

VALVE

Motor

Winch 

Brake

Motor Code 010, 011, 012, 013

Motor Code 020, 029, & 039

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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