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CSB0033 - Allied Systems Company

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1. QUARTERLY SEMI ANNUALLY 3 months 6 months Ql Ql REQUIRED REQUIRED QUARTERLY SEMI ANNUALLY 3 months 6 months Ql Ql REQUIRED FOR IDLED UNITS WITH UNKNOWN MAINTENANCE AND REPAIR HISTORY IT IS HIGHLY RECOMMENDED THAT THE HOIST UNDERGO A TEAR DOWN INSPECTION PRIOR TO BEING PLACED INTO SERVICE IF PERSONNEL LIFTING IS EXPECTED WITH SUCH A HOIST A TEAR DOWN INSPEC TION IS REQUIRED BEFORE USE Pre Use or Daily Inspection Must include but is not limited to the following inspec tions that will be performed prior to placing the crane into service and then as necessary during extended opera tion This inspection must be performed by a qualified crane operator or qualified crane inspector 1 Check for external oil leaks and repair as necessary CSB0033 PAGE 2 of 10 This is extremely important due to the accelerated wear that will result from insufficient lubricating oil in the hoist Hoists with a sight glass check oil level daily Hoists without a sight glass check oil level monthly if no external oil leaks are detected Lubri cant level must be maintained between the minimum and maximum levels midway up sight glass or at bottom of level plug port as equipped Use only the recommended type of lubricant Refer to the spe cific hoist service manual and or the latest revision Braden Service Bulletin 503 2 Check the ratchet and pawl mechanism if equipped for proper operation and full spring force enga
2. month Severe Duty Crane hoist is operated more than 200 hours per month OR where 50 of the lifts exceed 75 of the Braden rated capacity for the hoist Allied Systems Co reserves the right to make changes to new equipment without incurring the obligation to make such changes to equipment previously manufactured Printed in USA The following chart lists the inspections that are required for each type of usage category PRE USE DAILY INSPECTION INSPECTION USAGE CATEGORY REQUIRED REQUIRED IDLED Not used for 3 IN IN months or longer SERVICE Qo Ql SERVICE Qo al INFREQUENT USAGE less than ten hours per month REQUIRED Qo Ql REQUIRED QO QI MODERATE USAGE 10 50 hours per month REQUIRED REQUIRED QO QI QI REQUIRED QO QI REQUIRED MONTHLY QO QI HEAVY USAGE 50 200 hours per month SEVERE USAGE 200 hours per month or 50 of lifts exceed 75 rated capacity REQUIRED REQUIRED QO QI QI QO Qualified Operator QI Qualified Inspector NOTE QUARTERLY SEMI ANNUAL INSPECTION BEFORE PLACED BEFORE PLACED BEFORE PLACED ANNUAL INSPECTION TEAR DOWN INSPECTION REQUIRED REFER TO IN NOTE 1 SERVICE QOo Ql 5 YEARS 3 YEARS IF NOT SUBJECT TO FULL INSPECTION PROGRAM REQUIRED REQUIRED Qo Ql Ql 4 YEARS 2 YEARS IF NOT SUBJECT TO FULL INSPECTION PROGRAM REQUIRED REQUIRED Ql Ql 3 YEARS 1 5 YEARS IF NOT SUBJECT TO FULL INSPECTION PROGRAM REQUIRED
3. If a sample shows a sud den rise in contaminant level action should be taken to determine what has changed NOTE OIL ANALYSIS CANNOT DETECT NOR WARN AGAINST A FATIGUE FAILURE CSB0033 PAGE 5 of 10 BRAKE TEST PROCEDURE FOR BRADEN Gearmatic HOISTS All BRADEN planetary hoists have a spring ap plied hydraulically released multiple disc brake inside the hoist housing Gearmatic hoists have a large single brake disc This brake holds a sus pended load when the directional control valve is in neutral or when hydraulic power is lost A brake clutch assembly permits the power train and drum to rotate in the direction to lift a load while the brake remains fully applied A load cannot be lowered however without applying hydraulic pres sure to the release port and releasing the brake Hoists ordered for personnel handling cranes will have a needle valve in the brake release line They will also have a tee in the brake release line between the needle valve and the brake release port on the hoist One opening in the tee is capped With the valve closed and the cap removed from the tee the brake is isolated from system pressure and vented to atmosphere The brake cannot be released under these conditions by actuating the directional control valve One purpose of the valve tee combination is to provide a means to test the brake the other is to provide a means to lower a load when hydraulic power is lost BRAKE RELEASE POR
4. is highly recommended that the hoist undergo a tear down inspection prior to being placed into service NOTE OIL ANALYSIS ALONE CANNOT DE TECT NOR WARN AGAINST COMPONENT FATIGUE FAILURE CSB0033 PAGE 4 of 10 A tear down inspection includes the hoist being com pletely disassembled cleaned inspected and repaired as required Replacement of all worn cracked corrod ed or distorted parts such as pins bearings shafts gears brake rotors brake plates drum and base should occur as required All seals and O rings should be replaced at this time Any deficiencies including but not limited to those above shall be corrected immediately All of the following operations MUST be performed BEFORE the hoist is placed back into service l The rebuilt hoist MUST be line pull tested to the rated load of the hoist hoist rating will vary with motor gear ratio and drum options with a dyna mometer or equivalent load measuring device This test load shall be the maximum rating of the hoist for the specific application at the normal relief valve setting for the hoist NOT the reduced rating used for personnel lifts 2 The hoist must be dynamically tested by rotating the drum several times in both the hoisting and lower ing directions while under a load of at least 30 of the hoist lifting capacity Check for smooth operation during this procedure 3 The hoist internal friction brake shall be tested per the procedures on pag
5. the motor from running dry 4 Fill the standpipe with hydraulic oil making certain that oil is not running out of the brake valve If oil is running out of the brake valve stop the emergency lowering procedure Remove the spring retainer CSB0033 PAGE 8 of 10 and tap the main spool of the brake valve to the closed position Replace the spring retainer After completing the emergency lowering procedure the brake valve MUST be serviced and repaired if the spool was stuck 5 Connect a hand pump to the open port in the tee 6 Slowly operate the hand pump up to no more than 1 000 psi 6 900 kPa A suspended load will slowly come down when the static brake is re leased Releasing the pressure on the hand pump will cause the load to stop If a chattering noise is heard while the load is coming down pump the hand pump to a slightly higher pressure until the A WARNING DO NOT TOUCH THE MOTOR BRAKE VALVE OR STANDPIPE WHILE LOWER ING A LOAD THEY MAY BECOME HOT ENOUGH TO CAUSE BURNS noise stops Do not exceed 1 500 psi 10 350kPa to the brake release port 7 Always remove the hoist from service to inspect the brake components for signs of overheating and replace if necessary following this procedure Refer to the applicable Braden or Gearmatic service manual for details 8 If this procedure was performed due to a ma func tion of the hoist remove the hoist from service and perform a complete teardown and inspecti
6. AKE CLUTCH SLIP PAGE MAKE CERTAIN THAT THE GEAR OIL VISCOSITY USED IN YOUR HOIST IS CORRECT FOR YOUR PREVAILING AMBI ENT TEMPERATURE CSB0033 PAGE 3 of 10 Tear down Inspection Tear down inspections of BRADEN hoists should be completed per the usage schedule defined below Magnetic Particle Inspection MPI of the internal ring gear and reduction gears must be performed during tear down inspections to aid in the detection of cracks in the ring gears due to fatigue The preferred inspec tion method is the Fluorescent Wet Magnetic Particle Inspection using ultraviolet light consistent with ASTM E709 For further information related to this inspec tion and for testing of the older CH150 ring gears P N 24446 refer to BRADEN Service Bulletin LIT2162 Severe Duty Perform tear down inspection MPI an nually Heavy Usage Perform tear down inspection MPI at least every 3 years Moderate Usage Perform tear down inspection MPI at least every 4 years Infrequent Usage Perform tear down inspection MPI at least every 5 years It is strongly recommended that any moderate or infre quent usage hoist that is also used for personnel lifting undergo tear down inspections on a maximum basis of once every 3 years Any hoist that has NOT been subject to regular oil sample analysis must undergo a tear down inspec tion on an annual 12 month basis Also if a hoist has an unknown history of repair and or maintenance it
7. SERVICE BULLETIN Tel 503 625 2560 Allied MARINE CRANE EE A Division of Allied Systems Company 2300 Oregon Street Sherwood Oregon 97140 9799 USA Fax 503 625 7616 DATE January 8 2007 BULLETIN NO CSB0033 PAGE 1 of 10 SECTION Operation amp Service MODEL S All Subject Inspection Testing Preventive Maintenance and Special Operating Instructions For Braden Gearmatic Planetary Hoists A WARNING READ AND UNDERSTAND THESE ENTIRE INSTRUCTIONS BEFORE OPERATING OR SERVICING YOUR BRADEN GEARMATIC HOIST RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE FAILURE TO PROPERLY OPERATE MAINTAIN AND SERVICE A HOIST MAY LEAD TO LOSS OF LOAD CONTROL AND RESULT IN PROPERTY DAMAGE SERIOUS INJURY OR DEATH These instructions apply to the following planetary hoists PD5 GH5 BG6 any design series PD7 BG8 any design series Equal Speed only PD 12 any design series PD15B B design series only PDI7A CH150A CH175A CH185A CH210A CH230A CH240A CH330A CH400A CH500A CH600A CH640 CH22B B design series only GH30 GH50 with external motor amp brake valve ANY TIME A HOIST EXHIBITS ERRATIC OPERATION AND OR UNUSUAL NOISE THE HOIST MUST BE TAKEN OUT OF SERVICE UNTIL IT IS INSPECTED AND SERVICED BY A QUALIFIED TECHNI CIAN CONTINUED OPERATION OF A HOIST WITH A DEFECT IN A CRITICAL COMPONENT MAY LEAD TO LOSS OF LOAD CONTROL PROPERTY DAMAGE SERIOUS INJURY OR DEATH Record Retention A l
8. T ON WINCH NEEDLE VALVE ae q Ll Si BR PORT COUNTERBALANCE VALVE aaa MOTOR CASE DRAIN DR PORT ON COUNTERBALANCE VALVE LOWERING PORT Brake Test Procedure Hoists Equipped With Brake Valves Test to be performed with no load on the hoist Remove the lockwire on the needle valve handle and close the valve tightly Remove the plug or cap in the tee in the brake re lease circuit With the hydraulic power unit running move the directional control valve handle slowly to the full open lowering position Increase the engine speed if necessary to bring sys tem pressure up to the relief valve setting The hoist drum should remain stationary If the drum rotates the hoist should be disassembled CSB0033 PAGE 6 of 10 i awp Relative location of needle valve to other components and fittings on the winch motor and counter balance valve af ON MOTOR and the brake components should be examined for wear In addition the brake springs should be measured for correct free length in those hoists using helical compres sion springs Replace any parts showing excessive wear and any spring whose length is shorter than the minimum shown in the applicable hoist Service Manual Reassemble the brake and hoist and repeat the above steps When testing is complete be sure to reinstall the plug or cap in the tee fully open the needle valve and install lockwire to secure the valve in posit
9. e 6 of this manual 4 After inspection or rebuild and testing a new cer tificate for personnel handling shall be issued by the inspector service technician effective on the date the hoist is placed back in service A sample certificate is shown below and shall include at a minimum all of the information depicted here Name of Service Company Approved by BRADEN for handling personnel if used and maintained in accordance with BRADEN 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 Oil Change The hoist gear oil must be changed after the first 100 operating hours then on an annual basis at a minimum thereafter In severe duty applications the gear oil should be changed every six months Use the recom mended lubricants Refer to the applicable hoist service manual or Braden Service Bulletin 503 Rev 3 or later for the recommended lubricants Gear Oil Sampling and Analysis Proper gear oil sampling and analysis is a vital part of a comprehensive preventive maintenance program Information obtained from the oil analysis allows the maintenance technician to substitute preventive maintenance for more costly unscheduled down time or a far more dangerous failure Early detection of accelerated component wear allows the
10. e lubricant from the hoist gear cavity as described on page 5 and analyze it for wear metals content correct viscosity lubricant deterioration moisture and other contaminants If the oil sample contains an high amount of metallic particles the hoist must be taken out of service to undergo a tear down inspection NOTE OIL ANALYSIS CANNOT DETECT NOR WARN AGAINST A FATIGUE FAILURE Annual Inspection This inspection must be carried out by a qualified crane inspector The annual inspection MUST include but not be limited to the following 1 Perform the Pre Use Daily Inspection Quarterly inspection and Semi Annual Inspection 2 Change the lubricating oil in the hoist gear cavity after an oil sample has been taken as described on page 5 Refill the hoist to the proper level with recommended lubricant Refer to Braden Service Bulletin 503 Rev 3 AX WARNING FAILURE TO USE THE PROPER TYPE AND VISCOSITY OF PLANETARY GEAR OIL MAY CONTRIBUTE TO INTERMITTENT BRAKE CLUTCH SLIPPAGE WHICH COULD RESULT IN PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH SOME GEAR LUBRICANTS CONTAIN LARGE AMOUNTS OF EP EXTREME PRESSURE AND ANTI FRICTION ADDITIVES WHICH MAY CONTRIBUTE TO BRAKE CLUTCH SLIPPAGE OR DAMAGE TO BRAKE FRIC TION DISCS OR SEALS OIL VISCOSITY WITH REGARD TO AMBIENT TEMPERTURE IS ALSO CRITICAL TO RELIABLE BRAKE CLUTCH OPERATION OUR TESTS IN DICATE THAT EXCESSIVELY HEAVY OR THICK GEAR OIL MAY CONTRIBUTE TO INTERMITTENT BR
11. gement of the pawl with the ratchet wheel Adjust or repair as necessary 3 Check hydraulic fittings and hoses for chaffing dete rioration or corrosion and repair as necessary 4 Visually inspect for corroded loose or missing bolts pins or other fasteners and replace or tighten as necessary 5 Visually inspect rotation indicator transmitters anti two blocking switches and other safety equipment and repair as necessary Quarterly Inspection every three months Must include but is not limited to the following inspec tions that must be performed by a qualified crane operator or qualified crane inspector A qualified crane inspector shall perform inspections on cranes assigned a moderate heavy or severe usage category 1 Perform the pre use inspection 2 On hoists used for personnel handling the internal spring applied brake shall be tested in accordance with the procedure on page 6 of these instructions 3 Inspect for corrosion of fasteners hoist base drum etc and repair replace as required to maintain the structural integrity of the hoist Semi Annual Inspection every six months Must include but is not limited to the following inspec tions that must be performed by a qualified crane operator or qualified crane inspector A qualified crane inspector shall perform inspections on cranes assigned a moderate heavy or severe usage category 1 Perform the Pre Use and Quarterly inspections 2 Take a sample of th
12. ion The above procedure utilizes the hoist hydraulic motor to test the brake s ability to resist approximately 115 of the rated hoist load Brake Test Procedure For Standard Hoists Not Equipped With The Needle Valve Test to be performed with no load on the hoist Remove and cap or plug the brake release line from fitting in the hoist brake release port With the hydraulic power unit running move the directional control valve handle slowly to the full open lowering position Increase the engine speed if necessary to bring system pressure up to the relief valve setting The hoist drum should remain stationary If the hoist drum rotates the hoist should be disas sembled and the brake components should be exam ined for wear In addition the brake springs should be measured for the correct free length in those hoists using helical compression springs Replace any parts showing excessive wear and any spring whose free length is shorter than the minimum shown in the applicable hoist Service Manual Reassemble the brake and hoist and repeat the above steps When testing is complete reattach the brake release line to the brake release port fitting The above procedure utilizes the hoist hydraulic motor to test the brake s ability to resist approximately 115 of the rated hoist load CSB0033 PAGE 7 of 10 EMERGENCY LOWERING PROCEDURES FOR HOISTS WITH GEAR MOTORS The following procedure releases the multip
13. latform as described in API OSHA or ANSI ASME standards e The crane must be in good working order and equipped with all required safety equipment including an anti two blocking device or warning signal and a boom angle and length indicator Two blocking occurs when the load block or hook assembly comes in con tact with the upper block or point sheave assembly and often results in damage to the wire rope rigging crane and or hoist e Personnel being lifted or supported shall wear safety belts with lanyards attached to designated points unless lifting over water If lifting over water provide approved personal flotation devices PFD s e The lift shall be made under controlled conditions and under the direction of an appointed qualified signal per son e The operator and signal person shall conduct a test lift without personnel in the personnel platform to verify adequacy of the crane footing or support The crane outriggers if so equipped must be fully extended and properly set e Cranes shall not travel move locations while per sonnel are on the personnel platform e The platform must be landed or tied off and all brakes set before personnel enter or exit If there are any questions concerns or conflicts with other safety standards contact the BRADEN Product Support Department PO Box 547 Bro ken Arrow OK 74013 USA Telephone 1 918 251 8511 or via e mail at winch service paccar com Additi
14. le disc brake while leaving the brake valve closed Since gear type motors are not zero leakage devices inter nal motor leakage permits the load to slowly rotate the motor although its outlet is blocked by the closed brake valve This procedure will NOT work if there is little or no oil in the motor Using properly rated pipe and fittings the standpipe described below may be permanently installed in the hydraulic system to avoid installing one in an emergency 1 Remove the lockwire on the needle valve handle and close the valve tightly A WARNING THE STANDPIPE REFERRED TO IN STEP 3 BELOW MUST BE USED ATTEMPT ING THIS PROCEDURE WITH NO OIL IN THE MOTOR OR WITH THE BRAKE VALVE STUCK IN THE OPEN POSITION WILL CAUSE THE LOAD TO FREE FALL WHICH COULD RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH 2 Remove the plug in the tee 3 Remove both main hoses from the motor Attach a standpipe to the lowering motor port opposite side of the motor from the brake valve Install a plug into the hoisting port in the brake valve The standpipe is simply a length of pipe approximately 12 inches 305 mm long attached to a 90 elbow The other end of the elbow is attached to the lowering motor port or manifold The standpipe is installed with the long open end pointing up in a vertical position to serve as a small reservoir While the load is being lowered hydraulic oil MUST be added to the stand pipe as necessary to prevent
15. og of written dated and signed records of ALL inspec tions load tests maintenance repairs or modifications must be kept readily available in an appropriate location for a minimum of four 4 years To provide custom ers with qualified outlets for hoist service and repairs BRADEN has established authorized Service Centers These Service Centers have factory trained service technicians up to date service information extensive parts inventories complete testing facilities and are Usage and Inspection Inspection procedures for hoists are divided into five general categories based upon their usage or duty cycle which in turn determines different appropriate intervals for inspections The usage categories must be assigned by the crane user on a consistent crane by crane basis The five crane hoist usage categories are as follows Idled The crane hoist has not been used for three months audited by BRADEN on a regular basis for compliance BRADEN strongly recommends the use of BRADEN au thorized Service for maintenance repair and inspection of BRADEN Gearmatic products Contact the Braden Technical Support Department at 918 251 8511 for the names of current authorized Service Centers Infrequent Usage The crane hoist is used less than ten hours per month based on a three month average Moderate Usage Crane hoist used 10 50 hours per month based on a three month average Heavy Usage Crane hoist used 50 200 hours per
16. on to correct the cause of the malfunction before return ing the hoist to service PERSONNEL HANDLING BRADEN recognizes that most hoists and cranes are designed and intended for handling materials and not personnel The crane or hoist is only to be used to handle personnel if it can be shown there is no less hazardous way of carrying out the job In these situations all safety precautions must be strictly adhered to BRADEN recommends adherence to the latest revision of API 2C RP 2D and or ANSI ASME standard B30 5 and or OSHA and or other applicable standards for your application It is important that you obtain a copy of all applicable safety standards and that you read and understand them prior to using the hoist In addition to or in conjunction with the applicable standards BRADEN requires e The hoist must be maintained in accordance with the recommendations in this document and the service procedures in the Installation Maintenance and Ser vice Manual for your specific hoist e When handling personnel the allowable line pull will be limited to 30 of the hoist rated line pull for the respective layer of wire rope on the drum This reduc tion increases the hoist design factor from 3 1 to 10 1 approximately Example a hoist rated at 15 000 Ibs on the first layer will be rated at 15 000 x 0 3 4 500 Ibs on the first layer when handling personnel e Personnel are only permitted to ride in an approved personnel p
17. onal information can be obtained from the following organizations Booklet on Hoisting Personnel Crane Institute of America Inc 1063 Maitland Center Commons Suite 100 Mait land Florida 32751 USA 800 832 2726 OSHA Standard 29 CFR 1926 550 Cranes Derricks Hoists Elevators and Conveyors Occupational Safety and Health Administration OSHA 200 Constitution Ave N W Washington D C 20210 USA 202 219 4667 ANSI ASME Standard B30 5 American National Standards Institute ANSI 11 W 42nd Street New York New York 10036 USA 212 642 4900 API Specification 2C and RP 2D American Petroleum Institute API 1220 L Street N W Washington DC 20005 USA 202 682 8375 CSB0033 PAGE 9 of 10 This Page Intentionally Left Blank CSB0033 PAGE 10 of 10
18. scheduling of corrective maintenance Prepare the hoist by cleaning the drain plug area and drain extension tube in order to obtain an uncontaminated sample Operate the hoist in both directions for one or two minutes to thoroughly mix the gear oil then take the sample from the midstream flow of the oil to obtain an accurate representation of the oil condition After taking the oil sample continue with the oil change or refill the hoist gear cavity to the proper level with recommended lubricant A WARNING HOT OIL MAY CAUSE PERSONAL INJURY AND OR BURNS TO UNPROTECTED SKIN MAKE CERTAIN THE OIL HAS COOLED TO A SAFE TEMPERATURE TYPICALLY LESS THAN 110 F OR 43 C BEFORE TAKING AN OIL SAMPLE CHANGING OIL OR SERVIC ING THE HOIST General guidelines for iron contaminant level 100 500 ppm Normal 500 800 pom Caution Abnormal Sample Change oil and retake sample after 50 hours of operation If second sample is above 500 ppm remove hoist from service and perform tear down inspection to determine source of contamination 800 ppm Unacceptable Remove hoist from ser vice and perform tear down inspection to determine source of contamination Iron contaminant levels will be on the high side of Normal during break in Equally important as the level of contamination is the change in level of contamination An effective oil analysis program should provide the technician with a view of the progression of wear or a trend

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