SERIES

PD12C
PD15B
HYDRAULIC HOIST
WITH FREE FALL
Information in this publication is specific to those hoists with
Free Fall. For additional information, refer to the PD12C,
PD15B and PD17A Installation, Maintenance and Service
Manual, publication LIT-2103
PACR
WINCH DIVISION
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE (918) 251-8511 FAX (918) 259-1575
www.paccarwinch.com
PB-226
6/2003
PRINTED IN U.S.A.
PD12C & PD15B
FULL RELEASE & CONTROLLED FREE FALL
GENERAL SAFETY RECOMMENDATIONS
Personnel must not be allowed to
pass or stand under a suspended
load. Accidentally activating the hoist
free fall mechanism could result in the
load free-falling to the ground which
could result in property damage, per-
sonal injury or death.
When operating the full release free fall, no attempt
may be made to retard or stop the descending load
using the hoist controls. Since the full release mech-
anism is not designed to stop a descending load, any
attempt to do so could result in damage to the hoist
and/or the machine it is mounted on, which could
result in property damage, personal injury or death.
Equipment operators must receive sufficient training and practice to be able to antici-
pate the response of the hoist to control handle movement. Failure to properly train
operators may result in sudden loss of load control, which could result in property dam-
age, personal injury or death.
IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCT AND/OR SYSTEMS
DESCRIBED HEREIN OR OF RELATED ITEMS CAN CAUSE PROPERTY DAMAGE PERSON-
AL INJURY OR DEATH.
This document and other information from PACCAR Winch Division provides product and/or sys-
tem options for further investigation by users having technical expertise. It is important that you
analyze all aspects of your applicaiton and review the information concerning the products or sys-
tems in this manual. Due to the variety of operating conditions and applicaitons for these products
or systems, the user of the entire system, through his own analysis and testing, is solely respon-
sible for making the final selection of the products and systems and assuring that all performance,
safety and warning requirements are met.
Free fall hoists are designed to operate properly with the motor and brake valve originally installed
at the factory. If, for any reason, a different motor and/or brake valve is to be installed, written
approval must be obtained from the PACCAR Winch Division Engineering Department. Improper
hydraulic hook-up or failure to use an approved motor and/or brake valve may result in sudden loss
of load control, which could result in property damage, personal injury or death.
FOLLOW THE WARM-UP PROCEDURE STATED IN
LIT-2103 R1.
FULL RELEASE FREE FALL TESTING AND OPERA-
TION
A light test load (1000 lbs (454 kg) approximately) should
be lifted a few feet from the ground. The free fall control
valve handle should be moved into the full release posi-
tion. The handle should then be detented in that position.
If the ambient temperature is very low, the load may fall
at a fairly low velocity, but once the brake housing has
warmed up the load should fall freely. Once the operator
has gained a feel for the controls, the load and drop dis-
tance may be increased. NO ATTEMPT SHOULD BE
MADE TO RETARD THE SPEED OF THE DESCEND-
ING LOAD, OR TO STOP THE DESCENDING LOAD.
Any attempt to do this may result in a wire rope failure,
severe damage to the hoist, or destabilizing the crane or
structure on which the hoist is mounted.
CONTROLLED FREE FALL TESTING AND OPERATOR
TRAINING
A light load (1000 lbs (454 kg) approximately) should be
lifted a few feet from the ground. The operator should
move the controlled free fall valve handle smoothly and
slowly towards the release position. As soon as the load
starts to move, the operator should stop moving the han-
dle. This test is to determine that the controlled free fall is
working and to give the operator a feel for the handle
movement required to initially release the load. Over short
lowering distances it will be difficult to bring the load to a
smooth stop before it reaches the ground. Very smooth
movements of the control handle are required in order to
modulate the speed of the descending load.
Once the operator has obtained the feel for the control
handle release point, the load may be raised higher, this
will give the operator a better opportunity to modulate the
speed of the descending load, both to speed up and slow
down to a stop.
When the operator has become confident using the 1000
lb (454 kg) load, then the load may be increased incre-
mentally to the maximum free fall design load for the crane
or other support structure, or 4600 lbs (2090 kg) bare drum
line pull, whichever is the least.
The operator should never operate the valve abruptly, as
this will cause the load to accelerate at a high rate, and to
reach a high velocity. The metering pump (see Controlled
Free Fall Circuit on following pages) will then over com-
pensate, and slow the load down even to a stop. If this
should happen, the control valve should be closed
smoothly, but not abruptly, and the lowering cycle restart-
ed. If the valve is not closed while the metering pump is
bringing the load to a near or actual stop, pressure will rise
very quickly in the release circuit, and the cycle will begin
again resulting in a rapid surging while lowering this load.
Under no circumstances should the opera-
tor let go of the handle, or return the han-
dle to neutral abruptly, as this will cause the
free fall brake to apply instantaneously
leading to a severe shock load throughout
the hoisting system. Attempting to stop a
descending load with a full release mecha-
nism could result in damage to the hoist
and/or the machine it is mounted on, which
could result in property damage, personal
injury or death.
Personnel must not be allowed to pass or
stand under a suspended load. Accidentally
activating the hoist free fall mechanism could
result in the load free-falling to the ground
which could result in property damage, per-
sonal injury or death.
The drum assembly consists of three basic assemblies:
a) Drum with integral ring gear. The drum is not inter-
changeable with the drum used on the standard hoist.
b) Output planetary gear set
c) Primary planetary gear set
The full & controlled release free fall group consists of
a large diameter multi-plate wet disc brake, which is
clamped between the rear face of the brake housing and
a spring applied piston. A brake shaft is splined to the
brake plates. The brake shaft passes through the base
side plate and into the drum, where it is splined into the
outer planet carrier. Thus, when in normal hoisting and
lowering mode the brake plates are clamped by the
spring applied piston, preventing the brake shaft and out-
put planet carrier from rotating.
When the free fall is activated, hydraulic pressure is
applied to the piston, which is then moved back com-
pressing the brake springs, and releasing the multi-disc
brake. This allows the brake shaft and output planet car-
rier to rotate, and in turn allows the cable drum to freely
rotate. The output sun gear and input planet carrier
assembly also rotate, but the input sun gear and motor
shaft remain stationary.
Control Group (controlled free fall only) The control
group consists of three elements:
a) A metered oil supply to the controlled free fall brake
release piston. This oil supply is set between 1.6 gpm
(6.1 lpm) and 1.8 gpm (6.8 lpm). The lower setting is
used if it is desired to restrict the lowering velocity to a
fairly low value, and the higher setting is used if lower-
ing speeds of approximately 1500 fpm (457 mpm) are
required. The actual lowering speed of the load will
vary depending on the working layer at the time and
the drum barrel diameter.
b) The metered oil supply passes through the control
valve. The valve has been selected with a particular
metering spool to provide good control over the wide
range of loads which will be handled.
c) Between the control valve and the brake release port,
the hydraulic line is divided, one side going to the
brake release port and the other side going to the
metering pump.
The metering pump is attached externally to the end of
the free fall brake housing and is keyed to the brake shaft,
so that when the brake is released and the brake shaft
rotates, it drives the pump.
When the pressure increases in the brake release line,
the drum is allowed to rotate and the load begins to accel-
erate downwards. The brake shaft rotates at approxi-
mately the same speed as the drum and drives the meter-
ing pump. As the speed increases, the metering pump
begins to draw oil away from the brake release line, and
thus decreases the brake release pressure. This stabi-
lizes the velocity for a given handle movement on the
control valve and also limits the maximum velocity should
the control valve be fully open, however, as mentioned
above, if the control valve is fully opened abruptly, it will
cause the metering pump to overcompensate, causing
the load to descend in a rapid surging motion.
FREE FALL OPERATION
To
Drain
1.8 gpm (6.8 lpm)
to
2.2 gpm (8.3 lpm)
Cooling Oil In
Free Fall
Brake
Release Port
1.6 gpm (6.1 lpm) to
1.8 gpm (6.8 lpm)
800 psi
(5500 kPa)
Port 1
Port 2
P
T
PD12C Controlled Free Fall Circuit
Valve Supplied by Customer
Valvoil SV10S02G106C103A
Optional 06 Detent. See Text
Free Fall
Brake
Release Port
Normal Location of Vent Plug
for Hoists Mounted Upright
1.5 gpm
(5.7 lpm)
MINIMUM
1500 psi
(10300 kPa)
Oil Level
Plug
Alternate Location
of Vent Plug for
Hoists Mounted
Inverted
PD12C Full Release Free Fall Circuit
Metering
Pump
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Controlled Free Fall Parts
Full Release Free Fall Parts
Apply Loctite #242 to
threads and torque to
75 lb-ft (103 N-m)
Apply Loctite #242 to
threads and torque to
9 lb-ft (12 N-m)
Apply Loctite #242 to
threads and torque to
75 lb-ft (103 N-m)