Seccin 1Carta de Capacidad

Nominal

Seccin 2Gra

Seccin 3El Cable de Acero y su

enrollamiento

Seccin 4La Pluma y sus

Accesorios

Seccin 5Los Malacates y sus

Accesorios

961306 HOIST COMPONENTS

Seal Kit No.:961274-57

** USE 961274-58 BRAKE CLUTCH ASSEMBLY

1
1
1

QTY.
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
1
3
3
6
3
3
1
3
3
6
6
3
1
1
8
32
1
1
1
1
1
8
1
1
1
1
1
1
1
16
2
3
1
1
10
9
1
1
1

BASIC MATERIAL LIST

Cable Wedge (3/4 1)

DESCRIPTION
Brake Cylinder
Brake Piston
Brake Piston Plate
Backup Plate
Belleville Spring
Spring Guide
Retaining Ring
Snap Ring
Snap Ring
O-Ring
O-Ring
Backup Ring
Backup Ring
Street Elbow 45
Outer Brake Race
Inner Brake Race
Snap Ring
Sprag Bearing Retainer
Sprag Clutch
Sprag Bearing
Primary Planet Carrier
Primary Planet Gear
Primary Planet Gear Shaft
Thrust Washer
Roller Bearing
Rollpin
Output Planet Carrier
Output Planet Gear
Output Planet Gear Shaft
Thrust Washer
Roller Bearing
Rollpin
Support End Plate
Bearing Support
Capscrew (5/8 18 X 2 1/4 Gr 8)
Lockwasher (1/2)
Reducer Bushing
Relief Valve
Motor End Plate
Motor Adapter
O-Ring
Capscrew (3 in. Special)
Ring Gear
Ring Gear Reducer
Primary Sun Gear
Cable Drum Closure
Output Sun Gear
Thrust Washer
Cable Drum
Capscrew (1/2 13 X 1 1/2 Gr 5)
Tie Plate
Bearing Spacer
Bearing
Bearing
Brake Disc
Friction Disc
O-Ring
Oil Seal
Oil Seal

71

Plug
Brake Plate Spacer
Nipple

ITEM
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
19
20
21
24
26
27
28
29
30
31
34
35
36
37
38
39
40
41
42
43
44
45
48
49
50
51
53
54
55
56
57
58
59
60
61
62
64
65
66
67
68
69
70

72
73
76

PART NO.
961274-1
961274-2
961274-3
961274-4
961274-5
961274-6
961274-7
961274-8
961274-9
961274-10
961274-11
961274-12
961274-13
961191-3
**
**
**
**
**
**
961304-02
961274-34
961304-03
961274-36
961274-37
961244-21
961304-12
961304-10
961274-41
961348-08
961343-08
See Item 31
961264-01
961274-20
948214-05
961188-2
961244-31
961274-21
961264-02
961274-22
961274-23
961274-24
961274-46
961274-47
961274-48
961264-03
961274-50
961274-51
961264-04
961244-15
961264-05
961304-11
961274-25
961274-26
961274-27
961274-28
961264-06
961274-29
961274-30
See page
3.X
961188-29
961274-31
961324-05

Seccin 6El Motor del Giro

Seccin 7Cabina del operador

Seccin 8La Planta de Potencia

Hidrulica y el Sistema Hidrulico

Brake Test and Emergency Lowering Procedures

For Hoists Ordered for API 2C Cranes
All Braden planetary hoists have a spring-applied, hydraulically-released, multiple-disc brake
located inside the drum. This brake acts to hold a suspended load in a stationary position when the
directional control valve is in neutral or in the event of loss of hydraulic power. A brake clutch
assembly permits the power train and drum to rotate in the direction to lift a load even if the brake is
engaged. A load cannot be lowered, however, without first releasing the brake by applying
hydraulic pressure to the release port.
Hoists ordered for API 2C cranes will have a needle valve located in the brake release line. Those
hoists also have a tee located in the brake release line between the needle valve and the brake
release port on the hoist. One opening in the tee is plugged. With the valve closed and the plug
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 in the event of loss of hydraulic power.

g.

f.

e.

d.

c.

b.

a.

When testing is complete, be sure to re-install the plug in the tee, fully open the valve
and replace the lockwire.

Reassemble the brake and hoist and repeat the above steps.

Replace any parts showing excessive wear, and any spring whose length is shorter than
the minimum shown in the Braden service manual.

If the drum rotates, the brake should be examined for wear. Also, the brake springs
should be measured for correct length in those hoists using helical compression springs.

Increase the engine speed, if necessary, to bring system pressure up to the relief valve
setting. The winch drum should remain stationary.

With the hydraulic power unit running, move the hoist directional control valve handle to
the full-open lowering position.

Remove the plug in the tee.

Remove the lockwire on the valve handle, and close the valve tightly.

1. Brake Test Procedure

h.

The above procedure tests the brake's ability to resist about 115% of the rated hoist load.
603511 Rev. 3
Page 1 of 2

e.

d.

c.

b.

a.

Connect a hand pump to the opening in the tee.

Fill the standpipe with hydraulic oil, making certain that oil is not running out of the brake
valve (counterbalance valve). If oil is running out of the brake valve (counterbalance
valve), remove the spring retainer and tap the spool to the closed position.

Remove both main hoses from the motor, and attach a standpipe to the motor port on
the opposite side of the motor from the brake valve (counterbalance valve).

Remove the plug in the tee.

Remove the lockwire on the valve handle, and close the valve tightly.

2. Emergency Lowering Procedure

f.

Pump the hand pump up to about 1000 psi. A suspended load will slowly come down;
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 higher pressure
until the noise stops. Do not touch the motor or standpipe while using this procedure;
these items will become very hot.
CAUTION - The above lowering procedure opens the multiple-disc brake while leaving
the brake valve (counterbalance valve) closed. Since hydraulic motors are not zero leak
devices, internal motor leakage permits the load to slowly rotate the motor even though
its outlet is blocked by the closed brake valve (counterbalance valve). This procedure
will not work if there is little or no oil in motor. Attempting to use this procedure with no
oil in the motor will cause the load to free fall. This procedure will also cause the load to
free fall if the brake valve (counterbalance valve) is stuck in the open position. The
purpose of the standpipe is to insure that the motor is full of oil. The standpipe is simply
a length of pipe (about 1 foot long) attached to a 90 elbow. The other end of the elbow
is attached to a short nipple and fitting suitable for mounting on the motor port or
manifold. The standpipe is installed with the 1 foot pipe pointed up and in a vertical
position. While lowering, oil must be added to the standpipe as necessary. The pipe
size should be at least as big as the motor port size.
WARNING- Never allow the standpipe to run out of oil. The load will free fall if there is
little or no oil in the stand pipe.
NOTE- The hydraulic oil used to fill the stand pipe must be filtered oil to prevent
contaminated hydraulic oil from entering the hydraulic motor. Filter the hydraulic oil to
meet a cleanliness level of ISO 16/13 or cleaner.

603511 Rev. 3
Page 2 of 2

Prueba del freno y procedimiento para bajar la carga en Emergencia para malacates
utilizados en gras bajo la Especificacin API 2C.
Todos los malacates BRADEN tienen un freno aplicado por la fuerza de resortes, liberado
hidrulicamente, de multiples discos que est localizado en el interior del tambor.
Este freno sostiene la carga suspendida en una determinada posicin cuando la valvula de
control direccional se encuentra en neutro o en el caso de perdida de potencia hidrulica.
El conjunto embrague-freno permite rotar al tambor cuando se eleva la carga aunque en
freno este aplicado; pero, la carga no puede ser bajada sin previamente liberar el freno y
aplicar potencia hidrulica al motor.
Los malacates utilizados en gras bajo la E specificacin API 2C, tienen una vlvula de
aguja en la lnea que libera el freno. Adems una tee instalada en la lnea que libera el
freno entre la vlvula de aguja y la conexin de la lnea al motor del malacate.
Una de las vias de la tee esta bloqueada con un tapn.
Con la vlvula cerrada remueva el tapn de la tee. El freno esta aislado del sistema de
presin y puede ser venteado a la atmsfera.
El freno no se libera bajo estas condiciones sino hasta actuar sobre la vlvula direccional
de control.
Los propsitos del conjunto tee-vlvula son la prueba del freno y el permitir bajar la carga
en el caso de prdida de potencia hidrulica.
1.- Prueba del freno.
a) Retirar el sello de alambre colocado sobre la manigueta de la vlvula, y girar la
manigueta hasta la posicin del vlvula cerrada.
b) Remover el tapn de la tee.
c) Con el motor funcionando y con potencia hidrulica disponible, mueva el mando de la
vlvula direccional de control correspondiente a la posicin completamente abierta de
bajar la carga.
Page 1 of 3
604091 sh01r00.doc Rev. 0 Spanish
Emergency Lowering Procedure. (Spanish)

d) Incremente la velocidad del motor si es necesario hasta llegar a la presin de descarga

de la vlvula de alivio. El tambor del malacate debe permanecer parado, sin girar.
e) Si el tambor gira, posiblemente existen piezas desgastadas y el freno debe ser
inspeccionado. Tambin, en los malacates que utilizan resortes de compresin
helicoidales se debe verificar la longitud de los mismos.
f) Remplazar todas las partes desgastadas y los resortes con longitudes ms cortas que la
mnima especificada en el Manual de Servico BRADEN.
g) Re-ensamblar el freno y el malacate y repetir los literales anteriores.
h) Cuando la prueba haya sido completada satisfactoriamente no olvidar de re-instalar el
tapn en la tee, de girar la manigueta de la vlvula hata la posicin completamente
abierta, y, de re-establecer el sello de alambre sobre la manigueta de la vlvula.
El procedimiento de prueba del freno descrito habilita a resistir alrededor del 115 % de la
carga nominal del malacate.

2.- Bajar la carga en Emergencia

a) Retirar el sello de alambre colocado sobre la manigueta de la vlvula, y girar la
manigueta hasta la posicin del vlvula cerrada.
b) Remover el tapn de la tee.
c) Desconectar las dos mangueras principales del motor hidrulico e instalar una tubera
provisional al motor sobre el lado opuesto a la vlvula de freno. (Vlvula de contrabalance ).
d) Llenar la tubera provisional con aceite hidrulico sin permitir que el mismo salga por la
vlvula del freno (Vlvula de contra-balance). Si el aceite esta saliendo por la vlvula del
freno, saque el resorte y golpee el carrete a la posicin cerrada.
e) Conectar una bomba manual a la tee en el lugar del tapn retirado.
f) Bombear y elevar la presin con la bomba manual hasta 1000 psi. aproximadamente.
La carga suspendida comenzar a bajar despacio; al eliminar la presin la carga se
Page 2 of 3
604091 sh01r00.doc Rev. 0 Spanish
Emergency Lowering Procedure. (Spanish)

detendr. Si ruidos son escuchados mientras la carga est bajando, incremente la presin
con la bomba manual hasta eliminar los mismos. No toque el motor o la tubera provisional
mientras efecta este procedimiento puesto que estarn muy calientes.

PRECAUCION:
El procedimiento decrito libera el freno de multiples discos mientras la valvula del freno est
cerrada (Vlvula de contra-balance). Puesto que los motores hidrulicos tienen fugas de
fludo hidrulico, stas permiten a la carga a hacer rotar despacio al motor aunque la
vlvula del freno se encuentre completamente cerrada.
Este procedimiento no trabajar si la cantidad de aceite en el motor es mnima o no hay
aceite.
Al intentar utilizar este procedimiento con el motor sin aceite la carga caer libremente.
Este procedimiento, tambin causa la caida libre de la carga si la vlvula del freno (Vlvula
de contra-balance) esta trabada en posicin abierta.
El propsito de la tubera provisional es asegurar que el motor tenga aceite. La tubera
provisional es simplemente aproximadamente 1 pie de tubo con un codo de 90 grados en
uno de los extremos. El otro extremo del codo est conectado a un pequeo neplo con el
respectivo accesorio que permite ser instalado al motor o cabezal. La tubera provisional
debe instalarse con en tramo de tubo verticalmente y hacia arriba.
Si el nivel de aceite en la tubera provisional baja, aceite hidrulico debe ser aadido tanto
como sea necesario.
El dimetro de la tubera provisional debera ser como mnimo igual al dimetro de la
conexin de entrada del motor.
NOTA:
El aceite hidrulico a ser utilizado para la tubera provisional debe ser filtrado para prevenir
la contaminacin del aceite hidrulico del sistema. El filtro debe estar dentro de las
Especificaciones de Nivel de Limpieza ISO 16/13 o mayor grado de Nivel de Limpieza.

Page 3 of 3
604091 sh01r00.doc Rev. 0 Spanish
Emergency Lowering Procedure. (Spanish)

Seccin 9Sistema de Aire

Seccin 10Sistema elctrico

BRADEN
CH165A & CH230B
PLANETARY HOIST

www.paccarwinch.com

P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013

PHONE (918) 251-8511 FAX (918) 259-1575

PACR WINCH DIVISION

INSTALLATION, MAINTENANCE AND SERVICE MANUAL

LIT-2319
AUGUST 2006
PRINTED IN U.S.A.

TABLE OF CONTENTS
FOREWORD.........................................................................................................................2
MODEL & SERIAL NUMBER LOCATION.........................................................................3
EXPLANATION OF MODEL NUMBER..............................................................................3
GLOSSARY OF TERMS......................................................................................................4
GENERAL SAFETY RECOMMENDATIONS....................................................................5
BASIC OPERATION.............................................................................................................7
EXPLODED VIEW OF MAJOR COMPONENTS.............................................................9
INSTALLATION....................................................................................................................10
WIRE ROPE INSTALLATION............................................................................................11
HOIST OPERATION...........................................................................................................12
HYDRAULIC CIRCUIT........................................................................................................13
RECOMMENDED FASTENER TORQUE........................................................................13
PREVENTIVE MAINTENANCE........................................................................................14
RECOMMENDED GEAR OIL............................................................................................15
OIL SAMPLING AND ANALYSIS......................................................................................16
TROUBLESHOOTING........................................................................................................17
DISASSEMBLY PROCEDURE.........................................................................................21
PLANETARY CARRIER SERVICE..................................................................................23
OVER-RUNNING CLUTCH SERVICE............................................................................25
BRAKE CYLINDER SERVICE..........................................................................................27
REVERSING DRUM ROTATION DIRECTION................................................................30
HOIST ASSEMBLY.............................................................................................................32
BRAKE VALVE SERVICE.................................................................................................34
BRAKE VALVE OPENING PRESSURE TEST....................................................................36
METRIC CONVERSION CHART......................................................................................37

THIS PAGE INTENTIONALLY LEFT BLANK

FOREWORD
CH165A & CH230B
The following service instructions have been prepared to provide assembly, disassembly and
maintenance information for the BRADEN Model CH165A & CH230B series hoist. It is suggested
that before doing any work on these units, all assembly and disassembly instructions should be read
and understood.
Some illustrations in this manual may show details or attachments that are different from your hoist.
Also, some components have been removed for illustrative purposes.
Continuing product improvement may cause changes in your hoist, which are not included in this
manual. Whenever a question arises regarding your BRADEN hoist or this manual, please contact
BRADEN Product Support Department for the latest available information.
Telephone- 1-918-251-8511
08:00-16:30 Central Time Zone, Monday thru Friday
FAX- 1-918-259-1575
www.paccarwinch.com

Serial Number
Data Plate

165
DESIGN
RATING

GEAR
RATIO

B - 35

MOTOR
SIZE

DRUM
SIZE

OPTION

110 - 01 - 1

EXPLANATION OF SERIAL NUMBER

CH
MAX
RATING

DESIGNATES CONSTRUCTION HOIST

DESIGNATES 16,500 (CH165) OR 23,000 (CH230) LB DESIGN FIRST LAYER LINE PULL
DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
DESIGNATES TOTAL GEAR REDUCTION (CH165= 25, 26; CH230= 35, 36)
DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV (110 = 11.0 CU IN REV)
DESIGNATES THE DRUM OPTION
PERMITS TESTING AND INSPECTION PER API 2C FOR OFFSHORE CRANES

CONSTRUCTION
HOIST

CH
165
B
35
110
01
1

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 lowering
direction, the brake valve blocks the flow of oil out of the motor until the internal static brake is released. It then controls
lowering speed based on the load and flow of oil to the motor. All the heat generated by controlling the speed of the load
is dissipated by the hydraulic system, not by the internal static brake.
Grooved Drum - A cable drum with grooves on the barrel to ensure the first layer of cable
spools properly onto the drum. The grooves can be cast or machined into the drum, or cast
or machined into separate pieces that are mechanically fastened to the drum. NOTE: Only
one size cable can be used on a grooved drum.
Sprag or Over-Running Clutch - A mechanical one-way clutch on the input shaft of the
hoist, between the input shaft and the static mechanical brake. The clutch allows the input
shaft to turn freely in the direction required to spool cable onto the drum (i.e. lift a load), then immediately locks the hoist
gear train to the mechanical brake when the hoist is stopped, holding the load in place.
Static, Mechanical, or Load-Holding Brake - A multi-disc, spring applied, hydraulically released brake that works
together with the sprag clutch to hold a suspended load. This brake is not designed to stop a load being lowered, but
holds the load in place when the hoist is not being operated.
First Layer Line Pull Rating - The maximum rated line pull (in pounds or kilograms) on the first layer of cable. The
maximum rating for any particular hoist is based on maintaining an acceptable structural design factor and service life.
Certain combinations of drum, gear ratio, motor and hydraulic pressure, may reduce this rating.
First Layer Line Speed Rating - The maximum rated line speed (in feet or meters per minute) on the first layer of cable.
Certain combinations of drum, gear ratio, motor and hydraulic flow may reduce or increase this rating.
D/d Ratio - The ratio of cable drum barrel diameter (D) to wire rope diameter (d). Current ANSI standards require a
minimum of 17:1.

BARREL
DIAMETER

EXAMPLES:
If you know the cable diameter you want to use, multiply it by 17 to get the MINIMUM cable drum barrel diameter. (i.e.
inch wire rope X 17 = 8.5 inches - this is the minimum hoist barrel diameter)
If you know the barrel diameter, divide it by 17 to get the MAXIMUM wire rope diameter.
(i.e. 10 inch barrel diameter / 17 = 0.588, or 9/16 inch - this is the maximum wire rope diameter)
Cable Drum Dimensions FLANGE
DIAMETER

DISTANCE
BETWEEN
FLANGES

Angles a and b should be a minimum of

degree and a maximum of 1 degrees.

First sheave or load should be centered

between the drum flanges, so that angle a
and angle b are equal.

Fleet Angle - The angle between the wire ropes position at the extreme end wrap on a drum, and a line drawn
perpindicular to the axis of the drum, through the center of the nearest fixed sheave or load attachment point.

A
B

Wrap - A single coil of wire rope wound on a drum.

Layer - All wraps of wire rope on the same level between drum flanges.
Freeboard - The amount of drum flange that is exposed radially past the last layer of wire rope. Minimum freeboard varies
with the regulatory organization. ASME B30.5 requires in. minimum freeboard.

GENERAL SAFETY RECOMMENDATIONS

22. Ground personnel should stay in view of the operator

and clear of the hoist drum. Do not allow ground personnel
near wire rope under tension. A safe distance of 1 times
the working length of the wire rope should be maintained.

21. Assure that personnel who are responsible for hand

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

20. Never operate hoist controls unless you are properly

positioned at the operators station and you are sure
personnel are clear of the work area.

19. Never attempt to clean, oil or perform any maintenance

on a machine with the engine or prime mover running,
unless instructed to do so in this manual.

18. The BRADEN designed wire rope anchors are not

intended to support the rated load. ALWAYS maintain a
minimum of five (5) wraps of wire rope on the drum. It is
recommended that the last five (5) wraps of wire rope be
painted bright red to serve as a visual reminder.

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
for the equipment and a thorough knowledge of the machines performance capabilities. The following recommendations
are offered as a general safety guide. Local rules and regulations will also apply.

1. Be certain equipment (boom, sheave blocks, pendants,

etc.) is either lowered to the ground or blocked securely
before servicing, adjusting, or repairing hoist.
2. Be sure personnel are clear of work area BEFORE
operating hoist.
3. Read all warning and caution tags provided for safe
operation and service of the hoist and become familiar with
the operation and function of all controls before operating
the hoist.
4. Inspect rigging and hoist at the beginning of each work
shift. Defects should be corrected immediately. Do not
operate a hoist with defects.
5. Keep equipment in good operating condition. Perform
scheduled servicing and adjustments listed in the
Preventive Maintenance section of this manual.
6. An equipment warm-up procedure is recommended for
all start-ups and essential at ambient temperatures below
+40F (+4C). Refer to Warm-up Procedure listed in the
Preventive Maintenance section of this manual.

23. Install guarding to prevent personnel from getting any

part of body or clothing caught at a point where the cable
is wrapped onto the drum or drawn through guide rollers or
potential pinch points.
24. Install switches or valves that will shut off power to the
hoist, in locations where they can be reached by anyone
entangled in the wire rope before being drawn into the hoist
or any pinch point.

7. Do not exceed the maximum pressure (PSI, kPa) or

flow (GPM, lpm) stated in the hoist specifications found in
the specific sales brochure.

9. Protective gloves should be used when handling wire

rope.

25. Deadman controls, which automatically shut off

power to the hoist whenever the operator leaves his station
or releases the hoist control lever, should be installed
whenever practical.

8. Operate hoist line speeds to match job conditions.

10. Never attempt to handle wire rope when the hook end
is not free. Keep all parts of body and clothing clear of
cable rollers, cable entry area of fairleads, sheaves and
hoist drum.

29. All hoist controls shall be located within easy reach

of the operator. The controls shall be installed in such a
location that the operator is removed from the electrical
path to ground if the load, rigging, or wire rope come in
contact with or within proximity to an electrically energized
conductor.

28. Whenever possible, install the hoist in a location that is

not immediately adjacent to a normal operators station.

27. Avoid sudden shock loads or attempting to jerk a

load free. This type of operation may cause heavy loads,
in excess of rated capacity, which may result in failure of
wire rope, hoist or crane structure.

26. Never allow anyone to position any part of body under

a suspended load.

17. Do not use knots to secure or attach wire rope.

16. Use correct anchor for wire rope and pocket in drum.

15. Keep hydraulic system clean and free from

contamination at all times.

14. Use recommended hydraulic oil and gear lubricant.

13. Do not weld on any part of the hoist without approval

from PACCAR Winch Engineering.

12. Never use wire rope with broken strands. Replace

wire rope that is damaged. Refer to wire rope supplier
manual.

11. When winding wire rope on the hoist drum, never

attempt to maintain tension by allowing wire rope to slip
through hands. Always use Hand-Over-Hand technique.

CAUTION

WARNING
!

If there is any question regarding the preceding safety

recommendations, or the safe operation of your hoist,
please contact the Braden Product Support Department at
1-918-251-8511, Monday through Friday from 0800 to 1630
hours, CST, by fax at 1-918-259-1575, or via the internet at
www.paccarwinch.com for the latest available information.

CAUTION This emblem is used to warn against

potential or unsafe practices which COULD
result in personal injury and product or property
damage if proper procedures are not followed.

CAUTION

Safety and informational callouts used in this manual include:

30. Before operating the hoist, be sure ALL safety

procedures for the equipment or vehicle the hoist is
mounted on are properly followed and/or in place.

!
WARNING This emblem is used to warn
against hazards and unsafe practice which
COULD result in severe personal injury or death
if proper procedures are not followed.

DESCRIPTION OF HOIST

two

operating

STATIC
BRAKE

PUMP

STATIC
BRAKE

PUMP

STATIC
BRAKE

MOTOR

MOTOR

MEDIUM PRESSURE

BRAKE
VALVE

MOTOR

LOW PRESSURE MEDIUM PRESSURE

BRAKE
VALVE

LOW PRESSURE

BRAKE
VALVE

BASIC OPERATION
The CH165A & CH230B hoists are made up of the
following sub-assemblies:
1.
Hydraulic motor and brake valve
2.
Brake cylinder and brake clutch assembly
3.
Hoist base components
4.
Hoist drum and gear train
(Refer to illustration on page 9)
THEORY OF OPERATION
The primary sun gear is directly coupled to the hydraulic
motor by the inner race of the brake clutch assembly. As
the motor turns in the hoisting direction (clockwise for -01
drums) the planetary assemblies reduce the input speed
of the motor and rotate the ring gear and winch drum.
Since the output planet carrier is held from turning by the
drum bearing support on -01 drums, the drum rotates in
the opposite direction of the motor input shaft. On -02
and -21 drums the output carrier is splined to the drum,
and the drum rotates in the same direction as the input
shaft. In the hoisting direction, the static brake remains
fully applied and the input shaft rotates freely through the
sprag clutch. When the motor is stopped, the load tries
to rotate the hoist gear train in the opposite direction.
The sprag clutch on the input shaft immediately locks
up, allowing the fully applied static brake to hold the
load from dropping. See Dual Brake System - Operation
for a detailed description of the lowering sequence of
operation.
Dual Brake System Description

has

The dual brake system consists of a dynamic brake

system and a static brake system.
The dynamic brake system
components:
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

PUMP

LOW PRESSURE MEDIUM PRESSURE

FIGURE 2

TO
TANK

TO
TANK

FIGURE 4

TO
TANK

FIGURE 3

HIGH PRESSURE

HIGH PRESSURE

HIGH PRESSURE

The static brake is released by the brake valve pilot

pressure 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.
The static friction brake is a load holding brake only
and has nothing to do with dynamic braking or rate of
descent of a load.
The brake clutch is splined to the primary sun gear shaft
between the motor and the primary sun gear. It will allow
this shaft to turn freely in the direction to raise a load and
lock up to force the brake discs to turn with the shaft in
the direction to lower a load. Figures 5 and 6.
The hydraulic cylinder, when pressurized, will release the
spring pressure on the brake discs, allowing the brake
discs to turn freely.

Dual Brake System Operation

When hoisting a load, the brake clutch which connects
the motor shaft to the primary sun gear, allows free
rotation. The sprag cams lay over and permit the inner
race to turn free of the outer race. Figure 5. The static
friction brake remains fully engaged. The hoist, in raising
a load, is not affected by any braking action. Figure 2.
When the lifting operation is stopped, the load attempts
to turn the primary sun gear in the opposite direction.
This reversed input causes the sprag cams to instantly
roll upward and firmly lock the shaft to the fully engaged
friction brake. Figure 6.
When the hoist is powered in reverse, to lower the load,
the motor cannot rotate until sufficient pilot pressure
is present to open the brake valve. Figures 3 & 4. The
friction brake within the hoist will completely release at
a pressure lower than that required to open the brake
valve. The extent to which the brake valve opens will
determine the amount of oil that can flow through it and
the speed at which the load will be lowered. Increasing
the flow of oil to the hoist motor will cause the pressure
to rise and the opening in the brake valve to enlarge,
speeding up the descent of the load. Decreasing this
flow causes the pressure to lower and the opening in the
brake valve to decrease thus slowing the descent of the
load.
When the control valve is shifted to neutral, the pressure
will drop and the brake valve will close, stopping the
load. The friction brake will engage and hold the load
after the brake valve has closed.
When lowering a load very slowly for precise positioning,
very little oil flow actually occurs through the hoist motor.
The pressure will build up to a point where the static
brake will release sufficiently to allow the load to rotate

the motor through its own internal leakage. This feature results
in a very slow speed and extremely accurate positioning.

Stopped,
holding
load

Static Friction Brake Applied

Hoisting

Static Friction Brake Applied

The friction brake receives very little wear in the lowering

operation. All of the heat generated by the lowering and
stopping of a load is absorbed by the hydraulic oil where it can
be readily dissipated.

Sprag
Cams

Figure 5

Sprag
Cams

Figure 6
8

CH230B/ CH165 -01 Drum Components

CH230B/ CH165 -02 Drum Components

INSTALLATION

CAUTION

WARNING
!

In general terms; for continuous operation at ambient

temperatures between 50 and 110F (10-43C) use ISO VG
46 68 (SAE20); for continuous operation between 10 and
90F (-12 and 32C) use ISO VG 32 (SAE10W).

Maximum cold weather start-up viscosity should not exceed

5000 SUS with a pour point at least 20F (11C) lower than
the minimum temperature.

Oil having 150 to 330 SUS viscosity at 100F (38C) and

viscosity index of 100 or greater will give good results
under normal temperature conditions. The use of an oil
having a high viscosity index will minimize cold-start trouble
and reduce the length of warm-up periods. A high viscosity
index will minimize changes in viscosity with corresponding
changes in temperature.

9.High quality hydraulic oil is essential for satisfactory

performance and long hydraulic system component life.

8.The hydraulic oil filter should have a 10 micron nominal

rating and be a full-flow type.

7. The hoist directional control valve must be a threeposition, four-way valve without detents and with a spring
centered motor spool such that the valve returns to the
centered position whenever the handle is released, and
both work ports are opened to tank (open center, open port,
see schematic below).

DO NOT use a control valve with any detents or latching

mechanism that would hold the control valve in an
actuated or running position when the operator releases
the control handle. Use of the wrong type of control valve
could lead to unintentional operation of the hoist, which
could result in property damage, personal injury or death.

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 plug is positioned above the oil level.

WARNING

CAUTION

2. When mounting the hoist, use four 1 in. grade 8

capscrews or bolts and nuts using both mounting holes in
each end plate. Use narrow, hardened washers under the
bolt heads and nuts

!
DO NOT weld hoist to mounting surface. Welding may
not provide adequate structural support for winch loads.
This may cause loss of load control, which could result
in property damage, injury or death. Welding may also
damage bearings and seals, resulting in premature failure.
3. The vent plug must always be located above the
horizontal centerline of the hoist drum. If the hoist is
mounted on a pivoting surface, be sure the vent remains
above the centerline at all times. If necessary, reposition
the bearing support.
4. It is important that the hoist be mounted on a surface that
will not flex when the hoist is in use, since this could bind
the working parts of the hoist. Also, be sure the hoist is
mounted on a flat surface. If necessary, use shim stock to
insure proper mounting. The mounting surface must be flat
within 6 0.020 inches (.5 mm).
5. Hydraulic lines and components that operate the hoist
should be of sufficient size to assure minimum back
pressure at the hoist motor ports. To insure adequate
static brake load holding ability, back pressure on the hoist
should not exceed 100 psi (690 kPa).
6. Make certain that the hoist drum is centered behind
the first sheave and the fleet angle does not exceed 1
degrees.
The hoist should also be mounted perpendicular to an
imaginary line from the center of the drum to the first
sheave to ensure even spooling. (ref. drawing on page 4)

Recommended Control
Valve Schematic

10

If there is interference or the wedge does not seat firmly,

contact the Braden Product Support Department at 1-918251-8511 to determine the proper wedge size.
It is important that the wire rope have the proper
tensioning when it is installed on the drum. When the
wire rope is first installed, you should operate the hoist,
with light to moderate loads, with reeving that lets you
place these loads on the block and the drum with all the
rope off the drum except for the last five wraps.

Using a hammer and brass drift, drive the wedge as deep

into the pocket as possible to ensure it is fully seated and
no further movement is detected. Applying a load on the
wire rope will also help seat the wedge in the pocket.
Check to ensure the wedge does not protrude from either
end of the pocket, causing it to interfere with proper
spooling of wire rope onto the drum (see figures 1 & 2).

Take the free end of the wire rope and insert it through the
small opening on the cable drum. Loop the wire rope and
push the free end about 3/4 of the way back through the
pocket. Install the wedge as shown in figure 1, then pull
the slack out of the wire rope. The dead end of the rope
needs to extend slightly beyond the end of the wedge as
shown in figure 2.

(ONE PIECE CABLE WEDGE)

WIRE ROPE INSTALLATION

CAUTION

WARNING

THE CABLE ANCHORS ALONE ON HOISTS ARE NOT

INTENDED TO HOLD RATED LOADS.
Hoist loads applied directly to the wire rope anchor may
cause the wire rope to pull free and result in the sudden loss
of load control and cause property damage, personal injury or
death. A minimum of 5 wraps of wire rope must be left on the
drum barrel to achieve rated load.

Drive down from

this side

Figure 2

-Dead end of wire rope and/or wedge

may interfere with proper spooling
-Wedge may be too small

Wedge pulled too

far through anchor
pocket

Wedge and wire rope fully seated in pocket

Correct Installations

The wedge and anchor pocket must be clean and dry. The
end of the wire rope being anchored to the drum must be
clean and dry and not frayed. Anything on the end of the wire
rope to keep it from fraying (i.e. tape or wire) must not be
in contact with the wedge when the installation is complete.
Consult the wire rope manufacturer on the proper treatment
of the dead end of the wire rope. Some rope manufacturers
recommend when using rotation resistant wire rope, that the
rope end be seized, welded or brazed before inserting the
wire rope into the wedge socket to prevent core slippage or
loss of rope lay.

Figure 1

Incorrect Installations
Wedge not fully
seated

-Wire Rope not tight against wedge

-Wedge may be too large

11

HOIST OPERATION

If the hoist is holding the load securely, proceed with normal

operations in accordance with the equipment manufacturers
operating procedures and load charts.

Slowly pay-out wire rope from the hoist drum until it reaches
the load. Securely fasten the hoist cable to the load and
be sure all ground personnel are a safe distance from the
load. Slowly lift the load a short distance and stop. A small
amount of bounce may be observed, depending on the
weight of the load, size and type of wire rope, reaving and
the amount of boom extension. Allow the load to stabilize
and then watch for any sign of downward movement or
cable drum rotation. The hoist static brake should hold the
load in place without allowing any downward movement
at all. If the load creeps down, it should be lowered to the
ground immediately and the source of the problem identified
and corrected.

of cable. The hoist should perform these operations in a

smooth and controlled manner. If the hoist does not operate
smoothly or makes any unusual sounds, the source of the
problem should be identified and corrected before any
attempt is made to lift a load.

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 slippage and
damage to brake friction discs or seals. Oil viscosity with
regard to ambient temperature is also critical to reliable
brake operation. Our tests indicate that excessively
heavy or thick gear oil may contribute to intermittent
brake slippage. Make certain that the gear oil viscosity
used in your hoist is correct for your prevailing ambient
temperature.

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 operation of the piece of
equipment on which the hoist is mounted (i.e. crane, truck crane, etc.). If you have any questions concerning the safe
operation of this hoist or the equipment it is mounted on, contact the equipment manufacturer that installed the hoist, or the
Braden Product Support Department at 1-918-251-8511, Monday through Friday, 0800 to 1630 hours CST, by fax at 1-918259-1575, or via the internet at www.paccarwinch.com.

Ground personnel must stay in view of the operator and

clear of the load and hoist drum at all times. Do not allow
personnel near the hoist line under tension. Do not allow
personnel near the hoist drum while the hoist is in operation.
Do not allow personnel to be in line with the load. Do
not allow personnel to stand under a suspended load. A
safe distance of at least 1 times the working length of
the cable should be maintained by ground personnel. A
broken cable and/or lost load may cause property damage,
personal injury or death

Failure to properly warm up the hoist, particularly under low

ambient temperature conditions, may result in temporary
brake slippage due to high back pressures attempting to
release the brake, which could result in property damage,
severe personal injury or death.

Warm-up Procedures
A warm-up procedure is recommended at each start-up
and is essential at ambient temperatures below +40F
(4C).
The engine should be run at its lowest recommended RPM
with the hydraulic hoist control valve in neutral allowing
sufficient time to warm up the system. The hoist should
then be operated at low speeds, raise and lower with no
load on the hook, several times to prime all lines with warm
hydraulic oil, and to circulate gear lubricant through the

CAUTION
If the hoist is mounted on a crane that has an extendable
boom, care must be taken to pay-out cable as the boom is
extended. Failure to pay-out sufficient cable could result
in a two-blocking condition that could result in damage to
and/or failure of the hoist, cable, sheaves and/or boom.
planetary gear sets.
After the hoist/boom is properly positioned, we recommend
the operator slowly pay-out, then haul-in a short length

12

TYPICAL HYDRAULIC CIRCUIT

WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE

WINCH BRAKE

BRAKE
VALVE

CONTROL
VALVE

BR

DR

WINCH BRAKE

2-SPEED
SELECTOR
VALVE

WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE

NOTE: The hydraulic circuit shown below is representative of typical Braden hoists. Options and accessory equipment
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. (ALWAYS have the hoist model and serial number when contacting the factory)

BRAKE
VALVE

BR

DR

CONTROL
VALVE

PUMP

PUMP

RECOMMENDED BOLT TORQUE

The general purpose torque shown in the chart applies to SAE Grade 5 & Grade 8 bolts, studs and standard steel full,
thick and high nuts.
Higher or lower torques for special applications will be specified such as the use of spanner nuts, nuts on shaft ends, jam
nuts and where distortion of parts or gaskets is critical.

110

75

50

31

17

115

80

55

35

23

13

210

150

110

70

45

24

12

160

110

80

50

35

18

Torque (LB-FT)
Grade 5
Grade 8
Dry Lubed Dry Lubed

150

13

1 1/2

Torque (LB-FT)
Bolt Dia. Thds Per
Grade 5
Grade 8
Dry Lubed Dry Lubed
Inches
Inch
10
265
200
3/4
380
280
16
9
7/8
420
325
600
450
14
8
485
910
640
1
680
14
7
1 1/8
790
590
1290
970
12
7
1120
835
1 1/4
1820 1360
12
6
1460 1095 2385 1790
1 3/8
12
6
1940 1460 3160 2370
12

RECOMMENDED FASTENER TORQUE

Lubricated torque values based on use of SAE 30 engine oil applied to threads and face of bolt or nut.

Bolt Dia. Thds Per

Inches
Inch
20
1/4
28
18
5/16
24
16
3/8
24
14
7/16
20
13
1/2
20
12
9/16
18
11
18
5/8

CAUTION

WARNING
!

2. Change the lubricating oil in the hoist drum after an oil

sample is taken.

1. Perform the Pre-Use and Quarterly Inspections.

Annual Inspection, Testing & Preventive Maintenance

or semi-annually in Severe Duty Applications.

4. Take a sample of the gear oil from the hoist drum

following the oil sampling procedure on page 16. The
oil sample must be taken prior to changing the gear oil.
Analyze the sample for wear metals, viscosity, signs of
overheating, oxidation, water and other contaminants. If the
oil sample contains an unusual amount of metallic particles,
the hoist should be removed from service and undergo a
tear-down inspection.

3. The hydraulic system filters should be changed after

the first 50 hours of operation then every 500 hours or
quarterly or in accordance with the crane manufacturers
recommendations.

2. Inspect all hoist fasteners for tightness and corrosion.

Replace all corroded fasteners and tighten per the torque
specifications on page 13.

1. Perform the Pre-use Inspection.

Quarterly Inspection (every 3 months) or monthly in

Severe Duty Applications or prior to placing the machine in
service if it has not been used for three months or more.

Failure to properly warm up the hoist, particularly under low

ambient temperature conditions, may result in temporary
brake slippage due to high back pressures attempting to
release the brake, which could result in property damage,
severe personal injury or death.

6. A warm-up procedure is recommended at each start-up

and is mandatory at ambient temperatures below +40F
(4C). The engine should be run at its lowest RPM with the
hydraulic hoist control in neutral allowing sufficient time to
warm up the system. The hoist should then be operated
at low speeds, hoisting and lowering with no load, several
times to prime all hydraulic lines with warm oil and to
circulate lubricant through the planetary gear sets.

PREVENTATIVE MAINTENANCE
A regular program of preventive maintenance for your
planetary hoist is required to minimize the need for
emergency servicing and promote safe, reliable hoist
operation.
The user of Braden hoist products is responsible for hoist
inspection, testing, operator training and maintenance
noted below with frequency dependent upon the severity of
the hoist duty cycle and the thoroughness of the preventive
maintenance program. Field experience, supported by
engineering tests, indicate the three service procedures
listed below are the most critical to safe, reliable hoist
operation and MUST be observed.
Regular Gear Oil Changes Use of Proper Gear Oil recommended type for
prevailing ambient temperatures and additives.
Periodic Disassembly and Inspection of All Wear
Components in compliance with ANSI specification
B30.5c, 1987 and API RP 2D.
Crane inspection records as well as records of preventive
maintenance, repairs and modifications must be available
for a minimum of five (5) years. These records should
include but not limited to, hoist model and serial number,
name and employer of repair technician, date and
description of work performed.
Pre-use Inspection (each shift the hoist is used): This
inspection must be performed prior to placing the crane into
service and then as necessary during the day for extended
operation.
1. Check for external oil leaks and repair as necessary.
This is extremely important due to the accelerated wear
that can be caused by insufficient lubricating oil in the
hoist. Lubricant level must be visible in the lower half of
the sight glass. Use only recommended lubricants. See
Recommended Lubricants chart in this manual.
2. Check hydraulic plumbing for damage, such as chafed or
deteriorating hoses and repair as necessary.
3. Visually inspect for loose or missing bolts, pins, keepers
or cotter pins and replace or tighten as necessary.
4. The gear oil should be changed after the first 100 hours
of operation or 30 days. The regular gear oil change
intervals may be adopted after the first oil change.
5. Inspect the full length of wire rope, rigging and
all sheaves according to the wire rope and crane
manufacturers recommendations.

The gear oil must be changed to remove wear particles

that impede reliable and safe operation of the brake clutch
and erode bearings and seals. Failure to change gear oil
at recommended intervals may contribute to intermittent
brake slippage, loss of load control, injury or death.

14

The gear oil should be changed whenever the ambient

temperature changes significantly and an oil from a different
viscosity range would be more appropriate. Oil viscosity is
critical to reliable brake clutch operation. Our tests indicate
that excessively heavy or thick gear oil may contribute to
intermittent brake clutch slippage. Make certain the gear
oil viscosity used in your hoist is correct for your prevailing
ambient temperature.

Failure to use the proper type and viscosity gear oil may
result in loss of load control, property damage, injury or
death.
Vent Plug

Oil Level Sight

Gauge

Oil Drain
Hole(s)

Recommended Planetary Gear Oil

-40

-40

-30

-20

-30

-10

10

20

30

40

NOTE: If the oil sampling/analysis has not been performed

as required, tear-down inspections will be required. Refer
to Hoist Disassembly section of this manual.
To change the gear oil, slowly rotate the drum until the oil
drain plug is aligned with the lower oil port access hole.
Install a short length of pipe threaded for 1 in. NPT into the
threaded drain port in the cable drum. Reach through the
pipe with a long hex-key and remove the drain plug. The oil
will drain out the length of pipe and not between the drum
and base. When the oil has drained, install the plug and
remove the drain pipe. Removing the vent plug will hasten
the oil drain. Rotate the drum until the drain port is aligned
with the fill/level port in the end bracket. Refill the hoist with
recommended lubricant. Install the plug securely.

DO NOT insert fingers through oil drain hole to determine

drain hole alignment. Movement of the drum could result
in sever injury should appendages be present in the drain
hole.

3. The vent plug is located in the drum bearing support. It

is important to keep the vent plug clean and unobstructed.
Whenever the gear oil is changed, the vent plug should be
removed, cleaned in solvent and reinstalled. Do not paint
over the vent plug or replace with a solid plug or grease
fitting.

50

60

MOBIL SHC 629 or 630

SYNTHETIC OR EQUIVALENT

10

20

80

90

30

100

110

40

50

120
EXXON SPARTAN EP220 OR EQUIVALENT
AGMA 5 EP, ISO VG 220

70

PREVAILING AMBIENT TEMPERATURE

EXXON SPARTAN EP150 OR EQUIVALENT

AGMA 4 EP, ISO VG 150

-10

Spartan EP 150

Exxon

Mobilgear 629

Mobil

Omala 220

Omala 150

Shell

Gear Compound
American
IndustrialEP220
Oils 220

Gear Compound
American
IndustrialEP150
Oils 150

Chevron

oC

130 oF

NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.

-20

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 slippage and damage to brake friction
discs or seals. Oil viscosity with regard to ambient temperature is also critical to reliable brake operation. Our tests
indicate that excessively heavy or thick gear oil may contribute to intermittent brake slippage. Make certain that the gear
oil viscosity used in your hoist is correct for your prevailing ambient temperature.
oF

oC

Texaco

Mobilgear 630

Texaco Meropa 150, previously used as factory fill, may no longer be widely available due to current market conditions. As of
mid-year 2002, planetary hoists are factory filled with Exxon Spartan EP150, or equivalent. Consult your oil supplier for other
equivalent oils if required.

Meropa 150

Spartan EP 220

9/2002

Meropa 220

15

Tear-down Inspection
Any hoist that has not been subjected to regular oil sample
analysis should undergo a tear-down inspection every 24
months. Also, if a hoist has an unknown history of repair
and/or maintenance, the hoist should undergo a tear-down
inspection prior to being placed into service.
A tear-down inspection of the hoist should include the
complete disassembly, cleaning, inspection and replacement
of all worn, cracked, corroded or distorted parts such as
pins, bearings, shafts and brake components. All seals and
o-rings should be replaced during a tear-down inspection.
Always use new Spirol pins in the planet gear shafts.

Any deficiency must be corrected immediately.

Before placing the hoist back in service, the rebuilt hoist
must be pull tested to the rated load of the hoist with a
dynamometer or equivalent measuring device. The hoist
should be dynamically tested by rotating the drum several
times, in both raising and lowering directions, while under
load of at least 30 % of the hoist rated lifting capacity. Check
for smooth, quiet operation during this procedure.

Moisture contamination will lead to the formation of acids

that damage all internal components. Silica found in the oil
typically indicates dirt and contaminated lubricant supply
or poor maintenance practices.

In all contaminate monitoring, equally important as the

level of contamination, is the change in the amount of
contamination compared to previous samples.

701 ppm & up Unacceptable Abnormal Sample (tear

down inspection required)

400 to 700 ppm

Caution Abnormal Sample
(monitor more frequently), tear-down inspection may be
required.

100 to 400 ppm Normal

Iron Contaminates

Note: The first oil change usually contains more wear

metals. Following the initial break-in period, the wear metal
levels should stabilize at a lower number.

Analysis
General Guide Lines
(After approximately 250 hours of operation)

OIL SAMPLING AND ANALYSIS

Proper oil sampling and analysis of the sample, is a
vital part of a comprehensive preventive maintenance
program. Information obtained from the oil analysis is
best utilized in conjunction with a regular program of
preventive maintenance. The early warning of abnormal
wear provided by an analysis program allows the user to
substitute preventive maintenance for a far more costly and
dangerous failure that may lead to loss of load control that
could result in property damage, personal injury or death.
Early detection of accelerated component wear allows the
scheduling of corrective maintenance and can reduce inoperation failures and costly down time.
Taking a Valid Oil Sample
Prepare the hoist by cleaning the drain area and drain
extension tube in order to obtain an uncontaminated
sample. Operate the hoist in both directions for one to two
minutes and then take the oil sample from the drain port as
soon as possible. Do not take the sample from the first oil
out of the drain port. Take a sample from the mid-stream
flow of the oil to obtain an accurate representation of the
oil condition. After taking an oil sample, refill hoist with
recommended lubricant.

Hot oil may cause personal injury and/or burns

to unprotected skin. Make certain the oil has
cooled to a safe temperature (less than 110F or
43C) before taking an oil sample, changing oil
or servicing the hoist.

16

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.
- Gear oil leaks
- A sudden rise in wear particles from oil analysis

PROBABLE CAUSE

Remove the pilot hose and fitting

from the brake valve, then use a 5/32
inch Allen wrench to remove the pilot
orifice. The diameter of the orifice is
approximately .020 inches (.5 mm).
Clean and install the pilot orifice tightly
in the brake valve.

REMEDY

The hoist MUST be removed from service until the problem has been corrected. If a hoist has been subjected to a
sudden heavy load (shock-load) or overload, the hoist must be removed from service, disassembled and all internal
components thoroughly inspected for damage. Continued operation with a defect may result in loss of load control,
property damage, injury or death.

TROUBLE
1. The problem could be a plugged
A
or loose pilot orifice. The pilot orifice
The hoist will not lower the load or not is a small pipe plug with a hole drilled
through it, located behind the pilot port
lower the load smoothly.
fitting on the brake valve. If it becomes
plugged, it will prevent the pilot pressure,
from the manifold, from opening the
brake valve. If it becomes loose, it will
allow an unregulated amount of oil in to
operate the brake valve causing erratic
brake valve operation.
NOTE: Some brake valves do not use a
separate pilot orifice plug.

2. The friction brake may not be Check brake cylinder seal as follows:
releasing as a result of a defective brake
A. Disconnect the swivel tee from the
cylinder seal.
brake release port. Connect a hand
NOTE: If the brake cylinder seal is pump with accurate 0-2000 psi (13,800
defective you will usually find oil leaking kPa) gauge and shut-off valve to the
from the hoist vent plug.
fitting in the brake release port.
B. Apply 1000 psi (6,900 kPa) to the
brake. Close shut-off valve and let stand
for five (5) minutes.
C. If there is any loss of pressure in five
(5) minutes, the brake cylinder should
be disassembled for inspection of the
sealing surfaces and replacement of the
seals. Refer to Brake Cylinder Service
section of this manual.

3. Friction brake will not release as a Disassemble brake to inspect brake

result of damaged brake discs.
discs. Check stack-up height as
described in Brake Cylinder Service
section of this manual.

17

TROUBLE
B
Oil leaks from vent plug

C
The brake will not hold a load with the
control lever in neutral

D
The hoist will not hoist the rated load

Same as A2.

REMEDY

1. Same as A2.

Case drain back pressure must not

exceed 100 psi (690 kPa) for gear
motors and 44 psi (304 kPa) for piston
motors. Inspect hydraulic system for
a restriction in the return line to the
reservoir.

PROBABLE CAUSE

2. Motor seal may be defective

as a result of high back pressure
in the motor case drain circuit or
contaminated oil. Contamination
will usually cause the seal to wear a
groove in the motor shaft.
Oil analysis may indicate contamination
has worn motor shaft and seal.
Thoroughly flush entire hydraulic system
and install new filters and oil. Install new
motor seal.
1. Excessive system back pressure The pressure at the motor lowering port
acting on the brake release port.
is also transmitted to the brake release
pilot circuit. Inspect hydraulic circuit for
restrictions, plugged filters or control
valves not centering.

A. Install an accurate 0-5000 psi

(34,500 kPa) gauge into the inlet port
of the brake valve.

Check relief pressure as follows:

If necessary, use shim stock to level

hoist. Refer to Hoist Installation.
First loosen, then evenly retighten all
hoist mounting bolts to recommended
torque.

Reinforce mounting surface.

Brake clutch may be damaged or worn.

Disassemble and inspect brake clutch
as described in Over-running Clutch
Service.

Improper planetary gear oil may cause

the brake clutch to slip. Drain old
gear oil and flush winch with solvent.
Thoroughly drain solvent and refill hoist
with recommended planetary gear oil
listed in Preventive Maintenance.

2. Friction brake will not hold due to Same as Remedy of Trouble A3.
worn or damaged brake discs.

3. Brake clutch is slipping.

1. The hoist may be mounted on

an uneven or flexible surface which
causes distortion of the hoist base and
binding of the gear train. Binding in
the gear train will absorb horsepower
needed to hoist the rated load and
cause heat.

2. System relief valve may be set too

low. Relief valve needs adjustment or
repair.

18

TROUBLE
Trouble D Continued From
Previous Page

E
The winch runs hot

PROBABLE CAUSE

3. Be certain hydraulic system

temperature is not more than
180F (82C). Excessive hydraulic
oil temperatures increase motor
internal leakage and reduces motor
performance.

REMEDY
B. Apply a stall pull load on the hoist
while monitoring pressure.
C. Compare gauge reading to hoist
specifications. Adjust relief valve as
required.
NOTE: If pressure does not increase
in proportion to adjustment, relief valve
may be contaminated or worn out. In
either case, the relief valve may require
disassembly or replacement.

Same as remedies for Trouble D1 &

D2.
Same as remedies for Trouble E2.

5. Rigging and sheaves not operating

efficiently.

Same as remedies for Trouble D1.

Perform rigging service as

recommended by crane manufacturer.

4. Hoist line pull rating is based on 1st Refer to hoist performance charts for
additional information.
layer of wire rope.

1. Same as D1.

Fill/drain to proper level.

2.
Be certain that the hydraulic Thoroughly clean exterior and flush
system temperature is not more than interior.
180F (82C). Excessive hydraulic oil
temperatures may be caused by:
A. Plugged heat exchanger.

B. Too low or too high oil level in Same as remedies for Trouble D2.
hydraulic reservoir.
C. Same as D2
D.
Hydraulic pump not operating Engine low on horsepower or R.P.M.
efficiently.
Tune/adjust engine.
Check suction line for damage.
Pump worn. Replace pump.
E. Hydraulic oil is wrong viscosity for Use correct hydraulic oil.
operating conditions.

3.
Excessively worn or damaged Disassemble hoist to inspect/ replace
internal winch parts.
worn parts.

19

TROUBLE
F

PROBABLE CAUSE
REMEDY

Same as remedies for Trouble D2.

Same as remedies for Trouble E2.

4. Hydraulic motor 2-speed control not Inspect and repair motor displacement
shifting correctly.
control.

3. Controls being operated too quickly. Conduct operator training as required.

2. Hydraulic oil flow to motor may be

too low.

Hoist chatters or surges while raising 1. Same as D2.

rated load.

G
The wire rope does not spool smoothly 1. The hoist may be mounted too close Check mounting distance and fleet
to the main sheave, causing the fleet angle. Reposition hoist as required to
on the drum.
angle to be more than 1 degrees.
achieve to 1 degree fleet angle.

2. The hoist may not be mounted Refer to Hoist Installation.

perpendicular to an imaginary line
between the center of the cable drum
and the first sheave.

3. Could possibly be using the wrong Consult wire rope manufacturer for
lay rope. There is a distinct advantage recommendation of wire rope that best
in applying rope of the proper direction suits your application.
of lay. When the load is slacked off,
the several wraps on the drum will stay
closer together and maintain an even
layer. If rope of improper lay is used,
the coils will spread apart each time the
load is removed. Then, when hoisting
is resumed, the rope has a tendency
to criss-cross and overlap on the drum.
The result is apt to be a flattened and
crushed rope.

4. The hoist may have been overloaded, Replace wire rope and conduct operator/
causing permanent set in the wire rigger training as required.
rope.

20

8. There are two 1/2 inch NC tapped holes in the drum

closure (item 33). Install two capscrews or threaded eyebolts to aid in removing the closure from the cable drum.
Remove and discard the O-Ring (item 17) from the O.D. of
the drum closure.

Lifting Eye

7. Remove the motor end plate from the drum.

6. Remove the twenty (20) capscrews and lockwashers from

the two (2) tie plates, and remove the plates.

5. Remove the eight capscrews that secure the brake

cylinder to the motor side plate. Lift the brake cylinder out of
the hoist and place on a clean work surface. Disassembly of
the brake cylinder will be discussed in the Brake Cylinder
Service section of this manual. Remove and discard the VRing seal that was under the brake cylinder. Do not remove
the four (4) capscrews holding the motor adapter to the brake
cylinder at this time. Refer to Brake Cylinder Service later
in this manual.

brake clutch assembly will be discussed in the Brake Clutch

Service section of this manual.

DISASSEMBLY PROCEDURE
1. Remove the wire rope from the hoist drum and wind
onto a cable reel as recommended by the wire rope
manufacturer. Power-wash the hoist and all motor piping
to remove contamination that might enter open hose and
motor ports. Align the drain plug in the cable drum with the
lowest access hole in the bearing support end plate before
removing the hoses and piping. Drain the gear oil from the
hoist as described in the Preventive Maintenance section
of this manual.

CAUTION
The CH165A/CH230B with the standard 01 drum weighs
approximately 1100 lb (500 kg). Make certain lifting
equipment has adequate capacity. Using undersized
or poorly maintained lifting equipment may result in a
dropped load, property damage injury or death.

CAUTION
Do not attempt to disassemble/assemble the hoist in
the horizontal position as thrust washers may become
dislodged and the gear train out of alignment that may
cause severe gear train damage that may result in loss of
load control, property damage, injury or death.
2. Stand the winch up on the drum bearing support end with
the motor end up. Secure the hoist in this position so that it
does not fall over and cause property damage or personal
injury.
3. Tag and remove the hydraulic hoses that connect the
brake valve and motor to the brake release port.

4. Remove the four capscrews and lockwashers securing

the motor and lift the motor off the hoist. Cover the motor
ports to prevent contamination. Remove the brake clutch
assembly from the brake cylinder. Disassembly of the

21

9. For -01 and -02 drums, the primary sun gear (item 22),
primary planet carrier assembly (item 300), and output
planet carrier assembly (item 400) can now be lifted out of
the cable drum.
For -02 drums only, there are also two 1/2 inch NC tapped
holes in the ring gear adapter (item 33). Install two capscrews
or threaded eye-bolts into these holes and lift the ring gear
adapter and ring gear out of the cable drum.
10. Lift the cable drum (item 10) off of the drum support
assembly (item 3)
11. Thoroughly clean and inspect all disassembled
components at this time. Inspect bearings in the drum
closure and cable drum (items 9 & 16), and replace as
required. Inspect sealing surfaces on the drum support and
brake cylinder and repair any damaged areas if possible, or
replace components as required. During a complete winch
teardown, drum seals (items 18 and 70) and V-Ring seals
(items 6 and 20) should always be replaced. Inspect thrust
washers (items 13 and 15) for signs of excessive wear,
heat damage or metal transfer and replace as necessary.
Inspect the ring gear teeth for nicks, spalling or excessive
wear. Replace if wear in contact areas is greater than 0.015
in. (0.4 mm) when compared to unworn area of teeth.

22

3. Note that the roll pin is slightly recessed into the carrier
when properly installed. With a center punch, stake the
carrier next to the pin hole as shown. This will distort the
hole and prevent the pin from backing out in operation.
Repeat these steps for each of the three planet gears.

2. Carefully align the pin hole in the carrier with the hole in
the shaft and drive a new roll pin into place. ALWAYS use
NEW roll pins. When properly positioned, 50% of the roll
pin will engage the planet gear shaft and 50% will remain in
the carrier.

Driving planet shafts with a hammer may cause damage

to the hardened thrust washers which could lead to
catastrophic gear train failure which could result in loss of
load control, property damage, injury or death

CAUTION

1. Install a bearing (5) into a planet gear (2) and place a

thrust washer (4) on each side of the gear. Position this
sub-assembly into an opening in the carrier. Slide a planet
gear shaft (3) through the carrier (1), thrust washer (4),
bearing (5) and remaining thrust washer (4). DO NOT drive
shafts into carrier with a hammer. Shafts should move
freely when properly aligned.

Assembly

PLANET CARRIER SERVICE

PRIMARY PLANET CARRIER

Disassembly
1. Remove the planet gears by first driving the roll pins (6)
into the center of the planet gear shafts (3). Push the planet
gear shafts far enough out of the planet carrier to expose
the roll pin hole. Use a pin punch to drive the roll pins from
the shafts. DO NOT reuse roll pins
2. Now you can remove the planet shafts, bearings, thrust
washers and gears. Thoroughly clean all parts and inspect
for damage and wear. The bearing rollers should not exhibit
any irregularities. If the rollers show any sign of spalling,
corrosion, discoloration, material 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
impair the cages ability to separate, retain and guide the
rollers properly, the bearing should be replaced. The thrust
washer contact areas should be free from any surface
irregularities that may cause abrasions or friction. The
gears and shafts should be inspected for abnormal wear or
pitting. Replace if necessary

23

-01 Drum

-02 Drum

OUTPUT PLANET CARRIER

Disassembly

Assembly
1. Place the output planet carrier on a clean work surface
with the splined end of the housing down.
01 Drums only
Install the thrust plate (6) into the
center bore of the
housing and secure in place with
retaining ring (7).
2. Apply oil soluble grease to a
thrust washer (4) and install it on
one side of a planet gear (2). Place
the planet gear on a clean work
surface with the thrust washer
down. Apply oil soluble grease to
the bore of the gear and stack a row
of loose bearing rollers (5) into the
planet gear using the grease to hold
the rollers in position. There are 22
rollers in each row. Install a bearing
spacer (9) into the gear. Install a
second row of bearing rollers on
top of the bearing spacer. Place
the remaining thrust washer on top of the planet gear.
Carefully slide the planet gear sub-assembly into the planet
carrier. Install a planet gear shaft into the planet carrier and
through the planet gear bearings. DO NOT drive shafts into
carrier with a hammer. Shafts should move freely when
properly aligned.

CAUTION
Driving planet shafts with a hammer may cause damage
to the hardened thrust washers which could lead to
catastrophic gear train failure which could result in loss of
load control, property damage, injury or death.
3. Follow steps 2 and 3 of the Primary Planet Carrier
assembly procedure to install and stake a NEW roll pin in
the carrier.
Repeat this procedure for each of the planet gears.

24

1. Remove the planet gears by first driving the roll pins (8)
into the center of the planet gear shafts (3). Push the planet
gear shafts far enough out of the planet carrier to expose
the roll pin hole. Use a pin punch to drive the roll pins from
the shafts. DO NOT reuse roll pins.
2. Remove the planet shafts, bearing rollers, spacers,
thrust washers and gears. Thoroughly clean all parts and
inspect for damage and wear. The bearing rollers should
not exhibit any irregularities. If the rollers show any sign
of spalling, corrosion, discoloration, material displacement
or abnormal wear, they should be replaced. The thrust
washer contact areas should be free from any surface
irregularities that may cause abrasions or friction. The
gears and shafts should be inspected for abnormal wear or
pitting. Replace if necessary.

2. Use a small punch and hammer to tap one of the

bearings (item 44) off of the inner race. The over-running
clutch can now be removed from the inner race. Closely
inspect the over-running clutch and the polished surfaces of
the inner and outer race for wear, cracks, pitting, corrosion
or mechanical damage. Closely inspect the bearings
for any signs of damage, wear, corrosion, pitting or heat
discoloration.

1. Remove one of the retaining rings (item 47) from the

outer race (item 42). Push the inner race (item 50),
bearings (item 44) and over-running clutch (item 46)
through the outer race.

Disassembly

OVER-RUNNING CLUTCH SERVICE

The polished surfaces of the inner and outer race and the
over-running cams must be perfectly smooth to insure
positive engagement of the clutch. The slightest defect
may reduce clutch effectiveness, which may lead to loss of
load control and result in property damage, injury or death.
It is generally recommended to replace the entire clutch
assembly if any component is defective. For these reasons,
the over-running clutch assembly should be disassembled
for inspection only if the hoist has exhibited any unusual
operation that would point toward a clutch malfunction, or
the over-running clutch assembly shows external signs of
mechanical damage.
NOTE: Outer race (item 42), Inner race (item 50) and
Over-running clutch (item 46) are NOT SOLD individually
as replacement parts. If any of these parts require
replacement, the entire over-running clutch assembly must
be replaced. Carefully note the relative orientation between
the inner and outer races, and the direction of free rotation
of the inner race. The clutch MUST be re-assembled
correctly for proper hoist operation.

25

Assembly
1. If both bearings (item 44) have been removed from the
inner race, install one of them now.
2. Install the over-running clutch onto the inner race.
Rotate the inner race slightly to get the clutch started onto
the inner race.
3. Install the other bearing onto the inner race.
4. The outer race should have one retaining ring (item 47)
installed in one end. Carefully slide the inner race, with
bearings and clutch, into the outer race. Install the other
retaining ring into the outer race.
Shown above are the two types of clutch assemblies used
in CH165 and CH210 hoists. The drawings show each
type properly assembled.

26

Failure to assemble the over-running clutch assembly with

all parts oriented correctly may result in reduced brake
effectiveness, which may lead to loss of load control and
result in property damage, injury or death.

Disassembly

-01 DRUM

-02 DRUM

1. Thoroughly clean and inspect all parts at this time.

Check sealing surfaces on both the motor adapter and
brake cylinder. Be sure the brake release port is open and
free of contamination.

Clean and Inspect

BRAKE CYLINDER SERVICE

CAUTION
The motor adapter is under spring tension from the brake
springs. Loosen each of the capscrews one turn at a time
until spring tension is released.
1. Stand the brake assembly on the splined end, with the
motor adapter up. Remove the four capscrews (item 14)
and lockwashers (item 15). Use a criss-cross pattern
and loosen each capscrew one turn at a time until spring
tension is released.
2. Remove the motor adapter (item 2). Lift out all the
brake discs (item 3), friction discs (item 40) and the spacer
(item 8).
3. Remove and discard the O-Ring and backup ring (items
11 & 12) from the motor adapter. Remove and discard the
seal (item 5) from the brake cylinder. Remove the steel
piston backup ring (item 6).
2. Place friction brake disc on flat surface and check for
4. Remove the pressure plate (item 7) and the springs and distortion with a straight edge. Friction material should
appear even across entire surface with groove pattern
separator (items 9 & 10) from the brake cylinder.
visible. Replace friction disc if splines are worn to a

27

point, disc is distorted, friction material is burned or worn

unevenly, or groove depth is less than 0.003 in. (0.08 mm).

3. Place steel disc on flat surface and check for distortion

with a straight edge. Check surface for signs of material
transfer or excessive heat. Replace steel disc if distorted,
heat discolored, or mechanically damaged.
4. Check brake spring free length. Minimum free length
is 1-7/16 in. (36.5 mm). Check springs for any signs of
cracking or failure. If a brake spring must be replaced for
any reason, then ALL brake springs must be replaced.

Assembly
1. Place the motor adapter on a clean work surface with the
motor mounting surface down. Apply a light coat of oil to a
new backup ring (item 12) and O-Ring (item 11) and install
them into the groove on the motor adapter. Backup rings
are always placed on the low pressure side of the O-Ring.
In this case, the backup ring is toward the motor mounting
surface. Lightly oil the brake cylinder seal (item 5) and
install it onto the motor adapter with the seal lip down.
2. Install a steel brake disc (item 3) into the motor adapter,
followed by a friction disc (item 4). Continue to alternately
install steel and friction discs until there are 8 steel and 7
friction discs. A steel disc will be on top.
3. Install the brake plate spacer (item 8) on top of the last
steel disc.
4. To check brake stack height, place pressure plate (item
7) on top of brake spacer. Hold pressure plate down firmly
by hand and measure gap (in three places) between motor
adapter and pressure plate. Average gap must measure
between 0.160 in. (4 mm) maximum and 0.080 in. (2.0 mm)
minimum. If the gap exceeds the maximum limit, there may
be too many discs in the stack-up or the discs are distorted.
If the gap is less than the minimum, there may be too few
discs or the discs are worn beyond their serviceable limit and
should be replaced. When the gap is within the minimum
and maximum values, remove the pressure plate and all
brake discs. Lubricate all friction discs with the same oil to
be used in the hoist. Install all brake discs and brake plate
spacer as described in steps 2 and 3.

28

CAUTION
Failure to replace brake springs as a set may result in
uneven brake application pressure and repeated brake
spring failure.

Seal

O-Ring
Backup Ring

Measure gap between

pressure plate and
motor adapter

5. Place the brake cylinder on a clean work surface with the

drum end down. Install the spring spacer (item 10), then
the 18 springs (item 9.)

Always use the molded spring spacer to properly position

the springs in the brake cylinder. Failure to install the
spring spacer may allow the springs to contact each other
and become damaged. This could result in loss of load
control, property damage, injury or death.
6. Install the pressure plate (item 7) into the brake cylinder.
Be careful that none of the springs fall over. Install the steel
backup ring (item 6). Apply an oil soluble grease to a new
O-Ring (item 13) and install it in the brake housing.
7. Apply an oil soluble grease to the sealing surface of the
brake cylinder and the piston seal. Turn the brake cylinder
over and lower it onto the motor adapter, being careful not to
damage the piston seal or O-Ring on the adapter. Be careful
the O-Ring (item 13) does not fall out of place, and the oil
passages are aligned. The alternate assembly method
below could also be used.
8. Turn the entire assembly over and install the four capscrews
and lockwashers. After the capscrews make contact with the
motor adapter, evenly tighten them one turn at a time until
the motor adapter is drawn tight against the brake cylinder,
then torque to the recommended value.

NOTE: The close fitting backup ring may be depressed

slightly to one side to lodge it in the brake cylinder bore and
temporarily hold the pressure plate and springs in place
while the brake cylinder is inverted and lowered over the
motor adapter.
As an alternate, the motor adapter and brake plates can be
turned over and installed into the brake cylinder, holding the
brake plates and spacer in place through the center opening.
Be careful to not pinch your fingers between the spacer plate
and the pressure plate.

BRAKE CYLINDER PRESSURE TEST

1. Install a -6 ORB fitting into the brake release port on the
motor adapter. Connect a hand pump with an accurate
0-2,000 psi (0-13,800 kPa) gauge and shut-off valve to this
fitting. Apply 1,000 psi (6,900 kPa) to the brake and close
the shut-off valve. Let the unit stand for five minutes. If
there is any loss of pressure, the brake cylinder should be
disassembled for inspection of the sealing surfaces, seal
and O-Ring. When the source of the pressure leak has
been determined and corrected, re-assemble the brake
cylinder and repeat the test.
2. WHILE PRESSURE IS APPLIED AND THE BRAKE IS
RELEASED, install the over-running clutch assembly into
the brake pack. Turn the clutch back and forth to align the
splines on all the friction discs. Release the pressure on
the brake cylinder and remove the clutch assembly. The
brake cylinder is now complete and ready to be installed in
the hoist.

29

LOWERING
PORT

REVERSING DIRECTION OF
DRUM ROTATION
MOTOR
CASE
DRAIN

MOTOR

Figure B

MOTOR
CASE
DRAIN

M= MANIFOLD BLOCK

(090, 110, & 120 MOTORS ONLY)

Figure A

DRN

BR

HOISTING
PORT
BRAKE
RELEASE
CIRCUIT

DRN

BR

HOISTING
PORT

MOTOR

BRAKE
RELEASE
CIRCUIT

LOWERING
PORT

The procedure below applies to single speed gear motors. For two speed gear motors, the motor must disassembled and
the center section with the shift spool turned 180 degrees.
In order to change the direction of rotation, 2 things must be changed on the hoist. First, the motor hoist and lower
directions of rotation must be changed to the opposite direction. This is done by exchanging positions of the brake valve
and manifold block on the motor. Secondly, the brake clutch assembly must be made effective for the opposite direction of
rotation. This is done by reversing the inner race of the brake clutch assembly.
Figures A and B above show typical CH165A/230B motor installations. Note that the only difference between the
two drawings is the motor is rotated 180 (the belly of the motor moves to the opposite side). If the motor shaft rotates
clockwise in figure A when the hoisting port is pressurized, it will rotate counterclockwise in figure B.
1. Remove the four capscrews if equipped securing the brake valve to the motor. Remove the four capscrews securing
the manifold block to the motor. Disconnect the motor case drain hose at the motor.
NOTE: Some installations have the brake release hose connected directly to the motor, instead of to the manifold block.
In this case, disconnect the brake release hose at the motor port. Stand winch up on drum support with the motor end up
and secure in this position.
2. Before removing the motor, it is a good idea to note or mark the position of the motor in relation to the winch, since it
will be rotated 180 when reinstalled. Rotating the motor allows the hoist and lowering hoses to connect on the same
side of the hydraulic motor as in the previous setup. Remove the capscrews securing the motor to the winch and carefully
remove the motor.
3. Remove the brake clutch assembly from the brake cylinder.
4. Remove the snap ring (47) from one-end of the brake clutch assembly and push the inner race out of the assembly.
Refer to Over-Running Clutch Service section of this manual for drawings.
5. Use a punch to remove the bearing on one side of the inner race so the sprag assembly can be removed. Remove the
sprag assembly and flip over so that the direction of free rotation is reversed. Note: the sprag assembly is etched with
arrows indicating both the free turn and lock direction.
6. Using a press or punch reinstall the bearing on the inner race.
7. Slide the inner race into the outer race while ensuring the sprag cams do not catch on the outer race. Install the snap
ring and ensure it is fully seated in the groove.

30

For - 01 Drums
Before installing the brake clutch, be sure the inner race turns free in the opposite direction the drum will turn to haul-in
wire rope. An easy way to check the rotation is to hold the outer race in one hand
and rotate the inner race. Install the brake clutch with as shown in drawing above.

For -02 or -21 Drums

Before installing the brake clutch, be sure the inner race turns free in the same direction the drum
will turn to haul-in wire rope. An easy way to check the rotation is to hold the outer race in one hand
and rotate the inner race. Install the brake clutch as shown in drawing above.

Be certain the snap ring is seated in the groove in the splined bore of the inner race. This snap ring will keep the brake
clutch assembly correctly positioned in the center of the friction brake pack. Binding of the brake or brake failure may
occur if snap ring is omitted, which may cause winch failure resulting in property damage, injury or death.
-02 and -21 Drum
8. Install a new O-ring on the motor pilot. Rotate the motor 180 from its original position and install it onto the brake
cylinder. Install and tighten motor capscrews to recommended torque.
9. Install new O-rings in the brake valve and manifold block. Attach the brake valve and manifold block to the motor using
the original capscrews and tighten to recommended torque.
10. Connect the motor case drain hose to the motor case drain port. NOTE: On two speed motors, the case drain and
shift drain should be connected directly to tank. DO NOT use the drain connection
on the brake valve.
11. If your winch had the brake release hose connected directly to the motor, the original motor
port must be plugged and the hose connected to the motor pressure port near the manifold block (lowering port).
12. Operate the winch slowly in both directions and check for oil leaks and/or unusual sounds from the hoist. The winch
should operate smoothly in both directions. Refer to WIRE ROPE INSTALLATION and properly install rope onto the hoist
drum.
13. Before returning the hoist to full service, a light load should be lifted and held a few feet off the
ground to be sure the static brake is functioning properly. The hoist should also be able to slowly
lower the load in a smooth and controlled manner. If the hoist does not perform either of these
functions, refer to TROUBLESHOOTING for additional information.

31

Drum
Closure

10. Install the eight capscrews and lockwashers (214 & 215)

9. Place the motor end plate onto the drum, aligning it

approximately with the support end plate and centered
on the drum. Install a new v-ring seal (20) onto the brake
cylinder. Lubricate the seal and bearing surfaces of the
brake cylinder, seal and bearing. Install the brake cylinder
assembly into the drum and motor end plate in the same
orientation as it was removed.

8. Install a new bearing (16) into the drum closure (23) if

replacement is necessary. Make certain to press the bearing
against the shoulder in the bearing bore. Coat the outside
diameter of a new seal (18) with non-hardening sealant. With
the spring side toward the bearing, press the seal into the
drum closure until the seal is even with the outer edge of the
closure. Install a new o-ring (17) into the drum closure. Apply
general purpose grease to the outside diameter of the drum
closure and install it into the drum. When properly installed,
the outer edge of the drum closure will extend beyond the
drum by approximately .034 in. (0.9 mm). If the drum closure
can not be installed as shown, one or more components may
be out of position. The most common cause is the thrust
washers are out of position or the output planet carrier is not
seated. DO NOT proceed with assembly until the source of
the problem has been identified and corrected.

Drum

7. Install the primary sun gear (22) into the primary planet
carrier. Apply general purpose grease to thrust washer (15)
and place it on top of the primary planet carrier. Center the
thrust washer on the primary planet carrier
-02 Drums: Install the ring gear adapter (33) into the ring
gear.

6. Apply general purpose grease to thrust washer (13) and

install it onto the pilot of the primary planet carrier (300).
Turn the primary planet carrier over and install it into the ring
gear while meshing the planet gears with the ring gear and
the splines of the carrier with the output sun gear.

the ring gear teeth with the planet gear teeth.

HOIST ASSEMBLY

1. Place the drum support assembly on a clean work surface

with the bearing support facing up. Lubricate the bearing
and sealing surfaces on the bearing support. Install a new
V-Ring seal onto the bearing support.

2. Install a new bearing in the drum if replacement is

necessary, making certain to press it against the shoulder in
the bottom of the bearing bore. Coat the outside diameter
of a new seal with a sealant. Turn the spring side of the seal
toward the bearing, and press the seal into the seal bore,
leaving it EVEN with the outer surface of the drum bore.
3. Turn the drum over, and set it down on the bearing support.
Be careful not to damage the seal when lowering the drum
onto the bearing support.
4. -01 Drums: Install the output planet carrier (400) into the
drum while meshing the planet gears with the ring gear and
the planet carrier with the drum bearing support.
-02 Drums: Lower the output planet carrier (400) into the
drum, making certain the splines on the carrier mesh with
the splines in the drum.
5. Install the output sun gear (12) in to the output planet
carrier.
-02 Drums: Lower the ring gear into the drum while meshing

32

through the brake cylinder into the end plate. Loosely tighten
all capscrews until just snug against the brake cylinder.
Continue to tighten the capscrews in a criss-cross pattern
one turn at a time until the motor end plate is drawn tightly
up against the brake cylinder.
11. Install the two tie plates (28) onto the end plates using
all 20 capscrews and lock washers (25 & 26). Be sure the
curved sides of the tie plates are toward the top of the hoist.
Evenly tighten all tie plate and brake cylinder/end plate
capscrews to 80 lb.-ft (109 N-m) torque.
12. Install the over-running brake clutch into the center
of the brake pack. Refer to page 25 & 26 for correct
orientation of the clutch. The input (motor) side of the
clutch is the end facing the motor with the longest spline
engagement. It may be necessary to rotate the drum and
hoist gear train slightly to align the splines of the shaft with
the splines of the brake clutch. If the clutch does not align
with the brake discs and input sun gear, install a handpump onto the brake release port and apply approximately
1000 PSI (6900 kPa) to fully release the spring applied
brake and permit easy alignment of the brake components.
The internal retaining ring in the clutch bore should be
seated against the input sun gear when correctly installed.
13. Lubricate and install a new O-Ring onto the hydraulic
motor pilot. Engage the motor shaft with the inner race
of the over-running clutch and lower the motor into place.
Install motor capscrews and lockwashers and torque to
correct value.
14. Install all hydraulic lines disconnected during
disassembly and route hoses to avoid chafing. Be careful to
clean lines and fittings if there is a chance that paint chips
or other contamination has entered the ports. Tighten all
connections.
15. After the hoist assembly is complete, check all
capscrews and hydraulic lines to make certain they have
been properly installed and tightened correctly. Fill the
hoist gear cavity to the center of the sight gauge or level
plug. Refer to the Recommended Lubricant section of this
manual.
16. Before returning the hoist to service, it should be tested
on a hydraulic test stand that can operate the hoist to at
least 35% of the rated flow, pressure and load. A moderate
load should be lifted and held 3 ft. (1m) off the ground to
be sure the static brake is functioning properly. The hoist
should be able to slowly lower the load in a smooth and
controlled manner. If the hoist does not perform these
functions correctly, refer to the Trouble Shooting section
of this manual.

33

11
10

20

19

11

18

18

19

16

15

10

19
4
5

17

22

12

14

14

BRAKE VALVE SERVICE

20

19
4
5

15

8
13
3
21

Most CH165 & 230B Series hoists are supplied with

our Braden 1-1/2 brake valve. It is a reliable hydraulic
valve with internal components manufactured to close
tolerances. Due to these close tolerances, several
individual parts are not available as replacement parts
and are noted in the following parts lists as NSS (Not
Serviced Separately).
Before disassembling the brake valve, be sure you have
conducted all applicable troubleshooting operations and
are certain the brake valve is causing the malfunction.
Thoroughly clean the outside surfaces of the valve and
work in a clean dust-free area, as cleanliness is of utmost
importance when servicing hydraulic components.
1 1/2 inch brake valves built after mid-March 1997 contain
a spring seat (item 22) between the spool spring and the
spool. This provides a slightly larger, more uniform area
for the spring to seat against the spool. The result is
increased spring service life and improved repeatability of
pressure/flow modulation over the full compression range
of the spring.
The spring retainer has been modified to allow for the
additional thickness of the spring seat and a groove
machined into the hex end cap serves as a visual indication
that the valve contains the new spring seat. The spring
seat improvement may be added to earlier brake valves
by installing kit, Part Number 62805. Items 3, 7, 13, 14
and 22 are included in the kit. We recommend that this
kit be installed whenever the brake valve is removed for
inspection or service.
It is always a good practice to check the initial opening
or cracking pressure of the brake valve whenever the
hoist is serviced or inspected. Refer to Braden Service
Bulletin 527 for complete brake valve test and adjustment
procedures.

21

20

19

18

17

16

15

14

13

12

11

10

ITEM

Spring Seat

Shim

Check Spring

Pipe Plug

O-Ring

Back-up Ring

O-Ring

Back-up Ring

O-Ring

Main Piston Spring

Check Valve Spring

Check Ball

Reducer

Check Valve Poppet

Damper Piston Extension

Damper Piston

Main Piston

Plug

Spring Retainer

Check Valve Retainer

Valve Housing

DESCRIPTION

QTY.

25662

25373

18009

21123

24777

24776

24778

24186

24434

24190

24428

24436

24423

101017

NSS

NSS

24420

101016

24424

NSS

PART NO.

101015

22

DISASSEMBLY

1. Remove the fitting, motor drain check ball and spring.

2. Remove the spool spring retainer and spool spring. Remove

the spool plug and carefully remove the spool assembly.
Remove the damper piston from the spool. The piston will
come out of the spool slowly, because of a partial vacuum
formed between the two. Use extreme care to avoid damaging
the polished surfaces of either piece.

3. Remove the check valve spring retainer, spring and check

valve poppet.

34

CLEAN AND INSPECT

3. Lubricate the spool and damper piston O-rings with

hydraulic oil. Carefully install the damper piston into the
spool. Carefully install the spool into the valve housing.
Always install the spool into the valve body from the plug
end, so the O-ring enters the bore first. Install the spring
seat, spool spring, damper piston extension and spring
retainer.

4. Install the check valve poppet, spring and check valve

retainer.

1. Discard all O-rings and back-up rings. Clean all parts in

solvent and blow dry. Inspect polished surfaces of spool and
damper piston for damage that may cause binding or leakage.
Inspect spool bore in valve housing for damage or scoring.
Inspect check valve seat in valve housing and check valve
poppet. If the spools, bores or valves are damaged, the entire
brake valve must be replaced. Check the free length of main
piston spring. Replace if less than 3 7/16 in. (87.3 mm) long.
Check the free length of the check valve spring. Replace if less
than 1 1/2 in. (38.1 mm) long.

2. Inspect the 0.020 inch (0.5 mm) orifice in the end of the spool
to be certain it is open.

6. The brake valve is now completely assembled and

ready to be installed on the hoist motor.

5. Install the motor drain check ball, spring and fitting.

O-RING

ASSEMBLY

BACK-UP RING
1. Install new O-rings and back-up rings on the spool and
damper pistons 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 piston set for
ten (10) minutes before installing them into the brake valve
housing. This will allow the O-rings to return to their original
size after being stretched.
2. Install new O-rings on the plug and spool retainers.

35

BRAKE VALVE OPENING PRESSURE TEST

Whenever brake components are replaced or a brake
component malfunctions or fails, the entire brake system
should be inspected and tested. Your testing must
include checking the brake valve opening pressure
in addition to a thorough inspection of the failed
components.
Preparation:
Begin the inspection by verifying that the brake valve
and motor piping is correct for this application. If you
are not certain, contact your nearest Braden distributor,
the crane OEM, or the Braden factory Product Support
Department before proceeding. Do not attempt repairs
on equipment you are not familiar with. Fully remove the
load from the hoist and block or secure any moveable
parts of the crane or hoist before proceeding with
brake valve test. It will be necessary to lower the hook
block or ball to the ground (deck) since the brake will
be completely released. Make certain the test area is
clear of all unauthorized personnel as the hoist will be
operated in raise and lower functions.
Brake Valve Pressure Test
1. Shut off the engine or motor driving the hydraulic
system and vent residual pressure as recommended by
the crane OEM.
2. Install an accurate 0-2000 psi (0-13,800 kPa)
pressure gauge teed into the brake release line, located
at the lowering (non-brake valve) side of the hydraulic
motor. This is typically a -4 JIC connection.
3. To eliminate the slight drag effect of the internal multidisc brake, remove the brake release line from the hoist
brake port and install a plug in the line or close to the
needle valve if so equipped.
4. To the internal brake port, install a hand pump with
an accurate 0-2000 psi (0-13,800 kPa) gauge. Operate
the hand pump and apply approximately 1000 psi (6,900
kPa) to the brake port to fully release the brake. Close
the hand pump valve to hold the brake released during
the remainder of the test.
5. Operate the crane power source at full throttle and
VERY slowly move the winch control lever toward the
lowering direction while monitoring the brake valve
opening pressure. Record the pressure when the cable
drum begins to turn in the lowering direction.
6. The initial lowering pressure should be no lower than
575 psi for the 1.5-inch Braden brake valve, P/N 81609
which is used on most single speed motors on CH165A
& CH230B planetary hoists.

If the inutial lowering pressure is less than the specification

listed
the brake valve should be adjusted.
ADJUSTMENT OF BRAKE VALVE
1. Inspect the main spool spring to make certain it is not
damaged. If the spring is in good condition, the brake valve
opening pressure should be adjusted by installing shims
between the spring retainer, item 3, and the main piston
spring. A maximum of .062 in. (1.6 mm) shims are allowed in
the 1.5 in. valves. Additional shims may result in accelerated
spring failure due to over-compensation.
2. If the spring requires more than the maximum number of
shims listed above to achieve the recommended opening
pressure, the spring should be replaced.
3. Inspect the brake valve piston and damper piston for
scoring and seal ring condition. The seal rings should be
replaced following disassembly and inspection. If there is
any scoring of the pistons and/or the brake valve housing, the
entire brake valve must be replaced.
4. Inspect the check valve poppet and seat for irregular wear
or damage. It the poppet set is damaged the entire brake
valve must be replaced. Tighten the spring retainers to 40
lb-ft torque.
NOTE: Always recheck the brake operation following
inspection or adjustment, prior to placing the hoist back in
service.

36

inches (in.)
feet (ft.)
miles (mi.)

inches2 (sq.in.)
feet2 (sq.ft.)

inches3 (cu.in.)
quarts (qts.)
gallons (gal.)
inches3 (cu.in.)
feet3 (cu.ft.)
feet3 (cu.ft.)
fluid ounce (fl.oz.)
0.01639
0.94635
3.7854
16.39
28.317
0.02832
29.57

28.35
0.4536
907.18
0.90718
1013.05

3600
6.895
0.0703
0.069
0.2488
100

X 0.746
X 0.0226

X
X
X
X
X
X

X
X
X
X
X

X
X
X
X
X
X
X

X 645.15
X 0.0929

X 25.4
X 0.3048
X 1.6093

kilometers/hour (km/hr)
meters/second (m/s)
meters/minute (m/min)

X 0.3937
X 3.281
X 0.6214

= inches (in.)
= feet (ft.)
= miles (mi.)

X 1.34
X 44.25

X
X
X
X
X
X

X
X
X
X
X

X
X
X
X
X
X
X

0.2961
0.145
14.22
14.5
4.0193
0.01

0.03527
2.2046
0.001102
1.1023
0.000984

61.024
1.0567
0.2642
0.06102
0.03531
35.315
0.03381

= pound-inches (in.lbs.)
= pound-feet (ft.-lbs.)
= pound-feet (ft.-lbs.)

= horsepower (hp)
= ft.-lbs./min.

= inches Hg (60oF)
= pounds/sq.in. (PSI)
= pounds/sq.in. (PSI)
= pounds/sq.in. (PSI)
o
= inches H2O (60 F)
= bars

=
=
=
=
=

=
=
=
=
=
=
=

ounces (oz.)
pounds (lbs.)
tons (2000 lbs.)
tons (2000 lbs.)
tons (long) (2240 lbs.)

inches3 (cu.in.)
quarts (qts.)
gallon (gal.)
inches3 (cu.in.)
feet 3 (cu.ft.)
feet 3 (cu.ft.)
fluid ounce (fl.oz.)

X 0.000155 = inches2 (sq.in.)

= feet 2 (sq.ft.)
X 10.764

X 8.851
X 0.7376
X 7.233

0.1 or 10-1
0.01 or 10-2
0.001 or 10-3
0.000.001 or 10-6

= miles/hour (m/h)
= feet/second (ft./sec.)
= feet/minute (ft./min.)

=
=
=
=

X 0.6214
X 3.281
X 3.281

(d)
(c)
(m)
(m)

Fahrenheit = (1.8oC) + 32

deci
centi
milli
micro

COMMON METRIC PREFIXES

1,000,000 or 106
1,000 or 103
100 or 102
10 or 101

Metric to English

newton-meters (N-m)
newton-meters (N-m)
kilogram/meter (kg-m)

TORQUE

kilowatts (kW)
watts (W)

POWER

kilopascals (kPa)
kilopascals (kPa)
kilograms/sq.cm. (kg/cm2)
bars
kilopascals (kPa)
kilopascals (kPa)

PRESSURE

grams (g)
kilograms (kg)
kilograms (kg)
metric tons (t)
kilograms (kg)

MASS

liters (l)
liters (l)
liters (l)
centimeters3 (cc)
liters (l)
meters3 (m3)
milliliters (ml)

VOLUME

millimeters 2 (mm 2)
meters2 (m 2)

AREA

millimeters (mm)
meters (m)
kilometers (km)

LINEAR

METRIC CONVERSION TABLE

=
=
=
=

Celsius = 0.556 (oF - 32)

TEMPERATURE

= kilometers/hour (km/hr)
= meter/second (m/s)
= meter/minute (m/min)

VELOCITY

= newton-meters (N-m)
= newton-meters (N-m)
= kilograms/meter (kg-m)

= kilowatts (kW)
= watts (W)

= kilopascals (kPa)
= kilopascals (kPa)
= kilograms/sq.cm. (kg/cm 2)
= bars
= kilopascals (kPa)
= kilopascals (kPa)

= grams (g)
= kilograms (kg)
= kilograms (kg)
= metric tons (t)
= kilograms (kg)

= liters (l)
= liters (l)
= liters (l)
= centimeters3 (cc)
= liters (l)
= meters3 (m 3)
= millileters (ml)

= millimeters 2 (mm 2)
= meters2 (m 2)

= millimeters (mm)
= meters (m)
= kilometers (km)

English to Metric

ounces (oz.)
pounds (lbs.)
tons (2000 lbs.)
tons (2000 lbs.)
tons (long) (2240 lbs.)

inches Hg (60oF)
pounds/sq.in. (PSI)
pounds/sq.in. (PSI)
pounds/sq.in. (PSI)
o
inches H2O (60 F)
bars

horsepower (hp)
ft.-lbs./min.

(M)
(k)
(h)
(da)

X 0.11298
X 0.3048
X 0.3048

pound-inches (in.-lbs.) X 0.11298

pound-feet (ft.-lbs.)
X 1.3558
pound-feet (ft.-lbs.)
X .1383

miles/hour (m/h)
feet/second (ft./sec.)
feet/minute (ft./min.)

mega
kilo
hecto
deka

37

1.0
2.0
3.0
4.0

5.0 Serial Number Record

6.0 Troubleshooting
7.0 Replacement Parts List

R SERIES SLIP RING

Safety Instructions
Installation
Maintenance
Storage

R-SERIES SLIP RING

10102 F Street Omaha, NE 68127-1181 l Tel: 402/339-9300 or 800/521-4888

Fax: 402/339-9627 or 800/780/8329
P/N 969000 2006.07.21 Rev. 4

CONDUCTIX INCORPORATED
The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE CREATED BY THE DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS
MANUAL. Insul-8 makes no warranty (and assumes no liability) as to function of equipment or operation of systems built
according to customer design or of the ability of any of its products to interface, operate or function with any portions of
customer systems not provided by Insul-8.
Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and
material discovered and reported to Seller within one year after shipment of such goods to Buyer.
Except where the nature of the defect is such that it is appropriate, in Sellers judgment, to effect repairs on site, Sellers
obligation hereunder to remedy defects shall be limited to repairing or replacing (at Sellers option) FOB point of original
shipment by Seller, any part returned to Seller at the risk and cost of Buyer. Defective parts replaced by Seller shall
become the property of Seller.
Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service
recommended by Seller and altered only as authorized by Seller. Seller is not responsible for defects which arise from
improper installation, neglect, or improper use or from normal wear and tear.
Additionally, Sellers obligation shall be limited by the manufacturers warranty (and is not further warranted by Seller) for
all parts procured from others according to published data, specications or performance information not designed by or
for Seller.
Seller further agrees to replace or at Sellers option to provide a refund of the sales price of any goods that do not
conform to applicable specications or which differ from that agreed to be supplied which non-conformity is discovered
and forthwith reported to Seller within thirty (30) days after shipment to the Buyer. Sellers obligation to replace or refund
the purchase price for non-conforming goods shall arise once Buyer returns such goods FOB point of original shipment by
Seller at the risk and cost of Buyer. Goods replaced by Seller shall become the property of Seller.
There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title and
freedom from encumbrances and, except as herein expressly stated and particularly, and without limiting the foregoing,
there is no guarantee or warranty, express or implied, of merchantability or of fitness for any particular purpose
or against claim of infringement or the like.
Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyers
design or of the ability of any goods to interface, operate or function with any portions of Buyers system not provided by
Seller.
Sellers liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising
out of, connected with, or resulting from the manufacture, sale, delivery, resale, repair, replacement or use of any products
or services shall in no case exceed the price paid for the product or services or any part thereof which give rise to the
claim. In no event shall Seller be liable for consequential, special, incidental or other damages, nor shall Seller be liable in
respect of personal injury or damage to property not the subject matter hereof unless attributable to gross misconduct of
Seller, which shall mean an act or omission by Seller demonstrating reckless disregard of the foreseeable consequences
thereof.

R SERIES SLIP RING

P/N 969000 2006.07.21 Rev. 4

Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and
recommended capacities and design functions or under abnormal conditions. Seller assumes no liability for loss of time,
damage or injuries to property or persons resulting from the use of Sellers products. Buyer shall hold Seller harmless
from all liability, claims, suits and expenses in connection with loss or damage resulting from operation of products or
utilization of services, respectively, of Seller and shall defend any suit or action which might arise there from in Buyers
name - provided that Seller shall have the right to elect to defend any such suit or action for the account of Buyer. The
foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.

1.0 SAFETY

Larger than 10.5 bore size: Consult Factory

1.4.2.2 Standard RPM ratings depend upon bore size and

if the slip ring is equipped with or without ball bearings.

1.4.2.1 R-Series Slip Rings are intended for industrial use

and require a permanent mounting means.

U.S. 1-800-521-4888
Canada: 1-800-667-2487

1.3.4 If you have any questions about the use or

the installation of your R-Series Slip Ring that are not
answered in this documentation contact the factory for
assistance.

1.2.3 WARNING: Modification may cause safety

and fire hazards. Contact the manufacture regarding any
modifications which could affect safety or reliability.

1.2.2 WARNING: Modification of this equipment

may cause excessive wear or failure and will void the
warranty.

1.1.4 Information regarding the current and voltage rating

of each slip ring is recorded on a tag permanently fastened
to the ring assembly.

1.1.3 Do not use this slip ring with electrical loads greater
than the rated current and voltage. (See page 8).

1.0.1 ATTENTION: Read this entire booklet prior to attempting any installation and / or maintenance.
1.1 Electrical Warnings
1.1.1 Install and ground the slip ring and the entire unit
in accordance with the National Electric Code and local
codes and/or ordinances.
1.1.2 DANGER: Hazard of electrical shock or burn.
Always disconnect the power from the collector ring
before attempting to perform any service function. Follow
lock out/tag-out procedures as outlined in OSHA section
1910.147 where appropriate.

1.2 Operational Warnings

1.2.1 Slip rings must be enclosed and protected
from any contact by personnel. Means for the provision
of this protection is the responsibility of the user. Various
enclosure styles are available from Insul-8.

1.3 Maintenance Warnings

1.3.1 Exercise care while servicing, adjusting,
and operating the slip ring.
1.3.2 Periodically check all fasteners and
hardware to assure tightness.
1.3.3 Install all mounting fasteners and
hardware so as to maintain tightness under vibration.

1.4 Specifications & Listings

1.4.1 R-Series Slip Ring products are built to UL
specifications but are not generally certified or listed by an
independent certifying or regulatory body.
1.4.2 The following specifications apply to all R- Series
Slip Rings.

Standard RPM Ratings:

Bore Size
RPM w/o BB RPM w/ BB
1.5
125
500
2.5
75
225
4.0
35
125
8.0
25
100

1.5 Temperature & Ampere / Voltage

Ratings
O

1.5.2 The actual amperage/voltage rating of the

Slip Ring assembly is noted on the label.
Connections to the assembly must be sized to
the ratings of the circuit (refer to NEC table
310-16, 17, 18, 19 and applicable notes).
R SERIES SLIP RING

1.5.1 Standard R-Series Slip Ring is rated to withstand a

maximum ambient temperature of 220 F., 104 C.

P/N 969000 2006.07.21 Rev. 4

1.6 Markings
1.6.2 The marking on slip rings include the
maximum amperage and voltage.

P/N 969000 2006.07.21 Rev. 4

Note: To avoid putting strain on the outboard bearings,

the drive connection must be a loose link or floating type
connection.

2.3.2.3 Bring a pin, torque arm, or suitable member to

hold the brush carriage stationary (or rotate it) into the
0.53 dia. holes provided on the outboard bearing.

flexible wire for brush and core terminations. All wire sizes
and types must be appropriate to the required amperage
and voltage (refer to NEC Table 310-16, 17, 18, 19 and
applicable notes).

Note: User must enclose the slip ring appropriately to meet

safety codes and to protect ring.

2.1.2 Carry unit by horizontally supporting

outboard bearings.

2.0 INSTALLATION

1.6.1 Every slip ring is marked with a label on

the outboard bearing (or enclosure) which includes the
Insul-8 name and logo, the product catalog number and
the individual product serial number.

2.1 Handling
2.1.1 NOTE: NEVER SUPPORT UNIT BY
CORE AND/OR BRUSH LEADS

2.2 Application Types

2.2.1 Slip ring assemblies can be purchased with or
without an enclosure.
Such Enclosures are:
U wrap around shroud
revolving enclosure with shaft flange
stationary enclosure with rotating elbow
U
U

2.3 Mounting & Connections

2.3.1 Warning: During installation of the slip
ring, proper air gap must be maintained between
conductive items, and all terminal connections. Refer
to U.L. 508 standards.
2.3.1.1 Install the slip ring assembly on the shaft and lock
it into place with set screws on the drive collar.
2.3.1.2 Slip ring assemblies are to be mounted on the
center axis of the application.
2.3.1.3 Bring a pin, bolt, torque arm, or suitable member
to hold the brush carriage stationary (or rotate it) into the
0.53 dia. holes provided on the outboard bearing. To
avoid putting strain on the bearings, the drive connection is
to be a loose link or floating type connection.
2.3.2 Slip rings w/o Enclosure or Wrap
around Shroud.
2.3.2.1 Install the slip ring assembly on the shaft and lock
into place with set screws provided in the drive collar. The
mounting shaft must extend at least 80% of the length
of the slip ring assembly core. It is recommended to
dog point the drive collar set screws when mounting the
assembly onto the shaft to prevent the core from coming
loose. Slip ring assembly can be mounted with either the
core or brush carriage rotating.

R SERIES SLIP RING

2.3.2.2 Make electrical connections at lugs on the brush

holders and ends of core lead wires or buss bars. If
equipped with wrap around cover, electrical leads to brush
carriage of slip ring come through the side assembly (NPT
hub if provided) and connect brush holders or terminal
strips. Be sure electrical connections on the brush
assemblies do not interfere or exert tension on the brush
holders and/or carriage assembly. We recommend using

Brush Carriage

Outboard Bearing

Brush

User Shaft

0.53 Drive
Holes on

Set Screw

BORE
1-1/2
2-1/2
4
8
B.C.
4-1/2
8-1/4
12-3/8
16

connect to screw connectors on brush holders or terminal

strips. Electrical lead connections to the core of the slip
ring come through the middle of the shaft and connect to
core leads of the slip ring. (see 2.2.1.2)

Brush Holder

2.3.3.1 Mount the assembly by either the shaft flange or

internal threads at end of shaft to rotating or stationary
point. Can be mounted with either the enclosure or shaft/
flange rotating.

2.3.3 Slip Ring in Revolving

Enclosure (RU)

2.3.3.2 Slip ring is accessed by removal of enclosure side

panels or bolted on cover.

Hub

Swivel Elbow

Mounting Feet

R SERIES SLIP RING

SU Enclosure

Four 7/16 holes

2.3.4.4 Electrical leads to brush carriage of slip ring come

through the side of enclosure (NPT hub if provided) and
connect to brush holders or terminal strips. (see 2.2.1.2).

2.3.4.3 Connect core electrical leads through the swivel

elbow provided. Swivel elbow is either held stationary or
rotated with a suitable link mechanism such as mechanical
or conduit connection.

2.3.3.4 Enclosure to be held stationary or rotated by

means of a suitable loose link mechanism such as
mechanical drive arm or conduit
connection

2.3.3.3 Electrical leads to brush carriage of slip ring come

through the side of enclosure (NPT hub if provided) and

2.3.4 Slip Ring in Swivel Enclosure

(SU) (RAQ/RBQ)
2.3.4.1 Mount the enclosure using the mounting straps or
mounting feet provided. The assembly can be operated
with either the enclosure or swivel rotating.

RU Enclosure

1.0 NPT
(Hollow Shaft)

Shaft Flange

2.3.4.2 Slip ring is accessed by removal of enclosure side

panels or bolted on cover.

Enclosure Cover

Ering

Four 9/32 holes on 9 1/4 B.C.

P/N 969000 2006.07.21 Rev. 4

2.3.5.4 For XSU explosion proof assembly mounting and

wiring instructions, refer to section ring 2.3.3: Slip Ring in
SU style Revolving Enclosure.

2.3.5 Explosion Proof Enclosures

(XRU, XSU, and XSU with Optional
Air Pass)
2.3.5.1 For all explosion proof enclosures, user must seal
incoming and outgoing electrical conduit according to the
National Electric Code.
2.3.5.5 Note: A loose drive arm type connection is
required for the rotating all XRU and XSU assemblies.

Access
Panels

2.3.5.2 Slip ring is accessed by removal of enclosure side

panels or bolted on cover.
Mounting Holes
(4 places, 8-15/16 x 8-3/4 Bolt Pattern

Air Pass
(Optional)

P/N 969000 2006.07.21 Rev. 4

NOTE: Proper brush lead connections

2.4.7 For wiring the optional two wire heater with

thermostat: from the power source, connect one lead to
the positive connection and the other lead to a negative
connection (power in and power out).

Conduit Fitting
for Core Leads

Enclosure

Fittings for Brush Leads

2.3.5.3 For XRU explosion proof assembly mounting and

wiring instructions, refer to section 2.3.3: Slip Ring in RU
style Revolving Enclosure.

2.4 Wiring and Connections

2.4.1 Perform all wiring according to National Electrical
Code guidelines and any applicable local codes.
2.4.2 The connectors in the optional core lead terminal
blocks require 5/16 of stripped insulation.
2.4.3 The optional core lead terminal block provides
connections to the rings. Use the appropriate crimp
connectors if the terminal block is not supplied. See
section 2.1 illustration.
2.4.4 Screws used in the electrical connections must be
tightened to achieve the designed electrical rating.
2.4.5 Make connections with stranded wire whenever
possible.

R SERIES SLIP RING

2.4.6 Brush lead connections are numbered to

corresponding core lead connections. Wire connections
accordingly.

3.1 Lubrication

bolt at 10 in-lb. max.

3.3.3 Inspect brush terminations at the holder to
assure that no external force is imposed on the holder.
We recommend flexible or soft wire leads for these
terminations. Use external clamps to support the entire
weight of the leads.

Post

4) Remove Allen screw located on side of holder

between top terminal screw and spring.
5) Remove holder assembly from post.
6) To reassemble, replace the assembly in the
reverse fashion. Set clamp bolt at 10 in-lb.
max.

Allen Screw

Holder

Spring

Brush

3.3.2 Check brush holder clamps for tightness. Set clamp

3.2.2 Make the first inspection shortly after installation

and before operation and after every 200 - 400 hours
of operation depending on conditions. Make continuing
inspections on a regular basis based upon your
preventative maintenance schedule.

3.1.2 CAUTION: Do not apply any lubricants or solvent

cleaning agents to any part of the slip ring. Use only
dry air to clean slip ring assembly.

3.0 MAINTENANCE

3.1.1 All bearings are lubricated for life at the factory.

Additional lubrication should not be required.

3.2 Inspections
3.2.1 Before performing inspections and maintenance
procedures, insure all power is disconnected and all safety
procedures (lock-out / tag-out) are followed.

3.3 Brush Holders

3.3.1 Inspect brush holders for proper alignment. Locate
brush holders so that the entire brush contact surface rides
squarely on the ring with the brush moving freely in the
brush holder. Position brush holders so the brush makes
contact with the middle of the conductor and is not offset.

3.4 Brushes
3.4.1 Inspect for wear. If the distance from the top of the
insulator to the lower part of the brush spring is 0.093 or
less, replace the brush.
3.4.2 Inspect brush contact surface by removing the brush
if required. Remove surface dirt, oxidation, pitting, or
other contaminants by using a wire brush or 320 grit sand
paper. Slip ring cleaning kit available (see section 7.0).
Care is to be taken not to load-up the brush surface with
dust or contaminants.
3.4.3 To remove and replace brush on plastic square post
mounted brush holder:
1) Remove the brush shunt lead and brush lead
wiring from top of brush holder by removing top
terminal screw.
2) Lift spring slightly with a hook type tool.
3) Tilt brush out from under the spring and away
from holder for removal.
4) To reassemble, replace the brush in the
reverse fashion.
3.4.4 To remove and replace brush holder assembly on
plastic square post mounted brush holder:

R SERIES SLIP RING

1) Remove the brush shunt and brush lead wiring

from top of brush holder by
removing top terminal screw.
2) Lift spring slightly with a hook type tool.
3) Tilt brush out from under the spring and away
from holder for removal.
P/N 969000 2006.07.21 Rev. 4

3.4.5 To remove and replace metal type DF style brush

holder assembly on fiberglass brush post:
1) Remove the brush shunt leads and brush lead
wiring from top of brush holder by removing
cable connection bolts and or lugs.
2) Remove top brush holder clamp.
3) Slide the remaining brush assembly frame out
from under the brush post.
4) To reassemble, replace assembly in the
reverse fashion. Set clamp bolt at 30lb. max.

3.5 Brush Fit Inspection

3.5.1 Brushes must run at 90O + 3O square on the rings.
If brush is not square, adjust position of brush holder on
brush post.
3.5.2 Brushes need not run on the center of the rings, but
there should be no forceful friction against the insulators.
3.5.3 The brush spring cross-bar must be seated in the
brush slot.

3.6 Brush Springs

3.6.1 Inspect and test brush springs to assure uniform
brush pressure. If brush springs fall below recommended
pressure, replace entire brush holder.

Frame
Spring
Pressure
Measurement
Cross-bar Seated
in Brush Slot

90
3

Ring Surface

Brush
15
35
75
200

Clamp

Post

Shunt
Leads

200 Amp
Brush
Brush Holder

Brush

Spring
1.0 lb. min
1.5 lbs. min
3.0 lbs. min
2.5 lbs. min

Table 3.3.3 Brush Spring Tension

Insulator

5 lb. Scale

3.8 Electrical Connections

Brush Spring

3.7 Rings

P/N 969000 2006.07.21 Rev. 4

3.8.1 Inspect all electrical connections for corrosion and

tightness. Loose and/or corroded terminations will cause a
concentration of excessive heat.

R SERIES SLIP RING

3.7.1 Inspect the ring surface for dirt, oxidation, or other

contaminants. A properly operating ring will have a film
that appears burnished in color with a darker surrounding
color where the brushes track. If the ring requires
cleaning, order Slip Ring Polishing Kit Part No. 41286.

3.9.1 Brush posts are supported between two outboard

bearings. The brush posts extend to the outboard
bearings and are secured by a notch in the outboard
bearing. The notch prevents rotation of the brush post.

The brush posts are cut to an exact length in order to

provide the proper spacing. Locate the outboard bearings
against the insulator and have a 0.20 clearance without
deformation of the material.

3.9 Brush Rigging

3.9.2 Spacing between the outboard bearings is critical to

assure the free rotation of the brush carriage rigging.

eliminate internal condensation. Condensation can be

eliminated with the addition of a breather, drain and a
thermostatically controlled heater. Consult factory for
details.

Caution: Do not overtighten the outboard brush post jam

nuts. Make a final check to assure there is no binding of
the outboard brush rigging or binding of the brushes with
insulator barriers.

3.10 Enclosure Inspection

3.10.1 Moisture is a major cause of slip ring deterioration.
Water will corrode parts and breakdown insulation. Dust
and dirt present within the enclosure will effect the proper
operation of the assembly. Most dusts cause excessive
brush and slip ring wear, and conductive dust, if allowed to
accumulate will form a path for short circuiting.
3.10.2 A properly designed NEMA 4 enclosure will be dust
tight and watertight. However, NEMA 4 enclosures do not

3.10.3 Periodically perform an inspection by removing the

enclosure and checking for condensation, water and dust
collection. If contaminants are found, wipe the enclosure
and the assembly with a lint free cloth. If the problem
persists, take steps to remedy the leakage or condensation
problem.

during extended periods of storage. Remove absorbent

material before putting collector ring into operation.

4.0 STORAGE
4.1 When storing the slip ring, keep it at room temperature
in a clean, dry protective place. Place selfcontained or
bagged absorbent material in the collector ring enclosure

Date of Purchase:

Serial No.:

Catalog No. Slip Ring:

5.0 SERIAL NUMBER RECORD

5.1 Make the following information available when
ordering replacement parts or discussing the slip ring with
the factory by recording the information in the spaces
provided here. This information is located on your packing
slip, factory invoice, and serial number tag.

R SERIES SLIP RING

What to Check

Verify brush wear per Section 3.2.3

Check spring pressure per Section 3.2.4
Intermittent Signal
Check contact surfaces for cleanness.
(Ring Polishing Kit available. See Replacement Parts.)
or
Loss of Signal
Visually check for spring fit and function. Adjust or replace
as necessary
Check core wiring for short circuit

Problem

6.0 TROUBLESHOOTING
6.1 Some possible problems are
addressed in the table here, otherwise,
contact the factory at the numbers
provided on the back page.

P/N 969000 2006.07.21 Rev. 4

7.0 REPLACEMENT PARTS

ITEM #1 Brushes

200 Amp

150 Amp

110 Amp

75 Amp

35 Amp

15 Amp

N/A

N/A

02841

02840

30069A

30068A

30066A

15 Amp Signal Circuits 30067A

02848

02847

DRA3-20A-2500

02846

02845

30069B

30068B

30066B

30067B

2.5, 3.0, 3.5

DRA3-20A-4000x2

02853

02852

DRA3-20A-4000

02851

02850

30069C

30068C

30066C

30067C

4.0, 4.5, 5.0, 6.0 6.5

DRA3-20A-8000x2

02858

02857

DRA3-20A-8000

02856

02855

30069D

30068D

30066D

30067D

8.0, 10.0, 10.5

Slip Ring Bore Sizes

225 Amp

N/A

DRA3-20A-2500x2

DRA3-20A-8000x3

1.5

300 Amp

N/A

DRA3-20A-4000x3

AMPERAGE

400 Amp

DRA3-20A-2500x3

P/N 969000 2006.07.21 Rev. 4

N/A

R SERIES SLIP RING

600 Amp
10

150 Amp

110 Amp

75 Amp

35 Amp

15 Amp

AMPERAGE

02805

02804

02803

02802

02801

02800

Single

02806(x2)

02805(x2)

02811

02810

02809

02808

02807

Double

ITEM #2 Brush Holders

225 Amp
02806

5.0

4.5

4.0

3.5

3.0

2.5

1.5

Bore Diameter

41353

30073

30073

30073

30079Z

30079Z

30079Z

30061

Out Board
Bearing

ITEM #3

ITEM #4

R515-DTK-6

R60A3.5-DK
100505
R515-DTK
1
To be cut to
length at time of R515-DTK-4.5
assembly
R515-DTK-5.0

Brush Post
Material

R1345

R60A3-DK

R60A-K

30121

Drive Collars

ITEM #5

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

30015Z

Retaining
Ring

ITEM #6

100186

100210

R559/R469-8A-6

R559/R469-8A-50

R559/R469-8A-45

R559/R469-8A

R498/R392-8A-35

100203

100200

41188

Bearing Ring w/
insulator

ITEM #7

Brushes and holders are sold

as a single unit in these amp
ranges

300 Amp
200 Amp
400 Amp

6.0
30076

R1345-10000M

600 Amp

8.0

30076

11

10.0

R SERIES SLIP RING

Special bore sizes: Consult Factory

Slip Ring Cleaning Kit: Part No. 41286

P/N 969000 2006.07.21 Rev. 4

4.5
R469-B-4.5
R469-B-4.5
R469-4A-4.5
R469-4A-4.5
R469-8A-4.5
R469-4A-4.5
R469-4A-4.5
R469-8A-4.5
R469-8A-4.5
R469-8A-4.5
R469-8A-4.5
R469-8A-4.5

5.0
R469-B-5000
R469-B-5000
R469-4A-5000
R469-4A-5000
R469-8A-5000
R469-4A-5000
R469-4A-5000
R469-8A-5000
R469-8A-5000
R469-8A-5000
R469-8A-5000
R469-8A-5000

R SERIES SLIP RING

P/N 969000 2006.07.21 Rev. 4

ITEM #8 *(see also SPACERS for circuits rated 110AMPS and above)
Slip Ring Bore Size
Amps/Voltage
1.5
2.5
3.0
3.5
4.0
R392-B-2500 R392-4A-3000-M R392-B-3500 R469-B-4000
15A/250V Silver
R983
15A/250V
R983
R392-B-2500 R392-4A-3000-M R392-B-3500 R469-B-4000
35A/250V
R27-4D
R392-4A
R392-4A-3000-M R392-4A-3500
R469-4A
35A/600V
R27-4E
R392-4A
R392-4A-3000-M R392-4A-3500
R469-4A
75A/600V
R27-8C
R392-8A
R392-8A-3000-M R392-8A-3500
R469-8A
110A/600V
R27-4E
R392-4A
R392-4A-3000-M R392-4A-3500
R469-4A
150A/600V
N/A
R392-8A
R392-8A-3000-M R392-8A-3500
R469-4A
200A/600V
N/A
R392-8A
R392-8A-3000-M R392-8A-3500
R469-8A
225A/600V
N/A
R392-8A
R392-8A-3000-M R392-8A-3500
R469-8A
300A/600V
N/A
R392-8A
R392-8A-3000-M R392-8A-3500
R469-8A
400A/600V
N/A
R392-8A
R392-8A-3000-M R392-8A-3500
R469-8A
600A/600V
N/A
R392-8A
R392-8A-3000-M R392-8A-3500
R469-8A
Slip Ring Bore Size
6.0
8.0
10.0
R469-B-6000
R1191-4
R1191-4-10000
R469-B-6000
R1191-4
R1191-4-10000
R469-4A-6000
R1191-4
R1191-4-10000
R469-4A-6000
R1191-4
R1191-4-10000
R469-8A-6000
R1191-8
R1191-8-10000
R469-4A-6000
R1191-4
R1191-4-10000
R469-4A-6000
R1191-8
R1191-8-10000
R469-8A-6000
R1191-8
R1191-8-10000
R469-8A-6000
R1191-8
R1191-8-10000
R469-8A-6000
R1191-8
R1191-8-10000
R469-8A-6000
R1191-8
R1191-8-10000
R469-8A-6000
R1191-8
R1191-8-10000

15A/250V Silver
15A/250V
35A/250V
35A/600V
75A/600V
110A/600V
150A/600V
200A/600V
225A/600V
300A/600V
400A/600V
600A/600V

12

Amps/Voltage
15A/250V Silver
15A/250V
35A/250V
35A/600V
75A/600V
110A/600V
150A/600V
200A/600V
225A/600V
300A/600V
400A/600V
600A/600V

15A/250V Silver
15A/250V
35A/250V
35A/600V
75A/600V
110A/600V
150A/600V
200A/600V
225A/600V
300A/600V
400A/600V
600A/600V

2.5

SPACERS (not shown in exploded diagram)

Slip Ring Bore Size
3.0
3.5

1.5

R392-8M
R392-8M
R392-8M
R392-8M
R392-8M
R392-8M
R392-8M

5.0

6.0

8.0

R392-8M-3000-M R392-8M-3500
R392-8M-3000-M R392-8M-3500
R392-8M-3000-M R392-8M-3500
R392-8M-3000-M R392-8M-3500
R392-8M-3000-M R392-8M-3500
R392-8M-3000-M R392-8M-3500
R392-8M-3000-M R392-8M-3500
Slip Ring Bore Size

4.0

10.0

R469-8M
R469-8M
R469-8M
R469-8M
R469-8M
R469-8M
R469-8M

*Spacers are required in conjunction with insulators (Item #8) on circuits

rated 110 Amps and above.

R27-8M
R27-8M
N/A
N/A
N/A
N/A
N/A

4.5

R469-8M-5000
R469-8M-5000
R469-8M-5000
R469-8M-5000
R469-8M-5000
R469-8M-5000
R469-8M-5000

R469-8M-6000
R469-8M-6000
R469-8M-6000
R469-8M-6000
R469-8M-6000
R469-8M-6000
R469-8M-6000

R1191-8M
R1191-8M
R1191-8M
R1191-8M
R1191-8M
R1191-8M
R1191-8M

13

R1191-8M-10000
R1191-8M-10000
R1191-8M-10000
R1191-8M-10000
R1191-8M-10000
R1191-8M-10000
R1191-8M-10000

*Spacers are required in conjunction with insulators (Item #8) on circuits

rated 110 Amps and above.R469-8M-4500

R469-8M-4500
R469-8M-4500
R469-8M-4500
R469-8M-4500
R469-8M-4500
R469-8M-4500
R469-8M-4500

ITEM #9 Barrier
Only 1.5 bore slip rings have barriers next to the outboard bearings
Barrier Part Number R27-B
ITEM #10 Z-Ring
Consult Factory for individual replacement rings

R SERIES SLIP RING

ITEM #12 Core Bolts

Consult Factory for replacement core bolts

ITEM #11 Brush Post Bolts

Consult Factory for replacement brush holder bolts

P/N 969000 2006.07.21 Rev. 4

14

NOTES

R SERIES SLIP RING

P/N 969000 2006.07.21 Rev. 4

P/N 969000 2006.07.21 Rev. 4

NOTES

R SERIES SLIP RING

15

Power and Data Transfer Systems

Conductor Bar
Cable Festoon Systems
Radio Controls
Push-Button Pendants Station
Cable & Hose Reels
Motor Driven Reels
Cable Protection Systems
Slip Rings
Visit us on the web for the most up to date information at:

175 BOULEVARD J.F. KENNEDY

ST. JEROME, QUEBEC J7Y4B5

CANADA

PHONE: 402 / 339-9300

TOLL FREE: 800 / 521-4888
FAX: 402 / 339-9627

10102 F STREET
OMAHA, NE 68127

USA

PHONE: 3 / 9706 88 44
FAX: 3 / 794 92 98

14 ENGLAND STREET
DANDENONG, VICTORIA 3175

AUSTRALIA

www.conductix.us

PHONE: 450 / 565-9900

TOLL FREE: 800 / 667-2487
FAX: 512 / 432-6985

E-MAIL: info@conductix.com.au
P/N 969000 2006.07.21 Rev. 4

E-MAIL: info@conductix.us
R SERIES SLIP RING

E-MAIL: infoCanada@conductix.us

16

Service Manual HY09-SM300/US

Service Manual
PGP/PGM315, 330, 350, 365

Effective:
April 15, 2002
Supersedes: July 1, 1998

PGP/PGM 300 Series

PGP/PGM 300 Series

Service Manual HY09-SM300/US

Single Pump

Multiple Pump

Cast Iron
Housings

Low-friction
Bushing Coating

Case Hardened Gears

Split-flange or ODT
Ports
High Temperature
Seals

One-piece Drive
Shaft & Gear
Long Shaft Journals Superior
Bearing Surface

SAE 2- or 4-Bolt
Mountings

Balanced Thrust Plates

Minimize Friction and Leakage

Internal Passage Constantly

Lubricates Bushings

Large Passages for

Better Pump Feed
Extended Studs
Available for Mounting
Support

Use Genuine Parker Replacement parts

Legal Notification

WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL
INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users
having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due
to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of
the products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its
subsidiaries at any time without notice.

Offer of Sale
The items described in this document are hereby offered for sale by Parker Hannifin Corporation, its subsidiaries or its authorized distributors. This offer and its acceptance are governed
by the provisions stated in the Offer of Sale.
Copyright 2002, Parker Hannifin Corporation, All Rights Reserved.

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

315/330/350/365
Service Manual
General Instructions
These service instructions will familiarize you with
Parker's single and multiple pumps

the units

their component parts

the relative position of each part
proper methods for assembly or disassembly of
To facilitate the repair of these units and before any
work is done, we suggest that you first read all of the
steps used in disassembly and assembly.
Dirt is the enemy of any hydraulic system. The first
requirement for good maintenance of hydraulic
equipment is cleanliness. MAKE SURE YOU
DISASSEMBLE AND ASSEMBLE YOUR
HYDRAULIC EQUIPMENT IN A CLEAN AREA.
The pictures show Model PGP365. Notes in the
text cover variations between this unit and the
other models.
It is important to airblast all parts and wipe them with
a clean, lintless cloth before assembly.
USE CAUTION IN GRIPPING ALL PARTS
IN THE VISE TO AVOID DAMAGING
MACHINED SURFACES.
A pump must be driven in the direction of rotation for
which it was built; otherwise, pressure will blow the
shaft seal. Check the exploded view and notes at right
for proper direction of rotation.

Parker's
Replacement Parts
Parker's replacement parts are of original equipment
standards. For assured quality of material and workmanship, and for compatibility in assembly, USE
ONLY GENUINE PARTS.
Check all replacement parts before installing them to
be certain that they were not damaged in shipment.

PGP/PGM 300 Series

Service Manual HY09-SM300/US

Items shaded apply to

multiple assemblies only.
NOTE:
For PGP315 and PGP330 ONLY - Plug 5
required in position A and position B.
For PGP350 and PGP365 ONLY - Plug 5 in
position B gives clockwise rotation. Plug 5 in
position A gives counterclockwise rotation.

PARTS LIST
1. Snap Ring
2. Outboard Bearing
3. Seal
4. Shaft End Cover
5. Plug
6. Bushings
7. Channel Seal
8. Thrust Plates
9. Integral Drive Shaft
and Gear Set
10. Gasket Seal

11. Dowel Pins (Solid for

PGP/PGM 315, 330 and
350. Hollow for PGP/PGM
365 ONLY.)
Gear Housing
Bearing Carrier
Connecting Shaft
Matched Gear Set
Gear Housing
Port End Cover
Studs or Cap Screws
Washers
Nuts
12.
13.
14.
15.
16.
17.
18.
19.
20.

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series

Service Manual HY09-SM300/US

Tool List
Arbor press
Awl
1 1/2" Dia. steel ball
Bearing puller (Owatonna Tool Co.
M D - 956 or equivalent)
Bushing remover tool (See A)
Clean, lintless cloths
Deburring tool (an old file with
cutting teeth ground off)
Machinist's hammer
Soft hammer
Permatex Aviation Form-A-GasketTM
No. 3 non-hardening sealant or equivalent
Medium grit carborundurn stone
Seal removal tool (See B)
Oil and grease
Snap ring pliers
Prick punch
Bushing installation tool (See C)
Scale ( 1/32" or 1/64" graduations)
Small screw driver
Torque wrench
Vise with 6" minimum opening.
Bar for lip seal installation
Note: For PGP/PGM315 use 1 5/8" dia. x 2" bar.
For PGP/PGM330 use 1 3/4" dia. x 2" bar.
For PGP/PGM350 use 2 1/2" dia. x 2" bar
For PGP/PGM365 use 2 1/2" dia. x 2" bar.
Special steel sleeve ( see sketch )

Special Steel Sleeve

The special steel sleeve is
used to insert the drive shaft
through the lip seal without
damage and can be made
from bar stock: For the PGP/
PGM315 use a 1 " dia. x 3-1/
8" bar; for the PGP/PGM330
use a 1-1/8" or 1-1/4" dia. x
4- 5/8" bar; for the PGP/
PGM350 use a 1-3/8" dia. x
4-5/8" bar; for the PGP/
PGM365 use a 1- 1 /2" dia. x
4-5/8" bar. The drawing and
chart give details for making
this special tool.

PGP/PGM
365

PGP/PGM
350

PGP/PGM
330

PGP/PGM
315

PGP/PGM
350

PGP/PGM
315
PGP/PGM
330

Bushing Puller: The bushings in PGP/PGM315, 330, 350 and 365

pumps may be removed from their bores, using blind hole collet-type
bushing pullers similar to those manufactured by Owatonna Tool Co.
The table below illustrates the modifications necessary to adapt the
OTC collets to this task. Equivalent pullers from other suppliers may
be modified in similar fashion.

PGP/PGM
365

PGP/PGM
350

PGP/PGM
330

PGP/PGM
315

Seal Removal Tool

Easily made from an
old screw driver. Heat
the tip and bend as
shown. Grind the tip
to fit the notch behind
the shaft seal.

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

Start Disassembly Here

PGP/PGM 300 Series

Service Manual HY09-SM300/US

2) Use a socket wrench

to remove the 4 cap
screws on single units or
the 4 hex nuts, studs
and washers of multiple
units.

CAUTION:
1. If prying off sections becomes necessary, take extreme care not to mar or damage machined surfaces. Excessive force while prying
can result in misalignment and seriously damage parts.
2. If parts are difficult to fit during assembly, tap gently with a soft hammer (never use an iron hammer).
3. Gears are closely matched, therefore they must be kept together as sets when removed from a unit. Handle with care to avoid
damage to the journals or teeth. Avoid touching gear journals.
4. Never hammer bushings into bores; use an arbor press.

1) Place the pump in a

vise with the drive shaft
pointIng down. Caution:
DO NOT GRIP ON OR
NEAR ANY MACHINED
SURFACES DURING
ASSEMBLY OR
DISASSEMBLY.
Match-mark all sections.
Be sure to align these
marks when
reassembling.

4) Remove the thrust

plate. Examine and
replace if necessary.
See wear guide page 10.

For multiple assemblies

only

6) Lift the gear housing

from the bearing carrier.
If prying is necessary,
take care not to damage
machined surfaces.
Examine and replace
if necessary.
(See page 10)

3) Lift off the port end

cover. If prying is
necessary, be careful not
to damage the machined
surfaces. Dowel pins will
remain in either the port
end cover or the gear
housing.

5) Carefully remove the

drive and driven gears.
Avoid tapping the gear teeth
together or against other
hardened surfaces. Keep
these gears together
because they are a matched
set. Examine and replace if
necessary. (See page 10).
Remove the thrust plate
from the bearing carrier.
Examine and replace if
necessary.
For multiple assemblies only

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series

Service Manual HY09-SM300/US
7) Carefully lift or pry off
the bearing carrier to
prevent damage to
contact face and edges.
Dowel pins will remain in
either the bearing carrier
or the gear housing.
DO NOT REMOVE THEM.

10) Inspect all bushings

for scoring or
discoloration and
replace if necessary.
Use a bushing puller as
shown in the tool list to
remove bushings (see
page 4).

For multiple assemblies only

9) Lift or pry off the first

section gear housing. Be
careful not to damage
machined surfaces.
Examine and replace if
necessary (see page 10).

12) Use a bearing puller

to remove the outboard
bearing.

8) Remove the
connecting shaft.
Remove the thrust plate.
Examine and replace if
necessary. (See page
10). Remove the driven
gear and the integral gear
and drive shaft. Keep
these together as they
are a matched set.
Examine and replace if
necessary. (*See page
10). Be careful not to
damage the machined
surfaces of the gears.

11) If the pump is

equipped with an
outboard bearing, place
the shaft end cover in
the vise with the
mounting face up.
Remove the snap ring
with snap ring pliers. If a
unit is equipped with a
spiral-lock retaining ring,
remove with a small
screwdriver or awl.

13) Grip the shaft end

cover in a vise with the
mounting face down.
Remove double lip seal
by inserting the special
seal removal tool (see
Tool List) into the notch
between the double lip
seal and the shaft end
cover. Tap the seal out
and discard.
Remove and discard all
rubber and polymer seals.

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series

Service Manual HY09-SM300/US

1) Stone all machined

surfaces with a medium
grit carborundurn stone.

2) If the bushings have

been removed, deburr
the bushing bores with an
emery cloth. Rinse parts
in a solvent. Air blast all
the parts and wipe with
a clean, lintless cloth
before starting assembly.

Start Assembly Here

3) Grip shaft end cover in

vise with mounting face
down. Examine plug or
plugs* to be sure they're
tightly in place.
Replacement is necessary
only if parts are damaged.
Remove with screwdriver.

4) New plugs should be

screwed in tightly. Stake
the plug with a prick
punch at both ends of the
screwdriver slot and
around edges. Peen the
edge of the hole 1/32" to
1/16" with a1-1/2"
diameter steel ball.
NOTE: If new plug or
plugs are being installed,
coat threads with
LoctiteTM thread sealant.

5) Note: Assembly steps 5, 6, 7 & 8

apply to shaft end cover, bearing
carrier and portend cover.
Any bushings removed from the
shaft end cover, portend cover
or bearing carrier should be
assembled in the drive bores with
the groove to the top of unit (12
o'clock). Assemble the bushings in
the driven bores with the groove to
the bottom of the unit (6 o'clock).
The PGP/PGM315 does not have
grooved bushings, therefore the
bushing seams should be placed
at the 12 and 6 o'clock positions.

6) Bushings should be
pressed into the bores,
one at a time, using the
special installation tool
and an arbor press. Be
sure the that the grooves
(or seams) are positioned
as stated in Step #5. The
bushings must be pressed
into the bores flush with
the casting face. Be sure
to support the castings
so that they are square
and level.

*PGP/PGM315 and 330

have two plugs in both the
shaft end and port end
covers. PGP/PGM350 and
365 have one plug on the
outlet side of their shaft end
and port end covers.

7) Repeat Steps 1 and 2,

stone and rinse parts.

8) See that dowel pins

are in place in any new
castings. Examine all of
the dowels. Before
inserting, make certain
that the hole is clean and
free from burrs. Gently
start the pin straight into
the hole and tap lightly
with a soft hammer.

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series

11) Install the snap ring in

the groove to retain the
outboard bearing.

9) Before inserting a new lip

seal in the shaft end cover,
coat the outer edge of the
lip seal and its recess with
Permatex Aviation
Form-A-Gasket No. 3
non-hardening sealant or
equivalent. With the metal
side of the lip seal up, press
it into the mounting flange
side of the shaft end cover
with an arbor press and bar
(see Tool List on page 4).
Be careful not to damage
the lip of the seal. Press in
until flush with the recess.
Wipe off excess sealant.
12) Grease the new gasket
seals and insert them into
the grooves in both sides of
all gear housings. Position
the first gear housing over
the shaft end cover and
dowels. Tap it with a soft
hammer until it rests tightly
against the shaft end cover.
Be careful not to pinch the
gasket seal. Also be sure
that the large rounded core
is on the inlet side.

10) If the unit is equipped

with an outboard bearing,
guide the bearing into its
recess in the shaft end
cover. This is a light
press fit. It may be
necessary to lightly tap
the bearing into the
bore.

Service Manual HY09-SM300/US

13) Assemble the channel

seals into the grooves in
the thrust plates with the
flat side of the seal facing
away from the thrust plate
as shown below.

Thrust
Plate

16) Slip the thrust plate

with the seal over the gear
journals and into the
housing bore. The flat side
of the seal should face up
with the relief groove
facing the outlet side. (For
single pump assemblies
go directly to Step #21).

14) Gently slip the thrust

plate through the gear
housing and into place on
the shaft end cover. The
channel seal from Step
#13 should face the shaft
end cover. The relief
groove in the plate should
face the outlet side of the
pump.

Flat Side
of Seal

15) Slide the driven gear

through the housing and into
the bushing in the shaft end
cover. Coat the steel sleeve
tool with grease. Place the
lightly-greased drive shaft
inside the sleeve and slide
both through the shaft end
cover with a twisting motion,
until the integral gear rests
against the thrust plate.
Avoid damaging the double
lip seal. Remove the steel
sleeve. Squirt clean oil over
the gears.

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

17) Place the bearing

carrier onto the journals
of the drive and driven
gears. Be sure to line up
the dowel holes over the
dowel pins. When the
parts are parallel,
squeeze them together
or alternately tap over
each dowel until the
parts are together.

19) Place the thrust plate

in the gear housing per
Step #14. Insert the drive
and driven gears of the
second section in their
respective bearings. Make
certain the gears are in
contact with the thrust
plate face. Place the port
end cover plate in the
housing per Step #16.
For multiple assemblies
only

21) Place the port end

cover over the gear
journals. Align the dowels
with the holes in the
mating casting. Being
careful not to pinch the
gasket-seal, tap the port
end cover lightly in the
center between bearing
bores to engage the
dowels and to move parts
together in the final
seating.

PGP/PGM 300 Series

Service Manual HY09-SM300/US

18) Insert the connecting

shaft into the spline of
the drive gear. Position
and place the second
gear housing on the
bearing carrier as
outlined in Step #12.
For multiple assemblies
only

20) Check the plug or

plugs in the port end
cover to be sure that
they are tight. Follow the
procedure outlined in
Step #4 for new plugs.
For multiple assemblies
only

22) Thread the fasteners

into the shaft end cover
and tighten alternately or
cross corner. Rotate the
drive shaft with a 6"
wrench to check for
binding. If there is no
internal binding, torque
diagonally opposed
fasteners to 200 ft. lbs.
(2400 in. lbs.); 141 ft. lbs.
(1700 in. lbs.) for PGP/
PGM315 models; 450 ft.
lbs. (5400 in lbs.) for PGP/
PGM365.

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series

Service Manual HY09-SM300/US

Guideline for acceptable wear

Gear Housings
Wear in excess of .007" cut-out necessitates
replacement of the gear housing. Place a straight-edge
across bore. If you can slip a .007 feeler gage under
the straight-edge in the cut-out area, replace
the gear housing.
Pressure pushes the gears against the
housing on the low pressure side. As the
hubs and bushings wear, the cut-out
becomes more pronounced. Excessive
cut-outin a short period of time indicates excessive
pressure or oil contamination. If the relief valve settings
are within prescribed limits, check for shock pressures
or tampering.
When the cut-out is moderate, 007" or less, the gear
housing is in good condition and may be reused.
Gears
Any scoring on gear hubs necessitates
replacement. Scoring, grooving, or
burring of the outside diameter of the
teeth requires replacement. Nicking,
grooving, or fretting of teeth surfaces also
necessitates replacement.
Drive Shafts
Replace if there is any wear
detectable by touch in the seal
area or at the drive coupling. The
maximum allowable wear is .002".
Wear in the shaft seal area indicates oil
contamination. Wear or damage to splines, keys,
or keyways necessitates replacement.
Thrust Plates
The thrust plates seal the gear section at
the sides of the gears. Wear here will allow
internal slippage, that is, oil will bypass
within the pump.
A maximum of .002" wear is allowable. Replace
thrust plates if they are scored, eroded or pitted.
Check center of thrust plates where the gears mesh.
Erosion here indicates oil contamination.
Pitted thrust plates indicate cavitation or oil aeration.
Discolored thrust plates indicate overheating, likely due
to insufficient oil.

Dowel Pins
If either the dowel or dowel hole is damaged,
the dowel or machined casting, or both, must
be replaced.
If more than reasonable force is required to
seat dowels, the cause may be poorly deburred
or dirty parts; cocking of the dowel in the hole or
improper pin-to-hole fit.
Bushings
If gears are replaced, bushings must be
replaced. Bushings should fit into the bore with
a heavy press fit.
Seals and Gaskets
Replace all rubber and polymer seals,
including all "0" rings, thrust plate channel
seals, shaft seal and gasket seals.
Plugs
Examine the plugs in the shaft end and port
end cover to make sure that they are in the
proper position and tight. The PGP/PGM315 and
PGP/PGM330 should have two plugs in both the
shaft end and port end in tandem units only. The
PGP/PGM350 and PGP/PGM365 have one plug in
their shaft and port ends high pressure side only.

10

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

Lubrication and Oil

Recommendations
All parts, with the exception of the outboard bearing,
are lubricated by the hydraulic oil in the circuit.
Particular attention must be paid to keep clean oil in
the circuit system. Whenever there is a pump or
motor failure, and there is reason to feel that metal
particles may be in the system, the oil must be
drained, the entire system flushed clean and any
filter screens thoroughly cleaned or replaced. New oil
should be supplied for the entire system. Oil suitable
and recommended for use in circuits involving
Parker's pumps and motors should meet the following
specifications:
Viscosity:
50 SSU minimum @ operating temperature
7500 SSU maximum @ starting temperature
150 to 225 SSU @ 100 F. (37.8C.) (generally)
44 to 48 SSU @ 210 F. (98.9 C.) (generally)

Approximate SSU @

Viscosity Index: 90 minimum

Aniline Point: 175 minimum
Recommended Additives: Foam depressant,
rust and oxidation inhibitors. Filtration: 10 micron
recommended for maximum pump life.
Other Desirable Characteristics:
Stability of physical and chemical characteristics.
High demulsibility (low emulsibility) for separation
of water, air and contaminants.
Resistant to the formation of gums, sludges, acids,
tars and varnishes.
High lubricity and film strength.

PGP/PGM 300 Series

Service Manual HY09-SM300/US

General Recommendations:
A good-quality hydraulic oil conforming to the
characteristics listed above is essential to the
satisfactory performance and long life of any
hydraulic system.
The oil should be changed on regular schedules in
accordance with the manufacturer's recommendations,
and the system periodically flushed.
The oil temperature in the reservoir must not exceed
200 F., (93.3 C.) with a maximum temperature of
180 F. (82.2 C.) recommended. Higher temperatures
will result in rapid oil deterioration.
Reservoir capacity should equal in gallons the pump
output in gpm or the total gpm of all pumps, where
there is more than one in the system.
Oil poured into the reservoir should pass through a
100-mesh screen. Pour only clean oil from clean
containers into the reservoir. A 100-mesh screen may
be used in the suction line leading to the pump. A
suction filter should be of sufficient size to handle
twice the pump capacity. It must be cleaned and
checked regularly to avoid damage due to
contamination and cavitation.
Normal Temperatures:
O F. (-1 8 C.) to 100 F. (37.8 C.) Ambient 100 F.
(37.8 C.) to 180 F. (82.2 C.) System. Be sure your
oil is recommended for the temperatures you expect to
encounter.
Cold Weather Operation:
Oils for use in cold weather should have a viscosity
not exceeding 7500 SSU at the minimum start-up
temperature. A pour point of at least 20 F. below
start-up temperature is recommended. Start-up
procedures should allow for a gradual warm-up until
the oil reaches a reasonably fluid state.

Continued on the following page.

11

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series

Continued from the previous page

Recommended Start-up
Procedure For New or
Rebuilt Pump

Service Manual HY09-SM300/US

The Use of Other Fluids:

Automatic Transmission Fluid (ATF): In general, ATF
performance is satisfactory; however these fluids are
sometimes too expensive for normal use in hydraulic
systems.

Before connecting any lines to the pump, fill all ports

with clean oil to provide initial lubrication. This is
particularly important if the unit is located above the
oil reservoir.

Before installing a new or rebuilt pump, back off

the main relief valve until the spring tension on the
adjusting screw is relieved. This will avoid the
possibility of immediate damage to the replacement
unit in the event that the relief valve setting had
been increased beyond the recommended operating
pressure, prior to removing the old unit.

Diesel Fuel or Kerosene (Coal Oil): Though

sometimes used as dilutants for cold weather
operations, they are not recommended, as they
are not sufficiently refined.
Fire Resistant Fluids: DO NOT USE ANY FIRE
RESISTANT FLUIDS OR NON-PETROLEUM OILS
WITHOUT CONSULTING OUR TECHNICAL SERVICE
DEPARTMENT.
These suggestions are intended as a guide only.
OBTAIN YOUR FINAL FLUID RECOMMENDATIONS
FROM YOUR FLUID SUPPLIER.

After connecting the lines and mounting the

replacement unit, operate the pump at least two
minutes at no load and at low rpm (400 min.) During
this break-in period, the unit should run free and not
develop an excessive amount of heat. If the unit
operates properly, speed and pressure can then be
increased to normal operating settings.

ALWAYS USE AN ACCURATE GAUGE

WHEN ADJUSTING THE RELIEF VALVE
PRESSURE SETTING.

Reset the main relief valve to its proper setting while

the pump is running at maximum operating engine
(motor) speed for the vehicle.

12

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

Recommended
Test Procedure
Make certain that there is an adequate supply of oil for
the pump; at least one gallon of oiI for each gpm of
pump capacity.
If one section of a tandem pump is being tested,
make sure that all other sections not being tested
are adequately supplied with oil. If any of the other
sections run dry, or if plugs are left in ports, serious
and permanent damage will result.
The oil should be a good quality hydraulic oil rated at
150 SSU at 100 F., with the oil temperature held at
120 F. plus or minus 50 F. (Test procedures are
described in detail in SAE handbooks; see Hydraulic
Power Pump Test Procedure, SAE J745c.)
The feed line must be of adequate size with no more
than 5" mercury vacuum adjacent to the pump inlet. As
a rule, the feed line must provide a feed flow velocity
not in excess of 8 feet per second.
Feeding hot oil into a cold pump may cause the pump
to seize. Jog the pump by momentarily starting and
stopping repeatedly the driving engine or motor to
gradually equalize pump and oil temperatures.
Run the pump at least two minutes at no load and
moderate speed (not over 1500 rpm). If the pump
becomes excessively hot, shut down immediately and
locate the problem source.
Gradually increase pressure on pump, in 500 psi
increments until the desired test pressure has been
reached. This should take about five minutes.
Delivery should run close to rated catalog performance
figures, which are averaged from testing several
pumps. A 5% lower reading may be used as a rated
minimum if new or relatively new parts have been
used. When rebuilding the pump with parts from the
original pump, which, while worn, appear satisfactory
for reuse, a 10% or 15% lower reading may be
permitted, depending on the performance expected
from the equipment. One's own experience will prove
the best guide here.

PGP/PGM 300 Series

Service Manual HY09-SM300/US

Many repairmen measure the output at normal

operating speed and at zero pressure, then again at
1000 psi (or the operating pressure of the equipment)
and allow a volume decrease approximating the listing
below. It is a suggested reference only which makes
allowance for reused parts.
At test speeds other than 1800 rpm, gpm delivery will
vary almost proportionately, but the same (drop-off)
figures should be used.
Be sure to run the pump in the direction for which it
was designed and built. Driving the pump in the wrong
direction will build up pressure behind the shaft seal,
damaging it and necessitating replacement.
After completing testing procedures, the pump is
ready for installation and immediate duty operation
on equipment. Again, it must be remembered that
to prevent seizure, hot oil must not be fed into a
cold pump.

13

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series

Service Manual HY09-SM300/US
Offer of Sale

items sold hereunder, even if such apparatus has been specially converted or adapted for such manufacture and notwithstanding any charges
paid by Buyer. Unless otherwise agreed, Seller shall have the right to alter,
discard or otherwise dispose of any special tooling or other property in its
sole discretion at any time.
8. Buyers Property: Any designs, tools, patterns, materials, drawings,
confidential information or equipment furnished by Buyer or any other
items which become Buyers property, may be considered obsolete and
may be destroyed by Seller after two (2) consecutive years have elapsed
without Buyer placing an order for the items which are manufactured using
such property, Seller shall not be responsible for any loss or damage to
such property while it is in Sellers possession or control.
9. Taxes: Unless otherwise indicated on the face hereof, all prices and
charges are exclusive of excise, sales, use, property, occupational or like
taxes which may be imposed by any taxing authority upon the manufacture, sale or delivery of the items sold hereunder. If any such taxes must
be paid by Seller or if Seller is liable for the collection of such tax, the
amount thereof shall be in addition to the amounts for the items sold. Buyer
agrees to pay all such taxes or to reimburse Seller therefore upon receipt
of its invoice. If Buyer claims exemption from any sales, use or other tax
imposed by any taxing authority, Buyer shall save Seller harmless from
and against any such tax, together with any interest or penalties thereon
which may be assessed if the items are held to be taxable.
10. Indemnity For Infringement of Intellectual Property Rights: Seller
shall have no liability for infringement of any patents, trademarks, copyrights, trade dress, trade secrets or similar rights except as provided in this
Part 10. Seller will defend and indemnify Buyer against allegations of
infringement of U.S. Patents, U.S. Trademarks, copyrights, trade dress
and trade secrets (hereinafter Intellectual Property Rights). Seller will
defend at its expense and will pay the cost of any settlement or damages
awarded in an action brought against Buyer based on an allegation that an
item sold pursuant to this contract infringes the Intellectual Property Rights
of a third party. Sellers obligation to defend and indemnify Buyer is
contingent on Buyer notifying Seller within ten (10) days after Buyer
becomes aware of such allegations of infringement, and Seller having sole
control over the defense of any allegations or actions including all
negotiations for settlement or compromise. If an item sold hereunder is
subject to a claim that it infringes the Intellectual Property Rights of a third
party, Seller may, at its sole expense and option, procure for Buyer the right
to continue using said item, replace or modify said item so as to make it
noninfringing, or offer to accept return of said item and return the purchase
price less a reasonable allowance for depreciation. Notwithstanding the
foregoing, Seller shall have no liability for claims of infringement based on
information provided by Buyer, or directed to items delivered hereunder for
which the designs are specified in whole or part by Buyer, or infringements
resulting from the modification, combination or use in a system of any item
sold hereunder. The foregoing provisions of this Part 10 shall constitute
Sellers sole and exclusive liability and Buyers sole and exclusive remedy
for infringement of Intellectual Property Rights.
If a claim is based on information provided by Buyer or if the design for an
item delivered hereunder is specified in whole or in part by Buyer, Buyer
shall defend and indemnify Seller for all costs, expenses or judgments
resulting from any claim that such item infringes any patent, trademark,
copyright, trade dress, trade secret or any similar right.
11. Force Majeure: Seller does not assume the risk of and shall not be
liable for delay or failure to perform any of Sellers obligations by reason
of circumstances beyond the reasonable control of Seller (hereinafter
Events of Force Majeure). Events of Force Majeure shall include without
limitation, accidents, acts of God, strikes or labor disputes, acts, laws, rules
or regulations of any government or government agency, fires, floods,
delays or failures in delivery of carriers or suppliers, shortages of materials
and any other cause beyond Sellers control.
12. Entire Agreement/Governing Law: The terms and conditions set
forth herein, together with any amendments, modifications and any
different terms or conditions expressly accepted by Seller in writing, shall
constitute the entire Agreement concerning the items sold, and there are
no oral or other representations or agreements which pertain thereto. This
Agreement shall be governed in all respects by the law of the State of Ohio.
No actions arising out of the sale of the items sold hereunder or this
Agreement may be brought by either party more than two (2) years after
the cause of action accrues.
9/91-P

The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorized
distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. This offer and
its acceptance by any customer ("Buyer") shall be governed by all of the following Terms and Conditions. Buyers order for any such items, when communicated
to Parker Hannifin Corporation, its subsidiary or an authorized distributor ("Seller") verbally or in writing, shall constitute acceptance of this offer.
1. Terms and Conditions of Sale: All descriptions, quotations, proposals, offers, acknowledgments, acceptances and sales of Sellers products
are subject to and shall be governed exclusively by the terms and
conditions stated herein. Buyers acceptance of any offer to sell is limited
to these terms and conditions. Any terms or conditions in addition to, or
inconsistent with those stated herein, proposed by Buyer in any acceptance of an offer by Seller, are hereby objected to. No such additional,
different or inconsistent terms and conditions shall become part of the
contract between Buyer and Seller unless expressly accepted in writing
by Seller. Sellers acceptance of any offer to purchase by Buyer is
expressly conditional upon Buyers assent to all the terms and conditions
stated herein, including any terms in addition to, or inconsistent with those
contained in Buyers offer, Acceptance of Sellers products shall in all
events constitute such assent.
2. Payment: Payment shall be made by Buyer net 30 days from the date
of delivery of the items purchased hereunder. Amounts not timely paid
shall bear interest at the maximum rate permitted by law for each month
or portion thereof that the Buyer is late in making payment. Any claims by
Buyer for omissions or shortages in a shipment shall be waived unless
Seller receives notice thereof within 30 days after Buyers receipt of the
shipment.
3. Delivery: Unless otherwise provided on the face hereof, delivery shall
be made F.O.B. Sellers plant. Regardless of the method of delivery,
however, risk of loss shall pass to Buyer upon Sellers delivery to a carrier.
Any delivery dates shown are approximate only and Seller shall have no
liability for any delays in delivery.
4. Warranty: Seller warrants that the items sold hereunder shall be free
from defects in material or workmanship for a period of 18 months from
date of shipment from Parker Hannifin Corporation. THIS WARRANTY
COMPRISES THE SOLE AND ENTIRE WARRANTY PERTAINING TO
ITEMS PROVIDED HEREUNDER. SELLER MAKES NO OTHER WARRANTY, GUARANTEE, OR REPRESENTATION OF ANY KIND WHATSOEVER. ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO, MERCHANTABILITY AND FITNESS FOR PURPOSE,
WHETHER EXPRESS, IMPLIED, OR ARISING BY OPERATION OF
LAW, TRADE USAGE, OR COURSE OF DEALING ARE HEREBY
DISCLAIMED. NOTWITHSTANDING THE FOREGOING, THERE
ARE NO WARRANTIES WHATSOEVER ON ITEMS BUILT OR ACQUIRED WHOLLY OR PARTIALLY, TO BUYERS DESIGNS OR
SPECIFICATIONS.
5. Limitation Of Remedy: SELLERS LIABILITY ARISING FROM OR IN
ANY WAY CONNECTED WITH THE ITEMS SOLD OR THIS CONTRACT SHALL BE LIMITED EXCLUSIVELY TO REPAIR OR REPLACEMENT OF THE ITEMS SOLD OR REFUND OF THE PURCHASE
PRICE PAID BY BUYER, AT SELLERS SOLE OPTION. IN NO EVENT
SHALL SELLER BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND OR NATURE WHATSOEVER, INCLUDING BUT NOT LIMITED TO LOST PROFITS ARISING
FROM OR IN ANY WAY CONNECTED WITH THIS AGREEMENT OR
ITEMS SOLD HEREUNDER, WHETHER ALLEGED TO ARISE FROM
BREACH OF CONTRACT, EXPRESS OR IMPLIED WARRANTY, OR IN
TORT, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, FAILURE
TO WARN OR STRICT LIABILITY.
6. Changes, Reschedules and Cancellations: Buyer may request to
modify the designs or specifications for the items sold hereunder as well
as the quantities and delivery dates thereof, or may request to cancel all
or part of this order, however, no such requested modification or cancellation shall become part of the contract between Buyer and Seller unless
accepted by Seller in a written amendment to this Agreement. Acceptance
of any such requested modification or cancellation shall be at Sellers
discretion, and shall be upon such terms and conditions as Seller may
require.
7. Special Tooling: A tooling charge may be imposed for any special
tooling, including without limitation, dies, fixtures, molds and patterns,
acquired to manufacture items sold pursuant to this contract. Such special
tooling shall be and remain Sellers property notwithstanding payment of
any charges by Buyer. In no event will Buyer acquire any interest in
apparatus belonging to Seller which is utilized in the manufacture of the

14

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

About Parker Hannifin Corporation

PGP/PGM 300 Series

Service Manual HY09-SM300/US

Parker Hannifin Corporation

Parkers Charter
To be a leading worldwide manufacturer of components
and systems for the builders and users of durable
goods. More specifically, we will design, market and
manufacture products controlling motion, flow and
pressure. We will achieve profitable growth through
premier customer service.

Product Information

The Fluid Connectors

Group designs, manufactures
and markets rigid and flexible
connectors, and associated
products used in pneumatic
and fluid systems.

The Aerospace Group

is a leader in the development,
design, manufacture and
servicing of control systems
and components for aerospace
and related high-technology
markets, while achieving
growth through premier
customer service.

The Filtration Group

designs, manufactures and
markets quality filtration
and clarification products,
providing customers with
the best value, quality,
technical support, and
global availability.

The Seal Group designs,

manufactures and distributes
industrial and commercial
sealing devices and related
products by providing
superior quality and
total customer satisfaction.

The Climate & Industrial

Controls Group
designs, manufactures and
markets system-control and
fluid-handling components
and systems to refrigeration,
air-conditioning and industrial
customers worldwide.

North American customers seeking product information,

the location of a nearby distributor, or repair services
will receive prompt attention by calling the Parker
Product Information Center at our toll-free number:
1-800-C-PARKER (1-800-272-7537). In the UK, a similar
service is available by calling 0500-103-203.

The Hydraulics Group

designs, produces and
markets a full spectrum
of hydraulic components
and systems to builders
and users of industrial
and mobile machinery
and equipment.

Parker Hannifin is a leading global motion-control

company dedicated to delivering premier customer
service. A Fortune 500 corporation listed on the
New York Stock Exchange (PH), our components
and systems comprise over 1,400 product lines that
control motion in some 1,000 industrial and
aerospace markets. Parker is the only
manufacturer to offer its customers a choice of
hydraulic, pneumatic, and electromechanical
motion-control solutions. Our
Company has the largest distribution network in its
field, with over 7,500 distributors serving more
than 350,000 customers worldwide.

The Automation Group

is a leading supplier of
pneumatic and electromechanical components
and systems to automation
customers worldwide.

The Instrumentation
Group is a global leader
in the design, manufacture
and distribution of highquality critical flow
components for worldwide
process instrumentation,
ultra-high-purity, medical
and analytical applications.

15

Parker Hannifin Corporation

Gear Pump Division
Youngstown, OH

Parker Hannifin Corporation

Gear Pump Division
1775 Logan Avenue
Youngstown, OH 44501 USA
Tel: (330) 746-8011
Fax: (330) 746-1148
www.parker.com

Service Manual HY09-SM300/US

04/02 T&M 2.5M

RADIUS

PARTS OF LINE (FALLS)

UNITS

55M3000EQE

SAFE WORKING
LOAD

BARGRAPH
(%SWL)

BOOM TIP
HEIGHT

DUTY NUMBER

WYLIE I3000 LATTICE CRANE WITH HOIST ROPE

LOAD SENSOR(S) INTERFACE DESCRIPTION
SLEW ANGLE
BOOM LENGTH
HOIST IN USE
STATE DISPLAY
BOOM ANGLE
LOAD ON
HOOK

Shows parts of line (falls). Also

used to scroll down in menus or
decrease modiable values.

Shows hoists for selection. Also

used to scroll up in menus or
increase modiable values.

Shows systems modes.

Bypass the motion cut (lockout).

Enter the rigging mode.

Shows all the information

regarding the actual crane
conguration.

Shows the menu for the selection

of duty by number or by crane
conguration.

Shows the problem source when

a fault is detected.

DISPLAY BUTTONS PRESENTATION

Escape from a menu list. Also

used to cancel modication of a
value.

Switch the load display between

the actual load and the tare
load.

i3000 Quick Reference

Press button #1 and button #4 simultaneously to reset

the system. This could be usefull if the system stalls or
becomes unstable due to DC power supply regulation.

Select button. Used to select a

highlighted item in a menu.

Lattice Crane with Dynamometer

i3000 Quick Reference

i3000 BASIC OPERATION

Hoist Selection:
Push the HOIST button to display hoist selection.
Scroll up or down with buttons #2 or #3 to highlight the
desired selection.
Push button #4 to conrm your choice.
Parts of line (falls) selection:
Push the PARTS button (#3) to display parts of line
selection.
Scroll up or down with buttons #2 or #3 to highlight
the desired selection.
Push button #4 to conrm your choice.

Changing conguration by the duty number:

Push the DUTY button (#7) to display the duty menu.
The duty number should be already highlighted.
Push button #4 to enter the duty number menu.
Scroll up or down to highlight the desired number for
the rst digit.
Push button #4 to conrm your choice.
Scroll up or down to highlight the desired number for
the second digit.
Push button #4 to conrm your choice.
Repeat steps 6 and 7 for the last two digits.

Changing conguration by parameters selection:

Push the DUTY button (#7) to display the duty menu.
Scroll up or down to highlight the parameter you wish to
change.
Push button #4 to display available choices for this
parameter.
Scroll up or down to highlight the desired conguration.
Push button #4 to conrm your selection.
Repeat steps 1 to 5 for every parameter you need to
change.

55M3000EQE

i3000 Quick Reference

i3000 Quick Reference

Bypassing a lock-out condition:

Depress and hold the BYPASS button to momentarily override a lock-out.
The BYPASS button must be re-pushed after 15 seconds.

Information on the crane conguration:

To display the actual conguration of the crane, press the
INFO button (#8).
Push it a second time to display the system version.

Failure information:
When the state display show X faults detected ! press ?
push the (?) button (#6) to show which fault has been
detected.
Lattice Crane with Dynamometer

Two-Block
Condition
Detected

Overload
Warning
(Red Light)

Motion
Cut
(Red Light)

55M3000EQE

Rated Capacity
Limited by the
Hoist Rope

WARNING LIGHTS AND INDICATORS

Approach
Warning
(Yellow Light)

Preset Limit(s)
Reached

i3000 Quick Reference

The i3000 must be set to the crane parameters (e.g. correct boom
length, exact number of part of lines, outriggers extended or retracted
etc.) before operating the crane or when changing the parameters.
Wrong adjustment may cause the indicator system to show a safe
condition in the event of an overload!

Lattice Crane with Dynamometer

i3000 Quick Reference

55M3000EQE

SYSTEM CONFIGURATION AND DIAGNOSTIC MENU

UNITS SELECTION:
It is possible to choose between 5 unit combinations. Each measure of length,load and pressure will be
displayed on the main display. Proceed as follows to change these units:
1- Push the MODE button (#1).
2- Scroll down with the down button (#3) to highlight
the cong.system line.
3- Push the select button (#4) to conrm your choice.
4- Scroll down to highlight the units line.
5- Push the select button (#4) to enter the units menu.
6- Scroll up or down (button #2 or #3) to highlight the
desired unit combination.
7- Push the select button (#4) to conrm your choice.

i3000 Quick Reference

i3000 Quick Reference

FAULTS ENABLED OR DISABLED:

In the main display, when there is a fault, the state display will shows 1 fault detected !
press ? as long as the fault exists. If you dont want the state display to warn you when a
fault is detected, just disable it as follows:
1- Push the MODE button (#1).
2- Scroll down with the down button (#3) to highlight
the cong.system line.
3- Push the select button (#4) to conrm your choice.
4- Scroll down to highlight the faults enabl. line.
5- Push the select button (#4) to switch to
faults disab..
6- Push the ESC button (#5) to return to the normal mode.
To enable the faults again, repeat steps 1-6.

DIAGNOSTIC MENU:
The diagnostic menu can be very helpful to verify the sensors signals.
To view the diagnostic men proceed as follows:
1- Push the MODE button (#1).
2- Scroll down with the down button (#3) to highlight the diagnostic line.
3- Push the select button (#4) to enter into the diagnostic info menu.
4- Scroll up and down to visualize all pages.
5- Push the ESC button (#5) to go back to the normal mode.

Lattice Crane with Dynamometer

LIMIT
REACHED

CUT-OFF
CONDITION

55M3000EQE

free zone (two walls)

variable limit radius

variable limit height

limit high (roof)

Shows which zone is programmed:

i3000 RANGE LIMITING DEVICE (OPTIONAL)

APPROACH WARNING OF
THE LIMIT

Shows which limit is reached:

RADIUS
HEIGHT
WALL

ALARMS:

i3000 Quick Reference

LIMIT PROGRAMMING:
There are 4 types of limits that can be programmed: LIMIT HIGH, FREE ZONE, VARIABLE LIMIT HEIGHT and
VARIABLE LIMIT RADIUS. Because only one limit may be programmed at a time, you will need to delete any
previously programmed limit. When a limit is programmed, the associated icon will be displayed in the
area zone. When you program a zone, just follow the instructions at the bottom of the screen.
ACCESSING THE RANGE LIMITING MODE:
1- Push the Mode button (#1) to display the mode menu.
2- Scroll down with button #3 once to highlight the range limiting option.
3- Push button #4 to enter the range limiting menu.
1) LIMIT HIGH:
1- Access the range limiting mode.
2- Use the up (#2) and down (#3) buttons to highlight
limit high and push button #4 to conrm your choice.
3- Boom up to the desired boom tip height limit.
4- Push button #4 to conrm the maximum boom tip height position. As
you release button #4, an 8 second countdown will allow you to boom
down before your programmed height limit becomes active.
5- The display will automatically return to the normal mode.

2) FREE ZONE:
1- Access the range limiting mode.
2- Use the up (#2) and down (#3) buttons to
highlight free zone and push button #4 to conrm your choice.
3- Rotate the crane to the rst limit position (rst wall).
4- Push button #4 to conrm that this will be the position of the rst wall.
5- Rotate the crane to the second limit position (second wall).
6- Push button #4 to conrm. This will be the position of the second wall.
As you release button #4, an 8 second countdown will allow you to
rotate the crane between the two walls before your programmed free
zone limit becomes active.
7- The display will automatically return to the normal mode.
Lattice Crane with Dynamometer

i3000 Quick Reference

i3000 RANGE LIMITING DEVICE (OPTIONAL)

55M3000EQE

3) VARIABLE LIMIT HEIGHT:

1- Access the range limiting mode.
2- Use the up and down buttons to highlight variab.limit height.
3- Push button #4 to conrm your choice.
4- Rotate the crane to the rst limit position (rst wall).
5- Push button #4 to conrm that this will be the position of the rst wall.
6- Rotate the crane toward the second limit position (second wall) with
the boom tip always at the maximum height permitted by the surrounding
environment.
7- Push button #4 to conrm the position of the second wall. As you release button #4, an 8 second
countdown will allow you to return between the two walls and boom down below the height limit
before your programmed variable height limit becomes active.
8- The display will automatically return to the normal mode.

i3000 Quick Reference

i3000 Quick Reference

4) VARIABLE LIMIT RADIUS:

1- Access the range limiting mode.
2- Use the up and down buttons to highlight variab.limit radius.
3- Push button #4 to conrm your choice.
4- Rotate the crane to the rst limit position (rst wall).
5- Push button #4 to conrm that this will be the position of the rst wall.
6- Rotate the crane toward the second limit position (second wall) with
the boom tip always at the maximum radius permitted by the surrounding
environment.
7- Push button #4 to conrm the position of the second wall. As you release
button #4, an 8 second countdown will allow you to return between the
two walls and boom up within the allowed radius limit before your programmed variable radius
limit becomes active.
8- The display will automatically return to the normal mode.

DELETING A PROGRAMMED LIMIT:

1- Access the range limiting mode.
2- Push button #4 to display the delete limit menu.
3- Scroll down to highlight yes.
4- Push button #4 to conrm that you want to delete the limit.
5- Push the ESC button (#5) to return to the normal mode.

Lattice Crane with Dynamometer

Ref: VH mai 2003

i3000
DATA LOGGER OPTION
Operators Manual

55M3000GLE Rev. A

Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
TN38 9BA

Wylie Systems
(Rayco Technology Group)
2440 Dalton Avenue
Ste-Foy, Qc
CANADA
G1P 3X1

Tel: (+44) 1-424-421235

Fax: (+44) 1-424-433760

Rayco Electronic Systems

(Rayco Technology Group)

1020 9th Avenue SW

Suite 124
Bessemer, AL
USA 35022

Tel: (418) 266-6600

Fax: (418) 266-6610

Wylie Systems
(Rayco Technology Group)

Tel: (205) 481-2080

Fax: (205) 481-2081

Copyright 2003
Systme lectronique Rayco
Tous droits rservs.

General description

Operators manual

The purpose of this manual is to provide the customer with the operating
procedures essential for the promotion of proper machine operation
for its intended purpose. The importance of proper usage cannot
be overstressed. All information in this manual should be read and
understood before any attempt is made to operate the machine.
Since the manufacturer has no direct control over machine application
and operation, conformance with good safety practice in this area is
the responsibility of the user and his/her operating personnel.
All procedures herein are based on the use of the system under proper
operating conditions, with no deviations from the original design.
Alteration and/or modication of the equipment is strictly forbidden
without written approval from Rayco Technology Group.
The i3000 Wylie Systems Rated Capacity Indicator (RCI) is to be regarded
only as an aid to the operator . When the parameters are set correctly,
the indicator will warn the crane operator of an approaching overload
condition that could cause damage to equipment, property, and/or
injury to the operator or site workers in the vicinity of the crane and its
load.
This system must never be used, under any circumstances, as a substitute
for the good judgment of a crane operator when carrying out approved
crane-operating procedures. Responsibility for the safe operation of
the crane lies with the crane operator. The indicator equipment will not
necessarily prevent crane damage due to overloading and related
causes if not set properly.
Before operating a crane equipped with a Wylie systems RCI, the
operator must carefully read the information in both this manual
and the crane manufacturer operators manual. He must also have
read and understood the CIMA safety manual, the latest ASME B30.5
standard and the current OSHA, federal, state and local regulations
applicable to his job. Correct functioning of the system depends upon
routine daily inspection.
Any suspected faults or apparent damage should be immediately
reported to the responsible authority before using the crane.
i3000 data logger option

5- DATA DOWNLOAD
5.1- Connection To A Personal Computer
5.2- Entering Download Mode Of The i3000 System
5.3- Using The Analysis Software To Download Data

4-PC SOFTWARE INSTALLATION

4.1- Starting The Installation
4.2- Installation Procedure

3- CALIBRATION
3.1- Setting The Data Logger Time And Date
3.2- Setting The Crane Identity
3.3- Users ID

2- NORMAL OPERATION
2.1- Password
2.2- The Data Logger Clock
2.3- Data Logger Clock Battery

1- GENERAL DESCRIPTION OF THE DATA LOGGER OPTION

1.1- Introduction
1.2- Data Logger Fundamental System Components
1.2.1- i3000 Data Logger Memory Board
1.2.2- Communication Interface Box
1.2.3- Data Logger Download PC Cable
1.2.4- Data Logger Analysis Software CD-ROM

page 24
page 24
page 25
page 26
page 26
page 29
page 31
page 31
page 32

page 20
page 20
page 20
page 21

page 18
page 18
page 19

page 14
page 14
page 16
page 17

page 11
page 11
page 12
page 13

page 8
page 8
page 8
page 9
page 9
page 10
page 10

General description

6- THE DATA LOGGER ANALYSIS SOFTWARE

6.1- Employee List
6.2- Add Downloaded Data To Database
6.3- Data Analysis
6.3.1- How To Print A Report
6.3.2- Retrieving Information About A Specic Lift
6.4- Graphic Tool
6.4.1- How To Print A Graphic
6.4.2- Other Graphic Examples

page 33

TABLE OF CONTENTS

7- EVENTS THAT CAN BE LOGGED

Operators manual

page 34
7

8- DATA LOGGER CAPACITY

i3000 data logger option

-1-

Introduction

General description

GENERAL DESCRIPTION OF THE DATA LOGGER OPTION

1.1
This manual details the operating procedure of a Wylie data logger in an i3000 system
and the analysis of collected data on a PC using Wylie data logger supplied software.
The Wylie data logger memory board is mounted in the i3000 cpu box if specied at
the time of order for a new system. The cpu box will be supplied complete with data
logger memory board and compatible operating system software. In addition to this
memory board, the standard data logger kit includes: a communication interface box,
a download cable and software.

Data Logger Fundamental System Components

If a datalogger option is retrotted to an existing i3000 system, consult Wylie Systems for
details as a different operating system software is needed.

1.2

Description

Qty

Except where stated, the following parts are supplied as standard:

Wylie Systems
Part No.

1
1
1
1

Operators manual

i3000 DATA LOGGER MEMORY BOARD

COMMUNICATION INTERFACE BOX
DATA LOGGER DOWNLOAD PC CABLE
DATA LOGGER ANALYSIS SOFTWARE CD-ROM

22BCB0114
33J0031
33V0039
55SW0001

i3000 data logger option

1.2.1

i3000 Data Logger Memory Board

Communication Interface Box

General description

The i3000 data logger memory board is mounted on top of the cpu board inside the
cpu box. This printed circuit board contains 4 megabytes of ash memory to record all
the events that can be logged by the i3000. Also present on this board is a 3 volt lithium
battery to support time keeping during periods when the i3000 system is turned off.

1.2.2

Operators manual

The communication interface box is normally located inside the operators cab in a
convenient and easy to reach area. This box is used to download the data from the
i3000 memory board to a portable computer (laptop) using the supplied cable.

i3000 data logger option

1.2.3

Data Logger Download PC Cable

Data Logger Analysis Software CD-ROM

General description

The data logger download cable is used to link the communication interface box to a
laptop serial port in order to download all the recorded events from the i3000 system to
a computer.

1.2.4

PC System Requirements

Operators manual

The data logger analysis software must be installed on a PC in order to download the
information and also to erase the data logger contents if desired. Once downloaded,
in the PC, the information can be viewed, sorted and printed out using this specially
designed software.

1.3

10

-Pentium 100 CPU or Higher

-CD ROM Drive
-Windows 95
-16 MByte of RAM
-40 MByte of Free Hard Disk Space

TThe recommended minimum system requirements are:

i3000 data logger option

-2NORMAL OPERATION

Password

Operation

During normal operation of the i3000, data logging is entirely transparent and proceeds
without any actions from the operator provided that the data logger clock is functional
and that the amount of stored data is not approaching the capacity of the data
logger.

2.1

Wait...

The crane is ready to use!

When an i3000 system equipped with a data logger is powered up, the operator must
enter his personal 5 digit password to identify himself. Failure to enter a valid password
for a particular crane results in the disabling of the crane (if the crane is tted with an
optional motion cut system). The password list (all the passwords that can unlock the
i3000 system) must be set in the calibration mode under the user id menu. See section
3 calibration for details.

Enter your password here

11

Operators manual

You will be asked to enter your personal password each time the
system is powered up. Use the small numerical value printed on each
button to enter your code.

i3000 data logger option

2.2

The Data Logger Clock

Normal Mode Screen

Push The INFO Button 3 times

The Logger Info Screen

12

Operation

Operators manual

Time

The i3000 Memory Board is tted with a real time clock circuit. The clock must be properly
set for correct data logger operation. To see data logger information such as time and
date, press the INFO button 3 times from the normal mode screen. To adjust time and
date see the calibration section of this manual.

Date

i3000 data logger option

2.3

Data Logger Clock Battery

Operation

The battery supports time keeping during periods when the i3000 system is turned
off. Battery life is dependent on operating temperature and humidity conditions but
is expected to be in excess of 5 years. If the clock backup battery should become
discharged to a level below 2.1 Volts, a warning message will appear on the normal
mode screen. Push the help button to see a short description of the problem.

Push The HELP Button

This message means that your loggers

battery needs to be changed

13

24.5 mm

CR2450
dimensions

Operators manual

Data Logger Battery Location

If this warning is ignored and the battery should eventually become so discharged as
to stop the clock, all the data from this point will be unusable. Due to the use of ash
memory, the data prior to the battery failure will not be lost but the clock will have to
be set again. Refer to the calibration section of this manual regarding the adjustment
of time and date. For replacement of the battery use a 3V lithium coin cell # CR2450 or
CR2450N or contact Wylie Systems.

Data Logger Memory Board

(inside the i3000 cpu box)
i3000 data logger option

5 mm

-3CALIBRATION

Calibration

Some data logger parameters such as time, date, crane identity and the password list
can be edited in the calibration mode of the i3000 system. These parameters cannot be
changed by the crane operator as the calibration mode is password protected. As a
crane eet manager, you can obtain the password by contacting Wylie Systems.
To enter into the calibration mode, rst make sure you are in the normal mode. If you see
a crane on the display, you are in the normal mode. If you are not in the normal mode,
press the ESC BUTTON as many times as necessary to reach it. Once in the normal mode,
press the MODE button and select calibration using the DOWN (#3) button. When
calibration is highlighted, press ENTER (#4) to open this mode.

to

Highlight calibration and

press
enter calibration mode

or

DOWN

to open this menu.

buttons to

Setting The Data Logger Time And Date

If it is the rst time since the last power up or reset of the system that the calibration mode
is accessed, a screen will appear asking you to enter your password. The calibration
menu is protected to prevent your data from being modied inadvertently. Enter your
ve digit password to go directly to the rst screen of the calibration menu.

3.1

Once in the calibration mode, use the UP

14

Operators manual

The calibration mode menu order is

different from one version to another.
Here in this screen the datalogger
data line is located at position #21. It can
be somewhere else in your version...

highlight the DATALOGGER DATA line then press ENTER

i3000 data logger option

DAY) Push
.

to edit the day eld. Use the UP or DOWN

choose the correct day and press

button to highlight the month eld.

or

or

to conrm your choice.

to edit the month eld. Use the UP or DOWN

MONTH) Push the DOWN

Push
choose the correct month and press

button to highlight the year eld.

or

to conrm your choice.

to edit the year eld. Use the UP or DOWN

YEAR) Push the DOWN

Push
choose the correct year and press

button to highlight the hour eld.

or

to conrm your choice.

to edit the hour eld. Use the UP or DOWN

HOUR) Push the DOWN

Push

choose the correct hour and press

Calibration

button to

Operators manual

button

button to

button to

button to

24H
CLOCK

to conrm your choice.

or

button to highlight the minute eld.

15

to edit the minute eld. Use the UP or DOWN

MINUTE) Push the DOWN

Push

to choose the correct minute and press

i3000 data logger option

3.2

Setting The Crane Identity

Calibration

The crane identity is a name which should be entered by the customer during i3000
calibration to provide a unique identity for a particular machine. The crane identity
may consist of any of the characters from 0 to 9 or A to Z plus the DASH (-) in any order
and may be up to eight characters long. Note that a blank space ends the name entry
if the crane identity name contains less than eight characters.

To edit the crane identity name, proceeds as follow:

button

button to highlight the

button to choose the rst character and

to edit it.

or

1) Enter the calibration mode (see the beginning of section 3 for details).

to access it.

2) Highlight the DATALOGGER DATA line using the UP or DOWN

then press

or

3) Once in the datalogger data screen use the DOWN

crane identity line then press

when its done.

4) Use the UP or DOWN

press

5) The cursor shifts automatically to the next character once your selection

Operators manual

is made. Repeat step #4 for characters 2 to 8 and remember to use the space

16

The Datalogger Data Screen

(no character) if your crane identity has less than 8 characters...

i3000 data logger option

3.3

Users ID

Calibration

In the User ID menu you can decide which password(s) will unlock the i3000 system for
a particular crane. You can enter up to 200 different passwords that will work only for
this machine. Each password must be 5 digits long (numbers only 0,1,2...9). The user id
number is logged by the Wylie Data Logger during system power up and thus identify
exactly which operator downloaded records apply. Each employee must have his own
password. Do not give the same user id (password) to more than one employee as
the recorded events from those workers with the same number will be confused when
downloaded in the same PC.

To edit your password list, proceeds as follow:

or

button

button

Operators manual

button to select the desired number and

to edit it.

or

1) Enter the calibration mode (see the beginning of section 3 for details).

to access it.

2) Highlight the USERS ID line using the UP or DOWN

then press
3) Once in the users id screen use the UP or DOWN

or

to highlight one of the 200 user id lines, then press

when its done.

4) Use the UP or DOWN

press

5) The cursor shifts automatically to the next digit once your selection

17

The Users ID Screen

is done. Repeat step #4 for digits 2 to 5.

i3000 data logger option

-4PC SOFTWARE INSTALLATION

My Computer

Starting The Installation

Software installation

The Wylie Systems data logger analysis software must be installed on a PC in order to
download the information from the crane and also to erase the data logger contents if
desired. The windows based software is supplied on an installation CD-ROM with each
data logger system. It is not necessary for the data logger to be connected to the PC
during the installation procedure.

4.1
1- Insert the installation disc into the PCs CD-ROM drive.

2- On your desktop, double-click on MY COMPUTER.

18

Operators manual

4- Double-click on the LOG3K.EXE icon to

start the installation procedure.

3- Double-click on the Wylie Logger 1_1 disc.

i3000 data logger option

4.2

19

Software installation

Operators manual

You are now ready to install the Data

Logger Analysis Software. Click next
on this dialogue box. The installation
will continue ending with a message
as to whether it has been successful
or not. Replace the installation disc
in its case and store in a safe place.

The rst thing that will appears after

launching the installation process is
a welcome to i3000 setup dialogue
box. Select NEXT to continue after
closing any opened les.

Installation Procedure

The next dialogue box suggests

Logger I3000 as the name of
the program manager group to
be added in the start menu. Click
next...

i3000 data logger option

-5DATA DOWNLOAD

Connection To A Personal Computer

Data download

The data logger analysis software must be installed on a PC as described in section 4 of

this manual prior to beginning the download process. The data logger is connected with
a PC using the supplied data download pc cable. The pc cable is 5 feet long and the
data logger is xed on the crane thus a Laptop PC is suitable for downloading data.

5.1

i3000 CPU BOX

i3000 DISPLAY

COMMUNICATION
INTERFACE BOX
5 WAY
CON

LAPTOP PC
COM1

Figure 1 Connection to a personal computer (PC)

Operators manual

Entering Download Mode Of The i3000 System

Data logger
download pc
cable

Connect one end of the data logger pc cable to the 5 way socket on the communication
interface box and the other end to the COM1 serial port on the Laptop PC as shown
in gure 1.

5.2

20

Enter the calibration mode of the i3000 system (see

the beginning of section 3 for details). Highlight the
DOWNLOAD LOGGED DATA line using the UP or DOWN
button but do not press ENTER to start the process
immediately, you have to start the analysis software
on the PC rst. Just highlight this line download
logged data for now.
i3000 data logger option

5.3

Data download

Using The Analysis Software To Download Data

Start the data analysis software by selecting from the

START menu: choose PROGRAMS then LOGGER I3000
and nally LOGGER.

The Wylie data logger software window is opened.

21

Operators manual

Under the UPLOAD pulldown menu, choose UPLOAD DATALOGGER RECORDS.

i3000 data logger option

Data download

Once you have selected UPLOAD DATALOGGER RECORDS from the UPLOAD menu,
this dialogue box will appears:

You have 15 seconds to start the download process by pressing the ENTER button of
the i3000 system. This step assumes that the i3000 system is ready to download (see
section 5.2 of this manual for details).

Push this button on the i3000 system

to start the download process

22

Operators manual

Wait until the succeed !! message appears on the dialogue box then click close and
the download process is nished. It can take up to 25 minutes in case of a full data
logger board.
i3000 data logger option

Data download

When all the data is loaded into the PC, the data logger is automatically erased. If an
error occurs during the data transfer then you will have to restart the download process
from the beginning, but no data will be lost.
If an error message no response!!! occurs during data transfer, check the connection
between the PC and the communication interface box. If the connection is good,
make sure you use the PC serial port #1. You can change the default serial port under
the UTILITY menu if you are connected to another serial port of your PC.

Make sure that the Wylie analysis software is the only program running on your PC
using serial port #1. Opening the analysis software twice could result in communication
problems with the data logger also.

23

Operators manual

The data is saved as a pure text le for use with the database
software. This le is saved at: C:\i3k-Datalogger under the name
of CRANE IDENTITY.LOG where crane identity is the name given
to your machine (see section 3.2 for details).

The time taken for a download depends on the amount of data

held in the logger board and is approximately 25 minutes for a
100% full logger.

If you are still unable to communicate with the data logger close all programs running
on your PC, reset the i3000 system and start the download procedure over (from the
beginning of section 5 of this manual).

i3000 data logger option

-6THE DATA LOGGER ANALYSIS SOFTWARE

Analysing software

The data analysis software is used to download the data into the PC (see section 5 for
details) but its primary function is to produce many different reports and charts based on
user choices. There are options to print reports on a specied lift, running time, warnings
given, motion cut bypass actions etc. all of which can be ltered or sorted by date, by
user, or by crane. Together with the charting tools supplied, these reports provide a
powerful and easy to use eet management system.

Employee List

This section assumes that the data logger has been is use on the crane and therefore
data has been gathered and downloaded to the PC. Since data download is already
done at this step, it is not necessary to have the i3000 connected to the PC.

6.1

24

Operators manual

This button is
used to change
an employees
user ID.

To remove an employee
from the list click this
button.

You can sort your list by employee

name or by user ID number.

The rst thing you have to do with your data analysis software is to input the employee
list with their corresponding user id number (see section 3.3 for details on the user id).
Remember that a user id is a 5 digit number and that number must be associated with
only one employee among your employee list. The employee list is located under the
SEARCH menu.

Click here to add the

name and the user ID of
a new employee.

Click here to print

your employee list.

i3000 data logger option

6.2

Add Downloaded Data To Database

Analysing software

After data have been downloaded from the i3000 data logger board to the PC, the
data must be loaded (merged) into the PC database from the temporary text le. Once
merged to the database, data can be viewed, sorted and printed.

2) Then click on the CHOOSE A CRANES

IDENTITY button.

If your download came from a machine named CRANE-04 in the crane identity eld
of the i3000 system (see section 3.2 for details) then the temporary text le to be merged
to the database will be named CRANE-04.LOG. To include the data of a .LOG text
le into the database, proceed as follows:
1) From the UPLOAD menu, choose the
MERGE TO DATABASE line.

Operators manual

Each data logger download

must be merged to the
database in order to view it,
analyse it or print it.

4) Click on the MERGE button to start the

data transfer to the database.

25

3) Select the appropriate crane identity

from the list and click the SELECT button.

i3000 data logger option

6.3

Data Analysis

Analysing software

The working time

section is used to
view or print reports
on total working
time for a particular
crane or a particular
employee.

All the analysis tools provided by Wylie Systems can be found in the SEARCH menu.
There are options to view or print reports on a specied lift, working time by employee or
by crane, warnings given, overide actions etc. all of which can be ltered or sorted by
date, by user, or by crane.

The crane lifting

section
allows
detailed display
and print of each
recorded lift.
The secarch menu

The bypass detection or atb detection

sections permits display and print of
recorded motion cut override and
two block condition.

How To Print a Report

The crane warning section

permits simple display and
print of approach, overload
and motion cut warnings
without other lift information.

6.3.1

The example below shows how to print a working time by crane report. However,
printing another kind of report is very similar so we will not describe them all here.

Operators manual

If you want to print a working time report on a particular crane for a dened period of
time, proceeds as follow:

26

1- From the SEARCH menu, highlight the WORKING TIME line

and choose in the pop-up menu SEARCH BY CRANE.

i3000 data logger option

2- Click this button to determine which crane to print report for.

Analysing software

3- Use the small arrows to decide on which date interval the

report will be based on.
4- Push the OK button when done.

Operators manual

5- A screen showing all the events for the selected date interval
will be displayed.

27

6- Click this button to produce a print preview of your report.

i3000 data logger option

Use the arrows to

toggle between pages
if your report contains
2 pages or more

Working time by crane print preview

28

Analysing software

Operators manual

Zoom in or zoom out

to t the print preview
to your screen

7- The print preview of your report is displayed. Print it by pressing

this button.

i3000 data logger option

6.3.2

Retrieving Information About a Specic Lift

Analysing software

Each lift exceeding 20% of the safe working load is recorded by the data logger board.
Hence you can retrieve information about each lift such as the actual load, radius,
boom angle, warnings reached etc. To view or print information regarding a specic lift,
follow these steps:
1- Select CRANES LIFTING from the SEARCH menu.

2- Push this button to choose a crane.

29

Operators manual

3- Select a date interval that include the lift you are looking for then press OK.
i3000 data logger option

Analysing software

4- In the screen below, choose the lift to analyse by selecting it from the list.

5- Information regarding the selected lift is displayed here.

Operators manual

6- To print a general or detailed report of the lifts list, click one of these buttons.

30

Example of a detailed lift report

In a detailed lift report, each lift is displayed separately and it

shows all the information gathered during this specic lift.

i3000 data logger option

6.4

Graphic Tool

Analysing software

Graphic tools provided by the Wylie Systems datalogger can be found in the GRAPHIC
VIEW menu. There are options to view or print graphic representation of:
- Total number of lifts,
- Number of lifts performed within each 10% band of SWL,
- Total time in a warning condition (approach, overload or motion cut),
- Working time.

How To Print a Graphic

Each of those graphics can be based on a specic month or a whole year.

6.4.1

Operators manual

4- Choose a
graphic type
among these
three choices.

The example below shows how to print a crane total number of lifts for the year 2002.
However, printing another kind of graphic is very similar so we will not describe them all
here.

31

2- Push this button to choose a crane.

1- From the GRAPHIC VIEW menu, click on the LIFTING line.

3- Select the
year 2002
using the
arrows.

i3000 data logger option

6.4.2

Analysing software

5- Push this button to print your total number of lifts for the year 2002.

32

Operators manual

This graph compares the working time of a

crane for each month of the year 2002.

Other Graphic Examples

Here is a graph representing

the
number of lifts performed in the month
of june 2002 within each 10% band of
safe working load (SWL).

i3000 data logger option

-7EVENTS THAT CAN BE LOGGED

33

Description of Event
System Power-Up Date and Time
Crane Type as Recorded in the Chart Data Chip
i3000 Operating System Version
Approach Warning Threshold as % SWL
Overload Warning Threshold as % SWL
Cut Warning Threshold as % SWL
Crane Identity Number
Used (operator) Identity
Start of Lift Date and Time
Units of Measure for this Lift
Current Duty Number
Current Number of Falls
Crane Conguration Table (CCT) Number
Time when Approach Warning Set
Actual Radius at Approach Warning
Time when Approach Warning Cleared
Time when Overload Warning Set
Actual Radius at Overload Warning
Time when Overload Warning Cleared
Time when Cut Warning Set
Actual Radius at Cut Warning
Time when Cut Warning Cleared
End of Lift Date and Time
Maximum % SWL Reached During the Lift
Maximum Actual Load at Max % SWL
Radius at Max % SWL
Maximum Actual Radius reached during the Lift
Minimum Actual Radius reached during the Lift
Max. Main Boom Angle reached during the Lift
Min. Main Boom Angle reached during the Lift
SWL at Max % SWL
Boom Angle at Max % SWL
Anti Two-Block Detected Time and Date
Motion Cut Bypass Time and Date
System Power-Down Date and Time
Maximum Moment (load x radius)
Static Load
Log Static Moment

Analysing software

Operators manual

When logged
System Power-Up
System Power-Up
System Power-Up
System Power-Up
System Power-Up
System Power-Up
System Power-Up
System Power-Up
Start of Lift (Load > 20%SWL)
Start of Lift (Load > 20%SWL)
Start of Lift (Load > 20%SWL)
Start of Lift (Load > 20%SWL)
Start of Lift (Load > 20%SWL)
When Approach Threshold reached
When Approach Threshold reached
When return below Threshold
When Overload Threshold reached
When Overload Threshold reached
When return below Threshold
When Cut Threshold reached
When Cut Threshold reached
When return below Threshold
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
When an ATB is Detected
When a Bypass is Detected
System Power-Down
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)
End of Lift (Load < 20%SWL)

Table 1: Possible Logged Events

Not all data that can be logged are necessarily logged as some relevant events may
not occur. For example if no warnings were involved no warning information would be
logged. Table 1 lists all possible logged events for W3650 data logger software 1.1.

Event number
7
3
4
18
42
66
1
201
12
5
9
10
11
19
22
31
43
46
55
67
70
79
13
14
91
92
113
124
155
165
195
203
200
204
202
205
206
207
i3000 data logger option

-8DATA LOGGER CAPACITY

Analysing software

It is difcult to predict how many complete records can actually be held in the data
logger because the length of a record can vary depending on events. The worst case
scenario is when a system is turned on, the crane performs one lift in which all three
warnings occur and is then powered down many times a day.
Conversely performing many lifts each time the crane is used and avoiding any warnings
increases capacity in terms of number of records as the power up information is logged
relatively few times.
Consider a crane shift to be a cycle where the i3000 is powered-up and performs a
number of lifts with a number of warnings occurring and is then powered down. Table 1
shows typical examples of number of lift records versus Lifts per crane Shift and warnings.
A Cut Warning implies that all three warnings have occurred as the Cut threshold is
always higher than Approach or Overload.

1
20 087

12 595

19 051

18 141

11 781

Cut Warning on every

5th Lift

13 540

13 074

9 425

Cut Warning on every

Lift

Table 1 Predicted Numbers of Lift Records Possible

10
21 209

Number Lifts per Crane

No Warnings Occurring
Shift

50

20

10

Number Lifts
per Day

1.4

3.2

5.8

9.7

Capacity
(Years)

Operators manual

Table 2 show how many years it will take before reaching the data logger full capacity
assuming: 4 power-up/power-down a day, 1 motion cut every 5 lifts and a 5 day a week
working schedule.

50

0.7
34

100

Table 2 Predicted Number of Years of data logging capacity

i3000 data logger option

i3000 data logger option

Notes

35

Operators manual

OPERATION AND MAINTENANCE

INSTRUCTIONS
FOR
ROOF TOP MARINE AIR CONDITIONERS
AND CEILING PLENUMS

MODE DEMPLOI ET UTILISATION

CLIMATISEUR MARINE
DE TOIT
ET PLENUM DE PLAFOND

I.
II.
III.
IV.
V.
VI.

TABLE OF CONTENTS
2

4
8

The size of the vehicle, amount of window area, amount of

insulation, direct exposure to the sun, outside temperature and
the number of people in the recreational vehicle may increase
the heat gain to such an extend that the capacity of the air
conditioner is exceeded.

SECTION I - GENERAL INFORMATION

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Ceiling Plenum Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Standard Ceiling Plenum Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wall Thermostat Identification And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTE
The optional Elect-A-Heat heating assembly is intended to
take the chill out of the indoor air when the air is a few
degrees too cool for comfort. The heating assembly is an
effective chill chaser. It is not a substitute for a furnace.
As a general rule, air entering the air conditioner will be cooled
about 15 to 20 degrees, depending on the outside temperature
and humidity conditions.

As long as this temperature difference is being maintained

between the return air and discharge air, the air conditioner is
operating at its capacity. If the desired inside temperature
(normally 80 degrees F) cannot be maintained, then the heat
gain of the RV is too great for the capacity of the air
conditioner.

For example, if the air entering the return air grilles in the air
conditioner is 80 degrees F, the air leaving the discharge grilles
in the air conditioner will be 60 to 65 degrees F.

When searching for a qualified technician, please reference

your RV Products Authorized Service Center List. The
servicers listed are familiar with your recreation vehicle
product. If the air conditioner is still under warranty, an
authorized servicer must be used for any repair required on the
air conditioner. Using an unauthorized servicer may void your
warranty.

Parking the vehicle in a shaded area, keeping windows and

doors shut and avoiding the use of heat producing appliances
in the vehicle will help to reduce the heat gain. When
possible, the addition of insulation and tinted glass (especially
in uninsulated vans) should be considered.

These roof mount air conditioners were designed to operate

from a 115 VAC, 60 HZ, 1 Phase power supply. Anytime an air
conditioner is not operating properly, the power supply
should be examined by a qualified technician to verify that the
air conditioner is receiving the proper power supply.

This is due to the limited electrical power normally available in

most trailer parts and/or economic limitations on the use of
generators with enough capacity to handle large air
conditioners. If more than 1 ton of cooling is desired, then the
use of two air conditioners is recommended.
The ability of the air conditioner to maintain the desired inside
temperature depends on the heat gain of the recreational
vehicle.

B.

The Thermostat (temperature control) - In the

cooling mode, the thermostat regulates the ON
and OFF temperature setting at which the

The Operation section explains the operational

characteristics of each mode of operation.

roof top unit and ceiling assembly. Figure 1 shows

selector switch location and lists all available
functions by model.

SECTION II - CONTROL PANEL

If your RV air conditioner is operated from the control panel
located in the ceiling assembly, then there are three controls
on the ceiling assembly that help you control the air
conditioner. They are as follows:
A.

The Selector Switch - The selector switch determines

which mode of operation the air conditioner will be
in. By rotating the selector switch, the operator can
obtain any system function desired. System
functions vary depending upon options of both the

compressor will operate.

For Heat/Cool models, the thermostat also controls
the ON and OFF temperature settings of the
heater assembly (See Figure 1).

C.

FIGURE 1

Louvers - The louvers are located at both ends of the

ceiling assembly shroud and are used in directing
the discharge air from the unit.

A.

I.
Turn the selector switch to the LOW COOL or
HIGH COOL position.

For Cooling (Refer to Figure 1, Page 3)

II.

C.

Operation During Cooler Nights (Cooling

Operation)

Position the louvers to the desired direction the

discharge air is to flow.

SECTION III - OPERATION

B.

It is important, when the outdoor temperature drops in the

evening or during the night to below 75 degrees F, that the
thermostat (temperature control) be set at a midpoint between
Warmer and Cooler. If the setting is at cooler, the
cooler (evaporator) coil may become iced-up and stop cooling.
During the day when the temperatures have risen above
75 degrees F, reset the thermostat switch to the desired
setting.

Rotate the thermostat (temperature control) to the

position that is the most comfortable to you. The
thermostat will turn the compressor on when the
temperature of the air entering the air conditioner
rises a few degrees above the setting you have
selected. When the temperature of the air entering
the air conditioner drops below the selected setting,
the thermostat will turn the compressor off. The air
conditioner, while in the cooling mode, will continue
to cycle the compressor on and off in the above
mentioned fashion until the selector switch is turned
to another mode of operation.

Short Cycling

NOTE
Should icing-up occur, it is necessary to let the cooling
(evaporator) coil defrost before normal cooling operation is
resumed. During this time, operate the unit in the HIGH
FAN position with the system at maximum air flow. When
increased or full air flow is observed, the cooling coil should
be clear of ice.
III.
When an air conditioner is in operation, its compressor
circulates refrigerant under high pressure. Once off, it will
take two to three minutes for this high pressure to equalize.

For Heating (Elect-A-Heat Ceiling Assembly

Model Only) Refer to Figure 1, Page 3)

The air conditioning compressor is unable to start against

high pressure. Therefore, once the air conditioner is turned
off, it is important to leave it off for two to three minutes
before restarting.
IV.

NOTE
The optional Elect-A-Heat heating assembly is intended to
take the chill out of the indoor air when the air is a few
degrees too cool for comfort. The heating assembly is an
effective chill chaser. It is not a substitute for a furnace.

Owner

C.

B.

Position the louvers to the desired direction the

discharge air is to flow.

Rotate the thermostat (temperature control) switch to

the position that is the most comfortable to you. The
thermostat will turn the heater on when the
temperature of the air entering the air conditioning
unit drops below this setting a few degrees and
automatically turns off when the temperature of the
air entering the air conditioner rises a few degrees
above this setting. The heater will continue to cycle
on and off in this fashion until the selector switch is
turned to another mode of operation.

Discharge air temperature can be controlled to some

extent by opening or closing the louvers.
When the louvers are closed, the warmest localized
discharge air is achieved. Fully opened louvers will
throw the warm discharge air to the back and front
of the vehicle for more efficient circulation and
faster warm-up. Although the air temperature is
lower with the louvers fully opened, the heating
capacity is still the same.

A.

Position the louvers to the desired direction the

discharge air is to flow.

Turn the selector switch for LOW FAN or for

maximum air flow, to HIGH FAN.

For Air Circulation Only (Refer to Figure 1, Page 3)

B.

NOTE
When the selector switch is in the LOW FAN or HIGH
FAN position, the blower motor will operate continuously.

IMPORTANT

We recommend that the filters be cleaned or changed at least

every two weeks when the air conditioner is in operation.

An even more serious condition occurs when the air

conditioner is operated without a filter. When this happens
the lint, dirt, grease, etc. that are normally stopped by the
filter are now accumulating in the cooling coil. This not only
leads to a loss of air volume and a possible icing-up of the
cooling coil, but could also result in serious damage to the
operating components of the air conditioner.

Do not operate your air conditioner for extended periods of

time without the filter installed.

SECTION IV - MAINTENANCE

Turn the selector switch to the LOW HEAT

position. At LOW HEAT, the fan operates on
low speed with heat output at maximum.

Do not expect the heating coil on your heater to glow.

Because the fan draws in cold air and forces it over the coil,
the coil will not turn red. A hint of red may occur where the
moving air does not directly touch the coil.
A.

1.

One of the biggest advantages to your new RV Products air

conditioner is that the maintenance needed to keep the unit
in good care is minimal. In fact about the only thing you,
the owner, must take care of is the cleaning and replacement
of the filters.
Filters are made from long life natural fibers which can be
cleaned and reused, and which completely filter the
circulated air when the air conditioner is in operation. If the
filters are not cleaned at regular intervals, they may become
partially clogged with lint, dirt, grease, etc. A clogged filter
will product a loss of air volume and may eventually cause
an icing-up of the cooling (evaporator) coil.

4.

3.

2.

1.

Remove filter from grill and either clean or

exchange with new filter.

If the vehicle is equipped with a flush mount

ceiling assembly, remove the four return air grill
screws (See Figure 5, Page 7).

Take filters out and either clean or exchange with

other filters (See Figure 2).

Lower the grille and filters from the ceiling

assembly.

Disengage the two 1/4-turn fasteners that secure

the ceiling assembly grille to the ceiling assembly
(See
Figure 2).

Cleaning and/or changing the filters:

5.

NOTE

II.

Service Person

If replacement filters are necessary, the filters

can be purchased from most RV Products
Authorized Service Centers. It is recommended
that spare filters be carried with the RV at all times
to replace worn, torn or deteriorated filters.

A.

Electrical - All electrical work and/or inspection

should be performed only by qualified service
personnel. Contact your nearest RV Products
Service Center if electrical problems should arise.

FIGURE 2

Mechanical Integrity - The air conditioner should be

inspected periodically to be sure that the bolts which
secure the unit to the roof are tight and in good
shape. Also, an examination of the plastic shroud
covering the air conditioner on the top of the roof
should be made periodically. Be sure the four
mounting screws and washers are snug and holding
the shroud to the air conditioner. Also examine the
shroud to be sure it is not developing cracks or has
suffered damage from impact.

B.

Check Points - Failure to start or to cool the air are

sometimes problems with air conditioning units.
The RV Products air conditioner is designed to
operate on 115 volt electrical power. If the
compressor on the air conditioner fails to start,
check with your RV Products Service Center to
determine that the proper wire size is connected to
the unit, the proper circuit breakers are installed as
protection devices on the electrical circuit and the
proper sized extension cord is being used for the
distance covered from the utility outlet to the RV.
The required minimum wire size is #12 AWG for
lengths up to 25 feet (larger wire size for greater
distances). Each air conditioning unit must be
protected with a 20 amp time delay fuse or
circuit breaker.
If the air conditioner continues to trip off the circuit
breakers, have an electrician check the starting
amperage and running amperage on the unit. If the
circuit breaker continues to trip off and the electrical
consumption is found to be normal, it will require
the replacement of the faulty circuit breaker.
If all electrical power to the air conditioner is normal
but neither the fan or the compressor will operate,
the connector plug located behind the ceiling
assembly control box should be checked to determine
whether it is faulty.

C.

Lubrication

On the heating-cooling air conditioner models, if all

electrical power to the unit is normal and the fan
runs but you never get any heated air, then the
electrical plug to the heating unit should be checked
for a secure connection. If this does not correct the
malfunction, the heating thermostat or limit switch
may be faulty.

D.

DANGER
DISCONNECT THE POWER SUPPLY TO THE UNIT
BEFORE SERVICING TO PREVENT A SHOCK HAZARD
OR POSSIBLE INJURY FROM MOVING PARTS.

The blower drive motor on some units may include oiling

cups at the top of the motor. There is no requirement to oil
the journals under normal operating conditions.

However, if lubrication to the unit is desired, use only

SAE 20 non-detergent type oil. DO NOT OVER OIL - three
to four drops in each oil hole once a year is sufficient.

SECTION V. WALL THERMOSTAT IDENTIFICATION

AND OPERATION
ELECTRONIC SINGLE STAGE HEAT/COOL THERMOSTAT

Suggested Fuse To Protect Wiring Leading To

Thermostat.

Not Found In Cool Only Applications.

FIGURE 3

Heat/Cool Thermostat
Shown
Cool Only Model Has No Reference To
Heat On Face Of Thermostat
FIGURE 4

OPERATION
The chart below shows the system functions with the Heat/Cool thermostat. After the entire
air conditioning system (and furnace system) is installed, check each position function. Disregard
references to heat functions when using the Cool Only thermostat.

All cooling functions controlling to setpoint have a short cycle protection time delay of 3 minutes. There will
be no delay if the cycle OFF time exceeds 3 minutes.
* There is no heat switch or furnace function available with the Cool Only thermostat.

5.

4.

An optional three year extended parts only contract

is available at an additional cost of $89.95. To obtain
this optional three year parts contract, fill out the
application card stapled to the front of this envelope.
Please mail the card and a check or money order to
the address above. Applications must be made
within ninety (90) days of the original purchase.

Carefully read your limited two year product

warranty which is packed with the product.

IMPORTANT

SECTION VI - WARRANTY SERVICE

Lets face it. Sometimes even the best products may need
service. To obtain warranty service on your RV Products air
conditioner, please contact your selling dealer, or you may
access our web site on the Internet at www.rvcomfort.com
for answers to the most frequently asked questions and
service center locations.
RV Products support help may be accessed by E-mail at
RVPSupport@Airxcel.com.

6.

8
9
9
10
12
12

Inquiries about your RV Products air conditioner

must include the model and serial numbers and the
date of purchase. The model and serial numbers can
be found on the I.D. label located on the air
conditioner basepan return air opening at the bottom
of the roof unit. This information may also be found
on the air conditioner rating plate.

TABLE DES MATIRES

Renseignements gnraux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panneau de contrle du plenum de plafond standard . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fonctionnement du plnum de plafond standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entretien . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fonctionnement et identification du thermostat mural . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service de garantie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RV Products
A Division of Airxcel, Inc.
P.O. Box 4020
Wichita, KS 67204

All written correspondence should be directed to:

I.
II.
III.
IV.
V.
VI.

La capacit du climatiseur de maintenir la temprature

intrieure voulue dpend du gain de chaleur du vhicule
rcratif.

Ceci peut provenir du fait quil y a des sources limites

dalimentation lectrique disponibles dans la plupart des
parcs de caravanes et/ou des limites conomiques quant
lutilisation de gnratrices ayant une capacit suffisante
pour de gros climatiseurs. Sil faut plus dune tonne de
refroidissement, alors il est recommand dutiliser deux
climatiseurs.

connaissent votre produit de vhicule rcratif. Si le

climatiseur est encore sous garantie, il faut utiliser un agent
autoris pour toute rparation ncessaire. Le fait dutiliser un
agent non-autoris peut annuler votre garantie.

SECTION I. RENSEIGNEMENTS GNRAUX

REMARQUE
Le montage de chauffage Elect-A-Heat optionnel est conu
pour couper le froid de lair lintrieur du vhicule qui est
un peu trop frais pour le confort. Le systme de chauffage
est efficace pour enlever le froid et non pas pour
remplacer lappareil de chauffage.
Ces climatiseurs de toit furent conus pour fonctionner
partir dune source dalimentation de 115 V. c.a., 60 hz, 1
phase. Lorsquun climatiseur ne fonctionne pas
correctement, lalimentation lectrique doit tre examine par
un technicien qualifi afin de vrifier que le climatiseur reoit
la bonne alimentation de courant.
Se reporter la liste de centres de service autoriss de RV
Products pour trouver un technicien qualifi. Les centres

La taille du vhicule, le nombre de fentres, la quantit

disolant, lexposition directe au soleil, la temprature
extrieure ainsi que le nombre de personnes dans le vhicule
peuvent tellement augmenter la chaleur que la capacit du
climatiseur est dpasse.
En rgle gnrale, lair qui entre dans le climatiseur sera
refroidi denviron 15 20 degrs selon la temprature et
lhumidit de lextrieur.
Par exemple, si lair qui entre dans les grilles dentre dair du
climatiseur est de 80 degrs F (24 degrs C), lair quittant les
grilles de sortie dair du climatiseur sera de 60 65 degrs F
(13 16 degrs C).

Aussi longtemps que cette diffrence de temprature est

maintenue entre lentre et la sortie dair, le climatiseur
fonctionne sa capacit. Si lon ne peut conserver la
temprature intrieure voulue (normalement 80 degrs F (24
degrs C)), alors le gain de chaleur du VR est trop lev pour
la capacit du climatiseur.
Le fait de stationner le vhicule lombre, de garder les
fentres et les portes fermes et dviter dutiliser des
appareils dgageant de la chaleur aidera rduire le gain de
chaleur. On peut aussi considrer ajouter de lisolant et des
verres teints (tout particulirement dans les caravanes nonisoles).

B.

C.

Arateurs - Les arateurs se trouvent aux deux

extrmits du couvercle du plafond et servent
diriger la dcharge dair de lappareil.

Pour les modles chaleur/refroidissement, le

thermostat contrle aussi les rglages de
temprature ON (marche) et OFF (arrt) du
radiateur. Voir figure 1.

Le thermostat (contrle de temprature) - sous le

mode de refroidissement, le mode de
refroidissement, le thermostat contrle le rglage de
temprature ON (marche) et OFF (arrt) du
chauffage.

SECTION II. PANNEAU DE CONTRLE

Si votre climatiseur de VR fonctionne partir dun panneau
de contrle au plafond, il y a alors trois commandes au
plafond pour aider contrler le climatiseur. Les voici:
A.

Le slecteur - Le slecteur dtermine le mode de

fonctionnement du climatiseur. En le tournant,
loprateur peut obtenir toute fonction du systme
voulue. Celles-ci varient selon les options de lunit
du toit et du plafond. Le figure 1 illustrents
lemplacement du slecteur et numrents toutes les
fonctions disponibles par modle.
La section fonctionnement explique les
caractristiques de fonctionnement de chaque mode.

Placer le slecteur la position LOW COOL

(refroidissement faible) ou HIGH COOL
(refroidissement fort).

lcoulement de lair dcharg.

Fonctionnement durant les nuits plus froides
(fonctionnement de refroidissement)

Sil y a de la glace qui saccumule, il est alors ncessaire de

laisser le serpentin du refroidisseur (vaporateur) dgeler
avant de reprendre le fonctionnement de refroidissement
normal. Durant ce temps, faire fonctionner lappareil en
position HIGH FAN (ventilateur fort) avec le systme au

REMARQUE

Il est important, lorsque la temprature extrieure descend au

cours de la soire et la nuit sous 75 degrs F, de rgler le
thermostat (contrle de temprature) un point central entre
Warmer (plus chaud) et Cooler (plus frais). Si le rglage
est Cooler, le serpentin du refroidisseur (vaporateur)
peut accumuler de la glace et cesser de refroidir. Durant le
jour, lorsque les tempratures dpassent 75 degrs F, rgler le
commutateur du thermostat au rglage voulu.

II.

SECTION III. FONCTIONNEMENT

A.

Faire tourner le thermostat (contrle de temprature)

la position la plus confortable. Le thermostat met
le compresseur en marche lorsque la temprature de
lair qui entre dans le climatiseur augmente de
quelques degrs au-dessus du rglage choisi.
Lorsque la temprature de lair qui entre dans le
climatiseur tombe sous ce rglage, il arrtera le
compresseur. Le climatiseur, en mode de
refroidissement, continuera mettre le compresseur
en marche puis larrter de la manire indique
prcdemment jusqu ce que le slecteur soit plac
dans un autre mode de fonctionnement.

Pour le refroidissement (se reporter aux figure 1,

page 3)

B.

Placer les arateurs dans la direction voulue pour

I.

C.

Fonctionnement en courts cycles

maximum de la circulation dair. Lorsque cette circulation

augmente ou fonctionne au maximum, le serpentin du
refroidisseur ne devrait pas avoir de glace.
III.
Lorsquun climatiseur fonctionne, son compresseur fait
circuler le rfrigrant sous haute pression. Arrt, il faut deux
trois minutes pour que cette haute pression sgalise.

Pour chauffer (modle de plafond Elect-A-Heat

seulement) (se reporter aux figure 1, page 3)

Le compresseur du climatiseur est incapable de dmarrer

contre une haute pression, donc, lorsque le climatiseur est
arrt, il est important de le laisser arrter pendant deux trois
minutes avant de le faire redmarrer.
IV.

REMARQUE
Le montage de chauffage Elect-A-Heat optionnel est conu
pour couper le froid de lair lintrieur du vhicule qui est un
peu trop frais pour le confort. Le systme de chauffage est
efficace pour enlever le froid, mais non pas pour remplacer
lappareil de chauffage.
Ne pas sattendre ce que le serpentin de chauffage de votre
appareil de chauffage produise de lincandescence. Puisque
le ventilateur aspire de lair froid et le fait passer sur le
serpentin, celui-ci ne peut devenir rouge. Il peut y avoir une
incandescence lorsque lair passe directement sur le
serpentin.
A.

Placer le slecteur LOW HEAT (faible chaleur) et

le ventilateur fonctionne vitesse rduite la sortie
de chaleur au maximum.

C.

temprature de lair qui entre dans le climatiseur

augmente au-dessus de ce rglage, il arrtera le
compresseur. Le chauffage continuera passer de
marche arrt de la manire indique prcdemment
jusqu ce que le slecteur soit plac dans un autre
mode de fonctionnement.
Placer les arateurs dans la direction voulue pour
lcoulement de lair dcharg. La temprature de
dcharge dair peut tre contrle jusqu un certain
point en ouvrant ou en fermant les arateurs.
Lorsque les arateurs sont ferms, lon peut
atteindre lair de dcharge le plus chaud. Les
arateurs entirement ouverts dchargeront lair
chaud vers larrire et lavant du vhicule pour une
circulation plus efficace et un rchauffement plus
rapide. Bien que la temprature de lair soit moins
leve lorsque les arateurs sont entirement
ouverts, la capacit de chauffage sera encore la
mme.

A.

Placer les arateurs dans la direction voulue pour

lcoulement de lair dcharg.

Placer le slecteur LOW FAN (ventilateur faible)

ou pour une circulation dair maximale, HIGH
FAN (ventilateur fort).

Pour la circulation dair seulement (se reporter aux figure

1, page 3)

B.

REMARQUE
Lorsque le slecteur est en position LOW FAN ou
HIGH FAN, le moteur soufflerie fonctionne
continuellement.

Ne pas faire fonctionner votre climatiseur pendant de

longues priodes sans filtre.

IMPORTANT

sont pas nettoys intervalles rguliers, ils peuvent tre

bloqus partiellement par de la poussire, de la graisse, de la
peluche, etc. Un filtre bloqu provoquera une perte de
volume dair et pourra ventuellement tre responsable de
laccumulation de glace sur le serpentin du refroidisseur
(vaporateur).

SECTION IV. ENTRETIEN

B.

Propritaire

Faire tourner le thermostat (contrle de temprature)

la position la plus confortable. Le thermostat met
le compresseur en marche lorsque la temprature de
lair qui entre dans le climatiseur diminue de
quelques degrs sous le rglage choisi. Lorsque la

1.

Un des plus grands avantages de votre nouveau climatiseur

de RV Products est que lentretien ncessaire pour conserver
votre appareil en bon tat est minime. En fait tout ce que
vous avez faire, comme propritaire, est de nettoyer et de
remplacer les filtres.
Les filtres sont fabriqus de fibres naturelles de longue dure
que lon peut nettoyer et rutiliser, et qui filtrent entirement
lair circul lorsque le climatiseur fonctionne. Si les filtres ne

10

Lorsque le climatiseur fonctionne sans filtre, il peut y avoir

un problme plus grave car la poussire, la graisse, la
peluche, etc. arrtes normalement par le filtre
saccumulent maintenant dans le serpentin du refroidisseur.
Ceci provoque une perte de volume dair et une accumulation
possible de glace sur le serpentin du refroidisseur, mais
cela peut aussi provoquer de graves dommages aux
composants du climatiseur.
Nous recommandons de nettoyer ou de changer les filtres au
moins toutes les deux semaines lorsque le climatiseur
fonctionne.

4.

3.

2.

1.

Retirez le filtre de la grille et nettoyez-le ou

remplacez-le avec un nouveau filtre.

Si le vhicule est dot dun montage de plafond

affleurant, retirez les quatre vis des grilles de reprise
dair (voir la figure 5, page 7).

Sortir les filtres et nettoyer ou changer avec

dautres filtres (voir figure 2).

Abaissez la grille et les filtres de lassemblage du

plafond.

Retirer les deux vis qui retiennent le couvercle du

montage du plafond. Voir figure 2.

Nettoyer et/ou changer les filtres:

5.

REMARQUE

A.

II.
lectricit - Tous les travaux et/ou inspections
lectriques ne doivent tre effectus que par un
personnel dentretien qualifi. Sadresser au Centre
dentretien RV Products sil y a des problmes.

Responsable de lentretien

Si des filtres de remplacement sont ncessaires,

on peut se les procurer auprs de la plupart des
Centres de service autoriss RV Products. Il est
recommand de toujours avoir des filtres de
rechange dans votre VR en tous temps pour
remplacer les filtres dtriors, uss ou dchirs.

B.

Points de contrle - Les climatiseurs ont quelquefois

des problmes de dmarrage ou de refroidissement.
Le climatiseur RV Products est conu pour
fonctionner sur un courant lectrique de 115V. Au
cas o le compresseur du climatiseur refuserait de
dmarrer, sadresser au Centre dentretien RV
Produits pour dterminer si le climatiseur est
aliment par un cblage de calibre adquat, si la
protection du circuit lectrique est assure par des
disjoncteurs appropris et si le calibre du cble de

11

rallonge, raccordant la prise de secteur du vhicule,

est aussi adquat. Jusqu 7,6 m, le calibre minimum
de fil requis est 1,5 mm (#12 AWG). Un calibre plus
fort est requis pour une distance plus longue.
Chaque climatiseur doit tre protg par un fusible
action diffre ou par un disjoncteur.
Si le climatiseur fait dclencher continuellement le
disjoncteur, faire vrifier par un lectricien
lamprage de dmarrage et de marche. Si le
dclenchement du disjoncteur se poursuit alors que
le consommation lectrique reste normale, il sera
ncessaire de remplacer le disjoncteur dfectueux.
Si, alors que lalimentation lectrique du climatiseur
est normale, ni le ventilateur ni le compresseur ne
fonctionnent, vrifier la connexion de la prise situe
larrire de la bote de commande du module.

C.

Lubrification

Intgrit mcanique - Le climatiseur devrait tre

inspect rgulirement pour sassurer que les
boulons qui retiennent lappareil au toit sont serrs
et en bon tat. Il serait aussi utile de faire un examen
du couvercle de plastique couvrant le climatiseur sur
le toit. Sassurer que les quatre vis de montage et
les rondelles sont bien en place et retiennent le
couvercle au climatiseur. Examiner aussi le
couvercle pour sassurer quil ny a aucune fissure
ou de dommages suite un choc.

Si lalimentation en lectricit du module est normale

et le ventilateur fonctionne, mais si vous ne recevez
pas dair chaud, vrifier la connexion de la fiche du
fil de raccordement du module de chauffage pour
sassurer que le contact est bien tabli. Si ceci ne
corrige pas le problme, il se peut que le thermostat
ou le disjoncteur de scurit soit dfectueux.

D.

DANGER
DBRANCHER LA SOURCE DALIMENTATION
LAPPAREIL AVANT TOUT ENTRETIEN POUR VITER
LES DANGERS DE CHOC LECTRIQUE OU LA
POSSIBILIT DE BLESSURES CAUSES PAR LES
PICES MOBILES.
Le moteur dentranement de la soufflerie de certains
appareils peut inclure des godets graisseurs au sommet du
moteur. Il ny a aucune raison dhuiler les tourillons sous
des conditions normales de fonctionnement. Sil faut
toutefois lubrifier lappareil, utiliser seulement de lhuile du
type non-dtergent SAE 20. NE PAS METTRE TROP
DHUILE - trois quatre gouttes dans chaque trou dhuile,
une fois par an, suffisent.

SECTION V. FONCTIONNEMENT ET IDENTIFICATION

DU THERMOSTAT MURAL

chauffage), vrifier chaque fonction de position. Ignorer les

rfrences aux fonctions de chaleur en utilisant le thermostat
de nrefroidissement seulemento.

FONCTIONNEMENT
Le tableau suivant illustre les fonctions du systme avec
thermostat nchaleur/refroidissemento. Aprs linstallation
complte du systme de climatisation (et du systme de

1.

Lisez soigneusement la garantie limite de deux ans,

laquelle est emballe avec le produit.

VI. GARANTIE

2.

Vous pouvez galement vous procurer un contrat

prolong de trois ans couvrant uniquement les
pices dtachables moyennant un supplment de
89,95 $US. Pour ce faire, remplissez la carte de
demande agrafe lavant de cette enveloppe.
Veuillez envoyer la carte et un chque ou un mandat
ladresse mentionne ci-dessus. Les demandes
doivent tre faites dan les quatre-vingt-dix (90)
jours suivant lachat initial.

IMPORTANT

3.

Pour tout renseignement propos de votre

climatiseur de RV Products, vous devez indiquer le
nom du modle, les numros de srie et la date
dachat. Le nom du modle et les numros de srie
sont inscrits sur ltiquette de lidentification place
sur lorifice de reprise dans le plateau situ la
partie infrieure du climatiseur de toit. Ces
informations figurent aussi sur la plaque
signaltique du climatiseur.

RV Products
A Division of Airxcel, Inc.
P.O. Box 4020
Wichita, KS 67204

Il convient de le dire, mme les produits de la plus haute

qualit ont parfois besoin dtre rpars. Pour vous prvaloir
de rparations sous garantie pour votre climatiseur RV
Products, veuillez communiquer avec votre dtaillant. Vous
pouvez galement visiter notre site Web ladresse
www.rvcomfort.com pour consulter les rponses aux
questions les plus frquemment poses ainsi que les
adresses des centres de service.
De mme, vous pouvez entrer en contact avec le service de
soutien la clientle par courrier lectronique au
RVPSupport@Airxcel.com.
Toute correspondance crite doit tre envoye ladresse
suivante:
RV Products
A Division of Airxcel, Inc.
P.O. Box 4020
Wichita, KS 67204

1976F212 (9-06) PP

SERVICE MANUAL
FOR
6700, 7000, 8000 & 9000 SERIES
AIR CONDITIONERS
(MECHANICAL CONTROLS ONLY)

FOR WALL MOUNT THERMOSTATS AND LOW VOLTAGE CONTROL

CIRCUITS, REFER TO THEIR APPROPRIATE MANUALS
FOR ELECTRICAL CHECKOUTS ON DELTA T AND DELTA TX
AIR CONDITIONERS, REFER TO MANUAL R-332 (2-86)

This service manual is primarily intended for the use of

qualified individuals specially trained and experienced in the
service of this type of equipment and related system
components.

PREFACE

!WARNING - SHOCK HAZARD!

Installation and service personnel are required by some states,

counties or cities to be licensed. Persons not qualified shall
not attempt to service this equipment or interpret this service
manual.
SCOPE

SOME DIAGNOSTIC TESTING MAY BE DONE ON

ENERGIZED CIRCUITS. ELECTRICAL SHOCK CAN
OCCUR IF NOT TESTED PROPERLY. TESTING TO
BE DONE BY QUALIFIED TECHNICIANS ONLY.

DANGER

TO PREVENT THE POSSIBILITY OF SEVERE

PERSONAL INJURY, DEATH OR EQUIPMENT
DAMAGE DUE TO ELECTRICAL SHOCK, ALWAYS
BE SURE THE POWER SUPPLY TO THE APPLIANCE
IS DISCONNECTED BEFORE DOING ANY WORK ON
THE APPLIANCE. THIS CAN NORMALLY BE
ACCOMPLISHED BY SWITCHING THE BREAKER
FOR THE AIR CONDITIONER TO OFF,
DISCONNECTING ALL EXTERNAL ELECTRICAL
CONNECTIONS AND CORDS, SWITCHING ON
BOARD ELECTRICAL GENERATORS AND
INVERTORS TO OFF, AND REMOVING THE CABLE
FROM EACH POSITIVE TERMINAL ON ALL
STORAGE AND STARTING BATTERIES.

This is not a basic refrigeration and air conditioning manual

and does not therefore, cover the principles of refrigeration or
air conditioning. The user of this manual should have
already accomplished a thorough study of refrigeration and
air conditioning.
WARNING
Improper installation may damage equipment, can create
a hazard and will void the warranty.
The use of components not tested in combination with
these units will void the warranty, may make the
equipment in violation of state codes, may create a hazard
and may ruin the equipment.

6757-7201
SERVICE TEST DEVICE
This test device is an invaluable aid in quickly diagnosing repairs
to all RV Products roof top air conditioners produced after 1979.

TABLE OF CONTENTS

V.

IV.

III.

II.

I.

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Problems And Their Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools And Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Handling Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigeration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

13

10

Basic Components and Their Functions

Refrigeration System Diagram

VI.

QUICK DIAGNOSIS CHART

Fan And Compressor Will Not Run

No Power 115V
Selector Switch

Possible Causes

17
17
17
20-21

14
14

Ref. Page Number

Note: This charge represents problems with units having mechanical controls - if the air conditioner
is equipped with a wall thermostat, please refer to the appropriate manual.

Fan Will Not Run

Selector Switch
Fan Run Capacitor
Motor
Wiring (Mis-wired)

Problem

Compressor Will Not Run

15
15
15
15
15
20-21
16-17
20-21

19

Selector Switch
Thermostat
Low Voltage
Overload
Compressor
Wiring (Mis-wired)
PTCR or Potential Relay
Start Capacitor
Run Capacitor

Cooling Performance

DISCHARGE
LINE

CONDENSER
FAN
FAN
MOTOR

SUCTION
LINE

COMP.

LOW SIDE

EVAPORATOR
BLOWER

EVAPORATOR

BASIC COMPONENTS AND THEIR FUNCTIONS

REFRIGERATION SYSTEM DIAGRAM

CONDENSER COIL

HIGH SIDE

The purpose of this part of the Service Manual is to acquaint

the Service Technician with the system components so that
when he has a problem, he can intelligently analyze and
isolate the problem and efficiently correct it.
The high side pressure is also referred to as head pressure or
condensing pressure, and the low side pressure is also
referred to as suction pressure or evaporator pressure.

systems exists from the discharge port of the compressor to

the cap tube. The low side is from the cap tube to the
compressor cylinders. The dividing points then are the cap
tube and compressor cylinders.

I. REFRIGERANT CIRCUIT
Refrigerant Charge

Capillary Tube (Cap Tube)

Evaporator Coil

The refrigerant remains at nearly constant temperature

(called evaporator temperature or low side saturation
temperature) in the evaporator as long as there are both liquid
and vapor together. However, near the outlet of the
evaporator coil, all of the liquid has boiled (evaporated) away
and from there on the temperature of the vapor rises (the
vapor becomes superheated). It is necessary that the vapor
become superheated because it passes through the suction
line to the compressor and the compressor can only pump
superheated vapor any vapor (which might be present if the
vapor were not superheated) could cause serious mechanical
damage to the compressor.

As the heat leaves the air, the air temperature drops and some
of the moisture in the air condenses from a vapor to a liquid.
The liquid water (condensate) is drained onto the roof of the
recreational vehicle. As the heat enters the refrigerant in the
evaporator, it causes the refrigerant to evaporate (change
from a liquid to a vapor). Thus the name evaporator.

The purpose of the finned evaporator coil is to transfer the

heat from the warm and moist indoor air to the cold low
pressure refrigerant.

4.

The refrigerant enters the cap tube from the condenser as a

warm high pressure liquid. As the refrigerant flows through
the small diameter cap tube, the pressure drops rather rapidly.
As the pressure drops, a tiny amount of the liquid refrigerant
will vaporize. This vaporization requires heat which must
come from the liquid refrigerant itself - thus the liquid
temperature is constantly lowered as it passes through the cap
tube. As the refrigerant leaves the cap tube, it is still mostly
liquid; however, a small portion has changed to a vapor
called flash gas. When the liquid refrigerant passes from the
cap tube to the evaporator, it is at low side pressure and will
therefore, vaporize at low temperature as it picks up heat
from the air being conditioned.

3.

It is impossible to state the exact pressures that will exist in

the high side or low side because those pressures will both
vary with different temperature and humidity conditions both
inside and outside the recreational vehicle.

BASIC COMPONENTS AND

THEIR FUNCTIONS

1.
The systems covered by this service manual all use a
refrigerant called monochlorodifluoromethane (better known
as R-22).
We know that R-22 is not a deadly gas because many of us
have breathed it many times and we are still living. But, no
one has said that R-22 is completely safe to breathe; so, a
wise service technician will always keep a work space well
ventilated if R-22 can escape into the air. IF R-22 COMES
IN CONTACT WITH ANY OPEN FLAME, PHOSGENE
GAS IS CREATED AND ONE SHOULD AVOID
BREATHING THE FUMES.
The temperature at which R-22 changes to toxic gases and
acids varies with the amount or concentration of water
present i.e. the greater the concentration of water, the lower
the temperature and vice versa. High temperatures normally
exist inside a refrigeration circuit, so we must keep the circuit
as absolutely dry as possible to prevent the formation of
destructive acids.
Liquid R-22 in the atmosphere will always be at about -41.
Therefore, always wear safety glasses when working with
R-22.
Again unburned R-22 is not a deadly gas, so by using
reasonable safety precautions, the service technician will not
be hurt by it.

High and Low Sides

In addition to being almost non-toxic, R-22 is nonflammable, non-explosive, non-corrosive and miscible
(mixable) with oil. It also has a rather high latent heat value.
This means that is must absorb a large amount of heat per lb.
to vaporize or change from a liquid to a vapor; and it must
give up a large amount of heat per lb. to condense or change
from a vapor to a liquid.
2.

It is customary for air conditioning technicians to use the

terms high side and low side. In doing so, we refer to the
parts of the refrigeration circuit which, when the system is
running, contain high pressure refrigerant (high side) and
low pressure refrigerant (low side). The high side of these

5.

Suction Line

Compressor

The suction line is the tube which carries the superheated

vapor refrigerant from the evaporator to the compressor.
6.

c)

b)

a)

Discharge Line

a supply of special refrigeration oil. A small portion

of the oil will circulate out through the system with
the refrigerant, but will constantly return to the
compressor with the refrigerant, so the compressor
will not run out of oil.

a pump which is designed to pump superheated

vapor only,

an electric motor which drives the compressor,

The compressor is called a hermetic compressor which means

that it is completely sealed (welded together). It is, therefore,
not internally field serviceable. Inside the compressor
housing are basically:

7.

Condenser Coil

The discharge line carries the refrigerant out of the

compressor and to the condenser coil. Remember that as the
refrigerant entered the compressor, it was superheated vapor.
The refrigerant enters the compressor, where more heat is
added and is compressed into a smaller space. The
refrigerant, therefore, leaves the compressor highly
superheated so if the discharge line is hot to the touch
(burns), dont be surprised it should be.
8.
The purpose of the finned condenser coil is to transfer heat
from the high pressure refrigerant to the warm outdoor air.
As the outdoor air passes over the coil, the heat transfer will
cause the air temperature to rise. Thus the condenser
discharge air will be several degrees warmer than the
condenser entering air.
As the refrigerant passes through the first few tubes of the
condenser, its temperature will be lowered or it will be desuperheated. After the refrigerant is de-superheated, it will
begin to condense or change from a vapor to a liquid and will
remain at a nearly constant temperature throughout almost all
of the remainder of the coil. This temperature is called the
condensing temperature or high side saturation temperature
and will always be higher than the condenser entering air
temperature.
Near the bottom of the condenser, the refrigerant will all be
condensed to a liquid and from there on its temperature will
drop to more nearly the temperature of the outdoor air. After
the temperature of the refrigerant drops below condensing or

saturation temperature, we call its condition sub-cooled

liquid.

Motors and Fans

II. AIR HANDLING CIRCUITS

During all of the three processes in the condenser (desuperheating, condensing, sub-cooling), the refrigerant gives
up heat; but most of the heat is given up during the
condensing process.

1.

Filters

One motor turns both the condenser fan blade and evaporator
air blower. The condenser (outdoor) fan is an axial flow
(propeller) type and the evaporator (indoor) fan or blower is a
centrifugal (squirrel cage) type.
2.

Safety

III. ELECTRIC POWER CIRCUITS

The filters should always be in place when the system is

running. More important than their purpose of cleaning the
air in the living space is the protection the filters give the
evaporator coil. Without filters, a wet evaporator coil will
quickly stop up so that adequate air cannot pass through it.
Filters must be installed to completely fill the filter rack so
that no air can flow around them or by-pass them and carry
dust, lint, etc. to the evaporator. To clean an evaporator that
has not been properly protected by its filter, the entire unit
must be removed from the recreational vehicle and the coil
cleaned with special detergent and water.

1.

Voltage (electrical pressure), whether high or low, will not

hurt you. It is the current through vital parts of your body
that does the damage, and under the right conditions, 115
volts (domestic USA) is plenty to drive a deadly dose of
current (amperes) through your body.
Another imminent danger from electric shocks in addition to
electrocution is reaction. An electrical shock causes
uncontrollable muscular contractions which can cause further
injuries.
Remember that electricity can be very dangerous, but you can
safely work with it. In order to be safe, you must know what
you are doing. You must work deliberately and carefully.
You must think safety before each move.

2.

Wire Size

Power Supply - from Commercial Utility

THINK SAFETY

1)

The power supply to the air conditioner must be wired

through a circuit breaker or time delay fuse. The power
supply must be 20 amperes and 12 AWG wire minimum.
Any size

Color Code

larger at any time may be used and should be used if the

length of the wire is over 32 feet.
2)

c)

b)

a)

The wire with the white insulation is the

neutral. There should be 115 volts
(domestic USA) between the neutral and the
hot (black) wire, but there should be 0 volts
between the neutral and the ground (the
green wire or the frame of the air
conditioner). There must be no switches,
fuses, disconnects, etc. of any kind in the
neutral wire.

The wire with black insulation is the hot

wire and there should be 115 volts
(domestic USA) between it and either of the
other wires. All switches, fuses, circuit
breakers, disconnects, etc. should be in this
line.

Voltage

The third wire may be covered with green

insulation or it may be a bare metal wire. It
is the ground wire. There must be 115 volts
(domestic USA) between this wire and the
hot (black) wire and 0 volts between it and
the neutral (white) wire. The ground wire
must be securely fastened to the air
conditioner cabinet. A ground screw is
provided for this purpose.

The electric power from the electric service panel should be

delivered through a 3 conductor cable and the Service
Technician should check to be sure the color code is correct.
The electrician probably installed the cable with the colors
according to code, but dont bet your life on it.

3)

Power Supply - Generated by on-board motor

generator

The voltage (electrical pressure) at the unit should be

115 volts (domestic USA) and all electrical components will
perform best at the correct voltage. However, the voltage will
vary and the air conditioning system will perform
satisfactorily within plus or minus 10% of the rated (115)
voltage (domestic USA). Therefore, the voltage has to be
between 103.5 volts and 126.5 volts.
3.

If the power supply for the recreational vehicle is supplied by

an on-board motor generator, its wiring may be identical to

the commercial power described above.
There are, however, some motor generators on which both the
current carrying leads are insulated from the ground. That is
to say; there is no grounded neutral, so there will be 115 volts
(domestic USA) between the black and white leads, but there
will be 0 volts between either lead and ground.

Selector Switch - Free Delivery Ceiling Assemblies

WARNING: The service technician must keep in mind

when checking to make sure that the power is turned off.
Check only between the hot (black) lead and the neutral
(white) lead.
4.
The selector switch is mounted on the left side of the interior
ceiling assembly. The selector switch allows the unit to be
operated on high to low blower only, or high to low blower
with compressor operation for cooling. On heating and
cooling models, the selector switch can also switch in the
electric heater at low blower operation only.

Terminals

Lo Heat
Lo Fan
Hi Fan
Lo Cool
Hi Cool

Switch Position

To check the selector switch, remove wires from the terminals

and rotate the switch to the proper position and read
continuity as follows:

L-1-3
L-1
L-2
L-1-4
L-2-4

Thermostat (Mechanical Rotary)

* If you do not wish to remove the wires from each terminal,

disconnect the 9 pin plug from the a/c unit.
5.

Compressor Motor

The thermostat (temperature controller) is mounted on the

right side of the interior ceiling assembly. The thermostat
controls the on-off cycle of the compressor when the selector
switch is in the cooling position and on heating and cooling
models, the on-off cycle of the electric heater when the
selector switch is in the heating position. The thermostat is
actuated by sensing the temperature of the return air through
the vent where the bulb is located. Terminal continuity
should make and break if ambient air temperature is between
65 and 90 degrees F.
6.

The compressor motor is located inside the hermetic

compressor housing and therefore not accessible for service or
visual observation in the field. However, the motor winding

1)

If the resistance between any two terminals is 0

ohms, the motor windings are shorted.

condition can be analyzed by using an ohm meter. Be sure to

remove all the leads from the compressor terminals before
making this check.

2)

If the resistance between any terminal and the

compressor housing is anything but infinity, the
winding is grounded.
If the resistance between any two terminals is
infinity, the winding is open.

3)

Overload Switch

On a good compressor, the highest resistance will be between

the R (run) and S (start) terminals. The lowest resistance will
be between the C (common) and R (run) terminals. The
intermediate resistance will be between the C (common) and
S (start) terminals. Notice that compressors have the
identification of the terminals marked on either the terminal
cover or on the compressor housing.
7.

High Amperes (Current)

Mounted on the outside of the compressor housing is a two

terminal overload switch. Note: We have a few models with
internal overloads that are non-serviceable. The switch is
connected in series with the common terminal, so if the
switch opens, it will cut the power to the compressor motor.
The switch will open as the result of either or both of two
conditions that could be harmful to the compressor.
1)

High Temperature (Thermal)

The switch contains a heater which increases in temperature

as the current increases. The higher temperature warps the
switch and will cause it to open before the windings reach a
dangerous temperature.
2)
The switch is clamped tightly against the compressor housing
and located close to the windings. Therefore, as the windings
reach a higher temperature, it takes less current to cause the
switch to open.

Fan Motor

As can be seen, the switch is always affected by a

combination of current to the compressor and winding
temperature.
8.

The air conditioning unit has one double end shaft fan motor.
On one shaft end is mounted a centrifugal or squirrel cage
blower which draws air (return air) out of the recreational
vehicle and blows the conditioned air down into the
recreational vehicle. On the other end is mounted an axial
flow or propellor type fan which circulates outdoor air

through the condenser coil.

* Some models use a squirrel cage on both ends of the motor.
An important step in installing a replacement fan motor is to
check the direction of rotation before it is installed. On all
models, the condenser fan pulls the air through the coil.
Fan Motor Check Procedure

c)

b)

The brown wires from the motor connect to

the fan capacitor.

The white wire from the motor connects to

the fan capacitor or a white wire in a wire
nut then the white wire connects through
the disconnect plug to the thermostat.

The black wire from the motor connects to a

black wire inside a wire nut then the black
wire connects through the disconnect plug
to the selector switch. The red wire from
the motor connects to a red wire in a wire
nut then the red wire connects through the
disconnect plug to the selector switch.

Be sure the motor leads are connected to the proper

points
a)

If a fan motor refuses to perform properly, it can be checked

in the following manner:
9.

2.

To check the motor winding resistance carefully,

check the resistance between each of the wires and
ground (preferably a copper refrigerant tube for a
good connection). These readings must be infinity.
Any continuity means the windings are grounded.
If there is a reading of 0 between any two leads, the
motor is shorted and is no good. If there is a reading
of infinity (no meter reading at all) between any two
leads, the winding is open and the motor is no good.
Note:

A motor with 2 brown leads will have an

O reading between 1 brown wire and either
the black or white wire.

Good Capacitor

Run Capacitors

a)

Discharge the capacitor with a 20,000 ohm (approx.

3 watt) resistor or larger.

Disconnect all electrical power to the air conditioner.

This test must be done with a analog type meter.

OPEN

SHORT

LOW

LOW

Indicator moves to the right side

of the scale and stays there
(indicating a completed circuit).
The capacitor is shorted.

HIGH

LOW

If the capacitor is shorted, the indicator will move towards and sometimes hit zero
ohms, and will stay there. This indicates a completed circuit through the inside of
the capacitor (shorted). Shorted capacitors are defective and must be replaced.

Shorted Capacitor

Indicator shows no movement.

Needle stays to the left side. If needle
shows no movement after reversing the
leads, the capacitor is open.

HIGH

If the capacitor is open, the indicator will show no deflection

or movement. Reverse the leads and test again. If there is no
indicator movement on the second test, the capacitor is open.
Open capacitors are defective and must be replaced.

Open Capacitor

Indicator sweeps back and forth

as shown above. Capacitor is good.

HIGH

CAPACITOR

9.

b)

You may discharge capacitors with a standard volt

meter if you use a scale over 500 volts and touch the
leads (one lead to each side of the capacitor). The
volt meter will discharge the capacitor.

OHM METER

If the capacitor is good, the indicator will move from infinity

(the left side), towards zero ohms and slowly return back to
infinity. Reverse the leads and test again. The result should
be the same.

c)

Identify and disconnect the wiring from the

capacitor.

OK

The purpose of the run capacitors is to give the motors

starting torque and to maintain high power factor during
running. The run capacitors are always connected between
the start and run or main terminals of the motor.

CAPACITORS

On some older models, one of the terminals of the run

capacitors will have a red dot (the identified terminal). The
identified terminal should always be connected to the run or
main terminal of the motor and to the neutral line.

Capacitor Check
There are several capacitor test devices available. The ohm
meter is one of them. The ohm meter cannot verify a
capacitors MFD (microfarrad) value. However, the following
procedures will show you how to use an ohm meter to
determine if the capacitor is good, open, shorted or grounded.

d)

Set and zero the ohm meter on the highest scale.

Before testing any capacitor, always perform the following

procedure:

e)

When testing for a good, open or shorted capacitor,

perform the following checks: Place the ohm meter
leads across the capacitor terminals (one lead on
each terminal) and perform a continuity test. Then
observe the action of the meter needle or indicator.
Reverse the leads and test again. The result should
be the same. Note: If the capacitor had not been
properly discharged, a false reading could be
indicated on the first test. Always test several times
(reversing the leads with each test). This will verify
the capacitors condition.

Grounded Capacitor

OHM METER

HIGH

Start Capacitor

CAPACITOR

LOW

Indicator moves to the right side of

the scale and stays there
(indicating a completed circuit).
The capacitor is grounded.

GROUNDED

When testing for a grounded capacitor, perform a continuity

check between each terminal on the capacitor and the bare
metal of the capacitor case. Any indication of a circuit
(constant resistance) from either terminal to case, indicates a
grounded capacitor. Grounded capacitors are defective and
must be replaced.

10.

(A)

Start (Potential) Relay

Most models use a start capacitor and a start relay to give the
compressor high starting torque. The compressor will,
therefore, start against normal pressure difference (head
pressure minus suction pressure) even when shut down for a
short period of time. The start relay will disconnect the start
capacitor when the motor reaches approximately 75%
running speed.
11.

1)

Normally closed contacts internally between

terminals #1 and #2 which switch in the start
capacitor in parallel to the run capacitor during shut
down and then switch out the start capacitor when
the motor reaches approximately 75% normal
running speed.

The start relay consists of

2)

A high voltage coil internally between terminals #5

and #2 to actuate the contacts. The coil is too weak
on line voltage to actuate the contacts, but it is

10

11.

connected in series with the start winding and it gets

the generated voltage of the start winding portion of
the compressor motor. This generated voltage is
much higher than line voltage and varies with the
speed of the motor. Therefore, since the relay is
designed to open the contacts at 75% of normal
running voltage (measured between terminals #5 and
#2), the contacts will open (thus disconnect the start
capacitor) at approximately 75% of normal running
speed.
(B)

Positive Temperature Coefficient Resistor

(Commonly Known As PTCR Start
Device)

Heating Element

The resistor acts like a potential relay in that it takes the start
capacitor out of the start circuit, but uses resistance of
electrical flow (back EMF from compressor) instead of
opening a set of contacts. The service person should be careful
handling the resistors. They will be hot during operation (up
to 160 degrees F). The air conditioner needs to be off for 3-5
minutes during cycle time and when servicing to let the
resistor cool down.
12.

Limit Switch

The heating element is a resistance heater of 1600 watts (5600

BTUH) capacity and is connected across the line when the
selector is set for heating and the thermostat is calling for heat.
The current draw of the heater (element only) will be 13.3
amperes at 120 volts (domestic USA models).
13.

The limit switch is a safety switch and is mounted in the

heating element frame. It will open and break the circuit on
temperature rise in case the air flow through the heater
becomes low enough to cause the heater to overheat.

IV. TOOLS AND EQUIPMENT

In order to service the equipment covered by this Service
Manual, a technician will need all the common mechanics
tools such as wrenches, screwdrivers, hammers, etc.

Ammeter
Ohm Meter
Volt Meter
Refrigerant Recovery Equipment
Charging Cylinder
Vacuum Pump
Vacuum Gauge
Leak Detector
Brazing Equipment
Gauge Manifold

In addition to the common mechanics tools, in order to do

refrigeration and electrical work, he will need special tools and
equipment such as:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

1.

second) if there is one volt of pressure.

Ammeter And Its Use

An ammeter is an instrument for measuring electric current.

Current electricity is actually electrons moving from one atom
to another through a conductor. In order to intelligently use
electricity, we must have a measurement of a quantity of
electrons.

b)

a)

The diameter of the wire. The longer the wire, the

greater the resistance because there is more metal to
carry the current.

The material the conductor is made of; silver, copper

and aluminum are good conductors. This means that
in any given size wire, these materials will have low
resistance. Silver has the lowest resistance, but its
price is too high, so we use copper.

If the reading between any two terminals is infinity, we can

determine that the winding is open the wire is broken or
burned in two. If the reading between any two terminals is 0
ohms, the insulation is burned off the winding and we can
determine that the compressor motor is shorted. If the reading
between any terminal and the compressor housing is anything
except infinity, we can determine that the compressor motor is
grounded. An open, shorted or grounded compressor must be
replaced. The fan motor windings can be checked by the same
method as the compressor motor winding. The only difference
being that the windings are made of smaller gauge wire and
the resistance will be higher. The fan motor has no push on

The previous examples show two conditions that can be

detected by an ohm meter; (1) a closed, 0 resistance conductor
and (2) an open circuit which reads infinity or no continuity.
Now lets consider something in between the windings of a
compressor. If we attach the ohm meter probes to the common
and run terminals of the compressor, we can read the
resistance of the main or run winding. The winding is a solid
and continuous copper wire so there will be continuity through
it; but instead of 0 ohms, as there was through the closed
switch, this winding is of such small wire and so long that
there is resistance. Now lets attach the probes to the common
and start terminals to get the resistance of the start of phase
winding. Since this winding is made of even smaller and
longer wire, its resistance will be greater than the main
winding. Now lets attach the probes to the start and run
terminals to read the resistance through both windings. This
reading is the same number of ohms as the total of the two
previous readings.

With the switch open, there is not a continuous conductor

through it so we say there is no continuity. If the ohm meter
reads anything other than infinity, we say we do have
continuity. As can be seen from the above example, an ohm
meter is a good instrument for checking to see if the contacts
of a switch, thermostat, relay, overload, etc. are closing
properly or creating continuity.

If the probes of an ohm meter are attached to the terminals of a

closed switch, the meter will read 0. This means that there is
virtually no resistance to current flow through the switch.
Now, if the switch is turned off, the contacts will be open and
there will be very high resistance. In fact, the resistance is so
high it is an infinite number of ohms so we call this reading
infinity.

An ohm meter is really a resistance meter that is calibrated in

ohms. The ohm meter has its own power source, a small dry
cell, which forces a small amount of current through a
conductor via the meter probes. The meter must be calibrated
to read 0 ohms when the probes are touched together each time
it is used because as the dry cell loses its charge, the meter will
get out of calibration.

Ohm Meter And Its Use

The instrument we use to measure the number of amperes is

called an ammeter. These instruments have snap-around
jaws that will allow you to read the current through a wire
without detaching the wire from the system. Always buy an
energizer with the instrument so that you can accurately read
low current circuits. These meters also have volt meter and
ohm meter attachments so they are an excellent multi-purpose
meter. NO TECHNICIAN SHOULD EVER ATTEMPT A
SERVICE CALL WITHOUT ONE.
2.

c)

The length of the wire. The longer the wire, the

greater the resistance. In fact, the resistance of any
wire varies in direct ratio with its length.

An ohm meter or resistance meter indicates the resistance of a

circuit to current flow. Just as every water pipe or hose has a
resistance to water flow or every air duct has resistance to air
flow, so does every wire have resistance to the flow of electric
current. There is no such thing as a conductor with zero
resistance to electron flow although sometimes we will be
measuring the resistance of a conductor and find it so low
that we cannot detect any resistance; so we call the resistance
zero. What we mean is that the resistance is so low that we
cant find it. The amount of resistance or holding back force
of the wire or conductor depends on:

d)

The temperature of the conductor. The resistance of

most - but not all - conductors increases as the
temperature of the conductor rises. Hence, the
resistance of the filament of a light bulb is rather low
when it is turned off and cooled down; but when the
power is turned on, the filament temperature
increases until it glows and the resistance increases.

Resistance to electron flow is measured in units called ohms.

An ohm is actually the amount of resistance that will hold the
current down to one ampere (one coulomb of electrons per

11

terminals, but we know by referring to the wiring diagram,

that the black wire is the common terminal, the red wire is
the start terminal and the white wire is the run terminal.
Notice that when we are using an ohm meter, the power must
be turned off. It is also important to disconnect all wires
from a conductor being checked with an ohm meter to
prevent any chance of feedback.

Volt Meter And Its Use

An Ammeter is an essential instrument to have and use, and

is a real bargain because it is three instruments in one.
3.

Refrigerant Recovery Equipment

A volt meter is used on live circuits so use

extreme care. THINK SAFETY!

CAUTION

A volt meter measures the amount of electrical pressure in an

electrical conductor just as a tire gauge measures the amount
of air pressure in an automobile tire. If we attach one volt
meter probe to the hot line and the other probe to the neutral
line of a standard circuit, the meter reading will be the
electromotive (electron moving) force or pressure difference
between the two lines. This is the amount of pressure we
have available to push electricity (electrons) through the light
bulbs to make the motors turn, etc. In the above example, we
should find approximately 115 volts (domestic USA models)
or units of electrical pressure. Remember, a volt meter
always registers the voltage pressure difference between two
points.

4.
The Environmental Protection Agency has implemented strict
regulations on refrigerant handling and refrigerant recovery
equipment.
Check with your local EPA office regarding what type of
certification you must have to open or work on the refrigerant
sealed system.

3.

2.

1.

Charging Equipment

Technician Certification deadline was

November 14, 1993.

All recovery equipment must meet EPA standards

(check with your local office).

There shall be no venting of refrigerant into the

atmosphere after July 1, 1992.

In accordance to the Clean Air Act passed in 1980:

5.

The amount of charge in any refrigerant system must be kept

12

accurate to within a fraction of an ounce to prevent damage to

the compressor and insure proper performance. Systems must
not be charged to a certain amperage pull. They must not be
charged to certain suction line temperature.

1.

An electronic scale made especially for charging a/c

systems of critical charge. (Note: The charge must
not be weighed in with inaccurate bathroom scales,
or,

The recommended field instrument for charging the right

amount of R-22 into the system is either:

2.

A Dial-A-Charge of 5 lb. capacity. Do not use the

Dial-A-Charge 10 lb. capacity or any other charging
cylinder on which the graduations of the scale are
such that the instrument cannot be read accurately.

Vacuum Pump

Follow the charging cylinder manufacturers instructions

carefully.
6.

It has long been recognized that the worst enemy of a

refrigeration system is water. R-22 (and other refrigerants)
will break down and change to strong acids at elevated
temperatures in the presence of water. The greater the
concentration of water, the lower the temperature at which the
refrigerant will break down. The only way to remove the
water from a system to a satisfactory level is to vaporize it and
draw it out of the system with a vacuum pump.

Vacuum Gauge

A good quality vacuum pump is one of the finest pieces of

machinery there is, so it deserves the best of care. Keep it
clean and protected. The oil should be changed each time
before it is used.
7.

Leak Detectors

To go with a good vacuum pump, a good quality vacuum

gauge must be used. The pump may not pump a good vacuum
due to contamination of the oil. Also a leak in the system or
service hoses may prevent a deep vacuum from being reached.
The length of time that it takes for the pump to evacuate a
system will vary with the amount of moisture and air in the
system. The gauge will not show a deep vacuum (under 200
microns) until all of the water has been boiled out. Also, if a
system has even a very small leak, it cannot be properly
evacuated. So a good gauge will indicate whether or not we
have a dry system with no leaks. The vacuum gauge to get is a
thermistor type. Remember, when you buy a gauge, it must be
read accurately at 200 microns and below.
8.

It is strongly recommended that a Service Technician carry

two types of leak detectors at all times.

With an electronic leak detector, a leak is sometimes

difficult to pinpoint you can find the general area
of the leak, but not its exact location. A soap bubble
type leak detector will show its exact location.

1.

Most all electronic leak detectors are very sensitive

and are field reliable. A word of warning do not
give it a whiff of refrigerant as a test to see if it is
working because its sensitivity and life expectancy
diminishes as it is exposed to refrigerant.

2.

Brazing Equipment

Always use this instrument as a final leak test. It

will find the very small leaks that take several weeks
to cause trouble but will cause a burn out if not
repaired.

9.
For all brazing work, you need a torch type that burns with a
soft flame that is easy to control and is hot enough for brazing
refrigerant tubes. The easiest and most satisfactory brazing
rod to use is Sil Fos or Stay Silv 15% silver. This rod can
be used to blend with any brazing rod that exists on todays
units.

like, how hot was the weather, what time was it, etc. He is a
rich source of information. Listen to everything he says. You
will compliment him and he will help you to identify the
problem.
Always be alert for a customer who has been working on his
own equipment. Check all wiring and visually inspect all
motors, fans, capacitors, dampers, tubing, etc.
When a Service Technician gets all the information he can
from the customer, he then examines the equipment for more
facts that might lead to the cause of the problem (always be on
the alert for loose or burned wires, smoke stains, kinked or
broken tubes, oil stains, etc. - those things which would
obviously cause a malfunction or would indicate a
malfunction).
After he gets all the available information together, he starts
asking himself questions:
What causes has the information eliminated and why? (For
instance, if the compressor is running, that eliminates a
tripped circuit breaker as the cause of the problem.)
What are the possible causes?
Which of the possible causes are the most probable ones?
How should I check them out?

CAUTION
Always have a dry powder fire
extinguisher with you (not in your truck)
while you are brazing.

For each of his questions, he expects an answer. Since there is

no one else around qualified to answer his questions, he must
supply the answers himself.

Answer:
1.

Nothing runs.

What are the possible causes?

The power supply could be dead. Check for open circuit breaker or
fuse at service panel. Check for 115 volts domestic USA models or
240 volts export/overseas models between hot line (black) and neutral
(white) at power entrance at unit.

Question:

The customer turns the selector switch to the Cool position

and the thermostat to a low temperature (below room
temperature) and nothing happens. This is surely a serious
problem, but it is usually the easiest to correct.

1.

Problem

ISOLATE THE PROBLEM THE SOLUTION IS SIMPLE.

As his questions and answers eliminate the possible causes one

by one, he will soon identify the reason for the malfunction.
Then he can repair it.

Gauge Manifold

When a recreational vehicle owner calls for service on his air

conditioner, let him explain exactly what has happened; when
the air conditioner first gave him trouble, what is sounded

V. SERVICE PROBLEMS AND

THEIR SOLUTIONS

The R-22 that is in the system will have to be released to a

refrigerant recovery system (see equipment manufacturers
guide for system access information).

Connecting the gauge manifold to the system is necessary to

read the suction pressure and head pressure, and to
intelligently analyze a system for malfunction. Any service
technician will naturally hesitate to connect his gauges
because to do so involves opening a hermetic system.

Basically a gauge manifold consists of a compound gauge and

a high pressure gauge mounted on a manifold with hand
valves to isolate the common (center) connection or open it to
either side as desired.

Gauge manifold sets are used for checking pressures,

evacuating and recharging the a/c.

10.

13

2.

Terminals
Lo Heat
Lo Fan
Hi Fan
Lo Cool
Hi Cool

Switch Position

The selector switch could be open. Rotate the

selector switch and check for continuity between the
appropriate terminals.

L-1-3
L-1
L-2
L-1-4
L-2-4
Notice that when we are using an ohm meter, the
power must be turned off. It is also important to
disconnect all wires from a conductor being checked
with an ohm meter to prevent any chance of
feedback.

Inadequate Cooling

Problem
2.

2.

3.

The ceiling assembly louvers could be completely

closed.
This problem is easy to find and it is usually corrected
by opening the discharge louvers.
The fan could be at fault.

Shorted or open capacitor See capacitor

test.

Seized bearings This does not often occur;

but if it does, a few drops of oil will usually
free them temporarily. If the shaft is scored
in the bearings, it will soon tighten up again.
Now is the time to replace the motor.
Partially burned motor windings See fan
motor check procedure.

A mechanical problem such as the wheel (squirrel

cage) loose on the shaft is usually rather obvious.
Checking why a fan motor does not come up to speed
is a little more involved.
A)

b)

c)

The evaporator coil face could be coated with lint,

dirt, etc.

Question:

Answer:

Question:

Because, if it were low on charge or if the

cap tube was even partially plugged, the low
side would be starved for refrigerant and
therefore, the suction line would be warm.
Also, the compressor housing would be
hot.

Why not?

No.

Could the system be low on charge or the

cap tube plugged?

Problem

4.

Answer:

Then why isnt it cooling properly?

3.

The customer says he gets inadequate cooling for a while

after he turns the system on and then it seems to quit cooling
completely. As soon as the housing is removed from the unit
with the system running, we observe that the suction line is
coated with frost.

Question:

Because the evaporator is not picking up

the heat load.

Dirt or lint on the coil will restrict the flow of air

through the coil and the unit must be removed from
the recreational vehicle and the soil must be
thoroughly cleaned with strong detergent (Coil X,
Calclean, etc.) and water. Be sure to protect the fan
motor and electrical controls during cleaning by
covering them with polyethylene sheet. After the
system is cleaned, allow it to thoroughly dry for
several hours (before turning it on) to prevent
electrical shorts.

Answer:

What could cause the evaporator to not

pick up the heat load?

Question:

What are the possible causes?

The customer turns the selector switch to Cool and the

thermostat to a low temperature (below room temperature).
The fan runs OK, but the unit does not cool. When the unit
housing is removed, we observe that the compressor does not
run and it does not hum (the compressor is completely dead).

No compressor (Does not try to start).

Before system is put back into operation, be sure the

filter is properly installed to prevent recurrence of
dirty coil.

Question:

This is the most probable cause and, of course, the

easiest to check and correct.

The filter could be dirty.

(possible causes and repairs)

1.

Answer:

14

Answer:
1.

2.

3.

4.

The selector switch may be open to the

compressor.
Rotate the switch to the compressor position and
check the selector switch terminals (L to 4) with
ohm meter for continuity.
Thermostat may be open.
Rotate the switch and check the thermostat terminals
with ohm meter. The contacts should open and close
if the ambient air temperatures are between 60 and
90 degrees F.
Overload switch may be open.
Check around overload switch with ohm meter.
Compressor winding may be open.
Check out compressor windings with ohm meter
(See page 8).
Notice that when we are using an ohm meter, the
power must be turned off. It is also important to
disconnect all wires from a conductor being checked
with an ohm meter to prevent any chance of
feedback.

No Cooling.

Problem
4.
The customer turns the selector switch to Cool and the
thermostat to a low temperature (below room temperature).
The fan runs OK, but the unit does not cool. When the unit
housing is removed, we observe that the compressor does not
run; however, it periodically hums for 15 to 30 seconds.

Answer:

What are the possible causes of the

problem.

No - because we know that power is

getting to the common and run terminals of
the compressor to make it hum and the
Thermal-Current Overload switch is
breaking the circuit to protect the
compressor from burn out.

Question:

Question:

The possible causes are

Could the cause of the trouble be the

circuit breaker or fuse, the selector switch or
the thermostat?

Answer:

15

1.

2.

3.

4.

5.

a)

Check the voltage between #1 on the

overload switch and the R terminal of the
compressor while it is not humming. This
voltage must be 115 volts domestic USA
models or 240 volts export/overseas models.
No less than minus 10% is allowable.

The voltage could be low

b)

Check the voltage from C or R of the

compressor while it is humming (trying to
start). The latter reading will probably be
lower, but it still must be 103.5 volts
minimum domestic USA or 216 volts
minimum export/overseas models.

If the first reading is above 103.5V domestic USA and

the second is under 103.5V domestic USA, there is
too much voltage drop in the lines - a situation which
must be corrected for the air conditioner to perform
safely and satisfactorily.
A capacitor could be shorted, weak or open.
Turn the power off.
Caution There is always a chance that a capacitor is
holding a residual charge, so before touching a
terminal, discharge the capacitor as explained earlier
in this booklet.
Remove capacitors, visually examine them and test
them per instructions given in earlier section on
capacitor testing (See page 9).
If the capacitors test OK, replace them and carefully
reconnect the wires. Be sure the wires are connected
to the right terminals.
Start relay contacts could be open if so equipped.
Turn off all power, then check for continuity with
ohm meter between terminals 1 & 2.
Compressor start winding could be open or
grounded.
Check compressor windings per instructions. See the
section on the compressors (See page 8).
Compressor could be mechanically stuck.
This very rarely occurs and when it does, it is usually
after a lengthy shutdown. This should be considered
only after all the above possible causes have been
positively eliminated. To free a stuck compressor, use
your hermetic analyzer according to the
manufacturers instructions.

Problem
5.

Compressor trips breaker or thermal current

overload.

Compressor trips circuit breaker or thermal current overload

immediately (no hum). Note that this problem is different
from the previous one in that in the previous problem, the
compressor did hum for several seconds.

The compressor winding is shorted or grounded,

or

What are the possible causes?

With the selector switch in Fan Only position, the fan

works OK.
Question:

1.

Answer:

2.

1.

Check compressor windings per instructions (See

page 8).

With the power turned off, check the resistance

between all three compressor terminals and ground.
If any continuity is found, locate the ground and
correct it.

How do I repair it?

The circuit breaker or thermal current overload is

weak, (this rarely occurs, but it can occur after the
switch has tripped out many times. The only repair
is to replace the circuit breaker or overload).

Question:

2.

If the above checks are OK, replace the switch that

is tripping out.

Answer:

3.

Compressor makes loud growling noise.

Problem
6.

Which components can we determine are

working OK from the symptoms?

Customer has turned the unit off and called for service
because he believes the air conditioner is surely burning up
since it makes such a loud noise. On inspection, we find that
the compressor starts but draws high current and continues to
make the growling noise until the thermal current overload
trips out.
Question:

16

The power is getting to the compressor.

Answer:
1.
The start circuit is starting the compressor OK.

Then why the noise?

2.

Question:
The start capacitor is staying in the circuit
and the compressor is running with too much
capacitance. This condition is caused by; 1)
the compressor does not come up to speed
and does not supply adequate voltage to
actuate the potential relay, or 2) the potential
relay contacts are welded shut, or 3) the
potential relay coil is open.

The capacitors and relay are providing the starting

torque.

Answer:

How do I repair it?

3.

Question:

2.

1.

Check compressor windings per instructions.

Check out the potential relay with hermetic analyzer

or try a new potential relay.

Check the voltage between C and R terminals of

the compressor. Low voltage can cause the
compressor to not come up to speed.

Answer:

3.

Fan Vibration.

Problem
7.

The customer complains that the unit vibrates excessively. We

turn selector switch to fan/low or fan/high and the vibrations
are not appreciably reduced (we quickly eliminate the
compressor as the source of vibration).

Question:

How can I determine which part of the fan

assembly is causing the vibration?

The fan motor and fans were carefully balanced at the factory,
but they are fragile enough that they can be bent by rough
handling.

Answer:

By removing the fan wheels one at a time

and running it each time until the vibration
stops. To correct the problem, replace the
faulty part.

Fan wont run.

Problem
8.

The customer turns the system to fan/low or fan/high and

nothing happens. When he turns the selector switch to
Cool, the compressor starts but still no fan.
What could cause the fan to be dead?

The selector switch could be open.

Question:
Answer:
1.

Terminals
Lo Heat
Lo Fan
Hi Fan
Lo Cool
Hi Cool

Switch Position

The safest way to check a selector switch is to turn

off all power, remove the wires and with an ohm
meter, check for continuity between terminals L&1
for low speed fan connection and terminals L&2 for
high speed fan connection. The meter should read 0
ohms.

L-1-3
L-1
L-2
L-1-4
L-2-4
Fan motor windings could be open, shorted or
grounded.

The electrical circuit to the fan motor leads could be

open. Check all connections (including wire nuts) to
the fan motor red, black and white wires.

2.

3.

Fan capacitor may be shorted, weak or open.

Be sure power is off. Check motor windings per

instructions (See page 8).

4.
To check fan capacitor, follow same procedure that
is outlined for compressor run capacitors (See page
9).

Compressor runs but wont pump.

Problem
9.

The customer turns the selector to a Cool position and the

thermostat to a low temperature setting (below room
temperature). The fan runs OK, but the unit does not cool.
On examination we find that the compressor does run. It
runs quietly and smoothly. We check the compressor current
and find that it is below the FLA rating. The evaporator is
warm, the suction line is warm. There are two possible
problems, either the compressor valves are broken or the unit
is completely out of charge. At this point, you must break
into the system to locate the problem.

17

Compressor cycling off and on.

Problem
10.
The customer says he gets inadequate cooling even though he
has several times set the thermostat down to call for a lower
temperature until it is now all the way down to the lowest
possible setting.

What could cause the compressor to cycle

off and on?

On investigation, we find that the compressor is cycling off

and on.
Question:

The thermostat is out of calibration. Turn off power.

Check with ohm meter.

Two things.

1.

The compressor is cycling on the thermal current

overload.

Answer:

2.

Question:

Compressor is running hot or compressor is

drawing excess current or both.

What could cause the switch to open and

close?

With the power on, check the voltage between the

terminals of the overload while the compressor is not
running. If the meter reads 115 volts domestic USA
models or 240 volts export/overseas models, the
compressor is cycling on this switch (see page 8 for
description and function of this switch).

Answer:

1.

Feeling the compressor dome - it will normally

(during warm weather - above 85) be too hot to be
comfortable if you keep your hand on it. If it is
burning hot, it is probably overheating. The normal
compressor housing temperature varies with outside
temperature and evaporator load so determining
whether or not it is too high is a matter of judgement
based on experience.

Check by:

2.

Measuring the current (amperes) through the black

wire which leads from #5 on the potential relay to the
overload switch. This current may be compared to
the unit FLA rating.
Remember that the overload switch is sensitive to both high
temperature and high current. Since this is true, we cant
specify a definite temperature or amperage at which the
switch will open. As the temperature rises, the current at
which the switch will open goes down. As the temperature
goes down, the current at which the switch will open goes
up.

in coming to a conclusion.

a)
Higher than normal discharge line
temperature

Overcurrent

What could cause the compressor to draw

overcurrent or to overheat?

b)

Higher than normal liquid line temperature

The indications of non-condensables in the system

are:
Dirty condenser coil.

c)
Higher than normal compressor temperature

High voltage can drive excessive current through the

motor windings. Low voltage can cause the
compressor to slow down, overload and draw
excessive current. Check the voltage between C
and R terminals on the compressor while it is
running. The volt meter must read between 103.5
volts and 126.5 volts (domestic USA models - plus
or minus 10%).

High or low voltage.

Indicators of low charge are:

The compressor is dependent on a good supply of cool

suction gas for cooling. If the system charge is low;
there will be less than a normal amount of refrigerant
passing through the compressor, less compressor heat
will be carried away by the refrigerant, and therefore,
the compressor will overheat. NOTE LOW
CHARGE WILL NOT CAUSE OVERCURRENT.
It will, in fact, cause the current to be low.

This very rarely occurs and should be considered

only after all other possible causes have been
positively eliminated.

Low Charge.

d)
5.

Overcharge or non-condensables in the system.

a)

The evaporator will be starved for liquid

refrigerant so the suction line and a portion
of the evaporator coil will be warmer than
normal. This is the condition we refer to as
too much superheat. How much of the
evaporator coil will be starved for liquid
refrigerant depends on the degree of
undercharge.

Check fan blade, fan motor and capacitor.

Either an overcharge of refrigerant or noncondensables in the system will cause high head
pressure and consequently, excessive current. Be
especially suspicious if you discover evidence of the

The active portion of the evaporator coil

which does have some liquid refrigerant will
be colder than normal and many times will
frost because the suction pressure will be
low. How much of the coil is active depends
on the degree of undercharge.

b)

a)

Cooler than normal suction line. With an

overcharge, the suction line will usually
sweat all the way to the compressor.

Overcurrent which may be checked as

previously outlined.

The indications of overcharge are:

system having been open (service valves in the

system, extra pinch off marks, etc.).

b)

The compressor temperature will be

noticeably higher than normal.

c)

Cooler than normal discharge line. The

discharge line should be highly superheated
and therefore, at high temperature.

Feeling lines with your fingers is a very inexact

method of gathering information and cannot be
considered accurate. So use this information only to
form preliminary judgements in your diagnosis of
trouble and consider as many indicators as possible

Note: Low charge situations may be

mimicked by problems such as dirty filters,
dirty evaporator coils, air flow restrictions
and low load conditions. Do not attempt to
tap into the system unless you are
specifically trained in refrigeration system
repairs.

c)

Condenser fan does not come up to speed.

Check the appearance of the coil. If it is coated with

lint, cottonwood fuzz, leaves, etc., it is insulated and
it cannot give up its heat to the outside air. A dirty
condenser will cause high head pressure which will
in turn cause both high current draw and high
temperature at the compressor.

Question:

Answer:
1.

2.

3.

4.

18

6.

Plugged up cap tube.

A cap tube can become stopped up by oil sludge or
contaminants in the system. This will only occur if
the system has been open to allow moisture or other
contaminants to enter the system or if the
compressor has been overheated for a lengthy period
of time.

It is difficult to determine the difference between a stopped

up cap tube and a low charge because the symptoms will be
nearly the same.
To repair either a low charge or stopped up cap tube,
we will have to install service valves and attach
gauge manifold. If after the correct amount of
refrigerant has been charged into the system, and it
has low charge symptoms, we will know the cap tube
is plugged and will have to be replaced.

No heat - Heat Strip.

Problem
12.

Question:

1.

The selector switch could be open

(See page 7).

The limit switch or the heating

element could be open. Check
with continuity.

What are the possible causes of no heat

problem?

The customer says that he has turned the selector switch to

Heat position and the blower works OK, but no heat.

Answer:

2.

3.
The thermostat could be open
(See page 7).
In all three cases, turn off power and check
for continuity with an ohm meter.

Cooling Performance Check

Problem
13.

1.

With a standard dial type or digital thermometer,

measure the temperature of the air immediately

Start the air conditioning unit and allow it to run for

at least one-half hour. Possibly longer if it is
extremely warm outside (the objective is to saturate
the evaporator coil before we begin running a
temperature test).

Make sure the filters, the evaporator coil and the condenser
coils are clean and all supply air registers are open wide.

2.

19

5.

4.

3.

Temperature differences greater than 22 degrees are

possible in warm dry weather. Restricted air flow
over the evaporator may also cause greater than 22
degree temperature differences.

A properly running air conditioning unit should have

a temperature difference of approximately 18 to 22
degrees F. Note: Slightly less temperature differences
are possible under extremely humid conditions. (The
unit may have to run longer to remove moisture).

Subtract from this temperature the temperature of the

air immediately leaving the supply air louvers (if it is
a ducted air conditioning unit, use the closest
discharge register and make sure the temperature
sensing device is measuring supply air temperature
only).

entering the return air grille of the air conditioning

unit.

6.

Compressor running amps should be checked as

follows. Note the amperage listed on the air
conditioner rating plate (RLA) is determined at
design conditions only. These conditions are 95
degrees outdoor temperature and 80 degrees indoor
temperature.
Since the outdoor temperature is mostly responsible
for the amount of compressor amperage, this figure
will have to be adjusted for changes in outdoor
temperature approximately 1 amp for every 5 degrees
in temperature change (from 95 degrees) up or down
accordingly.

TYPICAL WIRING DIAGRAMS

6700 SERIES
AIR CONDITIONERS & CEILING ASSEMBLIES

20

6798-7XX, 6798A7XX SERIES

6799-7XX, 6799A7XX SERIES
6799-8XX SERIES
AIR CONDITIONERS & CEILING ASSEMBLIES

21

7000 & 8000 SERIES

6799A8XX SERIES
6799B8XX SERIES
AIR CONDITIONERS

22

CEILING ASSEMBLY WIRING DIAGRAMS

6759, 7000, 8000 SERIES COOL ONLY

6759, 7000, 8000 SERIES HEAT/COOL

23

WIRING DIAGRAM FOR 9000 SERIES

ROOF MOUNT AIR CONDITIONERS

WIRING DIAGRAM FOR

9330X715, 9330X716 HEAT/COOL CEILING ASSEMBLIES

24

WIRING DIAGRAM
9330X713, 9330X714 COOL ONLY
CEILING ASSEMBLIES

25

1976F141 (12-03)

RV Products
A Division of Airxcel, Inc.
P. O. Box 4020
Wichita, KS 67204

OPERATION AND MAINTENANCE

INSTRUCTIONS
FOR
ROOF TOP MARINE AIR CONDITIONERS
AND CEILING PLENUMS

MODE DEMPLOI ET UTILISATION

CLIMATISEUR MARINE
DE TOIT
ET PLENUM DE PLAFOND

I.
II.
III.
IV.
V.
VI.

TABLE OF CONTENTS
2

4
8

The size of the vehicle, amount of window area, amount of

insulation, direct exposure to the sun, outside temperature and
the number of people in the recreational vehicle may increase
the heat gain to such an extend that the capacity of the air
conditioner is exceeded.

SECTION I - GENERAL INFORMATION

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Ceiling Plenum Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Standard Ceiling Plenum Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wall Thermostat Identification And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTE
The optional Elect-A-Heat heating assembly is intended to
take the chill out of the indoor air when the air is a few
degrees too cool for comfort. The heating assembly is an
effective chill chaser. It is not a substitute for a furnace.
As a general rule, air entering the air conditioner will be cooled
about 15 to 20 degrees, depending on the outside temperature
and humidity conditions.

As long as this temperature difference is being maintained

between the return air and discharge air, the air conditioner is
operating at its capacity. If the desired inside temperature
(normally 80 degrees F) cannot be maintained, then the heat
gain of the RV is too great for the capacity of the air
conditioner.

For example, if the air entering the return air grilles in the air
conditioner is 80 degrees F, the air leaving the discharge grilles
in the air conditioner will be 60 to 65 degrees F.

When searching for a qualified technician, please reference

your RV Products Authorized Service Center List. The
servicers listed are familiar with your recreation vehicle
product. If the air conditioner is still under warranty, an
authorized servicer must be used for any repair required on the
air conditioner. Using an unauthorized servicer may void your
warranty.

Parking the vehicle in a shaded area, keeping windows and

doors shut and avoiding the use of heat producing appliances
in the vehicle will help to reduce the heat gain. When
possible, the addition of insulation and tinted glass (especially
in uninsulated vans) should be considered.

These roof mount air conditioners were designed to operate

from a 115 VAC, 60 HZ, 1 Phase power supply. Anytime an air
conditioner is not operating properly, the power supply
should be examined by a qualified technician to verify that the
air conditioner is receiving the proper power supply.

This is due to the limited electrical power normally available in

most trailer parts and/or economic limitations on the use of
generators with enough capacity to handle large air
conditioners. If more than 1 ton of cooling is desired, then the
use of two air conditioners is recommended.
The ability of the air conditioner to maintain the desired inside
temperature depends on the heat gain of the recreational
vehicle.

B.

The Thermostat (temperature control) - In the

cooling mode, the thermostat regulates the ON
and OFF temperature setting at which the

The Operation section explains the operational

characteristics of each mode of operation.

roof top unit and ceiling assembly. Figure 1 shows

selector switch location and lists all available
functions by model.

SECTION II - CONTROL PANEL

If your RV air conditioner is operated from the control panel
located in the ceiling assembly, then there are three controls
on the ceiling assembly that help you control the air
conditioner. They are as follows:
A.

The Selector Switch - The selector switch determines

which mode of operation the air conditioner will be
in. By rotating the selector switch, the operator can
obtain any system function desired. System
functions vary depending upon options of both the

compressor will operate.

For Heat/Cool models, the thermostat also controls
the ON and OFF temperature settings of the
heater assembly (See Figure 1).

C.

FIGURE 1

Louvers - The louvers are located at both ends of the

ceiling assembly shroud and are used in directing
the discharge air from the unit.

A.

I.
Turn the selector switch to the LOW COOL or
HIGH COOL position.

For Cooling (Refer to Figure 1, Page 3)

II.

C.

Operation During Cooler Nights (Cooling

Operation)

Position the louvers to the desired direction the

discharge air is to flow.

SECTION III - OPERATION

B.

It is important, when the outdoor temperature drops in the

evening or during the night to below 75 degrees F, that the
thermostat (temperature control) be set at a midpoint between
Warmer and Cooler. If the setting is at cooler, the
cooler (evaporator) coil may become iced-up and stop cooling.
During the day when the temperatures have risen above
75 degrees F, reset the thermostat switch to the desired
setting.

Rotate the thermostat (temperature control) to the

position that is the most comfortable to you. The
thermostat will turn the compressor on when the
temperature of the air entering the air conditioner
rises a few degrees above the setting you have
selected. When the temperature of the air entering
the air conditioner drops below the selected setting,
the thermostat will turn the compressor off. The air
conditioner, while in the cooling mode, will continue
to cycle the compressor on and off in the above
mentioned fashion until the selector switch is turned
to another mode of operation.

Short Cycling

NOTE
Should icing-up occur, it is necessary to let the cooling
(evaporator) coil defrost before normal cooling operation is
resumed. During this time, operate the unit in the HIGH
FAN position with the system at maximum air flow. When
increased or full air flow is observed, the cooling coil should
be clear of ice.
III.
When an air conditioner is in operation, its compressor
circulates refrigerant under high pressure. Once off, it will
take two to three minutes for this high pressure to equalize.

For Heating (Elect-A-Heat Ceiling Assembly

Model Only) Refer to Figure 1, Page 3)

The air conditioning compressor is unable to start against

high pressure. Therefore, once the air conditioner is turned
off, it is important to leave it off for two to three minutes
before restarting.
IV.

NOTE
The optional Elect-A-Heat heating assembly is intended to
take the chill out of the indoor air when the air is a few
degrees too cool for comfort. The heating assembly is an
effective chill chaser. It is not a substitute for a furnace.

Owner

C.

B.

Position the louvers to the desired direction the

discharge air is to flow.

Rotate the thermostat (temperature control) switch to

the position that is the most comfortable to you. The
thermostat will turn the heater on when the
temperature of the air entering the air conditioning
unit drops below this setting a few degrees and
automatically turns off when the temperature of the
air entering the air conditioner rises a few degrees
above this setting. The heater will continue to cycle
on and off in this fashion until the selector switch is
turned to another mode of operation.

Discharge air temperature can be controlled to some

extent by opening or closing the louvers.
When the louvers are closed, the warmest localized
discharge air is achieved. Fully opened louvers will
throw the warm discharge air to the back and front
of the vehicle for more efficient circulation and
faster warm-up. Although the air temperature is
lower with the louvers fully opened, the heating
capacity is still the same.

A.

Position the louvers to the desired direction the

discharge air is to flow.

Turn the selector switch for LOW FAN or for

maximum air flow, to HIGH FAN.

For Air Circulation Only (Refer to Figure 1, Page 3)

B.

NOTE
When the selector switch is in the LOW FAN or HIGH
FAN position, the blower motor will operate continuously.

IMPORTANT

We recommend that the filters be cleaned or changed at least

every two weeks when the air conditioner is in operation.

An even more serious condition occurs when the air

conditioner is operated without a filter. When this happens
the lint, dirt, grease, etc. that are normally stopped by the
filter are now accumulating in the cooling coil. This not only
leads to a loss of air volume and a possible icing-up of the
cooling coil, but could also result in serious damage to the
operating components of the air conditioner.

Do not operate your air conditioner for extended periods of

time without the filter installed.

SECTION IV - MAINTENANCE

Turn the selector switch to the LOW HEAT

position. At LOW HEAT, the fan operates on
low speed with heat output at maximum.

Do not expect the heating coil on your heater to glow.

Because the fan draws in cold air and forces it over the coil,
the coil will not turn red. A hint of red may occur where the
moving air does not directly touch the coil.
A.

1.

One of the biggest advantages to your new RV Products air

conditioner is that the maintenance needed to keep the unit
in good care is minimal. In fact about the only thing you,
the owner, must take care of is the cleaning and replacement
of the filters.
Filters are made from long life natural fibers which can be
cleaned and reused, and which completely filter the
circulated air when the air conditioner is in operation. If the
filters are not cleaned at regular intervals, they may become
partially clogged with lint, dirt, grease, etc. A clogged filter
will product a loss of air volume and may eventually cause
an icing-up of the cooling (evaporator) coil.

4.

3.

2.

1.

Remove filter from grill and either clean or

exchange with new filter.

If the vehicle is equipped with a flush mount

ceiling assembly, remove the four return air grill
screws (See Figure 5, Page 7).

Take filters out and either clean or exchange with

other filters (See Figure 2).

Lower the grille and filters from the ceiling

assembly.

Disengage the two 1/4-turn fasteners that secure

the ceiling assembly grille to the ceiling assembly
(See
Figure 2).

Cleaning and/or changing the filters:

5.

NOTE

II.

Service Person

If replacement filters are necessary, the filters

can be purchased from most RV Products
Authorized Service Centers. It is recommended
that spare filters be carried with the RV at all times
to replace worn, torn or deteriorated filters.

A.

Electrical - All electrical work and/or inspection

should be performed only by qualified service
personnel. Contact your nearest RV Products
Service Center if electrical problems should arise.

FIGURE 2

Mechanical Integrity - The air conditioner should be

inspected periodically to be sure that the bolts which
secure the unit to the roof are tight and in good
shape. Also, an examination of the plastic shroud
covering the air conditioner on the top of the roof
should be made periodically. Be sure the four
mounting screws and washers are snug and holding
the shroud to the air conditioner. Also examine the
shroud to be sure it is not developing cracks or has
suffered damage from impact.

B.

Check Points - Failure to start or to cool the air are

sometimes problems with air conditioning units.
The RV Products air conditioner is designed to
operate on 115 volt electrical power. If the
compressor on the air conditioner fails to start,
check with your RV Products Service Center to
determine that the proper wire size is connected to
the unit, the proper circuit breakers are installed as
protection devices on the electrical circuit and the
proper sized extension cord is being used for the
distance covered from the utility outlet to the RV.
The required minimum wire size is #12 AWG for
lengths up to 25 feet (larger wire size for greater
distances). Each air conditioning unit must be
protected with a 20 amp time delay fuse or
circuit breaker.
If the air conditioner continues to trip off the circuit
breakers, have an electrician check the starting
amperage and running amperage on the unit. If the
circuit breaker continues to trip off and the electrical
consumption is found to be normal, it will require
the replacement of the faulty circuit breaker.
If all electrical power to the air conditioner is normal
but neither the fan or the compressor will operate,
the connector plug located behind the ceiling
assembly control box should be checked to determine
whether it is faulty.

C.

Lubrication

On the heating-cooling air conditioner models, if all

electrical power to the unit is normal and the fan
runs but you never get any heated air, then the
electrical plug to the heating unit should be checked
for a secure connection. If this does not correct the
malfunction, the heating thermostat or limit switch
may be faulty.

D.

DANGER
DISCONNECT THE POWER SUPPLY TO THE UNIT
BEFORE SERVICING TO PREVENT A SHOCK HAZARD
OR POSSIBLE INJURY FROM MOVING PARTS.

The blower drive motor on some units may include oiling

cups at the top of the motor. There is no requirement to oil
the journals under normal operating conditions.

However, if lubrication to the unit is desired, use only

SAE 20 non-detergent type oil. DO NOT OVER OIL - three
to four drops in each oil hole once a year is sufficient.

SECTION V. WALL THERMOSTAT IDENTIFICATION

AND OPERATION
ELECTRONIC SINGLE STAGE HEAT/COOL THERMOSTAT

Suggested Fuse To Protect Wiring Leading To

Thermostat.

Not Found In Cool Only Applications.

FIGURE 3

Heat/Cool Thermostat
Shown
Cool Only Model Has No Reference To
Heat On Face Of Thermostat
FIGURE 4

OPERATION
The chart below shows the system functions with the Heat/Cool thermostat. After the entire
air conditioning system (and furnace system) is installed, check each position function. Disregard
references to heat functions when using the Cool Only thermostat.

All cooling functions controlling to setpoint have a short cycle protection time delay of 3 minutes. There will
be no delay if the cycle OFF time exceeds 3 minutes.
* There is no heat switch or furnace function available with the Cool Only thermostat.

5.

4.

An optional three year extended parts only contract

is available at an additional cost of $89.95. To obtain
this optional three year parts contract, fill out the
application card stapled to the front of this envelope.
Please mail the card and a check or money order to
the address above. Applications must be made
within ninety (90) days of the original purchase.

Carefully read your limited two year product

warranty which is packed with the product.

IMPORTANT

SECTION VI - WARRANTY SERVICE

Lets face it. Sometimes even the best products may need
service. To obtain warranty service on your RV Products air
conditioner, please contact your selling dealer, or you may
access our web site on the Internet at www.rvcomfort.com
for answers to the most frequently asked questions and
service center locations.
RV Products support help may be accessed by E-mail at
RVPSupport@Airxcel.com.

6.

8
9
9
10
12
12

Inquiries about your RV Products air conditioner

must include the model and serial numbers and the
date of purchase. The model and serial numbers can
be found on the I.D. label located on the air
conditioner basepan return air opening at the bottom
of the roof unit. This information may also be found
on the air conditioner rating plate.

TABLE DES MATIRES

Renseignements gnraux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panneau de contrle du plenum de plafond standard . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fonctionnement du plnum de plafond standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entretien . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fonctionnement et identification du thermostat mural . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service de garantie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RV Products
A Division of Airxcel, Inc.
P.O. Box 4020
Wichita, KS 67204

All written correspondence should be directed to:

I.
II.
III.
IV.
V.
VI.

La capacit du climatiseur de maintenir la temprature

intrieure voulue dpend du gain de chaleur du vhicule
rcratif.

Ceci peut provenir du fait quil y a des sources limites

dalimentation lectrique disponibles dans la plupart des
parcs de caravanes et/ou des limites conomiques quant
lutilisation de gnratrices ayant une capacit suffisante
pour de gros climatiseurs. Sil faut plus dune tonne de
refroidissement, alors il est recommand dutiliser deux
climatiseurs.

connaissent votre produit de vhicule rcratif. Si le

climatiseur est encore sous garantie, il faut utiliser un agent
autoris pour toute rparation ncessaire. Le fait dutiliser un
agent non-autoris peut annuler votre garantie.

SECTION I. RENSEIGNEMENTS GNRAUX

REMARQUE
Le montage de chauffage Elect-A-Heat optionnel est conu
pour couper le froid de lair lintrieur du vhicule qui est
un peu trop frais pour le confort. Le systme de chauffage
est efficace pour enlever le froid et non pas pour
remplacer lappareil de chauffage.
Ces climatiseurs de toit furent conus pour fonctionner
partir dune source dalimentation de 115 V. c.a., 60 hz, 1
phase. Lorsquun climatiseur ne fonctionne pas
correctement, lalimentation lectrique doit tre examine par
un technicien qualifi afin de vrifier que le climatiseur reoit
la bonne alimentation de courant.
Se reporter la liste de centres de service autoriss de RV
Products pour trouver un technicien qualifi. Les centres

La taille du vhicule, le nombre de fentres, la quantit

disolant, lexposition directe au soleil, la temprature
extrieure ainsi que le nombre de personnes dans le vhicule
peuvent tellement augmenter la chaleur que la capacit du
climatiseur est dpasse.
En rgle gnrale, lair qui entre dans le climatiseur sera
refroidi denviron 15 20 degrs selon la temprature et
lhumidit de lextrieur.
Par exemple, si lair qui entre dans les grilles dentre dair du
climatiseur est de 80 degrs F (24 degrs C), lair quittant les
grilles de sortie dair du climatiseur sera de 60 65 degrs F
(13 16 degrs C).

Aussi longtemps que cette diffrence de temprature est

maintenue entre lentre et la sortie dair, le climatiseur
fonctionne sa capacit. Si lon ne peut conserver la
temprature intrieure voulue (normalement 80 degrs F (24
degrs C)), alors le gain de chaleur du VR est trop lev pour
la capacit du climatiseur.
Le fait de stationner le vhicule lombre, de garder les
fentres et les portes fermes et dviter dutiliser des
appareils dgageant de la chaleur aidera rduire le gain de
chaleur. On peut aussi considrer ajouter de lisolant et des
verres teints (tout particulirement dans les caravanes nonisoles).

B.

C.

Arateurs - Les arateurs se trouvent aux deux

extrmits du couvercle du plafond et servent
diriger la dcharge dair de lappareil.

Pour les modles chaleur/refroidissement, le

thermostat contrle aussi les rglages de
temprature ON (marche) et OFF (arrt) du
radiateur. Voir figure 1.

Le thermostat (contrle de temprature) - sous le

mode de refroidissement, le mode de
refroidissement, le thermostat contrle le rglage de
temprature ON (marche) et OFF (arrt) du
chauffage.

SECTION II. PANNEAU DE CONTRLE

Si votre climatiseur de VR fonctionne partir dun panneau
de contrle au plafond, il y a alors trois commandes au
plafond pour aider contrler le climatiseur. Les voici:
A.

Le slecteur - Le slecteur dtermine le mode de

fonctionnement du climatiseur. En le tournant,
loprateur peut obtenir toute fonction du systme
voulue. Celles-ci varient selon les options de lunit
du toit et du plafond. Le figure 1 illustrents
lemplacement du slecteur et numrents toutes les
fonctions disponibles par modle.
La section fonctionnement explique les
caractristiques de fonctionnement de chaque mode.

Placer le slecteur la position LOW COOL

(refroidissement faible) ou HIGH COOL
(refroidissement fort).

lcoulement de lair dcharg.

Fonctionnement durant les nuits plus froides
(fonctionnement de refroidissement)

Sil y a de la glace qui saccumule, il est alors ncessaire de

laisser le serpentin du refroidisseur (vaporateur) dgeler
avant de reprendre le fonctionnement de refroidissement
normal. Durant ce temps, faire fonctionner lappareil en
position HIGH FAN (ventilateur fort) avec le systme au

REMARQUE

Il est important, lorsque la temprature extrieure descend au

cours de la soire et la nuit sous 75 degrs F, de rgler le
thermostat (contrle de temprature) un point central entre
Warmer (plus chaud) et Cooler (plus frais). Si le rglage
est Cooler, le serpentin du refroidisseur (vaporateur)
peut accumuler de la glace et cesser de refroidir. Durant le
jour, lorsque les tempratures dpassent 75 degrs F, rgler le
commutateur du thermostat au rglage voulu.

II.

SECTION III. FONCTIONNEMENT

A.

Faire tourner le thermostat (contrle de temprature)

la position la plus confortable. Le thermostat met
le compresseur en marche lorsque la temprature de
lair qui entre dans le climatiseur augmente de
quelques degrs au-dessus du rglage choisi.
Lorsque la temprature de lair qui entre dans le
climatiseur tombe sous ce rglage, il arrtera le
compresseur. Le climatiseur, en mode de
refroidissement, continuera mettre le compresseur
en marche puis larrter de la manire indique
prcdemment jusqu ce que le slecteur soit plac
dans un autre mode de fonctionnement.

Pour le refroidissement (se reporter aux figure 1,

page 3)

B.

Placer les arateurs dans la direction voulue pour

I.

C.

Fonctionnement en courts cycles

maximum de la circulation dair. Lorsque cette circulation

augmente ou fonctionne au maximum, le serpentin du
refroidisseur ne devrait pas avoir de glace.
III.
Lorsquun climatiseur fonctionne, son compresseur fait
circuler le rfrigrant sous haute pression. Arrt, il faut deux
trois minutes pour que cette haute pression sgalise.

Pour chauffer (modle de plafond Elect-A-Heat

seulement) (se reporter aux figure 1, page 3)

Le compresseur du climatiseur est incapable de dmarrer

contre une haute pression, donc, lorsque le climatiseur est
arrt, il est important de le laisser arrter pendant deux trois
minutes avant de le faire redmarrer.
IV.

REMARQUE
Le montage de chauffage Elect-A-Heat optionnel est conu
pour couper le froid de lair lintrieur du vhicule qui est un
peu trop frais pour le confort. Le systme de chauffage est
efficace pour enlever le froid, mais non pas pour remplacer
lappareil de chauffage.
Ne pas sattendre ce que le serpentin de chauffage de votre
appareil de chauffage produise de lincandescence. Puisque
le ventilateur aspire de lair froid et le fait passer sur le
serpentin, celui-ci ne peut devenir rouge. Il peut y avoir une
incandescence lorsque lair passe directement sur le
serpentin.
A.

Placer le slecteur LOW HEAT (faible chaleur) et

le ventilateur fonctionne vitesse rduite la sortie
de chaleur au maximum.

C.

temprature de lair qui entre dans le climatiseur

augmente au-dessus de ce rglage, il arrtera le
compresseur. Le chauffage continuera passer de
marche arrt de la manire indique prcdemment
jusqu ce que le slecteur soit plac dans un autre
mode de fonctionnement.
Placer les arateurs dans la direction voulue pour
lcoulement de lair dcharg. La temprature de
dcharge dair peut tre contrle jusqu un certain
point en ouvrant ou en fermant les arateurs.
Lorsque les arateurs sont ferms, lon peut
atteindre lair de dcharge le plus chaud. Les
arateurs entirement ouverts dchargeront lair
chaud vers larrire et lavant du vhicule pour une
circulation plus efficace et un rchauffement plus
rapide. Bien que la temprature de lair soit moins
leve lorsque les arateurs sont entirement
ouverts, la capacit de chauffage sera encore la
mme.

A.

Placer les arateurs dans la direction voulue pour

lcoulement de lair dcharg.

Placer le slecteur LOW FAN (ventilateur faible)

ou pour une circulation dair maximale, HIGH
FAN (ventilateur fort).

Pour la circulation dair seulement (se reporter aux figure

1, page 3)

B.

REMARQUE
Lorsque le slecteur est en position LOW FAN ou
HIGH FAN, le moteur soufflerie fonctionne
continuellement.

Ne pas faire fonctionner votre climatiseur pendant de

longues priodes sans filtre.

IMPORTANT

sont pas nettoys intervalles rguliers, ils peuvent tre

bloqus partiellement par de la poussire, de la graisse, de la
peluche, etc. Un filtre bloqu provoquera une perte de
volume dair et pourra ventuellement tre responsable de
laccumulation de glace sur le serpentin du refroidisseur
(vaporateur).

SECTION IV. ENTRETIEN

B.

Propritaire

Faire tourner le thermostat (contrle de temprature)

la position la plus confortable. Le thermostat met
le compresseur en marche lorsque la temprature de
lair qui entre dans le climatiseur diminue de
quelques degrs sous le rglage choisi. Lorsque la

1.

Un des plus grands avantages de votre nouveau climatiseur

de RV Products est que lentretien ncessaire pour conserver
votre appareil en bon tat est minime. En fait tout ce que
vous avez faire, comme propritaire, est de nettoyer et de
remplacer les filtres.
Les filtres sont fabriqus de fibres naturelles de longue dure
que lon peut nettoyer et rutiliser, et qui filtrent entirement
lair circul lorsque le climatiseur fonctionne. Si les filtres ne

10

Lorsque le climatiseur fonctionne sans filtre, il peut y avoir

un problme plus grave car la poussire, la graisse, la
peluche, etc. arrtes normalement par le filtre
saccumulent maintenant dans le serpentin du refroidisseur.
Ceci provoque une perte de volume dair et une accumulation
possible de glace sur le serpentin du refroidisseur, mais
cela peut aussi provoquer de graves dommages aux
composants du climatiseur.
Nous recommandons de nettoyer ou de changer les filtres au
moins toutes les deux semaines lorsque le climatiseur
fonctionne.

4.

3.

2.

1.

Retirez le filtre de la grille et nettoyez-le ou

remplacez-le avec un nouveau filtre.

Si le vhicule est dot dun montage de plafond

affleurant, retirez les quatre vis des grilles de reprise
dair (voir la figure 5, page 7).

Sortir les filtres et nettoyer ou changer avec

dautres filtres (voir figure 2).

Abaissez la grille et les filtres de lassemblage du

plafond.

Retirer les deux vis qui retiennent le couvercle du

montage du plafond. Voir figure 2.

Nettoyer et/ou changer les filtres:

5.

REMARQUE

A.

II.
lectricit - Tous les travaux et/ou inspections
lectriques ne doivent tre effectus que par un
personnel dentretien qualifi. Sadresser au Centre
dentretien RV Products sil y a des problmes.

Responsable de lentretien

Si des filtres de remplacement sont ncessaires,

on peut se les procurer auprs de la plupart des
Centres de service autoriss RV Products. Il est
recommand de toujours avoir des filtres de
rechange dans votre VR en tous temps pour
remplacer les filtres dtriors, uss ou dchirs.

B.

Points de contrle - Les climatiseurs ont quelquefois

des problmes de dmarrage ou de refroidissement.
Le climatiseur RV Products est conu pour
fonctionner sur un courant lectrique de 115V. Au
cas o le compresseur du climatiseur refuserait de
dmarrer, sadresser au Centre dentretien RV
Produits pour dterminer si le climatiseur est
aliment par un cblage de calibre adquat, si la
protection du circuit lectrique est assure par des
disjoncteurs appropris et si le calibre du cble de

11

rallonge, raccordant la prise de secteur du vhicule,

est aussi adquat. Jusqu 7,6 m, le calibre minimum
de fil requis est 1,5 mm (#12 AWG). Un calibre plus
fort est requis pour une distance plus longue.
Chaque climatiseur doit tre protg par un fusible
action diffre ou par un disjoncteur.
Si le climatiseur fait dclencher continuellement le
disjoncteur, faire vrifier par un lectricien
lamprage de dmarrage et de marche. Si le
dclenchement du disjoncteur se poursuit alors que
le consommation lectrique reste normale, il sera
ncessaire de remplacer le disjoncteur dfectueux.
Si, alors que lalimentation lectrique du climatiseur
est normale, ni le ventilateur ni le compresseur ne
fonctionnent, vrifier la connexion de la prise situe
larrire de la bote de commande du module.

C.

Lubrification

Intgrit mcanique - Le climatiseur devrait tre

inspect rgulirement pour sassurer que les
boulons qui retiennent lappareil au toit sont serrs
et en bon tat. Il serait aussi utile de faire un examen
du couvercle de plastique couvrant le climatiseur sur
le toit. Sassurer que les quatre vis de montage et
les rondelles sont bien en place et retiennent le
couvercle au climatiseur. Examiner aussi le
couvercle pour sassurer quil ny a aucune fissure
ou de dommages suite un choc.

Si lalimentation en lectricit du module est normale

et le ventilateur fonctionne, mais si vous ne recevez
pas dair chaud, vrifier la connexion de la fiche du
fil de raccordement du module de chauffage pour
sassurer que le contact est bien tabli. Si ceci ne
corrige pas le problme, il se peut que le thermostat
ou le disjoncteur de scurit soit dfectueux.

D.

DANGER
DBRANCHER LA SOURCE DALIMENTATION
LAPPAREIL AVANT TOUT ENTRETIEN POUR VITER
LES DANGERS DE CHOC LECTRIQUE OU LA
POSSIBILIT DE BLESSURES CAUSES PAR LES
PICES MOBILES.
Le moteur dentranement de la soufflerie de certains
appareils peut inclure des godets graisseurs au sommet du
moteur. Il ny a aucune raison dhuiler les tourillons sous
des conditions normales de fonctionnement. Sil faut
toutefois lubrifier lappareil, utiliser seulement de lhuile du
type non-dtergent SAE 20. NE PAS METTRE TROP
DHUILE - trois quatre gouttes dans chaque trou dhuile,
une fois par an, suffisent.

SECTION V. FONCTIONNEMENT ET IDENTIFICATION

DU THERMOSTAT MURAL

chauffage), vrifier chaque fonction de position. Ignorer les

rfrences aux fonctions de chaleur en utilisant le thermostat
de nrefroidissement seulemento.

FONCTIONNEMENT
Le tableau suivant illustre les fonctions du systme avec
thermostat nchaleur/refroidissemento. Aprs linstallation
complte du systme de climatisation (et du systme de

1.

Lisez soigneusement la garantie limite de deux ans,

laquelle est emballe avec le produit.

VI. GARANTIE

2.

Vous pouvez galement vous procurer un contrat

prolong de trois ans couvrant uniquement les
pices dtachables moyennant un supplment de
89,95 $US. Pour ce faire, remplissez la carte de
demande agrafe lavant de cette enveloppe.
Veuillez envoyer la carte et un chque ou un mandat
ladresse mentionne ci-dessus. Les demandes
doivent tre faites dan les quatre-vingt-dix (90)
jours suivant lachat initial.

IMPORTANT

3.

Pour tout renseignement propos de votre

climatiseur de RV Products, vous devez indiquer le
nom du modle, les numros de srie et la date
dachat. Le nom du modle et les numros de srie
sont inscrits sur ltiquette de lidentification place
sur lorifice de reprise dans le plateau situ la
partie infrieure du climatiseur de toit. Ces
informations figurent aussi sur la plaque
signaltique du climatiseur.

RV Products
A Division of Airxcel, Inc.
P.O. Box 4020
Wichita, KS 67204

Il convient de le dire, mme les produits de la plus haute

qualit ont parfois besoin dtre rpars. Pour vous prvaloir
de rparations sous garantie pour votre climatiseur RV
Products, veuillez communiquer avec votre dtaillant. Vous
pouvez galement visiter notre site Web ladresse
www.rvcomfort.com pour consulter les rponses aux
questions les plus frquemment poses ainsi que les
adresses des centres de service.
De mme, vous pouvez entrer en contact avec le service de
soutien la clientle par courrier lectronique au
RVPSupport@Airxcel.com.
Toute correspondance crite doit tre envoye ladresse
suivante:
RV Products
A Division of Airxcel, Inc.
P.O. Box 4020
Wichita, KS 67204

1976F212 (9-06) PP