BG8B Service Manual
Contents
1. N N no9 IN no5 Po NJO WIC AIK DIK ClO o 18 30 inches in feet ft miles mi inches sq in feet sq ft inches cu in quarts qts gallons gal inches cu in feet cu ft feet cu ft fluid ounce fl oz ounces 02 pounds Ibs tons 2000 Ibs tons 2000 Ibs tons long 2240 Ibs inches Hg 60 F pounds sq in PSI pounds sq in PSI pounds sq in PSI inches H O 60 F bars horsepower hp ft Ibs min pound inches in lbs METRIC CONVERSION TABLE Metric to Engli lish to Metric LINEAR 25 4 millimeters mm 0 3048 meters m 1 6093 kilometers km millimeters mm meters m kilometers km AREA 645 15 0 0929 millimeters mm meters m millimeters mm meters m VOLUME 0 01639 0 94635 3 7854 16 39 28 317 0 02832 29 57 liters l liters I liters I centimeters cc liters l meters m millileters ml liters I liters I liters I centimeters3 cc liters I meters3 m3 milliliters ml MASS 28 35 0 4536 907 18 0 90718 1013 05 grams g kilograms kg kilograms kg metric tons t kilograms kg grams g kilograms kg kilograms kg metric tons t kilograms kg PRESSURE kilopascals kPa kilopascals kPa kilograms sq cm kg cm bars kilopascals kPa kilopascals kPa2. 1774 is BR PORT SAE 4 ORB 7 16 20 THD 27 ITEM BRAKE VALVE ASSEMBLY DESCRIPTION Valve Housing NSS Check Valve Retainer NSS Spring Retainer NSS Plug NSS Spool NSS Damper Piston NSS O ring Check Valve Poppet NSS Pilot Orifice Check Valve Spring Spool Spring O ring O ring O ring Back up Ring Back up Ring Check Ball 1 4 in Check Ball Spring 19 Elbow Fitting 22 Shim AR NSS NOT SERVICED SEPARATELY REPLACE COMPLETE VALVE ASSEMBLY DISASSEMBLY 10 11 12 13 14 15 16 17 18 Jo l gt po gt gt gt gt 2 2 2 25 Jo H lt 1 Remove the pilot orifice from the brake release BR port using a 5 32 in Allen wrench 2 Remove the elbow fitting motor drain check ball and spring 3 Remove the spool spring retainer and spool spring Check spring free length Replace spring if less than 1 15 16 in 49 2 mm long 6 Remove spool plug and carefully remove spool assembly Remove the damper piston from the spool The piston will come out slowly because of a partial vacuum formed as it is removed Use extreme care to avoid damaging the polished surfaces of the piston or spool Remove the check valve spring retainer spring and check valve poppet Check spring free length Replace spring if less than 1 1 2 in 38 1 mm long CLEAN AND INSPECT 1 2 Discard all O rings and b
3. kilopascals kPa kilopascals kPa kilograms sq cm kg cm2 bars kilopascals kPa kilopascals kPa POWER kilowatts kW watts W kilowatts kW watts W TORQUE 0 11298 newton meters N m newton meters N m 0 3937 3 281 0 6214 inches in feet ft miles mi 0 000155 inches sq in 10 764 61 024 1 0567 0 2642 0 06102 0 03531 35 315 0 03381 0 03527 2 2046 feet sq ft inches cu in quarts ats gallon gal inches cu in feet cu ft feet cu ft fluid ounce fl oz ounces 02 pounds Ibs 0 001102 tons 2000 lbs 1 1023 tons 2000 lbs 0 000984 tons long 2240 Ibs 0 2961 0 145 14 22 14 5 4 0193 0 01 8 851 inches Hg 60 F pounds sq in PSI pounds sq in PSI pounds sq in PSI inches H O 60 F bars horsepower hp ft lbs min pound inches in lbs 0 7376 7 233 1 3558 1383 newton meters N m kilogram meter kg m pound feet ft lbs pound feet ft lbs pound feet ft Ibs pound feet ft Ibs newton meters N m kilograms meter kg m VELOCITY 0 11298 kilometers hour km hr 0 3048 meter second m s 0 3048 meter minute m min 0 6214 3 281 3 281 miles hour m h feet second ft sec feet minute ft min kilometers hour km hr meters second m s meters minute m min miles hou
4. 3 Friction brake will not release as a result of damaged brake discs 1 Same as A2 2 Motor seal may be defective as a result of high system back pressure or contaminated oil 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 Clean and install the pilot ori fice tightly in the brake valve Check brake cylinder seal as follows A Disconnect the swivel tee from the brake release port Connect a hand pump with accurate 0 2000 psi gauge and shut off valve to the 4 J I C fitting in the brake release port B Apply 1000 psi to the brake Close shut off valve and let stand for five 5 minutes C If there is any loss of pressure in five 5b minutes the brake cylinder should be disassembled for inspection of the sealing surfaces and replacement of the seals Refer to Motor Support Brake Cylinder Service Disassemble brake to inspect brake discs Check stack up height as described in Motor Support Brake Cylinder Service Same as A2 System back pressure must not exceed 150 psi Inspect hydraulic system for a restriction in the return line from the con trol valve to the reservoir Be sure control valve and plumbing is properly sized to winch motor Oil analysis may indicate contamination has worn motor shaft and seal Thoroughly flush entire hydraulic system and install new filte
5. B Rotate bearing support until vent plug is positioned correctly and bolt holes are aligned C Evenly tighten bolts to recommended torque 5 Hydraulic lines and components that operate the winch should be of sufficient size to assure minimum back pressure at the winch The motor manufacturer recommends that the back pressure not to exceed 100 psi 690 kPa for optimum motor seal life 150 psi 1 030 kPa is the maximum allowable back pres sure The standard winch is supplied with the motor internally drained If high back pressures are encountered the motor may be externally drained directly to tank to improve motor seal life For back pressures exceeding 150 psi 1 030 kPa consult BRADEN Service Department 6 The winch should be mounted perpendicular to an imaginary line from the center of the drum to the first sheave to insure even spooling Make certain the fleet angle does not exceed 1 1 2 degrees WINCH ASSEMBLY W BRAKE VALVE amp STATIC BRAKE BRAKE VALVE Ie L WINCH BRAKE CONTROL VALVE d UN PUMP T EEN LI 7 The winch directional control valve must be a three position four way valve with a motor spool such that when the valve is in the center position both work ports are open to tank open center open port High quality hydraulic oil is essential for satisfactory performance and long hydrauli
6. Hold pressure plate down firmly by hand and measure clearance in three places between motor support and pressure plate Average gap must measure between 127 in 8 mm maximum and 060 in 1 5 mm mini mum If the gap exceeds the maximum limit there are too many brake discs in stack up or the discs are distorted If the gap is less than the min imum there are too few discs in stack up or the discs are worn out When stack height is correct remove pressure plate and continue assembly 21 6 Lubricate the brake piston seal and motor sup port sealing surface with petroleum jelly or hydraulic oil Install new piston seal to motor sup port seal lip down OLDER STYLE BRAKE CYLINDER 7 Install brake springs into brake cylinder NEW STYLE BRAKE CYLINDER 7A When using the new style brake cylinder without milled spring pockets install the spring spacer then the brake springs A WARNING A Always use the molded spring spacer with the new brake cylinder The brake springs must be properly positioned by the spring spacer 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 Install pressure plate into brake cylinder followed by the piston back up ring The close fitting pis ton back up ring may be depressed slightly to one side to lodge the back up ring in the brake cylinder bore and
7. primary planet carrier The primary planet carrier drives the output sun gear which drives the output planet gears The output planet carrier is splined to the bearing support and cannot rotate As the output planet gears are driven by the out put sun gear they drive the ring gear cable drum DUAL BRAKE SYSTEM The dual brake system consists of a dynamic brake system and a static brake system The dynamic brake system has two operating compo nents 1 Brake valve assembly 2 Hydraulic motor The brake valve is basically a counterbalance valve The counterbalance valve is mounted to the hoist port of the motor on units with 020 029 and 039 motors Units with the 071 motor use a counterbalance valve cartridge in the brake valve block which is bolted to the motor The operational theory of both systems is the same Acheck valve allows free flow of oil to the motor in the haul in direction and a pilot operated spring loaded spool valve blocks the flow of oil out of the motor when the control valve is placed in neutral When the control valve is placed in the pay out position the spool valve remains closed until sufficient pilot pressure is applied to the end of the spool to shift it against spring pressure and open a passage After the spool valve cracks open the pilot pressure becomes flow depend ent and modulates the spool valve opening which con trols the pay out speed The static brake system has three operating compo n
8. retainer Install the motor drain check ball spring and elbow fitting Install the pilot orifice into the valve housing The brake valve is complete and ready to be installed on the winch motor REVERSING DIRECTION OF DRUM ROTATION 020 029 034 039 motors ONLY Motor Case Drain O OY DRN Brake M Lowering Valve Motor Port BR Hoisting Port Brake Release Circuit A M Manifold Block Case Drain DRN Brake M Lowering Valve Motor Port X x BR Q Q i Hoisting Port Brake Release Circuit In order to change the direction of rotation 2 things must be changed on the winch First the motor must be made to rotate in 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 BG8 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 securi
9. temporarily hold the pressure plate and springs in place while you lower the brake cylinder over the motor support Apply petroleum jelly to the entire sealing surface of the brake cylinder and to the piston seal Install the brake cylinder over the motor support being careful to avoid damaging the piston seal or motor support O ring A press may be necessary to avoid cocking the brake cylinder during instal lation Install motor support capscrews and evenly tight en to recommended torque 22 BRAKE CYLINDER PRESSURE TEST Install the 4 J I C fitting into the brake release port Connect a hand pump with accurate 0 2000 psi 0 13 800 kPa gauge and shut off valve to this fitting Apply 1000 psi 6 900 kPa to the brake Close shut off valve and let stand for five 5 minutes If there is any loss of pressure in five 5 minutes the brake cylinder should be disas sembled for inspection of the sealing surfaces and brake piston WHILE PRESSURE IS APPLIED AND THE BRAKE RELEASED install the brake clutch assembly in the brake pack short end of the inner race toward motor Turn the clutch back and forth as you align the outer race splines with the brake disc splines Release the pressure on the brake cylinder then remove the brake clutch assembly The brake cylinder assembly is now complete and ready to be installed in the winch BRAKE CLUTCH SERVICE DISASSEMBLY 1 Remove the snap ring and sprag bushing r
10. AUTION A necessary Apply a non hardening sealant on the Thi l ill k th tbutplanet I outside diameter of a new seal Install the spring IS Snap MNJ WE KCS NE BEIT paner carrer Gor side of the seal toward the bearing then press into the drum using a flat plate to avoid distortion Be sure drain plug is installed securely rectly positioned in the winch Gear train damage may occur if this snap ring is omitted 6 Install the output sun gear and thrust washer into the output planet carrier TIP 2 pieces of stiff wire with an L shaped hook on one end can be used to lower the planet carri er assemblies into the drum 7 Install the output planet carrier into the drum while meshing the planet gears with the ring gear and the planet housing with the bearing support 8 Install the primary sun gear and thrust washer into the primary planet carrier Lubricate the bearing support with petroleum jelly adapter in addition to sun gear shaft The thrust or gear oil and install in base and drum plate between the primary and output sun gears is not captive within the carrier assembly Apply a VENT PLUG small amount of oil soluble grease or petroleum ABOVE CENTERLINE jelly to the thrust plate and center it on the output sun gear before installing the primary planet carri er assembly 3 Center the drum in the opening of the base ipse 23 1 gear ratio winches have a sun gear A CAUTION A Be sure the vent pl
11. BRADEN BG8A and BG8 amp B HYDRAULIC WINCH INSTALLATION MAINTENANCE AND SERVICE MANUAL VACCAR winch Division P O BOX 547 BROKEN ARROW OK U S A 74013 oa 2a PHONE 918 251 8511 FAX 918 259 1575 Printed in U S A Copyright 2010 PACCAR Winch Division All rights reserved www paccarwinch com FOREWORD Read and understand this entire publication before operating or servicing your BRADEN GEARMATIC winch Retain this manual for future reference The minimum service intervals specified are for operating hours of the prime mover This manual contains instructions which provide installation preventive maintenance and service information for the Model BG8 series winch It is suggested that before doing any work on these units all assembly and disas sembly instructions should be read and understood Some illustrations in this manual may show details or attachments that are different from your winch Also some components have been removed for illustrative purposes Continuing product improvement may cause changes in your winch which may not be included in this manual When a question arises regarding your winch or this manual contact yo
12. ack 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 scor ing Inspect check valve seat in valve housing and check valve poppet If the spools bores or valves are damaged the entire valve must be replaced as these parts are not serviced sepa rately Inspect the 020 inch orifice in the end of the spool and the pilot orifice to be certain they are open 28 ASSEMBLY 1 Install new O rings on the plug and spring retain ers di Install new O rings and back up rings on the spool and damper piston as shown It is impor tant that each back up ring is on the correct side of its O ring Take care not to cut the O rings dur ing assembly Let the spool and damper piston set for ten minutes before installing them in their respective bores This will allow the O rings to return to their original size after being stretched Lubricate the spool and damper piston O rings with hydraulic oil Carefully install the damper piston into the spool Lubricate the spool bore and spool O rings with hydraulic oil Carefully install the spool into the valve housing Always install the spool from the plug end as shown to minimize the possibility of damaging the O ring Install the plug spool spring and spring retainer Install the check valve poppet spring and check valve spring
13. and clear of winch drum Do not allow ground winch cable personnel near winch line under tension A safe dis 15 Never attempt to handle winch cable when the hook tance of at least 1 1 2 times the length of the cable end is not free Keep all parts of body and clothing should be maintained Never allow anyone to stand clear of cable rollers cable entry area of fairleads under a suspended load and winch drum On machines having hydraulically mechanically 16 When winding winch cable on the winch drum never and or cable controlled equipment be certain the attempt to maintain tension by allowing winch cable equipment is either lowered to the ground or to slip through hands Always use Hand Over blocked securely before servicing adjusting and or Hand technique repairing the winch Always apply the prime mover 17 1 i di if parking brakes and lower equipment before dis Instal guaraimg to prevent alice Om geting any part of body or clothing caught at a point where mounting the prime mover m l the cable is wrapped onto the drum or drawn Inspect rigging winch and hydraulic hoses at the through fairlead guide rollers beginning of each work shift Defects should be cor 18 D id f the winch rected immediately Do not weld on any part of the winch Keep equipment in good operating condition 19 T not knots o T eae Perform scheduled servicing and adjustments listed ey SIZE eaae anchor TOT edo and POCret in the Preventive Mai
14. c system component life Oil having 150 to 330 SUS viscosity at 100 F 88 C 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 mini mize 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 Maximum cold weather start up viscosity should not exceed 5000 SUS with a pour point at least 20 F 7 C lower than the minimum temperature Under continuous operating conditions the tempera ture of the oil at any point in the system must not exceed 180 82 C Optimum oil temperature is generally considered to be 120 140 F 49 60 C In general terms for continuous operation at ambi ent temperatures between 50 and 110 F 10 to 43 C use SAE 20W for continuous operation between 10 and 90 F 12 to 32 C use SAE 10W for applications colder than 10 F 12 C contact the BRADEN Service Department The use of multi vis cosity oils is generally not recommended 9 The hydraulic oil filter should have a 10 micron nom inal rating and be full flow type WIRE ROPE INSTALLATION Correct Installation Drive from this side Wedge and wire rope fully seated in pocket Figure 7 Figure 8 Take the free end of the wire rope and insert it through the small opening of the a
15. 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 low ered Increasing the flow of oil to the winch 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 returned to neutral or hold the pilot 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 position ing no oil flow actually occurs through the winch motor The pressure will build up to a point where the friction 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 The friction brake receives very little wear in the lower ing 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 WINCH INSTALLATION 1 The winch should be mounted with the centerline of the drum in a horizontal position The mounting plane of the base may be rota
16. en nennen rsen eene nnns 8 PREVENTIVE MAINTENANCE RECOMMENDED OIL CHANGE INFORMATION ene 9 Mie zeiselcem 11 WINCH DISASSEMBLY iti erre tue te Pre edu e Red dne 15 PLANET CARRIER SERVICE petet etur red vested ee pe tec tan 17 MOTOR SUPPORT BRAKE CYLINDER SERVICE eee 19 BRAKE CLUTCH SERVIGE 2 rtr rtl te rd edi D rrt a 23 WINCH ASSEMBLY niet ttl tette a dan re ke egit Pea eu dade 25 BRAKE VALVE SERVICE rtr tenter treinta e oeenn era an idian 27 REVERSING DIRECTION OF DRUM ROTATION eneeenee en 29 RECOMMENDED FASTENER TORQUE serene 30 Safety and informational callouts used in this manual include A WARNING A A CAUTION A 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 This symbol is used for informational callouts or service tips 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 GENERAL SAFETY RECOMMENDATIONS Safety for operators and ground personnel is of prime concern Always take the necessary precautions to ensure safety to others as well as yourself To ensure safety the prime mover and winch must be operated with care and concern by the
17. en replacing steel brake discs the motor support or brake cylinder care must be taken to properly identify the correct parts Splined discs and their mating motor support and brake cylinder will remain available as spare parts New lobed steel brake separator plates and motor support Note groove on outside diameter of motor support Although most photos in this section show splined discs all procedures are the same except where specifically noted DISASSEMBLY 1 After removing the motor support and brake clutch assembly continue brake cylinder disas sembly by removing the spacers friction brake discs and steel brake discs 2 Remove the piston back up ring and pressure plate 3 Remove the brake springs CLEAN AND INSPECT 1 Thoroughly clean and inspect all parts at this time Check brake piston sealing surfaces on brake cylinder and motor support Be sure brake release port is free of contamination 2 Check oil seal and bearing surfaces on brake cylinder for damage or wear ASSEMBLY 3 Place friction brake disc on flat surface and check for distortion with a straight edge Friction material should appear even across entire sur face with groove pattern visible Replace friction disc if splines are worn to a point disc is distort ed friction material is worn unevenly or groove pattern is worn away 1 Begin assembly by placing motor support on workbench with motor mounting sur
18. ents 1 Spring applied multiple friction disc brake pack 2 Over running brake clutch assembly 3 Hydraulic brake cylinder and spring plate The static brake consists of alternately stacked friction and steel brake discs The steel brake discs are exter nally splined to the motor adapter and cannot rotate The friction discs are internally splined to the outer brake hub of the over running brake clutch When com pressed by spring force the brake pack locks the over running brake clutch outer brake hub to the motor adapter The static brake is released by the pilot pressure at a pressure lower than that required to open the pilot oper ated brake 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 friction brake is primarily a load holding brake and will provide dynamic braking only during extremely slow operation when there is insufficient flow to open the brake valve The sprag type over running brake clutch is installed between the inner brake race and the outer brake hub The over running brake clutch allows the inner brake race and input shaft to turn freely in the direction to haul in cable and locks up to force the friction brake discs to turn with the inner brake race and input shaft to pay out cable The brake pack remains fully applied when haul ing in cable and must be released by pilot pressure to allow the brake discs to t
19. etainer from one end only 2 Pull the inner race out Examine the race for scor ing wear or indentations caused by the sprag cams 3 Use a screwdriver and mallet to remove the sprag bushing from one end of the outer race There are four special cut outs in the bushing for this purpose Be careful not to damage the bushing inside sur face If a bushing s inside surface is damaged or shows wear replace it 23 Next slide the sprag clutch out inspect the sprag clutch closely for abnormal wear cracks pitting or corrosion Check small clips for breakage or bright spots the signs of excessive wear Unless the outer race or remaining sprag bushing is damaged or shows excessive wear there is no need for fur ther disassembly f disassembly is necessary remove the bushing according to the procedure covered in Step No three 3 All brake clutch assembly parts should be thoroughly cleaned and inspected before assembly A WARNING A The polished surfaces of the races and sprag cams must be perfectly smooth to insure positive engage ment of the clutch The slightest defect may reduce brake clutch effectiveness which could result in property damage severe personal injury or death The entire brake clutch assembly must be replaced if inner race outer race and or sprag cams are defective ASSEMBLY Press a sprag bushing into the outer race using a mechanical or hydraulic press A flat plate of approximately t
20. face down Install new O ring and back up ring as shown 4 Place steel brake disc on flat surface and check for distortion with a straight edge Check surface for signs of material transfer or heat Replace steel disc if splines are worn to a point disc is distorted or heat discolored 2 Install a brake spacer into the motor support Not required with lobed discs 5 Check brake spring free length minimum free length is Model Spring minimum free length BG8A 13 16 in 30 2 mm BG8B 15 16 in 23 81 mm Check springs for any sign of cracking or failure If a brake spring must be replaced for any rea son then ALL brake springs must be replaced A CAUTION A Failure to replace brake springs as a set may result in uneven brake application pressure and repeated brake spring failure 20 3 4 5 Insert first a steel brake disc against the spacer followed by a friction brake disc then alternate steel and friction discs until seven 7 friction and eight 8 steel discs have been installed Finish with a steel brake disc on top NOTE It is a good practice to pre lubricate the discs in light motor oil prior to assembly Install the remaining brake spacer on top of the last steel brake disc This is the only spacer used with lobed discs To check brake stack height place pressure plate on top of brake spacer
21. he brake cylinder and carefully install brake cylin der into base and drum Be careful that the brake cylinder pilot fits into the thrust washer on the pri mary planet carrier When correctly installed the brake cylinder will fit against the winch base 13 Install and tighten brake cylinder capscrews and lockwashers Tighten to recommended torque 14 Install the brake clutch assembly When installed correctly the cam should turn freely in the opposite direction the drum turns to pull wire rope in An easy way to check the rotation is to hold the outer race in one hand and rotate the cam 26 15 16 17 18 If the brake discs are misaligned preventing the installation of the clutch apply 750 1000 psi 5170 6900 kPa to the brake release port with a hand pump The brake discs will move freely with the brake released permitting alignment of the discs brake clutch and input sun gear Install a new o ring on the motor pilot then lubricate with petroleum jelly or gear oil Engage the motor shaft with the inside race of the brake clutch and lower motor into place Install and tighten cap screws to recommended torque Install the hoses and fittings to the brake cylinder release port manifold and brake valve After the winch assembly is complete check all capscrews and fittings to make certain they have been tightened correctly Refill the winch with the recommended oil listed under Preventive Maintenance a
22. he same diameter as the bushing flange outside diameter should be placed between the press and bushing during assembly to protect the bushing Be certain the bushing flange is against the shoulder in the outer race 2 Turn the assembly over and install the sprag clutch in the bore of the outer race 3 Press the remaining bushing into the race Again make sure the bushing is against the shoulder 4 Next install a sprag bushing retainer then a snap ring on the inner race Be sure the snap ring is seated in the snap ring groove 5 Slide the inner race through the bushings and sprag clutch the race will have to be rotated in the free wheeling direction to start it through the sprag clutch If the inner race will not go through the bushings the bushings have probably been dam aged and should be replaced 24 Install the second retainer and snap ring Make certain the snap ring is seated in the groove prop erly A WARNING A 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 this snap ring is omitted WINCH ASSEMBLY 1 Place winch base on side with bearing support end 5 Stand winch on bearing support end and install up snap ring on bearing support 2 Install a new bearing in the drum if replacement is C
23. he wire rope is installed on the hoist drum pass the wire rope through all reeving and extend the boom to maximum length and height to reel out as much wire rope off the drum as possible until you reach the last five wraps Apply a one ton weight to the hook and slowly reel in the wire rope while an assistant monitors the cable spooling at a safe distance from the hoist drum If necessary stop reeling in while the assistant packs the wire rope tightly Resume spooling on the wire rope only after you are certain the assistant is a safe distance from the hoist drum and wire rope PREVENTIVE MAINTENANCE A regular program of preventive maintenance for your To drain the gear oil align the drain plug in the planetary winch is strongly recommended to minimize drum with the hole in the support side of the base the need for emergency servicing and promote safe Install a short piece of 1 in pipe into the threaded reliable winch operation drum port to prevent oil from draining onto winch base NOTE The service intervals suggested in this manual Insert a wrench through the 1 in pipe and remove will optimize component service life The intervals may the drain plug Install plug securely after oil has be gradually increased or decreased with experience of been drained Refill with recommended planetary a particular lubricant and the recommendations of an gear oil Capacity is 4 U S pints 1 9 I independent oil analysis All service intervals are s
24. into inside surface of drum teeth for nicks spalling or excessive wear Replace if wear is greater than 0 015 in 0 4 mm when compared to unworn area of teeth PLANETARY CARRIER SERVICE OUTPUT PLANET CARRIER DISASSEMBLY 1 Remove the planet gears by driving the roll pins into the center of the planet shafts 2 Use a punch to drive the roll pins from the planet shafts Do not reuse the roll pins 3 Now you can remove the planet shafts bearings spacer 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 17 1 discoloration material displacement or abnormal wear the bearing should be replaced Likewise the cage should be inspected for unusual wear or defor mation particularly the cage bars If there is any damage that will impair the cage s ability to sepa rate retain and guide the rollers properly the bear ing 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 pit ting Replace if necessary ASSEMBLY Place the output planet carrier on workbench with splined coupling side down Install output thrust plate in center of carrier Insert two 2 bearings and a bearing spacer into a gear with the
25. l spread apart each time the load is removed Then when winding 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 winch may have been over Replace wire rope and conduct loaded causing permanent set in the operator rigger training as required wire rope DISASSEMBLY OF WINCH SERVICE PRECAUTIONS Before any part is removed from the winch all serv ice instructions should be read and understood Work in a clean dust free area as cleanliness is of utmost importance when servicing hydraulic equip ment Inspect all replacements parts prior to installation to detect any damage which might have occurred in shipment Use only genuine BRADEN replacement parts for optimum results Never reuse expendable parts such as oil seals and O rings Inspect all machined surfaces for excessive wear or damage before reassembly operations are begun Lubricate all O rings and oil seals with gear oil prior to installation Use a sealing compound on the outside surface of oil seals and a light coat of thread sealing compound on pipe threads Avoid getting thread compound inside parts or passages which conduct oil Thoroughly clean all parts in a good grade of non flammable safety solvent Wear protective clothing as required After troubleshooting the winch and its hydraulic system as covered in the Troubleshooting section and the prob
26. le lift the brake cylinder assembly out of the drum and base being careful to avoid damaging the sealing and bearing surfaces Refer to Motor us Support Brake Cylinder Service for additional information 7 BG8A ONLY Remove the drum closure Remove and discard the o ring from the inside of the drum Remove the seal from the drum closure BG8B The seal is mounted in the drum Remove the seal and drum closure from the drum 8 Clean and inspect the bearing in the drum closure and replace if required 12 13 14 9 Remove the primary sun gear and thrust washer 19 from the primary planet carrier 16 NOTE 23 1 gear ratio winches have a sun gear adapter in addition to the sun gear shaft 10 Remove the primary planet carrier from the drum Refer to Planet Carrier Service for additional infor mation Remove the output sun gear and thrust washer from the output planet carrier By Remove the output planet carrier from the drum Refer to Planet Carrier Service for additional infor mation Remove snap ring from bearing support Stand winch on motor end with bearing support up then remove bearing support capscrews and bear ing support being careful to avoid damaging the sealing and bearing surfaces Slide drum out of base onto a work bench and remove seal and bearing from support end Thoroughly clean and inspect drum and base Check ring gear machined
27. lem is determined to be in the winch use the fol lowing procedure to disassemble the winch Oil Drain Opening Remove the wire rope from the winch drum and align the drain hole in the drum with a hole in the support side plate before removing the hoses and mounting bolts After the winch is removed from its mounting thoroughly clean the outside surfaces To drain the oil install a short piece of 1 inch pipe in the larger threads of the drain hole If necessary insert a bar into the anchor pocket and manually rotate the drum in the direction to hoist a load until the drain holes are aligned 2 Use a 5 16 inch Allen wrench to remove the drain plug through the pipe Drain the oil into a suitable container and dispose of used oil in an environmen tally friendly manner Begin disassembly by removing the oil level plug and standing the winch on the bearing support end Tag and remove the hydraulic hoses that connect the brake valve and manifold to the brake cylinder Remove the capscrews securing the motor and lift the motor off the winch Remove and discard the O ring installed on the pilot of the motor Remove the brake clutch assembly from the motor support Refer to Brake Clutch Service for addi tional information 6 Remove the brake cylinder capscrews and install two 2 capscrews and a short piece of chain into the motor mounting bolt holes Using the chain as a hand
28. nchor pocket Loop the wire rope and push the free end about 3 4 of the way back through the pocket Install the wedge then pull the slack out of the wire rope The wedge will slip into the pocket and secure the wire rope into the drum The standard cable anchor or wedge shipped with the hoist P N 74780 will anchor 3 8 to 9 16 inch 10 14 mm wire rope For 1 4 to 5 16 inch 6 8 mm wire rope use P N 24119 For 5 8 to 34 inch nylon or polyester rope use P N 26095 A WARNING A The cable anchor or wedge is designed to hold rated load when installed correctly with properly prepared wire rope Always maintain a minimum of five 5 complete wraps of wire rope on the drum As a visu al safety warning paint the last five wraps of wire rope red Failure to properly install the cable anchor or wedge and keep five wraps of wire rope on the drum may result in a dislodged cable anchor or wedge and loss of load control property damage and severe injury to personnel or death Incorrect Installation F WF fl fiL i Ew Lr q Xa SW d v 7 il iban i Wedge pulled too 4 Wedge not al M far through tl fully seated 4 anchor pocket M CENA MI SSS Me eT Figure 10 Maintain even tension of approximately one ton on the wire rope when spooling it onto the cable drum DO NOT pinch wire rope through wood blocks to maintain tension as the wire rope may be permanently damaged After t
29. nd install the oil level plug Operate the winch slowly in both directions and check for oil leaks and or unusual sounds from the winch The winch should operate smoothly in both directions Refer to WIRE AND BRAIDED ROPE INSTALLATION and properly install rope onto the winch drum Before returning the winch 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 winch should also be able to slowly lower the load in a smooth and controlled manner If the winch does not perform either of these func tions refer to TROUBLESHOOTING for addition al information BRAKE VALVE SERVICE The BRADEN brake valve is a reliable hydraulic valve with internal components manufactured to close tolerances Due to the close tolerances and mating of components the valve housing spool pis ton and check poppet are not available as replace ment parts Before disassembling the brake valve be sure you have conducted all applicable troubleshooting oper ations 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 com ponents SECTION A A 0 7 Z SS Yd 22 3 12 DRAIN PORT eA o A lea 4 Loe 7 UU z
30. ng 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 dis connect the brake release hose at the motor port Stand winch up on drum support with the motor end up and secure in this position 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 Remove the capscrews securing the motor to the winch and carefully remove the motor 3 Remove the brake clutch assembly from the motor support Turn the clutch over and re install 29 it into the center of the brake pack Be sure the inner race engages the input planet gear shaft Install a new O ring on the motor pilot Rotate the motor 180 from its original position and install it onto the winch Install and tighten motor capscrews to recommended torque Install new O rings in the brake valve and mani fold block Attach the brake valve and manifold block to the motor using the original capscrews and tighten to recommended torque Connect the motor case drain hose to the motor case drain port If your winch had the brake release hose con nected directly to the motor the original motor port must be plugged and the ho
31. ntenance section of this man AVEA OTU ual 20 Use recommended hydraulic oil and gear lubricant An equipment warm up procedure is recommended 21 Keep hydraulic system clean and free from contam for all start ups and is essential at ambient temper ination at all times atures below 40 F 4 C Refer to Warm up 22 The BRADEN GEARMATIC wire rope anchors are capable of supporting the rated load when installed properly For additional safety ALWAYS maintain a minimum of five 5 wraps of wire rope on the drum THEORY OF OPERATION DESCRIPTION OF WINCH The winch has three basic assemblies 1 Hydraulic motor assembly and brake valve 2 Cable drum assembly 3 Brake cylinder and motor adapter The hydraulic motor is bolted to the motor adapter which in turn is bolted to the brake cylinder and the winch base The cable drum assembly is supported by anti friction bearings which are located by the brake housing at one end and the bearing support at the other end The ring gear for both planetary sets is machined on the inside surface of the cable drum PLANETARY GEAR TRAIN 7 7 Power Flow A hoisting The hydraulic motor shaft is directly coupled to the inner brake hub which is connected to the input shaft which acts as the sun gear for the primary planetary set When driven by the input shaft the primary planet gears walk around the ring gear machined in the cable drum and drive the
32. operator for the equipment and a thorough knowledge of the machine s performance capabilities The following recommendations are offered as a general safety guide Local rules and regulations will also apply Read all warning and caution tag information and become familiar with all controls before operating winch Procedure listed in the Preventive Maintenance section of this manual 10 Be sure of equipment stability before operating winch 11 The winches described herein are neither designed Never attempt to clean oil or perform any mainte nor intended for use or application to equipment nance on a machine with the engine running used in the lifting or moving of persons unless instructed to do so in this manual 12 Do not exceed the maximum pressure or flow stat Never operate winch controls unless you are prop ed in the winch specifications erly positioned at the operators station and you are 13 Operate winch line speeds to match job conditions sure personnel are clear of the work area Avoid sudden shock loads or attempting to jerk Assure that personnel who are responsible for hand load free This type of operation may cause heavy signals are clearly visible and that the signals to be loads in excess of rated capacity which may result used are thoroughly understood by everyone in failure of cable and winch Ground personnel should stay in view of the opera 14 Leather gloves should be used when handling tor
33. p procedure is recommended at each operating hours or six 6 months whichever start up and is essential at ambient temperatures occurs first below 40 F 4 C The prime mover should be run at its lowest recom mended RPM with the hydraulic winch control valve in neutral allowing sufficient time to warm up the system The winch should then be operated at low speeds forward and reverse several times to prime all lines with warm hydraulic oil and to circu late gear lubricant through the planetary gear sets A WARNING A Failure to properly warm up the winch 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 8 Oil Analysis We recommend an oil analysis be conducted on the gear oil at regular intervals Wear metals should be monitored for early detection of problems and lubricant effectivity In severe applications the winch should be completely disassembled to inspect for excessive wear every 2 000 hours of operation or 12 months whichever occurs first Recommended Planetary Gear Oil Field experience supported by extensive engineer ing tests indicates the use of the proper planetary gear oil is essential to reliable and safe operation of the brake clutch and obtaining long gear train life For simplicity BRADEN has listed one 1 readily a
34. pecified for operating hours of the prime mover Vent Plug above drum centerline Oil Level Plug 1 Oil Level 3 Vent Plug The gear oil level should be checked every 500 The vent plug is located in the drum support as operating hours or three 3 months whichever shown It is very important to keep this vent clean occurs first To check the oil level remove the large and unobstructed Whenever gear oil is changed plug located in the center of the drum support The remove vent plug clean in solvent and reinstall oil should be level with the bottom of this opening Do not paint over the vent or replace with a solid If additional oil in needed refer to Recommended plug Planetary Gear Oil 4 Hydraulic System The original filter element should be replaced after the first fifty 50 hours of operation then every 500 operating hours or three 3 months or in accor dance with the equipment manufacturer s recom mendations Wire Rope Inspect entire length of wire rope according to wire rope manufacturers recommendations 6 Mounting Bolts Tighten all winch base mounting bolts to recom mended torque after the first one hundred 100 hours of operation then every 1000 operating Oil Drain 5 Opening 2 Oil Change hours or six 6 months whichever occurs first The gear oil should be changed after the first one 7 Warm up Procedures hundred 100 hours of operation then every 1 000 A warm u
35. r m h feet second ft sec feet minute ft min TEMPERATURE Celsius 0 556 F 32 Fahrenheit 1 8 C 32 COMMON METRIC PREFIXES 1 000 000 or 106 1 000 or 10 100 or 10 10 or 10 deci centi milli micro 0 1 or 10 0 01 or 10 0 001 or 10 0 000 001 or 10
36. ressure If it is determined a brake ly requires no further adjustment The brake valve valve adjustment is required the entire brake can be manually piloted open by its adjusting screw valve should be replaced Manually opening the brake valve could cause The brake valve cartridge is easily removed from internal winch damage and may cause loss of load the valve block for cleaning inspection or control during lowering operations which may result replacement but is not designed to be disas in property damage personal injury or death sembled in the field In the event it has been determined the brake valve should be disassem bled the entire cartridge should be replaced 10 A The winch will not lower the load or not lower the load smoothly Oil leaks from vent plug TROUBLE SHOOTING 1 The problem could be a plugged or loose pilot orifice The pilot orifice is a small pipe plug with a hole drilled through it located behind the pilot port fitting on the brake valve If it becomes plugged it will prevent the pilot pres sure 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 which causes erratic brake valve operation 2 The friction brake may not be releas ing as a result of a defective brake cylinder seal NOTE If the brake cylinder seal is defective you will usually find oil leaking from the winch vent plug
37. rs and oil Install new motor seal TROUBLE PROBABLE CAUSE REMEDY C The brake will not hold a load with the control lever in neutral D The winch will not hoist the rated load 1 Excessive system back pressure acting on the brake release port 2 Friction brake will not hold due to worn or damaged brake discs 3 Brake clutch is slipping 1 The winch may be mounted on an uneven or flexible surface which caus es distortion of the winch 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 3 Be certain hydraulic system temper ature is not more than 180 degrees F Excessive hydraulic oil temperatures increase motor internal leakage and reduce motor performance 4 Winch line pull rating is based on 1st layer of wire rope 5 Rigging and sheaves not operating efficiently The same as Remedy 2 of Trouble B2 Same as Remedy 3 of Trouble A3 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 winch with recom mended planetary gear oil listed in Preventive Maintenance Brake clutch may be damaged or worn Disassemble and inspect brake clutch as described in Brake Clutch Service Reinforce mounting surface If necessary use shim stock
38. se connected to the motor pressure port near the manifold block lowering port Operate the winch slowly in both directions and check for oil leaks and or unusual sounds from the winch The winch should operate smoothly in both directions Refer to WIRE AND BRAIDED ROPE INSTALLATION and properly install rope onto the winch drum Before returning the winch 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 winch should also be able to slowly lower the load in a smooth and controlled manner If the winch does not perform either of these func tions refer to TROUBLESHOOTING for addition al information RECOMMENDED FASTENER TORQUE 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 Lubricated torque values based on use of SAE 30 wt engine oil applied to threads and face of bolt or nut Avoid using thread lubricants as the applied torque may vary by 10 40 depending upon product used eae LB FT Torque LB FT GOS TES Dia Thds Per Inches meh 0 E D 2 Bolt Dia Thds Per Grade5 Inches Inch 5 16 r c o D N n2 o C1 TM A D ce C1 A c1 oo N o AB ce R n2 eo o eo pers eo N c E k c1 C2 N o O1 C1 C1 C5 ee a a e jak o1 co
39. spacer between the bearings Place a thrust washer on each side of the gear and posi tion in a carrier opening Slide the shaft through the carrier thrust washer bearing gear sub assembly and remaining thrust washer 3 Carefully align the pin hole in the carrier with the hole in the planet gear shaft and drive the roll pin into place Always use NEW roll pins 4 Note that the roll pin is slightly recessed in the car rier when properly installed With a center punch stake the carrier next to the pin hole as shown This will distort the hole so the pin will not back out Repeat these steps for each of the three planet gears PRIMARY PLANET CARRIER 1 To service the primary planet carrier the steps are the same as for the output carrier except there is only one bearing for each gear and no bearing spacer NOTE All BG8 winches have a round thrust plate hie the primary and output sun gears In winches with a 23 1 ratio the plate is not con tained in the primary planet carrier In all other ratios the thrust plate is captive in the carrier assembly MOTOR SUPPORT BRAKE CYLINDER SERVICE NOTE Starting late 2000 Braden changed the steel brake separator discs from a splined tooth design to a lobed design This required a change to the motor support and brake cylinder and the addition of a spring spacer A winch with the lobed discs can be identified by a machined groove on the outside diam eter of the motor support Wh
40. ted in any position around this centerline 2409 S2 t Nim IA f eS ae SE Berth paste DA 2 Because of the design of the mounting base the direction of line pull should only be as shown in the above illustration Line pulls in any other direction must be approved by BRADEN Engineering 4 THRU HOLES 0 656 in 17 mm 5 813 in 148 mm 11 625 in 295 mm 3 When mounting the winch use all four 4 mounting holes and grade 5 8 8 or better bolts and nuts Tighten to recommended torque It is important that the winch is mounted on a surface that will not flex when the winch is in use and cause binding of the gear train Binding in the gear train will result in accelerated wear and heat Also be sure the winch is mounted on a flat surface If necessary use shim stock to insure the mounting surface is flat within 0 020 in 0 5 mm VENT PLUG ABOVE CENTERLINE 4 The vent plug must always be located above the hor izontal centerline If the winch is mounted on a pivot ing surface be sure vent plug remains above the centerline in all positions If necessary reposition bearing support and vent plug as follows A Remove bearing support bolts
41. to level winch Refer to Winch Installation First loosen then evenly retighten all winch mounting bolts to recommended torque Check relief pressure as follows A Install an accurate 0 4000 psi 27 580 kPa gauge into the inlet port of the brake valve B Apply a stall pull load on the winch while monitoring pressure C Compare gauge reading to winch 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 disas sembly or replacement Same as remedies for Trouble D1 amp D2 Same as remedies for Trouble E2 TROUBLE PROBABLE CAUSE REMEDY TROUBLE D CONTINUED FROM PREVIOUS PAGE E The winch runs hot 4 Winch line pull rating is based on 1st layer of wire rope 5 Rigging and sheaves not operating efficiently 1 Same as D1 2 Be certain that the hydraulic system temperature is not more than 180 degrees F Excessive hydraulic oil tem peratures may be caused by A Plugged heat exchanger B Too low or too high oil level in hydraulic reservoir C Same as D2 D Hydraulic pump not operating effi ciently 3 Excessively worn or damaged inter nal winch parts Refer to winch performance charts for additional information Perform rigging service as recommended by crane manufacturer Same as remedies for Trouble D1 Thoroughl
42. ug is located above the horizon tal centerline for the intended application Oil leak age may occur if vent is positioned incorrectly 9 Install the primary planet carrier meshing the plan 4 Tighten the bearing support capscrews to the rec et gears with the ring gear and the planet housing ommended torque with the output sun gear 25 A CAUTION A When all components are correctly installed the pri mary planet gears will be approximately 3 8 in 9 5 mm below the ring gear as shown above Binding and damage to the gear train may result if one or more of the thrust washers is incorrectly installed DO NOT proceed with assembly if the primary planet gears are not engaged with the ring as shown in the drawing above Check the location of all thrust washers to be sure they are properly posi tioned 10 Install a new bearing in the drum closure if required BG8A ONLY Apply a non hardening sealant on the outside surface of a new oil seal Install with spring side of the seal toward the bearing using a flat plate to avoid distortion Install a new o ring in the drum 11 Lubricate the drum opening with petroleum jelly or gear oil and install the drum closure into the drum BG8B ONLY Apply a non hardening sealant on the outside surface of a new oil seal Install with spring side of the seal toward the drum closure using a flat plate to avoid distortion 12 Lubricate the pilot oil seal and bearing surfaces of t
43. ur nearest BRADEN GEARMATIC deal er or the factory Service Department at 1 918 251 8511 Monday Friday 8 00 a m to 4 30 p m CST or by FAX at 1 918 259 1575 Provide the complete winch model and serial number when making inquiries The model and serial numbers are stamped into the base to the left of the hydraulic motor PARTS AND SERVICE BRADEN GEARMATIC provides parts and service through a network of authorized dealers Parts and service are not available directly from the factory For the name of your nearest dealer consult your local phone directory or call us at the phone number shown above EXPLANATION OF MODEL NUMBER BG DESIGNATES BRADEN GEARMATIC 8 DESIGNATES 8 000 LB APPROXIMATE FIRST LAYER LINE PULL B DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES 34 DESIGNATES TOTAL GEAR REDUCTION nd 23 23 06 1 34 34 2 1 59 59 06 1 69 23 12306 Lower 039 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN REV DECIMAL POINT ELIMINATED EXAMPLE 039 3 9 CU IN REV 01 DESIGNATES THE DRUM OPTION 1 PERMITS TESTING AND INSPECTION PER API 2C RECOMMENDATIONS TABLE OF CONTENTS FOREWORD faci 1 MODEL NUMBER EXPLANATION eeeereeeennenn duon emeret ene 1 GENERAL SAFETY RECOMMENDATIONS eene enne 3 THEORY OF OPERATION abicere teret E ect t ei o e Pr en 4 WINCH INSTALLATION eese nennen nennen nnren e aaa 6 WIRE ROPE INSTALLATION nenn
44. urn freely and pay out cable DUAL BRAKE SYSTEM OPERATION When hoisting or pulling a load the brake clutch allows free rotation of the inner brake race and input shaft The sprag cams lay over and permit the inner race to turn free of the outer brake hub Figure 2 The friction brake remains fully engaged The winch in raising a load is not affected by any braking action during haul in STATIC FRICTION BRAKE APPLIED IN LR AUR i SPRAG CAMS p PERMITS FREE SHAFT ROTATION WHILE HOISTING Figure 2 When the haul in operation is stopped the load attempts to turn the input shaft in the opposite direction This reversed input causes the sprag cams to instantly engage and firmly lock the inner brake race to the outer brake hub Figure 3 STATIC FRICTION BRAKE APPLIED al DE elles n E IN TI SPRAG CAMS Figure 3 LOAD ATTEMPTS TO ROTATE SHAFT IN OPPOSITE DIRECTION BRAKE CLUTCH LOCKS SUN GEAR SHAFT TO FRICTION BRAKE When the winch is powered in reverse to pay out cable the motor and gear train will not rotate until suffi cient pilot pressure is supplied to open the brake valve The friction brake within the winch will
45. vailable product in each temperature range which has been tested and found to meet our specifica tions This is not to say that other lubricant brands would not perform equally as well If the following lubricant brands are not available in your area make certain your lubricant vendor sup plies you with oil that is equivalent to those prod ucts listed below BRADEN planetary winches are factory filled with Exxon Spartan 150 or equivalent AGMA No 4EP gear oil PREVAILING AMBIENT TEMPERATURE F 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 F MOBILGEAR 600 XP 220 OR EQUIVALENT AGMA 5 EP ISO VG 220 MOBILGEAR 600 XP 150 OR EQUIVALENT AGMA 4 EP ISO VG 150 MOBILGEAR SHC 150 SYNTHETIC OR EQUIVALENT C 40 30 20 10 0 10 20 30 40 50 C NOTE SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS OFFSHORE li CRANES SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING Planetary hoists are factory filled with Mobilgear 600 XP 150 or equivalent Consult your oil supplier for other equivalent oils if required wm O Ge O Te Mobilgear 600 XP 150 Omala 150 Gear Compounds EP 150 Meropa 150 Mobilgear 600 XP 220 Omala 220 Gear Compounds EP 220 Meropa 220 071 MOTOR The brake valve cartridge may be unique in that m PN WARN N G A turning the adjusting screw in clockwise lowers The brake valve cartridge is factory set and normal the release p
46. y clean exterior and flush interi or Fill drain to proper level Same as remedies for Trouble D2 Prime mover low on horsepower or R P M Tune adjust prime mover Check suction line for damage If pump is belt driven belts are slipping Replace tighten belts Pump worn Replace pump Disassemble winch to inspect replace worn parts TROUBLE PROBABLE CAUSE REMEDY Winch chatters while 1 Same as D2 Same as remedies for Trouble D2 raising ratod load 2 Hydraulic oil flow to motor may be Same as remedies for Trouble E2 too low 3 Controls being operated too quickly Conduct operator training as required G The wire rope does not 1 The winch may be mounted too Check mounting distance and fleet angle spool smoothly on the close to the main sheave causing the Reposition winch as required drum fleet angle to be more than 1 1 2 degrees 2 The winch may not be mounted per Refer to Winch Installation pendicular 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 rec lay rope There is a distinct advantage ommendation of wire rope that best suits in applying rope of the proper direction your application of lay When the load is slacked off the several coils on the drum will stay clos er together and maintain an even layer If rope of improper lay is used the coils wil
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