Braden winch or this manual
Contents
1. personal injury or death A safe distance of at least 1 1 2 times the working length of the rope or cable should be maintained by ground personnel Typical Winch Maneuver When possible position winch such that the centerline of the winch drum is perpendicular to the winch load The angle the winch must pull from fleet angle must not exceed 1 1 2 If the fleet angle exceeds 1 1 2 the cable will not spool correctly resulting in damaged cable and prematurely worn winch components Disengage the drum clutch as described earlier and pull cable off of winch drum If equipped apply shoe or band type drum brake to control drum over spin or birdnesting A WARNING A The small shoe and band type drum brakes are to be used to control drum over spin or birdnesting only They are NOT intended to control the winch load The worm gear set and safety brake are designed to hold the winch load Attempting to hold a load using a shoe or band type drum brake may result in the loss of a winch load property damage severe personal injury or death Avoid powering out winch cable as this practice causes unnecessary heat and accelerated wear of winch brake components Securely attach winch cable to load in such a manner to avoid damage to the load or cable Fully engage the drum clutch as described earlier A WARNING A Worm gear winch clutches may disengage and drop or lose control of a load if they are not fully engaged at the b2. underwound vs overwound refer to the winch Safety Brake section of this manual It should be noted that some winch models are de signed to operate without a worm shaft brake and rely on the worm gear set alone to hold the load A WARNING A On winches equipped with worm shaft brakes the wire rope must be installed for the correct direction of drum rotation for the brake to be effective Winding cable onto the winch with the brake set for opposite rotation may result in the loss of winch load control and cause property damage severe injury or death Generally speaking wire rope is secured to the cable drum by one of four common methods u bolt clamp set screw wedge and pocket or cable ferrule Refer to the procedure which matches your winch A WARNING Worm gear winch cable anchors u bolts set screws wedges etc are NOT designed to hold rated loads Winch loads applied directly to the cable anchor may cause the cable to pull free and result in the sudden loss of load control and cause property damage severe personal injury or death A minimum of 5 wraps of cable must be left on the drum barrel to achieve rated load Do not use knots to secure or attach winch cable We suggest that the last 5 wraps of cable be painted bright red to serve as a visual warning DIA U Bolt Clamp Prepare the end of the wire rope as recommended by the wire rope manufacturer Pass the wire rope through the U bolt clamp until the
3. 46 68 200 6 465 750 00 22 32 40 57 134 172 F 57 78 C 170 190 F 77 88 140 750 300 1 500 pump inlet cavitation will be the limiting consideration on most systems Cold Weather Operation Oils selected for use in cold weather operation should be selected in accordance with pump manufacturer s guidelines In general the minimum pour point of the fluid should be at least 20 F 11 C below the mini mum expected startup temperature Startup procedures should allow for a gradual warm up until the fluid reaches a reasonably fluid state Filtration Cleanliness of hydraulic fluid is of extreme importance Experience has shown that excessive contamina tion will severely affect component life In general a filter with a Beta 10 gt 20 and a system cleanliness of ISO 18 13 should be adequate for motors used on Braden products Other components in the hydraulic system may require a higher degree of filtration Direct Mount Hydraulic Motors Char Lynn The mounting flange support bearing and shaft seal has been eliminated from these motors to greatly reduce the package size of the winch when compared to conventional add on adapters and motors The orbital motor drive shaft couples directly to the winch worm shaft The conventional worm shaft oil seal and motor shaft seal are replaced by a quad ring seal and seal container which must separate the heavy worm gear oil from the hydrau
4. Front End of Truck ENGINE ROTATION OVER DRUM RIGHT HAND LEFT HAND UNDER DRUM LEFT HAND RIGHT HAND OPPOSITE ENGINE OVER DRUM LEFT HAND RIGHT HAND ROTATION UNDER DRUM RIGHT HAND LEFT HAND RIGHT HAND LEFT HAND WORM WORM pa When ordering designate worm and gear set as such Y N N R RA Right worm and gear set L RA Left worm and gear Q KUK BLA Right Hand Assembly Right Hand Assembly 2 R LA Right worm and gear set L LA Left worm and gear set LEFT HAND GEAR Left Hand Assembly Left Hand Assembly WINCH OPERATION Drum Clutch Operation Visually check that drum clutch is fully engaged shift handle at full travel or locked in detent before operat ing the winch drum under load WARNING DO NOT move the load the winch or the winch platform before making certain the drum clutch is set to engage and the clutch is fully engaged A partially engaged drum clutch may jump out of engagement A load on the winch line may prevent a partially engaged clutch from disengaging but any change in the load may allow the clutch to disengage unexpectedly This may cause a loss of load control which could result in property damage injury or death Procedure for Shifting Clutch where equipped A To Engage Clutch 1 Insure winch motor or PTO is not running and the winch cable and cable drum are not loaded The prime mover is stopped in neutral with parking brake set 2 Lift lock knob on
5. absorbs the inertia of the PTO gear train if so equipped A band type brake or small shoe type brake is installed on most worm gear winches to reduce wire rope birdnesting when the drum clutch is disengaged to pull wire rope out by hand These drum brakes are NOT designed for load holding WORM GEAR HOUSING 4 pores ANN l Vou 24 V WORM SAFETY BRAKE WORM WORM BEARINGS WORM SHAFT Terminology Often Used With Worm Gear Winches Starting Input Torque The torque applied to the winch input shaft required to start a rated load up ward from a suspended position It is expressed in pound feet pound inches kilogram meters or New ton meters May be referred to as static torque Running Input Torque The torque applied to the winch input shaft required to maintain upward move ment of rated load It is expressed in pound feet pound inches kilogram meters or Newton meters May also be referred to as dynamic torque Rated Input Speed The maximum permissible in put speed at rated load expressed in RPM Exceed ing rated input speed may cause damage to the worm gear set Full Drum or Maximum Layers A drum containing the maximum number of cable layers which would leave a freeboard of 0 7 x the cable diameter below the drum flange Drum Storage Capacity The maximum length of wire rope which may be wound on a cable drum without exceeding the maximum number of layers It is e
6. installed on Generally the worm gear housing is matched to the same side the power take off is mounted to the transmission to make routing of hoses or dive lines easier If the PTO is mounted to the right hand side of the transmission then specify RA for winch assembly LA for left hand PTO mount ing 3 The standard assembly configuration for low mount front bumper installations would position the input shaft or hydraulic motor toward the rear radiator 4 The standard assembly configuration for upright mounted installations would position the input shaft or hydraulic motor toward the front cab If the worm shaft is to point toward the rear wheels specify rear drive 5 The standard assembly configuration of the winch safety brake is always for overwind of the cable onto the winch drum If underwind drum rotation is required you must specify set brake for underwind 6 Power take off output shaft rotation is determined in relation to the vehicle engine It may be termed en gine rotation or opposite engine rotation Winches Mounted Behind Cab of Truck PLAIN HANGER 2 Speed Hanger Bearing BEARING H2 amp FH2 and PHD Power Take Off Direction of Worm and Gear Power Divider Rotation Spooling Required Worm and Gear Required ENGINE ROTATION OVER DRUM LEFT HAND RIGHT HAND UNDER DRUM RIGHT HAND LEFT HAND OPPOSITE ENGINE OVER DRUM RIGHT HAND LEFT HAND ROTATION UNDER DRUM LEFT HAND RIGHT HAND Winches Mounted on
7. screw the worm thread into engagement with the worm gear Place the input end bearing container and gaskets over the input end of the worm shaft Lift the worm shaft up into full engagement with the worm and push the bearing container into the orm gear housing Install the input end bearing container capscrews and tighten finger tight at this time Place the brake end bearing container and gaskets over the brake end of the worm shaft and support the worm shaft as you push the bearing container into the worm gear housing 32 Install the safety brake housing without rotor and discs and capscrews Evenly tighten the brake housing and bearing container capscrews to recommended torque Attach dial indicator base to worm gear hous ingtoplace probe of dial indicator squarely against the end of the worm shaft Grasp the cable drum and rotate firmly in one direction and hold constant tension Zero the dial indicator Now firmly rotate the drum in the other direction and hold constant tension Record the worm shaft end play and compare with specifications If too tight remove the bearing container capscrews and bearing container and add one shim at a time between the bearing container and the worm gear housing Then recheck end play If too loose remove one gasket at a time to achieve the recommended end play Complete end play adjustment procedure by reassembling the brake as described in Oil Cooled Safety Brake Service Retighten the bearing containe
8. the rotor housing disc area stationary while rotating the worm shaft in the haul in direction If the shaft turns free of the rotor housing in haul in it is correctly installed Install the outer friction disc pressure plate and leaf spring assembly refer to the draw ings following Install the brake housing using new gaskets and seals as required Evenly tighten capscrews to recom mended torque Refill the winch to the proper level with recommended oil 29 MS20 winches and larger In the drawing on the left the leaf spring is shown properly positioned Winches smaller than MS20 in the safety brake housing Note that it IS NOT located between the cast lugs The drawing on the right shows the leaf spring properly positioned in relationship to the pressure plate The dotted lines rep resent the position of the cast lugs in the housing when the pressure plate is in place A WARNING Periodic inspection and adjustment of the safety brake is required due to normal wear Failure to main tain the safety brake adjustment may prevent the winch from holding the maximum rated load securely Lossof control may result in property damage severe personal injury or death Note that the leaf spring is posi tioned between the cast ribs in the safety brake housing f the brake rotor is not installed for the proper direction of winch rotation the brake will not be effec tive wiich may result in the loss of load control and cau
9. to disengage unexpectedly This could result in loss of load control property damage injury or death S DO NOT attempt to engage drum clutch while cable drum is rotating B gt DO NOT attempt to disengage drum clutch with a load applied to the winch cable Engaging or disengaging the drum clutch while the cable drum is rotating or under load may result in damage to drum clutch components Damaged drum clutch components may disengage under load which could result in loss of load control property damage injury or death Refer to the appropriate BRADEN maintenance publication for more information Install this label near winch controls PN 100600 The warning label shown above is available through all Braden dealers Have your dealer order part number 100600 Itis a self adhesive weather resistant vinyl label that we recommend be installed near the winch controls of all Braden winches with a drum clutch Copyright 2008 PACCAR Winch Division All Rights Reserved 40
10. work surface so that the input shaft is away from you and the oil cooled safety brake is toward you The winch shown in drawing is a front drive left hand assembly with under winding cable spooling 2 Remove the drain plug and drain the oil into a suitable container as described previously 3 Remove the capscrews which secure the safety brake housing to the worm housing Remove the safety brake housing containing the leaf spring assembly and pressure place 4 Remove the outer friction disc Mark the outer surface of the safety brake rotor assembly to assist in reas sembly Remove the rotor assembly and inner friction disc Remove the bearing container from the worm housing Note the number and total thickness of the gaskets removed Gaskets may be reused if not dam aged 5 Using a pair of locking type pliers and a hammer remove the sprocket key from the input end of the shaft Remove any burrs or sharp edges on the shaft end and around the keyway to prevent damage to the shaft seal 6 Remove the input end bearing container Note the number and total thickness of the gaskets removed be cause the same amount thickness must be replaced to keep the original worm shaft end play adjustment Remove the worm shaft worm and bearing assembly from the worm housing by rotating the shaft until the worm thread is disengaged from the worm gear teeth 7 Insert the worm shaft into the opposite side of the worm housing and rotate the shaft to
11. 00 Ibs 53 4 KN or higher When properly serviced and adjusted this break will provide reliable ser vice for many years Description The oil cooled safety brake consists of a brake rotor assembly located between two friction discs An adjust able leaf spring assembly pushes against a pressure plate to hold the discs against the rotor The safety brake is located on the worm shaft of the winch and is contained in the brake housing The spring tension may be adjusted to compensate for component wear until wear limits are reached The adjusting nut is readily accessible without removing any parts from the winch A WARNING Slow unwinding of the cable drum under load may be a warning that the safety brake needs adjustment or repair Do not continue to use a winch with a worn brake Loss of load control may result in property dam age severe personal injury or death SPRING LOADED ROLLER PLUNGER The rotor assembly see illustration is actually a one way clutch which allows the worm shaft to turn freely in the haul in direction but immediately locks up when winch operation is complete and the load tries to back drive the winch When the winch is powered in the haul in direction the rotor driver turns free of the rotor disc due to the tapered design of the roller pocket When input power is removed and the load tries to drive the worm shaft in the opposite direction the rollers are forced to the narrow end of their pockets and
12. 08 203 149 12 1979 1485 3234 2427 18 OIL CAPACITIES AND WORM SHAFT END PLAY WINCH MODEL OIL CAPACITY WORM END PLAY Pints Lt Inches mm 7 8 21 002 007 05 18 5 8 15 002 007 05 18 MU2 M3 MS3 AMS3 MSU3 AMSUS 3 4 18 007 015 18 38 CM5 HCM5 EC4 LU4 ALU2 LGU2 ALGU2 8 08 OS4 1 47 007 015 18 38 MF6 2 95 218 1 07 3 1 42 212213 34 229 8 9 59 59 MS10 AMS10 MSU12 5 2 37 010 020 25 51 AMSU12 MU15 6 2 84 6 2 84 1015 025 38 64 7 3 31 015 025 38 64 7 1 2 3 55 010 020 25 51 7 1 2 3 55 001 006 025 15 000 002 00 05 OIL CAPACITY GIVEN FOR REFERENCE ONLY ALWAYS FILL TO LEVEL PLUG AS UNITS ARE OFTEN INSTALLED IN VARIOUS POSITIONS WHICH MAY REQUIRE MORE OR LESS OIL 36 COMMON HYDRAULIC EQUATIONS SHOWN IN U S UNITS To Find Example Motor Output System pressure PSI x Motor Size cu in Torque Starting x 1591 x Motor Starting Efficiency System Pressure 2500 PSI System Flow 35 GPM Motor size 6 Cu in Motor Starting Eff 70 2500 PSI x 6 cu in x 1591 x 70 eff 1670 in Ibs torque To Find Motor _ System Flow GPM 231 90 Vol Eff RPM Motor Size cu in Example 36 x 21 x 80 1213 RPM Motor Output Speed Find Input Torque Required in Ibs Example Input Torque Req
13. 1 Motor case drain optional Case drain not required unless peak backpressure exceeds 600 psi 4137 kPa If problems are encountered while shifting the motor the addition of a case dain line may resolve the problem 21 NORMALLY NORMALLY SERIES PARALLEL CASE DRAIN s Manual Override Auxillary Actuation Port Selector PORT A The main motor spool can be installed in either direction as shown above to reverse normal motor op eration Note that the spring is always on the side of the spool opposite the pilot port Normally Parallel spool position Solenoid de energized low speed high torque mode Solenoid energized high speed low torque mode Normally Series spool position Solenoid de energized high speed low torque mode Solenoid energized low speed high torque mode Motors are installed at the factory with the spool in the normally parallel position The two position manual override selector is also shown above The motor can be manually shifted if the solenoid is faulty or 12 volt power is unavailable Position 1 is the normal operating mode Position 2 is the equivalent of energizing the solenoid Note that with the selector in this position energizing the solenoid has no affect on motor operation PORT SIZES Port A amp B 10 SAE O Ring Boss 7 8 14 Thread Port T All 4 SAE O Ring Boss 7 16 20 Thread NOTE Long port adapters P N 102342 are used in ports A amp B to aid inst
14. 18 B L LA A DESIGN TESTED EET ANE TO SAE J706A ASSEMBIY RA RIGHT HAND BR BRADEN SPEED ASSEMBLY REDUCER DRUM FURNISHED BY CUST Re RIGHT HAND CONVERTIBLE BASE E amp EC HIGH EFFICIENCY RAE CONSTANT DUTY H HYDRAULIC DRIVE EB EXTENSION SHAFT M MECHANICAL DRIVE ONE SIDE ONLY MF MARINE FISHING EEB EXTENSION SHAFT INDUSTRY DESIGN BOTH SIDES OS OSHA SPEC DRUM SPL SPECIAL UT UTILITY INDUSTRY REDUCER DRUM UNIT CONTROLLED DRUM CLUTCH OFTEN FURNISHED BY ADJUSTABLE SHOE TYPE CUSTOMER DRUM BRAKE A REMOTE CONTROLLED DRUM CLUTCH SHOE TYPE DRUM BRAKE B REMOTE CONTROLLED ADJUSTABLE BAND TYPE 10 BASIC WINCH MODEL DRUM BRAKE AND DRUM CLUTCH 18 18 IN NOMINAL DRUM BARREL LENGTH BETWEEN DRUM FLANGES S SPACER ADDED BETWEEN WORM GEAR AND HOUSING GEAR CUT INFORMATION The following information will help you determine the cut of thread direction of the worm and worm gear and the assembly configuration of the worm gear housing designated in the winch model number Example R right cut gear set left hand assembly 1 All winch model assembly designations are specified for standing at the rear of the vehicle looking for ward Left side is often referred to as driver or street side right side may be referred to as passenger or curb side 2 The assembly designation for the winch RA LA describes which side of the winch the worm gear hous ing is
15. 567 0 2642 0 06102 0 03531 35 315 0 03381 liters l liters I liters I centimeters3 cc liters meters3 m3 milliliters ml x lt x x x gt x MASS 28 35 0 4536 907 18 0 90718 1013 05 grams g kilograms kg kilograms kg metric tons t kilograms kg 0 03527 2 2046 grams g kilograms kg kilograms kg metric tons t kilograms kg 1 1023 PRESSURE 3600 6 895 0 0703 0 069 bars 0 2488 kilopascals kPa 100 kilopascals kPa kilopascals kPa kilopascals kPa kilograms sq cm kg cm kilopascals kPa kilopascals kPa kilograms sq cm kg cm2 bars kilopascals kPa kilopascals kPa POWER 0 746 0 0226 kilowatts kW watts W kilowatts kW watts W TORQUE 0 11298 1 3558 1383 newton meters N m newton meters N m kilograms meter kg m newton meters N m newton meters N m kilogram meter kg m VELOCITY 0 11298 0 3048 0 3048 kilometers hour km hr meter second m s meter minute m min 0 6214 3 281 3 281 kilometers hour km hr meters second m s meters minute m 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 inches in feet ft miles mi 0 000155 inches sq in feet sq ft inches cu i
16. BRADEN RECOVERY WINCH INSTALLATION OPERATION AND PREVENTATIVE MAINTENANCE MANUAL This manual must always accompany winch and remain within easy access of winch operator Read and understand this manual before installing operating or servicing your Braden recovery winch PACCAR WINCH DIVISION PB 162 R3 Box 547 Broken Arrow Oklahoma 74013 4 2010 PHONE 918 251 8511 FAX 918 259 1575 Printed in U S A www paccarwinch com FOREWORD Read and understand this entire manual before operating or servicing your Braden winch Retain this manual for future reference The minimum service intervals specified are for operating hours of the prime mover This manual contains installation operation and preventive maintenance instructions for most current model Braden Worm Gear winches As there are many product variations you must become familiar with your Braden winch to fully benefit from the information contained in this publication Some illustrations in this manual may show details or attachments which may be different from your winch Also some components may be removed for illustrative purposes Whenever a question arises regarding your Braden winch or this manual please contact your nearest Braden dealer of the Braden Service Department at 918 251 8511 Monday Friday 8 00 am to 4 30 p m CST or by FAX at 918 259 1575 Provide the complete winch model and serial number when making inquiries Parts and Service Br
17. Conversion 38 Maximum Line Speedand Torque Information 39 2 GENERAL SAFETY RECOMMENDATIONS Safety informational callouts in this manual include A WARNING Warning This emblem is usedto warn againsthaz ardsandunsafepracticewhichcouldresultinsevere injury or death if proper procedures are not followed CAUTION A Caution This emblem is used to warn against potential or unsafe practices which could result in injury and product or property damage if proper procedures are not followed Safety for operators and ground personnel is of prime concern Always take the necessary precau tions to ensure safety of others as well as yourself To ensure safety the prime mover and winch must be operated with care and concern by the 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 WARNING A Failure to obey the following safety recommen dations may result in property damage injury or death 1 Read all warning tag information and become fa miliar with all controls before operating winch 2 Never attempt to clean oil or perform any main tenance on a machine with the engine or prime mover running unless instructed to do so in this manual 3 Never operate winch controls unless you are pr
18. To Find Torque Example Motor Size 6 37 cu in Requried To Drive _ Pump Size Cu in x System Pressure PS Pressure 2500 PSI PumpFt Lbs 2 x x x 90 Mech 72 637 x 2500 2815 Tx 31406 x 90 Dinh 2346 ft Ibs Line Pull x Radius Input Torque Reduction Ratio x Gear Efficiency 37 En 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 oz 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 60 F bars horsepower hp ft Ibs min pound inches in Ibs pound feet ft Ibs pound feet ft Ibs miles hour m h feet second ft sec feet minute ft min METRIC CONVERSION TABLE lish to Metric Metric to English LINEAR 25 4 0 3048 1 6093 millimeters mm meters m kilometers km 0 3937 3 281 0 6214 millimeters mm meters m kilometers km AREA 645 15 0 0929 millimeters mm meters m millimeters mm meters m 10 764 VOLUME 0 01639 0 94635 3 7854 16 39 28 317 0 02832 29 57 liters liters I liters I centimeters cc liters meters m millileters ml 61 024 1 0
19. able drum to take advantage of the worm shaft brake which is effective in one direction only SPRING MISSING OR WORN CORNER OF LOCK POCKET DO NOT USE SPRING SHARP CORNER OF LOCK POCKET GOOD To install the bayonet type capstan push the capstan onto the extension shaft against spring tension then turn counter clockwise viewed from the outside to the stop Release the capstan and verify that the spring has pushed the capstan outward into the lock position A WARNING Exposed areas of extension shafts and or capstan shafts are dangerous Clothing and other items may become tangled and wrapped around the shaft when rotating Appropriate guarding should be installed to prevent any part of the body or clothing from contacting the shaft when it is rotating Failure to provide ap propriate guarding could result in property damage injury or death Auxiliary Rigging Snatch Block An auxiliary sheave or Snatch Block as it is often called increases the versatility of the winch and is highly recommended for the following applications When fleet angles exceed 1 1 2 When winch loads exceed the safe winch or wire rope capacity When slower line speeds are required for precise load control Securely attach snatch block to anchor point following manufacturers recommendations Only use a snatch block of the recommended type and load capacity for your application Tree Protector If a winch cable or snatc
20. aden provides parts and service through a network of authorized dealers Parts and service are not avail able directly from Braden For the name of your nearest dealer consult your local phone directory or call Braden at the phone number shown above TABLE OF CONTENTS GENERAL SAFETY RECOMMENDATIONS 3 WORM GEAR WINCH TERMINOLOGY 5 THEORY OF OPERATION 5 WINCH MODEL NUMBER AND ASSEMBLY IDENTIFICATION 7 WINCH OPERATION Drum Clutch Operation cups aids rh ayama M ERE E 10 Basic Winch Operating Method 12 Winch Break In 13 Capstan Use isse diie peere ERERE UR Pad Ee tone nbus 13 A xillary RIGGING ee ouch nhe RP 14 WINCHINSTALLATION 16 PREVENTATIVE MAINTENANCE RecommendedPreventativeMaintenancelIntervals 26 Worm Shaft End Play Adjustment 27 Safety Brake Service amp 28 Assembly Change Instructions 32 SPECIFICATIONS Recommended Worm GearOil 34 Recommended Fastener Torque 35 Oil Capacity and Worm Shaft End Play 36 Common Hydraulic 37 Metric
21. adjust worm shaft end play as follows 1 Remove hydraulic motor and motor adapter from winch if equipped Remove safety brake housing if equipped Remove drive sprocket or sheave from worm shaft if equipped Retighten bearing container capscrews to recommended torque values from torque chart 2 Attach dial indicator base to worm gear housing and place probe of dial indicator squarely against the end of the worm shaft 27 3 Grasp the cable drum and rotate firmly in one direction and hold constant tension Zero the dial indicator Now firmly rotate the drum in the other direction and hold con stant tension Record the worm shaft end play and com pare with specifications 4 If too tight remove the bearing container capscrews and bearing container and add one shim gasket at a time be tween the bearing container and the worm gear housing Then recheck end play If too loose remove one gasket at a time to achieve the recommended 5 Complete end play adjustment procedure by re tightening the bearing container capscrews to the recommended torque refilling winch with recommended worm gear oil and adjusting the worm gear safety brake Refer to Oil Capacity And Worm Shaft End Play chart in Specifications section Safety Brake Service amp Adjustment Oil Cooled Type Brake Service and Adjustment The Braden oil cooled safety brake is installed on the model OS4 and all winches with a capacity rating of 12 0
22. allation of motor control lines Port Sizes Port A amp B 10 SAE o ring boss 7 8 14 Thread Port T All 4 SAE O ring Boss 7 16 20 Thread NOTE Long Port Adapters PN 103342 are used in Ports A amp B to aid installation of motor control lines 22 Low Speed Power elements in parallel solenoid de energized MASTER SPOOL High Speed Power elements in series solenoid energized 23 Wire Rope Installation All winches are rated at bare drum line pull As the cable drum fills the line pull will decrease loss of lever age as the line speed increases larger circumference Therefore install the minimum lenoth of cable pos sible for your application so that the winch will operate on lower layers smaller diameter and deliver the maximum line pull Using larger cable will not always increase strength as the larger cable may be more prone to bending fatigue failure than smaller wire rope Consult your wire rope supplier for his recommendations for the wire rope and other rigging which best suits your application Most winches utilize some type of worm shaft brake which acts with the worm gear system to hold the load Most of these brakes allow free rotation of the worm shaft in the haul in direction and lock up to provide resis tance in the pay out direction Install the wire rope so that when the worm shaft turns easily the wire rope is pulled in If you wish to wind the cable onto the drum for the opposite direction
23. and the worm gear set inspected c Refill winch to proper level with recommended worm gear oil Refer to Recommended Worm Gear Oil chart in Specifications section of this manual Worm Shaft End Play Adjustment When repairing the winch the worm shaft end play should be carefully checked Excessive worm shaft end lay will cause oil leaks around the worm shaft seals and greater heating and wear of the worm gear set Too little worm shaft end play will not allow for thermal expansion of the worm which may cause damage to the worm shaft bearings and bearing containers Worm shaft end play is adjusted by adding or removing gaskets between the worm gear housing and the bearing container Refer to the Oil Capacity and Worm Shaft End Play chart for specifications Before ad justing worm shaft end play the worm gear set should be inspected for excessive wear or shock load dam age Shock loaded gears may be distorted to the point where the self locking gear design no longer provides adequate braking action and the worm shaft safety brake repeatedly requires adjustment or slips under heavy loads Severely worn gears may not have adequate strength to withstand shock loads and heavy pulls If the gears have been distorted the tips of the gear teeth may appear to be leaning in one direction in rela tion to the gear tooth root Do not confuse this with the normal worm gear tooth helix angle Replace all worn or damaged parts as required Check
24. ap stan shaft Install guarding to prevent personnel from getting any part of body or clothing caught at a point where rope is wound onto a capstan cable is wound onto a cable drum or where rope and or cable is drawn through guide rollers 2 ei Install switches or valves which will shut off pow er to the drive or winch in locations where they can be reached by anyone entangled in the rope or cable before being drawn onto the capstan cable drum guide rollers or any pinch point 22 Deadman controls which automatically shut off power to the capstan drive or winch when ever the operator leaves his station should be installed whenever possible 23 Never allow anyone to stand under a suspended load 24 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 cable and or winch 25 Whenever possible install the capstan drive or winch in a location where the rotating capstan shaft or extension shaft is not adjacent to a nor mal operators station 26 All winch and or capstan controls shall be locat ed within easy reach of the operator The con trols shall be installed in such a location that the operator is removed from the electrical path to ground if the load rigging cable or rope come in contact with or within proximity to an energized conductor 27 All rope used on a capstan must be non con du
25. ation involves lifting loads and does not require the clutch to be disengaged Braden strongly recommends the drum clutch be mechanically locked in the fully engaged position to avoid acci dental disengagement of the clutch A WARNING A Accidental disengagement of the clutch while lifting or lowering a load may cause a loss of load control which could result in property damage injury or death 10 Procedure For Determining Condition of Clutch Lugs There is typically a negative draft angle on the load bearing faces of the clutch and drum lugs to prevent disengagement of the clutch under load Since these surfaces cannot be visually inspected on all winches without disassembling the winch the following procedure was devised to insure that the clutch lug condition is such that the clutch cannot disengage under load 1 Fully engage clutch as described above 2 Power about 10 feet 9 m of cable off the drum 3 Power in very slowly while holding 2 4 Ib 1 2 Kg of tension on the cable This tension must be maintained throughout the bal ance of this procedure The purpose of this step is to take up the EGATIVE slack in the power train and maintain a no slack condition RAFT 4 Stop the winch leaving the clutch engaged and approximately 3 feet 1m of cable off drum 5 Mark one line on or near the outside diameter of the drum flange and another on the worm gear housing adjacent to the first line 6 While maintaining cable tensi
26. brake drum One feature of this brake is that it may be adjusted for increased load requirements or it may be fully released for special applications It should be noted that the majority of a worm gear winch s braking effort is achieved by the inability to back drive the worm gear set The band type safety brake provides additional resistance to rotation of a worm shaft and absorbs the inertia of the P T O gear train if so equipped 31 ADJUSTING NUT EXTERNAL VIEW ADJUSTING NUT The brake band and cover must be installed over the brake drum so that the worm shaft can turn freely to haul in a load and must overcome the resistance of the brake band to pay out a load Adjustment Loosen the jam nut on the brake band stud next to the tension spring Turn the adjusting nut clockwise in 12 turn increments to tighten the brake and counter clockwise to loosen the brake When adjustment is com pleted tighten the jam nut Assembly Change Instructions This procedure provides instructions for changing Braden worm gear winches equipped with the oil cooled safety brake from a left hand assembly to a right hand assembly or from a right hand assembly to a left hand assembly No additional parts required NOTE There is a different housing for AHU7 LA winches and AHU7 RA winches which allows the hy draulic motor to bolt directly to the housing The new housing is needed to change the assembly on AHU7 winches 1 Place the winch on a sturdy
27. cting such that the operator is removed from the electrical path to ground if the load rigging or rope come in contact with or within proximity to an energized conductor WORM GEAR WINCH TERMINOLOGY AND THEORY OF OPERATION WORM GEAR CABLE DRUM SHAFT BEARING LEG BASE ANGLE The model shown above is a MS50 2B R RA The illustration shown above points out the basic components of a typical upright worm gear winch Torque is applied to the input end of the worm shaft by a PTO driven sprocket and chain or a hydraulic or electric motor The steel worm and worm shaft are supported by anti friction roller bearings Tapered bearings are shown in this illustration while ball bearings and needle roller bearings may be used on other models As the steel worm turns the threads push or pull the aluminum bronze alloy worm gear The worm gear is keyed to the drum shaft which is supported on bronze bushings in the worm gear housing and bearing leg A sliding dog type clutch is splined or keyed to the cable drum shaft The drum clutch transmits the torque of the worm gear to the cable drum An oil cooled automatic safety brake is installed on the end of the worm shaft on most winches with a 12 000 pound 5 444 Kg or greater rated capacity The majority of the worm gear winch s load holding ability is achieved by the inability to back drive the worm gear set The safety brake provides additional resistance to rotation of the worm shaft and
28. e supplied with some Paccar winches These ferrules are for use with standard six strand IWRC Independent Wire Rope Core type wire rope Refer to ferrule selection chart in the Specifications section of this manual n 2 eee Step Two E 222 Insert cable through the small opening of the ferrule Spread strands lay them individual grooves spiral wedges Tap wedges and cable into the ferrule leaving approximately 3 8 in 10 mm extending from the top The first load will seat cable and wedges securely in the ferrule 25 PREVENTIVE MAINTENANCE Recommended Preventive Maintenance Intervals A regular program of preventive maintenance for your Braden winch will minimize the need for emergency servicing and promote long product life and trouble free service The service intervals suggested in this manual will optimize component service life The intervals may be gradually increased or decreased with experience of a particular lubricant and evaluation of your application A WARNING Never attempt to service a winch with the prime mover running as accidental engagement may result in property damage severe personal injury or death Make certain all load is removed from winch cable and cable drum before servicing winch A loaded winch cable may rapidly unspool resulting in property damage severe personal injury or death Daily when winch is in regular use 1 Inspect cable and rigging for b
29. efore installing a bayonet type capstan make certain the spring is properly located in the bore The spring holds the capstan in the lock position on the extension or capstan If the spring is omitted the capstan may come off of the shaft and cause sudden loss of load control which may result in property damage personal injury or death Also closely inspect the edges of the lock pocket to make certain they are still sharp and not rounded from extensive use A badly worn lock pocket may prevent the capstan from locking securely to the shaft which could allow the capstan to come off the shaft and cause a sudden loss of load control which may result in property damage personal injury or death Make certain that the vehicle is positioned such that the load line and hand line are perpendicular to the center of the capstan barrel Do not allow rope to pull against either flange of the capstan as the rope may get damaged or may jump over flange and cause a sudden loss of load control which may result in property damage personal injury or death If a bolt on capstan is being used make certain that a 34 in X 5 1 4 in 19 X 133 mm Grade 8 capscrew and self locking nut are used A soft bolt or pin may shear off and cause a sudden loss of load control which may result in property damage personal injury or death 13 As a general rule always wrap rope around the capstan in the same direction that wire rope is wrapped around the c
30. eginning of a lift or pull The winch operator must visually determine that the clutch is fully engaged before lifting or pulling a load Failure to do so may result in property damage severe personal injury or death Release band type drum brake if so equipped and engage winch control Operate controls smoothly to avoid jerking of load Operate winch at slowest speed practicable for your application to reduce worm gear heat rise and maintain winch load control Observe winch operation carefully to make certain that all ground personnel remain clear of winch cable and load and that load does not shift requiring the repositioning of the winch cable or winch When the load is properly positioned stop the winch The automatic safety brake and worm gear set are designed to hold the load when properly adjusted Refer to Safety Brake Service amp Adjustment Secure the load in position Pay out enough winch cable to remove all tension on cable and drum Disengage drum clutch and disconnect winch cable from load 12 Engage drum clutch as described earlier When possible visually determine that the drum clutch is fully en gaged Wind winch cable back onto cable drum while maintaining minimum fleet angle and sufficient tension to cause the cable to spool properly being careful to keep hands and clothing away from cable drum and fair lead rollers Winch Break In As aworm gear winch operates the steel worm will burnish a uni
31. end extends 1 1 2 2 wire rope diameters beyond the clamp Evenly tighten the U bolt clamp nuts until the wire rope deforms slightly under the U bolt and the rope is held securely 24 SETSCREW Set Screw Clamp Prepare the end of the wire as recommended by the wire rope manufacturer Insert the wire rope into the anchor hole in the cable drum barrel until it is visible from the open end but does not protrude beyond the end of the hole Tighten the set screw until the wire rope deforms slightly under the set screw and the rope is held securely Wedge and Pocket Prepare the end of the wire rope as recommended by the wire rope manufacturer Pass the free end of the wire rope through the small opening of the cable drum anchor pocket Loop the wire rope and push the free end about of the way back through the pocket 4 Install the wedge the loop then pull the slack out of the loop with the working line wedge will slip into the pocket and secure the wire rope into the drum Cable wedges are designed to accommodate specific wire rope sizes Refer to the applicable sales specifi cation brochure for additional information A CAUTION A The free end of the wire rope should be toward the center of the cable drum and the working line should exit the anchor pocket next to the drum flange to achieve even spooling of wire rope INSTALLATION OF SPIRAL FERRULES Re usable field installed spiral ferrules ar
32. erature for maximum allowable back pressure Directional Control Valve Most installation instructions and schematic diagrams published by Braden correctly describe the control valve to be used but do not specify the valve to be spring centered and without detents The updated control valve description and schematic representation appear below The directional control valve must be a three position four way valve without detents and with a spring centered motor spool such that the valve returns to the centered position whenever the han dle is released and both work ports are open to tank open center open port A WARNING A DO NOT use acontrol valve with any detents or latching mecha nism 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 op eration of the capstan drive and or winch which could result in property damage personal injury or death Hydraulic Fluid We have briefly listed the most important characteristics to consider when evaluating a hydraulic fluid Correct viscosity High viscosity index VI High film strength for proper lubrication High oxidation resistance Good water separating ability Good anti rust properties Good resistance to foaming and Good anti wear ability We recommend a premium quality industrial anti wear hydraulic fluid be used with the motors on Braden p
33. h block must be secured to a tree or other structure for recovery applications a heavy nylon web sling of proper capacity rating should be used to avoid inflicting serious damage to the tree A WARNING A A poorly attached or undersized snatch block may break loose and cause a sudden loss of load control which could result in property damage severe personal injury or death 14 TO MOVE A LOAD O 10 000 Ib 44 5 KN lt 20 000 15 CAP 89 WHEELS BLOCKED WHEELS BLOCKED 20 000 Ib CAP 89 kN 20 000 Ib 10 000 Ib 1 OAD 44 5 KN 9000 kg 10 000 Ib 44 5 SELF RECOVERY 20 000 Ib CAP toap 0 10 000 Ib 44 5 s 20 000 Ib 5 w 9000 kg H M ANCHOR 10 000 Ib 44 5 kN POINT WINCH INSTALLATION General The winch must be securely mounted to a rigid surface which will not flex when the winch is in use The winch should be installed with the centerline of the drum in a horizontal position and the worm shaft located in a horizontal position and below the cable drum The mounting surface must be flat within 020 in 50 mm to maintain proper alignment of the worm gear housing and bearing leg assembly Contact the factory for deviations from the above requirements A WARNING A Flexing or uneven mounting surfaces will produce internal winch distortion which may result in rapid com ponent wear overhea
34. he worm gear Fleet Angle That angle between the wire rope s position at the extreme end wrap on a drum and a line drawn perpendicular to the axis of the drum through the center of the nearest fixed sheave or load attach ment point Refer to illustration below V2 MIN 11 2 MAX TO LOAD OR FIRST SHEAVE WINCH MODEL NUMBER AND ASSEMBLY IDENTIFICATION Braden worm gear winches are identified by model and serial number stamped into a smooth surface near the top of the worm gear housing The winch model number and serial number must be referenced when ordering service parts or requesting information Do not try to identify a Braden winch by using a raised or foundry casting number Winch Model Number Winch Serial Number A M 5 U 3 10 F EB R RA A DESIGN TESTED RA RIGHT HAND TO SAE J706A ASSEMBLY C CONVERTIBLE BASE E ELECTRIC DRIVE H HYDRAULIC DRIVE L LIGHTWEIGHT GEAR CUT L LEFT HAND HOUSING GEAR CUT M MECHANICAL DRIVE R RIGHT HAND EB EXTENSION SHAFT G REVISED GEAR PROFILE S SPACER ADDED BETWEEN ONE SIDE ONLY WORM GEAR AND EEB EXTENSION SHAFT HOUSING BOTH SIDES SPL SPECIAL U UNDERSLUNG OR LOW MOUNT 3 BASIC MODEL NUMBER F FRONT OR BUMPER MOUNT IN MOST COMMON INSTALLATION 10 10 IN NOMINAL DRUM BARREL LENGTH BETWEEN DRUM FLANGES UPRIGHT WINCHES Winch Model Number Winch Serial Number UPRIGHT MODEL A M 5 10
35. lic oil To achieve optimum motor life run in new motor for approximately one hour at no more than 30 of rated pressure before application of full load Always be sure all hydraulic lines and motor are filled with oil prior to any load application 18 ACAUTION A Failure to properly install and run in a new hydraulic motor will result in accelerated component wear and unsatisfactory winch performance Hydraulic Circuits REQUIRED Relief Free Flow Valve Braden Part No 29656 MOTOR CIRCUIT 100 PSI A 689 kPa MINIMUM UJ CASE DRAIN KOS iii LA aa aasma maana t 1 2 gpm 8 87 6 LPM LUT LUT I 3 WAY SHIFT VALVE SINGLE MOTOR TWO SPEED MOTOR NOTE A case drain is required for all applications TWO SPEED SINGLE SPEED 19 SPECIFICATIONS Two Speed Winches Motor Back Pressure Limits 100 PSI 689 kPa Differential pressure is 100 PSI 689 kPa Continuous Capstan quired to shift the motor into high speed 200 PSI 1379 kPa Intermittent Winch 600 PSI 4137 kPa Peak customer supplied 3 way hydraulic valve is re quired to shift the motor into high speed S in Port Sizes 6 mm valve rated for over 2 0 GPM 7 6 Ipm is A and B Supply Ports 10 SAE adequate and may be manually electrically or O Ring Boss 7 8 14 Thread otherwise remotely actuated to suite the appli T Tank P
36. lock the ro tor driver to the rotor disc The disc is locked in place by the friction discs and the load is held The friction discs are held against the rotor disc at all times but only experience relative movement when the winch is being powered out to lower a load SERVICING Drain oil from worm gear housing as described earlier Remove the capscrews which secure the brake hous ing to the worm housing Remove the brake housing leaf spring assembly pressure plate and outer brake disc Before removing the rotor assembly mark it to insure that it will be reinstalled in the same direction of rotation Remove the rotor assembly and inner friction disc Inspect the rotor assembly for damaged rollers roller springs plungers or rotor discs Replace rotor as an assembly if any part is damaged or unit fails to turn smoothly in the free direction and lock firmly in the op posite direction The leaf spring should be replaced as an assembly if it has lost its tension has cracked spring leaves or damaged adjuster threads After thorough cleaning and inspection reassemble brake using the following procedure Install a new rotor drive key into the worm shaft Pre lubricate brake discs with worm gear oil and place the inner friction disc over the worm shaft against the bearing container Install the rotor assembly onto the worm shaft in the same direction as it was removed Check that the rotor assembly has been properly installed by holding
37. m from the center of the shaft Select the weight that matches the torque from the chart If the weight can be hung two feet 610 mm from the shaft use one half the weight shown It is a good idea to tighten the brake adjustment first then apply the weight and loosen the adjustment until the weighted wrench begins to move Retighten until the wrench stops 30 Method 2 For Mechanically Driven Winches Only Disengage the drum clutch Engage the power take off to drive the winch in the reel out direction With the truck in neutral operate the engine at 1 500 r p m and disengaoe the truck clutch If the safety brake is prop erly adjusted the winch drive sprocket will stop turning immediately The brake will overcome the inertia of the gear train from the truck transmission through the safety brake Method 3 May Be Used For Hydraulically driven Winches Thoroughly inspect winch drum clutch wire rope and rigging Repair or replace as required Refer to the Maximum Load and Input RPM chart in the specifications section of this manual to determine the safe work ing limits of your particular winch Securely attach winch cable to test load which should be the maximum weight anticipated in your application Raise load a short distance then stop Winch should hold the load With engine recommended PTO ing speed lower load and stop before load contacts ground Winch should stop and hold the load securely If when u
38. n quarts qts gallon gal inches cu in feet cu ft feet cu ft fluid ounce fl oz ounces oz pounds lbs 0 001102 tons 2000 lbs tons 2000 Ibs 0 000984 tons long 2240 Ibs inches Hg 60 F pounds sq in PSI pounds sq in PSI pounds sq in PSI inches 60 F bars horsepower hp ft lbs min pound inches in Ibs pound feet ft Ibs pound feet ft Ibs miles hour m h feet second ft sec feet minute ft min 0 1 or 10 0 01 or 10 0 001 or 10 0 000 001 or 10 MAXIMUM LINE SPEED AND TORQUE INFORMATION FOR STANDARD BRADEN WINCH ASSEMBLIES MAXIMUM MAXIMUM TORQUE TORQUE pounds spego speep Requineo F P M R P M 8 RQUE TORQUE WINCH REQUIRED MODEL REQUIRED LB IN LB IN STATIC 1 370 150 0 27 400 112 50 26 764 300 450 600 17 843 1 200 2 500 480 0S4 142 680 13 700 6 850 E 8 3 e gt n2 z 12 Sig 888885 S Nj N m N o e B e o P 480 600 1 200 670 2 000 400 0 67 1 670 2 770 a 5 o e 8 o ojejo RB o 25 w gt S 2 6 slr t 38 88 gt
39. on disengage the clutch slowly and observe the lines The drum flange should move 1 16 in 5 16 in 1 5 8 mm in the direction that spools cable onto the drum If less than 1 16 in 1 5 mm travel occurs or if the travel is in the opposite direction the winch should be disassembled and the clutch visually inspected for wear and or damage and replaced if necessary The drum clutch should be routinely inspected using the above procedure FULLY DISENGAGED CLUTCH FULLY ENGAGED CLUTCH WIRE ROPE MAY BE PULLED WINCH MAY BE OPERATED OFF OF WINCH CABLE DRUM BY HAND UNDER LOAD PARTIALLY ENGAGED CLUTCH DANGEROUS DO NOT OPERATE WINCH 11 Basic Winch Operating Method Before taking your new winch to the jobsite we suogest that you operate the winch under no load conditions to familiarize yourself with the winch controls at various line speeds Engine speed PTO controls and winch controls will influence your feel of the winch operation Remote lever controls air shift cylinders and emergency stop systems should be adjusted at time of installation and all operators fully trained on their operation under a no load condition WARNING A Ground personnel must stay in view of the operator and clear of load and capstan drive or winch Do not allow personnel near rope or cable under tension or to be in line with the load A broken rope or cable and or loss of load control may cause property damage
40. operly positioned at the operators station and you are sure personnel are clear of the work area 4 Assure that personnel who are responsible for hand signals are clearly visible and that the sig nals to be used are thoroughly understood by ev eryone 5 Ground personnel should stay in view of the operator and clear of winch drum Do not allow ground personnel near winch line under tension A safe distance of at least 1 1 2 times the length of the unspoiled cable should be maintained 6 On machines having hydraulically mechanical ly and or cable controlled equipment or attach ments be certain the equipment is blocked se curely before servicing adjusting and or repairing the winch Always apply the parking brakes be fore dismounting a vehicle 7 Inspect rigging and winch at the beginning of each work shift Defects should be corrected im mediately 8 Keep equipment in good operating condition Perform scheduled servicing and adjustments listed in the Preventive Maintenance section of this manual 9 An equipment warm up procedure is recom mended for all start ups and essential at ambi ent temperatures below 40 F 5 C Refer to Warm Up Procedure listed in the Preventive Maintenance section of this manual 10 Worm gear winch clutches may disengage and drop or lose control of a load if they are not fully engaged at the beginning of a lift or pull The winch operator must visually determine tha
41. ort Single Speed 4 SAE cation NOTE In low speed the 3 way valve O Ring Boss 7 16 20 Thread must connect the motor port S to tank to prevent Two Speed 6 SAE a false motor shift to high speed O Ring Boss 9 16 18 Thread S Two Speed Shift Port 4 SAE Due to the design of the Char Lynn 2 speed mo O Ring Boss Port 7 16 20 Thread tor valving some applications may experience a high pitched noise when operated in one direc tion of high speed rotation This can be corrected by creating a limited back pressure on the motor port B port closest to the motor mounting flange This may be accomplished by installing relief free flow valve which will apply a back pressure to only port B of the Char Lynn motor A typical valve would be Sun Hydraulic YCFC FEN BK 250 PSI 1724 kPa Braden part number 29656 NOTE A relief free flow valve such as 29656 is required with all 2 speed motors Run the winch at full speed no load and increase the back pressure until the high pitched noise decreases This will typically occur at 250 300 psi 1 724 2 069 kPa Parker Hannifin 700 Series Two Speed Motors Beginning in August 1997 the Parker Hannifin 700 Series motor replaced the Char Lynn 2000 Series as the optional two speed motor for worm gear products The Parker motor uses a 12 volt solenoid shift valve to shift the motor between low and high speeds The back pressure valve required for the Char Lynn motor is not needed with
42. que wear pattern onto the aluminum bronze alloy worm gear For this reason we recommend that a worm gear should not be replaced without also re placing the steel worm A proper break in of a new winch or a repaired winch with a new worm gear set is needed to produce a gear wear pattern which will maximize component life Follow the procedure listed below to properly break in a Braden worm gear winch before operating at rated capacity Make certain the winch is properly mounted to the vehicle Refer to Winch Installation section of this man ual Fill winch to oil level plug with recommended worm gear oil The proper oil level for most worm gear winches is near or slightly above the centerline of the worm shaft Locate the proper oil level plug for your application Refer to Preventive Maintenance section for additional information Spool the new cable onto the winch at very low speed while monitoring worm gear housing temperature if a load is used to hold tension on new wire rope The first ten winching operations should be made at approxi mately 60 of rated capacity and at less than rated line speed to obtain a good worm gear wear pattern Never operate winch at speeds higher than the published maximum input RPM for the given load as exces sive heat and accelerated worm gear wear may result Capstan Use Braden has provided two basic types of capstans Quick disconnect bayonet type and a bolt on type WARNING B
43. r capscrews to the recommended torque and refill winch with recommended worm gear oil Adjust the worm gear safety brake as described earlier IF YOUR WINCH IS EQUIPPED WITH A CABLE DRUM BAND BRAKE THE FOLLOWING ADDITIONAL INSTRUCTIONS ARE APPLICABLE 9 Remove the drum clutch and band brake control shafts from the base of the winch This is accomplished by loosening the set screws in the thrust collars and levers then pulling the control shafts from the winch Do not disconnect any parts from the drum brake band unless they prevent its removal from reversing Remove all levers and collars from the shafts and brake band anchor bracket from the base angle 10 Remove the brake band from the cable drum turn around from the original position and replace on the cable drum Install the control shafts collars levers and set screws Secure the brake band anchor bracket to the base angle as shown 11 Attach the brake band link to the brake band and the anchor bracket Since the control shafts are reversed because of the brake band arrange ment it is necessary to change the control link age for the winch clutch as well 12 This illustration shows a front drive right hand assembly with over wind cable spooling 33 SPECIFICATIONS Recommended Worm Gear We have published the following specifications to help you determine which lubricant is best suited to your application For simplicity Braden has listed readily available produc
44. re rope wound on a drum Layer All wraps on the same level between drum flanges Freeboard The amount of drum flange that ex tends radially past the last layer of wire rope Mean Drum A theoretical point located midway be tween the first layer of wire rope on the cable drum barrel and the top layer Often used as a reference point in measuring winch performance Gear Set Efficiency The relationship between the input horsepower transmitted to the winch by the prime mover and the output horsepower transmit ted by the winch to the wire rope Expressed as a percentage Extension Shaft the standard cable drum shaft is extended or replaced by an extra long shaft which permits the use of capstans or CR reels at the side of the vehicle Usually installed on the curb side of the vehicle most extension shafts are limited to an standard length of 44 to 46 1 2 in 112 118 cm from the cable drum center line Capstan Usually a small removable drum used to apply force to fiber rope wrapped around the barrel with tension applied by hand Most have a nominal barrel diameter of 7 in 178 mm CR Reel Collapsible recovery reels are used for picking up and coiling power and telephone lines which have been removed from the poles and low ered to the ground Most CR reels have a nominal barrel diameter of 20 in 508 mm Bull Gear Bronze alloy gear powered by the steel worm Braden refers to the bull gear as t
45. roducts Consistent use of the proper fluid which matches the motor design and application will reduce mo tor wear and give better overall performance Viscosity One of the most important hydraulic fluid characteristics to consider is viscosity The oil selected must have the proper viscosity to maintain a lubricating film between bearing and sealing surfaces at maximum operat ing temperatures and still be able to flow easily during a cold start up 17 Viscosity index VI is a measure of the way viscosity changes with temperature The smaller the viscosity change with temperature the higher the VI Multiple viscosity oils such as SAE 10W 30 contain additives to improve viscosity index a general rule we do not recommend multiple viscosity oils Oils with a viscosity of 100 SUS 21 centistokes at working temperatures will provide best overall performance The following chart provides some general guidelines for selecting a hydraulic oil Motor Design Conventional Gear Geroller and Gerotor Optimum Viscosity SUS Centistokes 100 21 100 200 20 43 Maximum Startup Viscosit SUS Centistokes E y 7 500 1 620 10 000 2 1 00 ATF Fluids OK Maximum Operating Tem 200 F 93 C 180 F 82 C perature Typical Viscosity Index VI 90 105 90 105 Hydraulic System ISO VG SUS ISO VG SUS Operating Temperature CST 40 C 100 F CST 40 C 100 F 90 125 32 52 105 140 F 41 60 118 154
46. roken wires or other damage as recommended by the wire rope and rigging manufacturer 2 Carefully inspect drum clutch and adjust shift mechanism to make certain it can be fully engaged and dis engaged Refer to Drum Clutch Operations Weekly 1 Perform all daily inspections 2 Check worm gear housing oil level and fill to the proper level with recommended oil The proper oil level for most worm gear winches is near the centerline of the worm shaft Locate the proper oil level plug for your application For boom tip winches turret winches and winches mounted upside down fill to level plug or halfway up on worm and be certain that the safety brake has sufficient oil when it is located in the highest position Overfilling the winch may result in oil leaks Underfilling the winch may result in rapid wear of the worm gear set 3 Lubricate the grease fittings on the bearing legs and cable drum On some winches you may have to un spool the wire rope to gain access to the grease fittings in the cable drum Use a high quality moly type grease with a rating of NLGI 2 or better 4 Inspect and retighten as required all winch mounting fasteners Inspect and repair as required all winch mounting brackets and welds Monthly 1 Check alignment of sprockets chains and PTO shafts to minimize wear on mechanical drive components Refer to Winch Installation 2 Check adjust hydraulic system relief valve to ensure proper performance and componen
47. rty damage severe personal injury or death 34 RECOMMENDED FASTENER TORQUE The general purpose torque shown in the chart applies to SAE Grade 5 amp 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 Lubricated Torque values based on use of SAE 30wt 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 Torque LB FT N m Diam per 150 115 210 160 11 2 6 1940 1460 203 156 285 217 2360 1979 To convert LB FT to Kg m multiply LB FT value by 0 1383 NOTE Aluminum housing use Grade 5 torque value 35 3160 4284 Torque LB FT N m Diam per m 20 8 6 12 9 aj 10 265 200 380 280 28 11 8 16 12 16 359 271 515 380 is 18 17 13 24 18 9 420 325 600 450 24 23 17 33 24 14 569 441 813 610 16 31 23 45 35 i 8 640 485 910 680 24 42 81 61 47 14 868 658 1234 922 14 50 35 70 50 395 7 790 590 1290 970 20 68 47 95 68 12 1071 800 1749 1315 m 13 75 55 110 80 iia 7 1120 835 1820 1360 20 102 75 149 108 12 1518 1132 2468 1817 80 2370 3214 9 16 12 110 150 110 13 8 6 1460 1095 2385 1790 18 149 1
48. s 2 o 8 2 ja ead nd ad ad 282 8 2 888 8 8 3585585 8888 8 gt eo 600 1 200 1 74 21 27 amp el 330 420 590 990 1 500 220 N 2 rc m a All line pulls and line speeds are for first layer of cable OS4 3 amp 4 multiply RPM by 0 6 and FPM by 1 2 a SPEED REDUCERS amp SPECIAL APPLICATION WINCHES MAXIMUM STARTING MODEL INCH POUNDS INPUT SPEED INPUT TORQUE R P M LB IN 30 000 BR30B 20 000 17 26 8 ajo S BR40 _ 8 1 000 To convert pounds line pull to KN multiply pounds value by 004448 To convert Ib in torque to Nm multiply Ib in value by 113 80 9 23 29 39 _ 52 89 102 1 18 21 2 5380 35 4035 910 2 690 FFE 23 E 64 1 13 52 2 15 20 29 5 50 X 66 e 8 5 2 re 39 WINCH DRUM CLUTCH CONTROL A WARNING DO NOT move the load or the winch platform or operate the winch before making certain the drum clutch is set to engage and the clutch is fully DISENGAGED engaged ENGAGED A load on the winch line may prevent a partially engaged clutch from disengag ing but any change in the load may allow the clutch
49. se property damage severe personal injury or death ADJUSTMENT There are three 3 methods for adjusting the Braden oil cooled safety brake Method 1 is the preferred method and is used at the factory as the standard adjustment procedure Method 2 and 3 may be used when the proper tools are not available Method 3 may be used for periodic field adjustment and as a final test for method 2 Method 1 Disengage the drum clutch Adjustment is made by turning the brake adjustment nut in the center of the safe ty brake housing counter clockwise to tighten the brake or clockwise to loosen it Some winch models are equipped with an adjusting screw lock plate on the end of the brake housing which is locked into place with two small capscrews These capscrews must be removed before the brake can be adjusted A torque wrench can be equipped with a special adapter or socket which will engage the key similar to the one shown in the illustration in the input end of the worm shaft Proper torque can then be applied to the worm shaft to adjust the brake refer to torque chart below NOTE Only the input end of the worm shaft must be turned with the torque wrench NOT the brake adjusting nut In the event that the special adapter is not available the use of a pipe wrench and weights has been successful in some cases To use the pipe wrench method place the wrench on the input shaft in a horizontal position Hang a weight from the handle one foot 305 m
50. shift handle where applicable to disengage lock detent Move handle to lull travel to engage clutch If shift handle lock knob will not engage detent hole the clutch is not fully engaged At this point it may be necessary to manually rotate the cable drum slightly in either direction to align clutch lugs while holding slight pressure on shift handle B To Disengage Clutch 1 Insure winch motor or PTO is not running and the winch cable and cable drum are not loaded The prime mover is stopped in neutral with parking brake set 2 Lift lock knob on shift handle where applicable to disengage lock detent Move shift handle full travel to disengage clutch If shift handle has resistance to shift cable drum may be manually rotated in the direction to haul in cable to relieve the self energized load on the drum clutch lugs and allow the shift A WARNING DO NOT attempt to engage drum clutch while cable drum is rotating DO NOT attempt to disengage drum clutch with a load applied to the winch cable DO NOT use cheaters to extend the shift handle length or other means to apply undue force on the shift handle Engaging or disengaging the drum clutch while the cable drum is rotating or under load or the use of undue force may result in damage to drum clutch components Damaged drum clutch components may disengage under load and cause a loss of load control which could result in property damage injury or death NOTE your oper
51. sing one of these methods for checking the adjustment the brake does not hold turn the adjusting nut 1 2 turn in the counter clockwise direction and repeat the testing sequence until the brake holds properly Do not adjust the safety brake to higher torque values than shown in the chart below this will cause excessive heating glazing and abnormal wear of the friction discs under normal pay out operations Using a winch with worn brake components may result in a loss of load control which could cause property dam age severe personal injury or death Torque Torque AC12 BR40 ALGU2 24 33 AMU7 40 54 M5 MU5 AMU5 M6 MS6 AMS6 35 47 AMGUS AMS7 MU10 MS18 45 61 M9 UT12 MU9 MSU9 MGUS MU7 AMS9 AMSUS UT15 60 81 MS10 AMS10 AMSU10 50 68 MSU12 AMSU12 MS12 OS4 1 amp 2 16 1 24 33 MS20 AMS20 MS30 MS50 95 129 OS4 3 amp 4 32 1 BR30 BR30B 16 22 W150A M150A 350 475 Models UT15 and W150A are equipped with a spring applied multi disc oil brake which is adjusted by turning the adjusting screw clockwise to tighten and counter clockwise to loosen all others counter clockwise to tighten Dry Band Type Automatic Safety Brake The Braden dry band type automatic safety brake is used on several models of winches with capacity rat ings of less than 12 000 pounds 53 4 kN The brake utilizes an external contracting self energizing dry brake band acting on the worm shaft
52. t protection on hydraulically driven systems 3 Service hydraulic system filters strainers as recommended by the system manufacturer 4 Check drum clutch to be certain that the negative draft angle is clearly evident on the clutch and drum lugs Replace a worn sliding clutch clutch plate or cable drum Refer to Drum Clutch Operations 26 A WARNING DO NOT use the winch if the negative draft angle is worn straight or the edges of the clutch lugs are rounded or chipped A defective drum clutch may suddenly become disengaged which could cause a loss of load control which may result in property damage personal injury or death 5 Check adjust worm shaft safety brake if equipped Yearly 1 Check adjust worm shaft end play if winch has been in heavy use Refer to Worm Shaft End Play Adjust ment procedure 2 Change oil as follows a Place winch in level position and remove drain plug Drain oil into a suitable container and dispose of in an environmentally responsible manner A WARNING Hot oil may cause injury Make certain oil has cooled to a safe temperature before servicing b Install drain plug and fill winch with kerosene and run for 5 minutes with no load to dislodge any accu mulated contaminants Drain the kerosene into the container and reinstall plug Note It is normal to see a small amount of fine bronze particles in the drain oil If large flakes or chips are present the winch should be disassembled
53. t the clutch is fully engaged before lifting or pulling a load Check drum clutch to be certain that the negative draft angle is clearly evident on the clutch and drum lugs Replace a worn sliding clutch clutch plate or cable drum Do not use the winch if the negative draft angle is worn straight or the edges of the clutch lugs are rounded or chipped 11 The winches described herein are neither de signed nor intended for use or application to equipment used in the lifting or moving of per sons 12 Do not exceed the maximum pressure PSI kPa or flow GPM LPM stated in the winch specifi cations for hydraulically driven winches 13 Match winch line speeds to job conditions 14 Leather gloves should be used when handling winch cable 15 Never attempt to handle winch cable when the hook end is not free Keep all parts of body and clothing clear of cable rollers cable entry area of fairlead and winch drum 16 When winding winch cable on the winch drum Never attempt to maintain tension by allowing winch cable to slip through hands Always use hand over have technique being careful to keep hands and clothing away from winch drum and fairlead rollers 17 Never use winch cable with broken strands Re place winch cable 18 Do not weld on any part of the winch 19 Use recommended hydraulic oil and gear lubri cant 20 Appropriate guards should be installed around ex posed portions of an extension shaft and or c
54. tect against injury A sufficient final sprocket reduc tion between the hanger bearing or pillow block and the winch is recommended to reduce torque loads ap plied to the PTO drive shafts and to provide a reduced winch line speed for better load control PTO driveline angularity must not exceed the driveline manufacturer s recommendation A B STRAIGHT EDGE Use straight edge to ensure axial alignment of Make certain all pillow blocks PTO and hanger all sprockets bearing shafts are parallel to each other 16 As a general rule adjust drive chain sag to 25 in 6 3 mm per 1 ft 305 mm of sprocket To keep vibration to a minimum make certain PTO drive shaft U joints are aligned from end to end Hydraulic Drive System General If the winch is hydraulically driven make certain the entire hydraulic system is clean and all components control valve linkage pump relief valve and filters function properly Hydraulic lines hoses and compo nents must be of sufficient size to assure minimum back pressure Back pressure is measured at the outlet or low pressure side of the hydraulic motor when the winch or capstan drive is operated Back pressure is caused by all restrictions to flow between the motor and reservoir High back pressure will cause excessive system heat require higher pressure to achieve specified performance waste horsepower and damage seals Consult the motor manufacturer s service lit
55. the Parker motor These two features should simplify installation of winches with the Parker motor The two speed function in the Parker motor is a series parallel design which should provide better efficiency than the Char Lynn motor Mounting flange and shaft dimensions are the same as the Char Lynn motor so field replacements can be made easily Note however the Parker motors are 12 to 1 1 2 inches longer than the Char Lynn motors they replace The Parker motors are normally supplied to operate in low speed high torque mode with the solenoid de energized The motor is shifted into high speed low torque mode by energizing the 12 volt solenoid This sequence can be reversed by reversing the main motor spool as shown in the drawing on page 22 The motors are also equipped with a manual override selector on the solenoid If for some reason 12 volt power is not available the motor can be manually shifted as shown in the drawing The hydraulic schematics that follow show the motor operation with the spool in the normal position 20 Motor Circuit Main Motor Spool Double Power Control Elements Case Drain See Note 1 Parker Hannifin 700 Series Two Speed Hydraulic Motor Motor is shown with the solenoid de energized and the power elements in parallel low speed high torque mode This is the normal configuration for the motor Energizing the solenoid shifts the motor into high speed low torque mode NOTE
56. ting poor winch performance or improperly engaged drum clutch mechanism which may disengage and drop or lose control of a load causing property damage severe injury or death The winch should be mounted or operated perpendicular to an imaginary line from the center of the cable drum to the first sheave or load to ensure even cable spooling Make certain this fleet angle does not exceed 1 1 2 Fleet angles greater than 1 1 2 will cause uneven cable spooling onto the cable drum which may result in damaged cable It is the responsibility of the person s installing the winch to make certain that the winch is secured to the vehicle with equivalent or greater strength capscrews than Braden has used to secure the winch to the base angles The winch base angles should be securely mounted to the vehicle frame in a manner acceptable to the vehicle manufacturer The frame adapter brackets should be bolted to the winch base angles as close to the worm gear housing and bearing leg assembly as practicable This method would provide the greatest strength and minimize distortion All mounting fasteners must be SAE Grade 8 10 9 metric or better and evenly tightened to the torque values shown in the chart found in the Specifications section of this manual Mechanical Drive System General If the winch is mechanically driven make certain guards are installed over exposed drive train components PTO shafts couplings sprockets and chains etc to pro
57. ts in each temperature range which has been tested and found to meet our specifications 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 supplies you with oil that is equivalent to those products listed below F 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 F 40 30 20 10 0 10 20 30 40 50 35 C A AGMA Grade 3 EP Mobilgear 600xp 100 or equivalent B AGMA Grade 5 EP Mobilgear 600xp 220 or equivalent C AGMA Grade 7 EP Mobilgear 600xp 460 or equivalent D AGMA Grade 8 EP Mobilgear 600xp 680 or equivalent Brand recommendations in tier C climate range MOBIL Mobilgear 600xp 460 SHELL Omala 460 CHEVRON Gear Compounds EP460 TEXACO Meropa 460 NOTE For cold weather applications synthetic versions of the recommended oils may be used Please note that use of synthetic oils in worm gear winches requires the gear set to be broken in with mineral oil before using the synthetic oil Failure to break in the gear set with mineral oil will cause slippage between the gears which could allow the load to slip or fall A WARNING Do not use aftermarket additives in worm gear oil Some additives may contain substances which could cause glazing of brake discs or impede the firm locking action in the brake rotor assembly Both symptoms could reduce load control which may result in prope
58. uired 1500 in 05 Required Motor System Pressure PSI x 1591 x Motor Starting EFF System Pressure 2000 PSI Size cu in Motor Starting Eff 7096 1500 in Ibs 200 PSI x 1591 x JOEFF 6 73 cu in motor required To Find _ Input Torque Required Ibs Example Input Torque Required 1800 in Ibs Pressure PSI Motor Size cu in x 1591 x Motor Starting EFF Motor Size 6 cu in Required to Motor Starting Eff 70 Drive Motor 1800 in Ibs _ Sarl x x NER 2694 PSI Required To Find _ Motor Size Cu in x Desired RPM Example Motor Size 6 cu in Required Flow 231 x 90 Vol Eff Desired RPM 2000 For Desired RPM 6 cu in x 2000 RPM _ 25 x 90 2 58 GPM Required To Find Example System Pressure 2500 PSI Required _ System Pressure PSI x System Flow GPM System Flow 35 GPM Horsepower 1714 x 80 Pump Eff 2500 PSI x 35 GPM _ To Drive Pump 1714 x 80 Pump Eff 64 Horsepower To Find Maximum Example Available Horsepower 50 Pressure If _ Available Horsepower x 1714 x 80 Pump Eff System Flow 35 GPM Horsepower and Flow GPM Flow are Fixed SOHP O Pump x x 80 Pump Eff _ 1959 PSI Maximum Pressure To Find Maximum Example Available Horsepower 50 Flow If _ Available Horsepower x 1714 x 80 Pump System Pressure 2500 PSI Horsepower and System Pressure Pressure are 50 HP x 1714 x_80 Pump Eff 274 GPM Max System Flow Fixed 2500 PSI
59. xpressed in feet or meters Rated Line Pull The line pull on any layer that results from the output torque which produces maxi mum rated line pull on the first layer Rated first lay er line pull is based on maintaining an acceptable structural safety factor while providing an accept able component service life Line pull is expressed in pounds or kilograms Rated Line Speed The line speed on any cific layer that results from rated input speed It is expressed in feet minute or meters minute Thermal Rating Duty Cycle The result of a test expressed as the distance feet or meters a load travels up and down while hoisting and lowering a specified weight until the lubricating oil rises from 100 F to 250 F 38 C to 121 C 250 F 121 C is the maximum intermittent gear oil temperature al lowed Most gear oils break down rapidly at higher temperatures and seals may be damaged Largest Recommended Wire Rope Size Should be no larger than 1 8th the cable drum barrel diam eter for most recovery applications Drum Clutch Also known as a dog clutch or jaw clutch consists of two or more drive lugs which engage similar driven lugs to transmit torque to the cable drum Free Spooling The operation of manually unspool ing wire rope from the cable drum by pulling on the free end of the rope while the cable drum is discon nected declutched from its power train Wrap A single coil of wi
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