Knuckle_Boom_Crane_Assy.pdf

BRADEN

SERIES

PD12C

PD15B

PD17A HYDRAULIC WINCH

INSTALLATION, MAINTENANCE AND SERVICE MANUAL

PACRWINCH DIVISION

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

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

www.paccarwinch.comLIT2081 R1

3/2003

PRINTED IN U.S.A.

– 1 –

FOREWORD

Read this entire publication and retain it for future reference.

If you have any questions regarding your Braden Planetary Winch or this publication, call the Braden Service Department at 1-918-251-8511, 08:00-1630 hours, CT, Monday through Friday.

The minimum service intervals specified are for operating hours of the prime mover.

The following service instructions have been prepared to provide assembly, disassembly and maintenance information for the BRADEN Model PD12C, PD15B and PD17A series winch. It is suggested that before doing any work on these units, all assembly and disassembly instructions should be read and understood.

Some pictures in this manual may show details or attachments that are different from your winch. Also, some components have been removed for illustrative purposes. Illustrations and pictures in this manual are of a “typical” unit sold through our distribution channels. Some winches, particularly those sold directly to original equipment manufacturers, may differ slightly in appearance.

Whenever a question arises regarding your BRADEN winch, please contact BRADEN Service Department for the latest available information.

Serial Numbers and Model Numbers are located to the left hand side of the hydraulic motor, stamped into the base. Always refer to the Serial Number and Model Number when requesting information or service parts.

EXPLANATION OF MODEL NUMBER

PD DESIGNATES POWER DRUM

12 DESIGNATES 12,000 LB. APPROXIMATE FIRST LAYER LINE PULL

C DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES

29 DESIGNATES TOTAL GEAR REDUCTION

064 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV

(DECIMAL POINT ELIMINATED. EXAMPLE 064 = 6.4 CU IN/REV)

02 DESIGNATES THE DRUM OPTION

U DESIGNATES UNDERWOUND CABLE DRUM – OPTIONAL

L DESIGNATES LEFT HAND BASE – OPTIONAL

1 PERMITS TESTING AND INSPECTION PER API 2C FOR OFFSHORE CRANES

P D 1 2 C – 2 9 0 6 4 – 0 2 – U L – 1

POWER MAX. DESIGN GEAR MOTOR DRUM ROTATION BASE OPTION

DRUM RATING MODEL RATIO SIZE OPTION

– 2 –

TABLE OF CONTENTS

GENERAL SAFETY RECOMMENDATIONS .......................................................PAGE 3

THEORY OF OPERATION

WINCH INSTALLATION

RECOMMENDED FASTENER TORQUE

WIRE AND BRAIDED ROPE INSTALLATION

TWO SPEED MOTOR CASE DRAIN PLUMBING

PREVENTIVE MAINTENANCE –

RECOMMENDED OIL CHANGE INFORMATION

TROUBLE SHOOTING

WINCH DISASSEMBLY

EXPLODED VIEW DRAWING AND PARTS KEY ....................................................18-19

PLANET CARRIER SERVICE

MOTOR SUPPORT – BRAKE CYLINDER SERVICE

BRAKE CLUTCH SERVICE

WINCH ASSEMBLY

BRAKE VALVE SERVICE

REVERSING DIRECTION OF DRUM ROTATION

– 3 –

GENERAL SAFETY RECOMMENDATIONS

Safety and informational callouts used in this manual include:

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 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 – 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.

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.

1. Be certain equipment (boom, sheave blocks, pendants, etc.) is either lowered to the ground or blocked securely before servicing, adjusting, or repairing winch.

2. Be sure personnel are clear of work area BEFORE operating winch.

3. Read all warning and caution tag information provided for safe operation and service of winch.

4. Inspect rigging and winch at the beginning of each work shift. Defects should be corrected immediately.

5. Keep equipment in good operating condition.

Perform scheduled servicing and adjustments listed in the “Preventive Maintenance” section of this manual.

6. An equipment warm-up procedure is recommended for all start-ups and essential at ambient temperatures below +40°F (4°C). Refer to “Warm-up Procedure” listed in the “Preventive Maintenance” section of this manual.

7. Operate winch line speeds to match job conditions.

8. Leather gloves should be used when handling wire rope.

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

10. When winding wire rope on the winch drum, never attempt to maintain tension by allowing wire rope to slip through hands. Always use “Hand-Over-Hand” technique.

11. Never use wire rope with broken strands. Replace wire rope.

12. Do not weld on any part of the winch.

13. Use recommended hydraulic oil and gear lubricant.

14. Keep hydraulic system clean and free from contamination at all times.

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

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

17. The BRADEN designed 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.

18. Never attempt to clean, oil or perform any maintenance on a machine with the engine or prime mover running, unless instructed to do so in this manual.

19. Never operate winch controls unless you are properly positioned at the operators station and you are sure personnel are clear of the work area.

20. Assure that personnel who are responsible for hand signals are clearly visible and that the signals to be used are thoroughly understood by everyone.

21. 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 _ times the length of the cable should be maintained.

22. Do not exceed the maximum pressure, PSI (kPa), or flow, GPM (LPM), stated in the winch specifications for hydraulically driven winches.

23. Install guarding to prevent personnel from getting any part of body or clothing caught at a point where the cable is wrapped onto the drum or drawn through guide rollers.

24. “Deadman” controls, which automatically shut off power to the winch whenever the operator leaves his station, should be installed whenever practicable.

25. Never allow anyone to stand under a suspended load.

26. Avoid sudden “shock” loads or attempting to “jerk” load free. This type of operation may cause heavy loads, in excess of rated capacity, which may result in failure of cable and winch.

CAUTION

CAUTIONWARNING! !

– 4 –

DESCRIPTION OF WINCH

The winch has four basic component parts:

1. Winch base

2. Hydraulic motor and brake valve

3. Brake cylinder and motor support

4. Drum assembly

The drum assembly consists of three basic assemblies:

1. Drum with integral ring gear

2. Output planetary gear set

3. Primary planetary gear set

The hydraulic motor is bolted to the motor support which in turn is bolted to the brake cylinder and the base. The motor end of the drum, running on a ball bearing, is supported by the brake cylinder. The other end of the drum runs on a ball bearing on the support bolted to the base. The ring gear for both planetary sets is machined into the drum’s inside surface.

WINCH OPERATION

The hydraulic motor drives the sun gear of the primary planetary gear set through the splined inner race of the brake clutch. When driven by the sun gear, the primary planet gears walk around the ring gear in the drum and drive the primary planet carrier.

The primary planet carrier drives the output planet sun gear which, in turn drives the output planet gears. The output planet carrier is splined to the bearing support and cannot rotate. Therefore, as the output planet gears are driven by the sun gear, they will drive the ring gear/drum.

Dual Brake System – Description The dual brake system consists of a dynamic brake system and a static brake system.

The dynamic brake system has two operating components:

1. Brake valve assembly

2. Hydraulic motor

The brake valve is basically a counterbalance valve.

It contains a check valve to allow free flow of oil to the motor in the hoisting direction and a pilot operated, spring-loaded spool valve that 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 lowering 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-dependent and modulates the spool valve opening which controls the lowering speed.

Figures 2, 3 and 4.

The static brake system has three operating components:

1. Spring Applied, Multiple Friction Disc Static Brake

2. Brake Clutch Assembly

3. Hydraulic Piston and Cylinder

Figure 2

HOISTING

Figure 3

LOWERING 1

THEORY OF OPERATION

High PressureMedium PressureLow Pressure

Static Brake

Brake Valve

Pump

Motor

Control Valve

To Tank

High PressureMedium PressureLow Pressure

Static Brake

Brake Valve

Pump

Motor

Control Valve

To Tank

– 5 –

Figure 4

LOWERING 2

The static brake is released by the brake valve pilot pressure at a pressure lower than that required to open the pilot operated spool valve. This sequence assures that dynamic braking takes place in the brake valve and that little, if any, heat is absorbed by the friction brake.

The friction brake is a load holding brake only and has nothing to do with dynamic braking or rate of descent of a load.

The brake clutch is splined to the primary sun gear shaft between the motor and the primary sun gear. It will allow this shaft to turn freely in the direction to raise a load and lock up to force the brake discs to turn with the shaft in the direction to lower a load. Figures 5 and 6.

The hydraulic cylinder, when pressurized, will release the spring pressure on the brake discs, allowing the brake discs to turn freely.

Dual Brake System – Operation When hoisting a load, the brake clutch which connects the motor shaft to the primary sun gear, allows free rotation. The sprag cams lay over and permit the inner race to turn free of the outer race. Figure 5. The friction brake remains fully engaged. The winch, in raising a load, is not affected by any braking action. Figure 2.

When the lifting operation is stopped, the load attempts to turn the primary sun gear in the opposite direction.

This reversed input causes the sprag cams to instantly roll upward and firmly lock the shaft to the fully engaged friction brake. Figure 6.

When the winch is powered in reverse, to lower the load, the motor cannot rotate until sufficient pilot pressure is present to open the brake valve. Figures 3

& 4. The friction brake within the winch will completely release at a pressure lower than that required to open the brake valve. The extent to which the brake valve opens will determine the amount of oil that can flow through it and the speed at which the load will be lowered. Increasing the flow of oil to the 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 shifted to neutral, the pressure will drop and the brake valve will close, stopping the load. The friction brake will engage and hold the load after the brake valve has closed.

When lowering a load very slowly for precise positioning, no oil flow actually occurs through the winch motor. The pressure will build up to a point where the 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 lowering operation. All of the heat generated by the lowering and stopping of a load is absorbed by the hydraulic oil where it can be readily dissipated.

Figure 5

Figure 6

STATIC FRICTION BRAKE APPLIED

PERMITS FREE SHAFT ROTATION

WHILE HOISTING

STATIC FRICTION BRAKE APPLIED

SPRAG CAMS

LOAD ATTEMPTS TO ROTATE SHAFT IN

OPPOSITE DIRECTION.

BRAKE CLUTCH LOCKS SUN GEAR SHAFT

TO FRICTION BRAKE.

SPRAG CAMS

High PressureMedium PressureLow Pressure

Static Brake

Brake Valve

Pump

Motor

Control Valve

To Tank

– 6 –

1. The winch should be mounted with the centerline of the drum in a horizontal position. The mounting plane of the base may be rotated in any position around this centerline.

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.

3.

When mounting the winch, use all eight (8) mounting holes and grade 5 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).

4. The vent plug must always be located above the horizontal centerline. If the winch is mounted on a pivoting 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.

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 pressure. 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 INSTALLATION

30°

75°

VENT PLUG

ABOVE CENTERLINE

SHADED AREAS REPRESENT

ACCEPTABLE DIRECTIONS OF

LINE PULL

CL

– 7 –

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).

8. High quality hydraulic oil is essential for satisfactory performance and long hydraulic system component life.

Oil having 150 to 330 SUS viscosity at 100°F (38°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 minimize cold-start trouble and reduce the length of warm-up periods. A high viscosity index will minimize changes in viscosity with corresponding changes in temperature.

Maximum cold weather start-up viscosity should not exceed 5000 SUS with a pour point at least 20°F (11°C) lower than the minimum temperature.

Under continuous operating conditions the temperature 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 ambient 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-viscosity oils is generally not recommended.

9. The hydraulic oil filter should have a 10 micron nominal rating and be full flow type.

RECOMMENDED FASTENER TORQUE

The general purpose torque shown in the chart applies to SAE Grade 5 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.

BOLT THD TORQUE LB-FT.

DIA. PER (N•m)

INCHES INCH DRY LUBED

1/4 20 9 6

28 (12) (8)

5/16 18 18 13 24 (24) (18)

3/8 16 31 23 24 (42) (31)

7/16 14 50 37 20 (68) (50)

1/2 13 75 55 20 (102) (75)

9/16 12 110 80 18 (149) (109)

5/8 11 150 115 18 (203) (156)

BOLT THD TORQUE LB-FT.

DIA. PER (N•m)

INCHES INCH DRY LUBED

3/4 10 265 200

16 (359) (271)

7/8 9 420 325 14 (569) (441)

1 8 640 485 14 (868) (658)

1 1/8 7 790 590 12 (1071) (800)

1 1/4 7 1110 835 12 (1505) (1132)

1 3/8 6 1460 1095 12 (1980) (1485)

1 1/2 6 1940 1455 12 (2630) (1973)

To convert lb. ft. to kg•m, multiply lb. ft. value by 0.1383.

WINCH BRAKE

BRAKE

VALVE

PUMP

CONTROL

VALVE

WINCH ASSEMBLY

W/BRAKE VALVE

& STATIC BRAKE

BR

DR

– 8 –

WIRE AND BRAIDED

ROPE INSTALLATION

ANCHORING WIRE ROPE

Take the free end of the wire rope and insert it through the small opening of the anchor pocket.

Loop the wire rope and push the free end about _ 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 anchor is designed to accommodate several different sizes of wire rope. You may anchor 7/16 and 1/2 in. (11 & 13 mm) wire rope by inserting the wedge, large end first. Anchor 9/16 and 5/8 in.

(14 & 16 mm) wire rope by inserting the wedge, small end first.

ANCHORING BRAIDED ROPE

A special wedge is used to anchor 1 and 1 1/8 in. (25 & 28 m) braided rope. The installation procedure is the same as for anchoring wire rope.

TWO SPEED MOTOR

CASE DRAIN PLUMBING

Winches built prior to 1991 with two speed motor, Part No. 26182, have the motor case drain connected to the drain port of the brake valve. This may result in accelerated motor shaft wear and leakage. The following modification should be made to the motor hydraulic piping to prevent this type of seal damage.

1. Remove the motor case drain hose from the brake valve drain port and install plug, Item 1, into the valve port. Remove the hose from the case drain port elbow, Item 4.

2. Install a new case drain hose, Item 2, onto the motor case drain elbow, Item 4.

3. Install the tee adapter, Item 3, into the two-speed motor shift valve drain port (identified by long end cap).

4. Install the new motor case drain hose, Item 2, onto the tee adapter.

Correct Installation

Incorrect Installation

Drive from this side

Wedge and wire rope fully seated in pocket

Figure 7 Figure 8

Figure 9 Figure 10

Wedge not fully seated

Wedge pulled too far through anchor pocket

– 9 –

The following minimum service intervals are specified for operating hours of the prime mover.

1. Oil Level The gear oil level should be checked every 500 operating hours or three (3) months, whichever occurs first. To check the oil level, remove the large plug located in the center of the drum support. The oil should be level with the bottom of this opening.

If additional oil in needed, refer to “Recommended Planetary Gear Oil”.

2. Oil Change The gear oil should be changed after the first one hundred (100) hours of operation, then every 1,000 operating hours or six (6) months, whichever occurs first. The gear oil must be changed to remove wear particles that impede the reliable and safe operation of the brake clutch and erode bearings, gears and seals. Failure to change gear oil at these suggested minimum intervals may contribute to intermittent brake slippage which could result in property damage, severe personal injury or death.

The gear oil should also be changed whenever the ambient temperature changes significantly and an oil from a different temperature range would be more appropriate. Oil viscosity with regard to ambient temperature is critical to reliable brake

PREVENTIVE MAINTENANCE

A regular program of preventive maintenance for your planetary winch is strongly recommended to minimize the need for emergency servicing and promote safe, reliable winch operation.

Field experience, supported by engineering tests, indicate the three (3) service procedures listed below are the MOST critical to safe, reliable winch operation and must be observed.

• Regular Gear Oil Changes – every 1000 hours or six (6) months

• Use of Proper Gear Oil – recommended type for prevailing ambient temperature

• Annual Disassembly and Inspection of All Wear Items – in compliance with American National Standards Institute

(ANSI) specification B30.5c 1987 and American Petroleum Institute (API) recommended practice RP 2D section 3.

5. Install a case drain hose for the tee directly to the reservoir. Minimum hose size is –6, 3/8 in. (9.5 mm).

Maximum drain line back pressure is 100 PSI (7 Kg/cm2) measured at the motor case drain port.

Parts needed for modification:

Item Qty P/N Description 1 1 25663 Plug –4 (Aeroquip 900598-4S) 2 1 13707 Hose 17 in. OAL

(-4 JIC Fml Svl/-4 Hose / 1/8 NPT ml)

3 1 29078 Tee –4 (Aeroquip 203003-4-4S)

– 10 – clutch operation. Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake clutch slippage. Make certain that the gear oil viscosity used in your winch is correct for your prevailing ambient temperature.

Failure to use the proper type and viscosity of planetary gear oil may contribute to brake clutch slippage which could result in property damage, severe personal injury or death. Refer to “Recommended Planetary Gear Oil” for additional information.

3. Vent Plug The vent plug is located in the drum support as shown. It is very important to keep this vent clean and unobstructed. Whenever gear oil is changed, remove vent plug, clean in solvent and reinstall.

Do not paint over the vent or replace with a solid plug.

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 accordance with the equipment manufacturer’s recommendations.

5. Wire Rope Inspect entire length of wire rope according to wire rope manufacturers recommendations.

6. Mounting Bolts Tighten all winch base mounting bolts to recommended torque after the first one hundred

(100) hours of operation, then every 1000 operating hours or six (6) months, whichever occurs first.

7. Warm-up Procedures A warm-up procedure is recommended at each start-up and is essential at ambient temperatures below +40°F (4°C).

The prime mover should be run at its lowest recommended 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 circulate gear lubricant through the planetary gear sets.

8. Recommended Planetary Gear Oil Field experience, supported by extensive engineering 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 available product 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.

BRADEN planetary winches are factory filled with Texaco Meropa 150 or equivalent AGMA No. 4EP gear oil.

9. Inspection In compliance with ANSI specification number B30.5c1987 and API Recommended Practice RP 2D section 3, we recommend that the winch be disassembled for a thorough inspection of all wear items every 2,000 hours of operation or twelve (12) months, whichever occurs first.

A. Bearings and Gears – Refer to DISASSEMBLY OF WINCH, page 15; and PLANET CARRIER SERVICE, page 20.

B. Brake Cylinder – Refer to MOTOR

SUPPORT – BRAKE CYLINDER SERVICE,

pages 22 and 23.

C. Brake Clutch – Refer to BRAKE CLUTCH SERVICE, page 26.

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.

Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slippage which could result in property damage, severe personal injury or death. Some gear lubricants contain large amounts of EP (extreme pressure) and anti-friction additives which may contribute to brake clutch slippage and damage to brake friction discs or seals. Oil viscosity with regard to ambient temperature is also critical to reliable brake clutch operation. Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake clutch slippage. Make certain that the gear oil viscosity used in your winch is correct for your prevailing ambient temperature.

– 11 –

TROUBLE

A The winch will not lower the load or not lower the load smoothly.

PROBABLE CAUSE

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 pressure, from the manifold, from opening the brake valve. If it becomes loose, it will allow an unregulated amount of oil in to operate the brake valve which cause erratic brake valve operation.

2. The friction brake may not be releasing 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.

3. Friction brake will not release as a result of damaged brake discs.

REMEDY

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 orifice 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

(5) 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”.

TROUBLESHOOTING

If a winch ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping or chattering) appropriate troubleshooting tests and repairs should be performed immediately.

Continued operation in this manner may result in property damage, serious personal injury or death.

RECOMMENDED PLANETARY GEAR OIL

PREVAILING AMBIENT TEMPERATURE

oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF

EXXON SPARTAN EP220 OR EQUIVALENT

AGMA 5 EP, ISO VG 220

EXXON SPARTAN EP150 OR EQUIVALENT

AGMA 4 EP, ISO VG 150

MOBIL SHC 629 or 630

SYNTHETIC OR EQUIVALENT

oC -40 -30 -20 -10 0 10 20 30 40 50 oC NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE

CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.

Texaco Meropa 150, previously used as factory fill, may no longer be widely available due to current market conditions. As of mid-year 2002, planetary hoists are factory filled with Exxon Spartan EP150, or equivalent. The chart below relates the Texaco products to 4 currently available oils. Consult your oil supplier for other equivalent oils if required.

i

Texaco MobilExxon Shell

Meropa 150

Meropa 220

Mobilgear 629Spartan EP 150 Omala 150

Mobilgear 630Spartan EP 220 Omala 220

Chevron

American Industrial Oils 150

American Industrial Oils 220

9/2002

RECOMMENDED PLANETARY GEAR OIL

PREVAILING AMBIENT TEMPERATURE

oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF

EXXON SPARTAN EP220 OR EQUIVALENT

AGMA 5 EP, ISO VG 220

EXXON SPARTAN EP150 OR EQUIVALENT

AGMA 4 EP, ISO VG 150

MOBIL SHC 629 or 630

SYNTHETIC OR EQUIVALENT

oC -40 -30 -20 -10 0 10 20 30 40 50 oC NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE

CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.

Texaco Meropa 150, previously used as factory fill, may no longer be widely available due to current market conditions. As of mid-year 2002, planetary hoists are factory filled with Exxon Spartan EP150, or equivalent. The chart below relates the Texaco products to 4 currently available oils. Consult your oil supplier for other equivalent oils if required.

i

Texaco MobilExxon Shell

Meropa 150

Meropa 220

Mobilgear 629Spartan EP 150 Omala 150

Mobilgear 630Spartan EP 220 Omala 220

Chevron

American Industrial Oils 150

American Industrial Oils 220

Texaco MobilExxon Shell

Meropa 150

Meropa 220

Mobilgear 629Spartan EP 150 Omala 150

Mobilgear 630Spartan EP 220 Omala 220

Chevron

American Industrial Oils 150

American Industrial Oils 220

9/2002

OIL CAPACITIES: (PD12C/PD15B) 01, 02 & 22 DRUM - 6 PINTS 04, 05 & 23G DRUM – 7 PINTS (PD17A) - 14 PINTS NOTE: Capacities are approximate. Refer to “Oil Level” earlier in this section

– 12 –

B

Oil leaks from vent plug.

PROBABLE CAUSE

1. Same as A2.

2. Motor seal may be defective as a result of high system back pressure or contaminated oil.

REMEDY

Same as A2.

System back pressure must not exceed 150 psi. Inspect hydraulic system for a restriction in the return line from the control 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 filters and oil. Install new motor seal.

C

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

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.

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 recommended 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”.

D

The winch will not hoist the rated load.

1. The winch may be mounted on an uneven or flexible surface which causes 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.

Reinforce mounting surface.

If necessary, use shim stock 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.

– 13 –

TROUBLE “D” CONTINUED

FROM PREVIOIUS PAGE

PROBABLE CAUSE

3. Be certain hydraulic system temperature 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.

REMEDY

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 disassembly or replacement.

Same as remedies for Trouble D1 & D2.

Same as remedies for Trouble E2.

Refer to winch performance charts for additional information.

Perform rigging service as recommended by crane manufacturer.

E

The winch runs hot. 1. Same as D1.

2. Be certain that the hydraulic system temperature is not more than 180 degrees F. Excessive hydraulic oil temperatures 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 efficiently.

3. Excessively worn or damaged internal winch parts.

Same as remedies for Trouble D1.

Thoroughly clean exterior and flush interior.

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.

– 14 –

F Winch “chatters” while raising rated load.

PROBABLE CAUSE

1. Same as D2.

2. Hydraulic oil flow to motor may be too low.

3. Controls being operated too quickly.

REMEDY

Same as remedies for Trouble D2.

Same as remedies for Trouble E2.

Conduct operator training as required.

G

The wire rope does not spool smoothly on the drum.

1. The winch may be mounted too close to the main sheave, causing the fleet angle to be more than 1-1/2 degrees.

2. The winch may not be mounted perpendicular to an imaginary line between the center of the cable drum and the first sheave.

3. Could possibly be using the wrong lay rope. There is a distinct advantage in applying rope of the proper direction of lay. When the load is slacked off, the several coils on the drum will stay closer together and maintain an even layer. If rope of improper lay is used, the coils will spread apart each time the load is removed. Then, when 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 overloaded, causing permanent set in the wire rope.

Check mounting distance and fleet angle. Reposition winch as required.

Refer to “Winch Installation”.

Consult wire rope manufacturer for recommendation of wire rope that best suits your application.

Replace wire rope and conduct operator/rigger training as required.

– 15 –

SERVICE PRECAUTIONS

• Before any part is removed from the winch, all service instructions should be read and understood.

• Work in a clean, dust free area as cleanliness is of utmost importance when servicing hydraulic equipment.

• 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 problem is determined to be in the winch, use the following procedure to disassemble the winch.

1. 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.

3. 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.

4. 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.

DISASSEMBLY OF WINCH

– 16 –

5. Tag and remove the hoses and fittings from the brake cylinder release port.

6. Remove the brake clutch assembly from the motor support. Refer to “Brake Clutch Service” for additional information.

7. Remove the motor support capscrews and install two (2) capscrews and a short piece of chain into the motor mounting bolt holes. Using the chain as a handle, lift the motor support out of the brake cylinder being careful to avoid damaging the sealing surfaces. Remove and discard the O-ring and back-up ring from the motor support.

Refer to “Motor Support-Brake Cylinder Service” for additional information.

8. Remove the brake cylinder capscrews and install two (2) capscrews and a short piece of chain into the motor support mounting bolt holes. Using the chain as a handle, lift the brake cylinder out of the drum and base, being careful to avoid damaging the sealing or bearing surfaces. Refer to “Motor Support-Brake Cylinder Service” for additional information.

For PD15B winches, the drum closure cannot be removed through the opening in the base. If your winch has a cast base, remove the bearing support, as described in step 15, and remove the drum from the base. Then proceed with steps 9 thru 14. If your winch has a three piece base, remove the motor end side plate and continue with step 9.

9. Using two heel type pry bars placed between the primary planet carrier and the drum closure, pry upward to remove the drum closure. Remove and discard the O-ring from the outside of the drum closure.

10. Remove the seal and bearing from inside of closure.

– 17 –

11. Remove the primary sun gear and thrust washer from the primary planet carrier.

12. Remove the primary planet carrier from the drum.

Refer to “Planet Carrier Service” for additional information.

13. Remove the output sun gear and thrust washer from the output planet carrier.

14. Remove the output planet carrier from the drum.

Refer to “Planet Carrier Service” for additional information.

15. Stand winch on motor end with bearing support up; then remove eight (8) bearing support capscrews and bearing support being careful to avoid damaging the sealing or bearing surfaces.

16. Slide drum out of base onto a work bench and remove seal and bearing from support end.

17. Thoroughly clean and inspect drum and base.

Check ring gear (machined 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.

– 18 –

– 19 –

– 20 –

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, discoloration, material displacement or abnormal wear, the bearing should be replaced. Likewise, the cage should be inspected for unusual wear or deformation, particularly the cage bars. If there is any damage that will impair the cage’s ability to separate, retain and guide the rollers properly, the bearing should be replaced. The thrust washer contact areas should be free from any surface irregularities that may cause abrasions or friction.

The gears and shafts should be inspected for abnormal wear or pitting. Replace if necessary.

ASSEMBLY

1. Place the output planet carrier on workbench with splined coupling side down. Install output thrust plate in center of carrier.

PLANET CARRIER SERVICE

PD17A winches have an internal retaining ring to hold the thrust plate into the carrier. This retaining ring MUST be properly installed and fully seated before the planet gears are installed.

– 21 –

2. Insert two (2) bearings and a bearing spacer into a gear with the spacer between the bearings.

Place a thrust washer on each side of the gear and position 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. When properly positioned, 50% of the roll pin will engage the planet gear shaft and 50% will remain in the planet carrier.

4. Note that the roll pin is slightly recessed in the carrier 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.

i NOTE: PD17A winches DO NOT have a thrust plate in the primary planet assembly.

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NOTE: Starting mid-year 1996, 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 diameter of the motor support. When 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 disassembly 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.

MOTOR SUPPORT-BRAKE CYLINDER SERVICE

DISASSEMBLY

– 23 –

3. Place friction brake disc on flat surface and check for distortion with a straight edge. Friction material should appear even across entire surface with groove pattern visible. Replace friction disc if splines are worn to a point, disc is distorted, friction material is worn unevenly, or groove pattern is worn away.

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.

5. Check brake spring free length; minimum free length is 1 3/16 in. (30.2 mm). Check springs for any sign of cracking or failure. If a brake spring must be replaced for any reason, then ALL brake springs must be replaced.

ASSEMBLY

1. Begin assembly by placing motor support on workbench with motor mounting surface down.

Install new O-ring and back-up ring as shown.

2. Install a brake spacer into the motor support. (Not required with lobed discs.)

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

– 24 –

3. 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.

4. Install the remaining brake spacer on top of the last steel brake disc. (This is the only spacer used with lobed discs.)

5. To check brake stack height, place pressure plate on top of brake spacer. Hold pressure plate down firmly by hand and measure clearance in three places between motor support and pressure plate.

Average gap must measure between .153 in. (4

mm) maximum and .080 in. (2 mm) minimum. 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 minimum, 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.

6. Lubricate the brake piston seal and motor support sealing surface with petroleum jelly or hydraulic oil.

Install new piston seal to motor support, 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.

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.

– 25 –

8. Install pressure plate into brake cylinder followed by the piston back-up ring. The close-fitting piston back-up ring may be depressed slightly to one side to lodge the back-up ring in the brake cylinder bore and temporarily hold the pressure plate and springs in place while you lower the brake cylinder over the motor support.

9. 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 installation.)

10. Install motor support capscrews and evenly tighten to recommended torque.

BRAKE CYLINDER PRESSURE TEST

1. 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 disassembled for inspection of the sealing surfaces and brake piston.

2. 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.

3. 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.

DISASSEMBLY

1. Remove the snap ring and sprag bushing retainer from one end only.

2. Pull the inner race out. Examine the race for scoring, 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 surface. If a bushing’s inside surface is damaged or shows wear, replace it.

4. 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 further disassembly. If 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.

ASSEMBLY

1. Press a sprag bushing into the outer race, using a mechanical or hydraulic press. A flat plate of approximately the 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.

– 26 –

BRAKE CLUTCH SERVICE

WARNING

The polished surfaces of the races and sprag cams must be perfectly smooth to insure positive engagement of the clutch. The slightest defect may reduce brake clutch effectiveness, which may lead to loss of load control and result in property damage, personal injury or death. It is generally recommended to replace the entire brake clutch assembly if any component is defective.

CAUTIONWARNING! !

i NOTE: The brake clutch on PD17A winches uses a stepped inner race, which eliminates one retaining ring and bushing retainer. The larger end of the inner race is toward the motor.

– 27 –

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. NOT necessary on PD17A due to stepped design.

5. Slide the inner race through the bushings…