Installation, Maintenaince and Service Braden PD15B,PD12C,PD17A

BRADENSERIES

PD12CPD15BPD17A HYDRAULIC WINCH

INSTALLATION, MAINTENANCE AND SERVICE MANUAL

PACRWINCH DIVISIONP.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013PHONE (918) 251-8511 FAX (918) 259-1575www.paccarwinch.comLIT2081 R1

3/2003PRINTED IN U.S.A.

– 1 –

FOREWORDRead 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 ServiceDepartment 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 maintenanceinformation for the BRADEN Model PD12C, PD15B and PD17A series winch. It is suggested that before doing anywork 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, somecomponents 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 equipmentmanufacturers, may differ slightly in appearance.

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

Serial Numbers and Model Numbers are located tothe left hand side of the hydraulic motor, stampedinto the base. Always refer to the Serial Numberand Model Number when requesting informationor service parts.

EXPLANATION OF MODEL NUMBER

PD DESIGNATES POWER DRUM12 DESIGNATES 12,000 LB. APPROXIMATE FIRST LAYER LINE PULLC DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES29 DESIGNATES TOTAL GEAR REDUCTION064 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV

(DECIMAL POINT ELIMINATED. EXAMPLE 064 = 6.4 CU IN/REV)02 DESIGNATES THE DRUM OPTIONU DESIGNATES UNDERWOUND CABLE DRUM – OPTIONALL DESIGNATES LEFT HAND BASE – OPTIONAL1 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 OPTIONDRUM RATING MODEL RATIO SIZE OPTION

– 2 –

TABLE OF CONTENTS

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

THEORY OF OPERATION...............................................................................................4

WINCH INSTALLATION ...................................................................................................6

RECOMMENDED FASTENER TORQUE ........................................................................7

WIRE AND BRAIDED ROPE INSTALLATION .................................................................8

TWO SPEED MOTOR CASE DRAIN PLUMBING ..........................................................8

PREVENTIVE MAINTENANCE –

RECOMMENDED OIL CHANGE INFORMATION ..............................................9

TROUBLE SHOOTING ..................................................................................................11

WINCH DISASSEMBLY .................................................................................................15

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

PLANET CARRIER SERVICE .......................................................................................20

MOTOR SUPPORT – BRAKE CYLINDER SERVICE ...................................................22

BRAKE CLUTCH SERVICE...........................................................................................26

WINCH ASSEMBLY .......................................................................................................28

BRAKE VALVE SERVICE ..............................................................................................32

REVERSING DIRECTION OF DRUM ROTATION ........................................................34

– 3 –

GENERAL SAFETY RECOMMENDATIONSSafety and informational callouts used in this manual include:

Safety for operators and ground personnel is of prime concern. Always take the necessary precautions to ensuresafety to others as well as yourself. To ensure safety, the prime mover and winch must be operated with care andconcern 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 againsthazards and unsafe practice which COULD result insevere personal injury or death if proper proceduresare not followed.

CAUTION – This emblem is used to warn againstpotential or unsafe practices which COULD result inpersonal injury and product or property damage ifproper procedures are not followed.

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

2. Be sure personnel are clear of work area BEFOREoperating winch.

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

4. Inspect rigging and winch at the beginning of eachwork shift. Defects should be correctedimmediately.

5. Keep equipment in good operating condition.Perform scheduled servicing and adjustments listedin the “Preventive Maintenance” section of thismanual.

6. An equipment warm-up procedure is recommendedfor all start-ups and essential at ambienttemperatures below +40°F (4°C). Refer to “Warm-up Procedure” listed in the “PreventiveMaintenance” 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 clothingclear of cable rollers, cable entry area of fairleadsand winch drum.

10. When winding wire rope on the winch drum, neverattempt to maintain tension by allowing wire rope toslip through hands. Always use “Hand-Over-Hand”technique.

11. Never use wire rope with broken strands. Replacewire 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 installedproperly. For additional safety, ALWAYS maintain aminimum of five (5) wraps of wire rope on the drum.

18. Never attempt to clean, oil or perform anymaintenance on a machine with the engine or primemover running, unless instructed to do so in thismanual.

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

20. Assure that personnel who are responsible for handsignals are clearly visible and that the signals to beused are thoroughly understood by everyone.

21. Ground personnel should stay in view of theoperator and clear of winch drum. Do not allowground personnel near winch line under tension. Asafe distance of at least 1 _ times the length of thecable should be maintained.

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

23. Install guarding to prevent personnel from gettingany part of body or clothing caught at a point wherethe cable is wrapped onto the drum or drawnthrough guide rollers.

24. “Deadman” controls, which automatically shut offpower to the winch whenever the operator leaveshis station, should be installed wheneverpracticable.

25. Never allow anyone to stand under a suspendedload.

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

CAUTIONCAUTIONWARNING! !

– 4 –

DESCRIPTION OF WINCHThe winch has four basic component parts:

1. Winch base2. Hydraulic motor and brake valve3. Brake cylinder and motor support4. Drum assembly

The drum assembly consists of three basicassemblies:

1. Drum with integral ring gear2. Output planetary gear set3. Primary planetary gear set

The hydraulic motor is bolted to the motor supportwhich in turn is bolted to the brake cylinder and thebase. The motor end of the drum, running on a ballbearing, is supported by the brake cylinder. The otherend of the drum runs on a ball bearing on the supportbolted to the base. The ring gear for both planetarysets is machined into the drum’s inside surface.

WINCH OPERATIONThe hydraulic motor drives the sun gear of theprimary planetary gear set through the splined innerrace of the brake clutch. When driven by the sungear, the primary planet gears walk around the ringgear in the drum and drive the primary planet carrier.

The primary planet carrier drives the output planetsun gear which, in turn drives the output planetgears. The output planet carrier is splined to thebearing support and cannot rotate. Therefore, as theoutput planet gears are driven by the sun gear, theywill drive the ring gear/drum.

Dual Brake System – DescriptionThe dual brake system consists of a dynamic brakesystem and a static brake system.The dynamic brake system has two operatingcomponents:

1. Brake valve assembly2. Hydraulic motor

The brake valve is basically a counterbalance valve.It contains a check valve to allow free flow of oil to themotor in the hoisting direction and a pilot operated,spring-loaded spool valve that blocks the flow of oilout of the motor when the control valve is placed inneutral. When the control valve is placed in thelowering position, the spool valve remains closeduntil sufficient pilot pressure is applied to the end ofthe spool to shift it against spring pressure and opena passage. After the spool valve cracks open, thepilot pressure becomes flow-dependent andmodulates the spool valve opening which controlsthe lowering speed.

Figures 2, 3 and 4.

The static brake system has three operatingcomponents:

1. Spring Applied, Multiple Friction Disc StaticBrake

2. Brake Clutch Assembly3. 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


Static Brake

Brake Valve

Pump

Motor

Control Valve

To Tank

– 5 –

Figure 4

LOWERING 2

The static brake is released by the brake valve pilotpressure at a pressure lower than that required to openthe pilot operated spool valve. This sequence assuresthat dynamic braking takes place in the brake valveand that little, if any, heat is absorbed by the frictionbrake.

The friction brake is a load holding brake only and hasnothing to do with dynamic braking or rate of descentof a load.

The brake clutch is splined to the primary sun gearshaft between the motor and the primary sun gear. Itwill allow this shaft to turn freely in the direction to raisea load and lock up to force the brake discs to turn withthe shaft in the direction to lower a load. Figures 5 and6.

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

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

When the lifting operation is stopped, the load attemptsto turn the primary sun gear in the opposite direction.This reversed input causes the sprag cams to instantlyroll upward and firmly lock the shaft to the fullyengaged friction brake. Figure 6.

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

& 4. The friction brake within the winch will completelyrelease at a pressure lower than that required to openthe brake valve. The extent to which the brake valveopens will determine the amount of oil that can flowthrough it and the speed at which the load will belowered. Increasing the flow of oil to the winch motorwill cause the pressure to rise and the opening in thebrake valve to enlarge, speeding up the descent of theload. Decreasing this flow causes the pressure to lowerand the opening in the brake valve to decrease thusslowing the descent of the load.

When the control valve is shifted to neutral, thepressure will drop and the brake valve will close,stopping the load. The friction brake will engage andhold the load after the brake valve has closed.

When lowering a load very slowly for precisepositioning, no oil flow actually occurs through thewinch motor. The pressure will build up to a pointwhere the brake will release sufficiently to allow theload to rotate the motor through its own internalleakage. This feature results in a very slow speed andextremely accurate positioning.

The friction brake receives very little wear in thelowering operation. All of the heat generated by thelowering and stopping of a load is absorbed by thehydraulic oil where it can be readily dissipated.

Figure 5

Figure 6

STATIC FRICTION BRAKE APPLIED

PERMITS FREE SHAFT ROTATIONWHILE HOISTING

STATIC FRICTION BRAKE APPLIED

SPRAG CAMS

LOAD ATTEMPTS TO ROTATE SHAFT INOPPOSITE DIRECTION.

BRAKE CLUTCH LOCKS SUN GEAR SHAFTTO FRICTION BRAKE.

SPRAG CAMS


Static Brake

Brake Valve

Pump

Motor

Control Valve

To Tank

– 6 –

1. The winch should be mounted with the centerlineof the drum in a horizontal position. The mountingplane of the base may be rotated in any positionaround this centerline.

2. Because of the design of the mounting base, thedirection of line pull should only be as shown inthe above illustration. Line pulls in any otherdirection must be approved by BRADENEngineering.

3.

When mounting the winch, use all eight (8)mounting holes and grade 5 or better bolts andnuts. Tighten to recommended torque.

It is important that the winch is mounted on asurface that will not flex when the winch is in use,and cause binding of the gear train. Binding in thegear train will result in accelerated wear and heat.Also, be sure the winch is mounted on a flatsurface. If necessary, use shim stock to insure themounting surface is flat within 0.020 in. (0.5 mm).

4. The vent plug must always be located above thehorizontal centerline. If the winch is mounted on apivoting surface, be sure vent plug remains abovethe centerline in all positions. If necessary,reposition bearing support and vent plug asfollows:

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 thewinch should be of sufficient size to assureminimum back pressure at the winch. The motormanufacturer recommends that the back pressurenot to exceed 100 psi (690 kPa) for optimummotor seal life. 150 psi (1,030 kPa) is themaximum allowable back pressure. The standardwinch is supplied with the motor internally drained.If high back pressures are encountered, the motormay be externally drained directly to tank toimprove motor seal life. For back pressuresexceeding 150 psi (1,030 kPa) consult BRADENService Department.

6. The winch should be mounted perpendicular to animaginary line from the center of the drum to thefirst sheave to insure even spooling. Make certainthe fleet angle does not exceed 1-1/2 degrees.

WINCH INSTALLATION

30°

75°

VENT PLUGABOVE CENTERLINE

SHADED AREAS REPRESENTACCEPTABLE DIRECTIONS OFLINE PULL

CL

– 7 –

7. The winch directional control valve must be athree position four way valve with a motor spoolsuch that when the valve is in the center positionboth work ports are open to tank (open center,open port).

8. High quality hydraulic oil is essential forsatisfactory performance and long hydraulicsystem component life.

Oil having 150 to 330 SUS viscosity at 100°F(38°C) and viscosity index of 100 or greater willgive good results under normal temperatureconditions. The use of an oil having a highviscosity index will minimize cold-start trouble andreduce the length of warm-up periods. A highviscosity index will minimize changes in viscositywith corresponding changes in temperature.

Maximum cold weather start-up viscosity shouldnot exceed 5000 SUS with a pour point at least20°F (11°C) lower than the minimum temperature.

Under continuous operating conditions thetemperature of the oil at any point in the systemmust not exceed 180° (82°C). Optimum oiltemperature is generally considered to be 120-140°F (49-60°C).

In general terms; for continuous operation atambient temperatures between 50 and 110°F (10to 43°C) use SAE 20W; for continuous operationbetween 10 and 90°F (-12 to 32°C) use SAE 10W;for applications colder than 10°F (-12°C), contactthe BRADEN Service Department. The use ofmulti-viscosity oils is generally not recommended.

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

RECOMMENDED FASTENER TORQUEThe general purpose torque shown in the chart applies to SAE Grade 5 bolts, studs and standard steel full, thickand high nuts.

Higher or lower torques for special applications will be specified such as the use of spanner nuts, nuts on shaftends, 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 LUBED1/4 20 9 6

28 (12) (8)

5/16 18 18 1324 (24) (18)

3/8 16 31 2324 (42) (31)

7/16 14 50 3720 (68) (50)

1/2 13 75 5520 (102) (75)

9/16 12 110 8018 (149) (109)

5/8 11 150 11518 (203) (156)

BOLT THD TORQUE LB-FT.DIA. PER (N•m)

INCHES INCH DRY LUBED3/4 10 265 200

16 (359) (271)

7/8 9 420 32514 (569) (441)

1 8 640 48514 (868) (658)

1 1/8 7 790 59012 (1071) (800)

1 1/4 7 1110 83512 (1505) (1132)

1 3/8 6 1460 109512 (1980) (1485)

1 1/2 6 1940 145512 (2630) (1973)

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

WINCH BRAKE

BRAKEVALVE

PUMP

CONTROLVALVE

WINCH ASSEMBLYW/BRAKE VALVE& STATIC BRAKE

BR

DR

– 8 –

WIRE AND BRAIDEDROPE INSTALLATIONANCHORING WIRE ROPE

Take the free end of the wire rope and insert itthrough the small opening of the anchor pocket.Loop the wire rope and push the free end about _ ofthe way back through the pocket. Install the wedge,then pull the slack out of the wire rope. The wedgewill slip into the pocket and secure the wire rope intothe drum. The anchor is designed to accommodateseveral different sizes of wire rope. You may anchor7/16 and 1/2 in. (11 & 13 mm) wire rope by insertingthe wedge, large end first. Anchor 9/16 and 5/8 in.(14 & 16 mm) wire rope by inserting the wedge, smallend 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 isthe same as for anchoring wire rope.

TWO SPEED MOTORCASE DRAIN PLUMBINGWinches built prior to 1991 with two speed motor,Part No. 26182, have the motor case drainconnected to the drain port of the brake valve. Thismay result in accelerated motor shaft wear andleakage. The following modification should be madeto the motor hydraulic piping to prevent this type ofseal damage.

1. Remove the motor case drain hose from thebrake valve drain port and install plug, Item1, into the valve port. Remove the hose fromthe case drain port elbow, Item 4.

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

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

4. Install the new motor case drain hose, Item2, onto the tee adapter.

Correct Installation

Incorrect Installation

Drive fromthis side

Wedge and wirerope fully seatedin pocket

Figure 7 Figure 8

Figure 9 Figure 10

Wedge notfully seated

Wedge pulledtoo far throughanchor pocket

– 9 –

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

1. Oil LevelThe gear oil level should be checked every 500operating hours or three (3) months, whicheveroccurs first. To check the oil level, remove the largeplug located in the center of the drum support. Theoil should be level with the bottom of this opening.If additional oil in needed, refer to “RecommendedPlanetary Gear Oil”.

2. Oil ChangeThe gear oil should be changed after the first onehundred (100) hours of operation, then every 1,000operating hours or six (6) months, whicheveroccurs first. The gear oil must be changed toremove wear particles that impede the reliable andsafe operation of the brake clutch and erodebearings, gears and seals. Failure to change gearoil at these suggested minimum intervals maycontribute to intermittent brake slippage whichcould result in property damage, severe personalinjury or death.

The gear oil should also be changed whenever theambient temperature changes significantly and anoil from a different temperature range would bemore appropriate. Oil viscosity with regard toambient temperature is critical to reliable brake

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

Field experience, supported by engineering tests, indicate the three (3) service procedures listed below are the MOSTcritical 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.

1

3

2

4

5. Install a case drain hose for the tee directly to thereservoir. Minimum hose size is –6, 3/8 in. (9.5 mm).Maximum drain line back pressure is 100 PSI (7Kg/cm2) measured at the motor case drain port.

Parts needed for modification:

Item Qty P/N Description1 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 thatexcessively heavy or thick gear oil may contributeto intermittent brake clutch slippage. Make certainthat the gear oil viscosity used in your winch iscorrect for your prevailing ambient temperature.Failure to use the proper type and viscosity ofplanetary gear oil may contribute to brake clutchslippage which could result in property damage,severe personal injury or death. Refer to“Recommended Planetary Gear Oil” for additionalinformation.

3. Vent PlugThe vent plug is located in the drum support asshown. It is very important to keep this vent cleanand unobstructed. Whenever gear oil is changed,remove vent plug, clean in solvent and reinstall.Do not paint over the vent or replace with a solidplug.

4. Hydraulic SystemThe original filter element should be replaced afterthe first fifty (50) hours of operation, then every 500operating hours or three (3) months, or inaccordance with the equipment manufacturer’srecommendations.

5. Wire RopeInspect entire length of wire rope according to wirerope manufacturers recommendations.

6. Mounting BoltsTighten all winch base mounting bolts torecommended torque after the first one hundred(100) hours of operation, then every 1000 operatinghours or six (6) months, whichever occurs first.

7. Warm-up ProceduresA warm-up procedure is recommended at eachstart-up and is essential at ambient temperaturesbelow +40°F (4°C).The prime mover should be run at its lowestrecommended RPM with the hydraulic winchcontrol valve in neutral allowing sufficient time towarm up the system. The winch should then beoperated at low speeds, forward and reverse,several times to prime all lines with warm hydraulicoil, and to circulate gear lubricant through theplanetary gear sets.

8. Recommended Planetary Gear OilField experience, supported by extensiveengineering tests, indicates the use of the properplanetary gear oil is essential to reliable and safeoperation of the brake clutch and obtaining longgear train life.

For simplicity, BRADEN has listed one (1) readilyavailable product in each temperature range whichhas been tested and found to meet ourspecifications. This is not to say that other lubricantbrands would not perform equally as well.

If the following lubricant brands are not available inyour area, make certain your lubricant vendorsupplies you with oil that is equivalent to thoseproducts listed below.

BRADEN planetary winches are factory filled withTexaco Meropa 150 or equivalent AGMA No. 4EPgear oil.

9. InspectionIn compliance with ANSI specification numberB30.5c1987 and API Recommended Practice RP2D section 3, we recommend that the winch bedisassembled for a thorough inspection of all wearitems 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, particularlyunder low ambient temperature conditions, mayresult in temporary brake slippage due to high backpressures attempting to release the brake, whichcould result in property damage, severe personalinjury or death.

Failure to use the proper type and viscosity ofplanetary gear oil may contribute to intermittent brakeclutch slippage which could result in propertydamage, severe personal injury or death. Some gearlubricants contain large amounts of EP (extremepressure) and anti-friction additives which maycontribute to brake clutch slippage and damage tobrake friction discs or seals. Oil viscosity with regardto ambient temperature is also critical to reliablebrake clutch operation. Our tests indicate thatexcessively heavy or thick gear oil may contribute tointermittent brake clutch slippage. Make certain thatthe gear oil viscosity used in your winch is correct foryour prevailing ambient temperature.

CAUTIONWARNING! !

CAUTIONWARNING! !

– 11 –

TROUBLE

AThe winch will not lower the load or notlower the load smoothly.

PROBABLE CAUSE

1. The problem could be a plugged orloose pilot orifice. The pilot orifice is asmall pipe plug with a hole drilled throughit, located behind the pilot port fitting onthe brake valve. If it becomes plugged, itwill prevent the pilot pressure, from themanifold, from opening the brake valve. Ifit becomes loose, it will allow anunregulated amount of oil in to operatethe brake valve which cause erratic brakevalve operation.

2. The friction brake may not be releasingas a result of a defective brake cylinderseal.

NOTE: If the brake cylinder seal isdefective you will usually find oil leakingfrom the winch vent plug.

3. Friction brake will not release as aresult of damaged brake discs.

REMEDY

Remove the pilot hose and fitting fromthe brake valve, then use a 5/32 inchAllen wrench to remove the pilot orifice.The diameter of the orifice isapproximately .020 inches. Clean andinstall the pilot orifice tightly in the brakevalve.

Check brake cylinder seal as follows:

A. Disconnect the swivel tee from thebrake release port. Connect a handpump with accurate 0-2000 psi gaugeand shut-off valve to the –4 J.I.C. fitting inthe brake release port.

B. Apply 1000 psi to the brake. Closeshut-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 bedisassembled for inspection of thesealing surfaces and replacement of theseals. Refer to “Motor Support-BrakeCylinder Service”.

Disassemble brake to inspect brakediscs. Check stack-up height asdescribed in “Motor Support-BrakeCylinder Service”.

TROUBLESHOOTINGIf a winch ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping orchattering) 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 OILPREVAILING 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 EQUIVALENTAGMA 5 EP, ISO VG 220


MOBIL SHC 629 or 630SYNTHETIC OR EQUIVALENT

oC -40 -30 -20 -10 0 10 20 30 40 50 oCNOTE: 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


Chevron

American Industrial Oils 150


9/2002

RECOMMENDED PLANETARY GEAR OILPREVAILING AMBIENT TEMPERATURE

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



MOBIL SHC 629 or 630SYNTHETIC OR EQUIVALENT

oC -40 -30 -20 -10 0 10 20 30 40 50 oCNOTE: 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


Meropa 150

Meropa 220



Chevron




Meropa 150

Meropa 220



Chevron



9/2002

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

CAUTIONWARNING! !

– 12 –

TROUBLE

B

Oil leaks from vent plug.

PROBABLE CAUSE

1. Same as A2.

2. Motor seal may be defective as aresult of high system back pressureor contaminated oil.

REMEDY

Same as A2.

System back pressure must notexceed 150 psi. Inspect hydraulicsystem for a restriction in the returnline from the control valve to thereservoir. Be sure control valve andplumbing is properly sized to winchmotor.

Oil analysis may indicatecontamination has worn motor shaftand seal. Thoroughly flush entirehydraulic system and install newfilters and oil. Install new motor seal.

C

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

1. Excessive system back pressureacting on the brake release port.

2. Friction brake will not hold due toworn or damaged brake discs.

3. Brake clutch is slipping.

The same as Remedy 2 of TroubleB2.

Same as Remedy 3 of Trouble A3.

Improper planetary gear oil maycause the brake clutch to slip. Drainold gear oil and flush winch withsolvent. Thoroughly drain solventand refill winch with recommendedplanetary gear oil listed in“Preventive Maintenance”.

Brake clutch may be damaged orworn. Disassemble and inspectbrake clutch as described in “BrakeClutch Service”.

D

The winch will not hoist the ratedload.

1. The winch may be mounted on anuneven or flexible surface whichcauses distortion of the winch baseand binding of the gear train. Bindingin the gear train will absorbhorsepower needed to hoist therated load and cause heat.

2. System relief valve may be set toolow. Relief valve needs adjustmentor repair.

Reinforce mounting surface.

If necessary, use shim stock to levelwinch. Refer to “Winch Installation”.

First loosen, then evenly retighten allwinch mounting bolts torecommended torque.

Check relief pressure as follows:

A. Install an accurate 0-4000 psi(27,580 kPa) gauge into the inletport of the brake valve.

– 13 –

TROUBLE

TROUBLE “D” CONTINUEDFROM PREVIOIUS PAGE

PROBABLE CAUSE

3. Be certain hydraulic systemtemperature is not more than 180degrees F. Excessive hydraulic oiltemperatures increase motorinternal leakage and reduce motorperformance.

4. Winch line pull rating is based on1st layer of wire rope.

5. Rigging and sheaves notoperating efficiently.

REMEDY

B. Apply a stall pull load on the winchwhile monitoring pressure.

C. Compare gauge reading to winchspecifications. Adjust relief valve asrequired.

NOTE: If pressure does notincrease in proportion to adjustment,relief valve may be contaminated orworn out. In either case, the reliefvalve may require disassembly orreplacement.

Same as remedies for Trouble D1 &D2.

Same as remedies for Trouble E2.

Refer to winch performance chartsfor additional information.

Perform rigging service asrecommended by cranemanufacturer.

E

The winch runs hot. 1. Same as D1.

2. Be certain that the hydraulicsystem temperature is not more than180 degrees F. Excessive hydraulicoil temperatures may be caused by:

A. Plugged heat exchanger.

B. Too low or too high oil level inhydraulic reservoir.

C. Same as D2.

D. Hydraulic pump not operatingefficiently.

3. Excessively worn or damagedinternal winch parts.

Same as remedies for Trouble D1.

Thoroughly clean exterior and flushinterior.

Fill/drain to proper level.


Prime mover low on horsepower orR.P.M. Tune/adjust prime mover.

Check suction line for damage.

If pump is belt driven, belts areslipping. Replace/tighten belts.

Pump worn. Replace pump.

Disassemble winch to inspect/replaceworn parts.

– 14 –

TROUBLE

FWinch “chatters” while raising ratedload.

PROBABLE CAUSE

1. Same as D2.

2. Hydraulic oil flow to motor may betoo low.

3. Controls being operated tooquickly.

REMEDY


Same as remedies for Trouble E2.

Conduct operator training asrequired.

G

The wire rope does not spoolsmoothly on the drum.

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

2. The winch may not be mountedperpendicular to an imaginary linebetween the center of the cabledrum and the first sheave.

3. Could possibly be using the wronglay rope. There is a distinctadvantage in applying rope of theproper direction of lay. When theload is slacked off, the several coilson the drum will stay closer togetherand maintain an even layer. If ropeof improper lay is used, the coils willspread apart each time the load isremoved. Then, when winding isresumed, the rope has a tendency tocriss-cross and overlap on the drum.The result is apt to be a flattenedand crushed rope.

4. The winch may have beenoverloaded, causing permanent setin the wire rope.

Check mounting distance and fleetangle. Reposition winch as required.

Refer to “Winch Installation”.

Consult wire rope manufacturer forrecommendation of wire rope thatbest suits your application.

Replace wire rope and conductoperator/rigger training as required.

– 15 –

SERVICE PRECAUTIONS• Before any part is removed from the winch, all

service instructions should be read andunderstood.

• Work in a clean, dust free area as cleanliness is ofutmost importance when servicing hydraulicequipment.

• Inspect all replacements parts, prior to installation,to detect any damage which might have occurredin shipment.

• Use only genuine BRADEN replacement parts foroptimum results. Never reuse expendable partssuch as oil seals and O-rings.

• Inspect all machined surfaces for excessive wearor damage . . . before reassembly operations arebegun.

• Lubricate all O-rings and oil seals with gear oil priorto installation.

• Use a sealing compound on the outside surface ofoil seals and a light coat of thread sealingcompound on pipe threads. Avoid getting threadcompound inside parts or passages which conductoil.

• Thoroughly clean all parts in a good grade of non-flammable safety solvent. Wear protective clothingas required.

After troubleshooting the winch and its hydraulicsystem as covered in the “Troubleshooting” section,and the problem is determined to be in the winch,use the following procedure to disassemble thewinch.

1. Remove the wire rope from the winch drum andalign the drain hole in the drum with a hole in thesupport side plate before removing the hosesand mounting bolts. After the winch is removedfrom its mounting, thoroughly clean the outsidesurfaces. 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 pocketand manually rotate the drum in the direction tohoist a load until the drain holes are aligned.

2. Use a 5/16 inch Allen wrench to remove the drainplug through the pipe.

3. Begin disassembly by removing the oil level plugand standing the winch on the bearing supportend. Tag and remove the hydraulic hoses thatconnect the brake valve and manifold to thebrake cylinder.

4. Remove the capscrews securing the motor, and liftthe motor off the winch. Remove and discard theO-ring installed on the pilot of the motor.

DISASSEMBLY OF WINCH

– 16 –

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

6. Remove the brake clutch assembly from the motorsupport. Refer to “Brake Clutch Service” foradditional information.

7. Remove the motor support capscrews and installtwo (2) capscrews and a short piece of chain intothe motor mounting bolt holes. Using the chainas a handle, lift the motor support out of thebrake cylinder being careful to avoid damagingthe 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 installtwo (2) capscrews and a short piece of chain intothe motor support mounting bolt holes. Using thechain as a handle, lift the brake cylinder out ofthe drum and base, being careful to avoiddamaging the sealing or bearing surfaces. Referto “Motor Support-Brake Cylinder Service” foradditional information.

For PD15B winches, the drum closure cannotbe removed through the opening in the base. Ifyour winch has a cast base, remove the bearingsupport, as described in step 15, and remove thedrum from the base. Then proceed with steps 9thru 14. If your winch has a three piece base,remove the motor end side plate and continuewith step 9.

9. Using two heel type pry bars placed between theprimary planet carrier and the drum closure, pryupward to remove the drum closure. Removeand discard the O-ring from the outside of thedrum closure.

10. Remove the seal and bearing from inside ofclosure.

– 17 –

11. Remove the primary sun gear and thrust washerfrom the primary planet carrier.

12. Remove the primary planet carrier from the drum.Refer to “Planet Carrier Service” for additionalinformation.

13. Remove the output sun gear and thrust washerfrom the output planet carrier.

14. Remove the output planet carrier from the drum.Refer to “Planet Carrier Service” for additionalinformation.

15. Stand winch on motor end with bearing supportup; then remove eight (8) bearing supportcapscrews and bearing support being careful toavoid damaging the sealing or bearing surfaces.

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

17. Thoroughly clean and inspect drum and base.Check ring gear (machined into inside surface ofdrum) teeth for nicks, spalling or excessive wear.Replace if wear is greater than 0.015 in. (0.4mm) when compared to unworn area of teeth.

– 18 –

– 19 –

– 20 –

OUTPUT PLANET CARRIERDISASSEMBLY

1. Remove the planet gears by driving the roll pinsinto the center of the planet shafts.

2. Use a punch to drive the roll pins from the planetshafts. Do not reuse the roll pins.

3. Now you can remove the planet shafts, bearings,spacer, thrust washers and gears. Thoroughlyclean all parts and inspect for damage and wear.The bearing rollers should not exhibit anyirregularities. If the rollers show any sign ofspalling, corrosion, discoloration, materialdisplacement or abnormal wear, the bearingshould be replaced. Likewise, the cage shouldbe inspected for unusual wear or deformation,particularly the cage bars. If there is any damagethat will impair the cage’s ability to separate,retain and guide the rollers properly, the bearingshould be replaced. The thrust washer contactareas should be free from any surfaceirregularities that may cause abrasions or friction.The gears and shafts should be inspected forabnormal wear or pitting. Replace if necessary.

ASSEMBLY

1. Place the output planet carrier on workbenchwith splined coupling side down. Install outputthrust plate in center of carrier.

PLANET CARRIER SERVICE

PD17A winches have an internal retaining ring to hold thethrust plate into the carrier. This retaining ring MUST beproperly installed and fully seated before the planet gearsare installed.

CAUTION

– 21 –

2. Insert two (2) bearings and a bearing spacer intoa gear with the spacer between the bearings.Place a thrust washer on each side of the gearand position in a carrier opening. Slide the shaftthrough the carrier, thrust washer, bearing-gearsub-assembly and remaining thrust washer.

3. Carefully align the pin hole in the carrier with thehole in the planet gear shaft and drive the roll pininto place. Always use NEW roll pins. Whenproperly positioned, 50% of the roll pin willengage the planet gear shaft and 50% will remainin the planet carrier.

4. Note that the roll pin is slightly recessed in thecarrier when properly installed. With a centerpunch, stake the carrier next to the pin hole asshown. This will distort the hole so the pin will notback out. Repeat these steps for each of thethree planet gears.

PRIMARY PLANET CARRIER1. To service the primary planet carrier, the steps

are the same as for the output carrier exceptthere is only one bearing for each gear and nobearing spacer.

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

– 22 –

NOTE: Starting mid-year 1996, Braden changed thesteel brake separator discs from a splined tooth designto a lobed design. This required a change to the motorsupport and brake cylinder and the addition of a springspacer. A winch with the lobed discs can be identifiedby a machined groove on the outside diameter of themotor support. When replacing steel brake discs, themotor support or brake cylinder, care must be taken toproperly identify the correct parts. Splined discs, andtheir mating motor support and brake cylinder willremain available as spare parts.

New lobed steel brake separator plates and motorsupport. Note groove on outside diameter of motorsupport.

Although most photos in this section show splineddiscs, all procedures are the same except wherespecifically noted.

DISASSEMBLY

1. After removing the motor support and brake clutchassembly, continue brake cylinder disassembly byremoving the spacers, friction brake discs and steelbrake discs.

2. Remove the piston back-up ring and pressureplate.

3. Remove the brake springs.

CLEAN AND INSPECT

1. Thoroughly clean and inspect all parts at this time.Check brake piston sealing surfaces on brakecylinder and motor support. Be sure brake releaseport is free of contamination.

2. Check oil seal and bearing surfaces on brakecylinder for damage or wear.

MOTOR SUPPORT-BRAKE CYLINDER SERVICE

DISASSEMBLY

– 23 –

3. Place friction brake disc on flat surface and checkfor distortion with a straight edge. Friction materialshould appear even across entire surface withgroove pattern visible. Replace friction disc ifsplines are worn to a point, disc is distorted, frictionmaterial is worn unevenly, or groove pattern isworn away.

4. Place steel brake disc on flat surface and check fordistortion with a straight edge. Check surface forsigns of material transfer or heat. Replace steeldisc if splines are worn to a point, disc is distortedor heat discolored.

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

ASSEMBLY

1. Begin assembly by placing motor support onworkbench with motor mounting surface down.Install new O-ring and back-up ring as shown.

2. Install a brake spacer into the motor support. (Notrequired with lobed discs.)

Failure to replace brake springs as a set may result inuneven brake application pressure and repeatedbrake spring failure.

CAUTION

– 24 –

3. Insert first, a steel brake disc against the spacerfollowed by a friction brake disc then alternate steeland friction discs until seven (7) friction and eight(8) steel discs have been installed. Finish with asteel brake disc on top.NOTE: It is a good practice to pre-lubricate thediscs in light motor oil prior to assembly.

4. Install the remaining brake spacer on top of the laststeel brake disc. (This is the only spacer used withlobed discs.)

5. To check brake stack height, place pressure plateon top of brake spacer. Hold pressure plate downfirmly by hand and measure clearance in threeplaces between motor support and pressure plate.Average gap must measure between .153 in. (4mm) maximum and .080 in. (2 mm) minimum. If thegap exceeds the maximum limit, there are toomany brake discs in stack-up or the discs aredistorted. If the gap is less than the minimum, thereare too few discs in stack-up or the discs are wornout. When stack height is correct, remove pressureplate and continue assembly.

6. Lubricate the brake piston seal and motor supportsealing surface with petroleum jelly or hydraulic oil.Install new piston seal to motor support, seal lipdown.

OLDER STYLE BRAKE CYLINDER7. Install brake springs into brake cylinder

NEW STYLE BRAKE CYLINDER7A.When using the new style brake cylinder without

milled spring pockets, install the spring spacer, thenthe brake springs.

Always use the molded spring spacer with the newbrake cylinder. The brake springs must be properlypositioned by the spring spacer. Failure to install thespring spacer may allow the springs to contact eachother and become damaged. This could result in lossof load control, property damage, injury or death.

CAUTIONWARNING! !

– 25 –

8. Install pressure plate into brake cylinder followedby the piston back-up ring. The close-fitting pistonback-up ring may be depressed slightly to one sideto lodge the back-up ring in the brake cylinder boreand temporarily hold the pressure plate and springsin place while you lower the brake cylinder over themotor support.

9. Apply petroleum jelly to the entire sealing surfaceof the brake cylinder and to the piston seal. Installthe brake cylinder over the motor support beingcareful to avoid damaging the piston seal or motorsupport O-ring. (A press may be necessary to avoidcocking the brake cylinder during installation.)

10. Install motor support capscrews and evenly tightento recommended torque.

BRAKE CYLINDER PRESSURE TEST

1. Install the –4 J.I.C. fitting into the brake releaseport. Connect a hand pump with accurate 0-2000psi (0-13,800 kPa) gauge and shut-off valve to thisfitting. 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 bedisassembled for inspection of the sealing surfacesand brake piston.

2. WHILE PRESSURE IS APPLIED AND THEBRAKE RELEASED, install the brake clutchassembly in the brake pack, short end of the innerrace toward motor. Turn the clutch back and forthas you align the outer race splines with the brakedisc splines.

3. Release the pressure on the brake cylinder thenremove the brake clutch assembly. The brakecylinder assembly is now complete and ready to beinstalled in the winch.

DISASSEMBLY

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

2. Pull the inner race out. Examine the race forscoring, wear or indentations caused by the spragcams.

3. Use a screwdriver and mallet to remove the spragbushing from one end of the outer race. There arefour special cut-outs in the bushing for thispurpose. Be careful not to damage the bushinginside surface. If a bushing’s inside surface isdamaged or shows wear, replace it.

4. Next, slide the sprag clutch out, inspect the spragclutch closely for abnormal wear, cracks, pitting orcorrosion. Check small clips for breakage or brightspots; the signs of excessive wear. Unless theouter race or remaining sprag bushing is damagedor shows excessive wear, there is no need forfurther disassembly. If disassembly is necessary,remove the bushing according to the procedurecovered in Step No. three (3). All brake clutchassembly parts should be thoroughly cleaned andinspected before assembly.

ASSEMBLY

1. Press a sprag bushing into the outer race, using amechanical or hydraulic press. A flat plate ofapproximately the same diameter as the bushingflange outside diameter should be placed betweenthe press and bushing during assembly to protectthe bushing. Be certain the bushing flange isagainst the shoulder in the outer race.

– 26 –

BRAKE CLUTCH SERVICE

WARNINGThe polished surfaces of the races and sprag camsmust be perfectly smooth to insure positiveengagement of the clutch. The slightest defect mayreduce brake clutch effectiveness, which may lead toloss of load control and result in property damage,personal injury or death. It is generallyrecommended to replace the entire brake clutchassembly if any component is defective.

CAUTIONWARNING! !

i NOTE: The brake clutch on PD17A winchesuses a stepped inner race, which eliminates oneretaining ring and bushing retainer. The largerend of the inner race is toward the motor.

– 27 –

2. Turn the assembly over and install the sprag clutchin 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 snapring on the inner race. Be sure the snap ring isseated in the snap ring groove. NOT necessary onPD17A due to stepped design.

5. Slide the inner race through the bushings andsprag clutch (the race will have to be rotated in thefree-wheeling direction to start it through the spragclutch). If the inner race will not go through thebushings, the bushings have probably beendamaged and should be replaced.

6. Turn the assembly over with the snap ring down.Install the second retainer and snap ring. Makecertain the snap ring is seated in the grooveproperly.

7. This is a completed brake clutch assembly.

WARNINGBe certain the snap ring is seated in the groove in thesplined bore of the inner race. This snap ring willkeep the brake clutch assembly correctly positionedin the center of the friction brake pack. Binding of thebrake or brake failure may occur if this snap ring isomitted.

CAUTIONWARNING! !

– 28 –

1. Place winch base on side with bearing support endup.

2. Install a new bearing in the drum if replacement isnecessary. Apply a non-hardening sealant on theoutside diameter of the new seal. Install the springside of the seal next to the bearing, then press intothe drum, using a flat plate to avoid distortion. Besure drain plug is installed securely.

3. Center the drum in the opening of the base.Lubricate the bearing support with petroleum jellyor gear oil and install in base and drum.

WINCH ASSEMBLYNOTE: PD15B winches ONLY

The drum closure will not fit through the opening in the base. For winches with a three piece base, first assemble thebearing support side plate (91) to the base plate (90). Go to step 1 and follow the assembly procedure. Install themotor end side plate and tie bar(s) after installing the drum closure in step 10.

For winches with a one piece cast base, use the following assembly procedure. With the drum horizontal, install theoutput planet carrier assembly, output sun gear (34), thrust washer (43), primary planet carrier assembly, thrust washer(31) and drum closure. (Apply a light coat of grease to the thrust washer to hold them in position.) Position the drumin the base and install the bearing support. (Refer to step 3 for two caution statements.) You may have to rotate thebearing support or planet gears to engage the bearing support with the output planet carrier. Install and hand tightenthe bearing support capscrews. Stand winch on bearing support end and visually check to verify the primary thrustplate is properly positioned. (Refer to caution and drawings in step 16.) Install the primary sun gear and proceed tostep 11 to complete winch assembly. Tighten bearing support capscrews to recommended torque after motor isinstalled.

Winches with a three piece fabricated base usespecial shoulder capscrews to fasten side plates tothe base plate. DO NOT use standard capscrews intheir place.

Make certain the snap ring is installed on the bearingsupport. This snap ring will keep the output planetcarrier correctly positioned in the winch. Gear traindamage may occur if this snap ring is omitted.

CAUTION

CAUTION

– 29 –

4. Tighten the bearing support capscrews to therecommended torque.

5. Stand winch on bearing support end. Install theoutput sun gear and thrust washer into outputplanet carrier.

6. Install the output planet carrier into the drum whilemeshing the planet gears with the ring gear andthe planet housing with the bearing support.

7. Install the primary sun gear and thrust washer intothe primary planet carrier.

8. Install the primary planet carrier, meshing theplanet gears with the ring gear and the planethousing with the output sun gear.

9. Install a new bearing in the drum closure asrequired. Use sealant on the outside surface of theoil seal. Install with spring side of the seal towardbearing, using a flat plate to avoid distortion.

Install a new O-ring in the groove on the O.D. of thedrum closure.

Be sure the vent plug is located above the horizontalcenterline for the intended application. Oil leakagemay occur if vent is positioned incorrectly.

O-RING GROOVE

CAUTION

– 30 –

10. Lubricate the O-ring and drum opening withpetroleum jelly or gear oil and install the drumclosure into the drum.

11. Lubricate the pilot, oil seal and bearing surfaces ofthe brake cylinder and carefully install brakecylinder into base and drum. Locate the brakerelease port toward the lower rear corner of thebase. Tighten brake cylinder capscrews torecommended torque.

12. Install the brake clutch assembly with the short endof the inner race toward motor.

When installed correctly, the inner race should turnfreely in the opposite direction the drum turns topull wire rope in. An easy way to check the rotationis to hold the outer race in one hand, and rotate theinner race.

If the clutch free wheels in the wrong direction,disassemble the clutch and reverse the inner race.Refer to "Brake Clutch Service” for additionalinformation.

13. If the brake discs are misaligned, preventing theinstallation of the clutch, then with a hand pump,apply 750-1000 psi to the brake release port. Thebrake discs will move freely with the brakereleased, permitting alignment of the discs, brakeclutch and input sun gear.

14. Install the hoses and fittings to the brake cylinderrelease port.

WARNINGBe certain the snap ring is seated in the groove in thesplined bore of the inner race. This snap ring willkeep the brake clutch assembly correctly positionedin the center of the friction brake pack. Binding of thebrake or brake failure may occur if this snap ring isomitted.

CAUTIONWARNING! !

– 31 –

15. Install a new O-ring on the motor pilot thenlubricate with petroleum jelly or gear oil.

Measure the distance from the motor mountingsurface to the inner brake race. With allcomponents properly installed, this distance shouldbe 11/16 in. (17.5 mm) to 3/4 in. (19.1 mm). If thisdistance is less than 9/16 in. (14.3 mm), theprimary spacer may be positioned as shown belowand should be checked.

The Primary Thrust Plate is shown wedgedbetween the planet gears and the planet carrier.Note that the Primary Sun Gear and the entireBrake Clutch Assembly have moved to the right(toward the hydraulic motor).

16. Engage the motor shaft with the brake clutch innerrace and lower motor into place. Tightencapscrews to recommended torque.

17. Install the hoses that connect the manifold andbrake valve to the brake cylinder.

18. After the winch assembly is complete, check allcapscrews and fittings to make certain they havebeen tightened correctly.

Refill the winch with the recommended oil listedunder “Preventive Maintenance”, and install the oillevel plug.

Care must be taken to assure the primary thrust plateremains properly located in its counterbore when themotor is installed for the first time, or is beingreinstalled on the winch. It is possible for the primarythrust plate to drop out of its counterbore andbecome wedged between the planet gears and theplanet carrier. If the winch is operated with theprimary thrust plate wedged between primary gearsand the planet carrier, or with a thrust washer out ofposition, severe damage to internal winchcomponents could result.

CAUTION

i NOTE: The following caution DOES NOT applyto PD17A winches. Proceed to step 16.

– 32 –

The BRADEN brake valve is a reliable hydraulic valvewith internal components manufactured to closetolerances. Due to the close tolerances and mating ofcomponents, the valve housing, spool, piston andcheck poppet are not available as replacement parts.

Before disassembling the brake valve, be sure youhave conducted all applicable troubleshootingoperations and are certain the brake valve is causingthe malfunction.

Thoroughly clean the outside surfaces of the valve andwork in a clean dust free area, as cleanliness is ofutmost importance when servicing hydrauliccomponents.

DISASSEMBLY

1. Remove the pilot orifice from the brake release(BR) port using a 5/32 in. Allen wrench.

2. Remove the elbow fitting, motor drain check balland spring.

3. Remove the spool spring retainer and spool spring.Check spring free length. Replace spring if lessthan 1 15/16 in. (49.2 mm) long.

BRAKE VALVE SERVICE

12

1

181719

9

12322

DRAINPORT 6

11

14

16

13

15

5

4

71028

A

A

"BR" PORTSAE -4 ORB(7/16-20 THD)

SECTION A-A

ITEM DESCRIPTION QTY.1 Valve Housing (NSS) 12 Check Valve Retainer (NSS) 13 Spring Retainer (NSS) 14 Plug (NSS) 15 Spool (NSS) 16 Damper Piston (NSS) 17 O-Ring 18 Check Valve Poppet (NSS) 19 Pilot Orifice 1

10 Check Valve Spring 111 Spool Spring 112 O-Ring 213 O-Ring 114 O-Ring 115 Back-up Ring 116 Back-up Ring 117 Check Ball (1/4 in.) 118 Check Ball Spring 119 Elbow Fitting 122 Shim A.R.

NSS - NOT SERVICED SEPARATELY. REPLACE

COMPLETE VALVE ASSEMBLY

BRAKE VALVE ASSEMBLY

– 33 –

4. Remove spool plug and carefully remove spoolassembly.

5. Remove the damper piston from the spool. Thepiston will come out slowly, because of a partialvacuum formed as it is removed. Use extreme careto avoid damaging the polished surfaces of thepiston or spool.

6. Remove the check valve spring retainer, spring andcheck valve poppet. Check spring free length.Replace spring if less than 1-1/2 in. (38.1 mm)long.

CLEAN AND INSPECT1. Discard all O-rings and back-up rings. Clean all

parts in solvent and blow dry. Inspect polishedsurfaces of spool and damper piston for damagethat may cause binding or leakage. Inspect spoolbore in valve housing for damage or scoring.Inspect check valve seat in valve housing andcheck valve poppet. If the spools, bores or valvesare damaged, the entire valve must be replaced asthese parts are not serviced separately.

2. Inspect the .020 inch orifice in the end of the spooland the pilot orifice to be certain they are open.

ASSEMBLY1. Install new O-rings on the plug and spring retainers.

2. Install new O-rings and back-up rings on the spooland damper piston as shown. It is important thateach back-up ring is on the correct side of its O-ring. Take care not to cut the O-rings duringassembly. Let the spool and damper piston set forten minutes before installing them in theirrespective bores. This will allow the O-rings toreturn to their original size after being stretched.

3. Lubricate the spool and damper piston O-rings withhydraulic oil. Carefully install the damper pistoninto the spool.

4. Lubricate the spool bore and spool O-rings withhydraulic oil. Carefully install the spool into thevalve housing. Always install the spool from theplug end as shown to minimize the possibility ofdamaging the O-ring. Install the plug, spool springand spring retainer.

5. Install the check valve poppet, spring and checkvalve spring retainer.

6. Install the motor drain check ball, spring and elbowfitting.

7. Install the pilot orifice into the valve housing.

8. The brake valve is complete and ready to beinstalled on winch motor.

– 34 –

1. Remove the four capscrews securing the brakevalve to the motor. Remove the four capscrewssecuring the manifold block to the motor.Disconnect the motor case drain hose at the motor.NOTE: Some installations have the brake releasehose connected directly to the motor, instead of tothe manifold block. In this case, disconnect thebrake release hose at the motor port. Stand winchup on drum support with the motor end up andsecure in this position.

2. Before removing the motor, it is a good idea to noteor mark the position of the motor in relation to thewinch, since it will be rotated 180° when reinstalled.Remove the capscrews securing the motor to thewinch and carefully remove the motor.

3. Remove the brake clutch assembly from the motorsupport.

4. Remove the snap ring and sprag bushing retainerfrom one end only of the brake clutch assembly.

5. Pull the inner race out. Examine the race forscoring, wear or indentations caused by the spragcams. If the inner race is not completely smooth,the assembly should be replaced.

REVERSING DIRECTION OF DRUM ROTATION(029, 034, 039, 051, 064 & 049/024 motors ONLY)

In order to change the direction of rotation, 2 things must be changed on the winch. First, the motor must be made torotate in the opposite direction. This is done by exchanging positions of the brake valve and manifold block on themotor. Secondly, the brake clutch assembly must be made effective for the opposite direction of rotation. This is doneby reversing the inner race of the brake clutch assembly.

Figures “A” and “B” above show typical PD12C motor installations. Note that the only difference between the twodrawings is the motor is rotated 180° (the “belly” of the motor moves to the opposite side). If the motor shaft rotatesclockwise in figure ‘A” when the hoisting port is pressurized, it will rotate counterclockwise in figure “B”.

MotorCase Drain

Brake ReleaseCircuit

Brake ReleaseCircuit

HoistingPort

MotorCase Drain

MotorBrakeValve M Lowering

Port

DRN DRN

BR BR

HoistingPort

LoweringPortMotor

BrakeValve M

M = Manifold Block

“A” “B”

– 35 –

6. Turn the sprag assembly around and slide the innerrace (with 1 snap ring and bushing retainer)through the bushings and sprag clutch (the race willhave to be rotated in the free-wheeling direction tostart it through the sprag clutch). Install theremaining bushing retainer and snap ring. Makecertain the snap ring is properly seated in thegroove.

7. Before installing the brake clutch, be sure the innerrace turns free in the opposite direction the drumwill turn to haul-in wire rope. An easy way to checkthe rotation is to hold the outer race in one handand rotate the inner race. Install the brake clutchwith the short end of the inner race toward themotor.

8. Install a new O-ring on the motor pilot. Rotate themotor 180° from its original position and install itonto the winch. Install and tighten motorcapscrews to recommended torque.

9. Install new O-rings in the brake valve and manifoldblock. Attach the brake valve and manifold block tothe motor using the original capscrews and tightento recommended torque.

10. Connect the motor case drain hose to the motorcase drain port. NOTE: On two speed motors, thecase drain and shift drain should be connecteddirectly to tank. DO NOT use the drain connectionon the brake valve. See “TWO SPEED MOTORCASE DRAIN PLUMBING” for additionalinformation.

11. If your winch had the brake release hoseconnected directly to the motor, the original motorport must be plugged and the hose connected tothe motor pressure port near the manifold block(lowering port).

12. Operate the winch slowly in both directions andcheck for oil leaks and/or unusual sounds from thewinch. The winch should operate smoothly in bothdirections. Refer to “WIRE AND BRAIDED ROPEINSTALLATION” and properly install rope onto thewinch drum.

13. Before returning the winch to full service, a lightload should be lifted and held a few feet off theground to be sure the static brake is functioningproperly. The winch should also be able to slowlylower the load in a smooth and controlled manner.If the winch does not perform either of thesefunctions, refer to “TROUBLESHOOTING” foradditional information.

Be certain the snap ring is seated in the groove in thesplined bore of the inner race. This snap ring willkeep the brake clutch assembly correctly positionedin the center of the friction brake pack. Binding of thebrake or brake failure may occur if this snap ring isomitted.

CAUTIONWARNING! !

– 36 –

PD17A Rotation Indicator Proximity SensorSome PD17A models have a rotation indicator proximity sensor and hub between the motor and thewinch. If the sensor is removed or replaced, use the following procedure for adjustment and testing.Refer to the drawing below for item numbers.

Install a new O-ring (item 108) onto motor pilot. Install sensor hub (item 123) onto motor shaft,positioning the sensor hub so that one of the lobes will be directly under the sensor port. Install themotor onto the winch. Install capscrews and lockwashers (items 101 & 102) securing the motor tomotor adapter.

Install flatwasher (item 121) and O-ring (item 122) onto new sensor (item 120). Apply a small amountof silicone sealant to the threads just below the washer and O-ring. DO NOT apply sealant to the endof the sensor or to the threads of the sensor port where it could be pushed into the winch. Install thesensor into the motor adapter until it contacts the sensor hub. Back sensor out of the port 2 completeturns. Attach wire harness to sensor to verify proper sensor operation. IT IS NOT necessary to operatethe winch motor. If sensor light is on, hold sensor from turning and tighten jam nut against motoradapter. If light is off or blinks intermittently, adjust sensor inward toward sensor hub until light remainson, then tighten jam nut.

HydraulicMotor

If sensor hub is not correctly positioned with a lobe directly under the sensor port, proper adjustment maynot be possible and severe damage to the sensor and internal winch components may result.

CAUTION

inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.)miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)

inches2 (sq.in.) X 645.15 = millimeters2 (mm2) millimeters2 (mm2) X 0.000155 = inches2 (sq.in.)feet2 (sq.ft.) X 0.0929 = meters2 (m2) meters2 (m2) X 10.764 = feet2 (sq.ft.)

inches3 (cu.in.) X 0.01639 = liters (l) liters (l) X 61.024 = inches3 (cu.in.)quarts (qts.) X 0.94635 = liters (l) liters (l) X 1.0567 = quarts (qts.)gallons (gal.) X 3.7854 = liters (l) liters (l) X 0.2642 = gallon (gal.)inches3 (cu.in.) X 16.39 = centimeters3 (cc) centimeters3 (cc) X 0.06102 = inches3 (cu.in.)feet3 (cu.ft.) X 28.317 = liters (l) liters (l) X 0.03531 = feet3 (cu.ft.)feet3 (cu.ft.) X 0.02832 = meters3 (m3) meters3 (m3) X 35.315 = feet3 (cu.ft.)fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fl.oz.)

ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)pounds (lbs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)tons (2000 lbs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 lbs.)tons (2000 lbs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 lbs.)tons (long) (2240 lbs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.)

inches Hg (60oF) X 3600 = kilopascals (kPa) kilopascals (kPa) X 0.2961 = inches Hg (60oF)pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)pounds/sq.in. (PSI) X 0.0703 = kilograms/sq.cm. (kg/cm2) kilograms/sq.cm. (kg/cm2) X 14.22 = pounds/sq.in. (PSI)pounds/sq.in. (PSI) X 0.069 = bars bars X 14.5 = pounds/sq.in. (PSI)inches H2O (60oF) X 0.2488 = kilopascals (kPa) kilopascals (kPa) X 4.0193 = inches H2O (60oF)bars X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01 = bars

horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)ft.-lbs./min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-lbs./min.

pound-inches (in.-lbs.) X 0.11298 = newton-meters (N-m) newton-meters (N-m) X 8.851 = pound-inches (in.lbs.)pound-feet (ft.-lbs.) X 1.3558 = newton-meters (N-m) newton-meters (N-m) X 0.7376 = pound-feet (ft.-lbs.)pound-feet (ft.-lbs.) X .1383 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.233 = pound-feet (ft.-lbs.)

miles/hour (m/h) X 0.11298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.6214 = miles/hour (m/h)feet/second (ft./sec.) X 0.3048 = meter/second (m/s) meters/second (m/s) X 3.281 = feet/second (ft./sec.)feet/minute (ft./min.) X 0.3048 = meter/minute (m/min) meters/minute (m/min) X 3.281 = feet/minute (ft./min.)

mega (M) = 1,000,000 or 106 deci (d) = 0.1 or 10-1

kilo (k) = 1,000 or 103 centi (c) = 0.01 or 10-2

hecto (h) = 100 or 102 milli (m) = 0.001 or 10-3

deka (da) = 10 or 101 micro (m) = 0.000.001 or 10-6

oCelsius = 0.556 (oF - 32) oFahrenheit = (1.8oC) + 32

COMMON METRIC PREFIXES

TEMPERATURE

POWER

TORQUE

VELOCITY

VOLUME

MASS

PRESSURE

METRIC CONVERSION TABLE

LINEAR

AREA

English to Metric Metric to English

FOR BEST RESULTS,ALWAYS USE GENUINE BRADEN PARTS.

Copyright 2003 PACCAR Winch Division. All rights reserved.

Installation, Maintenaince and Service Braden PD15B,PD12C,PD17A

Documents

output sun

primary sun

braden service

output planet

primary planet

minimum service

brake clutch

severe personal