BRADEN - Elvic
Contents
1. Inside Back Cover FOREWORD Read and understand this entire publication before operating or servicing your BRADEN winch Retain this manual for future reference The minimum service intervals specified are for operating hours of the prime mover The following service instructions have been prepared to provide assembly disassembly and maintenance information for the Model AX5A series winch It is suggested that before doing any work on these units all assembly and disassembly instructions should be read and understood Some illustrations in this manual may show details or attachments which may be different from your winch Also some components may be removed for illustrative purposes Continuing product improvement may cause changes in your winch which may not be included in this manual When a question arises regarding your winch or this manual contact your nearest BRADEN dealer or the factory Service Department at 918 251 8511 Monday Friday 8 00 a m to 4 30 p m CST or by Fax at 918 259 1575 Provide the com plete winch model number and serial number when making inquiries The model and serial numbers are stamped into the data plate attached to the base to the left of the hydraulic motor PARTS AND SERVICE BRADEN provides parts and service through a network of authorized dealers Parts and service are not available direct ly from the factory For the name of your nearest dealer consult your local phone directory or call u2. BRADEN PACCAR Gearmatic WINCH DIVISION BG4 HYDRAULIC PLANETARY WINCH 4 000 LB CONTINUOUS DUTY 5 000 LB INTERMITTENT DUTY INSTALLATION MAINTENANCE AND SERVICE MANUAL wiNcH DIVISION P O BOX 547 BROKEN ARROW OK U S A PHONE 918 251 8511 FAX 918 259 www paccarwinch com TABLE OF CONTENTS PAGE FOREWORD must 2 PARTS AND SERVIC Bis in reae dass 2 GENERAL SAFETY RECOMMENDATIONS 3 THEORY OF OPERATION tete ntis huis oiera thes ete Bees 4 HYDRAULIC CIRCUIT esenc m 4 WINCH AND WIRE ROPE INSTALLATION 5 DIMENSIONAL DATA ccosoroccetseccooseiecaxeocesedasvanegosgecaisadegespedaes 6 7 PREVENTATIVE MAINTENANCE 7 8 RECOMMENDED GEAR OIL nr ern Feu y he ko ke Rn 8 9 WINCH EXPLODED VIEW DRAWING AND BILL OF MATERIAL 10 FARTS KE e X UTC X x 11 TROUBLE SHOOTING 12 14 WINCH m 15 WINCH DISASSEMBLY 15 DRUM ASSEMBLY SERVICE dosis dbcva seco m 16 PLANET CARRIER SERVICE yaqa 16 BRAKE CYLINDER ENDPLATE SERVICE 17 WINCH ASSEMBLY paka 18 19 FASTENER TORQUE CHART 20 METRIC CONVERSION TABLE
3. 1 Read all warning tag information and become familiar with all controls before operating winch 2 Never attempt to clean oil or perform any maintenance on a machine with the engine running unless instruct ed to do so in the service manual 3 Never operate winch controls unless you are properly seated at the operators station on the prime mover and you are sure personnel are clear of the work area 4 Assure that personnel who are responsible for hand signals are clearly visible and that the signals to be used are thoroughly understood by everyone 5 Ground personnel should stay in view of the prime mover operator and clear of winch drum Do not allow ground personnel near winch line under tension A safe distance of at least 172 times the length of the cable should be maintained 6 machines having hydraulically mechanically and or cable controlled equipment be certain the equipment is either lowered to the ground or blocked securely before servicing adjusting and or repairing the winch Always apply the prime mover parking brakes and lower equip ment before dismounting the prime mover 7 nspect rigging winch and hydraulic hoses at the beginning of each work shift Defects should be cor rected immediately 8 Keep equipment in good operating condition Perform scheduled servicing and adjustments listed in the Preventive Maintenance section of this manual 9 Anequipment warm up procedure is recommended fo
4. After all the causes listed above have been investigated and it is found that the winch will stall at maximum pres sure without developing the maximum pull on the bare drum the trouble may be in the winch REMEDY Install a pressure gauge in the haul in port and apply a stall pull on the winch If pressure is low increase relief valve setting until recommended pressure is obtained NOTE f 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 Remove relief valve disassemble and clean parts thor oughly in a suitable solvent Reassemble and install relief valve according to specifications Reset pressure Check belts when pump is at full PSI kg cm stall pull on winch Tighten belts if they are found to be slipping Check oil level in the reservoir Check the suction line for damage externally and internally Replace suction line if necessary Reinforce mounting surface If necessary use steel shim stock to level winch First loosen then evenly retighten all winch mounting bolts to recommended torque Same as remedy for A 5 Same as remedy for B 4 Refer to winch performance charts for additional informa tion Install a pressure gauge in the motor haul in port and apply a stall pull on the winch If the pressure is up to maximum and the bare drum line pull is less than the specified l
5. F 10 C and 1109F 43 C use SAE 20W for continu ous operation between 10 F 129C and 90 F 32 C use 10W for applications colder than 10 F 12 C contact the BRADEN Service Department The use of multi viscosity oils is generally not recommended 5 The hydraulic oil filter should have a 10 micron nominal rating and be full flow type 6 The vent plug in the motor adapter must be located close to top dead center as possible If the winch is mounted on a pivoting surface the vent plug must remain above the centerline of the cable drum to pre vent gear oil leakage 0002005252 7 Refer to Dimensional Drawing for relationship between drum rotation and which port is pressurized WIRE ROPE INSTALLATION Since the static brake on this winch is effective both direc tions cable can be wound onto the drum in either direction without any modifications to the winch The cable drum has two anchor pockets to accommodate this Take the free end of the wire rope and insert it through the small opening of the anchor pocket you are going to use Loop the wire rope and push the free end about three fourths of the way back through the pocket Install the cable anchor with the small end toward the drum then pull the slack out of the wire rope The cable anchor will slip into the pocket and secure the wire rope to the drum A minimum of five 5 standard cable anchor wedge supplied with the winch wr
6. WARNING WARNING This emblem is used to warn against haz ards and unsafe practices 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 per sonal injury or product or property damage if proper procedures are not followed THEORY OF OPERATION DESCRIPTION OF WINCH The winch has three basic assemblies 1 Hydraulic motor brake valve block and counter balance cartridges 2 Static brake assembly 3 Cable drum assembly The hydraulic motor is bolted to the motor adapter which in turn is bolted to the brake cylinder end plate of the winch The cable drum assembly is supported on each end by an anti friction ball bearing The ball bearings are located on the end plate and the end plates are connected by two tie plates The ring gear for the single planetary reduction set is machined into the inside of the cable drum The cable drum features two anchor pockets for winding cable on the drum in either direction PLANETARY GEAR TRAIN z NN Ss z PM 2 SSSSS SG H T TNI INE m n LEM zi HYDRAULIC CIRCUIT The hydraulic motor shaft is directly splined to the brake co
7. shims under the winch mounting pads to achieve even mounting 3 The hydraulic lines and components that operate the winch should be of sufficient size to assure minimum back pressure at the winch The back pressure at the motor must not exceed 100 psi 690 kPa to maintain full brake system design factor and optimum motor seal life 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 4 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 389 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 high viscosity index will minimize changes in viscosity with corresponding changes in temperature Maximum cold weather start up viscosity should not exceed 5 000 SUS with a pour point at least 209 F 119C lower than the minimum ambient temperature Under continuous operating conditions the temperature of the oil at any point in the system must not exceed 180 F 829C 1209F 49 C to 140 F 60 C is generally consid ered optimum In general terms For continuous operation at ambient temperatures between 50
8. 9 BRAKEVALVEBLOCK f 1 40 COUNTERBALANCE CARTRIDGE 1 40A CHECKVALVECARTRIDOE 1 42 VENTPLUG 1 43 TUBEASSEMBLY 1 44 CAPSCREW 5 16 18X31 2G8Z 2 47 CAPSCREW 5 16 18X1G8Z2 8 48 LOCKWASHER 5162 A 11 TROUBLE A Winch will not pull maximum load TROUBLE SHOOTING PROBABLE CAUSE System relief valve may be set too low If this trouble occurs suddenly after working at maximum pull a particle of dirt may be lodged under the system relief valve holding it partially open If this is the cause a considerable loss in line speed may be noticed as the load on the cable is increased If the pump is belt driven the belt may be slipping The oil level in the reservoir may be too low The suction line may be restricted or have an air leak causing cavitation at the inlet port This will cause the pump to make a whining noise The winch may be mounted on an uneven or flexible surface which caus es distortion of the winch base and binding of the gear train Binding in the gear train will absorb horsepower needed to generate the rated line pull and cause heat Be certain hydraulic system tempera ture is not more than 180 F 829C Excessive hydraulic oil temperatures increase motor internal leakage and reduce motor performance Winch line pull rating is based on 1st layer of wire rope Expected line pull may be in excess of winch rating
9. C 629 or 630 SYNTHETIC OR EQUIVALENT 40 30 20 10 0 10 20 30 40 50 C H 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 Teo Eme c Meropa 150 Spartan EP 150 Mobilgear 629 Omala 150 American Industrial Oils 150 Meropa 220 Spartan EP 220 Mobilgear 630 Omala 220 American Industrial Oils 220 9 2002 Oil capacity is 2 pints BRADEN BG4 HYDRAULIC PLANETARY WINCH COMPONENTS 10 BG4 PARTS KEY 5 CAPSCREW 3 8 16X1G8Z2 8 6 LOCKWASHER 38Z 8 7 SIGHT GAUGE C 1 8 OW SEAL J 1 9 BALLBEARING 1 10 OLSEAL J 1 11 BALBEARING 1 3 SPRING 4 000 LB RATING SPRING 5 000 LB RATING BRAKE COUPLING 1 30 RETAININGRING 31 SPRINGPLATE CE 1 32 BRAKEPISTONSEAL 1 33 BRAKE PLATE SPACER 2 34 FRICTONDSC CE 35 STEELDISC 97 GASKET 38 MOTOR ADAPTER j 1 3
10. aps of wire rope should remain on the cable drum at all is intended for 5 16 to 72 in 8 to 13 mm wire times Refer to General Safety Recommendations for additional information DIMENSIONAL DATA Inches Dimensions shown in millimeters a LOWERING PORT SAE 10 ORB 7 8 14 THD 53 TYP 4 MTG HOLES STING POR SAE 10 7 8 14 THD Pressurized port B for counterclockwise drum rotation when viewed from motor end DIMENSIONAL DATA Millimeters Dimensions shown in millimeters Pressurize port B for counterclockwise drum rotation when viewed from motor end PREVENTIVE MAINTENANCE A regular program of preventive maintenance for your plan etary winch is strongly recommended to minimize the need for emergency servicing and promote safe reliable winch operation Field experience s
11. dapter should be evenly removed in 1 or 2 turn increments since the motor adapter is under spring tension Remove the capscrews 47 and lockwashers 48 holding the motor adapter 38 to the endplate 2 Install 2 cap screws and a short piece of chain into the motor mount ing holes Using the chain as a handle lift the motor adapter out of the endplate Remove and discard the O ring 36 from the motor adapter Remove and dis card the brake piston seal 32 Remove brake plate spacers 33 steel discs 35 friction discs 34 spring plate 31 springs 27 and spring spacer 28 2 Thoroughly clean and inspect all parts at this time Check brake piston sealing surfaces on motor adapter and brake cylinder endplate Be sure the brake release port in the endplate shown above is free of contami nation Remove the vent plug 42 from the motor adapter clean in solvent and reinstall DO NOT paint over the vent or replace it with a solid plug 17 Place each friction disc on a 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 uneven ly or groove pattern is worn away Place each steel disc on a flat surface and check for distortion with a straight edge Check surface for signs of material transfer or heat Replace steel disc if spline
12. edy for F 6 WINCH SERVICE FOREWORD TO WINCH SERVICE 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 replacement 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 dam age 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 flamma ble safety solvent Wear protective clothing as required Refer to exploded view drawing for item numbers used in service procedures Perform all applicable trouble shooting operations BEFORE disassembling winch A WARNING A DO NOT CLEAN BRAKE FRICTION DISKS IN SOLVENT SOLVENT MAY CAUSE DAMAGE TO FRICTION MATERIAL WHICH MAY RESULT IN BRAKE FAILURE AND LOSS OF LOAD CONTROL WINCH ASSEMBLY 1 Disconnect all hoses and fittings at the winch 15 Stand the winch on the bearing support plate R
13. emove the brake release tube assembly 43 between the brake valve block and the brake cylinder end plate Remove the capscrews 50 and lockwashers 51 which secure the motor 49 to the motor adapter 38 and lift the motor out of the motor adapter Remove and discard the O ring 37 installed on the pilot of the motor 3 Remove the brake coupling 29 and sun gear 41 from the winch holding the tinplates 4 to the brake cylinder endplate Remove the brake cylinder endplate from the drum Remove the other four capscrews and lockwashers holding the tieplates to the bearing support endplate Remove the planet assembly from the drum and sepa rate the drum from the bearing support endplate DRUM ASSEMBLY SERVICE Remove the bearing and seal from each end of the drum Check the ring gear teeth machined into the inside surface of the drum for nicks spalling or exces Sive wear Replace the drum if wear is greater than 0 015 in 0 4 mm when compared to unworn area of teeth Install new bearings in the drum if replacement is nec essary Apply a non hardening sealant on the outside diameter of each new seal and press the seals into the drum using a flat plate to avoid distortion PLANET CARRIER SERVICE First drive the rollpins 17 into the center of the planet pins 14 Now you can remove the planet shaft 14 two thrust races 16 planet gear 13 and roller bear ing 15 Repeat this procedure for t
14. ers cc centimeters3 cc feet cu ft 28 317 liters I liters I feet cu ft 0 02832 meters m meters3 m3 fluid ounce fl oz 29 57 millileters ml milliliters ml 61 024 inches cu in 1 0567 quarts qts 0 2642 gallon gal 0 06102 inches cu in 0 03531 feet cu ft 35 815 feet cu ft 0 03381 fluid ounce fl oz liters x x x x x x gt MASS ounces oz 28 35 grams g grams g 0 03527 ounces oz pounds Ibs 0 4536 kilograms kg kilograms kg 2 2046 pounds Ibs tons 2000 Ibs 907 18 kilograms kg kilograms kg 0 001102 tons 2000 16 tons 2000 Ibs 0 90718 metric tons t metric tons t 1 1023 tons 2000 Ibs tons long 2240 Ibs 1013 05 kilograms kg kilograms kg 0 000984 tons long 2240 Ibs PRESSURE inches Hg 60 F pounds sq in PSI pounds sq in PSI pounds sq in PSI inches H O 60 F kilopascals kPa kilopascals kPa kilopascals kPa kilopascals kPa kilograms sq cm kg cm kilograms sq cm kg cm2 bars bars kilopascals kPa kilopascals kPa inches Hg 60 F pounds sq in PSI pounds sq in PSI pounds sq in PSI inches 60 F bars kilopascals kPa kilopascals kPa bars POWER horsepower hp kilowatts kW kilowatts KW horsepower hp ft Ibs min watts W watts W ft lbs min TORQUE newton meters N m newton meters N m kilogram meter kg m p
15. he other two plan et 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 16 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 sep arate 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 Insert a bearing into a planet gear and place a thrust race on each side of the gear Position this assembly in the planet carrier and slide the planet gear shaft through the carrier Align the pin hole in the shaft with the hole in the carrier and drive a NEW rollpin into place Always use NEW rollpins When properly posi tioned the rollpin will be slightly below the surface of the carrier With center punch stake the carrier next to the pin hole as shown This will distort the hole so the pin will not back out when in service Repeat these steps for each of the three planet gears BRAKE CYLINDER ENDPLATE SERVICE Disassembly and Inspection 1 NOTE The capscrews in the motor a
16. ine pull the trouble will be in the winch Disassemble winch according to disassembly instructions and check that gear train turns freely If gear train is found to be satisfactory inspect the hydraulic motor according to the service instructions for the hydraulic motor TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Rigging and sheaves not operating Perform rigging and sheave service as recommended by efficiently manufacturer B Same as 2 Same as 4 Same as A 6 Same as remedy for A 2 Same as remedy for A 4 Same as remedy for A 5 amp B 4 Considerable If this trouble has increased gradually Remove and inspect pump If satisfactory consult the dis reduction in the hydraulic pump or winch motor assembly instructions for the winch and remove and line speed may be worn inspect the motor according to the service instructions for the hydraulic pump C Control valve may be restricted in its Check the travel of the control valve spool The spool trav z travel el should be the same in both directions Reverse Same as A 1 Same as remedy for A 1 speed is Oil may be too thick causing a high Follow warm up procedure in Preventive Maintenance slower than resistance to rotation at the brake section forward plates and causing the relief valve to speed D Brake will not hold when control valve is returned to by pass Same as F 1 Excessive system back pressure act ing on the b
17. k 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 RECOMMENDED FASTENER n Torque LB FT Bolt Dia Thds supa s s Inches Inch Dry Lubed Dry Lubed 18 24 20 13 12 Torque LB FT Bolt Dia Thds Per sus z C Inches Inch 20 10 Cw s Dry Lubed Dry Lubed 1 1 4 1120 1820 1360 1 3 8 1460 1095 2385 1790 11 2 1940 1460 3160 2370 METRIC CONVERSION TABLE MULTIPLY BY TO GET MULTIPLY TO GET LINEAR inches in X 25 4 millimeters mm millimeters mm X 0 3937 inches in feet X 0 3048 meters meters m X 3 281 feet ft miles mi X 1 6093 kilometers km kilometers km X 0 6214 miles mi AREA millimeters mm 0 000155 inches sq in meters m 10 764 feet sq ft inches sq in 645 15 millimeters mm feet sq ft 0 0929 meters m VOLUME inches cu in 0 01639 liters 1 quarts qts 0 94635 liters liters 1 gallons gal 3 7854 liters l liters 1 inches cu in 16 39 centimet
18. nd install the endplate assembly onto the drum lt d NS 11 Install the brake coupling into the brake pack with the flat end of the coupling toward the motor Turn the 19 12 coupling back and forth to align the outer splines with the brake disc splines The coupling must engage all the brake discs and the snap ring in its center must rest on the sun gear Evenly tighten the eight 8 capscrews around the motor adapter one turn at a time until the motor adapter is firmly seated to the endplate Torque the capscrews to their proper value Install a new O ring 37 on the motor pilot and lubricate with petroleum jelly or gear oil Install the motor onto the motor adapter with two capscrews 50 and lock washers 51 Torque the capscrews to their proper value RECOMMEND FASTENER TORQUE 13 Install a hand pump with an accurate 0 2 000 psi 0 13 800 kPa gauge and shut off valve to the brake release port Apply 1 000 psi 6 900 kPa to the brake and close the shut off valve Let the brake stand for five 5 minutes If there is any loss of pressure the brake pack should be disassembled for inspection of the sealing surfaces and the brake piston Release the pressure remove the hand pump and install the brake release tube 43 between the brake valve block 39 and the brake release port The general purpose torque shown in the chart applies to SAE Grade 5 bolts studs and standard steel full thic
19. ound inches in Ibs 0 11298 newton meters N m pound feet ft Ibs 1 3558 newton meters N m pound feet ft Ibs 1383 kilograms meter kg m pound inches in Ibs pound feet ft Ibs pound feet ft Ibs VELOCITY miles hour m h 0 11298 kilometers hour km hr feet second ft sec 0 3048 meter second m s feet minute ft min 0 3048 meter minute m min kilometers hour km hr meters second m s meters minute m min miles hour m h feet second ft sec feet minute ft min TEMPERATURE Celsius 0 556 F 32 Fahrenheit 1 8 X C 32 COMMON METRIC PREFIXES 1 000 000 or 10 deci 0 1 or 10 1 000 or 10 centi 0 01 10 100 or 102 milli 0 001 or 10 10 or 10 micro 0 000 001 or 10
20. r all start ups and is essential at ambient temperatures below 40 F Refer to Warm up Procedure listed in the Preventive Maintenance section of this manual 10 Be sure of equipment stability before operating winch 11 The winches described herein are neither designed nor intended for use or application to equipment used in the lifting or moving of persons 12 Do not exceed the maximum pressure PSI or flow stated in the winch specifications 13 Operate winch line speeds to match job conditions 14 Leather gloves should be used when handling winch cable 15 Never attempt to handle winch cable when the hook end is not free 16 When winding winch cable on the winch drum never attempt to maintain tension by allowing winch cable to slip through hands Always use hand over hand technique 17 Never use winch cable with broken strands Replace winch cable 18 Do not weld on any part of the winch 19 Do not use knots to secure or attach winch cable 20 Use recommended hydraulic oil and gear lubricant 21 Keep hydraulic system clean and free from contamina tion at all times 22 Use correct size cable anchor for cable and pocket in winch drum 23 The BRADEN wire rope anchors are capable of sup porting the rated load when installed properly For additional safety ALWAYS maintain a minimum of five 5 wraps of wire rope on the drum Safety informational callout s used in this manual include
21. rake release port Same remedy for F1 Install a pressure gauge at the pay out port of the hydraulics motor Operate the pump at full throttle and monitor pressure in neutral and haul in positions If the pressure is greater than 50 PSI check for restrictions in the return line from the winch to the control valve and the con trol valve to the reservoir neutral after lifting a load Friction brake will not hold due to Disassemble winch to inspect replace worn parts worn or damaged brake disks Same as D 2 or 2 Same as remedy for D 1 or 2 E 2 Winch is being overloaded Install a pressure gauge at the haul in port and apply a stall pull on the winch If the pressure is higher than the maxi Brake will not mum specified PSI reduce the pressure control or stop the After the causes listed above have Disassemble the brake assembly according to the disas load when been investigated and found to be sat sembly instructions Inspect the brake springs and brake lowering isfactory the trouble may be in the plates winch TROUBLE H Winch chatters while 4 raising rated load TROUBLE SHOOTING PROBABLE CAUSE The friction brake may not be releasing as a result of a defective brake der seal NOTE If the brake cylinder seal is defective you will usually notice oil leak ing from the winch vent plug Friction brake will not release as a result of damaged brake disk
22. rough it and the speed at which the cable drum will turn Increasing the flow of oil to the winch motor will cause the pressure to rise and the opening in the car tridge to enlarge speeding up the cable drum Decreasing the flow causes the pressure to drop and the opening in the cartridge to decrease slowing down the cable drum When the control valve is returned to the neutral or center position pressure will rapidly drop and the counterbalance cartridge will close stopping the load The friction brake will engage and hold the load after the cartridge is closed WINCH AND WIRE ROPE INSTALLATION 1 The winch should be mounted with the centerline of the cable drum in a horizontal position The mounting plane of the winch may be rotated in any position around this centerline providing the vent in the motor adapter is above the centerline of the cable drum The vent should be as close to top dead center as possible 2 When mounting the winch use all four 4 mounting holes and grade eight 8 bolts and nuts Evenly tight en the nuts to the torque in the Recommended Torque chart Refer to Dimensional Drawing for bolt hole size and pat tern 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 accel erated wear and heat Also the mounting surface should be flat with x 0 020 inches necessary install
23. s Same as B 4 Same as 3 Same as A 5 Control valve handle being operated too quickly Insufficient gear oil in cable drum Control valve does not have good metering characteristics Same as A 5 Be certain that the hydraulic system temperature is not more than 180 degrees F Excessive hydraulic oil tem peratures may be caused by A Plugged heat exchanger B Too low or too high oil level in hydraulic reservoir C Same as 1 D Hydraulic pump not operating effi ciently Excessively warn or damaged internal winch parts Same as 7 Same as A 1 Same as B 4 Hydraulic oil flow to motor may be too low Same as F 6 REMEDY Disassemble and inspect the brake cylinder seal Disassemble brake to inspect brake disks Same as for B 4 Same as remedy for A 3 Same as remedy for A 5 Operate control valve smoothly when starting and stopping load Conduct operator training as required Remove oil level plug and check oil level level See Winch Installation section for control valve specifica tions Fill to proper Same as remedy for A 5 Thoroughly clean exterior and flush interior Fill drain to proper level Same as remedy for A 1 Remove and inspect pump Check suction line for damage If pump is belt driven belts may be slipping Replace tighten belts Same as remedy for F 7 Same as remedy for A 1 Same as remedy for B 4 Increase pump rpm Same as rem
24. s 4 to the bearing sup port end plate using capscrews 4 and lockwashers 6 ACAUTION Make certain the snap ring is installed on the bearing support This snap ring will keep the planet carrier correctly positioned in the winch Gear train damage 3 Install the other brake plate spacer 33 and the spring may occur if this snap ring is omitted plate 31 as shown 18 10 Fasten the two tie plates to the endplate with cap screws 5 and lockwashers 6 and torque all eight 8 tie plate capscrews to their proper value Check that the drum turns freely in both directions without binding or any interference Install the sun gear 41 meshing with the teeth on the planet gears in the drum 7 Lubricate the bearing support and sealing surface with petroleum jelly or gear oil and place the cable drum 3 on the bearing support endplate Check that the drum rotates freely on the bearing 8 Install the planet carrier assembly into the drum while Be certain the snap ring 30 is seated in the groove meshing the planet gears with ring gear and the planet in the splined bore of the brake coupling 29 This carrier with the bearing support snap ring will keep the brake coupling correctly posi tioned in the center of the friction brake pack Binding of the brake or brake failure may occur if this snap ring is omitted 9 Lubricate the bearing support and sealing surface on the brake cylinder endplate a
25. s 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 should also be changed whenever the ambient temperature changes significantly and an oil from a different temperature range would be more appropriate Oil viscosi ty with regard to ambient temperature is critical to reliable brake operation 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 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 motor adapter 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 manufacturer s recommendations 6 Mounting Bolts Tighten all winch base mo
26. s are worn to a point disc is distorted or heat discolored Check free length of each brake spring Minimum free length is 15 16 inch 23 8 mm Check springs for any signs of cracking or failure If a brake spring must be replaced for any reason then ALL brake springs must be replaced Failure to replace brake springs as a set may result in uneven brake application pressure and repeated brake spring failure WINCH ASSEMBLY 4 Install the spring locator 28 and the eight 8 springs p 27 into the brake cylinder end plate 2 1 Place the motor adapter on workbench with the motor mounting surface down Install a new O ring 36 Lubricate the brake piston seal with petroleum jelly or hydraulic oil and install on the motor support with the seal lip down as shown above 5 While holding the motor adapter and brake assembly together turn it over and install into the brake cylinder end plate Install the eight 8 capscrews 47 and lock washers 48 but do not tighten them at this time 2 Install a brake spacer 33 into the motor support Insert a steel disc 35 against the spacer followed by a friction disc 34 Alternately install steel and friction discs until eight 8 friction discs and nine 9 steel discs have been installed Finish with a steel disc on top NOTE Itis good practice to lubricate the discs in gear oil prior to assembly 6 Loosely attach the two tie plate
27. s at the phone num ber shown above Serial Number and Model Number are located to the left of the hydraulic motor stamped into the data plate Always refer to the Serial Number and Model Number when requesting information or service parts EXPLANATION OF MODEL NUMBER BG 4 A 05 119 01 H T 1 T p T 1T T BRADEN MAX DESIGN GEAR MOTOR DRUM HIGH LINE GEARMATIC RATING MODEL RATIO SIZE SIZE PULL OPTION BG DESIGNATES BRADEN GEARMATIC 4 DESIGNATES 4 000 LB 1 810 kg FIRST LAYER LINE PULL CONTINUOUS DUTY A DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES 05 DESIGNATES TOTAL GEAR PRODUCTION 119 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN REV DECIMAL POINT ELIMINATED 119 11 9 cu in rev 195 cu 01 DESIGNATES THE DRUM H DESIGNATES 5 000 LB 2 270 kg FIRST LAYER LINE PULL INTERMITTENT DUTY APPLICATIONS 2 GENERAL SAFETY RECOMMENDATIONS Safety for operators and ground personnel is of prime con cern 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 A WARNING A FAILURE TO OBEY THE FOLLOWING SAFETY RECOMMENDATIONS MAY RESULT IN PROPER TY DAMAGE PERSONAL INJURY OR DEATH
28. the gear train or cable drum from rotat ing in either direction The solid brake coupling makes the static brake effective both directions This means the stat ic brake must be released before the winch can operate in either the hoist or lower direction The static brake is released by pilot pressure applied to the brake cylinder lt releases at a pressure lower than that required to open the pilot operated counterbalance car tridge This sequence assures that dynamic braking is done by the counterbalance cartridge and that little if any heat is absorbed by the friction brake The static or friction brake is primarily a load holding brake and will provide dynamic braking only during extremely slow operation when there is insufficient flow and pressure to open the counterbalance cartridge OPERATION Since the static brake on this winch is effective both direc tions the brake must be hydraulically released to operate the winch in either the hoist or lower direction This also means cable can be wound onto the drum in either direction without any modifications to the winch When the winch is powered in either direction the motor cannot rotate until sufficient pilot pressure is present to open the correct counterbalance cartridge The friction brake will completely release at a pressure lower than required to open the counterbalance cartridge The extent to which the cartridge opens will determine the amount of oil that can flow th
29. unting bolts to recommended torque after the first one hundred 100 hours of operation then every 1000 operating hours or six 6 months whichev er occurs first 7 Warm up Procedure A warm up procedure is recommended at each start up and is essential at ambient temperatures below 40 F 49C The prime mover should be run at its lowest recommended RPM with the hydraulic winch control valve in neutral allow ing sufficient time to warm up the system The winch should then be operated at low speeds forward and reverse sev eral times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear sets A WARNING A Failure to properly warm up the winch particularly under low ambient temperature conditions may result in temporary brake slippage due to high back pres sures attempting to release the brake which could result in property damage severe personal injury or death 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 and obtaining long gear train life For simplicity we have listed one 1 readily available prod uct 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 a
30. upling which is connected to the sun gear of the plane tary reduction set The planet carrier is splined to the bear ing support end plate and cannot rotate The hydraulic motor rotates the brake coupling and sun gear driving the planet gears which in turn drive the ring gear cable drum DUAL BRAKE SYSTEM Dynamic Brake The dynamic brake system consists of two basic compo nents 1 Brake valve block and counterbalance cartridges 2 Hydraulic motor The counterbalance cartridges are installed into a brake valve block which also contains an internal shuttle valve The shuttle valve directs hydraulic pressure to the brake release port of the winch when the winch is operated in either direction Static Brake The static brake consists of three basic components 1 Spring applied multiple friction disk brake pack 2 Solid brake coupling 3 Hydraulic brake cylinder and spring plate The brake pack consists of alternatively stacked friction and steel brake disks The steel brake disks are externally splined to the motor adapter and cannot rotate The friction disks are internally splined to the brake coupling When the winch is not being operated spring force compresses the Winch Brake Winch Pilot Operated Check Valve Control Valve WINCH CONTROL CIRCUIT SINGLE SPEED BRAKE EFFECTIVE BOTH DIRECTIONS brake pack and locks the brake coupling to the motor adapter preventing
31. upported by engineering tests indicates 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 pre vailing ambient temperature Annual Disassembly and Inspection of 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 LOWERING PORT SAE 10 ORB 7 8 14 THD p 12 4 MTG HOLES aS HOISTING POR SAE 10 ORB 7 8 14 THD 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 is 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 reli able and safe operation of the brake clutch and erode bear ing
32. vailable in your area make certain your lubricant vendor supplies you with oil that is equivalent to those products listed below Planetary winches are factory filled with Exxon Spartan EP 150 or equivalent 9 Inspection In conditions with ANSI specification number B30 5c1987 and API Recommended Practice RP 2D section 3 we rec ommend that the winch be disassemble for a thorough inspection of all wear items every 2 000 hours of opera tion or twelve 12 months whichever occurs first A WARNING A Failure to use the proper type and viscosity of plane tary gear oil may contribute to intermittent brake slip page which could result in property damage severe personal injury or death Some gear lubricants con tain large amounts of EP extreme pressure and anti friction additives which may contribute to brake slip page and damage to brake friction discs or seals Oil viscosity with regard to ambient temperatures is also critical to reliable brake operation Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake slippage Make certain that the gear oil viscosity used in your winch is correct for your prevailing ambient temperature RECOMMENDED PLANETARY GEAR OIL PREVAILING AMBIENT TEMPERATURE F 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 F EXXON SPARTAN EP220 OR EQUIVALENT AGMA 5 EP ISO VG 220 EXXON SPARTAN EP150 OR EQUIVALENT AGMA 4 EP ISO VG 150 MOBIL SH
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