BRADEN PD12C Series Manual

BRADEN
SERIES
PD12C
PD15B
PD17A HYDRAULIC WINCH
INSTALLATION, MAINTENANCE AND SERVICE MANUAL
PACR
WINCH DIVISION
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE [phone] FAX [phone]
www.paccarwinch.com
LIT2103 R3
07/2007
PRINTED IN U.S.A.

– 1 –
FOREWORD
Read this entire publication and retain it for future reference.
If you have any questions regarding your Braden Planetary Winch or this publication, call the Braden Service
Department at 1-918-251-8511, 08:00-1630 hours, CT, Monday through Friday.
The minimum service intervals specified are for operating hours of the prime mover.
The following service instructions have been prepared to provide assembly, disassembly and maintenance
information for the BRADEN Model PD12C, PD15B and PD17A series winch. It is suggested that before doing any
work on these units, all assembly and disassembly instructions should be read and understood.
Some pictures in this manual may show details or attachments that are different from your winch. Also, some
components have been removed for illustrative purposes. Illustrations and pictures in this manual are of a “typical”
unit sold through our distribution channels. Some winches, particularly those sold directly to original equipment
manufacturers, may differ slightly in appearance.
Whenever a question arises regarding your BRADEN winch, please contact BRADEN Service Department for the
latest available information.
Serial Numbers and Model Numbers are located to
the left hand side of the hydraulic motor, stamped
into the base. Always refer to the Serial Number
and Model Number when requesting information
or service parts.
EXPLANATION OF MODEL NUMBER
PD DESIGNATES POWER DRUM
12 DESIGNATES 12,000 LB. APPROXIMATE FIRST LAYER LINE PULL
CDESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
29 DESIGNATES TOTAL GEAR REDUCTION
064 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV
(DECIMAL POINT ELIMINATED. EXAMPLE 064 = 6.4 CU IN/REV)
02 DESIGNATES THE DRUM OPTION
UDESIGNATES UNDERWOUND CABLE DRUM – OPTIONAL
LDESIGNATES LEFT HAND BASE – OPTIONAL
1PERMITS TESTING AND INSPECTION PER API 2C FOR OFFSHORE CRANES
PD 12 C – 29 064 – 02 – U L – 1
POWER MAX. DESIGN GEAR MOTOR DRUM ROTATION BASE OPTION
DRUM RATING MODEL RATIO SIZE OPTION

– 2 –
TABLE OF CONTENTS
GENERAL SAFETY RECOMMENDATIONS .......................................................PAGE 3
THEORY OF OPERATION...............................................................................................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
PD17A ROTATION INDICATOR PROXIMITY SENSOR ...............................................36

– 3 –
GENERAL SAFETY RECOMMENDATIONS
Safety and informational callouts used in this manual include:
Safety for operators and ground personnel is of prime concern. Always take the necessary precautions to ensure
safety to others as well as yourself. To ensure safety, the prime mover and winch must be operated with care and
concern by the operator for the equipment and a thorough knowledge of the machine’s performance capabilities.
The following recommendations are offered as a general safety guide. Local rules and regulations will also apply.
WARNING – This emblem is used to warn against
hazards and unsafe practice which COULD result in
severe personal injury or death if proper procedures
are not followed.
CAUTION – This emblem is used to warn against
potential or unsafe practices which COULD result in
personal injury and product or property damage if
proper procedures are not followed.
1. Be certain equipment (boom, sheave blocks,
pendants, etc.) is either lowered to the ground or
blocked securely before servicing, adjusting, or
repairing winch.
2. Be sure personnel are clear of work area BEFORE
operating winch.
3. Read all warning and caution tag information
provided for safe operation and service of winch.
4. Inspect rigging and winch at the beginning of each
work shift. Defects should be corrected
immediately.
5. Keep equipment in good operating condition.
Perform scheduled servicing and adjustments listed
in the “Preventive Maintenance” section of this
manual.
6. An equipment warm-up procedure is recommended
for all start-ups and essential at ambient
temperatures below +40°F (4°C). Refer to “Warm-
up Procedure” listed in the “Preventive
Maintenance” section of this manual.
7. Operate winch line speeds to match job conditions.
8. Leather gloves should be used when handling wire
rope.
9. Never attempt to handle wire rope when the hook
end is not free. Keep all parts of body and clothing
clear of cable rollers, cable entry area of fairleads
and winch drum.
10. When winding wire rope on the winch drum, never
attempt to maintain tension by allowing wire rope to
slip through hands. Always use “Hand-Over-Hand”
technique.
11. Never use wire rope with broken strands. Replace
wire rope.
12. Do not weld on any part of the winch.
13. Use recommended hydraulic oil and gear lubricant.
14. Keep hydraulic system clean and free from
contamination at all times.
15. Use correct anchor for wire rope and pocket in
drum.
16. Do not use knots to secure or attach wire rope.
17. The BRADEN designed wire rope anchors are
capable of supporting the rated load when installed
properly. For additional safety, ALWAYS maintain a
minimum of five (5) wraps of wire rope on the drum.
18. Never attempt to clean, oil or perform any
maintenance on a machine with the engine or prime
mover running, unless instructed to do so in this
manual.
19. Never operate winch controls unless you are
properly positioned at the operators station and you
are sure personnel are clear of the work area.
20. Assure that personnel who are responsible for hand
signals are clearly visible and that the signals to be
used are thoroughly understood by everyone.
21. Ground personnel should stay in view of the
operator and clear of winch drum. Do not allow
ground personnel near winch line under tension. A
safe distance of at least 1 _ times the length of the
cable should be maintained.
22. Do not exceed the maximum pressure, PSI (kPa),
or flow, GPM (LPM), stated in the winch
specifications for hydraulically driven winches.
23. Install guarding to prevent personnel from getting
any part of body or clothing caught at a point where
the cable is wrapped onto the drum or drawn
through guide rollers.
24. “Deadman” controls, which automatically shut off
power to the winch whenever the operator leaves
his station, should be installed whenever
practicable.
25. Never allow anyone to stand under a suspended
load.
26. Avoid sudden “shock” loads or attempting to “jerk”
load free. This type of operation may cause heavy
loads, in excess of rated capacity, which may result
in failure of cable and winch.
CAUTION
CAUTION
WARNING
! !

– 4 –
DESCRIPTION OF WINCH
The winch has four basic component parts:
1. Winch base
2. Hydraulic motor and brake valve
3. Brake cylinder and motor support
4. Drum assembly
The drum assembly consists of three basic
assemblies:
1. Drum with integral ring gear
2. Output planetary gear set
3. Primary planetary gear set
The hydraulic motor is bolted to the motor support
which in turn is bolted to the brake cylinder and the
base. The motor end of the drum, running on a ball
bearing, is supported by the brake cylinder. The other
end of the drum runs on a ball bearing on the support
bolted to the base. The ring gear for both planetary
sets is machined into the drum’s inside surface.
WINCH OPERATION
The hydraulic motor drives the sun gear of the
primary planetary gear set through the splined inner
race of the brake clutch. When driven by the sun
gear, the primary planet gears walk around the ring
gear in the drum and drive the primary planet carrier.
The primary planet carrier drives the output planet
sun gear which, in turn drives the output planet
gears. The output planet carrier is splined to the
bearing support and cannot rotate. Therefore, as the
output planet gears are driven by the sun gear, they
will drive the ring gear/drum.
Dual Brake System – Description
The dual brake system consists of a dynamic brake
system and a static brake system.
The dynamic brake system has two operating
components:
1. Brake valve assembly
2. Hydraulic motor
The brake valve is basically a counterbalance valve.
It contains a check valve to allow free flow of oil to the
motor in the hoisting direction and a pilot operated,
spring-loaded spool valve that blocks the flow of oil
out of the motor when the control valve is placed in
neutral. When the control valve is placed in the
lowering position, the spool valve remains closed
until sufficient pilot pressure is applied to the end of
the spool to shift it against spring pressure and open
a passage. After the spool valve cracks open, the
pilot pressure becomes flow-dependent and
modulates the spool valve opening which controls
the lowering speed.
Figures 2, 3 and 4.
The static brake system has three operating
components:
1. Spring Applied, Multiple Friction Disc Static
Brake
2. Brake Clutch Assembly
3. Hydraulic Piston and Cylinder
Figure 2
HOISTING
Figure 3
LOWERING 1
THEORYOF OPERATION
High Pressure
Medium Pressure
Low Pressure
Static Brake
Brake Valve
Pump
Motor
Control Valve
To Tank
High Pressure
Medium Pressure
Low Pressure
Static Brake
Brake Valve
Pump
Motor
Control Valve
To Tank

– 5 –
Figure 4
LOWERING 2
The static brake is released by the brake valve pilot
pressure at a pressure lower than that required to open
the pilot operated spool valve. This sequence assures
that dynamic braking takes place in the brake valve
and that little, if any, heat is absorbed by the friction
brake.
The friction brake is a load holding brake only and has
nothing to do with dynamic braking or rate of descent
of a load.
The brake clutch is splined to the primary sun gear
shaft between the motor and the primary sun gear. It
will allow this shaft to turn freely in the direction to raise
a load and lock up to force the brake discs to turn with
the shaft in the direction to lower a load. Figures 5 and
6.
The hydraulic cylinder, when pressurized, will release
the spring pressure on the brake discs, allowing the
brake discs to turn freely.
Dual Brake System – Operation
When hoisting a load, the brake clutch which connects
the motor shaft to the primary sun gear, allows free
rotation. The sprag cams lay over and permit the inner
race to turn free of the outer race. Figure 5. The friction
brake remains fully engaged. The winch, in raising a
load, is not affected by any braking action. Figure 2.
When the lifting operation is stopped, the load attempts
to turn the primary sun gear in the opposite direction.
This reversed input causes the sprag cams to instantly
roll upward and firmly lock the shaft to the fully
engaged friction brake. Figure 6.
When the winch is powered in reverse, to lower the
load, the motor cannot rotate until sufficient pilot
pressure is present to open the brake valve. Figures 3
& 4. The friction brake within the winch will completely
release at a pressure lower than that required to open
the brake valve. The extent to which the brake valve
opens will determine the amount of oil that can flow
through it and the speed at which the load will be
lowered. Increasing the flow of oil to the winch motor
will cause the pressure to rise and the opening in the
brake valve to enlarge, speeding up the descent of the
load. Decreasing this flow causes the pressure to lower
and the opening in the brake valve to decrease thus
slowing the descent of the load.
When the control valve is shifted to neutral, the
pressure will drop and the brake valve will close,
stopping the load. The friction brake will engage and
hold the load after the brake valve has closed.
When lowering a load very slowly for precise
positioning, no oil flow actually occurs through the
winch motor. The pressure will build up to a point
where the brake will release sufficiently to allow the
load to rotate the motor through its own internal
leakage. This feature results in a very slow speed and
extremely accurate positioning.
The friction brake receives very little wear in the
lowering operation. All of the heat generated by the
lowering and stopping of a load is absorbed by the
hydraulic oil where it can be readily dissipated.
Figure 5
Figure 6
STATIC FRICTION BRAKE APPLIED
PERMITS FREE SHAFT ROTATION
WHILE HOISTING
STATIC FRICTION BRAKE APPLIED
SPRAG CAMS
LOAD ATTEMPTS TO ROTATE SHAFT IN
OPPOSITE DIRECTION.
BRAKE CLUTCH LOCKS SUN GEAR SHAFT
TO FRICTION BRAKE.
SPRAG CAMS
High Pressure
Medium Pressure
Low Pressure
Static Brake
Brake Valve
Pump
Motor
Control Valve
To Tank

– 6 –
1. The winch should be mounted with the centerline
of the drum in a horizontal position. The mounting
plane of the base may be rotated in any position
around this centerline.
2. Because of the design of the mounting base, the
direction of line pull should only be as shown in
the above illustration. Line pulls in any other
direction must be approved by BRADEN
Engineering.
3.
When mounting the winch, use all eight (8)
mounting holes and grade 5 or better bolts and
nuts. Tighten to recommended torque.
It is important that the winch is mounted on a
surface that will not flex when the winch is in use,
and cause binding of the gear train. Binding in the
gear train will result in accelerated wear and heat.
Also, be sure the winch is mounted on a flat
surface. If necessary, use shim stock to insure the
mounting surface is flat within 0.020 in. (0.5 mm).
4. The vent plug must always be located above the
horizontal centerline. If the winch is mounted on a
pivoting surface, be sure vent plug remains above
the centerline in all positions. If necessary,
reposition bearing support and vent plug as
follows:
A. Remove bearing support bolts.
B. Rotate bearing support until vent plug is
positioned correctly and bolt holes are
aligned.
C. Evenly tighten bolts to recommended
torque.
5. Hydraulic lines and components that operate the
winch should be of sufficient size to assure
minimum back pressure at the winch. The motor
manufacturer recommends that the back pressure
not to exceed 100 psi (690 kPa) for optimum
motor seal life. 150 psi (1,030 kPa) is the
maximum allowable back pressure. The standard
winch is supplied with the motor internally drained.
If high back pressures are encountered, the motor
may be externally drained directly to tank to
improve motor seal life. For back pressures
exceeding 150 psi (1,030 kPa) consult BRADEN
Service Department.
6. The winch should be mounted perpendicular to an
imaginary line from the center of the drum to the
first sheave to insure even spooling. Make certain
the fleet angle does not exceed 1-1/2 degrees.
WINCH INSTALLATION
30°
75°
VENT PLUG
ABOVE CENTERLINE
SHADED AREAS REPRESENT
ACCEPTABLE DIRECTIONS OF
LINE PULL
C
L

– 7 –
7. The winch directional control valve must be a
three position four way valve with a motor spool
such that when the valve is in the center position
both work ports are open to tank (open center,
open port).
8. High quality hydraulic oil is essential for
satisfactory performance and long hydraulic
system component life.
Oil having 150 to 330 SUS viscosity at 100°F
(38°C) and viscosity index of 100 or greater will
give good results under normal temperature
conditions. The use of an oil having a high
viscosity index will minimize cold-start trouble and
reduce the length of warm-up periods. Ahigh
viscosity index will minimize changes in viscosity
with corresponding changes in temperature.
Maximum cold weather start-up viscosity should
not exceed 5000 SUS with a pour point at least
20°F (11°C) lower than the minimum temperature.
Under continuous operating conditions the
temperature of the oil at any point in the system
must not exceed 180° (82°C). Optimum oil
temperature is generally considered to be 120-
140°F (49-60°C).
In general terms; for continuous operation at
ambient temperatures between 50 and 110°F (10
to 43°C) use SAE 20W; for continuous operation
between 10 and 90°F (-12 to 32°C) use SAE 10W;
for applications colder than 10°F (-12°C), contact
the BRADEN Service Department. The use of
multi-viscosity oils is generally not recommended.
9. The hydraulic oil filter should have a 10 micron
nominal rating and be full flow type.
RECOMMENDED FASTENER TORQUE
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.
To convert lb. ft. to kg•m, multiply lb. ft. value by 0.1383.
WINCH BRAKE
BRAKE
VALVE
PUMP
CONTROL
VALVE
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
BR
DR
Dry Lubed Dry Lubed Dry Lubed Dry Lubed
Torque (LB-FT)
Grade 5
Grade 8
1/4
20
28
5/16
3/8
18
24
16
24
7/16
1/2
9/16
5/8
8
6
12
9
17
13
24
18
45
35
70
50
23
31
50
35
80
110
80
150
110
110
55
75
150
115
210
160
14
20
13
20
12
18
11
18
265
200
Torque (LB-FT)
Grade 5
Grade 8
380
280
7/8
9
14
420
325
600
450
3/4
10
16
680
1 1/8
7
12
790
590
1290
970
1
8
14
640
7
12
1120
835
910
485
1460
1820
1360
1 3/8
6
12
1460
1095
2385
1790
1 1/4
3160
2370
RECOMMENDED FASTENER TORQUE
Bolt Dia.
Inches
Thds Per
Inch
Bolt Dia.
Inches
Thds Per
Inch
1 1/2
6
12
1940

– 8 –
WIRE AND BRAIDED
ROPE INSTALLATION
ANCHORING WIRE ROPE
Take the free end of the wire rope and insert it
through the small opening of the anchor pocket.
Loop the wire rope and push the free end about _ of
the way back through the pocket. Install the wedge,
then pull the slack out of the wire rope. The wedge
will slip into the pocket and secure the wire rope into
the drum. The anchor is designed to accommodate
several different sizes of wire rope. You may anchor
7/16 and 1/2 in. (11 & 13 mm) wire rope by inserting
the wedge, large end first. Anchor 9/16 and 5/8 in.
(14 & 16 mm) wire rope by inserting the wedge, small
end first.
ANCHORING BRAIDED ROPE
Aspecial wedge is used to anchor 1 and 1 1/8 in. (25
& 28 m) braided rope. The installation procedure is
the same as for anchoring wire rope.
TWO SPEED MOTOR
CASE DRAIN PLUMBING
Winches built prior to 1991 with two speed motor,
Part No. 26182, have the motor case drain
connected to the drain port of the brake valve. This
may result in accelerated motor shaft wear and
leakage. The following modification should be made
to the motor hydraulic piping to prevent this type of
seal damage.
1. Remove the motor case drain hose from the
brake valve drain port and install plug, Item
1, into the valve port. Remove the hose from
the case drain port elbow, Item 4.
2. Install a new case drain hose, Item 2, onto
the motor case drain elbow, Item 4.
3. Install the tee adapter, Item 3, into the two-
speed motor shift valve drain port (identified
by long end cap).
4. Install the new motor case drain hose, Item
2, onto the tee adapter.
Correct Installation
Incorrect Installation
Drive from
this side
Wedge and wire
rope fully seated
in pocket
Figure 7 Figure 8
Figure 9 Figure 10
Wedge not
fully seated
Wedge pulled
too far through
anchor pocket

– 9 –
The following minimum service intervals are specified
for operating hours of the prime mover.
1. Oil Level
The gear oil level should be checked every 500
operating hours or three (3) months, whichever
occurs first. To check the oil level, remove the large
plug located in the center of the drum support. The
oil should be level with the bottom of this opening.
If additional oil in needed, refer to “Recommended
Planetary Gear Oil”.
2. Oil Change
The gear oil should be changed after the first one
hundred (100) hours of operation, then every 1,000
operating hours or six (6) months, whichever
occurs first. The gear oil must be changed to
remove wear particles that impede the reliable and
safe operation of the brake clutch and erode
bearings, gears and seals. Failure to change gear
oil at these suggested minimum intervals may
contribute to intermittent brake slippage which
could result in property damage, severe personal
injury or death.
The gear oil should also be changed whenever the
ambient temperature changes significantly and an
oil from a different temperature range would be
more appropriate. Oil viscosity with regard to
ambient temperature is critical to reliable brake
PREVENTIVE MAINTENANCE
Aregular program of preventive maintenance for your planetary winch is strongly recommended to minimize the need
for emergency servicing and promote safe, reliable winch operation.
Field experience, supported by engineering tests, indicate the three (3) service procedures listed below are the MOST
critical to safe, reliable winch operation and must be observed.
•Regular Gear Oil Changes – every 1000 hours or six (6) months
•Use of Proper Gear Oil – recommended type for prevailing ambient temperature
•Annual Disassembly and Inspection of All Wear Items – in compliance with American National Standards Institute
(ANSI) specification B30.5c 1987 and American Petroleum Institute (API) recommended practice RP 2D section 3.
1
3
2
4
5. Install a case drain hose for the tee directly to the
reservoir. Minimum hose size is –6, 3/8 in. (9.5 mm).
Maximum drain line back pressure is 100 PSI (7
Kg/cm2) measured at the motor case drain port.
Parts needed for modification:
Item Qty P/N Description
1 1 25663 Plug –4 (Aeroquip 900598-4S)
2 1 13707 Hose 17 in. OAL
(-4 JIC Fml Svl/-4 Hose /
1/8 NPT ml)
3 1 29078 Tee –4 (Aeroquip 203003-4-4S)

– 10 –
clutch operation. Our tests indicate that
excessively heavy or thick gear oil may contribute
to intermittent brake clutch slippage. Make certain
that the gear oil viscosity used in your winch is
correct for your prevailing ambient temperature.
Failure to use the proper type and viscosity of
planetary gear oil may contribute to brake clutch
slippage which could result in property damage,
severe personal injury or death. Refer to
“Recommended Planetary Gear Oil” for additional
information.
3. Vent Plug
The vent plug is located in the drum support as
shown. It is very important to keep this vent clean
and unobstructed. Whenever gear oil is changed,
remove vent plug, clean in solvent and reinstall.
Do not paint over the vent or replace with a solid
plug.
4. Hydraulic System
The original filter element should be replaced after
the first fifty (50) hours of operation, then every 500
operating hours or three (3) months, or in
accordance with the equipment manufacturer’s
recommendations.
5. Wire Rope
Inspect entire length of wire rope according to wire
rope manufacturers recommendations.
6. Mounting Bolts
Tighten all winch base mounting bolts to
recommended torque after the first one hundred
(100) hours of operation, then every 1000 operating
hours or six (6) months, whichever occurs first.
7. Warm-up Procedures
Awarm-up procedure is recommended at each
start-up and is essential at ambient temperatures
below +40°F (4°C).
The prime mover should be run at its lowest
recommended RPM with the hydraulic winch
control valve in neutral allowing sufficient time to
warm up the system. The winch should then be
operated at low speeds, forward and reverse,
several times to prime all lines with warm hydraulic
oil, and to circulate gear lubricant through the
planetary gear sets.
8. Recommended Planetary Gear Oil
Field experience, supported by extensive
engineering tests, indicates the use of the proper
planetary gear oil is essential to reliable and safe
operation of the brake clutch and obtaining long
gear train life.
For simplicity, BRADEN has listed one (1) readily
available product in each temperature range which
has been tested and found to meet our
specifications. This is not to say that other lubricant
brands would not perform equally as well.
If the following lubricant brands are not available in
your area, make certain your lubricant vendor
supplies you with oil that is equivalent to those
products listed below.
BRADEN planetary winches are factory filled with
Texaco Meropa 150 or equivalent AGMA No. 4EP
gear oil.
9. Inspection
In compliance with ANSI specification number
B30.5c1987 and API Recommended Practice RP
2D section 3, we recommend that the winch be
disassembled for a thorough inspection of all wear
items every 2,000 hours of operation or twelve (12)
months, whichever occurs first.
A. Bearings and Gears – Refer to
DISASSEMBLYOF WINCH, page 15; and
PLANET CARRIER SERVICE, page 20.
B. Brake Cylinder – Refer to MOTOR
SUPPORT– BRAKE CYLINDER SERVICE,
pages 22 and 23.
C. Brake Clutch – Refer to BRAKE CLUTCH
SERVICE, page 26.
Failure to properly warm up the winch, particularly
under low ambient temperature conditions, may
result in temporary brake slippage due to high back
pressures attempting to release the brake, which
could result in property damage, severe personal
injury or death.
Failure to use the proper type and viscosity of
planetary gear oil may contribute to intermittent brake
clutch slippage which could result in property
damage, severe personal injury or death. Some gear
lubricants contain large amounts of EP (extreme
pressure) and anti-friction additives which may
contribute to brake clutch slippage and damage to
brake friction discs or seals. Oil viscosity with regard
to ambient temperature is also critical to reliable
brake clutch operation. Our tests indicate that
excessively heavy or thick gear oil may contribute to
intermittent brake clutch slippage. Make certain that
the gear oil viscosity used in your winch is correct for
your prevailing ambient temperature.
CAUTION
WARNING
! !
CAUTION
WARNING
! !

– 11 –
TROUBLE
A
The winch will not lower the load or not
lower the load smoothly.
PROBABLE CAUSE
1. The problem could be a plugged or
loose pilot orifice. The pilot orifice is a
small pipe plug with a hole drilled through
it, located behind the pilot port fitting on
the brake valve. If it becomes plugged, it
will prevent the pilot pressure, from the
manifold, from opening the brake valve. If
it becomes loose, it will allow an
unregulated amount of oil in to operate
the brake valve which cause erratic brake
valve operation.
2. The friction brake may not be releasing
as a result of a defective brake cylinder
seal.
NOTE: If the brake cylinder seal is
defective you will usually find oil leaking
from the winch vent plug.
3. Friction brake will not release as a
result of damaged brake discs.
REMEDY
Remove the pilot hose and fitting from
the brake valve, then use a 5/32 inch
Allen wrench to remove the pilot orifice.
The diameter of the orifice is
approximately .020 inches. Clean and
install the pilot orifice tightly in the brake
valve.
Check brake cylinder seal as follows:
A. Disconnect the swivel tee from the
brake release port. Connect a hand
pump with accurate 0-2000 psi gauge
and shut-off valve to the –4 J.I.C. fitting in
the brake release port.
B. Apply 1000 psi to the brake. Close
shut-off valve and let stand for five (5)
minutes.
C. If there is any loss of pressure in five
(5) minutes, the brake cylinder should be
disassembled for inspection of the
sealing surfaces and replacement of the
seals. Refer to “Motor Support-Brake
Cylinder Service”.
Disassemble brake to inspect brake
discs. Check stack-up height as
described in “Motor Support-Brake
Cylinder Service”.
TROUBLESHOOTING
If a winch ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping or
chattering) appropriate troubleshooting tests and repairs should be performed immediately.
Continued operation in this manner may result in property damage, serious personal injury or death.
OIL CAPACITIES: (PD12C/PD15B) 01, 02 & 22 DRUM - 6 PINTS 04, 05 & 23G DRUM – 7 PINTS (PD17A) - 14 PINTS
NOTE: Capacities are approximate. Refer to “Oil Level” earlier in this section
CAUTION
WARNING
! !

– 12 –
TROUBLE
B
Oil leaks from vent plug.
PROBABLE CAUSE
1. Same as A2.
2. Motor seal may be defective as a
result of high system back pressure
or contaminated oil.
REMEDY
Same as A2.
System back pressure must not
exceed 150 psi. Inspect hydraulic
system for a restriction in the return
line from the control valve to the
reservoir. Be sure control valve and
plumbing is properly sized to winch
motor.
Oil analysis may indicate
contamination has worn motor shaft
and seal. Thoroughly flush entire
hydraulic system and install new
filters and oil. Install new motor seal.
C
The brake will not hold a load with
the control lever in neutral.
1. Excessive system back pressure
acting on the brake release port.
2. Friction brake will not hold due to
worn or damaged brake discs.
3. Brake clutch is slipping.
The same as Remedy 2 of Trouble
B2.
Same as Remedy 3 of Trouble A3.
Improper planetary gear oil may
cause the brake clutch to slip. Drain
old gear oil and flush winch with
solvent. Thoroughly drain solvent
and refill winch with recommended
planetary gear oil listed in
“Preventive Maintenance”.
Brake clutch may be damaged or
worn. Disassemble and inspect
brake clutch as described in “Brake
Clutch Service”.
D
The winch will not hoist the rated
load.
1. The winch may be mounted on an
uneven or flexible surface which
causes distortion of the winch base
and binding of the gear train. Binding
in the gear train will absorb
horsepower needed to hoist the
rated load and cause heat.
2. System relief valve may be set too
low. Relief valve needs adjustment
or repair.
Reinforce mounting surface.
If necessary, use shim stock to level
winch. Refer to “Winch Installation”.
First loosen, then evenly retighten all
winch mounting bolts to
recommended torque.
Check relief pressure as follows:
A. Install an accurate 0-4000 psi
(27,580 kPa) gauge into the inlet
port of the brake valve.

– 13 –
TROUBLE
TROUBLE “D” CONTINUED
FROM PREVIOIUS PAGE
PROBABLE CAUSE
3. Be certain hydraulic system
temperature is not more than 180
degrees F. Excessive hydraulic oil
temperatures increase motor
internal leakage and reduce motor
performance.
4. Winch line pull rating is based on
1st layer of wire rope.
5. Rigging and sheaves not
operating efficiently.
REMEDY
B. Apply a stall pull load on the winch
while monitoring pressure.
C. Compare gauge reading to winch
specifications. Adjust relief valve as
required.
NOTE: If pressure does not
increase in proportion to adjustment,
relief valve may be contaminated or
worn out. In either case, the relief
valve may require disassembly or
replacement.
Same as remedies for Trouble D1 &
D2.
Same as remedies for Trouble E2.
Refer to winch performance charts
for additional information.
Perform rigging service as
recommended by crane
manufacturer.
E
The winch runs hot. 1. Same as D1.
2. Be certain that the hydraulic
system temperature is not more than
180 degrees F. Excessive hydraulic
oil temperatures may be caused by:
A. Plugged heat exchanger.
B. Too low or too high oil level in
hydraulic reservoir.
C. Same as D2.
D. Hydraulic pump not operating
efficiently.
3. Excessively worn or damaged
internal winch parts.
Same as remedies for Trouble D1.
Thoroughly clean exterior and flush
interior.
Fill/drain to proper level.
Same as remedies for Trouble D2.
Prime mover low on horsepower or
R.P.M. Tune/adjust prime mover.
Check suction line for damage.
If pump is belt driven, belts are
slipping. Replace/tighten belts.
Pump worn. Replace pump.
Disassemble winch to inspect/replace
worn parts.

– 14 –
TROUBLE
F
Winch “chatters” while raising rated
load.
PROBABLE CAUSE
1. Same as D2.
2. Hydraulic oil flow to motor may be
too low.
3. Controls being operated too
quickly.
REMEDY
Same as remedies for Trouble D2.
Same as remedies for Trouble E2.
Conduct operator training as
required.
G
The wire rope does not spool
smoothly on the drum.
1. The winch may be mounted too
close to the main sheave, causing
the fleet angle to be more than 1-1/2
degrees.
2. The winch may not be mounted
perpendicular to an imaginary line
between the center of the cable
drum and the first sheave.
3. Could possibly be using the wrong
lay rope. There is a distinct
advantage in applying rope of the
proper direction of lay. When the
load is slacked off, the several coils
on the drum will stay closer together
and maintain an even layer. If rope
of improper lay is used, the coils will
spread apart each time the load is
removed. Then, when winding is
resumed, the rope has a tendency to
criss-cross and overlap on the drum.
The result is apt to be a flattened
and crushed rope.
4. The winch may have been
overloaded, causing permanent set
in the wire rope.
Check mounting distance and fleet
angle. Reposition winch as required.
Refer to “Winch Installation”.
Consult wire rope manufacturer for
recommendation of wire rope that
best suits your application.
Replace wire rope and conduct
operator/rigger training as required.

– 15 –
SERVICE PRECAUTIONS
•Before any part is removed from the winch, all
service instructions should be read and
understood.
• Work in a clean, dust free area as cleanliness is of
utmost importance when servicing hydraulic
equipment.
•Inspect all replacements parts, prior to installation,
to detect any damage which might have occurred
in shipment.
•Use only genuine BRADEN replacement parts for
optimum results. Never reuse expendable parts
such as oil seals and O-rings.
•Inspect all machined surfaces for excessive wear
or damage . . . before reassembly operations are
begun.
•Lubricate all O-rings and oil seals with gear oil prior
to installation.
•Use a sealing compound on the outside surface of
oil seals and a light coat of thread sealing
compound on pipe threads. Avoid getting thread
compound inside parts or passages which conduct
oil.
•Thoroughly clean all parts in a good grade of non-
flammable safety solvent. Wear protective clothing
as required.
After troubleshooting the winch and its hydraulic
system as covered in the “Troubleshooting” section,
and the problem is determined to be in the winch,
use the following procedure to disassemble the
winch.
1. Remove the wire rope from the winch drum and
align the drain hole in the drum with a hole in the
support side plate before removing the hoses
and mounting bolts. After the winch is removed
from its mounting, thoroughly clean the outside
surfaces. To drain the oil, install a short piece of
1 inch pipe in the larger threads of the drain hole.
If necessary, insert a bar into the anchor pocket
and manually rotate the drum in the direction to
hoist a load until the drain holes are aligned.
2. Use a 5/16 inch Allen wrench to remove the drain
plug through the pipe.
3. Begin disassembly by removing the oil level plug
and standing the winch on the bearing support
end. Tag and remove the hydraulic hoses that
connect the brake valve and manifold to the
brake cylinder.
4. Remove the capscrews securing the motor, and lift
the motor off the winch. Remove and discard the
O-ring installed on the pilot of the motor.
DISASSEMBLYOF WINCH

– 16 –
5. Tag and remove the hoses and fittings from the
brake cylinder release port.
6. Remove the brake clutch assembly from the motor
support. Refer to “Brake Clutch Service” for
additional information.
7. Remove the motor support capscrews and install
two (2) capscrews and a short piece of chain into
the motor mounting bolt holes. Using the chain
as a handle, lift the motor support out of the
brake cylinder being careful to avoid damaging
the sealing surfaces. Remove and discard the O-
ring and back-up ring from the motor support.
Refer to “Motor Support-Brake Cylinder Service”
for additional information.
8. Remove the brake cylinder capscrews and install
two (2) capscrews and a short piece of chain into
the motor support mounting bolt holes. Using the
chain as a handle, lift the brake cylinder out of
the drum and base, being careful to avoid
damaging the sealing or bearing surfaces. Refer
to “Motor Support-Brake Cylinder Service” for
additional information.
For PD15B winches, the drum closure cannot
be removed through the opening in the base. If
your winch has a cast base, remove the bearing
support, as described in step 15, and remove the
drum from the base. Then proceed with steps 9
thru 14. If your winch has a three piece base,
remove the motor end side plate and continue
with step 9.
9. Using two heel type pry bars placed between the
primary planet carrier and the drum closure, pry
upward to remove the drum closure. Remove
and discard the O-ring from the outside of the
drum closure.
10. Remove the seal and bearing from inside of
closure.

– 17 –
11. Remove the primary sun gear and thrust washer
from the primary planet carrier.
12. Remove the primary planet carrier from the drum.
Refer to “Planet Carrier Service” for additional
information.
13. Remove the output sun gear and thrust washer
from the output planet carrier.
14. Remove the output planet carrier from the drum.
Refer to “Planet Carrier Service” for additional
information.
15. Stand winch on motor end with bearing support
up; then remove eight (8) bearing support
capscrews and bearing support being careful to
avoid damaging the sealing or bearing surfaces.
16. Slide drum out of base onto a work bench and
remove seal and bearing from support end.
17. Thoroughly clean and inspect drum and base.
Check ring gear (machined into inside surface of
drum) teeth for nicks, spalling or excessive wear.
Replace if wear is greater than 0.015 in. (0.4
mm) when compared to unworn area of teeth.

Retaining ring (item 30)
is not used on PD17A
winches
PD17A winches use an
internal retaining ring
(item 16, not shown) to
hold item 38 into the
output planet carrier.
BRADEN PD12C/PD15B/PD17A COMPONENTS PD17A winches use only 1
each of items 52 and 53 due
to the shoulder on item 50.
(shoulder is toward motor)
– 18 –