BRADEN CH SERIES Manual

BRADEN
2ND GENERATION
“CH” SERIES
PLANETARY HOISTS
INSTALLATION, MAINTENANCE AND SERVICE MANUAL
CH150A
CH175A
CH185A
CH230A
C2H150A
C2H175A
C2H185A
C2H230A
PB-154
8/99
Printed in U.S.A.
PACR WINCH DIVISION
P.O. BOX 547 BROKEN ARROW, OK U.S.A.7401
3
PHONE [phone] FAX [phone]
www.paccarwinch.com

test

1
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . .3
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HOIST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
WIRE ROPE WEDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
RECOMMENDED BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
RECOMMENDED GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
HOIST DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
EXPLODED VIEW DRAWING AND PARTS KEY . . . . . . . . . . . . . . . . . . . .18
BRAKE CYLINDER SERVICE AND ASSEMBLY . . . . . . . . . . . . . . . . . . . .21
BRAKE CYLINDER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
PLANET CARRIER SERVICE AND ASSEMBLY . . . . . . . . . . . . . . . . . . . .24
BRAKE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
HOIST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
REVERSING DIRECTION OF DRUM ROTATION . . . . . . . . . . . . . . . . . . .34
BRAKE VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
METRIC CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

2
CH 150 A -23090 01 G -1
CONSTRUCTION
HOIST
MAX
RATING
DESIGN
MODEL
GEAR
RATIO
DRUM
SIZE
MOTOR
SIZE
EXPLANATION OF MODEL NUMBER
MODEL NUMBER AND SERIAL NUMBER
When information on a hoist is needed, always refer
to the model number and serial number. Both are
located on the top of the motor side end plate as
indicated above.
FOREWORD
Read this entire publication and retain it for future reference.
The following service instructions have been prepared to provide assembly, disassembly and maintenance information for
the BRADEN Model CH series winch. It is suggested that before doing any work on these units, all assembly and disas-
sembly 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.
Continuing product improvement may cause changes in your winch, which are not included in this manual. Whenever a
question arises regarding your BRADEN Winch or this manual, please contact BRADEN Service Department at 1-918-251-
8511, 08:00 - 16:30 hours, CST, Monday through Friday, for the latest available information.
CH DESIGNATES CONSTRUCTION HOIST (C2H DESIGNATES TWO SPEED)
150 DESIGNATES 15,000 LB FIRST LAYER LINE PULL
ADESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
23 DESIGNATES TOTAL GEAR REDUCTION
090 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV (DECIMAL POINT ELIMINATED
EXAMPLE 090 – 9.0 CU IN/REV)
01 DESIGNATES THE DRUM OPTION
GDESIGNATES OTHER DRUM OPTIONS (G = GROOVED; M = MACHINED; P = RATCHET AND PAWL;
U = UNDERWOUND)
1PERMITS TESTING AND INSPECTION PRE API2C FOR OFFSHORE CRANES
DRUM
OPTION
OPTION
MODEL NUMBER
AND
SERIAL NUMBER

3
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, pen-
dants, 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. Refer to “Warm-up Procedure” listed in
the “Preventive Maintenance” section of this manual.
7. Do not exceed the maximum pressure (PSI) or flow
(GPM) stated in the winch specifications.
8. Operate winch line speeds to match job conditions.
9. Leather gloves should be used when handling wire
rope.
10. Never attempt to handle wire rope when the hook end
is not free.
11. 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.
12. Never use wire rope with broken strands. Replace
wire rope.
13. Do not weld on any part of the winch.
14. Use recommended hydraulic oil and gear lubricant.
15. Keep hydraulic system clean and free from contamina-
tion at all times.
16. Use correct anchor for wire rope and pocket in drum.
17. Do not use knots to secure or attach wire rope.
18. 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.
Safety and informational callouts used in this manual
include:
GENERAL SAFETY RECOMMENDATIONS
CAUTION
CAUTION
!!
CAUTION
WARNING
! !

4
DESCRIPTION OF HOIST
The hoist is made up of the following sub-assemblies:
1. Hydraulic motor and brake valve
2. Drum, drum closure, ball bearings and oil seals
3. Support end plate and bearing support
4. Motor end plate and motor adapter
5. Tie plates
6. Brake clutch assembly
7. Brake cylinder assembly and multiple-disc brake parts
8. Primary planetary reducer
9. Secondary planetary reducer
10. Ring gear and adapter
THEORY OF OPERATION
The primary sun gear, being coupled to the hydraulic motor
by the inner race of the brake clutch assembly, turns with
the motor. As the primary sun gear turns, the primary plan-
et gears, which are meshed with the primary sun gear and
ring gear, walk around the stationary ring gear, causing the
primary carrier to turn in the same direction as the motor
shaft, but at a reduced speed. The primary carrier is
meshed with the output sun gear which, therefore, turns in
the same direction and at the same speed as the primary
carrier. The output sun gear causes the output planet gears
to walk around the ring gear, turning the output carrier and
drum in the same direction as the primary carrier, but at a
further reduced speed.
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 con-
tains 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.
See 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
BASIC OPERATION
Pump
Brake
Valve
Static
Brake
Motor
Control
Valve
Low Pressure Medium Pressure High Pressure
Pump
Brake
Valve
Static
Brake
Motor
Control
Valve
Low Pressure Medium Pressure High Pressure
To
Tank
To
Tank
Pump
Brake
Valve
Static
Brake
Motor
Control
Valve
Low Pressure Medium Pressure High Pressure
To
Tank
Figure 2
Figure 4
Figure 3

5
The static brake is released by the brake valve pilot pres-
sure at a pressure lower than that required to open the pilot
operated spool valve. This sequence assures that dynam-
ic 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 noth-
ing 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 pres-
ent 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 pres-
sure will build up to a point where the brake will release suf-
ficiently 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
Static Friction Brake Applied
Sprag
Cams
Permits free
shaft rotation
while hoisting
Load attempts to rotate shaft in opposite direction.
Brake clutch locks sun gear shaft to friction brake.
Sprag
Cams
Hoisting
Stopped,
Holding
Load

6
THE CABLE ANCHORS ALONE ON HOISTS ARE NOT
DESIGNED TO HOLD RATED LOADS. Winch loads
applied directly to the wire rope anchor may cause the
wire rope to pull free and result in the sudden loss of load
control and cause property damage, personal injury or
death. A minimum of 3 wraps of wire rope must be left on
the drum barrel to achieve rated load.
INSTALLATION
GENERAL REQUIREMENTS
1. The hoist should be mounted with the centerline of the drum in
a horizontal position. The mounting plane can be rotated to any
position around this centerline.
2. When mounting the hoist, use at least grade five bolts and nuts,
and use both mounting holes in each end gate.
3. It is important that the hoist be mounted on a surface that will not
flex when the hoist is in use, since this could bind the working
parts of the hoist. Also, be sure the hoist is mounted on a flat sur-
face. If necessary, use shim stock to insure proper mounting.
The mounting surface should be flat within + or -.020 inches.
4. Hydraulic lines and components that operate the hoist should be
of sufficient size to assure minimum back pressure at the hoist.
The motor manufacturer recommends that the back pressure
not exceed 100 psi for maximum motor seal life. 150 psi is the
maximum allowable back pressure. The standard CH150A,
CH175A, CH185A, CH230A, C2H150A, C2H175A, C2H185A
and C2H230A hoists are supplied with the motor internally
drained. If high back pressures are encountered, the motor can
be drained directly to tank to improve motor seal life. To insure
adequate static brake load holding ability, back pressure on the
hoist should not exceed 200 psi. For pressures exceeding 200
psi, consult Braden Engineering.
5. Make certain that the hoist drum is centered behind the first
sheave and the fleet angle does not exceed 1 ½ degrees. The
hoist should also be mounted perpendicular to an imaginary line
from the center of the drum to the first sheave to insure even
spooling.
6. The hoist 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 opened directly to tank.
7. The hydraulic oil filter should have a 10 micron nominal rating
and be a full-flow type.
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 vis-
cosity index of 100 or greater will give good results under normal
temperature conditions. The use of an oil having a high viscosi-
ty index will minimize cold-start trouble and reduce the length of
warm-up periods. A high viscosity index will minimize changes in
viscosity with corresponding changes in temperature.
Maximum cold weather start-up viscosity should not exceed
5000 SUS with a pour point at least 20°F lower than the mini-
mum temperature.
Under continuous operating conditions the temperature of the oil
at any point in the system must not exceed 180°. 120-140°F is
generally considered optimum.
In general terms; for continuous operation at ambient tempera-
tures between 50 and 110°F, use SAE 20W; for continuous
operation between 10 and 90°F, use SAE 10W; for applications
colder than 10°F, contact the BRADEN Service Department.
The use of multi-viscosity oils is generally not recom-
mended.
CAUTION
WARNING
! !
WIRE ROPE INSTALLATION
The wedge and anchor pocket must be clean and dry. The
end of the wire rope being anchored to the drum must be
clean and dry and not frayed. Anything on the end of the
wire rope to keep it from fraying (i.e. tape or wire) must not
be in contact with the wedge when the installation is com-
plete. Consult the wire rope manufacturer on the proper
treatment of the dead end of the wire rope. Some rope
manufacturers recommend when using rotation resistant
wire rope, that the rope end be seized, welded or brazed
before inserting the wire rope into the wedge socket to pre-
vent core slippage or loss of rope lay.
Take the free end of the wire rope and insert it through the
small opening on the cable drum. Loop the wire rope and
push the free end about 3/4 of the way back through the
pocket. Install the wedge as shown in figure 7, then pull the
slack out of the wire rope. The “dead” end of the rope
needs to extend slightly beyond the end of the wedge as
shown in figure 8.
Using a hammer and brass drift, drive the wedge as deep
into the pocket as possible to ensure it is fully seated and
no further movement is detected. Applying a load on the
wire rope will also help seat the wedge in the pocket.
Check to ensure the wedge does not protrude from either
end of the pocket, causing it to interfere with proper spool-
ing of wire rope onto the drum (see figures 9 & 10). If there
is interference or the wedge does not seat firmly, contact
the Braden Product Support Department at 918-251-8511
to determine the proper wedge size.

7
It is important that the wire rope have the proper tensioning
when it is installed on the drum. When the wire rope is first
installed, you should operate the hoist, with light to moder-
ate loads, with reeving that let’s you place these loads on
the block and the drum with all the rope off the drum except
for the last three wraps.
Drive from
this side
Wedge and wire rope
fully seated in pocket
Correct Installation
Figure 7 Figure 8
Incorrect Installations
Wedge not
fully seated
Wedge pulled too far
through anchor pocket
• Wire rope not tight against wedge
• Wedge may be too large
• “Dead” end of wire rope and/or wedge may
interfere with proper spooling
• Wedge may be too small
WIRE ROPE WEDGE PART NUMBERS
WINCH MODEL
CH150A, C2H150A, CH185A, C2H185A .
CH230A and C2H230A . . . . . . . . . . . . . .
CH175A and C2H175A . . . . . . . . . . . . . .
WEDGE PART NO.
24493* for 7/16 thru 5/8 in. (11 - 16 mm); 24494 3/4 thru 1 in. (19 - 25 mm)
24493 for 7/16 thru 5/8 in. (11 - 16 mm); 24494* 3/4 thru 1 in. (19 - 25 mm)
24492* for 7/16 in. thru 7/8 in. (11 - 22 mm)
* Standard Anchor
Figure 9 Figure 10

8
WINCH BRAKE
BRAKE
VALVE
PUMP
CONTROL
VALVE
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
BR
DR
WINCH BRAKE
BRAKE
VALVE
2-SPEED
SELECTOR
VALVE
PUMP
CONTROL
VALVE
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
TP
BR
DR
A
HYDRAULIC CIRCUITS
2 SPEED CIRCUITSINGLE SPEED CIRCUIT
RECOMMENDED BOLT TORQUE
The general purpose torque shown in the chart applies to SAE Grade 5 bolts, studs and standard steel full, thick and
high nuts.
Higher or lower torques for special applications will be specified such as the use of spanner nuts, nuts on shaft ends,
jam nuts and where distortion of parts or gaskets is critical.
Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut.
Bolt Dia. Thds per Bolt Dia. Thds per
Inches Inch Dry Lubed Inches Inch Dry Lubed
20 10
28 16
18 9
24 14
16 8
24 14
14 7
20 12
13 7
20 12
12 6
18 12
11 6
18 12
1/2
9/16
Torque LB-FT
1/4
5/16
6
13
5/8
9
18
31
50
75
110
150
3/8
7/16
23
27
55
80
115
Torque LB-FT
3/4
265
200
7/8
420
325
1
640
485
1 1/8
790
590
1 1/2
1940
1455
1 1/4
110
835
1 3/8
1460
1095

9
PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your planetary winch is strongly recommended to minimize the need
for emergency servicing and promote safe, reliable winch operation.
Field experience, supported by engineering tests, indicate the three (3) service procedures listed below are the MOST
critical to safe, reliable winch operation and must be observed.
• Regular Gear Oil Changes – every 1000 hours or six (6) months
• Use of Proper Gear Oil – recommended type for prevailing ambient temperature
• Annual Disassembly and Inspection of All Wear Items – in compliance with American National Standards Institute
(ANSI) specification B30.5c 1987 and American Petroleum Institute (API) recommended practice RP
2D section 3.
The following minimum service intervals are specified
for operating hours of the prime mover.
ating 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 person-
al 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 vis-
cosity with regard to ambient temperature is critical to
reliable brake clutch operation. Our tests indicate that
excessively heavy or thick gear oil may contribute to intermit-
tent brake clutch slippage. Make certain that the gear oil vis-
cosity 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 person-
al 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 unob-
structed. 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 oper-
ating 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.
1. Oil Level
The gear oil level should be checked every 500 oper-
ating hours or three (3) months, whichever occurs first.
To check the oil level, remove the plug located in 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 hun-
dred (100) hours of operation, then every 1,000 oper-
Oil Level
Plug

10
6. Mounting Bolts
Tighten all winch base mounting bolts to recommended torque
after the first one hundred (100) hours of operation, then every
1000 operating hours or six (6) months, whichever occurs first.
7. Warm-up Procedures
A warm-up procedure is recommended at each start-up and is
essential at ambient temperatures below +40°F (4°C).
The prime mover should be run at its lowest recommended
RPM with the hydraulic winch control valve in neutral allowing
sufficient time to warm up the system. The winch should then
be operated at low speeds, forward and reverse, several times
to prime all lines with warm hydraulic oil, and to circulate gear
lubricant through the planetary gear sets.
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
clutch and obtaining long gear train life.
Failure to use the proper type and viscosity of plane-
tary 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
CAUTION
WARNING
! !
CAUTION
WARNING
! !
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 tempera-
ture.
For simplicity, BRADEN has listed one (1) readily avail-
able 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 per-
form 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 API GL-2/3 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 disassem-
bled for a thorough inspection of all wear items every
2,000 hours of operation or twelve (12) months,
whichever occurs first.
A. Bearings and Gears – Refer to DISASSEMBLY
OF WINCH, item17 on page 19; and PLANET
CARRIER SERVICE, item 3 on page 20.
B. Brake Cylinder – Refer to MOTOR SUPPORT –
BRAKE CYLINDER SERVICE, Clean and Inspect,
pages 22 and 23.
C. Brake Clutch – Refer to BRAKE CLUTCH SERVICE,
item 4 on page 26.
RECOMMENDED GEAR OIL
PREVAILING AMBIENT TEMPERATURE
oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
TEXACO MEROPA 220 OR EQUIVALENT
API GL-2/3
TEXACO MEROPA 150 OR EQUIVALENT
API GL-2/3
MOBIL SHC 630
SYNTHETIC
oC -40 -30 -20 -10 0 10 20 30 40 50 oC
NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE CRANES,
SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.

11
TROUBLE SHOOTING
TROUBLE REMEDYPROBABLE CAUSE
CAUTION
WARNING
! !
If a winch ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping or chattering) appro-
priate troubleshooting tests and repairs should be performed immediately. Continued operation in this manner may
result in property damage, serious personal injury or death.
A
Disassemble brake to inspect
brake discs. Check stack-up
height as described in “Motor
Support-Brake Cylinder Service”.
3. Friction brake will not release as
a result of damaged brake discs.
Check brake cylinder seal as fol-
lows:
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 cylin-
der should be disassembled for
inspection of the sealing surfaces
and replacement of the seals.
Refer to “Motor Support-Brake
Cylinder Service”.
2. The friction brake may not be
releasing as a result of a defec-
tive brake cylinder seal.
NOTE: If the brake cylinder seal
is defective you will usually find
oil leaking from the winch vent
plug.
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.
1. The problem could be a plugged
or loose pilot orifice. The pilot ori-
fice 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 opera-
tion.
The winch will not lower the load
or not lower the load smoothly.

12
TROUBLE REMEDYPROBABLE CAUSE
Oil leaks from vent plug.
Reinforce mounting surface.
If necessary, use shim stock to
level winch. Refer to “Winch
Installation”.
First loosen, then evenly retight-
en all winch mounting bolts to
recommended torque.
Check relief pressure as follows:
A. Install an accurate 0-4000 psi
gauge into the inlet port of the
brake valve.
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.
The winch will not hoist the rated load
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 rec-
ommended planetary gear oil list-
ed in “Preventive Maintenance”.
Brake clutch may be damaged or
worn. Disassemble and inspect
brake clutch as described in
“Brake Clutch Service”.
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 brake will not hold a load with the
control lever in neutral.
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 contam-
ination has worn motor shaft and
seal. Thoroughly flush entire
hydraulic system and install new
filters and oil. Install new motor
seal.
1. Same as A2.
2. Motor seal may be defective as a
result of high system back pres-
sure or contaminated oil.
B
C
D

13
TROUBLE REMEDYPROBABLE CAUSE
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.
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.
1. Same as D1.
2. Be certain that the hydraulic sys-
tem 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 effi-
ciently.
3. Excessively worn or damaged
internal winch parts.
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 recom-
mended by crane manufacturer.
3. Be certain hydraulic system tem-
perature 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 operat-
ing efficiently.
TROUBLE “D” CONTINUED FROM
PREVIOUS PAGE
The winch runs hot.
E

14
REMEDYTROUBLE PROBABLE CAUSE
F
Winch “chatters” while raising rated
load.
G
1. Same as D2.
2. Hydraulic oil flow to motor may be
too low.
3. Controls being operated too
quickly.
Same as remedies for Trouble D2.
Same as remedies for Trouble E2.
Conduct operator training as required.
The wire rope does not spool smooth-
ly on the drum.
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.
1. The winch may be mounted too
close to the main sheave, caus-
ing the fleet angle to be more
than 1½ 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 over-
loaded, causing permanent set in
the wire rope.

15
1. Remove the wire rope from the hoist drum and align
the drain plug in the drum with the hole in the support
end plate before removing the hoses and mounting
bolts. After the hoist is removed from its mounting,
clean the outside surfaces.
3. Use a 3/8” drive extension to remove the drain plug
through the pipe. If the drain holes were not aligned
before the hoist was removed from its mounting, the oil
can be drained through the fill/vent plug in the bearing
support by turning the hoist up on the bearing support
end.
2. To drain the oil, screw a short piece of 1” pipe into the
larger threads of the drain hole.
6. Remove the sixteen (16) capscrews and lockwashers
(20 in the CH185A and C2H185A models) from the two
(2) tie plates, and remove the plates.
5. Remove the four (4) capscrews and lockwashers
securing the motor and lift the motor off the hoist.
Remove and discard the O-ring installed on the out-
side of the motor pilot.
4. Begin the disassembly by standing the hoist on the
end opposite the motor. Tag and remove the hydraulic
hoses that connect the brake valve and the motor
(manifold in the case of a two-speed motor) to the
brake release port.
DISASSEMBLY PROCEDURE FOR HOIST

16
10. Remove the brake clutch assembly from the brake
cylinder. Refer to the section on disassembly of
the brake clutch assembly.
7. Remove the tee fitting from the brake cylinder nipple.
9. Remove the brake cylinder nipple, then remove the
motor end plate.
8. Remove the eight (8) capscrews and lockwashers from
the motor adapter, and remove the motor adapter.
Remove and discard the O-ring that was under the
motor adapter.
11. Remove the brake plate spacer and brake and friction
discs.
12. Remove the brake cylinder assembly, and place it on a
clean, dry surface so as not to damage the splines.
Refer to the section on disassembly of the brake cylin-
der assembly.
13. Next, remove the primary sun gear.

17
15. Lift out the ring gear adapter.
19. Lift out the ring gear. Inspect the gear for abnormal
wear or pitting.
18. Remove the thrust bearing that was under the primary
planet carrier assembly, then remove the output sun
gear.
17. Remove the primary planet carrier assembly. Refer to
the section on disassembly of the primary planet carri-
er assembly.
16. Remove thrust bearing and two races.
14. Remove the cable drum closure by using two (2) cap-
screws from the motor adapter and a short piece of
chain. Lift the closure out of the drum. Remove and
discard the O-ring and the seal. Inspect the bearing
for wear. If replacement is necessary, use a bearing
driver to remove the bearing.

18
21. Lift the drum off the support end plate.
20. Remove the output planet carrier assembly. You can
make hooks like the ones shown to make removal
easier. Refer to the section on disassembly of the out-
put planet carrier assembly.
23. Check the bearing support sealing surface for nicks
and burrs. It is not necessary to remove the bearing
support from the support end plate unless it has been
damaged.
22. Turn the drum over and remove and discard the seal.
Inspect the bearing in the end of drum. If replacement
is necessary, use a bearing driver to remove the bear-
ing.