Paccar Winch BRADEN Gearmatic BG6A Manual

INSTALLATION, MAINTENANCE AND
SERVICE MANUAL
BG6A & BG6B
HYDRAULIC PLANETARY HOIST
PACR WINCH DIVISION
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE [phone] FAX [phone]
www.paccarwinch.com
LIT2286 R2
5/2010
Printed in U.S.A.
Copyright 2010 PACCAR Winch Division.
All rights reserved.

TABLE OF CONTENTS
PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PARTS AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DIMENSIONAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
HOIST AND WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
RECOMMENDED GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
HOIST EXPLODED VIEW DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
PARTS KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
HOIST SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HOIST DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
BRAKE CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-21
BRAKE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
PLANET CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-25
HOIST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-29
REVERSING DIRECTION OF DRUM ROTATION . . . . . . . . . . . . . . . . . . . . . .30
FASTENER TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
METRIC CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
.Safety informational callout's used in this manual include:
WARNING - This emblem is used to warn against
hazards and unsafe practices which could result in
severe personal injury or death if proper proce-
dures are not followed.
CAUTION - This emblem is used to warn against
potential or unsafe practices which could result in
personal injury or product or property damage if
proper procedures are not followed.
CAUTION
1

2
FOREWORD
Read and understand this entire publication before operating or servicing your BRADEN hoist. Retain this manu-
al 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 infor-
mation for the Model BG6 series hoist. 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 hoist. Also,
some components may be removed for illustrative purposes.
Continuing product improvement may cause changes in your hoist which may not be included in this manual.
When a question arises regarding your hoist 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 complete hoist model number and serial number when making inquiries. The model and serial num-
bers 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 avail-
able directly from the factory. For the name of your nearest dealer, consult your local phone directory or call us
at the phone number shown above.
EXPLANATION OF MODEL NUMBER
BG6 B 29 029 01 -1 H
HOIST
MODEL
DESIGN
MODEL
GEAR
RATIO
MOTOR
SIZE
DRUM
SIZE
BG6
B
29
029
01
-1
H
DESIGNATES BRADEN GEARMATIC HOIST MODEL
DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
DESIGNATES TOTAL GEAR REDUCTION
DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV
DECIMAL POINT ELIMINATED (029 = 2.9 cu in./rev [47.5 cu cm])
DESIGNATES THE DRUM
PERMITS TESTING AND INSPECTION PER API 2C RECOMMENDATIONS
DESIGNATES HIGH LINE PULL OPTION
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.
HIGH LINE
PULL OPTION
API

3
GENERAL SAFETY
RECOMMENDATIONS
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 hoist 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.
1. Read all warning tag information and become familiar
with all controls before operating hoist.
2. Never attempt to clean, oil or perform any mainte-
nance on a machine with the engine running, unless
instructed to do so in the service manual.
3. Never operate hoist 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 hoist drum. Do not allow
ground personnel near hoist line under tension. A
safe distance of at least 1½times the working length
of the cable should be maintained.
6. On 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 hoist. Always apply the prime mover parking
brakes and lower equipment before dismounting the
prime mover.
7. Inspect rigging, hoist and hydraulic hoses at the
beginning of each work shift. Defects must be cor-
rected before operating hoist.
8. Keep equipment in good operating condition.
Perform scheduled servicing and adjustments listed
in the "Preventive Maintenance" section of this
manual.
9. An equipment warm-up procedure is recommended
for all start-ups and is essential at ambient tempera-
tures below +40ºF (4.4ºC). Refer to "Warm-up
Procedure" listed in the "Preventive Maintenance"
section of this manual.
10. Be sure of equipment stability before operating hoist.
11. The winches described herein are neither designed
nor intended for use or application to equipment used
in the lifting or moving of persons unless specially
equipped from the factory. Refer to preventative
maintenance section for more information.
12. Do not exceed the maximum pressure (PSI/ kPa) or
flow (GPM/ LPH) stated in the hoist specifications.
13. Operate hoist line speeds to match job conditions.
14. Never handle the cable when hook end is free and
wear protective gloves when handling wire rope.
15. When winding hoist cable on the hoist drum, never
attempt to maintain tension by allowing hoist cable to
slip through hands. Always use "hand-over-hand"
technique.
16. Follow wire rope manufacturer’s guidelines and appli-
cable standards (such as ASME and API) for rigging
and inspecting wire rope.
17. Do not weld on any part of the hoist.
18. Use recommended hydraulic oil and gear lubricant.
19. Keep hydraulic system clean and free from contami-
nation at all times.
20. Use correct size cable anchor for cable and pocket in
hoist drum.
21. 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.
FAILURE TO OBEY THE FOLLOWING SAFETY REC-
OMMENDATIONS MAY RESULT IN PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.

4
DIMENSIONAL DATA - 01 DRUM
013 MOTOR
NOTE: Other motor options available as special order
9.52
4X O.59
MOUNTING HOLES
11.13
HOIST
4.04
3.78
12.50
6.25
.88
1.09
6.00
11.57
7.50
6.38
B
7.28
1.99
3.94
10.05
7.88
LOWER PORT
SAE -16 ORB
(1 5/16-12 ORB)
1.57
4.12
A
HOIST PORT
SAE -16 ORB
(1 5/16-12 THD)
MOTOR A B
020 20.06 3.81
029 20.56 4.06
039 21.01 4.32
6.25
12.50
1.75
LOWERING PORT
SAE -10 ORB
(7/8-14 THD)
.62
11.57
6.00
1.09
10.05
7.88
3.94
HOIST
MOTOR DRAIN
SAE -4 ORB
(7
16 -20 THD)
HOIST PORT
SAE -10 ORB
(7/8-14 THD)
1.38
2.15
5.27
4.12
19.76
7.28
11.13
7.50
4X 0.53
MOUNTING HOLES
9.52
7.00
1.27
MOTORS 020, 029, & 039

5
20.06
7.28 4.12
2.20
5.37 MOTOR DRAIN
SAE -4 ORB
(7
16 -20 THD)
HOIST PORT
SAE -10 ORB
(7/8 -14 THD)
1.38
14.56
7.50
1.16 7.84
10.14
4X .656
MTG HOLES
HOIST
1.75
15.91
7.95
LOWERING
PORT
SAE -10 ORB
(7
8-14 THD)
.62
15.28
8.00
.63
3.75
15.00
6.63
.87
MOTOR A B
020 20.58 4.07
029 21.08 4.32
039 21.08 4.32
A
B
.656
4 Holes
4.04
15.91
3.78
3.75
6.63
14.56
15.00
.63
15.28
.88
1.22
10.26
8.00
.67
7.28
7.84
HOIST PORT
SAE -16 ORB
(1 5/16-12 THD)
7.50
4.12
1.99
7.95
HOIST
LOWER PORT
SAE -16 ORB
(1 5/16-12 THD)
NOTE:Other motor options available as special order
DIMENSIONAL DATA - 02 DRUM
013 MOTOR
MOTORS 020, 029, & 039

THEORY OF OPERATION
DESCRIPTION OF HOIST
The hoist has four basic component parts:
1. Hoist base
2. Hydraulic motor group
3. Brake cylinder and motor adapter
4. Cable drum with gear train
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 sup-
ported 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 the planetary gear train is machined into
the drum’s inside surface.
HOIST 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.
NOTE: The special order 07 (7:1) gear ratio has only one
planetary gear set
Dual Brake System – Description
The dual brake system consists of a dynamic brake sys-
tem and a static brake system.
The dynamic brake system has two operating compo-
nents:
1. Brake valve assembly
2. Hydraulic motor
The brake valve is basically a counterbalance valve with
improved metering. 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.
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
NOTE: Some special order models have a solid hub for
brake effective both directions.
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
dynamic braking takes place in the brake valve and that
little, if any, heat is absorbed by the friction brake.
6
Winch Brake
Brake
Valve
Pump
Control
Valve
Winch Assembly
W/Brake Valve
& Static Brake
DR
BR
HYDRAULIC CIRCUIT
PUMP
CONTROL
VALVE
Motor
Winch
Brake
Motor Code 010, 011, 012, 013
Motor Code 020, 029, & 039

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.
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, see figure 2. The static brake
remains fully applied. The hoist, in hoisting, is not affect-
ed by any braking action.
When the hoisting 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 fric-
tion brake.
When the hoist is powered in reverse to lower the load,
the motor cannot rotate until sufficient pilot pressure is
present to open the brake valve. The friction brake with-
in the hoist 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 hoist 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 slow-
ing 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 static brake will engage and hold the load after the
brake valve has closed.
When lowering a load very slowly for precise positioning
little or no oil flow actually occurs through the hoist 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. Most of the heat generated by the lowering and
stopping of a load is absorbed by the hydraulic oil where
it can be readily dissipated.
7

HOIST AND WIRE ROPE
INSTALLATION
1. The hoist should be mounted with the centerline of
the cable drum in a horizontal position. The mounting
plane of the hoist 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 hoist, 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.
The hoist must be mounted on a surface that will not flex
when the hoist is in use, and cause binding of the gear
train. Binding in the gear train will result in accelerated
wear and heat. Also, the mounting surface must be flat
with ± 0.020 in. (.5mm). If necessary, install shims under
the hoist mounting pads to achieve even mounting.
3. The hydraulic lines and components that operate the
hoist should be of adequate size to assure minimum
back pressure at the hoist. The back pressure at the
motor must not exceed 50 psi (345 kPa) to maintain
full system design braking and optimum motor seal
life.
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 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 100oF (38oC) 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 trou-
ble and reduce the length of warm-up periods. A high vis-
cosity index will minimize changes in viscosity with corre-
sponding changes in temperature.
Maximum cold weather start-up viscosity should not
exceed 5,000 SUS with a pour point at least 20oF (-7oC)
lower than the minimum ambient temperature.
Under continuous operating conditions the temperature of
the oil at any point in the system must not exceed 180ºF
(82oC). 120oF (49oC) to 140oF (60oC) is generally consid-
ered optimum.
In general terms:
For continuous operation at ambient temperatures
between 50oF (10oC) and 110oF (43oC), use SAE 20W;
for continuous operation between 10oF (-12oC) and 90oF
(32oC), use 10W; for applications colder than 10oF (-
12oC), 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 nomi-
nal rating and be full flow type; or one in accordance
with recommendations of the pump manufacturer.
6. The vent plug in the motor adapter must be located
close to top dead center as possible. If the hoist is
mounted on a pivoting surface, the vent plug must
remain above the centerline of the cable drum to pre-
vent gear oil leakage.
7. Refer to "Dimensional Drawing" for relationship
between drum rotation and which port is pressurized.
WIRE ROPE INSTALLATION
Since the static brake on this hoist is "effective both direc-
tions", cable can be wound onto the drum in either direc-
tion without any modifications to the hoist. 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 pock-
et and secure the wire rope to the drum. A minimum of
five (5) wraps of wire rope should remain on the cable
drum at all times. Refer to "General Safety
Recommendations" for additional information.
The standard cable anchor wedge supplied with the hoist
is intended for 5/16 to ½in. (8 to 13 mm) wire rope.
8

A regular program of preventive maintenance for your
planetary hoist is strongly recommended to minimize the
need for emergency servicing and promote safe, reliable
hoist operation.
Field experience supported by engineering tests, indi-
cates the three (3) service procedures listed below are the
MOST critical to safe, reliable hoist operation and must be
observed.
• Regular Gear Oil Changes - initial break-in oil
change after 250 hours (2 Months), then every 1000
hours or six (6) months thereafter.
•Use of Proper Gear Oil - recommended type for pre-
vailing ambient temperature. See chart on page 10
•Periodic Disassembly and Inspection of All Wear
Items - in compliance with American National
Standards Institute (ANSI) specification B30.5c 1987
and American Petroleum Institute (API) recommend-
ed practice RP 2D section 3.
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 200 operating
hours, once per month, when an oil leak is spotted, or
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 addi-
tional 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 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 proper-
ty damage, severe personal injury or death.
The gear oil should also be changed whenever the ambi-
ent 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 operation. Make certain that the gear oil
viscosity used in your hoist is correct for your prevailing
ambient temperature. Failure to use the proper type and
viscosity of planetary gear oil may contribute to brake slip-
page which could result in property damage, severe per-
sonal 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 hoist 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 Procedure
A warm-up procedure is recommended at each start-up
and is essential at ambient temperatures below +40oF
(4oC). The prime mover should be run at its lowest rec-
ommended RPM with the hydraulic hoist control valve in
neutral allowing sufficient time to warm up the system.
The hoist should then be operated at low speeds, hoist
and lower, several times to prime all lines with warm
hydraulic oil, and to circulate gear lubricant through the
planetary gear sets
9
Failure to properly warm up the hoist, 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.
PREVENTIVE MAINTENANCE

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 readily available products 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.
Planetary winches are factory filled with Exxon Spartan
EP 150 or equivalent.
9. Periodic Teardown/ Inspection
We recommend that the hoist be disassemble for a thor-
ough inspection of all wear items every 2,000 hours of
operation or twelve (12) months, whichever occurs first.
10
PREVAILING AMBIENT TEMPERATURE
o
F-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
o
F
AGMA 5 EP, ISO VG 220
AGMA 4 EP, ISO VG 150
MOBILGEAR SHC 150
SYNTHETIC OR EQUIVALENT
o
C-40 -30 -20 -10 0 10 20 30 40 50
o
C
NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.
i
TexacoShell
Meropa 150
Meropa 220
Omala 150
Omala 220
Chevron
Gear Compounds EP 150
Gear Compounds EP 220
PREVAILING AMBIENT TEMPERATURE
oF-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
AGMA 5 EP, ISO VG 220
AGMA 4 EP, ISO VG 150
SYNTHETIC OR EQUIVALENT
oC-40 -30 -20 -10 0 10 20 30 40 50 oC
NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.
i
TexacoShell
Meropa 150
Meropa 220
Omala 150
Omala 220
Chevron
Gear Compounds EP 150
Gear Compounds EP 220
TexacoMobil Shell
Meropa 150
Meropa 220
Omala 150
Omala 220
Chevron
Gear Compounds EP 150
Gear Compounds EP 220
MOBILGEAR 600 XP 220 OR EQUIVALENT
MOBILGEAR 600 XP 150 OR EQUIVALENT
Mobilgear 600 XP 150
Mobilgear 600 XP 220
Planetary hoists are factory filled with Mobilgear 600 XP 150, or equivalent. Consult your oil supplier for other equivalent
oils if required.
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 hoist is correct for your
prevailing ambient temperature.
Gear Oil Capacity
-01 and -02 drums = 2 Pints (0.9 L)

11
A.
Hoist will not
pull maxi-
mum load.
1. System relief valve may be set too
low.
2. If this trouble occurs suddenly after
working at maximum pull, a particle
of dirt may be lodged under the sys-
tem relief valve, holding it partially
open. If this is the cause, a consid-
erable loss in line speed may be
noticed as the load on the cable is
increased.
3. If the pump is belt driven, the belt
may be slipping.
4. 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.
5. The hoist may be mounted on an
uneven or flexible surface which
causes distortion of the hoist 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.
6. Be certain hydraulic system temper-
ature is not more than 180oF (82oC).
Excessive hydraulic oil temperatures
increase motor internal leakage and
reduce motor performance.
7. Hoist line pull rating is based on 1st
layer of wire rope. Expected line pull
may be in excess of hoist rating.
8. After all the causes listed above
have been investigated and it is
found that the hoist will stall at maxi-
mum pressure without developing
the maximum pull on the bare drum,
the trouble may be in the hoist.
Install a pressure gauge in the haul-in port and apply a
stall pull on the hoist. If pressure is low, increase relief
valve setting until recommended pressure is obtained.
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 disassem-
bly or replacement.
Remove relief valve, disassemble and clean parts thor-
oughly in a suitable solvent.
Reassemble and install relief valve. Reset pressure
according to specifications.
Check belts when pump is at full PSI (kg/cm2) (stall pull
on hoist). 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 hoist.
First loosen, then evenly retighten all hoist mounting bolts
to recommended torque.
Same as remedy for A-5.
Same as remedy for B-4
Refer to hoist performance charts for additional informa-
tion.
Install a pressure gauge in the motor haul-in port and
apply a stall pull on the hoist. If the pressure is up to max-
imum and the bare drum line pull is less than the speci-
fied line pull, the trouble will be in the hoist.
Disassemble hoist 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 PROBABLE CAUSE REMEDY
TROUBLE SHOOTING

12
TROUBLE SHOOTING
TROUBLE PROBABLE CAUSE REMEDY
A. 9. Rigging and sheaves not operating
efficiently.
Perform rigging and sheave service as recommended by
manufacturer.
B.
Considerable
reduction in
line speed.
1. Same as A-2.
2. Same as A-4.
3. Same as A-6.
4. If this trouble has increased gradual-
ly, the hydraulic pump or hoist motor
may be worn.
Same as remedy for A-2.
Same as remedy for A-4.
Same as remedy for A-5 & B-4.
Remove and inspect pump. If satisfactory, consult the
disassembly instructions for the hoist and remove and
inspect the motor according to the service instructions for
the hydraulic pump.
C.
Reverse
speed is
slower than
forward
speed.
1. Control valve may be restricted in its
travel.
2. Same as A-1.
3. Oil may be too thick causing a high
resistance to rotation at the brake
plates and causing the relief valve to
by-pass.
4. Same as F-1.
Check the travel of the control valve spool. The spool
travel should be the same in both directions.
Same as remedy for A-1.
Follow warm-up procedure in “Preventive Maintenance”
section.
Same remedy for F1.
D.
Brake will
not hold
when control
valve is
returned to
neutral after
lifting a load.
1. Excessive system back pressure
acting on the brake release port.
2. Friction brake will not hold due to
worn or damaged brake disks.
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 hoist to the control valve and the
control valve to the reservoir.
Disassemble hoist to inspect/replace worn parts.
E.
Brake will
not control or
stop the
load when
lowering.
1. Same as D-2 or 2.
2. Hoist is being overloaded.
3. After the causes listed above have
been investigated and found to be
satisfactory, the trouble may be in
the hoist.
Same as remedy for D-1 or 2.
Install a pressure gauge at the haul-in port and apply a
stall pull on the hoist. If the pressure is higher than the
maximum specified PSI, reduce the pressure.
Disassemble the brake assembly according to the disas-
sembly instructions. Inspect the brake springs, and
brake plates.

13
TROUBLE SHOOTING
TROUBLE PROBABLE CAUSE REMEDY
F.
The hoist will
not lower the
load or not
lower the load
smoothly.
1. The friction brake may not be releas-
ing as a result of a defective brake
cylinder seal.
NOTE: If the brake cylinder seal is
defective you will usually notice oil
leaking from the hoist vent plug.
2. Friction brake will not release as a
result of damaged brake disks.
3. Same as B-4.
4. Same as A-3.
5. Same as A-5.
6. Control valve handle being operated
too quickly.
7. Insufficient gear oil in cable drum.
8. Control valve does not have good
metering characteristics.
Disassemble and inspect the brake cylinder seal.
Disassemble brake to inspect brake disks.
Same as remedy for B-4.
Same as remedy for A-3.
Same as remedy for A-5.
Operate control valve smoothly when starting and stop-
ping a load. Conduct operator training as required.
Remove oil level plug and check oil level. Fill to proper
level.
See “Hoist Installation” section for control valve specifica-
tions.
G.
The hoist runs
hot.
1. Same as A-5.
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 A-1.
D Hydraulic pump not operating effi-
ciently.
3. Excessively warn or damaged internal
hoist parts.
4. Same as F-7.
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.
H.
Hoist
“chatters”
while raising
rated load.
-
1. Same as A-1.
2. Same as B-4.
3. Hydraulic oil flow to motor may be too
low.
4. Same as F-6.
Same as remedy for A-1.
Same as remedy for B-4.
Increase pump rpm.
Same as remedy for F-6.

14
Braden/ Gearmatic BG6A & BG6B Components
ITEM DESCRIPTION QTY
1BASE 1
2CABLEDRUM 1
3CABLEDRUMCLOSURE 1
5PRIMARYSUNGEAR 1
19 THRUST RACE 1
20 THRUST RACE 1
21 BEARING SUPPORT 1
27 OIL SEAL 1
28 BALL BEARING 2
29 SNAP RING 1
31 O-RING 1
32 OIL SEAL 1
33 LOCKWASHER 6
34 CAPSCREW 6
ITEM DESCRIPTION QTY
49 16166-8 PLUG 1
51 DRIVE SCREW 4
53 LOCKWASHER 6
54 CAPSCREW 6
55 CABLE WEDGE 1
70 INPUT SHAFT 1
100 BRAKE CLUTCH ASY. 1
222 BRAKE CYLINDER/BG6B 1
223 MOTOR ADAPTER 1
233 LOCKWASHER 8
234 CAPSCREW 8
235 SPRING PLATE 1
236 U-CUP SEAL 1
237 RELIEF VALVE 1-5 PSI 1

15
ITEM DESCRIPTION QTY
238 BRAKE PLATE SPACER 1
244 FRICTION DISC 7*
245 BRAKE DISC 8*
246 O-RING 1
247 SPRING 6*
257 SPRING LOCATOR 1
300 PRIMARY PLANET CARRIER ASY. 1
304 OUTPUT SUN GEAR 1
313 PRIMARY PLANET CARRIER 1
314 PRIMARY PLANET GEAR 3
315 PLANET GEAR SHAFT 3
316 BEARING ROLLER 3
317 THRUST WASHER 6
318 ROLLPIN 3
ITEM DESCRIPTION QTY
330 1941006 SNAP RING 1
372 SNAP RING 1
400 OUTPUT PLANET CARRIER ASY. 1
406 OUTPUT PLANET CARRIER 1
407 OUTPUT PLANET GEAR 3
408 OUTPUT PLANET GEAR SHAFT 3
409 ROLLER BEARING 6
410 BEARING SPACER 3
411 THRUST BEARING 6
412 ROLLPIN 3
100 BRAKE/CLUTCH ASSY/GH5/PD5 1
200 BRAKE CYLINDER ASSY 1
300 PRIMARY PLANET CARRIER ASSY 1
400 OUTPUT PLANET CARRIER ASSY 1
700 HYD MOTOR GROUP 1
REFER TO MATERIAL LIST FOR PART NO. LISTINGS
*= QUANTITY OF PART
DISPLAYED MAY NOT BE
ACCURATE FOR YOUR
APPLICATION. CONSULT
RESPECTIVE MATERIAL
LIST FOR ACCURATE
QUANTITY’S
“B” Model Brake Cylinder

HOIST SERVICE
FOREWORD TO HOIST SERVICE
Before any part is removed from the hoist, 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 ship-
ment.
Use only genuine BRADEN replacement parts for opti-
mum 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 hoist.
HOIST DISASSEMBLY
1. Disconnect all hoses and fittings at the hoist.
2. Stand the hoist on the bearing support plate. Remove
the brake release tube assembly (59) between the
brake valve block and the brake cylinder end plate.
Remove the capscrews and lockwashers which
secure the motor to the motor adapter, and lift the
motor out of the motor adapter. Remove and discard
the O-ring installed on the pilot of the motor.
3. Remove the overrunning clutch assembly (100) and
sun gear (70) from the hoist.
4. Remove six capscrews (33 & 34) from the the base
(1), remove brake cylinder assembly.
5. Lift out primary sun gear (70). Then lift out cable drum
closure (3).
6. Lift out primary planetary gear assembly (300), fol-
lowed by removing the output planetary assembly
(400). Thrustwashers (20 & 39) are set between pri-
mary planetary gear and output planetary gear.
These are not secured and may fall out upon removal
of planetary assemblies.
7. Stand hoist assembly on motor mount flange and
remove six drum support capscrews (33, 34, 53, &
54). Removee drum bearing support (21). Drum can
now be lifted from base. Drum bearing and seal (27
& 28) are pressed into drum enclosure.
16
DO NOT CLEAN BRAKE FRICTION DISKS IN SOL-
VENT. SOLVENT MAY CAUSE DAMAGE TO FRIC-
TION MATERIAL WHICH MAY RESULT IN BRAKE
FAILURE AND LOSS OF LOAD CONTROL.

DRUM ASSEMBLY SERVICE
1. Remove the bearing and seal from support end of the
drum. Check the ring gear teeth (machined into the
inside surface of the drum) for nicks, spalling or
excessive wear. Replace the drum if wear is greater
than 0.015 in. (0.4 mm) when compared to unworn
area of teeth.
2. 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.
17

NOTE: Starting mid-year 1996, Braden changed the steel
brake separator discs from a splined tooth design to a
lobed design. This required a change to the motor sup-
port and brake cylinder and the addition of a spring spac-
er. A hoist with the lobed discs can be identified by a
machined groove on the outside diameter of the motor
support. When replacing steel brake discs, the motor sup-
port or brake cylinder, care must be taken to properly
identify the correct parts. Splined discs, and their mating
motor support and brake cylinder will remain available as
spare parts.
New lobed steel brake separator plates and motor sup-
port. Note groove on outside diameter of motor support.
Although most photos in this section show splined discs,
all procedures are the same except where specifically
noted.
1. After removing the motor support and brake clutch
assembly, continue brake cylinder disassembly by
removing the spacers, friction brake discs and steel
brake discs.
2. Remove the piston back-up ring and pressure plate.
3. Remove the brake springs.
CLEAN AND INSPECT
1. Thoroughly clean and inspect all parts at this time.
Check brake piston sealing surfaces on brake cylin-
der and motor support for scoring or wear. Be sure
brake release port is free of contamination.
2. Check oil seal and bearing surfaces on brake cylinder
for damage or wear.
18
MOTOR SUPPORT-BRAKE CYLINDER SERVICE
DISASSEMBLY