Paccar Winch BRADEN PD21A Series Manual

BRADEN
PD21A
PLANETARY HOIST
INSTALLATION, MAINTENANCE AND SERVICE MANUAL
LIT2158 R2
9/2007
Printed in U.S.A.
PACR
WINCH DIVISION
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE [phone] FAX [phone]
www.paccarwinch.com

TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MODEL & SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
EXPLANATION OF MODEL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
EXPLODED VIEW OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
HOIST OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
RECOMMENDED FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
RECOMMENDED GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
OIL SAMPLING AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
PLANETARY CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
OVER-RUNNING CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
BRAKE CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
HOIST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
MOTOR GROUP ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
BRAKE VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1

MODEL NUMBER
AND
SERIAL 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 indi-
cated above.
FOREWORD
The following service instructions have been prepared to provide assembly, disassembly and maintenance infor-
mation for the BRADEN Model PD21A series hoist. 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 hoist. Also, some com-
ponents have been removed for illustrative purposes.
Continuing product improvement may cause changes in your hoist, which are not included in this manual.
Whenever a question arises regarding your BRADEN hoist or this manual, please contact BRADEN Service
Department for the latest available information.
PD POWER DRUM
21 DESIGNATES BASIC MODEL NUMBER
ADESIGNATES MODEL SERIES
50 DESIGNATES TOTAL GEAR REDUCTION (50:1)
PPISTON TYPE HYDRAULIC MOTOR
065 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV
(065 = 6.5 CU IN/REV.)
08 DRUM MODEL
GGROOVED DRUM
2
PD 21 A - 50 P 065 - 08 G
EXPLANATION OF MODEL NUMBER

Brake Valve - A hydraulic counterbalance valve is usually bolted to the hoist port of the hydraulic motor. It allows
oil to flow freely through the motor in the hoisting direction. When oil pressure tries to rotate the motor in the low-
ering direction, the brake valve blocks the flow of oil out of the motor until the internal static brake is released. It
then controls lowering speed based on the load and flow of oil to the motor. All the heat generated by controlling
the speed of the load is dissipated by the hydraulic system, not by the internal static brake.
Grooved Drum - A cable drum with grooves on the barrel to ensure the first
layer of cable spools properly onto the drum. The grooves can be cast or
machined into the drum, or cast or machined into separate pieces that are
mechanically fastened to the drum. NOTE: Only one size cable can be used
on a grooved drum.
Sprag or Over-Running Clutch - A mechanical one-way clutch on the input shaft of the hoist, between the input
shaft and the static mechanical brake. The clutch allows the input shaft to turn freely in the direction required to
spool cable onto the drum (i.e. lift a load), then immediately locks the hoist gear train to the mechanical brake when
the hoist is stopped, holding the load in place.
Static, Mechanical, or Load-Holding Brake - A multi-disc, spring applied, hydraulically released brake that works
together with the sprag clutch to hold a suspended load. This brake is not designed to stop a load being lowered,
but holds the load in place when the hoist is not being operated.
First Layer Line Pull Rating - The maximum rated line pull (in pounds or kilograms) on the first layer of cable.
The maximum rating for any particular hoist is based on maintaining an acceptable structural design factor and
service life. Certain combinations of drum, gear ratio, motor and hydraulic pressure, may reduce this rating.
First Layer Line Speed Rating - The maximum rated line speed (in feet or meters per minute) on the first layer
of cable. Certain combinations of drum, gear ratio, motor and hydraulic flow may reduce or increase this rating.
D/d Ratio - The ratio of cable drum barrel diameter (D) to wire rope diameter (d). Current ANSI standards require
a minimum of 17:1.
EXAMPLES:
If you know the cable diameter you want to use, multiply it by 17 to get the MINIMUM cable drum barrel diameter.
(i.e. ½inch wire rope X 17 = 8.5 inches - this is the minimum hoist barrel diameter)
If you know the barrel diameter, divide it by 17 to get the MAXIMUM wire rope diameter.
(i.e. 10 inch barrel diameter / 17 = 0.588, or 9/16 inch - this is the maximum wire rope diameter)
Cable Drum Dimensions -
Fleet Angle - The angle between the wire rope’s position at the extreme end wrap on a drum, and a line drawn
perpindicular to the axis of the drum, through the center of the nearest fixed sheave or load attachment point.
3
GLOSSARY OF TERMS
a
b
First sheave
or load
First sheave or load should be
centered between the drum
flanges, so that angle “a” and
angle “b” are equal.
Angles “a” and “b” should be a
minimum of ½degree and a
maximum of 1½degrees.
Wrap - A single coil of wire rope wound on a drum.
Layer - All wraps of wire rope on the same level between drum flanges.
Freeboard - The amount of drum flange that is exposed radially past the last layer of wire rope. Minimum free-
board varies with the regulatory organaization. ASME B30.5 requires ½in. minimum freeboard.
Flange
Diameter
Barrel
Diameter
Distance
Between
Flanges

4
1. Be certain equipment (boom, sheave blocks, pen-
dants, etc.) is either lowered to the ground or
blocked securely before servicing, adjusting, or
repairing hoist.
2. Be sure personnel are clear of work area BEFORE
operating hoist.
3. Read all warning and caution tags provided for safe
operation and service of the hoist and become
familiar with the operation and function of all con-
trols before operating the hoist.
4. Inspect rigging and hoist at the beginning of each
work shift. Defects should be corrected immediate-
ly. Do not operate a hoist with defects.
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 tempera-
tures below +40°F (+4°C). Refer to “Warm-up
Procedure” listed in the “Preventive Maintenance”
section of this manual.
7. Do not exceed the maximum pressure (PSI, kPa) or
flow (GPM, lpm) stated in the hoist specifications
found in the specific sales brochure.
8. Operate hoist line speeds to match job conditions.
9. Protective gloves should be used when handling
wire rope.
10. 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,
sheaves and hoist drum.
11. When winding wire rope on the hoist 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 that is damaged. Refer to wire rope sup-
plier manual.
13. Do not weld on any part of the hoist without
approval from PACCAR Winch Engineering.
14. Use recommended hydraulic oil and gear lubricant.
15. Keep hydraulic system clean and free from contam-
ination 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 not
intended to support the rated load. ALWAYS main-
tain a minimum of five (5) wraps of wire rope on the
drum. It is recommended that the last five (5) wraps
of wire rope be painted bright red to serve as a visu-
al reminder.
19. Never attempt to clean, oil or perform any mainte-
nance on a machine with the engine or prime mover
running, unless instructed to do so in this manual.
20. Never operate hoist controls unless you are proper-
ly positioned at the operators station and you are
sure personnel are clear of the work area.
21. Assure that personnel who are responsible for hand
signals are clearly visible and that the signals to be
used are thoroughly understood by everyone.
22. Ground personnel should stay in view of the opera-
tor and clear of the hoist drum. Do not allow ground
personnel near wire rope under tension. A safe dis-
tance of 1½times the working length of the wire
rope should be maintained.
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 or potential “pinch points”.
24. Install switches or valves that will shut off power to
the hoist, in locations where they can be reached by
anyone entangled in the wire rope before being
drawn into the hoist or any “pinch point”.
25. “Deadman” controls, which automatically shut off
power to the hoist whenever the operator leaves his
station or releases the hoist control lever, should be
installed whenever practical.
26. Never allow anyone to position any part of body
under a suspended load.
27. Avoid sudden “shock” loads or attempting to “jerk” a
load free. This type of operation may cause heavy
loads, in excess of rated capacity, which may result
in failure of wire rope, hoist or crane structure.
28. Whenever possible, install the hoist in a location
that is not immediately adjacent to a “normal” oper-
ator’s station.
29. All hoist controls shall be located within easy reach
of the operator. The controls shall be installed in
such a location that the operator is removed from
the electrical path to ground if the load, rigging, or
wire rope come in contact with or within proximity to
an electrically energized conductor.
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 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.

30. Before operating the hoist, be sure ALL safety pro-
cedures for the equipment or vehicle the hoist is
mounted on are properly followed and/or in place.
If there is any question regarding the preceding safety
recommendations, or the safe operation of your hoist,
please contact the Braden Product Support Department
at 1-918-251-8511, Monday through Friday from 0800
to 1630 hours, CST, by fax at [phone], or via the
internet at www.paccarwinch.com for the latest avail-
able information.
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.
CAUTION
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.
Safety and informational callouts used in this manual include:
5

BASIC OPERATION
DESCRIPTION OF HOIST
The PD21A hoist is made up of the following sub-
assemblies:
1. Hydraulic motor and brake valve
2. Brake cylinder and brake clutch assembly
3. Hoist base components
4. Hoist drum and gear train
(Refer to illustration on page 8)
THEORY OF OPERATION
The primary sun gear is directly coupled to the hydraulic
motor by the inner race of the brake clutch assembly.
As the motor turns in the hoisting direction (clockwise),
the planetary assemblies reduce the input speed of the
motor and rotate the ring gear and winch drum. Since
the output planet carrier is held from turning by the
brake cylinder, the drum rotates in the opposite direction
of the motor input shaft. In the hoisting direction, the
static brake remains fully applied and the input shaft
rotates freely through the sprag clutch. When the motor
is stopped, the load tries to rotate the hoist gear train in
the opposite direction. The sprag clutch on the input
shaft immediately locks up, allowing the fully applied
static brake to hold the load from dropping. See Dual
Brake System - Operation for a detailed description of
the lowering sequence of operation.
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 direc-
tion 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 compo-
nents:
1. Spring Applied, Multiple Friction Disc Static Brake
2. Brake Clutch Assembly
3. Hydraulic Piston and Cylinder
Pump
Brake
Valve
Static
Brake
Motor
Control
Valve
Low Pressure Medium Pressure High Pressure
To
Tank
Figure 2
Pump
Brake
Valve
Static
Brake
Motor
Control
Valve
Low Pressure Medium Pressure High Pressure
To
Tank
Figure 3
6
Pump
Brake
Valve
Static
Brake
Motor
Control
Valve
Low Pressure Medium Pressure High Pressure
To
Tank
Figure 4

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 static 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 rota-
tion. The sprag cams lay over and permit the inner race
to turn free of the outer race. Figure 5. The static friction
brake remains fully engaged. The hoist, 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 hoist 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 fric-
tion brake within 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 slowing the descent of
the load.
When the control valve is shifted to neutral, the pres-
sure 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 position-
ing, very little oil flow actually occurs through the hoist
motor. The pressure will build up to a point where the
static 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 lower-
ing 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.
7
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

Base
Components
Drum &
Gear Train
Motor &
Brake Valve
Brake Cylinder &
Brake Clutch
Support End Bracket
Detail
PD21A COMPONENTS
8

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 complete. Consult the wire rope manufac-
turer 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 prevent 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 fig-
ure 1, 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 2.
9
THE CABLE ANCHORS ALONE ON HOISTS ARE
NOT INTENDED TO HOLD RATED LOADS. Hoist
loads applied directly to the wire rope anchor may
cause the wire rope to pull free and result in the sud-
den loss of load control and cause property damage,
personal injury or death. A minimum of 5 wraps of
wire rope must be left on the drum barrel to achieve
rated load.
INSTALLATION
GENERAL REQUIREMENTS
1. The hoist must be mounted with the centerline of the drum
in a horizontal position. The mounting plane can be rotated
to any position around this centerline, providing the vent
plug is positioned above the oil level.
2. When mounting the hoist, we recommend grade eight bolts
and nuts. All mounting holes in the hoist base must be used.
3. The vent plug must always be located above the horizontal
centerline of the hoist drum. If the hoist is mounted on a piv-
oting surface, be sure the vent remains above the centerline
at all times. If necessary, reposition the bearing support.
4. 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 mount-
ed on a flat surface. If necessary, use shim stock to insure
proper mounting. The mounting surface must be flat within
±0.020 inches (.5 mm).
5. Hydraulic lines and components that operate the hoist
should be of sufficient size to assure minimum back pres-
sure at the hoist motor ports. To insure adequate static brake
load holding ability, back pressure on the hoist should not
exceed 100 psi (690 kPa).
6. Make certain that the hoist drum is centered behind the first
sheave and the fleet angle does not exceed 1½degrees.
The hoist should also be mounted perpendicular to an
imaginary line from the center of the drum to the first sheave
to ensure even spooling. (ref page 3)
7. The hoist directional control valve must be a three-position,
four-way valve without detents and with a spring centered
motor spool such that the valve returns to the centered posi-
tion whenever the handle is released, and both work ports
are opened to tank (open center, open port).
8. The hydraulic oil filter should have a 10 micron nominal rat-
ing and be a full-flow type.
9. High quality hydraulic oil is essential for satisfactory perform-
ance 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 nor-
mal temperature conditions. The use of an oil having a high vis-
cosity 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 tempera-
ture.
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°F (82°C).
120-140°F (49-60°C) is generally considered optimum.
In general terms; for continuous operation at ambient tempera-
tures between 50 and 110°F (10-43°C), use SAE 20W; for con-
tinuous operation between 10 and 90°F (-12 and 32°C), use
SAE 10W; for applications colder than 10°F (-12°C), contact the
BRADEN Product Support Department. The use of multi-vis-
cosity oils is generally not recommended.
WIRE ROPE INSTALLATION - (ONE PIECE CABLE WEDGE)
DO NOT use a control valve with any detents or latching
mechanism that would hold the control valve in an actuated
or running position when the operator releases the control
handle. Use of the wrong type of control valve could lead
to unintentional operation of the hoist, which could result in
property damage, personal injury or death.
Recommended Control
Valve Schematic

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 spooling of wire rope onto the drum (see figures
3 & 4). 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.
It is important that the wire rope have the proper ten-
sioning when it is installed on the drum. When the wire
rope is first installed, you should operate the hoist, with
light to moderate 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 five wraps.
Drive from
this side
Wedge and wire rope
fully seated in pocket
Figure 1 Figure 2
10
Correct Installation
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
Figure 3 Figure 4

11
HOIST OPERATION
The following warnings and instructions are basic to safe hoist operation. Please read them carefully and follow
them each time your hoist is operated. These instructions are provided in addition to any information furnished by
the Original Equipment Manufacturer. Equipment operators should be completely familiar with the overall opera-
tion of the piece of equipment on which the hoist is mounted (i.e. crane, truck crane, etc.). If you have any ques-
tions concerning the safe operation of this hoist or the equipment it is mounted on, contact the equipment manu-
facturer that installed the hoist, or the Braden Product Support Department at 918-251-8511, Monday through
Friday, 0800 to 1630 hours CST, by fax at [phone], or via the internet at www.paccarwinch.com.
Ground personnel must stay in view of the operator
and clear of the load and hoist drum at all times. Do
not allow personnel near the hoist line under ten-
sion. Do not allow personnel near the hoist drum
while the hoist is in operation. Do not allow person-
nel to be in line with the load. Do not allow person-
nel to stand under a suspended load. A safe dis-
tance of at least 1½times the working length of the
cable should be maintained by ground personnel. A
broken cable and/or lost load may cause property
damage, personal injury or death.
Failure to properly warm up the hoist, 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 plan-
etary gear oil may contribute to intermittent brake
clutch slippage which could result in property dam-
age, severe personal injury or death. Some gear
lubricants contain large amounts of EP (extreme
pressure) and anti-friction additives which may
contribute to brake slippage and damage to brake
friction discs or seals. Oil viscosity with regard to
ambient temperature is also critical to reliable
brake operation. Our tests indicate that excessive-
ly heavy or thick gear oil may contribute to intermit-
tent brake slippage. Make certain that the gear oil
viscosity used in your hoist is correct for your pre-
vailing ambient temperature.
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 engine should be run at its lowest recommended
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, raise and
lower, several times to prime all lines with warm
hydraulic oil, and to circulate gear lubricant through the
planetary gear sets.
After the hoist/boom is properly positioned, we recom-
mend the operator slowly pay-out, then haul-in a short
length of cable. The hoist should perform these opera-
tions in a smooth and controlled manner. If the hoist
does not operate smoothly or makes any unusual
sounds, the source of the problem should be identified
and corrected before any attempt is made to lift a load.
Slowly pay-out wire rope from the hoist drum until it
reaches the load. Securely fasten the hoist cable to the
load and be sure all ground personnel are a safe dis-
tance from the load. Slowly lift the load a short distance
and stop. Asmall amount of “bounce” may be
observed, depending on the weight of the load, size and
type of wire rope, reaving and the amount of boom
extension. Allow the load to stabilize and then watch for
any sign of downward movement or cable drum rota-
tion. The hoist static brake should hold the load in place
without allowing any downward movement at all. If the
load creeps down, it should be lowered to the ground
immediately and the source of the problem identified
and corrected.
If the hoist is holding the load securely, proceed with
normal operations in accordance with the equipment
manufacturer’s operating procedures and load charts.
If the hoist is mounted on a crane that has an extend-
able boom, care must be taken to pay-out cable as
the boom is extended. Failure to pay-out sufficient
cable could result in a “two-blocking” condition that
could result in damage to and/or failure of the hoist,
cable, sheaves and/or boom.
CAUTION

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
12
WINCH BRAKE
BRAKE
VALVE
PUMP
CONTROL
VALVE
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
BR
DR
TYPICAL HYDRAULIC CIRCUIT
NOTE: The hydraulic circuit shown below is representative of typical Braden hoists. Options and accessory equip-
ment may result in changes to the circuit shown. If there are any questions regarding the hydraulic circuit, refer
to information supplied by the original equipment manufacturer, or contact the Braden Product Support Department
at the number given in the Foreword of this manual. (ALWAYS have the hoist model and serial number when con-
tacting the factory)
The general purpose fastener torque chart shown below applies to SAE Grade 5 and 8 capscrews, studs and nuts.
Higher or lower torque values may be specified for special applications. The lubricated torque values are based
on SAE 30W engine oil applied to the threads of black phosphate treated bolts and nuts. Zinc plated fasteners use
the “lubricated” torque value.
HOIST ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE

PREVENTIVE MAINTENANCE
CAUTION
WARNING
! !
A regular program of preventive maintenance for your
planetary hoist is required to minimize the need for
emergency servicing and promote safe, reliable hoist
operation.
The user of Braden hoist products is responsible for
hoist inspection, testing, operator training and mainte-
nance noted below with frequency dependent upon the
severity of the hoist duty cycle and the thoroughness of
the preventive maintenance program.
Field experience, supported by engineering tests, indi-
cate the three service procedures listed below are the
most critical to safe, reliable hoist operation and MUST
be observed.
• Regular Gear Oil Changes -
• Use of Proper Gear Oil – recommended type for pre-
vailing ambient temperatures and additives.
• Periodic Disassembly and Inspection of All Wear
Components – in compliance with ANSI specification
B30.5c, 1987 and API RP 2D.
Crane inspection records as well as records of preven-
tive maintenance, repairs and modifications must be
available for a minimum of five (5) years. These records
should include but not limited to, hoist model and serial
number, name and employer of repair technician, date
and description of work performed.
Pre-use Inspection (each shift the hoist is used): This
inspection must be performed prior to placing the crane
into service and then as necessary during the day for
extended operation.
1. Check for external oil leaks and repair as necessary.
This is extremely important due to the accelerat-
ed wear that can be caused by insufficient lubri-
cating oil in the hoist. Lubricant level must be visi-
ble in the lower half of the sight glass. Use only rec-
ommended lubricants. See Recommended
Lubricants chart in this manual.
2. Check hydraulic plumbing for damage, such as
chafed or deteriorating hoses and repair as neces-
sary.
3. Visually inspect for loose or missing bolts, pins,
keepers or cotter pins and replace or tighten as nec-
essary.
4. The gear oil should be changed after the first 100
hours of operation or 30 days. The regular gear oil
change intervals may be adopted after the first oil
change.
5. Inspect the full length of wire rope, rigging and all
sheaves according to the wire rope and crane man-
ufacturer’s recommendations.
6. A warm-up procedure is recommended at each start-
up and is mandatory at ambient temperatures below
+40°F (4°C). The engine should be run at its lowest
RPM with the hydraulic hoist control in neutral allow-
ing sufficient time to warm up the system. The hoist
should then be operated at low speeds, hoisting and
lowering with no load, several times to prime all
hydraulic lines with warm oil and to circulate lubri-
cant through the planetary gear sets.
Quarterly Inspection (every 3 months) or monthly in
Severe Duty Applications or prior to placing the
machine in service if it has not been used for three
months or more.
1. Perform the Pre-use Inspection.
2. Inspect all hoist fasteners for tightness and corro-
sion. Replace all corroded fasteners and tighten per
the torque specifications on page 12.
3. The hydraulic system filters should be changed after
the first 50 hours of operation then every 500 hours
or quarterly or in accordance with the crane manu-
facturer’s recommendations.
4. Take a sample of the gear oil from the hoist drum fol-
lowing the oil sampling procedure on page 15. The
oil sample must be taken prior to changing the gear
oil. Analyze the sample for wear metals, viscosity,
signs of overheating, oxidation, water and other con-
taminants. If the oil sample contains an unusual
amount of metallic particles, the hoist should be
removed from service and undergo a tear-down
inspection.
Annual Inspection, Testing & Preventive
Maintenance or semi-annually in Severe Duty
Applications.
1. Perform the Pre-Use and Quarterly Inspections.
2. Change the lubricating oil in the hoist drum after an
oil sample is taken.
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.
The gear oil must be changed to remove wear parti-
cles that impede reliable and safe operation of the
brake clutch and erode bearings and seals. Failure to
change gear oil at recommended intervals may con-
tribute to intermittent brake slippage, loss of load con-
trol, injury or death.
13

The gear oil should be changed whenever the ambi-
ent temperature changes significantly and an oil
from a different viscosity range would be more
appropriate. Oil viscosity is 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 the gear oil vis-
cosity used in your hoist is correct for your prevailing
ambient temperature.
NOTE: If the oil sampling/analysis has not been per-
formed as required, tear-down inspections will be
required. Refer to Hoist Disassembly section of this
manual.
To change the gear oil, slowly rotate the drum until
the oil drain plug is aligned with the lower oil port
access hole. Install a short length of pipe threaded
for 1 in. NPT into the threaded drain port in the cable
drum. Reach through the pipe with a long hex-key
and remove the drain plug. The oil will drain out the
length of pipe and not between the drum and base.
When the oil has drained, install the plug and
remove the drain pipe. Removing the vent plug will
hasten the oil drain. Rotate the drum until the drain
port is aligned with the fill/level port in the end brack-
et. Refill the hoist with recommended lubricant.
Install the plug securely.
3. The vent plug is located in the drum bearing support.
It is important to keep the vent plug clean and unob-
structed. Whenever the gear oil is changed, the vent
plug should be removed, cleaned in solvent and
reinstalled. Do not paint over the vent plug or replace
with a solid plug or grease fitting.
Failure to use the proper type and viscosity gear oil
may result in loss of load control, property damage,
injury or death.
Recommended Planetary Gear Oil
For simplicity, Braden has listed available products in each temperature range that have 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.
Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slip-
page 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 slippage and dam-
age to brake friction discs or seals. Oil viscosity with regard to ambient temperature 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 temper-
ature.
14

Tear-down Inspection
Any hoist that has not been subjected to regular oil
sample analysis should undergo a tear-down inspection
every 24 months. Also, if a hoist has an unknown histo-
ry of repair and/or maintenance, the hoist should under-
go a tear-down inspection prior to being placed into
service.
A tear-down inspection of the hoist should include the
complete disassembly, cleaning, inspection and
replacement of all worn, cracked, corroded or distorted
parts such as pins, bearings, shafts and brake compo-
nents. All seals and o-rings should be replaced during a
tear-down inspection. Always use new Spirol pins in the
planet gear shafts.
Any deficiency must be corrected immediately.
Before placing the hoist back in service, the rebuilt hoist
must be pull tested to the rated load of the hoist with a
dynamometer or equivalent measuring device. The
hoist should be dynamically tested by rotating the drum
several times, in both raising and lowering directions,
while under load of at least 30% of the hoist rated lifting
capacity. Check for smooth, quiet operation during this
procedure.
15
Proper oil sampling and analysis of the sample, is a
vital part of a comprehensive preventive maintenance
program. Information obtained from the oil analysis is
best utilized in conjunction with a regular program of
preventive maintenance. The early warning of abnor-
mal wear provided by an analysis program allows the
user to substitute preventive maintenance for a far
more costly and dangerous failure that may lead to loss
of load control that could result in property damage,
personal injury or death. Early detection of accelerated
component wear allows the scheduling of corrective
maintenance and can reduce in-operation failures and
costly down time.
Taking a Valid Oil Sample
Prepare the hoist by cleaning the drain area and drain
extension tube in order to obtain an uncontaminated
sample. Operate the hoist in both directions for one to
two minutes and then take the oil sample from the drain
port as soon as possible. Do not take the sample from
the first oil out of the drain port. Take a sample from the
mid-stream flow of the oil to obtain an accurate repre-
sentation of the oil condition. After taking an oil sample,
refill hoist with recommended lubricant.
Analysis
General Guide Lines
(After approximately 250 hours of operation)
Note: The first oil change usually contains more “wear
metals”. Following the initial break-in period, the wear
metal levels should stabilize at a lower number.
Iron Contaminates
100 to 500 ppm Normal
501 to 800 ppm Caution – Abnormal Sample (moni-
tor more frequently), tear-down
inspection may be required.
801 ppm & up Unacceptable – Abnormal Sample
(tear down inspection required)
In all contaminate monitoring, equally important as the
level of contamination, is the change in the amount of
contamination compared to previous samples.
Moisture contamination will lead to the formation of
acids that damage all internal components. Silica found
in the oil typically indicates “dirt” and contaminated
lubricant supply or poor maintenance practices.
OIL SAMPLING AND ANALYSIS
Hot oil may cause personal injury and/or burns to
unprotected skin. Make certain the oil has cooled to
a safe temperature (less than 110°F or 43°C) before
taking an oil sample, changing oil or servicing the
hoist.

TROUBLESHOOTING
16
TROUBLE REMEDY
PROBABLE CAUSE
A
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 (13,800 kPa) gauge
and shut-off valve to the fitting in
the brake release port.
B. Apply 1000 psi (6,900 kPa) 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 sur-
faces and replacement of the
seals. Refer to “Brake Cylinder
Service” section of this manual.
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 hoist 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 (.5 mm). Clean and install
the pilot orifice tightly in the
brake valve.
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 opera-
tion.
The hoist will not lower the load
or not lower the load smoothly.
The following troubleshooting section is provided as a general guide. You may also need to contact the Original
Equipment Manufacturer (OEM) for additional information.
If a hoist exhibits any sign of:
- Erratic operation such as poor load control, load creeping down or chattering.
- Unusual noise.
- Gear oil leaks.
- A sudden rise in wear particles from oil analysis
The hoist MUST be removed from service until the problem has been corrected. If a
hoist has been subjected to a sudden heavy load (shock-load) or overload, the hoist
must be removed from service, disassembled and all internal components thoroughly
inspected for damage. Continued operation with a defect may result in loss of load con-
trol, property damage, injury or death.
3. Friction brake will not release as
a result of damaged brake discs.
Disassemble brake to inspect
brake discs. Check stack-up
height as described in “Brake
Cylinder Service” section of this
manual.

TROUBLE REMEDYPROBABLE CAUSE
Oil leaks from vent plug. Same as A2.
Case drain back pressure must
not exceed 70 psi (480 kPa).
Inspect hydraulic system for a
restriction in the return line to the
reservoir.
Oil analysis may indicate con-
tamination 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 back pressure in
the motor case drain circuit or
contaminated oil.
B
The pressure at the motor lower-
ing port is also transmitted to the
brake release pilot circuit.
Inspect hydraulic circuit for
restrictions, plugged filters or
control valves not centering.
Same as Remedy 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 hoist with rec-
ommended planetary gear oil
listed in “Preventive
Maintenance”.
Brake clutch may be damaged or
worn. Disassemble and inspect
brake clutch as described in
“Over-running 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.
C
D
The hoist will not hoist the rated
load
1. 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
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 hoist. Refer to “Hoist
Installation”.
First loosen, then evenly retight-
en all hoist mounting bolts to rec-
ommended torque.
Check relief pressure as follows:
A. Install an accurate 0-5000 psi
(34,500 kPa) gauge into the inlet
port of the brake valve.
17

B. Apply a stall pull load on the hoist
while monitoring pressure.
C. Compare gauge reading to hoist
specifications. Adjust relief valve
as required.
NOTE: If pressure does not
increase in proportion to adjust-
ment, relief valve may be con-
taminated or worn out. In either
case, the relief valve may require
disassembly or replacement.
3. Be certain hydraulic system tem-
perature is not more than 180°F
(82°C). Excessive hydraulic oil
temperatures increase motor
internal leakage and reduces
motor performance.
4. Hoist line pull rating is based on
1st layer of wire rope.
5. Rigging and sheaves not operat-
ing efficiently.
Same as remedies for Trouble
D1 & D2.
Same as remedies for Trouble
E2.
Refer to hoist performance
charts for additional information.
Perform rigging service as rec-
ommended by crane manufac-
turer.
Same as remedies for Trouble
D1.
Thoroughly clean exterior and
flush interior.
Fill/drain to proper level.
Same as remedies for Trouble
D2.
Engine low on horsepower or
R.P.M. Tune/adjust engine.
Check suction line for damage.
Pump worn. Replace pump.
Use correct hydraulic oil.
Disassemble hoist to inspect/
replace worn parts.
1. Same as D1.
2. Be certain that the hydraulic
system temperature is not
more than 180°F (82°C).
Excessive hydraulic oil temper-
atures 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.
E. Hydraulic oil is wrong viscosity
for operating conditions.
3. Excessively worn or damaged
internal winch parts.
The winch runs hot.
E
TROUBLE PROBABLE CAUSE REMEDY
TROUBLE “D” CONTINUED FROM
PREVIOUS PAGE
18

TROUBLE PROBABLE CAUSE REMEDY
F
Hoist “chatters” or surges while rais-
ing rated load.
G
1. Same as D2.
2. Hydraulic oil flow to motor may be
too low.
3. Controls being operated too quickly.
4. Hydraulic motor 2-speed control not
shifting correctly.
Same as remedies for Trouble D2.
Same as remedies for Trouble E2.
Conduct operator training as required.
Inspect and repair motor displacement
control.
The wire rope does not spool
smoothly on the drum.
Check mounting distance and fleet
angle. Reposition hoist as required
to achieve ½to 1½degree fleet
angle.
Refer to “Hoist 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 hoist may be mounted too close
to the main sheave, causing the fleet
angle to be more than 1½degrees.
2. The hoist may not be mounted per-
pendicular 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 advan-
tage in applying rope of the proper
direction of lay. When the load is
slacked off, the several wraps 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 hoisting 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 hoist may have been over-
loaded, causing permanent set in
the wire rope.
19
H
Sensor does not read drum rotation
properly.
1. Sensor may need to be adjusted.
2. Sensor may not have correct supply
voltage.
3. Sensor may be defective.
Rotate drum slowly.
A. If sensor light stays on, loosen lock
nuts and slowly turn the sensor
CCW until sensor light blinks on and
off. Continue turning sensor 1/4 to
1/2 CCW after light blinking starts
and tighten lock nuts until snug to
avoid damage to the sensor.
B. If sensor light does not come on or
blink, loosen locknuts and slowly
turn the sensor CW until sensor light
blinks on and off. Continue turning
sensor 1/4 to 1/2 CW after light
blinking starts and tighten locknuts
until snug to avoid damage to sen-
sor.
Test voltage at sensor plug, pin1,
brown wire. Voltage must be 9-24
volts DC. If voltage is too low or 0
volts, test electrical harness for open
circuit.
Replace sensor. Adjust sensor as
described above in H1.