Paccar BRADEN/GEARMATIC BG8A Manual

BG8A and BG8B
HYDRAULIC WINCH
INSTALLATION, MAINTENANCE,
AND SERVICE MANUAL
LIT2204 Rev 7
February 2017
Printe d in USA
©2017 PACCAR Inc.
All rights reserved
BG8A
BG8B
Visit our Web site at www.paccarwinch.com for the most comprehensive collection of winch, hoist, and drive
information on the Internet. Most publications and specification sheets are available for downloading.
WRITE HOIST SERIAL NUMBER BELOW
}
First 2 numbers indicate
year manufactured
For serial number location, see page 1

FOREWORD
Read and understand this entire publication before operating or servicing your BRADEN/GEARMATIC winch.
Retain this manual for future reference. The minimum service intervals specified are for operating hours of the
prime mover. This manual contains instructions which provide installation, preventive maintenance, and service
information for the Model BG8 series winch. It is suggested that before doing any work on these units, all assembly
and disassembly instructions should be read and understood.
Some illustrations in this manual may show details or attachments 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 may not be included in this manual.
When a question arises regarding your winch, or this manual, contact your nearest BRADEN/GEARMATIC dealer
or the factory Service Department at 1-918-251-8511, Monday - Friday, 8:00 a.m. to 4:30 p.m. CST. Provide the
complete winch model and serial number when making inquiries. The model and serial numbers are stamped into
the base, to the left of the hydraulic motor.
PARTS AND SERVICE
BRADEN/GEARMATIC provides parts and service through a network of authorized dealers. Parts and service are
not available 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
BG BRADEN GEARMATIC
8 8,000-LB. APPROXIMATE FIRST-LAYER LINE PULL
B MODEL SERIES RELATING TO DESIGN CHANGES
34 TOTAL GEAR REDUCTION
23 = 23.06:1; 34 = 34.2:1; 59 = 59.06:1; 69/23 (69.19:1 Hoist, 23.06:1 Lower)
039 HYDRAULIC MOTOR DISPLACEMENT IN CUBIC INCHES/REV
(DECIMAL POINT ELIMINATED. EXAMPLE 039 = 3.9 CUBIC INCHES/REV)
01 DRUM OPTION
-1 PERMITS TESTING AND INSPECTION PER API 2C RECOMMENDATIONS
1
HOIST SERIAL NUMBER
HOIST MODEL NUMBER
The hoist model number and
serial number are stamped
onto the data plate of the
motor side end plate. Both of
these numbers are extremely
important in the shipment of
the proper replacement parts,
and your order should always
reference them.

Foreword ..........................................................................................................................1
Model and Serial Number Explanation.............................................................................1
General Safety Recommendations ................................................................................ 3
Theory of Operation .........................................................................................................4
Winch Installation .............................................................................................................6
Wire Rope Installation ......................................................................................................8
Preventive Maintenance ..................................................................................................9
Recommended Oil Change Information .........................................................................10
Troubleshooting ..............................................................................................................11
Winch Disassembly ........................................................................................................15
Planet Carrier Service ....................................................................................................17
Motor Support – Brake Cylinder Service ........................................................................19
Brake Clutch Service ......................................................................................................23
Winch Assembly .............................................................................................................25
Brake Valve Service .......................................................................................................27
Reversing Direction of Drum Rotation............................................................................29
Recommended Fastener Torque ...................................................................................30
TABLE OF CONTENTS
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.
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:
2
This symbol is used for informational
callouts or service tips.
CAUTION
!
!
! WARNING !

1. Read all warning and caution tag information and
become familiar with all controls before operating
winch.
2. Never attempt to clean, oil or perform any mainte-
nance on a machine with the engine running, unless
instructed to do so in this manual.
3.. Never operate winch controls unless you are prop-
erly positioned at the operators station 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 opera-
tor and clear of winch drum. Do not allow ground
personnel near winch line under tension. A safe dis-
tance of at least 1-1/2 times the length of the cable
should be maintained. Never allow anyone to stand
under a suspended load.
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 winch. Always apply the prime mover
parking brakes and lower equipment before dis-
mounting the prime mover.
7. Inspect rigging, winch and hydraulic hoses at the
beginning of each work shift. Defects should be cor-
rected immediately.
8. Keep equipment in good operating condition.
Perform scheduled servicing and adjustments listed
in the “Preventive Maintenance” section of this
manual.
9. An equipment warm-up procedure is recommended
for all start-ups and is essential at ambient tem-
peratures below +40°F (4°C). Refer to “Warm-up
Procedure” listed in the “Preventive Maintenance”
section of this manual.
10. Be sure of equipment stability before operating
winch.
11. The winches described herein are neither designed
nor intended for use or application to equipment
used in the lifting or moving of persons.
12. Do not exceed the maximum pressure or flow stated
in the winch specifications.
13. Operate winch line speeds to match job conditions.
Avoid sudden “shock” loads or attempting to “jerk”
load free. This type of operation may cause heavy
loads in excess of rated capacity, which may result
in failure of cable and winch.
14. Leather gloves should be used when handling
winch cable.
15. Never attempt to handle winch cable when the hook
end is not free. Keep all parts of body and clothing
clear of cable rollers, cable entry area of fairleads
and winch drum.
16. When winding winch cable on the winch drum,
never attempt to maintain tension by allowing winch
cable to slip through hands. Always use “Hand-
Over-Hand” technique.
17. Install guarding to prevent personnel from get-
ting any part of body or clothing caught at a point
where the cable is wrapped onto the drum or drawn
through fairlead guide rollers.
18. Do not weld on any part of the winch.
19. Do not use knots to secure or attach winch cable.
Use correct size cable anchor for cable and pocket
in winch drum.
20. Use recommended hydraulic oil and gear lubricant.
21. Keep hydraulic system clean and free from contami-
nation at all times.
22. The BRADEN/GEARMATIC 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.
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 winch must be operated with care and
concern by the operator for the equipment and a thorough knowledge of the machine’s performance capabilities.
The following recommendations are offered as a general safety guide. Local rules and regulations will also apply.
3

DESCRIPTION OF WINCH
The winch has three basic assemblies:
1. Hydraulic motor assembly and brake valve
2. Cable drum assembly
3. Brake cylinder and motor adapter
The hydraulic motor is bolted to the motor adapter
which in turn is bolted to the brake cylinder and the
winch base. The cable drum assembly is supported
by antifriction bearings which are located by the brake
housing at one end and the bearing support at the other
end. The ring gear for both planetary sets is machined
on the inside surface of the cable drum.
PLANETARY GEAR TRAIN
The hydraulic motor shaft is directly coupled to the
inner brake hub which is connected to the input shaft
which acts as the sun gear for the primary planetary
set. When driven by the input shaft, the primary planet
gears walk around the ring gear machined in the cable
drum and drive the primary planet carrier.
The primary planet carrier drives the output sun gear
which drives the output planet gears. The output planet
carrier is splined to the bearing support and cannot
rotate. As the output planet gears are driven by the
output sun gear, they drive the ring gear/cable drum.
DUAL BRAKE SYSTEM
The dual brake system consists of a dynamic brake
system 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.
The counterbalance valve is mounted to the hoist port
of the motor on units with 020, 029 and 039 motors.
Units with the 071 motor use a counterbalance valve
cartridge in the brake valve block which is bolted to
the motor. The operational theory of both systems is
the same. A check valve allows free flow of oil to the
motor in the haul-in direction and a pilot operated,
spring-loaded spool valve 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 pay-out posi-
tion, 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 pay-out speed. .
The static brake system has three operating compo-
nents:
1. Spring-applied, multiple friction-disc brake pack
2. Overrunning brake clutch assembly
3. Hydraulic brake cylinder and spring plate
The static brake consists of alternately stacked fric-
tion and steel brake discs. The steel brake discs are
externally splined to the motor adapter and cannot
rotate. The friction discs are internally splined to the
outer brake hub of the overrunning brake clutch. When
compressed by spring force, the brake pack locks the
overrunning brake clutch outer brake hub to the motor
adapter.
The static brake is released by the pilot pressure at a
pressure lower than that required to open the pilot oper-
ated brake valve. This sequence assures that dynamic
braking takes place in the brake valve and that little, if
any, heat is absorbed by the friction brake.
The friction brake is primarily a load holding brake and
will provide dynamic braking only during extremely slow
operation when there is insufficient flow to open the
brake valve.
The sprag type overrunning brake clutch is installed
between the inner brake race and the outer brake hub.
The overrunning brake clutch, allows the inner brake
race and input shaft to turn freely in the direction to haul
in cable and locks up to force the friction brake discs to
turn with the inner brake race and input shaft to pay out
cable. The brake pack remains fully applied when haul-
ing in cable and must be released by pilot pressure to
allow the brake discs to turn freely and pay-out cable.
THEORY OF OPERATION
4
Power Flow
(hoisting)

DUAL BRAKE SYSTEM – OPERATION
When hoisting or pulling a load, the brake clutch allows
free rotation of the inner brake race and input shaft. The
sprag cams lay over and permit the inner race to turn
free of the outer brake hub (Figure 1). The friction brake
remains fully engaged. The winch, in raising a load, is
not affected by any braking action during haul-in.
When the haul-in operation is stopped, the load
attempts to turn the input shaft in the opposite direction.
This reversed input causes the sprag cams to instantly
engage and firmly lock the inner brake race to the outer
brake hub (Figure 2).
When the winch is powered in reverse, to pay-out
cable, the motor and gear train will not rotate until
sufficient pilot pressure is supplied to open the brake
valve. 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 low-
ered. 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 returned to neutral or “hold,”
the pilot 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 position-
ing, no oil flow actually occurs through the winch motor.
The pressure will build up to a point where the friction
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.
5
Hoisting
Stopped
Holding
Load
Sprag Cams
Permits free sharotation
while hoisting.
Sprag Cams
Static friction brake applied
Load attempts to rotate shain opposite direction.
Brake clutch locks sun gear shato friction brake.
Figure 2
Figure 1

1. The winch should be mounted with the centerline
of the drum in a horizontal position. The mounting
plane of the base may be rotated in any position
around this centerline.
2. Because of the design of the mounting base, the
direction of line pull should only be as shown in the
above illustration. Line pulls in any other direction
must be approved by BRADEN Engineering.
3. When mounting the winch, use all four (4) mount-
ing holes and grade 5 (8.8) or better bolts and nuts.
Tighten to recommended torque.
It is important that the winch is mounted on a surface
that will not flex when the winch is in use, and cause
binding of the gear train. Binding in the gear train will
result in accelerated wear and heat. Also, be sure
the winch is mounted on a flat surface. If necessary,
use shim stock to insure the mounting surface is flat
within 0.020 inch (0.5 mm).
4. The vent plug must always be located above the
horizontal centerline. If the winch is mounted on a
pivoting surface, be sure vent plug remains above
the centerline in all positions. If necessary, reposition
bearing support and vent plug as follows:
A. Remove bearing support bolts.
B. Rotate bearing support until vent plug is
positioned correctly and bolt holes are
aligned.
C. Evenly tighten bolts to recommended
torque.
5. Hydraulic lines and components that operate the
winch should be of sufficient size to assure minimum
back pressure at the winch. The motor manufacturer
recommends that the back pressure not to exceed
100 PSI (690 kPa) for optimum motor seal life. 150
PSI (1,030 kPa) is the maximum allowable back
pressure. The standard winch is supplied with the
motor internally drained. If high back pressures are
encountered, the motor may be externally drained
directly to tank to improve motor seal life. For back
pressures exceeding 150 PSI (1,030 kPa) consult
BRADEN Service Department.
6. The winch should be mounted perpendicular to an
imaginary line from the center of the drum to the first
sheave to insure even spooling. Make certain the
fleet angle does not exceed 1-1/2 degrees.
WINCH INSTALLATION
VENT PLUG
ABOVE CENTERLINE
C
L
6
6.75 in.
(171 mm)
13.5 in.
(343 mm)
11.625 in.
(295 mm)
5.813 in.
(148 mm)
4 THRU HOLES
0.656 in. (17 mm)
C
L
DRUM
240o
30o
30o

7. The winch directional control valve must be a three
position four way valve with a motor spool such that
when the valve is in the center position both work
ports are open to tank (open center, open port).
8. High quality hydraulic oil is essential for satisfactory
performance and long hydraulic system component
life.
Oil having 150 to 330 SUS viscosity at 100°F (38°C)
and viscosity index of 100 or greater will give good
results under normal temperature conditions. The
use of an oil having a high viscosity index will
minimize cold-start trouble and reduce the length of
warm-up periods. 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
(-7° C) lower than the minimum temperature.
Under continuous operating conditions, temperature
of the oil at any point in the system must not exceed
180°F (82°C). Optimum oil temperature is generally
considered to be 120°F-140°F (49°C-60°C).
In general terms; for continuous operation at ambi-
ent temperatures between 50°F and 110°F (10°C
to 43°C) use SAE 20W; for continuous operation
between 10°F and 90°F (-12°C to 32°C) use SAE
10W; for applications colder than 10°F (-12°C), con-
tact the BRADEN Service Department. The use of
multiviscosity oils is generally not recommended.
9. The hydraulic oil filter should have a 10 micron nomi-
nal rating and be full-flow type.
7
HOIST BRAKE
BRAKE
VALVE
PUMP
CONTROL
VALVE
HOIST ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
BR
DR

Take the free end of the wire rope and insert it through
the small opening of the anchor pocket. Loop the wire
rope and push the free end about 3/4 of the way back
through the pocket. Install the wedge, then pull the
slack out of the wire rope. The wedge will slip into the
pocket and secure the wire rope into the drum.
The standard cable anchor or wedge shipped with the
hoist, P/N 74780 will anchor 3/8- to 9/16-inch (10-14
mm) wire rope. For 1/4- to 5/16-inch (6-8 mm) wire
rope, use P/N 24119. For 5/8- to 3/4-inch nylon or poly-
ester rope use P/N 26095.
Maintain even tension of approximately one ton on the
wire rope when spooling it onto the cable drum. DO
NOT pinch wire rope through wood blocks to maintain
tension as the wire rope may be permanently damaged.
After the wire rope is installed on the hoist drum, pass
the wire rope through all reeving and extend the boom
to maximum length and height to reel out as much wire
rope off the drum as possible until you reach the last
five wraps. Apply a one ton weight to the hook and
slowly reel in the wire rope while an assistant monitors
the cable spooling at a safe distance from the hoist
drum. If necessary, stop reeling in while the assistant
packs the wire rope tightly. Resume spooling on the
wire rope only after you are certain the assistant is a
safe distance from the hoist drum and wire rope.
WIRE ROPE INSTALLATION
8
Correct Installation Incorrect Installation
Drive from
this side
Wedge and wire
rope fully seated
in pocket
Wedge not
fully seated
Wedge pulled
too far through
anchor pocket
The cable anchor or wedge is designed to hold rated
load when installed correctly with properly prepared
wire rope. Always maintain a minimum of five (5)
complete wraps of wire rope on the drum. As a visual
safety warning, paint the last five wraps of wire rope
red. Failure to properly install the cable anchor or
wedge and keep five wraps of wire rope on the drum
may result in a dislodged cable anchor or wedge and
loss of load control, property damage, and severe
injury to personnel or death.
! WARNING !

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.
NOTE: The service intervals suggested in this manual
will optimize component service life. The intervals may
be gradually increased or decreased with experience
of a particular lubricant and the recommendations of an
independent oil analysis.
All service intervals are specified for operating hours of
the prime mover.
1. Oil Level
The gear oil level should be checked every 500
operating hours or three (3) months, whichever
occurs first. To check the oil level, remove the large
plug located in the center of the drum support. The
oil should be level with the bottom of this opening.
If additional oil in needed, refer to “Recommended
Planetary Gear Oil.”
2. Oil Change
The gear oil should be changed after the first
one hundred (100) hours of operation, then every
1,000 operating hours or six (6) months, whichever
occurs first.
To drain the gear oil, align the drain plug in the
drum with the hole in the support side of the base.
Install a short piece of 1-inch pipe into the threaded
drum port to prevent oil from draining onto winch
base.
Insert a wrench through the 1-inch pipe and
remove the drain plug. Install plug securely after oil
has been drained. Refill with recommended plan-
etary gear oil. Capacity is 4 U.S. pints (1.9L).
3. Vent Plug
The vent plug is located in the drum support as
shown. It is 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 accor-
dance with the equipment manufacturer’s recom-
mendations.
5. Wire Rope
Inspect entire length of wire rope according to wire
rope manufacturers recommendations.
6. Mounting Bolts
Tighten all winch base mounting bolts to recom-
mended 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).
PREVENTIVE MAINTENANCE
9
Oil Level Plug
Oil Drain
Opening
Vent Plug
(above drum centerline)

The prime mover should be run at its lowest rec-
ommended 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 circu-
late gear lubricant through the planetary gear sets.
8. Oil Analysis
We recommend an oil analysis be conducted
on the gear oil at regular intervals. Wear metals
should be monitored for early detection of problems
and lubricant effectivity. In severe applications,
the winch should be completely disassembled to
inspect for excessive wear every 2,000 hours of
operation or 12 months, whichever occurs first.
Recommended Planetary Gear Oil
Field experience, supported by extensive engineer-
ing tests, indicates the use of the proper planetary
gear oil is essential to reliable and safe operation of
the brake clutch and obtaining long gear train life.
For simplicity, BRADEN has listed one (1) readily
available product in each temperature range which
has been tested and found to meet our specifica-
tions. This is not to say that other lubricant brands
would not perform equally as well.
If the following lubricant brands are not available
in your area, make certain your lubricant vendor
supplies you with oil that is equivalent to those
products listed below.
BRADEN planetary winches are factory filled with
Exxon Spartan 150 or equivalent AGMA 4EP gear oil.
Failure to properly warm up the winch, particu-
larly 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.
071 MOTOR
The brake valve cartridge may be unique in that
turning the adjusting screw in, clockwise, lowers
the release pressure. If it is determined a brake
valve adjustment is required, the entire brake
valve should be replaced.
The brake valve cartridge is easily removed
from the valve block for cleaning, inspection or
replacement, but is not designed to be disas-
sembled in the field. In the event it has been
determined the brake valve should be disassem-
bled, the entire cartridge should be replaced.
The brake valve cartridge is factory set and nor-
mally requires no further adjustment. The brake
valve can be manually piloted open by its adjusting
screw. Manually opening the brake valve could
cause internal winch damage and may cause loss
of load control during lowering operations which
may result in property damage, personal injury, or
death.
10
! WARNING !
! WARNING !
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
o
C -40 -30 -20 -10 0 10 20 30 40 50
o
C
SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS SUSTAINED
FAST DUTY CYCLES OR FREQUENT WINCHING.
TexacoShell
Meropa 220
Meropa 150
Omala S2 G 220
Omala S2 G 150
Chevron
Gear Compounds EP 220
Gear Compounds EP 150
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
o
C -40 -30 -20 -10 0 10 20 30 40 50
o
C
SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS
Mobil
Mobilgear 600 XP 220
Mobilgear 600 XP 150
Winches are factory filled with Mobilgear 600 XP 150 or equivalent. Consult your oil supplier for other equivalent
oils if required.
Omala S4 GX 150
Mobilgear SHC 150
Use gear oil detailed in Range A
Range A
Range B
Range C
Use gear oil detailed in Range B
Use gear oil detailed in Range C

TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
A
The winch will not lower
the load or not lower the
load smoothly.
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 pres-
sure, 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
causes erratic brake valve operation.
2. 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 find oil leaking
from the winch vent plug.
3. Friction brake will not release as a
result of damaged brake discs.
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 inch. Clean and install the pilot orifice
tightly in the brake valve.
Check brake cylinder seal as follows:
A. Disconnect the swivel tee from the
brake release port. Connect a hand pump
with accurate 0-2000 PSI gauge and shut-
off valve to the –4 JIC fitting in the brake
release port.
B. Apply 1000 PSI to the brake. Close
shut-off valve and let stand for five (5)
minutes.
C. If there is any loss of pressure in five
(5) minutes, the brake cylinder should be
disassembled for inspection of the sealing
surfaces and replacement of the seals.
Refer to “Motor Support — Brake Cylinder
Service.”
Disassemble brake to inspect brake discs.
Check stack-up height as described in
“Motor Support — Brake Cylinder Service.”
B
Oil leaks from vent plug. 1. Same as A2.
2. Motor seal may be defective as a
result of high system back pressure or
contaminated oil.
Same as A2.
System back pressure must not exceed
150 PSI. Inspect hydraulic system for a
restriction in the return line from the con-
trol valve to the reservoir. Be sure control
valve and plumbing is properly sized to
winch motor.
Oil analysis may indicate contamina-
tion has worn motor shaft and seal.
Thoroughly flush entire hydraulic system
and install new filters and oil. Install new
motor seal.
11

TROUBLE PROBABLE CAUSE REMEDY
C
The brake will not hold
a load with the control
lever in neutral.
1. Excessive system back pressure
acting on the brake release port.
2. Friction brake will not hold due to
worn or damaged brake discs.
3. Brake clutch is slipping.
The same as Remedy 2 of Trouble B2.
Same as Remedy 3 of Trouble A3.
Improper planetary gear oil may cause
the brake clutch to slip. Drain old gear oil
and flush winch with solvent. Thoroughly
drain solvent and refill winch with rec-
ommended planetary gear oil listed in
“Preventive Maintenance.”
Brake clutch may be damaged or worn.
Disassemble and inspect brake clutch as
described in “Brake Clutch Service.”
D
The winch will not hoist
the rated load.
1. The winch may be mounted on
an uneven or flexible surface which
causes distortion of the winch base
and binding of the gear train. Binding
in the gear train will absorb horsepower
needed to hoist the rated load and
cause heat.
2. System relief valve may be set too
low. Relief valve needs adjustment or
repair
3. Be certain hydraulic system tem-
perature is not more than 180°F.
Excessive hydraulic oil temperatures
increase motor internal leakage and
reduce motor performance.
4. Winch line pull rating is based on
first layer of wire rope.
5. Rigging and sheaves not operating
efficiently.
Reinforce mounting surface.
If necessary, use shim stock to level
winch. Refer to “Winch Installation.”
First loosen, then evenly retighten all
winch mounting bolts to recommended
torque.
Check relief pressure as follows:
A. Install an accurate 0-4000 PSI (27,580
kPa) gauge into the inlet port of the brake
valve.
B. Apply a stall pull load on the winch
while monitoring pressure.
C. Compare gauge reading to winch spec-
ifications. 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 disas-
sembly or replacement.
Same as remedies for Trouble D1 and
D2.
Same as remedies for Trouble E2.
12

TROUBLE PROBABLE CAUSE REMEDY
TROUBLE “D”
CONTINUED FROM
PREVIOUS PAGE 4. Winch line pull rating is based on 1st
layer of wire rope.
5. Rigging and sheaves not operating
efficiently.
Refer to winch performance charts for
additional information.
Perform rigging service as recommended
by crane manufacturer.
E
The winch runs hot. 1. Same as D1.
2. Be certain that the hydraulic system
temperature is not more than 180°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 inter-
nal winch parts.
Same as remedies for Trouble D1.
Thoroughly clean exterior and flush inte-
rior.
Fill/drain to proper level.
Same as remedies for Trouble D2.
Prime mover low on horsepower or RPM
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.
13

TROUBLE PROBABLE CAUSE REMEDY
F
Winch “chatters” while
raising rated load.
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.
G
The wire rope does not
spool smoothly on the
drum.
1. The winch may be mounted too
close to the main sheave, causing
the fleet angle to be more than 1-1/2
degrees.
2. The winch may not be mounted
perpendicular to an imaginary line
between the center of the cable drum
and the first sheave.
3. Could possibly be using the wrong
lay rope. There is a distinct advantage
in applying rope of the proper direction
of lay. When the load is slacked off,
the several coils on the drum will stay
closer together and maintain an even
layer. If rope of improper lay is used,
the coils will spread apart each time the
load is removed. Then, when winding
is resumed, the rope has a tendency
to crisscross 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.
Check mounting distance and fleet angle.
Reposition winch as required.
Refer to “Winch Installation.”
Consult wire rope manufacturer for rec-
ommendation of wire rope that best suits
your application.
Replace wire rope and conduct operator/
rigger training as required.
14

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

6. Remove the brake cylinder capscrews and install
two (2) capscrews and a short piece of chain into
the motor mounting bolt holes. Using the chain as
a handle, lift the brake cylinder assembly out of the
drum and base, being careful to avoid damaging
the sealing and bearing surfaces. Refer to “Motor
Support — Brake Cylinder Service” for additional
information.
7. (BG8A ONLY) Remove the drum closure. Remove
and discard the O-ring from the inside of the drum.
Remove the seal from the drum closure.
(BG8B) The seal is mounted in the drum. Remove
the seal and drum closure from the drum.
8. Clean and inspect the bearing in the drum closure
and replace if required.
9. Remove the primary sun gear and thrust washer
from the primary planet carrier.
NOTE: 23:1 gear ratio winches have a sun gear
adapter in addition to the sun gear shaft.
10. Remove the primary planet carrier from the drum.
Refer to “Planet Carrier Service” for additional infor-
mation.
11. Remove the output sun gear and thrust washer
from the output planet carrier.
12. Remove the output planet carrier from the drum.
Refer to “Planet Carrier Service” for additional
information.
13. Remove snap ring from bearing support.
14. Stand winch on motor end with bearing support up;
then remove bearing support capscrews and bear-
ing support being careful to avoid damaging the
sealing and bearing surfaces.
15. Slide drum out of base onto a work bench and
remove seal and bearing from support end.
16. Thoroughly clean and inspect drum and base.
Check ring gear (machined into inside surface of
drum) teeth for nicks, spalling or excessive wear.
Replace if wear is greater than 0.015 inch (0.4 mm)
when compared to unworn area of teeth.
16

OUTPUT PLANET CARRIER
DISASSEMBLY
1. Remove the planet gears by driving the roll pins into
the center of the planet shafts.
2. Use a punch to drive the roll pins from the planet
shafts. Do not reuse the roll pins.
3. Now you can remove the planet shafts, bearings,
spacer, thrust washers and gears. Thoroughly clean
all parts and inspect for damage and wear. The
bearing rollers should not exhibit any irregularities.
If the rollers show any sign of spalling, corrosion,
discoloration, material displacement or abnormal
wear, the bearing should be replaced. Likewise, the
cage should be inspected for unusual wear or defor-
mation, particularly the cage bars. If there is any
damage that will impair the cage’s ability to sepa-
rate, retain and guide the rollers properly, the bear-
ing should be replaced. The thrust washer contact
areas should be free from any surface irregularities
that may cause abrasions or friction. The gears and
shafts should be inspected for abnormal wear or
pitting. Replace if necessary.
ASSEMBLY
1. Place the output planet carrier on workbench with
splined coupling side down. Install output thrust
plate in center of carrier.
2. Insert two (2) bearings and a bearing spacer into a
gear with the spacer between the bearings. Place a
thrust washer on each side of the gear and position
in a carrier opening. Slide the shaft through the car-
rier, thrust washer, bearing-gear sub-assembly and
remaining thrust washer.
PLANETARY CARRIER SERVICE
17

3. Carefully align the pin hole in the carrier with the
hole in the planet gear shaft and drive the roll pin
into place. Always use NEW roll pins.
4. Note that the roll pin is slightly recessed in the car-
rier when properly installed. With a center punch,
stake the carrier next to the pin hole as shown.
This will distort the hole so the pin will not back out.
Repeat these steps for each of the three planet
gears.
PRIMARY PLANET CARRIER
1. To service the primary planet carrier, the steps
are the same as for the output carrier except there
is only one bearing for each gear and no bearing
spacer.
NOTE: All BG8 winches have a round thrust plate
between the primary and output sun gears. In
winches with a 23:1 ratio, the plate is not contained
in the primary planet carrier. In all other ratios, the
thrust plate is captive in the carrier assembly.
18

19
NOTE: Starting late 2000, BRADEN changed the steel
brake separator discs from a splined tooth design to
a lobed design. This required a change to the motor
support and brake cylinder and the addition of a spring
spacer. A winch 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 support 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 illustrations in this section show splined
discs, all procedures are the same except where spe-
cifically 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 backup ring and the 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. Be sure brake release port
is free of contamination.
2. Check oil seal and bearing surfaces on brake cylin-
der for damage or wear.
MOTOR SUPPORT — BRAKE CYLINDER SERVICE
DISASSEMBLY