Paccar BRADEN HP125B Manual

1
BRADE
N
HP125B
HYDRAULIC RECOVERY WINCH
INSTALLATION, MAINTENANCE AND SERVICE MANUAL
LIT2430 R3
08-2011
PRINTED IN U.S.A.
PACR
WINCH DIVISION
P.O.BOX 547 BROKEN ARROW, OK U.S.A.7401
3
PHONE [phone] FAX [phone]
www.paccarwinch.com

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TABLE OF CONTENTS
FOREWORD...............................................................................................................4
GENERAL SAFETY RECOMMENDATIONS ..............................................................5
THEORY OF OPERATION..........................................................................................6
WINCH INSTALLATION..............................................................................................8
HYDRAULIC CIRCUIT..............................................................................................10
WIRE ROPE INSTALLATION....................................................................................11
PRE-DELIVERY CHECK LIST..................................................................................12
WINCH OPERATION ................................................................................................12
DRUM CLUTCH OPERATION..................................................................................14
AUXILIARY RIGGING...............................................................................................17
PREVENTIVE MAINTENANCE.................................................................................18
RECOMMENDED PLANETARY GEAR OIL..............................................................20
TROUBLESHOOTING ..............................................................................................21
SERVICE PRECAUTIONS........................................................................................24
RECOMMENDED BOLT TORQUE...........................................................................24
WINCH DISASSEMBLY............................................................................................26
HP125B UPPER LEVELASSEMBLY........................................................................28
PLANETARY CARRIER SERVICE............................................................................31
INTERMEDIATE PLANET CARRIER SERVICE.......................................................32
FINAL PLANET CARRIER SERVICE........................................................................33
OVER-RUNNING CLUTCH SERVICE......................................................................34
BRAKE CYLINDER SERVICE ..................................................................................35
HP125B ROTATION CHANGE..................................................................................37
WARNING – This emblem is used to warn against haz-
ards and unsafe practices which could result in severe
personal injury or death if proper procedures are not
followed.
CAUTION – This emblem is used to warn against po-
tential or unsafe practices which could result in person-
al injury or product or property damage if proper proce-
dures are not followed.
CAUTION
Safety Informational callouts used in this manual include:

4
FOREWORD
Read and understand this manual before operating or servicing your BRADEN winch. Retain this manual for future
reference.
The minimum service intervals specified are for the operating hours of the prime mover.
This manual contains installation, operation and preventive maintenance instructions for most current model BRADEN
Planetary Recovery winches.As there are many product variations, you must become familiar with your BRADEN winch
to fully benefit from the information contained within this publication.
Some illustrations in this manual may show details or attachments that may be different from your winch, and some
components may be removed for illustrative purposes.
Whenever a question arises regarding your BRADEN winch or this manual, please contact your nearest BRADEN dis-
tributor or the PACCAR Winch Division Product Support Department at:
Telephone- 1-918-251-8511
08:00-16:30 Central Time Zone, Monday thru Friday
FAX- 1-918-259-1575
www.paccarwinch.com
Provide the complete winch model and serial number when making inquiries.
Parts and Service
BRADEN provides parts and service through a network of BRADEN distributors. Parts and service are not available
directly from the PACCAR Winch Division. For the name of your nearest BRADEN distributor, consult your local phone
directory, or contact BRADEN as described above.
EXPLANATION OF MODEL NUMBER
HP 125 B - LP - 157 120/064 - 01
HP DESIGNATES HYDRAULIC PLANETARY RECOVERY WINCH
125 DESIGNATES 125,000 POUND FIRST LAYER LINE PULL
B DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
LP DESIGNATES LOW PROFILE
157 DESIGNATES TOTAL GEAR RATIO (157:1)
120/064 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT (12.0 CU IN, 6.4 CU IN/REV)
01 DESIGNATES THE DRUM OPTION
UNIT IDENTIFICATION MODEL NUMBER
AND
SERIAL NUMBER
When information is needed, always refer to
the model number and serial number. Both
are located on the top portion of brake cylin-
der assembly

5
GENERAL SAFETY RECOMMENDATIONS
Safety for operators and ground personnel is of prime con-
cern.Always take the necessary precautions to ensure the
safety of others as well as yourself. To properly ensure
safety, the prime mover and winch MUST be operated with
care and concern by the operator for the equipment. The
operator MUST also have a thorough knowledge of the
machine’s performance capabilities.
1. Read and understand ALL warning tag information,
and become familiar with ALL controls BEFORE op-
erating the winch.
2. NEVER attempt to clean, oil or perform maintenance
on a machine with the engine or prime mover running,
unless instructed to do so in this manual.
3. NEVER operate the winch controls unless you are
properly positioned at the operator’s station, you are
sure ALL personnel are clear of the work area AND
you are properly trained in the operation of the winch.
4. Assure that personnel who are responsible for hand
signals are clearly visible and that the signals to be
used are thoroughly understood by all involved.
5. Ground personnel should stay in view of the operator
and clear of the winch drum. DO NOT allow ground
personnel near a winch line under tension. A safe dis-
tanceofat least1½timesthe lengthoftheoutstretched
cable should be maintained.
6. On machines having hydraulically, mechanically and/
or cable controlled equipment or attachments, ensure
the equipment is blocked securely before servicing,
adjusting or repairing the winch. ALWAYS apply the
parking brakes before dismounting a vehicle.
7. Inspect the winch and rigging at the beginning of each
work shift. Defects should be corrected immediately.
DO NOT operate a defective winch.
8. Keep equipment in good operating condition. Perform
scheduled service and adjustments as defined in the
“Preventive Maintenance” section of this manual.
9. Anequipment warm-up procedure is recommendedfor
all start-ups, and is essential at ambient temperatures
below +40°F (5°C). Refer to the “Warm-Up Procedure”
listed in the “Preventive Maintenance” section of this
manual.
10. Check the drum clutch to be certain that the negative
draft angle is clearly evident on the clutch and clutch
plate. DO NOT use the winch if the negative draft
angles are worn straight, or if the edges of the clutch
plate are rounded or chipped.
11. External clutches on recovery winches may disengage
and drop or lose control of a load if they are NOT fully
engaged at the beginning of a lift or pull. The winch op-
erator must visually determine that the clutch is fully
engaged before lifting or pulling a load.
12. The winches described in this manual are neither de-
signed nor intended for use or application to equip-
ment used in the lifting or moving of persons.
13. DO NOT exceed the maximum pressure, PSI (kPa), or
flow, GPM (LPM), stated in the winch specifications.
14. Operate the winch at line speeds to match the job con-
ditions.
15. Protective gloves should be worn when handling wire
rope.
16. NEVER attempt to handle wire rope when the hook
end is not free. Keep all parts of body and clothing
clear of cable rollers, cable entry area of fairleads and
winch cable drum.
17. When winding wire rope on the cable drum, NEVER
attempt to maintain tension by allowing the wire rope
to slip through hands. ALWAYS use the “Hand-Over-
Hand” technique.
18. NEVER use wire rope with broken strands. Replace
damaged wire rope.
19. DO NOT weld on any part of the winch without ap-
proval of PACCAR Winch Division Engineering.
20. Use the recommended hydraulic oil and gear lubri-
cant.
21. Keep the hydraulic system clean and free of contami-
nation at all times.
22. Use the correct anchor for the wire rope and pocket in
the drum. DO NOT use knots to secure or attach the
wire rope to the drum or hook.
23. The cable anchor or ferrule is NOT intended to support
full rated load. ALWAYS maintain a minimum of five
(5) wraps on the drum. It is recommended the last five
(5) wraps of wire rope be painted bright red to serve as
a visual reminder.
24. Install guarding to prevent personnel from getting any
part of body or clothing caught at a point where the ca-
ble is wrapped onto the drum or drawn through guide
rollers or other “pinch points”.
25. Install switches or valves that will shut off power to the
winch, in locations where they can be reached by any-
one entangled in the wire rope before being drawn into
the winch drum or other “pinch point”.
26. “Deadman” controls, which automatically shut off pow-
er to the winch whenever the operator leaves his sta-
tion, should be installed whenever possible.
Failure to obey the following safety recommendations
may result in property damage, injury, or death.

6
27. NEVER allow anyone to stand or position any part of
his or her body under a suspended load.
28. 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
a failure of the wire rope and/or the winch.
29. Whenever possible, install the winch in a location that
is not immediately adjacent to a “normal” operator’s
station.
30. ALL winch controls should 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 comes into contact with or within proximity to an
electrically energized conductor.
BASIC DESCRIPTION
The winch consists of the following sub-assemblies:
1. Hydraulic motor and brake valve
2. Planetary gear reducer assembly
3. Static brake system
4. Cable drum, drum shaft and clutch
5. Base
The primary sun gear is directly coupled to the hydraulic
motor by the inner race of the brake clutch assembly. As
the motor shaft turns in the haul-in direction, the planetary
assemblies reduce the speed input by the motor to rotate
the cable drum. In the haul-in direction, the static brake
remains fully applied and the input shaft rotates freely
through the sprag clutch. When the motor is stopped, the
load attempts to rotate the winch gear train in the opposite
direction locking the brake clutch to the input shaft, allow-
ing the fully applied static brake to hold the load firm.
DUAL BRAKE SYSTEM
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
better metering characteristics for load control. It contains
a check valve to allow free oil flow to the motor in the haul-
in 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. With the control valve
lever moved toward the pay-out direction, the spool valve
remains closed until sufficient pilot pressure is applied to
the end of the spool to shift it against the spring pressure
and open a passage. After the spool valve cracks open,
the pilot pressure becomes flow dependent and modulates
the spool valve opening, controlling the pay-out speed of
the winch. See Figures 1, 2, and 3.
The static brake system has three main components for
all winches:
1. Spring-Applied, Multiple Friction Disc Static Brake
2. Hydraulic Piston and Cylinder
3. Brake Clutch Assembly
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 ensures that dy-
namic braking takes place within the brake valve, and that
little, if any, heat is absorbed by the static, friction brake.
The static friction brake is load holding brake only, and has
nothing to do with dynamic braking or the rate of descent
of a load.
The brake clutch assembly is splined to the primary sun
gear shaft between the hydraulic motor and primary sun
gear. It will allow this shaft to turn freely in the direction
to haul-in a load, and locks up to force the brake discs to
turn with the shaft in the pay-out direction. See Figures 4
and 5.
The hydraulic brake cylinder, when pressurized, will re-
lease the spring pressure on the brake discs, allowing the
discs to turn freely.
THEORY OF OPERATION

7
Motor
Control Valve
Pump
To Tank
Brake Valve
Static Brake
Medium
Pressure
Low
Pressure
High
Pressure
Figure 1
Figure 2
Figure 3
Motor
Control Valve
Pump
To Tank
Brake Valve
Static Brake
Medium
Pressure
Low
Pressure
High
Pressure
Motor
Control Valve
Pump
To Tank
Brake Valve
Static Brake
Medium
Pressure
Low
Pressure
High
Pressure
Sprag Cams
Figure 4
Static Friction Brake Applied
Permits free shaft rotation while hoisting
Hoisting
Sprag Cams
Figure 5
Static Friction Brake Applied
Load attempts to rotate shaft in opposite direction
Brake clutch locks sun gear shaft to friction brake
Stopped,
Holding
Load

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WINCH INSTALLATION
HP Series winches are configured for bed mount on a
truck with the motor end to the passenger side of the ve-
hicle and the wire rope overwound on the drum.Any other
installation arrangement will require modifications to the
winch before installation.
Headache racks or other protective structures designed
to protect the winch, truck, cab, and vehicle occupants
should be designed to enable easy access and servic-
ing of the winch. Braden recommends using a structure
designed to be easily removed should the need arise to
disassemble the winch for servicing.
1. Atank line for the hydraulic motor case drain isrequired
from the shift block tee fitting on the two-speed motor
or from the motor case drain port on the single speed
motor. Size the tank line so that backpressure in the
line is below the limits given in note number six below.
2. The winch must be mounted to a flat, rigid surface
which will not flex under load. The mounting surface
must be flat within .020 in. (.05 mm) between mount-
ing fasteners. If necessary, use shim stock to ensure
proper mounting.
3. The centerline of the cable drum must be horizontal
and mounted perpendicular to the direction of pull. The
fleet angle, or the angle created from an imaginary line
from the center of the cable drum to the load or first
sheave and from this load point back to the drum bar-
rel intersection with the drum flange, must not exceed
1½°. Fleet angles in excess of 1½° will create uneven
spooling resulting in rapid drum or wire rope wear.
4. Grade 8, or better, fasteners are recommended for
mounting fasteners.
5. The winch base angles must be mounted securely to
the vehicle frame in a manner acceptable to the ve-
hicle manufacturer. Any frame adapter brackets used
should be bolted to the winch base angles as close to
the gear housing and bearing leg assemblies as pos-
sible. This will ensure the greatest strength while mini-
mizing distortion. Consult vehicle manufacturer before
making any modifications to the vehicle frame.
6. Hydraulic lines and components to operate the winch
should be of sufficient size as to minimize the back-
pressure at the hydraulic motor work ports.
For conventional gear type motors, backpressure at
full flow should NOT exceed 100 PSI (690 kPa) for
maximum motor shaft seal life. If high backpressures
are encountered, the motor case drain can be con-
nected direct to the reservoir. For backpressures in
excess of 100 PSI (690 kPa), contact PACCAR Winch
Division Technical Support.
Winches equipped with Rineer 2-speed vane type or
piston type motors MUST be limited to 35 PSI (240
kPa) backpressure.
7. The winch directional control valve MUST be a three-
position, four-way valve without detents and with a
spring-centered motor spool, such that the valve re-
turns to the center (Neutral) position 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 nomi-
nal rating and be a full-flow type.
9. High quality hydraulic oil is essential for satisfactory
performance and long hydraulic system component
life.
Hydraulic oils having a viscosity of 150 – 300 SUS @
100°F (30 – 56 cSt @ 40°C) and a viscosity index (VI)
of 100 or greater will provide good results under normal
temperature condition. The use of oil having a high VI will
minimize cold start-up problems and reduce the length of
warm-up periods. A high VI will also minimize changes in
viscosity with corresponding changes in temperature.
NOTE: For MAGNUM series winches equipped with
Rineer vane type hydraulic motors, the hydraulic oil se-
lected MUST remain above 100 SUS @ 100°F (20 cSt @
40°C) at all operating temperatures.
Flexing or uneven mounting surfaces will produce in-
ternal winch distortion which may result in rapid com-
ponent wear, overheating, poor winch performance
or an improperly engaged drum clutch which may be-
come disengaged and result in dropped loads or loss
of load control causing property damage, severe injury
or death.
DO NOT use a control valve with any detents or latch-
ing mechanism that will hold the control valve in an ac-
tuated or running position when the operator releases
the control lever. Use of the wrong type of control valve
could lead to unintentional operation of the winch, which
could result in property damage, injury or death.
Failure to install a case drain line will result in a blown
out shaft seal on the hydraulic motor and the winch will
fill with hydraulic oil.
CAUTION

9
Maximum cold weather start-up viscosity should not ex-
ceed 5000 SUS with a pour point of at least 20°F (11°C)
lower than the minimum expected temperature.
Under continuous operating conditions the temperature of
the oil at any point in the system should not exceed 180°F
(82°C). 120°-140°F (49°-60°C) is generally considered
optimum.
In general terms; for continuous operation at ambient
temperatures 50°-110°F (10°-43°C), use SAE 20W; for
continuous operation at 10°-90°F (-12°-32°C), use SAE
10W; and for applications at ambient temperatures below
10°F (-12°C), contact the PACCAR Winch Division Prod-
uct Support Department. NOTE: The use of multi-viscosity
oils is generally not recommended.
10. Maximum air pressure of 130 psi for clutch and brake
air cylinders.

10
TYPICAL HYDRAULIC CIRCUITS
NOTE: The hydraulic circuits shown below are representative of typical HP125B winches with single and two-speed
hydraulic motors and brake valves. Options and accessory equipment may result in changes to the circuits defined.
If there are any questions regarding the hydraulic circuit, refer to the information supplied by the original equipment
manufacturer, or contact the PACCAR Winch Division Product Support Department, as previously defined. (ALWAYS
have the winch model and serial number available when contacting PACCAR Winch Division.)
2-Speed Hyd. Motor Sub-Assy Control Circuit
(”A” Port Toward Flange)
ITEM 7
WINCH
BRAKE
LOWER ITEM 13
CASE DRAIN
(CUSTOMER)
HOIST
BRAKE
VALVE
CHECK
VALVE
12V DC
SOLENOID
2-SP HYD MOTOR
2 - SPEED
SELECTOR
VALVE
P
T
TA
G
P2
P1
BR
BA
Two Speed
30 85 86 87 87A
Electric Shift Circuit
Hella 87499 Relay
(or equivalent -
12 Volt DC,
40 Amp, SPDT)
+12 VDC Power
Normally Open SPST Switch*
(Engaging Switch Shifts Motor
to High Speed) Motor
Solenoid
* DO NOT use a
momentary contact
switch. This type of
switch will return to the
open position when
released, shifting the
motor back to low speed.
12
3
1. Ground
2. Empty
3. Apply 12V DC power to shift
motor to High Speed
NOTE:
Terminals 1 and 3
may be reversed.
X
BRAKE
BR
DR
CONTROL
PUMP
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
WINCH
WINCH CONTROL CIRCUIT
EXTERNAL CASE DRAIN REQ’D
BRAKE
VALVE
VALVE
Single Speed

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WIRE ROPE INSTALLATION
Winches are rated at bare drum line pull, meaning the maximum load capability will be reached on the first layer of wire
rope. As the cable drum fills, the line pull will decrease (loss of leverage) as the line speed increases (larger circum-
ference). Therefore, it is best to install the minimum length of wire rope possible for your application so the winch will
operate on the lowest layers, delivering the maximum load capability.
Use of larger diameter wire rope will not always increase strength as the larger wire rope may be more prone to bending
fatigue failure due to the drum diameter. Consult your wire rope supplier for their recommendations regarding the best
wire rope and rigging for your application.
Winch wire rope anchors or ferrules are NOT intended to hold rated loads. Winch loads applied directly to the cable
anchor may cause the wire rope to pull free and result in sudden loss of load control and cause property damage,
injury or death. A minimum of five (5) wraps of wire rope must be left on the drum barrel to achieve rated load.
INSTALLATION OF U-BOLT TYPE CLAMPS
Prepare the end of the wire rope as recommended by the wire rope manufacturer. Pass the wire rope through the U-bolt
until the end extends 1.5 – 2 wire rope diameters beyond the clamp. Evenly tighten the U-bolt nuts until the wire rope
deforms slightly under the U-bolt and the wire rope is securely held.
INSTALLATION OF SPIRAL FERRULES
Re-useable, field installed spiral ferrules are available from PACCAR Winch Division or your wire rope supplier. These
ferrules are for use with six (6) strand, IWRC (Independent Wire Rope Core) type wire rope. Refer to cable capacity
specifications on page 14.
Insert wire rope through the small diameter end of the
ferrule. Spread the strands and insert the spiral wedges
between the strands and the core. Lay the strands in the
individual grooves in the spiral wedges.
Tap the wedges and wire rope end into the ferrule, leav-
ing approximately 3/8 in. (10 mm) extending from the top.
The first load applied to the winch will seat the wire rope
and wedges securely in the ferrule.
STEP ONE STEP TWO

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PRE-DELIVERY CHECKLIST
Before releasing the winch to the end user, the following checklist should be reviewed and each item verified.
INSPECTION
Check gear oil and refill as needed.
Lubricate all grease fittings.
Inspect winch mounting fasteners and torque
as required.
Check for loose or missing bolts, pins, keepers
and cotter pins. Replace as needed.
Check controls - adjustment and operation.
Verify winch operating pressure and flow.
Verify proper brake band operation.
Inspect for external oil leaks. Repair as needed.
✔
WINCH OPERATION
The following warnings and instructions are basic to safe
winch operation. Please read them carefully and follow
them any time the winch is in use. These instructions are
provided in addition to any information provided by the
Original Equipment Manufacturer. Equipment operators
should be completely familiar with the overall operation of
the vehicle to which the winch is installed. If you have any
questions concerning the safe operation of this winch or
the equipment to which it is mounted, contact the equip-
ment manufacturer that installed the winch, or the PAC-
CAR Winch Division Product Support Department, as pre-
viously described.
The winch directional control valve, described earlier,
controls haul-in and pay-out functions of the winch. Mov-
ing the control lever in the haul-in direction will cause the
winch to pull in the load toward the vehicle. Moving the
control lever in the pay-out direction will cause the winch
to feed wire rope off the drum.
Two-speed winches are equipped with a two-speed hy-
draulic motor and solenoid operated shift valve, elimi-
nating the need to add extra valves to allow two-speed
operation. A 12V DC toggle switch is required to actuate
the solenoid. The motors are spring-biased to low-speed
mode. Actuating the toggle switch will energize the sole-
noid, allowing pilot pressure to act on the shift spool in the
motor, shifting the motor to high-speed mode.
Ground personnel MUST stay in view of the operator
and clear of the load and cable drum at all times. DO
NOT allow personnel near the winch line while under
tension. DO NOT allow personnel near the cable drum
during winch operation. DO NOT allow personnel to be
in line with the load. DO NOT allow personnel to stand
under a suspended load. A safe distance of 1½ times
the working length of the cable should be maintained by
ground personnel. A broken wire rope and/or lost load
may cause property damage, injury or death.
Failure to properly warm up the winch, particularly un-
der low ambient temperature conditions, may result in
temporary brake slippage due to high back pressures
attempting to release the brake, which may result in
property damage, injury or death.
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, 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 ambi-
ent temperature is also critical to reliable brake opera-
tion. Testing indicates that excessively heavy or thick
gear oil may contribute to intermittent brake slippage.
Make certain that the gear oil viscosity used in your
winch is correct for your prevailing ambient tempera-
ture.

13
NOTE: During typical winching operations, it is generally
recommended to operate the vehicle engine at high idle
RPM and use the winch control valve to control oil flow,
and thus winch line speed as needed.
Position the vehicle such that the centerline of the winch
drum is perpendicular to the winch load whenever pos-
sible. The wire rope fleet angle must not exceed 1½°. If
the fleet angle exceeds 1½°, the wire rope will not spool
correctly eventually resulting in damaged wire rope and
prematurely worn winch components.
Either power out the wire rope using the hydraulic system,
or disengage the drum clutch and pull the wire rope off the
drum by hand (freespool).
Securely attach the wire rope to the load in such a manner
as to avoid damaging the load or rigging. Fully engage the
drum clutch (see Drum Clutch Operation).
Ensure the band brake is released and engage the winch
control lever. Operate the winch controls smoothly to avoid
“jerking” the load and maintain good load control.
Observe the winch operation carefully to make certain all
ground personnel remain clear of the wire rope and load,
and that the load does not shift, which may require reposi-
tioning the wire rope or the vehicle.
Once the load is positioned properly, move the lever back
to neutral to stop the winch. Secure the load as required.
Pay out just enough wire rope to remove all tension on the
cable drum. Disengage the drum clutch and disconnect
the wire rope from the load.
Re-engage the drum clutch. Ensure the drum clutch is
fully engaged.
Wind the wire rope onto the cable drum while maintaining
the minimum fleet angle and sufficient tension to allow the
wire rope to spool properly, being careful to keep hands
and clothing away from the cable drum and/or fairlead roll-
ers.
The band brake on the clutch end of the cable drum
is used to control drum overspin or “birdnesting” ONLY
when operating in freespool mode with the drum clutch
disengaged. DO NOT attempt to control any winch load
using the band brake. Attempting to control or hold any
load with the band brake may result in loss of load,
property damage, injury or death.
When operating the winch in the pay-out direction,
ALWAYS bring the load to a complete stop BEFORE
attempting to shift the motor into high speed mode.
“Shifting-on-the-fly”, or attempting to shift while the load
is still moving, will result in pressure intensification be-
tween the brake valve and the hydraulic motor, which
can damage the motor, brake valve, or other hydraulic
components. Failure of these components may cause
loss of load control which could lead to personal injury
or death.

14
DRUM CLUTCH OPERATION
Visually ensure that the drum clutch is fully engaged and
the clutch control lever is at full travel or locked in its de-
tent BEFORE attempting to use the winch under load.
NOTE: Actuation of the drum clutch is typically accom-
plished using either air cylinder controls or some form of
mechanical control (i.e. push-pull cable, mechanical link-
ages, etc.). Any means used to control the drum clutch
must allow full travel of the lever without binding the clutch,
or should include locking detents at each position.
To ENGAGE the drum clutch:
1. Insure the winch motor is stopped and there is no load
on the wire rope. The prime mover must be stopped in
neutral and the parking brake must be set.
2. Move the clutch control lever fully into the “Engage”
position. If the lever will not settle into the fully engaged
position, the clutch is not fully engaged. At this point,
it may be necessary to MANUALLY rotate the cable
drum slightly in either direction to align the clutch lugs,
while continuing to hold slight pressure on the control
lever. Once the clutch lugs are properly aligned, the
clutch should easily engage fully with the clutch plate
on the cable drum.
To DISENGAGE the drum clutch:
1. Insure the winch motor is stopped and there is no load
on the wire rope. The prime mover must be stopped in
neutral and the parking brake must be set.
2. Move the control lever fully into the “Disengage” posi-
tion. If the control lever has any resistance to shift, the
cable drum may be MANUALLY rotated in the direction
to haul-in wire rope to relieve the self-energized load
on the clutch lugs and allow the clutch to properly dis-
engage.
NOTE: If your application involves lifting loads and does
not require the clutch to be disengaged, it is strongly rec-
ommended that the drum clutch be mechanically blocked
in the fully engaged position to avoid accidental disen-
gagement of the clutch under load.
DO NOT move the load, the winch, or the winch plat-
form BEFORE making certain the drum clutch is set to
“ENGAGE” and the clutch is fully engaged. A partially
engaged drum clutch may “jump out” of engagement. A
load on the winch line may prevent a partially engaged
clutch from disengaging, but any change in load condi-
tion may allow the clutch to become disengaged unex-
pectedly. This action may cause a loss of load control
which could result in property damage, injury or death.
Accidental disengagement of the clutch while lifting or
lowering may cause a loss of load control, which could
lead to property damage, injury or death.
DO NOT attempt to engage the drum clutch while the
cable drum is rotating. DO NOT attempt to disengage
the drum clutch with a load applied to the wire rope. DO
NOT use “cheaters” to extend the shift lever length or
other means to apply undue force on the lever. Engag-
ing or disengaging the drum clutch while the cable drum
is rotating or under load, or the use of undue force, may
result in damage to the drum clutch components. Dam-
aged drum clutch components may allow the drum
clutch to become disengaged under load, and cause a
loss of load control, which could result in property dam-
age, injury or death.

15
PROCEDURE FOR DETERMINING THE
CONDITION OF CLUTCH LUGS:
There is normally a “negative draft” angle on the load bear-
ing faces of the clutch and clutch plate to prevent clutch
disengagement under load. In addition to visual inspec-
tion of the clutch surfaces, the following procedure may be
used to ensure that the clutch cannot inadvertently disen-
gage under load:
1. Fully engage the clutch (as previously described).
2. Power approximately 10 ft. (3 m) of wire rope off the
drum.
3. Power in very slowly while holding slight pressure on
the wire rope to eliminate any slack in the wire rope
and the power train. This slight pressure and no-slack
condition must be maintained throughout this proce-
dure.
4. Stop the winch with the clutch fully engaged, leaving
approximately 3 ft. (1 m) of wire rope extended beyond
the drum.
5. Mark one line on or near the tip of the drum flange
nearest the gear housing, and a second line on the
gear housing adjacent to the first.
6. While maintaining tension on the wire rope, SLOWLY
disengage the drum clutch and observe the marked
lines. The drum flange should move 1/16 – 5/16 in.
(1.5 – 8 mm) in the haul-in direction. If the drum moves
LESS than 1/16 in. (1.5 mm), or if the drum rotates
in the opposite direction, the winch should be disas-
sembled and the clutch components visually inspected
for wear and/or damage and replaced as needed. The
drum clutch should be routinely inspected using this
procedure.
PARTIALLY ENGAGED CLUTCH
DANGEROUS!
DO NOT OPERATE WINCH
FULLY DISENGAGED CLUTCH
WIRE ROPE MAY BE PULLED OFF OF WINCH CABLE DRUM
BY HAND.
BEARING
LEG
Clutch fully
seated against
bearing leg
CLUTCH
ENGAGED CLUTCH
WINCH MAY BE OPERATED UNDER LOAD.
CLUTCH
DRUM
Clutch fully
seated against
drum

16
The Warning Label shown above is available through all Braden dealers. Have your
dealer order part number 100600. It is a self-adhesive weather-resistant vinyl label
that we recommend be installed near the winch controls of all Braden winches with
a drum clutch.

17
AUXILIARY RIGGING
Snatch Block
An auxiliary sheave, or snatch block, may increase the
versatility of the winch, and is highly recommended in the
following applications:
• When fleet angles exceed 1½°.
• When winch loads exceed the safe winch or wire rope
capacity.
• When slower line speeds are required for precise load
control.
Securely attach the snatch block to the anchor point fol-
lowing the block manufacturer’s recommendations.
Tree Protector
If the wire rope or a snatch block must be anchored to a
tree or other structure for recovery purposes, a heavy ny-
lon web sling of proper capacity rating should be used to
avoid causing serious damage to the tree.
OIL DRAIN
-8 O-RING PLUG
MOTOR DRAIN PORT
SAE -4 JIC
HOIST PORT
SAE -16 O-RING
BOSS PORT
12 DC SHIFT SOLENOID VALVE
FOR 2-SPEED OPERATION
HOIST
OIL LEVEL
-8 O-RING PLUG
LOWERING PORT
SAE -16 O-RING
BOSS PORT
OIL FILL & VENT
-8 O-RING PLUG
CLUTCH DISENGAGE
PORT
CLUTCH ENGAGE
PORT
BRAKE ENGAGE
PORT
Apoorly attached or undersized snatch block may break
loose from the anchor point and cause a sudden loss of
load control, which may result in property damage, in-
jury or death.
NOTES:
1. OIL CAPACITY: 12.5 PTS.
2. 1.25 CABLE FERRULE (29429) SUPPLIED WITH WINCH. FERRULES
FOR OTHER CABLE SIZES MAY BE PURCHASED SEPARATELY.
1.00 CABLE FERRULE (29427)
1.13 CABLE FERRULE (29428)
3. MAXIMUM AIR PRESSURE OF 130 PSI FOR CLUTCH AND BRAKE
CYLINDER.

18
A regular program of preventive maintenance for your
winch is required to minimize the need for emergency ser-
vicing and will promote safe, reliable winch operation.
The user of PACCAR Winch products is responsible for
winch inspection, testing, operator training and the main-
tenance noted below, with frequency dependent on the
severity of the winch duty cycle and the thoroughness of
the preventive maintenance program.
Field experience, supported by engineering testing, indi-
cate the two service procedures listed below are the most
critical to safe, reliable winch operation and MUST be ob-
served.
• Regular Gear Oil Changes
• Use of Proper Gear Oil – recommended type for pre-
vailing ambient temperatures and additives.
Recommended Preventive Maintenance Intervals:
Daily (when winch is in use)
1. Inspect the wire rope and rigging for broken wires or
other damage, as recommended by the wire rope and
rigging manufacturer(s).
2. Carefully inspect the drum clutch and adjust the shift
mechanism as required to ensure the clutch can be
fully engaged and disengaged. (Refer to “Drum Clutch
Operation”.)
3. Check for external oil leaks – both hydraulic and gear
oil – and repair as required. This is extremely important
due to the accelerated wear that can be caused by in-
sufficient lubrication within the winch. Gear oil must be
maintained at the proper level. Use only recommended
lubricants. (See “Recommended Lubricants” in this
manual.)
4. Check hydraulic motor plumbing for damage, such as
chafed or deteriorating hoses, and repair as needed.
5. Visually inspect for loose or missing bolts, pins, keep-
ers or cotter pins, and tighten or replace as needed.
Weekly
1. Perform all daily inspections.
2. Check gear oil level, and refill as needed with the rec-
ommended lubricant.
3. Lubricate the grease fittings on the bearing leg, cable
drum ends and clutch. On some winches, you will have
to disengage the clutch to gain access to the drum
bushing grease fitting on the clutch end of the drum.
Use a high-quality, moly-type grease, with a rating of
NLGI-2 or better.
4. Inspect the gear housing breather to ensure the fitting
is not clogged with dirt or grease. Clean or replace as
needed.
5. Inspect all winch mounting fasteners. Retighten or re-
place as required.
6. Inspect any structural welds, and repair as needed.
Monthly
1. Perform all daily and weekly inspections.
2. Inspect the drum clutch and clutch plate to ensure the
negative draft angle is clearly evident. Replace worn
clutch components as required. (Refer to “Drum Clutch
Operation” in this manual.)
3. Check the hydraulic system relief valve setting to en-
sure proper performance and protection of hydraulic
components. Adjust or repair as required.
4. Inspect hydraulic system filters and strainers. Follow
the system manufacturer’s service recommendations
for repair or replacement.
5. Inspect the band brake for wear or chipping away of
the brake lining material. Adjust or replace as needed.
Yearly
1. Perform all daily, weekly and monthly inspections.
2. Replace gear oil.
NOTE: If the winch is used in excess of 40 hours per week,
the gear oil should be changed every 6 months.
NEVER attempt to service a winch with the prime mover
running as accidental engagement may result in prop-
erty damage, injury or death. Make certain ALL load
is removed from the wire rope and winch cable drum
BEFORE servicing the winch. A loaded wire rope may
rapidly and unexpectedly unspool, resulting in property
damage, injury or death.
PREVENTIVE MAINTENANCE
Hot oil can cause severe injury. Make certain the oil has
cooled to a safe temperature before servicing.
DO NOT use the winch if the negative draft angle on
the clutch is not present or is worn straight, or if the
clutch plate edges are rounded or chipped. A defective
drum clutch may suddenly become disengaged causing
a loss of load control, which may result in property dam-
age, injury or death.

19
Inspection Performed Daily Weekly Monthly Yearly
Inspect wire rope and rigging XXXX
Inspect for external oil leaks XXXX
Check for damaged hoses / lines XXXX
Check gear oil level / refill XXX
Lubricate grease fittings XXX
Inspect breather fitting XXX
Inspect structural welds XXX
Check hydraulic relief valve setting XX
Inspect hydraulic filters / strainers XX
Inspect band brake XX
Replace gear oil
(1) (2)
X
NOTES:
X
Check for loose or missing bolts,
pins, keepers, or cotter pins
X
X
X
X
Inspect drum clutch and shift
mechanism for proper engagement
X
X
X
X
X
(2) For winch operation in excess of 40 hours per week, oil changes should occur every 6
months instead of yearly.
(1) Change the gear oil after the first 100 hours or 30 days of use, whichever occurs first.
Inspection Interval
Inspect winch mounting fasteners -
torque as required
X
X
X
Inspect negative draft angle on drum
clutch and clutch plate
HP50A
HP50B
7.7/3.8
Motor
HP50B
8.0/4.0
Motor
HP70A
HP75A
8.9/4.5
Motor
HP75A
13.0/6.5
Motor
HP125A HP125B HP160A
Rated Bare Drum Line Pull
50,000 Lb
(22,680 kg)
50,000 Lb
(22,680 kg)
50,000 Lb
(22,680 kg)
70,000 Lb
(31,750 kg)
75,000 Lb
(34,110 kg)
75,000 Lb
(34,110 kg)
125,000 Lb
(56,700 kg)
125,000 Lb
(56,700 kg)
160,000 Lb
(72,580 kg)
Bare Drum Line Speed - Single Speed
41 fpm
(12 mpm)
57 fpm
(17 mpm)
Bare Drum Line Speed - Low Speed
23 fpm
(7 mpm)
31 fpm
(9 mpm)
26 fpm
(8 mpm)
24 fpm
(7 mpm)
26 fpm
(8 mpm)
27 fpm
(8 mpm)
21 fpm
(6 mpm)
21 fpm
(6 mpm)
14 fpm
(4 mpm)
- High Speed
53 fpm
(16 mpm)
62 fpm
(19 mpm)
53 fpm
(16 mpm)
55 fpm
(17 mpm)
55 fpm
(17 mpm)
54 fpm
(16 mpm)
47 fpm
(14 mpm)
47 fpm
(14 mpm)
29 fpm
(9 mpm)
Wire Rope Capacity -
3
/
4
" (20 mm)
480 ft
(146 m)
480 ft
(146 m)
480 ft
(146 m)
-
7
/
8
" (22 mm)
350 ft
(106 m)
350 ft
(106 m)
350 ft
(106 m)
327 ft
(99 m)
327 ft
(99 m)
327 ft
(99 m)
- 1" (25 mm)
250 ft
(76 m)
250 ft
(76 m)
250 ft
(76 m)
226 ft
(69 m)
226 ft
(69 m)
226 ft
(69 m)
327 ft
(99 m)
327 ft
(99 m)
- 1
1
/
8
" (29 mm) 200 ft
(55 m)
209 ft
(63 m)
209 ft
(63 m)
224 ft
(68 m)
224 ft
(68 m)
- 1
1
/
4
" (32 mm) 209 ft
(63 m)
209 ft
(63 m)
390 ft
(118 m)
- 1
3
/
8
" (35 mm)
365 ft
(110 m)
- 1
1
/
2
" (38 mm) 256 ft
(80 m)
Overall Gear Ratio 98:1 104:1 104:1 81:1 122:1 88:1 156:1 156:1 206:1
Maximum Pressure - Single Speed Motor
2700 PSI
(18,600 kPa)
2800 PSI
(19,300 kPa)
- 2-Speed Motor
2700 PSI
(18,600 kPa)
2400 PSI
(16,548 kPa)
2000 PSI
(13,790 kPa)
2600 PSI
(17,900 kPa)
2670 PSI
(18,410 kPa)
2400 PSI
(16,548 kPa)
2600 PSI
(17,900 kPa)
2600 PSI
(17,900 kPa)
2500 PSI
(17,200 kPa)
Maximum Flow - Single Speed Motor
60 GPM
(227 LPM)
110 GPM
(416 LPM)
- 2-Speed Motor
40 GPM
(151 LPM)
60 GPM
(227 LPM)
50 GPM
(190 LPM)
60 GPM
(227 LPM)
60 GPM
(227 LPM)
60 GPM
(227 LPM)
85 GPM
(322 LPM)
85 GPM
(322 LPM)
65 GPM
(246 LPM)
Winch Weight - Single Speed Motor
1,040 LB
(472 kg)
1,475 LB
(670 kg)
- 2-Speed Motor
1,075 LB
(488 kg)
990 LB
(450 kg)
990 LB
(450 kg)
1,500 LB
(680 kg)
1,340 LB
(608 kg)
1,340 LB
(608 kg)
1,800 LB
(817 kg)
1,785 LB
(810 kg)
3,850 LB
(1746 kg)
Gearbox Oil Capacity (pints)
14
(6.6 L)
8
(3.7 L)
8
(3.7 L)
20
(9.5 L)
11
(5.2 L)
11
(5.2 L)
12.5
(5.9 L)
12.5
(5.9 L)
28
(13.3 L)
SPECIFICATIONS

20
RECOMMENDED PLANETARY GEAR OIL
Field experience, supported by engineering endurance tests, indicates the use of the proper gear oil and a program
of regular preventive maintenance will help provide extended gear train life and reliable winch brake performance. For
this reason, BRADEN has published the following specifications to assist in determining which lubricant is best suited
to your application.
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.
Unless otherwise specified, it is recommended that the gear oil be changed after the first one hundred (100) hours
or thirty (30) days of machine operation, then every one thousand (1,000) hours or twelve (12) months, whichever
occurs first. The gear oil should also be changed whenever the ambient temperature changes significantly and an oil
from a different temperature range would be more appropriate.
A warm-up procedure is recommended at each start-up and is essential at ambient temperatures below +40°F (4°C).
The prime mover should be run at its lowest recommended RPM with the hydraulic winch control valve in neutral al-
lowing sufficient time to warm up the system. The winch should then be operated at low speeds, forward and reverse,
several times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear sets.
If you have any questions regarding this bulletin or your BRADEN planetary winch, please contact the BRADEN
Product Support Department at 1-918-251-8511, Monday through Friday from 08:00 to 16:30 hours CST, or by fax at
1-918-259-1575.
Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slippage
which could result in property damage, severe personal injury or death. Some gear lubricants contain large amounts
of EP (extreme pressure) and anti-friction additives which may contribute to brake clutch slippage or damage to brake
friction discs or seals. Oil viscosity with regard to ambient temperature is also critical to reliable brake clutch opera-
tion. Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent brake clutch slippage.
Make certain that the gear oil viscosity used in your winch is correct for your prevailing ambient temperature.
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
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
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
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 properly warm up the winch, particularly under low ambient temperature conditions, may result in temporary
brake slippage due to high back pressures attempting to release the brake, which could result in property damage,
severe personal injury or death.