Paccar Braden TR20A Manual

TR20A
}
First 2 numbers indicate
year manufactured
WRITE WINCH SERIAL NUMBER BELOW
For serial number location see page 3
©2019 PACCAR Inc.
All rights reserved
LIT2736
February 2019
Printed in USA
Visit our Website 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.
TR20A
Recovery Winch
INSTALLATION AND SERVICE MANUAL

2
FOREWORD
Foreword ..................................................................................................................... 2
Model Identification ..................................................................................................... 3
Explanation of Model Number..................................................................................... 3
Glossary ...................................................................................................................... 4
General Safety Recommendations ............................................................................. 5
Theory of Operation .................................................................................................... 7
Free-spool Clutch Instructions..................................................................................... 9
Winch Installation ...................................................................................................... 10
Wire Rope Installation ............................................................................................... 11
Preventive Maintenance............................................................................................ 11
Troubleshooting......................................................................................................... 14
TR20A Cross-section ................................................................................................ 18
TR20A Components.................................................................................................. 19
Winch Disassembly ................................................................................................... 20
Brake Service ............................................................................................................ 22
Carrier Service .......................................................................................................... 24
Winch Assembly........................................................................................................ 24
Recommended Fastener Torque .............................................................................. 25
Metric Conversion Table ........................................................................................... 27
Table of Contents
Managing Waste
PACCAR Winch believes in a life-cycle approach to our products. We encourage best practices regarding “Going
Green” — making environmentally responsible decisions to “reduce, reuse, and recycle.”
• At the end of the winch’s useful life, it is highly recommended to drain and recycle any oil remaining in the equipment.
• Please use a metal recycler for winch disposal to reduce landll waste.
The U.S. Environmental Protection Agency has developed required practices, called “management standards,” for busi-
nesses that handle used oil and metal wastes. Specic guidelines are available at the EPA and API websites as well as
your state’s environmental agency website:
• https://www.epa.gov/
• http://recycleoil.org/
Read this entire publication and retain it for future reference.
For inquiries regarding your BRADEN TR20A recovery winch or this publication, please contact PACCAR Winch Techni-
cal Support at 918-251-8511, Monday through Friday, 8:00 a.m. to 4:30 p.m. (CST).
The following service manual has been prepared to provide maintenance information for the BRADEN TR20A recovery
winch.
Some illustrations in this manual may show details or attachments di󰀨erent from your winch. Some components have
been removed for illustrative purposes. Drawings in this manual represent a typical unit sold through our distribution
channels. Some winches, particularly those sold directly to original equipment manufacturers, may di󰀨er in appearance
and options.

3
Model numbers and serial numbers are stamped on a
nameplate located to the left of the hydraulic motor.
Always refer to the model number and serial number when
requesting information or service parts.
MODEL IDENTIFICATION
EXPLANATION OF MODEL NUMBER
TO ORDER:
1. List model and serial numbers of the winch.
2. Refer to cross-section drawing (exploded view), select the component(s) needed, and note item number.
3. Find item number on parts list. Show part number, description, and quantity required on your order.
4. Refer to Parts List and show price for each component or assembly.
TTowing/trailer application
RRecovery application
20 20,000-pound rst-layer line pull
AModel series related to design changes
29 Gear ratio
080 Motor displacement/size
01 Drum type
TCable tensioner; T= tension plate, R= tension roller
LA Left-hand (L) or right-hand (R) assembly
LM Low mount
T R 20 A - 29 - 080 - 01T - LA - LM
APPLI-
CATION
MAX
RATING
MODEL
SERIES
GEAR
RATIO
MOTOR
DISPLACE-
MENT / SIZE
LEFT
ASSY
APPLI-
CATION
LOW
MOUNT
DRUM
TYPE

4
Brake Valve — A hydraulic counterbalance valve should be connected to the reel-in port of the hydraulic motor. It allows
oil to ow freely through the motor in the winching direction. When oil pressure tries to rotate the motor in the reel-out
direction, the brake valve blocks the ow of oil out of the motor until the internal static brake is released. It then controls
reel-out speed based on the load and ow 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.
Sprag or Overrunning Clutch — A mechanical one-way clutch on the input shaft of the winch, 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, then immediately locks the winch gear train to the mechanical brake when the winch is stopped, holding
the load in place.
Static, Mechanical, or Load-holding Brake — A multidisc, spring-applied, hydraulically released brake that works
together with the sprag clutch to hold a load. This brake is not designed to stop a load being lowered, but holds the load
in place when the winch is not in operation.
First-layer Line-pull Rating — The maximum rated line pull (in pounds or kilograms) on the rst layer of cable. The
maximum rating for any particular winch 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 rst layer of
cable. Certain combinations of drum, gear ratio, motor, and hydraulic ow may reduce or increase this rating.
D/d Ratio — The ratio of cable drum barrel diameter (D) to wire/synthetic rope diameter (d). Current SAE standards
require a minimum of 8:1.
EXAMPLES:
If you know the cable diameter you want to use, multiply it by 8 to get the MINIMUM cable drum barrel diameter (such
as 1/2-inch wire rope X 8 = 4 inches — this is the minimum winch barrel diameter).
If you know the barrel diameter, divide it by 8 to get the MAXIMUM wire/synthetic rope diameter.
(such as 8-inch barrel diameter / 8 = 1 — this is the maximum wire/synthetic rope diameter)
Cable Drum Dimensions —
a
b
First sheave
or load
First sheave or load should be cen-
tered between the drum anges, so
that angles A and B are equal.
Angles A and B should be a minimum
of 1/2 degree and a maximum of 1-1/2
degrees.
Wrap — A single coil of wire/synthetic rope wound on a drum.
Layer — All wraps of wire/synthetic rope on the same level between drum anges.
Freeboard — Amount of drum ange that is exposed radially past the last layer of wire/synthetic rope. Minimum freeboard varies
with the regulatory organization. ASME B30.5 requires 1/2-inch minimum freeboard. SAE J706 requires minimum freeboard of 0.7d,
where d is rope diameter.
Grooved Drum — A cable drum with grooves on the barrel to ensure the
rst 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.
Barrel
Diameter
Flange
Diameter
Distance
Between
Flanges
Fleet Angle — The angle between the wire/synthetic rope position at the extreme end wrap on a drum, and a line drawn
perpendicular to the axis of the drum, through the center of the nearest xed sheave or load attachment point.
GLOSSARY

5
1. Be certain equipment (boom, sheave blocks, pendants,
etc.) is either lowered to the ground or blocked securely
before servicing, adjusting, or repairing winch.
2. Be sure personnel are clear of work area BEFORE op-
erating winch.
3. Read all warning and caution tags provided for safe
operation and service of the winch and become familiar
with the operation and function of all controls before
operating the winch.
4. Inspect rigging and winch at the beginning of each work
shift. Defects should be corrected immediately. Do not
operate a winch with defects.
5. Keep equipment in good operating condition. Perform
scheduled servicing and adjustments listed in the Pre-
ventive Maintenance section of this manual.
6. An equipment warm-up procedure is recommended for
all start-ups and essential at ambient temperatures be-
low +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, bar) or ow
(GPM, lpm) stated in the winch specications found in
the specic sales brochure.
8. Operate winch line speeds to match job conditions.
9. Protective gloves should be worn when handling wire/
synthetic rope.
10. Never attempt to handle wire/synthetic rope when the
hook end is not free. Keep all parts of body and cloth-
ing clear of cable rollers, cable entry area of fairleads,
sheaves, and winch drum.
11. When winding wire/synthetic rope on the winch drum,
never attempt to maintain tension by allowing wire rope
to slip through hands. Always use hand-over-hand tech-
nique.
12. Never use wire/synthetic rope with broken strands. Re-
place wire/synthetic rope that is damaged. Refer to wire
rope supplier manual.
13. Do not weld on any part of the winch without approval
from PACCAR Winch Engineering.
14. Use recommended hydraulic oil and gear lubricant.
15. Keep hydraulic system clean and free from contamina-
tion at all times.
16. Use correct cable anchor for wire/synthetic rope and
pocket in drum.
17. Do not use knots to secure or attach wire/synthetic rope.
18. The BRADEN-designed wire/synthetic rope anchors are
not intended to support the rated load. ALWAYS main-
tain a minimum of ve wraps of wire rope on the drum or
a minimum of eight wraps of synthetic rope on the drum.
It is recommended that the last ve wraps of wire rope or
last eight wraps of synthetic rope be painted bright red to
serve as a visual reminder.
19. Never attempt to clean, oil or perform any maintenance
on a machine with the engine or prime mover running,
unless instructed to do so in this manual.
20. Never operate winch controls unless you are properly
positioned at the operators station and you are sure per-
sonnel are clear of the work area.
21. Assure that personnel who are responsible for hand sig-
nals are clearly visible and that the signals to be used
are thoroughly understood by everyone.
22. Ground personnel should stay in view of the operator
and clear of the winch drum. Do not allow ground per-
sonnel near wire/synthetic rope under tension. A safe
distance of 1-1/2 times the working length of the 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 o󰀨 power to the
winch, in locations where they can be reached by any-
one entangled in the rope before being drawn into the
winch or any pinch point.
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 o󰀨ered as a general safety guide. Local rules and regulations will also apply.
GENERAL SAFETY RECOMMENDATIONS

6
GENERAL SAFETY RECOMMENDATIONS
Safety Informational callouts used in this manual include the following:
25. Deadman controls, which automatically shut o󰀨 power
to the winch whenever the operator leaves his station
or releases the winch 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
rope, winch, or vehicle structure.
28. Whenever possible, install the winch in a location that is
not immediately adjacent to a normal operator’s station.
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.
CAUTION
!
!
!WARNING !
29. All winch 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/synthetic rope
come in contact with or within proximity to an electrically
energized conductor.
30. Before operating the winch, be sure ALL safety proce-
dures for the equipment or vehicle the winch is mounted
on are properly followed and/or in place.
ADDITIONAL REFERENCE
PUBLICATION
For cross-section diagrams and
complete list of components, please
refer to LIT2732: Parts List for TR20A
recovery winches.

7
THEORY OF OPERATION
DESCRIPTION OF WINCH
The winch consists of three basic assemblies:
1. Hydraulic motor, brake valve block and counter- balance
cartridges
2. Static brake assembly
3. Cable drum assembly
The hydraulic motor is bolted to the motor adapter which, in
turn, is bolted to the brake cylinder end plate of the winch.
The cable drum assembly is supported on each end by an
antifriction ball bearings. The ball bearings are located in
the end plates and the end plates are connected by two tie
plates. The dual stage planetary reduction multiples motor
torque and delivers it to the drum. The cable drum features
an anchor hole with two setscrews for winding cable onto the
drum in either direction.
DESCRIPTION OF DUAL BRAKE SYSTEM
Dynamic Brake
The dynamic brake system consists of two basic compo-
nents:
1. Brake valve block and counterbalance cartridges
2. Hydraulic motor
The counterbalance cartridges are installed into a brake
valve block which also contains an internal shuttle valve.
The shuttle valve directs hydraulic pressure to the brake re-
lease port of the winch when the winch is operated in either
direction.
Static Brake
The static brake consists of three basic components:
1. Spring-applied, multiple friction disk brake pack
2. Solid brake coupling
3. Hydraulic brake cylinder and spring plate
The brake pack consists of alternately stacked friction
and steel brake disks. The steel brake disks are externally
splined to the motor adapter and cannot rotate. The friction
disks are internally splined to the brake coupling. When the
winch is not being operated, spring force compresses the
brake pack and locks the brake coupling to the motor adapt-
er, preventing the gear train or cable drum from rotating in
either direction. The solid brake coupling makes the static
brake e󰀨ective both directions. This means the static brake
must be released before the winch can operate in either the
hoist or lower direction.
The static brake is released by pilot pressure applied to the
brake cylinder. It releases at a pressure lower than that re-
quired to open the pilot-operated counterbalance cartridge.
This sequence assures that dynamic braking is accom-
plished by the counterbalance cartridge and that little heat, if
any, is absorbed by the friction brake.
The static or friction brake is primarily a load-holding brake
and will provide dynamic braking only during extremely slow
operation when there is insu󰀩cient ow and pressure to
open the counterbalance cartridge.

8
THEORY OF OPERATION
HOIST
LOWER
OPERATION OF DUAL BRAKE SYSTEM
Because the static brake on this winch is e󰀨ective both di-
rections, the brake must be hydraulically released to operate
the winch in either the hoist or lower direction.
This also means cable can be wound onto the drum in either
direction without any modications to the winch.
When the winch is powered in either direction, the motor
cannot rotate until su󰀩cient pilot pressure is present to open
the correct counterbalance cartridge. The friction brake
will completely release at a pressure lower than required
to open the counterbalance cartridge. The extent to which
the cartridge opens will determine the amount of oil that can
ow through it and the speed at which the cable drum will
turn. Increasing the ow of oil to the winch motor will cause
the pressure to increase and the opening in the cartridge to
enlarge, speeding up the cable drum. Decreasing this ow
causes the pressure to drop and the opening in the cartridge
to decrease, slowing down the cable drum.
When the control valve is returned to the neutral or center
position, pressure will rapidly drop and the counterbalance
cartridge will close, stopping the load. The friction brake will
engage and hold the load after the cartridge is closed.

9
PROCEDURE FOR SHIFTING
MANUAL CLUTCH
A. To Disengage Clutch (Activate Free-spool)
1. Ensure winch motor is not running and the cable drum
is not loaded. The prime mover (hydraulic supply) is
stopped in neutral with parking brake set.
2. Lift clutch shift handle to disengage clutch. If shift handle
has resistance to shift, cable drum may be manually ro-
tated in the direction to payout cable relieving the self-
energized load and allowing the shift.
FREE-SPOOL CLUTCH INSTRUCTIONS
Visually check that clutch and clutch handle are fully engaged, before operating the winch drum under load. Do not
attempt to move the clutch shift handle with a load on the cable.
Do not use “cheaters” to extend the shift handle length or other means to apply undue force on the shift handle. A
partially engaged drum clutch may jump out of engagement causing a sudden loss of load control which may result
in property damage, severe personal injury, or death.
!WARNING !
B. To Engage Clutch
1. Ensure winch motor is not running and the cable drum is
not loaded. The prime mover is stopped in neutral with
parking brake set.
2. Lower shift handle to engage clutch. If shift handle will
not engage detent hole, the clutch is not fully engaged.
At this point it may be necessary to rotate the cable drum
slightly in either direction to align clutch.
Reel-in and
reel-out ports
Lift handle to disengage
free-spool clutch
Rope retention

10
1. The winch should be mounted with the centerline of the
drum in a horizontal position. The clutch actuator may be
indexed at time of order for best t.
2. Hydraulic lines and components that operate the winch
should be of su󰀩cient size to assure minimum back pres-
sure at the winch. The motor manufacturer recommends
that back pressure not exceed 100 PSI (6.9 bar) for op-
timum motor seal life. To limit potential problems arising
from high back pressures, the motor should be externally
drained directly to tank to improve motor seal life. For
back pressures exceeding 150 PSI (10.3 bar), consult
PACCAR Winch Technical Support.
3. High-quality hydraulic oil is essential for satisfactory per-
formance 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 un-
der normal temperature conditions. The use of 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 correspond-
ing changes in temperature.
Maximum cold weather start-up viscosity should not ex-
ceed 5,000 SUS with a pour point at least 20°F (11°C)
lower than the minimum temperature. Under continu-
ous operating conditions the temperature of the oil at
any point in the system must not exceed 180°F (82°C).
120°F to 140°F (49°C to 60°C) is generally considered
optimum.
In general terms; for continuous operation at ambient
temperatures between 50°F and 110°F (10°C and 43°C),
use SAE 20W; for continuous operation between 10°F
and 90°F (–12°C and 32°C), use SAE 10W; for applica-
tions colder than 10°F (–12°C), contact PACCAR Winch
Technical Support. The use of multiviscosity oils is gener-
ally not recommended.
4. The hydraulic oil lter should have a 10-micron nominal
rating and be full-ow type.
WINCH INSTALLATION
HYDRAULIC CIRCUIT
SINGLE-SPEED MOTOR CIRCUIT TWO-SPEED MOTOR CIRCUIT

11
A pass-through hole with two setscrews is used to secure
the cable to the drum. The anchoring system is designed for
1/2-inch through 9/16-inch (12 mm through 14 mm) diameter
cable.
CABLE WRAP DIRECTION
Cable can be wound onto the drum in either direction. The
static brake is e󰀨ective in both directions.
SECURING CABLE TO DRUM
1. Determine the direction of drum rotation to haul-in cable.
2. Insert cable end into anchor hole of drum until even with
other end of hole.
3. Coat anchor setscrew threads with antiseize compound
and then secure rope by tightening to 75±10 lbs.-ft..
1. Oil Level
The gear oil level should be checked every 500 operating
hours or three months, whichever occurs rst. Use sight
glass to check oil level. The level should be within the upper
and lower limits of the glass. If additional oil is needed, refer
to the Preventive Maintenance section of this manual.
WIRE ROPE INSTALLATION
PREVENTIVE MAINTENANCE
Rope anchors are NOT designed to hold rated loads.
Winch loads applied directly to the cable anchor may
cause the rope to pull free and result in the sudden
loss of load control and cause property damage, per-
sonal injury, or death. A minimum of three wraps of
rope must be left on the drum barrel to achieve rat-
ed load. Do not use knots to secure or attach winch
rope. We suggest that the last three wraps of rope
be painted or marked bright red to serve as a visual
warning.
!WARNING !
Mounting
holes
Oil drain
Oil level
sight glass
Oil fill

12
4. Mounting Bolts
Retorque winch mounting hardware after the rst 100 hours
of operation, then every 1,000 operating hours or six months,
whichever occurs rst.
5. Rope
Inspect entire length of rope according to rope manufactur-
er’s recommendations.
6. Hydraulic Power Supply
The original lter element should be replaced after the rst
50 hours of operation, then every 500 operating hours or
three months, or in accordance with the equipment manu-
facturer’s recommendations.
7. Warm-up Procedure
A warm-up procedure is recommended at each start-up and
is essential at ambient temperatures below +40°F (4°C).
The hydraulic power supply should be run at its lowest rec-
ommended RPM with the hydraulic winch control valve in
neutral allowing su󰀩cient time to warm up the system. The
winch should then be operated at low speeds, forward and
reverse, several times to prime all lines with warm hydraulic
oil, and to circulate gear lubricant through the planetary gear
sets.
Failure to change gear oil at these suggested mini-
mum intervals may contribute to intermittent brake
slippage which could result in property damage, se-
vere personal injury, or death.
!WARNING !
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 could result in
property damage, severe personal injury, or death.
!WARNING !
Vent 1–5 psi
2. Oil Change
The gear oil should be changed after the rst 100 hours of
operation, then every 1,000 operating hours or six months,
whichever occurs rst. The gear oil must be changed to re-
move wear particles that impede the reliable and safe opera-
tion of the brake clutch and erode bearings, gears and seals.
The gear oil should also be changed whenever the ambient
temperature changes signicantly and an oil from a di󰀨erent
temperature range would be more appropriate. Oil viscos-
ity with regard to ambient temperature is critical to reliable
brake clutch operation. Our tests indicate that oil with ex-
cessive viscosity or high EP content may contribute to inter-
mittent brake clutch slippage. Make certain that the gear oil
viscosity is correct for your prevailing ambient temperature.
Refer to Recommended Planetary Gear Oil section of this
manual for additional information.
3. Vent Plug
The vent plug is located at the motor mount area. It is im-
portant 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.
PREVENTIVE MAINTENANCE

13
8. Recommended Planetary Gear Oil
Field experience, supported by engineering endurance tests, indicates that 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, PACCAR Winch has published the following specifications to assist in determining which lubricant is best
suited to your application.
For simplicity, PACCAR Winch 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
equivalent to those products listed below.
PREVAILING AMBIENT TEMPERATURE
oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
oC -40 -30 -20 -10 0 10 20 30 40 50 oC
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
oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
oC -40 -30 -20 -10 0 10 20 30 40 50 oC
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.
RECOMMENDED GEAR OIL
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
PREVENTIVE MAINTENANCE
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 extreme-pressure (EP) and antifriction additives, which may contribute to brake clutch slippage or damage to brake
friction discs or seals. NOTE: DO NOT use oil that is labeled as meeting “API Service GL-5.” Oil viscosity, af-
fected by ambient temperature, is also critical to reliable brake clutch operation. Our tests indicate excessively heavy
or thick gear oil may contribute to intermittent brake clutch slippage. Make certain the gear oil viscosity used in your
winch is correct for your prevailing ambient temperature.
!WARNING !

14
The following troubleshooting section is provided as a general guide. You may also need to contact the original equipment
manufacturer (OEM) for additional information.
A
Winch will not reel out under load
or does not reel out smoothly.
Remove the pilot hose and tting from
the brake valve, then use a 5/32-inch
Allen wrench to remove the pilot orice.
The diameter of the orice is approxi-
mately .020 inches (.5 mm). Clean and
install the pilot orice tightly in the brake
valve.
Check brake cylinder seal as follows:
A. Disconnect the hose from the brake
release port. Connect a hand pump with
accurate 0–2,000 PSI (0–137.9 bar)
gauge and shut-o󰀨 valve to the tting in
the brake release port.
B. Apply 1,000 PSI (68.9 bar) to the
brake. Close shut-o󰀨 valve and let stand
for ve minutes.
C. If there is any loss of pressure in ve
minutes, the brake cylinder should be
disassembled for inspection of the seal-
ing surfaces and replacement of the
seals. Refer to Brake Service section of
this manual.
Disassemble brake to inspect brake
discs. Check stack-up height as de-
scribed in Brake Service section of this
manual.
1. The problem could be a plugged
or loose pilot orice. The pilot orice
is a small pipe plug with a hole drilled
through it, located behind the pilot port
tting 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 causing er-
ratic brake valve operation.
NOTE: Some brake valves do not use a
separate pilot orice plug.
2. The friction brake may not be releas-
ing as a result of a defective brake cyl-
inder seal.
NOTE: If the brake cylinder seal is de-
fective you will usually nd oil leaking
from the winch vent plug.
3. Friction brake will not release as a re-
sult of damaged brake discs.
TROUBLE PROBABLE CAUSE REMEDY
TROUBLESHOOTING
If a winch exhibits any sign of:
• Erratic operation such as poor load control, load creep, or chatter
• Unusual noise
• Oil leaks
• A sudden increase in wear particles from oil analysis
Then the winch MUST be removed from service until the problem has been corrected. If a winch has been subjected
to a sudden heavy load (shock-load) or overload, the winch 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
control, property damage, injury, or death.
!WARNING !

15
B
Oil leaks from vent plug.
Same as A2.
Case drain back pressure must not ex-
ceed 100 PSI (6.9 bar) for gear motors
and 44 PSI (3 bar) for piston motors.
Inspect hydraulic power supply for a
restriction in the return line to the res-
ervoir.
Oil analysis may indicate contamination
has worn motor shaft and seal. Thor-
oughly ush entire hydraulic power sup-
ply and install new lters 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 mo-
tor case drain circuit or contaminated
oil. Contamination will usually cause
the seal to wear a groove in the motor
shaft.
TROUBLE PROBABLE CAUSE REMEDY
C
Brake will not hold a load with the
control lever in neutral.
The pressure at the motor reel-out port
is also transmitted to the brake release
pilot circuit. Inspect hydraulic circuit for
restrictions, plugged lters or control
valves not centering.
Same as Remedy of Trouble A3.
Improper planetary gear oil may cause
the brake discs to slip. Drain old gear oil
and ush winch with solvent. Thorough-
ly drain solvent and rell winch with rec-
ommended planetary gear oil listed in
Preventive Maintenance section of this
manual.
1. Excessive system back pressure act-
ing on the brake release port.
2. Friction brake will not hold due to
worn or damaged brake discs.
3. Brake discs are slipping.
D
Winch does not reel in the rated load.
Reinforce mounting surface.
If necessary, use shim stock to level
winch. Refer to Winch Installation sec-
tion of this manual.
First loosen, then evenly retighten all
winch mounting bolts to recommended
torque.
Check relief pressure as follows:
A. Install an accurate 0–5,000 PSI
(0–344.7 bar) gauge into the inlet port
of the brake valve.
1. The winch may be mounted on
an uneven or exible surface which
causes distortion of the winch base
and binding of the gear train. Binding in
the gear train will absorb horsepower
needed to winch the rated load and
cause heat.
2. Hydraulic power supply relief valve
may be set too low. Relief valve needs
adjustment or repair.

16
Trouble “D” Continued From
Previous Page
B. Apply a stall pull load on the winch
while monitoring pressure.
C. Compare gauge reading to winch
specications. Adjust relief valve as
required.
NOTE: If pressure does not increase
in proportion to adjustment, relief valve
may be contaminated or worn out. In
either case, the relief valve may require
disassembly or replacement.
Same as remedies for Trouble D1 and
D2.
Same as remedies for Trouble E2.
Refer to winch performance charts for
additional information.
Perform rigging service as recom-
mended by crane manufacturer.
3. Be certain hydraulic power supply
temperature is not more than 180°F
(82°C). Excessive hydraulic oil temper-
atures increase motor internal leakage
and reduces motor performance.
4. Winch line-pull rating is based on
rst layer of wire/synthetic rope.
5. Rigging and sheaves not operating
e󰀩ciently.
TROUBLE PROBABLE CAUSE REMEDY
E
Winch runs hot.
Same as remedies for Trouble D1.
Thoroughly clean exterior and ush in-
terior.
Fill/drain to proper level.
Same as remedies for Trouble D2.
Engine low on horsepower or RPM
Tune/adjust engine.
Check suction line for damage.
Pump worn. Replace pump.
Use correct hydraulic oil.
Disassemble winch to inspect and/or
replace worn parts.
1. Same as D1.
2. Be certain that the hydraulic power
supply temperature is not more than
180°F (82°C). Excessive hydraulic oil
temperatures may be caused by:
A. Plugged heat exchanger.
B. Too low or too high oil level in hy-
draulic reservoir.
C. Same as D2.
D. Hydraulic pump not operating e󰀩-
ciently.
E. Hydraulic oil is wrong viscosity for
operating conditions.
3. Excessively worn or damaged inter-
nal winch parts.

17
G
Wire/synthetic rope does not spool
smoothly on the drum.
Check mounting distance and eet
angle. Reposition winch as required to
achieve 1/2 to 1-1/2 degree eet angle.
Consult wire/synthetic rope manufactur-
er for recommendation of wire/synthetic
rope that best suits your application.
Replace wire/synthetic rope and con-
duct operator/rigger training as re-
quired.
1. The winch may be mounted too close
to the fairlead, causing the eet angle to
be more than 1-1/2 degrees.
2. Could be using the wrong lay rope.
There is a distinct advantage in applying
rope of the proper wind or lay. When the
load is slacked o󰀨, the several wraps on
the drum will stay closer together and
maintain an even layer. If rope of im-
proper lay is used, the coils will spread
apart each time the load is removed.
Then, when winching is resumed, the
rope has a tendency to crisscross and
overlap on the drum. The result is apt to
be a attened and crushed rope.
3. The winch may have been overload-
ed, causing permanent set in the wire/
synthetic rope.
F
Winch chatters or surges while lifting
rated load.
TROUBLE PROBABLE CAUSE REMEDY
Same as remedies for Trouble D2.
Same as remedies for Trouble E2.
Conduct operator training as required.
1. Same as D2.
2. Hydraulic oil ow to motor may be
too low.
3. Controls being operated too quickly.

18
TR20A CROSS-SECTION
Part number 09512
ADDITIONAL REFERENCE
PUBLICATION
For cross-section diagrams and complete list of components, please refer to LIT2732: Parts List for TR20A recovery winches.

19
ITEM
NO.
DESCRIPTION PART NO. QTY.
100 Primary carrier assembly 84654 1 200 Secondary carrier assembly 84656 1 300 Parts group, manual clutch 84653 1 400 Parts group, hydraulic motor 65253 1 001 End plate 111417 1 002 Ball bearing 29142 2 003 Seal, 4.72 6.30 .47 111497 2 004 O-ring 21033 2 005 Housing, ring gear 111406 1 006 Washer, hard 101440 8 007 Capscrew 104309 8 008 Ring gear 111404 1 009 Thrust washer, 3.00 3.75 .03 111450 1 010 Thrust washer, 2.50 3.25 .03 111638 1
011 Thrust race 27718 1
012 Sun, primary 111422 1 014 Drive, shaft 111420 1 015 Cover, housing 111414 1 016 Washer 100858 16 017 Capscrew 11766 16 018 Plug 25665 2
TR20A COMPONENTS
Part number 09512
ITEM
NO.
DESCRIPTION PART NO. QTY.
019 16574-0012 Sight gauge 70193 1 020 Drum, TR20A-01 111418 1 021 End plate, brake 111655 1 022 Spring locator 100136 1 023 Spring 26094 12 024 Spring plate 25552 1 025 U-cup seal 25594 1 026 Brake plate spacer 25550 1 027 Brake hub 111544 1 028 Snap ring 27535 1 029 Brake disc 102314 7 030 Friction disc 25541 6 031 O-ring 70138 1 032 Motor adapter, SAE A2 111679 1 033 16496-4 Plug 69325 1 034 Relief valve 1–5 PSI 10074 1 035 Tie plate 111419 2 036 Washer 100860 8 037 Capscrew 25119 8 038 Setscrew 24032 2 039 Nameplate, TR20A J706 111776 1 040 Drive screw 11842 4

20
WINCH DISASSEMBLY
1. Remove plug and drain oil.
2. Remove brake hose from brake valve and brake cylin-
der housing.
3. Remove motor assembly from motor support by remov-
ing two bolts and two washers. Remove brake coupling.
4. Remove the free-spool clutch assembly.
5. Remove the gear housing cover by removing eight
screws and eight washers. Remove O-ring.
6. Remove thrust washer, primary sun gear, primary carrier
spacer, primary carrier assembly, output carrier spacer,
output carrier assembly, input shaft, and ring gear.