Installation, Maintenance and Service Manual: Winch Division
Installation, Maintenance and Service Manual: Winch Division
Installation, Maintenance and Service Manual: Winch Division
RW300A
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WINCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
RECOMMENDED FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
RECOMMENDED PLANETARY HOIST GEAR OIL . . . . . . . . . . . . . . . . . . . . .11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
DISASSEMBLY OF WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
BRAKE CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
BRAKE CLUTCH ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
PLANET CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
WINCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CROSS-SECTION DRAWING AND PARTS KEY . . . . . . . . . . . . . . . . . . . . . .26
METRIC CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1
FOREWORD
Read this entire publication and retain it for future reference.
The minimum service intervals specified are for operating hours of the prime mover.
The following service instructions have been prepared to provide assembly, disassembly and maintenance infor-
mation for the Braden Model RW300A. It is suggested that before doing any work on this unit, 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.
Whenever a question arises regarding your winch or this manual, please contact the Braden Technical Support
Department via phone at (918)-251-8511, from 08:00 to 16:30 hours, CT, Monday through Friday, via fax at (918)-
259-1575, or via email at winch.service@paccar.com, for the latest available information.
Model Number
Serial Number OIL LEVEL
SIGHT GLASS
RW 300 A - 69 - V 086/050 - B S
WINCH MAX DESIGN GEAR PISTON MOTOR BRAKE OPTION
RATING MODEL RATIO MOTOR SIZE
2
GENERAL SAFETY RECOMMENDATIONS
Safety and informational callouts used in this manual include:
CAUTION
WARNING – This emblem is used to warn against CAUTION – This emblem is used to warn against
hazards and unsafe practice which COULD result in potential or unsafe practices which COULD result in
severe personal injury or death if proper procedures personal injury and product or property damage if
are not followed. proper procedures are not followed.
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.
1. Be certain equipment (boom, mast, sheave blocks, 14. Keep hydraulic system clean and free from contam-
pendants, etc.) is either lowered to the ground or ination at all times.
blocked securely before servicing, adjusting, or 15. Use correct anchor method for wire rope and pock-
repairing winch. et in drum. Do not use knots to secure or attach
2. Be sure personnel are clear of work area BEFORE wire rope. For additional safety, ALWAYS maintain
operating winch. a minimum of five (5) wraps of wire rope on the
3. Read all warning and caution tag information provid- drum.
ed for safe operation and service of winch. 16. Never attempt to clean, oil or perform any mainte-
4. Inspect rigging and winch at the beginning of each nance on a machine with the engine or prime mover
work shift. Defects should be corrected immediately. running, unless instructed to do so in this manual.
5. Keep equipment in good operating condition. 17. Never operate winch controls unless you are prop-
Perform scheduled servicing and adjustments listed erly positioned at the operators station and you are
in the “Preventive Maintenance” section of this man- sure personnel are clear of the work area.
ual. 18. Assure that personnel who are responsible for hand
6. An equipment warm-up procedure is recommended signals are clearly visible and that the signals to be
for all start-ups and essential at ambient tempera- used are thoroughly understood by everyone.
tures below +40°F (4°C). Refer to “Warm-up 19. Ground personnel should stay in view of the opera-
Procedure” listed in the “Preventive Maintenance” tor and clear of winch drum. Do not allow ground
section of this manual. personnel near winch line under tension.
7. Operate winch line speeds to match job conditions. 20. Do not exceed the maximum pressure, PSI (kPa), or
8. Leather gloves should be used when handling wire flow, GPM (LPM), stated in the winch specifications.
rope. 21. Install guarding to prevent personnel from getting
9. Never attempt to handle wire rope when the hook any part of body or clothing caught at a point where
end is not free. Keep all parts of body and clothing the cable is wrapped onto the drum or drawn
clear of cable rollers, cable entry area of fairleads, through guide rollers.
sheaves and winch drum. 22. “Deadman” controls, which automatically shut off
10. When winding wire rope on the winch drum, never power to the winch whenever the operator leaves
attempt to maintain tension by allowing wire rope to his station, should be installed whenever practica-
slip through hands. Always use “Hand-Over-Hand” ble.
technique. 23. Never allow anyone to stand under a suspended
11. Never use wire rope with broken strands. Replace load.
wire rope. 24. Avoid sudden “shock” loads or attempting to “jerk”
12. Do not weld on any part of the winch. load free. This type of operation may cause heavy
loads, in excess of rated capacity, which may result
13. Use recommended hydraulic oil and gear lubricant. in failure of cable and winch.
3
THEORY OF OPERATION
DESCRIPTION OF WINCH The static brake system has three operating compo-
The winch has four basic component parts: nents:
1. Winch base 1. Spring Applied, Multiple Friction Disc Static Brake
2. Hydraulic motor and brake valve 2. Brake Clutch Assembly
3. Brake cylinder and motor support 3. Hydraulic Piston and Cylinder
4. Drum assembly Figure 2
The drum assembly consists of four basic assemblies:
1. Drum with integral ring gear Static Motor
2. Output planetary gear set Brake
3. Secondary planetary gear set
4. Primary planetary gear set To
Brake
The hydraulic motor is bolted to the brake cylinder and Tank
Valve
the base. The motor end of the drum, running on dual
tapered bearings, is supported by the brake cylinder.
The other end of the drum runs on a spherical bearing Pump
on the support bolted to the base. The ring gear for the
planetary sets is machined into the drum’s inside sur-
face.
Control
WINCH OPERATION Valve
The hydraulic motor drives the sun gear of the primary Low Pressure Medium Pressure High Pressure
planetary gear set through the splined inner race of the
brake clutch. When driven by the sun gear, the primary
planet gears walk around the ring gear in the drum and Figure 3
drive the primary planet carrier. Static Motor
Brake
The primary planet carrier drives the secondary sun
gear. The secondary planet gears drive the secondary
planet carrier, which drives the output sun gear. The To
Brake Tank
output planet carrier is splined to the brake cylinder and Valve
cannot rotate. Therefore, as the output planet gears are
driven by the sun gear, they will drive the ring
gear/drum. Pump
The dynamic brake system has two operating compo- Low Pressure Medium Pressure High Pressure
nents:
1. Brake valve assembly
Figure 4
2. Hydraulic motor
The brake valve is basically a counterbalance valve. It Static Motor
contains a check valve to allow free flow of oil to the Brake
motor in the hoisting direction and a pilot operated,
spring-loaded spool valve that blocks the flow of oil out
To
of the motor when the control valve is placed in neutral. Brake
Tank
When the control valve is placed in the lowering posi- Valve
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 Pump
spool valve cracks open, the pilot pressure becomes
flow-dependent and modulates the spool valve opening
which controls the lowering speed. Control
Valve
Figures 2, 3 & 4 show a simplified version of the brake
valve for illustrative purposes. Low Pressure Medium Pressure High Pressure
4
The static brake is released by the brake valve pilot Figure 5 Static Friction Brake Applied
pressure at a pressure lower than that required to open
the pilot operated spool valve. This sequence assures
that dynamic braking takes place in the brake valve and Sprag
that little, if any, heat is absorbed by the friction brake. Cams
5
WINCH INSTALLATION
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
BRAKE
VALVE
WINCH BRAKE
BR
19° 19°
CASE
DRAIN
CONTROL
VALVE
1. The winch must be mounted with the centerline of
the drum in a horizontal position. Due to the design
of the winch base group, the cable departure angle
must only be in the shaded area as shown. When
PUMP
mounting the winch, use all four mounting holes with
1.25 in. grade 8 capscrews, hardened washers and
nuts tightened to recommended torque.
a
b
First sheave
or load
6
SPECIFICATIONS
Unit weight without wire rope, approximate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1370 lb. (621 kg)
Higher and lower torque values for special applications will be specified; such as the use of spanner nuts, nuts
on shaft ends, jam nuts and where distortion of parts or gaskets is critical.
Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut.
Avoid using thread lubricants as the applied torque may vary by 10-40% depending upon product used.
Q
Torque (LB-FT) Torque (LB-FT)
Bolt Dia. Thds Per Grade 5 Grade 8 Bolt Dia. Thds Per Grade 5 Grade 8
Inches Inch Dry Lubed Dry Lubed Inches Inch Dry Lubed Dry Lubed
20 10
1/4 8 6 12 9 3/4 265 200 380 280
28 16
18 9
5/16 17 13 24 18 7/8 420 325 600 450
24 14
16 8
3/8 31 23 45 35 1 640 485 910 680
24 14
14 7
7/16 50 35 70 50 1 1/8 790 590 1290 970
20 12
13 7
1/2 75 55 110 80 1 1/4 1120 835 1820 1360
20 12
12 6
9/16 110 80 150 110 1 3/8 1460 1095 2385 1790
18 12
11 6
5/8 150 115 210 160 1 1/2 1940 1460 3160 2370
18 12
To convert lb. ft. to kg-m, multiply lb. ft. value by 0.1383.
7
WIRE ROPE INSTALLATION
Prepare the end of the wire rope as recommended by
the wire rope manufacturer. Insert the free end of the
wire rope through the opening in the drum flange. Push
the wire rope into the anchor pocket until the end of the The clamp plate wire rope anchor system is not capa-
wire rope is even with the outer edge of the pocket. ble of supporting the rated load. Always MAINTAIN a
Install the clamp plate onto the drum flange with the thin minimum of five wraps of wire rope on the cable
end of the clamp wedge toward the dead end of the wire drum. If the wire rope is fully reeled out, the wire rope
rope. Apply a light load of approximately 500 lb. (227 may slip out of the drum causing a loss of load con-
kg) to the wire rope as the new wire rope is wound onto trol which may result in property damage, injury or
the cable drum. death. We suggest that the last 5-6 wraps of wire
rope be painted bright red to serve as a visual warn-
The anchor system is designed for use only with 7/8 in. ing.
(22mm) wire rope.
8
PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your Inspection procedures for hoists are divided into five
planetary hoist is strongly recommended to minimize general categories based upon the hoist usage or duty
the need for emergency servicing and promote safe, cycle, which in turn determines different, appropriate
reliable hoist operation. The user of Braden products is intervals for inspections. The usage categories must be
responsible for hoist inspection, testing and mainte- assigned by the hoist user/owner on a consistent unit-
nance with frequency dependent upon the severity of by-unit basis. The five hoist usage categories are as fol-
the hoist duty cycle and thoroughness of the preventive lows:
maintenance program in effect.
Idled: - The hoist has not been used for three months.
Infrequent Usage - The hoist is used less than ten
hours per month based on a three month average.
Any time a hoist exhibits erratic operation and/or Moderate Usage - Hoist used 10-50 hours per month
unusual noise, the hoist must be taken out of service based on a three month average.
until it is inspected and serviced by a qualified techni- Heavy Usage - Hoist used 50-200 hours per month.
cian. Continued operation of a hoist with a defect in a Severe Duty - Hoist is operated more than 200 hours
critical component may lead to loss of load control, per month OR where 50% of the lifts exceed 75% of the
property damage, injury or death. Braden rated capacity for the hoist.
A record of written, dated and signed inspections, load
The following chart lists the inspections that are
tests, maintenance and repairs or modifications must be
required for each type of usage category.
kept readily available in an appropriate location for a
minimum of five years.
INSPECTION
PRE-USE SEMI-ANNUAL ANNUAL TEAR-DOWN
DAILY INSPECTION INSPECTION INSPECTION
USAGE INSPECTION
CATEGORY
REQUIRED IF
IDLED REQUIRED REQUIRED MAINTENANCE
Not used for BEFORE PLACED BEFORE PLACED -- & REPAIR
3 months IN SERVICE IN SERVICE HISTORY
UNKNOWN
5 YEARS
INFREQUENT 3 YEARS IF NOT
USAGE REQUIRED REQUIRED REQUIRED SUBJECT TO
less than ten hours FULL INSPECTION
per month PROGRAM
4 YEARS
MODERATE 2 YEARS IF NOT
USAGE REQUIRED REQUIRED REQUIRED SUBJECT TO
10-50 hours per FULL INSPECTION
month PROGRAM
3 YEARS
HEAVY USAGE 1.5 YEARS IF NOT
50-200 hours per
REQUIRED
REQUIRED REQUIRED SUBJECT TO
month SEMI-ANNUALLY
FULL INSPECTION
(6 months)
PROGRAM
SEVERE USAGE
200+ hours per month REQUIRED REQUIRED 1 YEAR
REQUIRED
or 50% of lifts exceed QUARTERLY SEMI-ANNUALLY
75% rated capacity (3 months) (6 months)
9
Pre-Use or Daily Inspection: Semi-Annual Inspection
Must include but is not limited to the following inspec- (every six months):
tions that will be performed prior to placing the hoist into Must include but is not limited to the following inspec-
service and then as necessary during extended opera- tions performed by a qualified technician.
tion. This inspection must be performed by a qualified
technician. 1. Perform the Pre-Use inspection.
HOIST
2. Take a lubricant sample as described later in this
section and analyze it for wear metals content, cor-
rect viscosity, lubricant deterioration, moisture and
other contaminants. If the oil sample contains a high
OIL FILL & DRAIN
SAE -8 ORB
CABLE POCKET AND amount of metallic particles, the hoist must be taken
ANCHOR TO ACCEPT
(3/4-16 THRD) 7/8 WIRE ROPE out of service to undergo a tear-down inspection.
Note: Oil analysis cannot detect nor warn against a
fatigue failure.
OIL FILL
OIL FILL/DRAIN
ACCESS
MODEL NO.
SERIAL NO.
3. Perform a brake test as described later in this sec-
ACCESS HOLE
HOLE
tion.
3. Visually inspect for corroded, loose or missing fas- 1. Perform the Pre-Use and Semi-Annual inspections.
teners and tighten or replace as required.
2. Change hoist gear cavity lubricating oil after an oil
4. Inspect the entire length of wire rope and rigging as sample has been taken as described later in this
recommended by the wire rope and rigging manu- section. Refill the hoist to the proper level with rec-
facturer. ommended lubricant. Refer to "Recommended
Planetary Hoist Gear Oil" later in this section for
5. Inspect all safety devices such as anti-two-blocking more information.
switches and limit switches and repair as required.
On new hoists, change gear oil after the first 50
6. A warm-up procedure is recommended at each start- operating hours then every 500-1000 operating
up and is essential at ambient temperatures below hours or annually depending upon hoist usage as
40°F (4°C). The engine should be run at low RPM shown on Page 9.
with the hoist control valve in neutral allowing suffi-
cient time to warm up the hydraulic system. The
hoist should then be operated without a load, at low
speeds, raise then lower several times to prime all
lines with warm hydraulic oil and to circulate gear
lubricant through the planetary gear train.
Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slip-
page which could result in property damage, severe personal injury or death. Some gear lubricants contain large
amounts of EP (extreme pressure) and anti-friction additives which may contribute to brake clutch slippage or
damage to brake friction discs or seals. Oil viscosity with regard to ambient temperature is also critical to reliable
brake clutch operation. Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent
brake clutch slippage. Make certain that the gear oil viscosity used in your hoist is correct for your prevailing
ambient temperature.
i
NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.
Texaco Meropa 150, previously used as factory fill, may no longer be widely available due to current market conditions. As of
mid-year 2002, planetary hoists are factory filled with Exxon Spartan EP150, or equivalent. The chart below relates the Texaco
products to 4 currently available oils. Consult your oil supplier for other equivalent oils if required.
Meropa 220 Spartan EP 220 Mobilgear 630 Omala 220 Gear Compounds EP 220
9/2002
11
SPECIAL TOOLS
2 each ½-13NC eye bolt
2 each ¾-10NC eye bolt:
NOTE: The first two items below are required only if NOTE: If a press is available (with at least 5
the motor support is separated from the ring inches of travel), only part (A) shown
gear. The other tools are required to service below is required (center hole not
the brake assembly. required). If a press is not available,
all parts shown and listed below are
3 each 7/8 - 9NC x 6 inch long capscrews required.
A ratcheting internal snap ring pliers capable 1 each 1 - 8 NC threaded rod, 14 inches long
of handling an N5000 700 snap ring. 1 each 1 - 8 NC nuts
1 each 1 inch plain washer
All units use a single coil spring to apply the
internal brake. The following spring compres-
sor must be fabricated and is strongly recom-
mended.
6.00
2.00 5.37
0.50 1.06
2.00
1.06
0.38
0.75
9.50
1.00
2.00 WELD
14.00
8.50
10.00
0.75
4.00 WELD
12
TROUBLESHOOTING
If a hoist ever exhibits any sign of erratic operation, or load control difficulties (load creeping down or chatter-
ing) appropriate troubleshooting tests and repairs must be performed immediately. Continued operation of a
hoist with a defect may result in property damage, injury or death.
2. The friction brake may not be releasing as Check brake cylinder seal as follows:
a result of a defective brake cylinder seal.
A. Disconnect the swivel tee from the brake
NOTE: If the brake cylinder seal is defec- release port. Connect a hand pump with
tive you will usually find oil leaking from the accurate 0-2000 psi gauge and shut-off valve
winch vent plug. to the –4 J.I.C. fitting in the brake release port.
3. Friction brake will not release as a result of Disassemble brake to inspect brake discs.
damaged brake discs. Check stack-up height as described in “Motor
Support-Brake Cylinder Service”.
B
Oil leaks from vent plug. 1. Same as A2. Same as A2.
2. Motor seal may be defective as a result Motor case drain back pressure must not
of high back pressure or contaminated exceed 40 psi (275 kPa). Inspect hydraulic
oil. system for a restriction in the return line to
the reservoir. Be sure plumbing is properly
sized to winch motor.
13
TROUBLE PROBABLE CAUSE REMEDY
C
The brake will not hold a 1. Excessive system back pressure acting on System back-pressure must not exceed 100
load with the control lever the brake release port. psi (690 kPa). Inspect hydraulic system for
in neutral. restriction in the circuit from the motor to the
reservoir.
2. Friction brake will not hold due to worn or Same as Remedy 3 of Trouble A3.
damaged brake discs.
3. Brake clutch is slipping. 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 recommended
planetary gear oil listed in “Preventive
Maintenance”.
D
The winch will not hoist the 1. The winch may be mounted on an uneven Reinforce mounting surface.
rated load. or flexible surface which causes distortion
of the winch base and binding of the gear If necessary, use shim stock to level winch.
train. Binding in the gear train will absorb Refer to “Winch Installation”.
horsepower needed to hoist the rated load
and cause heat. First loosen, then evenly retighten all winch
mounting bolts to recommended torque.
2. System relief valve may be set too low. Check relief pressure as follows:
Relief valve needs adjustment or repair.
A. Install an accurate gauge into the inlet
port of the brake valve.
3. Be certain hydraulic system temperature Same as remedies for Trouble D1 & D2.
is not more than 180°F (82°C). Excessive
hydraulic oil temperatures increase motor Same as remedies for Trouble E2.
and pump internal leakage and reduce
performance.
4. Winch line pull rating is based on 1st layer Refer to winch performance charts for addi-
of wire rope. tional information.
5. Rigging and sheaves not operating effi- Perform rigging service as recommended by
ciently. rig manufacturer.
14
TROUBLE PROBABLE CAUSE REMEDY
E
The winch runs hot. 1. Same as D1. Same as remedies for Trouble D1.
B. Too low or too high oil level in hydraulic Fill/drain to proper level.
reservoir.
F
Winch “chatters” while 1. Same as D2. Same as remedies for Trouble D2.
raising rated load. 2. Hydraulic oil flow to motor may be too low. Same as remedies for Trouble E2.
3. Controls being operated too quickly. Conduct operator training as required.
G
The wire rope does not 1. The winch may be mounted too close to Check mounting distance and fleet angle.
spool smoothly on the the main sheave, causing the fleet angle Reposition winch as required.
drum. to be more than 1-1/2 degrees.
3. Could possibly be using the wrong lay Consult wire rope manufacturer for recom-
rope. There is a distinct advantage in mendation of wire rope that best suits your
applying rope of the proper direction of lay. application.
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 criss-cross and overlap
on the drum. The result is apt to be a flat-
tened and crushed rope.
4. The winch may have been overloaded, Replace wire rope and conduct operator/rig-
causing permanent set in the wire rope. ger training as required.
15
DISASSEMBLY OF WINCH
See cross-section illustration on page 26 and parts key 6. Remove the brake release hose adapter from the
for reference. brake release port to prevent damage. Remove the
motor pilot adapter (40) from the brake cylinder.
1. Remove the wire rope from the cable drum and
rotate the drum until the fill/drain plug is at the bot- 7. With a suitable hoist, turn the hoist over with the
tom, six o'clock position. Remove the drain plug and motor end down. Remove the capscrews and lock-
capture the gear oil in a suitable container. Recycle washers (99,100) that retain the tie-plates (101) to
or dispose of used oil in an environmentally respon- the end-brackets (96, 97). Remove the drum bear-
sible manner. Install the drain plug. ing support and end-bracket assembly from the
cable drum.
2. Label the hydraulic hoses as they are removed from
the hoist motor. Install plugs in the open hoses and 8. Remove the 16 socket head capscrews and lock-
motor ports to reduce entrainment of dirt in the open washers (12, 13) from the drum flange end (5). With
port. a plastic face mallet, unseat the drum flange end (5)
from the drum ring gear (60). Remove the drum
flange end from the drum ring gear.
CAUTION
The RW300 hoist weighs approximately 1370 lbs.
(621 kg). Use adequate lifting equipment.
16
11. Remove the secondary planet carrier assembly (68) 14. Remove the twelve capscrews and lockwashers
from the drum ring gear. The output sun gear (64) (82, 83) that secure the motor end-bracket (96) to
will come out with the secondary sun gear. If the the brake cylinder (34). Install three 7/8 - 9 jack-
thrust washer (66) stayed on the output planet car- screws, 6 inches long, evenly spaced into the end-
rier remove it and set aside with the secondary plan- bracket mounting bolt holes. Apply general purpose
et carrier. grease to the threads to reduce friction. Evenly
tighten the jack-screws against the drum ring gear
flange to push the brake cylinder out of the drum
ring gear and separate the bearings. When the two
pieces have separated, you will hear the bearing
cone drop off the brake cylinder journal onto the pile
of shop towels.
17
BRAKE CYLINDER SERVICE
Fabricate the spring compressor tool as illustrated in
the “Tools” section of this manual.
DISASSEMBLY
BACKUP RING
O-RING
BACKUP RING
5. Install new O-rings and backup rings (27, 28, 30, 31)
1. Set the motor support/brake cylinder on a bench with into the brake cylinder as shown. It is VERY impor-
the motor end down. tant to position the O-rings and backup rings as
shown above to prevent brake cylinder leakage.
7. Install the piston stop (32) and the brake spring (55).
19
Brake Cylinder Pressure Test
CAUTION
The brake spring must be compressed approximate-
ly 4 inches (10 cm) and has a compressed force of
approximately 1,500 lb (680 kg). Extreme care
should be observed while completing this step to
avoid sudden release of the spring. DO NOT stand
directly in front of the spring while it is being com-
pressed.
20
BRAKE CLUTCH ASSEMBLY SERVICE
Before disassembling the brake clutch, make note of 3. Apply a light coat of winch lubricant to all compo-
the freewheeling direction of the inner brake race (50). nents as they are assembled. Install the roller bear-
Hold the outer race (42) and try to turn the inner race in ing (58) into the outer race (42). Install spacer (47)
both directions. It should turn free of the outer race in on top of roller bearing. Install the sprag clutch
one direction only. If the inner race will not turn freely in assembly (46). NOTE: The sprag assembly con-
either direction, or turns freely in both directions, the sists of three parts; two u-shaped bronze spacers
sprag clutch assembly has been damaged and must be and a cam assembly. The bronze spacers are
replaced. installed with their open end toward the cam assem-
bly, one spacer on each side. Rotate the cam
assembly while gently pushing it into the outer race.
21
PLANET CARRIER SERVICE
OUTPUT PLANET CARRIER 5. Install a retaining ring (21) in the bore of a planet
gear. Be sure it is completely seated in the groove.
1. The preferred method of removing the planet pin
(18), is to first remove the roll pin (24). This can usu-
ally be done by using a punch or small pry bar to
drive or push the roll pin out of the planet carrier
(63). Access to the roll pin is gained through a
drilled hole in the end of the planet pin. If this
method is not successful, the roll pin must be
sheared by driving or pressing the planet pin out of
the carrier. A piece of pipe or tubing long enough to
hold the planet pin may be used to support the car-
rier while each pin is removed. Adequately support
the assembly and drive or press out one planet pin,
shearing the roll pin. 6. Install a bearing spacer (20) into the bore of the
planet gear. Be sure the step on the spacer is
toward the retaining ring.
22
Thoroughly clean all parts and inspect for damage
and wear. The bearing rollers should be examined
for any signs of spalling, corrosion, discoloration,
material displacement or abnormal wear. If any of
these conditions are found, the rollers should be
replaced. Gears should be inspected for abnormal
wear or pitting and replaced as necessary. Inspect
all machined surfaces and bearing bores for signs of
damage or excessive wear.
23
WINCH ASSEMBLY
The following procedure should be used to assemble er-bore in the output planet carrier holds the split
the complete winch. It assumes all the sub-assemblies rings in the groove. The split rings must be centered
have been properly serviced as described earlier in this for the planet carrier to install over the brake cylin-
manual. der splines.
1. Install the motor end-bracket (96) onto the fully 5. Install two ½-13 eye bolts into the output planet car-
assembled brake cylinder. Install the 12 capscrews rier. With a hoist, install the output planet carrier into
and lockwashers (82, 83) only snug at this time. the drum ring gear. Rotate each gear to align the
They will be tightened to recommended torque after teeth as you lower the carrier. Rotate the carrier to
both end-brackets have been installed. If the lapped align the carrier with the brake cylinder splines.
metal face seal assembly (33) is being replaced, When aligned, the carrier will drop down onto the
install one half of the seal in the brake cylinder and splines and capture the split rings.
the other half in the drum ring gear. The old seal is
simply pried out of position. Thoroughly clean the 6. Install thrust washer (66), onto the second stage
seal seat areas. planet assembly (with output sun gear). A light coat
of oil soluble grease should be used to hold it in
Note: Handle the new seals with great care. The place during assembly. Slide the planet assembly
smooth metal contact surfaces must remain perfect- into the ring gear and engage the output sun gear
ly flat and free of dents or nicks for the seal to oper- with the output planet gears. The second stage
ate leak free. Alcohol acts as a lubricant for rubber. planet gears should now be at least 1/8 inch (3 mm)
If alcohol in not available, a light coating of oil may below the top of the teeth cut into the drum ring
be used. gear. If they are above the ring gear teeth, the unit
is not properly assembled to this point. Either the
Apply denatured alcohol to the large o-rings and thrust washer (66) is improperly positioned, or the
place them in the seal seat in the housings. Apply output planet carrier is not fully engaged onto the
denatured alcohol to the o-ring again and evenly brake cylinder (possibly caused by the split ring not
push the lapped metal face seal into the o-ring. You being fully seated). Remove the second stage plan-
may need the assistance of another technician to et assembly and/or the output planet assembly to
help push the metal face seal into place. Do not use determine and correct the cause of the problem
punches or metal tools directly on the seal surface before proceeding.
as the lapped surface is easily damaged.
7. Install thrust washer (70) onto the primary planet
2. Install bearing cone (36) onto the brake cylinder and assembly (with second stage sun gear). A light coat
new bearing cups (35, 56) into the drum ring gear. of oil soluble grease should be used to hold it in
Place the brake cylinder on the workbench with the place during assembly. Install the primary planet
motor side down. Apply a light coat of oil to the assembly onto the second stage planet assembly,
metal face seals and to the bearing cones and cups. engaging the second stage sun gear with the sec-
Place the drum ring gear onto the brake cylinder. ond stage planet gears. Visually check to be sure
The face seals will hold the two components slight- the thrust washer is properly positioned.
ly apart.
8. Install the primary sun gear (2) through the center of
3. Install bearing cone (57) onto the brake cylinder. the primary planet assembly.
Use a brass punch to gently start the bearing onto
the brake cylinder journal. 9. Press a new bearing (88) if required, into the drum
flange. Use a flat steel plate that is slightly smaller
Note: Fabricate the bearing compression tool OD than the drum bearing as a pressure plate to
shown in the “Tools” section of this manual. press the new drum bearing into the drum flange
bore until it is fully seated at the bottom. Apply non-
4. Using the bearing compression tool, or large frame hardening sealant to the outside diameter of a new
hydraulic press, press the bearing cone down into drum seal then install the new seal into the drum
the bearing cup. Make certain the bearing cone is flange. Use a flat steel plate as a driver and press
fully seated in the cup. Remove any burs or nicks the new seal into the drum flange until it is even with
from the split rings and install the split rings into the the outside edge of the drum flange.
groove in the brake cylinder. The two halves of the
split ring must be centered in the groove. The count-
24
CAUTION 16. Install new o-rings onto the motor pilot adapter (39,
40, 41) and install the adapter into the brake cylin-
In the following step, the drum flange/primary ring der. Install the motor sub-assembly onto the winch.
gear may suddenly drop onto the drum ring gear Install and tighten capscrews and lockwashers (78,
when all primary planet gear teeth are aligned with 79) to 380 lb.-ft. (515 N-m) torque. Install the brake
those in the flange. DO NOT work with your fingers release signal hose from the lowering port of the
between the drum flange and the drum ring gear. motor to the brake release port on the brake cylin-
der.
10. Carefully set the drum flange (5) onto the drum ring
gear, engaging the primary planet gears with the 17. Fill winch to the oil level port or the centerline of the
ring gear teeth machined into the inside surface. assembly with recommended gear oil. Refer to
Turn the drum flange to align the bolt holes with "Recommended Gear Oil" in the "Specifications"
those in the drum ring gear and install the 16 cap- section of this manual.
screws and lockwashers (12, 13). Tighten the cap-
screws (12) to 210 lb.-ft. (285 N-m) torque in an Note: Whenever a winch has been repaired, it should
alternating cross-over pattern. be tested on a test tower or tested on the original equip-
ment. The following test procedure is offered as a sug-
11. Install the drum bearing support/end-bracket gestion only; equipment specifications will dictate the
assembly onto the drum assembly. For added safe- test required.
ty, remove two of the drum bearing support cap-
screws (89) and replace them with two 5/8 - 11 eye 1. Install the winch as recommended in the
bolts so that a hoist may be used to lift the drum "Installation" section of this manual.
flange. After the end-bracket is installed, remove the
eye bolts and install the drum bearing support cap- 2. Install wire rope as recommended by the wire rope
screws (89) snugly at this time. supplier. If unknown, make certain first layer, the
most important, is tightly packed onto the cable
12. Install the tie plates (101) onto the end-brackets with drum and maintain approximately 500 lb. (226 kg)
capscrews and lockwashers (99, 100). Only hand tension load on all layers of wire rope.
tighten the capscrews at this time.
3. Rope off a secure test area for test lift. Make certain
13. Place assembled winch onto a flat surface and no personnel will be under a suspended load. Lift a
evenly tighten the tie plate capscrews (99) to 105 test load of approximately 2500 pounds (1134 kg)
lb.-ft. (142 N-m) torque. Tighten the motor end- approximately 3 feet (1 meter) and return the con-
bracket capscrews (82) to 600 lb.-ft. (814 N-m) trols to neutral/hold. If the load is held firmly, raise
torque in an alternating cross-over pattern. Tighten then lower the test load the full height of the
the drum bearing support capscrews (89) to 210 lb.- boom/mast as available. Increase the load and
ft. (285 N-m) torque. repeat the test. If no problems are found, the winch
may be placed into service. If any malfunction is
14. Turn the winch up on end with the motor end up. detected, the winch must be removed from service
Secure the winch in this position so that it does not until the problem is corrected and the winch passes
fall over. Install the brake release hose adapter into the lift tests. Make a permanent record of the winch
the brake release port. Attach a hand-pump to the repairs that include the date of repair, what was
adapter and apply approximately 500 PSI (3450 wrong before the repair, what was done, what parts
kPa) to release the brake. were used, the test performed and the name of the
technician(s).
15. Install the brake clutch assembly/brake hub into the
brake cylinder. You must align all of the brake discs
and the input sun gear splines. The brake clutch
assembly should bottom out with the input sun gear
against the snap ring in the inside diameter of the
inner brake race. After the brake clutch assembly is
fully seated, release the pressure from the hand-
pump then remove the hand pump.
25
METRIC CONVERSION TABLE
English to Metric Metric to English
LINEAR
inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)
feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.)
miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)
AREA
2 2 2
inches (sq.in.) X 645.15 = millimeters (mm ) millimeters 2 (mm 2) X 0.000155 = inches2 (sq.in.)
feet2 (sq.ft.) X 0.0929 = meters2 (m 2) meters2 (m 2) X 10.764 = feet 2 (sq.ft.)
VOLUME
3
inches (cu.in.) X 0.01639 = liters (l) liters (l) X 61.024 = inches3 (cu.in.)
quarts (qts.) X 0.94635 = liters (l) liters (l) X 1.0567 = quarts (qts.)
gallons (gal.) X 3.7854 = liters (l) liters (l) X 0.2642 = gallon (gal.)
inches3 (cu.in.) X 16.39 = centimeters3 (cc) centimeters3 (cc) X 0.06102 = inches3 (cu.in.)
feet3 (cu.ft.) X 28.317 = liters (l) liters (l) X 0.03531 = feet 3 (cu.ft.)
feet3 (cu.ft.) X 0.02832 = meters3 (m 3) meters3 (m3) X 35.315 = feet 3 (cu.ft.)
fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fl.oz.)
MASS
ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)
pounds (lbs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)
tons (2000 lbs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 lbs.)
tons (2000 lbs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 lbs.)
tons (long) (2240 lbs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.)
PRESSURE
inches Hg (60oF) X 3600 = kilopascals (kPa) kilopascals (kPa) X 0.2961 = inches Hg (60oF)
pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.0703 = kilograms/sq.cm. (kg/cm 2) kilograms/sq.cm. (kg/cm2) X 14.22 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.069 = bars bars X 14.5 = pounds/sq.in. (PSI)
o o
inches H2O (60 F) X 0.2488 = kilopascals (kPa) kilopascals (kPa) X 4.0193 = inches H2O (60 F)
bars X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01 = bars
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
ft.-lbs./min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-lbs./min.
TORQUE
pound-inches (in.-lbs.) X 0.11298 = newton-meters (N-m) newton-meters (N-m) X 8.851 = pound-inches (in.lbs.)
pound-feet (ft.-lbs.) X 1.3558 = newton-meters (N-m) newton-meters (N-m) X 0.7376 = pound-feet (ft.-lbs.)
pound-feet (ft.-lbs.) X .1383 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.233 = pound-feet (ft.-lbs.)
VELOCITY
miles/hour (m/h) X 0.11298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.6214 = miles/hour (m/h)
feet/second (ft./sec.) X 0.3048 = meter/second (m/s) meters/second (m/s) X 3.281 = feet/second (ft./sec.)
feet/minute (ft./min.) X 0.3048 = meter/minute (m/min) meters/minute (m/min) X 3.281 = feet/minute (ft./min.)
TEMPERATURE
o o o
Celsius = 0.556 ( F - 32) Fahrenheit = (1.8 X oC) + 32
30