INSTALLATION, MAINTENANCE AND SERVICE BRADEN SERIES PD10FOR BEST RESULTS, USE ONLY FACTORY CERTIFIED REPLACEMENT PARTS. Serial Numbers and Model Numbers are lo- cated to the side of hydraulic motor, stamped into side plate. Always refer to the Serial Num- ber and Mode! Number when requesting infor- mation or service parts. WARNING! GOODS ARE NOT DESIGNED FOR USE IN THE LIFTING OR MOVING OF PERSONS! ‘The winches described herein are neither designed nor intended for use or application to equi ‘used in the lifting or moving of persons. ‘THE CABLE CLAMPS ALONE ON WINCHES ARE NOT DESIGNED To HOLD RATED LOADS. ‘Therefore, a minimum of S wraps of cable must be left on drum barrel to achieve rated load. DO NOT EXCEED MANUFACTURER'S RECOMMENDATIONS REGARDING HYDRAULIC ‘SYSTEM PRESSURE (P.S.L) AND FLOW RATE (GPM) Hydraulic system must be desighed to assure safe operating performance within the rated capacity of the winch and ail other components.DESCRIPTION OF WINCH The winch has three basic component parts: 1. Winch Base and Side Plates. 2, Hydraulic Motor and Brake Valve 3. Cable Drum Assembly The Cable Drum Assembly is made up of four basic assemb! 4. Cabie Drum 2. Brake Assembly 3, Primary Planetary Reducer 4, Final Planetary Reducer ‘The hydraulic motor Is bolted directly to the brake as- ‘sembly housing (brake cylinder). This housing Is bolted and doweled to the side plate. The motor end of the cable drum, which houses a large bushing, is supported by the brake housing. A quad ring in the bushing pre- vents oil leakage. The ring gear of both planetary re- ducers is splined to the brake housing ‘The final planet carrier is supported through a roller bearing by a shaft projecting from the other side plate. The cable drum is supported on this end by the final planet carrier to which it is splined. HOW IT OPERATES The hydraulic motor drives the sun gear of the pri- mary planetary reducer. The output is transmitted, by the planet carrier, to the sun gear of the final planetary reducer. This output is transmitted directly to the cable drum by a splined fitting between the planet carrier and the drum THE BRAKE SYSTEM The automatic braking system consists of a dynamic braking sub-system and a static braking sub-system, The dynamic braking sub-system has two operating component parts: 1. Brake Valve Assembly 2. Hydraulic Motor The brake valve Is basically a counterbalance valve. It contains a check vaive to allow free flow of oil to the ‘motor in a hoisting direction of rotation, and a pilot ‘operated check valve that prevents flow of oil out of the motor when the operating valve is placed in neutral. ‘When the operating valve is placed in the reverse or lowering position the check valve remains closed until sufficient pressure is present for the pilot piston to open the check valve. After the check valve cracks open, the pilot pressure becomes flow-dependent and modulates the check valve opening which controls the rate of descent of the load The static braking sub-system has three operating component parts: 1. Spring Applied, Multiple Disc Friction Brake 2. Over-running Brake Clutch 3, Hydraulic Piston and Cylinder (Brake Release and Balance) The static brake is released by the brake valve pilot pressure at a point lower than that required to open the pilot operated check valve. This sequence assures that ‘dynamic braking takes place in the brake vaive and that Iittle, if any, heat is absorbed by the friction brake. The friction brake is a load holding brake only and has nothing to do with dynamic braking or rate of de- scent of a load, ‘The over-running clutch is splined to the primary sun gear shaft between the motor and the primary sun gear. t will allow this shaft to turn freely in a rotation to raise a load and force the brake disc to turn with the shaft in rotation to lower a load. The hydraulic cylinder, when pressurized, will release the spring pressure on the brake discs. This is a double- acting cylinder and is balanced to back pressure when the winch is not being operated. HOW IT OPERATES When the winch is powered in a hoisting direction, the drive from the motor to the primary sun gear runs, free. The over-running clutch between the drive shaft and the brake discs allows complete freedom of rotation in this direction. The brake remains fully engaged as the brake release piston is balanced to back pressure. When the lifting operation is stopped, the brake, be- ing fully engaged, prevents the load from lowering. When the winch is powered to reverse, the motor can- not rotate until sufficient pressure is present to open the brake valve, The friction brake within the winch will completely release at a pressure lower than that re- quired to open the brake valve. The extent to which this valve opens will determine the amount of oil that can flow through it and the speed at which the load will be lowered. Increasing the flow of oil to the winch motor will cause the pressure to rise and the opening in the brake valve to enlarge, speeding up the descent of the load. Decreasing this fiow causes the pressure to lower, the opening in the brake valve to decrease, slowing down the descent of the load, When the operating valve is shifted to neutral the pressure will drop, the brake valve will close, stopping the load. The friction brake will engage after the valve has closed and hold the load. When lowering a load very slowly for precise posi tioning, no oil flow actually occurs through the winch motor. The pressure will build up to a point where the brake will release sufficiently 10 allow the load to rotate the motor through its own leakage. This feature results ina very slow speed and extremely accurate positioning, ‘SUMMARY The winch, in raising a load, is not affected by any braking action. When lowering a load the brake valve has complete contro! of the speed at which it is low- ered, When the winch is stopped by returning the con- trol level to neutral — the brake valve stops the load and the friction brake engages to hold the load. ‘Thus the brake receives very little wear in lowering operations. All of the heat generated by the lowering and stopping of a load is absorbed by the hydraulic oil where it can be readily dissipated. The only heat ab- sorbed by the winch in either hoisting or lowering is, due to the efficiency losses within the winch itself.feces Cc—-—* eon | Sane reaaeeeas i La i ] mee one | ESR YET eee Po ato Calne | won| we re sats | tae | ERS L fee cc at a at [eee fe Pre [5 oe aun ew exec rw FEE POON] vw FE | ra | aa wo | Tf aaa) =| — ~ pina “no | % [20200] io [270] 210) — = 7 | po al za fail rain x | 90 fm pele = eee te ii a = mal [I SE rower ae | o al — [-[-] sy rows | * ‘a0 700 | 260) ‘600| 275) 5 po10-is2 a 198 we) 600 | 23) ate | ee row | 3 < | i Pou os ical cE |> poieza iar ™ tes 00 EJ |. fost |e To es 2 [| \ rama | x | 0520 ws x | arn ye a ae | | Peas sa so] rl So | sel 9 | so “Toh aH EW RPT MG ANE CABLE SPEED CABLE PULL 8 ~ 7% we « we we ° Foe L308 ! - ¥ ‘T0e oALLoNs Pew MINUTE workine PRESSURE 7.5. asin an pa8ce town ont at ayer of al for PDO wih 3 ao ar ru, =CROSS-SECTIONAL VIEW ncn ltd oryINSTALLATION SUGGESTIONS 1, The winch should be mounted with the centerline of the cable drum in a horizontal position. ‘The mounting plane can be in any position around this horizontal centerline, 2. itis important that the winch is mounted on a surface that will not flex when the winch is sed, since this would bind working parts of the winch. Be sure that the winch is not mounted ‘nan uneven surface. If necessary, use shim stocks to insure even mounting. Mounting sur- faces should be co-planar +.020" 3, Hydraulic lines that operate the winch should be of sufficient dlameter to assure that back pressure at the winch will not exceed 150 P.S.1. High back pressures will cause premature motor seal failure. 44, The winch directional control valve must be 4-way, 3 position, parallel circuit with motor type spool. Work ports must open directly into tank in neutral position. 5, Hydraulic oil filter should have 10 micron nominal rating and be a full flow type. MAINTENANCE SUGGESTIONS 1. CHECKING OIL LEVEL 1. Unwind the cable far enough to expose the two pipe plugs in the drum barr 2, Turn the winch drum until one plug is at the highest point on the drum. Oil should be level Tith the bottom of the lowest plug. Add approved 90 weight gear oil through top plus. if necessary. Il, OIL CHANGE INFORMATION 1, Oil should be changed after first two (2) months operating time. 2. Oil should then be changed every six months. |. OIL CAPACITY RECOMMENDATIONS [power onum MODEL on garaeiTY POWER ORUM MODEL Om APAGITY Bi as 28 P0077 25 275 a7 i071 and TIA Beatie POTOTETAT 35 POIOT 276 Po10-7-120 25 BOOT 226 PIO TZ 7 PO1O-77-120 225 HE PDI0-79-1-2 85 POTTS is 35 = = 1V.APPROVED GEAR OIL BRAND DESCRIPTION ‘SAE-00 amb Fon 0 Leder 7 Philips | Philips Worm Gear Oi 8382 ‘Sinclair Pennant EP cd ‘Stanogeet 8 Maropa od USE ONLY FACTORY CERTIFIED REPLACEMENT PARTS.SUGGESTIONS FOR TROUBLE SHOOTING A. Winch will not lower toad Wy this ts probably caused by stoppage of the orifice plug in the brake valve. 2. Fo heck ofifice plug, remove hose, item 70 from brake valve, item 45. Rlemove the plug, using a 6°32" Rien wrench. Check the hole in the plug with a wire bt fess than 020" diameter. if the hole Is open, the fault is probably not in the brake valve. 3, Disassemble the winch brake cylinder and release piston to determine cause of non-elease of brake. B. Winch leaks a large volume of oll through the vent plug tiraig is caused by nydraulic oll leaking into the winch Ta She oF both of the following; Gamaged or worn hhyoraulle motor shaft seal, damaged ring in the ‘winch brake mechanism. 2, Bigsonnect hoses, items 71 and 70, and tee, item 32, Rom the brake release port. Attach the hose of 2 tyaraule hand pump, which is equlpped with a dial ge that reads 1000 PS. or more tothe nipple just ereeed. Apply 1000 PSI. to the brake, The brake 2Apat hold this pressure for ten minutes. If pressure folds, detach the pump Nose and connect it to the Drake’ balancing input, and repeat the pressure test. 43, Hite preceding test fails, the brake cylinder ovings tye leaking and should be replaced. 4, it pressure nolds on the preceding test, then the thydrautie motor shaft seal is leaking and should Be replaced, Motor seal failure is usually due to high system back pressure. C. Winch will not hoist rated load yBe certain that the winch has not been mounted on be used. 2, Check for proper hydraulic pressure to the inlet port In the side of the brake valve. This pressure should bbe checked right at the valve for accurate readings. 3, Be certain that the hydraulic system which operates the winch is not running more than 180°F- ‘4, Remember that the winch ratings are established on the first layer of cable. 5. Be certain that any cable sheaves, used with the winch, are operating efficiently Winch runs hot (over 200°F.) or makes excessive noise. Make certain that the winch has not been mounted on an uneven surface. 2, Be certain that the hydraulic system which oper- Stes the winch is not running more than 180°F. . Winch chatters while raising rated capacity load. + the relief valve in the hydraulic system may be trying to by-pass. 2. The flow of hydraulic fluid to the motor may be low. F. Winch vibrates or chatters when lowering rated capacity load. {the orifice plug in the brake valve is probably loose, Remove hose, item 70, from brake valve, item 46. Check orifice plug for tightness, This plug should be snug in the orifice hole. Use a Bia Alien wrench to snug-up the orifice plug in the hole. Do not damage the part by over: tightening. Replace hose. See service bulletin at Be neven surface. If necessary, shim stock should back of service Dok. FOR ANY PROBLEM NOT COVERED ABOVE, CONSULT THE FACTORY FOR ASSISTANCE 'A regular program of preventive maintenance will tend 16 eliminate the need for much emergency servicing and ingure a long lle and trouble-free service from your planetary winch, SOME THINGS TO REMEMBER IN YOUR SERVICING OPERATIONS: @ ver 2 ean, ds tes sen 08 lm 6 vimsk mpoance wen wort ay myaicte eaument Inspect all roplacement parts, prior to installation, to detect any damage which might have occurred in shipment. Use only factory certified replacement parts for optimum results. Hasse reuse expendable parts such as oil seals, O-rings and quad rings: ‘Although they tray appear to be in good condition, many times they are not. a © veer ate nrg nep a wens suas oxezsve wen of dame an al pas. an peetione are DeQun Lubricate all O-rings and oll seals with oil prior to installation.COMPONENTS — MODEL PD10 @ PD10 SERIES O-RING KIT NO. 61259” 200 re ee ee ee USE ONLY FACTORY CERTIFIED REPLACEMENT PARTS. —6—BASIC MATERIAL LIST a 7e%a| (WATERIAL LIST VARIABLES [POTO77-1 Wot Nate 2 Not 3 te & NOTES Lengtn fallen nea capsrows wi vary fa aerent models of rake Nes, Make cetan a ast 172" 0 caseN thvescsengege maar. ar No, 21134 — Grade allen head apace 7/16 x 3-sed with Dake ‘a 222%, att Ne, 24012 — Grade 8 aen ead Tapseren, 7/46 x 3-1/6 used wal trae valve 23608. pat Na. 24222 — Grade 8 aen oad Talsien F196 x S172 ase wih ‘toe vate 24210, 26223 and 1586, ‘previous brake valves tave been ‘persded with bake vate gat aT BeFetaeo. See steven but n back oh service nat “Tis eseembly pat no, 81330) nt used wih ore valves 22688, 24228. 24210, E1266. Sen servic beta i Baek ot ‘erven manual (ne pice ing ganas ben rele y Soong pas, “aro Baa # JoESCRITION Nats: Note 5: 1 z3s00 Jane Gea Cousng 4% | eas Una ear soi Mummers aw 78-0526, use Seema OG. Sel oes 2078 SMoltbe, ue sun ea 2005 Sera Nom tlw 78-2820, we Serna ot. enh Mombe 2 Tekaes ry PART #JoESCRION ate 7: te 8 oes | 2a [Reg Gear Coup >| 25aas bing Gear order hydraulic motor ane coupling spe Sc, ee stv etn ‘Serak Numbers, plow 78-05268, use Site cyimaer 81320. Seral Numibess hove 70-05288. use Drake cylinder bar. Serial Numbers below 78-0269, use ipa ey semen ‘oszeb use input salt 22616 ote 10: Serah Numbers below 78-05268, ust Spacer 2IN10, Sera tubers bow Hos068, use spacer 22417 ote 11: Use 61524 on, IWRC wire Rope, US ‘i820 on Non atating Wire RopeDiseesembly of winch may be done from either end. Remove the winch from the equipment on which itis mounted. For complete disassembly, place the winch in a hori zontal position, drain off and flush. For partial disassembly, trom either end, the oi need not be drained. DISASSEMBLY FROM THE MOTOR END ‘stand winch In vertical position, resting on side plate, tem 43 with the motor UP. ‘hemove hose assemblies, Items 17, 47, 70 and 71- Remove two (2) eansorews and lockwashers, tems 26 and 20 that secure the motor: Remove hydraulic motor, Item 15. Remove O-ring, Item 26 from the motor pilot Remove motor coupling, Item 5. Remove spacer, Item 53. Remove input shaft, Item 38. Remove brake clutch assembly, Item 1. Remove input sun gear, Item 4. Fis completes partial disassembly from the motor end To reassemble the winch from this point, reverse the fore” ‘going procedure, NOTE 1 — It's important to check the rotation of the brake crutch assembly, lem 1, when itis installed inthe winch, ‘Wen installed correctly, the cam and input shat enould tun realy in the same direction the drum turns to pull wire ‘Braden assemblies, this wil be counter Seckwise as viewed from the motor end. An easy way 1° cee e rotation i t hold the race in one hand, arc rotate the cam with the input shaft <1 tne brake Is instaled opposite to the above procedure, tna winch wil be working against the brake, the brake wit wre elease, and there will be no forward rotation of the winch. NOTE 2—In reassembly, itis important to caretuly aon at ‘splines to enable the parts to seat properly. NOTE 3 — Install new O-rings to replace those removed PROCEDURE FOR DISASSEMBLY OF THE BRADEN MODEL PD10 POWER DRUM DISASSEMBLY FROM THE DRUM SUPPORT END Stand winch in a vertical position on motor end with side plate, Item 42, resting on blocks high enough from the work surface to allow clearance for hydraulic motor, ranifold and brake valve. If complete disassembly was Ttarted on the other end, the blocks will not be needed ‘Tamove nuts (or capscrews depending on model) ‘and lockwashers that secure the side plate to the base. ‘Remove nut and lockwasher, Items 57 and 20, from spacer capscrew, item 45. acer ave side plate, Item 43, drum support, tem 35, ‘and oll seal, Item 11, as a complete assembly. ‘The final planet carrier assembly, Iter 3, can now Be removed with the aid of a small hook inserted Into Dear fag area. It there is evidence of oll leakage through {he planet carrier around the planet gear shafts, refer to age 13 for disassembly and reassembly of final planet carrier assembly. Remove output sun gear, Item 7 Remove ring gear, Item 8. Remove primary planet carrier assembly, !tem 2- Tr complete disassembly was started on other end bypass the remainder of this paragraph and proceed byte the next paragraph. Remove Input sun gear, tem vt Remove input shalt, Item 38. Remove brake clutch dosembly, Item 1, Remove spacer, Item $3. Remove motor coupling, Item 5. Remove cable drum assembly, Set winch on base. Remove nuts (or capscrews depending on mode!) and lockwashers that secure the motor side plate 10 the base. Remove side plate, Item 42, and brake cylinder as- sembly, Item 37, from base, Item 44. orrove alx (6) capscrews and lockwashers, Items 22 ‘and 19, With plastic hammer tap side plate, ttem 42, to foosen from brake cylinder dowel pins, Item 48. For disassembly of brake cylinder, refer to brake cylinder section. Item 36.PROCEDURE FOR REASSEMBLY OF THE BRADEN MODEL PD10 POWER DRUM Assemble brake cylinder assembly per instructions in brake cylinder section. Assemble brake clutch assembly per instructions in brake clutch section. ‘Assemble final planet carrier assembly per instruc- tions in final planet carrier section. Assemble primary planet carrier assembly per in- structions in primary planet carrier section. Attach brake cylinder assembly, Item 37, to motor side plate, Item 42, with six (6) capscrews and lock- washers, Items 22 and 19, and four (4) or two (2) dowel pins, Item 48, Coat new quad ring, Item 13, with a light lubricating il and install in groove in cable drum bushing. Itis recommended that a light lubricating oll be used on O-rings and the surfaces to be sealed. Install cable drum, Item 37, using care not to damage the quad ring. Install primary planet carrier assembly, Item 2, in Place in ring gear, Item 8. Install this assembly on brake cylinder by engaging teeth In ring gear with teeth on brake cylinder. Install retaining ring, Item 14, in groove on output sun gear, Item 7. Install output’ sun gear, Item 7 (all models except PD10-77-120). ‘On mode! PD10-77-120 only, slip thrust bearing, Item 14, onto output sun gear, Item 7. Insert this assembly Into spline of primary planet carrier. Install O-ring, Item 12, in groove on final pla tier, ttem 3. Install final planet carrier assembly, Item 3. All splines and gears must be aligned for this step. Planet carrier ‘may required a few light taps with a plastic hammer to be seated properly in the drum. Gare should be taken to Prevent damage to the O-ring seal. Install base, Item 44. Secure to motor side plate, item 42, with nuts (or capscrews depending on model) and lockwashers, Items 50 and 57. Check oil seal, Item 11, for damage. Replace if neces- sary (new seal is recommended). Press seal into drum ‘Support, Item 35. Attach drum support, Item 35, to side Plate, Item 43, with six (6) capscrews and lockwashers, tems 55 and 19. yt care Install side plate assembly, carefully engaging drum ‘support into roller bearing and oil seal onto wear sleeve. ‘Secure side plate, Item 43, to base, Item 44, with nuts (or capscrews depending on model) and lockwashers, Items 50 and §7. Install spacer pipe, item 41, capscrew, Item 45, lock- washer, Item 20, and hex nut, Item 57. Be certain that vent plug, Item 10, is in place. Turn winch over and stand on side plate, Item 43. Install input sun gear, item 4, IMPORTANT: Check the rotation of the brake clutch assembly, Item 1. When installed correctly, the cam and input shaft should tur freely in the same direction the drum turns to pull wire rope in. For most Braden as- semblies, this will be counterclockwise as viewed from the motor and. An easy way to check the rotation Is to hhold the race in one hand, and rotate the cam with the input shaft. {If the brake clutch Is Installed opposite to the above Procedure, the winch will be working against the brake, the brake will not release and there will be no forward rotation of the winch, Insert the brake clutch assembly, Item 1, into the brake cylinder assembly, Item 37. Align splines and install input shaft, Item 38, through, brake clutch assembly, Item 1, into input sun gear, Item 4, Install spacer, Item 53. Install motor coupling, Item 5. (See service bulletin In back of manual). NOTE: If plumbing fittings were re- ‘moved from brake cylinder, they should be replaced before the motor is reinstalled on the brake cylinder. Install nipples, Item 29, and tee, Item 32. Use a good rade of thread compound with Teflon on these fittings. Insert O-ring, Item 26, after coating with oll into coun- terbore in brake cylinder. Install hydraulic motor, Item 15, in place on the brake cylinder, Item 37. Secure with two (2) with capscrews and lockwashers, Items 25 and 20. For hydraulic hook-up see service bulletin in back of service manual, !foll was drained from winch, refill with approved 90 weight gear oll according to the chart in maintenance section.PRIMARY PLANET CARRIER ASSEMBLY, PART NO. 81317 & 81327 — MATERIAL LIST nex Pant | paar. o'lory. | vescpnion | ntwoen | women [3 op mene ery DISASSEMBLY PROCEDURE Remove rollpin, Item 4, by inserting a %s" punch into hole provided in planet carrier, Item 1. A few taps fn the punch will drive the rollpin into the planet gear shaft, Item 3, thus allowing removal of the shaft and Planet gear, Item 2, for inspection. REASSEMBLY PROCEDURE Install planet gear, Item 2, into planet carrier, Item 1. Insert planet gear shaft, Item 3, into planet carrier through hole provided, passing it through planet gear and into planet carrier. Align rollpin holes. Install new rollpin, item 4. This pin should be countersunk to Ys" FINAL PLANET CARRIER ASSEMBLY, AND ASSEMBLY INSTRUCTIONS _ Drive old rollpin completely from the shaft and use new rolipin, 46" x 34", for reassembly. below the surface of the planet carrier. With a center- bunch, dimple the edge of rollpin hole to keep the pin from backing out, Install remainder of gears, shafts and pins in the manner described. PART NO. 81318, 81328 & 81539 — MATERIAL LIST AND ASSEMBLY INSTRUCTIONS neu DescRerion Pana Corie DISASSEMBLY PROCEDURE Remove rollpin, Item 4, by inserting a %«" punch into hole provided in planet carrier, Item 1. A few taps ‘on the punch will drive the rollpin into the planet gear shaft, Item 3, thus allowing removal of the shaft, planet gear, Item 2, and O-ring, Item 5, for inspection. Drive old. rollpin from shaft. ‘After removing all shafts, gears, O-rings and pins, roller bearing, !tem 7, thrust washer, Item 8, and thrust washer pins, Item 9, can be removed. For best performance, the O-ring seals and rolipins should be replaced with new parts prior to reassembly of the planet carrier. REASSEMBLY PROCEDURE Insert planet gear, Item 2, into planet carrier, Item 1 Install O-ring, Item 5, in groove of planet gear shatt Hem 3, and coat lightly with oi Insert rollpin end of shaft into hole in planet carrier on O-ring side, pass through gear. Press or tap lightly until pin end of shaft is aligned with rollpin hole in Planet carrier. Install new rollpin, Item 4, to lock shaft in place and prevent rotation, Countersink rollpin to" below su face of planet carrier. Dimple edge of hole with center- Punch to prevent pin from backing out. Install remainder of gears, shafts, O-rings and roll- pins in manner described, Insert roller bearing, Item 7, into hole provided. Install wear sleeve, Item 6, by using @ hand press to Prevent damage to the part. Install thrust washer, Item 8, secured by pins, Item 3. Coat O-ring (Item 12 on Basic Material List) with oil and install in groove in planet carrier. —10—BRAKE CYLINDER ASSEMBLY, PART NO. 81478 — MATERIAL LIST AND ASSEMBLY INSTRUCTIONS DESCRIPTION Te | ctv. | voaer DESCRIPTION O-Ring | 16 | 21097 | Brake Spring Brake Disc 7_| 1 _| 21038 | Retaining Ring ‘Brake Rin; 8 | 2 | 2100 [one Backup Plate 8 | 1 | 21212 | Brake Release Piston Friction Dise 10 | 1 | 22620 | Brake oytinaer DISASSEMBLY PROCEDURE Set cylinder into a hand operated arbor press and apply sufficient pressure to the brake ring, Item 3, to depress the brake springs. Remove retaining ring, Item 7, with retaining ring pliers. Remove as an assembly: brake ring, Item 3, O-ring, Item 8, backup plate, Item 4, friction discs, Item 5, brake discs, Item 2, brake release piston, Item 9, and brake springs, Item’. Remove two (2) O-rings, Item 1, and one (1) O-ring, Item 8. REASSEMBLY PROCEDURE Prior to reassembly of parts, clean brake cylinder, tem 10, by applying air pressure to all grooves and oll passages. Set brake cylinder on flanged end. Use new O-rings throughout when reassembling brake cylinder, Lightly coat all O-rings with oil before installing. Install O-rings in grooves of brake cylinder, Item 10. Set brake ring, Item 3, on flat surface with O-ring groove up and install O-ring, item 8. Insert backup Plate, Hem 4, friction disc, Item 5, then brake disc, Item 2; alternate until 5 friction disc and 5 brake disc are in place, finishing with a brake disc, Item 2. Install brake release piston, Item 9. NOTE: Check clearance between the brake ring, Item 8, and the brake piston, Item 9, to insure proper operation — YOU MUST HAVE FROM 3/32" TO 1/8" Due to manufacturing tolerances, the amount of steel brake disc, Item 2, may vary. It there is not ‘enough clearance, remove brake piston, Item 9, and install one (1) or more brake disc, Item 2, on top of disc package. If there Is too much clearance, remove ‘one (1) friction disc, Item 5, and add one or more extra brake disc, Item 2, to top of brake package to get proper clearance. DO NOT USE LESS THAN FOUR (4) FRICTION DISC. Reinstall brake piston. BRE [Pista Coat sealing surfaces of the brake release piston ‘and brake ring with oil. Insert sixteen (16) brake springs, Item 6, into holes in brake release piston. Set brake cylinder, Item 10, down over brake assem- bly, aligning teeth of brake ring, Item 3, with teeth in brake oylinder and push into place. Turn brake cylinder assembly over and set into a hand operated arbor press. Lay retaining ring, Item 7, ‘on end of assembly. Apply enough pressure to com- press the brake springs to the extent that the retain- ing ring groove is visible. Install the retaining ring in its groove and release the pressure. Do not use a power press for this assembly since too much pres- sure may be generated resulting in damage to the brake cylinder assembly. Remove cylinder {rom press. Test brake cylinder as- sembly per instructions on page 13.BRAKE CYLINDER ASSEMBLY, PART NO. 81329— MATERIAL LIST AND ASSEMBLY INSTRUCTIONS DESCAPTION ||" TEN PART ba ar] arr TEMary. [PART | vescarnion — ||'s0"]orv. | "ab DESCRIPTION + [2 | 10082 [Oring 3 [5 [21028 | rake Oise [4 [21002 [rake Ring 2 [1 | roar [oring @ | 6 | 21097 | Brake Spring 10 | 1 | 21292 [Brake Release Piston 3 | 5 | 21096 | Friction Dise 7_|+_| 21026 | Retaining Ring 11 | + | 21210 | Brake Retease Gyiinaer Le aivas [ease & [2 [zie foros 12 [1 [aoe [erate Grier DISASSEMBLY PROCEDURE Set cylinder into a hand operated arbor press and apply sufficient pressure to the brake ring, Item 9, to depress the brake springs. Remove retaining ring, Item 7, with retaining ring pliers. Remove as an assembly: brake ring, Item 9, O-ring, tem 8, backup plates, Item 4, friction discs, Item 3, brake discs, Item 5, brake release piston, Item 10, and brake springs, Item 6. The brake release cylinder, Item 11, with O-tings, Items 2 and 8, can now be driven from the brake cylinder, Item 12, by using a plece of hardwood or plastic and a small hammer. Remove two (2) O-rings, Item 1 REASSEMBLY PROCEDURE Prior to reassembly of parts, clean brake cylinder, tem 12, by applying air pressure to all grooves and oll passages. Set brake cylinder on flanged end, Use new O-rings throughout when reassembling brake cylinder. Lightly coat all O-rings with ol! before installing Install O-ring, Item 2, in external groove on brake release cylinder, Item 11, Insert brake release cylinder carefully into its seat in brake cylinder, Item 12, using care not to damage the O-ring. Install O-ring in groove of brake release cylinder Install two (2) O-rings, Item 1, in grooves in brake cylinder, Item 12. Set brake ring, Item 9, on flat surface with O-ring groove up and install O-ring, Item 8. Insert one back- up plate, Item 4, friction disc, Item 3, then brake disc, Item 5; alternate until 5 friction disc and 5 brake disc are in place. Install two Item 4, backup plates on top next to brake piston, Item 10. —12— NOTE: Check clearance between the brake ring, tem 9, and the brake piston, Item 10, to insure proper ‘operation — YOU MUST HAVE FROM 3132" TO 1/8". ‘Due to manufacturing tolerances, the amount of steel brake disc, Item 5, may vary. If there is not ‘enough clearance, remove brake piston, Item 10, and the two (2) backup plates, Item 4, and install one (1) or more brake disc, item 5, on top of disc package. If there is too much clearance, remove one (1) friction disc, Item 3, and add one or more extra brake disc, Item 5, to top of brake package to get proper clear. ance. DO NOT USE LESS THAN FOUR (4) FRICTION DISC. Reinstall two backup plates and brake piston. Coat sealing surfaces of the brake release piston and brake ring with oil. Insert sixteen (16) brake springs, Item 6, into holes in brake release piston. Set brake cylinder, Item 12, down over brake assem- bly, aligning teeth of brake ring, Item 9, with teeth in brake cylinder and push into place. Turn brake cylinder assembly over and set into a hand operated arbor press. Lay retaining ring, Item 7, ‘on end of assembly. Apply enough pressure to com-press the brake springs to the extent that the retain- ing ting groove is visible. Install the retaining ring in its groove and release the pressure. Do not use a power press for this assembly since too much pres- TESTING THE REASSEMBLED BRAKE CYLINDER FOR LEAKS Turn motor side of the assembly in the upward position. Observe two holes with 1/4” N.PLT. threads. These two holes are the pressure inputs into the brake cylinder which operate the brake. When pres- sure is applied to one side, the brake is released and the winch can be operated in a reverse direction for lowering the load. The second hole Is for balancing the floating piston to back pressure. Install nipple, Item 29, in brake release port. Tl port is located at 90° from motor bolt holes. Connect a hydraulic hand pump which is equipped with a dial gauge that reads to 1000 PSI or more. Apply 1000 PSI pressure into brake cylinder and hold for about five minutes. If the pressure holds, the installation of the brake piston is proper. If the piston assembly does not hold pressure and the gauge indicates loss of pressure, check the hose BRAKE CLUTCH ASSEMBLY, PART NO. 81316— MATERIAL LIST AND ASSEMBLY INSTRUCTIONS sure may be generated, resulting in damage to the brake cylinder assembly. Remove cylinder from press. Test brake cylinder as outlined below. and fittings from the pump to the brake cylinder for Teaks. If no leaks are visible, the brake cylinder as- sembly must be disassembled and the O-rings and all parts checked for damage where leakage could occur. During the time that pressure is applied, check the brake friction discs. There should be no tension on the discs. Centering and aligning the discs with the brake clutch assembly is recommended and will be helpful in the final assembly to the motor end of the winch. Use the pressure for checking the other side of the piston by attaching the hand pump to the other port. Pressure here will not release the brake as only back pressure of the hydraulic system will be present when the winch is operated. If the brake cylinder holds pressure in both tests, the brake cylinder assembly is ready for installation. TF Tor. | AR" [_oescnenon — |[RE"[ are. | FART | _oesonierin 1 [1 atost_ [Brake Race 3 [2 | 2819 [Retaining Ring 2 [4 | 12068 [Brake Roller © [| m0 [Serine 3 [1 | zoe | Brake Gam 7 [ «| 24061_| Pinger [2 | 2882 [Brake Rotor Reta DISASSEMBLY PROCEDURE Whenever the winch is disassembled for main- tenance or overhaul, the brake clutch assembly should be disassembled and inspectec Remove one (1) retaining ring, Item 6. Remove brake roller retainer, Item 4. This will release the brake cam, Item 3, brake roll- ers, Item 2, plungers, Item 7, and springs, Item 6, from the brake race, Item 1. ‘The brake cam, Item 3, should be examined for indentations caused by the roller, Item 2. If the cam faces have been damaged, usually due to shock loads of overloading, the cam should be replaced. ‘The plunger, Item 7, should be visually examined for indications of damage and replaced if necessary. NOTE: The cam should be replaced if the brake plung- ers require replacement. The springs, Item 6, should be replaced at time of overhaul or any time their overall free length meas- ures less than 7/8 of an inch. Use only factory certi- fied Braden replacement parts. REASSEMBLY PROCEDURE Insert brake cam, Item 3, into brake race, Item 1, just far enough to insert springs, Item 6, plungers, Item 7, and rollers, Item 2. ‘By Using the input shaft, Item 38 on Variable Ma- terial Lists, to hold the cam, the springs, plungers and rollers can be inserted with the aid of a small screwdriver. ‘After the springs, plungers and rollers are installed and the cam is in place, install the brake roller re- tainer, Item 4, and secure with retaining ring, Item 5. After all parts have been installed, rotate the brake ‘cam with the aid of the input shaft. It should turn in only one direction. =13—PROCEDURE FOR INSTALLING CABLE ANCHOR KIT 61520 ON NON-ROTATING CABLE 1. Install the anchor on the cable. 2. Wire tie cable 2" from the end and separate and broom the strands as shown. Unravel the center strands first. Be sure all the strands are completely unraveled. 3. Clean working surfaces of the cable and anchor of oil, grease and foreign material which may affect the friction, Remove wire tie. ‘4, Insert plug into the center of the cable so the plug 's flush with the end of the cable. Pull cable and ‘plug into the casting. Drive the cable and plug into the casting with a hammer unti the plug stops. Plug will protrude approximately 1/8" from the back of the casting. PROCEDURE FOR INSTALLING CABLE ANCHOR KIT 61521 ON IWRC CABLE 1, Install the anchor on the cable and separate the ‘strands as shown in the sketch. 2. Clean working surtaces of the cable and anchor of oil, grease and other foreign material which may affect the friction between the parts. 8. Install plug shown so that the cable center strand is in the plug center and flush with the ridge on the plug. Space remaining strands equally around the plug. Pull cable and plug into the casting. Drive plug and cable into the casting with a hammer until the plug stops. Plug will protrude approximately 3/8” from back of casting Braden has no control over the actual installation of the cable on a winch and therefore does not take the responsi- bilty for cable and anchor performance. PROCEDURE FOR INSTALLING CABLE ANCHOR KIT 61254 JE,CABLE,USE CABLE BUSHING 22488 sCABLE,NO BUSHING NECESSARY CABLE, DRILL HOLE TOMfe'DIA. CABLE BUSHING —14—PROCEDURE FOR ANCHORING CABLE WITH SINGLE WEDGE 1, Clean working surfaces of the cable, wedge and ee pocket of cil, grease, tar or other foreign materia oe ‘which may affect the friction between the parts. Form a bend in the cable as shown in figure 1 ae Pass the end of the cable through a hole in steel Shae ea plate (see Figure 2) and nit it with a large plastic ‘THIS DIRECTION mallet to form the two sharp bends. (See Table NOTE: CABLE MAY ATTACH AT EITHER END OF DRUM Fiowe ‘4, Place cable wedge, into the bend in the cable and pull cable and wedge into pocket by hitting at point “A” until Br wir x into pocket (see Fi TW er wedge no longer moves into pocket (see Figure 4). /— CABLE WEDGE Flowe 4 Figure 2 5. To assure proper seating of the wedge, a load should ‘be applied to the live end of the cable. The greater the 3. Pull end of cable through cable hole and pocket as oad the better the seating. Hitting at point “A” with ‘shown in Figure 3. load applied will help tighten it more. Braden has no control over the actual installation of the cable on winch and therefore does not take the responsibilty for cable and anchor performance. =re PROCEDURE FOR ANCHORING CABLE WITH DOUBLE WEDGE Clean working surfaces of the cable, wedge and pocket of oll, grease, tar or other foreign material ‘which may affect the friction between the parts. Form a bend in the cable as shown in Figure 1. Pass. the end of the cable through a hole in a steel plate {see TableLtor distance “L") Susy A VAZP LE LL 3. Pull end of cable through cable hole and pocket as shown in Figure 3, came CABLE SPOOLS IN ‘THIS DIRECTION NOTE: CABLE MAY ATTACH AT EitHen'END OF DAUM Fioue 3 4. Place cable wedge, Part 1, into the bend in the cable and pull cable and wedge Into pocket by hitting at point “A” until wedge no longer moves: Into pocket (see Figure 4) Figure 4 —16—Position shaft extending from part 1 of the cable wedge 50 part 2 can be installed. Place part 2 of the cable wedge onto shaft as shown in Figure 3 and install self locking nut. Tighten nut to clamp free end of cable and draw wedges together. 7. To assure proper seating of the wedge, a load Braden has no control over the actual installation of the cable on a winch and therefore does not take the responsi- bility for cable and anchor performance. TABLEI CABLE CLAMP PARTS GROUP APPLICATION should be applied to the live end of the cable. The ‘greater the load the batter the seating. After a load is applied to the cable, the nut should be checked to assure itis stil tight. ‘An alternate method of seating the wedge is to alternately hit at point A and tighten nut until both ‘wedges are seated and nutis tight CHART Listing of Parts Group and Length ‘L” (IN) Cable Size TAB 12 36 5/8 34 718. Parts Parts Parts Parts Parts Parts Winch Group L Group L Group L Group L_ Parts L_ Group L. POIOT D . PD10-1-27 2 . PDIO-71, a " PDIO-71-1 : : PD10-71-127 : * PD10-71-120, : ‘ PO10-75 61429 9% 61429 9% 61429 9% 61429 9% POIO-75-2 61429 9% 61429 9% 61429 9% 61479 9% PO10-77 61420 9% 61429 9% 61429 9% 61429 O% PD10-77-1 61420 9% 61429 0% 61429 9% 61429 9% PO10-77-127 61429 9% 61429 9% 61429 9% 61429 9% PD10-77-120 61429 9% 61429 9% 61429 9% 61420 9% POIO-77-2 61420 9% 61429 9% 81429 9% 61479 6% PDI0-79-1-2 61429 9% 61429 9% 81429 9% 61479 6% PD10D-2 61454 9% 61454 9% 61455 10% 61455 10% POIST . . POIE-ST 61429 61420 9% 61429 9% 61429 9% POIS-75 61429 61429 9% 61429 9% 61429 9% POIS-75-2 61429 61420 9% 61429 9% 61479 6% POIS-77 61429 9% 61429 9% 61429 9% 61429 9% POIE-77-2 61429 9% 61429 9% 61429 9% 61479 8% POIS-7I-1 : I PD15-77-1 61429 9% 61429 9% 61429 9% 61429 9% PO20-79-1-2 61429 7% 61429 8% “see page 14 =7-SERVICE BULLETIN ‘‘A”’ ‘A potential problem exists when part numbers 21055 ‘0r 24060 motor couplings are used in conjunction with the M51A Commercial Shearing Motor. The MS1A motor shaft does not have a shoulder on the spiine, thus allowing the motor coupling to slide too far onto the motor shaft. The resut will be a possible insufficient = 1 1 I 21055 J OLD STYLE COUPLING 81593 NEW STYLE COUPLING SUBJ: MOTOR & COUPLING REPLACEMENT ON PD10 WINCHES ‘engagement with the input shaft, which could shear the teeth and cause a winch fallure. Replacement coupling part number 81593 should be installed on all PD10 winches at ime of motor replacement. The two. styles of motor and motor couplings are shown below. The 81593 coupling can be used with either motor. 9 ''6 i—=sNAP RING (24031) COUPLING (24030) 1BSERVICE BULLETIN INSTALLATION & MAINTENANCE OF BRADEN 1%,” BRAKE VALVES 81596 Four different 1%" brake valves, part numbers 22235, 23688, 24223 and 24210, are currently in use on Braden pianetary winches that require this size valve. Each valve replaced the one preceding it in the above se- ‘quence with a resulting improvement in winch performance. These valves are purchased by Braden from an out: side supplier Starting midyear 1980, Braden will manufacture and furnish a Braden-designed 11,” brake valve which will greatly improve the performance of winches on which itis used. This valve has been designated the HV0A* (part number 81586) and will be phased in as inventories of the alder-style valves are depleted. The HVBOA will interchange with any of the previous valves with minor plumbing changes and possibly different length mounting bolts — The HVBOA requires 314” allen head capscrews, part number 24222, The following data is intended to assist you in connecting the various valves to your winch. —19—81586 ‘RAKE BALANCE PORT (BP) IF 50 EQUIPPED ‘TO BRAKE RELEASE (3A) ‘To MOTOR ‘AND MOTOR MANIFOLD "TO BRAKE BALANCE * TO BRAKE TO BRAKE RELEASE (BA) RELEASE (BR) yowoToR — ANDMOTOR | To MOTOR ‘AND MOTOR DRAIN MANIFOLD DRAIN MANIFOLD NOTE: No! For use on the following Braden Models For use on the following Braden Models ‘Only: PO10, PD10D, PD15, PD20, C2H10 Only: P10, PD10D, PO15, PD20, C2H10 & C2H100. ‘& C2H100. 22235 ee eye MAINTENANCE CHECK VALVE USED 0 aRAKE 22295 Adjustment Proce: Gure: Tee a 0-3000 PSI prescure gauge into brake Folease ine. Hydraulic ol temperature should be above 60" F 1. With no load on winch and at engine le (minimum flow, sot valve at 500-600 PSI while lowering hook 2. It winch will not lower Smoothly. increase pres, Sure, but do not exceed | Al tive valves have a_small oni Repair tor 22298 wave ~ Part No 6865 500 FSI at Governor APM | focated in the Brake Release Port (rnaximum flow) when lower] that can become plugged. When the NoTE: {no with no Toad on winch. | Grtice Ie blocked, the winch wil not NOTE:. tne folowing Braden Models Pressures above 1500 PSI | (ower a load, I this occurs, remove Fo oes ane eOD, FDIS, POZO, C2H10 wil damage o-rings inbrake | the orice as shown, clean, replace &.C2H100 eylinder. and tighten securely. scREW RELEASE (BR) {OTHER MODELS ‘AND MOTOR ‘ARE NON-ADJUSTABLE MANIFOLD