BG6A & BG6B

HYDRAULIC PLANETARY HOIST

INSTALLATION, MAINTENANCE AND

SERVICE MANUAL

PACR WINCH DIVISION

P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
LIT2286 R2 PHONE (918) 251-8511 FAX (918) 259-1575
5/2010 Copyright 2010 PACCAR Winch Division.
Printed in U.S.A. All rights reserved. www.paccarwinch.com
 TABLE OF CONTENTS
PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PARTS AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DIMENSIONAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
HOIST AND WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
RECOMMENDED GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
HOIST EXPLODED VIEW DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
PARTS KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
HOIST SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HOIST DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
BRAKE CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-21
BRAKE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
PLANET CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-25
HOIST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-29
REVERSING DIRECTION OF DRUM ROTATION . . . . . . . . . . . . . . . . . . . . . .30
FASTENER TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
METRIC CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

.Safety informational callout's 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 practices which could result in potential or unsafe practices which could result in
severe personal injury or death if proper proce- personal injury or product or property damage if
dures are not followed. proper procedures are not followed.

1
FOREWORD
Read and understand this entire publication before operating or servicing your BRADEN hoist. Retain this manu-
al 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 Model BG6 series hoist. It is suggested that before doing any work on these units, all assembly and
disassembly instructions should be read and understood.

Some illustrations in this manual may show details or attachments which may be different from your hoist. Also,
some components may be removed for illustrative purposes.

Continuing product improvement may cause changes in your hoist which may not be included in this manual.
When a question arises regarding your hoist or this manual, contact your nearest BRADEN dealer or the factory
Service Department at 918-251-8511, Monday - Friday, 8:00 a.m. to 4:30 p.m. CST, or by Fax at 918-259-1575.
Provide the complete hoist model number and serial number when making inquiries. The model and serial num-
bers are stamped into the data plate attached to the base, to the left of the hydraulic motor.

PARTS AND SERVICE

BRADEN provides parts and service through a network of authorized dealers. Parts and service are not avail-
able directly from the factory. For the name of your nearest dealer, consult your local phone directory or call us
at the phone number shown above.

Serial Number and Model Number are located to

the left of the hydraulic motor, stamped into the
data plate. Always refer to the Serial Number
and Model Number when requesting information
or service parts.

EXPLANATION OF MODEL NUMBER

BG6 B 29 029 01 -1 H
HOIST DESIGN GEAR MOTOR DRUM API HIGH LINE
MODEL MODEL RATIO SIZE SIZE PULL OPTION

BG6 DESIGNATES BRADEN GEARMATIC HOIST MODEL

B DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
29 DESIGNATES TOTAL GEAR REDUCTION
029 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV
DECIMAL POINT ELIMINATED (029 = 2.9 cu in./rev [47.5 cu cm])
01 DESIGNATES THE DRUM
-1 PERMITS TESTING AND INSPECTION PER API 2C RECOMMENDATIONS
H DESIGNATES HIGH LINE PULL OPTION

2
GENERAL SAFETY 9. An equipment warm-up procedure is recommended
RECOMMENDATIONS for all start-ups and is essential at ambient tempera-
tures below +40ºF (4.4ºC). Refer to "Warm-up
Safety for operators and ground personnel is of prime Procedure" listed in the "Preventive Maintenance"
concern. Always take the necessary precautions to section of this manual.
ensure safety to others as well as yourself. To ensure
safety, the prime mover and hoist must be operated with 10. Be sure of equipment stability before operating hoist.
care and concern by the operator for the equipment, and
a thorough knowledge of the machine's performance 11. The winches described herein are neither designed
capabilities. The following recommendations are offered nor intended for use or application to equipment used
as a general safety guide. Local rules and regulations will in the lifting or moving of persons unless specially
equipped from the factory. Refer to preventative
maintenance section for more information.

12. Do not exceed the maximum pressure (PSI/ kPa) or

FAILURE TO OBEY THE FOLLOWING SAFETY REC- flow (GPM/ LPH) stated in the hoist specifications.
OMMENDATIONS MAY RESULT IN PROPERTY
13. Operate hoist line speeds to match job conditions.
DAMAGE, PERSONAL INJURY OR DEATH.
also apply. 14. Never handle the cable when hook end is free and
1. Read all warning tag information and become familiar wear protective gloves when handling wire rope.
with all controls before operating hoist.
15. When winding hoist cable on the hoist drum, never
2. Never attempt to clean, oil or perform any mainte- attempt to maintain tension by allowing hoist cable to
nance on a machine with the engine running, unless slip through hands. Always use "hand-over-hand"
instructed to do so in the service manual. technique.

3. Never operate hoist controls unless you are properly 16. Follow wire rope manufacturer’s guidelines and appli-
seated at the operators station on the prime mover cable standards (such as ASME and API) for rigging
and you are sure personnel are clear of the work and inspecting wire rope.
area.
17. Do not weld on any part of the hoist.
4. Assure that personnel who are responsible for hand
signals are clearly visible and that the signals to be 18. Use recommended hydraulic oil and gear lubricant.
used are thoroughly understood by everyone.
19. Keep hydraulic system clean and free from contami-
nation at all times.
5. Ground personnel should stay in view of the prime
mover operator and clear of hoist drum. Do not allow 20. Use correct size cable anchor for cable and pocket in
ground personnel near hoist line under tension. A hoist drum.
safe distance of at least 1½ times the working length
of the cable should be maintained. 21. The BRADEN wire rope anchors are capable of sup-
porting the rated load when installed properly. For
6. On machines having hydraulically, mechanically additional safety, ALWAYS maintain a minimum of five
and/or cable controlled equipment, be certain the (5) wraps of wire rope on the drum.
equipment is either lowered to the ground or blocked
securely before servicing, adjusting and/or repairing
the hoist. Always apply the prime mover parking
brakes and lower equipment before dismounting the
prime mover.

7. Inspect rigging, hoist and hydraulic hoses at the

beginning of each work shift. Defects must be cor-
rected before operating hoist.

8. Keep equipment in good operating condition.

Perform scheduled servicing and adjustments listed
in the "Preventive Maintenance" section of this
manual.

3
DIMENSIONAL DATA - 01 DRUM
013 MOTOR

MOTOR DRAIN LOWERING PORT

19.76 SAE -4 ORB 12.50
SAE -10 ORB
7.28 4.12 5.27 7 6.25 1.75
(16 -20 THD) (7/8-14 THD)
2.15

HOIST PORT HOIST

SAE -10 ORB
(7/8-14 THD)

7.50
.62
11.57
11.13 1.38

6.00

4X 0.53 3.94
1.27 7.00 MOUNTING HOLES 1.09
7.88
9.52 10.05

NOTE: Other motor options available as special order

MOTORS 020, 029, & 039

HOIST
A
12.50
6.25
7.28 B 4.04
4.12 HOIST PORT 3.78
SAE -16 ORB LOWER PORT
(1 5/16-12 THD) SAE -16 ORB
(1 5/16-12 ORB)

11.13
7.50 1.99
11.57 .88

6.00

4X O.59 3.94
1.57 6.38 1.09
MOUNTING HOLES 7.88
9.52 10.05

MOTOR A B
020 20.06 3.81
029 20.56 4.06
039 21.01 4.32

4
 DIMENSIONAL DATA - 02 DRUM
013 MOTOR

20.06 15.91
7.28 4.12 5.37 MOTOR DRAIN 7.95
2.20 SAE -4 ORB 1.75
7
(16 -20 THD)
HOIST
LOWERING
PORT
HOIST PORT SAE -10 ORB
SAE -10 ORB
(78 -14 THD)
(7/8 -14 THD)

7.50 .62

1.38 15.28
14.56

8.00

.63
4X .656
1.16 7.84 MTG HOLES .87 6.63 3.75
10.14 15.00

NOTE:Other motor options available as special order

MOTORS 020, 029, & 039

15.91
A 3.78 7.95
7.28 4.12
4.04

B HOIST PORT HOIST

SAE -16 ORB LOWER PORT
(1 5/16-12 THD) SAE -16 ORB
(1 5/16-12 THD)

14.56
7.50 1.99

.88 15.28

8.00

.63

1.22 .67
.656
7.84 4 Holes 6.63 3.75
10.26 15.00

MOTOR A B
020 20.58 4.07
029 21.08 4.32
039 21.08 4.32

5
 NOTE: The special order 07 (7:1) gear ratio has only one
THEORY OF OPERATION planetary gear set
Dual Brake System – Description
DESCRIPTION OF HOIST
The dual brake system consists of a dynamic brake sys-
The hoist has four basic component parts: tem and a static brake system.
1. Hoist base The dynamic brake system has two operating compo-
2. Hydraulic motor group nents:
3. Brake cylinder and motor adapter 1. Brake valve assembly
4. Cable drum with gear train 2. Hydraulic motor
The brake valve is basically a counterbalance valve with
The hydraulic motor is bolted to the motor support which improved metering. It contains a check valve to allow free
in turn is bolted to the brake cylinder and the base. The flow of oil to the motor in the hoisting direction and a pilot
motor end of the drum, running on a ball bearing, is sup- operated, spring-loaded spool valve that blocks the flow of
ported by the brake cylinder. The other end of the drum oil out of the motor when the control valve is placed in
runs on a ball bearing on the support bolted to the base. neutral. When the control valve is placed in the lowering
The ring gear for the planetary gear train is machined into position, the spool valve remains closed until sufficient
the drum’s inside surface. pilot pressure is applied to the end of the spool to shift it
against spring pressure and open a passage. After the
HOIST OPERATION spool valve cracks open, the pilot pressure becomes flow-
The hydraulic motor drives the sun gear of the primary dependent and modulates the spool valve opening which
planetary gear set through the splined inner race of the controls the lowering speed.
brake clutch. When driven by the sun gear, the primary
planet gears walk around the ring gear in the drum and The static brake system has three operating components:
drive the primary planet carrier. 1. Spring Applied, Multiple Friction Disc Static Brake
2. Brake Clutch Assembly
The primary planet carrier drives the output planet sun 3. Hydraulic Piston and Cylinder
gear which, in turn drives the output planet gears. The
output planet carrier is splined to the bearing support and NOTE: Some special order models have a solid hub for
cannot rotate. Therefore, as the output planet gears are brake effective both directions.
driven by the sun gear, they will drive the ring gear/drum.
The static brake is released by the brake valve pilot pres-
sure at a pressure lower than that required to open the
pilot operated spool valve. This sequence assures that
dynamic braking takes place in the brake valve and that
little, if any, heat is absorbed by the friction brake.

HYDRAULIC CIRCUIT
Motor Code 020, 029, & 039 Motor Code 010, 011, 012, 013
Motor
Winch Assembly
W/Brake Valve
& Static Brake
Brake
Valve Winch
Winch Brake Brake
BR

DR

Control
Valve
CONTROL
VALVE

Pump
PUMP

6
The friction brake is a load holding brake only and has When the control valve is shifted to neutral, the pressure
nothing to do with dynamic braking or rate of descent of a will drop and the brake valve will close, stopping the load.
load. The static brake will engage and hold the load after the
brake valve has closed.
The brake clutch is splined to the primary sun gear shaft
between the motor and the primary sun gear. It will allow When lowering a load very slowly for precise positioning
this shaft to turn freely in the direction to raise a load and little or no oil flow actually occurs through the hoist motor.
lock up to force the brake discs to turn with the shaft in the The pressure will build up to a point where the brake will
direction to lower a load. release sufficiently to allow the load to rotate the motor
through its own internal leakage. This feature results in a
The hydraulic cylinder, when pressurized, will release the very slow speed and extremely accurate positioning.
spring pressure on the brake discs, allowing the brake
discs to turn freely. The friction brake receives very little wear in the lowering
operation. Most of the heat generated by the lowering and
Dual Brake System – Operation stopping of a load is absorbed by the hydraulic oil where
it can be readily dissipated.
When hoisting a load, the brake clutch which connects the
motor shaft to the primary sun gear, allows free rotation.
The sprag cams lay over and permit the inner race to turn
free of the outer race, see figure 2. The static brake
remains fully applied. The hoist, in hoisting, is not affect-
ed by any braking action.

When the hoisting operation is stopped, the load attempts

to turn the primary sun gear in the opposite direction. This
reversed input causes the sprag cams to instantly roll
upward and firmly lock the shaft to the fully engaged fric-
tion brake.

When the hoist is powered in reverse to lower the load,

the motor cannot rotate until sufficient pilot pressure is
present to open the brake valve. The friction brake with-
in the hoist will completely release at a pressure lower
than that required to open the brake valve. The extent to
which the brake valve opens will determine the amount of
oil that can flow through it and the speed at which the load
will be lowered. Increasing the flow of oil to the hoist motor
will cause the pressure to rise and the opening in the
brake valve to enlarge, speeding up the descent of the
load. Decreasing this flow causes the pressure to lower
and the opening in the brake valve to decrease thus slow-
ing the descent of the load.

7
 In general terms:
HOIST AND WIRE ROPE
For continuous operation at ambient temperatures
INSTALLATION between 50oF (10oC) and 110oF (43oC), use SAE 20W;
for continuous operation between 10oF (-12oC) and 90oF
(32oC), use 10W; for applications colder than 10oF (-
1. The hoist should be mounted with the centerline of
12oC), contact the BRADEN Service Department. The
the cable drum in a horizontal position. The mounting
use of multi-viscosity oils is generally not recommended.
plane of the hoist may be rotated in any position
around this centerline providing the vent in the motor 5. The hydraulic oil filter should have a 10 micron nomi-
adapter is above the centerline of the cable drum. nal rating and be full flow type; or one in accordance
The vent should be as close to top dead center as with recommendations of the pump manufacturer.
possible.
6. The vent plug in the motor adapter must be located
2. When mounting the hoist, use all four (4) mounting
close to top dead center as possible. If the hoist is
holes and grade eight (8) bolts and nuts. Evenly tight-
mounted on a pivoting surface, the vent plug must
en the nuts to the torque in the "Recommended
remain above the centerline of the cable drum to pre-
Torque" chart.
vent gear oil leakage.
Refer to "Dimensional Drawing" for bolt hole size and pat-
tern. 7. Refer to "Dimensional Drawing" for relationship
between drum rotation and which port is pressurized.
The hoist must be mounted on a surface that will not flex
when the hoist is in use, and cause binding of the gear
train. Binding in the gear train will result in accelerated WIRE ROPE INSTALLATION
wear and heat. Also, the mounting surface must be flat
with ± 0.020 in. (.5mm). If necessary, install shims under Since the static brake on this hoist is "effective both direc-
the hoist mounting pads to achieve even mounting. tions", cable can be wound onto the drum in either direc-
3. The hydraulic lines and components that operate the tion without any modifications to the hoist. The cable
hoist should be of adequate size to assure minimum drum has two anchor pockets to accommodate this. Take
back pressure at the hoist. The back pressure at the the free end of the wire rope and insert it through the small
motor must not exceed 50 psi (345 kPa) to maintain opening of the anchor pocket you are going to use. Loop
full system design braking and optimum motor seal the wire rope and push the free end about three-fourths of
life. the way back through the pocket. Install the cable anchor
with the small end toward the drum, then pull the slack out
The hoist directional control valve must be a three position of the wire rope. The cable anchor will slip into the pock-
four way valve with a motor spool such that when the et and secure the wire rope to the drum. A minimum of
valve is in the center position both work ports are open to five (5) wraps of wire rope should remain on the cable
tank (open center, open port). drum at all times. Refer to "General Safety
Recommendations" for additional information.
4. High quality hydraulic oil is essential for satisfactory
performance and long hydraulic system component
life.

Oil having 150 to 330 SUS viscosity at 100o F (38o C) and

viscosity index of 100 or greater will give good results
under normal temperature conditions. The use of an oil
having a high viscosity index will minimize cold start trou-
ble and reduce the length of warm-up periods. A high vis-
cosity index will minimize changes in viscosity with corre-
sponding changes in temperature.

Maximum cold weather start-up viscosity should not

exceed 5,000 SUS with a pour point at least 20o F (-7oC)
lower than the minimum ambient temperature.
The standard cable anchor wedge supplied with the hoist
Under continuous operating conditions the temperature of is intended for 5/16 to ½ in. (8 to 13 mm) wire rope.
the oil at any point in the system must not exceed 180ºF
(82oC). 120oF (49oC) to 140oF (60oC) is generally consid-
ered optimum.

8
PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your 3. Vent Plug
planetary hoist is strongly recommended to minimize the The vent plug is located in the motor adapter. It is very
need for emergency servicing and promote safe, reliable important to keep this vent clean and unobstructed.
hoist operation. Whenever gear oil is changed remove vent plug, clean in
solvent and reinstall.
Field experience supported by engineering tests, indi-
cates the three (3) service procedures listed below are the Do not paint over the vent or replace with a solid plug.
MOST critical to safe, reliable hoist operation and must be
observed. 4. Hydraulic System
The original filter element should be replaced after the first
• Regular Gear Oil Changes - initial break-in oil fifty (50) hours of operation, then every 500 operating
change after 250 hours (2 Months), then every 1000 hours or three (3) months, or in accordance with the
hours or six (6) months thereafter. equipment manufacturer's recommendations.

• Use of Proper Gear Oil - recommended type for pre- 5. Wire Rope
vailing ambient temperature. See chart on page 10 Inspect entire length of wire rope according to wire rope
manufacturer's recommendations.
• Periodic Disassembly and Inspection of All Wear
Items - in compliance with American National 6. Mounting Bolts
Standards Institute (ANSI) specification B30.5c 1987 Tighten all hoist base mounting bolts to recommended
and American Petroleum Institute (API) recommend- torque after the first one hundred (100) hours of operation,
ed practice RP 2D section 3. then every 1000 operating hours or six (6) months,
whichever occurs first.
The following minimum service intervals are specified for
operating hours of the prime mover. 7. Warm-up Procedure
A warm-up procedure is recommended at each start-up
1. Oil Level and is essential at ambient temperatures below +40oF
The gear oil level should be checked every 200 operating (4oC). The prime mover should be run at its lowest rec-
hours, once per month, when an oil leak is spotted, or ommended RPM with the hydraulic hoist control valve in
whichever occurs first. To check the oil level, remove the neutral allowing sufficient time to warm up the system.
large plug located in the center of the drum support. The The hoist should then be operated at low speeds, hoist
oil should be level with the bottom of this opening. If addi- and lower, several times to prime all lines with warm
tional oil is needed, refer to "Recommended Planetary hydraulic oil, and to circulate gear lubricant through the
Gear Oil". planetary gear sets

2. Oil Change
The gear oil should be changed after the first one hundred
(100) hours of operation, then every 1,000 operating
hours or six (6) months, whichever occurs first. The gear
oil must be changed to remove wear particles that impede
Failure to properly warm up the hoist, particularly
the reliable and safe operation of the brake clutch and
under low ambient temperature conditions, may result
erode bearings, gears and seals. Failure to change gear in temporary brake slippage due to high back pres-
oil at these suggested minimum intervals may contribute sures attempting to release the brake, which could
to intermittent brake slippage which could result in proper- result in property damage, severe personal injury or
ty damage, severe personal injury or death. death.

The gear oil should also be changed whenever the ambi-

ent temperature changes significantly and an oil from a
different temperature range would be more appropriate.
Oil viscosity with regard to ambient temperature is critical
to reliable brake operation. Make certain that the gear oil
viscosity used in your hoist is correct for your prevailing
ambient temperature. Failure to use the proper type and
viscosity of planetary gear oil may contribute to brake slip-
page which could result in property damage, severe per-
sonal injury or death. Refer to "Recommended Planetary
Gear Oil" for additional information.

9
8. Recommended Planetary Gear Oil

Field experience, supported by extensive engineering

tests, indicates the use of the proper planetary gear oil is
essential to reliable and safe operation of the brake and
obtaining long gear train life. Failure to use the proper type and viscosity of plane-
tary gear oil may contribute to intermittent brake slip-
For simplicity, we have listed readily available products in page which could result in property damage, severe
each temperature range which has been tested and found personal injury or death. Some gear lubricants con-
to meet our specifications. This is not to say that other tain large amounts of EP (extreme pressure) and anti-
lubricant brands would not perform equally as well. friction additives which may contribute to brake slip-
page and damage to brake friction discs or seals. Oil
If the following lubricant brands are not available in your viscosity with regard to ambient temperatures is also
area, make certain your lubricant vendor supplies you critical to reliable brake operation. Our tests indicate
with oil that is equivalent to those products listed below. that excessively heavy or thick gear oil may contribute
to intermittent brake slippage. Make certain that the
Planetary winches are factory filled with Exxon Spartan gear oil viscosity used in your hoist is correct for your
EP 150 or equivalent. prevailing ambient temperature.

9. Periodic Teardown/ Inspection

We recommend that the hoist be disassemble for a thor-

ough inspection of all wear items every 2,000 hours of
operation or twelve (12) months, whichever occurs first.

PREVAILING AMBIENT TEMPERATURE

oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF

MOBILGEAR 600 XP 220 OR EQUIVALENT

AGMA 5 EP, ISO VG 220

MOBILGEAR 600 XP 150 OR EQUIVALENT

AGMA 4 EP, ISO VG 150

MOBILGEAR SHC 150

SYNTHETIC OR EQUIVALENT

oC -40 -30 -20 -10 0 10 20 30 40 50 oC

NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
i CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.

Planetary hoists are factory filled with Mobilgear 600 XP 150, or equivalent. Consult your oil supplier for other equivalent
oils if required.

Mobil Shell Chevron Texaco

Mobilgear 600 XP 150 Omala 150 Gear Compounds EP 150 Meropa 150
Mobilgear 600 XP 220 Omala 220 Gear Compounds EP 220 Meropa 220

Gear Oil Capacity

-01 and -02 drums = 2 Pints (0.9 L)

10
 TROUBLE SHOOTING
TROUBLE PROBABLE CAUSE REMEDY
1. System relief valve may be set too Install a pressure gauge in the haul-in port and apply a
A. low. stall pull on the hoist. If pressure is low, increase relief
valve setting until recommended pressure is obtained.
Hoist will not
pull maxi- NOTE: If pressure does not increase in proportion to
mum load. adjustment, relief valve may be contaminated or worn
out. In either case, the relief valve may require disassem-
bly or replacement.

2. If this trouble occurs suddenly after Remove relief valve, disassemble and clean parts thor-
working at maximum pull, a particle oughly in a suitable solvent.
of dirt may be lodged under the sys- Reassemble and install relief valve. Reset pressure
tem relief valve, holding it partially according to specifications.
open. If this is the cause, a consid-
erable loss in line speed may be
noticed as the load on the cable is
increased.

3. If the pump is belt driven, the belt Check belts when pump is at full PSI (kg/cm2) (stall pull
may be slipping. on hoist). Tighten belts if they are found to be slipping.

4. The oil level in the reservoir may be Check oil level in the reservoir. Check the suction line for
too low. The suction line may be damage, externally and internally. Replace suction line if
restricted or have an air leak causing necessary.
cavitation at the inlet port. This will
cause the pump to make a whining
noise.

5. The hoist may be mounted on an Reinforce mounting surface.

uneven or flexible surface which
causes distortion of the hoist base If necessary, use steel shim stock to level hoist.
and binding of the gear train.
Binding in the gear train will absorb First loosen, then evenly retighten all hoist mounting bolts
horsepower needed to generate the to recommended torque.
rated line pull and cause heat.

6. Be certain hydraulic system temper- Same as remedy for A-5.

ature is not more than 180oF (82oC).
Excessive hydraulic oil temperatures Same as remedy for B-4
increase motor internal leakage and
reduce motor performance.

7. Hoist line pull rating is based on 1st Refer to hoist performance charts for additional informa-
layer of wire rope. Expected line pull tion.
may be in excess of hoist rating.

8. After all the causes listed above Install a pressure gauge in the motor haul-in port and
have been investigated and it is apply a stall pull on the hoist. If the pressure is up to max-
found that the hoist will stall at maxi- imum and the bare drum line pull is less than the speci-
mum pressure without developing fied line pull, the trouble will be in the hoist.
the maximum pull on the bare drum,
Disassemble hoist according to disassembly instructions
the trouble may be in the hoist.
and check that gear train turns freely. If gear train is
found to be satisfactory, inspect the hydraulic motor,
according to the service instructions for the hydraulic
motor.

11
 TROUBLE SHOOTING
TROUBLE PROBABLE CAUSE REMEDY

9. Rigging and sheaves not operating Perform rigging and sheave service as recommended by
A. efficiently. manufacturer.

1. Same as A-2. Same as remedy for A-2.

B. 2. Same as A-4. Same as remedy for A-4.
3. Same as A-6. Same as remedy for A-5 & B-4.
Considerable 4. If this trouble has increased gradual- Remove and inspect pump. If satisfactory, consult the
reduction in ly, the hydraulic pump or hoist motor disassembly instructions for the hoist and remove and
line speed. may be worn. inspect the motor according to the service instructions for
the hydraulic pump.

1. Control valve may be restricted in its Check the travel of the control valve spool. The spool
C. travel. travel should be the same in both directions.
Reverse 2. Same as A-1. Same as remedy for A-1.
speed is 3. Oil may be too thick causing a high Follow warm-up procedure in “Preventive Maintenance”
slower than resistance to rotation at the brake section.
forward plates and causing the relief valve to
speed. by-pass.
4. Same as F-1. Same remedy for F1.

1. Excessive system back pressure Install a pressure gauge at the “pay-out” port of the
D. acting on the brake release port. hydraulics motor. Operate the pump at full throttle and
Brake will monitor pressure in “neutral” and haul-in positions. If the
not hold pressure is greater than 50 PSI, check for restrictions in
when control the return line from the hoist to the control valve and the
valve is control valve to the reservoir.
returned to
neutral after 2. Friction brake will not hold due to Disassemble hoist to inspect/replace worn parts.
lifting a load. worn or damaged brake disks.

1. Same as D-2 or 2. Same as remedy for D-1 or 2.

E. 2. Hoist is being overloaded. Install a pressure gauge at the haul-in port and apply a
stall pull on the hoist. If the pressure is higher than the
Brake will maximum specified PSI, reduce the pressure.
not control or
stop the 3. After the causes listed above have Disassemble the brake assembly according to the disas-
load when been investigated and found to be sembly instructions. Inspect the brake springs, and
lowering. satisfactory, the trouble may be in brake plates.
the hoist.

12
 TROUBLE SHOOTING
TROUBLE PROBABLE CAUSE REMEDY

1. The friction brake may not be releas- Disassemble and inspect the brake cylinder seal.
F. ing as a result of a defective brake
cylinder seal.
The hoist will NOTE: If the brake cylinder seal is
not lower the defective you will usually notice oil
load or not leaking from the hoist vent plug.
lower the load 2. Friction brake will not release as a Disassemble brake to inspect brake disks.
smoothly. result of damaged brake disks.
3. Same as B-4. Same as remedy for B-4.
4. Same as A-3. Same as remedy for A-3.
5. Same as A-5. Same as remedy for A-5.
6. Control valve handle being operated Operate control valve smoothly when starting and stop-
too quickly. ping a load. Conduct operator training as required.
7. Insufficient gear oil in cable drum. Remove oil level plug and check oil level. Fill to proper
level.
8. Control valve does not have good See “Hoist Installation” section for control valve specifica-
metering characteristics. tions.

1. Same as A-5. Same as remedy for A-5.

G. 2. Be certain that the hydraulic system
temperature is not more than 180
The hoist runs degrees F. Excessive hydraulic oil
hot. temperatures may be caused by:
A. Plugged heat exchanger. Thoroughly clean exterior and flush interior.
B. Too low or too high oil level in Fill/drain to proper level.
hydraulic reservoir.
C Same as A-1. Same as remedy for A-1.
D Hydraulic pump not operating effi- Remove and inspect pump.
ciently.
3. Excessively warn or damaged internal Check suction line for damage. If pump is belt driven,
hoist parts. belts may be slipping. Replace/tighten belts.
4. Same as F-7. Same as remedy for F-7.

1. Same as A-1. Same as remedy for A-1.

H. 2. Same as B-4. Same as remedy for B-4.
3. Hydraulic oil flow to motor may be too Increase pump rpm.
Hoist low.
“chatters” 4. Same as F-6. Same as remedy for F-6.
while raising
rated load.

13
Braden/ Gearmatic BG6A & BG6B Components

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

1 BASE 1 49 16166-8 PLUG 1
2 CABLE DRUM 1 51 DRIVE SCREW 4
3 CABLE DRUM CLOSURE 1 53 LOCKWASHER 6
5 PRIMARY SUN GEAR 1 54 CAPSCREW 6
19 THRUST RACE 1 55 CABLE WEDGE 1
20 THRUST RACE 1 70 INPUT SHAFT 1
21 BEARING SUPPORT 1 100 BRAKE CLUTCH ASY. 1
27 OIL SEAL 1 222 BRAKE CYLINDER/BG6B 1
28 BALL BEARING 2 223 MOTOR ADAPTER 1
29 SNAP RING 1 233 LOCKWASHER 8
31 O-RING 1 234 CAPSCREW 8
32 OIL SEAL 1 235 SPRING PLATE 1
33 LOCKWASHER 6 236 U-CUP SEAL 1
34 CAPSCREW 6 237 RELIEF VALVE 1-5 PSI 1

14
 REFER TO MATERIAL LIST FOR PART NO. LISTINGS

“B” Model Brake Cylinder

*= QUANTITY OF PART
DISPLAYED MAY NOT BE
ACCURATE FOR YOUR
APPLICATION. CONSULT
RESPECTIVE MATERIAL
LIST FOR ACCURATE
QUANTITY’S

ITEM DESCRIPTION QTY

ITEM DESCRIPTION QTY 330 1941006 SNAP RING 1
238 BRAKE PLATE SPACER 1 372 SNAP RING 1
244 FRICTION DISC 7* 400 OUTPUT PLANET CARRIER ASY. 1
245 BRAKE DISC 8* 406 OUTPUT PLANET CARRIER 1
246 O-RING 1 407 OUTPUT PLANET GEAR 3
247 SPRING 6* 408 OUTPUT PLANET GEAR SHAFT 3
257 SPRING LOCATOR 1 409 ROLLER BEARING 6
300 PRIMARY PLANET CARRIER ASY. 1 410 BEARING SPACER 3
304 OUTPUT SUN GEAR 1 411 THRUST BEARING 6
313 PRIMARY PLANET CARRIER 1 412 ROLLPIN 3
314 PRIMARY PLANET GEAR 3 100 BRAKE/CLUTCH ASSY/GH5/PD5 1
315 PLANET GEAR SHAFT 3 200 BRAKE CYLINDER ASSY 1
316 BEARING ROLLER 3 300 PRIMARY PLANET CARRIER ASSY 1
317 THRUST WASHER 6 400 OUTPUT PLANET CARRIER ASSY 1
318 ROLLPIN 3 700 HYD MOTOR GROUP 1

15
 2. Stand the hoist on the bearing support plate. Remove
HOIST SERVICE the brake release tube assembly (59) between the
brake valve block and the brake cylinder end plate.
FOREWORD TO HOIST SERVICE Remove the capscrews and lockwashers which
secure the motor to the motor adapter, and lift the
Before any part is removed from the hoist, all service motor out of the motor adapter. Remove and discard
instructions should be read and understood. the O-ring installed on the pilot of the motor.

Work in a clean, dust free area as cleanliness is of utmost

importance when servicing hydraulic equipment.

Inspect all replacement parts, prior to installation, to

detect any damage which might have occurred in ship-
ment.

Use only genuine BRADEN replacement parts for opti-

mum results. Never reuse expendable parts such as oil
seals and O-rings.

Inspect all machined surfaces for excessive wear or dam- 3. Remove the overrunning clutch assembly (100) and
age…before reassembly operations are begun. sun gear (70) from the hoist.

Lubricate all O-rings and oil seals with gear oil prior to 4. Remove six capscrews (33 & 34) from the the base
installation. (1), remove brake cylinder assembly.

Use a sealing compound on the outside surface of oil

seals and a light coat of thread sealing compound on pipe
threads. Avoid getting thread compound inside parts or
passages which conduct oil.

Thoroughly clean all parts in a good grade of non-flamma-

ble safety solvent. Wear protective clothing as required.

Refer to exploded view drawing for item numbers used in

service procedures.

• Perform all applicable trouble shooting operations

BEFORE disassembling hoist.

5. Lift out primary sun gear (70). Then lift out cable drum
closure (3).
DO NOT CLEAN BRAKE FRICTION DISKS IN SOL-
6. Lift out primary planetary gear assembly (300), fol-
VENT. SOLVENT MAY CAUSE DAMAGE TO FRIC-
lowed by removing the output planetary assembly
TION MATERIAL WHICH MAY RESULT IN BRAKE
(400). Thrustwashers (20 & 39) are set between pri-
FAILURE AND LOSS OF LOAD CONTROL.
mary planetary gear and output planetary gear.
These are not secured and may fall out upon removal
of planetary assemblies.
HOIST DISASSEMBLY
1. Disconnect all hoses and fittings at the hoist. 7. Stand hoist assembly on motor mount flange and
remove six drum support capscrews (33, 34, 53, &
54). Removee drum bearing support (21). Drum can
now be lifted from base. Drum bearing and seal (27
& 28) are pressed into drum enclosure.

16
DRUM ASSEMBLY SERVICE
1. Remove the bearing and seal from support end of the
drum. Check the ring gear teeth (machined into the
inside surface of the drum) for nicks, spalling or
excessive wear. Replace the drum if wear is greater
than 0.015 in. (0.4 mm) when compared to unworn
area of teeth.

2. Install new bearings in the drum if replacement is nec-

essary. Apply a non-hardening sealant on the outside
diameter of each new seal and press the seals into
the drum, using a flat plate to avoid distortion.

17
 MOTOR SUPPORT-BRAKE CYLINDER SERVICE
NOTE: Starting mid-year 1996, Braden changed the steel
brake separator discs from a splined tooth design to a
lobed design. This required a change to the motor sup-
port and brake cylinder and the addition of a spring spac-
er. A hoist with the lobed discs can be identified by a
machined groove on the outside diameter of the motor
support. When replacing steel brake discs, the motor sup-
port or brake cylinder, care must be taken to properly
identify the correct parts. Splined discs, and their mating
motor support and brake cylinder will remain available as
spare parts.

3. Remove the brake springs.

CLEAN AND INSPECT

New lobed steel brake separator plates and motor sup-

port. Note groove on outside diameter of motor support.

Although most photos in this section show splined discs,

all procedures are the same except where specifically
noted.

DISASSEMBLY

1. Thoroughly clean and inspect all parts at this time.

Check brake piston sealing surfaces on brake cylin-
der and motor support for scoring or wear. Be sure
brake release port is free of contamination.

1. After removing the motor support and brake clutch

assembly, continue brake cylinder disassembly by
removing the spacers, friction brake discs and steel
brake discs.

2. Check oil seal and bearing surfaces on brake cylinder

for damage or wear.
2. Remove the piston back-up ring and pressure plate.

18
 ASSEMBLY

3. Place friction brake disc on flat surface and check for

1. Begin assembly by placing motor support on work-
distortion with a straight edge. Friction material should
bench with motor mounting surface down. Install new
appear even across entire surface with groove pattern
O-ring and back-up ring as shown.
visible. Replace friction disc if splines are worn to a
point, disc is distorted, friction material is worn
unevenly, or groove pattern is worn away.

4. Place steel brake disc on flat surface and check for

distortion with a straight edge. Check surface for
signs of material transfer or heat. Replace steel disc
if splines are worn to a point, disc is distorted or heat
discolored.

2. Install a brake spacer into the motor support. (Not

required with lobed discs.)

5. Check brake spring free length; minimum free length

is 15/16 in. (23.8 mm). Check springs for any sign of
cracking or failure. If a brake spring must be replaced
for any reason, then ALL brake springs must be
replaced.

CAUTION
Failure to replace brake springs as a set may result in
uneven brake application pressure and repeated brake
spring failure.

19
 6. Lubricate the brake piston seal and motor support
3. Insert first, a steel brake disc against the spacer fol- sealing surface with petroleum jelly or hydraulic oil.
lowed by a friction brake disc then alternate steel and Install new piston seal to motor support, seal lip down.
friction discs until seven (7) friction and eight (8) steel
discs have been installed. Finish with a steel brake
disc on top.
NOTE: It is a good practice to pre-lubricate the discs
in light motor oil prior to assembly.

OLDER STYLE BRAKE CYLINDER

7. Install brake springs into brake cylinder

4. Install the remaining brake spacer on top of the last

steel brake disc. (This is the only spacer used with
lobed discs, except on some of the 67:1 ratio units
with the 1.3 displacement motors, two of the spacers
are stacked on the brake discs.)

NEW STYLE BRAKE CYLINDER

7A. When using the new style brake cylinder without
milled spring pockets, install the spring spacer, then
5. To check brake stack height, apply light pressure to the brake springs.
the brake spacer. Hold brake spacer down firmly by CAUTION

hand and measure clearance in three places between ! WARNING !

uppermost motor support flange and brake spacer.
Always use the molded spring spacer with the new
Brake spacer must rise above uppermost flange .080
brake cylinder. The brake springs must be properly posi-
in. (2 mm) maximum and .000 in (.00 mm). If the gap
tioned by the spring spacer. Failure to install the spring
exceeds the maximum limit, there are too many brake
spacer may allow the springs to contact each other and
discs in stack-up or the discs are distorted. If the gap
become damaged. This could result in loss of load con-
is less than the minimum, there are too few discs in
trol, property damage, injury or death.
stack-up or the discs are worn out.

20
8. Apply petroleum jelly to the entire sealing surface of
the brake cylinder and to the piston seal. Install the
brake cylinder over the motor support being careful to
avoid damaging the piston seal or motor support O- BRAKE CYLINDER PRESSURE TEST
ring. (A press may be necessary to avoid cocking the 1. Install the –4 J.I.C. fitting into the brake release port.
brake cylinder during installation.) Connect a hand pump with accurate 0-2000 psi (0-
13,800 kPa) gauge and shut-off valve to this fitting.
9. Install motor support capscrews and evenly tighten to Apply 1000 psi (6,900 kPa) to the brake. Close shut-
recommended torque. off valve and let stand for five (5) minutes. If there is
any loss of pressure in five (5) minutes, the brake
cylinder should be disassembled for inspection of the
sealing surfaces and brake piston.

2. WHILE PRESSURE IS APPLIED AND THE BRAKE

RELEASED, install the brake clutch assembly in the
brake pack, short end of the inner race toward motor.
Turn the clutch back and forth as you align the outer
race splines with the brake disc splines.

3. Release the pressure on the brake cylinder then

remove the brake clutch assembly. The brake cylin-
der assembly is now complete and ready to be
installed in the hoist.

21
 BRAKE CLUTCH SERVICE
DISASSEMBLY

1. Remove the snap ring and sprag bushing retainer

from one end only.

4. Next, slide the sprag clutch out, inspect the sprag

clutch closely for abnormal wear, cracks, pitting or
corrosion. Check small clips for breakage or bright
spots; the signs of excessive wear. Unless the outer
race or remaining sprag bushing is damaged or
shows excessive wear, there is no need for further
disassembly. If disassembly is necessary, remove the
bushing according to the procedure covered in Step
No. three (3). All brake clutch assembly parts should
be thoroughly cleaned and inspected before assem-
bly.
CAUTION
I
! WARNING !
The polished surfaces of the races and sprag cams
must be perfectly smooth to insure positive engagement
2. Pull the inner race out. Examine the race for scoring,
of the clutch. The slightest defect may reduce brake
wear or indentations caused by the sprag cams.
clutch effectiveness, which may lead to loss of load con-
trol and result in property damage, personal injury or
death. It is generally recommended to replace the
entire brake clutch assembly if any component is defec-
tive.

ASSEMBLY

3. Use a screwdriver and mallet to remove the sprag

bushing from one end of the outer race. There are
four special cut-outs in the bushing for this purpose.
Be careful not to damage the bushing inside surface. 1. Press a sprag bushing into the outer race, using a
If a bushing’s inside surface is damaged or shows mechanical or hydraulic press. A flat plate of approx-
wear, replace it. imately the same diameter as the bushing flange out-
side diameter should be placed between the press
and bushing during assembly to protect the bushing.
Be certain the bushing flange is against the shoulder
in the outer race.

22
 6. Turn the assembly over with the snap ring down.
2. Turn the assembly over and install the sprag clutch in Install the second retainer and snap ring. Make cer-
the bore of the outer race. tain the snap ring is seated in the groove properly.

3. Press the remaining bushing into the race. Again,

make sure the bushing is against the shoulder.

7. This is a completed brake clutch assembly.

4. Next, install a sprag bushing retainer, then a snap ring

on the inner race. Be sure the snap ring is seated in
the snap ring groove.

CAUTION

! WARNING !
WARNING
Be certain the snap ring is seated in the groove in the
5. Slide the inner race through the bushings and sprag splined bore of the inner race. This snap ring will keep
clutch (the race will have to be rotated in the free- the brake clutch assembly correctly positioned in the
wheeling direction to start it through the sprag clutch). center of the friction brake pack. Binding of the brake or
If the inner race will not go through the bushings, the brake failure may occur if this snap ring is omitted.
bushings have probably been damaged and should
be replaced.

23
 PLANET CARRIER SERVICE
OUTPUT PLANET CARRIER
DISASSEMBLY

1. Remove the planet gears by driving the roll pins into

the center of the planet shafts. 3. Now you can remove the planet shafts, bearings,
spacer, thrust washers and gears. Thoroughly clean
all parts and inspect for damage and wear. The bear-
ing rollers should not exhibit any irregularities. If the
rollers show any sign of spalling, corrosion, discol-
oration, material displacement or abnormal wear, the
bearing should be replaced. Likewise, the cage
should be inspected for unusual wear or deformation,
particularly the cage bars. If there is any damage that
will impair the cage’s ability to separate, retain and
guide the rollers properly, the bearing should be
replaced. The thrust washer contact areas should be
free from any surface irregularities that may cause
abrasions or friction. The gears and shafts should be
inspected for abnormal wear or pitting. Replace if nec-
essary.

ASSEMBLY
2. Use a punch to drive the roll pins from the planet
shafts. Do not reuse the roll pins.

1. Place the output planet carrier on workbench with

splined coupling side down. Install output thrust plate
in center of carrier.

24
2. Insert two (2) bearings and a bearing spacer into a
gear with the spacer between the bearings. Place a
thrust washer on each side of the gear and position in 4. Note that the roll pin is slightly recessed in the carrier
a carrier opening. Slide the shaft through the carrier, when properly installed. With a center punch, stake
thrust washer, bearing-gear sub-assembly and the carrier next to the pin hole as shown. This will dis-
remaining thrust washer. tort the hole so the pin will not back out. Repeat these
steps for each of the three planet gears.

PRIMARY PLANET CARRIER

1. To service the primary planet carrier, the steps are the
same as for the output carrier except there is only one
bearing for each gear and no bearing spacer.

3. Carefully align the pin hole in the carrier with the hole
in the planet gear shaft and drive the roll pin into
place. Always use NEW roll pins. When properly posi-
tioned, 50% of the roll pin will engage the planet gear
shaft and 50% will remain in the planet carrier.

25
 HOIST ASSEMBLY

3. Center the drum in the opening of the base. Lubricate

the bearing support with petroleum jelly or gear oil
and install in base and drum.

1. Place hoist base on side with bearing support end up.

CAUTION
2. Install a new bearing in the drum if replacement is
necessary. Apply a non-hardening sealant on the out- Be sure the vent plug is located above the horizontal
side diameter of the new seal. Install the spring side centerline for the intended application. Oil leakage
of the seal next to the bearing, then press into the may occur if vent is positioned incorrectly.
drum, using a flat plate to avoid distortion. Be sure
drain plug is installed securely. 4. Tighten the bearing support capscrews to the recom-
mended torque.

5. Stand hoist on bearing support end. Install the output

sun gear and thrust washer into output planet carrier.
CAUTION
Make certain the snap ring is installed on the bearing
support. This snap ring will keep the output planet car-
rier correctly positioned in the hoist. Gear train damage
may occur if this snap ring is omitted.

26
 O-RING GROOVE

9. Install a new bearing in the drum closure as required.

Use sealant on the outside surface of the oil seal.
6. Install the output planet carrier into the drum while Install with spring side of the seal toward bearing,
meshing the planet gears with the ring gear and the using a flat plate to avoid distortion.
planet housing with the bearing support.
Install a new O-ring in the groove on the O.D. of the
7. Install the primary sun gear and thrust washer into the drum closure.
primary planet carrier.

10. Lubricate the O-ring and drum opening with petrole-

8. Install the primary planet carrier, meshing the planet um jelly or gear oil and install the drum closure into
gears with the ring gear and the planet housing with the drum.
the output sun gear.
11. Lubricate the pilot, oil seal and bearing surfaces of the
brake cylinder and carefully install brake cylinder into
base and drum. Locate the brake release port toward
the lower rear corner of the base. Tighten brake cylin-
der capscrews to recommended torque.

27
 13. If the brake discs are misaligned, preventing the
installation of the clutch, then with a hand pump, apply
750-1000 psi to the brake release port. The brake
discs will move freely with the brake released

12. Install the brake clutch assembly.

NOTE: The snap ring installed in the bore of the inner

race is not centered in the splines. The long spline
engagement end MUST always install toward the
motor to permit proper positioning of the brake clutch 14. Install the hoses and fittings to the brake cylinder
within the internal brake assembly. release port.
When installed correctly, the inner race should turn 15. Install a new O-ring on the motor pilot then lubricate
freely in the opposite direction the drum turns to pull with petroleum jelly or gear oil.
wire rope in. An easy way to check the rotation is to
hold the outer race in one hand, and rotate the inner 16. Engage the motor shaft with the brake clutch inner
race from the motor side. race and lower motor into place. Tighten capscrews
to recommended torque.
If the clutch free wheels in the wrong direction, disas-
semble the clutch and reverse the inner race. Refer 17. Install the hoses that connect the manifold and brake
to "Brake Clutch Service” for additional information. valve to the brake cylinder.

18. After the hoist assembly is complete, check all cap-

screws and fittings to make certain they have been
tightened correctly.

Refill the hoist with the recommended oil listed under

“Preventive Maintenance”, and install the oil level
plug.

CAUTION

! WARNING !
WARNING
Be certain the snap ring is seated in the groove in the
splined bore of the inner race. This snap ring will keep
the brake clutch assembly correctly positioned in the
center of the friction brake pack. Binding of the brake or
brake failure may occur if this snap ring is omitted.

28
19. Install a hand pump with an accurate 0-2,000 psi (0-
13,800 kPa) gauge and shut-off valve to the brake
release port. Apply 1,000 psi (6,900 kPa) to the brake
and close the shut-off valve. Let the brake stand for
five (5) minutes. If there is any loss of pressure, the
brake pack should be disassembled for inspection of
the sealing surfaces and the brake piston. Release
the pressure, remove the hand pump and install the
brake release tube (43) between the brake valve
block (39) and the brake release port.

29
 REVERSING DIRECTION OF DRUM ROTATION
Motor
Case Drain

Motor
DRN
Case Drain
DRN

Brake Lowering Brake Lowering

Motor M Motor M
Valve Port Valve Port

BR BR

Hoisting Hoisting
Port Port

Brake Release Brake Release

Circuit M = Manifold Block Circuit
“A” “B”
NOTE: Only BG6A and BG6B hoists equipped with gear motors and Braden cast brake valves are capable of being
configured for opposite, or underwound drum rotation.
In order to change the direction of rotation, 2 things must be changed on the winch. First, the motor must be made to
rotate in the opposite direction. This is done by exchanging positions of the brake valve and manifold block on the
motor. Secondly, the brake clutch assembly must be made effective for the opposite direction of rotation. This is done
by reversing the inner race of the brake clutch assembly.
Figures “A” and “B” above show typical BG6 gear motor installations. Note that the only difference between the two
drawings is the motor is rotated 180° (the “belly” of the motor moves to the opposite side). If the motor shaft rotates
clockwise in figure ‘A” when the hoisting port is pressurized, it will rotate counterclockwise in figure “B”.

1. Remove the four capscrews securing the brake valve

to the motor. Remove the four capscrews securing
the manifold block to the motor. Disconnect the motor
case drain hose at the motor. NOTE: Some installa-
tions have the brake release hose connected directly
to the motor, instead of to the manifold block. In this
case, disconnect the brake release hose at the motor
port. Stand winch up on drum support with the motor
end up and secure in this position.

2. Before removing the motor, it is a good idea to note or

mark the position of the motor in relation to the winch, 4. Remove the snap ring and sprag bushing retainer
since it will be rotated 180° when reinstalled. Remove from one end only of the brake clutch assembly.
the capscrews securing the motor to the winch and
carefully remove the motor.

5. Pull the inner race out. Examine the race for scoring,
wear or indentations caused by the sprag cams. If the
3. Remove the brake clutch assembly from the motor inner race is not completely smooth, the assembly
support. should be replaced.

30
 7. Before installing the brake clutch, be sure the inner
race turns free in the opposite direction the drum will
turn to haul-in wire rope. An easy way to check the
rotation is to hold the outer race in one hand and
rotate the inner race from the motor side. Install the
brake clutch.

NOTE: The snap ring installed in the bore of the inner

race is not centered in the splines. The long spline
engagement end MUST always install toward the
motor to permit proper positioning of the brake clutch
within the internal brake assembly.
6. Turn the sprag assembly around and slide the inner
race (with 1 snap ring and bushing retainer) through
the bushings and sprag clutch (the race will have to be
rotated in the free-wheeling direction to start it through
the sprag clutch). Install the remaining bushing retain-
er and snap ring. Make certain the snap ring is prop-
erly seated in the groove.

CAUTION

! WARNING !
Assemble so that inner race Be certain the snap ring is seated in the groove in the
freewheels in the opposite splined bore of the inner race. This snap ring will keep
direction of desired cable
drum rotation for hoisting the brake clutch assembly correctly positioned in the
when viewed from motor side. center of the friction brake pack. Binding of the brake or
brake failure may occur if this snap ring is omitted.

8. Install a new O-ring on the motor pilot. Rotate the

motor 180° from its original position and install it onto
the winch. Install and tighten motor capscrews to rec-
ommended torque.
9. Install new O-rings in the brake valve and manifold
block. Attach the brake valve and manifold block to
the motor using the original capscrews and tighten to
recommended torque.
10. Connect the motor case drain hose to the motor case
drain port.
11. If your winch had the brake release hose connected
directly to the motor, the original motor port must be
plugged and the hose connected to the motor pres-
sure port near the manifold block (lowering port).
12. Operate the winch slowly in both directions and check
for oil leaks and/or unusual sounds from the winch.
The winch should operate smoothly in both directions.
Refer to “WIRE AND BRAIDED ROPE INSTALLA-
TION” and properly install rope onto the winch drum.
13. Before returning the winch to full service, a light load
should be lifted and held a few feet off the ground to
be sure the static brake is functioning properly. The
winch should also be able to slowly lower the load in
a smooth and controlled manner. If the winch does
not perform either of these functions, refer to “TROU-
BLESHOOTING” for additional information.

31
RECOMMEND FASTENER TORQUE
The general purpose torque shown in the chart applies to SAE Grade 5 bolts, studs and standard steel full, thick and
high nuts.

Higher or lower torques 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.

RECOMMENDED FASTENER TORQUE

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

32
 METRIC CONVERSION TABLE
MULTIPLY: BY: TO GET: MULTIPLY: BY: TO GET:
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
inches2 (sq.in.) X 645.15 = millimeters 2 (mm 2) 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
o
inches Hg (60 F) 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

COMMON METRIC PREFIXES

mega (M) = 1,000,000 or 106 deci (d) = 0.1 or 10-1
kilo (k) = 1,000 or 103 centi (c) = 0.01 or 10-2
hecto (h) = 100 or 102 milli (m) = 0.001 or 10-3
deka (da) = 10 or 101 micro (m) = 0.000.001 or 10-6

33