BRADEN

CH150A/CH230A w/Auxiliary Brake

PLANETARY HOIST

INSTALLATION, MAINTENANCE AND SERVICE MANUAL

PACR WINCH DIVISION

P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
LIT2222 R1 PHONE (918) 251-8511 FAX (918) 259-1575
6/2005
Printed in U.S.A. Copyright 2005 PACCAR Winch Division. All rights reserved. www.paccarwinch.com
 TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HOIST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
HOIST OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
RECOMMENDED BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
TEAR DOWN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
RECOMMENDED GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
INSPECTION RECORDS AND RETENTION . . . . . . . . . . . . . . . . . . . . . . . . .16
OIL SAMPLING AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
AUXILIARY BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
EMERGENCY LOWERING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . .20
PERSONNEL HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
EXPLODED VIEW AND PARTS KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
HOIST DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
BRAKE CYLINDER SERVICE AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .35
PLANET CARRIER SERVICE AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .38
AUXILIARY BRAKE SERVICE AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .40
BRAKE CLUTCH SERVICE AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .42
HOIST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
REVERSING DIRECTION OF DRUM ROTATION . . . . . . . . . . . . . . . . . . . . . .49
BRAKE VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
METRIC CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

1
 FOREWORD
The information in this manual has been prepared to provide assistance with safe installation, operation and serv-
icing of your new Braden planetary hoist. It is strongly recommended that you read and understand this entire man-
ual before installing and operating your hoist.

Some pictures in this manual may show details or attachments that are different from your hoist. Also, some com-
ponents may have been removed for illustrative purposes.

Please note that this manual is not specific to any one hoist. Whenever a question arises regarding your hoist or
this manual, please contact the Braden Technical Support Department via phone at (918)-251-8511, from 08:00 to
16:30 hours, CST, Monday through Friday, via fax at (918)-259-1575, or via email at winch.service@paccar.com,
for the latest available information.

MODEL NUMBER AND SERIAL NUMBER

When requesting information for your Braden hoist, always refer to the model code and serial number. The serial
number is a seven-digit number. The first two (2) digits indicate the year of manufacture. Example: 04XXXXX =
built in 2004.

SERIAL NUMBER
MODEL NUMBER

EXPLANATION OF MODEL NUMBER

CH 230 A - AB - 36 090 01 G - 1
CONSTRUCTION MAX DESIGN AUXILIARY GEAR MOTOR DRUM DRUM OPTION
HOIST RATING MODEL BRAKE RATIO SIZE SIZE OPTION

CH DESIGNATES CONSTRUCTION HOIST

230 DESIGNATES 23,000 LB FIRST LAYER LINE PULL
A DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
AB DESIGNATES AUXILIARY BRAKE
36 DESIGNATES TOTAL GEAR REDUCTION
090 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV (DECIMAL POINT ELIMINATED
(EXAMPLE 090 = 9.0 CU IN/REV)
01 DESIGNATES THE DRUM OPTION
G DESIGNATES OTHER DRUM OPTIONS (G = GROOVED)
1 PERMITS TESTING AND INSPECTION PRE API2C FOR OFFSHORE CRANES

2
 GENERAL SAFETY RECOMMENDATIONS
Safety of operators and ground personnel is of prime concern. Always take the necessary precautions to ensure
safety of others as well as yourself. To ensure safe operation, the prime mover and hoist must be operated with
care and concern for the equipment and a thorough knowledge of the machine's performance capabilities and lim-
itations. The following recommendations are offered as a general safety guide. Local rules and regulations will also
apply.
1. Be certain equipment (boom, sheave blocks, pen-
dants, etc.) is either lowered to the ground or
blocked securely before servicing, adjusting or
repairing the hoist.
2. Be sure personnel are clear of the work area
BEFORE operating the hoist.
3. Read all warning and caution tags provided for safe
operation and service of the hoist, and become
familiar with the operation and function of all con-
trols before operating the hoist.
4. Inspect rigging and hoist at the beginning of each
work shift. Any defect should be corrected immedi-
ately. DO NOT operate a hoist with any defect.
5. Keep all equipment in good operating condition.
Perform scheduled servicing and adjustments
defined in the "Preventive Maintenance" section of
this manual.
6. An equipment warm-up procedure is recommended
for all start-ups, and is essential at ambient temper-
atures below +40°F (+4°C). Refer to the "Warm-Up
Procedure" listed in the "Preventive Maintenance"
section of this manual.
7. DO NOT exceed the maximum pressure or flow
stated in the hoist specifications found in the specif-
ic hoist sales brochure. Damage to the hydraulic
components and/or hoist gearing can occur.
8. Operate the hoist with the proper line speeds to
match the job conditions.
9. Protective gloves should be worn when handling
wire rope.
10. NEVER attempt to handle the wire rope when the
hook end is not free. Keep all body parts and cloth-
ing clear of cable rollers, cable entry area of fair-
leads, sheaves and the cable drum.
11. When winding wire rope onto the hoist drum,
NEVER attempt to maintain tension by allowing the
wire rope to slip through the hands. Always use the
"Hand-Over-Hand" technique.
3
12. NEVER use wire rope with broken strands. Replace
wire rope that is damaged. Refer to the wire rope
user's manual or supplier information for further
information.
13. DO NOT weld on any part of the hoist without the
approval of PACCAR Winch Engineering.
14. See recommended hydraulic oil and gear lubricant.
15. Keep your hydraulic system clean and free from
contamination at all times.
16. Use the correct anchor for the wire rope style and
size, and to match the pocket in the drum.
17. DO NOT use knots to secure or attach wire rope to
the hoist drum or load.
18. The Braden designed wire rope anchors are NOT
designed to support the full rated load. ALWAYS
maintain a minimum of five (5) wraps of wire rope on
the cable drum. It is recommended that the last five
(5) wraps of wire rope be painted bright red or
orange to serve as visual reminder.
19. Never attempt to clean, oil or perform any mainte-
nance on a machine with the engine or prime mover
operating, unless instructed to do so in this manual.
20. NEVER operate the hoist controls unless you are
properly positioned at the operator's station, are
properly trained and are sure personnel are clear of
the work area.
21. Assure that personnel who are responsible for hand
signals are clearly visible, and that the signals to be
used are thoroughly understood by everyone.
22. Ground personnel should stay in view of the opera-
tor and clear of the hoist drum and load at all times.
DO NOT allow ground personnel near any wire rope
under tension. A safe distance of 1½ times the work-
ing length of the wire rope should be maintained.
23. Install guarding to prevent personnel from getting
any part of the body or clothing caught at a point
where the cable is wrapped onto the drum, or drawn
through guide rollers or other potential "pinch
points".
24. Install switches or valves that will shut off power to
the hoist, in locations where they can reached by
anyone that may be entangled in the wire rope
before being drawn into the hoist or any other "pinch
point".
25. "Deadman" controls, which automatically shut off
power to the hoist whenever the operator leaves his
station or releases the control lever, should be
installed whenever practical.
26. NEVER allow anyone to position any part of their
body under a suspended load.
27. Avoid sudden "shock" loads, or attempting to "jerk"
a load free. This type of operation may cause heavy
loads in excess of rated capacity, which may result
in failure of the wire rope, hoist or crane structure.
Safety and informational callouts used in this manual include:
WARNING
CAUTION
! !
WARNING - This emblem is used to warn against
hazards and unsafe practices which COULD result in
severe personal injury or death if proper procedures
are not followed.
3/4 NC FLANGE NUT, OR HEX NUT
AND FLAT HARDENED WASHER.
SPECIAL TOOLS
3/4 inch - 10 NC
ALL-THREAD
11.00
7.00
1.75
WELD
4
28. Whenever possible, install the hoist in a location
that is not immediately adjacent to a "normal" oper-
ator's station.
29. All hoist controls shall be located within easy reach
of the operator. The controls shall be installed in
such a location that the operator is removed from
the electrical path to ground if the load, rigging, or
wire rope comes in contact with, or within proximity
to, an electrically charged conductor.
30. Before operating the hoist, be sure ALL safety pro-
cedures for the equipment or vehicle the hoist is
mounted on are properly followed and/or in place.
If there is any question regarding the safety recommen-
dations, or the safe operation of your Braden hoist,
please contact the Braden Technical Service
Department.
CAUTION
CAUTION- This emblem is used to warn against
potential or unsafe practices which COULD result in
personal injury and property damage if proper proce-
dures are not followed.
Ø 7/16
2.50 0.50
1.00 0.75 WELD
0.375
2.125
NOTE: THE 3/4 x 3/8 SLOTS NOT REQUIRED,
BUT USEFUL FOR CENTERING TOOL WHEN
RE-ASSEMBLING BRAKE.
0.50
 BASIC OPERATION
DESCRIPTION OF HOIST
The hoist is made up of the following sub-assemblies:
1. Hydraulic motor and brake valve
2. Cable drum, drum closure, ball bearings and oil
seals
3. Base, bearing support and motor adapter
4. Brake clutch assembly
5. Brake cylinder assembly and multi-disc brake parts
6. Planetary gear assemblies and ring gear
7. Auxiliary brake system
THEORY OF OPERATION
The hydraulic motor shaft is directly coupled to the pri-
mary sun gear through the inner race of the brake clutch
assembly. As the motor turns in the hoisting direction,
the planetary gear assemblies reduce the speed provid-
ed by the motor and rotate the hoist cable drum.
the pilot operated spool valve. This sequence assures
that dynamic braking takes place within the brake valve,
and that little, if any, heat is absorbed by the static fric-
tion brake.
The static friction brake is a load holding brake only, and
has nothing to do with dynamic braking or rate of
descent of a load. The static brake system consists of
the following components:
1. Multi-disc, spring-applied brake cylinder assembly
2. Brake clutch assembly
3. Hydraulic piston and brake cylinder
Figure 2
Static Motor
Brake

In the hoisting direction, the static brake assembly Brake To

remains fully applied and the input shaft rotates freely Valve Tank
within the brake clutch assembly. With the motor
stopped, or the winch in neutral, the load tries to rotate
the hoist gear train in the opposite direction. The brake Pump
clutch on the input shaft immediately locks up, allowing
the fully applied static brake to hold the load from drop-
ping. Control
Valve
DUAL BRAKE SYSTEM WITH AUXILIARY BRAKE- DESCRIPTION
The dual brake system consists of a dynamic brake sys- Low Pressure Medium Pressure High Pressure
tem and a static brake system, both located on the
motor end of the hoist. The auxiliary brake system is
installed on the end of the hoist opposite the motor end. Figure 3
Static Motor
The dynamic brake system consists of two operating
components: Brake
1. Brake valve assembly
2. Hydraulic motor To
Brake Tank
Valve
The brake valve is basically a counterbalance valve. It
contains a check valve to allow free flow of oil to the
motor in the hoisting direction and a pilot operated, Pump
spring loaded spool valve that blocks oil flow out of the
motor when the control lever is returned to neutral.
When the control lever is moved into the lowering posi- Control
tion, the spool valve remains closed until sufficient pilot Valve
pressure is applied to the end of the spool to shift it
against the spring pressure and open a passage. After Low Pressure Medium Pressure High Pressure
the spool valve cracks open, the pilot pressure
becomes flow dependent and modulates the spool
valve opening, which controls the lowering speed of the
hoist. (See figures 2, 3 & 4).

The static brake is released by the brake valve pilot

pressure at a pressure lower than that required to open
5
 Figure 4
Static Motor
Brake
To
Brake
Tank
Valve
Pump
Control
Valve
Low Pressure Medium Pressure High Pressure
The brake clutch is splined to the primary sun gear shaft
between the motor and the primary sun gear. It will
allow this shaft to turn freely in the direction to raise a
load, and lock up to force the brake discs to turn with
the shaft in the direction to lower a load. (See figures 5
& 6).
The hydraulic brake cylinder, when pressurized, will
release the spring pressure on the brake discs, allowing
the brakes discs to turn freely.
Please note that this static load holding brake is only
released in the direction of lowering a load.
The auxiliary brake system consists of the following
components:
1. Multi-disc, spring-applied brake cylinder assembly
2. Brake shaft
3. Pressure reducing valve
4. Shuttle Valve
The auxiliary brake is coupled directly to the hoist drum
by the brake shaft. The brake cylinder assembly
requires hydraulic pressure to force the brake piston
against the brake springs to relieve the spring force and
release the brake. The shuttle valve allows oil to be
applied to the auxiliary brake in both hoisting and lower-
ing directions, without affecting the static brake in the
hoisting direction. The pressure reducing valve limits
the hydraulic pressure from the hydraulic system to the
brake cylinder assembly. It is factory preset to 1000 PSI
(6,900 kPa) and requires no adjustment.
DUAL BRAKE SYSTEM WITH AUXILIARY BRAKE - OPERATION
When hoisting a load, the brake clutch, which connects
the motor shaft to the primary sun gear, allows free rota-
tion of the gear train. The sprag cams lay over and per-
mit the inner race to turn free of the outer race. (See fig-
ure 5). The friction brake remains fully applied, but the
shuttle valve allows oil to the auxiliary brake to release
6
the brake. For extremely light loads (such as in empty
hook conditions), some slight scrubbing of the auxiliary
brake plates may occur. The fully applied static brake
has no effect on the hoist during lifting operations.
When the lifting operation is stopped, the load attempts
to turn the primary sun gear in the opposite direction.
This reverse input causes the sprag cams to instantly
roll upward and firmly lock the shaft to the fully applied
static brake. (See figure 6).
When the hoist is powered in the lowering direction, the
motor cannot rotate until there is sufficient pilot pressure
to open the brake valve. (See figures 3 & 4). The stat-
ic friction brake will completely release at a pressure
lower than that required to open the brake valve, typi-
cally 400 - 450 PSI (2,760 - 3,100 kPa) and 600 -700
PSI (4,140 - 4,830 kPa) respectively. 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 causing the
brake valve opening 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 in size, thus slowing the descent of the load.
When the control valve is shifted to neutral, the pres-
sure will drop and the brake valve will close, stopping
the load. The static friction brake will engage and hold
the load firm after the brake valve has closed.
When lowering a load very slowly for precise position-
ing, no oil flow actually occurs through the hoist motor.
The pressure will rise to a point where the brake will
release sufficiently to allow the load to rotate the motor
through its own internal leakage. This feature results in
a very slow speed for extremely accurate positioning.
The friction brake receives very little wear in the lower-
ing operation. 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.
During both lifting and lowering operations, the auxiliary
brake will open to allow the drum to operate. In the lift-
ing direction, the shuttle valve diverts the oil flow away
from the static hoist brake and allows the release of the
auxiliary brake. The pressure required to completely
release the auxiliary brake is 400 - 450 PSI (2,760 -
3,100 kPa). During lowering, the oil from the brake
valve is sent to both the static brake and the auxiliary
brake, allowing both brakes to be released simultane-
ously. This action assures that both brakes are released
before the brake valve opens, further assuring that
dynamic braking takes place within the brake valve.
Figure 5 Static Friction Brake Applied Figure 6
Static Friction Brake Applied
Sprag
Sprag
Cams
Cams

Hoisting Stopped,
Holding
Load

Permits free
shaft rotation
while hoisting
Load attempts to rotate shaft in opposite direction.
Brake clutch locks sun gear shaft to friction brake.

7
 INSTALLATION
GENERAL REQUIREMENTS
1. The hoist must be mounted with the centerline of the drum
in a horizontal position. The mounting plane can be rotated
to any position around this centerline, providing the vent
plug is positioned above the oil level.
2. When mounting the hoist, we recommend grade eight bolts
and nuts. All mounting holes in the hoist base must be used.
3. The vent plug must always be located above the horizontal
centerline of the hoist drum. If the hoist is mounted on a piv-
oting surface, be sure the vent remains above the centerline
at all times. If necessary, reposition the bearing support.
4. It is important that the hoist be mounted on a surface that will
not flex when the hoist is in use, since this could bind the
working parts of the hoist. Also, be sure the hoist is mount-
ed on a flat surface. If necessary, use shim stock to insure
proper mounting. The mounting surface should be flat with-
in ± 0.020 inches.
5. Hydraulic lines and components that operate the hoist
should be of sufficient size to assure minimum back pres-
sure at the hoist motor ports. Back pressure at full flow rate
should not exceed 100 psi for maximum motor seal life. 150
psi is the maximum allowable peak intermittent back pres-
sure. If high back pressures are encountered, the motor can
be drained directly to tank to improve motor seal life. To
insure adequate static brake load holding ability, back pres-
sure on the hoist should not exceed 150 psi. For pressures
exceeding 150 psi, consult Braden Engineering.
6. Make certain that the hoist drum is centered behind the first
sheave and the fleet angle does not exceed 1½ degrees.
The hoist should also be mounted perpendicular to an
imaginary line from the center of the drum to the first sheave
to ensure even spooling.
7. The hoist directional control valve must be a three-position,
four-way valve without detents and with a spring centered
motor spool such that the valve returns to the centered posi-
tion whenever the handle is released, and both work ports
are opened to tank (open center, open port).
WIRE ROPE INSTALLATION -
THE CABLE ANCHORS ALONE ON HOISTS ARE
NOT DESIGNED TO HOLD RATED LOADS. Winch
loads applied directly to the wire rope anchor may
cause the wire rope to pull free and result in the sud-
den loss of load control and cause property damage,
personal injury or death. A minimum of 5 wraps of
wire rope must be left on the drum barrel to achieve
rated load.
The wedge and anchor pocket must be clean and dry.
The end of the wire rope being anchored to the drum
must be clean and dry and not frayed. Anything on the
end of the wire rope to keep it from fraying (i.e. tape or
8
Recommended Control
Valve Schematic
! WARNING !
DO NOT use a control valve with any detents or latching
mechanism that would hold the control valve in an actuat-
ed or running position when the operator releases the con-
trol handle. Use of the wrong type of control valve could
lead to unintentional operation of the hoist, which could
result in property damage, personal injury or death.
8. The hydraulic oil filter should have a 10 micron nominal rat-
ing and be a full-flow type.
9. High quality hydraulic oil is essential for satisfactory perform-
ance and long hydraulic system component life.
Oil having 150 to 330 SUS viscosity at 100°F (38°C) and vis-
cosity index of 100 or greater will give good results under nor-
mal temperature conditions. The use of an oil having a high vis-
cosity index will minimize cold-start trouble and reduce the
length of warm-up periods. A high viscosity index will minimize
changes in viscosity with corresponding changes in tempera-
ture.
Maximum cold weather start-up viscosity should not exceed
5000 SUS with a pour point at least 20°F (11°C) lower than the
minimum temperature.
Under continuous operating conditions the temperature of the
oil at any point in the system must not exceed 180°F (82°C).
120-140°F (49-60°C) is generally considered optimum.
In general terms; for continuous operation at ambient tempera-
tures between 50 and 110°F (10-43°C), use SAE 20W; for con-
tinuous operation between 10 and 90°F (-12 and 32°C), use
SAE 10W; for applications colder than 10°F (-12°C), contact the
BRADEN Product Support Department. The use of multi-vis-
cosity oils is generally not recommended.
(ONE PIECE CABLE WEDGE)
wire) must not be in contact with the wedge when the
installation is complete. Consult the wire rope manufac-
turer on the proper treatment of the dead end of the wire
rope. Some rope manufacturers recommend when
using rotation resistant wire rope, that the rope end be
seized, welded or brazed before inserting the wire rope
into the wedge socket to prevent core slippage or loss
of rope lay.
Take the free end of the wire rope and insert it through
the small opening on the cable drum. Loop the wire
rope and push the free end about 3/4 of the way back
through the pocket. Install the wedge as shown in fig-
ure 1, then pull the slack out of the wire rope. The
“dead” end of the rope needs to extend slightly beyond
the end of the wedge as shown in figure 2.
Using a hammer and brass drift, drive the wedge as
deep into the pocket as possible to ensure it is fully
seated and no further movement is detected. Applying
a load on the wire rope will also help seat the wedge in
the pocket.
Check to ensure the wedge does not protrude from
either end of the pocket, causing it to interfere with
proper spooling of wire rope onto the drum (see figures
3 & 4). If there is interference or the wedge does not
seat firmly, contact the Braden Product Support
Department at 918-251-8511 to determine the proper
wedge size.
It is important that the wire rope have the proper ten-
sioning when it is installed on the drum. When the wire
rope is first installed, you should operate the hoist, with
light to moderate loads, with reeving that let’s you place
these loads on the block and the drum with all the rope
off the drum except for the last three wraps.

Correct Installation
Drive from
this side

Wedge and wire rope

fully seated in pocket

Figure 1 Figure 2

Incorrect Installations

Wedge pulled too far

through anchor pocket
Wedge not
fully seated

• Wire rope not tight against wedge • “Dead” end of wire rope and/or wedge may
• Wedge may be too large interfere with proper spooling
• Wedge may be too small
Figure 3 Figure 4
9
 HOIST OPERATION
The following warnings and instructions are basic to safe hoist operation. Please read them carefully and follow
them each time your hoist is operated. These instructions are provided in addition to any information furnished by
the Original Equipment Manufacturer. Equipment operators should be completely familiar with the overall opera-
tion of the piece of equipment on which the hoist is mounted (i.e. crane, truck crane, etc.). If you have any ques-
tions concerning the safe operation of this hoist or the equipment it is mounted on, contact the equipment manu-
facturer that installed the hoist, or the Braden Gearmatic Product Support Department at 918-251-8511, 8:00 am
to 16:30 pm CST, Monday through Friday.
Ground personnel must stay in view of the operator
and clear of the load and hoist drum at all times. Do
not allow personnel near the hoist line under tension.
Do not allow personnel near the hoist drum while the
hoist is in operation. Do not allow personnel to be in
line with the load. Do not allow personnel to stand
under a suspended load. A safe distance of at least
1½ times the working length of the cable should be
maintained by ground personnel. A broken cable
and/or lost load may cause property damage, per-
sonal injury or death.
Failure to properly warm up the hoist, particularly
under low ambient temperature conditions, may
result in temporary brake slippage due to high back
pressures attempting to release the brake, which
could result in property damage, severe personal
injury or death.
Failure to use the proper type and viscosity of plan-
etary gear oil may contribute to intermittent brake
clutch slippage which could result in property dam-
age, severe personal injury or death. Some gear
lubricants contain large amounts of EP (extreme
pressure) and anti-friction additives which may con-
tribute to brake slippage and damage to brake fric-
tion discs or seals. Oil viscosity with regard to ambi-
ent temperature is also critical to reliable brake oper-
ation. Our tests indicate that excessively heavy or
thick gear oil may contribute to intermittent brake
slippage. Make certain that the gear oil viscosity
used in your hoist is correct for your prevailing ambi-
ent temperature.
Warm-up Procedures
A warm-up procedure is recommended at each start-up
and is essential at ambient temperatures below +40°F
(4°C).
The prime mover should be run at its lowest recom-
mended RPM with the hydraulic hoist control valve in
neutral allowing sufficient time to warm up the system.
10
The hoist should then be operated at low speeds, for-
ward and reverse, several times to prime all lines with
warm hydraulic oil, and to circulate gear lubricant
through the planetary gear sets.
Basic Hoist Operation
The hoist should be positioned so the fleet angle is
between ½ and 1½ degrees. This would not apply to a
crane or other application having a “point” sheave.
CAUTION
If the hoist is mounted on a crane or any other device
that has an extendable boom, care must be taken to
pay-out cable as the boom is extended. Failure to
pay-out sufficient cable could result in a “two-block-
ing” condition that could result in damage to and/or
failure of the hoist, cable, sheaves and/or boom.
After the hoist/boom is properly positioned, we recom-
mend the operator slowly pay-out, then haul-in a short
length of cable. The hoist should perform these opera-
tions in a smooth and controlled manner. If the hoist
does not operate smoothly or makes any unusual
sounds, the source of the problem should be identified
and corrected before any attempt is made to lift a load.
Slowly pay-out wire rope from the hoist drum until it
reaches the load. Securely fasten the hoist cable to the
load and be sure all ground personnel are a safe dis-
tance from the load. Slowly lift the load a short distance
and stop. A small amount of “bounce” may be
observed, depending on the weight of the load, size and
type of wire rope, reaving and the amount of boom
extension. Allow the load to stabilize and then watch for
any sign of downward movement or cable drum rota-
tion. The hoist static brake should hold the load in place
without allowing any downward movement at all. If the
load creeps down, it should be lowered to the ground
immediately and the source of the problem identified
and corrected.
If the hoist is holding the load securely, proceed with
normal operations in accordance with the equipment
manufacturer’s operating procedures and load charts.
 TYPICAL HYDRAULIC CIRCUITS
NOTE: The hydraulic circuits shown below are representative of typical Braden and Braden-Gearmatic hoists with
single and two-speed hydraulic gear motors and brake valves. Options and accessory equipment may result in
changes to the circuits shown. If there are any questions regarding the hydraulic circuit, refer to information sup-
plied by the original equipment manufacturer, or contact the Braden Product Support Department at the number
given in the Foreword of this manual. (ALWAYS have the hoist model and serial number when contacting the fac-
tory.)

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

PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your planetary hoist is required to minimize the need for emer-
gency servicing and promote safe, reliable hoist operation.

The user of any Braden hoist product is responsible for hoist inspections, testing, operator training and the main-
tenance procedures defined below, with the frequency being dependent upon the severity of the hoist duty cycle
and the thoroughness of the maintenance program. The hoist duty cycle is defined as follows:
• Infrequent usage - Any hoist used less than 10 hours per month
• Frequent usage - Any hoist used in excess of 10 hours, but less than 50 hours per month
• Heavy usage - Any hoist used in excess of 50 hours, but less than 150 hours per month
• Severe duty - any hoist used in excess of 150 hours per month, or where 80% of the loads exceed 75% of the
hoist rated capacity.

11
Field experience, supported by engineering testing, indicates the three service procedures listed below are most
crucial to safe, reliable hoist operation and MUST be observed.
• Regular gear oil changes
• Use of proper gear oil - recommended type for prevailing ambient temperatures, and additives used
• Periodic disassembly and inspection of all wear components - in compliance with ANSI specification B30.5c
and API RP 2D.

The procedures defined below are recommended for all hoists in usage categories up to and including heavy
usage. For severe duty application hoists, the recommended inspection times are specified.

Initial Oil Change:

The gear oil within the hoist should be changed after the first 100 hours of operation, or 30 days. Regular oil
change intervals may be established after this initial oil change, based on usage and sampling results.

INSPECTION
PRE-USE QUARTERLY SEMI-ANNUAL ANNUAL TEAR-DOWN
DAILY INSPECTION INSPECTION INSPECTION INSPECTION
USAGE INSPECTION
CATEGORY

REQUIRED REQUIRED REQUIRED REQUIRED IF

IDLED
BEFORE PLACED BEFORE PLACED BEFORE PLACED MAINTENANCE
Not used for 3
IN IN IN ---- & REPAIR
months
SERVICE SERVICE SERVICE HISTORY
QO QO QO/QI UNKNOWN

REQUIRED REQUIRED REQUIRED REQUIRED 5 YEARS

INFREQUENT
QO QO/QI QO/QI QI 3 YEARS IF NOT
USAGE SUBJECT TO
less than ten FULL INSPECTION
hours per month PROGRAM

REQUIRED REQUIRED REQUIRED REQUIRED 4 YEARS

MODERATE
QO QI QI QI 2 YEARS IF NOT
USAGE SUBJECT TO
10-50 hours per FULL INSPECTION
month PROGRAM

REQUIRED REQUIRED REQUIRED REQUIRED 3 YEARS

HEAVY USAGE QI MONTHLY QUARTERLY SEMI-ANNUALLY 1.5 YEARS IF NOT
50-200 hours per QI (3 months) (6 months) SUBJECT TO
month QI QI FULL INSPECTION
PROGRAM
SEVERE USAGE
200+ hours per REQUIRED REQUIRED REQUIRED REQUIRED 1 YEAR
month or 50% of QI QI QUARTERLY SEMI-ANNUALLY
lifts exceed 75% (3 months) (6 months)
rated capacity QI QI

QO = Qualified Operator
QI = Qualified Inspector

12
Pre-Use Inspection:
(At the beginning of each shift the hoist is in use)
These procedures MUST be performed prior to placing
the crane or vehicle into service, and then as necessary
during extended operation. This inspection must be per-
formed by a qualified crane operator or qualified crane
inspector.
1. Check for external oil leaks and repair as needed.
This is extremely important due to the accelerat-
ed wear that will result from insufficient lubricat-
ing oil in the hoist. The gear lubricant level MUST
be maintained at the proper level. The oil level
should be visible in the lower half of the sight glass.
Use only the recommended type of lubricant. Refer
to page 16 of this manual and Braden Service
Bulletin 503 (latest revision) for gear oil recommen-
dations.
OIL FILL & VENT
OIL LEVEL
SIGHT GAUGE
OIL DRAIN (BRAKE HOUSING)
Second Drain Port Located in
Cable Drum
2. Inspect the vent plug to ensure it is not clogged.
Clean in solvent and replace as needed.
3. Check the ratchet and pawl mechanism (if equipped)
for proper operation and for full engagement of the
pawl with the ratchet wheel. Repair or adjust as nec-
essary. Be sure to grease the pins and bushings at
this time.
4. Check the hydraulic plumbing for damage, such as
chafed or deteriorating hoses, and repair as neces-
sary.
5. Visually inspect for corroded, loose or missing bolts,
pins or other fasteners, and replace or tighten as
necessary.
6. Visually inspect rotation indicator sensors, anti-two
blocking switches and other safety equipment, and
repair as necessary.
7. Inspect the full length of wire rope, rigging and all
sheaves, according to the wire rope and vehicle or
crane manufacturer's recommendations.
8. A warm-up procedure is recommended at each start-
up, and is mandatory at ambient temperatures below
+40°F (+4°C). The vehicle engine should be run at
13
its lowest recommended idle RPM with the hoist
control in neutral allowing sufficient time to warm up
the hydraulic system. The hoist should then be oper-
ated at low speeds, hoisting and lowering under no
load, several times to prime all the hoist hydraulic
lines with warmed oil, and to circulate lubricant
through the planetary gear sets.
Failure to properly warm up the hoist, particularly
under low ambient temperature conditions, may
result in temporary brake slippage due to high back
pressures attempting to release the brake, which
could result in property damage, severe personal
injury or death.
Quarterly Inspection:
Every three (3) months, or monthly in Severe Duty
Application, or prior to placing the machine in service if
it has not been used for a period of 3 months or longer.
Documentation of the inspection records must be kept
with the hoist / crane for a minimum of two (2) years
from the date of inspection. This inspection must be car-
ried out by a qualified crane operator or qualified crane
inspector. A qualified crane inspector shall perform
inspections on cranes assigned a moderate, heavy or
severe usage category.
1. Perform ALL prior inspections (Pre-use inspection).
2. Hoists used in personnel handling applications
MUST have the internal spring-applied brake tested
as defined on page 18 of this manual.
3. Hoists equipped with auxiliary brake assemblies
MUST have the auxiliary brake tested as defined on
page 19 of this manual.
4. Inspect all fasteners for tightness and the presence
of corrosion. Replace ALL corroded fasteners and
tighten to the proper torque value for the fastener
size and type. (Refer to torque specifications on
page 11 of this manual.)
5. Inspect the hoist structural components (base, sup-
ports, drum, etc.) for corrosion and repair or replace
as required to maintain the structural integrity of the
hoist.
6. Change the hydraulic system filter(s). Hydraulic fil-
ters should be changed after the first 50 hours of
crane operation, then every 500 hours or quarterly,
or in accordance with the crane manufacturer's rec-
ommendations.
Semi-Annual Inspection:
Every six (6) months, or quarterly in Severe Duty
Applications. Documentation of the inspection records
must be kept with the hoist / crane for a minimum of two
(2) years from the date of inspection. This inspection
must be carried out by a qualified crane operator or
qualified crane inspector. A qualified crane inspector
shall perform inspections on cranes assigned a moder-
ate, heavy or severe usage category.
The gear oil should be changed whenever the ambient
temperature changes significantly, indicating that an oil
of a different viscosity range would be more appropri-
ate.

1. Perform ALL prior inspections (Pre-use and
Quarterly inspections).
2. Take a sample of the hoist gear oil from the hoist
drum following the oil sampling procedure on page
17 of this manual. The oil sample MUST be taken
BEFORE changing the gear oil.
Have the sample analyzed for wear metals, viscosity,
signs of overheating, oxidation, moisture and other con-
taminants. If the oil sample contains an unusual amount
of metallic particles, the hoist should be removed from
service and undergo a tear-down inspection.
Proper oil viscosity is critical to reliable brake clutch
operation. Testing indicates that excessively heavy
or thick gear oils may contribute to intermittent brake
clutch slippage. Make certain the gear oil viscosity
used in your hoist is correct for your prevailing ambi-
ent temperature. Failure to use the proper type and
viscosity of gear oil may result in loss of load control,
property damage, injury or death.
NOTE: If the oil sampling/analysis has not been per-
formed as required, tear-down inspections will be
required. Refer to tear-down inspection procedures.

NOTE: Oil analysis alone cannot detect nor warn
against component fatigue failure.
Annual Inspection:
Semi-annually in Severe Duty Applications.
Documentation of the inspection records must be kept
with the hoist / crane for a minimum of two (2) years
from the date of inspection. This inspection must be car-
ried out by a qualified crane inspector. The annual
inspection MUST include, but not be limited, to the fol-
lowing:
1. Perform ALL prior inspections (Pre-Use, Quarterly
and Semi-Annual inspections).
To change the gear oil, unwind all the wire rope off the
cable drum to expose the drum drain plug; then rotate
the drum until the plug is located at the bottom and
remove the plug. Also, remove the drain and vent plug
from the end of the auxiliary brake assembly to drain the
oil from this area.
3. The vent plug must be kept clean and unobstructed.
Whenever the gear oil is changed, remove the vent
plug and clean it in solvent before reinstalling it. DO
NOT paint over the vent plug or replace it with a solid
plug or grease fitting.

2. Change the hoist gear oil, after an oil sample has

been taken. Refer to page 16 of this manual and
Braden Service Bulletin 503 (latest revision) for gear
oil recommendations.

The gear oil must be changed to remove the wear

particles that impede safe and reliable operation of
the brake clutch, and erode bearings and seals.
Failure to change the gear oil at the recommended
intervals may contribute to intermittent brake slip-
page, loss of load control, injury or death. Refill the
hoist with the recommended lubricant.

14
 TEAR DOWN INSPECTION
Tear down inspections of BRADEN hoists should be
completed per the usage schedule defined below.
Magnetic Particle Inspection (MPI) of the internal ring
gear and reduction gears must be performed during
tear down inspections to aid in the detection of cracks in
the ring gears due to fatigue. The preferred inspection
method is the Fluorescent Wet Magnetic Particle
Inspection using ultraviolet light consistent with ASTM
E709. For further information related to this inspection,
and for testing of the older CH150 ring gears, P/N
24446, refer to BRADEN Service Bulletin LIT2162.
Severe Duty - Perform tear down inspection / MPI
annually
Heavy Usage - Perform tear down inspection / MPI
at least every (3) years
Moderate Usage - Perform tear down inspection /
MPI at least every (4) years
Infrequent Usage - Perform tear down inspection /
MPI at least every (5) years
It is also strongly recommended that any moderate or
infrequent usage hoist that is also used for personnel
lifting undergo tear down inspections on a maximum
basis of once every (3) years.
Any hoist that has NOT been subject to regular oil
sample analysis must undergo a tear down inspec-
tion on an annual (12 month) basis. Also, if a hoist
has an unknown history of repair and/or maintenance, it
is highly recommended that the hoist undergo a tear
down inspection prior to being placed into service.
NOTE: Oil analysis alone cannot detect nor warn
against component fatigue failure.
A tear down inspection includes the hoist being com-
pletely disassembled, cleaned, inspected and repaired
as required. Replacement of all worn, cracked, corrod-
ed or distorted parts, such as pins, bearings, shafts,
gears, brake rotors, brake plates, drum and base
should occur as required. All seals and O-rings should
be replaced at this time.
Any deficiencies including, but not limited to, those
above, shall be corrected immediately.
All of the following operations MUST be performed
BEFORE the hoist is placed back into service.
1. The rebuilt hoist MUST be line pull tested to the
rated load of the hoist (hoist rating will vary with
motor, gear ratio and drum options) with a
dynamometer or equivalent load measuring device.
This test load shall be the maximum rating of the
hoist for the specific application (at the normal relief
valve setting for the hoist) - NOT the reduced rating
used for personnel lifts.
2. The hoist must be dynamically tested by rotating the
drum several times, in both the hoisting and lower-
ing directions, while under a load of at least 30% of
the hoist lifting capacity. Check for smooth operation
during this procedure.
3. The hoist internal friction brake shall be tested per
the procedures on page 18 of this manual.
4. If equipped with an auxiliary drum brake, the auxil-
iary brake shall be tested as defined on page 19 of
this manual.
5. After inspection or rebuild and testing, a new certifi-
cate for personnel handling shall be issued by the
inspector / service technician, effective on the date
the hoist is placed back in service. A sample certifi-
cate is shown below, and shall include, at a mini-
mum, all of the information depicted here.

Name of Service Company

Approved by BRADEN for handling personnel
if used and maintained in accordance with BRADEN
Recommendations For Personnel Handling Hoists

Hoist Model No.: _______________________________

Hoist Serial No.: _______________________________
Date of Inspection: _______________________________
Work Order/Job No:_______________________________
Inspector’s Name: _______________________________
For a copy of recommendations call or write: BRADEN
PO Box 547, Broken Arrow, OK, 74012, USA (918) 251-8511

15
 RECOMMENDED PLANETARY GEAR OIL
Field experience, supported by engineering endurance tests, indicates the use of the proper gear oil and a pro-
gram of regular preventive maintenance will help provide extended gear train life and reliable hoist brake perform-
ance. For this reason, BRADEN has published the following specifications to assist in determining which lubricant
is best suited to your application.

Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slip-
page which could result in property damage, severe personal injury or death. Some gear lubricants contain large
amounts of EP (extreme pressure) and anti-friction additives which may contribute to brake clutch slippage or
damage to brake friction discs or seals. Oil viscosity with regard to ambient temperature is also critical to reli-
able brake clutch operation. Our tests indicate that excessively heavy or thick gear oil may contribute to inter-
mittent brake clutch slippage. Make certain that the gear oil viscosity used in your hoist is correct for your pre-
vailing ambient temperature.

For simplicity, BRADEN has listed available products in each temperature range that have been tested and found
to meet our specifications. This is not to say that other lubricant brands would not perform equally as well.
If the following lubricant brands are not available in your area, make certain your lubricant vendor supplies you with
oil that is equivalent to those products listed below.

PREVAILING AMBIENT TEMPERATURE

oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
EXXON SPARTAN EP220 OR EQUIVALENT
AGMA 5 EP, ISO VG 220

EXXON SPARTAN EP150 OR EQUIVALENT

AGMA 4 EP, ISO VG 150

MOBILGEAR SHC 150 or 220

SYNTHETIC OR EQUIVALENT

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

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

Texaco Meropa 150, previously used as factory fill, may no longer be widely available due to current market conditions. As of
mid-year 2002, planetary hoists are factory filled with Exxon Spartan EP150, or equivalent. The chart below relates the Texaco
products to 4 currently available oils. Consult your oil supplier for other equivalent oils if required.

Texaco Exxon Mobil Shell Chevron

Meropa 150 Spartan EP 150 Mobilgear 629 Omala 150 Gear Compounds EP 150

Meropa 220 Spartan EP 220 Mobilgear 630 Omala 220 Gear Compounds EP 220
9/2002

INSPECTION RECORDS & RETENTION

Crane inspection records, as well as records of preventive maintenance, repairs and modifications to the hoist(s)
should be available and accessible for a minimum of two (2) years. These records should include, but not be lim-
ited to, hoist model and serial number, name and employer of repair / inspection technician, date and description
of preventive maintenance, functional test reports and repairs.

To provide our customers with the highest qualified outlets for hoist service and repair, BRADEN has established
Braden Authorized Service Centers. These Authorized Service Centers are equipped with factory-trained service
personnel, up-to-date service information, extensive parts inventories and complete testing facilities, and are audit-
ed by BRADEN on a regular basis for compliance. BRADEN strongly recommends the use of BRADEN
Authorized Service Centers for maintenance, repair and inspection of BRADEN planetary hoists. Consult the
BRADEN Technical Service Department at (918)-251-8511 for the name of your nearest BRADEN Authorized
Service Center.

16
 OIL SAMPLING AND ANALYSIS
Proper oil sampling, and analysis of the sample, is a Analysis
vital part of a comprehensive preventive maintenance
General Guidelines
program. Information obtained from oil analysis is best
(After approximately 250 hours of operation)
utilized in conjunction with a regular preventive mainte-
nance program. The early warning of abnormal wear
Iron Contaminates:
provided by an analysis program allows the user to sub-
stitute preventive maintenance for a far more costly and 100-500 ppm Normal
dangerous failure that may lead to loss of load control
that could result in property damage, personal injury or 501 - 800 ppm Caution - Abnormal sample (moni-
death. Early detection of accelerated component wear tor more frequently). Tear down
allows the scheduling of corrective maintenance and inspection may be required.
can reduce in-operation failures and costly down time.
Above 800 ppm Unacceptable - Abnormal Sample.
Taking a Valid Oil Sample Tear down inspection required.
Prepare the hoist by cleaning the drain area and drain
Note: During normal break-in, iron contaminant levels
extension tube in order to obtain an uncontaminated
will typically be on the high end of the "normal" range.
sample. Operate the hoist in both directions for one to
two (1 - 2) minutes, then take the oil sample from the
In all contaminate monitoring, equally important as the
drain port as soon as possible. DO NOT take the sam-
level of contamination, is the change in the amount of
ple from the first oil out of the drain port. Take a sample
contamination as compared to previous samples. An
from the mid-stream flow of the oil to obtain an accurate
effective oils analysis program should provide the tech-
representation of the oil condition. After taking the sam-
nician with a view of the progression of wear, or a trend.
ple, check the oil level and add new oil as required.
Abrupt changes in the level of contamination between
Refer to page 16 of this manual for gear lubricant rec-
samples should indicate the need for further inspection.
ommendations.
NOTE: Oil analysis alone cannot detect nor warn
against component fatigue failure.
Hot oil may cause personal injury and/or burns to
unprotected skin. Make certain the oil cooled to a
safe temperature (less than 110°F, or 43°C) before
sampling, changing oil or servicing the hoist.

17
 BRAKE TEST PROCEDURE
(For Internal Spring-Applied Load Holding Brake)
All BRADEN hoists employ a spring-applied, hydrauli-
cally released, multiple disc brake inside the hoist hous-
ing. This brake holds a suspended load when the direc-
tional control valve is in its neutral position, or when
hydraulic power is lost. An over-running brake clutch, or
sprag-type clutch assembly, permits the power train and
drum to rotate in the direction to lift a load, while the
brake remains fully applied. A load cannot be lowered,
however, without first applying hydraulic pressure to the
release port and releasing the brake.
BRAKE RELEASE PORT ON WINCH
NEEDLE VALVE
"BR" PORT ON
COUNTERBALANCE VALVE
MOTOR CASE DRAIN
"DR" PORT ON
COUNTERBALANCE
VALVE
HOIST PORT
ON MOTOR
The needle valve/tee combination serves (2) purposes:
1. Provides a means to test the brake.
2. Provides a means to lower a suspended load when power is lost.
Brake Test Procedure (for API designated hoists):
NOTE: Brake test to be performed with no load on the
hoist. The weight of the wire rope, hook block and over-
haul ball or hook weights are acceptable.
NOTE: If the hoist is equipped with a ratchet and pawl
mechanism, the pawl lever MUST be disengaged from
the ratchet wheel by disconnecting the cylinder and
rotating the pawl lever clear of the drum and ratchet
wheel.
1. Remove the lock wire on the needle valve handle
and close the valve tightly.
2. Remove the cap from the tee in the brake release
circuit.
3. With the hydraulic power unit (HPU) running, move
the directional control valve handle slowly to the full
open, lowering position.
4. Increase the engine speed, if necessary, to bring the
18
Hoists ordered for personnel handling cranes will also
have a needle valve installed in the brake release line
and a tee fitting installed between the needle valve and
the brake release port on the hoist. One end of the tee
is capped. The needle valve is shipped in the open posi-
tion and held open with a lock wire. With the valve
closed and the cap removed from the tee, the brake is
now isolated from system pressure and vented to
atmosphere. The brake cannot be released under these
conditions by actuating the directional control valve.
Relative position of the needle
valve to other components and
fittings on the winch, motor and
counterbalance valve.
system pressure up to the relief valve setting. The
hoist drum should remain stationary.
5. This procedure utilizes the hoist hydraulic motor to
test the brake's ability to resist approximately 115%
of the hoist rated capacity.
Once the brake test is completed, be sure to reinstall
the cap on the tee, fully open the needle valve and
replace the lock wire in the handle.
If the drum rotates or slips during the test, the hoist
should be disassembled and the brake should be exam-
ined for wear or damage. In addition, for hoists using
helical brake springs, the springs should be measured
for the correct free length.
Replace any parts exhibiting excessive wear, and any
spring whose length is outside the dimensions defined
in the manual. Reassemble the brake and hoist and
repeat the test.
 AUXILIARY BRAKE TEST PROCEDURE
NOTE: Brake test to be performed with no load on the
hoist. The weight of the wire rope, hook block and over-
haul ball or hook weights are acceptable.
NOTE: If the hoist is equipped with a ratchet and pawl
mechanism, the pawl lever MUST be disengaged from
the ratchet wheel by disconnecting the cylinder and
rotating the pawl lever clear of the drum and ratchet
wheel.
NOTE: AB (aux. brake) Hoists now include a second
needle valve like that used on the API designated hoists
for emergency brake release, which can be used to iso-
late the auxiliary brake. Some early AB hoists did not
include the second needle valve.
1. Remove the lock wire on the needle valve handle in
the auxiliary brake circuit and close the valve tightly.
Remove the cap from the tee in the auxiliary brake
release circuit.
Note: For early units without the needle valve,
remove the brake release hose from the fitting on
the auxiliary brake housing. Plug the end of the
hose, and leave the brake release port fitting open to
atmosphere.
3. Increase the engine speed, if necessary, to bring the
system pressure up to the relief valve setting. The
hoist drum should remain stationary.
4. This procedure utilizes the hoist hydraulic motor to
test the brake's ability to resist at least 100% of the
hoist rated capacity.
Once the brake test is completed, be sure to reinstall
the cap on the tee, fully open the needle valve and
replace the lock wire in the handle, if so equipped, or
reattach the hose to the brake release port fitting.
If the drum rotates or slips during the test, the hoist
should be disassembled and the brake should be exam-
ined for wear or damage. In addition, the brake springs
should be measured for the correct free length.
Replace any parts exhibiting excessive wear, and any
spring whose length is outside the dimensions defined
in the manual. Reassemble the brake and hoist and
repeat the test.

2. With the hydraulic power unit (HPU) running, move

the directional control valve handle slowly to the full
open, hoisting position.

19
 EMERGENCY LOWERING PROCEDURES
For Units Employing Only the Internal
Spring-Applied Load Holding Brake
An emergency load lowering condition exists when a
load is suspended and the hydraulic power supply to
the hoist has been disabled for some reason.
The following procedure releases the multiple disc
brake while leaving the brake valve closed. Since gear
type motors are not zero leakage devices, internal
motor leakage permits the load to slowly rotate the
motor although its outlet is blocked by the closed brake
valve. This procedure will NOT work if there is little or no
oil in the motor. Using properly rated pipe and fittings
the standpipe described below may be permanently
installed in the hydraulic system to avoid installing one
in an emergency.
The standpipe is simply a length of pipe (approximately
12 inches (305 mm long) attached to a 90° elbow. The
other end of the elbow is attached to a short nipple and
fitting suitable for mounting to the motor port or mani-
fold. The standpipe is installed with the standpipe point-
ing up in a vertical position. While the load is being low-
ered, oil MUST be added to the standpipe as necessary
to prevent the motor from running dry.
The standpipe defined above MUST be used.
Attempting this procedure with no oil in the motor or
with the brake valve stuck in the open position will
cause the load to free fall, which could result in prop-
erty damage, personal injury or death.
1. Remove the lock wire on the needle valve handle
and close the valve tightly.
2. Remove the plug in the tee.
3. Remove both main hoses from the motor and attach
a standpipe to the motor port on the opposite side of
the motor from the brake valve. NOTE: This port
may be fitted with a manifold.
4. Fill the standpipe with hydraulic oil, making certain
that oil is not running out of the brake valve. If oil is
running out of the brake valve, stop the emergency
lowering procedure. Remove the spring retainer and
tap the main spool of the brake valve to the closed
position. Replace the spring retainer. If the main
spool was stuck in the open position, after complet-
ing the emergency lowering procedure, the brake
valve MUST be repaired or replaced.
5. Connect a hand pump to the opening in the tee.
20
Do not touch the motor, brake valve or standpipe
while lowering a load. They may become hot enough
to cause burns.
6. Operate the hand pump up to about 1,000 psi (6,900
kPa). A suspended load will slowly come down.
Releasing the pressure on the hand pump will cause
the load to stop. If a chattering noise is heard while
the load is coming down, increase the pressure until
the noise stops. DO NOT exceed 1,500 PSI (10,350
kPa) to the brake release port.
7. Always inspect the brake plates for signs of over-
heating and replace if necessary following this pro-
cedure. Refer to the service section of this manual
for details.
8. If this procedure was performed due to a malfunction
of the hoist, remove the hoist from service and per-
form a teardown and inspection to correct the cause
of the malfunction before returning the hoist to serv-
ice.
For Units Employing the Auxiliary Brake
System
An emergency load lowering condition exists when a
load is suspended and the hydraulic power supply to
the hoist has been disabled for some reason.
Equipment required for this procedure is as follows:
- (2) hand pumps
Note: Two (2) hand pumps will be required for
this procedure. One should be equipped with
-4 JIC adapters, and one should be equipped
with -6 JIC adapters.
- A stand-pipe will be installed on the lowering port of
the hoist as described in the previous section.
- Common hand tools and approximately 10 gallons
(39 l) of hydraulic oil in a container or funnel that can
be easily poured into the stand-pipe.
- Drain pans and absorbent material to contain
spilled oil.
1. Remove the pilot hose from the release port of the
ABS housing.
2. Install the hydraulic hand-pump with the -6 adapters
to the open release port of the ABS housing. With
 the hand-pump, slowly apply pressure to observe if
there is any movement of the suspended load. If the
load begins to lower, there may be a gear train fail-
ure in the hoist. The load may be lowered by control-
ling the pressure to the ABS port; more pressure
releases faster, less pressure releases slower.
Lower the load VERY SLOWLY to minimize the heat
generated by the slipping ABS brake discs.
The stand-pipe must be kept full of oil. Attempting to
lower a load with no oil in the motor or with a brake
valve stuck open will cause the load to free-fall,
which could result in property damage, injury to per-
sonnel or death.

3. If no movement is observed, apply 800 PSI (5500

kPa) to the ABS release port and keep the hand-
pump valve closed to hold the pressure in the ABS
and keep the ABS released. Do not touch the hydraulic motor or brake housing
while lowering a load. They may become hot and
4. Move to the motor end of the hoist. Close the brake cause burns.
isolation needle valve and remove the cap/plug from
the static brake release port tee.

5. Install the hand-pump equipped with the -4 JIC

adapters to the static brake release port tee.
The hoist MUST be removed from service following
6. Install the stand-pipe described previously to the an actual emergency load lowering procedure. The
lowering port of the motor. Fill the stand pipe with hoist MUST be disassembled and all parts thorough-
hydraulic oil and have a helper stationed by the ly inspected for damage. All wear items MUST be
stand-pipe with additional oil. Remove the hose from replaced along with new brake components, motor
the hoisting port on the brake valve to make certain and brake valve. The hoist MUST be load tested
oil is not running through the motor and out a brake before returning to service. Failure to repair the hoist
valve that is stuck open. If oil is running through the following an emergency load lowering may result in
brake valve, tap the main spool retainer cap with a loss of load control due to damaged components.
hammer to dislodge the stuck spool. If this does not
close the brake valve, remove the spool spring
retainer cap and tap the spool back into the closed
position with a hammer and punch. Install the spool
and spring retainer caps and proceed with the emer-
gency load lowering. If the main spool was stuck in
the open position, the brake valve MUST be
replaced following the emergency lowering.

7. SLOWLY apply pressure with the hand-pump to the

brake release port. The load will begin to lower at
approximately 250-400 PSI (1700-2750 kPa). As the
load begins to lower the helper must make certain
the stand pipe is kept full of oil. If a chattering noise
is heard while the load is coming down, the brake
discs are dragging. Increase the pressure from the
hand-pump slightly to further release the brake. DO
NOT exceed 1500 PSI (10,350 kPa).

21
 PERSONNEL HANDLING
Most hoists and cranes are designed and intended for handling materials and not personnel. The crane or hoist
is only to be used to handle personnel if it can be shown there is no less hazardous way of carrying out
the job. In these situations, all safety precautions must be strictly adhered to. BRADEN recommends adherence
to the latest revision of API 2D (RP 2D) and/or ANSI/ASME standard B30.5 and/or OSHA and/or other applicable
standards for your application. It is important that you obtain a copy of all applicable safety standards, and that
you read and understand them prior to using the hoist. In addition to, or in conjunction with, the applicable
standards, BRADEN requires:

• The hoist MUST be maintained in accordance with BRADEN recommendations in Braden publication PB-308
and the service procedures in this Installation, Maintenance and Service Manual.
• When handling personnel, the allowable line pull will be limited to 30% of the hoist rated line pull. This
reduction increases the hoist design factor from 3:1 to 10:1, approximately. Example: a hoist rated at 15,000
lbs. on the first layer will be rated at 15,000 x 0.3 = 4,500 lbs. on the first layer when handling personnel.
• Personnel are only permitted to ride in an approved personnel platform as described in API, OSHA or
ANSI/ASME standards.
• The crane MUST be in good working order and equipped with all required safety equipment, including an anti
two-blocking device or warning signal and a boom angle and length indicator. Two-blocking occurs when the
load block or hook assembly comes in contact with the upper block or point sheave assembly and often results
in damage to the wire rope, rigging and/or hoist.
• Personnel being lifted or supported shall wear safety belts with lanyards attached to designated points unless
lifting over water. If lifting over water, provide approved personal flotation devices (PFD's).
• The lifting and supporting shall be made under controlled conditions and under the direction of an appointed
signal person.
• The operator and signal person shall conduct a test lift, without personnel in the personnel platform, to verify
adequacy of the crane footing or support. The crane outriggers, if so equipped, must be fully extended and
properly set.
• Cranes shall not travel (move locations) while personnel are on the personnel platform.
• The platform must be landed or tied off, and all brakes set before personnel enters or exits.

Additional information can be obtained from the following organizations:

- Booklet on "Hoisting Personnel", Crane Institute of America Inc., 1063 Maitland Center Commons, Suite 100,
Maitland, Florida, 32751 USA (800) 832-2726
- OSHA Standard 29 CFR 1926.550 - Cranes, Derricks, Hoists, Elevators, and Conveyors, Occupational Safety
and Health Administration (OSHA), 200 Constitution Ave. N.W., Washington D.C. 20210 USA (202) 219-4667
- ANSI/ASME Standard B30.5, American National Standards Institute (ANSI), 11 W. 42nd Street, New York, New
York 10036 USA (212) 642-4900
- API Specification RP 2D, American Petroleum Institute (API) 1220 L Street, N.W., Washington, DC 20005 USA
(202) 682-8375

22
 TROUBLE SHOOTING
If a hoist ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping or chattering),
appropriate trouble shooting tests should be performed immediately. Continued operation in this manner may
result in property damage, serious personal injury or death.
TROUBLE PROBABLE CAUSE
A
The hoist will not lower 1. The problem could be a plugged pilot
the load, or will not orifice in the brake valve. The pilot ori-
lower the load smoothly. fice is a small pipe plug with a hole
drilled through, located under the pilot
port fitting in the brake valve "BR"
port. If it becomes plugged, it will pre-
vent the pilot pressure from the mani-
fold from opening the brake valve. If it
becomes loose, it will allow an unreg-
ulated amount of oil in to operate the
brake valve which can cause erratic
brake valve operation.
2. The static friction brake may not be
releasing as a result of a defective
brake cylinder seal.
NOTE: If the brake cylinder seal is
defective, you will typically find oil
leaking from the hoist vent plug.
3. The static friction brake will not
release as a result of damaged brake
discs.
4. The auxiliary (ABS) brake may not be
releasing due to a defective brake
cylinder seal.
23
REMEDY
Remove the pilot hose and fitting from
the brake valve, then use a 5/32 in. hex
wrench to remove the pilot orifice. The
diameter of the orifice is approximately
.020 in. (0.5 mm). Clean the orifice and
reinstall tightly, or install a new orifice
plug into the brake valve port.
Check the brake cylinder seal as follows:
A. Disconnect the swivel tee from the
brake release port. Connect a h a n d
pump with an accurate 0-2000 PSI (0-
13,800 kPa) pressure gauge and shut-
off valve to the -4 JIC fitting in the brake
release port.
B. Apply 1000 PSI (6,900 kPa) to the
brake. Close shut-off valve and let stand
for five (5) minutes.
C. If there is any loss of pressure in five
(5) minutes, the brake cylinder should be
disassembled for inspection of the seal-
ing surfaces and replacement of the
seals. Refer to "Motor Support - Brake
Cylinder Service".
Disassemble the brake to inspect the
brake discs. Check the stack-up height
as described in "Motor Support - Brake
Cylinder Service".
Check the ABS brake cylinder seal as
follows:
A. Remove the brake pilot pressure hose
from the fitting on the ABS brake hous-
ing.
B. Attach a hand pump with an accurate
0-2000 PSI (0-13,800 kPa) pressure
gauge to the ABS release port fitting.
 TROUBLE PROBABLE CAUSE
TROUBLE “A” CONTINUED
FROMPREVIOUS PAGE
5. The ABS brake may not release as a
result of damaged internal compo-
nents.
6. The ABS brake may not be releasing
due to an incorrect or no pilot pres-
sure signal.
7. The ABS brake may not be releasing
properly due to incorrect free flow
check valve pressure within the brake
valve.
24
REMEDY
C. Apply 800 PSI (5,500 kPa) to the
ABS release port. Check the cable drum
to determine if it spins freely. If it does
not, slowly increase the pressure until
the drum is free. DO NOT exceed 1,200
PSI (8,300 kPa) in this port.
D. If the ABS brake assembly will not
hold pressure, the brake assembly must
be disassembled and inspected or
repaired, as defined in "Auxiliary Brake
Service".
Disassemble the brake to inspect the
internal parts. Refer to "Auxiliary Brake
Service" for further information.
Check the ABS brake release pilot pres-
sure as follows:
A. Install an accurate 0-2000 PSI (0-
13,800 kPa) pressure gauge to the ABS
release line between the hose and port
fitting.
B. Remove the shuttle valve from the
inlet port (Port 2) of the pressure reduc-
ing valve body.
C. Attach a hand pump with an accurate
0-2000 PSI (0-13,800 kPa) pressure
gauge to the inlet port of the valve body.
Apply 1000 PSI (6,900 kPa) to the valve,
and record the pressure on the ABS port
gauge. Adjust the pressure reducing
valve, as required, to attain 1000 PSI
(6,900 kPa) on the ABS port gauge. If
the correct pressure cannot be reached,
the pressure reducing valve cartridge
should be replaced.
The free flow check valve within the
brake valve should open fully at approx-
imately 400 PSI. If an incorrect or weak
spring is present, the check valve can
open early allowing scrubbing in the ABS
brake. Replace the spring or check pop-
pet as needed.
 TROUBLE PROBABLE CAUSE
B
Oil leaks from the vent 1. Same as A2.
plug.
2. The hydraulic motor shaft seal may be
defective as a result of high system
back pressure or contaminated
hydraulic fluid.
3. Same as A4.
C
The brake will not hold a 1. Excessive system back pressure may
load with the control be present and acting on the hoist
lever in neutral. brake release port and/or the ABS
brake port.
2. The static friction brake will not hold
due to worn or damaged brake discs.
3. The over-running brake clutch may be
slipping.
4. Same as A5.
D
The hoist will not raise 1. The hoist may be mounted on an
the rated load. uneven or flexible surface which can
cause distortion of the hoist base
and/or binding of the hoist gear train.
Binding in the gear train will reduce
available horsepower to the hoist and
create heat.
25
REMEDY
Same as A2.
System back pressure must not exceed
150 PSI (1,035 kPa). Inspect the
hydraulic system for a restriction in the
return line from the control valve to the
reservoir. Be sure the control valve and
lines are properly sized to the hoist
motor.
Oil analysis may indicate contamination
has worn the motor shaft and seal.
Thoroughly flush the entire hydraulic
system and install new filters and oil.
Install new motor shaft seal.
Same as A4.
Same as B2.
Same as A3.
Improper planetary gear oil can cause
the brake clutch to slip. Drain the exist-
ing gear oil and flush the hoist with sol-
vent. Thoroughly drain the solvent and
refill the hoist using the recommended
planetary gear oil defined in "Preventive
Maintenance".
The brake clutch may be damaged or
worn. Disassemble and inspect the
brake clutch assembly as described in
"Brake Clutch Service".
Same as A5.
Reinforce the mounting surface.
If necessary, use shim stock to level the
hoist. Refer to "Installation".
First loosen, then, evenly retighten all
hoist mounting fasteners to the recom-
mended torque.
 TROUBLE PROBABLE CAUSE REMEDY
TROUBLE “D” CONTINUED
FROMPREVIOUS PAGE
2. The system relief valve may be set too Check the relief valve pressure, as fol-
low. The relief valve may need adjust- lows:
ment, repair or replacement.
1. Install an accurate 0-4000 PSI (0-
27,600 kPa) pressure gauge into the
inlet port of the brake valve.
2. Apply a stall load on the hoist while
monitoring the pressure.
3. Compare the pressure gauge reading
to the hoist specifications. Adjust the
relief valve as needed.

NOTE: If the pressure does not increase

in proportion to the adjustment, the relief
valve may be contaminated or worn.
Disassemble and repair, or replace the
relief valve as needed.

3. Ensure the hydraulic system tempera- Same as D1, D2 and E2.

ture is not more than 180°F (82°C).
Excessive hydraulic oil temperatures
increase hydraulic motor internal leak-
age while reducing motor perform-
ance.

4. Hoist line pull rating is based on the Ensure the load is not excessive based
first layer of wire rope. on the working layer. Refer to hoist per-
formance charts for additional informa-
tion.

5. Rigging and sheaves may not be Perform rigging inspection and service
operating efficiently. as recommended by the crane manufac-
turer.

6. Same as A4. Same as A4.

7. Same as A6. Same as A6.

E
The hoist runs hot. 1. Same as D1. Same as D1.

2. Ensure the hydraulic system temper-

ature is not more than 180°F (82°C).
Excessive hydraulic oil temperatures
may be caused by:

A. Plugged heat exchanger. Thoroughly clean exterior and flush

interior.

B. Too low or too high oil level in the Correct oil level. Fill or drain as needed.
hydraulic reservoir.

C. Same as D2. Same as D2.

26
 TROUBLE PROBABLE CAUSE REMEDY
TROUBLE “E” CONTINUED
FROMPREVIOUS PAGE D.Hydraulic pump not operating effi- Prime mover low on horsepower or
ciently. RPM. Tune or adjust prime mover as
required.

Check suction line for damage. Repair

as needed.

If pump is belt driven, ensure belts are

tensioned properly and not slipping.

Pump worn. Repair or replace as

required.

3. Excessively worn or damaged internal Disassemble hoist and inspect. Replace

hoist components. worn or damaged items as needed.

4. Excessive back pressure may be act- Same as A7.

ing on the free flow check valve within
the brake valve.

F
The hoist "chatters" 1. Same as D2. Same as D2.
while raising the rated
load. 2. Hydraulic oil flow to motor may be Same as E2.
too low.

3. Control lever possibly being moved Controls should be operated smoothly.

too quickly. Moving the lever too quickly into the full
open position can cause surging in the
hydraulic system. Conduct operator
training as required.

4, Same as A4. Same as A4.

5. Same as A5. Same as A5.

6. Same as A6 Same as A6

G
The hoist fails to raise 1. The hydraulic motor may be worn. Install 0-4000 PSI (0-27,800 kPa) pres-
the load. sure gauges to the inlet and outlet ports
of the motor. Apply a stall load to the
hoist and compare the gauge readings.
If the difference is excessive, repair or
replace the motor as required.

2. Same as A4. Same as A4.

3. Same as A5. Same as A5.

4. Same as A6. Same as A6.

27
 TROUBLE PROBABLE CAUSE REMEDY
H
The wire rope does not 1. The hoist may be installed too close to Check the mounting distance and fleet
spool smoothly on the the main sheave, increasing the fleet angle. Reposition the hoist as needed.
cable drum. angle above the 1½° maximum.

2. The hoist may not be mounted per- Refer to "Installation" for more informa-
pendicular to an imaginary line tion.
between the center of the cable drum
and the first, or lead, sheave.

3. Opposite hand, or the wrong lay, of Consult the wire rope manufacturer for
wire rope could be in use. wire rope recommendations to best suit
your application.
There is a distinct advantage in apply-
ing wire rope of the proper direction of
lay. When the load is slacked off, the
coils remaining on the drum will
remain closer together and maintain a
more even layer. If wire rope of incor-
rect lay is used, the coils will spread
apart each time the load is removed.
When hoisting is resumed, the wire
rope tends to criss-cross and overlap
lower layers on the drum. This will
usually result in flattened and crushed
wire rope.

4. The hoist may have been overloaded, Replace the wire rope, and conduct
causing the wire rope to take a perma- operator or rigger training as required.
nent set.

28
EXPLODED VIEW

For part numbers, refer to the

Material List for your hoist.

29
 PARTS KEY

ITEM NO. DESCRIPTION QTY.

100 Sprag Clutch Assembly 1
200 Brake Cylinder Assembly 1
300 Primary Planet Carrier Assembly 1
400 Output Planet Carrier Assembly 1
700 Motor Assembly 1
800 Auxiliary Brake Assembly 1
1 Capscrew 12
3 Auxiliary Brake Shaft 1
4 Oil Level Sight Gauge 1
5 Vent/Relief Plug 1
7 Oil Seal 1
8 Support End Plate 1
9 Tie Plate (with holes for valve block) 1
10 Cable Drum Closure 1
12 Output Sun Gear 1
13 Thrust Washer 1
15 Thrust Washer 1
16 Bearing 2
17 O-Ring 1
18 Seal 1
22 Primary Sun Gear 1
23 Cable Drum Closure 1
24 Motor End Plate 1
25 Capscrew 20
26 Lockwasher 8
26 Lockwasher 20
27 Capscrew 8
28 Tie Plate 1
29 Approval Plate 1
30 Drive Screw 8
31 Plug 1
31 Plug 1
32 Nameplate 1
33 Reducer Bushing 1
34 Adapter Fitting 1
34 Adapter Fitting 1
35 Elbow Fitting 1
36 Hose Assembly (14 in. long) 1
37 Valve Block 1
38 Lockwasher 2
39 Capscrew 2
40 Cap 1
41 Elbow Fitting 1
42 Hose Clip 1
43 Hose Assembly (24 in. long) 1
44 Hose Assembly (40 in. long) 1
50 Ring Gear 1
51 Ring Gear Adapter 1

30
HOIST DISASSEMBLY
1. Remove the wire rope from the cable drum and
rotate the drum until the drain plug is facing down-
ward. DO NOT remove the motor hoses or hoist
mounting bolts until the drain plug is in the proper
position. After the hoist has been removed from its
mounting plate, thoroughly clean all the outside sur-
faces. Drain the oil as described in "Preventive
Maintenance".

2. Place the hoist on a stable surface with the motor

facing up. Use support blocks to limit damage to the
sight gauge and vent plug.

4. Remove the capscrews and washers securing the

hydraulic motor to the hoist. Lift the motor off the
A typical hoist with a -01 cable drum and auxiliary
hoist end plate. Remove and discard the o-ring that
brake assembly weighs approximately 1,400 lbs
seals the motor pilot.
(635 kg). Ensure your lifting equipment is of ade-
quate capacity. Attempting to lift the hoist with inade-
quate equipment may result in personal injury or
damage to the hoist or property.
A hydraulic gear motor and brake valve assembly
weighs approximately 120 lbs (54 kg). Use the prop-
er precautions when handling these parts to elimi-
nate the possibility of component damage or person-
al injury.

3. Tag and remove the hoses connecting the brake

valve to the motor and brake release port.

5. Remove the capscrews and washers from the tie

plates, and remove the tie plates.
BRADEN recommends that the motor ONLY be
removed from a hoist positioned on end as described
above. A thrust washer located behind the input sun
gear may become displaced if the motor is removed
from the hoist while in a normally installed horizontal
position, and the over-running brake clutch and input
sun gear are allowed to slide out of position with the
motor. A displaced input sun gear thrust washer may
cause catastrophic gear train failure that could result
in property damage, injury or death.

31
 9. Remove the over-running brake clutch assembly.
Refer to "Brake Clutch Assembly" section for further
information.
NOTE: It may be helpful to mark the outboard end
6. Remove the hydraulic fitting from the brake cylinder of the inner and outer races of the brake clutch
nipple. assembly at this time with a metal marking pen or
other means to aid reassembly later.

7. Remove the capscrews and washers from the motor

adapter, and remove the motor adapter. Remove
and discard the o-ring below the motor adapter.

10. Remove the brake plate spacer and the stack of

brake discs from the brake cylinder.

8. Remove the brake cylinder nipple, and remove the

end plate.

CAUTION
When removing the motor end plate, make sure the
end plate comes free from the brake cylinder.
Raising the motor end plate with the brake cylinder 11. Remove the brake cylinder from the cable drum and
stuck in position can allow the brake cylinder to fall place it on a clean, dry surface, so as not to damage
free leading to damage or possible injury. the splines. Refer to "Brake Cylinder Service" sec-
tion for further information.

32
12. Remove the primary sun gear. 15. Remove the thrust bearing set from the planet car-
rier.

13. Remove the cable drum closure. Install two (2) short
½-13 UNC bolts through a short length of chain, or
insert two (2) ½-13 UNC eyebolts in to the puller
holes. Lift the drum closure straight out of the cable 16. Remove the primary planet carrier assembly. Refer
drum. It may be necessary to tap the drum closure to "Planet Carrier Assembly Service" section for fur-
with a soft hammer to break it free. Remove and dis- ther information.
card the outer o-ring and inner seal. Inspect the
bearing for wear or damage.

17. Remove the thrust washer that was located

between the planet carrier assemblies and the out-
14. Remove the ring gear adapter from the end of the put sun gear.
ring gear.

33

18. Carefully lift the ring gear out of the drum. Inspect
the ring gear for abnormal wear, pitting or other
damage.
19. Remove the output planet carrier assembly from the
drum. Two (2) long ¼-20 UNC bolts inserted into the
hoes in the ends of the planet gear shafts make
handling the planet carrier much easier. Refer to
"Planet Carrier Assembly Service" section for fur-
ther information.
20. Lift the cable drum off the support end plate.
A -01 cable drum weighs approximately 315 lbs (143
kg). Use the proper precautions when handling these
parts to eliminate the possibility of component dam-
age or personal injury.
34
21. Turn the cable drum over and remove and discard
the oil seal. Inspect the drum bearing for abnormal
wear or damage. Replace as needed.
22. Remove the capscrews securing support end plate
to the auxiliary brake housing. Lift the end plate off
the brake housing. Refer to "Auxiliary Brake
Assembly Service" for further information.
CLEAN AND INSPECT
Thoroughly clean all parts in a good grade of non-flam-
mable safety solvent. Use the proper personal protec-
tive equipment, such as rubber gloves, safety glasses,
etc.
Thoroughly inspect all parts for excessive wear, nicks,
scratches, and other damage that would render them
unusable. If a part is questionable, replace it.
ALWAYS replace o-rings, seals and spirol pins.
At regular service intervals, inspect the roller bearings
and thrust washers within the planet carrier assemblies
to ensure that beyond any doubt, they will continue to
perform as intended when reinstalled.
Always coat o-rings, seals, bearings and bushings with
clean oil or grease during assembly.
Use a sealing compound on the outside housing of oil
seals, and a light coat thread sealing compound or seal-
ing tape on pipe fitting threads. Be careful to not get this
sealant inside parts or passages that conduct oil.
BRAKE CYLINDER SERVICE

1. Place the brake cylinder assembly on a stable work
surface with the large end down. Use the spring
compressor tool, defined on page 4, or a shop press
to compress the backup plate enough to remove the
retaining ring.
5. Turn the brake cylinder over, with the large end fac-
ing up. Remove the retaining ring and the brake pis-
ton plate.

CAUTION
Make certain that the threaded rod of the compres-
sion tool is fully engaged into the lower plate. If a
press is used, be careful to apply only as much pres-
sure as required to allow removal of the retaining
ring. The use of too much force can damage compo-
nents.

2. Carefully remove the retaining ring. Be careful to not

let the snap ring pliers slip out of the retaining ring
during removal.
3. Release the compression on the spring pack. When
using the compression tool, be sure to hold the
threaded rod while turning the upper nut.
6. Push the brake piston down toward the table. Turn
the brake cylinder over and remove the piston.
Remove and discard the o-rings. Inspect the back-
up rings for nicks or cuts and replace as needed. Be
careful to not damage the o-ring groove surfaces.

4. Remove the spring guide and belleville spring stack.
Inspect the spring guide for any damage that might
prevent free movement of the springs. Inspect the
springs for cracking or displaced material. Replace
any defective parts.
7. Inspect the brake cylinder sealing surfaces for nicks
or scratches. Check the internal splines for notches
that might prevent free movement of the brake
discs. Ensure the oil port is clear of any debris.

35
BRAKE CYLINDER ASSEMBLY
Back-up Rings

O-Rings

5. Install the eight (8) belleville springs onto the spring

1. Lubricate the o-rings and back-up rings with clean
oil and install them onto the brake piston.
NOTE: The concave surface of the back-up ring
must be located next to the o-ring.
Let the assembly set for 10 minutes in order to allow
the seals to return to their original shape before fur-
ther assembly.
guide. The first spring should rest against the snap
ring on the spring guide, with the concave side
toward the snap ring. Alternate the direction of the
remaining springs until all are installed. The last
spring should be facing the opposite direction from
the first.

Back-up
Rings

O-Rings

6. Place the back-up plate over the spring guide on top

of the spring stack. Insert the spring stack into the
brake cylinder.

2. Here, the o-rings and back-up rings are shown cor-

rectly installed. The back-up rings must be located
outside the o-rings.

3. Lubricate the outside of the piston with clean oil or

light grease.

4. With the brake cylinder resting on the large end,
insert the piston into the brake cylinder. Make sure
the piston is placed squarely into the bore, and
press into the piston bore. Be careful not to cut or
pinch the seals.
7. Use the compression tool, defined on page 4, or a
shop press to compress the springs. Compress the
springs just far enough to clear the retaining ring
groove in the cylinder bore.

36
 CAUTION
Make certain that the threaded rod of the compres-
sion tool is fully engaged into the lower plate. If a
press is used, be careful to apply only as much pres-
sure as required to allow removal of the retaining
ring. The use of too much force can damage compo-
nents.

8. Install the retaining ring. Be careful to not let the

snap ring pliers slip out of the retaining ring during
removal. Ensure the retaining ring is inserted fully
into the groove.

9. Release the compression on the spring pack. When

using the compression tool, be sure to hold the
threaded rod while turning the upper nut.
11. Connect a hand pump with a 0-2000 PSI (0-13,800
kPa) pressure gauge to the brake release port fit-
ting. Apply 1000 PSI (6,900 kPa) and let the assem-
bly stand for 3-5 minutes. If the pressure drops, the
seals must be checked to ensure they were not
damaged or rolled out of position during assembly.

10. Turn the brake cylinder over and install the brake
piston plate over the piston and install the retaining
ring into the groove in the piston.

37
PLANET CARRIER SERVICE
1. Using a punch, drive the spirol pins into the center of
the planet gear shafts.
2. Remove the planet gear shafts, thrust washers,
bearings and planet gears from the carrier.
NOTE: The output planet carrier has two (2) bear-
ings per planet gear. The primary planet carrier has
only one (1) bearing per planet gear.
3. On the primary planet carrier only, remove the thrust
washer from the pocket inside the carrier after the
planet gears have been removed.
38
4. Inspect the roller bearings closely for wear or dam-
age. Inspect the bearing rollers for spalling, corro-
sion, discoloration, displaced material or abnormal
wear. Inspect the bearing cage for unusual wear or
deformation, particularly on the cage separator bars.
Any damage that will impair the bearing cage's abil-
ity to separate, retain and properly guide the rollers
is cause for replacement.
5. Inspect the thrust washers. Ensure the contact faces
are free from any defect or surface irregularity that
can cause excessive friction or abrasion. Replace as
needed.
6. Inspect the planet gears for abnormal wear, pitting or
cracking. Replace as needed.
7. Use a punch to drive the spirol pins out of the plan-
et gear shafts, and discard the spirol pins. Inspect
the bearing surface of the shafts for abnormal wear,
spalling, discoloration, displaced material or corro-
sion. Replace as needed.
8. Inspect the planet carrier gear shaft bores. Ensure
they are smooth with no burrs, and there is no elon-
gation of the holes.
PLANET CARRIER ASSEMBLY

2. Using a small punch, align the holes in the shaft and

carrier and insert a NEW spirol pin the carrier.

NOTE: ALWAYS use new spirol pins when a carrier

has been disassembled for any reason. Use of exist-
ing pins can lead to improper fit and the pin backing
out of position while in service.

1. Insert the roller bearing(s) into the planet gear - one

(1) bearing in each of the primary planet gears; two
(2) bearings in each output planet gear. Place a
thrust washer on each side of the gear and slide the
gear onto the carrier opening. Align the bore with the
bore in the carrier and carefully slide a gear shaft
through the carrier bore, thrust washers and gear.

CAUTION
DO NOT attempt to force the gear shaft through the
bore by tapping with a hammer, or other means. It
should slide easily into position. Forcing it through
the bore can damage the gear shaft or thrust wash-
er, which can cause internal damage to the hoist if
left alone or unnoticed.
3. Drive the spiral pin into place. The pin should be
installed so that approximately half of the length of
the pin is inserted into the gear shaft. Once in place,
using a center punch or small chisel, dent the carri-
er next to or across the hole. This will slightly deform
the carrier to keep the pin from backing out during
hoist operation.
4. Repeat the above steps for each remaining planet
gear.

NOTE: Follow the above steps for the primary plan-

et carrier assembly also. However, the internal thrust
washer must be installed in the pocket inside the
carrier before the gears are installed.

NOTE: Align the spirol pin hole in the gear shaft with
the hole in the carrier before inserting the shaft fully
into the carrier.

39
AUXILIARY BRAKE SERVICE
1. Carefully turn the auxiliary brake assembly over and
place it with the end cover facing upward. Use the
proper precautions to keep from damaging the bear-
ing and seal surfaces at the end of the brake hous-
ing.
NOTE: Place the cable drum on the floor with the
motor end facing up. This will provide a stable plat-
form in which to locate the auxiliary brake assembly
to allow proper servicing.
The auxiliary brake assembly weighs approximately
390 lbs (177 kg). Use the proper precautions when
handling these parts to eliminate the possibility of
component damage or personal injury.
2. Carefully loosen the capscrews in a slow, alternat-
ing manner to remove the spring force on the brake
housing cover. Remove the brake housing cover
and discard the o-ring. The ball bearing at the end
of the brake shaft may come out with the cover.
Take care to not drop it.
The brake housing cover is under direct spring force
of approximately 2,000 lbs (907 kg). Use extreme
caution when removing the cover capscrews. Use of
careless or improper disassembly methods can
result in severe injury or death.
3. Remove the brake springs. Inspect the springs for
damage or deformation. Check the spring free
length which should be no less than 1.938 in. (49
mm). If any spring is damaged or of incorrect length,
replace ALL springs.
4. Using 3/8-16 UNC eyebolts inserted in the lifting
holes, lift the piston out of the housing. Tap the
edges of the housing with a soft hammer to break
the suction and relieve the seal drag between the
piston and housing.
40
The brake piston weighs approximately 78 lbs (35
kg). Use the proper precautions when handling these
parts to eliminate the possibility of component dam-
age or personal injury.
5. Remove and discard the o-rings and back-up rings
from the piston. Inspect the piston groves for
scratches, burrs or other damage.
6. Remove the brake plates, friction discs and spacer
from the housing.
7. Lay the friction plates on a clean, flat surface and
check for distortion or warpage. The friction sur-
faces should be well defined with visible oil grooves.
The splines should be uniform and square-ended. If
they are worn to a point, they should be replaced.
8. Inspect the steel brake plates in the same manner
as the friction plates. Check for distortion, warpage
or discoloration indicating excessive heat. Replace
as required.
9. Remove the brake shaft and thrust washer. Inspect
the bearing surfaces of the brake shaft for wear or
damage. Inspect the splines at both ends of the
shaft for burrs or other damage. The large splines
should have no indentions that would impair the
ability of the brake plates to slide smoothly during
brake release. Ensure the thrust washer is smooth
and flat.
10. Inspect the splines in the brake housing to ensure
there are no indentions can cause the brake plates
to hang up in operation, impairing their ability to
slide during brake release. Also, ensure the oil pas-
sage is clear of obstructions and the sealing sur-
faces are not scratched or otherwise damaged.
AUXILIARY BRAKE ASSEMBLY
1. Place the brake housing into a supporting structure 9. Using 3/8-16 UNC eyebolts inserted in the lifting
with the large end facing up. The supporting struc- holes, lower the piston into the brake housing.
ture can be the motor end of the cable drum, the
hoist ring gear, or other square-cut tubular structure
that will allow the housing to clear the work surface The brake piston weighs approximately 78 lbs (35
by a minimum of 2 in. (50 mm). kg). Use the proper precautions when handling these
parts to eliminate the possibility of component dam-
age or personal injury.
The brake housing weighs approximately 145 lbs (66
kg). Use the proper precautions when handling these Ensure the piston is located squarely in the bore,
parts to eliminate the possibility of component dam- then, carefully press the piston into the bore to the
age or personal injury. seals.
NOTE: To aid assembly, use two (2) ½-13 UNC
bolts with large washers inserted into housing bolt
2. Insert the thrust washer into the pocket in the bot-
holes located 180° apart. Using two (2) heel bars
tom of the brake housing.
inserted under the washers, apply even pressure to
3. Insert the brake shaft into the brake housing. Take both heel bars to press the piston into place.
care to keep from dropping the brake shaft and
damaging the thrust washer.
4. Place the large brake plate spacer into the bottom of
the brake housing.
5. Install a metal brake plate into the brake housing
against the spacer. Alternately, install the friction
discs and brake plates into the housing. Alignment
of the slots and holes in the brake plates is not crit-
ical.
NOTE: When installing new brake plates, soak the
friction plates in new oil prior to installation.
6. Lubricate the o-rings and back-up rings with clean
10. Insert twenty-five (25) brake springs into the piston.
oil and install them onto the brake piston.
NOTE: The concave surface of the back-up ring 11. If the bearing is loose or is being replaced, press it
must be located next to the o-ring. fully into the bore in the cover.
Let the assembly set for 10 minutes in order to allow 12. Lubricate the o-ring and install it into the groove on
the seals to return to their original shape before fur- the end cover and install the cover. Position the
ther assembly. cover such that the vent and drain ports are located
90° from the brake release port on the side of the
7. Here, the o-rings and back-up rings are shown cor- brake housing. Apply Loc-Tite 242 to clean, dry bolt
rectly installed. The back-up rings must be located threads and install the bolts and washers slowly and
outside the o-rings. evenly, in a criss-cross pattern, to avoid binding in
O-Ring
the assembly. Torque the bolts to 110 lb-ft (150 N-
Back-up Ring
m).

Back-up Ring
CAUTION
O-Ring If the end cover does not mate correctly to the hous-
ing, a brake plate may be out of position and may be
damaged.

13. Connect a hand pump with a 0-2000 PSI (0-13,800

kPa) pressure gauge to the brake release port fit-
ting. Apply 800 PSI (5,500 kPa) and let the assem-
bly stand for 3-5 minutes. Turn the brake shaft by
hand to ensure the brake is released. If the brake
shaft will not turn, slowly increase the pressure in
the piston until it becomes free. If the pressure
8. Lubricate the outside of the piston with clean oil or drops, the seals must be checked to ensure they
light grease. were not damaged or rolled out of position during
assembly.
41
BRAKE CLUTCH SERVICE
1. Remove the retaining ring and sprag bushing retain-
er from one end only.
2. Rotate the inner race in the free-turning direction
and pull it from the assembly. Inspect the inner race
for scoring, discoloration, wear or indentions caused
by the sprag cams. If the inner race is not complete-
ly smooth, the entire brake clutch assembly must be
replaced.
3. Using a screwdriver or a small punch and a mallet,
remove the sprag bushing from one end of the outer
race. There are four (4) cutouts, or notches on the
inside face of the bushing for this purpose. If the
inside surface of the bushing is damaged or worn, it
should be replaced.
42
4. Remove the sprag bearing from the outer race.
Inspect the sprag closely for abnormal wear, discol-
oration, cracks, pitting or corrosion. Check the
retainer clips between the cams for excessive wear,
as seen by broken or missing clips, or bright spots
on the outer face.
5. Remove the remaining sprag bushing and inspect,
as described in step 3.
6. Closely inspect the bore of the outer race for wear,
scratches, indentions or discoloration. Any abnor-
mality is reason for replacement. All brake clutch
parts should be thoroughly cleaned and inspected
before assembly.
The polished surfaces of the races and sprag cams
MUST be perfectly smooth to insure positive
engagement of the brake clutch. The slightest defect
may reduce the brake clutch effectiveness and
cause a loss of load control, which can result in prop-
erty damage, severe injury or death. If any compo-
nent is defective, replace the entire brake clutch
assembly.
Use of the proper gear oil inside the hoist is CRITI-
CAL to the function of the brake clutch assembly.
Improper gear oil or excessive additives in the oil can
cause the sprag bearing to slip against the races.
This slippage can lead to loss of load control which
can result in property damage, severe injury or
death. Refer to the oil specifications in the
"Preventive Maintenance" section of this manual,
and the latest printing of Service Bulletin 503 for fur-
ther information regarding planetary hoist gear oil.
BRAKE CLUTCH ASSEMBLY
5. Slide the inner race through the sprag clutch.
The inner race will have to be rotated in the free-
wheeling direction to start it into the sprag clutch.
If the inner race will not go through the bushings, the
bushings may have been damaged and may need
replaced.

1. Press a sprag bushing into the outer race, using a

shop press. A flat plate of approximately the same
diameter as the bushing flange diameter should be
used between the press and the bushing during
assembly to protect the bushing. Ensure the bushing
flange is fully resting against the shoulder in the
outer race.
6. Turn the assembly over, with the retaining ring down,
and install the second retainer and retaining ring.
Ensure the retaining ring is fully seated in the
groove.

2. Turn the assembly over, with the sprag bushing

down, and install the sprag clutch into the outer race.
Ensure the sprag cams are all laying in the same
direction during assembly. 7. Install the small retaining into the groove in the bore
of the inner race.
3. Press the remaining sprag bushing into the outer
race. Ensure the bushing is fully resting against the
shoulder in the outer race.

Ensure the retaining ring is fully seated in the groove

4. Install a sprag bearing retainer and retaining ring
onto one end of the inner race. Ensure the retaining
ring is fully seated in the groove.
in the splined bore of the inner race. This retaining
ring keeps the brake clutch assembly correctly posi-
tioned in the center of the friction brake stack.
Binding of the brake or brake failure may occur if this
snap ring is omitted, which may result in property
damage, severe injury or death.

43
HOIST ASSEMBLY
1. Clean all parts before reassembling.
2. Place the auxiliary brake assembly on a stable plat-
form at or near floor-level with the brake shaft facing
up. Use support blocks as needed to provide stabil-
ity.
The auxiliary brake assembly weighs approximately
390 lbs (177 kg). Use the proper precautions when
handling these parts to eliminate the possibility of
component damage or personal injury.
Brake
Release Port
3. Place the support end plate over the brake housing.
Position the end plate such that the mounting pad is
to your RH side when looking directly at the brake
release port in the brake housing. Apply Loc-Tite
242 to clean, dry bolt threads and install the bolts
with 110 lb-ft (150 N-m) torque.
4. Lubricate the seal and bearing surfaces on the
brake housing.
44
5. If necessary, install the bearing into the cable drum
bore, ensuring that it is fully seated against the
shoulder in the bottom of the bore. Apply sealing
compound to the outside diameter of the oil seal.
Turn the spring side of the seal toward the bearing
and press the seal into bore by applying constant,
even pressure. The seal is fully installed when the
outer surface is located flush to the drum face.
6. Turn the drum over and place it onto the brake shaft.
Be careful while lowering the drum into position to
keep from damaging the drum seal.
A -01 cable drum weighs approximately 315 lbs (143
kg). Use the proper precautions when handling these
parts to eliminate the possibility of component dam-
age or personal injury.
NOTE: Due to attempting to align both the drum
bearing and the splines on the brake shaft simulta-
neously, it may be necessary to release the auxiliary
brake to aid assembly. Use the hand pump as
described in the test procedure for the auxiliary
brake to release the brake and allow the brake shaft
to move slightly, aiding drum alignment.
7. Lower the output planet carrier assembly into the
cable drum, making sure the teeth on the planet car-
rier mesh with the teeth in the cable drum.
8. Install the ring gear over the planet carrier assem-
bly. The ring gear teeth must mesh with the planet
gears. Ensure that the end with the deepest splines
is installed over the planet carrier.
9. Install the output sun gear and thrust washer.
Center the thrust washer over the planet carrier so
that the primary planet carrier pilot can be installed
through it.
10. Install the primary planet carrier assembly into the
ring gear, meshing the planet gears with the ring
gear teeth. The hub end of the carrier faces down-
ward engaging the output sun gear teeth. Ensure
the pilot on the hub end installs through the thrust
washer.
11. Install the thrust bearing set onto the carrier. The
.063 in. (1.6 mm) thick thrust race installs against
the carrier, followed by the needle bearing and the
.092 in. (2.3 mm) thick thrust race.
45
12. Install the ring gear adapter, hub end facing up,
meshing the adapter with the ring gear teeth.
13. If necessary, install the bearing into the drum clo-
sure, ensuring that it is fully seated against the
shoulder in the bottom of the bore. Apply sealing
compound to the outside diameter of the oil seal.
Turn the spring side of the seal toward the bearing
and press the seal into bore by applying constant,
even pressure. The seal is fully installed when the
outer surface is located flush to the face of the clo-
sure.
14. Lubricate the o-ring and install in into the O.D.
groove of the drum closure. Lubricate the O.D. of
the closure and install it into the cable drum, with the
seal side facing up.
15. Install the primary sun gear, meshing with the plan-
et gear teeth.
16. Install the brake cylinder assembly over the primary
sun gear, making certain the splines on the brake
cylinder engage the ring gear adapter splines.
17. Install the brake clutch assembly over the primary
sun gear. Before engaging the brake clutch to
the sun gear, be sure the inner race turns freely
in the SAME direction as the drum in the HOIST-
ING direction.
18. Install the brake discs. Start with a metal brake
plate, then alternately install a friction disc and
brake plate, and end with a single brake plate on top
of the stack. If installing new friction discs, be sure
to soak them in new oil before installation.
46
19. Install the brake plate spacer on top of the brake
stack.
20. Measure the stack-up height of the brake stack
between the end of the brake cylinder and the brake
plate spacer as shown. The stack-up height should
measure .18 - .25 in. (4.5 - 6.4 mm). If the stack-up
measurement is low, add a brake plate, as needed.
DO NOT exceed .25 in. (6.4 mm) high.
21. Install the motor end plate. Make sure the notched
area aligns with the brake release port.
22. Install the special pipe nipple into the brake release
port. Use a good grade of thread sealant or sealing
tape on the threads.
23. Lubricate the brake cylinder o-ring and install it over 25. Attach the tie plates to the end plates. Locate the
the brake cylinder. Push it all the way against the curved edge toward the top of the hoist. Secure the
motor end plate. tie plates using the SPECIAL shoulder bolts and
washers, and torque to 110 lb-ft (150 N-m).

CAUTION
DO NOT use standard capscrews to install the tie
plates. The SPECIAL shoulder bolts are used as
locating dowels for the hoist assembly. Use of stan-
dard fasteners can lead to looseness in the hoist,
possibly resulting in excessive wear and heat gener-
ation inside the hoist.

24. Install the motor adapter over the brake cylinder

using the SPECIAL BRADEN capscrews and wash-
ers. Torque to 110 lb-ft (150 N-m).

DO NOT use standard capscrews to secure the

motor adapter to the end plate.
The capscrews used to secure the motor adapter to
the end plate are of SPECIAL design, and MUST be
used. Using standard capscrews to mount the motor
adapter can result in joint failure that can allow the 26. Install the tee fitting and hose to the brake release
motor shaft to come uncoupled from the brake clutch pipe nipple. Use a good grade of thread sealant or
and gear train. Failure of this type can result in loss sealing tape on the threads. The hose will be
of load control which can result in property damage, installed toward the LH side of the hoist assembly.
severe injury or death.

27. Lubricate the motor o-ring, and install it over the

motor pilot.

47
28. Align the motor shaft into the brake clutch assembly
inner race, and lower the motor into position on the
motor adapter. Install the motor bolts and washers,
and torque to 110 lb-ft (150 N-m).
TANK DRAIN
30. After the assembly is completed, check all fasteners
and fittings for tightness or proper torque, as
required. Ensure all hoses follow correct routing
procedures and none are kinked or twisted.
48
29. Install the remaining motor hoses, valves and fit-
tings, per the drawing below.
NOTE: Some hoists may have steel tubing instead
of hoses.
HOIST PORT
LOWERING PORT
31. Fill the hoist to the sight gauge level with the proper
gear lubricant. Refer to the oil specifications in
"Preventive Maintenance" section of this manual,
and the latest printing of BRADEN Service Bulletin
503.
 REVERSING DIRECTION OF DRUM ROTATION
This procedure applies in general terms to standard hoists with Commercial Intertech gear motors. For
information concerning hoists with other types of motors, consult the BRADEN Service Department at
the phone number listed in the FOREWORD section of this manual.
Motor Case Drain Motor Case Drain

Lowering Lowering
Drn Port Drn Port

“A” Brake Hydraulic

Brake Hydraulic
Valve Motor M M
Valve Motor
Br Br
M = Manifold Block

Hoisting Hoisting
Port Port

Brake Release Circuit Brake Release Circuit

In order to change the direction of drum rotation, 2 things must be changed on the hoist. 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 rota-
tion. This is done by reversing the brake clutch.
Figures “A” and “B” above show typical motor installations. Note that the only difference between the two draw-
ings is the motor is rotated 180° (the “belly” of the motor moves to the opposite side). If the motor shaft in figure
“A” rotates clockwise when the hoisting port is pressurized, the motor shaft in figure “B” will rotate counterclock-
wise.
1. Stand the hoist up on the motor support with the
motor up and secure in this position. 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 direct-
ly to the motor, instead of to the manifold block as
shown above. In these cases, disconnect the brake
release hose from the motor.
2. Before removing the motor, it is a good idea to mark
the position of the motor in relation to the hoist, since 4. Remove the snap ring and sprag bushing retainer
it will be rotated 180° when re-installed. Remove the from one end only of the brake clutch assembly.
capscrews securing the motor to the hoist and care-
fully remove the motor.
3. Remove the brake clutch assembly from the hoist.
Carefully inspect the splines on both ends of the
inner race.
a. If they are the same, the entire brake clutch
assembly can be turned over and re-installed in the
hoist. Before installing the brake clutch, be sure
the inner race turns free in the same direction
the drum will turn to haul-in wire rope. An easy
way to check the rotation is to hold the outer race in
5. Pull the inner race out. Examine the race for scor-
one hand and rotate the inner race. Proceed to step
ing, wear or indentations caused by the sprag cams.
8.
If the inner race is not completely smooth, the entire
b. If the splines in each end of the inner race are
brake clutch assembly must be replaced.
not the same, proceed to step 4.
49

6. Turn the sprag assembly around and slide the inner
race (with 1 snap ring and bushing retainer) through
the bushing 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 retainer and snap ring. Make sure the snap
ring is properly seated in the groove.
7. Install the brake clutch assembly into the hoist.
Before installing the brake clutch, be sure the
inner race turns free in the same 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.
8. Install a new O-ring on the motor pilot. Rotate the
motor 180° from its original position and install it
onto the hoist. Install and tighten motor capscrews
to recommended 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.
50
10.Connect the motor case drain hose to the motor
case drain port. NOTE: On two speed motors, the
case drain and shift drain ports should be connected
directly to tank. DO NOT use the drain connection
on the brake valve. See “TWO SPEED MOTOR
CASE DRAIN PLUMBING” for additional informa-
tion.
11. If your hoist 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. The hoist
should operate smoothly in both directions. Refer to
“WIRE ROPE INSTALLATION” and properly install
wire rope onto the winch drum.
13.Before returning the hoist 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 controlled manner. If the winch does not perform
either of these functions, refer to “TROUBLE
SHOOTING” for additional information.
 BRAKE VALVE SERVICE
This CH Series hoist is supplied with our Braden 1-1/2”
ITEM DESCRIPTION QTY.
brake valve. It is a reliable hydraulic valve with internal
1 Valve Housing (NSS) 1
components manufactured to close tolerances. Due to
2 Check Valve Retainer (NSS) 1
these close tolerances, several individual parts are not
3 Spring Retainer (NSS) 1
available as replacement parts and are noted in the fol-
4 Plug (NSS) 1
lowing parts lists as NSS (Not Serviced Separately).
5 Spool (NSS) 1
Before disassembling the brake valve, be sure you 6 Damper Piston (NSS) 1
have conducted all applicable troubleshooting opera- 7 Damper Piston Extension 1
tions and are certain the brake valve is causing the mal- 8 Check Valve Poppet (NSS) 1
function. 10 Reducer 1

Thoroughly clean the outside surfaces of the valve and 11 Check Ball 1

work in a clean dust-free area, as cleanliness is of 12 Check Valve Spring 1

utmost importance when servicing hydraulic compo- 13 Main Piston Spring 1

nents. 14 O-Ring 1
15 Back-up Ring 1
16 O-Ring 1
17 Back-up Ring 1
18 O-Ring 1
19 Pipe Plug 1
1 1/2 INCH BRAKE VALVE 20 Check Spring 1
21 Shim as req'd
22 Spring Seat 1

20 11 10 19 1 1/2 inch brake valves built after mid-March 1997 con-

tain a spring seat (item 22) between the spool spring
and the spool. This provides a slightly larger, more uni-
form area for the spring to seat against the spool. The
result is increased spring service life and improved
repeatability of pressure/flow modulation over the full
compression range of the spring.
The spring retainer has been modified to allow for the
additional thickness of the spring seat and a groove
19
0 11 10 19 machined into the hex end cap serves as a visual indi-
4 cation that the valve contains the new spring seat. The
spring seat improvement may be added to earlier brake
1 2 12 14 valves by installing kit, Part Number 62805. Items 3, 7,
13, 14 and 22 are included in the kit. We recommend
that this kit be installed whenever the brake valve is
removed for inspection or service.
8 It is always a good practice to check the initial opening
13 or “cracking” pressure of the brake valve whenever the
19 hoist is serviced or inspected. Refer to Braden Service
3
4 Bulletin 527 for complete brake valve test and adjust-
21 ment procedures.
5

15 18 17 16 22 6 7 14

51
DISASSEMBLY

1. Remove the fitting, motor drain check ball and 3. Remove the check valve spring retainer, spring and
spring. check valve poppet.

2. Remove the spool spring retainer and spool spring.

Remove the spool plug and carefully remove the
spool assembly. Remove the damper piston from
the spool. The piston will come out of the spool
slowly, because of a partial vacuum formed between
the two. Use extreme care to avoid damaging the
polished surfaces of either piece.

52
CLEAN AND INSPECT
1. Discard all O-rings and back-up rings. Clean all 2. Install new O-rings on the plug and spool retain-
parts in solvent and blow dry. Inspect polished sur- ers.
faces of spool and damper piston for damage that
may cause binding or leakage. Inspect spool bore in
valve housing for damage or scoring. Inspect check
valve seat in valve housing and check valve poppet.
If the spools, bores or valves are damaged, the
entire brake valve must be replaced. Check the free
length of main piston spring. Replace if less than
3 7/16 in. (87.3 mm) long. Check the free length of
the check valve spring. Replace if less than 1 1/2 in.
(38.1 mm) long.

3. Lubricate the spool and damper piston O-rings with

2. Inspect the 0.020 inch (0.5 mm) orifice in the end of
the spool to be certain it is open.
hydraulic oil. Carefully install the damper piston into
the spool. Carefully install the spool into the valve
housing. Always install the spool into the valve body
from the plug end, so the O-ring enters the bore first.
Install the spring seat, spool spring, damper piston
extension and spring retainer.

4. Install the check valve poppet, spring and check

valve retainer.

ASSEMBLY 5. Install the motor drain check ball, spring and fitting.

6. The brake valve is now completely assembled and

O-RING ready to be installed on the winch motor.

BACK-UP RING

1. Install new O-rings and back-up rings on the spool

and damper pistons as shown. It is important that
each back-up ring is on the correct side of its O-ring.
Take care not to cut the O-rings during assembly.
Let the spool and piston set for ten (10) minutes
before installing them into the brake valve housing.
This will allow the O-rings to return to their original
size after being stretched.

53
 METRIC CONVERSION TABLE
English to Metric Metric to English
LINEAR
inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)
feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.)
miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)

AREA
2 2 2
inches (sq.in.) X 645.15 = millimeters (mm ) millimeters 2 (mm 2) X 0.000155 = inches2 (sq.in.)
feet2 (sq.ft.) X 0.0929 = meters2 (m 2) meters2 (m 2) X 10.764 = feet 2 (sq.ft.)

VOLUME
inches3 (cu.in.) X 0.01639 = liters (l) liters (l) X 61.024 = inches3 (cu.in.)
quarts (qts.) X 0.94635 = liters (l) liters (l) X 1.0567 = quarts (qts.)
gallons (gal.) X 3.7854 = liters (l) liters (l) X 0.2642 = gallon (gal.)
inches3 (cu.in.) X 16.39 = centimeters3 (cc) centimeters3 (cc) X 0.06102 = inches3 (cu.in.)
feet3 (cu.ft.) X 28.317 = liters (l) liters (l) X 0.03531 = feet 3 (cu.ft.)
feet3 (cu.ft.) X 0.02832 = meters3 (m 3) meters3 (m3) X 35.315 = feet 3 (cu.ft.)
fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fl.oz.)

MASS
ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)
pounds (lbs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)
tons (2000 lbs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 lbs.)
tons (2000 lbs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 lbs.)
tons (long) (2240 lbs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.)

PRESSURE
inches Hg (60oF) X 3600 = kilopascals (kPa) kilopascals (kPa) X 0.2961 = inches Hg (60oF)
pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.0703 = kilograms/sq.cm. (kg/cm 2) kilograms/sq.cm. (kg/cm2) X 14.22 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.069 = bars bars X 14.5 = pounds/sq.in. (PSI)
o o
inches H2O (60 F) X 0.2488 = kilopascals (kPa) kilopascals (kPa) X 4.0193 = inches H 2O (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 = (1.8oC) + 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

54