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INSTALLATION, MAINTENANCE,
Visit our Web site at www.paccarwinch.com for the most comprehensive collection of winch, hoist, and drive
information on the Internet. Most publications and specification sheets are available for downloading.
LIT2204 Rev 7
February 2017
Printe d in USA
BG8A and BG8B
HYDRAULIC WINCH
AND SERVICE MANUAL
WRITE HOIST SERIAL NUMBER BELOW
First 2 numbers indicate
year manufactured
For serial number location, see page 1
BG8A
BG8B
©2017 PACCAR Inc.
All rights reserved
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Table of Contents
Related Manuals for Paccar BRADEN/GEARMATIC BG8A
Summary of Contents for Paccar BRADEN/GEARMATIC BG8A
- Page 1 Visit our Web site at www.paccarwinch.com for the most comprehensive collection of winch, hoist, and drive information on the Internet. Most publications and specification sheets are available for downloading. LIT2204 Rev 7 ©2017 PACCAR Inc. February 2017 All rights reserved...
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Page 2: Foreword
FOREWORD Read and understand this entire publication before operating or servicing your BRADEN/GEARMATIC winch. Retain this manual for future reference. The minimum service intervals specified are for operating hours of the prime mover. This manual contains instructions which provide installation, preventive maintenance, and service information for the Model BG8 series winch. -
Page 3: Table Of Contents
TABLE OF CONTENTS Foreword ..........................1 Model and Serial Number Explanation................1 General Safety Recommendations ................3 Theory of Operation ......................4 Winch Installation ......................6 Wire Rope Installation ......................8 Preventive Maintenance ....................9 Recommended Oil Change Information .................10 Troubleshooting ......................11 Winch Disassembly ......................15 Planet Carrier Service ....................17 Motor Support –... -
Page 4: General Safety Recommendations
GENERAL SAFETY RECOMMENDATIONS Safety for operators and ground personnel is of prime concern. Always take the necessary precautions to ensure safety to others as well as yourself. To ensure safety, the prime mover and winch must be operated with care and concern by the operator for the equipment and a thorough knowledge of the machine’s performance capabilities. -
Page 5: Theory Of Operation
THEORY OF OPERATION DESCRIPTION OF WINCH The brake valve is basically a counterbalance valve. The counterbalance valve is mounted to the hoist port The winch has three basic assemblies: of the motor on units with 020, 029 and 039 motors. 1. - Page 6 DUAL BRAKE SYSTEM – OPERATION When hoisting or pulling a load, the brake clutch allows When the winch is powered in reverse, to pay-out free rotation of the inner brake race and input shaft. The cable, the motor and gear train will not rotate until sprag cams lay over and permit the inner race to turn sufficient pilot pressure is supplied to open the brake free of the outer brake hub (Figure 1).
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Page 7: Winch Installation
WINCH INSTALLATION 1. The winch should be mounted with the centerline It is important that the winch is mounted on a surface of the drum in a horizontal position. The mounting that will not flex when the winch is in use, and cause plane of the base may be rotated in any position binding of the gear train. - Page 8 Oil having 150 to 330 SUS viscosity at 100°F (38°C) HOIST ASSEMBLY W/BRAKE VALVE and viscosity index of 100 or greater will give good & STATIC BRAKE results under normal temperature conditions. The BRAKE VALVE use of an oil having a high viscosity index will HOIST BRAKE minimize cold-start trouble and reduce the length of warm-up periods.
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Page 9: Wire Rope Installation
WIRE ROPE INSTALLATION Correct Installation Incorrect Installation Drive from this side Wedge pulled too far through Wedge not Wedge and wire anchor pocket fully seated rope fully seated in pocket Take the free end of the wire rope and insert it through Maintain even tension of approximately one ton on the the small opening of the anchor pocket. -
Page 10: Preventive Maintenance
PREVENTIVE MAINTENANCE A regular program of preventive maintenance for your To drain the gear oil, align the drain plug in the planetary winch is strongly recommended to minimize drum with the hole in the support side of the base. the need for emergency servicing and promote safe, Install a short piece of 1-inch pipe into the threaded reliable winch operation. -
Page 11: Recommended Oil Change Information
The prime mover should be run at its lowest rec- the winch should be completely disassembled to ommended RPM with the hydraulic winch control inspect for excessive wear every 2,000 hours of valve in neutral allowing sufficient time to warm up operation or 12 months, whichever occurs first. -
Page 12: Troubleshooting
TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY The winch will not lower 1. The problem could be a plugged Remove the pilot hose and fitting from the the load or not lower the or loose pilot orifice. The pilot orifice brake valve, then use a 5/32-inch Allen load smoothly. - Page 13 TROUBLE PROBABLE CAUSE REMEDY The brake will not hold 1. Excessive system back pressure The same as Remedy 2 of Trouble B2. a load with the control acting on the brake release port. lever in neutral. Same as Remedy 3 of Trouble A3. 2.
- Page 14 TROUBLE PROBABLE CAUSE REMEDY TROUBLE “D” CONTINUED FROM PREVIOUS PAGE 4. Winch line pull rating is based on 1st Refer to winch performance charts for layer of wire rope. additional information. 5. Rigging and sheaves not operating Perform rigging service as recommended efficiently.
- Page 15 TROUBLE PROBABLE CAUSE REMEDY 1. Same as D2. Same as remedies for Trouble D2. Winch “chatters” while raising rated load. 2. Hydraulic oil flow to motor may be Same as remedies for Trouble E2. too low. 3. Controls being operated too quickly. Conduct operator training as required.
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Page 16: Winch Disassembly
DISASSEMBLY OF WINCH SERVICE PRECAUTIONS 2. Use a 5/16-inch Allen wrench to remove the drain • Before any part is removed from the winch, all service plug through the pipe. Drain the oil into a suitable instructions should be read and understood. container and dispose of used oil in an environmen- •... - Page 17 10. Remove the primary planet carrier from the drum. Refer to “Planet Carrier Service” for additional infor- mation. 6. Remove the brake cylinder capscrews and install two (2) capscrews and a short piece of chain into the motor mounting bolt holes. Using the chain as 11.
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Page 18: Planet Carrier Service
PLANETARY CARRIER SERVICE OUTPUT PLANET CARRIER discoloration, material displacement or abnormal wear, the bearing should be replaced. Likewise, the DISASSEMBLY cage should be inspected for unusual wear or defor- mation, particularly the cage bars. If there is any damage that will impair the cage’s ability to sepa- rate, retain and guide the rollers properly, the bear- ing should be replaced. - Page 19 PRIMARY PLANET CARRIER 1. To service the primary planet carrier, the steps are the same as for the output carrier except there is only one bearing for each gear and no bearing spacer. NOTE: All BG8 winches have a round thrust plate between the primary and output sun gears.
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Page 20: Motor Support - Brake Cylinder Service
MOTOR SUPPORT — BRAKE CYLINDER SERVICE NOTE: Starting late 2000, BRADEN changed the steel brake separator discs from a splined tooth design to a lobed design. This required a change to the motor support and brake cylinder and the addition of a spring spacer. - Page 21 ASSEMBLY 3. Place friction brake disc on flat surface and check for distortion with a straight edge. Friction mate- 1. Begin assembly by placing motor support on work- rial should appear even across entire surface bench with motor mounting surface down. Install with groove pattern visible.
- Page 22 3. Insert first, a steel brake disc against the spacer followed by a friction brake disc then alternate steel and friction discs until all discs have been installed. Finish with a steel brake disc on top. 6. Lubricate the brake piston seal and motor support NOTE: It is a good practice to prelubricate the discs sealing surface with petroleum jelly or hydraulic oil.
- Page 23 BRAKE CYLINDER PRESSURE TEST 8. Install pressure plate into brake cylinder followed by the piston backup ring. The close-fitting piston backup ring may be depressed slightly to one side to lodge the backup ring in the brake cylinder bore 1. Install the –4 JIC fitting into the brake release port. and temporarily hold the pressure plate and springs Connect a hand pump with accurate 0-2000 PSI in place while you lower the brake cylinder over the...
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Page 24: Brake Clutch Service
BRAKE CLUTCH SERVICE DISASSEMBLY 4. Next, slide the sprag clutch out, inspect the sprag clutch closely for abnormal wear, cracks, pitting or corrosion. Check small clips for breakage or 1. Remove the snap ring and sprag bushing retainer bright spots; the signs of excessive wear. Unless from one end only. - Page 25 2. Turn the assembly over and install the sprag clutch 6. Turn the assembly over with the snap ring down. in the bore of the outer race. Install the second retainer and snap ring. Make cer- tain the snap ring is seated in the groove properly. 3.
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Page 26: Winch Assembly
WINCH ASSEMBLY 1. Place winch base on side with bearing support end 5. Stand winch on bearing support end and install snap ring on bearing support. 2. Install a new bearing in the drum if replacement is CAUTION necessary. Apply a nonhardening sealant on the This snap ring will keep the output planet carrier outside diameter of a new seal. - Page 27 13. Install and tighten brake cylinder capscrews and lockwashers. Tighten to recommended torque. 14. Install the brake clutch assembly. When installed correctly, the cam should turn freely in the opposite direction the drum turns to pull wire 3/8 inch rope in. An easy way to check the rotation is to hold 9.5 mm) the outer race in one hand, and rotate the cam.
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Page 28: Brake Valve Service
BRAKE VALVE SERVICE The BRADEN brake valve is a reliable hydraulic valve BRAKE VALVE ASSEMBLY with internal components manufactured to close toler- ITEM DESCRIPTION QTY. ances. Because of the close tolerances and mating Valve Housing (NSS) of components, the valve housing, spool, piston and Check Valve Retainer (NSS) check poppet are not available as replacement parts. - Page 29 ASSEMBLY 1. Install new O-rings on the plug and spring retainers. 4. Remove spool plug and carefully remove spool assembly. 5. Remove the damper piston from the spool. The 2. Install new O-rings and backup rings on the spool piston will come out slowly, because of a partial and damper piston as shown.
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Page 30: Reversing Direction Of Drum Rotation
REVERSING DIRECTION OF DRUM ROTATION (020, 029, 034, 039 motors ONLY) Motor Case Drain Motor Case Drain Brake Lowering Brake Lowering Motor Motor Valve Port Valve Port Hoisting Hoisting Port Port Brake Release Brake Release Circuit Circuit M = Manifold Block Figure 4 Figure 3 To change the direction of rotation, two things must be changed on the winch. -
Page 31: Recommended Fastener Torque
9. Before returning the winch to full service, a light load should be lifted and held a few feet off the ground to be sure the static brake is functioning properly. The winch should also be able to slowly lower the load in a smooth and controlled manner. - Page 32 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)
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