winch hoist and recovery winch application data
TRANSCRIPT
WINCH
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WINCH HOIST AND RECOVERY WINCH APPLICATION DATA
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I WIRE ROPE SECTION
Wire Rope .................................................................................................................1Basic Components & Strand Patterns .............................................................1Core Materials .........................................................................................................2Strand Materials .....................................................................................................2Factors Aff ecting Selection & Wire Materials ...............................................2Construction ............................................................................................................3Wire Rope Spooling ..............................................................................................3D/d Ratio & D/d Ratio Comparison .................................................................4Insuffi cient D/d Ratio ...........................................................................................4Strength Loss Over Drums & Sheaves ............................................................5Bending & Proper Groove Size ..........................................................................5Fleet Angle ...............................................................................................................6Drum Width vs Sheave Distance ......................................................................6Spooling Devices ...................................................................................................7Level Wind Devices & Grooved Drums...........................................................7Tension Roller, Level Wind Device & Fairlead (4-Way Roller) ..................7Multi-Part Block System ......................................................................................8Sheave Effi ciency & Multi-Part Block Example ............................................8Selection Of Proper Design Factor ..................................................................9Trouble Shooting ................................................................................................ 10Calculating Drum Capacity ............................................................................. 11Typical Wire Rope Anchors .............................................................................. 11
II WINCH SELECTION SECTION
Winch Selector .................................................................................................... 13Planetary Model Number And Serial Number ........................................ 14Worm Gear Model And Serial Number ...................................................... 14Planetary Hoist Terminology ......................................................................... 15Basic Planetary Hoist Operation ................................................................... 18Dual Brake System - Operation ......................................................................21Dual Brake System With Auxiliary Brake - Operation .............................22Worm Gear Terminology ..................................................................................24
TABLE OF CONTENTS
i
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II WINCH SELECTION SECTION
Basic Worm Gear Recovery Winch Operation ................................................................. 26Typical Recovery Winch Operation .................................................................................... 27Common Hydraulic Equations....... ...................................................................................... 28Hoisting Or Pulling & Inclines ............................................................................................... 30Assuming A Rolling Load .01 Coeff . Of Friction ............................................................. 31Assuming A Sliding Load .10 & 1.00 Coeff . Of Friction ................................................ 31Incline Example Problem ....................................................................................................... 32Duty Cycle ................................................................................................................................... 32Theoretical Thermal Ratings To Reach 250º F ................................................................. 33Worm Gear vs Planetary ......................................................................................................... 34Worm Gear Effi ciency & Planetary Effi ciency.................................................................. 34Worm Gear vs Planetary ......................................................................................................... 35Gear Set Comparison .............................................................................................................. 35Line Speed By Layer ................................................................................................................. 36Line Pull By Layer ...................................................................................................................... 36Winch Performance By Layer ............................................................................................... 37Drum Size Requirements ....................................................................................................... 37Barrel Diameter ......................................................................................................................... 37Application Checklist .............................................................................................................. 38Selection Of Motor Type ........................................................................................................ 40Fixed Displacement Motors .................................................................................................. 40Variable Displacement Motors ............................................................................................ 40Gear Motor Operation ............................................................................................................ 41Gear Motor Comparison ........................................................................................................ 41Gear Motor .................................................................................................................................. 42Piston Motor ............................................................................................................................... 42Geroler Motor ............................................................................................................................ 43Vane Motor ................................................................................................................................. 44Basic Hydraulic Schematic - Single Speed Motor ......................................................... 45Basic Hydraulic Schematic - Two Speed Motor .............................................................. 46Brake Types ................................................................................................................................. 47Static Brake ................................................................................................................................. 47Dynamic Brake ........................................................................................................................... 48Heat Load .................................................................................................................................... 48Selection Of Gear Ratio .......................................................................................................... 49Winch Application .................................................................................................................... 50Application Example ............................................................................................................... 50Static vs Dynamic ..................................................................................................................... 51Hydraulic Considerations ...................................................................................................... 51Troubleshooting ....................................................................................................................... 51
TABLE OF CONTENTS
ii
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III RECOVERY WINCH SECTION
Typical Applications .............................................................................................. 54Major Markets ......................................................................................................... 54Types Of Recovery Products .............................................................................. 55Worm Gear Recovery Winches .......................................................................... 55Worm Gear Recovery Winch Components ................................................... 56Oilfi eld Planetary Recovery Winches .............................................................. 57Mechanical and Hydraulic Drives .................................................................... 58Hydraulic Motor Adapters .................................................................................. 58Mechanical Drive vs Hydraulic Drive .............................................................. 58Recovery Winches - Right Hand vs Left Hand ............................................. 60Recovery Winches - Front Mount vs Rear Mount ....................................... 61Typical Worm Gear Recovery Winch Installations ...................................... 62Model Code - Low Mount Worm Gear ........................................................... 63Model Code - Upright Worm Gear ................................................................... 63Special Purpose Recovery Products ................................................................ 65Maximum Line Speed Torque Information .................................................. 67Theoretical Thermal Rating (Intermittent Duty) ......................................... 68Recovery Winch Cross Reference List ............................................................. 70
IV PLANETARY HOISTS SECTION
BRADEN GEARMATIC Planetary Hoists .......................................................... 71BRADEN GEARMATIC Planetary Hoist Features .......................................... 72BRADEN GEARMATIC Planetary Hoist Model Code ................................... 72BRADEN GEARMATIC Planetary Hoist Components ................................. 74Basic Operation - Parking ................................................................................... 75Basic Operation - Lowering ................................................................................ 75Basic Operation - Hoisting .................................................................................. 76Basic Hydraulic Circuit ......................................................................................... 77Features ..................................................................................................................... 78
TABLE OF CONTENTS
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NOTES
iv iv
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WIRE ROPE
BASIC COMPONENTS AND STRAND PATTERNS
• Components In A Wire Rope
• Materials
• Design & Construction
• Proper Spooling
• Mult-Part Block Systems
• Design Factors / Strengths
• Trouble Shooting
• Wire Rope Anchors
• Calculating Drum Capacity
Wire rope consists of three basic components. While few in number, these vary in both complexity and confi guration to produce ropes for specifi c purposes or characteristics. The three basic components of a standard wire rope design are:
• the core
• multi-wire strands laid helically around a core• wires that form the strand
Wire for rope is made in several materials and types: these include steel, iron, stainless steel, monel, and bronze. By far, the most widely used material is high-carbon steel. This is available in a variety of grades each of which has properties related to the basic curve for steel rope wire. Wire rope manufacturers select the wire type that is most appropriate for requirements of the fi nished product.
Wire
Strand
Core
Wire Rope
6 X 25 Independent Wire Rope Core (IWRC)
Six strands, 25 wires per strand
Dyform-18
High-strength
Low-rotation
Dyform-6
Greater bonding life
WIRE ROPE 1
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WIRE ROPE
BASIC COMPONENTS AND STRAND PATTERNS
• FC = Fiber Core
• Steel Core
- IWRC = Independent Wire Rope Center
- WSC = Wire Strand Core
• High-carbon Steel
• Specialty Metals
• High Strength Synthetic Fibers
STRAND MATERIALS
0
2040
60
80
100
120140
IPS EIPS EEIPS
• Strength (Resistance to Breakage)• Resistance to Bending Fatigue• Resistance to Vibration Fatigue• Resistance to Abrasion• Resistance to Crushing• Reserve Strength
• IPS - Improved Plow Steel• EIPS - Extra Improved Plow Steel• EEIPS - Extra Extra Improved Plow Steel
Grades of wire rope are referred to as traction steel (TS), mild plow steel (MPS), plow steel (PS), improved plow steel (IPS), extra improved plow steel (EIPS), and extra extra improved plow steel (EEIPS). (These steel grade names originated at the earliest stages of wire rope development and have been retained as refer-ences to the strength of a particular size and grade of rope.) The plow steel strength curve forms the basis for calculating the strength of all steel rope wires. The tensile strength (psi) of any steel wire grade is not constant, it varies with the diameter and is highest in the smallest wires.
The chart above shows that as the number of wires in each strand increases (i.e. the wires get smaller), the resistance to bending fatigue increases, but the resistance to abrasion decreases.
2 WIRE ROPE
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CONSTRUCTION
WIRE ROPE SPOOLING
Right Regular Lay
Left Regular Lay
Left Lang Lay
Right Lang Lay
Under Drum Over Drum
Over Drum Under Drum
Left Hand - Left Lay
Right Hand - Right Lay
WIRE ROPE 3
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D/d RATIO COMPARISON
INSUFFICIENT D/d RATIO
Recovery Winch S.A.E. D/d Standard: 8:1
4 in. (101.6 mm) Drum dia
.5 in. (12.7 mm) Wire Rope dia
d
D
Example:
(Drum diameter I Wire Rope diameter)
Hoist ANSI D/d Standard: 17:1
8.5 in. (215.9 mm) Drum dia
.5 in. (12.7 mm) Wire Rope dia
Example:
= 8:1
= 17:1
4 WIRE ROPE
“Spiraling” – Cause: Insuffi cient drum diameter and/or excessive load
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WIRE ROPE 5
STRENGTH LOSS OVER DRUMS AND SHEAVES
BENDING AND PROPER GROOVE SIZE
2 6 10 14 18 22 3026 34 38
50
60
70
80
90
100
BENDING EFFICIENCY
Right
Wrong
Right
Wrong
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6 WIRE ROPE
FLEET ANGLE
DRUM WIDTH VS SHEAVE DISTANCE
ADrum Width Between Flanges
B1
Max. Distance to First Sheave
(½º Fleet Angle per Side)
B2
Min. Distance to First Sheave
(1½º Fleet Angle per Side)
in. mm ft m ft m
6 152 28.7 8.7 9.5 2.9
8 203 38.3 11.7 12.7 3.9
10 254 47.9 14.6 15.9 4.8
12 305 57.5 17.5 19.1 5.8
14 355 67.1 20.4 22.3 6.8
16 406 76.6 23.3 25.4 7.7
18 457 86.2 26.3 28.6 8.7
20 508 95.8 29.2 31.8 9.7
22 559 105.4 32 35.0 10.7
24 610 115.0 35 38.2 11.6
26 660 124.5 38 41.3 12.6
28 711 134.1 41 44.5 13.6
30 762 143.7 44 47.7 14.5
32 813 153.3 47 50.9 15.5
34 865 162.9 49.6 54.1 16.5
36 915 172.4 11 57.2 17.4
38 965 182.0 52.5 60.4 18.4
40 1016 191.6 58.4 63.6 19.4
Fleet Angle (Left)
1½º Max. - ½º Min.
Fleet Angle (Right)
1½º Max. - ½º Min.
A
B2
B1
H
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WIRE ROPE 7
SPOOLING DEVICES
LEVEL WIND DEVICES AND GROOVED DRUMS
Diamond Screw Level Wind Grooved Drum
TENSION ROLLER, LEVEL WIND DEVICE, AND FAIRLEAD (4-WAY ROLLER)
• Tension Plates or Rollers
• Level WInd Devices
• Grooved Drums
• Fairlead Assemblies
Benefi cial in
slack wire rope
condition only
Hurst Level Wind Protects wire rope
during side pulls
Groo ed Dr m
HOISTHOIST
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8 WIRE ROPE
MULTI-PART BLOCK SYSTEMS
SHEAVE EFFICIENCY AND MULTI-PART BLOCK EXAMPLE
Parts Of Line
With Plain Bearing Sheaves
With Roller Bearing Sheaves
1 1.090 1.0402 0.568 0.5303 0.395 0.3604 0.309 0.2755 0.257 0.2256 0.223 0.1917 0.199 0.1678 0.188 0.1489 0.167 0.13510 0.156 0.12311 0.147 0.14412 0.140 0.106
Multi-part Block Example:
Load = 20,000 lbParts of line = 4Roller Bearing Sheaves
What Line Pull Is Required At Winch?
(20,000 LB Load) x (.275 Sheave Effi ciency) = 5,500 Lb Line Pull Required At The Winch
1 Part 2 Part 3 Part 4 Part 5 Part
To determine the number of parts of line, count the number of cables between the fi xed sheave and the load. Do not count the line from the winch to the fi xed sheave.
Note: This method is for hoisting applications only. DOES NOT apply to recovery applications where the load line is connected back to the recovery vehicle.
WINCH
WIRE ROPE 9
SELECTION OF PROPER DESIGN FACTOR
• Speed of Operation
– Acceleration & Deceleration
• Length of Rope
• Number, Size & Location of Sheaves & Drums
• Rope Attachments
• Conditions Causing Corrosion & Abrasion
• Danger to Human Life or Property
Wire Rope Size
Nominal Breaking Strength
(lbs.)
2:1 Design Factor
(lbs.)
3:1 Design Factor
(lbs.)
3.5:1 Design Factor
(lbs.)
4:1 Design Factor
(lbs.)
5:1 Design Factor
(lbs.)
1/4 5,880 2,940 1,960 1,680 1,470 1,176
3/8 13,120 6,560 4,373 3,749 3,280 2,624
1/2 23,000 11,500 7,667 6,571 5,750 4,600
5/8 35,800 17,900 11,933 10,229 8,950 7,160
3/4 51,200 25,600 17,067 14,629 12,800 10,240
1 89,800 44,900 29,933 25,657 22,450 17,960
1 1/8 113,000 56,500 37,667 32,286 28,250 22,600
1 1/4 138,800 69,400 46,267 39,657 34,700 27,760
6 x 19 IWRC IMPROVED PLOW STEEL (IPS)
Wire Rope Size
Nominal Breaking Strength
(lbs.)
2:1 Design Factor (lbs.)
3:1 Design Factor (lbs.)
3.5:1 Design Factor (lbs.)
4:1 Design Factor (lbs.)
5:1 Design Factor (lbs.)
1/4 6,800 3,400 2,267 1,943 1,700 1,360
3/8 15,100 7,550 5,033 4,314 3,775 3,020
1/2 26,600 13,000 8,867 7,600 6,650 5,320
5/8 41,200 20,600 13,733 11,771 10,300 8,240
3/4 58,800 29,400 19,600 16,800 14,700 11,760
1 103,400 51,700 34,467 29,543 25,850 20,680
1 1/8 130,000 65,000 43,333 37,143 32,500 26,000
1 1/4 159,800 79,900 53,267 45,657 39,950 31,960
6 x 19 IWRC EXTRA IMPROVED PLOW STEEL (EIPS)
Wire Rope Size
Nominal Breaking Strength
(lbs.)
2:1 Design Factor (lbs.)
3:1 Design Factor (lbs.)
3.5:1 Design Factor (lbs.)
4:1 Design Factor (lbs.)
5:1 Design Factor (lbs.)
1/2 29,200 14,600 9,733 8,343 7,300 5,840
5/8 45,400 22,700 15,133 12,971 11,350 9,080
3/4 64,800 32,400 21,600 18,514 16,200 12,960
1 115,000 57,500 38,333 32,857 28,750 23,000
1 1/8 143,000 71,500 47,667 40,857 35,750 28,600
1 1/4 175,800 87,900 58,600 50,229 43,950 35,160
DYFORM 18 HSLR
Wire Rope Size
Nominal Breaking Strength
(lbs.)
2:1 Design Factor (lbs.)
3:1 Design Factor (lbs.)
3.5:1 Design Factor (lbs.)
4:1 Design Factor (lbs.)
5:1 Design Factor (lbs.)
1/2 29,200 14,600 9,733 8,343 7,300 5,840
5/8 45,400 22,700 15,133 12,971 11,350 9,080
3/4 64,800 32,400 21,600 18,514 16,200 12,960
1 115,000 57,500 38,333 32,857 28,750 23,000
1 1/8 143,000 71,500 47,667 40,857 35,750 28,600
1 1/4 175,800 87,900 48,600 50,229 43,950 35,160
6 x 19 IWRC EXTRA EXTRA IMPROVED PLOW STEEL (EEIPS)
WINCH
TROUBLESHOOTING
Problem:
Rope climbing one fl ange
Possible causes:
• Hoist Not Perpendicular With First Sheave
• Hoist Not Centered On First Sheave
• Drum Flanges Not Straight
Problem:
Rope stacks in center of drum
Possible causes:
• Excessive fl eet angle (Hoist too close to fi rst sheave)
Problem:
Rope climbs both fl anges
Possible causes:
• Insuffi cient fl eet angle (Hoist too far from fi rst sheave)
Problem:
Rope not spooled smoothly
Possible causes:
• Wrong lay or wire rope
• Insuffi cient over haul weight
• Load removed from wire rope
• First layer improperly installed
Problem:
Rope “knifes in” to lower layers
Possible causes:
• Lower layers installed with insuffi cient load
• Incorrect groove width
10 WIRE ROPE
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L = Length of wire rope ft (m) all other dimensions in. (mm)
L = (A+D) x A x B x KA
D
B
C
CALCULATING DRUM CAPACITY
TYPICAL WIRE ROPE ANCHORS
U-Bolt Anchor Set Screw Anchor
Wedge Anchor
All drums require minimum fi ve (5) wraps of rope left on drum at all times
WIRE ROPE 11
Values of K
Rope DiameterK
Rope DiameterK
in. mm in. mm
1/4 6 3.29 5/8 16 0.607
5/16 8 2.21 3/4 19 0.428
3/8 9 1.56 7/8 22 0.308
7/16 11 119 1 25 0.239
1/2 13 0.925 1-1/8 28 0.191
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NOTES
12 WIRE ROPE
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WINCH SELECTOR
• General information
- Model and serial number location
- Planetary hoist terminology
- Basic planetary hoist operation
- Worm gear terminology
- Basic worm gear recovery winch operation
- Common hydraulic equations
• Do you want to pull or hoist a load?
• What is the maximum weight or amount you want to pull or hoist?
• How far do you want to pull or hoist the above load?
• Do you need to pull or hoist this amount with the drum full?
• How fast do you want to pull or hoist the above load?
• What size wire rope do you need to use?
• How much wire rope do you want to store on the winch drum?
• What is your power source?
WINCH SELECTION 13
WINCH
PLANETARY MODEL/SERIAL NUMBERS
WORM GEAR MODEL/SERIAL NUMBERS
When information on a hoist is needed, always refer to the model number and serial number. They are steel stamped into the hoists at the locations shown above. The serial number is a seven digit number. The fi rst two digits represent the year of manufacture.
Example: 02XXXXX, built in 2002.
Model and Serial Numbers
Braden worm gear winches are identifi ed by model and serial numbers stamped into a smooth surface near the top of the worm gear housing.
The winch model number and serial number must be referenced when ordering service parts or requesting information.
Do not try to identify a Braden winch by using a raised or foundry casting number.
Model and Serial Numbers
14 WINCH SELECTION
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PLANETARY HOIST TERMINOLOGY
Observe hoist
from this side
Observe hoist
from this side
Overwound Cable
Right-hand base
(standard confi guration)
Left-hand base
WINCH SELECTION 15
Brake Valve - A hydraulic counterbalance valve is usually bolted to the hoist port of the hydraulic motor. It allows oil to fl ow freely through the motor in the hoisting direction.
When oil pressure tries to rotate the motor in the lowering direction, the brake valve blocks the fl ow of oil out of the motor until the internal static brake is released. It then controls lowering speed based on the load and fl ow of oil to the motor. All the heat generated by controlling the speed of the load is dissipated by the hydraulic system, not by the internal static brake.
Grooved Drum - A cable drum with grooves on the barrel to ensure the fi rst layer of cable spools properly onto the drum.
The grooves can be cast or machined into the drum, or cast or machined into separate pieces that are mechanically fastened to the drum.
Note: Only one size cable can be used on a grooved drum.
to determine
base confi guration
to determine
base confi guration
Observe hoist
from this side
Observe hoist
from this side
Underwound Cable
Right-hand base
(standard confi guration)
Left-hand base
to determine
base confi guration
to determine
base confi guration
HOISTHOIST
HOISTHOIST
WINCH
Sprag or Overrunning Clutch - A mechanical one-way clutch on the input shaft of the hoist, between the input shaft and the static mechanical brake. The clutch allows the input shaft to turn freely in the direction required to spool cable onto the drum (i.e. lift a load), then immediately locks the hoist gear train to the mechanical brake when the hoist is stopped, holding the load in place.
Static, Mechanical, or Load-Holding Brake - A multi-disc, spring applied, hydraulically released brake that works together with the sprag clutch to hold a suspended load. This brake is not designed to stop a load being lowered, but holds the load in place when the hoist is not being operated.
First Layer Line Pull Rating - The maximum rated line pull (in pounds or kilograms) on the fi rst layer of cable. The maximum rating for any particular hoist is based on maintaining an acceptable structural design factor and service life. Certain combinations of drum, gear ratio, motor and hydraulic fl ow may reduce or increase this rating.
First Layer Line Speed Rating - The maximum rated line speed (in feet or meters per minute) on the fi rst lay of cable. Certain combinations of drum, gear ratio, motor and hydraulic fl ow may reduce or increase this rating.
D/d Ratio - The ratio of cable drum barrel diameter (D) to wire rope diameter (d). Current ANSI standards require a minimum of 17:1.
Examples:
If you know the cable diameter you want to use, multiply it by 17 to get the minimum cable drum barrel diameter.
I.e., ½ in. (13 mm) wire rope X 17 = 8.5 in (221 mm) = minimum hoist barrel diameter
If you know the barrel diameter, divide it by 17 to get the maximum wire rope diameter.
I.e., 10 in. (254 mm) barrel diameter / 17 = 0.588 or 9/16 (14 mm) = maximum wire rope diameter
PLANETARY HOIST TERMINOLOGY (CONTINUED)
16 WINCH SELECTION
WINCH
Cable Drum Dimensions -
Fleet Angle - The angle between the wire rope’s position at the extreme end wrap on a drum, and a line drawn perpendicular to the axis of the drum, through the center of the nearest fi xed sheave or load attachment point.
Wrap - A single coil of wire rope wound on a drum.
Layer - Wraps of wire rope on the same level between drum fl anges.
Freeboard - The amount of drum fl ange that is exposed radially past the last layer of wire rope. Minimum freeboard varies with the regulatory organization. ASME B30.5 requires ½ in. minimum freeboard.
Barrel
Diameter
Flange
Diameter
Distance
between
Flanges
PLANETARY HOIST TERMINOLOGY (CONTINUED)
First sheave or load should be centered between the drum fl anges, so that angles A and B are equal.
Angles A and B should be a minimum of ½º and a maximum of 1½º
½º Min
½º Min
A
BFirst Sheave
or Load
A
B
Distance
Fleet Angles A & B:
1½º Max. - ½º Min.
A=B
1½º Max
1½º Max
WINCH SELECTION 17
WINCH
BASIC PLANETARY HOIST OPERATION
DESCRIPTION OF HOIST
1. Hydraulic motor and brake valve 2. Drum, drum closure, ball bearings and oil seals 3. Base, bearing support and motor adapter 4. Brake clutch assembly 5. Brake cylinder assembly and multiple - disc brake 6. Planetary gear reducer assemblies
THEORY OF OPERATIONThe primary sun gear is directly coupled to the hydraulic motor by the inner race of the brake clutch assembly. As the motor turns in the hoisting direction (normally clock-wise), the planetary assemblies reduce the input speed of the motor and rotate the winch drum. If the output planet carrier is held from turning by the bearing support, the drum rotates in the opposite direction of the motor input shaft. If the ring is held stationary, the drum rotates in the same direction as the motor shaft.
In the hoisting direction, the static brake remains fully applied and the input shaft rotates freely through the sprag clutch. When the motor is stopped, the load tries to rotate the winch gear train in the opposite direction. The sprag clutch on the input shaft immediately locks up, allowing the fully applied static brake to hold the load from dropping. (See Dual Brake System - Operation for a detailed description of the lowering sequence of operation.)
Dual Brake System - Description
The dual brake system consists of a dynamic brake system and a static brake system.
The dynamic brake system has two operating components: 1. Brake valve assembly 2. Hydraulic motor
The brake valve is basically a counterbalance valve. It contains a check valve to allow free fl ow of oil to the motor in the hoisting direction and a pilot operated, spring-loaded spool valve that blocks the fl ow of oil out of the motor when the control valve is placed in neutral.
When the control valve is placed in the lowering position, the spool valve remains closed until suffi cient pilot pressure is applied to the end of the spool to shift it against spring pressure and open a passage.
18 WINCH SELECTION
WINCH
After the spool valve cracks open, the pilot pressure becomes fl ow-dependent and modulates the spool valve opening which controls the lowering speed.
The static brake system has three operating components:
1. Spring Applied, Multiple Friction Disc Static Brake 2. Brake Clutch Assembly 3. Hydraulic Piston and Cylinder
BASIC PLANETARY HOIST OPERATION (CONTINUED)
WINCH SELECTION 19
WINCH
BASIC PLANETARY HOIST OPERATION (CONTINUED)
HOISTING
LOWERING
20 WINCH SELECTION
HYDRAULIC
BRAKE
RELEASE
MOTOR
BRAKE
VALVE
OIL
IN PUMP
TO TANK
CONTROL VALVE
HYDRAULIC
BRAKE
RELEASEMOTOR
BRAKE
VALVE
OIL
INPUMP
TO TANK
CONTROL VALVE
HYDRAULIC
BRAKE
RELEASE MOTOR
BRAKE
VALVE
OIL
IN
PUMP
TO TANK
CONTROL VALVE
HYDRAULIC
BRAKE
RELEASEMOTOR
BRAKE
VALVE
OIL
IN PUMP
TO TANK
CONTROL VALVE
HYDRAULIC
BRAKE
RELEASEMOTOR
BRAKE
VALVE
OIL
IN
PUMP
TO TANK
CONTROL VALVE
WINCH
BASIC PLANETARY HOIST OPERATION (CONTINUED)
DUAL BRAKE SYSTEM - OPERATION
The static brake is released by the brake valve pilot pressure at a pressure lower than that required to open the pilot operated spool valve. This sequence assures that dynamic braking takes place in the brake valve and that little, if any, heat is absorbed by the static, friction brake.
The hydraulic cylinder, when pressurized, will release the spring pressure on the brake discs, allowing the brake discs to turn freely.
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.
When the control valve is placed in the hoisting position, hydraulic oil fl ows freely through the brake valve to the motor. The static brake remains fully engaged, as the sprag cams lay over and permit the inner race to turn free of the outer race.
Sprag Cams
STOPPED - HOLDING LOAD
Load attempts to rotate shaft in opposite direction.
Brake clutch locks sun gear shaft to friction brake.
HOISTING
Permits free shaft rotation while hoisting.
The winch, in raising a load, is not aff ected by any braking action. When hoisting is stopped, the sprag clutch immediately engages the friction brake.
WINCH SELECTION 21
HOIST
HOLD
WINCH
When hoisting a load, the brake clutch, which connects the motor shaft to the primary sun gear, allows free rotation of the gear train. The sprag cams lay over and permit the inner race to turn free of the outer race. The friction brake remains fully applied, but the shuttle valve allows oil to the auxiliary brake to release 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 eff ect on the hoist during lifting operations.
DUAL BRAKE SYSTEM - OPERATION (CONTINUED)
When the lifting operation is stopped, the load attempts to turn the primary sun gear in the opposite direction. This reversed input causes the sprag cams to instantly roll upward and fi rmly lock the shaft to the fully engaged friction brake.
When the hoist is powered in reverse, to lower the load, the motor cannot rotate until suffi cient pilot pressure is present to open the brake valve. The friction brake within the hoist will completely release at a pressure lower than that required to open the brake valve. The extent to which the brake valve opens will determine the amount of oil that can fl ow through it and the speed at which the load will be lowered. Increasing the fl ow of oil to the hoist motor will cause the pressure to rise and the opening in the brake valve to enlarge, speeding up the descent of the load. Decreasing this fl ow causes the pressure to lower and the opening in the brake valve to decrease thus slowing the descent of the load.
When the control valve is shifted to neutral, the pressure will drop and the brake valve will close, stopping the load. The friction brake will engage and hold the load after the brake valve has closed.
When lowering a load very slowly for precise positioning, no oil fl ow actually occurs through the hoist motor. The pressure will build up to a point where the brake will release suffi ciently to allow the load to rotate the motor through its own internal leakage. This feature results in a very slow speed and extremely accurate positioning.
The friction brake receives very little wear in the lowering 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.
DUAL BRAKE SYSTEM WITH AUXILIARY BRAKE - OPERATION
Auxiliary Brake
22 WINCH SELECTION
WINCH
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 fi rmly lock the shaft to the fully applied static brake.
When the hoist is powered in the lowering direction, the motor cannot rotate until there is suffi cient pilot pressure to open the brake valve. The static friction brake will completely release at a pressure lower than that required to open the brake valve, typically 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 fl ow through it, and the speed at which the load will be lowered. Increasing the fl ow 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 fl ow 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 pressure will drop and the brake valve will close, stopping the load. The static friction brake will engage and hold the load fi rm after the brake valve has closed.
When lowering a load very slowly for precise positioning, no oil fl ow actually occurs through the hoist motor. The pressure will rise to a point where the brake will release suffi ciently 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 lowering 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 lifting direction, the shuttle valve diverts the oil fl ow 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 simultaneously. This action assures that both brakes are released before the brake valve opens, further assuring that dynamic braking takes place within the brake valve.
DUAL BRAKE SYSTEM WITH AUXILIARY BRAKE - OPERATION (CONTINUED)
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 position whenever the handle is released, and both work ports are opened to tank (open center, open port).
WINCH SELECTION 23
WINCH
WORM GEAR TERMINOLOGY
Starting Input Torque - The torque applied to the winch input shaft required to start a rated load upward from a suspended position. It is expressed in pound-feet, pound-inches, kilogram-meters or Newton-meters. May be referred to as static torque.
Running Input Torque - The torque applied to the winch input shaft required to maintain upward movement of rated load. It is expressed in pound-feet, pound-inches, kilogram-meters or Newton-meters. May also be referred to as dynamic torque.
Rated Input Speed - The maximum permissible input speed at rated load expressed in RPM. Exceeding rated input speed may cause damage to the worm gear set.
Full Drum or Maximum Layers - A drum containing the maximum number of cable layers which would leave a freeboard of 0.7 x the cable diameter below the drum fl ange.
Drum Storage Capacity - The maximum length of wire rope which may be wound on a cable drum without exceeding the maximum number of layers. It is expressed in feet or meters.
Rated Line Pull - The line pull on any layer that results from the output torque which produces maximum rated line pull on the fi rst layer. Rated fi rst layer line pull is based on maintaining an acceptable structure safety factor while providing an acceptable component service life. Line pull is expressed in pounds or kilograms.
Rated Line Speed - The line speed on any specifi c layer that results from rated input speed. It is expressed in feet/minute or meters/minute.
Thermal Rating (Duty Cycle) - The result of a test, expressed as the distance (feet or meters) a load travels up and down while hoisting and lowering a specifi ed weight until the lubricating oil rises from 100º F to 250º F (38º C to 121º C). 250º F (121º C) is the maximum intermittent gear oil temperature allowed. Most gear oils “break down” rapidly at higher temperatures and seals may be damaged.
Largest Recommended Wire Rope Size - Should be no larger than 1/8th the cable drum barrel diameter for most recovery applications.
Drum Clutch - Also known as a “dog-clutch” or “jaw-clutch,” consists of two or more drive lugs which engage similar driven lugs to transmit torque to the cable drum.
Free Spooling - The operation of manually unspooling wire rope from the cable drum by pulling on the free end of the rope while the cable drum is disconnected (declutched) from its power.
Wrap - A single coil of wire rope wound on a drum.
Layer - All wraps on the same level between drum fl anges.
Freeboard - The amount of drum fl ange that extends radially past the last layer of wire rope.
24 WINCH SELECTION
WINCH
WORM GEAR TERMINOLOGY (CONTINUED)
Mean Drum - A theoretical point located midway between the fi rst layer of wire rope on the cable drum barrel and the top layer. Often used as a reference point in measuring winch performance.
Gear Set Effi ciency - The relationship between the input horsepower transmitted to the winch by the prime mover and the output horsepower transmitted by the winch to the wire rope. Expressed as a percentage.
Extension Shaft - The standard cable drum shaft is extended or replaced by an extra long shaft which permits the use of capstans or CR reels at the side of the vehicle, most extension shafts are limited to a standard length of 44 to 46-1/2 in. (112-118 cm) from the cable drum center-line.
Capstan - Usually a small removable drum used to apply force to fi ber rope wrapped around the barrel with tension applied by hand. Most have a nominal barrel diameter of 7 in. (178 mm).
CR Reel - Collapsible recovery reels are used for picking up and coiling power and telephone lines which have been removed from the poles and lowered to the ground. Most CR reels have a nominal barrel diameter of 20” (508 mm).
Bull Gear - Bronze alloy gear powered by the steel worm. Braden refers to the “bull gear” as the worm gear.
Fleet Angle - The angle between the wire rope’s position at the extreme end wrap on a drum, and a line drawn perpendicular to the axis of the drum through the center of the nearest fi xed sheave or load attachment point.
WINCH SELECTION 25
First sheave or load should be centered between the drum fl anges, so that angles A and B are equal.
Angles A and B should be a minimum of ½º and a maximum of 1½º
½º Min
½º Min
A
BFirst Sheave
or Load
A
B
Distance
Fleet Angles A & B:
1½º Max. - ½º Min.
A=B
1½º Max
1½º Max
WINCH
BASIC WORM GEAR RECOVERY WINCH OPERATION
Procedure for Shifting Clutch (Where Equipped):
A To Engage Clutch
1. Insure winch motor or PTO is not running and the winch cable and cable drum are not loaded. The prime mover is stopped in neutral with parking brake set.
2. Lift lock knob on shift handle (where applicable) to disengage lock detent. Move handle to full travel to engage clutch. If shift handle lock knob will not engage detent hole, the clutch is not fully engaged. At this point it may be necessary to manually rotate the cable drum slightly in either direction to align clutch lugs while holding slight pressure on the shift handle.
B To Disengage Clutch
1. Ensure winch motor or PTO is not running and the winch cable and cable drum are not loaded. The prime mover is stopped in neutral with parking brake set.
2. Lift lock knob on shift handle (where applicable) to disengage lock detent. Move shift handle full travel to disengage clutch. If shift handle has Resistance to shift, cable drum may be manually rotated in the direction to haul-in cable to relieve the self-energized load on the drum clutch lugs and allow shift.
Note: If your operation involves lifting loads and does not require the clutch to be disengaged, Braden strongly recommends the drum clutch be mechanically locked in the fully engaged position to avoid accidental disengagement of the clutch.
Basic Winch Operating Method - Engine speed, PTO controls will infl uence your “feet” of the winch operation. Remote lever controls, air-shift cylinders and emergency stop systems should be adjusted at time of installation and all operators fully trained on their operation under a no-load condition.
Typical Winch Maneuver - When possible, position winch such that the centerline of the winch drum is perpendicular to the winch load. The angle the winch must pull from (fl eet angle) must not exceed 1-1/2º. If the fl eet angle exceeds 1-1/2º, the cable will not spool correctly resulting in damaged cable and prematurely worn winch components.
Disengage the drum clutch, as described earlier, and pull cable off of winch drum. If equipped, apply shoe or band type drum brake to control drum over-spin or “birdnesting.”
Avoid powering out winch cable as this practice causes unnecessary heat and accelerated wear of winch brake components.
Securely attach winch cable to load in such a manner to avoid damage to the load or cable. Fully engage the drum clutch as described earlier.
Release band type drum brake, if so equipped, and engage winch control. Operate controls smoothly to avoid “jerking” of load. Operate winch at slowest speed practicable for your application to reduce worm gear heat rise and maintain winch load control.
26 WINCH SELECTION
WINCH
BASIC WORM GEAR RECOVERY WINCH OPERATION (CONTINUED)
Observe winch operation carefully to make certain that all ground personnel remain clear of winch cable and load and that load does not shift requiring the repositioning of the winch cable or winch. When the load is properly positioned, stop the winch. The automatic safety brake and worm gear set are designed to hold the load when properly positioned , stop the winch. The automatic safety brake and worm gear set are designed to hold the load when properly adjusted. (Refer to “Safety Brake Service & Adjustment)
Secure the load in position. Pay out enough winch cable to remove all tension on cable and drum. Disengage drum clutch and disconnect winch cable from load.
Engage drum clutch as described earlier. When possible, visually determine that the drum clutch is fully engaged.
Wind winch cable back onto cable drum while maintaining minimum fl eet angle and suffi cient tension to cause the cable to spool properly being careful to keep hands and clothing away from cable drum and fairhead rollers.
TYPICAL RECOVERY WINCH OPERATION
The 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 position whenever the handle is released, and both work ports are opened to tank (open center, open port).
WINCH SELECTION 27
WINCH
28 WINCH SELECTION
COMMON HYDRAULIC EQUATIONS
TO FIND:
Motor Output Torque, Starting
Motor RPM
Required Motor Size (cu. in.)
Required Flow for Desired RPM:
6 cu. in. x 2000 RPM
System Flow (GPM) x 231 x .90 Vol. Efficiency.=
Example: 35 gpm x 231 x .906 cu. in.
= 1213 rpm Motor Output Speed
Motor Size (cu. in.)
= System pressure (psi) x Motor Size (cu. in.) x .1591 x Motor Starting Efficiency
System Pressure = 2500 psiSystem Flow = 35 gpmMotor Size = 6 cu. in.Motor Starting Efficiency = 70%2500 PSI x 6 cu. in. x .1591 x .70 (eff) = 1670 lb in. torque
Example:
Input Torque Required (in. lb)=
System Pressure (PSI) x .1591 x Motor Starting Efficiency
Input Torque Required = 1500 lb in.System Pressure = 2000 PSIMotor Starting Efficiency = 70%
Example:
= 6.73 cu. in. motor required200 PSI x .1591 x .70 Efficiency
1500 lb in.
Motor Size (cu. in.) x Desired RPM=
231 x .90 Vol. Efficiency
Motor Size = 6 cu. in.Desired RPM = 2000
Example:
231 x .90 = 58 GPM Required
WINCH
WINCH SELECTION 29
TO FIND:
Required Horsepower To Drive Pump
Maximum Pressure If Horsepower And Flow Are Fixed
Maximum Flow If Horsepower And Flow Are Fixed
COMMON HYDRAULIC EQUATIONS (CONTINUED)
System Pressure (PSI) x System Flow (GPM)=
1714 x .80 Pump Efficiency
System Pressure = 2500 PSISystem Flow = 35 GPM
Example:
= 64 Horsepower1714 x .80 Pump Efficiency
2500 PSI x 35 GPM
Available Horsepower x 1714 x .80 Eff.=
System Flow (GPM)
Available Horsepower = 50System Flow = 35 GPM
Example:
35 GPM50 HP x 1714 x .80 Pump Efficiency
Available Horsepower x 1714 x .80 Eff.=
System Pressure (psi)
Available Horsepower = 50System Pressure = 2500 PSI
Example:
= 27.4 GPM Max. System Flow2500 PSI
50 HP x 1714 x .80 Pump Eff.
= 27.4 GPM Max. System Flow
WINCH
HOISTING OR PULLING & INCLINES
HOISTING:
Load on hoist is equal to weight of load. Load on hoist can be reduced by multi-parting the wire rope. (See Wire Rope Section, page 8.)
PULLING ON LEVEL SURFACE:
Load on winch is reduced by a factor based on the friction between the load being moved and the surface it is sliding on. (See page 16.)
PULLING ON INCLINED SURFACE:
Load on winch is reduced by a factor based on the friction between the load being moved and the surface it is sliding on, plus the slope of the incline. (See page 16.)
x
y
x
y
30 WINCH SELECTION
WINCH
ASSUMING A ROLLING LOAD OF .01 COEFFICIENT OF FRICTION
ASSUMING A SLIDING LOAD OF .01 COEFFICIENT OF FRICTION
% OF GRADE ANGLE PULL/WEIGHT
0.00 0º 0.10
17.63 10º 0.27
36.40 20º 0.44
57.74 30º 0.59
83.91 40º 0.72
119.18 50º 0.83
173.21 60º 0.92
274.75 70º 0.97
567.13 80º 1.00
Infinity 90º 1.00
SLIDING LOAD .10 COEFFICIENT GREASED SURFACE
% OF GRADE ANGLE PULL/WEIGHT
0.00 0º 1.00
17.63 10º 1.16
36.40 20º 1.28
57.74 30º 1.37
83.91 40º 1.41
119.18 50º 1.41
173.21 60º 1.37
274.75 70º 1.28
567.13 80º 1.16
Infinity 90º 1.00
SLIDING LOAD 1.00 COEFFICIENT LOCKED RUBBER TIRES ON DRY CONCRETE
% OF GRADE ANGLE PULL/WEIGHT
0.00 0º 0.01
17.63 10º 0.18
36.40 20º 0.35
57.74 30º 0.51
83.91 40º 0.65
119.18 50º 0.77
173.21 60º 0.87
274.75 70º 0.94
567.13 80º 0.99
Infinity 90º 1.00
ROLLING LOAD .01 COEFFICIENT
WINCH SELECTION 31
WINCH
DUTY CYCLE
= How far do you want to pull or hoist the load? (Distance from A to B)
= How frequently and how fast do you want to pull or hoist the load?
32 WINCH SELECTION
Load = 10,000 lb20 Foot Long Ramp3.5 Foot RiseRolling Load
3.5 Ft. Rise20 Ft. Ramp = 17.5% of Grade
17.5% of Grade = .18 Pull/Weight
10,000 lb x .18 Pull/Weight = 1,800 lb Pull
INCLINE EXAMPLE PROBLEM
A B
WINCH
THEORETICAL THERMAL RATINGS TO REACH 250° F 9 — WORM GEAR MODELS
WINCH SELECTION 33
MO
DEL
1K1.
5K2K
3K4K
5K6K
8K10
K12
K15
K18
K20
K25
K30
K35
K40
K45
K50
K60
K70
K80
K90
K10
0K15
0K
AMS3
750
460
330
210
140
110
9060
50AM
SU3
750
460
330
210
140
110
9060
50AL
U2
Con
t.57
041
026
018
014
011
080
60AM
GU
5C
ont.
1,18
084
053
037
029
023
016
013
010
080
6050
ALG
U2
Con
t.89
063
040
028
021
017
012
010
080
AMU
7C
ont.
1,18
084
053
037
029
023
016
130
100
8060
5050
AMS7
Con
t.1,
530
1,09
068
047
037
030
021
016
013
010
080
70AM
S10
Con
t.C
ont.
1,55
098
068
053
042
030
023
019
014
012
010
080
60AM
SU10
Con
t.C
ont.
1,55
098
068
053
042
030
023
019
014
012
010
080
60AM
SU12
Con
t.C
ont.
Con
t.1,
200
830
6 40
520
370
290
230
180
140
130
100
8070
AMS2
0C
ont.
Con
t.C
ont.
1,56
01,
080
840
670
480
370
300
230
190
160
130
100
9070
60M
S30
Con
t.C
ont.
Con
t.1,
890
1,31
01,
020
820
590
450
360
280
230
200
150
120
100
9080
7060
MS5
0C
ont.
Con
t.C
ont.
Con
t.C
ont.
Con
t.C
ont.
1,04
080
065
049
040
036
028
022
019
016
014
012
010
080
7060
50W
150
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
*WA
RNIN
G: D
o no
t ope
rate
win
ch in
this
cate
gory
. Dam
age
to th
e ge
arse
t will
occ
ur.
MU
8A50
040
027
517
012
090
7540
Leng
th o
f pul
l in
feet
to 2
50º F
. reg
ardl
ess
of s
peed
or l
ayer
(pou
nds
pull)
WINCH
WORM GEAR VS PLANETARY RM GEAR VS PLANETARY
WORM GEAR VS PLANETARY EFFICIENCY
40%—50% EFFICIENT 90%—98% EFFICIENT
10 HP
INPUT
10 HP
INPUT5 HP
HEAT
0.5 HP
HEAT
5 HP WORK
9.5 HP WORK
34 WINCH SELECTION
WINCH
For the same load and line speed, a worm gear winch will require approximately twice the input horsepower as a planetary hoist.
WORM GEAR VS PLANETARY EFFICIENCY
12,000 LB Hydraulic Winches
Worm Gear Planetary AHSU3–10F–096 PD12C–29064–02
GEAR SET COMPARISON
WORM GEAR PLANETARY
ADVANTAGESSelf Locking High Efficiency
Simple / Reliable Continuous Duty Cycle
Lower Cost High Line Speeds
DISADVANTAGESLow Efficiency Complex Brake
Limited Duty Cycle Higher Cost
Limited Line Speed Higher Operator Skill
WAHS A
WINCH SELECTION 35
WINCH
LINE SPEED BY LAYER
LINE PULL BY LAYER
36 WINCH SELECTION
5.16 in.
6.28 in.61,875 lb in. TORQUE
5.156 in.= 12,000 lb
61,875 lb in. TORQUE
6.281 in.= 9,850 lb
1st Layer
12,000 lb
250 fpm
3rd Layer
9,850 lb
305 fpm
WINCH
WINCH PERFORMANCE BY LAYER
DRUM SIZE REQUIREMENTS
WORM GEAR
Small barrel diameter
Limited rope storage
BARREL DIAMETER (D/d)
PLANETARY
Large barrel diameter
Additional rope storage
Where
D = Drum Diameter
d = Rope Diameter
SAE D/d Standard for RECOVERY WINCH: 8:1
example:
ANSI D/d Standard for HOISTS 17:1
example:
WINCH SELECTION 37
4.0 in. drum
5.0 in. wire rope= 8:1
Layer Line Pull (lb) Line Speed (fpm) Rope Capacity (ft)
1 12,000 250 65
2 10,820 277 138
3 9,850 305 218
4 9,040 332 305
5 8,360 360 399
PD12C-29064-02 2700 psi @ 80 gpm (9/16 in. Wire Rope)
8.5 in. drum
5.0 in. wire rope= 17:1
WINCH
INTERACTIVE APPLICATION CHECKLIST
PACCAR WINCH LIT2238, Customer Application Checklist, is useful for gathering customer information.
An interactive version of this form is accessible via the PACCAR WINCH intranet and Note ‘Reset’ and ‘Print’ buttons at bottom. Form may also be configured to generate and save an XML file of entered data.
If desired, the next page may be reproduced and used.
38 WINCH SELECTION
3/4
X
WINCH
WINCH
MOTOR TYPES
FIXED-DISPLACEMENT MOTORS
VARIABLE-DISPLACEMENT MOTORS
• Gear
• Piston
• Geroter
• Vane
40 WINCH SELECTION
GEAR VANE
GEROTOR AXIAL PISTON
BENT AXIS PISTON
SWASH PLATE PISTON
WINCH
GEAR MOTOR OPERATION
• Two teeth react to high pressure and rotate the gears.• Pressure in mesh zone acts on one tooth.• Trapped pressure does not affect torque.• Only two teeth have tank pressure opposing rotation.
GEAR MOTOR STARTING EFFICIENCY COMPARISON
WINCH SELECTION 41
STANDARD Tooth Form MODIFIED Tooth Form
85% AVG
70% MIN
88% AVG
70% MIN
83% AVG
600 MINIMUM SMOOTH OPERATING RPM 600
WINCH
GEAR MOTOR
• Low cost• High horsepower for size
• High horsepower for size• High line speeds• High starting efficiency (75–85%)• Low speed operation (250–400 rpm)
• Poor low speed operation (50–600 rpm)• Poor starting efficiency (75–85%)• Noise at high rpm
• Noise at high rpm• High speed efficiency loss
STANDARD Tooth Form MODIFIED Tooth Form
PISTON MOTOR
• Highest horsepower for size• Wide speed range (50 to 4000+ rpm)• Quieter operation• High volumetric efficiency• High pressure capability• High starting efficiency
• Higher cost• Dirt sensitive
ADVANTAGES DISDVANTAGES
42 WINCH SELECTION
STANDARD Tooth Form MODIFIED Tooth Form
ADVANTAGES
DISADVANTAGES
WINCH
GEROLER MOTOR
• Low speed operation
• Low to moderate cost
• Good volumetric efficiency (90–96%)
• Moderate-to-high starting efficiency (70–80%)
• Small “envelope”
• Limited flow capacity
• Wide range in static & dynamic efficiency
• Moderate noise
ADVANTAGES DISDVANTAGES
WINCH SELECTION 43
WINCH
VANE MOTOR
• Quiet operation
• Small “envelope”
• Higher cost
• Low starting efficiency
• Sensitive to shock loading
• Dirt sensitive
ADVANTAGES DISDVANTAGES
44 WINCH SELECTION
Fixed Displacement Variable Displacement
WINCH
BASIC HYDRAULIC SCHEMATIC, SINGLE-SPEED MOTOR
WINCH SELECTION 45
WINCH MOTOR
BRAKE
VALVE
WINCH
BRAKE
WINCH ASSY
W/BRAKE VALVE
& STATIC BRAKE
CONTROL
VALVE
PUMP
WINCH
BASIC HYDRAULIC SCHEMATIC, TWO-SPEED MOTOR
46 WINCH SELECTION
WINCH MOTOR
BRAKE
VALVE
WINCH
BRAKE
WINCH ASSY
W/BRAKE VALVE
& STATIC BRAKE
CONTROL
VALVE
TWO-SPEED
SELECTORVALVE
PUMP
WINCH
BRAKE TYPES
• Static (Braden)
• Dynamic (Gearmatic)
• Brake valve (Braden)
• Band brake
STATIC BRAKE
WINCH SELECTION 47
STATIC BRAKE
MOTOR
PUMP
Low Pressure
TO TANK
Medium Pressure High Pressure
WINCH
BASIC HYDRAULIC SCHEMATIC, DUAL-SPEED MOTOR
HEAT LOAD
• Dynamic brake
- Winch housing
- Hydraulic system
• Brake valve with static brake
- Hydraulic system
• Band brake
- Atmosphere
- Poor load control
48 WINCH SELECTION
Low Pressure Medium Pressure High Pressure
MOTOR
DYNAMIC BRAKE
WINCH
GEAR RATIO SELECTION
• Smooth operation
• Good low-speed operation
• Adapts well to low-horsepower systems
• Can adapt to smaller, low-cost motors
• Limited high-speed operation
• Limited horsepower transmission
Advantages Disdvantages
WINCH SELECTION 49
HIGH REDUCTION (example: 60:1)
• High line speed
• High horsepower transmission
• Reduced noise in some applications
• Poor low-speed performance
• Sacrifice of some smoothness of operation
• Requires larger, more expensive motors
Advantages Disdvantages
LOW REDUCTION (example: 20:1)
WINCH
WINCH APPLICATION
• 1st-layer line pull
• 1st-layer line speed
• Wire rope diameter
• Wire rope storage capacity
Information required
APPLICATION EXAMPLE
A truck crane has a 16–ton hook load on four parts of line. Wire rope diameter is .50 inches
and 400 feet of storage is required. Desired hook speed minimum is 42 fpm. Horsepower available
is 100 hp.
Make a winch selection from this information.
Horsepower formulas
Mechanical horsepower
Winch load
Winch line speed
Overall winch performance
HORSEPOWER (HYD) =
HORSEPOWER (MECH) =LINE PULL x LINE SPEED
33,000 lb-ft/minute x WINCH EFFICIENCY
HORSEPOWER =
HORSEPOWER =16 tons x 2,000 lb/ton x 42 ft/min
33,000 lb-ft/min x 0.65 EFFICIENCY
MECHANICAL HORSEPOWER
16 tons x 2,000 lb/ton x 0.275 SHEAVE EFFICIENCY = 8,800 lb LINE PULL REQUIRED AT WINCH
42 fpm AT HOOK X 4 PARTS OF LINE = 168 fpm AT WINCH
LINE PULL = 8,800 lb
LINE SPEED = 168 fpm
• Pressure (psi)
• Flow (gpm)
50 WINCH SELECTION
LOAD (lb) x SPEED (fpm)
33,000 x WINCH EFFICIENCY
PRESSURE x FLOW
1714 x WINCH EFFICIENCY
WINCH
STATIC VS. DYNAMIC
Torque to start rotation (start to lift
a suspended load)
Torque to continue rotation
(keep a load moving once started)
Static efficiency Dynamic efficiency
• 1 to 1.5 x pump flow
• De-aeration
• Heat dissipation
Reservoir sizing and design
HYDRAULIC CONSIDERATIONS
• Reduces working pressure
• Leads to shaft seal failure
• Winch brake malfunction
Excessive backpressure
• Brake valve pilot orifice plugged or loose
• Brake cylinder seal defective
• Damaged brake will not release
Load cannot be lowered smoothly or lowered at all
TROUBLESHOOTING
• Brake cylinder seal defective
• Motor shaft seal failure
Oil leaks from vent plug
• Excessive back pressure
• Worn or damaged brake discs
• Brake clutch worn and slipping
Brake will not hold the load in neutral
• Mounting surface causing binding
• Relief valve set too low or needs repair
• Hoisting rated load on top layer
• Rigged improperly
Winch will not hold hoist rated load
WINCH SELECTION 51
WINCH
TROUBLESHOOTING (continued)
• Mounting surface binding the winch
• Heat exchanger blocked
• Reservoir level
• Relief valve set too low
• Poor pump efficiency
Winch runs hot
• Relief valve set too low
• Oil flow to motor too low
• Operator error or improper control valve
• Winch not mounted properly
Winch “chatters” when hoisting
• Improper fleet angle
• Mounting off center
• Wrong rope lay
• Wire rope taken set (overload)
Spooling problems
52 WINCH SELECTION
WINCH
WINCH SELECTION 53
WINCH
TYPICAL APPLICATIONS
• Tilt Deck Car Carriers
• Wreckers/Tow Trucks
• Utility O.E.M. Products & Add-On Equipment
• Underground Cable Pulling
• Oilfield “Hot Shot” Vehicles
• Oilfield Rig Moving Vehicles
• Pipeline Construction
• Drilling/Work-Over Rigs
• Refuse Hauling
• Roll-Off Hauling
• Machinery Moving & Rigging
• Railroad Car Moving
• Boat Hauling Trucks
• House Moving Vehicles
• Highway Maintenance Vehicles
• Logging/Forestry
• Trailers
• Military Recovery Vehicles
• General Construction
MAJOR MARKETS
• Wrecker
• Car Carrier
• Logging
• Forestry
• Truck Crane
• Mobile Crane
• Oilfield
• Pipeline
• Military
• Machinery Moving & Rigging
• Construction
• Trailer
• General Hydraulic
• Refuse
• Utility
• Compaction
• Drill Support
• General Truck
54 RECOVERY WINCHES
WINCH
RECOVERY WINCHES 55
TYPES OF RECOVERY PRODUCTS
• Low-Mount (8,000 - 35,000 lb Line Pull)
• Upright (10,000 - 150,000 lb Line Pull)
Worm Gear Units
Planetary Recovery Units
• BG25R (25,000 lb Line Pull)
• Special Purpose Products (Various Ratings)
• H20R & H35R (20,000 - 35,000 lb Line Pull)
• Oilfield Planetary Recovery Winches
Low Mount
WORM GEAR RECOVERY WINCHES
Upright
Model Line Pull
lb kg
MU8/HU8 8,000 3,636
ALU2/AHU2 10,000 4,545
AMSU3/AHSU3 10,000 4,545
ALGU2/AHGU2 12,000 5,454
AMU7/AHU7 20,000 9,090
AMGU5/AHGU5 20,000 9,090
AMSU10/AHSU10 30,000 13,636
WINCH
WORM GEAR RECOVERY WINCH COMPONENTS
Worm GearHousing
Drum Shaft
Worm Brake
Drum Band Brake*
Clutch**
Bearing Leg
ShifterFork
Base Angle
* Avoids drum overrun and cable birdnesting.** Negative draft angle resists disengaging under load.
Dr
Be
Worm Gear
WORM GEAR RECOVERY WINCH OPTIONS
• Mechanical Drive
• Hydraulic Motor Drive
• Low Mount
• Upright
• Band Brake
• Remote Controlled Clutch and/or Band Brake
• Extension Shaft (Single or Double)
• Left or Right Assembly
• Left or Right Hand Gear Set
56 RECOVERY WINCHES
WINCH
Model First-layer Line Pull Line Speed Rope Capacity
lb kg fpm mpm ft m
HP35A 35,000 15,909 53 16 26 8
HP50B 50,000 22,727 39 12 37 11
HP65A 68,500 31,070 28 9 47 14
HP75A 75,000 34,090 26 8 43 13
HP80A 80,000 38,260 27 10 52 16
HP100B 100,000 45,360 52 16 47 14
HP125B 125,000 56,695 46 14 47 14
HP130A 130,000 59,091 21 6 42 13
OILFIELD PLANETARY RECOVERY WINCHES
RECOVERY WINCHES 57
WINCH
MECHANICAL DRIVE vs. HYDRAULIC DRIVE
• Simple Design & Service• Simple Operation• Greater Versatility, Power, & Speed• Overload Protection• High Efficiency• Power Beyond Capability
• Semi-skilled Operation• Loss of Efficiency• No Overload Protection• Higher Service Skill Required• Higher Maintenance• Higher Initial Cost
Advantages Disadvantages
Mechanical Drive Hydraulic Drive
MECHANICAL and HYDRAULIC DRIVES
HYDRAULIC MOTOR ADAPTER
Adaapts hydraulic motor to existing mechanical drive winch
58 RECOVERY WINCHES
WINCH
RECOVERY WINCHES – RIGHT-HAND vs. LEFT-HAND
59
LEFT-HAND ASSEMBLY
All views are of HOUSING side of winch. Assume clockwise rotation of the input shaft.
Drum Rotation
Drum Rotation
Drum Rotation
Drum Rotation
Left-Hand Gear Set
Right-Hand Gear Set
Left-Hand Gear Set
Right-Hand Gear Set
RIGHT-HAND ASSEMBLY
Left Side of Truck
Right Side of Truck
Drum Rotation
Drum Rotation
Drum Rotation Drum
Rotation
Left-Hand Gear Set
Right-Hand Gear Set
Left-Hand Gear Set
Right-Hand Gear Set
WINCH
RECOVERY WINCHES – RIGHT-HAND vs. LEFT-HAND (continued)
LEFT-HAND ASSEMBLY
RIGHT-HAND ASSEMBLY
Low or Front Mount Winch Upright or Bed Mount Winch
Input
Input Input
Input
Passenger Side
Driver Side
Low Mount as Bumper Winch
Upright Mounted in Bed
Wire Rope
Wire Rope
<VIEW
60 RECOVERY WINCHES
WINCH
RECOVERY WINCHES – FRONT MOUNT vs. REAR MOUNT
Front Mount, Right-hand Assembly Rear Mount, Right and Left-hand Assemblies
RECOVERY WINCHES 61
WINCH
TYPICAL WORM GEAR RECOVERY WINCH INSTALLATIONS
Front Mount Terminology and Conventions
Input shaft or hydraulic motor toward the truck cab.
Right or left-hand assembly indicates which side of the drum the gear housing is located
(determined while sitting in the drivers position or standing behind the vehicle).
Extension shaft toward the curb side.
Haul-in is over the top of the cable drum (overwound).
Right or left hand gear cut determines the direction the input shaft will turn to rotate the
drum in the correct haul-in direction.
Right-hand assembly and right hand gear cut - input shaft rotates counter-clockwise to haul-in (overwound).
Right-hand assembly and left hand gear cut - input shaft rotates clockwise to haul-in (overwound).
Left-hand assembly and right hand gear cut – input shaft rotates counter-clockwise to haul-in (overwound).
Left-hand assembly and left hand gear cut – input shaft rotates clockwise to haul-in (overwound).
Rear Mount Terminology and Conventions
Input shaft or hydraulic motor toward the truck cab.
Right or left-hand assembly indicates which side of the drum the gear housing is located
(determined while sitting in the drivers position or standing behind the vehicle).
Haul-in is over the top of the cable drum (overwound).
Right or left hand gear cut determines the direction the input shaft will turn to rotate the
drum in the correct haul-in direction.
Left-hand assembly and right hand gear cut – input shaft rotates counter-clockwise to haul-in (overwound).
Left-hand assembly and left hand gear cut – input shaft rotates clockwise to haul-in (overwound).
Right-hand assembly and right hand gear cut – input shaft rotates counter-clockwise to haul-in (overwound).
Right-hand assembly and left hand gear cut – input shaft rotates clockwise to haul-in (overwound).
NOTE: Worm gear winches may be operated where haul-in is under the bottom of the drum
(underwound). In these cases, the brake must be “set for underwind”. This should be specified at the time of order or may be
done in the field. Contact the factory for additional information.
62 RECOVERY WINCHES
WINCH
A B S U 3 - 10 F EB R RA
Left Hand AssemblyRight Hand Assembly
Left Hand Gear CutRight Hand Gear Cut
Extension Shaft(One Side Only)Extension Shaft
Special(Both Sides)
Front or Bumper MountIs Most Common Install
10" Normal Drum Barrel
Designed & TestedTo SAE J706A
Convertible BaseElectric DriveHydraulic Drive
Mechanical DriveLightweight Housing
Revised Gear ProfileSpacer Added BetweenWorm Gear & Housing
Underslung or Low Mount
Basic Winch Model
A
CEHLM
GS
U
3
-
----
--
-
-
--
--
-
-
-
-
-
RALA
RL
EB
EEB
SPL
F
10Length Between Flanges
MODEL CODE – LOW MOUNT WORM GEAR
MODEL CODE – UPRIGHT WORM GEAR
Low Mount Upright
RECOVERY WINCHES 63
WINCH
SPECIAL-PURPOSE RECOVERY PRODUCTS
HUP-12A
PD35A
PD18D
PLANETARY RECOVERY WINCHES/UNIVERSAL BUMPERS
PD18C
PD18D
64 RECOVERY WINCHES
WINCH
SPECIAL-PURPOSE RECOVERY PRODUCTS
BD12A DIGGER DRIVE
WR30 WORM GEAR SWING DRIVE
SD40 SWING DRIVE
BP200B UNDERGROUND CABLE PULLING WINCH
PCD24B PLANETARY CAPSTAN DRIVE
RECOVERY WINCHES 65
WINCH
SPECIAL-PURPOSE RECOVERY PRODUCTS
Bumper Packages
• Winch and bumper assemblies tested in compliance with SAE J706 to twice the rated load
• Cable rollers for full load capacity up to 45º from center
• Optional built-in toolbox, street or curbside extension shafts, and two-speed hydraulic motors
• Modular construction for easy maintenance and installation
• Capstan-only bumper packages
Capstan and Capstan Drives
• Ductile iron capstan
• Lighter aluminum capstan for line applications
Extension Shaft Winches
• Double extension shaft on some models
• Mechanical or hydraulic drive
• Two-speed hydraulic motors
• Wire rope roller assembly
Speed Reducers and Swing Drives
• High output torque
• Slow to medium speeds
• Precise control
• Smooth operation
Model BP200B
• Specifically designed for underground cable pulling applications
• Diamond screw level wind system
• Adjustable-drag free spool & two-speed hydraulic motor
66 RECOVERY WINCHES
WINCH
WINCH MODEL
LINE PULL
POUNDS
MAX. LINE
SPEED FPM
MAX. INPUT SPEED
RPM
TORQUE REQUIRED
LB IN STATIC
TORQUE REQUIRED
LB IN DYNAMIC
WINCH MODEL
LINE PULL
POUNDS
MAX. LINE
SPEED FPM
MAX. INPUT SPEED
RPM
10,000 16 400 2,770 1,9908,000 20 500 2,220 1,6006,000 26 660 1,665 1,2004,000 40 1,000 1,110 8002,000 58 1,440 555 400
No Load 80 2,000 - - 20,000 28 480 5,900 4,50016,000 35 600 4,720 3,60012,000 47 800 3,540 2,7008,000 71 12,000 2,360 1,8005,000 89 1,540 1,480 1,130
No Load 102 1,740 - -
10,000 16 400 2,770 1,990
30,000 18 330 8,070 6,140
8,000 20 5,000 2,220 1,590
25,000 21 400 6,725 5,120
6,000 26 670 1,660 1,190
20,000 27 500 5,380 4,090
4,000 40 1,000 1,110 800
15,000 35 660 4,035 3,070
2,000 58 1,440 550 400
10,000 53 910 2,690 2,050
No Load 80 2,000 - -
5,000 68 1,300 1,345 1,020
12,000 19 580 1,950 1,500
No Load 97 1,850 - -
10,000 23 700 1,625 1,250
45,000 18 330 13,300 9,980
8,000 29 870 1,300 1,000
35,000 23 420 10,340 7,760
6,000 39 1,160 975 750
25,000 32 590 7,390 5,540
4,000 52 1,550 650 500
15,000 54 990 4,430 3,330
2,000 72 2,200 325 250
10,000 79 1,130 2,960 2,220
No Load 72 2,200 - -
No Load 84 1,500 - -
20,000 19 480 3,950 3,000
100,000 12 180 35,160 27,000
15,000 25 640 2,960 2,250
80,000 15 220 28,130 21,600
10,000 38 960 1,980 1,500
60,000 20 300 21,100 16,200
5,000 60 1,540 990 750
40,000 29 440 14,060 10,800
No Load 79 2,000 - -
20,000 43 650 7,030 5,400
20,000 28 400 7,050 5,350
15,000 50 750 5,280 4,050
15,000 37 530 5,290 4,010
5,000 66 1,000 1,760 1,350
10,000 56 800 3,520 2,680
No Load 66 1,000 - -
5,000 88 1,280 1,760 1,340
150,000 15 300 35,066 27,400
No Load 140 2,000 - -
112,500 22 450 26,764 20,550
35,000 15 280
75,000 30 600 17,843 13,700
30,000 18 330
37,500 60 1,200 8,921 6,850
25,000 21 400
No Load 125 2,500 - -
20,000 27 50015,000 35 66010,000 53 9805,000 68 1,300
No Load 93 1,740
9,420 7,1638,070 6,1406,730 5,1105,380 4,0904,040 3,0702,690 2,0501,350 1,020
- -
ALGU2
AMU7
AMGU5
AMSU12
AMS20
MS50
W150A
LOW MOUNT WORM GEAR WINCHES
AMSU3
UPRIGHT WORM GEAR WINCHES
AMS3
AMS7
AMS10 AMSU10
TORQUE REQUIRED
LB IN STATIC
TORQUE REQUIRED
LB IN DYNAMIC
MAXIMUM LINE SPEED/TORQUE INFORMATION
(All line pulls & line speeds are for 1st layer of cable)
To convert lb line pull to kN,
multiply lb value by .004448.
To covert lb in. torque to Nm,
multiply lb in.value by .113
RECOVERY WINCHES 67
WINCH
MO
DEL
1K1.
5K2K
3K4K
5K6K
8K10
K12
K15
K18
K20
K25
K30
K35
K40
K45
K50
K60
K70
K80
K90
K10
0K15
0K
AMS3
750
460
330
210
140
110
9060
50AM
SU3
750
460
330
210
140
110
9060
50AL
U2
Con
t.57
041
026
018
014
011
080
60AM
GU
5C
ont.
1,18
084
053
037
029
023
016
013
010
080
6050
ALG
U2
Con
t.89
063
040
028
021
017
012
010
080
AMU
7C
ont.
1,18
084
053
037
029
023
016
130
100
8060
5050
AMS7
Con
t.1,
530
1,09
068
047
037
030
021
016
013
010
080
70AM
S10
Con
t.C
ont.
1,55
098
068
053
042
030
023
019
014
012
010
080
60AM
SU10
Con
t.C
ont.
1,55
098
068
053
042
030
023
019
014
012
010
080
60AM
SU12
Con
t.C
ont.
Con
t.1,
200
830
6 40
520
370
290
230
180
140
130
100
8070
AMS2
0C
ont.
Con
t.C
ont.
1,56
01,
080
840
670
480
370
300
230
190
160
130
100
9070
60M
S30
Con
t.C
ont.
Con
t.1,
890
1,31
01,
020
820
590
450
360
280
230
200
150
120
100
9080
7060
MS5
0C
ont.
Con
t.C
ont.
Con
t.C
ont.
Con
t.C
ont.
1,04
080
065
049
040
036
028
022
019
016
014
012
010
080
7060
50W
150
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
*WA
RNIN
G: D
o no
t ope
rate
win
ch in
this
cate
gory
. Dam
age
to th
e ge
arse
t will
occ
ur.
MU
8A50
040
027
517
012
090
7540
Leng
th o
f pul
l in
feet
to 2
50º F
. reg
ardl
ess
of s
peed
or l
ayer
(pou
nds
pull)
THEORETICAL THERMAL RATING (Intermittent Duty)
68 RECOVERY WINCHES
WINCH
THEORETICAL THERMAL RATING (Intermittent Duty)
LOW - MOUNT WORM GEAR WINCHES
1st LAYER LINE PULLBRADEN TULSA RAMSEY DP REMARKS
LB KG
8,000 3,630 MU8A 938 246 N/A Mech. Input
8,000 3,630 HU8A H938 H246 8GAAX3L1A Hyd. Mtr. Input
10,000 4,535 ALU2-10F 1060 400 N/A Mech. Input
10,000 4,535 AHU2 H1060 H400 10GHAAX3L1A Hyd. Mtr. Input
10,000 4,535 AMSU3-10F 1060 400 N/A Mech. Input
10,000 4,535 AHSU3-10F H1060 H400 10GHAAX3L1A Hyd. Mtr. Input
12,000 5,445 ALGU2-10F 1242 600 N/A Mech. Input
12,000 5,445 AHGU2-10F H1242 H600 12JAAX3L1H Hyd. Mtr. Input
20,000 9,070 AMU7-14F 12 700 N/A Mech. Input
20,000 9,070 AHU7-14F H12 H700 15UBEX3R3G Hyd. Mtr. Input
20,000 9,070 AMGU5-12F 18G 800 N/A Mech. Input
20,000 9,070 AHGU5-12F H18G H800 N/A Hyd. Mtr. Input
30,000 13,610 AMSU10-12F 24 930 N/A Mech. Input
30,000 13,610 AHSU10-12F H24 H930 30BBX3L1F Hyd. Mtr. Input
35,000 15,875 AMSU12-12F N/A 940 N/A Mech. Input
35,000 15,875 AHSU12P-12F N/A H940 N/A Hyd. Mtr. Input
RECOVERY WINCHES 69
WINCH
RECOVERY WINCH CROSS-REFERENCE LIST
UPRIGHT WORM GEAR WINCHES
1st LAYER LINE PULLBRADEN TULSA RAMSEY DP REMARKS
LB KG
10,000 4,535 AMS3-10 1138 R10 N/A Mech. Input
10,000 4,535 AHS3-10 H1138 HR10 N/A Hyd. Mtr. Input
20,000 9,070 AMS7-15 19 R20A N/A Mech. Input
20,000 9,070 AHS7-15 H19 HR20A 20BCX3L3G Hyd. Mtr. Input
20,000 9,070 AMS7-15A N/A N/A N/A Mech. Input
20,000 9,070 AHS7-15A N/A N/A N/A Hyd. Mtr. Input
20,000 9,070 AMS7-15B 23 R20 N/A Mech Input
20,000 9,070 AHS7-15B H23 HR20 N/A Hyd. Mtr. Input
30,000 13,610 AMS10-18 N/A R30A N/A Mech. Input
30,000 13,610 AHS10-18 N/A HR30A 30BBX3L1F Hyd. Mtr. Input
30,000 13,610 AMS10-18A N/A N/A N/A Mech. Input
30,000 13,610 AHS10-18A N/A N/A N/A Hyd. Mtr. Input
30,000 13,610 AMS10-18B 34 R30 N/A Mech. Input
30,000 13,610 AHS10-18B H34 HR30 N/A Hyd. Mtr. Input
45,000 20,410 AMS20-18B 64 R45 N/A Mech. Input
45,000 20,410 AHS20P-18B H64 HR45 N/A Hyd. Mtr. Input
60,000 27,215 MS30-20B 70 R65L N/A Mech. Input
60,000 27,215 HS30P-18B H70 HR65L 65AAX4L1D Hyd. Mtr. Input
100,000 45,360 MS50-20B 80 R100L N/A Mech. Input
100,000 45,360 HS50P-20B H80 HR100L 100BBX4L1D Hyd. Mtr. Input
70 RECOVERY WINCHES
WINCH
BRADEN GEARMATIC PLANETARY HOISTS
MODEL1st LAYER LINE PULL
LB KG
BG3B 3,000 1,363
BG4B 4,000 1,818
BG6B 6,000 2,727
BG8B 8,000 3,636
PD12C 12,000 5,454
PD15B 15,000 6,818
PD17A 17,000 7,727
PD21A 20,250 9,205
GH15B 15,000 6,818
GH30B 26,840 12,200
GH50B 44,000 20,000
CH165A 16,500 7,500
CH175B 17,500 7,954
CH210A 21,000 9,545
CH230B 23,000 10,454
CH280A 28,000 12,727
CH400B 40,000 18,181
PLANETARY HOISTS 71
WINCH
72 PLANETARY HOISTS
BRADEN GEARMATIC PLANETARY HOIST FEATURES
• High line-pull
• Patented Braden brake valves
• Anti-friction bearings throughout, with all parts
running in oil
• Easily adapted
• High-capacity brake
• Full-load wire rope anchors*
*API and other regulatory organizations specify keeping 5 wrap of wire rope on drum at all times.
• Gear ratios
• High-speed reverse
• Personnel handling (offshore cranes)
• Auxiliary Brake
• Ratchet and pawl
• Tension rollers
• Hydraulic motor
• Motor displacement
• High-pressure piston motors
• Low-flow motors
• Two-speed motors
• Drum options
• Various sizes
• Grooved drums
• Free fall
• Controlled (CF)
• Full-release (FF)
• Encoders
• Last-wrap and 3rd-wrap indicators
• EMM (Electronic Maintenance Module
BRADEN GEARMATIC PLANETARY HOIST OPTIONS
WINCH
Braden and Gearmatic Planetary Hoists are available in a wide variety of configurations with optional drums, gear ratios, and motor displacements to meet your requirements.
The configuration of each product may be determined by this typical model numbering system:
PD 12 C — FF — 41 V 039 — 02 G R — 1
POWERDRUM
MAXRATING
MODELSERIES
OPTION GEARRATIO
MOTORTYPE
MOTORSIZE*
DRUM CODE
DRUM AND BASE OPTIONS
CHARACTER DESIGNATION
PD POWER DRUM
12 MAXIMUM RATED LINE PULL CAPACITY, LB. (X 1,000)
C MODEL SERIES (DESIGN CHANGES)
FF FULL-RELEASE FREE FALL OPTION (CF = CONTROLLED FREE FALL)
41 TOTAL GEAR REDUCTION RATIO (THE PD12C IS AVAILABLE in 21:1, 29:1, 41:1, and 59:1 RATIOS)
V V=VARIABLE-SPEED PISTON MOTOR (P=FIXED-DISPLACEMENT PISTON MOTOR, NO LETTER=SINGLE OR TWO-SPEED GEAR MOTOR
039 HYDRAULIC MOTOR DISPLACEMENT, CU INCHES/REVOLUTION (033/024 INDICATES TWO-SPEED MOTOR–IN THIS CASE, EITHER 3.3 OR 2.4 CU. IN. MAY BE SELECTED
02 DRUM CODE (COMMON DRUM OPTIONS FOR MOST MODELS INCLUDE –01, –02, –04, –05, –06, –22, AND –25)
G GROOVED CABLE DRUM OPTION
R TENSION ROLLER OPTION
1 API 2C CERTIFICATION OPTION - PERMITS LIFTING & LOWERING OF PERSONNEL FOR OFFSHORE CRANE APPLICATIONS
OTHER OPTIONS
U UNDERWOUND CABLE DRUM OPTION
L LEFT-HAND BASE OPTION
P RATCHET AND PAWL OPTION
* WHERE NO MOTOR IS SPECIFIED, “000” OR SAE MOTOR SHAFT AND BOLT PATTERN (FOR EXAMPLE, “C4C” ) WILL BE PROVIDED
BRADEN GEARMATIC PLANETARY HOIST MODEL CODE
PLANETARY HOISTS 73
WINCH
74 PLANETARY HOISTS
BRADEN GEARMATIC PLANETARY HOIST COMPONENTS
SPRAGCLUTCH
BRAKEPISTON
BRAKEPLATES
BASE
HYDRAULICMOTOR
BRAKEVALVE
SECONDARYPLANET SET
PRIMARYPLANET SET
PRIMARYSUN GEAR
SECONDARYSUN GEAR
RING GEAR& DRUM
BRAKEPLATES
SPRAGCLUTCH
WINCH
PLANETARY HOISTS 75
BASIC OPERATION
PARKING
LOWERING
Static brake is fully applied by spring force. Sprag clutch is locked. Hydraulic motor is stationary - drum remains stationary.
Static brake is hydraulically released. Lowering speed is controlled by oil flow through brake valve and motor. Braking is done by brake valve, heat is absorbed into hydraulic system.
WINCH
76 PLANETARY HOISTS
BASIC OPERATION
HOISTING
STATIC BRAKE APPLIED WHILE HOISTING
UNIDIRECTIONAL CLUTCH
Free Direction Locked Up
Static conditions maintained
in brake pack during hoistingPositive locking when hoisting terminated
Static brake remains fully applied. Input sun gear rotates in “free” direction of sprag clutch.
HOIST HOLD
WINCH
PLANETARY HOISTS 77
BASIC HYDRAULIC CIRCUIT
For a more detailed description of hoisting and lowering operations, see Winch Selection Section, Basic Planetary Hoist Operation.
Static
Disc Brake
Winch
Assembly
to Tank
Brake
Valve
Motor
Control Valve
Pump
Oil In
WINCH
78 PLANETARY HOISTS
FEATURES
BRADEN PATENTED BRAKE VALVES
Full-load
AnchorAnti-friction Bearings Throughout High-capacity
Brake
High-effi ciency
Motor
EASILY SERVICED THROUGH MOTOR END
WINCH
PLANETARY HOISTS 79
NOTES
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