Owner s Man ual. For 4HPF/4HWF/4HBP Series Helical/Parallel, Helical/Worm, Helical/Bevel and Planetary Gear Power Winches

Transcription

1 Red this Own er s Mn u l thor ough ly e fore op er t ing the equip ment. Keep it with the equip ment t ll times. Re plce ments re vil le from Thern, Inc., PO Box 347, Winon, MN 55987, IMPORTANT: Plese record product informtion on pge 2. This informtion is re quired when clling the fc to ry for service. Owner s Mn ul For 4HPF/4HWF/4HBP Series Helicl/Prllel, Helicl/Worm, Helicl/Bevel nd Plnetry Ger Power Winches

2 pge 2 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches Two-Yer Limited Wrrnty Plese record the following: Dte Purchsed: Model No.: Seril No.: This informtion is required when clling the fctory for service. Thern, Inc. wrrnts its products ginst defects in mteril or workmnship for two yers from the dte of purchse y the originl using uyer, or if this dte cnnot e estlished, the dte the product ws sold y Thern, Inc. to the deler. To mke clim under this wrrnty, contct the fctory for n RGA numer. The product must e returned, prepid, directly to Thern, Inc., 5712 Industril Prk Rod, Winon, Minnesot The following informtion must ccompny the product: the RGA numer, the dte of purchse, the description of the climed defect, nd complete explntion of the circumstnces involved. If the product is found to e defective, it will e repired or replced free of chrge, nd Thern, Inc. will reimurse the shipping cost within the contiguous USA. This wrrnty does not cover ny dmge due to ccident, misuse, use, or negligence. Any ltertion, repir or modifiction of the product outside the Thern, Inc. fctory shll void this wrrnty. This wrrnty does not cover ny costs for removl of our product, downtime, or ny other incidentl or consequentil costs or dmges resulting from the climed defects. This wrrnty does not cover rke discs, wire rope or other wer components, s their life is suject to use conditions which vry etween pplictions. FACTORY AUTHORIZED REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY TO THE CONSUMER. THERN, INC. SHALL NOT BE LIABLE FOR ANY INCIDEN- TAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WAR- RANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY. Some sttes do not llow the exclusion or limittion of incidentl or consequentil dmges, or llow limittions on how long n implied wrrnty lsts, so the ove limittion or exclusion my not pply to you. This wrrnty gives you specific legl rights, nd you my lso hve other rights which vry from stte to stte. Note: Thern, Inc. reserves the right to chnge the design or discontinue the production of ny product without prior notice. Aout This Mnul The Occuptionl Sfety nd Helth Act of 1970 sttes tht it is the employer s re spon si il i ty to provide workplce free of hzrd. To this end, ll equipment should e instlled, operted, nd mintined in complince with pplicle trde, industril, federl, stte, nd locl regultions. It is the equipment own er's re spon - si il i ty to o tin copies of these regultions nd to determine the suit il i ty of the equip ment to its intended use. This Owner s Mnul, nd wrning lels ttched to the equip ment, re to serve s guidelines for hzrd-free instlltion, op er tion, nd mintennce. They should not e understood to prepre you for every pos si le sitution. Informtion contined in this Owner's Mnul is pplicle only to the Thern 4HPF/4HWF/4HBP Series Power Winches. Do not use this mnul s source of in for m tion for ny other equip ment. The following symols re used for emphsis throughout this mn u l: Filure to follow WARNING! instructions my result in equipment dm ge, property dmge, nd/or serious personl injury. Filure to follow CAUTION! instructions my result in equipment dmge, prop er ty dmge, nd/or minor personl injury. Importnt! Filure to follow Importnt! instructions my result in poor per for mnce of the equipment.

3 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge 3 Suggestions for Sfe Opertion DO the following: Red nd comply with the guidelines set forth in this Owner s Mn u l. Keep this mnul, nd ll lels ttched to the winch, redle nd with the equip ment t ll times. Contct Thern, Inc. for replcements. Check luriction efore use. Instll the wire rope securely to the winch drum. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 4 wrps on the drum the wire rope could come loose, cusing the lod to escpe. Keep hnds wy from the drum, gers, wire rope, nd other moving prts of the equip ment. Equip the winch with lod rke if it is used to lift lods, or drg lods on n incline. Contct Thern Inc. for more informtion. Keep ll unnecessry personnel wy from winch while in opertion. Keep out of the pth of the lod nd out of the pth of roken wire rope tht might snp ck nd cuse injury. Disconnect electric power efore servicing the equipment. DO NOT do the following: Do not lift people, or things over people. Do not wlk or work under lod or in the line of force of ny lod. Do not exceed the lod rting of the winch or ny other component in the sys tem. To do so could result in filure of the equipment. Do not use clutch equipped models to lift lods, or pull lods up n in cline. Ac ci den tl relese of the clutch could result llow the lod to escpe. Do not use more thn one winch to move lod unless ech winch ws designed for use in multiple winch system. Do not use dmged or mlfunctioning equipment. To do so could result in fil ure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equip ment fil ure. Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use pproved rigging connectors to secure the wire rope to the lod. Do not operte the winch with drive gurds or ger covers removed or im prop er ly instlled. Do not divert your ttention from the opertion. Sty lert to the pos si il i ty of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stop ping the lod smoothly. Shock lods overlod the equipment nd my cuse dmge. Do not leve suspended lod unttended unless specific precutions hve een tken to secure the lod nd keep people wy from the winch nd out from under the lod. Do not djust the rke with the winch holding lod. Accidentl relese of the rke could result in loss of the lod.

4 pge 4 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 1.1 Instlling the Winch Importnt! Inspect the winch immeditely following instlltion ccording to the Instructions for Periodic Inspection. This will give you record of the condition of the winch with which to com pre future inspections. A qulified professionl should inspect or design the foundtion to insure tht it will provide dequte support. Locte the winch so it will e visile during the entire opertion. When positioning the winch use the lifting holes provided or sling wrpped round drum. Do not ttempt to lift or position winch y using lifting hole on reducer. This hole is designed to lift reducer only. Do not weld the winch frme to the foundtion or support structure. Welding the frme my void wrrnty, contct Thern, Inc. Use fsteners s instructed. Do not instll the winch in n re defined s hzrdous y the Ntionl Elec tric Code, unless instlltion in such n re hs een thoroughly p proved. Do not instll the winch ner corrosive chemicls, flmmle mterils, ex plo sives, or other elements tht my dmge the winch or injure the op er tor. Ad e qute ly protect the winch nd the opertor from such elements. Position the winch so the opertor cn stnd cler of the lod, nd out of the pth of roken wire rope tht could snp ck nd cuse injury. Attch the winch to rigid nd level foundtion tht will support the winch nd its lod under ll lod conditions, including shock loding CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on instlling the equipment LOCATE THE WINCH in n re cler of trffic nd other ostcles. Mke sure the winch is ccessile for min te nnce nd op er tion LOCATE THE WINCH in n re with dequte tempertures. Check the motor nd reducer mn u fc tur er s informtion for mient tem per ture rt ings POSITION THE WINCH to llow ccess for proper luriction INSTALL THE WINCH on horizontl surfce. The winch is designed nd ssemled for horizontl se mounting. Specil con sid er tion must e tken if mount ing ver ti cl ly or upside-down. Plese contct Thern, Inc MAINTAIN A FLEET ANGLE etween 1/2 nd 1-1/2 degrees. The proper fleet ngle minimizes wire rope dmge y helping the wire rope wind uni form ly onto the drum. See Figure FASTEN THE WINCH SECURELY to the foundtion. For Stndrd products referred to in this mnul, use corse thred fsteners, grde 5 or etter. Be sure to check the torque required for your fstener selection efore mounting winch. Mke sure the winch is secured to solid foundtion le to support the winch nd the lod under ll conditions with design fctors sed on ccepted engineering prctices. Non-stndrd products tht vry from the originl design my hve different fstening requirements. Contct structurl engineer or Thern, Inc. for this informtion. CONTACT A QUALIFIED PROFESSIONAL FOR MOUNTING INSTRUCTIONS TO COMPLY WITH LOCAL CODES.

5 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge Instlling the Brether Plug Importnt! Sve the seled plug for use when the winch is removed for storge or trnsport. Instll the rether plug to vent het nd pressure. Filure to do so could result in pressure uildup which could dmge the reducer. For shipment, the reducer is filled with luricnt nd seled to prevent lu ri c tion loss. SEW Eurodrive reducers re supplied with the rether plug instlled. Before opertion the lck ruer sel locted on the rether plug MUST BE REMOVED. Refer to the reducers mnufcturer's instructions. Some units supplied my not hve rether plug instlled for shipment. Instll the rether plug efore opertion REMOVE THE SEALED PLUG from the rether plug hole CHECK THE LUBRICANT LEVEL in the reducer to mke sure no lu ri cnt ws lost during shipment. Refer to the reducer mnufcturer s in struc tions INSTALL THE BREATHER PLUG. The reth er plug is wired to the reducer or ttched in plstic g. Refer to the reducer mnufcturer s informtion. Importnt! Use sheve or roller guide to direct the wire rope to the drum whenever possile. Instll sheves, trcks nd other equipment so they will remin fixed under ll lod conditions. Follow the recommendtions of the equipment mnufcturer. Use sheves of proper dimeter to minimize wer on the wire rope. Follow the rec om men d tions of the sheve mnufcturer. Figure 1 Mintining the Fleet Angle When wire rope trvels over sheve or through roller guide min tin fleet ngle y locting the sheve or guide n pproprite distnce from the drum, shown s distnce A. fixed sheve or roller guide smooth drum 1/2 to 1-1/2 de grees distnce A center line When wire rope trvels directly to the lod mintin fleet ngle y con trol ling sideto-side movement of the lod with trcks or guide rils. Allowing the lod to move too fr to one side cuses stress on the drum flnge which my cuse dmge. lod smooth drum 1/2 to 1-1/2 de grees center line trcks or guide rils

6 pge 6 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 1.3 Connecting Electric Power Importnt! Use electricl equipment with the correct rting nd Un der writ er s L o r to ry (UL) pproved. Alwys disconnect electric cur rent when the winch is not in use. Instll proper rnch circuits, disconnect devices, protection, nd ground ing s required y rticle 430 of the Ntionl Electric Code. All electricl work must e performed y licensed electricin. Filure to do so could result in electric shock or poor winch opertion. All control devices must e momentry contct type. Instll ll control de vic es so the winch motor will stop when the opertor releses the device. Locte control devices so the opertor will e le to view the lod through the entire opertion. Locte control devices so the opertor will e cler of the lod, the wire rope, nd the pth of roken wire rope tht could snp ck nd cuse injury. Figure 2 Instlling the Wire Rope Recessed Anchor It is the responsiility of the owner to provide equipment for con trol ling the winch. Elec tri cl control pckges re ville from Thern. The fol low ing guide lines re sup plied s reference for the instller CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on electricl instlltion CHECK THE COMPONENT MANUFACTURER S INSTRUCTIONS for instlling nd connecting the motor, rke, nd other equipment. correct typicl instlltion shown right ly underwound nchor screw INSTALL A FUSE or circuit reker in the power supply circuit, s re quired y the Ntionl Electric Code INSTALL A DISCONNECT DEVICE in the power supply circuit, s re quired y the Ntionl Electric Code. This should e switch you cn lock in the OFF position to prevent unuthorized use of the winch CONNECT ELECTRIC STARTER CONTROLS to the motor. Mke sure the lod rke is wired for fst rking on rkemotors tht offer this func tion. Check the com po nent mn u fc tur er s informtion CONNECT ELECTRIC POWER SUPPLY, with ground wire, to the elec tric strter control ox. Check the component mnufcturer s informtion for wiring digrm CONNECT OTHER ELECTRIC EQUIPMENT to the proper terminls in the electric control ox CHECK THE CURRENT t the motor nd mke sure it grees with the current rting mrked on the winch nmeplte. If current rting is in cor rect, hve the cir cuit inspected y licensed electricin. incorrect TEST ELECTRICAL CONNECTIONS y operting the winch. ROTATION OF THE DRUM must gree with the lels on the control device, either UP nd DOWN, or FORWARD nd REVERSE. CHECK THE LOAD BRAKE, mke sure it releses when the motor is ON, nd en gg es when the motor is OFF. Mke sure the fst rke function op er tes correctly on rkemotors tht include this feture. CONTACT THE FACTORY OR A QUALIFIED PROFESSIONAL FOR HELP.

7 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge Instlling the Wire Rope Importnt! Use wire rope nd other rigging equipment rted for the size of the lrgest lod you will e moving. Do not drg the wire rope through dirt or deris tht could cuse dm ge, or poor opertion. Alwys wer protective clothing when hndling wire rope. Figure 3 Instlling the Wire Rope Flnge Anchor Instll the wire rope securely to the winch drum. A poorly secured wire rope could come loose from its nchor nd llow the lod to escpe DETERMINE WHICH DIRECTION the drum must rotte to wind nd un wind wire rope PURCHASE THE PROPER WIRE ROPE for your ppliction. Keep the following in mind when se lect ing wire rope. Contct reputle wire rope supplier for help. BREAKING STRENGTH of new wire rope should e t lest 3 times gret er thn the lrgest lod plced on the winch. If lods re lifted or pulled on n incline, the reking strength must e t lest 5 times greter thn the lrgest lod. These re minimum vlues nd will vry with the type of lod nd how you re mov ing it. nchor screw c WIRE ROPE LAY must gree with the winding direction of the drum to help insure proper winding. WE RECOMMEND 7 x 19 glvnized ircrft cle for dimeters up to 5/16 inch, nd 6 x 37 IWRC improved plow steel (IPS) or extr improved plow steel (EIPS) wire rope for di m e ters of 3/8 inches nd up ANCHOR THE WIRE ROPE to the drum using either the recessed or flnge nchor. correct pss wire rope through slot in flnge nd into nchor nchor screw FOR RECESSED ANCHOR INSTALLATION. See Figure 2. PASS THE WIRE ROPE under the drum from the front nd through the recessed nchor hole. Mke sure t lest 1/2 inch of wire rope ex tends pst the set screw, nd the end of the wire rope does not pro trude out where it will in ter fere with wire rope wind ing onto the drum. TIGHTEN THE SETSCREW in the recessed nchor lock to securely hold the wire rope in plce. FOR FLANGE ANCHOR INSTALLATION. See Figure 3. correct typicl instlltion shown right ly underwound PASS THE WIRE ROPE under the drum from the front nd through the slot in the drum flnge. LOOP THE WIRE ROPE through oth holes in the nchor lock so the end of the wire rope is locted in the hole with the nchor screw. Mke sure t lest 1/2 inch of wire rope ex tends pst the set screw, nd the end of the wire rope does not pro trude out where it will hit other components s the drum is turning. Models my come with only one flnge nchor lock or flnge nchor lock with only one hole. TIGHTEN THE SETSCREW in the nchor lock to securely hold the wire rope in plce WIND FOUR FULL WRAPS of wire rope onto the drum y operting the winch while holding the wire rope tught. These wrps serve s nchor wrps nd must remin on the drum t ll times. incorrect

8 pge 8 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 2.1 Generl Theory of Opertion Importnt! Limit nonuniform winding y keeping tension on the wire rope nd y mintining the proper fleet ngle. To help insure rted per for mnce, mke sure voltge t the motor is equl to the motor s voltge rting. It is your responsiility to detect nd ccount for different fctors ffecting the condition nd per for mnce of the equipment THE PULL REQUIRED to move the lod must not exceed the lod rting of the winch. Consider the totl force required to move the lod, not the weight of the lod THIS EQUIPMENT CAN develop forces tht will exceed the lod rting. It is the responsiility of the equipment user to limit the size of the lod. In spect the equip ment reg u lr ly for dmge ccording to the in struc tions contined in this mnul nd in the component mnufcturer s informtion USE A LOAD BRAKE on ll winches used to lift lods or drg lods on n incline. Although new worm ger winch my pper to hold the lod in plce, this chr c ter is tic will diminish with use. Do not de pend on winch gering to hold the lod in plce PERFORMANCE RATINGS of the equipment re ffected y the mount of wire rope wound on the drum, the wy in which it is wound, nd the wy the winch is used. c DRUM CAPACITY depends on how tightly nd evenly the wire rope is wound on the drum. Actul drum cpcities re usully 25-30% less thn vlues shown in performnce Tles, due to loose winding nd overlpping. LINE SPEED increses with ech dditionl lyer of wire rope wound onto the drum. The weight of the lod does not ffect line speed. LOAD RATING represents the mximum pull tht cn e plced on new equip ment. Lod rtings re ssigned vlues for specific mounts of lod trvel or wire rope ccumultion. The lod rting decreses s lyers of wire rope c cu mu lte on the drum DUTY RATINGS refer to the type of use the equipment is su ject to. Consid er the following when determining duty rting. c d ENVIRONMENT: hrsh environments include hot, cold, dirty, wet, corro sive, or explosive surroundings. Protect the equip ment from hrsh en vi - ron ments when possile. MAINTENANCE: poor mintennce, mening poor clening, luriction, or inspection, leds to poor opertion nd possile dmge of the equip ment. Minimize poor mintennce y crefully following the in struc tions contined in this mnul. LOADING: severe loding includes shock loding nd moving lods tht ex ceed the lod rting of the equipment. Avoid shock lods, nd do not ex ceed the lod rting of the equip ment. FREQUENCY OF OPERATION: frequent strt nd stop func tions in crese wer nd shorten the life spn of the ger trin nd lod rke com po nents. Lengthy opertions cuse luriction to ecome hot, which lso decreses the life spn of the ger trin. Increse mintennce of the equipment if used in frequent opertions. CONTACT THE FACTORY FOR MORE INFORMATION.

9 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge Breking-In the Winch BREAK-IN OCCURS during the first 10 hours of norml op er tion. During rek-in, mting surfces ecome polished, nd clernces increse. This is desired for efficient opertion of erings nd gers INSPECT THE WINCH following rek-in ccording to the Instructions for Periodic Inspection. See section 3.3 Inspecting the Equipment. 2.3 Prepring for Opertion Importnt! When determining whether the lod will exceed the lod rting, consider the totl force required to move the lod. Red nd comply with the guidelines set forth in this Owner s Mn u l. Keep this mnul, nd ll l els ttched to the winch, redle nd with the equip ment t ll times. Contct Thern, Inc. for re plce ments. Do not lift people, or things over people. Do not wlk or work under lod or in the line of force of ny lod. Do not exceed the lod rting of the winch or ny other component in the sys tem. To do so could result in filure of the equipment. Equip the winch with lod rke if it is used to lift lods, or drg lods on n incline. Contct Thern Inc. for more informtion. Do not use more thn one winch to move lod unless ech winch ws designed for use in multiple winch system. Do not use dmged or mlfunctioning equipment. To do so could result in fil ure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equip ment fil ure. Do not operte the winch with drive gurds or ger covers removed or im prop er ly instlled. Check luriction efore use CONSIDER THE OPERATION. Do not egin until you re sure you cn perform the entire opertion without hzrd INSPECT ALL COMPONENTS of the system. c INSPECT THE WINCH nd other equipment ccording to the Instructions for Frequent Inspection. OPERATORS must e in good helth, lert, thoroughly trined in op er t ing the equipment, nd properly clothed (hrd ht, sfety shoes nd sfety glss es, no loose clothing). THE LOAD must e cler of other ojects nd free to move. Mke sure the lod will not tip, spin, roll wy, or in ny wy move uncontrollly KNOW YOUR LOAD nd mke sure you do not exceed the lod rting of the winch or ny other equipment in the system.

10 pge 10 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 2.4 Attching the Lod Figure 4 Attching Lod ltch closed tight ginst hook Do not wrp the wire rope round the lod. This dmges the wire rope nd could llow the lod to escpe. Use sling or other pproved lifting device CLEAR OBJECTS from the pth of the lod so you cn move it freely nd oserve it t ll times during the opertion ATTACH THE LOAD using nylon sling, or other pproved lifting device. Follow the recommendtions of the sling mnufcturer. sling seted in sddle of hook SEAT THE SLING in the sddle of the hook with the hook ltch com plete ly closed. See Figure 4. CENTER THE LOAD on the hook so it will remin lnced nd not tip or rotte to one side.

11 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge Moving the Lod Importnt! Oey stop signl from nyone. Mintin tension on the wire rope to keep it tightly nd evenly wound on the drum. If the winch nd lod re not visile during the entire op er tion, get help from nother person. Appoint supervisor if more thn one person is involved in the opertion. This will reduce con fu sion nd increse sfety. When lifting lod, use tg line to keep the lod from swinging or twist ing, while keeping yourself wy from the lod. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 4 wrps on the drum the wire rope could come loose, cusing the lod to escpe. Keep ll unnecessry personnel wy from winch while in opertion. Keep out of the pth of the lod nd out of the pth of roken wire rope tht might snp ck nd cuse injury. Keep hnds wy from the drum, gers, wire rope, nd other moving prts of the equipment. Do not divert your ttention from the opertion. Sty lert to the pos si il i ty of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stop ping the lod smoothly. Shock lods overlod the equipment nd my cuse dmge. Do not leve suspended lod unttended unless specific precutions hve een tken to secure the lod nd keep people wy from the winch nd out from under the lod MOVE THE LOAD slowly nd smoothly, only smll distnce t first. Mke sure the lod is lnced nd securely ttched efore continuing USE THE CONTROL DEVICE to operte the winch. The control device should e momentry contct type, so the winch will stop when the op er tor releses the control OBSERVE THE WIRE ROPE s it winds onto the drum. If it ecomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope efore continuing. Continued opertion with overlpped or uneven wire rope cn dmge the wire rope nd shorten its life OBSERVE THE REDUCER during opertion for signs of overheting. Fre quent overheting my e sign of dmge, or my indicte the need for lrger power winch. WATCH FOR SMOKE, the smell of urnt luricnt, nd other signs of over het ing. Use thermocouple or other device to monitor reducer tem per ture. STOP THE OPERATION if the reducer overhets, nd llow the winch to cool. Continued opertion my cuse dmge.

12 pge 12 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 2.6 Operting the Clutch (clutch models only) Do not use clutch equipped models to lift lods, or pull lods up n in cline. Ac ci den tl relese of the clutch could llow the lod to escpe. Engge the clutch completely efore operting the winch. Operting the winch with relesed or prtilly engged clutch my cuse dmge. Do not engge or disengge the clutch with the winch under power or loded DISENGAGE THE CLUTCH with the clutch hndle, nd unwind the wire rope for hook-up to the lod ENGAGE THE CLUTCH with the clutch hndle. You my need to ro tte the drum y hnd to lign the clutch jws ADJUST THE DRAG BRAKE if necessry, to control the rottion of the drum when the clutch is disengged. Not ll clutch models include drg rke.

13 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge Emergency Opertion (for models equipped with this feture) Do not djust the rke with the lod suspended. Accidentl relese of the rke could llow the lod to escpe. Do not leve suspended lod unttended unless specific precutions hve een tken to secure the lod nd keep unnecessry personnel wy from the winch nd from under the lod IN CASE OF POWER FAILURE, turn the control device to OFF nd DIS CON NECT electric power. Leve electric power DIS CON NECT ED MAKE SURE SAFETY PRECAUTIONS hve een tken to secure the lod nd keep unnecessry personnel wy from the winch nd from under the lod while operting the emergency hnd crnk IF EQUIPPED WITH A BRAKE MOTOR you must disengge the rke on the motor efore using the emergency hnd crnk. Operting the emergency hnd crnk with the rke on the motor engged could result in equipment dmge or filure. c It is recommended for two people to operte the winch using the emergency hnd crnk. If the winch is equipped with rke motor, ssign one person to operte the hnd crnk while the other is ssigned to operte the rke. Hve control of the hnd crnk efore disengging the rke on the motor. Accidentl relese of the rke could llow the lod to escpe. If the winch is not equipped with rke motor, ssign one person to operte the hnd crnk while the other is ssigned to oserve nd control the lod. Alwys follow the rke mnufcturers operting instructions for engging or disengging the rke DO NOT USE AN IMPACT WRENCH to operte the emergency hnd crnk option of the winch. To do so could result in equipment dmge or filure. Use drill-motor ENGAGE THE BRAKE nd remove the hndle or drill-motor efore operting the winch under power. ANY QUESTIONS ON OPERATING THE EMERGENCY HAND CRANK OPTION OR WINCH APPLICATION CONTACT THERN, INC.

14 pge 14 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 3.1 Clening the Winch Importnt! Increse the frequency of min te nnce procedures if the winch is: Operted for long periods. Used to pull hevy lods. Operted in wet, dirty, hot, or cold surroundings. Clen the winch to remove dirt nd help prevent rust nd cor ro sion CLEAN THE WINCH every six months or whenever it is dirty. c WIPE ALL EQUIPMENT to remove dirt nd grese. LEAVE A LIGHT FILM of oil on ll surfces to protect them ginst rust nd corrosion. WIPE OFF excessive mounts of oil to void the ccumultion of dirt REMOVE ALL UNNECESSARY OBJECTS from the re round the winch.

15 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge Luricting the Winch Importnt! Do not leve plug holes in the reducer open. Open plug holes will llow dirt nd moisture to con tm i nte the luriction. Mke sure luricnt hs tem per ture rting pproprite for the mient tempertures of the opertion. Replce the mo tor er ings if the motor is dis s sem led for ny reson. Figure 5 Luricting the Flnge Bering flnge ering, luricte with NLGI no. 2EP grese Mke sure the rether plug is clen nd open to vent het nd pres sure. Poor ventiltion my cuse overheting nd result in dmge to oil sels nd other equipment. Fill the speed reducer to the proper level without overfilling. Too much or too little luricnt will cuse overheting nd result in dmge to sels, er ings, nd gers. Luricte the winch prop er ly to help protect it from wer nd rust. Red the following in struc tions crefully MOTOR BEARINGS re typiclly luricted for life y the mnufcturer. Some motors require periodic luriction. Refer to the motor mn u fc tur er s in for m tion for specific in struc tions LUBRICATE THE REDUCER ccording to the mnufcturer s in struc tions. c CHECK OIL LEVEL efore every opertion nd every 10 hours during op er tion. Remove the level plug nd mke sure oil is even with the plug hole. FILL THE REDUCER ccording to the mnufcturer's instructions. Fill the re duc er until oil reches the level plug. Do not mix dif fer ent luricnts. CHANGE REDUCER LUBRICANT t lest every 2 yers, or whenever it is dirty or contminted LUBRICATE FLANGE BEARING t lest every 10 hours of opertion. Insert NLGI #2 EP (Extreme Pressure) grese through the grese zerk. Refer to the ering mnufcturer s informtion for specific instructions. See Figure LUBRICATE THE WIRE ROPE y following the wire rope mn u fc tur er s rec om men d tions.

16 pge 16 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 3.3 Inspecting the Equipment Importnt! Strt n inspection progrm s soon s you put the winch into use. Appoint qulified person to e responsile for regulrly in spect ing the equipment. Keep written records of in spec tion. This llows comprison with com ments from previous in spec tions so you cn see chng es in con di tion or per for mnce. Do not use dmged or mlfunctioning equipment. Plce n OUT OF OR DER sign on the winch. Do not use the winch until the sign is re moved y qulified mintennce person who hs completely corrected the prolem. Inspect the winch to detect signs of dmge or poor opertion efore they e come hzrdous. See Tle 1 - Inspection Checklist CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the winch nd other equipment CHECK COMPONENT MANUFACTURER S INSTRUCTIONS for in spect ing the motor, rke, reducer, erings, wire rope, nd other equip ment In struc tions for Frequent Inspection Perform frequent inspections: Before ech opertion. Every 3 hours during opertion. Whenever you notice signs of dmge or poor opertion. Frequent Wire Rope Inspection: Use ASME B30.7 s guideline for rope inspection, replcement nd mintennce. Check the wire rope, end connections nd end fittings for corrosion, kinking, ending, crushing, irdcging or other signs of dmge. Check the numer, distriution nd type of visile roken wires. See prgrph c nd Figure 6. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 8. Tke extr cre when inspecting sections of rpid deteriortion such s sections in contct with sddles, sheves, repetitive pickup points, crossover points nd end connections. VISUALLY INSPECT the entire winch nd ll other equipment involved in the opertion. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. Mke sure the wire rope is instlled correctly nd nchored securely to the drum. Check the reducer for signs of lekge. Mke sure the entire winch is properly luricted. Mke sure the rether plug is clen, open, nd instlled correctly. Mke sure mounting fsteners re tightened securely. Mke sure the foundtion is in good condition, nd cple of supporting the winch nd its lod under ll lod conditions. Check electricl wiring nd connections for wer, corrosion, cuts, nd other dmge. Check clutch opertion, if pplicle, to mke sure it moves freely nd engges com plete ly. TEST WINCH PERFORMANCE y operting the winch with lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the winch responds to the control device. It must rotte s shown on the control lels, nd it must turn off when you relese the control. Check the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep, the rke needs d just ment. Refer to rke mnufcturer s instructions. Completely correct ll prolems efore continuing. Use the Trou le shoot ing Chrt to help determine the cuse of certin prolems. See Tle 2.

17 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge 17 Figure 6 Broken Wires wire strnd Perform periodic inspections: Every 6 months. Whenever you return the winch to service from storge. Whenever you notice dmge or poor opertion in frequent in spec tion. Whenever you hve, or think you my hve, overloded or shock loded the winch. Figure 7 Lod Hook Inspection twist throt opening thick ness one ly Wire rope ssemly must e replced if more thn 6 wires re ro ken in one ly, or if more thn 3 wires re roken in one strnd in one ly. The wire rope ssemly must e replced if the throt opening is 15% wider thn nominl, if the thick ness is 10% less thn nominl, or if the hook is twisted 10 or more Instructions for Periodic Inspection c d VISUALLY INSPECT the winch nd ll other equipment. Check the finish for wer, flking, or other dmge. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. If the equipment ws overloded, or if you notice crcks or other signs of overloding nd dmge promptly remove equipment from use nd hve it repired or replced. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE ROPE. Check ll fsteners for stripped threds, wer, ends, nd other dm ge. Check the gerox for signs of lekge. Contct the fctory if there re ny signs of luricnt leking from the gerox. Mke sure the rether plug is clen, open nd instlled correctly, Mke sure the entire winch is properly luricted. Check clutch opertion, if pplicle, to mke sure it moves freely nd engges com plete ly. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. DRAIN A SMALL AMOUNT OF LUBRICANT from the reducer into clen continer. Check the luricnt for dirt, metl prticles, wter, nd other signs of con tm i n tion. Completely drin the reducer if luricnt is con tm i nt ed. INSPECT THE WIRE ROPE ccording to the wire rope mnufcture's recommendtions or follow ccepted industry stndrds for wire rope inspections. Alwys wer protective clothing when hndling wire rope. Check the entire length of wire rope for ent wires, crushed res, ro ken or cut wires, corrosion, nd other dmge. Crefully inspect res tht pss over sheves or through roller guides. Note the loction nd concentrtion of roken wires. Replce wire rope if more thn 6 wires re roken in one ly, or more thn 3 wires re ro ken in one strnd in one ly. See Figure 6. Mke sure the lod hook or other device is securely ttched to the wire rope, nd the wire rope where it is ttched is not fryed, corroded, ro ken, or otherwise dmged. Mesure the throt opening, thickness, nd twist of the hook. Replce the hook if it shows signs of dmge. See Figure 7. Mke sure hook ltch opens without inding nd closes when relesed. Check the nchor holes in the drum nd the surrounding re for signs of wer or distortion. PLACE enough weight to keep the wire rope stright nd tightly drwn. Mesure the dimeter of the wire rope, especilly in res where wer is noticele. Replce the wire rope if the dimeter mesures elow the minimum dimeter t ny point. See Figure 8.

18 pge 18 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches Figure 8 Rope Dimeter correct di me ter in cor rect The wire rope ssemly must e replced if the dimeter mesures less thn the minimum dimeter t ny point. wire rope dimeter up to 5/16 in up to 1/2 in up to 3/4 in up to 1-1/8 in up to 1-1/2 in minimum dimeter 1/64 in (.0156 in) 1/32 in (.0313 in) 3/64 in (.0469 in) 1/16 in (.0625 in) 3/32 in (.0938 in) e f g h i MOVE THE DRUM with your hnds. Check for excessive movement indicting worn or loose gers or er ings. Excessive movement is cused y overloding or overheting, nd is sign tht your ppliction my re quire lrger power winch. Disssemle the winch if necessry. Inspect keys, erings, sels, nd shfts for wer, distortion, nd other dmge. INSPECT THE FOUNDATION AND RIGGING Check mounting fsteners for stripped threds, wer, nd other dmge. Check the foundtion for crcks, corrosion, nd other dmge. TEST WINCH PERFORMANCE y operting the winch with lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Oserve the rotting drum, look for signs of loose or misligned er ings. Mke sure the lod moves smoothly without hesittion or strin. Mke sure the winch responds to the control device. It must rotte s shown on the control lels, nd it must turn off when you relese the control. Check the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep, the rke needs d just ment. Refer to rke mnufcturer s instructions. DISCONNECT ELECTRIC POWER nd inspect electricl equipment. Check electricl wires for worn insultion, cuts, corroded connections, nd other dmge. Check voltge of electricl supply with UL pproved voltmeter. If volt ge is low, hve licensed electricin inspect the circuit. Mke sure the electricl control ox is securely instlled. Look inside the control ox for signs of moisture, corrosion, urn mrks, crcks, nd other dmge. CONNECT ELECTRIC POWER. Completely correct ll prolems efore continuing. Use the trou le shoot ing chrt to help determine the cuse of certin prolems. See Tle 2.

19 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge 19 Tle 1 Inspection Checklist checked oxes indicte dmge or prolem in need of repir dmges prolems generl fi nish wethered, fl king, otherwise dmged winch jerks or hesittes during opertion prts crcked, ent, rusted, worn, otherwise dmged unusul noises, other signs of mlfunction fsteners stripped threds, ent, worn, otherwise dmged loose, not tightened to proper torque reducer gers, erings, or shfts loose, worn, otherwise dmged not properly luricted luricnt lekge luricnt contminted wire rope ent, crushed, otherwise dmged wire rope loosely or unevenly wound roken wires, see Figure 6 replce if more thn 6 wires in one ly, numer per strnd = or 3 wires in one strnd in one ly, re roken numer per ly = dimeter reduced, see Figure 8 replce if less thn 45/64" (.703 inch) dimeter = end connections corroded, rusted, worn, otherwise dmged not securely ttched hook or other device twisted, ent, worn, otherwise dmged, see Figure 7 hook ltch fils to close when relesed replce if twist is 10 degrees or more, twist = replce if throt width is 15% lrger thn nominl throt width = replce if thickness is 10% less thn nominl thickness = drum nchor hole worn, distorted, otherwise dmged excessive movement or cklsh motor motor urnt out, otherwise dmged volt ge t motor low rke rke worn, roken, otherwise dmged rke does not operte properly control device electric components corroded, urnt, otherwise dmged fils to control winch properly electric circuit electric wires worn, cut, corroded, otherwise dmged wires unprotected, ostructing trffi c connections loose, corroded, otherwise dmged voltge t motor = lels nd pltes dirty, illegile, otherwise dmged loosely ttched or missing comments uthorized signture dte

20 pge 20 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches Tle 2 Trouleshooting Chrt Contct the fctory for ssemly/disssemly instructions. Disssemly of the gerox efore contcting Thern, Inc. voids ll wrrnties. prolem cuse correction motor won't run circuit reker tripped or fuse lown... reset circuit reker or replce fuse electricl connections loose or dmged... inspect, repir nd tighten s necessry electric power supply filure... contct power compny motor urnt out or dmged... repir or replce s necessry motor runs, drum doesn't turn loose or roken ger keys... inspect nd replce s necessry loose, stripped or roken gers... inspect nd replce s necessry motor tries to turn ut cn't unit overheted... llow to cool lod too hevy... lighten lod voltge t motor too low... inspect supply circuit nd rewire s needed electric rke not operting properly... inspect nd repir s necessry gers or erings roken or locked... inspect nd replce s necessry rke does not operte properly rke relese lever in relese position... move to lock position voltge to rke incorrect... check voltge t control ox, repir s needed rke djusted incorrectly... djust rke rke discs or solenoid worn or dmged... inspect nd replce s necessry rke components seized up or dmged... inspect nd repir s necessry luricnt lekge worn erings... inspect nd replce s necessry dmged oil sels or gskets... inspect nd replce s necessry crcked or dmged reducer... inspect nd repir s necessry excessive end ply on drive shft loose or dmged keys or keywys... inspect nd replce s necessry excessively worn gers... inspect nd repir s necessry excessive worn gers or erings lod too hevy... lighten lod poor luriction of reducer or erings... inspect nd luricte s necessry overheting operted too long without rest... llow to cool lod too hevy... lighten lod poor luriction... inspect nd luricte s necessry rether plug clogged or dmged... clen or replce rether plug ering seized up... inspect nd replce s necessry unusul noises high pitched squek poor luriction... inspect nd luricte s necessry grinding noise contminted oil... drin, clen nd luricte the winch roken gers or erings... inspect nd replce s necessry whining motor lod too hevy... lighten lod motor overheted... llow to cool motor erings urnt out... replce motor or erings rttling noise loose fsteners or setscrews... tighten ll olts nd screws worn or loose drg rke... inspect nd repir or tighten s necessry hevy thump during opertion contminnts in luricnt... drin, clen nd luricte the winch loose setscrews or keys in gers or shfts... inspect nd repir s necessry erings defective... inspect nd replce s necessry

21 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge Repiring the Winch Importnt! It is your responsiility to de ter mine when to replce prts. When considering whether to continue using prt or to re plce it, re mem er tht replcing it is the est wy to void further equip ment dmge. Replce spring pins, retining rings, nd oil sels whenever the winch is disssemled for in spec tion or repir. Appoint qulified person to e responsile for ll repirs to the equipment GET FACTORY AUTHORIZATION for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the winch REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repir prts REFINISH AREAS where the pint is worn or flking. A good finish helps to protect ginst corrosion nd wether dmge. c REMOVE THE FINISH from dmged res, down to the re metl. CLEAN THE AREA thoroughly. REPAINT with high qulity primer nd finishing cot TO ORDER REPAIR PARTS, contct your locl deler. Include the fol low ing informtion when ordering: model numer seril numer (or code numer) prt numer dte purchsed, nd from whom description of wht hppened, or wht is wrong your nme nd return ddress

22 pge 22 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches 4.1 Trnsporting the Winch Importnt! Keep record of wht you ship, nd when you send it ENSURE THE BREATHER is in the upper most position on the reducer to prevent the loss of luriction during shipment PACK THE WINCH in n upright position for trnsport, using the originl pckging mterils, if possile. c d FASTEN THE WINCH to wooden se using olts, to keep it from mov ing during trnsport. SEAL THE WINCH in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. CONSTRUCT WOODEN SIDES nd top to enclose the winch in solid pro tec tive crte. PACK LOOSE PARTS in smll ox es or ship seprtely INSPECT THE WINCH ccording to the Instructions for Periodic In spec tion efore instlling it in new loction. 4.2 Storing the Winch FILL THE REDUCER with luricnt, nd mke sure the rether plug is clen nd properly instlled. Add rust preventtive for long term storge. Follow the reducer mnufcturer s instructions SEAL THE WINCH in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge STORE THE WINCH upright, in cool clen plce wy from corrosive chem i cls nd moisture ROTATE THE DRUM PERIODICALLY to keep ering nd gers sur fc es from ecoming lcquered. Relese the rke to rotte the drum INSPECT THE WINCH ccording to the Instructions for Periodic In spec tion efore instlling it for opertion TEST INSULATION RESISTANCE in the motor to detect mois ture dm ge. Refer to the motor mnufcturer s in struc tions DRAIN THE REDUCER nd fill with proper luricnt prior to opertion. See section 3.2 Luricting the Winch.

23 Owner's Mnul for Thern 4HPF/4HWF/4HBP Series Power Winches pge 23

24 Thern, Incorported 5712 Industril Prk Rod Winon, MN PHN FAX