Owner s Man ual. For MTA1000 and MTA2000 Series Cycloidal Gear Air Winches

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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 MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches

2 pge 2 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches Wrrnty Sttement Plese record the following: Dte Purchsed: Model No.: Seril No.: This informtion is required when clling the fctory for service. Thern, Inc. wrrnts ech new products to e free from defects in mteril nd workmnship under norml use nd service for period of 24 months from the dte of purchse y the originl using uyer. Genuine Thern, Inc. replcement prts nd components will e wrrnted for 30 dys from the dte of purchse, or the reminder of the originl equipment wrrnty period, whichever is longer. Under no circumstnces will this wrrnty cover n product or component thereof, which, in the opinion of the compny, hs een sujected to misuse, unuthorized modifictions, ltertion, n ccident or shipping dmge. This wrrnty lso shll not pply to products tht re operted improperly, improperly mintined or improperly stored. 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. Brke discs, wire rope or other wer components re not covered under this wrrnty, s their life is suject to use conditions which vry etween pplictions. Any ltertion, repir or modifiction of the product outside the Thern, Inc. fctory shll void this wrrnty. Thern, Inc. in no wy wrrnts pneumtic, hydrulic or electric motors nd control vlves or other trde ccessories since these items re wrrnted seprtely y their respective mnufcturers. 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. To mke clim under this wrrnty, contct the fctory for n RGA numer. The product must e returned, prepid, directly to Thern, Inc. or to n uthorized service center. A completed wrrnty clim form must ccompny the product. If the product is found to e defective, it will e repired or replced free of chrge, nd Thern, Inc. will reimurse the shipping costs. 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. The informtion contined in this mnul is pplicle only to the Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air 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 MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 3 Figure 1 Seril Tg 5712 INDUSTRIAL PK RD WINONA, MN USA (507) READ OWNER S MANUAL NOT FOR LIFTING PEOPLE OR THINGS OVER PEOPLE MODEL # SERIAL # 1ST LAYER RATING (LBS) MID DRUM RATING (LBS) FULL DRUM RATING (LBS) 1ST LAYER SPEED (FPM) MID DRUM SPEED (FPM) FULL DRUM SPEED (FPM) DRUM SIZE (IN.) ID OD W ROPE SIZE (IN.) VOLTAGE PRESSURE FLOW CODE # PART # A5957 Figure 1A - Seril Tg Loction Seril Tg Loction

4 pge 4 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 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 5 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 5 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. Ensure rkes hold prior to mking complete lift y lifting lod short distnce. Then relese the control nd set the rke. For the uto-rke winches, the rke is set y returning the control lever to the neutrl position. If there is slck wire rope condition, the hoisting mechnisms shll e inspected to ensure ll wire ropes re properly seted on drums nd in sheves, efore resuming winch opertion. Disconnect ir supply nd leed off pressure efore servicing the equipment.

5 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 5 Suggestions for Sfe Opertion 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 system. To do so could result in filure of the equipment. 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 filure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equipment filure. Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use sling or other pproved lifting device. Do not operte the winch with drive gurds or ger covers removed or improperly instlled. Do not divert your ttention from the opertion. Sty lert to the possiility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stopping 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 lod suspended. Do not disssemle the ir cylinder for the utomtic nd rke. Improper disssemly could cuse personl injury. Contct fctory.

6 pge 6 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 1.1 Instlling the Winch Importnt! Inspect the winch immeditely following instlltion ccording to Section 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 moving nd positioning the winch, lift using the lifting eyes or hndles in the frme or with sling wrpped round drum. 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. All supporting structure, mounting hrdwre nd ttching hrdwre must e in ccordnce with ll pplicle stndrds codes nd regultions. Ensure proper selection nd instlltion of wire rope nd sheves. Sheves nd sheve mounting must e designed nd selected in ccordnce with ll pplicle stndrds, codes, nd regultions. Improper instlltion of wire rope or sheve cn cuse uneven spooling nd wire rope dmge tht could cuse lod to escpe. 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. 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 2 Mintining the Fleet Angle When wire rope trvels over sheve or through roller guide mintin 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 side-to-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

7 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 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 mintennce nd opertion LOCATE THE WINCH in n re with dequte tempertures (-4 o to 122 o F). Check the motor nd reducer mnufcturer s informtion for mient temperture rtings INSTALL THE WINCH on horizontl surfce. The winch is designed nd ssemled for horizontl se mounting. Specil considertion must e tken if mounting verticlly 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 uniformly onto the drum. See Figure FASTEN THE WINCH SECURELY to the foundtion. FOR STANDARD 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-STANDARD 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.

8 pge 8 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 1.2 Instlling the Brether Plug Mke sure the rether plugs re clen nd open to vent het nd pres sure. Poor ventiltion will cuse overheting nd result in dmge to oil sels nd other equipment. See Figures 3A nd 3B. For shipment, the winch motor nd reducer re filled with luricnt. Brether plugs come pre-instlled on the motor nd MTA2000 reducer VERIFY THE BREATHER PLUG is instlled on the motor. On MTA2000 models, lso verify tht the rether plug is instlled in the reducer. Refer to mnufcturer's informtion. MTA1000 reducers re grese pcked CHECK THE LUBRICANT LEVEL in the motor nd verify tht no luricnt ws lost during shipment. For MTA2000 models, lso check the reducer luricnt level to mke sure no luricnt ws lost. See section Luricting the Winch. Figure 3A Instlling the Brether Plug - MTA1000 Motor Brether Plug Figure 3B Instlling the Brether Plug(s) - MTA2000 Motor Brether Plug Reducer Brether Plug

9 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge Connecting the Air Supply Importnt! Use components rted for the power supply you will e using. Alwys disconnect the ir supply when the winch is not in use. When removing the ir hoses from the unit, plug the open ports. The F-R-L must e comptile with the required ir supply. Check tht the direction indictors on control mtch lod direction. Remove port cps from exhust ports for opertion. Filure to do so my result in equipment dmge nd limit performnce. See Figure 9 on pge 18. All control devices must e momentry 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. It is the responsiility of the owner to provide equipment for controlling the winch. The following guidelines re supplied s reference for the instller. INSTALL A F-R-L ON YOUR UNIT BEFORE WINCH OPERATION. A FILTER-REGULATOR-LUBRICATOR UNIT MUST BE USED WHILE OPERATING EQUIPMENT TO MAINTAIN WARRANTY. THERN WILL NOT COVER ANY DAMAGE TO EQUIPMENT CAUSED BY DIRTY, POOR, CONTAMINATED OR NON-LUBRICATED AIR SUPPLY. SEE FIGURE CONSULT APPLICABLE CODES AND REGULATION for specific instructions regrding ir supply instlltion nd ckup CHECK THE COMPONENT MANUFACTURER'S INSTRUCTIONS for instlling nd connecting the motor nd other equipment ENSURE n ccessile shut off vlve hs een instlled in the ir supply line nd mke sure others re wre of its loction THE AIR SUPPLY must e clen nd free from moisture. ALL AIR SUPPLY LINES should e purged with clen, moisture free ir or nitrogen efore connecting to winch inlet. SUPPLY LINES should e s short nd stright s instlltion conditions will permit. Long trnsmission lines nd excessive use of fittings, elows, tees, gloe vlves etc. cuse reduction in pressure due to restrictions nd surfce friction in the lines ALWAYS USE n ir line lurictor with these motors. THE LUBRICATOR must hve n inlet nd outlet t lest s lrge s the inlet on the motor. Instll the ir line lurictor s close to the ir inlet on the motor s possile. LUBRICATOR must e locted no more thn 10 ft. (3 m) from the motor. c AIR LINE LUBRICATOR should e replenished dily nd set to provide 6 to 9 drops per minute of SAE 10W oil. A fine mist will e exhusted from the throttle control vlve when the ir line lurictor is functioning properly.

10 pge 10 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches Figure 4 Mufflers Muffler instlled in vlve exhust port Muffler instlled in motor exhust port IT IS RECOMMENDED tht n ir line striner/filter e instlled s close s prcticl to the motor ir inlet port, ut efore the lurictor, to prevent dirt from entering the motor. The striner/filter should provide 20 micron filtrtion nd include moisture trp. Clen the striner/filter periodiclly to mintin its operting efficiency MOISTURE THAT REACHES THE AIR MOTOR through ir supply lines is primry fctor in determining the length of time etween service overhuls. c MOISTURE TRAPS cn help to eliminte moisture. AIR RECEIVERS collect moisture efore it reches the motor. INSTALLING AN AFTERCOOLER t the compressor tht cools the ir to condense nd collect moisture prior to distriution through the supply lines is lso helpful THE AIR MOTOR SHOULD BE INSTALLED s ner s possile to the compressor or ir receiver. Recommended pressures nd volumes re mesured t the point of entry to the ir motor INSTALL MUFFLERS in oth exhust ports to reduce noise. See Figure CHECK THE AIR PRESSURE t the regultor nd mke sure it grees with the pressure rting mrked on the winch nmeplte. CHECK ll ir connections efore pplying pressure. Verify fittings re connected tightly TEST AIR CONNECTIONS y slowly opening the ir line to ensure ir connections re sound prior to moving lod. Then grdully operte 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 utomtic nd rke. Mke sure it releses when the motor is on, nd engges when the motor is off. CONTACT THE FACTORY OR A QUALIFIED PROFESSIONAL FOR HELP. Figure 5 Filter-Regultor-Lurictor Unit (F-R-L) PSI guge instlled on regulted lurictor side Regultor Air Out Air In Lurictor Filter

11 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge Adjusting the Drum Gurd Do not djust or remove drum gurd pnels while winch is in use. Remove only the drum gurd pnels necessry to provide sufficient clernce etween the drum gurd nd wire rope. Proper gurd pnel plcement should not llow the wire rope to come into contct with drum gurd pnels during winch opertion. Be sure to tke into ccount the rnge of lyers intended to e used from the durtion of the instlltion of the winch nd the intended fleet ngles of the rope. Pnels cn e removed y loosening the fsteners t the ends of the pnels nd pulling them out individully. Store un-used pnels in cse future winch loctions require different rope exit ngle. See Figures 6A nd 6B. Figure 6A Removing the Gurd Pnel(s) Gurd Pnel Removed Figure 6B Adjusting the Drum Gurd Adjust Gurd to Allow Adequte Rope Clernce

12 pge 12 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 1.5 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 7A Instlling the Wire Rope Recessed 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. Inspect wire rope prior to instlltion. See Section DETERMINE WHICH DIRECTION the drum must rotte to wind nd unwind wire rope. See Figure 7B PURCHASE THE PROPER WIRE ROPE for your ppliction. Keep the following in mind when selecting 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 you contct n uthorized Thern distriutor or n uthorized wire rope deler for proper wire rope sizing nd selection. correct typicl instlltion shown right ly underwound ANCHOR THE WIRE ROPE to the drum using the lock nchor. See Figure 7A. PASS THE WIRE ROPE through the hole in the nchor lock. Mke sure t lest 1/2 inch of wire rope extends pst the set screw, nd the end of the wire rope does not protrude out where it will hit other components s the drum is turning. TIGHTEN THE SETSCREW in the nchor lock to securely hold the wire rope in plce WIND FIVE 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 Figure 7B Wire Rope Wrp Directions winch is suitle for oth overwound or underwound use underwound overwound

13 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge Generl Theory of Opertion Importnt! Limit nonuniform winding y keeping tension on the wire rope nd y mintining the proper fleet ngle. To help ensure rted per for mnce, mke sure the ir pressure t the motor is equl to the winch s pressure rting. It is your responsiility to detect nd ccount for different fctors ffecting the condition nd per for mnce of the equipment. When determining whether the lod will exceed the lod rting, consider the totl force required to move the lod THE FORCE 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. Inspect the equipment regulrly for dmge ccording to the instructions 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. The nd rke cn e either mnully or utomticlly engged. When engged, they lock the drive trin to the winch frme, therey stopping drum rottion when the control is relesed or plced in the neutrl position. WHEN OPERATING REMOTELY with only mnul nd rke, n opertor must e present t winch for mnul opertion of nd rke PERFORMANCE RATINGS of the equipment re ffected y the mount of wire rope wound on the drum, the wy in which it is wound, ir power supply, 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. Line speed will lso vry with lod weight nd ir power supply. LOAD RATING represents the mximum lod/force tht cn e plced on new equipment. Lod rtings re ssigned vlues for specific mounts of lod trvel or wire rope ccumultion. The lod rting decreses s lyers of wire rope ccumulte on the drum, s is descried on the seril tg DUTY RATINGS refer to the type of use the equipment is suject to. Consider the following when determining duty rting. c d ENVIRONMENT: hrsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from hrsh environments when possile. MAINTENANCE: poor mintennce, mening poor clening, luriction, or inspection, leds to poor opertion nd possile dmge of the equipment. Minimize poor mintennce y crefully following the instructions contined in this mnul. LOADING: severe loding includes shock loding nd moving lods tht exceed the lod rting of the equipment. Avoid shock lods, nd do not exceed the lod rting of the equipment. FREQUENCY OF OPERATION: frequent strt nd stop functions increse wer nd shorten the life spn of the ger trin nd lod rke components. Lengthy opertions cuse luriction to ecome hot, which lso decreses the life spn of the ger trin nd rkes. Increse mintennce of the equipment if used in frequent opertions. CONTACT FACTORY FOR MORE INFORMATION.

14 pge 14 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 2.2 Inspecting/Adjusting the Brke Brke surfces ecome hot during opertion. Do not touch hot surfces nd e sure to wer protective gloves. Do not djust rke with the winch holding lod. Accidentl relese of the rke could llow the lod to escpe. Keep hnds wy from the drum, gers, wire rope nd other moving prts of the equipment. Do not disssemle the ir cylinder for the utomtic nd rke. Improper disssemly could cuse personl injury. Contct fctory INSPECTING THE BAND BRAKE DRUM BAND BRAKE should e inspected for oil, grese nd glzing. These occurrences re not uncommon ut need to e fixed efore opertion continues. If the rke lining is oil-soked, replce the rke nd. A fine grit emery cloth should e used to snd ny glzed re to remove them. MEASURE BAND THICKNESS to mintin rke effectiveness. Brke nd must e replced efore nd rke wers through. It is recommended to replce the nd rke efore the rke mteril mesures less thn.015 inch thickness t ny given point TEST BRAKE to ensure proper opertion. At first lyer, the rke djustment shll e set to hold minimum sttic lod of 125% first lyer lod rting without slipping. (See product nmeplte for first lyer rting). This will provide proper dynmic opertion t 100% loding. Check ll rke surfces for wer, deformtion, or foreign deposits. If poor opertion or visul dmge is witnessed, contct fctory nd hve rke repired ADJUSTING THE BAND BRAKE FOR MANUAL BAND BRAKES c d e MAKE SURE there is no lod on the winch. RELEASE WIRE ROPE TENSION on the drum. RELEASE TENSION OF BRAKE BANDS y disengging the rke nd hndle. ROTATING THE ADJUSTMENT NUT clockwise will tighten the rke nd. Adjustments should e mde in increments of 1/8 rottion. See Figure 8. CHECK THE ADJUSTMENT y engging the nd rke. The rke is properly djusted when it tkes etween 4 nd 6 ls of force eing pplied to the hndle to e pushed into the locked position (hndle over center) with no lod on the winch. If not, repet step "d" until correct.

15 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 15 Importnt! The linkges on the uto-rke model should not e llowed to lock over-center s they do on mnul rke. Locking over-center cretes jerky strts/ stops, so djustment needs to e regulrly monitored to void locking over-center. Do not over-tighten djustment nut; rke nd will drg which cn cuse slow opertion nd/or dmge to the winch ADJUSTING THE BAND BRAKE AUTO-BRAKE MODELS c d MAKE SURE there is no lod on the winch. RELEASE WIRE ROPE TENSION on the drum. PLACE ADJUSTMENT WRENCH on djustment nut nd momentrily disengge the rke (move the control lever out of neutrl) while simultneously turning the nut clockwise 1/8 turn. Be creful not to lift the lod during this procedure. See Figure 8B. CHECK THE ADJUSTMENTS y lifting the lod short distnce (less thn six inches) nd verify tht the rke holds. 1. If the rke does not hold the lod, repet -c. 2. If the rke drgs during norml opertion, turn the nut counter-clockwise 1/8 turn to give the nd more room to expnd. 3. If the rke does not properly stop nd hold the lod fter trying ll djustment rnges, the rke linkges my need to e gresed, or the rke components my e worn nd should e replced. Figure 8A Mnul Bnd Brke Adjustment Adjustment Nut Figure 8B Automtic Bnd Brke Adjustment Adjustment Nut

16 pge 16 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 2.3 Breking-In The Winch Remove exhust port cps for opertion if pplicle. Filure to do so my result in equipment dmge nd limit performnce. See Figure BEFORE THE WINCH IS PLACED INTO SERVICE or for winches tht hve een in storge for period of more thn one month, the following strt-up procedure is required. See Figure 9. c INSPECT THE WINCH nd other equipment ccording the Instructions for Periodic Inspection. WHEN FIRST OPERATING THE WINCH it is recommended tht the motor e driven slowly in oth directions for few minutes. ENSURE BRAKE HOLDS prior to mking complete lift y lifting lod short distnce nd relesing control PRIOR TO INITIAL USE, ll new, ltered or repired winches shll e tested to ensure proper opertion. See Figure 9 nd Section Luricting the Winch. CHECK THAT THE OIL LEVEL in motor nd the MTA1-S reducer is correct. ALL NEW DRUM BRAKE BAND LININGS require "run-in" period. Operte the winch without lod in the pyout direction while grdully pplying the rke. Allow the rke to slip for pproximtely one minute. Winch motor my stll s drum rke nd lining fully engges. Do not llow rke to overhet. Look for signs of overheting (smoke, hot to touch, urnt pint, etc.) Check opertion of rke following run-in. See Section Inspecting/Adjusting the Brke INSPECT THE WINCH following the rek-in ccording to the Instructions for Periodic Inspection. See Section Inspecting the Equipment.

17 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge Prepring for Opertion To void prolonged virtion exposure, pendnt control units re ville if winch will e operted for extended periods of time. Red nd comply with the guidelines set forth in this Owner s Mn u l. Keep this mnul ccessile to opertors t ll times, 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. The winch must e equipped with lod rke if it is used to lift lods or drg lods on n incline. Do not use more thn one winch to move lod unless ech winch ws designed for 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 nd void the wrrnty. Check luriction efore use CONSIDER THE OPERATION. Do not egin until you re sure you cn perform the entire opertion without hzrd. WHEN OPERATING REMOTELY with only mnul nd rke, n opertor must e present t winch for mnul opertion of nd rke A PRE-OPERATION MEETING ttended y the winch opertor, ground crew, signl person nd the person in chrge of the tsk to e performed shll e held to pln nd review the procedure to e followed, including: Signls. Approprite numer of signl persons nd ground crew. Designte responsiility. THIS MEETING SHALL BE HELD prior to the eginning of opertions t ech new work loction nd therefter for ny new employees ssigned to the opertion. DURING THIS MEETING it is recommended tht comprehensive pln to cover emergency procedures e worked out prior to exercising the winch cpilities.

18 pge 18 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches INSPECT ALL COMPONENTS of the system. INSPECT THE WINCH nd other equipment ccording to Section Instructions for Frequent Inspection. c OPERATORS shll e physiclly competent nd hve no helth condition which might ffect their ility to ct, nd they must hve good hering. Opertors who re ftigued or hve exceeded their norml shift period shll check ll relted regultions regrding pproved work periods prior to opertion. Refer to trining progrm. The opertor must thoroughly understnd proper methods of rigging nd ttching lods nd should hve good ttitude regrding sfety. 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. Figure 9 Motor nd Vlve inlet port NOTE: Thern recommends instlling mufflers in exhust ports to reduce noise. For opertion without mufflers, remove port cps from exhust ports. In oth cses it is recommended tht opertors use hering protection. vlve exhust port 1 motor exhust port 2

19 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge Attching the Lod Figure 10 Attching Lod ltch closed tight ginst hook Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse 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 10. Alwys mke sure the lod is properly seted in the sddle of the hook. Do not tip lod the hook s this my llow the lod to slip out of enggement nd leds to spreding nd eventul filure of the hook. CENTER THE LOAD on the hook so it will remin lnced nd not tip or rotte to one side.

20 pge 20 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 2.6 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. Lifting nd lowering speeds shll e opertor-controlled nd e s slow s prcticl. The winch opertor(s) shll remin t the controls t ll times. Figure 11 Lever Control Keep t lest 5 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 5 wrps on the drum the wire rope could come loose, cusing the lod to escpe. Keep ll unnecessry personnel wy from the winch. 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. Winches must use controls tht spring return to neutrl nd stop ll motion when relesed. Vrious controls re ville with the winches nd re dependent on ir supply, loction to winch nd degree of control required. Opertor(s) must mintin visul or udio contct with personnel nd the lod t ll times. Opertor(s) must remin t the controls t ll times. Monitor surrounding conditions to prevent the lod from contcting hzrdous ostructions. Use spotters or signl person to ssist with positioning the lod in confined or limited visiility res. Do not divert your ttention from the opertion. Sty lert to the possiility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stopping 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. Before operting, the following conditions shll exist: Figure 11 Pendnt Control c d WIRE ROPE shll e free of kinks. MULTIPLE PART LINES shll not e twisted round ech other. THE PRIMARY POINT of wire rope ttchment shll e centered over the lod so tht the lod will not tilt nd remin level. IF THERE IS SLACK wire rope condition, the hoisting mechnisms shll e inspected to ensure ll wire ropes re properly seted on drums nd in sheves, efore resuming winch opertion USE THE CONTROL DEVICE to operte the winch. The control device must e momentrily type, so the winch will stop when the opertor releses the control. See Figures 11 nd THE MANUAL BAND BRAKE is engged y pulling down on the hndle nd disengged y pushing up. If the hndle is pushed down fully nd motor control is relesed or in the neutrl position, it should lock in tht position nd prevent drum rottion, until disengged y the opertor. The rke must e kept properly djusted to hold the required lod. See Figure 12.

21 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 21 Figure 12 Mnul Bnd Brke THE AUTOMATIC BAND BRAKE is engged nd disengged y the cylinder. When engged it should lock in tht position nd prevent drum rottion, until disengged y the opertor. The rke must e kept properly djusted to hold the required lod 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. Disengge OBSERVE THE REDUCER, MOTOR AND BRAKE during opertion for signs of overheting. Frequent 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 overheting. Use thermocouple or other device to monitor reducer temperture. Engge c STOP THE OPERATION if the reducer, motor or rke overhets, nd llow the winch to cool. Continued opertion my cuse dmge. WHEN PAYING OUT oserve the motor for overspeeding. If over sped, it my eject oil from the motor, shortening the life of the motor IN CASE OF AIR SUPPLY FAILURE, shut off the ir supply line vlve, relieve the ir line pressure nd DISCONNECT the ir supply line from the winch. Leve the ir supply DISCONNECTED. See section Emergency Opertion.

22 pge 22 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 2.7 Emergency Opertion Emergency lowering opertions must e performed y minimum of two personnel trined in the opertion of the winch. Communiction must e estlished etween personnel nd the winch opertor. The opertor should e le to visully monitor the lod through its full rnge of trvel EMERGENCY OPERATION PROCEDURE for ir winch with mnul nd rke nd suspended lod cn e ccomplished one of two wys: USING AN ALTERNATIVE AIR SUPPLY Engge the mnul nd rke to hold the lod. Do not let go of the nd rke hndle during emergency opertion of winch. The mnul nd rke is engged y pulling down the hndle nd disengged y pushing up. In cse of ir supply filure, put the control in neutrl nd disconnect the ir supply. Leve the primry ir supply disconnected during emergency opertion. Hve second person connect secondry source of ir to the inlet port of the control vlve. Tking cre, operte the mnul nd rke nd control vlve to lower the lod. Remove the lod from the lod line. EMERGENCY LOWERING WITHOUT BACKUP AIR SUPPLY: Engge mnul nd rke to hold the lod. DO NOT let go of the nd rke hndle during emergency opertion of the winch. The mnul nd rke is engged y pulling down the hndle nd disengged y pushing up. Set control vlve to neutrl position. Disconnect ir supply nd leve disconnected during emergency opertion. Open the control vlve to the pyout position nd grdully disengge the nd rke to slowly lower the lod EMERGENCY OPERATION PROCEDURE for ir winch with utomtic nd rke nd suspended lod cn e ccomplished one of two wys. Either wy, n lternte ir pressure source must e ville to perform nd emergency lowering procedure. USING AN ALTERNATIVE AIR SUPPLY: Connect the ckup ir supply to the inlet of the winch. Operte the control vlve s norml to py out the line until the lod is lowered. Remove the lod from the line.

23 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 23 Figure 15 Emergency Stop Button press to engge, rotte clockwise to relese c EMERGENCY LOWERING WITH BACKUP AIR SUPPLY: Disconnect primry winch ir supply nd leve disconnected during emergency opertion. Instll n djustle vlve in-line with the ir pressure source, nd connect to the inlet port of the uto-rke cylinder. Do not pressurize until redy to lower the lod. Slowly dd pressure to the uto-rke cylinder to relese the nd's clmping force, nd meter the pressure s the lod slowly descends. Remove the lod from the line fter it hs een lowered. SHUTOFF VALVE/EMERGENCY STOP OPERATION If winch is supplied with n emergency stop utton, when need rises to stop or remove the ir supply from the winch, engge the emergency stop utton y pressing it down. Once the sitution hs een resolved, relese emergency stop utton y rotting it clockwise. See Figure 15. Pendnt Control ANY QUESTIONS ON OPERATION OR WINCH APPLICATION CALL THERN, INC.

24 pge 24 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches 3.1 Clening the Winch Clen the winch to remove dirt nd help prevent rust nd corrosion CLEAN THE WINCH every six months or whenever it is dirty. Wipe down ll equipment to remove dirt nd grese REMOVE ALL UNNECESSARY OBJECTS from the re round the winch. 3.2 Luricting the Winch Importnt! Do not leve plug holes in the reducer or motor open. Open plug holes will llow dirt nd moisture to contminte the luriction. Mke sure luricnt hs temperture rting pproprite for the mient tempertures of the opertion. Luricte the winch properly to help protect it from wer nd rust. Red the following instructions crefully. Mke sure the rether plugs re clen nd open to vent het nd pres sure. Poor ventiltion will cuse overheting nd result in dmge to oil sels nd other equipment. Fill the motor to the proper level without overfilling. MTA2000 reducers must lso e filled to the proper level. Too much or too little luricnt will cuse overheting nd result in dmge to equipment. For shipment, the winch motor nd reducer re filled with luricnt, nd the motor rether nd reducer rether plug(s) re instlled. MTA1000 reducers re grese pcked nd seled. This reducer does not require oil fill or rether plugs LUBRICATE THE MOTOR AND REDUCER ccording to the mnufcturer s in struc tions. c d FILL THE MOTOR with oil efore operting the winch. Add oil until it reches the level check plug. Do not mix different luricnts. See Tle 1. FOR MTA2000 MODELS, lso fill the reducer with oil until it reches the recommended level in the sight tue. 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. See Figure 13. CHANGE MOTOR LUBRICANT AND MTA2000 reducer luricnt t lest every 2 yers, or whenever it is dirty or contminted. See Figure LUBRICATE THE WIRE ROPE y following the wire rope mn u fc tur er s rec om men d tions IF WINCH IS DISASSEMBLED, clen ll prts thoroughly nd cot erings nd sels with clen grese. Use sufficient grese to provide good protective cot.

25 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 25 Figure 13 - MTA Series OIL DRAIN/FILL PROCESS. See Figure 13. Motor Oil Level Motor Drin Plug MTA2000 REDUCER 1. Remove oil drin plug t ottom of reducer. 2. Remove rether plug from top of reducer. See Figure 3B. 3. Allow ll oil to drin. This my require tipping the winch to the motor side out 45 o. 4. Replce oil drin plug. 5. Fill oil t rether loction until the indictor reds full. 6. Replce rether plug ck on top of reducer. MOTOR 1. Remove oil drin plug t ottom of motor. 2. Remove rether plug t top of motor. 3. Allow ll oil to drin. 4. Replce oil drin plug. 5. Remove oil level plug. 6. Fill oil until level with oil level plug hole. 7. Replce level plug nd rether plug. Tle 1 - Approved Motor Oil Tle Model Oil Amount (oz) MTA100 MoilSHC630 3 MTA200 MoilSHC Tle 1 - Approved MTA2000 Reducer Oil Amient Temperture 1 o F o C Chevron/ Texco Oil Exxon Oil Moil Oil Shell Oil BP Oil -4 to 14 o -20 to -10 o Tellus T15 Tle 2 - Approved MTA1000 Reducer Grese Amient Temperture 1 o F o C Exxon Grese -4 to to -10 Becon to to 50 Unirex N2 Grese (NLGI Grde #2) MTA1000 reducers ship with Unirex N2 grese. This informtion is provided for reference purposes. The MTA1000 reducer grese is considered mintennce-free. 14 to 41 o -10 to 5 o EP Ger Compound to 95 o 0 to 35 o EP Ger Compound 100, to 122 o 30 to 50 o EP Ger Compound 220, 320, 460 Sprtn EP 68 Moilger 600 XP 68 (ISO) VG 68) Sprtn EP 100, EP 150 Sprtn EP 220, EP 320, EP 460 Moilger 600 XP 100, 150 (ISO VG 100, 150) Moilger 600 XP 220, 320, 460 (ISO CG 220, 460) Oml S2 G 68 Oml S2 G 100, 150 Oml S2 G 220, 320, 460 Energol GR-XP 68 Energol GR-XP 100, GR-XP 150 Energol GR-XP 220, GR-XP 320, GR-XP 460 MTA2000 reducer shll e fi lled until the oil reches the recommended level in the sight tue. This my require 9oz or more depending on how thoroughly the reducer ws drined. MTA2000 reducer will ship with 600XP For opertion in tempertures colder thn those listed here, plese contct the fctory for suggested luricnts.

26 pge 26 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air 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 inspecting the equipment. Keep written records of inspection. This llows comprison with comments from previous inspections so you cn see chnges in condition or performnce. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. Importnt! Increse the frequency of mintennce procedures if the winch is: Operted for long periods. Used to pull hevy lods. Operted in wet, dirty, hot or cold surroundings. 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 3 - 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 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 nd motor for signs of lekge. Mke sure the entire winch is properly luricted. Mke sure the motor nd reducer rether plugs re clen, open, nd instlled correctly. The MTA1000 uses seled reducer with no plug. 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 ir supply nd connections for wer, corrosion, cuts, nd other dmge. Perform frequent inspections: Before ech opertion. Every 3 hours during opertion. Whenever you notice signs of dmge or poor opertion. 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 under norml operting conditions, the rke needs d just ment. See Section Inspecting/ Adjusting the Brkes. Completely correct ll prolems efore continuing. Use the Trou leshoot ing Chrt to help determine the cuse of certin prolems. See Tle 4.

27 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches pge 27 Perform periodic inspections: Every 6 months except for s noted elow. Whenever there is noticele dmge, loose fsteners, or poor opertion during frequent inspection. Whenever you return the winch to service from storge. Whenever the winch hs, or my hve een, overloded or shock loded Instructions for Periodic Inspection, See Tle 3. VISUALLY INSPECT the winch nd ll other equipment. Disssemly my e required in order to properly inspect individul components. Contct fctory for ssemly/disssemly instructions. Disssemly efore contcting Thern, Inc. voids ll wrrnties. 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 nd 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 loosening, stripped threds, wer, ends, nd other dm ge. Check the reducer nd motor for signs of lekge. Mke sure the motor nd MTA2000 reducer rether plug re clen, open nd instlled correctly. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. 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 14. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 15. 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. c DRAIN A SMALL AMOUNT OF LUBRICANT from the motor nd MTA2000 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 nd motor if luricnt is con tm i nt ed. Mke sure the winch is completely luricted. See section Luricting the winch. INSPECT THE WIRE ROPE ccording to the wire rope mnufcturer's recommendtions, or follow ccepted industry stndrds for wire rope inspection. 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 14. 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 16. 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.

28 pge 28 Owner's Mnul for Thern MTA1000 nd MTA2000 Series Cycloidl Ger Air Winches Figure 14 Broken Wires wire strnd one ly Wire rope ssemly must e re plced 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. Figure 15 Rope Dimeter cor rect di me ter 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 Figure 16 Lod Hook Inspection twist throt opening in cor rect minimum dimeter 19/64 in (.2969 in) 31/64 in (.4844 in) d 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 gers, keys, erings, sels, nd shfts for wer, distortion, nd other dmge. 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 Fig ure 15. 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 equl to 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 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. Mke sure the lod moves smoothly without hesittion or strin. 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 under norml operting conditions, the rke needs d just ment. See Section Inspecting/ Adjusting the Brkes. DISCONNECT AIR SUPPLY nd inspect equipment. Check ir supply nd connections for wer, corrosion, cuts nd other dmge. CONNECT AIR SUPPLY. Completely correct ll prolems efore continuing. Use the trou le shoot ing chrt to help determine the cuse of certin prolems. See Tle 4. thick ness 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

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