Owner s Manual. For TH330MR1 Hydraulic Winches Dedicated for Personnel Lifting

Transcription

1 Red this Owner s Mnul thoroughly before operting the equipment. Keep it with the equipment t ll times. Replcements re vilble from Thern, Inc., PO Box 347, Winon, MN 55987, IMPORTANT: Plese record product informtion on pge 2. This informtion is required when clling the fctory for service. Owner s Mnul For TH330MR1 Hydrulic Winches Dedicted for Personnel Lifting

2 pge 2 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 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 be free from defects in mteril nd workmnship under norml use nd service for period of 24 months from the dte of purchse by the originl using buyer. Genuine Thern, Inc. replcement prts nd components will be 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 been subjected 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 subject to use conditions which vry between 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 by 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 INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WARRANTY 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 bove 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 number. The product must be 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 be defective, it will be repired or replced free of chrge, nd Thern, Inc. will reimburse the shipping costs. Note: Thern, Inc. reserves the right to chnge the design or discontinue the production of ny product without prior notice. About This Mnul The Occuptionl Sfety nd Helth Act of 1970 sttes tht it is the employer s responsibility to provide workplce free of hzrd. To this end, ll equipment should be instlled, operted, nd mintined in complince with pplicble trde, industril, federl, stte, nd locl regultions. It is the equipment owner's responsibility to obtin copies of these regultions nd to determine the suitbility of the equipment to its intended use. This Owner s Mnul, nd wrning lbels ttched to the equipment, re to serve s guidelines for hzrd-free instlltion, opertion, nd mintennce. They should not be understood to prepre you for every possible sitution. The informtion contined in this mnul is pplicble only to the Thern TH330MR1 Hydrulic Winches. Do not use this mnul s source of informtion for ny other equipment. The following symbols re used for emphsis throughout this mnul: Filure to follow WARNING! instructions my result in equipment dmge, property dmge, nd/or serious personl injury. Filure to follow CAUTION! instructions my result in equipment dmge, property dmge, nd/or minor personl injury. Importnt! Filure to follow importnt! instructions my result in poor performnce of the equipment.

3 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge 3 Figure 1 Seril Tg Figure 1b Seril Tg Loction seril tg

4 pge 4 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting Suggestions for Sfe Opertion DO the following: Red nd comply with the guidelines set forth in this Owner s Mnul. Keep this mnul, nd ll lbels ttched to the winch, redble nd with the equipment t ll times. Contct Thern, Inc. for replcements. Dedicte this winch for personnel lifting only. Lift only one rider t time with this winch using n pproved device (personnel hrness, botswin s chir, bosun s chir, etc ). Check for leks before 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 potentil injury to the rider. Keep hnds wy from the drum, wire rope, slck line detector pinch points, nd other moving prts of the equipment. Ensure brkes hold prior to mking complete lift by lifting the person short distnce (less thn one foot) nd relesing control. If there becomes slck wire rope condition, the hoisting mechnisms shll be inspected to ensure ll wire ropes re properly seted on drums nd in sheves before resuming winch opertion. Depressurize lines nd ccumultor nd then disconnect hydrulic supply before servicing the equipment. See Section De-Pressurizing the Accumultor. Alwys wer hering protection when operting the winch. Although winch does not present pprecible sound pressure levels, noise in the lift re my exceed cceptble levels.

5 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge 5 Suggestions for Sfe Opertion DO NOT do the following: Do not lift lods 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 multiple winches to lift or lower single rider. 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 lift point. This dmges the wire rope nd could cuse the rope to fil. Do not operte the winch with gurds or covers removed or improperly instlled. Do not divert your ttention from the opertion. Sty lert to the possibility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the person being lifted. Avoid shock lods by strting nd stopping the opertion smoothly. Shock lods overlod the equipment nd my cuse dmge or personl injury. Do not leve suspended person unttended. Do not lift mterils, except hnd tools ccompnied by the rider, provided tht the totl weight of the rider, lifting device, nd tools do not exceed the sfe working lod (SWL). Do not use the lifting eyes of the winch for regulr lifting or s tie-off point. Do not operte the winch in inclement wether conditions, especilly when lightning is present. Use of ground strp is recommended to prevent dmge to the winch in cse of lightning strike. Do not touch brke rotors s they become hot during norml opertion. Do not remove the seril plte or ny sfety lbels on the winch. Do not touch ny hydrulic plumbing s prts my become hot during opertion.

6 pge 6 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 1.1 Personnel Lifting Winch Overview Importnt! Some gencies my require (for winches) dditionl, redundnt sfety devices tht Thern does not furnish. Additionl devices my be required to bring the system up to pplicble codes, stndrds, nd regultions. Before using Personnel Lifting Winch, be sure to check ll regultions; locl, stte, federl nd country, tht my pply to the use of winch or winch system for lifting nd lowering people. The personnel lifting device, (hrness, bosun s chir, bot swin s chir, etc ) shll be pproved by the mnufcturer for personnel lifting. All supporting structure, mounting hrdwre nd ttching hrdwre must be in ccordnce with ll pplicble stndrds codes nd regultions. Ensure proper selection nd instlltion of wire rope nd sheves. Sheves nd sheve mounting must be designed nd selected in ccordnce with ll pplicble stndrds, codes, nd regultions. Improper instlltion of wire rope or sheves cn cuse uneven spooling nd wire rope dmge tht could cuse lod to escpe. Winch is not pproved for lifting below deck. Keep rider in view t ll times. Do not instll the winch in n re defined s hzrdous by the Ntionl Electric Code, unless instlltion in such n re hs been thoroughly pproved. Do not instll the winch ner corrosive chemicls, flmmble mterils, explosives, or other elements tht my dmge the winch or injure the opertor. Adequtely 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 broken wire rope tht could snp bck 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. Personnel lifting shll only be performed in pplictions specificlly pproved by regultory bodies. Regultory bodies, not the mnufcturer, hve determined suitble use. Personnel Lifting Winches mnufctured by Thern re furnished with limittions; pprovl for ny use in personnel lifting pplictions utomticlly termintes for ny of the following resons: Winch does meet other pplicble codes nd stndrds. Winch is not prt of n pproved system. Winch is not properly mintined in n "s new" condition with ll prts intct nd properly djusted. Winch is used in pplictions not pproved by codes nd regultions, or is used in pplictions inconsistent with mnufcturer's opertion nd mintennce mnul. Chnges in ny of the stndrds or regultions fter Thern's initil shipment of the product. More thn one winch is used to ttch to common rider WINCHES ARE DESIGNED for the purpose of lifting people nd mnufctured to comply with pplicble stndrds nd specifictions of governing bodies. The minimum mbient temperture during winch opertion is -4 F (-20 C) WINCHES ARE DESIGNED to meet the requirements of ANSI/ASSE A10.22 for non-guided workers' hoists.

7 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge IN FURNISHING PERSONNEL LIFTING WINCHES TO CUSTOMERS, Thern wrrnts tht it is the owner's nd user's responsibility to determine the suitbility of personnel lifting winch for prticulr ppliction. Further, it is the owner's nd user's responsibility to check nd stisfy ll locl, stte, federl, nd country requirements to the lifting nd lowering of persons IT IS THE RESPONSIBILITY of the winch owner/user to mke personnel wre of ll federl, stte nd locl rules, codes nd compny sfety rules, regultions nd instructions nd to estblish progrms to: b c d e f TRAIN AND DESIGNATE WINCH OPERATORS. TRAIN AND DESIGNATE WINCH INSPECTION nd mintennce personnel. ENSURE PERSONNEL, frequently involved with rigging the rider, re trined in ttching the rider to the winch nd other lod hndling tsks. ENSURE SAFETY PROCEDURES re followed. ENSURE ALL ACCIDENTS or sfety violtions re properly reported, nd pproprite corrective ction is tken prior to further use. ENSURE ALL WINCH WARNING TAGS, lbels nd the Owner's Mnul supplied with the winch re red NOISE AND VIBRATION At rted lod nd mximum speed: Vibrtion Level: 0.7m/s 2 ( < 0.1 g's ) Noise per dba: < 85

8 pge 8 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 1.2 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 compre future inspections. A qulified professionl should inspect or design the foundtion to insure tht it will provide dequte support. Locte the winch so the rider will be visible during the entire opertion. When moving nd positioning the winch, refer to Section 4.1 Trnsporting the Winch. 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 personnel pltform (lod) ttching hrdwre must be in ccordnce with ll pplicble stndrds codes nd regultions. Ensure proper selection nd instlltion of wire rope nd sheves. Sheves nd sheve mounting must be designed nd selected in ccordnce with ll pplicble stndrds, codes, nd regultions. Improper instlltion of wire rope or sheves cn cuse uneven spooling nd wire rope dmge tht could cuse rider (lod) to drop. Do not instll the winch in n re defined s hzrdous by the Ntionl Electric Code, unless instlltion in such n re hs been thoroughly pproved. Do not instll the winch ner corrosive chemicls, flmmble mterils, explosives, or other elements tht my dmge the winch or injure the opertor. Adequtely 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 broken wire rope tht could snp bck 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. Thern personnel lifting systems re equipped with upper nd lower trvel limiting devices. The upper limit setting should provide verticl clernce from the upper block, nd the lower limit shll be set so tht the winch cnnot be operted with less thn 5 nchor wrps wound on the drum t ny time CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on instlling the equipment LOCATE THE WINCH in n re cler of trffic nd other obstcles. Mke sure the winch is ccessible for mintennce nd opertion LOCATE THE WINCH in n re with dequte tempertures. (-20 to 60 C, -4 to 140 F) USE LIFTING EYES to properly trnsport winch nd ensure tht it remins level during trnsporttion nd instlltion. Refer to Section 4.1 Trnsporting the Winch for more informtion INSTALL THE WINCH on horizontl surfce. The winch is designed nd ssembled for horizontl bse mounting CONSIDER THE ERGONOMIC IMPACT of the winch's height on mnul opertion. To help prevent opertor injury due to stretching/reching, consider plcing riser between the winch nd the mounting deck. Riser must be sufficient in strength, nd must meet ll pplicble stndrds, codes, nd regultions.

9 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge 9 Importnt! Use sheve or roller guide to direct the wire rope to the drum whenever possible. 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 recommendtions of the sheve mnufcturer nd ensure conformnce with pplicble stndrds, codes nd regultions MAINTAIN A MAXIMUM FLEET ANGLE of 1-1/2 degrees. The proper fleet ngle minimizes wire rope dmge by helping the wire rope wind uniformly onto the drum. See Figure 2. Instll the led sheve t lest 20 feet from the center of the winch drum to llow for proper fleet ngle nd slck line detector functionlity FASTEN THE WINCH SECURELY to the foundtion. Use corse thred fsteners, grde ISO M (or ANSI Grde 5, 5/8 ) or better. Fstener certifictions my be required by pplicble stndrds, codes, nd regultions. Be sure to check the torque required for your fstener selection before mounting winch. Mke sure the winch is secured to solid foundtion ble to support the winch nd the rider under ll conditions with design fctors bsed on ccepted engineering prctices THE WIRE ROPE EXIT ANGLE must be between verticl nd specified ngle from verticl. This limittion is required for proper opertion of the slck line detector. See Figure 3. CONTACT A QUALIFIED PROFESSIONAL FOR MOUNTING INSTRUCTIONS TO COMPLY WITH LOCAL STANDARDS, CODES AND REGULATIONS. Figure 2 Mintining the Fleet Angle When wire rope trvels over sheve or through roller guide mintin fleet ngle by 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 degrees center line distnce A Figure 3 Wire Rope Exit Angle 0 o 15 o underwound s shown

10 pge 10 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 1.3 Connecting the Hydrulic Supply Importnt! Use components rted for the hydrulic supply you will be using. Alwys disconnect the supply when the winch is not in use. When removing the hoses/lines from the unit, plug the open ports. The pressure regultor on the winch my be pre-set nd locked if required by the product stndrd. Do not modify locked setting on the regultor. Contct Thern for instructions if re-djustment is required. Check tht the lbel on the control mtch rider direction. Importnt! Alwys connect the drin port directly to the reservoir. Filure to do so cn cuse the sfety circuits to mlfunction. Figure 4 Flow Control Flow Adjustment Knob Locte winch so the opertor will be ble to view the rider through the entire opertion. Locte winch so the opertor will be cler of the rider, the wire rope, nd the pth of broken wire rope tht could snp bck nd cuse injury. Check tht the direction indictors on control mtch rider direction. Do not use your hnds to feel for leks. Injection hzrd exists tht cn require surgery. Use piece of pper to find ny leks. The winch is designed to llow only up to 105 fpm (32.0 mpm) rope speed t full drum. Do not djust the flow control to llow the speed to exceed 105 fpm (32.0 mpm). There re vrious pressure settings controlled by the min control mnifold. These re set t the fctory nd should not be djusted ccept by uthorized personnel. If there is problem within the winch hydrulic system, contct Thern Service for ssistnce. It is the responsibility of the owner to provide equipment for powering the winch. The following guidelines re supplied s reference for the instller. The TH330MR1 is designed for use in hydrulic circuit utilizing pressure-compensted pump or fixed displcement pump with relief vlve. In either cse, the supply source must be protected by relief vlve ginst pressure spikes tht my be generted from the vlves in the min control mnifold. Pressure should be set to 1750 psi (120 br) into the winch. Higher pressure my be used, but cnnot exceed 3000 psi (206 br). The connections to the winch re clerly mrked on the rer of the control cbinet. The lbels re: P in is the pressure inlet port nd should follow ll clenliness requirements. T is the min return port nd should be filtered on its wy to the reservoir. Drn is the pilot drin port nd must be returned to the reservoir directly nd seprtely from the tnk port, preferrbly bove fluid level. The mximum speed of the winch my be set using the flow control vlve in the min control mnifold (Figure 4) regrdless of the supply flow nd pressure. Turning the djustment screw clockwise will slow the winch while counter-clockwise will increse mximum speed CHECK THE COMPONENT MANUFACTURER'S INSTRUCTIONS for instlling uxilliry equipment ENSURE n ccessible shut off vlve hs been instlled in the hydrulic supply line nd mke sure others re wre of its loction. A shut-off vlve tht shuts off the hydrulic circuits when the E-stop is ctivted is included s prt of the min control mnifold. An inline shut-off is recommended for dded security.

11 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge THE HYDRAULIC SUPPLY must be clen nd free from moisture. Oil in the system nd to the winch must meet n ISO clenliness level of 18/13. An optionl filter is vilble for the winch. NOTE: Oil smples should be submitted on regulr bsis to verify clenliness. b ALL HYDRAULIC SUPPLY LINES should be clen before connecting to winch inlet. SUPPLY LINES should be s short nd stright s instlltion conditions will permit. Long trnsmission lines nd excessive use of fittings, elbows, tees, globe vlves etc. cuse reduction in pressure due to restrictions nd surfce friction in the lines or n increse in tnk nd/or drin pressure THE WINCH SHOULD BE INSTALLED s ner s possible to the hydrulic power unit (HPU). Recommended pressures nd flow rte re mesured t the point of entry to the winch CHECK THE PRESSURE t the P in port on the min control mnifold to mke sure it grees with the pressure rting on the winch nmeplte TEST ALL CONNECTIONS, including those inside the cbinet, by running the HPU in short bursts to ensure hydrulic connections hve not loosened during shipment. After it is verified tht the system does not lek, grdully operte the winch, continully checking for leks. Do not use your hnds to feel for leks. Injection hzrd exists tht cn require surgery. Use piece of pper to find ny leks. b ROTATION OF THE DRUM must gree with the direction indicted on the lbel for the control device. CHECK THE AUTOMATIC LOAD BRAKES. Mke sure they relese when the motor is pplied power by the control lever nd engge when the control lever is returned to the neutrl position. The procedure for testing the brkes cn be found in the brke section of this mnul. See Section Inspecting the Brkes OPERATION IN COLD CONDITIONS IF THE AMBIENT TEMPERATURE drops below freezing, low-viscosity oil should be used in the winch nd opertion my be sluggish. CONTACT THE FACTORY OR A QUALIFIED PROFESSIONAL FOR HELP.

12 pge 12 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 1.4 Instlling the Wire Rope Importnt! Use wire rope nd other rigging equipment rted for the size of the lrgest lod you will be moving. Winch is only designed for the size of wire rope s indicted on the seril tg of the winch nd on the wedge. See Figure 1. Verify tht the wire rope nd other rigging equipment re rted for mn-riding use s required by pplicble stndrds, codes, nd regultions. Wire rope for personnel lifting devices is to be in ccordnce with API 2C nd API 9A. Do not drg the wire rope through dirt or debris tht could cuse dmge, or poor opertion. Alwys wer protective clothing when hndling wire rope. Be sure to reeve the wire rope through the slck line detector before ttching the rope to the drum. See Figure 7. Follow recommendtions for minimum distnce requirements between drum flnge outside dimeter nd top lyer of wire rope. The minimum cler drum flnge must be 2 inches. Instll the wire rope securely to the winch drum. A poorly secured wire rope could come loose from its nchor nd cuse the rider to be injured DETERMINE WHICH DIRECTION the drum must rotte to wind nd unwind wire rope. See Figure PURCHASE THE PROPER WIRE ROPE for your ppliction. Keep the following in mind when selecting wire rope. Contct reputble wire rope supplier for help. Winch is designed for specific size of wire rope. See Figure 1B for ssistnce in locting your seril tg which will indicte the wire rope size for your winch. The nchor wedge is lso for single size wire rope. b c d e COMPLY with API 2C nd API 9A stndrd for wire rope. BREAKING STRENGTH of new wire rope should be t lest 10 times greter thn the sfe working lod of the winch. WIRE ROPE LAY must gree with the winding direction of the drum to help insure proper winding. RECOMMENDED wire rope size for TH330MR1 winch is 5/16 dimeter. THE WIRE ROPE GRADE shll be pproved for mnlifting use nd must meet ll pplicble stndrds, codes, nd regultions for mnlifting. Synthetic rope hs not been pproved for use on this winch ANCHOR THE WIRE ROPE to the drum using the wedge nd socket in the drum. See Figure 5. b c PASS THE WIRE ROPE through the slck line detector rm s shown in Figure 7. PASS THE WIRE ROPE through the drum wedge socket, then round the wedge s shown in Figure 5. PULL ROPE TIGHT so wedge is set securely in the drum wedge socket. It is bsolutely criticl tht the wedge is seted sufficiently into the cble nchor socket WIND FIVE FULL WRAPS of wire rope onto the drum by operting the winch while holding the wire rope tught. These wrps serve s nchor wrps nd must remin on the drum t ll times.

13 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge 13 Figure 5 Wire Rope Instlltion Procedure Step 1 Step 2 Step 3 Step 4 pss wire rope through wedge socket pss rope round wedge minimum til length to be no less thn 1-7/8 inches (47.6 mm) set wedge in socket ensure wire rope is secured nd pull tut til length must be t lest 1 7/8 inches Figure 6 Correct/Incorrect Wire Rope Instlltion CORRECT underwound pyout wire rope wrpped tightly INCORRECT wire rope wrpped too loosely

14 pge 14 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting Figure 7 Wire Rope Routing for Slck Line Detector roller spreder

15 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge Setting Trvel Limits Adjust the rotry trvel limit setting to ensure opertion is within sfe prmeters. Setting of the upper limit should prevent movement beyond minimum verticl clernce of six (6) feet from the upper sheve block. The lower limit should be set to mintin minimum of 5 wrps of the wire rope round the drum t ll times. Limit set points re dependent on speed of opertion, use cution with setting limits. Typiclly, limits should be set for the highest speed to be encountered. A trined opertor should be closely monitoring winch opertion to ensure tht n improperly djusted limit does not llow the rider to move beyond the specified rnge. Trvel limits re not intended s the primry mens of stopping winch opertion or for the positioning of the rider, they re to prevent over trveling SET LIMITS by performing the following ctions: REMOVE the gurd pnel. See Figure 12. b c d e f REMOVE the rotry trvel limit cover. LOOSEN the lrge locking screw in the center of the column. Individul limits cn now be set. Refer to Figure 8. FOR UPPER LIMIT ADJUSTMENT turn the screw lbeled "1" (red) on the top of the cm clockwise to reduce verticl trvel, or counter-clockwise to increse verticl trvel. Operte the winch nd mke djustments until the opertion is stopped by the switch t the desired loction. FOR LOWER LIMIT ADJUSTMENT turn the screw lbeled "3" (yellow) on the top of the cm counter-clockwise to reduce verticl trvel, or clockwise to increse verticl trvel. Operte the winch nd mke djustments until the opertion is stopped by the switch t the desired loction. AFTER SETTING BOTH LIMITS, tighten the locking screw nd re-check the limits. Re-instll cover nd gurd. NOTE: THERE MUST A MINIMUM OF 4 DRUM REVOLUTIONS between upper nd lower trvel limit for the limits to operte correctly. Figure 8 Setting Limits SETTING INSTRUCTIONS 1. LOOSEN CENTER SCREW. 2. LOCATE SCREW FOR DIRECTION OF TRAVEL. 3. TURN UPPER TRAVEL LIMIT CLOCKWISE TO REDUCE TRAVEL OR COUNTER CLOCKWISE TO INCREASE. 4. TURN UPPER LIMIT COUNTER CLOCKWISE TO REDUCE TRAVEL OR CLOCKWISE TO INCREASE. 5. TIGHTEN CENTER SCREW AND VERIFY SETTING. PAINT SCREW YELLOW FOR CAM 3 LOWER LIMIT PAINT SCREW RED FOR CAM 1 UPPER LIMIT

16 pge 16 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 1.6 Adjusting the Slck Line Detector Importnt! Alwys be sure tht the slck line detector vlve is tightly ttched to the winch, nd verify tht it functions properly before every lift. If slck line detector vlve is not properly djusted, the vlve could premturely hlt the lowering opertion of the winch. Bewre of moving prts nd pinch points ny time person is within the swing rdius of the slck line detector rm. Alwys help the slck line detector rm lift into running position if it is in downwrd resting position. Filure to help the lift the rm, could cuse the rm to snp up quickly ADJUST THE POSITION of the slck line detector vlve every time the wire rope tke-off ngle is chnged, or when improper djustment cuses lunging or incpbility of lifting. b c d e f ELEVATE SLACK LINE DETECTOR ARM until it is t the ngle where it will be running with tut wire rope. This cn be ccomplished by hving helper physiclly lift the rm into position, or by pplying smll lod to the wire rope to lift the rm. LOOSEN THE SCREWS on the vlve mount until the vlve ssembly will rotte on the pivot pin. ROTATE THE VALVE ASSEMBLY on the pivot pin until the vlve roller is centered in the detent slot of the slck line rm. See Figure 9. MAINTAIN THE CORRECT DISTANCE between the roller wheel nd the rm. The vlve should fully extend with the roller in the detent, nd the vlve should fully retrct if the roller is contcting the rm surfce. TIGHTEN THE SCREWS on the vlve mount per recommended torque sequence. See Figure 10. TEST THE SLACK LINE DETECTOR djustment by performing very short lift, nd verify tht it will descend smoothly. As the wire rope becomes or is equipped with slck t the end of the lift, the vlve should trigger the motor to hlt. g REPEAT STEPS through g if the slck line detector is not functioning s intended. Figure 9 Slck Line Vlve Roller Adjustment Figure 10 Vlve Mount Tightening Procedure Keep prllel gp while tightening Alternte Tightening Detent Slot

17 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge Generl Theory of Opertion Importnt! Limit nonuniform winding by keeping tension on the wire rope nd by mintining the proper fleet ngle. It is your responsibility to detect nd ccount for different fctors ffecting the condition nd performnce of the equipment. When determining if the rider will exceed the lod rting, consider the totl force required to lift the person (plus hrness nd relted devices), nd not just the sttic weight of the person 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 responsibility 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. When engged, they lock the drive trin to the winch frme, thereby stopping drum rottion when the control is relesed or plced in the neutrl position PERFORMANCE RATINGS of the equipment re ffected by the mount of wire rope wound on the drum, hydrulic power supply, nd the wy the winch is used. 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 tbles, due to loose winding nd overlpping. The outermost lyer of rope in ny lod cse must be minimum of 2 inches below the edge of the drum flnge. b LINE SPEED increses with ech dditionl lyer of wire rope wound onto the drum. Line speed will lso vry with rider weight DUTY RATINGS refer to the type of use the equipment is subject to. Consider the following when determining duty rting. b c d ENVIRONMENT: hrsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from hrsh environments when possible. MAINTENANCE: poor mintennce, mening poor clening, lubriction, or inspection, leds to poor opertion nd possible dmge of the equipment. Minimize poor mintennce by 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 brke components. Lengthy opertions cuse oil to become hot. Increse mintennce of the equipment if used in frequent opertions. CONTACT FACTORY FOR MORE INFORMATION.

18 pge 18 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 2.2 Breking-In The Winch BEFORE THE WINCH IS PLACED INTO SERVICE or for winches tht hve been in storge for period of more thn one month, the following strt-up procedure is required. b c INSPECT THE WINCH nd other equipment ccording to the Instructions for Periodic Inspection. WHEN FIRST RUNNING THE MOTOR operte the motor slowly in both directions for few minutes. ENSURE BRAKE HOLDS prior to mking complete lift by lifting test lod short distnce nd relesing control PRIOR TO INITIAL USE, ll new, ltered or repired winches shll be tested to ensure proper opertion. See Section 3.3.4h INSPECT THE WINCH following the brek-in ccording to the Instructions for Periodic Inspection. See section Inspecting the Equipment.

19 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge Inspecting the Brkes Figure 11 Cliper Assembly Do not relese the brkes with the winch holding rider or n out-of-blnce rope lod. Accidentl relese of the brkes could llow the rider to descend or the rope to unspool. Keep hnds wy from the drum, gers, wire rope nd other moving prts of the equipment. Cliper Assembly Figure 12 Removl/Reinstlltion of Brke Gurd Pnel INSPECTING THE CALIPER BRAKE. See Figure 11. b c d e REMOVE THE GUARD PANEL on the bck side of the winch to revel the brke cliper pds. See Figure 12. CALIPER BRAKE ROTOR should be inspected frequently for oil, grese, nd mechnicl wer. If oil nd/or grese re present on the rotor, wipe the rotor clen with towel or rg. If mechnicl wer is found, locte the source of the problem nd contct fctory to hve the rotor nd worn components repired or replced. CALIPER BRAKE PADS should be inspected frequently for oil, grese, foreign contminnts, nd uneven wer. If ny unwnted mterils re found on the brke pds, wipe them off with towel or rg. Replce both of the brke pds if one or both re worn unevenly, or if they hve foreign mterils embedded in the friction surfce. TO MEASURE THE CALIPER GAP, use the steps below. The gp is crucil to mintin brke effectiveness, becuse s the brke wers, the gp increses, nd the holding torque decreses. 1. PRESSURIZE THE BRAKE to 200 PSI mximum to fully relese the clmping force. 2. SHIFT THE BRAKE ASSEMBLY to the left until the right-hnd pd touches the rotor. 3. MEASURE THE GAP between the left hnd pd nd the rotor using feeler guge. See Figure IF THE BRAKE GAP IS GREATER THAN.286 INCHES, replce the pds, becuse the gp is crucil for mintining dequte brke holding torque. Pds my seem to hve dditionl wer life t the time when replcement is required, but the brke holding cpcity is reduced when the totl gp exceeds the llowble mount. Therefore, ALWAYS replce the pds if the gp requirement is not met. RE-INSTALL THE GUARD PANEL on the bck side of the winch fter checking brke. See Figure 12.

20 pge 20 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting Figure 13 Mesuring Sttic Brke Pd Thickness BRAKE MAINTENANCE Your Cliper brke is spring-pplied hydrulic-relesed brke. The brke is under constnt spring tension. Do not dismount brke without first pressurizing the brke housing to retrct the piston. Once dismounted, relese pressure slowly. Prior to instlling the brke, pressurize to 200 psi to relese the brke pistons. If the brke ws shipped with temporry spcer between the friction pds, discrd. b Align brke over brke disc nd mount with by sliding over the brke rils. c Disc should be ligned between friction pds so tht disc does not contct pds when brke is fully relesed. d The brke disc should hve less thn.020" run-out. e Instll Hydrulic fittings in brke port. Minimum relese pressure required is 200 psi. Mx pressure 400 psi. Pd Mesurement f Inspect the brke pds frequently for signs of wer. The brke tngentil force directly diminishes with friction pd wer. INSPECTING THE STATIC CALIPER BRAKE (BEARING-SIDE) REMOVE THE GUARD PANEL on the bck side of the winch (if not lredy removed) to revel the brke cliper pds. b STATIC CALIPER BRAKE ROTOR should be inspected frequently for oil, grese, nd mechnicl wer. If oil nd/or grese re present on the rotor, wipe the rotor clen with towel or rg. If mechnicl wer is found, locte the source of the problem nd contct fctory to hve the rotor nd worn components repired or replced. c STATIC CALIPER BRAKE PADS should be inspected frequently for oil, grese, foreign contminnts, nd uneven wer. If ny unwnted mterils re found on the brke pds, wipe them off with towel or rg. Replce ll the brke pds if one or more re worn unevenly, or if they hve foreign mterils embedded in the friction surfces. d MEASURE BRAKE PAD THICKNESS frequently to check for excessive wer. See Figure 14. If either of the two visible pds is mesured to be less thn inches thick, replce ll the pds. There is no prcticl procedure for mesuring the gp in the sttic brke. e REPLACE THE GUARD PANEL on the bck side of the winch fter checking both brkes. MAINTENANCE: To replce friction pds, pressurize the brke to min 200 psi prior to dismounting. b Remove the ded side by removing the (4) HHCS s. c Remove friction pds from the live side pd holders by removing the brss screws. Note these screws re different from the brss screws used in the ded side friction pds nd must be reinstlled in the live side pd holders only. d Remove remining (2) friction pds from the ded using the sme process. e Instll new friction pds. Use removble thred locker on ll brss screws when reinstlled. f Ressemble the ded side nd spcer to the live side by instlling the (4) HHCS s nd tighten to 30 ft.-lbs. of torque. g Remount brke. Refer to instlltion instructions.

21 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge Prepring for Opertion Figure 14 Signls Red nd comply with the guidelines set forth in this Owner s Mnul. Keep this mnul, nd ll lbels ttched to the winch, redble nd with the equipment t ll times. Contct Thern, Inc. for replcements. Do not wlk or work under lod or in the line of force of ny lod. hoist 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 nd/or personl injury. The winch must hve two, independent, fil-sfe brkes in functioning condition. Do not use more thn one winch to move common rider. Do not use dmged or mlfunctioning equipment. To do so could result in filure of the equipment, or personl injury. lower Do not modify the equipment in ny wy. To do so could cuse equipment filure, or personl injury. Do not operte the winch with gurds removed or improperly instlled. Do not operte the winch without the nti-tmper tg on the brke relese nut. stop Do not operte the winch in windy conditions. If the rider begins to swy from the wind, return the person sfely to the ground nd continue the lifting opertion when the wind hs subsided. Do not use the instlltion lifting ers for regulr lifting opertions. The lifting ers re only for trnsporting the winch CONSIDER THE OPERATION. Do not begin until you re sure you cn perform the entire opertion without hzrd. move slowly A PRE-OPERATION MEETING ttended by the winch opertor, ground crew, signlperson, persons to be lifted nd the person in chrge of the tsk to be performed shll be held to pln nd review the procedure to be followed, including: Signls. Procedures for sfe use nd ttchment of rider. Approprite number of signl persons nd ground crew. Designte responsibility. b THIS MEETING SHALL BE HELD prior to the beginning 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 be worked out prior to exercising the winch cpbilities.

22 pge 22 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting INSPECT ALL COMPONENTS of the system. b c d INSPECT THE WINCH nd other equipment ccording to the Instructions for Frequent Inspection. OPERATORS shll be physiclly competent nd hve no helth condition which might ffect their bility 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. The opertor must thoroughly understnd proper methods of rigging nd ttching riders nd should hve proctive ttitude regrding sfety. THE RIDER S PATH must be cler of other objects nd free to move. REMOVE SNOW AND ICE buildup from the winch, wire rope, nd sheves before operting the winch. Ice buildup could jm the wire rope nd cuse n overlod sitution. If brke dust ccumultes on or ner the clipers, clen using compressed ir KNOW YOUR LOAD nd mke sure you do not exceed the lod rting of the winch or ny other equipment in the system. Before operting, the following conditions shll exist: b c d WIRE ROPE shll be free of kinks. ADJACENT LINES shll not be twisted round the wire rope. THE PRIMARY POINT of wire rope ttchment shll be such tht the rider will not tilt nd remin level. IF THERE HAS BEEN A SLACK wire rope condition, the hoisting mechnisms shll be inspected to ensure ll wire ropes re properly seted on drums nd in sheves, before resuming winch opertion BEFORE THE WINCH IS PLACED INTO SERVICE or for winches tht hve been in storge for period of more thn one month, the following strt-up procedure is required. b INSPECT THE WINCH nd other equipment ccording the Instructions for Periodic Inspection. WHEN FIRST RUNNING THE MOTOR operte the motor slowly in both directions for few minutes.

23 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge Attching the Rider Do not wrp the wire rope round the lift point of the rider s hrness; this dmges the wire rope nd could cuse the rope to fil. Use ttchment components nd methods pproved for lifting personnel. Alwys mke sure the personnel lifting hrness/device ttchment point is properly seted in the sddle of the hook, if pplicble CLEAR OBJECTS from the pth of the rider so tht he/she cn be moved freely nd visibly it t ll times during the opertion ATTACH THE RIDER using n pproved personnel lifting device. Follow the recommendtions of the device mnufcturer. Alwys purchse hrness tht meets pplicble stndrds, codes, nd regultions for mnlifting.

24 pge 24 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 2.6 Operting the Winch Importnt! Obey stop signl from nyone. Mintin tension on the wire rope to keep it tightly nd evenly wound on the drum. If the winch nd rider re not visible during the entire opertion, get help from nother person. Appoint supervisor if more thn one person is involved in the opertion. This will reduce confusion nd increse sfety. When lifting person, tg line cn be used to keep the rider from swinging or twisting. Be sure to follow recommendtions of the hrness mnufcturer for using the tg line. The winch opertor shll remin t the controls t ll times. Lifting nd lowering speeds shll be opertor-controlled nd be s slow s prcticl. 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 rider to fll uncontrolled. Keep ll unnecessry personnel wy from the winch. Keep out of the pth of the rider, nd out of the pth of broken wire rope tht might snp bck nd cuse injury. Keep hnds wy from the drum, gers, wire rope, nd other moving prts of the equipment. Opertors must mintin visul contct with personnel nd the rider t ll times. Opertors must remin t the controls t ll times. Monitor surrounding conditions to prevent the rider from contcting hzrdous obstructions. Use spotters or signl persons to ssist with positioning the rider in confined or limited visibility res. Do not divert your ttention from the opertion. Sty lert to the possibility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the rider. Avoid shock lods by strting nd stopping the rider smoothly. Shock lods overlod the equipment nd my cuse dmge or injury. Do not leve suspended rider unttended MOVE THE RIDER slowly nd smoothly, only smll distnce t first. Mke sure the rider is blnced nd securely ttched before continuing. Ensure tht the brkes hold prior to mking complete lift by lifting the person short distnce (less thn one foot) nd relesing control USE THE CONTROL DEVICE to operte the winch. The control device is momentry, so the winch will stop when the opertor releses the control. See Figure THE AUTOMATIC BRAKES re spring pplied, hydrulic relesed (SAHR) brkes. The brkes disengge when the motor is operted. When the control vlve is plced in the neutrl position, the brkes utomticlly engge, preventing drum rottion OBSERVE THE WIRE ROPE s it winds onto the drum. If it becomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope before continuing. Continued opertion with overlpped or uneven wire rope cn dmge the wire rope nd shorten its life OBSERVE THE MOTOR AND BRAKE during opertion for signs of overheting. Frequent overheting my be sign of dmge. b WATCH FOR SMOKE, the smell of burnt lubricnt, nd other signs of overheting oil temperture. Supply oil should not exceed 85 o C. STOP THE OPERATION if the motor or brke overhets, nd llow the winch to cool. Continued opertion my cuse dmge.

25 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge IN CASE OF HYDRAULIC SUPPLY FAILURE, see section Emergency Opertion SHOULD THE WINCH stop operting unexpectedly, filure my hve occurred or one of the limits reched. Figure 15 Controls Line Speed Indictor E-Stop Throttle Hour Meter

26 pge 26 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 2.7 Emergency Opertion Emergency lowering opertions must be performed by minimum of two persons trined in the opertion of the winch. Alwys reset the brkes fter n emergency lowering procedure, nd mke sure tht they function properly before the next regulr lifting opertion. Communiction must be estblished between rider, spotters, nd the winch opertors. The opertors should be ble to visully monitor the rider through their full rnge of trvel. Filure to operte mnul lowering properly my result in injury to the rider. Follow instructions s printed. OPERATING WINCH IN THE EVENT OF POWER FAILURE Ech winch is equipped with two emergency brke relese mechnisms. See Figures 16 nd 17. Importnt! Ensure tht the power source is isolted before relesing brkes. Alwys open disc brke relese prior to relesing the cliper brke EMERGENCY LOWERING PROCEDURE with emergency brke relese. The winch is equipped with two utomtic brkes which re spring set nd pressure relesed. In the event of power filure, the brkes will utomticlly set until hydrulic pressure is re-pplied, or until the brkes re mnully relesed with the relese nut on the cliper brke body, nd the mnul brke relese vlve locted inside the control cbinet. See Figure 16. Figure 16 Emergency Brke Relese Emergency Brke Relese Knob

27 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge 27 Figure 17 Emergency Brke Relese RELEASE THE DISC BRAKE 1. Lock out the power source. 2. Hold relese vlve in the unlocked position. Mke sure tht the drum does not begin to rotte with the sttic disc brke relesed. b SLOWLY RELEASE THE CALIPER BRAKE. See Figure Remove the nti-tmper tg on the sttic brke relese nut. Emergency Brke Relese Nut c 2. Verify tht the rider s pth is cler for the emergency descent, nd tht ll spotters re redy for the opertion. 3. It requires pproximtely 90 kgs (200 lbs) to strip the rope from the drum. Depending on the rider nd rigging instlled, it my require tg line in order to ssist the rider descent. 4. Slowly tighten the relese nut with the supplied wrench until the brke brely strts to drift. Keep the wrench engged with the nut during the entire opertion to mintin control of the descent speed. 5. Crefully lower the rider to sfety by modulting the brke pressure with the relese nut position. Do not llow overspeeding to occur, nd do not bruptly hlt the decents. AFTER THE RIDER HAS RETURNED TO SAFETY, RESET THE BRAKES TO NORMAL OPERATION SETTING. 1. Allow relese vlve to return to the closed position. 2. Reset the cliper brke relese nut to its originl position. 3. When power is restored, be sure tht both brkes function nd individully hold the rider s intended before the next regulr opertion. 4. Instll new nti-tmper tg on the cliper brke relese nut WHEN THE NEED ARISES TO STOP THE OPERATION OF THE WINCH QUICKLY, engge the emergency stop button by pressing it down. Once the sitution hs been resolved, relese emergency stop button by pulling it up to the run position. ANY QUESTIONS ON OPERATION OR WINCH APPLICATION CALL THERN, INC.

28 pge 28 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting 3.1 Clening the Winch Importnt! Increse the frequency of mintennce procedures if the winch is: Operted for long periods. Operted in wet, dirty, hot or cold surroundings. 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 on nd round winch, noting nd fixing ny oil leks. b c d WIPE ALL EQUIPMENT to remove dirt nd grese. WIPE OFF excessive mounts of oil to void ccumultion of dirt. DO NOT POWER WASH the winch. There re sels nd other non-seled res where wter cn intrude nd dmge the winch. REMOVE OIL ACCUMULATION from round the winch cused by lekge REMOVE ALL UNNECESSARY OBJECTS from the re round the winch CLEAN dust from or round brke cliper with compressed ir.

29 Owner's Mnul for TH330MR1 Hydrulic Winches for Personnel Lifting pge Lubricting the Winch Importnt! Lubricte the winch properly to help protect it from wer nd rust. Red the following instructions crefully LUBRICATE THE WIRE ROPE by following the wire rope mnufcturer s recommendtions IF WINCH IS DISASSEMBLED, clen ll prts thoroughly nd cot berings nd sels with clen grese. Use sufficient grese to provide good protective cot. Apply grese to motor shft splines LUBRICATE THE MOTOR/BRAKE shft splines with NLG1 #2EP grese LUBRICATE THE BRAKE MOUNTING RAILS LUBRICATE BOTH BRAKE MOUNTING RAILS t lest every 10 hours of opertion. Insert NLGI #2 EP (Extreme Pressure) grese through the grese zerk. See Figure 18. NOTE: Berings re seled bll berings. Contct fctory for replcements if they lek lubricnt or mke excessive noise. Figure 18 Lubricting the Brke Rils Grese Zerks