pge 2 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes Two-Yer Limited Wrrnty Plese reord the following: Dte Purhsed: Model No.: Seril No.: This

Transcription

1 Red this Own er s Mn u l thor ough ly e fore op er t ing the equip ment. Keep it with the equip ment t ll times. Re ple ments re vil le from Thern, In. IMPORTANT: Plese reord produt informtion on pge 2. This informtion is re quired when lling the f to ry for servie. Owner s Mn ul For 4WS nd 4HS Series Worm/Spur nd Helil/Spur Ger Power Winh es

2 pge 2 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes Two-Yer Limited Wrrnty Plese reord the following: Dte Purhsed: Model No.: Seril No.: This informtion is required when lling the ftory for servie. Thern, In. wrrnts its produts ginst defets in mteril or workmnship for two yers from the dte of purhse y the originl using uyer, or if this dte nnot e estlished, the dte the produt ws sold y Thern, In. to the deler. To mke lim under this wrrnty, ontt the ftory for n RGA numer. The produt must e returned, prepid, diretly to Thern, In., 5712 Industril Prk Rod, Winon, Minnesot The following informtion must ompny the produt: the RGA numer, the dte of purhse, the desription of the limed defet, nd omplete explntion of the irumstnes involved. If the produt is found to e defetive, it will e repired or repled free of hrge, nd Thern, In. will reimurse the shipping ost within the ontiguous USA. This wrrnty does not over ny dmge due to ident, misuse, use, or negligene. Any ltertion, repir or modifition of the produt outside the Thern, In. ftory shll void this wrrnty. This wrrnty does not over ny osts for removl of our produt, downtime, or ny other inidentl or onsequentil osts or dmges resulting from the limed defets. This wrrnty does not over rke diss, wire rope or other wer omponents, s their life is sujet to use onditions whih vry etween pplitions. 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 exlusion or limittion of inidentl or onsequentil dmges, or llow limittions on how long n implied wrrnty lsts, so the ove limittion or exlusion my not pply to you. This wrrnty gives you speifi legl rights, nd you my lso hve other rights whih vry from stte to stte. Note: Thern, In. reserves the right to hnge the design or disontinue the prodution of ny produt without prior notie. Aout This Mnul The Ouptionl Sfety nd Helth At of 1970 sttes tht it is the employer s re spon si il i ty to provide workple free of hzrd. To this end, ll equipment should e instlled, operted, nd mintined in ompline with pplile trde, industril, federl, stte, nd lol regultions. It is the equipment own er's re spon - si il i ty to o tin opies 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 tthed to the equip ment, re to serve s guidelines for hzrd-free instlltion, op er tion, nd mintenne. They should not e understood to prepre you for every pos si le sitution. The informtion ontined in this mnul is pplile only to the Thern 4WS nd 4HS Series Power Winhes. Do not use this mnul s soure 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! instrutions my result in equipment dm ge, property dmge, nd/or serious personl injury. Filure to follow CAUTION! instrutions my result in equipment dmge, prop er ty dmge, nd/or minor personl injury. Importnt! Filure to follow importnt! instrutions my result in poor per for mne of the equipment.

3 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge 3 Suggestions for Sfe Opertion DO the following: Red nd omply with the guidelines set forth in this Owner s Mn u l. Keep this mnul, nd ll lels tthed to the winh, redle nd with the equipment t ll times. Contt Thern, In. for replements. Chek gerox for lurition or lekge efore use. Instll the wire rope seurely to the winh drum. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nhor wrps. With less thn 4 wrps on the drum the wire rope ould ome loose, using the lod to espe. Keep hnds wy from the drum, gers, wire rope, nd other moving prts of the equip ment. Equip the winh with lod rke if it is used to lift lods, or drg lods on n inline. Contt Thern In. for more informtion. Keep ll unneessry personnel wy from winh while in opertion. Keep out of the pth of the lod nd out of the pth of roken wire rope tht might snp k nd use injury. Disonnet eletri power efore serviing the equipment. DO NOT do the following: Do not lift people, or things over people. Do not wlk or work under lod or in the line of fore of ny lod. Do not exeed the lod rting of the winh or ny other omponent in the sys tem. To do so ould result in filure of the equipment. Do not use luth equipped models to lift lods, or pull lods up n in line. A i den tl relese of the luth ould llow the lod to espe. Do not use more thn one winh to move lod unless eh winh ws designed for multiple winh system. Do not use dmged or mlfuntioning equipment. To do so ould result in fil ure of the equipment. Do not modify the equipment in ny wy. To do so ould use equip ment fil ure. Do not wrp the wire rope round the lod. This dmges the wire rope nd ould use the lod to espe. Use pproved rigging onnetors to seure the wire rope to the lod. Do not operte the winh with drive gurds or ger overs removed or im prop er ly instlled. Do not divert your ttention from the opertion. Sty lert to the pos si il i ty of idents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shok lods y strting nd stop ping the lod smoothly. Shok lods overlod the equipment nd my use dmge. Do not leve suspended lod unttended unless speifi preutions hve een tken to seure the lod nd keep people wy from the winh nd out from under the lod. Do not djust the rke with the winh holding lod. Aidentl relese of the rke ould llow the lod to espe.

4 pge 4 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes 1.1 Instlling the Winh Importnt! Inspet the winh immeditely following instlltion ording to the Instrutions for Periodi Inspetion. This will give you reord of the ondition of the winh with whih to om pre future inspetions. A qulified professionl should inspet or design the foundtion to insure tht it will provide dequte support. Lote the winh so it will e visile during the entire opertion. Do not ttempt to lift or position winh y using frme re. This my use dmge to winh. When positioning the winh use the lifting holes provided or sling wrpped round drum. Do not ttempt to lift or position winh y using lifting hole on reduer. This hole is designed to lift reduer only. Do not weld the winh frme to the foundtion or support struture. Welding the frme my void wrrnty, ontt Thern, In. Use fsteners s instruted. Do not instll the winh in n re defined s hzrdous y the Ntionl Eletri Code, unless instlltion in suh n re hs een thoroughly p proved. Do not instll the winh ner orrosive hemils, flmmle mterils, explo sives, or other elements tht my dmge the winh or injure the op er tor. Ad e qute ly protet the winh nd the opertor from suh elements. Position the winh so the opertor n stnd ler of the lod, nd out of the pth of roken wire rope tht ould snp k nd use injury. Atth the winh to rigid nd level foundtion tht will support the winh nd its lod under ll lod onditions, inluding shok loding CONSULT APPLICABLE CODES AND REGULATIONS for speifi rules on instlling the equipment LOCATE THE WINCH in n re ler of trffi nd other ostles. Mke sure the winh is essile for min te nne nd op er tion LOCATE THE WINCH in n re with dequte tempertures. Chek the motor nd reduer mn u f tur er s informtion for mient tem per ture rt ings POSITION THE WINCH to insure proper lurition INSTALL THE WINCH on horizontl surfe. The winh is designed nd ssemled for horizontl se mounting. Speil on sid er tion must e tken if mount ing ver ti l ly or upside-down. Plese ontt Thern, In 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 uniform ly onto the drum. See Figure FASTEN THE WINCH seurely to the foundtion. FOR STANDARD PRODUCTS referred to in this mnul, use orse thred fsteners, grde 5 or etter. Be sure to hek the torque required for your fstener seletion efore mounting winh. Mke sure the winh is seured to solid foundtion le to support the winh nd the lod under ll onditions with design ftors sed on ept ed en gi neer ing pr ti es. NON-STANDARD PRODUCTS tht vry from the originl design my hve different fstening requirements. Contt struturl engineer or Thern, In. for this informtion. TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED PRO FES - SION AL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPEC I FI C- A TIONS FOR THE MOUNTING OF THERN PRODUCTS.

5 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge Instlling the Brether Plug Importnt! Sve the seled plug for use when the winh is removed for storge or trnsport. Instll the rether plug to vent het nd pressure. Filure to do so ould result in pressure uildup whih ould dmge the reduer. For shipment, the reduer is filled with lurint nd seled to prevent lu ri tion loss. NOTE: SEW nd Nord reduers ship with the rether plug pre-instlled on the reduer REMOVE THE SEALED PLUG from the rether plug hole INSTALL THE BREATHER PLUG. The reth er plug is wired to the reduer or tthed in plsti g. Refer to the reduer mnufturer s informtion CHECK THE LUBRICANT LEVEL in the reduer to mke sure no lu ri nt ws lost during shipment. Refer to the reduer mnufturer s in stru tions. Importnt! Use sheve or roller guide to diret the wire rope to the drum whenever possile. Instll sheves, trks nd other equipment so they will remin fixed under ll lod onditions. Follow the reommendtions of the equipment mnufturer. Use sheves of proper dimeter to minimize wer on the wire rope. Follow the re om men d tions of the sheve mnufturer. Figure 1 Mintining the Fleet Angle When wire rope trvels over sheve or through roller guide mintin fleet ngle y loting the sheve or guide n pproprite distne from the drum, shown s distne A. fixed sheve or roller guide smooth drum 1/2 to 1-1/2 de grees distne A enter line When wire rope trvels diretly to the lod mintin fleet ngle y on trol ling side-to-side movement of the lod with trks or guide rils. Allowing the lod to move too fr to one side uses stress on the drum flnge whih my use dmge. lod smooth drum 1/2 to 1-1/2 de grees enter line trks or guide rils

6 pge 6 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes 1.3 Conneting Eletri Power Importnt! Use eletril equipment with the orret rting nd Un der writ er s L o r to ry (UL) pproved. Alwys disonnet eletri ur rent when the winh is not in use. Instll proper rnh iruits, disonnet devies, protetion, nd ground ing s required y rtile 430 of the Ntionl Eletri Code. All eletril work must e performed y liensed eletriin. Filure to do so ould result in eletri shok or poor winh opertion. All ontrol devies must e momentry ontt type. Instll ll ontrol de vi es so the winh motor will stop when the opertor releses the devie. Lote ontrol devies so the opertor will e le to view the lod through the entire opertion. Lote ontrol devies so the opertor will e ler of the lod, the wire rope, nd the pth of roken wire rope tht ould snp k nd use injury. Figure 2 Instlling the Wire Rope Reessed Anhor orret typil instlltion shown right ly underwound nhor srew It is the responsiility of the owner to provide equipment for on trol ling the winh. Ele tri l ontrol pkges re ville from Thern. The fol low ing guide lines re sup plied s referene for the instller CONSULT APPLICABLE CODES AND REGULATIONS for speifi rules on eletril instlltion CHECK THE COMPONENT MANUFACTURER S INSTRUCTIONS for instlling nd onneting the motor, rke, nd other equipment INSTALL A FUSE or iruit reker in the power supply iruit, s re quired y the Ntionl Eletri Code INSTALL A DISCONNECT DEVICE in the power supply iruit, s required y the Ntionl Eletri Code. This should e swith you n lok in the OFF position to prevent unuthorized use of the winh CONNECT ELECTRIC STARTER CONTROLS to the motor. Mke sure the lod rke is wired for fst rking on rkemotors tht offer this fun tion. Chek the om po nent mn u f tur er s informtion CONNECT ELECTRIC POWER SUPPLY, with ground wire, to the ele tri strter ontrol ox. Chek the omponent mnufturer s informtion for wiring digrm CONNECT OTHER ELECTRIC EQUIPMENT to the proper terminls in the eletri ontrol ox CHECK THE CURRENT t the motor nd mke sure it grees with the urrent rting mrked on the winh nmeplte. If urrent rting is in or ret, hve the ir uit inspeted y liensed eletriin. inorret TEST ELECTRICAL CONNECTIONS y operting the winh. ROTATION OF THE DRUM must gree with the lels on the ontrol devie, either UP nd DOWN, or FORWARD nd REVERSE. CHECK THE LOAD BRAKE, mke sure it releses when the motor is ON, nd en gg es when the motor is OFF. Mke sure the fst rke funtion op er tes orretly on rkemotors tht inlude this feture.

7 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge Instlling the Wire Rope Importnt! Use wire rope nd other rigging equipment rted for the size of the lrgest lod you will e moving. Do not drg the wire rope through dirt or deris tht ould use dm ge, or poor opertion. Alwys wer protetive lothing when hndling wire rope. Figure 3 Instlling the Wire Rope Flnge Anhor Instll the wire rope seurely to the winh drum. A poorly seured wire rope ould ome loose from its nhor nd llow the lod to espe DETERMINE WHICH DIRECTION the drum must rotte to wind nd un wind wire rope PURCHASE THE PROPER WIRE ROPE for your pplition. Keep the following in mind when se let ing wire rope. Contt reputle wire rope supplier for help. BREAKING STRENGTH of new wire rope should e t lest 3 times gret er thn the lrgest lod pled on the winh. If lods re lifted or pulled on n inline, 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. nhor srew WIRE ROPE LAY must gree with the winding diretion of the drum to help insure proper winding. WE RECOMMEND 7 x 19 glvnized irrft le for dimeters up to 5/16 inh, nd 6 x 37 IWRC improved plow steel (IPS) or extr improved plow steel (EIPS) wire rope for di m e ters of 3/8 inhes nd up ANCHOR THE WIRE ROPE to the drum using either the reessed or flnge nhor. orret pss wire rope through slot in flnge nd into nhor nhor srew FOR RECESSED ANCHOR INSTALLATION. See Figure 2. PASS THE WIRE ROPE under the drum from the front nd through the reessed nhor hole. Mke sure t lest 1/2 inh of wire rope ex tends pst the set srew, nd the end of the wire rope does not pro trude out where it will in ter fere with wire rope wind ing onto the drum. TIGHTEN THE SET SCREW in the reessed nhor lok to seurely hold the wire rope in ple. FOR FLANGE ANCHOR INSTALLATION. See Figure 3. PASS THE WIRE ROPE under the drum from the front nd through the slot in the drum flnge. orret typil instlltion shown right ly underwound LOOP THE WIRE ROPE through oth holes in the nhor lok so the end of the wire rope is loted in the hole with the nhor srew. Mke sure t lest 1/2 inh of wire rope ex tends pst the set srew, nd the end of the wire rope does not pro trude out where it will hit other omponents s the drum is turning. Note: The numer of holes through the nhor lok my vry. Winhes hve one or two holes through the nhor lok. TIGHTEN THE SET SCREW in the nhor lok to seurely hold the wire rope in ple WIND FOUR FULL WRAPS of wire rope onto the drum y operting the winh while holding the wire rope tught. These wrps serve s nhor wrps nd must remin on the drum t ll times. inorret

8 pge 8 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes 2.1 Generl Theory of Opertion Importnt! Limit nonuniform winding y keeping tension on the wire rope nd y mintining the proper fleet ngle. To help insure rted per for mne, mke sure voltge t the motor is equl to the motor s voltge rting. It is your responsiility to detet nd ount for different ftors ffeting the ondition nd per for mne of the equipment THE PULL REQUIRED to move the lod must not exeed the lod rting of the winh. Consider the totl fore required to move the lod, not the weight of the lod THIS EQUIPMENT CAN develop fores tht will exeed the lod rting. It is the responsiility of the equipment user to limit the size of the lod. In spet the equip ment reg u lr ly for dmge ording to the in stru tions ontined in this mnul nd in the omponent mnufturer s informtion USE A LOAD BRAKE on ll winhes used to lift lods or drg lods on n inline. Although new worm ger winh my pper to hold the lod in ple, this hr ter is ti will diminish with use. Do not de pend on winh gering to hold the lod in ple PERFORMANCE RATINGS of the equipment re ffeted y the mount of wire rope wound on the drum, the wy in whih it is wound, nd the wy the winh is used. DRUM CAPACITY depends on how tightly nd evenly the wire rope is wound on the drum. Atul drum pities re usully 25-30% less thn vlues shown in performne tles, due to loose winding nd over lp ping. LINE SPEED inreses with eh dditionl lyer of wire rope wound onto the drum. The weight of the lod does not ffet line speed. LOAD RATING represents the mximum pull tht n e pled on new equip ment. Lod rtings re ssigned vlues for speifi mounts of lod trvel or wire rope umultion. The lod rting dereses s lyers of wire rope u mu lte on the drum DUTY RATINGS refer to the type of use the equipment is su jet to. Consid er the following when determining duty rting. d ENVIRONMENT: hrsh environments inlude hot, old, dirty, wet, orro sive, or explosive surroundings. Protet the equip ment from hrsh en vi - ron ments when possile. MAINTENANCE: poor mintenne, mening poor lening, lurition, or inspetion, leds to poor opertion nd possile dmge of the equip ment. Minimize poor mintenne y refully following the in stru tions ontined in this mnul. LOADING: severe loding inludes shok loding nd moving lods tht ex eed the lod rting of the equipment. Avoid shok lods, nd do not ex eed the lod rting of the equip ment. FREQUENCY OF OPERATION: frequent strt nd stop fun tions in rese wer nd shorten the life spn of the ger trin nd lod rke om po nents. Lengthy opertions use lurition to eome hot, whih lso dereses the life spn of the ger trin. Inrese mintenne of the equipment if used in frequent opertions. CONTACT THE FACTORY FOR MORE INFORMATION.

9 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge Breking-In the Winh BREAK-IN OCCURS during the first 10 hours of norml op er tion. During rek-in, mting surfes eome polished, nd lernes inrese. This is desired for effiient opertion of erings nd gers INSPECT THE WINCH following rek-in ording to the Instrutions for Periodi Inspetion. See setion 3.3 Inspeting the Equipment. 2.3 Prepring for Opertion Importnt! When determining whether the lod will exeed the lod rting, onsider the totl fore required to move the lod CONSIDER THE OPERATION. Do not egin until you re sure you n perform the entire opertion without hzrd INSPECT ALL COMPONENTS of the system. INSPECT THE WINCH nd other equipment ording to the Instrutions for Frequent Inspetion. OPERATORS must e in good helth, lert, thoroughly trined in op er t ing the equipment, nd properly lothed (hrd ht, sfety shoes nd sfety glsses, no loose lothing). THE LOAD must e ler of other ojets nd free to move. Mke sure the lod will not tip, spin, roll wy, or in ny wy move unontrollly KNOW YOUR LOAD nd mke sure you do not exeed the lod rting of the winh or ny other equipment in the system. 2.4 Atthing the Lod Figure 4 Atthing Lod lth losed tight ginst hook Do not wrp the wire rope round the lod. This dmges the wire rope nd ould use the lod to espe. Use sling or other pproved lifting devie CLEAR OBJECTS from the pth of the lod so you n move it freely nd oserve it t ll times during the opertion ATTACH THE LOAD using nylon sling, or other pproved lifting devie. Follow the reommendtions of the sling mnufturer. sling seted in sddle of hook SEAT THE SLING in the sddle of the hook with the hook lth om plete ly losed. See Figure 4. CENTER THE LOAD on the hook so it will remin lned nd not tip or rotte to one side.

10 pge 10 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes 2.5 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 winh 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 redue on fu sion nd inrese sfety. When lifting lod, use tg line to keep the lod from swinging or twist ing, while keeping yourself wy from the lod MOVE THE LOAD slowly nd smoothly, only smll distne t first. Mke sure the lod is lned nd seurely tthed efore ontinuing USE THE CONTROL DEVICE to operte the winh. The ontrol devie should e momentry ontt type, so the winh will stop when the op er tor releses the ontrol OBSERVE THE WIRE ROPE s it winds onto the drum. If it eomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope efore ontinuing. Continued opertion with overlpped or uneven wire rope n dmge the wire rope nd shorten its life OBSERVE THE REDUCER during opertion for signs of overheting. Frequent overheting my e sign of dmge, or my indite the need for lrger power winh. WATCH FOR SMOKE, the smell of urnt lurint, nd other signs of over het ing. Use thermoouple or other devie to monitor reduer temper ture. STOP THE OPERATION if the reduer overhets, nd llow the winh to ool. Continued opertion my use dmge. 2.6 Operting the Cluth (luth models only) Do not use luth equipped models to lift lods, or pull lods up n in line. A i den tl relese of the luth ould llow the lod to espe. Engge the luth ompletely efore operting the winh. Operting the winh with relesed or prtilly engged luth my use dmge. Do not engge or disengge the luth with the winh under power or loded DISENGAGE THE CLUTCH with the luth hndle, nd unwind the wire rope for hook-up to the lod ENGAGE THE CLUTCH with the luth hndle. You my need to ro tte the drum y hnd to lign the luth jws. Visully inspet the luth for omplete enggement ADJUST THE DRAG BRAKE if neessry, to ontrol the rottion of the drum when the luth is disengged. Not ll luth models inlude drg rke.

11 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge Emergeny Opertion Do not djust the rke with the lod suspended. Aidentl relese of the rke ould llow the lod to espe. Do not leve suspended lod unttended unless speifi preutions hve een tken to seure the lod nd keep unneessry personnel wy from the winh nd from under the lod IN CASE OF POWER FAILURE, turn the ontrol devie to OFF nd DIS- CON NECT eletri power. Leve eletri power DIS CON NECT ED MAKE SURE SAFETY PRECAUTIONS hve een tken to seure the lod nd keep unneessry personnel wy from the winh nd from under the lod while operting the emergeny hnd rnk IF EQUIPPED WITH A BRAKE MOTOR you must disengge the rke on the motor efore using the emergeny hnd rnk. Operting the emergeny hnd rnk with the rke on the motor engged ould result in equipment dmge or filure. It is reommended for two people to operte the winh using the emergeny hnd rnk. If the winh is equipped with rke motor, ssign one person to operte the hnd rnk while the other is ssigned to operte the rke. Hve ontrol of the hnd rnk efore disengging the rke on the motor. Aidentl relese of the rke ould llow the lod to espe. If the winh is not equipped with rke motor, ssign one person to operte the hnd rnk while the other is ssigned to oserve nd ontrol the lod. Alwys follow the rke mnufturers operting instrutions for engging or disengging the rke DO NOT USE AN IMPACT WRENCH to operte the emergeny hnd rnk option of the winh. To do so ould result in equipment dmge or filure. Use drill-motor ENGAGE THE BRAKE nd remove the hndle or drill-motor efore operting the winh under power. ANY QUESTIONS ON OPERATING THE EMERGENCY HAND CRANK OP- TION OR WINCH APPLICATION CONTACT THERN, INC.

12 pge 12 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes 3.1 Clening the Winh Importnt! Inrese the frequeny of min te - nne proedures if the winh is: Operted for long periods. Used to pull hevy lods. Operted in wet, dirty, hot, or old surroundings. Clen the winh to remove dirt nd help prevent rust nd or ro sion CLEAN THE WINCH every six months or whenever it is dirty. WIPE ALL EQUIPMENT to remove dirt nd grese. LEAVE A LIGHT FILM of oil on ll surfes to protet them ginst rust nd orrosion. WIPE OFF exessive mounts of oil to void the umultion of dirt REMOVE ALL UNNECESSARY OBJECTS from the re round the winh. 3.2 Luriting the Winh Importnt! Do not leve plug holes in the reduer open. Open plug holes will llow dirt nd moisture to on tm i nte the lurition. Mke sure lurint hs temper ture rting pproprite for the mient tempertures of the opertion. Reple the mo tor er ings if the motor is dis s sem led for ny reson. Figure 5 Luriting the Flnge Berings flnge ering, lurite with NLGI #2 EP grese Mke sure the rether plug is len nd open to vent het nd pres sure. Poor ventiltion my use overheting nd result in dmge to oil sels nd other equipment. Fill the speed reduer to the proper level without overfilling. Too muh or too little lurint will use overheting nd result in dmge to sels, er ings, nd gers. Lurite the spur gers efore operting the winh nd periodilly during opertion. Filure to lurite the gers will use dmge or deformtion of the ger teeth. Lurite the winh prop er ly to help protet it from wer nd rust. Red the following in stru tions refully MOTOR BEARINGS re typilly lurited for life y the mnufturer. Some motors require periodi lurition. Refer to the motor mn u f tur er s in for m tion for speifi in stru tions LUBRICATE THE REDUCER ording to the mnufturer s in stru tions. CHECK OIL LEVEL efore every opertion nd every 10 hours during oper tion. Remove the level plug nd mke sure oil is even with the plug hole. FILL THE REDUCER ording to the mnufturer's instrutions. Fill the re du er until oil rehes the level plug. Do not mix dif fer ent lurints. CHANGE REDUCER LUBRICANT t lest every 2 yers, or whenever it is dirty or ontminted LUBRICATE THE SPUR GEARS t lest every 10 hours of opertion. Insert NLGI #2 EP (Extreme Pressure) grese through the grese zerk in the ger gurd to lurite the ger teeth LUBRICATE FLANGE BEARINGS t lest every 10 hours of opertion. Insert NLGI #2 EP (Extreme Pressure) grese through the grese zerk. Refer to the ering mnufturer s informtion for speifi instrutions. See Figure LUBRICATE THE WIRE ROPE y following the wire rope mn u f tur er s re om men d tions.

13 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge Inspeting the Equipment Importnt! Strt n inspetion progrm s soon s you put the winh into use. Appoint qulified person to e responsile for regulrly inspet ing the equipment. Keep written reords of inspe tion. This llows omprison with om ments from previous inspe tions so you n see hng es in on di tion or per for mne. Do not use dmged or mlfuntioning equipment. Ple n OUT OF OR DER sign on the winh. Do not use the winh until the sign is re moved y qulified mintenne person who hs ompletely orreted the prolem. Inspet the winh to detet signs of dmge or poor opertion efore they e ome hzrdous. See Tle 1 - Inspetion Cheklist CONSULT APPLICABLE CODES AND REGULATIONS for speifi rules on inspeting the winh nd other equipment CHECK COMPONENT MANUFACTURER S INSTRUCTIONS for inspet ing the motor, rke, reduer, erings, wire rope, nd other equip ment In stru tions for Frequent Inspetion Perform frequent inspetions: Before eh opertion. Every 3 hours during opertion. Whenever you notie signs of dmge or poor opertion. Frequent Wire Rope Inspetion: Use ASME B30.7 s guideline for rope inspetion, replement nd mintenne. Chek the wire rope, end onnetions nd end fittings for orrosion, kinking, ending, rushing, irdging or other signs of dmge. Chek the numer, distriution nd type of visile roken wires. See prgrph nd Figure 7. Chek the wire rope for redution of rope dimeter from loss of ore support, or wer of outside wires. See Figure 9. Tke extr re when inspeting setions of rpid deteriortion suh s setions in ontt with sddles, sheves, repetitive pikup points, rossover points nd end onnetions. VISUALLY INSPECT the entire winh nd ll other equipment involved in the opertion. Chek ll equipment for rks, dents, ending, rust, wer, orrosion nd other dmge. Mke sure the wire rope is instlled orretly nd nhored seurely to the drum. Chek the reduer for signs of lekge. Mke sure the entire winh is properly lurited. Mke sure the rether plug is len, open, nd instlled orretly. Mke sure mounting fsteners re tightened seurely. Mke sure the foundtion is in good ondition, nd ple of supporting the winh nd its lod under ll lod onditions. Chek eletril wiring nd onnetions for wer, orrosion, uts, nd other dmge. Chek luth opertion, if pplile, to mke sure it moves freely nd engges om plete ly. TEST WINCH PERFORMANCE y operting the winh with lod not exeeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winh. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore ontinuing. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the winh responds to the ontrol devie. It must rotte s shown on the ontrol lels, nd it must turn off when you relese the ontrol. Chek the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod ontinues to ost or reep under norml operting onditions, the rke needs d just ment. Refer to rke mnufturer s instrutions.

14 pge 14 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes Perform periodi inspetions: Every 6 months. Whenever you return the winh to servie from storge. Whenever you notie dmge or poor opertion in frequent in spe tion. Whenever you hve, or think you my hve, overloded or shok loded the winh. Figure 6 Broken Wires wire strnd one ly Wire rope ssemly must e repled 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 Instrutions for Periodi Inspetion VISUALLY INSPECT the winh nd ll other equipment. Disssemly my e required in order to properly inspet individul omponents. Contt ftory for ssemly/disssemly instrutions. Disssemly of the gerox efore ontting Thern, In. voids ll wrrnties. Chek the finish for wer, flking, or other dmge. Chek ll equipment for rks, dents, ending, rust, wer, orrosion nd other dmge. If the equipment ws overloded, or if you notie rks nd other signs of overloding nd dmge, promptly remove equipment from use nd hve it repired or repled. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE ROPE. Chek ll fsteners for stripped threds, wer, ends, nd other dm ge. Chek the gerox for signs of lekge. Contt the ftory if there re ny signs of lurint leking from the gerox. Mke sure the rether plug is len, open nd instlled orretly. Remove gurds nd visully inspet spur gers for poor lignment, exes sive wer, or ro sion, nd other dmge. Mke sure ger teeth nd winh erings re properly lu ri t ed. Chek luth opertion, if pplile, to mke sure it moves freely nd engges om plete ly. Mke sure ll lels nd pltes re redle, firmly tthed, free of dmge nd len. Replements re ville from the ftory. DRAIN A SMALL AMOUNT OF LUBRICANT from the reduer into len ontiner. Chek the lurint for dirt, metl prtiles, wter, nd other signs of ontm i n tion. Completely drin the reduer if lurint is on tm i nt ed. Figure 7 Lod Hook Inspetion twist throt opening thikness The wire rope ssemly must e repled if the throt opening is 15% wider thn nominl, if the thik ness is 10% less thn nominl, or if the hook is twisted 10 or more. INSPECT THE WIRE ROPE ording to the wire rope mnufture's reommendtions or follow epted industry stndrds for wire rope inspetions. Alwys wer protetive lothing when hndling wire rope. Chek the entire length of wire rope for ent wires, rushed res, ro ken or ut wires, orrosion, nd other dmge. Crefully inspet res tht pss over sheves or through roller guides. Note the lotion nd onentrtion of roken wires. Reple wire rope if more thn 6 wires re roken in one ly, or more thn 3 wires re ro ken in one strnd in one ly. See Figure 6. Mke sure the lod hook, nhor fitting or other devies re seurely tthed to the wire rope, nd the wire rope where they re tthed is not fryed, orroded, ro ken, or otherwise dmged. Mesure the throt opening, thikness, nd twist of the hook. Reple the hook if it shows signs of dmge. See Figure 7. Mke sure hook lth opens without inding nd loses when relesed. Chek the nhor holes in the drum nd the surrounding re for signs of wer or distortion.

15 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge 15 Figure 8 Rope Dimeter dimeter d MOVE THE DRUM with your hnds. Chek for exessive movement inditing worn or loose gers or erings. Exessive movement is used y overloding or overheting, nd is sign tht your pplition my re quire lrger power winh. orret inorret Disssemle the winh if neessry. Inspet gers, keys, erings, sels, nd shfts for wer, distortion, nd other dmge. The wire rope ssemly must e repled if the dimeter mesures less thn the minimum dimeter t ny point. nominl wire rope dimeter up to 5/16 in mximum llowle redution from nominl dimeter 1/64 in (.0156 in) e f PLACE ENOUGH WEIGHT to keep the wire rope stright nd tightly drwn. Mesure the dimeter of the wire rope, espeilly in res where wer is notiele. Reple the wire rope if the dimeter mesures elow the minimum dimeter t ny point. See Figure 8. INSPECT FOUNDATION AND RIGGING. Chek mounting fsteners for stripped threds, wer, nd other dmge. up to 1/2 in up to 3/4 in up to 1-1/8 in up to 1-1/2 in 1/32 in (.0313 in) 3/64 in (.0469 in) 1/16 in (.0625 in) 3/32 in (.0938 in) g Chek the foundtion for rks, orrosion, nd other dmge. TEST WINCH PERFORMANCE y operting the winh with test lod equl to the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winh. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore ontinuing. Oserve the rotting drum, look for signs of loose or misligned er ings. Mke sure the winh responds to the ontrol devie. It must rotte s shown on the ontrol lels, nd it must turn off when you relese the ontrol. Mke sure the lod moves smoothly without hesittion or strin. Chek the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod ontinues to ost or reep under norml operting onditions, the rke needs d just ment. Refer to rke mnufturer s instrutions. h DISCONNECT ELECTRIC POWER nd inspet eletril equipment. Chek eletril wires for worn insultion, uts, orroded onnetions, nd other dmge. Chek voltge of eletril supply with UL pproved voltmeter. If voltge is low, hve liensed eletriin inspet the iruit. Mke sure the eletril ontrol ox is seurely instlled. Look inside the ontrol ox for signs of moisture, orrosion, urn mrks, rks, nd other dmge. i CONNECT ELECTRIC POWER. Chek power supply t the motor nd mke sure it grees with the motor rting. Do not operte the winh until proper power is supplied to the motor. Completely orret ll prolems efore ontinuing. Use the trou le shoot ing hrt to help determine the use of ertin prolems. See Tle 2.

16 pge 16 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes 3.4 Repiring the Winh Importnt! It is your responsiility to deter mine when to reple prts. When onsidering whether to ontinue using prt or to re ple it, re mem er tht repling it is the est wy to void further equip ment dmge. Appoint qulified person to e responsile for ll repirs to the equipment GET FACTORY AUTHORIZATION for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the winh REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repir prts REFINISH AREAS where the pint is worn or flking. A good finish helps to protet ginst orrosion nd wether dmge. REMOVE THE FINISH from dmged res, down to the re metl. CLEAN THE AREA thoroughly. REPAINT with high qulity primer nd finishing ot TO ORDER REPAIR PARTS, ontt your lol deler. Inlude the follow ing informtion when ordering: model numer seril numer (or ode numer) prt numer dte purhsed, nd from whom desription of wht hppened, or wht is wrong your nme nd return ddress

17 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge 17 Tle 1 Inspetion Cheklist heked oxes indite dmge or prolem in need of repir dmges prolems generl fi nish wethered, fl king, otherwise dmged winh jerks or hesittes during opertion prts rked, ent, rusted, worn, otherwise dmged unusul noises, other signs of mlfuntion fsteners stripped threds, ent, worn, otherwise dmged loose, not tightened to proper torque reduer gers, erings, or shfts loose, worn, otherwise dmged not properly lurited lurint lekge lurint ontminted spur gering gers, keys, or shfts loose, worn, otherwise dmged not properly lurited or ligned wire rope ent, rushed, otherwise dmged wire rope loosely or unevenly wound roken wires, see Figure 6 reple if more thn 6 wires in one ly, numer per strnd = or 3 wires in one strnd in one ly, re roken numer per ly = dimeter redued, see Figure 8 reple if dimeter is exessively worn dimeter = end onnetions orroded, rusted, worn, otherwise dmged not seurely tthed hook or other devie twisted, ent, worn, otherwise dmged, see Figure 7 hook lth fils to lose when relesed reple if twist is 10 degrees or more twist = reple if throt width is 15% lrger thn nominl throt width = reple if thikness is 10% less thn nominl thikness = drum nhor worn, distorted, otherwise dmged exessive movement or klsh motor motor orroded, urnt out, otherwise dmged motor is sluggish, or opertes poorly rke rke worn, orroded, otherwise dmged rke does not operte properly ontrol devie eletri omponents orroded, urnt, otherwise dmged fils to ontrol winh properly eletri iruit eletri wires worn, ut, orroded, otherwise dmged wires unproteted, ostruting trffi onnetions loose, orroded, otherwise dmged voltge t motor = lels nd pltes dirty, illegile, otherwise dmged loosely tthed or missing omments uthorized signture dte

18 pge 18 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes Tle 2 Trouleshooting Chrt Contt the ftory for ssemly/disssemly instrutions. Disssemly of the gerox efore ontting Thern, In. voids ll wrrnties. prolem use orretion motor won t run motor runs, drum doesn t turn motor tries to turn ut n t rke does not operte properly lurint lekge exessive end ply on drive shft exessively worn gers or erings overheting unusul noises high pithed squek grinding noise whining motor rttling noise hevy thump during opertion iruit reker tripped or fuse lown reset iruit reker or reple fuse eletril onnetions loose or dmged.....inspet, repir nd tighten s neessry eletri power supply filure ontt power ompny motor urnt out or dmged repir or reple s neessry loose or roken ger keys inspet nd reple s neessry loose, stripped or roken gers inspet nd reple s neessry unit overheted llow to ool lod too hevy lighten lod voltge t motor too low inspet supply iruit nd rewire s needed eletri rke not operting properly inspet nd repir s neessry gers or erings roken or loked inspet nd reple s neessry rke relese lever in relese position move to lok position voltge to rke inorret hek voltge t ontrol ox, repir s needed rke djusted inorretly djust rke rke diss or solenoid worn or dmged....inspet nd reple s neessry rke omponents seized up or dmged....inspet nd repir s neessry worn erings inspet nd reple s neessry dmged oil sels or gskets inspet nd reple s neessry rked or dmged reduer inspet nd repir s neessry loose or dmged keys or keywys inspet nd reple s neessry exessively worn gers inspet nd repir s neessry lod too hevy lighten lod poor lurition of reduer or erings inspet nd lurite s neessry operted too long without rest llow to ool lod too hevy lighten lod poor lurition inspet nd lurite s neessry rether plug logged or dmged len or reple vent plug s needed ering seized up inspet nd reple s neessry poor lurition inspet nd lurite s neessry ontminted lurition drin, len nd lurite the winh roken gers or erings inspet nd reple s neessry lod too hevy lighten lod motor overheted llow to ool motor erings urnt out reple motor or erings loose fsteners or set srews tighten ll fsteners nd srews worn or loose drg rke inspet nd repir or tighten s neessry ontminnts in lurint drin, len nd lurite the winh loose set srews or keys in gers or shfts...inspet nd repir s neessry erings defetive inspet nd reple s neessry

19 Owner's Mnul for Thern 4WS nd 4HS Series Power Winhes pge Trnsporting the Winh Importnt! Keep reord of wht you ship, nd when you send it REMOVE THE BREATHER PLUG nd instll seled plug to prevent the loss of lu ri tion during shipment. If seled plug is not ville, mke sure tht the rether plug is loted t the upper most plug lotion to prevent lurint from leking out PACK THE WINCH in n upright position for trnsport, using the originl pkging mterils, if possile. d FASTEN THE WINCH to wooden se using olts, to keep it from moving during trnsport. SEAL THE WINCH in plsti with desint to help protet it from rust, orrosion, nd other dmge. CONSTRUCT WOODEN SIDES nd top to enlose the winh in solid pro te tive rte. PACK LOOSE PARTS in smll ox es or ship seprtely INSPECT THE WINCH ording to the Instrutions for Periodi In spe - tion efore instlling it in new lotion. 4.2 Storing the Winh FILL THE REDUCER with lurint, nd mke sure the rether plug is len nd properly instlled. Add rust preventtive for long term storge. Follow the reduer mnufturer s instrutions SEAL THE WINCH in plsti with desint to help protet it from rust, orrosion, nd other dmge STORE THE WINCH upright, in ool len ple wy from orrosive hem i ls nd moisture ROTATE THE DRUM PERIODICALLY to keep ering nd gers sur f es from eoming lquered. Relese the rke to rotte the drum INSPECT THE WINCH ording to the Instrutions for Periodi In spe - tion efore instlling it for opertion TEST INSULATION RESISTANCE in the motor to detet mois ture dmge. Refer to the motor mnufturer s in stru tions DRAIN THE REDUCER nd fill with proper lurint prior to opertion. See setion 3.2 Luriting the Winh.