Red this Owner s Mnul thoroughly efore operting the equipment. Keep it with the equipment t ll times. Replcements re ville from Thern, Inc., PO Box 347, Winon, MN 55987, 507-454-2996. www.thern.com IMPORTANT: Plese record product informtion on pge 2. This informtion is required when clling the fctory for service. ORIGINAL TEXT Owner s Mnul For M452 nd M492 Series Spur Ger Hnd Winches
pge 2 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Two-Yer Limited Wrrnty Plese record the following: Dte Purchsed: Model No.: Code No.: This informtion is required when clling the fctory for service. Thern, Inc. wrrnts its products ginst defects in mteril or workmnship for two yers from the dte of purchse y the originl using uyer, or if this dte cnnot e estlished, the dte the product ws sold y Thern, Inc. to the deler. To mke clim under this wrrnty, contct the fctory for n RGA numer. The product must e returned, prepid, directly to Thern, Inc., 5712 Industril Prk Rod, Winon, Minnesot 55987. The following informtion must ccompny the product: the RGA numer, the dte of purchse, the description of the climed defect, nd complete explntion of the circumstnces involved. If the product is found to e defective, it will e repired or replced free of chrge, nd Thern, Inc. will reimurse the shipping cost within the contiguous USA. This wrrnty does not cover ny dmge due to ccident, misuse, use, or negligence. Any ltertion, repir or modifiction of the product outside the Thern, Inc. fctory shll void this wrrnty. This wrrnty does not cover ny costs for removl of our product, downtime, or ny other incidentl or consequentil costs or dmges resulting from the climed defects. This wrrnty does not cover rke discs, wire rope or other wer components, s their life is suject to use conditions which vry etween pplictions. FACTORY AUTHORIZED REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY TO THE CONSUMER. THERN, INC. SHALL NOT BE LIABLE FOR ANY 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 ove limittion or exclusion my not pply to you. This wrrnty gives you specific legl rights, nd you my lso hve other rights which vry from stte to stte. Note: Thern, Inc. reserves the right to chnge the design or discontinue the production of ny product without prior notice. Aout This Mnul The Occuptionl Sfety nd Helth Act of 1970 sttes tht it is the employer s responsiility to provide workplce free of hzrd. To this end, ll equipment should e instlled, operted, nd mintined in complince with pplicle trde, industril, federl, stte, nd locl regultions. It is the equipment owner's responsiility to otin copies of these regultions nd to determine the suitility of the equipment to its intended use. This Owner s Mnul, nd wrning lels ttched to the equipment, re to serve s guidelines for hzrd-free instlltion, opertion, nd mintennce. They should not e understood to prepre you for every possile sitution. The informtion contined in this mnul is pplicle only to the Thern Model M452 nd M492 Spur Ger Hnd Winches. Do not use this mnul s source of informtion for ny other equipment. The following symols 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.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 3 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 lels ttched to the winch, redle nd with the equipment t ll times. Contct Thern, Inc. for replcements. Check luriction efore use. Instll the wire rope securely to the winch drum. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. Filure to do so could cuse the lod to escpe. Keep hnds wy from the drum, gers, wire rope, nd other moving prts of the equipment. Keep ll unnecessry personnel wy from the winch while in opertion. Keep out of the pth of the lod nd out of the pth of roken wire rope tht might snp ck nd cuse injury. DO NOT do the following: Do not lift people, or things over people. Do not wlk or work under lod or in the line of force of ny lod. Do not exceed the lod rting of the winch or ny other component in the system. Do not operte with other thn mnul power. Do not use more thn one winch to move lod unless ech winch ws designed for use in multiple winch system. Do not use dmged or mlfunctioning equipment. To do so could result in filure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equipment filure. Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use sling or other pproved rigging device. Do not operte the winch with gurds removed or improperly instlled. Do not divert your ttention from the opertion. Sty lert to the possiility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stopping the lod smoothly. Shock lods overlod the equipment nd my cuse dmge. Do not lift lods or pull lods on n incline unless the winch is equipped with rke. Do not leve suspended lod unttended unless specific precutions hve een tken to secure the lod nd keep people wy from the winch nd from under the lod.
pge 4 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches 1.1 Instlling the Winch Importnt! Inspect the winch immeditely following instlltion ccording to the Instructions for Periodic Inspection. This will give you record of the condition of the winch with which to compre future inspections. A qulified professionl should inspect or design the foundtion to insure tht it will provide dequte support. Locte the winch so it will e visile during the entire opertion. Do not instll the winch in n re defined s hzrdous y the Ntionl Electric Code, unless instlltion in such n re hs een thoroughly pproved. Do not instll the winch ner corrosive chemicls, flmmle 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 roken wire rope tht could snp ck nd cuse injury. Attch the winch to rigid nd level foundtion tht will support the winch nd its lod under ll lod conditions, including shock loding. 1.1.1 Consult pplicle codes nd regultions for specific rules on instlling the equipment. 1.1.2 Locte the winch in n re cler of trffic nd ostcles tht could interfere with opertion. Mke sure the winch is ccessile for mintennce nd opertion. 1.1.3 Mintin fleet ngle etween 1/2 nd 1-1/2 degrees. The proper fleet ngle minimizes wire rope dmge y helping the wire rope wind uniformly onto the drum. See Figure 1. 1.1.4 Fsten the winch securely to the foundtion. FOR STANDARD PRODUCTS referred to in this mnul, use 1/2 inch corse thred fsteners, grde 5 or etter, torque dry to 75 ft l without luriction for the M452 series. Use 3/4 inch corse thred fsteners, grde 5 or etter, torque dry to 260 ft l without luriction for M492 series. Mke sure the winch is secured to solid foundtion sed on ccepted engineering prctices. non-stndrd products tht vry from the originl design my hve different fstening requirements. Contct structurl engineer or Thern, Inc. for this informtion. To comply with locl codes, contct qulified professionl to otin proper structure or foundtion specifictions for the mounting of thern products.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 5 1.2 Instlling the Wire Rope Importnt! Use wire rope nd other rigging equipment rted for the size of the lrgest lod you will e moving. Do not drg the wire rope through dirt or deris tht could cuse dmge, or poor opertion. Alwys wer protective clothing when hndling wire rope. Instll the wire rope so it is wound correctly s shown, or the winch will not work properly, nd the lod could escpe. See Figure 3. Instll the wire rope securely to the winch drum. A poorly secured wire rope could come loose from its nchor nd llow the lod to escpe. Do not operte the winch unless the hirpin clip is ssemled to the shft. 1.2.1 Purchse the proper wire rope for your ppliction. Keep the following in mind when selecting wire rope. Contct reputle wire rope supplier for help. c Breking strength of new wire rope should e t lest 3 times greter thn the lrgest lod plced on the winch. If lods re lifted or pulled on n incline, the reking strength must e t lest 5 times greter thn the lrgest lod. These re minimum vlues nd will vry with the type of lod nd how you re moving it. Wire rope ly must gree with the winding direction of the drum to help insure proper winding. We recommend 7 x 19 glvnized ircrft cle for dimeters up to 5/16 inch, nd 6 x 37 IWRC improved plow steel wire rope for dimeters of up to 3/4 inch. (A mximum rope dimeter of 1/2 inch is recommended due to the drum dimeter.) Importnt! Use sheve or roller guide to direct the wire rope to the drum whenever possile. Instll sheves, trcks nd other equipment so they will remin fixed under ll lod conditions. Follow the recommendtions of the equipment mnufcturer. Use sheves of proper dimeter to minimize wer on the wire rope. Follow the recommendtions of the sheve mnufcturer. Figure 1 Mintining the Fleet Angle When wire rope trvels over sheve or through roller guide mintin fleet ngle y locting the sheve or guide n pproprite distnce from the drum, shown s distnce A. fixed sheve or roller guide distnce A smooth drum 1/2 to 1-1/2 degrees center line When wire rope trvels directly to the lod mintin fleet ngle y controlling sideto-side movement of the lod with trcks or guide rils. Allowing the lod to move too fr to one side cuses stress on the drum flnge which my cuse dmge. lod smooth drum 1/2 to 1-1/2 degrees center line trcks or guide rils
pge 6 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Figure 2 Cotter Pins 1.2.2 Instll the hndle. Plce the hndle weldment on the drum shft nd instll the hir pin clip to hold it in plce. The hir pin clip fits in the groove in the drum shft. end rms ck c Loosen the set screws in the hndle weldment, remove the cotter pin from the end of the hndle ssemly nd insert it in the hndle weldment. Adjust hndle length to suit the opertion nd tighten the set screws. Shorten hndle length for light lods or quick opertion. Increse hndle length for hevy lods or slow opertion. Insert the cotter pin in the end of the hndle nd end the rms ck to secure it in plce. See Figure 2. Figure 3 Wire Rope Instlltion instll the wire rope so it is underwound on the drum s shown 1.2.3 INSTALL THE HAND WHEEL (Optionl line item offered y Thern). REMOVE THE HAIRPIN CLIP from the end of the drum shft. REMOVE THE HANDLE ASSEMBLY nd the flt hndle weldment from the drum shft. c d e SLIDE THE HAND WHEEL onto the shft until the ger teeth re completely meshed. REPLACE THE HAIRPIN CLIP. KEEP THE HAIRPIN CLIP in plce t ll times to prevent the Hnd Wheel from ccidentlly ecoming disengged from the winch. 1.2.4 Anchor the wire rope to the winch drum. See Figure 3. Pss the end of the wire rope through the nchor hole, until t lest 1/2 inch of rope extends out the other side. M452 tighten set screw Tighten the set screw until it flttens the wire rope ginst the nchor hole. Use enough force to drive the point of the set screw securely into the wire rope. 1.2.5 Turn the hndle clockwise to wind wire rope onto the drum. If wire rope unwinds from the drum when the hndle is rotted clockwise, the wire rope is instlled incorrectly. Instll the wire rope correctly efore continuing. 1.2.6 Wind four full wrps of wire rope onto the drum y operting the winch while holding the wire rope tught. These wrps serve s nchor wrps nd must remin on the drum t ll times. M492
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 7 2.1 Generl Theory of Opertion Importnt! Limit nonuniform winding y keeping tension on the wire rope nd y mintining the proper fleet ngle. It is your responsiility to detect nd ccount for different fctors ffecting the condition nd performnce of the equipment. 2.1.1 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. 2.1.2 This equipment cn develop forces tht will exceed the lod rting. It is the responsiility of the equipment user to limit the size of the lod. Inspect the equipment regulrly for dmge ccording to the instructions contined in this mnul. 2.1.3 Use disc rke on ll hnd winches used to lift lods or pull lods on n incline. 2.1.4 Performnce rtings of the equipment re ffected y the mount of wire rope wound on the drum, the wy in which it is wound, nd the wy the winch is used. c Drum cpcity depends on how tightly nd evenly the wire rope is wound on the drum. Actul drum cpcities re usully 25-30% less thn vlues shown in performnce Tles, due to loose winding nd overlpping. Force required to lift the lod increses with ech dditionl lyer of wire rope wound onto the drum. The vlue shown in performnce Tles is sed on n empty drum, nd mximum hndle length. Lod rting represents the mximum pull tht cn e plced on new equipment. Lod rtings re ssigned vlues for specific mounts of lod trvel or wire rope ccumultion. The lod rting decreses s lyers of wire rope ccumulte on the drum. 2.1.5 Duty rtings refer to the type of use the equipment is suject to. Consider the following when determining duty rting. c d Environment: hrsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from hrsh environments when possile. mintennce: poor mintennce, mening poor clening, luriction, or inspection, leds to poor opertion nd possile dmge of the equipment. Minimize poor mintennce y crefully following the instructions contined in this mnul. loding: 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 Opertion: frequent or lengthy opertions increse wer nd shorten the life spn of gers, erings, nd other components. Increse mintennce of the equipment if used in frequent opertions. Contct the fctory for more informtion.
pge 8 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches 2.3 Breking-In the Winch 2.3.1 Brek-in occurs during the first 10 hours of norml opertion. During rek-in, mting surfces ecome polished, nd clernces increse. This is desired for efficient opertion of erings nd gers. 2.3.2 Inspect the winch following rek-in ccording to the Instructions for Periodic Inspection. 2.4 Prepring for Opertion Importnt! When determining whether the lod will exceed the lod rting, consider the totl force required to move the lod. 2.4.1 Consider the opertion. Do not egin until you re sure you cn perform the entire opertion without hzrd. 2.4.2 Inspect ll components of the system. Inspect the winch nd other equipment ccording to the Instructions for Frequent Inspection. Opertors must e in good helth, lert, thoroughly trined in operting the equipment, nd properly clothed (hrd ht, sfety shoes nd sfety glsses, no loose clothing). c The lod must e cler of other ojects nd free to move. Mke sure the lod will not tip, spin, roll wy, or in ny wy move uncontrollly. 2.4.3 Know your lod nd mke sure you do not exceed the lod rting of the winch or ny other equipment in the system. 2.5 Attching the Lod Figure 4 Attching Lod ltch closed tight ginst hook Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use sling or other pproved lifting device. 2.5.1 Cler ojects from the pth of the lod so you cn move it freely nd oserve it t ll times during the opertion. 2.5.2 Attch the lod using nylon sling, or other pproved lifting device. Follow the recommendtions of the sling mnufcturer. sling seted in sddle of hook Set the sling in the sddle of the hook with the hook ltch completely closed. See Figure 4. Center the lod on the hook so it will remin lnced nd not tip or rotte to one side.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 9 2.6 Moving the Lod Importnt! Oey stop signl from nyone. Mintin tension on the wire rope to keep it tightly nd evenly wound on the drum. If the winch nd lod re not visile during the entire 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 lod, use tg line to keep the lod from swinging or twisting, while keeping yourself wy from the lod. Remove the winch hndle when the winch is not in use, to help void unuthorized use. Do not use the hndle or hnd wheel s rke or nchor for lod. 2.6.1 Engge the rtchet when winding wire rope onto the drum, disengge the rtchet to unwind the wire rope. Do not engge the rtchet while the winch gers re turning. Stop the winch efore engging the rtchet. Disengge the rtchet y moving the lod slightly to remove pressure from the rtchet, then pull out nd turn the rtchet kno 90 degrees. 2.6.2 Turn the hndle or Hnd wheel clockwise to wind wire rope onto the drum. If wire rope unwinds from the drum when the hndle is rotted clockwise, the wire rope is instlled incorrectly. Instll the wire rope correctly efore continuing. 2.6.3 Move the lod slowly nd smoothly, only smll distnce t first. Mke sure the lod is lnced nd securely ttched efore continuing. Mke sure you re not in line with cle movement. Grip the hndle tightly t ll times during opertion. When using the wheel, grip the wheel rim tightly using oth hnds. Do not gr the spokes or rech etween the spokes. c If you relese the hndle or hnd wheel on units not equipped with disc rke, the lod my ckdrive cusing it to spin. Do not try to stop spinning hndle or wheel, step cler until the spinning stops. 2.6.4 Oserve the wire rope s it winds onto the drum. If it ecomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope efore continuing. Continued opertion with overlpped or uneven wire rope cn dmge the wire rope nd shorten its life. 2.6.5 TO QUICKLY WIND OR UNWIND unloded wire rope, move the hndle to or instll the hnd wheel on the countershft. Do not ttempt to move lod with the hndle or hnd wheel instlled on the countershft. When using the hnd wheel, the hirpin clip cnnot e ssemled to the winch. To prevent losing the clip, leve it ttched to the drum shft until you re redy to reposition the hnd wheel ck to the drum shft.
pge 10 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches 3.1 Clening the Winch Importnt! Increse the frequency of mintennce procedures if the winch is: Operted for long periods. Used to pull hevy lods. Operted in wet, dirty, hot, or cold surroundings. Clen the winch to remove dirt nd help prevent rust nd corrosion. 3.1.1 Clen the winch every six months or whenever it is dirty. c Wipe ll equipment to remove dirt nd grese. Leve light film of oil on ll surfces to protect them ginst rust nd corrosion. Wipe off excessive mounts of oil to void the ccumultion of dirt. 3.1.2 Remove ll unnecessry ojects from the re surrounding the winch. 3.2 Luricting the Winch Importnt! Mke sure luricnt hs temperture rting pproprite for the mient tempertures of the opertion. Luricte the spur gers efore ech opertion, nd periodiclly during opertion. Filure to luricte the gers will cuse dmge or deformtion of ger teeth. Luricte the winch properly to help protect it from wer nd rust. Red the following instructions crefully. 3.2.1 Consult mnufcturer s recommendtions for specific informtion on luricting the wire rope nd other equipment. 3.2.2 Luricte winch erings nd shfts t lest every 6 months. c Apply 2 to 3 drops of SAE 30 non-detergent oil to erings nd shfts t ll friction points. Rotte the drum severl times to llow the oil to penetrte, nd wipe off excess oil to void ccumultion of dirt. DO NOT LUBRICATE the hnd wheel when in use. You need it dry for secure grip. 3.2.3 Luricte winch gers efore every opertion nd t lest every 10 hours during opertion. Apply light film of open ger luricnt to the ger teeth on ll gers. Use Spryon S00201 or equivlent open ger lue. For dirty conditions use dry luricnt such s dry grphite or Moly. 3.2.4 Luricte the wire rope nd other equipment y following the mnufcturer s recommendtions.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 11 3.3 Inspecting the Equipment Importnt! Strt n inspection progrm s soon s you put the winch into use. Appoint qulified person to e responsile for regulrly inspecting the equipment. Keep written records of inspection. This llows comprison with comments from previous inspections so you cn see chnges in condition or performnce. Perform frequent inspections: Before ech opertion. Every 3 hours during opertion. Whenever you notice signs of dmge or poor opertion. Frequent Wire Rope Inspection: Use ASME B30.7 s guideline for rope inspection, replcement nd mintennce. Check the wire rope, end connections nd end fittings for corrosion, kinking, ending, crushing, irdcging or other signs of dmge. Check the numer, distriution nd type of visile roken wires. See prgrph 3.3.4 nd Figure 5. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 7. Tke extr cre when inspecting sections of rpid deteriortion such s sections in contct with sddles, sheves, repetitive pickup points, crossover points nd end connections. Do not use dmged or mlfunctioning equipment. Plce n OUT OF ORDER sign on the winch. Do not use the winch until the sign is removed y qulified mintennce person who hs completely corrected the prolem. Inspect the winch to detect signs of dmge or poor opertion efore they ecome hzrdous. See Tle 1. 3.3.1 Consult pplicle codes nd regultions for specific rules on inspecting the winch nd other equipment. 3.3.2 Consult mnufcturer s recommendtions for informtion on inspecting the wire rope nd other equipment. 3.3.3 Instructions for Frequent Inspection Visully inspect the entire winch nd ll other equipment involved in the opertion. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. Mke sure the wire rope is instlled correctly nd nchored securely to the drum. Mke sure the winch is properly luricted. Mke sure the set screws holding the hndle in plce re tight, nd the hir pin clip is instlled. Mke sure mounting fsteners re tightened securely. Mke sure the foundtion is in good condition, nd cple of supporting the winch nd its lod under ll lod conditions. Test winch performnce y moving test lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Mke sure the hndle rottes freely in oth directions. Mke sure the rtchet engges nd disengges completely. If equipped with rke, check the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep under norml operting conditions, the rke needs repir or replcement. Contct Thern, Inc. Completely correct ll prolems efore continuing. Use the Trouleshooting Chrt to help determine the cuse of certin prolems. See Tle 2.
pge 12 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Perform periodic inspections: Every 6 months. Whenever you return the winch to service from storge. Whenever you notice dmge or poor opertion in frequent inspection. Whenever you hve, or think you my hve, overloded or shock loded the winch. Figure 5 Broken Wires wire strnd one ly Wire rope ssemly must e replced if more thn 6 wires re roken in one ly, or if more thn 3 wires re roken in one strnd in one ly. Figure 6 Lod Hook Inspection twist throt opening 3.3.4 Instructions for Periodic Inspection c Visully inspect the winch nd ll other equipment. Check the finish for wer, flking, or other dmge. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. If the equipment ws overloded, or if you notice crcks or other signs of overloding nd dmge, promptly remove equipment from use nd hve it repired or replced. Do not continue to use dmged or overloded equipment or wire rope. Check ll fsteners for striped threds, wer, ending, nd other dmge. Check the foundtion for crcks, corrosion, nd other dmge. Mke sure the winch is properly luricted. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. Inspect the wire rope ccording to the wire rope mnufcture's recommendtions or follow ccepted industry stndrds for wire rope inspections. Alwys wer protective clothing when hndling wire rope. Check the entire length of wire rope for ent wires, crushed res, roken or cut wires, corrosion, nd other dmge. Crefully inspect res tht pss over sheves or through roller guides. Note the loction nd concentrtion of roken wires. Replce wire rope if more thn 6 wires re roken in one ly, or more thn 3 wires re roken in one strnd in one ly. See Figure 5. Mke sure the lod hook, nchor fitting or other devices re securely ttched to the wire rope, nd the wire rope where they re ttched is not fryed, corroded, roken, or otherwise dmged. Mesure the throt opening, thickness, nd twist of the hook. Replce the hook if it shows signs of dmge. See Figure 6. Mke sure hook ltch opens without inding nd closes when relesed. Check the nchor holes in the drum nd the surrounding re for signs of wer or distortion. move the drum with your hnds. Check for excessive movement indicting worn or loose gers, erings, or shfts. Slight endply in the driveshft is norml. Excessive movement is cused y overloding or overheting, nd is sign tht your ppliction my require lrger winch. thickness The wire rope ssemly must e replced if the throt opening is 15% wider thn nominl, if the thickness is 10% less thn nominl, or if the hook is twisted 10 or more. d e Plce enough weight to keep the wire rope stright nd tightly drwn. Mesure the dimeter of the wire rope, especilly in res where wer is noticele. Replce the wire rope if the dimeter mesures elow the minimum dimeter t ny point. See Figure 7. Remove the winch from the foundtion. Check fsteners for stripped threds, wer, ends, nd other dmge. Check the frme for ending, distortion, crcks nd other dmge. A ent frme is cused y overloding, nd is sign tht your ppliction my require winch with lrger lod rting.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 13 Figure 7 Rope Dimeter correct dimeter incorrect The wire rope ssemly must e replced if the dimeter mesures less thn the minimum dimeter t ny point. wire rope size minimum dimeter 1/8 in 7/64 in (.1094 in) 3/16 in 11/64 in (.1719 in) 1/4 in 15/64 in (.2344 in) 5/16 in 19/64 in (.2969 in) 3/8 in 11/32 in (.3438 in) 1/2 in 15/32 in (.4688 in) 5/8 in 37/64 in (.5781 in) 3/4 in 45/64 in (.7031 in) f Test winch performnce y operting the winch with lod equl to the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Oserve the rotting drum, look for signs of loose or misligned erings. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the hndle rottes freely in oth directions. Mke sure the rtchet engges nd disengges completely. If equipped with rke, check the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep under norml operting conditions, the rke needs repir or replcement. Contct Thern, Inc. Completely correct ll prolems efore continuing. Use the trouleshooting chrt to help determine the cuse of certin prolems. See Tle 2. Tle 1 Inspection Checklist checked oxes indicte dmge or prolem in need of repir dmges prolems generl finish wethered, flking, otherwise dmged winch jerks or hesittes during opertion prts crcked, ent, rusted, worn, otherwise dmged unusul noises, other signs of mlfunction fsteners stripped threds, ent, worn, otherwise dmged loose, not tightened to proper torque gers excessively worn, crcked, corroded, otherwise dmged loose or improperly luricted rtchet rtchet corroded, crcked, worn, otherwise dmged rtchet does not engge or disengge rke ssemly rke corroded, crcked, worn, otherwise dmged rke does not operte properly drum nchor hole worn, distorted, otherwise dmged excessive movement or cklsh wire rope ent, crushed, otherwise dmged wire rope loosely or unevenly wound roken wires, see Figure 5 replce if more thn 6 wires in one ly, numer per strnd = or 3 wires in one strnd in one ly, re roken numer per ly = dimeter reduced, see Figure 7 replce if dimeter is excessively worn dimeter = end connections corroded, rusted, worn, otherwise dmged not securely ttched lod hook twisted, ent, worn, otherwise dmged, see Figure 6 hook ltch fils to close when relesed replce if twist is 10 degrees or more twist = replce if throt width is 15% lrger thn nominl throt width = replce if thickness is 10% less thn nominl thickness = lels nd pltes dirty, illegile, otherwise dmged loosely ttched or missing comments: uthorized signture: dte
pge 14 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Tle 2 Trouleshooting Chrt Contct the fctory for detiled instructions if you re required to disssemle the winch or rke for ny reson. Disssemly of the winch or rke efore contcting Thern, Inc. voids ll wrrnties. prolem cuse correction hndle turns, drum doesn't turn loose or roken spring pins...inspect winch nd rke, repir s necessry loose, stripped or roken gers...inspect gers nd repir s necessry hndle turns hrd or not t ll rtchet on winch engged...disengge winch rtchet lod too hevy...lighten lod spring pins loose or roken on winch or rke...inspect winch nd rke, repir s necessry disc rke dmged or locked...inspect rke, repir s necessry gers or erings roken or locked...inspect nd repir s necessry rke does not operte properly friction discs worn or dmged...inspect nd replce s necessry friction discs dmged from over luriction...inspect nd replce s necessry disc rke rtchet pwl dmged...inspect nd repir s necessry excessively worn gers or erings lod too hevy...lighten lod (excessive cklsh) poor luriction of gers or erings...inspect nd reluricte s necessry overheting operted too long without rest...llow to cool lod too hevy...lighten lod poor luriction...inspect nd luricte s necessry ering seized up...inspect nd replce s necessry unusul noises high pitched squek poor luriction...inspect nd reluricte s necessry grinding noise contminted luriction...clen nd reluricte winch dirt in rke or winch gers...inspect nd clen s necessry roken gers or erings...inspect nd replce s necessry rttling noise loose olts, set screws or other fsteners...tighten ll olts nd other fsteners uneven clicking noise in rke roken ger tooth in rke...inspect nd repir s necessry wek clicking noise in rke spring or rtchet pwl dirty or dmged...inspect nd clen or repir s necessry worn rke rtchet pwl, ger, or spring...inspect nd replce s necessry no clicking noise in rke rtchet incorrectly instlled...disssemle nd instll correctly rtchet pwl dmged or worn excessively...inspect nd replce s necessry
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 15 3.4 Repiring the Winch Importnt! It is your responsiility to determine when to replce prts. When considering whether to continue using prt or to replce it, rememer tht replcing it is the est wy to void further equipment dmge. Replce ll spring pins nd retining rings when you disssemle the winch or rke for repir or replcement. Appoint qulified person to e responsile for ll repirs to the equipment. 3.4.1 Get fctory uthoriztion for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the winch. 3.4.2 Replce dmged or poorly operting prts with Thern repir prts. 3.4.3 Refinish res where the pint is worn or flking. A good finish helps to protect ginst corrosion nd wether dmge. c Remove the finish from dmged res, down to the re metl. Clen the re thoroughly. Repint with high qulity primer nd finishing cot. 3.4.4 To order repir prts, contct your locl deler. Include the following informtion when ordering: model numer seril numer (or code numer) prt numer dte purchsed, nd from whom description of wht hppened, or wht is wrong your nme nd return ddress 4.1 Trnsporting the Winch Importnt! Keep record of wht you ship, nd when you send it. 4.1.1 Pck the winch using the originl pckging mterils, if possile. 4.1.2 Sel the winch in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. 4.1.3 Inspect the winch ccording to the Instructions for Periodic Inspection efore instlling it in new loction. 4.2 Storing the Winch 4.2.1 Sel the winch in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. 4.2.2 Store the winch in cool clen plce wy from corrosive chemicls nd moisture. 4.2.3 Rotte the drum periodiclly to keep ering nd gers surfces from ecoming lcquered. 4.2.4 Inspect the winch ccording to the Instructions for Periodic Inspection efore instlling it for opertion.
pge 16 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Spur Ger Hnd Winch Model M452 item description prt numer qty. 1 DRUM C1022 1 2 FRAME D1001 1 3 HEX JAM NUT NYLK.312-18NC SST A4379 2 4 CAPSCREW HEXHD.312-18NC X.625 SST A4170 2 5 BEARING HOUSING ASSEMBLY A1442 2 6 COUNTERSHAFT B1381 1 7 RADIAL BALL BEARING 1.00ID X 2.00OD X.75 STL A1439 2 8 RETAINING RING EXT 1.000 SST A4381 2 9 PINION 2.25OD X 2.0PD X 1.71RD A5388 1 10 SET SCREW SOKHD NYLK.250-20NC X.250 SST A3943 1 11 KEY.250 X.250 X 1.750 A5394 1 12 KEY.250 X.250 X 1.250 A5393 1 13 COUNTERSHAFT GEAR C1102 1 14 SET SCREW SOKHD NYLK.375-16NC X.625 SST A3948 2 15 FLAT HANDLE ASSEMBLY B1181 1 16 HAIR PIN CLIP.750 X.093 DIA SST A4380 1 17 DRUM SHAFT B1047 1 18 COTTER PIN.187 X 1.250 SST A4309 1 19 HANDLE ASSEMBLY B1045 1 20 RATCHET PIN A1624 1 21 SLOTTED SPRING PIN.156 X.750 SST A4277 2 22 COMPRESSION SPRING.658OD X.048WD X 1.000 SST A1397 2 23 RATCHET PIN KNOB A1620 1 24 SLOTTED SPRING PIN.156 X 1.500 SST A4278 1 25 SET SCREW SQHD.312-18NC X.500 SST A4266 1 26 HANDLE GRIP A1043 1 27 BRAKE HANDLE B1173 1 28 BRAKE BAND ASSEMBLY C1104 1 29 FLAT WASHER SMALL OD.312 X.750 SST A2941 1 30 WASHER HELSPRLK.312 X.596 X.078 SST A3936 1 31 BRAKE HANDLE BUSHING A1438 1 32 HEX NUT.312-18NC SST A4324 1 33 LABEL LOAD RATING A7526 1 34 LABEL CAUTION A2175 1 35 LABEL CODE 10477 1 36 LABEL WARNING A1979 1 37 LABEL OIL A2176 2 38 LABEL CABLE TAKEUP A1923 1 39 LABEL WARNING A2691 1
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 17 37 7 6 5 3 4 2 1 8 9 10 11 14 37 38 12 8 13 19 18 39 15 16 17 26 21 22 20 23 24 27 28 29 30 31 32 33 34 35 36 25
pge 18 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Spur Ger Hnd Winch Model M452B 1 item description prt numer qty. 1 DRUM C1022 1 2 FRAME D1001 1 3 HEX JAM NUT NYLK.312-18NC SST A4379 2 4 CAPSCREW HEXHD.312-18NC X.625 SST A4170 2 5 DRUM SHAFT B1047 1 6 BEARING HOUSING ASSEMBLY A1442 2 7 COUNTER SHAFT B1381 1 8 BALL BEARING RAD 1.00ID X 2.00OD X.75 STL A1439 2 9 RETAINING RING EXT 1.000 SST A4381 2 10 PINION A5388 1 11 SET SCREW SOKHD NYLK.250-20NC X.250 SST A3943 1 12 KEY.250 X.250 X 1.750 A5394 1 13 KEY.250 X.250 X 1.250 A5393 1 14 COUNTERSHAFT GEAR C1102 1 15 SET SCREW SOKHD NYLK.375-16NC X.625 SST A3948 2 16 BRAKE SUBASSEMBLY C2731 1 17 HANDLE ASSEMBLY B1015 1 18 COTTER PIN.187 X 1.250 SST A4309 1 19 RATCHET PIN A1624 1 20 SLOTTED SPRING PIN.156 X.750 SST A4277 2 21 COMPRESSION SPRING.658OD X.048WD X 1.000 SST A1397 2 22 RATCHET PIN KNOB A1620 1 23 SLOTTED SPRING PIN.156 X 1.500 SST A4278 1 24 HAIR PIN CLIP.750 X.093 DIA SST A4380 1 25 LABEL LOAD RATING A2169 1 26 LABEL CAUTION A2175 1 27 LABEL CODE 10477 1 28 LABEL WARNING A1979 1 29 LABEL OIL A2176 2 30 LABEL CABLE TAKEUP A1923 1 1 See Hnd Operted Disc Brke mnul (A6191) for rke informtion.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 19 8 7 6 5 29 2 3 4 1 9 10 11 12 13 9 14 29 30 15 16 17 18 19 22 23 20 21 26 27 25 24 28
pge 20 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Spur Ger Hnd Winch Model M452B-A 1 item description prt numer qty. 1 DRUM C2727 1 2 FRAME D1487 1 3 HEX JAM NUT NYLK.312-18NC SST A4379 2 4 CAPSCREW HEXHD.312-18NC X.625 SST A4170 2 5 SET SCREW SOKHD NYLK.375-16NC X.625 SST A3948 2 6 BRAKE SUBASSEMBLY C2731 1 7 HANDLE ASSEMBLY B1015 1 8 COTTER PIN.187 X 1.250 SST A4309 1 9 BEARING HOUSING ASSEMBLY A1442 2 10 DRUM SHAFT B2776 1 11 BALL BEARING RAD 1.00ID X 2.00OD X.75 STL A1439 2 12 COUNTER SHAFT B2775 1 13 RETAINING RING EXT 1.000 SST A4381 2 14 KEY.250 X.250 X 1.750 A5394 1 15 PINION 2.25OD X 2.0PD X 1.71RD A5388 1 16 SET SCREW SOKHD NYLK.250-20NC X.250 SST A3943 1 17 KEY.250 X.250 X 1.250 A5393 1 18 COUNTERSHAFT GEAR C1102 1 19 HAIR PIN CLIP.750 X.093 DIA SST A4380 1 20 LABEL LOAD RATING A7609 1 21 LABEL CAUTION A2175 1 22 LABEL CODE 10477 1 23 LABEL WARNING A1979 1 24 LABEL OIL A2176 2 25 LABEL CABLE TAKEUP A1923 1 1 See Hnd Operted Disc Brke mnul (A6191) for rke informtion.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 21 15 16 13 14 12 11 10 24 9 3 4 2 1 5 17 13 18 24 25 6 8 7 21 22 20 23 19
pge 22 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Spur Ger Hnd Winch Model M492 Model M492-12 item description prt numer qty. prt numer qty. 1 FRAME D1038 1 SD1129 1 2 RADIAL BALL BEARING A1520 2 A1520 2 3 COUNTERSHAFT B1225 1 SB1312 1 4 RETAINING RING EXT 1.250 SST A3892 2 A3892 2 5 MACHINERY BUSHING 1.250 X 1.875 X 18GA A3921 2 A3921 2 6 SET SCREW SOKHD NYLK.375-16NC X.500 SST A3947 2 A3947 2 7 1 SET SCREW SOKHD NYLK.500-13NC X.625 SST A3949 1 A3949 1 7 2 SET SCREW SOKHD NYLK.500-13NC X 1.000 SST A8322 1 A8322 1 8 DRUM SHAFT B1224 1 SB1314 1 9 BEARING HOUSING ASSEMBLY B1443 1 B1443 1 10 MACHINERY BUSHING 1.500 X 2.250 X 18GA A3924 2 A3924 2 11 DRUM C1077 1 SC1159 1 12 BEARING HOUSING ASSEMBLY B2839 1 B2839 1 13 FLAT HANDLE ASSEMBLY B1228 1 B1228 1 14 HANDLE ASSEMBLY B1045 1 B1045 1 15 COTTER PIN.187 X 1.250 SST A4309 1 A4309 1 16 HAIR PIN CLIP.750 X.093 DIA SST A4380 1 A4380 1 17 BRAKE HANDLE BUSHING A1438 1 A1438 1 18 CAPSCREW HEXHD.312-18NC X 1.250 SST A4173 1 A4173 1 19 HEX NUT.312-18NC SST A4324 1 A4324 1 20 FLAT WASHER SMALL OD.312 X.750 SST A2941 1 A2941 1 21 WASHER HELSPRLK.312 X.596 X.078 SST A3936 1 A3936 1 22 SLOTTED SPRING PIN.187 X.750 SST A4282 1 A4282 1 23 COUNTERSHAFT GEAR C1121 1 C1121 1 24 KEY.250 X.250 X 1.750 A2674 1 A2674 1 25 RATCHET PIN A1622 1 A1622 1 26 RATCHET PIN KNOB A1620 1 A1620 1 27 COMPRESSION SPRING.658OD X.048WD X 1.000 SST A1397 2 A1397 2 28 SLOTTED SPRING PIN.156 X.750 SST A4277 1 A4277 1 29 SLOTTED SPRING PIN.156 X 1.500 SST A4278 1 A4278 1 30 PINION A1515 1 A1515 1 31 SET SCREW SOKHD NYLK.250-20NC X.250 SST A3943 1 A3943 1 32 KEY.250 X.250 X 2.500 A5180 1 A5180 1 33 SET SCREW SQHD.250-20NC X.750 SST A4264 2 A4264 2 34 HANDLE GRIP A1043 1 A1043 1 35 BRAKE HANDLE B1173 1 B1173 1 36 BRAKE BAND ASSEMBLY B1233 1 B1233 1 37 LABEL LOAD RATING A7527 1 A7730 1 38 LABEL CAUTION A2175 1 A2175 1 39 LABEL CODE 10477 1 10477 1 40 LABEL WARNING A1979 1 A1979 1 41 LABEL OIL A2176 2 A2176 2 42 LABEL CABLE TAKEUP A1923 1 A1923 1 43 LABEL WARNING A2691 1 A2691 1 1 For use with wire rope greter thn 9/16 inch. 2 For use with 9/16 inch wire rope or smller.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 23 41 1 2 3 4 5 6 7 8 9 10 11 32 30 31 25 26 27 28 29 24 6 23 4 41 42 12 13 22 43 16 14 15 17 18 19 20 21 34 35 38 39 37 40 33 36
pge 24 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Spur Ger Hnd Winch Model M492B 1 Model M492B-12 1 item description prt numer qty. prt numer qty. 1 FRAME D1038 1 SD1129 1 2 RADIAL BALL BEARING A1520 2 A1520 2 3 COUNTERSHAFT B1225 1 SB1312 1 4 RETAINING RING EXT 1.250 SST A3892 2 A3892 2 5 MACHINERY BUSHING 1.250 X 1.875 X 18GA ZPLIRDI ST A3921 2 A3921 2 6 SET SCREW SOKHD NYLK.375-16NC X.500 SST A3947 2 A3947 2 7 2 SET SCREW SOKHD NYLK.500-13NC X.625 SST A3949 1 A3949 1 7 3 SET SCREW SOKHD NYLK.500-13NC X 1.000 SST A8322 1 A8322 1 8 DRUM SHAFT B1224 1 SB1314 1 9 BEARING HOUSING ASSEMBLY B1443 1 B1443 1 10 MACHINERY BUSHING 1.500 X 2.250 X 18GA ZPLIRDI ST A3924 2 A3924 2 11 DRUM C1077 1 SC1159 1 12 BEARING HOUSING ASSEMBLY B2839 1 B2839 1 13 COUNTERSHAFT GEAR C1121 1 C1121 1 14 KEY.250 X.250 X 1.750 A2674 1 A2674 1 15 RATCHET PIN A1622 1 A1622 1 16 RATCHET PIN KNOB A1620 1 A1620 1 17 COMPRESSION SPRING.658OD X.048WD X 1.000 SST A1397 2 A1397 2 18 SLOTTED SPRING PIN.156 X.750 SST A4277 2 A4277 2 19 SLOTTED SPRING PIN.156 X 1.500 SST A4278 1 A4278 1 20 PINION A1515 1 A1515 1 21 SET SCREW SOKHD NYLK.250-20NC X.250 SST A3943 1 A3943 1 22 KEY.250 X.250 X 2.500 A5180 1 A5180 1 23 BRAKE SUBASSEMBLY C3559 1 C3559 1 24 HANDLE ASSEMBLY B1015 1 B1015 1 25 COTTER PIN.187 X 1.250 SST A4309 1 A4309 1 26 HAIR PIN CLIP.750 X.093 DIA SST A4380 1 A4380 1 27 LABEL LOAD RATING A7700 1 A7731 1 28 LABEL CAUTION A2175 1 A2175 1 29 LABEL CODE 10477 1 10477 1 30 LABEL WARNING A1979 1 A1979 1 31 LABEL OIL A2176 2 A2176 2 32 LABEL CABLE TAKEUP A1923 1 A1923 1 1 See Hnd Operted Disc Brke mnul (A6191) for rke informtion. 2 For use with wire rope greter thn 9/16 inch. 3 For use with 9/16 inch wire rope or smller.
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 25 31 1 2 3 4 5 6 7 8 9 10 11 22 20 21 15 16 17 18 19 14 6 13 4 31 12 32 23 26 24 25 27 28 29 30
pge 26 Owner's Mnul for Thern M452 nd M492 Series Hnd Winches Spur Ger Hnd Winches Performnce Chrcteristics 3 lod rting (l) wire drum cpcity (ft) 1 single doule force 2 model 1st mid full rope 1st mid full ger ger to lift numer description lyer drum drum di. (in) lyer drum drum rtio rtio 1000 l M452 4000 l mrine duty 4000 3300 2500 1/4 23 130 300 4.42:1 19.54:1 10 l (for pulling only) 5/16 18 89 200 (doule ger) 3/8 14 64 140 M452B 4000 l mrine duty 4000 3300 2500 1/4 23 130 300 19.54:1 10 l with rke (for lifting) 5/16 18 89 200 (doule ger) 3/8 14 64 140 M452B-A 4000 l mrine duty 4000 3300 2500 1/4 13 83 190 19.54:1 10 l with rke (for lifting) 5/16 9 56 120 (doule ger) 4 inch drum width 3/8 7 40 89 M492 10,000 l mrine duty 10,000 7400 5400 5/16 27 240 540 5.00:1 25.00:1 8 l (for pulling only) 3/8 21 170 390 (doule ger) 1/2 15 100 230 M492B 10,000 l mrine duty 10,000 7400 5400 5/16 27 240 540 25.00:1 8 l with rke (for lifting) 3/8 21 170 390 (doule ger) 1/2 15 100 230 M492-12 10,000 l mrine duty 10,000 7400 5400 5/16 46 380 850 5.00:1 25.00:1 8 l (for pulling only) 3/8 37 270 610 (doule ger) 12 inch drum width 1/2 27 160 360 M492B-12 10,000 l mrine duty 10,000 7400 5400 5/16 46 380 850 25.00:1 8 l with rke (for lifting) 3/8 37 270 610 (doule ger) 12 inch drum width 1/2 27 160 360 1 Actul drum cpcities my e 25-30% less, due to nonuniform winding. Wire rope tension will lso ffect drum cpcity. 2 Approximte hndle force required to lift 1000 l with n empty drum, nd mximum hndle length. 3 Performnce Chrcteristics re for stndrd products referred to in this mnul. Non-stndrd products my vry from the originl design. Contct Thern, Inc. for this informtion. Hnd Wheel Model HW452 Model HW492 item description prt numer qty. prt numer qty. 1 HAND WHEEL C1210 1 C1211 1 2 BEARING SLEEVE A3642 1 A3636 1 3 BEARING SLEEVE A4366 1 A3635 1 4 1 LABEL CODE NUMBER 10477 1 10477 1 5 1 LABEL MODEL A1921 1 A1922 1 6 1 LABEL WARNING A2224 1 A2224 1 1 These items re not shown in prts drwing. 1 2 3
Owner's Mnul for Thern M452 nd M492 Series Hnd Winches pge 27 NOTES:
Thern, Incorported 5712 Industril Prk Rod Winon, MN 55987 PH 507-454-2996 FAX 507-454-5282 EMAIL: info@thern.com www.thern.com Thern Europe Windmolen 22 7609 NN Almelo Netherlnds PH +31-548-659-052 EMAIL: europe@therneurope.eu