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 4WM2 Series Worm Ger Hnd Winch
pge 2 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch Two-Yer Limited Wrrnty Plese record the following: Dte Purchsed: Model Numer: Code Numer: 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 4WM2 Series Worm Ger Hnd Winch. 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 4WM2 Series Worm Ger Hnd Winch 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 gerox for luriction or lekge efore use. Instll the wire rope securely to the winch drum. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 4 wrps on the drum the wire rope could come loose, cusing the lod to escpe. Keep hnds wy from the drum, 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. To do so could result in filure of the equipment. Do not use more thn one winch to move lod unless ech winch ws designed for use in multiple winch system. Do not use dmged or mlfunctioning equipment. To do so could result in filure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equipment filure. Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use pproved rigging connectors to secure the wire rope to the lod. Figure 1 Duty Rting Model 4WM2 Winch Duty Cycle Rting with Drill-Motor 15 minute Do not continue to operte winch with drill-motor if gerox or rke show signs of overheting. Allow winch to cool to mient temperture efore continuing opertion. Do not lift lods or pull lods on n incline unless the winch is equipped with lod rke. Do not divert your ttention from the opertion. Sty lert to the possiility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stopping the lod smoothly. Shock lods overlod the equipment nd my cuse dmge. Do not leve suspended lod unttended unless specific precutions hve een tken to secure the lod nd keep people wy from the winch nd from under the lod. Do not djust the winch rke with the lod suspended. Do not exceed the duty cycle rting of the winch when operting with drillmotor, nd do not operte the winch with drill-motor tht exceeds 400 rpm or n impct wrench. To do so could result in equipment dmge or filure. See Figure 1.
pge 4 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch 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 weld the winch frme to the foundtion or support structure. Welding the frme my void wrrnty, contct fctory. Use fsteners s instructed. 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 APPLICABLE CODES AND REGULATIONS for specific rules on instlling the equipment. 1.1.2 LOCATE THE WINCH in n re cler of trffic nd ostcles. Mke sure the winch is ccessile for mintennce nd opertion. 1.1.3 LOCATE THE WINCH in n re with dequte tempertures. The winch is rted for opertion in mient tempertures rnging from 0 to 100 F. 1.1.4 POSITION THE WINCH to llow ccess for proper luriction. 1.1.5 MAINTAIN A FLEET ANGLE etween 1/2 nd 1-1/2 degrees. The proper fleet ngle minimizes wire rope dmge y helping the wire rope wind uniformly onto the drum. See Figure 2. 1.1.6 FASTEN THE WINCH SECURELY to the foundtion. FOR STANDARD PRODUCTS referred to in this mnul, use 3/8 inch corse thred fsteners, grde 5 or etter, torqued dry to 30 ft-ls without luriction. Mke sure the winch frme is secured to solid foundtion le to support the winch nd the lod under ll conditions with design fctors sed on ccepted engineering prctices. NON-STANDARD PRODUCTS tht vry from the originl design my hve different fstening requirements. Contct structurl engineer or Thern, Inc. for this informtion. TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED PROFESSIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFICATIONS FOR THE MOUNTING OF THERN PRODUCTS.
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 5 1.2 Instlling the Brether Plug Importnt! Sve the extr oil plug for use when the winch is removed for storge or trnsport. Instll the rether plug to vent het nd pressure from the gerox. Filure to do so could result in pressure uildup which could dmge the equipment. For shipment, the gerox is seled with n oil plug, nd the rether plug is ttched to the gerox or shipped in seprte envelope. 1.2.1 REMOVE THE OIL PLUG nd instll the rether plug in the proper loction. Mke sure the rether plug is ove the level of the oil. See Figure 3. 1.2.2 CHECK THE OIL LEVEL in the gerox to mke sure no oil ws lost during shipment. See Section 3.3 Luricting the Winch. Instll the rether plug to vent het nd pressure from the gerox. Filure to do so could result in pressure uildup which cn cuse the gerox to lek or dmge the equipment. 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 2 Mintining the Fleet Angle When wire rope trvels over sheve or through roller guide mintin fleet ngle y locting the sheve or guide n pproprite distnce from the drum, shown s distnce A. fixed sheve or smooth drum roller guide 1/2 to 1-1/2 degrees center line distnce A When wire rope trvels directly to the lod mintin fleet ngle y controlling side-to-side movement of the lod with trcks or guide rils. Allowing the lod to move too fr to one side cuses stress on the drum flnge which my cuse dmge. lod smooth drum 1/2 to 1-1/2 degrees center line trcks or guide rils Figure 3 Brether Plug Instlltion rether plug rether plug rether plug rether plug floor mount wll mount wll mount ceiling mount (hndle down) (hndle up)
pge 6 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch 1.3 Instlling the Hndle Figure 4 Instlling the Hndle The winch includes 1-1/8 inch hex drive input. You cn ttch the hndle to this input, or you cn use 1-1/8 inch hex socket to power drive the winch with mximum 400 rpm drill-motor. Remove the hndle efore power driving the winch with drill-motor. loosen thumscrew nd slide hndle in direction shown thumscrew 1.3.1 LOOSEN THE THUMBSCREW nd slide the hndle towrd the medllion s shown. See 4A. 1.3.2 LINE UP THE NOTCH in the hndle with the point of the hex in the medllion. See 4B. notch 4A Slide Hndle In 1.3.3 SLIDE THE HANDLE AND MEDALLION ASSEMBLY onto the hex drive until the flt of the hndle lines up with the groove in the hex drive. See 4C. 1.3.4 SLIDE THE HANDLE outwrd wy from the medllion to the desired length nd tighten the thumscrew. See 4D. line up notch with point of hex in medllion medllion notch 4B Line Up Notch groove slide hndle ssemly onto hex drive until hndle flt lines up with groove 4C Slide Hndle onto Hex slide hndle out to desired length nd tighten thumscrew thumscrew lrger turning rdius: hevier lods, slower turns smller turning rdius: lighter lods, fster turns 4D Adjust Hndle Length
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 7 1.4 Instlling the Wire Rope Importnt! Use wire rope nd other rigging equipment rted for 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 securely to the winch drum. A poorly secured wire rope could come loose from its nchor nd llow the lod to escpe. Do not use 3/16 inch or smller wire rope on stndrd drums. To do so could cuse dmge to the wire rope nd llow the lod to escpe. Instll the wire rope so it is wound correctly s shown or the winch nd rke will not work properly, nd could llow the lod to escpe, see Figure 5. 1.4.1 PURCHASE THE PROPER WIRE ROPE for your ppliction. Keep the following in mind when selecting wire rope. Contct reputle wire rope supplier for help. Figure 5 Instlling the Wire Rope instll the wire rope so it is underwound on the drum s shown tighten set screw c BREAKING 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 LAY must gree with the winding direction of the drum to help insure proper winding. WE RECOMMEND 7x19 glvnized ircrft wire rope for dimeters up to 5/16 inch. Do not use 3/16 inch or smller wire rope for units with stndrd drums. 1.4.2 ANCHOR THE WIRE ROPE to the drum using either the set screw or quick disconnect nchor. SET SCREW ANCHOR. See Figure 5. Wire rope ssemlies with nchor fittings cn e purchsed from Thern, Inc. hndle rottion UP tighten set screw typicl instlltion shown left ly underwound PASS THE WIRE ROPE under the drum from the front nd position it in the slot in the drum. Mke sure t lest 1/2 inch of wire rope extends pst the set screw, nd the end of the wire rope does not protrude out where it will interfere with wire rope winding onto the drum. TIGHTEN THE SET SCREW to hold the wire rope in plce. Hold the wire rope down while tightening so the wire rope does not push up out of the slot. QUICK DISCONNECT ANCHOR. See Figure 5. PASS THE WIRE ROPE under the drum from the front nd position the nchor fitting in the groove in the drum. PULL THE WIRE ROPE to firmly lodge the nchor fitting in plce. 1.4.3 TURN THE HANDLE COUNTER-CLOCKWISE to wind wire rope onto the drum. If wire rope unwinds from the drum when the hndle is rotted counter-clockwise, the wire rope is instlled incorrectly. Instll the wire rope correctly efore continuing. See Figure 5. 1.4.4 WIND FOUR FULL WRAPS of wire rope onto the drum y operting the winch while holding the wire rope tught. These wrps serve s nchor wrps nd must remin on the drum t ll times. CONTACT A REPUTABLE WIRE ROPE SUPPLIER FOR HELP.
pge 8 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch 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 FORCE REQUIRED to move the lod must not exceed the lod rting of the winch. Consider the totl force required to move the lod, not the weight of the lod. 2.1.2 THE AMOUNT OF TIME required to move the lod must not exceed the 15 minute duty cycle rting of the winch, when operting with drill-motor. 2.1.3 THIS EQUIPMENT CAN develop forces tht will exceed the lod rting. It is the responsiility of the equipment user to limit the size of the lod. Inspect the equipment regulrly for dmge ccording to the instructions contined in this mnul nd in component mnufcturer s informtion. 2.1.4 USE A LOAD BRAKE on ll winches used to lift lods or pull lods on n incline. Although new winch my pper to hold the lod in plce, this chrcteristic will diminish with use. Do not depend on gering to hold the lod in plce. 2.1.5 PERFORMANCE RATINGS of the equipment re ffected y the mount of wire rope wound on the drum, the wy in which it is wound, nd the wy the winch is used. c DRUM CAPACITY depends on how tightly nd evenly the wire rope is wound on the drum. Actul drum cpcities re usully 25-30% less thn vlues shown in performnce Tles, due to loose winding nd overlpping. 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. LOAD RATING 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. 2.1.6 DUTY RATINGS refer to the type of use the equipment is suject to. Consider the following when determining duty rting. The winch hs 15 minute duty cycle rting, when operting with drill-motor. c d ENVIRONMENT: hrsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from hrsh environments when possile. MAINTENANCE: poor mintennce, mening poor clening, luriction, or inspection, leds to poor opertion nd possile dmge of the equipment. Minimize poor mintennce y crefully following the instructions contined in this mnul. LOADING: severe loding includes shock loding nd moving lods tht exceed the lod rting of the equipment. Avoid shock lods, nd do not exceed the lod rting of the equipment. FREQUENCY OF OPERATION: frequent 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. Length of opertion should not exceed 15 minute duty cycle rting when operting with drill-motor. CONTACT THE FACTORY FOR MORE INFORMATION.
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 9 2.2 Breking-In the Winch 2.2.1 BREAK-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. 2.2.2 INSPECT THE WINCH following rek-in ccording to the Instructions for Periodic Inspection. See section 3.4 Inspecting the Equipment. 2.3 Prepring for Opertion Importnt! When determining whether the lod will exceed the lod rting, consider the totl force required to move the lod. 2.3.1 CONSIDER THE OPERATION. Do not egin until you re sure you cn perform the entire opertion without hzrd. 2.3.2 BEFORE EACH OPERATION inspect ll components of the system. INSPECT THE WINCH nd other equipment ccording to the Instructions for Frequent Inspection. Do not operte winch until ll defects hve een corrected. c OPERATORS must e in good helth, lert, nd thoroughly trined in operting the equipment, nd properly clothed (sfety equipment s required, no loose clothing, no loose jewelry). THE LOAD must e cler of other ojects nd free to move. Mke sure the lod will not tip, ind, or in ny wy move uncontrollly. 2.3.3 KNOW YOUR LOAD nd mke sure you do not exceed the lod rting of the winch or other equipment in the system. 2.4 Attching the Lod Figure 6 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. 2.4.1 CLEAR OBJECTS from the pth of the lod so you cn move it freely nd oserve it t ll times during the opertion. 2.4.2 ATTACH THE LOAD using nylon sling, or other pproved rigging device. Follow the recommendtions of the sling mnufcturer. sling seted in sddle of hook SEAT THE SLING in the sddle of the hook with the hook ltch completely closed. See Figure 6. CENTER THE LOAD on the hook so it will remin lnced nd not tip or rotte to one side.
pge 10 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch 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 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. Remove the winch hndle nd secure the drum using the drum lock when the winch is not in use, to help void unuthorized use. 2.5.1 MOVE THE LOAD slowly nd smoothly, only smll distnce t first. Mke sure the lod is lnced nd securely ttched efore continuing. 2.5.2 TURN THE HANDLE COUNTER-CLOCKWISE to wind wire rope onto the drum. If wire rope unwinds from the drum when the hndle is rotted counter-clockwise, the wire rope is instlled incorrectly. Instll the wire rope correctly efore continuing. See Figure 7. 2.5.3 GRIP THE HANDLE TIGHTLY t ll times during opertion. If you relese the hndle the lod my ckdrive cusing the hndle to spin. Do not try to stop spinning hndle, step cler until the spinning stops. 2.5.4 OBSERVE THE WIRE ROPE s it winds onto the drum. If it ecomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope efore continuing. Continued opertion with overlpped or uneven wire rope cn dmge the wire rope nd shorten its life. 2.5.5 FOLLOW THE GUIDELINES BELOW to operte the winch with drillmotor. DO NOT EXCEED THE DUTY CYCLE RATING of the winch when operting with mximum 400 rpm drill-motor. See Figure 1. Figure 7 Opertion hndle rottion UP c d ALLOW THE WINCH AND BRAKE TO COOL DOWN to mient temperture in rest periods etween opertions. USE A MAXIMUM 400 RPM DRILL -MOTOR with 1-1/8 inch hex socket to power drive the input shft on the winch. The drill-motor should e set for low speed opertion if possile. Thern recommends using drillmotor rted for 400 rpm t 10 mps. THE LOAD RATING OF THE WINCH my decrese when operted with drill-motor. Check the winch nmeplte. 2.5.6 OBSERVE THE GEARBOX AND BRAKE during opertion for signs of overheting. Frequent overheting my e sign of dmge, or my indicte the need for lrger winch. WATCH FOR SMOKE, the smell of urnt luricnt, nd other signs of overheting. Use thermocouple or other device to monitor gerox nd rke temperture. The temperture of the gerox should not exceed 150 F. STOP THE OPERATION if the gerox or rke overhets, nd llow the winch to cool until it reches mient temperture. Continued opertion my cuse dmge.
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 11 3.1 Clening the Winch Importnt! Increse the frequency of mintennce procedures if the winch is: Operted frequently. 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 CLEAN THE WINCH every 6 months or whenever it is dirty. c WIPE ALL EQUIPMENT to remove dirt nd grese. LEAVE A LIGHT FILM of oil on ll surfces to protect them ginst rust nd corrosion. WIPE OFF excessive mounts of oil to void the ccumultion of dirt. 3.1.2 REMOVE ll unnecessry ojects from the re surrounding the winch. 3.2 Adjusting the Brke Importnt! Do not over tighten the rke, since this will cuse prts to wer nd ecome dmged. Figure 8 Adjusting the Brke Do not djust the rke with the lod suspended. Accidentl relese of the rke could llow the lod to escpe. 3.2.1 ADJUST THE BRAKE whenever it ppers to need djustment, or t lest every 3 months. 3.2.2 TO CHECK THE BRAKE on the 4WM2 series y operting with test lod equl to the winch lod rting: RAISE THE LOAD, then lower it nd stop it out one foot off the ground. turn rke djusting nuts clockwise 1/4 turn OBSERVE THE LOAD when stopped. If it continues to cost or creep, the rke needs djustment. Contct the fctory for ssistnce. FOR MANUALLY OPERATED WINCHES, djust the rke nuts ccording to the input shft torque rnge specified for the winch, turning the nuts clockwise y 1/4 turns etween torque redings. See Tle 1. Do not djust the rke with the lod suspended. DO NOT OVERTIGHTEN mechnicl rke djusting nuts. 3.2.3 TIGHTEN THE BRAKE y turning the djusting nuts clockwise out 1/4 turn. Continue to test nd tighten the rke y lternte tightening of ech rke nut until it stops nd holds the lod securely. See Figure 8. 3.2.4 A DECELERATION DISTANCE while stopping is typiclly 6 inches. 3.2.5 IF THE LOAD CONTINUES TO COAST or creep, contct the fctory. Tle 1 Torque 1 While Lowering for 4WM2 Units Unit Under No Lod Under Lod Direction 2 4WM2 2-4 ft-ls 4-10 ft-ls clockwise 1 Do not djust rke with lod suspended. 2 Complete 1 full rottion of input shft. 3 Tighten rke until the minimum vlue is otined. See Figure 8.
pge 12 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch 3.3 Luricting the Winch Importnt! Do not leve plug holes in the gerox open. Open plug holes will llow dirt or moisture to contminte the grese. Mke sure luricnt hs temperture rting pproprite for the mient tempertures of the opertion. Figure 9 Outord Bering outord ering, luricte with NLGI no. 2 grese Mke sure the rether plug is clen nd open to vent het nd pressure. Poor ventiltion my cuse overheting nd result in equipment dmge. Check the gerox for proper oil level efore opertion. Too much or too little oil will cuse overheting nd result in equipment dmge. Luricte the winch properly to help protect it from wer nd rust. Red the following instructions crefully. 3.3.1 THE WINCH IS SHIPPED from the fctory with the proper mount (44 ounces) of Moilger 600 XP 220 luricnt in the gerox. Luricte the winch s follows, see Figures 9 nd 10. 3.3.2 CHECK OIL LEVEL efore every opertion nd every 10 hours during opertion. Remove the level check plug nd mke sure oil is even with the plug hole. Add oil to the gerox if necessry. Do not use synthetic luricnts nd do not mix different luricnts. See Figure 10. 3.3.3 CHANGE GEARBOX OIL t lest every 6 months, or whenever it is dirty or contminted. Remove the drin plug to drin oil from the gerox. See Figure 10. 3.3.4 LUBRICATE THE OUTBOARD BEARING t lest once every month or more, depending on usge. Use grese gun to insert NLGI no. 2 grese until clen grese ppers t the sels. The ering will squek if it is dry. See Figure 9. 3.3.5 LUBRICATE THE WIRE ROPE nd other equipment y following the mnufcturer s recommendtions. Figure 10 Plug Instlltion filler/ rether plug level check plug filler/ rether plug level check plug filler/ rether plug level check plug level check plug filler/rether plug drin plug drin plug drin plug drin plug floor mount wll mount wll mount ceiling mount (hndle down) (hndle up)
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 13 3.4 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. 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 2 - Inspection Checklist. 3.4.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the winch nd other equipment. 3.4.2 CONSULT MANUFACTURER S RECOMMENDATIONS for informtion on inspecting the wire rope nd other equipment. 3.4.3 Instructions for Frequent Inspection Perform frequent inspections: Before ech opertion. Every 3 hours during opertion. Whenever you notice signs of dmge or poor opertion. Frequent Wire Rope Inspection: Use ASME B30.7 s guideline for rope inspection, replcement nd mintennce. Check the wire rope, end connections nd end fittings for corrosion, kinking, ending, crushing, irdcging or other signs of dmge. Check the numer, distriution nd type of visile roken wires. See prgrph 3.4.4 c nd Figure 11. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 13. Tke extr cre when inspecting sections of rpid deteriortion such s sections in contct with sddles, sheves, repetitive pickup points, crossover points nd end connections. VISUALLY INSPECT the entire winch nd ll other equipment involved in the opertion. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. Mke sure the wire rope is instlled correctly nd nchored securely to the drum. Mke sure the winch is properly luricted. Mke sure the thumscrew holding the hndle in plce is tight. Check the gerox for signs of lekge, nd mke sure it is filled with the proper luricnt. Contct the fctory if there re ny signs of luricnt leking from the gerox. Mke sure the rether plug is clen, open, nd instlled correctly. Mke sure 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 PERFORMANCE y moving the winch with lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the hndle rottes freely in oth directions. 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 djustment. See section 3.2 Adjusting the Brke. Completely correct ll prolems efore continuing. Use the Trouleshooting Chrt to help determine the cuse of certin prolems. See Tle 3.
pge 14 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch Perform periodic inspections: Every 6 months, or more frequently if drill driven. 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 11 Broken Wires wire one ly 3.4.4 Instructions for Periodic Inspection VISUALLY INSPECT the winch nd ll other equipment. Disssemly my e required in order to properly inspect individul components. Contct fctory for ssemly/disssemly instructions. Disssemly of the gerox efore contcting Thern, Inc voids ll wrrnties. Check the finish for wer, flking, or other dmge. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. If the equipment ws overloded, or if you notice crcks nd other signs of overloding nd dmge promptly remove equipment from use nd hve it repired or replced. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE ROPE. Check ll fsteners for stripped threds, wer, ending, nd other dmge. Check the gerox for signs of lekge. Contct fctory if there re ny signs of luricnt leking from the gerox. Mke sure the rether plug is clen, open, nd instlled correctly. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. Check the foundtion for crcks, corrosion, nd other dmge. strnd 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 12 Lod Hook Inspection twist throt opening 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. c DRAIN A SMALL AMOUNT OF OIL into clen continer. Check the oil for dirt, metl prticles, wter, nd other signs of contmintion. Completely drin the gerox if oil is contminted. Mke sure the gerox is properly luricted. See section 3.3 Luricting the Winch. INSPECT THE WIRE ROPE ccording to the wire rope mnufcturer's recommendtions or follow ccepted industry stndrds for wire rope inspection. Alwys wer protective clothing when hndling wire rope. Check the entire length of wire rope for ent wires, crushed res, 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 11. 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 12. 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.
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 15 Figure 13 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) d e f g h 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. Disssemle the winch if necessry. Inspect gers, keys, erings, sels, nd shfts for wer, corrosion, distortion, nd other dmge. Contct fctory for ssemly/disssemly instructions. Disssemly of the product efore contcting Thern, Inc. voids ll wrrnties. PLACE enough weight to keep the wire rope stright nd tightly drwn. Mesure the dimeter of the wire rope, especilly in res where wer is noticele. Replce the wire rope if the dimeter mesures elow the minimum dimeter t ny point. See Figure 13. LUBRICATE THE ENTIRE WINCH. INSTALL THE WIRE ROPE. TEST WINCH PERFORMANCE y operting the winch with lod equl to the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Oserve the rotting drum, look for signs of loose or misligned erings. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the hndle rottes freely in oth directions. 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 djustment. See section 3.2 Adjusting the Brke. Completely correct ll prolems efore continuing. Use the trouleshooting chrt to help determine the cuse of certin prolems. See Tle 3.
pge 16 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch Tle 2 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 gerox gers, erings, or shfts loose, worn, otherwise dmged not properly luricted oil lekge oil contminted wire rope ent, crushed, otherwise dmged wire rope loosely or unevenly wound roken wires, see Figure 11 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 13 replce if dimeter is excessively worn dimeter = end connections corroded, rusted, worn, otherwise dmged not securely ttched hook or other device twisted, ent, worn, otherwise dmged, see Figure 12 hook ltch fils to close when relesed replce if twist is 10 degrees or more twist = replce if throt width is 15% lrger thn nominl throt width = replce if thickness is 10% less thn nominl thickness = drum nchor worn, distorted, otherwise dmged excessive movement or cklsh rke rke worn, corroded, otherwise dmged rke does not operte properly lels nd pltes dirty, illegile, otherwise dmged loosely ttched or missing comments uthorized signture dte
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 17 Tle 3 Trouleshooting Chrt Contct the fctory for detiled instructions on re-seling the gerox if you re required to disssemle the gerox for ny reson. Disssemly of the gerox efore contcting Thern, Inc. voids ll wrrnties. prolem cuse correction hndle turns, drum doesn t turn loose or roken spring pins or shfts inspect winch nd rke, repir s necessry loose, stripped or roken gers or keys repir s necessry hndle turns hrd or not t ll unit overheted llow to cool lod too hevy gerox contminted with dirt or deris keys or spring pins loose or roken rke nd too tight rke roken or locked gers or erings roken or locked lighten lod inspect nd reluricte s necessry inspect winch nd rke, repir s necessry loosen rke nd redjust inspect nd repir s necessry inspect nd replce s necessry rke does not operte properly wire rope instlled improperly reinstll wire rope correctly rke djusted incorrectly rke worn or dmged rke components roken or locked djust rke inspect nd replce s necessry inspect nd repir s necessry luricnt lekge worn erings inspect nd replce s necessry oil sels leking or dmged gskets leking or dmged crcked or dmged gerox gercse plugs not tightened rether plug clogged or dmged inspect nd replce s necessry tighten fsteners or replce gsket inspect nd repir s necessry tighten clen or replce vent plug s needed excessive end ply on drive shft loose or dmged keys or keywys inspect nd replce s necessry thrust wsher or ering worn out excessively worn gers excessively worn gers or erings lod too hevy lighten lod poor luriction of gers or erings overheting operted too long without rest llow to cool unusul noises lod too hevy poor luriction rether plug clogged or dmged ering seized up inspect nd replce s necessry inspect nd repir s necessry inspect nd luricte s necessry lighten lod inspect nd luricte s necessry clen or replce vent plug s needed inspect nd replce s necessry high pitched squek poor luriction inspect nd luricte s necessry grinding noise contminted luriction drin, clen nd luricte the winch dirt in winch gers roken gers or erings inspect nd clen s necessry inspect nd replce s necessry rttling noise loose fsteners or set screws tighten ll fsteners nd screws hevy thump during opertion contminnts in luricnt drin, clen nd luricte the winch loose set screws or keys in gers or shfts erings defective inspect nd repir s necessry inspect nd replce s necessry ck drive rke out of djustment djust rke per mnul
pge 18 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch 3.5 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 spring pins, retining rings, nd oil sels whenever the winch is disssemled for inspection or repir. During ressemly, use Loctite 598 Ultr Blck to crete sel etween the two hlves of the gerox nd the input shft. Contct the fctory for detiled instructions. Disssemly of the gerox efore contcting Thern, Inc. voids ll wrrnties. Appoint qulified person to e responsile for ll repirs to the equipment. 3.5.1 GET FACTORY AUTHORIZATION for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the winch. 3.5.2 REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repir prts. 3.5.3 REFINISH AREAS where the pint is worn or flking. A good finish helps to protect ginst corrosion nd wether dmge. c REMOVE THE FINISH from dmged res, down to the re metl. CLEAN THE AREA thoroughly. REPAINT with high qulity primer nd finishing cot. 3.5.4 TO ORDER REPAIR PARTS, 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
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 19 4.1 Trnsporting the Winch Importnt! Keep record of wht you ship, nd when you send it. 4.1.1 REMOVE THE BREATHER PLUG nd instll seled oil plug to prevent the loss of luriction during shipment. 4.1.2 PACK THE WINCH in n upright position for trnsport, using the originl pckging mterils, if possile. c d FASTEN THE WINCH to wooden se using lg olts, to keep it from moving during trnsport. SEAL THE WINCH in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. CONSTRUCT WOODEN SIDES nd top to enclose the winch in solid protective crte. PACK LOOSE PARTS in smll oxes or ship seprtely. 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 LUBRICATE THE WINCH s necessry, nd mke sure the rether plug is clen nd properly instlled. Add rust preventtive for long term storge. 4.2.2 SEAL THE WINCH in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. 4.2.3 STORE THE WINCH upright, in cool clen plce wy from corrosive chemicls nd moisture. 4.2.4 ROTATE THE DRUM PERIODICALLY to keep ering nd gers surfces from ecoming lcquered. 4.2.5 INSPECT THE WINCH ccording to the Instructions for Periodic Inspection efore instlling it for opertion. 4.2.6 LUBRICATE THE WINCH PROPERLY prior to opertion. Refer to Section 3.3 Luricting the Winch.
pge 20 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch Model 4WM2 Worm Ger Hnd Winch item description prt numer qty. 1 REDUCER ASSEMBLY D2058 1 2 HEX INPUT ASSEMBLY B3705 1 3 KEY.188 X.188 X 1.000 A7310 1 4 HANDLE MEDALLION ASSEMBLY B4218 1 5 HEX NUT.375-16NC A3017 6 6 SETSCREW SQHD.250-20NC X.875 A7536 1 7 DRUM C3381 1 8 GROOVE PIN.312 X 2.500 A7284 1 9 FRAME D1913 1 10 FLANGE BEARING A7285 1 11 CARRIAGE BOLT.375-16NC X 1.250 A7283 2 12 BREATHER PLUG A3408 1 13 LABEL WARNING DO NOT ADJUST BRAKE WHEN A2658 1 14 NAMEPLATE A6889 1 15 LABEL CODE NUMBER 10477 1 16 LABEL WARNING TO AVOID INJURY OR PROP... A1978 1 17 LABEL WARNING KEEP HANDS AWAY FROM DRUM A2659 2 18 LABEL WARNING A7406 1 19 LABEL MODEL/CAPACITY A7473 1 16 17 4 13 1 2 3 8 9 10 11 5 18 12 14 15 5 6 7 19
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 21 Model 4WM2V Worm Ger Hnd Winch - Verticl Mount item description prt numer qty. 1 REDUCER ASSEMBLY D2058 1 2 HEX INPUT ASSEMBLY B3705 1 3 KEY.188 X.188 X 1.000 A7310 1 4 HANDLE MEDALLION ASSEMBLY B4218 1 5 HEX NUT.375-16NC A3017 6 6 SETSCREW SQHD.250-20NC X.875 A7536 1 7 DRUM C3381 1 8 GROOVE PIN.312 X 2.500 A7284 1 9 FRAME D2173 1 10 FLANGE BEARING A7285 1 11 CARRIAGE BOLT.375-16NC X 1.250 A7283 2 12 BREATHER PLUG A3408 1 13 LABEL WARNING DO NOT ADJUST BRAKE WHEN A2658 1 14 NAMEPLATE A6889 1 15 LABEL CODE NUMBER 10477 1 16 LABEL WARNING TO AVOID INJURY OR PROP... A1978 1 17 LABEL WARNING KEEP HANDS AWAY FROM DRUM A2659 2 18 LABEL WARNING A7406 1 19 LABEL MODEL/CAPACITY A7473 1 16 4 13 1 2 3 8 9 10 11 5 18 12 19 14 15 5 6 7 17
pge 22 Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch Reducer Assemly D2058 item description prt numer qty. 1 CAPSCREW HEXHD.312-18NC X.750 A3032 12 2 BEARING HOUSING ASSEMBLY B3582 1 3 BRAKE DRUM SPACER A2642 2 4 THRUST BEARING.628ID X 1.250OD X.125 A7291 1 5 DRUM BRAKE ASSEMBLY B1700 1 6 FLAT WASHER.656ID X 1.875OD X.094 A7292 2 7 SHIM.626/.630 X 1.00 X.018/.022 A3308 1 8 PIPE PLUG SQHD.125-27NPT X.35 A3407 1 9 DOWEL PIN.188 X.500 A7308 2 10 BALL THRUST BEARING.753ID X 1.685OD X.625 A1498 1 11 BEARING HOUSING ASSEMBLY INPUT SIDE B3581 1 12 CAPSCREW HEXHD.312-18NC X 1.000 A3028 4 13 WORM SHAFT C3276 1 14 PIPE PLUG HEXSOC.125-27NPT X.31 A3405 2 15 BRAKE BAND CONNECTOR ASSEMBLY B2917 1 16 HEX JAM NUT NYLK.375-16NC A3180 2 17 COVER D2052RED 1 18 GEARCASE D2051RED 1 19 STUD.375-16NC X 1.312 A7279 4 20 DRUM SHAFT ASSEMBLY C3414 1 21 OIL SEAL 1.125ID X 1.874OD X.250 A7287 1 22 PIPE PLUG HEXSOC.375-18NPT X.425 A3290 4 23 SPRING WASHER.380 X.750 X.034 A3296 1 2 3 1 4 5 6 7 3 8 9 10 12 11 13 1 14 15 16 17 18 19 20 23 22 21
Owner's Mnul for Thern 4WM2 Series Worm Ger Hnd Winch pge 23 Pressure Plte Assemly 1 B3688 item description prt numer qty. 1 PRESSURE PLATE B3643 1 2 PIN A3269 1 3 PRESSURE PLATE BASE A3268 1 4 TORSION SPRING A3277 1 5 SPACER TUBE A3273 1 6 CAPSCREW HEXHD.250-20NC X.375 A7434 2 7 RETAINING RING.500 A3278 2 1 B3688 supplied with crne winches 4WM2-K nd 4WM2V-K. 1 2 3 4 5 6 7 Hndle Medllion Assemly B4218 item description prt numer qty. 1 HANDLE ASSEMBLY B4187 1 2 THUMB SCREW.312-18NC X.750 SST A8167 1 3 MEDALLION B4189 1 4 SLOTTED SPRING PIN.187 X.750 SST A4282 1 1 2 3 4 4WM2 Performnce Chrcteristics 1 lod rting (l) drum cpcity (ft) wire rope 1st mid full 1st mid full ger force to lift di. (in) lyer drum drum lyer drum drum rtio 1000 l 1/4 2000 1500 1200 11 35 77 32:1 14 l 5/16 2000 1500 1200 8 23 52 32:1 14 l 1 Performnce Chrcterirstics re for stndrd products referred to in this mnul. Non-stndrd products my vry from the originl design. Contct Thern, Inc. for this informtion.
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 Bedrijvenprk Twente 454e 7602 KM Almelo Netherlnds PH +31-546-898-380 EMAIL: europe@thern.com