Thern 4WM2 Series Worm Gear Hand Winch Owner's Manual

Read this Own er’s Man u al thor ough ly be fore op er at ing the equip ment. Keep it with the equip ment at all times.

Re place ments are avail able from Thern, Inc., PO Box 347,

Winona, MN 55987,

507-454-2996.

www.thern.com

IMPORTANT: Please record product information on page 2. This information is re quired when calling the fac to ry for service.

A7535G-0613

Owner’s Man ual

For

4WM2 Series

Worm Gear Hand Winch

page 2 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Two-Year Limited Warranty

Please record the following:

Date Purchased:

Model Number:

Code Number:

This information is required when calling the factory for service.

Thern, Inc. warrants its products against defects in material or workmanship for two years from the date of purchase by the original using buyer, or if this date cannot be established, the date the product was sold by Thern, Inc. to the dealer. To make a claim under this warranty, contact the factory for an RGA number. The product must be returned, prepaid, directly to Thern, Inc., 5712 Industrial Park Road, Winona, Minnesota 55987. The following information must accompany the product: the RGA number, the date of purchase, the description of the claimed defect, and a complete explanation of the circumstances involved. If the product is found to be defective, it will be repaired or replaced free of charge, and Thern, Inc. will reimburse the shipping cost within the contiguous USA.

This warranty does not cover any damage due to accident, misuse, abuse, or negligence. Any alteration, repair or modifi cation of the product outside the Thern, Inc. factory shall void this warranty. This warranty does not cover any costs for removal of our product, downtime, or any other incidental or consequential costs or damages resulting from the claimed defects. This warranty does not cover brake discs, wire rope or other wear components, as their life is subject to use conditions which vary between applications.

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 states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.

Note: Thern, Inc. reserves the right to change the design or discontinue the production of any product without prior notice.

About This Manual

The Occupational Safety and Health Act of 1970 states that it is the employer’s re spon si bil i ty to provide a workplace free of hazard. To this end, all equipment should be installed, operated, and maintained in compliance with applicable trade, industrial, federal, state, and local regulations. It is the equipment own er's re spon si bil i ty to ob tain copies of these regulations and to determine the suit abil i ty of the equip ment to its intended use.

This Owner’s Manual, and warning labels attached to the equip ment, are to serve as guidelines for hazard-free installation, op er a tion, and maintenance. They should not be understood to prepare you for every pos si ble situation.

The information contained in this manual is applicable only to the Thern 4WM2

Series Worm Gear Hand Winch. Do not use this manual as a source of in for ma tion for any other equip ment.

The following symbols are used for emphasis throughout this man u al:

Failure to follow ‘WARNING!’ instructions may result in equipment dam age, property damage, and/or serious personal injury.

Failure to follow ‘CAUTION!’ instructions may result in equipment damage, prop er ty damage, and/or minor personal injury.

Important!

Failure to follow ‘important!’ instructions may result in poor per for mance of the equipment.

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Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Suggestions for Safe Operation

page 3

DO the following:

Read and comply with the guidelines set forth in this Owner’s Manual. Keep this manual, and all labels attached to the winch, readable and with the equipment at all times. Contact Thern, Inc. for replacements.

Check gearbox for lubrication or leakage before use.

Install the wire rope securely to the winch drum.

Keep at least 4 wraps of wire rope wound on the drum at all times, to serve as anchor wraps. With less than 4 wraps on the drum the wire rope could come loose, causing the load to escape.

Keep hands away from the drum, wire rope, and other moving parts of the equipment.

Keep all unnecessary personnel away from the winch while in operation.

Keep out of the path of the load, and out of the path of a broken wire rope that might snap back and cause injury.

Figure 1 – Duty Rating

Model

Winch Duty Cycle Rating with Drill-Motor

4WM2 15 minute

Do not continue to operate winch with drill-motor if gearbox or brake show signs of overheating.

Allow winch to cool to ambient temperature before continuing operation.

DO NOT do the following:

Do not lift people, or things over people. Do not walk or work under a load or in the line of force of any load.

Do not exceed the load rating of the winch or any other component in the system. To do so could result in failure of the equipment.

Do not use more than one winch to move a load unless each winch was designed for use in a multiple winch system.

Do not use damaged or malfunctioning equipment. To do so could result in failure of the equipment.

Do not modify the equipment in any way. To do so could cause equipment failure.

Do not wrap the wire rope around the load. This damages the wire rope and could cause the load to escape. Use approved rigging connectors to secure the wire rope to the load.

Do not lift loads or pull loads on an incline unless the winch is equipped with a load brake.

Do not divert your attention from the operation. Stay alert to the possibility of accidents, and try to prevent them from happening.

Do not jerk or swing the load. Avoid shock loads by starting and stopping the load smoothly. Shock loads overload the equipment and may cause damage.

Do not leave a suspended load unattended unless specifi c precautions have been taken to secure the load and keep people away from the winch and from under the load.

Do not adjust the winch brake with the load suspended.

Do not exceed the duty cycle rating of the winch when operating with a drillmotor, and do not operate the winch with a drill-motor that exceeds 400 rpm or an impact wrench. To do so could result in equipment damage or failure.

See Figure 1.

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page 4 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

1.1

Installing the Winch

Important!

• Inspect the winch immediately following installation according to the Instructions for Periodic

Inspection. This will give you a record of the condition of the winch with which to compare future inspections.

• A qualifi ed professional should inspect or design the foundation to insure that it will provide adequate support.

• Locate the winch so it will be visible during the entire op er a tion.

• Do not weld the winch frame to the foundation or support structure. Welding the frame may void warranty, contact factory. Use fasteners as instructed.

Do not install the winch in an area defi ned as hazardous by the Na tion al Elec-

tric Code, unless installation in such an area has been thor ough ly ap proved.

Do not install the winch near corrosive chemicals, fl ammable materials, ex-

plo sives, or other elements that may damage the winch or injure the op er a tor.

Ad e quate ly protect the winch and the operator from such el e ments.

Position the winch so the operator can stand clear of the load, and out of the path of a broken wire rope that could snap back and cause injury.

Attach the winch to a rigid and level foundation that will support the winch and its load under all load conditions, including shock loading.

1.1.1

CONSULT APPLICABLE CODES AND REGULATIONS for specifi c rules on installing the equipment.

1.1.2

LOCATE THE WINCH in an area clear of traffi c and obstacles. Make sure the winch is accessible for main te nance and op er a tion.

1.1.3

LOCATE THE WINCH in an area with adequate temperatures. The winch is rated for operation in ambient temperatures ranging from 0° to 100° F.

1.1.4

POSITION THE WINCH to insure proper lubrication.

1.1.5

MAINTAIN A FLEET ANGLE between 1/2 and 1-1/2 degrees. The proper fl eet angle minimizes wire rope damage by helping the wire rope wind uni form ly onto the drum. See Figure 2.

1.1.6

FASTEN THE WINCH SECURELY to the foundation. a

FOR STANDARD PRODUCTS referred to in this manual, use 3/8 inch coarse thread fasteners, grade 5 or better, torqued dry to 30 ft-lbs without lubrication. Make sure the winch frame is secured to a solid foundation able to support the winch and the load under all conditions with design factors based on accepted engineering practices.

b

NON-STAN DARD PRODUCTS that vary from the original design may have different fastening requirements. Contact a structural engineer or Thern,

Inc. for this information.

TO COMPLY WITH LOCAL CODES, CONTACT A QUAL I FIED PRO-

FES SION AL TO OBTAIN PROPER STRUCTURE OR FOUN DA TION

SPEC I FI CA TIONS FOR THE MOUNTING OF THERN PROD UCTS.

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Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

1.2

Installing the Breather Plug

page 5

Important!

• Save the extra oil plug for use when the winch is removed for storage or transport.

Install the breather plug to vent heat and pressure from the gearbox. Fail ure to do so could result in pressure buildup which could damage the equip ment.

For shipment, the gearbox is sealed with an oil plug, and the breather plug is attached to the gearbox or shipped in a separate en ve lope.

1.2.1

REMOVE THE OIL PLUG and install the breather plug in the proper lo ca tion. Make sure the breather plug is above the level of the oil. See Figure 3.

1.2.2

CHECK THE OIL LEVEL in the gearbox to make sure no oil was lost during shipment. See Section 3.3 Lubricating the Winch.

Install the breather plug to vent heat and pressure from the gearbox. Failure to do so could result in pressure buildup which can cause the gearbox to leak or damage the equipment.

Important!

• Use a sheave or roller guide to direct the wire rope to the drum whenever possible.

• Install sheaves, tracks and other equipment so they will remain fi xed under all load conditions.

Follow the recommendations of the equipment manufacturer.

• Use sheaves of proper diameter to minimize wear on the wire rope.

Follow the rec om men da tions of the sheave manufacturer.

Figure 2 – Maintaining the Fleet Angle

• When wire rope travels over a sheave or through a roller guide – main-

tain fl eet angle by locating the sheave or guide an appropriate distance from the drum, shown as distance “A”.

fi xed sheave or roller guide smooth drum

1/2 to 1-1/2 de grees center line distance “A”

• When wire rope travels directly to the load – maintain fl eet angle by con trol ling side-to-side movement of the load with tracks or guide rails.

Allowing the load to move too far to one side causes stress on the drum fl ange which may cause damage.

load smooth drum

1/2 to 1-1/2 de grees center line tracks or guide rails

Figure 3 – Breather Plug Installation

breather plug breather plug breather plug breather plug fl oor mount

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wall mount

(handle down) wall mount

(handle up) ceiling mount

page 6 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

1.3

Installing the Handle

Figure 4 – Installing the Handle

loosen thumbscrew and slide handle in direction shown thumbscrew notch

4A – Slide Handle In

The winch includes a 1-1/8 inch hex drive input. You can attach the handle to this input, or you can use a 1-1/8 inch hex socket to power drive the winch with a maximum 400 rpm drill-motor. Remove the handle before power

driving the winch with a drill-motor.

1.3.1

LOOSEN THE THUMBSCREW and slide the handle toward the medallion as shown. See 4A.

1.3.2

LINE UP THE NOTCH in the handle with the point of the hex in the medallion. See 4B.

1.3.3

SLIDE THE HANDLE AND MEDALLION ASSEMBLY onto the hex drive until the fl at of the handle lines up with the groove in the hex drive.

See 4C.

1.3.4

SLIDE THE HANDLE outward away from the medallion to the desired length and tighten the thumbscrew. See 4D.

line up notch with point of hex in medallion notch medallion

4B – Line Up Notch

groove slide handle assembly onto hex drive until handle fl at lines up with groove

4C – Slide Handle onto Hex

slide handle out to desired length and tighten thumbscrew thumbscrew larger turning radius: heavier loads, slower turns smaller turning radius: lighter loads, faster turns

4D – Adjust Handle Length

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Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

1.4 Installing the Wire Rope

page 7

Important!

• Use wire rope and other rigging equipment rated for the largest load you will be moving.

• Do not drag the wire rope through dirt or debris that could cause damage, or poor operation.

• Always wear protective clothing when handling wire rope.

Install the wire rope securely to the winch drum. A poorly secured wire rope could come loose from its anchor and allow the load to escape.

Do not use 3/16 inch or smaller wire rope on standard drums. To do so could cause damage to the wire rope and allow the load to escape.

Install the wire rope so it is wound correctly as shown or the winch and brake will not work properly, and could allow the load to escape, see Figure 5.

Figure 5 – Installing the

Wire Rope

install the wire rope so it is underwound on the drum as shown tighten set screw

Wire rope assemblies with an chor fi ttings can be pur chased from Thern, Inc.

handle rotation UP tighten set screw typical installation shown left lay – underwound

1.4.1

PURCHASE THE PROPER WIRE ROPE for your application. Keep the following in mind when selecting a wire rope. Contact a reputable wire rope supplier for help.

a

BREAKING STRENGTH of new wire rope should be at least 3 times great er than the largest load placed on the winch. If loads are lifted or pulled on an incline, the breaking strength must be at least 5 times greater than the larg est load. These are minimum values and will vary with the type of load and how you are mov ing it.

b

WIRE ROPE LAY must agree with the winding direction of the drum to help insure proper winding.

c

WE RECOMMEND 7x19 galvanized aircraft wire rope for diameters up to

5/16 inch. Do not use 3/16 inch or smaller wire rope for units with stan-

dard drums.

1.4.2

ANCHOR THE WIRE ROPE to the drum using either the set screw or quick dis con nect anchor.

a

SET SCREW ANCHOR. See Figure 5.

• PASS THE WIRE ROPE under the drum from the front and po si tion it in the slot in the drum. Make sure at least 1/2 inch of wire rope ex tends past the set screw, and 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 to hold the wire rope in place. Hold the wire rope down while tight en ing so the wire rope does not push up out of the slot.

b

QUICK DISCONNECT ANCHOR. See Figure 5.

• PASS THE WIRE ROPE under the drum from the front and position the anchor fi tting in the groove in the drum.

• PULL THE WIRE ROPE to fi rmly lodge the anchor fi t ting in place.

1.4.3

TURN THE HANDLE COUNTER-CLOCKWISE to wind wire rope onto the drum. If wire rope unwinds from the drum when the han dle is rotated counter-clockwise, the wire rope is installed incorrectly. Install the wire

rope correctly before continuing. See Figure 5.

1.4.4

WIND FOUR FULL WRAPS of wire rope onto the drum by operating the winch while holding the wire rope taught. These wraps serve as anchor

wraps and must remain on the drum at all times.

CONTACT A REPUTABLE WIRE ROPE SUPPLIER FOR HELP.

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page 8 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

2.1

General Theory of Operation

Important!

• Limit nonuniform winding by keeping tension on the wire rope and by maintaining the proper fl eet angle.

• It is your responsibility to detect and account for different factors affecting the condition and performance of the equipment.

2.1.1

THE PULL REQUIRED to move the load must not exceed the load rating of the winch. Consider the total force required to move the load, not the weight of the load.

2.1.2

THE AMOUNT OF TIME required to move the load must not exceed the 15 minute duty cycle rating of the winch, when operating with a drill-motor.

2.1.3

THIS EQUIPMENT CAN develop forces that will exceed the load rating.

It is the responsibility of the equipment user to limit the size of the load.

In spect the equip ment reg u lar ly for damage according to the instructions contained in this manual and in component manufacturer’s information.

2.1.4

USE A LOAD BRAKE on all winches used to lift loads or pull loads on an incline. Although a new winch may appear to hold the load in place, this char ac ter is tic will diminish with use. Do not depend on gearing to hold the

load in place.

2.1.5

PERFORMANCE RATINGS of the equipment are affected by the amount of wire rope wound on the drum, the way in which it is wound, and the way the winch is used.

a

DRUM CAPACITY depends on how tightly and evenly the wire rope is wound on the drum. Actual drum capacities are usually 25-30% less than values shown in performance Tables, due to loose winding and overlapping.

b

FORCE REQUIRED TO LIFT the load increases with each additional layer of wire rope wound onto the drum. The value shown in per for mance Tables is based on an empty drum, and maximum handle length.

c

LOAD RATING represents the maximum pull that can be placed on new equip ment. Load ratings are assigned values for specifi c amounts of load travel or wire rope accumulation. The load rating decreases as layers of wire rope ac cu mu late on the drum.

2.1.6

DUTY RATINGS refer to the type of use the equipment is sub ject to. Con-

sid er the following when determining duty rating. The winch has a 15 minute duty cycle rating, when operating with a drill-motor.

a

ENVIRONMENT: harsh environments include hot, cold, dirty, wet, cor-

ro sive, or explosive surroundings. Protect the equip ment from harsh en vi -

ron ments when possible.

b

MAINTENANCE: poor maintenance, meaning poor cleaning, lubrication, or inspection, leads to poor operation and possible damage of the equip ment.

Minimize poor maintenance by carefully following the in struc tions con-

tained in this manual.

c

LOADING: severe loading includes shock loading and moving loads that ex ceed the load rating of the equipment. Avoid shock loads, and do not

ex ceed the load rating of the equip ment.

d

FREQUENCY OF OPERATION: frequent or lengthy operations increase wear and shorten the life span of gears, bearings, and other components.

Increase maintenance of the equipment if used in frequent operations.

Length of operation should not exceed 15 minute duty cycle rating when

operating with a drill-motor.

CONTACT THE FACTORY FOR MORE INFORMATION.

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Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch page 9

2.2

Breaking-In the Winch

2.2.1

BREAK-IN OCCURS during the fi rst 10 hours of normal operation. During break-in, mating surfaces become polished, and clearances increase. This is desired for effi cient operation of bearings and gears.

2.2.2

INSPECT THE WINCH following break-in according to the Instructions for

Periodic Inspection.

Important!

• When determining whether the load will exceed the load rating, consider the total force required to move the load.

2.3

Preparing for Operation

2.3.1

CONSIDER THE OPERATION. Do not begin until you are sure you can perform the entire operation without hazard.

2.3.2

BEFORE EACH OPERATION inspect all components of the system.

a

INSPECT THE WINCH and other equipment according to the Instructions for Frequent Inspection. Do not operate winch until all defects have been corrected.

b

OPERATORS must be in good health, alert, and thoroughly trained in operating the equipment, and properly clothed (safety equipment as required, no loose clothing, no loose jewelry).

c

THE LOAD must be clear of other objects and free to move. Make sure the load will not tip, bind, or in any way move uncontrollably.

2.3.3

KNOW YOUR LOAD and make sure you do not exceed the load rating of the winch or other equipment in the system.

2.4

Attaching the Load

Figure 6 – Attaching Load

latch closed tight against hook sling seated in saddle of hook

Do not wrap the wire rope around the load. This damages the wire rope and could cause the load to escape. Use a sling or other approved lifting device.

2.4.1

CLEAR OBJECTS from the path of the load so you can move it freely and observe it at all times during the operation.

2.4.2

MAKE SURE THE WIRE ROPE is not twisted. A twisted wire rope could cause objects to spin and can cause premature wear of wire rope.

2.4.3

ATTACH THE LOAD using a nylon sling or other approved lifting device.

Follow the recommendations of the manufacturer. See Figure 6.

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page 10 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

2.5

Moving the Load

Important!

• Obey a stop signal from anyone.

• Maintain tension on the wire rope to keep it tightly and evenly wound on the drum.

• If the winch and load are not visible during the entire operation, get help from another person.

• Appoint a supervisor if more than one person is involved in the operation. This will reduce confusion and increase safety.

• Remove the winch handle and secure the drum using the drum lock when the winch is not in use, to help avoid unauthorized use.

Figure 7 – Operation

handle rotation

UP

2.5.1

MOVE THE LOAD slowly and smoothly, only a small distance at fi rst.

Make sure the load is balanced and securely attached before 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 handle is rotated counter-clockwise, the wire rope is installed incorrectly. Install the wire

rope correctly before continuing. See Figure 7.

2.5.3

GRIP THE HANDLE TIGHTLY at all times during operation. If you re lease the handle the load may backdrive causing the handle to spin. Do not try to

stop a spinning handle, step clear until the spinning stops.

2.5.4

OBSERVE THE WIRE ROPE as it winds onto the drum. If it becomes loose, uneven, or overlapped, stop the operation and rewind the wire rope before continuing. Continued operation with overlapped or uneven wire

rope can damage the wire rope and shorten its life.

2.5.5

FOLLOW THE GUIDELINES BELOW to operate the winch with a drillmo tor.

a

DO NOT EXCEED THE DUTY CYCLE RATING of the winch when operating with a maximum 400 rpm drill-motor. See Figure 1.

b

ALLOW THE WINCH AND BRAKE TO COOL DOWN to ambient temperature in rest periods between operations.

c

USE A MAXIMUM 400 RPM DRILL -MOTOR with a 1-1/8 inch hex socket to power drive the input shaft on the winch. The drill-motor should be set for low speed operation if possible. Thern recommends using a drill-motor rated for 400 rpm at 10 amps.

d

THE LOAD RATING OF THE WINCH may decrease when operated with a drill-motor. Check the winch nameplate.

2.5.6

OBSERVE THE GEARBOX AND BRAKE during operation for signs of overheating. Frequent overheating may be a sign of damage, or may

indicate the need for a larger winch.

a

WATCH FOR SMOKE, the smell of burnt lubricant, and other signs of overheating. Use a thermocouple or other device to monitor gearbox and brake temperature. The temperature of the gearbox should not exceed 150° F.

b

STOP THE OPERATION if the gearbox or brake overheats, and allow the winch to cool until it reaches ambient temperature. Continued operation

may cause damage.

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Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Important!

Increase the frequency of maintenance procedures if the winch is:

• Operated frequently.

• Used to pull heavy loads.

• Operated in wet, dirty, hot, or cold surroundings.

page 11

3.1

Cleaning the Winch

Clean the winch to remove dirt and help prevent rust and corrosion.

3.1.1

CLEAN THE WINCH every 6 months or whenever it is dirty.

a

WIPE ALL EQUIPMENT to remove dirt and grease.

b

LEAVE A LIGHT FILM of oil on all surfaces to protect them against rust and corrosion.

c

WIPE OFF excessive amounts of oil to avoid the accumulation of dirt.

3.1.2

REMOVE all unnecessary objects from the area surrounding the winch.

3.2

Adjusting the Brake

Important!

• Do not over tighten the brake, since this will cause parts to wear and become damaged.

Do not adjust the brake with the load suspended. Accidental release of the brake could allow the load to escape.

Figure 8 – Adjusting the

Brake

turn brake adjusting nuts clock wise

1/4 turn

3.2.1

ADJUST THE BRAKE whenever it appears to need adjustment, or at least every 3 months.

3.2.2

TO CHECK THE BRAKE on the 4WM2 series by operating with a test load equal to the winch load rating: a

RAISE THE LOAD, then lower it and stop it about one foot off the ground.

b

OBSERVE THE LOAD when stopped. If it continues to coast or creep, the brake needs adjustment. Contact the factory for assistance.

• FOR MANUALLY OPERATED WINCHES, adjust the brake nuts according to the input shaft torque range specifi ed for the winch, turning the nuts clockwise by 1/4 turns between torque readings. See Table 2. Do not

adjust the brake with the load suspended.

• DO NOT OVERTIGHTEN mechanical brake adjusting nuts.

3.2.3

3.2.4

TIGHTEN THE BRAKE by turning the adjusting nuts clock wise about 1/4 turn. Continue to test and tight en the brake by alternate tightening of each brake nut until it stops and holds the load securely. See Figure 8.

A DECELERATION DISTANCE while stopping is typically 6 inches.

3.2.5

IF THE LOAD CONTINUES TO COAST or creep, contact the factory.

Table 1 – Torque

1

While Lowering for 4WM2 Units

Unit Under No Load Under Load Direction

2

4WM2 2-4 ft-lbs 4-10 ft-lbs clockwise

1

Do not adjust brake with load suspended.

2

Complete 1 full rotation of input shaft.

3

Tighten brake until the minimum value is obtained. See Figure 8.

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page 12 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

3.3

Lubricating the Winch

Important!

• Do not leave plug holes in the gearbox open. Open plug holes will allow dirt or moisture to contaminate the grease.

• Make sure lubricant has a tem-

per a ture rating appropriate for the ambient temperatures of the operation.

Figure 9 – Outboard

Bearing

outboard bearing, lubricate with

NLGI no. 2 grease

Make sure the breather plug is clean and open to vent heat and pressure.

Poor ventilation may cause overheating and result in equipment damage.

Check the gearbox for proper oil level before operation. Too much or too little oil will cause overheating and result in equipment damage.

Lubricate the winch properly to help protect it from wear and rust. Read the following instructions carefully.

3.3.1

THE WINCH IS SHIPPED from the factory with the proper amount (44 ounces) of Mobilgear 600 XP 220 lubricant in the gearbox. Lubricate the winch as follows, see Figures 9 and 10.

3.3.2

CHECK OIL LEVEL before every operation and every 10 hours during operation. Remove the level check plug and make sure oil is even with the plug hole. Add oil to the gearbox if necessary. Do not use synthetic lubricants

and do not mix different lubricants. See Figure 10.

3.3.3

CHANGE GEARBOX OIL at least every 6 months, or whenever it is dirty or contaminated. Remove the drain plug to drain oil from the gearbox. See

Figure 10.

3.3.4

LUBRICATE THE OUTBOARD BEARING at least once every month or more, depending on usage. Use a grease gun to insert NLGI no. 2 grease until clean grease appears at the seals. The bearing will squeak if it is dry.

See Figure 9.

3.3.5

LUBRICATE THE WIRE ROPE and other equipment by following the manufacturer’s recommendations.

Figure 10 – Plug Installation

fi ller/ breather plug level check plug fi ller/ breather plug level check plug drain plug drain plug fl oor mount wall mount

(handle down) fi ller/ breather plug level check plug level check plug fi ller/breather plug drain plug drain plug wall mount

(handle up) ceiling mount

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Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

3.4

Inspecting the Equipment

page 13

Important!

• Start an inspection program as soon as you put the winch into use.

• Appoint a qualifi ed person to be responsible for regularly inspecting the equipment.

• Keep written records of inspection. This allows comparison with comments from previous inspections so you can see changes in condition or performance.

Perform frequent inspections:

• Before each operation.

• Every 3 hours during operation.

• Whenever you notice signs of damage or poor operation.

Frequent Wire Rope Inspection:

• Use ASME B30.7 as a guideline for rope inspection, replacement and maintenance.

• Check the wire rope, end connections and end fi ttings for corrosion, kinking, bending, crushing, birdcaging or other signs of damage.

• Check the number, distribution and type of visible broken wires.

See paragraph 3.4.4 c and Figure

11.

• Check the wire rope for reduction of rope diameter from loss of core support, or wear of outside wires. See Figure 13.

• Take extra care when inspecting sections of rapid deterioration such as sections in contact with saddles, sheaves, repetitive pickup points, crossover points and end connections.

Do not use damaged or malfunctioning equipment. Place an “OUT OF OR DER” sign on the winch. Do not use the winch until the sign is re moved by a qual i fi ed maintenance person who has completely corrected the prob lem.

3.4.1

Inspect the winch to detect signs of damage or poor operation before they be come hazardous. See Table 1 Inspection Checklist.

CONSULT APPLICABLE CODES AND REGULATIONS for specifi c rules on inspecting the winch and other equipment.

3.4.2

CONSULT MANUFACTURER’S RECOMMENDATIONS for in for ma tion on in spect ing the wire rope and other equipment.

3.4.3

In struc tions for Frequent Inspection

a

VISUALLY INSPECT the entire winch and all other equipment involved in the operation.

• Check all equipment for cracks, dents, bending, rust, wear, corrosion and other damage.

• Make sure the wire rope is installed correctly and anchored securely to the drum.

• Make sure the winch is properly lubricated.

• Make sure the thumbscrew holding the handle in place is tight.

• Check the gearbox for signs of leakage, and make sure it is fi lled with the proper lubricant. Contact the factory if there are any signs of lubricant leaking from the gearbox.

• Make sure the breather plug is clean, open, and installed correctly.

• Make sure mounting fasteners are tightened securely.

• Make sure the foundation is in good condition, and capable of supporting the winch and its load under all load conditions.

b

TEST WINCH PERFORMANCE by moving the winch with a load not exceeding the load rating.

• Listen for unusual noises, and look for signs of damage as you operate the winch.

• Make sure the wire rope winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing.

• Make sure the load moves smoothly, without hesitation or strain.

• Make sure the handle rotates freely in both directions.

• Check the brake. Raise the load, then lower it and stop it a few feet off the ground. If the load continues to coast or creep under normal operating conditions, the brake needs ad just ment. See section 3.2 Adjusting the

Brake.

Completely correct all problems before continuing. Use the Trou ble shoot ing

Chart to help determine the cause of certain problems. See Table 3.

A7535G-0613

page 14 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Perform periodic inspections:

• Every 6 months, or more frequently if drill driven.

• Whenever you return the winch to service from storage.

• Whenever you notice damage or poor operation in a frequent inspection.

• Whenever you have, or think you may have, overloaded or shock loaded the winch.

Figure 11 – Broken Wires

wire strand

Figure 12 – Load Hook

Inspection

twist one lay

Wire rope assembly must be re-

placed if more than 6 wires are bro ken in one lay, or if more than

3 wires are broken in one strand in one lay.

throat opening thickness

The wire rope assembly must be replaced if the throat opening is

15% wider than nominal, if the thick ness is 10% less than nominal, or if the hook is twisted 10° or more.

3.4.4

Instructions for Periodic Inspection

a

VISUALLY INSPECT the winch and all other equipment.

• Disassembly may be required in order to properly inspect individual components. Contact factory for assembly/disassembly instructions. Disassembly of the gearbox before contacting Thern, Inc voids all warranties.

• Check the fi nish for wear, fl aking, or other damage.

• Check all equipment for cracks, dents, bending, rust, wear, corrosion and other damage. If the equipment was overloaded, or if you notice cracks and other signs of overloading and damage promptly remove equipment from use and have it repaired or replaced. DO NOT CONTINUE TO

USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE

ROPE.

• Check all fasteners for stripped threads, wear, bending, and other dam age.

• Check the gearbox for signs of leakage. Contact factory if there are any signs of lubricant leaking from the gearbox.

• Make sure the breather plug is clean, open, and installed correctly.

• Make sure all labels and plates are readable, fi rmly attached, free of damage and clean. Replacements are available from the factory.

• Check the foundation for cracks, corrosion, and other damage.

b

DRAIN A SMALL AMOUNT OF OIL into a clean con tain er.

• Check the oil for dirt, metal particles, water, and other signs of con tam i-

na tion. Completely drain the gearbox if oil is con tam i nat ed.

• Make sure the gearbox is properly lubricated. See section 3.3 Lubricating the Winch.

c

INSPECT THE WIRE ROPE according to the wire rope manufacturer's recommendations or follow accepted industry standards for wire rope inspection.

• Always wear protective clothing when handling wire rope.

• Check the entire length of wire rope for bent wires, crushed areas, bro ken or cut wires, corrosion, and other damage. Carefully inspect areas that pass over sheaves or through roller guides.

• Note the location and concentration of broken wires. Replace wire rope if more than 6 wires are broken in one lay, or more than 3 wires are bro ken in one strand in one lay. See Figure 11.

• Make sure the load hook, anchor fi tting, or other devices are securely attached to the wire rope, and the wire rope where they are attached is not frayed, corroded, bro ken, or otherwise damaged.

• Measure the throat opening, thickness, and twist of the hook. Replace the hook if it shows signs of damage. See Figure 12.

• Make sure hook latch opens without binding and closes when released.

• Check the anchor holes in the drum and the surrounding area for signs of wear or distortion.

A7535G-0613

Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch page 15

Figure 13 – Rope Diameter

correct incorrect

The wire rope assembly must be replaced if the diameter measures less than the minimum diameter at any point.

wire rope diameter

1/8 in

3/16 in

1/4 in

5/16 in

diameter

minimum diameter

7/64 in (.1094 in)

11/64 in (.1719 in)

15/64 in (.2344 in)

19/64 in (.2969 in) d

MOVE THE DRUM with your hands.

• Check for excessive movement indicating worn or loose gears, bearings, or shafts. Slight endplay in the driveshaft is normal. Excessive movement is caused by overloading or overheating, and is a sign that your application may require a larger winch.

• Disassemble the winch if necessary. Inspect gears, keys, bearings, seals, and shafts for wear, corrosion, distortion, and other damage. Contact factory for assembly/disassembly instructions. Disassembly of the product before contacting Thern, Inc. voids all warranties.

e

PLACE enough weight to keep the wire rope straight and tightly drawn.

• Measure the diameter of the wire rope, especially in areas where wear is noticeable. Replace the wire rope if the diameter measures below the minimum diameter at any point. See Figure 13.

f

LUBRICATE THE ENTIRE WINCH.

g

INSTALL THE WIRE ROPE.

h

TEST WINCH PERFORMANCE by operating the winch with a load equal to the load rating.

• Listen for unusual noises, and look for signs of damage as you operate the winch.

• Make sure the wire rope winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing.

• Observe the rotating drum, look for signs of loose or misaligned bear ings.

• Make sure the load moves smoothly, without hesitation or strain.

• Make sure the handle rotates freely in both directions.

• Check the brake. Raise the load, then lower it and stop it a few feet off the ground. If the load continues to coast or creep under normal operating conditions, the brake needs ad just ment. See section 3.2 Adjusting the

Brake.

Completely correct all problems before continuing. Use the trou ble shoot ing chart to help determine the cause of certain problems. See Table 3.

A7535G-0613

page 16 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Table 2 – Inspection Checklist

checked boxes indicate damage or problem in need of repair

general

damages

fi nish weathered, fl aking, otherwise damaged

problems

winch jerks or hesitates during operation

comments

fasteners

gearbox

parts cracked, bent, rusted, worn, otherwise damaged

stripped threads, bent, worn, otherwise damaged

bent, crushed, otherwise damaged

broken wires, see Figure 11

unusual noises, other signs of malfunction

loose, not tightened to proper torque

gears, bearings, or shafts loose, worn, otherwise damaged not properly lubricated

oil leakage oil contaminated

wire rope loosely or unevenly wound wire rope replace if more than 6 wires in one lay, or 3 wires in one strand in one lay, are broken

diameter reduced, see Figure 13 replace if diameter is excessively worn

end connections corroded, rusted, worn, otherwise damaged

hook or other device twisted, bent, worn, otherwise damaged, see Figure 12 number per strand = number per lay = diameter =

not securely attached

hook latch fails to close when released

drum

brake

labels and plates replace if twist is 10 degrees or more replace if throat width is 15% larger than nominal replace if thickness is 10% less than nominal

anchor worn, distorted, otherwise damaged

brake worn, corroded, otherwise damaged

dirty, illegible, otherwise damaged twist = throat width = thickness =

excessive movement or backlash

brake does not operate properly

loosely attached or missing

authorized signature date

A7535G-0613

Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch page 17

Table 3 – Troubleshooting Chart

Contact the factory for detailed instructions on re-sealing the gearbox if you are required to disassemble the gearbox for any reason. Disassembly of the gearbox before contacting Thern, Inc. voids all warranties.

problem

handle turns, drum doesn’t turn

cause

• loose or broken spring pins or shafts

• loose, stripped or broken gears or keys

correction

inspect winch and brake, repair as necessary repair as necessary

handle turns hard or not at all

brake does not operate properly

lubricant leakage

• unit overheated

• load too heavy

• gearbox contaminated with dirt or debris

• keys or spring pins loose or broken

• brake band too tight

• brake broken or locked

• gears or bearings broken or locked

• wire rope installed improperly

• brake adjusted incorrectly

• brake worn or damaged

• brake components broken or locked

• worn bearings

• oil seals leaking or damaged

• gaskets leaking or damaged

• cracked or damaged gearbox

• gearcase plugs not tightened allow to cool lighten load inspect and relubricate as necessary inspect winch and brake, repair as necessary loosen brake and readjust inspect and repair as necessary inspect and replace as necessary reinstall wire rope correctly adjust brake inspect and replace as necessary inspect and repair as necessary inspect and replace as necessary inspect and replace as necessary tighten fasteners or replace gasket inspect and repair as necessary tighten

excessive end play on drive shaft

• breather plug clogged or damaged

• loose or damaged keys or keyways

• thrust washer or bearing worn out

• excessively worn gears

excessively worn gears or bearings • load too heavy

• poor lubrication of gears or bearings

overheating • operated too long without rest

• load too heavy

• poor lubrication

• breather plug clogged or damaged

• bearing seized up

unusual noises high pitched squeak grinding noise rattling noise heavy thump during operation back drive

• poor lubrication

• contaminated lubrication

• dirt in winch gears

• broken gears or bearings clean or replace vent plug as needed inspect and replace as necessary inspect and replace as necessary inspect and repair as necessary lighten load inspect and lubricate as necessary allow to cool lighten load inspect and lubricate as necessary clean or replace vent plug as needed inspect and replace as necessary inspect and lubricate as necessary drain, clean and lubricate the winch inspect and clean as necessary inspect and replace as necessary

• loose fasteners or set screws

• contaminants in lubricant tighten all fasteners and screws drain, clean and lubricate the winch

• loose set screws or keys in gears or shafts inspect and repair as necessary

• bearings defective inspect and replace as necessary

• brake out of adjustment adjust brake per manual

A7535G-0613

page 18 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

3.5

Repairing the Winch

Important!

• It is your responsibility to determine when to replace parts.

When considering whether to continue using a part or to replace it, remember that replacing it is the best way to avoid further equipment damage.

• Replace spring pins, retaining rings, and oil seals whenever the winch is disassembled for inspection or repair.

• During reassembly, use Loctite

598 Ultra Black to create a seal between the two halves of the gearbox and the input shaft.

Contact the factory for detailed instructions. Disassembly of the gearbox before contacting Thern,

Inc. voids all warranties.

• Appoint a qualifi ed person to be responsible for all repairs to the equipment.

3.5.1

GET FACTORY AUTHORIZATION for all repairs. Unauthorized repairs will void the warranty, and may lead to damage or failure of the winch.

3.5.2

REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repair parts.

3.5.3

REFINISH AREAS where the paint is worn or fl aking. A good fi nish helps to protect against corrosion and weather damage.

a

REMOVE THE FINISH from damaged areas, down to the bare metal.

b

CLEAN THE AREA thoroughly.

c

REPAINT with a high quality primer and fi nishing coat.

3.5.4

TO ORDER REPAIR PARTS, contact your local dealer. Include the following information when ordering:

• model number

• serial number (or code number)

• part number

• date purchased, and from whom

• description of what happened, or what is wrong

• your name and return address

A7535G-0613

Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch page 19

Important!

• Keep a record of what you ship, and when you send it.

4.1

Transporting the Winch

4.1.1

REMOVE THE BREATHER PLUG and install a sealed oil plug to prevent the loss of lubrication during shipment.

4.1.2

PACK THE WINCH in an upright position for transport, using the original packaging materials, if possible.

a

FASTEN THE WINCH to a wooden base using lag bolts, to keep it from moving during transport.

b

SEAL THE WINCH in plastic with a desiccant to help protect it from rust, corrosion, and other damage.

c

CONSTRUCT WOODEN SIDES and top to enclose the winch in a solid protective crate.

d

PACK LOOSE PARTS in small boxes or ship separately.

4.1.3

INSPECT THE WINCH according to the Instructions for Periodic Inspection before installing it in a new location.

4.2

Storing the Winch

4.2.1

LUBRICATE THE WINCH as necessary, and make sure the breather plug is clean and properly installed. Add a rust preventative for long term storage.

4.2.2

SEAL THE WINCH in plastic with a desiccant to help protect it from rust, corrosion, and other damage.

4.2.3

STORE THE WINCH upright, in a cool clean place away from corrosive chemicals and moisture.

4.2.4

ROTATE THE DRUM PERIODICALLY to keep bearing and gears surfaces from becoming lacquered.

4.2.5

INSPECT THE WINCH according to the Instructions for Periodic Inspection before installing it for operation.

4.2.6

LUBRICATE THE WINCH PROPERLY prior to operation. Refer to Section 3.3 Lubricating the Winch.

A7535G-0613

page 20 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Model 4WM2 Worm Gear Hand Winch item description

11

12

13

14

15

16

17

18

19

6

7

8

9

10

1

2

3

4

5

REDUCER ASSEMBLY

HEX INPUT ASSEMBLY

KEY .188 X .188 X 1.000

HANDLE MEDALLION ASSEMBLY

HEX NUT .375-16NC

SETSCREW SQHD .250-20NC X .875

DRUM

GROOVE PIN .312 X 2.500

FRAME

FLANGE BEARING

CARRIAGE BOLT .375-16NC X 1.250

BREATHER PLUG

LABEL WARNING DO NOT ADJUST BRAKE WHEN

NAMEPLATE

LABEL CODE NUMBER

LABEL WARNING TO AVOID INJURY OR PROP...

LABEL WARNING KEEP HANDS AWAY FROM DRUM

LABEL WARNING

LABEL MODEL/CAPACITY

part number

D2058

B3705

A7310

B4218

A3017

A7536

C3381

A7284

D1913

A7285

A7283

A3408

A2658

A6889

10477

A1978

A2659

A7406

A7473

1

1

2

1

1

1

1

1

1

1

1

1

1

2

qty.

1

1

1

1

6

16

17

13

1

2 3

4

8

9

10

11 5

18

12

14

15

5

6

7

19

A7535G-0613

Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Model 4WM2V Worm Gear Hand Winch - Vertical Mount item description

11

12

13

14

15

16

17

18

19

6

7

8

9

10

1

2

3

4

5

REDUCER ASSEMBLY

HEX INPUT ASSEMBLY

KEY .188 X .188 X 1.000

HANDLE MEDALLION ASSEMBLY

HEX NUT .375-16NC

SETSCREW SQHD .250-20NC X .875

DRUM

GROOVE PIN .312 X 2.500

FRAME

FLANGE BEARING

CARRIAGE BOLT .375-16NC X 1.250

BREATHER PLUG

LABEL WARNING DO NOT ADJUST BRAKE WHEN

NAMEPLATE

LABEL CODE NUMBER

LABEL WARNING TO AVOID INJURY OR PROP...

LABEL WARNING KEEP HANDS AWAY FROM DRUM

LABEL WARNING

LABEL MODEL/CAPACITY

part number

D2058

B3705

A7310

B4218

A3017

A7536

C3381

A7284

D2173

A7285

A7283

A3408

A2658

A6889

10477

A1978

A2659

A7406

A7473

1

1

2

1

1

1

1

1

1

1

1

1

1

2

qty.

1

1

1

1

6

16

page 21

13

1

2 3

4

8

9

10

11 5

18

12

19

14

15

A7535G-0613

5

6

7

17

page 22 Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Reducer Assembly item description

16

17

18

19

20

11

12

13

14

15

6

7

8

9

10

1

2

3

4

5

21

22

23

CAPSCREW HEXHD .312-18NC X .750

BEARING HOUSING ASSEMBLY

BRAKE DRUM SPACER

THRUST BEARING .628ID X 1.250OD X .125

DRUM BRAKE ASSEMBLY

FLAT WASHER .656ID X 1.875OD X .094

SHIM .626/.630 X 1.00 X .018/.022

PIPE PLUG SQHD .125-27NPT X .35

DOWEL PIN .188 X .500

BALL THRUST BEARING .753ID X 1.685OD X .625

BEARING HOUSING ASSEMBLY INPUT SIDE

CAPSCREW HEXHD .312-18NC X 1.000

WORM SHAFT

PIPE PLUG HEXSOC .125-27NPT X .31

BRAKE BAND CONNECTOR ASSEMBLY

HEX JAM NUT NYLK .375-16NC

COVER

GEARCASE

STUD .375-16NC X 1.312

DRUM SHAFT ASSEMBLY

OIL SEAL 1.125ID X 1.874OD X .250

PIPE PLUG HEXSOC .375-18NPT X .425

SPRING WASHER .380 X .750 X .034

D2058 part number

A3032

B3582

A2642

A7291

B1700

A7292

A3308

A3407

A7308

A1498

B3581

A3028

C3276

A3405

B2917

A3180

D2052RED

D2051RED

A7279

C3414

A7287

A3290

A3296

1

2

1

4

1

1

2

2

1

1

qty.

2

1

12

1

1

1

4

1

1

4

2

1

1

2

3

4

1

5

7

3

6

8

9

10

11

12

13

1

14

15

16

17

18

19

20

23

22

21

A7535G-0613

Owner's Manual for Thern 4WM2 Series Worm Gear Hand Winch

Pressure Plate Assembly

1 item description

1

2

3

4

5

6

7

PRESSURE PLATE

PIN

PRESSURE PLATE BASE

TORSION SPRING

SPACER TUBE

CAPSCREW HEXHD .250-20NC X .375

RETAINING RING .500

1 B3688 supplied with crane winches 4WM2-K and 4WM2V-K.

B3688 part number

B3643

A3269

A3268

A3277

A3273

A7434

A3278

qty.

1

1

1

1

1

2

2

1

Handle Medallion Assembly item description

1

2

3

4

HANDLE ASSEMBLY

THUMB SCREW .312-18NC X .750 SST

MEDALLION

SLOTTED SPRING PIN .187 X .750 SST

3

2

4 5

6

7

B4218 part number qty.

B4187

A8167

B4189

A4282

1

1

1

1

1

2 3

4

page 23

4WM2 Performance Characteristics 1

wire rope dia. (in)

1/4

5/16

1st layer

2000

2000 load rating (lb) mid drum

1500

1500 full drum

1200

1200

1st layer

11

8 drum capacity (ft) mid drum

35

23 full drum

77

52 gear ratio

32:1

32:1 force to lift

1000 lb

14 lb

14 lb

1 Performance Characterirstics are for standard products referred to in this manual. Non-standard products may vary from the original

design. Contact Thern, Inc. for this information.

A7535G-0613

Thern, Incorporated

5712 Industrial Park Road

Winona, MN 55987

PHN 507-454-2996

FAX 507-454-5282

EMAIL: [email protected]

www.thern.com