Thern Liberty 3CP1S-HM, Liberty 3CP2S-HM Owner's Manual

Read this Owner’s Manual
thoroughly before operating
the equipment. Keep it with
the equipment at all times.
Replacements are available
from Thern, PO Box 347,
Winona, MN 55987,
507-454-2996.
www.thern.com
IMPORTANT: Please record
product information on
page 2. This information is
required when calling the
factory for service.
ORIGINAL TEXT
Owner’s Manual
For 3CP Liberty Series
Capstan Winches
A21392-E-1122
Page 2
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Two-Year Limited Warranty
Please record the following:
Date Purchased:
Model No.:
Serial No.:
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
modification 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 specific 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
responsibility 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 owner's
responsibility to obtain copies of these regulations and to determine the suitability
of the equipment to its intended use.
This Owner’s Manual, and warning labels attached to the equipment, are to serve
as guidelines for hazard-free installation, operation, and maintenance. They
should not be understood to prepare you for every possible situation.
The information contained in this manual is applicable only to the Thern 3CP1 and
3CP2 series Capstan winches. Do not use this manual as a source of information for
any other equipment.
The following symbols are used for emphasis throughout this manual:
Failure to follow ‘WARNING!’ instructions may result in equipment damage,
property damage, and/or serious personal injury.
Failure to follow ‘CAUTION!’ instructions may result in equipment damage,
property damage, and/or minor personal injury.
Important!
Failure to follow ‘important!’ instructions may result in poor performance of
the equipment.
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Page 3
Suggestions for Safe Operation
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.
Before each use inspect the winch for leaks or other damage.
Install the rope securely to the winch drum.
Install the winch in a well-lit area, free of clutter and trip hazards. It should
be positioned where there is a good line of sight of the winch, rigging and load
being moved. Use a spotter if load path is obstructed. The mounting should
take into consideration the ergonomics of handling the rope as well as operating the rope lock.
Use the proper amount of rope wraps on the drum to keep the hand effort to
about 20 pounds of pull. This will vary based on the load being moved, rope
size, and rope construction. See section 1.3 for additional information.
Keep hands away from the pinch points between the drum and the rope, and
other moving parts of the equipment.
Wear hearing protection when operating the winch.
Keep all unnecessary personnel away from winch while in operation. Keep
out of the path of the load.
Disconnect electric power before servicing the equipment.
Stay out of path of potential spring back of broken rope.
Position the winch such that the load line fleet angle is minimized. See section
1.1 for additional information.
Secure the rotation stop used with the swivel mount, when supplied, before
operation to prevent unexpected rotation. Properly align winch with load to
prevent rotation or damage to rotation stop.
Before operation with the swivel mount, when supplied, verify the pivot bolt
and nut are secure with safety cotter pin properly in place.
Ensure mounting surface or vehicle is rated for expected loads, including
potential shock loads.
Use only Thern manufactured accessories with the Thern 3CP1 and 3CP2
series capstan winches. Use of non-Thern accessories may result in injury,
poor performance, and loss of warranty.
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Suggestions for Safe 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. Doing 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 a multiple winch system.
Do not use damaged or malfunctioning equipment. Doing so could result in
failure of the equipment.
Do not position yourself under the load being moved.
Do not position yourself between the winch and the load being moved.
Do not operate the winch with rope lock, rope keeper gate, drive guards or
gear covers removed or improperly installed.
Do not install rope with hand line next to reducer. Always have the load line
closest to the reducer.
Do not let go of the rope when operating the winch.
Do not modify the equipment in any way. Doing so could cause equipment failure.
Do not wrap the rope around the load. This damages the rope and could cause
the load to escape. Use approved rigging connectors to secure the rope to the
load.
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 rely on winch to hold unattended loads. Do not leave a suspended load.
Do not operate the winch without the rope lock.
Do not adjust the rope lock while the lock is securing the rope. Accidental
release of the rope or injury may occur.
Do not position the winch where the load line or hand line will result in an
excessive fleet angle. See section 1.1 for additional information.
Do not operate the winch without all fasteners and pins securely in place.
Do not use the hitch mount accessory with lightweight or otherwise unstable
vehicles that may move during operation.
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
1.1
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 qualified professional should
inspect or design the
foundation to insure that it will
provide adequate support for the
winch.
• Locate the winch so it will be
visible during the entire operation.
• Do not weld the winch frame to
the foundation or support
structure. Welding the frame may
void warranty, contact Thern, Inc.
Use fasteners as instructed.
Do not install the winch near corrosive chemicals, flammable materials,
explosives, or other elements that may damage the winch or injure the
operator. Adequately protect the winch and the operator from such elements.
Do not install the winch in an area defined as hazardous or potentially
explosive.
Position the winch so the operator can stand clear of the load, and out of the
path of a broken 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. Swivel mount
units may also be mounted to appropriate Thern Hitch Mount Accessory
(3CP1S-HM or 3CP2S-HM).
1.1.1
1.1.2
Figure 1
1.1.4
15°
MAX
1.1.5
a
ROPE
LOCK
SWIVEL MOUNT
ROTATION STOP
Installing the Winch
Do not install the winch in an area defined as hazardous by the National
Electric Code unless installation in such an area has been thoroughly
approved.
1.1.3
LOAD LINE
FLEET ANGLE
Page 5
CONSULT APPLICABLE CODES AND REGULATIONS for specific
rules on installing the equipment.
LOCATE THE WINCH in an area clear of traffic and other obstacles. Make
sure the winch is accessible for maintenance and operation.
LOCATE THE WINCH in an area with ambient temperatures between -4°F
to +122°F (-20°C to +50°C)
LOCATE THE WINCH to maintain an appropriate fleet angle. The rope
fleet angle should never exceed 15 degrees when exiting the drum or
rope lock. Secure the rotation stop used with the swivel mounting bracket
before operation to prevent unexpected rotation. Properly align winch with
load to prevent rotation or damage to rotation stop. See Figure 1.
FASTEN THE WINCH securely to the foundation or Thern Hitch Mount
Accessory 3CP1S-HM or 3CP2S-HM.
FOR STANDARD PRODUCTS referred to in this manual, use a minimum
of four coarse thread fasteners, 1/2 – 5/8 inch grade 5 (12 – 16mm, grade
8.8) or better. Make sure the winch is secured to a solid foundation or Thern
Hitch Mount Accessory 3CP1S-HM or 3CP2S-HM to able to support the
winch and load under all conditions with design factors based on accepted
engineering practices.
Table 1: Suggested Fastener Torque Values (ft-lbs)
HAND LINE
FLEET ANGLE
15°
MAX
Plain & Dry
Zinc Plated
Lubricated
(eg. loctite)
1/2 inch grade 5
75
65
55
5/8 inch grade 5
150
65
160
125
55
135
110
49
120
M12 grade 8.8
M16 grade 8.8
Refer to manufacturer’s instructions for other fastener types with specific
torque or installation instructions.
b
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NON-STANDARD PRODUCTS that vary from the original design may
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
have different fastening requirements. Contact a structural engineer or Thern,
Inc. for this information.
1.1.6
HITCH MOUNT ACCESSORY should be attached to an appropriate vehicle
using the supplied clevis and cotter pin. 3CP1 hitch mount accessory should
be attached to a 2 inch receiver (Class 4). 3CP2 hitch mount accessory
should be attached to a 2 1/2 inch receiver (Class 5).
Do not use the hitch mount accessory with lightweight or otherwise
unstable vehicles that may move during operation.
DO NOT ATTEMPT TO USE THE 3CP2 WINCH WITH THE
3CP1 HITCH MOUNT. DOING SO MAY CAUSE LOSS OF LOAD
RESULTING IN PROPERTY DAMAGE AND/OR PERSONAL
INJURY.
Important!
• Use components rated for the
power supply you will be using.
TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED
PROFESSIONAL TO OBTAIN PROPER STRUCTURE OR
FOUNDATION SPECIFICATIONS FOR THE MOUNTING OF
THERN PRODUCTS.
• Always disconnect electric power
when the unit is not in use.
Image 1
1.2
Connecting Electric Power
Only use winch with proper branch circuits, disconnect devices, protection,
and grounding as required by article 430 of the National Electric Code.
Locate control devices so the operator will be able to view the load through
the entire operation.
Locate control devices so the operator will be clear of the load.
Image 2
1.2.1
a
USE AN APPROPRIATELY sized extension cord to plug into a grounded
120 Volt nominal single phase, 50 or 60 Hertz power source. See Image 1.
MINIMUM RECOMMENDED GENERATOR size is 2400 watts
continuous and 4500 Starting (peak) watts.
Table 2:
Image 3
Extension Cord
Maximum Cord
Diameter (gauge)
Length (feet)
14
75
12
125
10
200
8
300
6
500
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Page 7
Important!
1.2.2
PLUG IN foot switch cord as shown in Image 2.
• Use synthetic fiber rope and other
rigging equipment rated for the
size of the largest load you will be
moving.
1.2.3
TWIST FOOT SWITCH PLUG CLOCKWISE to secure.
1.2.4
TEST POWER BY operating the foot switch as shown in Image 3.
1.3
Installing the Rope
• Do not drag the synthetic fiber
rope through dirt or debris to
avoid causing damage or poor
operation.
• Use proper protection when
handling synthetic fiber rope.
Image 4
Wrap the rope securely to the drum. A poorly secured rope could slip and
allow the load to escape.
Select a rope that has a high melting point, low stretch, and a good resistance
to abrasion. Avoid rope materials that may glaze when subjected to heat
caused by friction with the drum or that may build up a static charge. Do not
use polypropylene rope.
Always install the rope overwound so the load line is closest to the motor.
Failure to do so can cause an unsafe condition and may result in equipment
damage or injury.
Image 5
Never add or subtract rope wraps to the drum while the load is suspended.
1.3.1
1.3.2
Image 6
1.3.3
Image 7
Thern recommends ½ inch – ¾ inch (12.5 – 19mm) synthetic rope. Follow
all guidelines, instructions, and load limitations of the rope manufacturer.
TO INSTALL ROPE, open safety gate. See Image 4. Wrap the rope
counter-clockwise (looking at the drum from the bell) with the load line
starting at the narrow end of the drum closest to the motor. See Image 5.
USE THE PROPER NUMBER OF ROPE WRAPS on the drum for
the load being lifted or lowered. The number of wraps required varies
depending with the weight of the load and should result in about 20 pounds
of effort by the user to allow easy operation. Four wraps are a good starting
point, but adding or subtracting wraps may be required to find the proper
number. See Figure 2. Avoid placing too many wraps on the drum as
this can lead to uncontrolled lifting.
Figure 2
MECHANICAL ADVANTAGE
7
6
Image 8
NUMBER OF WRAPS
5
4
3
2
1
0
0
10
20
30
40
50
60
OUTPUT FORCE/INPUT FORCE
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70
80
90
1 00
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
1.3.4
Important!
• To help ensure rated performance,
make sure voltage at the motor is
equal to the motor’s voltage rating.
• It is your responsibility to detect
and account for different factors
affecting the condition and
performance of the equipment.
INSERT ROPE INTO ROPE LOCK by pulling open cam and positioning
rope as shown in Image 6. Do not operate the winch without the rope
lock.
1.3.5
RELEASE THE CAM to secure rope in place. See Images 7 and 8.
1.3.6
TO REMOVE ROPE, reverse the steps above.
2.1
2.1.1
2.1.2
a
2.1.3
a
b
General Theory of Operation
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.
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.
Inspect the equipment regularly for damage according to the instructions
contained in this manual.
LOAD RATING represents the maximum pull that can be placed on new
equipment.
DUTY RATINGS refer to the type of use the equipment is subject to.
Consider the following when determining duty rating:
ENVIRONMENT: harsh environments include hot, cold, dirty, wet,
corrosive, or explosive surroundings. Protect the equipment from harsh
environments when possible.
MAINTENANCE: poor maintenance, meaning poor cleaning, lubrication,
or inspection, leads to poor operation and possible damage of the equipment.
Minimize poor maintenance by carefully following the instructions
contained in this manual.
Figure 3
3CP1 and 3CP2 Series Duty Cycle @ 20°C Ambient
The duty cycle data shown in figure 2 was collected with a 20°C ambient
temperature. Ambient temperatures above and below this will have an
effect on the duty cycle.
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
c
d
Page 9
LOADING: severe loading includes shock loading and moving loads that
exceed the load rating of the equipment. Avoid shock loads, and do not
exceed the load rating of the equipment.
FREQUENCY OF OPERATION: frequent start and stop functions increase
wear and shorten the life span of the power train and load brake components.
Lengthy operations cause power train to become hot, which also decreases
the life span of the gear train. See Figure 3.
Important!
• When determining whether the
load will exceed the load rating,
consider the total force required
to move the load.
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.2
a
b
c
2.3.3
2.3.4
A21392-E-1122
Breaking-In the Winch
BREAK-IN OCCURS during the first few minutes of normal operation.
During break-in, mating surfaces become polished, and clearances increase.
This is desired for efficient operation of bearings and gears.
INSPECT THE WINCH following break-in according to the Instructions
for Periodic Inspection. See Section 3.2 - Inspecting the Equipment.
Preparing for Operation
CONSIDER THE OPERATION. Do not begin until you are sure you can
perform the entire operation without hazard.
INSPECT ALL COMPONENTS of the system.
INSPECT THE WINCH and other equipment according to the Instructions
for Frequent Inspection.
OPERATORS must be in good health, alert, thoroughly trained in operating
the equipment, and properly clothed (hard hat, hearing protection, safety
shoes, gloves and safety glasses, no loose clothing).
THE LOAD must be clear of other objects and free to move. Make sure the
load will not tip, spin, roll away, or in any way move uncontrollably.
KNOW YOUR LOAD and make sure you do not exceed the load rating of
the winch or any other equipment in the system.
HAVE A METHOD FOR HANDLING ROPE. As the rope is pulled off
the drum, lay the rope into a container. Use a clean box or wastebasket. This
will help prevent tripping or entanglement with the rope.
Page 10
Important!
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
2.4
Attaching the Load
• Obey a stop signal from anyone.
• Maintain tension on the synthetic
fiber 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.
Do not wrap the rope around the load. This damages the rope and could cause
the load to escape. Use an approved lifting device.
2.4.1
2.4.2
2.4.3
ATTACH THE ROPE TO THE LOAD using an approved lifting device.
Follow the recommendations of the rope, shackle, and/or sling manufacturer.
Knots and other rope terminations may decrease the strength of the rope.
DO NOT ATTEMPT to move a load that is directly above the winch.
Reposition the winch to achieve the least amount of fleet angle to the load.
See Figure 1.
2.5
Moving the Load
2.5.1
SECURELY GRASP HAND LINE end of rope.
Image 6
2.5.2
2.5.3
Image 7
2.5.4
2.5.5
Image 8
CLEAR OBJECTS from the path of the load so you can move it freely and
observe it at all times during the operation.
a
MOVE THE LOAD slowly and smoothly, only a small distance at first.
Make sure the load is balanced and securely attached before continuing.
Make sure the supporting structure, winch mount bracket(s), and/or vehicle
is stable and secure before continuing.
USE FOOT SWITCH CONTROL to operate the winch motor. The foot
pedal is a momentary contact type so the winch will stop when the operator
releases the switch.
TO RAISE THE LOAD, pull on hand-line end of rope. See Image 7.
Always ensure hand-line is running through rope lock during operation.
OBSERVE THE ROPE as it winds onto the drum. Keep tension on the
hand-line of the rope. If it becomes loose, uneven, or overlapped, stop the
operation and re-wind the rope before continuing. Continued operation
with overlapped or uneven rope can damage the rope or cause a
dangerous and unsafe condition.
EYE NUT TIE-OFF POINTS are supplied with 3CP1S and 3CP2S mounting
hardware. See Parts Diagrams. Load ratings vary with model and attachment angle. Use multiple or alternate tie-off points if necessary.
Angle from Verticle
3CP1S-AFS
3CP2S-AFS
Eye Nut Load Rating
up to 30 degrees
1000 lbs (450 kg)
up to 45 degrees
600 lbs (300 kg)
up to 45 degrees
550 lbs (250 kg)
up to 30 degrees
2000 lbs (900 kg)
up to 45 degrees
1000 lbs (450 kg)
up to 45 degrees
900 lbs (400 kg)
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
2.5.6
a
b
2.5.7
Over Temperature Light
2.5.8
a
Overcurrent Breaker
b
2.6
2.6.1
2.6.2
2.6.3
a
2.6.4
a
b
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Page 11
TO LOWER THE LOAD, raise the load slightly to remove tension on the
rope lock cam. See Image 7.
PULL CAM OPEN to disengage from rope. Use the rope lock pull cord to
hold the cam open during lowering. See Image 6.
PAY OUT HAND LINE to lower the load. To reduce rope wear, lower the
load without the motor running.
ALLOW THE WINCH TO COOL DOWN to ambient temperature during
rest periods between operations.
OBSERVE THE WINCH during operation for signs of overheating.
Frequent overheating may be a sign of damage. IF the unit is equipped with
an over temperature indicating light on the bottom of the motor and the light
comes on during operation, safely lower the load and allow the winch to
cool to ambient temp and ensure the light goes out before continuing lifting
operations. See Table 2 – Troubleshooting Chart for additional information.
Continued operation while hot may cause damage to the winch and the
rope.
WATCH FOR SMOKE, the smell of burnt lubricant, and other signs
of overheating. Use a thermocouple or other device to monitor winch
temperature. The maximum allowable surface temperature of the motor is
65°C. Prevent rope damage by limiting the heat transfer from the drum to
the rope.
IF unit is equipped with over current protection AND the breaker trips during lifting operations, safely lower and evaluate the load. This is an indication that the load being lifted is too heavy. If the load is within the capacity
of the winch, the breaker may be reset using the installed pushbutton and
lifting operations continued. If the breaker continues to trip and the load is
not too heavy, contact Thern Technical Support.
Operating Rope Lock
PULL ON THE ROPE LOCK PULL CORD to allow for rope entry. See
Image 6.
RELEASE CAM to engage on rope. See Image 7. Always run rope through
rope lock.
PULL ROPE to raise load. See Image 7.
TO STOP, release tension on rope and let cam close to secure. See Image 8.
TO LOWER LOAD while winch is running, raise the load to remove
tension on the cam. See Image 7.
PULL CAM OPEN to disengage from rope. See Image 6.
PAY OUT HAND LINE while cam is held open, to allow load to lower.
Use the rope lock pull cord to hold the cam open during use.
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
2.7
Adjusting The Rope Lock
Image 9
Do not adjust rope lock while under load.
2.7.1
2.7.2
2.7.3
Image 10
LOOSEN OR REMOVE the socket head cap screws on the motor end of
the rope lock assembly. See Image 9.
ADJUST ROPE LOCK to the desired location and tighten the socket
head cap screws to 37 ft-lb. The rope lock adjustment should take into
consideration the ergonomics of handling the rope.
ADJUST THE ANGLE OF THE CAM BLOCK by loosening the small
socket head cap screw as shown in image 10. Rotate the cam block to the
desired position and tighten the small socket head cap screw to a minimum
of 5 ft-lbs to prevent unwanted rotation of the rope lock.
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Important!
3.1
Increase the frequency of
maintenance procedures if the
unit is:
• Operated for long periods.
• Used to pull heavy loads.
• Operated in wet, dirty, hot, or
cold surroundings.
Page 13
Cleaning the Winch
Keep capstan clean of dirt and free of oil. Never allow oil to collect on the
drum. Clean the winch to remove dirt and help prevent rust and corrosion.
3.1.1
CLEAN THE WINCH whenever it is dirty.
a
WIPE ALL EQUIPMENT with a mild detergent to remove dirt and grease.
b
WIPE OFF excessive amounts of oil to avoid the accumulation of dirt.
3.1.2
DO NOT APPLY grease or oil to drum.
3.2
Inspecting the Equipment
Important!
• Start an inspection program as
soon as you put the winch into use.
• Appoint a qualified 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.
Do not use damaged or malfunctioning equipment. Use Lock Out/Tag Out
procedures per your company.
Completely correct all problems before continuing. Use the troubleshooting
chart to help determine the cause of certain problems. See Table 2.
Inspect the winch to detect signs of damage or poor operation before they become
hazardous. See Table 1 - Inspection Checklist.
3.2.1
3.2.2
a
Instructions for Frequent Inspection
VISUALLY INSPECT the winch and all other equipment.
• Check all equipment for cracks, dents, bending, rust, wear, corrosion and
other damage.
• Check the reducer for signs of leakage.
Perform periodic inspections:
• Make sure the mounting fasteners are tightened securely. When using the
swivel mount, make sure the cotter pin used with the pivot bolt castle nut
is securely in place.
• Every 6 months.
• Whenever you return the winch
to service from storage.
• Make sure the foundation is in good condition, and capable of supporting
the winch and its load under all load conditions.
• 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.
CONSULT APPLICABLE CODES AND REGULATIONS for specific
rules on inspecting the winch and other equipment.
• Check electrical wiring and connections for wear, corrosion, cuts, and
other damage.
b
TEST WINCH PERFORMANCE by operating 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.
Frequent Rope Inspection:
• Make sure the load moves smoothly, without hesitation or strain.
• Use rope manufacturers guidelines for rope inspection, replacement and maintenance.
• Make sure the winch responds to the foot pedal control. It must rotate when
you actuate and turn off when you release the control.
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Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Table 1 – Inspection Checklist
checked boxes indicate damage or problem in need of repair
damages
general
problems
finish weathered, flaking, otherwise damaged
winch jerks or hesitates during operation
parts cracked, bent, rusted, worn, otherwise damaged
unusual noises, other signs of malfunction
fasteners
stripped threads, bent, worn, otherwise damaged
loose, not tightened to proper torque
reducer
gears, bearings, or shafts loose, worn, otherwise damaged
not properly lubricated
lubricant leakage
lubricant contaminated
end connections
corroded, rusted, worn, otherwise damaged
not securely attached
drum
worn, distorted, otherwise damaged
excessive movement or backlash
motor
motor corroded, burnt out, otherwise damaged
motor is sluggish, motor pulls high amps, or
operates poorly
brake
brake worn, corroded, otherwise damaged
brake does not operate properly
control device
electric components corroded, burnt, otherwise damaged
fails to control winch properly
electric circuit
electric wires worn, cut, corroded, otherwise damaged
wires unprotected, obstructing traffic
connections loose, corroded, otherwise damaged
voltage at motor =
dirty, illegible, otherwise damaged
loosely attached or missing
labels and plates
comments
authorized signature
date
A21392-E-1122
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
3.2.3
a
Page 15
Instructions for Periodic Inspection
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.
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.
• Check the finish for wear, flaking, 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 ROPE.
• Appoint a qualified person to be
responsible for all repairs to the
equipment.
• Check all fasteners for stripped threads, wear, bends, and other damage.
• Check the gearbox for signs of leakage. Contact the factory if there are
any signs of lubricant leaking from the gearbox.
• Make sure all labels and name-plates are legible, firmly attached, free of
damage and clean. Replacements are available from the factory.
Important!
b
INSPECT ROPE. Refer to rope manufacturer's guidelines for inspection.
• Keep a record of what you ship,
and when you send it.
c
MOVE THE DRUM with your hands.
• Check for excessive movement indicating worn or loose gears, fasteners,
or bearings. Excessive movement is caused by overloading, overheating,
or loose fasteners, and is a sign that your application may require a larger
power winch.
d
• Disassemble the winch if necessary. Inspect keys, bearings, seals, and shafts for wear, distortion, and other damage. Contact factory.
INSPECT FOUNDATION AND RIGGING.
• Check mounting fasteners for stripped threads, wear, and other damage.
• Check the foundation (or Thern Hitch Mount Accessory 3CP1S-HM or
3CP2S-HM) for cracks, corrosion, and other damage. e
TEST WINCH PERFORMANCE by operating the winch with a test load
equal to the load rating.
• Listen for unusual noises and look for signs of damage as you operate the
winch.
• Observe the rotating drum. Look for signs of loose or misaligned
bearings.
• Make sure the winch responds to the control device. It must rotate
counterclockwise when looking at the drum from the bell. It must turn off
when you release the control.
• Make sure the load moves smoothly without hesitation or strain.
• Check the internal brake. Raise the load, then lower it and suspend it a
few feet off the ground. If the drum continues to rotate contact the factory.
• Check the rope lock. Raise the load, then lower it and suspend it a few
feet off the ground. If the rope slips through the rope lock contact the
factory.
f
DISCONNECT ELECTRIC POWER and inspect electrical equipment.
• Check electrical wires for worn insulation, cuts, corroded connections,
and other damage.
A21392-E-1122
Page 16
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Table 2 – Troubleshooting Chart
Contact the factory for assembly/disassembly instructions. Disassembly of the gearbox before contacting Thern, Inc.
voids all warranties.
lubricant leakage
• worn bearings. . . . . . . . . . . . . . . . . . . . . . . . . . contact factory
• damaged oil seals or gaskets. . . . . . . . . . . . . . contact factory
• cracked or damaged reducer . . . . . . . . . . . . . . inspect and repair as necessary
excessive end play on drive shaft
• loose or damaged keys or keyways . . . . . . . . . contact factory
• excessively worn gears. . . . . . . . . . . . . . . . . . . inspect and repair as necessary
excessively worn gears or bearings
• load too heavy. . . . . . . . . . . . . . . . . . . . . . . . . . lighten load
• poor lubrication of reducer or bearings. . . . . . . contact factory
overheating
• operated too long without rest. . . . . . . . . . . . . . allow to cool
*As indicated by the over temperature light
• load too heavy. . . . . . . . . . . . . . . . . . . . . . . . . . lighten load
• poor lubrication. . . . . . . . . . . . . . . . . . . . . . . . . contact factory
• bearing seized up . . . . . . . . . . . . . . . . . . . . . . . contact factory
(IF equipped) or other indications.
unusual noises
high pitched squeak
• poor lubrication. . . . . . . . . . . . . . . . . . . . . . . . . contact factory
grinding noise
• contaminated lubrication. . . . . . . . . . . . . . . . . . replace as necessary
whining motor
• broken gears or bearings . . . . . . . . . . . . . . . . . contact factory
• load too heavy. . . . . . . . . . . . . . . . . . . . . . . . . . lighten load
• motor overheated . . . . . . . . . . . . . . . . . . . . . . . allow to cool
• motor bearings burnt out. . . . . . . . . . . . . . . . . . replace motor or bearings
rattling noise
• loose fasteners or set screws. . . . . . . . . . . . . . tighten all fasteners and screws
heavy thump during operation
• contaminants in lubricant . . . . . . . . . . . . . . . . . replace as necessary
• loose set screws or keys in gears or shafts . . . inspect and repair as necessary
excessively loud or unusual noise
while running motor
• bearings defective. . . . . . . . . . . . . . . . . . . . . . . contact factory
• worn out motor brushes . . . . . . . . . . . . . . . . . . contact factory
motor runs intermittently,
not as expected, or does not run
• worn out motor brushes . . . . . . . . . . . . . . . . . . contact factory
• overcurrent breaker tripped (IF equipped) . . . . reset breaker (see section 2.5.8b)
• Bad connection or power source . . . . . . . . . . . check local power source connections
A21392-E-1122
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
3.3
3.3.1
3.3.2
a
3.3.3
Page 17
Repairing the Winch
GET FACTORY AUTHORIZATION for all repairs. Unauthorized repairs
will void the warranty and may lead to damage or failure of the winch.
REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern
repair parts.
MOTOR BRUSH LIFE will vary depending on use and duty cycle. Expect
approximately 70-75 hours of runtime if frequently running loaded. Contact
Thern for replacement kit.
REFINISH AREAS or replace components where the finish is worn or
flaking. A good finish 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 finishing coat.
d
DO NOT APPLY PAINT to plated winch components.
3.3.4
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
3.3.5
THE GEARMOTOR of Thern Liberty Capstan is a sealed motor that comes
lubricated from the factory for the life of the winch. Changing or adding
lubricant is not required.
Table 3 – Weight Chart
ModelDescription
lbs
kg
63
28.6
3CP1M-AFS
1,000 pound capacity capstan winch with fixed floor/wall mount
3CP1S-AFS
1,000 pound capacity capstan winch with swivel mount
77
34.9
3CP1S-HM
Hitch mount for 1,000 pound capacity 3CP1S swivel capstan
26
11.8
3CP2M-AFS
2,000 pound capacity capstan winch with fixed floor/wall mount
70
31
3CP2S-AFS
2,000 pound capacity capstan winch with swivel mount
93
42
3CP2S-HM
Hitch mount for 2,000 pound capacity 3CP2S swivel capstan
45
20
A21392-E-1122
Page 18
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
4.1
Transporting the Winch
When not in use, place the capstan in a durable container or a secure location. This
will help prevent damage from being struck by other objects or theft of product.
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.2.3
4.2.4
PACK THE WINCH for transport using the original packaging materials, if
possible. If the original packaging is not available, see the following.
INSPECT THE WINCH according to the Instructions for Periodic
Inspection before installing it in a new location.
CARRY THE WINCH using the handle and rope lock bar to securely grip
the winch to carry it safely.
Storing the Winch
SEAL THE WINCH in plastic with a desiccant to help protect it from rust,
corrosion, and other damage.
STORE THE WINCH upright, in a cool clean place away from corrosive
chemicals and moisture.
ROTATE THE DRUM PERIODICALLY to keep bearing and gear
surfaces from becoming lacquered.
INSPECT THE WINCH according to the Instructions for Periodic
Inspection before installing it for operation.
A21392-E-1122
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Page 19
Model 3CP1S-AFS Swivel Capstan Winch
item
1
2
3
5
6
7
8
9
10
11
12
13
14
15
description
MOTOR REDUCER DPL 200:1 115/1/60
SWIVEL MOUNT ASSEMBLY 3CP1S-AFS
CAPSCR SOKHD M12-1.75 X 35MM ZNPL 12.9
WASHER FLT M12 X 24MM X 2.5MM ZNPL
WELDMENT DRUM 3CP1M-AFS
KEY BES 8MM X 7MM X 40MM STL
WASHER HELSPRLK M12 - 12.7mm ZNPL
RETAINER DRUM PLATE
ROPE LOCK ASSEMBLY
ROTATION LOCK ASSEMBLY .750-16NF SST
CAPSCR HEXHD .500-13NC X 1.500 ZNPL GR5
WASHER FLT SAE .500 X 1.062 X .095 ZNPL
NUT EYE 3/8 BAIL 1/2-13UNC
CAPSTAN FOOTSWITCH ASSEMBLY
part number
A21173
A27374
A21951
A9879
A21400
A9180
A10123
A21950
A24639
A28900
A3134
A2932
A27838
A24640
qty.
1
1
7
6
1
1
1
1
1
1
4
8
4
1
part number
A31303
A31476
A21951
A9383
A9879
A21400
A9180
A10123
A21950
A24639
A28900
A3164
A2932
A30456
A24640
qty.
1
1
3
4
6
1
1
1
1
1
1
4
8
4
1
Model 3CP2S-AFS Swivel Capstan Winch
item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
description
MOTOR REDUCER DPL 556:1 115/1/60
SWIVEL MOUNT ASSEMBLY 3CP2S-AFS
CAPSCR SOKHD M12-1.75 X 35MM ZNPL 12.9
CAPSCR SOKHD M12-1.75 X 50MM ZNPL 12.9
WASHER FLT M12 X 24MM X 2.5MM ZNPL
WELDMENT DRUM 3CP1M-AFS
KEY BES 8MM X 7MM X 40MM STL
WASHER HELSPRLK M12 - 12.7mm ZNPL
RETAINER DRUM PLATE
ROPE LOCK ASSEMBLY
ROTATION LOCK ASSEMBLY .750-16NF SST
CAPSCR HEXHD .500-13NC X 1.750 ZNPL GR5
WASHER FLT SAE .500 X 1.062 X .095 ZNPL
NUT EYE 7/16 BAIL .500-13UNC
CAPSTAN FOOTSWITCH ASSEMBLY
A21392-E-1122
Page 20
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Model 3CP1M-AFS Capstan Winch
item
1
2
4
6
8
9
10
11
12
13
description
MOTOR REDUCER DPL 200:1 115/1/60
WELDMENT FRAME 3CP1M-AFS
CAPSCR SOKHD M12-1.75 X 35MM ZNPL 12.9
WASHER FLT M12 X 24MM X 2.5MM ZNPL
WELDMENT DRUM 3CP1M-AFS
KEY BES 8MM X 7MM X 40MM STL
WASHER HELSPRLK M12 - 12.7mm ZNPL
RETAINER DRUM PLATE
ROPE LOCK ASSEMBLY
CAPSTAN FOOTSWITCH ASSEMBLY
part number
A21173
A21384
A21951
A9879
A21400
A9180
A10123
A21950
A24639
A24640
qty.
1
1
7
6
1
1
1
1
1
1
part number
A31303
A21384
A31471
A21951
A9383
A9879
A21400
A9180
A9180
A10123
A21950
A24639
A24640
qty.
1
1
1
3
6
10
2
1
1
1
1
1
1
Model 3CP2M-AFS Capstan Winch
item
1
2
3
4
5
6
7
8
9
10
11
12
13
description
MOTOR REDUCER DPL 556:1 115/1/60
WELDMENT FRAME 3CP1M-AFS
FRAME SUPPORT PLATE
CAPSCR SOKHD M12-1.75 X 35MM ZNPL 12.9
CAPSCR SOKHD M12-1.75 X 50MM ZNPL 12.9
WASHER FLT M12 X 24MM X 2.5MM ZNPL
NUT HEX NYLK M12-1.75 ZNPL CL8
WELDMENT DRUM 3CP1M-AFS
KEY BES 8MM X 7MM X 40MM STL
WASHER HELSPRLK M12 - 12.7mm ZNPL
RETAINER DRUM PLATE
ROPE LOCK ASSEMBLY
CAPSTAN FOOTSWITCH ASSEMBLY
A21392-E-1122
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Page 21
Model 3CP1S-HM Capstan Winch
item
16
17
description
WELDMENT 3CP1S HITCH MOUNT
PIN HITCH .625 X 3.000 EFF LENGTH ZNPL
part number
A27215
A27214
qty.
1
1
part number
A31521
A30677
qty.
1
1
Model 3CP2S-HM Capstan Winch
item
18
19
description
WELDMENT 3CP2S HITCH MOUNT
PIN HITCH .625 X 4.000 EFF LENGTH ZNPL
18
19
A21392-E-1122
Page 22
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
NOTES:
A21392-E-1122
Owner's Manual for Thern 3CP Liberty Series Capstan Winches
Thern, Incorporated
Corporate Headquarters
& Manufacturing
5712 Industrial Park Road
Winona, MN USA
1-800-843-7648
Phone: 1-507-454-2996
www.thern.com
A21392-E-1122
Page 23
Thern Europe
Siriusdreef, 17-27, 2132 WT
Hoofddorp
The Netherlands
Phone: +31-546-898-380
[email protected]
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