Thern 2W40 Series Worm Gear Hand Winch Owner's Manual
Below you will find brief information for Worm Gear Hand Winch 2W40 Series. This manual contains information about safe operation, installation and maintenance of the 2W40 Series worm gear hand winches. It also includes instructions about the proper way to install the wire rope, handle and breather plug.
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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.
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Owner’s Man ual
For
2W40 Series
Worm Gear Hand Winches
page 2 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Two-Year Limited Warranty
Please record the following:
Date Purchased:
Model No.:
Code 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 war ran ty, contact the factory for an RGA number. The prod uct must be re turned, pre paid, di rect ly to Thern, Inc., 5712 Industrial Park Road, Winona, Min ne so ta 55987. The fol low ing in for ma tion must ac com pa ny the product: the RGA number, the date of pur chase, the de scrip tion of the claimed defect, and a com-
plete ex pla na tion of the circumstances involved. If the product is found to be defective, it will be re paired or re placed free of charge, and Thern, Inc. will re im burse the ship ping cost within the con tig u ous USA.
This warranty does not cover any dam age due to accident, misuse, abuse, or negligence. Any alteration, repair or mod i fi ca tion of the product outside the Thern, Inc. factory shall void this war ran ty. This warranty does not cover any costs for removal of our product, down time, or any other incidental or con se quen tial costs or damages resulting from the claimed defects. This war ran ty does not cover brake discs, as these are wear components and their life is sub ject to use con di tions which vary be tween applications.
FACTORY AUTHORIZED REPAIR OR RE PLACE MENT AS PRO VID ED UNDER THIS WARRANTY IS THE
EXCLUSIVE REMEDY TO THE CON SUM ER. THERN, INC. SHALL NOT BE LIABLE FOR ANY INCIDEN-
TAL OR CON SE QUEN TIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON
THIS PRODUCT. EXCEPT TO THE EX TENT PROHIBITED BY AP PLI CA BLE LAW, ANY IMPLIED WAR-
RANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TIC U LAR PURPOSE ON THIS PRODUCT IS
LIMITED IN DURATION TO THE DURATION OF THIS WAR RAN TY.
Some states do not allow the exclusion or limitation of incidental or con se quen tial damages, or allow lim i ta tions on how long an implied warranty lasts, so the above limitation or ex clu sion may not apply to you. This war ran ty 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 2W40
Series Worm Gear Hand Winches. 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 2W40 Series Worm Gear Hand Winches
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 lubrication 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 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.
Table 1 – Duty Rating
With Mechanical Brake 15 minutes
Without Mechanical Brake 60 minutes
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.
NOTE - 2W40-L Series not intended for drill-motor 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 out from under the load.
Do not adjust the brake with the load suspended if winch is equipped with a load brake.
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 Table 1.
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page 4 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
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 com pare 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 Thern, Inc. 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
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 1.
1.1.5
POSITION THE WINCH to allow access for proper lubrication.
1.1.6
FASTEN THE WINCH securely to the foundation. a
FOR STANDARD PRODUCTS referred to in this manual, use 1/2 - inch coarse thread fasteners, grade 5 or better, torque dry to 75 ft lb without lubrication. Make sure the winch 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-STANDARD 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 C-
A TIONS FOR THE MOUNTING OF THERN PROD UCTS.
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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 1 – 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”.
smooth drum fi xed sheave or roller guide
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 sideto-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
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1.2
Installing the Breather Plug
Important!
• Save the extra oil plug(s) for use when the winch is removed for storage, service or transport.
Install the breather plug(s) to vent heat and pressure from the gearbox or brake. Fail ure to do so could result in pressure buildup which can cause the gearbox or brake to leak or damage the equipment.
For shipment, the gearbox and brake are sealed with oil plugs, and the breather plug(s) are attached to the gearbox or shipped in a separate en ve lope.
1.2.1
REMOVE THE OIL PLUG(S) and install the breather plug(s) in the proper lo ca tion. Make sure the breather plug(s) are above the oil level.
See Figures 2a and 2b.
1.2.2
CHECK THE OIL LEVEL in the gearbox and brake to make sure no oil was lost during shipment. See section 3.3 Lubricating the Winch.
Figure 2a – Breather Plug Installation
2 breather plugs
1 breather plug
1 breather plug
1 breather plug fl oor mount wall mount
(handle down) wall mount
(handle up)
Figure 2b – Breather Plug Installation - Non-Brake Units
breather plug breather plug breather plug ceiling mount breather plug fl oor mount wall mount
(handle down) wall mount
(handle up) ceiling mount
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1.3
Installing the Handle
Figure 3 – Installing the Handle (2W40-M Series)
When operating winch with handle not at full extension use caution. The end of the handle may hit operator while rotating.
loosen thumbscrew and slide handle in direction shown thumbscrew notch
3A – Slide Handle In
line up notch with point of hex in medallion notch medallion
3B – Line Up Notch
The 2W40-M series 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.
The 2W40-L series does not include a hex drive input and is not intended
for operation with a drill-motor.
1.3.1
LOOSEN THE THUMBSCREW and slide the handle toward the medallion as shown. See 3A.
1.3.2
LINE UP THE NOTCH in the handle with the point of the hex in the medallion. See 3B.
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 3C.
1.3.4
SLIDE THE HANDLE outward away from the medallion to the desired length and tighten the thumbscrew. See 3D.
1.3.5
FOR 2W40-L SERIES MODELS, install the handle as follows. See Figure 4.
a
INSERT THE HANDLE in the handle socket, adjust handle length to suit the operation, and tighten the set screw to hold it in place.
b
INSERT THE COTTER PIN in the end of the handle and bend the arms back to secure in place.
groove slide handle assembly onto hex drive until handle fl at lines up with groove
3C – Slide Handle onto Hex
Figure 4 – Installing the Handle (2W40-L Series)
larger turning radius: heavier loads, slower turns smaller turning radius: lighter loads, faster turns slide handle out to desired length and tighten thumbscrew thumbscrew loosen fas ten er to adjust han dle length cotter pin larger turning radius: heavier loads, slower turns smaller turning radius: lighter loads, faster turns
3D – Adjust Handle Length
Adjust Handle Length (2W40-L Series)
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1.4
Installing the Wire Rope
Important!
• Use wire rope and other rigging equipment rated for the size of the largest load you will be moving.
• Do not drag the wire rope through dirt or debris that could cause dam age, 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.
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.
Install plug to prevent wire rope wrapping in keyhole slot. Wire rope wrapping in slot could damage the wire rope and allow the load to escape. See Figure 5.
Install wire rope anchor fi tting to hold the largest load on the winch. Undersized or improperly installed anchor fi tting could come loose from the wire rope or keyhole slot and 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 install keyhole slot plug set screw anchor install keyhole slot plug quick disconnect wire rope anchor fi tting
Wire rope assemblies with an chor fi ttings can be pur chased from Thern, Inc.
1.4.1
PURCHASE THE PROPER WIRE ROPE for your application.
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 7 x 19 galvanized aircraft cable for diameters up to
5/16 inch, and 6 x 37 IWRC improved plow steel for 3/8 inch and up.
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 recessed anchor hole 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 until it fl attens the wire rope against the anchor hole. Use enough force to drive the point of the set screw securely into the wire rope. b
QUICK DISCONNECT AN CHOR. See Figure 5.
• REMOVE PLUG from quick disconnect anchor.
• PASS THE WIRE ROPE under the drum from the front and position the anchor fi tting in the keyhole slot in the drum.
• RE-INSTALL PLUG and tighten until plug is fl ush with the drum spool surface and will not come loose during operation.
• PULL THE WIRE ROPE fi rmly to anchor the fi tting in the keyhole slot.
The anchor fi tting needs to be larger than the keyhole slot and be able to hold the load.
1.4.3
WIND FOUR FULL WRAPS of wire rope onto the drum by op er at ing the winch while holding the wire rope taught. These wraps serve as anchor
wraps and must remain on the drum at all times. See Figure 5.
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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 per for mance of the equipment.
Table 1 – Duty Rating
With Mechanical Brake 15 minutes
Without Mechanical Brake 60 minutes
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.
NOTE - 2W40-L Series not intended for drill-motor operation.
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 duty cycle rating of the winch. To do so could result in equipment damage or failure. See Table 1.
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 over lap ping.
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 a
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. For duty ratings, see Table 1. Consider the following when determining duty rating.
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 the duty cycle rating of the winch.
To do so could result in equipment damage or failure. See Table 1.
CONTACT THE FACTORY FOR MORE INFORMATION.
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page 10 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
2.2
Breaking-In the Winch
2.2.1
BREAK-IN OCCURS during the fi rst few hours of normal operation. Dur ing break-in, mating surfaces become polished, and clearances in crease. This is de sired for effi cient operation of bearings and gears.
2.2.2
INSPECT THE WINCH following break-in according to the Instructions for
Periodic Inspection. See section 3.4 Inspecting the Equipment.
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
INSPECT ALL COMPONENTS of the system.
a
INSPECT THE WINCH and other equipment according to the Instructions for Frequent Inspection.
b
OPERATORS must be in good health, alert, thoroughly trained in op er at ing the equipment, and properly clothed (hard hat, safety shoes and safety glass es, no loose clothing).
c
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.
2.3.3
KNOW YOUR LOAD and make sure you do not exceed the load rating of the winch or any other equipment in the system.
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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 rigging 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
ATTACH THE LOAD using a nylon sling, or other approved rigging de vice.
Fol low the recommendations of the sling manufacturer.
a
SEAT THE SLING in the saddle of the hook with the hook latch com plete ly closed. See Figure 6.
b
CENTER THE LOAD on the hook so it will remain balanced and not tip or rotate to one side.
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 op er a tion, get help from another person.
• Appoint a supervisor if more than one person is involved in the operation. This will reduce con fu sion and increase safety.
• When lifting a load, use a tag line to keep the load from swinging or twist ing, while keeping yourself away from the load.
• Remove the winch handle when the winch is not in use, to help avoid un au tho rized use.
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 con tinu ing.
2.5.2
TURN THE HANDLE COUNTER-CLOCKWISE to wind wire rope onto the drum. If wire rope un winds from the drum when the han dle is ro tat ed counter-clock wise, the wire rope is in stalled in cor rect ly. Install the wire
rope cor rect ly be fore con tinu ing. See Figure 5.
2.5.3
DO NOT EXCEED DUTY CYCLE RATING of the winch. See Table 1.
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
ALLOW THE WINCH TO COOL DOWN to ambient temperature in rest periods between op er a tions.
2.5.6
OBSERVE THE GEARBOX AND BRAKE during operation for signs of overheating. Fre quent overheating may be a sign of damage, or may
indicate the need for a larger winch.
a
WATCH FOR SMOKE, the smell of burnt oil, and other signs of over heat-
ing. Use a thermocouple or other device to monitor gearbox temperature.
The temperature of the oil should not exceed 180° 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 dam age.
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page 12
Important!
Increase the frequency of main te nance procedures if the winch is:
• Operated for long periods.
• Used to pull heavy loads.
• Operated in wet, dirty, hot, or cold surroundings.
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
3.1
Cleaning the Winch
Clean the winch to remove dirt and help prevent rust and cor ro sion.
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 sur round ing the winch.
3.2
Adjusting the Brake
(for models equipped with this feature)
Important!
• Do not overtighten the brake, since this will cause parts to wear and become damaged.
Figure 7 – Adjusting the
Brake
2W40-B Series
turn brake adjusting nuts clock wise
1/4 turn
mechanical
brake
Do not adjust the brake with the load suspended. Accidental release of the brake could allow the load to escape.
The torque can be measured by using a dial type torque wrench or equal to measure the handle effort (torque) required to turn the input shaft.
3.2.1
ADJUST THE BRAKE whenever it appears to need adjustment, or at least every 3 months.
3.2.2
CHECK THE BRAKE by operating the winch with a 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, follow the instruction below:
• FOR 2W40-B SERIES use a torque wrench with 1 1/8 socket installed on the input shaft hex. Rotate the torque wrench one complete clockwise revolution of the input shaft. Adjust the brake nuts based on the torque reading and the torque setting specifi ed for the winch. See Table 2. Do
not adjust the brake with the load suspended.
• TIGHTEN THE BRAKE by turning the adjusting nuts clockwise about
1/4 turn. Continue to test and tighten the brake by alternate tightening of each brake nut until brake stops and holds the load securely. See Figure 7.
Table 2 - Torque Adjustment
1
Condition Torque Setting (ft-lbs)
Under No Load
Under Load
10 - 40
4 (minimum) 3
1 Do not adjust brake with load suspended.
2 Complete 1 full rotation.
3 Tighten brake until the minimum value is obtained.
Direction 2
Clockwise
Clockwise
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3.3
Lubricating the Winch
page 13
Important!
• Do not leave plug holes in the reducer open. Open plug holes will allow dirt and moisture to con tam i nate the lubrication.
• Make sure lubricant has a tem-
per a ture rating appropriate for the ambient temperatures of the operation.
Install the breather plug(s) to vent heat and pressure from the gearbox or brake. Fail ure to do so could result in pressure buildup which can cause the gearbox or brake to leak or damage the equipment.
Breather plug(s) must be located above the oil level otherwise oil will leak through the plug. See Figure 1.
Check the gearbox and mechanical brake for proper level before operating. Too much or too little oil will cause overheating and result in equipment damage.
Figure 8 – Lubricating the
Flange Bearing
fl ange bearing, lubricate with
NLGI no. 2 grease
Important!
• For wall mounts with mechanical brake and handle down, remove from wall to allow oil to properly drain from the brake and gearbox.
Lubricate the winch prop er ly to help protect it from wear and rust. Apply thread sealant to pipe plugs when re-installing to prevent oil leaks. Read the following in struc tions carefully.
3.3.1
THE WINCH is shipped from the factory with the proper amount of
Mobilgear 600XP220 lubricant in the gearbox and brake. Lubricate the winch as follows. See Figure 9.
3.3.2
CHANGE GEARBOX AND BRAKE OIL after the fi rst 40 hours of operation.
3.3.3
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 and brake if necessary. Do not use synthetic
lubricants and do not mix different lu bri cants.
3.3.4
CHANGE GEARBOX AND MECHANICAL BRAKE OIL at least every
6 months, or whenever it is dirty or con tam i nat ed. Remove the drain plug to drain oil from the gear box and brake. See Figures 9a and 9b.
a
For wall mount installations with a mechanical brake fi ll the bottom compartment (brake or gearbox), then top compartment. Allow time for oil to settle and check oil level at level check plug. Apply thread sealant to pipe plug threads upon re-installation.
b
For ceiling mount installation fi ll the gearbox fi rst, then brake if equipped.
Allow time for oil to settle and check gearbox oil level at level check plug.
Apply thread sealant to pipe plug threads upon re-installation.
3.3.5
LUBRICATE THE FLANGE BEARING at least once ev ery month or more, depending on usage. Use a grease gun to insert NLGI no. 2 grease until clean grease appears at the seals. The bear ing will squeak if it is dry. See Figure 8.
3.3.6
LUBRICATE THE WIRE ROPE and other equipment by following the manufacturers recommendations.
A10777A-0514
page 14 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Figure 9a – Lubricating the Winch - Brake Units
level check plug fi ller/breather plug fi ller/ breather plug level check plug fi ller/breather plug fi ller plug fi ller/breather plug fi ller/level check plug level check plug level check plug drain plug drain plug fl oor mount drain plug wall mount
(handle down) drain plug wall mount
(handle up)
Note: Drain plugs are hexagon socket pipe plugs. Do not remove bolts or nuts to drain oil.
ceiling mount
Figure 9b – Lubricating the Winch - Non-Brake Units
level check plug fi ller/ breather plug fi ller/breather plug fi ller/breather plug level check plug level check plug fi ller/breather plug level check plug drain plug drain plug fl oor mount drain plug wall mount
(handle down) drain plug wall mount
(handle up)
Note: Drain plugs are hexagon socket pipe plugs. Do not remove bolts or nuts to drain oil.
ceiling mount
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
3.4
Inspecting the Equipment
page 15
Important!
• Start an inspection program as soon as you put the winch into use.
• Appoint a qualifi ed person to be responsible for regularly in spect-
ing the equipment.
• Keep written records of in spec-
tion. This allows comparison with com ments from previous in spec-
tions so you can see chang es in con di tion or per for mance.
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. 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.
Inspect the winch to detect signs of damage or poor operation before they be come hazardous.
3.4.1
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 and mechanical brake 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 or brake.
• 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 a test 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.
• On models equipped with a brake, 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, 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 4.
A10777A-0514
page 16 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Perform periodic inspection:
• Every 6 months.
• 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 have, overloaded or shock loaded the winch.
Figure 10 – Broken Wires
wire strand
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.
one lay
3.4.4
Instructions for Periodic Inspection, see Table 3.
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 and mechanical brake for signs of leakage. Contact factory if there are any signs of lubricant leaking from the gearbox or brake.
• Make sure the breather plug is clean, open and installed correctly.
• Make sure the winch outboard bearing is properly lubricated.
• Make sure all labels and plates are readable, fi rmly attached, free of damage and clean. Replacements are available from the factory.
b
DRAIN A SMALL AMOUNT OF OIL from the gearbox and brake 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 and brake is properly lubricated. See Section 3.3
Lubricating the Winch.
Figure 11 – Load Hook
Inspection
twist 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.
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 17
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 10.
• Check the wire rope for reduction of rope diameter from loss of core support, or wear of outside wires. See Figure 12.
• 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.
Figure 12 – Rope Diameter
correct
The wire rope assembly must be replaced if the diameter measures less than the minimum diameter at any point.
wire rope diameter
1/4 in
5/16 in
3/8 in
1/2 in
diameter
incorrect minimum diameter
15/64 in (.2344 in)
19/64 in (.2969 in)
11/32 in (.3438 in)
15/32 in (.4688 in) c
INSPECT THE WIRE ROPE according to the wire rope manufacture’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 10.
• Make sure hooks and other fi ttings are securely attached to the wire rope, and the wire rope where they are attached is not frayed, cor rod ed, 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 11.
• Make sure any hook latches open without binding and close when released.
• Check the anchor holes in the drum and the surrounding area for signs of wear or distortion.
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.
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 12.
f
INSPECT THE FOUNDATION AND RIGGING.
• Check mounting fasteners for stripped threads, wear, and other damage.
• Check the foundation for cracks, corrosion, and other damage.
g
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.
• 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.
• On models equipped with a brake, 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, 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 4.
A10777A-0514
page 18 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
3.5
Repairing the Winch
Important!
• It is your responsibility to de-
ter mine when to replace parts.
When considering whether to continue using a part or to re place it, re mem ber that replacing it is the best way to avoid further equip ment damage.
• Replace spring pins, retaining rings, and oil seals whenever the winch is disassembled for in spec tion or repair.
• During reassembly, use loctite
598 Ultra Black to create a seal between gearbox covers, end caps or mechanical brake if equipped.
Contact 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 fol low-
ing 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
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 19
Table 3 – Inspection Checklist
checked boxes indicate damage or problem in need of repair
general
damages
fi nish weathered, fl aking, otherwise damaged
comments
fasteners
reducer
wire rope
parts cracked, bent, rusted, worn, otherwise damaged
stripped threads, bent, worn, otherwise damaged
gears, bearings, or shafts loose, worn, otherwise damaged
lubricant leakage
bent, crushed, otherwise damaged
broken wires, see Figure 10 replace if more than 6 wires in one lay, or 3 wires in one strand in one lay, are broken
end connections
hook or other device
diameter reduced, see Figure 12 replace if wire rope is excessively worn
corroded, rusted, worn, otherwise damaged
twisted, bent, worn, otherwise damaged, see Figure 11
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
authorized signature problems
winch jerks or hesitates during operation
unusual noises, other signs of malfunction
loose, not tightened to proper torque
not properly lubricated
lubricant contaminated
wire rope loosely or unevenly wound number per strand = number per lay = diameter =
not securely attached
hook latch fails to close when released twist = throat width = thickness =
excessive movement or backlash
brake does not operate properly
loosely attached or missing
date
A10777A-0514
page 20 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Table 4 – 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 cause correction
handle turns, drum doesn’t turn • loose or broken spring pins or shafts ................... inspect winch and brake, repair as necessary
• loose, stripped or broken gears or keys ............... repair as necessary
handle turns hard or not at all • unit overheated ..................................................... allow to cool
• load too heavy ...................................................... lighten load
• gearbox contaminated with dirt or debris ............. inspect and relubricate as necessary
• keys or spring pins loose or broken ...................... inspect winch and brake, repair as necessary
• brake band too tight .............................................. loosen brake and readjust
• brake broken or locked ......................................... inspect and repair as necessary
• gears or bearings broken or locked ...................... inspect and replace as necessary
brake does not operate properly • wire rope installed improperly ............................... reinstall wire rope correctly
• brake adjusted incorrectly .................................... adjust brake
• brake worn or damaged ....................................... inspect and replace as necessary
• brake components seized up or damaged ........... inspect and repair as necessary
lubricant leakage • worn bearings ....................................................... inspect and replace as necessary
• oil seals leaking or damaged ................................ inspect and replace as necessary
• gaskets leaking or damaged ................................ tighten fasteners or replace gasket
• cracked or damaged gearbox ............................... inspect and repair as necessary
• gearcase plugs not tightened ............................... tighten
• breather plug clogged or damaged ...................... clean or replace vent plug as needed
excessive end play on drive shaft • loose or damaged keys or keyways ..................... inspect and replace as necessary rattling noise heavy thump during operation knocking noise back drive
• thrust washer or bearing worn out ........................ inspect and replace as necessary
• excessively worn gears ........................................ inspect and repair as necessary
excessive worn gears or bearings • load too heavy ...................................................... lighten load
overheating
• poor lubrication of gears or bearings .................... inspect and lubricate as necessary
• operated too long without rest .............................. allow to cool
• load too heavy ...................................................... lighten load
• poor lubrication ..................................................... inspect and lubricate as necessary
• breather plug clogged or damaged ...................... clean or replace breather plug
• bearing seized up ................................................. inspect and replace as necessary
unusual noises high pitched squeak grinding noise
• poor lubrication ..................................................... inspect and lubricate as necessary
• contaminated lubrication ...................................... drain, clean and lubricate the winch
• dirt in winch gears ................................................ inspect and clean as necessary
• broken gears or bearings ..................................... inspect and replace as necessary
• loose fasteners or set screws ............................... tighten all fasteners and screws
• contaminants in lubricant ...................................... 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 mechanical brake
• loose or worn parts on input shaft ........................ contact factory
• brake out of adjustment ........................................ adjust brake per manual
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 21
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(S) and install a sealed oil plug(s) to prevent the loss of lu bri ca tion 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 mov ing 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 pro tec tive crate.
d
PACK LOOSE PARTS in small box es or ship separately.
4.1.3
INSPECT THE WINCH according to the Instructions for Periodic In spec tion 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(s) are 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 chem i cals and moisture.
4.2.4
ROTATE THE DRUM PERIODICALLY to keep bearing and gears sur fac es from becoming lacquered.
4.2.5
INSPECT THE WINCH according to the Instructions for Periodic In spec tion before installing it for operation.
4.2.6
LUBRICATE THE WINCH PROPERLY prior to operation. See Section 3.3
Lubricating the Winch.
Series 2W40 Performance Characteristics
1 model number
2W40-L
2W40-BL
2W40-M
2W40-BM
load rating (lb)
1st mid full layer drum drum
4000 2800 2200
4000 2800 2200
4600 3300 2500
4600 3300 2500
wire rope dia. (in)
.38
.38
.38
.38
drum capacity (ft)
1st mid full layer drum drum
14
14
14
14
65
65
65
65
140
140
140
140
gear ratio
26:1
26:1
31:1
31:1
force
2 to lift
18
18
11
11
1000 lb approx.
ship wt. (lb)
111
107
123
119
1 Performance Characteristics are for standard products referred to in this manual. Non-standard products may vary from the original
design. Contact Thern, Inc. for this information.
2 Approximate handle force required to lift 1,000 lb with an empty drum, and maximum handle length.
A10777A-0514
page 22 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Model 2W40-L
24
25
26
27
28
29
30
31
16
17
18
19
20
21
22
23
32
33
34
35
36
37
38
39
40
8
9
10
11
12
13
14
15
4
5
6
7
item
1
2
3
description
END CAP
CAPSCR HEXHD .375-16NC X 1.000 ZNPL GR5
INPUT SHAFT
SEAL OIL .750ID X 1.375OD X .250
BRG RAD BALL .750ID X 1.625OD X .31W STL
PLUG BREATHER .375-18NPT X .48 PLN STL
BRG BALL THRUST .753ID X 1.685OD X .625
WORM SPACER
KEY .188 X .188 X 2.000 4140 HT BER
WORM 3.250OD X 2.750PD X 2.17RD 1 LEAD
GEARCASE MACHINING
SHIM .760/.786 X 1.235/1.265 X .018/.024
PLUG PIPE HEXSOC .375-18NPT X .425 SAE
PIN SLOTTED SPRING .250 X 1.500 STL
HANDLE ASSEMBLY
HANDLE SOCKET
SETSCR SQHD .375-16NC X .500 ZNPL STL
PIN COTTER .187 X 1.250 ZNPL STL
KEY .500 X .500 X 1.000 4140 HT BES
WORM GEAR 8.12OD X 7.750PD X 7.469RD
DRUM SHAFT
BRG RAD BALL 45MM X 85MM X 19MM
FRONT COVER MACHINING
SHIM 1.883 X 2.750 X .060 STL
SEAL OIL 1.625ID X 2.252 X .313
BACK COVER MACHINING
CAPSCR HEXHD .375-16NC X 1.500 ZNPL GR5
PIN GROOVE TYPE A .500 X 3.750 ALYSTL
FRAME WELDMENT
BRG FLNG 1.44ID 4 BOLT SETSCR LOCK
NUT HEX NYLK .500-13NC ZNPL GR2
CAPSCR HEXHD .500-13NC X 2.000 ZNPL GR5
PLUG PIPE HEXSOC .500-14NPT X .63 SAE
SETSCR SOKHD NYLK .375-16NC X .625
DRUM WELDMENT
LABEL MODEL/CAPACITY 2W40-L SERIES
LABEL WARNING KEEP HANDS AWAY FROM DRUM
LABEL NAMEPLATE THERN LOGO
LABEL WARNING FOR NON BRAKE WINCHES
LABEL DATE OF MANUFACTURE
A10866
A3725
A3155
A10120
C4605
D3182
A9968
C4378
A10124
A9967
C4377
A3236
A2558
C4379
A10429
A2897
part number
B4866
A2922
B5094
A9518
A9793
A3408
A1498
A10243
A3255
B5392
D3244
A4389
A3290
A4499
B1015
A2894
A3126
A3128
C4637
A10873
A2659
A6889
A10806
10477
1
4
1
1
1
4
2
1
2
1
1
1
1
2
1
1
1
1
1
2
1
1
1
4
1
2
6
2
1
1
1
2
1
1
2
2
4
qty.
2
12
1
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 23
6
5
4
3
2
1
7 8 9 10 8 7 12 5 13 1
11
14
15
16 17
18
4
2
21
22
2
23
SECTION A-A
20 19
SECTION B-B
35 34 33 32 31 30
24 25 26 27 28 29
40
B
B
38
39
A
A
36
37
A10777A-0514
page 24 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Model 2W40-BL
40
41
42
43
44
45
46
47
32
33
34
35
36
37
38
39
48
49
50
51
52
53
54
55
56
57
24
25
26
27
28
29
30
31
16
17
18
19
20
21
22
23
8
9
10
11
12
13
14
15
4
5
6
7
item
1
2
3
description
PLUG PIPE HEXSOC .375-18NPT X .425 SAE
BRAKE HOUSING MACHINING
MACHINING COVER BRAKE
CAPSCR HEXHD .375-16NC X 1.000 ZNPL GR5
BRG RAD BALL .750ID X 1.625OD X .31W STL
BRG RAD BALL 1.000 X 2.000 X .375
INPUT SHAFT
THRUST BEARING
BRG CLUTCH 1.000ID X 1.312OD X 1.063 STL
BRAKE DRUM
CAPSCR HEXHD .312-18NC X .750 ZNPL GR5
BRAKE BAND ASSEMBLY
PIN DOWEL .250 X 2.000 ALYSTL
CONNECTOR BUSHING
NUT HEX NYLK .500-13NC ZNPL GR2
BRAKE BAND CONNECTOR
PLUG BREATHER .375-18NPT X .48 PLN STL
BRG BALL THRUST .753ID X 1.685OD X .625
WORM SPACER
WORM 3.250OD X 2.750PD X 2.17RD 1 LEAD
KEY .188 X .188 X 2.000 4140 HT BER
GEARCASE MACHINING
SHIM .760/.786 X 1.235/1.265 X .018/.024
END CAP
PIN SLOTTED SPRING .250 X 1.500 STL
HANDLE ASSEMBLY
HANDLE SOCKET
SETSCR SQHD .375-16NC X .500 ZNPL STL
PIN COTTER .187 X 1.250 ZNPL STL
SEAL OIL .750ID X 1.375OD X .250
KEY .500 X .500 X 1.000 4140 HT BES
WORM GEAR 8.12OD X 7.750PD X 7.469RD
DRUM SHAFT
BRG RAD BALL 45MM X 85MM X 19MM
FRONT COVER MACHINING
SHIM 1.883 X 2.750 X .060 STL
SEAL OIL 1.625ID X 2.252 X .313
BACK COVER MACHINING
CAPSCR HEXHD .375-16NC X 1.500 ZNPL GR5
PIN GROOVE TYPE A .500 X 3.750 ALYSTL
FRAME WELDMENT
BRG FLNG 1.44ID 4 BOLT SETSCR LOCK
CAPSCR HEXHD .500-13NC X 2.000 ZNPL GR5
PLUG PIPE HEXSOC .500-14NPT X .63 SAE
SETSCR SOKHD NYLK .375-16NC X .625
DRUM WELDMENT
WASHER SPRING .559 X 1.100 X .039 SPR STL
O-RING .750 X .875 X .063 NITRILE
O-RING .375 X .500 X .063 NITRILE
LABEL WARNING DO NOT ADJUST BRAKE UNDER LOAD
LABEL WARNING INSTALL WIRE ROPE AS SHOWN
LABEL WARNING INSTALL WIRE ROPE AS SHOWN
LABEL MODEL/CAPACITY 2W40-L SERIES
LABEL WARNING KEEP HANDS AWAY FROM DRUM
LABEL NAMEPLATE THERN LOGO
LABEL WARNING POINTS 1-10 FOR 4X
LABEL DATE OF MANUFACTURE
C4605
D3182
A9968
C4378
A10124
A9967
C4377
A3236
A2558
C4379
A10429
A2894
A3126
A3128
C4637
A9846
A9813
A9814
A2658
A7406
A10680
A10873
A2659
A6889
A2655
10477
A9803
A3408
A1498
A10243
B5392
A3255
D3244
A4389
B4866
A4499
B1015
A10866
A3725
A3155
A9518
A10120
part number
A3290
D3257
C4450
A2922
A9793
A2056
B4872
A9804
A9844
B4995
A3032
B4991
A9845
A9812
A2897
1
2
1
1
1
4
1
1
1
4
2
1
2
1
1
1
1
1
1
1
1
1
4
2
1
1
1
2
1
1
1
1
1
1
1
2
1
1
2
2
2
2
2
6
1
2
1
4
3
1
1
1
12
4
1
1
qty.
12
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 25
17
8
7
6
13
12
10
11
9
5
4
14 15 16 17 18
20 21 22 19
23
5
24
26
27 28
29
25
30
33
34
4
47
48
49
3
2 1
35 32 31
SECTION A-A
46 45
SECTION B-B
44 43
15
36 37 38 39 40 41
SECTION C-C
42
B
C
57
B
C
A10777A-0514
55
A
56
A
54
53 52 51 50
page 26 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Model 2W40-M
24
25
26
27
28
29
30
31
16
17
18
19
20
21
22
23
32
33
34
35
36
37
38
8
9
10
11
12
13
14
15
4
5
6
7
item
1
2
3
description
END CAP
CAPSCR HEXHD .375-16NC X 1.000 ZNPL GR5
INPUT SHAFT
SEAL OIL .750ID X 1.375OD X .250
BRG RAD BALL .750ID X 1.625OD X .31W STL
PLUG BREATHER .375-18NPT X .48 PLN STL
BRG BALL THRUST .753ID X 1.685OD X .625
WORM SPACER
KEY .188 X .188 X 2.000 4140 HT BER
WORM 1.75OD X 1.500PD X 1.22RD 2 LEAD
GEARCASE MACHINING
SHIM .760/.786 X 1.235/1.265 X .018/.024
PLUG PIPE HEXSOC .375-18NPT X .425 SAE
PIN SLOTTED SPRING .250 X 1.500 STL
HANDLE SOCKET
HANDLE ASSEMBLY
KEY .500 X .500 X 1.000 4140 HT BES
WORM GEAR 8.12OD X 7.750PD X 7.469RD
DRUM SHAFT
BRG RAD BALL 45MM X 85MM X 19MM
FRONT COVER MACHINING
SHIM 1.883 X 2.750 X .060 STL
SEAL OIL 1.625ID X 2.252 X .313
BACK COVER MACHINING
CAPSCR HEXHD .375-16NC X 1.500 ZNPL GR5
PIN GROOVE TYPE A .500 X 3.750 ALYSTL
FRAME WELDMENT
BRG FLNG 1.44ID 4 BOLT SETSCR LOCK
NUT HEX NYLK .500-13NC ZNPL GR2
CAPSCR HEXHD .500-13NC X 2.000 ZNPL GR5
PLUG PIPE HEXSOC .500-14NPT X .63 SAE
SETSCR SOKHD NYLK .375-16NC X .625
DRUM WELDMENT
LABEL MODEL/CAPACITY 2W40-M SERIES
LABEL WARNING KEEP HANDS AWAY FROM DRUM
LABEL NAMEPLATE THERN LOGO
LABEL WARNING FOR NON BRAKE WINCHES
LABEL DATE OF MANUFACTURE
B5275
A10120
C4401
D3182
A9968
C4378
A10124
A9967
C4377
A3236
A2558
C4379
A10429
A2897
A2894
A3126
part number
B4866
A2922
B5094
A9518
A9793
A3408
A1498
A9564
A3255
A1612
D3244
A4389
A3290
A4499
A10122
A3128
C4637
A10786
A2659
A6889
A10806
10477
4
1
1
4
1
4
1
1
2
1
2
1
1
1
1
2
1
1
1
1
2
1
1
2
6
1
1
1
1
2
1
1
2
2
4
qty.
2
12
1
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 27
6
5
4
3
2
1
7 8 9 10 8 7 12 5 13
1
11
14
15
16
4
2
19
20
2
21
SECTION A-A
18 17
SECTION B-B
33 32 31 30 29 28
22 23 24 25 26 27
A
38
B
B
A10777A-0514
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37
A
34
35
page 28 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
Model 2W40-BM
40
41
42
43
44
45
46
47
32
33
34
35
36
37
38
39
48
49
50
51
52
53
54
55
24
25
26
27
28
29
30
31
16
17
18
19
20
21
22
23
8
9
10
11
12
13
14
15
4
5
6
7
item
1
2
3
description
PLUG PIPE HEXSOC .375-18NPT X .425 SAE
BRAKE HOUSING MACHINING
MACHINING COVER BRAKE
CAPSCR HEXHD .375-16NC X 1.000 ZNPL GR5
BRG RAD BALL .750ID X 1.625OD X .31W STL
BRG RAD BALL 1.000 X 2.000 X .375
INPUT SHAFT
THRUST BEARING
BRG CLUTCH 1.000ID X 1.312OD X 1.063 STL
BRAKE DRUM
CAPSCR HEXHD .312-18NC X .750 ZNPL GR5
BRAKE BAND ASSEMBLY
PIN DOWEL .250 X 2.000 ALYSTL
CONNECTOR BUSHING
NUT HEX NYLK .500-13NC ZNPL GR2
BRAKE BAND CONNECTOR
PLUG BREATHER .375-18NPT X .48 PLN STL
BRG BALL THRUST .753ID X 1.685OD X .625
WORM SPACER
WORM 1.75OD X 1.500PD X 1.22RD 2 LEAD
KEY .188 X .188 X 2.000 4140 HT BER
GEARCASE MACHINING
SHIM .760/.786 X 1.235/1.265 X .018/.024
END CAP
PIN SLOTTED SPRING .250 X 1.500 STL
HANDLE SOCKET
HANDLE ASSEMBLY
SEAL OIL .750ID X 1.375OD X .250
KEY .500 X .500 X 1.000 4140 HT BES
WORM GEAR 8.12OD X 7.750PD X 7.469RD
DRUM SHAFT
BRG RAD BALL 45MM X 85MM X 19MM
FRONT COVER MACHINING
SHIM 1.883 X 2.750 X .060 STL
SEAL OIL 1.625ID X 2.252 X .313
BACK COVER MACHINING
CAPSCR HEXHD .375-16NC X 1.500 ZNPL GR5
PIN GROOVE TYPE A .500 X 3.750 ALYSTL
FRAME WELDMENT
BRG FLNG 1.44ID 4 BOLT SETSCR LOCK
CAPSCR HEXHD .500-13NC X 2.000 ZNPL GR5
PLUG PIPE HEXSOC .500-14NPT X .63 SAE
SETSCR SOKHD NYLK .375-16NC X .625
DRUM WELDMENT
WASHER SPRING .559 X 1.100 X .039 SPR STL
O-RING .750 X .875 X .063 NITRILE
O-RING .375 X .500 X .063 NITRILE
LABEL WARNING DO NOT ADJUST BRAKE UNDER LOAD
LABEL WARNING INSTALL WIRE ROPE AS SHOWN
LABEL WARNING INSTALL WIRE ROPE AS SHOWN
LABEL MODEL/CAPACITY 2W40-M SERIES
LABEL WARNING KEEP HANDS AWAY FROM DRUM
LABEL NAMEPLATE THERN LOGO
LABEL WARNING POINTS 1-10 FOR 4X
LABEL DATE OF MANUFACTURE
A9968
C4378
A10124
A9967
C4377
A3236
A2558
C4379
A10429
A2894
A3126
A3128
C4637
A9846
A9813
A9814
A2658
A7406
A10680
A10786
A2659
A6889
A2655
10477
A9803
A3408
A1498
A9564
A1612
A3255
D3244
A4389
B4866
A4499
A10122
B5275
A9518
A10120
C4401
D3182
part number
A3290
D3257
C4450
A2922
A9793
A2056
B4872
A9804
A9844
B4995
A3032
B4991
A9845
A9812
A2897
4
2
1
2
1
1
1
4
1
4
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
2
2
2
2
2
6
1
2
1
4
3
1
1
1
12
4
1
1
qty.
12
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 29
17
8
7
13
12
10
11
9
6
5
4
14 15 16 17 18 20
22
21 19
27
23
5
24
25
26
3
28
2 1 30 29
SECTION A-A
45
46
47
33
31
32
4
44 43
SECTION B-B
42 41
15
34 35 36 37 38 39
SECTION C-C
40
B
C
55
B
C
A10777A-0514
53
A
54
A
52
51 50 49 48
page 30 Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches
A10777A-0514
Owner's Manual for Thern 2W40 Series Worm Gear Hand Winches page 31
A10777A-0514
Thern, Incorporated
5712 Industrial Park Road
Winona, MN 55987
PHN 507-454-2996
FAX 507-454-5282
EMAIL: [email protected]
www.thern.com
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Key Features
- Worm gear drive
- Mechanical brake (optional)
- Adjustable handle
- Heavy-duty construction
- Easy to install and use
