Thern 4WP2D Series Worm Gear Power Winch 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, Inc., 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.
Owner’s Manual
For
4WP2D Series
Worm Gear Power Winches
A8328D-0114
page 2
Owner's Manual for Thern 4WP2D Series Worm Gear Power 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, as these are wear components and 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 4WP2D
Series Worm Gear Power 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 4WP2D Series Worm Gear Power 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.
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.
Disconnect power before servicing the equipment.
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 use clutch equipped models to lift loads, or drag loads on an incline.
Accidental release of the clutch could result in loss of the 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 specific 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.
Do not exceed the 5 minute duty cycle rating of the winch. To do so could result in
equipment damage or failure.
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Owner's Manual for Thern 4WP2D Series Worm Gear Power 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.
• 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.
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.
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.
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 specific
rules on installing the equipment.
1.1.2
LOCATE THE WINCH in an area clear of traffic and obstacles. Make sure
the winch is accessible for maintenance and operation.
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
fleet angle minimizes wire rope damage by helping the wire rope wind uniformly onto the drum. See Figure 2.
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 3/8 - inch
coarse thread fasteners, grade 5 or better, torque dry to 30 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 QUALIFIED PROFESSIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFICATIONS FOR THE MOUNTING OF THERN PRODUCTS.
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
1.2
page 5
Installing the Breather Plug
Important!
• Save the oil plug for use when
the winch is removed for storage
or transport.
Install the breather plug to vent heat and pressure from the gearbox. Failure
to do so could result in pressure buildup which can cause the gearbox to leak
or damage the equipment.
For shipment, the gearbox is sealed with an oil plug, and the breather plug
is attached to the gearbox or shipped in a separate envelope.
1.2.1
REMOVE THE OIL PLUG and install the breather plug in the proper location. Make sure the breather plug is above the level of the oil. See Figure 1.
1.2.2
CHECK THE OIL LEVEL in the gearbox to make sure no oil was lost during shipment. See Section 3.3 Lubricating the Winch.
Figure 1 – Breather Plug Installation
breather plug
breather plug
breather plug
breather plug
floor mount
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
fixed 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 recommendations of
the sheave manufacturer.
wall mount
(motor down)
wall mount
(motor up)
ceiling mount
Figure 2 – Maintaining the Fleet Angle
When wire rope travels over a sheave or through a roller guide – maintain fleet
angle by locating the sheave or guide an appropriate distance from the drum,
shown as distance “A”.
fixed sheave or
roller guide
smooth drum
1/2 to 1-1/2 degrees
distance “A”
When wire rope travels directly to the load – maintain fleet angle by controlling 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 flange which may cause damage.
load
smooth drum
1/2 to 1-1/2 degrees
tracks or guide rails
A8328D-0114
center
line
center
line
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
1.3
Removing Motor Drain Plugs
Some electric motors are equipped with screw plugs which are designed to
be removed to provide drain holes.
1.3.1
LOCATE THE LOWEST POINT ON THE ELECTRIC MOTOR.
1.3.2
REMOVE THE SCREW PLUG located at this lowest point. See Figure 3.
Figure 3 – Motor Drain Plug Removal
remove
screw plug
from this
location
floor mount
remove
screw plug
from this
location
remove
screw plug
from this
location
remove screw plug
from this location
wall mount
(motor down)
wall mount
(motor up)
ceiling mount
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
1.4
page 7
Connecting Power
Important!
• Use components rated for the
power supply you will be using.
• Always disconnect power when
the winch is not in use.
Install proper branch circuits, disconnect devices, protection, and grounding
as required by article 430 of the National Electric Code.
All electrical work must be performed by a licensed electrician. Failure to do
so could result in electric shock or poor winch operation.
All control devices must be momentary contact type. Install all control devices so the winch motor will stop when the operator releases the device.
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, the wire rope,
and the path of a broken wire rope that could snap back and cause injury.
It is the responsibility of the owner to provide equipment for controlling the
winch. Controls are available from Thern. The following guidelines are supplied as a reference for the installer.
1.4.1
CONSULT APPLICABLE CODES AND REGULATIONS for specific
instructions regarding power supply installation and hookup.
1.4.2
FOR ELECTRIC WINCHES: install a fuse or circuit breaker, and a disconnect device in the power supply circuit, as required by the National Electric
Code. The disconnect device should be a switch you can lock in the OFF
position to prevent unauthorized use of the winch.
1.4.3
CONNECT THE POWER CORD to a grounded outlet.
1.4.4
FOR PNEUMATIC WINCHES: install a regulator, filter, lubricator and
drier in the air supply line. Failure to operate with clean, dry, lubricated air
will void warranty.
1.4.5
FOR HYDRAULIC WINCHES: install a filter in the hydraulic supply line.
Use Mobil DTE hydraulic fluid, or equal, with a viscosity range of
100 – 200 SUS.
1.4.6
INSTALL A CONTROL DEVICE in the power supply line and connect
power to the motor. Make sure the control device is a momentary contact
type so the motor will stop when the operator releases the control.
1.4.7
CONNECT OTHER EQUIPMENT to the power supply as necessary.
1.4.8
CHECK POWER SUPPLY at the motor and make sure it agrees with the
motor rating. Do not operate the winch until proper power is supplied to the
motor.
1.4.9
TEST CONNECTIONS by operating the winch. The rotation of the drum
must agree with the labels on the control device, and the motor must stop
when the control is released.
CONTACT THE FACTORY OR A QUALIFIED PROFESSIONAL FOR HELP.
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
1.5
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 damage, or poor operation.
• Always wear protective clothing
when handling wire rope.
Figure 4 – Installing the
Wire Rope
Install the wire rope securely to the winch drum. A poorly secured wire rope
could come loose from its anchor and allow the load to escape.
Do not use 3/16 inch or smaller wire rope on standard drums. To do so could
cause damage to the wire rope and allow the load to escape.
Install the wire rope so it is wound correctly as shown or the winch and
brake will not work properly, and could allow the load to escape, see Figure 4.
1.5.1
PURCHASE THE PROPER WIRE ROPE for your application. Keep the
following in mind when selecting a wire rope. Contact a reputable wire rope
supplier for help.
a
BREAKING STRENGTH of new wire rope should be at least 3 times
greater 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
largest load. These are minimum values and will vary with the type of load
and how you are moving it.
b
WIRE ROPE LAY must agree with the winding direction of the drum to
help insure proper winding.
c
WE RECOMMEND 7x19 galvanized aircraft cable for diameters up to 5/16
inch. Do not use 3/16 inch or smaller wire rope on standard drums.
install the wire rope so it is
underwound on the drum as shown
tighten
set screw
1.5.2
a
ANCHOR THE WIRE ROPE to the drum using either the set screw or quick
disconnect anchor.
SET SCREW ANCHOR. See Figure 4.
• PASS THE WIRE ROPE under the drum from the front and position it in
the slot in the drum. Make sure at least 1/2 inch of wire rope extends past
the set screw, and the end of the wire rope does not protrude out where it
will interfere with wire rope winding onto the drum.
• TIGHTEN THE SET SCREW to hold the wire rope in place. Hold the
wire rope down while tightening so the wire rope does not push up out of
the slot.
b
QUICK DISCONNECT ANCHOR. See Figure 4.
• PASS THE WIRE ROPE under the drum from the front and position the
anchor fitting in the groove in the drum.
• PULL THE WIRE ROPE to firmly lodge the anchor fitting in place.
1.5.3
WIND FOUR FULL WRAPS of wire rope onto the drum by operating the
winch while holding the wire rope taught. These wraps serve as anchor
wraps and must remain on the drum at all times. See Figure 4.
CONTACT A REPUTABLE WIRE ROPE SUPPLIER FOR HELP.
typical installation shown
underwound
Wire rope assemblies with
anchor fittings can be purchased
from Thern, Inc.
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
2.1
• To help insure rated performance,
make sure power supply at the
motor is equal to the motor’s
power rating.
• It is your responsibility to detect
and account for different factors affecting the condition and
performance of the equipment.
General Theory of 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 5
minute duty cycle rating of the winch.
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.
Inspect the equipment regularly 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
characteristic 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.
Important!
• Limit nonuniform winding by
keeping tension on the wire rope
and by maintaining the proper
fleet angle.
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 lapping.”
b
LINE SPEED increases with each additional layer of wire rope wound onto
the drum. Line speed will also vary with load weight and power supply for
pneumatic and hydraulic models. Load weight does not affect line speed for
electric models.
c
LOAD RATING represents the maximum pull that can be placed on new
equipment. Load ratings are assigned values for specific amounts of load
travel or wire rope accumulation. The load rating decreases as layers of wire
rope accumulate on the drum.
2.1.6
DUTY RATINGS refer to the type of use the equipment is subject to. Consider the following when determining duty rating. The winch has a 5 minute
duty cycle rating.
a
ENVIRONMENT: harsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from harsh environments when possible.
b
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.
c
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.
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 5 minute duty cycle rating.
CONTACT THE FACTORY FOR MORE INFORMATION.
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
2.2
2.2.1
BREAK-IN OCCURS during the first 30 to 60 minutes of operation. During
break-in, mating surfaces become polished, and clearances increase. This is
desired for efficient 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.
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.
Important!
• When determining whether the
load will exceed the load rating,
consider the total force required
to move the load.
Breaking-In the Winch
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 operating
the equipment, and properly clothed (hard hat, safety shoes and safety
glasses, 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
2.4
KNOW YOUR LOAD and make sure you do not exceed the load rating of
the winch or any other equipment in the system.
Attaching the Load
Figure 5 – Attaching Load
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.
latch closed
tight against
hook
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 device. Follow the recommendations of the sling manufacturer.
a
SEAT THE SLING in the saddle of the hook with the hook latch completely
closed. See Figure 5.
b
CENTER THE LOAD on the hook so it will remain balanced and not tip or
rotate to one side.
sling seated in
saddle of hook
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
2.5
Moving the Load
2.5.1
MOVE THE LOAD slowly and smoothly, only a small distance at first.
Make sure the load is balanced and securely attached before continuing.
2.5.2
USE THE CONTROL DEVICE to operate the winch. The control device
should be momentary contact type, so the winch will stop when the operator
releases the control.
Important!
• Obey a stop signal from anyone.
page 11
• Maintain tension on the wire
rope to keep it tightly and evenly
wound on the drum.
2.5.3
• If the winch and load are not visible during the entire operation,
get help from another person.
DO NOT EXCEED DUTY CYCLE RATING of the winch. This equipment
is rated for a 5 minute duty cycle.
2.5.4
• Appoint a supervisor if more
than one person is involved in
the operation. This will reduce
confusion and increase safety.
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 operations.
2.5.6
OBSERVE THE GEARBOX AND BRAKE during operation for signs of
overheating. Frequent overheating may be a sign of damage, or may
indicate the need for a larger winch.
• When lifting a load, use a tag line
to keep the load from swinging or
twisting, while keeping yourself
away from the load.
a
WATCH FOR SMOKE, the smell of burnt oil, and other signs of overheating. Use a thermocouple or other device to monitor gearbox temperature.
The temperature of the oil should not exceed 150° F.
b
STOP THE OPERATION if the gearbox or brake overheats, and allow the
winch to cool until it reaches ambient temperature. Continued operation
may cause damage.
2.6
Figure 6 – Operating the
Clutch
clutch
Do not engage or release the clutch while the winch drum is turning.
Engage the clutch completely before operating the winch. Operating the
winch with a released or partially engaged clutch may cause damage, or allow
the load to escape.
2.6.1
RELEASE THE CLUTCH with the clutch handle, and unwind the wire rope
for hookup to the load. See Figure 6.
2.6.2
ENGAGE THE CLUTCH with the clutch handle. You may need to rotate
the drum by hand to align the clutch jaws. Visually inspect the clutch for
complete engagement.
engage
disengage
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Operating the Clutch
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
2.7
Emergency Operation
(for models equipped with this feature)
Do not adjust the brake with the load suspended. Accidental release of the
brake could allow the load to escape.
Do not leave a suspended load unattended unless specific precautions have
been taken to secure the load and keep unnecessary personnel away from the
winch and from under the load.
2.7.1
IN CASE OF POWER FAILURE, turn the control device to OFF and DISCONNECT electric power. Leave electric power DISCONNECTED.
2.7.2
MAKE SURE SAFETY PRECAUTIONS have been taken to secure the load
and keep unnecessary personnel away from the winch and from under the
load while operating the emergency hand crank.
2.7.3
IF EQUIPPED WITH A BRAKE MOTOR you must disengage the brake on
the motor before using the emergency hand crank. Operating the emergency
hand crank with the brake on the motor engaged could result in equipment
damage or failure.
a
It is recommended for two people to operate the winch using the emergency
hand crank.
b
If the winch is equipped with a brake motor, assign one person to operate the
hand crank while the other is assigned to operate the brake. Have control of
the hand crank before disengaging the brake on the motor. Accidental release of the brake could allow the load to escape.
c
If the winch is not equipped with a brake motor, assign one person to operate
the hand crank while the other is assigned to observe and control the load.
d
Always follow the brake manufacturers operating instructions for engaging
or disengaging the brake.
2.7.4
DO NOT USE AN IMPACT WRENCH to operate the emergency hand
crank option of the winch. To do so could result in equipment damage or
failure. Use a drill-motor.
2.7.5
DO NOT EXCEED THE 5 MINUTE DUTY CYCLE rating of the winch if
operating with a drill-motor and do not operate the winch with a drill-motor
that exceeds 400 rpm. To do so could result in equipment damage or failure.
2.7.6
ENGAGE THE BRAKE and remove the handle or drill-motor before operating the winch using electric power.
ANY QUESTIONS ON OPERATING THE EMERGENCY HAND CRANK
OPTION OR WINCH APPLICATION CONTACT THERN, INC.
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Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
3.1
page 13
Cleaning the Winch
Clean the winch to remove dirt and help prevent rust and corrosion.
Important!
3.1.1
Increase the frequency of maintenance procedures if the winch is:
• Operated for long periods.
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.
• Used to pull heavy loads.
• Operated in wet, dirty, hot, or
cold surroundings.
3.1.2
3.2
Important!
• Do not overtighten the brake,
since this will cause parts to wear
and become damaged.
Figure 7a – Adjusting the
Brake
turn brake adjusting
nuts clockwise
1/4 turn
Figure 7b – Adjusting the
Brake
CLEAN THE WINCH every 6 months or whenever it is dirty.
REMOVE ALL UNNECESSARY OBJECTS from the area surrounding the
winch.
Adjusting the Brake
Do not adjust the brake with the load suspended. Accidental release of the
brake could allow the load to escape.
3.2.1
ADJUST THE BRAKE whenever it appears to need adjustment, or at least
every 3 months.
3.2.2
CHECK THE ELECTRIC BRAKE ON THE MOTOR (if equipped) by
operating the winch with a test load equal to the winch load rating.
a
DISENGAGE THE ELECTRICAL BRAKE under no load. See Figure 7a.
b
RAISE THE LOAD, then lower it and stop it about one foot off the ground.
b
OBSERVE THE LOAD when stopped. If it continues to coast or creep, the
brake needs adjustment. Refer to the brake manufacturer's instructions, or
contact the factory for assistance.
d
RE-ENGAGE THE MECHANICAL BRAKE by following the instructions
below.
3.2.3
CHECK THE MECHANICAL BRAKE on the 4WP2D series by operating
with a test load equal to the winch load rating:
a
DISENGAGE THE ELECTRICAL BRAKE (if equipped) under no load.
Keep disengaged during procedures b and c below. See Figure 7b.
b
RAISE THE LOAD, then lower it and stop it about one foot off the ground.
c
OBSERVE THE LOAD when stopped. If it continues to coast or creep,
follow the instructions below:
brake
release
knob
• Tighten the brake by turning the adjusting nuts clockwise about 1/4 turn.
Continue to test and tighten the brake by alternating the tightening of each
brake nut until the brake stops and holds the load securely. See Figure 7b.
• DO NOT OVERTIGHTEN mechanical brake adjusting nuts.
d
A8328D-0114
RE-ENGAGE THE ELECTRICAL BRAKE (if equipped).
3.2.4
A DECELERATION DISTANCE while stopping is typically 6 inches.
3.2.5
IF THE LOAD CONTINUES TO COAST or creep, contact the factory.
page 14
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
Lubricating the Winch
3.3
Important!
• Do not leave plug holes in the
reducer open. Open plug holes
will allow dirt and moisture to
contaminate the lubrication.
Make sure the breather is clean and open to vent heat and pressure. Poor ventilation may cause overheating and result in equipment damage.
Check the gearbox for proper level before operating. Too much or too little oil
will cause overheating and result in equipment damage.
• Make sure lubricant has a temperature rating appropriate for
the ambient temperatures of the
operation.
Figure 8 – Lubricating the
Flange Bearing
Lubricate the winch properly to help protect it from wear and rust. Read the
following instructions carefully.
3.3.1
FOR 4WP2D SERIES, the winch is shipped from the factory with the proper
amount (44 ounces) of Mobilgear 600 XP220 lubricant in the gearbox. Lubricate the winch as follows. See Figure 9.
3.3.2
MOTOR BEARINGS are typically lubricated for life by the manufacturer.
flange bearing, lubricate
with NLGI no. 2 grease
a
REPLACE MOTOR BEARINGS if the motor is disassembled for any reason.
b
REFER TO MOTOR MANUFACTURER’S INFORMATION for specific
instructions regarding motor lubrication.
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 if necessary. Do not use synthetic lubricants
and do not mix different lubricants. See Figure 9.
3.3.4
CHANGE GEARBOX OIL at least every 6 months, or whenever it is dirty
or contaminated. Remove the drain plug to drain oil from the gearbox. See
Figure 9.
3.3.5
LUBRICATE THE FLANGE BEARING at least once every month or more,
depending on usage. Use a grease gun to insert NLGI no. 2 grease until clean
grease appears at the seals. The bearing will squeak if it is dry. See Figure 8.
3.3.6
LUBRICATE THE WIRE ROPE and other equipment by following the
manufacturers recommendations.
Figure 9 – Lubricating the Winch
filler/breather
plug
level check plug
filler/breather
plug
filler/
level
breather
check plug
plug
drain
plug
filler/breather
plug
drain
plug
level
check
plug
level
check
plug
drain plug
drain plug
floor mount
wall mount
(motor down)
wall mount
(motor up)
ceiling mount
A8328D-0114
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
3.4
page 15
Inspecting the Equipment
Important!
• Start an inspection program as soon
as you put the winch into use.
Do not use damaged or malfunctioning equipment. Place an “OUT OF ORDER” sign on
the winch. Do not use the winch until the sign is removed by a qualified maintenance
person who has completely corrected the problem.
• 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.
Inspect the winch to detect signs of damage or poor operation before they
become hazardous.
3.4.1
CONSULT APPLICABLE CODES AND REGULATIONS for specific
rules on inspecting the winch and other equipment.
3.4.2
CONSULT MANUFACTURER’S RECOMMENDATIONS for information
on inspecting the wire rope and other equipment.
3.4.3
Instructions for Frequent Inspection
a
Perform frequent inspections:
• Before each operation.
VISUALLY INSPECT the entire winch and all other equipment involved in
the operation.
• Every 3 hours during operation.
• Check all equipment for cracks, dents, bending, rust, wear, corrosion and
other damage.
• Whenever you notice signs of
damage or poor operation.
• Make sure the wire rope is installed correctly and anchored securely to
the drum.
• Make sure the winch is properly lubricated.
• Check the gearbox for signs of leakage, and make sure it is filled with the
proper lubricant. Contact the factory if there are any signs of lubricant
leaking from the gearbox.
Figure 10 – Broken Wires
• Make sure the breather plug is clean, open, and installed correctly.
wire
• Make sure mounting fasteners are tightened securely.
one
lay
• Make sure the foundation is in good condition, and capable of supporting
the winch and its load under all load conditions.
• Check electrical wiring and connections for wear, corrosion, cuts, and
other damage.
strand
Wire rope assembly must be replaced if more than 6 wires are
broken in one lay, or if more than
3 wires are broken in one strand
in one lay.
• Check clutch operation, if applicable, to make sure it moves freely and
engages completely.
b
TEST WINCH PERFORMANCE by moving a test load equal to 10% of the
rated capacity.
• 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 winch responds to the control device. It must rotate as shown
on the control labels, and it must turn off when you release the control.
• 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 adjustment. See Section 3.2 Adjusting the Brake.
Completely correct all problems before continuing. Use the Troubleshooting
Chart to help determine the cause of certain problems. See Table 2.
A8328D-0114
page 16
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
Perform periodic inspections:
3.4.4
a
• Every 6 months.
Instructions for Periodic Inspection, see Table 1.
VISUALLY INSPECT the winch and all other equipment.
• Whenever you return the winch
to service from storage.
• 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.
• Whenever you notice damage
or poor operation in a frequent
inspection.
• 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.
• Whenever you have, or think you
may have, overloaded or shock
loaded the winch.
• Check all fasteners for stripped threads, wear, bending, and other damage.
• Check the gearbox for signs of leakage. Contact factory if there are any
signs of lubricant leaking from the gearbox.
Figure 11 – Load Hook
Inspection
• Make sure the breather plug is clean, open and installed correctly.
twist
• Make sure the winch outboard bearing is properly lubricated.
• Check clutch operation, if applicable, to make sure it moves freely and
engages completely.
throat
opening
• Make sure all labels and plates are readable, firmly attached, free of damage and clean. Replacements are available from the factory.
b
thickness
The wire rope assembly must be replaced if the throat opening is 15%
wider than nominal, if the thickness
is 10% less than nominal, or if the
hook is twisted 10° or more.
DRAIN A SMALL AMOUNT OF OIL from the gearbox into a clean container.
• Check the oil for dirt, metal particles, water, and other signs of contamination. Completely drain the gearbox if oil is contaminated.
• Make sure the gearbox is properly lubricated. See Section 3.3 Lubricating
the Winch.
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, broken
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 broken
in one strand in one lay. See Figure 10.
• Make sure hooks and other fittings are securely attached to the wire rope,
and the wire rope where they are attached is not frayed, corroded, broken,
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.
A8328D-0114
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
Figure 12 – Rope Diameter
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 100 POUNDS of tension on the wire rope.
diameter
correct
nominal
wire rope
diameter
• 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.
incorrect
The wire rope assembly must be
replaced if the diameter measures
less than the minimum diameter
at any point.
maximum allowable
reduction from
nominal diameter
1/4 in
15/64 in (.2344 in)
5/16 in
19/64 in (.2969 in)
page 17
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 bearings.
• Make sure the load moves smoothly, without hesitation or strain.
• Make sure the winch responds to the control device. It must rotate as
shown on the control labels, and it must turn off when you release the
control.
• 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 adjustment. See Section 3.2 Adjusting the Brake.
h
DISCONNECT POWER and inspect power supply equipment.
• Check supply lines for wear, cuts, corroded connections, and other damage.
• Check control devices and other power supply components for signs of
moisture, corrosion, burn marks, cracks, and other damage.
i
CONNECT POWER.
• Check power supply at the motor and make sure it agrees with the motor rating. Do not operate the winch until proper power is supplied to the
motor.
Completely correct all problems before continuing. Use the troubleshooting
chart to help determine the cause of certain problems. See Table 2.
A8328D-0114
page 18
Owner's Manual for Thern 4WP2D Series Worm Gear Power 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
bent, crushed, otherwise damaged
wire rope loosely or unevenly wound
wire rope
broken wires, see figure 10
replace if more than 6 wires in one lay,
number per strand =
or 3 wires in one strand in one lay, are broken
number per lay =
diameter reduced, see figure 12
replace if diameter is excessively worn
diameter =
end connections
corroded, rusted, worn, otherwise damaged
not securely attached
hook or other device
twisted, bent, worn, otherwise damaged, see figure 11
hook latch fails to close when released
replace if twist is 10 degrees or more,
twist =
replace if throat width is 15% larger than nominal
throat width =
replace if thickness is 10% less than nominal
thickness =
drum
anchor worn, distorted, otherwise damaged
excessive movement or backlash
motor
motor corroded, burnt out, otherwise damaged
motor is sluggish or operates poorly
brake
brake worn, corroded, otherwise damaged
brake does not operate properly
power supply
components corroded, burnt, otherwise damaged
control device fails to control winch properly
supply lines worn, cut, corroded, otherwise damaged
supply lines unprotected, obstructing traffic
connections loose, corroded, otherwise damaged
power supply at motor =
clutch
worn, bent corroded, otherwise damaged
does not move freely or engage completely
labels and plates
dirty, illegible, otherwise damaged
loosely attached or missing
comments
authorized signature
date
A8328D-0114
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
page 19
Table 2 – 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
motor won't run
cause
correction
• circuit breaker tripped or fuse blown .................... reset circuit breaker or replace fuse
• poor power supply ................................................ inspect and repair as necessary
• power supply lines loose or damaged .................. inspect, repair and tighten as necessary
• power supply failure ............................................. check power supply source
• motor burnt out or damaged ................................. repair or replace as necessary
motor runs, drum doesn't turn
• loose or broken spring pins or keys ...................... inspect and replace as necessary
• clutch disengaged ................................................ stop motor and engage clutch
• loose, stripped or broken gears ............................ inspect and replace as necessary
motor tries to turn but can't
• unit overheated ..................................................... allow to cool
• load too heavy ...................................................... lighten load
• poor power supply ................................................ inspect supply circuit and repair as needed
• band brake too tight .............................................. loosen brake and readjust
• brake broken or locked ......................................... inspect and replace 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 reducer ............................... inspect and repair as necessary
• hydraulic equipment leaking or damaged ............. inspect and replace as necessary
excessive end play on drive shaft
• loose or damaged keys or keyways ..................... inspect and replace as necessary
• excessively worn gears ........................................ inspect and repair as necessary
excessive worn gears or bearings
• load too heavy ...................................................... lighten load
• poor lubrication of gears or bearings .................... inspect and lubricate as necessary
overheating
• 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
• poor lubrication ..................................................... inspect and lubricate as necessary
grinding noise
• contaminated lubrication ...................................... drain, clean and lubricate the winch
whining motor
• load too heavy ...................................................... lighten load
• broken gears or bearings ..................................... inspect and replace as necessary
• motor overheated ................................................. allow to cool
• motor bearings burnt out ...................................... replace motor or bearings
whistling noise
• air leak in pneumatic equipment ........................... inspect and repair as necessary
rattling noise
• loose fasteners or setscrews ................................ tighten all fasteners and screws
heavy thump during operation
• contaminants in lubricant ...................................... drain, clean and lubricate the winch
• loose setscrews or keys in gears or shafts ........... inspect and repair as necessary
A8328D-0114
page 20
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
3.5
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 flaking. A good finish helps
to protect against corrosion and weather damage.
Important!
• It is your responsibility to determine when to replace parts.
When considering whether to
continue using a part or to replace
it, remember that replacing it
is the best way to avoid further
equipment damage.
• Replace spring pins, retaining
rings, and oil seals whenever the
winch is disassembled for inspection or repair.
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.
3.5.4
• During reassembly, use loctite
598 Ultra Black to create a seal
between the two halves of the
gearbox and the input shaft.
Contact factory for detailed
instructions. Disassembly of the
gearbox before contacting Thern,
Inc voids all warranties
• Appoint a qualified person to be
responsible for all repairs to the
equipment.
Repairing the Winch
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
A8328D-0114
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
4.1
REMOVE THE BREATHER PLUG and install a sealed oil plug to prevent
the loss of lubrication during shipment.
4.1.2
PACK THE WINCH in an upright position for transport, using the original
packaging materials, if possible.
a
FASTEN THE WINCH to a wooden base using lag bolts, to keep it from
moving during transport.
b
SEAL THE WINCH in plastic with a desiccant to help protect it from rust,
corrosion, and other damage.
c
CONSTRUCT WOODEN SIDES and top to enclose the winch in a solid
protective crate.
d
PACK LOOSE PARTS in small boxes or ship separately.
4.1.3
4.2
A8328D-0114
Transporting the Winch
4.1.1
Important!
• Keep a record of what you ship,
and when you send it.
page 21
INSPECT THE WINCH according to the Instructions for Periodic Inspection before installing it in a new location.
Storing the Winch
4.2.1
LUBRICATE THE WINCH as necessary, and make sure the breather plug is
clean and properly installed. Add a rust preventative for long term storage.
4.2.2
SEAL THE WINCH in plastic with a desiccant to help protect it from rust,
corrosion, and other damage.
4.2.3
STORE THE WINCH upright, in a cool clean place away from corrosive
chemicals and moisture.
4.2.4
ROTATE THE DRUM PERIODICALLY to keep bearing and gears surfaces
from becoming lacquered.
4.2.5
INSPECT THE WINCH according to the Instructions for Periodic Inspection before installing it for operation.
4.2.6
TEST INSULATION RESISTANCE in the motor to detect moisture damage. Refer to the motor manufacturer’s instructions.
4.2.7
LUBRICATE THE WINCH PROPERLY prior to operation. See Section 3.3
Lubricating the Winch.
page 22
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
4WP2D Series Assembly
item
11
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
172
182
19
20
21
1
2
description
MOTOR
KEY .188 X .188 X 1.375
CAPSCREW HEXHD .375-16NC X 1.000
HELSPRLK WASHER .375 X .683 X .094
REDUCER ASSEMBLY
HEX NUT .375-16NC
SETSCREW SQHD .312-18NC X .875
DRUM
FRAME
CARRIAGE BOLT .375-16NC X 1.250
FLANGE BEARING
BREATHER PLUG .375-18NPT X .48
GROOVE PIN TYPE A .312 X 2.500
LABEL WARNING POINTS
LABEL WARNING KEEP HANDS AWAY FROM DRUM
LABEL WARNING DISCONNECT ELECTRIC POWER
LABEL REMOVE DRAIN PLUGS
LABEL DRAIN PLUG WITH ARROW
LABEL WARNING
LABEL WARNING DO NOT ADJUST BRAKE WHEN
LABEL NAMEPLATE
part number
MTR4WP2D
A5178
A2922
A2926
D2595
A3017
A7703
C3381
D1913
A7283
A7285
A3408
A7284
A2655
A2659
A2256
A8338
A8339
A7406
A2658
A5957
qty.
1
1
4
4
1
6
1
1
1
2
1
1
1
1
2
1
1
8
1
1
1
Motor varies.
Some electric motors are equipped with screw plugs which are designed to be removed to provide drain holes.
5 6 7 15
8 9
6 10
11
14
3 4
2 1
12
16 17 18
19
20
21
13
A8328D-0114
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
page 23
4WP2D8 Series Assembly
item
11
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
description
MOTOR
KEY .188 X .188 X 1.375 4140
CAPSCREW HEXHD .375-16NC X 1.000
HELSPRLK WASHER .375 X .683 X .094
REDUCER ASSEMBLY
HEX NUT .375-16NC
SETSCREW SQHD .312-18NC X .875
DRUM
FRAME
BREATHER PLUG .375-18NPT X .48
CARRIAGE BOLT .375-16NC X 1.250
FLANGE BEARING 1.062
HANDLE
CAPSCREW HEXHD .312-18NC X 1.000
CAPSCREW HEXHD .312-18NC X .625
PRESSURE PLATE
GROOVE PIN TYPE A .312 X 2.500
LABEL WARNING POINTS
LABEL WARNING KEEP HANDS AWAY FROM DRUM
LABEL WARNING DISCONNECT ELECTRIC POWER
part number
MTR4WP2D
A5178
A2922
A2926
D2600
A3017
A7703
D2281
D2248
A3408
A7283
A7285
B3620
A3028
A3529
B3861
A7284
A2655
A2659
A2256
212
222
23
24
25
LABEL REMOVE DRAIN PLUGS
LABEL DRAIN PLUG WITH ARROW
LABEL WARNING
LABEL WARNING DO NOT ADJUST BRAKE WHEN
LABEL NAMEPLATE
A8338
A8339
A7406
A2658
A5957
1
2
qty.
1
1
4
4
1
6
1
1
1
1
2
1
2
4
2
1
1
1
2
1
1
8
1
1
1
Motor varies.
Some electric motors are equipped with screw plugs which are designed to be removed to provide drain holes.
5 6 7 8 19
9
18
3 4
1 2
10
19
6 11
20 21 22
23 13
14
15
12
25 24
A8328D-0114
17
16
page 24
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
4WP2DC Series Assembly
item
11
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
312
322
33
34
35
36
37
1
2
description
MOTOR
KEY .188 X .188 X 1.375
CAPSCREW HEXHD .375-16NC X 1.000
HELSPRLK WASHER .375 X .683 X .094
REDUCER ASSEMBLY
HEX NUT .375-16NC
SETSCREW SOKHD .312-18NC X .375
DRUM
FRAME
ZERK DRIVE .250
TOP CLUTCH
CAPSCREW SOKHD .375-16NC X 1.000
BEARING FLANGE 1.062
CARRIAGE BOLT .375-16NC X 1.250
PUSH PULL CLAMP
FLAT WASHER SAE .750 X 1.469 X .134
SPRING PLUNGER NYLK .375-16NC X 1.125
BOTTOM CLUTCH
HELSPRLK WASHER .312 X .586 X .078
CAPSCREW SOKHD .312-18NC X 1.250
GROOVE PIN TYPE A .312 X 2.500
CAPSCREW SOKFLTHD 10-24NC X 1.250
BREATHER PLUG .375-18NPT X .48
HANDLE
CAPSCREW HEXHD .312-18NC X 1.000
CLUTCH HUB
CAPSCREW HEXHD .312-18NC X .625
LABEL WARNING POINTS
LABEL WARNING KEEP HANDS AWAY FROM DRUM
LABEL WARNING DISCONNECT ELECTRIC POWER
LABEL REMOVE DRAIN PLUGS
LABEL DRAIN PLUG WITH ARROW
LABEL WARNING
LABEL CLUTCH DISENGAGED
LABEL CLUTCH ENGAGE
LABEL WARNING DO NOT ADJUST BRAKE WHEN
LABEL NAMEPLATE
part number
MTR4WP2D
A5178
A2922
A2926
D2601
A3017
A3745
D2337
D2248
A3988
C3695
A3445
A7285
A7283
A7785
A6500
A7792
C3697
A2925
A3548
A7284
A7794
A3408
B3620
A3028
B3927
A3529
A2655
A2659
A2256
A8338
A8339
A7406
A7842
A7843
A2658
A5957
qty.
1
1
4
4
1
6
1
1
1
1
1
2
1
2
1
1
2
1
1
1
1
4
1
2
2
1
2
1
2
1
1
8
1
1
1
1
1
Motor varies.
Some electric motors are equipped with screw plugs which are designed to be removed to provide drain holes.
A8328D-0114
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
5
6
7
page 25
8
29
9
28
3 4
1 2
23
33
24
30 31 32 22
10 11 12
25
26
13
27
6 14
37
36
21
20
18
19
A8328D-0114
16 15
17
35
34
page 26
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
Reducer Assembly
D2595
item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
description
CAPSCREW HEXHD .312-18NC X .750
BEARING HOUSING ASSEMBLY
THRUST BEARING .753ID X 1.250OD X .125
SHIM .751/.755 X 1.12 X .032
BRAKE DRUM ASSEMBLY
FLAT WASHER .781ID X 1.875OD X .090
FLAT WASHER .765ID X 1.254OD X .060
PIPE PLUG SQHD .125-27NPT X .35
DOWEL PIN .188 X .500
BALL THRUST BEARING
OIL SEAL 1.250ID X 1.687OD X .250
INPUT SHAFT
MOTOR MOUNT
PIPE PLUG HEXSOC .125-27NPT X .31
BRAKE BAND CONNECTOR
HEX JAM NUT NYLK .375-16NC
CAPSCREW HEXHD .312-18NC X 1.000
HELSPRLK WASHER .312 X .586 X .078
SPRING WASHER .380 X .750 X .034
COVER
part number
A3032
B4265
A8181
A8182
B4266
A8184
A8185
A3407
A7308
A8186
A8187
C3749
D2594
A3405
B2917
A3180
A3028
A2925
A3296
D2052RED
21
22
23
24
25
GEARCASE
PIPE PLUG HEXSOC .375-18NPT X .425
OIL SEAL 1.125ID X 1.874OD X .250
STUD .375-16NC X 1.312
DRUM SHAFT ASSEMBLY
D2449RED
A3290
A8188
A7279
C3414
3
4
5 6 7
8 9
10
11
12 13
16
D2600
qty.
12
1
1
1
1
2
1
1
2
1
1
1
1
2
1
2
4
4
1
1
D2601
part number
A3032
B4265
A8181
A8182
B4266
A8184
A8185
A3407
A7308
A8186
A8187
C3749
D2594
A3405
B2917
A3180
A3028
A2925
A3296
D2052RED
1
4
1
4
1
qty.
12
1
1
1
1
2
1
1
2
1
1
1
1
2
1
2
4
4
1
1
D2449RED
A3290
A8188
A7279
C3623
1
4
1
4
1
part number
A3032
B4265
A8181
A8182
B4266
A8184
A8185
A3407
A7308
A8186
A8187
C3749
D2594
A3405
B2917
A3180
A3028
A2925
A3296
D2052RED
D2449RED
A3290
A8188
A7279
C3694
qty.
12
1
1
1
1
2
1
1
2
1
1
1
1
2
1
2
4
4
1
1
1
4
1
4
1
17 18
15
1
2
19
20
14
21
22
23
25
24
A8328D-0114
Owner's Manual for Thern 4WP2D Series Worm Gear Power Winches
Pressure Plate Assembly
B36881
item
1
2
3
4
5
6
7
8
part number
B3643
A3269
A3268
A3277
A3273
A7434
–
A3278
1
2
description
PRESSURE PLATE
PIN
PRESSURE PLATE BASE
TORSION SPRING
SPACER TUBE
CAPSCREW HEXHD .250-20NC X .375
FLAT WASHER
RETAINING RING .500
page 27
B38612
qty.
1
1
1
1
1
2
–
2
part number
B3858
B3859
B3860
A3277
A3273
A7434
A3052
A3278
qty.
1
1
1
2
2
2
2
2
B3688 option for 4WP2D series winches – sold separately.
B3861 supplied with 4WP2D8 series winches.
1
2
3
4
5
6 7
8
4WP2D Series – Performance Characteristics 1
model
4WP2D-800-26
4WP2D-800-40
4WP2D-1500-26
4WP2D-1500-40
4WP2D8-800-26
4WP2D8-800-40
4WP2D8-1500-26
4WP2D8-1500-40
4WP2DC-800-26
4WP2DC-800-40
4WP2DC-1500-26
4WP2DC-1500-40
motor motor
codes
hp
A,B,D,E
1
D,E
1.5
D,E
2
B,D,E
3
A,B,D,E
1
D,E
1.5
D,E
2
B,D,E
3
A,B,D,E
1
D,E
1.5
D,E
2
B,D,E
3
Motor Codes
A
B
D
E
115 volt
230 volt
230 volt
460 volt
A8328D-0114
load rating (lb)
1st
mid
full
layer
drum
drum
800
590
460
800
590
460
1500
1100
900
1500
1100
900
800
460
330
800
460
330
1500
900
600
1500
900
600
800
460
330
800
460
330
1500
900
600
1500
900
600
1
1 phase
1 phase
3 phase
3 phase
2
wire
rope
dia. (in)
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
line speed (fpm)
1st
full
layer drum
26
45
40
68
26
45
40
68
26
65
40
97
26
65
40
97
26
65
40
97
26
65
40
97
drum capacity (ft)2
1st
mid
full
layer
drum drum
11
35
77
11
35
77
11
35
77
11
35
77
19
130
280
19
130
280
19
130
280
19
130
280
12
87
190
12
87
190
12
87
190
12
87
190
approx.
ship
wt. (lb)
75
75
75
75
100
100
100
100
100
100
100
100
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.
Actual drum capacities may be 25-30% less, due to nonuniform winding. Tension in wire rope will
also affect drum capacity.
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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