owner’s manualowners manual for ta150kgmr1 pneumatic winches for personnel lifting page 7...

Owner’s ManualFor TA150KGMR1 Pneumatic WinchesDedicated for Personnel Lifting

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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 TA150KGMR1 Pneumatic Winches for Personnel Liftingpage 2

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Warranty StatementThern, Inc. warrants each new products to be free from defects in material and workmanship under normal use and service for a period of 24 months from the date of purchase by the original using buyer. Genuine Thern, Inc. replace-ment parts and components will be warranted for 30 days from the date of purchase, or the remainder of the original equipment warranty period, whichever is longer.

Under no circumstances will this warranty cover an product or component thereof, which, in the opinion of the company, has been subjected to misuse, unauthorized modifications, alteration, an accident or shipping damage. This warranty also shall not apply to products that are operated improperly, improperly maintained or improperly stored.

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. Brake discs, wire rope or other wear components are not covered under this warranty, as their life is subject to use conditions which vary between applications. Any alteration, repair or modification of the product outside the Thern, Inc. factory shall void this warranty.

Thern, Inc. in no way warrants pneumatic, hydraulic or electric motors and control valves or other trade accessories since these items are warranted separately by their respective manufacturers.

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.

To make a claim under this warranty, contact the factory for an RGA number. The product must be returned, prepaid, directly to Thern, Inc. or to an authorized service center. A completed warranty claim form must ac-company the product. If the product is found to be defective, it will be repaired or replaced free of charge, and Thern, Inc. will reimburse the shipping costs.

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

About This ManualThe 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 TA150KGMR1 Pneumatic 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.

Please record the following:Date Purchased:

Model No.:

Serial No.:

This information is required when calling the factory for service.

Owner's Manual for TA150KGMR1 Pneumatic Winches for Personnel Lifting page 3

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Figure 1a – Serial Tag

5712 INDUSTRIAL PK RDWINONA, MN 55987 USA

(507) 454-2996

PART # A11151A

MODEL #

SERIAL #

DATE OF MANUFACTURE

1ST LAYER RATING KG (LBS)

FULL DRUM RATING KG (LBS)

DRUM SIZE MM

ROPE SIZE MM (INCH)

1ST LAYER SPEED MPM (FPM)

FULL DRUM SPEED MPM (FPM)

AIR FLOW RATE CMPM (SCFM)

AIR PRESSURE BAR (PSIG)

MINIMUM DESIGN TEMPERATURE DEG C (F)

MAXIMUM NUMBER OF ROPE LAYERS

ID OD W

DRUM SIZE INCH ID OD W

Figure 1b - Serial Tag Location

Serial Tag Location


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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.

Dedicate this winch for personnel lifting only.

Lift only one rider at a time with this winch using an approved device (personnel harness, boatswain’s chair, bosun’s chair, etc…).

Check lubricant before use.

Install the wire rope securely to the winch drum.

Keep at least 5 wraps of wire rope wound on the drum at all times, to serve as anchor wraps. With less than 5 wraps on the drum the wire rope could come loose, causing potential injury to the rider.

Keep hands away from the drum, wire rope, slack line detector pinch points, and other moving parts of the equipment.

Ensure brakes hold prior to making complete lift by lifting the person a short distance (less than one foot) and releasing control.

If there becomes a slack wire rope condition, the hoisting mechanisms shall be inspected to ensure all wire ropes are properly seated on drums and in sheaves before resuming winch operation.

Depressurize and disconnect air supply before servicing the equipment.

Always wear hearing protection when operating the winch. Sound pressure levels can exceed 86 dBa.


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Suggestions for Safe Operation

DO NOT do the following:

Do not lift loads 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 multiple winches to lift or lower a single rider.

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 lift point. This damages the wire rope and could cause the rope to fail.

Do not operate the winch with guards or covers removed or improperly installed.

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 person being lifted. Avoid shock loads by starting and stopping the operation smoothly. Shock loads overload the equipment and may cause damage or personal injury.

Do not leave a suspended person unattended.

Do not lift materials, except hand tools accompanied by the rider, provided that the total weight of the rider, lifting device, and tools do not exceed the safe working load (SWL).

Do not use the lifting eyes of the winch for regular lifting or as a tie-off point.

Do not operate the winch in inclement weather conditions, especially when lightning is present. Use of a ground strap is recommended to prevent damage to the winch in case of lightning strike.

Do not touch brake rotors as they become hot during normal operation.

Do not remove the serial plate or any safety labels on the winch.


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1.1 Personnel Lifting Winch Overview

All supporting structure, mounting hardware and attaching hardware must be in accordance with all applicable standards codes and regulations.

Ensure proper selection and installation of wire rope and sheaves. Sheaves and sheave mounting must be designed and selected in accordance with all applicable standards, codes, and regulations. Improper installation of wire rope or sheave can cause uneven spooling and wire rope damage that could cause a load to escape.

Winch is not approved for lifting below deck unless a secondary air supply is available.

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.

Personnel lifting shall only be performed in applications specifically approved by regulatory bodies. Personnel lifting with this winch is strictly limited to off-shore marine applications specifically approved by maritime regulatory bodies. Regulatory bodies, not the manufacturer, have determined suitable use.

Personnel Lifting Winches manufactured by Thern are furnished with limitations; approval for any use in personnel lifting applications automatically terminates for any of the following reasons:

• Winch does meet other applicable codes and standards.

• Winch is not part of an approved system.

• Winch is not properly maintained in an "as new" condition with all parts intact and properly adjusted.

• Winch is used in applications not approved by codes and regulations, or is used in applications inconsistent with manufacturer's operation and maintenance manual.

• Changes in any of the standards or regulations after Thern's initial shipment of the product.

• More than one winch is used to attach to a common rider.

1.1.1 WINCHES ARE DESIGNED for the purpose of lifting people and manufactured to comply with applicable standards and specifications of governing bodies. The minimum ambient temperature during winch operation is -4 F (-20 C).

1.1.2 WINCHES ARE DESIGNED AND ASSESSED to meet the requirements of governing bodies for the offshore oil industry.

Important!

• Many agencies require (for winches) additional, redundant safety devices that Thern does not furnish. Additional devices are often required to bring the system up to applicable codes, standards, and regulations.

• Before using a Personnel Lifting Winch, be sure to check all regulations; local, state, federal and country, that may apply to the use of a winch or winch system for lifting and lowering people.

• The personnel lifting device, (harness, bosun’s chair, boat swain’s chair, etc…) shall be approved by the manufacturer for personnel lifting.


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1.1.3 IN FURNISHING PERSONNEL LIFTING WINCHES TO CUSTOMERS, Thern warrants that it is the owner's and user's responsibility to determine the suitability of a personnel lifting winch for a particular application. Further, it is the owner's and user's responsibility to check and satisfy all local, state, federal, and country requirements to the lifting and lowering of persons.

1.1.4 IT IS THE RESPONSIBILITY of the winch owner/user to make personnel aware of all federal, state and local rules, codes and company safety rules, regulations and instructions and to establish programs to:

a TRAIN AND DESIGNATE WINCH OPERATORS.

b TRAIN AND DESIGNATE WINCH INSPECTION and maintenance personnel.

c ENSURE PERSONNEL, frequently involved with rigging the rider, are trained in attaching the rider to the winch and other load handling tasks.

d ENSURE SAFETY PROCEDURES are followed.

e ENSURE ALL ACCIDENTS or safety violations are properly reported, and appropriate corrective action is taken prior to further use.

f ENSURE ALL WINCH WARNING TAGS, labels and the Owner's Manual supplied with the winch are read.

1.1.5 NOISE AND VIBRATION

At rated load and maximum speed:

Vibration Level: 18.5 m/s2 lowering; 6.2 m/s2 lifting

Noise level: 86 dBA per ISO 11201


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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 the rider will be visible during the entire operation.

• When moving and positioning the winch, refer to Section 4.1 Transporting the Winch.

• 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.

1.2 Installing the Winch

All supporting structure, mounting hardware and personnel platform (load) attaching hardware must be in accordance with all applicable standards codes and regulations.

Ensure proper selection and installation of wire rope and sheaves. Sheaves and sheave mounting must be designed and selected in accordance with all applicable standards, codes, and regulations. Improper installation of wire rope or sheave can cause uneven spooling and wire rope damage that could cause a rider (load) to drop.

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.

Thern personnel lifting systems are equipped with upper and lower travel limiting devices. The upper limit setting should provide a vertical clearance from the upper block, and the lower limit shall be set so that the winch cannot be operated with less than 5 anchor wraps wound on the drum at any time.

1.2.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on installing the equipment.

1.2.2 LOCATE THE WINCH in an area clear of traffic and other obstacles. Make sure the winch is accessible for maintenance and operation.

1.2.3 LOCATE THE WINCH in an area with adequate temperatures. (-20° to 60° C, -4° to 140° F).

1.2.4 USE LIFTING EYES to properly transport winch and ensure that it remains level during transportation and installation. Refer to Section 4.1 Transporting the Winch for more information.

1.2.5 INSTALL THE WINCH on a horizontal surface. The winch is designed and assembled for horizontal base mounting.

1.2.6 CONSIDER THE ERGONOMIC IMPACT of the winch's height on manual operation. To help prevent operator injury due to stretching/reaching, consider placing a riser between the winch and the mounting deck. Riser must be sufficient in strength, and must meet all applicable standards, codes, and regulations.


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Figure 2 – Maintaining the Fleet Angle

• Whenwireropetravelsoverasheaveorthrougharollerguide–maintainfleetanglebylocatingthesheaveorguideanappropriatedistancefromthedrum,shownasdistance“A”.

smoothdrum

1/2to1-1/2degrees

distance“A”

center line

fixedsheaveorrollerguide

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 recommenda-tions of the sheave manufacturer and ensure conformance with applicable standards, codes and regulations.

1.2.7 MAINTAIN A MAXIMUM FLEET ANGLE of 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.

• Install the lead sheave at least 20 feet from the center of the winch drum to allow for proper fleet angle and slack line detector functionality.

1.2.8 FASTEN THE WINCH SECURELY to the foundation. Use coarse thread fasteners, grade ISO M16 8.8 (or ANSI Grade 5, 5/8”) or better. Fastener certifications may be required by applicable standards, codes, and regulations. Be sure to check the torque required for your fastener selection before mounting winch. Make sure the winch is secured to a solid foundation able to support the winch and the rider under all conditions with design factors based on accepted engineering practices.

1.2.9 THE WIRE ROPE EXIT ANGLE must be between vertical and a specified angle from vertical. This limitation is required for proper operation of the slack line detector. See Figure 4.

CONTACT A QUALIFIED PROFESSIONAL FOR MOUNTING INSTRUCTIONS TO COMPLY WITH LOCAL STANDARDS, CODES AND REGULATIONS.


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1.3 Installing the Breather Plug

Make sure the breather plugs are clean and open to vent heat and pressure. Poor ventilation will cause overheating and result in damage to oil seals and other equipment.

For shipment, the winch motor and reducer are filled with lubricant and motor breather plugs installed.

1.3.1 VERIFY THE BREATHER PLUG is installed on the motor. See Figure 22a. Refer to the motor manufacturer’s information. The reducer is not equipped with a breather plug.

1.3.2 CHECK THE LUBRICANT LEVEL in the motor and reducer to make sure no lubricant was lost during shipment. See section 3.2 - Lubricating the Winch.


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1.4 Connecting Air Supply to the Winch

All control devices must be momentary 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 rider through the entire operation.

Locate control devices so the operator will be clear of the rider, the wire rope, and the path of a broken wire rope that could snap back and cause injury.

Check that the direction indicators on control match rider direction.

NOTE: THE DIVERTER VALVE CAN BE USED AS A SHUT-OFF VALVE UNLESS A SECONDARY AIR SUPPLY IS INSTALLED.

It is the responsibility of the owner to provide equipment for powering the winch, The following guidelines are supplied as a reference for the installer.

1.4.1 CHECK THE COMPONENT MANUFACTURER'S INSTRUCTIONS for installing auxilliary equipment.

1.4.2 ENSURE an accessible shut off valve has been installed in the air supply line and make sure others are aware of its location.

A shut-off valve that shuts off the air when the E-stop is activated is included as part of the air preparation unit (APU). An inline shut-off is recommended for added security.

1.4.3 THE AIR SUPPLY must be clean and free from moisture. The dew point of the air supply shall be low enough as to prevent condensation from forming in the pneumatic components as the air is passed through the system.

Air preparation unit comes installed on the winch. The APU will provide lubricant so external lubricator is not required.

a ALL AIR SUPPLY LINES should be purged with clean, moisture free air or nitrogen before connecting to winch inlet.

b SUPPLY LINES should be as short and straight as installation conditions will permit. Long transmission lines and excessive use of fittings, elbows, tees, globe valves etc. cause a reduction in pressure due to restrictions and surface friction in the lines.

c AIR LINE LUBRICATOR on the winch should be replenished daily and set to provide 3-4 drops per minute.

1.4.4 MOISTURE THAT REACHES THE AIR MOTOR through air supply lines is a primary factor in determining the length of time between service overhauls.

a MOISTURE TRAPS can help to reduce moisture.

b AIR RECEIVERS collect moisture before it reaches the motor.

c INSTALLING AN AFTERCOOLER at the compressor that cools the air to condense and collect moisture prior to distribution through the supply lines is also helpful.

1.4.5 THE WINCH SHOULD BE INSTALLED as near as possible to the compressor or air receiver. Recommended pressures and volumes are measured at the point of entry to the air motor.

1.4.6 CHECK THE AIR PRESSURE at the motor and make sure it agrees with the pressure rating marked on the winch nameplate.

Important!

• Use components rated for the air supply you will be using.

• Always disconnect the air supply when the winch is not in use. When removing the air hoses from the unit, plug the open ports.

• Never install an additional lubricator in-line for this winch. A filter-regulator-lubricator is integrated into the winch, and pre-lubrication will clog the winch’s filter.

• The pressure regulator on the winch may be pre-set and locked if required by the product standard. Do not modify a locked setting on the regulator. Contact Thern for instructions if re-adjustment is required.

• Check that the indicators on the control match rider direction.


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1.4.7 TEST AIR CONNECTIONS by slowly opening the air line to ensure air connections are sound. After it is verified that the system does not leak, gradually operate the winch.

a ROTATION OF THE DRUM must agree with the direction indicated on the labels for the control device.

b CHECK THE AUTOMATIC LOAD BRAKES. Make sure they release when the motor is applied power by the control lever and engage when the control lever is returned to the neutral position. The procedure for testing the brakes can be found in the brake section of this manual. See Section 2.3 - Inspecting the Brakes.

1.4.8 OPERATION IN COLD CONDITIONS

a IF THE AMBIENT TEMPERATURE drops below freezing, anti-frost oil should be used in the lubricator and low temperature lubricant in the motor.

CONTACT THE FACTORY OR A QUALIFIED PROFESSIONAL FOR HELP.


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Figure 3 – Guard Panel Placement

1.5 Adjusting the Drum Guard

Do not adjust or remove drum guard panels while winch is in use.

If drum guard is installed on winch, shift/re-locate the panels of the drum guard to leave sufficient clearance between the drum guard and wire rope. Do not allow wire rope to come into contact with drum guard panels during winch operation. Be sure to take into account the range of layers intended to be used for the duration of the installation of the winch and the intended fleet angles of the rope. Panels can be removed by loosening the fasteners at the ends of the panels. Once loose, remove panel and others as needed. Store un-needed panels or re-install them elsewhere on the drum guard frame. See Figure 3.


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1.6 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 cause the rider to be injured.

1.6.1 DETERMINE WHICH DIRECTION the drum must rotate to wind and unwind wire rope. See Figure 7.

1.6.2 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. Winch is designed for a specific size of wire rope. See Figure 1B for assistance in locating your serial tag which will indicate the wire rope size for your winch.

a COMPLY with API 2C and API 9A standard for wire rope.

b BREAKING STRENGTH of new wire rope should be at least 10 times greater than the safe working load of the winch.

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

d RECOMMENDED wire rope size for TA150KGMR1 winch is 7/16" diameter.

e THE WIRE ROPE GRADE shall be approved for manlifting use and must meet all applicable standards, codes, and regulations for manlifting. Synthetic rope has not been approved for use on this winch.

1.6.3 ANCHOR THE WIRE ROPE to the drum using the wedge socket in the drum. See Figure 5.

a PASS THE WIRE ROPE through the slack line detector arm as shown in Figure 7.

b PASS THE WIRE ROPE through the drum wedge socket, then around the wedge as shown in Figure 5.

c PULL ROPE TIGHT so wedge is set securely in the drum wedge socket. It is absolutely critical that the wedge is seated sufficiently into the cable anchor socket.

1.6.4 WIND FIVE 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.

Figure 4 – Wire Rope Exit Angle

Important!

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

• Winch is only designed for the size of wire rope as indicated on the serial tag of the winch. See Figure 1. Verify that the wire rope and other rigging equipment are rated for man-riding use as required by applicable standards, codes, and regulations.

• Wire rope for personnel lifting devices is to be in accordance with API 2C and API 9A.

• 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.

• Be sure to reeve the wire rope through the slack line detector before attaching the rope to the drum. See Figure 7.

• Follow recommendations for minimum distance requirements between drum flange outside diameter and top layer of wire rope. The minimum clear drum flange must be 2 times the wire rope diameter of the winch.

90o

underwoundasshown


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Figure 5 – Wire Rope Installation Procedure

Figure 6 – Correct/Incorrect Wire Rope Installation

passwireropethroughwedgesocket

setwedgeinsocket ensurewireropeissecuredandpulltaut

passropearoundwedge

minimumtaillengthtobenolessthan17/8inches(47.6mm)

Step1 Step2 Step3 Step4

taillengthmustbeatleast17/8inches

underwoundpayoutwireropewrappedtightly

wireropewrappedtoolooselyCORRECT INCORRECT


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Figure 7 – Wire Rope Routing for Slack Line Detector

roller spreader


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1.7 Setting Travel Limits

Adjust the travel limit switch setting to ensure operating within safe parameters. Setting of the upper limit should prevent a minimum vertical clearance of six (6) feet from the upper sheave block. The lower limit should be set to maintain a minimum of 5 wraps of the wire rope around the drum at all times.

Limit set points are dependent on speed of operation, use caution with setting limits. Typically, limits should be set for the highest speed to be encountered. A trained operator should be closely monitoring winch operation to ensure that an improperly adjusted switch does not allow the rider to move beyond the specified range. Travel limits are not intended as the primary means of stopping winch operation or for the positioning of the rider, they are to prevent over traveling.

1.7.1 SET LIMITS by performing the following actions:

a REMOVE the limit switch cover.

b LOOSEN the large locking screw in the center of the column. Individual limits can now be set. Refer to Figure 8.

c FOR UPPER LIMIT ADJUSTMENT turn the screw labeled "1" (red) on the top of the cam counter-clockwise to reduce vertical travel, or clockwise to increase vertical travel. Operate the winch and make adjustments until the operation is stopped by the switch at the desired location. When the upper travel limit has been reached, the indicator on the control will appear.

d FOR LOWER LIMIT ADJUSTMENT turn the screw labeled "3" (yellow) on the top of the cam clockwise to reduce vertical travel, or counter-clockwise to increase vertical travel. Operate the winch and make adjustments until the operation is stopped by the switch at the desired location. When the lower travel limit has been reached, the indicator on the control will appear.

e AFTER SETTING BOTH LIMITS, tighten the locking screw and re-check the limits. Re-install cover.

NOTE: THERE MUST A MINIMUM OF 4 REVOLUTIONS between upper and lower travel limit for the switches to operate correctly.

Figure 8 – Setting Limits


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1.8 Adjusting the Slack Line Detector1.8.1 ADJUST THE POSITION of the slack line detector valve every time the

wire rope take-off angle is changed, or when improper adjustment causes lunging or incapability of lifting.

a ELEVATE SLACK LINE DETECTOR ARM until it is at the angle where it will be running with a taut wire rope. This can be accomplished by having a helper physically lift the arm into position, or by applying a small load to the wire rope to lift the arm.

b LOOSEN THE SCREWS on the valve mount until the valve assembly will rotate on the pivot pin.

c ROTATE THE VALVE ASSEMBLY on the pivot pin until the valve roller is centered in the detent slot of the slack line arm. See Figure 9.

d MAINTAIN THE CORRECT DISTANCE between the roller wheel and the arm. The valve should fully extend with the roller in the detent, and the valve should fully retract if the roller is contacting the arm surface.

e TIGHTEN THE SCREWS on the valve mount per recommended torque sequence. See Figure 10.

f TEST THE SLACK LINE DETECTOR adjustment by performing a very short lift, and verify that it will descend smoothly. As the wire rope becomes slack after lowering the load, the valve should trigger the motor to halt and the slack line indicator should activate.

g REPEAT STEPS “a” through “g” if the slack line detector is not functioning as intended.

Important!

• Always be sure that the slack line detector valve is tightly attached to the winch, and verify that it functions properly before every lift.

• If slack line detector valve is not properly adjusted, the valve could prematurely halt the lowering operation of the winch.

• Beware of moving parts and pinch points any time a person is within the swing radius of the slack line detector arm.

• Always help the slack line detector arm lift into running position if it is in a downward resting position. Failure to help the lift the arm, could cause the arm to snap up quickly, or get pinched in the downward position.

Figure 9 – Slack Line Valve Roller Adjustment

Figure 10 – Valve Mount Tightening Procedure

AlternateTightening

Detent Slot

Keepaparallelgapwhiletightening


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2.1 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 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 the component manufacturer’s information.

2.1.3 USE A LOAD BRAKE on all winches used to lift loads. When engaged, they lock the drive train to the winch frame, thereby stopping drum rotation when the control is released or placed in the neutral position.

2.1.4 PERFORMANCE RATINGS of the equipment are affected by the amount of wire rope wound on the drum, air power supply, and the way the winch is used.

a DRUM CAPACITY depends on how tightly and evenly the wire rope is wound on the drum. Actual drum capacities are usually 25-30% less than values shown in performance tables, due to loose winding and overlapping. The outermost layer of rope in any load case must be a minimum of 2.5 rope diameters below the edge of the drum flange.

b LINE SPEED increases with each additional layer of wire rope wound onto the drum. Line speed will also vary with rider weight and air power supply.

2.1.5 DUTY RATINGS refer to the type of use the equipment is subject to. Consider the following when determining duty 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 start and stop functions increase wear and shorten the life span of the gear train and load brake components. Lengthy operations cause lubrication to become hot, which also decreases the life span of the gear train and brake. Increase maintenance of the equipment if used in frequent operations.

CONTACT FACTORY FOR MORE INFORMATION.

Important!

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

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

• When determining if the rider will exceed the load rating, consider the total force required to lift the person (plus harness and related devices), and not just the static weight of the person


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2.2 Breaking-In The Winch2.2.1 BEFORE THE WINCH IS PLACED INTO SERVICE or for winches that

have been in storage for a period of more than one month, the following start-up procedure is required.

a INSPECT THE WINCH and other equipment according to the Instructions for Periodic Inspection.

b WHEN FIRST RUNNING THE MOTOR operate the motor slowly in both directions for a few minutes.

c ENSURE BRAKE HOLDS prior to making complete lift by lifting a test load a short distance and releasing control.

2.2.2 PRIOR TO INITIAL USE, all new, altered or repaired winches shall be tested to ensure proper operation. See Section 3.3.4h.

a CHECK THAT THE OIL LEVEL in motor, reduction gear assembly are correct.

2.2.3 INSPECT THE WINCH following the break-in according to the Instructions for Periodic Inspection. See section 3.3 - Inspecting the Equipment.


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2.3 Inspecting the Brakes

Do not adjust brakes with the winch holding a rider or an out-of-balance rope load. Accidental release of the brakes could allow the rider to descend or the rope to unspool.

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

2.3.1 INSPECTING THE DYNAMIC CALIPER BRAKE (MOTOR-SIDE)

a REMOVE THE GUARD PANEL on the back side of the winch to reveal the brake caliper pads.

b DYNAMIC CALIPER BRAKE ROTOR should be inspected frequently for oil, grease, and mechanical wear. If oil and/or grease are present on the rotor, wipe the rotor clean with a towel or rag. If mechanical wear is found, locate the source of the problem and contact factory to have the rotor and worn components repaired or replaced.

c DYNAMIC CALIPER BRAKE PADS should be inspected frequently for oil, grease, foreign contaminants, and uneven wear. If any unwanted materials are found on the brake pads, wipe them off with a towel or rag. Replace both of the brake pads if one or both are worn unevenly, or if they have foreign materials embedded in the friction surface.

d MEASURE BRAKE PAD THICKNESS frequently to check for excessive wear. See Figure 14. If either of the two pads is measured to be less than 0.460 inches thick, check the caliper gap, as the pads my need to be replaced.

Figure 11 – Caliper Assembly

Figure 12 – Removal/Reinstallation of Brake Guard Panel


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e TO MEASURE THE CALIPER GAP, use the steps below. The gap is crucial to maintain brake effectiveness, because as the brake wears, the gap increases, and the holding torque decreases.

1. PRESSURIZE THE BRAKE to 60 PSI min to fully release the clamping force.

2. SHIFT THE BRAKE ASSEMBLY to the left until the right-hand pad touches the rotor.

3. MEASURE THE GAP between the left hand pad and the rotor using a feeler gauge. See Figure 13.

4. IF THE BRAKE GAP IS GREATER THAN .286 INCHES, replace the pads, because the gap is crucial for maintaining adequate brake holding torque. Pads may seem to have additional wear life at the time when replacement is required, but the brake holding capacity is reduced when the total gap exceeds the allowable amount. Therefore, ALWAYS replace the pads if the gap requirement is not met.

f REPLACE THE GUARD PANEL on the back side of the winch after checking both brakes.

2.3.2 INSPECTING THE STATIC CALIPER BRAKE (BEARING-SIDE)

a REMOVE THE GUARD PANEL on the back side of the winch (If not already removed) to reveal the brake caliper pads.

b STATIC CALIPER BRAKE ROTOR should be inspected frequently for oil, grease, and mechanical wear. If oil and/or grease are present on the rotor, wipe the rotor clean with a towel or rag. If mechanical wear is found, locate the source of the problem and contact factory to have the rotor and worn components repaired or replaced.

c STATIC CALIPER BRAKE PADS should be inspected frequently for oil, grease, foreign contaminants, and uneven wear. If any unwanted materials are found on the brake pads, wipe them off with a towel or rag. Replace all the brake pads if one or more are worn unevenly, or if they have foreign materials embedded in the friction surfaces.

d MEASURE BRAKE PAD THICKNESS frequently to check for excessive wear. See Figure 14. If either of the two visible pads is measured to be less than 0.210 inches thick, replace all the pads. There is no practical procedure for measuring the gap in the static brake.

e REPLACE THE GUARD PANEL on the back side of the winch after checking both brakes.

2.2.3 TEST BRAKES TO VERIFY HOLDING STRENGTH AFTER REPAIRS. Brakes shall be tested per requirements of applicable standards, codes, and regulations. Contact factory for information on unit-specific test requirements.

Figure 13 – Measuring Dynamic Brake Caliper Gap

Figure 14 – Measuring Static Brake Pad Thickness

CaliperClearance

Feeler Gauge

PadMeasurement


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2.4 Preparing for Operation

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.

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 and/or personal injury.

The winch must have two, independent, fail-safe brakes in functioning condition.

Do not use more than one winch to move a common rider.

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

Do not modify the equipment in any way. To do so could cause equipment failure, or personal injury.

Do not operate the winch with guards removed or improperly installed.

Do not operate the winch without the anti-tamper tag on the static and dynamic brake release nuts.

Do not operate the winch in windy conditions. If the rider begins to sway from the wind, return the person to safe ground and continue the lifting operation when the wind has subsided.

Do not use the installation lifting ears for regular lifting operations. The lifting ears are only for transporting the winch.

Check lubricant before use.

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

2.4.2 A PRE-OPERATION MEETING attended by the winch operator, ground crew, signalperson, persons to be lifted and the person in charge of the task to be performed shall be held to plan and review the procedure to be followed, including:

• Signals.

• Procedures for safe use and attachment of rider.

• Appropriate number of signal persons and ground crew.

• Designate responsibility.

a THIS MEETING SHALL BE HELD prior to the beginning of operations at each new work location and thereafter for any new employees assigned to the operation.

b DURING THIS MEETING it is recommended that a comprehensive plan to cover emergency procedures be worked out prior to exercising the winch capabilities.

Figure 15 – Signals

hoist

stop

moveslowly

lower


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2.4.3 INSPECT ALL COMPONENTS of the system.

a INSPECT THE WINCH and other equipment according to the Instructions for Frequent Inspection.

b OPERATORS shall be physically competent and have no health condition which might affect their ability to act, and they must have good hearing. Operators who are fatigued or have exceeded their normal shift period shall check all related regulations regarding approved work periods prior to operation. The operator must thoroughly understand proper methods of rigging and attaching riders and should have a proactive attitude regarding safety.

c THE RIDER’S PATH must be clear of other objects and free to move.

d REMOVE SNOW AND ICE buildup from the winch, wire rope, and sheaves before operating the winch. Ice buildup could jam the wire rope and cause an overload situation.

If brake dust accumulates on or near the calipers, clean using compressed air.

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

Before operating, the following conditions shall exist:

a WIRE ROPE shall be free of kinks.

b ADJACENT LINES shall not be twisted around the wire rope.

c THE PRIMARY POINT of wire rope attachment shall be such that the rider will not tilt and remain level.

d IF THERE HAS BEEN A SLACK wire rope condition, the hoisting mechanisms shall be inspected to ensure all wire ropes are properly seated on drums and in sheaves, before resuming winch operation.

2.4.5 BEFORE THE WINCH IS PLACED INTO SERVICE or for winches that have been in storage for a period of more than one month, the following start-up procedure is required.

a INSPECT THE WINCH and other equipment according the Instructions for Periodic Inspection.

b WHEN FIRST RUNNING THE MOTOR operate the motor slowly in both directions for a few minutes.


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2.5 Attaching the Rider

Do not wrap the wire rope around the lift point of the rider’s harness; this damages the wire rope and could cause the rope to fail. Use attachment components and methods approved for lifting personnel.

Always make sure the personnel lifting harness/device attachment point is properly seated in the saddle of the hook, if applicable.

2.5.1 CLEAR OBJECTS from the path of the rider so that he/she can be moved freely and visibly it at all times during the operation.

2.5.2 ATTACH THE RIDER using an approved personnel lifting device. Follow the recommendations of the device manufacturer. Always purchase a harness that meets applicable standards, codes, and regulations for manlifting.

Figure 16 – Controls

E-Stop

UpperLimit

HourMeter

LowerLimit

SlackLineControl Lever


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2.6 Operating the Winch

Keep at least 5 wraps of wire rope wound on the drum at all times, to serve as anchor wraps. With less than 5 wraps on the drum the wire rope could come loose, causing the rider to fall uncontrolled.

Keep all unnecessary personnel away from the winch. Keep out of the path of the rider, and out of the path of a broken wire rope that might snap back and cause injury.

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

Operators must maintain visual or audio contact with personnel and the rider at all times. Operators must remain at the controls at all times.

Monitor surrounding conditions to prevent the rider from contacting hazardous obstructions.

Use spotters or signal persons to assist with positioning the rider in confined or limited visibility areas.

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 rider. Avoid shock loads by starting and stopping the rider smoothly. Shock loads overload the equipment and may cause damage or injury.

Do not leave a suspended rider unattended.

2.6.1 MOVE THE RIDER slowly and smoothly, only a small distance at first. Make sure the rider is balanced and securely attached before continuing. Ensure that the brakes hold prior to making a complete lift by lifting the person a short distance (less than one foot) and releasing control.

2.6.2 USE THE CONTROL DEVICE to operate the winch. The control device is momentary, so the winch will stop when the operator releases the control. See Figure 16.

2.6.3 THE AUTOMATIC CALIPER BRAKES are spring applied, air released brakes. The brakes automatically disengage when the motor is operated. When the control valve is placed in the neutral position, the brakes automatically engage, preventing drum rotation.

2.6.4 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.

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 rider are not visible during the entire operation, get help from another person.

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

• When lifting a person, a tag line can be used to keep the rider from swinging or twisting. Be sure to follow recommendations of the harness manufacturer for using the tag line.

• The winch operator shall remain at the controls at all times.

• Lifting and lowering speeds shall be operator-controlled and be as slow as practical.


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2.6.5 OBSERVE THE REDUCER, MOTOR AND BRAKE during operation for signs of overheating. Frequent overheating may be a sign of damage.

a WATCH FOR SMOKE, the smell of burnt lubricant, and other signs of overheating. Use a thermocouple or other device to monitor reducer temperature.

b STOP THE OPERATION if the reducer, motor or brake overheats, and allow the winch to cool. Continued operation may cause damage.

2.6.6 IN CASE OF AIR SUPPLY FAILURE, see section 2.7 - Emergency Operation.

2.6.7 USE GLOVES designed to reduce the impact of vibration if controlling winch by manual lever on the control valve.

2.6.8 SHOULD THE WINCH stop operating unexpectedly, check the indicators on the control panel. The three indicators will show if either the limits are exceeded, or the line has gone slack. The indicators merely inform the operator what stopped the winch. They DO NOT indicate a failure. If none of the indicators have been triggered, something may have failed.

Figure 17 – Emergency Brake Release

Emergency BrakeRelease


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2.7 Emergency Operation

Emergency lowering operations must be performed by a minimum of two persons trained in the operation of the winch.

Always reset the brakes after an emergency lowering procedure, and make sure that they function properly before the next regular lifting operation.

Communication must be established between rider, spotters, and the winch operators. The operators should be able to visually monitor the rider through their full range of travel.

Do not exceed the limitations of the alternative power supply or the winch when running in emergency operation mode.

OPERATING WINCH IN THE EVENT OF POWER FAILURE

Each winch is equipped with two emergency brake release mechanisms (see Figure 17) and a pneumatic diverter valve (see Figure 18).

2.7.1 EMERGENCY LOWERING PROCEDURE with emergency brake release.

The winch is equipped with two automatic caliper brakes which are spring set and pressure released. In the event of a power failure, the brake will automatically set until air pressure is re-applied, or until the brakes are manually released with the release nuts on the brake bodies. See Figure 17.

a SLOWLY RELEASE THE STATIC BRAKE (BEARING-SIDE).

1. Remove the locking/guarding device on the static brake release nut.

2. Slowly tighten the release nut until the brake is disengaged. Make sure that the drum does not begin to rotate with the static brake released.

b WHEN READY TO LOWER THE RIDER, SLOWLY RELEASE THE DYNAMIC BRAKE (MOTOR-SIDE).

1. Remove the anti-tamper tag on the static brake release nut.

2. Verify that the rider’s path is clear for the emergency descent, and that all spotters are ready for the operation.

3. It requires approximately 90 kgs (200 lbs) to strip the rope from the drum. Depending on the rider and rigging installed, it may require a tag line in order to assist the rider descent.

4. Slowly tighten the release nut until the brake barely starts to drift. Keep the wrench engaged with the nut during the entire operation to maintain control of the descent speed.

5. Carefully lower the rider to safety by modulating the brake pressure with the release nut position. Do not allow overspeeding to occur, and do not abruptly halt the decents.

c AFTER THE RIDER HAS RETURNED TO SAFETY, RESET THE BRAKES TO NORMAL OPERATION SETTING.

1. Reset the release nuts to their original positions.

2. Install a new anti-tamper tag on the static and dynamic brake release nuts.

3. When power is restored, be sure that both brakes function and individually hold the rider as intended before the next regular operation.


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2.7.2 EMERGENCY OPERATION PROCEDURE with a power diverter valve and an alternative air supply.

a Verify that all pressure is exhausted from the winch system.

b Remove the pipe plug in the secondary input port on the diverter valve. See Figure 18.

c Connect the alternative air supply to the secondary input port, and slowly turn on the pressure.

d Slowly open the diverter valve in the respective direction to apply the alternative air pressure to the winch.

e Operate the winch normally to return the rider to safety.

f After primary power is restored, turn the diverter valve to the normal operation position.

NOTE: THE DIVERTER VALVE CAN BE USED AS A SHUT-OFF VALVE UNLESS A SECONDARY AIR SUPPLY IS INSTALLED.

SHUTOFF VALVE/EMERGENCY STOP OPERATION

Each winch is supplied with a shutoff valve (See Figure 18) and an emergency stop button (See Figure 16).

2.7.3 WHEN THE NEED ARISES TO STOP OR REMOVE THE PRIMARY AIR SUPPLY to the winch, turn the handle of the valve to the closed position to stop air flow to the winch and relieve air from the winch. Once the situation has been resolved, return the handle of the shutoff valve to the open position slowly, to gradually return air supply to the winch. See Figure 18.

2.8.4 WHEN THE NEED ARISES TO STOP THE OPERATION OF THE WINCH QUICKLY, engage the emergency stop button by pressing it down. Once the situation has been resolved, release emergency stop button by rotating it clockwise, and letting it snap up to the “run” position. See Figure 16.

ANY QUESTIONS ON OPERATION OR WINCH APPLICATION CALL THERN, INC.

Figure 18 – Pneumatic Diverter Valve

SecondarySupply

Primary Supply


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

3.1.1 CLEAN THE WINCH every six months or whenever it is dirty. Wipe down all equipment to remove dirt and grease on and around winch, noting that the muffler may have an oil film around it.

a WIPE ALL EQUIPMENT to remove dirt and grease.

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

c DO NOT POWER WASH the winch. There are seals and other non-sealed areas where water can intrude and damage the winch.

d REMOVE OIL ACCUMULATION from around the winch caused by lubricant in the exhaust.

3.1.2 REMOVE ALL UNNECESSARY OBJECTS from the area around the winch.

3.1.3 CLEAN dust from or around brake calipers with compressed air.

Important!

Increase the frequency of mainte-nance procedures if the winch is:

• Operated for long periods.

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


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3.2 Lubricating the Winch

Make sure the breather plugs are clean and open to vent heat and pressure. Poor ventilation will cause overheating and result in damage to oil seals and other equipment.

Fill the reducer and motor to the proper level without overfilling. Too much or too little lubricant will cause overheating and result in damage to equipment.

For shipment, the winch motor and reducer are filled with lubricant. The motor has a breather installed, while the reducer remains plugged.

3.2.1 LUBRICATE THE REDUCER AND MOTOR according to the manufacturer’s instructions.

a FILL MOTOR with lubricant before operating the winch. Fill the reducer and motor until lubricant reaches the level check plug. Do not mix different lubricants. See Table 1.

b CHECK LUBRICANT LEVEL OF MOTOR before every operation and every 10 hours during operation. Remove the level plug and make sure lubricant is even with the plug hole. If there are any signs of leakage or water, change the lubricant. See Figures 21 and 22.

c CHANGE REDUCER LUBRICANT every 5 years and motor lubricant every 2 years (or 5000 hours), or whenever it is dirty or contaminated. See Figures 21 and 22.

d THE REDUCER is not equipped with a breather plug.3.2.2 LUBRICATE THE WIRE ROPE by following the wire rope manufacturer’s

recommendations.3.2.3 IF WINCH IS DISASSEMBLED, clean all parts thoroughly and coat

bearings and seals with clean grease. Use sufficient grease to provide a good protective coat.

3.2.4 OIL DRAIN/FILL PROCESS (MOTOR)

a REMOVE fill and drain plugs.

b ALLOW the oil to drain completely.

c REMOVE the level plug.

d INSTALL the drain plug.

e FILL THE MOTOR with lubricant until it shows at the level plug hole.

f FINISH by the installing the fill and level plugs.

g CLEAN AREA around winch if any lubricant is on surface near winch to reduce risk to operators of winch or in area.

3.2.5 LUBRICATE THE FLANGE BEARING

a LUBRICATE FLANGE BEARINGS at least every 10 hours of operation. Insert NLGI #2 EP (Extreme Pressure) grease through the grease zerk. Refer to the bearing manufacturer’s information for specific instructions. See Figure 19.

3.2.6 LUBRICATE THE BRAKE MOUNTING RAILS

a LUBRICATE ALL FOUR BRAKE MOUNTING RAILS at least every 10 hours of operation. Insert NLGI #2 EP (Extreme Pressure) grease through the grease zerk. See Figure 20.

Important!

• Do not leave plug holes in the reducer or motor open. Open plug holes will allow dirt and moisture to contaminate the lubricant.

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

Figure 19 – Lubricating the Flange Bearing

Figure 20 – Lubricating the Brake Rails

GreaseZerk

GreaseZerks


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Table 1 – Motor and Reducer Lubrication Table

LOCATION OIL TYPE OR EQUIVALENT FILL REQUIREMENT (ml)MOTOR MOBIL SHC 630 75

REDUCER MOLYWHITE No. 00 GREASE 600

Figure 21 – Reducer Fill, Drain, and Check Locations

Figure 22b – Motor Fill and Drain Locations (bottomshown)

Figure 22a – Motor Fill and Drain Locations

(topshown)

3.3 Inspecting the Equipment

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.

Inspect the winch to detect signs of damage or poor operation before they become hazardous. See Table 2 - Inspection Checklist.

3.3.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the winch and other equipment.

3.3.2 CHECK COMPONENT MANUFACTURER’S INSTRUCTIONS for inspecting the motor, brake mechanisms, reducer, bearings, wire rope, and other equipment.

3.3.3 Instructions 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 wire rope is installed correctly and anchored securely to the drum.

• Check the reducer and motor for signs of lubricant leakage.

• Make sure the entire winch is properly lubricated.

• Make sure the motor 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 rider under all load conditions.

• Check air supply and connections for wear, corrosion, cuts, and other damage.

• Check the slack line detector roller and bearings for wear and other damage.

• Check the slack line detector valve for proper function, and ensure that it is tightly mounted.

• Check the pressure roller assembly to ensure free motion, and make sure that it is applying adequate force to aid the spooling of the wire rope. Verify that the rollers are not excessively worn, and that there are no components wearing on the wire rope.

Fill & Drain

Fillthroughbreatherplug

Check

Drain

Check


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b TEST WINCH PERFORMANCE by operating the winch with 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 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 under normal operating conditions, contact the factory.

Completely correct all problems before continuing. Use the Troubleshooting Chart to help determine the cause of certain problems. See Table 3.

3.3.4 Instructions for Periodic Inspection, See Table 2.

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 before contacting Thern, Inc. voids all warranties.

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

other damage. If the equipment was overloaded, or if you notice cracks and other signs of overloading and damage, promptly remove equipment from use and have it repaired or replaced. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE ROPE.

• Check all fasteners for stripped threads, wear, bends, and other damage.• Check all fasteners for proper torque levels. Some fasteners will require

disassembly of the winch in order to inspect and retorque.• Check the reducer and motor for signs of leakage.• Make sure the motor breather plug is clean, open and installed correctly.• Make sure all labels and plates are readable, firmly attached, free of

damage and clean. Replacements are available from the factory.

b DRAIN A SMALL AMOUNT OF LUBRICANT from the motor into a clean container.• Check the lubricant for dirt, metal particles, water, and other signs of

contamination. Completely drain the motor if lubricant is contaminated.• Make sure the winch is completely lubricated. See section 3.2 -

Lubricating the Winch.

c INSPECT THE TRAVEL LIMIT ASSEMBLY

Note: Pneumatic rotary travel limits need periodic inspection to verify accurate operations and ensure there are no damaged or loose components.• REMOVE guard covering rotary limit switch.• ENSURE drive gears are meshing correctly and are free of damage.

Visually inspect enclosure for damage such as cracks or chips.

Important!

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

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

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

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

Perform frequent inspections:

• Before each operation.

• Every 3 hours during operation.

• Whenever you notice signs of damage or poor operation.

Perform periodic inspections:

• Every 12 months except for as noted below.

• Whenever there is noticeable damage, loose fasteners, or poor operation during frequent inspection.

• Whenever you return the winch to service from storage.

• Whenever the winch has, or may have been, overloaded or shock loaded.


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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 fittings for corrosion, kinking, bending, crushing, birdcaging or other signs of damage.

• Check the number, distribution and type of visible broken wires. See paragraph 3.3.4 d and Figure 23.

• Check the wire rope for reduction of rope diameter from loss of core support, or wear of outside wires. See Figure 24.

• 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.

• REMOVE cover and check the O-ring to ensure it is not in need of replacement, and that all screws are tight. Tighten any screws that may have loosened during operation.

• CHECK tubing connections for leaks and verify that there are no sharp bends or kinks in the tube routing.

• REPLACE COVER and check limits for accuracy. Make adjustments to positions as necessary. See Section 1.7 - Setting Travel Limits.

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

• Always wear protective clothing when handling wire rope.• Check the entire length of wire rope for bent wires, crushed areas, broken

or cut wires, corrosion, and other damage. Carefully inspect areas that pass over sheaves or through roller guides.

• Make sure the load hook or other device is securely attached to the wire rope, and the wire rope where it is 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 25.

• Make sure hook latch opens without binding and closes when released.• Check the anchor holes in the drum and the surrounding area for signs of

wear or distortion.

FOR STANDARD RUNNING WIRE ROPE:• 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. See Figure 23

FOR ROTATION RESISTANT WIRE ROPE:• Wire rope assembly must be replaced if there are 2 or more wire breaks in

6 rope diameters or 4 or more wire breaks in 30 rope diameters. (Note: 6 rope diameters in 1 inch rope is a length of 6 inches.)

e MOVE THE DRUM with your hands. Check for excessive movement indicating worn or loose gears or bearings. Excessive movement is caused by overloading or overheating, and is a sign that your application may require a larger power winch. Disassemble the winch if necessary. Inspect bearings, seals, and shafts for wear, distortion, and other damage.

f 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 24.

g INSPECT THE FOUNDATION AND RIGGING.• Check mounting fasteners for stripped threads, wear, and other damage.• Check the foundation for cracks, corrosion, and other damage.

wire

strand

onelay

Figure 23 – Broken Wires

Wireropeassemblymustbere-placedifmorethan6wiresarebrokeninonelay,orifmorethan3wiresarebrokeninonestrandinonelay.


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h 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 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.

• Make sure the load moves smoothly without hesitation or strain.• Check the brake. Raise the load, then lower it and stop it a few feet off

the ground. If the load continues to coast or creep under normal operating conditions, contact the factory.

h DISCONNECT AIR SUPPLY and inspect equipment.• Check air supply and connections for wear, corrosion, cuts and other damage.

i CONNECT AIR SUPPLY.

Completely correct all problems before continuing. Use the troubleshooting chart to help determine the cause of certain problems. See Table 3.Figure 25 – Load Hook

Inspection

throatopening

twist

thickness

Thewireropeassemblymustbereplacedifthethroatopeningis15%widerthannominal,ifthethicknessis10%lessthannominal,orifthehookistwisted10°ormore.

Figure 24 – Rope Diameter

diameter

Thewireropeassemblymustbereplacedifthediametermeasureslessthantheminimumdiameteratanypoint.wire rope minimum size diameter

up to 7/16 in 27/64 in (.4218 in)

incorrectcorrect


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Table 2 – Inspection Checklist

damages problemsgeneral finishweathered,flaking,otherwisedamaged winchjerksorhesitatesduringoperation

partscracked,bent,rusted,worn,otherwisedamaged unusualnoises,othersignsofmalfunction

fasteners strippedthreads,bent,worn,otherwisedamaged loose,nottightenedtopropertorque

reducer gears,bearings,orshaftsloose,worn,otherwisedamaged notproperlylubricated

lubricantleakage lubricantcontaminated

wire rope bent,crushed,otherwisedamaged wireropelooselyorunevenlywound

brokenwires,seeFigure23

replaceifmorethan6wiresinonelay, numberperstrand=

or3wiresinonestrandinonelay,arebroken numberperlay=

diameterreduced,seeFigure24

replaceifdiameterisexcessivelyworn diameter=

end connections corroded,rusted,worn,otherwisedamaged notsecurelyattached

hook or other device twisted,bent,worn,otherwisedamaged,seeFigure25 hooklatchfailstoclosewhenreleased

replaceiftwistis10degreesormore twist=

replaceifthroatwidthis15%largerthannominal throatwidth=

replaceifthicknessis10%lessthannominal thickness=

drum anchorworn,distorted,otherwisedamaged excessivemovementorbacklash

motor motorcorroded,wornout,otherwisedamaged motorissluggish,oroperatespoorly

brake brakeworn,corroded,otherwisedamaged brakedoesnotoperateproperly

control device controlcomponentscorroded,wornout,otherwisedamaged failstocontrolwinchproperly

air supply airlinescracked,cut,corroded,otherwisedamaged wiresunprotected,obstructingtraffic

connectionsloose,corroded,otherwisedamaged pressureatmotor=

labels and plates dirty,illegible,otherwisedamaged looselyattachedormissing

comments

authorized signature date

checkedboxesindicatedamageorprobleminneedofrepair


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Table 3 – Troubleshooting ChartContact the factory for assembly/disassembly instructions. Disassembly before contacting Thern, Inc. voids all warranties.problem cause correctionmotor won’t run •noairsupplytowinch . . . . . . . . . . . . . . . . . . . .checkairsupplylineconnectionsandhoses

•loadtoheavy . . . . . . . . . . . . . . . . . . . . . . . . . . .lightenload

•motordamaged . . . . . . . . . . . . . . . . . . . . . . . . .repairorreplaceasnecessary

•slacklinevalveimproperlyadjusted . . . . . . . . .inspectandadjustasnecessary

winch runs slow •improperhoseorfittingsize checkfittings,connectionsforsizeandlength. Replacepartsthatmayrestrictairflow.Inspect airlinefilter.Makesurebothexhaustportsare notrestricted.

• loadtooheavy . . . . . . . . . . . . . . . . . . . . . . . . .lightenload

•motormaybedamaged . . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

•bearingseizedup . . . . . . . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

•exhaustportsrestricted . . . . . . . . . . . . . . . . . . .removecapandinstallmufflers

motor runs, drum doesn’t turn •looseorbrokengearkeysorsplines . . . . . . . .inspectandreplaceasnecessary

•loose,strippedorbrokengears . . . . . . . . . . . .inspectandreplaceasnecessary

motor tries to turn but can’t •unitoverheated . . . . . . . . . . . . . . . . . . . . . . . . .allowtocool

•loadtooheavy . . . . . . . . . . . . . . . . . . . . . . . . . .lightenload

•motormaybedamaged . . . . . . . . . . . . . . . . . .inspectandrepairasnecessary

•insufficientairsupply . . . . . . . . . . . . . . . . . . . . .verifyairsupplypressureandvolumeatwinch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inletmeettherequirementslisted

•brakemaynotbereleased . . . . . . . . . . . . . . . .inspectandrepairasnecessary

•gearsorbearingsbrokenorlocked . . . . . . . . .inspectandreplaceasnecessary

air lines freeze •waterinairsupply installordrainairsystemmoisturetraps, moisturecollectingairreceiversand compressoraftercoolers.Aftercorrective actionshavebeentaken,disconnectlinesat winchinletandpurgewithclean,dryairor nitrogenpriortoattachingloadandoperating winch.

brake does not operate properly •brakereleaseleverinreleaseposition . . . . . . .movetolockposition

•lowairsupplypressureondiscbrake ensureairpressureattheinletto discbrakeis50psi

•brakeadjustedincorrectly . . . . . . . . . . . . . . . . .inspectandadjustbrake

•brakewornordamaged . . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

•brakecomponentsseizedupordamaged . . . .inspectandrepairasnecessary


lubricant leakage •wornbearings . . . . . . . . . . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

•damagedoilsealsorgaskets . . . . . . . . . . . . . .inspectandreplaceasnecessary

•crackedordamagedreducerormotor . . . . . . .inspectandrepairasnecessary

excessive end play on drive shaft •looseordamagedkeys,keywaysorsplines . . .inspectandreplaceasnecessary

•excessivelyworngears . . . . . . . . . . . . . . . . . . .inspectandrepairasnecessary

excessively worn gears or bearings •loadtooheavy . . . . . . . . . . . . . . . . . . . . . . . . . .lightenload

•poorlubricationofreducerorbearings . . . . . . .inspectandlubricateasnecessary


A12876A-0115

Table 3 – Troubleshooting Chart (continued)Contact the factory for assembly/disassembly instructions. Disassembly before contacting Thern, Inc. voids all warranties.problem cause correctionoverheating •operatedtoolongwithoutrest . . . . . . . . . . . . . .allowtocool


•poorlubrication . . . . . . . . . . . . . . . . . . . . . . . . .inspectandlubricateasnecessary

•breatherplugcloggedordamaged . . . . . . . . . .cleanorreplaceventplugasneeded

•bearingseizedup . . . . . . . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

•lowlubricantlevelinmotororreducer . . . . . . .checklubricantlevelsandaddordrainasnecessary

•contaminatedlubrication . . . . . . . . . . . . . . . . . .drain,cleanandlubricateasnecessary

unusual noises

highpitchedsqueak •poorlubrication . . . . . . . . . . . . . . . . . . . . . . . . .inspectandlubricateasnecessary

grindingnoise •contaminatedlubrication . . . . . . . . . . . . . . . . . .drain,cleanandlubricatethewinch

•brokengearsorbearings . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

knockingmotor •loadtooheavy . . . . . . . . . . . . . . . . . . . . . . . . . .lightenload

•motoroverheated . . . . . . . . . . . . . . . . . . . . . . .allowtocool

•damagedmotor . . . . . . . . . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

rattlingnoise •loosefastenersorsetscrews . . . . . . . . . . . . . .tightenallfastenersandscrews

heavythumpduringoperation •contaminantsinlubricant . . . . . . . . . . . . . . . . .drain,cleanandlubricatethewinch

•loosesetscrewsorkeysingearsorshafts . . .inspectandrepairasnecessary

•bearingsdefective . . . . . . . . . . . . . . . . . . . . . . .inspectandreplaceasnecessary

comments

authorized signature date


A12876A-0115

3.4 Repairing the Winch3.4.1 GET FACTORY AUTHORIZATION for all repairs. Unauthorized repairs

will void the warranty, and may lead to damage or failure of the winch.

3.4.2 REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repair parts.

3.4.3 REFINISH AREAS where the paint is worn or flaking. A good finish helps to protect against corrosion and weather damage.

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

b CLEAN THE AREA thoroughly.

c REPAINT with a high quality primer and finishing coat.

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

• model number (See Figure 1)

• serial number (or code number) (See Figure 1)

• part number

• date purchased, and from whom

• description of what happened, or what is wrong

• your name and return address

Important!

• It is the owner's 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.

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

• Turn off air system and depressurize air lines before performing any maintenance.

Figure 26a – Transporting the Winch


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4.1 Transporting the Winch4.1.1 REMOVE THE BREATHER PLUG and install a sealed plug to prevent the

loss of lubrication during shipment.

4.1.2 LIFT AND MOVE THE WINCH using the designated lifting eyes.

a LIMIT THE ANGLE of each line between 45 degrees and 90 degrees from horizontal. See Figure 26b.

b DO NOT USE the guards or any other components for lifting the winch, or tying down.

4.1.3 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 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. See Figure 26a.

d PACK LOOSE PARTS in small boxes or ship separately.

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

4.2 Storing the Winch4.2.1 FILL THE REDUCER AND MOTOR with lubricant, and make sure the

breather plug is clean and properly installed. Add a rust preventative for long term storage. Follow the reducer and motor manufacturers' instructions.

4.2.2 SECURE THE WINCH using mounting holes in winch to bolt down, or similar process, for storage.

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

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

4.2.5 ROTATE THE DRUM PERIODICALLY to keep bearing and gears surfaces from becoming lacquered. Release the brakes to rotate the drum. Follow the procedure for manually releasing the brakes in Section 2.7 - Emergency Operation.

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

4.2.7 DRAIN THE MOTOR and fill with proper lubricant prior to operation. See Section 3.2 - Lubricating the Winch.

Important!

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

Figure 26b – Line Angles

45-90o 45-90o


A12876A-0115

RecommendedFleet Angle Distance

CenterLine Load

LeadSleeve

Fleet Angle

FLEET ANGLEDrum

DiameterFlange

DiameterDrumWidth

FleetAngle Dist.*

Series (in) (mm) (in) (mm) (in) (mm) (ft) (m)

TA150KGMR1 10.75 273 18.00 457 12.00 305 20 3.7

* Lead sheave must be high enought to allow 16.5 ft (5 m) of active travel. See Section 1.7 for additional information.

TA150KGMR1 LOAD RATING

Load Rating 1st Layer 330 lb 150 kg

Load Rating Mid-Drum 330 lb 150 kg

Load Rating Full Drum 330 lb 150 kg

Line Speed 1st Layer* 87 fpm 26.5 m/min

Line Speed Mid Drum* 93 fpm 28.3 m/min

Line Speed Full Drum* 91 fpm 27.7 m/min

Pressure 75 psi 5.2 bar

Flow 45 scfm 1.3 m3/min

Pipe Inlet Size .5 in 12.7 mm

Hose Size .5 in 12.7 mm

Minimum Design Temp - 4o F - 20o C

Max Rope Layers 6 6

* Line speeds are estimated values based on testing and may vary based on conditions of air supply. Speeds shown are at max line pull.

TA150KGMR1 DRUM CAPACITIESDrum Width 12 in (305 mm)

RopeDiameter

Breaking Strength*

1st Layer

Mid Drum

Full Drum

(in) (mm) (lb) (kg) (ft) (m) (ft) (m) (ft) (m)

.44 11 20,400 9253 65 19 210 64 460 140

* Values based on 6x37 IWRC EIPS wire rope.


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MAINTENANCE LOG:

DATE:HOUR METER READING:MAINTENANCE PERFORMED







A12876A-0115

NOTES:

Thern, Incorporated5712 Industrial Park RoadWinona, MN 55987

PHN 507-454-2996FAX 507-454-5282

EMAIL: [email protected]

owner’s manualowners manual for ta150kgmr1 pneumatic winches for personnel lifting page 7...

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