Owner s Manual For 3WG4 Series Worm Gear Power Winches ORIGINAL TEXT

Transcription

1 Red this Owner s Mnul thoroughly efore operting the equipment. Keep it with the equipment t ll times. Replcements re ville from Thern, Inc., PO Box 347, Winon, MN 55987, IMPORTANT: Plese record product informtion on pge 2. This informtion is required when clling the fctory for service. ORIGINAL TEXT Owner s Mnul For 3WG4 Series Worm Ger Power Winches

2 pge 2 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Two-Yer Limited Wrrnty Plese record the following: Dte Purchsed: Model No.: Seril No.: This informtion is required when clling the fctory for service. Thern, Inc. wrrnts its products ginst defects in mteril or workmnship for two yers from the dte of purchse y the originl using uyer, or if this dte cnnot e estlished, the dte the product ws sold y Thern, Inc. to the deler. To mke clim under this wrrnty, contct the fctory for n RGA numer. The product must e returned, prepid, directly to Thern, Inc., 5712 Industril Prk Rod, Winon, Minnesot The following informtion must ccompny the product: the RGA numer, the dte of purchse, the description of the climed defect, nd complete explntion of the circumstnces involved. If the product is found to e defective, it will e repired or replced free of chrge, nd Thern, Inc. will reimurse the shipping cost within the contiguous USA. This wrrnty does not cover ny dmge due to ccident, misuse, use, or negligence. Any ltertion, repir or modifiction of the product outside the Thern, Inc. fctory shll void this wrrnty. This wrrnty does not cover ny costs for removl of our product, downtime, or ny other incidentl or consequentil costs or dmges resulting from the climed defects. This wrrnty does not cover rke discs, s these re wer components nd their life is suject to use conditions which vry etween pplictions. 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 sttes do not llow the exclusion or limittion of incidentl or consequentil dmges, or llow limittions on how long n implied wrrnty lsts, so the ove limittion or exclusion my not pply to you. This wrrnty gives you specific legl rights, nd you my lso hve other rights which vry from stte to stte. Note: Thern, Inc. reserves the right to chnge the design or discontinue the production of ny product without prior notice. Aout This Mnul The Occuptionl Sfety nd Helth Act of 1970 sttes tht it is the employer s responsiility to provide workplce free of hzrd. To this end, ll equipment should e instlled, operted, nd mintined in complince with pplicle trde, industril, federl, stte, nd locl regultions. It is the equipment owner's responsiility to otin copies of these regultions nd to determine the suitility of the equipment to its intended use. This Owner s Mnul, nd wrning lels ttched to the equipment, re to serve s guidelines for hzrd-free instlltion, opertion, nd mintennce. They should not e understood to prepre you for every possile sitution. The informtion contined in this mnul is pplicle only to the Thern 3WG4 Series Worm Ger Power Winches. Do not use this mnul s source of informtion for ny other equipment. The following symols re used for emphsis throughout this mnul: Filure to follow WARNING! instructions my result in equipment dmge, property dmge, nd/or serious personl injury. Filure to follow CAUTION! instructions my result in equipment dmge, property dmge, nd/or minor personl injury. Importnt! Filure to follow importnt! instructions my result in poor performnce of the equipment.

3 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge 3 Suggestions for Sfe Opertion DO the following: Red nd comply with the guidelines set forth in this Owner s Mnul. Keep this mnul, nd ll lels ttched to the winch, redle nd with the equipment t ll times. Contct Thern, Inc. for replcements. Check luriction efore use. Instll the wire rope securely to the winch drum. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 4 wrps on the drum the wire rope could come loose, cusing the lod to escpe. Keep hnds wy from the drum, wire rope, nd other moving prts of the equipment. Keep ll unnecessry personnel wy from winch while in opertion. Keep out of the pth of the lod nd out of the pth of roken wire rope tht might snp ck nd cuse injury. Disconnect power efore servicing the equipment. DO NOT do the following: Do not lift people, or things over people. Do not wlk or work under lod or in the line of force of ny lod. Do not use clutch equipped models to lift lods, or drg lods on n incline. Accidentl relese of the clutch could result in loss of the lod. Do not exceed the lod rting of the winch or ny other component in the system. To do so could result in filure of the equipment. Do not use more thn one winch to move lod unless ech winch ws designed for use in multiple winch system. Do not use dmged or mlfunctioning equipment. To do so could result in filure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equipment filure. Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use pproved rigging connectors to secure the wire rope to the lod. Do not lift lods or pull lods on n incline unless the winch is equipped with lod rke. Do not divert your ttention from the opertion. Sty lert to the possiility of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stopping the lod smoothly. Shock lods overlod the equipment nd my cuse dmge. Do not leve suspended lod unttended unless specific precutions hve een tken to secure the lod nd keep people wy from the winch nd out from under the lod. Do not djust the rke with the lod suspended if winch is equipped with lod rke. Do not exceed the duty cycle rting of the winch. To do so could result in equipment dmge or filure. See Tle 1.

4 pge 4 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches 1.1 Instlling the Winch Importnt! Inspect the winch immeditely following instlltion ccording to the Instructions for Periodic Inspection. This will give you record of the condition of the winch with which to compre future inspections. A qulified professionl should inspect or design the foundtion to insure tht it will provide dequte support. Locte the winch so it will e visile during the entire opertion. Do not weld the winch frme to the foundtion or support structure. Welding the frme my void wrrnty, contct Thern, Inc. Use fsteners s instructed. Do not instll the winch in n re defined s hzrdous y the Ntionl Electric Code, unless instlltion in such n re hs een thoroughly pproved. Do not instll the winch ner corrosive chemicls, flmmle mterils, explosives, or other elements tht my dmge the winch or injure the opertor. Adequtely protect the winch nd the opertor from such elements. Position the winch so the opertor cn stnd cler of the lod, nd out of the pth of roken wire rope tht could snp ck nd cuse injury. Attch the winch to rigid nd level foundtion tht will support the winch nd its lod under ll lod conditions, including shock loding CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on instlling the equipment LOCATE THE WINCH in n re cler of trffic nd ostcles. Mke sure the winch is ccessile for mintennce nd opertion LOCATE THE WINCH in n re with dequte tempertures. The winch is rted for opertion in mient tempertures rnging from 0 to 100 F MAINTAIN A FLEET ANGLE etween 1/2 nd 1-1/2 degrees. The proper fleet ngle minimizes wire rope dmge y helping the wire rope wind uniformly onto the drum. See Figure POSITION THE WINCH to llow ccess for proper luriction FASTEN THE WINCH securely to the foundtion. FOR STANDARD PRODUCTS referred to in this mnul, use 1/2 - inch corse thred fsteners, grde 5 or etter, torque dry to 75 ft l without luriction. Mke sure the winch is secured to solid foundtion le to support the winch nd the lod under ll conditions with design fctors sed on ccepted engineering prctices. NON-STANDARD PRODUCTS tht vry from the originl design my hve different fstening requirements. Contct structurl engineer or Thern, Inc. for this informtion. TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED PROFESSIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFICATIONS FOR THE MOUNTING OF THERN PRODUCTS.

5 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Instlling the Brether Plug Importnt! Sve the extr oil for use when the winch is removed for storge or trnsport. Instll the rether (s) to vent het nd pressure from the gerox nd rke. Filure to do so could result in pressure uildup which cn cuse the gerox or rke to lek or dmge the equipment. For shipment, the gerox nd rke re seled with n oil (s), nd the rether (s) is(re) ttched to the gerox or shipped in seprte envelope REMOVE THE OIL PLUG nd instll the rether (s) in the proper loction. Mke sure the rether (s) is(re) ove the level of the oil. See Figure CHECK THE OIL LEVEL in the gerox or rke to mke sure no oil ws lost during shipment. See section Luricting the Winch. Figure 1 Brether Plug Instlltion 3WG4-B Series 2 rether s 1 rether 1 rether 1 rether ) floor mount ) wll mount c) wll mount d) ceiling mount (motor down) (motor up) 3WG4-M Series 1 rether 1 rether 1 rether 1 rether ) floor mount ) wll mount c) wll mount d) ceiling mount (motor down) (motor up)

6 pge 6 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Importnt! Use sheve or roller guide to direct the wire rope to the drum whenever possile. Instll sheves, trcks nd other equipment so they will remin fixed under ll lod conditions. Follow the recommendtions of the equipment mnufcturer. Use sheves of proper dimeter to minimize wer on the wire rope. Follow the recommendtions of the sheve mnufcturer. Figure 2 Mintining the Fleet Angle When wire rope trvels over sheve or through roller guide mintin fleet ngle y locting the sheve or guide n pproprite distnce from the drum, shown s distnce A. fixed sheve or roller guide distnce A smooth drum 1/2 to 1-1/2 degrees center line When wire rope trvels directly to the lod mintin fleet ngle y controlling sideto-side movement of the lod with trcks or guide rils. Allowing the lod to move too fr to one side cuses stress on the drum flnge which my cuse dmge. lod smooth drum 1/2 to 1-1/2 degrees center line trcks or guide rils

7 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Connecting Power Importnt! Use components rted for the power supply you will e using. Alwys disconnect power when the winch is not in use. Instll proper rnch circuits, disconnect devices, protection, nd grounding s required y rticle 430 of the Ntionl Electric Code. All electricl work must e performed y licensed electricin. Filure to do so could result in electric shock or poor winch opertion. All control devices must e momentry contct type. Instll ll control devices so the winch motor will stop when the opertor releses the device. Locte control devices so the opertor will e le to view the lod through the entire opertion. Locte control devices so the opertor will e cler of the lod, the wire rope, nd the pth of roken wire rope tht could snp ck nd cuse injury. It is the responsiility of the owner to provide equipment for controlling the winch. Controls re ville from Thern. The following guidelines re supplied s reference for the instller CONSULT APPLICABLE CODES AND REGULATIONS for specific instructions regrding power supply instlltion nd hookup FOR ELECTRIC WINCHES: instll fuse or circuit reker, nd disconnect device in the power supply circuit, s required y the Ntionl Electric Code. The disconnect device should e switch you cn lock in the OFF position to prevent unuthorized use of the winch CONNECT THE POWER CORD to grounded outlet FOR PNEUMATIC WINCHES: instll filter, regultor, lurictor nd drier in the ir supply line. Filure to operte with clen, dry, luricted ir will void wrrnty INSTALL A CONTROL DEVICE in the power supply line nd connect power to the motor. Mke sure the control device is momentry contct type so the motor will stop when the opertor releses the control CONNECT OTHER EQUIPMENT to the power supply s necessry CHECK POWER SUPPLY t the motor nd mke sure it grees with the motor rting. Do not operte the winch until proper power is supplied to the motor TEST CONNECTIONS y operting the winch. The rottion of the drum must gree with the lels on the control device, nd the motor must stop when the control is relesed. CONTACT THE FACTORY OR A QUALIFIED PROFESSIONAL FOR HELP.

8 pge 8 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches 1.4 Instlling the Wire Rope Importnt! Use wire rope nd other rigging equipment rted for the size of the lrgest lod you will e moving. Do not drg the wire rope through dirt or deris tht could cuse dmge, or poor opertion. Alwys wer protective clothing when hndling wire rope. Figure 3 Instlling the Wire Rope instll the wire rope so it is underwound on the drum s shown tighten set screw Instll the wire rope securely to the winch drum. A poorly secured wire rope could come loose from its nchor nd llow the lod to escpe. Instll the wire rope so it is wound correctly s shown or the winch nd rke will not work properly, nd could llow the lod to escpe. See Figure 3. Instll to prevent wire rope wrpping in keyhole slot. Wire rope wrpping in slot could dmge the wire rope nd llow the lod to escpe. See Figure 3. Instll wire rope nchor fitting to hold the lrgest lod on the winch. Undersized or improperly instlled nchor fitting could come loose from the wire rope or keyhole slot nd llow the lod to escpe. See Figure PURCHASE THE PROPER WIRE ROPE for your ppliction. Contct reputle wire rope supplier for help. BREAKING STRENGTH of new wire rope should e t lest 3 times greter thn the lrgest lod plced on the winch. If lods re lifted or pulled on n incline, the reking strength must e t lest 5 times greter thn the lrgest lod. These re minimum vlues nd will vry with the type of lod nd how you re moving it. c WIRE ROPE LAY must gree with the winding direction of the drum to help insure proper winding. WE RECOMMEND 7 x 19 glvnized ircrft cle for dimeters up to 5/16 inch, nd 6 x 37 IWRC improved plow steel for 3/8 inch nd up ANCHOR THE WIRE ROPE to the drum using either the set screw or quick disconnect nchor. SET SCREW ANCHOR. See Figure 3. set screw nchor instll keyhole slot PASS THE WIRE ROPE under the drum from the front nd position it in the recessed nchor hole in the drum. Mke sure t lest 1/2 inch of wire rope extends pst the set screw, nd 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 until it flttens the wire rope ginst the nchor hole. Use enough force to drive the point of the set screw securely into the wire rope. QUICK DISCONNECT ANCHOR. See Figure 3. REMOVE PLUG from quick disconnect nchor. See Figure 3. PASS THE WIRE ROPE under the drum from the front nd position the nchor fitting in the keyhole slot in the drum. RE-INSTALL PLUG nd tighten until is flush with the drum spool surfce nd will not come loose during opertion. quick disconnect wire rope nchor fitting Wire rope ssemlies with nchor fittings cn e purchsed from Thern, Inc. PULL THE WIRE ROPE firmly to nchor the fitting in the keyhole slot. The nchor fitting needs to e lrger thn the keyhole slot nd e le to hold the lod WIND FOUR FULL WRAPS of wire rope onto the drum y operting the winch while holding the wire rope tught. These wrps serve s nchor wrps nd must remin on the drum t ll times. See Figure 3.

9 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Generl Theory of Opertion Importnt! Limit nonuniform winding y keeping tension on the wire rope nd y mintining the proper fleet ngle. To help insure rted performnce, mke sure power supply t the motor is equl to the motor s power rting. It is your responsiility to detect nd ccount for different fctors ffecting the condition nd performnce of the equipment THE PULL REQUIRED to move the lod must not exceed the lod rting of the winch. Consider the totl force required to move the lod, not the weight of the lod THE AMOUNT OF TIME required to move the lod must not exceed the duty cycle rting of the winch. To do so could result in equipment dmge or filure. See Tle THIS EQUIPMENT CAN develop forces tht will exceed the lod rting. It is the responsiility of the equipment user to limit the size of the lod. Inspect the equipment regulrly for dmge ccording to the instructions contined in this mnul nd in component mnufcturer s informtion USE A LOAD BRAKE on ll winches used to lift lods or pull lods on n incline. Although new winch my pper to hold the lod in plce, this chrcteristic will diminish with use. Do not depend on gering to hold the lod in plce PERFORMANCE RATINGS of the equipment re ffected y the mount of wire rope wound on the drum, the wy in which it is wound, nd the wy the winch is used. Tle 1 Duty Rting With Mechnicl Brke Without Mechnicl Brke 15 minutes 60 minutes Do not continue to operte winch if gerox or rke show signs of overheting. Allow winch or rke to cool to mient temperture efore continuing opertion. Non-stndrd configurtions my hve lower motor duty rtings. See motor nmeplte for motor duty rtings. c DRUM CAPACITY depends on how tightly nd evenly the wire rope is wound on the drum. Actul drum cpcities re usully 25-30% less thn vlues shown in performnce Tles, due to loose winding nd over lpping. LINE SPEED increses with ech dditionl lyer of wire rope wound onto the drum. Line speed will lso vry with lod weight nd power supply for pneumtic models. Lod weight does not ffect line speed for electric models. LOAD RATING represents the mximum pull tht cn e plced on new equipment. Lod rtings re ssigned vlues for specific mounts of lod trvel or wire rope ccumultion. The lod rting decreses s lyers of wire rope ccumulte on the drum DUTY RATINGS refer to the type of use the equipment is suject to. For duty rtings, see Tle 1. c d ENVIRONMENT: hrsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from hrsh environments when possile. MAINTENANCE: poor mintennce, mening poor clening, luriction, or inspection, leds to poor opertion nd possile dmge of the equipment. Minimize poor mintennce y crefully following the instructions contined in this mnul. LOADING: severe loding includes shock loding nd moving lods tht exceed the lod rting of the equipment. Avoid shock lods, nd do not exceed the lod rting of the equipment. FREQUENCY OF OPERATION: frequent or lengthy opertions increse wer nd shorten the life spn of gers, erings, nd other components. Increse mintennce of the equipment if used in frequent opertions. Length of opertion should not exceed the duty cycle rting of the winch. To do so could result in equipment dmge or filure. See Tle 1. CONTACT THE FACTORY FOR MORE INFORMATION.

10 pge 10 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches 2.2 Breking-In the Winch BREAK-IN OCCURS during the first few hours of opertion. During rekin, mting surfces ecome polished, nd clernces increse. This is desired for efficient opertion of erings nd gers INSPECT THE WINCH following rek-in ccording to the Instructions for Periodic Inspection. See section Inspecting the Equipment. 2.3 Prepring for Opertion Importnt! When determining whether the lod will exceed the lod rting, consider the totl force required to move the lod CONSIDER THE OPERATION. Do not egin until you re sure you cn perform the entire opertion without hzrd INSPECT ALL COMPONENTS of the system. INSPECT THE WINCH nd other equipment ccording to the Instructions for Frequent Inspection. c OPERATORS must e in good helth, lert, thoroughly trined in operting the equipment, nd properly clothed (hrd ht, sfety shoes nd sfety glsses, no loose clothing). THE LOAD must e cler of other ojects nd free to move. Mke sure the lod will not tip, spin, roll wy, or in ny wy move uncontrollly KNOW YOUR LOAD nd mke sure you do not exceed the lod rting of the winch or ny other equipment in the system.

11 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Attching the Lod Figure 4 Attching Lod ltch closed tight ginst hook Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use sling or other pproved rigging device CLEAR OBJECTS from the pth of the lod so you cn move it freely nd oserve it t ll times during the opertion ATTACH THE LOAD using nylon sling, or other pproved rigging device. Follow the recommendtions of the sling mnufcturer. sling seted in sddle of hook SEAT THE SLING in the sddle of the hook with the hook ltch completely closed. See Figure 4. CENTER THE LOAD on the hook so it will remin lnced nd not tip or rotte to one side. 2.5 Moving the Lod Importnt! Oey stop signl from nyone. Mintin tension on the wire rope to keep it tightly nd evenly wound on the drum. If the winch nd lod re not visile during the entire opertion, get help from nother person. Appoint supervisor if more thn one person is involved in the opertion. This will reduce confusion nd increse sfety. When lifting lod, use tg line to keep the lod from swinging or twisting, while keeping yourself wy from the lod MOVE THE LOAD slowly nd smoothly, only smll distnce t first. Mke sure the lod is lnced nd securely ttched efore continuing USE THE CONTROL DEVICE to operte the winch. The control device should e momentry contct type, so the winch will stop when the opertor releses the control DO NOT EXCEED DUTY CYCLE RATING of the winch. See Tle OBSERVE THE WIRE ROPE s it winds onto the drum. If it ecomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope efore continuing. Continued opertion with overlpped or uneven wire rope cn dmge the wire rope nd shorten its life ALLOW THE WINCH TO COOL DOWN to mient temperture in rest periods etween opertions OBSERVE THE GEARBOX AND BRAKE during opertion for signs of overheting. Frequent overheting my e sign of dmge, or my indicte the need for lrger winch. WATCH FOR SMOKE, the smell of urnt oil, nd other signs of overheting. Use thermocouple or other device to monitor gerox temperture. The temperture of the oil should not exceed 180 F. STOP THE OPERATION if the gerox or rke overhets, nd llow the winch to cool until it reches mient temperture. Continued opertion my cuse dmge.

12 pge 12 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches 2.6 Emergency Opertion (for models equipped with this feture) Do not djust the rke with the lod suspended. Accidentl relese of the rke could llow the lod to escpe. Do not leve suspended lod unttended unless specific precutions hve een tken to secure the lod nd keep unnecessry personnel wy from the winch nd from under the lod IN CASE OF POWER FAILURE, turn the control device to OFF nd DISCONNECT electric power. Leve electric power DISCONNECTED MAKE SURE SAFETY PRECAUTIONS hve een tken to secure the lod nd keep unnecessry personnel wy from the winch nd from under the lod while operting the emergency hnd crnk IF EQUIPPED WITH A BRAKE MOTOR you must disengge the rke on the motor efore using the emergency hnd crnk. Operting the emergency hnd crnk with the rke on the motor engged could result in equipment dmge or filure. c d It is recommended for two people to operte the winch when using the emergency hnd crnk. If the winch is equipped with rke motor, ssign one person to operte the hnd crnk while the other is ssigned to operte the rke. Hve control of the hnd crnk efore disengging the rke on the motor. Accidentl relese of the rke could llow the lod to escpe. If the winch is not equipped with rke motor, ssign one person to operte the hnd crnk while the other is ssigned to oserve nd control the lod. Alwys follow the rke mnufcturers operting instructions for engging or disengging the rke DO NOT USE AN IMPACT WRENCH to operte the emergency hnd crnk option of the winch. To do so could result in equipment dmge or filure. Use drill-motor DO NOT EXCEED THE DUTY CYCLE rting of the winch. See Tle ENGAGE THE BRAKE nd remove the hndle or drill-motor efore operting the winch using electric power. ANY QUESTIONS ON OPERATING THE EMERGENCY HAND CRANK OPTION OR WINCH APPLICATION CONTACT THERN, INC.

13 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Clening the Winch Importnt! Increse the frequency of mintennce procedures if the winch is: Operted for long periods. Used to pull hevy lods. Operted in wet, dirty, hot, or cold surroundings. Clen the winch to remove dirt nd help prevent rust nd corrosion CLEAN THE WINCH every 6 months or whenever it is dirty. c WIPE ALL EQUIPMENT to remove dirt nd grese. LEAVE A LIGHT FILM of oil on ll surfces to protect them ginst rust nd corrosion. WIPE OFF excessive mounts of oil to void the ccumultion of dirt REMOVE ALL UNNECESSARY OBJECTS from the re surrounding the winch. Importnt! Do not overtighten the rke, since this will cuse prts to wer nd ecome dmged. Figure 5 Adjusting the Brke mechnicl rke turn rke djusting nuts clockwise 1/4 turn 3.2 Adjusting the Brkes (for models equipped with this feture) Do not djust either rke with the lod suspended. Accidentl relese of either rke could llow the lod to escpe. Instll the wire rope so it is wound correctly s shown or the winch nd rke will not work properly, nd could llow the lod to escpe. See section 1.4 Instlling the Wire Rope. The 3WG4-B Series is equipped with mechnicl rke nd the 3WG4-M Series is equipped with n electric motor rke. Non-stndrd products tht vry from the originl design my e equipped with oth rkes ADJUST THE MECHANICAL BRAKE (if equipped) whenever it ppers to need djustment, or t lest every 3 months. CHECK THE MECHANICAL BRAKE y operting with test lod equl to the winch lod rting. Figure 5 Disengging the Electricl Brke rke relese kno RAISE THE LOAD, then lower it nd stop it out foot off the ground. OBSERVE THE LOAD when stopped. If it continues to cost or creep, follow the instructions elow: TIGHTEN THE MECHANICAL BRAKE y turning the djustment nut clockwise y 1/4 turns. Continue to test nd tighten the rke y lternting tightening of ech rke nut until it stops nd holds the lod securely. See Figure 5. Do not djust the rke with the lod suspended. Do not overtighten mechnicl rke djusting nuts. A DECELERATION DISTANCE while stopping is typiclly 6 inches. IF THE LOAD CONTINUES TO COAST or creep, contct the fctory.

14 pge 14 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches CHECK THE ELECTRIC BRAKE ON MOTOR (if equipped) y operting the winch with test lod equl to the winch lod rting: RAISE THE LOAD, then lower it nd stop it out one foot off the ground. OBSERVE THE LOAD when stopped. If it continues to cost or creep, the rke needs djustment. Refer to the rke mnufcturer's instructions, or contct the fctory for ssistnce CHECK THE MECHANICAL AND ELECTRICAL BRAKES (if equipped with oth) y operting the winch with test lod equl to the winch lod rting: Mechnicl Brke Check c d e f DISENGAGE THE ELECTRIC BRAKE (if equipped) under no lod. Keep disengged during procedures nd c elow. See Figure 5. RAISE THE LOAD, then lower it nd stop it out one foot off the ground. OBSERVE THE LOAD when stopped. If it continues to cost or creep, follow the instructions elow: TIGHTEN THE MECHANICAL BRAKE y turning the djustment nut clockwise y 1/4 turns. Continue to test nd tighten the rke y lternting tightening of ech rke nut until it stops nd holds the lod securely. See Figure 5. DO NOT OVERTIGHTEN mechnicl rke djusting nuts. A DECELERATION DISTANCE while stopping is typiclly 6 inches. RE-ENGAGE THE ELECTRICAL BRAKE (if equipped). IF THE LOAD CONTINUES TO COAST or creep, contct the fctory. Electricl Brke Check c RAISE THE LOAD, then lower it nd stop it out one foot off the ground. OBSERVE THE LOAD when stopped. If it continues to cost or creep, the rke needs djustment. Refer to the rke mnufcturer's instructions, or contct the fctory for ssistnce. A DECELERATION DISTANCE while stopping is typiclly t lest hlf tht of the mechnicl rke test.

15 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Luricting the Winch Importnt! Do not leve holes in the reducer open. Open holes will llow dirt nd moisture to contminte the luriction. Mke sure luricnt hs temperture rting pproprite for the mient tempertures of the opertion. Figure 6 Luricting the Flnge Bering Instll the rether (s) to vent het nd pressure from the gerox or rke. Filure to do so could result in pressure uildup which cn cuse the gerox or rke to lek or dmge the equipment. Brether (s) must e locted ove the oil level otherwise oil will lek through the. See Figures 7 nd 7. Check the gerox nd mechnicl rke for proper level efore operting. Too much or too little oil will cuse overheting nd result in equipment dmge. Luricte the winch properly to help protect it from wer nd rust. Apply thred selnt to pipe s when re-instlling to prevent oil leks. Red the following instructions crefully THE WINCH is shipped from the fctory with the proper mount of Moilger 600XP220 luricnt in the gerox nd rke for mounting orienttion "". Luricte the winch s follows. See Figures 7 nd MOTOR BEARINGS re typiclly luricted for life y the mnufcturer. flnge ering, luricte with NLGI no. 2 grese REPLACE MOTOR BEARINGS if the motor is disssemled for ny reson. REFER TO MOTOR MANUFACTURER S INFORMATION for specific instructions regrding motor luriction. Importnt! For wll mounts with mechnicl rke, remove from wll to llow oil to properly drin from the rke nd gerox CHECK OIL LEVEL efore every opertion nd every 10 hours during opertion. Remove the level check nd mke sure oil is even with the hole. Add oil to the gerox nd rke if necessry. Do not use synthetic luricnts nd do not mix different luricnts CHANGE GEARBOX AND MECHANICAL BRAKE OIL t lest every 6 months, or whenever it is dirty or contminted. Remove the drin to drin oil from the gerox nd rke. See Figures 7 nd LUBRICATE THE FLANGE BEARING t lest once every month or more, depending on usge. Use grese gun to insert NLGI no. 2 grese until clen grese ppers t the sels. The ering will squek if it is dry. See Figure LUBRICATE THE WIRE ROPE nd other equipment y following the mnufcturer's recommendtions.

16 pge 16 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Figure 7 Luricting the Winch - 3WG4-B Series level check filler/rether filler filler/rether level check filler/rether level check rether level check filler level check drin drin drin drin ) floor mount ) wll mount c) wll mount d) ceiling mount (motor down) (motor up) Figure 7 Luricting the Winch - 3WG4-M Series level check filler/rether filler/rether filler/rether filler/rether level check level check level check drin drin drin drin ) floor mount ) wll mount c) wll mount d) ceiling mount (motor down) (motor up) NOTE: Drin s re hexgon socket pipe s. Do not remove olts or nuts to drin oil.

17 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Inspecting the Equipment Importnt! Strt n inspection progrm s soon s you put the winch into use. Appoint qulified person to e responsile for regulrly inspecting the equipment. Keep written records of inspection. This llows comprison with comments from previous inspections so you cn see chnges in condition or performnce. Perform frequent inspections: Before ech opertion. Every 3 hours during opertion. Whenever you notice signs of dmge or poor opertion. Figure 8 Broken Wires wire strnd one ly Wire rope ssemly must e replced if more thn 6 wires re roken in one ly, or if more thn 3 wires re roken in one strnd in one ly. Do not use dmged or mlfunctioning equipment. Plce n OUT OF ORDER sign on the winch. Do not use the winch until the sign is removed y qulified mintennce person who hs completely corrected the prolem. Disconnect power on motorized units efore servicing equipment. Do not operte the winch until proper power is supplied to the motor. Inspect the winch to detect signs of dmge or poor opertion efore they ecome hzrdous CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the winch nd other equipment CONSULT MANUFACTURER S RECOMMENDATIONS for informtion on inspecting the wire rope nd other equipment Instructions for Frequent Inspection VISUALLY INSPECT the entire winch nd ll other equipment involved in the opertion. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. Mke sure the wire rope is instlled correctly nd nchored securely to the drum. Mke sure the winch is properly luricted. Check the gerox nd mechnicl rke for signs of lekge, nd mke sure it is filled with the proper luricnt. Contct the fctory if there re ny signs of luricnt leking from the gerox or rke. Mke sure the rether is clen, open, nd instlled correctly. Mke sure mounting fsteners re tightened securely. Mke sure the foundtion is in good condition, nd cple of supporting the winch nd its lod under ll lod conditions. Check electricl wiring nd connections for wer, corrosion, cuts, nd other dmge. TEST WINCH PERFORMANCE y moving test lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the winch responds to the control device. It must rotte s shown on the control lels, nd it must turn off when you relese the control. Check the rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep, the rke needs djustment. See section Adjusting the Brke. Completely correct ll prolems efore continuing. Use the Trouleshooting Chrt to help determine the cuse of certin prolems. See Tle 3.

18 pge 18 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Perform periodic inspections: Every 6 months. Whenever you return the winch to service from storge. Whenever you notice dmge or poor opertion in frequent inspection. Whenever you hve, or think you my hve, overloded or shock loded the winch Instructions for Periodic Inspection, see Tle 2. VISUALLY INSPECT the winch nd ll other equipment. Disssemly my e required in order to properly inspect individul components. Contct fctory for ssemly/disssemly instructions. Disssemly of the gerox efore contcting Thern, Inc voids ll wrrnties. Check the finish for wer, flking, or other dmge. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. If the equipment ws overloded, or if you notice crcks nd other signs of overloding nd dmge, promptly remove equipment from use nd hve it repired or replced. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE ROPE. Check ll fsteners for stripped threds, wer, ending, nd other dmge. Check the gerox nd mechnicl rke for signs of lekge. Contct fctory if there re ny signs of luricnt leking from the gerox or rke. Mke sure the rether is clen, open nd instlled correctly. Mke sure the winch outord ering is properly luricted. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. Frequent Wire Rope Inspection: Use ASME B30.7 s guideline for rope inspection, replcement nd mintennce. Check the wire rope, end connections nd end fittings for corrosion, kinking, ending, crushing, irdcging or other signs of dmge. Check the numer, distriution nd type of visile roken wires. See prgrph c nd Figure 8. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 10. Tke extr cre when inspecting sections of rpid deteriortion such s sections in contct with sddles, sheves, repetitive pickup points, crossover points nd end connections. c DRAIN A SMALL AMOUNT OF OIL from the gerox nd rke into clen continer. Check the oil for dirt, metl prticles, wter, nd other signs of contmintion. Completely drin the gerox if oil is contminted. Mke sure the gerox nd rke is properly luricted. See section Luricting the Winch. INSPECT THE WIRE ROPE ccording to the wire rope mnufcture s recommendtions, or follow ccepted industry stndrds for wire rope inspection. Alwys wer protective clothing when hndling wire rope. Check the entire length of wire rope for ent wires, crushed res, roken or cut wires, corrosion, nd other dmge. Crefully inspect res tht pss over sheves or through roller guides. Note the loction nd concentrtion of roken wires. Replce wire rope if more thn 6 wires re roken in one ly, or more thn 3 wires re roken in one strnd in one ly. See Figure 8. Mke sure hooks nd other fittings re securely ttched to the wire rope, nd the wire rope where they re ttched is not fryed, corroded, roken, or otherwise dmged. Mesure the throt opening, thickness, nd twist of the hook. Replce the hook if it shows signs of dmge. See Figure 9.

19 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge 19 Figure 9 Lod Hook Inspection twist throt opening thickness The wire rope ssemly must e replced if the throt opening is 15% wider thn nominl, if the thickness is 10% less thn nominl, or if the hook is twisted 10 or more. Figure 10 Rope Dimeter correct dimeter incorrect The wire rope ssemly must e replced if the dimeter mesures less thn the minimum dimeter t ny point. wire rope size minimum dimeter 1/4 in 15/64 in (.2344 in) 5/16 in 19/64 in (.2969 in) 3/8 in 11/32 in (.3438 in) 1/2 in 15/32 in (.4688 in) d e f g h i Mke sure ny hook ltches open without inding nd close when relesed. Check the nchor holes in the drum nd the surrounding re for signs of wer or distortion. MOVE THE DRUM with your hnds. Check for excessive movement indicting worn or loose gers, erings, or shfts. Slight end ply in the driveshft is norml. Excessive movement is cused y overloding or overheting, nd is sign tht your ppliction my require lrger winch. PLACE enough weight to keep the wire rope stright nd tightly drwn. Mesure the dimeter of the wire rope, especilly in res where wer is noticele. Replce the wire rope if the dimeter mesures elow the minimum dimeter t ny point. See Figure 10. INSPECT THE FOUNDATION AND RIGGING Check mounting fsteners for stripped threds, wer, nd other dmge. Check the foundtion for crcks, corrosion, nd other dmge. TEST WINCH PERFORMANCE y operting the winch with test lod equl to the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the winch. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Oserve the rotting drum, look for signs of loose or misligned erings. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the winch responds to the control device. It must rotte s shown on the control lels, nd it must turn off when you relese the control. Check the rkes. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep, the rke needs djustment. See section Adjusting the Brkes. DISCONNECT POWER nd inspect power supply equipment. Check supply lines for wer, cuts, corroded connections, nd other dmge. Check control devices nd other power supply components for signs of moisture, corrosion, urn mrks, crcks, nd other dmge. CONNECT POWER. Check power supply t the motor nd mke sure it grees with the motor rting. Do not operte the winch until proper power is supplied to the motor. Completely correct ll prolems efore continuing. Use the trouleshooting chrt to help determine the cuse of certin prolems. See Tle 3.

20 pge 20 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Tle 2 Inspection Checklist checked oxes indicte dmge or prolem in need of repir dmges prolems generl finish wethered, flking, otherwise dmged winch jerks or hesittes during opertion prts crcked, ent, rusted, worn, otherwise dmged unusul noises, other signs of mlfunction fsteners stripped threds, ent, worn, otherwise dmged loose, not tightened to proper torque reducer gers, erings, or shfts loose, worn, otherwise dmged not properly luricted luricnt lekge luricnt contminted wire rope ent, crushed, otherwise dmged wire rope loosely or unevenly wound roken wires, see Figure 8 replce if more thn 6 wires in one ly, numer per strnd = or 3 wires in one strnd in one ly, re roken numer per ly = dimeter reduced, see Figure 10 replce if wire rope is excessively worn dimeter = end connections corroded, rusted, worn, otherwise dmged not securely ttched hook or other device twisted, ent, worn, otherwise dmged, see Figure 9 hook ltch fils to close when relesed replce if twist is 10 degrees or more, twist = replce if throt width is 15% lrger thn nominl throt width = replce if thickness is 10% less thn nominl thickness = drum nchor worn, distorted, otherwise dmged excessive movement or cklsh motor motor corroded, urnt out, otherwise dmged motor is sluggish or opertes poorly rke rke worn, corroded, otherwise dmged rke does not operte properly power supply components corroded, urnt, otherwise dmged control device fils to control winch properly supply lines worn, cut, corroded, otherwise dmged supply lines unprotected, ostructing trffic connections loose, corroded, otherwise dmged power supply t motor = lels nd pltes dirty, illegile, otherwise dmged loosely ttched or missing comments uthorized signture dte

21 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge 21 Tle 3 Trouleshooting Chrt Contct the fctory for detiled instructions on re-seling the gerox if you re required to disssemle the gerox for ny reson. Disssemly of the gerox efore contcting Thern, Inc. voids ll wrrnties. prolem cuse correction motor won't run circuit reker tripped or fuse lown... reset circuit reker or replce fuse motor runs, drum doesn't turn mechnicl rke does not operte properly poor power supply... inspect nd repir s necessry power supply lines loose or dmged... inspect, repir nd tighten s necessry power supply filure... check power supply source motor urned out or dmged... repir or replce s necessry loose or roken groove pin or keys... inspect nd replce s necessry loose, stripped or roken gers... inspect nd replce s necessry wire rope instlled improperly... reinstll wire rope correctly rke djusted incorrectly... djust rke rke worn or dmged... inspect nd replce s necessry rke components roken or locked... inspect nd repir s necessry motor rke does not operte properly rke relese lever in relese position... move to lock position luricnt lekge excessive end ply on drive shft excessively worn gers or erings overheting unusul noises high pitched squek grinding noise whining motor rttling noise hevy thump during opertion knocking noise voltge to rke incorrect... check voltge t control ox, repir s needed rke djusted incorrectly... contct fctory rke discs or solenoid worn or dmged... inspect nd replce s necessry rke components seized up or dmged... inspect nd repir s necessry worn erings... inspect nd replce s necessry oil sels leking or dmged... inspect nd replce s necessry gskets leking or dmged... tighten fsteners or replce gsket crcked or dmged reducer... inspect nd repir s necessry loose or dmged keys or keywys... inspect nd replce s necessry thrust wsher or ering worn out... inspect nd replce s necessry excessively worn gers... inspect nd repir s necessry lod too hevy... lighten lod poor luriction of gers or erings... inspect nd luricte s necessry operted too long without rest... llow to cool lod too hevy... lighten lod poor luriction... inspect nd luricte s necessry rether clogged or dmged... clen or replce vent s needed ering seized up... inspect nd replce s necessry poor luriction... inspect nd luricte s necessry contminted luriction... drin, clen nd luricte the winch roken gers or erings... inspect nd replce s necessry lod too hevy... lighten lod motor overheted... llow to cool motor erings urnt out... replce motor or erings loose fsteners or set screws... tighten ll fsteners nd screws contminnts in luricnt... drin, clen nd luricte the winch loose set screws or keys in gers or shfts... inspect nd repir s necessry mechnicl rke needs djustment... djust mechnicl rke loose or worn prts on input shft... contct fctory

22 pge 22 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Importnt! It is your responsiility to determine when to replce prts. When considering whether to continue using prt or to replce it, rememer tht replcing it is the est wy to void further equipment dmge. Replce spring pins, retining rings, nd oil sels whenever the winch is disssemled for inspection or repir. During ressemly, use loctite 598 Ultr Blck to crete sel etween gerox covers, end cps or mechnicl rke if equipped. Contct fctory for detiled instructions. Disssemly of the gerox efore contcting Thern, Inc. voids ll wrrnties. Appoint qulified person to e responsile for ll repirs to the equipment. 3.5 Repiring the Winch GET FACTORY AUTHORIZATION for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the winch REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repir prts REFINISH AREAS where the pint is worn or flking. A good finish helps to protect ginst corrosion nd wether dmge. c REMOVE THE FINISH from dmged res, down to the re metl. CLEAN THE AREA thoroughly. REPAINT with high qulity primer nd finishing cot TO ORDER REPAIR PARTS, contct your locl deler. Include the following informtion when ordering: model numer seril numer (or code numer) prt numer dte purchsed, nd from whom description of wht hppened, or wht is wrong your nme nd return ddress

23 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge Trnsporting the Winch Importnt! Keep record of wht you ship, nd when you send is REMOVE THE BREATHER PLUG(S) nd instll seled oil (s) to prevent the loss of luriction during shipment PACK THE WINCH in n upright position for trnsport, using the originl pckging mterils, if possile. c d FASTEN THE WINCH to wooden se using lg olts, to keep it from moving during trnsport. SEAL THE WINCH in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. CONSTRUCT WOODEN SIDES nd top to enclose the winch in solid protective crte. PACK LOOSE PARTS in smll oxes or ship seprtely INSPECT THE WINCH ccording to the Instructions for Periodic Inspection efore instlling it in new loction. 4.2 Storing the Winch LUBRICATE THE WINCH s necessry, nd mke sure the rether is clen nd properly instlled. Add rust preventtive for long term storge SEAL THE WINCH in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge STORE THE WINCH upright, in cool clen plce wy from corrosive chemicls nd moisture ROTATE THE DRUM PERIODICALLY to keep ering nd gers surfces from ecoming lcquered INSPECT THE WINCH ccording to the Instructions for Periodic Inspection efore instlling it for opertion TEST INSULATION RESISTANCE in the motor to detect moisture dmge. Refer to the motor mnufcturer s instructions LUBRICATE THE WINCH PROPERLY prior to opertion. See section Luricting the Winch. 3WG4 Series Performnce Chrcteristics 1 lod rting (l) wire line speed (fpm) drum cpcity (ft) 2 pprox. motor motor 1st mid full rope 1st full 1st mid full ship series codes hp lyer drum drum di. (in) lyer drum lyer drum drum wt. (l) 3WG4-M/B3500-9S6 BCDE / WG4-M/B S6 BCDE / WG4-M/B4000-9S6 A / WG4-M/B4600-9S6 BCDE / WG4-M/B S6 CDE / Motor Codes A 115 volt 1 phse B 230 volt 1 phse C 208 volt 3 phse D 230 volt 3 phse E 460 volt 3 phse 1 Performnce Chrcteristics re for stndrd products referred to in this mnul. Non-stndrd products my vry from the originl design. Contct Thern, Inc. for this informtion. 2 Actul drum cpcities my e 25-30% less, due to nonuniform winding. Tension in wire rope will lso ffect drum cpcity.

24 pge 24 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Model 3WG4-M item description prt numer qty. 1 END CAP B CAPSCR HEXHD NC X ZNPL GR5 A BRG RAD BALL.750ID X 1.625OD X.31W STL A INPUT SHAFT B SEAL OIL.750ID X 1.375OD X.250 A PLUG BREATHER NPT X.48 PLN STL A BRG BALL THRUST.753ID X 1.685OD X.625 A WORM SPACER A WORM 1.75OD X 1.500PD X 1.22RD 2 LEAD A KEY.188 X.188 X HT BER A GEARCASE MACHINING D SHIM.760/.786 X 1.235/1.265 X.018/.024 A PLUG PIPE HEXSOC NPT X.425 SAE A CAPSCR SOKHD NC X ZNPL ALYSTL A BRAKE MOTOR SEE TABLE 1 16 KEY.188 X.188 X HT BES A WASHER HELSPRLK.375 X.683 X.094 ZNPL A COVER PROTECTIVE FOR NORD SK1SI63 A REDUCER SEE TABLE 1 20 KEY.375 X.375 X HT BER A KEY.188 X.188 X HT OER A REDUCER ADAPTER B REDUCER MOUNT C KEY.500 X.500 X HT BES A WORM GEAR 8.12OD X 7.750PD X 7.469RD C HANDLE B DRUM SHAFT D BRG RAD BALL 45MM X 85MM X 19MM A FRONT COVER MACHINING C SHIM X X.060 STL A SEAL OIL 1.625ID X X.313 A BACK COVER MACHINING C CAPSCR HEXHD NC X ZNPL GR5 A PIN GROOVE TYPE A.500 X ALYSTL A FRAME WELDMENT C BRG FLNG 1.44ID 4 BOLT SETSCR LOCK A NUT HEX NYLK NC ZNPL GR2 A CAPSCR HEXHD NC X ZNPL GR5 A PLUG PIPE HEXSOC NPT X.63 SAE A SETSCR SOKHD NYLK NC X.625 A DRUM WELDMENT C LABEL WARNING KEEP HANDS AWAY FROM DRUM A LABEL WARNING DO NOT MANUALLY RELEASE BRAKE A LABEL WARNING DISCONNECT ELECTRIC POWER A LABEL WARNING POINTS 1-10 A LABEL NAMEPLATE POWER WINCHES A LABEL NAMEPLATE THERN LOGO A WG4-M Series Motor nd Reducer Tle Model Motor Brke Description Reducer Description 3WG4-M3500-9S6-D,E B HP 1725RPM /460/3/60 145TC B4877 SK1SI63 7.5:1 140TC 3WG4-M S6-B B5339-2HP 1740RPM 115/ /1/60 145TC B5084 SK1SI63 5:1 140TC 3WG4-M S6-D,E B2976-2HP 1725RPM /460/3/60 145TC B5084 SK1SI63 5:1 140TC 3WG4-M4000-9S6-A B2621 B HP 1725RPM 115/ /1/60 56C B6070 SK1SI63 7.5:1 56C 3WG4-M4600-9S6-B B5339-2HP 1740RPM 115/ /1/60 145TC B4877 SK1SI63 7.5:1 140TC 3WG4-M4600-9S6-D,E B2976-2HP 1725RPM /460/3/60 145TC B4877 SK1SI63 7.5:1 140TC 3WG4-M S6-D,E B5439-3HP 1725RPM /460/3/60 145TC B5084 SK1SI63 5:1 140TC 1 Brke is doule C-fce rke. On model 3WG4-M4000-9S6-A only.

25 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge SECTION A-A SECTION B-B A B B 47 A

26 pge 26 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches Model 3WG4-B item description prt numer qty. 1 PLUG PIPE HEXSOC NPT X.425 SAE A BRAKE HOUSING MACHINING D MACHINING COVER BRAKE C CAPSCR HEXHD NC X ZNPL GR5 A BRG RAD BALL.750ID X 1.625OD X.31W STL A BRG RAD BALL X X.375 A INPUT SHAFT B THRUST BEARING A BRG CLUTCH 1.000ID X 1.312OD X STL A BRAKE DRUM B CAPSCR HEXHD NC X.750 ZNPL GR5 A BRAKE BAND ASSEMBLY B PIN DOWEL.250 X ALYSTL A CONNECTOR BUSHING A NUT HEX NYLK NC ZNPL GR2 A BRAKE BAND CONNECTOR A PLUG BREATHER NPT X.48 PLN STL A BRG BALL THRUST.753ID X 1.685OD X.625 A WORM SPACER A WORM 1.75OD X 1.500PD X 1.22RD 2 LEAD A KEY.188 X.188 X HT BER A GEARCASE MACHINING D SHIM.760/.786 X 1.235/1.265 X.018/.024 A SEAL OIL.750ID X 1.375OD X.250 A CAPSCR SOKHD NC X ZNPL ALYSTL A BRAKE MOTOR SEE TABLE 1 27 KEY.188 X.188 X HT BES A WASHER HELSPRLK.375 X.683 X.094 ZNPL A COVER PROTECTIVE FOR NORD SK1SI63 A REDUCER SEE TABLE 1 31 KEY.375 X.375 X HT BER A KEY.188 X.188 X HT OER A REDUCER ADAPTER B REDUCER MOUNT C KEY.500 X.500 X HT BES A WORM GEAR 8.12OD X 7.750PD X 7.469RD C HANDLE B DRUM SHAFT D BRG RAD BALL 45MM X 85MM X 19MM A FRONT COVER MACHINING C SHIM X X.060 STL A SEAL OIL 1.625ID X X.313 A BACK COVER MACHINING C CAPSCR HEXHD NC X ZNPL GR5 A PIN GROOVE TYPE A.500 X ALYSTL A FRAME WELDMENT C BRG FLNG 1.44ID 4 BOLT SETSCR LOCK A CAPSCR HEXHD NC X ZNPL GR5 A PLUG PIPE HEXSOC NPT X.63 SAE A SETSCR SOKHD NYLK NC X.625 A DRUM WELDMENT C WASHER SPRING.559 X X.039 SPR STL A O-RING.750 X.875 X.063 NITRILE A O-RING.375 X.500 X.063 NITRILE A LABEL WARNING DO NOT ADJUST BRAKE UNDER LOAD A LABEL WARNING INSTALL WIRE ROPE AS SHOWN A LABEL WARNING INSTALL WIRE ROPE AS SHOWN A LABEL WARNING KEEP HANDS AWAY FROM DRUM A LABEL WARNING POINTS 1-10 A LABEL WARNING DISCONNECT ELECTRIC POWER A LABEL NAMEPLATE POWER WINCHES A LABEL NAMEPLATE THERN LOGO A WG4-B Series Motor nd Reducer Tle Model Motor Description Reducer Description 3WG4-B3500-9S6-B B HP 1725RPM 115/ /1/60 145TC B4877 SK1SI63 7.5:1 140TC 3WG4-B3500-9S6-C,D,E B HP 1740RPM /460/3/60 145TC B4877 SK1SI63 7.5:1 140TC 3WG4-B S6-B B3798 2HP 1725RPM /1/60 145TC B5084 SK1SI63 5:1 140TC 3WG4-B S6-C,D,E B5273 2HP 1740RPM /460/3/60 145TC B5084 SK1SI63 5:1 140TC 3WG4-B4000-9S6-A B HP 1725RPM 115/ /1/60 56C B6070 SK1SI63 7.5:1 56C 3WG4-B4600-9S6-B B3798 2HP 1725RPM /1/60 145TC B4877 SK1SI63 7.5:1 140TC 3WG4-B4600-9S6-C,D,E B5273 2HP 1740RPM /460/3/60 145TC B4877 SK1SI63 7.5:1 140TC 3WG4-B S6-C,D,E B5071 3HP 1725RPM /460/3/60 145TC B5084 SK1SI63 5:1 140TC

27 Owner's Mnul for Thern 3WG4 Series Worm Ger Power Winches pge SECTION B-B SECTION A-A SECTION C-C A B C 55 B C A

28 Thern, Incorported 5712 Industril Prk Rod Winon, MN PH FAX Thern Europe Bedrijvenprk Twente 454e 7602 KM Almelo Netherlnds PH