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Form BU-8A15G

OPERATION AND MAINTENANCE MANUAL

for

AIR WINCH

Model BU-8A15G

1500 lb Capacity (679.5 kg)

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manualcontains important safety, installation, operation and maintenance information.Make this manual available to all persons responsible for the operation, installationand maintenance of these products.

Do not use this winch for lifting, supporting, or transporting people or lifting or supporting loads overpeople.

Always operate, inspect and maintain this winch in accordance with American National StandardsInstitute Safety Code (ANSI B30.7) and any other applicable safety codes and regulations.

Refer all communications to WINTECH International Inc. or your nearest Distributor.

SEP 2005Form BU-8A15GEdition 1B01-0298

WARNING

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TABLE OF CONTENTS

Description Page No.

Safety InformationDanger, Caution, Warning and Notice ...........................................................................................................................3Safe Operating Instructions ........................................................................................................................................... 4Warning Labels ............................................................................................................................................................. 4

InstallationMounting ....................................................................................................................................................................... 5Wire Rope ..................................................................................................................................................................... 5Electrical Component Installation ................................................................................................................................. 6Initial Operating Checks ................................................................................................................................................ 6

OperationPower Operation ............................................................................................................................................................ 7Tensioning ..................................................................................................................................................................... 7 Brake Operation ........................................................................................................................................................... 7

InspectionRecords and Reports ..................................................................................................................................................... 8Frequent Inspection ....................................................................................................................................................... 8Periodic Inspection ........................................................................................................................................................ 9Winches not in Regular Use .......................................................................................................................................... 9

LubricationLubrication Interval Chart ........................................................................................................................................... 10Recommended Lubricants ........................................................................................................................................... 10Bearings and Pivot Points ........................................................................................................................................... 10Gears ............................................................................................................................................................................ 10Wire Rope ................................................................................................................................................................... 10Reduction Gear ............................................................................................................................................................ 10Motor ........................................................................................................................................................................... 11

TroubleshootingTroubleshooting Chart ................................................................................................................................................ 12

MaintenanceAdjustments ................................................................................................................................................................. 13General Disassembly ................................................................................................................................................... 13Disassembly ................................................................................................................................................................. 13Cleaning, Inspection and Repair ................................................................................................................................. 14Assembly Instructions ................................................................................................................................................. 15Testing ......................................................................................................................................................................... 15

Parts Ordering InformationReturn Goods Policy ................................................................................................................................................... 16Warranty ...................................................................................................................................................................... 17Office Locations .......................................................................................................................................................... 18

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SAFETY INFORMATION

The National Safety Council, Accident Prevention Manualfor Industrial Operations, Eighth Edition and other recog-nized safety sources make a common point: Employeeswho work near material handling equipment or assist inhooking on or arranging a load should be instructed in saferigging procedures. From a safety standpoint, one factor isparamount: conduct all pulling operations in such a mannerthat if there were an equipment failure, no personnel wouldbe injured. This means keep out of the line of force of anyload.

The Occupational Safety and Health Act of 1970 generallyplaces the burden of compliance with the owner/employer,not the manufacturer. Many OSHA requirements are notconcerned or connected with the manufactured product butare, rather, connected with the final installation. It is theowner’s responsibility and user’s responsibility to deter-mine the suitability of a product for any particular use.Check all applicable industry, trade association, federal,state and local regulations. Read all operating instructionsand warnings before operation.

Rigging: It is the responsibility of the operator to exercisecaution, use common sense and be familiar with properrigging techniques. See ANSI/ASME B30.9 for rigginginformation, American National Standards Institute, 1430Broadway, New York, NY 10018.

This manual has been produced by Wintech International toprovide dealers, mechanics, operators and companypersonnel with the information required to install, operate,and maintain the products described herein.It is extremely important that mechanics and operators befamiliar with the servicing procedures of these products, orlike or similiar products, and are physically capable ofconducting the procedures. These personnel shall have ageneral working knowledge that includes:1. Proper and safe use and application of mechanics

common hand tools as well as special Wintech Interna-tional or recommended tools.

2. Safety procedures, precautions and work habitsestablished by accepted industry standards.

Wintech International can not know of, nor provide all theprocedures by which product operations or repairs may beconducted and the hazards and/or results of each method.If operation or maintenance procedures not specificallyrecommened by the manufacturer are conducted, it must beensured that product safety is not endangered by theactions taken. If unsure of an operation or maintenanceprocedure or step, personnel should place the product in asafe condition and contact supervisors and/or the factoryfor technical assistance.

Inspection and safety information contained in this manualis based, in part, on the American National StandardsInstitute Safety Code (ASME B30.7). However, it should benoted that ASME B30.7 covers "Base Mounted Hoists"and does not specifically apply to winches used as bargepullers or in horizontal pulling applications.This manual provides important information for all person-nel involved with the safe installation, operation and propermaintenance of this product. Even if you feel you arefamiliar with this or similar equipment, you should read thismanual before operating the product.

Danger, Warning, Caution and NoticeThroughout this manual there are steps and procedureswhich, if not followed, may result in an injury. The follow-ing signal words are used to identify the level of potentialhazard.

Danger is used to indicate thepresence of a hazard which willcause severe injury, death, orsubstantial property damage if thewarning is ignored.

Warning is used to indicate thepresence of a hazard which cancause severe injury, death, orsubstantial property damage if thewarning is ignored.

Caution is used to indicate thepresence of a hazard which will orcan cause minor injury or propertydamage if the warning is ignored.

Notice is used to notify people ofinstallation, operation, or mainte-nance information which is importantbut not hazard-related.

Safety Summary

WARNING• Do not use this winch for lifting or lowering loads or forsupporting, or transporting people.• The supporting structures and load-attaching devicesused in conjunction with this winch must provide anadequate safety factor to handle the rated load, plus theweight of the winch and attached equipment. This is thecustomer’s responsibility. If in doubt, consult a registeredstructural engineer.• Electrical installation should be performed by licensedelectricians in accordance with the latest edition of theNational Electrical Code (ANSI/NFPA 70) and anyapplicable local, state and national electrical codes andordinances.

DANGER

WARNING

CAUTION

NOTICE

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WARNING LABELS

Each winch is supplied from the factory with the warninglabels shown. If the labels are not attached to your winch,order new labels and install. Read and obey all warningsand other safety information attached to this winch. Labelsare shown smaller than actual size.

SAFE OPERATING INSTRUCTIONS

of the winch.7. Never place your hand in the throat area of a hook or

in the vicinity of the wire rope as it spools onto thedrum.

8. Position the winch in such a way as to minimize thefleet angle of the cable (perpendicularity of the cableto the drum). Excessive side pulls will result in stackedwinding of cable onto one side of thedrum and place high loads on the side frames andbearings of the winch.

9. Keep hands, clothing, etc., clear of moving parts.10. Do not force a hook into place by hammering.11. Be certain the load is properly seated in the saddle of

the hook.12. Do not pull the load on the tip of the hook.13. Never run the wire rope over a sharp edge. Use a

sheave.14. Pay attention to the load at all times when operating

the winch.15. Make sure all people are clear of the loadpath.16. Never use the winch for lifting or lowering loads and

never allow anyone to stand on a moving load.17. Ease the slack out of the wire rope when starting a

pull.18. Never weld or cut on a load held by the winch.19. Do not operate winch if jamming, overloading, or

binding occurs.20. After use, properly secure winch and all loads.21. Always rig loads properly and carefully.

The following warnings and operating instructions havebeen adapted in part from American National (Safety)Standard ASME B30.7 and are intended to avoid unsafeoperating practices which might lead to injury or propertydamage.

Wintech International recognizes that most companies whouse winches have a safety program in force at their facility.In the event that some conflict exists between a rule setforth in this publication and a similar rule already set by anindividual company, the more stringent of the two shouldtake precedence.

Safe Operating Instructions are provided to make anoperator aware of dangerous practices to avoid and are notnecessarily limited to the following list. Refer to specificsections in the manual for additional safety information.

1. Only allow personnel trained in safety and operation ofthis product to operate and maintain the winch.

2. Only operate a winch if you are physically fit to do so.3. When a “DO NOT OPERATE” sign is placed on the

winch, or controls, do not operate the winch until thesign has been removed by designated personnel.

4. Before each shift, the operator should inspect thewinch for wear or damage. Never use a winch thatinspection indicates is worn or damaged.

5. Do not use winch if hook latch on a hook has beensprung or is broken. Check that the hook latches areengaged before using.

6. Only pull loads less than or equal to the rated capacity

WINTECH

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Prior to installing the winch, carefully inspect it forpossible shipping damage.Winches are supplied fully lubricated from the factory.

• Owners and users are advised to examine specific, localand other regulations, including AmericanNational Standards Institute and/or OSHA Regulationswhich may apply to a particular type of use of this productbefore installing or using winch.

Mounting1. Mount the winch on a rigid surface capable of

supporting the winch and that will prevent deflectingor distortion of the winch when operated at maximumcapacity.

2. Choose a site that uses as short a wire rope aspractical.

WARNING

• The winch is not a balanced load. Use extreme care whenlifting winch into position.

3. When a lead sheave is used, it should be aligned withthe center of the drum. The diameter of the leadsheave must be at least 18 times the diameter of thewire rope.

4. Maintain a fleet angle between the sheave and winchof no more than 1-1/2°. For every inch (25 mm) of drumlength the lead sheave must be at least 1.6 feet (0.5 m)from the drum.

5. Make sure the mounting surface is flat to within1/16 in. (1.6 mm). Shim as necessary.

5a. For mounting using the rigid base holes mount thewinch on a flat surface and/or shim to ensure all 4bolts are against the surface/shim before tighteningbolts.

5b. For anchoring using the rear anchor eyes. attach a 7/16" shackle in the eye and sling to an anchor pointusing a minimum sling length of 6 feet.

6. Position the winch so there is enough space formanual operation and for maintenance personnel toaccess the winch for inspection and maintenance.

7. Mounting bolts or screws must be Grade 8 (metric10.9) or better. Secure using nuts with lockwashers orself-locking nuts.

8. Tighten mounting bolts evenly. For Grade 8 dry threadfasteners torque to 380 ft. lbs(515 Nm).for 3/4 inchbolts and 900 ft. lbs. (1220 Nm) for 1 inch bolts. If theGrade 8 fasteners are plated, lubricated or a threadlocking compound is used, torque to 280 ft. lbs. (380Nm) for 3/4 inch bolts and 680 ft. lbs. (922 Nm) for 1inch bolts.

CAUTION

INSTALLATION

Safe Installation Procedures1. Do not use wire rope as a ground (earth) for welding.2. Do not attach a welding electrode to winch or wire

rope.3. Never run the wire rope over a sharp edge. Use a

correctly sized sheave. Refer to the "MOUNTING"section for specific instructions.

4. Do not weld on or to any part of the winch.5. Always maintain at least three full, tight wraps of wire

rope on the drum.6. Verify the gears and winch components are lubricated

before using winch. Refer to the "LUBRICATION"section for specific information.

Wire RopeWire Rope SelectionConsult a reputable wire rope manufacturer or distributorfor assistance in selecting the appropriate type and size ofwire rope and, where necessary, a protective coating. Usea wire rope which provides an adequate safety factor tohandle the actual working load and that meets all appli-cable industry, trade association, federal, state and localregulations.When considering wire rope requirements the actualworking load must include not only the static or deadload but also loads resulting from acceleration, retardationand shock load. Consideration must also be given to thesize of the winch wire rope drum, sheaves and method ofreeving. Wire rope construction must be 6 X 19 or 6 X 37IWRC right lay to permit correct installation of wire ropeanchor.

NOTE: The maximum wire rope diameter is limited by thesize of the wire rope anchor hole.

CAUTION• Ensure the wire rope diameter provides an adequatesafety factor.

Safe Wire Rope Handling Procedures1. Always use gloves when handling wire rope.2. Never use wire rope which is twisted, frayed or

kinked.3. Never use wire rope as a sling.4. Always ensure wire rope is correctly spooled and first

layer is tight.5. Always maintain at least three full wraps of wire rope

on the drum.

Installing Wire Rope

CAUTION

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• Install the wire rope so that it comes off the top of thedrum (overwound).• Maintain at least 3 wraps of wire rope on the drum at alltimes.

1. Cut wire rope to length. To prevent fraying of strands,fuse wire rope ends in accordance with the wire ropemanufacturer's instructions.

2. Feed the end of wire rope through the hole in the drumflange. Loosely weave the wire rope through theanchor block starting at the inner hole, then backthrough the outer hole, and then through the centerhole.

3. Allow the end of the wire rope to extend about 2 in.through the center hole. Pull the smaller loop tight.

4. Pull large loop tight so it presses the wire rope endtight against the drum flange.

5. While keeping the wire rope under tension, wind thewire rope onto the drum.

CAUTION• Make sure the first wrap of wire rope is flush againstthe drum flange.

Wire Rope SpoolingTo compensate for uneven spooling and the decrease inline pull capacity as the drum fills up, use as short a wirerope as practical. When rewinding wire rope apply tensionto the end of the wire rope to eliminate line slack. Thishelps achieve level winding and tight spooling.

RiggingMake sure all wire rope blocks, tackle and fasteners have asufficient safety margin to handle the required load underall conditions. Do not allow wire rope to contact sharpedges or make sharp bends which will cause damage towire rope, use a sheave. Refer to the wire ropemanufacturer's handbook for proper sizing, use and care ofwire rope.

Electrical Component InstallationElectrical WiringThe motor and brake voltage, phase and cycle must matchthe electrical power supply source. Ensure the powersupply is properly grounded. Insulate and enclose allelectrical connections.

WARNING• Electrical installation should be performed by licensedelectricians in accordance with the latest edition of theNational Electrical Code (ANSI/NFPA 70) and anyapplicable local, state and national electrial codes andordinances.• Never use a 230V motor with a 115V power supply. Themotor can be permanently damaged.• Switches and starter enclosures must be properly

grounded.NOTE: Electrical installation must be performed by aqualified electrician who is knowledgeable with the NECarticle 430 and any applicable local, state and nationalelectrical codes and ordinances.

Electrical power supply voltage must be within 5% (+/-) ofmotor requirements.1. For a 230V motor, the power supply required range is

218V to 242V.2. For a 460V motor, the power supply required range is

437V to 483V.

Brake ConnectionsBrake power connections depend upon winch motor andbrake operating voltages. Drawing MHTPA0249 showsmotor and brake connections for 460V.

ToBrake

ToStarter

T1

Motor

460V Motor and 460V BrakeElectrical Connections

T2

T3

T4

T7

T5

T8

T6

T9

(Dwg. MHTPA0249)

Electrical ControlsA momentary contact, reversing drum switch isrecommeded for the winch control, unless remote orautomatic control of the winch is required.If remote or automatic control is required, an electromag-netic reversing starter is recommended. The starter can beused with either a hand held pendant control or with a wallmounted remote control station. Automatic controldepends on application.Contact the Wintech International factory for assistance onspecific applications.

Initial Operating Checks1. Prior to initial winch operation verify oil level in

reduction gear and grease components as described inthe "LUBRICATION" section.

2. Ensure all winch mounting fasteners are tight and wirerope is spooled correctly onto the drum for underwindoperation.

3. Operate winch, without load, slowly in both direc-tions. During operation inspect winch components forabnormal noises, indications of binding and misalign-ment of parts.

4. Operate winch, with light load, slowly in both direc-tions. During operation inspect winch components forabnormal noises, indications of binding and misalign-

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OPERATION

The four most important aspects of winch operation are:1. Follow all safety instructions when operating the

winch.2. Allow only people trained in safety and the operation

of this winch to operate this product.3. Subject each winch to a regular inspection and main-

tenance procedure.4. Be aware of the winch capacity and weight of load at

all times.

WARNING

• Only allow personnel trained in safety and operation ofthis winch to operate this product.• To avoid damage to the rigging, the structure support-ing the rigging, and the winch, do not “two-block” the endof the wire rope.• A creeping load can cause death or injury. Do notrely on the reducer assembly or brake to hold a load.

InspectionBefore each shift inspect winch as described in "FrequentInspection" of the "INSPECTION" section.

Power Operation

WARNING

• A creeping load can cause death or injury. Do not relyon the gear reduction or brake to hold a load. Engageholding dog.

CAUTION

• Operating winch for time periods longer than recom-mended may result in motor damage.

The winch motor has an intermittent duty rating of 15minutes. This is the number of minutes the motor may beoperated during a one hour period when the winch iscarrying the full rated load. When operating the winchavoid unnecessary 'jogging' of the controls.

TensioningMotor Tensioning1. Connect wire rope to the load.2. Engage the holding dog by placing the holding dog

lever in the forward position.3. Using the motor, slowly take up slack wire rope.

Ensure wire rope is spooled evenly and tightly ontodrum.

4. Using the motor, tension the wire rope.

Brake OperationBrakes are supplied with hand-operated release mecha-nism. This allows opening of the brake without energizingthe motor to facilitate adjustments on the winch.The brake requires a lever to be inserted into the releasearm. Pulling the lever away from the motor will open thebrake. The brake will reset automatically, once the lever isreleased. The lever, when not in use can be attached to thecooling fan fins of the motor with a clamp.

For more Specs Reference: 'Gear/motor Reducer' and 'Motor/Brakemotor'manuals included within this manual binder.

WARNING

• To lower loads, jog brake release lever to preventmotor and brake from overspeeding the normaloperating rpm.

CAUTION

• To prevent friction disc overheating, wear andpossible damage, do not energize and operate motorwith the brake engaged.

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Inspection information is based in part on the AmericanNational Standards Institute Safety Codes (ASME B30.7).However, it should be noted that ASME B30.7 appliesspecifically to “Base Mounted Drum Hoists” and not towinches used as barge pullers or in horizontal pullingapplications.

WARNING• All new, altered or modified equipment should beinspected and tested to 110% of rated capacity by person-nel trained in safety, operation and maintenance of thisequipment to ensure safe operation at rated specificationsbefore placing equipment in service.

Frequent and periodic inspections should be performed onequipment in regular service. Frequent inspections arevisual examinations performed by operators or personneltrained in safety and operation of this equipment andinclude observations made during routine equipmentoperation. Periodic inspections are thorough inspectionsconducted by personnel trained in the safety, operationand maintenance of this equipment. Inspection intervalsdepend upon the nature of the critical components of theequipment and the degree of their exposure to wear,deterioration or malfunction.Careful inspection on a regular basis will reveal potentiallydangerous conditions while still in the early stages,allowing corrective action to be taken before the conditionbecomes dangerous.Deficiencies revealed through inspection, or noted duringoperation, must be reported to designated personneltrained in safety, operation and maintenance of thisequipment. A determination as to whether a conditionconstitutes a safety hazard must be decided, and thecorrection of noted safety hazards accomplished anddocumented by written report before placing the equipmentin service.

Records and ReportsInspection records, listing all points requiring periodicinspection should be maintained for all load bearingequipment. Written reports, based on severity of service,should be made on the condition of critical parts as amethod of documenting periodic inspections. Thesereports should be dated, signed by the person who per-formed the inspection, and kept on file where they arereadily available for review by authorized personnel.

Wire Rope ReportsRecords should be maintained as part of a long-range wirerope inspection program. Records should include thecondition of wire rope removed from service. Accuraterecords will establish a relationship between visualobservations noted during frequent inspections and theactual condition of wire rope as determined by periodicinspections.

Frequent InspectionOn equipment in continuous service, frequent inspectionshould be made by operators at the beginning of each shift.In addition, visual inspections should be conducted duringregular operation for damage or evidence of malfunction.

1. OPERATION. During operation visually inspect andlisten for abnormal noises which could indicatepotential problems. Do not operate the winch unlessthe wire rope feeds onto the drum smoothly. If wirerope binds or jumps, clean and lubricate wire rope. Ifproblem persists, check wire rope fleet angle orreplace the wire rope. Make sure the drive mechanismoperates properly, check for sticking or other signs ofmalfunction. Repair if necessary. Do not operate thewinch until all defects have been corrected. To test thebrake, apply a pull to the end of the wire rope andcheck that the brake does not slip.

2. WINCH. Prior to operation, visually inspect winchshafts, gears, brakes, motor, electrical wiring, side-plates and drum for indications of damage. Do notoperate winch until noted discrepancies have beenreviewed and inspected further by personnel trained inthe operation, safety and maintenance of this winch.

3. WIRE ROPE. Visually inspect all wire rope which canbe expected to be in use during the day’s operations.Inspect for damage indicated by distortion of wire ropesuch as kinking, “birdcaging,” core protrusion, mainstrand displacement, corrosion, broken or cut strands.Check for wear of crown wires. Replace at 1/3 wear ofthe original diameter of any crown wire. If anydamage is evident, do not operate winch until thediscrepancies have been reviewed and inspectedfurther by personnel trained in the operation, safetyand maintenance of this winch.

NOTICE• The full extent of wire rope wear cannot be determined byvisual inspection. At any indication of wear inspect thewire rope in accordance with instructions in “PeriodicInspection.”

INSPECTION

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4. LUBRICATION. Visually inspect wire rope and winchcomponents. Clean and lubricate as necessary.

5. BRAKE. Before loading winch operate the brakerelease knob. During operation, with a load, stopwinch in position. Brake should hold load up tomaximum winch capacity.

6. MOTOR. Before loading winch, operate motor in bothdirections. Motor and winch should operate smoothlywithout sticking or binding.

Periodic InspectionPeriodic inspection intervals for equipment use undervarious operating conditions are listed below:

NORMAL HEAVY SEVEREyearly yearly quarterly

Disassembly may be required as a result of initial indica-tions of inspections or in order to properly inspect theindividual components. Maintain written records ofperiodic inspections to provide an accumulative basis forcontinuing evaluation. Inspect all items listed in “FrequentInspection.” Also inspect the following:1. SIDE FRAMES. Check for deformed, cracked or

corroded main components. Replace damaged parts.

2. FASTENERS. Check retainer rings, split pins,capscrews, nuts, and other fasteners on winch, includ-ing mounting bolts. Replace if missing or damaged andtighten if loose.

3. DRUM AND SHEAVES. Check for cracks, wear ordamage. Replace if necessary.

4. WIRE ROPE. Additionally inspect for the following:a. Build-up of dirt and corrosion. Clean with steam or

a stiff wire brush to remove dirt and corrosion ifnecessary.

b. Loose or damaged end connection. Replace ifloose or damaged.

c. Check wire rope anchor is securely mounted in drum.d. Verify wire rope diameter. Measure the diameter of

the wire rope from crown-to-crown throughout thelife of the wire rope. Recording of the actualdiameter should only be done with the wire ropeunder equivalent loading and in the same operat-ing section as accomplished during previousinspections. If the actual diameter of the wire ropehas decreased more than 1/64 in. (0.4 mm) athorough examination of the wire rope should beconducted by an experienced inspector todetermine the suitability of the wire rope to remainin service. (Refer to Dwg. MHTPA0056).

Crownto

Crown

(Dwg. MHTPA0056)

5. MOTOR. Visually inspect exterior for damage, wearand cleanliness. Inspect wiring for damaged, frayed orexposed wires. Verify motor operation is smooth,without sticking or binding, in both directions. Inspectand lubricate as described in the "LUBRICATION"section.

6. ALL COMPONENTS. Inspect for wear, damage,distortion, deformation and cleanliness. If externalevidence indicates damage, disassemble as required toconduct a detailed inspection. Inspect gears, shafts,bearings, sheaves, springs, chain and covers. Replaceworn or damaged parts. Clean, lubricate and reas-semble.

7. BRAKE. Ensure proper operation. Visually inspectbrake during operation. If indicated by poor operationor visual damage, disassemble and repair brake. Checkall brake surfaces for wear, deformation or foreigndeposits. Clean and replace components as necessary.Replace friction discs when thickness is less than 1/8inch (3 mm).

8. SUPPORTING STRUCTURE. Check for distortion,wear and continued ability to support winch. Ensurewinch is firmly mounted and that fasteners are in goodcondition and tight.

9. LABELS AND TAGS. Check for presence andlegibility of labels. Replace if damaged or missing.

10. ELECTRICAL COMPONENTS. Check for loosewires, corrosion and indications of deterioration.

11. DRIVE CHAIN. Check for excessive wear of chaindrive sprockets and chain stretch.

Winches Not in Regular Use1. Winches which have been idle for a period of one

month or more, but less than six months, shall be givenan inspection conforming to the requirements of“Frequent Inspection” before being placed in service.

2. Winches which has been idle for a period of over sixmonths shall be given a complete inspection conform-ing with the requirements of “Periodic Inspection”before being place in service.

3. Standby winches shall be inspected at least semi-annually in accordance with the requirements of“Frequent Inspection”. In abnormal operating condi-tions winches should be inspected at shorter intervals.

Testing Prior to initial use, all new, altered or repaired

winches shall be tested to insure proper operation.

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LUBRICATION

Lubrication intervals are based on intermittent operation ofthe winch eight hours each day, five days per week. If thewinch is operated continuously, more than eight hours perday, or under heavy or severe environments lubricationshould be performed more frequently. Use only recom-mended lubricants. Other lubricants may affect theperformance of the winch. Recommended lubricants arebased on winch operation in environments relatively freeof dust, moisture, and corrosive fumes. Approval for theuse of other lubricants, or recommendations on the properlubricant use in specific environmental situations shouldbe obtained from Wintech International. Failure to observethis precaution may result in damage to the winch and/orthe associated components.

INTERVAL LUBRICATION CHECKS

Start of each shift Visually inspect winch gearlubrication.

Monthly Lubricate components supplied bygrease fittings.Inspect wire rope lubrication andcleanliness.Check reduction gear oil level.

Yearly Drain and refill winch reductiongear oil.

(TBL.LUB-ELWN)Recommended LubricantsOil

Temperature Type Oil1. Below 32 °F (0 °C) SAE 10W2. 32° to 80 °F (0° to 27 °C) SAE 20W3. Above 80 °F (27 °C) SAE 30W

GreaseTemperature Type Grease

1. -20° to 50 °F EP 1 multipurpose(-30° to 10 °C) lithium-based grease

2. 30° to 120 °F EP 2 multipurpose(-1° to 49 °C) lithium-based grease

General LubricationCorrect lubrication is one of the most important factors inmaintaining efficient winch operation.1. The recommended grade of oil must be used at all

times since the use of unsuitable oil may result inexcessive temperature rise, loss of efficiency andpossible damage to the gears. Refer to the'Recommeded Lubricants' section.

2. Drain and replace oil according to the operatingenvironment as defined by the Periodic inspectioninterval table in the "INSPECTION" section, or morefrequently if desired.

3. Always inspect removed oil for evidence of internaldamage or contamination (metal shavings, dirt, water,etc.).

4. Always drain oil into a suitable container.5. Add oil slowly to prevent spilling.

Bearings and Pivot PointsComponents with grease fittings should be lubricatedmonthly with 2 or 3 pumps from a grease gun, or morefrequently, depending on severity of service. Rotatecomponents slowly as grease is applied.When the winch is disassembled, clean all parts thor-oughly and coat bushings and shafts with clean grease.Apply sufficient grease to provide a good protective coat.Refer to 'Recommended Lubricants' for grease type.

GearsLubricate working surfaces of all gear teeth. Brush withgrease as often as necessary to keep teeth liberallycovered. If grease becomes contaminated with sand, dirt orother abrasive materials clean off old grease and apply newgrease.Apply sufficient grease to provide a good protective coat.Refer to 'Recommended Lubricants' for grease type.

Wire RopeFollow the wire rope manufacturer’s instructions. At aminimum, observe the following guidelines.1. Clean with a brush or steam to remove dirt, rock dust or

other foreign material on the surface of the rope.

CAUTION

• Do not use an acid-based solvent. Only use cleaningfluids and lubricants specified by the wire rope manufac-turer.

2. Apply a wire rope lubricant, or SAE 30W oil.3. Brush, drip or spray lubricant weekly, or more

frequently, depending on severity of service.

Reduction GearThe reducer assembly is shipped with the correct gradeand quantity of lubricating oil from the factory.Check oil level before initial operation. If the winch is usedat a normal frequency replace the oil in the reducer assembly once every two years. To ensure correctperformance, highest efficiency and long life, it is essentialthat the lubricating oil be maintained at the correct level,The oil level can be checked by removing the oil level plug. The oil level must be even with the bottom of thethreaded hole.

1 1

NOTE:

Drain and replace oil in the reduction gear after the first 50hours of initial winch operation. Thereafter, replacereduction gear oil yearly if operated in normal conditionsor more frequently in severe conditions. Always replacefluid if assembly has been repaired or disassembled.

NOTICE

• Drain oil into a suitable container and recycle or disposeof properly.

MotorThe motor ball bearings are pre-packed with grease and donot require periodic greasing. Ensure replacement bearingsare of the same type and are packed with grease capable ofwithstanding temperature ranges of -20 °F to +329 °F (-29°C to +165 °C). Contact Wintech International for assistancein determining replacement motor parts.

BrakeThe brake does not require lubrication. Care should betaken to ensure lubricants do not come into contact withthe brake internals. Brake friction discs that are contami-nated with oil or grease must be replaced.

For more Specs Reference:'Gear/motor Reducer' and 'Motor/Brakemotor'manuals included within this manual binder.

1 2

This section provides basic troubleshooting information. Determination of specific causes to problems are best identified bythorough inspections performed by personnel trained in safety, operation and maintenance of this equipment. The chartbelow provides a brief guide to common winch problems, probable causes and solutions.

TROUBLESHOOTING

(TBL.ETBLSHOT)

SYMPTOM CAUSE SOLUTION

Motor overheats Motor not connected for the proper voltage. Check power supply, connections and wiring.

Supply voltage varies outside the allowabletolerance.

Assure correct supply voltage.

Ambient temperature is too high. Ensure cool air gets to the moto.

Motors allowable duty cycle is exceeded.To many starts per hour.

Reduce the duty cycle to allowable limits.

Winch is overloaded. Reduce load.

Motor does not run. Blown fuse. Determine and correct cause of failure andreplace fuse.

Motor protection device faulty. Check protection device for faults.

Motor hums and draws highcurrent.

Faulty or defective wiring. Have motor repaired by qualified service shop.

Motor will not start or startssluggishly.

Motor is not connected for correct voltage. Check wiring diagrams and correct wiring.

Large voltage and/or frequency fluctuationat starting.

Ensure stable power supply.

Motor runs in wrong direction. Motor supply leads misconnected. Switch two supply leads.

Chain jumps on sprockets or ismaking a snapping noise.

Sprockets may be out of alignment. Align sprockets correctly.

Chain requires lubrication. Clean and lubricate chain.

Brake does not release. Maximum air gap exceeded because of wornbrake pad.

Readjust brake. If brake pad is toally worn, replacebrake disc.

Rectifier failed. Replace brake coil and rectifier.

Incorrect supply voltage to rectifier. Correct the supply voltage.

Winch does not brake. Brake pad worn or air gap is too large. Replace Brake and adjust brake.

1 3

MAINTENANCE

WARNING

• Before performing maintenance, remove all loads fromthe winch. Isolate the winch electrically by pulling fuses,opening circuit breakers and disconnecting wires fromthe power source to the motor and brake. Tag winch motorcontroller and power source:

DANGER - DO NOT OPERATEEQUIPMENT BEING REPAIRED

• Only allow service personnel trained in maintenanceand operation of this equipment to perform maintenance.• After performing maintenance on load bearing parts,test unit to 110% of its rated capacity before returningto service. (Testing to more than 110% might berequired to comply with standards and regulations setforth in areas outside the USA.)

AdjustmentsBrake Adjustments (Eurodrive Motors Only)The following brake adjustment procedures are suitablefor Eurodrive motor brakes. Consult the factory for brakeadjustment procedures on other models. If the brake liningand brake coil are satisfactory, then check brake adjust-ment. A properly adjusted brake air gap is critical forcorrect operation.Prolonged use of the brake will wear the brake disc lining.This wear increases the air gap. When the air gap ap-proaches its maximum value, the brake must be re-adjusted. To re-adjust the brake, use the followingprocedures:

1. Remove the fanguard, fan retainer ring, fan, rubberseal and any accessories mounted on the motor at thefan end.

2. Insert a feeler guage between the brake coil body andthe stationary disc, tighten the brake adjustment nutsuntil the minimum value for the air gap is reachedequally around the brake. For Specs:(REF: 'Motors & Brakemotors' InstructionManual) - Included within this manual binder.

3. If correct air gap adjustment cannot be achieved thebrake disc may be worn beyond the acceptable limits.Measure the thickness of the brake disc to determineif this has occured. If the brake disc is worn below theminimum thickness it must be replaced. For Specs:(REF: 'Motors & Brakemotors' InstructionManual) - Included within this manual binder.

4. Re-install accessories, rubber seal, fan, fan retainerring and fanguard.

5. Since the stationary disc will move away from the coilbody during the brakes operation it is important thereis free play in the release arm. Ensure a play of0.06 to 0.08 in. (1.5 to 2 mm) in the release arm. Thesprings should be placed between the release arm andnuts to eliminate noise.

Chain AdjustmentRemove chain guard.Check the condition of the chain for damage or wear.Check the chain adjustment as follows:1. Place a straight edge on top of the chain bridging the

two chain sprockets.2. Place a measuring rule on the top of the chain mid-

point between the two chain sprockets. Apply aninward force perpendicular to the chain. Proper chaintension is 3/8 in. (10 mm) on the rule side.

3. To increase chain tension, tighten adjustment bolts atbase of motor until correct chain tension is achieved.

General DisassemblyThe following instructions provide the necessary informa-tion to disassemble, inspect, repair, and assemble thewinch. Drawings of the winch and associated componentsare provided in the parts section to assist in part indentifi-cation. If a winch is being completely disassembled forany reason, follow the order of the topics as they arepresented. It is recommended that all maintenance work onthe winch be performed in a clean, dust free work area.During winch disassembly observe the following:

1. Never disassemble the winch any further than isnecessary to accomplish the needed repair. A goodpart can be damaged during the course of disassem-bly.

2. Never use excessive force when removing parts.Tapping gently around the perimeter of a part with asoft hammer should be sufficient to loosen the part.

3. Do not heat a part with a flame to free it for removal,unless the part being heated is already worn ordamaged beyond repair and no additional damage willoccur to other parts.

In general, the winch is designed to permit easy disassem-bly and assembly. The use of heat or excessive forceshould not be required.

4. To prevent dirt and other foreign matter from gettinginto bearings or other moving parts keep the work areaas clean as practical.

5. When grasping a part in a vise always use leather orcopper-covered vise jaws to protect the part. This isespecially important when clamping threaded areasand machined surfaces of parts.

Winch Disassembly

Disconnect all power to the winch before startingdisassembly. Remove wire rope and limit switches ifequipped.1. Remove capscrews and lift off chain guard.2. Disconnect and remove chain.

1 4

3. Loosen setscrews and remove sprocket and key fromthe motor and reduction assembly shaft.

4. Remove capscrews, lockwashers, washers and lock-nuts. Using an overhead hoist with sufficient capacityto safely support the weight of the motor and reduc-tion assembly, remove the motor and reductionassembly from the frame.

5. Remove capscrews, lockwashers, washers and lock-nuts from drum/shaft bearings. Using an overheadhoist with sufficient capacity to safely support theweight of the drum/shaft assembly, remove the drum/shaft assembly from the frame.

6. Remove bearings from each end of drum/shaftassembly.

7. Carefully set the drum/shaft assembly in an area whichwill not cause damage to the sprocket teeth.

Motor/Reduction Gear assembly

NOTICE• Motor/reduction disassembly is not recommended ordiscussed in this manual. For additional information onmotor/reduction disassembly reference the: 'Gear/motor Reducer' and 'Motor/Brakemotor'manuals included within this manual binder.

• To prevent damage to components, do not useexcessive force when removing the motor/reductionassembly.

CAUTION• To prevent possible equipment damage and/or injurysupport the motor/reduction gear before removingfrom winch assembly.

NOTICE• Disassemble the motor/reduction gear only if repairsare required. To prevent damage to components, donot use excessive force when removing the motor/reduction gear assembly.

1. Disconnect motor/reduction gear assembly from frameby removing capscrews, locknuts and lockwashers.

2. Remove drain plugs. Remove fill plug. Drain thereduction gear oil into a suitable container and disposeof oil in an environmentally safe manner. It isrecommended that the motor/reduction gear assemblybe moved to a clean work area before continuingdisassembly.

Drum

1. Using a hoist, support the drum. If the wire rope is onthe drum, secure the wire rope end to keep it out ofthe way.

2. Remove all accessible paint and surface imperfections

from the drum shaft. Coat the exposed shaft surfacewith oil.

3. Remove the capscrews securing the drum shaftbearings to the frame.

4. Carefully lower the drum/shaft assembly to the groundafter bearings has been removed.

Cleaning, Inspection and RepairUse the following procedures to clean, inspect, and repairthe winch and associated components.CleaningClean all winch component parts in solvent (except forinternal brake and motor parts). The use of a stiff bristlebrush will facilitate the removal of accumulated dirt andsediments on the gears, frames and drum. Dry each partusing low pressure, filtered compressed air.

InspectionAll disassembled parts should be inspected to determinetheir fitness for continued use. Pay particular attention tothe following:1. Inspect all gears for worn, cracked, or broken teeth.2. Inspect all bearings for wear, scoring, or galling.3. Inspect all electrical wires, connections and covers.

Replace damaged, frayed and broken wires.Connections must be tight. Remove corrosion atconnections using a wire brush. Covers and seals mustprovide an air-tight seal.

4. Inspect shafts for ridges caused by wear. If ridgescaused by wear are apparent on shafts, replace theshaft.

5. Inspect all threaded items and replace those havingdamaged threads.

RepairComponent repairs are limited to the removal of smallburrs and other minor surface imperfections from gears,bushings and shafts. Use a fine stone or emery cloth forthis work.1. Inspect all parts for evidence of damage. Worn or

damaged parts must be replaced. Contact WintechInternational for specific replacement partsinformation.

2. Using a fine stone or emery cloth, smooth out allminor nicks, burrs, or galled spots on shafts, bores,pins, and bushings.

4. Examine the gear teeth carefully. Using a fine stone oremery cloth, remove any small nicks or burrs. Replacethe gear if any teeth are chipped, cracked, stretched ormissing.

5. Using a fine stone or emery cloth, polish the edges ofall shaft shoulders to remove small nicks which mayhave been caused during handling.

6. Remove any nicks and burrs caused by capscrews,nuts and lockwashers.

7. Disassemble corroded electrical connections andindividually clean items, or replace fasteners, clamps

1 5

and wires as necessary.

Bearings

WARNING• Bearings that are loose or worn must be replaced.Failure to observe this precaution will result inadditional component damage.

1. Inspect the new bearing. Remove minor nicks andburrs using fine emory cloth or a stone. Lightlylubricate the bearing with grease recommended in the"LUBRICATION" section.

Winch Assembly

1. Position frame on a flat and sturdy surface or work-bench.

2. Wipe clean and lightly lubricate bearing shafts on thedrum. Install one bearing on each drum shaft.

3. Using an overhead hoist with sufficient capacity tosafely support the weight of the drum/shaft assembly.Position the drum/shaft assembly on the frame.

4. Align the bearing mounting holes with mounting holeson frame.

5. Install mounting bolts, locknuts, lockwashers andtorque to specifications.

Torque specs:Bolts(3/4-10nc), locknuts, lockwashers [Dry-380ft.lbs.(515Nm), Lubricated-280 ft.lbs.(380Nm)].

6. Using an overhead hoist with sufficient capacity tosafely support the weight of the motor/reductionassembly. Position the motor/reduction assembly onthe frame.

CAUTION

• To prevent possible damage to equipment and/orinjury support the motor/reduction gear assemblyduring installation onto winch.

7. Align the motor/reduction mounting holes withmounting holes on frame.

8. Loosely install mounting bolts, locknuts, lockwashers.9. Install key and sprocket on output shaft of motor/

reduction assembly.

NOTICE

• Do not force sprocket onto output shaft by hammer-ing. Doing so may cause premature bearing failure.

10. Using a straight edge position sprocket so it alignswith the sprocket on the drum. Install setscrews withLoctite® 609 or equivalent and tighten.

11. Install chain, to obtain correct chain tension it may benecessary to use a chain half link.

12. Chain tension is obtained by tightening the adjustmentbolts located on the frame at the base of the motor/reduction assembly. For proper chain tension refer-ence the 'Chain Adjustment' instructions in the"MAINTENANCE" section.

13. After chain tension is correct tighten and torquemotor/reduction gear assembly bolts to frame.

Torque specs:Bolts(3/4-10nc), locknuts, lockwashers [Dry-380ft.lbs.(515Nm), Lubricated-280 ft.lbs.(380Nm)].

14. Install chain guard, tighten bolts.15. When assembled, lubricate as described in the

"LUBRICATION" section.16. When completely assembled verify winch operation as

described in 'Testing' in the "MAINTENANCE"section.

17. Check all warning labels and tags are clearly visible.

TestingOperational TestsPrior to initial use, all new, altered or repaired winchesshould be tested to ensure proper operation.

a) Check all mounting bolts are in good conditionand properly secured.

b) Check operation of limit switches, and locking orsafety devices when provided.

d) Operate winch in both directions with no load.

Load TestPrior to initial use, all new, extensively repaired, or alteredwinches shall be load tested by or under the direction of aperson trained in safety, and the operation and maintenanceof this winch. A written report must be completed confirm-ing the testing and rating of the winch. Test loads shouldnot be more than 110% of the rated line pull.

1 6

PARTS ORDERING INFORMATION

Return Goods Policy

Wintech International will not accept any returned goods forwarranty or service work unless prior arrangements havebeen made and written authorization has been providedfrom the location where the goods were purchased.

When the life of the unit has expired, it is recommendedthat it be disassembled, degreased and parts separated asto materials so that they may be recycled.

For additional information contact:

Wintech International Inc.5319 Shreveport/Blanchard Hwy.Shreveport, LA. 71107Phone: (318) 929-1242 1-888-946-8325Fax: (318) 929-1245

The use of other than Wintech International replacement parts may damage or impair the operation of this winch.For your convenience and future reference it is recom-mended that the following information be recorded.

Model Number:

Serial NumbersWinch:Motor:Brake:

Date Purchased:

When ordering replacement parts, please specify thefollowing:1. Complete model number and serial number(s) as they

appear on the nameplates.2. Part number(s) and part description as shown in this

manual.3. Quantity required.

The winch nameplate is located on the side frame. Themotor nameplate is located on the motor housing, and thebrake nameplate is located on the brake housing.If a nameplate is not attached to your unit, order a newnameplate and install it. See the parts list for the partnumbers.

NOTICE

• Continuing improvement and advancement of design maycause changes to this equipment which are not included inthis manual. Manuals are periodically revised to incorpo-rate changes. Always check the manual edition numberon the front cover for the latest issue.

1 7

HOIST AND WINCH LIMITED WARRANTYWintech International (Wintech) warrants to the original user of its Hoists and Winches (Products) to befree of defects in material and workmanship for aperiod of one year from the date of purchase.Wintech will repair, without cost, any Product foundto be defective, including parts and laborcharges, or at its option, will replace suchProducts or refund the purchase price less areasonable allowance for depreciation, inexchange for the Product. Repairs or replace-ments are warranted for the remainder of theoriginal warranty period.

If any Product proves defective within its originalone year warranty period, it should be returned toany Authorized Hoist and Winch ServiceDistributor, transportation prepaid with proof ofpurchase or warranty card.

This warranty does not apply to Products whichWintech has determined to have been misused orabused, improperly maintained by the user, orwhere the malfunction or defect can be attributedto the use of non-genuine Wintech parts.

IMPORTANT NOTICEIt is our policy to promote safe delivery of allorders.

This shipment has been thoroughly checked,packed and inspected before leaving our plant andreceipt for it in good condition has been receivedfrom the carrier. Any loss or damage which occursto this shipment while enroute is not due to anyaction or conduct of the manufacturer.

Visible Loss or DamageIf any of the goods called for on the bill of ladingor express receipt are damaged or the quantity isshort, do not accept them until the freight orexpress agent makes an appropriate notation onyour freight bill or express receipt.

Concealed Loss or DamageWhen a shipment has been delivered to you inapparent good condition, but upon opening the

crate or container, loss or damage has taken placewhile in transit, notify the carrier’s agent immedi-ately.

Damage ClaimsYou must file claims for damage with the carrier. Itis the transportation company’s responsibility toreimburse you for repair or replacement of goodsdamaged in shipment. Claims for loss or damage inshipment must not be deducted from theWintech International invoice, nor should payment ofWintech International invoice be withheld awaitingadjustment of such claims as the carrier guaran-tees safe delivery.

You may return products damaged in shipment tous for repair, which services will be for youraccount and form your basis for claim against thecarrier.

Wintech makes no other warranty, and all impliedwarranties including any warranty ofmerchantability or fitness for a particularpurpose are limited to the duration of theexpressed warranty period as set forth above.Wintech’s maximum liability is limited to thepurchase price of the Product and in no eventshall Wintech be liable for any consequential,indirect, incidental, or special damages of anynature rising from the sale or use of the Product,whether based on contract, tort, or otherwise.

Note: Some states do not allow limitations onincidental or consequential damages or how longan implied warranty lasts so that the abovelimitations may not apply to you.

This warranty gives you specific legal rights andyou may also have other rights which may varyfrom state to state.

WARRANTY

1 8Printed in USA

For Order Entry, Order Status, andTechnical Support:

Wintech International Inc.5319 Shreveport/Blanchard Hwy.Shreveport, LA. 71107

Phone: (318) 929-1242 1-888-946-8325Fax: (318) 929-1245

United States Office Location