BLOOM MANUFACTURING INC.
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NEW WINCH OPERATORS MUST READ AND UNDERSTAND IT
Safety, Warranty, Maintenance & Repair, Installation and Operation Manual
Bloom™ Hydraulic Cable Winches
800HC, 1000HC & 1100HC & 1200HC Series
All Bloom winches have the model and serial number stamped on the gear case cover. Please take a few
minutes to record these numbers for future use.You will need these numbers for orderingparts orgatherin
service information from the factory:
Model #______________________________ Serial #______________________________
Thank you for your purchase of a quality Bloom product !
THIS MANUAL MUST BE KEPT WITH THE WINCH AT ALL TIMES AND
.
REV. 07-2007
B l o o m M a n u f a c t u r i n g I n c .
Winch Division
1443 220th Street
Independence, IA 50644
www.bloommfg.com
Email: sales@bloommfg.com engineering@bloommfg.com
800-394-1139 tel
319-827-1139 tel
319-827-1140 fax
Table of Contents
(a)
Cl
d I
t
(a)
Cable C
y (sp
)
y( p )
1. General Safety Requirements 4. Winch Break In
2. Warranty 5. Winch Installation
3. Maintenance & Repair 6. Winch Operation
ean an
(b) Oil Change Information (b) The Importance of a Proper Fleet Angle
(c) Oil Level (c) Wire Rope Anchor & Wrapping
(d) Recommended Gear Oil (d) Automatic Safety Brakes & Adjustment
(e) Inserts:
-Assembly (specific model)
- Disassembl
- Parts List (specific model)
-Assembly Check Valve Kit
- Replacement of Clutch Handle and Yoke
Merchandise may not be returned without approval from factory. The customer will be charged for placing the returned
goods in salable condition plus a restocking charge of 25%. All returns must be shipped prepaid.
nspec
onsiderations
ecific model
Please note that not all of the sections of the Table
of Contents apply to each model purchased
Section 1 General Safety Requirements
THIS SYMBOL MEANS
• Attention!
• Become Alert!
• Your Safety Is Involved
SIGNAL WORDS: Note the use of the signal words DANGER, WARNING AND CAUTION with the safety messages.
The appropriate signal word for each has been selected using the following guidelines:
• DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
This signal word is to be limited to the most extreme situations typically for machine components
which, for functional purposes, cannot be guarded.
• WARNING:
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious
injury, and includes hazards that are exposed when guards are removed. It may also be used to
alert against unsafe practice.
Take Note! This Safety Alert Symbol Found Throughout This
Manual Is Used To Call Your Attention To Instructions Involving
Your Personal Safety And The Safety Of Others. Failure To
Follow These Instructions Can Result In Injury Or Death.
2
• CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
Bloom Mfg Inc. 319-827-1139 319-827-1140 fax www.bloommfg.com
CAUTION
the
t this winch
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cause failure of the cable or of the winch
This sample manual is based upon general industry considerations and does not take into account product or manufacturer
WARNING
• Bloom winches are not to be used to lift, hoist, or move people. If your task involves lifting or moving people, you
must use
• Cable anchors on Bloom winches are not designed to hold the rated load of the winch. You must keep at least five (5)
wraps of cable on the drum to ensure that the cable doesn’t come loose. We suggest that the last 5 wraps of cable be
painted bright red to serve as a visual warning.
• Stay clear of suspended loads and of cable under tension. A broken cable or dropped load can cause serious injury or
death.
• No equipment should be installed, operated, or maintained by any person who has not carefully read all contents of this
manual. Serious physical injury or property damage can result from failure to read and apply the instructions contained
therein. Therefore, we urge you to read all operating instructions and warnings carefully. If any instruction or warning is
not clear, or if you feel you need additional information, please contact Bloom Mfg Inc. This manual should not be
understood to prepare you for every possible situation. It is the owner’s and user’s responsibility to determine the
suitability of a product for a particular use. Applicable industry, trade association, federal, state, and local regulations
should be reviewed.
• Make sure that all equipment, including the winch and cable, is maintained properly. Pay especially close attention to the
clutch, making sure that it fully engages when shifted.
Winches equipped with free spooling dog clutch should never be used in a lifting application.
proper equipment, no
Failure to Heed The Following Warnings
May Result In Serious Injury Or Death
.
• Avoid shock loads. This type of load imposes a strain on the winch many times the actual weight of the load and can
.
• Bloom products are sold on the strict understanding that all products selection is the full responsibility of the purchaser.
• Bloom accepts no liability for the use, misuse or incorrect application of its products.
• Leather gloves should be used when handling winch cable.
• Ensure the correct equipment is obtained and installed for the application.
• Ratings shown in Bloom literature are applicable only to new products.
• Working load limits shown are the maximum load the product is authorized to support under normal environmental
conditions. Shock loading and abnormal conditions must be taken into account when selecting products.
• In general, products displayed in Bloom literature are used as parts of a system. As a result, we can only recommend
within the working load limits, or other stated limitations, the use of products for this purpose.
• Working load limits or safety factors for each Bloom product may be affected by wear, misuse or environmental
conditions. Regular inspection must be conducted to ensure the equipment continues to meet the published standards.
If you have questions not answered in this manual or require additional copies or the manual is damaged, please contact
Bloom Mfg., Inc., 1443 220th Street, Independence, Iowa 50644.
specific exposures or needs. This sample manual may not be adopted by a product manufacturer as its manual, but may
be used by the manufacturer in the process of developing its own manual, based upon its specific products and operations,
after consulting with its advisor.
THINK S-A-F-E-T-Y FIRST Bloom Mfg Inc. 319-827-1139
3
Section 2
EXPRESSLY DISCLAIMS ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE
p
pp p, y,
Warranty
LIMITED NINETY (90) DAY WARRANTY FOR HYDRAULIC CABLE & CAPSTAN WINCHES
Effective date January 1, 1999
Bloom Mfg. Inc., Independence, Iowa 50644, provides the following LIMITED NINETY (90) DAY WARRANTY on its product to
the purchaser of this product and to any person to whom such product is transferred during the duration of this warranty. The
warrantor's obligation shall be limited to repairing or replacing at the factory in Independence, Iowa, any part or parts which
shall within the NINETY (90) DAY period hereinafter specified be returned to it with transportation prepaid and which upon
examination by Bloom Mfg. Inc. shows to have been defective. This warranty shall not apply if:
(a) the product has been altered, repaired or modified outside the warrantor's factory in any way that would adversely affect
its operation.
(b) the product has been subject to careless or negligent misuse, damage or use of improper oil while in the possession of the
purchaser or any person to whom the product was transferred by the purchaser or was installed or operated other than in
accordance with the manufacturer's operating instructions.
(c) the product was used with accessories not recommended by Bloom Mfg. Inc. or for loads in excess of those listed as rated
for the product.
(d) in the case of hydraulic motors, Bloom Mfg. Inc. will not accept responsibility and warranty will be subject to manufacturer's
warranty.
The NINETY (90) DAY LIMITED WARRANTY period shall commence with the date the product is sold to the purchaser by the
dealer or if this date cannot be established, the date the product was sold by Bloom Mfg. Inc. to the dealer.
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE ARE LIMITED TO
THE DURATION OF THIS WARRANTY - NINETY (90) DAYS -AFTER SAID (90) DAYS, BLOOM MFG. INC.
.
Purchase or other acceptance of the product by the claimant shall be on the condition and agreement that BLOOM MFG.
INC. SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL OR CONTINGENT DAMAGE, SECONDARY
CHARGES OR LOSS OR EXPENSE RESULTING FROM ANY ALLEGED DEFECT, FAILURE OF ARTICLE TO OPERATE
PROPERLY, OR FOR THE NEGLIGENCE OF OTHERS OR DAMAGES OF ANY KIND.
Bloom Mfg. Inc. is not responsible for the cost, of removal of product, damages due to removal or any other expenses
incurred in shipping the product to or from Bloom Mfg. Inc. or the installation of the repaired or replacement product. The
consumer must bear these expenses.
To make a claim under this warranty, write directly to Bloom Mfg. Inc., Independence, Iowa 50644, identifying the product and
giving its location and follow the company's return instructions which will be provided by the company. Bloom Mfg. Inc. will
make its best efforts to re
(60) DAYS after return of the product to the company.
air or replace the product, if found to be defective within the terms of this warranty, within SIXTY
This warranty is exclusive and in lieu of all other warranties whether written, oral or implied (including any warranty of
merchantability or fitness for a particular purpose.
4
For Best Results, Only Use Bloom Replacement Parts 800-394-1139
Section 3 Maintenance & Repair
(a)
Clean and Inspect:
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they can be used again. Always coat O
rings, bearings, bushings and the rubber parts of seals with oil during
assembly.
Make sure that there is no load on the winch cable and that all of the
hydraulic hoses have been disconnected before servicing unit.
CAUTION
A winch, like other types of machinery, needs to have regular maintenance if it is to perform properly, give lasting service,and
provide safe winching.
Thoroughly clean all of the parts in a good grade of cleaning solvent; one that is not flammable, not toxic and will not
cause skin rashes. If necessary, use rubber gloves. Inspect all parts for wear, nicks, scratches and damage that would
render them unusable. If a part is questionable, it is better to replace it rather than take a chance on premature failure
when the winch is placed back in service. Always replace O-rings and seals, and it is a good idea to use new roll pins
as well. Sometimes it is permissible to reuse bearings and bushings...it depends on how much use they have had. The
rollers should not exhibit any surface irregularities. If the rollers show any sign of spalling, corrosion, discoloration,
material displacement or abnormal wear, the bearings should be replaced.
Likewise, the cage should be inspected for unusual wear or deformation, particularly the cage bars. If there is any
damage that will impair the cage’s ability to separate, retain, and guide the rollers properly, the bearing should be
replaced. The thrust washer contact areas should be free from any surface irregularity that might cause excessive
abrasion or friction. If the winch was disassembled only to replace damaged seals after a short period of service, it is
not necessary to replace the bearings. Experience and common sense, along with a good inspections, will determine if
Use a light coat of thread sealing compound on pipe fittings and plugs.
(b) Oil Change Information:
The winch vent/fill and drain plugs are located at the base of the face plate. Oil should be changed every 100 hours of
operating time, or every six months, whichever comes first.
(c) Oil Level:
To check the oil level, remove the level plug. The oil should be level with the bottom of this opening. If more oil is
needed, use the recommended gear oil listed below.
OIL CAPACITY CHART
Winch
Note:
Base mounted position is
Type
Cable
when the worm shaft is
below the bronze gear.
Cable
Bloom Mfg Inc. 319-827-1139 319-827-1140 fax www.bloommfg.com
Winch Series
800HC,
1000HC, 1100HC
1200HC
Base Mounted
Position*
1 Pint
2 Pints
All Other Mounting
Positions
2 Pints
3 Pints
5
(d) Recommended Gear Oil:
•
Use extreme care when first spooling cable onto the winch. Do not run the winch at
that y
h is
ly
d in order for it to f
yy , yy
Thread
13 UNC
13 UNC
13 UNC
13 UNC
Use BLOOM ULLTRA-LUBE NO. 601 trans-worm gear oil; available from Bloom in pints or quarts. For emergency
situations when BLOOM ULLTRA-LUBE NO. 601 is not immediately available, use Phillips 66 Company SAE grade
80W90 superior multi-purpose gear oil (Phillips 80W90 SMP) meeting API classification GL-5 or equivalent brand.
Continuous use of oil other than BLOOM ULL TRA-LUBE NO. 601 or Phillips 80W90 SMP oil may shorten the life of the
gears. DO NOT mix BLOOM #601 or Phillips 80W90 SMP with more than 50% of any other kind of oil.
Section 4 Winch Break In
• Winches, like any other kind of machinery, require a “break in” to perform well and to
maximize their life.
high speeds when performing this operation.
• Make sure that the cable is unrolled in a line (to prevent kinks) and slowly inhaul the
winch to install the cable.
CAUTION
• Do not exceed one half rated load or one half rated line speed for the first thirty
minutes of operation. This will ensure that the worm and gear have an opportunity to
wear in properly.
• Periodically, check the gearbox for temperature rises and allow the winch to cool
down between pulls.
Section 5
CAUTION
HARDWARE
REQUIREMENTS
Winch Installation
•You must make sure
properly and to ensure safe operation.
• The mount must be flat to ensure proper alignment between the gearbox side, the
drum, and the clutch.
• Winches must never be fastened directly to the frame of a truck. Mounting
brackets should be used.
• With a hydraulically driven winch, make sure the hydraulic system is clean and that
all components function properly, especially the relief valve.
Winch Series
Base Mount (steel)
Thickness
Angle Mounts (steel)
Length
Width
Thickness
our winc
secure
800HC
1/2”
2-1/2”
2-1/2””
1/4”
mounte
1000HC
1/2”
2-1/2”
2-1/2””
1/4”
1100HC
1/2”
2-1/2”
2-1/2””
1/4”
unction
1200HC
1/2”
2-1/2”
2-1/2””
1/4”
Capscrews (Hexhead)
Size
Grade
Torque / Tightening (foot pounds)
6
THINK S-A-F-E-T-Y FIRST Bloom Mfg Inc. 319-827-1139
1/2”
5
57
1/2”
5
57
1/2”
5
57
1/2”
5
57
Section 6
Do not attempt to defeat the relief valve.
(2)
Engage the drum clutch dog (make sure clutch is fully engaged).
Drum
Cable Diameter (inches)
Winch Seri
Winch Operation
• To familiarize yourself with the winch, run it for a few minutes to understand the controls and the “feel” of the winch.
• Pay particular attention to the controls and how they operate. Make sure you understand which way the winch will
rotate when the control lever is moved.
• Always make sure that all people are clear of the load and of the cable area before beginning a winching operation.
• Ensure that proper protective wear is worn while operating winch.
• A broken cable can fly in any direction.
•
• If you have any doubts about the capability of the winch to lift or move a load, either put a “snatch block” in the line or
get a bigger piece of equipment.
Winch pulling application:
(1)Attach winch cable to load.
(3)Make sure no one is in the immediate area of the load or of the cable
(4)Begin winching the load slowly, watching carefully to ensure that the load is moving normally.
(5)When the load is positioned where you want it, stop the winch.
DRUM CAPACITY
(FEET)
es
800HC,
1000HC,
1100HC,
& 1200HC
Designation 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8
S ----- 120 70 45 30 25 ----- ----S8 ----- 260 160 105 75 55 ----- ----L ----- 175 105 65 45 30 ----- ----L8 ----- 390 240 160 110 80 ----- ----XL10 ----- 840 550 340 250 170 ----- ----XL12 ----- 1320 840 580 380 280 ----- ----XL14 ----- 1900 1180 760 540 410 ----- -----
Consult your local cable supplier for recommendations on the best type of cable
and hardware to use in your specific application.
(a) Cable Considerations:
As the number of layers of cable on a winch increases, the rated lifting capacity of the winch goes down. If you are
operating at near the top of the drum flanges, the effective rating of the winch is about half of what it is on the first layer.
You should, therefore, only keep as much cable on the winch as you need for your job.
For Best Results, Only Use Bloom Replacement Parts 800-394-1139
7
Never use larger or smaller cable on your winch than is recommended for it. The use of larger cable will not allow you to
Direction To Raise Load
d hyd
) to hold
d loads.
pull larger loads and may, in fact, break easier than the proper size cable. The use of smaller cable may overheat the
winch due to the increased running time with more cable.
(b) The Importance of a Proper Fleet Angle:
Maintaining the proper fleet angle is important to the success of your winching operation, the life of your winch and the
life of the cable you are using. The fleet angle can best be described by the following diagram:
The fleet angle should be kept as small as possible to ensure proper spooling and to maximize cable and winch life. To
promote even cable spooling, keep the fleet angle below three degrees. Never pull directly against the flange of the
winch cable drum as this may cause the cable or the winch to break. Adherence to these instructions will ensure better
spooling.
(c) Wire Rope Anchor & Wrapping:
Prepare the end of the wire rope as recommended by the wire rope manufacturer. Pass the free end of the wire rope
through the small opening of the cable drum anchor pocket. Lock the cable into the drum by tightening the cable anchor
set screw.
PROPER FLEET ANGLE
Cable Anchor
Set Screw
Drum
Centerline
Cable
Fleet Angle
3 Deg. Max.
PROPER WRAPPING OF WIRE ROPE
Cable
Drum will turn counter clockwise
LOAD
to spool cable onto drum
(d) Automatic Safety Brake:
Bloom 800H, 1000H, 1100H & 1200H series winches are equipped with an automatic hydraulic failsafe brakes ( spring
applie
Spring applied hydraulic release brake automatically holds load when hydraulic pressure is released. There are
no adjustments to these brakes. They are adjusted only at the factory. DO NOT attempt to change any brake setting in
the field. Double counter balance valve adds additional load holding capability by locking hydraulic oil in motor.
Bloom Mfg Inc. 319-827-1139 319-827-1140 fax www.bloommfg.com
raulic release
suspende
8
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