PARTS LIST AND PART DRAWING ......................................................................... 13-16
SPECIFICATIONS*
Rated Line Pull (lbs.) 177,9 kN (40,000 lb)
Noise Level 76db
Ambient Tempereature Range -28C to 60C (-20F to 140F)
Gear Reduction 51.35:1
Weight (without rope) 365 kg (804 lb)
*Rated line pull
per layer
*Rope capacity
per Layer
*Line speed
at 64,3 LPM
(at 17 GPM)
* These specifications are based on recommended 20mm (.787") Bridon Dyform
34LR/PI/MAX 1960 grade wire rope or equivilant with minimum breaking strength
of 355,8 kN (80,000 lb) and a 195 cc (11.9 cu in /rev)
kN
Lbs.
M.
Ft.
MPM
FPM
12LAYER OF ROPE
177,9
40,000
9
30
4,2
13.8
149,5
33,600
19
65
5,0
16.3
345
128,5
28,900
33
110
5,7
18.8
113,0
25,400
48
160
6,5
21.3
100,1
22,700
65
215
7,3
23.8
WARNINGS:
THE USER SHALL ENSURE THAT THE OPERATING PERSONNEL ARE GIVEN THE NECESSARY TRAINING.
THE OPERATOR SHALL ALWAYS WORK IN COMPLIANCE WITH THE OPERATING INSTRUCTIONS.
A MOTOR SPOOL (OPEN CENTER) DIRECTIONAL CONTROL VALVE IS REQUIRED FOR BRAKE OPERATION.
CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING.
DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.
STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE.
DO NOT EXCEED MAXIMUM LINE PULL RATINGS SHOWN IN TABLE.
DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PEOPLE.
A MINIMUM OF 2 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.
AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR. EXCESSIVE “INCHING” SHALL BE AVOIDED.
USER’S RESPOSIBILITY FOR CE COMPLIANCE
1. Use only a motor spool (open center) control valve per Hydraulic System Requirements.
2. If a remote-operated winch control valve is used, refer to Hydraulic System Requirements for Emergency Stop
components to be installed.
3. Adjust system relief pressure per Hydraulic System Requirements.
4. Mount winch per Winch Mounting Instructions.
5. Install 20mm (.787 inch), grade 1960 wire rope with minimum breaking strength of 355,8kN (80,000 lb). Maximum rope length of 65 m (215 ft) for five layers maximum. Attach rope per Rope Installation Instructions. Hook
must have a safety latch and a minimum breaking strength of 445 kN.
1
Refer to the performance charts below to properly match your hydraulic system to the winch performance. The
charts consist of: (1) Line Pull first layer kN (lb) vs. Working Pressure (PSI). (2) Line Speed, first layer MPM
(FPM) vs. flow LPM (GPM).
HYDRAULIC SYSTEM REQUIREMENTS
1. Motor spool (open center) control valve.
2. Emergency Stop:
A. If winch is controlled by a direct-operated manual valve, that valve serves as the E-stop.
B. If a remote operated control valve is used, a solenoid-operated hydraulic dump valve, normally open to
tank, and an emergency stop switch (to open the dump valve) is required. The E-stop switch is to be
normally closed and have a red, resettable push button actuator with yellow background. The E-stop
switch must be easily accessible to the operator.
3. Relief valve set at 193 bar (2800 psi) which is the rated capacity limiter.
4. Flow rate of 64,3 LPM (17 GPM) maximum. Do not exceed 75,7 LPM (20 GPM) or motor and winch may be
damaged.
5. Hydraulic fluid with a viscosity between 20-43 cSt (100-200 SUS). Maximum operating temperature 85C
(180F). Cleanliness level of ISO 17-14 or better.
DUAL-A & B PORT CONTROL
WITH BRAKE RELEASE SHUTTLE
TYPICAL LAYOUT
MOTOR
BRAKE
PORT
HIGH PRESSURE LINE
12,7 mm (.50 in)
I.D. MINIMUM
PROVIDED BY USER
LOW PRESSURE LINE
19 mm (.75 in) I.D. MINIMUM
DUMP VALVE
*
PUMP
MAX. FLOW &
PRESSURE AT
RATED LOAD:
64,3 LPM (17 GPM)
193 bar (2800 PSI)
PERFORMANCE CHARTS
10,6 (35)
9,1 (30)
7,6 (25)
6,1 (20)
4,6 (15)
3,1 (10)
1,5 (5)
0
LINE SPEED-FIRST LAYER MPM (FPM)
018,937,956,7
(0)(5)(10)(15)
FLOW LPM (GPM)
BASED ON 195 cc (11.9 cu in) MOTOR
64,3
(17)
3 POSITION
4 WAY VALVE
(MOTOR SPOOL)
REQUIRED ONLY IF REMOTE-OPERATED CONTROL VALVE IS USED. SEE 2B
*
IN HYDRAULIC SYSTEMS REQUIREMENTS. NOT REQUIRED FOR A
DIRECT-OPERATED MANUAL VALVE.
LOW SPEED
HIGH SPEED
177,9 (40,000)
155,6 (35,000)
133,4 (30,000)
111,2 (25,000)
89,0 (20,000)
66,7 (15,000)
LINE PULL-FIRST LAYER kN (lb)
44,5 (10,000)
0
WORKING PRESSURE bar (PSI) AT 64,3 LPM (17 GPM)
SYSTEM RELIEF
193 BAR (2800 PSI)
(RATED CAPACITY LIMITER)
0137,9
68,9
(0)(2000)
(1000)
E-STOP SWITCH
*
(3000)
206,8
2
WINCH FRAME MOUNTING
Use (8) 7/8 inch diameter grade 5 or better bolts to attach mounting frame to wrecker.
ROPE INSTALLATION
1. Unwind rope by rolling it out along the ground to prevent kinking. Securely wrap end of wire rope, op-
posite hook, with plastic or similar tape to prevent fraying.
2. Insert the end of rope into the slot on the inside of the drum flange. Pull the wire rope through the
pocket on the outside of the drum flange and loop back into pocket around the anchor “puck”. Use a
soft hammer to drive the back side of the wire rope, firmly seating the wire rope and anchor into the
pocket.
3. Carefully run the winch in the “reel-in” direction. Keeping tension on end of rope, spool all the rope on-
to the rope drum, taking care to form neatly wrapped layers.
INSERT WIRE ROPE
INTO SLOT IN
DRUM FLANGE
AS SHOWN
ANCHOR
PUCK
PULL WIRE ROPE
THRU POCKET AND
LOOP BACK INTO POCKET
AS SHOWN
CLUTCH OPERATION
To engage clutch:
1. Move the clutch control valve to the “clutch engaged” position.
2. Anytime the temperature is below freezing, run the motor in the “rope out” direction only until the drum
starts to turn. In extreme cold temperatures (below 0˚ F/-18˚ C), pull out on the rope by hand only
until the drum starts to turn.
3. Wait at least 3 seconds for the clutch to fully engage, after which the winch is ready to winch in the
rope.
WARNING: Do not attempt to engage the clutch by first running the winch motor and then moving the
clutch control valve to the "clutch-engaged" position while the motor is running. Do not start picking up
the load at the same time the clutch is being engaged.
To disengage clutch:
1. Run the winch in the "rope out" direction until the load is off the rope.
2. Move the clutch control valve to the "clutch-disengaged" position.
3. The rope may now be pulled off by hand.
WINCH OPERATION
The best way to get acquainted with how your winch operates is to make test runs before you use it. Plan
your test in advance. Remember, you hear your winch, as well as see it operate. Learn to recognize the
sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Gain confidence in
operating your winch and its use will become second nature with you.
The uneven spooling of rope, while pulling a load, is not a problem, unless there is a rope pileup on one end
of drum. If this happens, reverse the winch to relieve the load and move your anchor point further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of the rope.
3
MAINTENANCE
Adhering to the following maintenance schedule will keep your winch in top condition and performing as it should with a minimum of repair.
A. WEEKLY
1.
Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and
repair.
2. Check the pressure relief plug in the gear housing cover. Be sure that it is not plugged.
3. Lubricate cable with light oil.
B. MONTHLY
1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are
loose. Use grade 5 or better bolts.
Inspect the cable. If the cable has become frayed with broken strands, replace immediately.
2.
C. ANNUALLY
1.
Drain the oil from the winch annually or more often if winch is used frequently.
2. Fill the winch to the oil level plug with clean kerosene. Run the winch a few seconds with no load in
the reel in direction. Drain the kerosene from the winch.
3. Refill the winch to the oil level plug with all-purpose SAE 75W-90 synthetic gear oil.
4. Inspect frame and surrounding structure for cracks or deformation.
END OF SERVICE MEASURES
When winch reaches the end of it’s serviceable life, dispose of per local environmental regulations.
TROUBLESHOOTING GUIDE
CONDITIONS POSSIBLE CAUSE CORRECTION
OIL LEAKS
FROM WINCH
1. Seals damaged or
worn.
2. Too much oil. 2. Drain excess oil. Refer to OPERATION.
1. Check air pressure to clutch cylinder: 100
PSI Minimum required. Refer to page 10 for
port location.
BRAKE WLL NOT
RELEASE
1. Brake line disconnected or blocked.
1. Check brake function.
4
INSTRUCTIONS FOR OVERHAUL
DIS-ASSEMBLY
1. Drain oil from gear housing cover by removing pipe plug #37 and relief fitting #32. Remove tensioner assembly.
32
37
Disconnect tube #40 from elbow #43 on valve #41 and fitting #29 on brake #30b. Remove motor #33 and gasket
2.
#30a by removing (2) capscrews #22. Remove valve #41, if needed, from motor by loosening (4) capscrews #16.
16
43
41
22
33
30a
40
5
3. Remove (12) capscrews #18 to remove gear housing cover and gasket from ring gear. Remove input thrust washer,
sun gear and input carrier assembly from inside ring gear. Remove ring gear and gasket. Remove output carrier assembly. Inspect gear housing cover bushing #15 for damage or wear. Replace if damaged or excessive wear.
31
42
31
15
5
18
4. Remove (8) capscrews #20 to remove clutch retainer plate #10 from clutch piston. Remove clutch #9.
9
10
20
6
5. Remove clutch housing #27 with piston #28 inside. To remove piston from clutch housing apply air to 1/8” port. Remove orings #28 and #35 and inspect for damage or wear.
35
27
36
28
6. Remove (9) springs #39, thrust washer #26, gasket #31, output shaft #12 and spacer #13 from gear end bearing. Inspect output shaft bushing #14 for damage or wear. Replace if damaged or excessive wear.
13
12
26
14
31
39
7
7. Remove winch tie bars #2 and #3 by removing (8) capscrews #19, (8) lock washers # 24, and (4) shoulder bolts
#25. Pull gear end bearing #7 from drum assembly #1.
2
3
25
24
19
25
19
24
24
7
25
25
19
24
19
8. Pull drum assembly #1 from end bearing #6. Remove quad-rings #34 from grooves in drum bushings. Remove input
shaft #11 from end bearing. Examine splined ends of input shaft for signs of wear, replace if damaged. Examine drum
assembly #1 for signs of wear.
6
8
4
11
38
34
1
34
8
If splines inside drum driver #102 are damaged, drum driver must be replaced. Remove drum driver by unscrewing (8)
9.
capscrews #105. If bushings show signs of wear, replace by pressing old bushings from drum #101 and removing orings from grooves in drum and drum driver. Place well oiled o-rings #106 into driver and drum. Place well oiled o-ring
#107 on outside of driver. Press bushings #104 into drum driver until flange is flush and #103 is flush against drum
106
101
107
103
102
106
104
.
105
10.
Remove brake assembly screws #17 from brake #36a attaching brake to end bearing #6. Remove coupling #4 and
gasket #36e from end bearing. Take note of mounting configuration for proper mounting of parts during re-assembly.
GUIDE DE DÉPANNAGE................................................................................................ 22
INSTRUCTIONS DE RÉVISION ................................................................................ 23-27
CONFIGURATIONS DE MONTAGE ............................................................................... 28
PLAN DIMENSIONNEL .............................................................................................. 29-30
LISTE ET SCHÉMA DES PIÈCES ............................................................................. 31-34
CARACTÉRISTIQUES TECHNIQUES*
Traction nominale du câble (lb) 177,9 kN (18 143,69 kg)
Niveau sonore 76 dB
Plage de température ambiante -28 °C à 60 °C (-20 °F à 140 °F)
Démultiplication 51.35:1
Poids (sans le câble) 365 kg (804 lb)
COUCHE DE CÂBLE 1 2 3 4 5
*Traction nominale par couche
de câble
*Capacité du câble par couche m
*Vitesse du câble à 64,3 l/min
(17 g/min)
*Ces caractéristiques se fondent sur un câble en acier recommandé de 20 mm (0,787 po), Bridon Dyform 34LR/PI/MAX de
calibre 1960 ou équivalent avec une force de rupture minimum de 355,8 kN (80 000 lb) et un moteur de 195 cm
kN
lb
pi
m/min
pi/min
177,9
40,000
9
30
4,2
13.8
149,5
33,600
19
65
5,0
16.3
128,5
28,900
33
110
5,7
18.8
113,0
25,400
48
160
6,5
21.3
100,1
22,700
65
215
7,3
23.8
3
(11,9 po3)/tr.
AVERTISSEMENTS :
L’UTILISATEUR DOIT VEILLER À CE QUE TOUT OPÉRATEUR REÇOIVE LA FORMATION NÉCESSAIRE.
L’OPÉRATEUR DOIT TOUJOURS TRAVAILLER EN CONFORMITÉ AVEC LES INSTRUCTIONS D’UTILISATION.
UN DISTRIBUTEUR À TIROIR CYLINDRIQUE DE MOTEUR (CENTRE OUVERT) EST OBLIGATOIRE POUR LE
FONCTIONNEMENT DU FREIN.
L’EMBRAYAGE DOIT ÊTRE ENTIÈREMENT ENCLENCHÉ AVANT DE COMMENCER TOUT TREUILLAGE.
NE PAS METTRE LE MOTEUR DU TREUIL EN MARCHE AVANT D’AVOIR ENCLENCHÉ L’EMBRAYAGE.
NE RELÂCHEZ JAMAIS L’EMBRAYAGE EN PRÉSENCE D’UNE CHARGE.
NE VOUS PLACEZ JAMAIS SOUS UNE CHARGE SOULEVÉE NI À PROXIMITÉ.
RESTEZ À L’ÉCART DU CÂBLE LORS DU TREUILLAGE. N’ESSAYEZ PAS DE GUIDER LE CÂBLE.
NE DÉPASSEZ PAS LES CARACTÉRISTIQUES DE TRACTION NOMINALES MAXIMALES INDIQUÉES DANS
LE TABLEAU.
N’UTILISEZ PAS LE TREUIL POUR SOULEVER, MAINTENIR OU TRANSPORTER DES PERSONNES.
IL CONVIENT DE CONSERVER AU MINIMUM DEUX TOURS DE CÂBLE AUTOUR DU TAMBOUR POUR
MAINTENIR LA CHARGE.
RESPONSABILITÉ DE L’UTILISATEUR POUR LA CONFORMITÉ AUX NORMES CE
1. Utilisez uniquement un distributeur à tiroir cylindrique de moteur (centre ouvert), conformément aux indications
fournies sous la rubrique Caractéristiques du système hydraulique.
2. En cas d’utilisation d’un distributeur de treuil commandé à distance, consultez la rubrique Caractéristiques du
système hydraulique pour déterminer les composants à installer pour le dispositif d’arrêt d’urgence.
3. Réglez la pression de décharge du système conformément aux instructions de la rubrique Caractéristiques du
système hydraulique.
4. Montez le treuil conformément aux instructions fournies sous la rubrique Installation du treuil.
5. Installez un câble en acier de 20 mm (0,787 po) de calibre 1960 avec une force de rupture minimale de 355,8 kN
(80 000 lb). La longueur de câble maximale est de 65 m (215 pi) pour cinq couches maximum. Attachez le câble
conformément aux instructions d'installation.
19
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