Beruflich Dokumente
Kultur Dokumente
MODELS
Left Hand Right Hand
20HL 20HR
25HL 50HL 25HR 50HR
75HL 75HR
WARNING
Do not use this winch for lifting, supporting, or transporting people or lifting or supporting loads over
people.
Always operate, inspect and maintain this winch in accordance with American National Standards
Institute Safety Code (ANSI B30.7) and any other applicable safety codes and regulations.
Refer all communications to WINTECH or your nearest Distributor.
Form MHD56073
Edition 1
June 2001 TECH
INTERNATIONAL, L.L.C.
71121867
© 2000 Wintech International Inc.
1
SAFETY INFORMATION
Inspection and safety information contained in this The National Safety Council, Accident Prevention Manual
manual is based, in part, on the American National for Industrial Operations, Eighth Edition and other
Standards Institute Safety Code (ASME B30.7). However, recognized safety sources make a common point: Employ-
it should be noted that ASME B30.7 covers "Base ees who work near material handling equipment or assist
Mounted Hoists" and does not specifically apply to in hooking on or arranging a load should be instructed in
winches used as barge pullers or in horizontal pulling safe rigging procedures. From a safety standpoint, one
applications. factor is paramount: conduct all pulling operations in
such a manner that if there were an equipment failure, no
This manual provides important information for all personnel would be injured. This means keep out of the
personnel involved with the safe installation, operation line of force of any load.
and proper maintenance of this product. Even if you feel
you are familiar with this or similar equipment, you The Occupational Safety and Health Act of 1970 generally
should read and understand this manual before operating places the burden of compliance with the owner/employer,
the product. not the manufacturer. Many OSHA requirements are not
concerned or connected with the manufactured product but
Danger, Warning, Caution and Notice are, rather, connected with the final installation. It is the
Throughout this manual there are steps and procedures owner’s responsibility and user’s responsibility to deter-
which, if not followed, may result in an injury. The mine the suitability of a product for any particular use.
following signal words are used to identify the level of Check all applicable industry, trade association, federal,
potential hazard. state and local regulations. Read all operating instructions
and warnings before operation.
Danger is used to indicate the
DANGER presence of a hazard which will Rigging: It is the responsibility of the operator to exercise
cause severe injury, death, or caution, use common sense and be familiar with proper
substantial property damage if the rigging techniques. See ANSI/ASME B30.9 for rigging
warning is ignored. information, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Warning is used to indicate the
WARNING presence of a hazard which can NOTICE
cause severe injury, death, or
substantial property damage if the • Using other than genuine WINTECH parts will void
warning is ignored. the warranty.
Safety Summary
WARNING
• Do not use this winch for lifting or lowering loads or
for supporting, or transporting people.
• The supporting structures and load-attaching devices
used in conjunction with this winch must provide an
adequate safety factor to handle the rated load, plus
the weight of the winch and attached equipment. This
is the customer’s responsibility. If in doubt, consult a
registered structural engineer.
2
SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions have 8. Check that the hook latches are engaged before using.
been adapted in part from American National (Safety) 9. When using two winches on one load ensure that each
Standard ASME B30.7 and are intended to avoid unsafe winch has a rated capacity equal to or more than the
operating practices which might lead to injury or property load. This provides adequate safety in the event of a
damage. sudden load shift.
WINTECH recognizes that most companies who use 10. Never place your hand in the throat area of a hook or
winches have a safety program in force at their facility. In in the vicinity of the wire rope as it spools onto the
the event that some conflict exists between a rule set forth drum.
in this publication and a similar rule already set by an 11. Position load correctly. Only pull in a straight line.
individual company, the more stringent of the two should Do not “side pull” or “yard”.
take precedence. 12. Keep hands, clothing, etc., clear of moving parts.
Safe Operating Instructions are provided to make an 13. Do not force a hook into place by hammering.
operator aware of dangerous practices to avoid and are not 14. Be certain the load is properly seated in the saddle of
necessarily limited to the following list. Refer to specific the hook.
sections in the manual for additional safety information. 15. Do not pull the load on the tip of the hook.
1. Only allow personnel trained in safety and o p - 16. Never run the wire rope over a sharp edge. Use a
eration of this product to operate and maintain the sheave.
winch. 17. Pay attention to the load at all times when operating
2. Only operate a winch if you are physically fit to do so. the winch.
3. When a “DO NOT OPERATE” sign is placed on the 18. Make sure all people are clear of the loadpath.
winch, do not operate the winch until the sign has 19. Never use the winch for lifting or lowering loads and
been removed by designated personnel. never allow anyone to stand on a moving load.
4. Before each shift, the operator should inspect the 20. Ease the slack out of the wire rope when starting a
winch for wear or damage. pull.
5. Never use a winch which inspection indicates is 21. Never weld or cut on a load held by the winch.
defective. 22. Do not operate winch if jamming, overloading, or
6. Do not use winch if hook latch on a hook has been binding occurs.
sprung or is broken. 23. After use, properly secure winch and all loads.
7. Only pull loads less than or equal to the rated capacity 24. Always rig loads properly and carefully.
of the winch.
WARNING LABEL
Each winch is supplied from the factory with the warning
label shown. If the label is not attached to your winch,
order a new label and install it. See the parts list for the
part number. Read and obey all warnings and other safety
information attached to this winch. Label may not be
shown actual size.
3
SPECIFICATIONS
Series/Capacity:
25H = 25 US Tons 22,680 kg ~ 22.5 metric tons
50H = 50 US Tons 45,360 kg ~ 45 metric tons
75H = 75 US Tons 68,039 kg ~ 68 metric tons
Options:
B = Angled deck bracket.
C = Overload clutch with handwheel.
D = Drum divider with second wire rope anchor.
G = Grooved drum.
P = Special paint: Marine 812 top coat.
Z = Sand blasted/carbozinc plating.
(TBL.MODELCD)
4
Drum Wire Rope Capacity ft. (m)
Length
(inches) 5/8 16 mm 3/4 18 mm 7/8 22 mm 1 26 mm 1-1/8 28 mm 1-1/4 32 mm
* Weights listed are for units manufactured before 15 July 1993; for actual weight of a specific unit reference the
shipping invoice.
** Capacities based on the following wire rope sizes: 25H = 1 inch wire rope; 50H = 1-1/4 inch wire rope;
75H = 1-1/2 inch wire rope.
(TBL.SPECCHRT)
5
INSTALLATION
• Owners and users are advised to examine specific, 3. When a lead sheave is used, it should be aligned with
local and other regulations, including American the center of the drum. The diameter of the lead
National Standards Institute and/or OSHA Regulations sheave must be at least 18 times the diameter of the
which may apply to a particular type of use of this wire rope.
product before installing or putting winch to use. 4. Maintain a fleet angle between the sheave and winch
of no more than 1-1/2°. For every inch (25 mm) of
Winch Configuration drum length the lead sheave must be at least 1.6 feet
(Ref. Dwg. MHTPA0457) (0.5 m) from the drum.
As viewed from the handwheel side of the winch, the
direction of wire rope take-off determines if winch is left
or right hand.
50HL
Left Hand Model
Handwheel
Wire Rope Take-off
50HR
Right Hand Model
Holding Dog
(Dwg. MHTPA0457) 5. Make sure the mounting surface is flat to within
1/16 in. (1.6 mm). Place shims at winch base to align
Mounting as required.
(Ref. Dwgs. MHTPA217 and MHTPA0470.) 6. Position the winch so there is enough space for the
1. Mount the winch on a rigid surface capable of operator to operate the handwheel, ratchet lever
supporting the winch and that will prevent deflecting (tensioning), foot brake and holding dog (releasing)
or distortion of the winch when operated at maximum and for maintenance personnel to access the winch for
capacity. inspection, maintenance and repair. The handwheel
2. Choose a site that uses as short a wire rope as rotation must be unobstructed for the full 360 degree
practical. rotation. Reposition winch if necessary. Refer to the
shaded area shown on Dwg. MHTPA0470 for
recommended clearances.
6
7. Mount the winch using the straight type deck bracket b. When using the angled brackets, both side frames
when welding to a steel deck. Mount the winch using must be mounted to the inside of the deck
the angle type deck bracket when bolting the winch to brackets.
the mounting surface. Refer to Dwg. MHTPA0217 9. Mounting bolts or screws must be Grade 8 or better.
and Table 1. Size for 25H winches is 3/4 inch (19 mm) diameter;
for 50H/75H winches, 1 inch (25 mm) diameter.
Secure using nuts with lockwashers or self-locking
nuts.
10. Tighten mounting bolts evenly. For dry thread
fasteners torque to 200 ft. lbs. (28 kg.m) for 3/4 inch
3/8 in. Fillet bolts and 500 ft. lbs. (69 kg.m) for 1 inch bolts. If the
Weld (minimum)
fasteners are plated, lubricated or a thread locking
compound is used, torque to 166 ft. lbs. (23 kg.m) for
3/4 inch bolts and 400 ft. lbs. (55 kg.m) for 1 inch
Straight type Angle type bolts.
Deck Bracket Deck Bracket
(Dwg. MHTPA0217)
Table 1
(Refer to Dwg. MHTPA0206.)
Bolt Pattern Dimensions
"A" "B" "D"
Model
in. mm in. mm in. mm
25H 2 51 13/16 21
50H 4 102
7 178 1-1/8 28
75H
7
When considering wire rope requirements the actual Wire Rope Wire Rope
working load must include not only the static or dead load Wedge
but also loads resulting from acceleration, retardation and
shock load. Consideration must also be given to the size of
the winch drum, sheaves, anchor wedge and the method of
reeving.
CAUTION
• Ensure the wire rope diameter provides an adequate Drum
safety factor.
Table 2 (Dwg. MHTPA0218)
Minimum and Maximum Wire Rope Size Applicability 3. Make sure the wire rope wedge is the correct size for
the wire rope. Cast numbers on the wedge indicate the
Minimum Wire Rope Maximum Wire Rope required wire rope size with which it is to be used.
Size Size 4. Install the wire rope wedge into anchor hole. Install
Model
the wedge from the side of the hole with the wire rope
inch mm inch mm end. Position the wedge so the serrated surface is on
25H 5/8 16 1 26 the wire rope. Insert the narrow end of the wedge
first. Position the wedge such that it is nearest the
50H 7/8 22 1-1/4 32
surface of the drum.
75H 1-1/8 28 1-1/2 40 5. Hammer the wedge into the wire rope anchor hole to
secure the wire rope.
Wire rope maximum diameter is limited by the size of the
6. Maintain tension on the wire rope while winding onto
wire rope anchor hole (located on the winch drum).
the drum at slow speed.
(TBL.WIREROPE)
CAUTION
Safe Wire Rope Handling Procedures
• Make sure the first wrap of wire rope is flush against
1. Always use gloves when handling wire rope.
the drum flange.
2. Never use wire rope which is twisted, frayed or
kinked.
Wire Rope Spooling
3. Never use wire rope as a sling.
To compensate for uneven spooling and the decrease in
4. Always ensure wire rope is correctly spooled and first
line pull capacity as the drum fills up, use as short a wire
layer is tight.
rope as practical. When rewinding wire rope apply tension
to the end of the wire rope to eliminate line slack. This
Installing Wire Rope
helps achieve level winding and tight spooling.
CAUTION
Rigging
• Install the wire rope so that it comes off the bottom of Make sure all wire rope blocks, tackle and fasteners have
the drum (underwind). sufficient safety margin to handle the required load. To
• Maintain at least 3 wraps of wire rope on the drum at prevent wire rope damage, do not allow wire rope to
all times. contact sharp edges or make sharp bends. Use a sheave.
1. Cut wire rope to length. To prevent fraying of strands, Refer to wire rope manufacturer's handbook for proper
fuse wire rope ends in accordance with the wire rope sizing, use and care of wire rope.
manufacturer's instructions.
2. Feed the end of wire rope into the wire rope anchor
hole. Position the end of the wire rope just beneath
the drum surface. Refer to Dwg. MHTPA0218.
8
OPERATION
The four most important aspects of winch operation are: 2. Place the ratchet extention tube over the ratchet lever
1. Follow all safety instructions when operating the handle and, from the front of the winch, pull down on
winch. the ratchet lever.
2. Allow only people trained in safety and the operation 3. Using the ratchet, tension the wire rope. Maximum
of this winch to operate this equipment. tensioning capacities are listed in Table 3.
3. Subject each winch to a regular inspection and main-
tenance procedure.
4. Be aware of the winch capacity and weight of load at CAUTION
all times. • When tensioning is complete, ensure the holding dog
is engaged and then remove and store the ratchet
extension handle, place the ratchet lever to its stowed
WARNING position, and ensure the ratchet dog is dis-engaged.
• Only allow personnel trained in safety and operation
of this winch to operate this product. Releasing Tension
• To avoid damage to the rigging, the structure sup- (Refer to Dwg. MHTPA0479.)
porting the rigging, and the winch, do not “two-block” To release wire rope tension:
the end of the wire rope. 1. Make sure the ratchet lever is in the stowed position.
2. Make sure the ratchet dog is disengaged from the
Inspection drive shaft ratchet gear.
Before each shift inspect winch as described in "Frequent 3. Rotate the holding dog release lever to the rear of the
Inspection" of the "INSPECTION" section. Repair or winch.
replace damaged parts. Lubricate as recommended in the 4. Place foot on the foot brake lever to apply firm
"LUBRICATION" section. pressure to the handwheel. This will prevent uncon-
trolled release of wire rope tension when the holding
Tensioning dog is disengaged.
(Refer to Dwg. MHTPA0479.)
Handwheel Tensioning
1. Connect wire rope to the load. WARNING
2. Engage the holding dog by placing the holding dog • Do not release holding dog with winch holding load
lever in the forward position. unless the ratchet dog is disengaged from the hand-
3. Take up slack wire rope by turning the handwheel in wheel shaft ratchet gear.
the clockwise direction (viewed facing handwheel). • Before releasing holding dog ensure handwheel
Ensure wire rope is spooled evenly and tightly onto rotation is not obstructed. Ensure personnel remain
drum. clear of spinning handwheel.
4. Using the handwheel, tension the wire rope. Maxi-
mum tensioning capacities are listed in Table 3. 5. Using a mallet, strike the end of the holding dog
Table 3 release lever until the holding dog is disengaged from
the drive shaft holding gear.
Tensioning Capacities
Holding Dog
Handwheel Ratchet
Release
Model Metric Metric Lever
US Tons US Tons
tons tons
25H 10 9.1 Forward
5 4.5 Ratchet (Take-off)
50H 15 13.6 Lever
(stowed)
75H 10 9.1 20 18.1
(TBL.HNDTNSNG)
Ratchet Tensioning Foot
Brake
1. To operate the ratchet dog, rotate the ratchet lever
from the stored position to engage the ratchet dog
with the drive shaft ratchet gear at approximately 45° (Dwg. MHTPA0479)
up from the horizontal.
9
Foot Brake 1. Engage the foot brake by depressing the brake pedal
(Refer to Dwg. MHTPB0477.) bar (50) to control the rate of release on unloaded
wire rope to prevent uncontrolled release and
DANGER "birdnesting" of the wire rope.
• Use of the foot brake to control drum speed is limited
to the pay out of unloaded wire rope. Do not attempt to
use the foot brake to control the rate of release of wire
rope under load.
INSPECTION
Inspection information is based in part on the American Records and Reports
National Standards Institute Safety Codes (ASME B30.7). Inspection records, listing all points requiring periodic
However, it should be noted that ASME B30.7 applies inspection should be maintained for all load bearing
specifically to “Base Mounted Drum Hoists” and not to equipment. Written reports, based on severity of service,
winches used as barge pullers or in horizontal pulling should be made on the condition of critical parts as a
applications. method of documenting periodic inspections. These
reports should be dated, signed by the person who per-
WARNING formed the inspection, and kept on file where they are
readily available for review.
• All new, altered or modified equipment should be Wire Rope Reports
inspected and tested by personnel trained in safety, Records should be maintained as part of a long-range wire
operation and maintenance of this equipment to ensure rope inspection program. Records should include the
safe operation at rated specifications before placing condition of wire rope removed from service. Accurate
equipment in service. records will establish a relationship between visual
Frequent and periodic inspections should be performed on observations noted during frequent inspections and the
equipment in regular service. Frequent inspections are actual condition of wire rope as determined by periodic
visual examinations performed by operators or personnel inspections.
trained in safety and operation of this equipment and
include observations made during routine equipment Frequent Inspection
operation. Periodic inspections are thorough inspections On equipment in continuous service, frequent inspection
conducted by personnel trained in the safety, operation should be made by operators at the beginning of each
and maintenance of this equipment. Inspection intervals shift. In addition, visual inspections should be conducted
depend upon the nature of the critical components of the during regular operation for damage or evidence of
equipment and the severity of usage. Frequent and malfunction.
periodic inspection intervals for equipment use under 1. WINCH. Prior to operation, visually inspect winch
various operating conditions are listed below: shafts, gears, brakes, sideplates and drum for indica-
tions of damage. Do not operate the winch unless the
1. Frequent Inspection: wire rope feeds onto the drum smoothly, and any
discrepancies noted have been reviewed and inspected
NORMAL HEAVY SEVERE further by personnel trained in the operation, safety
monthly weekly daily and maintenance of this winch.
2. Periodic Inspection: 2. WIRE ROPE. Visually inspect all wire rope which
can be expected to be in use during the day’s opera-
NORMAL HEAVY SEVERE
tions. Inspect for damage indicated by distortion of
yearly yearly quarterly wire rope such as kinking, “birdcaging,” core
protrusion, main strand displacement, corrosion,
Careful inspection on a regular basis will reveal poten-
broken or cut strands. Also inspect the drum flange
tially dangerous conditions while still in the early stages,
points, crossover points and repetitive pickup points.
allowing corrective action to be taken before the condition
If damage is evident, do not operate winch until the
becomes dangerous.
discrepancies have been reviewed and inspected
Deficiencies revealed through inspection, or noted during
further by personnel trained in the operation, safety
operation, must be reported to designated personnel
and maintenance of this winch.
trained in safety, operation and maintenance of this
equipment. A determination as to whether a condition
constitutes a safety hazard must be decided, and the NOTICE
correction of noted safety hazards accomplished and • The full extent of wire rope wear cannot be deter-
documented by written report before placing the equip- mined by visual inspection. At any indication of wear
ment in service. inspect the wire rope in accordance with instructions in
“Periodic Inspection.”
10
Periodic Inspection 6. FOOT BRAKE. Ensure proper operation. Visually
The frequency of periodic inspection depends on severity inspect foot brake during operation. Brake should
of usage: prevent the pay out of unloaded wire rope. If indi-
cated by poor operation or visual damage, disassemble
NORMAL HEAVY SEVERE
and repair brake. Check all brake surfaces for wear,
yearly yearly quarterly deformation or foreign deposits. Clean and replace
Disassembly may be required as a result of initial indica- components as necessary.
tions of inspections or in order to properly inspect the 7. SUPPORTING STRUCTURE. Check for distortion,
individual components. Disassembly steps are described in wear and continued ability to support winch. Ensure
the “MAINTENANCE” section. Maintain written records winch is firmly mounted and that fasteners are in
of periodic inspections to provide an accumulative basis good condition and tight.
for continuing evaluation. Inspect all items listed in 8. DOGS AND RATCHET GEARS. Check condition of
“Frequent Inspection.” Also inspect the following: gears and dogs. Verify smooth engagement and
1. SIDE FRAMES. Check for deformed, cracked or release with winch unloaded. Replace gears and dogs
corroded main components. Replace damaged parts. indicating cracked, chipped or worn surfaces.
2. FASTENERS. Check retainer rings, split pins, 9. OVERLOAD CLUTCH. Verify overload clutch
capscrews, nuts, and other fasteners on winch, disengages handwheel shaft from gears at specified
including mounting bolts. Replace if missing or line pull rating (maximum of 110% of winch rated
damaged and tighten if loose. line pull). Adjust or repair as necessary.
3. DRUM AND SHEAVES. Check for cracks, wear or 10. LABELS AND TAGS. Check for presence and
damage. Replace if necessary. legibility of labels. Replace if damaged or missing.
4. WIRE ROPE. Additionally inspect for the following:
a. Build-up of dirt and corrosion. Clean with steam Equipment Not in Regular Use
or a stiff wire brush to remove dirt and corrosion 1. Equipment which has been idle for a period of one
if necessary. month or more, but less than six months, shall be
b. Loose or damaged end connection. Replace if given an inspection conforming to the requirements
loose or damaged. of “Frequent Inspection” before being placed in
c. Check wire rope anchor is securely mounted in service.
drum. 2. Equipment which has been idle for a period of over
d. Verify wire rope diameter. Measure the diameter six months shall be given a complete inspection
of the wire rope from crown-to-crown throughout conforming with the requirements of “Periodic
the life of the wire rope. Recording of the actual Inspection” before being place in service.
diameter should only be done with the wire rope 3. Standby equipment shall be inspected at least semi-
under equivalent loading and in the same annually in accordance with the requirements of
operating section as accomplished during “Frequent Inspection”. In abnormal operating
previous inspections. If the actual diameter of the conditions equipment should be inspected at shorter
wire rope has decreased more than 1/64 in. (0.4 intervals.
mm) a thorough examination of the wire rope
should be conducted by an experienced inspector Testing
to determine the suitability of the wire rope to Operational Tests
remain in service. (Refer to Dwg. MHTPA0056). Prior to initial use, all new, altered or repaired winches
should be tested to ensure proper operation.
a) Operate winch in both directions with no load.
b) Check foot brake, ratchet dog, handwheel and
Crown holding dog operation.
to
Crown
c) Check operation of limit switches, and locking or
safety devices when provided.
d) Check all mounting bolts are in good condition
and properly secured.
11
INSPECTION AND MAINTENANCE REPORT
(Lo-Pro Barge Winch)
Model Number: Date:
Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspeciton ( ___ Monthly ___ Yearly).
CORRECTIVE
COMPONENT CONDITION
ACTION NOTES
Pass Fail Repair Replace
Bearings ---
Foot Brake
---
(Winch Unloaded)
Covers
Fasteners
Gears
Shafts
Springs
Supporting Structure
Holding Dog
Holding Gear
Ratchet Dog
Ratchet Gear
Other Components
(list in NOTES section)
* Refer to the Parts, Operation and Maintenance manual, Form #MHD56073, ' Testing' in the " INSPECTION" section to determine maximum test load.
(TBL.WNCHNSPC)
12
LUBRICATION
13
TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by
thorough inspections performed by personnel trained in safety, operation and maintenance of this equipment. The chart
below provides a brief guide to common winch problems, probable causes and solutions.
MAINTENANCE
WARNING Adjustments
Overload Clutch (optional feature) Adjustment
• Before performing maintenance, disconnect the load (Refer to Dwg. MHTPB0484.)
from the winch.
• Before starting maintenance, tag winch:
DANGER - DO NOT OPERATE - DANGER
EQUIPMENT BEING REPAIRED • Maximum allowable overload clutch setting is 110%
• Only allow service personnel trained in maintenance of rated line pull. Do not adjust setting greater than
and operation of this equipment to perform maintenance. 110% of rated line pull.
• After performing maintenance on load bearing parts,
test unit to 110% of its rated capacity before returning To adjust the overload clutch perform the following:
to service. Refer to 'Testing' in the "INSPECTION" 1. Loosen setscrew in set collar (82) and move out of the
section. way by sliding along shaft (80).
2. Using adjustment wrench (part number 51925), rotate
the adjustment nut (81) to set the overload clutch at
the desired line pull release.
14
Adjustments should be done with the winch unloaded. Disassembly
When an adjustment has been made, load the winch with Handwheel and Foot Brake
the desired line pull load and test the operation of the (Refer to Dwg. MHTPB0477.)
overload clutch. Repeat the following steps as required to 1. To remove handwheel (90) loosen setscrew (95) and
set the desired line pull load. slide handwheel straight out. Remove key (94) and
safely store until re-installation.
a. From the adjusting nut (81) end of the clutch
assembly, rotate the adjusting nut clockwise to On models before 15 July 1993: loosen four setscrews
increase the line pull load allowed. (95) on handwheel (90).
b. From the adjusting nut (81) end of the clutch
assembly, rotate the adjusting nut counterclock- 2. To remove the foot brake as an assembly, remove the
wise to decrease the line pull load allowed. cotter pin (55) and nut (58) from shaft (57). Pull
brake assembly from side frame (1).
3. When adjustments have been completed, slide set
collar (82) fully against the adjustment nut (81) and Ratchet Assembly
secure in place with setscrew. Use a thread sealing (Refer to Dwgs. MHTPC0475 and MHTPC0486.)
compound on the threads of the setscrew. 1. Slide ratchet lever (7) and ratchet gear (11) off of
handwheel shaft (39). Remove key (10) and safely
General Disassembly store until reinstallation.
The following instructions provide the necessary 2. If complete disassembly of ratchet is required, remove
information to disassemble, inspect, repair, and retaining ring (8) from either end of shaft (9). Tap
assemble the winch. Drawings of the winch and shaft through ratchet lever (7).
associated components are provided in the parts
section to assist in part indentification. If a winch is When removing shaft (9) from ratchet lever (7) the
being completely disassembled for any reason, follow washers (5), ratchet dog (6), spring (13) and spring guide
the order of the topics as they are presented. It is (12) will be separated from the ratchet assembly. Collect
recommended that all maintenance work on the winch these pieces and safely store until reinstallation.
be performed in a clean, dust free work area.
During winch disassembly observe the following: B-C (Cluster) Gear
1. Never disassemble the winch any further than is (Refer to Dwgs. MHTPC0475 and MHTPC0486.)
necessary to accomplish the needed repair. A good 1. Using a hoist, support the B-C gear (36) (50H unit),
part can be damaged during the course of disassem- or the cluster gear (36) (25H and 75H units).
bly. 2. Remove all paint and surface imperfections from the
2. Never use excessive force when removing parts. intermediate shaft (22). Coat the exposed shaft
Tapping gently around the perimeter of a part with a surface with oil.
soft hammer should be sufficient to loosen the part. 3. 25H (after 15 July 1993), 50H and 75H units:
3. Do not heat a part with a flame to free it for removal, loosen setscrew located in collar (38) until collar
unless the part being heated is already worn or rotates freely on intermediate shaft (22).
damaged beyond repair and no additional damage 4. Remove the capscrew (24) securing the intermediate
will occur to other parts. shaft (22) to the side frame (1).
5. 25H unit (before 15 July 1993): slide intermediate
In general, the winch is designed to permit easy disassem- shaft (22) through cluster gear (36), collar (38) and
bly and assembly. The use of heat or excessive force side frames (1 and 2).
should not be required. 50H units: slide intermediate shaft (22) through B-C
gears and side frames (1 and 2).
4. To prevent dirt and other foreign matter from getting 25H (after 15 July 1993) and 75H units: slide the
into bearings or other moving parts keep the work intermediate shaft (22) through cluster gear and side
area as clean as practical. frames (1 and 2).
5. When grasping a part in a vise always use leather or 6. Cover B-C (cluster) gear assembly to protect from
copper-covered vise jaws to protect the part. This is damage and lower to the ground after shaft has been
especially important when clamping threaded areas removed.
and machined surfaces of parts.
6. When installing do not tap on the bushing edge. Place
a wood block between the bushing and the hammer-
ing tool to prevent damage.
15
(Refer to Dwgs. MHTPC0475 and MHTPC0486.)
1. Using a hoist, support the drum (26). If the wire rope
WARNING
is on the drum, secure the wire rope end to keep it out • Bushings that are loose, worn or rotate in the frame,
of the way. gears or drum must be replaced. Failure to observe this
2. Remove all accessible paint and surface imperfections precaution will result in additional component damage.
from the drum shaft (23). Coat the exposed shaft (Reference "Bushing Chart" for maximum allowable
surface with oil. bushing wear.)
3. Remove the capscrew (24) securing the drum shaft
(23) to the side frame (1). All disassembled parts should be inspected to determine
4. Using a soft material rod and mallet, drive the drum their fitness for continued use. Pay particular attention to
shaft (23) through the drum (26) and side frames (1 the following:
and 2). 1. Inspect all gears for worn, cracked, or broken teeth.
5. Carefully lower the drum to the ground after shaft has 2. Inspect all bushings for wear, scoring, or galling.
been removed. Measure bushing inside diameters. Reference Table 4,
"Bushing Chart". Replace the bushing(s) if
Side Frames measurements are greater than the bore size (replace)
(Refer to Dwgs. MHTPC0475 and MHTPC0486.) shown.
1. If installed using straight deck brackets, one side
frame (1 or 2) should be attached to the inside and the Table 4
other side frame (1 or 2) to the outside of the deck
brackets (19). Remove the deck bracket capscrews Bushing Chart
(20) and nuts (21) to free the side frame attached to 25H Winch
the outside of deck bracket (19).
Bushing Bushing Bore Size Bore Size
2. If installed using angled deck brackets, both side
Location Item No. Original Replace
frames should be installed inside the deck brackets.
To disassemble unit, remove capscrews and nuts inch mm inch mm
holding deck brackets (19) to the foundation.
Frame (1) 14 1.133 28.8 1.195 30.4
3. On one side frame (1 or 2):
a. remove the nuts (34) securing the three spacer Gear (36) 35 2.199 55.9 2.261 57.4
shafts (28) to the side frame (1 or 2).
Drum (26) 25 3.016 76.6 3.078 78.2
b. remove the nut (34) securing the holding dog
shaft (43). 50H Winch
4. Carefully pull the side frame (1 or 2) away to provide Bore Size Bore Size
enough clearance to remove the handwheel shaft (39). Bushing Bushing Original Replace
5. Remove the nuts (34) from the spacer shafts (28) and Location Item No.
holding dog shaft (43). Remove the shafts. inch mm inch mm
Frame (1) 14 1.508 38.3 1.570 39.9
If installed, the wire rope guards are welded to two of the
spacer tubes (29) on spacer shafts (28). To remove, use a Gear (36) 35 2.765 70.2 2.827 71.8
hoist to support the wire rope guard when removing the
Drum (26) 25 4.018 102 4.080 103.6
spacer shafts. When shafts are removed, lower the wire
rope guard to the ground. 75H Winch
Bore Size Bore Size
Cleaning, Inspection and Repair Bushing Bushing Original Replace
Use the following procedures to clean, inspect, and repair Location Item No.
the winch and associated components. inch mm inch mm
Frame (1) 14 1.760 44.7 1.822 46.3
Cleaning
Clean all winch component parts in solvent (except for the Gear (36) 35 3.204 81.4 3.267 83
brake shoes). The use of a stiff bristle brush will facilitate Drum (26) 25 5.018 127.5 5.080 129
the removal of accumulated dirt and sediments on the
gears, frames and drum. If bushings have been removed it 3. Inspect shafts for ridges caused by wear. If ridges
may be necessary to carefully scrape old sealant from the caused by wear are apparent on shafts, replace the
bushing bores. Dry each part using low pressure, filtered shaft.
compressed air. Clean the brake shoes using a wire brush 4. Inspect all threaded items and replace those having
or emery cloth. Do not wash the brake shoe in liquid. If damaged threads.
the brake shoe linings are oil soaked, they must be
replaced.
Inspection
16
Repair Assembly
Component repairs are limited to the removal of small Overload Clutch (optional feature) Assembly
burrs and other minor surface imperfections from gears, (Refer to Dwg. MHTPB0484.)
bushings and shafts. Use a fine stone or emery cloth for 1. Slide set collar (82) over end of handwheel shaft (80).
this work. 2. Slide the following parts on the handwheel shaft (80)
1. Inspect all parts for evidence of damage. Worn or in the order in which they are listed:
damaged parts must be replaced. Refer to the a. Adjusting nut (81).
applicable parts listing for specific replacement parts b. Shaft seal (61). Lightly lubricate seal with type 'F'
information. automatic transmission fluid.
2. Using a fine stone or emery cloth, smooth out all c. Pilot plate (79).
minor nicks, burrs, or galled spots on shafts, bores, (1) Before sliding pilot plate (79) on shaft,
pins, and bushings. install 'O'-ring (78) in groove on inside lip of
4. Examine the gear teeth carefully. Using a fine stone pilot plate. Lightly lubricate 'O'-ring and
or emery cloth, remove any small nicks or burrs. shaft with type 'F' automatic transmission
Replace the gear if any teeth are chipped, cracked, fluid.
stretched or missing. d. Plate seal (77).
5. Using a fine stone or emery cloth, polish the edges of e. Disc springs (76).
all shaft shoulders to remove small nicks which may f. Spacer (75).
have been caused during handling. g. Pressure plate (74).
6. Remove any nicks and burrs caused by capscrews, 3. Place stop sleeve (69) on adjustment hub (67).
nuts and lockwashers. 4. Place inner spline (68) on adjustment hub (67) and
secure in place using capscrews (71) and lockwashers
Bushings (70).
(Refer to Dwgs. MHTPC0475 and MHTPC0486.) 5. Install the friction plates (72) and separator plates
Repair of bushings is limited to the removal of small nicks (73) on inner spline (68). Stagger the installation.
and burrs, using fine emory cloth or a stone. If the Begin with a friction plate, followed by a separator
bushing bore is worn, scored or exceeds the maximum plate, followed by a friction plate, etc. When installed
allowable diameter, it must be replaced. Refer to Table 4 there should be a friction plate at both ends of the
for bushing bore information. In components where there assembly.
are more than one bushing (i.e., gears, drums), it is 6. Install shaft key (66) on handwheel shaft (80). Slide
recommended that all bushings be replaced at the same adjustment hub (67) over end of shaft. Align groove
time to ensure uniform wear and component alignment. with shaft key. If required, using a soft mallet, tap
1. Bushings are press fit into the gear and drum adjustment hub into place on shaft key.
housings. To remove, use an inside puller. Carefully 7. Slide the parts listed in paragraph 2.b and 2.d through
remove the bushing, ensuring it is pulled out as 2.g onto the adjustment hub (67). Engage adjusting
straight as possible to prevent binding and scoring of nut (81) on threads of adjusting hub (67) to hold parts
the housing. in place.
2. Clean the component bushing housing. Remove 8. If required, install pinion sleeve bushings (62) in
minor nicks and burrs using fine emory cloth or a pinion drive assembly (63). Install shaft seal (61) in
stone. Lightly lubricate with grease recommended in geared end of pinion drive assembly. Lightly lubricate
the "LUBRICATION" section. seal and bushings with type 'F' automatic transmis-
3. Inspect the new bushing. Remove minor nicks and sion fluid.
burrs using fine emory cloth or a stone. Lightly 9. Slide thrust washer (65) on handwheel shaft (80).
lubricate the outside of the bushing with grease 10. Slide pinion drive assembly (63) on handwheel shaft
recommended in the "LUBRICATION" section. (80). Align the splines in the pinion drive assembly
4. To install: with the friction disc (72) splines and slide pinion
a. Place the bushing on the housing lip. Ensure the drive assembly over the adjustment hub assembly.
bushing edge mates with the sleeve edge in a full 11. Install handwheel shaft (80) on winch as described in
360° contact. the 'Winch Assembly' section. After pinion gear has
b. Place a block of wood, or similar soft material, on been meshed with the B-C (cluster) gear assembly,
the opposite end of the bushing. Using a mallet, adjust the overload clutch assembly.
carefully tap the bushing into the housing. Make a. Slide the pinion drive assembly fully over the
sure the bushing alignment remains straight adjustment hub assembly.
during installation. b. Tighten the adjustment nut (81) enough to
c. After bushing has been installed in side frame, remove all slack from the adjustment hub
remove grease fitting (16). Using the grease assembly.
fitting hole as a guide, drill a hole through the c. Fill with type 'F' automatic transmission fluid
bushing. Reinstall grease fitting. after removing screws (64). Reinstall screws (64).
17
Winch Assembly 9. Slide collar (38) against B-C (cluster) gear and secure
1. Install the deck brackets (19). Angled deck brackets with setscrew. Apply a thread sealing compound to
must be bolted to the foundation. Straight deck setscrew threads before tightening.
brackets must be welded to the foundation. Refer to the 9. When assembled, lubricate as described in the
"INSTALLATION" section for detailed information. "LUBRICATION" section.
2. Install one side frame (1 or 2) by placing it inside the 10. Test winch operation as described in 'Testing' in the
deck bracket. Attach securely with capscrews (20) and "INSPECTION" section.
nuts (21).
3. Install holding dog shaft (43) (with holding dog Ratchet Dog Assembly
assembly attached) and the spacer shafts (28) to the (Refer to Dwgs. MHTPC0475 and MHTPC0486.)
installed side frame (1 or 2). Secure with nuts (34). 1. To assemble ratchet lever, install spring (13) and
Slide spacer tubes (29) on spacer shafts (28). spring guide (12). Place ratchet dog (6) with a washer
4. Place the remaining side frame (1 or 2) on the outside (5) on each side in ratchet lever (7), install shaft (9)
of deck bracket (19) for straight type deck brackets; and secure with retaining rings (8).
place on the inside of deck bracket for angled type 2. Install key (10) on handwheel shaft (39).
deck bracket. Loosely install capscrews (20) and nuts 3. Slide ratchet lever (7) assembly and ratchet wheel
(21). Do not tighten. (11) on to handwheel shaft (39). Align ratchet wheel
a. Align holding dog shaft (43) with holes on side groove with key (10) and tap assembly into place.
frame (1 or 2).
b. Align spacer shafts with holes in side frame (1 or Handwheel and Foot Brake Assembly
2). (Refer to Dwg. MHTPB0477.)
c. Install and align handwheel shaft (39) with holes 1. Align handwheel (90) with key (94) on handwheel
in side frame (1 or 2). shaft (39) and tap into place. Secure with setscrew
d. Tighten capscrews (20) and nuts (21); ensure side (95).
frame (1 or 2) and shafts align as the side frame
is secured. On models before 15 July 1993: Tighten four setscrews
e. Install and tighten nuts (34) on holding dog shaft (95) on handwheel (90).
(43) and spacer shafts (28).
5. Lightly lubricate the drum (26) bushings (25) with 2. To install the foot brake as an assembly, install brake
grease recommended in the "LUBRICATION" assembly to side frame (1). To secure install the cotter
section. Using a hoist, lower the drum (26) between pin (55) and nut (58) to shaft (57).
the side frames.
6. Clean, lightly oil and install the drum shaft (23) from
the handwheel side of the winch. Secure drum shaft to
side frame (1) using capscrew (24).
18
25H, 50H AND 75H BARGE WINCH ASSEMBLY DRAWING (BEFORE 15 JULY 1993)
38
3
43
4 2
34
6 42 32
5
13 33
39
7
8 41 35
9 12 40
35
11
10
38
14
15
1 36
19
16 31
30
27
18
17
21
19
20
26 29
25
22
28
24 23
(Dwg. MHTPC0475)
19
25H, 50H AND 75H BARGE WINCH ASSEMBLY DRAWING (AFTER 15 JULY 1993)
3
37
43 32 16
49
4
48
6 42
5
13
50 39
7
5
8 41 35
34
9 12 40 33
35
11 1
10
38
14
15
1 36
19
31
18
30
17
27
59
21
19
20
26 29
25
22
28
24 23
(Dwg. MHTPC0486)
20
25H BARGE WINCH ASSEMBLY PARTS LIST
PA RT PA RT
IT E M D E S C R IP T IO N QTY IT E M D E SC R IP T IO N QTY
NUM BER NUM BER
NO. O F PA RT T O TA L NO. O F PA RT T O TA L
C om m on P arts
R ight Side F ram e 24 C apscrew 2 50160
1 (before 15 July 1993) * 1 25 B ushing, D rum 2 1293-1
S ide F ram e A nchor Wedge 5/8 inch 530
22948
L eft S ide F ram e A nchor Wedge 3/4 inch 529
27 1
2 (before 15 July 1993) * 1 A nchor Wedge 7/8 inch 528
S ide F ram e A nchor Wedge 1 inch 527
3 R atchet L ever E xtension 1 7900-35 30 G ear C over 1 7963
4 G rease F itting, D og 2 52676 Low er B racket, Left 7967-L
31 1
5 Washer 3 9779 Low er B racket, R ight 7967-R
6 R atchet D og 1 7907 32 U pper B racket 1 7967
7 R atchet L ever 1 7966 33 G rease F itting 3 53095
8 R etaining R ing 2 50810 34 N ut, S haft 8 50825
9 S haft 1 7914 35 C luster G ear B ushing 3 1293-2
10 K ey, R atchet W heel 2 19465-125 36 C luster G ear 1 9104
11 R atchet W heel 1 7965 Shaft C ollar (O ld S tyle) **
38 1
12 S pring G uide 1 7911 Set C ollar 4046-6
13 S pring 1 50807 40 Washer 1 9779-1
14 B ushing 2 1293-6 41 H olding D og 1 7968
15 P in 1 50823 42 H olding D og Lever 1 7969
16 G rease F itting, B ushing 2 53497 44 Washer, H olding D og 1 18492
17 C apscrew 2 50884 45 C apscrew 1 50824
18 R atchet S top 2 7917 46 Warning Tag *** 1 71087035
(TBL.25HPRTSA)
22
75H BARGE WINCH ASSEMBLY PARTS LIST
90
96
91
93
95
92 94
60 51
52
58
53
54
55
57
56
(Dwg. MHTPB0477)
24
HANDWHEEL AND FOOT BRAKE ASSEMBLY PARTS LIST
Foot Brake
--- Foot Brake Assembly 1 22956 323
56 Bracket 1 317
58 Nut 1 50880
(TBL.HANDL-FTB)
25
OVERLOAD CLUTCH (OPTIONAL FEATURE) ASSEMBLY DRAWING
26
OVERLOAD CLUTCH (OPTIONAL FEATURE) ASSEMBLY PARTS LIST
70 Lockwasher 6 51941
75 Spacer 1 8049
(TBL.CLUTCH)
ACCESSORIES
(TBL.ACCESORY)
27
HOLDING BRAKE ASSEMBLY (SPECIAL FEATURE) DRAWINGS
(Dwg. MHTPB0476)
Holding Brake Adjustment Drawing
Brake
Lever
Brake
Shoe
Adjusting
Nut
(Dwg. MHTPA0478)
28
HOLDING BRAKE ASSEMBLY (SPECIAL FEATURE) PARTS LIST
NOTICE Operation
1. The brake is normally engaged. The spring (107)
• The holding brake was a special order item provided maintains tension on the brake lever (119), which
on a few units prior to 15 July 1993. The information causes the brake shoes (108 and 110) to engage the
supplied is to be used for technical information on units brake drum (101).
containing the holding brake. 2. To disengage the brake, pull the brake lever (119) in
the opposite direction of spring tension.
Holding Brake Adjustment
(Refer to Dwg. MHTPA0478.) Inspection
1. Inspect spring (107). Spring tension should cause 1. Inspect brake shoe linings. If linings are oil soaked,
brake lever (119) to engage the brake shoes (108 and replace brake shoes as a set. If linings are slightly
110) with the brake drum (101) and prevent drum glazed, the glaze may be removed carefully with fine
rotation. emory cloth.
2. Pull brake lever (119) fully to disengage brake and 2. Measure the brake lining thickness. Acceptable
hold in this position. Adjust the nut (118) on adjust- thickness is between 1/8 and 3/16 inch (3.2 and 4.8
ment stud (115) until nut is flush with the end of the mm). If the brake lining is less than 1/8 inch (3.2
stud. Brake shoes (108 and 110) should be free of mm) replace the brake shoes (108 and 110) as a set to
brake drum (101). ensure uniform wear.
3. Release the brake lever (119) to engage brake. 3. Verify spring (107) tension causes brake lever (119)
4. Operate winch with no load while gradually tighten- to engage brake.
ing the adjusting nut (118) on adjustment stud (115). 4. Verify parts are not worn or damaged. Replace as
5. Brake is correctly adjusted when brake shoes (108 and necessary.
110) have engaged the brake drum (101) enough to
stop drum rotation.
29
PARTS ORDERING INFORMATION
The nameplate is located on the side frame. For additional information contact:
Each unit is supplied from the factory with the nameplate
shown. If a nameplate is not attached to your unit, order a WINTECH
new nameplate and install it. See the parts list for the part 5319 Shreveport-Blanchard Hwy.
numbers. Shreveport, La. 71107
30
WARRANTY
31
United States Office Location
For Order Entry, Order Status, and
Technical Support:
Printed in USA