M85817010_Manuale NH 25 UK-1.pdf

WORM GEAR HYDRAULIC WINCH

WARNING Read and understand this manual before installation and operation of winch.

V.I.M.E. srl Via Gramsci,15 40050 Funo Bologna Italy Tel. +39 051 861362 Fax +39 051 861961 E-mail: [email protected] / Web site: www.vimeindustrial.it - www.vimeindustrial.com

OPERATING SERVICE AND MAINTENANCE MANUAL

ENGLISH

VIME Industrial reserves the right to improve its products through changes in designed or materials as it may seem desiderable without being obligated to incorporate such changes in this manual.

VIME Industrial has no responsability for physical injury to persons, animals or property damages. That can result from failure to read and apply the instructions contained in the manual supplied with the winch and especially for: failure with global safety aspects - not correct linking to the source of energy - deficiency in the annual and monthly maintenance - improper uses - any alteration, repair or modification from unauthorized personnel.

04/0

9 -

ING

- RE

V M

- 0

1/ S

T -

01

WARNING

Do not operate this winch until you have fully read this manual.

Many accidents are due for non observance safety procedures. A good reason, most of it can be avoided by knowing causes and taking in advance the opportunity safety.

WARNING

Read and understand this manual before installation and operation of winch.

Model NH 25000 NH 25000 2X

Serial Number

Year

Rated line pull (single line) NH 25000 - NH 25000 2X 25.000 kg.

Wire rope NH 25000 - NH 25000 2X Dia. 24 mm - 26 mm

NH 25000 - NH 25000 2X 205 Bar

Weight (without cable) NH25000 - NH 25000 2X 530 Kg.

Max. working pressure

1

Table of contents

TABLE OF CONTENTS SECTION 1 SAFETY PROCEDURES 3 1.1 INTRODUCTION 3 1.2 SYMBOLS 4 1.3 WARNING SYMBOLS 4 1.4 DESCRIPTION 5 Winch description 5 Dimensional data winch mod. NH 25000 - NH 25000 2X 6 Specifications mod. NH 25000 - NH 25000 2X 6 Technical data mod. NH 25000 7 Performance charts (1st layer) mod. NH 25000 7 Technical data mod. NH 25000 2X LARGE DISPLACEMENT 8 Performance charts (1st layer) mod. NH 25000 2X 8 Technical data mod. NH 25000 2X SMALL DISPLACEMENT 9 Performance charts (1st layer) mod. NH 25000 2X 9 1.5 WINCH DECALS. SAFETY ADVICES 10 1.6 CONDITIONS OF SALE 10 1.7 SAFETY PROCEDURES 11 SECTION 2 MOUNTING 12 2.1 ROAD TRAFFIC 12 2.2 WINCH MOUNTING 12 2.3 HYDRAULIC SYSTEM REQUIREMENTS ONE SPEED MOTOR TYPICAL LAYOUT 14 2.4 HYDRAULIC SYSTEM REQUIREMENTS TWO SPEED MOTOR TYPICAL LAYOUT 15 2.5 HYDRAULIC MOTOR LINKING 17 2.6. AIR-CYLINDER LINKING 18 2.7 CABLE INSTALLATION 19 SECTION 3 OPERATION 21 3.1 OPERATION 21 SECTION 4 MAINTENANCE 24 4.1 MAINTENANCE 24 4.1.1 Monthly maintenance 24 4.1.2 Annual maintenance 26 SECTION 5 TROUBLE SHOOTING GUIDE 27 5.1 TROUBLE SHOOTING GUIDE 27 SECTION 6 PARTS LIST 29 6.1 PARTS LIST mod. NH 25000 29 6.2 PARTS DRAWING 31

2

1.1. INTRODUCTION Manual identified by code No.04/09 - ING - REV M - 01/ ST - 01 has 31 pages.

IMPORTANT At the delivery of this manual checks all data and for possibile incogruities.

VIME Industrial reserves the right to improbe its products through changes in designed or materials as it may seem desiderable without being obligated to incorporate such changes in this manual.

This manual contains useful ideas in obtaining the most efficient operation and maintenance from the winch and safety procedures one need to know before operating a winch.

For safety procedures, read carefully safety procedures in Chap.1.7.

Manual has to be kept intact and near to the winch for a prompt reading and consultation.

WARNING

In case of misunderstanding of this manual or parts of it, please contact VIME Industrial. For repair service contact VIME Industrial.

For a rapid consultations, manual is being shared in 6 sections: Section 1 Safety procedures Section 2 Mounting Section 3 Operation Section 4 Maintenance Section 5 Trouble shooting guide Section 6 Parts list

Section 1 Safety procedures

Section 1 contains alls data for winch operations and for SAFETY PROCEDURES.

Section 2 contains note about hydraulic system, winch and cable drum installations.

Section 3 contains all information for safety procedures.

Section 4 for winch periodic maintenance.

Section 5 is a guide for a trouble shooting should verify in winching operation.

Section 6 contains parts list codes and parts drawing.

All sections are shared in chapters progressi-ve numbered. Chapters are shared in subsections progressive numbered.

IMPORTANT

For a rapid reading see table of contents.

SECTION 1 SAFETY PROCEDURES

3

1.3 WARNING SYMBOLS

According to CE Directive Machinery 98/37 EEC and its amendements, on VIME winches there are, in a visibile position for the utiliser, the following symbols:

CABLE INJURES KEEP CLEAR ( roller fairlead )

READ CAREFULLY THE OPERATING SERVICE AND M A I N T E N A N C E M A N U A L ( winch identification decal )

KEEP SAFETY DISTANCE ( winch identification decal )

WEAR WORKING GLOVES ( winch identification decal )

In this manual there are three different symbols to prevent serious injuries.

DANGEROUS symbol

DANGEROUS

Used to indicate dangerous situation and prevent injury.

WARNING symbol

WARNING

Used to indicate dangerous situation for winch efficiency and for operator safety.

IMPORTANT symbol

IMPORTANT

Used to call attention on important informations which user must knowing

In addition to the symbols there is a symbol who gives notes.

NOTE symbol

NOTE

Used to call attention on informations or advices that could help on winching operation.

Symbols and notes are completed with messages and descriptions who warns about dangers or news. And above all indicate recommended procedures and information.

1.2 SYMBOLS

IMPORTANT

We recommend to respect the symbols above. It is necessary to recognize the meaning of symbols and keeping visibile and readable. If decals are damaged or unreadable replace it

4 Warning symbols

WARNING


1.4 DESCRIPTION

WINCH DESCRIPTION

Components:

1. Gear housing 2. Manual clutch shifter 3. Locking safety clutch (for manual clutch

only) 4. Air-clutch shifter (on request)

5. Standard size mounting angles 1004 mm 6. Radial hydraulic motor 1 or 2 speed 7. Drum size - distance between flanges :

diam.396

5

Winches model NH are worm gear hydraulic winches designed and built for a long life and gives best safe duty. Special bronze gear in aluminium alloy works with a hardened ground worm. Worm gear train provides load reversing protection.

Winches model NH are particularly indicated for heavy-duty rear truck carrier applications.

3 5

2

1

6

7

5

4

The winch is built for working on range temperature between 40C and +50C. Do not exceed the range temperature, it may be cause damages.

1.3.2 DIMENSIONAL DATA mod. NH 25000


PICT. 2

1.3.3 SPECIFICATIONS

1126 mm

1040 mm

825 mm115 mm

1030 mm

396 mm 330 mm400 mm90 mm

1155 mm

45

0 mm

19

5 mm

685 m

m

450 mm

797 mm

242 mm500 mm55 mm

1126 mm

1040 mm

825 mm115 mm

1030 mm

396 mm 330 mm400 mm90 mm

1155 mm

45

0 mm

19

5 mm

685 m

m

450 mm

797 mm

242 mm500 mm55 mm

420 m

m

330 m

m

105 mm

MANUAL CLUTCH SHIFTER

AIR-CYLINDER CLUTCH SHIFTER

! DANGEROUSDo not use winch to lift support or otherwise transport personnel

Rated line pull (1st layer) : Single speed 792 cc. or 714 cc. Two speed Max.792 cc. 25000 kgs. Min.493 cc. 15640 kgs.

Hydraulic radial motor :

Working pressure : 792 cc. - 205 bar 714 cc. - 230 bar 792 / 493 cc. - 205 bar

Drum freespooling :Manual clutch with safety lock into engaged positionDual action air - clutch shifter (optional) min.6 bar max.10 bar

25000 kgs.

Single speed 792 cc. or 714 cc. 2 speed 792/493 cc.

Worm gear ratio : 30:1

Drum length : 396 mmDrum diameter : 195 mm

Accessories : Heavy duty roller fairlead Galvanized level winder Worm gear drive train provide load reverse protection

Weight without cable : NH 25000 530 Kgs.

Compliance : Machinery Directive 98/37/EEC

6

7

1.3.4 TECHNICAL DATA mod. NH 25000 (Single speed hydr.motor 792 cc.)


79

LT/MIN RPM

3,16 2,20

2 43 51

198 7,92 5,40158 6,32 4,30

6,60

3,10 6,30 7,80

2,605,30

9,00

3,60 7,20

79

LT/MIN RPM

3,16 2,20

2 43 51

198 7,92 5,50158 6,32 4,40

6,80

3,206,50

8,10

2,705,40

9,40

3,70 7,50

MM KG

30:1

25.00020.23517.00014.65512.875

12345

24

30:1 26

25.00020.50517.38015.08013.320

12345

1.3.5 PERFORMANCES CHARTS AT THE 1 LAYER

WORKING PRESSURE(BAR)

LINE PULL - FIRST LAYER(Kg)

Litres/min

LINE SPEED(m/min)

4,10 8,20

10,20

4,30 8,5010,70

LAYERS

LAYERS

Specifications are subject to change without notification and without incurring obligation.Specifications in this publication are theoritical and may vary depending on hydraulic system, enviroment,etc.

NOTES

DISPLACEMENT 792 cc.

411 20,0

315 15,3363 17,7

14,5

76,756,739,0

19,216,9

36,6

72,653,5

1267

219195

5

32

4

0

MM 24 MM 26 MM 24 MM 26 MM

13,0

-10,7

-

23,710,7 -

12,29,9

-

22,1 9,9

LAYER

45

0

195

LAYERMT

DRUMDIAMETER

ROPE CAPACITYEACH LAYER

WIRE ROPECAPACITY

MTDRUM NH = 396 MM

429

325377

273

221195

KG 24 MM 26 MM 24 MM 26 MM

530 39 36 76 72

DISPLACEMENT 792 cc.

RATIO LAYERLINE PULL

WIRE ROPESIZE

LINE SPEEDMT/MIN

OILSUPPLY

DRUMREVOLUTION

LINE SPEEDMT/MIN

OILSUPPLY

DRUMREVOLUTION

WEIGHTWITHOUT

CABLE

WIRE ROPECAPACITY MT

MAX. WIRE ROPECAPACITY MT

st

0

5000

10000

15000

20000

25000

30000

85 125 165 2050,0

1,0

2,0

3,0

4,0

5,0

6,0

80 120 160 198

8

1.3.4 TECHNICAL DATA mod. NH 25000 (2 - speed hydr.motor Max. 792 cc.)


79

LT/MIN RPM

3,16 2,20

2 43 51

198 7,92 5,40158 6,32 4,30

6,60

3,10 6,30 7,80

2,605,30

9,00

3,60 7,20

79

LT/MIN RPM

3,16 2,20

2 43 51

198 7,92 5,50158 6,32 4,40

6,80

3,206,50

8,10

2,705,40

9,40

3,70 7,50

MM KG

30:1

25.00020.23517.00014.65512.875

12345

24

30:1 26

25.00020.50517.38015.08013.320

12345

1.3.5 PERFORMANCES CHARTS AT THE 1 LAYER



Litres/min

LINE SPEED(m/min)

4,10 8,20

10,20

4,30 8,5010,70

LAYERS

LAYERS


NOTES

MAX. DISPLACEM

ENT 792 cc.

411 20,0

315 15,3363 17,7

14,5

76,756,739,0

19,216,9

36,6

72,653,5

1267

219195

5

32

4

0

MM 24 MM 26 MM 24 MM 26 MM

13,0

-10,7

-

23,710,7 -

12,29,9

-

22,1 9,9

LAYER

45

0

195

LAYERMT

DRUMDIAMETER


WIRE ROPECAPACITY

MTDRUM NH = 396 MM

429

325377

273

221195

KG 24 MM 26 MM 24 MM 26 MM

530 39 36 76 72

MAX. DISPLACEM

ENT 792 cc.


WIRE ROPESIZE

LINE SPEEDMT/MIN

OILSUPPLY

DRUMREVOLUTION

LINE SPEEDMT/MIN

OILSUPPLY

DRUMREVOLUTION

WEIGHTWITHOUT

CABLE

WIRE ROPECAPACITY MT

MAX. WIRE ROPECAPACITY MT

st

0

5000

10000

15000

20000

25000

30000

85 125 165 2050,0

1,0

2,0

3,0

4,0

5,0

6,0

80 120 160 198

9

1.3.4 TECHNICAL DATA mod. NH 25000 (2 speed hydr. motor Min. 493 cc.)


79

LT/MIN RPM

5,07 3,50

2 43 51

198 12,72 8,80158 10,15 7,00

10,70

5,0010,0013,00

4,308,50

15,10

5,8011,60

79

LT/MIN RPM

5,07 3,50

2 43 51

198 12,72 8,80158 10,15 7,00

10,90

5,2010,4013,00

4,408,70

15,10

6,0012,00

MM KG

30:1

15.50012.54510.5409.0857.985

12345

24

30:1 26

15.50012.83010.8759.4358.330

12345

1.3.5 PERFORMANCE CHARTS AT THE 1 LAYER



Litres/min

LINE SPEED(m/min)

6,60 13,10

17,10

6,8013,7017,10

LAYERS

LAYERS


NOTES

MIN. DISPLACEM

ENT 493 cc.M

IN. DISPLACEMENTt 493 cc.

411 20,0

315 15,3363 17,7

14,5

76,756,739,0

19,216,9

36,6

72,653,5

1267219195

5

32

4

0

MM 24 MM 26 MM 24 MM 26 MM

13,0

-10,7

-

23,710,7 -

12,29,9

-

22,1 9,9

LAYER

45

0

195

LAYERMT

DRUMDIAMETER


WIRE ROPEQUANTITY

MT

DRUM NH = 396 MM

429

325377

273221

195

WEIGHTWITHOUT

CABLE

KG

WIRE ROPECAPACITY

MT

MAX. WIRE ROPECAPACITY

MT

24 MM 26 MM 24 MM 26 MM

530 39 36 76 72


WIRE ROPESIZE

LINE SPEEDMT/MIN

OILSUPPLY

DRUMREVOLUTION

st

LINE SPEEDMT/MIN

OILSUPPLY

DRUMREVOLUTION

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

9,0

10,0

80 120 160 1980

2000

4000

6000

8000

10000

12000

14000

16000

18000

85 125 165 205

A decal (1) onto the top of the gear housing gives: winch model, max. pulling capacity at the first layer, wire rope diameter, max. working pressure, serial number and year of built.The label (2) onto the roller fairlead, warns about rotating parts.

IMPORTANT

When ordering replacement parts or contact VIME Industrial customers service, please gives winch model, serial number and manufacture year.


Without any special requirements winch is delivered as shown in the Instruction mainte-nance manual cover picture, without the oil in the worm gear housing as indicated by the yellow paper decal (3), (pict.1), who gives recommended oil in its back side. If the yellow paper decal (3) is missed, inspect oil level, through oil level plug as shown in Chap. 4.1.1 monthly maintenance.

IMPORTANT Check if all decals and labels have been fitted and as a maintenance if decals ore labels are damaged or unreadable, replace it.

1.5 WINCH DECALS. SAFETY ADVICES

1.6 CONDITIONS OF SALE

The winch, except special customer require-ments is delivered assembled and tested. Wire rope and hook are not included in the standard winch version, only if required are included in the commitment. At the delivery, open carefully the packing. Inspect the winch and see if it is free from defects.

IMPORTANT

In case of damages or missing parts, inform carrier immediately.

10

PICT.1

2

ATTENZIONE !VERRICELLO SENZ'OLIO

ATENCION !CABRESTANTE SIN ACEITECAUTION !WINCH WITHOUT OIL

3 Back side

OLI RACCOMANDATI: ACEITE RECOMENDADO: RECOMMENDED OILS: ESSO SPARTAN EP 320SHELL OMALA 320

1

Do not operate this winch until you have carefully read and understand the warnings operation sections of this manual.

DANGEROUS

When winching is obligatory wear working gloves.

Manual or Air Clutch must be fully engaged before starting the winch.

Do not disengage manual or air clutch under load.

Leave clutch disengaged when winch is not in use (for manual clutch version only)

Do not exceed maximum line pull ratings.

In car carrier applications after pulling vehicle on carrier, be sure to secure vehicle to carrier bed. Do not maintain load on winch cab le wh i le transporting vehicle. Do not use winch as a tie down.


WARNING

Do not use winch to lift, support or otherwise transport personnel.

DANGEROUS

A minimum of 5 wraps of cable around drum barrel is necessary to hold the load, cable clamp is not designed to hold the load as shown in Chap.2.6 (pict.10 page18).

DANGEROUS

Stand clear of cable while pulling. A broken cable can cause serious injury or death. Do not try to guide cable. Do not disengage clutch under load.

DANGEROUS

According to CE Directive Machinery 98/37 EEC winch drum must be protected by a cover to avoid cable injures. The cover must be mounted by buyers who settle the winch.

1.7 SAFETY PROCEDURES

11

1

2

3

4

5

2.2 WINCH MOUNTING

2.1 ROAD TRAFFIC

Winch must be mounted on vehicles in compliance with regulation. Many countries require to keep up to date with traffic card. Do not drive vehicle not in compliance with

Chapitre 2 Installation

regulation or not up dated traffic card.

SECTION 2 MOUNTING

Winches mod. NH have been designed to be mounted on vehicles frame. Must be fitted horizontally to give best lubrication and securely mounted on a surface who can resist to the winch pulling, without having any flex within the base and the winch while in use. To fit the winch on vehicle chassis it should be better mounting a framework by u s i n g a n g l e s n o t i n f e r i o r t o : ANGLES : mm [ inch ]

150x150x15 - [ 5,9x5,9x0,591 ]

The winch mounting angles must be fitted through framework to the vehicle chassis with at least 8 anchorage points by using capscrews M33 class 10.9 ISO and lock nuts (pict.2).

IMPORTANT

Winch is built up for different model of trucks. Holes on the mounting angles are not present, installer will make it, taking in consideration the right winch position on truck.

WARNING

Winch must no be mounted directly onto the vehicle chassis.

Winch should be mounted as close to center and as perpendicular as possible to the direction of the line pull. This will keep the wire rope fleet angle centered onto the drum as small as possible.

12

PICT. 2

NOTE The 4 mounting holes for each side of mounting angles shown in pict.2, are not presents when winch is delivered. The mounting holes are shown in pict.2 as demonstration. Alls other holes are for accessories mounting.

Standard mounting angles are delivered mounted on winch : dimensions150x150x15 mm - 5,9x5,9x0,59 inch length 1004 mm - 39,53 inch

Dimensions

150,59

1505,91

1505,91

[inch]

MM

Winch Side mounting

DANGEROUS

If the proper fleet angle is not maintained, the wire rope could wind onto one side of the drum. This could cause failure of the winch or wire rope, resulting in damage, injury or death.

DANGEROUS

A wrong or inadequate winch mounting could damage the winch.

IMPORTANT

In the winch mounting, check the gear housing (1) and the drum support (2) (pict.3) are properly aligned for not compromising the winch working.

WARNING

Excessive bushing and gear wear and difficult in drum free spooling are usually symptoms of misalignements.

Section 2 Mounting

IMPORTANT

Once winch has been mounted, we suggest to disengage the winch drum, then runs drum manually to check winch misalignment.

NOTE

A certain resistance in drum rotation is given by drum band brake (3), mounted to avoid a cable birdnest when drum is in the freespooling.

Band brake (3) resistance can be adjusted, by set screw (4).

13

PICT. 3

4 3

1 2

AB

D

Section 2 Mounting

1. RADIAL HYDRAULIC MOTOR

2. CONTROL VALVE

3. HYDRAULIC PUMP

2.3 HYDRAULIC SYSTEM ONE SPEED Once the winch has been mounted onto the vehicle chassis (Chap. 2.2) should be connec-ted to the hydraulic circuit according to the typical lay-out shown below. If conditions where the hydraulic system has only a winch which is used intermittently, where ambient

14

PICT. 4

temperature are moderate, and where exces-sive back pressure or internal leakage are not present, a reservoir equal in size to the flow of the system can be used. Hose lengths should be kept as short as possibile. Sharp bends in hoses and tubing and 90 degree fittings should be avoided since they increase back pressure.

GAS 1 HIGH PRESSURE

GAS 1 HIGH PRESSURE

GAS 1

1/4

LOW

PRE

SSUR

E

3

5

4

2

HYDRAULIC CONTROL VALVE (3 positions, 4 ways,with integral relief valve)

GAS 2

LOW

PRE

SSUR

E

1

GAS 1 HIGH PRESSURE

6

WARNING

Do not exceed 200 Lt/min. If exceeded hydraulic motor may be damaged.

WARNING

The integral relief valve (ref.4 pict.4) setting should be no higher than the required pressure to operate the winch

as shown in winch performance data. Utilise higher pressure could damage hydraulic motor and winch as well.

IMPORTANT

Pressure or oil flow lowest to the recommended gives lower winch pulling capacity and lower winch speed line.

NOTE Hydraulic system shown in pict.4, is not included in winch equipment.

4. PRESSURE RELIEF VALVE

5. OIL RESERVOIR

6. FILTER: 25 m / 10 m

B A

D

GAS 1/2 LOW PRESSURE

NOTE

With the hydraulic motor mounted as shown in pict.above, utilise case drains indicated by letter D. As general rule utilise accor-ding to the winch mounting , the case drains placed on the top.

AB X

Y

D

Section 2 Mounting

1. RADIAL HYDRAULIC MOTOR TWO SPEED

2. CONTROL VALVE

3. HYDRAULIC PUMP

4. PRESSURE RELIEF VALVE

2.4 HYDRAULIC SYSTEM TWO SPEED

15

PICT. 4/1

GAS 1 HIGH PRESSURE

GAS 1 HIGH PRESSURE

GAS 1

1/4

LOW

PRE

SSUR

E 3

5

4

2

HYDRAULIC CONTROL VALVE (3 positions, 4 ways,with integral relief valve)

GAS 2

LOW

PRE

SSUR

E

1

GAS 1 HIGH PRESSURE

6

IMPORTANT

Port (X) select small motor displacement Port (Y) select large motor displacement

WARNING

Do not exceed 200 Lt/min. If exceeded hydraulic motor may be damaged.

WARNING

The integral relief valve (ref.4 pict.4)

setting should be no higher than the required pressure to operate the winch as shown in winch performance data. Utilise higher pressure could damage hydraulic motor and winch as well. IMPORTANT

Pressure or oil flow lowest to the recommended gives lower winch pulling capacity and lower winch speed line.

NOTE Hydraulic system, speed selector and shuttle valve shown in pict.4, are not included in winch equipment.

5. OIL RESERVOIR

6. FILTER: 25 m / 10 m

7. SHUTTLE VALVE

8. TWO SPEED SELECTOR VALVE

B A

D

GAS 1/2 LOW PRESSURE

NOTE

With the hydraulic motor mounted as shown in pict.above, utilise case drains indicated by letter D. As general rule utilise according to the winch mounting , the case drains placed on top.

7

2 SPEED

SELECTOR

VALVE

2 position

4 ways

with detent

HYDRAULIC MOTOR CASE DRAINS IS NECESSARY WITH RETURN LINE IN THE RESERVOIR

WARNING

NOTE

WINCH CONTROL VALVE (POS.2) SHOULD BE OBLIGATORY MOUNTED WITH RELIEF VALVE, TO PREVENT HYDRAULIC MOTOR DAMAGES IN CASE OF WRONG DISPLACEMENT SELECTIONS.

WARNING

SMALL or LARGE MOTOR DISPLACEMENT CAN BE SWITCHED WHILE THE MOTOR IS RUNNING BY ACTING THE 2 POSITION SELECTOR VALVE (POS.8)

PORT X GAS 1/4 HIGH PRESSURE

PORT Y GAS 1/4 HIGH PRESSURE

8

GAS 1

/4

HIGH

PRE

SSUR

E GA

S 1/4

LO

W P

RESS

URE

Section 2 Mounting 16

WARNING

The radial hydraulic motor mounted on winches mod. NH needs a caise drainage obligatory directly to the oil reservoir, a wrong or missed drainage line (pict.4 hydraulic system) will damage oil seals fitted onto the hydraulic motor adapter to maintain separate hydraulic motor oil to the gear box oil. Oil seals damaged will let hydraulic oil come into the gear housing. In case of excessive pression, hydraulic motor adapter could be dama-ged too. WARNING The winch control device should be positioned for safe operation of the

winch without hesitation or lost of time. They should also be designed so the operator or other persons are not exposed to any dangerous. IMPORTANT Winch control devices are at exclusive charge of the installer, who will also take care to place alls decals, to indicate the different winch function to avoid any misunderstanding to the winch operator while winching.

Section 2 Mounting

2.5 HYDRAULIC MOTOR LINKING

17

OIL TYPES: Mineral hydraulic oils are recommended with anti-wear additives (ISO HM ou HM , with minimum viscosity of 95. The use of different oils, hydraulic motor company must be contacted.

TEMPERATURE: When selecting hydraulic oils, it is very important consider the operating temperature of the hydraulic system. Oil temperature should lie between +30C [+85F] to +60C [+140F]. As a general rule, oil life is halved for each +8C [+15F] its temperature exceeds 60C [+140]. VISCOSITY: The viscosity of the oil should be at least 12 cSt and preferably within 20 cSt and 60 cSt when the operating temperature of the system has become stabilized.

FILTERING: It is necessary to keep the level of oil contamination at an acceptable level to ensure problem-free operation. To mantain a correct level of cleaning is necessary a return filter of 25 m. In very dirty enviroments, in complex systems, the recommended filtration is 10 m. In any case should refer to the vehicle hydraulic system designer recommen-dation where the winch will be mounted also about maintenance.

according to the radial hydraulic motor plumbing its shaft will turn in clockwise or counterclockwise, thats will determine a different winch drum rotation (pict.5).

Winches model NH are equipped with a worm gear drive train, who doesnt have pre-determined and obligatory drum pulling direction, who can be done in clockwise or counterclockwise direction.

NOTE

If the winch is equipped with accessories such as : Heavy-duty roller Fairlead and Level winder, these are fitted, without any indication in the winch order, as shown in this instruction maintenance manual.

PICT. 5 A B

Section 2 Mounting 18

Winches model NH can be equipped (on request) with DUAL ACTION air-cylinder clutch shifter to power drum free spooling. The pneumatic system works if air system is available on vehicle only.

Fit air plastic pipes from the air-cylinder ports G3/8 as shown (part E pict.6) to the dual action air lever valve as shown in typical layout (pict.7).

HOW DOES IT WORK:

Air flow through position X engage the drum.

Air flow through position Y disengage the drum.

IMPORTANT

For efficient operation of air-cylinder clutch shifter , utilize air pressure filtered and dried. It is important to keep

moisture from entering the winch. Moisture could cause corrosion. If tempe-rature fall down below 0, moisature could freeze and render the component inoperable. System works at the minimum pressure 6 bar. Pressure must not exceed 10 bar. The pneumatic system can works with temperature between 20C and + 80C .

WARNING

Not utilizing the proper air filters, the air clutch could be damaged , and compromise its function.

2.6 AIR-CYLINDER LINKING

PICT. 6

E

PORT X - G 3/8

POSITION ENGAGED

PORT Y - G 3/8

POSITION DISENGAGED

NOTE The dual action pneumatic lever valve and filter shown in (pict.7), are not included in the winch standard equipment.

Dual action pneumatic lever valve:

1. In let - Air pressure G 3/8 2. Out let G 3/8 3. Exhaust G 3/8 4. Out let G 3/8

5. Exhaust G 3/8 6. Filter 50 m 7. Pressure regulator

min.6 bar max.10 bar 8. Air cylinder for drum free spooling

24

315

67

8PICT. 7

A

A:A

Section 2 Mounting

1. Determine the drum rotation.

2. Inspect the clutch is fully engaged by checking :

MANUAL CLUTCH VERSION

the handle (1) as shown (pict.8) must be in the external position, if not pull the safety knob out (2) for unlocking the handle (1), and pull out fully the handle (1) then release the safety knob (2).

AIR CLUTCH VERSION

Air flow through position (X) of air cylinder as shown in (pict.9). Otherwise , act one more time the pneumatic lever valve, while turning

slowly the drum manually or hydraulically.

3. Unwind cable by rolling it out along the ground to prevent kinking.

4. If the end of the cable opposite to hook has not been properly machined, securely wrap end of the cable, (opposite hook), with plastic or similar to prevent fraying.

3. Place taped end of cable into the flange opening (1) (pict.10) and secure it with cable clamp (2 or 3) by tightening the nuts. The cable clamp can be mounted in position (2) or in position (3), according to the rope mounting.

6. Run the winch in the selected direction for rope winding, (a worm gear winch has not

2.7 CABLE INSTALLATION

19

PICT. 8

1

2

PICT. 9

X

MANUAL CLUTCH SHIFTER VERSION DRUM ENGAGED

AIR CLUTCH SHIFTER VERSION DRUM ENGAGED

Section 2 Mounting

a pre-determined drum rotation) keeping wire rope manually tensioned and re-spool the cable, making sure that it lays evenly.

DANGEROUS

When this operation has been completed, stop the winch, disengage the drum by pulling out the handle (1) after having unlock the safety knob. Once drum has been disengaged, manually complete the rope winding onto the winch drum.

Winch is ready.

WARNING

Recommended aircraft cable with breaking point not lower than 2160 N/mm.

20

PICT.10

DANGEROUS


DANGEROUS

Never try to enlarge the cable clamp hole. VIME Industrial company has not responsability in case of drum damage due to this unauthorized modification.

1

2

3

4

5

2

3

DANGER

A minimum of 5 wraps of cable around drum barrel is necessary to hold the load, cable clamp (2 or 3) is not designed to hold the load.

1

A

A:A

3.1. OPERATION

DANGEROUS

Before start winching check cable conditions, if cable becomes frayed with broken strands, replace immediately as described on Chap. 2.6 pict.10.

DANGEROUS


WARNING

Before operating check oil level and add oil if necessary as shown in Chap. 4.1.1.

WARNING

Before start winching, check conditions

Section 3 Operation

SECTION 3 OPERATION

21

OIL

PICT.11 MANUAL CLUTCH SHIFTER VERSION DRUM DISENGAGED

1

2

of manual or air clutch system for drum freespooling.

NOTE

A warm procedure is recommended at each start up and is essential at ambient temperatures below +40F (4C). The prime mover should be run at its lowest recommended RPM with the hydraulic winch control valve in neutral allowing sufficient time to warm up the system. The winch should be operated at low speeds, forward and reverse, several times to prime all lines with warm hydraulic oil, and to circulate gear lubricant through the worm gear sets.

A) For hooking onto the load rapidly:

1. Check drum clutch be fully disengaged.

VERSION WITH MANUAL CLUTCH SHIFTER checking the handle being fully in, if not, pull the handle fully in as shown (1) after having pulled out the safety knob (2),as shown (pict.11).

AIR CLUTCH SHIFTER VERSION DRUM DISENGAGED

Y

VERSION WITH AIR-CLUTCH SHIFTER: air through position (Y) of air cylinder as shown in (pict.11).

2. Now freespool by manually pulling out enough wire rope for the winching operation, hook the load in a point who can resist to the traction.

DANGEROUS

A minimum of 5 wraps of cable around the drum barrel is necessary to hold the load, cable clamp is not designed to hold the load in car carrier.

A

A:A

A) For hooking onto the load rapidly:

WARNING

Do not exceed maximum line pull ratings.

3. Engage the drum VERSION WITH MANUAL CLUTCH SHIFTER: by pulling the handle (1) out, after having disenga-ged the safety knob (2), as shown in (pict.12).

VERSION WITH AIR CLUTCH SHIFTER: air flow through position (X) of air cylinder as shown (pict.12).

4. Act hydraulic control valve manually or by radio control for winding rope onto the winch drum.

Section 3 Operation 22

PICT.12

1

2

3

4

5

1

X

2

AIR CLUTCH SHIFTER VERSION DRUM ENGAGED

MANUAL CLUTCH SHIFTER VERSION DRUM ENGAGED

Sliding jaw clutch fully engaged

Sliding jaw clutch not fully engaged

PICT.13 PICT.14

A

DANGEROUS If clutch has not been fully engaged, as shown in (pict.14), manually or via air operated cylinder, in winching operation, while is pulling a load, can cause the suddenly drum disengagement and as a consequence the load drifts.

Section 3 Operation 23

WARNING

Not proper extended clutch operation (manual or air system) even if doesnt cause a load drifts in a short period, could cause edge wear of sliding jaw clutch and drum clutch (part.A), till moment where would be impossible engage drum anymore, or will be not capable to keep load.

IMPORTANT

To assure a good clutch operation keep maintenance as recommended in Chap.4.1.1 monthly maintenance. For air clutch shifter version it is necessary make a right linking to the vehicle air circuit and needs filtres and pressure regulator.

IMPORTANT

Maintenance needs increase according to the winch operational conditions, as well as in case of occasional use.

DANGEROUS

Stand clear of cable while pulling. A broken cable can cause serious injury or death. Do not try guide cable. Do not disengage clutch under load.

WARNING

In car carrier applications after pulling vehicle on carrier, be sure to secure vehicle to carrier bed. Do not maintain load on winch cable while transporting vehicle, do not use winch as a tie down.

ATTENTION Check clutch must be fully enaged as shown in (pict.13).

AA:A

4.1.1 MONTHLY MAINTENANCE

Technical staff required: Technician or user

Procedure:

1. Inspect the cable for damage and lubricate frequently with viscous oils or light grease with additif adhesif with graphite or bisulfure molybdne. If cable becomes frayed with broken strands, replace immediately by following procedure indicated on Chap. 2.6.

2. Worm and gear are bathed in oil. Keep

oil to level hole.

Section 4 Maintenance

SECTION 4 MAINTENANCE

4.1 MONTHLY MAINTENANCE Winches mod. NH are designed to reduce maintenance to wire rope and oil level only.

24

3

3. To check oil level : remove oil level plug (1) and check oil level. Oil level should be kept up to oil level hole. If oil level is below level hole, remove breather plug (2) and add oil ESSO Spartan EP320 or IP Mellana 320. Tightening plugs.

IMPORTANT

Keep lubricated : drum clutch (4), the bushing trough grease fittings (5) and drum through the grease fittings (3). Never utilise high pressure grease system.

5

OIL

FIG.15

2

4

1

3. The Fairlead rollers must roll free to let wire rope slide perfectly. Elements such as: salt, water, oxydation and a bad maintenance can cause the rollers locking, and excessive wire rope wear. The Fairlead rollers bad operation, can cause their own rapid wear . We recom-mend to keep Vertical and Horizontal Fairlead rollers lubricated, with medium dense oil, between axe and rollers.

4. The Level winder roller must be kept

lubricated (C).

IMPORTANT

The Fairlead and level winder rollers are zinc plated.


MONTHLY MAINTENANCE Winches mod. NH could be equipped with Heavy-duty roller fairlead and Level winder. The Heavy-duty roller fairlead and Level

25

winder have rollers working on bearings.

IMPORTANT

Fairlead rollers are subject to scrapping with wire rope. Wear Fairlead rollers must be replaced.

WARNING

A wear Fairlead roller , especially if shows deep stripes, can damage wire rope.

Vertical Roller

Horizontal Roller

PICT.16

Example of level winder roller lubrication

C

Example of Fairlead rollers lubrication

4.1.2 ANNUAL MAINTENANCE

Technical staff required: Technician or user

Procedure:

At least once a year, it is necessary inspect oil level. To inspect oil level follow instruction as indicated in Chap.4.1.1 step 2. To fully replace the oil do as follow :

1. Remove breather plug (2) (pict.17) and oil level plug (1).

2. Drain oil from winch by removing drain plug (3) taking care to put the oil drained in a container (7 Lt. capacity).

3. Tighten drain plug (3) and fill up worm gear housing with new oil through oil hole (2) till reach oil level hole (1) (see table beside for oil quantity).


Recommended oil quantity:

4. Tighten oil level plug (1) and breather plug (2)

IMPORTANT

To avoid pollution the oil drained from the winch must be carried off in compliance with regulation.

WARNING

Inspect mounting capscrews and tighten if necessary.

Model Q.ty NH 25000 Min. 4,5 Lt. Max. 4,7 Lt.

26

2

3

1

FIG.17

Section 5 Trouble shooting guide

SECTION 5 TROUBLE SHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION Drum will not rotate by hand in the free spooling position.

- Winch misaligned. - Check winch mounting, Chap.2.2. pages 11 and 12.

Drum will not rotate under load. - Load greater than rated capa-city of winch.

- Check technical data on pages 6-7-8.

- Low hydraulic system pressure. - Check pressure refer to perfor-mance charts on pages 8. Set relief valve

Winch runs too slow. - Low hydraulic system flow rate. - Check flow rate refer to perfor-mance charts on pages 8.

- Hydraulic motor damaged. - Replace motor (ref.30) parts drawing pages 29-32.

- Winch misaligned. - Check winch mounting, Chap.2.2 pages 11 and 12.

Drum will not free spool. - Clutch doesnt disengage. - Replace clutch and keys18 - 21 (for air clutch only)-26.

- Winch misaligned. - Check winch mounting, Chap.2.2 pages 11 and 12.

Oil leakage. - Damaged oil seals, O-ring or gasket.

- Replace oil seals, O-ring and gasket.

- Oil plugs loosens. - Tighten oil plugs as shown in Chap. 4.1.1 and 4.1.2 .

- Excessive oil quantity in gear housing.

- Chap. 4.1.2 page 26.

- Missed or wrong case drains. - Check case drain according to hydraulic system typical layout shown (pict.4) page 13

27

5.1 TROUBLE SHOOTING GUIDE

Section 5 Trouble shooting guide

CONDITIONS POSSIBLE CAUSE CORRECTION - Bronze Gear worn out. - Replace the bronze gear

(ref.31) parts drawing pages 29-32.

- Bronze Gear damaged. - Replace the bronze gear (ref.31) parts drawing pages 29-32.

- Excessive heavy-duty operation - Check hydraulic motor and winch.

- Sliding jaw clutch and drum clutch with edge wear.

- Check sliding jaw clutch and drum clutch as shown in

- Drum shaft damaged. - Replace shaft (ref.37) and keys (ref.34-35) parts drawing pages 29-32.

Excessive noise. - Hydraulic system flow too high. - Check performance charts page 8.

- Oil level too low. - Check oil level, through oil level plug according instructions (Chap. 4.1.1.) page 28.

Cable birdnests when clutch is disengaged.

- Band brake must be adjusted.

- Band brake worn out.

- Adjust band brake as shown in (pict.3) page 12.

- Replace band brake.

Load drifts.

28

5.1 TROUBLE SHOOTING GUIDE

Section 6 Parts list 29

6.1 PARTS LIST FOR NH

SECTION 6 PARTS LIST

PART NO.

ITEM NO.

DESCRIPTION Q.TY

1 BREATHER PLUG 1

2 CAPSCREW TE M20x110 4


4 COVER 1

5 GASKET 2

6 CURVED SPRING LOCK WASHER A20 4


8 NUT M20 4

9 NUT M12 6

10 CAPSCREW M16X40 2


12 WASHER M16 8

13 FLANGE GEAR SIDE 1

14 BUSHING 2

15 CAPSCREW TE M 16X50 11

16 PIN 8X12 2

17 BRONZE GEAR Z=30 1

18 HUB 1

19 NUT M16 12

20 BEARING 2

21 GASKET 2

22 OIL PLUG 2

23 FLANGE 1

24 OIL SEAL 58X85X10 1

25 MOTOR FLANGE 1

26 CAPSCREW TE 16x50 6

27 HYDR. RADIAL MOTOR 1 SPEED 1

27 HYDR. RADIAL MOTOR 2 SPEED 1

28 CAPSCREW WORM 1

29 GEAR HOUSING 1

30 KEY 2

31 CLUTCH KEY 2

32 SHAFT 1

33 BUSHING 2

PART NO.

ITEM NO.

DESCRIPTION Q.TY

34 DRUM 1

35 CABLE CLAMP 1


37 THRUST WASHER 1

38 SLIDING JAW CLUTCH 1

39 THRUST WASHER 1

40 BUSHING 1

41 FORK 1

42 SPRING 1

43 CAPSCREW - REGISTER 1

44 LOCK NUT M12 1

45 BAND BRAKE 1

46 AXE 1

47 SNAP RING 2

48 GREASE FITTINGS 1

49 SUPPORT 1

49A SUPPORT FOR AIR CLUTCH 1

50 FLANGE 1

51 KNOB 1

52 LEVERAGE 1

53 SNAP RING 2

54 HANDLE 1

55 LEVER 1

56 CAPSCREW TE M12X80 1

57 LOCK NUT M12 1

58 SPRING 1

59 AXE 1



62 NUT M33 4

63 MOUNTING ANGLE 1

64 MOUNTING ANGLE MOTOR SIDE 1


66 AIR CYLINDER 1


PARTS LIST FOR NH

SECTION 6 PARTS LIST

PART NO.

ITEM NO.

DESCRIPTION Q.TY

67 CLIP 1

68 LEVERAGE 1

69 LOCK NUT M12 1


71 WASHER 16 4

72 LOCK NUT M16 1


74 SNAP RING 16 2

75 LEVERAGE BACK PLATE 1

76 LEVERAGE 1

PART NO.

ITEM NO.

DESCRIPTION Q.TY

6.3 PARTS DRAWING


3433

32

3130

25

27

64

63

21

23

54

55

5048

49

60

4033

39

37

10

11

56

57

46

60

65

1512

22

79

3

5

1

26

24

20

14

11

15

6261

339

41

4342

5958

51

45

65

6261

29

18

28

23

21

16

4 68

62

61

62

61

12

3635

20

1011

12 14

13

1911

15

17

47

53

52

44

9

2

38

101112

50

7349

A41

66

6867

71

7247

46

45

76

43 42

4447

7475

70

48 69

AIR

CLUT

CH S

HIFT

ER V

ERSI

ON

Documents

M85817010_Manuale NH 25 UK-1.pdf