Atlantic Products BW230C Parts list manual

Compact
Brake
Winch
Series
Installation instructions
and operating manual
for Atlantic Compact
Brake Winches.
PLEASE READ CAREFULLY BEFORE OPERATING THE WINCH
BW230C
BW240NC
BW260C
BW280NC
BW290C

Bolt-down SpecificationsWinch Dimensions

Brake Winch Spare Parts Listing
SAMPLE
BW52C (BW230/40/60/80)
BR52K (BW210/20)
31A (BW210/20/30/40)
10111B (BW260/80)
BR51F (BW210/20/30/40) - (Pre-Pack)
10111G (BW260/80) - (Pre-Pack)

Installation of the Winch
ATTACHING THE HANDLE
1. Turn handle adaptor clockwise until ratchet
has engaged.
2. Attach the handle once the ratchet has
engaged.
INSTALLING THE WINCH
1. Locate the winch in an area clear of traffic
and obstacles that could interfere with
its operation. Make sure the winch is
accessible for maintenance and operation.
2. The winch should be positioned onto a
solid / flat foundation base able to support
the winch and the load / unload operations
under all conditions.
3. Fasten the winch securely to the mounting
(base), utilising all four mounting holes
to ensure maximum capacity. 4ea. M10
galvanised or G316 stainless steel bolts,
flat and spring washers and nuts should be
used to secure the winch to its mounting.
INSTALLING WIRE CABLE / ROPE
Keep the following in mind when selecting.
Contact a reputable supplier for assistance.
1. Breaking strength of new wire cable / fibre
rope should be at least 2 times greater than
the rating of the winch.
2. Wire cable/fibre rope lay must agree with
the winding direction of the drum to insure
proper winding.
3. Secure the wire cable / fibre rope to the
winch drum as per the securing instructions
below.
4. Test the wire cable / fibre rope installation
by operating the winch.
5. Wind three full turns of wire cable onto the
drum by operating the winch whilst holding
the wire cable taut. These turns serve as
an anchor wraps and must remain on the
drum at all times.
Dependant on Winch model, two securing
methods for cable are applicable:
Instruction for securing a cable to a winch
using a plate clamp fitting:
1. Tape the cable end using 50mm – 70mm
of plastic tape. This is to stop the cable end
from fraying and causing injury in use.
2. Fold the end of the cable (approximately
30mm) back on itself and permanently kink
the end.
3. Feed the taped end of the cable through
the round hole of the drum flange (disc)
from inside the drum.
4. Place one of the cup head bolts into Hole 1
of the clamp fitting, with the head on the
inside of the drum assembly, and pull the
cable tight against the bolt. Attach the nut
and tighten.
5. Align the second hole in the plate with Hole
2, and secure with the second bolt and nut.
Instruction for securing a cable to a winch
using a single bolt fitting
1. Place the cup headed bolt into the square
hole with the head on the inside of the
drum assembly.
2. Screw on the combination nut and washer
only 2-3 threads.
3. Tape the cable end using 50mm – 70mm
of plastic tape. This is to stop the cable end
from fraying and causing injury in use.
4. Feed the taped end of the cable through
the round hole of the drum flange (disc)
from inside the drum and double back to
loop the cable under the bolt, behind the
washer and back towards the round hole.
5. While holding the cable in place under the
nut with the left hand, pull the cable tight
with the right hand.
6. Using the thumb of the left hand hold the
cable in place inside the drum and tighten
the nut to secure the cable in place.
Turn the handle to wind the wire cable
onto the winch drum. Uniformly wind the
wire cable onto the winch drum by holding
the wire cable taut.
Instruction for securing fibre rope to winch
– Note: Fibre rope to be ≤ Ø7mm
1. Take the winch drum with the gear facing
the assembler and the free end of the rope
and wrap three turns around the hub of the
drum in an anticlockwise direction.
2. Take the free end and pass it between the
three turns and the drum hub and then
pass the free end over the three turns on
the drum and under the last turn.
3. Pass free end of the rope under the last bite
and through the ‘cable’ hole in the flange.
Pull firmly so that the turns on the drum
lie reasonably flat. The length protruding
needs to be about 150mm.
4. Insert from inside the drum flange (centre
hole) the M6 square neck cup head bolt
and screw the M6 flanged serrated hexagon
nut onto the bolt.
5. Wrap the rope around the M6 bolt inside
the flanged serrated hexagon nut. Secure
the fibre rope by tightening the nut using
an M6 spanner. When securing, ensure that
the rope fibres do not catch on the bolt
threads and that the rope stays inside the
flanged section. Trim any excess rope.
6. The turns around the drum will have
become loose. Work the turns so that the
rope lays flat against the hub and there is
no slack.
IMPORTANT:
Inspect the winch immediately
following installation. This will give
provide a record of the condition of
the winch from which to compare
future inspections.
IMPORTANT:
Use wire cable/fibre rope and other
rigging equipment rated for the capacity
of the winch.
Do not drag the wire cable/fibre rope
through dirt or debris that could cause
damage, or poor operation.
Always wear protective clothing when
handling wire cable.
Install the wire cable/fibre rope securely
to the winch drum. A poorly secured wire
cable/fibre rope could come loose from
its anchor and could release the load.
Ensure the wire cable/fibre rope is
wound correctly or the winch may not
work properly and could release the
load.
Always ensure that a minimum of three
full turns remain on the winch drum at
all times.
WARNING:
Do not install the winch near corrosive
chemicals, flammable materials or
other elements that may damage
the winch or injure the operator.
Adequately protect the winch and
operator from such elements.
Position the winch so the operator
can stand clear of the load, and out of
the path of possible broken wire cable
that could snap back and cause injury.
Attach the winch to a rigid and level
foundation that will support the winch
and its load under all load conditions,
including shock loading.
DO THE FOLLOWING:
• Read carefully and comply with the
guidelines set forth in this Operating
Manual.
• Keep hands away from the drum, gears,
wire cable and other moving parts of the
equipment. Install the wire cable/fibre
rope securely to the winch drum.
• Keep your clothing clear of the cable,
rope and hook and its opening during
operation and/or when spooling.
• Tighten the brake winch handle adapter
before use to ensure optimal braking
ability.
• Ensure cable/rope is secured correctly
before use of the brake winch.
• Cable/rope is required to be wrapped
around drum a minimum 3 times, at all
times.
• Regularly examine all parts of the brake
winch and do not use if damaged. Repair
or replace any defective parts of the
brake winch.
• Keep out of the path of the load should
the wire cable/fibre rope break and snap
back and cause injury.
TEMPERATURE
• Winches may be operated in
temperatures from -25°C to +49°C
• Winches may be stored in temperatures
from -25°C to +63°C
• Winches shall not be forcefully or
rapidly cooled or heated. For example,
winches shall not be placed into sub-zero
refrigerated transport modules, nor
subjected to heat guns or gas torches.
DO NOT DO THE FOLLOWING:
• Do not lift people or lift a load over
people. Alert all people in close
proximity and keep non-operating users
away from the working area before use
of the brake winch.
• Never lift more than the capacity stated
on the brake winch.
• Never apply a load on the brake winch
with the cable in full extension.
• Do not walk or work under a load or in
the line of force of any load.
• Do not exceed the load rating of the
winch or any other component in the
system. To do so could result in failure of
the equipment.
• Do not use more than one winch to move
a load that exceeds the load rating of a
single winch. A shift in load weight could
overload the equipment.
• Do not use damaged or malfunctioning
equipment. To do so could result in
failure of the equipment.
• Do not modify the equipment in any way.
To do so could cause equipment failure.
• Never lubricate (grease) the braking
mechanism of the brake winch.
• Do not apply a load on the winch with
the wire cable/fibre rope fully extended.
• Never disengage the clutch while the
cable/rope is under tension.
• Never engage the clutch while the drum
is rotating.
• Never winch when there are less than
3 wraps of cable/rope on the drum.
• Never wrap the cable/rope around a load
as this will damage the cable/rope.
• Do not swing the load as this may cause
damage.
• Never leave a suspended load
unattended.
• Do not wrap the wire cable/fibre rope
around the load. This may damage the
wire cable/fibre rope and could cause the
load to fall. Use a sling or other approved
lifting device.
• Do not divert your attention from the
operation. Stay alert to the possibility of
accidents, and try to prevent them from
happening.
• Do not jerk or swing the load. Avoid
shock loads by starting and stopping the
load smoothly. Shock loads overload the
equipment and may cause damage.
• Do not leave a suspended load
unattended unless specific precautions
have been undertaken and keep people
away from the winch and out from under
the load.
GENERAL THEORY OF OPERATION
IMPORTANT: Limit non-uniform winding
by keeping tension on the wire cable. It
is the operators responsibility to detect
and account for different factors affecting
the condition and performance of the
equipment.
The pull required to move the load must not
exceed the load rating of the winch. Consider
the total force required to move the load, not
the weight of the load.
The winch can develop forces that will
exceed the load rating. It is the responsibility
of the winch operator to limit the size of the
load. Inspect the winch regularly for damage
according to the instructions contained in the
Owner’s Manual.
Performance ratings of the winch are
affected by the amount of wire cable wound
onto the drum, the way in which it is wound,
and the way the winch is used.
Drum capacity depends on how tightly and
evenly the wire cable is wound onto the
drum. Actual drum capacities are usually
25-30% less than the values shown in
performance tables, due to loose winding and
overlapping.
Load rating represents the maximum pull
that can be placed on a new winch. Load
ratings are assigned values for specific
amounts of load travel or wire cable
accumulation. The load rating decreases as
layers of wire cable accumulate on the drum.
Duty ratings refer to the type of use the winch
is subject to. Consider the following when
determining duty rating:
Environment: harsh environments include
hot, cold, dirty, wet or corrosive surroundings.
Protect the winch against harsh environments
when possible.
Maintenance: poor maintenance, meaning
poor cleaning, lubrication or inspection, leads
to poor operation and possible damage of
the winch. Minimise poor maintenance by
carefully following the instructions contained
in the Owner’s Manual.
Loading: severe loading includes shock
loading and moving loads that exceed the
load rating of the winch. Avoid shock loads,
and do not exceed the load rating of the
winch.
Frequency of operation: frequent or lengthy
operations increase wear and shorten the life
span of gears, bushes, and other components.
Increase maintenance of the winch if used in
frequent operations.
Important Safety Information

Inspections
PRE-OPERATIONAL INSPECTION
Visually inspect the entire winch and all
other associated equipment involved in the
operation.
• Check all equipment for cracks, dents,
bending, rust, wear, corrosion and other
damage.
• Check gears, shafts and bushes for wear,
and other damage.
• Make sure the wire cable is installed
correctly and anchored securely to the
drum
• Make sure the winch is properly
lubricated.
• Make sure the handle is securely held in
place.
• Make sure the mounting fasteners are
tightened securely
• Make sure the foundation is in good
condition, and capable of supporting
the winch and its load under all load
conditions.
Test winch performance by moving a test
load equal to 20% of the rated capacity.
• Listen for unusual noises, and look for
signs of damage as you operate the
winch.
• Make sure the winch cable winds evenly
and tightly onto the drum. If it is loose or
uneven, rewind it before continuing.
• Make sure the handle moves freely in
both directions.
Completely correct all problems before
continuing. Use the Troubleshooting Chart
(at end of this Section) to help determine
the cause of certain problems.
REGULAR INSPECTIONS
Visually inspect the entire winch and all
other associated equipment involved in
the operation.
• Do not continue to use the damaged or
overloaded equipment.
• Check the finish for wear, flaking, or
other damage.
• Check all equipment for cracks, dents,
bending, rust, wear corrosion and
other damage. If the equipment was
overloaded, or if you notice cracks and
other signs of overloading and damage,
promptly remove the equipment from
use and have it repaired or replaced.
• Inspect friction plates/pads and mating
surfaces for contamination, dust,
corrosion and wear. If necessary, lightly
remove surface contamination, etc.
REPLACE friction plates/pads if excessive
wear (to 1mm thick) is evident or are
either cracked or broken.
• Check all fasteners for stripped threads,
wear, bending, and other damage.
• Check gears, shafts and bushes for wear,
and other damage.
• Check the foundation for cracks,
corrosion, and other damage.
• Make sure the winch is properly
lubricated.
• Make sure all labels and plates are
readable, firmly attached, free from
damage and clean.
PERIODIC INSPECTIONS
Visually inspect the entire winch and all
other associated equipment involved in
the operation.
• Do not continue to use the damaged or
overloaded equipment.
• Detailed inspection of full length of rope
• Detailed inspection of both end
terminations
• Measuring hook wear
• Removing covers and looking at all
internal components
• Checking all nuts and bolts for tightness
• Review / assess the maintenance
procedures that are currently being
implemented, and comparing them to
the usage and environment
• Check the finish for wear, flaking, or
other damage.
• Check all equipment for cracks, dents,
bending, rust, wear corrosion and
other damage. If the equipment was
overloaded, or if you notice cracks and
other signs of overloading and damage,
promptly remove the equipment from
use and have it repaired or replaced.
• Inspect friction plates/pads and mating
surfaces for contamination, dust,
corrosion and wear. If necessary, lightly
remove surface contamination, etc.
REPLACE friction plates/pads if excessive
wear (to 1mm thick) is evident or are
either cracked or broken.
• Check all fasteners for stripped threads,
wear, bending, and other damage.
• Check gears, shafts and bushes for wear,
and other damage.
• Check the foundation for cracks,
corrosion, and other damage.
• Make sure the winch is properly
lubricated.
• Make sure all labels and plates are
readable, firmly attached, free from
damage and clean.
Technical inspections of the Brake Winch from pre-operational to periodic
inspections including major repairs (lubricants, torque specifications) are to be
performed by a vehicle mechanic.
PERFORM:
• Before each operation.
• Whenever you notice signs of damage
or poor operation
PERFORM:
• Every three (3) months.
• Whenever you return the winch to
service from storage.
• Whenever you notice damage or poor
operation in a frequent inspection.
• Whenever you have, or think you may
have, overloaded or shock loaded the
winch.
PERFORM:
• Every twelve (12) months.
• Whenever you return the winch to
service from storage.
• Whenever you notice damage or poor
operation in a frequent inspection.
• Whenever you have, or think you may
have, overloaded or shock loaded the
winch.
PREPARING FOR OPERATION
Consider the operation. Do not begin until
you are sure you can perform the entire
operation without hazard.
Inspect all components of the system.
Inspect the winch and other equipment in
accordance with Inspection instruction.
Operators should be in good health, alert and
suitably clothed (i.e. no loose clothing)
The load must be clear of objects and free to
move. Ensure the load will not tip, spin, roll
away, or in any way move uncontrollably.
Know your load and make sure you do not
exceed the load rating of the winch or any
other equipment in your system.
ATTACHING THE LOAD
Clear objects from the path of the load so you
can move it freely and observe it at all times
during the operation.
Attach the load using a nylon sling, or
other approved rigging device. Follow the
recommendations of the sling manufacturer.
Seat the sling in the saddle of the snap hook
with the hook latch completely closed.
Centre the load on the hook so it will remain
balanced and not tip or rotate to one side.
MOVING THE LOAD
Move the load slowly and smoothly, only a
small distance at first. Make sure the load
is balanced and securely attached before
continuing.
Observe the wire cable as it winds onto
the drum. If it becomes loose, uneven, or
overlapped, stop the operation and rewind
before continuing. Continued operation with
overlapped or uneven wire cable can damage
and shorten its life.
LUBRICATING THE WINCH
Lubricate the winch properly to help protect it
from wear and rust.
Ensure no lubricant comes in contact with the
brake pads (mechanism)
Lubricate the winch at least every three
months, by applying a light grade oil to the
shafts and bushes. Rotate the drum several
times to allow oil to penetrate, and wipe off
excess oil to avoid dirt accumulation.
CLEANING THE WINCH
Clean the winch to remove dirt and help
prevent rust and corrosion.
Clean the winch every three months or
whenever it is dirty.
Wipe all components to remove dirt and
grease.
Leave a light film of oil on all surfaces to
protect them against rust and corrosion.
Ensure no lubricant comes in contact with
the brake pads (mechanism)
Wipe off excess amounts of oil to avoid
accumulation of dirt.
Remove all unnecessary objects from the area
surrounding the winch.
INSPECTING THE WINCH
Inspect the winch to detect signs of damage
or poor operation before they become
hazardous.
DISCARDING THE WINCH
Each winch has a finite design life after which
it shall be discarded. The design life shall be
the lesser period of 7 (seven) years from the
date of commissioning or 8 (eight) years from
the date of purchase.
IMPORTANT:
When determining whether the load
will exceed the load rating, consider
the total force required to move the
load.
WARNING:
Do not wrap the wire cable / fibre rope
around the load. This may damage the
wire cable / fibre rope and could cause
the load to fall. Use a sling or other
approved lifting device.
IMPORTANT:
Obey a stop signal from anyone.
Maintain tension on the wire cable to
keep it tightly and evenly wound on
the drum.
If the winch and load are not visible
during the entire operation, get help
from another person.
Appoint a supervisor if more than one
person is involved in the operation.
This will reduce confusion and
increase safety.
Where possible, remove the handle
when the winch is not in use, to help
avoid unauthorised use.
IMPORTANT:
Make sure the lubricant has a
temperature rating appropriate for
the ambient temperatures of the
operation.
IMPORTANT:
Keep written records of inspection.
This allows comparison with
comments from previous inspections
so you can see changes in condition or
performance
IMPORTANT:
Increase the frequency of
maintenance if the winch is:
• Operated for long periods.
• Used to pull heavy loads.
• Operated in wet, dirty, hot or cold
surroundings.
Operations of the Brake Winch including non-technical periodic inspections,
maintenance requirements and adhering to the safety considerations outlined in
this instruction manual are to be performed by a qualified driver.
Preparation for Operation

Problem Possible Cause(s) Corrective Action
Handle turns, drum doesn’t turn • Loose or broken pins
• Loose, stripped or broken gears
• Inspect winch, repair as necessary
• inspect gears and repair as necessary
Handle turns hard or not at all • Gears broken or locked
• Load too heavy
• Pins loose or broken on winch
• Drum shaft broken or seized
• Brake disc damaged or locked
• inspect and repair as necessary
• Lighten load
• Inspect winch, repair as necessary
• Inspect, repair or replace as necessary
• Inspect brake, repair as necessary
Brake does not operate properly • Friction discs worn or damaged
• Friction discs damaged from lubrication
• Disc brake ratchet pawl damaged
• Handle adapter loose
• Inspect and replace as necessary
• Inspect and replace as necessary
• Inspect and repair as necessary
• Tighten handle adapter on drive shaft
Excessively worn gears or bushes
• Load too heavy
• Poor lubrication of gears or bushes
• Lighten load
• Inspect and relubricate as necessary
Overheating • Operated too long without rest
• Load too heavy
• Poor lubrication
• Bushings seized up / damaged
• Allow to cool
• Lighten load
• Inspect and lubricate as necessary
• Inspect and replace as necessary
Unusual noises
(high pitched squeak /
grinding noise / rattling noise)
• Poor lubrication
• Contaminated lubrication
• Loose bolts, or other fasteners
• Inspect and lubricate as necessary
• Clean and re-lubricate winch
• Tighten all bolts and other fasteners
Troubleshooting GuideInspections (continued)
Figure 1 - Broken Wires
The wire rope assembly must be replaced
if more than 6 wires are broken in one lay,
or if more than 3 wires are broken in one
strand in one lay.
Figure 2 - Load Hook Inspection
The wire rope assembly must be replaced
if the throat opening is 15% wider than
nominal, if the thickness is 10% less than
nominal, or if the hook is twisted 10
degrees or more.
Figure 3 - Rope Diameter
The wire rope assembly must be replaced if
the diameter measures less than the mini-
mum diameter at any point.
IF YOUR WINCH INSTALLED
WITH FIBRE ROPE:
1. Unwind the fibre rope completely.
• Check the entire length of fibre rope for
excessive wear, chafing, cuts, dirt and
grit, and other damage.
Then,
• Make sure the snap hook is securely
attached to the fibre rope.
• Check the throat opening, thickness, and
twist of the snap hook. Replace the hook
if it shows signs of damage. See figure 2.
• Make sure the hook latch opens without
binding and closes when released.
• Check the anchor holes in the drum
flange, clamp fittings and bolts for signs
of wear or distortion.
IF YOUR WINCH INSTALLED
WITH WIRE CABLE:
1. Remove the wire cable entirely from
the drum.
• Always wear protective clothing when
handling wire cable.
• Check the entire length of wire cable
for bent wires, crushed areas, broken or
cut wires, corrosion, and other damage.
Carefully inspect areas that pass over
sheaves or through roller guides.
• Note the location and concentration of
broken wires. Replace the wire cable if
more than 6 wires are broken in one lay,
or more than 3 wires are broken in one
strand in one lay. See Figure 1.
• Make sure the snap hook is securely
attached to the wire cable, and the wire
cable where it is attached is not frayed,
corroded, broken, or otherwise damaged.
• Check the throat opening, thickness, and
twist of the snap hook. Replace the hook
if it shows signs of damage. See figure 2.
• Make sure the hook latch opens without
binding and closes when released.
• Check the anchor holes in the drum
flange, clamp fittings and bolts for signs
of wear or distortion.
• Measure the diameter of the wire
cable, especially in areas where wear is
noticeable. Replace the wire cable if the
diameter measures below the minimum
diameter at any point. See figure 3.
2. Remove the winch from the
foundation.
• Check fasteners for stripped threads,
wear, bending, and other damage.
• Check the frame (winch body) for
bending, distortion, cracks, and other
damage. A bent frame is caused by
overloading, and is a sign that your
application may require a winch with a
larger load rating.
• Move the drum with your hands.
• Check for excessive movement indicating
worn or loose gears, bushings, or shafts.
• Disassemble the winch if necessary.
Inspect gears, shafts and bushes for wear,
corrosion, distortion, and other damage
3. Fasten the winch securely to the
foundation.
4. Install the wire cable.
5. Test winch performance by operating
the winch with a test load equal to the
load rating.
• Listen for unusual noises, and look for
signs of damage as you operate the
winch.
• Make sure the winch cable winds evenly
and tightly onto the drum. If it is loose or
uneven, rewind it before continuing.
• Make sure the handle moves freely in
both directions.

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www.atlanticproducts.com.au
All documentation meet AS1418.1 and AS1418.2. Last updated Aug 2021