Nabrico DF-356-UFW User manual

OM-DF356FST-001-A
NABRICO
DF-356 Upt Winch with FASST WinderTM Owner’s Manual

THIS PAGE IS INTENTIONALLY LEFT BLANK.

3
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
CONTENTS
SAFETY INFORMATION ........................................................................................ 4
1.1 GENERAL INFORMATION ............................................................................. 5
1.2 INSTALLATION OF EQUIPMENT................................................................... 6
1.3 INSTALLATION OF WIRE ROPE.................................................................... 8
2.1 OPERATING THE WINCH.............................................................................. 10
3.1 EQUIPMENT INSPECTION ........................................................................... 15
3.2 EQUIPMENT LUBRICATION ......................................................................... 17
3.3 CLEANING AND STORAGE.......................................................................... 18
A.1 DIMENSIONAL .............................................................................................. 19
A.2 BASE BAR COMPARISON............................................................................ 20
A.3 PARTS BREAKDOWN................................................................................... 22
A.4 PARTS LIST................................................................................................... 23
A.5 FLEET ANGLE .............................................................................................. 24
PRODUCT WARRANTY ........................................................................................ 25
PRODUCT NOTICES............................................................................................. 25
NABRICO
DF-356 Upt Winch with FASST WinderTM
Owner’s Manual
NABRICO
1250 GATEWAY DRIVE
GALLATIN, TN 37066
TEL: [phone] FAX: [phone]
www.nabrico-marine.com

4
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
SAFETY INFORMATION
CAUTION
Prior to installing and operating the winch, please read this manual thoroughly and carefully. Keep this
manual and all other instructions accessible at all times.
The Occupational Safety and Health Act of 1970 states that it is the employer’s responsibility to provide
a workplace free of hazard. To this end, all equipment should be installed, operated and maintained in
compliance with applicable trade, industrial, federal, state and local regulations. It is the equipment owner’s
responsibility to obtain copies of these regulations and to determine the suitability of the equipment for the
equipment owner’s intended use.
Although this manual will help you become familiar with the basic operation of the winch, it is by no means
a substitute for proper training by your company in the safe use of winches, barge rigging and other marine
equipment. This manual suggests methods of operation, but ultimately, the owners and operators of the
equipment are responsible for determining whether a particular method of operation is safe and appropriate
for the equipment being operated. Only individuals trained in the proper use of winches, barge rigging and
other marine equipment should operate these winches.
The typical operating environment of barge and towboat winches often includes very high forces, and the
potential hazards associated with these high forces should not be underestimated. Improper installation or
incorrect or unsafe use could result in injury or death to persons or cause equipment failure or damage.
Recommended Information for Safe Operation:
CAUTION
• Check lubrication before use.
• Do not apply tension to the winch unless there are 4 complete wraps of rope on the drum.
• Do not operate the equipment unless you have a firm stance on a non-slippery surface.
• Do not wrap the wire rope around the load. This will damage the wire rope and could cause the load to
escape. Rigging connectors are strongly recommended to secure the wire rope to the load.
• Keep fingers, loose clothing and any foreign objects away while operating the equipment.
• Do not divert attention away while operating the equipment. Stay alert to the possibility of accidents and
try to prevent them from happening.
• Always remain to the side of the equipment while in operation.
• Never operate the equipment from the front or when bystanders are in front of it.
• Operators and bystanders should stay clear of any load and the wire rope while the equipment is
operating.
• Avoid shock loads by starting and stopping the equipment smoothly. Shock loads can over load the
equipment which may cause damage.
• Under no circumstances should any equipment be used to move, raise or lower a person(s) or
equipment.
NOTICE
Inspect the equipment carefully at least once a month for loose fasteners, worn gears and pawls,
cracked welds and other damaged parts. If any worn, cracked or damaged parts are found, stop
use immediately and remove equipment from service until all appropriate repairs are completely
made.

5
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
1.1 GENERAL INFORMATION
EVERYTHING YOU NEED FROM THE
MODEL NO. HOLDING DOG
& OR BRAKE
LINE PULL @ FIRST LAYER
WITH ONE MAN (LBS) DRUM CAPACITIES (FT) WEIGHT
DF-356-UFW S. TONS HAND
WHEEL
RATCHET
W/STD. EXT. 5/8” 3/4” 7/8” 1” 1-1/8” LBS
40-11-M 40 8,000 17,800 340 219 132 115 60 1,650
40-18-M 40 8,000 17,800 563 363 224 198 107 1,875
NABRICO
nabrico-marine.com 615.442.1300
DF-356 FASST WINDER WINCH
Features & Specifications
• Hot-dipped Galvanized coating.
• Patented high load release dog with
secondary anti-backlash drag brake that is
activated automatically with the release of
the dog.
• High load release brake is a multi-disc
system that incorporates all stainless steel
moving parts.
• No hot work required: mounts to DF-3,
DF-156 and some competitors models.
• Heaviest winch in its class at 1,650 lbs.
• Incorporates our powerful FASST Winder
system.
• No ratchet or ratchet handle extension.
• Ergonomic height.
• Uses standard 40-ton winch drive train.
• 2 year warranty.
• Fully guarded gears.
• Fastest and easiest way to fully tighten a winch.

6
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
1.2 INSTALLATION OF EQUIPMENT
NOTICE
It is the responsibility of the customer, not the winch manufacturer, to properly locate and install the
winch with regard to the safety of those operating the machinery.
CAUTION
Install the equipment in an area where there is ample room to operate the unit without the
operator becoming entangled in the cable, lines, chains, winch mechanisms or other nearby
equipment.
1.2.1 All winches must be installed on a flat, rigid and non-slippery surface. Deck and structure must be
strong enough to withstand the weight and holding capacity of the winch and ultimate capacity of the
wire, and the forces likely to occur during operation. A qualified professional should inspect or design
the foundation to insure that it will provide adequate support.
1.2.2 Locate the winch in a suitable area free of traffic and obstacles. The winch should also be visible
during entire operation. Keep in mind that the winch needs to be accessible for proper lubrication,
maintenance and operation.
1.2.3 The DF-356 winch is made to mount with no hot work required when replacing a DF-3 or DF-156
winch. This winch also comes with its own set of base bars if the base bars from the DF-3 or DF-156
winch are no longer usable.
1.2.3.1 When mounting the DF-356 winch to the base bars from a DF-3 or DF-156 winch, not all of
the bolt holes will be filled (see appendix 2).
1.2.4 Mounting direction must be in line with the desired direction of cable pull. The front of the winch must
face in the direction from which the cable is reeled (see fig. #1). The winch drum, when properly used,
will reel the wire rope onto the bottom of the drum.
FIGURE #1 - MOUNTING POSITION
BACK OF WINCH
FRONT OF WINCH
WIRE ROPE

7
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
1.2.4.1 If the direction of the wire rope is not indicated on the winch, determine as follows:
Engage the locking pawl and disengage the brake system. Rotate the winch drum using
either the handwheel or hand ratchet. The only allowable direction for the drum to rotate is to
reel in the wire rope onto the drum at the bottom.
1.2.5 Check to ensure that there is enough clearance between winch drum and mounting surface. Check
to make sure there is enough clearance for proper operation of the handwheel and FASST WinderTM.
Rotate the FASST WinderTM back and forth checking for clearance issues (see fig. #2).
1.2.6 Maintain a fleet angle no greater than 1-1/2 degrees from winch drum to lead sheave (see appendix
5). The proper fleet angle helps to minimize wire rope damage by assisting the wire rope to wind
uniformly onto the drum.
1.2.7 Using sufficient tack welds, secure the base bars to the deck or doubler plate. This will prevent the
winch from becoming misaligned from heat distortion during the application of the seal weld.
1.2.8 Next apply a seal weld to the mounting fixture to permanently secure it to the deck. The seal weld will
prevent corrosion from occurring between the mounting fixture and mounting surface.
1.2.9 Inspect the winch immediately following installation. This inspection will give a good starting record of
the winch condition so that future inspections can be compared.
CAUTION
Remember that the weld has to be strong enough to withstand loads equal to or greater than
the capacity of the winch and ultimate capacity of the wire.
FIGURE #2 - FASST WINDERTM CLEARANCE
40°
40°
WINCH HANDWHEEL NOT SHOWN FOR CLARITY
WIRE ROPE

8
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
1.3 INSTALLATION OF WIRE ROPE
1.3.1 To install wire rope, rotate the drum of the winch so that the U-bolt nuts are easily accessed through
the round cut out located on the side of the winch (see fig. 3a).
1.3.2 Using a standard socket wrench with an extension, loosen the nuts.
1.3.3 If installing wire rope on a new winch, remove and discard the u-bolt spacer pipe. If replacing worn out
wire rope, remove the wire rope from the U-bolt and dispose of properly.
FIGURE #3 - INSTALLING THE WIRE ROPE
CAUTION
Remember to always wear the proper protective equipment when handling the wire rope.
1.3.4 Insert the new wire rope end under the winch drum and through the U-bolt from the front of the winch
so that approximately 3 to 4 inches extend through the U-bolt (see fig. 4b).
1.3.5 Tighten the U-bolt nuts evenly to secure the wire rope to the winch drum. The U-bolt will act as a vise
keeping the wire rope in place as the rest of the rope is reeled onto the winch. Retighten the U-bolt
after 24 hours.
NOTICE
Breaking strength of new wire rope should be a least 3 times greater than the largest load placed on
the winch. This minimum value may be greater depending on type of load and the method of moving
the load.
CAUTION
The U-bolt nuts must be retightened periodically to insure that the wire rope end is held in
place snugly against the drum flange. Over time and usage the rope will “crush” down at the
U-bolt creating the possibility that the rope end will escape.
CABLE
CLAMP
WINCH
DRUM
CABLE
CLAMP
ACCESS
WIRE
ROPE
EXTEND WIRE
ROPE 3” TO 4”
A) LOCATING THE CABLE CLAMP B) INSTALLING THE WIRE ROPE

9
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
1.3.6 Wind the wire rope onto the drum by operating the winch. Maintain tension on the wire rope to insure
that the first coil lays snugly against the drum flange and each successive coil is snug against the
previous coil. Make sure that the wire rope is being reeled in from the bottom on the winch drum.
1.3.7 Continue wrapping the wire rope until there are at least 3 to 4 complete wraps on the winch drum.
These wraps serve as an anchor and must remain on the drum at all times.
WARNING
In order for the winch to attain its full holding capacity, 3 to 4 complete wraps of the wire rope
must be on the winch drum at all times. Also, make sure the rope is installed securely to the
drum. A poorly secured wire rope could come loose from its anchor and allow the load to
escape.
NOTICE
Drum capacity depends on how tightly and evenly the wire rope is wound on the drum. Actual drum
capacities are usually 25% to 30% less than values given in performance tables when the wire rope
is loosely wound and overlapping. Also, line speed will increase with each additional layer of wire
rope that is wound onto the drum.

10
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
2.1 OPERATING THE WINCH
The DF-356 Upfit Winch with FASST WinderTM is operated by using either the hand wheel or FASST
WinderTM System. The winch is also equipped with a disc braking system, locking dog and anti-backlash
friction band. The following operating instructions will help you become familiar with these basic operating
components of the winch. These instructions are not a substitute for proper training by your company in the
safe use of winches, barge rigging and other marine equipment.
2.1.1 Handwheel Operation
2.1.1.1 Normally the winch is shipped with the handwheel mounted to the winch. If the handwheel
is not installed, upon receiving the winch, attach the handwheel to the handwheel hub using
the 4 bolts and lock washers that are included. Refer to the parts breakdown drawings
located in the appendix for location of the winch components.
2.1.1.2 After installing the handwheel, use it to turn the winch drum in either a clockwise or counter-
clockwise motion. The drum rotation, which is the same as the handwheel rotation, will spool
wire rope onto or off the bottom of the winch drum. If the winch drum will not rotate freely
refer to operation instructions for the brake and dog systems to ensure that nothing is locked
down.
WARNING
Do not use the handwheel as a brake or anchor for a load.
2.1.1.3 Prior to tightening the winch, engage the locking pawl per instructions 2.1.3.1.
2.1.1.4 The handwheel assembly is equipped with a speed handle that can be used for faster
operation.
2.1.1.5 When operating the winch, always maintain tension on the wire rope to keep it tightly and
evenly wound on the winch drum.
NOTICE
Breaking-in the winch occurs during the first 10 hours of normal operation. During break-in, mating
surfaces become polished and clearances increase. This is desired for efficient operation of the
bearings and gears.

11
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
2.1.2 FASST WinderTM Operation
2.1.2.1 The winch is equipped with a FASST WinderTM system for use when additional wire rope
tightening is needed. The FASST WinderTM should be placed in rest position when not being
used (see fig. #4).
2.1.2.2 To use the FASST WinderTM, firmly place both hands on the FASST Grab Handle and place
foot closest to winch on the FASST Foot Peg (see fig. #5). While keeping your opposite foot
firmly planted on the deck, pull on the FASST Grab Handle with both hands and push on the
FASST Foot Peg with your foot (see fig. #6). After the FASST WinderTM has traveled fully to
the engaged position, reverse this process to bring it back to the rest position. Continue this
motion until full tension has been acheived.
WARNING
Do not engage the FASST WinderTM while the winch gears are turning. Do not stand on or
within the travel area of the FASST WinderTM. Serious injury or even death may result.
2.1.2.3 Upon completion of using the FASST WinderTM system, return it to its resting position with
the handle positioned to the back of the winch.
FIGURE #4 - FASST WINDERTM MECHANISM
WINCH HANDWHEEL NOT SHOWN FOR CLARITY
BACK OF WINCH FRONT OF WINCH
WIRE ROPE
FASST GRAB HANDLE
FASST FOOT PEG

12
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
FIGURE #5 - FASST WINDERTM Rest Position
FIGURE #6 - FASST WINDERTM Forward Position

13
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
2.1.3 Locking Pawl and Anti-Backlash Friction Band Operation
The manual winch uses a combination locking pawl and anti-backlash friction band assembly to
secure the wire rope that is either being loaded or unloaded under tension. The locking pawl prevents the
load from releasing while tension is being applied to the wire rope. The anti-backlash friction band is used to
control the release of the rope under tension. This controlled release is necessary to avoid excessive payout
speeds that could result in line backlashing or rope fouling on the drum.
2.1.3.1 To engage the locking pawl, position the pawl release handle in the forward position (see
fig. #7a). While the handle is in this position the locking pawl is free to interact with the pawl
gear. This position of the handle also disengages the anti-backlash friction band.
2.1.3.2 To disengage the locking pawl, pull the pawl release handle towards the back of the winch
(see fig. #7b). As the locking pawl is lifted out of the pawl gear, the release handle will
engage the anti-backlash friction band.
2.1.3.3 Using the pawl release handle, the operator can now safely control the wire rope pay out
speed and relieve tension.
2.1.3.4 The pawl release handle can also be positioned so that both the locking pawl and friction
band are disengaged completely. This is accomplished by pulling the release handle as far
back as possible (see fig. #7c).
CAUTION
The anti-backlash friction band is not a substitute for securing a load. It is to only be used to
assist the operator in disengaging the locking dog and controlling wire rope pay out speeds.
a) Forward Position
locking pawl engaged and friction band disengaged
b) Drag Position
locking pawl disengaged and friction band engaged
c) Back Position
locking pawl and friction band disengaged
100% LOCKING PAWL
100% FRICTION BAND
LOCKING PAWL AND
FRICTION BAND RELEASE
FIGURE #7 - LOCKING DOG & ANTI-BACKLASH FRICTION BRAKE

14
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
2.1.4 Disc Brake Operation
The winch uses a multi-disc braking system to secure the loads placed on it. The brake system is
designed to hold loads equal to that of the winch capacity.
2.1.4.1 To engage the disc braking system, simply turn the brake handle clockwise. This allows the
handle shaft to screw into the brake housing thus clamping down the brake components.
Continue turning the handle until it becomes snug. The brake should now be set and ready
to maintain tension.
2.1.4.2 To disengage the disc braking system, simply turn the brake handle counter-clockwise. The
handle can be turned until it is in the fully open position. The brake should now be off and
the winch is ready to be loaded or unloaded.
CAUTION
Under no circumstances should loads of greater value than winch capacity be placed on the
brake system or winch. To do so could cause equipment failure and damage or personal injury.

15
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
3.1 EQUIPMENT INSPECTION
NOTICE
An inspection program should be started as soon as any equipment is put into service. A qualified
person should be appointed the responsibility of regularly inspecting the equipment. Written records
of inspections are recommended by the manufacturer.
3.1.1 Frequent Inspection
3.1.1.1 Visually inspect the equipment before each use. Check the equipment for cracks, bending,
wear, rust, corrosion and any other damage. If any problems are discovered, stop use
immediately and remove the equipment from service until all appropriate repairs are
completely performed.
3.1.1.2 ENSURE THAT EQUIPMENT IS PROPERLY LUBRICATED.
3.1.1.3 Check to ensure that the foundation is in good condition. Make sure that mounting fasteners
and other hardware are tightened securely.
3.1.1.4 Ensure that the wire rope is installed correctly and anchored securely to the drum. Also,
check to make sure the wire rope is in good condition.
3.1.2 Periodic Inspection
3.1.2.1 Periodic inspections should occur whenever equipment is returned to service from storage,
every six months in service, more frequently if an inspection discovers any damage or poor
operation, or in any case where the winch may have been over loaded or operationally
abused.
3.1.2.2 Visually inspect the equipment checking the finish for wear, flaking or other damage as listed
in the frequent inspection plan. Disassembly is recommended in order to properly inspect
individual components.
3.1.2.3 Check the winch drum by moving it with your hands. Check for excessive movement that
may be the result of worn or loose gears, bearings or shafts. Some play is normal while
excessive play may be the result of overloading.

16
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
3.1.3 Wire Rope Inspection
3.1.3.1 Wire rope inspection should be conducted according to the manufacturer’s recommendations
or accepted industry standards.
ACTUAL
DIAMETER
CORRECT MEASUREMENT INCORRECT MEASUREMENT
THE WIRE ROPE MUST BE REPLACED IF THE DIAMETER MEASURES LESS THAN
THE MINIMUM DIAMETER GIVEN BY THE ROPE MANUFACTURER
EXAMPLE - A 3
4
" WIRE ROPE HAS A MINIMUM DIAMETER OF 45
64
" (0.7031")
FIGURE #8 - WIRE ROPE DIAMETER
CAUTION
Remember to always wear the proper protective equipment when handling the wire rope.
3.1.3.2 Inspect the entire length of wire cable for bent or crushed areas, broken or cut wires,
corrosion and other damage. If any defect or damage is found the cable must be replaced.
3.1.3.3 Inspect end connections and fittings for corrosion, kinking, crushing or other damage. If any
corrosion or damage is found the cable must be replaced.
3.1.3.4 Check the wire rope diameter for signs of decreased area (see fig. #8). Diameter decrease
may be signs of wear and internal degradation in the wire rope. Generally, wire ropes
are manufactured larger than nominal diameter. When placed in service for the first time,
diameter can reduce slightly. Minimum diameter specifications can be obtained from the rope
manufacturer.

17
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
3.2 EQUIPMENT LUBRICATION
3.2.1 All grease fittings and external gearing should be lubricated using NABRICO’s suggested lubricants
or similar.
3.2.2 Drive shaft and drum shaft grease fittings should be lubricated at least once a month under normal
conditions and at least once a day under adverse conditions. Lubricate while gears are rotating slowly.
3.2.3 Drive gear teeth should be coated at least once a month. Application with an aerosol can is
recommended for uniform coverage. Graphite or other dry type lubricant should be used instead
of gear grease when the winch is subjected to large amounts of foreign material such as coal dust.
Always keep gear teeth as free of foreign material as possible.
RECOMMENDED LUBRICANT FOR USE WITH NABRICO DECK MACHINERY
HYDRAULIC OIL (OPEN LOOP) ENVIROLOGIC 3032
SPUR, HELICAL GEARS ENDURATEX EP220
ALL WORM GEARS ENDURATEX EP220
OPEN GEARING (SPRAY CAN)
EUREKA FLUID FILM SPRAY
MOBILTAC E
LUBRIPLATE OPEN GEAR SHEILDING
GREASE FITTINGS PEERLESS LLG #2
PRESERVATIVE TREATMENT MOBILARMA 524
SUMITOMO, NORD AND SEW
GEARBOXES
USE MANUFACTURER’S
RECOMMENDATIONS
SLEWING BEARINGS / DF-559 WINCH AQUA SHIELD
Note: Lubricant manufacturers shown are not exclusive recommendations. Consult your lubricant
source for more detailed information about oil selection.

18
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
3.3 CLEANING AND STORAGE
3.3.1 Cleaning the Equipment
3.3.1.1 The equipment should be regularly cleaned to remove dirt and to help prevent rust and
corrosion.
3.3.1.2 When cleaning, be sure to leave a light film of oil on all surfaces to protect them against the
elements of nature. Wipe off excessive amounts of oil to avoid the accumulation of dirt.
3.3.1.3 Remove all unnecessary objects from the area surrounding the equipment to prevent
hazardous situations from occurring.
3.3.2 Storing the Equipment
3.3.2.1 Lubricate the equipment as necessary to help prevent rust and corrosion during storage. Add
a rust preventive for long term storage.
3.3.2.2 Seal the equipment in plastic, if possible, to help prevent rust, corrosion and other damage.
3.3.2.3 Store the equipment upright in a cool clean place away from corrosive chemicals and
moisture.
3.3.2.4 Rotate the drum periodically to keep bearing and gear surfaces from becoming lacquered.

19
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
A.1 DIMENSIONAL

20
NABRICO DF-356 Upfit Winch with FASST WinderTM Owner’s Manual
OM-DF356FST-001-A
A.2 BASE BAR COMPARISON