Thern TSSBW Series User manual

Read this Owner’s Manual
thoroughly before operating
the equipment. Keep it with
the equipment at all times.
Replacements are available
from Thern, Inc., PO Box 347,
Winona, MN 55987,
507-454-2996.
www.thern.com
Owner’s Manual
For Thern
TSSBW Series Hand Winches
IMPORTANT: Please record
product information on
page 2. This information is
required when calling the
factory for service.
A10191-0309

Owner's Manual for Thern TSSBW Spur Gear Hand Winchespage 2
A10191-0309
90 Day Limited Warranty - TSSBW Series
Thern, Inc. warrants this product against defects in material or workmanship for 90 days from the date of purchase by
the original using buyer, or if this date cannot be established, the date the product was sold by Thern, Inc. to the dealer.
To make a claim under this warranty, contact the factory for an RGA number. The product must be returned, prepaid,
directly to Thern, Inc., 5712 Industrial Park Road, Winona, Minnesota 55987. The following information must ac-
company the product: the RGA number, the date of purchase, the description of the claimed defect, and a complete
explanation of the circumstances involved. If the product is found to be defective, it will be repaired or replaced free
of charge, and Thern, Inc. will reimburse the shipping cost within the contiguous USA.
This warranty does not cover any damage due to accident, misuse, abuse, or negligence. Any alteration, repair or
modification of the product outside the Thern, Inc. factory shall void this warranty. This warranty does not cover any
costs for removal of our product, downtime, or any other incidental or consequential costs or damages resulting from
the claimed defects. This warranty does not cover brake discs, wire rope or other wear components, as their life is
subject to use conditions which vary between applications.
FACTORY AUTHORIZED REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE
EXCLUSIVE REMEDY TO THE CONSUMER. THERN, INC. SHALL NOT BE LIABLE FOR ANY INCIDEN-
TAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON
THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WAR-
RANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS
LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY.
Some states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations on
how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives
you specific legal rights, and you may also have other rights which vary from state to state.
Note: Thern, Inc. reserves the right to change the design or discontinue the production of any product without
prior notice.
About This Manual
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 respon-
sibility to obtain copies of these regulations and to determine the suitability of the
equipment to its intended use.
This Owner’s Manual, and warning labels attached to the equipment, are to serve
as guidelines for hazard-free installation, operation, and maintenance. They should
not be understood to prepare you for every possible situation.
The information contained in this manual is applicable only to the Thern TSSBW
Series Spur Gear Hand Winches. Do not use this manual as a source of information
for any other equipment.
The following symbols are used for emphasis throughout this manual:
Failure to follow ‘WARNING!’ instructions may result in equipment damage,
property damage, and/or serious personal injury.
Failure to follow ‘CAUTION!’ instructions may result in equipment damage,
property damage, and/or minor personal injury.
Important!
Failure to follow ‘important!’ instructions may result in poor performance of
the equipment.
Please record the following:
Date Purchased:
Model No.:
Serial No.:
This information is required when
calling the factory for service.

Owner's Manual for Thern TSSBW Series Spur Gear Hand Winches page 3
A10191-0309
Suggestions for Safe Operation
DO the following:
Read and comply with the guidelines set forth in this Owner’s Manual. Keep
this manual, and all labels attached to the winch, readable and with the equip-
ment at all times. Contact Thern, Inc. for replacements.
Check lubrication before use.
Install the wire rope securely to the winch drum.
Keep at least 4 wraps of wire rope wound on the drum at all times, to serve as
anchor wraps. With less than 4 wraps on the drum the wire rope could come
loose, causing the load to escape.
Keep hands away from the drum, gears, wire rope, and other moving parts of
the equipment.
Keep all unnecessary personnel away from crane while in operation. Keep out
of the path of the load, and out of the path of a broken wire rope that might
snap back and cause injury.
DO NOT do the following:
Do not lift people, or things over people. Do not walk or work under a load or
in the line of force of any load.
Do not operate with other than manual power.
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 unless each winch was
designed for use in a multiple winch system.
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.
Do not wrap the wire rope around the load. This damages the wire rope and
could cause the load to escape. Use approved rigging connectors to secure the
wire rope to the load.
Do not operate the winch with guards removed or improperly installed.
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 lift loads or pull loads on an incline unless the winch is equipped with
a brake.
Do not leave a suspended load unattended unless specific precautions have
been taken to secure the load and keep people away from the winch and out
from under the load.

Owner's Manual for Thern TSSBW Spur Gear Hand Winchespage 4
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1.1 Installing the Winch
Do not install the winch in an area defined as hazardous by the National Elec-
tric Code, unless installation in such an area has been thoroughly approved.
Do not install the winch near corrosive chemicals, flammable materials, ex-
plosives, or other elements that may damage the winch or injure the operator.
Adequately protect the winch and the operator from such elements.
Position the winch so the operator can stand clear of the load, and out of the
path of a broken wire rope 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.
Install the wire rope securely to the winch drum. A poorly secured wire rope
could come loose from its anchor and could release the load. See figure 3 & 4.
1.1.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules
on installing the equipment.
1.1.2 LOCATE THE WINCH in an area clear of traffic and obstacles that could inter-
fere with operation. Make sure winch is accessible for maintenance and operation.
1.1.3 MAINTAIN A FLEET ANGLE between 1/2 and 1-1/2 degrees. The proper
fleet angle minimizes wire rope damage by helping the wire rope wind uni-
formly onto the drum. See figure 1.
1.1.4 FASTEN THE WINCH securely to the foundation.
aFOR STANDARD PRODUCTS referred to in this manual, use 3/8 inch
coarse thread fasteners, grade 5 or better. Torque for grade 5 fasteners with-
out lubrication is 30 ft. lb. Make sure mounting holes are secured to a solid
foundation able to support the winch and the load under all conditions with
design factors based on accepted engineering practices. For mounting rec-
ommendations, see figure 2.
b NON-STANDARD PRODUCTS that vary from the original design may
have different fastening requirements. Contact a structural engineer or Th-
ern, Inc. for this information.
TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED
PROFESSIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION
SPECIFICATIONS FOR THE MOUNTING OF THERN PRODUCTS.
Important!
• Inspect the winch immediately
following installation according
to the Instructions for Periodic
Inspection. This will give you
a record of the condition of the
winch with which to compare
future inspections.
• A qualified professional should
inspect or design the founda-
tion to insure that it will provide
adequate support.
• Locate the winch so it will be vis-
ible during the entire operation.
• Do not weld the winch frame to
the foundation or support struc-
ture. Welding the frame may void
warranty, contact Thern, Inc. Use
fasteners as instructed.

Owner's Manual for Thern TSSBW Series Spur Gear Hand Winches page 5
A10191-0309
Figure 1 – Maintaining the Fleet Angle
When wire rope travels over a sheave or through a roller guide – maintain fleet angle by lo-
cating the sheave or guide an appropriate distance from the drum, shown as distance “A”.
smooth drum
1/2 to 1-1/2 degrees
distance “A”
center line
fixed sheave
or roller
guide
When wire rope travels directly to the load – maintain fleet angle by controlling side-to-side
movement of the load with tracks or guide rails. Allowing the load to move too far to one
side causes stress on the drum flange which may cause damage.
1/2 to 1-1/2 degrees center line
smooth drum
tracks or guide rails
load
Important!
• Use a sheave or roller guide to
direct the wire rope to the drum
whenever possible.
• Install sheaves, tracks and other
equipment so they will remain
fixed under all load conditions.
Follow the recommendations of
the equipment manufacturer.
• Use sheaves of proper diameter
to minimize wear on the wire
rope. Follow the recommenda-
tions of the sheave manufacturer.
Figure 2 – Mounting
It is recommended that bolts be placed according to the bolt hole patterns displayed below.
*Note - Solid lines indicate recommended bolt holes.
TSSBW600 TSSBW900 TSSBW1300
1.2 Installing the Handle
1.2.1 INSTALL THE HANDLE as follows:
aPLACE THE HANDLE ASSEMBLY on the handle shaft
bSECURE HANDLE ASSEMBLY in place with flat washer and hex nut.
c TIGHTEN THE NUT until snug.

Owner's Manual for Thern TSSBW Spur Gear Hand Winchespage 6
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1.3 Installing the Wire Rope
Install the wire rope so it is wound correctly as shown, or the winch will not
work properly, and could release the load.
Install the wire rope securely to the winch drum. A poorly secured wire rope
could come loose from its anchor and could release the load.
1.3.1 PURCHASE THE PROPER WIRE ROPE for your application. Keep the
following in mind when selecting a wire rope. Contact a reputable wire rope
supplier for help.
a BREAKING STRENGTH of new wire rope should be at least 3 times
greater than the largest load placed on the winch. If loads are lifted or pulled
on an incline, the breaking strength must be at least 5 times greater than the
largest load. These are minimum values and will vary with the type of load
and how you are moving it.
b WIRE ROPE LAY must agree with the winding direction of the drum to help
insure proper winding.
c WE RECOMMEND 7 x 19 stainless steel wire rope diameter of 3/16 inch
for TSSBW600 and TSSBW900 models and 1/4 inch for TSSBW1300
models.
1.3.2 ANCHOR THE WIRE ROPE to the drum using the flange clip.
a PASS THE END OF THE WIRE ROPE through the hole in the flange.
bINSERT THE CARRIAGE BOLT, loop the wire rope around the bolt, and
install the clip so the wire rope is held by the curves of the clip.
cINSTALL THE JAM NUT and tighten it until the wire rope is flattened
against the drum flange.
1.3.3 TURN THE HANDLE CLOCKWISE to wind wire rope onto the drum. If
wire rope unwinds from the drum when the handle is rotated clockwise, the
wire rope is installed incorrectly. Install the wire rope correctly before
continuing.
1.3.4 WIND FOUR FULL WRAPS of wire rope onto the drum by operating the
winch while holding the wire rope taught. These wraps serve as anchor
wraps and must remain on the drum at all times.
Important!
• Use wire rope and other rigging
equipment rated for the size of the
largest load you will be moving.
• Do not drag the wire rope
through dirt or debris that could
cause damage, or poor operation.
• Always wear protective clothing
when handling wire rope.
Figure 3 – Wire Rope
Installation
Figure 4 – Wire Rope
Installation
overwound installation shown
for models 600 and 900
flange clip
anchor
flange clip
anchor
underwound installation shown
for model 1300

Owner's Manual for Thern TSSBW Series Spur Gear Hand Winches page 7
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2.1 General Theory of Operation
2.1.1 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.
2.1.2 THIS EQUIPMENT CAN develop forces that will exceed the load rating.
It is the responsibility of the equipment user to limit the size of the load.
Inspect the equipment regularly for damage according to the instructions
contained in this manual.
2.1.3 USE A DISC BRAKE on all hand winches used to lift loads or pull loads on
an incline.
2.1.4 PERFORMANCE RATINGS of the equipment are affected by the amount of
wire rope wound on the drum, the way in which it is wound, and the way the
winch is used.
a DRUM CAPACITY depends on how tightly and evenly the wire rope is
wound on the drum and diameter of wire rope used. Actual drum capacities
are usually 25-30% less than values shown in performance tables, due to
loose winding and overlapping.
b FORCE REQUIRED TO LIFT the load increases with each additional layer
of wire rope wound onto the drum. The value shown in performance tables is
based on an empty drum and maximum handle length.
c LOAD RATING represents the maximum pull that can be placed on new
equipment. Load ratings are assigned values for specific amounts of load
travel or wire rope accumulation. The load rating decreases as layers of wire
rope accumulate on the drum.
2.1.5 DUTY RATINGS refer to the type of use the equipment is subject to. Con-
sider the following when determining duty rating.
a ENVIRONMENT: harsh environments include hot, cold, dirty, wet, cor-
rosive, or explosive surroundings. Protect the equipment from harsh envi-
ronments when possible.
b MAINTENANCE: poor maintenance, meaning poor cleaning, lubrication,
or inspection, leads to poor operation and possible damage of the equipment.
Minimize poor maintenance by carefully following the instructions con-
tained in this manual.
c LOADING: severe loading includes shock loading and moving loads that
exceed the load rating of the equipment. Avoid shock loads, and do not
exceed the load rating of the equipment.
d FREQUENCY OF OPERATION: frequent or lengthy operations increase
wear and shorten the life span of gears, bearings, and other components.
Increase maintenance of the equipment if used in frequent operations.
CONTACT THE FACTORY FOR MORE INFORMATION.
Important!
• Limit nonuniform winding by
keeping tension on the wire rope
and by maintaining the proper
fleet angle.
• It is your responsibility to detect
and account for different fac-
tors affecting the condition and
performance of the equipment.

Owner's Manual for Thern TSSBW Spur Gear Hand Winchespage 8
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Figure 5 – Attaching Load
latch closed
tight against
hook
sling seated in
saddle of hook
Important!
• When determining whether the
load will exceed the load rating,
consider the total force required
to move the load.
2.2 Breaking-In the Winch
2.2.1 BREAK-IN 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 bearings and gears.
2.2.2 INSPECT THE WINCH following break-in according to the Instructions for
Periodic Inspection.
2.3 Preparing for Operation
2.3.1 CONSIDER THE OPERATION. Do not begin until you are sure you can
perform the entire operation without hazard.
2.3.2 INSPECT ALL COMPONENTS of the system.
a INSPECT THE WINCH and other equipment according to the Instructions
for Frequent Inspection.
b OPERATORS must be in good health, alert, thoroughly trained in operat-
ing the equipment, and properly clothed (hard hat, safety shoes and safety
glasses, no loose clothing).
c THE LOAD must be clear of other objects and free to move. Make sure the
load will not tip, spin, roll away, or in any way move uncontrollably.
2.3.3 KNOW YOUR LOAD and make sure you do not exceed the load rating of
the winch or any other equipment in the system.
2.4 Attaching the Load
Do not wrap the wire rope around the load. This damages the wire rope and
could cause the load to escape. Use a sling or other approved lifting device.
2.4.1 CLEAR OBJECTS from the path of the load so you can move it freely and
observe it at all times during the operation.
2.4.2 ATTACH THE LOAD using a nylon sling, or other approved lifting device.
Follow the recommendations of the sling manufacturer.
a SEAT THE SLING in the saddle of the hook with the hook latch completely
closed. See figure 5.
b CENTER THE LOAD on the hook so it will remain balanced and not tip or
rotate to one side.

Owner's Manual for Thern TSSBW Series Spur Gear Hand Winches page 9
A10191-0309
2.5 Moving the Load
2.5.1 MOVE THE LOAD slowly and smoothly, only a small distance at first.
Make sure the load is balanced and securely attached before continuing.
2.5.2 TURN THE HANDLE CLOCKWISE to wind wire rope onto the drum. If
wire rope unwinds from the drum when the handle is rotated clockwise, the
wire rope is installed incorrectly. Install the wire rope correctly before
continuing.
2.5.3 OBSERVE THE WIRE ROPE as it winds onto the drum. If it becomes
loose, uneven, or overlapped, stop the operation and rewind the wire rope
before continuing. Continued operation with overlapped or uneven wire
rope can damage the wire rope and shorten its life.
2.5.4 MOVE THE LOAD slowly and smoothly, only a small distance at first.
Make sure the load is balanced and securely attached before continuing.
2.5.5 OBSERVE THE WIRE ROPE as it winds onto the drum. If it becomes
loose, uneven, or overlapped, stop the operation and rewind the wire rope
before continuing. Continued operation with overlapped or uneven wire rope
can damage the wire rope and shorten its life.
Important!
• Obey a stop signal from anyone.
• Maintain tension on the wire
rope to keep it tightly and evenly
wound on the drum.
• If the winch and load are not vis-
ible 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.
• When lifting a load, use a tag line
to keep the load from swinging or
twisting, while keeping yourself
away from the load.
• Remove the winch handle when
the winch is not in use, to help
avoid unauthorized use.

Owner's Manual for Thern TSSBW Spur Gear Hand Winchespage 10
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3.1 Cleaning the Winch
Clean the winch to remove dirt and help prevent rust and corrosion.
3.1.1 CLEAN THE WINCH every six months or whenever it is dirty.
a WIPE ALL EQUIPMENT to remove dirt and grease.
b LEAVE A LIGHT FILM of oil on all surfaces to protect them against rust
and corrosion.
c WIPE OFF excessive amounts of oil to avoid the accumulation of dirt.
3.1.2 REMOVE ALL UNNECESSARY OBJECTS from the area surrounding the
winch.
3.2 Lubricating the Winch
Do not over lubricate the brake bushings on models equipped with a brake.
Over lubricating may cause oil to leak onto the friction discs, which may dam-
age the friction discs or result in poor operation of the disc brake.
Lubricate the spur gears before each operation, and periodically during op-
eration. Failure to lubricate the gears will cause damage or deformation of
gear teeth.
The winch is lubricated by the manufacturer at the factory. To ensure contin-
ued smooth operation and increased life, occasionally lubricate the winch to
help protect it from wear and rust. Read the following instructions carefully.
3.2.1 CONSULT MANUFACTURER’S RECOMMENDATIONS for specific
information on lubricating the wire rope and other equipment.
3.2.2 LUBRICATE WINCH BEARINGS AND SHAFTS at least every 10 hours
of operation.
a APPLY 2 TO 3 DROPS of SAE 30 non-detergent oil to bearings and shafts
at all friction points.
b ROTATE THE DRUM several times to allow the oil to penetrate, and wipe
off excess oil to avoid accumulation of dirt.
3.2.3 LUBRICATE WINCH GEARS before every operation and at least every 10
hours during operation.
a APPLY A LIGHT FILM of open gear lubricant to the gear teeth on all gears.
b USE SPRAYON 201 or equivalent open gear lube. For dirty conditions use a
dry lubricant such as dry graphite or Moly.
3.2.4 LUBRICATE THE WIRE ROPE and other equipment by following the
manufacturer’s recommendations.
Important!
Increase the frequency of mainte-
nance procedures if the winch is:
• Operated for long periods.
• Used to pull heavy loads.
• Operated in wet, dirty, hot, or
cold surroundings.
Important!
• Make sure lubricant has a tem-
perature rating appropriate for
the ambient temperatures of the
operation.

Owner's Manual for Thern TSSBW Series Spur Gear Hand Winches page 11
A10191-0309
3.3 Inspecting the Equipment
Do not use damaged or malfunctioning equipment. Place an “OUT OF ORDER”
sign on the winch. Do not use the winch until the sign is removed by a qual-
ified maintenance person who has completely corrected the problem.
Inspect the winch to detect signs of damage or poor operation before they
become hazardous.
3.3.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules
on inspecting the winch and other equipment.
3.3.2 CONSULT MANUFACTURER’S RECOMMENDATIONS for information
on inspecting the wire rope and other equipment.
3.3.3 Instructions for Frequent Inspection
a VISUALLY INSPECT the entire winch and all other equipment involved in
the operation.
• Check all equipment for cracks, dents, bending, rust, wear, corrosion and
other damage.
• Make sure the wire rope is installed correctly and anchored securely to
the drum.
• Make sure the winch and brake are properly lubricated.
• Make sure fasteners are installed to securely hold the handle in place.
• Make sure 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.
b TEST WINCH PERFORMANCE by operating the winch with a load not
exceeding the load rating.
• Listen for unusual noises, and look for signs of damage as you operate the
winch.
• Make sure the wire rope winds evenly and tightly onto the drum. If it is
loose or uneven, rewind it before continuing.
• Make sure the handle rotates freely in both directions.
Completely correct all problems before continuing. Use the Troubleshooting
Chart to help determine the cause of certain problems. See table 2.
Important!
• Start an inspection program as soon
as you put the winch into use.
• Appoint a qualified person to be
responsible for regularly in-
specting the equipment.
• Keep written records of inspec-
tion. This allows comparison with
comments from previous inspec-
tions so you can see changes in
condition or performance.
Perform frequent inspections:
• Before each operation.
• Every 3 hours during operation.
• Whenever you notice signs of
damage or poor operation.
Frequent Wire Rope Inspection:
• Use ASME B30.7 as a guideline
for rope inspection, replacement
and maintenance.
• Check the wire rope, end connec-
tions and end fittings for corrosion
kinking, bending, crushing, bird-
caging or other signs of damage.
• Check the number, distribution
and type of visible broken wires.
See paragraph 3.3.4 b and figure 5.
• Check the wire rope for reduc-
tion of rope diameter from loss of
core support, or wear of outside
wires. See figure 7.
• Take extra care when inspecting
sections of rapid deterioration
such as sections in contact with
saddles, sheaves, repetitive pickup
points, crossover points and end
connections.

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3.3.4 Instructions for Periodic Inspection, see table 1.
a VISUALLY INSPECT the winch and all other equipment.
• Disassembly may be required in order to properly inspect individual com-
ponents. Contact factory for assembly/disassembly instructions. Disassem-
bly of the winch or brake before contacting Thern, Inc. voids all warranties.
• Check the finish for wear, flaking, or other damage.
• Check all equipment, including wire rope for cracks, dents, bending, rust,
wear, corrosion and other damage. If the winch was overloaded, or if
you notice cracks and other signs of overloading and damage promptly
remove equipment from use and have it repaired or replaced. DO NOT
CONTINUE TO USE DAMAGED OR OVERLOADED EQUIP-
MENT OR WIRE ROPE.
• Check all fasteners for stripped threads, wear, bending, and other damage.
• Check the foundation for cracks, corrosion, and other damage.
• Make sure the winch and brake are properly lubricated.
• Make sure all labels and plates are readable, firmly attached, free of dam-
age and clean. Replacements are available from the factory.
b REMOVE THE WIRE ROPE entirely from the drum.
• Always wear protective clothing when handling wire rope.
• Check the entire length of wire rope 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 wire rope 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 6.
• Make sure the load hook or other device is securely attached to the wire
rope, and the wire rope where it is attached is not frayed, corroded, bro-
ken, or otherwise damaged.
• Measure the throat opening, thickness, and twist of the hook. Replace the
hook if it shows signs of damage. See figure 7.
• Make sure hook latch opens without binding and closes when released.
• Check the anchor holes in the drum flange for signs of wear or distortion.
c PLACE enough weight to keep the wire rope straight and tightly drawn.
• Measure the diameter of the wire rope, especially in areas where wear
is noticeable. Replace the wire rope if the diameter measures below the
minimum diameter at any point. See figure 8.
d REMOVE THE WINCH from the foundation.
• Check fasteners for stripped threads, wear, bends, and other damage.
• Check the frame 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.
e MOVE THE DRUM with your hands.
• Check for excessive movement indicating worn or loose gears, bearings,
or shafts.
f FASTEN THE WINCH securely to the foundation.
Perform periodic inspections:
• Every 6 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.
Figure 6 – Broken Wires
wire
strand
one
lay
Wire rope assembly must be re-
placed 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 7 – Load Hook
Inspection
throat
opening
twist
thickness
The wire rope assembly must be
replaced if the throat opening is
15% wider than nominal, if the
thickness is 10% less than nomi-
nal, or if the hook is twisted 10° or
more.

Owner's Manual for Thern TSSBW Series Spur Gear Hand Winches page 13
A10191-0309
Figure 8 – Rope Diameter
diameter
incorrect
correct
The wire rope assembly must be
replaced if the diameter measures
less than the minimum diameter at
any point.
wire rope
diameter minimum diameter
1/8 in 7/64 in (.1094 in)
3/16 in 11/64 in (.1719 in)
1/4 in 15/64 in (.2344 in)
Table 1 – Inspection Checklist
damages problems
general finish weathered, flaking, otherwise damaged winch jerks or hesitates during operation
parts cracked, bent, rusted, worn, otherwise damaged unusual noises, other signs of malfunction
fasteners stripped threads, bent, worn, otherwise damaged loose, not tightened to proper torque
gears excessively worn, cracked, corroded, otherwise damaged loose or improperly lubricated
brake assembly brake corroded, cracked, worn, otherwise damaged brake does not operate properly
drum anchor hole worn, distorted, otherwise damaged excessive movement or backlash
wire rope bent, crushed, otherwise damaged wire rope loosely or unevenly wound
broken wires, see figure 5
replace if more than 6 wires in one lay, number per strand =
or 3 wires in one strand in one lay, are broken number per lay =
diameter reduced, see figure 7
replace if diameter is excessively worn diameter =
end connections corroded, rusted, worn, otherwise damaged not securely attached
load hook twisted, bent, worn, otherwise damaged, see figure 6 hook latch fails to close when released
replace if twist is 10 degrees or more twist =
replace if throat width is 15% larger than nominal throat width =
replace if thickness is 10% less than nominal thickness =
labels and plates dirty, illegible, otherwise damaged loosely attached or missing
comments:
authorized signature: date
checked boxes indicate damage or problem in need of repair
g INSTALL THE WIRE ROPE.
h TEST WINCH PERFORMANCE by operating the winch with a load equal
to the load rating.
• Listen for unusual noises, and look for signs of damage as you operate the
winch.
• Make sure the wire rope winds evenly and tightly onto the drum. If it is
loose or uneven, rewind it before continuing.
• Observe the rotating drum, look for signs of loose or misaligned bearings.
• Make sure the handle rotates freely in both directions.
Completely correct all problems before continuing. Use the troubleshooting
chart to help determine the cause of certain problems. See table 2.

Owner's Manual for Thern TSSBW Spur Gear Hand Winchespage 14
A10191-0309
Table 2 – Troubleshooting Chart
Contact the factory for detailed instructions if you are required to disassemble the winch or brake for any reason.
Disassembly of the winch or brake before contacting Thern, Inc. voids all warranties.
problem cause correction
handle turns, drum doesn't turn • loose, stripped or broken gears . . . . . . . . . . . . . . inspect gears and repair as necessary
handle turns hard or not at all • load too heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . lighten load
• disc brake damaged or locked . . . . . . . . . . . . . . . inspect brake, repair as necessary
• gears or bearings broken or locked . . . . . . . . . . . inspect and repair as necessary
brake does not operate properly • friction discs worn or damaged. . . . . . . . . . . . . . . inspect and replace as necessary
• friction discs damaged from over lubrication . . . . inspect and replace as necessary
• disc brake ratchet pawl damaged. . . . . . . . . . . . . inspect and repair as necessary
excessively worn gears or bearings • load too heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . lighten load
(excessive backlash) • poor lubrication of gears or bearings . . . . . . . . . . inspect and relubricate as necessary
overheating • operated too long without rest . . . . . . . . . . . . . . . allow to cool
• load too heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . lighten load
• poor lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . inspect and lubricate as necessary
• bearing seized up . . . . . . . . . . . . . . . . . . . . . . . . . inspect and replace as necessary
unusual noises
high pitched squeak • poor lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . inspect and relubricate as necessary
grinding noise • contaminated lubrication . . . . . . . . . . . . . . . . . . . clean and relubricate winch
• dirt in brake or winch gears . . . . . . . . . . . . . . . . . inspect and clean as necessary
• broken gears or bearings . . . . . . . . . . . . . . . . . . . inspect and replace as necessary
rattling noise • loose bolts, set screws or other fasteners . . . . . . tighten all bolts and other fasteners
uneven clicking noise in brake • broken gear tooth in brake . . . . . . . . . . . . . . . . . . inspect and repair as necessary
weak clicking noise in brake • worn brake ratchet pawl, gear, or spring . . . . . . . inspect and replace as necessary
no clicking noise in brake • ratchet incorrectly installed. . . . . . . . . . . . . . . . . . disassemble and install correctly
• ratchet pawl damaged or worn excessively . . . . . inspect and replace as necessary
3.4 Repairing the Winch
3.4.1 GET FACTORY AUTHORIZATION for all repairs. Unauthorized repairs
will void the warranty, and may lead to damage or failure of the winch.
3.4.2 REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern
repair parts.
3.4.3 TO ORDER REPAIR PARTS, contact your local dealer. Include the follow-
ing information when ordering:
• model number
• serial number (or code number)
• part number
• date purchased, and from whom
• description of what happened, or what is wrong
• your name and return address
Important!
• It is your responsibility to de-
termine when to replace parts.
When considering whether to
continue using a part or to replace
it, remember that replacing it
is the best way to avoid further
equipment damage.
• Replace all retaining rings when
you disassemble the winch or
brake for repair or replacement.
• Appoint a qualified person to be
responsible for all repairs to the
equipment.

Owner's Manual for Thern TSSBW Series Spur Gear Hand Winches page 15
A10191-0309
TSSBW Series Spur Gear Hand Winch Performance Characteristics
load rating (lb) wire drum capacity (ft)1approx.
model 1st mid full rope 1st mid full gear handle2ship
number description layer drum drum dia. (in) layer drum drum ratio effort wt. (lb)
TSSBW600 600 lb capacity 600 400 200 3/16 3 35 78 4.2:1 23 lb 9
TSSBW900 900 lb capacity 920 500 300 3/16 5 73 160 5.0:1 23 lb 18
TSSBW1300 1300 lb capacity 1300 900 600 1/4 5 37 83 10.0:1 26 lb 22
1Actual drum capacities may be 25-30% less, due to nonuniform winding. Wire rope tension and diameter will also affect drum capacity.
2Approximate handle force required to lift the rated capacity.
Important!
• Keep a record of what you ship,
and when you send it.
4.1 Transporting the Winch
4.1.1 PACK THE WINCH using the original packaging materials, if possible.
4.1.2 SEAL THE WINCH in plastic with a desiccant to help protect it from rust,
corrosion, and other damage.
4.1.3 INSPECT THE WINCH according to the Instructions for Periodic Inspection
before installing it in a new location.
4.2 Storing the Winch
4.2.1 SEAL THE WINCH in plastic with a desiccant to help protect it from rust,
corrosion, and other damage.
4.2.2 STORE THE WINCH in a cool clean place away from corrosive chemicals
and moisture.
4.2.3 ROTATE THE DRUM periodically to keep bearing and gear surfaces from
becoming lacquered.
4.2.4 INSPECT THE WINCH according to the Instructions for Periodic Inspection
before installing it for operation.

Thern, Incorporated
5712 Industrial Park Road
Winona, MN 55987
PHN 507-454-2996
FAX [phone]
EMAIL: [email protected]
www.thern.com