Wintech 301 User manual

1
OPERATION AND MAINTENANCE MANUAL
for
STANDARD UPRIGHT ELECTRIC BARGE WINCHES
Form MHD56001
25 TON MODELS 50 TON MODELS
601 611 621
631 641
301 311 321
331 341 351
25 ton Barge Winch
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
containsimportantsafety,installation,operationandmaintenanceinformation. Make
this manual available to all persons responsible for the operation, installation and
maintenanceoftheseproducts.
Donotusethiswinchforlifting,supporting,ortransportingpeopleorliftingorsupportingloadsover
people.
Always operate, inspect and maintain this winch in accordance with American National Standards
InstituteSafetyCode(ANSIB30.7)andanyotherapplicablesafetycodesandregulations.
Referallcommunicationsto WintechInternationalInc. oryournearestDistributor.
FormMHD56001
Edition2
June 2003
71006746
©1999 Wintech International, L.L.C.
WARNING

2
• Electricalinstallationshouldbeperformedbylicensed
electriciansinaccordancewiththelatesteditionofthe
NationalElectricalCode(ANSI/NFPA70)andany
applicablelocal,stateandnationalelectricalcodesand
ordinances.
The National Safety Council, Accident Prevention Manual
for Industrial Operations, Eighth Edition and other recog-
nized safety sources make a common point: Employees
who work near material handling equipment or assist in
hooking on or arranging a load should be instructed in safe
rigging procedures. From a safety standpoint, one factor is
paramount: conduct all pulling operations in such a manner
that if there were an equipment failure, no personnel would
be injured. This means keep out of the line of force of any
load.
Tothe best ofour knowledge,Wintech International
Material Handling winches are manufactured in accordance
with the latest standards in effect at time of manufacture.
However, contrary to common belief, the Occupational
Safety and Health Act of 1970, as we understand it,
generally places the burden of compliance with the user,
not the manufacturer. Many OSHA requirements are not
concerned or connected with the manufactured product but
are, rather, connected with the final installation: “It is the
owner’s responsibility and user’s responsibility to deter-
mine the suitability of a product for any particular use.
Check all applicable industry, trade association, federal,
state and local regulations. Read all operating instructions
and warnings before operation.”
Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper
riggingtechniques. SeeANSI/ASMEB30.9 for rigging
information, AmericanNationalStandards Institute,1430
Broadway,NewYork,NY10018.
•UsingotherthangenuineWintechInternationalparts
willresultinthevoidofwarranty.
Inspection and safety information contained in this manual
is based, in part, on the American National Standards
Institute Safety Code (ANSI B30.7). However, it should be
noted that ANSI B30.7 covers "Base Mounted Hoists" and
does not specifically apply to winches used as barge
pullersor in horizontalpulling applications.
This manual provides important information for all person-
nel involved with the safe installation, operation and proper
maintenance of this product. Even if you feel you are
familiarwith this orsimilar equipment,you must readand
understand this manual before operating the product.
Danger,Warning,CautionandNotice
Throughout this manual there are steps and procedures
which,if not followed, may resultin ahazard. The follow-
ing signal words are used to identify the level of potential
hazard.
Danger is used to indicate the
presence of a hazard which will
cause severe personal injury, death,
or substantial property damage if the
warning is ignored.
Warning is used to indicate the
presence of a hazard which can
cause severe personal injury, death,
or substantial property damage if the
warning is ignored.
Caution is used to indicate the
presence of a hazard which will or
can cause minor personal injury or
property damage if the warning is
ignored.
Notice is used to notify people of
installation,operation,ormainte-
nanceinformation which is important
but not hazard-related.
SafetySummary
•Donotusethiswinchforliftingorloweringloadsorfor
supporting,ortransportingpeople.
•Thesupportingstructuresandload-attachingdevices
usedinconjunctionwiththiswinchmustprovidean
adequatesafetyfactortohandletheratedload,plusthe
weightofthewinchandattachedequipment. Thisisthe
customer’sresponsibility. Ifindoubt,consultaqualified
structuralengineer.
SAFETY INFORMATION
DANGER
CAUTION
NOTICE
WARNING
NOTICE
WARNING
WARNING

3
SAFE OPERATING INSTRUCTIONS
winch has a rated capacity equal to or more than the
load. This provides adequate safety in the event of a
sudden load shift or failure of one winch.
10. Never place your hand in the throat area of a hook or in
the vicinity of the wire rope as it spools onto the drum.
11. Position load correctly. Do not attach load on hook
except in a straight pulling line. Do not “side pull” or
“yard”.
12. Keep hands, clothing, etc., clear of moving parts.
13. Do not force a hook into place by hammering.
14. Be certain the load is properly seated in the saddle of
the hook.
15. Do not pull the load on the tip of the hook.
16. Never run the wire rope over a sharp edge. Use a
sheave.
17. Pay attention to the load at all times when operating
the winch.
18. Make sure all people are clear of the loadpath.
19. Never use the winch for lifting or lowering loads and
never allow anyone to stand on a moving load.
20. Ease the slack out of the wire rope when starting a pull.
21. Never weld or cut on a load held by the winch.
22. Do not operate winch ifjamming, overloading,or
binding occurs.
23. After use, properly secure winch and all loads.
24. Always rig loads properly and carefully.
The following warnings and operating instructions have
been adapted in part from American National (Safety)
Standard ANSI B30.7 and are intended to avoid unsafe
operating practices which might lead to personal injury or
property damage.
WintechInternationalrecognizesthatmostcompanies
who use winches have a safety program in force at their
facility. In the event that some conflict exists between a
rule set forth in this publication and a similar rule already
set by an individual company, the more stringent of the two
should take precedence.
Safe Operating Instructions are provided to make an
operator aware of dangerous practices to avoid and are not
necessarilylimited tothe following list. Refer to specific
sections in the manual for additional safety information.
1. Only allow qualified personnel (trained in safety and
operation) to operate and maintain the winch.
2. Only operate a winch if you are physically fit to do so.
3. When a “DO NOT OPERATE” sign is placed on the
winch, do not operate the winch until the sign has
been removed by designated personnel.
4. Before each shift, the operator should inspect the
winchforwear ordamage.
5. Never use a winch which inspection indicates is
defective.
6. Do not use winch if hook latch on a hook has been
sprung or is broken.
7. Only pull loads less than or equal to the rated capacity
of the winch. See warning labels attached to the
winch.
8. Check that the hook latches are engaged before using.
9. When using two winches on one load ensure that each
WARNING TAG
Each winch is supplied from the factory with the warning
tag shown. If the tag is not attached to your winch, order a
new tag and install it. See the parts list for the part
number. Read and obey all warnings and other safety
information attached to this winch. Tag may not be shown
actual size.

4
SPECIFICATIONS
Wire rope capacities are calculated for full drum storage and do not comply with ANSI or any other standards
which may require that the top layer not exceed a specified distance below the drum flange diameter. Figures
may vary from those published elsewhere.
Model Capacities (lbs) Holding (lbs) Line Speed (fpm) Phase Weight
No. Rated Stall* Hand Electric Dog Tested to No Rated Cycle, Net
Pull Pull Pull Brake (US tons) Load Pull HP Volts (lbs)
301 3,200 9,000 20,000 55,000 50,000 40 50 42 5230/460-3-60 728
311 4,200 11,500 20,000 55,000 50,000 40 35 31 5230/460-3-60 728
321 4,800 13,000 20,000 55,000 50,000 40 50 42 7.5 230/460-3-60 859
331 6,400 17,500 20,000 55,000 50,000 40 23 21 5230/460-3-60 728
341 6,400 17,500 20,000 55,000 50,000 40 35 31 7.5 230/460-3-60 859
351 8,500 23,500 20,000 55,000 50,000 40 17 15 5230/460-3-60 728
601 4,500 15,500 40,000 70,000 100,000 65 34 30 5230/460-3-60 1,290
611 6,500 22,000 40,000 70,000 100,000 65 34 30 7.5 230/460-3-60 1,331
621 8,500 28,000 40,000 70,000 100,000 65 17 15 5230/460-3-60 1,331
631 12,000 40,000 40,000 70,000 100,000 65 17 15 7.5 230/460-3-60 1,361
641 12,000 40,000 40,000 70,000 100,000 65 23 20 10 230/460-3-60 1,361
Metric
Model Capacities (kgs) Holding (kgs) Line Speed (m/m) Phase Weight
No. Rated Stall* Hand Electric Dog Tested to No Rated Cycle, Net
Pull Pull Pull Brake (US tons) Load Pull HP Volts (kgs)
301 1,452 4,082 9,072 24,948 22,680 40 15 13 5230/460-3-60 330
311 1,905 5,216 9,072 24,948 22,680 40 10.7 9.5 5230/460-3-60 330
321 2,177 5,897 9,072 24,948 22,680 40 15 13 7.5 230/460-3-60 390
331 2,903 7,938 9,072 24,948 22,680 40 76.4 5230/460-3-60 330
341 2,903 7,938 9,072 24,948 22,680 40 10.7 9.5 7.5 230/460-3-60 390
351 3,856 10,660 9,072 24,948 22,680 40 5.2 4.6 5230/460-3-60 330
601 2,041 7,031 18,144 31,752 45,360 65 10.4 9.1 5230/460-3-60 585
611 2,948 9,979 18,144 31,752 45,360 65 10.4 9.1 7.5 230/460-3-60 604
621 3,856 12,700 18,144 31,752 45,360 65 5.2 4.6 5230/460-3-60 604
631 5,443 18,144 18,144 31,752 45,360 65 5.2 4.6 7.5 230/460-3-60 617
641 5,443 18,144 18,144 31,752 45,360 65 76.1 10 230/460-3-60 617
Note: Capacities are rated on first layer.
* Stall pull rated at specific voltage with holding dog engaged.
Drum Wire Rope Capacity ft. (m)
Length 5/8 16 mm 3/4 18 mm 7/8 22 mm 1 26 mm 1-1/8 28 mm 1-1/4 32 mm
(in.)
Series 300
9286
86 196 62 130 40 116 24 --- --- --- ---
17 559 169 386 123 258 80 232 48 --- --- --- ---
35 1174 356 813 259 546 168 493 103 --- --- --- ---
52 1755 532 1216 387 818 251 740 155 --- --- --- ---
69 2336 708 1620 515 1090 335 986 206 --- --- --- ---
Series 600
11 --- --- --- --- 210 65 133 40 119 37 67 20
21 --- --- --- --- 418 129 265 79 240 74 136 41
41 --- --- --- --- 834 256 531 158 481 149 274 83
62 --- --- --- --- 1271 390 810 242 734 227 418 126
82 --- --- --- --- 1686 518 1075 321 975 302 556 168
(TBL.CAPACITY)
(TBL.SPECCHRT)

5
Model Code 341 L - RC - B17 - 12 - D
Series 25 Ton Standard Upright Winch (301, 311, 321, 331, 341 and 351)
50 Ton Standard Upright Winch (601, 611, 621, 631 and 641)
Configuration
L= Left Hand*
R = Right Hand*
RC = Remote Control Ready
VoltageA = 230-3-60
B= 460-3-60
C = Other Voltage
Drum Length
Distance Between Drum Flanges (in.).
Available lengths 25 Ton 9, 17, 35, 52 and 69.
Available lengths 50 Ton 11, 21, 41, 62 and 82.
Wire Rope Size
Number equals wire rope size in sixteenths, e.g. 3/4 in. (12/16 in. enter 12)
OptionsDB = Angle Deck Bracket.
C = Disengaging Clutch.**
G = Drum Grooving.**
D= Drum Divider Flange and additional wire rope anchor.**
F = Flange Mounted Ball Bearings.**
T = Torque Limiter Clutch.**
Control Systems require the following:
• Magnetic Reversing Starter
• Push Button Control
• Control Cord
Refer to Winch Controls on page 25 for additional information.
Model Code Explanation
* Left and right hand models are determined by which side of the winch the handwheel is mounted on. As illus-
trated,standingbehind the winch,facingthe wireropetake-off direction istheproper orientation fordetermining
rightorlefthandrequirements.
**Options arenot coveredin this manual. For additional information contactWintech Internationalor your
distributor.
(Dwg. MHTPA0253)(Dwg. MHTPA0261)
WIRE ROPE
TAKE-OFF WIRE ROPE
TAKE-OFF
DOG DOG
HANDWHEEL
HANDWHEEL
25T LEFT HAND
MODEL 25T RIGHT HAND
MODEL
WIRE ROPE
TAKE-OFF WIRE ROPE
TAKE-OFF
DOG DOG HANDWHEEL
HANDWHEEL
50TLEFTHAND
MODEL 50T RIGHT HAND
MODEL

6
8. Mounting bolts or screws must be 3/4 in. diameter (19
mm) Grade 8 or better. Use self-locking nuts or nuts
with lockwashers.
9. Tighten mounting bolts evenly and torque to 380 lb.
ft. (52 kg.m) dry. If the fasteners are plated, lubri-
cated or a thread locking compound is used torque to
280 lb.ft. (39 kg.m).
Bolt Pattern Dimensions
Series "A" "B" "D"
in. (mm) in. (mm) in. (mm)
300 4 102 14 356 23/32 18
600 4 102 13 330 23/32 18
300 Series 600 Series
Drum "C" Drum "C"
Length (in.) in. (cm) Length (in.) in. (cm)
9 20-1/4 51 11 25 63.5
17 28-1/4 72 21 35 89
35 46-1/4 118 41 55 140
52 63-1/4 161 62 76 193
69 80-1/4 204 82 96 244
(Dwg. MHTPA0206)
Safe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire
rope.
3. Never run the wire rope over a sharp edge. Use a
correctly sized sheave. See instruction 4 under
"MOUNTING".
4. Do not weld to any part of the winch.
5. Always maintain at least three full wraps of wire rope
on the drum.
6. Check gears are lubricated before using winch. See
"LUBRICATION" section.
Prior to installing the winch, carefully inspect it for
possible shipping damage.
Winches are supplied fully lubricated from the factory.
• Owners and users are advised to examine specific,
local or other regulations, including American
National Standards Institute and/or OSHA Regulations
which may apply to a particular type of use of this
product before installing or putting winch to use.
Mounting
1. Mount the winch on a rigid surface which is capable
of supporting the winch and will prevent deflecting or
distortion of the winch under maximum load.
2. Choose a site that uses as short a wire rope as
practical.
• The winch is not a balanced load. Use extreme care
when lifting winch into position.
3. When a lead sheave is used, it should be aligned with
the center of the drum. The diameter of the lead
sheave must be at least 18 times the diameter of the
wire rope.
4. Maintain a fleet angle between the sheave and winch
of no more than 1-1/2 degrees. For every inch ofdrum
length, the lead sheave must be at least 1.6 feet (0.5
m) from the drum.
5. Make sure the mounting surface is flat to within
1/16 in. (1.6 mm). Shim winch if necessary.
6. Position the winch so there is adequate room for the
operator and service personnel to access the winch.
The handwheel rotation must be a full 360 degrees
unobstructed. Reposition winch if necessary.
(Dwg. MHTPA0217)
7. The winch can be mounted using the straight type
deck bracket when welding to a steel deck or the
angle type deck bracket when bolting the winch to the
mounting surface.
INSTALLATION
CAUTION
WARNING
STRAIGHT TYPE
DECK BRACKET ANGLE TYPE
DECK BRACKET
3/8 in. FILLET
WELD (min)

7
Wire Rope
• Maintain at least 3 wraps of wire rope on the drum at
all times.
• Install the wire rope to come off the drum in an
underwind position.
Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor
for assistance in selecting the appropriate type and size of
wire rope and, where necessary, a protective coating. Use
a wire rope which provides an adequate safety factor to
handle the actual working load and meets all applicable
industry, trade association, federal, state and local
regulations.
When considering wire rope requirements the actual
working load must include not only the static or dead load
but also loads resulting from acceleration, retardation and
shock load. Consideration must also be given to the size
of the winch wire rope drum, sheaves and method of
reeving.
• Check wire rope diameter provides adequate safety
factor.
Model Min. Wire Rope Dia. Max. Wire Rope Dia.
in. (mm) in. (mm)
25 ton 5/8 16 1 26
50 ton 7/8 22 1-1/4 32
The maximum wire rope diameter is limited by the size of
the wire rope anchor hole.
Installing Wire Rope
• Position the wire rope so that it comes off the bottom
of the drum (underwind).
1. Cut wire rope to length and fuse end to prevent
fraying of strands in accordance with the wire rope
manufacturer's instructions.
2. Feed the fused end of the wire rope into the wire rope
anchor hole. Position the end of the wire rope just
beneath the drum surface. (See Dwg. MHTPA0218)
3. Make sure the wire rope wedge is the correct size for
the wire rope.
4. Install the wire rope wedge into anchor hole. Install
the wedge from the side of the hole with the wire rope
end. Position the wedge so the serrated surface is on
the wire rope. Insert the narrow end of the wedge
first. The wedge must be positioned so it is nearer the
surface of the drum.
(Dwg. MHTPA0218)
5. Hammer the wedge into the wire rope anchor hole to
secure the wire rope.
6. While keeping the wire rope under tension, wind the
wire rope onto the drum.
• Make sure the first wrap of wire rope is flush against
the drum flange.
Wire Rope Spooling
To allow for uneven spooling and decrease in line pull
capacity as the drum fills up, use as short a wire rope as
practical. To rewind wire rope apply tension to eliminate
slack. This helps achieve level winding and tight spool-
ing
Rigging
Make sure all wire rope blocks, tackle and fasteners have
sufficient safety margin to handle the required load. Do
not allow wire rope to contact sharp edges or make sharp
bends which will cause damage to wire rope, use a sheave.
Refer to wire rope manufacturer's handbook for proper
sizing, use and care of wire rope.
Safe Wire Rope Handling Procedures
1. Always use gloves when handling wire rope.
2. Never use wire rope which is twisted, frayed or
kinked.
3. Never use wire rope as a sling.
4. Always ensure wire rope is correctly spooled and first
layer is tight.
Wiring
Be sure phase, cycle and voltage of motor, magnetic
reversing starter and controls all match the electrical
service being used. Check power supply is correctly
grounded. All electrical connections must be properly
insulated and enclosed.
CAUTION
WARNING
WIRE ROPE
WEDGE WIRE ROPE
DRUM
CAUTION
CAUTION

8
• Never use a 230V motor with a 115V power supply.
The motor can be permanently damaged.
• Switches and starter enclosures must be grounded to
electrical supply system.
Power supply voltage must be within 4%. For 460V
motor, the power supply should be greater than 442V and
must not exceed 478V. For a 230V motor, the power
supply should be greater than 221V and not exceed 239V.
Brake Connections
Brake power connections depend on winch power voltage
and brake operating voltage. Drawings MHTPA0247 and
MHTPA0249 show the three possible combinations for
230/460V motors. See drawing MHTPA0198 for location
of brake power connection lines.
(Dwg. MHTPA0247)
(Dwg. MHTPA0249)
Controls
A momentary contact reversing drum switch is recom-
mended for the winch control unless remote or automatic
control of the winch is required. Refer to parts section for
recommended switches. See Wiring Diagram Dwg.
MHTPA0201 for three phase motors.
If remote or automatic control is required, an electromag-
netic reversing starter is recommended. The starter can be
used with either a hand held pendant or with a wall
mounted control station. Automatic control depends on
application. Refer to wiring diagrams for winches using
starters. For three phase motors see Dwg. MHTPA0198.
Contact your nearest distributor or the factory for recom-
mendations on specific applications.
WARNING
TO BRAKE
TO STARTER
T1
MOTOR
230V MOTOR & 230V
BRAKE CONNECTIONS
T7
T2
T8
T3
T9
T4
T5
T6
TO BRAKE
TO STARTER
MOTOR
T1
T2
T3
T4
T7
T5
T8
T6
T9
460V MOTOR & 460V
BRAKE CONNECTIONS

9
WIRING DIAGRAM
DRUM SWITCH CONNECTION DIAGRAM
(Dwg. MHTPA0201)
Top of Drum Switch Diagram is
Handle End, Knob Toward Viewer
230 Volt Three Phase
L1
L2
L3
T1
T7
T2
T8
T3
T9
T4
T5
T6
Motor
Drum Switch
To 230V
Brake
460 Volt Three Phase
Motor
Drum Switch
To 460V
Brake
L1
L2
L3
T1
T2
T3
T4
T7
T5
T8
T6
T9
Brake
Power
Brake
Motor
T3
T2
T1
RD
WH
BK
Pendant or
Control Station
X2
115V
460V
Transformer
460V Connection
2
3
1
FWD
VW
765
4REV
VW
Magnetic Reversing Starter (based on FURNAS class 22 starters)
L1 L2 L3
Transformer
230V Connection
230V
115V
H1 H2 H3
H4
X2 XF X1
H1 H2 H3
H4
X2 XF X1
FWD
REV
230/460 Volt, 3 Phase:
(Dwg. MHTPA0198)

10
The four most important aspects of winch operation are:
1. Follow all safety instructions when operating the
winch.
2. Allow only qualified people to operate the winch.
3. Subject each winch to a regular inspection and main-
tenance procedure.
4. Be aware of the winch capacity and weight of load at
all times.
• Only allow qualified personnel (trained in safety and
operation) to operate a winch.
• To avoid damage to the rigging, the structure sup-
porting the rigging, and the winch, do not “two-block”
the end of the wire rope.
Power Operation
• A creeping load can cause death or injury. Do not
rely on the gear reduction or brake to hold a load.
• Operating winch for time periods longer than sug-
gested may result in damage to the motor.
The motor on the winch has a intermittent duty rating of
15 minutes. This is the number of minutes the motor may
be operated during a one hour period when the winch is
carrying the full rated load.
When operating the winch avoid unnecessary jogging of
the controls.
OPERATION
Free Spool
• Never disengage the dog with tension on the wire rope
or if the drum is moving.
To disengage the dog (free spool) pull out spring loaded
plunger pin and rotate until plunger pin tab is clear of dog
lever. Dog lever will pivot to the lower position. Release
plunger pin to engage over the dog lever.
To engage the dog pull out spring loaded plunger pin and
rotate until plunger pin tab is clear of dog lever . Lift dog
lever to engage dog. Release plunger pin to engage under
the dog lever.
Hand Wheel Operation
A 28 in. (71 cm) diameter handwheel is available as an
option with the winch. Install the handwheel on the
square end of the power drive assembly and clamp into
position with setscrews.
• To avoid injury to personnel and damage to equip-
ment due to handle flying off while winch is operating,
remove handwheel before operating winch with motor.
In the event of a power failure the hand wheel can be used
to take-up wire rope after the wire rope has been con-
nected to the load. Place holding dog release lever in the
up position to engage the holding dog, take up the slack
with the handwheel while making sure the wire rope is
being uniformly spooled onto the drum. Tensioning may
be accomplished with the handwheel by firmly grasping
the rim of the handwheel with two hands and rotating.
WARNING
WARNING
WARNING
CAUTION
WARNING