TW 6 Le Terex: Instruction Manual

Instruction manual
TW 6 LE TEREX
Code : DO 080715 Edition : 08/2008

TW 6 LE TEREX Code DO 080715 - Ed. 08/2008
INSTRUCTIONS FOR THE USE OF THE HYDRAULIC WINCH

TW 6 LE TEREX
CONTENTS ................................................................................ Page
1 - Procedures for correct installation .................................. 3

1.1 - Main elements ..................................................................... 3
1.2 - General warnings ................................................................ 3
1.3 - Hydraulic system ................................................................. 4
2 - Technical aspects and information.................................. 5

2.1 - Identification and test information ....................................... 5
2.2 - Weight and dimensions ....................................................... 5
2.3 - Intended use ....................................................................... 5
2.4 - Winch hydraulic system with limit switch ............................. 5
2.5 - Lubrication ........................................................................... 5
2.6 - Installation ........................................................................... 5
3 - Operation ............................................................................ 6
3.1 - Connection to the hydraulic system .................................... 6
3.2 - Adjustment .......................................................................... 6
3.3 - Test before putting into operation ...................................... 6
4 - Maintenance ....................................................................... 7
4.1 - Changing oil ........................................................................ 7
5 - Warnings and hazards ...................................................... 8

5.1 - Safety devices ..................................................................... 8
5.2 - Hazards ............................................................................... 8
6 - Attachments ....................................................................... 9
6.1 - Winch identification data ..................................................... 9
6.2 - Dimensions and weights ..................................................... 10
6.3 - Conditions of use of the winch ............................................ 11
6.4 - Winch hydraulic system diagram ........................................ 12
DINAMIC OIL S.p.A. - Via Togliatti, 15 - 41030 BOMPORTO (MO) - Italy - Tel. 059/812611 - Fax 059/812606
-1-
Code DO 080715 - Ed. 08/2008 TW 6 LE TEREX
-2-
1 Procedures for correct

installation
The various winches manufactured by DINAMIC OIL

1.2 - General warnings
S.p.a. are produced with the maximum care and
tested individually with trial lifts of weights.
- Before starting to assemble the winch check that
In order to use the winch correctly and ensure cor- the direction of rotation of the lifting drum is the
rect long-term operation, it is advisable to study the same as that indicated by the arrow in the label on
following technical notes. the drum.
Winches with the opposite direction of rotation to
the standard one can be supplied on request.
THIS DEVICE IS NOT INTENDED FOR USE IN
SYSTEMS FOR LIFTING OR MOVING PEOPLE. - Our winches can be mounted with the fixing feet
facing downwards, upwards, or in any intermedi-
ate position.
Ensure that the support surface onto which the
1.1 - Main elements winch will be fixed is sufficiently rigid and flat. If this
is not the case, when the fixing screws are tight-
ened, forces are generated on the supports which
- Hydraulic motor: axial piston design.
are transmitted to the internal bodies causing
- Locking brake: made with bronze disks con- them to wear rapidly.
nected to the motor shaft, alternated with steel
- Always use all the fixing holes, normally four, and
discs connected to the winch structure, they are
use suitably sized screws for the holes and of
released by pressurized oil that supplies the hy-
class 10.9. Tighten the screws to the required
draulic motor and closed by Belleville washers
torque.
which, with the motor stopped, lock the various
disks. - Normally the winch is connected to the hydraulic
liquid circuit with three pipes.
- Epicyclic reduction gear: this is fitted inside the
Two pipes supply the motor and the third carries
drum and increases the couple available for lifting,
the drainage oil from the motor to the tank.
reducing the rotation speed of the drum in relation
Check that the diameter of the pipes is not lower
to that of the hydraulic motor. It has three stages
than that of the connection holes provided on the
and is sized to deliver the required couple for the
valve and motor.
lifting of the maximum weight.
Connect the drainage pipe directly to the hydraulic
- Lock and lowering control valve: fitted directly oil tank, without passing through the filter or other
to the hydraulic motor, this element is fundamental outlet collectors. The internal diameter of this pipe
for the safety of the winch. It prevents the motor must never be less than 1/4".
from losing control of the load during lowering.
- For the lubrication of internal parts (brake, reduc-
- Drum and related support structure: the drum tion unit, bearings), use ISO VG 150 oil (with EP
is made from steel tube and runs on ball bearings. additives).
The support structure is bolted type making it
extremely rigid and compact.
-3-
There would be a reduction in the pressure of the

1.3 - Hydraulic system
brake spring and a reduction in braking couple.
The hydraulic system to which the winch is con- To avoid malfunctions of the winch the pressure
nected is of particular importance for correct opera- driving the oil through the pipes, with the system
tion. It is essential that the winch control distributor, stopped, should never exceed 0,4 - 0,5 MPa.
in its central position, provides an outlet for the sides Another important element in the hydraulic system is
of the motor. the filter. A 10 micron filter is recommended. Peri-
It should therefore be an open center distributor, with odic replacement of the filter prolongs the life of all
an "H" shape, and the lever should have spring- the components of the system and helps to keep
return to the central position. If a closed center dis- down the oil circulation pressure in the pipes.
tributor is used the locking brake cannot function. A maximum pressure limiting valve is essential on
The brake opens automatically when the motor the winch supply system. Normally such a valve is an
starts up and closes again when the motor stops. integral part of the control distributor, but if one is not
present, a maximum pressure valve should be fitted
To open the brake, a small quantity of pressurized oil to the pipe lines, set at the maximum recommended
from the motor supply line is drawn off and sent to a pressure.
piston inside the brake body (minimum opening
pressure 1,8 - 2,0 MPa). The pressurized oil acts on
the pin of the springs that lock together the various
brake disks, allowing the free rotation of the motor
shaft.
When the winch is stopped by moving the distributor
lever to the central position the brake should close
with the springs pushing on the various disks and
locking the system. To allow this the pressurized oil
has to be released into the system through the two
motor supply lines. If the distributor is closed in its
central position, it does not allow free connection to
the motor supply lines with the tank, and the brake
will not close.
The winch might still operate without problems but
the following malfunction would occur:
- when the winch is stopped with a suspended load
it would tend to slowly move down with little jud-
ders.
As already stated, the diameter of the pipes must be
proportional to the oil volume supplied to the pump.
Pipes of insufficient diameter could cause an in-
crease in operating pressure throughout the system.
Even with the winch stopped, a degree of pressure
would be generated simply by the oil running through
the pipes.
When the winch is stopped with a suspended load
with the distributor connections open, the pressure,
after the depressurizing of the system, acts on the
brake piston.
-4-
2 Technical aspects and information
2.1 - Identification and test information 2.6 - Installation
- Before starting check the flatness and rigidity of

See para. 6.1. the slab to which the winch is to be fixed.
- Position the winch on the fixing slab and ensure
2.2 - Weight and dimensions that the four fixing legs rest perfectly on the slab
surface.
See para. 6.2.
- For fixing use class 10.9 screws and tighten to the
torque indicated in para. 6.3.
2.3 - Intended use
See para. 6.3.
2.4 - Winch hydraulic system with limit switch
See para. 6.4.
2.5 - Lubrication
The winch requires oil bath lubrication for the gears

inside the drum. It is therefore necessary, before
installing, to fill the drum to the required level as
indicated in para. 6.3.
This means filling the drum up to approximately its
horizontal axis. The recommended oil for lubrication
is ISO VG 150 (with EP additives).
-5-
3 Operation
Do not fit a cable longer than the maximum length

3.1 - Connection to the hydraulic system
(see para 6.3).
After installation, fit the two main pipes to the stop When fitting the cable, check that the rotation of the
valve flanged to the winch motor. drum is the same as that indicated by the arrow on
the winch drum.
Use adequately sized pipes so as to avoid significant
pressure loss along the pipes. The operating pres- The correct fitting of the cable reduces wear and
sure figures, given in the load diagrams, refer to use avoids the load from dropping suddenly. If during
with return pressure equal to atmospheric pressure. initial fitting the cable is not sufficiently compact,
when the load is applied the cable can easily jam
between underlying coils, causing damage to the
CHECK THE HYDRAULIC SYSTEM DIAGRAM cable and the load to drop suddenly.
(see para. 6.4). When the cable is fitted, reposition the arm of the
limit switch and refit the preloaded spring. Conduct a
few test lifts with weights, not above the permitted
1) - Connect the motor drainage directly to the
maximum, and check that the limit switches function
tank. The pressure on the drainage line, meas-
correctly.
ured near to the motor, must not exceed 0,10 -
0,15 MPa (1 - 1,5 bar). When the lower limit switch activates there should
always be at least 4 or 5 coils remaining around the
drum.
3.2 - Adjustment
The winch does not require any form of adjustment.

Never change the settings of the stop valve flanged
to the motor, since this could cause dangerous mal-
functions.
3.3 - Tests before putting into operation
Before fitting the cable to the drum, demount the

preloaded spring of the lower limit switch and rotate
back the trigger arm. Check that the breaking strain
of the cable and hook are at least 5 times as high as
the nominal lifting stain on the winch identification
plate.
If lifting directly by cable it is advisable to use anti-

rotation cable. The diameter of the cable should not
be less than 1/20 of the diameter of the drum.
-6-
4 Maintenance
4.1 - Changing oil
It is advisable to replace the lubricating oil of the

reduction gear mounted inside the drum every six
months or after 600 hours of use.
To replace the oil, unwind the cable until the cap found
on the drum about 60 mm from the motor side is
uncovered.
Place a container below the drum to collect the oil to
be replaced, undo the cap and rotate the drum 180°.
Empty the drum of oil, rotate it 180° and add enough

oil to fill the drum up to its horizontal axis, then replace
the cap.
-7-
5 Warnings and hazards
5.1 - Safety devices
A - Hydraulic pilot stop valve:

a) load stop;
b) motor drive control;
c) locking in the case of pipe breakage.
B - Brake: for locking the drum with a suspended

load.
C - Fleeting control: free extensions from the lat-

eral flanges of the drum, not less than 1,5 times
the thickness of the cable with respect to the last
layer of cable.
D - Limit switch devices (Machine Directive

4.1.2.6): must maintain the range of movement
of the load within the designed limits.
5.2 - Hazards
In accordance with the requirements of the Machine

Directive, whenever the drum cable assembly is
accessible to the operator or to anyone who might be
within its range of action, this assembly should be
covered with a guard. The various possible configu-
rations of the machine onto which our equipment is
installed should be borne in mind when making this
assessment.
-8-
6 Attachments
6.1 - Winch identification data
Argano tipo ___________ Codice ______________

Matricola ____________ Anno fabbr. ___________
Tiro max _________ KN
Cod. cliente _______________ Lotto ____________
Ordine cliente _____________________
UN02-0446GE
Fig. 6.1.1
-9-
6.2 - Dimensions and weights
50
n°4 Ø25
B
A
315
Ø575
520
615
10°
360
305
94
91,5
17
525
708
595
Ø365
Ø356
P
1247
91,5
147
Total weight with oil = 515 kg

D
509
D = M18 x 1,5
P = 1/2" BSP
411
A = 1" BSP
B = 1" BSP
UN02-0447GE
Fig. 6.2.1
- 10 -
6.3 - Conditions of use of the winch
- Nominal pull: 60 daN
- Axial piston hydraulic motor: REXROTH A6VM - 107
- Parking brake: static couple of 40 daNm
- Minimum brake opening pressure: 2 MPa (20 bar)
- Three stage epicyclic reduction: ratio 1 : 51,68
- Max. power supply capacity: 201 l/1'
- Max. lifting speed: 96,5 m/1'
- Max. quantity of Ø 16 mm cable: 228 m in five layers
- Lubrication oil volume: 20 l
- Winch fixing screws: 4 M 22 class 10.9 (screw couple 75 daNm)
- Total mass of winch with motor,

valve and lubricating oil: 515 kg
Classification of the mechanisms

- According to FEM 1.001: class of use T6
class of spectrum L2
class of mechanisms M6
- Winding ratio D/d: 21,25 (min. 18)
Performances with REXROTH A6VM - 107 motor Vmax 100 / Vmin 60 -

201 l/1' ∆P 210 - 215 bar capacity
Cable layer n 1 2 3 4 5
Max. pull daN 7400 6810 6300 5870 5500

4400 4000 3700 3520 3300
Max. speed m/1' 43 46,5 50 54 57,5

71,5 77,5 84 90 96,5
Cable quantity m 40 82 128 177 228
- 11 -
6.4 - Winch hydraulic system diagram
V1 Descent line
V2 Lifting line
C3 Connection to brake
D Drainage connection
1 Open center distributor
2 Maximum pressure limiting valve
3 Limit switch solenoid
V1 C3 V2
LOWERING HOISTING
UN02-0095MA_IN
Fig. 6.4.1
- 12 -

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Instruction manual

Code : DO 080715 Edition : 08/2008

INSTRUCTIONS FOR THE USE OF THE HYDRAULIC WINCH

CONTENTS ................................................................................ Page

1 - Procedures for correct installation .................................. 3

2 - Technical aspects and information.................................. 5

5 - Warnings and hazards ...................................................... 8

1 Procedures for correct

The various winches manufactured by DINAMIC OIL

There would be a reduction in the pressure of the

2 Technical aspects and information

2.1 - Identification and test information 2.6 - Installation

- Before starting check the flatness and rigidity of

2.3 - Intended use

See para. 6.3.

2.4 - Winch hydraulic system with limit switch

See para. 6.4.

The winch requires oil bath lubrication for the gears

Do not fit a cable longer than the maximum length

The winch does not require any form of adjustment.

3.3 - Tests before putting into operation

Before fitting the cable to the drum, demount the

If lifting directly by cable it is advisable to use anti-

4.1 - Changing oil

It is advisable to replace the lubricating oil of the

Empty the drum of oil, rotate it 180° and add enough

5 Warnings and hazards

5.1 - Safety devices

A - Hydraulic pilot stop valve:

B - Brake: for locking the drum with a suspended

C - Fleeting control: free extensions from the lat-

D - Limit switch devices (Machine Directive

In accordance with the requirements of the Machine

6.1 - Winch identification data

Argano tipo ___________ Codice ______________

6.2 - Dimensions and weights

Total weight with oil = 515 kg

6.3 - Conditions of use of the winch

- Nominal pull: 60 daN

- Axial piston hydraulic motor: REXROTH A6VM - 107

- Parking brake: static couple of 40 daNm

- Minimum brake opening pressure: 2 MPa (20 bar)

- Three stage epicyclic reduction: ratio 1 : 51,68

- Max. power supply capacity: 201 l/1'

- Max. lifting speed: 96,5 m/1'

- Max. quantity of Ø 16 mm cable: 228 m in five layers

- Lubrication oil volume: 20 l

- Winch fixing screws: 4 M 22 class 10.9 (screw couple 75 daNm)

- Total mass of winch with motor,

Classification of the mechanisms

- Winding ratio D/d: 21,25 (min. 18)

Performances with REXROTH A6VM - 107 motor Vmax 100 / Vmin 60 -

Max. pull daN 7400 6810 6300 5870 5500

Max. speed m/1' 43 46,5 50 54 57,5

6.4 - Winch hydraulic system diagram

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