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1 Operating nstructions & Parts Manual Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference. Dayton Hydraulic Winch Description The winch is a hydraulic powered winch with an -J-706 first layer rating of 15,000 lbs. Power from the hydraulic system is supplied to the winch s motor, driving a two stage planetary gearbox. The output of the gearbox drives the rope drum, winding in the wire rope and pulling or winching a load. This winch is equipped with a hydraulic release, spring applied, multiple disc, failsafe dry brake. The brake is designed to lock and hold the load whenever hydraulic pressure to the winch motor is interrupted. This winch has a freespooling clutch which allows the wire rope to be removed from the drum quickly. The winch is reversible so the rope can be powered in and out using the directional control valve in the hydraulic circuit. The winch is designed with many mounting options. t may be mounted using the feet or rails, in a horizontal or vertical configuration. The winch is not intended or approved for lifting, hoisting or transporting people. Unpacking Please unpack carefully and read the instructions before beginning. pecifications Drum Dia " (101.6mm) Drum ength " (255mm) Recommended Wire Rope Diameter /2 Max. ength ' (46.6m) Construction x 19 Weight (ess Rope) lb./56.7 kg Operating Pressure Continuous Min. 800 psi (55 bar) Max. 2,000 psi (138 bar) ntermittent Max. 2,250 psi (155 bar)* Operating Flows Continuous Min. 3 gal/min (11.4 PM) Max. 2,000 psi (138 bar)* ntermittent Max. 20 gal/min (76 PM)** ubrication - Grease filled gearbox lubricated with uper ube Grease, p/n *The intermittent pressure of 2,250 psi must not occur for a duration of more than 2 seconds. **The maximum intermittent pressure of 2,250 psi and maximum flow of 20 GPM must not occur simultaneously. The winch motor will be damaged. Form Rev 1/3/13 Package Contents: Description Winch assembly without motor (no wire rope) Motor assembly with load control Owner s Manual Performance Wire Rope Max. Pulling Capacity ayer lbs kg 1 15, , ine Pull ine peed Drum Capacity ayer 1 ayer 2 ayer 3 ayer 4 ayer 5 Psi Bar bs. kgs bs. kgs bs. kgs bs. kgs bs. kgs 1, , , , , , , , , , , , , , , , , , Gal. it. Ft. Meter Ft. Meter Ft. Meter Ft. Meter Ft. Meter Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min ength n. MM Ft. Meter Ft. Meter Ft. Meter Ft. Meter Ft. Meter Printed in U /012/K4 Figure 1 Quantity OT: 1. ll values are based on actual winch test data and measurements. 2. ine speed is based on standard 4", (101.6 mm), drum dia. with 1/2" dia., (12 mm), wire rope. 3. Drum capacity is based on standard 4", (101.6 mm), drum dia. with 1/2" dia., (12 mm), wire rope, value of K= pproximate values of line pull and line speed not listed may be found by interpolation. G H P Ñ O F R Ç

2 Dayton Operating nstructions and Parts Manual Dayton Hydraulic Winch G H Dimensions Mount Material Thickness ide Bolt ength Foot Bolt ength 10 1 /32 (255.0) 10 1 /14 (260.0) 10 (254.4) /16 (299.7) M10 x 1.5 Thd. (4) Places 10 1 /32 (255) /32 (317) 14 1 /8 (359) 2 1 / / / /8" 1 /2 30mm 35mm 40mm M12 x 1.75 Thd. (16) Places 1 50mm 50mm otes: 1. Mounting bolts must be grade 8.8 or better. 2. Torque mounting bolts to 75 Ft. b. 3. engths given in above chart allow for use of one flat washer and Helical lock washer. 4. imit air supply to 40 psi min. 80 psi max. going to freespool clutch. Figure 2 - ll Dimensions are in inches (millimeters) 6 3 /4 (171.2) 4 1 /2 (114.3) 6 13 /32 (162.6) /16 (303.5) 6 15 /16 (180) 14 1 /2 (368.5) /32 (712) #10 Ports Mounting pecifications This winch may be mounted on a flat plate using the threaded holes in the bottom of the winch castings or between rails using the threaded holes in the sides of the winch castings. ee the above diagram for hole sizes and locations. The following guidelines apply to all mounting schemes 1. The wire rope may be installed on the drum in the overwound or underwound condition, in either flat plate or rail mounting scheme. 2. ll fasteners used in mounting the winch should be M12 x 1.75 with a strength rating of Grade 8.8 or better. ll fasteners used in mounting the winch must comply with the lengths for material thicknesses listed in the bolt length table in the Dimensions section. 3. Use only the threaded holes provided to mount the winch. Do not drill and tap new hole(s) as the casting walls may not be thick enough to support a winched load. 4. Do not weld the winch or any parts of the winch. 5. fter mounting and tightening all bolts, place the winch in freespool and check the drum rotation. The drum on an improperly mounted winch may bind, causing poor freespooling and decreasing winch performance. f the drum does bind, loosen all mounting bolts. f the drum now rotates freely, tighten the bolts a bit at a time, checking rotation until the winch is securely fastened. f the drum continues to bind, it is probable that one or more of the mounting system s holes is out of position and requires correction. Precautions for foot down mounting 1. The plate to which the winch is fastened must be 1/2" (12.7 mm) thick steel minimum and flat. 2. ll eight mounting holes in the bottom of the support castings must be used to mount the winch. Precautions for rail mounting 1. The angle iron used for the rails must be 3x3x3/8 (75x75x10 mm) or larger. 2. ll eight mounting holes in the casting sides must be used. 2

3 Dayton Operating nstructions and Parts Manual Model General afety nformation These warnings and precautions must be observed at all times. 1. Before installing or operating the winch, read this manual. Do not allow anyone to operate the winch until they have read this manual and received proper instruction in the winch s use. 2. Do not operate the winch when under the influence of drugs, alcohol, or medication. 3. Winch is not to be used for moving people or anything containing people. 4. Do not work on or around the winch with the PTO engaged and/or hydraulic pump running. 5. Be sure the product, warning, and rating labels on the winch are not obstructed. 6. The winch should not be altered in any way without the written authorization of Dayton lectric Mfg. Co. 7. Use only factory approved accessories. on-approved components may void your warranty and/or fail under load. Dayton lectric Mfg. Co.will not be responsible for damage or honor any warranty claim arising from the use of non-factory approved accessories and/or components. These warnings and precautions must be observed when setting up and/or operating winch. 1. nspect the wire rope for kinks and/or damage before winching a load. Check all tackle for damage, proper function, and rating. Use only tackle whose rating meets or exceeds that of the winch. a. Pulley blocks and any attached tackle must have a working load rating at least twice that of the winch. 2. minimum of 5 wraps of wire rope must be on the drum before applying a load to the winch. The rope to drum attachment will not hold a load. 3. When moving a load, slowly take up the wire rope slack until it becomes taut. top, recheck all winching connections. Be sure all tackle is properly seated. Check the wire rope to be sure it is running properly in any pulleys. 4. f the winch stalls, or will not start the load, do not maintain hydraulic pressure to the motor. Break down the set up, install a pulley block, and use a double line technique. 5. Do not start and stop loads frequently. tarting and stopping places an unnecessary strain on the winch and may loosen wire rope and tackle connections. 6. Keep clear of the winch, wire rope, and the winching operation itself. Keep people out of the winching area. Operate the winch with a clear, unobstructed view of the winching operation. lways be aware of potential hazards, ask yourself, What will happen if the wire rope or any tackle breaks? 7. Do not move the winching or winched vehicle to assist in pulling the load. This may result in overloading the winch and/or the winch mounting system. 8. Do not allow the wire rope to pile up on one side of the drum. Doing so will damage the wire rope and, potentially, the winch. f the rope piles up, stop the operation, secure the load, and change the position of the winching vehicle so it pulls in a direct line. f it is not practical to move the winching vehicle, install a pulley block in the line to act as a guide. 9. When the winching operation is complete and the load is in position, use alternate means to secure the load for transport (i.e., chains, or nylon strap tie downs). The winch is not intended for holding a load during transport. The winch and/or wire rope may break due to shock loads greater than the rating generated during transport. 10. Use caution when powering out or lowering a load down a ramp or incline. tay clear of, and keep people, pets, and property out of the path of the load being lowered. The winch s hydraulic control circuit must make provisions for applications involving lowering of loads (see the hydraulic system/control circuit section of the manual). G H 3

4 Dayton Operating nstructions and Parts Manual Dayton Hydraulic Winch G H General afety nformation (Continued) Hydraulic ystem Requirements/Components/ Control Circuit PUMP / HORPOWR RQURMT The hydraulic system pump should be capable of delivering an oil flow of 15 Gallons/Minute, (57 itre/minute), Continuous. The pump must be capable of developing 2,000 psi (138 bar) continuous. The rating of the pump must be greater than 2,000 psi to account for line losses. We recommend a pump rated for 2,500 psi. These parameters equate to an input horsepower requirement of HP, assuming a 15 to 20% line loss. 1. The intermittent ratings of 20 GPM and 2250 psi must not occur simultaneously. The winch motor will be damaged. 2. f the hydraulic system powering the winch is capable of delivering higher flows and pressures than the winch rating, installation of a separate flow control and relief valve to protect the winch circuit is required. The winch may be used with hydraulic systems unable to deliver the recommended flow or pressure. Under these conditions the winch will not perform to specification. The winch will not operate when the pressure drops below 800 psi. Check the flow, pressure, and Performance Data in this manual to determine how the line speed and pull will be affected. DRCTO COTRO VV spring centered, 4-way directional control valve should be used to control the motor s rotation. The valve, if manually operated, should have metering capability. 1. The preferred spool configuration is a floating center. n the neutral position, P is blocked and and B ports are connected to T. 2. n open centered spool may be substituted for the floating center. n the neutral condition, all ports are connected to tank. Failure to install and use the proper valve will affect the brake operation. ny valve which does not drain the and B lines to tank in neutral will prevent the brake from engaging. 3. Check the rating for the directional control valve. n improperly sized directional valve will greatly reduce winch performance. 4. The 4-way valve may be fitted with an integral relief valve. FTRTO The hydraulic system should have a return line filter with a rating of 10 to 40 microns. HYDRUC FUD ny high grade, anti-wear, petroleum based hydraulic fluid with a viscosity rating not less than 100 U may be used. For maximum motor performance and life, the operating fluid temperature must be below 180º Fahrenheit (82º Centigrade). HO Hoses should have working pressure rating of 3000 psi (200 bar) or better. 1. For proper winch performance, use of hoses with an inside diameter of 3/4", (19 mm), is required. f individual hose lengths exceed 10 feet, (3 meters), 1" hose, (25 mm) should be installed. COCTO 1. The standard motor port size used is an #10 or 7/8-14 O-Ring. 2. The standard brake port size is an #4 or 7/16-20 O-ring. POWRG OUT OR OD OWRG CRCUT For applications requiring precise control of the load, or applications involving lifting and lowering, the winch motor has been fitted with a manifold containing dual load control valves. Failure to use this load control can lead to an uncontrolled, runaway load, motor cavitation and/or overload due to shock loading. 4

5 Dayton Operating nstructions and Parts Manual Model Figure 3 - Components COMPOT COMPOT DCRPTO DCRPTO 1- Tank/Reservoir 25 Gallon Min. Recommended. 2- uction strainer, 250 micron rating. 3- Pump, Rating of 2,500 psi 15 Gal./Min. 4- Directional control valve, 4-way, spring centered float center spool with integral relief valve. Rating of 2,500 psi and 15 Gal./Min. Required. ote: Open center spool with same ratings may be substituted. 5- Manifold, Dual oad Control Valves with integral shuttle valve. Rating of 3,000 psi min. load controls set at 800/850 psi with 4:1 pilot ratio. 6- Motor, check D plate on motor for specs. 7- Winch Brake. 8- Return filter, 10 to 40 micron rating. OT - nstallation of a heat exchanger in the return line is recommended. B- f total system pressure is regulated below 2,000 psi the relief valve in the 4-way valve may be eliminated. C- ystems with pumps capable of greater than 15 Gal/Min. require a flow control or restricting orifice to protect the motor. The wire rope to drum attachment will not support a load. minimum of 5 wraps of rope must be wound on the drum before winching a load. Observing the following guide lines will prolong the life of, and prevent damage to, the wire rope:.when installing a wire rope, roll out and untangle the rope before winching it onto the drum. Do not attempt to install a coiled wire rope. earn to recognize and clear kinking before the wire rope is damaged. Figure 5 G H Operation and Use This section deals with the operation of the winch and performing a winching operation. Read and follow the instructions and warnings carefully. The responsibility for safe operation of the winch and prevention of personal injury and property damage ultimately rests with you, the operator. There is no substitute for the use of good judgement and caution in operating a winch. TTO D CR OF TH WR ROP 1. The wire rope may be installed in the overwound or underwound condition. For flat plate, foot down installations the under wound condition is recommended. 2. The wire rope is attached to the drum by passing the end of the rope through the hole in the drum barrel and locking it in place by tightening the set screw. Figure 4 a b c Figure 6 (a)this is the start of a kink. t this time, the wire rope should be straightened. (b) The wire rope was pulled and the loop has tightened to a kink. The wire rope is now permanently damaged and must be replaced. (c) Kinking causes the wire strands under the greatest tension to break and thus reduces the load capacity of the wire rope. The wire rope must be replaced. B. Keep tightly wound wire rope on the drum. oose wraps will allow the rope to penetrate into the lower layers causing binding and crushing of the wire rope. 5

6 Dayton Operating nstructions and Parts Manual Dayton Hydraulic Winch G H Operation (Continued) C. Keep the winch in line with the load. This will prevent the rope from piling up on one side of the drum and damaging itself, the rope drum, or the winch. Do not attempt to guide the wire rope onto the drum with your hands or feet. nstead, stop the winching operation and reposition the winch. D.Use of a roller fairlead will help guide the rope onto the drum, and prevent the rope from rubbing against the mounting system or castings. This prevents the rope from damaging itself or the winch.. Do not allow the wire rope to contact the ground, rocks, or anything other than approved tackle during the winching process. F. Do not hook the wire rope back onto itself. Use a sling or chain to connect to the load. G.lways protect your hands by wearing leather or leather palmed gloves when handling wire rope. ever let the rope slide through your hands. nstead use a hand-over-hand motion to feed the wire rope. FRPOOG Freespooling occurs when the drum is disconected from the gearbox and/or out-put drive allowing the wire rope to be removed from the drum without supplying power to the winch motor. ever attempt to place the drum in freespool when there is a load on the wire rope. Forcing the drum into freespool with a load on the rope may result in personal injury and/or property damage to yourself or others. lways check that any load is secured by other means before attempting to place the drum into freespool. FRPOO MCHM 1. To place the winch in freespool, first remove any load from the wire rope and drum. Grasp the freespool handle, pull the trigger, and lift until the latch mechanism engages into the up position. The wire rope may now be pulled from the drum. 2. To re-engage the winch s drive, grasp the freespool handle, pull the trigger, and lower the handle. f the handle does not go all the way down, do not force it. This means the splined shaft is not lined up for proper engagement. Use the directional control valve to power the winch enough to just move the drum. The splined shaft should snap into place, and the handle will drop into its down position. Disengage ngage OPRTO OF TH FRPOO MCHM The sound of grinding gears while trying to engage the drive, (taking the winch out of freespool), is caused by the drive splines being rotated too quickly to allow engagement. Use the metering capability of the directional control valve to slow the motor rotation allowing the splines to engage and slide into full engagement. Do not continue to power the winch when you hear the sound of the gears grinding. RMOT FRPOO CODRTO 1. pplications which utilize a mechanical linkage to remotely activate the freespool mechanism need to address the following points in their design and construction. a. positive locking mechanism which locks the drive in both the winch or freespool position. b. f the linkage creates too high a drag or binds the action of the winch s freespool mechanism, a separate spring or bushings may need to be installed so the freespool clutch will self-engage. The winch s freespool spring may not be strong enough to pull a heavy or bound linkage into place. Figure 7 6

7 Dayton Operating nstructions and Parts Manual Model Operation (Continued) F-F BRK 1. The winch is fitted with standard multiple disc spring applied, hydraulic release, dry design fail-safe brakes. 2. Use the load rating by layer found on the product label as a guide for the brake rating by layer. 3. minimum pressure of psi is required to fully unlock the brake. Do not attempt to run the winch at pressures less than 800 psi (55 bar). The brake will release at 350 psi (24 bar), but the counterbalance valve will not open until 800 psi (55 bar) is reached. 4. The load holding capacity of the brake is reduced by the back or return line pressure. F TH BRK W OT HOD OD, CHCK TH YTM FOR XC BCK PRUR. TM UCH CRMPD HO OR DRTY FTR W GRTY CR BCK PRUR. The back pressure effects must be accounted for when winching a load. 5. Periodically test the brake by disconnecting and plugging the shuttle valve to brake line. lowly apply pressure to the motor. When the pressure reaches 1700 to 1800 psi, ( bar), the drum should start to slowly rotate. 6. ever apply a pressure greater than 2200 psi (152 bar) to the brake. f the drum starts to rotate at pressures below 1700 psi (117 bar), the brake is either worn or requires service. Maintenance ROUT MTC Your winch is designed to provide years of trouble free operation. s with any machine, periodic routine maintenance is required. Use the following as a guideline to keep your winch in top operating condition. The following items should be checked weekly. daily inspection of these items should be performed on winches in frequent use. Check all bolts, screws, and other fasteners mounting the winch and its accessories, to be sure they have not vibrated loose and fallen out. Check the wire rope for damage. Replace as required. Check the winch for hydraulic fluid leaks around the gearbox and brake. t the same time, check the casting for any cracks or other signs of damage. Be sure the freespool mechanism is operating properly. Check the hydraulic control circuit for proper function. Check hoses for deterioration, check all connections and fitting for leaks. The following items should be checked monthly. weekly inspection of these items shold be performed on winches in frequent use. Check the brake. Follow the guidelines listed in the section of this manual describing the brake. fter 50 hours of winching or annually: Change gearbox grease (approximately 1/4 lb. uper ube p/n ). Check brake function. ubricate freespool mechansim with light oil. Check tightness of mounting bolts and hydraulic connections. UBRCTO 1. The winch gearbox is grease lubricated with uper ube at the factory. f the winch is torn down and washed out, use grease p/n to repack. 2. ll freespool mechanism parts require periodic regreasing to keep them operating properly. ny high quality white automotive grease is acceptable. Grease p/n is recommended. n cold climates, a light oil should be substituted for grease. G H 7

8 Dayton Operating nstructions and Parts Manual Dayton lectric Winch Hydraulic ystem Troubleshooting Chart ymptom Possible Cause(s) Corrective ction ystem is inoperative 1. o hydraulic fluid in system; 1. Fill system and check for leaks. insufficient fluid in system. G H 2. Wrong hydraulic fluid in system. 2. Refer to manufacturer's specifications. Change fluid. 3. Dirty or clogged filter. 3. Drain fluid and replace filter or filter element. 4. Fluid line restriction. 4. Clean or replace. Fluid lines dirty or collapsed. 5. ir leaks in pump suction line. 5. Repair or replace as necessary. 6. Worn or dirty pump. 6. Clean, repair, or replace. Check alignment. Check for contaminated oil. Drain and flush system. 7. Badly worn components. 7. xamine and test for external leakage. Replace faulty components. Check for cause of wear. 8. eakage. 8. Check all components, particularly the relief valve, for proper setting. Refer to technical manuals. 9. xcessive load. 9. Check unit specifications for load limits. 10. lipping or broken pump drive Repair or or replace belts, couplings, etc. Check for for proper alignment alignement of of tension. ystem operates erratically 1. ir in system. 1. Check suction side of system for leaks. Repair. 2. Cold hydraulic fluid. 2. llow ample warm-up period. 3. Dirty or damaged components. 3. Clean and repair as necessary. 4. Restriction in filters or lines. 4. Clean and/or replace elements or lines. ystem operates slowly 1. Hydraulic fluid viscosity too high; 1. llow fluid to warm up before cold fluid. operating machine. 2. ow pump drive speed. 2. ncrease engine speed (check manual for recommendations). 3. ow fluid level. 3. Check reservoir and add fluid as necessary. 4. ir in system. 4. Check suction side for leaks. Repair. 5. Badly worn pump, valves, etc. 5. Repair or replace as needed. 6. Restrictions in filters or lines. 6. Clean and/or replace elements as needed. 7. mproper adjustments. 7. Check relief valves, etc. djust per manual. 8

9 Dayton Operating nstructions and Parts Manual Model Winch Troubleshooting Chart ymptom Possible Cause(s) Corrective ction Drum will not rotate at all 1. Brake not unlocking 1. Check shuttle valve Check hose for leak Check port for blockage Disassemble and inspect brake 2. Winch is improperly 2. Check mount. (ee mounted mounting section in this manual.) 3. ot enough pressure 3. Check pump and relief valve settings psi required to open counter balance valve Drum will not rotate 1. Brake not unlocking 1. ame as above under load 2. Freespool not engaged 2. ngage freespool 3. Damaged drive system 3. Teardown and inspect winch Winch runs too slow 1. Brake is not fully 1. Check pressure, released brake requires 350 psi (24 bar) to unlock ( psi required to open counter balance valves) 2. ow flow to motor 2. Check hydraulic circuit for leaks and faulty components Wire rope drum 1. Freespool lever not 1. Check lever will not freespool locked in position position 2. Winch is improperly 2. Check mount. (ee mounted mounting section in this manual.) Oil leak around motor 1. oose fitting 1. Tighten fitting 2. Damaged shaft seal 2. Replace motor in motor Oil leak around Damaged piston, seal Disassemble brake brake housing or casting and repair oad drifts High back pressure Run separate return line to tank. Check spool in directional control valve for proper configuration (ee Hydraulic Requirements) Drum chatters 1. Drive not fully engaged 1. Check freespool mechanism for full engagement and lock 2. ow flow 2. Check hydraulic circuit for leaks and faulty components G H 9

10 Dayton Operating nstructions and Parts Manual For Replacement Parts, call hours a day 365 days a year Please provide following information: -Model number -erial number -Part descriptions and number as shown in parts list G H a Figure 8 - xploded View 10

11 Dayton Operating nstructions and Parts Manual Model Replacement Parts ist Reference umber Description Part umber Quantity 1 M8 x 150 Hex head bolt M8 ockwasher Gearbox cover st tage Thrust pad st tage Ring gear st tage Carrier assembly nd tage un gear Ring gear spacer st tage un gear Drive shaft coupling a Coupling pacer Drive shaft mm x 6mm Key nd tage Thrust washer nd tage Carrier assembly nd Carrier Thrust washer Wave spring nd tage Ring gear pring pin Carrier body oil seal Ring gear spacer liding dog pring pin Clutch fork Gear box housing assembly Freespool pivot shaft Drag button spring Drag button atch plate M8 x 20 Hex head bolt M8 x 16 Hex head bolt M8 Flat washer Handle assembly V Face seal Drum bearing G H 11

12 Dayton Operating nstructions and Parts Manual Dayton lectric Winch G H Replacement Parts ist Reference umber Description Part umber Quantity 35 Drum assembly ocket head set screw M8 x 10 * 1 37 Tie Bar M12 x mm long bolt mm ockwasher Brake housing Disc spring Pressure plate Rotor (Hyd) brake Rotor thrust washer tationary disc Rotating disc Brake release U seal (sold only with 48) 48 Brake Repair Kit (includes Motor Mounting Hardware, 42, 45, 47) M8 x 40 Hex head cap screw /16-18 x 2 1 /2" Hex head cap screw /16" ockwasher Manifold Hydraulic motor Hydraulic fitting Hose assembly Bleed nipple Roller fairlead Rope tensioner (*) Purchase at Hardware supplier ( ) ot shown 12

13 Dayton Operating nstructions and Parts Manual otes G H 13

14 Dayton Operating nstructions and Parts Manual Dayton lectric Winch G H MTD WRRTY DYTO O-YR MTD WRRTY. Dayton lectric winches, Models covered in this manual, are warranted by Dayton lectric Mfg. Co. (Dayton) to the original user against defects in workmanship or materials under normal use for one year after date of purchase. ny part which is determined to be defective in material or workmanship and returned to an authorized service location, as Dayton designates, shipping costs prepaid, will be, as the exclusive remedy, repaired or replaced at Dayton s option. For limited warranty claim procedures, see PROMPT DPOTO below. This limited warranty gives purchasers specific legal rights which vary from jurisdiction to jurisdiction. MTTO OF BTY. To the extent allowable under applicable law, Dayton s liability for consequential and incidental damages is expressly disclaimed. Dayton s liability in all events is limited to and shall not exceed the purchase price paid. WRRTY DCMR. Dayton has made a diligent effort to provide product information and illustrate the products in this literature accurately; however, such information and illustrations are for the sole purpose of identification, and do not express or imply a warranty that the products are MRCHTB, or FT FOR PRTCUR PURPO, or that the products will necessarily conform to the illustrations or descriptions. xcept as provided below, no warranty or affirmation of fact, expressed or implied, other than as stated in the MTD WRRTY above is made or authorized by Dayton. PRODUCT UTBTY. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While Dayton attempts to assure that its products comply with such codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, review the product applications, and all applicable national and local codes and regulations, and be sure that the product, installation, and use will comply with them. Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you; (b) also, some jurisdictions do not allow a limitation on how long an implied warranty lasts, consequently the above limitation may not apply to you; and (c) by law, during the period of this imited Warranty, any implied warranties of implied merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed. PROMPT DPOTO. Dayton will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call dealer from whom the product was purchased. Dealer will give additional directions. f unable to resolve satisfactorily, write to Dayton at address below, giving dealer s name, address, date, and number of dealer s invoice, and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. f product was damaged in transit to you, file claim with carrier. Manufactured for Dayton lectric Mfg. Co., ake Forest, U... Manufactured for Dayton lectric Mfg. Co. ake Forest, U... 14

15 Manual de nstrucciones de Operación y ista de Partes Favor de leer y guardar estas instrucciones. éalas cuidadosamente antes de tratar de montar, instalar, operar o dar mantenimiento al producto que aquí se describe. Protéjase usted mismo y a los demás observando toda la información de seguridad. i no se siguen las instrucciones, se pueden sufrir daños, tanto personales como a la propiedad! Guarde estas instrucciones para futura referencia. Cabrestante Hidráulico Dayton Descripción l cabrestante es impulsado por energía hidráulica con una capacidad -J-706 de 6804 kg. para la primera capa. l sistema hidráulico entrega la energía al motor del cabrestante, accionando una caja de engranajes planetarios de dos etapas. a salida de la caja de engranajes acciona el tambor del cable metálico, enrollando el cable a la vez que tira de o mueve una carga. l cabrestante viene equipado con un alivio hidráulico a resorte, discos múltiples y un freno seco a prueba de falla. l freno ha sido diseñado para asegurar y sujetar la carga cuando se interrumpe la presión hidráulica que va hacia el motor del cabrestante. ste cabrestante tiene un embrague de enrollado libre que permite que el cable metálico se remueva del tambor rápidamente. l cabrestante es invertible de modo que el cable metálico pueda accionarse hacia adentro o hacia afuera usando la válvula de control de dirección en el circuito hidráulico. l cabrestante ha sido diseñado con muchas opciones para el montaje. e puede montar usando los pies o los rieles en una configuración ya sea horizontal o vertical. l cabrestante no tiene como fin, ni está aprobado, para levantar, izar ni para transportar personas. Desempaque Favor de desempacar esta caja cuidadosamente y leer las instrucciones antes de empezar. specificaciones: Diá. del tambor ,6 mm (4 ) ong. del tambor mm (10 ) Cable metálico recomendado Diámetro ,27 cm ongitud máxima ,6 m (153 ) Fabricación x 19 Peso (sin cable) ,7 kg./125 lb. Presión de operación Continua Mín. 55 bar (800 psi) Máx 138 bar (2000 psi) ntermitente Máx. 155 bar (2250 psi)* Flujos de operación Continuo Mín. 11,4 l/min. (3 gal/min.) Máx 138 bar (2000 psi)* ntermitente Máx 76 l/min. (20 gal/min.)** ubricación Caja de engranajes llena de grasa, lubricada con uper ube Grease, Ref. o *a presión intermitente de 155 bar no puede aplicarse por un período mayor de 2 segundos. **a presión máxima intermitente de 155 bar y el flujo máximo de 76 l/min. no pueden producirse simultáneamente. e dañará el motor del cabrestante. Formulario Contenido del paquete: Descripción Conjunto del cabrestante sin el motor (sin cable metálico) 1 Conjunto del motor con control de carga 1 Manual del Dueño 1 Rendimiento Capa del Capacidad de Tiro Máx. Cable Metálico lbs kg Tiro de la Cuerda Velocidad de la Cuerda Capacidad del Tambor Capa 1 Capa 2 Capa 3 Capa 4 Capa 5 Psi Bar bs. kg bs. kg bs. kg bs. kg bs. kg , , , Gal. it. Pies Metros Pies Metros Pies Metros Pies Metros Pies Metros Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. 7 26,5 10,0 3,0 14,5 4,4 15,5 4,7 17,0 5,2 20,0 6, ,6 18,5 5,6 23,0 7,0 25,0 7,6 30,0 9,1 32,0 9, ,0 27,0 8,2 33,0 10,1 37,0 11,3 42,0 12,8 47,0 14,3 ongitud Pulg. mm Pies Metros Pies Metros Pies Metros Pies Metros Pies Metros 10, , , , , ,6 mpresso en.uu /012/K4 Figura 1 Cantidad VO: 1. Todos los valores se basan en los datos de la prueba verdadera del cabrestante y sus medidas. 2. a velocidad de la cuerda se basa en un diámetro de tambor estándar de 101,6 mm (4 ), con un cable metálico de 12 mm (1/2 ) de diámetro. 3. a capacidad del tambor se basa en un diámetro de tambor estándar de 101,6 mm (4 ), con un cable metálico de 12 mm (1/2 ) de diámetro, valor de inercia = 0,9. 4. os valores aproximados del tiro y de la velocidad de la cuerda que no aparecen en la lista se pueden calcular por interpolación. P Ñ O

16 Manual de nstrucciones de Operación y ista de Partes Dayton Cabrestante Hidráulico Dayton Dimensiones P Ñ O Mount spesor del Material Material de Thickness Montaje 0,95 1,27 2,54 ide ongitud Bolt del Perno ength ateral 30mm 35mm 50mm Foot ongitud Bolt del Perno ength de Pie VO: 1. os pernos de montaje deben ser de calidad 8.8 o superior. 2. Torsione los pernos de montaje a 75 pies libra. 3. as longitudes indicadas en la tabla permiten el uso de las arandelas planas y de las arandelas de seguridad helicoidales. specificaciones de Montaje l cabrestante se puede montar en una placa plana, usando los agujeros roscados en la parte inferior de las piezas fundidas del cabrestante, o entre los rieles, usando los agujeros roscados en los lados de las piezas fundidas del cabrestante. Vea el diagrama anterior para los tamaños y las ubicaciones de los agujeros. as guías a continuación se aplican a todos los esquemas de montaje 1. l cable metálico se puede instalar en el tambor enrollándolo por la parte superior o la inferior, ya sea usando el esquema de montaje en placa o en riel. 2. Todos los sujetadores que se usen en el montaje del cabrestante deben ser de M12 x 1.75 con una capacidad de resistencia de calidad 8.8 o superior. Todos los sujetadores que se usan en el montaje del cabrestante deben cumplir con las longitudes para el espesor del material que se enumeran en la tabla de longitud de los pernos en la sección Dimensiones. 40mm 50mm 10 1 /32 (255,0) 10 1 /14 (260,0) 10 (254,4) /16 (299,7) Roscas de M10 x 1.5 (4) ugares 6 3 /4 (171,2) Figura 2 Todas las dimensiones están en pulgadas (milimetros) 4 1 /2 (114,3) 6 13 /32 (162,6) 3. Use solamente los agujeros roscados que vienen incluidos para montar el cabrestante. o taladre ni rosque agujero(s) nuevo(s) dado que las paredes de la pieza fundida puede que no sean lo suficientemente gruesas como para soportar la carga del cabrestante. 4. o suelde el cabrestante ni ninguna de sus partes. 5. Después de montar y apretar todos los pernos, coloque el cabrestante en enrollado libre y revise la rotación del tambor. l tambor de un cabrestante que se ha montado incorrectamente puede atascarse, produciendo un enrollado libre ineficiente y disminuyendo el rendimiento del cabrestante. i el tambor se atasca, suelte todos los pernos de montaje. i ahora el tambor empieza a rotar libremente, apriete los pernos un poco a la vez, revisando 10 1 /32 (255) /32 (317) 14 1 /8 (359) /16 (303,5) 6 15 /16 (180) 14 1 /2 (368,5) /32 (712) 2 1 /16 52,0 1 1 /4 31,8 4 1 /2 114,0 Roscas de M12 x 1.75 (16) ugares Orificios #10 la rotación hasta que el cabrestante quede firmemente sujeto. i el tambor continúa atascándose, es probable que uno o más de uno de los agujeros del sistema de montaje esté fuera de posición y necesite corregirse. Precauciones para el montaje con pie abajo 1. a placa en la cual el cabrestante está sujeto debe ser plana, y de acero de 12,7 mm (1/2 ) de espesor mínimo. 2. os ocho agujeros de montaje en la parte inferior de las piezas fundidas de soporte se deben usar para montar el cabrestante. Precauciones para el montaje en riel 1. l hierro en ángulo que se usa para los rieles debe ser de 75 x 75 x 10 mm (3 x 3 x 3/8 ), o más grande. 2. e deben usar los ocho agujeros de montaje en los lados de la pieza fundida. 2-p

17 Manual de nstrucciones de Operación y ista de Partes Dayton Modelo nformación de eguridad General stas advertencias y precauciones se deben observar en todo momento. 1. ntes de instalar o de operar el cabrestante, lea este manual. o permita que nadie opere el cabrestante a no ser que haya leído este manual y haya recibido la instrucción correcta sobre su uso. 2. o opere el cabrestante bajo la influencia de las drogas, del alcohol o de medicamentos. 3. l cabrestante no se debe usar para transportar personas ni nada que lleve personas. 4. o trabaje en o alrededor del cabrestante con la toma de potencia enganchada ni/o con la bomba hidráulica funcionando. 5. segúrese que las etiquetas del producto, de advertencias y de capacidad en el cabrestante no queden obstruidas. 6. l cabrestante no se puede alterar de ninguna manera sin la autorización por escrito de Dayton lectric Mfg. Co. 7. ólo use los accesorios aprobados por la fábrica. os componentes no aprobados pueden anular su garantía y/o pueden fallar bajo carga. Dayton lectric Mfg. Co. no se hará responsable por los daños, ni aceptará ningún reclamo de garantía, que surjan debido al uso de accesorios y/o componentes no aprobados por la fábrica. stas advertencias y precauciones se deben observar cuando se prepare el cabrestante y/o durante la operación de tiro. 1. nspeccione el cable metálico para verificar si está enredado y/o dañado antes de tirar de una carga. Revise todos los aparejos para verificar si están dañados, si funcionan correctamente y su capacidad. ólo use los aparejos que cumplan o excedan las capacidades del cabrestante. a. os cuadernales y todos los aparejos adjuntos deben tener por lo menos el doble de la capacidad de trabajo del cabrestante. 2. Debe haber un mínimo de 5 vueltas de cable metálico enrolladas en el tambor antes de aplicar una carga en el cabrestante dado que el accesorio entre el cable metálico y el tambor no sujetará la carga. 3. Cuando mueva una carga, lentamente remueva la flojedad del cable metálico hasta que quede tirante. Deténgase, vuelva a revisar todas las conexiones de tiro. segúrese que todos los aparejos queden asentados correctamente. Revise el cable metálico para asegurarse que está funcionando correctamente en todas las poleas. 4. i el cabrestante se para abruptamente o si no arranca la carga, no mantenga la presión hidráulica que va al motor. Desmonte la preparación, instale un cuadernal y use la técnica de cuerda doble. 5. o haga arrancar y parar las cargas frecuentemente. l arranque y la parada pone un esfuerzo innecesario en el cabrestante y puede soltar el cable metálico y las conexiones de los aparejos. 6. Manténgase alejado del cabrestante, del cable metálico y de la operación de tiro misma. Mantenga a las personas alejadas del área de tiro. Opere el cabrestante con una vista clara y despejada de la operación de tiro. iempre esté consciente de los peligros potenciales, y pregúntese a sí mismo qué puede suceder si el cable metálico o cualquiera de los aparejos se rompe? 7. o mueva el vehículo de tiro o el que está siendo tirado para ayudar al cabrestante a tirar de la carga. e puede sobrecargar el cabrestante y/o el sistema de montaje del cabrestante. 8. o permita que el cable metálico se amontone en un lado del tambor. sto dañará el cable metálico y potencialmente el cabrestante. i el cable metálico se amontona, detenga la operación, asegure la carga, y cambie la posición del vehículo de tiro de modo que tire en línea recta. i no es práctico mover el vehículo de tiro, instale un cuadernal en la cuerda para que funcione como una guía. 9. Cuando se haya completado la operación de tiro y la carga esté en su posición, use medios alternativos a fin de asegurar la carga para transportarla (es decir, cadenas o amarras de nilón). l cabrestante no tiene como fin sujetar una carga durante el transporte. l cabrestante y/o el cable metálico se pueden romper debido a una carga de choque mayor que la capacidad generada durante el transporte. 10. Tenga cuidado cuando saque o baje una carga en una rampa o en una inclinación. Manténgase alejado y mantenga a las personas, a los animales domésticos y a los bienes de propiedad fuera del paso de la carga que se está bajando. l circuito de control hidráulico del cabrestante debe prever las aplicaciones relacionadas con la bajada de cargas (Vea la sección istema Hidráulico/Circuito de Control en este manual). P Ñ O 3-p

18 Manual de nstrucciones de Operación y ista de Partes Dayton Cabrestante Hidráulico Dayton P Ñ O Requisitos/Componentes/ Circuito de Control del istema Hidráulico RQUTO D BOMB/CBO D FURZ a bomba del sistema hidráulico debe tener la capacidad de entregar un flujo continuo de aceite de 57 litros/minuto (15 galones/minuto). a bomba debe tener la capacidad de desarrollar 138 bar (2000 psi) continuamente. a capacidad de la bomba debe ser superior a 138 bar para considerar las pérdidas en la tubería. Recomendamos una bomba con una capacidad de 172 bar. stos parámetros implican una necesidad de caballos de fuerza, suponiendo que se produce una pérdida de 15 a 20% en la tubería. 1. as capacidades intermitentes de 76 l/min. y 155 bar no pueden producirse simultáneamente. e dañará el motor del cabrestante. 2. i el sistema hidráulico que está accionando el cabrestante tiene la capacidad de entregar flujos y presiones mayores que la capacidad del cabrestante, se necesita instalar una válvula de control de flujo y de alivio aparte para proteger el circuito del cabrestante. l cabrestante se puede usar con los sistemas hidráulicos que no tienen la capacidad de entregar la presión o el flujo recomendados. Bajo estas condiciones, el cabrestante no rendirá de acuerdo a las especificaciones. l cabrestante no opera cuando la presión baja a menos de 55 bar. Revise los datos de flujo, presión y rendimiento que aparecen en este manual para determinar en qué forma se verán afectados el tiro y la velocidad de la cuerda. VVU D COTRO D DRCCO e debe usar una válvula de control de cuatro direcciones, centrada a resorte, para controlar la rotación del motor. i la válvula se opera manualmente, debe tener capacidad de medición. 1. a configuración de carrete preferida es la de un centro flotante. n la posición de neutro, P está bloqueado y los orificios y B están conectados a T. 2. e puede sustituir un carrete centrado, abierto, por el centro flotante. n la condición de neutro, todos los orificios están conectados al tanque. i no se instala ni se usa la válvula correcta se afectará la operación del freno. Cualquier válvula que no drene la tubería o la B hacia el tanque en neutro impedirá que el freno se enganche. 3. Revise la capacidad de la válvula de control de dirección. Una válvula de dirección del tamaño incorrecto reducirá en gran medida el rendimiento del cabrestante. 4. a válvula de cuatro direcciones se puede integrar con una válvula de alivio. FTRCO l sistema hidráulico debe contar con un filtro de la tubería de retorno, con una capacidad de 10 a 40 micrones. CT HDRUCO e puede usar cualquier fluido hidráulico antidesgaste, de base de petróleo y de alta calidad, con una capacidad de viscosidad no menor de 100 U. Para lograr un rendimiento y duración máximos, la temperatura del fluido de operación debe estar por debajo de los 82 C (180 F). MGUR as mangueras deben tener una capacidad de presión de trabajo de 207 bar (3000 psi) o superior. 1. Para que el cabrestante entregue el rendimiento correcto es necesario usar una manguera con un diámetro interno de 19 mm (3/4 ). i la longitud de una manguera individual es superior a 3 metros (10 pies), se debe instalar una manguera de 25 mm (1 ). COXO 1. l tamaño estándar del orificio del motor es #10 o anillo O de 7/ l tamaño estándar del orificio del freno es #4 o anillo O de 7/ CRCUTO D CCOMTO HC FUR O D BJD D CRG n el caso de las aplicaciones que necesitan un control preciso de la carga o en aquéllas que involucran levantamiento o bajada, el motor del cabrestante cuenta con un múltiple que contiene válvulas de control de carga doble. i no se usa este control de carga, se puede producir una carga descontrolada que se escapa, la cavitación del motor y/o la sobrecarga debido a la carga de choque. 4-p

19 Manual de nstrucciones de Operación y ista de Partes Dayton Modelo Requisitos/Componentes/ Circuito de Control del istema Hidráulico (Continuación) Figura 3 - Componentes Operación y Uso sta sección cubre la operación del cabrestante y el proceso de tiro. ea y siga las instrucciones y las advertencias cuidadosamente. a responsabilidad de la operación segura del cabrestante y la prevención de lesiones personales y del daño a la propiedad en última instancia la tiene usted, el operador. o existe sustituto para el ejercicio del buen criterio y la precaución cuando se opera un cabrestante. TCO Y CUDDO D CB MTCO 1. l cable metálico se puede instalar con enrollado por la parte superior o por la inferior. n el caso de las instalaciones con una placa plana, con pie hacia abajo, se recomienda el enrollado por la parte inferior. 2. l cable metálico se fija al tambor pasando el extremo del cable a través del agujero en el barril del tambor y se asegura en su lugar apretando el tornillo de fijación. Figura 4 DCRPCO D O COMPOT 1- Tanque/depósito, se recomienda uno de 95 litros mínimo. 2- Colador de succión, capacidad de 250 micrones. 3- Bomba, capacidad de 172 bar, 57 l/min. 4- Válvula de control de 4 direcciones, carrete de flotación, centrado a resorte, con una válvula de alivio integral. e necesita una capacidad de 172 bar, 57 l/min. viso: se puede sustituir un carrete de centro abierto con las mismas capacidades. 5- Múltiple, válvulas de control de carga doble, con válvula de lanzadera integral. Capacidad de 207 bar mín., control de carga ajustado a 55/58 bar con una relación piloto de 4:1. 6- Motor, revise la placa del fabricante en el motor para verificar las especificaciones. 7- Freno del cabrestante. 8- Filtro de retorno, capacidad de 10 a 40 micrones. VO - e recomienda la instalación del intercambiador de calor en la tubería de retorno. B- i la presión del sistema total se regula a menos de 138 bar, se puede eliminar la válvula de alivio en la válvula de cuatro direcciones. C-os sistemas que cuentan con bombas con una capacidad superior a 57 l/min. necesitan un control de flujo o un orificio de restricción para proteger el motor. l accesorio del cable metálico al tambor no soporta una carga. s necesario enrollar el cable metálico un mínimo de 5 vueltas en el tambor antes de tirar de una carga. i se observan las guías siguientes, se prolongará su duración y se evitarán daños al cable metálico:.cuando instale el cable metálico, desenróllelo y desenrédelo antes de enrollarlo en el tambor. o trate de instalar un cable metálico enredado. prenda a reconocer los enredos y a desenredarlo antes de que el cable metálico se dañe. Figura 5 a b c Figura 6 a. ste es el comienzo de una torcedura. n este momento se tiene que enderezar el cable metálico. B. Mantenga el cable metálico enrollado apretadamente en el tambor. as vueltas sueltas permiten que penetre en las capas inferiores produciendo atascamientos y su aplastamiento. P Ñ O b. l cable metálico se tiró y el ojal se apretó en una torcedura. l cable metálico ahora está permanentemente dañado y se tiene que cambiar. c. l resultado de la torcedura es que cada trenza tira una cantidad distinta, haciendo que las que están bajo una tensión mayor se rompan y se reduzca la capacidad de carga del cable metálico. s necesario cambiarlo. 5-p

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