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The Quality is Transparent ENGLISH OPERATING SERVICE AND MAINTENANCE MANUAL WORM GEAR ELECTRIC WINCH Because of continued product improvement, we reserve the right to make changes without notice. EN 14492-1 SERVICE WORM GEAR WARNING Read and understand this manual before installation and operation of winch. Keep this manual with the winch at all times.
SECTION 1 The Quality is Transparent SAFETY PROCEDURES Section 5 Maintenance 1.1. INTRODUCTION Section 6 Trouble shooting guide Manual identified by code No. 12/2010 UK- Section 7 Parts list REV A - 11 - EN 14492-1 has 76 pages. Section 1 contains alls data for winch opera- IMPORTANT tions, for SAFETY PROCEDURES and full At the delivery of this manual checks all...
The Quality is Transparent 1.2 SYMBOLS IMPORTANT In this manual there are three different symbols to prevent serious injuries. Used to call attention on important informations which user must knowing. • “DANGEROUS “ symbol In addition to all warning symbols has been DANGEROUS used a symbol to underline the notes.
The Quality is Transparent 1.4 DESCRIPTION Model JE is a DC electric worm gear winch trucks mounting. with steel spur gear reduction. Designed for extend life and gives best safe duty. This WARNING winch is built according with higher safety The winch is built for working on range standards to complaint with Directive Machin- temperature between –20°C and +50°C.
1.4.14 JEC 2700/3600 12V/24V TECHNICAL DATA The Quality is Transparent DRUM WIRE ROPE ON WIRE ROPE WIRE ROPE WIRE ROPE LINE PULL DIAMETER LAYER QUANTITY SIZE MINIMUM BREAKING RATIO LAYER LAYER [KG] Ø [MM] [MT] [MT] LAYER [MM] LOAD EN 14492-1 8 MM 10 MM 8 MM 10 MM...
1.4.16 JEM 2700/3600 12V-24V TECHNICAL DATA The Quality is Transparent DRUM WIRE ROPE ON WIRE ROPE WIRE ROPE WIRE ROPE LINE PULL DIAMETER LAYER QUANTITY SIZE MINIMUM BREAKING RATIO LAYER LAYER [KG] Ø [MM] [MT] [MT] LAYER [MM] LOAD EN 14492-1 8 MM 10 MM 8 MM 10 MM...
1.4.18 JEL 2700/3600 12V-24V TECHNICAL DATA The Quality is Transparent DRUM WIRE ROPE ON WIRE ROPE WIRE ROPE WIRE ROPE LINE PULL DIAMETER LAYER QUANTITY SIZE MINIMUM BREAKING RATIO LAYER LAYER [KG] Ø [MM] [MT] [MT] LAYER [MM] LOAD EN 14492-1 8 MM 10 MM 8 MM 10 MM...
The Quality is Transparent 1.5 WINCH DECALS. SAFETY ADVICES PICT.2 24 V 24 V 12 V 12 V IMPORTANT A decal (1), onto the top of the clutch housing, gives: winch model, max. pulling capacity at When ordering replacement parts or 1st layer, wire rope diameter according to the contact VIME’s customers service, please rule,voltage, serial number and year of built.
The Quality is Transparent 1.6.1 PACKAGING IMPORTANT The standard packaging, if supplied, and unless otherwise agreed, is not rainproof and Dispose of packaging materials as is intended for shipping by ground and not stipulated by the applicable legislation. sea, and for areas which are under cover and not humid.
The Quality is Transparent 1.7 SAFETY PROCEDURES WARNING Do not operate this winch until you have carefully read and understand the warnings Do not use winch to lift, support or operation sections of this manual. otherwise transport personnel. WARNING DANGEROUS Winch use allowed by trained personnel A minimum of 5 wraps of cable around only.
WARNING VIME Industrial used to secure the winch to the base angles. The winch must be fitted Winch must no be mounted directly onto horizontally to give best lubrication and se- the vehicle chassis.
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The Quality is Transparent Winch can be mounted without the mounting Mounting hole locations, size and thread angle. depth are specified for every winch (pict.5-6- WARNING All mounting holes patterns should be used to bolt the winch. WARNING Use the mounting hole locations provided on the dimensional data pict.5-6-7 pair dimensions of surfaces must be re- spected.
The Quality is Transparent 2.3 FLEET ANGLE PICT.8 ANGOLO DI TIRO FLEET ANGLE 2.2 POSIZIONAMENTO DEL VERRICELLO SUL TELAIO tained, the wire rope could wind onto Winch should be mounted as close to centre and as perpendicular as possible to the one side of the drum.
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The Quality is Transparent IMPORTANT NOTE In the winch mounting, check the gear Turn by hands the drum, a certain resis- housing end (1) clutch housing end (2) tance will be given by teflon discs (ref.9) (pict.10), are properly aligned for not who breaking onto the drum lateral compromising the winch working.
The Quality is Transparent 2.5 WIRING DIAGRAM Once the winch has been mounted onto should be connected to the truck battery ac- the vehicle chassis (chapter 2.2-2.3-2.4) cording to the lay-out shown below (pict.11). PICT.11 SCR1 SCR2 REMOTE CONTROL SWITCH B.
The Quality is Transparent 2.5.1 ELECTRICAL CONNECTIONS PICT.12 PICT. 12a WARNING Connect cable (1), length (1,5 Mt), from power supply terminal (2) to battery switch terminal Connecting cable (1) to stud (2) on plas- (3). Connect cable (4), length (0,5 Mt), from tic solenoids cover, hold the inner battery switch terminal (3) to positive battery when tightening the outer nut (pict.12a).
The Quality is Transparent 2.5.2 TEST PROCEDURE FOR 12V SOLENOIDS Steps to follow when testing current flow Ground the solenoid to the motor (M) through 12V DC solenoids. with a wire as shown (pict.13, ref. L). It should be noted that when testing a 12 volt Attach positive (+) battery (B) wire to solenoid, the DC motor (M) and battery (B) the opposite side terminal (SD) of the...
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The Quality is Transparent WARNING To test the upper contacts (TT) of the solenoid use the same hook-up except When attaching wires to the motor and use the top terminals (pict.14). If the solenoids terminals, hold the inner nut solenoid is good, the motor will stop when tightening the outer nut.
The Quality is Transparent 2.5.3 TEST PROCEDURE FOR 24V SOLENOIDS Steps to follow when testing current flow (SD) of the solenoid to the solenoid through 24V DC solenoids. ground wire. It should be noted that when testing a 24 volt Attach the same small side terminals solenoid, the DC motor (M) and battery (B) (SD) of the solenoid to the motor hous-...
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The Quality is Transparent WARNING To test the upper contacts (TT) of the solenoid use the same hook-up except When attaching wires to the motor and use the top terminals (pict.14). If the solenoids terminals, hold the inner nut solenoid is good, the motor will stop when tightening the outer nut.
The Quality is Transparent 2.5.4 TEST PROCEDURE FOR MOTOR (12V-24V) The VIME electrical winch motor is a 4 pole, 4 WARNING coil series wound. When attaching wires to the motor and solenoids terminals, hold the inner nut The 4 pole, 4 coil feature provides high torque when tightening the outer nut.
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The Quality is Transparent To reverse the direction of rotation : WARNING Connect a jumper wire (at least 16 When attaching wires to the motor and mm²) from (F2) to (A) motor terminals. solenoids terminals, hold the inner nut when tightening the outer nut. Do not Attach a wire (at least 16 mm²) from allow the motor terminals to rotate positive (+) battery terminal to (F2)
The Quality is Transparent 2.6 AIR-OPERATED FREESPOOL LINKAGE The winches mod. JE can be equipped (on and dried. It is important to keep request) with air clutch shifter for drum moisture from entering the winch. freespooling DUAL ACTION. The pneumatic Moisture could cause corrosion.
The Quality is Transparent 2.7 LOAD LIMITING DEVICE JE electrical winches are current equipped Load limiting device is adjusted according to with limiting load device pre set in according the winch max rated line pull at first layer as with EN 14492-1. indicated on the decal.
The Quality is Transparent 2.8 WINCH CONFIGURATION JE electrical winches are supplied in standard load limiting device (10) is mounted to the configuration as shown (pict.22). Looking at opposite side, on the left. This configuration is the winch side from cover solenoids (8), spure defined “DX MOUNTING”...
The Quality is Transparent 2.9 WINCH DRUM ROTATION Worm gear electric winches JE are available shown in detailed view (C) and by with two different drum rotations to indicate following instructions in chapter 2.10. the different spooling direction of the rope, “A”...
The Quality is Transparent 2.9.2 “A” ROTATION (under drum) WARNING WARNING Cable must be winded onto the winch drum Utilize the winch with the cable winded (A rot.) as shown in (pict.25). Cable in the wrong way not enable to operate mounting must be executed as shown in the load limiting device or could stop the detailed view (C) and by following instruc-...
The Quality is Transparent 2.9.3 “B” ROTATION (over drum) WARNING WARNING Utilize the winch with the cable winded Cable must be winded onto the winch in the wrong way not enable to operate drum (B rot.) as shown in (pict.26). Cable mounting must be executed as the load limiting device or could stop the shown in detailed view (C) and by...
The Quality is Transparent 2.9.4 “B” ROTATION (under drum) WARNING WARNING Cable must be winded onto the winch Utilize the winch with the cable winded drum (B rot.) as shown in (pict.27). in the wrong way not enable to operate Cable mounting must be executed as the load limiting device or could stop the shown in detailed view (C) and by...
The Quality is Transparent 2.10 CABLE INSTALLATION EN 14492-1 strength 2160 N/mm². Wire rope mini- In the choice of cable to be fitted on drum for mum breaking load must be at least dou- first time or to replace the old one, follow ble of winch max.
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The Quality is Transparent STEP 1 PICT.30 Insert the end of the rope (10) opposite the hook, into proper slot (A) as shown in pict.30. WARNING Wire rope winding direction onto the drum must be respected as indicated in chapter 2.10. PICT.31 DANGEROUS When winching is obligatory wear...
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The Quality is Transparent STEP 4 PICT.33 Thread set screw (12) into threaded hole to secure the end rope (10) opposite to hook as shown in pict.33. STEP 5 PICT.34 Manually pull the rope out as shown in pict.34 till rope will wrap onto the drum barrel.
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The Quality is Transparent ROPE NOT PROPERLY MOUNTED PICT.37 While mounting the end rope (10) oppo- site to hook, throughout (B) by using set screw (12), take care do not allow wire rope to extend past seat (C) of drum as shown in pict.37.
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The Quality is Transparent CORRECT WIRE ROPE MOUNTING PICT.38 While mounting the end rope (10) oppo- site to hook, through hole (B) by using set screw (12), take care do not allow cable to extend past seat (C) of drum, as shown in pict.38.
SECTION 3 The Quality is Transparent OPERATION disengaged, sufficient time to warm up 3.1 OPERATION the system . The winch should be oper- ated at low speeds, forward and re- DANGEROUS verse, several times to circulate gear Before starting winch check cable lubricant through the worm gear.
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The Quality is Transparent IMPORTANT The low winch speed line eases this op- eration, provided that battery switch has Make sure the winch motor has stopped been placed in a truck area easily attain- fully before reversing. Quick winch re- able.
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The Quality is Transparent securely fastened to the vehicle/load. To power the winch: Power on battery switch: rotate the red key from Off position to On position as IMPORTANT shown (pict.39). Make sure the winch motor has stopped Connect the plug (6) on remote control fully before reversing.
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The Quality is Transparent For hooking onto the load rapidly: IMPORTANT Check drum clutch be fully disengaged: Onto the clutch axe (1) there is a seat (3) for dog point set screw (2) to hold VERSION WITH MANUAL CLUTCH the handle in the disengaged position. SHIFTER: the handle must be in vertical When disengaging rotate the handle in position (pict.41).
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The Quality is Transparent IMPORTANT VERSION WITH AIR-CYLINDER CLUTCH SHIFTER: checking the air- To insure an efficient drum clutch cylinder shaft (ref.3 pict.42a) being fully operation (air-clutch version) a proper out as shown. Differently act air lever connection to the vehicle air circuit must valve, air flow through X port G1/8”...
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The Quality is Transparent To pull the load: VERSION WITH AIR-CYLINDER CLUTCH SHIFTER: act air lever valve, WARNING air flow through Y port G1/8” (pict.44) engages drum. Checking the air- Do not exceed maximum line pull ratings. cylinder shaft (3) being in as shown (pict.44a).
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The Quality is Transparent DANGEROUS WARNING If clutch has not been fully engaged Check clutch must be fully engaged as (pict.46), in winching operation while is shown (pict.45). pulling a load, can cause the suddenly drum disengagement and as a conse- quence the load drifts.
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The Quality is Transparent DANGEROUS On remote control switch push the but- ton “WINDING” for winding rope onto Do not disengage clutch under load. the winch drum. DANGEROUS WARNING Never attempt to pull more than the Winch operator start pulling slowly and winch is rated for.
SECTION 4 The Quality is Transparent ACCESSORIES 4.1 ACCESSORIES ♦ JE winches have been designed to be Standard roller fairlead (ref.1, pict.49) equipped with several accessories such as : ♦ Cable tensioner (ref.2, pict.50) PICT.49 PICT.50 4.1.1 ROLLER FAIRLEAD 4.1.2 CABLE TENSIONER Roller fairlead is made up by 2 horizontal Cable tensioner is used to keep cable rollers and 2 vertical rollers, used for lateral...
4.2 RECOMMENDATIONS FOR USE The Quality is Transparent PICT.51 PICT.52 HOOK HOOK DANGEROUS 4.2.1 ROLLER FAIRLEAD Do not put hands or feet near rotating IMPORTANT parts or moving wire rope. Wire rope under tension can cause serious personal The use of roller fairlead does not insure injury.
The Quality is Transparent PICT.53 PICT.54 HOOK HOOK DANGEROUS 4.2.2 CABLE TENSIONER Do not put hands or feet near rotating IMPORTANT parts or moving wire rope. Wire rope under tension can cause serious personal The use of cable tensioner does not injury.
SECTION 5 The Quality is Transparent MAINTENANCE oil level only. 5.1 MAINTENANCE Winches mod. JE are designed to reduce maintenance to wire rope and gear housing PICT.55 5.1.1 MONTHLY MAINTENANCE Worm and gear are bathed in oil. Keep oil to level hole. Technical staff required : Technician or user SERVICE...
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The Quality is Transparent MONTHLY MAINTENANCE Spure gear housing (5) is lubricated and inspect the clutch shifter (ref.40, for the entire life with grease SHELL part list chapter 7.2-7.7, pages 72-79), OSSAGOL V. check for damage or excessive wear. Observe the jaws on the clutch, checking IMPORTANT for rounding of the driving faces.
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The Quality is Transparent MOUNTHLY MAINTENANCE WARNING damage the finish. At least every three months check bat- Cable tensioner roller is made in tery cables, electrical connections and copolymer acetate. This material re- duces maintenance. In very dirty envi- mounting bolts. Tighten if necessary. ronments, we recommend to keep maintenance and roller lubricated, with WARNING...
The Quality is Transparent PICT.59 Tighten oil level plug (1) and plug (2). 5.1.2 ANNUAL MAINTENANCE Technical staff required : Model Q.ty Technician or user SERVICE Worm gear housing gr.500 oil Spure gear housing, gr. 350 Procedure: grease At least once a year, it is necessary inspect oil level.
SECTION 6 The Quality is Transparent TROUBLE SHOOTING GUIDE 6.1 TROUBLE SHOOTING GUIDE CONDITIONS POSSIBLE CAUSE CORRECTION Check battery switch is On posi- tion chap. 3.1, pict.39, page 52. Loose connections. Inspect sole- noids motor contacts tighten, see chap.2.5 pages 33- No power Weak battery.
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The Quality is Transparent TROUBLE SHOOTING GUIDE CONDITIONS POSSIBLE CAUSE CORRECTION Long period of operation Cooling-off periods chap.3.1 page 50. Insufficient battery or insuffi- Replace the battery or check cient charging system alternator conditions Electrical cable from battery to The electrical cable is 2 mt. winch too long or too small length with 35mm²...
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The Quality is Transparent TROUBLE SHOOTING GUIDE CONDITIONS POSSIBLE CAUSE CORRECTION Clutch not engaged Follow instructions how to engage/ disengage drum chap. 3.1 pages 53- Shaft keys damaged Replace keys ref.21-22 parts draw- ing chap.7.2-7.7 pages 72-79. Motor runs but drum does not turn Drum shaft damaged Replace drum shaft ref.
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The Quality is Transparent TROUBLE SHOOTING GUIDE CONDITIONS POSSIBLE CAUSE CORRECTION Broken spring Replace spring, ref.42 parts drawing Clutch spring does not oper- chap.7.2-7.7 pages 72-79. Capscrew loose or worn Remove teflon plug ref.46 and tighten capscrew ref.45, parts Clutch does not lock at dis- drawing chap.7.2-7.7 pages 72-79.
SECTION 7 The Quality is Transparent PARTS LIST 7.1 JE 2700/3600 12V/24V CE WINCH PARTS LIST (dx mounting) COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY 01.0022 GEAR HOUSING SHORT MOUNTING ANGLE ( ROLLER 01.0032 FEARLEAD SIDE) 01.0091 MANUAL CLUTCH HOUSING 01.0052 SHORT DRUM MEDIUM MOUNTING ANGLE (ROLLER...
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The Quality is Transparent JE 2700/3600 12V/24V CE WINCH PARTS LIST (dx mounting) COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY *DD08OT BRASS NUT M8 *PPTM21107 RUBBER BOOT 01.0554 BLACK WIRE *PRL19X32X7 OIL SEAL 19x31x7 *FSBL15ADIN75281 FUSE 15A DIN 75281 *RND8OT BRASS WASHER D8 *VTTE06X20Z...
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The Quality is Transparent JE 2700/3600 12V/24V CE WINCH PARTS LIST (dx mounting) COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY BATTERY SWITCH 127/1 NUT M8 UNI 5587 127/2 LOCK WASHER D8 UNI 1751 *STCBTTR 08.099.000 127/3 PLUG 127/4 RUBBER CAP 127/5 POWER KEY 01.0091/P AIR CLUTCH HOUSING...
The Quality is Transparent 7.6 JE 2700/3600 12V/24V CE WINCH PARTS LIST (sx mounting) COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY 01.0022 GEAR HOUSING 01.0569 SHORT MOUNTING ANGLE 01.0091 MANUAL CLUTCH HOUSING 01.0570 MEDIUM MOUNTING ANGLE 01.0571 LONG MOUNTING ANGLE 01.0052 SHORT DRUM 01.0093...
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The Quality is Transparent JE 2700/3600 12V/24V CE WINCH PARTS LIST (sx mounting) COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY *DD08OT BRASS NUT M8 *PPTM21107 RUBBER BOOT *PRL19X32X7 OIL SEAL 19x31x7 01.0553 YELLOW WIRE *FSBL15ADIN7528 *RND8OT BRASS WASHER D8 FUSE 15A DIN 75281 *VTTE06X20Z CAPSCREW M6x20 UNI 5739...
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The Quality is Transparent JE 2700/3600 12V/24V CE WINCH PARTS LIST (sx mounting) COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY BATTERY SWITCH 127/1 NUT M8 UNI 5587 127/2 LOCK WASHER D8 UNI 1751 *STCBTTR 08.099.000 127/3 PLUG 127/4 RUBBER CAP 127/5 POWER KEY 01.0091/P AIR CLUTCH HOUSING...
The Quality is Transparent 7.11 JEC JEM JEL STANDARD ROLLER FAIRLEAD PARTS LIST COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY 01.0157 SHORT FRAME 01.0158 MEDIUM FRAME 01.0159 LONG FRAME 01.0161 VERTICAL ROLLER 01.0162 SHORT HORINZONTAL ROLLER 01.0225 MEDIUM HORINZONTAL ROLLER 01.0246 LONG HORINZONTAL ROLLER 01.0163...
The Quality is Transparent 7.13 JEC JEL ROPE TENSIONER PARTS LIST COD. REF. DESCRIPTION Q.TY COD. REF. DESCRIPTION Q.TY 01.0389 1C SHORT FRAME 01.0376 1L LONG FRAME 01.0502 2C SHORT ROLLER 01.0504 2L LONG ROLLER 01.0561 3C SHORT ROLLER SHAFT 01.0562 3L LONG ROLLER SHAFT *VTTSE6X16Z...
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