6/14/2023 | Page 1 of 2

Lexco Cable Phone: 1-708-697-7310

7320 W. Agatite Ave. Fax: 1-773-478-4584
Norridge, IL 60706 Email: [email protected]
Toll Free: 1-800-626-6556 Website: www.lexcocable.com
Phone: 1-773-588-8890

Item # G-5263-12.5T, 12.5 Ton (t) Working Load Limit (WLL) Green Pin® Super Bow Shackle
with Safety Bolt
1. Material: bow and pin alloy steel, Grade 8, quenched and tempered
2. Safety Factor: MBL equals 5 x WLL
3. Standard: meets performance requirements of US Fed. Spec. RR-C-271
Type IVA Class 3, Grade B
4. Finish: hot dipped galvanized (175 ton shackle is painted)

Green pin shackles are typically used on wire rope

loops for lifting or towing.

Specifications | Certification | Note

Specifications
WLL 12.5 ton
Bow
Diameter 1"
a
Pin
Diameter 1-1/8 "
b
Eye
Diameter 2-11/32 "
c
 6/14/2023 | Page 2 of 2

Eye
Width 1"
d
Inside
Width 1-23/32 "
e
Inside
Length 3-3/4 "
f
Bow
Width 2-11/16 "
g
Length
h 6-29/32 "
Bolt
Length 5-15/16 "
i
Width
j 4-7/8 "
Nut
Thickness 1"
k
Weight
Each 6.13 lb
Material Bow and Pin Alloy Steel, Grade 8, Quenched and Tempered
Safety
Factor MBL equals 5 x WLL
Standard Meets performance requirements of US Fed. Spec. RR-C-271 Type IVA Class 3, Grade B
Finish Hot Dipped Galvanized
Shackle
Type Bow

Certification

At no extra charges this product can be supplied with a works certificate, certificate of basic raw material,
manufacturer test certificate, EC Declaration of Conformity and all shackles starting from 150 tons are
supplied with a Lloyd's Register of Shipping Certificate on proof load.

Note
 HEAVY DUTY
POWER WINCHES
MONUMENTAL TASKS REQUIRE
MONUMENTAL TOOLS

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 1
LIFT 50 TONS, CUSTOMIZABLE
We build to suit. Thern power winches come in a wide
WHAT DO YOU GET? variety of base configurations, making it fast and
SIMPLE, RESPECT affordable to customize a winch to your application.

Mighty and reliable, Thern power

DURABLE
winches can lift, hoist, pull or Thern’s heavy duty power winches are built to take the
position up to 100,000 lb to handle around the clock punishment of hard working jobsites.
any task you’ve got. Our broad range Everything about them, from fabricated steel frame
to industrial strength controls, says “no kid gloves”
of standard models can be quickly required.
adapted to suit custom applications.
Plus our power winches feature top
EXPERIENCE
of the line gear reducers, rugged Thern has the experienced people you rely on to get
steel construction, load holding brake the right product for the job. Our unmatched know-how
motors, and legendary performance means you won’t end up with a solution that only creates
new problems.
and craftsmanship.

Series 4WS Series 4HS6-26M Series 4HS40-56M

Clutch model shown Clutch model shown

www.thern.com 1.800.843.7648
2 Thern products are not for lifting people or things over people. S309-0809
ONE IF BY LAND, THERN IF BY SEA A MINER’S BEST FRIEND
Just because something floats, doesn’t mean it isn’t Hard, heavy, dirty. That’s everything you need to know
heavy. Try raising and lowering accommodation about mining. Conditions are poor, mechanical strain
ladders, launching deep water research equipment or constant, and loads a bear, but Thern power winches
towing a vessel. It takes strength, control and stamina. can handle any task you find in a mine.
It takes a Thern heavy duty power winch.

WHEN IT COMES TO HANDLING, POWERFUL ENOUGH FOR POWER PLANTS

THERE’S BULK AND THERE’S BULK Everything about a power plant is big – from steel
Thern power winches are used to pull trains, position doors to flare stacks, and it all needs to be lifted,
barges, or lift behemoth conveyors. Why? They have lowered, or positioned. Durable and easily customized,
the muscle and endurance to do it over the long haul Thern power winches help keep power plants running.
without failure.

Series 4HWF Series 4HPF Series 4HPFC

Clutch model shown

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 3
 4WS SERIES
Thern 4WS series power winches feature dual stage gear FLANGE MOUNTED MOTOR is a
230/460 volt 3 phase motor, 60
reduction for economical handling of large loads. The cycle, IP 541, TEFC severe duty,
combination of helical/worm and spur gearing make these reversible, class B or F insulated,
continuous duty brakemotor.
winches ideal for applications requiring secure load control and
accurate positioning. Our modular design also means we can Standard motors comply with
relevant standards including NEMA,
quickly customize these winches to meet your MG1, ANSI, CSA, IEC1 and ABS.
specific requirements.
LOAD HOLDING MOTOR DISC BRAKE
is spring set, electrically released
for positive load control.

DUAL STAGE GEARING, comprised

of a worm or helical/worm and
spur gears, make winches well
suited for applications requiring
secure load control and accurate
positioning.

The heat treated worm or helical/

worm gear set provides improved
durability and operates in an oil
bath, enclosed in a high strength
cast iron gearcase, SAE class 30.
Double-lip oil seals keep oil in and
contaminants out. Large capacity
bearings ensure long life. Speed
reducers meet AGMA standards.

Guarded, heat treated spur gearing

provides secondary reduction.
Grease zerks allow for easy
lubrication.

FLANGE STYLE ROLLER BEARINGS EXTENDED STEEL DRUM SHAFT with ANSI B30.7 COMPLIANCE is available.
are self-aligning bearings with cast both ends captured in fabricated Please contact the factory.
housing to maintain smooth drum steel frame for optimal strength and
rotation. security.  

WELDED STEEL DRUM with outside WIRE ROPE ASSEMBLIES sold 2 YEAR “MOVE IT WITH CONFIDENCE”
flange anchors allow for uniform separately per customer request. LIMITED WARRANTY leads the
winding and help extend life of wire industry.
rope. Anchors allow cable to be over
wound or under wound from either
side of the drum.
1
Does not apply to 4WS9M18 Series winches.

www.thern.com 1.800.843.7648
4 Thern products are not for lifting people or things over people. S309-0809
 4WS SERIES
HP Load Rating Line Speed

4WS9M18 5 - 10 7,000 - 10,000 lb 10 - 30 fpm

4WS16M20 7.5 - 15 13,000 - 16,000 lb 15 - 35 fpm

4WS26M26 15 - 25 22,000 - 26,000 lb 10 - 35 fpm

OPTIONS AND ACCESSORIES A

DRUM MODIFICATIONS (A) include grooved drums, multiple compartment

drums and modified drum widths and diameters.

WINCH MOUNTING OPTIONS include base, wall or under hung installation.

CABLE PRESSURE BARS (B) help maintain uniform winding of wire rope.
Shown with double compartment and narrow drum width
modifications and rotary limit switch.
LIMIT SWITCHES (A) provide secondary shut-off for load travel in one or two
directions. B
MOTOR OPTIONS include air or hydraulic, voltage or phase changes, IP 55 or
65, class F or H insulated and multi-speed operation.

DUTY RATINGS include IEEE 45 marine duty, tropical duty, severe duty and
explosion proof ratings.

BRAKE OPTIONS include over-speed, caliper style, band, and more.

CONTROLS (C) are available in a wide range of standard and custom

configurations for single or variable speed.

CORROSION RESISTANT FINISHES (D) for harsh or hazardous environments.

Shown with cable pressure bar and grooved
MANUAL OVERRIDES for winch operation in power loss situations. drum modification.

D C

Shown with grooved drum modification and gray

epoxy finish.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 5
 4WS SERIES POWER WINCHES
4WS Series Performance Characteristics
1
Model Number Extensions Motor hp Load Rating Line Speed Motor Codes
Load Line Motor hp 1st Layer Mid Drum Full Drum 1st Layer Full Drum D 230 volt 3 phase
Rating Speed Codes1
E 460 volt 3 phase
(lb) (fpm) (lb) (kg) (lb) (kg) (lb) (kg) (fpm) (mpm) (fpm) (mpm)
F All other voltages
4WS9M18 7000 20 D,E,F 5 7,300 3,312 5,000 2,268 3,800 1,724 21 6.4 41 12.5 please contact
4WS9M18 7000 30 D,E,F 7.5 7,500 3,402 5,200 2,359 4,000 1,815 32 9.8 61 18.6 factory
4WS9M18 10000 10 D,E,F 5 10,000 4,536 6,900 3,130 5,300 2,405 13 4.0 24 7.3
4WS9M18 10000 20 D,E,F 7.5 10,000 4,536 6,900 3,130 5,300 2,405 21 6.4 41 12.5
4WS9M18 10000 30 D,E,F 10 10,000 4,536 6,900 3,130 5,200 2,359 32 9.8 61 18.6
4WS16M20 13000 15 D,E,F 7.5 13,000 5,897 8,800 3,992 6,700 3,040 14 4.3 26 7.9
4WS16M20 13000 20 D,E,F 10 13,300 6,033 9,100 4,128 6,900 3,130 18 5.5 35 10.7
4WS16M20 13000 35 D,E,F 15 13,000 5,897 8,900 4,038 6,700 3,040 35 10.7 68 20.7
4WS16M20 16000 15 D,E,F 7.5 16,000 7,258 11,100 5,035 8,500 3,856 12 3.7 24 7.3
4WS16M20 16000 20 D,E,F 10 16,000 7,258 11,100 5,035 8,500 3,856 16 4.9 31 9.4
4WS26M26 22000 20 D,E,F 15 22,800 10,343 16,700 7,576 13,200 5,988 18 5.5 31 9.4
4WS26M26 22000 25 D,E,F 20 22,600 10,252 16,500 7,485 13,100 5,943 25 7.6 43 13.1
4WS26M26 22000 35 D,E,F 25 22,200 10,070 16,300 7,394 12,900 5,852 36 11.0 63 19.2
4WS26M26 26000 10 D,E,F 10 26,200 11,885 19,400 8,800 15,400 6,986 10 3.0 17 5.2
4WS26M26 26000 15 D,E,F 15 26,000 11,794 20,200 9,163 16,500 7,485 16 4.9 27 8.2
Please contact factory or nearest Thern Distributor for firm fixed price and delivery.
4WS Series Drum Capacities
Electric Motor Controls
Wire Rope Breaking Drum 4WS9M18 4WS16M20 4WS26M26 Description Approx. Ship Wt.
Dia. Strength2 Capacity (lb) (kg)
(in) (mm) (lb) (kg) (ft) (m) (ft) (m) (ft) (m) 10S3D4 electric motor controls 230/3/60 to 3 hp 25 12
1st 87 26.5 – – – – 10S7D4 electric motor controls 230/3/60 to 7.5 hp 25 12
7
/16 11.2 20,400 9,254 Mid 670 204.2 – – – –
10S10D4 electric motor controls 230/3/60 to 10 hp 28 13
Full 1,500 457.2 – – – –
1st 76 23.2 – – – – 10S20D4 electric motor controls 230/3/60 to 20 hp 28 13
1
/2 12.7 26,600 12,066 Mid 520 158.5 – – – – 10S30D4 electric motor controls 230/3/60 to 30 hp 60 28
Full 1,170 356.6 – – – –
1st 67 20.4 89 27.1 – – 10S7E4 electric motor controls 460/3/60 to 7.5 hp 25 12
9
/16 14.2 33,600 15,240 Mid 420 128.0 690 210.3 – – 10S15E4 electric motor controls 460/3/60 to 15 hp 25 12
Full 930 283.5 1,530 466.3 – –
10S20E4 electric motor controls 460/3/60 to 20 hp 28 13
1st 59 18.0 78 23.8 – –
5
/8 16.0 41,200 18,688 Mid 340 103.6 560 170.7 – – 10S40E4 electric motor controls 460/3/60 to 40 hp 60 28
Full 760 231.6 1,250 381.0 – – Controls include NEMA 4 rated enclosure, and NEMA 4x rated pendant control on 50
1st 48 14.6 65 19.8 110 33.5 foot cord.
3
/4 19.1 58,800 26,671 Mid 240 73.2 400 121.9 670 204.2 Motor Controls sold separately.
Full 540 164.6 880 268.2 1,480 451.1 Please contact factory or nearest Thern Distributor for firm fixed price and delivery.
All prices include mounting and wiring to motor.
1st – – 54 16.5 94 28.7
7
/8 22.4 79,600 36,106 Mid – – 290 88.4 480 146.3
Full – – 640 195.1 1,070 326.1 4WS Series Drum Dimensions
1st – – 47 14.3 82 25.0 Drum Flange Drum Fleet Angle
1 25.4 103,400 46,902 Mid – – 220 67.1 370 112.8 Diameter Diameter Width Dist
Full – – 490 149.4 830 253.0 (ID) (OD) (W) (A)3
1st – – – – 71 21.6 (in) (mm) (in) (mm) (in) (mm) (ft) (m)
1-1/8 28.7 130,000 58,968 Mid – – – – 300 91.4
4WS9M18 9.00 229 20.00 508 18.00 457 29 8.8
Full – – – – 660 201.2
1st – – – – 63 19.2 4WS16M20 10.75 273 24.00 610 20.00 508 32 9.8
1-1/4 31.8 159,800 72,485 Mid – – – – 240 73.2 4WS26M26 14.00 356 28.00 711 26.00 660 42 12.8
Full – – – – 530 161.5
3 Recommended minimum distance between drum and lead sheave for smooth drum.
1st – – – – 56 17.1
Dimensions are for reference only and subject to change without notice. Please
1-3/8 34.9 192,000 87,090 Mid – – – – 200 61.0 contact factory for exact dimensions.
Full – – – – 440 134.1 ID

Values based on 6x37 IWRC EIPS wire rope.

Actual drum capacities 25-30% less, due to nonuniform winding. Wire rope tension will also Fleet Angle
2 affect drum capacity. Lead Sheave
Center
Wire rope should be selected based on the breaking strength to load rating ratio and application W Line
Load

parameters. Industry standards suggest a 5:1 breaking strength to load rating ratio for lifting and
a 3:1 ratio for pulling. Recommended
Fleet Angle Distance
A
OD

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6 Thern products are not for lifting people or things over people. S309-0809
 4WS SERIES POWER WINCHES
4WS Series
K
L
J

drum CL
H
D drum CL P
R
M E B
A
S (hole dia.) C
N
4WS Series Winch Dimensions
A B C D E H J K
(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
4WS9M18-7000-20 44.00 1,118 33.75 857 8.50 216 17.75 451 5.13 130 31.00 787 4.00 102 18.00 457
4WS9M18-7000-30 45.50 1,156 38.50 978 8.50 216 17.75 451 5.13 130 31.00 787 4.00 102 18.00 457
4WS9M18-10000-10 44.00 1,118 33.75 857 8.50 216 17.75 451 5.13 130 31.00 787 4.00 102 18.00 457
4WS9M18-10000-20 45.50 1,156 38.50 978 8.50 216 17.75 451 5.13 130 31.00 787 4.00 102 18.00 457
4WS9M18-10000-30 45.50 1,156 40.00 1,016 8.50 216 17.75 451 5.13 130 31.00 787 4.00 102 18.00 457
4WS16M20-13000-15 48.00 1,219 34.75 883 9.50 241 20.00 508 6.25 159 34.00 864 4.00 102 20.00 508
4WS16M20-13000-20 48.00 1,219 37.00 940 9.50 241 20.00 508 6.25 159 34.00 864 4.00 102 20.00 508
4WS16M20-13000-35 48.00 1,219 39.50 1,003 9.50 241 20.00 508 6.25 159 34.00 864 4.00 102 20.00 508
4WS16M20-16000-15 48.00 1,219 34.75 883 9.50 241 20.00 508 6.25 159 34.00 864 4.00 102 20.00 508
4WS16M20-16000-20 48.00 1,219 37.00 940 9.50 241 20.00 508 6.25 159 34.00 864 4.00 102 20.00 508
4WS26M26-22000-20 60.50 1,537 43.50 1,105 12.38 314 25.38 645 8.06 205 44.50 1,130 5.88 149 26.00 660
4WS26M26-22000-25 60.50 1,537 47.00 1,194 12.38 314 25.38 645 8.06 205 44.50 1,130 5.88 149 26.00 660
4WS26M26-22000-35 60.50 1,537 50.00 1,270 12.38 314 25.38 645 8.06 205 44.50 1,130 5.88 149 26.00 660
4WS26M26-26000-10 60.50 1,537 42.00 1,067 12.38 314 25.38 645 8.06 205 44.50 1,130 5.88 149 26.00 660
4WS26M26-26000-15 60.50 1,537 43.50 1,105 12.38 314 25.38 645 8.06 205 44.50 1,130 5.88 149 26.00 660

L M N P R S (Hole Dia.) Ship Wt.

(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lb) (kg)
4WS9M18-7000-20 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3⁄16 30 1,100 499
IMPORTANT:
4WS9M18-7000-30 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3⁄16 30 1,100 499
It is the owner’s
4WS9M18-10000-10 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3⁄16 30 1,100 499
or operator’s
4WS9M18-10000-20 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3⁄16 30 1,100 499
responsibility to
4WS9M18-10000-30 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3⁄16 30 1,160 527
determine the
4WS16M20-13000-15 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3⁄16 30 1,550 704
suitability of the
4WS16M20-13000-20 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3⁄16 30 1,610 731
equipment to its
4WS16M20-13000-35 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3⁄16 30 1,650 749
intended use.
4WS16M20-16000-15 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1- ⁄16
3
30 1,550 704
Study all applicable
4WS16M20-16000-20 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3⁄16 30 1,610 731
codes, manuals, and
4WS26M26-22000-20 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3⁄ 8 35 3,110 1,411
regulations. Be sure 4WS26M26-22000-25 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1- ⁄ 8
3
35 3,290 1,493
to read the Owner’s 4WS26M26-22000-35 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3⁄ 8 35 3,350 1,520
Manual supplied with 4WS26M26-26000-10 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3⁄ 8 35 3,070 1,393
the equipment before 4WS26M26-26000-15 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3⁄ 8 35 3,110 1,411
operating it. imensions are for reference only and subject to change without notice. Please contact factory for exact dimensions.
D

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 7
 4HS SERIES
Thern 4HS series power winches feature dual stage gear FLANGE MOUNTED MOTOR is a
230/460 volt 3 phase motor, 60
reduction for economical handling of large loads. The cycle, IP 55, TEFC severe duty,
combination of helical/bevel or helical/parallel and spur reversible, class F insulated,
continuous duty brakemotor.
gearing make these winches ideal for applications requiring
long travel distances and faster line speeds. Our modular Standard motors comply with
relevant standards including NEMA,
design also means we can quickly customize these winches to MG1, ANSI, CSA, IEC and ABS.
meet your specific requirements.
LOAD HOLDING MOTOR DISC BRAKE
is spring set, electrically released
for positive load handling.

DUAL STAGE GEARING, comprised

of a helical/bevel or helical/parallel
and a spur gears, make winches
well suited for applications requiring
long travel distances and faster line
speeds.

The heat treated helical/bevel or

helical/parallel gear set provides
improved durability and operates
in oil bath, enclosed in a high
strength cast iron gearcase, SAE
class 30. Double-lip oil seals keep
oil in and contaminants out. Large
capacity bearings ensure long
life. Speed reducers meet AGMA
standards.

Guarded, heat treated spur gearing

provides secondary reduction.
Grease zerks allow for easy
lubrication.

FLANGE STYLE ROLLER BEARINGS EXTENDED SOLID STEEL DRUM SHAFT ANSI B30.7 COMPLIANCE is available.
are self-aligning bearings with cast with both ends captured in fabricated Please contact the factory.
housing to maintain smooth drum steel frame for optimal strength and
rotation. security.  

WELDED STEEL DRUM with outside WIRE ROPE ASSEMBLIES sold 2 YEAR “MOVE IT WITH CONFIDENCE”
flange anchors allow for uniform separately per customer request. LIMITED WARRANTY leads the
winding and help extend life of wire industry.
rope. Anchors allow cable to be over
wound or under wound from either
side of the drum.

www.thern.com 1.800.843.7648
8 Thern products are not for lifting people or things over people. S309-0809
 4HS SERIES
Clutch Option HP Load Rating Line Speed
4HS6M x 2 - 7.5 5,000 - 6,600 lb 15 - 40 fpm
4HS11M x 5 - 10 9,000 - 11,000 lb 15 - 40 fpm
4HS16M x 5 - 15 13,000 - 16,000 lb 10 - 40 fpm
4HS26M x 10 - 20 22,000 - 26,000 lb 15 - 30 fpm
4HS40M x 20 - 40 33,000 - 40,000 lb 20 - 40 fpm
4HS56M x 30 - 50 48,000 - 56,000 lb 20 - 35 fpm

OPTIONS AND ACCESSORIES

DRUM MODIFICATIONS (A) include grooved drums, multiple compartment
drums and modified drum widths and diameters.

MANUALLY OPERATED JAW CLUTCH (B) disengages for rapid payout of wire
rope when not under load. Adjustable drag brake on the drum prevents A
over-spooling during payout. Clutch option is for horizontal pulling only.

WINCH MOUNTING OPTIONS include base, wall or under hung installation.

CABLE PRESSURE BARS (C) help maintain uniform winding of wire rope.

LIMIT SWITCHES (A) provide secondary shut-off for load travel in one or two
directions.
Shown with double compartment and narrow drum width
MOTOR OPTIONS include air or hydraulic, voltage or phase changes, IP 65, modifications and rotary limit switch.

class H insulated and multi-speed operation. B

DUTY RATINGS include IEEE 45 marine duty, tropical duty, severe duty and
explosion proof ratings.

BRAKE OPTIONS include over-speed, caliper style, band, and more.

CONTROLS (D) are available in a wide range of standard and custom

configurations for single or variable speed.

CORROSION RESISTANT FINISHES (E) for harsh or hazardous environments. C

MANUAL OVERRIDES for winch operation in power loss situations.

E D

Shown with double compartment drum modification and Shown with cable pressure bar and grooved
gray epoxy finish. drum modification.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 9
 4HS SERIES POWER WINCHES
4HS Series Performance Characteristics
Model Number Extensions Motor hp Load Rating Line Speed
Load Rating Line Speed Motor Codes1 Clutch Option2 hp 1st Layer Mid Drum Full Drum 1st Layer Full Drum
(lb) (fpm) (lb) (kg) (lb) (kg) (lb) (kg) (fpm) (mpm) (fpm) (mpm)
4HS6M 5000 15 D, E, F C 2 5,100 2,314 3,800 1,725 3,100 1,407 13 4.0 22 6.7
4HS6M 5000 20 D, E, F C 3 5,100 2,314 3,800 1,725 3,100 1,407 20 6.1 33 10.1
4HS6M 5000 30 D, E, F C 5 5,100 2,314 3,800 1,725 3,100 1,407 33 10.1 55 16.8
4HS6M 6600 15 D, E, F C 3 6,600 2,994 5,000 2,269 4,000 1,815 15 4.6 25 7.6
4HS6M 6600 25 D, E, F C 5 6,600 2,994 4,900 2,224 4,000 1,815 25 7.6 41 12.5
4HS6M 6600 40 D, E, F C 7.5 6,600 2,994 5,000 2,269 4,000 1,815 39 11.9 64 19.5
4HS11M 9000 20 D, E, F C 5 9,000 4,083 6,200 2,814 4,700 2,132 19 5.8 35 10.7
4HS11M 9000 30 D, E, F C 7.5 9,000 4,083 6,200 2,814 4,700 2,132 27 8.2 51 15.5
4HS11M 9000 40 D, E, F C 10 9,000 4,083 6,200 2,814 4,700 2,132 37 11.3 70 21.3
4HS11M 11000 15 D, E, F C 5 11,000 4,990 7,600 3,449 5,800 2,631 15 4.6 28 8.5
4HS11M 11000 20 D, E, F C 7.5 11,000 4,990 7,600 3,449 5,800 2,631 21 6.4 40 12.2
4HS11M 11000 30 D, E, F C 10 11,000 4,990 7,600 3,449 5,800 2,631 27 8.2 51 15.5
4HS16M 13000 20 D, E, F C 7.5 13,000 5,897 8,900 4,039 6,700 3,040 19 5.8 37 11.3
4HS16M 13000 25 D, E, F C 10 13,000 5,897 8,900 4,039 6,700 3,040 24 7.3 46 14.0
4HS16M 13000 40 D, E, F C 15 13,000 5,897 8,900 4,039 6,700 3,040 37 11.3 72 21.9
4HS16M 16000 10 D, E, F C 5 16,100 7,303 11,000 4,992 8,300 3,765 11 3.4 21 6.4
4HS16M 16000 15 D, E, F C 7.5 16,000 7,258 10,900 4,947 8,300 3,765 16 4.9 30 9.1
4HS16M 16000 20 D, E, F C 10 16,100 7,303 11,000 4,992 8,300 3,765 20 6.1 38 11.6
4HS26M 22000 15 D, E, F C 10 22,000 9,980 16,200 7,352 12,800 5,807 16 4.9 27 8.2
4HS26M 22000 25 D, E, F C 15 22,000 9,980 16,100 7,307 12,700 5,761 23 7.0 40 12.2
4HS26M 22000 30 D, E, F C 20 22,900 10,388 16,800 7,624 13,200 5,988 29 8.8 50 15.2
4HS26M 26000 15 D, E, F C 10 26,000 11,794 19,000 8,623 15,000 6,804 13 4.0 23 7.0
4HS26M 26000 20 D, E, F C 15 26,000 11,794 19,000 8,623 15,100 6,850 19 5.8 33 10.1
4HS26M 26000 25 D, E, F C 20 26,000 11,794 19,100 8,668 15,000 6,804 26 7.9 45 13.7
4HS40M 33000 20 D, E, F C 20 33,100 15,015 24,100 10,937 18,900 8,574 19 5.8 34 10.4
4HS40M 33000 30 D, E, F C 30 33,000 14,969 24,100 10,937 18,900 8,574 29 8.8 51 15.5
4HS40M 33000 40 D, E, F C 40 33,100 15,015 24,100 10,937 18,900 8,574 39 11.9 68 20.7
4HS40M 40000 20 D, E, F C 20 40,300 18,281 29,300 13,297 23,000 10,433 17 5.2 29 8.8
4HS40M 40000 25 D, E, F C 30 40,300 18,281 29,400 13,342 23,100 10,479 23 7.0 41 12.5
4HS40M 40000 35 D, E, F C 40 40,000 18,144 29,400 13,342 22,900 10,388 34 10.4 59 18.0
4HS56M 48000 20 D, E, F C 30 48,000 21,773 37,200 16,882 30,300 13,745 21 6.4 33 10.1
4HS56M 48000 30 D, E, F C 40 48,000 21,773 37,200 16,882 30,300 13,745 28 8.5 44 13.4
4HS56M 52000 35 D, E, F C 50 52,200 23,678 40,400 18,334 32,900 14,924 33 10.1 52 15.8
4HS56M 56000 20 D, E, F C 30 56,000 25,402 43,300 19,650 35,400 16,058 18 5.5 29 8.8
4HS56M 56000 25 D, E, F C 40 56,000 25,402 43,400 19,695 35,400 16,058 24 7.3 38 11.6
4HS56M 56000 30 D, E, F C 50 56,200 25,493 43,500 19,741 35,500 16,103 30 9.1 47 14.3
2 Clutch option for horizontal pulling only.
Please contact factory or nearest Thern Distributor for firm fixed price and delivery.
1
Motor Codes
D 230 volt 3 phase
Electric Motor Controls
E 460 volt 3 phase
Description Approx. Ship Wt. F All other voltages
(lb) (kg) please contact factory
10S3D4 electric motor controls 230/3/60 to 3 hp 25 12
10S7D4 electric motor controls 230/3/60 to 7.5 hp 25 12 4HS Series Drum Dimensions
10S10D4 electric motor controls 230/3/60 to 10 hp 28 13 Drum Diameter Flange Diameter Drum Width Fleet Angle Dist
10S20D4 electric motor controls 230/3/60 to 20 hp 28 13 (ID) (OD) (W) (A)3
10S30D4 electric motor controls 230/3/60 to 30 hp 60 28 (in) (mm) (in) (mm) (in) (mm) (ft) (m)
10S7E4 electric motor controls 460/3/60 to 7.5 hp 25 12 4HS6M 7.00 178 14.00 356 18.00 457 29 8.8
10S15E4 electric motor controls 460/3/60 to 15 hp 25 12 4HS11M 9.00 229 20.00 508 18.00 457 29 8.8
10S20E4 electric motor controls 460/3/60 to 20 hp 28 13 4HS16M 10.75 273 24.00 610 20.00 508 32 9.8
10S40E4 electric motor controls 460/3/60 to 40 hp 60 28 4HS26M 14.00 356 28.00 711 26.00 660 42 12.8
10S60E4 electric motor controls 460/3/60 to 60 hp 60 28 4HS40M 18.00 457 36.00 914 30.00 762 48 14.6
Controls include NEMA 4 rated enclosure, and NEMA 4x rated pendant control 4HS56M 24.00 610 43.00 1,092 36.00 914 58 17.7
on 50 foot cord.
3 Recommended minimum distance between drum and lead sheave for smooth drum.
Motor Controls sold separately. Please contact factory or nearest Thern
Distributor for firm fixed price and delivery. Dimensions are for reference only and subject to change without notice. Please contact factory
All prices include mounting and wiring to motor. for exact dimensions.

www.thern.com 1.800.843.7648
10 Thern products are not for lifting people or things over people. S309-0809
 4HS SERIES POWER WINCHES
4HS Series Drum Capacities
Wire Rope Dia. Breaking Strength4 Drum 4HS6M 4HS11M 4HS16M 4HS26M 4HS40M 4HS56M
Capacity
(in) (mm) (lb) (kg) (ft) (m) (ft) (m) (ft) (m) (ft) (m) (ft) (m) (ft) (m)
1st 80 24.4 – – – – – – – – – –
3
/8 9.7 15,100 6,849 Mid 380 115.8 – – – – – – – – – –
Full 850 259.1 – – – – – – – – – –
1st 68 20.7 – – – – – – – – – –
7
/16 11.2 20,400 9,254 Mid 290 88.4 – – – – – – – – – –
Full 640 195.1 – – – – – – – – – –
1st 60 18.3 76 23.2 – – – – – – – –
1
/2 12.7 26,600 12,066 Mid 220 67.1 520 158.5 – – – – – – – –
Full 500 152.4 1,170 356.6 – – – – – – – –
1st 53 16.2 67 20.4 89 27.1 – – – – – –
9
/16 14.2 33,600 15,240 Mid 180 54.9 420 128.0 690 210.3 – – – – – –
Full 400 121.9 930 283.5 1,530 466.3 – – – – – –
1st – – 59 18.0 78 23.8 – – – – – –
5
/8 16.0 41,200 18,688 Mid – – 340 103.6 560 170.7 – – – – – –
Full – – 760 231.6 1,250 381.0 – – – – – –
1st – – 48 14.6 65 19.8 – – – – – –
3
/4 19.1 58,800 26,671 Mid – – 240 73.2 400 121.9 – – – – – –
Full – – 540 164.6 880 268.2 – – – – – –
1st – – – – 54 16.5 94 28.7 – – – –
7
/8 22.4 79,600 36,106 Mid – – – – 290 88.4 480 146.3 – – – –
Full – – – – 640 195.1 1,070 326.1 – – – –
1st – – – – 47 14.3 82 25.0 – – – –
1 25.4 103,400 46,902 Mid – – – – 220 67.1 370 112.8 – – – –
Full – – – – 490 149.4 830 253.0 – – – –
1st – – – – – – 71 21.6 110 33.5 – –
1-1/8 28.7 130,000 58,968 Mid – – – – – – 300 91.4 580 176.8 – –
Full – – – – – – 660 201.2 1,290 393.2 – –
1st – – – – – – 63 19.2 95 29.0 160 48.8
1-1/4 31.8 159,800 72,485 Mid – – – – – – 240 73.2 460 140.2 730 222.5
Full – – – – – – 530 161.5 1,030 313.9 1,630 496.8
1st – – – – – – 56 17.1 85 25.9 140 42.7
1-3/8 34.9 192,000 87,090 Mid – – – – – – 200 61.0 390 118.9 610 185.9
Full – – – – – – 440 134.1 860 262.1 1,360 414.5
1st – – – – – – – – 77 23.5 130 39.6
1-1/2 38.1 228,000 103,420 Mid – – – – – – – – 330 100.6 510 155.4
Full – – – – – – – – 720 219.5 1,140 347.5
1st – – – – – – – – – – 110 33.5
1-5/8 41.3 264,000 119,750 Mid – – – – – – – – – – 430 131.1
Full – – – – – – – – – – 950 289.6
1st – – – – – – – – – – 110 33.5
1-3/4 44.5 306,000 138,800 Mid – – – – – – – – – – 370 112.8
Full – – – – – – – – – – 820 249.9
1st – – – – – – – – – – 97 29.6
1-7/8 47.7 348,000 157,851 Mid – – – – – – – – – – 320 97.5
Full – – – – – – – – – – 720 219.5
4 Valuesbased on 6x37 IWRC EIPS wire rope.
Actual drum capacities 25-30% less, due to nonuniform winding. Wire rope tension will also affect drum capacity.
Wire rope should be selected based on the breaking strength to load rating ratio and application parameters.
Industry standards suggest a 5:1 breaking strength to load rating ratio for lifting and a 3:1 ratio for pulling.

ID

IMPORTANT: Fleet Angle

It is the owner’s or operator’s responsibility to determine the suit- Lead Sheave
Center
ability of the equipment to its intended use. Study all applicable W Line
Load

codes, manuals, and regulations. Be sure to read the Owner’s Recommended

Manual supplied with the equipment before operating it. Fleet Angle Distance
A
OD

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S309-0809 Thern products are not for lifting people or things over people. 11
 4HS SERIES POWER WINCHES
4HS6-26M Series Winch Dimensions (see opposite page for diagram)
A B C D E F G H J
(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
4HS6M-5000-15 36.00 914 27.25 692 8.63 219 12.88 327 2.47 63 2.28 58 16.31 414 22.50 572 3.25 83
4HS6M-5000-20 36.00 914 29.25 743 8.63 219 12.88 327 2.47 63 2.28 58 16.31 414 22.50 572 3.25 83
4HS6M-5000-30 36.00 914 29.25 743 8.63 219 12.88 327 2.47 63 2.28 58 16.31 414 22.50 572 3.25 83
4HS6M-6600-15 36.00 914 29.25 743 8.63 219 12.88 327 2.47 63 2.28 58 16.31 414 22.50 572 3.25 83
4HS6M-6600-25 36.00 914 29.25 743 8.63 219 12.88 327 2.47 63 2.28 58 16.31 414 22.50 572 3.25 83
4HS6M-6600-40 36.00 914 29.25 743 8.63 219 12.88 327 2.47 63 2.28 58 16.31 414 22.50 572 3.25 83
4HS11M-9000-20 41.00 1,041 31.75 806 8.50 216 17.75 451 5.13 130 2.38 60 18.44 468 31.00 787 4.00 102
4HS11M-9000-30 41.50 1,054 34.75 883 8.50 216 17.75 451 5.13 130 2.38 60 18.44 468 31.00 787 4.00 102
4HS11M-9000-40 42.50 1,080 37.00 940 8.50 216 17.75 451 5.13 130 2.38 60 18.44 468 31.00 787 4.00 102
4HS11M-11000-15 41.00 1,041 31.75 806 8.50 216 17.75 451 5.13 130 2.38 60 18.44 468 31.00 787 4.00 102
4HS11M-11000-20 41.50 1,054 34.75 883 8.50 216 17.75 451 5.13 130 2.38 60 18.44 468 31.00 787 4.00 102
4HS11M-11000-30 42.50 1,080 37.00 940 8.50 216 17.75 451 5.13 130 2.38 60 18.44 468 31.00 787 4.00 102
4HS16M-13000-20 46.00 1,168 37.50 953 9.50 241 20.00 508 6.25 159 2.00 51 18.94 481 34.00 864 4.00 102
4HS16M-13000-25 47.00 1,194 39.50 1,003 9.50 241 20.00 508 6.25 159 2.00 51 18.94 481 34.00 864 4.00 102
4HS16M-13000-40 47.00 1,194 42.00 1,067 9.50 241 20.00 508 6.25 159 2.00 51 18.94 481 34.00 864 4.00 102
4HS16M-16000-10 46.00 1,168 34.50 876 9.50 241 20.00 508 6.25 159 2.00 51 18.94 481 34.00 864 4.00 102
4HS16M-16000-15 46.00 1,168 37.50 953 9.50 241 20.00 508 6.25 159 2.00 51 18.94 481 34.00 864 4.00 102
4HS16M-16000-20 47.00 1,194 39.50 1,003 9.50 241 20.00 508 6.25 159 2.00 51 18.94 481 34.00 864 4.00 102
4HS26M-22000-15 60.50 1,537 42.50 1,080 12.38 314 25.38 645 8.06 205 2.44 62 21.00 533 44.50 1,130 5.88 149
4HS26M-22000-25 60.50 1,537 45.00 1,143 12.38 314 25.38 645 8.06 205 2.44 62 21.00 533 44.50 1,130 5.88 149
4HS26M-22000-30 60.50 1,537 48.50 1,232 12.38 314 25.38 645 8.06 205 2.44 62 21.00 533 44.50 1,130 5.88 149
4HS26M-26000-15 60.50 1,537 42.50 1,080 12.38 314 25.38 645 8.06 205 2.44 62 21.00 533 44.50 1,130 5.88 149
4HS26M-26000-20 60.50 1,537 45.00 1,143 12.38 314 25.38 645 8.06 205 2.44 62 21.00 533 44.50 1,130 5.88 149
4HS26M-26000-25 60.50 1,537 48.50 1,232 12.38 314 25.38 645 8.06 205 2.44 62 21.00 533 44.50 1,130 5.88 149

K L M N P R S (Hole Dia.) Ship Wt.1

(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lb) (kg)
4HS6M-5000-15 18.00 457 – – 11.88 302 1.88 48 18.25 464 11.13 283 7
/8 22 570 259
4HS6M-5000-20 18.00 457 – – 11.88 302 1.88 48 18.25 464 11.13 283 7
/8 22 590 268
4HS6M-5000-30 18.00 457 – – 11.88 302 1.88 48 18.25 464 11.13 283 7
/8 22 590 268
4HS6M-6600-15 18.00 457 – – 11.88 302 1.88 48 18.25 464 11.13 283 7
/8 22 590 268
4HS6M-6600-25 18.00 457 – – 11.88 302 1.88 48 18.25 464 11.13 283 7
/8 22 590 268
4HS6M-6600-40 18.00 457 – – 11.88 302 1.88 48 18.25 464 11.13 283 7
/8 22 650 295
4HS11M-9000-20 18.00 457 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3/16 30 1,080 490
4HS11M-9000-30 18.00 457 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3/16 30 1,120 509
4HS11M-9000-40 18.00 457 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3/16 30 1,160 527
4HS11M-11000-15 18.00 457 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3/16 30 1,080 490
4HS11M-11000-20 18.00 457 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3/16 30 1,120 509
4HS11M-11000-30 18.00 457 – – 12.50 318 2.75 70 22.00 559 12.50 318 1-3/16 30 1,160 527
4HS16M-13000-20 20.00 508 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3/16 30 1,580 717
4HS16M-13000-25 20.00 508 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3/16 30 1,640 744
4HS16M-13000-40 20.00 508 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3/16 30 1,680 763
4HS16M-16000-10 20.00 508 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3/16 30 1,520 690
4HS16M-16000-15 20.00 508 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3/16 30 1,580 717
4HS16M-16000-20 20.00 508 10.00 254 13.50 343 2.75 70 27.50 699 16.25 413 1-3/16 30 1,640 744
4HS26M-22000-15 26.00 660 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3/8 35 3,130 1,420
4HS26M-22000-25 26.00 660 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3/8 35 3,170 1,438
4HS26M-22000-30 26.00 660 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3/8 35 3,350 1,520
4HS26M-26000-15 26.00 660 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3/8 35 3,130 1,420
4HS26M-26000-20 26.00 660 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3/8 35 3,170 1,438
4HS26M-26000-25 26.00 660 13.00 330 18.25 464 3.00 76 36.00 914 21.75 552 1-3/8 35 3,350 1,520
1 Weight
shown without clutch; contact factory for clutch weight.
Dimensions are for reference only and subject to change without notice. Please contact factory for exact dimensions.

IMPORTANT:
It is the owner’s or operator’s responsibility to determine the suitability of the equipment to its intended use. Study all applicable codes, manuals, and
regulations. Be sure to read the Owner’s Manual supplied with the equipment before operating it.

www.thern.com 1.800.843.7648
12 Thern products are not for lifting people or things over people. S309-0809
 4HS SERIES POWER WINCHES
4HS6-26M Series
K
L
J
drum CL
4HS40 H
D drum CL P
R
M E F
A B
C N
K
S (hole dia.) L
J
4HS40-56M Series
manual clutch lever
if included

drum CL P
drum CL H
R
D

M E B F S (hole dia.) N
A C

4HS40-56M Series Winch Dimensions

A B C D E F G H
(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
4HS40M-33000-20 91.00 2,311 60.00 1,524 14.00 356 27.00 686 6.75 171 2.63 67 24.63 626 51.00 1,295
4HS40M-33000-30 94.00 2,388 60.00 1,524 14.00 356 27.00 686 6.75 171 2.63 67 24.63 626 51.00 1,295
4HS40M-33000-40 96.00 2,438 60.00 1,524 14.00 356 27.00 686 6.75 171 2.63 67 24.63 626 51.00 1,295
4HS40M-40000-20 91.00 2,311 60.00 1,524 14.00 356 27.00 686 6.75 171 2.63 67 24.63 626 51.00 1,295
4HS40M-40000-25 94.00 2,388 60.00 1,524 14.00 356 27.00 686 6.75 171 2.63 67 24.63 626 51.00 1,295
4HS40M-40000-35 96.00 2,438 60.00 1,524 14.00 356 27.00 686 6.75 171 2.63 67 24.63 626 51.00 1,295
4HS56M-48000-20 108.00 2,743 72.00 1,829 18.00 457 32.00 813 8.75 222 2.63 67 23.13 588 62.00 1,575
4HS56M-48000-30 110.00 2,794 72.00 1,829 18.00 457 32.00 813 8.75 222 2.63 67 23.13 588 62.00 1,575
4HS56M-52000-35 113.00 2,870 72.00 1,829 18.00 457 32.00 813 8.75 222 2.63 67 23.13 588 62.00 1,575
4HS56M-56000-20 108.00 2,743 72.00 1,829 18.00 457 32.00 813 8.75 222 2.63 67 23.13 588 62.00 1,575
4HS56M-56000-25 110.00 2,794 72.00 1,829 18.00 457 32.00 813 8.75 222 2.63 67 23.13 588 62.00 1,575
4HS56M-56000-30 113.00 2,870 72.00 1,829 18.00 457 32.00 813 8.75 222 2.63 67 23.13 588 62.00 1,575

J K L M N P R S (Hole Dia.) Ship Wt.1

(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lb) (kg)
4HS40M-33000-20 7.00 178 30.00 762 – – 21.00 533 4.00 102 52.00 1,321 31.50 800 1-3/4 44 5,570 2,527
4HS40M-33000-30 7.00 178 30.00 762 – – 21.00 533 4.00 102 52.00 1,321 31.50 800 1-3/4 44 5,660 2,568
4HS40M-33000-40 7.00 178 30.00 762 – – 21.00 533 4.00 102 52.00 1,321 31.50 800 1-3/4 44 5,800 2,631
4HS40M-40000-20 7.00 178 30.00 762 – – 21.00 533 4.00 102 52.00 1,321 31.50 800 1-3/4 44 5,570 2,527
4HS40M-40000-25 7.00 178 30.00 762 – – 21.00 533 4.00 102 52.00 1,321 31.50 800 1-3/4 44 5,660 2,568
4HS40M-40000-35 7.00 178 30.00 762 – – 21.00 533 4.00 102 52.00 1,321 31.50 800 1-3/4 44 5,800 2,631
4HS56M-48000-20 7.00 178 36.00 914 18.00 457 25.00 635 4.50 114 63.00 1,600 34.50 876 1-3/4 44 9,220 4,183
4HS56M-48000-30 7.00 178 36.00 914 18.00 457 25.00 635 4.50 114 63.00 1,600 34.50 876 1-3/4 44 9,370 4,251
4HS56M-52000-35 7.00 178 36.00 914 18.00 457 25.00 635 4.50 114 63.00 1,600 34.50 876 1-3/4 44 9,480 4,301
4HS56M-56000-20 7.00 178 36.00 914 18.00 457 25.00 635 4.50 114 63.00 1,600 34.50 876 1-3/4 44 9,220 4,183
4HS56M-56000-25 7.00 178 36.00 914 18.00 457 25.00 635 4.50 114 63.00 1,600 34.50 876 1-3/4 44 9,370 4,251
4HS56M-56000-30 7.00 178 36.00 914 18.00 457 25.00 635 4.50 114 63.00 1,600 34.50 876 1-3/4 44 9,480 4,301
Weight
1 shown without clutch; contact factory for clutch weight.
Dimensions are for reference only and subject to change without notice. Please contact factory for exact dimensions.

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S309-0809 Thern products are not for lifting people or things over people. 13
 4HWF SERIES
Thern 4HWF series power winches feature helical/worm FLANGE MOUNTED MOTOR is a
gearing making them ideal for applications requiring secure 230/460 volt 3 phase motor, 60
cycle, IP 55, TEFC severe duty,
load control and accurate positioning. The enclosed, direct- reversible, class F insulated,
drive gearing design delivers dependable operation and helps continuous duty brakemotor.

reduce maintenance, while a modular design means we can Standard motors comply with
easily customize these winches to meet your relevant standards including NEMA,
MG1, ANSI, CSA, IEC and ABS.
exact specifications.
LOAD HOLDING MOTOR DISC BRAKE
is spring set, electrically released
for positive load control.

DIRECT DRIVE GEAR REDUCERS,

comprised of helical/worm gears,
deliver lower efficiencies from
65% to 76% making winches well
suited for applications requiring
secure load control and accurate
positioning.

The heat treated helical/worm

gear set provides improved
durability and operates in an oil
bath, enclosed in a high strength
cast iron gearcase, SAE class 30.
Double-lip oil seals keep oil in and
contaminants out. Large capacity
bearings ensure long life. Speed
reducers meet AGMA standards.

FLANGE STYLE ROLLER BEARINGS EXTENDED SOLID STEEL DRUM SHAFT ANSI B30.7 COMPLIANCE is available.
are self-aligning bearings with cast for uniform loading.   Please contact the factory.
housing to maintain smooth drum
rotation.

WELDED STEEL DRUM with outside WIRE ROPE ASSEMBLIES sold 2 YEAR “MOVE IT WITH CONFIDENCE”
flange anchors allow uniform winding separately per customer request. LIMITED WARRANTY leads the
and help extend life of wire rope. industry.
Anchors allow cable to be over
wound or under wound from either
side of the drum.

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14 Thern products are not for lifting people or things over people. S309-0809
 4HWF SERIES
HP Load Rating Line Speed
4HWF1M 1.5 - 2 1,500 lb 25 - 35 fpm
4HWF2M 2-3 2,000 lb 25 - 35 fpm
4HWF4M 3-5 4,000 lb 25 - 35 fpm
4HWF6M 5 - 7.5 6,000 lb 25 - 35 fpm
4HWF8M 7.5 - 10 8,000 lb 25 - 35 fpm

OPTIONS AND ACCESSORIES

DRUM MODIFICATIONS (A) include grooved drums, multiple compartment
drums and modified drum widths and diameters.

WINCH MOUNTING OPTIONS include base, wall or under hung installation.

A
CABLE PRESSURE BARS (B) help maintain uniform winding of wire rope.

LIMIT SWITCHES (C) provide secondary shut-off for load travel in one or two
directions.

MOTOR OPTIONS include air or hydraulic, voltage or phase changes, IP 65,

class F or H insulated, multi-speed operation.
Shown with double compartment drum modification.
DUTY RATINGS include IEEE 45 marine duty, tropical duty, severe duty and
explosion proof ratings.
B
BRAKE OPTIONS include over-speed, caliper style, band, and more.

CONTROLS (D) are available in a wide range of standard and custom

configurations for single or variable speed.

CORROSION RESISTANT FINISHES (E) for harsh or hazardous environments.

MANUAL OVERRIDES for winch operation in power loss situations.

Shown with cable pressure bar and grooved

drum modification.

E D C

Shown with grooved drum modification and gray

epoxy finish.

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S309-0809 Thern products are not for lifting people or things over people. 15
 4HWF SERIES POWER WINCHES
4HWF Series Performance Characteristics
1
Model Number Extensions Motor hp Load Rating Line Speed Motor Codes
Load Rating Line Speed Motor 1st Layer Mid Drum Full Drum 1st Layer Full Drum D 230 volt 3 phase
hp E 460 volt 3 phase
(lb) (fpm) Codes1 (lb) (kg) (lb) (kg) (lb) (kg) (fpm) (mpm) (fpm) (mpm)
F All other voltages
4HWF1M 1500 25 D, E, F 1.5 1,500 681 900 409 700 318 23 7.0 52 15.8 please contact
4HWF1M 1500 35 D, E, F 2 1,500 681 900 409 700 318 32 9.8 73 22.3 factory
4HWF2M 2000 25 D, E, F 2 2,200 998 1,500 681 1,200 545 22 6.7 40 12.2
4HWF2M 2000 35 D, E, F 3 2,200 998 1,500 681 1,200 545 34 10.4 63 19.2
4HWF4M 4000 25 D, E, F 3 4,000 1,815 2,500 1,134 1,800 817 21 6.4 47 14.3
4HWF4M 4000 35 D, E, F 5 4,000 1,815 2,500 1,134 1,800 817 35 10.7 78 23.8
4HWF6M 6000 25 D, E, F 5 6,000 2,722 4,400 1,996 3,400 1,543 24 7.3 42 12.8
4HWF6M 6000 35 D, E, F 7.5 6,000 2,722 4,400 1,996 3,400 1,543 35 10.7 61 18.6
4HWF8M 8000 25 D, E, F 7.5 8,100 3,675 5,800 2,631 4,500 2,042 27 8.2 47 14.3
4HWF8M 8000 35 D, E, F 10 8,100 3,675 5,800 2,631 4,500 2,042 39 11.9 64 19.5
Please contact factory or nearest Thern Distributor for firm fixed price and delivery.
4HWF Series Drum Capacities
Wire Rope Dia. Breaking Strength2 Drum Capacity 4HWF1M 4HWF2M 4HWF4M 4HWF6M 4HWF8M
(in) (mm) (lb) (kg) (ft) (m) (ft) (m) (ft) (m) (ft) (m) (ft) (m)
1st 43 13.1 51 15.5 – – – – – –
1
/4 6.4 7,0003 3,175 Mid 370 112.8 340 103.6 – – – – – –
Full 830 253.0 750 228.6 – – – – – –
1st 34 10.4 41 12.5 87 26.5 – – – –
5
/16 7.9 9,8003 4,445 Mid 250 76.2 230 70.1 950 289.6 – – – –
Full 560 170.7 500 152.4 2,120 646.2 – – – –
1st 27 8.2 33 10.1 70 21.3 – – – –
3
/8 9.7 15,100 6,849 Mid 180 54.9 160 48.8 680 207.3 – – – –
Full 400 121.9 360 109.7 1,520 463.3 – – – –
1st 23 7.0 28 8.5 60 18.3 76 23.2 – –
7
/16 11.2 20,400 9,254 Mid 130 39.6 120 36.6 510 155.4 450 137.2 – –
Full 300 91.4 270 82.3 1,140 347.5 990 301.8 – –
1st – – – – 52 15.8 66 20.1 – –
1
/2 12.7 26,600 12,066 Mid – – – – 400 121.9 350 106.7 – –
Full – – – – 890 271.3 770 234.7 – –
1st – – – – 46 14.0 58 17.7 89 27.1
9
/16 14.2 33,600 15,240 Mid – – – – 320 97.5 280 85.3 540 164.6
Full – – – – 710 216.4 620 189.0 1,210 368.8
1st – – – – – – 51 15.5 78 23.8
5
/8 16.0 41,200 18,688 Mid – – – – – – 230 70.1 440 134.1
Full – – – – – – 510 155.4 990 301.8
1st – – – – – – 42 12.8 65 19.8
3
/4 19.1 58,800 26,671 Mid – – – – – – 160 48.8 310 94.5
Full – – – – – – 360 109.7 700 213.4
1st – – – – – – – – 54 16.5
7
/8 22.4 79,600 36,106 Mid – – – – – – – – 230 70.1
Full – – – – – – – – 500 152.4
1st – – – – – – – – 47 14.3
1 25.4 103,400 46,902 Mid – – – – – – – – 180 54.9
Full – – – – – – – – 390 118.9
2
Values based on 6x37 IWRC EIPS wire rope.
3
Values based on 7x19 galvanized aircraft cable. Electric Motor Controls
Actual drum capacities 25-30% less, due to nonuniform winding. Wire rope tension will also affect drum capacity.
Wire rope should be selected based on the breaking strength to load rating ratio and application parameters. Industry Description Approx. Ship Wt.
standards suggest a 5:1 breaking strength to load rating ratio for lifting and a 3:1 ratio for pulling.
(lb) (kg)
10S3D4 electric motor controls 230/3/60 to 3 hp 25 12
IMPORTANT: 10S7D4 electric motor controls 230/3/60 to 7.5 hp 25 12
It is the owner’s or operator’s responsibility to determine the suitability of 10S10D4 electric motor controls 230/3/60 to 10 hp 28 13
10S7E4 electric motor controls 460/3/60 to 7.5 hp 25 12
the equipment to its intended use. Study all applicable codes, manuals, and 10S15D4 electric motor controls 460/3/60 to 15 hp 25 12
regulations. Be sure to read the Owner’s Manual supplied with the equipment Controls include NEMA 4 rated enclosure, and NEMA 4x rated pendant control
on 50 foot cord.
before operating it. Motor Controls sold separately. Please contact factory or nearest Thern
Distributor for firm fixed price and delivery. All prices include mounting and
wiring to motor.

www.thern.com 1.800.843.7648
16 Thern products are not for lifting people or things over people. S309-0809
 4HWF SERIES POWER WINCHES
V
4HWF Series

K
L J
A

drum CL
drum CL
H
D R P

B
M E C N
S (hole dia.)

4HWF Series Winch Dimensions

A B C D E H J K
(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
4HWF1M-1500-25 25.50 648 27.00 686 6.00 152 8.00 203 2.38 60 14.00 356 1.00 25 20.00 508
4HWF1M-1500-35 25.50 648 27.00 686 6.00 152 8.00 203 2.38 60 14.00 356 1.00 25 20.00 508
4HWF2M-2000-25 26.25 667 28.00 711 6.00 152 8.00 203 2.38 60 14.00 356 1.00 25 20.00 508
4HWF2M-2000-35 26.25 667 29.75 756 6.00 152 8.00 203 2.38 60 14.00 356 1.00 25 20.00 508
4HWF4M-4000-25 39.00 991 35.00 889 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HWF4M-4000-35 39.00 991 35.00 889 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HWF6M-6000-25 41.00 1,041 36.00 914 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HWF6M-6000-35 41.00 1,041 39.00 991 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HWF8M-8000-25 50.00 1,270 43.50 1,105 12.00 305 14.50 368 6.25 159 25.50 648 1.25 32 26.50 673
4HWF8M-8000-35 50.00 1,270 45.50 1,156 12.00 305 14.50 368 6.25 159 25.50 648 1.25 32 26.50 673

L M N P R S (Hole Dia.) V Ship. Wt.

(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lb) (kg)
4HWF1M-1500-25 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 190 87
4HWF1M-1500-35 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 190 87
4HWF2M-2000-25 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 240 109
4HWF2M-2000-35 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 240 109
4HWF4M-4000-25 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 480 218
4HWF4M-4000-35 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 480 218
4HWF6M-6000-25 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 650 295
4HWF6M-6000-35 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 710 323
4HWF8M-8000-25 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1-1/8 29 39.75 1,010 1,120 509
4HWF8M-8000-35 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1-1/8 29 39.75 1,010 1,180 536
Dimensions are for reference only and subject to change without notice. Please contact factory for exact dimensions.

4HWF Series Drum Dimensions

ID
Drum Diameter Flange Diameter Drum Width (W) Fleet Angle Dist
Fleet Angle (ID) (OD) (A)4
Lead Sheave
(in) (mm) (in) (mm) (in) (mm) (ft) (m)
Center Load
W 4.50 114 12.00 305 10.00 254 16 4.9
Line 4HWF1M
4HWF2M 5.50 140 12.00 305 10.00 254 16 4.9
Recommended
Fleet Angle Distance 4HWF4M 7.00 178 18.00 457 16.00 406 26 7.9
A
4HWF6M 9.00 229 18.00 457 16.00 406 26 7.9
OD
4HWF8M 10.75 273 22.00 559 20.00 508 32 9.8
4 Recommended minimum distance between drum and lead sheave for smooth drum.

Dimensions are for reference only and subject to change without notice. Please contact factory
for exact dimensions.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 17
 4HPF SERIES
Thern 4HPF series power winches feature FLANGE MOUNTED MOTOR is a
helical/parallel, high efficiency gearing making 230/460 volt 3 phase, 60 cycle, IP
55, TEFC severe duty, reversible,
them ideal for applications requiring long class F insulated, continuous duty
travel distances and faster line speeds. The brakemotor.

enclosed, direct-drive gearing design delivers Standard motors comply with

dependable operation and helps reduce relevant standards including NEMA,
MG1, ANSI, CSA, IEC and ABS.
maintenance, while a modular design means
we can easily customize these winches to LOAD HOLDING MOTOR DISC BRAKE
is spring set, electrically released
meet your exact specifications. for positive load control.

DIRECT DRIVE GEAR REDUCERS,

comprised of helical/parallel gears,
deliver high efficiencies from 88%
to 94% making winches well suited
for applications requiring long
travel distances and faster line
speeds. 

The heat treated helical/parallel

gear set provides improved dura-
bility and operates in an oil bath,
enclosed in a high strength cast
iron gearcase, SAE class 30.
Double-lip oil seals keep oil in and
contaminants out. Large capacity
bearings ensure long life. Speed
reducers meet AGMA standards.

FLANGE STYLE ROLLER BEARINGS are EXTENDED SOLID STEEL DRUM SHAFT ANSI B30.7 COMPLIANCE is available.
self-aligning with cast housings to for uniform loading. Please contact the factory.
maintain smooth drum rotation.

WELDED STEEL DRUM with outside WIRE ROPE ASSEMBLIES sold 2 YEAR “MOVE IT WITH CONFIDENCE”
flange anchors allow for uniform separately per customer request. LIMITED WARRANTY leads the in-
winding and help extend life of wire dustry.
rope. Anchors allow cable to be over
wound or under wound from either
side of the drum.

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18 Thern products are not for lifting people or things over people. S309-0809
 4HPF SERIES
Clutch Option HP Load Rating Line Speed A
4HPF2M 4HPF2MC 1-2 2,000 lb 20 - 35 fpm

4HPF3M 4HPF3MC 1.5 - 3 3,000 lb 20 - 35 fpm

4HPF5M 4HPF5MC 3-5 5,000 lb 20 - 35 fpm

4HPF7M 4HPF7MC 5 - 7.5 7,000 lb 25 - 40 fpm

4HPF9M 4HPF9MC 5 - 10 9,000 lb 20 - 40 fpm

4HPF15M 4HPF15MC 10 - 15 15,000 lb 20 - 35 fpm Shown with double compartment drum modification.

4HPF20M - 10 - 25 20,000 lb 20 - 40 fpm

B
4HPF25M - 15 - 30 25,000 lb 20 - 40 fpm

OPTIONS AND ACCESSORIES

DRUM MODIFICATIONS (A) include grooved drums, multiple compartment
drums and modified drum widths and diameters. C

MANUALLY OPERATED JAW CLUTCH (B) disengages for rapid payout of wire
rope when not under load. Adjustable drag brake on the drum prevents
over-spooling during payout. Clutch option is for horizontal pulling only.

WINCH MOUNTING OPTIONS include base, wall or under hung installation.

CABLE PRESSURE BARS (C) help maintain uniform winding of wire rope.

LIMIT SWITCHES (D) provide secondary shut-off for load travel in one or two Shown with cable pressure bar and grooved
directions. drum modification.
D
MOTOR OPTIONS include air or hydraulic, voltage or phase changes, IP 65,
class F or H insulated and multi-speed operation.

DUTY RATINGS include IEEE 45 marine duty, tropical duty, severe duty and
explosion proof ratings.

BRAKE OPTIONS include over-speed, caliper style, band, and more.

CONTROLS (E) are available in a wide range of standard and custom

configurations for single or variable speed. E

CORROSION RESISTANT FINISHES for harsh or hazardous environments.

MANUAL OVERRIDES for winch operation in power loss situations.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 19
 4HPF SERIES POWER WINCHES
4HPF Series Performance Characteristics
Model Number Extensions Motor hp Load Rating Line Speed
Load Rating Line Speed Motor hp 1st Layer Mid Drum Full Drum 1st Layer Full Drum
Codes1
(lb) (fpm) (lb) (kg) (lb) (kg) (lb) (kg) (fpm) (mpm) (fpm) (mpm)
4HPF2M 2000 20 D, E, F 1 2,100 953 1,300 590 1,000 454 17 5.2 38 11.6
4HPF2M 2000 35 D, E, F 2 2,100 953 1,300 590 1,000 454 34 10.4 76 23.2
4HPF3M 3000 20 D, E, F 1.5 3,000 1,361 2,100 953 1,600 726 19 5.8 33 10.1
4HPF3M 3000 35 D, E, F 3 3,300 1,497 2,300 1,044 1,800 817 33 10.1 59 18.0
4HPF5M 5000 20 D, E, F 3 5,000 2,268 3,100 1,407 2,300 1,044 22 6.7 49 14.9
4HPF5M 5000 35 D, E, F 5 5,000 2,268 3,100 1,407 2,300 1,044 37 11.3 81 24.7
4HPF7M 7000 25 D, E, F 5 7,300 3,312 5,400 2,450 4,300 1,951 24 7.3 40 12.2
4HPF7M 7000 40 D, E, F 7.5 7,300 3,312 5,400 2,450 4,300 1,951 38 11.6 64 19.5
4HPF9M 9000 20 D, E, F 5 9,000 4,083 6,500 2,949 5,100 2,314 21 6.4 37 11.3
4HPF9M 9000 40 D, E, F 10 9,000 4,083 6,500 2,949 5,100 2,314 41 12.5 73 22.3
4HPF15M 15000 25 D, E, F 10 14,300 6,487 10,900 4,945 8,800 3,992 26 7.9 41 12.5
4HPF15M 15000 35 D, E, F 15 15,100 6,850 11,500 5,217 9,300 4,219 36 11.0 59 18.0
4HPF20M 20000 20 D, E, F 10 20,100 9,118 14,100 6,396 10,800 4,899 17 5.2 31 9.4
4HPF20M 20000 40 D, E, F 25 20,100 9,118 14,000 6,351 10,800 4,899 43 13.1 81 24.7
4HPF25M 25000 20 D, E, F 15 25,200 11,431 19,200 8,710 15,500 7,031 20 6.1 32 9.8
4HPF25M 25000 40 D, E, F 30 25,000 11,340 19,000 8,619 15,400 6,986 42 12.8 68 20.7
4HPF2MC2 2000 20 D, E, F 1 2,100 953 1,300 590 1,000 454 17 5.2 38 11.6
4HPF2MC2 2000 35 D, E, F 2 2,100 953 1,300 590 1,000 454 34 10.4 75 22.9
4HPF3MC2 3000 20 D, E, F 1.5 3,300 1,497 2,300 1,044 1,800 817 17 5.2 60 18.3
4HPF3MC2 3000 35 D, E, F 3 3,300 1,497 2,300 1,044 1,800 817 34 10.4 61 18.6
4HPF5MC2 5000 20 D, E, F 3 5,000 2,268 3,100 1,407 2,300 1,044 21 6.4 45 13.7
4HPF5MC2 5000 35 D, E, F 5 5,000 2,268 3,100 1,407 2,300 1,044 36 11.0 80 24.4
4HPF7MC2 7000 25 D, E, F 5 7,300 3,312 5,400 2,450 4,300 1,951 25 7.6 42 12.8
4HPF7MC2 7000 35 D, E, F 7.5 7,300 3,312 5,400 2,450 4,300 1,951 36 11.0 61 18.6
4HPF9MC2 9000 20 D, E, F 5 9,000 4,083 6,500 2,949 5,100 2,314 21 6.4 37 11.3
4HPF9MC2 9000 40 D, E, F 10 9,000 4,083 6,500 2,949 5,100 2,314 41 12.5 73 22.3
4HPF15MC2 15000 20 D, E, F 10 15,100 6,850 11,500 5,217 9,300 4,219 22 6.7 36 11.0
4HPF15MC2 15000 35 D, E, F 15 15,200 6,895 11,600 5,262 9,400 4,264 35 10.7 57 17.4
Please contact factory or nearest Thern Distributor for firm fixed price and delivery.
1
Motor Codes
D 230 volt 3 phase
4HPF Series Drum Dimensions E 460 volt 3 phase
F All other voltages
Drum Diameter (ID) Flange Diameter (OD) Drum Width (W) Fleet Angle Dist (A)3 please contact factory
(in) (mm) (in) (mm) (in) (mm) (ft) (m)
4HPF2M 4.50 114 12.00 305 10.00 254 16 4.9
4HPF3M 5.50 140 12.00 305 10.00 254 16 4.9
4HPF5M 7.00 178 18.00 457 16.00 406 26 7.9
4HPF7M 9.00 229 18.00 457 16.00 406 26 7.9
4HPF9M 10.75 273 22.00 559 20.00 508 32 9.8
4HPF15M 11.50 292 22.00 559 20.00 508 32 9.8 Electric Motor Controls
4HPF20M 14.00 356 30.00 762 30.00 762 48 14.6
Description Approx. Ship Wt.
4HPF25M 16.00 406 30.00 762 30.00 762 48 14.6
3 Recommended minimum distance between drum and lead sheave for smooth drum. (lb) (kg)
Dimensions are for reference only and subject to change without notice. 10S3D4 electric motor controls 230/3/60 to 3 hp 25 12
Please contact factory for exact dimensions. 10S7D4 electric motor controls 230/3/60 to 7.5 hp 25 12
10S10D4 electric motor controls 230/3/60 to 10 hp 28 13
10S20D4 electric motor controls 230/3/60 to 20 hp 28 13
ID
10S30D4 electric motor controls 230/3/60 to 30 hp 60 28
10S7E4 electric motor controls 460/3/60 to 7.5 hp 25 12
Fleet Angle 10S15E4 electric motor controls 460/3/60 to 15 hp 25 12
Lead Sheave
10S20E4 electric motor controls 460/3/60 to 20 hp 28 13
Center Load
W Line 10S40E4 electric motor controls 460/3/60 to 40 hp 60 28
Controls include NEMA 4 rated enclosure, and NEMA 4x rated pendant
Recommended
Fleet Angle Distance control on 50 foot cord.
A Motor Controls sold separately. Please contact factory or nearest Thern
OD Distributor for firm fixed price and delivery. All prices include mounting
and wiring to motor.

www.thern.com 1.800.843.7648
20 Thern products are not for lifting people or things over people. S309-0809
 4HPF SERIES POWER WINCHES
4HPF Series Drum Capacities
Wire Rope Breaking Drum 4HPF2M 4HPF3M 4HPF5M 4HPF7M 4HPF9M 4HPF15M 4HPF20M 4HPF25M
Dia. Strength4 Capacity

(in) (mm) (lb) (kg) (ft) (m) (ft) (m) (ft) (m) (ft) (m) (ft) (m) (ft) (m) (ft) (m) (ft) (m)
1st 43 13.1 51 15.5 – – – – – – – – – – – –
1
/4 6.4 7,0005 3,175 Mid 370 112.8 340 103.6 – – – – – – – – – – – –
Full 830 253.0 750 228.6 – – – – – – – – – – – –
1st 34 10.4 41 12.5 87 26.5 – – – – – – – – – –
5
/16 7.9 9,8005 4,445 Mid 250 76.2 230 70.1 950 289.6 – – – – – – – – – –
Full 560 170.7 500 152.4 2,120 646.2 – – – – – – – – – –
1st 27 8.2 33 10.1 70 21.3 – – – – – – – – – –
3
/8 9.7 15,100 6,849 Mid 180 54.9 160 48.8 680 207.3 – – – – – – – – – –
Full 400 121.9 360 109.7 1,520 463.3 – – – – – – – – – –
1st 23 7.0 28 8.5 60 18.3 76 23.2 – – – – – – – –
7
/16 11.2 20,400 9,254 Mid 130 39.6 120 36.6 510 155.4 450 137.2 – – – – – – – –
Full 300 91.4 270 82 .3 1,140 347.5 990 301.8 – – – – – – – –
1st – – – – 52 15 66 20.1 – – – – – – – –
1
/2 12.7 26,600 12,066 Mid – – – – 400 121 350 106.7 – – – – – – – –
Full – – – – 890 271 770 234.7 – – – – – – – –
1st – – – – 46 14.0 58 17.7 89 27.1 – – – – – –
9
/16 14.2 33,600 15,240 Mid – – – – 320 97.5 280 85.3 540 164.6 – – – – – –
Full – – – – 710 216.4 620 189.0 1,210 368.8 – – – – – –
1st – – – – – – 51 15.5 78 23.8 84 25.6 – – – –
5
/8 16.0 41,200 18,688 Mid – – – – – – 230 70.1 440 134.1 420 128.0 – – – –
Full – – – – – – 510 155.5 990 301.8 940 286.5 – – – –
1st – – – – – – – – 65 19.8 69 21.0 130 39.6 – –
3
/4 19.1 58,800 26,671 Mid – – – – – – – – 310 94.5 300 91.4 930 283.5 – –
Full – – – – – – – – 700 213.4 660 201.2 2,070 630.9 – –
1st – – – – – – – – 54 16.5 57 17.4 110 33.5 – –
7
/8 22.4 79,600 36,106 Mid – – – – – – – – 230 70.1 210 64.0 670 204.2 – –
Full – – – – – – – – 500 152.4 480 146.3 1,490 454.2 – –
1st – – – – – – – – 47 14.3 57 17.4 97 29.6 110 33.5
1 25.4 103,400 46,902 Mid – – – – – – – – 180 54.9 210 64.0 520 158.5 470 143.3
Full – – – – – – – – 390 118.9 480 146.3 1,160 353.6 1,050 320.0
1st – – – – – – – – – – – – 85 25.9 96 29.3
1-1/8 28.7 130,000 58,968 Mid – – – – – – – – – – – – 420 128.0 380 115.8
Full – – – – – – – – – – – – 920 280.4 840 256.0
1st – – – – – – – – – – – – 76 23.2 86 26.2
1-1/4 31.8 159,800 72,485 Mid – – – – – – – – – – – – 330 100.6 300 91.4
Full – – – – – – – – – – – – 740 225.6 670 204.2
1st – – – – – – – – – – – – 68 20.7 76 23.2
1-3/8 34.9 192,000 87,090 Mid – – – – – – – – – – – – 280 85.3 250 76.2
Full – – – – – – – – – – – – 610 185.9 560 170.7
1st – – – – – – – – – – – – – – 69 21.0
1-1/2 38.1 228,000 103,420 Mid – – – – – – – – – – – – – – 210 64.0
Full – – – – – – – – – – – – – – 470 143.3
Values based on 6x37 IWRC EIPS wire rope.
Values based on 7x19 galvanized aircraft cable.
4
Actual drum capacities 25-30% less, due to nonuniform winding. Wire rope tension will also affect drum capacity.
5
Wire rope should be selected based on the breaking strength to load rating ratio and application parameters. Industry standards suggest a 5:1 breaking strength to load rating ratio for
lifting and a 3:1 ratio for pulling.

IMPORTANT:
It is the owner’s or operator’s responsibility to determine the suitability of
the equipment to its intended use. Study all applicable codes, manuals, and
regulations. Be sure to read the Owner’s Manual supplied with the equipment
before operating it.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 21
 4HPF

4HPF SERIES POWER WINCHES

4HPF Series V
K
L J

P
drum CL H drum CL
D R

B
M E S (hole dia.) C N
A

4HPF Series Winch Dimensions

A B C D E H J K
(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
4HPF2M-2000-20 37.50 953 17.00 432 6.56 167 8.00 203 2.38 60 14.50 368 1.00 25 20.00 508
4HPF2M-2000-35 39.00 991 17.00 432 6.56 167 8.00 203 2.38 60 14.50 368 1.00 25 20.00 508
4HPF3M-3000-20 42.00 1,067 17.00 432 6.56 167 8.00 203 2.38 60 14.25 362 1.00 25 20.00 508
4HPF3M-3000-35 42.00 1,067 17.00 432 6.56 167 8.00 203 2.38 60 14.25 362 1.00 25 20.00 508
4HPF5M-5000-20 54.50 1,384 26.00 660 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HPF5M-5000-35 54.50 1,384 26.00 660 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HPF7M-7000-25 56.00 1,422 26.00 660 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HPF7M-7000-40 59.00 1,499 26.00 660 9.63 245 12.00 305 5.13 130 21.00 533 1.00 25 30.50 775
4HPF9M-9000-20 64.50 1,638 31.00 787 12.00 305 14.50 368 6.25 159 25.50 648 1.25 32 26.50 673
4HPF9M-9000-40 69.50 1,765 31.00 787 12.00 305 14.50 368 6.25 159 25.50 648 1.25 32 26.50 673
4HPF15M-15000-25 71.50 1,816 31.00 787 12.00 305 14.50 368 6.25 159 25.50 648 1.25 32 26.50 673
4HPF15M-15000-35 74.00 1,880 31.00 787 12.00 305 14.50 368 6.25 159 25.50 648 1.25 32 26.50 673
4HPF20M-20000-20 90.00 2,286 43.00 1,092 18.88 480 19.50 495 6.75 171 34.50 876 1.50 38 32.00 813
4HPF20M-20000-40 97.00 2,464 43.00 1,092 18.88 480 19.50 495 6.75 171 34.50 876 1.50 38 32.00 813
4HPF25M-25000-20 94.00 2,388 43.00 1,092 18.88 480 19.50 495 6.75 171 34.50 876 1.50 38 32.00 813
4HPF25M-25000-40 100.00 2,540 43.00 1,092 18.88 480 19.50 495 6.75 171 34.50 876 1.50 38 32.00 813

L M N P R S (Hole Dia.) V Ship Wt.

(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lb) (kg)
4HPF2M-2000-20 10.00 254 7.56 192 0.63 16 15.75 400 7.86 200 19
/32 15 – – 170 78
4HPF2M-2000-35 10.00 254 7.56 192 0.63 16 15.75 400 7.86 200 19
/32 15 – – 200 91
4HPF3M-3000-20 10.00 254 7.56 192 0.63 16 15.75 400 7.86 200 19
/32 15 – – 250 114
4HPF3M-3000-35 10.00 254 7.56 192 0.63 16 15.75 400 7.86 200 19
/32 15 – – 260 118
4HPF5M-5000-20 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 500 227
4HPF5M-5000-35 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 500 227
4HPF7M-7000-25 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 650 295
4HPF7M-7000-40 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 760 345
4HPF9M-9000-20 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1 1/8 29 39.75 1,010 1,000 454
4HPF9M-9000-40 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1 1/8 29 39.75 1,010 1,120 509
4HPF15M-15000-25 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1 1/8 29 39.75 1,010 1,340 608
4HPF15M-15000-35 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1 1/8 29 39.75 1,010 1,370 622
4HPF20M-20000-20 16.00 406 21.00 533 1.50 38 40.00 1,016 20.00 508 1 3/8 35 48.00 1,219 2,400 1,089
4HPF20M-20000-40 16.00 406 21.00 533 1.50 38 40.00 1,016 20.00 508 1 3/8 35 48.00 1,219 2,620 1,189
4HPF25M-25000-20 16.00 406 21.00 533 1.50 38 40.00 1,016 20.00 508 1 3/8 35 48.00 1,219 3,190 1,447
4HPF25M-25000-40 16.00 406 21.00 533 1.50 38 40.00 1,016 20.00 508 1 3/8 35 48.00 1,219 3,440 1,561
Dimensions are for reference only and subject to change without notice. Please contact factory for exact dimensions.

www.thern.com 1.800.843.7648
22 Thern products are not for lifting people or things over people. S309-0809
 4HPF SERIES POWER WINCHES

4HPFC Series
V
K
H L J

drum CL P
G
D drum CL
R
F
M E B
A S (hole dia.) C N

4HPFC Series Winch Dimensions

A B C D E F G H J
(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
4HPF2MC-2000-20 38.50 978 17.00 432 6.00 152 8.00 203 2.38 60 0.88 23 19.88 505 17.00 432 1.00 25
4HPF2MC-2000-35 40.00 1,016 17.00 432 6.00 152 8.00 203 2.38 60 0.88 23 19.88 505 17.00 432 1.00 25
4HPF3MC-3000-20 41.00 1,041 17.00 432 6.00 152 8.00 203 2.38 60 0.88 23 19.88 505 18.25 464 1.00 25
4HPF3MC-3000-35 43.00 1,092 17.00 432 6.00 152 8.00 203 2.38 60 0.88 23 19.88 505 18.25 464 1.00 25
4HPF5MC-5000-20 55.00 1,397 26.00 660 9.63 245 12.00 305 5.13 130 – – 22.25 565 24.25 616 1.00 25
4HPF5MC-5000-35 55.00 1,397 26.00 660 9.63 245 12.00 305 5.13 130 – – 22.25 565 24.25 616 1.00 25
4HPF7MC-7000-25 56.00 1,422 26.00 660 9.63 245 12.00 305 5.13 130 – – 22.25 565 27.00 686 1.00 25
4HPF7MC-7000-40 58.50 1,486 26.00 660 9.63 245 12.00 305 5.13 130 – – 22.25 565 27.00 686 1.00 25
4HPF9MC-9000-20 66.00 1,676 31.00 787 12.00 305 14.50 368 6.25 159 – – 22.00 559 32.00 813 1.25 32
4HPF9MC-9000-40 71.00 1.803 31.00 787 12.00 305 14.50 368 6.25 159 – – 22.00 559 32.00 813 1.25 32
4HPF15MC-15000-25 72.50 1,842 31.00 787 12.00 305 14.50 368 6.25 159 – – 22.00 559 35.00 889 1.25 32
4HPF15MC-15000-35 74.50 1,892 31.00 787 12.00 305 14.50 368 6.25 159 – – 22.00 559 35.00 889 1.25 32

K L M N P R S (Hole Dia.) V Ship Wt.

(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (lb) (kg)
4HPF2MC-2000-20 20.00 508 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 270 123
4HPF2MC-2000-35 20.00 508 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 300 137
4HPF3MC-3000-20 20.00 508 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 280 128
4HPF3MC-3000-35 20.00 508 10.00 254 7.56 192 0.63 16 15.75 400 7.88 200 19
/32 15 – – 300 137
4HPF5MC-5000-20 30.50 775 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 550 250
4HPF5MC-5000-35 30.50 775 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 550 250
4HPF7MC-7000-25 30.50 775 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 700 318
4HPF7MC-7000-40 30.50 775 15.25 387 11.50 292 1.00 25 24.00 610 12.00 305 7
/8 22 – – 760 345
4HPF9MC-9000-20 26.50 673 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1-1/8 29 39.75 1,010 1,250 567
4HPF9MC-9000-40 26.50 673 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1-1/8 29 39.75 1,010 1,360 617
4HPF15MC-15000-25 26.50 673 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1-1/8 29 39.75 1,010 1,580 717
4HPF15MC-15000-35 26.50 673 13.25 337 14.50 368 1.13 29 28.75 730 14.38 365 1-1/8 29 39.75 1,010 1,620 735
Dimensions are for reference only and subject to change without notice. Please contact factory for exact dimensions.

IMPORTANT:
It is the owner’s or operator’s responsibility to determine the suitability of
the equipment to its intended use. Study all applicable codes, manuals, and
regulations. Be sure to read the Owner’s Manual supplied with the equipment
before operating it.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 23
 4HBP SERIES capacity up to 100,000 lbs

Thern 4HBP series power winches feature high efficiency FLANGE MOUNTED MOTOR is a
230/460 volt 3 phase, 60 cycle, IP
helical-bevel/planetary gearing making them ideal for heavy- 54, TEFC severe duty, reversible,
duty applications requiring long travel distances and quick line class F insulated, continuous duty
brakemotor.
speeds.
Standard motors comply with rel-
evant standards including NEMA,
The enclosed, direct-drive gearing design delivers dependable MG1, ANSI, CSA, IEC and ABS.
operation and helps reduce maintenance, while a modular
LOAD HOLDING MOTOR DISC BRAKE
design means we can easily customize these winches to meet is spring set, electrically released for
exact specifications. positive load control.

DIRECT DRIVE GEAR REDUCER with

helical-bevel/planetary gearing
delivers high efficiencies up to 88%
making winches well suited for
heavy-duty applications requiring
long travel distances and faster line
speeds.

The heat treated helical-bevel/plan-

etary gear set provides improved
durability and operates in an oil bath,
enclosed in a high strength cast iron
gear case, SAE class 30. Double-lip
oil seals keep oil in and contaminants
out. Large capacity bearings en-
sure long life. Speed reducers meet
AGMA standards.

PLANETARY GEAR DRIVE is a compact

design that results in a lighter weight
WELDED STEEL DRUM with flange an- WIRE ROPE ASSEMBLIES sold sepa- winch compared to conventional
chors allow for uniform winding and rately per customer request. gearing. Planetary gearing also pro-
help extend life of wire rope. Anchors vides a high peak load capacity.
allow cable to be over wound or ANSI B30.7 COMPLIANCE is available.
under wound from either side of the Please contact the factory. FLANGE STYLE ROLLER BEARINGS are
drum. self-aligning with cast housings to
2 YEAR MOVE IT WITH CONFIDENCE maintain smooth drum rotation.
CONTINUOUS SOLID STEEL DRUM LIMITED WARRANTY leads the industry.
SHAFT for uniform loading.

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24 Thern products are not for lifting people or things over people. S309-0809
 4HBP SERIES capacity up to 100,000 lbs

Load Rating Line Speed

4HBP Series 35,000 - 100,000 lbs up to 70 fpm

Shown with double compartment

drum modification.

OPTIONS AND ACCESSORIES B

DRUM MODIFICATIONS (A) include grooved drums, multiple compartment

drums and modified drum widths and diameters.

WINCH MOUNTING OPTIONS include base, wall or under hung installation.

CABLE PRESSURE BARS (B) help maintain uniform winding of wire rope.

LIMIT SWITCHES (C) provide secondary shut-off for load travel in one or two Shown with cable pressure bar and
directions. grooved drum modification.

MOTOR OPTIONS include air or hydraulic, voltage or phase changes, IP 55 or C

IP65, Class H insulated and multi-speed operation.

DUTY RATINGS include IEEE 45 marine duty, tropical duty, severe duty and
explosion proof ratings.

BRAKE OPTIONS include over-speed, caliper style, band, and more.

CONTROLS (D) are available in a wide range of standard and custom configura-
tions for single or variable speed. Shown with RLS option.

CORROSION RESISTANT FINISHES for harsh or hazardous environments.

D
MANUAL OVERRIDES for winch operation in power loss situations.

Standard control option.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 25
 CUSTOM APPLICATIONS
TUG BOAT TOW WINCH OIL REFINERY DOCKING TERMINAL
PROBLEM SOLUTION
to tow large vessels into large capacity winch
port during docking designed for heavy load
operations. handling in saltwater
environment.

PRODUCT FEATURES
Load Rating: 50,000 lb
Line Speed: 25 fpm
Travel Distance: 1,500 ft
Power: 408 VAC, 3 Phase
Large capacity drum to accommodate long travel distances.
Stainless steel level wind for uniform spooling of cable onto drum.
Double disc brake for additional static load holding capacity.
Epoxy finish for corrosion resistance in marine environment.
ABS design compliance

TOWED ARRAY SLIP RING WINCH FOREIGN NAVY

PROBLEM SOLUTION
deploying and retrieving custom winch fitted with
underwater sensor equip- slip ring and level wind to
ment. receive feedback.

PRODUCT FEATURES
Load Rating: 3,000 lb
Line Speed: 190 fpm
Travel Distance: 1,300 ft
Power: 440 VAC, 3 phase
Slip ring to receive electronic feedback from towed array.
Level wind to ensure uniform spooling of cable.
Variable speed drive for precise control of load.
Large diameter drum for faster line speeds.
Epoxy finish for corrosion resistance in saltwater environment.

ANNEALING FURNACE DOOR WINCH FLAT ROLLED STEEL MILL

PROBLEM SOLUTION PRODUCT FEATURES
to simultaneously lift single drum winch system Load Rating: 2,000 lb Extended drum with two
multiple doors on furnace to lift different sized doors Line Speed: 28 fpm and 56 fpm compartments at each end to
during the annealing pro- in unison. Travel Distance: 14 ft and 6 ft separate cable center lines.
cess. Power: 460 VAC, 3 phase Drum guard to help prevent
4-drum compartments with injury.
different diameters for different Slack line detector to prevent
line speeds. shock load if doors jam while
Grooved drums with pressure lowering.
roller bars for uniform winding Rotary and paddle style limit
of wire rope. switches to provide automatic
shut off with overtravel protection.

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26 Thern products are not for lifting people or things over people. S309-0809
 CUSTOM APPLICATIONS
SCREEN RAKE LIFTING WINCH METROPOLITAN WATER DISTRICT
PROBLEM SOLUTION
to lift screen rakes out of electric winch system
water canal for removal of with two part rigging and
debris. custom bolt hole pattern to
meet existing requirements.

PRODUCT FEATURES
Load Rating: 9,000 lb to deliver 18,000 lb with two-part rigging
Line Speed: 10 fpm
Travel Distance: 17 ft
Power: 460 VAC, 3 Phase
Narrow drum to accommodate short fleet angle distance.
Epoxy finish for durability in corrosive environment.

CONVEYOR MAINTENANCE WINCH COAL MINE IN WYOMING

PROBLEM SOLUTION
to lift a 50 ton conveyor winch mounted at top of
counterweight in gravity tower with two separate
take up tower during rou- two-part rigging lines to
tine conveyor maintenance. load.
Photo: Chmee

PRODUCT FEATURES
Load Rating: 56,000 lb to deliver 100,000 lb with two-part rigging
Line Speed: 18 fpm
Travel Distance: 50 ft
Power: 460 VAC, 3 phase
Dual compartment drum for two lift lines.
Controls with pendant for remote operation.

RAIL CAR PULLING WINCH SHIP UNLOADING TERMINAL IN CHILE

PROBLEM SOLUTION
to position up to ten railcars closed loop, single winch
during loading and un- system to move large loads
loading process. in two directions.
Photo: Chris McKenna
PRODUCT FEATURES
Load Rating: 30,000 lb
Line Speed: 40 fpm
Travel Distance: 625 ft
Power: 380 VAC, 3 phase, 50 hertz.
Extended grooved drum for single layer wrapping and uniform
speed.
Chain driven rotary limit switch to limit travel in both directions.
Epoxy gray finish for improved corrosion resistance in marine
environment.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 27
 CUSTOM APPLICATIONS
SUBMERGED LID LIFTING WINCH NUCLEAR POWER PLANT
PROBLEM SOLUTION
to raise hinged lids during removal of overhead mounted winch to provide
fuel rods from cylinders in a smooth lifting control.
cooling pool.
Photo: Simone Ramella
PRODUCT FEATURES
Load Rating: 4,000 lb
Line Speed: 10 fpm
Travel Distance: 8 ft
Power: 460 VAC, 3 phase
Variable speed controls for smooth
operation and overload protection.
Stainless steel drum and white epoxy finish for corrosion resistance.
Rotary limit switch to limit travel in both directions.
Grooved drum for uniform winding of wire rope.

LAUNCH WAY RETRIEVAL WINCH BARGE MANUFACTURER

PROBLEM SOLUTION
to pull barges into position during large capacity winch system to move
production at ship building and repair barges.
facility.

Photo: Alexander Solch PRODUCT FEATURES

Load Rating: 20,000 lb
Line Speed: 54 fpm
Travel Distance: 600 ft
Power: 460 VAC, 3 phase
Manual clutch to disengage drum for quick payout of unloaded cable.
Level wind to accommodate short fleet angle distances.

DREDGE POSITIONING WINCHES COUNTY WATER DISTRICT

PROBLEM SOLUTION
economical continuous back and forth positioning of multiple winch systems operating simultaneously from dif-
floating dredges in water settling basin. ferent locations around the basin.

PRODUCT FEATURES
Load Rating: 12,000 lb
Line Speed: 15 fpm
Travel Distance: 1,600 ft
Power: 460 VAC, 3 phase
Drum guard to help prevent injury.
Programmable computerized variable speed controls for automatic
operation.
Extended length drum with single layer wrapping for uniform
tensioning.

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28 Thern products are not for lifting people or things over people. S309-0809
 CUSTOM APPLICATIONS
CASCADING CHUTE POSITIONING WINCH BULK HANDLING FACILITY
PROBLEM SOLUTION
to vertically position cascading load winch system with two lift lines for
out chute during barge loading pro- controlled positioning of chute.
cess.
PRODUCT FEATURES
Load Rating: 9,800 lb
Line Speed: 15 fpm
Travel Distance: 40 ft
Power: 460 VAC, 3 phase
Grooved drum for uniform spooling of wire rope.
Non-standard drum length to increase cable capacity.
Rotary limit switch to limit travel in both directions.
Two cable anchors to accommodate two lift lines.
Custom color epoxy finish to meet customer’s safety specifications.

ACCOMMODATION LADDER WINCH SERVICE VESSEL OPERATOR

PROBLEM SOLUTION
to raise and lower service small, conveniently located
vessel accommodation winch for controlled posi-
ladder during boarding and tioning of ladder.
disembarking.

PRODUCT FEATURES
Load Rating: 1,500 lb
Line Speed: 65 fpm
Travel Distance: 65 ft
Power: 460 VAC, 3 phase
Pressure roller bar for uniform winding of wire rope.
Stainless steel control enclosure and epoxy finish for corrosion
resistance in marine environment.

ORBITER DOOR POSITIONING WINCH AEROSPACE COMPANY

PROBLEM SOLUTION
to open and close large steel orbiter closed loop winch system to pull
door at launch platform during pre- protective door in front of orbiter.
launch operations.
PRODUCT FEATURES
Load Rating: 65,000 lb
Line Speed: 13 fpm
Travel Distance: 63 ft
Power: 460 VAC, 3 phase
Single drum with two cable anchors for closed loop operation.
Grooved drum for uniform winding of cable.
Rotary limit switch to limit travel in both directions.
Yellow epoxy finish provides protection in harsh environment.
Variable speed controls with encoder for accurate positioning and
soft starting and stopping.

www.thern.com 1.800.843.7648
S309-0809 Thern products are not for lifting people or things over people. 29
A REPUTATION OF EXCELLENCE.
By the time he returned from his Air Force duty during World War II, Royal G. Thern, or Roy for
short, had already spent his lifetime around large machines and heavy equipment. Settling in to
the small town of Winona, Minnesota with his wife Lucille, the two combined their knowledge
to create a lever-operated chain hoist and a differential chain hoist. It was the beginning of a
long tradition of lifting and pulling innovation.

Today, Thern continues it’s 60-year tradition of excellence by providing standard and
customized load handling equipment to leading companies all around the world. The company
offers lifting and pulling solutions to a variety of industries, including aerospace, bulk material
handling, construction, manufacturing, oil and gas, and water/wastewater.

Thern Incorporated • 5712 Industrial Park Road • PO Box 347 • Winona, MN • 55987
507.454.2996 • 1.800.843.7648 • fax: 507.454.5282 • www.thern.com • e-mail: [email protected]

S309-0809
 SBEDN9

SHEAVE BLOCKS
SUPERLIFT is the number one sheave block brand in Australia. Whether working deep in an
underground mine, an oil platform, or in defense and construction industries, there’s a block to
suit every job. And all combine SUPERLIFT's legendary reliability and strength with world-
leading manufacturing technology. SUPERLIFT Hoist products make heavy work easy.

SUPER LIFT ENGINEERING PTY LTD

Copyright All Rights Reserved 2015
About Us
From its establishment in 1988 SuperLift has built a solid reputation for high quality safe, strong reliable lifting equipment. We have rapidly
become the world's largest and leading manufacturer of Australian made industrial lifting and rigging equipment. The satisfaction of our
customers is our number one concern... and it's their number one concern as well. That's why they keep coming back to SuperLift. They
won’t accept anything but the best and you shouldn't either.

Our customers know... SuperLift provides superior products at competitive prices. Call today for the quality, reliability, competitive pricing,
and full service you deserve.

Our manufacturing facility incorporates the latest in robotic manufacturing technology, computer aided design and manufacturing processes.
With the latest in technology we would have the most advanced facility in Australia for the manufacture of industrial lifting equipment.
Looking ahead, SuperLift's focus is clearly aimed at better serving the total needs of our customers. Further investment in manufacturing
technology and equipment will expand our product offering, providing more solutions to our customers' lifting needs.

SuperLift's commitment is to continue to research and develop/manufacture high quality safe, strong reliable lifting equipment to meet the
current and future needs of our customers. Meeting the demands of the increasingly complex, quality-conscious industrial world market is a
challenge we gladly accept.

This Data book has been produced to assist the salesperson, engineer, draftsperson, or rigger in selecting correct equipment for their
particular use. Do not hesitate to contact Superlift's technical advice department if you require any further information.

Our Facility
Our manufacturing facility incorporates the latest in robotic manufacturing technology, computer aided design and manufacturing processes.
Product testing utilizing our vertical and horizontal testing machine. With the latest in technology we would have the most advanced facility in
Australia for the manufacture of industrial lifting equipment.

Looking ahead, SuperLift's focus is clearly aimed at better serving the total needs of our customers. Further investment in manufacturing
technology and equipment will expand our product offering, providing more solutions to our customers' lifting needs.

Although all data contained in this data book / price list has been carefully compiled to make the information as complete as possible.
Superlift Engineering Pty Ltd will not be liable for any direct, indirect or consequential loss arising from the use of the information and material contained within this publication
Copyright © 1988 - 2015 Superlift Engineering Pty Ltd
All rights reserved. No part of this publication may be reproduced, or copied in any form or by any means without the prior written permission of Superlift Engineering Pty Ltd.
The copyright in the material contained within this publication belongs to Superlift Engineering Pty Ltd.

Ph: +(613) 9357 0277 visit us at www.superlift.com.au Fax: +(613) 9357 0621
 Contents
Description Page
Lifting Device – General Precautions 1
Reeving Of Sheave Blocks 2
Sheave Block Maintenance Information 3
Hand Operated Sheave Blocks to AS2089 60mm to 76mm 4
Hand Operated Sheave Blocks to AS2089 89mm to 114mm 5
Hand Operated Sheave Blocks to AS2089 127mm to 178mm 6
Hand Operated Sheave Blocks to AS2089 203mm to 254mm 7
Power Operated Sheave Blocks to AS2089 152mm to 300mm 8
Power Operated Sheave Blocks to AS2089 350mm to 450mm 9
Gin or Rubbish Blocks 9
Super Snatch Blocks 10
Hand Operated Sheaves to AS2089 11
Power Operated Sheaves to AS2089 11
Heavy Duty Sheaves 11
Special Purpose Blocks 12
Aerial Conductor Stringing Blocks 13
Heavy Duty Vertical Lead Blocks (AS1418) 14
Base Mounted Vertical Lead Blocks (AS2089) 15
Custom Products - Gallery 16
Quotation Template – Custom Sheaves 17
Quotation Template – Custom Sheave Blocks 18
Quotation Template – Custom Crane Blocks 19
Quotation Template – Custom Machined Hooks 20
Quotation Template – Custom Safety Latch Kits 21
Testing And Inspection 22
Terms & Conditions of Sale 23
Conversion Tables 24

Ph: +(613) 9357 0277 visit us at www.superlift.com.au Fax: +(613) 9357 0621
WARNING
LIFTING DEVICE - GENERAL PRECAUTIONS

LOAD RATINGS STATED ON ALL SUPERLIFT LIFTING DEVICES ARE APPLICABLE TO NEW OR AS NEW PRODUCTS ONLY AND APPLY TO THE MAXIMUM LOAD WHICH MAY BE SUPPORTED BY THE
HEAD FITTING, UNDER NORMAL ENVIRONMENTAL CONDITIONS, SHOCK LOADINGS MUST BE TAKEN INTO ACCOUNT WHEN SELECTING LOAD RATINGS ON LIFTING DEVICES AS THESE LOADS
ARE MUCH GREATER THAN STATIC LOADS. THE WORKING LOAD LIMIT (W.L.L.) OR SAFETY FACTOR ON ALL SUPERLIFT PRODUCTS MAY BE AFFECTED BY WEAR, MISUSE, OVERLOADING,
DEFORMATION, CORROSION OR OTHER CONDITIONS, REGULAR INSPECTION MUST BE CARRIED OUT TO DETERMINE WHETHER USE CAN BE CONTINUED OR THE PRODUCT WITHDRAWN FROM
SERVICE, SUPERLIFT LIFTING DEVICES SHOULD BE USED BY EXPERIENCED TRAINED PERSONNEL FAMILIAR WITH HOISTING SYSTEMS.

All the products manufactured by SUPERLIFT are sold with the express understanding that the purchaser is thoroughly familiar with the safe and proper use and
application of the product.

Responsibility for the use and application of the products rests with the user.

SUPERLIFT products are generally intended for tension or pull loads, side loading must be never be applied, as it exerts additional force or loading which the product is
not designed to accommodate.

Failure of the product can occur due to incorrect use, misapplication, abuse, or improper maintenance. Product failure could result in property damage, personal injury or
death.

 WORKING LOAD LIMIT - The maximum load or force the product is authorized to support in a particular service.
 PROOF LOAD - The average force to which a product may be subjected to before deformation occurs.
 SHOCK LOAD - A force that results from the rapid acceleration of a static load (jerking), these loads add significantly to the static load.
 STATIC LOAD - A constantly applied force or load.

 IMPROPER: Use of lifting devices could result in death or serious injury to avoid this -
 NEVER: Exceed working load limit
 NEVER: Hoist loads over or near people
 NEVER: Work under or near hoisted loads
 ALWAYS: Operate, inspect and maintain lifting equipment in accordance with all relevant safety standards.

WHEN ATTACHING OR MOVING A LOAD, THE OPERATOR / RIGGER, MUST MAKE SURE OF ALL OF THE FOLLOWING:

 The hoisting rope is free of kinks or twists and not wrapped around the load.
 The load is attached to the Crane Hook by means of a sling or other approved device allowing for single or duplex (rams horn) hooks.
 The sling and load will clear all obstacles or obstructions.
 The load is balanced and secured before lifting the load more than a few inches.
 Multiple lines are not twisted around each other.
 The hook is brought over the load in a manner to prevent swinging.
 There is no sudden acceleration or deceleration of the moving load.
 Do not allow anyone to ride on a load or hooks.
 Do not attempt lifts beyond the rated load capacity of a crane or slings.
 Do not lift a load from the side. Centre the crane directly over the load before hoisting to avoid swinging the load.
 Do not leave suspended loads unattended.

Spare parts are available from SUPERLIFT & authorized resellers; replace all worn or damaged parts.
USE ONLY GENUINE SUPERLIFT SPARE PARTS WHEN REPAIRING OR SERVICING SUPERLIFT PRODUCTS

1 All specifications & dimensions are subject to change without notice.

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
REEVING OF SHEAVE BLOCKS
When reeving a pair of sheave blocks one of which has more than two
sheaves the lead line should come off one of the centre sheaves of the
upper block to prevent toppling of the upper block and possible damage
to the rope. Always start reeving from the becket and avoid chaffing the
rope on the side plates, when you have completed reeving, the bottom
block must be at right angles to the top block as in Fig. 1.

The upper block has a greater hook load due to the pull on the lead rope.

The sheaves in these blocks revolve at different speeds; those nearest

the lead line rotate at the highest speed therefore wear out faster. For
applications, which require heavy lifting or high-speed operation, bronze
bushes or roller bearings should be specified when ordering.

LOADS ON SHEAVE BLOCKS

ANGLE Deg. FACTOR
A single sheave block used to change load line direction can be 0 2.00
subjected to total loads greatly different from the weight being lifted or 10 1.99
pulled. The total load value varies with the angle of wrap between the
20 1.97
incoming and departing lines to the block.
30 1.93
40 1.87
In the following chart multiply the factor by the line pull to obtain the total
45 1.84
load on the block as in Fig. 2.
50 1.81
60 1.73
E.g. Total Load = Line Pull x Factor Fig. 2 70 1.64
80 1.53
90 1.41
100 1.29
110 1.15
120 1.00
130 .84
140 .68
150 .52
160 .30
170 .17
180 .00

All specifications & dimensions are subject to change without notice. 2

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
 SHEAVE BLOCK - MAINTENANCE INFORMATION
SAFETY OF PERSONNEL
The regulatory authority may require that it be notified where a sheave block is to be used for personnel lifting.

STORAGE
Sheave blocks and ropes should be periodically overhauled and, when not in use, carefully stored in a satisfactory environment.

USE
Prior to use, sheave blocks should be thoroughly examined to determine whether they are safe to use, for their intended application,
they should only be used in a manner in which they are designed for.

Sheave blocks must be regularly inspected, lubricated and maintained for peak efficiency and extended usefulness
The frequency of inspection depends upon frequency and period of product use as well as environmental conditions, which are
contingent upon the user’s good judgement.

SPECIAL ATTENTION SHOULD BE GIVEN TO THE FOLLOWING PRIOR TO USE

a) Rope Groove, Examine the fit of the rope in the grooves of the sheaves to ensure that the grooves are correct for the rope size. A
worn sheave groove will result in a high rate of rope wear, particularly when a new rope is first reeved.

b) Hook, Check for damage, cracks, nicks, gouges, deformations of the throat opening, wear on saddle or load bearing point, and twist.

c) Safety Latch, Examine the safety latch for correct operation, deformation, broken springs etc

d) Swivel Head Fitting, Examine the nut or collar of the shank to ensure that it is securely fastened and free from visible defects, check
that the shank is not distorted and turns freely by hand, and that the clearance is not excessive. Grease or oil the shank and the
bearing surface of the nut or collar, if thrust bearings are fitted these must also be greased or oiled periodically depending on the
severity of use.

e) Side Straps and Side Plates, Examine for fractures, stretching, buckling, distortion and wastage due to corrosion. Buckled or distorted
side plates may allow the rope to jam between the sheave and the side or partition plate.

f) Sheaves, Examine the rope grooves for excessive wear and surface defects (e.g. bruising, chipping cracking etc) that may damage
the rope during use. The sheave should be checked to see that it turns freely on the axle and that the bush or bearing is not
excessively worn.

g) Axles, Examine axles for wear, and check that they are retained as intended.

h) Bearings & Bushes, (where fitted) make sure product rotates freely without any signs of binding.

i) Fasteners, Examine the security of nut’s bolts and other locking methods, especially after reassembly following a tear down
inspection.

j) Lubrication, Where provision is made for lubrication, ensure that the sheave block is adequately lubricated. If the block is not
lubricated regularly, its life is greatly reduced, and the efficiency of the tackle is impaired.

k) Painting, Do not paint the block in such a manner that free movement is impaired or lubrication points or grease nipples become
clogged. It is especially important that load or reference markings are not obliterated.

l) Heating, After any exposure of a block to temperatures exceeding 200 degrees Celsius (such as from a furnace, welding etc) that may
affect its serviceability, the block should be returned to SuperLift for evaluation.

m) Temperature Limits, Permissible ambient conditions for SUPERLIFT products are -40 degrees Celsius to +60 degrees Celsius & 100
% humidity.

n) Wear Limits, Maximum permissible wear at load bearing points on SUPERLIFT products is10 %

o) Replacement Parts, Use only genuine SUPERLIFT replacement parts.

Spare parts are available from SUPERLIFT & authorized resellers; replace all worn or damaged parts.
USE ONLY GENUINE SUPERLIFT SPARE PARTS WHEN REPAIRING OR SERVICING SUPERLIFT PRODUCTS

3 All specifications & dimensions are subject to change without notice.

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Hand Operated Sheave Blocks (AS 2089)
SuperLift sheave blocks range from 60mm dia. to 254mm dia. Hand operated and 152mm dia to 450mm dia Power operated, in snatch,
single, double and treble configurations.

Features:
 Safety latch fitted to hook as standard
 Drop forged swivel Hook or Eye
 Cast iron and steel machined sheaves to suit either wire rope or fibre rope
 Power operated blocks are fitted with high capacity bushes and beckets as standard
 Power operated blocks are fitted with a grease nipple to enable pressure grease lubrication
 Identification labels to show capacities and other relevant details
 Painted SuperLift industrial grey enamel

Optional Features P.O.A.:

 With ball or roller bearing
 With special grooves to suit other rope sizes
 Special coatings e.g. Zinc plated, Galvanizing, Epoxy Paints etc.
 Sheave blocks can be manufactured to suit any application.
 Test certificates only if requested at time of order.

Rope
Sheave WLL Rope Head Product Bush U/W
Type Dia. A B C D E F
Dia. (G) Kg Type Fitting Code Fitted Kg
(mm)
Eye SBH-001-ME
Fibre 10
Hook SBH-001-MH
Single 500 Eye SBH-001-WE
YES 168 35 1.0
Wire 5
Hook SBH-001-WH
Eye SBH-002-ME
Fibre 10
Hook SBH-002-MH
Double 500 Eye SBH-002-WE
YES 168 59 1.6
Wire 5
60 Fibre 10
Hook
Eye
Hook
SBH-002-WH
SBH-003-ME
SBH-003-MH
Treble 500 Eye SBH-003-WE
YES 168 83 1.8
Wire 5
Hook SBH-003-WH
Eye SBH-004-ME
Fibre 10
Hook SBH-004-MH
Snatch 500 Eye SBH-004-WE
YES 173 41 1.2
Wire 5
Hook SBH-004-WH
Eye SBH-011-ME
Fibre 12
Hook SBH-011-MH
Single 500 Eye SBH-011-WE
YES 189 35 1.0
Wire 6
Hook SBH-011-WH
Eye SBH-012-ME
Fibre 12
Hook SBH-012-MH
Double 500 Eye SBH-012-WE
YES 189 59 1.7
Wire 6
76 Fibre 12
Hook
Eye
Hook
SBH-012-WH
SBH-013-ME
SBH-013-MH
Treble 500 Eye SBH-013-WE
YES 189 83 2.0
Wire 6
Hook SBH-013-WH
Eye SBH-014-ME
Fibre 12
Hook SBH-014-MH
Snatch 500 Wire 6 Eye SBH-014-WE
YES 194 41 1.3
Hook SBH-014-WH

Special Sheave Blocks can be manufactured to suit any application.

All specifications & dimensions are subject to change without notice. 4

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Hand Operated Sheave Blocks (AS 2089)

Rope
Sheave WLL Rope Head Product Bush U/W
Type Dia. A B C D E F
Dia. (G) Kg Type Fitting Code Fitted Kg
(mm)
Eye SBH-021-ME
Fibre 14
Hook SBH-021-MH
Single 650 Eye SBH-021-WE
YES 253 38 1.7
Wire 7
Hook SBH-021-WH
Eye SBH-022-ME
Fibre 14
Hook SBH-022-MH
Double 650 Eye SBH-022-WE
YES 253 64 2.5
Wire 7
89 Fibre 14
Hook
Eye
Hook
SBH-022-WH
SBH-023-ME
SBH-023-MH
Treble 650 Eye SBH-023-WE
YES 253 87 3.4
Wire 7
Hook SBH-023-WH
Eye SBH-024-ME
Fibre 14
Hook SBH-024-MH
Snatch 650 Eye SBH-024-WE
YES 258 51 2
Wire 7
Hook SBH-024-WH
Eye SBH-031-ME
Fibre 16
Hook SBH-031-MH
Single 1000 Eye SBH-031-WE
YES 276 48 2.2
Wire 8
Hook SBH-031-WH
Eye SBH-032-ME
Fibre 16
Hook SBH-032-MH
Double 1000 Eye SBH-032-WE
YES 276 79 3.6
Wire 8
102 Fibre 16
Hook
Eye
Hook
SBH-032-WH
SBH-033-ME
SBH-033-MH
Treble 1000 Eye SBH-033-WE
YES 276 112 5
Wire 8
Hook SBH-033-WH
Eye SBH-034-ME
Fibre 16
Hook SBH-034-MH
Snatch 1000 Eye SBH-034-WE
YES 281 41 2.8
Wire 8
Hook SBH-034-WH
Eye SBH-041-ME
Fibre 18
Hook SBH-041-MH
Single 1250 Eye SBH-041-WE
YES 322 48 2.8
Wire 9
Hook SBH-041-WH
Eye SBH-042-ME
Fibre 18
Hook SBH-042-MH
Double 1250 Eye SBH-042-WE
YES 322 79 4.6
Wire 9
114 Fibre 18
Hook
Eye
Hook
SBH-042-WH
SBH-043-ME
SBH-043-MH
Treble 1250 Eye SBH-043-WE
YES 322 112 6.4
Wire 9
Hook SBH-043-WH
Eye SBH-044-ME
Fibre 18
Hook SBH-044-MH
Snatch 1250 Eye SBH-044-WE
YES 339 58 3.6
Wire 9
Hook SBH-044-WH
Special Sheave Blocks can be manufactured to suit any application.
5 All specifications & dimensions are subject to change without notice.
Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Hand Operated Sheave Blocks (AS 2089)

Rope
Sheave WLL Rope Head Product Bush U/W
Type Dia. A B C D E F
Dia. (G) Kg. Type Fitting Code Fitted Kg
(mm)
Eye SBH-051-ME
Fibre 20
Hook SBH-051-MH
Single 1500 Eye SBH-051-WE
Option 333 61 4.2
Wire 10
Hook SBH-051-WH
Eye SBH-052-ME
Fibre 20
Hook SBH-052-MH
Double 1500 Eye SBH-052-WE
Option 333 95 6.4
Wire 10
127 Fibre 20
Hook
Eye
Hook
SBH-052-WH
SBH-053-ME
SBH-053-MH
Treble 1500 Eye SBH-053-WE
Option 333 131 8.4
Wire 10
Hook SBH-053-WH
Eye SBH-054-ME
Fibre 20
Hook SBH-054-MH
Snatch 1500 Eye SBH-054-WE
Option 350 61 4.1
Wire 10
Hook SBH-054-WH
Eye SBH-061-ME
Fibre 24
Hook SBH-061-MH
Single 2000 Eye SBH-061-WE
Option 380 71 5.8
Wire 12
Hook SBH-061-WH
Eye SBH-062-ME
Fibre 24
Hook SBH-062-MH
Double 3000 Eye SBH-062-WE
Option 380 107 9.2
Wire 12
152 Fibre 24
Hook
Eye
Hook
SBH-062-WH
SBH-063-ME
SBH-063-MH
Treble 4000 Eye SBH-063-WE
Option 380 144 12.8
Wire 12
Hook SBH-063-WH
Eye SBH-064-ME
Fibre 24
Hook SBH-064-MH
Snatch 2000 Eye SBH-064-WE
Option 396 71 5.4
Wire 12
Hook SBH-064-WH
Eye SBH-071-ME
Fibre 28
Hook SBH-071-MH
Single 2500 Eye SBH-071-WE
YES 443 83 9
Wire 14
Hook SBH-071-WH
Eye SBH-072-ME
Fibre 28
Hook SBH-072-MH
Double 3750 Eye SBH-072-WE
YES 443 126 14.8
Wire 14
178 Fibre 28
Hook
Eye
Hook
SBH-072-WH
SBH-073-ME
SBH-073-MH
Treble 5000 Eye SBH-073-WE
YES 443 169 20.6
Wire 14
Hook SBH-073-WH
Eye SBH-074-ME
Fibre 28
Hook SBH-074-MH
Snatch 2500 Eye SBH-074-WE
YES 443 83 8.6
Wire 14
Hook SBH-074-WH
Special Sheave Blocks can be manufactured to suit any application.
All specifications & dimensions are subject to change without notice. 6
Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Hand Operated Sheave Blocks (AS 2089)

Rope
Sheave WLL Rope Head Product Bush U/W
Type Dia. A B C D E F
Dia. (G) Kg Type Fitting Code Fitted Kg
(mm)
Eye SBH-081-ME
Fibre 32
Hook SBH-081-MH
Single 4000 Eye SBH-081-WE
Option 500 94 13.4
Wire 16
Hook SBH-081-WH
Eye WHWHWH
SBH-082-ME
Fibre 32
Hook SBH-082-MH
Double 6000 Eye SBH-082-WE
Option 500 157 22
Wire 16
203 Fibre 32
Hook
Eye
Hook
SBH-082-WH
SBH-083-ME
SBH-083-MH
Treble 8000 Eye SBH-083-WE
Option 500 198 31
Wire 16
Hook SBH-083-WH
Eye SBH-084-ME
Fibre 32
Hook SBH-084-MH
Snatch 4000 Eye SBH-084-WE
Option 500 94 13.8
Wire 16
Hook SBH-084-WH
Eye SBH-091-ME
Fibre 36
Hook SBH-091-MH
Single 5000 Eye SBH-091-WE
YES 607 107 22.4
Wire 18
Hook SBH-091-WH
Eye SBH-092-ME
Fibre 36
Hook SBH-092-MH
Double 7500 Eye SBH-092-WE
YES 607 168 36.9
Wire 18
229 Fibre 36
Hook
Eye
Hook
SBH-092-WH
SBH-093-ME
SBH-093-MH
Treble 10000 Eye SBH-093-WE
YES 607 229 50.7
Wire 18
Hook SBH-093-WH
Eye SBH-094-ME
Fibre 36
Hook SBH-094-MH
Snatch 5000 Eye SBH-094-WE
YES 607 107 23.4
Wire 18
Hook SBH-094-WH
Eye SBH-101-ME
Fibre 40
Hook SBH-101-MH
Single 6000 Eye SBH-101-WE
YES 643 114 28.2
Wire 20
Hook SBH-101-WH
Eye SBH-102-ME
Fibre 40
Hook SBH-102-MH
Double 9000 Eye SBH-102-WE
YES 643 183 46.6
Wire 20
254 Fibre 40
Hook
Eye
Hook
SBH-102-WH
SBH-103-ME
SBH-103-MH
Treble 12000 Eye SBH-103-WE
YES 643 252 70.6
Wire 20
Hook SBH-103-WH
Eye SBH-104-ME
Fibre 40
Hook SBH-104-MH
Snatch 6000 Eye SBH-104-WE
YES 643 114 29
Wire 20
Hook SBH-104-WH
Special Sheave Blocks can be manufactured to suit any application.
7 All specifications & dimensions are subject to change without notice.
Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Power Operated Sheave Blocks (AS 2089)

Rope
Sheave WLL Rope Head Product Bush U/W
Type Dia. A B C D E F
Dia. (G) Kg Type Fitting Code Fitted Kg
(mm)
Eye SBP-061-E
Single 2000 Wire 8
Hook SBP-061-H
YES 380 71 5.8
Eye SBP-062-E
Double 3000 Wire 8 YES 380 107 9.2
152 Treble 4000 Wire 8
Hook
Eye
Hook
SBP-062-H
SBP-063-E
SBP-063-H
YES 380 144 12.8
Eye SBP-064-E
Snatch 2000 Wire 8
Hook SBP-064-H
YES 396 71 5.5
Eye SBP-071-E
Single 2500 Wire 10
Hook SBP-071-H
YES 443 83 9
Eye SBP-072-E
Double 3750 Wire 10 YES 443 126 15.2
178 Treble 5000 Wire 10
Hook
Eye
Hook
SBP-072-H
SBP-073-E
SBP-073-H
YES 443 169 21.2
Eye SBP-074-E
Snatch 2500 Wire 10
Hook SBP-074-H
YES 443 83 9
Eye SBP-081-E
Single 4000 Wire 12
Hook SBP-081-H
YES 500 94 13.8
Eye SBP-082-E
Double 6000 Wire 12 YES 500 157 22.8
203 Treble 8000 Wire 12
Hook
Eye
Hook
SBP-082-H
SBP-083-E
SBP-083-H
YES 500 198 32.2
Eye SBP-084-E
Snatch 4000 Wire 12
Hook SBP-084-H
YES 500 94 14.2
Eye SBP-091-E
Single 5000 Wire 13
Hook SBP-091-H
YES 607 107 23
Eye SBP-092-E
Double 7500 Wire 13 YES 607 168 37.9
229 Treble 10000 Wire 13
Hook
Eye
Hook
SBP-092-H
SBP-093-E
SBP-093-H
YES 607 229 51.3
Eye SBP-094-E
Snatch 5000 Wire 13
Hook SBP-094-H
YES 607 107 24
Eye SBP-101-E
Single 6000 Wire 14
Hook SBP-101-H
YES 643 114 28.8
Eye SBP-102-E
Double 9000 Wire 14 YES 643 183 47.5
254 Treble 12000 Wire 14
Hook
Eye
Hook
SBP-102-H
SBP-103-E
SBP-103-H
YES 643 252 68.1
Eye SBP-104-E
Snatch 6000 Wire 14
Hook SBP-104-H
YES 643 114 29.5
Eye SBP-111-E
Single 8000 Wire 16
Hook SBP-111-H
YES
Eye SBP-112-E SPECIFICATIONS
Double 12000 Wire 16 YES
300 Treble 16000 Wire 16
Hook
Eye
Hook
SBP-112-H
SBP-113-E
SBP-113-H
YES
AVAILABLE UPON
APPLICATION
Eye SBP-114-E
Snatch 8000 Wire 16
Hook SBP-114-H
YES
Special Sheave Blocks can be manufactured to suit any application.

All specifications & dimensions are subject to change without notice. 8

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Power Operated Sheave Blocks (AS 2089)

Rope
Sheave WLL Rope Head Product Bush U/W
Type Dia. A B C D E F
Dia. (G) Kg Type Fitting Code Fitted Kg
(mm)
Eye SBP-121-E
Single 10000 Wire 20
Hook SBP-121-H
YES
Eye SBP-122-E
Double 15000 Wire 20 YES
350 Treble 20000 Wire 20
Hook
Eye
Hook
SBP-122-H
SBP-123-E
SBP-123-H
YES
Eye SBP-124-E
Snatch 10000 Wire 20
Hook SBP-124-H
YES
Eye SBP-131-E
Single 10000 Wire 24
Hook SBP-131-H
YES

Double 15000 Wire 24

Eye SBP-132-E
YES SPECIFICATIONS
400 Treble 20000 Wire 24
Hook
Eye
SBP-132-H
SBP-133-E
YES
AVAILABLE UPON
Hook SBP-133-H APPLICATION
Eye SBP-134-E
Snatch 10000 Wire 24
Hook SBP-134-H
YES
Eye SBP-141-E
Single 10000 Wire 26
Hook SBP-141-H
YES
Eye SBP-142-E
Double 15000 Wire 26 YES
450 Treble 20000 Wire 26
Hook
Eye
Hook
SBP-142-H
SBP-143-E
SBP-143-H
YES
Eye SBP-144-E
Snatch 10000 Wire 26
Hook SBP-144-H
YES
Special Sheave Blocks can be manufactured to suit any application.

Gin or Rubbish Blocks (AS 2089)

SuperLift Gin or Rubbish Blocks are lightweight blocks widely used by roofers,
bricklayers and contractors for hoisting materials up high rise buildings.

Features:
 Lightweight heavy-duty steel construction
 Drop forged Swivel Eye as standard
 Hook type made to order only, minimum quantities apply.
 Identification labels to show capacities and other relevant details
 Supplied painted SuperLift Industrial grey enamel

WLL Sheave Fibre Rope

Product Code Type Bush Fitted U/W Kg
Kg. Dia. (mm) (mm)
GIN 001 E 1000 Single 250 22 No 6
GIN 001 BE 1000 Single 250 22 Yes 6
GIN 001 22 1000 Sheave Only 250 22 No 3
9 All specifications & dimensions are subject to change without notice.
Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Super Snatch Blocks (AS 2089)
SuperLift Super Snatch blocks are generally used in the construction, heavy recovery and shipping industries. They are small HIGH
CAPACITY blocks most commonly used for equalizer applications.
Features: Optional Features - P.O.A.
 Special rope groove profile to suit both dyneema & wire ropes
 Lightweight heavy-duty construction.  With ball or roller bearing
 Special high capacity bushes and grease nipple fitted as standard.  With special groove profiles to suit other rope sizes
 Safety screw pins fitted as standard c/w safety locking clip.  Special coatings e.g. Zinc plated, Galvanizing, Epoxy Paints etc.
 Interchangeable and removable head fittings.  Sheave blocks can be manufactured to suit any application.
 Supplied painted SuperLift Industrial grey enamel.  Thrust bearings if blocks are to rotate under load.
 Spare parts are always available.  Test certificates only if requested at time of order.

Sheave Dia. Wire Rope WLL Product U/W

Type A B C D E
(G) Dia. (mm) Kg Code Kg
Swivel Shackle SSB100S 66 53 333 4.4
Hook SSB100H 66 53 326 4.9
100 10-11 3000 Toggle SSB100T 188 66 53 3.4
Sheave Only SSB10010 2
Swivel Shackle SSB150S4 100 67 418 8.8
Hook SSB150H4 100 67 415 9.2
150 12-14 4500 Toggle SSB150T4 256 100 67 6
Sheave Only SSB15012 2.2
Swivel Shackle SSB150S 108 88 490 12
Hook SSB150H 108 88 472 12.3
150 16-18 8000 Toggle SSB150T 280 108 88 8
Sheave Only SSB15018 3.2
Swivel Shackle SSB200S 108 88 540 15.2
Hook SSB200H 108 88 522 15.5
200 18-20 8000 Toggle SSB200T 330 108 88 11
Sheave Only SSB20020 4.2
Swivel Shackle SSB250S 156 107 684 31.4
Hook SSB250H 156 107 615 33
250 22 10000 Toggle SSB250T 427 156 107 25
Sheave Only SSB25022 9.4
Swivel Shackle SSB300S 164 123 798 45
Hook SSB300H 164 123 748 48
300 26 15000 Toggle SSB300T 485 164 123 33
Sheave Only SSB30026 13
Swivel Shackle SSB350S 190 125 946 73.6
Hook SSB350H 190 125 890 78
350 28 20000 Toggle SSB350T 585 190 125 53
Sheave Only SSB35028 18
Swivel Shackle SSB400S 208 136 1014 115
Hook SSB400H 208 136 953 124
400 32 25000 Toggle SSB400T 660 208 136 96
Sheave Only SSB40032 32

Swivel shackle type Super Snatch Blocks are to suit standard grade S shackles (not included).
Super Snatch Blocks can be made to suit customer requirements.
All specifications & dimensions are subject to change without notice. 10
Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Sheaves (AS 2089)

HAND OPERATED SHEAVES TO AS 2089

Bush
Sheave Rope Rope Product Standard
Fitted as Shaft (B) C D U/W Kg
Dia. (A) Type Dia. (mm) Code pkt. size
Standard
Wire 5 SBH-001-30
60 12 18 21 0.4
Fibre 10 SBH-001-7
Wire 6 SBH-011-30
76 12 18 21 0.4
Fibre 12 SBH-011-7
Wire 7 SBH-021-30
89 YES 16 18 21 0.42
Fibre 14 SBH-021-7
10
Wire 8 SBH-031-30
102 20 25 28 0.8
Fibre 16 SBH-031-7
Wire 9 SBH-041-30
114 22 25 28 0.9
Fibre 18 SBH-041-7
Wire 10 SBH-051-30
127 OPTION 22 28 31 1.2
Fibre 20 SBH-051-7
Wire 12 SBH-061-30
152 5 OPTION 25 29 32 2.2
Fibre 24 SBH-061-7
Wire 14 SBH-071-30
178 YES 30 36 39 3.4
Fibre 28 SBH-071-7
Wire 16 SBH-081-30
203 OPTION 35 41 46 5.2
Fibre 32 SBH-081-7 1
Wire 18 SBH-091-30
229 45 51 55 8.2
Fibre 36 SBH-091-7
YES
Wire 20 SBH-101-30
254 45 57 62 12.4
Fibre 40 SBH-101-7
POWER OPERATED SHEAVES TO AS 2089
152 8 SBP-061-20 5 25 29 32 2.2
178 10 SBP-071-20 30 36 39 3.4
203 12 SBP-081-20 35 41 46 5.2
229 13 SBP-091-20 45 51 55 8.2
254 14 SBP-101-20 45 57 62 12.4
300 WIRE 16 SBP-111-20 1 YES 50 61 65 18
350 20 SBP-124-20 55 56 60 22.5
400 24 SBP-134-20 70 65 69 29
450 26 SBP-144-20 70 65 69 32
500 28 SBP-154-20 80 70 75 41
550 32 SBP-164-20 80 74 80 48
HEAVY DUTY SHEAVES
100 10 - 11 SSB10010 25 25 28 2
5
150 12 - 14 SSB15012 30 29 32 3
150 16 – 18 SSB15018 35 37 40 3
200 18 – 20 SSB20020 35 37 40 4.6
250 WIRE 22 SSB25022 YES 50 48 50 9.0
1
300 26 SSB30026 55 56 60 15.6
350 28 SSB35028 60 56 60 19.4
400 32 SSB40032 70 65 69 30
450 32 SSB45032 70 65 69 32
Special sheaves can be manufactured to suit any application.

11 All specifications & dimensions are subject to change without notice.

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Special Purpose Blocks
Snatch Sling block, Suitable for endless round slings or straps commonly used where hoisted objects require rotation under load
Features,
 Swivel hook with heavy duty safety latch
 Fully sealed roller bearings
 Fully enclosed sheave

SNATCH SLING BLOCK

Product Code WLL Kg Sheave Ø Strap / Sling U/W Kg
SSB50H 750 50 50 2.4

Single Head block, Suitable for offshore industries, most commonly used as the upper block for lifeboats on offshore platforms or ships
Features,
 Full stainless steel construction
 Fully sealed roller bearings

SINGLE HEAD BLOCK

Product Code WLL Kg Sheave Ø Wire Ø U/W Kg
SB150SS 8000 150 14 12

Snatch Mooring block, Suitable for offshore industries, most commonly used as quick rope release for ship mooring applications
Features,
 Hot dipped galvanised steel construction
 Fully sealed roller bearings
 Very quick and easy rope release design

MOORING BLOCK
Product Code WLL t Sheave Ø Rope Ø U/W Kg
MOR10E 10 250 40 35.1

Snatch Open Sided block, Suitable for offshore industries, most commonly used when quick rope insertion and retrieval is required
Features,
 Level Balanced steel construction
 Fully sealed roller bearings.

OPEN SIDED BLOCK

Product Code WLL t Sheave Ø Rope Ø U/W Kg
OS1005E 5 100 12 - 50 38.6
OS15010E 10 150 25 - 100 90.4
Special Sheave Blocks can be manufactured to suit any application.

All specifications & dimensions are subject to change without notice. 12

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Aerial Conductor Stringing Blocks
Superlift Stringing Blocks are generally used in the construction, and power transmission industries. They are unique load rated, blocks most
commonly used for aerial conductor installations.

Features:
 Special groove profiles to suit bare ropes, insulated cables or conductors
 High strength lightweight construction for easy handling
 Identification labels to show capacities and other relevant details

Optional Features - P.O.A.

 With ball or roller bearing
 With special groove profiles to suit other conductor sizes.
 Special coatings e.g. Zinc plated, Galvanizing, Epoxy Paints etc.
 Manufactured in stainless steel, for corrosion protection
 Special blocks can be manufactured to suit any application.
 Test certificates only if requested at time of order.

SNATCH BLOCK
Product Code WLL t Sheave Ø Rope / Con Ø U/W Kg
CSB16010E 1.25 160 10 6.8

SNATCH BLOCK
Product Code WLL kg Sheave Ø Rope / Con Ø U/W Kg
CSB15010H 500 150 10 3.8

SNATCH BLOCK
Product Code WLL t Sheave Ø Rope / Con Ø U/W Kg
CSB15032H 2 150 32 6

SNATCH BLOCK
Product Code WLL kg Sheave Ø Rope / Con Ø U/W Kg
CSB10032H 500 100 32 3.7

TREBLE BLOCK
Product Code WLL t Sheave Ø Rope / Con Ø U/W Kg
CTB1308E 2.5 130 8 6.8

QUAD BLOCK
Product Code WLL t Sheave Ø Rope / Con Ø U/W Kg
CQB120160E 5 120/160 10 18.6
EE10E
Special Sheave Blocks can be manufactured to suit any application.

13 All specifications & dimensions are subject to change without notice.

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Heavy Duty Vertical Lead Blocks (AS 1418)
Superlift Heavy duty Lead Blocks are generally used in the mining, and general industries. They are heavy duty, base mounted
blocks most commonly used for rope diversion on conveyors.

Features:
 Fully adjustable rope guard fitted as standard.
 Axles are fitted with a grease nipple to enable pressure grease lubrication
 Identification markings all relevant details
 Three bearing arrangements to choose from see below.
 Industrial zinc phosphate coating as standard

Optional Features - P.O.A.

 With special groove profiles to suit other rope sizes
 Special coatings e.g. Zinc plated, Galvanizing, Epoxy Paints etc.
 Manufactured in stainless steel, for corrosion protection
 Special blocks can be manufactured to suit any application.

Sheave Product Sheave Wire Rope

A B C D E F G H
Overall Dia. Code Only Code Dia (mm)

150 VLB150 - VSH150 - 8 - 12 50 80 100 60 18 100

200 VLB200 - VSH200 - 14 - 16 60 85 105 70 22 125
250 VLB250 - VSH250 - 14 - 20 65 95 120 80 23 150
300 VLB300 - VSH300 - 16 - 26 75 115 145 95 26 180
N/A 4
350 VLB350 - VSH350 - 16 - 32 90 125 170 120 33 216
400 VLB400 - VSH400 - 20 - 32 90 125 170 120 33 235
450 VLB450 - VSH450 - 20 - 32 115 155 255 195 33 260
600 VLB600 - VSH600 - 20 - 32 125 170 290 230 33 345
750 VLB750 - VSH750 - 26 - 40 140 185 140 400 200 33 430
8
900 VLB900 - VSH900 - 26 - 40 170 215 160 470 250 40 520

Determination of Product Code, Example:

150mm Dia. Vertical Lead Block for 10mm wire rope to suit roller bearing, c/w Seal and Seal Plates = VLB150/10/RBS

Bearing Arrangements Available.

 BB, High Capacity Bush
 RB, Sealed Roller Bearing.
 RBS, Sealed Roller Bearing with Triple Labyrinth Seal.

All specifications & dimensions are subject to change without notice. 14

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Base Mounted Lead Blocks (AS 2089)

Superlift Lead Blocks are generally used in the construction, and general industries. They are unique load rated, base mounted
blocks most commonly used for rope diversion or hoisting applications.

Features:
 Special rope groove profile to suit both high strength dyneema & wire ropes
 All blocks are fitted with high capacity bushes and two beckets as standard
 Power operated axles are fitted with a grease nipple to enable pressure grease lubrication
 Identification labels to show capacities and other relevant details
 Painted SuperLift industrial grey enamel

Optional Features - P.O.A.

 With ball or roller bearing.
 With special groove profiles to suit other rope sizes
 Special coatings e.g. Zinc plated, Galvanizing, Epoxy Paints etc.
 Manufactured in stainless steel, for corrosion protection
 Special blocks can be manufactured to suit any application.
 Test certificates only if requested at time of order.

HAND OPERATED LEAD BLOCKS

Product Code Product Code Sheave Only Sheave Ø F WLL Kg Rope Ø A B C D E G H J U/W Kg

BML-076-6 SBH-011-30 76 500 6 83 82 60 60 125.5 44 4 9 0.69

BML-102-8 SBH-031-30 102 1000 8 112 93 80 68 167 60 4 9 1.70
BML-127-10 SBH-051-30 127 1500 10 140 122 100 88 207 75 4 11 3.70
BML-152-12 SBH-061-30 152 2000 12 168 129 120 90 249 90 4 13 5.14
BML-178-14 SBH-071-30 178 2500 14 196 150 140 110 292 107 4 13 10.51
BML-203-16 SBH-081-30 203 4000 16 224 197 160 145 333 120 4 17 16.84
BML-229-18 SBH-091-30 229 5000 18 252 216 180 158 385.5 135 4 22 25.63
BML-254-20 SBH-101-30 254 6000 20 280 223 200 165 422 150 4 22 32.01

POWER OPERATED LEAD BLOCKS

BML-152-8 SBP-061-20 152 2000 8 168 129 120 90 249 90 4 13 5.14
BML-178-10 SBP-071-20 178 2500 10 196 150 140 110 292 107 4 13 10.51
BML-203-12 SBP-081-20 203 4000 12 224 197 160 145 333 120 4 17 16.84
BML-229-13 SBP-091-20 229 5000 13 252 216 180 158 385.5 135 4 22 25.63
BML-254-14 SBP-101-20 254 6000 14 280 223 200 165 422 150 4 22 32.01

15 All specifications & dimensions are subject to change without notice.

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
CUSTOM SHEAVE BLOCKS

40 t Quad 70 t Treble 40 t Quintuple 50 t snatch

CUSTOM CRANE HOOK BLOCKS

Insulated 63 t OHTC Block 50 t Quintuple Mobile Crane 25 t OHTC Block 20 t OHTC Block

CUSTOM LEAD BLOCKS

Inline Quad Vertical Lead Block Inline Double Lead Block 1500 Ø Vertical Lead Block Aluminium High Strength Lead Block

CUSTOM SHEAVES

750 Ø Fully Machined Steel 900 Ø Fully Machined Alloy Steel 1400 Ø Cast Alloy Steel 1930 Ø Cast Iron

Request for quotation forms for custom products are provided in the next few pages.
Fill in and return as indicated for prompt quotation.

All specifications & dimensions are subject to change without notice. 16

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CUSTOM SHEAVES REQUEST FOR
QUOTATION
CUSTOMER NAME DATE

ADDRESS CONTACT NAME

TELEPHONE FAX E-MAIL

SHEAVE
Rope Diameter (E) mm ________
Type of Rope (Please one only)

Fibre 
Wire 
Outside Diameter (A) mm ________
Boss Diameter (B) optional) mm ________
Rim Width (F) mm ________
Boss Width (G) mm ________
Material (if known) _______________________
Quantity ________
Shaft Diameter (D) mm ________
BEARINGS (Please one only)

High Capacity PTFE Bush 

Bronze Bush 
Roller Bearing 
Tapered Roller Bearing 
Bearing Part No. / Other (Please Specify) _______________________
Application / Environmental Conditions Used. _____________________

SPECIAL REQUIREMENTS
Coating (Otherwise standard SuperLift coating system used) _______________________________
Proof Load Testing (Please i if required) 
Other (Please Specify) ______________________
17 All specifications & dimensions are subject to change without notice.
Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
 CUSTOM SHEAVE BLOCKS REQUEST FOR
QUOTATION
CUSTOMER NAME DATE

ADDRESS CONTACT NAME

TELEPHONE FAX E-MAIL

BLOCK
Working Load Limit (At the Head Fitting) ______ Metric Tonnes
Application / Environmental Conditions Used. ___________________________
HEAD FITTING TYPE (Please one only)
Hook Single 
Duplex (Rams Horn) 
Swivel Eye 
Fixed Shackle 
Other (Please Specify) ___________________________
SHEAVES
Number of Sheaves ________
Type of Rope (Please one only)
Fibre 
Wire 
Rope Diameter ________ mm
Becket 
BEARINGS (Please one only)
High Capacity PTFE Bush 
Bronze Bush 
Roller Bearing 
Tapered Roller Bearing 
Other (Please Specify) ___________________________

SPECIAL REQUIREMENTS
Coating (Otherwise standard SuperLift coating system used) ___________________________
Proof Load Testing (Please if required) 
Other (Please Specify) ___________________________

All specifications & dimensions are subject to change without notice. 18

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
 CUSTOM CRANE BLOCKS REQUEST FOR
QUOTATION
CUSTOMER NAME DATE

ADDRESS CONTACT NAME

TELEPHONE FAX E-MAIL

TYPE OF CRANE (Please one only)

Over Head Travelling Crane (OHTC) 
Mobile Crane 
Application / Environmental Conditions Used. __________________________
SHEAVES
Number of Sheaves ________
Outside Diameter ________mm
Rope Diameter ________mm
BEARINGS
High Capacity PTFE Bush 
Bronze Bush 
Roller Bearing 
Tapered Roller Bearing 
Other (Specify) __________________________
BLOCK CAPACITY, DIMENSIONS & WEIGHT
If multiple sheaves centre distance between all sheaves __________________________mm
Working Load Limit ______ Metric Tonnes
Design Class ______
If Replacement Weight ______ KG
HEAD FITTING TYPE (Please one only)
Hook Single 
Duplex (Rams Horn) 
Swivel Eye 
Fixed Shackle 
Other (Please Specify) ___________________________
Motorized Hook 
SPECIAL REQUIREMENTS
Coating (Otherwise standard SuperLift coating system used)
Proof Load Testing (Please i if required) 
Other (Please Specify) ______________________
19 All specifications & dimensions are subject to change without notice.
Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
 CUSTOM MACHINED HOOKS REQUEST
FOR QUOTATION
CUSTOMER NAME DATE

ADDRESS CONTACT NAME

TELEPHONE FAX E-MAIL

HOOK
Working Load Limit (At the Head Fitting) ______ Metric Tonnes
Application / Environmental Conditions Used. ______________________

TYPE (Please one only)

Single 
Duplex (Rams Horn) 
Size (Din, Euro style) __________________
Other (Please Specify) __________________

DIMENSIONS
Shank length (A) __________________
Thread length (B) __________________
Thread Diameter (C) __________________
Shank Diameter (D) __________________

NUT (Please one only)

Round Nut 
Hexagon Nut 
Nut Locking, (Dim. A. must be exact to underside of nut, if required) 
Other (Please Specify) ______________________

SPECIAL REQUIREMENTS
Coating (Otherwise standard SuperLift coating system used) ______________________
Proof Load Testing (Please if required) 
Other (Please Specify) ______________________

All specifications & dimensions are subject to change without notice. 20

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
 CUSTOM SAFETY LATCH KITS REQUEST
FOR QUOTATION
CUSTOMER NAME DATE

ADDRESS CONTACT NAME

TELEPHONE FAX E-MAIL

HOOK
Working Load Limit (At the Head Fitting) ______ Metric Tonnes
Application / Environmental Conditions Used. ______________________

TYPE (Please one only)

Single 
Duplex (Rams Horn) 
Size (Din, Euro style) __________________
Other (Please Specify) __________________

DIMENSIONS
Shank Diameter (A) ________ mm
Length (B) ________ mm
Throat Opening (C) ________ mm
Distance (D) ________ mm
Lug Width (E) ________ mm
Hole Diameter (F) ________ mm

SPECIAL REQUIREMENTS
Coating (Otherwise standard SuperLift coating system used) ___________________
Other (Please Specify) ___________________

21 All specifications & dimensions are subject to change without notice.

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
TESTING AND INSPECTION

Mechanical Load Testing Facilities

Our laboratory testing facilities comply with the requirements of,
AS/NZS ISO/IEC 17020
AS/NZS ISO/IEC 17025
Class AA 250 tonne Horizontal Test Bed
Class AA 50 tonne Vertical Test Tower

Magnetic Particle Inspection (MPI)

Our laboratory testing facilities comply with the requirements of,
AS/NZS ISO/IEC 1171-1998
ASTM E1444
Magnetic Particle Inspection (MPI) is an extension of visual inspection. This critical technique for non-destructive
testing (NDT) is used for the detection of surface and near-surface flaws (discontinuities) in ferromagnetic materials.

All specifications & dimensions are subject to change without notice. 22

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
Terms & Conditions of Sale
1. Exclusion of other terms and conditions.

The following terms and condition shall apply to the sale of all goods by Super Lift Engineering Pty Ltd to the exclusion of any and all terms and conditions in any documents
submitted to Super Lift Engineering Pty Ltd by the customer.

2. Basis of acceptance of quotations.

All quotations are based on information provided by the customer (or by third parties on its behalf). Any extra cost or expense arising from incorrect information shall be paid by
the customer.

3. Prices.
Any quotation submitted or any price set out in any price list is based on the cost of labour and materials at the date of the price list or quotation. Super lift Engineering Pty Ltd
may at its discretion increase any such price to reflect changes in the price of labour and materials and manufacturing overheads.

4. Terms of payment.
Unless Super Lift engineering Pty Ltd in its discretion agrees to accept payment for goods on deferred terms, the customer shall pay for all goods delivered by Super Lift
Engineering Pty Ltd within 30 days from the last day of the month in which the goods are so despatched.
Minimum invoice value of $75, all orders below this figure will result in a surcharge being applied. Title of goods remains the property of Super Lift Engineering Pty Ltd until paid
for in full.

5. Literature.
Advertising and other literature provided by super lift engineering contains general information only and no such information is to form part of any contract between super lift
engineering and the customer.

6. Guarantee.

6.1; Super Lift Engineering agrees to repair or replace any parts or equipment supplied by in which develop defects as a result of the use by super lift engineering of faulty
material or workmanship within the period of three months after the date of delivery. Any parts that require repair or replacement shall be replaced at the works of Super lift
engineering. The cost of freight both ways is to be borne by the customer. Any repaired parts shall become the property of Super Lift Engineering Pty Ltd.
6.2; This guarantee does not include liability for fair wear and tear, negligence or wilful default.
6.3; The benefits conferred by this guarantee are in addition to all other rights and remedies in respect of the goods which the customer has under the trades practices act 1974
( "the act" ) or any binding enactment of any state or territory which cannot be excluded by agreement.
6.4; In a case in which the goods are other than a kind ordinarily acquired for personnel, domestic or household consumption Super Lift Engineering's liability for any breach of
a condition or warranty implied by division 2 of the act (other than a condition or warranty implied by section 69 of the act) is limited to any one or more of the following; (as
determined by Super Lift Engineering Pty Ltd in its absolute discretion).
( i ) the replacement of the goods or supply of equivalent goods; or
( ii ) the repair of the goods; or
( iii ) the payment of the cost of replacing of the goods or of acquiring equivalent goods; or
( iv ) the payment of the cost of having the goods repaired.
6.5; if Super Lift Engineering becomes liable to indemnify a seller pursuant to section 74h of the act then such liability is limited to a payment of the of the sum equal to either;
( i ) the cost of replacing the goods; or
( ii ) the cost of obtaining equivalent goods; or
( iii ) the cost of having the goods repaired, whichever the less.
6.6; the foregoing sets out the obligations of Super Lift Engineering Pty Ltd concerning the goods and all other conditions and warranties which may be lawfully excluded
whether as to merchantable quality, fitness for any particular purpose, conformity with description or with a sample and whether express or implied by the law are hereby
expressly negatived and excluded.
6.7; any alteration, modification or defacing of a Super lift product by any means will void all warranties and liabilities.

7. Delivery.
Any time for delivery which is given as an estimate only and super lift engineering will use all reasonable efforts to deliver by such time but in no case shall Super Lift
Engineering be liable for any consequential damages in respect of any loss suffered by the customer as a result of any failure to deliver by any specified date.

8. G.S.T.
Super Lift Engineering shall be entitled to charge and recover from the customer the amount of any G.S.T. payable in respect of the sale of the goods to the customer.

9. Risk.
All goods supplied by Super Lift Engineering Pty Ltd to the customer will be at the customer's risk from the time of despatch.

10. Victorian law.

This contract shall be construed and take effect in accordance with the laws of the state of Victoria, Australia.

11. Credits
A restocking and handling charge of 20 % of the invoice value or $120.00 will apply to all returned goods, whichever the greater.
No credits or returns will be accepted unless claims are made within seven days of despatch, all goods returned must be freight paid and invoice and return authorisation
number quoted. Specially manufactured or products not normally stocked or procured goods will not be accepted for credit.

12. Copyright
Price lists, catalogues, internet information, brochures, data sheets or images cannot be reproduced in any shape, manner or form, without the prior written permission from
Super Lift Engineering Pty Ltd

23 All specifications & dimensions are subject to change without notice.

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
 CONVERSION TABLES

Multiply By To Obtain Multiply By To Obtain

LENGTH MASS and DENSITY
centimetre 0.0328084 foot gram 15.43236 grain
centimetre 0.3937008 inch gram 0.001* kilogram (kg)
fathom 1.8288 metre (m) hundredweight (long) 50.80235 kilogram (kg)
foot 0.3048 metre (m) hundredweight (short) 45.35924 kilogram (kg)
foot 30.48 centimetre (cm) kilogram 1000.* gram (g)
foot 304.8 millimetre (mm) kilogram 35.27397 ounce (avoirdupois)
inch 0.0254* metre (m) kilogram 32.15074 ounce (troy)
inch 2.54 centimetre (cm) kilogram 2.204622 pound (avoirdupois)
inch 25.4 millimetre (mm) kilogram 0.06852178 slug
kilometre 0.6213712 mile (U.S. statute) kilogram 0.0009842064 ton (long)
metre 39.37008 inch kilogram 0.001102311 ton (short)
metre 0.5468066 fathom kilogram 0.001* ton (metric)
metre 3.28084 foot kilogram 0.001* tonne
metre 0.1988388 rod kilogram 0.01968413 hundredweight (long)
metre 1.093613 yard kilogram 0.02204622 hundredweight (short)
metre 0.0006213712 mile (U.S. statute) kilogram/metre³ 0.06242797 pound/foot³
micrometre (micron) 39.37008 microinch kilogram/metre³ 0.01002242 pound/gallon UK.liquid
millimetre 0.00328084 foot kilogram/metre³ 0.008345406 pound/gallon US.liquid
millimetre 0.03937008 inch pound (avoirdupois) 0.4535924 kilogram (kg)
yard 0.9144* metre (m) pound/foot³ 16.01846 kilogram/metre³
pound/inch³ 27.6799 gram/centimetre³
AREA pound/gallon US.liquid. 119.8264 kilogram/metre³
acre 4046.856 metre² (m²) pound/gallon UK.liquid. 99.77633 kilogram/metre³
acre 0.4046856 hectare slug 14.5939 kilogram (kg)
hectare 2.471054 acre ton (long 2240lb 1016.047 kilogram (kg)
metre² 1550.003 inch² ton (short 2000lb) 907.1847 kilogram (kg)
metre² 10.76391 foot² ton (metric) 1000.* kilogram (kg)
metre² 1.19599 yard² tonne 1000.* kilogram (kg)
metre² 0.0002471054 acre
yard2 0.8361274 metre² (m²) PRESSURE
atmosphere (14.6959
VOLUME (including CAPACITY) lb/inch²) 101,325 pascal (Pa)
foot³ 0.02831685 metre³ (m³) bar 100,000.* pascal (Pa)
foot³ 28.31685 litre bar 14.50377 pound/inch²
litre 0.001* metre³ (m³) bar 100,000.* newton/metre² (N/m²)
litre 0.2199692 gallon (U.K. liquid) kilogram/centimetre² 14.22334 pound/inch²
litre 0.264172 gallon (U.S. liquid) kilogram/metre² 9.806650* newton/metre² (N/m²)
litre 0.03531466 foot³ kilogram/metre² 9.806650* pascal (Pa)
metre³ 219.9692 gallon (U.K. liquid) kilogram/metre² 0.2048161 pound/foot²
metre³ 264.172 gallon (U.S. liquid) kilonewton/metre² 0.1450377 pound/inch²
metre³ 35.31466 foot³ newton/centimetre² 1.450377 pound/inch²
metre³ 1.307951 yard³ newton/metre² 0.00001 bar
metre³ 1000.* litre newton/metre² 1.0* pascal (Pa)
metre³ 61023.76 inch³ newton/metre² 0.0001450377 pound/inch²
millimetre³ 0.00006102376 inch³ newton/metre² 0.1019716 kilogram/metre²
yard3 0.7645549 metre³ (m³) newton/millimetre² 145.0377 pound/inch²
pascal 0.00000986923 atmosphere
FORCE and FORCE/LENGTH pascal 0.00001* bar
kilogram-force 9.80665* newton (N) pascal 0.1019716 kilogram/metre²
newton 0.1019716 kilogram-force pascal 1.0* newton/metre² (N/m²)
newton/metre 0.005710148 pound/inch pascal 0.02088543 pound/foot²
newton/metre 0.06852178 pound/foot pascal 0.0001450377 pound/inch²
ounce/force 0.2780139 newton (N) pound/foot² 4.882429 kilogram/metre²
pound/force 4.448222 newton (N) pound/foot² 47.88026 pascal (Pa)
pound/inch 175.1268 newton/metre (N/m) pound/inch² 0.06894757 bar
pound/foot 14.5939 newton/metre (N/m) pound/inch² 0.07030697 kilogram/centimetre²
POWER pound/inch²
pound/inch²
0.6894757
6.894757
newton/centimetre²
kilonewton/metre²
foot-pound/hour 0.0003766161 watt (W)
pound/inch² 6894.757 newton/metre² (N/m²)
foot-pound/minute 0.02259697 watt (W)
pound/inch² 0.006894757 newton/millimetre²
horsepower(electric) 746.* watt (W)
pound/inch² 6894.757 pascal (Pa)
horsepower (metric) 735.499 watt (W)
horsepower (U.K.) 745.7 watt (W)
horsepower(550 ft-lbs) 0.7456999 kilowatt (kW)
horsepower(550 ft-lbs) 745.6999 watt (W) * Where an asterisk is shown, the figure is exact.
kilowatt 1.341022 horsepower(550 ft-lbs)
Btu (International
Table)/hour 0.2930711 watt (W)

All specifications & dimensions are subject to change without notice. 24

Ph: +(613) 9357 0277 www.superlift.com.au Fax: +(613) 9357 0621
WIRE ROPE
USER MANUAL

ushamartin.com
USHA MARTIN GROUP
Usha Martin is one of the largest manufacturers of high quality wire
ropes in the world.
For more than 50 years, the group has been dedicated to excellence
and has implemented stringent process controls at each step of the
manufacturing process.

The Usha Martin Group, with it’s own coal and iron ore mines, 150 MW power plant and over 1
million tons of speciality steel manufacturing capacity, is a truly vertically integrated business.
It has a global base of steel wire rope manufacturing facilities located in India, the UK, Thailand and
Dubai with service centres spread over all of the key markets in Europe, Asia, Americas and Africa.

In this world without boundaries, Usha Martin is truly committed to preserve this legacy of quality all
over the world and continues to harness it’s global presence to deliver the best possible solutions for
it’s customers.
List of topics

Preface about rope use ......................................................... 2

Rope diameter and measurement ............................................ 3
Rope lay measurement and selection........................................ 4
Strength & breaking force...................................................... 6
Material & surface finish........................................................ 7
Benefits of compacted strands................................................. 8
Fleet angle and plastic impregnated core ropes............................ 9
Rope behaviour under load..................................................... 10
Rotational characteristics...................................................... 11
Block stability and use of swivel .............................................. 12
Wire rope lubrication............................................................ 14
Reel receipt and storage........................................................ 16
Serving and cutting.............................................................. 18
Rope pay out...................................................................... 19
Rope terminations............................................................... 20
Socketing operation............................................................. 22
Rope installation and training.................................................. 24
Lifting operations................................................................ 26
Rope winding over sheaves..................................................... 28
Contact pressure between rope and sheaves................................ 30
Rope relubrication............................................................... 32
Bending fatigue.................................................................. 33
Factors affecting bending fatigue............................................. 34
Guidelines for rope inspection................................................. 36
Inspection of grooves and sheaves............................................ 38
Typical rope damages and recommended actions.......................... 39
Discard criteria for visible broken wires..................................... 40
Discard criteria for diameter decrease, deformation and corrosion.. . . 42
Health and safety information................................................. 44
Appendix A Quick calculator................................................ 46
Appendix B Definitions....................................................... 47
Appendix C Reference documents......................................... 51
Appendix D Examples of strands and ropes constructions............. 52

01

This document is property of Usha Martin Italia. Reproduction is not allowed unless specifically agreed.
PREFACE ABOUT
ROPE USE
A wire rope can be simply considered as an Rope integrity management should always be
assembly of several strands laid helically in operated by properly trained personnel, who
different possible arrangements in order to should always refer to general regulations,
bear axial loads. specific customer standards, local legislation
To be fit for purpose, it must also ensure other and internal guidance.
features, like resistance to side loads, flexibility, The content of this document is a brief abstract
handling and stability. of rope characteristics and recommendations
This definition, however, does not cover for rope use and it is not intended to be
completely the implications of correct rope all-inclusive; specific matters can be followed
design, manufacturing, use and inspection, with special care to customer needs by our
as the real mandatory requirement must be, technical departments.
in any case, safety compliance, which allows
adequate working conditions for men and
environment.
To ensure high quality standards, our Company
has settled up a complete process, which includes
custom design software, state of the art
manufacturing equipment and skilled personnel
with proven expertise.

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ROPE DIAMETER AND
MEASUREMENT
Each rope is first of all characterized by the Diameter must be measured and recorded
nominal diameter and oversize, which have to immediately after rope receipt, as this value
be selected depending on system configuration has to be used as a baseline for following
and reference regulations. inspections.
According to EN12385-1, ISO and API standard, It has always to be considered that the actual
diameter measurement has to be taken on a diameter of the rope changes during use due
straight portion of the rope, either under no to initial stabilization, to the effect of working
tension or a tension not exceeding 5% of the tension and to wear generated by the passage
minimum breaking force, at two positions spaced over the reeving system.
at least one metre apart. At each position two Permanent diameter reduction after first pull
measurements, at right angles, of the can vary from 0.5% to 3% depending on rope
circumscribed circle diameter shall be taken. and core construction.
The most suitable measuring equipment is plate Diameter measurement is an essential tool which
gauge, capable to cover at least two strands can give an immediate and simple evaluation of
(see Figure 1). the overall condition of the rope.
For example, a localized diameter variation can
indicate undesired phenomena like geometrical
deformation, core distortion or presence of
heavy corrosion, while a distributed diameter
reduction can be associated to wear due to
intensive use. Ovalization is also a marker of
possible rope issues which have to be properly
addressed.

Figure 2 Sunken strand and associated diameter reduction

Figure 1 Diameter measurement

Figure 3 Core distortion and associated diameter increase

03

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ROPE LAY MEASUREMENT
AND SELECTION
Lay length represents one of the key The choice of a Lang or regular lay rope has to
characteristics of the rope and affects its be based on rope use and desired performance.
elasticity and performance under load. Lang lay ropes (i.e. ropes having same direction
It has to be periodically measured, as possible as the outer strands) give better stability
variations can indicate rope issues, like forced to side wear (phenomenon also known as
rotation during installation, or unlay due to “crushing”) as the contacts between the wires
excessive lifting height, or misalignment of the of adjacent rope wraps are smoother. They are
reeving components. particularly indicated up to 40 mm size ropes
used on deck cranes or small winches.
Regular lay ropes (i.e. ropes having opposite
direction in respect of the outer strands) ensure
improved rotation stability and are therefore
Figure 4 Lay length measurement for a six strand rope recommended for relevant lifting height or
high capacity cranes.

Figure 5 Lang lay (first figure)

and regular lay (second figure)

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The natural tendency of the rope to twist must In case of grooved drums, an adequate number
be in accordance with the direction of drum of safety wraps should remain in place to avoid
winding to get a tight contact between adjacent rope slipping, while in case of plain drums the
wraps, especially on the first layer. whole first layer should never be used, as it
In case of plain drum, right hand or left hand works as a bedding for the following layers.
lay direction must be selected in order to Painting the first layer or the safety wraps is
match the drum’s type and direction, as shown a good practice to clearly detect the use of a
in the figure. forbidden portion of rope.
These indications are not strictly required for
grooved drums, as in this case the rope is already
guided by the grooves themselves.
In case of grooved multilayers drums, lay
direction can be selected to facilitate the first
layer spooling or optimized considering the
rope layer that will be more frequently used
during operations.

Figure 6 Selection of lay direction

05

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STRENGTH & BREAKING
FORCE
A fundamental requirement for wire ropes is Good quality ropes must be composed of
the achievement of the minimum breaking ductile wires, which will break gradually
force that complies with the crane or winch following remarkable plastic deformation.
safe working load. These gradual breaks will be clearly noticeable
Rope breaking force can be seen as a function by a competent person with responsibility for
of metallic area, strength and spinning factor. rope integrity management.
These elements must be carefully combined to Ropes that rely solely on the use of extremely
confer reliable mechanical properties. high strength wires for their breaking force can
Metallic area depends on geometrical have severe implications in terms of safety,
construction, diameter oversize and as the wires will have the tendency to break
compacting level, strength is dependent on suddenly without giving proper notice of
the characteristics of the individual wires, and arising problems.
spinning factor is dependent on manufacturing The graph below compares the behaviour of
skill, geometrical construction and compacting wires with different strengths: the first figure
level. represents a brittle trend typical of high
However, it must be emphasised that a high strength steel (over 2160 N/mm²). The second
breaking force in itself is not sufficient to figure represents the typical trend of lower
ensure safe working conditions. strength steel (1770 and 1960 N/mm²).
These can be achieved if it is possible to It is therefore essential to adopt the minimum
detect within an acceptable time scale that possible strength level and to achieve the
the rope is approaching the end of its useful desired breaking force by a combination of
life or that the prescribed payload has been high compacting level, finely tuned geometrical
exceeded. construction and manufacturing reliability.

Figure 7 Stress - strain curves

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MATERIAL & SURFACE
FINISH
Correct selection of raw material is essential
in order to get the required breaking force and
mechanical characteristics.
Our wire ropes are manufactured using a high
carbon content, patented rod, which allows to
achieve high rope grades without the adoption
of extreme wire strength.
The rod is subjected to a drawing process,
which consists of a number of passages through
a series of tungsten carbide dies with a gradual Figure 8 Galvanized wire
diameter reduction. During this process, the
metallurgical structure of the rod changes Zinc is applied by a hot dip process in order
from a very thin perlite pattern to well aligned to avoid hydrogen embrittlement typical of
fibres with high tenacity and strength. electrochemical plating. Hot dip galvanizing
The combination of carbon content and creates a tight connection between zinc and
amount of drawing is determined depending on steel, virtually alloying them in one unique entity.
the specific application of the wire rope and For severe environmental conditions, improved
the required mechanical characteristics. surface finishing based on zinc aluminium
Steel has to be protected against corrosion alloys can also be adopted.
and consequently bright ropes, which are still It must be emphasised that surface finishing
popular for some applications, have a very has to be adopted in conjunction with adequate
limited use in oil and gas applications, while lubrication and maintenance levels in order to
zinc coating is highly recommended for the preserve wire rope performance.
marine environment.
The quantity of zinc which has to be applied
to wires is regulated by EN10264-2 – Steel
wire and wire products – Non ferrous metallic
coatings on steel wire – Zinc or zinc alloy coatings.
For rope used within the oil and gas industry,
the typical zinc thickness is approximately 20
to 25 microns, which complies with class B.

07

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BENEFITS OF COMPACTED
STRANDS
Ropes for heavy lifting and special applications
require a high load efficiency and breaking
load, which cannot be achieved using traditional
round strands. For this reason, these ropes
are typically composed of compacted Figure 9 Compacting process
through rollers or die
strands, where the level of compaction can be
designed and modulated depending on specific
requirements.
Compacted strands are created by passing
through a die or a series of rollers situated just
after the closing point of the stranding machines
as shown in the figures. Figure 10 Round strand, light and
high compacting level

The main benefit achieved by use of compacted strands adoption is the increase of metallic area in
respect to round strands, which leads to higher breaking force. Moreover, compacted strands allow
to achieve higher cooperation level of the individual wires, homogeneous and stable strand diameter,
resistance to side pressure, wear and abrasion.
Finally, the smoother contact surface between the strands and rounder profile gives better spooling
performance and resistance to crushing.

Figure 12 Contact surfaces

for a non compacted and a compacted rope
Figure 11 Round strand
versus compacted strand

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FLEET ANGLE AND PLASTIC
IMPREGNATED CORE ROPES
Rope routing must be carefully considered to Fleet angle should never exceed 2°, it can be
prevent early damage: one of the most critical increased up to 4° with the adoption of plastic
factors is the presence of deflection (i.e. fleet) impregnated core ropes.
angles between two sheaves or from the drum In this type of ropes, plastic is applied to the core
to the spooler. after its closing and is lightly heated and softened
before final closing in order to create a connection
between outer strands and core strands.
The plastic layer must not work as a cushion
(see left sketch), but must allow steel over
steel contact between the core and the
outer strands (see right sketch). This ensures
Figure 13 Fleet angle during spooling and rope rolling
long-lasting radial stiffness and rope stability.

When fleet exists, the rope is induced to roll

and slide into the groove, causing shortening
and increasing of the lay length and possible
permanent distortion of the rope structure,
such as birdcage or core protrusion.

Figure 16 Cushion layer versus

plastic impregnated core

Figure 14 Birdcage deformation

Figure 15 Core protrusion

09

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ROPE BEHAVIOUR
UNDER LOAD
When a rope is subjected to axial loads, the
elasticity of the material causes elongation
and consequential diameter reduction.
The first graph shows the relationship between
stress (ratio between load and metallic area)
and strain (ratio between elongation and initial
sample length). The slope of the curve is Young
modulus “E”, which multiplied by the metallic
section “A” gives the axial stiffness “EA”.
In the first phase of its use (up to point 1), Figure 17 Stress - strain curve for a wire
rope
rope shows a certain permanent stretch due to
the stabilization of the individual wires.
After this step, the trend is basically linear up
to the achievement of yield point (points 3 and
4), from which permanent plastic deformation
takes place, until the load reaches the actual
rope breaking force.
A typical example of relationship between rope
oversize (ratio between actual and nominal
diameter) is indicated in the second graph.
After training, every rope shows a permanent
diameter reduction due to the stabilization
of its structure. The initial diameter and the Figure 18 Rope oversize versus load

consequent reduction must be such to allow

smooth installation on the drum and good
spooling.

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ROTATIONAL
CHARACTERISTICS
Being composed by helically laid elements, Each rope is characterized by torque factor,
each rope has the natural tendency to twist which is used in the calculations when both
when subjected to axial loads. ends of the rope are fixed, and rotation factor
The level of twist is dependant on the (expressed in degrees/lay), which is used
geometrical arrangement and can be reduced when one end is free to rotate.
by compensating the core tendency to rotate Both torque factor and rotation factor
in one direction with an opposite tendency of strongly decrease after rope stabilization and
the outer layer, as typically applied to spin are negligible if the rope is always used at
resistant and non rotating ropes. same working load and lifting height.
Ropes are conventionally classified based on
the number of turns that a portion with length
of 1000 times the nominal rope diameter would
make when pulled at 20% MBF (see figure):
1. Non rotating: less than 1 turn
2. Low rotation: from 1 to 4 turns
3. Spin resistant: from 4 to 10 turns
4. Not non rotating: more than 10 turns

Figure 20 Torque factor for non rotating

and six strand ropes

Figure 19 Rope classification

based on number of turns
Figure 21 Rotation for different rope
constructions

11

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BLOCK STABILITY AND USE
OF SWIVEL
In case of single fall lifting a non rotating rope In case of special block arrangement, please
is typically recommended, while in case of contact us for a custom evaluation.
multi-part reeving arrangement, rope type When operating a non rotating rope in single
has to be selected depending on height of lift, fall mode, a swivel can be used to relieve the
block configuration and loading. rope of any induced rotation resulting from
A wrong rope selection or improper installation angular deflections at a sheave or drum.
and training can cause cabling phenomenon, Swivels must not be used with not non rotating
which can lead to permanent rope deformation, ropes, like 6 strand, as it would cause rope
like waviness, and severe operations issues. unlay, severe reduction of its breaking force
The maximum lifting height for a given rope and secondary fatigue of the steel core, not
torque factor “t” can be briefly calculated detectable during inspections.
using the approximate formulas shown in the
sketch (all dimensions are in m).

Figure 22 Multiple fall lifting

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 Figure 23 Calculation of maximum lifting height

Figure 24 Rope waviness

Figure 25 Example of swivel

13

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WIRE ROPE LUBRICATION

Proper lubrication is essential to maintain rope Lubricant can be applied during different
performance in use, protect it against corrosion manufacturing phases: stranding, core closing
and preserve its service life. and final closing.
Good quality lubricants are characterized by When applied during stranding, the lubricant
high adherence to steel in order to withstand is firmly engaged within the rope structure and
passage over the reeving system, light colouring reduces friction between the wires. If applied
which will not obstruct the detection of possible during core closing it creates a barrier against
rope damage and high compatibility with other external elements penetration and if applied
products, which is particularly important for during final closing it further increases protection
vessels operating globally. against corrosion.
Drop point has to be high enough to tolerate The quantity of lubricant applied during rope
rope storage and operation in warm environment, manufacture has to be carefully evaluated on
but with a safety borderline that is sufficient the basis of rope use and working environment.
to detect rope overheating during the use of
special devices such as heave compensators.
Since steel can suffer permanent deterioration
if subjected to high temperatures for extended
periods, a good temperature limitation and
consequent drop point is approximately 80°C.

Figure 26 Example of rope with very low outer lubrication

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If insufficient lubricant is applied, the rope The most typical levels of lubrication are
will not be adequately protected, however an shown in the following figure:
excess of lubricant may be squeezed out of • the first image refers to very small size
the rope during installation and use, thereby ropes, with lubrication applied only during
creating environmental and safety issues. stranding
This has to be carefully considered in case of • the second figure refers to ropes for
boom hoist ropes operating on offshore vessels, industrial lifting, with lubrication applied
which run over reeving systems composed of a during stranding and core closing
high number of sheaves. • the third figure refers to ropes for marine
Before rope installation and during rope use, environment applications, with lubrication
the lubrication level must be periodically also applied during final closing operations.
inspected to detect any overall or localised This is the most frequent option for oil and
faults and, where required, relubrication can be gas applications
performed by using appropriate pressure devices. • the fourth image shows a very high
For ropes operating subsea, lubricant should amount of lubricant, required for ropes
be applied during deployment in order to fill operating subsea or dealing with very
the strands gaps and prevent water penetration severe environmental conditions
and trapping.

Figure 27 Typical lubrication levels

15

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REEL RECEIPT AND
STORAGE
After receipt, the rope should be immediately Slings must have an adequate length to avoid
checked to verify its identity and condition flange ends overstress during reel lifting.
and should not be used without the possession The rope should be checked to verify that it is
of adequate documentation and certificates. not damaged when unloaded and transported to
The Certificate of Conformity by the manufacturer storage site and should not come into contact
should be stored in a safe designated place in with parts of the lifting devices, like hooks and
order to quickly identify the rope and carry forks.
out periodic inspections. Some recommendations for rope handling are
During loading, transferring and unloading indicated on specific labels applied on the reels.
operations, rope reels or coils should be
properly handled using slings or lifting beams.

Figure 28 Rope handling recommendations

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Storage conditions are essential to prevent The rope should not be stored in places which
rope damage: it should be avoided to keep the could be affected by chemical agents, corrosive
rope in very warm or humid environment, as matters or accidental damages and, if stored
this could break down the effectiveness of native outside, the reel should be positioned in order
lubrication and accelerate the deterioration to avoid direct contact with the ground and
process. If lubricant has the tendency to drain covered with waterproof material.
due to high temperature, the reel should be The rope marking should be clearly detectable
periodically rotated to maintain a homogeneous and readable in order to safely and quickly
distribution. identify the reel.

Figure 29 Reel handling

17

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SERVING AND CUTTING

During manufacturing process, the strands can Wire diameter shall be such to firmly hold the
be preformed in order to get a helical profile strands and, particularly in case of large size
just before closing and improve rope stability ropes, seven wires strands can be used as an
and handling. Similar purpose can be achieved alternative to single wires.
through postforming, which consists of the Before cutting the rope, a clear mark should
passage of the rope through a series of rollers. be applied on the cut area and servings should
With the exception of very specific applications, be applied at each side of the mark.
preforming and postforming level must be such Depending on its size, the wire rope can be
to stabilize the rope without reaching extreme fused and tapered or cut using high speed abrasive
levels, as this would make the rope very faint disc cutters, percussive or shearing methods,
during use. paying particular attention not to disturb the
Therefore, unless the rope has been subjected position of wires and strands below the serving.
to complete preforming, it will have the Rope core can be cut with no major issues in
tendency to unlay when cut. case it has the tendency to protrude in respect
For this reason, serving shall be applied before to the outer layer.
rope cutting to keep strands in position and
it has to be performed carefully, as its failure
may cause injuries or rope permanent damages.
Serving must be also performed before socketing
and in this case it has to allow socket medium
penetration between the rope and the socket bore.
d

Service length “L” should be at least equal to

L
two rope diameters “d” (see figure).
Figure 30 Serving dimensions and configuration
For preformed ropes one serving is typically
enough, while for not preformed ropes,
rotation resistant and parallel closed ropes a
minimum of two servings is recommended.
Serving material shall be tinned or galvanized
soft wire or strand for zinc/zinc alloy coated
wire ropes, and bright, tinned or galvanized
soft wire or strand for bright wire ropes.

Figure 31 Typical serving wire and strand dimensions

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ROPE PAY OUT

Ropes can be supplied on coils or reels depending

on size and customer requirements.
If the rope is supplied on a coil, it should be
placed on the ground and rolled out straight,
avoiding contamination with dust, grit, moisture
or other harmful material. Figure 32 Rope kink and associated deformation

The rope should never be pulled away from a

stationary coil as this will induce turns into the
rope and form kinks (see figure).

If the coil is too large to be physically handled, it may need to be placed on a turntable to pay it out
as the end of the rope is pulled away from the coil.
If the rope is supplied on a reel, a shaft of adequate strength should be passed through the reel
bore and the reel should be placed in a suitable stand which allows it to rotate and be braked to
avoid overrun during installation.
If a loop forms in the rope it should not be allowed to tighten to form a kink.
The reel stand should be mounted in a way that avoids reverse bend during reeving: for a drum with
an underwind rope, take the rope off the bottom of the supply reel.
Underwind is also preferable in respect to overwind, as it gives higher stability to the stand and less
risk of overturn.
When releasing the outboard end of the rope from the supply reel or coil, this should be done in a
controlled manner.

Figure 33 Recommendations for rope pay out

19

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ROPE TERMINATIONS

Ropes can be supplied with different end Temporary end connections must not be used
terminations depending on customer requirements. as lifting devices, as they are not designed to
Temporary end connections must be used only ensure Safe Working Load but only to allow
for rewinding or installation, while permanent the rope to be moved from the storage reel to
end connections can also be used for actual another reel or to the winch drum.
operations. Some examples of end connections are shown
Permanent connections allow the Safe Working in the following table. Special sockets or
Load to be maintained and are characterized connections can be provided on demand.
by a specific efficiency depending on the
connection type, which varies from 100% for
resin sockets to 80% for wedge sockets.

Figure 34 Detail of hoist and boom ropes

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 Figure 35 Examples of rope terminations

21

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SOCKETING OPERATION

Socketing must be performed by trained people Dirt, grease, scale or residues shall be removed
using proper procedures and equipment. from the inside of the socket basket to prevent
Socketing media can be metal or resin, which resin contamination.
is more extensively used due to ease of After having inserted the rope into the socket,
handling and safety. Moreover, heat generated all the individual wires shall be opened to form
during metal socketing can affect steel properties a brush, which shall be degreased to remove
of the rope. all traces of lubricant and shall be completely
According to EN12927, the length of the tapered dry before the socketing medium is poured
part of a socket shall be at least 5 times the into the socket. Wire shall not be straightened
nominal rope diameter or 50 times the outer when forming the brush, as this would reduce
wire diameter and the angle between the the efficiency of the socketing media.
generatrix and the axis of the cone shall be
from 5° to 9°.The socket basket neck diameter
shall be from 1,2 up to 1,3 times the rope
nominal diameter and shall have a cylindrical
portion long from 0,25 up to 0,5 times the
rope nominal diameter.
The internal socket profile must not have grooves,
as these would reduce resin penetration.
To perform proper socketing, the position of
the wires and strands of the non-socketed
Figure 36 Socket brush
portion of rope shall remain undisturbed during
the socketing operation, therefore adequate
servings are required.

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The wires shall be evenly distributed around The resin mixture shall be allowed to harden
the circumference within the socket basket after gelling and the socket shall not be moved
and the area where the rope enters the bore until the resin has hardened. Some resins
of the socket shall be sealed with a material contain a coloring component which turns into
that prevents leakage of resin and that shall blue during gelling.
be removed after socketing. Before starting Wires protruding after hardening due to resin
the operation, the socket must be aligned with loss of volume helps to verify the proper wires
the rope axis. distribution into the cone and does not need to
The operator shall follow the resin manufac- be covered or removed.
turer’s instructions, resin system packages or
kits shall not be sub-divided or used after the
expiry date indicated on the container or out
the prescribed temperature range.
The socket shall be filled from a single pouring
until the basket is full: the approximate resin
content in cc for a standard spelter socket can
be calculated using the formula in the sketch
Figure 37 Resin content and
(cone dimensions are in cm). cone dimensions

During the pouring and topping-up operation

and early stages of gelling, it is essential that
possible leaks are identified and stopped, as
such leaks may generate cavities near the neck
of the brush.

23

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ROPE INSTALLATION AND
TRAINING
Rope spooling and installation should be carried If higher tension has to be applied, the rope
out in accordance with a detailed plan issued has to be spooled on an intermediate reel or
by the user of the rope to prevent safety special reel requirements have to be agreed
hazards and early rope damage. with the rope supplier.
The installation tension should be at least the When first installing the rope, a pilot line
highest value between 2% of the rope MBF or having adequate breaking force to bear
10% of rope SWL. the installation pull should be reeved on the
This tension can be obtained directly using system and connected to the rope itself.
the spooling device or later during training The pilot line shall have same lay direction
stage, depending on rope size and equipment and type as the rope to be installed, otherwise
availability. twist could be induced and permanent damage
Standard rope reels are designed for could occur.
transportation and storage, therefore they A swivel should not be used during the installation
can bear a limited amount of pulling tension, of the rope.
which is approximately 3 times the reel diameter It is also important to note that there are
for steel reels, 0.5 times the reel diameter for operational limits related to some rope
wood reels (e.g. 1.5 meter steel reel can bear constructions: as a general guideline, the
up to 4.5 tons, 1.5 meter wood reel can bear maximum operating depth is 1300 meters for 6
un to 0.75 tons) up to a maximum of 10 tons strand ropes and 1000 meters for 8 strand ropes.
using two spindles for each flange.

Figure 38 Broken wire due to improper handling

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During pulling into the system, the rope Training is also essential to stabilize rope
should be carefully monitored and it should dimensions and to optimize rope lifetime and
not obstructed by any part of the structure that performance.
may bring damage and result in a loss of control. It is performed by lifting an adequate load for
The equipment should be run at limited speed at least three times using the full rope length,
to facilitate gradual rope stabilization. excluding the safety wraps which must always
Full load should never be applied during this remain on the drum: the load automatically
stage. generates proper backtension, diameter
During spooling, continuous check has to be stabilization and torque factor reduction.
performed to verify that no slack occurs in
the rope or cross-laps of rope develop at the
drum, as irregular coiling would inevitably
result in severe surface wear and rope distortion.
In multilayer drums, the crossover area (see
figure) must be carefully monitored.
A good spooling will show tight wraps and
uniform rope arrangement also in the crossover
zone and up to the last layers, which will reduce Figure 39 Crossover area

the risk of crushing, cut-in or early formation

of broken wires.

25

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LIFTING OPERATIONS

Applicable regulations give indications to For moving parts, further reduction must be
ensure that lifting equipment is safe when considered due rope internal friction and
new, that it is used safely and that it remains efficiency of the rotating parts.
safe for use. The efficiency of sheaves should also be
Equipment and accessories are marked with considered when calculating the lead line load.
their own safety working loads and must never In case of systems having same number of
be used out of the prescribed interval. They rotating sheaves and parts of line (e.g. 2 falls
should always be thoroughly examined according and two rotating sheaves, like in the first
to adequate inspection procedures, as well sketch), the lead line load can be calculated
as before first use, when moved to different by dividing the load by the efficiency coefficient
locations in respect to the original one and (e.g. as per the following table: lifting 80 tons
each time unexpected events which may affect in 2 parts mode with roller bearing sheaves will
safety occur. give a lead line load of 80 /1.94 = 41.2 tons).
Similar indications apply to wire ropes, which If additional rotating sheaves are used (see
should always be handled, maintained and second sketch), unless otherwise specified
inspected by competent persons using proper the resulting line load should be divided by
procedures (see also chapters related to wire 0.96, 0.98 or 0.99 (plain, roller bearing or high
rope inspection). efficiency sheaves) times the number of extra
When bent over stationary pins or sheaves, sheaves in respect to the rope bearing parts.
rope minimum breaking force is affected in
respect to linear load conditions depending on
D/d ratio, thus reducing its efficiency (see figure).

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 Figure 40 Reduction in rope efficiency in
case of bent over stationary components

Figure 41 Example of lead line factors

Figure 42 2 Falls with 2 rotating
sheaves and with an extra sheave

27

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ROPE WINDING OVER
SHEAVES
When a rope runs over the reeving, its strands For partial reverse bending (see second
are forced to modify their relative position to sketch), a lower distance could be accepted.
maintain contact with the system. Both in the case of reverse and simple
If the reeving arrangement is not properly bending, the sheaves have to be properly
designed, the strands cannot recover their designed in terms of size, groove configuration
natural location in the passage between and hardness.
adjacent components, therefore the rope can
suffer premature fatigue or localized damage.
This particularly applies in case of reverse
bending configuration, where the strands are
stretched and compressed between two sheaves.
To avoid permanent damage, for complete
Figure 43 Reverse bending and partial reverse bending
reverse bending (see first sketch) the minimum
recommended distance is about 100 times the
rope diameter.

Figure 44 Detail of rope winding

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As already mentioned, the typical minimum This figure does not apply in case of rollers or
recommended bending ratio is 20 times the sheaves with reduced bending ratio (up to 10),
rope nominal diameter, while the recommended since the rope has to deal with a relatively
groove oversize can vary from 1.06 to 1.1 small bending ratio.
times the rope diameter. In this case, it is always recommended to
In order to allow a smooth contact surface, the adopt a minimum bending ratio equal to the
rope should be in touch with the sheave for at winding angle (e.g. 2 D/d minimum in case of
least 1.5 times its lay length, which corresponds 2° winding angle).
approximately to a 60° winding angle for a
sheave having a bending ratio of 20.
For very small winding values the stress
induced to the rope is not very relevant, while
in the intermediate range, from 10° to 45°,
significant damage can occur, especially if the
component is located in the high tension side
of the reeving.

Figure 45 Relative service life depending on

winding angle

29

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CONTACT PRESSURE BETWEEN
ROPE AND SHEAVES
When the rope is bent over a component of Multistrand and non rotating ropes ensure a
the reeving system, it generates pressure better pressure distribution than six strand
which is dependent on its diameter, the ropes, as the higher number of outer strands
diameter of the component itself and the generates a wider contact surface (see figures
applied tension. of the next page).
In order to ensure proper performance, the Compacted strands and Lang’s lay ropes
groove material should give a smooth and further extend the contact surface.
hard contact. A good groove dimension is also important to
In case of inadequate material selection, the achieve a reduced pressure.
groove steel will be locally hardened, with The figures of the next page show different
consequent embrittlement and detachment of configurations depending on various groove
steel flakes, which can damage both the rope oversize: narrow, well dimensioned and
and the component itself. large groove.
The typical recommendation is to use hardened
steel with approximate 300 HB value.
In case of synthetic sheaves, the yield point
of the material should be higher than the
exerted pressure.
The nominal average pressure can be calculate
using the formula shown in the next page.

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 Figure 46 Rope pressure over a sheave

Figure 47 Pressure distribution of 6 strand

and non rotating rope

Figure 48 Pressure distribution

for narrow, well dimensioned and large grooves

31

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ROPE RELUBRICATION

The main purpose of lubrication is to maintain Before relubrication, rope must be cleaned to
rope performance in use and protect it against remove scales, moisture and other contaminants.
corrosion, which can determine rope discard Lubrication must be carried out on dry and clean
when reaching a high severity rating. rope using a lubricant compatible with the
Corrosion affects not only the residual original one and whose amount is not excessive,
breaking force, but also wire ductility and as this would make difficult to inspect the
mechanical characteristics, therefore it should rope and could lead to accumulation of debris
be carefully considered when inspecting a rope. which could generate abrasions.
Unless unexpected events, the protection Some typical lubrication modes are shown in
provided by the original manufacturing lubricant the following figure.
is enough to prevent rope corrosion during
shipment, storage and first period of use.
Lubricant conditions must be periodically
checked depending on rope working type and
environmental conditions.

Figure 49 Typical lubrication modes

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BENDING FATIGUE

Fatigue damage is a typical phenomenon which

is not caused by a single event, but by repeated
bending, tension and rotational stresses: since
the working life of wire ropes generally involves
several passages over drum and sheaves, this
damage has to be carefully considered during
operations.
The first factor to be considered with respect
to fatigue damage is the working load: taking a Figure 50 Effect of safety factor on service life
safety factor of 5 as a reference point, relative
service life of rope operating in the same system
with different loads is shown in the first figure.
Fatigue damage occurs gradually and becomes
evident when it reaches a point where it has
caused a high number of broken wires and
consequent wire elongation, which quickly
evolves until the rope gets to discard criteria.
The typical trend of fatigue growth is shown
in the second figure: it is clear that there is
a rapid increase in the curve slope after a
Figure 51 Fatigue progression
certain threshold, and this is strongly affected
by working load.

33

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FACTORS AFFECTING
BENDING FATIGUE
Since fatigue is an inherent phenomenon, it This can have some practical limitations,
cannot be eliminated, however it can be slowed especially when dealing with large size ropes.
down by adopting, when possible, particular Another approach which can be adopted
features with respect to rope design and without major expense is the selection of
system layout. proper groove size. The recommended value
With respect to rope design, the most effective is approximately 1.08 times the nominal rope
way to reduce fatigue evolution is by avoiding diameter, depending on rope type and possible
the use of extremely high strength wires fleet angle.
(over 2160 N/mm²). Fleet angle must be always considered and
As already mentioned, this improves steel limited, as it creates a stress within the
ductility allowing a better resistance to repeated structure of the rope and contributes to fatigue
bending cycles. build up.
Contrary to expectation, rope composed of In case of fleet angle, groove oversize should be
many small wires may not have higher fatigue increased to 1.10 or more in order to facilitate
resistance, especially when working at low the passage of the rope through the groove.
safety factor.
In terms of system design, there are several
strategies that can be adopted to preserve
rope life.
The first tool is to increase the bending ratio of
the component over which the rope is running.

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 Figure 52 Effect of bending ratio on service life

Figure 53 Effect of fleet angle on service life Figure 54 Effect of groove ratio on service life

35

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GUIDELINES FOR ROPE
INSPECTION
Wire ropes must be periodically inspected The frequency of inspections depends on
following regulations (e.g. ISO 4309) and regulations, type of crane and environment,
internal procedures to assess rope deterioration results of previous examinations, load spectrum
due to regular use or unexpected events and and experience related to similar ropes and
to ensure safe working conditions. systems.
Inspections can be carried out with the aid of The main modes of deterioration are: broken
visual or magnetic devices: in this case, it is wires or strands, decrease in rope diameter,
recommended to perform an initial inspection corrosion, deformation, mechanical or heat
before rope use to have a baseline for future damage and change in elastic behaviour of
comparisons. rope under load.
Each rope shall be inspected along its entire
length or, at the discretion of the competent
person, along the working length plus at least
five wraps on the drum. In this case, if a greater
working length is subsequently foreseen to be
used, that additional portion should also be
inspected.

Figure 55 Ropes used for construction cranes

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The following areas have to be inspected with Terminations, clamps and securing ferrules
particular care: should be also inspected with special care to
• drum anchorage and any section close and detect possible looseness due to vibrations,
in correspondence to rope termination cracks, distortion, wear or corrosion.
• in case of repetitive operations, any part After each periodic inspection, the competent
of the rope that lies over a sheave during person shall provide a rope inspection record
crane working and state a maximum time interval that shall
• rope portion which lies over a compensating not be exceeded before the next periodic
sheave inspection takes place.
• cross-over zones on multilayer drums The following sketch shows some examples
• rope sections subjected to reverse bending of typical points which require special care
over sheaves or rollers during inspection.
• section subjected to external damage, like
abrasion or heat.

Crossover and max fleet angle

Block and head heaves

Compensating sheaves

Figure 56 Areas requiring detailed inspection

37

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INSPECTION OF GROOVES
AND SHEAVES
Before installing the new rope, the condition The recommended bending ratio D/d (e.g.
and dimensions of interface parts, like drums, ratio between diameter of the component
sheaves and rope guards, should be checked and rope nominal diameter) depends on rope
to verify that they are within the operating construction. Some typical values for crane
limits as specified by the original equipment applications are shown in the following table
manufacturer. and are determined based on uniform stress
The groove diameter, which can vary from distribution of rope, strands and individual
5% to 10% above the nominal rope diameter, wires.
should be checked using a sheave gauge (see Other values can be found on specific regulations.
figure). Sheaves should also be checked to
ensure that they are free to rotate.

Figure 57 Grooves inspection: correct size, narrow and

large groove Figure 58 Bending ratio
between rope and sheave

When grooves become excessively worn, they

can be re-machined if sufficient wall thickness
will remain in the underlying material after
the machining has been carried out.
Improper groove finishing can generate irregular
rope routing and derailing over the sheave. Figure 59 Examples of recommended bending ratios
for cranes

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TYPICAL ROPE DAMAGES
AND RECOMMENDED ACTIONS

Listed actions are for general purpose only, please contact Usha technical assistance for specific recommendations.

39

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DISCARD CRITERIA FOR
VISIBLE BROKEN WIRES
Rope conditions have to be clearly assessed by If groups of broken wires are found in a section
a competent person based on discard criteria of rope which does not spool on and off the drum
provided by regulations and internal procedures. and breaks are concentrated in adjacent strands,
Discard criteria depend on the nature, it might be necessary to discard the rope.
occurrence and location of broken wires It shall be discarded as well if two or more
and on the rope construction and are based wire breaks are found at a termination or
on number of visible broken wires, diameter concentrated in the valleys in a rope lay
variation, corrosion and distortion or a length, as this could indicate the beginning of
combination of all these factors. fatigue phenomenon.
Number of visible broken wires takes in account If breaks occur randomly in rope sections
only the breaks due to regular use, that indicate running through sheaves, spooled on and off
fatigue pile up and approaching of end of rope a single layer drum or on crossover points of
safe life, therefore breaks due to improper a multilayer drum, the maximum amount is
handling may not be considered in this count if determined by specific regulations (e.g. ISO
not affecting safety conditions. 4309). Some examples of maximum allowed
Breaks protruding from the rope can be breaks for different rope use and constructions
removed if there is the risk that they generate are shown in the following table.
further damage to the equipment or to the
rope itself.

Figure 60 Crown and valley breaks due to fatigue

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 Figure 61 Maximum number of visible broken wires for typical rope constructions

The numbers depend on the assumption that For non rotating ropes this difference is not
outer wire breaks correspond to a certain remarkable due to their geometrical structure,
number of inner wire breaks. therefore there is no distinction due to lay
Typically, the number of inner broken wires direction.
due to use of a Lang lay rope is higher than Breaks distribution along the rope can indicate
the number of outer broken wires, therefore fatigue beginning, therefore the number of
damage detection is harder and the number of broken wires over a significant rope length
outer allowed breaks must be lower. (e.g. 30d) is not proportional to the number
On the other hand, in ordinary lay ropes more of localized broken wires in a specific portion
breaks occur on the outer surface, therefore (e.g. 6d), which could be due to other causes
they are more detectable and the allowed to be specifically investigated.
number is higher than the Lang lay value.

41

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DISCARD CRITERIA FOR
DIAMETER DECREASE,
DEFORMATION AND CORROSION
Diameter shall be periodically measured and Other damages, like flattened portion or
compared to the initial reference value (i.e. permanent bend, may not be cause of immediate
recorded measurement taken immediately discard, but they have to be inspected with
after receipt) to detect uniform or localized higher frequency, as the affected portions are
variations. likely to deteriorate and show broken wires at
Diameter decrease has to be calculated using faster rate than usual.
the below formula. Waviness should be assessed using a straight
In case of uniform decrease, the maximum bar and considering the gap between the rope
allowed value is 5% in respect to nominal and the cut surface (see figure): the maximum
diameter for non rotating ropes, 7.5% for other allowed gap “g” is 1/3 the rope nominal
rope constructions with steel core, 10% for diameter “d” if the deformation affects a
fibre core ropes. portion not running over sheaves or spooled on
A clear localized decrease indicates a severe the drum, otherwise it has to be reduced to 1/10.
failure of rope core and leads to immediate
rope discard.
Also in case of break of a complete strand,
rope has to be immediately discarded.
Ropes showing deformations like basket,
core or strand protrusion or distortion, kink Figure 62 Waviness assessment
or tightened loop shall be evaluated and can
remain in service if the damaged portion can
be removed and if the remaining part of rope
is still suitable for use.

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Corrosion should be evaluated after having Rope should also be discarded in case of severe
wiped the rope to remove contaminating fretting corrosion, which manifests as a dry
particles and should be assessed considering red powder and is caused by the continuous
type and severity. rubbing between dry wires and consequent
Rope should be discarded in case of heavy pitting particles oxidation.
and slack wires on the external surface, as
well as in case of internal corrosion, indicated
by the presence of debris extruding between
the outer strands.

Figure 63 Rope showing external corrosion

43

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HEALTH AND SAFETY
INFORMATION
As a general indication, applicable to all types Fibre cores are composed by synthetic or
of working environment, workers must be natural fibres and do not present a health
properly trained and have all the necessary hazard when handled, except in the unlikely
equipment and operating procedures to case that the core may have decomposed into
perform their job safely. a dust which may be inhaled.
Steel wire rope is a composite product containing Also the concentration of toxic fumes from the
different materials, which can be identified cores generated during cutting will be almost
based on the delivery note, invoice or certificate. negligible compared with the products generated
The main component of steel wire ropes by wire and lubricant.
covered by the various parts of EN 12385 is Same risk of toxic fumes inhalation applies to
carbon steel, which may be galvanized or plastic filling or covering.
coated with zinc aluminium alloy. The lubricants used in the manufacture of steel
Other components can be the fibre core, the wire ropes normally present minimal hazard to
lubricant and possible plastic filling or covering. the user, who should anyway take reasonable
Ropes produced from carbon, galvanizing coated care to minimize skin and eye contact and also
or stainless steel wires in the as-supplied avoid breathing their vapours and mists.
condition are not considered a health hazard.
However, during any subsequent processing
such as cutting, welding, grinding and cleaning,
dust and fumes may be produced which
contain elements that may affect the health
of exposed workers.

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Lubricants consist essentially of mixtures of oils, In the solid state, steel components of the
waxes, bitumen, resins, petroleum jelly, gelling rope present no fire or explosion hazard.
agents and fillers with minor concentrations of Organic elements, like lubricants, natural and
corrosion inhibitors, oxidation stabilizers and synthetic fibres and other natural or synthetic
tackiness additives and they are typically solid filling and covering materials are capable of
at ambient temperature. supporting fire.
To avoid the possibility of skin disorders, Ropes and components must be disposed of in
repeated or prolonged contact with mineral accordance with local Regulations.
or synthetic hydrocarbons should be avoided
and workers should always wear protective
clothing and gloves.
General and local exhaust ventilation should
be used to keep airborne dust or fumes below
established occupational exposure standards
and operators should wear approved dust and
fume respirators if these values are exceeded.
Protective equipment should be worn during ope-
rations creating eye hazards, as well as gloves and
other protective equipment when required.
A welding hood should be worn when welding
or burning.

45

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APPENDIX A
QUICK CALCULATOR
Quick calculation for general purpose evaluations or for preliminary design feasibility can be made
using the following formulas and tables, which provide a set of relevant nominal values.

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APPENDIX B
DEFINITIONS
• BREAKING FORCE 6. spinning loss factor (k): the ratio between
1. minimum breaking force (Fmin): specified either the calculated minimum breaking
value in kN, below which the measured force (Fc.min) and the calculated minimum
breaking force (Fm) is not allowed to fall aggregate breaking force (Fe.c.min) of the
in a prescribed breaking force test and rope or the specified minimum breaking
force (Fmin) and the specified minimum
normally obtained by calculation from
aggregate breaking force (Fe.min) of the
the product of the square of the nominal
rope, as determined from the ropemaker’s
diameter (d), the rope grade (Rr) and the
design [amended]
breaking force factor (K)
7. measured total spinning loss factor (km):
2. minimum breaking force factor (K): an the ratio between the measured breaking
empirical factor used in the determination force (Fm) of the rope and the measured
of minimum breaking force of a rope and aggregate breaking force of the rope,
obtained from the product of fill factor (f) before rope making
for the rope class or construction, spinning
• COATING
loss factor (k) for the rope class or
1. finish and quality of coating: the
construction and the constant π/4 condition of the surface finish of the wire
3. calculated minimum breaking force (Fc. e.g. uncoated (bright), zinc coated, zinc
min): value of minimum breaking force based alloy coated or other protective coating
on the nominal wire sizes, wire tensile and the class of coating, e.g. class B zinc
strength grades and spinning loss factor for coating, defined by the minimum mass of
the rope class or construction as given in coating and the adherence of the coating
the manufacturer’s rope design to the steel below
4. minimum aggregate breaking force (Fe. 2. mass of coating: the mass of coating
min): specified value, in kN, below which (obtained by a prescribed method) per
the measured aggregate breaking force is unit of surface area of the uncoated wire,
not allowed to fall in a prescribed test and expressed in g/m²
normally obtained by calculation from the • CORE
product of the square of the rope diameter 1. core: central element of a round rope
(d), the metallic cross sectional area factor around which are laid helically the strands
(C) and the rope grade (Rr) of a stranded rope or the unit ropes of a
5. measured aggregate breaking force cable laid rope
2. fibre core (FC): core made from either
(Fe.m): the sum of the measured breaking
natural fibres (NFC) or synthetic fibres
forces of all the individual wires taken
(SFC) (Note - Fibre cores are normally
from the rope
produced in the sequence fibres to yarns,
yarns to strands and strands to rope)

47

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3. steel core (WC): core made from steel • DIMENSIONS
wires arranged as a wire strand (WSC) or 1. dimension of round wire or strand: the
as an independent wire rope (IWRC) (Note diameter of the perpendicular cross-section
The steel core and/or its outer strands can of the wire or strand
also be covered with either fibre or solid 2. dimension of round rope:that diameter
polymer) which circumscribes the rope cross-section
4. solid polymer core (SPC): core consisting 3. outer wire factor (a): factor used in the
of a solid polymer material having a round calculation of the approximate diameter of
shape or a round shape with grooves. It the outer wires of the outer strand layer
may also contain an internal element of 4. outer wire diameter (δa): the value
wire(s) or fibre derived from the product of the outer wire
• CROSS SECTIONAL AREA AND MASS factor and the nominal rope diameter
1. fill factor (f): the ratio between the sum • GRADE AND TENSILE STRENGTH
of the nominal metallic cross-sectional 1. rope grade (Rr): a level of requirement
areas of all the wires in the rope and the of breaking force which is designated by a
circumscribed area of the rope based on number (e.g. 1770, 1960) (Note - It does
its nominal diameter not imply that the actual tensile strength
2. nominal metallic cross-sectional area grades of the wires in the rope are necessarily
factor (C): factor derived from fill factor of this grade)
and used in the calculation to determine 2. wire tensile strength grade (R): a level
the nominal metallic cross-sectional area of requirement of tensile strength of a
of a rope (Note - This can be expressed as wire and its corresponding range. It is
C = f • π/4) designated by the value according to the
3. nominal metallic cross-sectional area (A): lower limit of tensile strength and is used
the product of the nominal metallic when specifying wire and when determining
cross-sectional area factor (C) and the the calculated minimum breaking force or
square of the nominal rope diameter calculated minimum aggregate breaking
4. rope length mass factor (W): that factor force of a rope, expressed in N/mm²
which takes into account the mass of core 3. wire tensile strength (Rm): the ratio
and lubricant as well as the metallic between the maximum force obtained in a
elements tensile test and the nominal cross-sectional
5. nominal rope length mass (M): product of area of the test piece, expressed in N/mm²
the length mass factor and the square of
the nominal diameter

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• LAY around a core (single-layer rope) or centre
1. lay length (H): that distance (H) parallel (rotation-resistant or parallel-closed rope)
to the longitudinal rope axis in which the (Note - Stranded ropes consisting of three
outer wires of a spiral rope, the outer or four outer strands can, or cannot, have
strands of a stranded rope or the unit a core)
ropes of a cable-laid rope make one 4. single-layer rope: stranded rope consisting
complete turn (or helix) about the axis of of one layer of strands laid helically
the rope around a core
2. lay direction of rope: the direction right 5. rotation-resistant rope: stranded rope
(Z) or left (S) corresponding to the direction designed to generate reduced levels of
of the outer strands in a stranded rope torque and rotation when loaded (Note
in relation to the longitudinal axis of the - Rotation-resistant ropes generally
rope comprise an assembly of at least two
3. ordinary lay (sZ or zS): stranded rope in layers of strands laid helically around a
which the direction of lay of the wires in centre, the direction of lay of the outer
the outer strands is in the opposite direction strands being opposite to that of the
to the lay of the outer strands in the rope underlying layer. Ropes having three or
(Note - The first letter denotes strand four strands can also be designed to exhibit
direction; the second letter denotes rope rotational-resistant properties)
direction) 6. parallel-closed rope: stranded rope consisting
4. lang lay (zZ or sS): stranded rope in which of at least two layers of strands laid
the lay direction of the wires in the outer helically in one closing operation around a
strands is in the same lay direction as that strand or fibre centre
of the outer strands in the rope (Note - 7. compacted strand rope: rope in which the
The first letter denotes strand direction; strands, prior to closing of the rope, are
the second letter denotes rope direction) subjected to a compacting process such as
• ROPES drawing, rolling or swaging
1. rope construction: the detail and 8. compacted (swaged) rope: rope which
arrangement of the various elements of is subjected to a compacting (usually
the rope swaging) process after closing the rope,
2. rope class: a grouping of ropes of similar thus reducing its diameter
mechanical properties and physical 9. cable-laid rope: an assembly of several
characteristics (usually six) round stranded ropes
3. stranded rope: an assembly of several (referred to as unit ropes) closed helically
strands laid helically in one or more layers around a core(usually a seventh rope)

49

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• ROPE CHARACTERISTICS 3. Seale: parallel lay strand construction with
1. torque: torsional characteristic, the value the same number of wires in both layers
of which is usually expressed in Nm, at a 4. Warrington: parallel lay strand construction
stated tensile loading and determined by having an outer layer containing alternately
test when both rope ends are prevented large and small wires and twice the number
from rotating (Note - Torsional characteristics of wires as the inner layer
can also be determined by calculation) 5. Filler: parallel lay strand construction
2. turn: rotational characteristic, the value having an outer layer containing twice the
of which is usually expressed in degrees or number of wires than the inner layer, with
turns per unit length at a stated tensile filler wires laid in the interstices between
loading and determined by test when one the layers
end of the rope is free to rotate • WIRE
3. fully preformed rope: rope in which 1. outer wires: all wires positioned in the
the wires in the strands and strands in outer layer of a spiral rope or in the outer
the rope have their internal stresses layer of wires in the outer strands of a
reduced resulting in a rope which after stranded rope
removal of any serving, the wires and the 2. inner wires: all wires of intermediate
strands will not spring out of the rope layers positioned between the centre wire
formation and outer layer of wires in a spiral rope or
• STRAND all other wires except centre, filler, core
1. strand: an element of rope consisting of and outer wires in a stranded rope
3. filler wires: wires used in filler constructions
an assembly of wires of appropriate shape
to fill up the interstices between wire
and dimensions laid helically in the
layers
same direction in one or more layers
4. centre wires: wires positioned either at
around a centre (Note - Strands containing
the centre of a spiral rope or the centres
three or four wires in the first layer, or
of strands of a stranded rope
certain shaped strands (e.g. ribbon) cannot
5. core wires: all wires of the core of a
have a centre)
stranded rope
2. compacted strand: a strand which has
6. load-bearing wires: those wires in a
been subjected to a compacting process
rope which are regarded as contributing
such as drawing, rolling or swaging whereby
towards the breaking force of the rope
the metallic cross-sectional area of the 7. serving wire or strand: single wire or
wires remains unaltered whereas the shape strand used for making a close-wound
of the wires and the dimensions of the helical serving to retain the elements of a
strand are modified rope in their assembled position

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APPENDIX C
REFERENCE DOCUMENTS
The following list indicates some of the most
relevant documents about wire ropes definitions,
use, maintenance and inspection.

• EN 12385-1:2009 – Steel wire ropes – Safety • EN12927– Part 8 – Magnetic rope testing
Part 1: General requirements • ISO 17558:2006 – Steel wire ropes – Socketing
• EN 12385-2:2008 – Steel wire ropes – procedures – Molten metal and resin socketing
Safety Part 2: Definitions, designation and • ISO 4309:2010 – Cranes – Wire ropes – Care
classification and maintenance, inspection and discard
• EN 12385-3:2008 – Steel wire ropes – Safety • IMCA M171 – Crane specification document
Part 3: Information for use and maintenance • IMCA M179 – Guidance on the use of cable
• EN 12385-4:2008 – Steel wire ropes – Safety laid slings and grommets
Part 4: Stranded ropes for general lifting • IMCA M187 – Guidelines for lifting operations
applications • IMCA M194 – Wire rope integrity management
• EN 13411-3:2011 – Terminations for steel for vessels in the offshore industry
wire ropes – Safety Part 3: ferrules and • IMCA M197 – Guidance on non-destructive
ferrule-securing examination (NDE) by means of magnetic
• EN 13411-4:2011 – Terminations for steel rope testing
wire ropes – Safety Part 4: metal and resin • API 9A/ISO 10425:2003 – Steel wire ropes for
socketing the petroleum and natural gas industries
• EN 13411-5:2011 – Terminations for steel – Minimum requirements and terms of
wire ropes – Safety Part 5: U-bolt wire acceptance
rope grips • API RP 9B:2005 – American Petroleum
• EN 13411-6:2011 – Terminations for steel Institute recommended practice for
wire ropes – Safety Part 6: Asymmetric application, care and use of wire rope for
wedge socket oilfield services
• EN 13411-7:2011 – Terminations for steel • Wire rope technical board – Wire rope
wire ropes – Safety Part 7: Symmetric wedge user’s manual 4th edition
socket

51

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APPENDIX D
EXAMPLES OF STRANDS AND
ROPES CONSTRUCTIONS

Single lay 19 Seale compacted 25 Filler 26 Warrington Seale

7 (1-6) K19S (1-9-9) 25F (1-6-6F-12) compacted
K26WS (1-5-5+5-10)

29 Filler 31 Warrington Seale 36 Warrington Seale 41 Warrington Seale

29F (1-7-7F-14) compacted 36WS (1-7-7+7-14) compacted
K31WS (1-6-6+6-12) K41WS (1-8-8+8-16)

6xK7 – FC 6xK36WS - IWRC 6xK36WS - PWRC 8xK26WS – FC

8x19S - IWRC 10xK19S – IWRC 35xK7 57xK7

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Notes

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