INSTALLATION
Prior to installing the product, carefully inspect it for possible shipping damage.
Products are supplied fully lubricated from the factory. Check oil levels and adjust
as necessary before operating product. Refer to “LUBRICATION” section
on page 9 for recommended oils and lubrication intervals.
WARNING
•
Product not installed properly may fall or cause a load to fall resulting in
sever injury or death. Before installation and operation of this product refer
to Product Safety Information manual and all safety warnings pertaining
to this product.
CAUTION
•
Always install, operate, inspect, and maintain this product in accordance
with all applicable standards and regulations (state, country, and federal,
etc.). For example In the USA, the applicable standards are American
Society of Mechanical Engineers (ASME) and National Fire Protection
Agency (NFPA).
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Mounting
Care must be taken when moving, positioning or mounting the winch. In most cases,
lifting lugs have been provided to assist in handling the winch. If lug locations are
improper for your specific installation, great care should be taken to ensure that
winch, when lifted, will be properly balanced. Determine weight of your winch by
referring to “SPECIFICATIONS” section on page 3. Add weight of wire rope and other
installed options as necessary. Lift winch 3 to 4 inches (75 to 100 mm) off ground.
Verify winch is balanced and secure before continuing lift. Mount winch so axis of
drum is horizontal and that motor vent cap is not more than 15° off top vertical
center. If winch is to be mounted in an inverted position, motor case must be rotated
to position vent cap to the top.
1. The winch mounting surface must be flat and of sufficient strength to handle
rated load plus weight of winch and attached equipment. An inadequate
foundation may cause distortion or twisting of winch uprights and siderails
resulting in winch damage.
2. Make sure mounting surface is flat to within 0.005 inch (0.127 mm) per inch of
drum length. Shim if necessary. Refer to Table 5 ‘Mounting Surface Tolerance’
3. Mounting bolts must be Grade 8 or better. Use self-locking nuts or nuts with
lockwashers. Refer to Table 6 ‘Mounting Bolts’ on page 5.
4. Tighten mounting bolts evenly and torque to specification in torque chart. Refer
to ‘TORQUE CHART’ in Product Maintenance Manual.
5. Maintain a fleet angle between sheave and winch of no more than 1-1/2°. The
lead sheave must be on a center line with drum and, for every inch (25 mm) of
drum length, be at least 1.6 feet (0.5 metre) from the drum. Refer to Product
Safety Information Manual.
6. Do not weld to any part of winch.
Refer to Dwg. MHP0133 on page 11, A. Drum.
Table 5: Mounting Surface Tolerance
Drum Length
Mounting Surface Minimum Flatness
inch
mm
8
0.04
1.02
12
0.06
1.52
16
0.08
2.03
20
0.10
2.54
24
0.12
3.05
30
0.15
3.81
36
0.18
4.57
Table 6: Mounting Bolts
Models
Mounting Bolts
inch
mm
FA2.5i-MR/FA2.5i-MR-CE
5/8
16
FA5i-MR/FA5i-MR-CE
3/4
18
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Wire Rope
CAUTION
•
Maintain at least 3 tight wraps of wire rope on the drum at all times.
•
Do not use wire rope as a ground (earth) for welding.
•
Do not attach a welding electrode to winch or wire rope.
•
Install wire rope to come off drum for overwind operation (normal
application).
NOTICE
•
For underwound applications order the “U” option or contact factory prior
to operation.
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Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor for assistance in selecting
the appropriate type and size of wire rope and, where necessary, a protective
coating. Use a wire rope which provides an adequate safety factor to handle the
actual working load and meets all applicable industry, trade association, federal,
state and local regulations.
When considering wire rope requirements the actual working load must include not
only the static or dead load but also loads resulting from acceleration, retardation
and shock load. Consideration must also be given to the size of the winch wire rope
drum, sheaves and method of reeving. Maximum wire rope diameter is limited by
the wire rope anchor. It is recommended that wire rope construction be 6 X 19 or 6
X 37 IWRC right lay. Refer to Table 7 ‘Minimum and Maximum Wire Rope Size’
on page 5 for recommended sizes.
Table 7: Minimum and Maximum Wire Rope Size
Models
Minimum
Maximum
inch
mm
inch
mm
FA2.5i-MR/FA2.5i-MR-CE
5/8
16
5/8
16
FA5i-MR/FA5i-MR-CE
7/8
22
Note 1: Maximum wire rope diameter is limited by size of wire rope anchor hole.
Refer to Product Parts Information Manual for correct wire rope anchor part numbers.
Note 2: Wire rope diameter is fixed if grooved drum option is used.
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Installing Wire Rope
NOTICE
•
When installing wire rope, pressurize disc brake with a minimum of 45 psi
(3.1 bar) air from an auxiliary source.
Refer to Dwg. MHP2686 on page 11, A. Anchor; B. Wire Rope.
1. Cut wire rope to length in accordance with wire rope manufacturer’s
instructions.
2. Feed end of wire rope through drum anchor pocket hole.
3. Forming a loop, wrap loop around anchor, approximately 22 inches (559 mm)
of wire rope.
4. Pull wire rope anchor into position in drum anchor pocket. Ensure no extra (open
end) of wire rope is extending out of drum anchor pocket.
CAUTION
•
Make sure first wrap of wire rope is tight and lays flush against drum flange.
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Safe Wire Rope Handling Procedure
-
Always use gloves when handling wire rope.
-
Never use wire rope that is frayed or kinked.
-
Never use wire rope as a sling.
-
Always ensure wire rope is correctly spooled and the first layer is tight against
drum.
-
Always follow wire rope manufacturer’s recommendation on use and
maintenance of wire rope.
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Wire Rope Spooling
To compensate for uneven spooling and the decrease in line pull capacity as the
drum fills up, use as short a wire rope as practical. When rewinding apply tension to
the end of the wire rope to eliminate line slack. This helps achieve level winding and
tight spooling.
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Rigging
Make sure all wire rope blocks, tackle and fasteners have a sufficient safety margin
to handle required load under all conditions. Do not allow wire rope to contact sharp
edges or make sharp bends which will cause damage to wire rope, use a sheave.
Refer to wire rope manufacturer’s instructions for proper sizing, use and care of wire
rope.
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Safe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire rope.
3. Never run wire rope over a sharp edge. Use a correctly sized sheave.
4. When a lead sheave is used, it must be aligned with center of drum. The diameter
of lead sheave must be at least 18 times the diameter of wire rope. Refer to Dwg.
MHP2449 in Product Safety Information Manual.
5. Always maintain at least three full, tight wraps of wire rope on drum.
Form MHD56435 Edition 6
5
