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Air Supply
The air supply must be clean, free from moisture and lubricated to ensure optimum
motor performance. Foreign particles, moisture and lack of lubrication are the
primary causes of premature motor wear and breakdown. Using an air filter,
lubricator and moisture separator will improve overall product performance and
reduce unscheduled downtime. Refer to Dwg. MHP0191 on page 11, A. Air Out;
B. Lubricator; C. Regulator; D. Air In; E. Filter.
Refer to Table 2 ‘Specifications’ on page 4 for motor air consumption and rated
operating pressure. If air supply varies from what is recommended, product
performance will change.
Install air line lubricator, filter and regulator as close as possible to air inlet on motor.
Lubricator must be located no more than 10 ft (3 m) from motor. Air line accessories
package can also be mounted to the winch guard panel on the operator’s side or
opposite.
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Air Lines
Inside diameter of air supply lines must not be less than size specified in Table 2
‘Specifications’ on page 4. Before making final connections, all air supply lines should
be purged with clean, moisture free air or nitrogen before connecting to main air
inlet. Supply lines should be as short and straight as installation conditions will
permit. Long transmission lines and excessive use of fittings, elbows, tees, globe
valves, etc. cause a reduction in pressure due to restrictions and surface friction in
lines.
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Air Line Lubricator
Always use an air line lubricator with these motors. The lubricator must have an inlet
and outlet at least as large as inlet on motor.
CAUTION
•
Lubricator must be located no more than 10 ft (3 m) from motor.
•
Shut off air supply before filling air line lubricator.
The air line lubricator should be replenished daily and set to provide 2 to 3 drops
per minute of ISO VG 32 (SAE 10W) oil. A fine mist will be exhausted from control
valve when air line lubricator is functioning properly.
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Air Line Filter
It is recommended that an air line strainer/filter be installed before the lubricator to
prevent dirt from entering the motor. The strainer/filter should provide 20 micron
filtration and include a moisture trap. Clean the strainer/filter periodically to maintain
its operating efficiency.
NOTICE
•
When air filter is used ensure it allows air to pass through at products rated
scfm. Refer to “SPECIFICATIONS” on page 3.
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Air Pressure Regulator
If an air pressure regulator is used, install between lubricator and filter.
NOTICE
•
Do not adjust regulator for a CE marked product, these are preset at factory
and pressure gauges are not provided. Adjustment of regulator will effect
overload settings and product will no longer conform to CE regulations.
•
Not all products are CE approved, refer to products data (name) plate to
see if this applies.
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Moisture in Air Lines
Moisture that reaches the air motor through air supply lines is a primary factor in
determining the length of time between service overhauls. Moisture traps can help
to eliminate moisture. Other methods, such as an air receiver which collects moisture
before it reaches motor, or an aftercooler at compressor that cools air to condense
and collect moisture prior to distribution through supply lines, are also helpful.
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Mufflers
Ensure mufflers are installed in winch exhaust manifold and control valve exhaust
port. Check mufflers periodically to ensure they are functioning correctly.
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Shut Off Valve
Refer to the Product Safety Information Manual for information.
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Motor
For optimum performance and maximum durability of parts, provide recommended
air supply as measured at motor inlet. Refer to Table 2 ‘Specifications’ on page 4. The
air motor should be installed as near as possible to compressor or air receiver.
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Tensioning System (optional feature)
Refer to Dwg. MHP1176 on page 12; A. Payout; B. Motor; C. Haul-In; D. Brake; E.
Check Valve; F. Pressure Gauge; G. Regulator; H. Selector Valve; J. Manual Throttle;
K. Shuttle Valve; L. Quick Exhaust Valve; M. Air Supply.
The air supply line is connected to one of the two top ports on the control valve. This
will allow air to supply either the normal control valve or the auxiliary valve.
WARNING
•
Use only one control valve to operate winch at any time. Attempting to
OVERRIDE one control valve with the other will result in total loss of winch
control.
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Limit Switches
Limit switches are standard on -CE winches.
Pre-set limit switch settings prevent winch wire rope payout and haul-in by stopping
air flow to the winch motor when a defined set point has been reached. It is the
owner’s and operator’s responsibility to adjust winch operating limits prior to using
winch.
NOTICE
•
Settings for limit switch are for an overwound operation only.
To adjust set points:
Follow instructions in the order they appear for limit switch adjustment (use two
people to make adjustments). Refer to Dwg. MHP2688 on page 13, A. Center Nut;
B. Payout; C. Haul-In:
1. Remove cap from limit switch cover.
2. Partially unscrew center nut.
3.
PAYOUT: Rotate (#1) screw (counterclockwise) while slowly paying out until
winch shuts off.
4.
HAUL-IN: Rotate (#2) screw (clockwise) while slowly hauling in until winch shuts
off.
5. Tighten center nut.
6. Reinstall cap on limit switch cover and tighten.
WARNING
•
Ensure limit switch setpoints are established and operating properly before
putting winch into service.
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Press Roller
Ensure wire rope is positioned between press roller and drum barrel and springs
keep press roller in tight contact with wire rope.
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Initial Winch Operating Checks
Winches are tested for proper operation prior to leaving the factory. Before the winch
is placed into service the following initial operating checks should be performed.
1. When first running the motor inject a small amount of light oil into the inlet
connection to provide initial lubrication.
2. Check oil level in motor, reduction gear assembly and disc brake are correct. Top
off levels as required before operation as described in
3. Operate winch in both directions with no load for one to two minutes.
4. New brake band Lining Run-in Procedure: All new brake band linings require a
‘run-in’ period. Operate the winch without load in the payout direction while
gradually applying the brake. Allow the brake to slip for approximately one
minute. Winch motor may stall as drum brake band lining fully engages. Do not
allow brake to overheat.
5. Check operation of brakes. Adjust if necessary as described in “MAINTENANCE”
section in the Product Maintenance Information Manual.
6. Check operation of limit switches, locking mechanisms and all safety devices
when equipped.
7. Check foundation mounting fasteners are secure.
8. Install drum guard when provided.
For winches that have been in storage, the following start-up procedures are
required:
1. Give the winch an inspection conforming to requirements of
‘Winches Not in Regular Use’ on page 9.
2. Pour a small amount of ISO VG 32 (SAE 10W) oil in motor inlet port.
3. Operate motor for 15 seconds in both directions to flush out any impurities.
4. The winch is now ready for normal use.
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Form MHD56434 Edition 6
