Form MHD56349 Edition 1
5
Wire Rope
CAUTION
• Use only 5/8 inch (16 mm) wire rope on a winch designed to conform with
ANSI A10.22 standards.
• Maintain at least 4 tight wraps of wire rope on the drum at all times. Ensure
wire rope top layer is a minimum of 2 inches (50 mm) below drum flange edge.
Refer to Dwg. MHP2449 in Product Safety Information Manual “Winch Safe
Operating Practices” for Man Rider Winches.
• 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). Refer to Dwg. MHP2450 in Product Safety Information Manual
“Winch Safe Operating Practices” for Man Rider Winches.
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 on page 5 for minimum and maximum recommended
wire rope sizes.
Installing Wire Rope
NOTICE
• When installing wire rope, pressurize 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 opposite side of drum.
CAUTION
• Make sure first wrap of wire rope is tight and lays flush against drum flange.
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 manufactures’ recommendation on use and
maintenance of wire rope.
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.
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 handbook for proper sizing, use and care of wire rope.
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 diameter of wire rope. Always maintain
at least three full, tight wraps of wire rope on drum.
Winch Guard
Use of a winch guard is recommended on all winches.
WARNING
• Do not allow wire rope to come in contact with winch guard panels during
winch operation. Wire rope could become worn and damaged. Adjust winch
guard panels to clear wire rope travel angle.
Refer to Product Parts Information Manual.
Drum guard panels must be adjusted to suit wire rope departure angle. To reposition
winch guard panels remove nuts and slide out crossbar. Position panels to avoid wire
rope contact and install crossbar and nuts.
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 winch performance and reduce
unscheduled downtime. Install an emergency shut-off valve in the control valve inlet
line.
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 either side of
winch.
Refer to Table 2, “Specifications,” on page 4 for motor air consumption and rated
operating pressure. If air supply varies from what is recommended, winch
performance will change.
Refer to Dwg. MHP0191 on page 11,
A.
Air Out;
B.
Lubricator;
C.
Regulator;
D.
Air In;
E.
Filter.
Air Lines
Inside diameter of winch air supply lines must not be less than sizes specified in
Table 2 on page 4. Before making final connections, all air supply lines should be
purged with clean, moisture free air or nitrogen before connecting to winch 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.
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
• Shut off air supply before filling air line lubricator.
The air line lubricator should be replenished daily and set to provide 6 to 9 drops per
minute of ISO VG 32 (SAE 10W) oil. A fine mist will be exhausted from throttle
control valve when air line lubricator is functioning properly.
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.
Air Pressure Regulator
If an air pressure regulator is used, install between lubricator and filter. Set pressure
regulator to 90 psi (6.2 bar).
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.
Mufflers
Ensure mufflers are installed in winch exhaust manifold and control valve exhaust
port. Check mufflers periodically to ensure they are functioning correctly.
Table 7: Minimum and Maximum Wire Rope Size
Minimum
Maximum
inch
mm
inch
mm
5/8
16
7/8
22
Note 1:
Maximum wire rope diameter is limited by size of wire rope anchor hole.
