Form MHD56349 Edition 1
9
WARNING
• All new, altered or modified equipment should be inspected and tested by
Ingersoll Rand trained technicians to ensure safe operation at rated
specifications before placing equipment in service.
• Never use a winch that inspection indicates is damaged.
• Prior to using the winch to lift personnel, an initial inspection should be
conducted after assembly, major repairs or alteration, and when the system has
been idle for periods of longer than one month.
Daily checks, weekly and quarterly inspections should be performed on equipment in
regular use.
1.
Daily checks
are visual examinations performed by operators or personnel
instructed in safety and operation of this equipment and include observations
made during routine equipment operation.
2.
Weekly inspections
are thorough inspections conducted by
Ingersoll Rand
trained inspectors. Weekly inspections are also required prior to personnel lifting
if the system has been idle for periods in excess of one week, but less than one
month.
3.
Quarterly inspections
are a combination of weekly inspection requirements and
the performance of a static drop test
on guided cage systems only
to verify
operation of the cage’s safety clamp.
Winch Daily Checks and Weekly Inspections
On equipment in continuous service, weekly inspections are required. Maintain
written records of weekly inspections to provide an accumulative basis for continuing
evaluation. Disassembly may be required as a result of inspection findings.
In addition, daily checks, or visual inspections should be conducted by operators
during regular operation for damage or evidence of malfunction.
1. WINCH (DAILY). At the beginning of the shift, prior to operation, visually inspect
winch housings, controls, brakes, siderails and drum for indications of damage.
Do not operate the winch until all discrepancies noted have been reviewed,
inspected further and corrected by personnel instructed in the operation, safety
and maintenance of this winch.
WINCH (WEEKLY). Inspect the following:
a.
SIDE RAILS AND END UPRIGHTS. Check for deformed, cracked or corroded
main components. Replace damaged parts.
b.
FASTENERS. Check external retainer rings, split pins, capscrews, nuts, and
other fasteners on winch, including mounting bolts. Replace if missing or
damaged and tighten if loose.
c.
DRUM AND SHEAVES. Check for cracks, wear or damage. Replace damaged
parts.
2. WIRE ROPE (DAILY). Visually inspect all wire rope which can be expected to be in
use during the day’s operations. Inspect for wear and damage indicated by
distortion of wire rope such as kinking, “birdcaging”, core protrusion, main
strand displacement, corrosion, broken or cut strands. If damage is evident, do
not operate winch until the discrepancies have been reviewed and inspected
further by an experienced wire rope inspector.
NOTICE
• The full extent of wire rope wear cannot be determined by visual inspection.
At any indication of wear inspect the wire rope in accordance with the following
instructions.
WIRE ROPE (WEEKLY).
a.
Ensure wire rope is spooled onto the drum for overwind operation only and
that a minimum of 2 inches (50 mm) clearance is maintained between the
outside edge of the drum flange and the outermost layer of wire rope.
b.
Buildup of dirt and corrosion. Clean with steam or a stiff wire brush to
remove dirt and corrosion if necessary.
c.
Loose, frayed or damaged end connection. Replace if loose, frayed or
damaged. Ensure ends will not catch on personnel.
d.
Ensure the wire rope is securely anchored in the winch drum.
e.
Verify wire rope diameter. Measure the diameter of the wire rope from
crown-to-crown throughout the life of the wire rope. Recording of the
actual diameter should only be done with the wire rope under equivalent
loading and in the same operating section as accomplished during previous
inspections. If the actual diameter of the wire rope has decreased more
than 1/64 inch (0.4 mm) a thorough examination of the wire rope should
be conducted by an experienced inspector to determine the suitability of
the wire rope to remain in service.
3. AIR SYSTEM (WEEKLY). Visually inspect all connections, fittings, hoses and
components for indication of air leaks. Repair any leaks and replace damaged
components.
4. CONTROLS (DAILY AND WEEKLY). During operation of winch, verify response to
control is quick and smooth. If winch responds slowly or movement is
unsatisfactory, do not operate winch until all problems have been corrected.
5. BRAKES (WEEKLY). Ensure proper operation. Verify each brake system will hold a
150% rated load with full drum (as applicable to normal use) without slipping. If
indicated by poor operation or visual damage, disassemble and repair brake(s).
Check all brake surfaces for wear, deformation or foreign deposits. If drum brake
lining thickness is 0.062 inch (2 mm) or less anywhere along its edge replace
brake bands or linings. Clean and replace components as necessary. Test each
brake system independently.
6. LIMIT SWITCHES (WEEKLY). Verify winch limit switches operate at the set limits.
When actuated, limit switches interrupt air flow to the motor in the direction of
winch operation only. Adjust limit settings or repair to correct all noted
discrepancies.
7. ALL COMPONENTS (WEEKLY). Inspect for wear, damage, distortion, deformation
and cleanliness. If external evidence indicates damage, disassemble as required
to conduct a detailed inspection. Inspect gears, shafts, bearings, springs and
covers. Replace worn or damaged parts. Clean, lubricate and reassemble.
8. SUPPORTING STRUCTURE (WEEKLY). Check for distortion, wear and continued
ability to support winch. Ensure winch is firmly mounted and that fasteners are
in good condition and tight.
9. LABELS AND TAGS (WEEKLY). Check for presence and legibility of labels. Replace
if damaged or missing.
10. WIRE ROPE LINE SPEED MONITOR. Verify Line Speed Monitor displays line speed
and overspeed alarm lights at 100 feet per minute (+/- 10 feet) (30.5 metres per
minute; +/- 3 metres). If battery charge light is on, charge battery.
11. WINCH EXHAUST AND MUFFLER. Visually inspect exhaust hoses, connections and
muffler for damage. Ensure piping and muffler are correctly installed and direct
exhaust away from winch operator. Operator noise levels must not exceed 90 dBA
over an 8 hour period [Time Weighted Average (TWA)].
12. Ensure electrical ground (earth) is firmly connected and that wire is in good
condition. Replace wire if corroded or damaged.
Winch Initial and Quarterly Inspections
Disassembly may be required as a result of inspection findings or in order to properly
inspect the individual components. Maintain written records of initial and quarterly
inspections to provide an accumulative basis for continuing evaluation. Inspect all
items listed in “Weekly Inspection.” Also conduct the following:
1. INITIAL INSPECTION. Conduct all requirements of ‘Winch Daily and Weekly
Inspection’ and ‘Winch Testing’.
2. QUARTERLY INSPECTION. Conduct all requirements of ‘Winch Daily and Weekly
Inspection’ and ‘Winch Testing’.
Winches Not in Regular Use
1. Equipment which has been idle for a period of one month or more, but less than
six months, shall be given an inspection conforming to the requirements of
“Weekly Inspection” before being placed in service.
2. Equipment which has been idle for a period of over six months shall be given a
complete inspection conforming with the requirements of “Periodic Inspection”
before being place in service. Refer to Product Maintenance Information Manual.
3. Standby equipment shall be inspected at least semi-annually in accordance with
the requirements of “Weekly Inspection”.
Storing The Winch
1. Always store the winch in a no load condition.
2. Wipe off all dirt and water.
3. Oil the wire rope.
4. Place in dry location.
5. Before returning winch to service, follow instructions for ‘Winches Not In Regular
Use’ in the “INSTALLATION “ section on page 9.
LUBRICATION
To ensure continued satisfactory operation of winch, all points requiring lubrication
must be serviced with correct lubricant at proper time interval as indicated for each
assembly.
Refer to Table 10, for “Lubrication Intervals” for recommended lubrication intervals.
Use only those lubricants recommended. Other lubricants may affect winch
performance. Approval for use of other lubricants must be obtained from your
Ingersoll Rand
distributor. Failure to observe this precaution may result in damage
to winch and/or its associated components.
Table 9: Lubrication Intervals
Component
Interval
Check Air Line Lubricator
Daily
Check Motor Oil level
Daily
Change Motor Oil
1 Year or 1,000 hrs
of Winch Operation
Change Gearbox Oil
Change Disc Brake Oil
