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WARNING
• Only use manual wire rope for even spooling of unloaded wire rope.
• Do not use wire rope guide to force heavily loaded wire rope into position.
• Remove manual wire rope guide for normal operation.
• Keep clear of pinch points at wire rope guide pivot and where wire rope enters
guide.
• Do not place hand(s) on any part of the manual wire rope guide other then
the handle grip during wire rope spooling.
• Do not allow body or clothing between the travel stop and the manual wire
rope guide bar.
• Do not operate winch if wire rope guide is bent or damaged.
Inspect wire rope guide prior to each use, and monitor operation during use. Stop
operation and replace rollers if:
- Rollers do not roll smoothly.
- Wear on rollers prevents smooth operation.
- Wire rope contacts the steel support.
Ensure manual wire rope guide is moved the full length of the drum for even wire
rope spooling.
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Spooling and Handling Wire Rope
Always use gloves, or suitable hand protection when handling wire rope.
When spooling wire rope onto the drum ensure all prior wraps of wire rope are tight.
Refer to “WIRE ROPE SPOOLING” section on page 7.
WARNING
• Never allow personnel to grab or touch the wire rope when the winch is being
operated.
• Immediately stop winch operation if anyone enters an area 3 ft. (1 m) in
front of the winch or the load path area behind the winch. Refer to Dwg.
MHP2451 on page 11. A. No-Zone; B. Keep Clear of this Area; C. Keep Clear
of Load Path.
When handling wire rope never place your hand in the throat area of a hook or near
wire rope spooling onto or off of the winch drum. Always make sure the load is
properly seated in the saddle of the hook. Do not tipload the hook as this may allow
the load to slip out of engagement and leads to spreading and eventual failure of the
hook.
CAUTION
• Before removing slack from wire rope, ensure everyone is clear of wire rope.
Avoid yarding or side pulling at all times.Yarding or side pulling is an operation where
a load, that is outside of the winch drum width, is pulled toward the winch. Refer to
Dwg. MHP2449 and allowable fleet angle information on page 11. A. Sheave; B.
Fleet Angle; C. Drum Flange.
It is critical to not exceed the fleet angle and that wire rope does not contact sharp
edges (especially drum flange or winch parts). Exceeding the proper fleet angle can
damage the wire rope, reduce wire rope life and cause erratic spooling and operation.
While operating winch the operator should monitor the drum and wire rope as it spools
on and off of the drum. Ensure wire rope spools tightly and evenly across the drum
width. Poorly spooled wire rope can chafe excessively, leading to heat build up or
sparks.
When paying out ensure that wire rope is:
- smoothly paying out and drum is not over running the wire rope, causing
a slack wire rope condition
- seated in all sheaves and sheaves are rotating with wire rope
- not making any abnormal noises, such as snapping or popping
- not damaged or worn
- kept under tension to prevent loose wraps
- not less then three wraps on the drum.
When hauling-in ensure that wire rope is:
- tightly wound on drum (it may be necessary to add weight to load or apply
tension to wire rope to keep tight wraps on drum). Refer to “Tight Winding”
on page 7.
- spooled onto drum evenly with no overlapping.
- seated in all sheaves and sheaves are rotating with wire rope.
- not making any abnormal noises, such as snapping or popping.
- not damaged or worn.
- not allowed to exceed distance to flange dimension (as specified in Product
Information manuals). Refer to Dwg. MHP2458 on page 11. A. Correct
Spooling; B. Distance to Flange; C. Even, Tight Wraps on Drum.
WARNING
• Keep everyone clear of load and its path.
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Wire Rope Stowage
Ensure that winch wire rope is not inadvertently snagged, overloaded or pulled when
winch is idle and wire rope ends are anchored. Verify all surrounding equipment does
not interfere or come into contact with stowed and anchored wire rope. Failure to
observe these precautions can cause winch overload and severe internal damage.
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Rigging
For the purpose of this manual, rigging is considered any component that assists the
attachment of the load line to the load and winch as part of the application. Use only
approved rigging methods and never use the wire rope as a sling.
If visibility of riggers or hoist crew is impaired by dust, darkness, smoke, snow, fog
or rain, strict supervision of operation must be exercised and, if necessary, it should
be suspended.
DANGER
• Electrocution caused by contact of crane boom, load line or load with electric
power lines must be avoided.
When working with or around cranes that are within a boom’s length of any power
line ensure that a competent signal-person is stationed at all times within view of
the operator to warn him when any part of machine or its load is approaching the
minimum safe distance from the power line. Refer to ASME B30.5 for guidelines.
Caution must be exercised when working near overhead lines having long spans as
they tend to swing laterally due to wind and accidental contact could occur. Never
carry out any rigging or hoisting operation when the weather conditions are such
that hazards to personnel or property are created. The size and shape of the loads
being lifted must be carefully examined to determine if a safety hazard exists during
high wind speeds. Avoid handling loads presenting large wind catching surfaces which
could result in loss of control of the load during times of high or gusting winds, even
though the weight of the load is within the normal capacity of the equipment. Wind
loading can be critical on the manner in which the load is landed and the safety of
personnel handling it.
Wind loading can be critical on the manner in which the load is landed and the safety
of personnel handling it.
Personnel trained in safe rigging procedures must accomplish all rigging. All items
used in rigging should be certified for this use and sized for the load and application.
Personnel trained in safe load handling procedures should supervise moving of loads
that are rigged.
When moving a rigged load there should be one person designated as being the signal-
person. The signal-person shall be the only person authorized to give signals that will
control the move and must maintain visual contact with winch operator, load and
area under the load. Operator shall only obey the signal-person EXCEPT to obey a stop
signal regardless of who gives it.
Ensure signal-person is clearly visible and signals used are thoroughly understood by
everyone.
During the course of rigging, if it is necessary for the wire rope to change direction
or pass over a sharp edge this change in direction must be done using a sheave.
Table 1: Example of Sheave Sizes
Wire Rope Diameter
Min. Sheave Diameter
inch mm inch mm
1/4 6 4-1/2 108
3/8 9 6-3/4 162
1/2 13 9 234
5/8 16 11-1/4 288
3/4 18 13-1/2 324
7/8 22 15-3/4 396
1 26 18 468
When using a sheave check minimum D/d ratio for application.
D =
Sheave Pitch Diameter
d =
Wire Rope Diameter
Typically for hoisting applications an 18:1 ratio is required. Periodically check sheaves
for wear in accordance with sheave manufacturer recommendation. Refer to Table 1
‘Example of Sheave Sizes’ on page 10 .
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Form MHD56250 Edition 5