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Grooved drums are designed with the correct groove pitch and depth for one diameter
of wire rope. Refer to the Product Information Manuals to determine correct wire rope
size.
If wire rope size and grooved drum do not match, replace drum or wire rope. Use of
the wrong diameter wire rope on a grooved drum will cause improper spooling of the
first layer. It will also cause excessive wear, damage, erratic operation and shortened
life of the wire rope.
Winches without grooved drums are designed for a range of wire rope sizes. Refer to
the Product Information Manuals for the specific range. Using a wire rope of a larger
diameter than specified will result in decreased life of the wire rope. Damage to
internal wire rope strands can occur which cannot be seen with a visual inspection.
Ensure that wire rope is spooled onto the drum in the correct manner. Refer to Dwg.
MHP2458 on page 11. A. Correct Spooling; B. Distance to Flange; C. Even, Tight
Wraps on Drum.
When spooling is complete wire rope should:
- be tight on each layer.
- have single even layers.
- not be bunched.
- not exceed distance to flange dimension (as specified in Product Information
Manuals).
WINCH OPERATORS DUTIES AND RESPONSIBILITIES
When operating a winch, operators should always use personal protective equipment
appropriate to the operation. As a minimum this should include safety glasses,
hearing protection, gloves, safety shoes and hard hat. Other safety items as required
by individual companies should also be used.
The use of non-slip footwear is recommended if winch is located in an area that may
be muddy, wet or have slippery surfaces.
(Dwg. MHP2452)
(Dwg. MHP2455)
(Dwg. MHP2594)
(Dwg. MHP2596)
(Dwg. MHP2595)
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Inspections
Daily (Frequent) visual inspections should be performed by the winch operator at the
start of each shift, or at the time the winch is first used during each shift. Refer to
“WINCH INSPECTION” section of the Product Information Manuals provided with the
winch. The winch operator shall not perform periodic inspections, or maintenance on
a winch unless the operator has been trained to perform such inspections or
maintenance, and is designated by the winch owner to perform such inspections or
maintenance.
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Winch Operators Responsibilities
Participate in any winch training programs and be familiar with topics outlined in
“Training Programs” on page 4.
It is the responsibility of the operator to exercise caution, use common sense and be
familiar with operating procedures and duties.
Operators are not required to maintain the winch however, they are responsible for
operation and visual inspection of winch. The operator must thoroughly understand
proper methods of rigging and attaching loads and should have a good attitude
regarding safety. It is the operator's responsibility to refuse to operate the winch
under unsafe conditions.
Operators who are fatigued or have exceeded their normal shift period shall check all
related regulations regarding approved work periods prior to making a lift. Refer to
“Training Programs” on page 4.
Winch Operators Shall:
1. Physically competent and have no health condition which might affect their
ability to act.
2. Be trained on the winch controls and load movement direction before operating
the winch.
3. Watch for potential winch malfunctions that may require adjustment or repair.
4. Stop operation if malfunctions occur, and immediately advise their supervisor so
corrective action can be taken.
5. Check brake operation, by lifting load a short distance and releasing control.
6. Be aware of shut-off valve or electrical disconnect location and proper operation.
7. Confirm that winch inspections and lubrication checks have been completed.
Winch Operators Should:
1. Have normal depth perception, field of vision, hearing, reaction time, manual
dexterity, and coordination for the work being performed.
2. NOT be subject to seizures, loss of physical control, physical defects, or emotional
instability that could result in actions of the operator being a hazard to the
operator or others.
3. NOT operate a winch when under the influence of alcohol or drugs.
4. NOT operate a winch when under the influence of medication that could result in
actions of the operator being a hazard to the operator or others.
5. Verify that lubrication levels are correct.
6. Ensure power supply connections are tight and connected correctly.
7. Check direction indicators on control match load direction.
The operator must know the winch capacity during all operations. It is the operators’
responsibility to ensure that the load does not exceed the winch rating. On
Ingersoll Rand data (name) plates the capacities of the winch to which it is attached
are listed. The data (name) plate information used in conjunction with the Product
Information Manuals will give the operator the specific capacities of the winch.
Items to consider as part of the load:
- All rigging items.
- Shock loads that could cause the load to exceed winch rated capacity.
- If using a multi-winch lift, ensure winches are in unison and one winch is not
going faster or slower thereby putting an over load on other winch.
- Load gaining weight due to snow, ice or rain.
- The weight of the load line during a long payouts.
WINCH OPERATION
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General Operating Instructions
The following operating instructions have been adapted in part from American
National (Safety) Standard ASME B30.7 and are intended to avoid unsafe operating
practices which might lead to injury or property damage. Refer to specific sections
in the Product Information Manuals for additional safety information.
The four most important aspects of winch operation are:
1. Follow all safety instructions when operating winch.
2. Allow only people trained in safety and operation of this winch to operate this
equipment. Refer to “Training Programs” on page 4 .
3. Subject each winch to a regular inspection and maintenance program.
4. Be aware of winch capacity and weight of load at all times. Ensure load does not
exceed winch, wire rope and rigging ratings.
CAUTION
• If a problem is detected, immediately STOP operation and notify supervisor.
DO NOT continue operation until problem is corrected.
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Additional Important Winch Operating Procedures
1.
When a “DO NOT OPERATE” sign is placed on the winch, or controls, do not
operate the winch until the sign has been removed by designated personnel.
2. Keep hands, clothing, jewelry, etc. away from wire rope, drum and other moving
parts.
3. Operate the winch with smooth control movements. Do not jerk the load.
4. Do not lift or pull load into support structure or winch.
5. Ensure wire rope hook end is not attached or connected (stowed) to an unmovable
point prior to winch operation.
6. Immediately stop operation if load does not respond to winch control.
7. Ensure brake(s) hold prior to making complete lift by lifting load a short distance
and releasing control.
8. Ensure operator is trained on control valve and load movement directions.
Operators must maintain visual contact with the load, drum or wire rope at all times.
Drum rotation indicators can be provided to assist the sensing of load movement by
the operator.
At the completion of winch operation or when in a non-operational mode the
following actions should occur:
- Remove load from load line.
- Spool load wire rope back onto winch drum and secure. For load lines over
sheaves, secure in a position that will avoid a safety hazard in the area.
- Turn off/shut off or disconnect power supply.
- Secure winch against unauthorized and unwarranted use.
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Operating In Cold Weather
Cold weather operation can present additional hazards. At very cold temperatures
metal can become brittle. Use extreme care to ensure that load movements are smooth
and even. Lubricating fluids do not flow as readily. Make every effort to warm all
fluids and components before operation. Run product slowly in both directions with
no load to initially lubricate components.
8 Form MHD56250 Edition 5