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Operators will also be wearing increased clothing so operation, feel of controls, field
of vision and hearing could be impaired. Ensure that additional personnel/signal
person are used to maintain a safe operation.
WARNING
• Avoid sudden loading and erratic control operation.
Whenever temperature is below freezing, 32˚ F (0˚ C), extreme caution must be
exercised to ensure that no part of product, supporting structure or rigging is shock
loaded or impacted as brittle fracture of steel may result.
Optional low temperature products are available. Refer to model number on data
(name) plate and model code for approved operating temperature ranges.
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Operating Winch
During all winch operations, operator must be aware of load and its path. Load must
have a free unobstructed path from pick up to set down. This awareness is to ensure
that load does not contact any hazards. Some of the hazards to watch for and avoid
are:
- power lines, telephone lines and electrical cables.
- guide wires, other load lines, strung hoses.
- personnel in the path or under the load as it is moved. Personnel shall NEVER
be under or in the path of a moving load.
- lifting loads in wind gusts or high winds. Avoid swinging a suspended load.
- erratic control valve operation (can cause a sudden jerk on load which could
create an overload condition).
- bumping an obstacle such as buildings, support member, another load etc.
- when multi-parting the load line, the two sheaves come together (also called
Two-Blocking*).
During pulling (dragging) operations:
- watch for obstructions that could cause load to hang up, causing sudden
uncontrolled load shift.
- direct foot and vehicle traffic to ensure they maintain a safe distance from
the load path and load line.
WARNING
• To avoid damage to rigging, structure supporting rigging and winch, do not
“two-block”* the end of wire rope.
* Two blocking occurs when the winch wire rope is multi reeved using two separate
sheave blocks which are allowed to come in contact with each other during winch
operation. When this occurs extreme forces are exerted on wire rope and sheave blocks
which may result in equipment and or rigging failure.
WARNING
• Keep hands and clothing clear of gaps or spaces on winches. These areas can
become pinch points during operation.
(Dwg. MHP2454)
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Operating a Manual Band Brake
Winches with a manual band brake require the owner/user to operate both winch
control and band brake control simultaneously during operations. It is recommended
that owners/users practice operation of brake and winch control with lighter loads
until proficient with both functions.
When lowering loads near the winches rated load at very slow speeds, monitor the
temperature of the brake bands and/or brake housing. This load/speed combination
may result in automatic brakes dragging, which could cause heat build up. Indications
that the heat build up on the brake is excessive are:
- Housing surface temperatures in access of 120˚ C
- Visible indications of hot paint, such as blisters or scorching
- The smell of hot oil or burning paint
Stop all operations any time a hot brake is detected.
WARNING
• Operation of the winch with a brake dragging will cause heat build up in the
brake and could be a source of ignition in potentially explosive atmospheres.
When operating a winch with a manual drum brake, ensure the brake is fully released
when load is in motion. Use the control throttle to control the speed of the winch.
Do not drag the brake to control the winch speed. If the winch has only a manual
drum brake (no automatic brakes), set the brake to stop winch motion.
Operators must pay careful attention to brake operation at all times. At any indication
of loss of braking ability operator must immediately cease operation, shut off power
to the winch and inform their supervisor. Some indications of brake problems are:
- Brake bands or housings becoming very hot during operation, this is an
indication of excessive slippage
- Abnormal sounds, such as grinding, coming from brake parts during activation
of the brake, this is an indication of worn bands
- Brake(s) do not hold load when winch control is in neutral
During operation it is necessary for the operator’s hand to be close to the drum when
using a manual band brake. To minimize the possibility of contact:
- maintain a firm grip on brake lever handle and winch throttle control lever.
- ensure footing is clean, dry and firm.
- maintain a good comfortable posture, do not lean.
- ensure any loose clothing is tucked in or out of the way of the drum.
- ensure the band brake is correctly adjusted which will allow the operator to
stop drum rotation when the brake is fully engaged.
-
use Drum Guards which are available and recommended by Ingersoll Rand for
all winch installations.
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Operating Optional Items
n Limit Switches
Limit switches are available on some winches and are used to assist in controlling
haul-in and payout limits. Limit switches will require periodic checking and
adjustment to ensure accurate operations. A trained operator should be closely
monitoring winch operation while using these switches to ensure that a mis-adjusted
switch does not allow load to move beyond the specified range.
Limit switches are not intended as the primary means of stopping winch operation.
n Disengaging Clutch
Clutches are available on some winches and are used to disengage the drum from the
drive train, allowing wire rope to “freespool” from the drum. When the drum is in the
“freespool” mode, use of the band brake to control wire rope payout is required to
prevent a loosening of wraps on the drum. After wire rope is paid out and connected
to load, engage drum and slowly apply tension to wire rope.
WARNING
• Do not disengage clutch when there is a load on the winch. Load control can
be lost.
On winches with a clutch “freespool” option, wire rope should spool from drum with
minimal effort. When pulling wire rope from drum in the “freespool” mode do not
strain or lose balance and always look where going to avoid tripping.
n Drum Locking Pin
The drum locking pin provides a method to lock the drum preventing rotation. This
is accomplished by inserting a pin through a hole in the drum flange.
WARNING
• Ensure that all braking mechanisms are engaged and all personnel are clear
of winch load and rigging before disengaging locking pin.
• Extremely difficult locking pin release is an indication that load is held by
locking pin and braking mechanisms are not functioning properly. Do not
release locking pin until load control is established.
n Tensioning System
A tensioning system is optional on some winch models. This option automatically
maintains a pre-set tension on the load line at all times.
Tensioning the wire rope can cause it to “snap” up and down violently, keep personnel
away, also ensure any other obstructions are out of the way.
WARNING
• With tensioning system activated, wire rope will without notice payout or
haul-in. Personnel shall keep clear of load line and drum at all times.
Prior to activating the tensioning system the operator should operate winch to take
all slack out of load line. Upon activation of tensioning system, winch will
automatically take up any slack.
When disengaging tensioning system the operator should immediately take control
of the load though manual control. The operator should be aware of load size and
winch capacity to ensure proper control of load.
Adjustment of the tensioning regulator is required for new system installations or
when load capacities change. Refer to adjustment procedures in the Operation
Manuals supplied with the winch.
If a tensioning system option is used on a winch in a lifting application additional
precautions are required. When engaging the tensioning system, with a load
suspended from the winch, be prepared to make immediate adjustments to the
tensioning regulator to prevent the load from drifting down.
n
Manual Levelwind
Manual levelwind winches must have two automatic brakes. Only allow personnel that
are physically capable of simultaneously moving the wire rope guide handle through
its full travel range and operating the winch control valve to use this equipment. Use
a second operator to operate the wire rope guide as necessary. Primary winch operator
must monitor load at all times.
Form MHD56250 Edition 5
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