Check Attachment of Winch Rope

A	Wire rope
B	Wire rope lock
C	Connector sleeve with wedge plug
D	Hook

Correct assembly:

• The wire rope must run in line with the eye on the connector sleeve.

• The wire rope lock must only lock the end wire rope.

• The free end must be at least 6–9 times the diameter of the wire rope to make sure that the whole section of the wire rope that is either lashed-in or annealed and tapered is outside the connector sleeve.

The wire rope and winch eye must be checked:

• Before each use.

• When replacing the wire rope.

• When attaching the wire rope after shortening.

Check that the winch locking mechanism is fully engaged in the drum before use, following the attachment of the wire rope eye on the anchor point.

Checking Oil Level on Winch

1. •
   1.
   Run off enough wire from the winch drum so that the filler plug (A) and the level plug (B) are accessible.
2. •
   2.
   Turn the drum so that the filler plug (A) aligns in the top position and the level plug (B) aligns in horizontal position.
3. •
   3.
   Loosen and remove the level plug (B). The oil level must reach up to the hole.
4. •
   4.
   Fill oil in the hole for the filler plug (A) until it reaches the hole for the level plug (B) if necessary.
5. •
   5.
   Screw back the plugs (A, B).

Replace Oil on Winch

1. •
   1.
   Run off enough wire from the winch drum so that the filler plug (A) and the level plug (B) are accessible.
2. •
   2.
   Set the drum so that the filler plug (A) is aligned downwards. Undo the plug to drain out the old oil.
3. •
   3.
   Turn the drum so that the filler plug (A) aligns in the top position and the level plug (B) aligns in horizontal position.
4. •
   4.
   Remove the level plug (B).
5. •
   5.
   Fill oil at the hole for the filler plug (A) until it reaches the hole for the level plug (B).
6. •
   6.
   Screw back the plugs (A, B).

Check Winch Unit Attachment

1. •
   1.
   Check the tightening torque on attachment bolts (A).

Check Winch

1. •
   1.
   Check for damage, unwinding, wear, and corrosion on the winch wire rope (A).
2. •
   2.
   Check for damage, cracks, and wear on the hook (B) and check that it is properly mounted.

Lubricate Winch

1. •
   1.
   Remove the plug in the bottom of the gear housing once a year for draining. The gearing is permanently lubricated.
2. •
   2.
   Lubricate the drum brake disengager with oil if not rotating freely.
3. •
   3.
   Check drum brake. The brake acts on the cable drum only when the cable is wound manually.

Replace Winch Transmission Oil

1. •
   1.
   Replace the oil on the winch gear (A).
2. •
   2.
   Lubricate the drum brake disengager with oil if it does not rotate freely.

Replace Winch Transmission Oil

1. •
   1.
   Replace the oil on the winch gear (A).

General Checking Guidelines for Wire Ropes

Wire ropes must be scrapped when they display any of the following:

• Wire rope break at attachment

• Certain number and type of wire rope breaks

• Concentrations of wire rope breaks

• Occurrence of wire rope breaks due to operating time

• Occurrence of strand breaks

• Surface wear

• Effects of heat

• Reduced elasticity

• Decreased wire rope diameter

• Permanent extension of the wire rope

• Deformation of the wire rope

Checking Wire Rope for Wire Breaks

Wire breaks occur after a certain operating time depending on operating conditions and then occur more frequently. The number of wire breaks in relation to the operating time must be determined and documented. It can then be used to estimate the future increase in wire breaks and the foreseeable time point for scrapping. On 6 and 8-strand wire ropes, wire breaks are primarily superficial.

• Broken wires at wire rope ends indicate that they have been heavily loaded and can cause faulty end mountings. Shorten the wire rope and reattach it. Check that the length of the remaining wire rope sufficient.

• If there are concentrations of wire rope breaks, the wire rope must be scrapped. If such concentrations occur within a length less than 60 cm (23.6 in.) or on an individual strand, the wire rope must be scrapped. Even if the number of wire breaks is less than the maximum specified in the table.

In wire ropes with several layers of strands, only the outer, visible layer is considered. In wire ropes with steel cores, the core is regarded as an inner strand, and is not included. In the event of a wire break, two ends can be visible.

Checking Wire Rope for Strand Breaks

If there are strand breaks, scrap the wire rope.

Checking Wire Rope for Surface Wear

Inner surface wear is caused by friction between the wires and the strands.

Outer surface wear is caused by friction between the cable drums (rolls) and the wire rope under pressure (acceleration and braking). Outer surface wear is visible through the formation of reflected images on the outer wires.

Surface wear is increased through faulty or no lubrication, increasing the effect of dirt and dust. Surface wear reduces static tensile strength through reduction in the wire ropes metallic cross section and dynamic strength through surface wear nicks. If the wire ropes diameter decreases more than 7% in relation to the nominal diameter of the wire rope, it must be scrapped. It must be scrapped even if no wire breaks are detected.

Checking Wire Rope for Corrosion

Corrosion is especially problematic in marine environments and in areas where the air is polluted by industrial emissions. Corrosion can reduce operational strength through rust spots and static tensile strength through a reduction in the cross section of the wire rope. Severe corrosion can reduce elasticity.

Outer corrosion can be easily detected through visual examination.

Inner corrosion is more difficult to detect. Inner corrosion is characterized on the following:

• Absence of gap between the strands in the outer layer of the wire rope, often with wire breaks in the strands.

• The wire rope diameter varies.

The parts of the wire rope that are bent over discs usually have a decreased diameter. At any sign of corrosion, an authorized person must check the wire rope. If inner corrosion is detected, the wire rope must be scrapped.

Checking Wire Rope for Decreased Diameter

A decrease in the wire rope diameter can occur because of material fatigue. Material fatigue can be caused by:

• Inner surface wear and surface wear nicks

• Inner surface wear through friction between the strands and wires in the wire rope

• Fatigue in the plastic core

• A break in the steel core

• A break in the inner layer in a multi-strand wire rope

If the diameter of the wire rope decreases more than 10% in relation to the nominal diameter of the wire rope, it must be scrapped. It must be scrapped even if no breaks have been detected.

Checking Wire Rope for Reduced Elasticity

Under certain conditions, the wire rope loses its elasticity. Reduced elasticity is difficult to detect. If in doubt, consult a specialist. If the wire rope has lost elasticity, the following characteristics usually appear:

• Decrease in wire rope diameter

• Extension of the wire rope

• No gap between individual wires and between the strands. It causes during component pressing.

• Fine, brown dust inside the strands.

• Even if there are no visible wire breaks, the wire rope is noticeably stiffer.

• The wire ropes diameter decreases more quickly than during normal wear of the individual wire rope strands.

Reduced elasticity can lead to sudden wire rope breaks during heavy loads. The wire rope must be scrapped.

Checking Wire Rope for Heat Exposure

The effects of heat can be established through annealing color. Scrap the wire ropes that are exposed to extreme heat.

Check Tightening Torque on Winch

1. •
   1.
   Check tightening torque on side bolts (A).
2. •
   2.
   Check mounting, disengagement, and tightening torque on the winch (B).
3. •
   3.
   Check mounting, hydraulic motor, and tightening torque on the winch (C).