6. Do not weld to any part of winch.
Refer to Dwg. MHP0133 on page 10, A. Drum.
Table 5: Mounting Surface Tolerance
Drum Length
Mounting Surface Minimum Flatness
inch
mm
12
0.06
1.52
16
0.08
2.03
20
0.10
2.54
24
0.12
3.05
Table 6: Mounting Bolts
Models
Mounting Bolts
inch
mm
FA2i & FA2i-CE
5/8
16
Table 7: Bolt Hole Dimensions
Dimension
Drum Length (inches)
12
16
20
24
“A”
in.
20
mm
508
“B” (with Automatic Or Manual
Drum Brake)
in.
9.00
7.50
9.00
10.00
mm
229
191
229
254
“B” (without Automatic Or
Manual Drum Brake)
in.
7.50
6.25
7.75
9.00
mm
191
159
197
229
“C”
in.
0.69
mm
17.53
Number of Bolts
6
8
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Wire Rope
CAUTION
•
Maintain at least 3 tight wraps of wire rope on the drum at all times.
•
Do not use wire rope as a ground (earth) for welding.
•
Do not attach a welding electrode to winch or wire rope.
•
Install wire rope to come off drum for overwind operation (normal
application).
NOTICE
•
For horizontal applications order the “H” option or contact factory prior to
operation.
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Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor for assistance in selecting
the appropriate type and size of wire rope and, where necessary, a protective
coating. Use a wire rope which provides an adequate safety factor to handle the
actual working load and meets all applicable industry, trade association, federal,
state and local regulations.
When considering wire rope requirements the actual working load must include not
only the static or dead load but also loads resulting from acceleration, retardation
and shock load. Consideration must also be given to the size of the winch wire rope
drum, sheaves and method of reeving. Maximum wire rope diameter is limited by
the wire rope anchor. It is recommended that wire rope construction be 6 X 19 or 6
X 37 IWRC right lay. Refer to Table 8 ‘Minimum and Maximum Wire Rope Size’
on page 5 for recommended sizes.
Table 8: Minimum and Maximum Wire Rope Size
Models
Minimum
Maximum
inch
mm
inch
mm
FA2i &
FA2i-CE
1/2
13
5/8
16
Note 1: Maximum wire rope diameter is limited by size of wire rope anchor hole.
Refer to Product Parts Information Manual for correct wire rope anchor part numbers.
Note 2: Wire rope diameter is fixed if grooved drum option is used.
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Installing Wire Rope
NOTICE
•
When installing wire rope, pressurize disc brake with a minimum of 45 psi
(3.1 bar) air from an auxiliary source.
Refer to Dwg. MHP2686 on page 10, A. Anchor; B. Wire Rope.
1. Cut wire rope to length in accordance with wire rope manufacturer’s
instructions.
2. Feed end of wire rope through drum anchor pocket hole.
3. Forming a loop, wrap loop around anchor, approximately 22 inches (559 mm)
of wire rope.
4. Pull wire rope anchor into position in drum anchor pocket. Ensure no extra (open
end) of wire rope is extending out of drum anchor pocket.
CAUTION
•
Make sure first wrap of wire rope is tight and lays flush against drum flange.
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Safe Wire Rope Handling Procedure
-
Always use gloves when handling wire rope.
-
Never use wire rope that is frayed or kinked.
-
Never use wire rope as a sling.
-
Always make sure wire rope is correctly spooled and the first layer is tight
against drum.
-
Always follow wire rope manufacturer’s recommendation on use and
maintenance of wire rope.
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Wire Rope Spooling
To compensate for uneven spooling and the decrease in line pull capacity as the
drum fills up, use as short a wire rope as practical. When rewinding apply tension to
the end of the wire rope to eliminate line slack. This helps achieve level winding and
tight spooling.
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Rigging
Make sure all wire rope blocks, tackle and fasteners have a sufficient safety margin
to handle required load under all conditions. Do not allow wire rope to contact sharp
edges or make sharp bends which will cause damage to wire rope, use a sheave.
Refer to wire rope manufacturer’s instructions for proper sizing, use and care of wire
rope.
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Safe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire rope.
3. Never run wire rope over a sharp edge. Use a correctly sized sheave.
4. When a lead sheave is used, it must be aligned with center of drum. The diameter
of lead sheave must be at least 18 times the diameter of wire rope. Refer to Dwg.
MHP2449 in Product Safety Information manual.
5. Always maintain at least three full, tight wraps of wire rope on drum.
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Drum Guard
Use of a drum guard is recommended on all winches, and is standard on -CE winches.
Refer to the Product Parts Information Manual.
Drum guard panels must be adjusted to suit wire rope departure angle. To reposition
drum guard panels remove nuts and slide out crossbar. Position panels to avoid wire
rope contact and install crossbar and nuts.
WARNING
•
Do not allow wire rope to come in contact with drum guard panels during
winch operation. Wire rope could become worn and damaged. Adjust drum
guard panels to clear wire rope travel angle.
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Air Supply
The air supply must be clean, free from moisture and lubricated to ensure optimum
motor performance. Foreign particles, moisture and lack of lubrication are the
primary causes of premature motor wear and breakdown. Using an air filter,
lubricator and moisture separator will improve overall product performance and
reduce unscheduled downtime. Refer to Dwg. MHP0191 on page 10, A. Air Out;
B. Lubricator; C. Regulator; D. Air In; E. Filter.
Refer to Table 2 ‘Specifications’ on page 4 for motor air consumption and rated
operating pressure. If air supply varies from what is recommended, product
performance will change.
Install air line lubricator, filter and regulator as close as possible to air inlet on motor.
Lubricator must be located no more than 10 ft (3 m) from motor. Air line accessories
package can also be mounted to the winch guard panel on the operator’s side or
opposite.
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Air Lines
Inside diameter of air supply lines must not be less than size specified in Table 2
‘Specifications’ on page 4. Before making final connections, all air supply lines should
be purged with clean, moisture free air or nitrogen before connecting to main air
inlet. Supply lines should be as short and straight as installation conditions will
permit. Long transmission lines and excessive use of fittings, elbows, tees, globe
valves, etc. cause a reduction in pressure due to restrictions and surface friction in
lines.
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Air Line Lubricator
Always use an air line lubricator with these motors. The lubricator must have an inlet
and outlet at least as large as inlet on motor.
Form MHD56436 Edition 7
5
