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Wire Rope Reports
Records should be maintained as part of a long-range wire rope inspection
program. Records should include the condition of wire rope removed from
service. Accurate records will establish a relationship between visual
observations noted during frequent inspections and the actual condition of
wire rope as determined by periodic inspections.
Frequent Inspection
On equipment in continuous service, frequent inspection should be made
by operators at the beginning of each shift. In addition, visual inspections
should be conducted during regular operation for indications of damage or
evidence of malfunction (such as abnormal noises).
1.
WINCH. Prior to operation, visually inspect winch housings,
controls, brakes and drum for indications of damage. Do not operate
the winch unless the wire rope feeds onto the drum smoothly. Any
discrepancies noted must be reviewed and inspected further by
authorized personnel instructed in the operation, safety and
maintenance of this winch.
2.
WIRE ROPE. Visually inspect all wire rope which can be expected
to be in use during the day's operations. Inspect for wear and
damage indicated by distortion of wire rope such as kinking,
"birdcaging," core protrusion, main strand displacement, corrosion,
broken or cut strands. If damage is evident, do not operate winch
until the discrepancies have been reviewed and inspected further by
personnel instructed in the operation, safety and maintenance of this
winch.
• The full extent of wire rope wear cannot be determined by visual
inspection. At any indication of wear inspect the wire rope in
accordance with instructions in "Periodic Inspection."
3.
AIR SYSTEM. Visually inspect all connections, fittings, hoses and
components for indication of air leaks. Repair any leaks or damage.
Check and clean filters if equipped.
4.
CONTROLS. During operation of winch, verify response to control
is quick and smooth. If winch responds slowly or movement is
unsatisfactory, do not operate winch until all problems have been
corrected.
5.
BRAKES. During winch operation test brakes. Brakes must hold
load without slipping. Automatic brakes must release when winch
motor throttle is operated. If brakes do not hold load, or do not
release properly, the brakes must be adjusted or repaired.
6.
WIRE ROPE REEVING. Check reeving and ensure wire rope is
properly secured to the drum.
7.
LUBRICATION. Refer to the "LUBRICATION" section for
recommended procedures and lubricants.
Periodic Inspection
Frequency of periodic inspection primarily depends on the severity of
usage:
NORMAL
HEAVY
yearly
semiannually
Disassembly may be required for HEAVY or SEVERE usage. Keep
accumulative written records of periodic inspections to provide a basis for
continuing evaluation. Inspect all items listed in "Frequent Inspection."
Also inspect the following:
1.
FRAMES and UPRIGHTS. Check for deformed, cracked or
corroded main components. If external evidence indicates the need
for additional inspection return winch to your nearest
Ingersoll Rand service repair center.
2.
FASTENERS. Check retainer rings, split pins, capscrews, nuts, and
other fasteners on winch, including mounting bolts. Replace if
missing or damaged and tighten if loose.
3.
DRUM AND SHEAVES. Check for cracks, wear or damage.
Replace if necessary.
4.
WIRE ROPE. In addition to Frequent Inspection requirements, also
inspect for the following:
a.
Build-up of dirt and corrosion. Clean with steam or a stiff wire
brush to remove dirt and corrosion if necessary.
b.
Loose or damaged end connection. Replace if loose or
damaged.
c.
Check wire rope anchor is secure in drum.
8
d.
(Dwg. MHP0056)
5.
ALL COMPONENTS. Externally inspect for wear, damage,
distortion, deformation and cleanliness. Clean, replace or lubricate
components as required.
6.
BRAKE. Test brake to ensure proper operation. Brake must hold a
125% rated load with full drum without slipping. If indicated by
poor operation or visual damage, return winch to a authorized
service center for repair. Check all brake surfaces for wear,
deformation or foreign deposits. If brake lining thickness appears to
be worn, contaminated or damaged brake band should be replaced.
Clean and replace components as necessary.
7.
FOUNDATION OR SUPPORTING STRUCTURE. Check for
distortion, wear and continued ability to support winch and rated
load. Ensure winch is firmly mounted and that fasteners are in good
condition and tight.
8.
LABELS AND TAGS. Check for presence and legibility of labels.
Replace if damaged or missing.
1.
Equipment which has been idle for a period of one month or more,
but less than six months, shall be given an inspection conforming to
the requirements of "Frequent Inspection" before being placed in
service.
2.
Equipment which has been idle for a period of over six months shall
be given a complete inspection conforming with the requirements of
"Periodic Inspection" before being placed in service.
3.
Standby equipment shall be inspected at least semi-annually in
accordance with the requirements of "Frequent Inspection". In
SEVERE
abnormal operating conditions equipment should be inspected at
quarterly
shorter intervals.
Verify wire rope diameter. Measure the diameter of the wire
rope from crown-to-crown throughout the life of the wire rope.
Recording of the actual diameter should only be done with the
wire rope under equivalent loading and in the same operating
section as accomplished during previous inspections. If the
actual diameter of the wire rope has decreased more than 0,4
mm a thorough examination of the wire rope should be
conducted by an experienced inspector to determine the
suitability of the wire rope to remain in service. (Refer to Dwg.
MHP0056).
Winches Not in Regular Use
SAM0068 - Edition 4
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