I、OverviewThe Winch, has passed testing and inspecting of the authoritative departments and obtained license for production of construction winch issued by the General Administration of Quality Supervision, Inspection and Quarantine in China. The quality of winch conforms to the standard of GB/T 1955-2008 construction winch. Issued by the national quality supervision and inspection and Quarantine Bureau of industrial products production license, license number: XK21-004-00214.Construction winch is used for operations such as winching and towing heavy things, erecting equipment, piles driving, and coldly pulling reinforcing steel bar in such industries as constructions, metallurgy, mines, weight lifting. The working surroundings to which the winch is applicable are: temperature -10℃～+40℃ ( when surrounding temperature is below 00C, before start-up, lubricating oil should be heated up), humidity ≤85%，altitude below 1000m, no fire and explosion accident and so on. It uses 380V，50Hz, 3-phase alternating current power supply and ±5% tolerable voltage difference. Working grades of winch in use are M4 or M5; when increasing every grade working grade, its rated pull should correspondingly reduce 20%.Method indicating types of winch:Examples of method indicating types of winch:Single reeling drum fast speed winch with 32kN steel wire rope’s rated pullWinch JK3.2 GB/T1955-2008Single reeling drum slow speed winch with 50kN steel wire rope’s rated pullWinch JM5 GB/T1955-2008II、Structure and Working PrincipleStructure Figure maps of JK fast speed winch and JM slow speed winch can be seen in Figure 1 and Figure 2 respectively. Electrically-controlled winch implements its operations or braking through connecting or disconnecting power supply. When connecting electrical source, band-type brake of normally-closed brake（3）arrester will loose; electromotor（1）starts up; Then shaft coupling（2）drives speed retarder（5）; After reducing the speed of the speed retarder, through the drive of connecting tray（6）or open-style gear wheel（6）, the reeling drum（7）starts to work. When stopping machine, disconnect electrical source and normally-closed brake arrester will hold the braking wheel to make the reeling drum stop revolving, then the winch stops its running. Rising or falling of materials is reached through clockwise revolving and counterclockwise revolving.1-motor 2-shaft coupling 3-brake 4-cam control 5-decelerator 6-inner gear connecting tray 7-reeling drum 8-chassis 1-motor 2- shaft coupling 3- brake 4- cam control 5- deceleraror 6-open-style gear wheel 7-reeling drum 8-chassisFigure 1 JK type electrically-controlled fast speed winch Figure Figure 2 JM type electrically-controlled slow speed winch FigureIII、Technical Parameters tableDiameter（mm）Φ21.5 Φ21.5 Φ26 Φ26 Φ30Electromoto r Type YZR160L-6YZR160L-6 YZR180L-6YZR180L-6 YZR200L-6Power（kW）11 11 15 15 22Brake arrester YWZ B-300/45 YWZ B-300/45YWZ B-300/90YWZ B-300/90 YWZ B-300/90Appearance measurements(length×width × height) 1235×1230×8051620×1260×9451075×1598×9852090×1475×9562090×1475×956Weight of entire machine（kg）1560 1800 2650 2900 3000IV、Installation and Testing1. When installing, dismantling and moving the winch, it is necessary to keep stable and being not overly oblique without any clashes and fierce vibration.2. Installation of winchIts installation should be completed by professionals. The ground for installing the winch should be leveled off and much solid. The connection between winch and base should be reliable.2.1 When mobile using, fix the winch to timber sleepers block, and reliably and tightly connect timber block and chassis to ground anchor with steel wire rope. Be aware of avoiding any looseness.（See Figure 3）Figure 3 horizontal ground anchorSteel wire rope Steel wire ropeRound bar WinchThis installing method is suitable to winch being less than 3 tons. Concrete measurements forinstallation need to refer to such conditions as soil quality, soil specific gravity and earth stamina, and are determined by ground anchor standard pictures appropriate to local use.2.2 When using in a fixed place, make concrete groundwork, and find the horizontal lines by using a gradienter, and leave in advance a square-type hole with a section of 20x20(cm 2) （See Figure 4）; number of hole is decided by foundation bolt of the winch(see Figure 4).At first, fixing the foundation bolt, then inject concrete into holes; after ossifying, evenly tighten the nuts. If there are rooms between chassis and lower interface, add adjusting mat so as to prevent partly deforming of chassis. Hole depth of foundation should be determined according to local geological condition and type of winch(L,L1 value in the table only for reference).Figure 4 Layout Figure of concrete foundation boltType Parameter JK0.5 JK1 JK1.6 JK2 JK3.2 JK5 JK8 A(mm) 667 667 956 956 1270 1560 1550 B(mm) 420 420 560 560 900 1090 1218 C(mm) 0 0 0 0 0 545 579 n-d(mm) 4×Φ14 4×Φ14 4×Φ17 4×Φ17 4×Φ22 6×Φ25 6×Φ32 L1(mm) 400 400 450 450 600 700 850 L(mm) 350 350 300 300540640780TypeParameter JM1 JM1.6 JM2 JM3.2(4-bearing style) JM3.2(open-style gear wheel) A(mm)667956956968920motor central lined e c e l e r a t o r c e n t r a l l i n eReeling drum central line2.3 The running direction of steel wire rope of the winch usually is horizontal; the direction of running rope is in accordance with actual situation, from the underside of reeling drum or other directions. The deviation angle αvalue of horizontal reeling and extending of steel wire rope must in conformity with stipulations in Table 1. L value should normally equal 20 times Bt width of reeling drum, but ensuring αvalue to be in line with Table 1, and the location of guiding pulley (see Table 2)to be on vertical bisector (see Figure 5). The ratio of Pitch diameter of all pulleys and diameter of steel wire rope should be less than stipulations in Table 2.2.4 The winch working in the air should be sheltered by a rainproof canopy, which can ’t obstruct operators ’ eyesight and operators should be able to see the commanders and dragging objects. 2.5 Metal shells of structure and electrical devices of the winch should be evenly connected to the earth. Earth connecting resistance should not more than 4Ω.Choosing and installing of earth connecting devices should conform to stipulations of GB/T232. 2.6 When used for winching heavy things, the winch should be fixed with ascending overtravel limit switch.2.7 Notch panel type pulley is prohibited from using when choosing guiding pulley.2.8 The safety circling number of steel wire rope on reeling drum shouldn ’t be less than 3 circles. The end of steel wire rope should be reliably fixed. In order to ensure safety the distance from outside layer of steel wire rope to outside edge of side board of reeling drum should not be less than steel wire rope ’s diameter.2.9 The connection area between brake block andbrake wheel shouldn ’t be less than 80% of the total area. When loosening braking, the brake block mustbe completely separated from braking, and maintain certain clearance. The value of clearance are 1～2.5mm between brake strap and brake wheel, 0.25～1mm between brake block and brake wheel.V 、Choosing of Steel Wire Rope1. Steel wire rope used for winch should conform to stipulations of GB/T20118 and linear contact lay wire rope should be a priority for use. Safety parameter of steel wire rope (specific value between minimum breaking force of steel wire rope and rated load of winch) shouldn ’t be less than Ka value stipulated in Table 3.Table 3 Safety parameter Ka of steel wire rope Grade of workingM1M2 M3 M4 M5 M6 M7 M8 Safety parameter Ka3.15 3.353.554.04.55.67.19.02. The size of pulley rope slot should be about 10% more than nominal diameter of steel wire rope.3. Steel wire rope should have good lubrication; usually adopt lubricating oil with moderate and lowReeling drumGuiding rope pulley Figure 5viscidity; domestically-made oil for steel wire rope is recommended for use.4. In the environment of outdoor, humidity and erosion medium existing, choose galvanized steel wire rope.5. If finding one of the following cases, please use new wire rope.5.1 Surface layer wire diameter of steel wire rope was worn down and erosion rate is up to 40% of its original diameter.5.2 Diameter of steel wire rope has reduced 7%.5.3 Stranded or broken wire is discovered.5.4 The core cord of the entire steel wire rope has been squeezed out.5.5 For any things not detailed, inspect and discard as useless according to stipulations of GB/T 5972. VI、Regulations for OperationPreparation:1. Construction winch should be operated by workers who have been well-trained and are familiar with regulations for safe operation.2. Check out oil quantity and purity in speed retarder and brake arrester and see if there is oil in all lubricating parts (see page 9, Table for machine lubricating scope)3.Confirm the type, scope applied, working grade, rated load, rated speed, rope capacity etc. of the winch are in conformity with conditions for using. Overloading is strictly prohibited.4. Check if steel wire rope has been fixed reliably, and if there are stranded or broken threads in steel wire rope.5. If the electrical device consists of motor, control box and alternating current cam controller, handlebar should be placed on “0”positon.6. Before operating winch, firstly make a test-run for 5 minutes. After satisfying the following requirements, normal operation can be conducted.6.1 Brake is smooth and steady, safe and reliable; its actions are accurate and flexible (regulating method of brake arrester can be seen in detail in users’ manual of brake arrester.6.2 Actions of all driving parts and gliding parts are flexible without such phenomena as overly big noise and being stuck.6.3 No any looseness in all linked partsOperation:1. Turn on electrical source, according needed direction, turn the handwheel of cam control; after running of electromotor is smooth and steady, and turn to next position, up to maximum gear.2.Under normal circumstances, to stop the machine just needs to rotate the brake arrester to“0”position; at that time, resistor’s resistance will be gradually added to rotor circuit, rotating speed of electromotor will decrease, hydraulic pressure brake arrester starts to work, and then main device stops running.3．When in use of weight lifting electrical device, cam control can’t regulate speed; it only can be usedto switch resistance buffer start and can’t work on lower gear; it is required to regularly inspect dampproof condition of the electrical device. Principle drawing of electrical device can be seen in Appendix 2Requirements for use:1. The voltage of motor shouldn’t exceed 5% of rated value. The electromotor cannot be used in exceeding its continuous electric connection rate and maximum number of starting up.2. Don’t connect the braking reversely; when wanting to realize humping placement, don’t manually open the power-controlled brake controller.3. When the winch is in the state of working, operators cannot be off the operating position.4. Do not take the liberty of transforming the winch.5. Maximum load, withstood by datum layer and steel wire rope in various layers within datum layer, is the rated load. Maximum load, withstood by steel wire rope in various levels outside the benchmark level, is less than rated load. For added one layer, the pull force will relatively reduce 10% of rated pull force.6. When operating the host, steel wire rope can’t be dragged running on the ground; if necessary, install supporting roller or grooved roller. When steel wire rope crosses driveways, protective devices should be added so as to avoid persons treading on it and cars crushing on it. It is prohibited for people to cross the running steel wire rope or pass before the winch. Carrying workers on the site by the winch is not allowed.7. When winching by using many winchs, traction speed and weightlifting capability of winchs must be identical. United directing, united action and synchronized operation are necessary.8．During operation, operators should focus all their attentions on working and strictly follow the rules for operation, and, under urgent and risky circumstances, immediately stop their operation against risk signals like crying and calling send out by any people. After making clear the situations, continue their operations.9. When such phenomena as abnormal mechanism, abnormal sound, failure of braking, sharply rising of bearing temperature, etc. has occurred in winch operation, immediately stop running for inspect and repair and remove breakdowns.10. The steel wire rope should be neat and tidy. When overlapping or oblique winding is found, stop the machine to cope with it. When in revolving, pulling or treading on steel wire rope by hand or feet are strictly prohibited.11. When winching heavy things but keeping load for a longer time, please close the stop stopper; before running the machine again, loosen the stop stopper.12. If running the machine with heavy things, Braking by using stop stopper is strictly prohibited, use brake and gradually add force for braking. If adding force abruptly and forcefully, the machine will be possibly damaged.13. After ending work, heavy things must be placed on the ground; hanging heavy things in the air is not allowed.14. Before getting off duty, clean and maintain the winch, cut off the power supply and lock the switch box.VII、Repair and Maintenance1. The driving part of the winch such as reeling drum bearing, hinge of brake arrester and shaft pin of various parts, should be added some lubricant once before each shift’s operation. Every 48 hours of operation by using steel wire rope, the guiding pulley should be lubricated once. The height reached by lubricating oil surface in decelerator box should be within the scope of dipstick; under normal circumstance, check it once every week, and replace it once every half a year.2. After the winch’s running for 300 hours, carry out grade 1 maintenance, lubricate the entire machine again, check and adjust the brake , check the decelerator and replace with or add new lubricating oil to the height designated of oil surface.3. After the winch’s running for an accumulative working of 600 hours, carry out grade 2 maintenance and measure insulated resistance of electromotor; check the state of wearing down for rubbed surface, all involving parts, and rubber loop of connecting parts; check the state of all parts of gear wheel bearing and electrical components. If affecting the use of machine, please replace them at once.4. Every day, running of winch should be recorded in the list for recording running state; the contents of recording daily include working hours and load, and inspection, repair, adjustment and so on.5. Inspection and maintenance of winch should in conformity with the following regulations.5.1 The winch should have everyday inspection and regular inspection. Cycle, items, method and standard of inspection should according to regulations in appendix 1. When frequently using or using ina special place or environment, inspection of winch should add other items.5.2 Inspection, maintenance and repair should be implemented by professionals.5.3 During inspection and repair, pay attention to people’s safety. Apart from items for inspection or repair carried out necessarily in a state of starting up, inspection and repair of other items must be carried out after discharging load, shutting off power supply and locking up the power switch. The items for inspection and repair in a state of starting up, should be carried out at least by two people; one person among them should take charge of watching for safety of the other personnel, and be able to immediately stop the winch’s running under any special circumstances.5.4 After maintenance and repair, please inspect the winch according to inspecting items stipulated in Appendix 1.5.5 After the winch reached the aggregate working hours identified according to its using conditions, it should not be continuously used6. When transporting and maintaining, the winch should be placed in a dry locality. Good dampproof and antisepticising measures should be applied to all parts of it.7. When not using the winch for a long-term period, cut off its power supply; it should be kept in a place which is dry, ventilating, rainproof and without caustic gases; and appropriate antirust disposal should be applied to it.8. If one of the following cases occurs, reeling drum should be discarded as useless.8.1 Cracks or broken edge8.2 The wear abrasion amount of the husk thickness of reeling drum has reached 10% of original thickness.9. Parts of brake and clutch should be replaced if one of the following occurs.9.1 Cracks have occurred on any parts.9.2 The wear abrasion degree for friction liner of brake arrester has reached 50% of its original thickness.9.3 The wear abrasion degree of brake wheel has been up to 2～3mm. (Big diameter is opposed to big value, small diameter to small value)9.4 Plastic deformations related to spring9.5 The wear abrasion degree of shaft pin and shaft hole diameter has been up to 5% of its original diameter.9.6 Elastic components has been damaged or severely worn down.10. When one of the following cases occurs, driving wheel should be replaced.10.1 Cracks or broken gear teeth10.2 Gear surface rippling has reached 30% of field of conjugate action, and 10% of original gear thickness.10.3 The percentage of wear abrasion degree to original gear thickness has reached the following value: 10.3.1 Closed-style gear wheel driving: 10% (grade 1); 20% (other grades)10.3.2 Open-style gear wheel driving: 30%VIII、Common Breakdowns and Handling MethodIX、Table for machine lubricating scopeX、Spare partsSerial No. Names Raw material Quantity Connected parts1 Rubber loop polyurethane 20 shaft coupling2 seal ring Oil resistant rubber 4 gearbox3 Brake shoe 1pair brake4 Carbon brush 1set motor5 bearing 2 Drum support6 Brake tank 1 brakeSpare parts imageSerial No. Names Picture for reference1 Rubber loop2 seal ring3 Brake shoe4 Carbon brush5 bearing6 Brake tankAppendix 1 Cycle, item, method and standard for examinationExamining period Items examined Examiningmethod Examining standardEveryday Onemonth Threemonths1 year√Label Eyeing Make sure thatthe label isreliably fixed √Steel wire rope’s runningrope deviation angleEyeing、MeasuringMake sure thatit conforms tostipulations intable 1√Tightening of base frameand various partsExamining thefixed boltConfirming thatit is not loose√Electricalsystem OperatingswitchCheck switch’sactionConfirming thatactions arenormal√Wiring Check the Confirming thatAppendix 2 Electrical device ’s principle drawing1、Controlling principle drawing for Y series electromotor electrical device2、Controlling principle drawing for YZR weightlifting electromotor electrical deviceNote ：Z ：brake KT ：Cam controller RT ：ResistorFalling backwardFalling backward Rising forward Rising forward。
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