2009/06/15 Selection of Wire Rope and Use for PACCAR Winches {5163} Caterpillar

PACCAR Winches are supplied without a wire rope in order to allow the end user to select the most appropriate wire rope type, size, length, and end treatment for there particular needs.

Maximum winch performance, easiest wire rope handling, maximum wire rope service life, and lowest operating cost can generally be obtained by selecting:

• The smallest diameter wire rope with sufficient strength to withstand the actual working loads encountered in the end-user's specific application.

• The shortest length of wire rope sufficient to provide the actual working "strokex" length required for the end-user's specific application while still leaving at least five (5) wraps of the wire rope on the winch drum at full extension.

Wire rope lengths shown in Table 1 are theoretical maximum figures calculated from industry standard formulas. The actual maximum wire rope capacity may be substantially different depending on the specific wire rope type, the specific wire rope manufacturer and the installation method.

The following wire rope selection and use requirements must be strictly followed at all times:

• NEVER install a wire rope of a larger diameter than listed in the chart for each specific winch model.

• NEVER install a wire rope that is longer than listed in the chart for each winch model and approved wire rope diameter.

• NEVER operate the winch with any portion of spooled wire rope protruding above the winch drum flange.

• NEVER operate the winch with the wire rope on any layer higher than listed below for each winch model and approved wire rope diameter.

• NEVER operate the winch with a kinked or damaged wire rope or damaged rigging.

• NEVER attach a wire rope to the winch drum or hook using knots.

• ALWAYS use IWRC (Independent Wire Rope Core) type wire rope. Poly, nylon or sisal core wire rope is prone to crushing damage in winch applications.

• ALWAYS use a 6-strand wire rope when using PACCAR supplied ferrules with split spiral wedges.

• ALWAYS ensure the wire rope is secured to the winch drum with the correct size ferrule.

• ALWAYS make certain the working end of the wire rope is properly secured to the hook or tail-chain. Removable wedge sockets are required by regulatory organizations in some applications.

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Loss of load control and potential failure of the wire rope could result in a flying object hazard. A flying object hazard may result in personal injury or death. Follow all the listed requirements for the winch and the wire rope.

• Maximum Theoretical Wire Rope Capacity requires a wire rope manufactured with very tight dimensional control, in excellent condition and perfectly spooled onto the winch drum at all times. Attempting to install a wire rope equal to the Maximum Theoretical Wire Rope Capacity often results in violation of one or more of the strict requirements. PACCAR Winch strongly recommends limiting the installed wire rope length to the Maximum Practical Capacity listed.

• NR – Not Recommended Wire Rope Layer.

• X – Not Permitted Wire Rope Layer.

• Wire rope of a smaller diameter than listed for each winch model may be used at the same maximum length and same maximum number of layers as the smallest listed wire rope diameter. Always secure the wire rope to the winch drum anchor pocket with the proper ferrule.

• Refer to the wire rope and ferrule installation instructions in the winch service manuals.

• Inspect and maintain the wire rope per the wire rope manufacturer's recommendations.