7
4. Remove the chain guards from the sprocket(s) to be changed. Be careful to not lose the hard-
ware.
5. To loosen the chain loosen the jam nuts on the idler adjustment shaft.
6. Remove the chain connector and remove the chain from the sprocket(s) to be removed.
7. Loosen the set screw on the sprocket and remove the sprocket. Take note of the direction the
hub is mounted on the shaft. Be careful not to lose the key.
8. Place new sprocket on the shaft with the key in the keyway in the shaft.
9. Align the new sprocket(s) by placing a straight edge on the sprockets to align them with each
other.
10. Tighten the set screw on the new sprocket and the jam nuts on the idler sprocket adjustment
shaft.
11. Place the chain on the sprocket and add chain connector.
12. Adjust the idler sprocket to take up any slack in the chain. Check the tension in the chain by ro-
tating the drum by hand one complete revolution. Be careful not to over tighten the chain. There
should be at least 1/2 in. slack at it’s loosest position.
13. Replace the chain guards.
14. Set the timing of the level wind carriage by rotating the drum until the rope clamp is at the 12 to
1 o’clock position (6 to 7 o’clock for under-wind) when viewing the drum from the right side.
15. Position the carriage at a position of maximum travel at the drum end where the rope is to be
attached. The extreme end of the carriage travel is when the guide link is on the outside of the
end sprocket and at the mid-point of the vertical slot in the carriage.
16. Thread the end of the rope through the roller cage and attach it to the drum by means of the
rope clamp. See figure 2.
17. Drive the winch forward at a low speed, keeping sufficient tension on the rope. It is extremely
important that the first lay of rope be straight and compact. Slowly increase the drum speed and
spool on the remaining rope.
Whenever possible, a winch line holder should be used to prevent the rope from unwinding.
8. Wire Rope
8.1 Spooling
● When installing the wire rope observe the following recommendations: It is important to select
the correct winch rope for a particular application. Wire rope is specified by length, diameter,
number of strands, number of wires per strand, type of center and type of lay. The purpose is
to stress the importance of selecting the correct type of lay.
● There is a definite advantage in applying wire rope of the proper direction of lay when spooling
onto the smooth surface of the winch drum. A rope with an improper lay may cause the coils
will spread apart each time the load is removed. Installing the wire rope with the proper lay will
tend to keep the coils together when the load tension is removed. The correct lay will develop
tight coils and even layers.
● It is important to install the wire rope onto the winch drum with care. Kinking of the rope,
caused by the rope taking a spiral shape as a result of an unnatural twist, should be avoided.
● When removing wire rope from the reel and spooling onto the winch drum, the reel must be
supported on a horizontal axis and free to rotate. Spool the rope onto the drum with the natu-
ral bend in the same direction as it comes off the reel.
● If wire rope is received in a coil, it should be unwound with the coil in the vertical plane. Again,
spool the rope onto the winch drum with the natural bend in the same direction as it was on
the coil. Reverse bending of the wire rope should always be avoided or kept to a minimum.
IMPORTANT! Wire rope should always be under tension when spooling onto the winch drum.
● When the winch drum is in free spool and the drum shaft extension only is being used with a
capstan or reel, pass the winch line through the tail shelf sheave and hook the pulling eye to a
fixed section of the chassis. This will prevent the rope from unwinding or “clock-springing.”
● Likewise, when the winch is not in operation, attach the winch line quick hook to a solid mem-
ber on the tail shelf and slowly take up the slack. This will best maintain the rope under a
General Machine Products Co. Inc.
3111 Old Lincoln Highway Trevose, PA 9053-4996 USA 215-357-5500
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