POWER WRAPPING WIRE ROLL
Finished units installed by Miller Industries towing Equipment, Inc. do not have power-wrapped winch cables. Please see instructions below for proper power wrapping.
The appropriate way to power wrap wire rope is to follow the Wire Rope Technical Board procedures. I will summarize below:
1. Safety should be your first priority during power wrapping. Keep your hands and gloves clear of the cable at all times during this operation. Be sure you are not in a direct line with the drum during power wrapping in case of wire rope failure. The use of safety glasses is strongly recommended.
2. Properly attach the rope to the winch drum. This will vary between winches; some use clips, some use clamps, some use "hockey pucks". Determine the proper method and utilize it.
3. Stretch the rope out straight in a clean place such as paved parking lot so that the rope is not contaminated during installation. You may double it with a correctly sized snatch block if desired and/or to save space, but this may make step 6 more difficult. If you elect to wind the rope on first and then stretch it out and re-wind with power, always ensures if the rope comes off the "over" side of the reel, it goes on the drum in the same "over-wind" manner. The rule is over-over, or under-under to avoid any unnecessary twist.
4. As you pay in cable using the controls, each wrap should wind tightly against the preceding wrap. There should be no gaps between wraps. Use a wood, plastic, or rubber (non metallic) mallet as necessary to insure this, particularly on the bottom layer. If the cable wraps correctly without without intervention, however close supervision to the winch should be maintained at all times during installation.
5. Tension on the rope is specified in step 6; some tension on the first (primary) wraps on the bottom layer on a smooth-faced drum is also critical to ensure that the first layer is tight and true - wind slowly, and use a wood, plastic, or rubber (non-metallic) mallet to get rope tight and true. If the bottom layer is not wound properly there will be increasingly poorer winding at each successive layer. Refer to the winch manufacturer's literature for their recommendations on the number of and tensioning of the primary wrap.
6. Maintain appropriate tension of between 25% and 50% of wire rope Safe Working Load Limit at all times after the primary wraps. You may either use a large fixed object and winch towards it holding the brakes, or drag a large object towards you to maintain this constant tension. The objective is that each successive layer should not penetrate between wraps on the previous layer.
7. Repeat as needed for each winch.
* A "wrap" is defined as a 360 degree turn of wire rope on the drum.
* A "layer" is defined as a series of wraps that completely cover from the one side of the drum to the other side.
* Always inspect the rope for damage before installation. Refer to the Wire Rope Technical Board publications for more information.