User Manual for General Air Winch

An air winch, also known as an air tugger, is a single-drum, hand-operated type of winch powered by a piston-type air motor. It is mainly used for transporting or lifting heavy objects in departments such as oilfield drilling, metal mining, coal mining, and construction projects.

I. Safety Warning and Preface

Qualification Requirements: Installation, operation, and maintenance must be carried out by trained and qualified personnel.

Read the manual: Before installation and operation, please read and understand this manual and all safety markings on the air winch equipment.

Personal Protection: Operators must wear safety helmets, safety shoes, gloves, and other personal protective equipment.

Load Safety: Do not stand under the load! Please ensure that the load path is unobstructed and free from personnel and obstacles.

Working Pressure: Ensure that the air source pressure is always within the range specified on the air winch nameplate (usually 0.4–0.7 MPA).

II. Preparations Before Installation

1. Inspect the air winch equipment and tools

Opening the box for inspection: Compare with the delivery list to check if all the components, such as the main body of the air winch, handle/valve, hook, bolts, etc., are complete, and whether there is any damage during transportation.

Tool Preparation: Prepare the appropriate wrench, level, torque wrench, screwdriver, air pipe connector, adhesive tape, etc.

2. Select the installation location

Structural strength: The installation foundation (such as I-beams, supports) must be able to withstand all the forces and torques generated by the weight of the air winch and the maximum load, and should have a safety factor of at least 1.5 times.

Space requirements: Ensure there is sufficient space for operation, maintenance, and the winding of the wire rope/chains. Ensure that the operator has a clear view.

Environmental requirements: Avoid installation in high-temperature, explosive, or corrosive environments. If such environments are necessary for use, a specific explosion-proof air winch with a corresponding protection level must be selected.

3. Air source system preparation

Air source quality: Only dry and clean compressed air should be used. This is crucial for ensuring the lifespan and reliability of the air winch.

Pipeline dimensions: The inner diameter of the main air pipe must meet the requirements to ensure sufficient flow. It is generally recommended to use an air pipe with an inner diameter of ≥ Φ12mm.

III. Installation steps

1. Mechanical Installation

Fixed winch: Use the installation holes on the winch base as templates to position, mark, and drill holes on the installation surface. Use the high-strength bolts provided by the winch manufacturer or of a higher grade (such as 8.8 grade), as well as flat washers and spring washers. Use a torque wrench and, following the specified torque values (refer to the technical parameter table), tighten all bolts in a step-by-step, crosswise, and uniform manner.

Check for levelness/verticality: Use a level gauge to inspect the installation surface of the air winch to ensure it is level (or vertical, depending on the installation method), and avoid uneven loading.

2. Gas line connection

Interface identification: Locate the air intake of the winch, which is usually marked with “IN” or “P”.

Pipeline connection: Use the appropriate pipe joints and sealing tape (or sealant) to ensure a tight seal and prevent air leakage. Connect the prepared gas pipeline system (including the three-way valve, etc.) to the air intake of the winch. It is recommended to use a section of pressure-resistant spiral steel pipe or a PUR spring protection pipe near the winch to prevent the air pipe from being worn and to avoid accidental pulling.

3. Installation of the load suspension device

Inspect the hook: Ensure that the hook can rotate freely and that the safety tongue piece functions properly.

Connecting the load: Pass the steel wire rope or chain through the hook, and use standard rigging devices (such as shackles) for a secure connection.

IV. Post-installation Inspection and Commissioning

1. Leakage Test

• Without starting the air winch, turn on the air supply and apply soapy water to all air pipe joints and interfaces. Check for any bubbles to ensure there is no leakage.

2. No-load test

• Operation test: Slowly operate the control handle/button to test the “upward”, “downward” and “stop” functions.
• Check operation: Listen to whether the motor running sound is smooth and there is no abnormal noise. Observe whether the brake operates sensitively and reliably.
• Test limiters (if any): Test whether the upper and lower limit switches can accurately stop the winch at the specified positions.

3. Load Testing

• Light-load test: First, lift 25% to 50% of the rated load and run it several times to check all functions.
• Full-load test: In a safe area, lift 100% of the rated load and test the braking performance (stop halfway during lifting and check if there is any descent).
• Overload test (if required): Unauthorized testing is strictly prohibited! If a 125% overload test is needed, it must be conducted under the supervision of safety personnel and in accordance with specific procedures.

V. Daily Operation Precautions

• Before operation: Conduct daily inspections, including the air pipe, connectors, hoist hook, steel wire rope/chain, and brake.
• During operation: Proceed smoothly, avoid sudden starts and stops. Maintain concentration and keep a close eye on the load status at all times.
• After the operation: Ensure the load lands safely, shut off the gas supply, evacuate the residual air and moisture from the pipeline, and clean the winch thoroughly.
• Emergency situation: In case of any abnormality, immediately press the emergency stop button (if available) or close the gas source shut-off valve.

Important Note: This manual is a general guide. Before installing and operating any air winch, it is essential to first refer to and strictly follow the official manual provided by the winch equipment manufacturer and local safety regulations.

Dejun Cranes (Henan Dejun Industry Co., Ltd) has more than 30 years in winch filed, we have enough confidence to provide the top quality winch and suitable solution, any questions, contact us freely, our team always here!