Comeup CWG-30375 User manual

Electric Winch

Thank you for purchasing a Winch. This manual covers operation and

maintenance of the winch. All information in this publication is based on the latest

production information available at the time of printing.

General Safety Precautions

Winch is designed to give safe and dependable service if operated according to

the instructions. Read and understand this manual before installation and operation of the

winch.

Follow these general safety precautions:

˙Confirm that the winch complies with the using conditions

˙It is very important that the winch shall be mounted on a flat hard surface in order

to make sure the motor, drum and gearbox housing are aligned correctly

˙Don't use unsuitable accessories concerned.

˙Don't use unsuitable wire rope in construction , strength or having any defects.

˙Pay attention to the grounding , it provides a path of least resistance for electric current to

reduce the risk of shock.

˙Check the winch for smooth operation without load before loading operation.

˙Make sure the wire rope to be wound evenly in the first layer on the drum, rewind it if a

mixed windings in existence.

˙Wire rope can break without warning. Always keep a safe distance from the winch and

wire rope while under a load. Consult the wire rope manufacturer for wire rope ratings

and maintenance procedures.

˙Failure to adequately align, support, or attach winch to a suitable mounting base could

result in a loss of efficiency or premature failure of winch, wire rope, or mounting base.

The winch is not to be used to lift, support or otherwise transport personnel.

A minimum of five(5) wraps of rope around the drum is necessary to support the load

rated.

WARNING

Environment Precautions

DANGER

●The following environmental conditions may result in the possible

causes of winch trouble.

●Low temperature ●In a organic

below -10 ,high chemistry or℃

temperature explosive powder

above 40 o℃r condition

humidity above

90% conditions

Cause malfunction of spare parts Cause explosion※ ※

●In heavy acid or salty

conditions ●In a heavy general powder

Cause malfunction.※

of spare parts

●In the rain or snow

Cause rust or※

short circuit Cause malfunction※

of performances

I. Specification & Standard Accessories

1-1.Specification

Drum Size(mm) Load Rated

(kg) Speed(M/min)

Model Gear

Ratio

Length

Empty

Drum

Diameter

Full

Drum

Diameter

50Hz

60Hz

50Hz 60Hz

Motor

kw X

Power

Source

Percentage

Duty Cycle

13 ~ 20.6

15.6 ~ 24.7

3.8 x 4

CWG-30375

48:1

230 127 275 900

800

8.5 ~ 13.5

10.2 ~ 16.2

2.2 x 6

14 ~ 25

16.8 ~ 30

5.5 x 4

CWG-30565

50:1

312 140 320 1,100

1,000

9.2 ~ 16.4

11 ~ 20

3.8 x 6

6.9 ~ 12.6

8.3 ~ 15.1

5.5 x 4

CWG-30750

127:1

312 178 410 2,200

1,800

4.5 ~ 8.3

5.4 ~ 10

3.8 x 6

5.8 ~ 8.0

7 ~ 9.6 5.5 x 6

CWG-31500

192:1

405 356 570 3,500

3,000

4.4 ~ 6.1

5.3 ~ 7.3

3.8 x 8

8.0 ~ 12.2

10 ~ 15

11 x 4

CWG-34000

197:1

680 324 570 5,000

4,000

5.3 ~ 8.0

6.4 ~ 10

7.5 x 6

3 Phase

200V

220V

380V

400V

415V

440V

25% ED

Percentage duty cycle: The ratio of overall operating hours of motor to the working hours including the pause hours of the

motor. It’s expressed by percentage. Percentage Duty Cycle (%ED)= Tb x100(%)

Tb+Ts

Tb=Total sum of loading hours Ts=Total sum of stopping hours Tb + Ts = Approximately 1 to 10min

1-2. Accessories

Switch

Model Wire Rope 24 VAC

Control

CPB-61

PB-306

Safety

Hook

Base

Plate

CWG-30375

Ø10mm x 60 m V V * V V

CWG-30565

Ø12mm x 100 m V V * V V

CWG-30750

Ø16mm x 100 m V V * V V

CWG-31500

Ø18mm x 150 m V V * V V

CWG-34000

Ø22.4mm x 200 m V V * V V

Remark: V means standard accessory

* means option accessory

II. Performance Data

2-1. CWG-30375 / 30565

Model CWG-30375 CWG-30565

Motor kw x p 3.8 X 4

2.2 X 6 5.5 X 4 3.8 X 6

mm 10.0 12.0

Wire

Rope Size Breaking

kg 5,020 6,680

50Hz 1,420 1,960

Rated Load (kg)

60Hz 1,265 1,790

50Hz 13 8.5 14 9.2

Speed

(m/min) 60Hz 15.6

10.2 16.8 11.0

1st Layer

Rope-Winding

Cumulating Sum

(m)

9.5 11.9

50Hz 1,240 1,700

Rated Load (kg)

60Hz 1,100 1,550

50Hz 14.9

9.8 16.2 10.6

Speed

(m/min) 60Hz 17.9

11.7 19.4 12.7

2nd Layer

Rope-Winding

Cumulating Sum

(m)

20.3 25.8

50Hz 1,100 1,500

Rated Load (kg)

60Hz 980 1,350

50Hz 16.8

11.1 18.4 12.1

Speed

(m/min) 60Hz 20.2

12 22.1 14.5

3rd Layer

Rope-Winding

Cumulating Sum

(

)

32.6 41.5

50Hz 990 1,330

Rated Load (kg)

60Hz 880 1,200

50Hz 18.7

12.2 20.6 13.5

Speed

(m/min) 60Hz 22.4

14.7 24.7 16.2

4th Layer

Rope-Winding

Cumul

ating Sum

(

)

46.2 59.1

50Hz 900 1,200

Rated Load kg)

60Hz 800 1,100

50Hz 20.6

13.5 22.8 15.0

Speed

(M/min) 60Hz 24.7

16.2 27.4 17.9

5th Layer

Rope-Winding

Cumulating Sum

(m)

60 78.5

50Hz * 1,100

Rated Load kg)

60Hz * 1,000

50Hz * 25.0 16.4

Speed

(m/min) 60Hz * 30.0 19.7

6th Layer

Rope-Winding

Cumulating Sum

(m)

* 100

2-2. CWG-30750 / 31500 / 34000

Model CWG-30750 CWG-31500 CWG-34000

Motor kw x p

5.5 X 4 3.8 X 6 5.5 X 6 3.8 X 8 11 X 4 7.5 X 6

mm 16 18 22.4

Wire

Rope Size Breaking

kg 11,900 15,000 23,300

50Hz 4,000 4,800 7,500

Rated Load (kg)

60Hz 3,300 4,100 6,000

50Hz 6.9 4.5 5.8 4.4 8.0 5.3

Speed

(m/min) 60Hz 8.3 5.4 7.0 5.3 9.6 6.3

1st Layer

Rope-Winding

Cumulating Sum

(m)

11.3 25.3 31.9

50Hz 3,400 4,400 6,700

Rated Load (kg)

60Hz 2,800 3,800 5,300

50Hz 8.1 5.3 6.4 1.8 9.1 5.9

Speed

(m/min) 60Hz 9.7 6.3 7.6 5.7 10.9 7.1

2nd Layer

Rope-Winding

Cumulating Sum

(m)

24.4 53 68

50Hz 3,000 4,000 6,000

Rated Load (kg)

60Hz 2,400 3,400 4,800

50Hz 9.2 6 6.9 5.2 10.1 6.6

Speed

(m/min) 60Hz 11.1 7.2 8.3 6.3 12.1 7.9

3rd Layer

Rope-Winding

Cumulating Sum

(

)

39.4 83.1 108.2

50Hz 2,700 3,700 5,400

Rated Load (kg)

60Hz 2,200 3,200 4,300

50Hz 10.4 6.8 7.5 5.6 11.1 7.3

Speed

(m/min) 60Hz 12.4 8.1 9.0 6.8 13.4 8.8

4th Layer

Rope-Winding

Cumulating Sum

(

)

56.3 115.6 152.6

50Hz 2,400 3,500 5,000

Rated Load kg)

60Hz 2,000 3,000 4,000

50Hz 11.5 7.5 8.0 6.1 12.2 8.0

Speed

(M/min) 60Hz 13.8 9.0 9.7 7.3 14.6 9.6

5th Layer

Rope-Winding

Cumulatin

g Sum

(m)

75 150 200

50Hz 2,200 * *

Rated Load kg)

60Hz 1,800 * *

50Hz 12.6 8.3 * *

Speed

(m/min) 60Hz 15.2 9.9 * *

6th Layer

Rope-Winding

Cumulating Sum

(m)

100 * *

.Ⅲ

ⅢⅢ

ⅢWinching Principles

3-1.Load Rated

Load and speed vary according to how

much wire rope is on the drum. The first

layer of rope on the drum delivers the

slowest speed and the maximum

load. A full drum delivers the maximum

speed and the minimum load. For this

reason,winches are rated at their full drum

capacities.

3-2.Calculating Head Load

ηsheave coefficient:

No. of sheaves 1 2

Roller bearing 0.98

0.96

Sleeve bearing 0.96

0.92

3-3.Cart Puller Capacity





Choose the right winch

In most pulling applications you are dealing with a rolling road rather than pulling

a dead weight. Resistance to rolling is mostly influenced by the load, rolling

resistance, track gradient, track curvature, track conditions.

Load: Calculate the total weight of all the loaded cart to be moved simultaneously.

Rolling resistance: Resistance to rolling is influenced by the wheel journals, type of

lubrication used and the ambient temperature

Track gradient: For each one percent gradient, a rise of one meter for every 100

meter of track, the running line pull must be increased by 10 kg per

ton

Track curvature: To overcome the effects of wheels binding against rails on curved

sections of track, running line pull must be increase. For each

degree of curvature, the running line pull must be increased by 1kg

per ton

Track conditions: The condition of substandard track can vary considerably. .





Application condition example

1).Horizontal dual direction pulling of a rolling cart in and out of an oven using a

single wire rope extending from the winch drum

2).50 ton total load being moved included weight of cart

3).Steel cart wheels with precision wheel bearing

4).New track, 5∘curvature and 2% gradient

Fleet Angle





Railcar Pulling Capacity

1).Pull required per ton being moved: 10kg.

2).Total load being pulled: 80 ton

3).Required cart puller capacity

80 ton… total weight being moved

x (10 kg+20+5 kg) 10kg….Pull required per ton being moved

2,800 kg 20kg….For each one percent gradient, the running line pull

must be increased by 10 kg/ton

5kg…For each one degree of curvature, the running line

pull must be increased by 1 kg/ton

x 1.2 ….20% contingency for unpredictable track or cart

conditions

3,360 kg …..Minimum calculated cart puller capacity

3,500 kg …..Selected CWG-31500 winch rating 3,500 kg

3-4.Calculating Fleet Angle

The winch should be mounted as close

to center and as perpendicular as

possible to the direction of the line pull.

This will keep the wire rope fleet angle

centered on the drum as small as

possible.

If the proper fleet angle is not

maintained, the wire rope could wind

onto one side of the drum. This could cause failure of the winch or wire rope, resulting in

damage, injury or death.

Experience has shown that the best wire rope service is obtained when the maximum

fleet angle is not more than 1.5∘for smooth drums.

Therefore the correct distance between center of drum and of should be derived as follow.

Fleet angle of 1.5∘is the equivalents of approximately 19 cm of lead for each centimeter

of overall drum width.

Model Drum Width (mm) Fleet Angle Correct Distance (m)

CWG-30375 230 4.4

CWG-30565 312 6

CWG-30750 312 6

CWG-31500 405 7.7

CWG-34000 680

1.5°

Correct Distance

Width

3-5. Lubricant Specifications





For CWG-30750

All moving parts in the winch are permanently lubricated at the time of assembly.

Under normal conditions factory lubrication will suffice. If re-lubrication is

necessary after repair or disassembly use Castrol Alpha Spheerol L-EP 2 grease,

150 Viscosity (cSt) at 40 degree C.





For CWG-31500 & 34000

Gear lubrication is an important component in insuring the long life of your

winch. The type of lubricant will have a great influence. The gear oil your winch

was shipped with is Castrol Alpha Series, SP-460, a viscosity ( cSt ) is

457.81/29.83 at 40 /100 . Consult your local lubricant distributor on the℃ ℃

selection that best fits your climate and application.

The initial lubricant should be changed after the first 10 hours of operation.

Subsequent changes should be scheduled every 250 hours of operation or

annually.

3-6.Wire Rope Selection in Vertical Lifting

Recommended Wire Rope Safety Factor

Model

Dia. mm

Length ( m )

Const. Breaking Load ( kg )

50Hz 60Hz

CWG-30375 10 60 6 x 24 4,640 5.1 5.8

CWG-30565 12 100 6 x 24 6,680 6 6.6

CWG-30750 16 100 6 x 24 11,900 5.4 6.6

CWG-31500 18 150 6 x 24 15,000 4.2 5

CWG-34000 22.4 200 6 x 24 23,300 4.6 5.8

* means standard version on delivery, other size may be equipped upon request.

The minimum safety factor for most pulling & anchor handing winch and lifting & lowering winch is 3.5 and

5.5each.

3-7.Cable Selection

Switch cord

Model Power Lead CPB-61 assembly PB-306 assembly / Option

CWG-30375 5.5 mm21.25 mm21.25 mm2

CWG-30565 5.5 mm21.25 mm21.25 mm2

CWG-30750 5.5 mm21.25 mm21.25 mm2

CWG-31500 5.5 mm21.25 mm21.25 mm2

CWG-34000 5.5 mm21.25 mm21.25 mm2

The length of motor cable are subject to the distance less than 30 meters.

The length of switch cable are subject to the distance less than 30 meters.

For any other cases, the cable should use a bigger section.

.Ⅳ

ⅣⅣ

ⅣMaintenance and Inspection

The specified person performs the checking of winch.

Divide the checking into daily checking and periodic checking

The checking items, checking method and checking reference in daily checking and periodic checking

are to be in accordance with checking reference 1 & 2.

4-1.Checking Reference1

Classification of checks

Periodical

Daily

One

month

Three

month

One

year

Checking Item Checking Method

Checking Reference

◎Marking Lable and the like

Visual Existence of label

◎

Winding-in

direction of wire

rope

Visual , measuring

Fleet angle

θ=within 1.5 degree

◎

Installation

Loosing and centre

run-out foundation

Checking of

installing bolts

Existence of

abnomalities

◎Working Manual Reasonable actuation

◎Condition of

clamping of wiring

Decomposition

checking

Confirming of

accuracy of fastening

condition

◎

Wearing of

contact point

Decomposition

checking

To be free from

remarkable wearing

and damage

◎

Outer damage of

cable Visual

To be free from

exposure of

conductive wire

◎◎

Attaching

condition of earth

line

Visual

Existence of

abnormalities of

connecting wires

◎

Control/Switch

Condition of

insulation

Measure with 500v

insulation-

Resistance tester

1MΩmin

◎Condition

of insulation

Measure with

resistance tester

1MΩmin

◎

Motor

Staining damage

Decomposition

check

Existance of

abnormalities

◎Loosing of set

screws

Decomposition

check

To be free from

loosening

◎Wearing of lining

Decomposition

check

To be free from

remarkable wear and

damage

◎◎

Brake

Performance Visual

Distance to be not

more than 1.5% of

rope length to be

wound-in during 1

minute

◎Damage , wearing

Decomposition

check

To be free from

remarkable wear and

damage

◎

Gear

Condition

of grease feeding

Measuring

Existence of

suitability of amount

and deterioration

with grease Mobilux

EP2.Shell Unedo 2 or

Esso Beacon EP2

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