Comeup CWG-30375 User manual

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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

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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

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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
P
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

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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
(
m
)
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
(
m
)
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

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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
(
m
)
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
(
m
)
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 * *

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.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

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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°
13
Correct Distance
Width

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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.

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.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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4-2.Checking Reference
Classification of Checks
Periodical
Daily
One
month
Three
month
One
year
Checking Item Checking Method
Checking
Reference
◎
Breaking of base
wire Visual Less than 10%
◎
Decreasing of
diameter Visual 7% of normal
diameter max
◎
Kink phenomena
run-
out of
foundation
Visual
To be free
from kink
phenomena
◎Deforming or
corrosion Visual To be not remarkable
◎
Fastening condition
of end Visual
To be
sufficient for
hanging up of
load
◎
Condition of rope
winding-in Visual
To be free
from irregular
winding
◎Condition of feed
oil Visual
To be not
insufficient in
feed-out
◎
Wire Rope
Confirming of dead
turn of rope Visual
Confirming of
normalities of
operating-out
◎◎Frame Structure Visual
To be free
cracks,
rupture
harmful
deforation
◎◎Reture of flange Visual
To be free
cracks,
rupture,
harmful
deforation
◎
Drum
Wear of drum Visual
To be free
from
remarkable
wearing
◎Rotary direction Visual
Winding-in
direction is
normal
◎Rotary abnormal
sound Hear out
To be free
from
oscillation
and impact
sound
◎
Operation
Over load test Working Existence of
abnormalities

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Ⅴ
ⅤⅤ
Ⅴ. Trouble Shooting
When winch fails to start after several attempts, or if any defective operation to be
happened, check followings:
Observed Abnomal Possible Cause Solution
Wrong connection Connect correctlyNo reaction
No power source Check power source
Brake does not open Check brake ass’y
Wrong connection Connect correctly
Motor buzzes but does not
start
Burnt or communicated motor Rewind or replace motor
Overload
Brake does not open Check brake ass’y
Failing in restarting
Damaged wiring on the
control box
Check the wiring diagram
Considerable voltage drop ( It
can provoke non-opening of
brake)
Check voltage to make sure
the voltage shall be falling
within 5% of rated voltage
Brake does not open Check brake ass’y
Burnt or communicated motor Rewind or replace motor
Failing in lifting a load within
the lifting capacity
Wrong motor cable in size and
length
Collect the motor cable in size
and use a bigger section of
cable for longer distance
Considerable voltage drop ( It
can provoke non-opening of
brake)
Check voltage to make sure
the voltage shall be falling
within 5% of rated voltage
Damaged brake coil Measure the standard value
and replace brake coil
Improper brake gap Adjust brake gap
Brake does not open
completely
Brake disc wear down Replace brake disc
Crossed rotation Wrong connection Connect the wirings correctly
Grease leakage Damaged oil seal Replace oil seal
5-1.Standard value for brake disc
Model CWG-30375 CWG-30565
AC Voltage 220V 380V 415V 440V 220V 380V 415V 440V
Black & blue wires 25Ω96Ω117Ω
115Ω 28Ω108Ω 138Ω 126Ω
Black & red wires 11Ω42Ω51Ω51Ω12Ω36Ω48Ω56Ω
Red & blue wires 14Ω54Ω66Ω65Ω15Ω45Ω71Ω70Ω
Model CWG-30750/CWG-31500 CWG-34000
AC Voltage 220V 380V 415V 440V 220V 380V 415V 440V
Black & blue wires 28Ω108Ω128Ω126Ω9Ω27Ω42Ω41Ω
Black & red wires 12Ω48Ω57Ω56Ω4Ω17Ω19Ω18Ω
Red & blue wires 15Ω54Ω71Ω70Ω5Ω15Ω24Ω23Ω

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Ⅵ
ⅥⅥ
Ⅵ. Wiring Diagram

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Ⅶ
ⅦⅦ
Ⅶ. Replacement parts List
►CWG-30375
Ver01

15
►CWG-30565
Ver00

16
►CWG-30750
Ver01

17
►CWG-31500
Ver00

18
►CWG-34000
Ver00

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CWG02-2008-02-2000