WPT POWER WHP36S-HS Instruction Manual

PLANETARY HYDRAULIC HOIST 8,000 Lbs .
Installation & Maintenance Manual
WHP36S-HS Model
Because of continued product improvement, we reserve the right to make changes without notice.

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Contents
1.0 SAFETY RECOMMENDATIOINS…........................................................................................................ 3
2.0 SPECIFICATIONS AND PERFERMANCE .................................................................................................6
3.0 HOIST INSTALLATION.......................................................................................................................... 7
4.0 INSTALLATION DIMENSIONS .............................................................................................................. 12
5.0 HOIST OPERATION.............................................................................................................................13
6.0 EMERGENCY LOWERING PROCEDURES FOR HOISTS WITH GEAR MOTORS… .................................. 14
7.0 THE BRAKES CONTRAST TEST...........................................................................................................16
8.0 MAINTENANCE .................................................................................................................................17
9.0 TROUBLESHOOTING ........................................................................................................................18
10.0 ASSEMBLY DRAWING .....................................................................................................................20
11.0 BILL OF MATERIAL. .........................................................................................................................22

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1.0 SAFETY RECOMMENDATIONS
Safety for operators and ground personnel is of prime concern. Always take the
necessary precautions to ensure safety to others as well as yourself. To ensure safety,
the prime mover and hoist must be operated with care and concern by the operator for
the equipment and a thorough knowledge of the machine’s performance capabilities.
The following recommendations are offered as a general safety guide. Local rules and
regulations will also apply.
1. Be certain equipment (boom, sheave blocks, pendants, etc.) is either lowered to
the ground or blocked securely before servicing, adjusting, or repairing hoist.
2. Be sure personnel are clear of work area BEFORE operating hoist.
3. Read all warning and caution tag information provided for safe operation and
service of hoist.
4. Inspect rigging and hoist at the beginning of each work shift. Defects should be
corrected immediately.
5. Operate hoist line speeds to match job conditions.
6. Leather gloves should be used when handling wire rope.
7. Never attempt to handle wire rope when the hook end is not free. Keep all parts of
body and clothing clear of cable rollers, cable entry area of fairleads and hoist
drum.
8. When winding wire rope on the hoist drum, never attempt to maintain tension by
allowing wire rope to slip through hands. Always use “Hand-Over-Hand” technique.
9. Never use wire rope with broken strands. Replace wire rope.
10. Do not weld on any part of the hoist.
11. Use recommended hydraulic oil and gear lubricant.
12. Keep hydraulic system clean and free from contamination at all times.
13. Use correct anchor for wire rope and pocket in drum.
14. Do not use knots to secure or attach wire rope.
15. The WPT designed wire rope anchors are capable of supporting the rated load
when installed properly. For additional safety, ALWAYS maintain a minimum of

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five (5) wraps of wire rope on the drum.
16. Never attempt to clean, oil or perform any maintenance on a machine with the
engine or prime mover running, unless instructed to do so in this manual.
17. Never operate hoist controls unless you are properly positioned at the operator’s
station, and you are sure personnel are clear of the work area.
18. Assure that personnel who are responsible for hand signals are clearly visible and
that the signals to be used are thoroughly understood by everyone.
19. Ground personnel should stay in view of the operator and clear of hoist drum. Do
not allow ground personnel near hoist line under tension. A safe distance of at
least 1-1/2 times the length of the cable should be maintained.
20. Do not exceed the maximum pressure, PSI (kPa), or flow, GPM (LPM), stated in
the hoist specifications.
21. Install guarding to prevent personnel from getting any part of body or clothing
caught at a point where the cable is wrapped onto the drum or drawn through
guide rollers.
22. “Deadman” controls, which automatically shut off power to the hoist whenever the
operator leaves his station, should be installed whenever practicable.
23. Never allow anyone to stand under a suspended load.
24. Stay out from under and away from raised loads.
25. Stand clear of cable while pulling. Do not try to guide cable.
26. Do not exceed maximum line pull ratings shown in table.
27. The pressure and flow of hydraulic system should reach the shown in table.
28. The cable should be arranged on the drum neatly.
29. Do not use hoist to lift, support or otherwise transport people.
30. A minimum of 5 wraps of cable around the drum barrel is necessary to hold the
load.
31. When you change the rope, you should check intensity according to load.
32. Make sure that all equipment, including the hoist and cables, is maintained
properly.

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33. Avoid shock loads. This type of load imposes a strain on the hoist many times the
actual weight of the load and can cause failure of the cable or of the hoist.
34. Hoist operators must be trained in the proper, safe operation of the hoist.

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2.0 SPECIFICATIONS AND PERFORMANCES
Rated Line Pull
8,000 Lbs
Recommended Wire Rope Diameter
1/2 in
Drum Storage Capacity
443 ft
Hydraulic System Rated Flow
65 GPM
Hydraulic System Motor Pressure
2420 PSI
Max. Permissible Number of Layers
6
Ratio
34.2
Oil In Port
1 5/16”-12UN
Oil Out Port
1 5/16”-12UN
Weight (without cable)
474 Lbs
Maximum
Permissible
Number oflayers
Φ1/2” Cable
capacity (FT)
LinePull
(Lb.)
LineSpeed
(Ft/min)
1st layer
58
8000
243
2nd layer
122
7200
270
3rd layer
193
6550
297
4th layer
270
6000
324
5th layer
353
5540
351
6th layer
443
5140
378

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3.0 HOIST INSTALLATION
1. The hoist should be mounted with the centerline of the drum in a horizontal
position. The mounting plane of the base may be rotated in any position
around this centerline.
2. Because of the design of the mounting base, the direction of line pull should
only be as shown in the above illustration. Line pulls in any other direction
must be approved by WPT Engineering.
3. When mounting the hoist, use all four (4) mounting holes and grade 8 cap
screws and nuts. Tighten to recommended torque.
It is important that the hoist is mounted on a surface that will not flex
when in use, and cause binding of the gear train. Binding in the gear train
will result in accelerated wear and heat. Also, be sure the hoist is mounted
on a flat surface. If necessary, use shim stock to ensure the mounting
surface is flat within 0.020 in. (0.5 mm). Use stainless steel shim stock as
required.

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4. The vent plug must always be located above the horizontal centerline. If the
hoist is mounted on a pivoting surface, be sure vent plug remains above
the centerline in all positions. If necessary, reposition bearing support and
vent plug as follows:
A. Remove bearing support bolts.
B. Rotate bearing support until vent plug is positioned correctly and bolt
holes are aligned.
C. Evenly tighten bolts to recommended torque.
5. Hydraulic lines and components that operate the hoist must be of sufficient
size to assure minimum backpressure at the hoist motor ports. The
hydraulic backpressure measured at the motor work ports must be less
than 100 PSI (690 kPa) at full operating flow. Backpressure in excess of
100 PSI (690 kPa) will shorten motor shaft seal life and partially release
the load holding brake. The standard hoist is supplied with the gear motor
internally drained and connected the drain by-pass port on the WPT brake
valve. If high backpressures are encountered, the motor should be
externally drained directly to the reservoir and the “DRAIN” port on the brake
valve capped. All piston motors MUST be drained directly to the reservoir.
The piston motor case drain port must NEVER be exposed to more than 42
PSI (290 kPa); shaft seal damage will occur.
6. The hoist should be mounted perpendicular to an imaginary line from the
center of the drum to the first sheave to insure even spooling. Make certain
the fleet angle does not exceed 1-1/2 degrees.

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WARNING!
DO NOT use a control valve with any detents or latching mechanism that
would hold the control valve in an actuated or running position when the
operator releases the control handle. Use of the wrong type of control valve
could lead to unintentional operation of the hoist, which could result in
property damage, personal injury, or death.
The directional control valve must be a three position, four- way valve
without detents and with a spring centered motor spool such that the valve
returns to the centered position whenever the handle is released, and both
work ports are open to tank (open center, open port)
7. High quality hydraulic oil is essential for satisfactory performance and long
hydraulic system component life.
Oil having 150 to 330 SUS (30-60 cSt) viscosity at 104°F (40°C) and
viscosity index of 100 or greater will give good results under normal
temperature conditions. The use of an oil having a high viscosity
index will minimize cold-start trouble and reduce the length of warm-up
periods. A high viscosity index will minimize changes in viscosity with
corresponding changes in temperature.
Maximum cold weather start-up viscosity should not exceed 5000 SUS
(1000 cSt) with a pour point at least 20°F (11°C) lower than the minimum
temperature.

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Under continuous operating conditions the temperature of the oil at any
point in the system must not exceed 180°F (82°C). Optimum oil temperature
is generally considered to be 120-140°F (49-60°C).
In general terms; for continuous operation at ambient temperatures between
50 and 110°F (10 to 43°C) use ISO 46; for continuous operation between
10 and 90°F (-12 to 32°C) use ISO 32; for applications colder than 10°F
( - 12°C), contact the WPT Service Department. The use of multi-viscosity
oils is generally not recommended.
8. The hydraulic oil filter should have a 10-micron nominal rating and be full
flow type and meet the requirements of the hydraulic pump manufacturer.
RECOMMENDED FASTENER TORQUE
Higher or lower torques for special applications will be specified such as
the use of spanner nuts, nuts on shaft ends, jam nuts and where distortion
of parts or gaskets is critical.
Lubricated torque values based on use of SAE 30wt engine oil applied to
threads and face of bolt or nut.
Avoid using thread lubricants (such as anti-seize compound) as the applied
torque may vary by 10 - 40%, depending upon the product used.
To convert LB-FT to Kg-m, multiply LB-FT value by 0.1383

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WIRE AND BRAIDED ROPE INSTALLATION
ANCHORING WIRE ROPE
Take the free end of the wire rope and insert it through the small opening
of the anchor pocket. Loop the wire rope and push the free end about half of
the way back through the pocket. Install the wedge, then pull the slack out of
the wire rope. The wedge will slip into the pocket and secure the wire rope
into the drum.
7/16”-1/2”. (11-13mm) wire rope.

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4.0 INSTALLATION DIMENSIONS

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5.0 HOIST OPERATION
The hydraulic motor drives the sun gear of the primary planetary gear set through
the splined inner race of the overrunning brake clutch. When driven by the sun gear,
the primary planet gears walk around the ring gear in the drum and drive the primary
planet carrier.
The primary planet carrier drives the output planet sun gear which, in turn drives the
output planet gears.
The output planet carrier is splined to the bearing support and cannot rotate. Therefore,
as the output planet gears are driven by the sun gear, they will drive the ring
gear/drum.
WARM-UP PROCEDURES
A warm-up procedure is recommended at each start-up and is essential at
ambient temperatures below +40°F (4°C).
The prime mover should be run at its lowest recommended RPM with the
hydraulic hoist control valve in neutral allowing sufficient time to warm up the system.
The hoist should then be operated at low speeds, raise and lower, several times to
prime all lines with warm hydraulic oil, and to circulate gear lubricant through the
planetary gear sets.
WARNING
1. When you are using winch, shall not exceed the rated load, You should meet the
hydraulic system pressure and flow rate of winch performance requirements to be
met;
2. When you are lifting weights, You should carefully observe the movement of heavy
objects, ensure that heavy objects move correctly;
3. Hoist design for intermittent work, continuous intensive attention in the work of
worm gear case temperature shall not exceed 80 ℃ ;
4. Prohibition of the use of an insecure wire rope, wire rope wire break in such as
deformation, flattening, wear and abnormal, immediately replace the wire rope.
5. Wire rope should be checked before each use, ensuring perfect condition of steel
wire rope.
6. Working state, coils of wire rope on the rollers shall not be less than 5 laps;

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6.0 EMERGENCY LOWERING PROCEDURES FOR HOISTS WITH
GEAR MOTORS
The following procedure releases the multiple disc brake while leaving the brake valve
closed. Since gear type motors are not zero leakage devices, internal motor leakage
permits the load to slowly rotate the motor although its outlet is blocked by the closed
brake valve. This procedure will NOT work if there is little or no oil in the motor. Using
properly rated pipe and fittings, the standpipe described below may be permanently
installed in the hydraulic system to avoid installing one in an emergency.
CAUTION
The following procedure is specifically for use on hoists equipped with gear-type
hydraulic motors. For hoists equipped with other hydraulic motors (piston, vane, etc)
contact WPT winch for assistance BEFORE attempting this procedure.
1. Remove the lockwire on the needle valve handle and close the valve tightly.
WARNING
The standpipe referred to in step (3) below MUST be used. Attempting this
procedure with no oil in the motor or with the brake valve stuck in the open
position will cause the load to free fall, which could result in property damage,
personal injury or death.
2. Remove the plug in the tee.
3. Remove both main hoses from the motor. Attach a standpipe to the lowering
motor port (opposite side of the motor from the brake valve). Install a plug into
the hoisting port in the brake valve.
The standpipe is simply a length of pipe (approximately 12 inches (305mm) long)
attached to a 90°elbow. The other end of the elbow is attached to the lowering

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motor port or manifold. The standpipe is installed with the long, open end
pointing up in a vertical position to reservoir. While the load is being lowered,
hydraulic oil MUST be added to the standpipe as necessary to prevent to the
motor from running dry.
4. Fill the standpipe with hydraulic oil, making certain that oil is not leaking from the
brake valve plug. If oil is running out of the brake valve plug, stop the emergency
lowering procedure and repair the leak.
5. Connect a hand pump to the open port in the tee.
WARNING
Do not touch the motor, brake valve, or standpipe while lowering a load. They
may become hot enough to cause burns.
6. Slowly operate the hand pump up to no more than 1,000 psi (6,900kPa). A
suspended load was slowly come down when the pressure over 465 psi
(3200kPa). Releasing the pressure on the hand pump was cause the load to
stop. If a chattering noise is heard while the load is coming down, pump the
hand pump to a slightly higher pressure until the noise stops. Do not exceed
1,500 psi (10,350kPa) to the brake release port.
7. Always remove the hoist from service to inspect the brake components for signs
of overheating and replace following this procedure.
WARNING
Performing this procedure will create heat and may cause accelerated wear
of hoist brake system and hydraulic components. Inspection and replacement of
damaged brake assembly, hydraulic motor or brake valve components is critical
to the safe operation of the hoist braking system. Failure to replace damaged
components may result in loss of load control, property damage, personal injury,
or death.
8. If this procedure was performed due to a malfunction of the hoist, remove the
hoist from service and perform a complete teardown and inspection to correct
the cause of the malfunction before returning the hoist to service.

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7.0 THE BRAKES CONTRAST TEST
ALL WPT planetary hoists have a spring applied, hydraulically released, multiple disc
brake inside the hoist housing. This brake holds a suspended load when the
directional control valve is in neutral, or when the directional control valve is in neutral,
or when hydraulic power is lost. A brake clutch assembly permits the power train and
drum to rotate in the direction to lift a load, while the brake remains fully applied. A
load cannot be lowered, however, without applying hydraulic pressure to the release
port and releasing the brake.
Hoists ordered for personnel handling cranes will have a needle valve in the brake
release line. They will also have a tee in the brake release line between the needle
valve and the brake release port on the hoist. One opening in the tee is capped. With
the valve closed and the cap removed from the tee, the brake is isolated from system
pressure and vented to atmosphere. The brake cannot be released under these
conditions by actuating the directional control valve.
Relative location of needle valve to other components and fittings on the winch, motor
and counterbalance valve.
One purpose of the valve/tee combination is to provide a means to test the brake; the
other is to provide a means to lower a load when hydraulic power is lost.
Brake test procedure (Hoists Equipped With Brake Valves)：
(test to be performed with no load on the hoist)
1. Remove the lockwire on the needle valve handle and close the valve tightly.
2. Remove the plug or cap in the tee (in the brake release circuit).
3. With the hydraulic power unit running, move the directional control valve
handle slowly to the full open, lowering position.
4. Increase the engine speed, to bring system pressure up to the relief valve
setting (setting the system flow is be 60,100,150,180,200,220,246L/min).
The hoist drum still remain stationary.
5. If the drum rotates, the hoist should be disassembled and the brake
components should be examined for wear. In addition, the brake springs
should be measured for correct free length in those hoists using helical
compression springs.
6. Reassemble the brake and hoist and repeat the above steps.
7. When testing is complete, be sure to reinstall the plug or cap in the tee, fully
open the needle valve and stall lockwire to secure the valve in position.
8. The above procedure utilizes the hoist hydraulic motor to test the brake’s
ability to resist approximately 115% of the rated hoist load.

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8.0 MAINTENANCE
Adhering to the following maintenance schedule will keep your hoist in top condition
and performing as it should with a minimum of repair.
【 MONTHLY 】
1. Check the oil level and maintain it to the oil level to round hex head socket plug.
2. If oil is leaking out, determine location and repair.
3. Check the hoist mounting bolts. For any miss, please replace them and securely
tighten any that are loose..
4. Inspect the cable. If the cable has become frayed with broken strands, replace
immediately.
5. Inspect the oil pipeline, not damage or leak.
6．Lubricate cable with light oil.
【 ANNUALLY 】
1. Check the easily damage parts and replace immediately for any damage
2. Inspect frame and surrounding structure for cracks or deformation.
3. Drain the oil from the hoist annually or more often if hoist is used frequently.
4. Fill the hoist to the oil level plug with clean kerosene. Run the hoist a few second
with no load in the reel in direction. Drain the kerosene from the hoist.
5. Refill the hoist to the oil level plug with all purpose MOBIL 600XP150 gear oil
（about 1.9L）.
6. Suggest change the filter and seals of oil system once every half-year.
7. Suggest change the oil once a year.

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9.0 TROUBLESHOOTING
WARNING ！
If a hoist ever exhibits any sign of erratic operation, or load control difficulties (i.e. load
creeping or chattering) appropriate troubleshooting tests and repairs should be
performed immediately. Continued operation in this manner may result in property
damage, serious personal injury or death.
TROUBLE
POSSIBLE CAUSE
CORRECTION
A
The hoist will
not lower the
loador notlower
the load
smoothly.
1. The problem could be a plugged
or loose pilot orifice. The pilot
orifice is a small pipe plug with a
hole drilled through it, located
behind the pilot port fitting on the
brake valve. If it becomes
plugged, it will prevent the pilot
pressure, from the manifold, from
opening the brake valve. If it
becomes loose, it will allow an
unregulated amount of oil in to
operate the brake valve which
cause erratic brake valve
operation.
2. The friction brake may not be
releasing as a result of a
defective brake cylinder seal.
NOTE: If the brake cylinder seal is
defective you will usually find oil
leaking from the hoist vent plug.
1. Friction brake will not release as a
result of damaged brake discs.
Remove the pilot hose and fitting
from the brake valve, then use a
5/32 inch Allen wrench to remove the pilot
orifice. The diameter of the orifice is
approximately .020 inches.
Clean and install the pilot orifice tightly in
the brake valve.
Check brake cylinder seal as follows:
A. Disconnect the swivel tee from the
brake release port. Connect a hand pump
with accurate 0-2000 psi gauge and shut-
off valve to the –4 J.I.C. fitting in the brake
release port.
A. Apply 1000 PSI (6,900 kPa) to the
brake. Close shut-off valve and let
stand for fi ve (5) minutes.
B. If there is any loss of pressure in five
(5) minutes, the brake cylinder should
be disassembled for inspection of the
sealing surfaces and replacement of
the seals.
Disassemble brake to inspect brake discs.
B
Oil leaks from
vent plug.
1. Same as A2.
2. Motor seal may be defective as a
result of high system back pressure
or contaminated oil.
Same as A2.
System back pressure must not exceed
150 PSI (1,035 kPa). Inspect hydraulic
system for a restriction in the return line
from the control valve to the reservoir. Be
sure control valve and plumbing is properly
sized to hoist motor.

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Oil analysis may indicate contamination
has worn motor shaft and seal. Thoroughly
flush entire hydraulic system and install
new filters and oil. Install new motor seal.
C
The brake will
not hold a load
with the control
lever in neutral.
1. Excessive system back pressure
acting on the brake release port.
2. Friction brake will not hold due to
worn or damaged brake discs.
3. Brake clutch is slipping.
1. Replace the motor.
2. Increase the hydraulic system pressure.
D
Thehoistwill
not hoist the
rated load.
1. The hoist may be mounted on an
uneven or flexible surface which
causes distortion of the hoist base
and binding of the gear train. Binding
in the gear train will absorb
horsepower needed to hoist the rated
load and cause heat.
2. System relief valve may be set
too low. Relief valve needs
adjustment or repair.
3. Be certain hydraulic system
temperature is not more than 180
degrees F. Excessive hydraulic
oil temperatures increase motor
internal leakage and reduce
motor performance.
4. Hoist line pull rating is based on
1st layer of wire rope.
5. Rigging and sheaves not operating
efficiently.
Reinforce mounting surface.
If necessary, use shim stock to level hoist.
Refer to “Hoist Installation”.
First loosen, then evenly retighten all hoist
mounting bolts to recommended torque.
Check relief pressure as follows:
A. Install an accurate 0-4000 psi (27,580
kPa) gauge into the inlet port of the brake
valve.
B. Apply a stall pull load on the hoist while
monitoring pressure.
C. Compare gauge reading to hoist
specifications. Adjust relief valve as
required.
NOTE: If pressure does not increase in
proportion to adjustment, relief valve may
be contaminated or worn out. In either
case, the relief valve may require
disassembly or replacement.
Same as remedies for Trouble D1 &
D2.
Same as remedies for Trouble E2.
Refer to hoist performance charts for
additional information.
Perform rigging service as recommended
by crane manufacturer.
E
Thehoistruns
hot.
1. Same as D1.
2. Be certain that the hydraulic
system temperature is not more than
180 degrees F. Excessive hydraulic
oil temperatures may be caused by:
A. Plugged heat exchanger.
B. Too low or too high oil level in
hydraulic reservoir.
Same as remedies for Trouble D1.
Thoroughly clean exterior and flush interior.
Fill/drain to proper level.

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C. Same as D2.
D. Hydraulic pump not operating
efficiently.
3. Excessively worn or damaged
internal hoist parts.
Same remedies as D2
Same as remedies for Trouble D2.
Prime mover low on horsepower or
R.P.M. Tune/adjust prime mover.
Check suction line for damage.
If pump is belt driven, belts are slipping.
Replace/tighten belts.
Pump worn. Replace pump.
Disassemble hoist to inspect/replace worn
parts.
F
Hoist“chatters”
while raising
rated load.
1. Same as D2.
2. Hydraulic oil flow to motor may
be too low.
3. Controls being operated too
quickly.
Same as remedies for Trouble D2.
Same as remedies for Trouble E2.
Conduct operator training as required.
G
The wire rope
does not spool
smoothly onthe
drum.
1. The hoist may be mounted too
close to the main sheave, causing
the fleet angle to be more than
1-1 /2 degrees.
2. The hoist may not be mounted
perpendicular to an imaginary line
between the center of the cable drum
and the first sheave.
3. Could possibly be using the wrong
lay rope. There is a distinct
advantage in applying rope of the
proper direction of lay. When the load
is slacked off, the several coils on the
drum will stay closer together and
maintain an even layer.
If rope of improper lay is used, the
coils will spread apart each time the
load is removed. Then, when
winding is resumed, the rope has a
tendency to criss-cross and overlap
on the drum. The result is apt to be a
flattened and crushed rope.
4. The hoist may have been
overloaded, causing permanent set
in the wire rope.
Check mounting distance and fleet angle.
Reposition hoist as required.
Refer to “Hoist Installation”.
Consult wire rope manufacturer for
recommendation of wire rope that best
suits your application.
Replace wire rope and conduct
operator/rigger training as required