sidewinder pull and assist winch rev4 edit 27918
Contents
1. PULL AND ASSIST CAPSTAN WINCH OPERATION amp MAINTENANCE 70605 USA SIDEWINDER Copyright 2009 by General Machine Products Co Inc QC Final Inspection by Date Unit Serial Number Build Date All rights reserved No part of this publication may be copied reproduced or transmitted in any form whatsoever without the written permission of General Machine Products Co Inc GNP GMP 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 EMAIL info gmptools com March 29 2010 USA Ver 4 Manual P N 27918 REVISION HISTORY Rev v pue ui tor o1 03 2006 Original issue issue A A Miller US Version 03 09 2009 Update manual to be consistent with others 04 3 20 0 Added figure 8 instruction and illustrations A Konschak General Machine Products Co Inc 2 0124 CONTENTS 1 0 Introduction 2 0 Safety Instructions 3 0 General Description 4 0 Specification 5 0 Operating Procedure 6 0 Maintenance and Servicing 7 0 Towing Instructions 8 0 Equioment Layout 9 0 Spare Parts APPENDICES Appendix 1 Hydraulic Circuit Drawing 3 of 24 General Machine Products Inc 1 0 INTRODUCTION Founded by engineer George M Pfundt in 1936 GMP started op erations in a downtown Philadelphia building as a specialty ma chine shop doing work for the local Bell Telephone company and _ for the electric utility company GMP expan2. tion filter element and return line filter element Refill with fresh oil Check and reset all relief valves Refer to section 6 4 for further information Refer to section 4 for grades of hydraulic oil 6 5 3 Service the engine as per the engine manufacturers manual supplied with the winch 6 5 4 Check the condition of the tires and running gear Adjust and reset if necessary 6 5 5 In line planetary gearbox capstan drive Change the gearbox oil refer to section 4 for gear oil grades refer to the instruction manual supplied with the gearbox for further details on maintenance and servicing Page 14 of 24 General Machine Products Co Inc 6 4 RELIEF VALVE SETTING Reference should be made to the hydraulic circuit diagram on page 19 of this manual There are four relief valves in the circuit and with the exception of item 10 all have been factory pre set and should not be adjusted Item 10 is adjusted by the operator to set a maximum pulling tension If it is necessary to replace or adjust any of the relief valves the following guidance should assist Item 7 This is a Capstan directional control valve The relief valve is mounted in the body of this control valve and is the main system relief valve With a Dynamometer in the rope load line and with 4 complete turns around the capstan this relief valve should be set to relieve at 1200 Ibs 550 kg approx 1880 psi 130 Bar Note Relief valve adjustment is hidden b
3. PROCEDURE Prior to using the winch for any hauling application it is important to ensure that the rear prop legs are extended and lowered in order to level the winch and that the front jockey wheel is also lowered to a position where the winch is firm and stable The winch should be securely anchored to either a suitable vehicle ground anchors or other substantial holding point The winch should be in line with the direction of pull Refer to the pre winching maintenance checks in section 6 1 The capstan must be rotated from the Transverse transit position to the In Line working position Ensure that the retaining pin and hair pin are correctly replaced It may be necessary to remove the lighting board This is accomplished by first un plugging the connector from the rear jack on the trailer and then pulling the spring loaded release pins The complete lighting board can then be removed and stored safely Page 8 of 24 General Machine Products Co Inc 5 3 PAYING OUT ROPE The rope take up drum should be de clutched by removing the lynch pin at the end of the drum shaft grasping the drum flange pulling and then rotating Once the drum is free from its drive clutch it is free to rotate on the shaft and the rope can be pulled manually from the drum 5 4 STARTING THE ENGINE The engine manufacturer s operating and service manual form an integral part of this manual It is recommended that these instructions are read and fully
4. The capstan should be returned and fixed in the transverse transit position The lighting board should be re fitted and the light operation checked The winch should be preferably stored in a dry place e g garage or workshop Page 11 of 24 General Machine Products Co Inc 6 0 MAINTENANCE AND SERVICING It is recommended that this winch is serviced every 12 months regardless of its con dition or the number of operating hours used This will help to ensure reliable trouble free service It is imperative that any maintenance work is carried out by personnel suitably trained and qualified to do so 6 1 PRE WINCHING MAINTENANCE CHECK This should be carried out each day prior to the start of winching 6 1 1 Check the hydraulic oil level Oil should be visible within the black lines marked on the hydraulic oil level sight gauge Replenish if necessary with the correct grade of hydraulic oil to suit the climatic conditions Refer to the section 4 for grades of hy draulic oil required 6 1 2 Check the engine oil level as indicated in the engine manufacturers manual Replen ish if necessary 6 1 3 Check that there is enough fuel in the tank to complete the planned winching sched ule 6 1 4 Check the condition of the hydraulic hoses replace if damaged 6 1 5 Check the condition of the pulling rope particularly where it joins the drum Only use a good condition rope of suitable pulling capacity 6 1 6 Check that all sc
5. above shall apply instead 3 that a reconditioned used GMP product sold by GMP or a non owned product re paired by GMP or a new part sold by GMP will be free from original defects in material and workmanship for ninety days from the date the product was delivered to the pur chaser and or end user 1b The above warranties are contingent upon and subject to the condition that 1 the end user substantiates the date it purchased and received delivery of the product or part and 2 the product or part shall have been installed maintained and used in accordance with GMP s or the manufacturer s written instructions 2 The end user shall determine the suitability of GMP s product or part for intended use and the end user assumes all risk and liability whatsoever in connection therewith except to the ex tent set forth in this Limited Warranty 3a GMP reserves the right to request that the product or part be returned to us for examination and cannot be responsible for user charges incurred in the replacement of any product GMP s agreement to repair or replace is also subject to its inspection of the product and verification of the defect 3b Subject to immediate written notification of a defect or malfunction GMP will repair or re place that product or part at GMP s option returned freight prepaid to Trevose PA 3c To obtain repair or replacement service under the Limited Warranty the purchaser must contact the factory for a Retu
6. and can be split to enable removal of rope he capstan can be rotated through 90 on a swivel bracket from the inline working position to the transverse transit position when in tow When the winch is in the working mode the rear props are extended out of the chassis to provide greater stability Page 6 of 24 General Machine Products Co Inc 4 0 SPECIFICATION Max Pulling Capacity Rope Speed Max Capstan Diameter Dimensions Power Supply Load Indication Main Drive Gear Box Gear Oil Grades Controls see section 8 Hydraulic Circuit Hydraulic Oil Tank Capacity Hydraulic Oil Grade 1100 Ibs 500 kg 200 ft min 60 m min 32 813 mm Length 123 3124 mm Overall Width 69 1753 mm Height 57 1450 Weight 1400 Ibs 635 kg Track 60 1676 mm Tire Size F78 14 205 75D14 Coupling Lunette Ring Pintle hook Lighting Adapter 7 Way others available by request Honda GX390 13 HP Recoil Start Overhead Valve Cast Iron Cylinder Sleeve 1 5 Gallon tank Calibrated gauge bezel Fixed displacement tandem pumps to fixed displacement high torque motors In line planetary gearbox capstan drive MobileLube HD Plus 85W 140 Refer to the instruction manual supplied with the gearbox for alternative oil types and grades a Pay in pay out spring centered control valve b Detented take up drum drive control valve c Tension control knob d Tension indicator Closed c
7. aged 4 Keep hands feet and loose clothing away from moving parts Always stop the machine to carry out lubrication or servicing Check machine before starting for worn or damaged parts Check that all nuts and bolts are tight If machine is left unattended ensure that unauthorized use is prevented Never leave the machine unattended while in use Consider the use of safety barriers especially when used in public places 0 Beware of pinch points involved with rotating components e g rope cable drums capstans bullwheels shafts and chain drives 11 Beware of hot surfaces especially around the engine engine exhaust pipe and hy draulic oil tank 12 Some component and assembly parts are in excess of 55lb 25kg When lifting care must be taken ensure sufficient man power lifting gear is available to pre vent personal injury and damage to the machine 13 Beware of exposed electrical contacts especially around the engine Do not touch or allow metal objects to come into contact 14 Waste engine and hydraulic oils are to be disposed of via an environmen tally acceptable method e g passed on for recycling 15 Wear ear protection when engine is running to prevent ear damage 16 Machine may cause additional fire hazard if involved in an existing fire due to gaso line diesel oil and hydraulic oils involved 17 No personnel are to be in manholes or ducts when the winch is being operated 18 The machine must be operated
8. anges in equipment design or compo nents as progress in engineering or manufacturing methods may warrant 7 This Warranty shall be construed in accordance with the laws of the State of Pennsylvania of The United States of America 8 This Limited Warranty may not be modified in whole or in part except by writing signed by an authorized officer of GMP 22 of 24 General Machine Products Co Inc Page 23 of 24 General Machine Products Co Inc GMP 3111 Old Lincoln Hwy Trevose 19053 USA di TEL 1 215 357 5500 FAX 1 215 357 6216 EMAIL info gmptools com
9. apstan wrapping of the cable should ensure that the high tension side should be nearest to the gearbox and hydraulic motor 5 6 0 The winch is capable of being used to figure 8 fiber cable The capstan should be rotated to 45 and locked in place by the supplied bolt and nut as shown in photo below From Reel 10 of 24 General Machine Products Co Inc 5 6 REMOVING ROPE FROM SPLIT DRUMS The split drum has been designed to enable removal of the rope in a complete coil In order to achieve this ensure that the drum is fully engaged in its clutch and untie the rope from the drum It is often advantageous at this stage to tie a few wraps of waste string tie wraps tape around the rope coils ensuring that the string does not pass around one of the drum spokes This will help to keep the rope in a nice tight coil when released from the drum To remove the rope from the drum first remove the retaining pin on the drum s drive shaft Remove the locking bolt from the drum flange retaining nut The ears on the nut can now be used to release the nut by rotating counter clockwise Because of the tight ness of the rope on the drum a soft faced hammer may be used on the retaining nut s ears to help with the initial movement The nut and outer drum flange may then be re moved The rope coil may now be removed Re assemble the drum 5 7 ON COMPLETION OF THE WINCHING OPERATION The machine should be wiped down and cleaned
10. ded to a production 4 shop after landing a contract with Western Electric Com pany vend bes forming a close relation ship with Bell Telephone Laboratories in Murray Hill N J which enabled it to manufacture proto types of products for experimental use within the Bell System Having outgrown the original factory building the company built a 100 000 square foot plant in Trevose PA a Philadelphia suburb and moved there in 1957 Today GMP is recognized as a pre mier worldwide supplier of specialty tools and equipment for the outside plant market place The company s products are known for their robust design and durability to with stand many years of frequent use ORE s PE den Page 4 of 24 General Machine Products Co Inc 2 0 SAFETY INSTRUCTIONS THIS EQUIPMENT MUST ONLY BE USED BY AUTHORIZED PERSONNEL WHO HAVE BEEN SUITABLY TRAINED AND COMPETENT TO DO SO THESE INSTRUCTIONS ARE TO BE MADE AVAILABLE TO OPERATORS OF THIS EQUIPMENT AT ALL TIMES FAILURE TO OBSERVE THESE SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY AND OR PROPERTY DAMAGE 1 Read and understand the operation and maintenance manual supplied with this equipment Keep it in a convenient place for future reference 2 Keep children and untrained personnel away from this equipment while in operation 3 Keep all guards and safety devices in place Do not operate this equipment with guards removed or dam
11. ircuit system with full filtration and overload protection 16 5 Gal 63 Liters Tellus T 32 7 Way Plug Wiring Tail Lights Brown Left Turn Yellow White General Machine Products Co Inc 1 49 c 2 Lif VW 12 B us Right Turn Green Page 7 of 24 5 0 OPERATING PROCEDURE IT IS IMPERATIVE THAT ALL PERSONS USING OPERATING OR MAINTAINING THIS WINCH BE FULLY TRAINED AND COMPETENT TO DO SO AND HAVE READ THE ENTIRE OPERATING MANUAL GMP CANNOT BE HELD RESPONSIBLE FOR MIS USE OF THIS EQUIPMENT 5 1 CONTROLS The operator controls have been designed to be safe and simple to use with regard to ergonomic considerations The operators control station is complete with the following see section 8 a Control lever for winching in and paying out This provides bi directional selection of capstan rotation The valve spool has a soft start facility allowing for a limited creep and inching movement b Control lever for operation of the rear take up drum This lever should be in its oper ating position before operating the capstan If the winch is not being used this lever should be returned to its non operating position thus saving on fuel and preventing the hydraulic oil from overheating c Tension control knob This can be used to limit the actual pulling tension applied to the capstan d Pressure gauge which is also an indication of the pulling tension 5 2 PRE WINCHING
12. on firm ground 19 Stay clear of cables or lines under tension 20 Only use the machine for its intended purpose 21 Do not tamper with pressure relief valves or pressure reducing valves 22 Rear stabilizing props must be down and on solid surface before use D o Page 5 of 24 General Machine Products Co Inc 3 0 GENERAL DESCRIPTION The GMP SideWinder is a trailer mounted pull and assist capstan winch mounted on a sturdy all steel fabricated chassis It is equipped with torsional suspension axles stabilizing prop legs a front telescopic jockey wheel and a tow bar with a Lunette Ring The unit is easily pulled by a standard pickup truck The power source is a gasoline engine which drives the fixed displacement tandem mounted hydraulic pumps The hydraulic pump is attached to the en gine via a bell housing and flexible coupling One pump powers a hydraulic motor through an in line planetary gearbox to the capstan The second pump drives the rope take up drum again through a hydraulic motor The hydraulic oil tank is fitted with double filtration protection sight glass and filler breather Controls are operator friendly and very simple to use A spring centered lever controls the direction of rotation of the capstan while a detented lever en gages the take up drum drive A control knob is used to limit the rope cable tension using the panel mounted tension indicator The rope take up drum is removable
13. rew fasteners are tight 6 1 7 Check the hydraulic oil system for leaks rectify before proceeding 6 1 8 Clean any dirt or debris from the take up drum shaft and capstan face 12 of 24 General Machine Products Co Inc 6 2 MONTHLY MAINTENANCE This should be carried out at intervals not exceeding 4 weeks These intervals will de pend upon the degree of use of the winch 6 2 1 Carry out all the pre winching checks as detailed in 6 1 6 2 2 Check the function of all the lighting equipment this should be more frequent if regular problems arise 6 2 3 Check and adjust the tire pressures 6 2 4 With the engine and drum shaft running check the return filter condition indicator This is a red green indicator mounted on the hydraulic oil tank return line filter If the indica tor is well over into the red area replace the filter 6 2 6 Grease all bearings and grease fittings 6 2 7 Oil all moving parts to prevent corrosion 6 2 8 Apply oil to all oilite bushes 6 2 9 Check the condition of the towing breakaway chain If damaged replace immediately 13 of 24 General Machine Products Co Inc 6 3 ANNUAL SERVICING This should be carried out at approximately 12 monthly intervals by a qualified and experienced workshop team 6 3 1 Carry out all the work as specified above in section 6 2 6 3 2 Drain the hydraulic circuit of oil Clean the filler breather and replace Renew the suc
14. rn Material Authorization RMA Once obtained send the RMA along with the defective part or product transportation prepaid to General Machine Products Co Inc 3111 Old Lincoln Highway Trevose PA 19053 USA Tel 215 357 5500 3d The field labor and material charges incurred by an authorized GMP dealer or an end user to disassemble inspect repair and reassemble our product or part at their respective prime locations will not be reimbursed unless GMP has first reviewed and approved those charges 3e Incidental repair charges incurred by an authorized dealer or an end user for items such as 21 of 24 General Machine Products Co Inc labor transportation tolls lodging and meals at a location remote from its prime facility or to demount our product or part from its remote location and forward to its prime facility are not the responsibility of GMP and are not covered by this Warranty 3f Incidental repair charges incurred by an authorized GMP dealer or end user to remove con struction hardware modify a vehicle or otherwise gain access to GMP s product or part is a condition beyond GMP s control and is not covered by this Warranty 4a GMP products or parts which become part of a total assembly which has been designated and or manufactured by others are not covered by this Warranty unless GMP reviews the total assembly and expressly extends its warranty 4b Design material and workmanship furnished by other
15. s to install or operate a GMP product or part are not covered by this Warranty with respect to GMP s products or parts which are used in that particular assembly 4c Hydraulic pneumatic electrical or mechanical control equipment which is not manufac tured by GMP and which becomes a part of a GMP assembly is not covered by this Warranty 4d This warranty does not cover a GMP product or part which others have subjected to abuse improper installation improper operation alteration or negligence in storage or handling 5a THE ABOVE WARRANTIES ARE EXCLUSIVE AND ARE IN LIEU OF ALL WARRAN TIES OF MERCHANTABILITY FITNESS FOR PURPOSE OR OTHER WARRANTIES OR GUARANTEES OF ANY KIND OR DESCRIPTION EXPRESS OR IMPLIED 5b GMP ASSUMES NO LIABILITY WHATSOEVER INCLUDING WITHOUT LIMITATION ANY INJURY LOSS OR DAMAGE IN CONNECTION WITH THE INSTALLATION OR USE OF THIS PRODUCT OR PART EXCEPT AS STATED IN THIS LIMITED WARRANTY GMP WILL IN NO EVENT BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE PRODUCT OR PART 5c GMP S SOLE LIABILITY AND THE PURCHASER S SOLE REMEDY FOR A FAILURE OF A PRODUCT OR PART UNDER THIS LIMITED WARRANTY AND FOR ANY AND ALL CLAIMS ARISING OUT OF THE PURCHASE AND USE OF THE PRODUCT OR PART SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF THE PRODUCT OR PART THAT DOES NOT CONFORM TO THIS WARRANTY 6 GMP reserves the right without notice to make ch
16. safety chains are securely attached to the tow vehicle Make sure that the Jockey wheel is rotated up in the driving position and that the rear prop legs are securely retracted and locked Make sure all trailer lights are working properly Check tires for proper inflation mu W Page 16 of 24 General Machine Products Co Inc 8 0 EQUIPMENT LAYOUT 16 CAPSTAN TOW BAR ROPE TAKE UP DRUM JOCKEY WHEEL REAR PROP LEG CAPSTAN DRIVE GEARBOX ROPE TAKE UP DRUM HYDRAULIC MOTOR ENGINE HYDRAULIC PUMPS 10 HYDRAULIC OIL TANK 11 HYDRAULIC OIL TANK FILLER BREATHER 12 RETURN LINE FILTER 13 CONTROL PANEL 14 REAR LIGHTING BOARD 15 AXLE AND WHEELS 16 CAPSTAN HYDRAULIC MOTOR OON OOP WN 17 of 24 General Machine Products Co Inc CAPSTAN WINCH CONTROL PANEL WINCH IN PAYING OUT CONTROL LEVER ROPE TAKE UP DRUM OPERATION CONTROL LEVER TENSION CONTROL KNOB PRESSURE GAUGE TENSION INDICATOR DOWD HYDRAULIC OIL TANK SUCTION FILTER VP Page 18 of 24 General Machine Products Co Inc 9 0 USER REPLACEABLE PARTS Return Line Filter Replacement Replace the Return Line Filter when the filter gauge is in the red indicating higher return pressure i e clogged filter The gauge is found on the side of the filter housing and is green when filter is good 1 Unscrew the return 2 Remove old filter and re 3 Replace the top cap mak line filter top cap with a place with
17. the new one ing sure not to cross the 42mm wrench or socket and thread Check for leaks after remove tightening Typical User Replaceble Parts Part Number Oil Tank Filler Breather 32073 Oil Tank Suction Filter 32134 Return Line Filter 34421 Sight Level Gauge 32053 For spare parts call General Machine Products Co 3111 Old Lincoln Highway Trevose PA 19053 Tel 41 215 357 5500 Fax 1 215 357 6216 Email info GMPtools com VP Page 19 of 24 General Machine Products Co Inc OS BHT ROSAS 259 1 45 T 1 7 2317147 aana 254 4 Wmd 2 2 p General Machine Products Co Inc Page 20 of 24 GMP LIMITED WARRANTY 1a General Machine Products Co Inc GMP warrants to the purchaser and or end user 1 that a new product sold and manufactured by GMP will be free from original defects in material and workmanship for one year from the date the product was delivered to the purchaser and or end user or for the lifetime of the Modular Plug Presser 2 that a new product sold and not manufactured by GMP will be covered exclusively by the manufacturer s warranty However if that warranty coverage shall provide less coverage than the GMP Warranty for its manufactured products then the warranty set forth in Paragraph 1 a
18. under stood by all operating personnel before starting the engine Before starting the engine check the fuel level engine oil level and oil level in hy draulic tank 5 5 PULLING IN 5 5 1 The rope should be wrapped around the capstan such that a The rope to take up drum comes off the top of the capstan and is furthest away from the operator b The rope to the fiber cable load side comes off the top of the capstan and near est to the operator and gearbox Approximately four to five complete turns are re quired Operator Page 9 of 24 General Machine Products Co Inc 5 5 2 Operate the drum control lever to engage the drum drive This should be left in its operating position at all times that the winch is working At all other times it is advanta geous to return the drum control lever to its non operating position 5 5 3 Operate the winch control lever by pulling gently towards the operator The rope will now be pulled in and be wound onto the rope take up drum The speed of pulling can be increased or decreased by adjusting the engine speed control The specific maximum pulling tension is adjusted by the operator by turning the tension control knob to suit the application When winching is completed move the take drum operating lever to the off position 5 5 4 When being used as an assist winch the drum drive is not required and therefore the operator should ensure that the lever is in the off position C
19. y a protective cap and sealing washer Item 8 his relief valve is situated on the drum directional control valve This controls the rope tension between Capstan 10 and Drum when pulling in The valve should be set to relieve when the rope tension measures approx 85 110 Ibs 40 50 kg This measurement and adjustment should be made when the rope drum is almost empty Note Relief valve adjustment is hidden by a protective cap and sealing washer Item 2 his relief valve is mounted in an aluminum body connected to the drum hydraulic motor This valve prevents drum overrun when paying out under power With the rope drum almost empty the relief valve can be set so that a rope tension of approx 85 Ibs 40 kg will cause the drum to rotate Item 10 This relief valve is mounted in an aluminum body connected to the capstan hy draulic motor It is intended that the site supervisor will set this relief valve to give maximum rope tension to suit specific operating conditions There are two adjustments limiting for ward and reverse Control Panel Hear Control Panel Front Item 8 Item 7 Item 2 Item 10 Item 10 Forward Capstan Reverse Capstan Page 15 of 24 General Machine Products Co Inc 7 0 TOWING INSTRUCTIONS BEFORE TOWING gt Check the load is distributed to give a positive hitch weight to ensure stable towing Also ensure the hitch weight is within limit of the vehicle Ensure that the Pintle hook is locked and the
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