General Machine Products 70530 User Manual
Adams Model WG Worm Gear Winch
INSTALLATION, OPERATION & MAINTENANCE
P/N 70530
WG INTERMITTENT DUTY WINCH
Copyright 2012 by General Machine Products Co., Inc
All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form
whatsoever without the written permission of
GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA
TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: www.gmptools.com
General Machine Products Co., Inc.
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June 12 2012 USA Ver 6
Manual P/N 32194
TABLE OF CONTENTS
SCOPE ........................................................................................................................................ 3
1.00 GENERAL....................................................................................................................... 3
1.01 WINCH APPLICATION.................................................................................................... 3
1.02 WINCH MAJOR COMPONENTS .................................................................................... 3
1.03 WINCH CLUTCH GENERAL INFORMATION................................................................. 3
1.04 CALIPER TYPE, FREE SPOOL CONTROL (DRAG) BRAKE ........................................ 3
1.05 FULL LOAD BRAKE ........................................................................................................ 4
1.06 2 SPEED HYDRAULIC MOTOR .....................................................................................4
1.07 LEVEL WIND MECHANISM ............................................................................................ 4
1.08 ACCESSORIES ............................................................................................................... 4
2.00 IMPORTANT PRECAUTIONS......................................................................................... 5
3.00 INSTALLATION ...............................................................................................................6
3.01 GENERAL........................................................................................................................ 6
3.02 HYDRAULIC REQUIREMENTS ...................................................................................... 7
3.03 WINCH CLUTCH ............................................................................................................. 8
3.031 OPTIONAL CLUTCH POSITION SENSING.................................................................... 8
3.04 CALIPER TYPE DRAG BRAKE ...................................................................................... 9
3.041 GENERAL GUIDELINES................................................................................................. 9
3.042 CALIPER BRAKE ASSEMBLY...................................................................................... 10
3.043 RESERVOIR AND ACTUATOR .................................................................................... 10
3.05 WIRE ROPE INSTALLATION........................................................................................ 11
3.06 WINCH DRUM DIRECTION OF ROTATION ................................................................12
3.07 WINCH IDENTIFICATION ............................................................................................. 12
4.01 PRE-OPERATIONAL CHECKS..................................................................................... 12
4.02 WINCH BREAK-IN......................................................................................................... 13
5.00 WINCH OPERATION..................................................................................................... 13
5.01 EXTENSION SHAFT OPERATION ............................................................................... 13
6.00 MAINTENANCE............................................................................................................. 14
6.01 GENERAL...................................................................................................................... 14
6.02 LUBRICATION............................................................................................................... 15
6.03 WINCH IDENTIFICATION ............................................................................................. 16
6.04 CALIPER BRAKE ..........................................................................................................16
7.01 LEVEL WIND INTRODUCTION ................................................................................... 17
7.02 LEVEL WIND DESCRIPTION ....................................................................................... 17
7.03 WIRE ROPE INITIAL INSTALLATION ..........................................................................17
7.04 LEVEL WIND ADJUSTMENT........................................................................................ 18
7.05 LEVEL WIND LUBRICATION........................................................................................ 18
7.06 LEVEL WIND SPOOLING .............................................................................................18
7.07 INSTALLATION OF WIRE ROPE IN USE..................................................................... 18
7.08 WIRE ROPE LUBRICATION ......................................................................................... 18
DETAILS OF AIR SHIFT CLUTCH & CALIPER BRAKE............................................... 19
2 SPEED MOTOR CONTROL SCHEMATIC DWG. 28824 .......................................... 20
AIR SHIFT CLUTCH ELECTRICAL CONTROL SCHEMATIC DWG. 25687................ 21
AIR SHIFT CLUTCH PNEUMATIC CONTROL SCHEMATIC DWG. 25686.................22
AIR SHIFT CLUTCH WITH SENSORS WIRING DIAGRAM 25777 .............................23
COMPLETE WG WINCH DIMENSIONAL DRAWING .................................................. 24
MODEL WG WINCH SPECIFICATIONS....................................................................... 25
WARRANTY .................................................................................................................. 26
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SCOPE - This document contains information pertinent to the Installation, Operation and Maintenance of the Ad-
ams® Model WG Worm Gear Winch. The WG winch manufactured by General Machine Products Co., Inc. commencing in January 1, 2005 differ significantly from prior generations of Adams Winches in equipment design and
components. To obtain information on earlier model CD, LCD or UG winches, please see our website at
www.gmptools.com.
1.00 GENERAL - The information contained in this revision pertains exclusively to the Adams
®
Model WG
Winches manufactured after January 1, 2005 which have serial numbers of 05-3000 and higher.
1.01 WINCH APPLICATION - The winch has been specifically designed for placing communication cable and
electrical conductors. However, its robust construction makes the WG suitable for most applications where an
intermittent pull is required. Worm gear winches are designed and intended for intermittent duty application only;
using them in extremely long pulls may generate excessive heat and shorten the life of the winch.
CAUTION -THE WINCH WAS NOT DESIGNED FOR, NOR INTENDED TO BE USED FOR THE MOVEMENT OF PEOPLE. NEVER USE THE WINCH FOR MOVING PEOPLE.
In the typical automotive application, the winch is driven hydraulically. The truck engine provides the prime
source of power connected through a split shaft or side mount power take-off to a hydraulic pump. The pump provides hydraulic pressure and flow sufficient to drive the winch hydraulic motor that is coupled to the worm gear
and load holding brake. The load holding brake and motor are coupled directly to the winch gear box.
1.02 WINCH MAJOR COMPONENTS
● Gearbox ● Full Load Holding Brake
● Wire Rope Drum ● 2 Speed Hydraulic Motor
● Clutch Assembly ● Hanger
● Free Spool Control Brake ● Drum Shaft Extension
● Level Wind Assembly
1.03 WINCH CLUTCH GENERAL INFORMATION - The clutch provides a means of transferring the torque
from the drum shaft to the winch drum. The clutch plate is actuated by an air cylinder. When the winch clutch is
disengaged, the drum will rotate freely on the drum shaft. Power can still be transmitted through the drum shaft
to the drum shaft extension to drive a capstan or reel while the clutch is disengaged. To help determine clutch
position, engaged or disengaged, electronic clutch position sensing is an available option. See section 3.03.
1.04 CALIPER TYPE, FREE SPOOL CONTROL (DRAG) BRAKE - Under rapid winch line payout conditions,
it is extremely important to operate the caliper brake properly, taking care to maintain sufficient tension on the
wire rope. This will enable the level-wind assembly to operate properly, minimize over-spinning of the drum, and
help to prevent erratic lays of winch line on the drum.
All WG units are factory equipped with a caliper type drag brake assembly. The caliper brake is controlled by a
hydraulic actuator (supplied) that is intended to be mounted with the winch controls.
The purpose of the caliper brake is to control the speed of the winch drum when in the free spool mode. Movement of the actuator lever will force the brake pads together, applying friction to the drum brake rotor thereby re-
ducing the drum speed. Continued movement of the control lever will eventually force drum rotation to
stop.
CAUTION THE DRAG BRAKE IS USED TO CONTROL THE DRUM SPEED IN FREE SPOOL ONLY.
IT IS NEVER TO BE USED TO HOLD THE LOAD.
The brake assembly is mounted at the factory on two studs attached to the hanger on the right side of the winch.
The brake disc rotor is mounted at the factory on the clutch end drum flange.
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The remote actuator, reservoir, and flexible hose section are shipped loose with other winch hardware in the parts
box. These components are to be installed by the dealer or truck body builder. The closed circuit hydraulic system is shipped void of any fluid. Prior to operation, fill the system with only the exact type of fluid that was origi-
nally specified for your winch. This will be so designated on the caliper brake components and will be brake fluid
only on specific units or hydraulic oil only on specific units. Bleed and replenish with additional fluid of the correct
formulation, as required. Refer to section 3.04 of this manual.
1.05 ADJUSTABLE MULTIPLE DISC LOAD HOLDING OIL BRAKE - The load holding brake, which is
mounted on the gearbox, is an automatic device designed to hold the rated load of the winch, 20,000 lbs. (89 kN),
on a bare drum. The load holding brake is designed to release when the winch drum is rotating in the pull direction. The brake automatically engages when the winch drum rotates in reverse or payout direction. In order to relax the tension in the pulling line a small amount of reverse power is necessary. The load holding brake is factory
set and should be tightened only to the amount necessary to maintain desired tension on the pulling line.
The WG winch is equipped with an adjustable multiple disc oil
brake. This style of brake can be adjusted by turning hex adjuster counter-clockwise to increase brake and clockwise to
decrease brake.
In general, worm brakes on WG winches should only be
adjusted enough to hold the load you are currently working
with. Over adjustment will result in excessive heat
generation and brake wear.
Full Load Brake
1.06 2-SPEED MOTOR - The WG winch comes equipped with a 2-speed motor. The WG winch defaults to low
speed and can be shifted into high speed mode requiring a pilot pressure of 100 PSI to 150 PSI. The pilot pressure should come from a tee in the line from the hydraulic pump and the directional control valve via a twoposition, three-way selector valve which can be either manually or solenoid operated. For more information on
speed and pull values, please refer to the specification sheet on page 24.
There is a case drain on the motor with a 7/16-20 o-ring port and it MUST be connected to the tank using a
separate dedicated hydraulic line. For more information, see section 3.02 Hydraulic Requirements on page 7.
1.07 LEVEL WIND MECHANISM - The levelwind assembly is a derivative of Bell System specification 8414
and is a familiar sight on other Adams winches. The levelwind distributes the wire rope onto the drum with tight,
even lays. The tight, compact layers help to extend wire rope life by eliminating the upper layers from pulling
down into lower layers. The strain and damage to the wire rope from this action can lead to premature wire rope
failure. The levelwind also helps in maximizing the drum storage capacity. The even and compact layers allow for
more efficient wire rope storage.
1.08 ACCESSORIES - The drum shaft extension is an accessory that makes the WG winch even more versa-
tile. The shaft extension has a diameter of 2
7
/16 inch (Bell System standard) and is mounted on the winch drum
shaft by means of a coupling secured by a connecting pin. Designed with the conventional bayonet type of connection, it is ideally suited for driving a power reel or capstan. To mount a device onto the shaft extension, slide
the device spindle over the shaft extension, push all the way in, turn counter clockwise and pull out into the locked
position.
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The drum shaft extension projects from the curb side (right) of the winch only. The required shaft length
is determined by the width of the body.
The maximum allowable pull of the standard drum shaft extension is 1,000 pounds (4,7 kN) using a
standard 7 in. (18 cm) diameter capstan (GMP P/N 10727). Allowable pulls will be less when using a
larger diameter accessory and/or using a longer drum shaft extension.
2.00 IMPORTANT PRECAUTIONS
2.01 You must read, understand and observe the following precautions at all times when operating the winch:
CAUTION -THE WINCH WAS NOT DESIGNED FOR, NOR INTENDED TO BE USED FO R
THE MOVEMENT OF PEOPLE. NEVER USE THE WINCH FOR MOVING PEOPLE.
CAUTION -THE DRAG BRAKE IS USED TO CONTROL THE DRUM SPEED IN FREE SPOOL
ONLY.
IT IS NEVER TO BE USED TO HOLD THE LOAD.
CAUTION - SHIFTING OF THE CLUTCH SHOULD ONLY BE DONE WHEN THE DRUM ROTATION HAS STOPPED AND NO TENSION IS ON THE WIRE ROPE.
As required by OSHA, it is imperative, and the responsibility of the employer, to properly instruct the
winch operator and the crew relative to the safe working capabilities and operational limitations of the
winch, its accessories and especially the winch controls. The operator should never leave his posi-
tion at the controls while the winch is in operation or the winch line is under load.
Maintain complete coordination with other members of the crew, giving them clear instructions by hand
signal or reliable radio communication.
Stand clear of loads suspended by the winch line.
Do not stand inside of angles formed by the winch line.
As much as possible, do not stand where there is the danger of being struck by the wire rope if it
should fail or snag.
Never place hands on a moving winch line. Always stand clear of moving winch line.
When working around the winch, wire rope and the tail sheave, do not wear loose fitting clothing that
may become entangled with moving parts and cause possible serious injury.
Make certain that the wire rope is properly attached to the drum and that no less than one-half of the
first lay remains on the drum at all times.
Make certain that the eye at the end of the winch line is properly spliced or swaged.
Precautions continue on next page
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Wire rope (winch line) may be old, damaged or weakened by such defects as kinks, cuts, extreme bends
or loops. Such conditions are potentially dangerous and detrimental to safe operation of the winch. The
wire rope must be routinely inspected at regular intervals and replaced when worn. See Maintenance
Section 6.01 on page 15 for replacement criteria.
Make certain that the winch clutch is positively engaged before starting the pull.
Operate the winch as smoothly as possible. Sudden jerking pulls can place extreme loads on equipment,
causing damage or injury.
Do not operate the winch at speeds faster than necessary.
When pulling in, do not allow the wire rope to build up in one location on the drum. This can cause wire
rope "roll-over" and possible erratic, damaging pulls.
Loads on the winch, winch line or extension shaft must not exceed their rated capacity.
3.00 INSTALLATION
3.01 GENERAL - The following procedures are recommended to assure safe, trouble-free operation:
For typical automotive applications, the winch is normally mounted behind the chassis cab in the forward section
of the body load area, directly to the chassis frame.
For standard installations, orient the winch assembly on the chassis frame so that the level-wind is facing rearward and the drum shaft is projecting toward the right (curb) side as viewed from the rear of the vehicle looking
forward. The winch must be positioned on the truck chassis with the centerline of the drum upon the centerline of
the chassis. Sufficient clearance should be allowed between the front body panel or other restrictive members
and the winch to permit normal maintenance.
It is recommended that the winch be directly mounted only to the truck chassis frame. It is not recommended to
mount the winch to any other structural member, as on a sub-frame, without first contacting the factory for specific
application engineering support.
The hydraulic actuator for the caliper drag brake and the drum shaft extension are shipped in a parts box attached
to the winch or shipping crate.
IMPORTANT - To avoid corrosion problems when storing winches outside the parts boxes MUST be removed and
stored in an indoor area.
To protect the entire winch assembly against rust, the winch is prime painted and the drive housing is filled with oil
when shipped from the factory.
IMPORTANT - If the winch will be placed in outdoor inventory for an indefinite period, care should be taken to prevent oil contamination or rusting of internal components due to condensation.
CONTROLS - When the winch has been mounted, consideration must be given to the control of:
● Drum direction of rotation ● Winch clutch control
● Drum speed ● Drag brake caliper/actuator
Because of the wide variation in the type of controls available, it is the responsibility of the dealer to furnish and
install the controls in conformance with the customer's specifications. Proper sizing of each hydraulic component,
and by extension the complete hydraulic system, will avoid potential problems such as overheating, and will provide for economical operation throughout the service life of the system.
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3.02 HYDRAULIC REQUIREMENTS - To obtain the maximum rated pull and line speed using the 2-
speed motor supplied with the WG winch, the hydraulic system shall have a rated flow of 20 GPM (75 l/
min.) maximum. Hydraulic system pressure shall be 1750 psi (12066 kPa) operating with 2000 psi
(13790 kPa) maximum relief valve setting. The recommended hydraulic oil reservoir capacity for the
WG winch is 60 gallons (227 liters) of petroleum-based hydraulic fluid. For additional details and information concerning the 2-speed motor, refer to the illustration below and drawing # 28824 on page 19 of
this manual.
Port B
Two Position 3 Way Valve
Case
Drain
-4 port
Port A
Pilot Port
Pilot Pressure
100 psi min
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Recommended hydraulic line diameters are:
● Pump to control valve: 5/8 in. (16 mm)
● Control valve to tank: 5/8 in. (16 mm)
● Control valve through power beyond to hydraulic system: 5/8 in. (16 mm)
● Control valve work ports to hydraulic motor ports: 5/8 in. (16 mm)
● Pump to two-position, three-way selector valve for high speed feature: 1/4 in (6.4 mm)
● Two-position, three-way selector valve to pilot control valve for high speed feature: 1/4 in (6.4 mm)
Suggested Filtration, based on the hydraulic motor requirements, is 10 micron (nominal) filters. Consult a filter
supplier for specific filter recommendation.
The hydraulic motor case drain port must be ported to tank using a separate, dedicated
hydraulic line. Failure to do so could result in improper winch operation.
There are two connections from the control valve to the motor ports.
In order for the winch to operate correctly, connect the output from the control valve to port A of the motor, the port
farthest from the winch, and connect the return from the control valve to port B, the port closest to the winch.
Identification of connections from the individual valve ports to the motor ports is shown in drawing # 28824 on
page 19 and the illustration shown on previous page.
3.03 WINCH CLUTCH - The clutch plate is motivated by an air cylinder assembly that is mounted to the
hanger assembly. A fork is connected to the piston rod in the air cylinder and the fork contains 2 cam followers
which ride in a groove on the clutch plate. The air cylinder is plumbed to a two-position four-way directional control valve. The directional control valve is electrically operated, and is rated for 12 volts DC with a continuous duty
rating of 100%. A regulator is provided for maintaining a normal setting of 30-psi (207 kPa) supply pressure to the
directional control valve. The regulator is equipped with a Schrader valve stem to attach a pressure gauge (not
provided) to monitor input pressure to the cylinder as required.
The regulator has a
plumbed at the factory. At the time of installation, the only connection required is the air supply line to the aforementioned regulator port. Refer to drawing 25686 on page 21.
A terminal strip is provided for the electrical connection to the directional control valve. The terminal strip is located
on the hanger assembly. A two-position switch should be used to energize the solenoids in the directional control
valve. The solenoids control the positioning of the valve spool thereby directing the airflow to the two ports on the
air cylinder. There are three screws on the terminal strip, the center screw is for connection to the ground or common. The other two screws are for the connection to the switch. Each of the two connections from the terminal
strip should lead to one side of the two-position switch. Refer to drawing 25687 on page 20 for additional details.
3.031 OPTIONAL CLUTCH POSITION SENSING
Optional clutch position sensing is available. The electrical output can be wired to a load, such as a coil in a DC
relay, and the switch in the DC relay can control a set of lights to provide the operator with an indication of clutch
engagement or disengagement.
When the clutch position sensing option is ordered, the air cylinder that actuates the clutch is equipped with a
solid-state digital output limit sensor at each end of the cylinder. When the sensor detects the magnetic piston,
the current sinking device completes the circuit by connecting the load to the ground. The sensors are magnetically activated and while they work on the same principle as Hall effect sensors, they are exceedingly sensitive.
The sensors are 100% solid-state devices with no moving parts to wear, break, bounce or stick and they are fully
encapsulated in plastic resin.
The sensors must be wired as per drawing no. 25777 on page 23. Since the sensors detect the magnetic piston
in the air cylinder and not the switch used to activate the directional control valve, even manual actuation of the
clutch is detected by the sensors.
Warning - Reverse wiring will destroy the solid-state electronic components in the sensors.
1
/8 in. NPTF port for the incoming air supply. The directional control valve and the cylinder are
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3.04 CALIPER TYPE DRAG BRAKE - For reasons of safety and convenience, the drag brake is equipped with
a remote actuator. The remote actuator, reservoir and flexible hose section are shipped loose with other winch
mounting hardware in the parts box. These components are to be installed by the dealer.
3.041 GENERAL GUIDELINES - Hydraulic brake components are precision built mechanisms and must be
treated as such. Certain procedures must be followed at the time of installation to ensure their optimum performance, and a few of the more common procedures are listed below:
To properly locate the brake component or brake line, the installer must consider the following:
● Make it convenient for the operator.
● Use the shortest and most protected route.
● Avoid mounting near the engine, exhaust lines, muffler or anywhere that heat may be generated.
NOTE: Excessive heat transferred to the brake fluid may result in damage to the lines or seals.
● Mount the reservoir higher than the brake component to facilitate bleeding.
To properly mount components and brake lines to withstand the most severe vibration and service conditions, the
installer must consider the following:
● Use the right size bolt for the hole and secure with a steel lock washer.
● Secure tubing to frame with proper size tube clamps to avoid possible fractures or fittings loosening and
leaking.
● Use good, factory-flared lengths of steel tubing. Hand-made flares, when used, should be double flared.
Any flash or loose particles must be removed.
● Use flexible brake line between frame and body.
● If tubing passes through frame or firewall, a grommet or some other means should be used to protect line
from chafing.
● Use tubing rated for 1500-psi minimum for the line between the actuator and the caliper brake assembly.
The proper removal of air from the brake system is very important. A common problem occurs when air remains
trapped in the system causing a "spongy" actuator and inadequate braking. The bleeder screw in the brake assembly must be toward the top. The air in the system will always seek the highest level.
To properly bleed system:
1. Be certain that fittings are tight to avoid leaking.
2. Depress the actuator and open up the bleeder screw to allow the air to escape.
3. Re-tighten the bleeder screws and allow the actuator to return.
4. Repeat the cycle until actuator is firm.
5. Make several static brake applications and then repeat the cycle once more.
The closed circuit hydraulic system must not leak. Even the smallest leak could defeat what would otherwise be a
well operating and effective brake system. It could eventually deplete the reservoir and reduce the braking pressure.
To avoid leaks:
● Check connections during the bleeding and static brake processes to be sure they are tight.
● Always re-install new hoses, lines and fittings if they look the least bit questionable.
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