KINEMATICS MANUFACTURING INC. PLANETARY HYDRAULIC WINCH

MODEL P12D

PARTS AND INSTALLATION MANUAL

KMI 2221 West Melinda Lane

Phoenix, AZ 85027 (623) 770-8944 FAX (623) 780-8945

www.kinematicsmfg.com

TABLE OF CONTENTS

Planetary Winch Ordering Code ............................ Page 1

Model Description …………………………………… Page 2

Specifications …………………………………....…… Page 3

Installation Instructions ……………………………... Page 4

Installation & Dimensions ………………................. Page 5

Recommended Maintenance ………………………. Page 6

Assembly Drawing ………………….…….…………. Page 7

Hydraulic Circuit ………………………………….…. Page 8

Hydraulic System Recommendations .................... Page 9

Trouble shooting .................................................... Page 10 & 11

Service Instructions ............................................... Page 12-14

Torque Bolt Chart .................................................. Page 15

Replacement Parts ................................................ Page 16

Warranty ……………………………………….…….. Page 17

Page I

SERIES

2 2,205 lb. Line Pull 5 5,000 lb. Line Pull 6 6,000 lb. Line Pull 8 8,000 lb. Line Pull 12 12,000 lb. Line Pull 22 22,000 lb. Line Pull 30 30,000 lb. Line Pull

MOTOR WM51D-22 5.74 CID / 96CC

ROTATIONAL OPERATION

CC: Counter Clock Wise (Standard) C: Clock Wise CCF: Counter Clock Wise Freespool CF: Clock Wise Freespool 0: No Brake BD: Brake Effective Both Directions

DRUM

-1- 9.85” (250mm) x 15.75” (400mm) x 9.6” (245mm)

-2- 9.85” (250mm) x 15.75” (400mm) x 12.6”

(320mm) -3-

9.85” (250mm) x 15.75” (400mm) x 17.6” (447mm) OPTIONS

P: Painted G: Grooved Drum XX: Alternative Reduction Ratio O: Consult Factory for Other Options

SAMPLE ORDER CODE __ __ __ __ __ 1

P 12D CC 1 06 P

PLANETARY WINCH ORDER CODE

GENERAL DESCRIPTION: The Kinematics model P12D is a high performance planetary winch having equal speed in forward and reverse rotation. The P12D winch is rated at 12,000 pounds (5.4 metric tons) on the first layer of wire rope and is capable of pulling speeds of 200 FPM (61 M/min) on the top wire wrap layer. The standard winch configuration is powered by a winch gear motor through a 41:1 single stage planetary which is located inside the drum. All moving parts of the P12D are totally enclosed and run in an oil bath. Anti-Friction bearings are used on all turning components to assure a long trouble free service, with a minimum requirement for maintenance. FUNCTION IN FORWARD ROTATION (HOISTING): In forward rotation the output from the hydraulic motor is transmitted to the primary reduction stage through an input shaft. The planetary retainer is splined to the end bracket so that it cannot rotate. The rotation is transmitted to the cable drum through the planetary gear train. The P12D comes with an automatic disc static brake, which is completely fail-safe. The brake is spring applied and hydraulically released. During hoisting the brake remains “on”. The input shaft is connected to the brake through an over-running clutch. The clutch permits free rotation in the hoist direction, but does not permit rotation of the input shaft in the reverse direction. When hoisting is stopped the shaft locks against the disc brake and the maximum load is safely held. FUNCTION IN REVERSE ROTATION (LOWERING): In reverse rotation hydraulic pressure releases the brake against heavy-duty brake springs. The lowering speed is controlled with the winch control valve handle. The P12D incorporates a counterbalance valve, which acts as a dynamic brake while lowering the load. This dynamic brake insures seamless motion in reverse rotation.

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DESCRIPTION OF THE MODEL P12D

-1- -2- -3- Barrel Diameter 9.85" (250 mm) 9.85” (250 mm) 9.85” (250mm) Flange Diameter 15.75" (400 mm) 15.75” (400 mm) 15.75” (400mm) Barrel Length 9.60"(320 mm) 12.60" (244 mm) 17.6” (447mm) STANDARD HOISTING ROTATION Counter clockwise when viewed from motor side. CABLE STORAGE CAPACITY -1- -2- -3- 1/2" cable 388’ (118m) 509’ (155m) 711’ (217m) 9/16"cable 268’ (81m) 350’ (106m) 491’ (150m) 5/8" cable 261’ (80m) 342’ (104m) 478’ (146m) 3/4" cable 172’ (52m) 226’ (69m) 316’ (96m)

NOTE: The rated line pulls shown are for the winch only. Not the wire rope.

OPERATION STATISTICS

Maximum Pressure 2500 PSI (172 BAR) Maximum Volume 55 GPM (208) Full Brake Pressure Release 300 PSI (21 bar) Permissible Back Pressure 50 PSI (4 bar) SAE 90 Weight Lubricating Oil 14 OZ. PERFORMANCE STATISTICS Bare Drum Full Drum Line Pull 12,000LBS (5,454 Kg) 8,200 LBS (3,727) Line Speed 135 FPM (41 m/min) 200 FPM (61 m/min) WEIGHT 400 LBS 200 Kg Note: The warranty is null and void of any damage is incurred from excessive operating volume or pressure.

3

CABLE DRUM DIMENSIONS

P12D SPECIFICATIONS

Motor WM51D-22

INSTALLATION & OPERATION INSTRUCTIONS

INSTALLATION:

The initial mounting of the planetary winch is crucial in assuring proper performance. If the surface upon which the winch is mounted is uneven, distortion of the centerline could cause operating problems in both directions. Therefore, the following procedure should be followed exactly:

1) Mounting platform must be sufficiently rigid to assure that no deflection

occurs during the lifting operation.

2) All four mounting pads must make complete contact with the mounting surface.

3) If complete contact with the mounting surface of all four winch-mounting

pads cannot be achieved, then the problem area should be shimmed. The need for shimming should be determined before tightening all mounting bolts in order to avoid inducing excessive stress in the end castings.

4) Fill winch with SAE 90 gear oil through the oil level hole.

5) Use proper pressure relief protection and hydraulic hoses.

6) The drain line for winches with piston motors must be connected

directly to the reservoir. OPERATION:

1) For standard counterclockwise hoisting use the drum pocket labeled three. Wind the wire rope onto the cable drum in a counterclockwise direction when viewing the winch from the hydraulic motor end. If the wire rope is wound on the cable drum opposite to the direction of rotation the winch will lose its breaking capacity.

2) Control winch operation with a single lever control valve with a forward,

reverse and neutral position. Speed control is obtained by modulating the control valve lever. The disc brake will engage automatically when the control valve lever is returned to neutral.

3) Lubricating oil should be changed after 6 months of operation or 250

operating hours, which ever occurs first.

5

RECOMMENDED MAINTENANCE

To assure proper and reliable operation of the P12D planetary winch, the following preventive maintenance procedure should be carried out every six months or after every 250 hours of operation, whichever occurs first.

1) Disconnect all hydraulic hose lines and remove winch from mounting. 2) Disassemble winch per instructions. 3) Replace all 0-rings and oil seals. 4) Inspect for wear and replace worn parts. 5) Clean all parts with solvent before re-assembly. 6) Reassemble winch and refill with lubricating oil through filler hole.

NOTE: Although wire rope is not a winch component, it should be inspected regularly to be sure its rated capacity has not been impaired in any way.

When placing orders for replacement parts, please specify model number, serial number and manufacture date.

6

Drain (Per Motor Requirements) CONTROL VALVE MOTOR SPOOL FOUR WAY SPRING RETURN TO NEUTRAL RELIEF VALVE HYD PUMP FILTER

HYDRAULIC CIRCUIT

RESERVOIR 8

HYDRAULIC SYSTEM RECOMMENDATIONS

HYDRAULIC PUMPS:

To assure maximum performance of the P12D planetary winch, the pump should be capable of supplying 25 GPM at 2300 psi for the standard motor configuration.

HYDRAULIC RESERVOIR:

The hydraulic reservoir should be of such capacity that proper cooling of the circulated hydraulic oil is assured. To avoid mixing air with the hydraulic fluid, an overflow baffle should provide separation between the suction and return lines. All lines should enter the reservoir below the hydraulic fluid level. The reservoir should be mounted close to and above the hydraulic pump and should allow for free air circulation.

HYDRAULIC FLUID:

Tellus 32 or equivalent is the best suited hydraulic fluid and will eliminate the necessity of seasonal oil changes under normal temperature conditions. For continuous operation in below freezing temperatures, use a hydraulic fluid having a viscosity of 3000 SSU's at the lowest temperature encountered. Operating temperature of the hydraulic fluid should be within the range of 120° F to 180° F (49° C to 82° C). The fluid should be changed at least once a year as part of a preventive maintenance program.

HYDRAULIC CONTROL VALVE:

The control valve used for operating the P12D planetary winch must be a four-way spring-to-center type. This provides open flow from the pressure ports of the winch to the reservoir in neutral position of the motor spool. The better the "metering" characteristics of the control valve; the better will be the speed control.

HYDRAULIC PRESSURE RELIEF:

The control valve used for operating the winch requires a pressure relief set to 100 psi above the maximum operating pressure given in the specifications. Usually this is part of the hydraulic control valve. If this is not the case, a separate pressure relief valve must be installed.

BRAKE VALVE:

This valve is furnished as an integral part of the winch braking system. Its function is to provide smooth winch operation while lowering the load. Should any problems develop with this valve, Kinematics should so be informed.

HYDRAULIC HOSES & FILTER:

For pressure lines, use stratoflex 212-12 or equivalent. For return line filtration, use a 10-micron filter. If operating atmosphere is unusually dusty, use a 5-micron filter. To avoid accidental blockage of the return line, the recommended return line filter should have a bypass feature.

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TROUBLE SHOOTING

GENERAL In many cases, winch malfunctions can be traced to the hydraulic system. Therefore, it is advisable to first check the system when trouble occurs rather than dismantling the winch. Cable line speed (or drum revolutions) is a direct function of the hydraulic fluid flow rate. Should the winch fail to perform at the rated speed, the rate of flow of the hydraulic fluid should be checked with a flow meter. If the flow rate is below the motor rated flow rate, a check should be made of the hydraulic pump, relief valve and control valve. Cable line pull (or lifting capacity) is a direct function of the hydraulic fluid operating pressure. Should the winch fail to perform at the rated line pull, the pressure in the hydraulic system should be checked with a pressure gauge installed into the pressure line leading to the lifting port on the winch motor. Stall the winch to prevent drum rotation and open the control valve to check the hydraulic pressure reading on the gauge. If the pressure reading is less than the recommended relief valve setting, then the trouble source could be the hydraulic pump, relief valve or control valve. IMPORTANT: When checking the flow and pressure of the hydraulic system, the pump must be running at peak revolutions. Be certain the hydraulic reservoir is filled to the top level. If the check of the hydraulic systems shows it to be in order, look for the following probable causes of the indicated problems:

1) Winch will not pull maximum rated load (Rated load is established on the first layer of cable on the drum).

Winch will not operate at rated line speed (Rated line speed is established on the top layer of cable on the drum).

a) Winch is mounted on uneven surface. b) Cable sheaves or blocks used in conjunction with winch operation not

turning freely. c) Damaged or worn hydraulic motor. d) Relief valve may be set too low. e) Excessive back pressure in the hydraulic system.

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TROUBLE SHOOTING (Continued)

2) Winch will not reverse.

a) The brake does not release due to insufficient hydraulic pressure on the brake piston. Check the hydraulic pressure in the brake release line.

3) Brake will not hold.

a) Sprag clutch is broken.

b) Brake plates or divider plates have been damaged by excessive wear.

c) Brake valve spool sticking due to contaminants in the hydraulic

fluid.

d) Excessive return line pressure causing brake to release. Return line pressure should not exceed 50 PSI.

e) Incorrect spool in control valve holding hydraulic pressure against

brake piston when valve handle is in neutral position. For the automatic brake to function properly, both pressure ports of the winch must be open to the reservoir when valve handle is in neutral position.

4) Oil leaks

a) Oil leaking from between the cable drum flange and brake housing is due to hydraulic fluid under pressure entering the brake housing from the motor. This can only happen when the motor seal is damaged due to excess hydraulic pressure in the motor.

b) The drain line must always be connected directly to the hydraulic fluid reservoir. This will assure against the back pressure from developing within the winch which will result in oil leaks developing.

11

SERVICE INSTRUCTIONS

GENERAL: Kinematics Manufacturing Inc. is not liable for any damage or Injuries, which may occur while repairing or routinely servicing a winch.

If the winch is operating incorrectly refer to trouble-shooting section or contact KMI before proceeding with disassembly. Winch should only be disassembled if it is not feasible to return to factory for proper disassembly and inspection.

During disassembly, all parts should be inspected for wear and damage. Any abnormal wear should be reported to KMI.

A hydraulic press is preferred for putting together many of the high tolerance parts found in Kinematics planetary winches.

NOTE: Numbers in parenthesis (xx) are the part item numbers shown in the assembly drawing.

DISASSEMBLY PROCEDURE:

0-rings should be replaced during every re-assembly. PART I: Disassembly of Hydraulic Drive & Brake STEP 1: Drain drum (1) by removing pipe plug (24) and rotating drum. STEP 2: Detach the hydraulic brake line, which runs from the brake valve to

the underside of the brake housing (2). STEP 3: Remove the four hex head cap screws (32), which attach the motor

to the motor adapter (4). STEP 4: Remove the hydraulic motor with brake valve and check O-ring (27)

found on motor face.

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SERVICE INSTRUCTIONS (Continued)

STEP 5: Remove the eight hex head cap screws (32), which attach the motor

adapter (4) to the brake housing (2). Unscrew the hex head cap screws one turn at a time to relieve the pressure from the die springs.

Caution: The motor adapter is under extreme pressure. STEP 6: Remove the die springs (23). STEP 7: Pull out the piston (8) and check O-rings (29, 30). If a hydraulic hand

pump is available it may be used to remove the piston. Attach the hand pump to the brake port in the bottom of the brake housing (2). Pump slowly and pressure will force piston out of housing.

WARNING: Stand away from piston when removing with a hand pump as it may release with great force.

STEP 8: Pull out the input shaft (9). The brake assembly consisting of brake gear

(6), sprag clutch (22), sprag bearings (12) and retaining ring (19) are attached to the input shaft and will all come out together.

Note: If you can hold the brake gear in one hand and freely turn the input shaft inside it in both directions then the sprag clutch is broken. If this is the case, the input shaft, sprag clutch and brake gear must all be replaced.

Carefully unsnap retaining ring (19). The brake gear (6), sprag clutch (22) and sprag bearings (12) can be pulled of the input shaft.

STEP 9: Remove transmission discs (21), clutch discs (20), and brake spacer (7)

from the brake housing. ALL PARTS HAVE NOW BEEN REMOVED FROM THE DRIVE AND BRAKE ASSEMBLY. IN MOST CASES NO FURTHER DISASSEMBLY IS REQUIRED.

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SERVICE INSTRUCTIONS (Continued)

PART II: Disassembly of Main Winch STEP 1: Remove tie bars (11) held on by hex head cap screws (36). STEP 2: Pull brake housing (2) out of secured drum (1). Remove bearing (18)

and seal (17). STEP 3: Pull end bracket (1) out of secured drum (3). Remove bearing (21) and

seal (22). STEP 4: To remove the cap screws (34) holding the bearing retainer (5) onto the

drum (1). Discard the O-ring (28). STEP 5: Carefully remove planetary gear assembly from drum (1). PART III: Re-assembly STEP 1: Clean all parts thoroughly and inspect for undue wear. STEP 2: Apply grease to all O-rings and seals. STEP 3: Refer to Torque Bolt Chart on page 19 for tightening of all fasteners. STEP 4: Reassemble in reverse order of assembly. STEP 5: Fill Drum with 14 ounces of SAE 90 oil. IMPORTANT: BRAKE ASSEMBLY WILL BE RUINED IF SPRAG CLUTCH IS NOT INSTALLED CORRECTLY. PUSH SPRAG CLUTCH ONTO POLISHED SECTION OF SHAFT WHILE ROTATING SHAFT IN HAND. SHAFT SHOULD ROTATE FREELY IN CLOCKWISE DIRECTION WHEN VIEWED FROM THE MOTOR END OF THE SHAFT. THE MOTOR END HAS AN INTERNAL SPLINE FOR INSERTING THE MOTOR SHAFT. THE INPUT SHAFT SHOULD NOT BE ABLE TO ROTATE IN OPPOSITE (COUNTERCLOCKWISE) DIRECTION.

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TORQUE N - M

TORQUE LB - FT

BOLT DIA.

(INCHES)

1/4 9 12

5/16 18 24 3/8 32 43

7/16 50 68 1/2 75 102

9/16 110 149 5/8 150 203 3/4 265 359 7/8 420 570 1 640 868

1 1/8 800 1085 1 1/4 1000 1356 1 3/8 1200 1628 1 1/2 1500 2035

Page 15

BOLT TORQUE CHART

WHEN ORDERING REPLACEMENT PARTS ALWAYS QUOTE THE MODEL NO., SERIAL NO. AND MANUFACTURE DATE.

Model No. ____________________

Serial No. ______________________

Year of Mfg. ____________________

KMI RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND THE DESIGN OF KINEMATICS WINCHES AT ANY TIME WITHOUT PRIOR

NOTICE AND WITHOUT INCURRING ANY OBLIGATIONS

Page 16

K M I

WARRANTY

Kinematics Manufacturing Inc. warrants each new planetary hydraulic winch to be free from defects in material and workmanship and to provide reasonable performance under normal use and recommended maintenance procedures. Terms and conditions as follows: 1) Kinematics planetary winches are warranted to be free from defects in

workmanship or materials for a period of six (6) months from date of shipment from Kinematics warehouse.

2) Should any part of said winch be found, under normal use and service during

the warranty period, to be defective, Kinematics will replace said part, provided such part is returned to Kinematics.

3) This warranty shall not apply to winch upon which repairs or alterations have

been made (unless authorized by Kinematics) or for winches misused, neglected, or incorrectly installed.

4) Kinematics makes no warranty with respect to motors and other accessories,

which are subject to the warranties of their respective manufacturer. Kinematics’ liabilities limited to such repair or replacement subject to the conditions stated, and Kinematics shall not in any event be held liable for any consequential or contingent damage or for any expenses or delay caused by defective material or workmanship, and no allowance will be made for repairs, replacements or alterations unless made with Kinematics’ written approval.

5) Kinematics makes NO WARRANTY OF MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE and shall not be liable for any guarantees or warranties, express or implied, except those expressly set forth here in.

WARNING:

Kinematics planetary hydraulic winches described herein are neither designed nor intended for use or application to equipment used in the lifting or moving of persons and it is understood that all such use shall be at the sole risk of the user. The cable clamps on winches are not designed to hold rated loads. A minimum of 4-6 wraps of cable must remain on drum barrel to guarantee holding of rated loads.

RECOMMENDATIONS: Kinematics planetary hydraulic winches should not be stored beyond a period of one year without operation because of the limited shelf life of O-rings and oil seals used in the unit. Winches should always be stored inside and out of the weather.